Training - Motorpact

Motorpact™ MV motor startersField Service Training Presentation Motorpact™ Medium Voltage Motor Controllers Field Service Training Presentation  Open Page for providing Instructor Information,  Course Identification Number, Etc. Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 2 Outline  Outline…………………………………………………  Objective………………………………………………  Safety Precaution Notice……………………………  Introduction……………………………………………        3-8 9 10-11 12-13 14-15 16 17 18 19 20 Main Features…………………………………………. Model 1 vs Global Design…………………………… Applicable Standards & Certification………………… Controller Types………………………………………… Controller Applications………………………………… Contactor Ratings………………………………………. Enclosure and Busbar Ratings………………………… 21 Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 3 CT... – Without earthing switch installed – With earthing switch installed 22 23-24 25-26 27 28 29-37 29 30 31 32 33-34 35-37 38-40 Motorpact IEC_E_V0R8... Busbar Compartment……………………………………. Interlocks…………………………………………………….Outline  Components………………………………………………       Low Voltage Compartment………………………………. Operator Panel……………………………………………. Disconnector ……………. CPT. Load Compartment………………………………………. VT…. – Instrument Transformer .ppt Tony Narusevicius 02/2005 4 . LPCT‟s. – Contactor Cable Connection………………………… – Load Cable Termination……………………………… – Power Fuses…………………………………………… – Contactor………………………………………………. – Overview………………………………………………. Full Voltage Non Reversing……………………. – Electrical……………………………………………….Reduced Voltage Soft Start……………………. RVSS ...   – Mechanical……………………………………………. – Mechanical……………………………………………...Reduced Voltage Auto Transformer……………..Outline  Standard Configurations…………………………………  41 42-44 42-43 44 45-48 45-47 48 49-52 FVNR . 49-51 52 Motorpact IEC_E_V0R8. – Electrical………………………………………………. – Mechanical……………………………………………. RVAT ..ppt Tony Narusevicius 02/2005 5 . – Electrical………………………………………………... Voltage Presence Indication System . Earthing Switch Assembly………………………… MDT107 Thermal Diagnostic System…………………… Back Light…………………………………………………… Enclosure Incoming Section……………………………….ppt Tony Narusevicius 02/2005 6 . – Electrically and Mechanically………………………… Closing Coil Voltage & Current…………………………… 54 55 56-57 58-59 60-61 62-63 64 65-66 66 68 69-70 69 70 71 71 72  Contactor Operation………………………………………     Motorpact IEC_E_V0R8.. Closing the Contactor……………………………………… – Without earthing switch installed……………………...Outline  Options……………………………………………………        Blown Fuse Indication……………………………………. – With earthing switch installed………………………… Opening the Contactor……………………………………. Installing and Removing the Contactor………………….VPIS…………… Internal Arc Class Enclosure…………………………. .Outline  Initial Start-up (General Information)…………………………. – Replacing Trip Latch…………………………………… 73 74 75 76 77-79 80 81-82 81 82 83-86 83-84 85 86 87 88 89-90  Corrective Maintenance………………………………………. Troubleshooting……………………………………………. – Mechanism……………………………………………… Parts Replacement………………………………………… – Replacing Power Fuses………………………………..     Preparation…………………………………………………. Motorpact IEC_E_V0R8. – General………………………………………………….    Preventive Maintenance……………………………………….ppt Tony Narusevicius 02/2005 7 . – Replacing & Adjusting Vacuum Interrupter…………. Setting and Testing Protective Relays…………………… High Voltage Circuits………………………………………. Low Voltage Circuits……………………………………….  Cell Interlocks………………………………………………  Contactor …………………………………………………. 91 92-93 95 96 97-98 99-100 101-102 103-104      Motor Currents .ppt Tony Narusevicius 02/2005 8 .. Removal of Escutcheon…………………………………… Earthing Switch Adjustment Procedure…………………… Pivot Lever not Releasing Interlocks……………………. 105 106 107-108 109-113 114 Motorpact IEC_E_V0R8.Reference chart……………………… Instruction Bulletins……………………………………… Abbreviations……………………………………………… Hands-on Workshop……………………………………… Addendum…………………………………………………     Installation of Escutcheon…………………………………..Outline  Preventive Maintenance (continued)     Barriers……………………………………………………… Main busbar………………………………………………… Low Voltage Controls……………………………………… Protective Relays…………………………………………. Objective  The objective of this training is to prepare Schneider Field Service Engineers on the servicing of Motorpact medium voltage motor controllers.  Training in this presentation will cover:     an introduction to Motorpact (FVNR. RVSS) operation of Motorpact and components startup preventive maintenance and troubleshooting  Information provided in this training is intended to service as an information supplement to Instruction Bulletins and should never be used as a replacement for Instruction Bulletins.ppt Tony Narusevicius 02/2005 9 . Motorpact IEC_E_V0R8. RVAT. Explosion or Arc Flash  Only qualified employees who can recognize and can avoid hazards associated with Medium Voltage Systems and are familiar with the its construction and operation should operate. test.Safety Precaution Notice DANGER: Hazard of Electrical Shock. Always refer to the appropriate instruction documentation provided by Schneider Electric and other suppliers prior to servicing equipment. All sources of energy and loads have been identified. The loads have been removed then proper disconnects have been opened. calibrate.  All Instructions contained within this presentation assume no preventive or corrective maintenance will be done until the switchgear has been placed in an electrically safe condition.ppt Tony Narusevicius 02/2005 .  It is assumed preventive or corrective maintenance is performed on the switchgear at intervals of 1 to 5 years depending on severity of operating conditions. 1 0   Motorpact IEC_E_V0R8.  The information in this presentation is not a replacement for switchgear instruction manuals or component manuals. maintain or trouble shoot this equipment. It is the intent of this manual to provide an overview of Motorpact Medium Voltage Motor Control Equipment. tagged out.     Qualified persons must wear appropriate personal protective equipment (PPE) and follow safe electrical work practices whenever working on or near exposed energized parts. Control fuses are removed. And busbar is earthed using procedures appropriate for the equipment.Safety Precaution Notice DANGER: Hazard of Electrical Shock. Explosion or Arc Flash   The disconnects have been locked out. All low voltage circuits are de-energized and tested to insure no voltage is present. using properly rated test equipment and personal protective equipment. Motorpact IEC_E_V0R8. See NFPA 70E or Services Electrical Safety Procedure latest editions. Then tested for absence of voltage.ppt Tony Narusevicius 02/2005 1 1 .  Always read and understand HAZARD labels provide on the equipment and in documentation. Introduction Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 1 2 . Introduction  Motorpact is the name of the new line of 3 phase 50/60 Hz medium voltage motor controller released by Smyrna. I is smaller. Motorpact IEC_E_V0R8. P=E*I. so operating costs are less. I2R losses are also less. when E is large. TN in 2002  Motorpact Brands   IEC NEMA  Medium voltage motor controllers are normally used to start (switch) induction motors (Squirrel Cage) 225 kW and up because they do so at lower cost than low voltage motor controllers. Therefore. In some cases the cost of MV to LV transformers can be eliminated.ppt Tony Narusevicius 02/2005 1 3 . cables can be smaller and less expensive. Induction (Squirrel Cage). Motor Ranges are from 75 kW (100 hp) to 3800 kW (5. 50/60 hertz.  Standard .mechanically latched closed.magnetically held closed.Introduction Main Features  Main features of Motorpact motor controllers are as follows:     Rated 2400 to 7200 volts AC.100 hp). – IP3X – IP4X – NEMA1 – NEMA1A or NEMA 1 Gasketed   Internal Arc Classification Type AFLR available as an option. line to line.ppt Tony Narusevicius 02/2005 1 4 . Main busbar tin plated copper as standard with ratings up to 3150A.  