Service Information

1
Contents
Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Fuse Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of the Companion II Fuse . . . . . . . . . . . 3
Installation of Terminal Options . . . . . . . . . . . . . . . . 5
Re-fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRODUCT INFORMATION
Introduction
The Cooper Power Systems Companion II fuse is a back-
up cur rent-limiting fuse designed to be used in series with
a distribution cutout or similar fuse capable of interrupting
currents up to and including the minimum interrupting
current of the Companion II fuse. The Companion II fuse
limits the energy input during a high fault current condition.

Read This Manual First
Read and understand the contents of this manual and
follow all locally approved procedures and safety practices
before installing or operating this equipment.
Additional Information
These instructions cannot cover all details or variations in
the equipment, procedures, or process described nor
provide directions for meeting every possible contingency
during installation, operation, or maintenance. When
additional information is desired to satisfy a problem not
covered sufficiently for the user's purpose, please contact
your Cooper Power Systems sales representative.
Acceptance and Initial Inspection
Each Companion II fuse is completely inspected and
tested at the factory. It is in good condition when accepted
by the carrier for shipment. Upon receipt of the Companion
II fuse, inspect the connector thoroughly for damage and
loss of parts incurred during shipment. If damage or loss is
discovered, file a claim with the carrier immediately.
Handling and Storage
If the Companion II fuse is to be stored for an appreciable
time before installation, provide a clean, dry storage area.
Locate the Companion II fuse so as to minimize the
possibility of physical damage.
Quality Standards
ISO 9001:2008-Certified Quality Management System
Fusing Equipment
Companion II Back-up Current-Limiting Fuse
Installation Instructions
S240-64-1
Service Information
June 2010 Supersedes 6/99 1
Figure 1.
Companion II backup current-limiting fuse with spline stud
and eyebolt terminal options.
CAUTION:
The Cooper Power Systems Companion II fuse is
designed to be installed in accordance with normal
safe operating procedures. These instructions are
not intended to supersede or replace existing safety
and operati ng procedures. READ ALL THE
I NSTRUCTI ONS BEFORE I N STALL I NG THE
COMPANI ON I I DI STRI BUTI ON FUSE. The
Companion II fuse should be installed and serviced
only by personnel familiar with good safety practice
and the handl i ng of hi gh-vol tage el ectri cal
equipment.
EYEBOLT
TERMINAL
COMPANION II
FUSE BODY
SPLINE STUD
TERMINAL
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Companion II Back-up Current-Limiting Fuse Installation Instructions
2
The instructions in this manual are not intended as a
sub stitute for proper training or adequate experience
i n the safe operati on of the equi pment descri bed.
Only competent technicians, who are familiar with this
equipment should install, operate and service it.
A competent technician has these qualifications:
n Is thoroughly familiar with these instructions.
n Is trained in industry-accepted high- and low-voltage
safe operating practices and procedures.
n Is trained and authorized to energize, de-energize, clear,
and ground power distribution equipment.
n Is trained in the care and use of protective equipment
such as flash clothing, safety glasses, face shield, hard
hat, rubber gloves, hotstick, etc.
Fol l owi ng i s i mportant safety i nformati on. For safe
installation and operation of this equipment, be sure to
read and understand all cautions and warnings.
Safety Instructions
Following are general caution and warning statements that
apply to this equipment. Additional statements, related to
specific tasks and procedures, are located throughout the
manual.
DANGER:
Hazardous voltage. Contact with high voltage will
cause death or severe personal injury. Follow all
locally approved safety procedures when working
around high- and low-voltage lines and equipment.
!
WARNING:
Before installing, operating, maintaining, or testing
this equipment, carefully read and understand
the contents of this manual. Improper operation,
handling or maintenance can result in death, severe
personal injury, and equipment damage.
!
WARNING:
This equipment is not intended to protect human
life. Follow all locally approved procedures and
safety practices when installing or operating this
equipment. Failure to comply may result in death,
severe personal injury and equipment damage.
!
WARNING:
Power distribution and transmission equipment
must be properly selected for the intended
application. It must be installed and serviced
by competent personnel who have been trained
and understand proper safety procedures. These
instructions are written for such personnel and
are not a substitute for adequate training and
experience in safety procedures. Failure to properly
select, install or maintain power distribution and
transmission equipment can result in death, severe
personal injury, and equipment damage.
