SureSeT™ Medium Voltage, Metal-Clad, Indoor Switchgear5/15 kV with EvoPacT™ Medium Voltage Vacuum Circuit Breakers SureSeT Switchgear User Guide – Logistics, Installation, Operations, and Maintenance PDF
NNZ9886800EN, Rev. 01

Installation

This section contains instructions for installing SureSeT metal-clad indoor switchgear and devices. This section also covers site selection and preparation, foundation specifications, conduit location, and switchgear and device installation. Carefully read and follow all the safety precautions outlined below and throughout this section before performing any procedures. Continue to treat the equipment per the instructions found in the section Moisture Contamination Avoidance and Mitigation until the equipment is under normal operation. This equipment does not achieve its ratings until it is installed per record/as-built drawings, installed per the instructions contained in this document, and has operational environmental controls with appropriate settings to help mitigate environmental influences.

NOTE: If the assembly is stored prior to installation, follow the safety precautions found in the section Storage.
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 be installed, operated, and serviced only by qualified electrical personnel. 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.
  • Install the electrical equipment only in the environment for which it was designed.
  • Perform work on the equipment only after reading and understanding all of the instructions contained in this user guide and other associated user guides.
  • Turn off all power source to this equipment before working on or inside the equipment.
  • Always use a properly rated voltage sensing device to confirm power is off.
  • Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume all circuits are live until completely de-energized, tested, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding. Also, check interconnection diagrams and make sure there are no potential backfeed sources.
  • Never disconnect the main trip source of energized equipment.
  • Always practice lock-out and tag-out procedures according to OSHA requirements. 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.
  • Circuit breaker and switch contacts must be open and all springs discharged before attempting to open any circuit breaker or auxiliary compartment doors or performing maintenance work, disconnection, or removal of a circuit breaker.
  • Move circuit breakers to the test/disconnected position before attempting to open any circuit breaker or auxiliary doors or remove any rear compartment covers.
  • Conduct electrical testing to confirm no short-circuits were created during installation, maintenance, or inspection.
  • Never insert a circuit breaker into a circuit breaker compartment that is not complete and functional.
  • 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.
Failure to follow these instructions will result in death or serious injury.
DANGER
hazard of electric shock explosion, or arc flash
  • Do not allow the ambient operating temperatures to exceed the specified limits.
  • Provide adequate ventilation at all times to the equipment. Clean, dry, filtered air should be supplied. The ambient operating air must not be polluted by dust, particulates, smoke, corrosive and/or flammable gases, vapors, or salt. Protect the equipment from foreign objects and rodents.
  • Disconnect all high-voltage to the switchgear before accessing the horizontal bus compartment.
  • Do not use liquid fire extinguishers or water on electrical fires. Before extinguishing fires within the assembly, be absolutely certain the main power source is disconnected and the main and all feeder circuit breakers are open.
  • Carefully inspect the work area and remove any tools and objects left inside the equipment.
  • Replace all devices, doors, barriers, plates, panels, and covers before racking the circuit breaker in or out of the connected position and before turning on power to this equipment.
  • Remove any temporary source of low-voltage power prior to energizing.
  • Do not damage or modify busbar insulation.
  • Properly close all bus joint boots before energizing this equipment.
  • Remove any temporary source of low voltage power prior to energizing.
  • 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 or barriers removed. Contact the local Schneider Electric representative for additional instructions if the equipment does not function as described in this user guide.
  • All instructions in this user guide 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.

Site Selection and Preparation

Good site selection and preparation is essential for proper installation and reliable operation of the equipment. Carefully compare the plans and specifications with the customer order drawings provided. Be sure to provide adequate:

  • Ventilation at all times so the ambient temperature around the equipment does not exceed 104°F (40°C) or fall below 23°F (-5°C), (see Required Ambient Environment Temperatures for Switchgear Operation). Clean, dry, filtered air should be supplied.

  • Lighting in both the front and back aisle spaces. Also provide convenience outlets in both areas for electrical hand tool use.

  • Help protect against water damage:

    • Having a foundation with adequate floor drainage.

    • Do not pass the routing of sewer, water, and steam lines over or near the equipment. Dripping liquids that enter the equipment will cause damage.

    • Do not allow water to collect or run under the equipment.

    • Do not install the equipment over locations that could retain moisture, such as a cable vault, without sealing the equipment to not allow moisture to enter the equipment.

    • Understand that water or chemicals from a fire sprinkler system event will damage the equipment.

Required Ambient Environment Temperatures for Switchgear Operation

Ideal Conditions

Allowable Conditions

Normal Service Conditions

Ambient Air Temperature
Minimum value 23°F (-5°C)
Maximum value 104°F (40°C)
Average measured over a 24-hour period ≤ 95°F (35°C)

Average Relative Humidity
Measured over a 24-hour period ≤ 95%
Measured over a 1-month period ≤ 90%

Average Water Vapor Pressure
Measured over a 24-hour period ≤ 2.2 kPa
Measured over a 1-month period ≤ 1.8 kPa

Altitude Above Sea Level
Maximum value 3281 ft. (1000 m)

Atmosphere

The ambient air should be clean and must not be significantly polluted by dust, particulates, smoke, corrosive and/or flammable gases, vapors, or salt.
NOTE: The installation site selected must allow the equipment to operate only in the environment for which it was designed as specified throughout this document, particularly in the section Product Technical Datasheet.

The weight of the average complete switchgear section with circuit breakers and/or auxiliary drawers is 2,800 - 3,600 lbs. (1,270 - 1,630 kg.) for up to 40 kA. Make sure the site can support the weight of a complete switchgear section, as well as the combined weight of the entire switchgear line-up. Refer to the table Approximate Switchgear and Component Weights to determine approximate switchgear and component weights for handling and structural considerations.

Approximate Switchgear and Component Weights

Item

Rating

Weight

Switchgear Section (2 high section)

Up to 40 kA

3,600 lbs (1,633 kg)

Circuit Breaker

1200 A, 40 kA

340 lbs (155 kg)

2000 A, 40 kA

410 lbs (186 kg)

VT Drawer (three VTs)

15 kV

215 lb (98 kg)

CPT Drawer

15 kVA

348 lb (158 kg)

Surge Arresters (LAs; three intermediate)

15 kV

120 lb (54 kg)

Low Power Voltage Transformers (LPVTs; three)

15 kV

25 lb (11 kg)

Foundation

The switchgear must be installed on a flat, level surface. Schneider Electric recommends installing the switchgear on a concrete pad. The foundation for the switchgear must be leveled to 0.0625 in. (1.6 mm) in any square yard.