Two basic contactor types available. Motorpact IEC_E_V0R8.  Optional . Enclosure Types. Motor Types .  Standard controller cubicle width is 375 mm  500 mm and 750 mm .Introduction Main Features  Contactors are rated 200.  Metric hardware supplied as standard.ppt Tony Narusevicius 02/2005 1 5 . Motorpact IEC_E_V0R8.  Earthing switch available as an option  VPIS available as an option. and 400 amperes continuous (450 NEMA)  Controller interlocked for safe operation. 950 mm deep by 2300 mm high.NEMA only  One high construction only.  MDT107 thermal monitoring system available as an option. 1. 2004 Comments Drawout Panel None need cubicle width Prior Feb. The following chart identifies the differences between the two designs. 1. Feature Market LV Compartment Top Wireway Contactor Truck Track Built NEMA Model 1 Global NEMA & IEC Fixed Panel Mounted above LV Compartment need cubicle width After Feb.Introduction Model 1 vs Global Design  Motorpact units built prior to February 2004 are referred to as the Model 1 (Series A) product. 2004 Not Interchangeable Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 1 6 . Motorpact units built after February 2004 are referred to as the Global (Series B) product. CSA 22. NEMA ICS 3 part 2. EEMAC E14-1 IBC 2000 Seismic Standards E11 International Association Of Classification Societies (Marine) cULus UL certification to NEMA and CSA standards 1 7  Other certification .Part 8: low power current transformers High-voltage prefabricated switchgear and controlgear assemblies Voltage Presence Indicating Systems  Other standards     Motorpact IEC_E_V0R8.Part 1: current transformers Instrument transformers . #14 and #31.2.ppt Tony Narusevicius 02/2005 UL 347.Introduction Applicable Standards & Certification  Applicable IEC standards (STL qualification)   IEC 60694 IEC 62271-200    IEC 60470 IEC 60282-1 IEC 62271-102 IEC 60255 IEC 60044-1 IEC 60044-2 IEC 60044-8 IEC 61958      Common specification for high-voltage switchgear and controlgear AC metal-enclosed switchgear and controlgear for rated voltage above 1 kV and up to and including 52 kV (replaces IEC 60298 standard) High voltage alternating current contactors and contactor based motor starters High voltage fuses: limiting fuses Alternating current disconnectors and earthing switches Electrical relays Instrument transformers .Part 2: voltage transformers Instrument transformers . RVAT)   Motorpact SoftStart™ Auto Transformer Motorpact IEC_E_V0R8.Introduction Controller Types  Direct On Line (FVNR)   Non-reversing Mechanically latched  Reduced Voltage Non-Reversing (RVSS.ppt Tony Narusevicius 02/2005 1 8 . ppt Tony Narusevicius 02/2005 1 9 .Introduction Controller Applications  Compressor  Pump  Chiller  Fan  Conveyor  Chipper  Transformer Feeder  Capacitor Feeder Motorpact IEC_E_V0R8. 5 1200 300 80 ms or Less 25 ms or Less Motorpact IEC_E_V0R8.Introduction Contactor Ratings Minimum Voltage (kV) Max.4 7.ppt Tony Narusevicius 02/2005 2 0 .5 3.) Short Circuit Withstand at Rated Voltage (kA peak) Short Time Rating (kA) Symmetrical: 1 Second 30 Seconds Chopping Current (Average RMS Amps) Switching Frequency (Ops Per Hour): Standard Latched type only Maximum Closing Time Maximum Opening Time 2.000 250.500.000 2.000 5000 60 7.0 0.2 60 50/60 200/400A 250. Design Voltage (kV) BIL (kV) Frequency (Hz) Continuous Amps Electrical Endurance (number of operations) Mechanical Endurance (number of operations): Standard Latched type only Short Circuit Interrupting Amps (RMS Sym. ppt Tony Narusevicius 02/2005 2 1 .25 Second through IM to Main Power Fuse Dielectric Withstand (kV 1 Minute) Disconnector Mechanical Life 1.Introduction Enclosure and busbar Ratings Minimum Line to Line Voltage (kV) Maximum Line to Line Design Voltage (kV) BIL (kV) up to 3300 feet (1000 m) Frequency (Hz) Continuous Amps Short Circuit Withstand at Rated Voltage (kA Peak) Main Bus to Fuse Line Side Terminal Short Time Rating (kA) Symmetrical: Main Bus (2 Seconds) 0.2 60 50/60 200/400A 130 50 50 20 5000 Motorpact IEC_E_V0R8.0 7. Components Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 2 2 . Components Low Voltage Compartment  Low Voltage Panel   Protective Relay Circuit Monitor or Power Meter  Interior Component Panels     Painted White Provides a Mounting area for LV control components Isolated from MV Compartment Earthed Metal Partitions Provides termination point for LV field wiring Provides a 3 passage inter-unit Wireway for Communication, Control and LV Power  Top Wireway   Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 2 3 Components Low Voltage Compartment Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 2 4 Components Operator Panel Disconnector Closed Disconnector Open Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 2 5 E. Indicator of Disconnector Status F: Location for Earthing Switch Operation Padlock (optional) G: Disconnector Operating Access Port H. Earthing Switch operating Access Port (optional) I: J: Location for Disconnector Operation Padlock Interlock Shuttle (Not provided in Model 1) A C B D E F H I J G K K: Procedure Pictogram Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 2 6 . Disconnector Viewing Port.VPIS (optional) C: Push Button for Back Light (optional) D.Components Operator Panel A: Contactor Control Panel B: Voltage Presence Indication System . Components Disconnector  Means for disconnecting controller from the line or source to allow for inspection and testing. Light is available as an option.  Endurance .  Viewing window for visual inspection of the contacts.5000 operations.  Non-load break device  can interrupt CPT loads to 7 kVA  Mechanical interlock with contactor.  Two position . flame-retardant housing.Closed and Earthed. Motorpact IEC_E_V0R8.  Supports top fuse holders.  Arc-resistant.ppt Tony Narusevicius 02/2005 2 7 . ppt Tony Narusevicius 02/2005 2 8 .Components Busbar Compartment  Tin Plated Copper  No Riser busbar  Up to 3150 Amperes  Busbar Insulation available  Mounted and supported on disconnector  Single busbar for up to 5-375 mm cubicles  Reduces joints and maintenance  50 kA (2 sec) busbar Bracing Motorpact IEC_E_V0R8. ppt Tony Narusevicius 02/2005 2 9 .Components Load Compartment Overview Load Termination Box Power Fuses Vacuum Contactor LPCT or CT CPT and VT CPT and VT Fuses Motorpact IEC_E_V0R8. ppt Tony Narusevicius 02/2005 3 0 .Contactor Cable Connection  Contactor connected to cable termination pads  Single non-spliced Insulated Flexible busbar System Eliminates Joints and Maintenance   Uses a 360° radial-Swaged coldfused Compression Connection at all Terminal Ends – Maintenance Free – High Reliability Motorpact IEC_E_V0R8.Components Load Compartment . Load Cable Termination  Front Access or Front and Rear Accessibility  Full Height Cable Pulling Area  Load Cable Box allows for up to 1-240 mm2 or 2-120 mm2 Shielded Cables /  Features a Formex® flap over cable terminations  Provides dielectric protection at the cable terminations Motorpact IEC_E_V0R8.Components Load Compartment .ppt Tony Narusevicius 02/2005 3 1 .  Independently mounted from Contactor  Easy to inspect and maintain  Optional Insertion and Removal Tool Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 3 2 .Components Load Compartment .Power Fuses  Power Fuses provide short circuit protection for motor controller. Lightweight at approximately 20 kg Magnetically Held or Mechanically Latched Closing coils energized via an electronic drive unit that reduces the coil current electronically approximately 200 milliseconds after closing coils are energized. Dip switch on drive unit allows closing coils to be energized from discreet voltages of 100 to 250 volts. Motorpact IEC_E_V0R8.       200 A. 400 A. AC or DC.Components Load Compartment . 