GE CR194 User manual

CR194 Two-High Vacuum
Limitamp@ Control
BCS Switchgear Inc.
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TABLE OF CONTENTS
INTRODUCTION ..................................................................................................................................
3
DESCRIPTION .......................................................................................................................................4
Equipment Identification- CR Number Designation.. ................................................ 4
General ........................................................................................................................... 5
Ratings ............................................................................................................................ 5
Basic Impulse Level (BIL) ............................................................................................ 5
Dielectric Test Voltage .................................................................................................. 5
High-Voltage Vacuum Contactors ............................................................................... 5
Manual Disconnect (Isolation Switch) ........................................................................ 6
Mechanical Interlocking ............................................................................................... 8
Auxiliary Enclosures.. .................................................................................................... 8
Dimensions ................................................................................................................... .8
Power Fuses .................................................................................................................... 8
Blown Fuse Indicator 8cTrip ........................................................................................ 9
Power Fuse Conversion Instructions.. .......................................................................... 9
INSTALLATION ...................................................................................................................................
11
General ......................................................................................................................... 11
Receiving ...................................................................................................................... 11
Handling ...................................................................................................................... 11
Placement of Enclosure .............................................................................................. 11
Disassembly .................................................................................................................. 11
Contactor Removal ...................................................................................................... 12
Gaining Access to Horizontal Bus for Splicing ......................................................... 14
Taping Instructions for 5kV ....................................................................................... 16
Reassembly ................................................................................................................... 16
Incoming Power Connections .................................................................................... 17
Grounding ................................................................................................................... 17
Motor Cable Termination .......................................................................................... 18
Cable Termination Guidelines ................................................................................... 19
Control Connections ................................................................................................... 21
Mechanical Operation Check .................................................................................... 21
Vacuum Interrupter Integrity Test ............................................................................ 24
Preparation of Controller for Operation .................................................................. 25
Megger Check .............................................................................................................. 25
OPERATION ......................................................................................................................................
26
Operation Under Test Power ..................................................................................... 26
Normal Operation ....................................................................................................... 26
Normal High-Voltage Door Opening Procedure ..................................................... 27
High-Voltage Door Defeater Latch ............................................................................ 27
INSPECTION, MAINTENANCE & SERVICING ..............................................................................
28
Mechanical Operation Check .................................................................................... 28
Vacuum Interrupter Integrity Test ............................................................................ 28
Vacuum Contactor ...................................................................................................... 28
Isolation Mechanism ................................................................................................... 28
Torque Recommendations For Electrical Power Connections ............................... 30
Preventive Maintenance Guide .................................................................................. 30
2
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CR194 Two-High Vacuum Limitamp@ Control
WARNING: Before any adjustments, servicing,
parts replacement or any other act is performed
requiring physical contact with the electrical work-
ing components or wiring of this equipment, all
power must be removed and locked off from all
sources and all attached rotating equipment must
have come to a complete stop. User personnel
must be completely familiar with the following op-
erating and maintenance instructions before at-
tempting to service this equipment.
WARNING: The vacuum interrupter integrity test
should be performed before the high voltage
vacuum contactor is energized for the first time and
each time the contactor is returned to service after
maintenance, adjustment or repair. Failure to per-
form this test may result in serious injury or death.
CAUTION: Product is not intended for nuclear use.
INTRODUCTION
CR194 two-high vacuum Limitamp@ controllers are
designed to meet NEMA ICS 3, Part 2 “AC General
Purpose High-voltage Class E Controllers” and UL 34’7
requirements, and may be described as metal-enclosed
high-interrupting capacity vacuum contactor type
starter equipment with manual isolation. Individual
starters and controllers are designed for specific appli-
cations; the components and functions being dictated
by the purchaser specifications and needs. Controllers
may be fused or unfused.
The essential control functions for all types of a-c
motors consist of starting, stopping and overload pro-
tection. Vacuum Limitamp@ controllers also include
short-circuit protection, and other functions in great
variety as may be required for particular applications.
These instructions were prepared as a guide to
handling, installation, operation and maintenance of
the CR194 two-high vacuum Limitamp” controller.
Figure 1 shows a 36”wide two-high starter with induc-
tion motor controllers in top and bottom. Figure 2
shows the same controller with the low-voltage doors
open. Figure 3 shows the same controller with the
high-voltage doors open.
The intent of these instructions is to give the
purchaser the necessary general information to iden-
tify his controller as to type and function, to describe
suggested methods of installation, and to demonstrate
some techniques of operation and maintenance. The
purchaser should interpret these instructions for ap-
plicability to his particular controller by referring to
the nameplate data on the controller and to the elec-
trical diagrams supplied with the controller.
For application questions refer to GET-6840. For de-
tails on the high-voltage contactor refer to GEH-5306.
e
Figure 1.36”~widetwo-highinductionmotor controllers
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CR194Two-High VacuumLimitamp@Control
Figure 4. 36”wide twehigh with both
low-voltage doors open
DESCRIPTION
Figure 3.36’kide twehigh with both
high-voltage doors open
Equipment Identification-
CR Number Designation
CR194 Two-High Vacuum Limitamp@ Control
Starting and Speed Functions
A - Single-speed, full voltage
B - Single-speed, reduced voltage reactor type
C - Single-speed, reduced voltage, autotransformer type
D - Single-speed, part winding start
E - Single-speed, reduced voltage primary resistor
G - 2 speed, 1 winding full voltage
H - 2 speed, 1 winding reactor reduced voltage
J - 2 speed, 1 winding autotransformer reduced voltage
N - 2 speed, 2 winding full voltage
P - 2 speed, 2 winding reactor reduced voltage
Q- 2 speed, 2 winding autotransformer reduced voltage
Rotation and Braking
1 - Non reversing/non braking
2 - Reversing/non braking
4 - Non reversing/dynamic braking
5 - Reversing/dynamic braking
7 - Reversing/plugging
1 = NEMAEl (Unfused)
2 = NEMA E2 (Fused)
A - 26” I-HI
B - 34” l-HI
C - 48” l-HI
D - 36” 2-HI Stationary
E - 40” 2-HI Stationary
F - 36” 2-HI Drawout
G - 40” 2-HI Drawout
System Voltage
7 - 2400 Volts
8 - 4200 Volts
2 - 7200 Volts
0 - Other
Controlled Apparatus
0 - Synchronous Motor (brushless type)
1 - Induction Motor
2 - Synchronous Motor (ring type)
3 - Wound Rotor Motor
4 - Transformer Feeder
5 - Capacitor Feeder
6 -Other

