training - motorpact
TRANSCRIPT
-
8/4/2019 Training - Motorpact
1/114
MotorpactMV motor starters
Field Service Training Presentation
-
8/4/2019 Training - Motorpact
2/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
Motorpact Medium VoltageMotor Controllers
Field Service Training Presentation
Open Page for providing Instructor Information,
Course Identification Number, Etc.
-
8/4/2019 Training - Motorpact
3/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
Outline
Outline 3-8
Objective 9
Safety Precaution Notice 10-11
Introduction 12-13
Main Features. 14-15 Model 1 vs Global Design 16
Applicable Standards & Certification 17
Controller Types 18
Controller Applications 19
Contactor Ratings. 20
Enclosure and Busbar Ratings 21
-
8/4/2019 Training - Motorpact
4/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 4
Outline
Components 22 Low Voltage Compartment. 23-24
Operator Panel. 25-26
Disconnector . 27
Busbar Compartment.. 28
Load Compartment.. 29-37
Overview. 29
Contactor Cable Connection 30
Load Cable Termination 31
Power Fuses 32
Contactor. 33-34
Instrument Transformer - CT, LPCTs, CPT, VT... 35-37
Interlocks. 38-40
Without earthing switch installed
With earthing switch installed
-
8/4/2019 Training - Motorpact
5/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
Outline
Standard Configurations 41
FVNR - Full Voltage Non Reversing.. 42-44
Mechanical.. 42-43
Electrical.. 44
RVAT - Reduced Voltage Auto Transformer. 45-48
Mechanical.. 45-47
Electrical.. 48
RVSS - Reduced Voltage Soft Start.. 49-52
Mechanical.. 49-51
Electrical.. 52
-
8/4/2019 Training - Motorpact
6/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 6
Outline
Options 54 Blown Fuse Indication.. 55
Voltage Presence Indication System - VPIS 56-57
Internal Arc Class Enclosure. 58-59
Earthing Switch Assembly 60-61
MDT107 Thermal Diagnostic System 62-63
Back Light 64
Enclosure Incoming Section. 65-66
Contactor Operation 66
Installing and Removing the Contactor.. 68
Closing the Contactor 69-70
Without earthing switch installed.. 69
With earthing switch installed 70
Opening the Contactor. 71
Electrically and Mechanically 71
Closing Coil Voltage & Current 72
-
8/4/2019 Training - Motorpact
7/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 7
Outline
Initial Start-up (General Information). 73 Preparation. 74
Low Voltage Circuits. 75
Setting and Testing Protective Relays 76
High Voltage Circuits. 77-79
Corrective Maintenance.. 80
Troubleshooting. 81-82
General. 81
Mechanism 82
Parts Replacement 83-86
Replacing Power Fuses. 83-84
Replacing & Adjusting Vacuum Interrupter. 85
Replacing Trip Latch 86
Preventive Maintenance. 87
Cell Interlocks 88
Contactor .. 89-90
-
8/4/2019 Training - Motorpact
8/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 8
Outline
Preventive Maintenance (continued) Barriers 91
Main busbar 92-93
Low Voltage Controls 95
Protective Relays.. 96
Motor Currents - Reference chart 97-98
Instruction Bulletins 99-100
Abbreviations 101-102
Hands-on Workshop 103-104
Addendum 105
Installation of Escutcheon. 106
Removal of Escutcheon 107-108 Earthing Switch Adjustment Procedure 109-113
Pivot Lever not Releasing Interlocks.. 114
-
8/4/2019 Training - Motorpact
9/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 9
Objective
The objective of this training is to prepare Schneider Field ServiceEngineers on the servicing of Motorpact medium voltage motorcontrollers.
Training in this presentation will cover:
an introduction to Motorpact (FVNR, RVAT, 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.
-
8/4/2019 Training - Motorpact
10/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Safety Precaution NoticeDANGER: Hazard of Electrical Shock, Explosion or Arc Flash
Only qualified employees who can recognize and can avoid hazards associatedwith Medium Voltage Systems and are familiar with the its construction andoperation should operate, test, calibrate, maintain or trouble shoot this equipment.
The information in this presentation is not a replacement for switchgear instructionmanuals or component manuals. Always refer to the appropriate instructiondocumentation provided by Schneider Electric and other suppliers prior to servicingequipment. It is the intent of this manual to provide an overview of MotorpactMedium Voltage Motor Control Equipment.
It is assumed preventive or corrective maintenance is performed on the switchgearat intervals of 1 to 5 years depending on severity of operating conditions.
All Instructions contained within this presentation assume no preventive or correctivemaintenance will be done until the switchgear has been placed in an electrically safecondition.
All sources of energy and loads have been identified.
The loads have been removed then proper disconnects have been opened.
-
8/4/2019 Training - Motorpact
11/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
1
Safety Precaution NoticeDANGER: Hazard of Electrical Shock, Explosion or Arc Flash
The disconnects have been locked out, tagged out,
Then tested for absence of voltage, using properly rated test equipmentand personal protective equipment.
And busbar is earthed using procedures appropriate for the equipment.
All low voltage circuits are de-energized and tested to insure no voltage ispresent.
Control fuses are removed.
Qualified persons must wear appropriate personal protectiveequipment (PPE) and follow safe electrical work practices wheneverworking on or near exposed energized parts. See NFPA 70E orServices Electrical Safety Procedure latest editions.
Always read and understand HAZARD labels provide on the equipmentand in documentation.
-
8/4/2019 Training - Motorpact
12/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
2
Introduction
-
8/4/2019 Training - Motorpact
13/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
3
Introduction
Motorpact is the name of the new line of 3 phase 50/60 Hzmedium voltage motor controller released by Smyrna, 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 becausethey do so at lower cost than low voltage motor controllers. P=E*I,when E is large, I is smaller. Therefore, cables can be smaller and
less expensive. I2R losses are also less, so operating costs areless. In some cases the cost of MV to LV transformers can beeliminated.
-
8/4/2019 Training - Motorpact
14/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
4
IntroductionMain Features
Main features of Motorpact motor controllers are as follows: Rated 2400 to 7200 volts AC, line to line, 50/60 hertz.
Motor Ranges are from 75 kW (100 hp) to 3800 kW (5,100 hp).
Motor Types - Induction (Squirrel Cage).
Enclosure Types.
IP3X
IP4X
NEMA1
NEMA1A or NEMA 1 Gasketed
Internal Arc Classification Type AFLR available as an option.
Main busbar tin plated copper as standard with ratings up to 3150A.
Two basic contactor types available.
Standard - magnetically held closed.
Optional - mechanically latched closed.
-
8/4/2019 Training - Motorpact
15/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
5
IntroductionMain Features
Contactors are rated 200, and 400 amperes continuous (450NEMA)
Controller interlocked for safe operation.
Standard controller cubicle width is 375 mm
500 mm and 750 mm - NEMA only
One high construction only, 950 mm deep by 2300 mm high.
Metric hardware supplied as standard.
Earthing switch available as an option
VPIS available as an option.
MDT107 thermal monitoring system available as an option.
-
8/4/2019 Training - Motorpact
16/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
6
IntroductionModel 1 vs Global Design
Motorpact units built prior to February 2004 are referred to as theModel 1 (Series A) product. Motorpact units built after February2004 are referred to as the Global (Series B) product. Thefollowing chart identifies the differences between the two designs.
