Motor Controllers 600 Volts or Less
Installation And
Maintenance Instruction Manual
Storage
1. An indoor motor controller, which is not installed and energized
immediately, should be stored in a clean dry place where a uniform
temperature prevents condensation. Preferably, it should be stored in a
heated building, with adequate air circulation and protected from dirt and
water. Motor controllers should be stored where they are not subject to
mechanical damage.
2. An indoor motor controller that must be stored outdoors should be
securely covered for protection from weather conditions and dirt.
Temporary electrical heating should be installed to prevent condensation
approximately 150 watts is adequate for the average motor controllers
size and environment. All loose packing or flammable materials should
be removed before energizing space heaters.
3. An unenergized outdoor motor controller should be kept dry internally by
installing temporary heating or by energizing self -contained space heaters.
Handling
The following guidelines are provided to help avoid personal injury and
equipment damage during handling, and to facilitate moving the motor
controller at the job site.
1. Follow the manufacturer’s handling instructions for the specific equipment.
2. Handle the motor controller, with care, to avoid damage to components
and to the enclosure or its finish.
3. Keep the motor controller in an up right position unless otherwise specifically
permitted by the manufacturer.
4. Know the capabilities of the moving means available to handle the weight of
the motor controller.
5. When the motor controller is received, unpack it sufficiently to inspect
for concealed damage and to determine that the shipment is complete
and correct.
6. If the motor controller is to by stored for any length of tome, prior to
installation restore the packing for protection during that period. Where
conditions permit, leave the packing intact until the motor controller is at
its final installation position. When packing is removed, cover the top
and openings of the equipment during the construction period to protect
them against dust and debris.
Installation
1. Conduits should be installed to prevent moisture or water from entering
entering and accumulating within the enclosure. All conduits (including
stubs) should be bonded to the motor controller. All conduits should be
located in the areas recommended by the manufacturer to avoid cable
interference with structural members and live components.
2. Care should be exercised to make sure that the lugs which have been
provided are suitable for use with the type of cables being installed in the
motor controller.
3. If crimp lugs are used, crimp with the tools recommended by the lug
manufacturers.
4. Care should be exercised in stripping insulation from the conductors
to prevent the conductor from nick or ring. For aluminum, clean all
oxide from the stripped portion and at once apply inhibiting compound. All screw lugs should be tightened; use the manufacturer’s
torque values, if furnished.
5. Provisions should be made to locate conductors in the motor controller to avoid
physical damage and to avoid overheating. The conductors should be secured
in order to withstand available short-circuit currents. Follow the
manufacturer’s instructions for lacing or bracing cables. The largest practical
bending radius should be maintained to avoid damaging the insulation and to
avoid causing terminals to loosen.
6. All incoming and outgoing control connections should be made in
accordance with the motor controller manufacturer’s schematic and
wiring diagrams.
7. Installation of cables should be done at temperatures above freezing to
prevent cable insulation from cracking or splitting due to cold, unless
the cable is suitable for installation at temperatures below freezing.
Energizing Equipment
1. In order to minimize risk, damage, or both, there should be no load on the
motor controller when it is energized. Turn off all of the downstream loads,
including those such as distribution equipment and other devices which are
remote from the motor controller.
2. The equipment should be energized in sequence by starting at the source end of
the system and working towards the load end. In other words, energize the
main devices, and then the branch circuit devices. With barriers (if applicable)
in place, and doors closed and latched, turn the devices on with a firm positive
motion. Protective devices that are not quick-acting should not be “teased”
into the closed position.
3. After all disconnect devices have been closed, loads such as lighting circuits,
starters, contactors, heaters, and motors, may be turned on.
Preventive Maintenance
1. EXTERNAL CARE. Enclosures do not require any maintenance in a clean,
dry , and noncorrosive atmosphere. Enclosures in a marginal atmosphere
should be inspected periodically for excessive dust and dirt accumulation as
well as corrosive conditions. The more contaminated the atmosphere, the more
frequently the inspections should be conducted. Any accumulation should be
removed with a vacuum cleaner or manually cleaned during maintenance
shutdown periods for the equipment. Badly corroded enclosures should be
properly cleaned and
refinished as required for extended service.