450 A DC solenoid operated 3 NO and 3 NC auxiliary contacts furnished as standard.Contactor  A device for starting and stopping large 3 phase motors and interrupting locked rotor currents when required.ppt Tony Narusevicius 02/2005 3 3 . ppt Tony Narusevicius 02/2005 Contactor Rail Extended Contactor Withdrawn Position 3 4 .Components Load Compartment .Contactor Contactor Connected Position Motorpact IEC_E_V0R8. CT.ppt Tony Narusevicius 02/2005 3 5 . VT LPCT or CT mounted on contactor fixed contact mould assembly Optional VT for protection and metering (floor mounted) Optional fused CPT (floor mounted) CPT and VT fuses are enclosed (Easily accessible from the front) (floor mounted) Motorpact IEC_E_V0R8. CPT.Components Load Compartment .Instrument Transformer . LPCT. ppt Tony Narusevicius 02/2005 3 6 . directly to Sepam relays.  Caution: CT boots (white tubes) required to pass 60 kV BIL.  LPCT provides low voltage (mV) output.Instrument Transformer . proportional to load current. CT connections are made in the LV compartment.Components Load Compartment . LPCT  3 CT‟s are cast together as a 3 phase assembly  Mounted behind the primary stabs in the rear of contactor compartment. Do not remove.  The CT leads are permanently CT Leads attached to the CT‟s. CT CT Boot Motorpact IEC_E_V0R8.CT. There are no screw connections on the CT‟s in the rear.   Primary fuses for the CPT and VT are located at the bottom front of the contactor compartment and are accessible after the contactor and disconnector have been opened and earthed.CPT. There are test ports located on the fuse holders. CPT‟s up to 2 kVA are available. The VT is mounted on the floor behind the contactor and in front of the CPT.  CPT Fuse Holder Motorpact IEC_E_V0R8.Always test these fuses with a properly rated high voltage voltmeter to insure they are de-energized before removing.Components Load Compartment .Instrument Transformer . Danger . VT  Optional 300 VA single phase CPT in each contactor compartment for operating the contactor. Rated 100 VA.ppt Tony Narusevicius 02/2005 3 7 . 3 phase. The CPT is mounted on the floor behind the contactor. Optional single molded 3 phase open delta connected VT.  Not permitting the contactor to be closed unless:  The disconnector is closed.interface with contactor interlocks (See page 39 & 40) Motorpact IEC_E_V0R8.Components Interlocks  Interlocks are mechanical parts to promote safe operation of the equipment by not permitting the disconnector to be closed or opened unless:  The contactor is open and the medium voltage door is closed and latched and the earthing switch (optional) is in the unearthed position. the medium voltage door is closed and the earthing switch (optional) is in unearthed position.  Verify Schematic) Lower Interlocks .  The contactor (test position)can be tested through auxiliary circuits that are supplied as part of the NEMA offer.ppt Tony Narusevicius 02/2005 3 8 . Components Interlocks Main Interlocks .interface with contactor interlocks Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 3 9 .Human interface (Escutcheon removed for clarity) Interlock connection linkage with lower contactor interlocks Cradle Lower Interlocks . ppt Tony Narusevicius 02/2005 Lower Interlocks 4 0 .Components Interlocks Disconnector Port Hasp Indicator arm is part of the interlocks and is attached to the operating shaft of the contactor Linkage blocks contactor interlocks Moving the Disconnector Port Hasp to the right moves the linkage as shown Upper Interlocks Motorpact IEC_E_V0R8. ppt Tony Narusevicius 02/2005 4 1 .Standard Configurations Motorpact IEC_E_V0R8. Full Voltage Non Reversing .  375 mm wide Motorpact IEC_E_V0R8.Standard Configurations FVNR .ppt Tony Narusevicius 02/2005 4 2 .Mechanical  FVNR . It contains the following major components connected in series:    Disconnector “HRC fuses Vacuum contactor  Configuration is also known as a combination motor starter.Full Voltage Non Reversing motor controller is the most common motor controller configuration. Door D. E.Mechanical K A: LV Control Entry B: Inter-unit Wireway C: LV Compartment. LV Instrument Compartment. MV Compartment.Standard Configurations FVNR . 120 VAC Test Plug (typically NEMA) F: Operator Panel G: Load Terminal Pads H. mounted on disconnector) O: Disconnector P: Rear Access Covers (top & bottom) Q: Power Fuses R: Full Height Cable Pull Area S: LPCT or CT T: CPT and VT A B M C D N E O F G H P Q R S I J T L Motorpact IEC_E_V0R8. Door I: Vacuum Contactor J: CPT and VT Fuses K: Top Cable Entry Plate L. Arc Resistant Vent Flaps (optional) M: Surge Arrester location (not shown) N: Main busbar location (not shown.Full Voltage Non Reversing .ppt Tony Narusevicius 02/2005 4 3 . Electrical G Disconnector  IFU These diagram examples are taken from the following standard drawings which are not included in the presentation.Standard Configurations FVNR .ppt Tony Narusevicius 02/2005 FVNR Control Circuit 4 4 .  46033-641-00 .  46033-752-00 .Full Voltage Non Reversing . CPT 42M MFR CT FVNR 3-Line Diagram Motorpact IEC_E_V0R8.FVNR Control Circuit. They are shown for reference purposes only.FVNR 3-Line Diagram. ppt Tony Narusevicius 02/2005 Run Contactor Start Contactor Autotransformer 4 5 .Reduced Voltage AutoTransformer . They start the motor on reduced voltage.Mechanical  RVAT .  RVAT module is available in 1125 mm and 1500 mm width depending on the size of the autotransformer.  Autotransformer is shipped separately  NEMA also has a 750 mm enclosure Motorpact IEC_E_V0R8.  The Start and Run Contactors are in the top.module contains the autotransformer in the bottom compartment.Standard Configurations RVAT .  Main contactor and disconnector are located in the adjacent 375 mm wide cubicle .  50/60 Hz 375 mm Main 1125 mm or 1500mm Module Motorpact IEC_E_V0R8. taps are generally not supplied. 42%. The auto transformer is usually designed with a specific voltage reduction to start the specific motor.  In the IEC market.  The RVAT module doors are key interlocked with the main contactor and disconnector.ppt Tony Narusevicius 02/2005 4 6 . taps of 50%.Standard Configurations RVAT . 65%. and 64% of rated voltage starting torque. and 80% of rated voltage produces starting torque of 25%.Mechanical  Typically in the NEMA markets.  Surge protection is included.Reduced Voltage AutoTransformer . Reduced Voltage AutoTransformer .Mechanical A: Arc Resistant Vent Cover (optional) B: LV Control Cable Entry Plate C: MV Upper Door D: Run Contactor E: Start Contactor F: LV Door G: MV Lower Door H: Drawout Cradle I: Main busbar Compartment J: Main busbar Access Cover K: Earth busbar L: Door Interlock M: Autotransformer Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 4 7 .Standard Configurations RVAT .   46033-794-00 .Electrical These diagram examples are taken from the following standard drawings which are not included in the presentation.RVAT Control Circuit.RVAT 3-Line Diagram.ppt Tony Narusevicius 02/2005 RVAT Control Circuit 4 8 . Note: Closing Coil Driver connected for 30ms drop-out (42M) and Closing Coil Driver connected for 300ms drop-out (42S & 42R). RVAT 3-Line Diagram Motorpact IEC_E_V0R8.Reduced Voltage AutoTransformer .Standard Configurations RVAT . 46033-697-00 . They are shown for reference purposes only.  The main contactor and disconnector are located in the adjacent 375 mm cubicle. It bypasses the electronic module once the motor has reached speed. Soft Start Bypass Contactor RVSS SCR Stack Assembly Motorpact IEC_E_V0R8.  RVSS module is 750 mm wide.Mechanical  RVSS .  Bypass contactor is located in the top.Reduced Voltage Soft Start . They are for starting motors by electronically controlled reduced voltage.ppt Tony Narusevicius 02/2005 4 9 .Standard Configurations RVSS .module contains the 3 phase Soft Start Silicon Controlled Rectifier (SCR) stacks located in the bottom. Bypass Contactor Location  Electronic package by Motortronics Corp. Motorpact IEC_E_V0R8.  