Model III

Package Substations Class 6010

Instruction Bulletin
Retain for future use.

HAZARD CATEGORIES AND SPECIAL SYMBOLS

Read these instructions carefully and look at the equipment to become familiar with the device before trying to install, operate, service, or maintain it. The following special messages may appear throughout this bulletin or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of either symbol to a Danger or Warning safety label indicates that an electrical hazard exists which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

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DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury.

CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.

CAUTION
CAUTION, used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, can result in property damage. NOTE: Provides additional information to clarify or simplify a procedure.

PLEASE NOTE

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.
WARRANTY TO CUSTOMERS PURCHASING THROUGH AUTHORIZED SCHNEIDER ELECTRIC DISTRIBUTORS AND CUSTOMERS PURCHASING DIRECTLY FROM SCHNEIDER ELECTRIC. Schneider Electric warrants equipment manufactured by it to be free from defects in materials and workmanship for eighteen (18) months from date of invoice from Schneider Electric or its authorized sales channels. If within the applicable warranty period purchaser discovers such item was not as warranted and promptly notifies Schneider Electric in writing, Schneider Electric shall repair or replace the items or refund the purchase price, at Schneider Electrics option. This warranty shall not apply (a) to equipment not manufactured by Schneider Electric, (b) to equipment which shall been repaired or altered by others than Schneider Electric, (c) to equipment which shall have been subjected to negligence, accident, or damage by circumstances beyond Schneider Electrics control, or to improper operation, maintenance or storage, or to other than normal use or service. With respect to equipment sold but not manufactured by Schneider Electric, the warranty obligations of Schneider Electric shall in all respects conform and be limited to the warranty actually extended to Schneider Electric by its supplier. The foregoing warranties do not cover reimbursement for labor, transportation, removal, installation, or other expenses which may be incurred in connection with repair or replacement. Except as may be expressly provided in an authorized writing by Schneider Electric, Schneider Electric shall not be subject to any other obligations or liabilities whatsoever with respect to equipment manufactured by Schneider Electric or services rendered by Schneider Electric. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND IMPLIED WARRANTIES EXCEPT WARRANTIES OF TITLE, INCLUDING BUT NOT LIMITED TO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

WARRANTY

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Model III Package Substations Table of Contents

TABLE OF CONTENTS
Section 1Introduction ............................................................................ 5 Section 2Safety Precautions ................................................................. 6 Section 3Receiving, Handling, and Storage ........................................ 7 Initial Inspection ..................................................................................... 7 Handling ................................................................................................ 8 Unloading and Lifting....................................................................... 8 Towing and Moving ......................................................................... 9 Storing ................................................................................................... 9 Section 4Installation ............................................................................ 10 Substation Location ............................................................................. 10 Restricting Access to the Substation ................................................... 10 Electrical Connections ......................................................................... 10 Torque Guidelines for Transformer Electrical Connections ........... 11 Torque Guidelines for Circuit Breaker Electrical Connections....... 11 High Voltage Electrical Connections ................................................... 12 Conduit Area ....................................................................................... 12 Cable Pulling ....................................................................................... 12 Cable Terminations ............................................................................. 12 Section 5Pre-energizing Procedure Checklist .................................. 13 Section 6Interlocks .............................................................................. 16 Section 7HVL and HVL/cc Switch Operating Sequences ................. 16 Section 8Startup Testing to Energize................................................. 17 Pre-energizing Testing ........................................................................ 17 Drying the Core and Coil Assembly .................................................... 17 Drying Transformer Coils .................................................................... 17 Heaters and Lamps for Drying ............................................................ 18 Insulation Resistance Testing ............................................................. 18 Turns Ratio Test .................................................................................. 18 Effects of Humidity .............................................................................. 18 Energizing the Substation ................................................................... 19 Changing Tap Positions to Adjust Voltage .......................................... 20 Sound Level ........................................................................................ 20 Reduction of Structure Borne Noise .................................................... 21 Section 9Maintenance .......................................................................... 21 After a Major Fault ............................................................................... 22 Inspection Procedure for HVL and HVL/cc Switches .......................... 22 Transformer Inspection Procedure ...................................................... 22 Cleaning .............................................................................................. 23 Molded Case Circuit Breakers Inspection Procedure .......................... 23 Ground Fault Protection Systems ....................................................... 25 Section 10Adverse Circumstances .................................................... 25 Clean-up Following a Short Circuit ...................................................... 26 Water-Soaked Substations .................................................................. 26 Water-Sprayed or Splashed Substations (Clean Water Only) ............ 26 Inspection and Clean-up of Clean Water Sprayed or Splashed Substations .......................................................................................... 26

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Model III Package Substations List of Tables

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Section 11Optional Equipment ........................................................... 27 Temperature Monitoring Systems ....................................................... 27 Fans (Forced Air) ................................................................................. 28 Powerlogic Circuit Monitor ................................................................. 28 Other Optional Equipment ................................................................... 28 Section 12Replacement Parts ............................................................. 28 Section 13Reference Publications ...................................................... 28 Section 14Installation and Maintenance Log ..................................... 31

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LIST OF FIGURES

Figure 1: Figure 2: Figure 3: Figure 4: Figure 5: Figure 6:

Typical Unit Substation .......................................................... 5 Typical Nameplate ................................................................. 7 Typical Base .......................................................................... 8 Using a Spreader Bar ............................................................ 9 Instantaneous Trip Setting ................................................... 14 Key Interlock ........................................................................ 16

LIST OF TABLES

Table 1: Table 2: Table 3: Table 4: Table 5: Table 6: Table 7: Table 8: Table 9: Table 10: Table 11: Table 12:

Transformer Torque Values................................................. Incoming, Branch, and Neutral Lug ..................................... Multiple Conductor Neutral and/or Ground Bar ................... QED-3 Circuit Breaker Connector Bolts .............................. Insulation Resistance Values............................................... Blank Fillers and Extensions................................................ Factory-Set Temperature Alarm and Control Settings......... Installation Instructions ........................................................ Instruction and Maintenance Bulletins ................................. Ground Fault Field Test Instructions.................................... Distribution Reference Catalogs .......................................... Other Reference Literature ..................................................

11 11 11 11 18 24 28 28 29 29 29 30

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Model III Package Substations Section 1Introduction

SECTION 1INTRODUCTION

The package substation is made up of three sections: the incoming line section, the transformer section, and the low voltage distribution section. The incoming line section is a type HVL or HVL/cc switch, or an air terminal chamber. The transformer section is an open-ventilated, dry-type transformer, and the low voltage distribution section is I-LINE molded case circuit breakers or separately mounted molded case main circuit breaker. Each substation has its own specification and unique construction features. These features are detailed in the substation outline and nameplate drawings. This instruction bulletin is not an application guide for the package substation or a substitute for adequate training in safe working procedures for this and related electrical equipment. Installation of this electrical equipment may require special licenses or training. Consult applicable national, industry, and local codes for specific requirements. The successful operation of any substation depends on various factors, such as installation, loading, service conditions, and maintenance. The substation should be installed in conditions as specified in ANSI/IEEE Section C57.12.01 Usual Service Conditions, unless the transformer is designed specifically for operation in conditions other than the usual service conditions. NOTE: If additional information is needed that is not covered by this instruction bulletin, contact your Schneider Electric field sales representative, or Square D Services at 1-800-634-2003.

