Ge Cr194 User manual

CR

194

Vacuum

Limitamp

Control

One

-

High

Controllers

with

Stationary

M

Vacuum

Contactors

Caution

:

Product

is

not

i

ount

Wended

for

nuclea

ruse

.

Utilization

Voltage

-

2.4

through

7.2

kVac

26

-

wide

and

34

-

wide

,

One

-

High

,

400

Amp

(

For

48

-

wide

,

800

Amp

see

GEH

-

5396

)

,

/

$

-

t

*

H

v

4

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Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Table

of

Contents

Introduction

3

4

Description

Equipment

Identification

-

CR

Number

Designation

.

,

.

4

General

.

;

Ratings

Basic

Impulse

Level

(

BIL

)

Dielectric

Test

Voltage

High

Voltage

Vacuum

Contactors

Blown

Fuse

Indicator

Manual

Disconnect

(

Isolating

Mechanism

)

Mechanical

Interlocking

Auxiliary

Enclosures

Dimensions

Power

Fuses

Power

Fuse

Conversion

Instructions

Starting

Autotransformers

8

c

Reactors

Installation

General

Receiving

Handling

Placement

of

Enclosure

Disassembly

Sequence

of

Operation

Grounding

Incoming

Power

Connections

Motor

Connections

Extra

-

width

Enclosure

Power

Cable

Termination

Control

Connections

Reassembly

Replacing

Contactor

In

Enclosure

Mechanical

Operation

Check

Operation

General

Test

-

power

Circuit

Preparation

of

Controller

for

Operation

Normal

Operation

Door

Opening

Procedure

Inspection

,

Maintenance

,

8

c

Servicing

Vacuum

Contactor

Isolating

Mechanism

and

Mechanical

Interlock

Checking

Procedures

-

*

Mechanical

Interlock

&

Manual

Isolator

Vacuum

Interrupter

Integrity

Test

Procedure

Preventive

Maintenance

Guide

4

5

8

..

.

8

10

11

13

14

19

20

23

24

27

29

31

32

2

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

The

essential

control

functions

for

all

types

of

a

-

c

motors

consist

of

starting

,

stopping

,

and

overload

protection

.

Vacuum

Limitamp

controllers

also

include

short

-

circuit

protection

,

but

other

functions

are

provided

in

each

controller

as

they

are

applicable

to

the

type

of

motor

being

controlled

(

such

as

synchronous

and

wound

-

rotor

motors

)

.

Also

,

special

functions

are

provided

in

great

variety

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

.

This

includes

the

26

-

inch

wide

one

-

high

and

the

34

-

inch

wide

one

-

high

controller

.

Figure

1

shows

a

26

-

inch

wide

controller

and

Figure

2

shows

a

34

-

inch

wide

synchro

-

nous

controller

.

The

intent

of

these

instructions

is

to

give

the

Purchaser

the

necessary

general

information

to

identify

his

control

-

ler

as

to

type

and

function

,

to

describe

suggested

methods

of

installation

,

and

to

demonstrate

some

techniques

of

operation

and

maintenance

.

The

Pur

-

chaser

should

interpret

these

instructions

for

applicability

to

his

particular

controller

by

referring

to

the

nameplate

data

on

the

controller

and

to

the

electri

-

cal

diagrams

supplied

with

the

controller

.

If

the

controller

is

for

a

synchronous

motor

,

these

instructions

should

be

used

with

GEH

-

5201

.

For

applica

-

tions

questions

refer

to

GET

-

6840

.

For

details

on

high

-

voltage

contactor

refer

to

GEH

-

5306

.

Warning

:

Before

any

adjustments

,

servicing

,

parts

replacement

or

any

other

act

is

performed

requiring

physical

contact

with

the

electrical

working

components

or

wiring

of

this

equipment

,

power

must

be

removed

from

all

sources

and

all

attached

rotating

equipment

must

have

come

to

a

complete

stop

.

User

personnel

must

be

completely

familiar

with

the

following

operating

and

maintenance

instructions

before

attempting

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

perform

this

test

may

result

in

serious

injury

or

death

.

Introduction

Vacuum

Limitamp

controllers

are

designed

to

meet

NEMA

ICS

2

-

324

“

AC

General

Purpose

High

-

voltage

Class

E

Controllers

”

and

UL

347

requirements

,

and

may

be

described

as

metal

-

enclosed

high

-

interrupting

capacity

,

vacuum

-

contactor

-

type

starter

equipments

with

manual

isolation

.

Individual

starters

and

controllers

are

de

-

signed

for

specific

applications

;

the

components

and

functions

being

dictated

by

the

Purchaser

specifications

and

needs

.

