HVL/cc Medium Voltage, Metal-Enclosed Switchgear 2.4 to 38 kV, 60 to 150 kV BIL, 25 kA Short-time, Indoor or Outdoor – Instruction Bulletin PDF
6045–1

Installation

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
  • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462.
  • Turn off the power supply to the switchgear.
  • Turn off the switchgear before removing or installing fuses or making load-side connections.
  • Always use a properly rated voltage sensing device at all line and load-side fuse clips to confirm that the switchgear is off.
  • Never operate the switchgear with the access panels open.
Failure to follow these instructions will result in death or serious injury.

This chapter contains instructions for the installation of the equipment. Perform the installation in the following sequence:

  1. Site Preparation

  2. Switch Operation

  3. Access Panel Removal

  4. Field Assembly

  5. Cable Connections

  6. Fuse Inspection/Fuse Replacement (if necessary)

  7. Hi-pot Testing

Site Preparation

Good site preparation is necessary to avoid installation problems and help ensure proper switchgear operation. Compare the site plans and specifications with the switchgear drawings to be sure there are no discrepancies. Check the site to ensure that the equipment fits properly (see Approximate Dimensions and Weights 2.4–15 kV-Indoor, Approximate Dimensions and Weights 2.4–15 kV-Outdoor, and Approximate Dimensions and Weights 25.8–38 kV-Indoor).

The floor must be flat and level within 1/16 in. per ft. (2 mm per 305 mm), or a maximum of 1/4 in. (6 mm) within the area of the switchgear, to help prevent distortion of the enclosures.

The equipment is available with front-access only as an option.

Schneider Electric recommends placing the rear of indoor equipment a minimum of 4–6 in. from the wall. Allow five ft. (1,524 mm) of clearance on the front. However, minimum clearances must meet all local and national requirements.

On outdoor switchgear, five ft. of clearance (on the front and back only) is recommended.

Provide area ventilation at all times to maintain the ambient temperature around the equipment between 32° F and 104 °F (0 °C and 40 °C) (see Preventive Maintenance).

Adequate lighting and convenience outlets must be available near the switchgear. Route sewer, water, and steam lines away from the equipment. Provide floor drains to minimize water buildup.

Operating the Switches

Switches are shipped in the closed position. Switches must be opened or grounded (if equipped) to gain access into the load-side compartment (see Operating the Ground Switch (if equipped), Switchgear Operation (OTM), and Switchgear Operation (SEM)and Switchgear Operation (SEM)). The position of the switch blades may be obvious from the position indicator on the mimic bus, however, always look through the viewing ports to verify the blades actual position. A flashlight is helpful.

NOTE: Never leave the operating handle in the switch port. The motor will not operate.

Operating the Ground Switch (if equipped)

To operate the ground switch (see Operating the Ground Switch (if equipped)).

Operating the Ground Switch (if equipped)

  1. To GROUND the switch, insert the mechanism handle into the ground port located on the front of the mechanism compartment cover.

  2. Rotate the handle clockwise, charging the ground mechanism spring, until the ground mechanism advances past over-toggle. Once the mechanism moves past over-toggle, the ground mechanism springs release their energy. This causes the switch blades to rotate at speeds independent of the user into the GROUNDED position.

  3. Remove the mechanism handle.

To UNGROUND the switch, follow the steps previously outlined in this section except rotate the handle counterclockwise.

Operating Switchgear Equipped With an OTM

To operate switches equipped with an OTM (see Switchgear Operation (OTM)).

Switchgear Operation (OTM)

  1. To OPEN (O) the switch, insert the mechanism handle into the switch operating port located on the front of the mechanism compartment cover.

  2. Rotate the handle counterclockwise, until the operating mechanism advances beyond over-toggle.

    NOTE: Rotating the handle charges the open/close springs of the operating mechanism. Once the mechanism moves beyond over-toggle, the operating mechanism springs release their energy. This causes the switch blades to rotate at speeds independent of the user into the OPEN position.

