ITE 7850 Series Training manual

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
FEBRUARY
,
1975
MM
Mgg
'
i
mm
USE
SERIES
7850
High
Voltage
Motor
Starter
:
:
4
>
3
?
.
.
V
~
vs
>
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sr
;
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s
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:
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;
.
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'
'
.
V
INSTALLATION
OPERATION
MAINTENANCE
)
l
-
T
-
E
IMPERIAL
CORPORATION
WESTMINSTER
OPERATION
WESTMINSTER
,
MARYLAND
21157
Courtesy of NationalSwitchgear.com

%
<
INSTRUCTION
BULLETIN
IB
-
6.5
.
1
FEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
-
V
'
i
-
TABLE
OF
CONTENTS
-
INTRODUCTION
PAGE
NO
.
DESCRIPTION
AND
RATINGS
CONTACTOR
DATA
AND
FUSE
SPECIFICATIONS
FUSE
TIME
-
CURRENT
CURVES
1
-
3
4
5
-
6
INSTALLATION
4
RECEIVING
STORAGE
HANDLING
UNCRATING
GENERAL
PRE
-
INSTALLATION
INSPECTION
POSITIONING
ELECTRICAL
CONNECTIONS
ENCLOSURE
DIMENSIONS
FINAL
CHECKOUT
AND
INSTALLATION
.
-
•
-
.
7
8
9
•
S
'
.
•
r
‘
f
)
10
OPERATION
WIRING
SCHEMATIC
11
ROUTINE
INSPECTION
AND
MAINTENANCE
TROUBLE
SHOOTING
12
PARTS
LISTS
CABINET
-
INTERNAL
COMPONENTS
CONTACTOR
-
EXPLODED
VIEW
.
FUSE
AND
ARC
CHUTE
BARRIERS
13
-
14
15
-
17
18
>
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
1
FEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
INTRODUCTION
>
MAXIMUM
RATINGS
NEMA
CLASS
E
2
HIGH
VOLTAGE
STARTERS
AIR
BREAK
2500
-
5000
VOLTS
MAXIMUM
NEMA
CLASS
E
2
2200
-
2400
V
50
or
60
Hz
.
4000
-
4800
V
50
or
60
Hz
.
Squirrel
Cage
Motors
.
1500
HP
2500
HP
Synchronous
Motors
(
1.0
PF
)
.
..
(
0.8
PF
)
.
.
.
The
Series
7850
starter
provides
safe
and
dependable
operation
of
2200
V
thru
4800
V
,
50
/
60
Hertz
,
AC
motors
.
The
controllers
are
available
in
five
(
5
)
types
of
modular
enclosures
,
four
(
4
)
motor
control
center
types
and
one
(
1
)
wall
-
mounted
construction
.
1750
HP
1500
HP
3000
HP
2500
HP
interrupting
Rating
(
Sym
.
)
.
.
.
200
MV
A
350
MVA
.
Basic
impulse
Level
.
60
KV
60
KV
CONTROLLER
A
—
Door
Interlock
The
fully
rated
400
A
,
NEMA
Size
H
3
,
Class
E
2
controller
is
a
compact
design
with
numerous
safety
features
using
a
NEMA
Class
E
1
drawout
contactor
.
Front
accessible
power
and
control
fuses
,
isolated
by
removable
barriers
,
makes
fuse
removal
and
contact
change
an
easy
task
.
Con
-
tacts
and
coil
are
easily
changed
with
the
loosening
of
one
bolt
(
no
special
tools
required
)
.
The
controller
door
is
interlocked
with
the
main
isolating
switch
handle
.
The
door
cannot
be
opened
if
the
main
isolating
switch
is
in
the
energized
or
"
On
"
position
.
In
addition
the
handle
cannot
be
moved
to
the
"
On
"
position
while
the
door
is
open
.
In
case
of
an
emergency
,
a
defeater
is
provided
to
allow
the
door
to
open
while
the
switch
is
energized
.
The
defeater
can
be
reached
by
removing
the
set
screw
on
the
face
of
the
operating
mechanism
just
above
the
handle
assembly
.
Refer
to
Figure
No
.
2
.
Arc
chutes
are
individually
barriered
,
and
rotate
to
a
con
-
tact
inspection
position
without
the
use
of
tools
.
The
Series
7850
controller
compact
and
lightweight
design
allows
easy
handling
,
cutting
installation
costs
.
The
con
-
troller
'
s
reduced
size
,
fully
rated
at
400
A
,
allows
generous
wiring
area
further
reducing
installation
cost
.
This
same
400
A
controller
is
provided
for
200
A
applications
,
provid
-
ing
increased
contact
life
as
well
as
unmatched
flexibility
.
When
applied
to
the
400
A
application
,
with
the
proper
fuses
,
the
controller
'
s
reduced
size
provides
generous
wiring
This
unique
design
allows
greater
flexibility
in
B
—
Handle
and
Contactor
Interlock
To
prevent
accidental
withdrawal
of
the
contactor
when
it
is
in
the
energized
position
,
a
mechanical
interlock
is
pro
-
vided
.
To
move
the
operating
handle
from
the
"
On
"
to
the
"
Off
"
position
,
it
is
necessary
to
push
the
red
handle
release
button
located
below
the
operating
handle
and
hold
while
moving
from
"
On
"
to
"
Off
"
.
Reference
Figure
No
.
2
.
When
the
contactor
is
energized
it
should
not
be
possible
to
push
the
release
button
in
.
If
the
button
can
be
de
-
pressed
,
it
should
be
adjusted
as
shown
in
Figure
No
.
3
.
FUSE
TRIGGER
SHOULD
BE
FLUSH
WITH
TOP
OF
FUSE
END
STOP
—
-
)
space
.
making
field
changes
in
starter
position
as
well
as
changing
the
rating
of
the
starter
due
to
changing
HP
requirements
.
Utilization
of
one
design
throughout
400
A
also
reduces
spare
parts
stock
to
a
minimum
.
SINGLE
PHASE
PROTECTION
The
possibility
of
motor
burnout
caused
by
a
single
blown
fuse
has
been
eliminated
by
providing
,
as
standard
,
single
phase
protection
.
