Westinghouse IQ-2000 User manual

TD 11-720-B IQ-N)(H)
NOTE
All possible contingencies which may arise during installation, operation, or maintenance, and
a// details and variations of this equipment do not purport to be covered by these instructions.
If further information is desired by purchaser regarding his particular installation, operation or
maintenance of his equipment, the local Westinghouse Electric Corporation representative should
be contacted.
Effective April, 1985
Copyright
0
1985
Westinghouse Electric Corporation
Control Dlvism
Asheville, NC 28813
First Printing: February, 1986

IQ-1000 TD 11-720-B
TABLE OF CONTENTS
Sec./Par. Title Page Sec./Par. Title Page
1 10
1.1
1 2
1.3
1.4
15
1 6
2 2.0
2 1
2.1.1
2.1.2
2.2
2.2.1
2.2.2
23
2.4
25
3 3.0
3 1
3.2
3.3
3.3.1
3.3.2
3.3.3
3.4
4 4.0
4 1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1 .6
4 1.7
4.1.8
4.1.9
4.1.10
4.2
Description 4
General ” : ” ” 4
Features and Options 6
Specifications 6
Hardware Famlllarlzatlon 6
Use of Manual 8
Level of Repair .8
Factory Correspondence 8
Functional Theory 9
General .9
Sensing Inputs 9
RTD Module
Control Lines.. 9 .lO
Protective Functions 10
Load-Associated Protection 10
Rotor Temperature ProtectIon 10
True RMS 11
Motor Control Functions 12
Metering Functions
Jam Function
Temperature Effects
Typlcal Motor Protection Curves
Motor Current
Negative Sequence Currents
Positive Sequence Currents
Motor Control. :
Motor Starting
Long Acceleration Starting
Motor Stopping
AC Line Interruptions
Control Signal Wiring
Discrete Inputs :
Output Contacts
lnterposmg Relays
Wiring Considerations.
RTD Wiring
Grounding
.1 : 1: 1: 12 Installation 13
General 13
Ampgard Schematic .I3
Winng Plan Drawings 13
Winng Guidelines 13
Wire Routing I ,113
Types of Wire 13
Grounding
Wiring Checklist : 1. 15 . . 1.. .17
Startup 20
General .20
Operator Panel Description .20
RUN/PROGRAM Keyswitch 20
FUNCTION Window 21
VALUES Windows : .21
ADJUST Pushbuttons 21
STEP Pushbutton
CYCLE/SELECT Pushbutton : : .22
.22
RUN, PROGRAM LEDs 22
SET POINTS Pushbutton, LED .22
TRIP, ALARM LEDs : : 22
RESET Pushbutton 22
Initial Programming and
Wire Routing : :
Environmental Considerations
Setpoint Value Considerations
General
Wlnding Ten$&&~ : : : :
Motor Bearing Temperature
Load Bearing Temperature
Ground Fault..
Instantaneous Overcurrent
Locked Rotor Current : 1.
Long Acceleration
Jam
Underload Start. : : 1
Underload Run
Ultimate Trip
4.2.1
4.2.2
4.3
4.3.1
4.3.2
4.4
4.5
4.6
5 5.0
5.1
5.1.1
5.1.2
Sequencing Checks .23
Power Off. 23
Control Power Only 23
Entering Setpoints. .23
Setpolnt Record Sheet 23
Value Entry .24
Initial Control Checkout .25
lmtlal Motor Startup 26
lnitlal Main Power-on ..26
Application Considerations 1 27
General 27
Motor Protection .27
Overload ProtectIon w&out RTDs : 27
Overload Protection with RTDs 27
5.1.3.5
5 1.3.6
5.1.4
5.1.5
5.1.5.1
5.1.5.2
5.2
5.2.1
5.2.2
5.2.3
5.3
5.4
5 4.1
5.4.2
5.4.3
5.5
5.5.1
5.5.2
5.5 3
5.6
6 6.0
6.1
6.2
6.3
:z
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
6.24
6.25
6.26
6.27
6.28
7 7.0
71
7.1.1
7.1.2
7.1.3
7.1.4
7.2
Overvoltage I I I
Undervoltage
Pre-start Timer
Pre-run Timer
Pre-stop Timer.
Incomplete Sequence..
Anti-backspin
Anti-recycle, Min
Time Undervoltage : .: 1.
Post-start Timer
Post-stop Timer
Start Counts/Hours 1: 1.
Open/Unbalance Phase
Full-load Current
Current Transformer Ratio 1 1
Potential Transformer Ratio
Starter Class
31
31
31
31
31
31
31
35
.36
36
36
36
36
.40
.41
41
42
43
43
43
44
.44
44
45
. ..45
45
45
.45
48
48
49
.49
49
49
.49
50
51
51
51
53
53
54
. ..54
.54
55
55
Monitoring and Troubleshooting
General
Panel Operations
Normal Operational Reporting
Reviewing Setpoints
Monitoring Characteristics : : : :
Internal Diagnostics
Malfunction Isolation
55
56
.56
56
.59
59
59
59
. ..59
59
.62
62
62
.62
.63
5.1.3 Protectton Curve
5.1 .3.1 Instantaneous Overcurrent
5.1 .3.2 Allowable Locked-Rotor Current,
Time.
5.1 .3.3 Ultimate Trip
5.1.3.4 Underload Function
.28
.28 of the Starter
30 7.2.1 Panel Operating
.30 7.2.1.1 Alarm Conditions
30 7.2.1.2 Trip Conditions
2
CLICK ON ANY SUBJECT TO GO TO THAT PAGE