  3. Remove the mechanism handle.

To CLOSE (I) the switch, follow the steps previously outlined in this section except rotate the handle clockwise.

Operating Switchgear Equipped With an SEM

To operate switches equipped with an SEM (see Switchgear Operation (SEM)).

Switchgear Operation (SEM)

  1. Press the OPEN (O) push button. The operating mechanism springs release their energy, causing the switch blades to rotate into the OPEN position.

  2. CLOSE (I) the switch by inserting the mechanism handle into the spring charging port located on the front of the mechanism compartment cover.

  3. Rotate the handle clockwise to charge the open/close springs of the operating mechanism.

  4. Continue to rotate the handle until the spring charge indicator shows that the springs are fully charged. Both the open and close springs are now charged.

  5. Remove the mechanism handle.

  6. Press the CLOSE (I) push button. The operating mechanism springs release their energy, causing the switch blades to rotate into the CLOSE position (the opening springs remain charged).

Access Panel Removal

After the switch is placed in the OPEN or GROUNDED (if equipped) position, remove all appropriate access panels. Removal of these panels allows access to the necessary compartments to anchor and join shipping split frames, make bus and cable connections, install and/or remove fuses, and perform Hi-pot (dielectric) tests and pre-energization inspections.

Instructions for removing the load-side access panel are listed below. All other panels are bolted. The instrument compartment panel cannot be removed.

Removing the Load-side Access Panels

To remove the load-side access panels for Application A indoor or outdoor switchgear (see Removing the Load-side Access Panel-Application A):

Removing the Load-side Access Panel-Application A

  1. Verify that the switch is in the OPEN or GROUNDED (if equipped) position.

    NOTE: If the switchgear is equipped with a grounding switch, the switch must be in the GROUNDED position.

  2. Grasp the handle on the front of the access panel firmly and lift the access panel until the interlock tab clears the interlock slot.

  3. Tilt (pull) the panel out until it clears the front of the switchgear.

Follow the instructions listed below for removing the load-side access panels for Application B indoor or outdoor switchgear (see Removing the Load-side Access Panel-Application B):

Removing the Load-side Access Panel-Application B

  1. Verify that the switch is in the OPEN (O) or GROUNDED (if equipped) position.

    NOTE: If the switchgear is equipped with a grounding switch, then the switch must be in the GROUNDED position.

  2. Grasp both the top and bottom handles on the front of the load-side access panel.

    NOTE: Be sure to support the panel by grasping the TOP handle firmly.

  3. Pull the lower handle to release the latch retaining the access panel.

  4. While supporting the panel allow it to slide down gently.

  5. Pull out the panel to remove it.

Field Assembly

After proper site preparation, field assembly of shipping splits is required.

Field assembly includes:

  1. Anchoring and joining shipping split assemblies

  2. Bus connections

  3. Control wiring connections

CAUTION
improper bus alignment
Install the shipping split bus connectors only after the shipping sections are fastened in place and no additional movement will be made to the assembly.
Failure to follow these instructions can result in injury or equipment damage.

Anchoring and Joining the Shipping Split Frames

To join and anchor shipping split frames:

  1. Review the assembly drawings so that the switchgear sections are assembled in the correct order.

    NOTE: If the switchgear is to connect to an existing lineup, mount the connecting sections first.

  2. Locate and anchor the first shipping split.

    NOTE: Be sure to mount all shipping splits on the same plane and level to achieve proper connection.

Follow the instructions for anchoring indoor or outdoor shipping split units.

Indoor Shipping Splits

To anchor indoor shipping split frames to the floor, place the 3/8 in. anchoring bolts (supplied by customer) through the anchoring holes located in the flanges at the bottom of each enclosure (see Bolt Hole Locations for Indoor Enclosures).

Bolt Hole Locations for Indoor Enclosures

Outdoor Shipping Splits

  1. Remove the lifting angle assemblies. Retain the hardware and lifting angle assembly parts for future use. The angle is used for anchoring the shipping split. The flat plate is used as a rodent barrier.

