Instruction Bulletin Boletín de instrucciones Directives d'utilisation /2012

Transcripción

1 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Tablero de fuerza Masterclad para interiores con revestimiendo metálico y resistencia al arco de 5 15 kv Appareillage de commutation blindé Masterclad mc de 5 à 15 kv, résistant aux arcs, pour installation à l intérieur Instruction Bulletin Boletín de instrucciones Directives d'utilisation /2012 Retain for Future Use. / Conservar para uso futuro. / À conserver pour usage ultérieur.

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3 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Class 6055 ENGLISH Instruction Bulletin /2012 Retain for future use.

4 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. 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 safety alert symbol is not used with this signal word. Please Note NOTE: Provides additional information to clarify or simplify a procedure. 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.

5 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Table of Contents 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 Primary Contacts Current Transformer Ground Contact Bar Mechanism Operated Contacts (Optional) Truck Operated Contacts (Optional) Interlocks Voltage Transformer and Control Power Transformers Fuse Drawout Units Main Bus Compartment Cable Compartment Surge Arresters Safety Precautions Receiving, Handling, and Storage Receiving Handling Storage Site Selection and Preparation Foundation Conduit Location Installation Switchgear Installation Pre-Installation Procedures Installation Main Bus Installation Bus Bar Installation Circuit Breaker Installation 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 Circuit Breaker Removal Racking the Circuit Breaker Out of the CONNECTED Position Removing the Circuit Breaker from the Circuit Breaker Compartment 28 Locking Provisions Voltage Transformer Drawout Unit Inspection Racking the Voltage Transformer Drawout Unit Out of the CONNECTED Position Inspecting the Fuses Racking the VT Drawout Unit into the CONNECTED Position Voltage Transformer Drawer Voltage Transformer Drawer Interlocks Voltage Transformer Drawer Characteristics Voltage Transformer Drawer Wiring High-Potential Testing Test Preparation Phase-to-Phase Test Phase-to-Ground Test Phasing Cable Connections ENGLISH Schneider Electric All Rights Reserved 3

6 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Table of Contents 06/2012 ENGLISH Insulating the Cable Connections Operation...35 Start-Up...35 Preliminary Start-Up Procedures Installing and Testing Circuit Breakers in the TEST/DISCONNECT Position 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 Arc Shield Assembly...45 Installing the Arc Shield Assembly Configuration Drawings...48 Installation and Maintenance Log Schneider Electric All Rights Reserved

7 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 List of Figures 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 Figure 5: Truck Operated Contacts Figure 6: Drawout Voltage Transformer Figure 7: Bus Compartment Figure 8: Lifting Sling Figure 9: Typical Floor Plan (Not for Construction) Figure 10: Section Bolting Details Figure 11: Typical Main Bus Assembly (1200 A shown) Figure 12: Main Bus Connections, Side View Figure 13: Main Bus Connections, Top View Figure 14: Bus Compartment with Bus Cover Removed Figure 15: Glass Polyester Pass-through Figure 16: Door Handle Positions Figure 17: Inserting Circuit Breaker with a Lift Truck Figure 18: Masterclad Switchgear Circuit Breaker Compartment Figure 19: Test and Connected Position Arrows Figure 20: Circuit Breaker Secondary Disconnect (Male) Figure 21: Secondary Disconnect Handle and Connector Figure 22: Racking Handle Engaged onto Racking Shaft with Circuit Breaker in the TEST/DISCONNECT Position Figure 23: Removing the Circuit Breaker from the Compartment Figure 24: Devices That Can Be Padlocked Figure 25: Racking Handle Engaged onto Racking Shaft Figure 26: VT Drawer Compartment Figure 27: VT Drawer Door Latched Figure 28: VT Racking Handle Inserted Figure 29: Voltage Transformer Drawer in Withdrawn Position Figure 30: Voltage Transformer Wiring Figure 31: Power Cable Connection Insulation Figure 32: Typical Lift Truck Figure 33: Wall-Mounted Test Cabinet (Optional) Figure 34: Typical Indoor Plenum Application Figure 35: Plenum Assemblies Figure 36: Prepared Roof Detail Plenum (Lefthand and Righthand End Bays) Figure 37: Plenum Installation Detail Figure 38: Typical Arc Shield Application Figure 39: Arc Shield Assemblies Figure 40: Prepared Roof Detail Arc Shield (Lefthand and Righthand End Bays) Figure 41: Arc Shield Installation Detail Figure 42: Masterclad Arc Resistant Metal-Clad Indoor Switchgear Configurations ENGLISH Schneider Electric All Rights Reserved 5

