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CR194VacuumLimitamp ControlOne-High Controllers with Stationary MVacuum ContactorsCaution: Product is not i ountWended for nuclearuse.

Utilization Voltage -2.4 through 7.2 kVac26-wide and 34-wide, One-High, 400 Amp(For 48-wide, 800 Amp see GEH-5396)

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CR194 Vacuum Limitamp 400 Ampere Control

Table of Contents

Introduction 3

4DescriptionEquipment Identification-CR Number Designation ..,. 4General .....;RatingsBasic Impulse Level ( BIL)Dielectric Test VoltageHigh Voltage Vacuum ContactorsBlown Fuse IndicatorManual Disconnect (Isolating Mechanism )Mechanical InterlockingAuxiliary EnclosuresDimensionsPower FusesPower Fuse Conversion InstructionsStarting Autotransformers 8c Reactors

InstallationGeneralReceivingHandlingPlacement of EnclosureDisassemblyDisassembly Sequence of OperationGroundingIncoming Power ConnectionsMotor ConnectionsExtra-width EnclosurePower Cable TerminationControl ConnectionsReassemblyReplacing Contactor In EnclosureMechanical Operation Check

OperationGeneralTest-power CircuitPreparation of Controller for OperationNormal OperationDoor Opening Procedure

Inspection, Maintenance, 8c ServicingVacuum ContactorIsolating Mechanism and Mechanical InterlockChecking Procedures-* Mechanical Interlock & Manual IsolatorVacuum Interrupter Integrity TestTest ProcedurePreventive Maintenance Guide

4555588

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292929

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2




The essential control functions for all types of a-c motorsconsist of starting, stopping, and overload protection.Vacuum Limitamp controllers also include short-circuitprotection, but other functions are provided in eachcontroller as they are applicable to the type of motorbeing controlled (such as synchronous and wound-rotormotors) . Also, special functions are provided in greatvariety as may be required for particular applications.These instructions were prepared as a guide to handling,installation, operation and maintenance of all one-high,400 Amp types of Vacuum Limitamp controllers. Thisincludes the 26-inch wide one-high and the 34-inch wideone-high controller. Figure 1 shows a 26-inch widecontroller and Figure 2 shows a 34-inch wide synchro-nous controller.The intent of these instructions is to give the Purchaserthe necessary general information to identify his control-ler as to type and function, to describe suggestedmethods of installation, and to demonstrate sometechniques of operation and maintenance. The Pur-chaser should interpret these instructions forapplicability to his particular controller by referring tothe nameplate data on the controller and to the electri-cal diagrams supplied with the controller.If the controller is for a synchronous motor, theseinstructions should be used with GEH-5201. For applica-tions questions refer to GET-6840. For details onhigh-voltage contactor refer to GEH-5306.

Warning: Before any adjustments, servicing, parts replacementor any other act is performed requiring physical contact with theelectrical working components or wiring of this equipment,power must be removed from all sources and all attachedrotating equipment must have come to a complete stop.User personnel must be completely familiar with the followingoperating and maintenance instructions before attempting toservice this equipment.Warning: The vacuum interrupter integrity test should beperformed before the high-voltage, vacuum contactor is energizedfor the first time and each time the contactor is returned toservice after maintenance, adjustment, or repair.Failure to perform this test may result in serious injury or death.

IntroductionVacuum Limitamp controllers are designed to meetNEMA ICS2-324 “AC General Purpose High-voltage ClassE Controllers” and UL 347 requirements, and may bedescribed as metal-enclosed high-interrupting capacity,vacuum-contactor-type starter equipments with manualisolation. Individual starters and controllers are de-signed for specific applications; the components andfunctions being dictated by the Purchaser specificationsand needs. Controllers may be fused or unfused.

Figure 1. 26-inch wide one-high controller. Figure 2. 34-inch wide synchronous controller.

3




DescriptionEquipment Identification -CR Number DesignationBasic type designation for all Vacuum Limitamp Controlequipment is CR194 with significant alpha-numericsuffixes used to define rating, function, contactor typeand enclosure type.

CR194NEMA TYPE

1 = NEMA E1 (Unfused)2 = NEMA E2 (Fused)Starling and Spaed Functions

— EnclosureA — 26" 1-HIB — 34" 1-Hl

A — Single-speed, full voltagesB — Single-speed, reduced voltage reactor typeb — Single-speed, reduced voltage autotransformer typeD — Single-speed, part winding startE — Single-speed, reduced voltage primary resistorG — 2 speed, 1 winding full voltageH — 2 speed, 1 winding reactor reduced voltageJ — 2 speed, 1 winding autotransformer reduced voltageN — 2 speed, 2 winding full voltageP — 2 speed, 2 winding reactor reduced voltageQ — 2 speed, 2 winding autotransformer reduced voltage

System Voltage

7 — 2400 Volts8 — 4200 Volts2 — 7200 Volts0 — Other

Controlled Apparatus

0 — Synchronous Motor (brushless type)1 — Induction Motor2 — Synchronous Motor (ring type)3 — Wound Rotor Motor4 — Transformer Feeder5 — Capacitor Feeder6 — Other

Rotation and Braking

1 — Non reversing /non braking2 — Reversing/non braking4 — Non reversing/dynamic braking5 — Reversing/dynamic braking7 — Reversing/plugging

In general, the unit enclosures are divided into high-voltage and low-voltage compartments, each with its ownseparate door and with interior barriers between the two.See Figures 3, 4, and 5. To open the high-voltagecompartment door, the power must be disconnected by asequence of manual operations which requires de-energizing the high-voltage contactor, operating theisolating switch handle, and unlatching the door* Low-voltage doors may be entered without disconnecting thepower; however, this should be done with extreme careand cautionThe upper compartment of one-high controllers maycontain a low-voltage panel, hinged on the left side,which acts as a barrier to the high-voltage control powertransformer mounted on the upper rear cover.

GeneralThe basic Vacuum Limitamp controller is a front-connected assembly of components and conductors formotor starting, arranged for convenient access, in anenclosure which allows space and facilities for cabletermination, plus safety interlocking of doors andisolator to prevent inadvertent entrance to high-voltageparts. No back access is required. This equipment maybe rated up to 7.2 kV depending on the contactor andfuse ratings. Installation, operation, and service shouldbe performed only by experienced personnel trained inthis class of equipment.

4



CR194Vacuum Limitamp 400 Ampere Control

Interrupting Ratings At Utilization Voltage ShownThree-phase Symmetrical

System MVAMaximumContinuous

Amperes (RMS)

MaximumVolts Class E1

UnfusedClass E2Fused

2500 400 29 2004005000 50 4004007200 50 600

Basic Impulse Level (BIL)The standard BIT rating of Vacuum Limitamp control-lers is 60kV crest (design rating) . This rating excludesdry-type control transformers and starting reactors orautotransformers.

Dielectric Test Voltage2 1/4 x nameplate voltage plus 2000 volts.

High-voltage Vacuum ContactorsThe vacuum contactors used in Vacuum Limitampcontrollers are available in two different ratings: 400and 800 amperes. This publication covers only the 400ampere rating. The contactors are similar in operationbut very different in size and rating. For this reason theyare not directly interchangeable mechanically. SeeFigure 7.The contactors are easily removable from the controllerassembly by removing a few bolts that hold the contactorin position and by disconnecting the line and load powerconnections. The auxiliary contacts and the coil termi-nals are connected by means of a removable connectorthat is retained by two wing nuts. By removing thesewing nuts, the wiring harness is easily disconnected fromthe contactor. Refer to the information beginning onPage 13 of this publication that details the correctmethod for contactor removal.