TD 11-720-B IQ-N)00
SecSPar. Title Page SectPar. Title Page
7.2.2 Panel Inoperative
8 Unit Replacement
8.0 General
8.1 Processor Module Replacement
Figure Title Page Figure Title Page
1 .l
1.2
1.3
2.1
2.2
2.3
2.4
2.5
2.6
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4.1
IQ-2000, Model B, installed
in Ampgard Enclosure ..........
IQ-2000 Typical Installation .......
IQ-2000 Chassis ..............
System Overview (Simplified) ......
Symmetrical Components, Rotor ....
Symmetrical Components ........
Positive Sequence Currents ........
Negative Sequence Currents ......
Current Sampling Techniques ......
Ampgard Schematic ..............
Wiring to Draw-Out Panel .........
RTD Wiring (3-lead type)
Two-Lead RTD Wiring. ............... .;
Typical Grounding Plan ......
Jumper and Field Wiring ..... : ....
Ampgard Internal View, ...........
Operator Panel with Manual
References ...................
Setpoint Record Sheet (Typical) ....
Winding Temperature Displays ....
Rotor Temperature Tracking ........
Motor Protection Cu_rve ...........
Underload and Jam Protection .....
5.4
5.5
5.6
5.7
5.8
16
17
.i7
5.9
5.10
6.1
6.2
6.3
6.4
6.5
4.2
4.3
5.1
5.2
5.3
6.6
6.7
6.8
6.9
7.1
7.2
81
8.2
Motor Protection Curve (without RTDs)... .32
Motor Protection Curve (with RTDs) .... .33
Motor Start Cycle Events Diagram ...... .34
Motor Stop Cycle Events Chart ......... .37
Three Wire Momentary Pushbutton
Control with Time Delay Undervoltage
Function ........................ ..3 8
AC Interrupt Events Flow Chart. ........ .39
RTDWiring..........................4 3
Long Acceleration Events Diagram .... .48
Pre-start Events Diagram ............ .50
Pre-run Events Diagram ............... .51
Pre-stop Events Diagram ........... .52
Incomplete Sequence Events
Diagram ........................ .52
Time Undervoltage Timing ......... .53
Post-start Events Diagram ........... .54
Post-stop Events Diagram ............. .55
interposing Relay Wiring .............. .57
Display/Run Sequence Relations ....... .60
Reviewing Message .................. .60
IQ-2000 Chassis .................. .67
Terminal Designations .............. .69
Table Title Page Table Title Page
l.A
1.6
1.c
5.A
5.6
5.C
IQ-2000 Feature and Benefits
Communication Arrangements
Specifications
Input Circuit Characteristics.
Input Terminal Description
Momentary and Maintained Input
Terminals
Control Function Relay Contacts
Setpoint Function Index
5 8.B
6.C
6.D
39 7.A
40 7.0
7.c
41 7.D
42
44
Setpoint Record Sheet
Starter Classes
Relay Cl thru C4 Functions
Monitoring Operation
Troubleshooting: Alarm Conditions
Troubleshooting: Trip Conditions
Troubleshooting: Operator Panel
5.D
6.A Inoperative. 66
.66
.67
.67
.67
8.2 RTD Module Replacement .68
8.3 IQ-2000 Chassis Replacement .68
8.4 Terminal Identification.. : : : : : : : 68
LIST OF FIGURES
LIST OF TABLES
3