8 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear List of Tables 06/2012 ENGLISH List of Tables Table 1: Approximate Switchgear and Component Weights Table 2: Bolt Torque Table 3: One Minute Hi-Potential Test Table 4: Minimum Required Ceiling Height from Floor Schneider Electric All Rights Reserved

9 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Introduction 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 and 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. ENGLISH Figure 1: Masterclad Indoor Arc Resistant Switchgear with Type VR Drawout Circuit Breaker Schneider Electric All Rights Reserved 7

10 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 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. Figure 2: Typical Front Section Schneider Electric All Rights Reserved

11 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Introduction Circuit Breaker Compartment Figure 3: Circuit Breaker Compartment The circuit breaker compartment contains separate, but coordinated, features (Figure 3). ENGLISH Shutter actuator Racking arm Circuit breaker positioning rails Position latch brackets Ground bar Racking block lever Primary bushing assemblies (shutters open) Primary high voltage contacts Racking position indicator Ground & test/removable shorting device interlock Secondary disconnect handle Secondary disconnect receptacle Racking mechanism Compartment rating interlock Racking block bar (welded to racking shaft) Racking shaft Racking mechanism lockout provision (key interlock and padlock) Circuit Breaker Positioning Rails Racking Mechanism Secondary Disconnect Receptacle 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. 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. 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 Schneider Electric All Rights Reserved 9

12 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Introduction 06/2012 access the secondary disconnect handle. The door can be closed after the receptacle is connected to the breaker. ENGLISH 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 Current Transformer Ground Contact Bar Mechanism Operated Contacts (Optional) 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. Front-accessible, window-type, 600 V rated single- or multi-ratio current transformers are located around either the line or load primary voltageinsulated bushings. A maximum of two current transformers, depending on accuracy, can be mounted per phase two on the line, and two on the load. 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 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 Truck Operated Contacts (Optional) The truck operated contacts (Figure 5 on page 11) indicate whether the circuit breaker is in the CONNECTED or TEST/DISCONNECT position in the circuit breaker compartment Schneider Electric All Rights Reserved

13 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Introduction 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. ENGLISH Figure 5: Truck Operated Contacts Contact actuator Interlocks 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. 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 Schneider Electric All Rights Reserved 11

14 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Introduction 06/2012 ENGLISH 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. Figure 6: Primary fuses Drawout Voltage Transformer 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 Schneider Electric All Rights Reserved

15 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Introduction 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. Figure 7: Bus Compartment ENGLISH Pressure relief flaps Main bus compartment Pressure relief flaps Entry to main bus compartment Main bus access plates Circuit breaker compartments Cable 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 Schneider Electric All Rights Reserved 13

16 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Introduction 06/2012 ENGLISH 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 Schneider Electric All Rights Reserved

17 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Safety Precautions 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. ENGLISH Failure to follow these instructions will result in death or serious injury Schneider Electric All Rights Reserved 15

18 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Receiving, Handling, and Storage 06/2012 ENGLISH Receiving, Handling, and Storage Receiving 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. 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 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. 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. Figure 8: Lifting Sling Interior angle Safety hooks Lifting eyes Equipment top 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 Schneider Electric All Rights Reserved

19 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Receiving, Handling, and Storage Storage 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. ENGLISH Site Selection and Preparation Failure to follow this instruction can result in death or serious injury. 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. 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) 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 Schneider Electric All Rights Reserved 17

20 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Receiving, Handling, and Storage 06/2012 ENGLISH 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. Figure 9: Typical Floor Plan (Not for Construction) 72.0 (1829) Front Aisle 1.0 (25) 1.0 (25) 5.8 (146) 6.5 (165) 47.6 (1209) 1.5 (38) 4.5 (114) 94.0 (2388) 5.1 (130) 44.4 (1128) 3.0 (76) 1.0 (25) 6.9 (175) 36.0 (914) Rear Aisle 1.0 (25) Front 34.0 (864) 2.0 (51) 2.0 (51) Control conduit area (bottom) 27.0 (686) 25.8 (654) 10.0 (254) (406) (864) 10.0 (254) Rear 1.0 (25) 0.5 (12) door 5.8 (146) 6.5 (165) 1.5 (38) 4.5 (114) 5.1 (130) 9.0 (229) 6.1 (155) Six 0.50 in. (12.7 mm) diameter mounting holes 1.0 (25) Top or bottom conduit area Bottom conduit area 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 Schneider Electric All Rights Reserved

21 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Installation Installation Switchgear Installation Pre-Installation Procedures This section contains instructions for installing the Masterclad arc resistant metal-clad indoor switchgear assembly. This section contains instructions for installing the switchgear. 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. ENGLISH 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) Schneider Electric All Rights Reserved 19

