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Masterclad™ 5–15 kV Arc Resistant Metal-Clad

Indoor Switchgear

Class 6055

Instruction Bulletin

6055-62

06/2012

Retain for future use.

(2)

ENGLISH ENGLISH

Hazard Categories and Special

Symbols

Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

The addition of either symbol to a “Danger” or “Warning” safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

NOTE: Provides additional information to clarify or simplify a procedure.

Please Note

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, can result in death or serious injury.

CAUTION

CAUTION indicates a hazardous situation which, if not avoided, can result in minor or moderate injury.

NOTICE

NOTICE is used to address practices not related to physical injury. The

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Table of Contents

ENGLISH

Table of Contents

Introduction ... 7 Product Overview ... 8

Front Section with Secondary Control Devices ... 8

Circuit Breaker Compartment ... 9

Circuit Breaker Positioning Rails ... 9

Racking Mechanism ... 9

Secondary Disconnect Receptacle... 9

Racking Position Indicator ... 10

Primary Contacts ... 10

Current Transformer ... 10

Ground Contact Bar... 10

Mechanism Operated Contacts (Optional) ... 10

Truck Operated Contacts (Optional)... 10

Interlocks ... 11

Voltage Transformer and Control Power Transformers Fuse Drawout Units ... 12

Main Bus Compartment ... 13

Cable Compartment... 14

Surge Arresters... 14

Safety Precautions ... 15

Receiving, Handling, and Storage ... 16

Receiving ... 16

Handling ... 16

Storage ... 17

Site Selection and Preparation ... 17

Foundation ... 18 Conduit Location ... 18 Installation ... 19 Switchgear Installation ... 19 Pre-Installation Procedures ... 19 Installation... 19

Main Bus Installation ... 20

Bus Bar Installation ... 22

Circuit Breaker Installation ... 23

Installing the Circuit Breaker into the TEST/DISCONNECT Position. 24 Testing the Circuit Breaker in the TEST/DISCONNECT Position.. 25

Racking the Circuit Breaker into the CONNECTED Position... 26

Circuit Breaker Removal ... 27

Racking the Circuit Breaker Out of the CONNECTED Position... 27

Removing the Circuit Breaker from the Circuit Breaker Compartment 28 Locking Provisions ... 29

Voltage Transformer Drawout Unit Inspection ... 29

Racking the Voltage Transformer Drawout Unit Out of the CONNECTED Position ... 29

Inspecting the Fuses... 30

Racking the VT Drawout Unit into the CONNECTED Position ... 30

Voltage Transformer Drawer ... 30

Voltage Transformer Drawer Interlocks ... 31

Voltage Transformer Drawer Characteristics... 32

Voltage Transformer Drawer Wiring ... 32

High-Potential Testing ... 32 Test Preparation ... 32 Phase-to-Phase Test ... 32 Phase-to-Ground Test ... 33 Phasing ... 33 Cable Connections ... 33

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

Table of Contents 06/2012

ENGLISH

Insulating the Cable Connections ... 33

Operation ...35

Start-Up ...35

Preliminary Start-Up Procedures ... 35

Installing and Testing Circuit Breakers in the TEST/DISCONNECT Position ... 35

Operation ...36

Energizing the Switchgear ...36

Removing Circuit Breakers ...36

Inspection and Maintenance ...37

Main Bus Compartment ...37

Replacing the Fuses ...38

Re-Energizing ...38

Accessories ...39

Using the Lift Truck ...39

Test Cabinet (Optional) ...40

Ground and Test Devices ...40

Arc Exhausting Systems ...41

Plenum Assembly ...41

Installing the Plenum Assembly ... 42

Arc Shield Assembly ...45

Installing the Arc Shield Assembly ... 46

Configuration Drawings ...48

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

06/2012 List of Figures

ENGLISH

List of Figures

Figure 1: Masterclad Indoor Arc Resistant Switchgear

with Type VR Drawout Circuit Breaker ... 7

Figure 2: Typical Front Section ... 8

Figure 3: Circuit Breaker Compartment ... 9

Figure 4: Mechanism Operated Contacts ... 10

Figure 5: Truck Operated Contacts ... 11

Figure 6: Drawout Voltage Transformer ... 12

Figure 7: Bus Compartment ... 13

Figure 8: Lifting Sling ... 16

Figure 9: Typical Floor Plan (Not for Construction) ... 18

Figure 10: Section Bolting Details ... 19

Figure 11: Typical Main Bus Assembly (1200 A shown) ... 20

Figure 12: Main Bus Connections, Side View ... 21

Figure 13: Main Bus Connections, Top View ... 21

Figure 14: Bus Compartment with Bus Cover Removed ... 22

Figure 15: Glass Polyester Pass-through ... 22

Figure 16: Door Handle Positions ... 23

Figure 17: Inserting Circuit Breaker with a Lift Truck ... 24

Figure 18: Masterclad Switchgear Circuit Breaker Compartment ... 24

Figure 19: Test and Connected Position Arrows ... 25

Figure 20: Circuit Breaker Secondary Disconnect (Male) ... 25

Figure 21: Secondary Disconnect Handle and Connector ... 26

Figure 22: Racking Handle Engaged onto Racking Shaft with Circuit Breaker in the TEST/DISCONNECT Position ... 27

Figure 23: Removing the Circuit Breaker from the Compartment ... 28

Figure 24: Devices That Can Be Padlocked ... 29

Figure 25: Racking Handle Engaged onto Racking Shaft ... 29

Figure 26: VT Drawer Compartment ... 30

Figure 27: VT Drawer Door Latched ... 31

Figure 28: VT Racking Handle Inserted ... 31

Figure 29: Voltage Transformer Drawer in Withdrawn Position ... 32

Figure 30: Voltage Transformer Wiring ... 32

Figure 31: Power Cable Connection Insulation ... 34

Figure 32: Typical Lift Truck ... 39

Figure 33: Wall-Mounted Test Cabinet (Optional) ... 40

Figure 34: Typical Indoor Plenum Application ... 41

Figure 35: Plenum Assemblies ... 42

Figure 36: Prepared Roof Detail—Plenum (Lefthand and Righthand End Bays) ... 42

Figure 37: Plenum Installation Detail ... 44

Figure 38: Typical Arc Shield Application ... 45

Figure 39: Arc Shield Assemblies ... 45

Figure 40: Prepared Roof Detail—Arc Shield (Lefthand and Righthand End Bays) ... 46

Figure 41: Arc Shield Installation Detail ... 47

Figure 42: Masterclad Arc Resistant Metal-Clad Indoor Switchgear Configurations ... 48

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

List of Tables 06/2012

ENGLISH

List of Tables

Table 1: Approximate Switchgear and Component Weights ... 17

Table 2: Bolt Torque ... 23

Table 3: One Minute Hi-Potential Test... 33

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

06/2012 Introduction

ENGLISH

Introduction

This instruction bulletin contains instructions for receiving, handling, storing, installing, operating, and maintaining Masterclad™ 5–15 kV arc resistant metal-clad indoor switchgear. This equipment is manufactured by Schneider Electric under the brand name Square D™. This equipment is designed for use with Type VR drawout circuit breakers. The arc resistant design is one-high and two-high, with circuit breakers on the top and bottom and an auxiliary compartment with controls on the top.

