SIEMENS

Series 81000 Controllers

Instructions
Installation
Operation
with Drawout 93H3 or 94H3 Vacuum Contactors
2300, 4000, or 6600 Volts AC (Utilization Voltage)
Maintenance

2400, 4160, or 6900 Volts AC (Distribution Voltage)

MVC-9068

Bulletin MVC-9068
 A DANGER I
Hazardous voltages.

W i l l c a u s e death, s e r i o u s p e r s o n a l i nj u ry o r
equipment damage.

A lways d e- en ergize and ground th e equipm ent b efor e

maint enanc e .

Maint enanc e should b e p er form ed only by qua li fi ed p ersonnel. Th e us e o f

unauthorized parts in th e r epair o f th e equipm ent o r tamp ering b y un qualifi ed
p ersonnel will r esult in dang erous conditions which will caus e s ever e p ersonal
injury or equipment damage. Follow all safety instructions contain ed h er ein .

IMPORTANT

The information contain ed h er ein is g en eral in natur e and not int end ed for sp ecific
application purpos es . It does not r elieve th e us er o f r esponsibility to us e sound
practic es in application, installation, operation , and maint enanc e of th e equipm ent
purchas ed. Siem ens r es erves th e right to make chang es in th e sp ecifications
shown h er ein or to mak e improvem ents at any tim e without notic e or obligations.
Should a con flict aris e b etw e en th e g en eral i n formation contain ed in this
publication and th e cont ents of drawings or suppl em entary mat erial or both, th e
latter shall take pr ec ed enc e.

QUALIFIED PERSON
For th e purpos e o f this manual a qualifi ed p erson is on e who is familiar with th e
installation, construction or op eration o f th e equipm ent and th e ha zards invol ved.
In addition, this p erson has th e following qualifications :
(a ) is trained and authorized to d e- en ergi ze, cl ear, ground, and tag circuits and
equipm ent in accordance with establish ed safety practices.
(b ) is trained in th e prop er car e and us e of protective equipm ent such as rubber
g lo ves, hard hat, sa fety glass es or fac e shields, flash clothing, etc., in accordanc e
with establish ed safety practices.
(c ) is trained in r end ering first aid.

SUMMARY

Thes e instructions do not purport to co ver all d etails or variations in equipm ent nor to provid e for every possibl e
conting ency to b e m et in connection with instal lation , op eration , or maint enanc e. Should furth er information b e
d esir ed or should particu lar probl ems aris e which ar e not covered su ffici ently for th e purchas er's purpos es, th e
matter should b e r eferr ed to th e local sa l es o ffic e, list ed on back o f this instruction guid e .

Th e cont ents o f this instruction manua l shal l not b ecome part o f o r modi fy any prior o r existing agr eem ent
commitm ent or r elationship. Th e sal es contract contains the ent ire obligation o f Siem ens En ergy & Automation,
Inc. The warranty contain ed in th e contract b etw een th e parti es is the sole warranty of Siem ens Energy &
Automation, Inc . Any stat ements conta in ed h er ein do not create n ew warranti es or modify th e existing warranty.
Se ries 81000 Co n t ro l l e rs
Table of Contents
Introduction and Safety ........ .............. ............ ................ ............... ..2
Introduction .......................................................................................2
Qualified Person............................................................................... .2
Signal Words ..................... ...................... . . ........................................2
Dangerous Procedures ............ . . . . . . . . . . ................................... ............2
Field Service Operation ........... ....... ..................................... .............2
General Description ........ . ...... ......... .......................... .............. ....3-18
General
...................... .............. . . ........................................................
Basic Impulse Leve1
Dielectric Test . . . . . . . . . . . . ..................... .............. ............. . . . .....................4
. . . . ........... . . ............. ............................................
Ratings . .................... ...................................................................... . . . .4
Medium Voltage Contactors ............................................................4
Surge Protection .............................................................................. .4
Isolation and Automatic Shutter Mechanisms ............................. .4
Racking Mechanism and Mechanical Interlocks ............... ............5
Medium Voltage Compartment Door Interlock .............................5
Contactor Interlock ...........................................................................8
Test Switch ........................................................................................8
Mechanical Latch ..................................... ............... ..........................8
Detent Lever ....... ................................... ...........................................8
Contactor Engagement Warning Light . . . . . . . ...................................8
Line Switch Interlock (LSI) ........... ..................................... ..............8
Racking Switch Interlock (RSI) .............. . . ........................................8
Power Fuses ............................ . . .. . . . . . . .............................................11
Use of 93H3 or 94H3 Contactor in Other Cells ...........................11
Receiving, Handling and Storage . .................... ......... ........ ...... 19-21
Receiving .................................. .......................................................19
Handling 19
20
. . . . . . . . . ...... .............. ................................................ ............
Skid Removal
Contactor Removal .................................. ........... ......... ...................21
..................... .............................................................
Storage ...... ................................................................................... . . .21
Installation .................................................................................22-30
Operating Environment
Site Preparation and Mounting ............... ............... ....................... 22
..... .............. ..............................................
General Pre-Installation lnspection........................ . . ............ .........22
Grounding .................................. .......... . . . . .............. .........................22
Electrical Connection ........................ ......................................... .....22
Contactor Installation . . . . . . . . . . . . . . . ....... ..........................................24-29
Preinstallation Checks ..... . . . .....................................................24
Installation
Power Cable Termination. . . . . . ..... ....... . . . ................... .......................24
.......... . . . ................................ ..................................
Series 81000 Controllers .................... ...........................................24
Termination of Lead-Covered Cable
........................................ . . . .
Termination of Shielded Cables ..... . . . .... . . . . . . . . . . . ...... ................ ......
Siemens Advanced Motor Master System ........ ...... ........ .....31-32
SAMMS-MV System Description ................................ ..................31
Configuration .............................. ....................................................31
Protection Functions..... . . . ...............................................................31
Starter Types
Diagnostics ........................... ............ . . . . ............................ ........ . . . . . . . 32
............................................ ........ . . . . . . . . . . . . . . . ................
The SAMMS-MV Device Models ............................ . . ............ . . ......
Type 3UA T hermal Overload Relay .. ...... ...................... ......... .33-36
General......................................................... ...................... ..............33
Overload Relay Operation 33
33
............................................................
Application .
Cyclic Starting ............. ...................................................................34
... .......................................................... ........................
Cyclic Loading ................... ............................................ .................34
Single- Phasing ..............................................................................34
Causes for Relay Tripping ...................... .......................................34
3 Operational Checks ...................................................... .......... ........34
4 Test Procedures ........................................................ . . . . ..................34
Operational Test ................... ..........................................................34
100% Current Test ....................... ...................................................35
Coordination with Current-Limiting Motor Fuses ......................35
Operation .. .... .......... .................... .. ...... ......... ...... .. ............. .. .... .37-39
37
..
Pre-Energization Check .
38
......... ............................................. ..........
Energizing Equipment
...................................................................
Maintenance ................. ...... .. .............. ...... . ..... . .............. .. ..... .40-44
.40
...
Safety . .
.40
............................... .................................................... ..... ...
Recommended Maintenance and Lubrication
Mechanical and Electrical Operation of the Controller ............. .40
..........................
Vacuum Contactors ....... ................................................................41
Shutter Mechanism .......................................................................41
Racking Mechanism Adjustment ................................................ .41
Mechanical Interlocks ..... ...............................................................43
Electrical Interlocks .................... .............................. ......................43
Electrical Joints and Terminals .....................................................43
Periodic Cleaning ............ ...............................................................43
Dielectric Test ....................................... ..........................................43
Recommended Torque ................ ........................ ..........................43
Maintenance After a Fault . . . ......... ...... .............. ......45
45
.... ...... ...... ......
Genera1
.45
............. ....... ....... . . ...... ....................... .............. ....................
Inspection
22 Enclosures .............................. ........................................................45
........................ . . ...... . . ....................................................
Terminals and Internal Conductors ............. .................................45
Contactor ........ ............. ...................................................................45
Overload Relays ............................................................... ..............45
Fuse Holders .................... ..................... ..........................................45
Fuses . . ..................................................................... . . ......................45
24 Troubleshooting .... .. ... .... ....... ............................. ........ ........ ......46-48
.46
General
..................................................................... . . . ...................
30
30
31
32
I Cover: 1 000-93
I n t rod u ct i o n a nd Sa fety

81 000
Introduction Signal Words
The Series family of Medium Voltage Contro ller is The signa l words "Danger", "Warning" and "Caution" used in
designed to meet al l applicable N EM A standards . Successfu l this manual indicate the degree of hazard that may be
application and operation of this e quipment depends as encountered by the user. These words are defined as:
much upon proper installation and maintenance by the user
Danger Indicates an imminently hazardous situation
-
as it does upon the careful design and fabrication by
which, if not a voided, will result in death or serious injury .
Siemens .
War n i n g-1 ndicates a potentia l ly hazardous situation
The purpose of this Instruction Manual is to assist the user in
which, if not a voided , could result in death or serious injury .
de veloping safe and efficient procedures for the installation ,
maintenance and use of the e quipment . Caution-Indicates a potent ia lly hazardous situation
which , if not a voided, may resu lt in minor or moderate injury.
Contact the nearest Siemens representative if any additional
information is desired .

AoANGER
Dangerous Procedures
In addition to other procedures described in this manual as
dangerous , user personnel must adhere to the following :

Hazardous voltages. 1. Always work on de-energized e quipment. Always de

Will cause death, personal injury or property

energize a contactor, and remove it from the e quipment

damage.
before performing any tests , maintenance or repair.

2. Always let an interlock de vice or safety mechanism

Turn off power supplying this equipment before
perform its function without forcing or defeating the
a n y a djustm en t, servicing, wiring, parts
replacement. or any act requir ing physical de vice.
contact with electrical working com ponent s is
performed.
Field Service Operation
Siemens can provide competent , well-trained Field Service
This e quipment must be installed, operated and maintained Representatives to pro vide technical guidance and advisory
only by qualified persons thoroughly familiar with the assistance for t h e i nstall a t i o n , o ve r h a u l , r e p a i r and
e quipment instruction manuals and drawings. maintenance o f Siemens e qu ipment . processes and
systems. Contact regional service centers , sales offices or
the factory for details .
Qualified Person
For the purpose of this manual a "Qualified Person" is one
who is familiar with the installation , construction or operation
of the e quipment and the hazards involved . In addition , this
person has the following qualifications:
Training and authorization to energize, de-energize, clear,
ground and tag circuits and e quipment in accordance with
established safety practices.
Training in the proper care and use of protecti ve e quipment
such as rubber gl o ves , hard hat , safety g lasses , face
shields, flash c lothing, etc. , in accordance with established
safety procedures.

Training in rendering first aid.

2
Ge n e ra l De s c ript i o n

General and load co n n e ctio ns, m e ch a ni cal a nd electrical i nt erlo cks

T h e Si em e ns Ser i es 8 1 000 co ntrol l er is a n i nt egr at ed
sy s t em of co nt a ctors a nd co mpo n e nts arr a ng ed for
co nveni e nt access i nto u nits withi n a commo n e n closure
co nsisti ng of o n e or mor e freest andi ng structur al s ectio ns .
E a ch s e ctio n is 3 6 i n ch es wid e, 3 6 i n ch es d e ep, a nd 90
i nch es high (1 00 i n ches high with top mou nted m ai n bus ) .
R ef er to Figure 1.
The Seri es 81000 co ntroll er is a modul ar d esig n which can b e
arr a ng ed t o m e et s p e cifi c custom er sp ecif i c atio ns a nd
n e eds. E a ch s ectio n is d esig n ed to accept up to thr e e
st art ers with o n e low voltag e co ntro l p a n e l for each starter.
The u nit height m ay be either 30, 45 or 60 i n ch es.
The upper u nits of 1 -high a nd 2-high co ntroll ers m ay co ntai n
a low voltage p a n el or space for futur e start ers.
I n g e n er al, each starter u nit is divided i nto m edium volt ag e
a nd low voltage comp artm e nts, each with its ow n s ep ar at e
door a nd i nt erior b arri ers b etw een the two . T h e m edium
volt ag e comp artm ent co ntai ns the co nt actor cell modul e
upo n whi ch the shutt er m echa nism, racki ng m echa nism, li ne
ar e mou nted. The cel l modul e can b e either 29.88 i n ch es
(upper or middl e cells ) or 33 . 50 i n ches (low er cell ) d e ep.
The m edium voltag e comp artm ent also hous es the curr ent
transform ers and the co ntactor.
In order to op en the m edium voltag e u nit door, the co ntactor
must b e d e-en ergized and comp l et ely r ack ed-out, a nd the
door u nlatched. Low voltag e doors m ay be e nt er ed without
d i s co n n e cti ng t h e pow er, but this must b e do n e with
extr eme car e and caution.
The el ectrical power is distributed through the optio nal m ai n
horizo nt al bus whi ch ext e nds t h e e ntir e l e ngth o f t h e
co ntroll er. The bus m ay b e mounted i n the r ear o f t h e upp er
low voltage u nit or i nsid e a 1 0 i nch high top hat. See Figure 2.
E a ch vertical s e ctio n co ntai ni ng provisions for dr awout
co ntactors is f ed by cabl es or vertical bus system which is
co nnected to the horizontal bus. The cab l es or vertical bus
system i n tur n supp li es pow er through the stab ass embly
mou nted o n the cell module. The horizo nt al a nd vertical bus
or cabl e system is isol ated from the fro nt by m eans of b arri ers .

L_ 36.0" -1
1- (914.4) .

0 0 D D ll

D b
l
LV LV LV
MV
[ LV 0 0
-

n 0 0
0

::
0
-

100.0"

0 :o ';Q D P
r
90.0"
SPACE (2540>
r--
<2 286) MV MV
n
c

u MV D
D

0 MV

1 0 0 MV

D I 0 u: D D MV MV

1-High 5kV 1-High 7.2kV 2-High 5 k V 3-H igh 5kV

( ) Dimension in Millimeters

Figure 1. Typi cal Co nstru ctio n

3
Ge n e ra l De s c ript i o n

Basic Impulse Level

All Seri es 8 1 000 cont roll e rs have a b asic i mpu ls e l evel of
Horizontal Bus

I
l__
60 kV crest excluding co nt rol t ransfo rmers, starting reacto rs

\
Horizontal Bus Gr und Bus a nd autotransfo rmers .
\

\ --
Dielectric Test
.......
Ground Bus
\
10.0"
' '------ All co nt roll e rs a re facto ry t ested at 2.25 x n a m epl ate voltage

\
(254)
plus 2000 volts.
1\
-- Ratings

;
The Series 81000 cont roll ers a re rated in acco rd a nce with
Table 1, as w ell as the n a m epl ate o n f ro nt of the enclosu re.

r--
\.'
_I_-
Medium Voltage Contactors
Si e m e ns Typ e 93H3 5 o r 94H3 5 ( 5 kV) a nd Typ e 93H37 o r
9 4H37 (7 . 2 kV ) co nt a cto rs a r e u s ed i n S e ri es 8 1 000
90.0"
cont roll e rs. The 93H3 5 o r 94H3 5 co ntacto rs can accept 5 kV
< 2286)
pow e r fus es rat ed 2R th rough 24R. The 93H37 o r 9 4H37
----
cont acto r can accept 7.2 kV fus es rat ed 2R th rough 24R.
1- - - -- --
Typ e 93H3 5 o r 94H3 5 co ntacto rs with si ngl e o r doubl e barrel

......
fus es can b e i nstall ed i n any co mp a rt m e nt of on e, two and
c three-high 5 kV co nt roll e rs. Type 93H37 o r 9 4H37 contacto rs
0
LL.
.._ can only b e i nstall ed in on e-high 7.2kV co nt roll e rs.

Surge Protection
( ) Dimension in Millimeters The 93H3, 9 4H3, and 90H6 vacuu m contacto rs a re suit abl e
fo r appli cation without p rot ectio n f ro m su rg es rel ated to
swit ching with vacuu m, except fo r joggi ng or i n ching duty
Figure 2. Alte rnate Bus Lo cations (Sid e View )
with s mall (u nd e r 1 OOH P) moto rs. Fo r su ch applicatio ns,
m et al-oxid e su rg e a rresto rs o r su rg e li mit e rs should b e
sp ecified.
Table 1: 93H3 a nd 94H3 Cont acto r R atings R eg a rdl ess of t h e swit chi ng m e a ns e mplo y ed, if t h e
Enclosed
Interrupting
Impulse
insul atio n i nt eg rity o f t h e moto r is susp ect, such as fo r very
Capacity
old machin es, it may b e d esi rabl e to add su rg e p rotection fo r
I BILl
Maximum Continuous Level
Contactor Voltage Ampere Unfused Class E1 Fused Class E2
th e m a chin e, o r to consid e r upg radi ng t h e m a chi n e to
(kA)
Type Rating Rating Controller Controller (kV)
(MVA) mod ern i nsul atio n st a nd a rds .
9 3H 35 5.0kV 360 7kA@ 2.3-4.6kV 200@ 2.3kV 60
94H35 350@ 4.0kV Isolation and Automatic Shutter Mechanisms
400@ 4.6kV
Non-lo ad b re a k fi ng e r typ e st ab ass e mbl i es p ro vid e the
93H37 7.2kV 360 7kA@ 6.6kV 570@ 6.6kV 60 m e a ns fo r m a nu al isol ation o f t h e p o w e r ci r cuit, in
94H37
acco rd an ce with NEMA St anda rds requi rements.
Auxiliary Contacts: Each contactor is equipped with 3 N.O. a n d 4 N.C. The shutter mecha nis m op e ration is di rectly co nt roll ed by the
a u xiliary contacts for customer use. These contacts are rated 600V ,
10A ( N E M A Class A600). NOTE: On drawout co ntactors, 2 N.O. a n d 2 position o f th e r a cking m e ch anis m, and t h e mo vabl e
N.C. contacts are available for customer use. insul at ed shutt e r is lin ked to the racki ng ca ms, Figure 3 .