NOTE: To maintain seismic qualifications, equipment must be installed per the applicable instruction bulletins and in accordance with anchorage details provided by the Engineer of Record (EOR) for the site. Equipment attachment to a building structure, foundation, or mounting pad is the responsibility of the EOR. The EOR will size equipment installation attachments and supports to withstand the seismic demand at equipment installation location. Do not install equipment before approved seismic anchoring details have been obtained from the EOR and site preparations have been made. See the figure Recommended Switchgear Foundation Mounting for the anchor configuration used to qualify for seismic ratings. See the figures Floor Plan for Switchgear Rated Up to 40 kA, Front Floor Foundation Mounting Locations and Control Wiring Entry Cover Plates, Rear Compartment Removable Plates for Primary Cable Entry, and Holes for Anchoring the Switchgear to the Floor for anchoring locations of the switchgear.

Pour a 7 ft. (2.1 m)-wide aisle space in front of the mounting pad, finished to the same tolerance as the mounting pad. This level surface is necessary for the circuit breaker/auxiliary drawer lift truck to insert the devices into the section. Schneider Electric recommends including the clearance required for the lift truck to be flush with the mounting pad area. However, if the aisle and mounting pad are at different heights, the pad should:

  • extend no further than 8.5 in. (216 mm) in front of the base of the switchgear

  • be no more than approximately 4 in. (102 mm) higher than the aisle

Typically, a minimum of 3 ft. (0.91 m) is recommended on the left, right, and rear of the line-up to facilitate door and lift truck clearance when removing a device or performing installation and maintenance. Provide the following minimum clearances on the ends of the line-up to allow insertion and removal of circuit breakers and CPT/VT drawers.

Device Type and Minimum Clearance

Device Type

Minimum Required Clearance

Left End a

Right End a

Circuit breaker

26 in. (0.7 m) b

26 in. (0.7 m)c

Auxiliary (CPT/VT) drawer

a As seen when facing the front of the line-up.

b For door clearance.

c For lift truck clearance.

Conduits should be stubbed a maximum of 1 in. (25 mm) above floor level. To simplify moving the switchgear into place, keep all conduit flush with the surface of the floor. Position the conduit with extreme accuracy so there is no mechanical interference with the switchgear frame. Verify conduit placement for the entire switchgear line-up is accurate when compared to the customer order drawings. A typical section floor plan is shown for reference in the figure Floor Plan for Switchgear Rated Up to 40 kA but the installer should use the customer order drawings for foundation and installation specifications. Eliminate continuous loops of reinforcing rod or structural steel around any single conductor of a three-phase power circuit.

Recommended Switchgear Foundation Mounting

NOTE: This applied foundation mounting shown in the figure is mandatory to maintain seismic qualifications.
A

1.25 in. (32 mm) OD steel Belleville washer

 C

Equipment base

 E

0.88 in. (22 mm) dia. clearance hole
B

1/2-13 UNC SAE Grade 5 anchoring fastener

 D

Anchor assembly (as tested)

 F

Crown

Floor Plan for Switchgear Rated Up to 40 kA

A

72.0 in. (1829 mm) front aisle; 64.0 in.(1626 mm) minimum (not to scale)

 E

36.0 in. (914 mm) rear aisle (not to scale)
B

Control conduit area (bottom)

 F

Distance to wall: 36.0 in. (914 mm) to left or right wall; 26.0 in. (660 mm) minimum (not to scale)
C

Four (4) 0.75 in. (19 mm) diameter mounting holes

 G

1.6 (40) door
D

Top or bottom cable conduit area

    

Front Floor Foundation Mounting Locations and Control Wiring Entry Cover Plates

A

Switchgear foundation mounting location

 B

Control wiring entry cover plate

Rear Compartment Removable Plates for Primary Cable Entry

A

Top plate

 B

Bottom plate

Holes for Anchoring the Switchgear to the Floor

A

Four (4) .75 in. (19 mm) diameter mounting holes

Switchgear Installation

Shipping Group Installation

SureSeT 5/15 kV medium voltage, two-high, indoor metal-clad switchgear may be shipped in one or more shipping groups (typically made up of one or two sections separated by shipping splits), depending on the number of sections in the switchgear assembly. Before installing each shipping group, refer to the customer order drawings and section markings to help with proper alignment. Review the customer order drawings to verify the switchgear sections will be assembled in the correct order. Carefully measure and verify all the conduit placement and spacings on the foundation are accurate according to customer order drawings. Errors in conduit placement could prohibit proper switchgear installation.

When more than two shipping groups are involved, any error in conduit location can cause a cumulative error significant enough to prohibit proper installation by the assembly sequence described in this section. To lessen cumulative error, unload and install the middle shipping group first and work toward either end. Install the end shipping group which allows the most maneuverability first.

Prior to shipping group installation, remove the ground bus splice plate (see the figure Ground Bus Splice) and the main bus pass-through barrier assembly from each section that is positioned in the switchgear line-up at the end of a shipping split (see the figure Main Bus Pass-Through Barrier Removal). Carefully and temporarily store the bus and barrier(s) after removal. These parts will need to be reinstalled after the section is in place and prior to making the main bus connections. Prior to installation, if conduits are stubbed up above the surface of the foundation, the floor cover plates for the conduits will need to be removed before moving the sections into position (see the figures Floor Plan for Switchgear Rated Up to 40 kA, Front Floor Foundation Mounting Locations and Control Wiring Entry Cover Plates, Rear Compartment Removable Plates for Primary Cable Entry, and Holes for Anchoring the Switchgear to the Floor).

Main Bus Pass-Through Barrier Removal

A

Remove main bus pass-through barrier on right side of bay located at each shipping split prior to installing next section.

 B

Main bus pass-through barrier on right side of bay not located at shipping split does not need to be removed.

Sweep the pad and remove debris before installing any sections. Move the sections, with pallets intact, into place. If rollers must be used, move with the pallet in place. Remove the pallet only when the switchgear is in proper position on the pad. Lower the first section onto the pad. If necessary, place a 2 ft. x 6 ft. (0.6 m x 1.8 m) board across the assembly and pry it into place. Do not pry directly on the structure, doors, or covers. Before proceeding, verify that:

  • The primary cable conduits are in the center of the cutouts for each section.

  • The control power cable conduits are within the floor opening for each section.

  • Each section that is positioned in the switchgear line-up at a shipping split has the main bus pass-through barrier removed before installing the next shipping group.

  • The back of the section is square to the pad to help with alignment and has the proper clearance.

  • The mounting holes on each section line up with the holes in the mounting channels.

Level each section before installing the next. Move an adjacent switchgear shipping group into place. Install steel shims, when necessary, between floor channels and switchgear. After leveling a section and aligning it to neighboring section, verify that the sections fit snugly together and then bolt it to any previously installed sections before proceeding. If the sections do not fit snugly and properly together, remove the most recently placed section, check for obstructions, and try again. Do not attempt to pull sections together by tightening the hardware.

