Eaton VacClad-W User manual

Effective December 2010
Supersedes September 2001
Instruction Booklet IB32267ARC
VacClad-W 38 kV arc-resistant
switchgear indoor housings
Contents
Description Page
Receiving, handling, and storing ..............2
Installing indoor switchgear..................4
Adjusting and testing......................12
Operation of the system ...................12
Inspection and maintenance ................13
Lubrication..............................14
Renewal parts ...........................14
A further description of arc-
resistant VacClad-W switchgear .............15
Accessories .............................22
Primary bus joints field
taping procedure (38 kV) ...................25
Read and understand these instructions before
attempting installation, operation, or maintenance
of this equipment. This equipment must be
installed and serviced only by qualified electrical
personnel. Retain this document for future use.
CAUTION
THE SWITCHGEAR DESCRIBED IN THIS BOOK HAS
BEEN DESIGNED AND TESTED TO OPERATE WITHIN
ITS NAMEPLATE RATINGS. OPERATION OUTSIDE
OF THESE RATINGS MAY CAUSE THE EQUIPMENT
TO FAIL, RESULTING IN BODILY INJURY AND
PROPERTY DAMAGE.
PURPOSE
THIS INSTRUCTION BOOK HAS BEEN PREPARED
TO HELP ENGINEERS AND TECHNICIANS INSTALL,
OPERATE, AND MAINTAIN TYPE VACCLAD-W
SWITCHGEAR. FOR INFORMATION ON THE
APPLICATION OF THIS TYPE OF SWITCHGEAR, REFER
TO THE PERTINENT ANSI AND EEMAC STANDARDS,
AND TO EATON’S CONSULTING APPLICATION GUIDE.
DANGER
ALL APPLICABLE SAFETY CODES, SAFETY STANDARDS,
AND SAFETY REGULATIONS MUST BE STRICTLY
ADHERED TO WHEN INSTALLING, OPERATING, OR
MAINTAINING THIS EQUIPMENT.

2
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Section 1: Receiving, handling, and storing
indoor switchgear
1.1 Receiving indoor switchgear
The switchgear is shipped to the customer as completely
assembled as possible. Depending on the number of switchgear
vertical sections, it may be necessary to ship the switchgear in
several groups to facilitate handling.
Each indoor switchgear is bolted to wooden skids and covered
with weatherproof material.
VCP-W breakers are shipped in individual containers. See breaker
I.B. 3A74792 for breaker handling instructions.
Each switchgear group and all the cartons and crates are labeled
with the shop order number and a shipping weight. On one of the
groups there will be a shipping packet, securely attached, that
contains the shipping lists, drawings, and so on.
When the switchgear arrives at the installation site, check it to make
sure all the parts described on the shipping list have been received.
Do this before discarding the packing material to prevent losing
parts. If the switchgear has been damaged, file a claim as soon as
possible with the carrier and notify the nearest Eaton representative.
If the switchgear is going to be installed as soon as it has been
received, unpack it and handle it according to the procedure outlined
in the following paragraphs. If the switchgear is to be stored, inspect
it to make sure the shipment is complete and undamaged. Repack
it so it will be protected until it has been installed. (See section on
storage of equipment.)
1.2 Handling indoor switchgear
Table 1 gives the approximate weights of the various combinations
of switchgear and the various ratings of breakers.
The preferred method of handling all switchgear assemblies is by
crane. Lifting members are bolted to the top of each shipping group.
Put a crane hook through each of the four holes to lift and move the
group. After the group has been moved into installation position,
remove the lifting members and discard them. Figure 1 shows the
lifting members for indoor switchgear.
If a crane is not available, move the group into installation position
on rollers. Skids run the length of the group. If the group is to be
skidded sideways, the front and back skids are enough. If it is to
be moved across its depth (from front to back), put in several short
skids across the depth of the group and roll it into position.
ote:N Never maneuver the switchgear directly on the rollers. Always use the
skids to protect the switchgear from being distorted or damaged.
Handle all switchgear whether crated or not crated with great care.
The instrument panels on the front of the vertical sections contain
delicate instruments, relays, and meters that can be damaged by
rough handling. If the switchgear is not put into service right away,
cover it to keep clean. (See section on storage of equipment.)
Figure 1. Handling of Indoor Shipping Group
Arc Pressure
Relief Flaps
Remove and
Discard Lifting
Angles After the
Installation