CR194Two-High VacuumLimitamp@Control
General
The basic CR194 two-high vacuum Limitamp@ control-
ler is a front connected assembly of components and
conductors for motor starting, arranged in a conve-
nient two-high vertical stack. The enclosure allows
space and facilities for motor cable termination, plus
safety interlocking of doors and isolation switch to pre-
vent inadvertent entrance to high-voltage parts. Unless
specified otherwise, the motor cable barriers are in-
stalled for bottom motor cable entry, but are easily
field converted from bottom to top or top to bottom
motor cable entry. Removable conduit cutout covers
are provided in both the top & bottom (if a bottom is
provided) for bringing in motor cable & control wir-
ing. In an effort to provide for maximum motor cable
access in the compact 36”-wide two-high design, in-
coming power cable must be connected in a separate
cable entrance compartment or the two-high must be
bus connected to existing equipment. No back access
is required, although both back and side access is pos-
sible by removal of back and side panels. The equip-
ment may be rated up to 5.0 kV.
In general, the starters in both the top and the bottom
are divided into high-voltage and low-voltage
compartments, separated by doors and barriers.
Mounted on the high-voltage door of each starter is
the low-voltage control cavity, with the low voltage
door hinged to the high-voltage door. Access to the
low voltage panel is obtained by rotating the two ‘/4
turn latches on the low-voltage door, then opening the
door to the left. To open the high-voltage door, the
power must be disconnected by a sequence of
manual operations which requires de-energizing the
high-voltage contactor, operating the isolation switch
handle by rotating it downward, loosening the two
latch bolts on the high-voltage door, then opening the
door to the left. Low-voltage doors may be entered
without disconnecting the power, but this should be
done with caution.
Installation, operation and maintenance should be
performed only by experienced personnel trained in
this class of equipment.
Ratings
Refer to the panel data nameplate (see Figure 4) on
the front of the enclosure for detailed ratings appli-
cable to a particular controller. Equipment basic rat-
ings equal or exceed NEMA ICS 3, Part 2 for Class E2
Controllers, and are summarized below.
Starter Main Bus & Maximum Current Ratings
Starter Max.
Main Bus
Current
lBar/ 1 2 Bars/ Top 1 Bottom
Enclosure Type
Phase Phase Unit
Unit
Vented 12OOA 2000A 360A 4OOA
Non-Vented 12OOA 195QA 320A 320A
Figure 4. Operating handle, handle operating instructions
and panel data nameplate
Interrupting Ratings At Utilization Voltage Shown
Three-phase Symmetrical
Maximum Sytem mVA
Maximum Continuous Class El Class E2
Volts Amperes(RMS) Unfused Fused
2500 400 25 200
3600 400 37 300
5000 400 50
4m
Basic Impulse Level (BIL)
The standard BIL rating of vacuum Limitamp@ con-
trollers is 60kV crest (design rating). This rating ex-
cludes dry-type control transformers and starting reac-
tors & autotransformers.
Dielectric Test Voltage
2% times nameplate voltage plus 2000 volts.
High-Voltage Vacuum Contactors
The vacuum contactors used in vacuum Limitamp@
controllers are available in two different ratings: 400
and 800 amperes. This publication covers only the 400
ampere rating as used in CR194 two-high vacuum
Limitamp@. The 400 ampere and 800 ampere
contactors are similar in operation but very different
5