NOTE: For information on Type VR circuit breakers, refer to instruction

bulletins 6055-31 and 6055-33.

The switchgear assembly (Figure 1) consists of individually-grounded steel compartments. Each compartment has doors, barriers, and removable access panels to isolate the separate working functions. Exhaust vents are located at the top of each compartment, except for the auxiliary

compartment. All of the circuit breakers, instrument and control power transformers, relays, meters, and other components are factory assembled, wired, and tested as an assembly.

The installer normally makes only the external control, ground, and power connections at the terminals provided, and reconnects the wiring and bus bars at the shipping breaks.

Each assembly is custom designed, with standard structures and bus configurations arranged according to customer specifications. The

structures are then combined with the circuit breaker and other components necessary for the required protective scheme, metering, and number of feeders.

Complete customer drawings are furnished for each Masterclad switchgear assembly. The drawings include floor plans and elevations, one-line diagrams, bills of material, control schematics, and wiring diagrams.

Figure 1: Masterclad Indoor Arc Resistant Switchgear with Type VR Drawout Circuit Breaker

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

Introduction 06/2012

ENGLISH

Product Overview

Masterclad arc resistant metal-clad indoor switchgear is UL/cUL certified.

A Masterclad arc resistant switchgear line-up assembly consists of individual switchgear bays bolted together. The number of bays in an assembly depends on customer specifications.

Each switchgear bay is a separate, rigid, self-contained structure made of 10-gauge steel. A switchgear bay typically consists of:

Front section

— Circuit breaker compartments (upper and lower) — Auxiliary compartment with controls and door-mounted

components (upper)

— Section with secondary control devices

Main bus compartment

Cable compartment

Front Section with Secondary Control Devices The front section upper compartment includes front, hinged doors with

instruments, relays, control switches, terminal blocks, fuse blocks, and other required secondary control devices. The wiring space for inter-unit

connection and the customer control wiring connection is also included in the front section.

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

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Circuit Breaker Compartment The circuit breaker compartment contains separate, but coordinated,

features (Figure 3).

Circuit Breaker Positioning Rails Positioning rails (Figure 3), mounted on the side walls of the circuit breaker

compartment, capture and align the rollers on the circuit breaker to guide the breaker into the circuit breaker compartment.

Racking Mechanism The racking mechanism (Figure 3) is located on the circuit breaker

compartment floor. It is operated by a removable racking handle inserted into the front of the circuit breaker compartment so that it can be racked, only with the door closed. The circuit breaker is engaged by a gear-driven racking arm (Figure 3). As the arm rotates, it moves the circuit breaker into or out of the TEST/DISCONNECT or the CONNECTED position.

Secondary Disconnect Receptacle The secondary disconnect receptacle (Figure 3) is located on the lower right

floor of the compartment. The molded insulating receptacle contains 24 contacts and two tapered guide pins. Control power can be connected in the test position by rotating the secondary disconnect handle and pulling it forward (Figure 3). The breaker compartment door must be opened to

Figure 3: Circuit Breaker Compartment

Shutter actuator

Racking arm Circuit breaker positioning rails

Position latch brackets Ground bar

Racking position indicator

Secondary disconnect handle

Secondary disconnect receptacle

Racking mechanism

Racking block bar (welded to racking shaft)

Racking shaft Racking mechanism lockout provision (key interlock and padlock)

Primary bushing assemblies (shutters open)

Primary high voltage contacts

Racking block lever

Compartment rating interlock Ground & test/removable shorting device interlock

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

Introduction 06/2012

ENGLISH

access the secondary disconnect handle. The door can be closed after the receptacle is connected to the breaker.

Racking Position Indicator The racking position indicator, located beside the racking port

(Figure 3 on page 9), indicates if the circuit breaker is in either the TEST/DISCONNECT, TRANSPORT, or CONNECTED position, and whether the shutters are closed or opened. When the door is open, two arrows that line up with the front cover are visible on the left rail and indicate the position of the circuit breaker.

Primary Contacts The primary contacts are housed in primary bushing assemblies

(Figure 3 on page 9) that are covered at the open end by the shutter when the circuit breaker is in the TEST/DISCONNECT position.

Current Transformer Front-accessible, window-type, 600 V rated single- or multi-ratio current

transformers are located around either the line or load primary voltage-insulated bushings. A maximum of two current transformers, depending on accuracy, can be mounted per phase—two on the line, and two on the load.

Ground Contact Bar A ground bar (Figure 3 on page 9), located on the circuit breaker

compartment floor, is directly connected to the main ground bus. Sliding contact fingers, located on the underside of the circuit breaker, engage before the circuit breaker reaches the TEST position and remain continuously grounded.

Mechanism Operated Contacts (Optional) Mechanism operated contacts are compartment-mounted auxiliary contacts

that are operated by the circuit breaker mechanism (Figure 4). Like circuit breaker mounted auxiliary contacts, they indicate whether the circuit breaker is in the OPEN or CLOSED position. They operate in the

CONNECTED and TEST/DISCONNECTED positions (unless specified for CONNECTED only). Refer to the customer order drawings shipped with the equipment.

NOTE: The NORMALLY-OPEN “A” contacts and the NORMALLY-CLOSED

“B” contacts furnished are not convertible.

The mechanism operated contacts unit is mounted inside the front section of the circuit breaker compartment. It is operated by a mechanism that is driven vertically by a roller on the left side of the circuit breaker. The switch is located inside the breaker compartment.

Figure 4: Mechanism Operated Contacts

Contact actuator

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

06/2012 Introduction

ENGLISH

The truck operated contacts unit does not distinguish between the circuit breaker being in the TEST/DISCONNECT position or withdrawn completely from the compartment.

The truck operated contacts unit is mounted on the right side of the horizontal steel barrier in the top of the circuit breaker compartment. The switch is located inside the breaker compartment. It is operated by a spring-loaded lever. This lever is activated, just before the circuit breaker reaches the connected position, by a pin on the upper right side circuit breaker frame.

Interlocks

The circuit breaker compartment contains the following interlocks:

A racking block bar (Figure 3 on page 9) welded to the racking shaft will

hit an interlock pin on the circuit breaker when it is closed. This interlock mechanism will stop a closed circuit breaker from being racked into or out of the circuit breaker compartment.

The racking arm actuates an interlock located underneath the circuit

breaker. This interlock mechanism is designed to stop a circuit breaker from being closed when it is between the TEST/DISCONNECTED and CONNECTED positions.

