81000_303_med

Power Transmission & Distribution

Series 81000 ControllerWith Drawout 96H3 or 97H3 Vacuum Contactors 2300, 4000, or 6600 Volts AC (Utilization Voltage) 2400, 4160, or 6900 Volts AC (Distribution Voltage)

InstructionInstallationOperationMaintenanceE50001-U229-A303-X-US00

Hazardous voltages and high-speed moving parts.

Will cause death, serious injury or property damage.

Always de-energize and ground the equipment beforemaintenance. Read and understand this instruction manualbefore using equipment. Maintenance should be performedonly by qualified personnel. The use of unauthorized parts inthe repair of the equipment or tampering by unqualifiedpersonnel will result in dangerous conditions which will causedeath, severe injury or equipment damage. Follow all safetyinstructions contained herein.

IMPORTANT

The information contained herein is general in nature and not intended for specific

application purposes. It does not relieve the user of responsibility to use sound practices in

application, installation, operation, and maintenance of the equipment purchased. Siemens

reserves the right to make changes in the specifications shown herein or to make

improvements at any time without notice or obligations. Should a conflict arise between the

general information contained in this publication and the contents of drawings or

supplementary material or both, the latter shall take precedence.

QUALIFIED PERSON

For the purpose of this manual and product labels, a qualified person is one who is familiar

with the installation, construction, operation, or maintenance of the equipment and the

hazards involved. In addition, this person has the following qualifications:

(a) is trained and authorized to energize, de-energize, clear, ground, and tag circuits

and equipment in accordance with established safety procedures.

(b) is trained in the proper care and use of protective equipment such as rubber

gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance

with established safety practices.

(c) is trained in rendering first aid.

GENERAL

These instructions do not purport to cover all details or variations in equipment, nor toprovide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particularproblems arise which are not covered sufficiently for the purchasers purposes, the mattershould be referred to the local Siemens sales office.

The contents of this instruction manual shall not become part of or modify any prior orexisting agreement, commitment or relationship. The sales contract contains the entireobligation of Siemens Power Transmission & Distribution, Inc. The warranty contained in thecontract between the parties is the sole warranty of Siemens Power Transmission &Distribution, Inc. Any statements contained herein do not create new warranties or modifythe existing warranty.

1Introduction and Safety . . . . . . . . . . . . . . . . . . . . . . . . 2Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Qualified Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Dangerous Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 2Field Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Description . . . . . . . . . . . . . . . . . . . . . . . . . 3-22General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Basic Impulse Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Dielectric (Power Frequency Withstand) Test . . . . . . . . . 4Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Medium-Voltage Contactors . . . . . . . . . . . . . . . . . . . . . . 4Surge Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Isolation and Automatic Shutter Mechanisms . . . . . . . . 5Racking Mechanism and Mechanical Interlocks . . . . . . . 8Medium-Voltage Compartment Door Interlock . . . . . . . 9Contactor Interlock (Handle-Operated Racking) . . . . . . 9Contactor Interlock (Screw-Type Racking) . . . . . . . . . . 10Racking Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Test Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Mechanical Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Detent Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Contactor Engagement Warning Light . . . . . . . . . . . . . 11Line Switch Interlock (LSI) . . . . . . . . . . . . . . . . . . . . . . 11Racking Switch Interlock (RSI) . . . . . . . . . . . . . . . . . . . 11Power Fuses (Current-Limiting) . . . . . . . . . . . . . . . . . . 15Use of 96H3 or 97H3 Contactor

in Other Cell Types . . . . . . . . . . . . . . . . . . . . . . . . . 15

Receiving, Handling and Storage . . . . . . . . . . . . . 23-24Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Skid Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Contactor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-33Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . 25Site Preparation and Mounting . . . . . . . . . . . . . . . . . . 25General Pre-Installation Inspection . . . . . . . . . . . . . . . 25Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 25Contactor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 27Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . 27Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Power Cable Termination . . . . . . . . . . . . . . . . . . . . . . . 33Series 81000 Controllers . . . . . . . . . . . . . . . . . . . . . . . 33Termination of Lead-Covered Cables . . . . . . . . . . . . . . 33Termination of Shielded Cables . . . . . . . . . . . . . . . . . . 33

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36Pre-Energization Check . . . . . . . . . . . . . . . . . . . . . . . . . 34Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Energizing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-47Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Recommended Maintenance and Lubrication . . . . . . . 37Mechanical and Electrical Operation of the

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-38Vacuum Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Shutter Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Racking Mechanism Adjustment . . . . . . . . . . . . . . . 38-39Adjustments for Controllers With

Handle-Operated Racking . . . . . . . . . . . . . . . . . . . 40Adjustments for Controllers With

Screw-Operated Racking . . . . . . . . . . . . . . . . . . . . 41Mechanical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . 42Electrical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Electrical Joints and Terminals . . . . . . . . . . . . . . . . 42-43Periodic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Overload Relay Checks . . . . . . . . . . . . . . . . . . . . . . . . . 43Recommended Torque . . . . . . . . . . . . . . . . . . . . . . . . . 43

Maintenance After a Fault has Occurred . . . . . . . . . 44Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Terminals and Internal Conductors . . . . . . . . . . . . . . . 44Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Overload Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Fuse Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Contents

2Introduction and Safety

Introduction

The Series 81000 family of Medium-VoltageController equipment is designed to meet all theapplicable NEMA standards. Successful applicationand operation of this equipment depends as muchupon proper installation and maintenance by the user as it does upon the careful design andfabrication by Siemens.

The purpose of this instruction manual is to assist theuser in developing safe and efficient procedures for theinstallation, maintenance and use of the equipment.

Contact the nearest Siemens representative if anyadditional information is desired.

Qualified Person

For the purpose of this manual a Qualified Person is onewho is familiar with the installation, construction oroperation of the equipment and the hazards involved. In addition, this person has the following qualifications:

Training and authorization to energize, de-energize, clear, ground and tag circuits and equipment in accordance with establishedsafety practices.

Training in the proper care and use of protectiveequipment such as rubber gloves, hard hat, safetyglasses, face shields, flash clothing, etc., inaccordance with established safety procedures.

Training in rendering first aid.

Signal Words

The signal words Danger, Warning and Cautionused in this manual indicate the degree of hazard thatmay be encountered by the user. These words aredefined as:

Danger - Indicates an imminently hazardoussituation which, if not avoided, will result in death or serious injury.

Warning - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Caution - indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Dangerous Procedures

In addition to other procedures described in thismanual as dangerous, user personnel must adhere tothe following:

1. Always work only on de-energized equipment.Always de-energize a contactor, and remove it from the equipment before performing any tests,maintenance or repair.

2. Always let an interlock device or safety mechanismperform its function without forcing or defeatingthe device.

Field Service Operation

Siemens can provide competent, well-trained FieldService Representatives to provide technical guidanceand advisory assistance for the installation, overhaul,repair and maintenance of Siemens equipment,processes and systems. Contact regional servicecenters, sales offices or the factory for details, ortelephone Siemens Field Services at 1-800-347-6659 (919-365-2200 outside the U.S.)

For medium-voltage customer service issues, contactSiemens at 1-800-347-6659 (919-365-2200 outsidethe U.S.).

Hazardous voltages


Always de-energize and ground theequipment before maintenance. Installation,operation, or maintenance should beperformed only by qualified personsthoroughly familiar with the equipment,instruction manuals, and drawings. Read andunderstand this instruction manual beforeusing the equipment.

3General Description

The medium-voltage compartment also houses thecurrent transformers and the contactor.

In order to open the medium-voltage unit door, thedrawout contactor or fuse carriage must be de-energizedand completely racked-out, and the door unlatched. Low-voltage compartment doors may be opened withoutdisconnecting the power, but this must be done withextreme care and caution.

The electrical power is distributed through the optionalmain horizontal bus which extends the entire length ofthe controller. The bus may be mounted in the rear ofthe upper compartment or inside a 10 inches(254mm) high top hat (2000A maximum) and 13inches (330mm) (3000A). See Figure 2.

Each vertical section containing provisions for drawoutcontactors is fed by cables or a vertical bus system,which is connected to the horizontal bus. The cables orvertical bus system in turn supply power through thestab assembly mounted on the cell module.

The horizontal and vertical bus or cable system isisolated from the front by means of barriers.

Figure 1. Typical Construction

( ) Dimensions in Millimeters*103.0 (2616mm) with 3000A bus.