Bolt switchgear shipping groups together and re-install main bus pass-through barrier(s) at the shipping split(s). See the figure Hardware Sizes and Locations for bolt sizes and locations and the figure Bolting Shipping Sections Together for bolting details. All shipping groups must be bolted together before bolting sections to the foundation/channel sills, installing the horizontal main busbars, and making the ground bus splice connection. Verify all required section-to-section bolt locations have fasteners in place and the hardware is appropriately torqued (see the section Standard Fastener Torque Values for the Switchgear). After all the sections are level and bolted together, verify again that all shipping groups are in the correct position according to the customer order drawings. After verifying everything is correct, bolt the switchgear to the pad. For bolting, use four 1/2-13 SAE grade 5 (minimum) bolts with Belleville washers. Refer to the figure Recommended Switchgear Foundation Mounting.

Hardware Sizes and Locations

A

Carriage bolt x 10: 3/8–16 x 1 in., round head, short square neck, steel, SAE Grade 5

Keps nut x 10: 3/8–16, steel, SAE J238

 B

Carriage bolt x 6: 3/8–16 x 1 in., round head, short square neck, steel, SAE Grade 5

Keps nut x 6: 3/8–16, steel, SAE J238

Bolting Shipping Sections Together

A

Left section

 C

Carriage bolt x 6: 3/8–16 x 1 in., round head, short square neck, steel, SAE Grade 5

 E

Left section side sheet

 G

Keps nut x 6: 3/8–16, steel, SAE J238
B

Right section

 D

Main bus pass-through insulator face

 F

Right section side sheet

    

Front Compartments (Circuit Breaker/Auxiliary/LV) Door Operation

To OPERATE the door handles:

  1. To unlatch the door, pivot the handle out/up and then rotate the handle counter-clockwise until the latch system is free and allows the door to open. The door may be either opened or closed with the handle in this raised position.

  2. To latch the door, rotate the handle clockwise and then pivot the handle in/down. To fully latch the door the handle must be pushed down until fully vertical and flush with the handle casing. The door may be either padlocked and/or key-locked with the handle in this position.

NOTE: Do not force the handle during operation, as the latch system and handle are designed to operate freely. Inspect the system and contact Schneider Electric if unable to correct.

To OPEN a door:

  1. Unlock the key-lock or remove the padlock from the door handle (if installed).

  2. For circuit breaker compartment doors, remove the padlock, if installed, from the red push button or push button blocking cover found on the racking mechanism beam located near the lower, middle area of the circuit breaker compartment door.

  3. Unbolt the thumbscrews and/or rotate the door handle to the open position. then pull to open the door.

  4. The door can be opened until the door stay latch automatically moves into the bracket on the left side sheet (see the figure Hinged Door with Low Voltage Device Panel and Automatic Door Stay Latch).

NOTE: All doors come standard with this automatic door stay latch system except for certain low voltage instrumentation compartment doors. These doors have a stay rod that will need to be manually lifted and put into the hole on the front flange to retain the door in the open position (see the figure Manual Door Stay Rod).

To CLOSE a door:

  1. Manually pull the door stay latch out of the bracket on the left side sheet, then slightly push the door closed to move the door stay latch past the point of moving back into the bracket (see the figure Hinged Door with Low Voltage Device Panel and Automatic Door Stay Latch).

    NOTE: On low voltage instrumentation compartment doors that do not have this automatic door stay latch system, manually lift the stay rod out of the hole on the front flange and put back in the hole on the bracket (see the figure Manual Door Stay Rod).

  2. The door may be equipped with thumb screws and/or a handle for keeping the door closed. If the door has a handle, make sure the handle is rotated to the up position when closing the door.

  3. Push the door to close it, rotate the door handle towards the down position, and/or tighten the thumb screws. This will keep the door in the closed position, making the door ready for normal operation.

  4. The door handle (if equipped) may be padlocked or key-locked in the latched position.

Main Bus Installation

Install the main bus at the shipping split only after all sections are securely anchored in place and no additional movement of the assembly will occur. Busbar extensions for shipping splits are shipped with the miscellaneous items. Inspect epoxy bus insulation prior to installation and make sure the bus insulation is not damaged while installing.

A typical main bus assembly is shown in the figure Main Bus Assembly. The side and rear views of the assembly show the general arrangement of the main bus and riser bus. The side views (see the figure Main Bus Connections—Right Side View show the different bus connections and the orientation of the copper filler and splice plates.

Main Bus Assembly

A

1/2–13 SAE Grade 5 (minimum) hardware with Belleville washers

Main Bus Connections—Right Side View

A

Main bus

 D

Copper Splice Plate
B

1200 A Riser

 E

Copper Filler Plate
C

2000 A Riser

    
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.
  • Ensure busbar stand-off support insulators with fiberglass/polyester washers, rubber O-rings, and hardware are properly installed.
Failure to follow these instructions will result in death or serious injury.

The figure Stand-Off Bus Support for 1200 and 2000 A Bus illustrates a busbar stand-off support insulator installation. The installation is similar for either the standard molded fiberglass polyester standoffs (Group A insulation material) or optional porcelain standoffs (Group B insulation material). Fiberglass/polyester washers and rubber O-rings must be installed as shown to help protect the epoxy busbar insulation, provide dielectric integrity, and provide support under short-circuit conditions.

Stand-Off Bus Support for 1200 and 2000 A Bus

A

Fiberglass/polyester washer

 B

Rubber O-rings: 2 for 1200 A; 3 for 2000 A

To install the busbars, remove the rear compartment covers and access the main bus access covers through the rear compartment. Remove the main bus access covers and store the main bus access covers carefully during bus installation. Remove the main bus insulating boots that were shipped with the switchgear, from the section at a shipping split. Install one phase at a time by sliding the horizontal main busbars through the bus pass-through barriers and loosely bolting the horizontal main bus to the vertical riser bus.

NOTE: Do not bend or force the bus to make this connection. If necessary, loosen the pass-through barrier hardware. The barrier has sufficient clearance and adjustment to compensate for minor field misalignment of shipping sections. Properly re-torque the barrier hardware after the main bus hardware is fully torqued. If unable to make the connection without bending or forcing the bus, contact the local Schneider Electric representative.

Tighten the bolts used at the busbar joints only after all three main busbars are in place and properly fitted. Use a torque wrench to tighten the bolts for busbar connections as specified in the table Switchgear Bolt Torque Value.

After installation of switchgear line-up is complete, use a properly rated multimeter to check for electrical continuity along the full length of the main bus bar in the line-up.

Install supplied boots on main busbar joints. Close the boot joint with supplied tie-wrap. Clean and wipe down main bus compartment. Inspect the compartment for any work tools and remove. Reinstall main bus access covers.

Prior to start-up, re-install all barriers that were removed for installation and properly seal all bus joint boots. Refer to Start-Up for more information.

