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Instruction Bulletin - 01.4IB.46300

FlexTrol™ Class E2 Medium Voltage Controllers

5kV and 7.2kV - 400A and 800A

Motor Control with Eaton Contactors

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Summary of Contents for FlexTrol Class E2

Page 1: ...Instruction Bulletin 01 4IB 46300 FlexTrol Class E2 Medium Voltage Controllers 5kV and 7 2kV 400A and 800A Motor Control with Eaton Contactors Powered by Safety...

Page 2: ...Class E2 Medium Voltage Controllers with Eaton Contactor 01 4IB 46300 Contact Information Powell Electrical Systems Inc powellind com info powellind com Service Division 7232 Airport Blvd Houston Texa...

Page 3: ...t the safety alert symbol is used to address practices not related to personal injury CAUTION NOTICE NOTICE is used to address practices not related to personal injury Qualified Person For the purpose...

Page 4: ...Powered by Safety FlexTrol Class E2 Medium Voltage Controllers with Eaton Contactor 01 4IB 46300 This page is intentionally left blank...

Page 5: ...ctric Test 11 F Medium Voltage Contactors 11 G Manual Isolation Switch 12 H Mechanical Interlocking 14 I Auxiliary Compartments 16 J Power Fuses 16 K Starting Autotransformers or Reactors 17 L Dimensi...

Page 6: ...n 36 A General 36 B Preparation of the Controller for Operation 36 1 Cleaning 36 2 Lubricating 36 3 Manual Operation 37 4 Adjustments 37 5 Pre Startup Checks 37 6 Contactor Interlock Pre Start Up Chec...

Page 7: ...and Replacement Procedures 45 A Ordering Instructions 45 B Recommended Renewal Parts 45 1 Renewal Parts Quantity 45 C Replacement Procedures 45 1 Fuse Removal Replacement Procedure 46 2 Auxiliary Cont...

Page 8: ...ypical Dimensions for FlexTrol 15 Figure 8 Recommended Method for Lifting an Indoor Lineup 19 Figure 9 Typical FlexTrol Floor Plans 20 Figure 10 Ground Bus Splicing Configuration 25 Figure 11 Insulati...

Page 9: ...Tee Connection Joint 28 Table J Insulation of Dead End Bus Bar Joint 29 Table K Eaton Publication References 42 Table L Medium Voltage Vacuum Contactor Eaton 400A SL Renewal Replacement Parts 48 Table...

Page 10: ...Powered by Safety vi FlexTrol Class E2 Medium Voltage Controllers with Eaton Contactor 01 4IB 46300 This page is intentionally left blank...

Page 11: ...servicing maintenance or any act requiring the operator to make physical contact with the equipment the power source must be disconnected and the equipment grounded Failure to do so may result in deat...

Page 12: ...exact construction details of each particular type of FlexTrol Class E2 Medium Voltage Controllers The illustrations in this document are provided as general information to aid in showing component l...

Page 13: ...source N Exception No 1 An adequately rated permanently mounted test device shall be permitted to be used to verify the absence of voltage of the conductors or circuit parts at the work location provi...

Page 14: ...te operation of protective devices in case of unintentional energizing of the electric conductors or circuit parts B Safety Guidelines Study this instruction bulletin and all other associated document...

Page 15: ...ding these mechanisms is found in this instruction bulletin and in the instruction bulletin for the vacuum contactors 5 DO NOT ATTEMPT TO MANUALLY CLOSE THE VACUUM CONTACTOR ON AN ENERGIZED CIRCUIT 6...

Page 16: ...has DANGER WARNING CAUTION and instruction labels attached to various locations All equipment DANGER WARNING CAUTION and instruction labels shall be observed when the medium voltage controller is han...

Page 17: ...for applicability to his particular controller by referring to the drawings supplied with the controller The basic FlexTrol is an assembly of components and conductors for motor starting arranged for...

Page 18: ...Powered by Safety 8 01 4IB 46300 Equipment Description FlexTrol Class E2 Medium Voltage Controllers with Eaton Contactor Figure 1 FlexTrol 400A 800A a 400A Controller b 800A Controller a b...

Page 19: ...ad connections The contactor is held in place by a set of rails mounted in the lower part of the cell Current transformers are typically mounted immediately behind the main contactor under the load si...

Page 20: ...w voltage compartment shall only be entered with extreme care Figure 3 High and Low Voltage Compartments a b c d f g j e h i k l a Surge Arrester b Main Bus c Wireway d Isolation Switch e High Voltage...

Page 21: ...2500 50000 5000 50000 7200 50000 Note For additional vacuum contactor ratings information refer to Eaton Technical Data TD02003001E F Medium Voltage Contactors Two types of medium voltage vacuum cont...