Figure 3. 26-inch wide 400-ampere FVNR starter,

RatingsRefer to the panel data nameplate (see Figure 6) onfront of the enclosure for detailed ratings applicable to aparticular controller. Equipment basic ratings equal orexceed NEMA ICS2-324 for Class E2 Controllers, and aresummarized below.

Approximate Maximum Horsepower,Current 8c Voltage Ratings

2200-2400 Volts 4000-4800 Volts 7200 VoltsSynchronous Motors Synchronous Motors Synchronous MotorsContinuous Current

(RMS) (Amperes)InductionMotors

InductionMotors

InductionMotors0.8PF 0.8PF 1.0PF1.0PF 0.8PF • 1.0PF

400 Max. 34501600 1600 3725 48002000 3450 4800 6000

Note: Above ratings apply to controllers in NEMA 1, ventedenclosures, at 4CP C ambient.

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CR194 Vacuum Limitamp 400Ampere Control

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CR194 VacuumLimitamp 400Ampere Control

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Figure 11. View of disconnect switch in the CLOSEDposition. Barriers are removed for clarity.

Figure 9. View of various low-voltage components on swing panel.

7



CR194 VacuumLimitamp 400Ampere Control

Vacuum Limitamp Control is supplied standard withbolt-in type fuses. The fuse holders will accommodate2400-volt through 7200-volt fuses. The length of thesetypes of fuses vary and the lower fuse mount can beadjusted to the proper length by unbolting the mountfrom the back rail and remounting it in the properlocation. For 7200-volt applications, the fuses require aslightly different lower mounting strap and the top fusemounting strap must be changed. This requires that thedisconnect switch be disassembled. See Figure 8.

Manual Disconnect (Isolating Mechanism)

Vacuum Limitamp controllers, following the NEMAdefinition, provide a means for manually isolating thepower circuit by operation of a disconnecting device.The disconnecting mechanism consists of a quick-makequick-break, non-load break disconnect switch (seeFigures 11 through 13) which is controlled by theoperating handle (see Figure 6) . A fixed barrier (Figure13) , with a viewing window, is supplied to provideisolation from the energized bus parts. There are no

The vacuum contactors supplied with Vacuum Limitamp moving shutters that require maintenance. The quick-Control are magnetically operated by a dc coil fed by an make, quick-break, operating mechanism is shown inintegral rectifier and timed holding circuit. A base Figure 15.mounted contactor timing module (CTM) applies fullvoltage to the contactor coil for a time sufficient to fullyclose the contactor. A series capacitor is then switchedin to hold the contactor closed without overheating thecoil.

Load current must not be interrupted by the disconnectswitch. A mechanical interlock is provided to ensurethat the contactor is in the open position before theoperating handle can be actuated. Also, the contactorcannot be operated while the operating handle is beingmoved from one position to another.The mechanical isolator will accept up to four padlocksto prevent operation. See Figure 16.Blown Fuse Indicator

Blown fuse indication is activated by a trip bar located atthe rear of the top fuse holder. The blown fuse indica-tor requires bolt-in type fuses. When one or more of thefuses blow, a small indicator moves upward from the topcenter of the fuse to indicate which fuse has blown. Theright end of the trip bar has a cam that operates an anti-single phase contact which is wired to trip the controlleroff-line to prevent single phasing of the connected load.See Figure 10.

Mechanical InterlockingVacuum Limitamp equipment is designed so the high-voltage contactor performs all normal load currentinterrupting. The current-limiting fuses generallyinterrupt the fault currents.Note: The quick-make quick-break manual isolator will notinterrupt any load or fault current. '

A mechanical interference system is included with allVacuum Limitamp controllers (mechanical interlock),which prevents opening of the manually operatedisolating contacts unless the high-voltage contactor itselfis demonstrated by magnet position to be already open.This is to ensure that the contactor has opened thepower circuit and interrupted the current before thedisconnect switch may be operated. See Figure 17.Warning: The manual isolator should never be forciblyoperated . Its mechanical interference interlock should bedefeated only by knowledgeable and qualified electrical mainte-nance personnel who have de-energized all poioer feeding thecontroller.

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CR194 Vacuum Umitamp 400 Ampere Control

Warning: There is no emergency condition that can justify forc-ible operation of the manual isolator with the main contactorclosed. The isolator must be operated only with the contactor open.All high-voltage doors are interlocked by mechanicalinterference mechanism that lock high-voltage doorsclosed until the disconnect switch is in the OPENposition. This is done to prevent exposure to high-voltage.In one-high controllers the bottom door covers the high-voltage compartment. Other high-voltage doors may befull height to cover high-voltage parts located in auxiliarysections. These devices may include reactors, autotrans-formers or control power transformers, etc.Key interlocking is frequently used in lieu of mechanicalinterference mechanisms to lock high-voltage doorsclosed until power inside has been removed. Non-loadbreak switches are also key interlocked to preventoperation under load. In all cases of key interlocking, itis important to follow the operating sequence as de-scribed on the drawings furnished with the equipment.

On some one-high enclosure designs, a low-voltagecontrol panel mounted by hinges to the left side of theenclosure serves as a barrier to isolate the high-voltagecontrol power transformer and fuses. An interferencelatch, shown in Figure 54, prevents swinging this panelout until the high-voltage door is opened, thus ensuringthat high-voltage power to the Control Power Trans-former is disconnected.

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Auxiliary EnclosuresMany sizes of enclosures are furnished in VacuumLimitamp control lineups for various purposes. Someare tabulated below;

Wound rotor, secondary contactor and resistorcompartmentsBus transitions to switchgearBus transitions to transformersCable entrance compartmentsRectifier exciter compartmentsStarting reactor or autotransformercompartmentsRelay and metering compartmentsInstrument transformer compartmentsManual switch compartments

Refer to Figure 60 for details.

DimensionsVacuum Limitamp controllers are normally 30-inchesdeep and 90-inches high. Width varies for one-highcontrollers, induction motors, synchronous motorsother special applications, or cable space requirementsRefer to Figure 60 for typical outline dimensions.

Figure 18. Blown fuse Indicator shown in the NORMAL position.>

10




Power FusesBolted EJ-2 type current-limiting power fuses are sup-plied as standard with Vacuum Iimitamp controllers.These standard fuses are bolt-in type because the blownfuse - indicator and the trip bar that operates the anti-single phase contact block require precise alignment ofthe striker pin at the top of the fuse with the operators.Clip-in fuses are available as an option in 400 ampere tocover requirements for EJ-1 type fuses, but the “anti-single phase” indication/ trip functions are not availablewith clip fuses. Coordination information for EJ-2 typefuses is available in GES-5000, and for EJ-1 type fuses,GES-5002. Interrupting ratings are shown on page 5 ofthese instructions. Figure 18 shows the top of the boltedpower fuse assembly with the blown fuse indicators inthe normal position.

Power Fuse Conversion InstructionsBolt-in fuses used on Vacuum Limitamp and Air-breakLimitamp may be field converted from one to the otherby carefully following the instructions below.

Starting Autotransformers Sc ReactorsReduced voltage controllers include a reactor or au-totransformer designed for starting duty in accordancewith NEMAICS2-214. The duty cycle generally fur-nished is for medium-duty applications which consist ofthree 30-second starts spaced 30-seconds apart followedby a one-hour rest. To prevent overheating and possibledamage when applied on more severe duty (heavy duty)applications, special reactors or autotransformers mustbe specified. Thermostats are mounted on the reactorand transformer cores to offer protection against over-heating. These thermostats must be manually reset iftripped by high temperature.

