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August, 2012
QUALIFIED PERSON
SIGNAL WORDS
For the purposes of this manual and product
The signal words “Danger” , “Warning” and labels, a qualified person is one who is familiar
“Caution” used in this manual indicate the with the installation, construction, operation or
degree of hazard that may be encountered by maintenance of the equipment and the haz-
the user. These words are defined as: ards involved. In addition this person has the
following qualifications:
Danger - Indicates an imminently hazardous
situation which, if not avoided, will result in (a) is trained and authorized to energize,
death or serious injury. de-energize. clear, ground and tag cir-
cuits and equipment in accordance with
Warning - Indicates a potentially hazardous established safety practices.
situation which, if not avoided, could result in
death, serious injury or property damage. (b) is trained in the proper care and use of
protective equipment such as rubber
Caution - Indicates a potentially hazardous gloves, hard hat, safety glasses or face
situation which, if not avoided, may result in shields, flash clothing, etc., in accor-
minor or moderate injury. It may also be dance with established safety practices.
used to alert against unsafe practices.
(c) is trained in rendering first aid.
IMPORTANT
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to
be met in connection with installation, operation or maintenance. Should further information be desired or should particular
problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the local
Siemens sales office. The contents of this instruction manual shall not become part of or modify any prior or existing agree-
ment, commitment or relationship. The sales contract contains the entire obligation of Siemens. The warranty contained in the
contract between the parties is the sole warranty of Siemens. Any statements contained herein do not create new warranties
or modify the existing warranty.
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
5 Autotransformer Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 9
Caution
For the purpose of this manual and product labels, CAUTION
indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be used to
alert against unsafe practices.
General
Although no special mountings or foundations are normally
required, the controller should be mounted in a reasonably level
position and adequately secured to prevent shifting. Hazardous voltage.
Carefully remove any temporary packing, bracing, or blocking Will cause death or serious injury.
from each device. Operate each movable contact device manu- To avoid electrical shock or burn, turn off
ally to assure free movement. Remove all traces of foreign mat- main and control voltages before perform-
ter from all contact surfaces. ing installation or maintenance.
Check to see that there are no loose connections and that ade-
quate clearances are maintained for the installation. If these instructions are ignored and controller is energized with-
All external wiring from the controller must be made in strict out arc chutes in place, the warranty on this equipment is auto-
accordance with the main connection diagram supplied with the matically voided. Severe damage to controller components or
unit and the National Electrical Code. possible injury to personnel may result if contactors and starters
If supplied, the entire current transformer secondary circuit are operated without arc chutes in place.
should be checked for continuity of connections, as an open cir- Inspection
cuit could cause extremely high secondary voltages to be gen-
erated. The controller and all accessory devices are normally shipped in
a single package. As soon as it is received, carefully inspect for
Siemens field service technicians are available for installation shortage or damage. If accessory items are a part of the ship-
and start-up supervision if desired. The cost of this supervisory ment thoroughly check each for damage. Recheck entire ship-
service is usually offset by a considerable saving in installation ment against the shipping manifest. If any shortage or damage
time. For details, contact your nearest Siemens Sales Office. is found, immediately notify the local freight agent handling the
shipment. Proper notation should be made by the agent on the
Handling And Lifting freight bill to prevent any controversy or delay when a claim is
Shipment from the factory is usually accomplished by lag bolt- made.
ing the controller to a wooden skid. These controllers can be
moved with a fork lift truck providing the load is balanced and Storage
steadied to prevent tipping. The controller should be stored in a dry location at a uniform
Lifting eyebolts or angles are supplied as standard on larger temperature to prevent condensation.
units for use with crane or hoist. Spreader bars should be used Controllers designed for indoor applications do not have suffi-
when lifting eyebolts are provided. cient packaging for outdoor storage. Additional packaging for
The skid and lifting means should not be removed before instal- protection from the outside elements and temporary heat to
lation. prevent condensation should be installed.
Controllers designed for outdoor applications should have space
heaters installed with a temporary electrical hookup to prevent
condensation.
Do not apply power to the Controller until the Operation and Maintenance Start-Up sections have been studied.