Controllers

may

be

fused

or

unfused

.

Figure

1

.

26

-

inch

wide

one

-

high

controller

.

Figure

2

.

34

-

inch

wide

synchronous

controller

.

3

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Description

Equipment

Identification

-

CR

Number

Designation

Basic

type

designation

for

all

Vacuum

Limitamp

Control

equipment

is

CR

194

with

significant

alpha

-

numeric

suffixes

used

to

define

rating

,

function

,

contactor

type

and

enclosure

type

.

CR

194

NEMA

TYPE

1

=

NEMA

E

1

(

Unfused

)

2

=

NEMA

E

2

(

Fused

)

Starling

and

Spaed

Functions

—

Enclosure

A

—

26

"

1

-

HI

B

—

34

"

1

-

Hl

A

—

Single

-

speed

,

full

voltage

sB

—

Single

-

speed

,

reduced

voltage

reactor

type

b

—

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

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

Rotation

and

Braking

1

—

Non

reversing

/

non

braking

2

—

Reversing

/

non

braking

4

—

Non

reversing

/

dynamic

braking

5

—

Reversing

/

dynamic

braking

7

—

Reversing

/

plugging

In

general

,

the

unit

enclosures

are

divided

into

high

-

voltage

and

low

-

voltage

compartments

,

each

with

its

own

separate

door

and

with

interior

barriers

between

the

two

.

See

Figures

3

,

4

,

and

5

.

To

open

the

high

-

voltage

compartment

door

,

the

power

must

be

disconnected

by

a

sequence

of

manual

operations

which

requires

de

-

energizing

the

high

-

voltage

contactor

,

operating

the

isolating

switch

handle

,

and

unlatching

the

door

*

Low

-

voltage

doors

may

be

entered

without

disconnecting

the

power

;

however

,

this

should

be

done

with

extreme

care

and

caution

The

upper

compartment

of

one

-

high

controllers

may

contain

a

low

-

voltage

panel

,

hinged

on

the

left

side

,

which

acts

as

a

barrier

to

the

high

-

voltage

control

power

transformer

mounted

on

the

upper

rear

cover

.

General

The

basic

Vacuum

Limitamp

controller

is

a

front

-

connected

assembly

of

components

and

conductors

for

motor

starting

,

arranged

for

convenient

access

,

in

an

enclosure

which

allows

space

and

facilities

for

cable

termination

,

plus

safety

interlocking

of

doors

and

isolator

to

prevent

inadvertent

entrance

to

high

-

voltage

parts

.

No

back

access

is

required

.

This

equipment

may

be

rated

up

to

7.2

kV

depending

on

the

contactor

and

fuse

ratings

.

Installation

,

operation

,

and

service

should

be

performed

only

by

experienced

personnel

trained

in

this

class

of

equipment

.

4

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Interrupting

Ratings

At

Utilization

Voltage

Shown

Three

-

phase

Symmetrical

System

MVA

Maximum

Continuous

Amperes

(

RMS

)

Maximum

Volts

Class

E

1

Unfused

Class

E

2

Fused

2500

400

29

200

400

5000

50

400

7200

50

600

Basic

Impulse

Level

(

BIL

)

The

standard

BIT

rating

of

Vacuum

Limitamp

control

-

lers

is

60

kV

crest

(

design

rating

)

.

This

rating

excludes

dry

-

type

control

transformers

and

starting

reactors

or

au

totran

sformers

.

Dielectric

Test

Voltage

2

1

/

4

x

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

.

The

contactors

are

similar

in

operation

but

very

different

in

size

and

rating

.

For

this

reason

they

are

not

directly

interchangeable

mechanically

.

See

Figure

7

.

The

contactors

are

easily

removable

from

the

controller

assembly

by

removing

a

few

bolts

that

hold

the

contactor

in

position

and

by

disconnecting

the

line

and

load

power

connections

.

The

auxiliary

contacts

and

the

coil

termi

-

nals

are

connected

by

means

of

a

removable

connector

that

is

retained

by

two

wing

nuts

.

By

removing

these

wing

nuts

,

the

wiring

harness

is

easily

disconnected

from

the

contactor

.

Refer

to

the

information

beginning

on

Page

13

of

this

publication

that

details

the

correct

method

for

contactor

removal

.

Figure

3

.

26

-

inch

wide

400

-

ampere

FVNR

starter

,

Ratings

Refer

to

the

panel

data

nameplate

(

see

Figure

6

)

on

front

of

the

enclosure

for

detailed

ratings

applicable

to

a

particular

controller

.

Equipment

basic

ratings

equal

or

exceed

NEMA

ICS

2

-

324

for

Class

E

2

Controllers

,

and

are

summarized

below

.