A racking block lever (Figure 3 on page 9) will not allow racking

mechanism operation when the circuit breaker is not in the circuit breaker compartment. The shutter cannot be opened unless the circuit breaker is in the circuit breaker compartment.

A racking mechanism lockout provision (Figure 3 on page 9) is furnished

in each compartment for locking circuit breakers or voltage transformer (VT) drawout units out of the CONNECTED position. The racking mechanism lockout provision is located in the center of the compartment floor and has standard padlock provisions. It can be equipped with a key interlock when specified by the customer. The racking mechanism lockout prevents the racking of circuit breakers or VT drawout units

Figure 5: Truck Operated Contacts

Contact actuator

CAUTION

HAZARD OF EQUIPMENT DAMAGE

• Do not test interlocks by hand. Test interlocks by moving the circuit breaker over the compartment-mounted operating cams.

• Operate interlocks in the correct sequence.

Failure to follow these instructions can result in injury or equipment damage.

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

Introduction 06/2012

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when they are in the DISCONNECTED position. Circuit breakers or VT drawout units can be stored in the DISCONNECTED position with the racking mechanism locked.

The racking mechanism is not functional if the breaker compartment

door is opened. The circuit breaker compartment door can not be opened if the breaker or VT drawout units are not in the

DISCONNECTED position.The compartment rating interlocks (Figure 3 on page 9) stop accidental insertion of circuit breakers with incorrect current, voltage, or interrupting ratings into the compartment. The stationary interference brackets are mounted on the floor of the compartment and the mating part of the interlock system is mounted on the underside of each circuit breaker.

Each circuit breaker compartment may have permissive interlocks

(Figure 3 on page 9) that will prevent the insertion of a G&T or an RS device not intended for use in that circuit breaker compartment. The permissive interlocks are located beside the compartment rating interlock on the circuit breaker compartment floor. Refer to the specific Schneider Electric G&T and RS device instruction bulletin(s).

Voltage Transformer and Control Power Transformers Fuse Drawout Units

The voltage transformer (VT) and control power transformers (CPT) fuse drawout units are self-contained drawers. As the drawout units are racked into the compartments, the drawers roll on two positioning rails mounted on the sides of the compartment. The rails capture and align rollers on drawout units.

Floating, drawer-mounted, self-aligning contacts engage the stationary

primary contacts as the drawer is racked into the connected position.

A sliding contact finger, located on the bottom right side of the drawout

unit, engages the ground bar when the drawout unit is in the DISCONNECTED position and remains continuously grounded.

A static discharge ground contact, mounted in the top of the

compartment, grounds the primary contacts in the withdrawn position.

Control power transformers are stationary mounted or truck mounted, as

needed. Depending on the size of the transformer, they can be mounted remotely or within the switchgear.

Drawout voltage transformers (Figure 6) supply voltage indication for

metering and relaying purposes. Primary current limiting fuses are mounted on each voltage transformer.

When drawout voltage transformers are in the CONNECTED position

the secondary contacts, mounted on the bottom middle of the drawer, engage fixed compartment floor-mounted secondary contacts.

Secondary fuses for the voltage transformers are located in the front

control compartment. Refer to the customer order drawings shipped with the equipment.

Figure 6: Drawout Voltage Transformer

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

06/2012 Introduction

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Main Bus Compartment The main bus compartment is located in the center of the switchgear unit. It

is isolated from other compartments by metal plates and is accessible by removing the metal access plate (Figure 7) located between the main bus compartment and the load compartment.

Each busbar has epoxy insulation rated for 221° F (105° C) operation—heat shrink coating is optional. Glass polyester pass-throughs are used to separate the bus compartments between adjacent circuit breaker compartments.

NOTE: The busbar insulation must not be damaged or modified. Boots must

be in place before operating the equipment.

Bus boots insulate the connection in the main bus compartment,

overlapping the epoxy insulation on the busbars. The busbar insulation and boots form an integral insulating system for the equipment to meet its dielectric ratings.

Figure 7: Bus Compartment

Pressure relief flaps

Main bus

compartment Pressure relief flaps

Entry to main bus compartment Main bus access plates Cable compartment Circuit breaker compartments

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

Introduction 06/2012

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Cable Compartment The cable compartment is accessible by opening the rear door on the back

of the equipment. The load connectors are punched for terminating two cables per phase with a NEMA two-hole pattern standard.

Schneider Electric will provide lugs, upon request. For 15 kV, interphase barriers will be installed if insulating boots are not required by customer on cable connections. Tape and associated material for insulating cable terminations are not supplied.

A ground bus in the cable compartment has lugs on each end for the assembly ground. This ground bus is connected to each circuit breaker compartment ground contact bar and to the individual ground bars in each cable compartment. All instrument transformer, metering, and relaying grounds are also connected to this common ground system.

The dimensions of a typical ground bus cross section are:

0.25 x 2.0 in. (6 x 51 mm) for switchgear up to 50 kA

0.5 x 2.0 in. (13 x 51 mm) for 63 kA switchgear

Conduit must enter the cable compartments, in the areas shown on the customer drawings (Figure 9 on page 18), from either the top or bottom of the cable compartment.

Conduit should be stubbed in the concrete pad as part of the site

preparation before the assembly is installed, but top entrance conduit must be installed after the assembly is in place. The top and bottom covers can be removed, punched to fit the conduit, and put back in place. When required, zero-sequence current transformers are conveniently located in the cable compartment.

Various cable termination systems are used. These are detailed on the customer’s plans and specifications. Solderless or compression lugs can be supplied on the load connectors. Potheads can be supplied as an option. Tape and insulating material necessary for completing the field connection at the lug pad are not supplied with the assembly.

Surge Arresters Surge arresters are furnished only when listed in the user’s specifications.

When specified, surge arresters are mounted in the incoming and outgoing cable compartments.

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

06/2012 Safety Precautions

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Safety Precautions

This chapter contains important safety precautions that must be followed before attempting to install, service, or maintain electrical equipment. Carefully read and follow the safety precautions outlined below.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E and CSA Z462.

• Only qualified personnel familiar with medium voltage equipment are to perform work described in this set of instructions. Workers must understand the hazards involved in working with or near medium voltage circuits. • Perform such work only after reading and understanding all of the

instructions contained in this bulletin.

• Turn off all power supplying this equipment before working on it. • Always use a properly rated voltage sensing device to confirm that

power is off.

• Before performing maintenance on this device, disconnect all sources of electric power. Assume all circuits are live until they are completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power. Check interconnection diagrams and make sure there are no backfeed potential sources.

• Never disconnect the main trip source of energized equipment. • Place the circuit breaker in the TEST/DISCONNECTED position before

attempting to open the circuit breaker door.

• Handle this equipment carefully and install, operate, and maintain it correctly in order for it to function properly. Neglecting fundamental installation and maintenance requirements may lead to personal injury, as well as damage to electrical equipment or other property.

