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Masterclad™ 5–15 kV Arc Resistant Metal-Clad

Indoor Switchgear

ENGLISH
Class 6055

Instruction Bulletin
6055-62
06/2012
Retain for future use.
Hazard Categories and Special Read these instructions carefully and look at the equipment to become
Symbols familiar with the device before trying to install, operate, service or maintain
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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.

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

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

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

NOTICE
NOTICE is used to address practices not related to physical injury. The
safety alert symbol is not used with this signal word.

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.
6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Table of Contents

Table of Contents
Introduction ................................................................................................. 7

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Product Overview .................................................................................. 8
Front Section with Secondary Control Devices ............................... 8
Circuit Breaker Compartment .......................................................... 9
Circuit Breaker Positioning Rails ..................................................... 9
Racking Mechanism ........................................................................ 9
Secondary Disconnect Receptacle.................................................. 9
Racking Position Indicator ............................................................. 10
Primary Contacts ........................................................................... 10
Current Transformer ...................................................................... 10
Ground Contact Bar....................................................................... 10
Mechanism Operated Contacts (Optional) .................................... 10
Truck Operated Contacts (Optional).............................................. 10
Interlocks ....................................................................................... 11
Voltage Transformer and Control Power Transformers Fuse
Drawout Units ................................................................................ 12
Main Bus Compartment ................................................................. 13
Cable Compartment....................................................................... 14
Surge Arresters.............................................................................. 14
Safety Precautions .................................................................................... 15
Receiving, Handling, and Storage ............................................................. 16
Receiving ............................................................................................. 16
Handling .............................................................................................. 16
Storage ................................................................................................ 17
Site Selection and Preparation ............................................................ 17
Foundation .......................................................................................... 18
Conduit Location ................................................................................. 18
Installation ................................................................................................. 19
Switchgear Installation ........................................................................ 19
Pre-Installation Procedures ........................................................... 19
Installation...................................................................................... 19
Main Bus Installation ........................................................................... 20
Bus Bar Installation ............................................................................. 22
Circuit Breaker Installation .................................................................. 23
Installing the Circuit Breaker into the TEST/DISCONNECT Position. 24
Testing the Circuit Breaker in the TEST/DISCONNECT Position.. 25
Racking the Circuit Breaker into the CONNECTED Position......... 26
Circuit Breaker Removal ..................................................................... 27
Racking the Circuit Breaker Out of the CONNECTED Position..... 27
Removing the Circuit Breaker from the Circuit Breaker Compartment
28
Locking Provisions .............................................................................. 29
Voltage Transformer Drawout Unit Inspection ..................................... 29
Racking the Voltage Transformer Drawout Unit Out of the
CONNECTED Position .................................................................. 29
Inspecting the Fuses...................................................................... 30
Racking the VT Drawout Unit into the CONNECTED Position ...... 30
Voltage Transformer Drawer ............................................................... 30
Voltage Transformer Drawer Interlocks ......................................... 31
Voltage Transformer Drawer Characteristics................................. 32
Voltage Transformer Drawer Wiring .............................................. 32
High-Potential Testing ......................................................................... 32
Test Preparation ............................................................................ 32
Phase-to-Phase Test ..................................................................... 32
Phase-to-Ground Test ................................................................... 33
Phasing ............................................................................................... 33
Cable Connections .............................................................................. 33

© 2009–2012 Schneider Electric All Rights Reserved 3


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Table of Contents 06/2012

Insulating the Cable Connections .................................................. 33


Operation ...................................................................................................35
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Start-Up ...............................................................................................35
Preliminary Start-Up Procedures ................................................... 35
Installing and Testing Circuit Breakers in the TEST/DISCONNECT
Position .......................................................................................... 35
Operation .............................................................................................36
Energizing the Switchgear ...................................................................36
Removing Circuit Breakers ..................................................................36
Inspection and Maintenance .....................................................................37
Main Bus Compartment .......................................................................37
Replacing the Fuses ............................................................................38
Re-Energizing ......................................................................................38
Accessories ...............................................................................................39
Using the Lift Truck ..............................................................................39
Test Cabinet (Optional) ........................................................................40
Ground and Test Devices ....................................................................40
Arc Exhausting Systems ...........................................................................41
Plenum Assembly ................................................................................41
Installing the Plenum Assembly ..................................................... 42
Arc Shield Assembly ............................................................................45
Installing the Arc Shield Assembly ................................................. 46
Configuration Drawings .............................................................................48
Installation and Maintenance Log ..............................................................49

4 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 List of Figures

List of Figures Figure 1: Masterclad Indoor Arc Resistant Switchgear


with Type VR Drawout Circuit Breaker .................................. 7

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Figure 2: Typical Front Section ............................................................. 8
Figure 3: Circuit Breaker Compartment ................................................ 9
Figure 4: Mechanism Operated Contacts ........................................... 10
Figure 5: Truck Operated Contacts .................................................... 11
Figure 6: Drawout Voltage Transformer ............................................. 12
Figure 7: Bus Compartment ................................................................ 13
Figure 8: Lifting Sling .......................................................................... 16
Figure 9: Typical Floor Plan (Not for Construction) ............................ 18
Figure 10: Section Bolting Details ......................................................... 19
Figure 11: Typical Main Bus Assembly (1200 A shown) ...................... 20
Figure 12: Main Bus Connections, Side View ....................................... 21
Figure 13: Main Bus Connections, Top View ........................................ 21
Figure 14: Bus Compartment with Bus Cover Removed ...................... 22
Figure 15: Glass Polyester Pass-through ............................................. 22
Figure 16: Door Handle Positions ......................................................... 23
Figure 17: Inserting Circuit Breaker with a Lift Truck ............................ 24
Figure 18: Masterclad Switchgear Circuit Breaker Compartment ......... 24
Figure 19: Test and Connected Position Arrows .................................. 25
Figure 20: Circuit Breaker Secondary Disconnect (Male) ..................... 25
Figure 21: Secondary Disconnect Handle and Connector .................... 26
Figure 22: Racking Handle Engaged onto Racking Shaft with Circuit
Breaker in the TEST/DISCONNECT Position ..................... 27
Figure 23: Removing the Circuit Breaker from the Compartment ......... 28
Figure 24: Devices That Can Be Padlocked ......................................... 29
Figure 25: Racking Handle Engaged onto Racking Shaft .................... 29
Figure 26: VT Drawer Compartment ..................................................... 30
Figure 27: VT Drawer Door Latched ..................................................... 31
Figure 28: VT Racking Handle Inserted ................................................ 31
Figure 29: Voltage Transformer Drawer in Withdrawn Position ............ 32
Figure 30: Voltage Transformer Wiring ................................................. 32
Figure 31: Power Cable Connection Insulation .................................... 34
Figure 32: Typical Lift Truck ................................................................. 39
Figure 33: Wall-Mounted Test Cabinet (Optional) ................................ 40
Figure 34: Typical Indoor Plenum Application ...................................... 41
Figure 35: Plenum Assemblies ............................................................. 42
Figure 36: Prepared Roof Detail—Plenum
(Lefthand and Righthand End Bays) ................................... 42
Figure 37: Plenum Installation Detail .................................................... 44
Figure 38: Typical Arc Shield Application ............................................. 45
Figure 39: Arc Shield Assemblies ......................................................... 45
Figure 40: Prepared Roof Detail—Arc Shield
(Lefthand and Righthand End Bays) ................................... 46
Figure 41: Arc Shield Installation Detail ................................................ 47
Figure 42: Masterclad Arc Resistant Metal-Clad Indoor Switchgear
Configurations ..................................................................... 48

© 2009–2012 Schneider Electric All Rights Reserved 5


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
List of Tables 06/2012

List of Tables Table 1: Approximate Switchgear and Component Weights ............. 17


Table 2: Bolt Torque .......................................................................... 23
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Table 3: One Minute Hi-Potential Test............................................... 33


Table 4: Minimum Required Ceiling Height from Floor ...................... 41

6 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Introduction

Introduction This instruction bulletin contains instructions for receiving, handling, storing,
installing, operating, and maintaining Masterclad™ 5–15 kV arc resistant

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metal-clad indoor switchgear. This equipment is manufactured by
Schneider Electric under the brand name Square D™. This equipment is
designed for use with Type VR drawout circuit breakers. The arc resistant
design is one-high and two-high, with circuit breakers on the top and bottom
and an auxiliary compartment with controls on the top.
NOTE: For information on Type VR circuit breakers, refer to instruction
bulletins 6055-31 and 6055-33.
The switchgear assembly (Figure 1) consists of individually-grounded steel
compartments. Each compartment has doors, barriers, and removable
access panels to isolate the separate working functions. Exhaust vents are
located at the top of each compartment, except for the auxiliary
compartment. All of the circuit breakers, instrument and control power
transformers, relays, meters, and other components are factory assembled,
wired, and tested as an assembly.
The installer normally makes only the external control, ground, and power
connections at the terminals provided, and reconnects the wiring and bus
bars at the shipping breaks.
Each assembly is custom designed, with standard structures and bus
configurations arranged according to customer specifications. The
structures are then combined with the circuit breaker and other components
necessary for the required protective scheme, metering, and number
of feeders.
Complete customer drawings are furnished for each Masterclad switchgear
assembly. The drawings include floor plans and elevations, one-line
diagrams, bills of material, control schematics, and wiring diagrams.

Figure 1: Masterclad Indoor Arc Resistant Switchgear


with Type VR Drawout Circuit Breaker

© 2009–2012 Schneider Electric All Rights Reserved 7


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Introduction 06/2012

Product Overview Masterclad arc resistant metal-clad indoor switchgear is UL/cUL certified.
A Masterclad arc resistant switchgear line-up assembly consists of
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individual switchgear bays bolted together. The number of bays in an


assembly depends on customer specifications.
Each switchgear bay is a separate, rigid, self-contained structure made of
10-gauge steel. A switchgear bay typically consists of:
• Front section
— Circuit breaker compartments (upper and lower)
— Auxiliary compartment with controls and door-mounted
components (upper)
— Section with secondary control devices
• Main bus compartment
• Cable compartment

Front Section with Secondary Control Devices The front section upper compartment includes front, hinged doors with
instruments, relays, control switches, terminal blocks, fuse blocks, and other
required secondary control devices. The wiring space for inter-unit
connection and the customer control wiring connection is also included in
the front section.