Approximate

Maximum

Horsepower

,

Current

8

c

Voltage

Ratings

2200

-

2400

Volts

4000

-

4800

Volts

7200

Volts

Synchronous

Motors

Synchronous

Motors

Synchronous

Motors

Continuous

Current

(

RMS

)

(

Amperes

)

Induction

Motors

Induction

Motors

Induction

Motors

0.8

PF

0.8

PF

1.0

PF

1.0

PF

0.8

PF

•

1.0

PF

400

Max

.

3450

1600

3725

4800

2000

3450

4800

6000

Note

:

Above

ratings

apply

to

controllers

in

NEMA

1

,

vented

enclosures

,

at

4

CP

C

ambient

.

5

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

mmm

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Figure

6

.

Panel

data

nameplate

.

Figure

4

.

34

-

Inch

wide

400

-

ampere

FVNR

synchronous

starter

low

-

voltage

control

section

.

1

C

i

a

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-

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Figure

7

.

The

800

and

400

ampere

vacuum

contactors

.

Figure

5

.

34

-

inch

wide

400

-

ampere

FVNR

synchronous

starter

high

-

voltage

section

showing

the

400

-

ampere

contactor

.

c

6

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

tent

-

AS

~

;

Figure

10

.

Anti

single

-

phase

contact

block

-

wiring

removed

for

clarity

.

Figure

8

.

High

-

voltage

compartment

showing

fuse

assembly

.

v

‘

.

*

-

VS

..

.

1

•

>

'

r

*

u

,

v

.

’

T

:

.

Figure

11

.

View

of

disconnect

switch

in

the

CLOSED

position

.

Barriers

are

removed

for

clarity

.

Figure

9

.

View

of

various

low

-

voltage

components

on

swing

panel

.

7

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Vacuum

Limitamp

Control

is

supplied

standard

with

bolt

-

in

type

fuses

.

The

fuse

holders

will

accommodate

2400

-

volt

through

7200

-

volt

fuses

.

The

length

of

these

types

of

fuses

vary

and

the

lower

fuse

mount

can

be

adjusted

to

the

proper

length

by

unbolting

the

mount

from

the

back

rail

and

remounting

it

in

the

proper

location

.

For

7200

-

volt

applications

,

the

fuses

require

a

slightly

different

lower

mounting

strap

and

the

top

fuse

mounting

strap

must

be

changed

.

This

requires

that

the

disconnect

switch

be

disassembled

.

See

Figure

8

.

Manual

Disconnect

(

Isolating

Mechanism

)

Vacuum

Limitamp

controllers

,

following

the

NEMA

definition

,

provide

a

means

for

manually

isolating

the

power

circuit

by

operation

of

a

disconnecting

device

.

The

disconnecting

mechanism

consists

of

a

quick

-

make

quick

-

break

,

non

-

load

break

disconnect

switch

(

see

Figures

11

through

13

)

which

is

controlled

by

the

operating

handle

(

see

Figure

6

)

.

A

fixed

barrier

(

Figure

13

)

,

with

a

viewing

window

,

is

supplied

to

provide

isolation

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

in

integral

rectifier

and

timed

holding

circuit

.

A

base

Figure

15

.

mounted

contactor

timing

module

(

CTM

)

applies

full

voltage

to

the

contactor

coil

for

a

time

sufficient

to

fully

close

the

contactor

.

A

series

capacitor

is

then

switched

in

to

hold

the

contactor

closed

without

overheating

the

coil

.

Load

current

must

not

be

interrupted

by

the

disconnect

switch

.

A

mechanical

interlock

is

provided

to

ensure

that

the

contactor

is

in

the

open

position

before

the

operating

handle

can

be

actuated

.

Also

,

the

contactor

cannot

be

operated

while

the

operating

handle

is

being

moved

from

one

position

to

another

.

The

mechanical

isolator

will

accept

up

to

four

padlocks

to

prevent

operation

.

See

Figure

16

.

Blown

Fuse

Indicator

Blown

fuse

indication

is

activated

by

a

trip

bar

located

at

the

rear

of

the

top

fuse

holder

.

The

blown

fuse

indica

-

tor

requires

bolt

-

in

type

fuses

.

When

one

or

more

of

the

fuses

blow

,

a

small

indicator

moves

upward

from

the

top

center

of

the

fuse

to

indicate

which

fuse

has

blown

.

The

right

end

of

the

trip

bar

has

a

cam

that

operates

an

anti

-

single

phase

contact

which

is

wired

to

trip

the

controller

off

-

line

to

prevent

single

phasing

of

the

connected

load

.