Check all control circuit terminals with a voltmeter to make cer- The items shown on the preventive maintenance checklist on
tain that the equipment is totally de-energized. Use only page 19 should be included in the preventive maintenance
approved high voltage test equipment to check power termi- program.
nals. Do not attempt to measure high voltage with a volt-ohm
meter. Parts And Service
It is recommended that a safety ground be connected to the When ordering parts, always give description and catalog
power bus after the system has been de-energized, and prior to number of part desired and the following information for the
working on the equipment. Follow the procedure outlined in the controller.
pre-energization check section of this manual before power is
restored. Catalog Number
Siemens Sales Order Number
Item Number
Customer Identification Number
Reduced voltage controllers are used to reduce the magnitude Some reduced voltage controllers lower the starting current and
of line current drawn at starting or to reduce the starting torque torque by means of an autotransformer. Another common
of the motor applied to the drive load or both. Several types of means used for reduced voltage starting is connecting or recon-
reduced voltage controllers are available and each exhibits dif- necting the leads of multi-lead motors in various combinations.
ferent torque-current characteristics. When choosing a reduced This is typical of part winding and wye-delta starters.
voltage controller, the individual application should be studied Depending on the type of controller used, the motor will pro-
carefully so that the best controller is selected. duce a different amount of torque on starting for a given value
A typical induction motor (Design B Code F thru K) has a start- of current drawn from the line. Some controllers provide for
ing current of approximately 5 to 9 times rated motor current if adjustment of the starting current and torque by changing taps
connected across the line at 100% voltage. on autotransformers while in others, such as part-winding and
wye-delta controllers, the starting values are fixed by the motor
The starting torque produced by an induction motor is approxi- design. On starters having a multi-tap arrangement, changing to
mately proportional to the square of the stator current. For a higher tap setting (higher starting voltage) will reduce acceler-
example, a motor drawing 50% normal starting current pro- ating time and increase starting torque. Lower tap settings will
duces approximately 25% rated torque. All reduced voltage cause the accelerating period to be longer and will reduce the
controllers operate in some way to reduce the current drawn by torque produced during this period. Table 1 is a summary of
the motor (and hence reduce the torque) on starting. the characteristics of the different types of reduced voltage
controllers.
Starting current drawn by the motor 50% 65% 80% 65%Y 58%
Starting torque developed as % of 25% 42% 64%
that which would be developed on Increasing slightly 40%Y 33%
full voltage starting. with speed.
Smoothness of acceleration First in order Third in order Second in order
of smoothness of smoothness of smoothness
Allowable accelerating times 15 seconds at 200HP max 5 seconds max 5 - 60 seconds
(typical) or 30 seconds on > 200 HP Limited by Limited by
based on NEMA medium motor design\ motor design
Starting current and torque Adjustable within
Fixed
and adjustments limits of various taps
X Closed transition
Y Approximate values only. Exact values may be obtained from motor manufacturer
Z Full voltage start usually draws between 500% and 900% of full-load current
[ Open or closed transition
\ Starting mode time for part winding
] Percent of the motor phase winding current
^ 50% tap not standard for 50HP and smaller
Table 1 - General comparison for various methods of Reduced Voltage motor starting
Notes:
A. Class 36-branch circuit protection, fused disconnect or circuit breaker must be provided by installer since circuit
breaker or fusible disconnect is not factory installed.
B. Unwired auxiliary interlocks supplied in control relay (CR2) as specified by customer.
C. Unwired auxiliary interlocks are not shown on diagram for the “R” starter.
D. For protection of internal control circuit conductors in accordance with the N.E.C., use fuse kit 49MAFB4.
E. Remove jumper if thermal protective switch is provided.
F. 1, 2, 3CT may be located on line side of contactor depending on circuit design.
OPTIONAL
DISCONNECT
G. For separate source control connect separate source between TB points 12 and X2.
or CIRCUIT
BREAKER
OL
OL
CONNECTIONS FOR OPTIONAL DEVICES
OL
1CT
OL
OL
2CT
FOR MOTOR
OL
HP SEE
CONTROLLER
NAMEPLATE ETM
3CT
FOR STARTER
SIZES 1-4, ICT-3CT
ARE NOT USED 1LT
(A1) (A2)
4LT
5LT
(A1) (A2)
OPTIONAL DEVICES ARE FURNISHED PER
CONTRACT DOCUMENTS
(A1) (A2)
VOLTAGE
AS SPECIFIED
TR - Starting Timer
PER NAMEPLATE TAS - Auto Transformer Over
Temperature Switch
(A1) (A2) (95)
OL
(96)
MR - Master Control Relay
Ø - Customer Connection Point
# - Device Termination Point
(A1) (A2)
Figure 1
Motor Horsepower
Duty Cycle
Above 200 to
To 200 Under normal operating conditions
3000 inclusive
the transfer time should not exceed
On Off 15 sec. 30 sec.
the duty cycle of the autotransformer.