Ground Bus Connection

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
  • Connect the ground bus to the proper equipment ground per the local installation code requirements. The ground bus must be connected for proper operation of relaying and instrumentation, and for personnel safety.
Failure to follow these instructions will result in death or serious injury.

Connect the ground bus splice at each shipping split (see the figures Rear Compartment — One-High Section (rear compartment covers removed), Rear Compartment — Two-High Section (rear compartment covers removed), and Ground Bus Splice. Position the splice plate, then replace hardware on both ends.

NOTE: The ground bus must be connected for proper operation of relaying and instrumentation, and for personnel safety.

Use a torque wrench to tighten the bolts for the ground bus splice as specified in the table Switchgear Bolt Torque Value for busbar connections.

After installation of switchgear line-up is complete, use a properly rated multimeter to check for electrical continuity along the full length of the ground bus bar in the line-up.

Control Wiring Connections

Consult the customer wiring diagram for reconnection of wiring at the shipping split. Each wire is identified and was connected and verified during assembly at the factory. If the identification is missing or blurred, ring-out before connecting to avoid control circuit and instrument panel problems at start-up.

Circuit Breaker and Auxiliary (CPT/VT) Drawer Installation and Operation

This section contains instructions for operating, installing, and withdrawing the circuit breaker in the switchgear circuit breaker compartment. For further information on the circuit breaker, refer to Schneider Electric document number JYT3013100, EvoPacT MV Vacuum Circuit Breaker. This area also contains instructions for operating, installing, and moving the auxiliary (CPT/VT) drawers in the switchgear auxiliary compartments.

Circuit Breaker Compartment Interlock System Operation

The circuit breaker and the circuit breaker compartment are equipped with an interlock system (see the figure Compartment Interlocks). The interlocks are designed to:

  • help block the circuit breaker from being pushed into the compartment when the circuit breaker is closed

  • help block the circuit breaker from being closed while it is moved between the test/disconnected and connected position

  • help block the circuit breaker from being moved from the connected position when it is closed

  • discharge both the closing and opening springs when the circuit breaker is being removed or withdrawn from the circuit breaker compartment

Circuit Breaker Installation and Operation

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.
  • The circuit breaker must be installed and operated only by qualified electrical personnel. 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.
  • Install and operate the circuit breaker only in the environment for which it was designed.
  • Perform work on the equipment only after reading and understanding all of the instructions contained in this and other associated user guides.
  • Do not open the circuit breaker, close the circuit breaker, or rack the circuit breaker from one position to another with the circuit breaker compartment door open when the switchgear is energized.
  • Use only a SureSeT lift truck to insert and remove the EvoPacT MV circuit breaker.
  • Do not push on the front breaker covers or at the top of the breaker.
  • Do not force the circuit breaker to move inside the circuit breaker compartment. If a mechanism is not operating smoothly or circuit breaker movement is blocked, look for the cause.
  • Do not over torque the racking handle once the circuit breaker motion stops. Excessive torque will damage the racking mechanism if the circuit breaker does not move. Determine the cause before continuing if the circuit breaker is not in the desired position.
  • Remove the circuit breaker and contact the local Schneider Electric representative if the circuit breaker does not easily rack into the circuit breaker compartment when it is being moved to the connected position.
  • Reconnect the circuit breaker and repeat the rack-out process if the circuit breaker does not easily rack out of the circuit breaker compartment when it is being moved to the test/disconnected position. If satisfactory results are not achieved, contact Schneider Electric.
  • Only use the provided racking/charging handle or electrically with the optional integrated motorized racking system. Other methods to rack the circuit breaker should not be used and could damage the circuit breaker racking mechanism.
  • Do not exceed the racking mechanism maximum torque limit when racking a circuit breaker into or out of the connected position to help prevent damage to the circuit breaker or circuit breaker compartment.
Failure to follow these instructions will result in death or serious injury.

Installing the Circuit Breaker into the Circuit Breaker Compartment in the Test/Disconnected Position

SureSeT Switchgear User Guide Video –

Typically, the circuit breakers are shipped inside the equipment, but may also be shipped separately. If a circuit breaker is not in the circuit breaker compartment, follow these steps to insert it:

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

  2. Check the customer order drawings and nameplates, and that the secondary disconnect labels coordinate on the circuit breaker and the circuit breaker compartment (see figure Coordinating Circuit Breaker Compartment and Circuit Breaker Top Cover Secondary Disconnect Labels) to verify the circuit breaker is installed into the proper compartment.

  3. Verify the circuit breaker racking beam position indicator shows the symbol for "Test/Disconnected" and that the racking beam is flush with the front of the circuit breaker carrier pan, (see the figure Locking Tabs Fully Extended Into the Latch Plates).

  4. Open the circuit breaker compartment door (refer to the section Front Compartments (Circuit Breaker/Auxiliary/LV) Door Operation) with the automatic door stay latch engaged (see Hinged Door with Low Voltage Device Panel and Automatic Door Stay Latch).

  5. Prepare and use a SureSeT lift truck to insert the circuit breaker into the circuit breaker compartment. According to the instructions in the section SureSeT Circuit Breaker/Auxiliary Drawer Lift Truck.

    NOTE: A lift truck must be used to insert or remove the circuit breaker from switchgear regardless of whether or not the line-up is on a raised pad.

Racking the Circuit Breaker Into the Connected Position

To rack a circuit breaker into the connected position from the test/disconnected position, follow these steps:

  1. Remove the padlock, if installed, from the red push button or push button blocking cover (if equipped) found on the racking mechanism beam located near the lower, middle area of the circuit breaker compartment door.

  2. Remove the padlock, if installed, and unlock any key-lock (if equipped) from the compartment interlock plate mounted on the right rail in the circuit breaker compartment.

  3. Close and properly latch the circuit breaker compartment door per instructions in this user guide, (refer to Front Compartments (Circuit Breaker/Auxiliary/LV) Door Operation).

  4. With the circuit breaker compartment door closed and latched, push and hold in the red push button on the circuit breaker racking mechanism beam to open the circuit breaker racking port, and insert the circuit breaker racking/charging handle into the racking port. Engage the racking handle into the racking shaft and rotate the racking handle clockwise to rack the circuit breaker into the connected position. When in the connected position, the inward motion of the circuit breaker stops.

    NOTE: If the racking system is motorized, the circuit breaker may be racked in and out using electrical controls with the circuit breaker compartment door closed and latched.

  5. With the circuit breaker compartment door closed, the position indicator on the front of the racking mechanism beam shows that the circuit breaker is in the test/disconnected, transport, or connected position.

    NOTE: When the circuit breaker is being transported to or from the connected position, the racking position indicator will show a symbol for transport.

  6. Continue rotating the racking handle clockwise until the racking position indicator shows the symbol for connected position.