Should
a
fuse
blow
,
the
fuse
trigger
actuates
the
common
trip
bar
which
de
-
energizes
the
con
-
tactor
.
The
anti
-
single
phase
switch
should
be
closed
when
the
trip
bar
is
in
the
up
position
.
If
this
is
not
the
case
,
the
switch
can
be
adjusted
by
loosening
the
mounting
screws
and
moving
it
until
the
switch
is
closed
while
the
bar
is
up
.
Refer
to
Figure
No
.
1
for
correct
switch
location
.
INTERLOCK
SYSTEMS
The
Series
7850
enclosure
and
drawout
mechanism
inter
-
lock
systems
are
in
accordance
with
Nema
standards
and
provide
maximum
safety
for
personnel
and
equipment
.
LOOSEN
TO
AO
JUST
POSITION
OF
SWITCH
>
Figure
1
Single
Phase
Protection
Switch
Courtesy of NationalSwitchgear.com

>
INSTRUCTION
BULLETIN
IB
-
6.5
.
1
3
E
2
t
-
EBRUARY
.
1975
HIGH
VOLTAGE
STARTERS
ADJUST
TO
ELIMINATE PLAY
IN
RELEASE
BUTTON
WHILE
UNIT
IS
ENERGIZED
I
EMUH
KHX
:
l
.
MO
£
vunw
r
=
w
REMOVE
SET
SCREW
FOR
ACCESS
TO
DOOR
INTERLOCK
DEFEATER
i
\
ROTATE
DEFEATER
WITH
SCREWORIVER
TO
RELEASE
DOOR
INTERLOCK
9
-
*
•
»
HANDLE
RELEASE
BUTTON
Figure
3
Handle
&
Contactor
Interlock
Adjustment
S
ItiM
V
$
DUAL
CONTACTOR POSITION
INDICATION
Figure
2
Mechanical
Door Interlock
In
addition
to
the
'
ON
-
OFF
'
handle
indication
,
a
mechan
-
ical
indicator
mechanically
operated
by
the
magnet
gives
positive
indication
that the
contactor
is
in
either
the
Open
or
Energized
position
.
C
—
Mechanical
Latch
OVERCURRENT
PROTECTION
>
r
The
mechanical
latch
is mounted
on
the
right
contactor
carriage
rail
and
serves
to
locate
and
hold the
contactor
in
both
the
disengaged
and
test
positions
.
The
latch is
re
-
leased
by
pivoting
the
latch
assembly
upward
and
manually
rolling
the
controller
into
the
desired
position
.
Reference
Figure
No
.
4
.
Ambient
compensated
thermal overload
relays
with
exter
-
nal hand
reset
are
provided
as
standard
,
offering
accurate
and reliable
overload
protection
.
Special
switchboard
or
magnetic
type
overcurrent
protection
is
available
.
D
—
Switch
Electrical
Interlock
The
normally
open
electrical
interlock
(
located
on
the
left
side
of
the
rear
wall
of
the
main
switch
compartment
)
closes
only
when the
contactor
is
fully
engaged
,
supplying
power
to
the
control
circuit
.
The
switch
is
pre
set at
the
factory
and
no
adjustment
is
required
.
Reference
Figure
No
.
5
.
E
—
Test
Power
Switch
The
test
power
switch
interlock located
on
the
rear
of
the
left
contactor
carriage
rail
disconnects
the
test
circuit
when
the
contactor
is
moved
from
the
test
position
to
the
dis
-
engaged
position
.
If
this
does
not
occur
,
the
action
of
this
switch
may
be
adjusted
by
loosening
the
mounting
screws
as
shown
in
Figure
No
.
6
.
Figure
4
Pivot
Upward
to
Defeat
Mechanical
Latch
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
3
FEBRUARY
.
1975
*
•
•
•
HIGH
VOLTAGE
STARTERS
FINISH
The
metal
is
thoroughly
cleaned
,
degreased
and
phosphated
after
which
it
is
given
a
clear
water
rinse
followed
by
a
chromic
acid
rinse
.
The
metal
is
then
thoroughly
dried
after
which
an
epoxy
dry
powder
is
applied
electrostati
-
cally
to
a
minimum
thickness
of
1
-
3
/
4
mils
and
then
cured
in
an
oven
at
a
temperature
of
375
degrees
.
Our
standard
finish
exceeds
requirements
for
the
200
hour
salt
spray
test
for
corrosion
resistant
enclosures
.
Standard
color
is
ASA
-
61
,
Gray
.
ELECTRICAL
INTERLOCK
LOOSEN
TO
ADJUST
SWITCH
POSITION
Figure
5
Electrical
Interlock
Switch
ENCLOSURES
Rugged
,
heavy
gauge
steel
,
NEMA
1
construction
is
pro
-
vided
as
standard
(
for
optional
NEMA
types
,
consult
the
factory
)
.
Five
(
5
)
different
arrangements
of
enclosures
are
available
covering
a
broad
range
of
customer
requirements
.
Features
:
Basic
welded
starter
modules
,
29
"
wide
by
30
"
high
by
29
"
deep
.
All
enclosures
use
this
basic
module
,
pro
-
viding
great
flexibility
and
interchangeability
.
(
See
page
9
for
enclosure
variations
.
)
Add
-
on
type
modular
,
separate
low
voltage
compart
-
ments
with
individual
doors
.
.
Ventilated
openings
in
starter
module
doors
,
between
units
,
and
at
the
top
of
the
enclosure
for
heat
dissi
-
pation
.
Optional
load
terminals
can
be
provided
for
customer
motor
leads
in
a
separate
compartment
on
fully
rated
standoff
type
insulators
,
easily
accessible
from
the
inside
of
the
controller
compartment
by
removing
a
barrier
.
For
added
safety
,
optional
isolation
of
load
connections
can
be
provided
in
addition
to
the
isolated
line
connec
-
tions
which
are
provided
as
standard
.
Completely
self
-
contained
drawout
mechanism
with
alt
wheels
and
moving
parts
mounted
in
the
enclosure
,
allowing
a
lighter
controller
assembly
.
