Powell FlexTrol Class E2

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5kV and 7.2kV - 400A and 800A

Motor Control With Eaton Contactors

01.4IB.46300

FlexTrol™ Class E2 Medium Voltage Controllers

March 2019

Powell Electrical Systems, Inc.

Service Division - Houston

7232 Airport Blvd • Houston, TX • 77061

Tel: 1.800.480.7273

powellind.com

info@powellind.com

Main Page

Table of Contents5
Ch 1 General Information11
- S Cope12
- P Urpose12
- I Nstruction B Ulletins a Vailable E Lectronically12
- Associated B Ulletins12
Ch 2 Safety13
- S Afe Ork Ondition13
- S Afety G Uidelines14
- G Eneral14
- S Pecific15
- X-R Ays15
- S Afety Abels16
Ch 3 Equipment Description17
- G Eneral17
- F Lex T Rol ™ C Lass E2 M Edium V Oltage C Ontroller17
- Figure 1 Flextrol™ 400A & 800A18
- Figure 2 Two-High Vertical Section Rear View (400A)19
- Figure 3 High and Low Voltage Compartments20
- Atings21
  - Basic I21
- Basic Mpulse Evel21
  - D Ielectric T Est21
- M Edium V Oltage C Ontactors21
Table a Horsepower, Current, and Voltage Ratings21
Table B Voltage and Interrupting Ratings of Class E2 Medium Voltage Controllers21
- M Anual I Solation Switch22
- Figure 4 Eaton Type SL Medium Voltage Vacuum Contactor 400A22
- Figure 5 Eaton Type SL Medium Voltage Vacuum Contactor 800A23
- M Echanical Nterlocking24
- Figure 6 Isolating Switch Operating Handle24
- Figure 7 Typical Dimensions for Flextrol25
- A Uxiliary Ompartments26
- P Ower F Uses26
- S Tarting Utotransformers or Eactors27
- D Imensions27
Ch 4 Installation28
- G Eneral28
- R Eceiving28
- S Torage28
- Andling29
- Figure 8 Recommended Method for Lifting an Indoor Lineup29
- Figure 9 Typical Flextrol™ Floor Plans30
- P Ositioning of the E Nclosure31
- R Emoving the M Edium V Oltage V Acuum C Ontactor31
  - Removing the Vacuum Contactor from the High Voltage Compartment31
- P Ower Onnections33
Table C General Guideline for Outgoing Feeder Cables33
- G Rounding34
- Figure 10 Ground Bus Splicing Configuration35
- C Onnections36
- Main B Us Assembly I Nsulation36
- I Ncoming P Ower C Onnections36
  - Wrapping Bus Joint36
Table D Bolt Torque Values for Flextrol36
Table E Bus Wrapping Components36
Table F Insulation of Bus Bar37
Table G Insulation of Single Bus Bar Connection Joint37
Figure 11 Insulation of Bus Bar37
Figure 12 Single Bus Bar Connection Joint37
Table H Insulation of Double Bus Bar Connection Joint38
Table I Insulation of Tee Connection Joint38
- Applying PVC Boots39
- Cleaning Bus Insulation39
- Figure 15 Dead End Bus Joint Insulation39
Figure 13 Double Bus Bar Connection Joint38
Figure 14 Tee Connection Joint38
Table J Insulation of Dead End Bus Bar Joint39
- Figure 16 Flextrol™ - 400A40
- Figure 17 Flextrol™ - 800A40
- M Otor C Onnections41
- P Ower C Able T Ermination41
- C Ontrol C Ables and C Onnections42
- Figure 18 Low Voltage Compartment42
- Figure 19 Wire Way42
- G Round F Ault C Urrent T42
- I Nsulating P Rimary C Ables42
- M Echanical O Peration C Heck43
- S Urge Rotection43
- S Afety I Nterlocks44
Ch 5 Operation46
- G Eneral46
- P Reparation of the Ontroller for Peration46
- Est P Ower C Ircuit48
- Figure 21 Mechanical Interlock Verification48
- I -P Ot and M Egger T Est49
  - Preparing for the Hi-Pot and Megger Test49
  - Performing the Hi-Pot and Megger Test49
- P Re -O Peration T Est50
- S Tart50
Table K Eaton Publication References52
Ch 6 Maintenance53
- Maintenance P Recautions53
- P Reventative Maintenance G Uidelines53
Ch 7 Recommended Renewal Parts and Replacement Procedures55
- O Rdering I Nstructions55
- R Ecommended R Enewal P Arts55
  - Renewal Parts Quantity55
- Eplacement P Rocedures55
  - Fuse Removal/Replacement Procedure56
  - Auxiliary Contacts Inspection and Replacement57
- R Eplacement P Arts58
Table L Medium Voltage Vacuum Contactor Eaton 400A SL58
Table M Medium Voltage Vacuum Contactor Eaton 800A SL59
Table N R-Rated Clip-On Fuses for 400A Contactor60
Table O R-Rated Bolt-On Fuses for 800A Contactor61
Table P E-Rated Clip-On Fuses for 400A Contactor62
Table Q E-Rated Bolt-On Fuses for 800A Contactor62
Table R Control Relays63
Table S Current Transformers63
Table T Ground Current Transformers63
Table U Control Power Transformers - SNC64
Table V Control Power Transformer Primary Fuses64

Powell FlexTrol Class E2 - Page 65

Table of Contents