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belt coupled motor – generator sets

1. ED43B015 ED43B020 N A ED43B025 N A ED43B030 65 18 N A ED43B035 65 18 N A ED43B040 65 18 N A ED43B045 65 18 N A ED43B050 65 18 N A ED43B060 65 18 N A ED43BC 70 65 18 N A ED43B080 65 18 N A ED43B090 65 18 N A ED43B100 65 18 N A ED43B110 65 18 N A ED43B125 65 18 N A Molded Case Switch 100 ED43S100A 65 18 N A 125 ED438125A 65 18 N A SHIPPING 10 per carton Wt 38 ib IEC interrupting ratings are listed on page 51 Ordering Information Circuit Breaker Catalog Numbers ED6 Non Interchangeable Trip 2 Pole ED62B015 ED62B020 ED62B025 30 ED62B030 35 ED62B035 40 ED62B040 45 ED62B045 50 ED62B050 60 ED62B060 70 ED62B070 80 ED62B080 90 ED62B090 100 ED62B100 ED62B110 ED62B125 Molded Case Switch 100 ED62S100A 125 ED62S125A ED63B015 20 ED63B020 25 ED63B025 30 ED63B030 35 ED63B035 40 ED63B040 45 ED63B045 50 ED63B050 60 ED63B060 70 ED63B070 80 ED63B080 90 ED63B090 100 ED63B100 110 ED63B110 ED63B125 Molded Case Switch 100 ED63S100A 18 N A N A 125 ED63S125A 18 N A N A SHIPPING 10 per carton Wt 38 Ib interrupting ratings are listed below Includes self protecting instantaneous element will trip at cur rents over 1000A May be used on a circuit capable of delivering not more than the indicated fault current when protected by a fuse or circ
2. 2 ry LORD 2 88 2 20 6 33 Push To Trip Button 21Sq 269 A 0 Tri 12 50 1 End View 6 50 1 0 Off 11 10 1 See Detail D amp E Fi oo Terminal Rotates to Side View Positions Shown HHED6 Handle Operating Forces Operation Ib OFF to ON 8 10 ON to OFF 8 10 TRIPPED to RESET 14 drawing dimensions are shown in inches See detail drawings on page 9 HHEDS is 25 in longer FT E ED Frame Outline Drawings 3 Pole Types ED2 ED4 ED6 HED4 HED6 HHED6 ED6 ETI 19 Dia Mounting Holes 38 Dia x 13 Deep Counter bore 50 he T amp A EEIT Magnetic Adjustment Knob 38 Dia Push To Trip Button 21 Sq 36 Thick 3 Taper On pa 4 00 gt End View See Detail D amp E Page 9 Terminal Rotates to Side View Positions Shown HHED6 Handle Operating Forces Operation OFF to ON ON to OFF TRIPPED to RESET All drawing dimensions are shown in inches Q See detail drawings on page 9 G Switch does not have push to trip button HHED6 is 25 in longer
3. 1 16 Door Catch 1 12 Circuit Breaker 6 44 Mounting Panel Y 06 Min 19 Max Figure 2 35 36 I T E Fixed Depth Handle Operator Types 1 3 3R 4 4X 12 Installing Handle And Frame Assemblies Figure 3 Installing Door Catch If Required Figure 4 6 10 install Spring To Inner Bellcrank 2 7 8 9 Aux Switch Mounting Holes 12 13 14 11 Figure 3 1 Secure gasket 1 into groove of handle assembly 2 Mount handle assembly 2 and frame assembly 3 to enclosure flange using two 1 4 20 x 3 4 in socket head cap screws 4 and 1 4 in lockwashers 5 Tighten screws 4 to 75 in Ib 2 Attach link 6 to bellcrank 7 using the 5 16 dia x 5 8 in grooved pin 8 Secure pin 8 using the two 5 16 in E type retaining rings 9 3 Catalog numbers FDFBER 4 and FDFBEL 4 only Attach extension spring 10 to frame 3 and to inner bellcrank 7 4 Attach the interlock lever extension 11 to the interlock lever 12 and secure with 48 32 x 3 8 in screw 13 and 8 helical lockwasher 14 Tighten screw to 25 in Ib Mounting Holes if H 1 125 Top Handle Mtg n t Mounting Holes ifH 750 16 Interlock Lever Extension 17 18 Flange A ACA SCA AS Figure 4 1 If no door catch is provided with the enclosure weld the supplied door c
4. Parameter Parameter 30 10 10 Number 4 wire 3 wire wire 2 wire 1 Volts 1 L1 N 4W or L1 L2 4 4 2 Volts 2 L2 N 4W L2 L3 3W PA J v 3 Volts 3 L3 N 4W or L3 L1 3W v 4 Current 1 5 Current 2 v 7 6 Current 3 v 7 Watts Phase 1 v v v v 8 Watts Phase 2 v v v 9 Watts Phase 3 4 10 VA Phase 1 v v 11 VA Phase 2 12 VA Phase 3 v 13 VAr Phase 1 v A 14 VAr Phase 2 s 15 VAr Phase 3 P4 16 Power Factor Phase 1 v 17 Power Factor Phase 2 v 18 Power Factor Phase 3 4 v 19 Phase Angle Phase 1 v v PA 20 Phase Angle Phase 2 v v 21 Phase Angle Phase 3 P4 22 Volts Ave P4 24 Current Ave 25 Current Sum v 27 Watts Sum v v v M v 29 VA Sum v v v 31 VAr Sum 4 v v 32 Power Factor Ave v v 34 Average Phase Angle v A v P y 36 Frequency v v v 43 W Demand Import 4 s 4 44 W Demand Import v 4 v 53 A Demand v V 54 101 VL1 L2 calculated s 102 VL2 L3 calculated rompton 40 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Parameter Parameter 36 16 19 Number 4 wire 3 wire 3 wire 2 wire 103 VL3 L1 calculated 104 Average Line to Line Volts 4 113 Neutral Current 4 v s 118 THD Vol
5. g are L 4 LL THIS i H HHH E 1 FEH H TH La 8 HH HH 7 6 High Instantaneous f 6 5 Low Instantaneous t Seth 4 5 4 4 ai ed 4 T B HHHH 3 2r 4 2 H 1 1 09 1 H e 09 T m D 06 4 1 06 05 Maximum Clearing Time 05 9 1 125 Amp Circuit Breaker m 04 L 04 MH 03 Lf o3 600 zh 02 d id 1 oo 480V 01 240V 01 009 7 009 008 t e EN 008 007 E 007 006 4 _ Ea 006 ee 005 004 EH Pos Smeg 004 003 L4 IE 003 002 Lj 002 L4 001 L i I 001 Soo SONOS 8 Be 8 8 8 888888 N 2 TD 7100 Rev 4 ED Frame Time Current Curve TIME IN SECONDS 1CYCLE 8 8 9885085 Maximum Single Pole Trip Time at 25 C TIME CURRENT CHARACTERISTIC CURVE KT E SENTRON CIRCUIT BREAKER ED FRAME TYPE CED6 2 amp 3POLES For application and coordination purposes only Based on 40 C ambient cold start Connected with 4 feet of rated wire 60 C per terminal Tested in open air with current in all poles TYPE CED6 600 VOLTS 60 HZ 500 VOLTS DC INSTANTANEOUS TRIP TABLE RATING FIXED INSTANTANEOUS AMPERES TRIP AMPERES 15 25 400 700 30 125 600 1 000 INTERRUPTING RATING BREAKER SYM RMS AMPERES DC AMPS TYPE 240v 480 v 600 V 250 V 800 V CEDe 200kA 200kA 100kA 30 2 S0KA 3 P
6. I T E ED Frame Outline Drawings 2 and 3 Pole Types CED6 CED6 ETI2 19 Dia Mounting Holes 38 Dia x 13 Deep Counter bore Breaker 2 00 2 Pole 3 00 3 Pole Magnetic Adjustment Knob TH 38 Dia Push To Trip Button 21 Sq Front View End View Side View 3 91 Handle Operating Forces OFF to ON 8 10 ON to OFF 8 10 TRIPPED to RESET 14 drawing dimensions are shown in inches Only available as 3 pole breaker See detail drawings on page 9 B I T E ED Frame Detail Drawings 1 2 and 3 Pole Types ED2 ED4 ED6 HED4 HED6 HHED6 CED6 ED6 ETI CED6 ETI Detail A Thermal Magnetic Breaker Line End Detail Detail C Detail D Detail E drawing dimensions are shown in inches 10 I T E Pressure Wire Connectors DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS A Place terminal connector body 1 onto breaker tab 2 in ter minal cavity 3 Figure 1 B Insert cable into connector body between breaker tab and cable set screw except SA1