See

Figure

10

.

Mechanical

Interlocking

Vacuum

Limitamp

equipment

is

designed

so

the

high

-

voltage

contactor

performs

all

normal

load

current

interrupting

.

The

current

-

limiting

fuses

generally

interrupt

the

fault

currents

.

Note

:

The

quick

-

make

quick

-

break

manual

isolator

will

not

interrupt

any

load

or

fault

current

.

'

A

mechanical

interference

system

is

included

with

all

Vacuum

Limitamp

controllers

(

mechanical

interlock

)

,

which

prevents

opening

of

the

manually

operated

isolating

contacts

unless

the

high

-

voltage

contactor

itself

is

demonstrated

by

magnet

position

to

be

already

open

.

This

is

to

ensure

that

the

contactor

has

opened

the

power

circuit

and

interrupted

the

current

before

the

disconnect

switch

may

be

operated

.

See

Figure

17

.

Warning

:

The

manual

isolator

should

never

be

forcibly

operated

.

Its

mechanical

interference

interlock

should

be

defeated

only

by

knowledgeable

and

qualified

electrical

mainte

-

nance

personnel

who

have

de

-

energized

all

poioer

feeding

the

controller

.

gpB

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.

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of

the

disconnect

switch

in

the

OPEN

position

.

Barriers

are

removed

for

clarity

.

8

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Umitamp

400

Ampere

Control

*

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switch

shown

with

barrier

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place

.

Switch

shown

In

CLOSED

position

.

Figure

15

.

View

of

quick

-

make

quick

-

break

operator

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Figure

16

.

The

operating

handle

for

the

disconnect

may

be

padlocked

to

prevent

operation

.

Figure

14

.

View

of

handle

assembly

area

showing

test

power

interlocks

.

9

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Umitamp

400

Ampere

Control

Warning

:

There

is

no

emergency

condition

that

can

justify

forc

-

ible

operation

of

the

manual

isolator

with

the

main

contactor

closed

.

The

isolator

must

be

operated

only

with

the

contactor

open

.

All

high

-

voltage

doors

are

interlocked

by

mechanical

interference

mechanism

that

lock

high

-

voltage

doors

closed

until

the

disconnect

switch

is

in

the

OPEN

position

.

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

be

full

height

to

cover

high

-

voltage

parts

located

in

auxiliary

sections

.

These

devices

may

include

reactors

,

auto

trans

-

formers

or

control

power

transformers

,

etc

.

Key

interlocking

is

frequently

used

in

lieu

of

mechanical

interference

mechanisms

to

lock

high

-

voltage

doors

closed

until

power

inside

has

been

removed

.

Non

-

loadbreak

switches

are

also

key

interlocked

to

prevent

operation

under

load

.

In

all

cases

of

key

interlocking

,

it

is

important

to

follow

the

operating

sequence

as

de

-

scribed

on

the

drawings

furnished

with

the

equipment

.

On

some

one

-

high

enclosure

designs

,

a

low

-

voltage

control

panel

mounted

by

hinges

to

the

left

side

of

the

enclosure

serves

as

a

barrier

to

isolate

the

high

-

voltage

control

power

transformer

and

fuses

.

An

interference

latch

,

shown

in

Figure

54

,

prevents

swinging

this

panel

out

until

the

high

-

voltage

door

is

opened

,

thus

ensuring

that

high

-

voltage

power

to

the

Control

Power

Trans

-

former

is

disconnected

.

V

-

i

'

.

-

V

'

-

'

-

VS

-

•

V

i

-

X

-

V

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.

V

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Figure

17

.

Contactor

engagement

pawl

for

mechanical

interlock

.

Auxiliary

Enclosures

Many

sizes

of

enclosures

are

furnished

in

Vacuum

Limitamp

control

lineups

for

various

purposes

.

Some

are

tabulated

below

;

Wound

rotor

,

secondary

contactor

and

resistor

compartments

Bus

transitions

to

switchgear

Bus

transitions

to

transformers

Cable

entrance

compartments

Rectifier

exciter

compartments

Starting

reactor

or

autotransformer

compartments

Relay

and

metering

compartments

Instrument

transformer

compartments

Manual

switch

compartments

Refer

to

Figure

60

for

details

.

Dimensions

Vacuum

Limitamp

controllers

are

normally

30

-

inches

deep

and

90

-

inches

high

.

Width

varies

for

one

-

high

controllers

,

induction

motors

,

synchronous

motors

other

special

applications

,

or

cable

space

requirements

Refer

to

Figure

60

for

typical

outline

dimensions

.

Figure

18

.

Blown

fuse

Indicator

shown

in

the

NORMAL

position

.