SINGLE BARREL DOUBLE BARRELCAT. NO.55A21294£P “A”

CAT. NO.218A4293P “A

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BY CAREFULLY FOLLOWING THESE INSTRUC-TIONS, THE ABOVE FUSE VERSIONS MAY BEFIELD CONVERTED FROM ONE TO THEOTHER.

BY CAREFULLY FOLLOWING THESE INSTRUC-TIONS, THE ABOVE FUSE VERSIONS MAY BEFIELD CONVERTED FROM ONE TO THEOTHER.

1. LOOSEN BOTTOM BOLT (Y) WHILE INSURING FUSE BARRELDOES NOT ROTATE (SEE CAUTION).

2. ROTATE BOTTOM STRAP (X) 180 DEGREES.3. RETIGHTEN BOTTOM. BOLT (B) TO 23-31 FT/LBS WHILE EN-

SURING THAT FUSE BARREL DOES NOT TURN.

1. LOOSEN AND REMOVE BOTH BOTTOM BOLTS (Y) WHILE IN-SURING FUSE BARREL DOES NOT ROTATE (SEE CAUTION).

2. ROTATE BOTTOM STRAP (X) 180 DEGREES.3. REINSTALL BOTTOM BOLTS (Y) AND SPECIAL SPRING

WASHER (BELLEVILLE), RED PAINTED STRIPE ON WASHERTO FACE TOWARD BOLT HEAD.

CAUTION:0O NOT LOOSEN TOP BOLT OFFUSE. THIS WILL DAMAGE INTERNALELEMENTS OF FUSE.

4. TIGHTEN BOTTOM BOLTS (B) TO 23-31 FT/LBS WHILE INSUR-ING THAT FUSE BARREL DOES NOT TURN.

CAUTION: DO NOT LOOSEN TOP BOLT OFFUSE. THIS WILL DAMAGE INTERNALELEMENTS OF FUSE.

11



CR194 Vacuum Limitamp 400Ampere Control

Figure 21. Recommended method of lifting single panel.Figure 19. Vacuum Limitamp controller wrapped Inplastic film wrap ready for shipment.

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Figure 22. Recommended method of lifting a Vacuum Limitamplineup. Note that the lineup is suspended from an equalizing bar.Figure 20. Vacuum Limitamp controller with outside packaging

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Installation Placement of EnclosureIc is essential that the controller be securely fastened inan upright position on a level surface to allow properfunctioning of the internal devices. While there are noroll-out components, access will be improved if thecontroller is located at floor level with plenty of roomallowed for doors to swing fully open as shown on thedrawings supplied with the equipment.After the controller has been placed in position, thefloor mounting bolts may be installed and tightened.The location of these bolts is shown on the outlinedrawing furnished with each controller. These bolts are'/2-inch bolts and are usually located in each corner ofthe controller base.

GeneralThis section contains information on receiving andhandling, disassembly, power-cable termination, ground-ing, and reassembly to make the equipment ready foroperation.

ReceivingVacuum Limitamp controllers are fabricated as rigid,floor-mounted, self-supporting steel sections requiringno floor sills. They are crated and shipped in an uprightposition and, when received, should be kept upright.Some components may be shipped separately, such astdp-mounted resistors or potential transformers. Thesecomponents are identified by catalog number coincidingwith that of the section on which they are to bemounted.Plastic film wrap or corrugated cardboard is normallyused for domestic crating with the steel enclosuresections bolted to a wooden skid. See Figure 19. Afterreceiving, the packing may be removed and the equip-ment handled on the wooden skid. See Figure 20.

DisassemblyAfter the equipment has been set in place where it is tobe permanently connected, some internal disassembly isrequired to make the necessary external power-cable andcontrol-wire connections. Disassembly should be donein a definite sequence by following Figure 23 throughFigure 34, and as described below:

Disassembly Sequence of OperationWarning: Remove all power from the equipment before proceed-ing with disassembly.1. Move the manual isolator handle to the OFF position.Refer to the nameplate attached to the high-voltage doornear the handle. Figure 23-2 shows the method of firstdepressing the pusher with one hand and moving thehandle with the other. Refer to page 27 and 29 fornormal and emergency door opening procedures.2. Open both the top (low-voltage) and bottom (high-voltage) doors.

HandlingIt is always preferable to handle Limitamp controllers bythe lifting means provided. Figure 21 shows the recom-mended method of lifting a single section, while Figure22 shows the recommended method of lifting a lineup.Note that the lineup in figure 22 is suspended from anequalizing bar. A lineup should be supported at as manypoints as possible. If there is not enough headroom tolift the panel by its lifting beam, then a track jack can beused. The controller can be raised by placing a trackjack under the shipping skid. Rollers can then be placedunder the skid for rolling the equipment to its finallocation. The panel should then be raised by its liftingbeam, the shipping skid removed, and the panel set intoplace.The use of fork-lift trucks is not recommended, since theforks may damage the enclosure or interior parts of theequipment, and the equipment becomes very unstablewhen lifted from the bottom. If no other method ofhandling is available, the forks must go under the skidbottom to avoid damaging the equipment, and theassembly lifted only slightly to allow the skid to be slidalong a flat, level surface. However, the recommendedmethod is by crane as pictured.

Contactor RemovalNormally it is not necessary to remove the contactor fromits mount in order to make external power-cable andcontrol-wire connections. If the contactor is not to beremoved proceed to Step 4. Otherwise, follow the stepsoutlined below to remove the contactor from the controller.3. Contactor removal.

a. Remove.the wing nuts holding the contactorumbilical cord and connectors in place and savethe hardware. This hardware will be reused toremount the connector when the contactor isreinstalled. Unplug the connector and place thebracket in the lower front channel to the left of thecontactor for safe keeping. See Figure 24.

13




GroundingAll controller enclosures must be grounded. A stud iswelded to the lower back of the enclosure in the incom-ing-line compartment area for connection to thegrounding system. This connection must be madebefore making any power connection.If ground bus is ordered, the ground stud is connectedto the ground bus at the factory and the system groundcan be connected to the ground bus instead.The control and instrumentation circuits are groundedto the enclosure at the terminal board. This is normallythe only grounding point. It can be temporarily re-moved for test purposes; but it must be regroundedbefore the control is returned to operation.

b. Loosen the line side cable bolts at the bottom ofthe fuse assembly and save the hardware. Be surethe cables are free of their mounts and that theycan be freely removed. See Figure 27.

c. Remove the three load side connection bolts in thebottom of the contactor. These bolts are accessedthrough the openings at the bottom of thecontactor from the front. A socket wrench with anextension may be used to remove these bolts. Savethis hardware for reuse. See Figure 29.

Note: Do not loosen R.T,V. covered bolts.cl. There are two retaining nuts at both sides on the

lower front of the contactor. These nuts must beremoved. See arrows in Figure 29.

o. Slide the contactor out of the mounting base andlift it and the line side cables out of the enclosure.

f. Replace the three bolts removed from the load sideconnections in their holes and thread them in afew turns. These bolts will prevent reinstalling thecontactor until removed again. This serves as areminder that the bolts are there and need to bereinstalled when the contactor is being replaced.

4. Prepare to remove the horizontal compartmentbarrier by removing the two bolts shown in Figure SO.

5. Remove the horizontal barrier, Figure 30. ( If ahinged low-voltage panel is used, swing it to the left andout of the enclosure.)

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6. Remove the horizontal bus barrier bolts as shown inFigure 31, and then lift the barrier out of the enclosure.The horizontal bus is then exposed as shown in Figure 32.

