Powell FlexTrol Class E2 Training manual

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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FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
01.4IB.46300
Contact Information
Powell Electrical Systems, Inc.
powellind.com
[e-mail]
Service Division
7232 Airport Blvd
Houston, Texas 77061
Tel: [phone]

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01.4IB.46300
Signal Words
As stated in ANSI Z535.4-2007, the signal word is
a word that calls attention to the safety sign and
designates a degree or level of hazard seriousness.
The signal words for product safety signs are
“Danger”, “Warning”, “Caution” and “Notice”.
These words are defined as:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
!
DANGER
!
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
!
CAUTION
CAUTION, used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
CAUTION, used without 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 purposes of this manual, a qualified
person, as stated in NFPA 70E®, is one who has
skills and knowledge related to the construction
and operation of the electrical equipment and
installations and has received safety training to
recognize and avoid the hazards involved. In
addition to the above qualifications, one must also
be:
1. trained and authorized to energize,
deenergize, clear, ground, and tag circuits
and equipment in accordance with
established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
in accordance with established safety
practices.
3. trained in rendering first aid if necessary.

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FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
01.4IB.46300
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01.4IB.46300
Contents
Ch 1 General Information ................................................................................................1
A. Scope ...............................................................................................................................................................2
B. purpoSe ............................................................................................................................................................2
c. InStructIon BulletInS AvAIlABle electronIcAlly ....................................................................................................2
D. ASSocIAteD BulletInS ..........................................................................................................................................2
Ch 2 Safety .......................................................................................................................3
A. SAfe Work conDItIon .........................................................................................................................................3
B. SAfety GuIDelIneS ...............................................................................................................................................4
c. GenerAl ............................................................................................................................................................4
D. SpecIfIc .............................................................................................................................................................5
e. X-rAyS .............................................................................................................................................................5
f. SAfety lABelS ....................................................................................................................................................6
Ch 3 Equipment Description ............................................................................................7
A. GenerAl ............................................................................................................................................................7
B. fleXtrol™clASS e2 MeDIuM voltAGe controller ...............................................................................................7
c. rAtInGS .......................................................................................................................................................... 11
D. BASIc IMpulSe level ........................................................................................................................................ 11
e. fActory proDuctIon DIelectrIc 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. DiMensions .......................................................................................................................................17
Ch 4 Installation .............................................................................................................18
a. general ...........................................................................................................................................18
B. receiving ..........................................................................................................................................18
c. StorAGe ......................................................................................................................................................... 18
D. hAnDlInG ....................................................................................................................................................... 19
e. poSItIonInG of the encloSure ........................................................................................................................... 21
f. reMovInG the MeDIuM voltAGe vAcuuM contActor ........................................................................................... 21
1) Removing the Vacuum Contactor from the High Voltage Compartment ...............................................................21
G. poWer connectIonS ........................................................................................................................................ 23
h. GrounDInG ..................................................................................................................................................... 24
I . connectIonS ............................................................................................................24
J. MAIn BuS ASSeMBly InSulAtIon ......................................................................................................................... 26
k. IncoMInG poWer connectIonS .......................................................................................................................... 26
1) Wrapping Bus Joint ...............................................................................................................................................................26
2) Applying PVC Boots ..............................................................................................................................................................29
3) Cleaning Bus Insulation .......................................................................................................................................................29