• Do not make any modifications to the equipment or operate the system with interlocks and safety barriers removed. Contact your local Schneider Electric representative for additional instructions if the equipment does not function as described in this manual.

• Use out-of-service tags and padlocks when working on equipment. Leave tags in place until the work is completed and the equipment is ready to be put back into service.

• The complete assembly arrangement determines if the top or bottom contacts are the line side; both can be energized when the circuit breaker is removed from the compartment.

• Disconnect all sources of power to the switchgear before accessing the horizontal bus compartment.

• All breaker and auxiliary doors must be latched and all cable compartment doors must be bolted to maintain arc resistance.

• Carefully inspect your work area and remove any tools and objects left inside the equipment before energizing the switchgear.

• Replace all devices, doors, and covers before connecting the power to this equipment.

• All instructions in this manual are written with the assumption that the customer has taken these measures before performing maintenance or testing.

Failure to follow these instructions will result in death or serious injury.

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Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62

Receiving, Handling, and Storage 06/2012

ENGLISH

Receiving, Handling, and Storage

This section contains instructions for receiving, handling, and storing the Masterclad arc resistant metal-clad switchgear. This section also covers site selection and preparation, foundation specifications, and locating conduit.

Receiving

Masterclad arc resistant metal-clad switchgear is shipped in protective

crates or wrapping. Circuit breakers are shipped on pallets.

Upon receipt, compare the packing list to the equipment received to ensure that the order and shipment are complete. Claims for shortages or errors must be made in writing to Schneider Electric within 60 days of delivery. Failure to give such notice will constitute unqualified acceptance and a waiver of all such claims by the purchaser.

Immediately inspect the equipment for any damage that may have occurred in transit. If damage is found or suspected, file a claim with the carrier immediately and notify Schneider Electric. Delivery of equipment to a carrier at any of the Schneider Electric plants or other shipping point constitutes delivery to the purchaser regardless of freight payment and title. All risk of loss or damage passes to the purchaser at that time.

Handling

The switchgear is shipped in sections of one or two bays. Each shipping

section has four lifting eyes bolted onto the top.

NOTE: If using the plenum option, do not install until the switchgear is

moved to installation location. Refer to “Plenum Assembly” on page 41 for additional information.

Put a crane hook through each of the four lifting eyes (Figure 8) to lift and move the sections. Use load-rated cables or chains with safety hooks or shackles. A spreader bar may be necessary to maintain proper angles for lifting.

To prevent structural damage, rig the lifting sling so that the minimum angle between lifting cables or chains and the top of the equipment is 45°, and the maximum interior angle is 90°. If a crane is not available, contact Schneider Electric before using any other lifting method. After the equipment has been placed in position, remove and discard the lifting eyes. Screw the bolts back into place to cover the mounting holes.

CAUTION

HAZARD OF EQUIPMENT DAMAGE OR INJURY

If moving by crane, the interior angle of the lifting sling should not exceed 90°. Angles greater than 90° apply greater inward pressure of lifting lugs which can damage or dislodge lifting lugs from switchgear.

Failure to follow these instructions can result in injury or equipment damage.

Figure 8: Lifting Sling

45° 45° 90° Interior angle Safety hooks Lifting eyes Equipment top

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6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear

06/2012 Receiving, Handling, and Storage

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Storage

Keep equipment in a clean, dry, well-ventilated area. Circuit breakers should be protected from dust, foreign objects, and rodents. If space heaters are furnished in the assembly, energize them from an external source. Refer to schematic and wiring diagrams for a logical connection point, and for voltage and power requirements.

NOTE: If the space heaters are normally energized from a control power

transformer, open the control power transformer secondary circuit breaker, remove the primary current limiting fuses, and install an out-of-service tag before energizing the space heaters. This prevents backfeed to the main bus through the control power transformer.

If space heaters are not installed in the assembly, and the area is cold and damp, use a temporary heating source within the assembly. A minimum of 200 watts of heat per compartment is recommended. Avoid greasy, smoky heaters that can deposit carbon on insulation, causing tracking and eventual insulation breakdowns.

Site Selection and Preparation

Proper site selection is essential for reliable operation of the assembly. Carefully compare the plans and specifications with the customer drawings provided.

Provide adequate ventilation at all times so the ambient temperature

around the assembly does not exceed 104° F (40° C). If the ambient temperature exceeds 104° F (40° C), you will need to de-rate the equipment. Clean, dry, filtered air should be supplied.

Provide adequate lighting in both the front and back aisle spaces. Also,

provide convenient outlets in both areas for electrical hand tool use.

Provide adequate floor drainage.

Provide adequate safeguards against water damage. Route sewer,

water, and steam lines so they do not pass over or near the assembly— dripping liquids may damage the insulation.

Make sure the site can support the weight of the complete switchgear unit. Refer to Table 1 to determine switchgear and component weights for handling and other structural considerations.

DANGER

HAZARD OF ELECTRICAL SHOCK, EXPLOSION, OR ARC FLASH

When energizing space heaters from a remote source, remove the primary current limiting fuses of the control power transformer.

Failure to follow this instruction can result in death or serious injury.

DANGER

HAZARD OF EXPLOSION OR ARC FLASH

• Do not install the equipment beneath catwalks or other elevated personnel access routes.

• Maintain a minimum overhead clearance of 10 ft. (3 m).

• Install the equipment in an area that allows for forced ventilation to outside air.

Failure to follow these instructions will result in death or serious injury.

Table 1: Approximate Switchgear and Component Weights

Switchgear and Components Weight

Switchgear unit (one-high applications) 3500 lb (1591 kg) Switchgear unit (two-high applications) 4300 lb (1951 kg) Circuit breaker 1200 A, 40 kA 380 lb (170 kg) Circuit breaker 1200 A, 50 kA 430 lb (195 kg) Circuit breaker 2000 A, 40 kA 450 lb (205 kg) Circuit breaker 2000 A, 50 kA 500 lb (225 kg) Circuit breaker 3000 A, 50 kA 700 lb (320 kg) Circuit breaker 1200, 2000, 3000 A, 63 kA 800 lb (363 kg) VT drawout fuse unit (2) 15 kV 210 lb (95 kg) 3 intermediate arresters 15 kV 120 lb (55 kg)

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Foundation

The switchgear is designed to be mounted on the supplied base, leveled to

the specifications in the supplied base plan drawing, and grouted in the concrete pad.

NOTE: Typically, a minimum of 3 ft. (1 m) is necessary on the left, right, and

rear of the line-up and 6 ft. (1.8 m) on the front side for door clearance when removing the circuit breaker.

Figure 9 illustrates the typical floor plan. Refer to the customer order drawings before using the typical foundation specifications.

NOTE: For users in Mexico, an optional floor plan is available for 1200 A.

Review the complete customer drawing for each Masterclad assembly.