7. Undervoltage Trip m E 4 06 Aux Switch Bell Alarm Switch Si grees E Molded Case Switch E68312 LR42022 10848 8 32 ETI Breakers E10848 LR42022 Siemens Energy amp Automation Inc For Nearest Sales Office Power Distribution amp Controls Division 1 800 964 4114 or 800 241 4453 3333 Old Milton Parkway www sea siemens com For Product Information Alpharetta GA 30005 sales salesoffices html www sea siemens com power Installation and Operating Manual Switchboard Integra 1540 1000 0640 0440 0340 amp 0240 Digital Metering Systems Integra 1000 ak ots Loy S Amps ta Tyco Electronics UK Limited Crompton Instruments rompton Freebournes Road Witham Essex CM8 3AH UK Tel 44 1376 509 509 Fax 44 1376 509 511 tyco Electronics j Energy Division Crompton Switchboard Integra Multifunctional metering for Three phase Electrical Systems Models 1540 1000 0640 0440 0340 0240 Operating Instructions Important safety information is contained in the seperate installation leaflet Installers must familarise themselves with this inform n before installation Crompton Instruments Freebournes Road Witham Essex CM8 England Tel 44 0 1376 509 509 Fax 44 0 1376 509 511 E Mail crompton info tycoelectronics com Crompton Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics j Energy
8. Item Catalog No Item Catalog No Pressure Wire Connectors Rotary Handle Operators 15 25A SA1E025 Standard Depth E2RH1 Line amp Load Side Variable Depth E2RHV9 30 100A LN1E100 Flange Mount Handle Operator Single Pole Line Side Only Complete Mechanism FHOEO036 Multi Pole Line amp Load Side Handle FHOH CED6 Load Side Only Breaker Operator FHOEBO Standard Cable 36 in FHOEC036 30 60 LD1EO60 Optional Cable 48 in FHOECO48 Single Pole Load Side Only Door Latch Mechanisms CED6 Load Side Only Left Side DKL2 DKL3 70 100A LD1E100 Right Side DKR2 DKR3 Single Pole Load Side Only Electric Motor Operators E CED6 Load Side Only 120V AC MOG6E 120 110 125A TA1E6125 240V AC MOGE240 Line amp Load Side Connector Straps 2 and 3 Pole TC1ED6150 Outside Strap CS3600R 30 125A CS3602R Compression Connector eee eet el 15 125A CCE125 SOS Line amp Load Side Single Pole Mounting Bracket E2BMB Handle Blocking Device E2HBL Back Mounting Plate E2BMB Padlocking Device ED2HPL Mounting Screw Kits MSE6 7 MSE6100 Rear Connecting Studs SEEN Line Side Long RS2641 Enclosures Load Side Long RS2642 Breaker Types ED2 ED4 ED6 Line Side Short RS2643 HED4 HED6 HHED6 Load Side Short RS2644 ue 1 Mounting E2N1S h Mountin Plug In Adaptors Type ah ush Mounting ERN Line Side 3 Pole PC2657 i 70 100A EB Load Side 3 Pole PC2658 Type 12 E2N12 Switchboard Mounting Plates Breaker Type CED6 CED6 Breaker Type PL2617 Type 1 Surface Mounting
9. Check the door operation Latch on mechanism should engage latch tab 3 interior ring when breaker is ON and disengage latch tab when handle is rotated to OPEN DOOR position Enclosure door may be opened when breaker is ON by turning defeater screw 5 on rotary handle face plate Figure 4 in a clockwise direction Use 3 5 7 or 9 as a suffix number This indicates pipe length as related to enclosure depth Installation Diagrams B i ont AL 1 H Breaker Top or Line End of Circuit Breaker 1 8 32 Tapped Breaker Mtg Holes K Dia Shaft Breaker Mtg Holes Add Additional Mtg Holes when Square Enclosure Front Supplied by Customer Dimensions Inches 50 Tapped for 8 32 threads 375 4 125 pers pi va CED6 TypeCED6isused it Pod i N 3 pole Dimension shown is for 3 pole unit without accessory Breeker TUN i section For breaker with accessory section add 1 in to B Zd Mtg Surtace dimension M u BEL d SC pe a ed a Drilling Plan Load End View Figure 1 i i H i 1 le Spacer 1 t CED6 iad 5 Defeater Screw Breaker Mounting Mounting Handle Surface Enclosure Cover to Breaker Figure 2 Figure 3 Figure 4
10. Mechanical Testing Mechanical Operating Check Shunt Trip and or Undervoltage Trip A Reset the circuit breaker and turn handle to ON position NOTE With an undervoltage accessory assembled to the breaker without rated voltage applied to the coil the breaker will not RESET and turn ON Refer to Electrical Check on page 18 B While observing the slotted actuators in the accessory unit turn the breaker OFF and ON several times The blade actu ator slot 8 should nearly align with the locating tab when the breaker is OFF When the breaker is moved to the ON position the slot should travel clockwise approximately 40 Figure 3 C Place breaker in ON position and observe the trip latch actu ator 9 The actuator slot should rotate a few degrees coun terclockwise as the trip button 10 is depressed After the breaker has tripped the blade actuator slot and the cradle pin actuator slot 11 should nearly align with their respec tive locating tabs Figure 3 Bell Alarm Switch A For units with bell alarm contacts and either undervoltage or shunt trip follow above directions for shunt trip B For bell alarm only Reset breaker then turn to ON position Trip the breaker then observe the cradle pin actuator 11 The slot should nearly align with its locating tab Figure 3 Auxiliary Switch A For units with auxiliary contacts and either undervoltage or shunt trip follow directions above for shunt trip B Fo
11. H Turn the handle turn clockwise looking from inside the enclosure door and attach the latch plate roller to the han dle shaft while inserting the bent leg of the spring into the hole in the latch plate Fasten with a locking type flange nut Tighten the nut then loosen 1 turn to allow movement of the roller assemblies Figure 1 NOTE Straight leg of spring must rest against pin 12 on handle plate See inset on Figure 1 Place top spring 13 over top thin wall hex nut Attach lockout plate 14 to lockout screw using locking type flange nut Tighten flange nut Insert bent leg of spring into hole in lockout plate as shown in Figure 1 detail J Attach the interlock defeater lever 15 to the latch bar 16 with two 10 lockwashers and 10 24 screws NOTE The position of lever depends on enclosure depth Figure 3 K Weld or rivet the door catch 17 to the enclosure door User must supply the mounting hardware L Attach the door latch label to the door handle on the enclosure door Adjusting the Mechanism If using in conjunction with the FHOH or FHOH4 Handle Operator perform the following steps A With the door in the open unlatched position close the door but do not turn the door handle The lockout plate should latch the door partially closed B Turn the handle clockwise to stop This will engage the rollers against the enclosure flange securing the door fully closed C Check that the circu
12. 15 30 Amps 65 10 HED4 1 35 110 Amps 100 25 10 HED4 23 10 el oem HED6 2 3 P 100 18 30 2 P 25 3 HHEDe 23 10 65 25 CED6 23 P 200 200 100 2 50 3 For 500VDC applications the customer s power supply and load must be wired as shown in Figure 1 on page 4 RMS Symmetrical Amperes kA Breaker A 1 R 157 P1 Type Volts AC 50 60 Hz 220 40 380 415 500 ED4 3 P 65 18 NA HED4 3 P 100 42 NA HED6 3 100 30 NA CED6 3 200 200 NA Breaker IEC A R 947 2 Type c c9 ED6 3 P 65 17 35 9 18 5 Instantaneous Trip ETI motor circuit interrupters types ED6 ETI CED6 ETI adjustable instantaneous magnetic trip only are designed for use in welding circuits motor circuits and combination starters where short circuit protection only is required When used in combination starters they serve in conjunction with motor pro tective relays to offer the best available protection The relays guard against motor overloads and the circuit breaker provides short circuit protection Catalog information is located on page 50 Information and Instructions Operation and Maintenance MotorFull Load Amperes 20 33 34 45 46 56 57 68 69 81