  2. Rotate the angle and attach it to the side of the shipping split using the hardware retained in step 1.

  3. Anchor the enclosure to the foundation by placing the 3/4 in. anchoring bolts through the holes in the anchoring angles (see Anchoring Assemblies for Outdoor Enclosures).

    Anchoring Assemblies for Outdoor Enclosures

  4. Locate the next shipping split according to the assembly drawing.

  5. Level the shipping split and join it to the previously installed shipping split. Use 3/8-16, Grade 5 hardware to join shipping splits. Refer to Joining the Shipping Splits and Installing the End Panels for bolt hole locations.

    Joining the Shipping Splits and Installing the End Panels

  6. Anchor the shipping split.

    For indoor units, place the 3/8 in. anchoring bolts (supplied by customer) through the anchoring holes located in the flanges at the bottom of the enclosure (see Anchoring Subsequent Indoor Shipping Splits). See Torque Values.

    Anchoring Subsequent Indoor Shipping Splits

    For outdoor units, place 3/4 in. anchoring bolts through the holes located in the anchoring angles. Attach anchoring angles to the end units only of outdoor switchgear lineups (see Anchoring Subsequent Outdoor Shipping Sections). See Torque Values.

    Anchoring Subsequent Outdoor Shipping Sections

  7. Repeat steps 4 through 6 for each additional shipping split

  8. For outdoor units, rotate and reattach the flat plates (part of the lifting angle assembly) over the bolt holes left during removal of the lifting angle assemblies to help minimize rodent entry (see Anchoring Assemblies for Outdoor Enclosures).

Bus Connections

To make bus connections:

  1. Make sure the bus connector contact surfaces are clean. When necessary, clean the bus bars with a mild, non-abrasive cleaning agent such as ScotchBrite®. Be careful not to remove the bus bar’s silver-plating during cleaning.

  2. Install the bus connectors one phase at a time. Loosely bolt the bus joints. The bus connector hardware is provided and can be found in the carton packing. Use M-8 (8 mm) hardware for line side bus connections and M-10 (10 mm) for the load-side bus connections.

  3. After all three bus bars are in place and properly aligned, tighten the bolts using a torque wrench. See Torque Values for torque values.

    Bus Bar Connections

  4. Connect the ground bus at each shipping split, remove and retain the existing hardware. Position the unit, then re-install and tighten the hardware per Torque Values.

Torque Values

Bolt Size

(SAE #2 Steel Bolts)

Torque Values

Sheet Metal Joints

Electrical Connections

1/4-20

7 lb-ft. (9.5 N•m)

10 lb-ft. (13.5 N•m)

5/16-8

14 lb-ft. (19 N•m)

20 lb-ft. (27 N•m)

3/8-6

21 lb-ft. (28.5 N•m)

35 lb-ft. (47.5 N•m)

1/2-3

42 lb-ft. (57 N•m)

70 lb-ft. (95 N•m)

M8 (8 mm)

15 lb-ft. (20.5 N•m)

21 lb-ft. (28.5 N•m)

M10 (10 mm)

22 lb-ft. (30 N•m)

36 lb-ft. (49 N•m)

Control Wiring Connections

To make control-wiring connections:

  1. Consult the customer wiring diagrams for re-connection of control wiring at the shipping splits, when applicable. Each wire has been identified and previously connected during assembly when tested at the factory.

  2. Make all outgoing control connections according to the wiring diagrams. After wiring is complete, check all connections to verify they are properly completed and in their proper location.

Cable Connections

Before making the cable connections, determine the phase identity of each cable. Viewing the switchgear from the front, standard bus sequence is normally phased A-B-C front to rear, unless labeled otherwise.

DANGER
Hazard of electric shock explosion or arc flash
  • All cables must be terminated inside the field shapers with lugs supplied by Schneider Electric (see Example of a Typical Cable Connection).
  • Properly support cables so that landing pads are not bearing the weight of the cables.
Failure to follow these instructions will result in death or serious injury.

