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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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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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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01.4IB.46300
General Information
Ch 1 General Information
!
WARNING
The equipment described in this document may contain high voltages and currents which can
cause death or serious injury.
The equipment is designed for use, installation, and maintenance by knowledgeable users of such
equipment having experience and training in the field of high voltage electricity. This document and all
other documentation shall be fully read, understood, and all warnings and cautions shall be abided by. If
there are any discrepancies or questions, the user shall contact Powell immediately at 1.800.480.7273.
!
WARNING
Prior to adjustments, 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 death or serious injury.
NOTICE
The information in this instruction bulletin is not intended to explain all details or variations of the
Powell equipment, nor to provide for every possible contingency or hazard to be met in connection
with installation, testing, operation, and maintenance of the equipment. For additional
information and instructions for particular problems, which are not presented sufficiently for the
user’s purposes, contact Powell at 1.800.480.7273.
Powell reserves the right to discontinue and to change specifications at any time without incurring
any obligation to incorporate new features in products previously sold.
NOTICE
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01.4IB.46300
General Information
FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
a. scope
The information in this instruction bulletin
describes the following FlexTrol™Class E2
Medium Voltage Controllers (E2):
• 5.0kV, and 7.2kV Voltage Class for 400A
• 5.0kV, and 7.2kV Voltage Class for 800A
Note: You may see the Class E2 equipment
referred to as MVMCC.
B. purpose
The information in this instruction bulletin
is intended to provide information required
to properly operate and maintain FlexTrol
medium voltage controllers described in
Ch 1 General Information, A. Scope.
This instruction bulletin provides:
1. Safety guidelines
2. General descriptions of the operation and
maintenance of FlexTrol medium voltage
controllers
3. Instructions for installation and placing
FlexTrol medium voltage controllers into
service
4. Instructions for part replacement
5. Information for ordering renewal parts
6. Procedure for critical adjustments
7. Illustrations, photographs, and description
of the controllers
The illustrations contained in this document
may not represent the 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 locations only.
All illustrations and photos are shown using
deenergized equipment.
Follow the appropriate safety precautions
while handling any of the equipment. Failure
to do so may result in death or serious injury.
!
WARNING
To the extent required, the products described
herein meet the applicable ANSI, IEEE, and
NEMA Standards; however, no such assurance
is given with respect to local codes and
ordinances which may vary greatly.
c. instruction Bulletins availaBle electronically
Changes to the instruction bulletin may be
implemented at any time and without notice.
Go to powellind.com to ensure use of the current
instruction bulletin for Powell equipment.
NOTICE
For more information visit powellind.com.
To contact the Powell Service Division call
1.800.480.7273, or email
For specific questions or comments pertaining
to this instruction bulletin email
documents@powellind.com with the IB number
in the subject line.
D. associateD Bulletins
• 01.4IB.65220A Lift Devices for use
with PowlVac®and PowlVac-AR®, 5kV &
15kV Switchgear and PowlVac 38™and
PowlVac38-AR™Switchgear
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01.4IB.46300
Safety
Ch 2 Safety
a. saFe work conDition
The information in Section A is quoted from
NFPA 70E 2018 - Article 120, 120.5 Establishing an
Electrically Safe Work Condition.
120.5 Process or Establishing and Verifying an
Electrically Safe Work Condition. Establishing
and verifying an electrically safe condition shall
include all of the following steps, which shall be
performed in the order presented, if feasible:
1. Determine all possible sources of electrical
supply to the specific equipment. Check
applicable up-to-date drawings, diagrams,
and identification tags.
2. After properly interrupting the load current,
open the disconnecting device(s) for each
source.
3. Wherever possible, visually verify that all
blades of the disconnecting devices are
fully open or that drawout-type circuit
breakers are withdrawn to the fully
disconnected position.
4. Release stored electrical energy.
5. Release or block stored mechanical energy.
6. Apply lockout/tagout devices in accordance
with a documented and established
procedure.