Feature Model 1 Global Comments
Market NEMA NEMA & IEC
LV Compartment Drawout Panel Fixed Panel
Top Wireway NoneMounted above LV
Compartment
Contactor Truck Track need cubicle width need cubicle width Not Interchangeable
Built Prior Feb. 1, 2004 After Feb. 1, 2004
-
8/4/2019 Training - Motorpact
17/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
7
IntroductionApplicable Standards & Certification
Applicable IEC standards (STL qualification) IEC 60694 Common specification for high-voltage switchgear and controlgear IEC 62271-200 AC metal-enclosed switchgear and controlgear for rated voltage above
1 kV and up to and including 52 kV(replaces IEC 60298 standard)
IEC 60470 High voltage alternating current contactors and contactor based motorstarters
IEC 60282-1 High voltage fuses: limiting fuses IEC 62271-102 Alternating current disconnectors and earthing switches IEC 60255 Electrical relays IEC 60044-1 Instrument transformers - Part 1: current transformers IEC 60044-2 Instrument transformers - Part 2: voltage transformers IEC 60044-8 Instrument transformers - Part 8: low power current transformers IEC 61958 High-voltage prefabricated switchgear and controlgear assemblies
Voltage Presence Indicating Systems
Other standards UL 347, CSA 22.2, #14 and #31, NEMA ICS 3 part 2, EEMAC E14-1 IBC 2000 Seismic Standards E11 International Association Of Classification Societies (Marine)
Other certification cULus UL certification to NEMA and CSA standards
-
8/4/2019 Training - Motorpact
18/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
8
IntroductionController Types
Direct On Line (FVNR) Non-reversing
Mechanically latched
Reduced Voltage Non-Reversing(RVSS, RVAT)
Motorpact SoftStart
Auto Transformer
-
8/4/2019 Training - Motorpact
19/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
9
IntroductionController Applications
Compressor
Pump
Chiller
Fan
Conveyor
Chipper
Transformer Feeder
Capacitor Feeder
-
8/4/2019 Training - Motorpact
20/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
0
IntroductionContactor Ratings
Minimum Voltage (kV) 2.4Max. Design Voltage (kV) 7.2
BIL (kV) 60
Frequency (Hz) 50/60
Continuous Amps 200/400A
Electrical Endurance (number of operations) 250,000
Mechanical Endurance (number of operations):
Standard
Latched type only
2,500,000
250,000
Short Circuit Interrupting Amps (RMS Sym.) 5000
Short Circuit Withstand at Rated Voltage (kA peak) 60
Short Time Rating (kA) Symmetrical:
1 Second
30 Seconds
7.5
3.0
Chopping Current (Average RMS Amps) 0.5
Switching Frequency (Ops Per Hour):
Standard
Latched type only
1200
300
Maximum Closing Time 80 ms or Less
Maximum Opening Time 25 ms or Less
-
8/4/2019 Training - Motorpact
21/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
1
IntroductionEnclosure and busbar Ratings
Minimum Line to Line Voltage (kV) 1.0
Maximum Line to Line Design Voltage (kV) 7.2
BIL (kV) up to 3300 feet (1000 m) 60
Frequency (Hz) 50/60
Continuous Amps 200/400A
Short Circuit Withstand at Rated Voltage (kA Peak) Main Bus toFuse Line Side Terminal
130
Short Time Rating (kA) Symmetrical:Main Bus (2 Seconds)
0.25 Second through IM to Main Power Fuse
50
50
Dielectric Withstand (kV 1 Minute) 20
Disconnector Mechanical Life 5000
-
8/4/2019 Training - Motorpact
22/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
2
Components
-
8/4/2019 Training - Motorpact
23/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
3
ComponentsLow 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
Top Wireway
Provides termination point for LVfield wiring
Provides a 3 passage inter-unitWireway for Communication,Control and LV Power
-
8/4/2019 Training - Motorpact
24/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
4
ComponentsLow Voltage Compartment
-
8/4/2019 Training - Motorpact
25/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
5
ComponentsOperator Panel
Disconnector Closed Disconnector Open
-
8/4/2019 Training - Motorpact
26/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
6
ComponentsOperator Panel
A: Contactor Control Panel
B: Voltage Presence Indication System - VPIS(optional)
C: Push Button for Back Light (optional)
D. Disconnector Viewing Port.
E. Indicator of Disconnector Status
F: Location for Earthing Switch OperationPadlock (optional)
G: Disconnector Operating Access Port
H. Earthing Switch operating Access Port
(optional)
I: Location for Disconnector Operation Padlock
J: Interlock Shuttle (Not provided in Model 1)
K: Procedure Pictogram
A
BC
D
G
J
E
I
H
F
K
-
8/4/2019 Training - Motorpact
27/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
7
ComponentsDisconnector
Means for disconnecting controllerfrom the line or source to allow forinspection and testing.
Two position - Closed and Earthed.
Non-load break device
can interrupt CPT loads to 7 kVA
Mechanical interlock with contactor.
Viewing window for visual inspectionof the contacts. Light is available asan option.
Endurance - 5000 operations.
Arc-resistant, flame-retardanthousing.
Supports top fuse holders.
-
8/4/2019 Training - Motorpact
28/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
8
ComponentsBusbar 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
-
8/4/2019 Training - Motorpact
29/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 2
9
ComponentsLoad Compartment Overview
Load Termination Box
Power Fuses
Vacuum Contactor
LPCT or CT
CPT and VT
CPT and VT Fuses
-
8/4/2019 Training - Motorpact
30/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
0
ComponentsLoad Compartment - Contactor Cable Connection
Contactor connected to cabletermination pads
Single non-spliced InsulatedFlexible busbar System
Eliminates Joints and
Maintenance
Uses a 360 radial-Swaged cold-fused Compression Connectionat all Terminal Ends
Maintenance Free
High Reliability
-
8/4/2019 Training - Motorpact
31/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
1
ComponentsLoad Compartment - Load Cable Termination
Front Access or Front and RearAccessibility
Full Height Cable Pulling Area
Load Cable Box allows for up to1-240 mm2 or 2-120 mm2
Shielded Cables /
Features a Formex flap over
cable terminations
Provides dielectric protection atthe cable terminations
-
8/4/2019 Training - Motorpact
32/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
2
ComponentsLoad Compartment - Power Fuses
Power Fuses provide short circuitprotection for motor controller.
Independently mounted from Contactor
Easy to inspect and maintain
Optional Insertion and Removal Tool
-
8/4/2019 Training - Motorpact
33/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
3
ComponentsLoad Compartment - Contactor
A device for starting and stopping large 3phase motors and interrupting lockedrotor currents when required.
200 A, 400 A, 450 A
DC solenoid operated
3 NO and 3 NC auxiliary contacts
furnished as standard. Lightweight at approximately 20 kg
Magnetically Held or MechanicallyLatched
Closing coils energized via an electronicdrive unit that reduces the coil currentelectronically approximately 200
milliseconds after closing coils areenergized. Dip switch on drive unitallows closing coils to be energized fromdiscreet voltages of 100 to 250 volts, ACor DC.