Figure 2: Typical Front Section

8 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Introduction

Circuit Breaker Compartment The circuit breaker compartment contains separate, but coordinated,
features (Figure 3).

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Figure 3: Circuit Breaker Compartment

Shutter actuator

Racking arm
Primary bushing assemblies
Circuit breaker positioning rails (shutters open)
Primary high
voltage contacts
Position latch brackets

Ground bar

Racking block lever

Racking position indicator

Secondary disconnect handle


Ground & Secondary disconnect receptacle
test/removable
shorting device
interlock Racking mechanism

Racking block bar


(welded to racking shaft)
Compartment
rating interlock
Racking shaft

Racking mechanism lockout


provision (key interlock and padlock)

Circuit Breaker Positioning Rails Positioning rails (Figure 3), mounted on the side walls of the circuit breaker
compartment, capture and align the rollers on the circuit breaker to guide
the breaker into the circuit breaker compartment.

Racking Mechanism The racking mechanism (Figure 3) is located on the circuit breaker
compartment floor. It is operated by a removable racking handle inserted
into the front of the circuit breaker compartment so that it can be racked,
only with the door closed. The circuit breaker is engaged by a gear-driven
racking arm (Figure 3). As the arm rotates, it moves the circuit breaker into
or out of the TEST/DISCONNECT or the CONNECTED position.

Secondary Disconnect Receptacle The secondary disconnect receptacle (Figure 3) is located on the lower right
floor of the compartment. The molded insulating receptacle contains 24
contacts and two tapered guide pins. Control power can be connected in the
test position by rotating the secondary disconnect handle and pulling it
forward (Figure 3). The breaker compartment door must be opened to

© 2009–2012 Schneider Electric All Rights Reserved 9


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Introduction 06/2012

access the secondary disconnect handle. The door can be closed after the
receptacle is connected to the breaker.
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Racking Position Indicator The racking position indicator, located beside the racking port
(Figure 3 on page 9), indicates if the circuit breaker is in either the
TEST/DISCONNECT, TRANSPORT, or CONNECTED position, and
whether the shutters are closed or opened. When the door is open, two
arrows that line up with the front cover are visible on the left rail and indicate
the position of the circuit breaker.

Primary Contacts The primary contacts are housed in primary bushing assemblies
(Figure 3 on page 9) that are covered at the open end by the shutter when
the circuit breaker is in the TEST/DISCONNECT position.

Current Transformer Front-accessible, window-type, 600 V rated single- or multi-ratio current


transformers are located around either the line or load primary voltage-
insulated bushings. A maximum of two current transformers, depending on
accuracy, can be mounted per phase—two on the line, and two on the load.

Ground Contact Bar A ground bar (Figure 3 on page 9), located on the circuit breaker
compartment floor, is directly connected to the main ground bus. Sliding
contact fingers, located on the underside of the circuit breaker, engage
before the circuit breaker reaches the TEST position and remain
continuously grounded.

Mechanism Operated Contacts (Optional) Mechanism operated contacts are compartment-mounted auxiliary contacts
that are operated by the circuit breaker mechanism (Figure 4). Like circuit
breaker mounted auxiliary contacts, they indicate whether the circuit
breaker is in the OPEN or CLOSED position. They operate in the
CONNECTED and TEST/DISCONNECTED positions (unless specified for
CONNECTED only). Refer to the customer order drawings shipped with
the equipment.
NOTE: The NORMALLY-OPEN “A” contacts and the NORMALLY-CLOSED
“B” contacts furnished are not convertible.
The mechanism operated contacts unit is mounted inside the front section
of the circuit breaker compartment. It is operated by a mechanism that is
driven vertically by a roller on the left side of the circuit breaker. The switch
is located inside the breaker compartment.

Figure 4: Mechanism Operated Contacts

Contact
actuator

Truck Operated Contacts (Optional) The truck operated contacts (Figure 5 on page 11) indicate whether the
circuit breaker is in the CONNECTED or TEST/DISCONNECT position in
the circuit breaker compartment.

10 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Introduction

The truck operated contacts unit does not distinguish between the circuit
breaker being in the TEST/DISCONNECT position or withdrawn completely

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from the compartment.
The truck operated contacts unit is mounted on the right side of the
horizontal steel barrier in the top of the circuit breaker compartment. The
switch is located inside the breaker compartment. It is operated by a
spring-loaded lever. This lever is activated, just before the circuit breaker
reaches the connected position, by a pin on the upper right side circuit
breaker frame.

Figure 5: Truck Operated Contacts

Contact
actuator

Interlocks
CAUTION
HAZARD OF EQUIPMENT DAMAGE
• Do not test interlocks by hand. Test interlocks by moving the circuit
breaker over the compartment-mounted operating cams.
• Operate interlocks in the correct sequence.

Failure to follow these instructions can result in injury or


equipment damage.

The circuit breaker compartment contains the following interlocks:


• A racking block bar (Figure 3 on page 9) welded to the racking shaft will
hit an interlock pin on the circuit breaker when it is closed. This interlock
mechanism will stop a closed circuit breaker from being racked into or
out of the circuit breaker compartment.
• The racking arm actuates an interlock located underneath the circuit
breaker. This interlock mechanism is designed to stop a circuit breaker
from being closed when it is between the TEST/DISCONNECTED and
CONNECTED positions.
• A racking block lever (Figure 3 on page 9) will not allow racking
mechanism operation when the circuit breaker is not in the circuit
breaker compartment. The shutter cannot be opened unless the circuit
breaker is in the circuit breaker compartment.
• A racking mechanism lockout provision (Figure 3 on page 9) is furnished
in each compartment for locking circuit breakers or voltage transformer
(VT) drawout units out of the CONNECTED position. The racking
mechanism lockout provision is located in the center of the compartment
floor and has standard padlock provisions. It can be equipped with a key
interlock when specified by the customer. The racking mechanism
lockout prevents the racking of circuit breakers or VT drawout units

© 2009–2012 Schneider Electric All Rights Reserved 11


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Introduction 06/2012

when they are in the DISCONNECTED position. Circuit breakers or VT


drawout units can be stored in the DISCONNECTED position with the
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racking mechanism locked.


• The racking mechanism is not functional if the breaker compartment
door is opened. The circuit breaker compartment door can not be
opened if the breaker or VT drawout units are not in the
DISCONNECTED position.The compartment rating interlocks
(Figure 3 on page 9) stop accidental insertion of circuit breakers with
incorrect current, voltage, or interrupting ratings into the compartment.
The stationary interference brackets are mounted on the floor of the
compartment and the mating part of the interlock system is mounted on
the underside of each circuit breaker.
• Each circuit breaker compartment may have permissive interlocks
(Figure 3 on page 9) that will prevent the insertion of a G&T or an RS
device not intended for use in that circuit breaker compartment. The
permissive interlocks are located beside the compartment rating
interlock on the circuit breaker compartment floor. Refer to the specific
Schneider Electric G&T and RS device instruction bulletin(s).

Voltage Transformer and Control Power The voltage transformer (VT) and control power transformers (CPT) fuse
Transformers Fuse Drawout Units drawout units are self-contained drawers. As the drawout units are racked
into the compartments, the drawers roll on two positioning rails mounted
on the sides of the compartment. The rails capture and align rollers on
drawout units.

Figure 6: Drawout Voltage Transformer


• Floating, drawer-mounted, self-aligning contacts engage the stationary
primary contacts as the drawer is racked into the connected position.
• A sliding contact finger, located on the bottom right side of the drawout
Primary fuses unit, engages the ground bar when the drawout unit is in the
DISCONNECTED position and remains continuously grounded.
• A static discharge ground contact, mounted in the top of the
compartment, grounds the primary contacts in the withdrawn position.
• Control power transformers are stationary mounted or truck mounted, as
needed. Depending on the size of the transformer, they can be mounted
remotely or within the switchgear.
• Drawout voltage transformers (Figure 6) supply voltage indication for
metering and relaying purposes. Primary current limiting fuses are
mounted on each voltage transformer.
• When drawout voltage transformers are in the CONNECTED position
the secondary contacts, mounted on the bottom middle of the drawer,
engage fixed compartment floor-mounted secondary contacts.
• Secondary fuses for the voltage transformers are located in the front
control compartment. Refer to the customer order drawings shipped with
the equipment.

12 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Introduction

Main Bus Compartment The main bus compartment is located in the center of the switchgear unit. It
is isolated from other compartments by metal plates and is accessible by

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removing the metal access plate (Figure 7) located between the main bus
compartment and the load compartment.

Figure 7: Bus Compartment

Main bus Pressure relief flaps


Pressure relief flaps compartment

Entry to
main bus
compartment

Main bus
access plates

Circuit breaker compartments Cable compartment

Each busbar has epoxy insulation rated for 221° F (105° C) operation—heat
shrink coating is optional. Glass polyester pass-throughs are used to
separate the bus compartments between adjacent circuit breaker
compartments.
NOTE: The busbar insulation must not be damaged or modified. Boots must
be in place before operating the equipment.
Bus boots insulate the connection in the main bus compartment,
overlapping the epoxy insulation on the busbars. The busbar insulation and
boots form an integral insulating system for the equipment to meet its
dielectric ratings.

© 2009–2012 Schneider Electric All Rights Reserved 13


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Introduction 06/2012

Cable Compartment The cable compartment is accessible by opening the rear door on the back
of the equipment. The load connectors are punched for terminating two
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cables per phase with a NEMA two-hole pattern standard.