CR194 Two-High Vacuum Limitamp@ Control
in size and rating so are not interchangeable. Figure 5
shows the CR194 two-high stationary contactor. Figure
6 shows the CR194 two-high drawout contactor. The
400 ampere stationary contactors in the two-high
vacuum Limitamp@ and 26”-wide & 34”-wide stationary
vacuum Limitamp@ are the same basic contactor, but
are not directly interchangeable since the auxiliary
interlocks and wire harness are mounted differently
on the contactors, and the two-high stationary
contactor is mounted on a slide base. To use a 26”-
wide or 34”-wide 400 ampere stationary contactor in a
400 ampere two-high stationary enclosure, the auxil-
iary interlocks 8cwire harness should be removed frorr
the contactor, and the two-high auxiliary interlocks,
wire harness & slide base mounted on the contactor.
The same procedure but in reverse would be required
to use a two-high stationary contactor in a 26” or 34”-
wide stationary enclosure.
The stationary contactor is easily removed from the
controller by disconnecting the line and load power
LINE CABLE
SLIDE BASE
Figure5. CR194 two-high stationary contactor showing
auxiliary interlocks, wire harness, line cable and slide base
connections and sliding the contactor out. The auxiliary
contacts are electrically connected by means of a remov-
able umbilical cord plug that is retained by two wing
nuts. By removing these wing nuts, the wiring harness is
easily disconnected from the contactor. The drawout
contactor is removed in a similar manner by first remov-
ing the Positioning Bolts then sliding the contactor out.
Refer to the section titled “Contactor Removal” that
details these procedures.
The contactor is magnetically operated by a DC coil
fed by a rectifier and timed holding circuit. The base
mounted contactor timing module (CTM) shown in
Figure 7 applies full voltage to the contactor for a time
sufficient to fully close the contactor. Then it inserts a
capacitor into the circuit to hold the contactor closed
at a reduced voltage to prevent overheating the coil
and provide for fast dropout when power is removed.
6
Figure 6. Rear view of CR194 two-high drawout contactor
showing stab connectors.
- (CTM) W
TERMINAL 1
BOARD (TB) E :
H(
figure 7. View of low-voltage compartment showing
contactor timing module (CTM) , test-normal selector
switch (TSW) and terminal board (TB)
Manual Disconnect (Isolation Switch)
CR194 two-high vacuum Limitamp@ controllers, follow-
ing the NEMA definition, provide a means for manu-
ally isolating the high-voltage power circuit by opera-
tion of a disconnecting device. Each starter cubicle
(upper & lower) has its own disconnecting mecha-
nism, which consists of a quick-make, quick-break,
non-load break isolation switch (see Figures 8-l 1)
which is controlled by an operating handle (see Figure
4). A fixed barrier (Figures 10 and 11) with a viewing
window is supplied to provide isolation from the
energized bus parts.
NOTE: The quick-make, quick-break isolation switch will not
interrupt any load orfault current.
The isolation switch handle will accept up to four pad-
locks to prevent operation. See Figure 12.

CR194 Two-High Vacuum Limitamp@ Control
Figure8. View of isolation.&itch in the “ON” position.
Barriersand fuses are removed for clarity.
Barriersand fuses areremoved for clarity.
Figure10. View of isolationswitchin the “ON” position.
All barriersinstalledexcept for the
front transparentviewingwindow.
Figure11. View of isolationswitchin the “OFF” position.
All barriersinstalledexcept for the
front transparentviewingwindow.
I
t
Figure12. The isolationswitchhandle
maybe padlocked to preventoperation.
7