-
8/4/2019 Training - Motorpact
34/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
4
ComponentsLoad Compartment - Contactor
ContactorConnectedPosition
ContactorRailExtended
ContactorWithdrawnPosition
-
8/4/2019 Training - Motorpact
35/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
5
ComponentsLoad Compartment - Instrument Transformer - CT, LPCT, CPT, VT
LPCT or CTmounted on contactorfixed contact mouldassembly
Optional VT for protectionand metering(floor mounted)Optional fused CPT(floor mounted)
CPT and VT fuses are enclosed(Easily accessible from the front)(floor mounted)
-
8/4/2019 Training - Motorpact
36/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 3
6
ComponentsLoad Compartment - Instrument Transformer - CT, LPCT
3 CTs are cast together as a 3phase assembly
Mounted behind the primary stabsin the rear of contactorcompartment.
The CT leads are permanently
attached to the CTs. There areno screw connections on the CTs
in the rear. CT connections aremade in the LV compartment.
LPCT provides low voltage (mV)output, proportional to load
current, directly to Sepam relays. Caution: CT boots (white tubes)
required to pass 60 kV BIL. Donot remove.
CT Leads
CT
CT Boot
-
8/4/2019 Training - Motorpact
37/114
-
8/4/2019 Training - Motorpact
38/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 38
ComponentsInterlocks
Interlocks are mechanical parts topromote safe operation of the equipmentby not permitting the disconnector to beclosed or opened unless:
The contactor is open and the mediumvoltage door is closed and latched and the
earthing switch (optional) is in theunearthed position.
Not permitting the contactor to be closedunless:
The disconnector is closed, the mediumvoltage door is closed and the earthingswitch (optional) is in unearthed position.
The contactor (test position)can be testedthrough auxiliary circuits that are suppliedas part of the NEMA offer.
Verify Schematic)Lower Interlocks - interface withcontactor interlocks (See page 39 & 40)
-
8/4/2019 Training - Motorpact
39/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 39
ComponentsInterlocks
Main Interlocks - Human interface(Escutcheon removed for clarity)
Interlock connection linkagewith lower contactor interlocks
Cradle
Lower Interlocks - interface withcontactor interlocks
-
8/4/2019 Training - Motorpact
40/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 40
ComponentsInterlocks
Upper Interlocks Lower Interlocks
Linkage blockscontactor interlocks
Indicator arm is part of the interlocksand is attached to the operating shaft
of the contactorDisconnector Port Hasp
Moving the Disconnector PortHasp to the right moves thelinkage as shown
-
8/4/2019 Training - Motorpact
41/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 41
Standard Configurations
-
8/4/2019 Training - Motorpact
42/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 42
Standard ConfigurationsFVNR - Full Voltage Non Reversing - Mechanical
FVNR - Full Voltage NonReversing motor controller is themost common motor controllerconfiguration. It contains thefollowing major components
connected in series: Disconnector
HRC fuses
Vacuum contactor
Configuration is also known as acombination motor starter.
375 mm wide
-
8/4/2019 Training - Motorpact
43/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 43
Standard ConfigurationsFVNR - Full Voltage Non Reversing - Mechanical
A: LV Control Entry
B: Inter-unit Wireway
C: LV Compartment. Door
D. LV Instrument Compartment.
E. 120 VAC Test Plug (typically NEMA)
F: Operator Panel
G: Load Terminal Pads
H. MV Compartment. Door
I: Vacuum ContactorJ: 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, mounted ondisconnector)
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
K
J
I
H
G
F
E
D
B
C
A
T
S
L
M
N
O
P
Q
R
-
8/4/2019 Training - Motorpact
44/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 44
Standard ConfigurationsFVNR - Full Voltage Non Reversing - Electrical
FVNR 3-Line Diagram FVNR Control Circuit
These diagram examples are taken from
the following standard drawings which arenot included in the presentation. They areshown for reference purposes only.
46033-752-00 - FVNR 3-Line Diagram. 46033-641-00 - FVNR Control Circuit.
GDisconnector
IFU
CPT
CT
42M
MFR
-
8/4/2019 Training - Motorpact
45/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 45
Standard ConfigurationsRVAT - Reduced Voltage AutoTransformer - Mechanical
RVAT - module contains theautotransformer in the bottomcompartment.
The Start and Run Contactors arein the top. They start the motor onreduced voltage.
Main contactor and disconnectorare located in the adjacent 375 mmwide cubicle .
RVAT module is available in 1125mm and 1500 mm width dependingon the size of the autotransformer.
Autotransformer is shippedseparately
NEMA also has a 750 mmenclosure
Run Contactor
Start Contactor
Autotransformer
-
8/4/2019 Training - Motorpact
46/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 46
Standard ConfigurationsRVAT - Reduced Voltage AutoTransformer - Mechanical
Typically in the NEMA markets, taps of50%, 65%, and 80% of rated voltageproduces starting torque of 25%, 42%, and64% of rated voltage starting torque.
In the IEC market, taps are generally notsupplied. The auto transformer is usuallydesigned with a specific voltage reductionto start the specific motor.
The RVAT module doors are keyinterlocked with the main contactor anddisconnector.
Surge protection is included.
50/60 Hz375 mm
Main1125 mm or 1500mm
Module
-
8/4/2019 Training - Motorpact
47/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 4
7
Standard ConfigurationsRVAT - 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 busbarL: Door Interlock
M: Autotransformer
-
8/4/2019 Training - Motorpact
48/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 4
8
Standard ConfigurationsRVAT - Reduced Voltage AutoTransformer - Electrical
RVAT 3-Line Diagram RVAT Control Circuit
Note: Closing Coil Driver connected for 30ms drop-out (42M)and Closing Coil Driver connected for 300ms drop-out (42S & 42R).
These diagram examples are taken fromthe following standard drawings whichare not included in the presentation.
They are shown for reference purposesonly.
46033-794-00 - RVAT 3-Line Diagram.
46033-697-00 - RVAT Control Circuit.
-
8/4/2019 Training - Motorpact
49/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 4
9
Standard ConfigurationsRVSS - Reduced Voltage Soft Start - Mechanical
RVSS - module contains the 3phase Soft Start SiliconControlled Rectifier (SCR) stackslocated in the bottom. They arefor starting motors byelectronically controlled reducedvoltage.
Bypass contactor is located inthe top. It bypasses theelectronic module once the motorhas reached speed.
The main contactor and
disconnector are located in theadjacent 375 mm cubicle.
RVSS module is 750 mm wide.
Soft StartBypass Contactor
RVSS SCRStack Assembly
-
8/4/2019 Training - Motorpact
50/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
0
Standard ConfigurationsRVSS - Reduced Voltage Soft Start - Mechanical
The RVSS module doors are keyinterlocked with the main contactor anddisconnector. The main contactor anddisconnector must be locked open to openand access the auxiliary cubicle.
Electronic package by Motortronics Corp.
Protective relays and metering are built intothe Soft Start module.
50 / 60 Hz
Benefits, to mention a few:
Reduced Torque Starting
Smooth Acceleration
Overload, thermal capacity, undercurrent / load loss, phase imbalance
For additional information refer to InstructionBulletin 46032-700-04.