Schneider Electric will provide lugs, upon request. For 15 kV, interphase
barriers will be installed if insulating boots are not required by customer on
cable connections. Tape and associated material for insulating cable
terminations are not supplied.
A ground bus in the cable compartment has lugs on each end for the
assembly ground. This ground bus is connected to each circuit breaker
compartment ground contact bar and to the individual ground bars in each
cable compartment. All instrument transformer, metering, and relaying
grounds are also connected to this common ground system.
The dimensions of a typical ground bus cross section are:
• 0.25 x 2.0 in. (6 x 51 mm) for switchgear up to 50 kA
• 0.5 x 2.0 in. (13 x 51 mm) for 63 kA switchgear
Conduit must enter the cable compartments, in the areas shown on the
customer drawings (Figure 9 on page 18), from either the top or bottom of
the cable compartment.
Conduit should be stubbed in the concrete pad as part of the site
preparation before the assembly is installed, but top entrance conduit must
be installed after the assembly is in place. The top and bottom covers can
be removed, punched to fit the conduit, and put back in place. When
required, zero-sequence current transformers are conveniently located in
the cable compartment.
Various cable termination systems are used. These are detailed on the
customer’s plans and specifications. Solderless or compression lugs can be
supplied on the load connectors. Potheads can be supplied as an option.
Tape and insulating material necessary for completing the field connection
at the lug pad are not supplied with the assembly.

Surge Arresters Surge arresters are furnished only when listed in the user’s specifications.
When specified, surge arresters are mounted in the incoming and outgoing
cable compartments.

14 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Safety Precautions

Safety Precautions This chapter contains important safety precautions that must be followed
before attempting to install, service, or maintain electrical equipment.

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Carefully read and follow the safety precautions outlined below.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• Only qualified personnel familiar with medium voltage equipment are to
perform work described in this set of instructions. Workers must understand
the hazards involved in working with or near medium voltage circuits.
• Perform such work only after reading and understanding all of the
instructions contained in this bulletin.
• Turn off all power supplying this equipment before working on it.
• Always use a properly rated voltage sensing device to confirm that
power is off.
• Before performing maintenance on this device, disconnect all sources
of electric power. Assume all circuits are live until they are completely
de-energized, tested, grounded, and tagged. Pay particular attention to
the design of the power system. Consider all sources of power. Check
interconnection diagrams and make sure there are no backfeed
potential sources.
• Never disconnect the main trip source of energized equipment.
• Place the circuit breaker in the TEST/DISCONNECTED position before
attempting to open the circuit breaker door.
• Handle this equipment carefully and install, operate, and maintain it
correctly in order for it to function properly. Neglecting fundamental
installation and maintenance requirements may lead to personal injury,
as well as damage to electrical equipment or other property.
• Do not make any modifications to the equipment or operate the system
with interlocks and safety barriers removed. Contact your local
Schneider Electric representative for additional instructions if the
equipment does not function as described in this manual.
• Use out-of-service tags and padlocks when working on equipment.
Leave tags in place until the work is completed and the equipment is
ready to be put back into service.
• The complete assembly arrangement determines if the top or bottom
contacts are the line side; both can be energized when the circuit
breaker is removed from the compartment.
• Disconnect all sources of power to the switchgear before accessing the
horizontal bus compartment.
• All breaker and auxiliary doors must be latched and all cable
compartment doors must be bolted to maintain arc resistance.
• Carefully inspect your work area and remove any tools and objects left
inside the equipment before energizing the switchgear.
• Replace all devices, doors, and covers before connecting the power to
this equipment.
• All instructions in this manual are written with the assumption that the
customer has taken these measures before performing maintenance
or testing.

Failure to follow these instructions will result in death or


serious injury.

© 2009–2012 Schneider Electric All Rights Reserved 15


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Receiving, Handling, and Storage 06/2012

Receiving, Handling, and Storage This section contains instructions for receiving, handling, and storing the
Masterclad arc resistant metal-clad switchgear. This section also covers site
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selection and preparation, foundation specifications, and locating conduit.

Receiving Masterclad arc resistant metal-clad switchgear is shipped in protective


crates or wrapping. Circuit breakers are shipped on pallets.
Upon receipt, compare the packing list to the equipment received to ensure
that the order and shipment are complete. Claims for shortages or errors
must be made in writing to Schneider Electric within 60 days of delivery.
Failure to give such notice will constitute unqualified acceptance and a
waiver of all such claims by the purchaser.
Immediately inspect the equipment for any damage that may have occurred
in transit. If damage is found or suspected, file a claim with the carrier
immediately and notify Schneider Electric. Delivery of equipment to a carrier
at any of the Schneider Electric plants or other shipping point constitutes
delivery to the purchaser regardless of freight payment and title. All risk of
loss or damage passes to the purchaser at that time.

Handling The switchgear is shipped in sections of one or two bays. Each shipping
section has four lifting eyes bolted onto the top.
NOTE: If using the plenum option, do not install until the switchgear is
moved to installation location. Refer to “Plenum Assembly” on page 41 for
additional information.

Put a crane hook through each of the four lifting eyes (Figure 8) to lift and
CAUTION move the sections. Use load-rated cables or chains with safety hooks or
shackles. A spreader bar may be necessary to maintain proper angles
HAZARD OF EQUIPMENT DAMAGE for lifting.
OR INJURY
Figure 8: Lifting Sling
If moving by crane, the interior angle of the
lifting sling should not exceed 90°. Angles
greater than 90° apply greater inward pressure
of lifting lugs which can damage or dislodge
lifting lugs from switchgear.
Interior angle
Failure to follow these instructions can
result in injury or equipment damage. Safety hooks
90°
Lifting eyes
45° 45°
Equipment top

To prevent structural damage, rig the lifting sling so that the minimum angle
between lifting cables or chains and the top of the equipment is 45°, and the
maximum interior angle is 90°. If a crane is not available, contact Schneider
Electric before using any other lifting method. After the equipment has been
placed in position, remove and discard the lifting eyes. Screw the bolts back
into place to cover the mounting holes.

16 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Receiving, Handling, and Storage

Storage
DANGER

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HAZARD OF ELECTRICAL SHOCK, EXPLOSION, OR ARC FLASH
When energizing space heaters from a remote source, remove the
primary current limiting fuses of the control power transformer.

Failure to follow this instruction can result in death or serious injury.

Keep equipment in a clean, dry, well-ventilated area. Circuit breakers


should be protected from dust, foreign objects, and rodents. If space
heaters are furnished in the assembly, energize them from an external
source. Refer to schematic and wiring diagrams for a logical connection
point, and for voltage and power requirements.
NOTE: If the space heaters are normally energized from a control power
transformer, open the control power transformer secondary circuit breaker,
remove the primary current limiting fuses, and install an out-of-service tag
before energizing the space heaters. This prevents backfeed to the main
bus through the control power transformer.
If space heaters are not installed in the assembly, and the area is cold and
damp, use a temporary heating source within the assembly. A minimum of
200 watts of heat per compartment is recommended. Avoid greasy, smoky
heaters that can deposit carbon on insulation, causing tracking and eventual
insulation breakdowns.

Site Selection and Preparation


DANGER
HAZARD OF EXPLOSION OR ARC FLASH
• Do not install the equipment beneath catwalks or other elevated
personnel access routes.
• Maintain a minimum overhead clearance of 10 ft. (3 m).
• Install the equipment in an area that allows for forced ventilation to
outside air.

Failure to follow these instructions will result in death or


serious injury.

Proper site selection is essential for reliable operation of the assembly.


Table 1: Approximate Switchgear and
Carefully compare the plans and specifications with the customer
Component Weights
drawings provided.
Switchgear and Components Weight • Provide adequate ventilation at all times so the ambient temperature
Switchgear unit (one-high applications) 3500 lb (1591 kg) around the assembly does not exceed 104° F (40° C). If the ambient
Switchgear unit (two-high applications) 4300 lb (1951 kg)
temperature exceeds 104° F (40° C), you will need to de-rate the
equipment. Clean, dry, filtered air should be supplied.
Circuit breaker 1200 A, 40 kA 380 lb (170 kg)
• Provide adequate lighting in both the front and back aisle spaces. Also,
Circuit breaker 1200 A, 50 kA 430 lb (195 kg)
provide convenient outlets in both areas for electrical hand tool use.
Circuit breaker 2000 A, 40 kA 450 lb (205 kg)
• Provide adequate floor drainage.
Circuit breaker 2000 A, 50 kA 500 lb (225 kg)
• Provide adequate safeguards against water damage. Route sewer,
Circuit breaker 3000 A, 50 kA 700 lb (320 kg)
water, and steam lines so they do not pass over or near the assembly—
Circuit breaker 1200, 2000, 3000 A, 63 kA 800 lb (363 kg) dripping liquids may damage the insulation.
VT drawout fuse unit (2) 15 kV 210 lb (95 kg)
Make sure the site can support the weight of the complete switchgear unit.
3 intermediate arresters 15 kV 120 lb (55 kg)
Refer to Table 1 to determine switchgear and component weights for
handling and other structural considerations.

© 2009–2012 Schneider Electric All Rights Reserved 17


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Receiving, Handling, and Storage 06/2012

Foundation The switchgear is designed to be mounted on the supplied base, leveled to


the specifications in the supplied base plan drawing, and grouted in the
ENGLISH

concrete pad.
NOTE: Typically, a minimum of 3 ft. (1 m) is necessary on the left, right, and
rear of the line-up and 6 ft. (1.8 m) on the front side for door clearance when
removing the circuit breaker.
Figure 9 illustrates the typical floor plan. Refer to the customer order
drawings before using the typical foundation specifications.
NOTE: For users in Mexico, an optional floor plan is available for 1200 A.
Review the complete customer drawing for each Masterclad assembly.