Figure 1:

Typical Unit Substation

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ENGLISH

This instruction bulletin details information about installing, operating, and maintaining package substations.

Model III Package Substations Section 2Safety Precautions

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SECTION 2SAFETY PRECAUTIONS

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6

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E. Read and understand this entire instruction bulletin before installing, operating, or maintaining a package substation. Follow all applicable local and national codes. Only qualified electrical workers with training and expertise on high voltage circuits should perform work described in this set of instructions. These workers must understand the hazards involved in working with or near high voltage equipment. Such work should be performed only after reading this complete set of instructions. Use only electrically insulated tools, clothing, and protective gear when working around electrical equipment. The successful operation of substations depends upon proper handling, installation, operation, and maintenance. Neglecting fundamental installation and maintenance requirements will lead to personal injury, as well as damage to electrical equipment or other property. HVL or HVL/cc switches have features designed to promote proper operation, but it is not possible to eliminate every hazard with these features. Therefore, the person using this device is responsible for recognizing the potential hazards, for wearing protective safety equipment, and for taking adequate safety precautions. Do not make any adjustment to the equipment or operate the system with safety features removed. Contact your local Schneider Electric representative for additional instructions if the HVL or HVL/cc switch does not function as described in this manual. Before performing visual inspections, tests, or maintenance on this equipment, disconnect all sources of electric power. Assume that all circuits are live until they have ben completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeed. Always assume that terminal is energized unless it is checked with a properly rated meter to ensure the terminal is de-energized and grounded. Before servicing the transformer, ensure all static charge has been discharged by grounding the coils with an appropriate grounding device. If circuit breaker settings are adjusted, do not set the long time trip rating at a higher ampacity than the rating of the bus bar or load cables it supplies. Before energizing the substation, all unused I-LINE circuit breaker mounting spaces must be filled with blank fillers and/or extensions. Before replacing covers or closing doors, carefully inspect the bus work area for tools and objects left inside the equipment. Use care while removing or installing panels so that they do not extend into bus. Before making any electrical connection, take every precaution to see that all connections are de-energized and grounded. Introducing foreign objects into this equipment can cause a short circuit, which can result in severe damage, personal injury, or death. Short circuits can release large amounts of energy due to a rapid expansion of super-heated, ionized gases. Products of this instantaneous expansion can quickly engulf and burn personnel before preventive action can be taken. This short circuit source can cause additional injuries by propelling personnel or objects several feet from the equipment. Some foreign objects that can cause short circuits are tools, test leads, instruments not designed for high voltage circuits, wire, and other conduction or semi-conducting materials. Workers must also be careful to keep clothing and body parts out of the equipment. Failure to follow these instructions will result in death or serious injury.

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Model III Package Substations Section 3Receiving, Handling, and Storage

Initial Inspection

Before unloading the substation, perform the following inspection: 1. Remove the protective covering. 2. If the substation is provided with an HVL or HVL/cc switch, the substation is split for shipment. Review the shipping papers to ensure that the order and shipment is complete. 3. Inspect the substation for any obvious external damage that may have occurred during shipment. An internal inspection of the enclosure is not usually required unless possible external damage has been observed. If an internal inspection is required, carefully inspect the leads, bolted mechanical and electrical joints, the transformer core and coils, and accessory equipment, such as fans, controls, heater strips, control power transformers, or current transformers. List any noticeable damage on the receiving papers, file a claim with the carrier at once, and notify Schneider Electric. 4. After completing all of the above steps and if no problems are found, off load the substation. Refer to Handling on page 8. Figure 2: Typical Nameplate

Schneider Electric

POWER DRY II

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SECTION 3RECEIVING, HANDLING, AND STORAGE

Model III Package Substations Section 3Receiving, Handling, and Storage

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Handling

The transformer and low voltage section are built on a rigid base, which supports the transformer and LV section. See Figure 3. The base allows for lifting the entire substation at one time.

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Unloading and Lifting
8

Figure 3:

Typical Base

Follow these safety measures when handling the substation:

DANGER
TOP HEAVY LOAD Use a crane to unload the transformer. DO NOT UNLOAD using a forklift. The substation is top heavy and may become unbalanced. Keep all unnecessary personnel away while handling and moving the transformer. Failure to follow these instructions will result in death or serious injury. A crane is required to unload the substation. The approximate weight of the substation is shown on the transformer nameplate. The HVL or HVL/cc switch is provided with four lifting eyes on the top of the enclosure for lifting of the switch only. DO NOT attempt to lift the complete substation with these eyes.

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Model III Package Substations Section 3Receiving, Handling, and Storage

Follow these instructions to lift the transformer and LV section.

Figure 4:

Using a Spreader Bar

Spreader bar Protect paint from damage by slings

Substation Enclosure Sling Sling

Clevis pins (not provided)

2. Ensure the spreader bar is wider than the enclosure and protect the paint from the slings. 3. Lift the transformer and LV section from the base by the side holes provided; never lift from the ends. Always handle the substation in the normal, upright position. Do not tilt the substation. Towing and Moving After the substation has been off-loaded, a crane is preferred to move the transformer and LV section into position. When a crane cannot be used, the transformer and LV section can be skidded or moved on rollers. When doing so, take extra care not to damage the transformer. The HVL or HVL/cc switch may be moved with a forklift. If the substation must be stored, it is preferable to locate it in its permanent location on a concrete pad. If a level concrete surface is not available, take precautions to keep the unit from contacting an earthen surface. Protect the substation and connection points from the environment. Store Indoors Only. To reduce condensation and avoid moisture absorption in the transformer section while it is being stored, immediately install space heaters, incandescent lamps, or other small electric heaters. See Drying the Core and Coil Assembly on page 17 for more information. For storage of other equipment, refer to the applicable instruction bulletin(s) listed in Section 13Reference Publications on page 28 If the substation is stored for an extended time, make periodic inspections of the substation exterior and interior for corrosion or other possible damage. Always make an internal inspection before the substation is placed in service. If you have any concerns, contact Schneider Electric.

Storing

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1. Attach appropriately-sized clevis pins, slings, and a spreader bar. Figure 4 illustrates the use of these items, which are not supplied.