Door Interlock
SCR Stacks
Bypass ContactorLocation
-
8/4/2019 Training - Motorpact
51/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
1
Standard ConfigurationsRVSS - 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 ContactorJ: 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 CompartmentQ: Door Interlock
R: Ring Transformers
S: Silicone Control Rectifier Stacks
-
8/4/2019 Training - Motorpact
52/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
2
RVSS 3-Line Diagram RVSS Control Circuit
GDisconnector
CPT
To ControlCircuit
IFU
VTA
B
C
Main Board (MB)Terminal Block42M
42B
Soft StartSCR CKTS
Motor
PhaseB
PowerStack
PhaseC
PowerStack
PhaseA
PowerStack
120 VAC
42M
42BBX
MX BX
ContrTB
ContrTB
1
1 2
2
3
3
4
4
10 9 8 7
Soft Start TCB Board
Start Stop
1 6 7 8 9
MX
Standard ConfigurationsRVSS - Reduced Voltage Soft Start - Electrical
These diagram examples are taken from thefollowing standard drawings which are notincluded in the presentation. They are shownfor reference purposes only.
46033-727-00 - RVSS 3-Line Diagram.
46033-721-00 - RVSS Control Circuit.
-
8/4/2019 Training - Motorpact
53/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
3
Standard ConfigurationsRVSS - Reduced Voltage Soft Start - Electrical
= MV
= 120V
= 28V
= Fiber Optic
GateDrive
SensingSystems
OpticalIsolation
MagneticIsolation
LVControls
Motor
-
8/4/2019 Training - Motorpact
54/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
4
Options
-
8/4/2019 Training - Motorpact
55/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
5
Blown Fuse Indication Assembly
OptionsBlown Fuse Indication
Blown Fuse Indication is optional.
Assembly fits on top of power fuse clipassembly and couples to an insulated shaftthat actuates a microswitch used to openthe contactor or signal a fuse has blown.
Striker pin on end of power fuse actuatesthis blown fuse indicator assembly.
Provides Mechanical and ElectricalIndication of Blown Fuse Condition
2 Form C contacts can be used for:
Blown Fuse Tripping (back-up protection forrelay)
Blown Fuse indication only
Viewing Window in MV Door for mechanicalstatus indication
Available on all controller types
-
8/4/2019 Training - Motorpact
56/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 5
6
OptionsVoltage Presence Indication System - VPIS
VPIS is equipped with 3 neon lamps toindicate voltage presence
Basic Option, VPIS module
is located on the front of the escutcheon(operator panel) shown in the picture tothe right. (Also see Detail A on nextpage).
VPISs are wired to capacitive dividersthat are located on the load connectionbase. (See Detail B on next page).
An additional option allows for capacitivedividers to be installed near the mainbusbar/line side of the disconnector.These capacitive dividers are mountedin a cylindrical insulator. VPIS modulefor this application is mounted in the LVCompartment Door (Not Shown).
VPIS Module
O
-
8/4/2019 Training - Motorpact
57/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 57
OptionsVoltage Presence Indication System - VPIS
VPIS test ports are locatedbelow the neon lamps andsuitable for testing voltagewith proper rated voltage-sensing device. Thevoltage whenever the lampsare illuminated will be 40 -600V.
Warning - VPIS is not areplacement for testing ofvoltage prior to accessingthe MV compartment.Properly rated voltagesensing device must beused to ensure no voltage is
present before performingany maintenanceprocedures.
Refer to Instruction Bulletin46032-700-01 or 06.
L1 - C
L1 - B
L1 - A
Load Connection Base
Capacitive dividers usedfor Main busbar/Line Sidconnected VPISs.
Capacitive dividers
Escutcheon
VPIS Module
VPIS Module
O i
-
8/4/2019 Training - Motorpact
58/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 58
OptionsInternal Arc Enclosure Type AFLR
Controllers can be provided with an arc-resistant TypeAFLR rating up to 50 kA on all four sides(Front,Lateral, and Rear).
Pressure relief vent flaps for venting. Tunnel (plenum)can also be available.
Gasketing throughout enclosure, roof, rear panels, end
sheets, MV door, and between frames 8 point latching door with heavy duty vault style door
handle.
Natural interlocking of door hinge side.
3 mm sheet metal end sheets.
Compartmentalized construction.
Bolted interlocked rear panel to frame construction.
Top and bottom access panels.
Caulking of seams throughout enclosure.
O i
-
8/4/2019 Training - Motorpact
59/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 59
Open door viewing window(IEC standard)
OptionsInternal Arc Enclosure Type AFLR
Pressure Relief Vent Flaps
Interlocking Hinge SideBolted Interlock Rear Panel
8 point latching door withheavy duty vault style doorhandle.
O ti
-
8/4/2019 Training - Motorpact
60/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 60
OptionsEarthing Switch Assembly
Earthing switch is to earth the load cables. The earthing switch is interlocked and
cannot be closed until:
the contactor is in the open position.
the disconnector is open and in earthedposition.
the disconnector operating access port isclosed.
the shuttle is moved to the right.
When conditions are met, the earthingswitch access port can be opened and thehandle inserted to close the earthing switch
Approximately 10 turnscounterclockwise ofthe handle closes the switch and earths thecables.
Turning the handle clockwise opens theearthing switch
Disconnector Port Hasp
Shuttle
Earthing SwitchPort Hasp
O ti
-
8/4/2019 Training - Motorpact
61/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 61
Load Box
Earthing SwitchSprings
Earth Bar
OptionsEarthing Switch Assembly
The earthing switch is housed withinthe insulating base (load box).
The earthing switch is a springoperated quick making device, capableof closing 5kA symmetrical current ( 14kA peak) at 7.2 kV 5 times.
No interrupting capability. It earths the energy in cables, motor or
transformer.
A single earth bar is located behind theface of the load box and is forced bysprings to simultaneously engage all
three phase fingers attached to thecustomers load terminal pads.
Refer to Instruction Bulletin 46032-700-06 for additional operation and safetyinstructions.
O ti
-
8/4/2019 Training - Motorpact
62/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 62
OptionsDT1 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 DT1 system consists of a MDT107 electronic module (readout) and (2) CFO733 temperature sensors.The MDT107 module mounts in the LV compartment. Each temperature sensor has 3 sensor heads forattaching to the busbar.
Refer to Instruction Bulletin 46032-700-01 or 06 for rating and operation.
A. Temperature buildup setting switches
B. Ambient temperature correction setting switch
C. Red indicators (6) identifying the sensor (zone A or B) and thecircuit/sensor at the origin of the alarm
D. Green power on indicator and red 'wrench' fault indicator
E. Power supply terminals 24-250 V dc and 110-240 V ac
F. Module grounding terminal
G. Relay output dry contact connection terminals PRE-ALARM
(1NO, 20-21) ALARM' (1NCNO; 22-23-24)
Terminals 25 and 26 not used
The module's screw type connectors accept 2 wires withmaximum cross-section of 2.5 mm2.
G FE
C
B
A
D
O ti
-
8/4/2019 Training - Motorpact
63/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 63
OptionsDT1 Thermal Diagnostic System
O ti
-
8/4/2019 Training - Motorpact
64/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 64
OptionsBack Light
The back light assembly consists ofLEDs, a pushbutton and batteries.When the back light pushbutton ispressed, the back light illuminatesthe blades of the disconnector forvisual inspection through theviewing port.
