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TD03309002E
Technical Data
Page
2
Effective: January 2005
Storage, Handling,
Installation and
Maintenance of Controllers
4. For the connections between a DC
ammeter shunt and a remotely
mounted ammeter, choose a wire
size which will give the lead resis-
tance specified on the dial of the
ammeter. A remotely mounted
ammeter may have a calibrating
resistor to compensate for insuffi-
cient lead resistance. In this case
choose an oversize wire and
adjust the calibrating resistor to
obtain the correct lead resistance.
5. Before making any connections,
be certain that all leads to be han-
dled are dead. Make no connec-
tions with live conductors.
6. Make connections to power leads
last, applying proper lock-out tag-
out procedures.
7. A disconnecting means and short
circuit protection must be installed
ahead of the controller, unless
they are included as a part of the
controller.
8. With the power off, operate con-
tactors, relays and interlocks by
hand to see that they work freely.
Mechanical interlocks should pre-
vent the contacts of one contactor
from touching while the other con-
tactor is closed.
9. Turn the handles of rheostats, if
provided, throughout their travel to
see that the contact arm does not
stub in passing over the contacts.
10. See that all terminals and current
carrying joints are clean and tight.
Refer to published torque require-
ments of the controller.
11. Before starting, disconnect the
motor and check the operating
sequence of the controller. Discon-
nect power and then reconnect the
motor.
12. Close the circuit to the power sup-
ply. If a motor controller has sepa-
rate switches for the power circuit
and for the control circuit, always
close the power circuit switch first
and the control circuit switch last;
this sequence will prevent picking
up the contactors and then start-
ing the motor with the disconnect
switch.
If a DC motor has both a shunt field
and a series field, their polarities
should be the same. To check the rela-
tive polarities of these two fields, dis-
connect the shunt field and jog the
motor with the series field alone; then
reconnect the shunt field and jog the
motor again; if the motor jogs in the
same direction both times, the relative
polarities of the shunt and series fields
are correct.
If the controlled motor rotates in the
wrong direction, check its field polarity
and the power supply polarity or
phase rotation to be sure they agree
with the diagram. If so, for a DC motor
interchange the armature connections
A1 and A2. (Do not change the motor
internal connection between the brush
holder and the commutating field coil.)
For a three-phase AC motor, inter-
change any two of the power connec-
tions to the motor. For other AC
motors, refer to the instructions on the
motor nameplate.
Preventive Maintenance
Preventive maintenance should be a
program, a scheduled periodic action
that begins with the installation of the
equipment. At that time, specific man-
ufacturer’s instruction literature should
be consulted, then stored for future
reference. Follow-up maintenance
should be at regular intervals, as fre-
quently as the severity of duty justi-
fies. Time intervals of one week, or one
month, or one year may be appropri-
ate, depending on the duty. It is also
desirable to establish specific check
lists for each control, as well as a log-
book to record the history of incidents.
A supply of renewal parts should be
obtained and properly stored.
General guidelines
The whole purpose of maintaining
electrical equipment can be summa-
rized in two rules:
■
Keep those portions conducting that
are intended to be conducting.
■
Keep those portions insulated that
are intended to be insulated.
Good conduction requires clean tight
joints free of contaminates such as dirt
and oxides.
Good insulation requires the absence
of carbon tracking and the absence of
contaminants such as salt and dust
that become hydroscopic and provide
an unintended circuit between points
of opposite polarity.
WARNING
Maintenance of control components
requires that all power to these com-
ponents be turned OFF by opening and
locking open the branch circuit discon-
nect device, usually a switch or circuit
breaker located in the same enclosure
as the control components or in a
panel board or switchboard feeding
the control enclosure. Separate control
sources of power must also be discon-
nected. If control power is used during
maintenance, caution should be used
to prevent feedback of a hazardous
voltage through a control transformer.
Be alert to power factor correction
capacitors that may be charged. Dis-
charge them before working on any
part of the associated power circuit.
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