TD 11-720-B IQ-2000
Table l.A
IQ-2000 FEATURES AND BENEFITS
Feature
l Macro-processor based
control
Benefit
l Reliable service without need for numerous discrete components
l All 28 setpoint functions l Allows for wide-spread standardization of control types regardless of
available in all units parameters or starter types
l Undesired functions are sim- l No extra costs for unwanted features
ply programmed out l In-field removal or reactivation of functions
l Single model unit l Low inventory of spares possible
l Quick, inexpensive interchangeability during mamtenance
l Nonvolatile memory l No lost programs nor special back-up battenes
l Man-readable programming . No special language to be learned
l Setpomt values easily written with everyday numbers
l Setpotnts easily determined l Motor manufacturer’s data and a knowledge of the application are sufficient
l Simplified Operator Panel l No elaborate, complex keyboard
l Functions and diagnostic messages displayed in man-readable format
l Display window shows a l Install and maintain without extra and special test equipment
number of diagnostic
conditions
l Ease of startup
l Auxiliary contacts
l Low time-to-assemble factor
l Fast program entry
l Allow for additional process operations beyond the basic motor start-
ing/stopping
l Keylock mode switch
l Allow for external warmng devices when approaching setpoint thresholds
l Provides protection against program tampering while allowmg the monitonng
of programmed setpoints
l Communication data port
l Mlmmizes shut-downs for noncritical reasons
l All metering data, trip data, status annunciation, setpoints and dlagnostlc data
is available for remote analysis
Table 1.6
COMMUNICATION ARRANGEMENTS
Communication Type
Single Device RS232C
Description
A direct connection to an RS-232C compatible device where the IQ-2000 acts as a slave.
A COM 21 Communicatton Card plugs directly onto the Processor Module.
Communication to
any computer A Local Area Network, INCOM” is formed by 2 or more IQ-2000s connecting to a Trans-
later Box. The Translator Box is a slave to the main computer. In this arrangement the
COM 22 Communication Card is plugged into the Processor Module of each IQ-2000.
These cards are wired together using a shared non-shielded twisted pair to form a local
area network. The twisted pair is wired to a Translator Box containing a COM 23 Com-
munication Card which provides an RS-232C port.
Communication to an IBM- A Local Area Network, INCOM IS formed by 2 or more IQ-2000s connecting to a per-
compatible personal computer sonal computer via a shared non-shielded twisted pair of wires. The personal computer
acts as a master. In this arrangement the COM 22 Commumcation Card plugs into each
Processor Module. A COM 25 Communlcatlon Card is used in an expansion slot of the
personal computer.
5