The batteries should be replacedevery four years for properoperation.
Remove the escutcheon to accessbatteries.
Back lightpushbutton
Viewingport
Options
-
8/4/2019 Training - Motorpact
65/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 65
Cable connections: Incoming Line Sections
1250, 2500 or 3150A.
500 mm or 750 mm wide.
500mm Left and RightLocated in lineup.
Bottom Entry only.
750 mm Left, Center andRight. Located in lineup.
Top or Bottom Entry.
Pull Box -430 mm High.
Busbar connections:
Direct busbar connection to
other MV equipment viatransitions to MCset,MasterClad, HVL, HVL/cc,VisiVac and Model 4 motorcontrollers.
OptionsEnclosure Incoming Section
Incoming Cable Connection
Controller Bay375 mm Wide FVNR
Incoming Section500mm wide
Options
-
8/4/2019 Training - Motorpact
66/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 66
OptionsEnclosure 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, 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)
-
8/4/2019 Training - Motorpact
67/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 67
Contactor Operation
Contactor Operation
-
8/4/2019 Training - Motorpact
68/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 68
Contactor OperationInstalling and Removing Contactor
The disconnector must be in theopen position to open the mediumvoltage door for installation orremoval of the contactor.
To Install Contactor:
Pull rail assembly down.
Place contactor on rails.
Push contactor into cell unit until thecontactor stops.
Pull rail handle up, to rack contactor intofinal connected position (approximately.10 kg force).
To Remove Contactor:
Pull rail assembly down. Contactor willdisconnect from the contacts.
Pull contactor out from the cell on therail assembly.
Lift contactor to remove from rails.Contactor Rail Assembly shown pulled down
Contactor Operation
-
8/4/2019 Training - Motorpact
69/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 69
Contactor OperationClosing Contactor without an earthing switch Assembly
Close and latch the medium voltage door
Slide the disconnector access port hasp tothe right
Install disconnector handle in port and rotatehandle clockwise to close disconnector
Slide the disconnector access port hasp tothe left
Press the RUN pushbutton on disconnector
front operator cover to close contactor
Contactor Operation
-
8/4/2019 Training - Motorpact
70/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 70
Contactor OperationClosing Contactor with optional earthing switch Assembly
Check that earthing switch is earthed.
Close and latch MV door.
Slide shuttle to right.
Open earthing switch port.
Insert operating handle and rotate 10 turns
clockwise to open earthing switch.
Remove handle & close earthing switch port.
Slide shuttle to left.
Open disconnector port.
Insert handle and rotate clockwise to move
disconnector blades from earthed to closed.
Remove handle and close disconnector port.
Press RUN pushbutton on pushbutton panel
above disconnector to close contactor. Earthing SwitchPort Hasp
Shuttle
DisconnectorPort Hasp
Contactor Operation
-
8/4/2019 Training - Motorpact
71/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 71
Contactor OperationOpening the Contactor
To electrically open the contactorpress the STOP pushbutton on
front of the Disconnector operatorpanel.
Mechanically Latched Only
When control power is notavailable, to open the contactorpress the mechanical trip button onthe medium voltage door.
Contactor Operation
-
8/4/2019 Training - Motorpact
72/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 72
Contactor OperationContactor Closing Coil Voltage & Current
-
8/4/2019 Training - Motorpact
73/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 73
Initial Startup
(General Information)
Initial Start-up
-
8/4/2019 Training - Motorpact
74/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 74
Initial Start-upPreparation
Prior to Start
Obtain Protective and overload relay settings from the customer.
If Sepam or other electronic relay is supplied, obtain a laptop computer and software(Sepam or other) for loading and testing relay settings.
Obtain and study all drawings (FVNR, RVAT, RVSS) associated with the motorcontrollers being installed.
Obtain and study all instruction bulletins, leaflets for motor controllers, meters, relays
and other components being installed.
At Start-up
Inspect equipment for shipping and/or handling damage. Report any damage.
Inspect controllers for proper installation
Shipping skids are removed.
Equipment is installed level and bolted or welded to the pad.
Check that all litter, tools, etc. are removed from the equipment.
Verify mechanical and electrical interlocks work on each cubicle.
Verify that the controller nameplate information matches motor nameplate dataconcerning nominal voltage, FLA, HP, etc., cubicle by cubicle.
Verify correctly rated CTs, LPCTs, CPTs, and VTs are installed per drawings.
Initial Start-up
-
8/4/2019 Training - Motorpact
75/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 75
Initial Start-upLow Voltage Circuits
With high voltage source disconnected and earthed and all LV sourcesdisconnected, proceed cubicle by cubicle with the following:
Verify that all low voltage connections are tight and insulation is clean.
Hi-pot low voltage wiring at 1200 VAC for 1 second to verify insulation is good.
Connect test power through test plug. Do not energize high voltage circuit.
If RVSS is supplied, install and verify that Soft Start controller settings are correct per
customers specifications. Note: Special training is required to set Soft Startcontrollers.
Test that the START and STOP pushbuttons close and open the contactors.
If RVAT is supplied, verify closing and opening sequences of relays and contactorsare correct.
Placing a jumper across the CTR contact, pressing the start button should cause the relaysand contactors to pick up in this sequence: ISR, 1CR, SR, 42S, MR, 42M. This simulates the
motor starting on reduced voltage. Removing the CTR jumper causes the SR relay to drop out, 42S to drop out, ISR to drop out,
42S NC contact to close and pick up RR, 42R. This simulates the motor running on fullvoltage with main contactor 42M and run contactor 42R main contacts closed in series withthe motor. Start relay SR and start contactor 42S should be open.
Pressing the stop button should drop out all relays and contactors.
Initial Start-up
-
8/4/2019 Training - Motorpact
76/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 76
Initial Start-upSetting and Testing Protective Relays
Install Sepam, or other protective relay, settingsper customer specifications. A laptop computerand Sepam software # SFT2841PC isrecommended for installing, or changing relaysettings, and/or testing in a Windowsenvironment.
Test Sepam relays and actually trip the contactor
by injecting simulated overcurrents (10 to 50amps) into the CT secondary terminals on eachphase which feed the relay.
Measure and record relay times.
Follow testing instructions as outlined in SepamBulletin 63230-216-208B1.
When relay is fed from LPCTs, test Sepam relayby injecting currents through an ACE917adapter. Refer to Sepam manual.
Separate training for setting and testing Sepamrelays is recommended.
Sepam 1000+base unit with fixedadvanced UMI
CCA783
SPT2842parameter settingand operating softwareSPT2826disturbance recordingdisplay software
Initial Start-up
-
8/4/2019 Training - Motorpact
77/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 77
Initial Start-upHigh Voltage Circuits
Check each cubicle for the following:
Power fuses are the correct size per the drawing for that cubicle and thatthey have continuity.
High voltage connections are tight.
Insulation is clean and undamaged.
Load cable connections are tight.
All barriers are correctly installed.
Verify motor cables type, size and quantity/phase per customerspecifications.
Verity motor terminals are connected to correct phases for requireddirection of rotation.