Table 2: M axi mu m moto r fus e and t ra nsfo rmer fus e rati ng .

3 Phase Horsepower Rating at Utilization Voltage Transformer Loads

2300V 4000-4600V 6600V Maximum

Fused
Motor Maximum 3-Phase kVA Maximum
Contactor
Syn. S yn. S yn. Fuse at Distribution Voltage Transf
Type
Motors Ind. Motors Ind. Motors Ind. Rating Fuse
Motors Motors Motors Rating
0.8PF 1.0PF 0.8PF 1.0PF 0.8PF 1.0PF 2400V 4160V 4800V 6900V

93H35 1500 1750 1500 2500 3000 2500 - - - 24R 1500 2500 2500 - 450E
94H35

93H37 - - - - - - 4000 5000 4000 24R - - - 1500 200E

94H37

4
Ge n e ra l De s c ript i o n

As the handl e of the r ackin g m echanism is moved tow ards

the ON pos i tion, the insulated s hu tter uncovers the line stab
ass embly JUSt prior to ins er tion of the contactor l in e and lo ad
stab fing ers, Figure 4.

In the revers e operation, w hen the handl e is moved tow ards

the O F F position, the insu lated s hu tter covers the l in e s tab
ass embly, thus eff ectively isol ating all l ive hig h vol tage p arts,
Figure 5 .

Lab els on t h e s tation ary s hu tter cl e arly ind i c a t e if t h e

isol ating means i s O PE NE D (dis eng aged).

Racking Mechanism and Mechanical Interlocks

R a c king of dr awout con tactors is accompl is h ed using a
compound four-b ar m echanism op er ated by an extern al,
enclosur e mounted hand le. T he handl e can b e lo cked with
up to thr ee p adlo c ks in the O FF position.

M echani cal and el ectr i cal interlo cks ar e incorpor ated in the
r a c king m echan ism to p erform the following functions.

Medium Voltage Compartment Door Interlock

T he racking handl e is interlo cked with the door such that the
handl e cannot be moved to the ON position w hil e the door is
op en. R ef er to Figure 7.

T h e door- handl e interlo c k (item 2 in F i g u re 7) pro hibits

closing or op ening of the m edium vol tage comp artment door
excep t w h en the handl e is in the O F F pos ition. T he fl at Figure 4. Shu tter Shown in ON Position
profil e on the end of the handl e s h aft will not al low the door ( Upp er Stabs Expos ed )
handl e inter lo ck to p ass in or out unl ess the handl e is in the
O F F position. R ef er to Figure 7.

\
Movable Insulated

"OFF" Position
Shutter - Shown in

Figure 3 . Shu tter M echan ism Figure 5. S hutter S hown in O F F Pos ition

5
Ge n e ra l De s c ript i o n

R.H.
Vertical
Support
Shee \
Insulating

Shutter
Movable \ Retaining
Shutter / Strips
:/
\
Stationary Power Stabs (3) Tension
/(Line Side) , Spring
- - - - - - - -
Stationary Power Stabs (3)
- - - - - - - /
-

L.H.
(Load Side)
// :
/
/ Door
Vertical Interlock
1

Support /Lever
//
FO? INTERLOCKS --;------- Housing
Handle

.......,0'\\/"0.r
Stationary
Stab Insulators --+----+-+-

- ---- Clevis

Racking "' Locking Nut
Cams
'
" Connecting Rod
(Short>

\
Locking Nut

\ Clevis
Rocking Support
Switch Plate

/
Interlock Racking
(RSIJ Shaft Guide

,/
Plate
Mechanical
Enclosure
Frame
Latch

DETAIL A - 94H3 DETAIL B - 93H3

Figure 6. C ell Modul e

6
Ge n e ra l De s c riptio n

A DANGER
Hazardous voltages.
Will cause death, severe personal injury or
property damage.
The door-handle interlock should be defeated
only in the event of a malfunction in the racking
mechanism.

T he interlo c k may be defeat e d only by aut horize d a n d

qualified personnel. Do not attempt t o defeat t he interlo c k
unless all incoming power i s disconne cte d an d lo cked-out.

Never defeat t his interlo c k if t he re d conta ctor engagement

light is on.
T his interl o c k may be defeate d only by aut hor ize d an d
qual ifie d personnel requiring a ccess to t he un it in case of 1078-93
emergency .
T he defeater can be rea ched by removing a plastic cap from
t he lower part of t he handle housing, t hen by remov ing t he
Allen- hea d set s crew. The ra cking handle must be rotate d
approximately 23 degrees from t he fully upwar d ( O N )
position of t he han dle in or der to align t he Allen-hea d set
s crew with t he a ccess opening. When t he Allen- hea d set
s crew is remove d, t he handle can t hen be moved to t he OF F
pos ition allowing t he door to be opene d . Refer to Figure 8.

After t he malfunction has been corre cted, t he controller

s hould be restore d to normal operat ion by reversing t he
proce dure used to defeat t he interlo ck.

Door Interlock
Lever (1)
1079-93

D oor In terlock
/

Handle Shaft

Flat Profile

H a n dl e

1080-93

Figure 7. Door-Handle Interlo c k Figure 8. Proce dure for defeat ing t he door- handle interlock

7
Ge n e ra l De s c ript i o n

Contactor Interlock
To p revent accid ental ins ertion or withdrawal of th e cont acto r
when it is energiz ed, an interlock lever moves to engage notches
in th e cam wh en th e cont acto r is clos ed, thus p reventing
motion of th e racking mechanism . The int e rlo ck us ed with
type 94H3 cont acto rs is directly actuat ed, and is illust rat ed in

Red Contactor
Figures 1 1 and 12 . T h e typ e 93H3 cont acto rs employ a
Enga9ement
Warn1ng Light
cabl e actuated int e rlo ck, shown in Figures 1 3 and 14.

Test Switch
A t est swit ch is p ro vid ed to swit ch f rom run to t est mod e.
The switch is located on th e back s id e of th e doo r, mount ed
on the low volt age comp a rtm ent. See Figure 9. With the
cont acto r r a ck ed out and th e doo r opened, th e t est mod e can
b e s el e ct ed by rot ating th e sw it ch to th e t est mod e. With
th e sw it ch in th e t est mod e, th e cont acto r can b e el ectri cally

OFF
op erat ed in its r ack ed out posit ion. Once th e t est h as b een
'------

J
compl eted, th e cont a cto r can b e pl a c ed in op er ation by
swit ching to th e run mod e, closing th e doo r and racking in
th e cont actor by op e rating the racking h andle.
\,_. ,_, ,_

Figure 1 0. Cont acto r Engag err:::nt Warning Light

If th e h andl e is moved to O F F and th e red light st ays on, th e

ra cking m e ch an ism is not op e rating p rop e rl y and th e
cont acto r is eng ag ed. Do not attempt to open the high
voltage door. Dis conn ect and lo ck out all incoming pow e r
and ref e r to th e "Troubl eshooting" s ection.

A DANGER
Hazardous voltages.
Will cause death, severe personal injury
or property damage.
Do not attempt to open the high voltage doo r
if the r ed cont acto r eng ag em ent indicat ing
light is on.
Figure 9. Run- Test Sw itch

Mechanical Latch
Th e m ech an ical latch is mount ed on th e l eft h and side of th e
Line Switch Interlock (LSI)
guid e plate and s e rves to locate and hold th e contacto r in th e
All cont rol pow e r d e rived f rom th e s econd a ry of th e cont rol
d is engaged (test ) posit ion. The l at ch is rel eas ed by manually
pow e r t ransfo rm e r is carri ed f rom th e cont actor to th e low
pivoting th e l at ch ass embly upw a rd and rolling th e contacto r
vol t ag e cont rol p an el through a s et of cont a ct f ing e rs
out of th e enclosu re. R ef e r to Figure 6.
mount ed on th e rea r of th e cont acto r. R ef e r to Figure 6.
Detent Lever
Thes e contact fing e rs, along with th e m ating contact blo ck
This l ever is p ro vid ed to p rohibit rel ative motion b etw een
which is stat iona ry-mounted on th e guide plate, m ak e up th e
st ab fing e rs and stab ass embly. Slight initi al force is requi red
Line Sw it ch Int erlo ck ( LSI ).
on th e h andl e wh en moving it from th e O N to th e O F F
position to f ree th e d ri ver link pin f rom th e retaining slot in The function of this int e rlo ck is to dis conn ect th e load f rom
th e d et ent l ever. R ef e r to Figures 1 1 and 12 (for typ e 94H3 ) th e C P T s econd a ry p rior to dis eng ag ement of t h e m a in
o r 13 and 1 4 (fo r typ e 93H3). power st abs as th e contacto r is rack ed out.

Contactor Engagement Warning Light Racking Switch Interlock (RSI)

A red w arning l ight, mount ed abo ve th e h andl e housing is Th e R a cking Swit ch Int e rlo ck (RS I ) is a mi c ro- swit ch
en e rgiz ed only wh en th e cont actor is fully engag ed, and mount ed on th e guid e pl at e which fun ct ions to pr e vent
in coming pow e r is p r es ent, indep endent of th e condition of op e ration of th e cont acto r on th e t est pow e r when it is in th e #fWN>

th e contactor o r th e doo r. Wh en the h andl e is moved to th e eng ag ed (O N ) posit1on. As th e r a cking h andl e is moved f rom
OF F position, th e red w a rning light should alw ays go out, O FF to ON t h e no rm ally clos ed RSI cont a ct op ens and
indicating th e contacto r is fully dis eng aged and isolat ed f rom isolat es th e t est sou rce f rom th e cont rol ci rcuit. R ef e r to
th e st ab ass embly. R ef e r to Figure 10. Figure 6.

8
Ge n e ra l De s c r i pt i o n

Con+actor in Engaged (ON) Position

Contactor O pen

Door
Inter- lock
Lever

Handle

Drive
Llnk

Short

Rod
Connecting

Figure 1 1. 94H3 Racking Mechanism-H andl e i n "O N " Position

(Directly A ctuated Int er lock)

Contactor in Disengaged (OFF) Position

Contactor Closed Using Test Power

Door
Interlock
Lever-

Contactor
lnter-lock
Lever

Handle

-----f--7 ;:Dc===f1=====1
Drive
Link

C'
l
II_ _II

Figure 1 2. 9 4H3 Racking M echanism-H andl e i n " O F F " Positio n

(Directly A ctuated Interlock )

9
Ge n e ra l De s c riptio n

Contactor in Enoaoed (QNl Position

Contactor Open

Handle

Contactor

Interlock
Lever-

Short

Rod
ConnectinQ

Figure 13 . 93H3 Racki ng Mech anism-H andl e i n "ON" Positio n

(Cabl e A ctuated I nterlock)

Contactor in OlsenQaQed <OFFI Position

Contactor- Closed UslnQ Test Power-

Dr-Iver
Link

Contactor
lnter-lock
Lever-
)
OFF

Handle

Rod
ConnectlnQ

Figure 14. 93H3 Racking M echa nism-Ha nd le i n " O F F " Position

(Cabl e A ctuated I nt e rlock)

10
Ge n e ra l De s c ript i o n

Power Fuses
ANSI "R" rated current-limiting fuses Type FM are used for 7 .2kV Class E2 controllers. ANSI "E" rated fuses are used
motor starting duty in 5kV Class E2 controllers. ANSI "R" for most other applications.
rated fuses Type A720R are used for motor starting duty in

Table 3: Power Fuses

Maximum Continuous Minimum Interrupting
Catalog Current
Design Current Interrupting Rating
Number Designation
Voltage @40C Rating 50/60Hz

48FM2R-4G 2R ( 1 barrel) 70 1 90
48FM3R-4G 3R 1 00 225
S i n g l e Phase
48FM4R-4G 4R 1 30 330 80kA rms
48FM6R-4G 6R 1 70 500 Asy m m etrical
5080
48FM9R-4G 9R 200 740
(21 0MVA@ 2.4kV)
48FM 1 2R-4G 1 2R 230 955
(4 1 5MVA@ 4. 8kV)
48FM 1 8R-5G 1 8R (2 barrel) 390 1 440
48FM24R-5G 24R 450 1 91 0
A072F1 DOR0-2R 2R ( 1 barrel) 70 1 90
A072F 1 DOR0-3R 3R 1 00 225
A072F 1 DOR0-4R 4R 1 30 330 S i n g l e Phase
A072F 1 DOR0-6R 6R 1 70 500 80kA rms
7200 Asy m m etrica l
A072F1 DOR0-9R 9R 200 740
A072F1 DOR0- 1 2R 1 2R 230 955 (620MVA@ 7. 2kV)
A07282DAR0- 1 8R 1 8R (2 barrel) 390 1 440
A07282DAR0-24R 24R 450 1 91 0

Use of 93H3 o r 94H3 Contactor i n Other Cells

The types 93H3 and 94H3 contactors differ in the manner in interchangeabl e with the earlier 90H3 contact ors.
which the interlocks are constructed and operate. Therefore, Modifications necessary to allow use of a 93H3 or a 94H3
93H3 and 94H3 contactors are not interchangeable with each contactor in a 90H3, 93H3, or 94H3 cell are summarized in
o t h er. Similarly, these contactors are not directly Table 4.

Table 4: Modification Matrix for Use of 93H3/94H3 Contactor in 90H3/93H3/94H3 Cells

Contactor Type

93H3
Cell modification kit 25-213-200-501 required. Mount
per 25-154-488-424. Kit includes new interlock spring
90H3
a n d replacement mechanical latch. Mod ified cell will
a l low use of either 90H3 or 93H3 contactor.
94H3
Cell modification kit 25-154-555-805 requi red. Mount
per 25-213-213-405. Kit includes replacement interlock
parts. Mod ified cell will no longer a l low use of 90H3
contactor.

Cell modification kit 25-154-555-804 required. Mount

per 25-213-213-404. Kit includes replacement interlock
93H3 -
Power Cell parts. Modified c e l l will n o longer a l low use of 93H3
(Compa rtment) contactor.
Type
Modification of contactor required. R e move cable
interlock assembly from 93H3 contactor, a n d replace
with new interlock lever to convert to 94H3 configura-
94H3 tion. Cell interlock modification also required. Use -

modification kit 25-154-555-811, which includes parts

needed for contactor as well as for cell. Mount per 25-
213-213-411.

11
Ge n e ra l De s c ript i o n

CURRENT CHARACTERISTIC CURVES

Total Clearing Times
Type FM Current Llmltino Fuses
2400 & 4800 Volts 12R-24Rl

500
' '
THESE FLSES ARE DESIGNED 10 INTERRUPl SHORT

,,,
CIRCUIT CURRENIS GREATER THAN DR EOUAL TO THAT

300
SHOWN Al THE 1CO SECOD MINIMUM MELTING TIME.

IN SERIES UST BE COORD!

-o ITERRUPT
PROTECTIVE DEVI:ES
AfFD WITH FUSE CHARACTERISTICS zoo
LOWER CURRENTS.

- I

I
' ' ,-t
-
I
r 2R
\ ,...-
l 3R
-----
I
-
-
4R
---
--
_..f.I-'
.- I
1--
..-!-,-
I
6R
'
--- "

'
l--'

'

lZR
'

z

'
18R

I
r+-+t-t+--1-----++++1-t---+-+t+-H-t
I--24R

..
..
1

..

..
'

i
I
H-]---+1--1-
-
I ! I
-

I -1-l--IT,
I

'1--Hi= tliSI. MmWtmM

I
--

t-f---+--l--1--HIH+-ft-
'

;;
.a

' l
. 0&

.06
I
"'

_,,
"

I
.03

CURRENT IN AIIIPS x 10

Figure 15a. Time-Curre nt Ch aracteri stics Curves (Total C learing Ti mes)

Type FM Curre n t Li m iting Fuses 2400 & 4800 Vol ts (2R-24R)

12
Ge n e ra l De s c r ipt i o n

CURRENT CHARACTERISTIC CURVES

Total Clearlno Times
Type A120R Current Llmitlno Fuses
1200 Volts t2R-24RI

103814

[ !! 1000
CURRENT tN AWPERES 10

g ggg
g +
700
000

600
J"]]" l f ftooo
o
o1o
j
j f
tl
g
Jg
+--+ + -
f--+--+-
++++-- ----t--t-+-+-H-H----t-----t--l JN fERRUPT SHORT
--- 600

HA OR EQUAL T THAT 400

THESE FUSES ARE DESIGNED c 500

--t--1--
soo

SHOWN AT THe 100 SECGNO M:NIMUM MELTiNG TIME.

CIRCUIT CURRFNT5 GREATER

,00

PRDTECTIV[ O[VICES I N SERIES MUST c COORCI

ATED WITH FUSE CHARACTERISTIC fO INTERRJFT 200
200 f--+---t-+++--+---t----t-t---+-t-+t- - --+------+,----+---1
LOWER CURRENTS.