Incoming Power ConnectionsIncoming power connections to the bus may be made inany one of the enclosures in a lineup. Space for one500- MCM cable with stress cones per phase is availablein the standard 26-inch wide enclosure. A 34-inch wideenclosure is also optionally available when larger cablecapacities are required. The 34-inch enclosure isstandard with synchronous controllers and 7200 voltcontrollers. If shielded cable is used, refer to theinformation on Page 23 of this manual.In the one-high enclosure with horizontal power bus,incoming power connections are made on the left end ofthe bus bars. When the barriers are removed from theenclosure, both ends of the power bus and the groundbus are accessible from the inside of the enclosure. Toadd additional units to a line-up of enclosures, the new

7. Detach the switch barrier with the viewing window by enclosure can be located in position and, with the busremoving the ten bolts, Figure 33. Pull the barrier out ofthe enclosure.

splices furnished with the equipment, the bus connec-tions can be made to either side of the existingequipment. Figures 32 and 35 show the accessibility ofboth ends of the bus bars with the barriers removed and8. Remove the front cover of the lower incoming line

barrier, Figure 34, (if incoming cables are to be routedfrom the floor) or remove the top incoming line barrier(if cables are to be routed into the enclosure from the top).After the preceding steps have been completed, allpower termination points and bus connections arcaccessible. See Figure 35.

the low-voltage panel swung out. The splices must bebolted in place with the 14-inch hardware supplied withthe splice kit. Torque splice bolts to 35 lb.-ft.

14




Figure 23-1. Depress STOP push button. Figure 23-3, Handle OFF-Pusher bar OUT,

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Figure 23-2. Place isolator handle in the OFF position bydepressing pusher bar and rotating handle rapidly down. Figure 23-4. Turn door latches and open door.

15




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Figure 32* Exposed main bus after removal of main bus barrier. Figure 34. Lower Incoming line barrier.

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Figure 35. Main bus compartment with all barriersremoved and incoming line cables terminated.Figure 33. Isolator switch barrier showing bolts to be removed.

18




Motor ConnectionsMotor cables may enter from the top or bottom of theenclosure. In the one-high enclosure, the motor termi-nals arc located on the inside lower left wall as shown inFigure 36. The incoming leads should be trained formaximum space between phases and ground. Theconnections may be made before or after energizing themain bus and without shutting down adjacent equip-ment. Also see Figure 60.

Warning: If the main bus in energized while load cables are be-ing installed, all barriers must be in place and the disconnectswitch must be in the off position and the blades must be visu-ally checked to ensure that they are completely disconnected fromthe vertical bus.The motor terminals can accommodate up to one 500-MCM per phase with stress cones in the standard 26-inchwide enclosure. If larger cable entries are required, anoptional 84-inch wide cabinet is available.

Figure 36. Load terminals located on the left wall of the high-voltage compartment. The lower incoming line barrier and Isolator

switch barrier have been removed. Phase A is at the top.

19




Extra-width EnclosureA. special 34-inch-wide enclosure is available for terminat-ing shielded cable with stress cones, or for terminatingmore than one large cable per phase. The enclosuredesign permits space for termination of two 500-MCMcables per phase with stress cones* for motor and powerleads. Figures 35 and 38 show the space available in thisextra-width enclosure. Design is basically the same as the26-inch-wide one-high, and all data and information inthese instructions applicable to the 26-inch one-highdesign apply to the 34-inch-wide enclosure.

Power Cable Termination

In any installation, the cable should be prepared fortermination in accordance with the instructions of thecable manufacturer. However, the following generalrecommendations are given for proper cable termina -tion in Vacuum Limitamp equipment.

1. Pull in the cables in accordance with the paneloutline diagram and position them for maximumclearance between phase, ground and other cable orwire runs. Refer to Figure 60 of these instructions forrecommended location of incoming cables in a standardLimitamp controller.

Figure 38. Motor cable terminations in26-Inch or 34-inch wide enclosures.

Figure 39. Termination of cable in potheads.*General Electric Termi-Kit® stress cones.

20




2. Prepare the cable for termination in accordance withthe manufacturer’s instructions. For suggested terminat-ing methods, see pages 20 through 23 and Figures 39through 45.3. Bolt the cable terminals to the bus or other point oftermination.

COPPER LUG

GE NO. 0380 TAPEINSIDE FOR RUBBER ORNO.092 VC TAPE FOR VARNISHEDCAMBRIC IS RECOMMENDED.ALTERNATE: BUILD ENTIRE ENDSEAL WITH GE IRRASIL® TAPE.

OUTER LAYERIRRASIL TAPE

NOTE:FOR DETAILS OF ENDSEAL SEE FIG. 40 FOR &

RUBBER CABLE ANDFIG. 41 FOR VARNISHEDCAMBRIC CABLE.

MIN

— 4" »|'IN- FILL WITH SEALING

COMPOUND2"1CABLE LUG JUQGE IRRASIL'5' NO. 42005 TAPEmi> ** _

TxziCABLETERMINATORFITTINGo

7/GE IRRASIL®

NO. 42205 TAPE GE NO. 8380 CABLE INSULATIONSPLICE TAPE

Figure 42. Termination of interlocked-armor,non-shielded, 5000-volt cable.Figure 40. Termination of rubber-insulated, non-shielded,

non-lead-covered, 5000-volt cable.

6"1*W END OF

BRAIDI r ras i lNo. 42005taps

I r ra»i I No. 42005ta poH3/4"h~

rir?% *O j1/2"—I! RAID*

CABLE TAPE

iJ— -j t--- tCABLE INNERINSULATION

•“END SEAL

1. Cut cable to proper length leaving conductor sufficientlylong to extend Into the terminal lug.

2. Remove braid, tape, and Inner insulation and expose theconductor end for a distance of one Inch plus the length ofconductor to go Into the terminal lug.

3. Attach terminal to conductor.4. Taper the Insulation as shown.5. Remove the braid and tape, if any, six Inches from the

lug, exposing the Insulation. Leave one-half inch of originalcable tape extending beyond the cutback braid.

6. Apply the end seal using GE Irrasil® electrical tape. Ob-tain a smooth wrapping but do not stretch tape more thannecessary.

7. Bind down end of braid and tape, If any, with Irrasil tapeas shown on drawing.

8. Apply two layers half -lap of GE Irrasil® tape over all fromlug to exposed braid.

Figure 43. Termination of Interlocked-armor,shielded, 5000-volt cable.Figure 41. Termination of varnished-cambric-insulated,

non-shielded, non-lead-covered, 5000-volt cable.

21




4. If contact between the cable and an adjacent buscannot be avoided, as may be the case with the two 500-MCM cables per phase, tape the bus in the immediatevicinity of the cable contact point so that the surfacecreepage distance from the cable to the bare bus bar is atleast three inches. Thus, the surface creepage from thebare bus where the cable terminates, to the bare part ofthe bus where the cable touches, will be at least seveninches. The thickness of tape on the bus should beapproximately inch. General Electric No. 8380 tape isrecommended for most of the buildup and GeneralElectric No. 42005 Irrasil® tape is recommended over-all.5. Where more than two 500-MCM cables per phase arerequired, they should be brought into different sections,

or an incoming line compartment must be provided. Ifthe two 500-MGM cables must be terminated with stresscones, a cable entrance compartment must be ordered.6. Run all the low-voltage wires so as to avoid anypossible contact with high-voltage lines.