Figure
6
Test
Power
Switch
Adjustment
>
Courtesy of NationalSwitchgear.com

>
INSTRUCTION
BULLETIN
IB
-
6.5
.
1
GE
4
,
RUARY
,
1975
HIGH
VOLTAGE
STARTERS
r
»
*
>
CONTACTOR
OPERATION
DATA
Voltage
Frequency
Current
Interrupting
Capacity
Control
Voltage
Control
Current
:
(
120
volts
60
Hz
.
)
.
.
.
2500
/
5000
volts
50
/
60
Hz
.
360
amps
(
enclosed
rating
)
400
amps
(
open
rating
)
50
MVA
.
.
120
volts
,
50
/
60
Hz
.
Inrush
11.5
amp
0.25
amp
13
cycles
6
cycles
Sealed
Cycles
to
Close
Cycles
to
Open
"
R
"
RATED
AMP
-
TRAP
FUSE
SPECIFICATIONS
'
00
VOLTS
CONTINUOUS
RATING
-
55
°
C
l
-
T
-
E
CAT
.
NO
.
SIZE
INTERRUPTING
RATING
60
HZ
Single
Phase
80
,
000
Amperes
RMS
Asymmetrical
at
2400
Volts
70
,
000
Amperes
RMS
Asymmetrical
at
2750
Volts
A
240
R
-
2
R
A
240
R
-
3
R
A
24
QR
-
4
R
A
240
R
-
6
R
A
240
R
-
9
R
A
240
R
-
12
R
2
R
70
A
3
R
100
A
130
A
170
A
200
A
230
A
4
R
6
R
9
R
12
R
Three
Phase
210
MVA
Symmetrical
at
2400
Volts
210
MVA
Symmetrical
at
2750
Volts
A
240
R
-
18
R
18
R
390
A
24
R
A
240
R
-
24
R
450
A
4800
VOLTS
Single
Phase
100
,
000
Amperes
RMS
Asymmetrical
at
4800
Volts
90
,
000
Amperes
RMS
Asymmetrical
at
5200
Volts
Three
Phase
500
MVA
Symmetrical
at
4800
Volts
500
MVA
Symmetrical
at
5200
Volts
A
480
R
-
2
R
A
480
R
-
3
R
A
480
R
-
4
R
A
480
R
-
6
R
A
480
R
-
9
R
A
480
R
-
12
R
2
R
70
A
3
R
100
A
130
A
170
A
200
A
230
A
4
R
6
R
9
R
12
R
A
480
R
-
18
R
18
R
390
A
>
A
480
R
-
24
R
24
R
450
A
;
-
!
Courtesy of NationalSwitchgear.com

1
INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
5
FEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
TOTAL
CLEARING
TIME
-
CURRENT
CURVES
For
2400
and
4800
Volt
A
240
R
and
A
480
R
Amp
-
trap
"
R
"
Rated
Fuses
on
N
100
100
i
:
*
90
90
00
10
70
*
»
0
00
00
SKESS
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60
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20
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M
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CURRENT
IN
AMPERES
Courtesy of NationalSwitchgear.com

\
INSTRUCTION
8
ULLETIN
IB
-
6.5
.
1
PAGE
6
1
RUARY
,
1975
HIGH
VOLTAGE
STARTERS
MINIMUM
MELT
TIME
-
CURRENT
CURVES
For
2400
and
4800
Volt
A
240
R
and
A
480
R
Amp
-
trap
"
R
"
Rated
Fuses
at
at
at
at
at
ot
at
CD
N
m
•
o
CM
o
»
100
100
rV
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?
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;
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CURRENT
IN
AMPERES
:
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
7
FEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
INSTALLATION
RECEIVING
"
DO
NOT
MOVE
THE
OPERATING
HANDLE
"
Before
accepting
shipment
from
the
transportation
com
-
pany
,
a
thorough
inspection
of
the
Series
7850
High
Voltage
Starters
should
be
made
.
If
damage
has
been
incurred
during
transit
,
the
carrier
should
be
notified
at
once
and
damage
claim
filed
.
I
-
T
-
E
Imperial
Corporation
is
not
responsible
for
damage
after
equipment
is
released
to
the
carrier
.
I
-
T
-
E
Imperial
Corporation
will
,
upon
request
,
assist
in
filing
a
claim
with
the
carrier
.
The
nearest
I
-
T
-
E
Imperial
Corporation
Sales
Office
should
be
notified
and
all
pertinent
information
provided
.
For
shipping
purposes
the
handle
interlock
mechanism
has
been
blocked
.
Damage
will
occur
if
the
handle
is
operated
before
the
unit
is
completely
and
properly
unpacked
.
Reference
Figure
No
.
7
&
8
for
illustration
of
unpacking
procedure
.
Unlatch
the
two
(
2
)
1
/
4
turn
latches
and
open
the
door
.
Remove
the
tie
wraps
holding
the
interlock
mechanism
behind
the
operating
handle
.
Remove
the
shipping
stop
in
the
front
of
the
left
contactor
carriage
rail
.
The
contactor
is
now
free
to
be
slowly
pulled
forward
out
of
the
en
-
closure
.
The
contactor
will
latch
in
the
test
position
.
See
Figure
No
.
8
.
Once
in
this
position
the
protective
packing
over
the
fuses
and
arc
chutes
should
be
removed
.
Refer
-
ence
Figure
No
.
7
.
After
the
equipment
is
unpacked
it
should
be
checked
against
the
packing
list
.
Should
any
shortages
or
deviations
occur
,
contact
the
local
I
-
T
-
E
Imperial
Corporation
office
.
STORAGE
After
receipt
and
in
the
event
that
installation
cannot
be
made
at
once
,
the
unit
should
be
stored
in
a
clean
,
dry
,
well
-
ventilated
location
.
Indoor
types
of
equipment
should
not
be
stored
outdoors
even
if
completely
covered
.
If
units
are
subjected
to
either
low
temperature
or
moisture
,
approximately
100
watts
of
heat
should
be
introduced
into
each
section
.