50 / 60 Hz  Benefits.ppt Tony Narusevicius 02/2005 5 0 .Reduced Voltage Soft Start . under current / load loss. The main contactor and disconnector must be locked open to open and access the auxiliary cubicle. phase imbalance SCR Stacks  For additional information refer to Instruction Bulletin 46032-700-04.Mechanical  The RVSS module doors are key interlocked with the main contactor and disconnector. to mention a few:    Door Interlock Reduced Torque Starting Smooth Acceleration Overload.  Protective relays and metering are built into the Soft Start module.Standard Configurations RVSS . thermal capacity. ppt Tony Narusevicius 02/2005 5 1 .Reduced Voltage Soft Start .Mechanical A: Arc Resistant Vent Cover (optional) B: LV Control Entry Plate C: MV Upper Door D: LV Door E: HMI Soft Start Control Interface Module F: MV Lower Door G: Heater H: Customer Conduit Wireway I: By-pass Contactor J: Earth Fault Board (optional) K: Terminal Control Board L: Main busbar Compartment M: earth busbar N: Control Power & CPU Boards O: Main busbar Access Cover P: LV Compartment Q: Door Interlock R: Ring Transformers S: Silicone Control Rectifier Stacks Motorpact IEC_E_V0R8.Standard Configurations RVSS . 1 6 7 8 9 Start Stop RVSS Control Circuit 5 2 .  46033-727-00 .Electrical Disconnector IFU CPT To Control Circuit VT Soft Start SCR CKTS 42M A B C Main Board (MB) Terminal Block BX 120 VAC 1 3 Contr TB MX 1 3 Contr TB 2 4 2 4 G 42M 42B MX BX 9 8 7 Phase A Phase Power B Phase Stack Power C Stack Power Stack 10 42B Soft Start TCB Board  Motor RVSS 3-Line Diagram Motorpact IEC_E_V0R8.Reduced Voltage Soft Start . They are shown for reference purposes only.Standard Configurations RVSS .RVSS 3-Line Diagram.RVSS Control Circuit.ppt Tony Narusevicius 02/2005 These diagram examples are taken from the following standard drawings which are not included in the presentation.  46033-721-00 . Reduced Voltage Soft Start .Standard Configurations RVSS .Electrical Magnetic Isolation = MV = 120V = 28V = Fiber Optic Gate Drive Sensing Systems LV Controls Motor Optical Isolation Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 5 3 . ppt Tony Narusevicius 02/2005 5 4 .Options Motorpact IEC_E_V0R8. Options Blown Fuse Indication  Blown Fuse Indication is optional.  Striker pin on end of power fuse actuates this blown fuse indicator assembly.ppt Tony Narusevicius 02/2005 5 5 .  Provides Mechanical and Electrical Indication of “Blown Fuse” Condition   2 Form C contacts can be used for: Blown Fuse Tripping (back-up protection for relay) Blown Fuse indication only   Viewing Window in MV Door for mechanical status indication  Available on all controller types Blown Fuse Indication Assembly Motorpact IEC_E_V0R8.  Assembly fits on top of power fuse clip assembly and couples to an insulated shaft that actuates a microswitch used to open the contactor or signal a fuse has blown. These capacitive dividers are mounted in a cylindrical insulator.Options Voltage Presence Indication System .   An additional option allows for capacitive dividers to be installed near the main busbar/line side of the disconnector. VPIS module  is located on the front of the escutcheon (operator panel) shown in the picture to the right. VPIS module for this application is mounted in the LV Compartment Door (Not Shown). (See Detail B on next page).ppt Tony Narusevicius 02/2005 .VPIS  VPIS is equipped with 3 neon lamps to indicate voltage presence  Basic Option. VPIS‟s are wired to capacitive dividers that are located on the load connection base. (Also see Detail A on next page). VPIS Module 5 6 Motorpact IEC_E_V0R8. L1 .B L1 . The voltage whenever the lamps are illuminated will be 40 600V. Escutcheon  Warning . VPIS Module Properly rated voltage sensing device must be used to ensure no voltage is present before performing any maintenance procedures.VPIS VPIS Module  VPIS test ports are located below the neon lamps and suitable for testing voltage with proper rated voltagesensing device.VPIS is not a replacement for testing of voltage prior to accessing the MV compartment.A L1 .ppt Tony Narusevicius 02/2005 5 7 .  Refer to Instruction Bulletin 46032-700-01 or 06. Capacitive dividers used for Main busbar/Line Side connected VPIS‟s.C Load Connection Base Capacitive dividers Motorpact IEC_E_V0R8.Options Voltage Presence Indication System .  Bolted interlocked rear panel to frame construction. and Rear). end sheets.  3 mm sheet metal end sheets.Lateral. and between frames  8 point latching door with heavy duty vault style door handle.  Caulking of seams throughout enclosure.Options Internal Arc Enclosure Type AFLR  Controllers can be provided with an arc-resistant Type AFLR rating up to 50 kA on all four sides (Front. rear panels. MV door.  Top and bottom access panels.  Compartmentalized construction. roof. Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 5 8 . Tunnel (plenum) can also be available.  Natural interlocking of door hinge side.  Gasketing throughout enclosure.  Pressure relief vent flaps for venting. ppt Tony Narusevicius 02/2005 . Pressure Relief Vent Flaps Bolted Interlock Rear Panel Interlocking Hinge Side Open door viewing window (IEC standard) 5 9 Motorpact IEC_E_V0R8.Options Internal Arc Enclosure Type AFLR 8 point latching door with heavy duty vault style door handle. Earthing Switch Port Hasp    When conditions are met. Shuttle  Turning the handle clockwise opens the earthing switch Motorpact IEC_E_V0R8. the shuttle is moved to the right.  The earthing switch is interlocked and cannot be closed until:   the contactor is in the open position. the disconnector is open and in earthed position. the disconnector operating access port is closed.Options Earthing Switch Assembly  Earthing switch is to earth the load cables. the earthing switch access port can be opened and the handle inserted to close the earthing switch  Approximately 10 turns counterclockwise of the handle closes the switch and earths the cables.ppt Tony Narusevicius 02/2005 Disconnector Port Hasp 6 0 . Options Earthing Switch Assembly  The earthing switch is housed within the insulating base (load box).  The earthing switch is a spring operated quick making device.  A single earth bar is located behind the face of the load box and is forced by springs to simultaneously engage all three phase fingers attached to the customer‟s load terminal pads.  Refer to Instruction Bulletin 46032-70006 for additional operation and safety instructions. Motorpact IEC_E_V0R8.2 kV 5 times.  It earths the energy in cables. motor or transformer.  No interrupting capability. capable of closing 5kA symmetrical current ( 14 kA peak) at 7.ppt Tony Narusevicius 02/2005 Load Box Earth Bar Earthing Switch Springs 6 1 . 20-21) „ALARM' (1NCNO. F. E. Each temperature sensor has 3 sensor heads for attaching to the busbar. Motorpact IEC_E_V0R8.5 mm2.ppt Tony Narusevicius 02/2005 6 2 . B. D. G F E  A. Temperature buildup setting switches Ambient temperature correction setting switch Red indicators (6) identifying the sensor (zone A or B) and the circuit/sensor at the origin of the alarm Green power „on‟ indicator and red 'wrench' fault indicator Power supply terminals 24-250 V dc and 110-240 V ac Module grounding terminal A C B D G. The DT1 system consists of a MDT107 electronic module (readout) and (2) CFO733 temperature sensors. Relay output dry contact connection terminals „PRE-ALARM‟ (1NO. Refer to Instruction Bulletin 46032-700-01 or 06 for rating and operation. C.Options DT1 Thermal Diagnostic System   This system provides a means of monitoring and indicating conductor temperature rises in the controllers so corrective action can be initiated for a preset alarm or opening the contactor if over temperatures occur. The MDT107 module mounts in the LV compartment. 