IQ-mm TD 11-720-B
remain stored through power outages or until new program-
mung entries change the values.
The IQ-2000 is factory-shipped in any of the following ways:
Mounted in the low-voltage compartment of the
Ampgard”‘ enclosure
For Installation by an original equipment manufacturer
In a new motor command system
For Installation by the Westmghouse Engineering Serv-
ices Department into an existing motor starter
For installation by an end user in a motor starter
1.1 Features and Options-A list of features and benefits
is given in Table l.A. Since the IQ-2000 is a standardized pack-
age, there are very few optrons. Those currently available are:
RTD Module optron, whrch is required if resistance tem-
perature devices are used to monrtor motor and load or
motor bearing temperatures. The RTD Module is offered
for lo-ohm, loo-ohm, and 120-ohm applications.
Ground Fault Transformer option, which provides input
current signals. (Its ratio is always 50:5.)
Potential Transformers optron, whrch provides incom-
rng AC ltne phase and level Information.
Communication options, whrch provrde communication
of motor data to a remote device such as a computer or
programmable controller. The communication options are
described in more detail in publication number TD-11-730.
In all cases a Communication Card will be installed in-
srde the IQ-2000. Table 1.B lists and describes the 3 types
of communrcatron arrangements available.
1.2 Specifications - The specifications for the IQ-2000
motor command system are lrsted in Table 1.C.
1.3 Hardware Familiarization - The purpose of this Para-
graph is to familiarize the user with the main hardware
features of the IQ-2000. A complete description of the Oper-
ator Panel and the functions of each pushbutton IS given in
Chapter 4.
The IQ-2000 mounts in an optional enclosure, as shown in
the typical installation of Figure 1.2. Observe the Figure and
note the following explanation keyed to the callouts of the
Figure:
1. The enclosure is a Type 1
2. Cable connecting the Processor Chassis to the Oper-
ator Panel
3. Terminal block TB-A
4. Terminal block TB-B
5. Terminal block TB-R for connections to optional RTD
Module
AC line fuse
Terminal block TB-P for the Pl, P2, and P3 AC line
connections
Additional terminal block. When the IQ-2000 is in-
stalled by Westinghouse, this is assigned the desig-
nation TB. The TB terminal block IS not part of the
IQ-2000 hardware.
The various components of the 02000’s Processor Chas-
SIS are shown rn Figure 1-3. Observe the Figure and note the
following:
l The front cover of the IQ-2000 consists of a hinged ac-
cess door. (A screw secures it to the Chassis.)
Table l.C
SPECIFICATIONS
Input Power Requirements
120 VAC (*15%)
Frequency
50/60 Hz 6
Power Consumption
Processor: 60 VA
RTD Option: 6 VA
Communication Card: 5 VA
Current Transformer “Burden”
0.003 VA
Operating Temperature
-200 to 70°C q
(-4O to 158’F)
Storage Temperature
-2OO to +85%
(-4O to +185OF)
Humidity
0 to 95O R.H.
noncondensing
Fuses
Processor: 4 amp, 250 V slo-blo
Enclosure
Type 1
.1 Factory set; specify with order
Z The operating temperature range of the external
face of Operator Panel is limited to O0 to 55% (32O
to 13VF). This is not subject to the internal temper-
ature rise of the starter.
6

TD 11-720-B IQ-z@oo
Section 2
FUNCTIONAL THEORY
2.0 General - The IQ-2000 is a microprocessor-based sys-
tern that controls from 1 to 4 contactors associated with a mo-
tor starter. This Chapter describes how the hardware and
software function together to control, monitor and protect the
motor.
The description is divided into the following areas:
l Sensing inputs (Par. 2.1)
* Protective functions (Par. 2.2)
l Motor control functions (Par. 2.4)
l Metering functions (Par. 2.6)
2.1 Sensing Inputs - The IQ-2000 receives information
about motor current, line voltage and ground fault current as
well as control inputs such as motor starting and stopping
commands. (See Figure 2.1.) Optionally, RTD inputs supply
temperature data. The motor current is derived from 3 sepa-
rate current transformers which monitor each of 3 phases of
the AC line to the motor. Optionally, 3 phase potential trans-
formers may be used to monitor the line voltage being sup-
plied to the motor.
2.1.1 RTD Module -The optional RTD Module supplies in-
formation on the winding temperature from up to 6 RTDs
embedded in the stator windings of the motor. In addition,
RTD Module (optional)
Communlcatlons Module
(opttonal)
Figure 2.1 - System Overview (Simplified)
9