!
SAFETY FOR LIFE
Cooper Power Systems products meet or exceed all applicable industry standards relating to product safety. We actively
promote safe practices in the use and maintenance of our products through our service literature, instructional training
programs, and the continuous efforts of all Cooper Power Systems employees involved in product design, manufacture,
marketing and service.
We strongly urge that you always follow all locally approved safety procedures and safety instructions when working
around high-voltage lines and equipment and support our Safety For Life mission.
!
SAFETY
FOR LIFE
!
SAFETY
FOR LIFE
SAFETY INFORMATION
Thi s manual may contai n four types of hazard
statements:
DANGER:
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING:
Indicates a hazardous situation which, if not
avoided, could result In death or serious injury.
CAUTION:
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
CAUTION: Indicates a hazardous situation which, if
not avoided, could result in equipment damage
only.
Hazard Statement Definitions
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S240-64-1
3
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SAFETY
FOR LIFE
FUSE APPLICATION
When selecting the proper size Companion II fuse for each
installation, continuous current, voltage rating, and both
upstream and downstream coordination should be taken
into account.
The Companion II fuse rating indicates the largest Type K
fuse link that properly coordinates with the fuse. Select a
Companion II fuse size that is greater than or equal to the
Type K fuse link size used in the cutout at that location.
For fuse links other than Type K links, select the proper
Companion II fuse based on Table 1. For fuse links not
included in this table, contact your Cooper Power Systems
representative.
The voltage ratings recommended for the Companion II fuse
on most commonly encountered distribution systems are
listed in Table 2.
For further information concerning the coordination of the
Companion II fuse, see Cooper catalog section 240-64 or
contact your Cooper Power Systems representative.*
INSTALLATION PROCEDURE
Figures 2 through 6 show typical installations of the
Companion II fuse. It may be installed on the source side
(Figure 2) or load side (Figure 3) of a distribution cutout. It
may be hung from a bail attached to the overhead line
(Figure 4), or it may be attached directly to the transformer
bushing (Figures 5 or 6).
The lightning protection is connected to the line side of the
Companion II fuse and the distribution cutout.
Installation of the Companion II Fuse
Once the end terminals have been installed on the
Companion II fuse (refer to Installation of Terminal
Options on pg. 5):
1. Remove fuseholder from distribution cutout using a
hook stick.
n Al ways use a l oadbreak devi ce to open an
ener gi zed cut out . Fol l ow manuf act urer s
recommendations for operation of loadbreak tools
or cutouts which are designed to break load
current.
WARNING:
When installing on hot lines, be sure to observe
proper clearances between live and de-energized
parts. Use only approved safety practices.
Companion II
Fuse Rating
Coordinated With Fuse Links Up Through
Type K Type T
Edison
Type N
Edison
Type S
Edison
Type H
Edison
Type D
12K 12 8 20 5 8 1.5
25K 25 15 30 7 8 20
40K 40 20 50 15 8 20
Kearney
Type X
Kearney
Type QA
Kearney
Type 200
Kearney
Type KS
12K 2.5 15 10 3
25K 10 30 20 7
40K 15 50 30 15
TABLE 1
Companion II Fuse-Fuse Link Coordination
System Voltage (kV)
Recommended Companion II
Rating (kV)
Nominal Maximum
Four-Wire
Multigrounded
Neutral Delta
2.4 2.54 8.3
2.4/4.16 2.54/4.4 8.3
4.16 4.4 8.3
4.8 5.1 8.3
4.8/8.32 5.1/8.8 8.3
6.9 7.26 8.3
6.93/12 7.3/12.7 8.3
7.2 7.62 8.3
7.62/12.47 7.62/13.2 8.3
7.62 8.1 8.3
7.62/13.2 8.1/14.0 8.3
7.97 8.4 8.3
7.97/13.8 8.4/14.5 8.3
8.32 8.8 8.3
8.32/14.4 8.8/15.2 8.3
12/20.8 12.7/22 15.5
12.47 13.2* 8.3**
13.2/22.9 14/24.2 15.5
13.2 14* 8.3**
13.8 14.5* 8.3**
14.4/24.9 15.2/26.4 15.5
14.4 15.2 8.3**
19.9/34.5 21.1/36.5 23
34.5 36.5* 23**
46 48.3* 23**
TABLE 2
Companion II Fuse Voltage Application
* Fuse voltage ratings recommended for these systems are based on
simultaneous operation of the Companion II fuses for high current faults.