Termination of Lead-covered CableTermination of lead-covered cable requires the use ofpotheads (see Figure 39.) The pothead manufacturer’sinstructions should be followed in terminating the cableat the pothead. Standard Limitamp starters have spacefor locating one pothead of the pull-through type whichaccommodates up to and including 2/0, three-conduc-tor, 5000-volt cable. In this type of pothead, the threeconductors of the cable are fanned out within thepothead and pass completely through it , with thepothead sealing and terminating the lead covering. Forlarger cables, potheads with terminating bushings arerequired. In this case, or when more than one pull-through type is required, special cable entrancecompartments are available.Through-type potheads are satisfactory for varnished-cambric cable indoors. Paper-insulated cables are morehygroscopic and, since the only thing protecting theindividual conductors from moisture is tape on thesurface, high humidity might cause difficulty. Terminal-type potheads are required for paper-insulated cable.

GE NO. 8380 TAPE INSIDE FOR RUBBER ORNO. 992 VC TAPE FOR VARNISHED CAMBRICIS RECOMMENDED. ALTERNATE: BUILD ENTIREEND SEAL WITH GE IRRASIL® NO. 42005 TAPE

OCABLE LUG

1" IT v

!CABLE INSULATION|END SEAL

5"MIN

I12 Vi "GE NO. 8380 TAPE2"MIN

NO. 19 AWGTINNED COPPER WIRE

2"GE IRRASIL® NO. 42005 TAPE

SHIELDING TAPEGE NO. 8380 TAPE

^ GE IRRASIL® NO. 42005 TAPE

2"GROUNDSTRIP N

2

Termination of Pothead CableThe instructions for terminating lead-covered cable byusing potheads apply as well to those terminations ofother types of cable where potheads may be desired.

Figure 44. Termination of shielded, 5000-volt cableshowing stress-cone construction.

1. Maintains tight fit underload cycling and all cableoperating conditions.

2. Track-proof Insulating EPDMrubber.

3. Heavily-Insulated shieldedge protects high stressarea of stress cone.

4. High conductivity semi-conducting rubber relieveselectrical stress.

5. Internal step positionsstress cone properly oncable shield.

6. Ground clamp providespositive ground.

Termination on Non-shielded, Non-lead-covered CableThis cable is generally run through rigid conduit orcable raceways and brought into the enclosure by the useof conventional cable clamps and conduit fittings. Referto Figures 40 and 41 for termination details.

Termination of Interlocked-armor CableInterlocked-armor cable is terminated by means ofspecially designed cable fittings. These terminatorsconsist generally of mounting bracket, armor clamp, andsupporting base and bushing, with various modificationsavailable for special types of sealing.

SEMI-CONDUCTOR

Figure 45. TERMI-MATIC preformed stress cones (5 kV).

22




Interlocked-armor, Non-shielded CableRUBBER-COVERED -Refer to Figure 42 for generalinformation concerning termination. For details, referto Figure 40. Note that rubber-covered cable requiresonly taping near the terminal and not back to theterminator fitting. However';, if there is a possibility of oilcoming in contact with the rubber insulation, it would bewell to use a layer of Irrasil® No. 42005 tape all the wayback to the terminator fitting.VARNISHED-CAMBRIC -Refer to Figure 42 for generalinformation concerning termination , Note that var-nished-cambric cable requires taping back to theterminator fitting, since the individual conductors or“singles” have no braid.

Control ConnectionsConduit for control wires should be brought in the areasas shown in the outlines. There is room in both thebottom and top for the control conduits to be broughtinto the enclosure. In all Vacuum Limitamp controllers,the control connections are made through a terminalboard on the left side of the low-voltage control compart-ment. Refer to Figures 46 and 47 for details.

* 1 ., i -

VInterlocked-armor, Shielded CableInterlocked-armor, rubber-covered, and varnished-cambric insulated cables are sometimes shielded atratings of 5 kV and below. If they should be, proceed toterminate as detailed for other types of shielded cables.Refer to Figure 43.

htL\stm?- .

a;

Termination of Shielded CableIt is recommended that when shielded cable is used“stress-relief cones” be built up at the cable terminations,or else General Electric Termi-Matic® stress cones beused as shown in Figure 44 and Figure 45. This willrelieve the electrical stress which occurs in the areaaround the termination of the ground shield. Wheneverpossible, the conduit should be brought in through thebottom. A maximum of one 500-MCM cable per phasemay be terminated in one full-voltage starter section.Wien making shielded-cable terminations to Limitamp,the following procedure is recommended:

Use GE Termi-Matic system per Figure 45, or else buildstress cones with tape as follows:

1. Mark the cable at least 10 inches from the terminalpoint.2. Remove all shielding from the terminal end to thispoint, leaving sufficient ground strip to reach the nearestground connection.3. Proceed to build stress cones as prescribed by thecable manufacturer. Refer to Figure 43 and 44 for details.4. Tie all of the ground strips together and fasten themto ground bus (if ordered) or to a large stud on theenclosing case. (See note on grounding under item on“Wire and Cable Entrance”.)If the foregoing recommendations, along with the cablemanufacturer’s recommendations, are followed, thecable terminations should be satisfactory and reliable.These instructions apply to both rubber-covered andvarnished-cambric insulated shielded cables.

f ;>

Figure 46. Low-voltage compartment showing low-voltageterminal strip on left side of panel.

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Figure 47. High-voltage compartment showing low-voltagewiring trough. Low-voltage cables entering from the

floor should be routed through this channel.

23



CM94 VacuumLimitamp 400 Ampere Control

Control wires coming up through the floor should berun just behind the door hinges inside the channel (seeFigure 47) provided for this purpose and the wiresshould be terminated on the terminal board in the low-voltage compartment. Control wires entering from thetop of the enclosure should also be run in the channelprovided just behind the low-voltage door hinges andterminated on the terminal block.

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t -it IS JB8Reassembly

After all power and control-wire connections are made,the Vacuum Limitamp controller must be reassembledby following the sequence on pages 13 and 14 in reverseorder. If the controller is enclosed in a NEMA type 3enclosure, refer to Figure 51 for assembly instructions.Npte: Do not attempt to operate without all barriers reassembled.

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Replacing Contactor In EnclosureWhen replacing the contactor in the enclosure, thefollowing procedures should be followed:

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• *«i r - I * ' ••X '•

V 1o . #e400-Ampere Contactor1. Before installing the coxitactor, ensure that the cablesattached to the line side of the contactor are properlytightened to 35 lb-ft.2. Remove the three bus bar bolts that were placed inposition during contactor removal arid slide thecontactor onto its mounting base and ensure that theretaining studs protrude through the front of thecontactor side bars. Also ensure that the armatureinterlock is properly engaged in the interlock pawl onthe lower-right side wall. (See Figures 17 and 25)

Note: This mechanism transmits the contactor armature motionto the mechanical interlock and it is vital that this mechanismfunction properly.

3. Install and tighten the three load-side connectionbolts. See Figure 29.Caution: Be absolutely certain that these bolts are properly in-stalled and tightened. These are current carrying connectionsand must be tight or damage will result. These connectionsmust be tightened to 16 lb-ft. See Figure 29.4. Install the mounting nuts on the retaining studs oneach side of the contactor and tighten.5. Attach the line cables to the bottom of the fuseassembly. Be absolutely certain that these connectionsare properly tightened to 9 lb-ft. See Figure 48.

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i ii:

Figure 48. Line connection bolts for 400-ampere contactor.

Warning: Make certain that all barriers are replaced and boltedtightly into position. Make sure the line and load side termina-

tions of the contactor are tightened properly. Failure to performthese operations could result in failure of the unit to operatesafely and reliably.

Mechanical Operation CheckAll Power Off

With the main incoming power removed, operation ofthe isolating switch should be checked. This may beaccomplished as follows:

1. With the high-voltage door open (and power discon-nected) push in the door-operated release (A) , Figure49, with your left hand. This is not a normal functionand should only be used for initial equipment check out.