IQ2000 TD 11-720-B
RTDs assoctated with the motor bearings and load bearings
can also be monitored. The motor RTDs are used to supply
informatton for both the wrnding and rotor temperature pro-
tection function and the temperature monitoring function.
2.1.2 Control Lines - Momtoring of the signal lmes from the
machine or process associated with the starter is performed
by the Input monitoring area of the Processor Module. (This
is not shown in Figure 2.1.) These lines include the report-
back signals as well as the start and stop command lines.
These lines are used by the motor control area to enable and
dtsable both the main contactor and the auxiliary relays.
2.2 Protective Functions - Protective functions utilize mo-
tor conditions such as current and temperature on an ongo-
ing basis and first initiate an alarm condition, where
appropriate, and finally a trip condition. These conditions per-
form the following functions:
l Alarm condition energizes the Alarm Relay. Its contacts
are used external to the IQ-2000 for control or reporting
purposes.
l Trip condition removes the power from the motor and ac-
tuates a Trip Relay. The contacts of the Relay are used
external to the IQ-2000 for controlling or reporting
purposes.
When a trip condition occurs, the control stores the
metering functions such as motor current, temperature,
etc. This “picture” is maintained for use by maintenance
personnel until the RESET pushbutton is depressed.
The IQ-2000, Model B, is able to maintain the metering data
prior to a trip condition for a minimum of 12 hours after AC
power is removed.
The fault monitoring performed by the IQ-2000 can be divid-
ed into the following types:
l Load-associated protection (Par. 2.2.1)
l Rotor-temperature protection (Par. 2.22)
2.2.1 Load-Association Protection - The value of the mo-
tor current is used to detect the instantaneous overcurrent,
jam and underload setpoint functions. Information from the
load bearing RTDs IS compared with the setpoint values to
Initiate an alarm and/or a trip condition. (Note: all the setpoint
functions are described in detail in Chapter 6.)
2.2.2 Rotor Temperature Protection - Each motor design
has a specific damage curve usually referred to as its l*T curve
(current squared multiplied by time). In AC motors, the cur-
rent balance between phases IS of malor concern because
of the additional heating associated with an unbalance. This
currentunbalanceis caused mainly byavoltage unbalance,
the result of single phase loads on the three phase system,
and motor winding unbalance.
Wrth larger horsepower motors, the design is usually rotor
kmited. It therefore becomes important to determine the to-
tal heatmg effect on the rotor. For analysis, the motor can be
considered to have two rotors. (Refer to Figure 2.2) One is
the effect resultmg from balanced current and the other the
effect of unbalanced current. If perfect current balance exist-
ed In each phase of the motor current, then the II first com-
ponent used would be the line current squared with no error
In the heatmg projected from this current. This positive com-
ponent of current generates the motor output torque, work.
The second component of current is the negative sequence,
represented as 12,It IS a three phase current with a reverse
phase rotation from that of the AC source. This component
of current generates counter-torque to the motor output torque,
negative work. Because the torque generated, 12,does not
leave the rotor, it is absorbed as heat and therefore has a more
significant effect on the rotor heating than the I,. Thus any
three AC currents can be reoresented by the addition of II
plus I*,
12= I,2 + K122
Figure 2.2 - Symmetrical Components
10

