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I.B. 8926-1

MAINTENANCE OF MOTOR CONTROLLERS AFTER
A FAULT

In a motor branch circuit which has been properly in-
stalled, coordinated and in service prior to the fault, open-
ing of the branch-circuit short-circuit protective device
(fuse, circuit breaker, motor short-circuit protector, etc.)
indicates a fault condition in excess of operating over-
load.  This fault condition must be corrected and the
necessary repairs or replacements made before reener-
gizing the branch circuit.

It is recommended that the following general procedures
be observed by qualified personnel in the inspection and
repair of the motor controller involved in the fault.

Procedure.  Caution: All inspections and tests are to
be made on controllers and equipment which are
deenergized, disconnected and isolated so that ac-
cidental contact cannot be made with live parts and
so that all plant safety procedures will be observed.

Enclosure.  Substantial damage to the unit door or frame
such as deformation, displacement of parts or burning,
requires replacement of the entire unit.

Circuit breaker.  Examine the unit interior and the cir-

cuit breaker for evidence of possible damage.  If evi-
dence of damage is not apparent, the breaker may be
reset and turned ON.  If it is suspected that the circuit
breaker has opened several short-circuit faults or if signs
of circuit breaker deterioration appear within the enclo-
sure, the circuit breaker should be replaced.

Disconnect switch.  The external operating handle of
the disconnect switch must be capable of opening the
switch.  If the handle fails to open the switch or if visual
inspection after opening indicates deterioration beyond
normal wear and tear, such as overheating, contact blade
or jaw pitting, insulation breakage or charring, the switch
must be replaced.

Fuse holders.  Deterioration of fuse holders or theii in-
sulating mounts requires their replacement.

Terminals and internal conductors.  Indications ot arc-
ing damage and/or overheating such as discoloration and
melting of insulation require the replacement of dam-
aged parts.

Contactor.  Contacts showing heat damage, displace-
ment of metal, or loss of adequate wear allowance re-
quire replacement of the contacts and the contact
springs.  If deterioration extends beyond the contacts,
such as binding in the guides or evidence of insulation

CONTACTOR TROUBLESHOOTING CHART (Cont.)

Defect

Cause

Remedy

Overheating

Welding of
contacts

Ambient temperature is
too high

Line and/or cables are too
small

Excessive contact bounce
on closing

Jogging duty is too severe

Excessive inrush current

Vibration in starter mounting

Reduce load.  Privde better ventilation.  Relocate starter.  Use larger
block and run larger conductors betwee contactor and terminal block.

Correct coil overvoltage condition

Reduce jogging cycle

Motor has locked rotor code letter greater than G.  Most contactors
are designed for motors with code letters A through G.  therefore,
use larger contactor.  check factory for weld-resistant contact mate-
rial.

Move starter to location having less shock and vibration.  Insualte
starter from shcock and vibration.  Privde more rigid support for
starters

Reproduced by permission of the National Electrical Manufacturers Association from NEMA Standards Publication No. ICS
2-1978 (Rl983), Industrial Control Devices, Controllers and Assemblies, copyright 1978 by NEMA.

Summary of Contents for Freedom 2100

Page 1: ...allation and Maintenance Manual This electrical control equipment is designed to be in stalled operated and maintained by adequately trained workmen These instructions do not cover ll details vari ati...

Page 2: ...p cable entry At the bottom of each section a door 18 provides ready access to the bottom horizontal wireway 19 and neu tral bus if provided The bottom of each section is com pletely open to provide u...

Page 3: ...m of three padlocks is provided on each handle The device panel 6 is mounted on the drawout unit It will accommodate up to six pilot devices The overload reset button 20 is mounted on the unit door Fi...

Page 4: ...that the control center has been mishandled or shipped on its back or side remove the drawout units and make a complete inspection of the internal structure bus bars insulators and unit compo nents fo...

Page 5: ...out and or tagged out of service Where it is not feasi ble to de energize the system the following precau tions should be taken A Persons working near exposed parts that are or may be energized shoul...

Page 6: ...leveling each section and bolting the frames together if they are separated If necessary secure the MCC to walls or other supporting surfaces Do not depend on wooden plugs driven into holes in masonry...

Page 7: ...ith the MCC attached to one end of shipping section Refer to Figure 4 This method provides the most convenient access to the bolts and eliminates the need to remove the horizon tal bus barriers in tha...

Page 8: ...the MCC the kit is shipped with four bolts per phase an appropri ate quantities of related hardware For a single bus bar per phase the hardware is used as shown in Figure 6 for either 16 or 20 deep e...

Page 9: ...Where the MCC is supplied in a Type 3R enclosure for an outdoor application apply roof splice caps at each shipping block junction to maintain the enclosure integrity Fig 9 Quadruple Bar Splice Kits...