Figure 9: Typical Floor Plan (Not for Construction)

72.0 94.0 36.0


(1829) (2388) (914)
Front Aisle Rear Aisle
1.0 47.6 44.4 1.0
(25) (1209) (1128) (25)
5.8 6.5 4.5 5.1 3.0 6.9 1.0
1.0 1.5 (114)
(146) (165) (38) (130) (76) (175) (25)
(25)

10.0
(254)
2.0
(51)
34.0 Control conduit 25.8 16.0 34.0
Front (864) area (bottom) 27.0 Rear
(654) (406) (864)
(686)
2.0
(51) 10.0
(254)

1.0 0.5 5.1 1.0


1.5 4.5
(25) (12) (25)
(38) (114) (130) 9.0 6.1 Top or bottom
door
(229) (155) conduit area
5.8 6.5 Six 0.50 in. (12.7 mm)
(146) (165) Bottom conduit area
diameter mounting holes

Conduit Location Conduits should be stubbed a maximum of 1 in. (25 mm) above floor steel.
Conduit placement should be very accurate to ensure that there is no
mechanical interference with the switchgear floor steel. Avoid continuous
loops of reinforcing rod or structural steel around any single-conductor of a
three-phase power circuit.

18 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

Installation This section contains instructions for installing the Masterclad arc resistant
metal-clad indoor switchgear assembly.

ENGLISH
Switchgear Installation This section contains instructions for installing the switchgear.

Pre-Installation Procedures 1. The switchgear may be shipped in one or more shipping sections.
Review the assembly drawings to verify that switchgear sections will be
assembled in the correct order.
2. Verify that the conduit placement on the foundation is accurate
according to customer drawings. Error in conduit placement may prohibit
the proper installation of switchgear as described in this section
(see the note below).
3. Sweep the pad and remove debris before installing any sections.

Installation NOTE: When more than two shipping sections are involved, any error in
conduit location can cause a cumulative error significant enough to prohibit
the proper installation by the assembly sequence described in this section.
To lessen cumulative error, unload and install the center shipping section
first and work toward either end.
1. Move the sections into place. Install the end shipping section that allows
the most maneuverability first.
2. Before proceeding, verify:
— The conduits are in the center of the cutouts.
— The back of the unit is perpendicular to the pad and has
proper clearance.
— The mounting holes line up with the mounting channels.
3. Move an adjacent switchgear shipping section into place.
4. Verify that the switchgear sections are level, aligned, and fit snugly
together. If the sections do not fit properly, lift the most recently placed
section by crane, remove any obstructions, and re-install.
5. Bolt switchgear shipping sections together. See Figure 10 for bolt sizes
and locations.
Figure 10: Section Bolting Details

3/8-16 x 6-in.
screws
(20 supplied) 3/8-16 x 1.5-in.
screws
(6 supplied)

© 2009–2012 Schneider Electric All Rights Reserved 19


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

NOTE: All shipping sections must be bolted together in place before bolting
them to the channel sills or installing the horizontal main bus.
ENGLISH

6. Repeat steps 4–5 for additional switchgear shipping sections.


7. Verify that all switchgear shipping sections are in the correct position
according to the job drawing after all sections are bolted together.
8. Bolt the switchgear to the pad (front, center, and rear) using 1/2-13 SAE
Grade 5 bolts with Belleville washers (Figure 9 on page 18). Use nuts
with spring washer or tap in the pad to 1/2-13. Use six bolts per cell.

Main Bus Installation A typical main bus assembly is shown in Figure 11 below. Figure 12 shows
the side view of the assembly and the general arrangement of the main bus
and riser. Figure 13 shows the bus connections and orientation of the filler
and splice plates. See Figure 7 on page 13 for main bus access details.

Figure 11: Typical Main Bus Assembly (1200 A shown)

End Right Standard End Left

Front Rear B

Side View—1200 A Rear View—Bus Covers Removed

20 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

Figure 12: Main Bus Connections, Side View


1/4 x 6 1/4 x 6 (2) 1/4 x 6 (3) 3/8 x 6 1/4 x 6 1/4 x 6

ENGLISH
Filler Filler Filler Filler Filler Filler
1/4 x 6 1/4 x 6 1/4 x 6 (2) 1/4 x 6 1/4 x 6 (2) 1/4 x 6 1/4 x 6 (2) 3/8 x 6 1/4 x 6 (2) 3/8 x 6 1/4 x 6 (2) 3/8 x 6
Bus splice Main bus Bus splice Main bus Bus splice Main bus Bus splice Main bus Bus splice Main bus Bus splice Main bus

(2) 1/4 x 6 (3) 3/8 x 6 (2) 1/4 x 6 (2) 1/4 x 6


1/4 x 6 Riser Riser Riser Riser
Riser (2)
1/4 x 6 1/8 x 6 3/8 x 6
(2) 1/4 x 6
Riser Bus splice Filler
Filler
1200 A Riser 1200 A Riser 2000 A Riser 3000 A Riser 2000 A Riser 1200 A Riser
1200 A Main 2000 A Main 2000 A Main Bus 3000 A Main 3000 A Main Bus 3000 A Main Bus
(2) 3/8 x 6 1/4 x 6 Bus splice (2) 3/8 x 6
1200 A Riser Main bus 1200 A Riser Main bus
1/4 x 6
1/4 x 6 Riser 1/8 x 6
Bus splice
(2) 3/8 x 6 Riser Filler
1/4 x 6
Riser 3/8 x 6
(2) 3/8 x 6 Filler
1200 A Riser 1200 A Riser
Filler
3000 A Main Bus 3000 A Main Bus

Figure 13: Main Bus Connections, Top View

1/2-13 Hardware 1/2-13 Hardware 1/2-13 Hardware


with typical Belleville washers with typical Belleville washers with typical Belleville washers
Riser bus Main bus Riser bus Main bus Riser bus Main bus
and filler and filler and filler

Bus splice Bus splice Bus splice

Typical Standard Bay Typical Standard Bay Typical Standard Bay


3000 A Main Bus 2000 A Main Bus 1200 A Main Bus
3000 A Riser 2000 A Riser 1200 A Riser

© 2009–2012 Schneider Electric All Rights Reserved 21


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

Bus Bar Installation Follow the instructions in this section to install bus bars.
ENGLISH

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• Turn off all power supplying this equipment before working on it.
• Before performing maintenance on this device, disconnect all sources
of electric power. Assume all circuits are live until they are completely
de-energized, tested, grounded, and tagged. Pay particular attention to
the design of the power system. Consider all sources of power. Check
interconnection diagrams and make sure there are no backfeed
potential sources.
• Always use a properly rated voltage sensing device to confirm that
power is off.

Failure to follow this instruction will result in death or serious injury.

1. Remove the main bus covers. Figure 14 shows a bus compartment with
the cover removed.
Figure 14: Bus Compartment with Bus Cover Removed

Riser bus bars

2. Install one phase at a time by sliding the horizontal bus bars through the
glass polyester pass-throughs. There is one pass-through per section
installed on the right wall (see Figure 15).
Figure 15: Glass Polyester Pass-through

Glass polyester
pass-through

22 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

3. Loosely bolt the horizontal bus to the vertical bus.


Table 2: Bolt Torque
NOTE: Do not bend or force the bus bars to make this connection. The

ENGLISH
Bolt Mechanical Bus Bar through bushings and the divided insulating barrier may be loosened if
Size Joints Connections necessary. They have sufficient clearance and adjustment to allow for minor
4–7 lb-ft (5.42–
field misalignment of shipping sections.
1/4–20 —
9.50 N•m)
4. Tighten the bolts connecting the bus joints only after all three horizontal
11–15 lb-ft (14.90– bus bars are in place and properly aligned. Using a torque wrench,
5/16–18 —
20.33 N•m)
tighten bolts for bus bar connections in accordance with Table 2.
18–24 lb-ft (24.40– 30–40 lb-ft (40.67–
3/8–16 5. Install supplied boots on busbar joints. Close the boot joint with supplied
32.54 N•m) 54.23 N•m)
32–44 lb-ft (43.38– 47–62 lb-ft (63.72–
tie-wrap. Reinstall main bus cover.
1/2–13
59.65 N•m) 84.00 N•m)

Circuit Breaker Installation This section describes the installation of the circuit breaker.

WARNING
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• Only qualified personnel familiar with medium voltage circuits and
equipment should operate this equipment.
• Check the customer order drawings and nameplates on the circuit
breaker compartment to verify that the circuit breaker is installed into the
proper circuit breaker compartment.

Failure to follow these instructions can result in death or


serious injury.

Figure 16: Door Handle Positions The door handle (Figure 16) is the key to opening and closing the circuit
breaker door. The door handle has three positions (described below):
OPEN, READY-TO-CLOSE, and LATCH.
• OPEN
— Position where the door handle can be used to open the door. Rotate
OPEN the handle towards the OPEN position then pull to open the door.
When the handle is released after opening the door, it will
READY-TO-CLOSE automatically go to the READY-TO-CLOSE position.
LATCH • READY-TO-CLOSE
— Position of the handle used to close the circuit breaker door. When
closed, the door will remain closed but the latching feature is not
active. In the READY-TO-CLOSE position, the arc resistant feature
of the breaker door is not active.
• LATCH
— Position of the handle in normal operation of the switchgear. The
door is closed and latched. In the LATCH position, the arc
resistant feature is active. The handle can be padlocked in the
LATCH position.

© 2009–2012 Schneider Electric All Rights Reserved 23


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

Installing the Circuit Breaker into the 1. Check the customer order drawings and the nameplates on the circuit
TEST/DISCONNECT Position breaker compartment to verify that the circuit breaker is installed into the
ENGLISH

proper circuit breaker compartment.