    NOTE: When the racking position indicator shows the symbol for connected and is not moving any further, then the circuit breaker is fully racked into the circuit breaker compartment and the circuit breaker primary contacts are connected.

Racking the Circuit Breaker Out of the Connected Position

To rack a circuit breaker from the connected position to the test/disconnected position, follow these steps:

  1. Open the circuit breaker electrically with the compartment door closed, and properly latched Front Compartments (Circuit Breaker/Auxiliary/LV) Door Operation.

    NOTE: Pushing the red push button on the front of the racking mechanism to access the racking port will also trip a closed circuit breaker and a loud noise will occur as the spring discharges.

  2. With the circuit breaker compartment door still closed and latched, push and hold in the red push button on the circuit breaker racking mechanism beam to open the circuit breaker racking port, and insert the racking handle into the racking port on the front of the racking mechanism. Engage the racking handle into the racking shaft and rotate the racking handle in a counter-clockwise direction to move the circuit breaker to the test/disconnected position. When in the test/disconnected position, the outward motion of the circuit breaker stops.

    NOTE: If the racking system is motorized, then the circuit breaker may be racked in and out using electrical controls with the circuit breaker compartment door closed and latched.

  3. With the circuit breaker compartment door closed, the position indicator on the front of the racking mechanism beam shows that the circuit breaker is in the test/disconnected, transport, or connected position.

    NOTE: When the circuit breaker is being transported to or from the connected position, the racking position indicator will show a symbol for transport.

  4. Continue rotating the racking handle counter-clockwise until the racking position indicator shows the symbol for test/disconnected position.

    NOTE: When the racking position indicator shows the symbol for test/disconnected and is not moving any further, then the circuit breaker is fully racked out of the circuit breaker compartment and the circuit breaker primary contacts and secondary disconnecting plug for power and control are disconnected.

Withdrawing the Circuit Breaker from the Circuit Breaker Compartment

To remove a circuit breaker from the circuit breaker compartment, follow these steps:

  1. Make sure the circuit breaker is in the test/disconnected position and the circuit breaker is open.

  2. After confirming the opened circuit breaker is in the test/disconnected position, open the circuit breaker compartment door, refer to the section Front Compartments (Circuit Breaker/Auxiliary/LV) Door Operation with the automatic door stay latch engaged, see the figure Hinged Door with Low Voltage Device Panel and Automatic Door Stay Latch.

    NOTE: Confirm with the circuit breaker compartment door open, when the circuit breaker is in the test/disconnected position, the circuit breaker carrier pan should be flush with the back of the integrated racking mechanism beam, (see the figure Locking Tabs Fully Extended Into the Latch Plates).

  3. Prepare and use a SureSeT lift truck to remove the circuit breaker from the circuit breaker compartment according to the instructions in the section SureSeT Circuit Breaker/Auxiliary Drawer Lift Truck.

    NOTE: A lift truck must be used to insert or remove the circuit breaker from switchgear regardless of whether the switchgear is on a raised pad or not.

Control Power Plug Operation and Testing the Circuit Breaker in the Test/Disconnected Position

In normal operation, the top, secondary disconnect control power receptacle in the circuit breaker compartment automatically connects and disconnects to the plug on the circuit breaker as the circuit breaker is moved into and out of the connected position. The secondary disconnect power and control receptacle should remain latched, at the back of its travel in the location where it connects with the breaker in the racked-in, connected position (see the figure Secondary Disconnect Receptacle Assembly). However, this receptacle also provides a convenient method for electrically testing the operation of the circuit breaker mechanism.

To test the circuit breaker in the test/disconnected position:

  1. With the circuit breaker compartment door open, locate the handle attached to the secondary disconnect power and control receptacle. It is above the circuit breaker in the circuit breaker compartment. Rotate the handle downward, in a clockwise direction to an angle of approximately 60–90 degrees.

  2. Pull the handle of the top secondary disconnect receptacle forward until the receptacle engages with the secondary disconnect plug on the circuit breaker. The circuit breaker can now be electrically operated in the same way as when in the connected position.

    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. After checking all electrical functions, manually push the receptacle back to its normal, latched operating position. As the secondary disconnect receptacle is latching, allow the handle to rotate clockwise while continuing to push the handle until feeling the handle snap, counter-clockwise, into the latched position. The secondary disconnect receptacle should typically be put into this position before racking circuit breakers into the connected position.

Manual Spring Charging Mechanism

In normal operation (when the secondary disconnect power and control plug is engaged), the motor automatically charges the circuit breaker closing springs. The springs can also be charged manually (with the circuit breaker compartment door open) using the circuit breaker racking/charging handle. The circuit breaker charging mechanism uses the same handle as the one used by the circuit breaker and auxiliary compartment racking mechanisms. This feature is provided for testing and maintenance purposes, and for emergency operating conditions.

The circuit breaker charging port is located near the lower, middle area of the circuit breaker front cover. To manually charge the breaker, follow these steps:

  1. Insert the racking/charging handle into the charging port.

  2. Rotate the handle clockwise until the spring charge status indicator on the circuit breaker shows the spring is fully charged.

    NOTE: The charging port will not provide a hard stop when the circuit breaker is charged and the racking/charging handle will still be free to rotate in the port.

Refer to Schneider Electric document number JYT3013100, EvoPacT MV Vacuum Circuit Breaker for further detailed information.

Manual CLOSE and OPEN Push-Buttons

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.
  • Never manually close a circuit breaker in the connected position unless the opening source of power and protection relays are connected and operable.
  • Do not use the manual OPEN and CLOSE push-buttons on the front of the circuit breaker when the switchgear is energized.
Failure to follow these instructions will result in death or serious injury.

The circuit breaker manual CLOSE and OPEN push-buttons are located on the front cover of the circuit breaker. These push-buttons allow manual operation of the circuit breaker after it has been charged (manually or electrically). Use the push-buttons only when testing the circuit breaker during start-up or maintenance. The manual open and close buttons bypass most electrical interlocks on the circuit breaker control circuit.

Refer to Schneider Electric document number JYT3013100, EvoPacT MV Vacuum Circuit Breaker for more information.

Circuit Breaker Installation in Switchgear

With all primary and secondary disconnect control power circuits de-energized, insert each circuit breaker into its circuit breaker compartment if the circuit breaker was not shipped inside the switchgear. Make sure the racking mechanism locking tabs have engaged the compartment latch plates correctly in the test/disconnected positions. Verify proper connection of the low voltage plugs for additional features, if equipped.

NOTE: If a circuit breaker has been manually charged outside the compartment, manually discharge all stored energy in the circuit breaker mechanism. Otherwise, the automatic spring discharge interlock will discharge the circuit breaker during insertion (refer to the section Compartment Interlocks). A loud noise will occur as the spring discharges.

