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Cutler-Hammer AMPGARD Series Instructions Manual

26" wide vacuum-break starters rated 360 amperes, 7200 volts, stab-connected
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Cutler-Hammer
Instructions for 26" Wide Vacuum-Break Starters
Rated 360 Amperes, 7200 Volts, Stab-Connected
HAZARDOUS VOLTAGE.
READ AND UNDERSTAND THIS MANUAL IN ITS
ENTIRETY BEFORE INSTALLING OR OPERATING
CONTROLLER. INSTALLATION, ADJUSTMENT, REPAIR
AND MAINTENANCE OF THESE CONTROLLERS MUST
BE PERFORMED BY QUALIFIED PERSONNEL. A
QUALIFIED PERSON IS ONE WHO IS FAMILIAR WITH
THE CONSTRUCTION AND OPERATION OF THIS
EQUIPMENT AND THE HAZARDS INVOLVED.
THE CONTROLLER
Each Ampgard
®
motor starter (controller) consists of one
nonload-break isolating switch, one Type SJD, NEMA
Size H3, vacuum-break contactor, current-limiting fuses,
a set of current transformers, and some form of overload
protection. The isolating switch has a limited make and
break rating, suitable only for closing and opening limited
magnetizing current loads. The controller is designed to
start, stop and protect a three-phase medium-voltage
motor within the ratings shown in Table I. The controller
may also be used to switch transformer windings or
capacitor banks. Each Ampgard
of a steel structure that may also enclose a horizontal
bus system to distribute power to two or more sections
and a vertical bus system in each section connected to
the horizontal main bus system. They are configured for
full-voltage starting, nonreversing, single-speed applica-
tions.
Range Of
Normal
System
Utilization
Voltage
Voltage
2200-2500
2300
3800-5000
4000
6200-7200
6600
Nonmotor Applications at: >>>>>>>>>
Transformer Switching Rating =
Capacitor Switching Rating =
Effective 11/97
DANGER
®
controller occupies all
TABLE I. AMPGARD
Continuous
50 or 60 Hertz
Current
Horsepower Rating
Rating
Synchronous Motor
Enclosed
80% P.F.
360A
1500
360A
2500
360A
4000
2200 - 2500 Volts
1250 kVA
1200 kVAR
Fig. 1 Ampgard® Motor Controller, 26" Wide
®
EQUIPMENT RATINGS
Induction
100% P.F.
Motor
1750
1500
3000
2500
5000
4000
3800 - 5000 Volts
2250 kVA
2100 kVAR
Interrupting Capacity, 50-60 Hz
(rms) Symmetrical At
Nominal Utilization Voltage
Fuses
Controller
50,000 Amp
200,000 kVA
50,000 Amp
350,000 kVA
50,000 Amp
570,000 kVA
6200 - 7200 Volts
I.B. 48004
Isolating
Switch
Make/Break
Ratings
750 VA
600 VA
600 VA
3000 kVA
2400 kVAR

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Summary of Contents for Cutler-Hammer AMPGARD Series

  • Page 1: Controller, Ampgard

    Cutler-Hammer I.B. 48004 Instructions for 26" Wide Vacuum-Break Starters Rated 360 Amperes, 7200 Volts, Stab-Connected DANGER HAZARDOUS VOLTAGE. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE INSTALLING OR OPERATING CONTROLLER. INSTALLATION, ADJUSTMENT, REPAIR AND MAINTENANCE OF THESE CONTROLLERS MUST BE PERFORMED BY QUALIFIED PERSONNEL.

  • Page 2: Low-Voltage Components

    I.B. 48004 Page 2 MEDIUM-VOLTAGE COMPONENTS The flow of power through a vacuum-break controller (starter) can be traced by referring to the lower portion of Figure 5, where the controller is shown in the energized position. The line stab assembly mounted at the back of the enclosure also serves as the controller line terminals (1).

  • Page 3: Ampgard Components

    I.B. 48004 Page 3 ® Fig. 5 Ampgard Components Effective 11/97...

  • Page 4: Door Interference

    I.B. 48004 Page 4 LOW-VOLTAGE CONTROL COMPONENTS (Cont.) Pull-apart terminal blocks are mounted on the pan directly in front of the low-voltage panel. These terminal blocks permit mechanical and electrical separation of the contactor from the structure for servicing or replacement. Four Screws Those Ampgard ®...

  • Page 5: Enclosure

    I.B. 48004 Page 5 amperes, r.m.s. symetrical. The current transformers, SHORT-CIRCUIT AND OVERLOAD PROTECTION overload protector, and power circuit fuses are coordi- Overcurrent protection is provided by the current-limiting nated with the motor characteristics, so that the controller power circuit fuses and by the overload sensor supplied must be used with the motor for which it was designed.

  • Page 6: Contactor / Isolating Switch Interlock

    I.B. 48004 Page 6 MECHANICAL INTERLOCKS ® Before putting an Ampgard controller into service, become familiar with the mechanical interlocks. Door Interlock. With the isolating switch handle in the HORIZONTAL position, the door to the medium-voltage compartment can be opened. As soon as the door opens, a mechanical interlock becomes effective.

  • Page 7: Contactor, General Information

    I.B. 48004 Page 7 As a final precaution before touching any of the electrical alternates at line frequency. The arc usually does not parts of the starter, visually check to make certain that survive beyond the first half cycle after the contacts begin the shutter is closed, the green and white striped labels to separate.

  • Page 8: Contactor Handling

    I.B. 48004 Page 8 THE CONTACTOR (Continued) fuses, instrument-quality potential transformers with secondary fuses (when furnished), primary fuses for the The kickout spring is adjustable and occupies the space control power and potential transformers, and load side above the operating magnet. The kickout spring must be fuse clips for the power circuit fuses.