2. Verify that the racking position indicator (Figure 18 on page 24) reads
“TEST/DISCONNECT.”
3. To open the circuit breaker compartment door:
a. Remove the padlock (if installed) from the door handle.
b. Rotate the door handle to the OPEN position then pull to open
the door.
c. Release the door handle; it will automatically move to the
READY-TO-CLOSE position.
Figure 17: Inserting Circuit Breaker with a Use the supplied ramp or lift truck (as shown in Figure 17) to insert the
Lift Truck circuit breaker into the circuit breaker compartment. (A lift truck must be
used to insert the circuit breaker into switchgear on a raised pad.) For
instructions on using a lift truck, refer to “Using the Lift Truck” starting on
page 39.

WARNING
HAZARD OF PERSONAL INJURY
A lift truck supplied by the manufacturer must be used to install a circuit
breaker into switchgear on a raised pad.

Failure to follow this instruction can result in death or serious injury.

4. Align the rollers on each side of the circuit breaker with the positioning
rails (Figure 18) mounted on the side walls of the circuit
breaker compartment.
Figure 18: Masterclad Switchgear Circuit Breaker Compartment

Racking position
indicator

Positioning rail

Lift truck catch pins

24 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

WARNING

ENGLISH
HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE
Never force the circuit breaker into the circuit breaker compartment. If a
mechanism is not operating easily, inspect the equipment and remove any
foreign objects or debris.

Failure to follow this instruction can result in death or serious injury.

5. Push the circuit breaker into the compartment until the front of the circuit
breaker lines up with the test position arrows (Figure 19 on page 25)
located on top of the left positioning rail. When the circuit breaker is in
the TEST/DISCONNECT position, the release handle should engage.
NOTE: If the circuit breaker does not easily roll into the circuit breaker
compartment, remove the circuit breaker. If necessary, pull the release
handle to release the circuit breaker from the TEST/DISCONNECT
position. Repeat process. If satisfactory results are not achieved,
contact Schneider Electric.

Figure 19: Test and Connected Position Arrows

Connected
position arrow

Test position
arrow

Testing the Circuit Breaker in the The circuit breaker secondary disconnect (male, Figure 20) connects to the
TEST/DISCONNECT Position circuit breaker compartment secondary disconnect (female) located on the
floor of the circuit breaker compartment. This provides a convenient method
for electrically testing the operation of the circuit breaker mechanism.

Figure 20: Circuit Breaker Secondary Disconnect (Male)

Circuit breaker
secondary disconnect

1. Rotate the secondary disconnect handle (Figure 21 on page 26), located


on the floor of the circuit breaker compartment, upward 90°.
2. Pull the secondary disconnect handle out until the circuit breaker
compartment secondary disconnect (female, Figure 21 on page 26)
engages the circuit breaker secondary disconnect.

© 2009–2012 Schneider Electric All Rights Reserved 25


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

NOTE: The control circuit of the circuit breaker is now connected to control
power. If the control circuit is energized, this connection immediately
ENGLISH

activates the spring charging motor inside the circuit breaker.

Figure 21: Secondary Disconnect Handle and Connector

Circuit breaker
compartment
secondary
disconnect
(female)

Secondary
disconnect
handle

3. Push the CLOSE (I) pushbutton. If the spring charging motor was
correctly activated by the control circuit, the CLOSE (I) pushbutton
should release the closing latch, allowing the closing spring assembly to
discharge. The closing spring assembly pushes down on the crossbar,
that is connected to the vacuum interrupters, and closes the vacuum
interrupter contacts.
4. Push the OPEN (O) push button. If the opening spring assembly was
correctly charged (compressed) by the closing operation, the
mechanism will release the opening latch and allow the opening spring
assembly to discharge. The opening spring assembly pulls up on the
crossbar connected to the vacuum interrupters and opens the vacuum
interrupter contacts.

Racking the Circuit Breaker into the 1. Make sure the circuit breaker is OPEN (O).
CONNECTED Position NOTE: The circuit breaker must be in the OPEN (O) position when it is
racked into or out of its circuit breaker compartment. Interlocks will not
allow the racking shaft to rotate if the circuit breaker is not OPEN (O).

2. Close the circuit breaker compartment door.


WARNING a. Make sure the door handle is in the READY-TO-CLOSE position
HAZARD OF BODILY INJURY OR when closing the door. The door will stay closed, but the arc resistant
EQUIPMENT DAMAGE feature will not be active.
b. When the door is closed, rotate the door handle towards the LATCH
• Always keep circuit breaker compartment
position. This will latch the door in the closed position, making the
door closed when racking the circuit breaker
circuit breaker compartment ready for normal operation.
from one position to another when the
switchgear is energized. c. The door handle can be padlocked in the LATCH position.
• Beware of potential hazards, wear personal 3. Remove the padlock, if installed, from the racking port located at the
protective equipment, and take adequate bottom of the circuit breaker door (Figure 22 on page 27).
safety precautions. 4. Open the racking port, insert the provided racking handle into the port,
and engage the handle onto the racking shaft (Figure 22 on page 27).
Failure to follow these instructions can
result in death or serious injury. NOTE: If the circuit breaker does not easily rack into the circuit breaker
compartment, remove the circuit breaker and contact your local
Schneider Electric representative.

26 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

Figure 22: Racking Handle Engaged onto Racking Shaft with Circuit
WARNING Breaker in the TEST/DISCONNECT Position

ENGLISH
HAZARD OF BODILY INJURY OR
EQUIPMENT DAMAGE
Never force the circuit breaker into or out of the
circuit breaker compartment. If a mechanism is Padlockable
not operating easily, inspect the equipment and racking port

remove any foreign objects or debris.


Racking handle
Failure to follow this instruction can result
in death or serious injury.

5. Rotate the racking handle clockwise.


6. When the circuit breaker is being transported to or from the
CONNECTED position, the racking position indicator will read
TRANSPORT.
NOTE: When the racking position indicator reads “CONNECTED,” the
circuit breaker is fully racked into the circuit breaker compartment and
the circuit breaker’s primary contacts are connected.
7. Continue rotating the racking handle clockwise until the racking position
indicator reads “CONNECTED.”

Circuit Breaker Removal This section describes the removal of the circuit breaker.

Racking the Circuit Breaker Out of the 1. Make sure the circuit breaker is OPEN (O).
CONNECTED Position
WARNING
HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE
• Always keep circuit breaker compartment door closed when racking the
circuit breaker from one position to another when the switchgear
is energized.
• Beware of potential hazards, wear personal protective equipment and
take adequate safety precautions.

Failure to follow these instructions can result in death or


serious injury.

2. Insert the racking handle into the racking port and engage the racking
handle onto the racking shaft (Figure 22 on page 27).

WARNING
HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE
Never force the circuit breaker into or out of the circuit breaker
compartment. If a mechanism is not operating easily, inspect the
equipment and remove any foreign objects or debris.
Failure to follow this instruction can result in death or serious injury.

NOTE: If the circuit breaker does not easily rack out of the circuit breaker
compartment, reconnect the circuit breaker and repeat this process. If
satisfactory results are not achieved, contact Schneider Electric.

© 2009–2012 Schneider Electric All Rights Reserved 27


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

3. Rotate the racking handle counterclockwise. When the circuit breaker is


being transported to or from the CONNECTED position, the racking
ENGLISH

position indicator will read TRANSPORT.


NOTE: When the circuit breaker is moved from the CONNECTED
position to the TEST/DISCONNECT position, the auxiliary contacts
are disconnected.
4. Continue rotating the racking handle until the racking position indicator
reads TEST/DISCONNECT. Another half-turn is required—a stop is felt
when the racking handle reaches its final position—to unlock the door.

Removing the Circuit Breaker from the Circuit


Breaker Compartment
1. Open the circuit breaker compartment door.
Figure 23: Removing the Circuit Breaker
from the Compartment a. To open the circuit breaker door, remove the padlock (if installed)
from the door handle.
b. Rotate the door handle to the OPEN position then pull to open
the door.
c. Release the door handle and it will automatically move to the
READY-TO-CLOSE position.
2. Use the supplied ramp or lift truck as shown in Figure 23 on page 28 to
remove the circuit breaker from the circuit breaker compartment. (A lift
truck must be used to remove the circuit breaker from switchgear on a
raised pad.) For instructions on using a lift truck, see “Using the Lift
Truck” starting on page 39.
3. Pull the release handle to release the circuit breaker from the
TEST/DISCONNECT position. The circuit breaker will trip if it is closed.
4. Pull the circuit breaker out of the circuit breaker compartment.
NOTE: When the circuit breaker is removed, you will hear a loud noise
as the spring discharges.

28 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

Locking Provisions The following devices (Figure 24) can be locked with a padlock:
• The racking mechanism located in the circuit breaker compartment floor.

ENGLISH
• The circuit breaker door handle.
• The racking port.

Figure 24: Devices That Can Be Padlocked

Racking Mechanism Breaker Door Handle Racking Port

Voltage Transformer Drawout Inspect the voltage transformer (VT) drawout unit before energizing. Follow
Unit Inspection the steps below to perform the inspection.

Racking the Voltage Transformer Drawout Unit 1. With the VT compartment door closed, insert the racking handle into
Out of the CONNECTED Position the racking port and engage the handle onto the racking shaft
(see Figure 25 on page 29).

WARNING
HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE
Never force the primary fuse drawout unit into or out of the primary fuse
drawout unit compartment. If the racking mechanism is not operating
easily, inspect the equipment and remove any foreign objects or debris or
contact Schneider Electric.

Failure to follow this instruction can result in death or serious injury.

Figure 25: Racking Handle Engaged onto 2. Rotate the racking handle counterclockwise.
Racking Shaft NOTE: If the voltage transformer drawout unit does not easily rack out of
the CONNECTED position, contact Schneider Electric.
3. Verify that the grounding contact tabs, extending from the ground bar at
the top on the voltage transformer (VT) drawout compartment, touch the
fuse ground tabs on the VT drawout unit as it moves from the
CONNECTED position to the DISCONNECTED position. The tabs
can be seen through the viewing window in the VT compartment door.
4. Continue rotating the racking handle counterclockwise until the VT
Locking port drawout unit is fully racked to the DISCONNECTED position.