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SECTION 4INSTALLATION
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NOTE: Complete startup services are available from Square D Services. They can provide assistance in a variety of areas, from installation to comprehensive testing and verification of the new equipment. Contact Square D Services at 1-800-634-2003, 24-hours a day. Follow all local and national codes when locating the substation. Make sure the ventilated openings, on the top and bottom of the enclosure, are clear. Consult local and national codes to ensure all applicable requirements are satisfied. If the substation is located near combustible materials, make sure the location meets or exceeds the minimum clearances as required by the National Electric Code (NEC) or other applicable local codes. Locate the substation on a level foundation strong enough to support the weight of the substation, preferably of reinforced concrete. Schneider Electric recommends that you do not place the substation directly on an earthen surface. Ensure the foundation has adequate drainage. Seismic regulations may require that the substation be anchored to the pad.

Substation Location

Restricting Access to the Substation

Install the substation in an area that is secure and that allows only authorized personnel access to the substation.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH The transformer is not tamper proof, therefore restrict access to it. Allow only authorized personnel access to the transformer. Failure to follow this instruction will result in death or serious injury.

Electrical Connections

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Do not touch the windings of an energized transformer. Failure to follow this instruction will result in death or serious injury. The substation has both high voltage (HV) and low voltage (LV) connections. Multiple tap positions are available on the HV winding of the transformer to allow for adjustments, which may be necessary because of the specific supply voltage or transformer load characteristics. If tap adjustments are necessary, see Changing Tap Positions to Adjust Voltage on page 20. Connection points are clearly labeled on the transformer. Refer to the nameplate and wiring diagram to make the electrical connections. Follow these guidelines when making connections: 1. Clean the contact areas of the terminals (if applicable). 2. Use leads that are long enough to avoid mechanical strain caused by expansion and contraction. Strain can cause loose connections over time. 3. Using a torque wrench, ensure all bolted connections are torqued to the values given on the substation labels and in this bulletin. Refer to the tables on page 11 for torque information.

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Model III Package Substations Section 4Installation

Torque Guidelines for Transformer Electrical Connections

Bolt Size
Tinnerman nut Detail A Polyester insulator Detail B Tinnerman nut Detail C .3816 .3816 .7510 .2520 .5013 .5013 .6211 1.0014 Detail D Detail E .6211

Grade
2 2 5 2 2 5 2 1018 5

Application (see diagram at left)

Detail A Detail B, C, D Detail B Detail E Detail B, D Detail B Detail B Detail B Detail B

Torque Range
36 lb-ft (4.08.1 Nm) 1520 lb-ft (20.327.1 Nm) 100155 lb-ft (135.7210.3 Nm) 36 lb-ft (4.08.1 Nm) 4050 lb-ft (54.367.8 Nm) 4070 lb-ft (54.395.0 Nm) 8090 lb-ft (108.5122.1 Nm) 110170 lb-ft (149.2230.6 Nm) 110130 lb-ft (149.2176.4 Nm)

Bolt

Lock washer Belleville Nut* Belleville Nut* (Minimum 2 threads showing) Flat washer

Flat washer
*(Minimum 2 threads showing)

Bolt Flat washer Material

Torque Guidelines for Circuit Breaker Electrical Connections

Table 2:

Incoming, Branch, and Neutral Lug

Torque Value
180 lb-in (20 Nm) 250 lb-in (28 Nm) 340 lb-in (38 Nm) 620 lb-in (70 Nm)

Socket Size Across Flats

1/4 in. 5/16 in. 3/8 in. 1/2 in.

Table 3:

Multiple Conductor Neutral and/or Ground Bar

Torque Value
20 lb-in (2 Nm) 25 lb-in (3 Nm) 35 lb-in (4 Nm) 36 lb-in (4 Nm) 45 lb-in (5 Nm) 100 lb-in (11 Nm) 275 lb-in (31 Nm)

Screw Type Lug Wire Range Conductor Size

14-10 Cu, 12-10 Al 144 Slotted Head 141/0 141/0 6300 kcmil 8 Cu-Al 6-4 Cu-Al 14-8 Cu-Al 6-1/0 Cu-Al All All

Socket Head

Table 4:

QED-3 Circuit Breaker Connector Bolts

Torque Value Line/Load Connector Bolts
55-65 lb-in (67 Nm) 65-75 lb-in (78 Nm) 145-160 lb-in (1618 Nm) 130-150 lb-in (1517 Nm) 130-150 lb-in (1517 Nm)

Circuit Breaker Type

FA, FH, FC, FI KA, KH, KC, KI LA, LH MA, MH, MX, ME NA, NC, NX, NE

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Table 1:

Transformer Torque Values

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High Voltage Electrical Connections

Cable terminals for connecting incoming cables are located on the top of the HVL enclosure. Cable terminals for connecting incoming cables are located on the top or bottom of the HVL/cc enclosure. Install cable stress relief terminator kits on each high voltage cable (when shielded cable is used) before connecting to the HVL or HVL/cc switch. If an HVL or HVL/cc switch was provided, the transformer leads must be bolted to the terminals below the switch, or below the fuses, if provided. Refer to page 11 for torque information. If an HVL or HVL/cc switch was not provided, the transformer high voltage terminations are located in an air terminal chamber. Connection points are clearly labeled. Refer to the transformer nameplate and wiring diagram before making connections. Install cable stress relief terminator kits on each high voltage cable (when shielded cable is used) before connecting to the transformer terminals. Refer to page 11 for torque information.

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Conduit Area Cable Pulling Cable Terminations
12

1. Locate and terminate all conduit in the substation enclosure in the available conduit area designated on the equipment drawing. 2. Install the conduit properly. Use hubs and ring connectors to protect the cables and to prevent condensation on the conduit from entering the substation. NOTE: If top entry, do not use the top of the substation to support the weight of the conduit. Support the conduit independently. Under seismic conditions, the top of the substation can move as much as 3 inches (76 mm) in any direction. Any top incoming cables must accommodate this motion. 3. Bond all conduit, stubs, and ring connectors to the substation enclosure with approved electrical connections. 1. Use only cable sizes suitable for a proper fit with the corresponding lugs. 2. Pull the proper number of line-side and load-side cables according to the load served and the NEC. 3. Position the cables inside the substation so that they are not subject to physical damage. 4. Maintain the maximum possible bending radii and proper clearance to bus bars and grounded parts. If any cables are lying or bearing on structural members, support them to relieve this condition or place suitable protective material at the bearing point to protect the cable insulation. 5. Where cables enter or leave the substation or pass through any metal that has magnetic properties, be certain to run all phase conductors, including the neutral, through the same opening. Otherwise, overheating can result. See section 300-20(a) of NEC. 6. When instructed, brace or cable lace the conductors. 1. Strip a length of insulation from the end of the cable sufficient to fit into the full length of the lug barrel, being careful not to nick or ring the strands. Use a proper insulation stripping tool. 2. Thoroughly clean aluminum cable contact surfaces with a wire brush or scrub them with an abrasive cloth to remove oxides and foreign matter. 3. Immediately apply an acceptable joint compound to the bare aluminum surfaces.