Although the circuit breaker racking mechanism will typically not be operated while the circuit breaker is outside of the circuit breaker compartment, make sure the circuit breaker is fully racked out. Verify it is fully racked out by making sure the circuit breaker carrier truck is flush against the back plate of the racking mechanism beam with the mechanical position indicator on the racking beam showing it is in the test/disconnected position. The compartment racking mechanism lockout plate blocks insertion of the circuit breaker if a circuit breaker has been manually racked while outside the compartment and insertion is attempted.

Do not force circuit breakers into circuit breaker compartments. Compartment rating code plates block accidental insertion of circuit breakers with incorrect current, voltage, or interrupting ratings into the compartment. Confirm the label on the cover of the circuit breaker secondary disconnect power and control plug corresponds with the label on the secondary disconnect receptacle assembly in the circuit breaker compartment to provide further confirmation the circuit breaker is in the correct compartment (see Coordinating Circuit Breaker Compartment and Circuit Breaker Top Cover Secondary Disconnect Labels).

With all primary and secondary disconnect control power circuits de-energized, rack each circuit breaker into the connected position in the circuit breaker compartment. Observe the proper operation of the:

  • racking mechanism locking tabs in the latch plates

  • ground contacts

  • shutters

  • secondary disconnect plugs and receptacles connecting

  • additional features low voltage

  • plugs and receptacles connecting (if so equipped).

Remove each circuit breaker from its compartment. Open the shutters and check that visible signs of circumferential, uniform tracks are made by circuit breaker sliding primary contacts in the grease on stationary primary contacts inside the compartment insulator bushing assembly. Also check that the tracks appear to extend back approximately 0.5 in. (13 mm) from the front edge of each stationary primary contact inside the compartment insulator bushing assembly. Also confirm there are visible signs of uniform contact via tracks in the grease on each contact bar of the circuit breaker sliding primary contacts. Make sure the circuit breaker sliding ground contact leaves visible signs of contact via tracks in the grease and marks on the compartment ground bus contact bar.

CPT and VT Drawer Operation

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.
  • The auxiliary drawer must be installed and operated only by qualified electrical personnel. 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.
  • Install and operate the auxiliary drawer only in the environment for which it was designed.
  • Perform work on the auxiliary drawer only after reading and understanding all of the instructions contained in this and other associated user guides.
  • Do not force the auxiliary (CPT/VT) drawer to move inside the auxiliary compartment. If a mechanism is not operating smoothly or auxiliary drawer movement is blocked, look for the cause.
  • Use only a SureSeT lift truck to install and remove an auxiliary (CPT/VT) drawer.
  • Verify the auxiliary (CPT/VT) drawer racking mechanism dismounting bolt is connected to the racking mechanism in the compartment and is properly torqued before moving the auxiliary drawer with a racking mechanism.
  • Remove the auxiliary (CPT/VT) drawer and contact the local Schneider Electric representative if the drawer does not easily move into or rack into the auxiliary compartment when moving the drawer to the connected position.
  • Reconnect the auxiliary (CPT/VT) drawer and repeat the steps to move to the disconnected position if the drawer does not easily move out or rack out of the compartment when moving the drawer to the disconnected position. If satisfactory results are not achieved, contact Schneider Electric.
  • Do not over-torque the racking handle once the motion of the auxiliary (CPT/VT) drawer stops on auxiliary drawers and compartments equipped with racking mechanism. Excessive torque will damage the racking mechanism if the auxiliary drawer does not move. Determine the cause before continuing if the drawer is not in the desired position.
  • Only use the provided racking/charging handle or electrically with the optional integrated motorized racking system. Other methods to rack the auxiliary drawer should not be used and could damage the racking mechanism.
  • Do not exceed the racking mechanism maximum torque limit when racking an auxiliary drawer into or out of the connected position to help prevent damage to the drawer or auxiliary compartment.
Failure to follow these instructions will result in death or serious injury.

Moving an Auxiliary Drawer Out of the Connected Position to the Disconnected Position

When a racking mechanism is not installed:

  1. Open the compartment door per instructions in this user guide.

  2. On CPT compartments, open the secondary circuit breaker on the CPT drawer.

  3. Unscrew the two thumbscrews at the top left and right corners of the drawer (see the figures CPT Compartment and Drawer Features and VT Compartment and Drawer Features).

  4. Use the black pull handle, located on the front, middle of the drawer, to pull the drawer out of the connected position to the disconnected position (see the figures CPT Compartment and Drawer Features and VT Compartment and Drawer Features).

    NOTE: The arrow on the plate mounted on the middle, bottom of the drawer should align with the symbol for disconnected on the label located on the compartment floor (see the figures Auxiliary Compartment without Racking Mechanism Position Indicator (shown in Transport position) and Auxiliary Drawer Position Indicator Symbols).

When a racking mechanism is installed:

  1. On CPT compartments, first open the compartment door, open the secondary circuit breaker on the CPT drawer (see the figure CPT Secondary Circuit Breaker Operation), and then close the compartment door per instructions in this user guide.

  2. With the auxiliary compartment door closed, insert the racking handle into the racking port and engage the handle into the racking shaft (see the figures Auxiliary Compartment Door Faceplate with Racking Mechanism, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features).

  3. Rotate the racking handle counter-clockwise to rack the auxiliary drawer into the disconnected position. When in the disconnected position, the outward motion of the auxiliary drawer stops.

    NOTE: If the racking system is motorized, the drawer may be racked in and out using electrical controls.

  4. With the auxiliary compartment door closed, the position indicator on the front of the racking mechanism reflects if the auxiliary drawer is in the disconnected, transport, or connected position (see the figures Auxiliary Compartment Door Faceplate with Racking Mechanism, CPT Compartment and Drawer Features, Auxiliary Drawer Position Indicator Symbols, VT Compartment and Drawer Features).

    NOTE: When the auxiliary drawer is being transported to or from the connected position, the racking position indicator will show a symbol for transport (see the figure Auxiliary Drawer Position Indicator Symbols).

  5. Continue rotating the racking handle counter-clockwise until the racking position indicator shows the symbol for the disconnected position (see the figures Auxiliary Compartment Door Faceplate with Racking Mechanism, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features).

    NOTE: When the racking position indicator shows the symbol for disconnected and is not moving any further then the auxiliary drawer is fully racked out of the auxiliary compartment and the auxiliary drawer primary contacts are disconnected, (see the figure Auxiliary Drawer Position Indicator Symbols).

Moving an Auxiliary Drawer Into the Connected Position from the Disconnected Position

When a racking mechanism is not installed:

  1. Open the auxiliary compartment door per instructions in this user guide.

  2. Remove padlock, if installed, from a disconnected padlock bracket (if equipped with option) found on the front right side compartment floor area.