22-23-24)  Terminals 25 and 26 not used  The module's screw type connectors accept 2 wires with maximum cross-section of 2. Options DT1 Thermal Diagnostic System Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 6 3 . the back light illuminates the blades of the disconnector for visual inspection through the viewing port. Back light pushbutton Viewing port Motorpact IEC_E_V0R8.  The batteries should be replaced every four years for proper operation.  Remove the escutcheon to access batteries.Options Back Light  The back light assembly consists of LED‟s.ppt Tony Narusevicius 02/2005 6 4 . a pushbutton and batteries. When the back light pushbutton is pressed.  Busbar connections:  Controller Bay 375 mm” Wide FVNR Incoming Section 500mm wide Motorpact IEC_E_V0R8.  Pull Box -430 mm High. – Top or Bottom Entry. VisiVac and Model 4 motor controllers. Located in lineup.Options Enclosure Incoming Section Incoming Cable Connection  Cable connections:  Incoming Line Sections – 1250.  500mm Left and Right Located in lineup. HVL/cc. 2500 or 3150A. – 500 mm or 750 mm wide.  750 mm” Left. Direct busbar connection to other MV equipment via transitions to MCset. MasterClad. Center and Right. – Bottom Entry only.ppt Tony Narusevicius 02/2005 6 5 . HVL. VPIS (optional) J: Surge Arresters (optional) K: Earth busbar L: Main busbar Lug Pad M: Earth (earth) Riser Connection N: Current Transformer (optional) O: MV Cable Support Clamps (bottom entry) Motorpact IEC_E_V0R8.Options Enclosure Incoming Section Internal Arc Vent Cover (optional) B: LV Control Cable Entry Plate C: MV Upper Barrier D: MV Upper Door E: MV Lower Door F: VPIS Indicator Box (optional) G: MV Lower Barrier H: LV Inter-cubicle Top Wireway I: Capacitive Divider.ppt Tony Narusevicius 02/2005 6 6 . Contactor Operation Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 6 7 . Pull rail assembly down. to rack contactor into final connected position (approximately.ppt Tony Narusevicius 02/2005 6 8 . Push contactor into cell unit until the contactor stops.Contactor Operation Installing and Removing Contactor  The disconnector must be in the open position to open the medium voltage door for installation or removal of the contactor. Pull rail handle up. Lift contactor to remove from rails. 10 kg force).  To Remove Contactor:    Contactor Rail Assembly shown pulled down Motorpact IEC_E_V0R8. Contactor will disconnect from the contacts. Place contactor on rails. Pull contactor out from the cell on the rail assembly.  To Install Contactor:     Pull rail assembly down. Contactor Operation Closing Contactor without an earthing switch Assembly  Close and latch the medium voltage door  Slide the disconnector access port hasp to the right  Install disconnector handle in port and rotate handle clockwise to close disconnector  Slide the disconnector access port hasp to the left  Press the “RUN” pushbutton on disconnector front operator cover to close contactor Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 6 9 .  Remove handle and close disconnector port.  Remove handle & close earthing switch port.  Close and latch MV door. Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 7 0 .  Slide shuttle to right.  Slide shuttle to left.Contactor Operation Closing Contactor with optional earthing switch Assembly  Check that earthing switch is earthed.  Open disconnector port.  Insert handle and rotate clockwise to move disconnector blades from earthed to closed.  Open earthing switch port. Shuttle Earthing Switch Port Hasp Disconnector Port Hasp  Press “RUN” pushbutton on pushbutton panel above disconnector to close contactor.  Insert operating handle and rotate 10 turns clockwise to open earthing switch.  Mechanically Latched Only When control power is not available.ppt Tony Narusevicius 02/2005 7 1 .Contactor Operation Opening the Contactor  To electrically open the contactor press the “STOP” pushbutton on front of the Disconnector operator panel. Motorpact IEC_E_V0R8. to open the contactor press the mechanical trip button on the medium voltage door. ppt Tony Narusevicius 02/2005 7 2 .Contactor Operation Contactor Closing Coil Voltage & Current Motorpact IEC_E_V0R8. Initial Startup (General Information) Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 7 3 . – Verify mechanical and electrical interlocks work on each cubicle. RVAT.   Verify that the controller nameplate information matches motor nameplate data concerning nominal voltage. CPT‟s. etc. Obtain and study all instruction bulletins. Verify correctly rated CT‟s..Initial Start-up Preparation  Prior to Start     Obtain Protective and overload relay settings from the customer. and VT‟s are installed per drawings. obtain a laptop computer and software (Sepam or other) for loading and testing relay settings. relays and other components being installed. – Equipment is installed level and bolted or welded to the pad. cubicle by cubicle. etc.ppt Tony Narusevicius 02/2005 .  Inspect controllers for proper installation – Shipping skids are removed. tools. meters. are removed from the equipment. HP. FLA. RVSS) associated with the motor controllers being installed. Report any damage. If Sepam or other electronic relay is supplied. – Check that all litter. Obtain and study all drawings (FVNR. leaflets for motor controllers. 7 4 Motorpact IEC_E_V0R8.  At Start-up  Inspect equipment for shipping and/or handling damage. LPCT‟s. If RVSS is supplied. install and verify that Soft Start controller settings are correct per customer‟s specifications. Motorpact IEC_E_V0R8. This simulates the motor starting on reduced voltage. proceed cubicle by cubicle with the following:     Verify that all low voltage connections are tight and insulation is clean. Connect test power through test plug.ppt Tony Narusevicius 02/2005 7 5 . 42S NC contact to close and pick up RR. Do not energize high voltage circuit. pressing the start button should cause the relays and contactors to pick up in this sequence: ISR. – Removing the CTR jumper causes the SR relay to drop out. ISR to drop out. – Placing a jumper across the CTR contact. If RVAT is supplied. Test that the START and STOP pushbuttons close and open the contactors. verify closing and opening sequences of relays and contactors are correct. 42S to drop out. 42R. Start relay SR and start contactor 42S should be open. MR. Hi-pot low voltage wiring at 1200 VAC for 1 second to verify insulation is good. 42M. SR. This simulates the motor running on full voltage with main contactor 42M and run contactor 42R main contacts closed in series with the motor. Note: Special training is required to set Soft Start controllers. 1CR.Initial Start-up Low Voltage Circuits  With high voltage source disconnected and earthed and all LV sources disconnected.    Pressing the stop button should drop out all relays and contactors. 42S. Initial Start-up Setting and Testing Protective Relays  Install Sepam.  Test Sepam relays and actually trip the contactor by injecting simulated overcurrents (10 to 50 amps) into the CT secondary terminals on each phase which feed the relay. Follow testing instructions as outlined in Sepam Bulletin 63230-216-208B1.ppt Tony Narusevicius 02/2005 7 6 . settings per customer specifications.  Separate training for setting and testing Sepam relays is recommended. and/or testing in a Windows environment. A laptop computer and Sepam software # SFT2841PC is recommended for installing. SPT2842 parameter setting and operating software SPT2826 disturbance recording display software  When relay is fed from LPCT‟s. Refer to Sepam manual. or other protective relay.   