TD 11-720-B IQ-2000
240.'
O0
IA
Figure 2.3 - Symmetrical Components
Figure 2.4 - Positive Sequence Currents
Figure 2.5 - Negative Sequence Currents
Using vector analysis to determine the positive sequence, one
rotates phase B in the positive direction 120’ and phase C
in the positive direction 2409 (Refer to Figure 2.4.)
The result of ,, = IA+ (6 + i2oo) + (6 + 2400)
3
The negattve sequence is determined by rotating phase B in
the opposite or negative direction for 120” and phase C ro-
tated In the negative direction for 2409 (Refer to Figure 2.5.)
Thus the formula for 12becomes
I* = I4 + (IB 120“) + (lc - 240°)
3
Prior to the use of a microprocessor In the motor command
system, there was no practical way of determming the total
effect of the positive and negative sequence on a continu-
ous basts. Therefore, less than adequate assumptions had
to be made. This resulted in nuisance tripping and actual or
near-actual motor burnouts. The IQ-2000 microprocessor uses
a unique, patented system for determining these values. Ev-
ery 120° within each AC line cycle the instantaneous current
in each phase is detected. Thus in 1 cycle the microproces-
sor has 9 readings of current. (Refer to Figure 2.6.)
The current square, as used In the calculation of the rotor heat,
is:
12 = I,7 + K122
Here I22is weighted by K (usually 6) because of the dispropor-
tional heating caused by the negative sequence.
With the use of a microprocessor, the effects of both the posi-
tive and negative sequence are accurately taken into account.
Their combined effect is incorporated into a “rotor protec-
tlon algorithm.” The algorithm is really a microprocessor-
based program which effectively keeps track of the tempera-
ture of the rotor.
It is not necessary to pick an arbitrary phase unbalance set-
point to trip the motor. As long as the combined effect of the
positive and negattve sequence does not approach the mo-
tor damage curve, the motor is allowed to be utilized.
2.3 True RMS - If the line current sampling were always tak-
en at exact intervals of 1204 all the samples would be taken
from the same point on the waveform, and the current moni-
tored would have to be a true sine wave. Realistically, the cur-
rent monitored at the motor is shaped similar to a sine wave,
but it has many harmonics superimposed on the basic sine
wave. These are caused by the addition of power factor cor-
rection capacitors, solid state drives and adjustable-speed
drives backfeeding into the electrical system of the entire
plant.
Therefore, to obtain true RMS (root mean square) current, the
lme current sampling is delayed after every cycle of data ac-
cumulation by 10 degrees. Only after 12 individual sets of data
are collected - 36 pieces of data for each phase - does
the microprocessor actually calculate and monitor the RMS
current and separate it into its positive and negative
components.
11

IQ-2000 TD 11-720-B
240° 360’
First Set of Data
Second Set (If c
:
Iata
Three 11Calculations Using First Set of Data
11 = I,, + I,, + I,,
lr = I&* + l,, + 1,
II = I, + I,, + I,,
Three 12Calculations Using First Set of Data
I2 = I, + I,, + Ic,
12 = I,, + l,, + Ica
12 = I,, + l,, + IQ
Figure 2.6 - Current Sampling Techniques
Thus using the 10’ delayed sampling method, together with 2.4 Motor Control Functions - The motor control function
the rotor protectlon algorithms, the IQ-2000 IScapable of com- receives the “command” inputs to start and stop the motor,
bining the effects of time and RMS current (positive and nega- and coordinates the energizing and de-energizing of the con-
tive sequence) Into a single protective system. The addition tactor and auxiliary control relays.
of the optional Resistance Temperature Detection (RTD)
Module is also factored Into the rotor protective algorithm.
This results in a multi-dimensional model allowing full motor
utilization.
2.5 Metering Functions - The control calculates and dis-
plays the instantaneous and accumulated values obtained by
monitoring characteristics such as motor current, ground cur-
rent. RTD temperature values, etc. (Chapter 7 describes the
monitoring cababilities of the co&o1 In’ detail.)
12