It
is
recommended
that
the
factory
-
installed
plastic
covering
be
left
intact
until
the
equipment
is
ready
for
installation
.
GENERAL
PRE
-
INSTALLATION
INSPECTION
1
—
With
the
7850
PLD
lift
mechanism
or
other
lifting
means
in
position
,
defeat
the
mechanical
latch
mechanism
as
described
in
section
"
C
"
,
page
2
.
Roll
the
contactor
out
of
the
cabinet
and
follow
steps
2
—
8
below
.
HANDLING
)
All
Series
7850
Starters
should
be
handled
with
utmost
care
to
avoid
possible
damage
due
to
severe
shock
.
Ship
-
ping
skids
,
plastic
covering
,
and
open
crating
should
be
left
intact
as
long
as
possible
to
facilitate
handling
and
protection
.
Equipment
may
be
moved
with
fork
lift
type
equipment
or
by
the
'
use
of
rollers
.
Any
force
used
to
move
equipment
should
be
applied
to
the
skid
rather
than
the
units
themselves
.
Equipment
should
be
stabilized
while
being
moved
to
prevent
any
possibility
of
tipping
.
7850
Starters
may
also
be
moved
with
an
overhead
crane
.
When
using
overhead
equipment
,
the
slings
should
be
supported
under
the
skids
and
cable
spreaders
should
be
used
above
the
equipment
to
avoid
damage
.
7850
Starters
may
be
supplied
with
lifting
angles
,
if
specified
,
to
facilitate
more
convenient
overhead
handling
.
2
—
Check
all
parts
for
secure
mounting
and
good
electri
-
cal
connections
.
Inspect
visually
for
overall
good
condition
.
3
—
Check
fuses
for
snug
fit
in
clips
.
Check
fuse
clips
for
deformity
and
secure
mounting
.
4
—
By
defeating
door
and
handle
interlocks
(
reference
interlock
section
of
description
,
page
2
)
while
contac
-
tor
is
removed
from
the
cabinet
,
inspect
the
line
finger
assembly
and
operation
of
isolation
shutters
.
5
—
Manually
operate
the
contactor
shaft
.
Release
the
shaft
and
check
that
the
shaft
rotates
freely
and
instantly
out
of
engagement
.
6
—
Inspect
cabinet
for
dents
or
other
damage
.
Swing
door
to
make
sure
it
pivots
easily
.
Check
wiring
for
secure
connections
and
to
be
sure
insulation
is
in
good
condition
.
7
—
Check
control
circuit
plug
and
receptacles
for
bent
pins
or
other
damage
.
8
—
Make
sure
cable
clamps
and
insulators
are
in
good
condition
.
UNCRATING
CAUTION
DO
NOT
UNPACK
UNITS
BEFORE
READING
ALL
UNPACKING
INSTRUCTIONS
FULLY
Care
should
be
taken
during
unpacking
to
avoid
damage
to
units
.
Equipment
should
be
allowed
to
attain
room
temper
-
ature
before
removing
the
covering
in
order
to
minimize
condensation
.
When
the
unit
is
at
room
temperature
,
remove
covering
and
crating
material
.
>
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
"
AGE
8
.
BRUARY
,
1975
HIGH
VOLTAGE
STARTERS
>
Arc
Chute
Covers
Nylon
Strapping
Tape
Fuse
Covers
Shipping
Stop
Figure
7
Unpacking
instructions
Figure
8
Test
Position
POSITIONING
To
simplify
wiring
when
heavy
cables
are
required
,
the
contactor
carriage
assembly
and
the
horizontal
frame
work
between
compartments
may
be
removed
.
Reference
Figure
No
.
9
.
All
7850
Starters
should
be
positioned
with
as
much
clear
-
ance
as
possible
away
from
all
columns
and
obstructions
.
At
least
the
minimum
space
as
allowed
by
local
code
should
be
provided
in
front
of
the
unit
.
If
the
No
.
7850
PLD
lift
mechanism
is
to
be
used
,
allow
at
least
39
"
in
front
of
units
.
The
rear
of
these
devices
may
be
placed
against
the
wall
,
however
,
the
rear
covers
are
removable
and
the
units
may
be
mounted
with
space
behind
them
for
installation
convenience
,
cabinet
dimensions
.
Refer
to
outline
drawings
supplied
with
specific
equipment
for
exact
mounting
bolt
locations
and
conduit
areas
.
Line
connections
should
be
made
first
.
On
units
provided
with
horizontal
bus
,
a
separate
incoming
line
section
can
be
supplied
for
cable
sizes
as
specified
by
the
customer
.
When
separate
incoming
line
section
is
not
specified
,
the
units
are
bused
to
the
supply
.
Units
without
horizontal
bus
have
the
terminals
located
behind
the
removable
red
isolation
barriers
in
the
rear
of
the
cabinet
.
Remove
bolts
No
.
A
,
Figure
10
,
then
remove
barriers
No
.
B
.
Line
cables
coming
into
the
line
compartment
of
the
enclosure
are
connected
to
terminals
No
.
C
.
After
connection
is
made
,
replace
isolation
barriers
No
.
B
.
Reference
page
9
for
basic
Each
unit
is
provided
with
mounting
channels
that
may
either
be
set
on
the
floor
or
embedded
in
it
.
Although
•
these
units
are
free
standing
and
self
-
supporting
,
they
should
be
securely
bolted
down
with
anchor
bolts
to
elimi
-
nate
the
possibility
of
"
walking
"
in
the
event
of
a
seismic
event
.
In
addition
,
all
units
should
be
level
to
insure
proper
operation
.
When
positioning
the
Type
VI
wall
-
mounted
unit
,
care
should
be
taken
that
adequate
support
is
pro
-
vided
for
specified
weight
.
Load
cables
are
connected
directly
to
the
stationary
stabs
or
to
optional
load
terminal
shown
on
outline
drawing
supplied
with
the
specific
equipment
.
On
V
4
and
V
5
type
enclosures
,
load
terminals
are
located
behind
the
low
voltage
compartment
.
These
terminals
can
be
reached
by
removing
the
barrier
between
the
contactor
compartment
and
the
terminal
com
-
partment
.