CR194Two-High VacuumLimitamp@’Control
Mechanical Interlocking
Vacuum Limitamp@ equipment is designed so that the
high-voltage contactor performs all normal load cur-
rent interrupting. The current limiting fuses generally
interrupt any fault currents.
NOTE: The quick-make, quick-break isolation switch will not
interrupt any load orfault current.
A mechanical interference system is included with all
vacuum Limitamp@ controllers (mechanical interlock)
which prevents opening the isolation switch unless the
high-voltage contactor itself is demonstrated by mag-
net position to be already open. This is to insure that
the contactor has opened the power circuit and inter-
rupted the current before the isolation switch is oper-
ated. See Figure 13.
Figure1.3.Contactorengagementpaw1for
mechanicalinterlock
WARNING: The isolation switch handle should
never be forcibly operated. Its mechanical interfer-
ence interlock should be defeated only by knowl-
edgeable and qualified electrical maintenance per-
sonnel who have de-energized all power feeding
the controller.
WARNING: There is no emergency condition that
can justify forcible operation of the isolation
isolation switch handle must be operated only with
The high-voltage doors on the CR194 two-high vacuum
Limitamp@ are mechanically interlocked with the isola-
tion switch handle which keeps the high voltage door
closed until the isolation switch is in the “OFF” position.
This is done to prevent exposure to high voltage. Other
high voltage doors in a diverse Limitamp@ lineup may
use either mechanical linkage interlocking or key type
interlocking to prevent access to high-voltage compo-
nents such as reactors, autotransformers, auxiliary trans-
formers, power factor capacitors, etc. In all cases of key
interlocking, it is very important and imperative to follow
the key lock operating scheme as described in the draw-
ings furnished with the equipment.
Auxiliary Enclosures
Many types of ‘enclosures are furnished in vacuum
Limitamp@ control lineups for various purposes. Some
are listed below:
l Wound rotor secondary contactor and resistor
compartments
l Bus transitions to switchgear, transformer,
bus duct, etc.
l Cable entrance compartments
l Synchronous exciter compartments
l Starting reactor & autotransformer compartments
l Relay & metering compartments
l Non load-break switch compartments
l IC1074 load-break switch compartments
The details for these enclosures will be included in the
drawings furnished with the equipment.
Dimensions
Vacuum Limitamp@ controllers are normally 30-inches
deep and go-inches high. The width of the CR194 two-
high vacuum Limitamp@ is 36 inches (40 inches op-
tional). See Figure 50 for dimension details.
Power Fuses
Bolted EJ-2 type current limiting power fuses are sup-
plied as standard with vacuum Limitamp@ controllers.
Clip-in fuses are available as an option to cover re-
quirements for EJ-1 type fuses, but the blown fuse
(anti-single phase) indication/trip functions are not
available with clip fuses, since this feature requires
precise alignment of the striker pin at the top of the
fuse with the operators. Coordination information for
EJ-2 type fuses is available in GES-5000, and for EJ-1
type fuses, GES-5002. Interrupting ratings are shown
in the “Ratings” section of this instruction.

Blown Fuse Indicator & Trip
All bolted EJ-2 type fuses have inherent blown fuse in-
dication because the striker pin at the top of the fuse
protrudes out when the fuse is blown. In the CR194
two-high, the striker pin drives the blown fuse indica-
tor and trip bar which operates the blown fuse trip
(BFT) contact block. The BFT contact block can be
wired to trip the controller off line to prevent single
phasing of the connected load (anti-single phase pro-
tection). It can also be wired to an optional blown fuse
indicator mounted on the low-voltage door. Figure 14
shows the top of the bolted power fuse assembly with
the center blown fuse indicator in the “blown” posi-
tion and the two outside blown fuse indicators in the
“normal” position. Figure 15 shows the BFT contact
block, with wiring removed for clarity.
CR194 Two-High Vacuum Limitamp@ Control
Figure15. Blownfuse trip (BIT) contactblock
withwiringremoved for clarity
Figure14. Blownfuse indicatorswithcenterphaseindicating
“blown” and outsidephasesindicating“normal”

CR194Two-High VacuumLimitamp@Control
THIS PAGE BLANK
10

CR194 Two-High Vacuum Limitamp@ Control
INSTALLATION
General
This section contains information on receiving,
handling, disassembly, motor cable termination,
grounding and reassembly to make the equipment
ready for operation.
Receiving
CR194 two-high vacuum Limitamp@ controllers are
rigid, self supporting steel enclosures that require
no floor sills. They are placed on skids and shipped in
an upright position and, when received, should be
kept upright.
Some components such as top-mounted potential
transformers may be shipped separately. These
components are identified by a catalog number
coinciding with that of the section on which they are
to be mounted.
Plastic film wrap is normally used for domestic
packing, with the steel enclosure sections bolted to
a wooden skid. After receiving, the packing may be
removed and the equipment handled on the
wooden skid.
The equipment should be inspected for damage
that may have occurred during shipment, and any
such damage should be noted to the carrier if a claim
is to be made.
Handling
It is always preferable to handle Limitamp’ controllers
by the lifting means provided. A single section should
be lifted by connecting directly to the two lifting lugs
on top. However, an equalizing bar should be used for
a lineup as shown in Figure 16. A lineup should be
supported at as many points as possible.
If there is not enough head room to lift the panel
by its lifting means, then a track jack can be used. The
controller can be raised by placing a track jack
under the shipping skid. Rollers can then be placed
under the skid for rolling the equipment to its final
location. The panel should then be raised by its lifting
means, the shipping skid removed, and the panel
set into place.
The use of fork lift trucks is not recommended, since
the forks may damage the enclosure or interior parts
of the equipment, and the equipment becomes very
unstable when lifted from the bottom. If no other
method of handling is available, the forks must go un-
der the skid bottom to avoid damaging the equipment,
and the assembly lifted only slightly to allow the skid
to be slid along a flat, level surface.
Placement of Enclosure
It is essential that the controller be securely fastened in
an upright position on a level surface to allow proper
functioning of the internal devices. Access will be im-
proved if the controller is located at floor level with
Figure16. Recommended method of liftinga
vacuumL.imitamp”line-up.
Note thatthehe-up is suspendedfrom auequalizingbar
plenty of room allowed for doors to swing fully open as
shown on the drawings as supplied with the equipment.
After the controller has been placed in position,
floor mounting anchor bolts may be installed and
tightened. The location for these bolts for the CR194
two-high is shown in Figure 50, and on the Outline
Details section of the drawings furnished with
the equipment. Use %-inch bolts as indicated
in Figure 50.
Disassembly
After the equipment has been set in place where it is
to be permanently connected, some internal disassem-
bly is required to make the necessary horizontal main
bus and ground bus connections. Further disassembly
is required if it is desired to view the horizontal-to-ver-
tical bus connection. Disassembly should be done in a
definite sequence as indicated below.
NOTE: Other than the removal of external couer plates as re-
quired, and/or the rearrangement of the incoming motor
cable barriers if required, disassembly is not required to run
motor cable and control wire into the enclosure. Under nor-
mal circumstances, disassembly need only be done to the ex-
tent necessary to make the horizontal bus splice connection.
11