2. Push in the handle latch release (B) , Figure 49, withthe thumb of your right hand and lift the handle (C) ina rapid, positive motion from the OFF to the ON posi-tion. The door operated release (A) can now be

6. Manually operate the contactor armature and observe released. Near the top of the handle movement a sharpthat the mechanical interlock functions properly. If so, snap should be heard and the isolator switch contactsthe contactor is properly installed. should be in the closed position. The contacts may be

viewed by looking through the window supplied in themain fixed barrier. The contacts should be fully seatedon all three phases. The handle latch release (B) ,Figure 49, should pop fully out at the top of the handletravel (See Figure 57) .

7. Reconnect the control umbilical cord to thecontactor and be sure the retaining wing nuts are tight.Installation of the contactor is now complete.

24




3. Push in the latch release (B) and move the handle(G) mechanism from the ON to OFF position, again in arapid, positive motion.Near the bottom of the handle travel a sharp snap shouldagain be heard and the disconnect contacts should be fullyopen. Inspection may be made by viewing through thewindow provided in the fixed barrier. The handle latchrelease (B) , Figure 49, should pop fully out at the bottom ofthe handle travel (See Figure 57) .4. Repeat steps I and 2 until the disconnect switch isagain in the closed position. Simulate the contactorbeing energized by depressing the contactor armaturedownward until the contactor is in the fully closedposition. While holding the contactor in the closedposition, attempt to push in the latch release (B) . Therelease should move forward only slightly and the handleshould not rotate. Now, release the contactor armatureand depress the latch release. Attempt to close thecontactor armature. The armature should move slightlyand stop, preventing the contactor from moving to theclosed position.5. Repeat steps 1 and 2 above. When the handle (C) isrotated to the ON position, the door latch (G) shoulddrop to within 1% to 2 inches from the bottom of thehandle assembly ( H).6. If the mechanism fails to meet any of the abovechecks, an adjustment must be made to the interlockassembly as shown in Figure 50. This adjustment is madeto ensure that the interlock slider is moving properly. Ifthe contactor can be made to turn ON manually whenthe disconnect switch operating handle is in an interme-diate position, the interlock needs to be adjusted.Caution: Before making any adjustments, be sure that the con-tactor is in the fully off position and the disconnect switchhandle is in an intermediate position with the handle latch re-lease (B ), Figure 49, fully depressed.A. Loosen the bottom lacking nut (X) , Figure 50, while

holding the top adjusting nut (W) firmly in position.Also loosen the two retaining nuts at the top of the rod.

B. Turn the adjusting nut until the interlock slider is justslightly below the handle latch release rod (0.06 inches).

C. When the proper position has been reached hold thetop adjusting nut (W) and tighten the lower lockingnut (X) to hold the adjustment. Finally tighten thetwo locking nuts at the top of the rod.

D. Test the interlock mechanism again by followingSteps 1 through 6 above.

If the controller fails to meet any of the above checksDO NOT ENERGIZE THE CONTROLLER. Contactyour nearest General Electric sales office.7. Return the disconnect handle to the OFF position.

A Door-operated release (Not visible) G Door LatchB Handle latch release (Pusher) H Handle AssemblyC Handle

Figure 49. Operating handle parts.

W Top adjusting nutX Bottom locking nut

Figure 50. Adjusting the interlock mechanism.

Y Armature interlock rodZ Contactor armature

25




SEALERROOF COUPLING

/ / \ 1/2" x 13" X 1V4 " lg. (12)Add gussets to Joints of

roof channel supports onwalk»in type. Add couplingto roof joints. Use 3Msealer In all cracks,

1/2" X 13" X 2" lg. (6)ENCL. JOINTS

ROOF ENDCOVER

ur ea

fV0-GUSSETS 0.50" 0.50"/ SEALER> 7 s\TOP BRACE ANGLEREMOVE/.THESE

PARTS P0.25" - 0.25"1/2" X 13" Xr ig. (5)3M SEALER :

On sides of single casesand sides of oases on endsof lineups, use sealeraround cutouts under allcover plates. Also usesealer In all bolt holes.

Purpose of sealer is tohave weathertlght seal be-tween exposed Joints ofenclosures.

LINE UP ENDPLATEASSEMBLY

/

i eroADD ALL PARTSNOTED HERE v.o SEALER

— 0.50"0.50"--Where to apply:

Apply to one side of onecase at each Junction oflineup of cases.o o

BOTTOM BRACEANGLES

FLAT HEADBOLTS

SIDE VIEWFIG. A Method of Application:

Place the extrudedsealer strip with slightpressure 1/2-Inch In fromfront and rear edge of sideof case except 1/4-Inch Inat cutouts. Use two (2)strips side by side the fullheight of case. Also applyacross the top of the sideof the case 1/2-Inch down.See Fig. “A”.

i L1 K

R.H. END VIEW (AFTER A)SHOWING PARTS TO BE ADDED

FRONT CUTAWAY VIEWOF EXISTING EQUIPMENT

i

J! o.!rQFIG. BSPECIAL NOTE FOR FIELD

INSTALLATION BYCUSTOMER:

In addition to other In-structions shown, hard-ware should be removedand used to bolt newenclosures to existingenclosures. The end-plateassembly and gasketsshould be removed anddiscarded. After enclosuresare In place, Install roofcoupling furnished withnew enclosures.

Material:Extruded 3M sealer for-

mula EC1126, 1/4-Inchdiameter extruded bead x30-Inch long strips. Productof Minnesota Mining andManufacturing Co., 700Grand Avenue, Ridgefield,New Jersey.

The approximate totallength of sealer required ateach Junction will be 42feet, for non walk-ln and 70feet for walk-ln.

Figure 51. Assembly of outdoor enclosure.

26




OperationGeneralA test-power interlock (TPI) (See Figure 14) circuit andTest-Normal Selector Switch (TSW) (See Figure 9) isprovided to check out the control circuit of the completeunit without applying power to the motor. After allcontrol-circuit connections are made, the controllershould be put through its complete operating sequence,in the test position, as a final check.A wiring diagram which shows the circuit and connectionsthat apply to the controller is included with the controllerwhen it is shipped from the factory. All external wiringfrom the controller must be made in accordance withthe connection diagram supplied with the controller.

make a good contact when closed. The relay and contactorsare carefully adjusted at the facto17; however, should anadjustment of these devices be necessary, these adjustmentsare explained in the individual instructions for each device.After all connections have been properly made, all partsproperly assembled, and all components thoroughlyinspected and adjusted, the controller is ready for operation.

Normal Operation1. After all power and control connections are made,AND WITH THE ISOLATING DEVICE OPEN, meggerbetween phases at the motor terminals, and betweeneach phase and ground stud or bus, to ascertain that noshort circuits are present.2. Close the compartment doors and apply power to thecontroller.If the operating handle of the isolating mechanismcannot be moved to the closed position, it may be thatthe mechanical interlock device is preventing thismovement. To move the handle to the closed position,the highwoltage door must be fully closed and thecontactor must be open.

Test Power CircuitA complete operational check of the controller can be madewithout applying voltage to the motor or to the bus as follows:1. The isolating-device handle must be in the openposition. In the open position, contacts of the mechani-cally operated test-power interlock (TPI) will open thesecondary circuit of the control-power transformer,thereby isolating it. The Test-Normal Selector Switch(TSW) must be in the “Test” position to close the circuitto the test-power terminals on the control terminal board.