Sepam 1000+ base unit with fixed advanced UMI CCA783 Measure and record relay times. Motorpact IEC_E_V0R8. or changing relay settings. test Sepam relay by injecting currents through an ACE917 adapter. High voltage connections are tight. All barriers are correctly installed. The autotransformer is field installed. Verity motor terminals are connected to correct phases for required direction of rotation. Refer to Instruction Bulletin 46032700-06. size and quantity/phase per customer specifications. Verify taps are set on same tap on each phase.Initial Start-up High Voltage Circuits  Check each cubicle for the following:  Power fuses are the correct size per the drawing for that cubicle and that they have continuity.         Motorpact IEC_E_V0R8. Insulation is clean and undamaged. verify RVAT or RVSS cubicles are connected per drawings. Verify Lightning Arresters (LA‟s) are installed correctly. Load cable connections are tight.ppt Tony Narusevicius 02/2005 7 7 . If supplied. Verify motor cables type. Initial Start-up High Voltage Circuits  Continued:  With contactor open and out of cell; hi-pot across vacuum interrupters at 10 kV AC for 1 minute to verify vacuum is good. If vacuum is lost, bottle will flash over internally and it will be easy to open contact by pressing on insulating flange. With contactor closed; hi-pot contactor at 10 kV AC for 1 minute phase to phase and phase to earth to verify insulation is good. Test all the contactors. Hi-pot main busbar at 2X rated voltage for 1 minute line to line and line to earth per instructions given under preventive maintenance to verify insulation is good. Disconnect VT‟s, CPT‟s and LA‟s during test. Close disconnectors during this test. Close all doors and panels during this test. Megger motor leads with 5 kV megger and verify motor circuit insulation is good. Disconnect test control power cord from controls. Reinstall contactors, control fuses, VT and CPT fuses. Energize the main busbar from actual source and verify voltage magnitude and phase sequence are correct. Measure phase sequence with phase meter on VT secondaries. 7 8      Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 Initial Start-up High Voltage Circuits  Continued:  With the motor mechanically disconnected from the load for each motor, bump each motor momentarily to verify that the direction of rotation is correct. With correct motor direction confirmed for each motor, again disconnect all high and low voltage from the switchgear and open all contactors and disconnectors. Connect the motors to the loads mechanically. Make one final check that all litter, tools, etc. are removed from the equipment. Close all doors and install panels. Energize the switchgear with high voltage and low voltage. Start-up is complete. Motors are ready to start.        Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 7 9 Corrective Maintenance Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 8 0 Verify that the disconnector is fully earthed. Check that the Shuttle is fully to the right Check that the earthing switch (if supplied) is open.  Cannot close the disconnector. Verify that medium voltage door is closed and the door handle is fully engaged (vertical). Verify that key interlock keys are properly turned.  VPIS will not illuminate. Check that the medium voltage door is closed.  Cannot open the disconnector access port.        Cannot operate the earthing switch. Verify that the contactor is open. Verify that the disconnector access ports are closed.Corrective Maintenance Troubleshooting General Troubleshooting Condition  Cannot open the medium voltage door. Motorpact IEC_E_V0R8. Check that the disconnector is open. Verify that the medium voltage door is closed.ppt Tony Narusevicius 02/2005 8 1 . Verity that the incoming cable is energized.  Cannot operate the disconnector. Test for voltage using a properly rated voltage-sensing device on two of the test ports on the VPIS.  Cannot close the disconnector access port. Check that the earthing switch is closed.           Action Make sure the disconnector is earthed. Check that the medium voltage door is closed. Verify that key interlock keys are properly turned. Check for loose plug connector in low voltage compartment.Corrective Maintenance Troubleshooting Mechanism Troubleshooting Condition  Cannot Close the contactor electrically. Check for loose terminal connections. Verify that the Disconnector access port is closed. Check for loose terminal connections. Check the coil circuit.      Action Verify that the Disconnector is closed. Check the electrical interlocks (see equipment drawings).ppt Tony Narusevicius 02/2005 8 2 .          Cannot open a mechanically latched contactor electrically. Check control fuses. Check the electrical interlocks (see Equipment drawings). Check linkage to the contactor and contactor interlock arm assembly on the contactor for binding or hanging. Check for loose plug connector in low voltage compartment. Check control fuses. Motorpact IEC_E_V0R8. Check the coil circuit. Motorpact IEC_E_V0R8. rotate the fuse body slightly to help ease the fuse Note: Refer to Instruction Bulletin ferrule out of the lower fuseholder (see 46032-700-01 or 06 for additional figure to right). Grasp fuse by the lower end.ppt Tony Narusevicius 02/2005 8 3 . Open the contactor. Close the earthing switch (if installed). Place the disconnector in the earthed position. While gently pulling the fuse.Corrective Maintenance Parts Replacement . Rotate fuse and lubricate the fuse clips with Mobil® 28 red grease. information and for use of optional      Fuse Tool.Replacing Power Fuses  Removal of Fuses:  Always use a properly rated voltage sensing device to confirm that power is off and wear personal protective equipment appropriate for the hazard when handling the fuses. pull the fuse down to remove the fuse from the upper fuseholder.continued:  After fuse has been removed from the lower fuseholder. Motorpact IEC_E_V0R8.Replacing Power Fuses  Removal of Fuses .  Gently push while rotating the body to ease fuse into the fuseholder.  Insert fuse ferrule into the upper fuse holder.  Insert the lower end of fuse into the lower fuseholder.ppt Tony Narusevicius 02/2005 8 4 . (Striker pin assembly must always point upward). Note: Never insert both ends at once Note: Refer to Instruction Bulletin 46032-700-01 or 06 for additional information and for use of optional Fuse Tool.  Grasp fuse by the upper end.  Installation of Fuses:  Lubricate fuse clips with Mobil® 28 red grease.Corrective Maintenance Parts Replacement . Wear Gauge (supplied) Vacuum Interrupter Conductive Nut 41.5 mm “A” (M8 nut) Insulating flange Main Contact gap adjustment of the Vacuum Interrupter Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 8 5 .Replacing and Adjusting Vacuum Interrupter  Replacing an interrupter assumes the interrupter has been determined to be defective by failing a 10 kV AC Hi-pot test or other means.5 mm is obtained.  The main contact gap for new interrupters is set by turning the insulating flange until a gap of 41. This is necessary to make the contacts close simultaneously on all three phases.  Refer to Contactor Instruction Bulletin 46032-700-02 for instruction on replacement and/or adjustment to the Vacuum Interrupter.Corrective Maintenance Parts Replacement .  Equally important is to reset the gap dimension on interrupters not replaced. Corrective Maintenance Parts Replacement .ppt Tony Narusevicius 02/2005 8 6 .Replacing Trip Latch Armature Contactor Spring Washer Hex-Bolt (M6 x 12) Bolt (M8 x 16) Bolt (M8 x 16) Spring Washer Washer (Large) Roller Assembly Spring Washer Trip Coil Base of Contactor Coil Rating Latch Assembly Motorpact IEC_E_V0R8. ppt Tony Narusevicius 02/2005 8 7 .Preventive Maintenance Motorpact IEC_E_V0R8. Preventive Maintenance Cell Interlocks  Inspect and verify that cell interlocks are functioning properly. Prevent opening the contactor medium voltage door if the disconnector is closed. the contactor is open. Prevent closing the earthing switch (if supplied) if the disconnector is closed. and the earthing switch (if supplied) is in the earthed position.ppt Tony Narusevicius 02/2005 8 8 .   