>

10

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Umitamp

400

Ampere

Control

Power

Fuses

Bolted

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

blown

fuse

-

indicator

and

the

trip

bar

that

operates

the

anti

-

single

phase

contact

block

require

precise

alignment

of

the

striker

at

the

top

of

the

fuse

with

the

operators

.

Clip

-

in

fuses

are

available

as

an

option

in

400

ampere

to

cover

requirements

for

EJ

-

1

type

fuses

,

but

the

“

anti

-

single

phase

”

indication

/

trip

functions

are

not

available

with

clip

fuses

.

Coordination

information

for

EJ

-

2

type

fuses

is

available

in

GES

-

5000

,

and

for

EJ

-

1

type

fuses

,

GES

-

5002

.

Interrupting

ratings

are

shown

on

page

5

of

these

instructions

.

Figure

18

shows

the

top

of

the

bolted

power

fuse

assembly

with

the

blown

fuse

indicators

in

the

normal

position

.

Power

Fuse

Conversion

Instructions

Bolt

-

in

fuses

used

on

Vacuum

Limitamp

and

Air

-

break

Limitamp

may

be

field

converted

from

one

to

the

other

by

carefully

following

the

instructions

below

.

Starting

Autotransformers

Sc

Reactors

Reduced

voltage

controllers

include

a

reactor

or

au

-

totransformer

designed

for

starting

duty

in

accordance

with

NEMAICS

2

-

214

.

The

duty

cycle

generally

fur

-

nished

is

for

medium

-

duty

applications

which

consist

of

three

30

-

second

starts

spaced

30

-

seconds

apart

followed

by

a

one

-

hour

rest

.

To

prevent

overheating

and

possible

damage

when

applied

on

more

severe

duty

(

heavy

duty

)

applications

,

special

reactors

or

autotransformers

must

be

specified

.

Thermostats

are

mounted

on

the

reactor

and

transformer

cores

to

offer

protection

against

over

-

heating

.

These

thermostats

must

be

manually

reset

if

tripped

by

high

temperature

.

SINGLE

BARREL

DOUBLE

BARREL

CAT

.

NO

.

55

A

21294

£

P

“

A

”

CAT

.

NO

.

218

A

4293

P

“

A

CAT

.

NO

.

55

A

212942

P

"

A

”

CAT

.

NO

.

218

A

4293

P

“

A

-

l

CAUTION

I

.

ICAUTIONI

I

CAUTION

I

ICAUTIONI

jNf

t

^

ijii

AJ

BY

CAREFULLY

FOLLOWING

THESE

INSTRUC

-

TIONS

,

THE

ABOVE

FUSE

VERSIONS

MAY

BE

FIELD

CONVERTED

FROM

ONE

TO

THE

OTHER

.

BY

CAREFULLY

FOLLOWING

THESE

INSTRUC

-

TIONS

,

THE

ABOVE

FUSE

VERSIONS

MAY

BE

FIELD

CONVERTED

FROM

ONE

TO

THE

OTHER

.

1

.

LOOSEN

BOTTOM

BOLT

(

Y

)

WHILE

INSURING

FUSE

BARREL

DOES

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

WASHER

TO

FACE

TOWARD

BOLT

HEAD

.

CAUTION

:

0

O

NOT

LOOSEN

TOP

BOLT

OF

FUSE

.

THIS

WILL

DAMAGE

INTERNAL

ELEMENTS

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

OF

FUSE

.

THIS

WILL

DAMAGE

INTERNAL

ELEMENTS

OF

FUSE

.

11

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Figure

21

.

Recommended

method

of

lifting

single

panel

.

Figure

19

.

Vacuum

Limitamp

controller

wrapped

In

plastic

film

wrap

ready

for

shipment

.

gSipP

HBHHB

m

Figure

22

.

Recommended

method

of

lifting

a

Vacuum

Limitamp

lineup

.

Note

that

the

lineup

is

suspended

from

an

equalizing

bar

.

Figure

20

.

Vacuum

Limitamp

controller

with

outside

packaging

material

removed

and

ready

for

handling

.

t

?

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Installation

Placement

of

Enclosure

Ic

is

essential

that

the

controller

be

securely

fastened

in

an

upright

position

on

a

level

surface

to

allow

proper

functioning

of

the

internal

devices

.

While

there

are

no

roll

-

out

components

,

access

will

be

improved

if

the

controller

is

located

at

floor

level

with

plenty

of

room

allowed

for

doors

to

swing

fully

open

as

shown

on

the

drawings

supplied

with

the

equipment

.

After

the

controller

has

been

placed

in

position

,

the

floor

mounting

bolts

may

be

installed

and

tightened

.