EBrnM*M
, !I
100
'n.1
90

j---
ttt:Jttt=t+t+---+=+++H===+==+=+++m1
80
80

" f--+-+--++---+ 60

--1--r-HTH----'H-i l
K

J -\.
12R
--+-+-t-++-H++-------+--
H------++- - -\\-f--l-+\\+-1--+ -H--+r_\++- \\H"'"1-- -,8R --+---
-..- -++++-+ --t-----+----t--H---t-H
1 t-+++j
_\ 1\ -+---t+t--t-----
---
n' -t---
! : v-r- 24R i
1 I '\ I \
\ ! :

ooEmm-=--
1\ r..-
--
::
\ \

--'\-t---+--1 \ --!H--+--t t+--+--+-t-+- -

' -+--
.a

' TT--- -++--+-M--tr\ t-trtr

\ \
--r-t-rttt '

-+--+H+l -
.5

\ \1 \\ .\ \

CURRENT IN oll#'lRE5 " 10

Figure 1 5b. Ti m e- C u r re n t C h a racteristics C u rves (Tota l C learing Ti mes)

Type A720R Cu rrent L i m iting Fuses 7200 Vo l ts (2R-24R)

13
Ge n e ra l De s c ript i o n

CURRENT CHARACTERISTIC CURVES

Minimum MeltinQ Times
Type FM Curent LimitinQ fuses
2400 & 4800 Volts (2R-24R)

10

- uo n.0 rrTI::_ 8888888

CRET JN A.lof'(ill5

.. - <l> 8
-
1000
900 -r -r--r
"' "' """"'"'"'

oor-tTT1rr------+-+-++,+,--+- +-W-1--- -l
1-+++++----+---+--1-+--t-t+t+ +-
soo r+-t-;-++-----+---+-+-++-+-1- -
-+-
700

f-+1-t-+,-----t-+----t--+-H-t-Hr---- ---+-
-- t-

CiRCUIT CLR'lENTS GREATER T -J A OR EJUAL TO THAT

THESE FUSES ARE DESIGNED TQ INTERRUPT SHCT

f-+++H------+---t-_,r-t--t-t-t-t+-----+--1--H SH OWN AT THE 100 SECOND M!IMUM MEc TING liME.

PROIECIIVE DEVICES IN SERIES M U S I BE COORDIN

ATED WITH fUSE CHARACTERISTICS TO
LOWER CURRENTS.
INllRRUPI

10
'
.

iI I i I !I -----4 \ 1\ I \\ I _l_\
'=m!*g-
I ;

.!I
, ' -- ....L l \

--+1 rt-+\H-H\ --1\H!+- \ I+t;-t-

\
\ --+
.a

' \ \
\ -t-'-+t-r----t- -t-t--t-t-t-tt-1. 11
-----+-+-+-r+++-H

r-Ht --+---t--t-+-+- -t-t[--t-t---- -

-\ \ \
-+H-\+-\It--l---1 \ -+-, -++\ -+-\1
\ \ \ \
---H--+
1 ++ ------+--+-+-+++--'-+t----t-
'

I
--
. s

---+---++++
- 5

H-
. m, r-
_ - ' ttl. 1
--+---t--t-+++
1\
ttl +--11
'

_, r- -- --+-+-
' \1-+1,--+-+i\-\--1\e-+--!
-+++--t-t--+\-
+ : 1\ ++-:\ ++I j , +-'---
, -+- -

m=-r- -- - !ltntmlB!==!=fffil '

-

t\
\
-"9 + - .09

i1 \ \ I \ t---
--+-+-+-
+--t+-t ,
M -

f-++-t--t+------t---t-t--+--t-++t+-------1--- -+-
:
.07
-I ,')7

. -----+---+---+-+-+++++-- ---+--+-+-t-+H+, t- \ \ --\\:t--\t-

i\-----\!- \ '1+
-l H
\ -\t-ti
I\ ,
. 06

. ,.
,,

++H\:
i \
:
_____

t---+-
-+++1-t-- --+
\
"

t------+--+-

lt +++ 9tfJ --
, *-\-t\---t\\. - .1-\1-t+ -r---- --+---+-
t- - i+-
-t--t i -Ht- ,
_,,

i
+--+-++++
-+- ++- ---+,----+-LH+
-+-+- : +
-"-' .L .L L '---, __.J.___L-':-
g 3 '3
8 8 g g 2 g8
L..L
_l_l
_j__L- ______L____j

,
o_ .___t

.
.O

fURRENT lN AMPERES
0

1 Cl

Figure 1 6a. Ti m e-Cu rrent Characteristics Cu rves (Min i m u m Melting Ti m es)

Type FM C u rren t L i m iting Fuses 2400 & 4800 Volts (2R-24R)

14
Ge n e ra l De s c ript i o n

CURRENT CHARACTERISTIC CURVES

Minimum Melting Times
Type A270R Current Limiting Fuses
7200 Vol ts (2R-24RI

f-+++-t+---
-+- -+-+-+-+
--,--+-+ -+-
-r--- --+ THESE FUSES ARE 000
C !RCU IT TO THAT
DF,IGNED TO INTERRUPT SHORT

<00
500

100 SECOND ;lt.IU MELTING !If..

CURRENTS GRF AIER THAN OR EQUAL

300
SHOWN AT THE

ol- 200

lig
r:: -l-- +-ii -- ---- l ..
+

\ \
\ \ \ !\

.o;

[lJRRlNT IN Al.f'ERES 10

Figure 16b. Ti me-Cu rrent C h a racteristics Cu rves (M i n i m u m Melting Ti mes)

Type A720R Cu rrent L i m iting Fuses 7200 Volts (2R-24R)

15
Ge n e ra l De s c ript i o n

'I -- --
-

T
+
I

- --
FUSE SELECTION GUIDE FOR TYPE FM AND A720R FUSES
FOR SERIES 81000 CONTROLLER WITH TYPE 3UA
OVERLOAD RELAY INEMA CLASS 10>. BASED ON MAXIMUM
MOTOR ACCELERATING TIME OF 10 SECONDS.
_l

rn
Cl) I
'-
Cl) I
; -
a..
E
<!
+ f.--
'-
I +- T
0 I . '
400

I
u '
0
+'

I _,__.
i.J_
' -.,.-
Cl)
u
350 124R
l
I I
:;:
....
Cl)
U1
r
X !
-
300 18R
c:
Cl) I
1
'-
'- :
::J I
u 250 I
-o
0 L
0 I
....J
200
:::l
i.J_ 12R
2
....

0 150
9R
6R
I

:::i!
+
I

I

100 4R
l
I

3R I
50
2R
I
+
1I
- r-- I I
0
100 150 200 300 400 500 600 700 800 900,000 1500 2000 3000

Motor Locked Rotor Current - Amperes

Figure 17. Fuse Selection Guide

16
Ge n e ra l De s c ript i o n

--==-----r=::::==+==-r=+++=--=l===---=1=+
/+=+=+
00000- - -- -
<;l0000 I-------+- t--- +---
1 . --+-------+--t--+
800001-------+--+- +--+-+-++-+- --+--+
I
---+- --+--r-----r

/
I DOOOf----+- 1--+-
- -+--+--+-++++---------+--->..,___
/ ---+---+-1--+---+--H

6 0000 --- ----+--+ --+---+----+-4

, ---l -
50000f-
'oooo-------J--+-----t--+ t-1---H-+---- --+--->----+-

Type A720R
Fuse
( 2R-24R I
7.2kV

AVAILABLE CURRENT IN RMS SYMMtTRICAL AMPCRES

1 00000 ,----- n
90000 1-------1--l L
80000 --+----+--+---t-+--- -----+---
70000
60000
i I
50000 -t-

r-+
--

4CO;O I '

30000 --+--+-+-t----t-++-+-- --
'

r--+
2000v --

Type FM
Fuse
(2R-24RI
5kV

:c:
c 0 (_) o o o ooo 0 c
c 0 CJ 0 0 0 0 000 0 c
N -T .[l <JJ 1'- 100'> D 0
0

AvAILABLE CUQRENT IN RMS SYMMITRICAL AMPERES

Figure 18. Cu rrent Limiting C h a racteristics of Type FM a n d Type A720R

17
Ge n e ra l De s c ri pt i o n

Maximum
by Type FM and A720R Motor Fuses
Allowable Acceleration Times Permitted

MOTORS WITH ACCELERATION TIMES FALL-

lNG BELOW THE APPLICABLE FUSE CURVE
ARE PERMITTED TWO CONSECUTIVE STARTS,
AS FOLLOWS:
--

A. ONE START FROM AMBIENT

B. A COAST TO STOP

Q) 5000
Ul
C.A SECOND START
. ----

I....

4000
Q)
-- --

a. !
E t--
I

<{ !

c 3000

c
......

Q)
+--- '
I
r
'
--
I--

I
. -

l
I.... 1
2000
I

I....
24R I
--

::J

u
I....

1500 \

0
0
--

......
+--- -- -- ---

IX
I

-o I
Q)
1000
12R

..:::.
--

u
....__
0 "9R----
_J 800

\::
---
--

Q)
-------
"""'"

......

600
0 --
a. I
Q)
6R-
--

500 \
--

E

---- - ---- --- -- -

0
400
z

- ---

I....
-

0
4R
......
--

300

0

I
I I
--
---- -- - ------

--

200
-- - -

2R

150
I
--

5 10 15 20 25 30 35 40

Allowable Acceleration Time (In Seconds)

Figure 1 9. Maxi m u m Al lowa b l e Acce leration Times

18
 R e ce ivi n g , H a n dl i n g a n d Sto ra g e

Receiving
A n i m mediat e i ns pect ion s hou ld be mad e fo r a ny da mage
w hic h may have occu rred during s hi p m e nt u pon recei pt of
t his equi pment. The ins pection s hould includ e exa mi natio n
of t h e packaging mat erial a nd t h e equi p m ent wit hin. Be su re

/ ...
to look fo r concealed damage and do not d isca rd t h e pack (,
aging mat erial. If damage is found, note damage on Bill of .;jt
Lading prior to accepting recei pt of t he s hi pm e nt, if possibl e.
// ' / "

NOT E: The way visibl e s h ipping da mag e is t reated by t h e

D D D
consig n e e p rio r to signing t h e d el i v e ry rec ei pt ca n
d et e rmin e t h e outco me of t h e damage clai m to b e filed.
Not i ficat io n to t h e c a r ri e r wit hin t h e 1 5 day l i mit on
co ncealed da mag e is ess e ntial if loss result ing f ro m

D D D
uns ettl ed claims is to b e eli mi nat ed o r min i mized.

A clai m s hould b e i m m ediat ely filed with t h e ca rri e r, a nd

t h e Si emens sal es offic e s hould b e not ifi ed if damage o r
loss is disco vered. A d esc ri pt io n o f t he damage a nd as

D D D
muc h id e ntificatio n info rmation as possibl e s hould
acco mpa ny the claim.

Handling
The Seri es 8 1 000 cont roll ers a re s hi pped i n g rou ps of o n e to
t h ree v e rtical s ections w h ic h a re mount ed o n wood en
s hipping skids . Fo r 90- i nc h hig h cont rol lers, l ifting b rack ets
a re p ro vid ed fo r sing le f ra m es as s how n in Figure 20. Fo r
Figure 2 1 . Lifting fo r 2 o r 3 s ection g rou p, 90 " hig h units
90-inc h hig h g rou ps wit h multi pl e units, a lift ing c ha n nel is
provid ed on t h e to p of t h e g rou p, as s how n in Figure 21.

Cont roll e rs wit h to p mount ed ho rizo ntal bus a re p ro vid ed

wit h s id e mounted l if ting a ngles, as s how n in Figure 22.

E q u a I i z i ng Bar
B y R i g g er

L
,\ c7
I
I

I
I

D
"D D
:o D
D D D
Figure 20. Lifting a singl e 90 " hig h u n it. Figure 22. Lifti ng fo r units wit h to p mounted bus