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Model III Package Substations Section 5Pre-energizing Procedure Checklist

a. Insert the cable into the lug barrel and, using the crimping tool, make the specified number of crimps per the manufacturers recommendations. b. Wipe excess joint compound from the connector and insulation. c. With the cables connected, remount the lugs onto the bus bars, switches, or circuit breakers. Torque the bolts to the values given in the tables on page 11. 5. Set screw-type lugs may be furnished as main incoming lugs and are standard on molded case circuit breakers and QMB/QMJ fusible switches. Torque these lugs to, but do not exceed, the specified values. Torque values for circuit breaker and switch lugs are marked on these units. Torque values for other lugs are marked on the substation (Table 2 on page 11).

SECTION 5PRE-ENERGIZING PROCEDURE CHECKLIST

Conduct a complete inspection before the substation is energized to ensure that all components function and operate properly. Complete steps 124 before energizing the substation. 1. Check all field-installed bus bar connections. Torque values are listed on page 11. 2. Check all accessible connections for tightness. 3. Check all factory and field-installed lug terminations for tightness. 4. Check the rigidity of all bus bar supports. 5. Check the enclosure for dents or other damage that reduces electrical clearances inside the substation. 6. Remove all foam blocks, or other temporary cushioning or retaining material, from the electrical devices. 7. Manually open and close all switches, circuit breakers, and other operating mechanisms, checking for correct alignment and free operation. 8. Operate all electrically operated switches, circuit breakers, and other devices equipped with remote operators (not under load). An auxiliary source of control power may be necessary to accomplish this. 9. Check all relays, meters, and instrumentation to verify that all field installed wiring connections are made properly and that the devices function properly. 10. Current transformers (CTs) supplied for customer use require connection to a metering device load before energizing. Verify that the metering device load is properly connected, including main substation connections to remote equipment. 11. All CT circuits supplied by Schneider Electric for metering use are shorted for shipment. Remove shorting terminal screws on shorting terminal blocks or jumpers and store in the block.

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4. If compression-type lugs are furnished on any switch or circuit breaker, or as the main incoming power lugs, unbolt and remove them to create sufficient room for crimping the lugs to the cables with the crimping tool.

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12. Factory-installed molded case circuit breakers, 250 A frames or larger, have an adjustable magnetic trip, which is shipped on the LO setting. The markings between LO and HI settings represent a range of instantaneous magnetic trip values of 510 times the circuit breakers continuous current rating. To provide coordinated operation during a fault, adjust the magnetic trip as outlined in the respective instruction manual. All poles are adjusted simultaneously, using a screwdriver, by the single setting (Figure 5). Figure 5: Instantaneous Trip Setting

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14

Magnetic Trip Adjustment

13. On substations containing an electronic trip circuit breaker, set the tripping characteristic curve of the adjustable electronic trip unit as outlined in the respective instruction manual or coordinating study. NOTE: For molded case circuit breakers, refer to Section 13Reference Publications, beginning on page 28 for circuit breaker information. 14. Check all control wiring (when present) with the wiring diagrams to ensure that connections are properly made. 15. Inspect all insulation surfaces for dirt and moisture, including the primary support insulators and isolation barriers. If necessary, wipe with a clean cloth. 16. Fasten all barriers and covers in place. 17. Insert the proper keys in the interlocks, when used. 18. Verify that all grounding connections are correctly made.

CAUTION
HAZARD OF EQUIPMENT DAMAGE Do not pry open or spread the fuse mounting clips. This can cause a loose connection, resulting in overheating. Failure to follow this instruction can result in injury or equipment damage. 19. Conduct an electrical insulation resistance (megger) test to ensure that the substation is free from short circuits and undesirable grounds. Open all control power and metering disconnects or remove the fuses from the control circuits. With the neutral isolated from the ground and the HVL or HVL/cc switch and circuit breakers open, conduct electrical insulation
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Model III Package Substations Section 5Pre-energizing Procedure Checklist

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Exercise extreme care to prevent the HVL or HVL/cc switch from being energized while conducting the preliminary tests. If disconnect switches cannot be opened, disconnect the line leads. Failure to follow this instruction will result in death or serious injury. 20. After completing the electrical insulation resistance test, replace all control power fuses that may have been removed and close power disconnects that have been opened. 21. Check all field-installed wiring. Make certain it is clear of all live parts and secured, when instructed, to withstand fault currents. 22. Verify that all control wiring between sections is connected. 23. Vacuum to remove any dust, scrap wire, or other debris.

CAUTION
HAZARD OF EQUIPMENT DAMAGE Do not use an air hose to blow out the substation. The dust may settle inside relays and overcurrent devices, causing overheating and improper operation. Failure to follow this instruction can result in injury or equipment damage. 24. Replace all covers; check for any pinched wires, and then close the doors. Make certain all enclosure parts are aligned properly and fastened securely.

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tests from phase to phase, phase to ground, phase to neutral, and neutral-to-ground. If the resistance reads less than one megohm while testing with the branch circuit devices in the open position, the system may be unsafe and should be investigated. Consult Square D Services at 1-800-634-2003 to help correct any problems.

Model III Package Substations Section 5Pre-energizing Procedure Checklist / Section 6Interlocks

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SECTION 6INTERLOCKS
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Mechanical interlocks are standard features designed to promote proper operation of the substation. For example, the door interlock is designed to prevent opening the front door while the load interrupter switch is closed. Key interlocks (Figure 6) are optional equipment, often supplied in conjunction with metal-enclosed switchgear to direct proper operation of the equipment.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH When equipment is supplied with extra interlock keys, to be used during installation, the user is responsible for removing the extra keys. After reviewing the key interlock specifications, the user should provide only the necessary keys to properly operate the equipment. Extra keys should be destroyed or placed in a secure place, accessible to only selected personnel. If extra keys are made generally available, unauthorized personnel will have access to the equipment. Failure to follow this instruction will result in death or serious injury.

Figure 6:

Key Interlock

SECTION 7HVL AND HVL/CC SWITCH OPERATING SEQUENCES

Refer to the Schneider Electric instruction bulletins below for specific operating instructions for HVL and HVL/cc switches. 9840IM9301 (Alt. # 9840-3) Type HVL Load Interrupter Switch 6040IM9202 (Alt. # 6040-2) Metal-Enclosed Switchgear, 2.4kV38 kV 6045-1 HVL/cc Metal-Enclosed Switchgear, 2.4 kV17.5 kV

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Model III Package Substations Section 8Startup Testing to Energize

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Only qualified personnel should perform these tests. Disconnect ALL high voltage, low voltage, and neutral connections. Disconnect auxiliary equipment, such as lightning arresters, the fan and temperature control system, meters, or any other low voltage control system that is connected to the transformer windings that are involved in these tests. DO NOT disconnect the ground connection to the transformer frame. Failure to follow these instructions will result in death or serious injury.

Pre-energizing Testing

Before energizing the transformer and placing it in service, Schneider Electric recommends that the following tests be performed:

Insulation Resistance: Measures the resistance of the insulation between the primary and secondary windings and from each winding to ground. Turns Ratio: Measures the ratio of the primary to secondary turns to check for possible insulation degradation in the windings.