TD 11-720-B IQ-2mo
3.0 General - This Chapter describes general wiring and
wire-routing procedures to be followed by the electrical Instal-
latlon crew when installing the IQ-2000 and its associated
Ampgard starter with a motor and its related machine or proc-
ess equipment. The information listed here builds on earlier
chapters in this manual and will be unnecessarily difficult un-
less they are read first.
3.1 Ampgard Schematic - When the starter is supplied by
Westinghouse, the wiring between the Ampgard starter and
the IQ-2000 is factory installed. Each specific hardware con-
figuration is shown on a unique Ampgard Schematic shipped
with the unit. (A typical Ampgard Schematic is shown in Fig-
ure 3.1.) The drawing is for a Class Ii-202 induction, full-
voltage, non-reversing unit.
When the motor starter is not supplied by Westtnghouse, an
equivalent electrical scheme is developed by the retrofitter,
or onginal equipment manufacturer.
3.2 Wiring Plan Drawings - It is necessary for the customer
application engineer to develop a suitable wiring plan for use
by the installation team. It must reflect the control lines to the
IQ-2000 or between the IQ-2000 and its associated machine
or process equipment. In this manual the wiring plan is called
“wiring plan drawings,” although individual companies will
probably have different terminology. Whatever the term, these
drawings detail all customer wiring which must be performed
in the field after the Ampgard and its associated IQ-2000 is
shipped from Westinghouse.
The Ampgard Schematic shows all the control input and out-
put lines for the application; the wiring plan drawings list the
designations of these lines.
Note: in cases of “retrofits” where the IQ-2000 is shipped
separately wtthout an Ampgard starter, the wiring plan draw-
ings must list the:
l Wiring between the IQ-2000 and interposlng relays
l Maln contactor wiring
l Potential, current, ground current, and power transformer
wiring
In short, it must list all of the wiring that is normally document-
ed by the Ampgard Schematic.
3.3 Wiring Guidelines-The following wiring guidelines must
be observed by the electrical Installation crew when install-
ing the IQ-2000 and connecting it with its associated machine
or process equipment.
Section 3
INSTALLATION
3.3.1 Wire Routing - When routing wires between the Amp-
gard or other starter and the associated machine or process
equipment, follow these guidelines:
Insure that the lncommg AC power and all “foreign”
power sources are turned OFF and locked out before per-
r”““1
forming any work on the motor starter or IQ-2000. Failure
to observe this practice can result in serious or even fatal
injury and/or equipment damage.
Guideline 1 - All user-Installed control lines and the RTD
conductors connecting with the draw-out panel must be care-
fully coiled and secured to the factory-installed low-voltage
conductors. (See Figure 3.2.) This coil of conductors provides
a quantity of slack required for draw-out panel movement The
coil is positioned behind the panel as the panel is pushed
into the enclosure. In order to make the coil, bundle the con-
ductors neatly with tie-wraps, or equivalent means.
Once wiring is complete, insure that the coil is properly posi-
tloned and that it is able to clear any obstruction that may
exist as the draw-out panel moves In and out.
Guideline 2 - Do not route control or RTD conductors
through the high-voltage compartment of the motor starter
If it IS necessary to do so, consult the applications depart-
ment, Westinghouse Control Division, for speciftc instructions.
Guideline 3 - Separate the low-voltage (120 VAC) from the
high-voltage (440 VAC, or higher) conductors as much as pos-
sible In general, maintain a minimum distance of 1.5 ft. (45
cm) between the two types.
3.3.2 Types of Wire - The followlng guidelines list the gener-
ally acceptable types of conductors and winng practices used
in the industrial environment. For specific types of wire, con-
sult your application engineer.
Guideline 4 - Any low-voltage control wiring routed out of
the motor starter cabinet should be at least AWG No. 14
stranded copper wire.
Guideline 5 - The wiring between the RTD Module con-
tamed in the starter cabinet and the RTDs In the motor must
be AWG No. 18 3-conductor, shielded cable. (See Figure 3.3.)
Use Belden No. 8770, or equivalent. Note: In cases where the
leads from the motor or other resistance temperature devices
provide only 2 leads each, connect 2 conductors from the RTD
Module to one of these leads. Follow Figure 3.4 carefully when
selecting the 2 conductors to tie together. Also it is important
to connect the 2 conductors as close to the motor as possible.
13

IQ-2000 CT TD 11-720-B
73
Figure 3.1 - Ampgard Schematic Model B (typical)
14

TD 11-720-B
To top service entry
a) draw-out panel extended
b) draw-out panel retracted
Movement
Wire coiled behlnd panel 0 Wire cables to loop behind panel in an
unobstructed location.
Figure 3.2 - Wiring to Draw-Out Panel
Guideline 6 -Connect the shield and drain wire from RTD
cables to the common terminals on the RTD Module, as
shown In Figure 3.3. Note: connect the shield only at the RTD
Module. Use shrink tubing or electrical tape to Insure that the
shields do not make accidental contact with ground or other
terminals at the RTD end.
3.3.3 Grounding -A typical grounding plan for a starter is
15
shown !n Figure 3.5. Note carefully these guldeline before
maklng grounding connections.
Guideline 7 - Install an “equipment grounding conductor”
between the motor starter’s ground stud (or grounding bus)
and a suitable plant grounding bus or to earth ground. Con-
sult the local application engineer or the wiring plan draw-
lngs for Information on specific gauges.