The

location

of

these

bolts

is

shown

on

the

outline

drawing

furnished

with

each

controller

.

These

bolts

are

'

/

2

-

inch

bolts

and

are

usually

located

in

each

corner

of

the

controller

base

.

General

This

section

contains

information

on

receiving

and

handling

,

disassembly

,

power

-

cable

termination

,

ground

-

ing

,

and

reassembly

to

make

the

equipment

ready

for

operation

.

Receiving

Vacuum

Limitamp

controllers

are

fabricated

as

rigid

,

floor

-

mounted

,

self

-

supporting

steel

sections

requiring

no

floor

sills

.

They

are

crated

and

shipped

in

an

upright

position

and

,

when

received

,

should

be

kept

upright

.

Some

components

may

be

shipped

separately

,

such

as

tdp

-

mounted

resistors

or

potential

transformers

.

These

components

are

identified

by

catalog

number

coinciding

with

that

of

the

section

on

which

they

are

to

be

mounted

.

Plastic

film

wrap

or

corrugated

cardboard

is

normally

used

for

domestic

crating

with

the

steel

enclosure

sections

bolted

to

a

wooden

skid

.

See

Figure

19

.

After

receiving

,

the

packing

may

be

removed

and

the

equip

-

ment

handled

on

the

wooden

skid

.

See

Figure

20

.

Disassembly

After

the

equipment

has

been

set

in

place

where

it

is

to

be

permanently

connected

,

some

internal

disassembly

is

required

to

make

the

necessary

external

power

-

cable

and

control

-

wire

connections

.

Disassembly

should

be

done

in

a

definite

sequence

by

following

Figure

23

through

Figure

34

,

and

as

described

below

:

Disassembly

Sequence

of

Operation

Warning

:

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

door

near

the

handle

.

Figure

23

-

2

shows

the

method

of

first

depressing

the

pusher

with

one

hand

and

moving

the

handle

with

the

other

.

Refer

to

page

27

and

29

for

normal

and

emergency

door

opening

procedures

.

2

.

Open

both

the

top

(

low

-

voltage

)

and

bottom

(

high

-

voltage

)

doors

.

Handling

It

is

always

preferable

to

handle

Limitamp

controllers

by

the

lifting

means

provided

.

Figure

21

shows

the

recom

-

mended

method

of

lifting

a

single

section

,

while

Figure

22

shows

the

recommended

method

of

lifting

a

lineup

.

Note

that

the

lineup

in

figure

22

is

suspended

from

an

equalizing

bar

.

A

lineup

should

be

supported

at

as

many

points

as

possible

.

If

there

is

not

enough

headroom

to

lift

the

panel

by

its

lifting

beam

,

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

beam

,

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

under

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

.

However

,

the

recommended

method

is

by

crane

as

pictured

.

Contactor

Removal

Normally

it

is

not

necessary

to

remove

the

contactor

from

its

mount

in

order

to

make

external

power

-

cable

and

control

-

wire

connections

.

If

the

contactor

is

not

to

be

removed

proceed

to

Step

4

.

Otherwise

,

follow

the

steps

outlined

below

to

remove

the

contactor

from

the

controller

.

3

.

Contactor

removal

.

a

.

Remove

.

the

wing

nuts

holding

the

contactor

umbilical

cord

and

connectors

in

place

and

save

the

hardware

.

This

hardware

will

be

reused

to

remount

the

connector

when

the

contactor

is

reinstalled

.

Unplug

the

connector

and

place

the

bracket

in

the

lower

front

channel

to

the

left

of

the

contactor

for

safe

keeping

.

See

Figure

24

.

13

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Grounding

All

controller

enclosures

must

be

grounded

.

A

stud

is

welded

to

the

lower

back

of

the

enclosure

in

the

incom

-

ing

-

line

compartment

area

for

connection

to

the

grounding

system

.

This

connection

must

be

made

before

making

any

power

connection

.

If

ground

bus

is

ordered

,

the

ground

stud

is

connected

to

the

ground

bus

at

the

factory

and

the

system

ground

can

be

connected

to

the

ground

bus

instead

.

The

control

and

instrumentation

circuits

are

grounded

to

the

enclosure

at

the

terminal

board

.

This

is

normally

the

only

grounding

point

.

It

can

be

temporarily

re

-

moved

for

test

purposes

;

but

it

must

be

regrounded

before

the

control

is

returned

to

operation

.

b

.

Loosen

the

line

side

cable

bolts

at

the

bottom

of

the

fuse

assembly

and

save

the

hardware

.

Be

sure

the

cables

are

free

of

their

mounts

and

that

they

can

be

freely

removed

.