Drying the Core and Coil Assembly

CAUTION
FIRE HAZARD Do not exceed 100 C air temperature. Do not allow the lamps or heaters to contact the transformer coil insulation. Failure to follow these instructions can result in injury or equipment damage. The transformer MUST be kept dry during storage. Use lamps or heaters to keep the surface dry and the core and coil from absorbing moisture. Place the lamps or heaters a minimum of 4 to 6 inches (102 to 152 mm) away from the transformer coils. Good ventilation is essential.

Drying Transformer Coils

CAUTION
FIRE HAZARD Constant attendance during the drying process is recommended. Have a suitable fire extinguisher on hand for use in the event of an emergency. Failure to follow this instruction can result in injury or equipment damage.

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SECTION 8STARTUP TESTING TO ENERGIZE

NOTE: Complete startup services are available from Square D Services. They can provide assistance in a variety of areas, from installation to comprehensive testing and verification of the new equipment. Contact Square D Services at 1-800-634-2003, 24-hours a day.

Model III Package Substations Section 8Startup Testing to Energize

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The transformer core and coils MUST be dry before the transformer can be tested and energized. If the transformer has more than surface moisture present, more extensive drying may be required to ensure that the core and coils are dry. To dry the transformer, apply external heat to the transformer using the heater or lamp method described above. Drying time depends on the condition of the transformer, size, voltage, amount of moisture absorbed, and method of drying. Measuring insulation resistance is valuable in determining the drying status.

ENGLISH
Heaters and Lamps for Drying Insulation Resistance Testing Turns Ratio Test Effects of Humidity
18

Heaters: Blow the heated air from space heaters or other small heaters into the bottom grills of the transformer enclosure and through the winding ducts, not around the core sides. Lamps: Use six 150 watt lamps. Place two lamps under each coilone on each side of the core. Before performing the insulation resistance test, use a vacuum cleaner to clean the core and coil assembly. When measured in accordance with ANSI/IEEE Standard C57.94, the minimum insulation resistance should be as listed in Table 5: Table 5: Insulation Resistance Values
Insulation Resistance (M)
600 1000 1500 2000 3000

Winding kV Class
1.2 2.5 5.0 8.7 15.0

Perform the turns ratio test at each tap position and for the full winding: 1. Use a Transformer Turns Ratio (TTR) to measure the ratio between the primary and secondary windings. 2. Compare these measurements to the transformer nameplate voltage ratio. The measurements should be within 1/2 of 1% of the nameplate voltage ratio. Refer to ANSI C57.12.91 for additional information. When the transformer is energized, humidity is relatively unimportant. However, if the transformer is de-energized and allowed to cool to ambient temperature, high humidity may affect transformer start up and operation. If the shutdown occurs during low humidity, the transformer can be energized following normal startup procedures. No special precautions are necessary. If the transformer is shut down for longer than 24 hours during high humidity, then precautions are required, particularly if condensation occurs within the enclosure. After de-energizing the transformer, place space heaters below the core and coils to keep the transformer temperature a few degrees centigrade above that of the surrounding air. If heaters are not used, inspect the transformer for visible moisture and measure the insulation resistance. (See Drying Transformer Coils on page 17.) If moisture is present or if the insulation resistance is low, dry the transformer using one of the methods described in Drying the Core and Coil Assembly on page 17.

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Model III Package Substations Section 8Startup Testing to Energize

Energizing the Substation

1. Before energizing the substation, do the following:

NOTE: DO NOT remove the fiberglass tubing (if provided) that surrounds the high voltage cables. b. Verify the operation of fans, motors, controllers, relays, or other auxiliary devices. c. Verify the selection of taps and ratio connections against the transformer nameplate information. d. Torque all connections according to the torque guidelines on page 11, and ensure clearances are adequate between the transformer enclosure and internal bus bars. e. Remove all hand tools, equipment, or any other foreign material from inside the enclosure. Do not leave tools or other equipment on the core and coil assembly. 2. Energize the HVL or HVL/cc switch with the switch in the open position. 3. Energize the transformer with no load on the LV distribution section by closing the HVL or HVL/cc switch.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Only qualified personnel with appropriate measurement devices should measure the voltages on the transformer. Correct short circuit conditions detected during the checkout procedures described in Section 5Pre-energizing Procedure Checklist, beginning on page 13. Qualified electrical personnel must be present when energizing this equipment for the first time. Follow the instruction in this section to properly energize the I-Line panelboard or main breaker. Failure to follow these instructions will result in death or serious injury. 4. Check the transformer nameplate before measuring voltages and ensure that properly rated meters are used to verify the primary and secondary transformer voltages. 5. Verify the voltages on the transformer primary and secondary. If the voltages are not as required, use the taps to adjust the voltage. See Changing Tap Positions to Adjust Voltage on page 20. 6. No load should be on the I-Line panelboard or main breaker when it is energized. Turn off all downstream loads.

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a. Remove all shipping braces and shipping bolts (if present). They are clearly tagged or painted yellow.

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Changing Tap Positions to Adjust Voltage

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Before performing this procedure, review Section 2 Safety Precautions on page 6. Do not change the tap connections when the transformer is energized. Disconnect all power and verify the transformer is de-energized before servicing the transformer. Use a properly rated meter to measure for the presence of voltage at the terminal and to verify the transformer is de-energized. Do not rely on visual indications, such as switch position or fuse removal for determining a de-energized condition. Ensure no paths are present for backfeeding power to the transformer (such as through a tie-breaker). Failure to follow these instructions will result in death or serious injury. To change the tap position: 1. De-energize the transformer following the safety messages above and your companys lock-out/tag-out procedures. 2. Locate the transformer taps above the coils of the transformer. They can be accessed by removing the rear access panel on the back of the low voltage distribution section. 3. Use an appropriate grounding device to ground the coils and discharge any static charge. 4. Locate the tap jumpers. 5. Change the tap jumpers on each phase to the appropriate tap connection. The tap jumpers must be on the same tap position for each phase. 6. Torque the tap connections. Refer to the torque values on page 11. NOTE: For multiple voltages or other special arrangements, see the transformer nameplate. 7. Inspect the enclosure to ensure all hand tools, equipment, or any other foreign materials are removed from the enclosure. 8. Re-install the rear access panel. 9. Energize the transformer.

ENGLISH

Sound Level

All transformers have an inherent sound level that varies with the size of the units. The fundamental frequency is twice that of the applied voltage. Sound waves may be amplified by means of reflected waves and/or radiated waves via walls, floors, ceilings, mechanical vibrations of air ducts, conduits, and mounting bases. For average expected sound levels, refer to NEMA ST-20. To meet NEMA listed average sound levels, each unit should be installed in a location where there is a 10-foot clearance on all sides except floor or ground. Units located in close proximity to hard surfaces may produce higher than average sound levels. When transformers must be located in noise sensitive areas, precautions should be taken to avoid amplification of the transformer sound. Install the unit in an area where the noise will be least objectionable. Avoid rooms where hard surfaces are in close proximity to the transformer.