  • Page 9: Contactor Positions

    I.B. 48004 Page 9 CONTACTOR OPEN CONTACTOR CLOSED Fig. 12 Type SJD Contactor Positions Effective 11/97...

  • Page 10: Installation

    I.B. 48004 Page 10 CONTACTOR HANDLING (Cont.) 5. Disconnect the isolating switch auxiliary contact pull- apart terminal blocks located on the lower right-hand side of the isolating switch. 6. Loosen the hex-head bolt attaching the clevis at the end of the isolating switch interlock rod to the contactor mechanical interlock sufficiently far to free the clevis and rod.

  • Page 11: Disassembly, Key Points

    I.B. 48004 Page 11 Fig. 14 Key Points In Disassembly (Shown with door removed.) A. POSITIONING BOLT F. ISOLATING SWITCH MOUNTING SCREWS B. POWER CIRCUIT FUSES G. ISOLATING SWITCH OPERATING HANDLE C. CONTROL CONDUCTORS TO UPPER COMPARTMENT H. ISOLATING SWITCH AUXILIARY CONTACT TERMINAL BLOCKS D.
  • Page 12 I.B. 48004 Page 12 Remove the single positioning bolt Remove three power circuit fuses Separate the contactor side of the (A). Free the clevis attached to the (B) using the fuse puller (K) control wires from the terminal mechanical interlock arm. supplied.
  • Page 13 I.B. 48004 Page 13 If no vertical bus bars are present Free the isolating switch by Pull the isolating switch forward. and cable is used to connect removing two hex head bolts (F) CAUTION: It has no latch and will power to the line stabs, connect as shown.

  • Page 14: Start-Up Precautions

    General Precautions. Be sure that: 1. The corresponding controller and motor are con- For Isolating Switch. Be sure that: nected as shown on the Cutler-Hammer drawings. 1. The current-limiting motor-starting power circuit fuses This is particularly essential in this class of motor have been properly installed.

  • Page 15: Checkout Mechanical

    I.B. 48004 Page 15 For Contactor. Be sure that: CAUTION 1. THE FOUR PHASE BARRIERS ARE INSTALLED WHEN PROVIDED. 2. The contactor coil is electrically isolated, to prevent feedback into a control power transformer and a SOME DC HIGH POTENTIAL UNITS, OPERATING AS hazardous situation.

  • Page 16: Fuses

    I.B. 48004 Page 16 c) Be trained in rendering first aid. d) Be knowledgeable with respect to electrical installa- DANGER tion codes and standards, for example, the National Electrical Code (NEC). OPERATE THE ISOLATING SWITCH ONLY WITH ALL MAINTENANCE PROGRAM DOORS CLOSED AND COMPLETELY LATCHED.

  • Page 17: Contactor Maintenance

    I.B. 48004 Page 17 CONTACTOR MAINTENANCE HORIZONTIAL All work on this contactor should be done with the main circuit disconnect device open, and using a separate COMPARTMENT source of control power to operate the magnet. Before applying external control circuit power, make certain that the contactor coil circuit is electrically isolated, to prevent feedback into a control power transformer that could be hazardous.

  • Page 18: Coil Changing

    I.B. 48004 Page 18 CONTACTOR MAINTENANCE (Continued) TABLE II. COIL PERFORMANCE Contact Wear Allowance Drop-Out-To- Rated Pick-Up-To-Seal Full-Open Contact material vaporizes from the contact faces during Voltage Voltage Coil every interruption and condenses elsewhere inside the bottle. This is normal, and is provided for by overtravel, Above Below Below...

  • Page 19: Auxiliary Contacts For Contactor

    A. Armature travel incorrect, causing the contact springs tion. to be compressed into a solid, non-resilient “tube” 3. Remove leads to coil terminals, noting their position that stops the crossbar rigidly. Call Cutler-Hammer for later reconnection. Service for assistance. 4. Remove the two 0.313-inch magnet mounting bolts.

  • Page 20: Auxiliary Contacts For Isolating Switch

    I.B. 48004 Page 20 CONTACTOR MAINTENANCE (Continued) Auxiliary Contact Adjustment The 0.410 + .010-inch (10.4 + .25-mm) gap shown for the normally-closed Type L63 auxiliary contact in the insert OPERATING ARM picture in the lower portion of Figure 12 is factory set. The 0.410-inch (10.4-mm) gap is important and must be held.

  • Page 21: Contactor Connection Diagram

    I.B. 48004 Page 21 Fig. 17 Cable and Connection Diagram ISOLATING SWITCH MAINTENANCE closed. This latch may be deliberately by-passed and the shutter moved to the open position. Caution should be observed since the exposed line terminal stabs of the starter may be energized at line potential.

  • Page 22: Auxiliary Contact Replacement

    I.B. 48004 Page 22 ISOLATING SWITCH MAINTENANCE (Continued) spring plate and leads, is designed for replacing auxiliary ® switches used with Ampgard isolating switches. The kit includes two switch mechanisms, each with an inductive- Welded Jaws or Contacts load rating of 20 amperes at not more than 250 VAC. In the unlikely event that either the isolating switch fuse These switches serve as the low-voltage cutoff switch.

  • Page 23: Table Of Contents

    I.B. 48004 Page 23 INDEX Page Page Insulation Level ..........16, 17 Ampgard ® Components ..........3 Isolating Switch ............ 4, 9 Auxiliary Contacts for Contactor ......19 Isolating Switch / Contactor Interlock ....... 6 Auxiliary Contacts for Isolating Switch ....20 Isolating Switch Handle Positions ......
  • Page 24 I.B. 48004 Page 24 Cutler-Hammer 221 Heywood Road Arden, NC 28704 Effective 11/97 Printed in U.S.A./CCI...

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