13. Single pole test data at 25 C Sample instantaneous shown 100A breakers only For other instan taneous trip values see table 60 100 Seconds 300 50 40 30 20 8 7 6 5 4 3 Cea N T Tma 4 N Hill m a 8 1 I T 1 6 j 5 m LI LIDLLLILIILLZI L L 1 L4 AHH TD 7101 Multiples of Circuit Breaker Continuous Current Rating 1 000 2 000 3 000 4 000 5 000 6 000 7 000 8 000 9 000 10 SQNO23S NI INIL 47 48 Peak Let Thru Current p Amperes 103 ED Frame Peak Let Thru Current lp Curve Type CED6 5 6 7 8 910 20 30 40 50 60 70 8090 100 200 300 Maximum Available Symmetrical Peak Current TD 7101 A REV 2 5 6 7 8 910 20 30 40 50 60 70 8090 100 200 300 Available Short Circuit Current RMS Symmetrical Amperes x 10 Let Thru l t Amperes Sec x 10 ED Frame Let Thru 121 Curve Type CED6 1 2 4
14. To accept the displayed Demand Integration Time press The next Set up screen will appear Section 3 9 Resets Sys Volts To change the Demand Integration Time press and use this key to scroll through the available values Select the required value and press to accept it The Confirmation screen will appear Volts L3 N Volts 13 1 Amps L3 Value Press gt gt to accept the displayed value The next Set up screen will appear Section 3 9 Resets Press f to return to the Value screen and change the value Confirmation rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 27 tyco Electronics Energy Division 3 9 Resets 0240 0340 0440 0640 1000 1540 The following screens allow resetting of the Energy and Demand readings individually or altogether Resetting the cumulative Energy h resets both Active and Reactive Energy Resetting Demand d resets Active Power Demand Current Demand Maximum Active Power Demand Maximum Current Demand Press to move on to the next Set up screen without resetting any readings Sys Volts To reset one or more readings press 4f The first reset screen All will appear Reset None Use 1 to scroll through the parameters that can be reset h Active and reactive energy Sys Volts d Demands and maximum demands None no reset All h and d combined Volts L3 N eons L Selec
15. 3 Latch a 4 Ring Tab Mounting Screws Breaker 2 nia 7 Mtg Screws CED6 Pod L Enclosure Interior Enclosure Exterior Figure 5 Figure 6 29 I T E Rotary Handle Enclosure Mechanism Types 1 12 Mechanical Assembly Variable Depth E2RHV 3 5 7 or 99 Adaptor Bushing Lower Flange A With adapter bushing in place on bearing of lower mech B Place upper mechanism on upper flange flange with four anism place lower flange flange with the four tapped tapped holes and secure with four flat head screws Be sure holes on to the lower mechanism Secure with four flat latch on mechanism fits into elongated slot in flange head screws Pipe Clamps C Cut square shaft to desired dimension To do this subtract dimension D see dimension chart on page 29 from M D Place pipe clamp on the collar of each flange Do not dimension which is the distance from the back of the tighten breaker to inside of enclosure door E Place square shaft into bushing on lower mechanism and F With both lower and upper mechanisms in OFF position then place support pipe over this shaft and into collar or lower mechanism is OFF when square shaft is turned fully flange to the right place upper mechanism on to support pipe Make sure square shaft engages upper mechanism Use 3 5 7 or 9 as a suffix number This indicates pipe length as related to enclosure depth G Lay assembly on flat surface this wi
16. 53 83 84 1 14 1 15 1 45 1 46 1 68 1 69 2 00 76 1 29 1 30 1 75 1 76 2 29 2 30 2 68 2 69 3 18 1 23 1 99 2 00 2 75 2 76 3 52 3 53 4 14 4 15 4 90 2 30 3 83 3 84 5 37 5 38 6 52 6 53 7 68 7 69 9 10 4 23 6 91 6 92 9 61 9 62 11 91 11 92 13 83 13 84 16 40 6 15 10 37 10 38 14 22 14 23 18 06 18 07 20 75 20 76 24 50 8 84 14 22 14 23 19 60 19 61 24 99 25 00 28 83 28 84 34 00 13 84 23 06 23 07 31 52 31 53 39 99 40 00 46 14 46 15 54 50 24 23 41 52 41 53 56 91 56 92 68 45 68 46 76 91 76 92 90 90 38 46 55 37 55 38 70 75 70 76 84 60 84 61 96 14 96 15 113 60 Instantaneous Trip Adjustments High Low High Low High Low High Low High Low 2 3 4 High 125 25 185 30 270 115 185 255 40 325 375 180 300 410 50 520 600 315 540 740 100 890 1000 500 720 920 125 1100 1250 All values calibrated within guidelines of UL 489 Circuit Breaker Operation With the mechanism latched and the contacts open the operating handle will be in the OFF position Moving the han dle to the ON position closes the contacts and establishes a circuit through the breaker Under overload or short circuit con ditions sufficient to automatically trip or open the breaker the operating handle moves to a position between ON and OFF To relatch the circuit breaker after automatic operation move th
17. BELT COUPLED MOTOR GENERATOR SETS GENERAL USER S MANUAL MOTOR GENERATOR SETS WARNING DO NOT LIFT THE UNIT WITH LIFTING EYE BOLTS ON GENERATOR AND MOTOR USE 2 DIAMETER HOLES PROVIDED IN THE BASE DANGER HIGH VOLTAGE CAUTION CONNECT EQUIPMENT GROUND TO GROUND STUD AND INSULATE LEAD TERMINALS BEFORE STARTING THE GENERATOR FAILURE TO COMPLY MAY RESULT IN ELECTRICAL SHOCK AND DAMAGE TO THE UNIT TABLE OF CONTENTS BELT COUPLED MOTOR GENERATOR SETS GENERAL INSTRUCTIONS TENSIONING GUIDE FOR V BELT DRIVES BASIC TROUBLE SHOOTING FOR BELT COUPLED MOTOR GENERATOR SETS BASIC TROUBLE SHOOTING FOR V BELTS AND DRIVES MOTOR MANUAL GENERATOR MANUAL VOLTAGE REGULATOR MANUAL OUTPUT CIRCUIT BREAKER MANUAL OUTPUT METER PACKAGE MANUAL 1 0 2 0 3 0 BELT COUPLED MOTOR GENERATOR SETS GENERAL INSTRUCTIONS Georator Motor Generator MG Sets are inspected and fully tested at the factory before shipping Tests specifically conducted are 1 1 Examination of both motor and generator for general operation vibration and noise 1 2 Check of the output voltage of the generator and the setting of voltage regulator adjustments to the required output voltage 1 3 Check of the output frequency of the generator at no load If the frequency is not within standard limits called for in the specifications pulleys are turned machined to provide the correct frequency output The unit will then be re tested 1 4
18. Flange Mount Handle Operator Fixed Depth Flange Mount Handle Operator Door Latch Mechanism TELEMAND Electric Motor Operator Connecting Straps Single Pole Mounting Bracket Enclosures 2 Operating Characteristics Time Current Curves Let Thru Curves NOTE Information related to specific frame types or catalog numbers does not guarantee product availability Technical information may change due to product revisions Consult Siemens sales office concerning any variation of product information contained herein DANGER Hazardous voltages are present in the equipment which will cause death or severe personal injury and product failure Always de energize and ground the equipment before maintenance Maintenance should performed only by qualified personnel The use of unauthorized parts in the repair of the equipment or tampering by unqualified personnel will result in dangerous conditions which can cause severe personal injury or equipment damage Follow all safety instructions contained herein IMPORTANT The information contained herein is general in nature and is not intended for specific application purposes not is it intended as a training manual for unqualified personnel Refer to Note for definition of a qualified person It does not relieve the user of responsibility to use sound practices in application installation operation and maintenance of the equipment pur chased or in personnel safety pr