See
Figure
No
.
11
.
ELECTRICAL
CONNECTIONS
e
and
load
leads
can
be
connected
to
the
terminals
provided
simply
by
removing
the
contactor
from
the
cabinet
.
Be
sure
to
disconnect
the
control
plug
before
attempting
removal
of
contactor
.
External
control
connections
are
made
to
the
terminal
blocks
located
in
the
low
voltage
compartment
.
Location
of
low
voltage
compartment
is
specified
on
the
dimensional
drawing
which
is
supplied
with
the
individual
equipment
.
>
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
„
PAGE
9
FEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
HIGH
VOLTAGE
STARTER
ENCLOSURES
>
Space
Modules
Available
Dimensions
—
Inches
Height
Depth
Enclosure
Series
7850
Width
29
1
36
VI
45
29
1
36
90
V
2
2
36
36
90
V
3
2
40
36
90
V
4
3
40
36
90
V
5
TOP
VIEW
V
4
V
5
V
3
V
2
VI
i
36
"
36
"
36
"
36
"
36
"
1
1
I
I
i
LIFTING
ANGLES
40
"
29
"
*
29
"
h
-
^
-
v
11
"
-
*
7
"
-
*
45
"
30
"
30
"
i
30
"
45
"
l
90
"
90
"
15
"
WALL
MOUNTED
)
!
»
0
"
30
"
30
"
90
"
15
"
45
"
30
"
’
30
"
30
"
'
'
THREE
HIGH
TWO
HIGH
WIDE
ONE
HIGH
TWO HIGH
NARROW
FRONT
VIEW
ALL
MTG
.
HOLES
3
/
4
"
DIA
.
TYPICAL
B
A
A
B
A
B
A
-
*
r
—
c
—
c
r
—
c
—
©
*
-
L
3
>
A
D
D
D D
F
*
E
F
F
F E E
£
•
:
*
MOUNTING
LOCATIONS
(
Dimensions
in
Inches
)
F
D
E
B
C
A
Unit
2
-
1
/
4
24
-
1
/
4
2
-
3
/
B
17
-
1
/
4
20
-
7
/
8
3
-
9
/
16
V
2
2
-
1
/
4
20
-
7
/
8
24
-
1
/
4
2
-
3
/
8
3
-
9
/
16
17
-
1
/
4
V
3
>
2
-
1
/
4
24
-
1
/
4
2
-
3
/
a
3
-
9
/
16
17
-
1
/
4
20
-
7
/
8
V 4
2
-
1
/
4
24
-
1
/
4
2
-
3
/
8
3
-
9
/
16
17
-
1
/
4
20
-
7
/
8
V
5
[
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
10
FEBRUARY
.
HIGH
VOLTAGE
STARTERS
HORIZONTAL
FRAME
CONTACTOR
CARRIAGE
ASSEMBLY
Figure
10
Wiring
Without Horizontal
Bus
Figure
9
>
FINAL
CHECKOUT
AND
INSTALLATION
.
CAUTION
MAKE
SURE
MAIN
SWITCH
IS
LOCKED
OPEN
BEFORE
INSTALLING
CONTACTOR
Install
contactor
in
the
cabinet
in
the
test
position
.
See
Figure
No
.
8
for
test
position
.
Connect
the control
plug
.
Connect
120
volt
AC
test
source
to
the
proper
test
termi
-
nals
as
shown
in
the
wiring
diagram
provided
with
the
specific
device
.
(
The
high
voltage
control
transformer
is
not
connected
to
the circuit
in
the
test
position
.
)
Move
the
'
TEST
-
RUN
"
selector
switch
,
located
in
the low
voltage
compartment
,
to
the
'
TEST
"
position
.
Energize
the
contactor
.
Tilt
back
the
arc
chambers
and
inspect
the
(
Illustrated
with
barrier
removed
)
contacts
to
be
sure
they
mate
fully
and
evenly
across
the
full
surface
of
the
contacts
.
Return
the
arc
chutes
to
their
normal
position
.
Check
that the
arc
chutes
are
fully
en
-
gaged
.
Reference
Figure
No
.
12
.
While
the
unit
is
energized
,
depress
the
anti
-
single phasing
bar
,
the
contactor
should
de
-
energize
.
Re
-
energize
the
unit
and
push
the
contactor
back
into
the
enclosure
to
its
stop
position
!
The
contactor
should
de
-
energize
during
this
procedure
.
If
the
contactor
has
not
de
-
energized
by
the time
the
unit
has
reached
this
position
,
return
it
to
the
test
position
.
De
-
energize
the
contactor
using
the
control circuit
stop
button
.
Disconnect
the
control
plug
and
remove
the unit
from
the
cabinet
.
Check
the
operation
of
the
test
power
micro
-
switch
at
the
back
of
the
left
contactor
carriage
Tail
and
See
"
interlock
fyfSfrhS
*
REMOVABLE
BARRIER
-
ACCESS
TO
LOAD
TERMINALS
ON
V
4
AND
V
5
UNITS
>
Figure
11
Load
Terminals
Access
on
Type
V
4
and
V
5
Units
adjust
or
replace
as
necessary
,
section
of
description
,
page
2
,
section
E
.
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
11
FEBRUARY
,
1975
All
other
contactor
operating
assemblies
have
been
set
and
checked
at
the
factory
.
If
,
during
start
up
,
the
main
contactor
does
not
close
,
refer
to
maintenance
section
for
trouble
shooting
information
.
HIGH
VOLTAGE
STARTERS
>
OPERATION
MAKE
SURE
RAISED
BUTTONS
ON
CORE
SUPPORTS
SEAT
INTO
DE
-
PRESSIONS
ON
ARC
CHUTES
CAUTION
BEFORE
PLACING
UNIT
INTO
OPERATION
,
VERIFY
THAT
ALL
NECESSARY
FIELD
INSTALLATION
TESTS
,
INCLUDING
DIELECTRIC
AND
PROPER
PHASING
,
HAVE
BEEN
MADE
.
With
the
operating
handle
in
the
"
Off
"
position
,
check
to
be
sure
all
parts
removed
during
inspection
and
testing
have
been
replaced
.