90.0(2286)

100.0*(2540)

LV

LV

LV LV LV

LV LV

LV

LV

LV LV

SPACE

MV

MV

MVMV

1-High 5kV 1-High 7.2kV 2-High 5kV 3-High 5kV

MV MV

MV

MV

LV

36.0(914.4)

General

The Siemens Series 81000 controller is an integratedsystem of contactors and components arranged forconvenient access within a common enclosure consistingof one or more free-standing structural sections. Eachsection is normally 36 inches (914mm) wide, 36 inches(914mm) deep and 90 inches (2286mm) high (100inches (2540mm) high with the top mounted main busup to 2000A and 103 inches (2616mm) high with3000A main bus). Refer to Figure 1.

The Series 81000 controller is a modular design whichcan be arranged to meet specific customer specificationsand needs. Each section is designed to accept up to threestarters with one low-voltage control panel for eachstarter. The unit height may be either 30 (762mm), 45(1143mm) or 60 inches (1524mm).

The upper units of 1-high and 2-high controllers maycontain a low-voltage panel or space for future starters.

In general, each starter unit is divided into medium-voltage and low-voltage compartments, each with itsown separate door and interior barriers between thetwo. The medium-voltage compartment contains thedrawout carriage power cell module upon which theshutter mechanism, racking mechanism, line and loadconnections, mechanical and electrical interlocks aremounted. The cell module can be either 29.88 inches(759mm) (upper or middle cells) or 33.50 inches(851mm) (lower cell) deep.


Basic Impulse Level

All Series 81000 controllers have a basic impulse levelof 60kV peak, excluding control transformers, startingreactors and autotransformers.

Dielectric (Power Frequency Withstand) Test

All controllers are factory tested at 2.25 x nameplatevoltage plus 2000 volts, for one minute.

Ratings

The Series 81000 controllers are rated in accordancewith Table 1, and as shown on the nameplate on frontof the enclosure.

Medium-Voltage Contactors

Siemens Types 96H35 or 97H35 (5kV) and Types 96H37or 97H37 (7.2kV) contactors are used in Series 81000controllers. The 96H35 or 97H35 contactors can accept5kV power fuses rated 2R through 24R. The 96H37 or97H37 contactors can accept 7.2kV fuses rated 2Rthrough 24R.

Type 96H35 or 97H35 contactors with single or doublebarrel fuses can be installed in any compartment ofone, two and three-high 5kV controllers. Type 96H37 or97H37 contactors can only be installed in one-high7.2kV controllers, or in two-high controllers with 45inches (1143mm) high compartments.

Auxiliary Contacts: Each contactor is equipped with2 N.O. and 2 N.C. auxiliary contacts for customeruse. These contacts are rated 600V, 10A (NEMAClass A600).

Surge Protection

The 96H3, 97H3, and 96H6 vacuum contactors aresuitable for application without protection from surgesrelated to switching with vacuum, except for joggingor inching duty with small (under 100HP) motors. Forsuch applications, metal-oxide surge arresters or surgelimiters should be specified.

Regardless of the switching means employed, if theinsulation integrity of the motor is suspect, such as forvery old machines, it may be desirable to add surgeprotection for the machine, or to consider upgradingthe machine to modern insulation standards.

Figure 2. Alternate Bus Locations (Side View)

Table 1. 96H3 or 97H3 Contactor Ratings

Table 2. Maximum Motor Fuse and Transformer Fuse Rating

Horizontal Bus

( ) Dimensions in Millimeters*13.0 (330) with 3000A bus

Horizontal Bus

Ground Bus

90.0(2286)

10.0*(254)

Fro

nt

Fro

nt

Ground Bus

FusedContactor

Type

3 Phase Horsepower Rating at Utilization Voltage Transformer Loads

2300V 4000V 4600V 6600VMax.

MotorFuse

Rating

Maximum 3-Phase kVA atDistribution Voltage

Max.Transf.FuseRate

Syn.Motors

Syn.Motors Ind.

Motors

Syn.Motors

Syn.Motors Ind.

Motors

Syn.Motors

Syn.Motors Ind.

Motors0.8PF 1.0PF 0.8PF 1.0PF 0.8PF 1.0PF 2400V 4160V 4800V 6900V

96H3597H35

1500 1750 1500 2500 3000 2500 24R 1500 2500 2500 450E

96H3797H37

4000 5000 4000 24R 1500 200E

ContactorType

Max.VoltageRating

EnclosedCont.

AmpereRating

Interrupting Capacity ImpulseLevel(BIL)(kV)

UnfusedClass E1

Controller(kA)

Fused ClassE2

Controller(MVA)

96H3597H35

5.0 360 [email protected]@[email protected]

60

96H3797H37

7.2 360 4.2 [email protected] 60


Isolation and Automatic Shutter Mechanisms (Handle-Operated Racking)

Non-load break finger type stab assemblies provide themeans for manual isolation of the power circuit, inaccordance with NEMA requirements.

The shutter mechanism operation is directlycontrolled by the position of the racking mechanism,and the movable insulated shutter is linked to theracking cams, Figure 3.

As the handle of the racking mechanism is movedtowards the ON position, the insulated shutter uncoversthe line stab assembly just prior to engagement of thecontactor line and load stab fingers, Figure 4.

In the reverse operation, when the handle is movedtowards the OFF position, the insulated shutter coversthe line stab assembly, thus effectively isolating the lineside high voltage parts, Figure 5.

Labels on the stationary shutter clearly indicate if theisolating means is OPENED (disengaged, i.e., drawoutcarriage disengaged from line stabs, and shutter coveringline stabs).

Isolation and Automatic Shutter Mechanism (Screw-Type Racking) (97H3 and 96H6 only)

The automatic shutter system of controllers equippedwith the Screw-Type Racking Mechanism operates asdescribed in the section Isolation and Automatic ShutterMechanism (Handle-Operated Racking). The racking camis actuated by the racking screw assembly. The shutter isopened and closed as described in the section for Handle-Operated Racking. The racking handle is replaced by thecontactor position indicator. Refer to Figure 6a.

Figure 4. Line Shutter in ON Position (Line StabsExposed) (Note: Line Shutter Shown Blocked Open ForPhoto Purposes Only.)

Figure 5. Line Shutter in OFF Position (Line Stabs Hidden)Figure 3. Shutter Mechanism

Movable Insulated ShutterShown With Racking Handlein OFF Position, and WithShutter Covering Line Stab.

Links toRackingCam


Figure 6. Cell Module (Handle-Operated Racking)

L.H.VerticalSupport

StationaryStab Insulators

ShutterConnectingLinks

RackingCams

Line SwitchInterlockStationaryTerminal (LSI)

RackingShaft

ConnectingRod (Long)

Cam

EnclosureFrame

MechanicalLatch

GuidePlate

SupportPlate

Clevis

Locking Nut

Connecting Rod(Short)

Locking Nut

Clevis

DriverLink

HandleShaft

Handle

HandleHousing

DoorInterlockLever

TensionSpring

Stationary Power Stabs (3)(Load Side)

Stationary Power Stabs (3)(Line Side)

ShutterRetainingStrips

R.H.VerticalSupportInsulating

Sheet

MovableShutter

StationaryShutter

For Interlocks See Detail A (97H3) or B (96H3)

RackingSwitchInterlock(RSI)

Interlock

Detail A - 97H3 Detail B - 96H3

InterlockCable


Figure 6a. Cell Module 97H3 (Screw-Type Racking)Note: Shutter, Stationary Terminal LSI Switch and RSI Switch not shown.

Insulating Sheet

Stationary Stab Insulator

L.H. VerticalSupport

R.H. VerticalSupport

Connecting Rodswith Clevis andLocking Nuts

RackingShaft

RackingCams

Enclosure Frame

Contactor Interlock

Set Screw Door Interlock

Housing

ContactorPositionIndicator

MountingBracket

PadlockProvision

Safety Limit SwitchRacking Screw Assembly

Guide Plate


Racking Mechanism and Mechanical Interlocks (Handle-Operated Racking) (Refer to Figure 6)

Racking of drawout contactors or fuse carriages isaccomplished using a compound four-bar mechanismoperated by an external, enclosure mounted handle.The handle can be locked with up to three padlocks inthe OFF position.

Mechanical and electrical interlocks are incorporated inthe racking mechanism as described on page 9.

Racking Mechanism (Screw-Type Racking)(Refer to Figure 6a)

The Series 81000 controller (97H3 and 96H6 only) canbe equipped with an optional Screw-Type RackingMechanism, which can be operated electrically with anelectrical racking operator accessory (refer to Figure 6b)or manually with a racking crank accessory (refer toFigure 6c).