19. System House Randalls Research Park Randalls Way Leatherhead Surrey KT22 7TS England Support for Crompton Integra operation This is available via local sales and service centre Design considerations When integrating the Crompton equipment into a Metasys Network keep the following considerations in mind Make sure all Crompton equipment is set up started and running properly before attempting to integrate with the Metasys Network A maximum of 32 devices can be connected to any one NCM N2 Bus Vendor Address 1 247 Limited by co resident Modbus protocol Port Set up Baud Rate 9600 Duplex Full Word Length 8 Stop Bits 1 Parity None Interface RS485 rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 61 tyco Electronics Energy Division METASYS N2 application Integra 1560 1580 Point Mapping table Address Parameter Description Units 1 Voltage 1 Volts 2 Voltage 2 Volts 3 Voltage 3 Volts 4 Current 1 Amps 5 Current 2 Amps 6 Current 3 Amps 7 Voltage average Volts 8 Current average Amps 9 Power Watts Sum kW 10 VA Sum kVA 11 var Sum kvar 12 Power Factor average 13 Frequency Hz 14 Active Energy Import kWh 15 Reactive Energy Import kvarh 16 Watts Demand Import kW 17 Maximum Watts Demand Import kW 18 Amps Demand Amps 19 Maximum Amps Demand Amps 20 Volt
20. ment Type 4 4X ED6SS49 Stainless steel indoor or outdoor enclosure designed for use in areas where serious corrosion problems exist Meets NEMA Type 3 4 4X 12 and 13 requirements and UL 508 Type 4 and 4X requirements PADDLOCKING HASP AND STAPLE Dimension In Inches Catalog Number E2NIS EzNiF CLEGNTS CL E6NTF ezN3R ELESNSR EDGSSA wr ws erar 2225 iae 223 mo 75 S suffix is for surface mounted F suffix is for flush mounted For use with circuit breaker types ED2 ED4 ED6 HED4 HED6 For use with circuit breaker type CED6 NOTE Neutral supplied with each enclosure I T E Enclosures Types 7 9 12 7 9 EA 60 EB 100A Cast aluminum enclosure classified as explosion and fire hazard only enclosure for use in hazardous locations Class Group D Class ll Groups F and G Class Ill Type 12 12K E2N12 K A special industry sheet steel enclosure for indoor use in atmosphere containing particles of lint dust dirt sawdust and other foreign matter Type 12 12K CLE6N12 CLE6N12K 875 1 125 1 375 1 75 2 00 K O s 2 Required G For use with circuit breaker types ED2 ED4 ED6 HED4 HED6 For use with circuit
21. 0240 Issue 1 04 03 tyco Electronics Energy Division Press gt gt to accept the displayed Reading Top value The next Set up screen will appear Sys Volts Press 11 to return to the Edit screen Confirmation 3 15 8 Reading Bottom A1rb or A2rb Use these screens to specify the minimum or most negative value for the Reading Bottom value The method of setting the Reading Bottom screens is the same as for setting the Reading Top screens as described in Section 3 15 7 The Reading Bottom screens show A1rb or A2rb for the Analogue output 2 on the top line 3 15 9 Output A1ot A2ot Use these screens to set the maximum analogue output current in mA This current will represent the highest reading value You cannot specify a greater current than the actual value that the unit can supply e g 1 mA The method of setting the Output Top screens is the same as for setting the Reading Top screens as described in Section 3 15 7 The Output Top screens show A1ot or A2ot for the Analogue output 2 on the top line 3 15 10 Output Bottom A1ob or A2ob Use these screens to set the minimum or most negative analogue output current in mA This current will represent the lowest or most negative reading value The current cannot be set to a value that exceeds the actual capability of the unit e g it cannot be set it to 10 mA if the unit can only handle 1 mA The method of setting the Output Bottom screens is t
22. 1540 In Model 1000 and 1540 combined the PT Secondary Value is factory set as marked on the barrel The PT Secondary Value is user programmable on the 1540 and Integra 1560 two part This value must be set to the nominal full scale secondary voltage which will be obtained from the transformer when the potential transformer PT primary is supplied with the voltage defined in Section 3 6 Potential Transformer Primary Voltage This defines the actual full scale voltage that will be obtained from the PT secondary and measured by the unit The ratio of the full scale primary to full scale secondary voltage is the transformer ratio Given full scale primary and secondary voltages the unit knows what primary voltage to display for any given measured secondary voltage The secondary voltage displayed is in volts Following the previous example on a 2 2 kV system with 110V PT secondary set this screen to 110 0 If there is no PT associated with this unit leave this value unchanged and skip this step To accept the displayed PT Secondary Voltage press gt gt The next Set up screen will appear Section 3 8 Demand Integration Time Sys Volts To change the PT Secondary Voltage display press 4f Note that the decimal point edit screen will only appear when the display unit is connected to a transducer designed for connection to voltages in the range 57 7 to 139V Initially all the digits of the present value will be flashing and the
23. CLE6GNIS All Other Types PL2616 Type 1 Flush Mounting CLE6NIF f Type 3R CLE6N3R Ground Fault Sensing Relay Kits 30mA Type 12 CLE6N12 Basic Kit GFO1ED60 Basic Kit with Normally Open Bell Alarm GFO1ED60B0 Time Current Curves Basic Kit with Normally Closed Bell Alarm GFO1ED60BC Types ED2 ED4 ED6 HED4 HED6 HHED6 0 7100 CED6 TD 7101 Ground Fault Sensing Relay Kits bmA Basic Kit GFO1ED65 Let Thru Curves Basic Kit with Normally Open Bell Alarm GFO1ED65B0 Peak Current lp TD 7101 A Basic Kit with Normally Closed Bell Alarm GFO1ED65BC Pt TD 7101 B Rotary Handle Operators For 4 4x application order FHOH4 instead of FHOH Standard Depth D11CEU1 Consists of 4 screws and assorted washers and or nuts Variable Depth D11CEU2 9 Consists of 100 screws and hardware Rotary Handle Operators Complete Mechanism Standard Depth CRHOESD Variable Depth CRHOEVD Handle RHOH Breaker Operator RHOEBO Shaft Standard Depth RHOSSD Variable Depth RHOSVD 55 UL Listings and File Numbers Industry Specifications eve UL 489 CSA National Fire Protection Assoc National Electrical Code Item File Number Report Number Federal Specification W C 375B GEN Breakers E10848 LR13077 Terminal Connectors 23615 SP Underwriters Laboratories Inc UL 489 Plug In Connectors E23615 ian ian Bares E23815 Canadian Standards Association C22 2 No 5 Add On External Accessories E69455 LR13077 Shunt Trip