  3. If equipped with automatic disconnect latch bracket, raise up on the latch.

  4. Push on the drawer, in area near the black pull handle, located on the front, lower, middle of the drawer, to move the drawer out of the disconnected position to the connected position (see the figures CPT Compartment and Drawer Features and VT Compartment and Drawer Features).

    NOTE: The arrow on the plate mounted on the middle, bottom of the auxiliary drawer should align with the symbol for connected on the label located on the compartment floor and the auxiliary drawer front pan should come flush with the barriers in the compartment (see the figures Auxiliary Compartment without Racking Mechanism Position Indicator (shown in Transport position), Auxiliary Drawer Position Indicator Symbols, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features).

  5. Screw in the two thumb screws at the top left and right corners of the drawer (see the figures Auxiliary Compartment Door Faceplate with Racking Mechanism, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features).

  6. On CPTs, close the secondary circuit breaker.

  7. Close the auxiliary compartment door per instructions in this user guide.

When a racking mechanism is installed:

  1. Open the auxiliary compartment door per instructions in this user guide.

  2. Remove padlocks, if installed, from racking blocking cover and/or disconnected padlock bracket (if equipped with either option) found on the front right side compartment floor area.

  3. On CPTs, make sure the secondary circuit breaker is open (see the figures CPT Secondary Circuit Breaker Operation, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features).

  4. Verify the auxiliary drawer racking mechanism dismounting bolt is connected to the racking mechanism in the compartment and is properly torqued (see the figures CPT Compartment and Drawer Features and VT Compartment and Drawer Features, and the table Switchgear Bolt Torque Value).

  5. Close the auxiliary compartment door per instructions in this user guide.

  6. Insert the racking handle into the racking port and engage the handle into the racking shaft (see the figures Auxiliary Compartment Door Faceplate with Racking Mechanism, Auxiliary Drawer Position Indicator Symbols, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features).

  7. Rotate the racking handle clockwise to rack the auxiliary drawer into the connected position. When in the connected position, the inward motion of the auxiliary drawer stops.

    NOTE: If the racking system is motorized, then the drawer may be racked in and out using electrical controls.

  8. With the auxiliary compartment door closed, the position indicator on the front of the racking mechanism reflects if the auxiliary drawer is in the disconnected, transport, or connected position.

    NOTE: When the auxiliary drawer is being transported to or from the connected position, the racking position indicator will show a symbol for transport.

  9. Continue rotating the racking handle clockwise until the racking position indicator shows the symbol for connected position (see the figures Auxiliary Compartment Door Faceplate with Racking Mechanism and Auxiliary Drawer Position Indicator Symbols).

    NOTE: When the racking position indicator shows the symbol for connected and is not moving any further then the auxiliary drawer is fully racked into the auxiliary compartment and the auxiliary drawer primary contacts are connected.

  10. On CPT compartments, open the compartment door again, close the secondary circuit breaker (see the figures CPT Secondary Circuit Breaker Operation, CPT Compartment and Drawer Features, and VT Compartment and Drawer Features), and then re-close the compartment door per instructions in this user guide.

Removing an Auxiliary Drawer From a Compartment

  1. Open the auxiliary compartment door per instructions in this user guide.

  2. Make sure the auxiliary drawer is in the disconnected position.

  3. If equipped with a racking system, locate the racking mechanism dismounting bolt located on the middle, bottom of the auxiliary drawer and use a tool to unbolt the auxiliary drawer from the racking system in the compartment (see the figures CPT Compartment and Drawer Features and VT Compartment and Drawer Features). The dismounting bolt should remain with the auxiliary drawer.

  4. Pull out the left and right auxiliary compartment extension rails (see the figure Extension Rails in Fully Extended Position).

  5. Use the black pull handle, located on the front, middle of the drawer, to pull the drawer out onto the extension rails (see the figures CPT Compartment and Drawer Features and VT Compartment and Drawer Features).

    NOTE: This position can also be used to help perform inspection and maintenance of the auxiliary drawer.

  6. Prepare and use a SureSeT lift truck to remove the auxiliary drawer from the auxiliary compartment extension rails according to the instructions in the section SureSeT Circuit Breaker/Auxiliary Drawer Lift Truck.

Extension Rails in Fully Extended Position

CPT and VT Drawer Installation

Typically the auxiliary drawers are shipped in the switchgear in the connected position. If the drawers were shipped outside the equipment or are replacement drawers, use the SureSeT lift truck to move the drawer into the compartment and then follow the steps to move it to the connected position first. Refer to the section SureSeT Circuit Breaker/Auxiliary Drawer Lift Truck for further information on how to use the lift truck.

With all of the control power transformer (CPT) and voltage transformer (VT) drawers in the connected position, move all of the drawers to the connected position in all of the auxiliary compartments in the entire switchgear line-up. Observe the movement of the drawers and verify that:

  • the static primary discharge ground contacts in the compartments touch the moving drawer contacts

  • the primary and secondary contacts make proper contact

  • the auxiliary drawer sliding ground contact is swiping down the auxiliary compartment ground bar correctly

Visually inspect fuses for possible damage and make sure insulating boots are installed and properly closed. Replace the fuses if necessary.

DANGER
hazard of electric shock, explosion, or arc flash
  • Make sure CPT or VT drawer ground wires have adequate clearance from primary conductors.
  • Properly terminate auxiliary cables and the auxiliary cable shields. The cable shielding must be grounded at both ends of termination to the ground bus of each section and the cable stress cones must have adequate clearance from sources of ground potential and from other phases.
  • Properly discharge the residual charge on any previously energized auxiliary cables prior to performing work in the equipment.
Failure to follow these instructions will result in death or serious injury.

Prior to energization, verify spacing of all VT and CPT drawer cabling is adequate. If any auxiliary drawer ground wires have been modified or disconnected prior to installation, make sure the wires are re-terminated and routed properly, with adequate clearance from any primary conductors. After inspecting the auxiliary drawers, follow all the installation and start-up steps.

The bus from an auxiliary compartment is not designed to be unbolted from the connections to primary main bus or cable connection bus. The shielded cable connections from auxiliary compartments are designed to run parallel in sections, specifically at the cable termination points. However, when cables pass through side sheets, the cable insulation and grounded shielding of the cable jacket allow the cables to be grouped. The cable connections from auxiliary compartments are also not designed to be unbolted from the connections to primary main bus or cable connection bus. If, for some reason, an auxiliary cable is disconnected in the field, make sure it is properly terminated again. The cable shielding must be grounded at both ends of termination to the ground bus of each section and the cable stress cones must have adequate clearance from sources of ground potential and from other phases (Figure Cable Termination).

Cable Termination

A

Shielded MV cable

 C

Zip tie

 E

Cable lug

    
B

Adequate cable bending radius

 D

Stress cone

 F

Bus into auxiliary compartment

    
NOTE: Insulating boots are included in assembly, but not shown in figure for clarity.