Conduit Location

Conduits should be stubbed a maximum of 1 in. (25 mm) above floor steel.

Conduit placement should be very accurate to ensure that there is no mechanical interference with the switchgear floor steel. Avoid continuous loops of reinforcing rod or structural steel around any single-conductor of a three-phase power circuit.

Figure 9: Typical Floor Plan (Not for Construction) 72.0 (1829) 1.0 (25) 5.8 (146) 1.0 (25) 47.6 (1209) 1.5 (38) 6.5 (165) 2.0 (51) 4.5 (114) 94.0 (2388) 2.0 (51) 27.0 (686) 4.5 (114) 1.5 (38) 6.5 (165) 1.0 (25) 34.0 (864) 0.5 (12) door 5.8 (146) 25.8 (654) 5.1 (130) 9.0 (229) 6.1 (155) 5.1 (130) 44.4 (1128) 3.0 (76) 1.0 (25) 36.0 (914) 1.0 (25) 6.9 (175) 10.0 (254) 34.0 (864) 16.0 (406) 10.0 (254) 1.0 (25) Front Rear

Front Aisle Rear Aisle

Six 0.50 in. (12.7 mm) diameter mounting holes Control conduit

area (bottom)

Top or bottom conduit area Bottom conduit area

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Installation

This section contains instructions for installing the Masterclad arc resistant metal-clad indoor switchgear assembly.

Switchgear Installation

This section contains instructions for installing the switchgear.

Pre-Installation Procedures 1. The switchgear may be shipped in one or more shipping sections.

Review the assembly drawings to verify that switchgear sections will be assembled in the correct order.

2. Verify that the conduit placement on the foundation is accurate

according to customer drawings. Error in conduit placement may prohibit the proper installation of switchgear as described in this section (see the note below).

3. Sweep the pad and remove debris before installing any sections.

Installation NOTE: When more than two shipping sections are involved, any error in

conduit location can cause a cumulative error significant enough to prohibit the proper installation by the assembly sequence described in this section. To lessen cumulative error, unload and install the center shipping section first and work toward either end.

1. Move the sections into place. Install the end shipping section that allows the most maneuverability first.

2. Before proceeding, verify:

— The conduits are in the center of the cutouts.

— The back of the unit is perpendicular to the pad and has proper clearance.

— The mounting holes line up with the mounting channels. 3. Move an adjacent switchgear shipping section into place.

4. Verify that the switchgear sections are level, aligned, and fit snugly together. If the sections do not fit properly, lift the most recently placed section by crane, remove any obstructions, and re-install.

5. Bolt switchgear shipping sections together. See Figure 10 for bolt sizes and locations.

Figure 10: Section Bolting Details

3/8-16 x 6-in. screws

(20 supplied) 3/8-16 x 1.5-in. screws (6 supplied)

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NOTE: All shipping sections must be bolted together in place before bolting

them to the channel sills or installing the horizontal main bus. 6. Repeat steps 4–5 for additional switchgear shipping sections. 7. Verify that all switchgear shipping sections are in the correct position

according to the job drawing after all sections are bolted together. 8. Bolt the switchgear to the pad (front, center, and rear) using 1/2-13 SAE

Grade 5 bolts with Belleville washers (Figure 9 on page 18). Use nuts with spring washer or tap in the pad to 1/2-13. Use six bolts per cell.

Main Bus Installation

A typical main bus assembly is shown in Figure 11 below. Figure 12 shows

the side view of the assembly and the general arrangement of the main bus and riser. Figure 13 shows the bus connections and orientation of the filler and splice plates. See Figure 7 on page 13 for main bus access details.

Figure 11: Typical Main Bus Assembly (1200 A shown)

A B C

Rear View—Bus Covers Removed Side View—1200 A

Front Rear

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Figure 12: Main Bus Connections, Side View

Figure 13: Main Bus Connections, Top View

3000 A Main

1200 A Main 2000 A Main 2000 A Main Bus 3000 A Main Bus 3000 A Main Bus

1/4 x 6 Filler

1200 A Riser 1200 A Riser 2000 A Riser 3000 A Riser 2000 A Riser 1200 A Riser 1/4 x 6

Bus splice 1/4 x 6Main bus

1/4 x 6 Riser

1/4 x 6 Filler 1/4 x 6

Bus splice (2) 1/4 x 6Main bus

1/4 x 6 Riser (2) 1/4 x 6 Filler (2) 1/4 x 6 Filler 1/4 x 6

Bus splice (2) 1/4 x 6Main bus

(2) 1/4 x 6 Riser

(3) 3/8 x 6 Filler 1/4 x 6

Bus splice (2) 3/8 x 6Main bus

1/4 x 6 Filler 1/4 x 6

Bus splice (2) 3/8 x 6Main bus

1/4 x 6 Filler 1/4 x 6 Bus splice (2) 3/8 x 6 Main bus (3) 3/8 x 6 Riser (2) 1/4 x 6Riser 1/8 x 6 Bus splice (2) 1/4 x 6 Riser (2) 3/8 x 6 Filler

3000 A Main Bus 3000 A Main Bus

1200 A Riser 1200 A Riser (2) 3/8 x 6 Main bus (2) 3/8 x 6 Main bus 1200 A Riser 1200 A Riser 1/4 x 6 Bus splice 1/4 x 6 Bus splice 1/4 x 6 Riser (2) 3/8 x 6 Filler 3/8 x 6 Filler 1/8 x 6 Filler 1/4 x 6 Riser (2) 3/8 x 6 Riser

Typical Standard Bay 3000 A Main Bus

3000 A Riser

Typical Standard Bay 2000 A Main Bus

2000 A Riser

Typical Standard Bay 1200 A Main Bus

1200 A Riser

1/2-13 Hardware with typical Belleville washers Riser bus

and filler Main bus

Bus splice

1/2-13 Hardware with typical Belleville washers Riser bus

and filler Main bus

Bus splice

1/2-13 Hardware with typical Belleville washers Riser bus

and filler Main bus

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Bus Bar Installation

Follow the instructions in this section to install bus bars.

1. Remove the main bus covers. Figure 14 shows a bus compartment with the cover removed.

2. Install one phase at a time by sliding the horizontal bus bars through the glass polyester pass-throughs. There is one pass-through per section installed on the right wall (see Figure 15).

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E and CSA Z462.

• Turn off all power supplying this equipment before working on it. • Before performing maintenance on this device, disconnect all sources

of electric power. Assume all circuits are live until they are completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power. Check interconnection diagrams and make sure there are no backfeed potential sources.

• Always use a properly rated voltage sensing device to confirm that power is off.

Failure to follow this instruction will result in death or serious injury.

Figure 14: Bus Compartment with Bus Cover Removed

Figure 15: Glass Polyester Pass-through

Riser bus bars

Glass polyester pass-through

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3. Loosely bolt the horizontal bus to the vertical bus.

