Siemens Fusesaver User manual

usa.siemens.com/fusesaver
Fusesaver®
Medium-voltage circuit
breaker installation and
operation manual

Fusesaver | Installation and operation manual 1
Contents
1
Safety information
1.1 Qualified person 2
1.2 Signal words 3
1.3 Safety instructions 3
1.4 Proper application 3
2
Packing and storage
2.1 Packaging 4
2.2 Receipt and handling 5
of shipment
3
Workshop testing
3.1 Dielectric test 6
3.2 Resistance of main circuit 6
3.3 Communications module 7
battery test
3.4 Operations test 8
4
Installation procedure
4.1 Connecting cables 9
4.2 Fusesaver mounting 9
4.3 Communications module 13
attachment/fitting
4.4 Fusesaver configuration 14
4.5 Fusesaver status check 14
5
Operation
5.1 Automatic operation 15
5.2 Manual operation 15
5.3 Electrical isolation 16
5.4 External lever 16
5.5 Fault passage indication 17
5.6 Fusesaver event data 17
6
Maintenance
6.1 Firmware updating 18
6.2 Battery replacement 18
6.3 Battery charging 19
6.4 Fusesaver replacement 20
6.5 Return an item 21
6.6 Spare parts 21
6.7 Manufacturer’s product 21
liability
6.8 Fusesaver disposal 21
6.9 Battery disposal 21
7
Troubleshooting
8
Disposal

Fusesaver | Installation and operation manual 2
1 Safety information
This manual provides installation, operation
and testing procedures for the Siemens
Fusesaver. Thoroughly read this manual
before installing and operating your
Siemens Fusesaver.
The information contained herein is general
and not intended for specific application
purposes. It does not relieve the user of
responsibility to use sound practices in
application, installation, operation, and
maintenance of the equipment purchased.
Only qualified personnel who are familiar with
this equipment should install or operate it.
For the purpose of this instruction
manual, a qualified person is one
who is familiar with the installation,
construction or operation of the
equipment and the hazards involved.
In addition, this person has the
following qualifications:
• Is thoroughly familiar with this
manual.
• Is trained and authorized to switch,
de-energize, clear, ground, and tag
circuits and equipment in accordance
with established safety procedures.
• Is trained in techniques to distinguish
exposed energized parts from other
parts of electric equipment and to
determine the nominal voltage of
exposed live parts.
• Is trained in the proper techniques to
determine approach distances
specified in the applicable local
standards.
• Is trained in the decision-making
process necessary to determine the
degree and extent of the hazard and
the personal protective equipment
and job planning necessary to
perform the task safely.
• Is trained in the proper care and
use of protective equipment, such
as rubber gloves, hard hat, safety
glasses or face shields, flash clothing,
etc., in accordance with established
safety practices.
• Is trained in rendering first aid.
1.1 Qualified person

Fusesaver | Installation and operation manual 3
For the purpose of this manual and product labels, DANGER indicates an imminently
hazardous situation which, if not avoided will result in death or serious injury.
For the purpose of this manual and product labels, WARNING indicates a potentially
hazardous situation which, if not avoided, could result in death or serious injury.
For the purpose of this manual and product labels, CAUTION indicates a potentially
hazardous situation which, if not avoided, may result in minor or moderate injury.
For the purpose of this manual and product labels, NOTICE indicates a potentially
hazardous situation that, if not avoided, may result in property damage.
These instructions cannot cover all possible variations in equipment options,
site specific restrictions, local procedures, and every contingency that may emerge
during installation, operation or maintenance. When additional information is
required to address any particular problem not adequately explained in this
manual, please contact your local Siemens Service Center for further advice.
Hazardous voltage – danger to life!
Do not work on energized equipment. Always de-
energize and ground the lines before working on the
equipment.
If live-line work must be performed, follow the
requirements of local occupational health and safety
regulations and employ personal protective equipment
(PPE) suitable for the voltages involved. It is the user’s
responsibility to develop safe and adequate working
procedures complying with these requirements.
Fusesaver may be energized from either side.
Always consider all parts as energized until they
are de-energized, tested for absence of voltage and
grounded.
The correct Fusesaver model must be selected for
the network application. Fusesaver is suitable for
use on networks with phase-to-phase maximum
voltage levels of 27 kV. The user must assess the
potential load and fault current levels at the point of
application and confirm these are within the
capability of the Fusesaver model selected.
1 Safety information
1.2 Signal words
The signal words “DANGER”, “WARNING”, “CAUTION”, and “NOTICE” used in this
manual indicate the degree of hazard that may be encountered by the user.
These words are defined as:
1.3 Safety instructions
1.4 Proper application