2. OPENING ENCLOSURES. Foreign material, dirt, hardware, or debris should
be removed from the outside top surfaces to avoid the risk of anything falling
onto the equipment. Upon opening the cabinet or enclosure, equipment should
be inspected for any dust, dirt , moisture or evidence of moisture, or other
contamination. If any is found, the cause must be eliminated. This could
indicate an incorrectly selected, deteriorated, or damaged enclosure: unsealed
enclosure openings: internal condensation: condensate from an unsealed
conduit: or improper operating procedures (e.g., operating with enclosure door
or cover open).
3. CLEANING. Corroded or damaged parts should be replaced. Dirty, wet, or
contaminated parts of equipment should also be replaced unless they can be
cleaned effectively by vacuuming or wiping with dry cloth or soft brush. Use
care to avoid damaging delicate parts. Compressed air is not recommended for
cleaning because it may displace dirt, dust, or debris into other parts or
equipment or damage delicate parts. Liquid cleaners, including spray cleaners,
are not recommended unless specified by the equipment manufacturer, because
of the risk of residues causing damage or interfering with electrical or
mechanical functions. The inside bottom of the cabinet or enclosure should
also be cleaned, including removal of any hardware or debris, so that any new
or unusual wear or loss of parts occurring after the inspection may be more
readily detected during subsequent maintenance. Ventilation passages should
be kept open. If equipment depends on auxiliary cooling or heating, the
temperature control system should be checked and repaired if necessary to
assure proper functioning. Filters should be cleaned or replaced if necessary,
based on inspection or the time interval recommended by the manufacturer. If
dust or dirt has accumulated on heat sinks and /or components which generate
heat, it should be removed carefully by vacuuming, wiping, or brushing, since
such accumulation can reduce heat dissipation capability and lead to premature
failures.
4. Busbar, Wiring, and Terminal Connections. Any loose busbar or terminal
connection will cause overheating that will lead to equipment malfunction or
failure. Loose bonding or grounding can compromise safety and/or function.
Overheating in a bus or terminal connection will cause a discoloration in the
busbar which can easily be spotted where connections are visible oftentimes
too late to avoid replacement. An overheating busbar condition will feed on
itself and
lead to deterioration of the bus system as well as the equipment
connected to the bus such as: protective devices, bus stabs, insulated
leads, etc. Aluminum connections usually utilize parts that should not be
cleaned with abrasives. Busbar and terminal connections should be
inspected periodically to insure that all joints are properly tightened
Proper torque tightness is a factor of bolt size, bolt type, and type of
busbar and terminal material. Proper bolt tightness torque values for all
type of joints involves should be available in manufacturer’s
and instructional literature. Do not assume that busbar and terminal
hardware, once tightened to proper torque values, remains tight
indefinitely. Special attention should be given to busbars and terminal
hardware, once tightened to proper torque values, remain tight
indefinitely. Special attention should be given to busbars and terminal
connections in equipment rooms where excessive vibration or
heating/cooling cycles may cause more than normal loosening of bolted
bus an terminal connections. Busbar support insulators and barriers
should be inspected to ensure that they are free of contamination.
Insulators should be periodically checked for cracks and signs of arc
tracking. Defective units should be replaced. Loose mounting hardware
should be tightened. Examine insulation on conductors for overheating
or calling against metal edges that could progress into an insulation
failure. Any damaged conductors should be replaced. Replacement
conductors should be re-routed, braced or shielded if needed to avoid
similar damage in future operation. Temporary wiring should be
removed or replaced by permanent wiring.
5. DISCONNECTS. Disconnects should be examined on both the line and
load side for proper maintenance evaluation. Prior to initiating such an
evaluation, the source side disconnect device should be opened and
padlocked and tagged to avoid accidental energization by other
personnel during maintenance operations. Never assume that a
disconnect is in the open position because the handle mechanism is in
the open position. Always double-check for safety. Disconnect
switches generally have visible blade contacts and open-type disconnect.