The electrical racking operator accessory consists of amotor drive enclosure which installs on a mountingbracket on the enclosure frame. The unit includes apower cord, which can be connected to a convenientpower source in the vicinity of the controller.

Figure 6b. Electrical Racking Operator Figure 6c. Racking Crank

Instructions for mounting the electrical rackingoperator accessory and for racking the drawoutcarriages are provided on a label on the electricalracking operator accessory.

The racking handle for manual racking is replaced by acontactor position indicator. The racking mechanism andinterlocks are modified as described below.

Racking Mechanism and Mechanical Interlocks (Screw-Type Racking)

Racking of drawout contactors 97H3 or drawout fusecarriages for 96H6 controllers is accomplished byoperating a racking screw with an electric racking motoror racking crank. The access to the racking screw can beblocked by up to three padlocks. Mechanical andelectrical interlocks are incorporated in the rackingmechanism to perform the following functions.

General Description

9

Hazardous voltages.

Will cause death, serious injury, orproperty damage.

The door-handle interlock should be defeatedonly in the event of a malfunction in theracking mechanism.

Disconnect, ground, and lockout all powerbefore attempting to defeat interlock.

Never defeat this interlock if the redcontactor engagement light is on.

The defeater can be reached by removing a plastic capfrom the lower part of the handle housing, then byremoving the Allen-head set screw. The racking handlemust be rotated approximately 23 degrees from the fullyupward (ON) position of the handle in order to align theAllen-head set screw with the access opening. When theAllen-head set screw is removed, the handle can then bemoved to the OFF position allowing the door to beopened. Refer to Figure 8.

After the malfunction has been corrected, the controllershould be restored to normal operation by reversing theprocedure used to defeat the interlock.

Medium-Voltage Compartment Door Interlock (Screw-Type Racking)

The access hole to the racking screw is interlocked withthe door such that the electrical racking operatoraccessory or the racking crank cannot be connected to the racking screw while the door is open. Theinterlock is essentially similar to that shown in Figure 7.

The contactor position indicator prohibits closing andopening of the medium-voltage compartment doorexcept when the drawout contactor is in thedisconnected position (position indicator is in Dposition). The flat profile on the end of the contactorposition indicator will not allow the door interlock topass in or out unless the position indicator is in the Dposition similar to the door interlock for Handle-Operated Racking. Refer to Figures 12a and 12b.

The door interlock can be defeated similar to equipmentwith the Handle-Operated Racking system. Follow theinstructions in section Medium-Voltage CompartmentDoor Interlock (Handle-Operated Racking). Remove theAllen-head set screw as described and rotate thecontactor position indicator to defeat the door interlock.

Contactor Interlock (Handle-Operated Racking)

To prevent accidental insertion or withdrawal of thecontactor when it is closed, an interlock lever moves toengage notches in the cam when the contactor is closed,thus preventing motion of the racking mechanism. Theinterlock used with type 97H3 contactors is directlyactuated, and is illustrated in Figures 11a and 11b. Thetype 96H contactors employ a cable actuated interlock,shown in Figures 13a and 13b.

Figure 7. Door Interlock and Door-Handle Interlock (Handle-Operated Racking)

Medium-Voltage Compartment Door Interlock (Handle-Operated Racking)

The racking handle is interlocked with the door such thatthe handle cannot be moved to the ON position whilethe door is open. Refer to Figure 7.

The door-handle interlock (item 2 in Figure 7) prohibitsclosing or opening of the medium-voltage compartmentdoor except when the handle is in the OFF position. Theflat profile on the end of the handle shaft will not allowthe door-handle interlock to pass in or out unless thehandle is in the OFF position. Refer to Figure 7.

The interlock may be defeated only by authorized andqualified personnel. Do not attempt to defeat theinterlock unless all incoming power is disconnected,grounded, and locked-out.

Door InterlockLever (1)

Door Interlock

Door HandleInterlock (2)

Handle Shaft

Flat Profile

Handle

Hazardous voltages.


The door-handle interlock should be defeatedonly in the event of a malfunction in theracking mechanism.

Disconnect, ground, and lockout all powerbefore attempting to defeat interlock.

Never defeat this interlock if the redcontactor engagement light is on.

10

General Description

Figure 8. Procedure for Defeating the Door-Handle Interlock

Step 1: Remove plastic capfrom the handle housing.

Step 3: Rotate handle to fullydownward (OFF) position toallow door to be opened.

Step 2: Rotate handleapproximately 23 from thefully upward (ON) position, toalign the Allen-head set screwwith the access opening.Remove Allen-head set screw.

Contactor Interlock (Screw-Type Racking)

To prevent accidental insertion or withdrawal of thecontactor when it is closed, an interlock lever blocksaccess to the racking screw preventing connecting theelectric racking operator or the racking crank to theracking screw. The interlock is directly actuated. Referto Figure 12a.

There is also a safety limit switch installed such thatthe limit switch is activated and the NC (normallyclosed) contact is open prohibiting contactor closingwhen the electrical racking accessory or the rackingcrank is in place. Refer to Figure 12a.

Racking Crank (for Screw-Type Racking System)

The racking crank can be used to manually rack thedrawout contactor or drawout fuse carriage. Theracking crank consists of an offset handle with acustom socket assembly welded to the opposite end.The socket end of the crank is designed to engage thehex shoulder of the racking screw. To remove thecrank, simply pull the assembly off the racking screw.

Racking may only be performed with the contactorcompartment door closed and the vacuumcontactor open.

Insert the racking crank in the panel access hole toengage the racking screw. Rotate the racking crankclockwise until the contactor is in connected position(position indicator is in C position).

Rotate the racking crank counterclockwise until thecontactor is in disconnected position (positionindicator is in D position). The compartment door cannow be opened and the contactor can be removedfrom the cubicle.

11

General Description

Test Switch

A test switch is provided to switch from run to testmode. The switch is located on the back side of thedoor, mounted on the low voltage compartment. SeeFigure 9. With the contactor racked out and the dooropened, the test mode can be selected by rotating theswitch to the test mode. With the switch in the testmode, the contactor can be electrically operated in itsracked out position. Once the test has been completed,the contactor can be placed in operation by switchingto the run mode, closing the door and racking in thecontactor by operating the racking handle.

Mechanical Latch

The mechanical latch is mounted on the left hand sideof the guide plate and serves to locate and hold thecontactor in the disengaged (test) position. Thecontactor is released by manually pivoting the latchassembly upward and rolling the contactor out of the enclosure.

Detent Lever

This lever is provided to prohibit relative motionbetween stab fingers and stab assembly. Slight initialforce is required on the handle when moving it fromthe ON to the OFF position to free the driver link pinfrom the retaining slot in the detent lever. Refer to Figure 11a and 11b (for type 97H3) orFigures 13a and 13b (for type 96H).

Contactor Engagement Warning Light

A red warning light, mounted above the handlehousing is energized only when the contactor is fullyengaged (connected to the line and load stabs), andincoming power is present, independent of thecondition (open or closed) of the contactor or thedoor. When the handle is moved to the OFF position,the red warning light should always go out, indicatingthe contactor is fully disengaged and isolated from thestab assembly. Refer to Figure 10.

If the handle is moved to OFF and the red light stays on,the racking mechanism is not operating properly andthe contactor is engaged. Do not attempt to open thehigh voltage door. Disconnect and lockout all incomingpower and refer to the Troubleshooting section.

Line Switch Interlock (LSI)

All control power derived from the secondary of thecontrol power transformer is carried from thecontactor to the low voltage control panel through aset of contact fingers mounted on the rear of thecontactor. Refer to Figure 6.

These contact fingers, along with the mating contactblock, which is stationary-mounted on the guideplate, make up the Line Switch Interlock (LSI).

The function of this interlock is to disconnect the loadfrom the CPT secondary prior to disengagement of themain power stabs as the contactor is racked out.

Racking Switch Interlock (RSI)

The Racking Switch Interlock (RSI) is a microswitchmounted on the guide plate which functions toprevent operation of the contactor on the test powerwhen it is in the engaged (ON) position. As theracking handle is moved from OFF to ON the normallyclosed RSI contact opens and isolates the test sourcefrom the control circuit. Refer to Figure 6.

ON

OFF

Figure 9. Run-Test Switch

Figure 10. Contactor Engagement Warning Light(Handle-Operated Racking Shown)

Hazardous voltages.


Do not attempt to open the high voltage doorif the red contactor engagement light is on.