If supplied; verify RVAT or RVSS cubicles are connected per drawings.The autotransformer is field installed. Refer to Instruction Bulletin 46032-700-06. Verify taps are set on same tap on each phase.
Verify Lightning Arresters (LAs) are installed correctly.
Initial Start-up
-
8/4/2019 Training - Motorpact
78/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 78
Initial Start upHigh Voltage Circuits
Continued:
With contactor open and out of cell; hi-pot across vacuum interrupters at 10kV AC for 1 minute to verify vacuum is good. If vacuum is lost, bottle willflash over internally and it will be easy to open contact by pressing oninsulating flange. With contactor closed; hi-pot contactor at 10 kV AC for 1minute phase to phase and phase to earth to verify insulation is good. Testall the contactors.
Hi-pot main busbar at 2X rated voltage for 1 minute line to line and line toearth per instructions given under preventive maintenance to verifyinsulation is good. Disconnect VTs, CPTs and LAs 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 isgood.
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 magnitudeand phase sequence are correct. Measure phase sequence with phasemeter on VT secondaries.
Initial Start-up
-
8/4/2019 Training - Motorpact
79/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 79
Initial Start upHigh 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 iscorrect.
With correct motor direction confirmed for each motor, again disconnect allhigh and low voltage from the switchgear and open all contactors anddisconnectors.
Connect the motors to the loads mechanically.
Make one final check that all litter, tools, etc. are removed from theequipment.
Close all doors and install panels.
Energize the switchgear with high voltage and low voltage.
Start-up is complete.
Motors are ready to start.
-
8/4/2019 Training - Motorpact
80/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 80
Corrective Maintenance
Corrective Maintenance
-
8/4/2019 Training - Motorpact
81/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 81
Corrective MaintenanceTroubleshooting
General Troubleshooting
Condition Action
Cannot open the medium voltage door. Make sure the disconnector is earthed.
Verify that the disconnector access ports are closed.
Check that the earthing switch is closed.
Cannot close the disconnector. Verify that medium voltage door is closed and the door
handle is fully engaged (vertical).
VPIS will not illuminate.
Test for voltage using a properly rated voltage-sensingdevice on two of the test ports on the VPIS.
Verity that the incoming cable is energized.
Cannot operate the earthing switch. Check that the disconnector is open.
Check that the medium voltage door is closed.
Check that the Shuttle is fully to the right
Cannot operate the disconnector. Check that the earthing switch (if supplied) is open.
Check that the medium voltage door is closed.
Cannot open the disconnector accessport.
Verify that the contactor is open.
Verify that the medium voltage door is closed.
Verify that key interlock keys are properly turned.
Cannot close the disconnector accessport.
Verify that the disconnector is fully earthed.
Verify that key interlock keys are properly turned.
Corrective Maintenance
-
8/4/2019 Training - Motorpact
82/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 82
Corrective MaintenanceTroubleshooting
Mechanism TroubleshootingCondition Action Cannot Close the contactor electrically. Verify that the Disconnector is closed.
Verify that the Disconnector access port is closed.
Check for loose terminal connections.
Check for loose plug connector in low voltage compartment.
Check the coil circuit.
Check control fuses.
Check the electrical interlocks (see Equipment drawings).
Check linkage to the contactor and contactor interlock armassembly on the contactor for binding or hanging.
Cannot open a mechanically latchedcontactor electrically.
Check for loose terminal connections.
Check for loose plug connector in low voltage compartment.
Check the coil circuit.
Check control fuses.
Check the electrical interlocks (see equipment drawings).
Corrective Maintenance
-
8/4/2019 Training - Motorpact
83/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 83
Corrective MaintenanceParts Replacement - Replacing Power Fuses
Removal of Fuses:
Always use a properly rated voltagesensing device to confirm that power isoff and wear personal protectiveequipment appropriate for the hazardwhen handling the fuses.
Open the contactor.
Place the disconnector in the earthedposition.
Close the earthing switch (if installed).
Rotate fuse and lubricate the fuse clipswith Mobil 28 red grease.
Grasp fuse by the lower end. While
gently pulling the fuse, rotate the fusebody slightly to help ease the fuseferrule out of the lower fuseholder (seefigure to right).
Note: Refer to Instruction Bulletin46032-700-01 or 06 for additionalinformation and for use of optionalFuse Tool.
Corrective Maintenance
-
8/4/2019 Training - Motorpact
84/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 84
Corrective MaintenanceParts Replacement - Replacing Power Fuses
Removal of Fuses - continued:
After fuse has been removed fromthe lower fuseholder, pull the fusedown to remove the fuse from theupper fuseholder.
Installation of Fuses:
Lubricate fuse clips with Mobil 28
red grease. Grasp fuse by the upper end.
Insert fuse ferrule into the upperfuse holder. (Striker pin assemblymust always point upward).
Insert the lower end of fuse intothe lower fuseholder.
Gently push while rotating thebody to ease fuse into thefuseholder.
Note: Never insert both ends at once
Note: Refer to Instruction Bulletin 46032-700-01or 06 for additional information and for use ofoptional Fuse Tool.
Corrective Maintenance
-
8/4/2019 Training - Motorpact
85/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 85
Corrective MaintenanceParts Replacement - Replacing and Adjusting Vacuum Interrupter
Replacing an interrupter assumes theinterrupter has been determined to bedefective by failing a 10 kV AC Hi-pottest or other means.
Refer to Contactor Instruction Bulletin46032-700-02 for instruction onreplacement and/or adjustment to the
Vacuum Interrupter. The main contact gap for new
interrupters is set by turning theinsulating flange until a gap of 41.5mm is obtained.
Equally important is to reset the gap
dimension on interrupters notreplaced. This is necessary to makethe contacts close simultaneously onall three phases.
Main Contact gap adjustmentof the Vacuum Interrupter
41.5 mm
WearGauge
(supplied)
VacuumInterrupter
ConductiveNut
A (M8 nut)
Insulatingflange
Corrective Maintenance
-
8/4/2019 Training - Motorpact
86/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 86
Co ect e a te a ceParts Replacement - Replacing Trip Latch
Armature
Hex-Bolt (M6 x 12)
Spring Washer
Bolt (M8 x 16)
Spring Washer
Washer (Large)
Roller Assembly
Latch Assembly
Coil Rating
Base of Contactor
Trip Coil
Spring Washer
Bolt (M8 x 16)
Contactor
-
8/4/2019 Training - Motorpact
87/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 87
Preventive Maintenance
Preventive Maintenance
-
8/4/2019 Training - Motorpact
88/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 88
Cell Interlocks
Inspect and verify that cell interlocks are functioning properly.With the contactor in connected position, cell interlocks should:
Prevent closing the disconnector if the MV compartment access dooris closed, the contactor is open, and the earthing switch (if supplied) isin the earthed position.
Prevent opening the contactor medium voltage door if thedisconnector is closed.
Prevent closing the earthing switch (if supplied) if the disconnector isclosed.