3
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Table 1. Typical Weights (Approximate)
Type VCP-W 38 kV Arc-Resistant Switchgear
Type of Vertical Section Main Bus Ampere Rating Indoor Vertical Section Less Breaker lbs (kg)
Breaker 1200
2000
2500
3000
3500 (1591)
3700 (1682)
4000 (1818)
4000 (1818)
Auxiliary section (no breaker) 1200
2000
2500
3000
3000 (1364)
3200 (1450)
3500 (1591)
3500 (1591)
Type VCP-W Circuit Breaker
Breaker Type Current Ampere Rating Breaker Element Static Weight lbs (kg) Breaker Element Impact Weight lbs (kg)
380 VCP-W 16
380 VCP-W 25
380 VCP-W 32
380 VCP-W 21
600
1200
1600
2000
1070 (486)
1080 (491)
1090 (495)
1140 (518)
1605 (730)
1620 (736)
1635 (743)
1710 (777)
380 VCP-W 40 600
1200
1600
2000
2500
1070 (486)
1080 (491)
1090 (495)
1140 (518)
1240 (564)
1605 (730)
1620 (736)
1635 (743)
1710 (771)
1860 (854)
1.3 Storing indoor switchgear
Packaging for shipping is not suitable for storage. Part of the original
packaging may be discarded when switchgear is removed from the
carrier. Switchgear bus runs, because of their open connection ends,
are particularly vulnerable to moisture and dirt during storage.
If the switchgear must be stored for a while, prepare a suitable storage
space. Keep it indoors in a heated building that is clean and dry. The
floor should be smooth and level to prevent strain and distortion in
the equipment. Be sure the space is well drained so that there is no
standing water. Store the switchgear on its skids to keep it off the
floor and to allow air to move under it freely.
Take steps to prevent the switchgear against dampness, cement
dust, corrosive atmospheres, and extreme temperature changes.
To control condensation, make sure the equipment is well
ventilated. Install temporary space heaters if necessary.
Switchgear should be checked periodically for any signs
of deterioration.
Storing the switchgear outdoors is not recommended. It is the
responsibility of the purchaser to ensure protection during storage.
All spare parts and miscellaneous equipment should be stored with
the same care as the main switchgear.
Summary of storage procedures:
1. Check the ventilation of the switchgear itself and of protective
coverings. Serious damage can result from a non-ventilated
tarpaulin.
2. Check the ventilation of enclosed storage areas of buildings.
3. Check for adequate heat; when in doubt, provide heat.
4. Check for distortion.
5. Check for damage and standing water.
6. Check weather protection including open doors, windows,
drafts, and so on.
7. Do not store outdoors.
8. Inspect periodically.
ote:N For detailed instructions on storing switchgear, refer to Eaton drawing
700B214. A copy of the drawing is attached to each group of switchgear.
1.4 Recommended safety practices
The only people who should be allowed to install, operate, or
maintain this equipment are those who meet the qualification
requirements described in the National Electrical CodeT(NECT).
To perform work on this type of equipment, one must be trained
and experienced in working with high voltage circuits. They should
be familiar with the construction and operation of this equipment
and be aware of the hazards involved.
Before attempting to do any maintenance, always be sure to
de-energize both the primary and the secondary circuits.
Never leave a breaker in an intermediate position in its compartment.
Always crank the breaker into the fully connected or withdrawn position.
Before removing a bolted-on cover, first make sure that all the
circuits have been de-energized.
Never try to disconnect or open the secondary circuit of a current
transformer that is carrying load current. In this situation, the trans-
former develops a dangerous high voltage. Before attempting work,
either de-energize the circuit by opening the breaker or short-circuit
the secondary of the current transformer.