Visually inspect for any damage to the insulation or accumulation of dust on the bus or cable throughout the entire lengths of bus and cable, including on the cable stress cones. Replace the bus or cables in case of any signs of damage. Remove any dust accumulation with a clean, dry, lint-free cloth.

  1. Make sure all auxiliary cables adhere to the minimum bend radius or cable length so the cables route through the section without being stressed (see the figure Cables with Correct Routing).

    NOTE: Typically, the cables must have a minimum bend radius of 8 in. (203 mm) and the cable termination points must always maintain adequate dielectric clearances from other phases and ground potentials.

  2. Make sure gaskets are firmly in place in the knockout holes in the side sheets through which the auxiliary cables pass.

Cables with Correct Routing

NOTE: Insulating boots are included in assembly, but not shown in figure for clarity.
NOTE: The external surface of each shielded cable is at ground potential and must be positioned to have adequate dielectric clearances from all electrical conductors.

Dielectric Withstand Testing

Before making external power connections, perform a high-potential dielectric withstand test on the switchgear line-up bus and circuit breakers. To prepare for this test, do the following:

  1. Disconnect the surge arresters i.e., lightning arresters (LAs) and surge capacitors, when installed.

  2. Disconnect the CPT and/or VT drawer(s), if provided.

  3. Place each of the circuit breakers in the proper circuit breaker compartment in the connected position.

  4. Charge the circuit breaker operating springs manually, then close each circuit breaker by pressing the CLOSE (I) push button located on the front of the circuit breaker.

    Refer to the section Manual Spring Charging Mechanism for further circuit breaker operating instructions.

Use a transformer-type tester with a built-in voltmeter and milliammeter for dielectric withstand testing. Capacitor-loaded, bench-type testers with neon bulb indicators do not have sufficient capacity to give reliable results.

The table One-Minute High-Potential Dielectric Withstand Test* provides normal test values for dry, clean, new equipment. Field dielectric withstand tests are made at 75% of factory test voltages in accordance with ANSI standards.

One-Minute High-Potential Dielectric Withstand Test*

Switchgear Rated Maximum Voltage

Factory Test Voltage

Field Test Voltage

AC

DC

5 kV

19 kV

14 kV

20 kV

15 kV

36 kV

27 kV

38 kV

Phase-to-Phase Test

  1. Perform a phase-to-phase dielectric withstand test on the main bus.

    1. Gradually increase the voltage to the levels shown in Table 4.

    2. 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.

Phase-to-Ground Test

  1. Perform a phase-to-ground dielectric withstand test on the main bus.

    1. Gradually increase the voltage to the levels shown in Table 4.

    2. 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.

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 switchgear.

Phasing

In accordance with the standards, the phase arrangement within the three-phase assembled switchgear buses and primary connections is phased 1, 2, 3, from front to back, top to bottom, or left to right, as viewed from the front of the switchgear (the front-sub-section side). If, for any reason, the bus must be phased differently or identified by the user differently (such as with phases labeled A-B-C), then the different phase will be identified on the bus with a label.

Cable Connections

Be very careful when making all types of cable terminations, as terminations are essential to the successful operation of the electrical distribution system. To keep from exceeding the number of cable terminations permitted per phase per section configuration, refer to the table Recommended Maximum Number of Conductors Per Phase. Avoid sharp turns, edges, or corners to help 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 the cable connection termination as follows:

  1. Place 3M™ Scotchfil™ electrical insulating putty around the lugs and bolts to reduce the concentrated field created by the lug and bolt irregular shapes (see the figure High-Voltage Cable Lug Insulation ).

    1. Apply a layer of 3M Scotch® 13 electrical semiconducting tape over the Scotchfil insulating putty. Half-lap the tape, which must extend onto the conductor.

      NOTE: Do not extend the tape up over the bus epoxy insulation.

    2. Apply 3M Scotch 130C splicing tape over the Scotch 13 tape. Half-lap this tape for two layers on 5 kV installations, and four layers on 15 kV installations.

      NOTE: For 5 kV applications, extend this tape 1.5 in. (38 mm) up over the bus insulation and cable insulation. Extend the tape 2 in. (51 mm) for 15 kV applications.

  2. Apply two layers of 3M Scotch 22 electrical tape, extending the tape up over the Scotch 130C tape in all directions. The tape and other insulating materials for completing these field connections are not supplied with the switchgear.

  3. When potheads or cable terminators are supplied for terminating power cables, follow the cable manufacturer’s instructions for terminating the cables on 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.

NOTE: The external surface of each shielded cable is at ground potential and must be positioned a minimum of 6 in. (152 mm) from any live part (even if it is of the same phase potential), including insulated busbars.

High-Voltage Cable Lug Insulation

A

Fill voids with Scotchfil putty

 E

Two layers of tape
B

One layer Scotch 13 semiconducting tape

 F

0.5 in. (13 mm) Scotch 22 electrical tape
C

Scotch 130C splicing tape:

  • Two layers for 5 kV

  • Four layers for 15 kV

 G

Overlap Scotch 130C splicing tape over bus insulation:

  • 1.5 in. (38 mm) for 5 kV

  • 2 in. (51 mm) for 15 kV
D

NOTE: All taping is half-lapped.

 H
NOTE: Scotch 13 semiconducting tape must touch bus or terminals in at least one place. Tape should not overlap bus or cable insulation.

Cable Connection Example

A

Insulated primary cable connection bus

 B

2–hole NEMA terminal (FCI-Burndy type YA39A5 lug shown)

 C

15 kV, shielded indoor termination (TFT-153R-G shown)

 D

Four 750 kcmil cables from below

Recommended Maximum Number of Conductors Per Phase

Conductor Size
(kcmil)

Maximum Number of Conductors Per Phase (Total)

Two-High with Cable Duct Applications

Two-High with No Cable Duct Applications

One-High Standard Applications

One-High Applications with Landing Pad Adapters

Tie Bus with Barriers Applications

750

2 (6)

4 (12)

4 (12)

6 (18)

3 (9)

500

350

3 (9)

250
NOTES:

  1. Recommended number of conductors per phase is based on section type/application. This will help with the placement of ZSCT, auxiliary primary connection cables, surge arresters, etc.

  2. Conduit sizes and placement in foundation and applications with zero sequence current transformer (ZSCT) may reduce the number/size of cables per phase for some applications.

  3. Conduit sizes and placement in foundation and applications with zero sequence current transformer (ZSCT) shall be properly selected by the installer to ensure the optimal number of cables per phase.

  4. Voltage drop from cable lengths is not considered in table above.

  5. This information is only a recommendation and the actual application must be properly configured by the installer for each use.
QR Code is a registered trademark of DENSO WAVE INCORPORATED in Japan and other countries.

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