-
8/4/2019 Training - Motorpact
89/114
Preventive Maintenance
-
8/4/2019 Training - Motorpact
90/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 90
Contactor
With the contactor removed from the cell:
With contactor closed, measure contact wear ofeach interrupter. Replace interrupter(s) if 2.7 mmthick wear gauge cannot be inserted
With contactor open, hi-pot across vacuuminterrupters at 10 kV AC for 1 minute to verifyvacuum is good. If vacuum is lost, bottle will flashover internally and it is easy to open contact by
pressing on insulating flange.
With contactor closed, hi-pot contactor at 10 kVAC for 1 minute phase to phase and phase toground to verify insulation is good.
Inspect contactor closing coils and trip coils formechanically latched contactors, for evidence ofoverheating. Coil color should remain yellow and
not be turning brown or black. Observe if auxiliary contacts work and do not
show evidence of overheating. Replace asneeded.
Refer to Instruction manual 46032-700-02
WearGauge
(supplied)
Shaft
LowerFlange
Upper
Flange
2.7 mmMinimum
InsulatingFlange
Preventive Maintenance
-
8/4/2019 Training - Motorpact
91/114
Motorpact IEC_E_V0R8.ppt -
Tony Narusevicius 02/2005 91
Barriers
Verify all barriers are properlyin place to meet 60 kV BILimpulse requirements:
Required barriers are located:
Over the load cableterminations at the loadtermination box mounted on
the left hand side of thecubicle.
Above the CPT at the rear ofthe cell.
Between the right handcubicle side sheet and thefuses for double barrel fuseapplications.
Loadboxflexible barrier(removable)
Loadboxflexible barrier(non-removable)
CPT barrier(non-removable)
Loadbox Flexible Barriers
Preventive Maintenance
-
8/4/2019 Training - Motorpact
92/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005
92
Main busbar
De-energize the primary (high voltage) and
secondary circuits (control circuits). For rear accessible enclosures, remove the
outer panel and inner barrier from the rearof the enclosure to access the main busbarcompartment. (refer to illustration to theright).
For front accessible only enclosures you
must access the main busbar through thelow voltage compartment (refer toillustration on next page).
Inspect main busbar insulation andinsulators for cracks, treeing or otherevidence of insulation damage ofdeterioration.
If insulation is wet or damp, eliminatewater leak source. If insulation isdirty wipe clean.
Replace damaged insulation orinsulators as needed.
Accessing the busbar compartment in rearaccessible FVNR enclosure
Preventive Maintenance
-
8/4/2019 Training - Motorpact
93/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005
93
Main busbar
Continued
Inspect busbar and joints foroverheating such as discoloration.
Check and tighten all busbarconnections to 50 Nm...
Replace any damaged parts.
Prior to hi-potting the main busbar:
Remove the contactors from eachcell.
Do Not remove the power fuses forthis testing. (Can be jumped preventfuse damage)
Remove the VT fuses and CPTs.
Disconnect the LAs.
Close MV compartment doors.
Close the disconnector to the ON
position in each cell.
The earthing switch (if installed) mustbe in the open position.
Remove the Main busbar Access Panelin the Low Voltage Compartment on FVNR
Preventive Maintenance
-
8/4/2019 Training - Motorpact
94/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005
94
Main busbar
Continued
Hi-pot the main busbar line to lineand line to earth at 2X nominal voltsAC for 1 minute to verify mainbusbar insulation is good. The testvoltage can be injected directly onthe main busbar, or back fed
through one of the contactor cells,after defeating the interlocks.
Reconnect LAs, reinstall VT fuses
and CPTs on completion of testing.
Refer to Instruction Bulletin 46032-700-01 or 06 for additional
instruction.
Insulated Main busbar
Preventive Maintenance
-
8/4/2019 Training - Motorpact
95/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005
95
Low Voltage Controls
Prior to de-energizing the equipment for
maintenance: Verify that all meters and indicator lights
are working and functioning properly.
During shutdown of equipment.
Replace faulty lights and meters.
Check that all LV connections are tight.
Clean LV wiring and compartment asneeded.
Verify that all low voltage controls workelectrically and mechanically.
Danger: If any CT secondary circuit isopened for any reason duringmaintenance, it is mandatory that atemporary jumper be placed across the
CT at the CT terminal block An opencircuited CT can generate thousands ofvolts on the secondary terminals if theprimary winding is carry any current.
Note:
Following tools/parts needed toinstall and crimp 25 amp. male andfemale pins on blue connectors onrear of contactor:
Crimp tool #9501-0
turret head #9502-1
Insert tool #9099-0-0-0 Remove tool #9081-0-0-0
Male pin #MC114NR
Female pin #FC114NR
Jumpers
Preventive Maintenance
-
8/4/2019 Training - Motorpact
96/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005
96
Protective Relays
Sepam overcurrent relays do not
require periodic preventivemaintenance or secondary currentinjection test to verify if relays areworking. They continuously testthemselves.
Current injection testing is
recommended to verify Sepamrelays work correctly when themotor controllers arecommissioned.
Refer to Sepam Instruction Bulletin63230-216-208B1.
Sepam 1000+base unit with fixedadvanced UMI
CCA783
SPT2842parameter setting
and operating softwareSPT2826disturbance recordingdisplay software
-
8/4/2019 Training - Motorpact
97/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 9
7
Motor Currents Reference Chart
Motor Currents
-
8/4/2019 Training - Motorpact
98/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 9
8
Reference Chart
HP FLA 6 X FLA 15 SEC HP FLA 6 X FLA 15 SEC
300 75 449 3R 300 43 259 2R350 87 524 3R 350 50 302 2R
400 100 599 4R 400 58 346 2R
450 112 674 4R 450 65 389 3R
500 125 749 5R 500 72 432 3R
600 150 898 6R 600 86 518 3R
700 175 1048 9R 700 101 605 4R
800 200 1198 12R 800 115 691 4R
900 225 1348 13R 900 130 777 5R
1000 250 1497 16R 1000 144 864 6R
1250 312 1872 2 X 9R 1250 180 1080 9R
1500 374 2246 2 X 12R 1500 216 1296 13R
1750 437 2620 2 X 13R 1750 252 1512 16R
2000 499 2995 2 X 16R 2000 288 1728 19R
2250 561 3369 2 X 19R 2250 324 1944 2 X 9R
2500 624 3743 3 X 16R 2500 360 2160 2 X 9R
3000 749 4492 3000 432 2591 2 X 13R
3500 873 5240 3500 504 3023 2 X 16R4000 998 5989 4000 576 3455 2 X 19R
4500 1123 6738 4500 648 3887 3 X 16R
5000 1248 7486 5000 720 4319 3 X 16R
PF=.85, EFF.=.85 30 SECONDS MAX ACCELERATION TIME
2400 VOLT 4160 VOLT
-
8/4/2019 Training - Motorpact
99/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 9
9
Instruction Bulletins
Instruction Bulletins
-
8/4/2019 Training - Motorpact
100/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Description BulletinNumber
Comments
Motorpact Medium Voltage MotorControllers, Model 1 (Series A)
46032-700-01 Model 1 (Series A) Only
Motorpact 200/400/450A VacuumContactors Class 8198
46032-700-02 Bulletin applies to bothModel 1 and Global
Motorpact Medium Voltage Soft
Start
46032-700-04
Motorpact Medium Voltage MotorControllers, Global (Series B)
46032-700-06 Global (Series B) Only
Motorpact Application Guide 8198DB0101 Sales BulletinSepam 1000+ Model 20 DigitalRelay
63230-216-208B1
-
8/4/2019 Training - Motorpact
101/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Abbreviations
Abbreviations
-
8/4/2019 Training - Motorpact
102/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
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 switchAssembly
VPIS Voltage Presence IndicationSystem
LPCT Low Power Current Transducer
LV Low Voltage
MV Medium Voltage
O/L Over Load
RMS Root Mean Square
RVAT Reduced Voltage AutoTransformer
RVSS Reduced Voltage Soft Start
SCR Silicon Controlled Rectifiers
VA Volt Ampere
VT Voltage Transformer
(Potential Transformer)
-
8/4/2019 Training - Motorpact
103/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Hands On Workshop
Hands On Workshop
-
8/4/2019 Training - Motorpact
104/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
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
-
8/4/2019 Training - Motorpact
105/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Addendum
AddendumInstallation of Escutcheon
-
8/4/2019 Training - Motorpact
106/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Installation of Escutcheon
Equipment State:
Contactor open
Disconnector open
Earthing switch closed
1. Reference Assembly Drawing. 46035-439-53.
2. Open both the Low Voltage and Medium Voltage Doors.
3. Align Escutcheon with hasps and all other features.4. Push onto Upper Interlocks.
5. Make sure that the Indicator pin is seated in the Indicator Slide.
a. Verify engagement by attempting to move the slide with your finger.
b. Do not tighten any screws until pin is seated in slide.
6. Once the escutcheon is in place, secure the escutcheon and barrier
with four screws and washers (2 at top and 2 on the bottom).
5
AddendumRemoval of Escutcheon when MV door cannot be opened
-
8/4/2019 Training - Motorpact
107/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Removal of Escutcheon when MV door cannot be opened
Option 1 (Preferred) :1. Cut two pieces off bottom flange of the escutcheon.
2. Remove two top screws from upper flange of escutcheon.
3. Pull escutcheon forward to remove.
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
AddendumRemoval of Escutcheon when MV door cannot be opened
-
8/4/2019 Training - Motorpact
108/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
Removal of Escutcheon when MV door cannot be opened
Option 2:
1. Cut escutcheon horizontally from side to side just below the viewing window.2. Remove the 2 bolts from the top of the escutcheon.
3. Remove the top half of the escutcheon.
4. Relieve any condition that keeps the MV door from opening.
5. Once MV door is open, remove the 2 screws in the bottom flange of the escutcheon.
Cut
AddendumEarthing Switch Adjustment
-
8/4/2019 Training - Motorpact
109/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
0
1/4-3/8(7mm 10mm)Exposed Threads
earthingswitchOperatorLeadscrew
earthing switchThreadedCoupler
earthing switchRodWeldment
Jam Nut
Thread the coupler down tothe jam nut (do not tighten)BEFORE threading thecoupler onto the operatorleadscrew.
Figure 1 Figure 2
Earthing Switch Adjustment
1. With the earthing switch assembly in the closed (earthed) position, turn the Jam Nut on the earthingswitch Rod Weldment to position it 7mm - 10mm (1/4 - 3/8) from the bottom of the threads (Figure 1).
2. Thread the earthing switch Coupler onto the earthing switch Rod Weldment, down to the Jam Nut, but do nottighten (Figure 2).
AddendumEarthing Switch Adjustment
-
8/4/2019 Training - Motorpact
110/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
1
Earthing Switch Adjustment
3. With the earthing switch Operator Leadscrew in the lowered position, thread the
Coupler on to the earthing switch Operator Leadscrew @ 3 - 4 full turns.4. Turn (crank) the earthing switch Operator clockwise to move the earthing switch
to the open Loaded position. After 7 - 8 turns, visually check the position of thetop (head) of the earthing switch Operator Leadscrew - it should be near itsupper limit of travel. Continue turning the Operator SLOWLY until resistance isevident. Visually observe the position of each of the following:
a. Top (head) of the Operator Leadscrew (Figure 3).
b. Position of the earthing switch Pivot Link to the earthing switch RodKeeper (Figure 4).
THE PROPER ADJUSTMENT FOR THE OPEN LOADED POSITION IS
ACHIEVED WHEN THE TOP (HEAD) OF THE LEADSCREW TOPS OUT ATMAXIMUM 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).
If instead, the pivot link tops out against the rod keeper before the Leadscrewtops out, causing the rod keeper to bend or flex, then the earthing switch Couplermust be backed off (counter clockwise) from the Leadscrew to achieve the propersetting.
AddendumEarthing Switch Adjustment
-
8/4/2019 Training - Motorpact
111/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
1
Earthing Switch Adjustment
The relationship of the pivot link to the operator leadscrew is controlled by the turning of the coupler.
A 13mm crowfoot wrench with a socket extension can be used to access and adjust the coupler while the operatorleadscrew is in the top (maximum) position. If such a tool is not available, then the operator leadscrew can be lowered untilthe coupler is accessible with a 13mm open end wrench and incremental adjustments made until proper setting is achieved.
Leadscrew topped out (Max.Travel) in the earthing switchOperator Housing
earthing switchOperator Housing
earthing switch Pivot Linkposition against the RodKeeper Rod Keepershould NOT Bend or Flex
Rod Keeper
Pivot Link
Slot Link
Figure 3 Figure 4
AddendumEarthing Switch Adjustment
-
8/4/2019 Training - Motorpact
112/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
1
Earthing Switch Adjustment
5. When the proper earthing switch open Loaded adjustment is achieved, turn the
earthing switch Operator counterclockwise to move the earthing switch to theclosed (earthed position. After 7 - 8 turns, start visually observing the movementof the pivot link. The pivot link should not move until the slot link hastraveled to the opposite end of the slot and has bottomed out against thescrew/ bushing on the rod keeper (Figure 5).
Continue to Slowly turn the earthing switch Operator until the earthing switch
assembly closes quickly (fires) to the earthed position (Figure 6) and the earthingswitch door interlock retracts to allow opening of the Medium Voltage door.There should be no evidence of binding or resistance during closure/earthing ofthe earthing switch assembly.
6. When all adjustment are complete and proper earthing switch function isachieved, the jam nut must be tightened against the coupler with a 13mm openend wrench.
AddendumEarthing Switch Adjustment
-
8/4/2019 Training - Motorpact
113/114
Motorpact IEC_E_V0R8.ppt -Tony Narusevicius 02/2005 1
1
Earthing Switch Adjustment
(1.) Slot Link must travel to opposite (bottom)end, against the pivot screw/ bushing BEFOREthe (2.) pivot link moves away from the rodkeeper.
(1.) Slot Link
(2.) Pivot Link
Figure 5
earthed Position: Indicator
Pin is Bottomed Out inRadial Slot
Tighten jam nut againstcoupler when adjustmentsare complete
Figure 6
AddendumPivot Lever not Releasing Interlocks
-
8/4/2019 Training - Motorpact
114/114
Pivot Lever not Releasing Interlocks
1. Open medium voltage door and defeat interlocks.
2. Inspect the pivot lever attached to the left side sheet fordeformation and function.
3. If deformed replace with new part 46032-907-02.
Pivot Lever