19
R e ce ivi n g , H a ndl i n g a nd Sto ra g e
A wARNING
Heavy equipment.
Improper lifting can result in death,
severe personal injury, and/or sub
stantial property damage.
Exercise extreme care when h a n d l i n g
the m o tor contro l l e r.
Th e following p recautio ns mu st b e tak e n whenever moving a
moto r cont roll er:
1 . H a n dl e th e moto r co nt roll er with care to avoid da mag e to
compo n e nt s and to th e f rame o r it s finish .
2 . Do not r e m o v e t h e woo d e n shippi ng sk i d u ntil fi n al
install atio n po sitio n is reach e d .
3 . H a ndl e th e moto r cont roll e r in a n up right po sitio n o nly.
Moto r co nt roll ers a re no rmally f ro nt heavy, and f requ e ntly
top heavy . B al a nce th e load carefully a n d st eady the
moto r cont roll e r, if necessary, du ring mo vement. So me
moto r cont roll ers may co ntain heavy equip ment. such as
t ra n sfo rmers or reacto rs, th at can be adversely aff ected
by tilting.
4. Know the cap abilities of the moving means avail abl e to
h a n dl e the w eight of th e moto r co nt roll e r. A dequat e
h a n dling f a cilitie s shoul d b e a vail ab l e. E a ch v e rtic a l
sectio n , with co ntacto rs, w eigh s app roximately 1 500 lb s.
If a v e rtical s e ctio n co ntai n s pow e r f a cto r co rrectio n
cap a cito rs, reacto rs, o r l a rg e t ra n sfo rme rs, suffici e nt
additio nal w eight handling cap a city mu st b e allow ed.
5 . It is reco m mended that a cra ne o r hoist b e used to h a n dl e
th e cont rol ler if at all po ssibl e. I f a crane o r hoist i s not
avail abl e, a n d ot h e r h a n dl i ng m e a n s a r e n e c e s s a ry,
ext re m e c a r e mu st b e exe rci s e d to i n su re t h at t h e
e quip m e nt i s s e cu r e d du ri n g th e m o v e m e nt a n d
pl a c e m e nt o p e ratio n s to p re v e nt tipp i ng a n d f alling.
Jack s, p ryba rs, dollies, rol ler lift s, and simil a r devices all
re qui r e suppl e m e nt al blo cki ng b e n e ath t h e moto r
co nt roll e r, a n d rest raint s to p re v e nt tippi ng. T h e s e
devices a re not reco m mended d u e to the haza rds implicit
in their u se.
Th e fol lowing p recautio n s shou l d b e tak e n wh e n moving th e
co nt roll er with a cra n e o r hoist :
1 . Sel ect rigging l e ngth s to co mp e n sat e fo r a ny u n equ al
w eight dist ributio n .
2. Do not allow th e a ngl e b etw een th e lifting cabl es a n d
vertical to exceed 4 5 .
3. Do not pass rop e s o r cabl es th rough l ifting b racket s . Use
o n ly sli ngs with saf ety hooks or shackl es.
20
4. If o v e rh e a d rest rictio n s d o not p e r mit lifting by top
mou nt e d b ra ck et s , o r a ngl e s, the co nt roll e r m ay b e
u n d e rslu ng fro m th e b a s e . T h e sl i n g lo a d mu st b e
dist ributed evenly and padding o r sp reader b a rs mu st b e
u sed t o avoid scarring and structu ral damag e .
5. N ever lift th e co nt roll er abo ve a n area where p erso n n el
are located.
The following p recautio ns shoul d b e tak e n wh e n moving th e
cont roll e r with a fo rklift :
1 . Keep th e co nt roll er in an up right po sitio n o nly .
2 . M ak e su re th e load is p rop erly b al a nced o n th e fo rk s.
3. P la c e p rot ective mat e rial b etw e e n the co nt rol l e r a n d
fo rklift to p revent b enrl;1g a n d scrat ching.
4. Secu rely st rap the cont rol l e r to th e fo rklift to p revent
shifting o r tipping .
5 . Excessive sp eeds a n d su dden st a rt s, stops, a n d tu rns
mu st b e avoided wh en handling th e cont roll e r.
6. Lift th e cont roll e r o nly high enough to cl ear ob st n Jctio ns
on the floo r.
7 . Tak e c a r e to avoid collisio n s with st ru ctu r e s, oth e r
equip ment. o r p erso n nel wh en moving th e co nt ro ll e r.
8. N ever lift th e cont roll e r above an a rea wh ere p erso n nel
a re located.
The following p recautio n s shoul d b e t ak e n when moving th e
co nt rol l e r by rolling o n pip e s :
1 . Keep t h e co nt ro ll e r in a n up right po sitio n.
2 . Use e nough p eople a n d rest raining d evices to p revent
tipping .
3. The su rf ace over which the cont roll e r is ro ll ed must b e
l evel, cl e a n, a n d f re e o f ob st ru ctio n s. Never r o l l a
controller on an inclined surface.
4. It shoul d b e r e cog ni z e d t h at rolli ng a co nt rol l e r i s
esp ecially hazardou s t o fing ers, hands, a n d f e et a n d t he
cont roll e r is su sceptibl e to tipping. M e asu res s houl d b e
tak e n t o eliminate these h aza rds.
5. All pip es must b e the same outside diam et e r and shoul d
have no fl at spots. O nly st eel pip e shoul d b e used fo r this
pu rpo se.
Skid Removal
Skid r e mo val shoul d b e p e rf o r m e d ju st p rio r to f i n al
pl acement of the cont roll e r and is achieved by removing t h e
skid l ag bolt s. I f th e l ifting b rackets o r a ngl e s h ave b een
removed, reinstall th em on th e top of th e cont roll e r (to rqu e
bolt s to 40-50 ft- lb s. ) a n d att ach the cra n e rigging to remove
all sl a ck wit h o u t lifti ng th e e quip m e nt . T hi s is a
reco m mended saf ety measure to redu c e th e possibility of
tipp i ng. The l ag bolt s may now b e removed, th e cont roll er
lift ed, th e skids removed, th e cont roll er low ered into pl ace,
R e ce ivin g , H a ndl i n g a n d Sto ra g e
and the anchor bo lts secured. The l ast oper ation should be
perfor med with adequ ate rigging tension to prevent tipping .
A fter all additional shipp ing sect ions are secured in a s i milar
m anner, sections and b u s b ars should be J O in e d in
accord ance with instructions in the installation section o f this
manu al . Close doors as soon as possible to eli minate intrusion
of dirt and foreign materi als into the controller enclosure .
Contactor Removal
Controllers are nor mally shipped with the cont actors inst alled
and br aced in the vertical section (s ) . To f acilitate h andling o f
the cont actors, i t i s reco m mended th at they not b e re moved
fro m their shipping positions until after the vert ical section or
group o f vertic al sections h as been r e mo ved fro m the
wooden shipping skid and set into fin al posit ion. At this time,
the cont actors may be removed by unbolting the ret aining
br acket which secures the left front contactor whee l to the
guide p l ate.
NOTE: To avoid d a mage to the r acking mechanis m or
other co mponents, do not atte mpt to r ack the cont actor
be fore the ret aining br acket h as been re moved.
Storage
If the controller c annot be pl aced into ser vice re ason ably
soon after its receipt, it must be stored in a cle an, dry sp ace
where a uni for m te mper ature pre vents condens ation.
Pre fer ably, it should be stored in a he ated building, with
adequate air circul at ion, and protected fro m dirt and w ater.
Motor contro llers should be stored where they are not
subject to mechanic al d a m age.
I f the motor control ler is to be stored for any length of t i me
prior to installation, restore the p ack ing for protection during
th at period . Where cond it ions per mit, leave the p acking
int act unt il the motor controllers are at their fin al install ation
position . I f the p acking is re mo ved, co ver the top and
openings of the e quip ment during the construction per iod to
protect the m ag ainst dust and debris .
Outdoor storage is not reco m mended. Howe ver, if an indoor
motor controller must be stored outdoors, it should be se
curely co vered for protection fro m we ather conditions and
d irt. Te mporary electrical he ating should be installed to pre
vent condensation ; approxi mately 1 50 w atts per section is
adequate for the average motor controllers size and environ
ment. All loose p acking or fl a m m able materials should be
removed be fore energizing space he ating e quip ment .
An unenergized outdoor motor controller should be kept dry
internally by installing te mpor ary he ating (see abo ve ). If the
unit h as been provided with optional sel f-cont ained sp ace
he aters, these m ay be energi zed in lieu o f inst alling
te mporary he ating .
Any scr atches or gouges suffered fro m shipping or h andling
should be touched up with a can of spray paint to prevent rusting.
21
In sta l l a t i o n
AoANGER
Hazardous voltages.
Will cause death, personal injury or property
damage.
Disco nn ect a nd lockout i nco ming pow er
and c o n t r o l volt a g e s o u r c es b efor e
b eg i n ni n g w o r k o n this or a ny o t h er
el ectrical equi pment.
Ch eck all co ntrol circuit t er minals with a volt met er to mak e
c ertai n that th e equi pment is totally d e-energ ized.
Us e only a p pro ved high voltag e t est equi p m ent to ch eck
voltag e o n pow er t er mi nals. Do not att e m pt to m easur e high
voltag e with a volt-oh m met er.
It is r eco m m e nd ed that a saf ety grou nd b e conn ect ed to th e
pow er bus aft er th e syst em has b een d e- en ergized, and prior
to working o n th e equi pment.
Follow th e proc edur e outlined i n th e pr e-energization ch eck
s ectio n of this ma nual b efore power is r estor ed.
Operating Environment
Th e Seri es 8 1 000 controll er conforms with th e pro visio ns of
NEM A standard I CS 1 - 1 0 8, Altitud e Class 2 KM, which
d efin es the usual s er vic e condition for el ectr o mag n etic
control. It is d esig n ed for indoor us e wh er e th e t e m p eratur e
i nsid e th e controll er is higher than th e a mbient t e mperatur e .
Th e co ntroll er i s ca pabl e o f carrying its rated load wh e n th e
a mbi ent t e m p eratur e do es not exceed 40 'C ( 1 04 'F) a nd th e
altitud e does not exceed 6600 f e et (2000 m) above s ea l evel.
Wh er e u nu s ual s er v ic e condi tio ns e xist, or wh er e
t e m p eratur e or altitud e li mitatio ns ar e e xc e ed ed, th e
controll er co nstructio n, ratings, or prot ection may r e quire
alt eratio n . So me exa m pl es of unusual s er vic e conditio ns ar e
exc essive moistur e, vibration, or dust.
Site Preparation and Mounting
I nstallatio n shall be in accorda nc e with th e Natio nal Electrical
Code, A NS I, and N F PA 70 Sta ndards. U nl ess th e co ntroller
has b e e n d esig n ed for u nusual s er vice co nditions, it should
n o t b e locat ed wh er e it will b e e x pos ed to a mbi ent
t e m p eratur es abo ve 40 ' C (1 04 ' F), corrosi ve or explosive
fu mes, dust. va pors, dripping or sta nding wat er, ab nor mal
vib r a tio n, s h oc k , tilting, or oth er u nusual o p erati ng
co nditions.
Th e co ntroll er should b e install ed in a clean , dry, h eat ed plac e
w ith good ve ntilation. It should b e r eadily acc essibl e for
c leaning and i ns pectio n a nd should b e car efully s et u p and
l evel ed o n its supporting foundation and s ecur ed i n place. If
th e mounti ng site is not flat and l evel, th e controller must b e
shi m m ed wh er e n ec essary t o pr event distortio n o f th e
fra me.
Th e controll er can b e mount ed by many diff er ent fastening
22
syst ems i ncluding true drop in, cast in plac e, pow er actuat ed,
or threaded i ns ert fasten ers. See Figures 23 and 24 for
anchor bolt locations . Th e bolt patt er n is d e p end e nt o n
fra me width and d e pth, location i n th e lineup, a nd wheth er or
not s i ll chan n els ar e fur nished . Th e grou p arra ng e m e nt
drawing for each controll er d etails th e a nchor bolt locatio ns.
Th e coordination b etw een th e bolts a nd the controll er should
b e verifi ed prior to att e m pti ng i nstallatio n. E x pa ndabl e
ins erts i n pr e-drill ed hol es or i mb edd ed " L " bolts ar e
r eco m m e nd ed. Wood e n plugs driven i nto holes i n masonry
or co ncrete ar e not r eco m m end ed for anchoring i ns erts and
should never b e us ed. Th e bolt size must b e 1 /2 ".
Welding th e st eel bas e or sill chann els to a steel floor plat e is
an alt er nat e mou nting method es pecially r eco m m end ed in
ar eas subject to s eis mic a cti vity.
Grout i ng t h e sill cha nn els as indicat ed i n Figure 25, is
anoth er m ethod of fast e ni ng. This m ethod r equir es th e
fou ndatio n to b e grooved to acc ept th e sill cha n n els. Th e
actual groove di mens ions must b e coordi nated with th e floor
pla n layout o n th e group arrang e m e nt drawing i nclud ed i n th e
co ntroll er i nfor matio n pack et .
General Pre-Installation Inspection
1. Check all parts for s ecur e mounting a nd good el ectrica l
co n n ections. I ns pect visually for overall good condit ion.
2. I ns pect fra me for d e nts a nd oth er da mage. Swing doors
to make sure they pivot easi ly.
3. O p erat e th e rack ing m echanis m to i nsur e fr e e and
s mooth o peration. I ns pect th e stab ass embly and shutt er
mecha nis m .
4. Check fus es for sur e fit i n cli ps. Check fus e c li ps for
d efor miti es a nd s ecure mou nti ng.
5. Check co ntrol circuit plug and r ec e ptac les fo r b e nt pins
and oth er da mage.
6. Mak e sur e that cabl e cla mps a nd i nsulators ar e i n good
condition.
Grounding
Th e fra m e of each controll er must be gr ou nd ed . This
conn ectio n must b e mad e b efor e m a k i n g pow er
conn ections. If a ground bus is furnish ed, th e grou nd
co n n ection should b e mad e to th e ground bus. Th e co ntrol
and i nstru mentatio n circuits ar e grou nd ed to th e enclosur e.
This conn ectio n can b e t e m porarily r e mo v ed fo r t est
pur pos es, but it must be r eco n n ect ed b efore th e controll e r is
r eturn ed to o p eration.
Electrical Connection
To si mplify li n e and load cabl e co nnectio ns, th e co ntactors
and th e horizontal barri ers b etw een units may b e r e mo ved .
B e sure to d isconnect th e control plug b efor e att e m pting to
r e move th e contactor.
Li ne co n n ectio ns should b e mad e fi rst . See Figures 27-3 0
for d etails .
Insta l l a t i o n

fco------ 36 . 0 --------1

J-c>----- , l,\.:,-----<'ooj
liH.4l

bo
----- 36.0 --------1 .625 OIA. 2-lll.ES FOR

I
SILL ANCHOR Btl.TS WHEN
REO'O. II-FRONT,1-REARI
, , , .. . ..

2 9 . 50
FOR T1 , T2, T3 TO BCTTCJ.t C 741.3 1

CENTER L! NE OF CONDU I T ,
COhiPARTMENT.

MAX. NOMINAL R I G I D CONDUIT

SIZE 4( 1 01 . 6 1 .
F OR T1 , T 2 , T3 T O M l DOLE
OR L 1 . L z , LJ TO TOP

CENTER L INE OF CONDUIT MAX.

Cot.IPARTMENT.

N().IINAL R I G I D Ctt!DU I T S I ZE
3 .. C 16. 2 1 FOR CONTROL l U RES .

625 O!A. 4-HOL5

FOR ANCHOR BOLTS

Figure 23 . Top View a n d Typical Floor P l a n with B u s Located i n Top Compartm ent

r,,6 ,
. fc>------ :,6....,-------c-'1
c>---cl:;.:,
.

1 . 12
-----oeo"11
125 D [It, 2--+IDI..ES FDPt
SILL ANCHOR BCl..TS WHEN
1 21 . 41 1 REQ'D,c tTo1-..JIIII

.---r---
.
--.-v______ _

,ij?,L_-Ji c.,r1'l, -l-t-"!'--.l_

FCft Tl, T2,T3 TO MIDDLE
CDI'f'ARTMENT

29.50
l:c.
ALL COHOUITS MAX. RIGID
28.78 SIZE 3 .5 188.qJ,
1731.11) ( 141. 3 1

36.0

J
1914.41
I

68.5
FOR Tl,T2,TJ TO TOP
m;: U T
COMPARTMENT i
1g:
gbD !

.A
CONDUIT FOR

"""') - _L_jiL..l...J ...L

I
CONTROL WIRE

CENTER LINE OF CONDUIT MAX

COMPARTMENT.

... -T
lliLID
,......._ 31176.21 FOR CONTROL WIRES.
T-
NOMINAL RIGID CIHJUIT SIZE

n
_ __ _

FRONT FRC>T
FOR TI,TZ,TJ TO BOTTOM .lr. OU. 4-HDI..ES
2.13 FOR ANCHOR Ita.TS
(54.1 I
I I
COMPARTMENT

32.50
nzs.5J FlOOR PIN/

-L-...L__ u
I I

Figure 24. Top V i e w a n d Typica l Floor P l a n with B u s Located i n Top Hat Compartme n t

23
In sta l l at i o n

Installation
Aft er it has b e e n verifi ed that th e corr ect contactor h as b een
sel ect e d for a gi v e n m e di u m vol t ag e co mpart m ent . th e

------------ -----------

j "
Front
contactor may b e install ed as follow s :
I 1 . Open the m e diu m voltag e co mpart m ent door (h an dl e
mu st b e i n O F F po sition, r e d co nt actor engag e m e nt light

r rrl-- 3.0" 3 . 0" _,fT

mu st b e off ) .

2. 12, 1
_, 1_ < 7 6 . 2 > 6_
c7_
3 2 . 7 5 " __ . 2_l
1 . 12
2. Position th e co ntactor in front o f th e co mp art m e nt i n such
( 53, 8 ) I (831 . 9 )
_

( 28 , 4 )
---
I a w ay th at th e rear contactor wh eel s ar e lined up ju st to
I

the inside of th e sides of th e guide pl at e .
36.0 "
(914.4)
- -

NOTE: A lifting devic e o r ser vic e dolly i s r equir ed t o install

1 : Dimensic>n i n Mill i m e t e r s cont actor s in mi ddl e or upp er co mpart m ents of two- or
thr ee-high design s.

3 . Roll th e cont actor o nto th e gui d e pl at e an d into th e

Figure 25. Typic al Side View with Optio nal Sill Ch a n n el s
Lo a d t er mi n al s ar e con n ec t e d dir ectly to t h e curr e nt
tr a n sfor m er s loc at ed on the l eft si de of the st ar t er unit.
Vertical cable con duit s ar e provided for top or botto m load
c abl e con n ection. See Figure 26. Typical co nduit spac e for
top or botto m entry of load cables and control wir es i s given
in Figures 23 an d 24.
co mpart ment until it stop s . Use th e h an dl e s on th e front
of th e co ntactor for this purpose. Wh e n th e co ntactor i s
fully i nserted, th e mech a nical l atch (see Figure 6 ) shoul d
r o t at e to p r e v e nt it fro m rolling b ac k o u t of th e
co mpart ment.
4 . Co nnect th e control wiring h ar ness to th e co ntactor by
in serting th e h ar ness plug i nto th e r ec eptacl e on th e l eft
side of th e co nt actor.

5 . Clo se an d l atch th e mediu m voltage co mpart m e nt door.

Contactor I n sta l l ation

Preinstallation Checks
Corr ect i n stall ation of contactor s is essential to prop er con
troll er op er atio n. Befor e installing a cont actor in any mediu m
voltage co mpart ment, ob ser ve th e following ch ec k li st :
1. Ch ec k to see th at th e c atalog nu mber, p art nu mber and
pow er fu s e r ating given on th e co nt actor r ati ng l ab el
match es the i nfor matio n given o n th e mediu m voltag e
co mpartment r at i ng label.
2. Ch ec k th e following it e m s in th e contactor for agr eement
with th e i nfor matio n given on th e r ati ng l ab el :
a . Contactor typ e .
b . Contactor co ntinuou s a mp er e r at ing.
c. Power fu se type, "R " or " E" r ating and volt ag e .
d. Co ntrol tr an sfor mer pri mary fu se "E" r ating a n d voltage.
Power Cable Termination
Any t er minatio n for an i n sul ated pow er cable mu st provide
c ert ain b a sic el ectric al an d m echa nic al functio n s. These
essential r e quir e m ents i nclu de th e following :
1. Con n ec t t h e i n sul at e d c abl e co n ductor to e l ectric
equip ment, bus, or u n i n sulated co n ductor to provi de a
curr ent p ath.
2. Phy sic ally pro t ect a n d support t h e e n d of th e c abl e
co n ductor , i n sul ation, sh i el di ng sy st e m, a n d o v er a l l
jac ket, sh eath, or armor of th e c abl e.
3. Effectively co ntrol el ectrical gradient s to provi de both an
i nt ern al and ext ernal diel ectric str e ngth to m e et desir ed
i n sulation l evel s for th e c abl e sy st e m .
Series 81000 Controllers

A wARNING
T h e following g e n er al r eco m m e n datio n s ar e off er e d for
prop er c abl e t er mi n atio n in th e Seri es 8 1 000 controll er s.

1 . Positio n th e c abl e s for maxi mu m cl ear a nc e b etw een

Hazard of explosion or fire.
C a n cause serious i nj u ry, b u r n , or
equipment damage.
Before i nsta l l i n g contactor i n any com
pa rtm e n t, verify a g reement between
each on the fo l l o w i n g compa rtm e n t
l a bel data a n d t h e correspo n d i n g data
on the co n ta ctor l a b e l : Cata l o g N o . ;
P a r t N o . ; C o n ta c t o r A m p R a t i n g ;
Powe r F u se Type; Power Fuse Rati n g .
phases, groun d, an d other cab le wir e run s .
2. Avoi d any possibl e co ntact b etw een low voltag e wir es
and mediu m voltage c ables.
3 . Prepare cable ter mi natio ns i n accor danc e with th e c abl e
manuf actur er 's i n structio n s .
4 . I f contact b etw een th e c abl e a n d adjac ent bus c a n not b e
avoi d e d, t ap e th e bu s to approxi m at e ly 5/32 " (4 m m )
thic kness i n th e i m m ediate vici nity of th e cable co ntact
poi nt so that th e surfac e cr eep a g e di st a nc e fro m th e
cabl e to th e b ar e bu s b ar is at l e a st 3 " (7 6 m m ).

24
I n sta l l a ti o n

B o ttom E ntry T o p E ntry

Front

Typical
Stress --
Cone

S teel
Conduits
for Cables

Side View

Figure 26. Load Cable Ter m i n ation

25
In sta l l a tio n

Top E n try

Type TA2 TB2 TC2

V e r ti c a l

-F1l
V e r tical V e r tical Entry
>. >.

f-Rl ta;
Entry Entry
.... 10.0"

c
.._

w
I =
(254)
A.
0 0 o
.....
c c c
0
+'

0 0
.....

N N N
" i: " i: "i:
0 0 0
I I I

-1 3 6 . 0 " i -1 3 6 . 0 " I_ -j 36.0" l.