Example of a Typical Cable Connection

When cable terminations are made, follow the cable manufacturer's instructions in stripping the shield and cleaning the unshielded portion of the cable. Install the appropriate stress cone in accordance with the stress cone manufacturer's instructions. Cables should be securely fastened or braced to withstand short circuit forces and to minimize strain on the terminals.

Forming the Cables

When forming cables for termination within switchgear, avoid sharp turns, corners, and edges which could damage or weaken the cable insulation. Follow the cable manufacturer's instructions carefully in determining the minimum bending radius of cables.

Shielded Cables Through Window-Type Current Transformers

When routing shielded cable through window-type current transformers or ground sensor current transformers, the shield-ground connection wire is normally routed back through the current transformer and solidly grounded.

Unshielded Cable Connections

DANGER
HAZARD OF ELECTRICAL SHOCK, explosion, OR ARC FLASH
Maintain a minimum clearance of four in. (102 mm) between insulated cable and grounded metal parts or other phases.
Failure to follow these instructions will result in death or serious injury.

To meet switchgear requirements, follow the cable manufacturer’s instructions for proper clearance of cables, conduits, and bus. These items must be securely fastened or braced to withstand short circuit forces and to minimize strain on the terminals.

NOTE: Maximum length of unsupported cable is 18 inches (457 mm).

Example of Unshielded Cable Support

Fuse Replacement

Proper fuse replacement for this equipment is very important. If FuseLogic fuse trip system is installed, the correct removal and installation allows for proper function of the system. To maintain system coordination, always replace all three fuses even if only one has blown. Lubricate the fuse clips with Mobil® 28 red grease if needed.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
  • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462.
  • This equipment must only be installed and serviced by qualified electrical personnel.
  • Turn off all power supplying this equipment before working on or inside.
  • The Live Line Indicator is not an indicator of the absence of voltage.
  • Always use a properly rated voltage sensing device to confirm power is off.
  • Replace all devices, doors, and covers before turning on the power to this equipment.
  • The body of a fuse that has blown or carried load current can be EXTREMELY HOT and burn unprotected hands.
  • Never try to insert or remove both ends of the fuse at once. The fuse body is made of FRAGILE PORCELAIN (glass-like) and can shatter if handled incorrectly (see Fuse Removal (Application A shown) and Fuse Installation (Application A shown)).
  • When removing Square D (or Bussman equivalent) DIN-E style fuses, always remove the end opposite the switch first. This avoids damaging the Fuselogic system assembly and fuse (see Fuse Removal (Application A shown)). Never attempt to remove both ends at once.
  • When installing Square D (or Bussman equivalent) DIN-E style fuses, always install the end of the fuse nearest the switch first; then install the opposite end. Always push on the ferrule being inserted (see Fuse Installation (Application A shown)). Never attempt to install both ends at once.
  • While removing Mersen CS-3 style fuses, always remove the end nearest the switch first (see Removal of Mersen Fuses, Application A). Never attempt to remove both ends at once.
  • While installing Mersen CS-3 style fuses, always install the end opposite the switch first (see Installation of Mersen Fuses, Application A shown). Never attempt to install both ends at once.
  • Only use the fuse insertion and removal tools specified or provided by Schneider Electric to avoid damaging the fuse holders.
  • Do not use a metallic prybar/tool to pry the fuses out of the fuse clip. This can damage the fuse holders. Only use a non-marking, non-sparking and nonmetallic pry tool specified or provided by Schneider Electric.
  • Do not pry or support any tool on any part of the aluminum deflectors for fuse removal or insertion. This can damage the surface of the aluminum deflectors and degrade dielectric performance.
Failure to follow these instructions will result in death or serious injury.

If the HVLcc unit experiences a trip current, blown fuse, or other stressful condition, inspect the switch at the first opportunity:

  1. Make any necessary repairs.

  2. Inspect the fuse clips (both top and bottom) on each phase carefully for any form of damage like (but not limited to) arcing or burn marks.