Motorpact IEC_E_V0R8. With the contactor in connected position. cell interlocks should:  Prevent closing the disconnector if the MV compartment access door is closed. Clean and lube main contact stabs lightly with Mobil® 28 red grease. 8 9 Motorpact IEC_E_V0R8. Verify main contact fingers on rear of contactor align with stabs in cell.Preventive Maintenance Contactor  With the contactor removed from the cell:        Inspect HV connections and disconnectfingers for discoloration or other signs of overheating. Verify LV harnesses are firmly secured. Should take approximately 25 to 30 lbs. Tighten or replace parts as needed to correct. Do not lubricate black plastic bearings on ends of contactor armature shaft.ppt Tony Narusevicius 02/2005 . They are self lubricated. Tighten or replace parts as needed. Refer to Instruction manual 46032-700-02 for torque values. of force maximum on racking handle to engage main contacts if contacts are properly aligned. Inspect and insure LV connections are tight. If vacuum is lost.7 mm thick wear gauge cannot be inserted With contactor open. hi-pot contactor at 10 kV AC for 1 minute phase to phase and phase to ground to verify insulation is good.Preventive Maintenance Contactor  With the contactor removed from the cell:  Upper Flange      With contactor closed.ppt Tony Narusevicius 02/2005 9 0 . hi-pot across vacuum interrupters at 10 kV AC for 1 minute to verify vacuum is good. Observe if auxiliary contacts work and do not show evidence of overheating.7 mm Minimum Insulating Flange Motorpact IEC_E_V0R8. Replace as needed. bottle will flash over internally and it is easy to open contact by pressing on insulating flange. Replace interrupter(s) if 2. With contactor closed. measure contact wear of each interrupter. Coil color should remain yellow and not be turning brown or black. Inspect contactor closing coils and trip coils for mechanically latched contactors. for evidence of overheating. Refer to Instruction manual 46032-700-02 Lower Flange Shaft Wear Gauge (supplied) 2. Between the right hand cubicle side sheet and the fuses for double barrel fuse applications. Loadbox flexible barrier (removable) Loadbox flexible barrier (non-removable) CPT barrier (non-removable) Loadbox Flexible Barriers Motorpact IEC_E_V0R8.Preventive Maintenance Barriers  Verify all barriers are properly in place to meet 60 kV BIL impulse requirements:  Required barriers are located:    Over the load cable terminations at the load termination box mounted on the left hand side of the cubicle.ppt Tony Narusevicius 02/2005 9 1 . Above the CPT at the rear of the cell.  For front accessible only enclosures you must access the main busbar through the low voltage compartment (refer to illustration on next page).Preventive Maintenance Main busbar  De-energize the primary (high voltage) and secondary circuits (control circuits).  Replace damaged insulation or insulators as needed. remove the outer panel and inner barrier from the rear of the enclosure to access the main busbar compartment.  Inspect main busbar insulation and insulators for cracks. eliminate water leak source. Accessing the busbar compartment in rear accessible FVNR enclosure Motorpact IEC_E_V0R8. treeing or other evidence of insulation damage of deterioration.  If insulation is wet or damp. If insulation is dirty wipe clean. (refer to illustration to the right).ppt Tony Narusevicius 02/2005 9 2 .  For rear accessible enclosures. Remove the Main busbar Access Panel in the Low Voltage Compartment on FVNR Motorpact IEC_E_V0R8.  Prior to hi-potting the main busbar:        Remove the contactors from each cell. Close MV compartment doors.  Replace any damaged parts. (Can be jumped prevent fuse damage) Remove the VT fuses and CPT‟s. Disconnect the LA‟s. The earthing switch (if installed) must be in the open position. Do Not remove the power fuses for this testing.ppt Tony Narusevicius 02/2005 9 3 .Preventive Maintenance Main busbar Continued  Inspect busbar and joints for overheating such as discoloration.  Check and tighten all busbar connections to 50 Nm. Close the disconnector to the “ON” position in each cell... Preventive Maintenance Main busbar Continued Insulated Main busbar  Hi-pot the main busbar line to line and line to earth at 2X nominal volts AC for 1 minute to verify main busbar insulation is good.ppt Tony Narusevicius 02/2005 9 4 . or back fed through one of the contactor cells. The test voltage can be injected directly on the main busbar. after defeating the interlocks. Motorpact IEC_E_V0R8.  Reconnect LA‟s. reinstall VT fuses and CPT‟s on completion of testing.  Refer to Instruction Bulletin 46032700-01 or 06 for additional instruction. it is mandatory that a temporary jumper be placed across the CT at the CT terminal block An open circuited CT can generate thousands of volts on the secondary terminals if the primary winding is carry any current. male and female pins on blue connectors on rear of contactor:       Replace faulty lights and meters.Preventive Maintenance Low Voltage Controls  Prior to de-energizing the equipment for maintenance:  Verify that all meters and indicator lights are working and functioning properly. Crimp tool turret head Insert tool Remove tool Male pin Female pin #9501-0 #9502-1 #9099-0-0-0 #9081-0-0-0 #MC114NR #FC114NR Jumpers Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 9 5 . Verify that all low voltage controls work electrically and mechanically.     Note:  Following tools/parts needed to install and crimp 25 amp. Check that all LV connections are tight. Clean LV wiring and compartment as needed.  Danger: If any CT secondary circuit is opened for any reason during maintenance.  During shutdown of equipment.  Refer to Sepam Instruction Bulletin 63230-216-208B1.ppt Tony Narusevicius 02/2005 9 6 .  Current injection testing is recommended to verify Sepam relays work correctly when the motor controllers are commissioned. They continuously test themselves.Preventive Maintenance Protective Relays  Sepam overcurrent relays do not require periodic preventive maintenance or secondary current injection test to verify if relays are working. Sepam 1000+ base unit with fixed advanced UMI CCA783 SPT2842 parameter setting and operating software SPT2826 disturbance recording display software Motorpact IEC_E_V0R8. ppt Tony Narusevicius 02/2005 9 7 .Motor Currents Reference Chart Motorpact IEC_E_V0R8. =. EFF.Motor Currents Reference Chart HP 300 350 400 450 500 600 700 800 900 1000 1250 1500 1750 2000 2250 2500 3000 3500 4000 4500 5000 FLA 6 X FLA 2400 VOLT 75 449 87 524 100 599 112 674 125 749 150 898 175 1048 200 1198 225 1348 250 1497 312 1872 374 2246 437 2620 499 2995 561 3369 624 3743 749 4492 873 5240 998 5989 1123 6738 1248 7486 15 SEC 3R 3R 4R 4R 5R 6R 9R 12R 13R 16R 2 X 9R 2 X 12R 2 X 13R 2 X 16R 2 X 19R 3 X 16R HP 300 350 400 450 500 600 700 800 900 1000 1250 1500 1750 2000 2250 2500 3000 3500 4000 4500 5000 FLA 6 X FLA 4160 VOLT 43 259 50 302 58 346 65 389 72 432 86 518 101 605 115 691 130 777 144 864 180 1080 216 1296 252 1512 288 1728 324 1944 360 2160 432 2591 504 3023 576 3455 648 3887 720 4319 15 SEC 2R 2R 2R 3R 3R 3R 4R 4R 5R 6R 9R 13R 16R 19R 2 X 9R 2 X 9R 2 X 13R 2 X 16R 2 X 19R 3 X 16R 3 X 16R PF=.ppt Tony Narusevicius 02/2005 9 8 .85 30 SECONDS MAX ACCELERATION TIME Motorpact IEC_E_V0R8.85. ppt Tony Narusevicius 02/2005 9 9 .Instruction Bulletins Motorpact IEC_E_V0R8. Model 1 (Series A) Motorpact 200/400/450A Vacuum Contactors Class 8198 Motorpact Medium Voltage Soft Start Motorpact Medium Voltage Motor Controllers. Global (Series B) Motorpact Application Guide Sepam 1000+ Model 20 Digital Relay Bulletin Number 46032-700-01 