Red ContactorEngagementWarning Light

12

General Description

Figure 11a. 97H3 Racking Mechanism Handle in ON Position (Handle-Operated Racking, Directly Actuated Interlock)

Figure 11b. 97H3 Racking Mechanism Handle in OFF Position (Handle-Operated Racking, Directly Actuated Interlock)

Contactor in Disconnected (OFF) PositionContactor Closed Using Test Power

Contactor in Connected (ON) PositionContactor Open

ContactorInterlockLever


DoorInterlockLever

DoorInterlockLever

DetentLever

DetentLever

DriverLink

DriverLink

ShortConnectingRod

ShortConnectingRod

HandleON

OFF

Handle

ON

OFF

DriveLink

DriveLink

Connecting Rod

Connecting Rod

Cam

Cam

21.5(546mm)

Contactor in Connected (ON) Position

Contactor Open

Contactor in Disengaged (OFF) Position

Contactor Closed Using Test Power

13

General Description

Figure 12a. Cell Module 97H3 (Screw-Type Racking)

Figure 12b. Cell Module 97H3 (Screw-Type Racking)

Drawout Carriage in Connected (C) Position

Contactor Closed

Compartment Door Closed

Contactor in Disengaged (D) Position

Contactor Open

Compartment Door Open

Door InterlockLever

ContactorInterlock Lever

Safety LimitSwitch

Safety LimitSwitch Lever

Contactor Interlock Flapin Lower Position(Racking Access Blocked)

Door Interlock Flap inUpper Position (RackingAccess Not Blocked)

Door Interlock Flap inLower Position (RackingAccess Blocked)

Contactor InterlockFlap in UpperPosition (RackingAccess Not Blocked)

Link

Link

Connecting RodContactor Interlock

Indicator inConnected (C)Position

Indicator inDisconnected (D)Position

14

General Description

Figure 13a. 96H Racking Mechanism Handle in ON Position (Handle-Operated Racking, Cable Actuated Interlock)

Figure 13b. 96H Racking Mechanism Handle in OFF Position (Handle-Operated Racking, Cable Actuated Interlock)

Contactor in Engaged (ON) Position

Contactor Open

Contactor in Disconnected (OFF) Position

Contactor Closed Using Test Power

InterlockCable

DriveLink


DoorInterlockLever

DetentLever

DriverLink

HandleON

OFF

ConnectingRod

ShortConnectingRod

Cam

InterlockCable

DriveLink


DoorInterlockLever

DetentLever

DriverLink

Handle

ON

OFF

ConnectingRod

ShortConnectingRod

Cam

21.5

15

General Description

Power Fuses (Current-Limiting)

ANSI R rated fuses Type FM are used for motor startingduty in 5kV Class E2 controllers. ANSI R rated fuses Type A720R are used for motor starting duty in 7.2kVClass E2 controllers. ANSI E rated fuses are used formost other applications.

Time-current characteristics curves and other fuseapplication information is shown in Table 3 and Figures 14a-18.

Use of 96H3 or 97H3 Contactor in Other Cell Types

The types 96H3 and 97H3 contactors differ in themanner in which the interlocks are constructed andoperate. Therefore, 96H3 and 97H3 contactors are notinterchangeable with each other. Similarly, thesecontactors are not directly interchangeable with theearlier 90H3 contactors. Modifications necessary to allowuse of a 96H3 or a 97H3 contactor in a 90H3, 93H3, or94H3 cell are summarized in Table 4.

93H3 and 96H3 contactors are directly interchangeable.

94H3 and 97H3 contactors are directly interchangeable.Table 3. Power Fuses

Maximum DesignVoltage

Catalog Number Current DesignationContinuous Current

@ 40CMinimum Interrupting

RatingInterrupting Rating

50/60Hz

5080

48FM2R-4G 2R (1 Barrel) 70 190

Single Phase80kA rms

Asymmetrical

(210MVA @ 2.4kV)(415MVA @ 4.8kV)

48FM3R-4G 3R 100 225

48FM4R-4G 4R 130 330

48FM6R-4G 6R 170 500

48FM9R-4G 9R 200 740

48FM12R-4G 12R 230 955

48FM18R-5G 18R (2 Barrel) 390 1440

48FM24R-5G 24R 450 1910

7200

A072F1D0R0-2R 2R (1 Barrel) 70 190

Single Phase80kA rms

Asymmetrical

(620MVA @ 7.2kV)

A072F1D0R0-3R 3R 100 225

A072F1D0R0-4R 4R 130 330

A072F1D0R0-6R 6R 170 500

A072F1D0R0-9R 9R 200 740

A072F1D0R0-12R 12R 230 955

A072B2DAR0-18R 18R (2 Barrel) 390 1440

A072B2DAR0-24R 24R 450 1910

Contactor Type

93H3 or 96H3 94H3 or 97H3

Power Cell(Compartment)

Type

90H3

Cell modification kit 25-213-200-501 required.Mount per 25-154-488-424. Kit includes newinterlock spring and replacement mechanicallatch. Modified cell will allow use of either90H3, 93H3 or 96H3 contactor.

Cell modification kit 25-154-555-805 required.Mount per 25-213-213-405. Kit includesreplacement interlock parts. Modified cell willno longer allow use of 90H3 contactor.

93H3 or 96H3

Cell modification kit 25-154-555-804 required.Mount per 25-213-213-404. Kit includesreplacement interlock parts. Modified cell willno longer allow use of 93H3 contactor.

94H3 or 97H3

Modification of contactor required. Removecable interlock assembly from 93H3 or 96H3contactor, and replace with interlock toconvert to 94H3/97H3 configuration. Cellinterlock modification also required. Usemodification kit 25-154-555-811, whichincludes parts needed for contactor as well asfor cell. Mount per 25-213-213-411.

Table 4. Modification Matrix for Use of 96H3/97H3 Contactor in 90H3/93H3/94H3/96H3/97H3 Cells

16

General Description

100

200

300

400

500

600

800

1000900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01 100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01

CURRENT IN AMPERES x 10

TIM

E IN

SEC

ON

DS

TIME IN

SECO

ND

S


6R

9R

24R

18R

12R

4R

3R

2R

283121

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 109 20

30 40 50 60

70 80 90

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 109 20

30 40 50 60

70

80

90

Figure 14a. Time-Current Characteristic Curves (Total Clearing Times)Type FM Current Limiting Fuses 2400 & 4800 Volts (2R-24R)

Current Characteristic Curves

Total Clearing Times

Type FM Current Limiting Fuses

2400 & 4800 Volts (2R-24R)

These fuses are designed to interrupt short circuitcurrents greater than or equal to that shown at the100 second minimum melting time.

Protective devices in series must be coordinated withfuse characteristics to interrupt lower currents.

17

100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000

900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01 100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01


TIM

E IN

SEC

ON

DS

TIME IN

SECO

ND

S


103814

5R

9R

24R

18R

12R

4R

3R

2R

6R

103814

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 109

20

30

40 50 60

70 80

90

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8

109 20 30 40 50 60

70 80 90

Figure 14b. Time-Current Characteristic Curves (Total Clearing Times)Type A720R Current Limiting Fuses 7200 Volts (2R-24R)

General Description


Total Clearing Times

Type A720R Current Limiting Fuses

7200 Volts (2R-24R)



General Description

18

100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000

900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01 100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01


TIM

E IN

SEC

ON

DS

TIME IN

SECO

ND

S


280121

6R

9R

24R

18R

12R

4R

3R

2R

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 109

20 30 40 50 60

70 80

90

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 109

20 30

40 50

60 70 80

90

Figure 15a. Time-Current Characteristic Curves (Minimum MeltingTimes) Type FM Current Limiting Fuses 2400 & 4800 Volts (2R-24R)


Minimum Melting Times

Type FM Current Limiting Fuses

2400 & 4800 Volts (2R-24R)



19

General Description

100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000

900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01

100

200

300

400

500

600

800

1000

900

700

2000

3000

4000

5000

6000

7000

8000

900010000

1000900

800

700

600

500

400

300

200

100

90

80

70

60

50

40

30

20

10

9

8

7

6

5

4

3

2

1

.9

.8

.7

.6

.5

.4

.3

.2

.1

.09

.08

.07

.06

.05

.04

.03

.02

.01


TIM

E IN

SEC

ON

DS

TIME IN

SECO

ND

S


5R

9R

24R

18R

12R

4R

3R

2R

6R

103813

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 109

20 30 40 50

60

70 80 90

.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8

109 20 30

40 50 60

70

80 90

Figure 15b. Time-Current Characteristic Curves (Minimum MeltingTimes) Type A720R Current Limiting Fuses 7200 Volts (2R-24R)


Minimum Melting Times

Type A720R Current Limiting Fuses

7200 Volts (2R-24R)



20

General Description

Figure 16. Fuse Selection Guide

Fuse selection guide for type FM and A720R fuses for series 81000controller with type 3UA overload relay (NEMA Class 10).