(914.4) . ( 914.4) I
M a x . Cable/ <l> C o b l e/ <l>
( 9 14 . 4 )
Max . M a x . C a ble/<j)

< Non - Shielded) <Non - S hielded) ( S hie l d e d )

(1) 250 kcmil V ertical Entry V ertical E n t r y
<2l 750 k cmil < 2 l 7 5 0 kcmil
Horizontal Entry Horizontal E n t r y
(2) 500 kcmil ( 2 ) 500 kcmil

( ) Dimension 1n Millim eters

Figure 27. I n co m i ng Line Arra ngement with B u s Located on Top of the C u b i cle - Top E ntry

26
I n sta l l a t i o n

Bottom Entry

Type BA2 882 BC2 802

-- - --- - -

1 8 . 0"
- .,.____ l36.0"- I I I' I
< 457 . 2 )
MIN. I (914.4)
24 . 0 "
(685 . 8 )
36 . 0 "
r-( 9 1 4 . 4 )1
Max. Cable/ o M a x . C a b l e / l M a x . Cable/o M a x . C a b l e / 10
< N o n - S hielded)
500
< N o n - S hie l d e d ) < N o n - S hiel d e d )
(3) ( 4 ) 5 0 0 k c mil (1) k c mil
(Non- S h i e l d e d )
7 5 0 k c mil ( 6 ) 5 0 0 k cmil
( 3 ) 750 k c mi l
< S h i e lde d ) ( 4 ) 750 k cmil
500
< S hield e d )
(2) 750 k c mi l < Sh i e l d e d )
( 6 ) 5 0 0 k c mi l
< Shielde d )
( 4 ) 500 k c m i l
(1) k c mil

( 4 ) 7 5 0 kcmil (3) 750 k c mi l

B o ttom E n tr y

Type BE2

-I 36.0"I
I

( 91 4 . 4 )

-
M a x . Cable/o
< N o n Sh i e l d e d )
( 4 ) 5 0 0 k c m il
(3) 7 5 0 kcmil
<Shiel d e d )
( 4 ) 5 0 0 k c mil
(3) 750 k c mi l

I J Ll 1 m e r 1 s i o n rn fv1 i l l r rn e t e r s

Figure 28. I n co m i ng L i n e Arra n g e m e n t with B u s Located on Top of the Cu bicle - Bottom Entry

27
In sta l l a tio n

T o p Entry

Type TA.3 TB3 TC3 TD3

V e r ti c a l
E nt r y
V e r tical V e r ti c a l
E nt r y >. Entry

-
\....

l rS.
CT's

0
N
r---
...
0
I

I 36.0" I I 36.0" I I 36.0" I I 36.0" I

-1 ( 9 1 4 . 4 ) j4 -1 ( 9 1 4 . 4 ) j4 -1 ( 91 4 . 4 ) j4 -1 ( 9 1 4 . 4 ) j4
M a x . Cable/ <I> M a x . C a b le/ <I> Max. C o b l e / <I> M a x . C a b l e / <I>
<Non-Shielded) ( N o n - S h iel d e d ) < N o n - Sh i e l d e d ) < No n - S h iel d e d )
(1) 500 k c m i l V e r tical E n try V e r tic a l E n t r y ( 1) 5 0 0 k c mi l
< 2 > 750 k c mi l < 2 l 750 k c mil
Horiz o n t a l E n tr y Horizon tal E n t ry
( 2 ) 500 kcmil < 2 > 500 k cmil

Top Entry

Type TE 3

.J24 . 0"
( 68 5 . 8 )
Max . Cab l e/ cj>

(1 l 500
! Non-Sh i e l ded >
kcmi I

I J D i m e n s i o rl tn M i l l irn e t e r c;

Figure 29. I n co m i n g Line Arra n g e m e n t with B u s Located i n Rea r of the Cubicle - Top E ntry

28
I n sta l l a t i o n

Bottom Entry

Type B A3 BB3 BC 3 BD3

--

-1 o"J I 1.. (.36. 0 "

1 8 . 0"
o- 3 6 . 24 . o "
( 457 . 2 )
( 685. 8 ) -( I

M a x . C a b l e / dJ
( 91 4 . 4 ) ' ( 91 4 . 4 )
MIN.
M a x . Cable/ Max. Cable/ Ma x . C a b l e / >

( 1) 500 k c mil
( Non - S h i e l d e d ) ( N o n - S hi e l d e d ) (Non - Shielded)
(Non- Shielded)
( 2 ) 500 k c mil (4) 500 kcmil ( 4 ) 500 k c mil
( S hi e l d e d ) C3J 7 5 0 k c mil (3) 7 5 0 k c mil
C 2 J 5 0 0 k cm il (Shielded) ( S hiel d e d )
C 4 J 500 k c m i l ( 4 ) 5 0 0 k c mil
( 3 ) 750 kcmil ( 3 ) 7 50 k c mil

B o t t om E n t r y

Type BE3

- - --1

---
CT's
- I

)
..

- 9 1 4 . 4 > 1
i- 36 . 0 ''.1-

Max . Cable/
(Non- Shielded)
C 2 J 500 k c mi l
( 1 ) 7 5 0 k c mi l
( S hield e d )
< 2 > 500 k c mi l
( 1 ) 750 k c mi l

Figure 3 0. I n com i n g Line Arra n g e m ent with Bus Located i n Rear of the C u b i cle - Bottom Entry

29
In sta l l a tio n
Termination of Lead-Covered Cable
Pothe ad s are re quired to ter minate le ad-covered cable s. A
pothe ad is a her metically sealed de vi ce u sed to enclose and
protect cable e nd s. I t co nsists of a metallic body with o ne or
more por cel a in in sul a tor s. Foll ow the p o the ad
m a nu facturer 's i n stru ctions to ter minate the cable at the
pothe ad . I n ge ner al, the body i s arr a nged to accep t a variety
of o p ti o n al c able e n tr a n ce se al i ng f i t ti ng s, while the
por cel ai n s, in turn, are de sig ned to acco mmod ate a nu mber
of optional cable condu ctor and aeri al co n ne ctions.
Termination of Shielded Cables
I n order to redu ce and control the lo ngitudinal and r adial
ele ctrical stre s se s at the ter mination of the cable e nd to
Rubber J a c k e t
G r o u n d Strap . .
Final L ayer E le c trical T a p e
Figure 3 1. Typical Stress Cone
30
values within safe working li mits of the mater ial s u sed to
make up the ter minations, the most co m mon method i s to
gr adu ally i n crease the to tal thi ckne ss of in sul atio n at the
ter minatio n by add i ng i n sul ati ng tape s , or a prefor med
insul ating co mpone nt, in the for m of a cone. The cable shield
is carried up the cone surface and ter minated at a poi nt near
the l arge st d i a me ter of the co ne. Thi s co n str u c tio n i s
co m monly referred to as a stre ss cone and i s illustrated in
Figure 3 1. Le akage di stance " A " for i ndoor dry lo cation i s
reco m me nded to b e a mini mu m of 4 i nche s for working
vol tage up to 7200 vol ts.
NOTE: Co nsult individu al cab le supplier for reco m me nded
i nstall atio n pro cedure s and material s.
" A " L e a k a g e O i ' ta o c e -
/
/ Terminal Lug
/
/
p licing C o m p o u n d Tape
Semi - C ondu ctive T ap e
C o pper - Mesh Shielding T a p e
E l e c trical Tape
S i em e n s Adva nced M otor M aster System ( SA M M S-MV)

SAMMS-MV System Description

Si e m e ns Series 8 1 000 M ediu m Voltag e Controll e rs ar e
a vailabl e with SAMMS-MV, the Sie m e ns A dva nc ed Motor
Mast e r Syst em, s pecifically design ed for medi u m voltag e
machin es. The SAMMS-MV unit is a micro proc essor bas ed
softwar e co nfig u rabl e co ntrol e r s pecifically desig n e d for
motor control a pplications. It pro vi d es all co ntrol logic a n d
motor prot ection functio ns r equir ed for ty pical motor a ppli
cation. T h e SAMMS syst e m eli minat es the n e e d for
s e pa rat e o v erload r elays, ti m ers, co ntrol r elays, m et ers,
auxiliary contacts, pushb uttons and pilot lights.

Configuration
Control Units with the SAMMS-MV syst e m ar e equi pped
with curr e nt transfor mers a n d the SAMMS-MV u nit. A ha nd
h el d co m municator is us ed to s et para m et ers and dis play
data. The SAMMS u nit is pow er ed fro m the control pow er
transfor mer on the co ntactor. The devic e is mo unt ed i n the
low voltage co mpart ment for each start er, an d pro vides all
pushb utto n an d indicator fu nctions.

Protection Functions
Overloa d prot ection (with 5 % accuracy ) Figure 3 2. SAMMS-MV u nit an d Ha nd- H el d Co m m unicator
Choic e of 22 overload prot ection curves Starter Types
Phas e loss/ phas e unbalanc e prot ection T h e SAMMS softwar e library of mor e than 40 la d d e r

diagra ms co vers most stan dar d motor co ntrol a pplications.

I mpen ding overloa d trip alar m (o ption )
Start er ty pes inc lu d e :

Loc kout on ther mal o verloa d tri p
Across-the- li ne, no n-r eversi ng

Underc urr ent/loss of loa d prot ectio n (o ption)
Across-the-li ne, r eversing

M echa nical ja m prot ectio n (o ptio n)
Two-s peed, two-wi ndi ng

Proc ess current (loa d c urr ent ) alar m (o ption )
Two-s peed, on e- w 1 n ding, constant or variabl e tor que

The SAMMS syst em offers progra m mable co ntrol logic, a
desig n bas ed o n a stan dar d har dwar e a n d el ectro nic circ uit
co nfiguration that may b e mo difi e d by progra m mi ng the
co ntroll er 's micro proc essor. Ty pical motor co ntrol devic es,
such as ti mers, co nt rol r elays, p ushb utto ns, an d s el ector
switch es tra ditio nally locat e d in th e m e diu m volta g e
controll er, a re r eplac ed by SAMMS-MV software, a n d push
b utton s an d in d i cator s on t h e u nit control pa n el. Th e
SAMMS-MV controll er can b e prog ra m med to pro vide o ver
40 d iff er ent motor control circu it arrangements, an d is a r eli
able and practical protection system for all mediu m voltage motors .
Two-s peed, on e-wi nding, constant hors epower
R e d uc ed- voltag e, autotransfor mer o r r eactor
Table 5 is a listi ng of thes e standard circ uits .
For s p ec ial moto r co ntrol a p plications not co ver ed by the
l ibrary of stan dar d la dder d iagra ms, c ustom diagra ms ca n b e
constr uct e d using the SAMMS-MV i n put a n d o ut put devi ces
an d their assoc iat ed sy mbols . Si e m ens off ers a softwar e
pac kag e fo r us e o n a personal co m p ut er to develo p such
c usto m diagra ms.

Table 5. Standar d Circ uits for Starter Arrangements

Starter Type

1 Winding 1
2 Speed 2 Sped
Winding

HP
2 Speed Constant or Constant Autotransformer Reactor
Control Type FVNR FVR 2 Winding Variable Torque RVA RVA
Local 2-Wire .I .I .I .I .I .I .I
Local 3-Wire .I .I .I .I .I .I .I
Local 3-Wire Remote 2-Wire .I .I .I .I .I .I .I
Local/Remote 2-Wire .I .I .I .I .I .I .I
Local/Remote 3-Wire .I .I .I .I .I .I .I

.I
Local/Remote 3-Wire
- - - - - -
E lectrica l l y Interlocked
Remote 2-Wire .I .I .I .I .I .I .I
Remote 3-Wire .I .I .I .I .I .I .I

31
S i em e ns Adva nced M otor M aster System ( SA M M S- M V)

Diagnostics compares the fu nctions of each model.

The SAM M S-MV control ler provides visual diagnostics used
to quickly determine the cause of motor problems. The front
panel of the contro l l e r has eight diagnostic L E D 's to i n dicate :
C u rrent Phase U n ba l a nce
I m pending Overload Trip
T h e SA M M S-MV device i s d e s i g n e d f o r c r i t i c a l p rocess
control where prevention of downti me i s critica l . I t offers
motor control and protection along with motor diagnostic a n d
motor-d riven e q u i p ment protect i o n . E n g i n ee r i n g a n d oper
ating personnel have access to i m portant data enabl i ng them

to optimize motor-driven equipment capab i l ities, to maxim ize

Overload Tri p
the process system output, and to fac i l itate ma i ntenance.
External Trip
SAMMS-MVX i s a f u l l fu n c t i o n m o d e l , a p p l i c a b l e to a l l
I n complete Sequence control needs, from a s i m p l e across-th e-l i n e u n it to a more
G round Fault complicated reduced voltage scheme. It i n cl udes all of the
CPU Fault functions l i sted i n Table 6. Any of the standard control circu its

l i sted in Table 5 or a custom ci rcu it, may be down loaded .

Ready (Control Power Status)
In addition, the SAM M S-MV device can provide statistical
motor data, i n c l u d i n g the total elapsed motor r u n n i n g time,
n u mber of starts, and the n u mber of ove rload trips. T h i s
statistical data is stored i n t h e m icroprocessor's non-volati le
memory and d i s played using the hand held com m u nicator.
T h e c o m m u n i c a t o r c a n a l so be u s e d as a n a m m e t e r to
display a ny of the three phase motor c u rrents.
The SAMMS-MV Device Models
SAM M S-MV is ava i lable i n two models: SAM M S-MVX and
SAM M S-MVE. Each meets the va rious demands of i n d u strial
a n d c o m m e r c i a l s pecifications a n d i nsta l la t i o n s . Table 6
SAMMS-MVE is a model of SAM M S-MV tai lored to across
the-l ine ( FV N R ) appl ications. It provides a l l of the protective
f unctions of the SAM MS-MVX device, except that it has no
jam protection ( F23), loss of load protection/alarm ( F24), or
process current warn i n g ( F22) fu nctions. Fu nctions F3 a n d F5
associated with two-speed appl ications are not ava i l a b l e . N o
provision f o r a utomatic reset ( F8) is provided. SAM M S-MVE
a c c e pts o n e r e m ote i n p u t , a n d p r o v i d e s o n e o ut p u t to
actuate a single contactor. An alarm contact is not ava i lable
with SAM MS-MVE.
For additional i nformation on operation and ma i ntenance of
the SAM M S-MV u n it, refer to i n struction m a n u a l MVC-91 0 8 .

Table 6. SAM M S-MV Fu nctions and Models

Model
Function
Number Function SAMMS-MVX SAMMS-MVE
FO A m bient Temperature .I .I
F1 Control Circuit N u mber .I .I
F2 Size for Overload N o . 1 .I .I
F3 Size for Overload No. 2 (low speed) .I
F4 Full Load C u rrent for O L R No. 1 .I .I
F5 F u l l Load Current for OLR No. 2 .I
F6 Service Factor, and Type Motor .I .I
F6A Motor Type .I .I
F7 Overload Trip Class, and Cold Stall Time (class 2-23) .I .I
F7A Cold Stall Time .I .I
F8 Automatic Reset .I
F9 Phase U n balance .I .I
F10 Time to Restart .I .I
F11 E m e rgency Restart .I .I
F12 G ro u n d Fault Protection or Warning .I .I
F12A G ro u n d Fault Pickup Cu rrent .I .I
F13 Timer No. 1 .I .I
F14 Timer N o . 2 .I .I
F15 Motor Current .I .I
F16 Last Tri p Current .I .I
F17 Percent U nb a l a nce Current .I .I
F18 Tota l E lapsed R u n-Ti m e on Motor .I .I
F19 Total N u m ber of Motor Starts .I .I
F20 N u m be r of Overload Trips .I .I
F21 Reset Motor Data .I .I
F22 Set Process Current Warning .I
F23 J a m Protection .I
F23A J a m Pickup C u rrent .I
F24 Loss of Load Protection or Warning .I
F24A Loss of Load Pickup C u rrent .I
F25 Motor W i n d i n g Temperature as % of F u l l Load Temp. .I .I
F26 Baud Rate .I .I
F27 Address .I .I

32
Type 3 U A Th e r m a l Ove rl oad R e l ay
1173-93
Figure 3 3 . Type 3 U A Overload Relay
General
This section is i ntended to g u ide the user in the selection,
a p p l i cation a n d setti n g of the type 3UA thermal ove rload
rel ay, when used in m e d i u m voltage ( 2 . 3 -6 . 6 kV) motor
control a p p l i ca t i o n s . I t i s esse n t i a l t h a t t h e i nformation
c o n t a i n e d h e re b e s t u d i e d c a ref u l l y to e n s u re p r o p e r
c o o rd i n a t i o n b e t w e e n ove r l o a d r e l a y a n d p o w e r f u s e
characteristics.
Overload Relay Operation
The Typ e 3 U A ove r l o a d r e l a y i s d e s i g n e d a n d f a c t o ry
c a l i b rated to provide over-tempera t u re p rotect i o n for the
w i n d i ngs of th ree-phase AC m otors . The relay w i l l s h u t
d o w n t h e m ot o r a n d/or a c t i v a t e wa r n i n g a l a r m s u n d e r
conditions o f motor overloa d i n g , s i n g l e-pha s i n g , prolonged
acce l e ration and cert a i n conditions of freq u e n t restarting
operations. The internal heaters a re energized from the 5
a m p secondary w i n d i ngs of the phase cu rrent tra nsformers.
Application
Squ i rrel cage, synchronous and wou nd-rotor t h ree-p hase
motors may be protected by the type 3 U A overload relay
regardless of the type of starting e m p l oyed . The application
ta b l e (Tabl e 7) p ro v i d e s t h e c u rre n t r a n g e s a n d corre
sponding relay catalog n u mbers for specific motor f u l l load
currents divided by the appropriate current transformer ratios.
Markings on the relay adjustment dial denote motor f u l l load
amps, divided by the CT ratio. Tripping cu rrent is 1 25 % of
dial setti n g . The adjustment dial should be set on the basis
of full load cu rrent marked on the motor nameplate or on the
basis of actual measured ru n n i ng cu rrent.
For motors with a ma rked service factor not less than 1 . 1 5,
or motors with a ma rked temperature rise not over 40C, use
the form u l a below for determ i n i n g the dial setting:
Dial Setting = Nameplate F u l l Load C u rrent
(for 1 . 1 5 SF) Cu rrent Tra nsformer Ratio
I n case overload relay tripping occurs during motor starti n g or
a t m a x i m u m r u n n i n g c o n d i t i o n s , t h e ove r l o a d relay d i a l
setti ng can b e increased b y a factor not t o exceed 1 . 1 2 times
the val u e determined by the above form u l a in accordance
with N E C Article 430-34
F o r a l l o t h e r m otors rated for conti n u o u s d uty i n c l u d i ng
motors with a marked service factor of 1 .0, use the form u l a
below f o r determi n i ng the d i a l setti ng:
D i a l Setting = (0. 92) ( N a m ep late F u l l Load C u rrent)
(for 1 .0 SF) C u rrent Tra nsformer Ratio
In case overload relay tripping occurs d uring motor starti n g or
a t m ax i m u m r u n n i n g c o n d i t i o n s , the ove r l o a d relay d i a l
setting can b e increased by a factor not t o exceed 1 .04 times
the va l u e determined by the above form u l a i n accordance
with NEC Article 430-34.
N OT E: I f t h e m o t o r i s a h e r m e t i c a l l y s e a l e d t y p e
( s o m e t i m e s u s ed f o r a i r con d i t i o n i n g o r ref r i g e r a t i o n
drives) a magnetic type overload relay i s norm a l ly req u i red
due to the i n h e rent l i m ited thermal winding capacities of
these motors. Check a pp l ication .
After the d i a l setting has been determined, the relay having a
c u rrent ra n g e that wi l l i nc l u d e the d i a l sett i n g s h o u l d be
chose n . The dial setti ng m ust be made on each relay for the
i ndividual motor application.
F o r exa m p l e , for a p a rt i c u l a r motor, n a m e p late f u l l l o a d
c u rrent is 2 0 0 a mps, nameplate service factor is 1 . 1 5 a n d
cu rrent tra nsformer ratio is 300/5 amps. Then, u s i n g the fi rst
form ula,
Dial Setting 200 = 3.33
300/5
The relay with a range that w i l l incl ude the d i a l setting of 3.33
a mps m ust therefore be used. From Table 7, relay cata log
n u m b e r 3 UA59 00-1 E wou l d be c h osen having a sett i n g
ra nge from 2 . 5 t o 4 . 0 a m p s . T h i s setting permits t h e motor
to run up to its f u l l service factor before tri pping w i l l occur.
Note that relay 3 UA59 00-1 F ( 3 . 2 - 5 . 0 a mps) could have been
c h o s e n f o r t h i s a p p l i c a t i o n . E i t h e r re l a y w i l l work a n d
selection i s optiona l .
33
Type 3 U A Th e rm a l Ove r l oad R e l ay