See

Figure

27

.

c

.

Remove

the

three

load

side

connection

bolts

in

the

bottom

of

the

contactor

.

These

bolts

are

accessed

through

the

openings

at

the

bottom

of

the

contactor

from

the

front

.

A

socket

wrench

with

an

extension

may

be

used

to

remove

these

bolts

.

Save

this

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

be

removed

.

See

arrows

in

Figure

29

.

o

.

Slide

the

contactor

out

of

the

mounting

base

and

lift

it

and

the

line

side

cables

out

of

the

enclosure

.

f

.

Replace

the

three

bolts

removed

from

the

load

side

connections

in

their

holes

and

thread

them

in

a

few

turns

.

These

bolts

will

prevent

reinstalling

the

contactor

until

removed

again

.

This

serves

as

a

reminder

that

the

bolts

are

there

and

need

to

be

reinstalled

when

the

contactor

is

being

replaced

.

4

.

Prepare

to

remove

the

horizontal

compartment

barrier

by

removing

the

two

bolts

shown

in

Figure

SO

.

5

.

Remove

the

horizontal

barrier

,

Figure

30

.

(

If

a

hinged

low

-

voltage

panel

is

used

,

swing

it

to

the

left

and

out

of

the

enclosure

.

)

<

6

.

Remove

the

horizontal

bus

barrier

bolts

as

shown

in

Figure

31

,

and

then

lift

the

barrier

out

of

the

enclosure

.

The

horizontal

bus

is

then

exposed

as

shown

in

Figure

32

.

Incoming

Power

Connections

Incoming

power

connections

to

the

bus

may

be

made

in

any

one

of

the

enclosures

in

a

lineup

.

Space

for

one

500

-

MCM

cable

with

stress

cones

per

phase

is

available

in

the

standard

26

-

inch

wide

enclosure

.

A

34

-

inch

wide

enclosure

is

also

optionally

available

when

larger

cable

capacities

are

required

.

The

34

-

inch

enclosure

is

standard

with

synchronous

controllers

and

7200

volt

controllers

.

If

shielded

cable

is

used

,

refer

to

the

information

on

Page

23

of

this

manual

.

In

the

one

-

high

enclosure

with

horizontal

power

bus

,

incoming

power

connections

are

made

on

the

left

end

of

the

bus

bars

.

When

the

barriers

are

removed

from

the

enclosure

,

both

ends

of

the

power

bus

and

the

ground

bus

are

accessible

from

the

inside

of

the

enclosure

.

To

add

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

bus

removing

the

ten

bolts

,

Figure

33

.

Pull

the

barrier

out

of

the

enclosure

.

splices

furnished

with

the

equipment

,

the

bus

connec

-

tions

can

be

made

to

either

side

of

the

existing

equipment

.

Figures

32

and

35

show

the

accessibility

of

both

ends

of

the

bus

bars

with

the

barriers

removed

and

8

.

Remove

the

front

cover

of

the

lower

incoming

line

barrier

,

Figure

34

,

(

if

incoming

cables

are

to

be

routed

from

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

,

all

power

termination

points

and

bus

connections

arc

accessible

.

See

Figure

35

.

the

low

-

voltage

panel

swung

out

.

The

splices

must

be

bolted

in

place

with

the

14

-

inch

hardware

supplied

with

the

splice

kit

.

Torque

splice

bolts

to

35

lb

.

-

ft

.

14

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Figure

23

-

1

.

Depress

STOP

push

button

.

Figure

23

-

3

,

Handle

OFF

-

Pusher

bar

OUT

,

m

-

/

<

:

Figure

23

-

2

.

Place

isolator

handle

in

the

OFF

position

by

depressing

pusher

bar

and

rotating

handle

rapidly

down

.

Figure

23

-

4

.

Turn

door

latches

and

open

door

.

15

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

'

vi

§

|

:

.

ims

.

;

r

.

Figure

26

.

Unplug

the

umbilical

cord

assembly

.

Figure

24

.

Remove

wing

nuts

as

shown

.

rnm

^

.

%

*

,

*

.

v

.

y

•

J

-

>

;

*

Na

-

yfcJi

*

Figure

27

.

Unbolt

the

cables

from

the

bottom

of

the

fuse

assembly

.

Figure

26

.

View

showing

armature

interlock

.

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

!

-

*

:

&

$

Tiiiw

'

•

J

f

*

>

Hid

£

p

?

-

T

-

:

f

:

f

V

.

:

.

-

V

:

'

1

•

'

v

.

vi

'

"

?

V

.

>

:

-

•

^

v

•

;

‘

r

-

V

v

..