24. Crompton Instruments Manufacturer s Address Freebournes Road Witham Essex CM8 3AH UK declares that the products Product Names Integra 1560 Transducer and display Model Numbers INT 1561 INT 1562 INT 1563 INT 1564 INT 1581 INT 1582 INT1583 INT 1584 DiS 0240 015 0340 DIS 0640 DIS 0740 DIS 1540 conforms to the following standards LVD BS EN 61010 1 1993 Plus Amendment 2 July 1995 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use EMC BS EN 61326 1998A1 Emissions standard for Measurement Control and Laboratory Equipment Class A BS EN 61326 1998A1 Immunity standard for Measurement Control and Laboratory Equipment Annex A Supplementary Information The product complies with the requirements of the following EU directives and carries CE marking accordingly European Low Voltage Directive 73 23 EEC amended by 93 69 EEC by the standards route to compliance EMC Directive 89 336 EEC amended by 93 68 EEC by the standards route to compliance Signature of authorised person N F Dudley R amp D Manager Dated 30 April 2002 Registered Office Faraday Road Dorcan ompton Swindon Wiltshire SN3 5HH UK Registered No 550926 FM 21540 VAT No GB 681 471 425 rompton ISTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 65 tyco Electronics j Energy Division Notes rompton INSTRUMENTS 66 Integra 1540 1000 0640
25. Drill and tap four mounting holes 15 in the enclosure back panel using dimensions A and B from Table 1 C Mount the circuit breaker inside the back panel Align the holes in the panel with the mounting holes of the breaker D Insert the three plastic spacers 16 into the circuit breaker mounting holes for support as shown in Figure 6 E Instali the operating mechanism 17 on the spacers 16 and secure with the three 1 4 20 x 5 pan head screws and lockwashers Insert the 74 20 x 414 in pan head screw through the hole without a spacer 18 Mount the circuit breaker and operating mechanism to the enclosure panel with the screws supplied Securing Operating Cable to Frame Assembly A To attach the operating cable 14 to the frame assembly 4 move the operating handle 2 to the ON position and attach the cable swivel 19 to the outer hole of the bellcrank 6 Secure the connection with an E Ring Figure 7 B Secure the cable 14 to the frame assembly 4 by placing it between the cable retainer clip 20 and the shim 21 secure with two 10 32 x 3 in screws and lockwashers NOTE Detent 22 in cable retainer must align with the groove 23 in the cable s metal fitting Figure 7 INSTALLATION DIAGRAMS 15 Tapped Holes a m F Max 1 Me 3 F Max G t Figure 7 Outlines represent breaker operator
26. tyco Electronics Energy Division 2 Display Screens 2 1 Layout The screen is used in two main modes display of measured values and parameter setup In display mode three measured values can be shown one on each row For each row the LED indicators show the parameter being measured and the units The gt gt button moves between display screens In Set up mode the top row shows an abbreviation of the 25 parameter name the middle row shows the parameter value ee being set and the bottom row is used for confirmation of the REN entered value In general the 7 key changes a parameter value Amps L1 n and the gt gt key confirms a value and moves on to the next screen yey 5 Pr This example is the potential transformer primary voltage Volts 13 1 Amps 3 M confirmation screen Setup confirmation screen The example screens shown in this manual are those relating to the 1540 models the most complex The screens for simpler models are similar except that some of the parameters and values are omitted Section 1 1 shows the default display screens for the various models 2 2 Start Up Screens Initially when power is applied to the Integra Display two H H screens will appear The first screen lights the LED s and be pua opis used as a display LED check Sys Volts e E r rds uy uH Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Is
27. 0440 0340 0240 Issue 1 04 03 The Information contained in these installation instructions is for use only by installers trained to make electrical power installations and is intended to describe the correct method of installation for this product However Tyco Electronics has no control over the field conditions which influence product installation It is the user s responsibility to determine the suitability of the installation method the user s field conditions Tyco Electronics only obligations are those in Tyco Electronics standard Conditions of Sale for this product and in no case will Tyco Electronics be liable for any other incidental indirect or consequential damages arising from the use or misuse of the products Crompton is a trade mark Tyco Electronics UK Limited Crompton Instruments Freebournes Road Witham Essex CM8 3AH UK Tel 44 1376 509 509 Fax 44 1376 509 511 http energy tycoelectronics com
28. 152 Typical locked rotor current for across the line start can be as high as 600 to 800 of full load motor amps FLA Georator offers reduced voltage motor starters as a standard for units using 125 HP motors and above Part winding motor starters can reduce the starting current by 50 whereas Wye Delta motor starters can reduce starting current down to 33 of the normal starting current Solid State Soft Starters can significantly reduce the starting current of the motor to a controlled level usually selected by the user in the range of 25 55 of the motor full load current All motors used on Georator MG sets confirm with the EPACT mandate requirements for high efficiency induction motors Check input voltage periodically Voltage imbalances cause temperature rise in the motor A 3 5 voltage imbalance will typically cause 25 temperature rise in the motor The Neutral wire on the Generator side is provided for most wiring configurations for three phase Wye and single phase Delta or Zig Zag connections The Neutral wire if provided is not tied to the ground potential in the factory User to follow the installation requirements and codes pertaining to grounding Except in the case of MG Sets designed for special testing requirements with complete isolation of Input and Output the structural steel base is electrically bonded to the motor and generator frames through the mounting bolts of each thus confirming to NEC Article 250 1
29. 30 6 Bell Alarmi if any l GFO1E60BC Normally Closed 1 amp 3 Shunt Trip Functions when wired Bell Alarm Contact 30 6 per this sketch Figure 1 oo Handle Escutcheon Handie Cutout 120V AC Control 3 amp 4 Push to Test Leads Sensing Leads 810 50 DIA Hole to Access Push To Trip Button 1 25 single pole Ground Fault 2 25 multi pole o 20 A Relay Module Net Sensor Load Circuit Wiring Figure 2 Ground fault relay module can also be used on 1 or 2 pole ED Frame circuit breakers Accessory module is used on all ED Frame circuit breakers 21 22 I T E Rotary Handle Enclosure Mechanism Types 1 12 A DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS Standard Depth D11CEU1 Variable Depth D11CEU2 General Handle will permit locking the disconnect device in the OFF position using up to three locks having shackles up to 34 in dia Provision for locking in ON position is provided but the handle plate must have the material covering the locking notch removed This can be done with a hacksaw or file The handie has a voidable interlock Voiding the interlock requires insert ing a small screwdriver into the rectangular opening in the handle plate which will release the handle Mounti