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FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
01.4IB.46300
Contents
l. Motor connectIonS ........................................................................................................................................ 31
M. poWer cABle terMInAtIon ................................................................................................................................ 31
n. InSulAtInG prIMAry cABleS ............................................................................................................................... 32
o. GrounD fAult current trAnSforMerS (throuGh type) ....................................................................................... 32
p. control cABleS AnD connectIonS ..................................................................................................................... 32
Q. SurGe protectIon ........................................................................................................................................... 33
r. MechAnIcAl operAtIon check .......................................................................................................................... 33
S. SAfety InterlockS ............................................................................................................................................ 34
1) Isolating Switch Operating Handle ...................................................................................................................................34
2) Door Interlocks .......................................................................................................................................................................34
3 Contactor - Isolating Switch Mechanical Interlock .......................................................................................................35
4) Door Interference ..................................................................................................................................................................35
Ch 5 Operation ...............................................................................................................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 Check ...........................................................................................................................37
c. teSt poWer cIrcuIt ......................................................................................................................................... 38
D. hI-pot AnD MeGGer teSt ................................................................................................................................. 39
1) Preparing for the Hi-Pot and Megger Test .......................................................................................................................39
2) Performing the Hi-Pot and Megger Test ...........................................................................................................................39
e. pre-operAtIon teSt ......................................................................................................................................... 40
f. StArt-upproceDure ....................................................................................................................................... 40
1) Preliminary Checks ................................................................................................................................................................40
2) Setting of Adjustable Protective Devices .........................................................................................................................41
3) Medium Voltage Vacuum Contactor Inspection ...........................................................................................................41
4) Medium Voltage Vacuum Contactor Testing .................................................................................................................41
5) Isolating Switch Adjustment ...............................................................................................................................................41
6) Power Fuse Inspection ..........................................................................................................................................................42
Ch 6 Maintenance ..........................................................................................................43
A. MAIntenAnce precAutIonS ................................................................................................................................ 43
B. preventAtIve MAIntenAnce GuIDelIneS ............................................................................................................... 43

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01.4IB.46300
Ch 7 Recommended Renewal Parts 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 Contacts Inspection and Replacement ...........................................................................................................47
D. replAceMent pArtS .......................................................................................................................................... 48
Contents

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FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
01.4IB.46300
Figures
Figure 1 FlexTrol™400A & 800A ..................................................................................8
Figure 2 Two-High Vertical Section Rear View (400A) .................................................9
Figure 3 High and Low Voltage Compartments ........................................................10
Figure 4 Eaton Type SL Medium Voltage Vacuum Contactor 400A ..........................12
Figure 5 Eaton Type SL Medium Voltage Vacuum Contactor 800A ..........................13
Figure 6 Isolating Switch Operating Handle .............................................................14
Figure 7 Typical 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 Insulation of Bus Bar ....................................................................................27
Figure 12 Single Bus Bar Connection Joint ..................................................................27
Figure 13 Double Bus Bar Connection Joint ................................................................28
Figure 14 Tee Connection Joint ....................................................................................28
Figure 15 Dead End Bus Joint Insulation .....................................................................29
Figure 16 FlexTrol™- 400A ..........................................................................................30
Figure 17 FlexTrol™- 800A ..........................................................................................30
Figure 18 Low Voltage Compartment ..........................................................................32
Figure 19 Wire Way .......................................................................................................32
Figure 20 Isolation Switch Interlock ............................................................................35
Figure 21 Mechanical Interlock Verification ...............................................................38
Figure 22 Blown Fuse Indicator ....................................................................................42

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01.4IB.46300
Tables
Table A Horsepower, Current, and Voltage Ratings .......................................................11
Table B Voltage and Interrupting Ratings of Class E2 Medium Voltage Controllers .....11
Table C General Guideline for Outgoing Feeder Cables .................................................24
Table D Bolt Torque Values for FlexTrol™ .........................................................................................26
Table E Bus Wrapping Components ................................................................................26
Table F Insulation of Bus Bar ...........................................................................................27
Table G Insulation of Single Bus Bar Connection Joint ..................................................27
Table H Insulation of Double Bus Bar Connection Joint .................................................28
Table I Insulation of 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 M Medium Voltage Vacuum Contactor Eaton 800A SL
Renewal/Replacement Parts .............................................................................49
Table N R-Rated Clip-On Fuses for 400A Contactor ........................................................50
Table O R-Rated Bolt-On Fuses for 800A Contactor .......................................................51
Table P E-Rated Clip-On Fuses for 400A Contactor ........................................................52
Table Q E-Rated Bolt-On Fuses for 800A Contactor .......................................................52
Table R Control Relays .....................................................................................................53
Table S Current Transformers .........................................................................................53
Table T Ground Current Transformers ............................................................................53
Table U Control Power Transformers - SNC ....................................................................54
Table V Control Power Transformer Primary Fuses ........................................................54

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FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
01.4IB.46300
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