Table 7. 3UA Relay Application sta rting cu rrent. The torque that the motor w i l l develop is
p r o p o rt i o n a l to the s q u a re of the a p p l i e d v o l ta g e . F o r
Minimum Maximum Relay exa m ple, should t h e l i n e voltage drop 1 0 % from normal, the
Amps Amps Catalog No. motor will develop approximately 8 1 % as much torq ue as on
rated termi n a l voltage. Any loss i n developed torq u e may
1 .6 2.5 3UA59 00- 1 C produce a marginal acceleration condition . Such loads as
2.0 3.2 3 UA59 00- 1 0 p u m p s , c o m p r e s s o r s , f a n s , etc . , a r e n o r m a l l y sta rt e d
2. 5 4.0 3 UA59 00- 1 E u n loaded.
3.2 5.0 3 UA59 00- 1 F
I mproper operation of the u n loading features may extend the
Cyclic Starting a c c e l e r a t i n g t i m e to c a u s e o v e r l o a d r e l a y s to o p e ra t e .
Thermal overload relays acc u m u late heat on operation a n d Certa i n h i g h i n e rtia loads m a y i n h e rently have acce lerat i n g
a p p ro x i m a t e l y t w o m i n utes c o o l i n g t i m e s h o u l d e l a pse t i m e s i n excess o f t h a t which overload relays w i l l tolerate
before attem pt i n g to reset relays after tripping has occurred. without trippi n g . This condition may exist on d rives such as
Even though the relay can be successfu lly reset, its operating h a m m e rm i l l s o r i m pactors, ro l l and jaw c r u s h e r s , l a rg e
time on restart after tripping may be considerably shorter blowers, flywheel m-g sets, chi ppers, etc.
than that from a cold start. Approximately one hour cool i n g
W h e re motors have been esta b l is h e d as s u it a b l e for t h e
t i m e is requi red f o r t h e relays t o cool completely t o room
n o rma l ly l o n g accel erati ng t i m e s , it may be necessary t o
temperature after they have been de-energized.
bypass t h e overload relays during the starting i nterva l . T h i s
Therm a l ove rload relays wi l l trip d u e to acc u m u lated heat c a n be d o n e b y the addition o f controlled shorting contacts.
from jog g i n g or frequent resta rti n g operatio n s . However, Problems of this nature s h o u l d be referred to the factory with
thermal overload relays may not protect motors completely if complete operational detai l s . The motor load cu rrent s h o u l d
frequent restarting after tripping is attempted beca use the always be measured when relay t r i p p i n g occurs. The most
cool i n g t i m e of the m otors w h i c h t h ey a re p rotect i n g is common cause of relay tripping is the s i m p l e fact that the
considera bly longer than that of the relay elements . Joggi n g motors a re overloaded d uring operation.
a n d cycl i c starting s h o u l d be kept t o a n absol ute m i n i m u m to
prolong motor and contro l l e r l ife.
Operational Checks
U n d e r n o r m a l operat i n g conditions ove rload rel ays n ever
Cyclic Loading operate. After p ro l o n ged periods i n certa i n atmos p h e res,
Thermal overload relays may have a tendency to over-protect (corrosive, d usty, or g u m my) it is possi b l e that they may not
motors which serve h i g h ly fl uctuating loads. With this type o p e ra t e p r o p e r l y . The f o l l o w i n g o p e r a t i o n a l t e s t w i l l
of loading, the operating elements of the thermal overload demonstrate i f the overload relay i s f un ctioning properly at
relays tend to accu m u l ate the heat prod uced by the load the existing cal ibration sett i n g . This operational test s h o u l d
peaks a n d cause tripping even though the effective load ing be incl uded as a part o f t h e periodic m a i ntenance sched u l e .
may be wel l with i n motor rat i n g .

The effect of p u lsati n g type o f drive c a n be determined by

Test Procedures
c a l c u l a t i n g t h e root-m ea n-sq u a re va l u e from a record i n g
O b s e rve t h e f o l l o w i n g p r e c a u t i o n s w h i l e m a k i n g t h e
c u rrent chart or b y using a p l a n i meter with a cu rrent c h a rt
operational test:
showi ng a typicai load cycl e . S h o u l d tripping occur when the
effective loadi n g is within the rating of the motor, the setting 1 . All relay components m ust be at the same temperature at
of the relay can be proportionally i ncreased to correspond to the start of each test run. It may be necessary to wa it
the effective l o a di n g . If a satisfactory sett i n g can not be approxi mately one hour between each test r u n .
obta i ned, the factory s h o u l d be consu lted after f u l l details of
2 . If t h e relay is u s e d t o set t h e l o a d , t h e n it s h o u l d cool o n e
a ppl ication and loading a re obta i n e d .
hour before proceed i n g with t h e test.
3. The cu rrent m u st be held at the test va l u e d u r i n g the test
Single-Phasing run.
The Type 3UA thermal overload relay provides protection for
4. I f a l a b o ra t o ry type a m m et e r i s n o t ava i l a b l e , t h e n
th ree-phase motors a g a i nst overheati n g i n the event of a
a l lowance m ust b e made for the i naccuracy o f sta ndard
s i n g l e-phase or phase c u rrent u nbalance condition . When
meters.
any of the three phases i s opened, the relay senses this and
its curve sh ifts to a faster time-current characteristic, thus
making it more sensitive to the h i g h e r s i n g l e phase current.
Operational Test
I f the relay trips, it could be d u e to either a normal three
R e f e r to F i g u r e 3 4 f o r t e s t e q u i p m e n t re q u i r e d a n d
phase overload or s i n g l e phase conditio n .
connections. Proceed a s follows

1 . Check d i a l setting of relay as outlined in "Appl ication "

Causes for Relay Tripping section of these i n structions.
S h o u l d overload relay t r i p p i n g occur from a cold start-up,
2 . Adjust va riable autotransformer to s u pply three times the
abnormal starting conditions exist. The l i ne voltage should
current i n dicated on the overload relay dial. Relay should
rem a i n close to normal even w h i l e the motor is drawing high
trip i n 1 7-37 seconds.

34
Type 3 U A Th e rm a l Ove r l oad R e l ay

NOTE: A s l i g ht adj ustment of the d i a l setti n g may be a pp r o x i m a t e l y o n e-fou rth of t h e t i m e from a c o l d start.
necessary to arrive at this trip t i m e . If a s l ight adjustment S h o u l d ca ref u l c h e c k i n g of a n y relays reve a l t h e m to be
is made, it is recommended that the 1 00 % current test be s i g n ificantly out of c a l ibration, they may have been s u bjected
made as outlined below. to tamperi n g or h a n d l i ng damage and s h o u l d be replaced.

Coordination with Current-Limiting Motor Fuses

T h e ove r l o a d re l a y t i m e-c u rrent c h a ra cte ristics m ust be
se lected so that t h e power f u s e s a re p rotected a g a i n s t
Va riable Auto u n necessary operation or da mage d u ri n g motor starting o r
Tr a n s f o r m e r overload conditions. I n a properly coordi n ated system , the
L a b o r a t o r y Type
2 Amp. Min.

/
AC Ammeter overload relay will operate to open the main contactor before
( 1 0 - 1 5 Am p ) the fuse melts u n d e r motor l ocked-rotor conditions. The
//
-
10 Amp
com b i n ation of type 3 UA ove rload relay and power fuse

u
1
I
1 1 5 . 6 V o lt
Filament
T r ansformer )
rating supplied i n Series 8 1 000 contro l l e r is factory-selected
to p rovide p roper f u s e coord i n at i o n a n d opti m u m motor
protection.
<(
>
Proper coordination also e n s u res that the motor fuse can n ot
be s u bjected to cu rrents below its m i n i m u m i nterr u pti n g
1.()


rati n g (cu rrents which req u i re over 1 00 seconds t o melt the
fuse) for a period of time long enough to cause overheating
' and damage to the fuse. The overload relay m ust be set to

t
trip and open the contactor at currents i n this range before
the fuse becomes so overheated that it cannot i nterrupt.
3UA The overload relay and fuse characteristics can be compared
O v e r loa d by ove r l a y i n g t h e tra n sparent t im e-cu rrent c u rve for the
R e lay overload relay with the fuse m i n i m u m melting time c u rves.
The curves s h o u l d be positioned one over the other on a light
table so that the 1 00 % current mark on the overload c u rve is
a l igned with the cu rrent on the fuse curve correspond ing to
t h e d i a l sett i n g o n t h e ove r l o a d re l a y . F o r p r o p e r f u s e
Figure 3 4. Con nections and Equi pment for Operational Test
protection, t h e inte rsection o f t h e two curves m ust occur a t
or Calibration of Type 3 U A Overload Relay
a point u n der 1 00 second s .

100% Current Test

NOTE: I nsta l lation of power factor correction capacitors
T h e 1 0 0 % c u rrent test provides a c l os e c h e c k of r e l a y
can affect overload relay trip sett i n g .
operation . Proceed as fol lows :
If the capacitors a r e connected t o t h e l o a d (motor) side of
1 . Apply 1 1 5 % of the d i a l setting cu rrent through a l l three
t h e c u rre n t tra n sformers or d i rectly to t h e m otor, t h e
elements of the relay. Relay s h o u l d not trip with i n 3/4
overloads m ust b e derated. A five percent decrease in the
hour.
trip setting would be a nominal req u i rement. To accurately
2. Apply 1 25 % of the d i a l setting current through a l l th ree determ i n e the proper setting, operate the motor with the
elements of the relay. Relay should trip with i n 3/4 hour. c a p a c itors d i sc o n nected a n d m e a s u re the s e c o n d a ry
c u r r e n t of t h e c u r r e n t t r a n s f o r m e rs . C o n n e c t t h e
All relay operati n g elements m ust have coo led down to room
c a p a c itors a n d a g a i n m e a s u re t h e s e c o n d a ry c u r r e n t .
temperature before repeating the test or the trip times w i l l
Calcu late the percentage difference a n d decrease the trip
be su bsta nti a l ly faster than i n d icate d . S h o u l d a motor b e
setti ng accord i ng ly.
run n i ng n e a r fu l l l o a d a n d jam or sta l l , t h e relays w i l l trip i n

35
Type 3 U A Th e r m a l O ve r l oad R e l a y

Current Characteristic Curves

Type 3UA Thermal Overload Relay - NEMA Class 10
C a t . N o . 3UA5900 - 1 E , Setting R ange 2 . 5 - 4 . 0 Amp
Medium Voltage Control Applications

i'. of Dial Setting 0 0

0
0 0 0
0
0 0 0 0
0
"' 0 8 g 0 Ill g
1 0000 1 0000 "
"' "' "'

g
5 000 5000
-

. t
e
I

! ' I I I I

r
1 000 1 000

500 500
400
300

\v
200

-:3
I
fJ)
-o
1:::
1 00 :A 1 00
c
0 0
u u
<I> 50 50
Q)
(/') 40 (/)
--

- 30
-
<I> 20 I Q)
E I
E
;.::
10 10 ;.::

5
4
3

! I I !

.g

I l l !I I I

1 1 1 :I
0 0.1
0 0
i
g g ggg
.1

0 80
I

g
...- N rw"' V U"J 0
i'. o f Dial Setting
Ill
"'

NOTES:
1. Curves are based on "cold" start at 25' C ambient. For
full ruMing condition tripping times are lowered to 251. Relay Cot. No. Setting Range

1.6-2.5 Amps
of indicated values.
2. Band (1) shows maximum and minimum tripping charac 3UA59 00-1C
teristics for normal three-phose balanced load.
3. Curve !2) shows maximum tripping times for single
3UA59 00-10 2.0-3.2 Amps

phase conditions. 3UA59 00-1E 2.5-4.0 ,Amps

4. Motor Cline) current is equal to overload relay current
multipied by current transformer ratio. 3UA59 00-1F 3.2-5.0 Amps

Figure 3 5. Cu rrent Cha racte ristic Cu rves of Type 3 U A Overload Relay

36
Ope ra t i o n
A wARN I NG
Hazardous voltages.
C a n c a u s e s e r i o u s i n j u ry, b u r n o r
equipment damage.
A l l pre-energ izati o n ch ecks o u t l i ned i n
t h i s i n s t r u ct i o n m a n u a l m u s t b e
p e rf o r m e d befo re t h e e q u i p m e nt i s
e n e rg i z e d . T h i s e q u i p m e n t s h o u l d be
energ ized by q u a l ified perso n n e l on ly.
Pre-Energization Check
Aft e r i n sta l l a t i o n , f i e l d a d d i t i o n s , or m a i n t e n a n c e , t h e
fol lowi ng checkl ist should b e fol lowed :
1 . Retighten a l l accessible con nections in accordance with
the torque va lues provided i n Table 9 of the M a i ntenance
section of this m a n u a l .
2 . R e m ove a l l b l ocks o r o t h e r tem porary h o l d i n g m e a n s
used for s h i p m e n t f r o m a l l component devices i n t h e
contro l l e r i nterior.
3. Check the i ntegrity of the bus mounting means.
4 . Check the enclosure to see that it has not been damaged
i n such a manner as to reduce electrical spaci ngs.
5 . C o m p a re a l l c i rc u its f o r a g re e m e n t with the w i r i n g
diagrams which accompany the contro l l e r.
6. M a ke certain that external wiring is clear of bus, a n d a l l
p o w e r w i r i n g is phys i c a l l y s e c u red to w i t h s ta n d t h e
effects of t h e l a rgest fa u l t c u rrent w h i c h t h e s u p p l y
system is capable o f del iveri n g .
7 . Ve rify t h a t a l l g r o u n d c o n n e c t i o n s h a ve b e e n m a d e
properly. I f sections of t h e control l e r were sh i p p e d
separately, they m ust be con nected i n a m a n n e r t o assure
a continuous ground path.
8 . Check all devices for damage. M a ke necessary repa i rs or
replacement prior to energ i z i n g .
9. Be s u re that e a c h m o t o r i s c o n n ected t o i t s i n te n d e d
starter. Ascertain that fuse rati ng is i n agreement with the
rating specified i n the contactor catalog n u m ber.
1 0. M a n u a l ly exercise a l l contactors, magnetic devices, and
other operating mechanisms to make certai n that they are
properly a l igned and operate freely.
1 1 . W i t h a l l l o a d s d i s c o n n e c t e d , e x e rc i s e a l l e l ec t r i c a l ly
operated devices with test power to determ i n e that the
devices operate properly. Refer to the wiring diagrams
for the req u i re d control v o l t a g e , fre q u e n cy, a n d test
p o w e r te r m i n a l d e s i g n a t i o n s re q u i r e d t o t e s t t h e
contactor.
1 2 . Test the g round fa u lt protection system (if f u rnished) i n
accordance with t h e man ufacturer's i nstructions.
1 3. Set the adjustable cu rrent and voltage trip mechanisms (if
furnished) to proper values.
1 4. 1 ns ure that overload relay cu rrent ra nge and setti ng i s in
agreement with the full load c urrent and service factor
shown on the nameplate of each motor, taking into account
the current transformer ratio used i n the controller.
1 5. Make s u re that a l l fuses are completely i nserted in the clips.
1 6. 1f applicable, i nsta l l a ny necessary CT circuit wiring, and
re m ov e CT s h o r t c i r c u i t i n g j u m p e r s i n s t a l l e d f o r
sh ipment. (Do not remove CT short circuiting j u m pers if
no load circuit is connected to the CT) . If short circuiting
type term i na l b l oc k s a re p rovi d e d , a s s u re t h at s h o rt
c i rc u i ti n g sc rews a re remove d . C h e c k e a c h c u rr e n t
tra nsformer secondary c i rc u it f o r conti n u ity t h ro u g h its
protective devices to g ro u n d . D o n o t operate a motor
c o n t ro l ! e r w i t h a c u r r e n t t r a n s f o r m e r s ' s e c o n d a ry
protective circuit open .
1 7 . Check to i n s u re that a l l pa rts and barriers that may have
been removed d u r i n g wiring and i nsta l lation have been
properly rei nsta l l e d .
1 8. Before c l o s i n g t h e e n c l o s u re , rem ove a l l m etal c l i p s ,
scrap wire, and other debris from t h e contro l l e r i nterior. If
there is appreciable accum ulation of d ust or d i rt, clean out
the controller by using a brush, vacu u m cleaner or clean,
l i n t-free rags. Do not use compressed a i r, as it will only
redistribute conta m i na nts on other s u rfaces .
A wARNING
Hazardous voltages.
Can cause death or severe injury
Dielectric o r m egger testing s h o u l d o n ly
be co n d u cted by q u a l ified p e rs o n n e l .
R ef e r to test d e v i c e i n st r u ct i o n s fo r
safety i nstructions.
A wARNING
,
Vac u u m i nterrupters may emit x-ray
radiation. Can cause personal injury.
E x c e s s i ve d i e l ect r i c test v o l t a g e s c a n
c a u se x-ra d i at i o n to be e m itted fro m
vac u u m i nterrupters.
R efer to vacu u m co ntacto r i n struct i o n
m a n u a l for d i e lectric test proced u res.
1 9. After all of the power and control connections a re made
and with all incoming power disconnected, conduct a n elec
trical i nsulation resistance test on the power circuit to insure
that the contro l l e r is free from short circuits and g rounds.
A dielectric h i-pot test at 2.25 times the nominal system
voltage p l u s 2000 volts a pplied for one m i n ute between
phases and from a l l phases to ground is the preferred
method . B e s u re to d i scon nect a ny devices (control
power tra nsformer, etc. ) from the circuit which could be
damaged by the test voltage. If a h i g h-potential test set i s
n o t ava i lable, a megger test at 1 000 volts is a s u itable
37
Ope ra t i o n