Based on maximum motor accelerating time of 10 seconds.

Mo

tor

Full

Load

Cu

rren

t x

Serv

ice

Fact

or

- A

mp

eres

Motor Locked Rotor Current - Amperes

100

0

50

100

150

200

250

300

350

400

24R

18R

12R

9R6R

4R

3R

2R

150 200 300 400 500 600 700 800 9001000 1500 2000 3000

21

General Description

10000090000

80000

70000

60000

50000

40000

30000

20000

100009000

8000

7000

6000

5000

4000

3000

2000

1000

103815

24R18R12R9R6R5R4R3R2R

10000090000

80000

70000

60000

50000

40000

30000

20000

100009000

8000

7000

6000

5000

4000

3000

2000

1000

1000

0090

000

8000

0

7000

0

6000

0

5000

0

4000

0

3000

0

2000

0

1000

0

9000

8000

7000

6000

5000

4000

3000

2000

1000

900

800

700

600

500

400

300

200

100

AVAILABLE CURRENT IN RMS SYMMETRICAL AMPERES

24R18R

9R6R4R3R2R

12R

MAXIM

UM PE

AK CU

RREN

T

CIRCU

IT CAN

PROD

UCE -

2.6 x R

MS SY

M. AM

PS

1000

00

9000

0

8000

0

7000

0

6000

0

5000

0

4000

0

3000

0

2000

0

1000

0

9000

8000

7000

6000

5000

4000

3000

2000

100090

0

800

700

600

500

400

300

200

100

AVAILABLE CURRENT IN RMS SYMMETRICAL AMPERES

MAXIM

UM PE

AK CU

RREN

T

CIRCU

IT CAN

PROD

UCE -

2.6 x R

MS SY

M. AM

PS

284121

Figure 17. Current Limiting Characteristics of Type FM and Type A720R

Type A720RFuse

(2R-24R)7.2kV

Type FM Fuse

(2R-24R)5kV

Max

imu

m In

stan

tan

eou

s Pe

ak-L

et-T

hru

Am

per

esM

axim

um

Inst

anta

neo

us

Peak

-Let

-Th

ru A

mp

eres

22

5000

4000

3000

2000

1500

1000

800

600

500

400

300

200

150

2R

3R

4R

6R

9R

12R

18R

24R

Allowable Acceleration Time (In Seconds)

5 10 20 30 4015 25 35

Figure 18. Maximum Allowable Acceleration Times

Motors with acceleration times falling

below the applicable fuse curve are permitted two

consecutive starts, as follows:

A. One Start From Ambient

B. A Coast To Stop

C. A Second Start

Maximum Allowable Acceleration Times Permitted

by Type FM and A720R Motor FusesM

otor

Nam

epla

te L

ocke

d Ro

tor

Curr

ent

in A

mpe

res

Allowable Acceleration Time (In Seconds)

General Description

23

Receiving, Handling & StorageReceiving

Upon receipt of this equipment, an immediate inspectionshould be made for any damage which may haveoccurred during shipment. The inspection should includeexamination of the packaging material and the contactor.Be sure to look for concealed damage and do not discardthe packaging material. If damage is found, note damageon Bill of Lading prior to accepting receipt of theshipment, if possible.

Notification to the carrier within 15 day limit onconcealed damage is essential if loss resulting fromunsettled claims is to be eliminated or minimized.

A claim should be immediately filed with the carrier, andthe Siemens sales office should be notified if damage orloss is discovered. A description of the damage and asmuch identification information as possible shouldaccompany the claim.

Handling

Series 81000 controllers are shipped in groups of one tofive vertical sections which are mounted on woodenshipping skids. For 90-inch high controllers, lifting anglesare provided as shown in Figures 19 and 20.

Controllers with top mounted horizontal bus are providedwith side mounted lifting angles, as shown in Figure 22.

The following precautions must be taken whenevermoving a motor controller:1. Handle the motor controller with care to avoid

damage to components and to the frame or its finish.

2. Do not remove the wooden shipping skid until finalinstallation position is reached.

3. Handle the motor controller in an upright positiononly. Motor controllers are normally front heavy, andfrequently top heavy. Balance the load carefully andsteady the motor controller, if necessary, duringmovement. Some motor controllers may contain heavyequipment, such as transformers or reactors, that canbe adversely affected by tilting.

4. Know the capabilities of the moving means available tohandle the weight of the motor controller. Adequatehandling facilities should be available. Each verticalsection, with contactors, weighs approximately 1500lbs. If a vertical section contains power factor correctioncapacitors, reactors, or large transformers, sufficientadditional weight handling capacity must be allowed.

5. It is recommended that a crane or hoist be used tohandle the controller if at all possible. If a crane or

hoist is not available, and other handling means arenecessary, extreme care must be exercised to insurethat the equipment is secured during the movementand placement operations to prevent tipping andfalling. Jacks, prybars, dollies, roller lifts, and similardevices all require supplemental blocking beneath themotor controller, and restraints to prevent tipping.These devices are not recommended due to thehazards implicit in their use.

The following precautions should be taken when movingthe controller with a crane or hoist:1. Select rigging lengths to compensate for any unequal

weight distribution.

2. Do not allow the angle between the lifting cables andvertical to exceed 45o.

3. Do not pass ropes or cables through the liftingbrackets. Use only slings with safety hooks or shackles.

4. If overhead restrictions do not permit lifting by topmounted brackets, or angles, the controller may beunderslung from the base. The sling load must bedistributed evenly and padding or spreader bars mustbe used to avoid scarring and structural damage.

5. Never lift the controller above an area wherepersonnel are located.

Figure 19. Lifting a Single 90 High Unit

Figure 20. Lifting for 2 or 3 Section Group 90 High Units

IMPORTANT: The way visible shipping damage is treatedby the consignee prior to signing the delivery receipt candetermine the outcome of the damage claim to be filed.

Heavy equipment.

Improper lifting can result in death, serious personal injury or substantialproperty damage.

Use extreme care when handling the motorcontroller.

Dont Pass Ropes or CablesThrough Lift Holes: Use Slings,Safety Hooks or Shackles

Lifting Angle

LiftingAngle

EqualizingBar

Lifting Hole

Lift Point

1/2A A

45max

24

Receiving, Handling & Storage

The following precautions should be taken when movingthe controller with a forklift:1. Keep the controller in an upright position only.

2. Make sure the load is properly balanced on the forks.

3. Place protective material between the controller andforklift to prevent bending and scratching.

4. Securely strap the controller to the forklift to preventshifting or tipping.

5. Excessive speeds and sudden starts, stops, and turnsmust be avoided when handling the controller.

6. Lift the controller only high enough to clearobstructions on the floor.

7. Take care to avoid collisions with structures, otherequipment, or personnel when moving the controller.

8. Never lift the controller above an area wherepersonnel are located.

The following precautions should be taken when movingthe controller by rolling on pipes:1. Keep the controller in an upright position.

2. Use enough people and restraining devices to prevent tipping.

3. The surface over which the controller is rolled must belevel, clean, and free of obstructions. Never roll acontroller on an inclined surface.

4. It should be recognized that rolling a controller isespecially hazardous to fingers, hands, and feet andthe controller is susceptible to tipping. Measuresshould be taken to eliminate these hazards.

5. All pipes must be the same outside diameter andshould have no flat spots. Only steel pipe should beused for this purpose.

Skid Removal

Skid removal should be performed just prior to finalplacement of the controller and is achieved by removingthe skid lag bolts. If the lifting bracket or angles have beenremoved, reinstall them on the top of the controller (Referto Recommended Torque Values, Table 10) and attach thecrane rigging to remove all slack without lifting theequipment. This is a recommended safety measure toreduce the possibility of tipping. The lag bolts may now beremoved, the controller lifted, the skids removed, thecontroller lowered into place, and the anchor bolts secured.The last operation should be performed with adequaterigging tension to prevent tipping. After all additionalshipping sections are secured in a similar manner, sectionsand bus bars should be joined in accordance withinstructions in the installation section of this manual. Closedoors as soon as possible to eliminate entrance of dirt andforeign materials into the controller enclosure.