Fusesaver | Installation and operation manual 4
Do not open the box through the bottom flap as the box cutter
can cause damage to the Fusesaver.
2 Packing and storage
2.1 Packaging
Each Fusesaver or Fusesaver kit is
packaged in a cardboard box labeled
with a contents list and the serial
number of the Fusesaver.
To open the box, use a box cutter to
cut through the sealing tape and then
fold open the top flap to access the
contents. All items in the box can then
be easily removed. Other miscellaneous
items such as mounting hardware are
packed separately.
Typical Weights and Dimensions:
Package of line-mounted
Fusesaver
Package of cross arm/pole-mounted
Fusesaver
21.85” (555 mm) L x 14.37” (365 mm) W
x 9.84” (250 mm) H
21.85” (555 mm) L x 14.37” (365 mm)
W x 9.84” (250 mm) H
Approximately 18.73 lbs (8.5 kg) gross Approximately 27.56 lbs (12.5 kg)
gross

Fusesaver | Installation and operation manual 5
2 Packing and storage
2.2 Receipt and handling of shipment
On receipt, the contents of each box
should be checked for shipping damage,
and the manufacturer informed
immediately if any damage is evident:
• Check the cardboard box for
shipping damage.
• Major damage must be documented
photographically.
• Ensure that the transport
company confirms any damage
to the cardboard box.
The Fusesaver box should be
handled with care and protected
from water exposure. Store in a
clean and dry location.
Do not drop the Fusesaver or any of its parts or accessories.
Do not store the Fusesaver with the communications module connected.
This will drain the battery in the communications module.

Fusesaver | Installation and operation manual 6
Hazardous voltages are present during dielectric
testing.
Contact with an energized unit under test will
likely result in severe personal injury or death.
Dielectric testing should occur with a grounded
test cage to provide a physical barrier between the
technician and the equipment under test.
The vacuum interrupter may emit x-rays during
dielectric testing.
X-rays may be hazardous to your health.
Dielectric testing should be conducted within a solid
sheet metal cage made from ferrous material with a
minimum thickness of 0.06” (1.6 mm). The technician
should maintain a minimum 9.84 ft (3 m) distance to
the Fusesaver under test.
3 Workshop testing
3.1 Dielectric test
To confirm the dielectric integrity
of the vacuum interrupter the user
can apply a 48 kV ac (50/60 Hz)
voltage across the open contacts
of the Fusesaver for 60 seconds.
Note that vacuum interrupters can
experience self-extinguishing
momentary breakdowns under high
voltages. These momentary breakdowns
do not indicate a loss of vacuum or
failure of the test.
Every Fusesaver is inspected and tested at
the factory before dispatch. No further testing
by the end user is required. However, if the
user has a policy to do confirmation testing
before deployment, then the following
inspection and test regimes are possible
by suitably qualified personnel.
3.2 Resistance of main circuit
To confirm the integrity of the primary current path the user can measure the
resistance from terminal to terminal using a standard dc resistance meter with
a minimum 10 A capability.
The recommended resistance measurement by model is as follows:
Model type Low range Standard range High range
DC resistance µΩ <8070 <1350 <390