** For single-phase applications on delta systems, one fuse of this rating is
required in each phase.
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Companion II Back-up Current-Limiting Fuse Installation Instructions
4
2. Wire brush all terminals, connectors and electrical
conductors.
3. Apply an oxide inhibitor prior to making electrical
connections.
4. Insert Companion II fuse and conductors into
connectors and tighten.
n Maintain a minimum of 14" of clearance from the
source leads to the lower end of the Companion II
fuse and related energized hardware of the cutout.
n When mounting the Companion II fuse in the upper
terminal of a fused cutout, replace expendable caps
with solid caps.
n Make sure vents from the cutout fuse holder will not
direct expulsion gases towards the Companion II
fuse.
n Apply minimal cantilever load to the Companion II
fuse.
5. Re-energi ze the l i ne usi ng approved safety
procedures.
Figure 2.
Companion II fuse mounted on the source side of the cutout.
ARRESTER
COMPANION II
FUSE
CUTOUT FUSE
LINK IN FUSE-
HOLDER
TRANSFORMER
PRIMARY
BUSHING
Figure 3.
Companion II fuse mounted on the load side of the cutout.
ARRESTER
COMPANION II
FUSE
CUTOUT FUSE
LINK IN FUSE-
HOLDER
TRANSFORMER
PRIMARY
BUSHING
Figure 4.
Companion II fuse mounted from a bail attached to the
overhead line.
ARRESTER
COMPANION II
FUSE
CUTOUT FUSE
LINK IN FUSE-
HOLDER
TRANSFORMER
PRIMARY
BUSHING
S240-64-1
5
!
SAFETY
FOR LIFE
Installation of Terminal Options
Eyebolt Terminal
(Terminal Code - B)
1. Insert threaded end of the eyebolt terminal body
into the tapped center hole of the Companion II fuse
and torque the eyebolt terminal to 10-15 ft-lbs. (Figure
7.)
Parallel-Groove Terminal (Terminal Code - C)
1. Align the circular hole of the spade adapter with the
tapped center hole of the Companion II fuse.
2. Place the internal-tooth lock washer onto the bolt,
and insert the bolt through the spade adapter hole into
the tapped center hole of the fuse (as shown in Figure
8) and torque the bolt to 10-15 ft-lbs.
3. Assemble carriage bolt, terminal clamp, split lock
washer and hex nut on the spade adapter as shown
in Figure 8.
Spade Terminal
(Terminal Code - D)
1. Align the circular hole of the spade adapter with the
tapped center hole of the Companion II fuse.
2. Place the internal-tooth lock washer onto the bolt
and insert the bolt through the spade adapter hole
into the tapped center hole of the fuse and torque the
bolt to 10-15 ft-lbs. (Figure 9.)
Figure 7.
Eyebolt terminal.
1.57"
(40 mm)
Figure 8.
Parallel-groove terminal.
2.0"
(51 mm)
SPADE
ADAPTER
TERMINAL CLAMP
HEX NUT
CARRIAGE BOLT
BOLT
SPLIT LOCK
WASHER
INTERNAL-
TOOTH
LOCK
WASHER
Figure 5.
Transformer-mounted Companion II fuse with distribution
cutout.
ARRESTER
COMPANION II
FUSE
CUTOUT FUSE
LINK IN FUSE-
HOLDER
TRANSFORMER
PRIMARY
BUSHING
Figure 6.
CSP transformer-mounted Companion II fuse without
separate distribution cutout.
ARRESTER
COMPANION II
FUSE
TRANSFORMER
PRIMARY
BUSHING
Companion II Back-up Current-Limiting Fuse Installation Instructions
6
Spline Stud Terminal (Terminal Code - G)
1. Insert threaded end of the spline stud into the
tapped center hole of the Companion II fuse and
torque spline stud to 10-15 ft-lbs. (Figure 10.)
Offset Adapter
(Terminal Code - J)
1. Align the hole of the offset adapter with the tapped
center hole of the Companion II fuse.
2. Place the washer onto the bolt and insert the bolt
through the hole of the offset adapter into the tapped
center hole of the fuse and torque the bolt to 10-15
ft-lbs. (Figure 11.)
Figure 10.
Spline stud terminal.