4
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Section 2: Installing indoor switchgear
2.1 Outline of installation procedure
1. Prepare the installation foundation. It is recommended that floor
channels be embedded in the foundation to maintain a level surface.
2. At the factory, the switchgear lineup may have been divided
into groups to facilitate shipping. At the installation site, the
groups must be rejoined to form the switchgear lineup. Align
the groups, side-by-side, using the tie-bolt holes.
3. Bolt the groups together through the tie bolt holes.
4. Bolt or weld the base members of the vertical section frame,
front and rear, to the foundation channels.
5. Remove all shipping braces.
6. Connect the ground bus.
7. Connect the high voltage bus between the shipping group.
8. Connect the control wires.
9. Replace the metal barriers in the bus compartments.
10. Connect the main power cables and fully insulate the terminals
for the voltage class (see section on storage of equipment).
11. Replace the rear covers on all the vertical sections.
12. All 38 kV arc-resistant switchgear assemblies require an arc skirt
assembly to be installed above the roof of the switchgear for arc
expulsion containment.
13. Check the operation of the levering-in system in the breaker
compartments.
14. Check the potential transformers and the control power
transformers in the auxiliary compartments.
15. Perform loading check on both control and primary circuits to
ensure that the system is ready for operation.
2.2 Details of the installation
1. Prepare the foundation.
Review the floor plan drawings supplied for the order and the
following instructions carefully.
a. The minimum recommended clearances at the front, rear,
and sides of the switchgear are shown in Figure 2. Locate
the foundation so there is adequate space at the front, rear,
and sides of the switchgear lineup. Leave at least 6.6 feet
(2m) of unobstructed space above the roof of the switchgear
for arc expulsion. When applicable, an arc skirt is installed
within this space. No electrical equipment should be located
above the switchgear without proper protection suitable to
withstand arc expulsion.
b. Make sure that the foundation is flat, level, and in true plane.
c. Design the foundation so it will be strong enough to support
the weight of the switchgear without sagging. Table 1 gives
the weights of the various ratings of switchgear and breakers.
Be sure to take into account the shock or impact weight
that occurs when the breaker trips and when it closes.
The impact weight is 1.5 times the weight of the breaker.
The weights in the tables are only an approximation. The
actual weight will vary, depending on the type and the
amount of equipment in the switchgear. Use adequate
safety factors.
d. The recommended foundation consists of steel channels
embedded in a level concrete floor. The channels must lie in
a flat and level plane. A slope of 0.125 inch (3.175 mm) in 3
feet (0.9m) in any direction is acceptable. In no case may the
non-supporting areas of the foundation be higher than the
tops of the steel channels.
The anchor bolts, channels, and other materials are to
be furnished by the purchaser of the switchgear. A
4.00-inch (101.6 mm) structural channel is recommended
as the minimum size for the average indoor switchgear system
If unit substation transformers or high voltage switches
are part of the installation, be sure that the floor steel
under the transformer conforms to the specifications of
their manufacturers.
e. Install the conduits in the foundation.
When the primary and secondary cables enter the switchgear
from below, the conduits that carry them are embedded in
the foundation. A floor plan drawing is furnished with each
order. Use this drawing to determine the conduit locations.
Avoid circling of steel around single-phase cables rated 600A
or more to prevent overheating due to induced currents.

5
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Figure 2. Typical Indoor Base Plan
2. Align the shipping groups side-by-side on the foundation.
a. Remove the crating and packaging material from the groups
of switchgear that are going to be installed.
b. Let the shipping skids remain on each group until the group
has been moved into its final installation position. (The skids
help to protect the switchgear and to reduce the risk that it
will be damaged or distorted during the move.)
c. If an odd number of groups are to be installed, install the
middle one first. Then install the other groups, working out
from the middle.
If an even number of groups are to be installed, start with a
group on either side of the middle shipping break.
If a unit substation or a power center is being installed, line
up the power transformer and the adjacent switchgear group
first. Set them in the position called for on the drawing of the
base plan. Then install the rest of the groups.
d. Handling the switchgear by crane is the preferred method.
If no crane is available, the groups may be moved on the
skids and rollers.
Move the first group into position. Line up the bolt holes in
the base of the vertical sections with the bolt holes in the
steel channels in the foundation.
A few inches in front of the lineup, draw a baseline along
the length of the intended location of the switchgear. As the
groups are maneuvered into place, keep the front of each
group parallel to the baseline.
e. A bolt at each end of the wooden skids holds them to the
base of the group. Lift and remove the bolts, and discard
the skids.
f. Set the group into its installation position. Use a level to
make sure the group is level across its depth and along its
length. Use a plumb line to make sure the group is plumb.
(To level or plumb the group, use shims at the points where
the vertical sections will be bolted to the floors.)
Move each group into position and repeat the preceding
steps.
3. Bolt the groups together through the tie bolt holes.
a. Open rear doors (or remove rear covers) of the cells on side
of the shipping split. Install tie bolts between the shipping
splits. Refer to Figure 3 for the tie bolt locations. There are
five tie bolt locations at the rear of the rear-module. There are
four tie bolt locations at the rear of the mid-module. After all
tie bolts are installed, tighten the bolts.
b. Refer to Section 8.3 for instructions for breaker compart-
ment door. Open all front doors. Insert and tighten tie bolts
between the front upright members at each shipping split.
There are five tie bolt locations at the front and one location
at the rear of the mid-module. There are five tie bolt locations
at the front and two locations at the rear of the front-module.
( ) = Diagram dimensions in mm
a Anchor locations: indoor—0.5–13 inch bolts or weld, outdoor—0.5–13 inch bolts.
b Secondary conduit space: All—maximum of 1.00 inch (25.4) projection.
c Recommended minimum clearance to front of VacClad-W: 84 inches (2133.6).
d Recommended minimum clearance to LH or RH side of VacClad-W: 38 inches (965.2).
e Recommended minimum clearance to rear of VacClad-W: 42 inches (1066.8).
f Station ground connection provision.
g Finished foundation surface (including floor steel) must be flat and level and in true plane
h Primary conduit area for top or bottom entry.
i 4 inch (102 mm) channel