Close
the
doors
and
latch
the
two
(
2
)
1
/
4
turn
latches
.
The
operating
handle
may
now
be
moved
to
the
"
On
"
position
,
moving
the
contactor
into
the
engaged
position
.
Complete
electrical
sequence
of
a
typical
starter
can
be
traced
on
the
schematic
diagram
.
Figure
No
.
13
.
Figure
12
Engagement
of
Arc
Chutes
S
3
r
uO
aw
I
I
I
^
L
-
OZO
ICT
-
n
*
l
—
^
o
I
^
Si
bantermm
pJ
^
IJ
*
»
u
taarjhMS
«
»
U
S
.
JL
.
HI
P
“
~
\
A
.
iUUUUUUUUUUUlA
^
"
^
*
q
I
li
~
y
Tt
,
LI
tmaftaf
Hnft
ImtritoTb
0
E
i
j
Battif
SmUkktmktk
{
#
ftutin
)
WVYV
\
v
i
v
mrr
a
it
'
Tri
w
cu
ted
hw
SarttcA
(
In
ftKitiM
)
IT
|
i
tl
.
(
In
foftan
)
tat
Craft
lipifiH
Snra
mHC
E
>
-
-
fi
ftL
Cl
Is
m
G
3
—
i
-
i
-
—
>
®
H
1
Win
.
E
«
ntad
*
E
—
2
.
wi
IBB
a
—
1
Libia
*
nctesri
*
HMt
Mtri
fins
it
n
tte
bw
-
*
rt
cntacter
.
*
.
Mates
termalt
Mr
Nttep
3
-
0
Mftstn
tnrab
«
dart
*
.
as
.
S
3
m
Mi
Cute
ftoaw
*
fetch
Win
.
tatate
o
-
i
«
1
0
^
IM
fe
1
J
r
±
02
it
»
It
HrrH
>
j
Figure
13
Schematic
Diagram
5000
Volt
Starter
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
12
"
BRUARY
,
1975
HIGH
VOLTAGE
STARTERS
ROUTINE
INSPECTION
AND
MAINTENANCE
CAUTION
is
required
or
where
unusually
dirty
or
corrosive
conditions
exist
,
a
more
frequent
inspection
interval
is
recommended
.
MAKE
SURE
THE
CONTACTOR
IS
DISENGAGED
BEFORE
ANY
INSPECTION
OR
MAINTENANCE
PROCEDURES
ARE
ATTEMPTED
.
Contactors
should
be
routinely
cleaned
and
all
dirt
and
dust
removed
.
Special
attention
should
be
paid
to
the
•
stationary
and
movable
contact
faces
.
If
the
contacts
are
excessively
pitted
or
worn
,
they
should
be
replaced
.
Under
normal
operating
conditions
,
starters
should
be
in
-
spected
monthly
.
In
applications
where
frequent
starting
TROUBLE
SHOOTING
CHART
PROBLEM
PROBABLE
CAUSES
CORRECTIVE
ACTION
Contacts
chatter
Loose
connection
in
control
circuit
Tighten
connections
in
control
circuit
Defective
control
relay
Check
control
relay
-
replace
as
required
Defective
magnet
Check
coil
or
rectifier
Low
control
voltage
Check
line
voltage
Contacts
overheat
Loose
connection
Tighten
connections
Contacts
not
making
firmly
Check
for
weak
or
deformed
contact
spring
-
replace
as
required
'
Dirt
or
foreign
matter
on
contact
surfaces
Clean
contacts
Contact
material
consumed
Replace
contacts
Control
circuit
or
main
fuses
blown
Inspect
fuses
,
replace
if
blown
Contactor
will
not
close
Magnet
coil
defective
Check
magnet
operation
-
replace
coil
as
necessary
Control
relays
defective
Potential
transformer
defective
Check
control
relays
and
replace
if
defective
Check
potential
transformer
-
replace
if
defective
Overload
relay
defective
Check
overload
relay
and
replace
if
defective
Rectifier
defective
Check
rectifier
and
replace
if
defective
Remote
reset
button
.
or
solenoid
defective
Replace
defective
parts
TEST
-
RUN
switch
in
test
position
Move
switch
to
RUN
position
Anti
-
single
phase
Check
adjustment
,
alignment
and
switch
function
-
adjust
per
figure
1
Electrical
interlocks
defective
Check
function
of
interlocks
«
replace
as
required
>
,
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
13
FEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
Cabinet
—
Internal
Components
No
.
160045000
Handle
Assembly
—
1
Per
Switch
•
No
.
170019600
Over
-
Center
Mechanism
Assembly
—
1
Per
Switch
Figure
14
No
.
170019100
Rack
Assembly
—
1
Per
Switch
1
11
No
.
160044900
Shutter
and
Ground
Assembly
—
1
Per
Switch
No
.
150115000
Stab
Assembly
(
Transformer
to
Bus
Bar
)
—
2
Per
Switch
>
Figure
16
w
±
^
7
'
*
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
14
"
EBRUARY
.
1975
HIGH
VOLTAGE
STARTERS
No
.
140289100
Switch
Stop
—
2
Per
Switch
No
.
150121000
Auxiliary
Contact
Assembly
—
1
Per
Switch
Figure
17
i
t
No
.
150136900
Current
Transformer
Assembly
—
3
Per
Switch
(
Optional
)
Figure
18
No
.
150130900
Walking
Beam
Assembly
—
1
Per
Switch
No
.
170019000
Chassis
Assembly
—
1
Per
Switch
y
Figure
19
Courtesy of NationalSwitchgear.com

INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
16
FEBRUARY
,
1975
•
HIGH
VOLTAGE
STARTERS
I
i
!
Figure
20
.
Contactor
—
Exploded
View
Fig
.
&
Index No
.
Req
'
d
Per
Unit
Part
Number
Description
:
150137801
150137802
150118100
064449000
150108700
064449001
150119100
150120700
150120600
140278800
150104500
140279000
140277600
140296300
150133901
150133902
150104600
150103600
140289000
150101800
140277800
700057989
150118400
150107200
150105400
150108800
140295700
150117200
.