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Model III Package Substations Section 9Maintenance

Reduction of Structure Borne Noise

Loosen anchor bolts between the transformer and enclosure and let the unit rest on the vibration pads only. (Except on certified seismic units.) Use flexible conduit and bus connections. Avoid mounting the unit on walls, balconies, and floors with low masses. Avoid uneven mounting surfaces. If specified, low sound level transformers can be provided for most applications.

SECTION 9MAINTENANCE

NOTE: Complete maintenance services are available from Square D Services. They can provide assistance in a variety of areas, from installation to comprehensive testing and verification of the new equipment. Contact Square D Services at 1-800-634-2003, 24-hours a day. Inspect the substation regularly. The frequency of inspection depends on operating conditions. If the transformer is operating in usual service conditions as defined in ANSI/IEEE C57.12.01, an inspection once a year may be sufficient. However, for unusual locations where the air is contaminated with particles such as dust or chemical fumes, inspect the substation every three months or sooner. After the first few inspections, determine a more definite schedule based on the existing conditions.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Inspection, maintenance, and parts replacement must be performed only with the primary source(s) of power disconnected and locked open. Be absolutely sure no backfeed exists through any feeder circuit. Failure to follow this instruction will result in death or serious injury. De-energize the substation following the safety messages in Section 2 Safety Precautions on page 6 and your facilitys lock-out/tag-out procedures. 1. Vacuum the substation interior to remove any dirt and dust deposits. Wipe all bus bars, insulators, cables, and so forth, with a clean, dry, lintfree cloth. 2. Check the substation interior carefully for moisture, condensation buildup, and signs of any previous wetness. Moisture can cause insulation failures and rapid oxidation of current-carrying parts. Inspect all conduit entrances and cracks between the enclosure panels for dripping leaks. Condensation in conduits may be a source of moisture and must not be allowed to drip onto live parts or insulating material. Take the necessary steps to eliminate the moisture and seal off all leaks. 3. Inspect the substation for any signs of overheating. Discoloration and flaking of insulation or metal parts are indicators of overheating. NOTE: If overheating occurs, be sure that all conditions that caused the overheating have been corrected. Loose or contaminated connections can cause overheating. 4. Check the torque values on all electrical connections, including the ground connection(s). Tighten and/or repair if necessary. Refer to the torque values on page 11.

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Use acoustic absorbing materials on walls, floors, and ceilings. Avoid installation of units in corners, hallways, and stairways, and near heating and air conditioning ducts.

Model III Package Substations Section 9Maintenance

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5. Check for signs of rodent nesting in the substation. If required, use a good exterminating technique in the general area of the substation.

ENGLISH
After a Major Fault Inspection Procedure for HVL and HVL/cc Switches Transformer Inspection Procedure
22

NOTE: Do not place or use exterminating substances and chemicals inside the substation. Some of these products attract rodents. 6. Carefully inspect all devices for any visibly worn-out, cracked, or missing parts. 7. Manually open and close switches and circuit breakers several times to verify they are working properly. 8. Verify that all key interlocks and door interlocking provisions are working properly. 1. If the transformer is energized, de-energize the transformer in accordance with the safety messages on page 21, in Section 2 Safety Precautions on page 6, and your facilitys lock-out/tag-out procedures. 2. Remove the enclosure panels and inspect the transformer core and coil assembly for any physical damage. If damage has occurred, contact the Square D Medium Voltage Transformer facility at 704-283-7411.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Do not re-energize the transformer if the transformer has been damaged. Failure to follow these instructions will result in death or serious injury. 3. Using a torque wrench, ensure all bolted connections are torqued according to the torque guidelines in Table 1 on page 11. 4. Perform the tests described in Section 8Startup Testing to Energize on page 17. DO NOT re-energize the transformer if the test results are not acceptable. If no damage has occurred and all test results are acceptable, perform maintenance by following the procedures starting on page 21. Before performing any inspections, verify that the substation has been de-energized in accordance with the safety messages on page 21, in Section 2Safety Precautions on page 6, and your facilitys lock-out/tagout procedures. Give the switch an overall maintenance check at least once each year. Refer to the Schneider Electric instruction bulletins below for specific maintenance instructions for HVL and HVL/cc switches. 9840IM9301 (Alt. # 9840-3) Type HVL Load Interrupter Switch 6040IM9202 (Alt. # 6040-2) Metal-Enclosed Switchgear, 2.4kV38 kV 6045-1 HVL/cc Metal-Enclosed Switchgear, 2.4 kV17.5 kV Before performing any inspections, verify that the substation has been deenergized in accordance with the safety messages on page 21, in Section 2Safety Precautions on page 6, and your facilitys lock-out/tag-out procedures.

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Model III Package Substations Section 9Maintenance

Follow steps 14 to inspect the transformer

2. Remove the enclosure panel or door to access the transformer high voltage windings. 3. Check the enclosure for deterioration. If deterioration is present, determine the cause and correct (if possible). Repaint deteriorated areas. 4. Replace corroded hardware, as required. See Section 12 Replacement Parts on page 28.

Cleaning

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Before performing this procedure, review Section 2 Safety Precautions on page 6. Before servicing the transformer, ensure all static charge has been discharged by grounding the coils with an appropriate grounding device. Failure to follow these instructions will result in death or serious injury. To clean the transformer, follow these steps: 1. De-energize the transformer following the safety messages above and your facilitys lock-out/tag-out procedures. 2. Remove the rear enclosure panel to access the transformer high voltage windings.

CAUTION
HAZARD OF EQUIPMENT DAMAGE Do not push or pull the cloth through the coils. Failure to follow this instruction can result in injury or equipment damage. 3. Wipe down all parts of the core, being careful not to cut yourself on any sharp edges or protrusions. If possible, use a vacuum to remove any dust or debris. 4. Clean any loose debris and dust from around the coils, core frames, cables, bus bars, stand off insulators, and other surfaces within the enclosure. Make sure the enclosure floor is clean. Use a vacuum cleaner or simply wipe with towels. 5. Be sure to remove all rags or other maintenance equipment from the coil ducts and check for tools when finished. Confirm that the coil ducts are clear.

Molded Case Circuit Breakers Inspection Procedure

Molded case circuit breakers manufactured by Schneider Electric are designed as totally sealed units requiring minimal periodic maintenance. Exercise circuit breakers at least once a year to ensure proper operation. For general maintenance: 1. Trip the circuit breaker by pushing the Push to Trip button located on the face of the circuit breaker. (On most molded case circuit breakers this

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1. Clear away any debris or other foreign objects from all ventilation openings.

Model III Package Substations Section 9Maintenance

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button will be yellow). This procedure tests alarm switches if they are built into the circuit breaker, or electrical interlocks between two circuit breakers. This also exercises the trip mechanism. 2. Manually open and close the circuit breaker two to three times.