3. Close the isolating-device handle by moving thehandle with a rapid, positive motion to the extremeupper position until it latches into position. Unless thelatch ( pusher ) snaps out when the handle is moved to

2. Refer to the elementary and connection diagrams for the extreme positions, either in the open or closedthe required control voltage, frequency, and test-powerterminal designations. Connect the required test-powerto terminals provided on the terminal board in the low-voltage control compartment. Power may then be appliedto the low-voltage control circuit and the circuit testedfor proper operation.

position, the contact marked CPI (control-power inter-lock) will not close and the operation is not complete.4. Operate the controller in the normal manner withthe pilot devices (usually, push buttons) provided.5. After the preliminary operation check is made, checkthe motor for proper rotation.

Preparation of Controller for OperationOnce the panel is in place and the cable terminated, cleanthe inside with a brush, soft cloth, or dry compressed air.Make certain that any dirt, dust or bits of packing material,which may interfere with successful operation of the paneldevices, are removed from the panel.Caution: Care should be taken during the cleaning operation toprevent any dirt from being bloion into the inaccessible spaces ofthe devices.Before the controller can be operated, even for a tryoutwithout power, all devices must be placed in full operatingcondition. Also, check to ascertain that no tools or loosewires have been left within the panel during installation.Operate each device by hand to see that the moving partsoperate freely and without binding. Make sure that allelectrical contact tips are clean, free of grease and dirt, and

Door Opening ProcedureGeneralTo open the high-voltage doors to gain access to thecontactor or motor terminals, the contactor must be in thede-energized position. If the contactor is energized, thelatch on the disconnect handle cannot be pushed in, thehandle cannot be operated, nor can the door be opened.Depressing the stop button de-energizes the contactor.The latch release on the disconnect handle can then bedepressed, which opens an electrical interlock in thesecondary of the control-power transformer. When thelatch release has been depressed, the isolating switchhandle may be moved to the lower or open position.With the disconnect handle in the lower position, thehigh-voltage door may be opened by turning the V\ turnlatches.

27



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Warning: All power must be removed from the main bus beforeattempting to adjust the isolating switch mechanism.1. After removing all power to the controller, and asdescribed in steps 1 Sc 2 of the Mechanical OperationCheck, rotate the isolating switch handle to the ONposition. Then remove the fixed barrier (Figure 33) byremoving the retaining screws that hold it in place.Retain the hardware for reassembly.Some of the barrier mounting hardware is nylon typehardware. Note the location of these parts so they maybe reassembled properly.2. Near the end of each switch blade assembly, anadjusting nut is located along with a Belleville washertype spring. To adjust the blade pressure the nut mustbe adjusted. Loosen the small set screw located on eachof the retaining nuts to enable adjustment.3. Loosen the adjusting nut at the top of the blades.With your fingers retighten the nut until all the slack isout between the blades, stationary contact, spring washer8c nut, then tighten an additional Vx (one-eighth ) turn.This procedure provides the necessary 0.005 inch springcompression of the blades.4: Tighten the set screw on the nut to lock the adjust-ment in position. Use caution to prevent turning thenut on the main screw while tightening the set screw.5. When the adjustment is complete for all three phases,rotate the isolating switch handle to the OFF position.Then, apply a thin coating of Mobil Temp SHC-32grease to the contact surfaces of the male stab portion ofthe disconnect.To properly adjust the pivot point Belleville washer typespring, return the isolating switch handle to the ONposition per step 1 above. Then, follow the steps below:1. On each phase, loosen the set screw on the pivotpoint adjusting nut.2. Loosen the adjusting nut and then retighten usingyour fingers until the nut is just snug and no side play ofthe parts is evident.3. Using wrenches tighten the adjusting nut an addi-tional one-half ( Vi ) turn and tighten the set screw to holdthe adjustment in place.4. Rotate the isolating switch handle to the OFFposition, then reinstall the isolator switch barrier. Ifnecessary the viewing window may be cleaned beforereinstallation of the barrier. Use a soft cloth and a mildsoap and water solution or a commercial cleaner such asWindex or other similar cleaner.Warning: Severe injury or death may result if the equipment isenergized with the mechanical interlocks defeated. Remove allpower from the equipment before defeating any of the mechanicalinterlocking mechanisms.

Door-Defeater LatchWarning: The j'ollowing steps should only be taken as a lastresort to enter a malfunctioning controller; It is imperative thatall power to the main bus be removed before proceeding.IN CASE OF EMERGENCY, remove all power to thecontroller; then the high-voltage door may be openedwith the contactor in the closed position and with theisolating switch closed by using the hex-head bolts,located to the lower left of the isolating-switch handle, asfollows:

Warning: Do not proceed unless all power to the controller isremoved. Doors must not be opened with the power connected tothe bus.1. Turn the door latches Z\ turn counterclockwise.2.' Remove the right-hand hex-head bolt, as shown inFigure 52.3. Turn the left-hand bolt ]A turn counterclockwise.Figure 53 shows the bolts from the inside. The door maythen be opened.Warning: Defeating the door interlock leaves the controllerconnected to the bus. The bus power must be removed.On some one-high enclosures, the low-voltage controlpanel serves as a barrier to isolate the high-vokagecontrol-power transformer and fuses. An interferencepin, shown in Figure 54, prevents swinging this low-voltage panel out until the high-voltage door is opened.

Inspection, Maintenance, and ServicingVacuum ContactorComplete maintenance and adjustment instructions for thehigh-voltage contactors are presented in GEH-5306. Referto that instruction for all problems of servicing and adjust-ing; and to the proper renewal parts bulletin for renewal parts.Contactor tip life depends on the severity of the service,but in any case, it is recommended that the contactor tipwear be checked at least once a year or in very high dutycycle operations, after every 250,000 operations.

Isolating Mechanism and Mechanical InterlockWarning: Under no circumstances should the isolation switchbe inspected or adjusted with power applied to the main bus.The quick-make quick-break isolation switch assembly isadjusted and tested at the factory. Under normalcircumstances the switch does not need adjustment,however, if conditions require it the switch may beadjusted in the field. To adjust the isolating switch thefollowing steps should be followed:

29



wCR194 Vacuum Limitamp 400 Ampere Control

I WARNING: Defeating the door interlockleaves the controller connected to the bus.The bus power must be removed.©

Til NOTE

To check if sufficient (or safe) interlockingbetween door and door interlock bar exists,the following should be done:

A. Open high-voltage door.B. With the door open, close the isolator

switch by manually depressing the dooroperated release. See Figure 49.

C. Close door against interlock bar.D. Look through door cutout below handle

and visually determine If there is aminimum of 0.50-inch overlap (see sketch).

E. For a final check, close the door, close thedisconnect switch, and try to pull the dooropen. The door should not open.

DOOR INTERLOCK BAR

APPROX 0.50"k - n

H—L.©— liB

rjn_ .=j |

§> a?- p —J-KJ J \„Ji

ADJUST STOP NUTBEHIND DOOR SO THAT ILATCH MAY PIVOT |FREELY.

LOOK-THROUGHCUTOUT

i

ii tA! ! ! L—: : i

LATCH ASSEMBLY

FRONT VIEW

Figure 56. Checking procedures for mechanical door interlock.

HANDLEWARNING: Defeating the door Interlockleaves the controller connected to the bus.The bus power must be removed.

CONTROL POWERINTERLOCK

0.12

NOTE1. Set 0.12-inch gap (as shown) with pusher

extended (out position). See 0.60-lnchreference.

2. Then, check the Interlock operation withthe pusher depressed.

3. Both contacts must be open and have acontact gap of at least Yw Inch.

4. Insure the pusher pops out fully (see 0.60-Inch reference) in both the down (off) andup (on) positions.

CPI

2 N.C.SWITCH

0.60VREF

f 4- +7

PUSHER ROD

4 HANDLE LATCH RELEASE(PUSHER)

5/64"3

?Figure 57. Checking for proper operation of pusher and control power interlock (CPI).