30. A 30201 101 V 11 12 calculated 00 C8 X x 30203 102 V L2 L3 calculated 00 CA s X X X 30205 103 V L3 L1 calculated 00 CC X X X 30207 104 Average Line to Line Volts 00 CE A X v X 30225 113 Neutral Current 00 EO 4 X v 30235 118 THD Volts 1 Integra 1540 only 00 EA v A A A 30237 119 THD Volts 2 Integra 1540 only 00 EC A A X 30239 120 THD Volts 3 Integra 1540 only 00 EE x X 30241 121 THD Current 1 Integra 1540 only 00 F0 A A v 30243 122 THD Current 2 Integra 1540 only 00 F2 v A A X 30245 123 THD Current 3 Integra 1540 only 00 F4 A X X 30249 125 THD Voltage Mean Integra 1540 only 00 F8 4 v v 30251 126 THD Current Mean Integra 1540 only 00 FA v v 30255 128 Power Factor Ind Cap 00 FE 4 v INSTRUMENTS 58 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Modbus Holding Registers and Integra set up Holding registers are used to store and display instrument configuration settings All holding registers not listed in the table below should be considered as reserved for manufacturer use and no attempt should be made to modify their values The demand parameters may be viewed or changed using the Modbus protocol Each parameter is held in the 4X registers Modbus Function Code 03 is used to read the parameter and Function Code 16 is used to write
31. Assemble blocking device to breaker by positioning it above handle Figure 1 Insert tabs 1 into slots 2 on either side of pad Figure 2 ATTACHING I T E PADLOCKING DEVICE ED2HPL Assemble padlocking device to breaker by placing it over breaker handle Figure 3 Position tabs 1 into slots 2 on either side of pad Figure 4 tighten screws 3 to secure pad locking device Figure 1 2 M Figure 3 Figure 2 Figure 4 I T E Rear Connecting Studs P DANGER Mounting Preparation and Assembly Hazardous Voltage A Remove wire terminals from breaker Will cause death or severe injury B Select proper rear connect ng stud assembly as required Turn power off for line terminals Figure 3 and load terminals Figure 1 supplying switch C Align rear connecting studs with breaker terminals and board or panel secure to breaker terminals with 12 24 screws lock before installing san washers and flat washers Install line shields on line side of breaker Figure 3 SAFETY IN STRUCTIONS E Install two 3 8 16 silver finished brass nuts on the threaded end of each rear connecting stud Load Side Figure 1 Load Side Dimensions In Inches 1 Breaker VA CED6 C
32. Electrical Code and local codes Recommended use is 125 of full load amps as shown on the nameplate for motors with 40 C ambient 4 E C MOM DC eee anda service factor over 1 0 Recommended use is 115 of full load amps as shown on the nameplate for all other motors Do not use protection with larger capacities than recommended Three phase motors must have all three phases protected THERMAL PROTECTOR INFORMATION The nameplate will indicate one of the following 1 Motor is thermally protected 2 Motor is not thermally protected 3 Motor is provided with overheat protective device For examples refer to paragraphs below 1 Motors equipped with built in thermal protection have THERMALLY PROTECTED stamped onthe nameplate Thermal protectors open the motor circuit electrically when the motor overheats or is overloaded The protector cannot be reset until the motor cools If the protector is automatic it will reset itself If the protector is manual press the red button to reset 2 Motors without thermal protection have nothing stamped on nameplate about thermal protection 3 Motors that are provided with overheat protective device that does not open the motor circuit directly will indicate WITH OVERHEAT PROTECTIVE DEVICE A Motors with this type of Overheat Protective Device have protector leads brought out in the motor conduit box marked P 1 and P2
33. Frame Ass y Operating Arm Circuit Aux Switch Breaker Mounting Holes Handle Handle Figure 5 1 Move the operating handle and circuit breaker handle to the OFF position 2 Locate the circuit breaker over the mounting holes in the enclosure panel and position the breaker operator 20 or 23 onto the circuit breaker positioning the combination so that the operating arm engages the circuit breaker handle and the driver pin on the bell crank of the frame assembly 3 Proceed with specific ED frame instructions as follows Secure the breaker and breaker operator 20 to the enclo sure panel using the four 8 32 x four 3 8 in screws 21 four 48 lockwashers 22 and two spacers spacers sup plied with separate instructions Tighten the screws to 16 to 18 in Ibs 21 22 Ed Frame Circuit Breaker Driver Pin Trip Button Frame Ass y Slotted Holes Figure 6 Adjusting The Breaker Operator Figure 6 1 Check that the circuit breaker turns ON and OFF by moving the operating handle UP for ON and DOWN for OFF If the breaker does not turn ON loosen the mounting screws 21 or 24 and adjust the breaker operator upward 1 16 inch tighten the mounting screws to 16 to 18 in Ibs and check if the breaker turns ON Repeat if required 2 To check the TRIP RESET function move the handle to the ON position and push the TRIP button located on the front of the circuit b
34. Motor starter operation is checked Overload relay is tested 1 5 Meters are checked for general operation and calibrated if necessary 1 6 Tripping function of the circuit breaker is checked using the test button Users should follow national local and site codes for wiring protection and installation No holes are punched in either Motor Starter enclosure or Generator connection box for electrical connections The user should place these holes where most convenient for the installation In selecting a location for the Motor Generator Set consideration should be given to environment and ventilation Do not obstruct air flow for air intake and exhaust of the motor generator and pulleys amp belts or coupling Allow a distance of at least 3 feet around the perimeter of the unit Restricted ventilation will cause a motor generator to operate at higher than desired temperature Dirt dust chemicals snow oil grass weeds etc all can clog passages of an open frame motor Georator uses open drip proof motors and generators with drip covers as a standard Open drip proof construction is intended for use indoors where the atmosphere is relatively clean dry and non corrosive According to the NEMA 2 publication a drip proof machine is an open machine in which the ventilating openings are so constructed that successful operation is not interfered with when drops of liquid or solid particles strike or enter the enclosure at any angl