Repeat 3 min., 45 sec. 30 sec.
Allow cooling between trials if above duty
Rest 14 times X 2 times Y cycle timer setting is used.
Repeat 2 hours 1 hour
As above As above
X Total of 15 cycles
Y Total of 3 cycles
Table 2
Reduced Voltage Wye-Delta Open And Closed Pressing the start button energizes the (CR1) relay, (TR) timer,
Transition and (MR) relay. As soon as (CR1) and (MR) are energized the
normally open contacts close energizing the (S) contactor. With
These controllers are applicable only to motors wound for wye-
(S) contactor energized the (1M) contactor energizes. The (S)
delta starting and with all six leads brought out into the motor
and (1M) contactors remain energized while timer (TR) times
junction box. Motors should be suitable for starting with wind-
out. When the timing sequence ends (CR1) is de-energized
ings in wye connection and normal running with windings in
which opens the (CR1) contact, de-energizing the (S) contactors.
delta connection. Such motors would normally be marked with
As soon as the (S) contactors is de-energized the (2M) contac-
locked rotor KVA Code A.
tor is energized which connects the circuit to the motor in Delta.
Pressing stop, or overload relay trip, will de-energize all contac-
Open Transition tors and remove the motor from the line.
Refer to the typical schematic diagram shown in Figure 2. The wye-delta starter overload relays are connected in the motor
If 3-wire control is used, connect the momentary start pushbut- phase circuits in series with the (1M) contactor. Therefore, the
ton between terminals 2 and 3; stop pushbutton between 1 and overload relay current is 58% of the motor line current.
2. If 2-wire control is used, jumper terminals 2 and 3 and con- See page 15 for setting instructions.
nect a remote control contact between terminals 1 and 2.
(A1) (A2)
(A1) (A2)
(A1) (A2)
H3 H2 CONNECT ET M
VOLTAGE
AS SPECIFIED
PER NAMEPLATE
1LT
4LT
Legend Notes:
Ø - Customer Connection Point A. Class 36-branch circuit protection, fused disconnect or circuit breaker
1M - First Main Contactor must be provided by installer since circuit breaker or fusible disconnect is
2M - Second Main Contactor not factory installed.
S - Shorting Contactor B. For protection of internal control circuit conductors in accordance with the
MR - Master Control Relay N.E.C., use fuse kit 49MAFB4.
CR1 - Time Delayed Relay
CR2 - Relay C. Set TR for transition time required.
TR - Timer D. For separate control voltage connect source to terminals 1 and X2.
OL - Main Starter O/L Relay E. 2CT may be located on line side of contactor depending on circuit design.
(#) - Device Termination Point
F. Unwired auxiliary interlocks are not shown on diagram for the 1M starter.
Figure 2
Notes:
A. Class 36-branch circuit protection, fused dis-
connect or circuit breaker must be provided
by installer since circuit breaker or fusible dis-
connect is not factory installed.
B. For protection of internal control circuit con-
ductors in accordance with the N.E.C., use
fuse kit 49MAFB4.
C. Set TR for transition time required.
D. For separate control voltage connect source
to terminals 1 and X2.
E. 2CT may be located on line side of contactor
(A1) (A2) depending on circuit design.
F. Unwired auxiliary interlocks are not shown on
(A1) (A2) diagram for the 1M starter.
(A1) (A2)
H3 H2 CONNECT
VOLTAGE
AS SPECIFIED
ETM
PER NAMEPLATE
(A1) (A2)
1LT
4LT
(A1) (A2)
5LT
Notes:
A. Class 36-branch circuit protection, fused disconnect or circuit breaker must be provided by installer since circuit
breaker or fusible disconnect is not factory installed.
B. For protection of internal control circuit conductors in accordance with the N.E.C., use fuse kit 49MAFB4.
C. Set TR for transition time required.
CIRCUIT D. 2CT and 5CT may be located on line side of contactor depending on circuit design.
BREAKER E. For separate source control connect separate source between TB points 1 and X2.
(1CB)
OR F. Unwired auxiliary interlocks are not shown on diagram for the “1M starter.