140295800
160043101
160043102
160042500
150105100
140277900
See
info
supplied
-
with
equip
J
60043400
_
150
T
22700
100288800
140299300
700231520
150123004
150123005
700145050
011027900
140299400
140299200
.
012474900
700099600
140296300
021002400
140283400
160042700
150118700
150134100
700033177
160043500
033788805
700016320
700228275
034238000
150092900
150117400
140292600
150118300
850800060
140277000
150104200
150104000
140295000
140295200
010325300
140273400
140273300
150117500
023604100
Leftside
Frame
Assembly
Rightside
Frame
Assembly
Moving
Contact
Support
Assembly
Stationary
Contact
Support
Stationary
Contact
Support
Assembly
Stationary
Contact
Support
Bus
Bar
Assembly
Center
Pole
Bus Bar
-
Fuse
to
Stab
-
Line
Side
Bus Bar
-
Fuse
to
Contact
*
Line
Side
>
Stationary
Contact
Assembly
Connector
—
Blow
Out
Coil
Nut
Plate
—
Blow
Out
Coil
Insulator
—
Blow
Out
Coil
Stab
Clip
Core
Support
—
Left
Side
Core
Support
—
Right
Side
Blow
Out
Coil
Assembly
Blow
Out
Core
Assembly
Shim
Washer
—
Main
Shaft
Bearing
—
Main
Shaft
-
Contact
Spring
Separable
Contact
Finger
Assembly
Arc
Horn
&
Support
Assembly
Flexible
Shunt
Assembly
_
Movable
Contact
Assembly
Fuseblocfc
Assembly
Control
Fuse
Insulator
—
Fuseblocfc
—
Primary
Main
Shaft
Barrier
Service
Handle
Left
Hand
Slide
Right
Hand
Slide
Fuse
Clip
Fuse
Clip
Support
Spring
Fuse
End
Stop
&
Guide
Main Fuse
Arc
Chute
Assembly
Lever
Assembly
Nameplate
Insulator
—
Microswitch
Microswitch
Leftside
Support
Assembly
Rightside
Support
Assembly
Flat
Head
Cotter
Pin
Collar
Support
Plunger
*
Contact Carrier
Glastic
Insulator
Stab
Contact
Spring
Stop
—
Handle
Release
Mechanism
Core
Support
Assembly
Coil
-
110
-
120
V
50
/
60
Hz
Connector
Cord
Assembly
Wire
Clamp
Support
Bracket
Channel
For
Terminal
Blocks
3
-
Pole
Terminal Block
Terminal
Marker
Strip
Rectifier
Assembly
Adaptor
Plate
Support
for Contact
Block
Contact
Block
Insulator
Contact
Block
Relay
Stop
—
Armature
Frame
Frame
Assembly
Armature
Inner
Plate
Bumper
Spring
Armature
Striker
Plate
Striker
Plate
Shim
Lever
—
Contact
Block
Reset
Button
End
20
-
1
20
-
2
20
-
3
20
-
4
20
-
5
20
-
6
20
-
7
20
-
8
20
-
9
20
-
10
20
-
11
20
-
12
20
-
13
20
-
14
20
-
15
20
-
16
20
-
17
-
20
-
18
20
-
19
20
-
20
20
-
21
20
-
22
20
-
23
20
-
24
20
-
25
20
-
26
20
-
27
20
-
28
20
-
29
20
-
30
20
-
31
20
-
32
20
-
33
20
-
34
20
-
35
20
-
36
20
-
37
20
-
38
20
-
39
20
-
40
20
-
41
20
-
42
20
-
43
20
-
44
20
-
45
20
-
46
20
-
47
20
-
48
20
-
49
20
-
50
20
-
51
20
-
52
20
-
53
20
-
54
20
-
55
20
-
56
20
-
57
20
-
58
20
-
59
20
-
60
20
-
61
20
-
62
20
-
63
20
-
64
20
-
65
20
-
66
20
-
67
20
-
68
20
-
69
20
-
70
20
-
71
20
-
72
20
-
73
20
-
74
20
-
75
1
1
1
2
1
2
1
2
3
3
3
3
3
i
3
3
3
3
3
2
2
3
6
3
3
3
4
2
4
4
1
1
6
6
3
3
3
2
2
-
3
3
3
4
2
3
;
.
•
•
Courtesy of NationalSwitchgear.com

>
TRUCTION
wULLETIN
IB
-
6.5
.
1
PAGE
17
TEBRUARY
,
1975
HIGH
VOLTAGE
STARTERS
Figure
20
.
Contactor
—
Exploded
View
—
Continued
Fig
.
&
Index
No
.
Req
'
d
Per
Unit
i
Part Number
Description
?
20
-
76
20
-
77
20
-
78
20
-
79
20
-
80
20
-
81
20
-
82
20
-
83
20
-
84
20
-
85
20
-
86
20
-
87
20
-
88
20
-
89
20
-
90
20
-
91
20
-
92
20
-
93
20
-
94
20
-
95
20
-
96
.
20
-
97
20
-
98
20
-
99
20
-
100
20
-
101
20
-
102
20
-
103
20
-
104
20
-
105
20
-
106
20
-
107
20
-
108
20
-
109
20
-
110
20
-
111
20
-
112
20
-
113
20
-
114
20
-
115
20
-
116
20
-
117
20
-
118
20
-
119
20
-
120
20
-
121
20
-
122
20
-
123
20
-
124
20
-
125
20
-
126
20
-
127
20
-
128
20
-
129
20
-
130
20
-
131
20
-
132
20
-
133
20
-
134
20
-
135
20
-
136
20
-
137
20
-
138
20
-
139
20
-
140
20
-
141
20
-
142
20
-
143
20
-
144
20
-
145
010325300
140295400
150125200
140300200
140279600
140288300
700020010
140280300
140284200
See
info
supplied
with
equip
140296700
700188050
700129100
700249750
700249425
700199810
,
700199575
700250950
700250550
700130200
700202350
700204250
706203150
700203652
700204950
700205700
700251950
700251605
700130800
700208100
700208750
700209200
700209450
700209850
700252625
700252450
700131300
700131760
700211800
700253250
700131900
700254425
700213510
700129900
700211052
700253300
•
010543000
700130350
700201150
700251400
700203750
700130950
700194250
700129950
700201000
700130175
700185950
700191050
700250125
700250000
700198800
700189200
700249850
700186700
700199000
.