Page 10: ...Control Center set up for splice to Freedom Unitrol of F10 Unitrol Fig 11 Splice Plates Attached to Freedom 2100 Horizontal bus and Ground Bus at Top Fig 12 Horizontal bus Splice Freedom unitrol On Le...

Page 11: ...change the wire or lugs accordingly If crimp lugs are used crimp with the tools recommended by the manufacturer Use care in stripping insulation to avoid nicking or ring ing the metal All field wirin...

Page 12: ...and from these unit blocks along with load wiring through Size 3 to master terminal blocks located at the top o bottom of the structure See Figure 16 Master terminal blocks can be either fixed or draw...

Page 13: ...eneral rule allow the disconnect means and overcurrent protection to be located in the MCC pro vided the feeder taps from the transformer are sufficiently short and other requirements are met MAIN DIS...

Page 14: ...line connections sufficiently and tighten the lugs correctly Each incoming line compartment is equipped with a two piece spreader bar located about nine inches from the conduit entry Use this spreade...

Page 15: ...Bimetallic ambient compensated operated Trip free mechanism Electrically isolated NO NC contacts pull RESET button to test Overload trip indication Single phase protection UL listed CSA certified and...

Page 16: ...ter clockwise one setting at a time until the breaker trips in starting and then adjust upward one setting position This will insure that the circuit will open instantly on any current above the moto...

Page 17: ...the motor nameplate FLA full load amps B Tighten the heater pack mounting screws securely per r e c o m m e n d e d torque values listed below Heater Pack Numbers Recommended Torque H2001B thru H2017B...

Page 18: ...5 45 6 H2020 45 7 51 2 56 7 62 1 H2021 62 2 69 7 77 1 84 6 H2022 84 7 94 9 105 115 H2023 106 118 131 144 H2024 A B C D MAXIMUM RATINGS NEMA SIZE AMPERES SIZE AMPERS 0 18 1 27 F 32 Use 75 C copper con...

Page 19: ...47 H2008B A B C D FLA rating marked on heater pack multiplied by a transfomation ratio For motor FLA values not listed turn the dial clockwise for higher or counterclockwise for lower ratings Magnetic...

Page 20: ...s prior to energizing 9 Manually exercise all switches circuit breakers and other operating mechanisms to make certain that they are properly aligned and operate freely 10 Test any ground fault protec...

Page 21: ...allation unscrew prior to unit withdrawal Pull apart terminal blocks in the vertical wireway must be disengaged see Figure 27 and page 10 and wiring from the unit to other units to master terminal blo...

Page 22: ...When the unit is withdrawn free of the linkage a spring automatically moves the shutter to its closed po sition See Figure 31 and Figure 4 With the control unit removed the shutter should com pletely...

Page 23: ...lank door 2 Position the new unit door over the open space to ensure the hinges and latches are aligned If the spaces differ the hinges and latches on the struc ture must be re located to match the un...

Page 24: ...trical equipment refer to the applicable drawings covering the specific motor control center MCC and any other related inter connection drawings Follow any instructions which may be given for each dev...

Page 25: ...est ter minated with a crimp type lug that is attached to the con trol component When screw type lugs marked CU AL are used with aluminum wire joint should be checked for tightness every 200 operation...

Page 26: ...Page 26 I B 8926 1...

Page 27: ...as follows A Place a 020 inch feeler gauge between the arma ture and magnet with the armature held tightly against the magnet B Check continually in each phase i e determine if circuit from terminal t...

Page 28: ...ig 39 Normal Service Wear Fig 40 End of Service Life ABNORMAL WEAR CONDITIONS Contact Appearance Cause Curling and Separation Curling is usually a result of service that produces very high heat of Cor...

Page 29: ...pen the switch or if visual inspection after opening indicates deterioration beyond normal wear and tear such as overheating contact blade or jaw pitting insulation breakage or charring the switch mus...

Page 30: ...to service Before returning the controller to service checks must be made for the tightness of elec trical connections and for the absence of short circuits grounds and leakage All equipment enclosur...

Page 31: ...rsing F204 F206 F207 Full Voltage Reversing F214 F216 F217 Reduced Voltage Autotransformer Type F604 F606 F607 Reduced Voltage Part Winding Type F704 F706 F707 Reduced Voltage Closed Transition Star D...

Page 32: ...Page 32 I B 8926 1 Part 11 PLAN VIEWS...

Page 33: ...Page 33 I B 8926 1...

Page 34: ...s Size 5 non reversing and reversing vacuum I L 16999 Size 6 non reversing and reversing vacuum I L 17088 Metering IQ Data Plus TD 17195 Circuit Breakers Series C F frame I L 29ClOl Series C J frame I...

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