second choice.
Since wide variations can occur i n insulation values because
of atmospheric conditions, contam i nation and type of test
e q u i p ment d iscrete values can not be give n . H owever,
making and recordi n g tests on new equipment, and again
at regu l a r intervals, w i l l g ive a comparative i n dication of
i n s u l ation c h a n g e . M a i nta i n i n g a permanent record of
these val ues should be part of the m a intenance program.
2 0 . 1 nstal l covers, close doors, and m a ke certai n that no wires
are p i n c he d a n d that a l l e n c l o s u re pa rts a re properly
aligned and tightened.
1.
Energizing Equipment
In order to m i n i m ize risk of i n j u ry or d a m a g e , or bot h ,
t h e re s h o u l d b e n o l o a d o n t h e c o n t r o l l e r w h e n it i s
energized. Turn off a l l of t h e downstream loads, i n c l u d i ng
those such as d istribution equipment a n d other devices
which a re remote from the contro l l e r.
2. T h e e q u i p m e n t s h o u l d be e n e rg i zed i n s e q u e n c e by
sta rt i n g at the s o u rce e n d of the system and worki n g
towards t h e l o a d e n d . I n o t h e r words, e n e r g ize t h e
i ncoming power to the controller or group o f controllers,
then close the incom i n g l i ne load break switch if supplied,

A wARNING
a n d then rack i n the contactor.

3. After a l l d isco n nect devices have been closed, loads such

I as motors may be t u rned o n to verify that the system
operates as i ntended.

Hazardous voltages.
Can cause death, severe personal injury,
or equipment damage.
C o m p l ete a l l p r e- e n e rg i zati o n c h ecks
o u t l i n e d i n t h i s i n st r u c t i o n m a n u a l
before the e q u i p ment i s e nergized.

38
Ope ra t i o n

TEST SWITCH CONTACT
DEVELOPMENT n115V. OR 230V.
>--
z (J) XI X2
LSI
UJ
CPT
:;) -- --------------
a: >-- y ------------------------

A X
B X
c X 53
20

------<s
X= CONTACTS

.---=
5=-
5
CLOSED TEST

I
8 9 3
5
lA 4
RSI TFU
0
II
----rr=TI------m-=-
115V. OR 230V.
TEST POWER

START
STOP _j_ 3

J2
4

LEG END
CPT ....CONTROL POWER TRANSF.
CX F U .... FUSE FOR C P T SEC.
LSI ....LINE SWI TCH INTERLOCK
M .... MAIN C ONTAC TOR W2
M R .... MASTER RELAY
MR
Wl
RL .... HIGH V OLTAGE LIGHT

RSI .... RACKING SW ITCH INTERLOCK

TFU .... FUSE FOR TEST POWER

ADDIT IONAL AUXILIARY CONTACTS

Figure 3 6. Typical Control Ci rcuit D i a g ra m with Type 93H3 o r 94H3 Contactor

39
M a i n te n a n ce
A oANGER
Hazardous voltages.
Will cause death, severe personal injury,
or equipment damage.
Disco n n ect a n d lockout i ncom i n g power
a n d c o n t r o l v o l t a g e s o u rc e s b efo re
b eg i n n i n g w o r k o n t h i s or any ot h e r
e l ectric a l e q u i p ment.
Check all control circuit term i n a l s with a voltmeter to m a ke
certai n that the equipment is tota lly deenergized.
Use o n ly a p p roved h i g h voltage test e q u i p m e nt to check
voltage on power term i n a l s . Do not atte mpt to measure h i g h
voltage w i t h a volt-ohm meter.
Never attempt to withd raw a d rawout carriage or disconnect
a ny terminations when a defeater mechanism has been used
to open a compartment door.
It is recommended that a safety g round be connected to the
power bus after the system has been deenergized, and prior
to worki n g on the equipment.
Safety
For the safety of m a i ntenance personnel as well as others
w h o m i g h t be e x p o s e d to h a z a rd s a s s o c i a t e d w i t h
m a i ntenance activities, the safety related work practices of
N F PA 70E, Parts I I and I l l should a lways be followed when
working o n e lectrical e q u i p ment. M a i ntenance person n e l
s h o u l d b e tra i n e d i n the safety practices, proce d u res a n d
re q u i re m e n t s t h a t p e rta i n t o t h e i r r e s p e c t i v e j o b
assign ments. This m a n u a l should b e reviewed a n d reta i ned
i n a l o c a t i o n r e a d i l y a cc e s s i b l e f o r r e f e r e n c e d u r i n g
m a i ntenance of this eq u i pment.
The user m ust esta b l ish a periodic m a i ntenance program to
e n s u re tro u b l e-free a n d safe operation. The frequency of
i n s pection, periodic clea n i n g , and preventive m a i ntenance
sched ule will depend u pon the operation conditions. N F PA
Publication 7 0 8 " E lectrical Equipment M aintenance " may be
used as a g u ide to establ ish such a program . A preventive
m a i nt e n a n ce p r o g ra m is n o t i nt e n d e d to c o v e r
reconditioning o r major repair, but should b e designed
to reveal, if possible, the need for such actions in time to
prevent malfunctions during operation.
Recommended Maintenance and Lubrication
Periodic m a i ntenance a n d l ubrication should include all the
tasks shown i n Table 8. Recom mended procedures for each
of the l i sted tasks a re provided i n this section of the m a n u a l .
40
A wARN I NG
Failure to maintain the equipment will
result in death, serious injury or product
failure, and can prevent successful func
tioning of connected apparatus.
T h e i n s t r u ct i o n s c o n t a i n e d h e re i n
s h o u l d be c a refu l l y rev i e w e d , u n d e r
stood, a n d fo l lowed .
The m a i ntenance tasks in Table 8 m ust
be performed reg u l a rly.
Table 8: Maintenance Tasks
Mechanical a n d electrical operation of the contactors
Vac u u m contactor inspection
Sh utter mechanism i nspection
Racking mechanism check
Mechanical i nterlocks check
E lectrical i nterlock check
Check of term i na l s a n d joi nts
Periodic C l e a n i n g
Dielectric test
The l i st of tasks in Table 8 does not represent an exhaustive
s u rvey of m a i nt e n a n ce steps n e c e s s a ry to e n s u re safe
operation of the e q u i p m e n t . Pa rti c u l a r a p p l ications may
requ i re f u rther proce d u res. S h o u l d f u rther i nformation be
des i red or s h o u l d partic u l a r problems a rise w h i c h a re not
covered sufficiently for the Purchaser's pu rposes, the matter
should be referred to the local Siemens sales office.
A
DANGER
The use of u nauthorized parts in the repair of the
equipment, or tampering by u n q ualified personnel
will result in dangerous conditions.
W i l l c a u s e d ea t h , s e r i o u s i nj u r y or e q u i p m e n t
damage.
F o l low a l l safety i n structions conta i ned here i n .
Mechanical a n d Electrical Operation of the Controller
1 . Caref u l ly i n spect the doors, e nclos u re sides a n d dead
front s u rfaces ove r a l l u n its for excessive heat. As a
g e n e ra l rule, tem perature w h i c h the p a l m of the h a n d
cannot sta nd f o r a bout 3 seconds m a y i n dicate troub l e .
I nfra-red heat detectors a re ava i l a b l e f o r this pu rpose of
detecting heat p roblems.
2 . I n spect the contro l l e r a m i n i m u m of once each yea r, or
more often as deemed necessa ry. Look for a ny moisture
o r s i g n s of p re v i o u s w e t n e s s o r d r i p p i n g i n s i d e t h e
M a i n te n a n ce

controller. Condensation i n conduits or dripping from a n

outside source is a common cause of fai l u re .

a . S e a l off a ny cond uits that have dripped condensate,

and provide a n alternative means for the conduit to dra i n .

b . S e a l off any cracks or ope n i ngs which have a l l owed

moisture to enter the enclosure. E l i m inate the source of
a ny dripping on the enclos u re and a ny other sou rce
of moisture.

c . Replace and thoroughly d ry and clean a ny i n s u lating

material w hich is damp or wet or s hows a ny accum
u l ation of deposited material from previous wettings.
C o n d u ct a n e l ectr i c a l i n s u l a t i o n res i s ta n c e test as
deta i led i n " Pre-Energization Check" i n the Operation
s e c t i o n o f t h i s m a n u a l , to v e r i fy t h e d i e l e c t r i c
i ntegrity o f the affected i n s u lation.

3. Check a l l devices for m i s s i n g o r broken p a rts, p roper

spring tension, free movement, rusting or corrosion, d i rt
a n d excessive wear.

4. Exa m i ne a l l read i ly access i ble i n s u lating parts for cracks

or breakage and for arc s p latter, sooty deposits, oil or a rc . 1006-93

C l e a n off a r c splatter, o i l a n d sooty deposits, replace if any

Figure 3 7. Connection to Measure Contactor Pole Resistance

A wARNING
signs of burning, charring or carbon tracking are found.
M a ke s u re that the d i e lectric i nteg rity of the affected
pa rts is m a i ntained.

5 . Measure resistance across each contactor pole from the

l i n e to the load term i n a l as i n dicated i n Figure 3 7. If the Hazardous voltages.
r e s i s t a n c e ex ceed s the va l u e s i n d icated in Table 9,
Energized parts located behind shutter
loosen con nections and perform the fol lowi n g proced u re:
m ec h a n i s m can cause d eath, severe
a . Examine all joints for plating wear, replace if necessary. personal injury, or property damage.

b. Clean a l l surfaces. Replace parts if oxide films are formed. Disconnect a n d l ockout i ncom i n g power
before i n specting o r adj u sting the s h utter
c. Exa m i n e s p r i n g pres s u re by c o m p a ri n g it to oth er mech a n ism a n d associated p a rts.
s i m i la r springs, replace if necessary.
Vacuum Contactors
d . R et i g h t e n a l l c o n n ec t i o n s i n accorda n c e w i t h t h e
C o m p l ete m a i nte n a n ce i n st r u c t i o n s for m e d i u m voltage
reco m mended torq ue va l ues, Table 10.
contactors are presented i n MVC-9078.
e. Be s u re t h a t t h e c o n d i t i o n s t h a t c a u s e d t h e h i g h
Shutter Mechanism
r e s i s t a n c e va l u e s , h a v e b e e n c o r r e c t e d b e f o r e
I t is necessary to v i s u a l l y i n spect the s h utter mechan i s m
resu m i ng service.
components every time t h e contactor is removed from the
Table 9. M axi m u m resistance across l i ne-to-load terminals cell module. Periodic checks are strongly recom m e n d e d .
of each pole of the Series 8 1 000 contactors. Replace broken parts and adj ust l i n kage t o provide a b i n d
free motion .
Maximum Resistance
Contactor Fuse
(Main Contacts Closed) Racking Mechanism Adjustment
Type "R" Rating
Milliohms at 2oc The racking mech a n i s m for the Series 8 1 000 contro l lers is
None 1 .0 desig ned for smooth and easy operation . The mecha n i s m is
2R 11.9 factory adj u sted a n d with n o r m a l use, no m a i ntenance i s
3R 7.3
4R 5.6 req u i red, except f o r a l i g ht coat o f g rease at t h e movi n g
93H35 6R 4.1 joints. W h e n properly adj usted, t h e racking mech a n i s m w i l l
94H35 9R 3.1
12R 2 .7
provide t h e correct amo u nt o f l i ne and l o a d power stab f i n ger
18R 2.0 engagement and LS I engagement shown in Figure 3 8. I n
24R 1.8
order t o check for proper engagement of the contactor i n the
c e l l , the followin g procedure is recommended:
None 1 .0
2R 11.0 1 . D iscon nect all incoming power.
3R 7.3
4R 5.7 2. C o n n ect a n o h m m et e r or b u z z e r b e t w e e n a n y o n e
93H37
6R 4.1
94H37 stationary stab term i n a l a n d its mating d i sconnect finger
9R 3 .1
12R 2.6 assembly on the contactor.
18R 2.0
24R 1 .8

41
M a i n te n a n ce

A wARNING
Hazardous voltage may be developed
across the control transformer primary
winding.
Can cause death o r severe personal
injury.
D i scon nect the w i re from the LSI finger --------
a s se m b l y to t h e c o n t r o l tra n sfo r m e r ,.-

" X 1 " t e r m i n a l b efo r e a p p l y i n g a n y /'
/
voltage to the LSI. Reco n nect t h e w i re / --::... ->=c ____ _ __ Power Stabs
/ -' ---
__

after testing is comp leted. Disengage

4. Rack the contactor i n by movi ng the handle to the O N

positio n . Conti n u ity s h o u l d be i n d icated on t h e power
stab and the L S I .
\r
5 . S l ow l y r a c k t h e c o n ta ctor o u t by m o v i n g t h e h a n d l e
\
\ \ OFF
l
toward t h e O F F position until t h e LS I opens as i n dicated
by the o h m m eter. The h a n d l e p o s i t i o n s h o u l d be as
i n d icated in Figure 3 9 . Conti n u e m ovi n g t h e h a n d l e - 20"
Middle or T o p Comportment

toward O F F a n d observe t h e point a t which t h e power

d isconnect f i n g e r assembly d isengages from the stab
term i n a l . This should occur i n 1 5' -/+5' handle travel past
the point at which the LS I opens.

6 . If the LS I does not open at the specified handle pos ition ,

the LS I stationary term i n a l may be adj usted by loose n i ng
the mounting screws a n d s l i d i n g forward or back on the
g u ide plate as necessary. Do not change the location of
the LSI fi nger assembly on the contactor.

UA!I Dim "B "

Dim

U p p e r or iddle Cell .07" (1.8) .57" (14.5)

Lower Cell .21" (5.3) .43" (10.9)

( ) Dimension in Millimeters

\r
\
\ \ OFF
l-20"/\
: - -
IIILtJ
Bottom Co mp artmen t

_; 1

I rr=====
Line and Load
Terminals Figure 3 9. Racking Mechanism Adjustment

If the p roper a m o u n t of e n g a g e m e n t of the powe r stab

f i n g e rs a n d/or t h e LSI c a n not be obta i n e d , p e rform t h e
fol lowin g adj u stment proced u re :

1 . Disconnect a l l i ncoming power t o t h e contro l l e r, open the

med i u m voltage compartment door, rack out and remove
the contactor from the compartment.

2 . Loosen the lock n uts on each end of the long connecti n g

rod a n d adjust t h e length o f t h e rod b y rotating it until t h e
d i m e n s i o n s ( a n g l e m e a s u re m e n ts) i n F i g u re 3 9 a re
obta i ned. Retighten the lock n uts.

3 . Defeat the door i nterlock lever by p u s h i n g it in with a

screwdriver a n d move the handle to the ON position. Be
s u re the driver l i n k p i n engages the notch i n the detent
Figure 3 8. Check for Proper Stab Finger and LSI Connection lever.