CR194Two-High Vacuum Limifamp@Control
DISASSEMBLY SEQUENCE:
WARNING: Confirm that equipment is de-ener-
gized before proceeding with disassembly.
NOTE: If the rear of the enclosure is accessible, access to the
horizontal bus for splicing can be accomplished simply by re-
moval of the upper cover from the rear of the enclosure. Figure
28 shows the rear of the enclosure with the upper and lower
covers removed.
Step 1.
Move the isolation switch handles in both the upper &
lower starters to the full “OFF” (down) position (i.e.
the handle latch release pops back out). Refer to the
handle operating instruction nameplate attached to
the high-voltage door near the handle (See Figure 4).
Figure 1’7 shows the method of first depressing the
handle latch release with one hand and moving the
handle with the other.
Step 2.
Open both the upper & lower high-voltage doors.
f
Figure17. Operate handleby depressinghandlelatchrelease
withode hand andmovingthehandlewiththe otherhand.
Contactor Removal
NOTE: Before starting Contactor Removal procedure, per-
form Steps I U 2 above.
NOTE: The following steps describe the pocedure for contactor
removal for either the upPer or lower starter, but in order togain
access to the main bus splices, removal of only the upPer starter
contactor is necessary.
Step 3.
Remove the two wing nuts holding the contactor um-
bilical cord plug on the right side of the contactor.
Disconnect the plug and place it to the lower, right
out of the way.
NOTE: For stationary mounted contactors, follow Steps 4
and 5, then go to Step 7. For drawout contactors, go to Step 6.
xes LOAD SIDE CONNECTION BOLTS
Figure18. View of thestationarycontactorshowingremovalof
load side connectionbolts and contactorumbilical
plugwingnutlocations
Figure19. View of highvoltagesectionshowingthetwo
drawoutcontactorpositioningbolts andwingnutlocations.
Step 4.
Remove the three load side connection bolts at the
bottom, front of the contactor. Do not loosen the
R.T.V. covered bolts. See Figure 18.
Step 5.
Remove the three line side cable bolts at the bottom of
the power fuse assembly. See Figure 20.
Step 6.
Remove the two positioning bolts. See Figure 19.
12

CR194Two-High VacuumLimitamp@Control
LINE SibE CONNECTIONS CI,
Figure 20. View showing stationary contactor line side cable
connections at the power fuses
Step 7.
Slide the contactor forward approximately four (4)
inches until the slide safety stop engages in the plate
that is attached to the bottom of the contactor. The
safety stop is located on the left side of the contactor
mounting track. Figure 21 shows the safety stop for
a stationary contactor with the contactor removed
for clarity.
from the enclosure, be aware that the contactor
weighs 75 pounds and should be handled very care-
fully & deliberately using both hands. Do not grasp
the contactor by the top moving armature.
NOTE: A platform lift jack is available from GE that can be
used to aid in contactor removal and transport. Order cata-
log No. 55B534913PI.
Step 8.
To completely remove the contactor from the
enclosure, pull up on the safety stop and move the
contactor forward about one (1) inch. Then release
the safety stop and grasp the contactor with both
hands and move it forward and out of the enclosure.
Do not grasp the contactor by the top
moving armature.
Figure 21. View of slide safety stop and
main bus barriers with stationary contactor removed
13

CR194Two-High VacuumLimitamp@Control
Gaining Access To Horizontal Bus
For Splicing
WARNING: Confirm that equipment is de-ener-
gized before proceeding with disassembly.
NOTE: Insure Steps 1-8 above are completed before proceed-
ing with disassembly.
Step 9.
Once the upper contactor has been removed, the side
main bus barriers are accessible at the rear of the com-
partment. See Figure 21.
Figure 42. View of CR194 two-highhighvoltagesectionwith
drawoutcontactorremoved.
Step 10.
Remove the mounting bolts that hold the side main bus
barriers in place. Once the barriers are removed, the
ends of the main bus bars are visible as shown in Figure
23. Main and ground bus splices may now be made to
the section on either the left or right side of the starter.
Step 11.
Install bus splices per Figure 51. Once main bus
splices are installed, they must be taped in order to
maintain required electrical clearances. See “Taping
Instructions for 5kV” Section.
WARNING: Main bus splice bars must be taped
NOTE: If additional access is required on the left side of the
compartment, the control power transformer (CPT) and
transformer fuse block may be removed per Step 12 below. If
CPT 6’ CPTfuse block removal is not required, skip to the
note under Step 12.
Figure 23. Ends of mainbus exposed for splicing
(stationarycontactorremoved)
14