IO-..00 TD 11-720-B
Connect cable’s shreld and dram wire here. Do not connect cable’s shield and dram wire
at this end. Use tape to Insulate.
02000’s optional
RTD Module MOTOR
BEARINGS
i /
MOTOR
WINDINGS
Motor terminals
I
Display Window
B
A
B
A
Note: Wiring between motor RTDs and
IQ-2000 must be 3-wire
shielded cable.
1 Each shielded cable’s conductors must be connected on IQ-2000 as shown
3 Use of 3-lead RTDs is recommended.
3i RTDs must not be grounded at the motor, and no common connections between RTDs should be made at the IQ-2OOt
or the motor.
4 If motor or load bearing RTDs are used, they must be the same ohmic value and material.
% During the monitoring operation, the load bearing and motor beanng temperatures are displayed in the A and 6 VALUE!
windows, as listed here. (See Monitoring, Paragraph 4.15)
Figure 3.3 - RTD Wiring (3-Lead Type)
16

TD 11-720-B IQ-IMHH)
to the correct terminals on the RTD Module. (In this case
Figure 3.4 - Two-Lead RTD Wiring
3.4 Wiring Checklist - Complete the following checks on
the field-installed wiring before applying AC power for the first
time.
OX Venfy that the field-installed wiring is exactly as shown
on the wiring plan drawings.
~ If the appltcation contains an RTD Module, verify that the
Each item contained in the checklist also has a small box at cable shields are wired to the correct terminals, as shown
its immediate left. The box is intended to be used to provide in Figure 3.3. Also verify that the shield drain wires are
verification that a specific step has been performed. Follow insulated with tape or shrink tubing so they cannot ground
these checks in sequence. nor cause shorts.
When the Ampgard isolating switch and the htgh-voltage
door are open, the step-down control transformer is ac-
cessible. Remove the plug from the receptacle to disable
the secondary circuit, as shown in Figure 3.7.
Alternately, with starter motors other than the Ampgard.
disable the secondary circuit to remove AC power to the
IQ-2000 and the low-voltage control circuit of the motor
starter.
Verify that all “foreign” external power sources are dis-
connected from the starter cabinet.
Open the access door to the low-voltage compartment.
Examine the wmng terminals of the draw-out panel. Look
for foreiqn material, pieces of wire, screws. Check screws
Verify that unused RTD Module inputs, if any, are jum-
pered out. Each set of 3 unused inputs must be jumpered.
For example, if the 2 load bearing RTDs, as shown in Fig-
ure 3.3, are not used, jumper terminals 29,30 and 31. Also
separately jumper terminals 26, 27 and 28.
Be sure that cable shields and dram wires are not con-
nected at the RTD end. They are to be cut short and in-
sulated.
r In some cases there may be factory-installed jumpers be-
tween the terminals as shown in the solid jumpers in Fig-
ure 3.6. It is necessary to determine whether or not there
should be jumpers installed. Consult the wiring plan draw-
ings to determine if any jumpers should be in place or
for tightness. removed for each application
Motor starter
Incoming(1
3-phase 0
AC supply
Grounding electrode conductor
0 Ll Tl 0
0 L2 T2 o
0 L3 T3 @
Motor starter grounding
stud or bus
= Suitable earth ground or plant ground bus
Figure 3.5 - Typical Grounding Plan (simplified)
17

IQ-2000 TD 11-720-B
Contacts from control devices such as pressure switch, E Squares indicate Westmghouse TB terminal block con
level switch, etc. nections.
Note: if the control device is a programmable controller, I? If a field device - as shown in dashed lines - is to bs
its signal must energize a control relay and its “dry con- installed, remove the associated jumpers - as shown in
tact” wired to the 02000. solid lines - during installation.
Figure 3.6 - Jumper and Field Wiring (Typical)
18