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Instructional Booklet IB48041
Instructions for AMPGARD 400A
Medium Voltage Starter
Effective August 2024
Contents
Description
1. Introduction .....................................................2
1.1 Identification ...............................................2
1.2 Description ..................................................4
1.2.1 Controller ...........................................4
1.2.2 Low voltage components .................4
1.2.3 Isolation switch ..................................5
1.2.4 Power fuses ....................................... 6
1.2.5 Vacuum contactor .............................6
1.2.6 Safety interlocks.................................7
1.2.7 Low voltage control ..........................8
1.2.8 Current transformers........................9
1.2.9 Main bus..............................................9
2. Installation........................................................10
2.1 Handling......................................................10
2.2 Storage .......................................................10
2.3 Mounting ....................................................10
2.4 Bus splicing.................................................10
2.5 Power connections....................................10
2.6 Load cable termination.............................11
2.7 Control connections..................................12
3. Pre-startup checks ..........................................13
4. Maintenance ....................................................16
4.1 Insulation level ..........................................16
4.2 Fuses............................................................16
4.3 Contactor ...................................................16
4.4 Isolation switch .........................................18
4.5 Isolation switch replacement...................20
4.6 Door interlock ............................................21
4.7 Fastner torque specifications...................21
4.8 Support services ........................................22
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Summary of Contents for Eaton AMPGARD 400A
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Page 1: Table Of Contents
Instructional Booklet IB48041 Effective August 2024 Instructions for AMPGARD 400A Medium Voltage Starter Contents Description Page 1. Introduction .............2 1.1 Identification ..........2 1.2 Description ..........4 1.2.1 Controller ...........4 1.2.2 Low voltage components ....4 1.2.3 Isolation switch ........5 1.2.4 Power fuses ........6 1.2.5 Vacuum contactor ......6... -
Page 2: Introduction
Also contained on this nameplate is the factory’s general order number. This number should be given to the Eaton sales office if a question should arise concerning the equipment or if renewal parts are required. Refer to Figure 1 for typical location of rating nameplates Table 1. - Page 3 Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 Type SL, 400 A Additional Ratings Feature Rating Maximum interrupting current (3 operations) 8500 A (High interrupting) 4500 A (Standard interrupting) Rated current 400 A enclosed IEC make-break capability-AC4...
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Page 4: Description
Effective August 2024 1.2 Description 1.2.1 Controller The Ampgard 400A, 7.2 kV controller consists of a non-loadbreak isolation switch, medium voltage current-limiting fuses, one or more Type SL vacuum-break contactors, a set of current transformers, plus control and protection devices. The isolating switch has a limited make and break rating, suitable only for closing and opening limited transformer magnetizing currents. -
Page 5: Isolation Switch
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 1.2.3 Isolation switch An isolation switch viewing window is provided in the upper rear corner of the low voltage control compartment. After opening The controller isolation switch is rated to break the magnetizing the isolation switch and before opening the medium voltage current of a small control power transformer only. -
Page 6: Power Fuses
IB48020 for further details on the operation and maintenance of 1.2.4 Power fuses the latch mechanism. Ampgard controllers are supplied with Eaton Type CLS, CLE, or HLE current-limiting power fuses. Fuses may be either bolt-in or clip-in. All fuses include an indicator that pops up when the fuse has blown. -
Page 7: Safety Interlocks
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 1.2.6 Safety interlocks Mechanical and electrical interlocks are provided to ensure that the isolation switch cannot be opened or closed unless the main Ampgard controllers are manufactured with several built-in contactor is de-energized. -
Page 8: Low Voltage Control
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 1.2.7 Low voltage control A test plug and receptacle are typically supplied inside the low voltage section. The receptacle is wired to the secondary of the The low voltage control compartment is located in a steel pocket controller control power transformer. -