Page 22: ...the AC magnet could be as high as 60 of the coil rated voltage A mechanically latched contactor function optional is used when the vacuum contactor must stay closed during severe under voltage condit...

Page 23: ...s where the controller is back fed the grounding fingers should be removed from the isolation switch The switch consists of a fixed rear portion and a removable front portion The fixed portion include...

Page 24: ...vents opening the medium voltage door with the switch in the closed position Ensure that the medium voltage door is fully closed and latched using the two latches on the right side of the door to prev...

Page 25: ...r FlexTrol Note The drawings in Figure 7 should NOT be used for any construction purposes For construction information refer to the specific drawings furnished with the equipment 107 00 27 00 73 00 92...

Page 26: ...ed Defeating the interlock will expose energized components and may result in injury or death I Auxiliary Compartments A variety of enclosure sizes and medium voltage compartments are furnished in Fle...

Page 27: ...sible damage to the reactor or autotransformer L Dimensions Refer to the equipment drawings for the specific dimensions and an outline of the equipment The FlexTrol 400A application is normally a one...

Page 28: ...r capacitors These components are identified by a number coinciding with the number on the section on which they are to be mounted C Storage Shipping and storage of electrical equipment requires measu...

Page 29: ...ioned and handled by suitable lifting devices of adequate load ratings A maximum of 3 units can be lifted together During handling the rigging lengths of lifting equipment such as slings or cables sho...

Page 30: ...rollers with Eaton Contactor Figure 9 Typical FlexTrol Floor Plans Note The drawing in Figure 9 should NOT be used for any construction purposes For construction information refer to the specific draw...

Page 31: ...orrosion If welding facilities are not available the switchgear should be bolted to the floor channels CAUTION Do NOT work on a Medium Voltage Controller vacuum contactor with the control circuit ener...

Page 32: ...uses are deenergized iii For 400A contactors the fuses may be removed using a fuse puller for the clip on style fuses or by removing the bolts for the bolt on style fuses For 800A contactors the fuses...

Page 33: ...ailure to use caution when moving the contactor may result in equipment damage and or personal injury ix If the contactor is being replaced move the contactor interlock lever to the new contactor x Re...

Page 34: ...rrents or contact with dissimilar metals exists The resistance of the soil surrounding a station ground depends on the condition of the soil as well as its chemical content Dry loose sandy or frozen s...

Page 35: ...ment main bus by bars The equipment bars are normally silver plated Unplated bars either copper or aluminum should not be used to connect to plated bars 4 All field assembled primary conductor joints...

Page 36: ...any of the following methods Wrapping bus joints using tape or heat shrink material Applying PVC polyvinyl chloride boots K Incoming Power Connections Incoming power connections to the main bus may be...

Page 37: ...8 x 2 x 2 x 3 3 8 x 3 x 3 5 8 x 3 x 4 3 8 x 4 x 4 5 8 x 4 x 6 3 8 x 6 x 6 5 8 x 6 600V to 7200V 1 Layer Lap 2 4 5 6 8 9 11 12 4 2 3 3 4 5 5 6 Note Apply tape at medium tension to produce a void free...

Page 38: ...edges of joints HV Tape 0282A3529 P005 roll is 030 x 4 x 30 long HV Tape 0282A3529 P004 roll is 030 x 2 x 30 long Apply with mastic side down Figure 14 Tee Connection Joint Epoxy Insulation Thermoplas...

Page 39: ...t over the joint The boot should fit snugly around all conductors and flanges must contact each other in a smooth joint c Secure the boot with the furnished nylon wire ties to complete the joint insul...

Page 40: ...rollers with Eaton Contactor Figure 16 FlexTrol 400A a Isolation Switch and Shutter b Load Terminals c Power Fuses d Ground Connection e Contactor d a e c b Figure 17 FlexTrol 800A a Load Terminals b...

Page 41: ...e terminals to the bus or other point of termination 4 If contact between the cable and an adjacent bus cannot be avoided tape the bus in the immediate vicinity of the cable contact point so that the...

Page 42: ...ath cable or cable with shielding tape or braid is used it is recommended that the sheath or shield be grounded solidly to the switchgear ground bus The ground lead should be bonded to the sheath or s...

Page 43: ...he schematic and wiring diagrams furnished for each specific job for connection of all control wires to the designated terminal blocks CAUTION Control wiring terminal blocks are supplied in great vari...

Page 44: ...On the inside surface of the high voltage compartment door is a small projection located immediately above the operating handle opening This projection engages a rounded pin from the isolation switch...

Page 45: ...s in the CLOSED position the interlock lever on the vacuum contactor armature actuates a mechanical linkage which locks the operating handle operating mechanism of the isolating switch 4 Door Interfer...