CR194 Two-High Vacuum Limitamp@ Control
Step 12.
To remove the CPT, disconnect the control wires that
are attached to the transformer terminal board and
disconnect the two CPT high-voltage fuse leads that at-
tach to the lower terminals of the power fuse assembly.
Then remove the transformer and fuse block assembly
by removing the four (4) bolts that mount the trans-
former. See Figure 24 for view with CPT, CPT fuse
block and power fuses removed.
NOTE: It is typically not necessary to gain access to the main
to uertical bus connections, but this option is auailable as de-
tailed in Steps 13-16. If
access to these connections is not re-
quired, then disassembly is complete.
Step 13.
To access the main to vertical bus joints in the center
of the main bus, additional parts must be removed as
outlined below. First remove the three power fuses.
Step 14.
Remove the lower power fuse base assembly by
removing the eight (8) mounting screws on each side
of the lower fuse base assembly. Figure 25 shows the
compartment once the lower fuse base assembly has
been removed.
Step 15.
Remove the screws that mount the contactor lower
terminal assembly as shown in Figure 25. Also remove
the four (4) screws that mount the “U” shaped insula-
tion barrier at the rear of the compartment as shown
in Figure 25.
Step 16.
Move the contactor lower terminal assembly forward
and lift up and pull forward at the bottom of the “U”
shaped insulation barrier at the rear of the compart-
ment as shown in Figure 26. The barrier can then be
completely removed from the enclosure to fully ex-
pose the main to vertical bus joints as shown in Figure
27, which completes the disassembly.
Figure 24. CPT and stationary contactor removed to provide
better access to main bus bars on left side
Figure 25. View with lower fuse base assembly removed
(stationary contactor design)
15

REAR INSULATION u
BARRIER BEING
PULLED FORWARD 2% :
FOR REMOVAL \ ‘? ;
CtW4 Two-High VacuumLimitamp@Control
Taping Instructions for 5kV
For electrical clearance, motor terminals and bus
splices in the CR194 two-high must be taped. Use
Scotch #13OC linerless rubber splicing tape. Apply
tape using a medium tension to thin the 0.030” X 2”
tape to 0.024” X 1.75”. When completing wrapping, do
not keep tension on the last 2 or 3 inches of tape in
order to improve adhesion. Apply tape in two layers
with 2/3 overlap ( 6 thicknesses ). For bus splicing, ex-
tend the tape out of the two-high enclosure only
far enough to realize a 3.5” clearance from bare bus
to ground. When taping motor cable terminations,
tape the lug and entire cable terminal pad, and if win-
dow CT’s are used, overlap the tape onto the terminal
pad insulator support approximately one inch.
Reassembly
Reassembly of the equipment should be done by fol-
lowing the disassembly sequence in the reverse order,
being sure that all removed barriers get reinstalled
properly and following the contactor installation
procedure below.
WARNING: Do not attempt to operate equipment
without all barriers in place.
CONTACTOR LOWER TERMINAL
ASSEMBLY MOVED FORWARD
* I
f
Figure 26. Removalof rearinsulationbarrierto expose main
to verticalbusjoints (stationarycontactordesign)
Since reinstallation of the high-voltage stationary
contactor involves bolted high-voltage power connec-
tions, not only is it necessary to follow the correct reas-
sembly sequence, but also the bolted power connec-
tions need to be properly torqued as well. When re-
placing the contactor in the enclosure, the following
procedure should be followed:
Step 1.
If the contactor is a stationary type, insure that the
cables attached to the line side of the contactor are
properly torqued to 39 ft-lb.
NOTE: Do not grasp the contactor by the top mouing arma-
ture during installation.
Step 2.
Place the contactor onto its mounting base and slide
the contactor in until the slide safety stop engages and
latches the contactor in the intermediate position.
Then pull up on the safety stop and push the contactor
fully into the unit. Insure that the armature interlock
is properly engaged in the interlock paw1 on the right
side wall. See Figure 13 for close-up of interlock paw1
and Figure 40 for view of proper engagement.
WARNING: The interlock paw1 transmits the
contactor armature motion to the mechanical
j(I
barriers Figure 27.
view of main andverticalbus areawith
removed (stationarycontactordesign)
16