NOTE: Do not bend or force the bus bars to make this connection. The

through bushings and the divided insulating barrier may be loosened if necessary. They have sufficient clearance and adjustment to allow for minor field misalignment of shipping sections.

4. Tighten the bolts connecting the bus joints only after all three horizontal bus bars are in place and properly aligned. Using a torque wrench, tighten bolts for bus bar connections in accordance with Table 2. 5. Install supplied boots on busbar joints. Close the boot joint with supplied

tie-wrap. Reinstall main bus cover.

Circuit Breaker Installation

This section describes the installation of the circuit breaker.

The door handle (Figure 16) is the key to opening and closing the circuit breaker door. The door handle has three positions (described below): OPEN, READY-TO-CLOSE, and LATCH.

OPEN

— Position where the door handle can be used to open the door. Rotate the handle towards the OPEN position then pull to open the door. When the handle is released after opening the door, it will automatically go to the READY-TO-CLOSE position.

READY-TO-CLOSE

— Position of the handle used to close the circuit breaker door. When closed, the door will remain closed but the latching feature is not active. In the READY-TO-CLOSE position, the arc resistant feature of the breaker door is not active.

LATCH

— Position of the handle in normal operation of the switchgear. The door is closed and latched. In the LATCH position, the arc resistant feature is active. The handle can be padlocked in the LATCH position.

Table 2: Bolt Torque Bolt Size Mechanical Joints Bus Bar Connections 1/4–20 4–7 lb-ft (5.42– 9.50 N•m) — 5/16–18 11–15 lb-ft (14.90– 20.33 N•m) — 3/8–16 18–24 lb-ft (24.40– 32.54 N•m) 30–40 lb-ft (40.67– 54.23 N•m) 1/2–13 32–44 lb-ft (43.38– 59.65 N•m) 47–62 lb-ft (63.72– 84.00 N•m)

WARNING

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E and CSA Z462.

• Only qualified personnel familiar with medium voltage circuits and equipment should operate this equipment.

• Check the customer order drawings and nameplates on the circuit breaker compartment to verify that the circuit breaker is installed into the proper circuit breaker compartment.

Failure to follow these instructions can result in death or serious injury.

Figure 16: Door Handle Positions

OPEN

READY-TO-CLOSE LATCH

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Installing the Circuit Breaker into the TEST/DISCONNECT Position

1. Check the customer order drawings and the nameplates on the circuit breaker compartment to verify that the circuit breaker is installed into the proper circuit breaker compartment.

2. Verify that the racking position indicator (Figure 18 on page 24) reads “TEST/DISCONNECT.”

3. To open the circuit breaker compartment door:

a. Remove the padlock (if installed) from the door handle. b. Rotate the door handle to the OPEN position then pull to open

the door.

c. Release the door handle; it will automatically move to the READY-TO-CLOSE position.

Use the supplied ramp or lift truck (as shown in Figure 17) to insert the circuit breaker into the circuit breaker compartment. (A lift truck must be used to insert the circuit breaker into switchgear on a raised pad.) For instructions on using a lift truck, refer to “Using the Lift Truck” starting on page 39.

4. Align the rollers on each side of the circuit breaker with the positioning rails (Figure 18) mounted on the side walls of the circuit

breaker compartment.

Figure 17: Inserting Circuit Breaker with a Lift Truck

WARNING

HAZARD OF PERSONAL INJURY

A lift truck supplied by the manufacturer must be used to install a circuit breaker into switchgear on a raised pad.

Failure to follow this instruction can result in death or serious injury.

Figure 18: Masterclad Switchgear Circuit Breaker Compartment

Racking position indicator

Lift truck catch pins

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5. Push the circuit breaker into the compartment until the front of the circuit breaker lines up with the test position arrows (Figure 19 on page 25) located on top of the left positioning rail. When the circuit breaker is in the TEST/DISCONNECT position, the release handle should engage.

NOTE: If the circuit breaker does not easily roll into the circuit breaker

compartment, remove the circuit breaker. If necessary, pull the release handle to release the circuit breaker from the TEST/DISCONNECT position. Repeat process. If satisfactory results are not achieved, contact Schneider Electric.

Testing the Circuit Breaker in the TEST/DISCONNECT Position

The circuit breaker secondary disconnect (male, Figure 20) connects to the circuit breaker compartment secondary disconnect (female) located on the floor of the circuit breaker compartment. This provides a convenient method for electrically testing the operation of the circuit breaker mechanism.

1. Rotate the secondary disconnect handle (Figure 21 on page 26), located on the floor of the circuit breaker compartment, upward 90°.

2. Pull the secondary disconnect handle out until the circuit breaker compartment secondary disconnect (female, Figure 21 on page 26) engages the circuit breaker secondary disconnect.

WARNING

HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE

Never force the circuit breaker into the circuit breaker compartment. If a mechanism is not operating easily, inspect the equipment and remove any foreign objects or debris.

Failure to follow this instruction can result in death or serious injury.

Figure 19: Test and Connected Position Arrows

Connected position arrow

Test position arrow

Figure 20: Circuit Breaker Secondary Disconnect (Male)

Circuit breaker secondary disconnect

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NOTE: The control circuit of the circuit breaker is now connected to control

power. If the control circuit is energized, this connection immediately activates the spring charging motor inside the circuit breaker.

3. Push the CLOSE (I) pushbutton. If the spring charging motor was correctly activated by the control circuit, the CLOSE (I) pushbutton should release the closing latch, allowing the closing spring assembly to discharge. The closing spring assembly pushes down on the crossbar, that is connected to the vacuum interrupters, and closes the vacuum interrupter contacts.

4. Push the OPEN (O) push button. If the opening spring assembly was correctly charged (compressed) by the closing operation, the

mechanism will release the opening latch and allow the opening spring assembly to discharge. The opening spring assembly pulls up on the crossbar connected to the vacuum interrupters and opens the vacuum interrupter contacts.

Racking the Circuit Breaker into the CONNECTED Position

1. Make sure the circuit breaker is OPEN (O).

NOTE: The circuit breaker must be in the OPEN (O) position when it is

racked into or out of its circuit breaker compartment. Interlocks will not allow the racking shaft to rotate if the circuit breaker is not OPEN (O). 2. Close the circuit breaker compartment door.

a. Make sure the door handle is in the READY-TO-CLOSE position when closing the door. The door will stay closed, but the arc resistant feature will not be active.

b. When the door is closed, rotate the door handle towards the LATCH position. This will latch the door in the closed position, making the circuit breaker compartment ready for normal operation.

c. The door handle can be padlocked in the LATCH position. 3. Remove the padlock, if installed, from the racking port located at the

bottom of the circuit breaker door (Figure 22 on page 27).