ENGLISH
24

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH If circuit breaker settings are adjusted, do not set the long time trip rating at a higher ampacity than the rating of the bus bar or load cables it supplies; overheating can occur. Before energizing the substation, all unused I-LINE circuit breaker mounting spaces must be filled with blank fillers and/or extensions as listed in Table 6 on page 24. Failure to follow these instructions will result in death or serious injury.

CAUTION
HAZARD OF EQUIPMENT DAMAGE Do not remove the protective lubricant on the plug-on connectors. Failure to follow this instruction can result in injury or equipment damage. NOTE: If additional lubrication is required, apply a coating of electrical joint compound, catalog number PJC7201, to the plug-on connectors contact surfaces. Schneider Electric manual number 0600PD9602, Field Testing Industrial Molded Case Circuit Breakers, provides more in-depth information. (Refer to Section 13Reference Publications, beginning on page 28.) Contact your Schneider Electric field sales representative to obtain this manual. Refer to individual circuit breaker instruction manuals shipped with the substation for additional maintenance information, such as changing rating columns or adjustable settings and removing circuit breakers. If the instruction manual is not available, see Section 13Reference Publications of this manual for the appropriate number, and contact your Schneider Electric field sales representative to obtain this manual.

Table 6:

Blank Fillers and Extensions

Height Catalog No.
HNM1BL HNM4BL HLW1BL HLW4BL

Blank Fillers Blank Extensions

1.5 in. (38 mm) 4.5 in. (114 mm) 1.5 in. (38 mm) 4.5 in. (114 mm)

3. The universal test set, catalog number UTS3, is available to test all circuit breakers by Schneider Electric that are equipped with MICROLOGIC trip units. It runs trip unit tests automatically, with prompts to the user for initial information. Test modules for each circuit breaker frame are used to store data necessary for automatic tests.

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Model III Package Substations Section 10Adverse Cirmumstances

Series B MICROLOGIC trip units require test module CBTMB, which is included in UTS3. NOTE: Tests may be conducted with a circuit breaker installed; circuit breaker removal is not required. The substation must be de-energized.

Ground Fault Protection Systems

Check the terminal connections on the ground fault protection system at least once a year for tightness and corrosion. If the system can be tested with or without tripping the main or branch device, directions for testing the system are in the device manual. Otherwise, testing the ground fault protection system will trip the main or branch device to which it is connected. If the ground fault sensor or relay is physically or electrically damaged, replace it. If the ground fault protection system does not operate properly and additional equipment has been connected to the installation since the last maintenance test/check, de-energize the entire system and check for grounds on the neutral downstream from the main bonding jumper. If no downstream grounds are detected and the ground fault system is not operating properly, contact Square D Services at 1-800-643-2003. Likewise, if no additions have been made to the installation, and the ground fault protector does not operate properly, contact Square D Services. Refer to the ground fault field test instruction manual for additional testing information. If the manual is not available, refer to Section 13Reference Publications, beginning on page 28 of this manual to obtain the appropriate number. Contact your Schneider Electric field sales representative to obtain this manual.

SECTION 10ADVERSE CIRCUMSTANCES

This section includes, but is not limited to all electrical components of the substation. De-energize the substation following your companys lock-out/tag-out procedures.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying the substation before servicing. Use a properly rated voltage sensing device to verify that power is off. Before energizing the substation, all unused circuit breaker mounting spaces must be filled. Failure to follow these instructions will result in death or serious injury. NOTE: Before attempting to re-energize the substation following a fault, contact Square D Services at 1-800-634-2003 for special instructions. 1. If a short circuit occurs, make a thorough inspection of the entire system and verify that no damage to conductors or insulation has occurred. High mechanical and thermal stresses developed by short circuit currents may damage conductors and insulation. Check the overcurrent protection device that interrupted the short circuit current for possible arcing damage. Do not open sealed devices, such as molded case circuit breakers. These devices should be replaced if damaged. Before energizing the substation, all unused breaker mounting spaces must be filled. For more information

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Model III Package Substations Section 10Adverse Cirmumstances

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about these devices, refer to the appropriate instruction manual listed in Section 13Reference Publications, beginning on page 28.

ENGLISH
Clean-up Following a Short Circuit Water-Soaked Substations Water-Sprayed or Splashed Substations (Clean Water Only) Inspection and Clean-up of Clean Water Sprayed or Splashed Substations
26

2. Remove the enclosure panels and inspect the transformer core and coil assembly for any physical damage. If damage has occurred, contact Schneider Electric.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Do not re-energize the transformer if the transformer has been damaged. Failure to follow these instructions will result in death or serious injury. 3. Using a torque wrench, ensure all bolted connections are torqued according to the torque guidelines on page 11. 4. Perform the tests described in Section 8Startup Testing to Energize on page 17. Do not re-energize the transformer if the test results are not acceptable. If no damage has occurred and all test results are acceptable, perform maintenance by following the procedures in Section 9Maintenance on page 21. 5. Perform the tests and inspection of the HVL or HVL/cc switch as described in Section 9Maintenance on page 21. The insulating properties of some organic insulating materials may deteriorate during an electrical arc. Replace carbon-tracked insulation. NOTE: Contact Square D Services before cleaning a substation that has been subjected to a short circuit situation. Do not clean or repair a substation that has been exposed to large volumes of water or submerged at any time. Current carrying parts, insulation systems, and electrical components may be damaged beyond repair. Do not energize the substation. Contact Square D Services.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Turn off all power supplying this equipment before working on it. Use a properly rated voltage sensing device to verify that power is off. Failure to follow these instructions will result in death or serious injury. If the substation has been sprayed or splashed with small amounts of clean water, make a thorough inspection of the entire system and verify that no damage to conductors or insulation has occurred. Do not open sealed devices, such as molded case circuit breakers or fuses. These devices should be replaced if damaged. For more information about these devices, refer to the appropriate instruction manual listed in Section 13Reference Publications, beginning on page 28. Follow steps 1 through 9 only if:

No signs of physical damage to the equipment are present. The substation has not been submerged or exposed to water for long periods of time.
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Model III Package Substations Section 11Optional Equipment

The water that has been in contact with the substation has not entered any area of the enclosure that may contain wiring installed as intended and located above any live parts. Specifically, inspect for water entering through conduits located above live parts.

If any of these conditions have been met, contact Square D Services at 1-800-634-2003. If ALL of the conditions listed above are true, proceed as follows: 1. Completely de-energize the substation. Disconnect and electrically isolate the substation so no contact can be made with energized parts. 2. Wipe off all moisture from the bus bars, insulators, and insulation material with a clean, dry, lint-free cloth. Do not use cleansing agents or water displacement sprays. 3. Prepare the substation for insulation resistance (megger) testing by disconnecting all line-side supply connections and all load-side cable connections to isolate the substation from the wiring system. 4. Turn all circuit breakers or switches to their ON position. The substation must remain completely de-energized. 5. Use a megohmmeter with a capacity of 5001,000 Vdc and apply voltage from: a. Each phase-to-ground with circuit breaker ON. b. Phase-to-phase with circuit breaker ON. 6. Perform the megohm tests as described in step 5 above on the HVL or HVL/cc switch. 7. Perform the megger tests on the transformer as described in Section 8Startup Testing to Energize on page 17. 8. If the resistance measurements are less than 0.5 megohm for the switch and/or circuit breakers, or less than the values in Table 5 on page 18 for the transformer, call Square D Services at 1-800-634-2003 for recommendations. 9. If the resistance values are greater than 0.5 megohm for the switch and circuit breakers and greater than the Table 5 values for the transformer, the substation can be energized using the procedures listed in Section 8Startup Testing to Energize, beginning on page 17.