35. Output Power Continuous 73 Vdc at 3 5 Adc 255w Output Power Forcing 240 Vac Input Power 105 Vdc at 5 525w Regulation 1 0 Remote Voltage Adjustment Range 10 with 2000 ohm rheostat 5 with 1000 ohm rheostat Frequency Compensation Adjustable Roll off frequency 54 61 Hz for 60 Hz 45 51 Hz for 50 Hz Operation Weight6 5 oz Operating Temperature 40 C to 60 C Storage Temperature 65 C to 85 C Power Dissipation 8 watts maximum Size 3 94 L X 2 66 W X 2 20 H Voltage Buildup Internal provisions forautomatic voltage build up from generator residual voltage as low as 10 Vac EMI Suppression Internal Electromagnetic Interference Filter EMI Filter WARNING TO PREVENT PERSONAL INJURY OR EQUIPMENTDAMAGE ONLY QUALIFIED PERSONNEL SHOULD INSTALL OPERATE OR SERVICE THIS DEVICE CAUTION DO NOT megger or high pot the generator with the regulator connected DO NOT high pot the regulator The SE350 voltage regulator can be mounted in any plane following are mounting dimensions VIEWING TERMINAL END OF THE REGULATOR DIMENSIONS FOR MOUNTING TERMINAL SIDE UP 3 56 19 DIA 2 HOLES N D D E J R p uU i 231 R S 38 DIA ET 95 Tw SHOLES Q y 0 o L C i N c STABILITY ADJUST VOLTAGE ADJUST ACCESS HOLE ACCESS HOLE FIGURE 1 FUSE 4 Amp 250 V 5 X 20 mm fuse is supplie
36. Register Parameter Parameter Modbus Start Valid range Mode Number Address Hex High Low Byte Byte 40001 1 Demand Time 00 00 0 only r w 40003 2 Demand Period 00 02 8 15 20 30 minutes r w 40007 4 System Voltage 00 06 1V 400kV r wp 40009 5 System Current 00 08 1 9999 A r wp 40011 6 System Type 00 0A ro 40013 7 Relay Pulse Width 00 oc 3 5 10 x20mS r w 40015 8 Energy Reset 00 0 only wo 40023 12 Pulse Divisor 00 16 1 10 100 1000 r w 40025 13 Password 00 18 0000 9999 r w 40037 19 System Power 00 24 r o 40041 21 Register Order 00 28 2141 0 only wo 40299 150 Secondary Volts 01 2A Min Vin Max Vin r wp r w read write r wp read and write with password clearance ro read only wo write only Password Settings marked r wp require the instrument password to have been entered into the Password register before changes will be accepted Once the instrument configuration has been modified the password should be written to the password register again to protect the configuration from unauthorised or accidental change Power cycling also restores protection Reading the Password register returns 1 if the instrument is unprotected and 0 if it is protected from changes Demand Time is used to reset the demand period A value of zero must be written to this register to accomplish this Writing any other value will cause an error to be returned Reading this register after instrument restart or resetting demand period gives the number of minu
37. Shunt Trip and 2 1 Alarm Switch Auxiliary Switches Catalog Number N A N A N A N A S01ED62B SO1ED62AA SO2ED62B SO2ED62AA SOSED62B SO3ED62AA S15ED64B N A SO4ED64B N A N A N A S07ED62B SO7ED62AA SO9ED62B SO9ED62AA S11ED62B S11ED62AA S13ED62B S13ED62AA 1 Undervoltage Trip and 1 Alarm Switch 1 Undervoltage Trip and 2 Auxiliary Switches AC DC Catalog Number Catalog Number Catalog Number 120 UO1ED60 UO1ED62A UO1ED62AB UO1ED62B UO1ED62AA 208 UO2ED60 UO2ED62A UO2ED62AB UO2ED62B UO2ED62AA 240 U03ED60 U03ED62A UOSED62AB UOSED62B UOSED62AA 277 U16ED60 U16ED64A U16ED64AB U16ED64B N A UOGED60 UOGED64A UOGED64AB UOGED64B N A U08ED60 N A N A N A N A U13ED60 U13ED62A U13ED62AB U13ED62B U13ED62AA 48 U14ED60 U14ED62A U14ED62AB U14ED62B U14ED62AA 125 U10ED60 U10ED62A U10ED62AB U10ED62B U10ED62AA 250 U12ED60 U12ED62A N A N A U12ED62AA Ground Fault Relays Equipment Protection Only BOOED62 BOOED62 BOOED62 BOOED64 BOOED64 N A BOOED62 BOOED62 BOOED62 BOOED62 GFO1ED65 GF01ED65BO GFO1ED65BC GFO01ED60 GFO1ED60BO GF01ED60BC NOTE ry is 9898 on all ED Frame circuit r E to a circuit breaker Ordering Information Additional Accessories D For 4 4x application order RHOH4 instead of RHOH
38. These leads are intended for connection in series with the stop button of the 3 wire pilot circuit for the magnetic starter which controls the motor See Figure 1 B Thecircuit controlled by the above Overheat Protective Device must be limited to a maximum of 600 volts and 360 volt amps TO CONTROL VOLTAGE START HOLD LL M NES UP en eer FIGURE 1 NORMALLY CLOSED PROTECTORS Normally Open N O Motor Thermostats may be used in con l junction with controls installed by i Original Equipment Manufacturers be NORMALLY OPEN PROTECTORS CHANGING ROTATION 1 Keep hands and clothing away from rotating parts 2 Before the motor is coupled to the load determine proper rotation 3 Check rotation by jogging or bumping Apply power to the motor leads for a short period of time enough to just get motor shaft to rotate a slight amount to observe shaft rotating direction 4 Three phase interchange any two 2 of the three 3 line leads Single phase reconnect per the connection diagram on the motor FIGURE 1A REDUCED VOLTAGE STARTING Motors used on reduced voltage starting should be carefully selected based upon power supply limitations and driven load requirements The motors starting torque willbe reduced when using reduced voltage starting The elapsed time on the start step should be kept as short as possible and should not exceed 5 seconds It is recommended that this time be limited to 2 seconds Refer
39. To check voltage regulator remove leads F and F from the voltage regulator and noting polarity put a 12 V DC battery battery charger or DC power supply across F and F leads Then turn the MG on and the output voltage at no load should be high and stable If so the voltage regulator is the only thing that doesn t work Replace the regulator If this is not the case then a major generator problem exists that will need factory repair 2 The output frequency should be within plus or minus 1 percent A If the no load output frequency is above 1 check the input frequency where the output frequency will vary proportionally to the input frequency B If the loaded output frequency is low below 1 check input frequency for proportional relationship If the input frequency is OK and the input voltage is OK check for belt tensioning BASIC TROUBLE SHOOTING FOR V BELTS AND DRIVES Problem Probable Cause Trouble Shoot Short Belt Life Spin burns from belt slipping on drive sheave under a stalled load condition or when startin Gouges or extreme cover wear caused by belts rubbing on drive guards or other objects e Tension belts e Eliminate obstruction or realign drive to provide clearance High ambient temperature e Use high temperature belts e Provide ventilation e Shield belts Grease or oil on belts e Check for leaky bearings e Clean belts and sheaves Worn sheaves e Repla
40. Volts indicate which digit can currently be changed It thus acts as a cursor Where the cursor coincides with a genuine decimal annann point on the display the decimal point will flash Li LI LI Li Press the 11 key to scroll the value of the first digit from 0 through to 9 the value will wrap from 9 round to O For this example set it to 1 Press the gt gt key to confirm your setting and advance to the First digit next digit Use the t key to set the second digit to the required value Sys Volts Press the key to confirm your selection and advance to the next digit Use the t key to set the third digit to the required value Press the gt gt key to confirm your selection and advance to the next digit Third digit rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 19 tyco Electronics Energy Division Use the 11 key to set the fourth digit to the required value Press the gt gt key to confirm your selection If the unit accepts your entry the Confirmation screen will appear If the unit does not accept your entry e g an incorrect password a rejection screen will appear with dashes on the bottom line Fourth digit The Confirmation screen shows the entered number on the bottom row with all decimal points showing Sys Volts Vots L1 N If the displayed number is correct press the gt gt key to move to the next Set up screen If not pr