46032-700-02 46032-700-04 46032-700-06 Comments Model 1 (Series A) Only Bulletin applies to both Model 1 and Global Global (Series B) Only 8198DB0101 Sales Bulletin 63230-216-208B1 Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 1 0 .Instruction Bulletins Description Motorpact Medium Voltage Motor Controllers. ppt Tony Narusevicius 02/2005 1 0 .Abbreviations Motorpact IEC_E_V0R8. Abbreviations                 BIL Basic Impulse Level CT Current Transformer CPT Control Power Transformer FLA Full Load Ampere FVNR Full Voltage Non Reversing HMI Human Machine Interface HP Horse Power HV High Voltage kV Kilo Volt KVAC Kilo Volt Alternating Current LA Lightning Arrester earthing switch earthing switch Assembly VPIS Voltage Presence Indication System LPCT Low Power Current Transducer LV Low Voltage MV Medium Voltage        O/L RMS RVAT RVSS SCR VA VT Over Load Root Mean Square Reduced Voltage AutoTransformer Reduced Voltage Soft Start Silicon Controlled Rectifiers Volt Ampere Voltage Transformer (Potential Transformer) Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 1 0 . Hands On Workshop Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 1 0 . ppt Tony Narusevicius 02/2005 1 0 .Hands On Workshop              BIL Test Operate Interlocks Defeat Interlocks Install & Operate Contactor Replace Fuses Operate earthing switch Install Trip Latch Measure Interrupter wear Replace Vacuum Interrupter Hi-pot & Test controls Set & Test Sepam Relay Set & Test Soft Start Controller Review DT1 Temperature Monitor System Motorpact IEC_E_V0R8. ppt Tony Narusevicius 02/2005 1 0 .Addendum Motorpact IEC_E_V0R8. secure the escutcheon and barrier with four screws and washers (2 at top and 2 on the bottom). Reference Assembly Drawing. Do not tighten any screws until pin is seated in slide. 5 Motorpact IEC_E_V0R8. 46035-439-53. Push onto Upper Interlocks. 2. Align Escutcheon with hasps and all other features.Addendum Installation of Escutcheon  Equipment State:    Contactor open Disconnector open Earthing switch closed 1.ppt Tony Narusevicius 02/2005 1 0 . a. 6. 5. b. Once the escutcheon is in place. Verify engagement by attempting to move the slide with your finger. 4. Open both the Low Voltage and Medium Voltage Doors. Make sure that the Indicator pin is seated in the Indicator Slide. 3. CUT Note: Uses of a thin sharp tool will be needed to fit between the bottom of the escutcheon and the top of the MV Door. Cut two pieces off bottom flange of the escutcheon.Addendum Removal of Escutcheon when MV door cannot be opened  Option 1 (Preferred) : 1.ppt Tony Narusevicius 02/2005 1 0 . Pull escutcheon forward to remove. 2. Remove two top screws from upper flange of escutcheon. Motorpact IEC_E_V0R8. 3. 5. Cut escutcheon horizontally from side to side just below the viewing window. 2.ppt Tony Narusevicius 02/2005 1 0 . Relieve any condition that keeps the MV door from opening. Cut Motorpact IEC_E_V0R8. remove the 2 screws in the bottom flange of the escutcheon. Once MV door is open. 4. Remove the 2 bolts from the top of the escutcheon.Addendum Removal of Escutcheon when MV door cannot be opened  Option 2: 1. 3. Remove the top half of the escutcheon. 2.ppt Tony Narusevicius 02/2005 Figure 2 1 0 . earthing switch Threaded Coupler earthing switch Operator Leadscrew Thread the coupler down to the jam nut (do not tighten) BEFORE threading the coupler onto the operator leadscrew. but do not tighten (Figure 2). down to the Jam Nut. turn the Jam Nut on the earthing switch Rod Weldment to position it 7mm . 1/4”-3/8” (7mm – 10mm) Exposed Threads Jam Nut earthing switch Rod Weldment Figure 1 Motorpact IEC_E_V0R8.Addendum Earthing Switch Adjustment 1. Thread the earthing switch Coupler onto the earthing switch Rod Weldment. With the earthing switch assembly in the closed (earthed) position.10mm (1/4” .3/8”) from the bottom of the threads (Figure 1). 8 turns. Top (head) of the Operator Leadscrew (Figure 3). thread the Coupler on to the earthing switch Operator Leadscrew @ 3 . Continue turning the Operator SLOWLY until resistance is evident. Visually observe the position of each of the following: a. the pivot link tops out against the rod keeper before the Leadscrew tops out.Addendum Earthing Switch Adjustment 3. then the earthing switch Coupler must be backed off (counter clockwise) from the Leadscrew to achieve the proper setting. Motorpact IEC_E_V0R8. If instead. After 7 . With the earthing switch Operator Leadscrew in the lowered position. 4. Turn (crank) the earthing switch Operator clockwise to move the earthing switch to the open “Loaded” position. causing the rod keeper to bend or flex.it should be near it‟s upper limit of travel. Position of the earthing switch Pivot Link to the earthing switch Rod Keeper (Figure 4).4 full turns. b.ppt Tony Narusevicius 02/2005 1 1 . visually check the position of the top (head) of the earthing switch Operator Leadscrew . THE PROPER ADJUSTMENT FOR THE OPEN “LOADED POSITION IS ACHIEVED WHEN THE TOP (HEAD) OF THE LEADSCREW TOPS OUT AT MAXIMUM TRAVEL IN THE EARTHING SWITCH OPERATOR HOUSING (FIGURE 3) AT THE SAME TIME THE EARTHING SWITCH PIVOT LINK TOPS OUT (OR STOPS) AGAINST THE EARTHING SWITCH ROD KEEPER (FIGURE 4). then the operator leadscrew can be lowered until the coupler is accessible with a 13mm open end wrench and incremental adjustments made until proper setting is achieved.ppt Tony Narusevicius 02/2005 1 1 .Addendum Earthing Switch Adjustment Leadscrew topped out (Max. Travel) in the earthing switch Operator Housing earthing switch Pivot Link position against the Rod Keeper – Rod Keeper should NOT Bend or Flex Slot Link Rod Keeper earthing switch Operator Housing Pivot Link Figure 3 Figure 4 The relationship of the pivot link to the operator leadscrew is controlled by the turning of the coupler. Motorpact IEC_E_V0R8. If such a tool is not available. A 13mm crowfoot wrench with a socket extension can be used to access and adjust the coupler while the operator leadscrew is in the top (maximum) position. The pivot link should not move until the slot link has traveled to the opposite end of the slot and has bottomed out against the screw/ bushing on the rod keeper (Figure 5). the jam nut must be tightened against the coupler with a 13mm open end wrench. When the proper earthing switch open “Loaded” adjustment is achieved.8 turns.ppt Tony Narusevicius 02/2005 1 1 . 6. turn the earthing switch Operator counterclockwise to move the earthing switch to the closed (earthed position. Continue to Slowly turn the earthing switch Operator until the earthing switch assembly closes quickly (fires) to the earthed position (Figure 6) and the earthing switch door interlock retracts to allow opening of the Medium Voltage door. Motorpact IEC_E_V0R8.Addendum Earthing Switch Adjustment 5. There should be no evidence of binding or resistance during closure/earthing of the earthing switch assembly. After 7 . start visually observing the movement of the pivot link. When all adjustment are complete and proper earthing switch function is achieved. against the pivot screw/ bushing BEFORE the (2.) Slot Link (2.Addendum Earthing Switch Adjustment (1.) pivot link moves away from the rod keeper. Tighten jam nut against coupler when adjustments are complete (1.) Pivot Link earthed Position: Indicator Pin is Bottomed Out in Radial Slot Figure 5 Figure 6 Motorpact IEC_E_V0R8.) Slot Link must travel to opposite (bottom) end.ppt Tony Narusevicius 02/2005 1 1 . Open medium voltage door and defeat interlocks. 3. Inspect the pivot lever attached to the left side sheet for deformation and function. If deformed replace with new part 46032-907-02. 2. Pivot Lever Motorpact IEC_E_V0R8.ppt Tony Narusevicius 02/2005 1 1 .Addendum Pivot Lever not Releasing Interlocks 1.     . 9**' #
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