Page 9: Current Transformers
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 1.2.8 Current transformers 1.2.9 Main bus A three-phase current transformer (CT) is provided as standard Ampgard lineups are typically supplied with copper main bus. on all starters. The standard mounting location for the CT is The bus is located in a 12-inch-high bus compartment mounted under the contactor load connection assembly. -
Page 10: Installation
2.1 Handling installations require the controllers to be mounted 6 inches from rear or side walls. Refer to Eaton drawing 25A4254 for An Ampgard controller is insulated for high voltages and must be instructions on mounting in these special locations. It is the user’s protected against damage during handling. -
Page 11: Load Cable Termination
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 In two-high controller arrangements, the cables from one DANGER controller must pass through the controller located either above or below. An isolated steel cableway is provided for these cables. -
Page 12: Control Connections
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 2.7 Control connections Make sure that there is sufficient slack in the wiring to allow the medium voltage door to open properly.A horizontal low Control wires may enter the enclosure from either the top or voltage wireway is located at the bottom front of each lineup. -
Page 13: Pre-Startup Checks
Verify that the controller and motor are connected per the Eaton drawings. This is particularly essential in this class of equipment, as the fuse ratings, current transformers, and overload protection are based on the characteristics of the particular motor (or other load) to be controlled. - Page 14 Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 If the contactor mechanical interlocks are not working DANGER properly, they can be adjusted as follows: ALL SOURCES OF MEDIUM VOLTAGE MUST BE ISOLATED Close the isolation switch by moving the handle mech.
- Page 15 Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 Defeat door interlock by depressing plunger Small diameter rod Locknut Black clevis Small diameter rod attached Intersection - correct press pin here location Figure 26. Diagram of defeater lever (151B559), press pin...
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Page 16: Maintenance
If a fuse has blown due to a fault, it is likely that the other fuses experienced a similar overcurrent condition. For this reason, Eaton recommends that all three fuses be replaced. Ensure that the replacement fuses are of the same rating and mounting configuration as those originally supplied. - Page 17 Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 Line-side bolts (3) Bolt Figure 29. Remove bolt -down hardware Collar Load-side bolts (3) Figure 32. Remove three line-side and three load-side bolts (bolt-In contactor only) Figure 30. Unsnap pin collar For bolt-in contactors, line and load side bolts should be torqued to 20 ft-lbs (27 Nm) when re-installed.
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Page 18: Isolation Switch
After 5000 operations, the fingers and stabs should be relubricated with Chemours Krytox GPL-206 dielectric grease. Eaton part number for the grease is 53701XF0EY. Inspect isolation switch ( Figure 37) stabs for excessive wear, oxidation and pitting in the finger contact area. - Page 19 Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 DANGER FAILURE TO LOCK OUT INCOMING POWER BEFORE SERVICING THE FIXED PORTION OF THE SWITCH OR VERTICAL BUS CAN RESULT IN EQUIPMENT DAMAGE, SEVERE INJURY, OR DEATH.
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Page 20: Isolation Switch Replacement
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 Figure 41.Hold shutter open and clean stab fingers with cloth Figure 43. Inspect ground finger assembly for bent parts Figure 42.Stab contact area (viewed from rear of shutter mechanism) 4.5 Isolation switch replacement... -
Page 21: Door Interlock
Instructional Booklet IB48041 Instruction for AMPGARD 400A Medium Voltage Starter Effective August 2024 4.7 Fastener torque specifications DANGER IF THE SWITCH IS INSERTED WITH THE SHAFT IN THE CLOSED POSITION,THE SHUTTER MAY BE FORCED OPEN AND LIVE Torque values Metric... - Page 22 Instructional Booklet IB48041 Effective August 2024 NOTES:...
- Page 23 Instructional Booklet IB48041 Effective August 2024 NOTES:...
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Page 24: Support Services
CONTRACT BETWEEN THE PARTIES. Eaton contact information In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other- For the location of your nearest Eaton sales office or distributor, wise for any special, indirect, incidental or consequential damage call toll-free 1-800-525-2000 or log on to www.eaton.com.
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