Racking handle

© 2009–2012 Schneider Electric All Rights Reserved 29


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

Inspecting the Fuses Open the VT drawout compartment door to visually inspect fuses for
possible damage. Replace the fuses if necessary. See “Replacing the
ENGLISH

Fuses” starting on page 38.

Racking the VT Drawout Unit into the After inspecting the VT drawout unit, follow the steps below to rack it to the
CONNECTED Position CONNECTED position.
1. Close the VT drawout unit compartment door.
2. Insert the racking handle into the racking port and engage the handle
onto the racking shaft.
3. Rotate the racking handle clockwise until VT drawout unit is fully racked
to the CONNECTED position.
NOTE: If the voltage transformer drawout unit does not easily rack into
the CONNECTED position, rack the unit to the DISCONNECT position,
and remove any objects or debris from the compartment. Repeat this
process. If results are not satisfactory, contact Schneider Electric.

Voltage Transformer Drawer Figure 26 shows the voltage transformer (VT) drawer connected to the
load bus.

Figure 26: VT Drawer Compartment

Main Bus
VT Compartment
Compartment

Circuit Breaker Compartment Cable Compartment

30 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

This is a racking-through-the-door type compartment with interlocks


(see Figure 27). The racking port can be padlocked.

ENGLISH
Figure 27: VT Drawer Door Latched

Door handle
(latched position)
Auxiliary viewing window

Indicator viewing window

Voltage Transformer Drawer Interlocks The racking mechanism is not accessible if the door is not closed and
latched (Figure 28).
NOTE: The latching system is intended to be arc resistant. The auxiliary
door must be latched to activate the arc resistant feature.
The door cannot be opened if:
• The drawer is out of the DISCONNECTED position.
• The racking handle is inserted in the racking port (Figure 28).
— The racking mechanism uses the same racking handle as the
racking mechanism for the circuit breaker compartment.
Figure 28: VT Racking Handle Inserted

Racking handle

© 2009–2012 Schneider Electric All Rights Reserved 31


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

Voltage Transformer Drawer Characteristics The primary contacts and fuses are viewable through a window in the
voltage transformer (VT) drawer door. When the VT drawer is in the
ENGLISH

DISCONNECTED position, the primary contacts are viewable but not


accessible. A fuse discharge bar (Figure 29) is located in the front portion of
the compartment and is intended to return to ground any remaining voltage
that could be accumulated in the voltage transformers.

Figure 29: Voltage Transformer Drawer in Withdrawn Position

Fuse discharge
bar

Voltage Transformer Drawer Wiring The secondary contacts of the VT are linked to the control box through
secondary contacts located underneath the tray of the VT drawer
(see Figure 30).

Figure 30: Voltage Transformer Wiring

VT secondary
connection

Microswitches
(not shown)

High-Potential Testing Before making external power connections, perform a high-potential (hi-pot)
dielectric withstand test on the bus and circuit breakers as an assembly.

Test Preparation 1. Disconnect lightning arresters.


2. Withdraw the voltage transformer drawer (if provided).
3. Place each of the circuit breakers in its proper circuit breaker
compartment in the connected position. Charge their springs manually,
and then close each circuit breaker by using the CLOSE (I) push button.

Phase-to-Phase Test 1. Perform a phase-to-phase hi-pot test on the main bus.


a. Gradually increase the voltage to the levels shown in Table 3.
b. Verify that the equipment sustains the specified voltage without
flashover for one minute.
2. Turn off the test equipment. Discharge the phase bus to ground before
removing the test cables.

32 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation

Phase-to-Ground Test 1. Perform a phase-to-ground hi-pot test on the main bus.


a. Gradually increase the voltage to the levels shown in Table 3.

ENGLISH
b. Verify that the equipment sustains the specified voltage without
flashover for one minute.
2. Turn off the test equipment. Discharge the phase bus to ground before
removing the test cables.
Use a reliable transformer-type tester with a built-in voltmeter and
milliamp meter for hi-pot testing. Capacitor loaded bench-type testers with
neon bulb indicators do not have sufficient capacity to give reliable results.
Refer to Table 3 for the nominal test values for dry, clean, new assemblies.
Field hi-pot tests are made at 75% of factory test voltages in accordance
with ANSI standards.

Table 3: One Minute Hi-Potential Test1

Assembly Rated Factory Test Field Test Voltage


Maximum Voltage Voltage (AC) AC DC
5 kV 19 kV 14 kV 20 kV
15 kV 36 kV 27 kV 38 kV
1 AC voltages are 60 Hz rms symmetrical.

If satisfactory results are not obtained, locate the problem, correct it, and
rerun the test before proceeding. If results are acceptable, the power
cables, ground wires, external wiring, and battery (if supplied) can be
connected to the assembly. If results are not acceptable, contact your local
Schneider Electric representative.

Phasing In accordance with NEMA standards, all bus within the switchgear is phased
A-B-C left to right, top to bottom, and front to back when viewing the
assembly from the front (the circuit breaker compartment side). If, for any
reason, the bus must be phased differently, the different phases will be
identified on the bus with a label.

Cable Connections Be very careful when making cable terminations, as terminations are critical
to the successful operation of the electrical distribution system. Avoid sharp
turns, edges, or corners to prevent damage to the cable insulation. Follow
the cable manufacturer’s recommendations for minimum bending radius.
These instructions will vary, depending on the manufacturer.
Solderless or compression-type cable lugs are the most common method
for connecting power cables to metal-clad switchgear. When making the
terminations for each type of power cable, follow the cable manufacturer’s
instructions. After the cable connections are made, insulate them as follows.

Insulating the Cable Connections Insulating putty and tape (provided by customer) or other insulating means
may be used to insulate the power cable connections.
1. Place insulating putty, such as 3M® brand Scotchfil, around the lugs and
bolts to reduce the concentrated field created by their irregular shapes
(Figure 31 on page 34). Apply a layer of Scotch® brand No. 13 (or
equivalent) semiconducting tape over the insulating putty. Half-lap the
tape, which must extend onto the conductor. Do not extend the tape up
over the bus epoxy insulation. Apply Scotch No. 130C (or equivalent)
tape over the No. 13 tape. Half-lap this tape for two layers on 5 kV
installations and four layers on 15 kV installations. For 5 kV installations,

© 2009–2012 Schneider Electric All Rights Reserved 33


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation 06/2012

extend the tape 1-1/2 in. (38 mm) up over the bus insulation and cable
insulation. For 15 kV installations, extend the tape 2 in. (51 mm).
ENGLISH

2. Apply two layers of Scotch Brand No. 22 tape (or equivalent), extending
the tape up over the No. 130C tape in all directions. The tape and other
insulating materials for completing these field connections are not
supplied with the switchgear.
3. If potheads or cable terminators are supplied for terminating power
cables, follow the pothead manufacturer’s instructions for terminating
the cables in these devices. To facilitate installation of the power cables,
the bus side is not taped. After the cables are installed, insulate the
pothead-to-bus connections according to the cable lug insulation
instructions in this section.
Figure 31: Power Cable Connection Insulation
Fill voids with
Bus
Scotchfil Putty
0.5 in. (13 mm) Scotch No.22 tape
Layer Scotch No. 13
semi-conductor tape Overlap Scotch No. 130C tape
over cable insulation by:
Scotch No. 130C tape: 1.5 in. (38 mm) for 5 kV
2 layers for 5 kV 2 in. (51 mm) for 15 kV
4 layers for 15 kV
Note: Scotch No. 13 semi-conductor tape
must touch bus or terminals in at least one
place; tape should not overlap bus or
Lugs cable insulation

Overlap Scotch No. 130C tape


over cable insulation by:
Scotch No.22 1.5 in. (38 mm) for 5 kV
2 layers
2 in. (51 mm) for 15 kV

0.5 in. (13 mm) Scotch No.22 tape

NOTE: All taping is half-lapped

34 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Operation

Operation The section contains instructions for operating the Masterclad arc resistant
metal-clad indoor switchgear unit.

ENGLISH
Start-Up
DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• All personnel involved in the start-up operation should be thoroughly
familiar with the information in this instruction bulletin and customer
drawings provided before working on this equipment.
• Turn off all power supplying this equipment before working on it.
• Before performing maintenance on this device, disconnect all sources
of electric power. Assume all circuits are live until they are completely
de-energized, tested, grounded, and tagged. Pay particular attention to
the design of the power system. Consider all sources of power. Check
interconnection diagrams and make sure there are no backfeed
potential sources.
• Always use a properly rated voltage sensing device to confirm that
power is off.

Failure to follow these instructions will result in death or


serious injury.

Training of personnel for final start-up is available. Contact your local


Schneider Electric representative for more information.

Preliminary Start-Up Procedures 1. Turn off all main and control power supplying the equipment.
2. Vacuum every compartment. Remove all loose parts, tools,
miscellaneous construction items, and litter.
3. Verify that all insulating boots are installed.
4. Replace all of the main bus covers and any other barriers or covers that
were removed during installation.
5. Install the cable compartment back covers.
6. Connect the battery charger and batteries (if used) to the switchgear
control bus according to the order drawings.
7. Unblock all of the relays and set to the relay schedule. Using a relay
tester, verify the settings and electrical operation of each relay.
8. Verify that any control power transformer used has the current limiting
fuses in place. Pull the drawer out to the withdrawn position.
9. Check that the pressure relief flaps (Figure 7 on page 13) are closed and
free of obstructions.

Installing and Testing Circuit Breakers in the Follow the steps for installing and testing the circuit breaker in the
TEST/DISCONNECT Position TEST/DISCONNECT position outlined in “Installing the Circuit Breaker into
the TEST/DISCONNECT Position” on page 24.