•

vv

,

V

i

•

i

,

*

o

.

^

;

.

1

:

>

r

;

i

'

h

>

f

T

*

“

i

.

•

iv

.

Wi

.

-

S

-

:

?

&

:

%

I

.

-

Figure

30

,

Remove

the

bolts

shown

and

slide

the

horizontal

barrier

out

of

the

enclosure

.

Figure

28

.

Unbolt

the

cables

from

the

bottom

of

the

fuse

assembly

.

i

:

f

-

.

REMOVE

NUTSfv

•

>

••

m

"

'

,

K

7

!

.

S

'

!

.

:

!

;

i

Figure

31

.

Remove

the

horizontal

main

bus

barrier

bolts

shown

and

remove

the

barrier

.

Figure

29

.

Remove

the

three

load

-

side

connecting

bolts

,

(

do

not

adjust

the

R

.

T

.

V

.

covered

bolts

)

Remove

the

two

retaining

nuts

.

!

17

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

•

:

?

!

I

>

]

'

^

v

.

/

•

#

|

f

*

3

Lv

*

<

•

*

T

i

’

vv

-

.

v

$

9

%

i

.

v

-

v

-

1

m

.

w

®

«

Illfllllfsj

*

#

-

v

*

Vf

Figure

32

*

Exposed

main

bus

after

removal

of

main

bus

barrier

.

Figure

34

.

Lower

Incoming

line

barrier

.

,

?

f

/

Vi

-

;

i

•

V

•

f

-

•

v

:

’

-

\

*

•

.

-

V

.

!

#

i

t

;

:

I

'

^

i

f

,

.

1

:

<

1

•

i

"

•

l

(

o

7

'

.

;

I

•

*

.

m

.

I

-

4

-

$

*

Figure

35

.

Main

bus

compartment

with

all

barriers

removed

and

incoming

line

cables

terminated

.

Figure

33

.

Isolator

switch

barrier

showing

bolts

to

be

removed

.

18

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Motor

Connections

Motor

cables

may

enter

from

the

top

or

bottom

of

the

enclosure

.

In

the

one

-

high

enclosure

,

the

motor

termi

-

nals

arc

located

on

the

inside

lower

left

wall

as

shown

in

Figure

36

.

The

incoming

leads

should

be

trained

for

maximum

space

between

phases

and

ground

.

The

connections

may

be

made

before

or

after

energizing

the

main

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

disconnect

switch

must

be

in

the

off

position

and

the

blades

must

be

visu

-

ally

checked

to

ensure

that

they

are

completely

disconnected

from

the

vertical

bus

.

The

motor

terminals

can

accommodate

up

to

one

500

-

MCM

per

phase

with

stress

cones

in

the

standard

26

-

inch

wide

enclosure

.

If

larger

cable

entries

are

required

,

an

optional

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

Courtesy of NationalSwitchgear.com

CR

194

Vacuum

Limitamp

400

Ampere

Control

Extra

-

width

Enclosure

A

.

special

34

-

inch

-

wide

enclosure

is

available

for

terminat

-

ing

shielded

cable

with

stress

cones

,

or

for

terminating

more

than

one

large

cable

per

phase

.

The

enclosure

design

permits

space

for

termination

of

two

500

-

MCM

cables

per

phase

with

stress

cones

*

for

motor

and

power

leads

.

Figures

35

and

38

show

the

space

available

in

this

extra

-

width

enclosure

.

Design

is

basically

the

same

as

the

26

-

inch

-

wide

one

-

high

,

and

all

data

and

information

in

these

instructions

applicable

to

the

26

-

inch

one

-

high

design

apply

to

the

34

-

inch

-

wide

enclosure

.

Power

Cable

Termination

In

any

installation

,

the

cable

should

be

prepared

for

termination

in

accordance

with

the

instructions

of

the

cable

manufacturer

.

However

,

the

following

general

recommendations

are

given

for

proper

cable

termina

-

tion

in

Vacuum

Limitamp

equipment

.

1

.

Pull

in

the

cables

in

accordance

with

the

panel

outline

diagram

and

position

them

for

maximum

clearance

between

phase

,

ground

and

other

cable

or

wire

runs

.

Refer

to

Figure

60

of

these

instructions

for

recommended

location

of

incoming

cables

in

a

standard

Limitamp

controller

.

Figure

38

.

Motor

cable

terminations

in

26

-

Inch

or

34

-

inch

wide

enclosures

.

Figure

39

.

Termination

of

cable

in

potheads

.

*

General

Electric

Termi

-

Kit

®

stress

cones

.

20

Courtesy of NationalSwitchgear.com

GE CR194 User manual

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