Contactor Removal

Controllers are normally shipped with the contactorsinstalled and braced in their respective compartments. Tofacilitate handling of the contactors, it is recommendedthat they not be removed from their shipping positionsuntil after the vertical section or group of vertical sectionshas been removed from the wooden shipping skid and setinto final position. At this time, the contactors may beremoved by unbolting the retaining bracket which securesthe left front contactor wheel to the guide plate. Handlewith care to avoid damaging LSI disconnect finger on rearof contactor, and latch mechanism on latched contactors.

Storage

If the controller cannot be placed into service promptlyafter receipt, it must be stored in a clean, dry space wherea uniform temperature prevents condensation. Preferably, itshould be stored in a heated building, with adequate aircirculation, and protected from dirt and water. Motorcontrollers should be stored where they are not subject tomechanical damage.

If the motor controller is to be stored for any length of timeprior to installation, restore the packing for protection duringthat period. Where conditions permit, leave the packingintact until the motor controllers are at their final installationposition. If the packing is removed, cover the top andopenings of the equipment during the construction period toprotect them against dust and debris.

Outdoor storage is not recommended. However, if an indoormotor controller must be stored outdoors, it should besecurely covered for protection from weather conditions anddirt. Temporary electrical heating should be installed toprevent condensation; approximately 150 watts per section isadequate for the average motor controllers size andenvironment. All loose packing or flammable materials shouldbe removed before energizing space heating equipment.

An unenergized outdoor motor controller should be kept dryinternally by installing temporary heating (see above). If theunit has been provided with optional self-contained spaceheaters, these may be energized in lieu of installingtemporary heating.

Any scratches or gouges suffered from shipping or handlingshould be touched up with spray paint to prevent corrosion.

Heavy equipment.

Improper lifting can result in death, serious injury or substantial property damage.

Use extreme care when handling the motorcontroller.

Figure 21. Lifting for Units with Top Mounted Bus

Equalizing Barby Rigger

25

Installation

Hazardous voltages.


Disconnect, lockout, and ground incomingpower and control voltage sources beforebeginning work on this or any other electrical equipment.

Installation should be performed only byqualified personnel.

Introduction

Before performing any installation activities: Test all power terminals to verify that incoming

power has been disconnected. Use only approvedhigh voltage test equipment to check voltage onpower terminals. Do not attempt to measure high-voltage (over 600 volts) with a volt-ohm meter.

Check all control and secondary circuit terminals with avoltmeter to make certain that all sources of incomingcontrol and secondary voltage have been disconnected.

Connect safety grounds to power terminals after thesystem has been de-energized, and prior to workingon the equipment.

Perform all disconnecting, grounding, and lockout operations in accordance with established safety procedures.

Follow the procedure outlined in the Pre-EnergizationCheck section of this manual before power is restored.

Operating Equipment

The Series 81000 controller conforms with the provisions ofNEMA standards ICS1, clause 6, Altitude Class 2KM (class1KM for 96H6 contactors refer to Instruction ManualSGIM-9098B), which defines the usual service condition forelectromagnetic control. It is designed for indoor use wherethe temperature inside the controller is higher than theambient temperature. The controller is capable of carryingits rated load when the ambient temperature does notexceed 40oC (104oF) and the altitude does not exceed 6600feet (2000m) (3300 feet (1000m) for 96H6 contactors)above sea level. Where unusual service conditions exist, orwhere temperature or altitude limitations are exceeded, thecontroller construction, ratings, or protection may requirealteration. Some examples of unusual service conditions areexcessive moisture, vibration, or dust.

Site Preparation and Mounting

Installation shall be in accordance with the NationalElectrical Code, (NFPA 70) and NEMA standards. Unlessthe controller has been designed for unusual serviceconditions, it should not be located where it will beexposed to ambient temperatures above 40oC (104oF),corrosive or explosive fumes, dust, vapors, dripping orstanding water, abnormal vibration, shock, tilting, orother unusual operating conditions.

The controller should be installed in a clean, dry, heated place withgood ventilation. It should be readily accessible for cleaning andinspection and should be carefully set up and leveled on its supportingfoundation and secured in place. Supporting surfaces for the controllerat each anchor bolt must be level and in the same plane within 0.06"(1.6mm). There must not be any projection above this plane within thearea covered by the controller structures. If the mounting site does notmeet these conditions, the controller must be shimmed wherenecessary to prevent distortion of the frame.

The controller can be mounted by many different fastening systemsincluding true drop in, cast in place, power actuated, or threaded insertfasteners. See Figures 22 and 23 for anchor bolt locations. The boltpattern is dependent on frame width and depth, location in the lineup,and whether or not sill channels are furnished. The group arrangementdrawing for each controller details the anchor bolt locations. Thecoordination between the bolts and the controller should be verifiedprior to attempting installation. Expandable inserts in predrilled holes orimbedded "L" bolts are recommended. Wooden plugs driven into holesin masonry or concrete are not recommended for anchoring inserts andshould never be used. The bolt size must be 1/2".

Welding the steel base or sill channels to a steel floor plate is analternate mounting method especially recommended in areas subjectto seismic (earthquake) activity.

Grouting the sill channels (refer to Figure 24) is another method offastening the controller to the foundation. This method requires thefoundation to be grooved to accept the sill channels. The actual groovedimensions must be coordinated with the floor plan layout on the grouparrangement drawing included in the controller information packet.

General Pre-Installation Inspection

1. Check all parts for secure mounting and good electricalconnections. Inspect visually for overall good condition.

2. Inspect frame for dents and other damage. Swing doors to makesure they pivot easily.

3. Operate the racking mechanism to insure free and smoothoperation. Inspect the stab assembly and the shutter mechanism.

4. Check fuses for sure fit in clips. Check fuse clips for deformitiesand secure mounting.

5. Check control circuit plug and receptacles for bent pins and other damage.

6. Make sure that cable clamps and insulators are in good condition.

Grounding

The frame of each controller must be grounded. This connection must bemade before making power connections. If a ground bus is furnished, theground connection should be made to the ground bus. The control andinstrumentation circuits are grounded to the enclosure. This connection canbe temporarily removed for test purposes, but it must be reconnectedbefore the controller is returned to operation. If ground bus is notfurnished, ground connection should be made to the mounting bolt for themotor cable ground lug provided next to the T1, T2, and T3 connections.

Electrical Connection

To simplify line and load cable connections, the drawout contactorcarriages should be removed. Be sure to disconnect the control plugbefore attempting to remove the contactor.

Line connections should be made first. See Figures 26-29 for details.

26

Installation

Figure 22. Top View and Typical Floor Plan With Bus Located in Top Compartment

Figure 23. Top View and Typical Floor Plan With Bus Located in Top Hat Compartment.

For T1, T2, T3 to MiddleCompartment.

For T1, T2, T3 to BottomCompartment.

Center Line of Conduit Max.Nominal Rigid Conduit Size3(76.2) for Control Wires.

All Conduits Max.Rigid Size 3.5 (88.9)

Center Line of Conduit.Max. Nominal RigidConduit Size 4 (101.6)

For T1, T2, T3 to BottomCompartment.

For T1, T2, T3 to BottomCompartment

For T1, T2, T3 to BottomCompartment

For T1, T2, T3 to TopCompartment

For T1, T2, T3 to MiddleCompartment

For T1, T2, T3 toTop Compartment

Conduit forControl Wire

For T1, T2, T3 to MiddleCompartment

.625 Dia. 2-Holes for SillAnchor Bolts when Reqd(1-front, 1-rear)

.625 Dia. 2-Holes for SillAnchor Bolts when Reqd(1-front, 1-rear)

For T1, T2, T3 to Middleor L1, L2, L3 to TopCompartment.



Center Line of ConduitMax. Nominal RigidConduit Size 3.5(88.9)for Control Wires.