SECTION 11OPTIONAL EQUIPMENT

Temperature Monitoring Systems

This section provides information about optional equipment.

Optional temperature control modules are available on ventilated dry type transformers. The monitor controls the fans and provides alarm indication. See the manufacturers instruction manual included with the transformer documentation package for detailed information about the installation, operation, and maintenance of the monitor. The factory pre-set temperature alarm and control settings for ventilated transformers are listed in Table 7.

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The water that has been in contact with the substation has not been contaminated with sewage, chemicals, or other substances that can negatively affect the integrity of the electrical equipment.

Model III Package Substations Section 12Replacement Parts

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Table 7:
Stage
Fan On Alarm On Trip Signal

Factory-Set Temperature Alarm and Control Settings

Temperature Rise
Transformers with 80 C/150 C Temperature Rise Rating 110 C 195 C 220C Transformers with 115 C/150 C Temperature Rise Rating

ENGLISH
Fans (Forced Air) Powerlogic Circuit Monitor Other Optional Equipment

Fan On Alarm On Trip Signal

145 C 195 C 220 C Transformers with 150 C Temperature Rise Rating

Fan On Alarm On Trip Signal

180 C 195 C 220 C

When provided, bladed fans located above the transformer coils provide the forced air cooling. If specified, an optional POWERLOGIC Circuit Monitor may be supplied. See the instruction manual included with the substation documentation package for detailed information about the monitor. Other optional equipment, such as meters, current or potential transformers, or space heaters, may be supplied if specified. Some replacement parts for the transformer are available. Contact Schneider Electric for price and availability. When ordering parts, include as much information as possible. Provide full nameplate information and a description of the part that is needed. Sketches or photographs may be useful in describing the part. Often, the part number of a new part can be obtained from identification of the old part. Specify the rating, vertical section, and factory order number of the equipment in which the part is to be used.

SECTION 12REPLACEMENT PARTS

SECTION 13REFERENCE PUBLICATIONS

The following Schneider Electric publications are available through your Schneider Electric field sales representative. These include device replacement procedures and spare parts listings to make ordering and servicing of replacement parts quick and convenient. Any maintenance procedure or device not listed, such as an I-LINE panel, is not customer serviceable. Contact Schneider Electric for information.

Table 8:
Title

Installation Instructions
Publication Number
48940-158-02 48040-797-04 48040-732-03 48049-031-02 48049-033-01 48049-034-02 48040-008-08

FA, FH, FC, SFH Circuit Breakers NA, NC, SL 1200 I-LINE Circuit Breakers LI, LC I-LINE Circuit Breakers KA, KH, KC, KI, SKC, SKI Instructions FI Instructions LA, LH, SLA, Q4 Instructions Q2 Instruction Sheet

28

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Model III Package Substations Section 14Reference Publications

Table 8:
Title

Installation Instructions (continued)

MA, MH, SMA, SMH Instructions PA, PH Instruction Sheet FA-M01 and KA-M01 Motor Operator LA-M01 and MA-M01 Motor Operator PA-M02 Motor Operator SE Ground Fault Module (GFM) Ground Fault Protection SystemType GC MASTERPACT Universal Power Circuit Breaker QMB Fusible Switches HVL Switch Metal-Enclosed Switchear, 2.4 kV38 kV HVL/cc Metal-Enclosed Switchgear, 2.4 kV17.5 kV

48049-032-02 48040-189-05 48049-085-01 48049-086-01 48040-884-06 48040-495-06 48040-756-05 40268-292-01 48049-071-02 40268-525-02 9840IM9301 (Alt # 9840-3) 6040IM9202 (Alt. # 6040-2) 6045-1

Table 9:
Title
LE/LX Manual

Instruction and Maintenance Bulletins

Publication Number
48049-027-02 48049-028-02 48049-029-01 48040-940-03 48040-495-06 3020IM9301R10/97 3050IM9103 3050IM9101 3020IM9503

ME, MX Electronic Trip Circuit Breakers NE, NX Drawout Circuit Breakers PE/PX Manual SE Electronic Trip Circuit Breaker POWERLOGIC Circuit Monitor (CM-2050, 2150, 2250, 2350, 2450, 4000) POWERLOGIC System Display for MICROLOGIC Circuit Breakers (SD-100, SD-120) POWERLOGIC Power Interface for MICROLOGIC Circuit Breakers (PIF-3) POWERLOGIC Power Meter (PM-600, PM-620, PMD-32)

Table 10:
Title

Ground Fault Field Test Instructions

Publication Number
48040-757-04 63020-271-01 80043-054-01

Ground Fault Module (GFM) Field Test Procedure ME/NE/PE and MX/NX/PX Electronic Trip Circuit Breakers Type GCGround Fault Protection System

Table 11:
Title

Distribution Reference Catalogs

Section Number
600 4620 4620

Molded Case Circuit Breakers QMB Fusible Switches QMB Circuit Breaker Adapter Units

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Publication Number

Model III Package Substations Section 14Reference Publications

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Table 12:
Title

Other Reference Literature

Publication Number

ENGLISH
30

General Instructions for Proper Installation, Operation, and NEMA Publication PB2.1 Maintenance of Switchboards Rated 600 V or Less Application Guide for Ground Fault Protective Devices for Equipment Circuit Breakers Enclosed and Miscellaneous Distribution Switches Electrical Equipment Maintenance Molded Case Circuit Breakers Field Test and Maintenance NEMA Publication PB2.2 NEMA Publication AB-4 NEMA Publication KS-1 NFPA 70B-1999 Schneider Electric Bulletin No. 0600PD9602

For information about obtaining NEMA documents, write to: National Electrical Manufacturers Association (NEMA) Attention: Customer Service 1300 North 17th Street Suite 1847 Rosslyn, VA 22209

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Model III Package Substations Section 14Installation and Maintenance Log

DATE

INITIALS

ACTIONS

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SECTION 14INSTALLATION AND MAINTENANCE LOG

Instruction Bulletin Model III Package Substations

Schneider Electric
1010 Airpark Center Drive Nashville, TN 37217 USA 1-888-SquareD (1-888-778-2733) www.SquareD.com

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. 43500-054-30R1 20012004 Schneider Electric All Rights Reserved Replaces 43500-054-30 dated January 2001 02/2004