4. Open the racking port, insert the provided racking handle into the port,

Figure 21: Secondary Disconnect Handle and Connector

Circuit breaker compartment secondary disconnect (female) Secondary disconnect handle

WARNING

HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE

• Always keep circuit breaker compartment door closed when racking the circuit breaker from one position to another when the switchgear is energized.

• Beware of potential hazards, wear personal protective equipment, and take adequate safety precautions.

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5. Rotate the racking handle clockwise.

6. When the circuit breaker is being transported to or from the CONNECTED position, the racking position indicator will read TRANSPORT.

NOTE: When the racking position indicator reads “CONNECTED,” the

circuit breaker is fully racked into the circuit breaker compartment and the circuit breaker’s primary contacts are connected.

7. Continue rotating the racking handle clockwise until the racking position indicator reads “CONNECTED.”

Circuit Breaker Removal

This section describes the removal of the circuit breaker.

Racking the Circuit Breaker Out of the CONNECTED Position

1. Make sure the circuit breaker is OPEN (O).

2. Insert the racking handle into the racking port and engage the racking handle onto the racking shaft (Figure 22 on page 27).

NOTE: If the circuit breaker does not easily rack out of the circuit breaker

compartment, reconnect the circuit breaker and repeat this process. If satisfactory results are not achieved, contact Schneider Electric.

WARNING

HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE

Never force the circuit breaker into or out of the circuit breaker compartment. If a mechanism is not operating easily, inspect the equipment and remove any foreign objects or debris.

Failure to follow this instruction can result in death or serious injury.

Figure 22: Racking Handle Engaged onto Racking Shaft with Circuit Breaker in the TEST/DISCONNECT Position

Padlockable racking port

Racking handle

WARNING

HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE

• Always keep circuit breaker compartment door closed when racking the circuit breaker from one position to another when the switchgear is energized.

• Beware of potential hazards, wear personal protective equipment and take adequate safety precautions.

Failure to follow these instructions can result in death or serious injury.

WARNING

HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE

Never force the circuit breaker into or out of the circuit breaker compartment. If a mechanism is not operating easily, inspect the equipment and remove any foreign objects or debris.

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3. Rotate the racking handle counterclockwise. When the circuit breaker is being transported to or from the CONNECTED position, the racking position indicator will read TRANSPORT.

NOTE: When the circuit breaker is moved from the CONNECTED

position to the TEST/DISCONNECT position, the auxiliary contacts are disconnected.

4. Continue rotating the racking handle until the racking position indicator reads TEST/DISCONNECT. Another half-turn is required—a stop is felt when the racking handle reaches its final position—to unlock the door. Removing the Circuit Breaker from the Circuit

Breaker Compartment

1. Open the circuit breaker compartment door.

a. To open the circuit breaker door, remove the padlock (if installed) from the door handle.

b. Rotate the door handle to the OPEN position then pull to open the door.

c. Release the door handle and it will automatically move to the READY-TO-CLOSE position.

2. Use the supplied ramp or lift truck as shown in Figure 23 on page 28 to remove the circuit breaker from the circuit breaker compartment. (A lift truck must be used to remove the circuit breaker from switchgear on a raised pad.) For instructions on using a lift truck, see “Using the Lift Truck” starting on page 39.

3. Pull the release handle to release the circuit breaker from the

TEST/DISCONNECT position. The circuit breaker will trip if it is closed. 4. Pull the circuit breaker out of the circuit breaker compartment.

NOTE: When the circuit breaker is removed, you will hear a loud noise

as the spring discharges.

Figure 23: Removing the Circuit Breaker from the Compartment

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Locking Provisions

The following devices (Figure 24) can be locked with a padlock:

The racking mechanism located in the circuit breaker compartment floor.

The circuit breaker door handle.

The racking port.

Voltage Transformer Drawout

Unit Inspection

Inspect the voltage transformer (VT) drawout unit before energizing. Follow the steps below to perform the inspection.

Racking the Voltage Transformer Drawout Unit Out of the CONNECTED Position

1. With the VT compartment door closed, insert the racking handle into the racking port and engage the handle onto the racking shaft (see Figure 25 on page 29).

2. Rotate the racking handle counterclockwise.

NOTE: If the voltage transformer drawout unit does not easily rack out of

the CONNECTED position, contact Schneider Electric.

3. Verify that the grounding contact tabs, extending from the ground bar at the top on the voltage transformer (VT) drawout compartment, touch the fuse ground tabs on the VT drawout unit as it moves from the

CONNECTED position to the DISCONNECTED position. The tabs can be seen through the viewing window in the VT compartment door. 4. Continue rotating the racking handle counterclockwise until the VT

drawout unit is fully racked to the DISCONNECTED position.

Figure 24: Devices That Can Be Padlocked

Racking Mechanism Breaker Door Handle Racking Port

WARNING

HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE

Never force the primary fuse drawout unit into or out of the primary fuse drawout unit compartment. If the racking mechanism is not operating easily, inspect the equipment and remove any foreign objects or debris or contact Schneider Electric.

Failure to follow this instruction can result in death or serious injury. Figure 25: Racking Handle Engaged onto

Racking Shaft

Locking port

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Inspecting the Fuses Open the VT drawout compartment door to visually inspect fuses for

possible damage. Replace the fuses if necessary. See “Replacing the Fuses” starting on page 38.

Racking the VT Drawout Unit into the CONNECTED Position

After inspecting the VT drawout unit, follow the steps below to rack it to the CONNECTED position.

1. Close the VT drawout unit compartment door.

2. Insert the racking handle into the racking port and engage the handle onto the racking shaft.

3. Rotate the racking handle clockwise until VT drawout unit is fully racked to the CONNECTED position.

NOTE: If the voltage transformer drawout unit does not easily rack into

the CONNECTED position, rack the unit to the DISCONNECT position, and remove any objects or debris from the compartment. Repeat this process. If results are not satisfactory, contact Schneider Electric.

Voltage Transformer Drawer

Figure 26 shows the voltage transformer (VT) drawer connected to the

load bus.

Figure 26: VT Drawer Compartment

VT Compartment Main Bus Compartment

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This is a racking-through-the-door type compartment with interlocks (see Figure 27). The racking port can be padlocked.

Voltage Transformer Drawer Interlocks The racking mechanism is not accessible if the door is not closed and

latched (Figure 28).

NOTE: The latching system is intended to be arc resistant. The auxiliary

door must be latched to activate the arc resistant feature. The door cannot be opened if:

The drawer is out of the DISCONNECTED position.

The racking handle is inserted in the racking port (Figure 28).

— The racking mechanism uses the same racking handle as the racking mechanism for the circuit breaker compartment.

Figure 27: VT Drawer Door Latched

Indicator viewing window Auxiliary viewing window Door handle

(latched position)

Figure 28: VT Racking Handle Inserted

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Voltage Transformer Drawer Characteristics The primary contacts and fuses are viewable through a window in the

voltage transformer (VT) drawer door. When the VT drawer is in the DISCONNECTED position, the primary contacts are viewable but not accessible. A fuse discharge bar (Figure 29) is located in the front portion of the compartment and is intended to return to ground any remaining voltage that could be accumulated in the voltage transformers.