7. Use an adequately rated portable test
instrument to test each phase conductor or
circuit part to verify it is de-energized. Test
each phase conductor or circuit part both
phase-to-phase and phase-to-ground.
Before and after each test, determine
that the test instrument is operating
satisfactorily through verification on any
known voltage source.
NException 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, provided it meets the all
following requirements: (1) It is permanently
mounted and installed in accordance with
the manufacturer’s instructions and tests
the conductors and circuit parts at the point
of work; (2) It is listed and labeled for the
purpose of verifying the absence of voltage;
(3) It tests each phase conductor or circuit
part both phase-to-phase and phase-to-
ground; (4) The test device is verified as
operating satisfactorily on any known voltage
source before and after verifying the absence
of voltage.
NException No. 2: On electrical systems over
1000 volts, noncontact test instruments shall
be permitted to be used to test each phase
conductor.
Informational Note No. 1: See UL 61010-1,
Safety Requirements for Electrical Equipment
for Measurement, Control, and Laboratory
Use, Part 1: General Requirements, for
rating, overvoltage category, and design
requirements for voltage measurement
and test instruments intended for use on
electrical system 1000 volts and below.
N Informational Note No. 2: For additional
information on rating and design
requirements for voltage detectors, refer
to IEC 61243-1, Live Working - Voltage
Detectors - Part 1: Capacitive type to be used
for voltages exceeding 1kV a.c., or IEC 61243-
2, Live Working - Voltage Detectors - Part 2:
Resistive type to be used for voltages of 1kV
to 36kV a.c., or IEC 61243-3, Live Working -
Voltage Detectors - Part 3: Two-pole voltage
type.
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01.4IB.46300
Safety
FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
8. Where the possibility of induced voltages
or stored electrical energy exists, ground
the phase conductors or circuit parts
before touching them. Where it could be
reasonably anticipated that the conductors
or circuit parts being de-energized
could contact other exposed energized
conductors or circuit parts, apply temporary
protective grounding equipment in
accordance with the following:
a.. Placement. Temporary protective
grounding equipment shall be placed
at such locations and arranged in such
a manner as to prevent each employee
from being exposed to a shock hazard
(i.e., hazardous differences in electrical
potential). The location, sizing, and
application of temporary protective
grounding equipment shall be
identified as part of the employer’s job
planning.
b. Capacity. Temporary protective
grounding equipment shall be capable
of conducting the maximum fault
current that could flow at the point of
grounding for the time necessary to
clear the fault.
N Informational Note: ATSM F855, Standard
Specification for Temporary Protective
Grounds to be Used on De-energized Electric
Power Lines and Equipment, is an example
of a standard that contains information on
capacity of temporary protective grounding
equipment.
c. Impedance. Temporary protective
grounding equipment and connections
shall have an impedance low enough
to cause immediate 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 documentation before uncrating
the motor control.
Each user has the responsibility to instruct
and supervise all personnel associated with
usage, installation, operation, and maintenance
of this equipment on all safety procedures.
Furthermore, each user has the responsibility of
establishing a safety program for each type of
equipment encountered.
The medium voltage controllers described
in this instruction bulletin is operated by an
electromagnet assembly through a mechanical
linkage. It is mandatory that the following
rules be observed to ensure the safety of
personnel associated with usage, installation,
operation, and maintenance of the equipment.
The safety rules in this instruction bulletin are
not intended to be a complete safety program.
The rules are intended to cover only some of the
important aspects of personnel safety related to
Class E2 Medium Voltage Controllers.
c. general
1. Only supervised and qualified personnel
trained in the usage, installation, operation,
and maintenance of the motor control shall
be allowed to work on this equipment. It
is mandatory that this instruction bulletin,
any supplements, and service advisories be
studied, understood, and followed.
2. Maintenance programs must be consistent
with both customer experience and
manufacturer’s recommendations,
including service advisories and instruction
bulletin(s). A well-planned and executed
routine maintenance program is essential
for equipment’s reliability and safety.