700253100
700202850
.
700252550
700211550
140292400
Spring
Spacer
Support
-
Arm
-
Visual
Indicator
Visual
Indicator
Arm
Assembly
Spring
Return
Clip
Return
Spring
—
Armature
Eye
Bolt
Roller
for
Carriage
Slide
Latch
Stop
Control
Fuse
3
/
8
x
1
-
1
/
4
Socket
Hd
.
Shoulder
Scr
.
No
.
6
-
32
x
1.125
Rd
.
Hd
.
SMS
No
.
6
-
32
Hex
Nut
No
.
6
Lock Washer
No
.
6
Flat
Washer
No
.
10
-
32
x
1
/
2
"
Pan
Hd
.
SMS
No
.
10
-
32
x
3
/
8
"
Hex
Indented
W
/
W
TT
No
.
10
Split
Lockwasher
No
.
10
Flat
Washer
No
.
10
-
32
Steel
Hex
Nut
1
/
4
-
20
x
3
/
8
"
Phil
.
Pan
Hd
.
TT
Screw
1
/
4
-
20
x
1
"
Hex
Hd
.
SCS
1
/
4
-
20
x
5
/
8
"
Hex Hd
.
SCS
1
/
4
-
20
x
3
/
4
"
Hex Hd
.
SCS
1
/
4
-
20
x
1
-
1
/
4
"
Hex Hd
.
SCS
1
/
4
-
20
x
1.750
"
Hex Hd
.
SMS
1
/
4
Split
Lockwasher
S
.
S
.
.
1
/
4
Flat
Washer
1
/
4
-
20
Steel
Hex
Nut
5
/
16
-
18
x
5
/
8
"
Hex Hd
.
SCS
5
/
16
-
18
x
1
"
Hex
Hd
.
SCS
5
/
16
-
18
x
1
-
1
/
4
"
Hex
Hd
.
SCS
5
/
16
-
18
x
1
-
1
/
2
"
Hex
Hd
.
SCS
.
5
/
16
-
18
x
2
"
Hex Hd
.
SCS
5
/
16
Split
Lock Washer
5
/
16
Flat
Washer
-
Type
KD
(
S
.
A
.
E
.
)
5
/
16
-
18
Steel
Hex
Nut
5
/
16
-
18
Nylon
Insert
Nut
3
/
8
-
16
x
1
-
1
/
4
"
Hex Hd
.
SCS
3
/
8
Split
Lock
Washer
3
/
8
-
16
Steel
Hex
Nut
3
/
8
Belleville
Washer
1
/
2
x
1
-
1
/
4
"
Socket
Hd
.
Shoulder Scr
.
No
.
10
-
24
Steel
Hex
Nut
.
3
/
8
-
16
x
5
/
8
"
Hex
Hd
.
SMS
.
3
/
8
Lock
Washer
3
/
8
S
.
S
.
Flat
Washer
No
.
'
10
-
32
Palnut
No
.
10
-
32
x
1
-
1
/
4
"
Round
Hd
.
SMS
No
.
10
Flat
Washer
S
.
S
.
1
/
4
-
20
x
7
/
8
"
Fil
.
Hd
.
SMS
1
/
4
-
20
Palnut
No
.
10
-
24
x
3
/
4
Fit
.
Hd
.
SMS
‘
No
.
10
-
24
Palnut
No
.
10
-
32
x
1
"
Rd
.
Hd
.
SMS
No
.
10
-
32
Hex
Nut
No
.
6
-
32
x
3
/
8
"
-
Phil
.
Pan Hd
.
Taptite
Scr
.
No
.
8
-
32
x
5
/
8
"
Rd
.
Hd
.
SMS
No
.
8
Split
Lock
Washer
No
.
8
.
Flat
Washer
No
.
10
-
32
x
3
/
8
"
Phil
.
Pan Hd
.
Taptite
Scr
.
No
.
8
-
32
x
1
-
1
/
4
Phil
.
Hd
.
Taptite
Scr
.
No
.
6
SS
Split
Lock
Washer
'
No
.
6
-
32
x
1
/
2
"
Phil
.
Pan
Hd
.
SMS
Swage
No
.
10
-
32
x
3
/
8
"
Pan
Hd
.
SMS
3
/
8
"
Flat
Washer
1
/
4
-
20
x
1
/
2
"
Rd
.
Hd
.
SMS
5
/
16
Flat Washer
-
U
.
S
.
Std
.
3
/
8
-
16
x
1
"
Hex
Hd
.
SCS
Retaining
Nut
1
I
1
1
!
1
1
1
\
1
i
2
i
1
i
2
1
!
2
4
:
2
!
6
I
19
I
1
!
33
j
14
*
4
2
3
7
If
6
?
)
1
1
'
!
I
26
20
15
5
5
20
15
18
62
59
.
53
2
16
29
33
9
2
!
2
!
•
3
3
i
3
“
v
!
!
I
i
3
3
2
2
2
2
2
2
2
6
9
18
3
6
3
3
1
l
Courtesy of NationalSwitchgear.com

*
*
«
INSTRUCTION
BULLETIN
IB
-
6.5
.
1
PAGE
18
FEBRUARY
,
1975
.
w
HIGH
VOLTAGE
STARTERS
>
Figure
21
Fuse
and
Arc
Chute
Barriers
r
Fig
.
&
Index
Description
Part
Number
No
.
Typical
Controller
Fuse
Barriers
14
required
)
Center
Switch
Barrier
(
4
required
)
21
-
1
150104800
150104700
21
-
2
21
-
3
:
>
/
t
'
e
v
.
•
:
-
Sr
Si
.
V
"
r
•
si
,
;
t
J
.
>
ji
.
.
.
r
Courtesy of NationalSwitchgear.com