© 2009–2012 Schneider Electric All Rights Reserved 35


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Operation 06/2012

Operation Perform these steps before energizing the equipment. If necessary, use an
external control power source.
ENGLISH

1. Follow the steps outlined in “Racking the Circuit Breaker into the
CONNECTED Position” on page 26.
2. Electrically close and open the circuit breaker with the door-mounted
circuit breaker control switch. Open the circuit breaker by temporarily
closing the contacts of each protective relay. Reset the relay targets
after each operation.
3. Electrically operate from remote control locations and check the remote
indicating lights.
4. Operate all electrical interlocks, transfer schemes, lock-out relays, and
other control functions to ensure proper operation.
5. Remove the temporary source of low voltage power (if used) and make
the permanent connection of low voltage power.
6. If drawout fuses and drawout voltage transformers are included in the
installation, rack them into the connected position by following the steps
outlined in “Racking the VT Drawout Unit into the CONNECTED
Position” on page 30.
7. Using a properly rated voltage sensing device, verify again that trip
voltage is available at the circuit breaker control terminals in
each compartment.

Energizing the Switchgear To establish electrical service follow these steps:


1. Energize the incoming high voltage circuits.
2. Close the main circuit breakers.
3. Close the feeder circuit breakers.
4. Turn on loads one at a time.

Removing Circuit Breakers Follow the steps outlined in “Circuit Breaker Removal” on page 27.

36 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Inspection and Maintenance

Inspection and Maintenance Perform inspection and maintenance annually or more frequently based on
equipment usage—at least every 50 cycles. Abnormal operation or

ENGLISH
conditions may require immediate corrective action.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• Only qualified personnel familiar with medium voltage equipment are to
perform work described in this set of instructions. Workers must
understand the hazards involved in working with or near medium
voltage equipment.
• Before performing visual inspections, tests, or maintenance on this
device, disconnect all sources of electric power. Assume all circuits are
live until they are completely de-energized, tested, grounded, and
tagged. Pay particular attention to the design of the power system.
Consider all sources of power. Check interconnection diagrams and
make sure there are no backfeed potential sources.
• Turn off all power supplying this equipment before working on it.
• Always use a properly rated voltage sensing device to confirm that
power is off.
• Perform inspection and maintenance only with the main sources of
power disconnected and locked open with a “work” lock.

Failure to follow these instructions will result in death or


serious injury.

Main Bus Compartment 1. Turn off all main and control power supplying this equipment. Be sure
there is no backfeed through any feeder circuit. Always use a properly
rated voltage sensing device to confirm that power is off.
2. Ground the main and feeder circuits.
3. Disconnect and remove fuses.
4. Disconnect and remove the circuit breaker.
5. Remove the covers from each main bus compartment. Inspect the
NOTE: Slight discolorations or tarnish of the busbars, primary contact supports, and insulating barrier(s).
silver plate is normal. Severe discoloration of
6. Remove the insulating boots from the bus joints. Check all busbar
the silver plate is an indication of an improper
connections, and torque all 0.5 in. (13 mm) bolts to 55 lb-ft (74.28 N•m).
or loose contact and overheating. Clean the
discoloration from the contact surfaces of the 7. Vacuum each compartment to remove dust, spiderwebs, etc. Wipe off
busbar and primary contact. Use an abrasive the insulation with a clean cloth.
pad such as Scotch Brite. For questions 8. Lightly lubricate the moving primary and secondary contacts and fingers
concerning cleaning, repairing, or replacing with red Mobilgrease® 28 (Schneider Electric part number
bus bars contact your local Schneider 1615-100950).
Electric representative. 9. Lightly lubricate the following parts with red Mobilgrease 28
(Schneider Electric part number 1615-100950):
— Rollers and sliding parts
— Racking arm and shaft
— Shutter actuator

© 2009–2012 Schneider Electric All Rights Reserved 37


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Inspection and Maintenance 06/2012

Replacing the Fuses Follow the steps below to replace damaged fuses in the voltage transformer
drawout unit:
ENGLISH

NOTE: When replacing fuses, handle them carefully to avoid breakage. Do not
grasp the fuse in the middle. Replace all fuses, even if only one is damaged.
1. Follow the procedures outlined in “Voltage Transformer Drawout
Unit Inspection” on page 29 to withdraw the appropriate fuse
drawout unit.
2. Wearing personal protective equipment, such as insulated gloves and
a face shield, grasp the fuse near the fuse clip and pull while rotating
the fuse.
3. Insert the fuses one end at a time into the fuse clips.
4. Follow the racking procedures outlined in “Voltage Transformer Drawout
Unit Inspection” on page 29 to return the unit to the CONNECTED
position.

Re-Energizing Install all of the circuit breakers to the TEST/DISCONNECT position with
their secondary disconnects engaged.
1. Remove the ground from the main and feeder circuits.
2. Close and latch all compartment doors. Close and bolt all cable
compartment doors and power transformer drawer doors.
3. Connect the control power source.
4. Close the main source of power, and operate each circuit breaker
electrically in the TEST/DISCONNECTED position
(Figure 3 on page 9).
5. If all controls are functioning properly, disconnect the secondary
control plugs.
6. Rack the circuit breakers into the connected position (see “Racking the
Circuit Breaker into the CONNECTED Position” on page 26).
7. Energize the incoming high voltage circuits.
8. Close the main circuit breakers.
9. Close the feeder circuit breakers.
10. Turn on loads one at a time.

38 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Accessories

Accessories This section contains information about Masterclad arc resistant metal-clad
indoor switchgear accessories.

ENGLISH
Using the Lift Truck
If the switchgear will be installed on a raised pad, a circuit breaker lift truck
Figure 32: Typical Lift Truck (Figure 32) is required.

WARNING
HAZARD OF BODILY INJURY OR EQUIPMENT DAMAGE
Check the nameplate of the lift truck before using it. Circuit breakers
rated for 50 kA, and below, require a lift truck rated for 800 lbs (363 kg)
or more. Circuit breakers rated for 63 kA require a lift truck rated for
950 lbs (431 kg).

Failure to follow these instructions can result in death, serious


injury, or equipment damage.

Safety The cradle is raised and lowered by a self-braking worm and pinion drive
cable
system with a winch and wire cable. No ratchet release or locking is
required because of the automatic load-retaining clutch feature. Rotating
the handle clockwise raises the cradle. Rotating the handle
counterclockwise lowers the cradle.
To remove a circuit breaker from the circuit breaker compartment with the
lift truck:

For users in Mexico: 1. Push the lift truck toward the circuit breaker compartment so the cradle
An optional circuit breaker is square with the front of the circuit breaker cell.
installation ramp is available.
2. Raise the cradle until the cradle floor clears the catch pins on each side
of the circuit breaker compartment floor (Figure 5 on page 11).
3. Line up the holes in the brackets on the front of the cradle with the catch
pins on the circuit breaker compartment floor.
4. Lower the cradle until it is securely held by the catch pins.
5. Roll the circuit breaker onto the lift truck.
6. Secure the circuit breaker on the lift truck using the safety
cable provided.
7. Raise the cradle until it clears the catch pins.
8. Remove the lift truck and circuit breaker from the cell and lower the
cradle to the floor.
9. To remove the circuit breaker from the lift truck, disconnect the safety
cable from the front of the circuit breaker.
10. Push the circuit breaker slightly toward the back of the cradle and pull
the lever on the back of the cradle while rolling the circuit breaker off of
the cradle.

© 2009–2012 Schneider Electric All Rights Reserved 39


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Accessories 06/2012

Test Cabinet (Optional) An optional wall-mounted test cabinet (Figure 11 on page 20) is furnished
when listed in the user’s specifications. The test cabinet consists of a small
ENGLISH

enclosure including:
• A power on-off toggle switch.
• A white light indicating the power is on.
• A red light indicating the circuit breaker is closed.
• A green light indicating the circuit breaker is open.
• Close and open pushbuttons.
• An 8 ft. (2.44 m) cable with a secondary control receptacle that can be
plugged directly into the circuit breaker control plug.

Refer to the customer drawings for the external power connections and
requirements necessary for the cabinet. A convenient terminal block is
provided inside the test cabinet for these connections.

Figure 33: Wall-Mounted Test Cabinet (Optional)

Ground and Test Devices Two types of ground and test devices are available:
• Manual
• Electrical
Ground and test devices are safety devices, typically used for:
• Grounding of circuits during maintenance periods.
• Connection points for applying voltage for hi-pot testing and cable
testing access to both line side and load side circuits for phase
sequence testing.
NOTE: A complete description, operating instructions, and maintenance
information are included in a separate ground and test devices
instruction bulletin.

40 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Arc Exhausting Systems

Arc Exhausting Systems Two different, mutually exclusive, arc exhausting systems are available:
• A plenum for redirecting arc flash exhaust to a remote, safe location, and

ENGLISH
Table 4: Minimum Required Ceiling
Height from Floor • An arc shield for increasing the likelihood of protection from hazardous
arc flash gases and debris overflowing the top exhaust ports.
Standard application 192 in. (4880 mm)
NOTE: For 63 kA Masterclad switchgear, the plenum assembly is the only
Plenum application 150 in. (3810 mm)
exhaust system available.
Arc Shield application 192 in. (4880 mm)

Plenum Assembly The plenum is mounted on the top of each compartment to help redirect
explosive energies in the event of an electrical fault. The exhaust must
always be directed to a secure location.

Figure 34: Typical Indoor Plenum Application

Plenum Exhaust Duct Exhaust Duct


Section Section

End Cover

18.0 in.
(457.2 mm) Wall Exit Point Secure
Location
A secure area of
99.0 in. 30 ft. x 30 ft.
2514.6 mm) (9 m x 9 m)
is required outside
the control room.

1/2-13 3/8-16 Cap


2.8 in. 8.5 in. 1.5 in.
Threaded Screws (22 total) (38.1 mm)
Rod (70.8 mm) (215.9 mm)

1/2-13
Nut 1/2 in. 16.0 in.
Flat Washer (406.4 mm) 6.5 in.
(165.1 mm)

1 5/8 in. 1/3-13 Lock Nut 65.0 in.