Fusesaver | Installation and operation manual 7
3 Workshop testing
Communications module battery test
Blinks Charge Primary cell Rechargeable
0Flat DO NOT USE DO NOT USE
1Very
low
DO NOT USE Charge
before use
2Low USE NOT
RECOMMENDED
Charge
before use
3Marginal OK to use –
replace soon
Charge
before use
4Good OK to use OK to use
5Full OK to use OK to use
The LED blinks once brightly and then rapidly while the test is underway. At the
end of the test, the LED blinks a number of times to indicate the battery charge
level. This blink pattern repeats three times. For example, the blink pattern for a
battery with a “low” charge is: xx – 1s – xx – 1s – xx where “x” is a blink. Refer to
section 6.2 for how to recharge batteries.
3.3 Communications module battery test
The communications module is available in two versions:
• Primary cell (non-rechargeable).
• Rechargeable.
Do not electrically probe the three gold plated pins as this may damage
the communications module.
The user can check the battery charge level by pressing both actuating buttons
(red and green) simultaneously of the communications module when separated
from the Fusesaver.
ACTUATING
BUTTON
ACTUATING
BUTTON

Fusesaver | Installation and operation manual 8
3 Workshop testing
Fusesaver operation
3.4 Operations test
The user can conduct an operations test to confirm the Fusesaver can trip and
close. Connect the communications module to the Fusesaver and wait until the
LED blinks to confirm connection to the Fusesaver. To open the Fusesaver press
the GREEN actuating button. To close the Fusesaver press the RED actuating button.
After pressing the applicable actuating button, the LED starts flashing. After the
configured delay of up to 60 seconds, the Fusesaver operates. The indicator
changes color to confirm the operation.
Conducting excessive operations or leaving the communications module
connected to the Fusesaver for extended periods without primary line
current drains the battery in the communications module.

Fusesaver | Installation and operation manual 9
4 Installation procedure
Fusesaver installation can be achieved using
live-line or dead-line (under isolation) processes.
4.1 Connecting cables
The preferred method for connecting to the Fusesaver is with a cable that has a
two-hole NEMA palm crimped to one end. Aluminium cables and palms connected
with galvanized steel bolts are recommended wherever possible. If the connecting
cable is not aluminium, an appropriate bi-metallic lug classified for use with
aluminium terminals is required.
The cable used to connect to the Fusesaver should have the following typical values
by model type to achieve full current rating of the model:
Model Aluminium Copper
Low range > AWG 2 (30 mm²) > AWG 5 (15 mm²)
Standard range > AWG 0 (50 mm²) > AWG 3 (25 mm²)
High range > AWG 0000 (100 mm²) > AWG 000 (70 mm²)
The cable may be bare or insulated. Water blocking is not required. The same cable
used to connect the fuse to the main line is normally adequate for connecting to
the Fusesaver.
4.2 Fusesaver mounting
The Fusesaver is an electrically floating
device so it requires no grounding and
can be installed using three different
approaches. In all cases, the Fusesaver
should be mounted horizontally.
For mounting options not covered here
contact a Siemens Service Center.
The Siemens Service Center has
available general arrangement
drawings and solid models of various
configurations of the following
installation options, that the end user
can utilize to create their customized
pole top construction drawings.
4.2.1 Line mount installation
The most common method for
mounting of the Fusesaver is to
hang it directly from a suitably sized
conductor. The line clamp assembly
provides a mechanical mounting point
and is not an electrical connection as
it has an insulating sleeve between
the clamp and the line. A cable is still
required to provide an electrical
connection from the Fusesaver terminal
to the line.
Do not hang the Fusesaver device from an
undersized conductor. This may result in
conductor fatigue and failure of the conductor.
It is the user’s responsibility to determine whether
the size and type of conductor or dead-end that the
Fusesaver is being mounted from is mechanically
capable of supporting the weight of the Fusesaver.
As a guide, if the mounting of the Fusesaver causes
a kink in the conductor, then the conductor is not
suitable for line hanging of Fusesaver.