6
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
4. Check the entire lineup to make sure it is level and plumb prior
to bolting or welding to the foundation channels.
5. Remove all shipping blocks or braces.
a. Remove shipping braces from CT bushings in the main bus
compartment and CT spouts in the cable compartment.
b. Examine all meters, relays, and so on, and remove any
shipping blocks or braces. Remove lifting angles from top
of the units and discard them.
6. Connect the ground bus.
a. The ground bus in the switchgear is assembled in sections.
There is a joint in each housing. Solderless terminals are
provided on the ground bus in each end unit. Use these
terminals to connect the ground bus to the station ground.
Make the connection as direct as possible. It should be large
enough to carry the ground fault current of the installation.
Never house it in a metal conduit.
b. The standard ground bus is a 0.25 inch (6.4 mm) x 2.00 inch
(50.8 mm) copper busbar bolted to the cross members of the
frame in the bottom of each enclosure. The ground bus runs
through the center of each section through the length of the
entire switchgear system. Where the system is split for
shipping, a splice plate (and hardware) is furnished to
bridge the shipping break when the system is installed.
Refer to Figure 4.
ote:N The importance of adequate grounding cannot be overstressed. For
the design and installation of a grounding system, refer to electric power
distribution for industrial plants (IEEETSTD. 141); grounding of industrial
and commercial power systems (IEEE STD. 142); and the National
Electrical Code, Articles 100, 200, and 250.
For generating stations and larger substations, the ground resistance should
be 1 ohm or less. For industrial plants and small substations, the ground
resistance should be less than 5 ohms. (The National Electrical Code states
that the ground resistance should never exceed 25 ohms.)
Figure 3. Tie Bolt Locations
Figure 4. Ground Bus Installation
Ground Bus
(Rear View)
Ground Bus
Extension
(Rear View)

7
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
7. Connect the high voltage bus between the shipping groups.
a. Remove the horizontal metal barriers from the cable
compartment in the rear of the switchgear. Remove the
bus barrier. Also remove any other components such as
potheads, surge suppressers, and so on, that interfere with
access to the bus compartment.
ote:N Rear assembly of switchgear may vary. Figure 5 and Figure 6 show
the removal of necessary barriers (typical).
b. Obtain the section of bus that was removed to separate the
groups for shipping. Each section is labeled and shipped in
the carton with the details.
c. The surfaces in the bus joints are silver-plated. Clean the
plated surfaces of the bus section if necessary.
d. Slide the section of main bus through the supports in the
side of the vertical section. Slide the rubber snubber along
the bus until it fits inside the opening in the bus support.
When the bus section is disconnected for shipping, the
splice plates and hardware are left bolted to the end of the
bus in each of the adjoining vertical sections. Sandwich the
end of the disconnected section between the splice plates
and fit the other end of the section between the splice
plates on the end of the bus in the adjacent section. Bolt
the splice plates together on each end of the bus section.
Repeat these steps for each section of bus at each
shipping break.
Torque the bolts in the splice plate to the values shown
in Table 2.
Cover joints with the insulating boots provided. Figure 7 and
Figure 8 show the main bus installation and insulating boots.
Figure 5. Removal of Necessary Barriers
Figure 6. Removal of Necessary Barriers
(Main Bus Shown with Barrier Removed)
Main Bus
Barrier
Feeder Cable
Lugs
T-Boot-Main Bus
1C95090H01
Main Bus