  3. Contact your local Schneider Electric representative to replace parts if any erosion on the fuse clips exists.

  4. Perform a hi-pot test before placing the equipment back into service.

Fuse Removal Square D (or Bussman™ Equivalent) DIN-E Style Fuses

  1. Place the switch in the OPEN or GROUNDED position to access the load-side compartment (see Removing the Load-side Access Panels)

  2. Use a properly rated voltage sensing device to verify that power is off. The Live Line Indicator is not an indicator of the absence of voltage.

  3. Grasp the fuse by the end opposite the switch first. While gently pulling the fuse ferrule, rotate the fuse body slightly to help ease the fuse ferrule out of the fuse clip.

  4. After the fuse is removed from the fuse clip opposite the switch, pull the fuse down to remove the fuse from the remaining fuse clip.

NOTE: To maintain system coordination, always replace all three fuses even if only one has blown.

Fuse Removal (Application A shown)

Fuse Installation of Square D (or Bussmann equivalent) DIN-E Style Fuses

To install fuses:

  1. Using a properly rated voltage sensing device verify that power is off.

  2. Insert the fuse ferrule into the fuse clip that is nearest the switch (Top on Application A, Bottom on Application B). Be sure to orient the striker pin properly (see Fuse Characteristics and Striker Pin Directions (Application A position shown)).

    NOTE: The striker pin assembly must always point toward the switch. For Application A the pin is at the top of the fuse. On Application B the pin must be at the bottom. The fuse characteristics and striker pin directions are printed on the fuse label. Always turn the fuse so that the label is in the front and the arrow is pointed toward the switch (up-Application A, down-Application B).

    Fuse Characteristics and Striker Pin Directions (Application A position shown)

  3. Insert the remaining end of the fuse into the fuse clip opposite the switch. Gently push while rotating the fuse body to help ease the fuse ferrule into the fuse clip.

Fuse Installation (Application A shown)

Removal of Mersen Fuses

  1. Place the switch in the OPEN or GROUNDED position to access the load-side compartment (see Removing the Load-side Access Panels) .

  2. Use a properly rated voltage sensing device to verify that power is off.

  3. Insert nonmetallic pry tool/wedge inside the field shaper between fuse ferrule or body and fuse holder assembly in the end nearest the switch as shown in Pry Tool/Wedge Inside the Field Shaper (15 kV Single fuse shown for reference).

    Pry Tool/Wedge Inside the Field Shaper

  4. Gently pry fuse out of fuse clip and remove fuse from the end nearest the switch (see Pry Fuse Out and Remove).

    Pry Fuse Out and Remove

  5. After the fuse is removed from the fuse clip nearest the switch, pull the fuse to remove the fuse from the remaining fuse clip.

NOTE: To maintain system coordination, always replace all three fuses even if only one has blown.

Installation of Mersen Fuses

Always install the end of the fuse opposite the switch first; then install the near end.

  1. Use a properly rated voltage sensing device verify that power is off.

  2. Insert the fuse ferrule vertically into the round portion of the fuse clip that is opposite the switch (Bottom on Application A, Top on Application B). Start with the phase farthest away from the opening being accessed (C Phase if accessing from the front and A Phase if accessing from the back. Phase C is shown for reference in Striker Pin Orientation). Push and twist fuse to help with installation.

    NOTE: The fuse striker pin assembly must always point toward the switch. For Application A the pin is at the top of the fuse. For Application B the pin must be at the bottom. The fuse characteristics are printed on the fuse label. Always turn the fuse so that the label is in the front (up-Application A, down-Application B).

    Striker Pin Orientation

  3. Push and twist fuse to help with installation (see Fuse Installation).

    Fuse Installation

  4. Attach a ratchet strap around the end of the fuse nearest the switch, and around the fuse holder assembly as shown in Strap Positioning. Gently ratchet the fuse body into the fuse clip and insert the remaining end of the fuse into the fuse clip nearest the switch.

