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Instruction Booklet 

IB182047EN

Effective February 2018

Arc flash limiter (AFL)  

conversion system 

  

EATON

 www.eaton.com

Warnings and cautions

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 WARNING

IMPROPERLY OPERATING OR MAINTAINING THIS ARC FLASH LIMITER 

(AFL) CONVERSION SYSTEM CAN RESULT IN DEATH, SERIOUS PERSONAL 

INJURY, OR PROPERTY DAMAGE. 

 

READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING 

ANY OPERATION OR MAINTENANCE OF THE CIRCUIT BREAKER OR OTHER 

SYSTEM COMPONENT. 

 

INSTALLATION OF THIS AFL CONVERSION SYSTEM MUST BE PERFORMED 

ONLY BY QUALIFIED PERSONNEL THAT ARE TRAINED FOR THE 

INSTALLATION. 

 

SYSTEM MAINTENANCE SHOULD BE ATTEMPTED ONLY BY QUALIFIED 

PERSONNEL.  THIS INSTRUCTION BOOK SHOULD NOT BE CONSIDERED 

ALL INCLUSIVE REGARDING OPERATION OR MAINTENANCE PROCEDURES.  

IF FURTHER INFORMATION IS REQUIRED, CONTACT YOUR EATON 

REPRESENTATIVE.

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 WARNING

ALL SAFETY CODES, SAFETY STANDARDS, AND/OR REGULATIONS AS 

THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY 

FOLLOWED. 

 

SERIOUS INJURY, INCLUDING DEATH, CAN RESULT FROM FAILURE TO 

FOLLOW PROCEDURES OUTLINED IN THIS MANUAL, OR COMPLY WITH 

THE REQUIREMENTS OF APPLICABLE STANDARDS.

1 Introduction

1.1 Preliminary comments and safety precautions

This technical document is intended to cover most aspects associ-

ated with the application, operation, and maintenance of the Eaton 

arc flash limiter (AFL) conversion system equipped with a Type 

VCP-TR circuit breaker .  It is provided as a guide for authorized and 

qualified personnel only .  Please refer to the specific WARNINGS and 

CAUTIONS in Section 1 .1 .2 before proceeding .
If further information is required by the purchaser regarding a 

particular operation, application, or maintenance activity, contact your 

Eaton representative .

1.1.1 Warranty and liability information

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING 

WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OF 

MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE 

OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING 

THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS 

CONTAINED HEREIN .
In no event will Eaton be responsible to the purchaser or user in 

contract, in tort (including negligence), strict liability or otherwise 

for any special, indirect, incidental or consequential damage or loss 

whatsoever, including but not limited to damage or loss of use of 

equipment, plant, or power system, cost of capital, loss of power, 

additional expenses in the use of existing power facilities, or claims 

against the purchaser or user by its customers resulting from the 

use of the information and descriptions contained herein .

1.1.2 Safety precautions

All safety codes, safety standards, and/or regulations must be strictly 

observed in the operation and maintenance of this system .

m

 WARNING

THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE 

PROCEDURAL STEPS IN THIS DOCUMENT ARE FOR PERSONNEL SAFETY 

AND PROTECTION OF EQUIPMENT FROM DAMAGE.  AN EXAMPLE OF A 

TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO FAMILIARIZE 

PERSONNEL WITH THE STYLE OF PRESENTATION.  THIS WILL HELP TO 

INSURE THAT PERSONNEL ARE ALERT TO WARNINGS, WHICH MAY 

APPEAR THROUGHOUT THE DOCUMENT.  IN ADDITION, CAUTIONS ARE 

ALL UPPER CASE AND BOLDFACE AS SHOWN BELOW.

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 CAUTION

COMPLETELY READ AND UNDERSTAND THE MATERIAL PRESENTED IN 

THIS DOCUMENT BEFORE ATTEMPTING OPERATION OR APPLICATION OF 

THE EQUIPMENT.  IN ADDITION, ONLY QUALIFIED PERSONEL SHOULD BE 

PERMITTED TO PERFORM ANY WORK ASSOCIATED WITH THE EQUIPMENT.  

ANY WIRING INSTRUCTIONS PRESENTED IN THIS DOCUMENT MUST BE 

FOLLOWED PRECISELY.  FAILURE TO DO SO COULD CAUSE PERMANENT 

EQUIPMENT DAMAGE.

1.2 General information

The purpose of this instruction booklet is to provide instructions for 

the operation and maintenance of AFL conversion system equipped 

with a VCP-TR circuit breaker .  Designed to Institute of Electrical and 

Electronics Engineers (IEEE) Standards for reliable performance, 

ease of handling, and simplified maintenance, VCP-TR circuit break-

ers provide reliable control and protection for electrical equipment 

and circuits .  In addition, these technologically advanced circuit 

breakers provide higher insulation levels in less space, thus reducing 

the overall switchgear size .

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 WARNING

SATISFACTORY PERFORMANCE OF THE AFL CONVERSION SYSTEM 

IS CONTINGENT UPON PROPER APPLICATION AND ADEQUATE 

MAINTENANCE.  THIS INSTRUCTION BOOKLET MUST BE CAREFULLY 

READ AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE 

FOR LONG USEFUL LIFE OF THE CIRCUIT BREAKER AND OTHER SYSTEM 

COMPONENTS.