8
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Table 2. Bolt Torque Values for Bus Connection
Bolt Size in Inches (mm)
Bolt Material—Torque in Foot-Pounds (Nm)
High-Strength Steel Silicon Bronze
0.25 (6.4) 5 (6.78) 5 (6.78)
0.31 (7.9) 12 (16.27) 10 (13.56)
0.38 (9.6) 20 (27.12) 15 (20.34)
0.50 (12.7) 50 (67.8) 40 (54.24)
0.62 (15.7) 95 (128.82) 55 (74.58)
Figure 7. Main Bus Installation—Dimensions in Inches (mm)

9
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Figure 8. Insulating Boots
8. Connect the control wires.
a. Reconnect the wiring that was disconnected at the factory
for shipping. The wiring as well as the connecting points
are labeled.
b. Connect the wiring to the remote apparatus and to the
terminal blocks located in the control compartment, or
within the front of the vertical section.
9. Replace the metal barriers and any other parts that may have
been removed to gain access to the main bus compartments.
10. Connect the main power cables.
a. Before connecting a cable, determine its phase. The switch-
gear system is supplied with connections for phasing 1-2-3,
left to right (viewed from the front), unless indicated
otherwise on the shop order drawings.
b. If the two systems are to be paralleled, make sure the phase
rotation and the phase angles are the same. They must be
the same to prevent damaging the equipment. The phase
rotation must conform to the phase rotation on the shop
order drawing so that the instruments, meters, and relays
will operate properly.
c. When forming cables to fit inside the cable compartment,
avoid bending it sharply or kinking it. Make sure it does not
rest on sharp corners or edges that could damage the insulation.
d. Follow the instructions of the cable manufacturer to deter-
mine what minimum bending radii is permitted. Follow the
instructions on insulating the joints so that the insulation will
taper properly through the correct gradient. The insulation
will vary with the type and size of cable, and with the service
voltage for which it was designed.
e. Solderless connectors are usually furnished. The connection
must be insulated according to the recommendation of the
cable manufacturer.
f. If potheads or other types of terminators are furnished,
follow the instructions of the manufacturer when connecting
the cable to them. Use the flexible connectors to connect
the arial lugs to the conductors. This will keep strain off
the insulators of the pothead or the terminator. Tape (or
otherwise insulate) the entire joint (including the flexible
connectors). (See Section 10.)
g. If zero sequence current transformers are used, pass the
power cables through the transformer. Refer to Figure 34
and Figure 35.
11. Replace all metal barriers and secure rear doors (or rear covers)
on all the vertical sections.
Replace all metal barriers, vertical section of the bus barrier,
and any other components removed during hookup of the high
voltage bus. Replace them in a reverse manner from how they
were removed.
Close all rear doors (rear covers) and secure all bolts.
Refer to Figure 9.

10
Instruction Booklet IB32267ARC
Effective December 2010
VacClad-W 38 kV arc-resistant
switchgear indoor housings
EATON CORPORATION www.eaton.com
Figure 9. Assembled Switchgear (Shown with Rear Doors Opened)
CT Spout/Riser
Boot 1C95094G01
CT Bushing Through
Boot—1C95085H01
Incoming
CTs
Feeder
CTs
Auxiliary
Spout Boot
1C95095H01
12. 38 kV arc skirt assembly instructions.
Parts for arc skirt assembly are listed on the parts lists for
the order and supplied detail for field installation on top of the
switchgear lineup. Install the arc skirt assembly as follows.
The following instructions and illustrations show how to assemble
the arc skirts to a 38 kV switchgear enclosure. The arc skirts
are mounted to the roof to provide a degree of protection in
the event of an arc fault inside the enclosure. The arc skirts
are designed to direct the arc byproducts away from personnel
working near the enclosure.
It is important to completely read and to understand the
instructions before beginning any assembly.
Table 3. List of Parts Used
Item Number Description Eaton Number
138 kV front/rear vertical skirt 1C95598H01
238 kV side vertical skirt 1C95598H02
338 kV side vertical skirt-mounting strip 1C95598H04
438 kV vertical skirt seam cover 1C95598H05
538 kV side horizontal skirt 1C95700H02
638 kV middle horizontal skirt 1C95700H08
738 kV end horizontal skirt 1C95700H09
838 kV skirt support 1C95700H06
Step 1: Assembly of vertical skirt mounting strips (Figure 10). Bolt
one vertical skirt-mounting strip (Item 3) to the extreme left roof and
one to the extreme right roof. Use the existing roof bolts to secure
the skirt-mounting strips. Mount as shown in Figure 10.
Figure 10. Assembly of Skirt-Mounting Strips
CT Bushing End
Boot—1C95086G01