    Strap Positioning

  5. Remove ratchet strap.

Hi-Pot (Dielectric) Testing

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
  • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462.
  • Only qualified electrical personnel should perform this testing.
  • During testing maintain a minimum clearance of six ft. (1.8 m) from equipment.
Failure to follow these instructions will result in death or serious injury.

  1. Perform a standard sixty-cycle hi-pot (dielectric) test to measure insulation integrity. See Hi-Pot Test Values for hi-pot test values. In performing the hi-pot (dielectric) test, take the following minimum actions to help ensure the safety of personnel and equipment:

    • Restrict entry into the area to help prevent any unauthorized personnel from approaching the gear during testing.

    • Notify all persons that the test is going to be conducted.

    • Follow all local lockout and tag-out procedures.

    • Remove all fuses both low voltage and medium voltage.

    • Disconnect all potential transformer secondary connections.

    • Disconnect Surge (Lightning) arrestors (SAs or LAs) (if supplied)

    • Short all current transformer circuits at shorting block.

    • Capacitive dividers supplied with the equipment must be properly connected or grounded.

    • All ground connections must be properly made and tightened according to Torque Values. Refer to Bus Connections, Example of a Typical Cable Connection(“Installation Note”), and the “HVL/cc Grounding Switch Application” section of the “Metal Enclosed Load Interrupter Switchgear with HVL/cc Switches” catalog (6045CT9801).

    Hi-Pot Test Values

    Equipment Rating

    Field Test Voltages

    (AC)

    (DC)

    4.76 kV

    14 kV

    20 kV

    15 kV

    27 kV

    38 kV

    17.5 kV

    28.5 kV

    40 kV

    27 kV

    45 kV

    63 kV

    38 kV

    60 kV

    85 kV
    DANGER
    HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
    When using a DC voltage source, the load-side of the capacitive dividers must be grounded after the high-pot test is completed to discharge trapped charges.
    Failure to follow these instructions will result in death or serious injury.

  2. Apply the voltage to each phase individually for one minute with the other two phases and the enclosure grounded.

If the test is unsuccessful, inspect the insulators for leakage paths. If necessary, clean the surface of the insulator(s) and re-test. If problems persist, DO NOT ENERGIZE THE SWITCHGEAR. Contact your local Schneider Electric field sales office or your distributor.

After a successful test, restore the equipment by reversing any changes made for the hi-pot test (such as replacing fuses, disconnecting wires, etc.).

Final Inspection

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
  • Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462.
  • This equipment must only be installed and serviced by qualified electrical personnel.
  • Always assume that all circuits are live until they have been completely de-energized, tested, grounded, and tagged.
  • Exercise extreme care to so that the equipment is not energized while conducting the preliminary tests. If disconnect switches cannot be opened, disconnect the line leads.
Failure to follow these instructions will result in death or serious injury.

After the switchgear is installed and all interconnections are made, follow the steps listed below to test the equipment and perform a final inspection before placing it in service.

  1. Verify that a sixty-cycle hi-pot test has been preformed recently on the equipment. See Hi-Pot Test Values for test values and additional information.

  2. Check all control wiring with the wiring diagrams. Verify that all connections are properly made and tightened to the proper torque value (see Torque Values), all fuses are installed, current transformer circuits are complete, and all fault detection devices have been properly connected.

  3. Verify all insulating surfaces, including the primary support insulators and isolation barriers, are clean and dry.

  4. Verify all fuses are installed properly and do not exceed the nameplate rating.

  5. Before energizing any electric power source, make a final check of the equipment. Inspect every compartment for loose parts, tools, litter, and miscellaneous construction items.

  6. Review key interlock schemes carefully (if used). Insert only the proper keys in the locks. Remove all extra keys and store them where only authorized personnel can access them.

  7. Verify that all barriers and covers are properly secured.

QR Code is a registered trademark of DENSO WAVE INCORPORATED in Japan and other countries.

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