.625 Dia. 4-Holesfor Anchor Bolts

.625 Dia. 4-Holesfor Anchor Bolts

Center Line of Conduit.Max. Nominal RigidConduit Size 4 (101.6)

36.0(914.4)

36.0(914.4)

36.0(914.4)

6.06(153.9)

1.12(28.45)

4.17(105.9)

10.06(255.5)

34.94(887.5)

36.0(914.4)

34.94(867.5)

68.5(1739.9)

68.5(1739.9)

28.78(731.0)

4.0(101.6)

3.75(95.3)

32.50(825.5)

4.01(101.9)

Top View Floor Plan

Top View Floor Plan

Front Front

31.0(767.4)

21.88(555.8)

36.0(914.4)

36.0(914.4)

21.88(555.8)

4.68(118.9)

4.2(106.7)

18.83(478.3)

31.0(787.4)

32.75(831.9)

36.0(914.4)

4.2(106.7)

4.42(112.3)

1.12(28.5)

6.06(153.9)

10.06(255.5)

32.75(831.9)

2.13(54.1)

2.13(54.1)

( ) Dimensions in Millimeters


31.0(787.4) 29.50

(749.3)

29.50(749.3)

2.87 (72.9)

2.87 (72.9)

4.68(118.9)

32.50(825.5)

3.50(88.9)

3.50(88.9)

4.42(112.3)

27

Installation

Contactor Installation

Pre-Installation Checks

Correct installation of contactors is essential to propercontroller operation. Before installing a contactor inany medium-voltage compartment, observe thefollowing checklist:1. Check to see that the catalog number, part number

and power fuse rating given on the contactorrating label matches the information given on themedium-voltage compartment rating label.

2. Check the following items in the contactor for agreementwith the information given on the rating label:

a. Contactor type.

b. Contactor continuous ampere rating.

c. Power fuse type, R or E rating and voltage.

d. Control transformer primary fuse E rating and voltage.

Installation

After it has beenverified that the correct contactor has been selected for agiven medium-voltage compartment, the contactor maybe installed as follows:1. Open the medium-voltage compartment door

(handle must be in OFF position, red contactorengagement light must be OFF).

2. Position the contactor in front of the compartmentand align the rear contactor wheels with the insideedge of the guide plate sides.

3. Roll the contactor onto the guide plate and into thecompartment until it stops. Use the handle on thefront of the contactor for this purpose. When thecontactor is fully inserted, the mechanical latch(see Figure 6) should rotate to prevent it fromrolling back out of the compartment.

4. Connect the control wiring harness to the contactorby inserting the harness plug into the receptacle onthe left side of the contactor.

5. Close and latch the medium-voltage compartment door.

Figure 24. Typical Side View with Optional Sill Channels.

Load terminals are connected directly to the currenttransformers (if bar or wound type) or to the terminalsadjacent to the current transformers located on theleft side of the starter unit. Vertical conduits areprovided for top or bottom load cable isolation. SeeFigure 25. Typical conduit space for top or bottomentry of load cables and control wires is given inFigures 22 and 23.

Hazard of explosion or fire.

Can cause death, serious injury, burn, orequipment damage.

Before installing contactor in anycompartment, verify agreement betweeneach of the following compartment labeldata and the corresponding data on thecontactor label:

Catalog No. Power Fuse Type Contactor Amp Rating Part No. Power Fuse Rating

Heavy equipment.

Improper lifting device or dolly handling can cause death, personal injury, or property damage.

Observe all handling instructions in thisinstruction manual to prevent tipping ordropping equipment.

36.0(914.4)

32.75(831.9)

3.0(76.2)

Front

2.12(53.8)

1.12(28.4)

3.0(76.2)


28

Installation

Figure 25. Load Cable Termination

Bottom Entry

TypicalStressCone

SteelConduitsfor Cables

Side View

Top Entry

Front

29

Installation

Figure 26. Incoming Line Arrangement with Bus Located on Top of the Cubicle Top Entry

Top EntryH

oriz

onta

l En

try

Hor

izon

tal E

ntr

y

Hor

izon

tal E

ntr

y

Type

VerticalEntry

VerticalEntry

VerticalEntry

TA2 TB2

10.0(254)

36.0(914.4)

Max. Cable/

(Non-Shielded)(1) 250 kcmil

Max. Cable/ (Non-Shielded)Vertical Entry(2) 750 kcmil

Horizontal Entry(2) 500 kcmil

Max. Cable/ (Shielded)

Vertical Entry(2) 750 kcmil


36.0(914.4)

36.0(914.4)

20.0(508)

TC2


30

Installation

Figure 27. Incoming Line Arrangement with Bus Located on Top of the Cubicle Bottom Entry

Bottom Entry

Bottom Entry

Type BA2

Type BE2

BB2

Max. Cable/ (Non-Shielded)(6) 500 kcmil(4) 750 kcmil

(Shielded)(6) 500 kcmil(4) 750 kcmil



Max. Cable/ (Non-Shielded)(3) 750 kcmil

(Shielded)(2) 750 kcmil



36.0(914.4)

36.0(914.4)



36.0(914.4)

CTs

L1 L2 L3

36.0(914.4)

18.0(457.2)

Min.

BC2 BD2


31

Installation

Figure 28. Incoming Line Arrangement with Bus Located in Rear of Upper Compartment Top Entry

Top Entry

Top Entry

Type TA3

Type TE3

TB3








36.0(914.4)

36.0(914.4)

24.0(685.8)

CTsL1L2L3

36.0(914.4)

36.0(914.4)

TC3 TD3


Hor

izon

tal E

ntr

y

VerticalEntry

Hor

izon

tal E

ntr

y

VerticalEntry

32

Installation

Figure 29. Incoming Line Arrangement with Bus Located in Rear of Upper Compartment Bottom Entry

Bottom Entry

Bottom Entry

Type BA3

Type BE3

BB3








36.0(914.4)

24.0(685.8)



36.0(914.4)

CTs

36.0(914.4)

18.0(457.2)

Min.

BC3 BD3


33

Installation

Figure 30. Typical Stress Cone

Power Cable Termination

Any termination for an insulated power cable mustprovide certain basic electrical and mechanical functions.These essential requirements include the following:1. Connect the insulated cable conductor to electric

equipment, bus, or uninsulated conductor to providea current path.

2. Physically protect and support the end of the cableconductor, insulation, shielding system, and overalljacket, sheath, or armor of the cable.

3. Effectively control electrical gradients to provide bothan internal and external dielectric strength to meetdesired insulation levels for the cable system.

Series 81000 Controllers

The following general recommendations are offered forproper cable termination in the Series 81000 controllers.1. Position the cables for maximum clearance between

phases, ground, and other cable wire runs.

2. Avoid any possible contact between low voltage wiresand medium-voltage cables.

3. Prepare cable terminations in accordance with thecable manufacturers instructions.

4. If contact between the cable and adjacent bus cannotbe avoided, tape the bus to approximately 5/32"(4mm) thickness in the immediate vicinity of thecable contact point so that the surface creep distance from the cable to the bare bus bar is at least 3.5" (89mm).

Termination of Lead-Covered Cables

Potheads are required to terminate lead-covered cables.A pothead is a hermetically sealed device used toenclose and protect cable ends. It consists of a metallicbody with one or more porcelain insulators. Follow thepothead manufacturer's instructions to terminate thecable at the pothead. In general, the body is arrangedto accept a variety of optional cable entrance sealingfittings, while the porcelains, in turn, are designed toaccommodate a number of optional cable conductorand aerial connections.

Termination of Shielded Cables

In order to reduce and control the longitudinal and radialelectrical stresses at the termination of the cable end tovalues within safe working limits of the materials used tomake up the terminations, the most common method isto gradually increase the total thickness of insulation atthe termination by adding insulating tapes, or aperformed insulating component, in the form of a cone.The cable shield is carried up the cone surface andterminated at a point near the largest diameter of thecone. This construction is commonly referred to as astress cone and is illustrated in Figure 30.

Note: Consult individual cable supplier forrecommended installation procedures and materials.

Rubber Jacket

Ground Strap

Final Layer Electrical Tape

Electrical Tape

Copper-Mesh Shielding Tape

Semi-Conductive TapeSplicing Compound Tape

Terminal Lug

A Leakage Distance

34

Operation

Pre-Energization Check

After installation, field additions, or maintenance, thefollowing checklist should be followed:

1. Remove all blocks or other temporary holding meansused for shipment from all component devices in thecontroller interior. If the retaining bracket used forshipment of the contactors has not been removed,remove the retaining bracket which secures the leftfront contactor wheel to the guide plate.

2. Retighten all accessible connections in accordancewith the torque values provided in Table 7 of themaintenance section of this manual.

3. Check the integrity of the bus supports.

4. Check the enclosure to see that it has not beendamaged and that electrical spacing has not been reduced.

5. Compare all circuits for agreement with the wiringdiagrams which accompany the controller.

6. Make certain that external wiring is clear of bus,and all power wiring is physically secured towithstand the effects of the largest fault currentwhich the supply system is capable of delivering.

7. Verify that all ground connections have been madeproperly. If sections of the controller were shippedseparately, they must be connected in a manner toassure a continuous ground path.