Voltage Transformer Drawer Wiring The secondary contacts of the VT are linked to the control box through

secondary contacts located underneath the tray of the VT drawer (see Figure 30).

High-Potential Testing

Before making external power connections, perform a high-potential (hi-pot)

dielectric withstand test on the bus and circuit breakers as an assembly.

Test Preparation 1. Disconnect lightning arresters.

2. Withdraw the voltage transformer drawer (if provided). 3. Place each of the circuit breakers in its proper circuit breaker

compartment in the connected position. Charge their springs manually, and then close each circuit breaker by using the CLOSE (I) push button.

Figure 29: Voltage Transformer Drawer in Withdrawn Position

Fuse discharge bar

Figure 30: Voltage Transformer Wiring

VT secondary connection

Microswitches (not shown)

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Phase-to-Ground Test 1. Perform a phase-to-ground hi-pot test on the main bus.

a. Gradually increase the voltage to the levels shown in Table 3. b. Verify that the equipment sustains the specified voltage without

flashover for one minute.

2. Turn off the test equipment. Discharge the phase bus to ground before removing the test cables.

Use a reliable transformer-type tester with a built-in voltmeter and milliamp meter for hi-pot testing. Capacitor loaded bench-type testers with neon bulb indicators do not have sufficient capacity to give reliable results. Refer to Table 3 for the nominal test values for dry, clean, new assemblies. Field hi-pot tests are made at 75% of factory test voltages in accordance with ANSI standards.

If satisfactory results are not obtained, locate the problem, correct it, and rerun the test before proceeding. If results are acceptable, the power cables, ground wires, external wiring, and battery (if supplied) can be connected to the assembly. If results are not acceptable, contact your local Schneider Electric representative.

Phasing

In accordance with NEMA standards, all bus within the switchgear is phased

A-B-C left to right, top to bottom, and front to back when viewing the assembly from the front (the circuit breaker compartment side). If, for any reason, the bus must be phased differently, the different phases will be identified on the bus with a label.

Cable Connections

Be very careful when making cable terminations, as terminations are critical

to the successful operation of the electrical distribution system. Avoid sharp turns, edges, or corners to prevent damage to the cable insulation. Follow the cable manufacturer’s recommendations for minimum bending radius. These instructions will vary, depending on the manufacturer.

Solderless or compression-type cable lugs are the most common method for connecting power cables to metal-clad switchgear. When making the terminations for each type of power cable, follow the cable manufacturer’s instructions. After the cable connections are made, insulate them as follows.

Insulating the Cable Connections Insulating putty and tape (provided by customer) or other insulating means

may be used to insulate the power cable connections.

1. Place insulating putty, such as 3M® brand Scotchfil, around the lugs and

bolts to reduce the concentrated field created by their irregular shapes

(Figure 31 on page 34). Apply a layer of Scotch® brand No. 13 (or

equivalent) semiconducting tape over the insulating putty. Half-lap the tape, which must extend onto the conductor. Do not extend the tape up over the bus epoxy insulation. Apply Scotch No. 130C (or equivalent) tape over the No. 13 tape. Half-lap this tape for two layers on 5 kV installations and four layers on 15 kV installations. For 5 kV installations,

Table 3: One Minute Hi-Potential Test1

1 AC voltages are 60 Hz rms symmetrical.

Assembly Rated Maximum Voltage

Factory Test Voltage (AC)

Field Test Voltage

AC DC

5 kV 19 kV 14 kV 20 kV

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extend the tape 1-1/2 in. (38 mm) up over the bus insulation and cable insulation. For 15 kV installations, extend the tape 2 in. (51 mm). 2. Apply two layers of Scotch Brand No. 22 tape (or equivalent), extending

the tape up over the No. 130C tape in all directions. The tape and other insulating materials for completing these field connections are not supplied with the switchgear.

3. If potheads or cable terminators are supplied for terminating power cables, follow the pothead manufacturer’s instructions for terminating the cables in these devices. To facilitate installation of the power cables, the bus side is not taped. After the cables are installed, insulate the pothead-to-bus connections according to the cable lug insulation instructions in this section.

Figure 31: Power Cable Connection Insulation

Fill voids with Scotchfil Putty Layer Scotch No. 13 semi-conductor tape Scotch No. 130C tape:

2 layers for 5 kV 4 layers for 15 kV

Lugs

Scotch No.22 2 layers

NOTE: All taping is half-lapped

0.5 in. (13 mm) Scotch No.22 tape Overlap Scotch No. 130C tape over cable insulation by:

1.5 in. (38 mm) for 5 kV 2 in. (51 mm) for 15 kV

Note: Scotch No. 13 semi-conductor tape must touch bus or terminals in at least one place; tape should not overlap bus or cable insulation

Bus

0.5 in. (13 mm) Scotch No.22 tape

Overlap Scotch No. 130C tape over cable insulation by:

1.5 in. (38 mm) for 5 kV 2 in. (51 mm) for 15 kV

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Operation

The section contains instructions for operating the Masterclad arc resistant metal-clad indoor switchgear unit.

Start-Up

Training of personnel for final start-up is available. Contact your local Schneider Electric representative for more information.

Preliminary Start-Up Procedures 1. Turn off all main and control power supplying the equipment.

2. Vacuum every compartment. Remove all loose parts, tools, miscellaneous construction items, and litter.

3. Verify that all insulating boots are installed.

4. Replace all of the main bus covers and any other barriers or covers that were removed during installation.

5. Install the cable compartment back covers.

6. Connect the battery charger and batteries (if used) to the switchgear control bus according to the order drawings.

7. Unblock all of the relays and set to the relay schedule. Using a relay tester, verify the settings and electrical operation of each relay. 8. Verify that any control power transformer used has the current limiting

fuses in place. Pull the drawer out to the withdrawn position.

9. Check that the pressure relief flaps (Figure 7 on page 13) are closed and free of obstructions.

Installing and Testing Circuit Breakers in the TEST/DISCONNECT Position

Follow the steps for installing and testing the circuit breaker in the TEST/DISCONNECT position outlined in “Installing the Circuit Breaker into the TEST/DISCONNECT Position” on page 24.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

• Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E and CSA Z462.

• All personnel involved in the start-up operation should be thoroughly familiar with the information in this instruction bulletin and customer drawings provided before working on this equipment.

• Turn off all power supplying this equipment before working on it. • Before performing maintenance on this device, disconnect all sources

of electric power. Assume all circuits are live until they are completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power. Check interconnection diagrams and make sure there are no backfeed potential sources.

• Always use a properly rated voltage sensing device to confirm that power is off.

Failure to follow these instructions will result in death or serious injury.

References

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