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01.4IB.46300
Safety
3. Service conditions and controller
applications shall also be considered in the
development of safety programs. Variables
include ambient temperature; humidity;
actual continuous current; thermal cycling;
number of operations; interrupting duty;
and any adverse local conditions including
excessive dust, ash, corrosive atmosphere,
vermin, and insect infestations.
D. speciFic
1. DO NOT WORK ON AN ENERGIZED CLASS
E2 MEDIUM VOLTAGE CONTROLLER.
Before performing maintenance work
on a Class E2 Medium Voltage Controller,
deenergize and disconnect the power
supply for the controller, and remove the
Class E2 Medium Voltage Controller from
service.
2. DO NOT WORK ON AN ENERGIZED
MEDIUM VOLTAGE VACUUM
CONTACTOR. Before performing work on
a vacuum contactor, remove the vacuum
contactor from service and remove it from
the Class E2 Medium Voltage Controller.
3. DO NOT WORK ON A CLASS E2 MEDIUM
VOLTAGE CONTROLLER VACUUM
CONTACTOR WHEN THE CONTROL
CIRCUIT IS ENERGIZED.
4. EXTREME CARE MUST BE EXERCISED
TO KEEP ALL PERSONNEL, TOOLS, AND
OTHER OBJECTS CLEAR OF MECHANISMS
WHICH ARE TO BE OPERATED,
DISCHARGED, OR RELEASED. These
contactors utilize high energy mechanisms.
These mechanisms must be serviced only
by skilled and knowledgeable personnel.
Detailed information regarding 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. DO NOT USE AN OPEN VACUUM
CONTACTOR AS THE SOLE MEANS OF
ISOLATING A HIGH VOLTAGE CIRCUIT.
FOR COMPLETE ISOLATION, THE
ISOLATING SWITCH MUST BE IN THE
OFF POSITION.
7. ALL COMPONENTS SHALL BE
DISCONNECTED BY MEANS OF A
VISIBLE BREAK AND SECURELY
GROUNDED FOR THE SAFETY
OF PERSONNEL PERFORMING
MAINTENANCE OPERATIONS ON
THE CLASS E2 MEDIUM VOLTAGE
CONTROLLER.
8. Interlocks are provided to ensure the
proper operating sequences of the Class
E2 Medium Voltage Controller and vacuum
contactors for the safety of the user. If for
any reason an interlock does not function
as described, DO NOT MAKE ANY
ADJUSTMENTS, MODIFICATION, OR
DEFORM THE PARTS. DO NOT FORCE
THE PARTS INTO POSITION. CONTACT
POWELL FOR INSTRUCTIONS.
e. x-rays
X-Rays may be generated when high voltage
is applied across the contacts of a vacuum
interrupter. The intensity of x-radiation
depends on the level of peak voltage and
the size of the contact gap. At the normal
operating voltage for this type of equipment,
the x-radiation levels are negligible. At the
voltages specified for testing, personnel shall
be located no closer than one (1) meter (about
3 feet) from the vacuum contactor. THE
VACUUM CONTACTOR SHALL BE EITHER
FULLY OPEN, OR FULLY CLOSED WHEN
MAKING HIGH POTENTIAL TESTS. DO
NOT PERFORM TESTS WITH CONTACTS
PARTIALLY OPEN.
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FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
F. saFety laBels
The medium voltage controller 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 handled,
operated, or maintained.
Warning and Caution labels are located in
various places. Do not remove or deface any
of these warning/caution labels.
NOTICE
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01.4IB.46300
Equipment Description
Ch 3 Equipment Description
a. general
Portions of the following text have been taken
from Eaton Instructional Leaflet IB-48041,
effective December 2009.
FlexTrol™is designed to comply with applicable
NEMA ICS Standards Publications and UL 347.
These controllers are described as
metal-enclosed, high-interrupting capacity
motor starter equipment with manual isolation.
Each controller and starter is designed for
specific applications and the components and
functions are determined by the purchaser’s
specifications and needs (Figure 1).