8. Check all devices for damage. Make necessaryrepairs or replacement prior to energizing.

9. Be sure that each motor is connected to itsintended starter. Ensure that fuse rating is inagreement with the rating specified in thecontactor catalog number.

10. Manually exercise all operating mechanisms,contactors, magnetic devices, and other devices tomake certain that they are properly aligned andoperate freely.

11. With all loads disconnected, exercise all electricallyoperated devices with test power to determine thatthey operate properly. Refer to the wiring diagramsfor the required control voltage, frequency, and testpower terminal designations required to test thecontactor. For the contactor, this should alsoinclude tests at the lower limits of pickup voltage asshown in the instruction manual for the contactor.

12. Test the ground fault protection system (if furnished)in accordance with the manufacturer's instructions.

13. Set all devices with adjustable current and/orvoltage settings to proper values.

14. Ensure that overload relay current range and settingis in agreement with the full load current andservice factor shown on the nameplate of eachmotor, taking into account the current transformerratio used in the controller.

15. Make sure that all fuses are completely inserted inthe clips.

16. Install any necessary CT circuit wiring, and remove CTshort circuiting jumpers installed for shipment. (Donot remove CT short circuiting jumpers if no loadcircuit is connected to the CT). If short circuiting typeterminal blocks are provided, assure that shortcircuiting screws are removed or shorting links are inthe open position. Check each current transformersecondary circuit for continuity through its protectivedevices to ground. Do not operate a motor controllerwith a current transformer's secondary circuit open.

17. To prevent possible damage to equipment or injuryto personnel, check that all parts and barriers thatmay have been removed during wiring andinstallation have been properly installed.

18. Before closing the enclosure, remove all metalclips, scrap wire, and other debris from thecontroller interior. Remove any accumulation ofdust or dirt, clean out the controller by using abrush, vacuum cleaner or clean lint-free rags. Donot used compressed air, as it will only redistributecontaminants on other surfaces.

19. After all of the power and control connections aremade and with all incoming power disconnected,conduct dielectric tests in accordance with theDielectric Test section of this manual.

20. Install covers, close doors, and make certain that nowires are pinched and that all enclosure parts areproperly aligned and tightened.

21. Make sure that all current-carrying parts outside thecontroller have adequate current-carrying capacityand are correctly insulated in accordance with therequirements of the National Electric Code (NEC). Allelectrical connections should be made carefully perthe wiring diagram furnished with the equipment.Tighten all terminals to recommended torque values(see Table 7). Use recommended crimping tools ifcrimp lugs are supplied.

Hazardous voltages.


Disconnect, lockout, and ground incoming powerand control voltage sources before beginningwork on this or any other electrical equipment.

All pre-energization checks outlined in thisinstruction manual must be performed before theequipment is energized. This equipment shouldbe energized by qualified personnel only.

35

Energizing Equipment

1. In order to minimize risk of injury or damage, orboth, there should be no load on the controllerwhen it is initially energized. Turn off all of thedownstream loads, including those such asdistribution equipment and other devices which areremote from the controller.

2. The equipment should be energized in sequence bystarting at the source end of the system andworking towards the load end. In other words,energize the incoming power to the controller orgroup of controllers, then close the incoming lineload interrupter switch or circuit breaker (ifavailable) and then rack in the contactor.

3. After all disconnect devices have been closed,loads such as motors may be turned on to verifythat the system operates as intended.

Pre-Energization Check

An AC dielectric test, at 2.25 times the nominal systemvoltage plus 2000 volts, for one minute, should beperformed between all phases and from all phases toground prior to energizing the equipment. Be sure todisconnect from the circuit any devices (control powertransformer, surge limiters, surge arresters, etc.) whichcould be damaged by the test voltage.

If a high-potential test set is not available, a Megger* testat 1000 volts is a suitable second choice.

Since wide variations can occur in insulation valuesbecause of atmospheric conditions, contamination andtype of test equipment, discrete values for acceptabilitycannot be given. However, making and recording testson new equipment, and again at regular intervals, willgive a comparative indication of change in the conditionof insulation. Maintaining a permanent record of thesevalues should be part of the maintenance program.

Operation

Hazardous voltages.

Will cause death or serious injury.

Follow safe procedures. Exclude unnecessarypersonnel. Use safety barriers. Keep awayfrom equipment during application of testvoltages. Dielectric or Megger* testingshould only be conducted by qualifiedpersonnel. Refer to dielectric test equipmentinstructions for safety instructions.

Hazardous voltages.

Can cause death, serious injury, or personal damage.

Complete all pre-energization checksoutlined in this instruction manual before the equipment in energized.

Vacuum interrupters may emit X-ray radiation.

Can cause death or personal injury.

Excessive dielectric test voltage can cause X-radiation to be emitted from vacuum interrupters.

Refer to vacuum contactor instructionmanual for dielectric test proceduresapplicable to the vacuum contactor.

Note: Do not use DC high potential testersincorporating half-wave rectification. Thesedevices produce high peak voltages.

These high voltages will produce X-ray radiation.These devices also show erroneous readings ofleakage current when testing vacuum interrupters.

* Megger is a registered trademark of Megger Group, Ltd.

36

Installation

Figure 31. Typical Control Circuit Diagram with Type 96H3 or 97H3 Contactor (Latched Contactor with Electrical Trip)

Test Switch ContactDevelopment

LSI52

53

55

A1

ACE2

AC

A2

A2

1

13

5 4 12 13 16 17 18 19

14 84 83 21 22 32 31

1 2 2

(+)

(-)

54A

C B

X1

C L2

L1

J3

X2

RSI TFU

CXFU

RUN TEST

TRIP

CLOSE

Additional Auxiliary Contacts

RMI

Optional For Screw-TypeRacking Only

LMDC Drive Unit

LMCC

LMCC

115V. or 230V.CPT

115V. or 230V.Test Power

Push to Test

RL

C

20

8

6

11 F

E1

LM7

43 44

Rec.-1

44

22

LM5

B A G H K L M N

LM4 LM6 LM8

D 10 W1

Mech. Trip

43 13 14

TX

TTX TX

9

LegendCPT . . . .Control Power TransformerCXFU . .Fuse for CPT Sec.LSI . . . . .Line Switch InterlockLM . . . . .Main ContactorREC . . . .RectifierRL . . . . .High Voltage LightRSI . . . . .Racking Switch InterlockT . . . . . .Trip CoilTFU . . . .Fuse for Test PowerTX . . . . .Trip Aux. RelayLM CC . .Main Contactor Magnet CoilRMI . . . .Racking Motor Interlock

X= Contacts Closed

RUN TEST

A X

B X

C X

A1

37

Maintenance

Introduction

Before performing any maintenance: Test all power terminals to verify that incoming power

has been disconnected. Use only approved high voltagetest equipment to check voltage on power terminals.Do not attempt to measure high voltage (over 600volts) with a volt-ohm meter.

Check all control and secondary circuit terminalswith a voltmeter to make certain that all sources of incoming control and secondary voltage havebeen disconnected.

Connect safety grounds to power terminals after thesystem has been de-energized, and prior to workingon the equipment.

Perform all disconnecting, grounding, and lockout operations in accordance withestablished safety procedures.

Follow the procedure outlined in the Pre-EnergizationCheck section of this manual before power is restored.

General

For the safety of maintenance personnel as well asothers who might be exposed to hazards associatedwith maintenance activities, the safety related workpractices of NFPA70E, parts II and III should always befollowed when working on electrical equipment.Maintenance personnel should be trained in the safetypractices, procedures and requirements that pertain totheir respective job assignments. This manual should bereviewed and retained in a location readily accessiblefor reference during maintenance of this equipment.

The user must establish a periodic maintenance programto ensure trouble-free and safe operation. The frequencyof inspection, periodic cleaning and preventivemaintenance will depend upon the operating conditions.NFPA Publication 70B Electrical Equipment Maintenancemay be used as a guide to establish such a program.

A preventive maintenance program is not intended tocover reconditioning or major repair, but should bedesigned to reveal, if possible, the need for such actionsin time to prevent malfunctions during operation.

Recommended Maintenance and Lubrication

Periodic maintenance and lubrication should include allof the tasks shown in Table 5. Recommended proceduresfor each of the listed tasks are provided in this section ofthe manual, or in the references cited in this manual.

Table 5. Maintenance Tasks

The list of tasks in Table 5 does not represent an exhaustivesurvey of maintenance steps necessary to ensure safeoperation of the equipment. Particular applications mayrequire further procedures. Should further information bedesired or should particular problems arise which are notcovered suf

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