2.44"
(62 mm)
Figure 9.
Spade terminal.
2.0"
(51 mm)
0.41" (10.4 mm)
SQUARE HOLE
BOLT
SPADE
ADAPTER
INTERNAL-
TOOTH
LOCK
WASHER
Universal Adapter
(Terminal Code - L)
1. Align the circular hole of the spade adapter with
the tapped center hole of the Companion II fuse.
2. Place the internal-tooth lock washer onto the bolt
and insert the bolt through the spade adapter hole into
the tapped center hole of the fuse and torque the bolt
to 10-15 ft-lbs. (Figure 12.)
3. Assemble carriage bolt, external-tooth lock
washer, mounting stud, split lock washer and hex
nut on the spade adapter as shown in Figure 13.
Hot-Line Clamp-Bronze
(Terminal Code - M)
1. Install the spline stud terminal as described above
and shown in Figure 10.
2. Place the eyebolt terminal of the hot-line clamp
over the spline stud, align and torque (as required)
the eyebolt nut of the hot-line clamp as shown in
Figure 13.
Figure 11.
Offset adapter terminal.
3.8"
(97 mm)
OFFSET
ADAPTER
0.8"
(20 mm)
BOLT
WASHER
Figure 12.
Universal adapter terminal.
4.1"
(104 mm)
SPADE
ADAPTER
CARRIAGE
BOLT
EXTERNAL-
TOOTH LOCK
WASHER
SPLIT LOCK
WASHER
MOUNTING
STUD
HEX
NUT
BOLT
INTERNAL-
TOOTH LOCK
WASHER
Figure 13.
Hot-line clamp.
4.94"
(125 mm)
EYEBOLT OF
HOT-LINE
CLAMP
SPLINE
STUD
S240-64-1
7
!
SAFETY
FOR LIFE
Large Parallel-Groove Terminal
(Terminal Code - N)
1. Align the hole of the large parallel-groove
connectors short leg with the tapped center hole of
the Companion II fuse.
2. Place the split lock washer onto the bolt and insert
the bolt through the connector hole into the tapped
center hole of the fuse and torque the bolt to 10-15
ft-lbs. (Figure 14.)
3. Assemble carriage bolt, parallel-groove clamp, split
lock washer and hex nut on the connector as shown
in Figure 14.
RE-FUSING
1. Remove the fuseholder from the fuse cutout using
the manufacturer's recommended procedure.
2. Loosen the line terminal on the Companion II fuse
and remove the line conductor.
3. Loosen the terminal that connects the Companion II
fuse to the fuse cutout and remove the Companion II
fuse.
4. Check the Companion II fuse per the procedure in
the TESTING section.
5. Replace the operated fuse link with the proper type
and current rati ng usi ng the manuf acturers
recommended procedure.
TESTING
The Companion II fuse should always be tested after an
operation of the fuse cutout.
1. Perform a continuity check on the Companion II
fuse.
2. If the Companion II fuse does have continuity, go
to the Installation Procedure on page 2.
3. If the Companion II fuse does not have continuity,
replace the operated fuse with an appropriate new
fuse. The new fuse should have proper voltage and
current rating.
CAUTION:
Failure to check the Companion II back-up current-
limiting fuse may result in placing an operated/
damaged fuse back in service. This could result in
personal injury, fire or equipment damage.
CAUTION:
When removing the Companion II fuse, observe
appropri at e cl earances bet ween l i ve and
de-energized parts.
CAUTION:
Faults and/or visibly failed equipment should be
l ocated and repai red before re-i nstal l i ng a
replacement Companion II fuse.
Figure 14.
Large parallel-groove terminal (250 MCM).
2.3"
(58 mm)
PARALLEL-GROOVE
CLAMP
SPLIT LOCK
WASHER
SPLIT LOCK
WASHER
BOLT
HEX NUT
CARRIAGE BOLT
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Companion II Back-up Current-Limiting Fuse Installation Instructions
8
2010 Cooper Industries. All Rights Reserved.
Cooper Power Systems, Companion, Kearney and Edison are valuable
trademarks of Cooper Industries in the U.S. and other countries. You are
not permitted to use the Cooper Trademarks without the prior written
permission of Cooper Industries.
S240641 Rev 3 Supersedes Rev 2
2300 Badger Drive
Waukesha, WI 53188
www.cooperpower.com