Starting, stopping, and overload protection
are essential control functions for all types of
Alternating Current (AC) motors. Short-circuit
protection is a basic function included in
FlexTrol. Additionally, a large variety of
protective devices and functions can be
included in each controller depending on the
particular application and the type of motor
being controlled, such as synchronous or
wound-rotor motors.
These instructions are prepared as a general
guide that provides the necessary general
information for the FlexTrol type and function.
These instructions also include a suggested
method of installation with demonstrative
techniques for the operation and maintenance
of the equipment. Separate instructions
covering particular equipment, devices, or
components are not included in this instruction
bulletin, but are available upon request. The
purchaser should interpret these instructions
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 convenient access in an
enclosure which allows space and facilities for
cable termination, with safety interlocking of
the doors and isolator to prevent inadvertent
entrance to high voltage parts. This equipment
is rated 7200 volts maximum and may be
used on distribution voltages from 2400 to
7200 volts. Installation, operation, and service
should be performed only by experienced
personnel trained and qualified in this class of
equipment.
B. Flextrol™class e2 MeDiuM voltage controller
In general, FlexTrol consists of one-high or
two-high vertical sections of medium voltage
compartments. Each FlexTrol consists of a high
voltage and low voltage compartment. Also,
each compartment has a separate door and
barriers between the two compartments.
The controller consists of a non-load break
isolation switch, medium voltage current
limiting fuses, one or more Type SL
vacuum-break contactors, a set of current
transformers, plus control and protection
devices. The isolating switch has a limited
transformer magnetizing currents. The
controller is designed to start, stop, and
protect a three-phase medium voltage motor.
The controller may also be used to switch
transformer windings or capacitor loads.
For applications other than those indicated,
consult Powell. Each controller occupies all
or a portion of a steel structure that may also
enclose a horizontal bus system to distribute
power to two or more sections and a vertical
bus system to connect individual starters to the
horizontal bus.
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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
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01.4IB.46300
Equipment Description
Starters are available with bolt-in or clip-in
main fuses. Contactors may have bolted
connections or stab-in connections to the
starter cell.
The flow of current through a starter with
bolted fuses and a stab-in contactor can be
described as follows:
The line finger assembly mounted at the
back of the enclosure serves to connect
the isolation switch moving stabs to the
controller line terminals when the switch is
closed. Power flows from the switch moving
stabs through a flexible shunt to the upper
fuse mountings. The fuses are connected to
the lower fuse mountings that contain the
line-side stab connections to the line finger
assemblies for the main contactor. With
the main contactor energized, power flows
through the contactor’s vacuum interrupters to
the contactor load fingers, which are engaged
on to the contactor load-side stabs. Medium
voltage cables connect the load-side stabs to
the motor load 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-side stabs.
The motor load connections are mounted to
the left of the main fuses in the rear of the
compartment, facing forward.
Figure 2 Two-High Vertical Section Rear View
(400A)
To open the high voltage compartment
door, the power must be disconnected by
a sequence of manual operations which
require opening the medium voltage vacuum
contactor and deenergizing the load, operating
the isolating device, and unlatching the door.
The low voltage compartment door may be
entered without disconnecting the power.
The low voltage components are mounted
in the low voltage control compartment
located on the front of the controller
medium voltage door. The low voltage
compartment is fabricated from steel sheets
to provide isolation from the medium voltage
components mounted behind the low voltage
compartment. A window is provided in the
low voltage compartment to allow the user to
view the position of the isolation switch before
entering the medium voltage compartment.
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10
01.4IB.46300
Equipment Description
FlexTrol™Class E2 Medium Voltage Controllers with
Eaton Contactor
!
CAUTION
Control Power may be present in the low
voltage compartment. The low 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 Compartment
f. Medium Voltage Power Fuse
g. Isolation Switch Handle
h. Vacuum Contactor
i. Control Power Transformer
j. Contactor Hold Down Bolt
k. Low Voltage Compartment
l. Medium Voltage Compartment
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