Excessive heat in a disconnect switch can lead to deterioration of the
insulation and eventual failure of the device. Loose connections are the
major source of excessive heat. Terminal and busbar connections as well
as cable connections should be examined and tightened as required using
the manufacturer’s torque recommendations. Any device having
evidence of overheated conductors an carbonized insulation that could
also be caused by arching should be replaced. Contacts should be
examined for evidence of welding or excessive pitting. Damaged
disconnects with any evidence of these failure signs should be replaced.
Mechanism should be manually operated to ensure proper working
condition. Factory lubricated mechanisms will sometimes dry out after a
period of time in dry, heated atmospheres. Manufacturers’ maintenance
literature should be followed for roper lubrication instructions.
6. FUSES-WARNING. Fuses are normally used in conjunction with disconnect
switches. In no case should a dummy fuse copper slug, or length of wire ever
be used as a proper fuse substitute even on a temporary basis.
7. CONTACTORS. Since contactors are the working portion of a motor
controller, normal wear can be expected. Contacts and arc chutes of
electromechanical contactors should be checked for excessive burning beads of
molten material, and unusual erosion of the contact faces. Do not file or dress
contacts unless recommended by the manufacturer. Replace excessively worn
or pitted contacts with manufacturer recommended renewal parts, or replace the
contactor. All contacts of multi-pole devices should be replaced
simultaneously to avoid misalignment and uneven contact pressure. Arc chutes
and arc hoods should be replaced if they are broken or deeply eroded. Easily
dislodged dust or granules should be removed by vacuuming, wiping or light
brushing. Insulting surfaces should not be scraped, sanded or filled. A noisy
solenoid in a relay or contactor indicates failure to seat properly or a broken or
loose shading coil. The cause should be determined and corrected to avoid
overheating an coil damage. If a coil exhibits evidence of overheating
(cracked, melted, or burned insulation), it should be replaced, after the cause of
overheating has been detected and corrected. This could include the AC
magnet symptoms described above, or any binding that keeps the magnet from
seating properly when energized , or over voltage or under voltage conditions.
If melted coil insulation has flowed onto other parts, they should be cleaned or
replaced
8. MOTOR OVERLOAD RELAYS. Motor overload relays perform the
vital supervisory function of monitoring the overload current conditions
for the associated motor. The most commonly used overload relays
employ a thermal element signed to interpret the overheating condition
in the windings by converting the current in the motor leads to heat in
the overload relay element. As the heat in the thermal element reaches
predetermined amount, the control circuit to the magnetic contactor
holding coil is interrupted and the motor branch circuit is opened. The
two most common types of thermal elements in thermal overload relays
employ either a bimetal or a melting alloy joint to initiate the opening
action of the contactor. Heater elements are usually replaceable;
however, if a trip or burnout of the element occurs, the cause of this trip
or burnout should be identified and corrected. Replacement for the
heater element with one of a higher rating should not be done without
full consideration of the ambient temperature in without full
consideration of the ambient temperature in which the motor operates, as
well as all other motor data. Thermal overload relays are applied on the
basic of motor full-load current and the motor service factor found on the
motor rating nameplate. Complete records on all motors including motor
full-load amps together with proper manufacturer’s heater selection an
application charts should be included as a part of any maintenance file on
motor starters. General heater application charts are usually secured
inside the starter enclosure. Routine maintenance should include a
check for loose terminal or heater connections and signs of overheating.
Overheating can cause carbonization of the molding material creating
potential breakdowns as well as possibly altering the calibration of the
overload relay. Overload relay showing signs of excessive heating
should be replaced.
1. PILOT AND MISCELLANEOUS CONTROL DEVICES. Pilot and other
control devices consist of the control accessories normally employed with
motor starters and include: push buttons, selector switches, indicating lights,
timers, auxiliary relays, etc. Routine maintenance checks on these types of
devices generally include the following:
(a) Check for loose wiring
(b) Check for proper mechanical operation of operators and contact
blocks.
(c) Inspection of contacts (when exposed)
(d) Check for signs of overheating
(e) replacement of pilot lamps
10. INTERLOCKS. A contactor or starter may be provided with auxiliary
contacts that permit interlocking with other devices as well as serve other
position indicating functions. Proper maintenance of these electrical auxiliary
contacts include the following:
(a) Check for loose wiring
(b) Check for proper mechanical operation and alignment with the contactor
(c) Inspection of contacts (when exposed)
Mechanical interlocks can be classified in two categorized according to
their application: safety and functional performance. Safety interlocks
are designed to protect operating personnel by preventing accidental
contact with energized conductors and the hazards of electrical shock.