CR194 Two-High Vacuum Limitamp@
Control
Step 3.
If the contactor is a stationary type, install and torque
the three load side connection bolts to 16 ft-lb. (See
Figure 18), then attach the line cables to the bottom
of the fuse assembly and torque these connections to
9 ft-lb. (See Figure 20).
WARNING: Be absolutely certain that these bolts
are properly installed and torqued. These are cur-
Step 4.
If the contactor is a drawout type, reinstall the two
positioning bolts (See Figure 19).
Step 5.
Manually operate the contactor armature and observe
that the mechanical interlock functions properly.
Step 6.
Reconnect the control umbilical cord to the contactoi
and be sure the retaining wing nuts are tight. Installa-
tion of the contactor is now complete.
WARNING: Make certain that all barriers are re-
placed and bolted tightly into position. Make sure
the line and load side terminations of the station-
ary contactor are torqued properly. If the contactor
is drawout type, make sure the positioning bolts
are installed properly. Failure to perform these op-
erations could result in failure of the unit to oper-
ate safely and reliably.
Incoming Power Connections
The compact design of the two-high vacuum
Limitamp’ does not make it practical to terminate in-
coming power cables within the starter. The equip-
ment must either be bus spliced to existing equipment
or supplied with a separate cable entrance compart-
ment. If a separate cable entrance compartment is sup-
plied, refer to the Outline Summary & Outline Details
sections of the drawings provided with the equipment
to determine the recommended location for incoming
power cable entry. Also see the “Cable Termination
Guidelines” section of this instruction.
Grounding
All controller enclosures must be grounded, and the
CR194 two-high vacuum Limitamp@ is equipped with a
ground bus for that purpose. The two-high ground bus
should be bus connected to existing equipment or to a
separate cable entrance compartment. Figure 28 shows
the ground bus as seen from the rear of the enclosure
with the back cover removed.
In order to accommodate motor cable grounds, each
starter cubicle is equipped with a ground bus link that
is connected directly to the horizontal ground bus.
See Figure 29.
Figure 28. Rearviewof horizontalmainand
groundbuswithback coversremoved
GRO
BUS
Figure29. view of motor terminal areashowing
groundbus lii in lower starter

CR194Two-High VacuumLimitamp@Control
Motor Cable Termination
Each starter enclosure is equipped with provisions to
run motor cables into the top or bottom of the enclo-
sure. Removable conduit cutout covers are provided in
both the top & bottom (if a bottom is provided) for
bringing in motor cable. Figure 30 shows the covers in
the top. Cable size limits are indicated below. The mo-
tor cable troughs are located on the left side of the
equipment as shown in Figure 31. See the “Cable Ter-
mination Guidelines” section of this instruction for ad-
ditional information
MOTOR CABLE SIZE LIMITS IN CR194
TWO-HIGH LIMITAMP”
I
40” l-500 kcmil
With Shielded
With Shielded Cable and
Cable and Hand-Wrapped,
Prefabricated Non-cone
Stress Cones Stress Relief
l-250 kcmil 1-#3/0
Preferred Preferred
l-500 kcmil 1+4/o
Possible Possible
l-500 kcmil l-250 kcmil
If all barriers, including the properly placed motor
cable trough barriers, are in place, the top starter can
be motor cabled with the bottom starter energized and
“ON”, and the bottom starter can be motor cabled
with the top starter energized and “ON”.
WARNING: If one starter is to be motor cabled
with the other starter energized and/or “ON”, all
barriers including the motor cable trough barriers
must be properly installed (see below) and the iso-
lation switch handle for the unit being cabled
must be in the “OFF” (down) position and the
blades must be visibly checked to insure that they
are disconnected from the vertical bus.
When the equipment is shipped it will be assembled
for motor cable entry from the direction specified on
the order. If this information is not known by the fac-
tory, the unit will be shipped suitable for bottom en-
try. Once the equipment is installed in the field, the
cable entry path can be revised by following the steps
listed below.
CABLE ENTRY FROM BOTTOM
Step 1.
Cables to the bottom starter should be run straight
into the motor terminals using the “lower unit” area as
shown in the floor-plan view in Figure 50.
Step 2.
Cables to the top starter should be run in the motor
cable trough using the “upper unit” area as shown in
the floor plan view in Figure 50. This cable trough is
formed by two metal barriers in the left rear corner of
the lower compartment. Once the cables enter the up-
per compartment they can be formed forward to align
with the motor terminals.
Figure 30. Top view of two-high enclosure showing
conduit cutout cover plates
Figure 3 1. High-voltage doors open showing
motor cabling area
18