22 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Installation 06/2012 NOTE: All shipping sections must be bolted together in place before bolting them to the channel sills or installing the horizontal main bus. ENGLISH 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) End Right Standard End Left A Front Rear B C Side View 1200 A Rear View Bus Covers Removed Schneider Electric All Rights Reserved

23 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Installation Figure 12: Main Bus Connections, Side View 1/4 x 6 Bus splice 1/4 x 6 Filler 1/4 x 6 Main bus 1/4 x 6 Bus splice 1/4 x 6 Filler (2) 1/4 x 6 Main bus 1/4 x 6 Bus splice (2) 1/4 x 6 Riser (2) 1/4 x 6 Filler (2) 1/4 x 6 Main bus 1/4 x 6 Bus splice (3) 3/8 x 6 Riser (3) 3/8 x 6 Filler (2) 3/8 x 6 Main bus 1/4 x 6 Bus splice (2) 1/4 x 6 Riser 1/4 x 6 Riser 1/4 x 6 (2) 1/4 x 6 1/8 x 6 Riser Filler Bus splice 1200 A Riser 1200 A Riser 2000 A Riser 3000 A Riser 2000 A Riser 1200 A Riser 1200 A Main 2000 A Main 2000 A Main Bus 3000 A Main 3000 A Main Bus 3000 A Main Bus 1/4 x 6 Filler (2) 3/8 x 6 Main bus 1/4 x 6 Filler 1/4 x 6 Bus splice (2) 1/4 x 6 Riser (2) 3/8 x A Riser 1200 A Riser Filler 3000 A Main Bus 3000 A Main Bus (2) 3/8 x 6 Main bus (2) 3/8 x 6 1/4 x 6 Bus splice (2) 3/8 x A Riser Main bus 1200 A Riser Main bus 1/4 x 6 Bus splice 1/4 x 6 Riser 1/8 x 6 1/4 x 6 (2) 3/8 x 6 Riser Filler Riser 3/8 x 6 Filler (2) 3/8 x 6 Filler ENGLISH Figure 13: Main Bus Connections, Top View 1/2-13 Hardware with typical Belleville washers Riser bus Main bus and filler 1/2-13 Hardware with typical Belleville washers Riser bus Main bus and filler 1/2-13 Hardware with typical Belleville washers Riser bus Main bus and filler Bus splice Bus splice Bus splice 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 Schneider Electric All Rights Reserved 21

24 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Installation 06/2012 Bus Bar Installation Follow the instructions in this section to install bus bars. ENGLISH 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. 1. Remove the main bus covers. Figure 14 shows a bus compartment with the cover removed. Figure 14: Bus Compartment with Bus Cover Removed Riser bus bars 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). Figure 15: Glass Polyester Pass-through Glass polyester pass-through Schneider Electric All Rights Reserved

25 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Installation Table 2: Bolt Size 1/4 20 5/ /8 16 1/2 13 Bolt Torque Mechanical Joints 4 7 lb-ft ( N m) lb-ft ( N m) lb-ft ( N m) lb-ft ( N m) Bus Bar Connections lb-ft ( N m) lb-ft ( N m) 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 Install supplied boots on busbar joints. Close the boot joint with supplied tie-wrap. Reinstall main bus cover. ENGLISH Circuit Breaker Installation This section describes the installation of the circuit breaker. 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 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 READY-TO-CLOSE 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 Schneider Electric All Rights Reserved 23

26 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Installation 06/2012 ENGLISH Installing the Circuit Breaker into the TEST/DISCONNECT Position Figure 17: Inserting Circuit Breaker with a Lift Truck 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. 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. 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 18: Masterclad Switchgear Circuit Breaker Compartment Racking position indicator Positioning rail Lift truck catch pins Schneider Electric All Rights Reserved

27 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear 06/2012 Installation 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. ENGLISH Failure to follow this instruction can result in death or serious injury. 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. Figure 19: Test and Connected Position Arrows Connected position arrow Test position arrow 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. Figure 20: Circuit Breaker Secondary Disconnect (Male) Circuit breaker secondary disconnect 1. Rotate the secondary disconnect handle (Figure 21 on page 26), located on the floor of the circuit breaker compartment, upward 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 Schneider Electric All Rights Reserved 25

28 Masterclad 5 15 kv Arc Resistant Metal-Clad Indoor Switchgear Installation 06/2012 ENGLISH 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. Figure 21: Secondary Disconnect Handle and Connector Circuit breaker compartment secondary disconnect (female) Secondary disconnect handle 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 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. 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, and engage the handle onto the racking shaft (Figure 22 on page 27). NOTE: If the circuit breaker does not easily rack into the circuit breaker compartment, remove the circuit breaker and contact your local Schneider Electric representative Schneider Electric All Rights Reserved