Functional interlocks, such as those found on reversing contactors, are
designed to prevent the inadvertent closing of parallel contactors wired
to provide alternate motor operating conditions. Mechanical interlocks
should be examined to ensure that the interlock is free to operate and
bearing surfaced are free to operate and that bearing surfaces are free to
perform their intended function. Interlocks showing signs of excessive
wear and deformation should be replaced. Several types of locking or
interlocking features are used. A primary disconnect mechanism is
usually mounted directly on the disconnect device. It is mechanically
interlocked with the door to ensure that the door is held closed with the
disconnect in the “ON” position. A maintenance check should be made
to ensure that the adjustment is correct and that the interlock is
providing proper engagement. Disconnect operation mechanisms are
provided with padlocked “OFF” position for personnel safety. Most
disconnects are equipped with defeater mechanism that can be operated
to release door interlock mechanisms with the disconnect device in the
“ON” position. The use of the release mechanism should be limited to
qualified maintenance and operating personnel.
MAINTENANCE OF MOTOR CONTROLLER AFTER A
FAULT CONDITION
In a motor branch circuit which has been properly installed, coordinated and
in service prior to the fault, opening of the branch-circuit short-circuit protector,
etc.) indicates a fault condition in excess of operating overload. This fault
condition must be corrected and the necessary branch circuit.
It is recommended that the following general procedures be observed by
qualified personnel in the inspection and repair of the motor controller involved in
the fault. Manufacturers’ service instructions should also be consulted for
additional details.
Caution: It must be understood that all inspections and tests are to e made
on controller and equipment which tests are to be made on controllers and
equipment which are deenergized, disconnected and isolated so that accidental
contact cannot be made with live parts and so that all plant sofety procedures will
be observed.
1. ENCLOSURE. Substantial damage to the enclosure such as deformation,
displacement of parts or burning, requires replacement of the entire enclosure.
2. CIRCUIT BREAKERS. Examine the enclosure interior and the circuit breaker
for evidence of possible damage. If evidence of damages mot apparent, the
breaker may be reset and turned “ON.” If it is suspected that the circuit breaker
is opened several short-circuit faults or if signs of possible deterioration
beyond normal wear and tear, such as overheating, contact blade or jaw putting,
insulation breakage or charring, the switch must be replaced.
3. DISCONNECT SWITCH. The external operating handle must be
capable of opening the switch. If the handle fails to open the switch or if
visual inspection after opening indicates deterioration beyond normal
wear and tear, such as overheating, contact blade or jaw pitting,
insulation breakage or charring, the switch must be replace
4.FUSE HOLDRS. Deterioration of fuse holders or their insulation
mounts requires their replacement.
5. TERMINALS AND INERNAL CONDUCTORS. Indications of arcing
or overheating, or both, such as discoloration and melting of insulation
require the replacement of damaged parts.
6. CONTACTOR. Contacts showing heat damage, displacement of metal, or loss
of adequate wear allowance require replacement of the contacts and, where
applicable, the contact springs. If deterioration extends beyond the contacts,
such as binding in the guides or evidence of insulation damage, the damaged
parts of the entire contactor must be replaced.
7. OVERLOAD RELAYS. If burnout of the current element of an overload relay
has occurred, the complete overload relay must e replaced. Any indication that
an arc has struck and/or any indication of burning of the insulation of the
overload relay also requires replacement of the overload relay. If there is no
visual indication of damages that would require replacement to the overload
relay, the relay must be electrically or mechanically tripped to verify proper
functioning of the overload relay contact(s).
8. RETURN TO SERVICE. Before returning the controller to service, checks
must be made for tightness of electrical connections and for the absence of
short circuit, grounds an leakage. All equipment enclosures must be closed and
secured before the branch circuit is energized.
INGERSOLL-RAND
REMOTE MOTOR STARTER
600 VOLTS OR LESS
INSTALLATION AND MAINTENANCE
INSTRUCTION MANUAL