“T” Series (1651.0 mm)
Unistrut®

Exhaust Support Exhaust Mounting Flange

Plenum assemblies are shipped separately and are designed for installation
after the equipment is positioned. Plenum applications consist of the
following standard offerings:

NOTE: Customized exhaust section lengths are


available. Also, plenum assemblies are • Plenum — One per switchgear section
available for outdoor applications in • Exhaust Duct — Standard length is 79.0 in. (2006.6 mm)
Power Zone Centers. Call 888-778-8733 for • End Cover
more information. • Exhaust Support — Required for each 84.0 in. (2133.6 mm)
exhaust duct section

© 2009–2012 Schneider Electric All Rights Reserved 41


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Arc Exhausting Systems 06/2012

Installing the Plenum Assembly This section contains instructions for installing one or more plenum
assemblies on Masterclad switchgear.
ENGLISH

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• Only qualified personnel familiar with medium voltage equipment are to
perform work described in this set of instructions. Workers must
understand the hazards involved in working with or near medium
voltage circuits.
• Perform such work only after reading and understanding all of the
instructions contained in this bulletin.
• Turn off all power supplying this equipment before working on it.
• Always use a properly rated voltage sensing device to confirm that
power is off.
• Disconnect all sources of power to the switchgear before accessing the
horizontal Plenum exhaust area.

Failure to follow these instructions will result in death or serious


injury.

1. Remove the roof mounting hardware and the lifting angles.


NOTE: Hardware quantities listed are per cubicle.
NOTE: For end cubicles, remove only the hardware on the right and left
roof edges.

Figure 35: Plenum Assemblies Figure 36: Prepared Roof Detail—Plenum


(Lefthand and Righthand End Bays)

14.1 in.
(358.2 mm)

Rear 1/4-20
Cap Screws
(14 total) 44.2 in.
(1121.4 mm)

Plenum Section and End Cover


1/4-20
Cap Screws 1/4-20
(14 total) Thread-forming
Screws (20 total)

3/8-16
Cap Screws
(6 total)

1/4-20
Rear Cap Screws 9.1 in.
(15 total) (231.4 mm)

Exhaust Duct Section

NOTE: The plenum is designed to be lifted with a crane or tow motor.

42 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Arc Exhausting Systems

Refer to Figure 35 on page 42 and Figure 37 on page 44 for the following


steps.

ENGLISH
2. Install the plenum sections to the switchgear roof, using the included
1/4-20 cap screws and nuts along the mid-support and side-mounting
edges.
3. Install the end cover support and end cover to the plenum section
opposite the intended exhaust path, using the included 1/4-20 and
3/8-16 cap screws.
4. Connect adjacent plenum sections along the connection flange, using
the 1/8 in. gasket and 3/8-16 cap screws, washers, and nuts.
5. Repeat this process for adjacent switchgear sections.
6. Install the exhaust duct section to the adjacent connection flange, using
the 1/8 in. gasket and 3/8-16 cap screws, washers, and nuts.
7. Install the exhaust support with the support installation kit included with
each exhaust duct section (Figure 34 on page 41).
NOTE: For further assistance, call 888-778-2733.
8. Repeat this process until exhaust ducting reaches wall exit point.
NOTE: The final exhaust duct section will be of a custom length, as
specified when ordered, to accommodate the specific installation.
9. Connect the exhaust duct to the wall exit point, using the 1/8 in. gasket
and 3/8-16 cap screws, washers, and nuts.

© 2009–2012 Schneider Electric All Rights Reserved 43


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Arc Exhausting Systems 06/2012

Figure 37: Plenum Installation Detail


ENGLISH

3/8-16 1/8 in. Gasket


Anchor

Exhaust Flange Wall Mounting

1/8 in. Gasket


3/8 in. 3/8-16
Cone Cage Nut
Washer Connection Flange
3/8-16
Cap Screw 3/8 in.
Cone
Washer 3/8-16 Cap Screw

1/4-20 Cap Screw

Rear of
Equipment

Mid-Support Mounting Edge

3/8-16 Lock
Washers
(6 total)

3/8-16 Cage Nuts 1/8 in. Gasket


(8 total)

3/8-16
1/4-20 1/4-20 Cap Screws Cap Screws
Cap Screw (20 total) (6 total)

End Cover Support


Side Mounting Edge

44 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Arc Exhausting Systems

Arc Shield Assembly The arc shield is designed to raise the switchgear exhaust height, should an
arc event occur, thereby increasing the likelihood of protection at the front,

ENGLISH
rear, and sides of the equipment.

Figure 38: Typical Arc Shield Application

Arc Shield

31.2 in.
(792.5 mm)

99.0 in.
2514.6 mm)

The recommended minimum space around the equipment is:


• Ceiling height from floor — 192 in. (4887.0 mm)
• Rear and side of equipment — 40 in. (1000 mm)
• Front of equipment — 72 in. (1828.8 mm)
Arc shield assemblies are shipped separately and are designed for
installation after the equipment is positioned.

Figure 39: Arc Shield Assemblies

Front Front Front

Mounting Mounting Mounting


Flange Flange Flange
(3 sides) (2 sides) (3 sides)

Lefthand End Bay Arc Shield Section Intermediate Arc Shield Section Righthand End Bay Arc Shield Section

© 2009–2012 Schneider Electric All Rights Reserved 45


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Arc Exhausting Systems 06/2012

Installing the Arc Shield Assembly This section contains instructions for installing one or more arc shield
assemblies on Masterclad switchgear.
ENGLISH

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
• Apply appropriate personal protective equipment (PPE) and follow safe
electrical work practices. See NFPA 70E and CSA Z462.
• Only qualified personnel familiar with medium voltage equipment are to
perform work described in this set of instructions. Workers must
understand the hazards involved in working with or near medium
voltage circuits.
• Perform such work only after reading and understanding all of the
instructions contained in this bulletin.
• Turn off all power supplying this equipment before working on it.
• Always use a properly rated voltage sensing device to confirm that power
is off.
• Disconnect all sources of power to the switchgear before accessing the
top shield exhaust area.

Failure to follow these instructions will result in death or serious


injury.

1. Remove the roof mounting hardware and the lifting angles.


NOTE: Hardware quantities listed are per cubicle. Retain all removed
hardware for installing the arc shield.
NOTE: For end cubicles, remove only the hardware on the right and left
roof edges.

Figure 40: Prepared Roof Detail—Arc Shield


(Lefthand and Righthand End Bays)

14.1 in.
(358.2 mm)

1/4-20
Cap Screws
(7 total)

1/4-20
Thread-forming
Screws (20 total)

3/8-16
Cap Screws
(6 total)

1/4-20
Cap Screws 9.1 in.
(15 total) (231.4 mm)

46 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Arc Exhausting Systems

NOTE: The arc shield is designed to be Refer to Figure 39 and Figure 41 for the following steps.
lifted with a crane or tow motor. Arc
2. Install the lefthand end bay arc shield section to the leftmost section of

ENGLISH
shields mount to the switchgear roof
using the 1/4-20 and 3/8-16 hardware the switchgear roof, using the included screws along the three mounting
retained in step 1. flange edges.
3. Install the next intermediate (if more than one switchgear section
remaining needs arc shielding), or the righthand end bay arc shield
section (if only one switchgear section remaining needs arc shielding) to
the switchgear roof, using the included screws along the mounting
flange edges.
4. Connect adjacent arc shield sections along the connection flange, using
the included 3/8-16 cap screws, washers, and nuts.
5. Connect adjacent arc shield section tops with an arc shield splice, using
the included 3/8-16 cap screws, washers, and nuts.
6. Repeat this process for adjacent switchgear sections until the righthand
end bay arc shield section is installed.
Figure 41: Arc Shield Installation Detail

3/8 in.
Cone Arc Shield Splice
Washer

3/8-16 Splice
Cap Screw

3/8 in.
Cone
Washer 3/8-16
Cage Nut

1/4-20
Cap Screw
3/8-16
Cap Screw

Front and Rear Mounting

3/8-16
Cap Screw

3/8-16
Lock
1/4-20 Thread-forming
Washer
Screw

End Bay Flange Mounting

© 2009–2012 Schneider Electric All Rights Reserved 47


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Configuration Drawings 06/2012

Configuration Drawings
ENGLISH

Figure 42: Masterclad Arc Resistant Metal-Clad Indoor Switchgear Configurations

E E
C
C

D D

A A
B B

1-High Auxiliary/Breaker (1200 A) 1-High Auxiliary/Breaker (2000 A)

F C
C
G D

A B A B

H H

2-High Breaker/Breaker (1200/2000 A or 1200/1200 A) 1-High Breaker (3000 A)

A. Bottom Circuit Breaker Compartment B. Bottom Load Compartment


C. Main Bus Compartment D. Control Instrument Compartment
E. Auxiliary Device Compartment F. Top Breaker Compartment
G. Top Load Compartment H. Sub Floor

48 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation and Maintenance Log

Installation and Maintenance Log

ENGLISH
Date Initials Actions

© 2009–2012 Schneider Electric All Rights Reserved 49


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear 6055-62
Installation and Maintenance Log 06/2012
ENGLISH

Date Initials Actions

50 © 2009–2012 Schneider Electric All Rights Reserved


6055-62 Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
06/2012 Installation and Maintenance Log

ENGLISH

© 2009–2012 Schneider Electric All Rights Reserved 51


Masterclad™ 5–15 kV Arc Resistant Metal-Clad Indoor Switchgear
Instruction Bulletin
ENGLISH

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.
Masterclad™, Square D™, and Schneider Electric™ are trademarks or registered trademarks of
Schneider Electric USA, Inc. Schneider Electric. Other trademarks used herein are the property of their respective owners.
330 Weakley Road
Smyrna, TN 37167 USA 6055-62 06/2012
1-888-778-2733 Replaces 6055-62 10/2009
www.schneider-electric.us © 2009–2012 Schneider Electric All Rights Reserved