CR194 Two-High Vacuum Limitamp@ Control
NOTE: If the two metal barriers that form the rear cable
trough (See Figure 3.2) are mounted in the upper compart-
ment, they can be moved to the lower compartment toform the
necessary trough.
Once the motor cables are terminated,
the cable lugs and the complete motor terminal pads
must be taped to maintain necessary electrical clear-
(See “Taping Instructions for 5kV” section).
Figure 32. View of cable trough barriers that mount
in top or bottom compartment
CABLE ENTRY FROM TOP
Step 1.
Cables to the top starter should be run straight into
the motor terminals using the “upper unit” area as
shown in the top view in Figure 50.
Step 2.
Cables to the bottom starter should be run in the mo-
tor cable trough using the “lower unit” area as shown
in the top view in Figure 50. This cable trough is
formed by two metal barriers in the left rear corner of
the upper compartment. Once the cables enter the
lower compartment they can be formed forward to
align with the motor terminals.
NOTE: If the two metal bawiers that form the rear cable
trough (See Figure 32) are mounted in the lower compart-
ment, they can be moved to the upPer compartment toform
the necessary trough.
WARNING: Once the motor cables are terminated,
the cable lugs and the complete motor terminal pads
ances. (See “Taping Instructions for 5kV” section).
Cable Termination Guidelines
The following general guidelines apply whether motor
cable or incoming power cable is being terminated in
the Limitamp@ lineup. In any installation, cable should
be prepared for termination in accordance with the in-
structions of the cable manufacturer.
Step 1.
Pull in the cables for maximum clearance between
phase, ground and other cable or wire runs.
Step 2.
Prepare the cable for termination in accordance with
the manufacturer’s instructions. Some possible termi-
nation methods are shown in Figures 33-38.
Step 3.
Bolt the cable terminals to the point of termination.
Step 4.
If contact between the cable and an adjacent bare bus
cannot be avoided, as well may be the case in some in-
coming line situations, tape the bus in the immediate vi-
cinity of the cable contact point so that the surface
creepage distance from the cable to the bare bus bar is at
least three inches. Thus the surface creepage from the
bare bus where the cable terminates to the nearest bare
part of the bus the cable touches will be at least seven
inches. (See “Taping Instructions for 5kV’ section).
TERMINATION OF NON-SHIELDED,
NON-LEAD-COVERED CABLE
This cable is generally run through rigid conduit or
cable raceways and brought into the enclosure by the
use of conventional cable clamps and conduit fittings.
Refer to Figures 33 & 34 for termination details.
GE IRRASILQ
SPLICE TAPE
Figure 33. Termination of rubber-insulated, non-shielded,
non-lead-covered, 5000-volt cable
19

CR194 Two-High Vacuum Limitamp@’ Control
II No. 4200
CABLE TAPE
1. Cut cable to proper length leaving conductor sufficiently
long to extend into the terminal lug.
2. Remove braid, tape, and inner insulation and expose the
conductor end for a distance of one inch plus the length of
conductor 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 original
cable 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 than
necessary.
7. Bind down end of braid and tape, if any, with lrrasil tape
as shown on drawing.
6. Apply two layers half-lap of GE Irrasile tapeover-all from
lug to exposed braid.
Figure 34. Termination of varnishedcambric-insulated,
non-shielded, non-leadcovered, 5000-volt cable
TERMINATION OF INTERLOCKED-ARMOR CABLE
Interlocked-armor cable is terminated by means of
specially designed cable fittings. These terminators
consist generally of mounting bracket, armor clamp,
and supporting base and bushing with various modifi-
cations available for special types of sealing.
INTERLOCKED-ARMOR, NON-SHIELDED CABLE
RUBBER-COVERED- Refer to Figure 35 for general
information concerning termination. For details, refer
to Figure 33. Note that rubber covered cable requires
taping only near the terminal and not back to the ter-
minator fitting.
VARNISHED-CAMBRIC- Refer to Figure 35 for gen-
eral information concerning termination. Note that
varnished-cambric cable requires taping back to the
terminator fitting since the individual conductors or
“singles” have no braid. See Figure 34.
INTERLOCKED-ARh,iOR, SHIELDED CABLE
Interlocked-armor, rubber-covered, and varnished-
cambric insulated cables are sometimes shielded at rat-
ings of 5kV and below. If they should be, proceed to
terminate as detailed for other types of shielded
cables. Refer to Figure 36.
de-
COPPER LUG
OUTER LAYER
IRAASIL TAPE
NOTE:
FOR DETAILS OF END
SEALSEE FIG. 33 FOR
RUBBER CABLE AND
QE NO. 8390 TAPE
INSIDEFDRRUBBEROR
NO. OO2VC TAPE FOR VARNISHED
CAMBRICIS RECOMMENDED.
ALTERNATE:BUILD ENTlRE END
SEAL WITH QE IRRASIL. TAPE.
FIG. 34 FOR VARNISHED
CAMBRIC CABLE.
FILL WITH SEALINQ
COMPOUND
Figure 35. Termination of interlocked-armor,
non-shielded, 5000-volt cable
+& COPPER LUG
5” MIN
I
!!!ili%
STRESS
COPPER SHIELDING ‘”
BRAID-GROUNDED
TO STRUCTURE OR
ARMOR.
FILL
SEAI WITH
JNG COMPOUND
INSU
ILATING BUSHING K NUT
STRUCTURE’ @
CONE
CABLE TERMINATOR
FITTING
CABLE ARMOR
Figure 36. Termination of interlocked-armor,
shielded, 5000-volt cable
20