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 WARNING

THE AFL CONVERSION SYSTEM DESCRIBED IN THIS INSTRUCTION 

BOOKLET IS DESIGNED AND TESTED TO OPERATE WITHIN THEIR 

NAMEPLATE RATINGS.  OPERATION OUTSIDE OF THESE RATINGS MAY 

CAUSE THE  EQUIPMENT TO FAIL, RESULTING IN DEATH, SEVERE BODILY 

INJURY, AND PROPERTY DAMAGE. 

 

ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS 

THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY 

FOLLOWED.

Содержание AFL

Страница 1: ...ents Description Page 1 Introduction 2 2 AFL conversion system and components 3 3 Typical installation performed by qualified personnel 5 4 AFL conversion system control unit 7 5 Maintenance 8 6 Parts List 8 Appendix A 9 Arc flash limiter AFL conversion system ...

Страница 2: ...ost of capital loss of power additional expenses in the use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information and descriptions contained herein 1 1 2 Safety precautions All safety codes safety standards and or regulations must be strictly observed in the operation and maintenance of this system m WARNING THE WARNINGS AND...

Страница 3: ...n and a set of current sensors are added to the secondary side of the transformer to feed the ARMS feature on the breaker trip unit In some cases the original discon nect switch is retained The control unit also includes a breaker control switch and breaker status LEDs for breaker control The 520MCV trip unit with Maintenance Mode in the breaker inter faces with the ARMS switch mounted in the cont...

Страница 4: ...ll introduce an increased risk of destructive high voltage transients into the system Transient voltages have been proven to cause transformer failures during switching To mitigate this risk it is highly recommended Eaton Power Systems Engineering PSE conduct a switching transient study to determine the optimal surge protection surge arrester RC snubber and or damping resistor needed to mitigate s...

Страница 5: ... joints and connections and insure they meet the standards identified in NEC Table 490 24 Qualified field service technicians will install the disconnect switch to breaker connections These will usually be copper bus work typically 1 4 x 2 or 1 4 x 3 6 35 x 50 8 mm or 6 35 x 76 2 mm In some cases the connections will be cable instead of copper bus work depending on the rating of the breaker Refer ...

Страница 6: ...th the AFL conversion system it was designed based on the results of the optional study of the customer s existing original electrical system performed by Eaton PSE Figure 7 Typical custom snubber Qualified field service technicians will install the control unit either on the enclosure door or mounted remotely based on the customer s preference If a remotely mounted control unit is selected the co...

Страница 7: ...s 50 51 protection 2 Breaker control switch The breaker control switch is used to open and close the breaker 3 Red indicating LED pushbutton The red indicating LED pushbutton indicates the breaker is closed 4 White indicating LED pushbutton The white indicating LED pushbutton indicates the springs of the breaker are charged 5 Green indicating LED pushbutton The green indicating LED pushbutton indi...

Страница 8: ... 3 Current sensor 3 AFL control unit 120 Vac NEMA 1 1 Copper phase A load 1 Copper phase B load 1 Copper phase C load 1 Copper phase A line 1 Copper phase B line 1 Copper phase C line 1 Phase barrier 2 Nameplate Eaton AFL Assembly 1 Nameplate AFL Ratings 1 Table 2 Torque values for general mounting and screw size conversion Decimal size in Standard size Torque in lbs Torque ft lbs 112 4 40 10 0 8 ...

Страница 9: ...T OVERLAP A SPECIFIED DISTANCE MEASURED ALONG THE PRE INSULATION STARTING FROM THE POINT WHERE THE PRE INSULATION ENDS AND THE EXPOSED CONDUCTOR BEGINS METHODS GENERAL 1 ELONGATE INSULATING TAPE 10 TO 25 PERCENT DURING APPLICATION TO INSURE A SMOOTH TIGHT FIT ON PADS ELONGATE CORNERS ONLY 2 SHOULD A TAPE ROLL EXPIRE START THE NEW ROLL BY OVERLAPPING THE PREVIOUS END BY 5 TURN T JOINTS WITH HARDWAR...

Страница 10: ... 030 THICK PAD 2 STARTING 50 INCH FROM CENTER AND EXTENDING OVER PREINSULATION AT LEAST 1 0 INCH WITH 1 1 4 LAPS APPLY 3 00 X 030 THICK PAD 3 STARTING 1 00 FROM PAD 2 AT CENTER AND EXTENDING 1 00 IN OVER PREINSULATION PER FIG 8 6 APPLY ONE LAYER OF INSULATING TAPE 1 00X 030 USING 2 3 LAP AND EXTENDING 0 50 INCH MINIMUM BEYOND THE PADS ON THE PREINSULATION PER FIG 9 7 APPLY A SECOND LAYER OF INSULA...

Страница 11: ...ated pothead bushing Pothead ground lead must be carried through the Zero Sequence current transformer and solidly grounded on the load side of the ct as shown Use 6 wire with 600 V insulation Power cables Conduit when used Cable connections to switchgear terminals when used with Insulated Pothead Conduit must be terminated and solidly grounded on the load side of the current transformer Zero Sequ...

Страница 12: ...between Eaton and the purchaser THERE ARE NO UNDERSTANDINGS AGREEMENTS WARRANTIES EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETW...

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