Page 46: ...e armature of many of the relays and vacuum contactors Ensure all blocks and ties are removed to prepare FlexTrol for full operating condition Inspect the compartment and equipment for loose hardware...

Page 47: ...emoval of the primary fuses is sufficient to protect the CPT or PT s Cables to the load should be disconnected Although an AC test is recommended a DC test may be performed if only a DC test unit is a...

Page 48: ...Close the main contactor with test power and attempt to operate the switch while holding the door interlock plunger in Figure 21 a The mechanical interlock should prevent the switch from operating h A...

Page 49: ...fore returning the unit to service D Hi Pot and Megger Test 1 Preparing for the Hi Pot and Megger Test Use the following information to prepare for the pre operation test a Ensure the motor control ce...

Page 50: ...rol center 2 Close the isolating switch by placing the operating handle in the extreme upper position until it latches into the ON position Figure 6 a If the operating handle is not properly closed an...

Page 51: ...oltage Vacuum Contactor Inspection All adjustments pertaining to the vacuum contactor are described in the following Eaton Publications 400A IB 48041 800A IB 48041 4 Medium Voltage Vacuum Contactor Te...

Page 52: ...ure 22 a or perform continuity tests to determine the condition of the fuses When visually inspecting a fuse if the colored indicator on top of the fuse extends outwards the fuse is in the OPEN positi...

Page 53: ...following deteriorating conditions 1 Contamination by dirt and dust in the environment including wood fibers coal dust cement lamp black and lint 2 Contamination by chemicals in the environment such...

Page 54: ...ng discoloring and deterioration 6 The isolating switch mechanism has a life expectancy of approximately 10 000 operations If the application requires that the mechanism operates more than twice each...

Page 55: ...dures D Replacement Parts Table L through Table V for a list of renewal parts for equipment described in this document 1 Renewal Parts Quantity The needed quantity of renewal spare parts varies The pu...

Page 56: ...i Remove the fuse from the fuse mounting studs iii Install the replacement fuse on the four mounting studs Hold the fuse in place and install the two upper flat washers lock washers and nuts Torque th...

Page 57: ...scorching or heat damage Replace any damaged contacts The contact have a mean time between failure MTBF rating of 20 million operations if used within the operating specifications b To remove the cont...

Page 58: ...Set of 3 2147A11G61 0 81 inch dia 5kV Max 3 Amp Set of 3 2147A11G49 0 81 inch dia 5kV Max 5 Amp Set of 3 2147A11G55 SL Contactor Operating Coils 2147A58G11 Latch Coil with Rectifier 24VDC 2147A58G25...

Page 59: ...843D943G22 L 64 Auxiliary Interlocks 2 NC 843D943G23 Barrier Assemblies Contactor Barrier Assembly 2147A89G07 Contactor Fuse Support Barrier Assembly 2147A89G06 Load or Line Fingers Contactor Line Fi...

Page 60: ...umber 2R 70 50kA A480R2R 1 3R 100 50kA A480R3R 1 4R 130 50kA A480R4R 1 6R 170 50kA A480R6R 1 9R 200 50kA A480R9R 1 12R 230 50kA A480R12R 1 18R 390 50kA A480R18R 1 24R 450 50kA A480R24R 1 Voltage Ratin...

Page 61: ...R 19R 300 50kA A051B1DAR0 19R 24R 450 50kA A051B2DAR0 24R 32R 540 50kA A051B2DAR0 32R 38R 600 50kA A051B2DAR0 38R 48X 750 50kA A051B3DAR0 48X 57X 900 50kA A051B3DAR0 57X Voltage Rating of 7 2kV R Desi...

Page 62: ...55F1D0R0 200E 250E 250 63kA A055F2D0R0 250E 300E 300 63kA A055F2D0R0 300E 350E 350 63kA A055F2D0R0 350E Table Q E Rated Bolt On Fuses for 800A Contactor Voltage Rating of 5 5kV E Designation Ampere Ra...

Page 63: ...ormers Part Number Description 21 101 CT ITI 100 5A C10 21 101MR CT ITI 100 5A MR 21 151 CT ITI 150 5A C20 21 201 CT ITI 200 5A C20 21 250 CT ITI 25 5A 21 251 CT ITI 250 5A C20 21 301 CT ITI 300 5A C2...

Page 64: ...tor 2 4 5 5kV fuse holder not required Part Number Description A500T1E 1 1E 5kV fuses for 1kVA CPT A500T2E 1 2E 5kV fuses for 2kVA CPT 400A Contactor 7 2kV fuse holder not required Part Number Descrip...

Page 65: ...46300 FlexTrol Class E2 Medium Voltage Controllers March 2019 Powered by Safety Powell Electrical Systems Inc Service Division Houston 7232 Airport Blvd Houston TX 77061 Tel 1 800 480 7273 powellind...

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