30

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TOPNOTE

1. Adjust depressor bracket(s) by bending todepress Interlock plungers equally withhandle In OFF position.

2. Loosen screws “A”, depress Interlockplungers (2 or 3) all the way, then movedepressor back 0.04 to 0.06 Inch for slackand tighten screws.

VIEW

DEPRESSOR( 2 )

r +1 N.O.1 N.C.TPISWITCHES LSIDE

VIEW

2 TO HANDLEh-zX oGCMAIN DISCONNECT ROD ASSEMBLY u.

Figure 58. Checking test power Interlock (TPI) adjustments.

Checking Procedures -Mechanical Interlock & Manual Isolator (SeeFigures 56-58)1. Check the door mechanical interlock for properinterference. See Figure 56.2. Check for proper operation of pusher rod andControl Power Interlock (CPI) operation. See Figure 57.3. Check the Test Power Interlock (TPI) adjustment.See Figure 58.

Warning: The vacuum interrupter integrity test should be per-formed before the high-voltage contactor is energized for the firsttime and each time it is returned to service after maintenance,adjustment, or repair (See GEH-5306 ). Otherwise the vacuuminterrupter' integrity test should be performed annually.Caution should be exercised during this test since high voltagetesting is potentially hazardous. First open the controllerisolating switch then completely isolate the contactor by discon-necting the bolted connections at the contactor load terminalsprior to performing the high potential test. Also remove CPTprimary fuses,

Failure to perform these tests may cause serious injury or death.High potential test instruments can be purchased toperform the vacuum interrupter integrity test. Thefollowing is a recommended test instrument:

Hipotronics Model 7BT 60AUse of a DC Hipot is not recommended because resultsmay indicate a problem with a good interrupter. If youwish to use DC Hipot, set for 28kV, but if interrupterfails, confirm failed interrupter using above AC Hipot.

Vacuum Interrupter Integrity TestWarning: The controller isolation switch ( QMQB) must beplaced in the off position and the motor load must have come toa complete stop before attempting to perform the vacuum inter-rupter' integrity test.Caution: X-ray emission may be produced if an abnormallyhigh voltage is applied across the open contacts of a vacuum in-terrupter. Do not apply a voltage across the 400A CR193B con-tactor that is higher than 20.0 hV RMS.

Test ProcedureNote: Before performing vacuum integrity test, confirm thatboth the armature gap setting and contact wear adjustment(GEH-5306, Sections 5 & 6) are proper.1. Disconnect load side power leads from contactor andCPT primary fuses.2. With the contactor in the open position connect thetest leads to the contactor power terminals as shown inFigure 59. Apply the recommended test voltage (perabove) and hold for a minimum of five (5) seconds.

GeneralThis test determines the internal dielectric conditionand vacuum integrity of the vacuum interrupters. Priorto performing this test the outside surfaces of thevacuum interrupters should be wiped clean of anycontaminants with a non-linting cloth or industrial typewiper. During this test each interrupter should bechecked separately.

31




In these routine inspections, four basic categories ofdeteriorating influences should be kept in mind:

la. The effect of foreign material: Dirt and dust fromthe environment such as wood fibers, coal dust, cement,lamp black, lint.lb. The effect of chemicals in the atmosphere: such assulfur dioxide, chlorine, some hydrocarbons and saltwater.2. Mechanical wear and fatigue on all moving parts.3. Heat.4. Loose joints and connections.5. Perform vacuum interrupter integrity test as de-scribed in these instructions.Follow directions in these instructions for obtainingaccess to all sections of the controller including high-voltage door interlocking. Also, refer to GEH-5306 fordirections relative to inspection of the high-voltagecontactor.The following are some specific recommendations:

1. Check for cleanliness generally, but particularly foraccumulation of any foreign material on insulators.Voltage failures can result from tracking across insula-tion surfaces when they are dirty. The primary circuitinsulation on the controller may be checked phase tophase and phase to ground using a 2500 volt megger.2. Check for abrasive material accumulated in theisolating mechanism and mechanical interlock bearingand cam surfaces.3. Check for buildup of dust or dirt which would reduceany air or surface voltage clearances.

Figure 59, Method of connecting test leads to Interrupterfor vacuum integrity test.

3. Reverse the leads and repeat the test.4. If no breakdown occurs the interrupter is in accept-able condition. If a breakdown occurs the interruptershould be replaced. Refer to the “Interrupter Replace-ment” section in GEH-5306.Note: No attempt should be made to try to compare the condi-tion of one vacuum interrupter with another nor to correlate thecondition of any interrupter to low values of DC leakage cur-rent. There is no significant correlation.5. Alter the high potential voltage is removed from theinterrupters, the metal end caps of the interruptersshould be discharged with a grounding stick to removeany residual electrical charge. 4. Excessive heat can cause wire and cable insulation

breakdown. Therefore, check for any evidence of6. Make sure that all connections are tightened properly melting, discoloring, deterioration of wire and cable,

to 16 lb.-ft. Reconnect load cables and replace CPT fuses,5. The isolating mechanism has a life expectancy ofapproximately 6000 operations. If the application issuch that the mechanism is operated more than twiceeach day, then the mechanism should be checked at theend of each 1000 operations, otherwise a yearly inspec-tion is recommended.6. Periodic checks of dimensions of the isolating mecha-nism and mechanical interlocks is strongly recom-mended. Follow the section in these instructionsentitled “ISOLATING MECHANISM AND MECHANI-CAL INTERLOCK”.7. When any part of the isolating mechanism andmechanical interlock is replaced, all dimensions andchecking procedures referred to under No. 6 <tboveshould be followed to be sure the system is in normalworking order.

Preventive Maintenance GuideWarning: Before performing any preventive maintenance on theVacuum Limitamp controller all power must be removed fromthe equipment and all rotating equipment must have coasted toa complete stop.Maximum trouble-free service from Vacuum Limitampcontrollers requires periodic inspection, preventivemaintenance, and periodic cleaning. A definite sched-ule should be maintained for inspection, the frequencydepending upon operating conditions. Preventivemaintenance activity should then be established as theresult of periodic inspection.

32



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NOTE:B - INCOMING POWER TERMINAL CONNECTIONB1 -AC POWER BUSC - CONfTROL LEAD TERMINAL BOARDD - MOTOR LEAD TERMINAL CONNECTIONE - GROUND BUSTERMINAL CONNECTIONF - GROUND TERMINAL CONNECTIONG - SPACE REQUIRED TO OPEN DOORS 90 DEGREESJ - MOUNTING HOLES FOR 1/2 IN.DIA.ANCHOR BOLTSK - SPACE AVAILABLE FOR INCOMING CONDUITM - RECOMMENDED POSITION FOR INCOMING MOTOR CONDUrTN - RECOMMENDED POSITION FOR INCOMING CONTROL CONDUITP - RECOMMENDED POSITION FOR INCOMING POWER CONDUIT

* - INDICATES TERMINAL LOCATION - APPROX.FOR CABLE LENGTH

A - APPROXIMATE UNCRATED WEIGHT- ADD 5 PERCENT FOR DOMESTIC SHIPPING WEIGHT- ADD 20 PERCENT FOR EXPORT SHIPPING WBGHT

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These instructions do not purport to cover all details or variations in equipment nor to provide for every possiblecontingency to be met in connection with installation , operation or maintenance. Should further information bedesired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, thematter should be referred to the GE Company.

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GE Electrical Distribution & Control

General Electric CompanyP.0. Box 480, 6801 Industrial Dr., Mebane, N.C. 27302

GEH-5305A 0594 PSA © 1994 General Electric CompanyV



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