DISCONNECT
(1DISC)
OPTIONAL
Legend
1M - No. 1 Starter
2M - No. 2 Starter
CR1 - Relay
CR2 - Relay
TR - Starting Timer
MR - Master Control Relay
Ø - Customer Connection
(#) - Device Termination Point
(A1) (A2)
(A1) (A2)
H1 H3 H2 H4
1LT
X1 X2
4LT
5LT
(A1) (A2)
Figure 4
Overload Protection
Protection from motor overload during the starting and running circuit. Each overload has a current adjustment range with the
period is provided by the overload relay (OL). It provides pro- adjustment dial reading out in motor full load amps (FLA). In
tection against overloads and momentary surges but does not addition to the markings on the dial, there are audible clicks
protect against short circuit fault currents. For protection which allow for extremely fine tuning. Note that while thermal
against the latter, high interrupting capacity fuses or circuits overloads require a heater selection based on a relatively wide
breakers should be installed ahead of the controller, per N.E.C. range, these overloads have many clicks covering the same
requirements. ampere range.
Overload protection consists of three-pole overload relay(s). The For overload relays other than solid state overloads, divide the
3 phase overload relay provides outstanding motor protection motor full load amps by the current transformer ratio. For exam-
including single phase protection and an adjustable setting with- ple, the ratio of a 300/5 ct is 60/1. Divide the FLA by 60 to get
out changing of heaters. the current value that the overload will actually see.
The adjustment dial should be set from actual motor full load Note: The overload relay is a NEMA Class 10, 20 design and will
current in accordance with the overload relay adjustment trip within 10 to 20 seconds at a current of 600% of dial setting.
instructions using the overload factors of 58% for wye-delta or See overload relay instructions for motor service factor require-
50% for part winding. ments before setting the overload relays.
For size 5 through 7 starters, three separately mounted current
transformers are provided and the overload relay is indirectly Mechanical Sequence Interlock
powered from these CT secondaries. Set the overload relay dial
A mechanical sequence interlock is provided on all autotrans-
setting to the FLA of the motor for solid state overload.
formers and wye-delta controllers to prevent the simultaneous
Self-powered solid-state overload relays generate their own run- closing of both starting and running contactors.
ning power and do not need a separate source of 120V to power
the circuit board. The overload also provides phase loss protec- Optional Protective Devices
tion for the motor by tripping within three seconds when there
is a complete loss of one phase of the three phase motor branch Power monitor relays, ground fault relays, over-under current
relays, etc., may require adjustments prior to start-up. Refer to
the instruction sheets provided with each device for proper set-
ting/resetting.
Hazardous voltage.
Can cause death or serious injury.
To avoid electrical shock or burn, turn off
main and control voltages before perform-
ing installation or maintenance.
Welded Contacts
Î Check for abnormal currents or short circuits
Î Check for repeated jogging or inching
Hazardous voltage.
Will cause death or serious injury. Î Check for weak contact springs
To avoid electrical shock or burn, turn off Î Check for low voltage during starting
main and control voltages before perform-
Î Check for momentary power interruptions
ing installation or maintenance.
Î Check for chattering of local/remote control signals
Whenever assistance is desired from Siemens personnel,
please contact the nearest Siemens Sales Office. All informa- Overload/Breaker Tripping, Main Fuses Opening
tion required under the “Maintenance, Parts and Service”, sec- Î Check for short circuits and loose power connections
tion of this instruction must be given. Î Check for single phasing or phase unbalance
Listed below are possible trouble areas with possible causes. Î Check starting current, running current, and motor acceler-
ating time against overload settings
Control Fuses Opened
Î Check for shorted wires (frayed or bare wires shorted to Î Check for high ambient temperature within enclosure
ground or together) or shorted coils Î Check for proper fuse type/sizing and circuit breaker trip unit
Î Check for jammed or binding contactor/relay contact carriers selection and adjustment
Resistor Failure
Starter Fails To Operate Î Check for proper sequence and timing
Î Check protective devices and settings. Some devices must
be reset manually, and also may require time delay. Î Check for proper mechanical and electrical interlock opera-
tion
Î Check for proper operation/wiring of local remote pilot
devices Î Check for excessive recycling of starter
Î Check for loose or open control wiring Î Check for loose power and control connections
Failure to properly maintain the equipment can result in This checklist does not represent an exhaustive survey of main-
severe personal injury and product failure. The instructions tenance steps necessary to insure safe operation of the equip-
contained herein should be carefully reviewed, understood ment. Particular applications may require further procedures.
and followed. The following maintenance procedures must be Should further information be desired or should particular prob-
performed regularly: lems arise which are not covered sufficiently for the purchaser’s
purposes, the matter should be referred to the local Siemens
Sales Office.
Dust Clean
Fuse clips, bolt connection clamps Check for spring clip pressure, tightness of clamps.
Fuse ferrules If copper, polish; check for loose ferrules and proper
fuse size.
Arc chutes Check for breaks and excessive burning. Make sure arc
chutes are set firmly in place.