42
M a i n te n a n ce
4. M a n ua l l y rotate the contactor interlock lever so that the
tab on the end of the lever engages the notch i n the ca m .
Loosen the lock n uts on each e n d o f the short con necting
rod a n d adjust the length of the rod by rotati n g it until the
di mension between the tab and the cam notch shown i n
Figure 40 is obta i n e d . Retighten the lock n uts .
NOTE: Cells located i n bottom compartments are deeper
than cells i n middle or u pper compartments. The racking
mechanism l i n kages for bottom cells a re s l i g htly d ifferent
and m ust be adj u sted differently from those of shorter
cells which are located i n middle or upper compartments.
D e p e n d i n g on c e l l l o c a t i o n , d e te r m i n e t h e p r o p e r
d imension between the tab a n d cam notch from Figure 40
a n d adj u st the mechanism accordi n g ly.
A wARNING
Mechanical Interlocks
Hazardous voltages.
Can cause death, severe personal injury,
or property damage.
Do n ot attem pt to u se excessive force or
leverage to defeat the m ec h a n ical i nter
l ocki n g system a n d g a i n access to t h e
h i g h voltage u n it.
I nterlocks are designed to help prevent possible equipment
d a m a g e o r p e rso n a l i nj u ry res u l t i n g from a c c i d e n tal o r
i ntentional misuse o f eq u i p ment.
Never attem pt to operate this equipment u n l ess all i nterlocks
are insta l led and operating p roperly.
All mechanical i nterlocks a re factory adjusted for smooth and
positive operation . With normal use, no mai ntenance s h o u l d
be req u ired, except for:
a) a light coat of grease on the moving parts and pivots and
b) adjustment to a l low the interlocking levers and latches to
pivot freely
Electrical Interlocks
Line Switch I nterlock ( L S I ) - See R a c k i n g M ec h a n i s m
Adj ustment
Racking Switch I nterlock ( R S I ) - Refer to Figure 6. I n spect
for m e c h a n i c a l a n d e l ectrica l i ntegrity of the switch . To
a dj u st. loosen t h e two sc rews c o n n ecti n g the m o u n t i n g
bracket t o t h e g u ide p late, and locate t h e rol ler o f t h e m icro
switch under the cam assembly of the rear shaft.
Electrical Joints and Terminals
Caref u l ly i nspect a l l visible accessi b l e electrical j o i nts a n d
term i n a l s i n t h e bus and w i r i n g system.
1 . Retighten bolts a n d n uts at bus joi nts if there is any sign
of overheatin g or looseness. Refer to " Recom mended
Torque Va l u es " , Table 1 0 .
2 . I f j o i nts or termi nations appear t o be b a d l y discolored,
corroded o r p itted , o r show evid e n c e of h a v i n g b e e n
s u bj ected to h i g h tem peratures, t h e p a rts s h o u l d be
disassembled and cleaned or replaced.
3 . Exa m i n e a l l w i re or cable connections for evidence of
looseness or overheati n g . Retig hten, if n ecessary. I f
major d iscoloration o f cable i n s u lation or if cable da mage
is apparent. replace the da maged portion of the cable.
4. C l os e l y exa m i n e fuse c l i p s . If t h e r e i s any s i g n of
ove rheati n g o r loose ness, check t h e s p r i n g pressu re,
tightness of clamps, etc. Replace the fuse clips if the
spring pressu re compares u nfavorably with that of other
s i m i l a r fuse clips i n the contro l l e r. M a ke s u re that fuses
are completely i nserted.
5. Exa m i ne all joi nts for plating wear, rep lace if the plating
worn out. Special attention should be paid to the stab
f i n g e rs u n d e r s u c h adverse e n v i ro n m e n t a l c o n d i t i o n s
where s u lf u r dioxide, c h l o r i n e , s o m e hydrocarbons a n d
saltwater exist i n t h e atmosphere. Replace if evidence o f
copper oxide or other f i l ms a re formed . Use Siemens
c o n t a c t f i n g e r l u b r i c a n t n u m be r 1 5- 1 7 1 -3 7 0- 0 0 1 to
protect the stab f i n g e r j o i nt from dete rioratio n . Worn
plating on the stabs can resu lt i n overheating and may
lead to flashover. Plating wear throug h can be expected
after approximately 1 500 racking operations.
6 . E xa m i n e i n s u l a t i o n o n c o n d u ctor f o r ove r h e a t i n g o r
chafing agai nst metal edges that c o u l d progress i nto a n
i n s u l a t i o n fa i l u re . R e p l a c e a ny d a m aged c o n d uctors,
e n s u re replacement conductors a re braced or shielded if
needed to avoid s i m i l a r damage i n future operatio n .
7 . Be sure that any conditions that caused overheating have
been corrected .
Periodic Cleaning
Acc u m u lation of d ust and foreign materia l such as coa l d u st,
c e m e n t d u st, o r l a m p b l a c k m u st be r e m oved f ro m t h e
contro l l e r a n d a l l s u rfaces m ust be wi ped clean at regu l a r
i n t e rva l s . D u st c a n c o l l ect m o i st u r e , c a u s i n g v o l t a g e
brea kdown . D o not u s e c o m pressed a i r a s it w i l l o n ly
redistribute conta m i n a nts on other s u rfaces.
Dielectric Test
Perform d i e l ectric tests a s d i s c u s s e d u n d e r " E l ectri c a l
Connection s " i n t h e I nsta l lation section o f t h i s m a n u a l .
Recom mended Torque
When m a k i n g bolted assembl ies, the fol lowi n g
c o n s i d e r a t i o n s s h o u l d b e g e n e ra l l y f o l l o w e d . T h e
reco m mended torque i s determ i n ed by the s ize of hardware
used. Refer to Table 10.
43
M a i n te n a n ce

Table 10. Recom mended Torq ue Va l ues

2/3 1 /2 1 /2
Standard Torque
Thread Standard Torque Standard Torque Standard Torque
Metal-to-Metal
Size Metal-to-Insert Compound-to-Insert Compound-to-Compound
(ln.-lbs.)
(ln.-lbs.) (ln.-lbs.) (ln.-lbs.)

8-32 14-20 10-14 7-10 7-10

10-32 20-30 13-20 10-15 10-15
1/4-20 40-60 26-40 20-30 20-30
5/16-18 168-228 110-150 84-114 84-114
3/8-16 240-360 160-240 120-180 120-180
1/2-13 480-600 320-400 240-300 240-300

Door
I nter l ock
Lever Hand l e
I nter l ock
/"' Lever

ON
) /
./
I nter I ock

.o
Cam Rotated
to Rocked - I n
Pos i t i on

Ce l l i n Top or M i dd l e
Coartment

( _J
I nter l ock
/"' L ever
,

Short
../
connect r no 1j
1 'I [
I nter l ock
Cam Rotated
Rod
to RacKed- I n

I.:. II_ . 25
P os i t i on

C e l l i n Bottom
Dr i v e COfll)a rtment
L i nk

Figure 40. Racking Mec h a n i s m Adj ustment-ON Position

44
M a i n te n a n ce Afte r a Fa u l t

AoANGER
Enclosures
Exte r n a l e v i d e n ce of e n c l os u re d e f o r m a t i o n u s u a l ly i s
indicative o f damage with i n . Extensive damage w i l l requ i re
r e p l a c e m e n t of t h e e n c l o s u re p a rts a n d t h e e n c l o s e d
Hazardous voltages. equipment. I n s u re that door mou nted equipment a n d safety
i n te r l o c k s f u n c t i o n properly. Ve r i fy t h a t h i ng e a n d l a t c h
W i l l cause electric shock, burn o r
i ntegrity is mainta i ned.
electrocution.
Disco n n ect a n d lockout i ncom i n g power
a n d c o n t ro l v o l t a g e s o u rc e s befo re
Terminals and Internal Conductors
beg i n n i n g w o r k o n t h i s or any ot h e r
R e p l a c e a l l d a m a g e d pa rts w h i c h s h o w e v i d e n c e of
electrica l eq u i pm ent.
d i scoloration, melting or a rc i n g damage. Specia l attention
should be paid to the stab fi ngers.
Check a l l control circuit term i n a l s with a voltmeter to make
certai n that the equipment is tota l ly deenergized.
Contactor
Use o n ly a p proved high voltage test e q u i pment to check
R e f e r to p u b l i c a t i o n M V C - 9 0 7 8 I n s t r u c t i o n s f o r t h e
voltage on power term i n a l s . Do not attempt to measure h i g h
I nsta l lation, Operatio n , a n d M a i ntena nce of Medi u m Voltage
voltage w i t h a volt-ohm meter.
Vac u u m Contactors.
Never attempt to withdraw a drawout carriage or discon nect
any term i n ations when a defeater mechanism has been used
to open a compartment door. Overload Relays
The complete overload relay m ust be rep laced if burnout of
It is recommended that a safety ground be connected to the
the heater e lement has occu rred . Any indication of an arc
power bus after the system has been deenergized, and prior
s t r i k i n g or b u r n i n g t h e o v e r l o a d r e l a y a l s o re q u i r e s
to working on the equipment.
replacement.
Follow the procedure outlined i n the pre-energization checks
I f there i s no visual i n d i cation of damage that would req u ire
section of this m a n u a l before power is restored .
r e p l a c e m e n t , c o n ta c t o p e r a t i o n m u s t be v e r i f i e d by
e l e c t r i c a l l y or m e c h a n i c a l l y t r i p p i n g a n d r e s e tt i n g t h e
overload relay.
General
The excessive cu rrents occurri ng during a fa u lt may res u lt i n
structu re, c o m p o n e n t a n d/or con d u ctor d a m a g e d u e to
Fuse Holders
mechanical d i stortion, the rma l d a mage, metal deposits or
R e place fuse holders if the i n s u lation mou nts, barriers, or
smoke. After a fa u lt, repai r the cause of the fa u lt, i nspect a l l
fuse c l i ps s h ow signs of d a mage, deteriorat i o n , h e a t i n g ,
equipment p e r N E MA Sta ndards Publication N o . I CS 2-302
distortion or looseness.
a n d m a ke a n y necessary repa i rs or replacement prior to
placing the equipment i nto service a g a i n . Be sure that a l l
rep lacements ( i f a ny) are o f the p roper rating a n d are suitable
Fuses
for the a p p l i c at i o n . If i n d o u bt c o n s u l t your f i e l d s a l e s
Always replace a l l three fuses in a three p hase c i rcuit even
representative.
t h o u g h o n ly one o r two a re open c i rc u ited s i n c e i nterna l
d a m a g e s u ff e r e d b y f u s e s n ot r e p l a c e d c o u l d res u l t i n
n u isance s h utdown later.
Inspection
The following a reas s h o u l d be i nspected after a f a u lt has Perform the " Pre-Energization Check" procedures detailed i n
occurred. this m a n u a l before restoring t h e equ ipment t o service.

45
Tro u b l e s h oot i n g

General 2. Nameplate data on contactor or contro l l e r.

I n the event that operatin g problems a re encou ntered, use
3. Duty cycle and any detai l s of operati o n .
the fol lowing troubleshooting chart Table 11 to isolate the
cause of the probl e m and find the remedy. If the corrective 4 . Length o f t i m e i n service a n d approximate total n um ber of
action g iven in the chart fails to correct the d ifficu lty, consult operations.
your Siemens representative.
5 . Voltage, current a n d frequ ency.
The following i nformation is req u i red if it is necessary to
6 . Description o f any pro b l e m .
contact Siemens rel af1ve to the equipment prob l e m .
7 . A n y other pertinent i nformation, s u c h as d rawing, layout
1 . M a n u fa c t u re r's o r d e r n u m b e r ( a n d p a rt n u m b e r, i f
and schematic n um ber.
ava i l a b l e ) .

Table 11. Trou bleshooti ng Chart

PROBLEM CAUSES R E M E DY

Doors w i l l not close or Enclos u re is not bolted down tightly Using level, add shims as necessary,
a re out of a l ignment on perfectly level s u rface. and tighten a nchoring bolts .

E nclosure sprung out of shape. Stra ighten or repai r cubicle.

Door h inges not properly adj u sted . Remove door h i nges. Add or
s ubtract shims as necessary.

B i nd i n g of racking or sh utter Warpage or breakage of sh utter Replace sh utter mechanism or

mecha nism or mechanical i nterlocks mechanism or housing components. housing component as req u i red to
i n s u re smooth operatio n .

Mechanism componenta a re See mai ntenance section on adjust-

binding. i n g racking, sh utter a n d I nterlock
mecha nism.

Rough hand l i ng d u r i n g tra nsporta- Adj ust mecha nism and replace
tion or i nsta l lation . broken parts.

Contactor w i l l not close Control circuit or main fuse blown . I n spect fuses, replace if blown .

I ncoming power l i ne not energized. Close feeder circuit breaker or

tie switch .

L i n e switch interlock ( L S I ) is not Adjust per i nstructions in the

adjusted properly. mai ntenance secti o n .

M a i n contactor c o i l C h e c k magnet operation, replace

coil as necessary.

Master R e l ay ( M R ) defective. Check and replace if defective.

Control power transformer defective. Check and replace if necessary.
Overload relay tripped or defective. Check and replace if necessary.
Defective rectifier. Check and replace i f necessary.

Selector switch ( R U N-TEST) is not Switch should be i n the " R U N "

i n proper position. position.

Missing j u m pers, loose connections, Check wiring d iagram caref u l ly to

remote connections, etc. m a ke sure that a l l external or a lter-
rnate connecf1ons have been made
satisfactorily. This is especially true
where remote protective or control
devices a re used.

Contactor chatter Loose connection i n control circuit. Tighten con nections in control
circuit.

Defective master relay. Check and replace if necessa ry.

Defective coil or d rive board Check main coil and rectifier,

replace if necessary.
H ig h Altitude Consult Siemens.
Low control voltage Check l i n e voltage.

46
Tro u b l e s h ooti n g
Table 11. Trou bleshooting Chart (conti n ued)
PROBLEM
B u rnout of rectifier
Overload relays trip during starting
or soon after motor is u p t o speed
Overload relays fail to trip on
overload current
CAUSES
B urnout of operati ng m a i n coi l .
Motor overloaded.
Motor being started too frequently
at close i nterva l s .
Excessive motor acceleration time.
Low line voltage.
Overload relay not adjusted to
motor capabilities.
Incorrect relay or relay set incorrectly.
Relays set i ncorrectly.
Relay tripping mechanism jammed.
Incorrect relay or relay set incorrectly.
Current transformers with improper
ratio or with short-circuited secondary
terminals.
R E M E DY
Replace m a i n coil a n d check
circuit for shorted term inals, etc.
Limit starting load and r u n n i n g
load to motor capabil ities.
Jogging and starting operations
m ust be l i m ited t o capabil ities of
the motor. Check starting limitations
i n motor instruction manual before
repeated starts.
The starting of high i nertia loads
may not permit the use of standard
overload relay applications. For
accelerating times of 1 0 seconds or
more, special overload relay bypass
devices a n d circuits wou l d usually
be required. Contact the factory
regarding such problems and supply
complete data on locked-rotor start-
ing current and total accelerating
time under maximum load
conditions.
Line voltage should be maintained
between +/- 1 0 % of motor name-
plate voltage.
Adjust relay setting in accordance
with instructions for the overload
relay. Adjustment should corre-
spond to thermal rating of the motor,
including temperature rise, d uty and
service factor.
Contact factory.
Set in accordance with relay
instructions.
Replace relay.
Check relay selection and adjustment
per overload relay instructions.
Current transformers must have a
step-down ratio to correspond to
full load motor current and relay
selection. Protective jumpers may be
provided at current transformer
secondary terminals or on terminal
block connections to guard against
open transformer secondary circuit,
and jumpers must be removed before
placing equipment in operation.
47
Tro u b l e s h ooti n g
Table 11. Tro u bleshooting Chart (conti n ued)
PROBLEM
B lowin g of motor power fuses
B lowi n g of primary control
transformer fuses
B lowi n g of secondary control
transformer fuses
48
CAUSES
S hort circuit on the load side of the
motor fuses.
Joggi n g or too frequent start i n g .
F u s e s interna lly damaged because
of i m proper h a n d l i n g .
S horted primary winding in
control transformer.
Fuse may be " open " due to rough
h a n d l i n g before i nsta l l i n g .
Secondary fuses n o t properly
coord i nate d .
Abnormal c urrent or s hort circ u it
in control .
R E M E DY
Use megger and other test instru-
ments to locate fault a n d correct.
O n frequent starting, f u s e s accum-
ulate a bnorma l heat and cool more
slowly than do overload relays.
Since fuses more closely follow
coo l i n g and heating or motor
windings, successive starting oper-
ations m ust be l i m ited to the safe
capacity of the motor to prevent
fuse b l owing from th i s cause.
Check s ize rati ng on fuse name-
p late agai nst data label in med i u m
voltage compartment. A l l t h ree
fuses m ust agree.
Fuses are selected on the basis of
motor full load cu rrent, locked-
rotor cu rrent and starting time.
Approximate s izes can be deter-
m i ned by referring to Figure 18,
in the General Description section
of this m a n u a l .
M otor power fuses a re made up
o f m ultiple stra nds of fine silver
ribbon which may be broken if
fuses are d ropped or rou g h ly
handled. Several i ndividual strands
can be broken without the trip ta r-
get indicating a blown fuse. H a n d l e
f u s e s caref u l ly, i n sta l l i n g them i n
clips on t h e top o f t h e vac u u m
contactor w i t h the i n dicator toward
the front.
R e place or repa i r tra nsformer.
Replace fuse.
Melting characteristics of secon-
d a r y f u s e s h o u l d n ot i ntersect
melting characteristic of primary
fuse. Rating of sta ndard N E C fuse
should not exceed twice the
secondary current rating.
Check for fau lty operation of
economizing relay, shorted mag-
net coils, s horted rectifiers,
grounds, loose or bent connections,
mechanical binding i n relay and
contactor mechan isms, excessive
operations and incorrect secondary
terminal connections.
SI EM ENS
Siemens E n e rgy
& Automation, I nc .
Switchgear and
Motor Control Division
PO. Box 29503
Raleign, NC 27626-0503
(91 9) 365-6660

Bul letin MVC-9068 (new) 5M 0794FP Printed in U . S .A. 1 994 Siemens Energy & Automation, Inc.
SIEMENS is a reg1stered trademark of S1emens AG.
SAMMS, SAMMS-MV and Senes 8 1 000 are