41. are generated in all rotating shaft systems In some cases the amplitude of these vibrations at critical speeds may cause damage to either the generator its driver or both lt is therefore necessary to examine the torsional vibration effect on the entire rotating system IT IS THE RESPONSIBILITY OF THE GENERATOR SET ASSEMBLER TO ASSURE THE TORSIONAL COMPATIBILITY OF THE GENERATOR AND ITS DRIVER Drawings showing pertinent dimensions and weights of the rotating assembly will be supplied by Marathon Electric upon request e MARATHON A Subsidiary of Regal Beloit Corporation ENVIRONMENTAL CONSIDERATIONS The MagnaPLUS generator is designed for heavy duty industrial applications however dirt moisture heat and vibration are enemies of rotating electrical machinery Excessive exposure to the elements may shorten generator life The temperature of the cooling air entering the intake openings of the generator should not exceed the ambient temperature shown the generators nameplate Generators intended for outdoor application should protected with housings having adequate ventilation Although the standard insulation systems are moisture and humidity resistant space heaters are recommended for extreme conditions If the generator is to be installed in an area where blowing sand and dust are present the enclosure should be fitted with filters Filters reduce erosion on the generator s insulation by blocking high velocity abra
42. available for all ED Frame circuit breakers Rear connection studs or plug in connector assemblies are also available 1 2 and 3 pole The latter mounting arrange ment permits removal of the circuit breaker from its leads without physically coming in contact with either the line or load terminals Special features such as a shunt trip auxiliary and alarm switches and undervoltage trip devices are available for field adaptation The installation and or removal of these devices is to be accomplished by qualified personnel only These devices are mounted externally and Underwriters Laboratories listed page 53 Information concerning them is found on pages 16 19 and 51 Thermal Magnetic ED2 ED4 ED6 HED4 HED6 HHED6 CED6 type circuit breakers provide complete overload and short circuit protec tion by use of a time delay thermal trip element and an instan taneous magnetic trip element Fixed instantaneous trip values are shown in the table below Fixed Instantaneous Trip 30 125 600 1000 Circuit breakers are calibrated at the factory under controlled temperature conditions for application at 40 C 104 F ambient to meet requirements as outlined in UL 489 standard for molded case circuit breakers Catalog information is found on pages 48 50 National Electric Code 240 11 A current limiting overcurrent protective device which when inter rupting currents in its current limiting range will reduce the current flow ing
43. breaker type CED6 Add suffix when Type 12 with knockouts is required NOTE Neutral supplied with each enclosure 45 ED Frame Time Current Curve Types ED2 ED4 ED6 HED4 HED6 HHED6 a 8 8 8 8 588888 o o ooooo8 8 8 8888888 e 286508 N e TM ORDO N e N e 0 e 10 000 7 I T 15000 51000 1 Time Current Characteristic Curve 2 000 7 000 T i IN I T E Sentron Circuit Breaker 7 000 5 000 1 ED Fi T ED2 ED4 ED6 HED4 HED6 HHED6 Pd son Ia 4 000 ni i For application and coordination purposes only Based on 2000 3 000 40 Cambient cold start Connected with 4 feet of rated wire t 3 000 i 60 C per terminal Tested in open air with current in all poles 2000 H type ED2 240 volts 60 Hz
44. decimal point position will be illuminated This is to indicate that initially the multiplier must be selected Decimal Point Press 7 to change the decimal point position Press gt gt to accept the decimal point position The Digit Edit screen appears Set the display to read the value of the PT Secondary voltage as described in Section 3 2 Number Entry Procedure Sys Volts Volts L1 N After the last digit has been set and accepted the Confirmation screen will appear Volts L3 N Volts 13 1 mps Digit Edit rompton INSTRUMENTS 26 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Press gt gt to accept the displayed value Depending on the model this may take you out of the Set up screens and back to the last selected Display screen Press i1 to return to the Decimal Point screen The secondary value may only be set to values within the range defined by the factory voltage build option These nominal rms input voltages are as shown in the relevant measurement transducer specification see separate document for two part products or Section 4 2 1 Inputs for combined products Confirmation 3 8 Demand Integration Time 0240 0340 0440 0640 1000 1540 This screen is used to set the period over which current and power readings are integrated see Section 1 4 Demand The value displayed represents time in minutes
45. has tripped unless a separate bell alarm accessory contact Siemens for appropriate catalog number is provided to energize a customer furnished warning device After the circuit breaker trips automatically it is neces sary to press the OFF button to move the breaker handle to the reset position Automatic Reset For automatic reset an auxiliary switch Contact Siemens for appropriate Catalog Number is used to return the breaker to the OFF RESET position after it has been tripped This auxil iary switch is mounted inside the breaker and wired in parallel with the OFF button When the breaker trips the auxiliary Switch closes thus energizing the motor circuit which moves the breaker to the OFF RESET position Bottom View Figure 1 I T E TELEMAND Electric Motor Operator Catalog Numbers MOE6120 MOE6240 After the motor operated mechanism has reset the breaker the motor operator internal limit switch opens the circuit To provide automatic reset the ON pushbutton must be a single pole dou ble throw device and it must be wired per Figure 3 Manual Operation Operate the cover latch and swing the hinged motor operator cover away from the breaker to expose the breaker handle To return to electrical operation rotate cam to a position that matches the breaker handle See instruction label inside operator 12 72 Load Side Figure 2 GRD Green Ground Customer Supplied Equipmen
46. in the faulted circuit to a magnitude substantially less than that obtainable in the same circuit if the device were replaced with a solid conductor having comparable impedance Underwriters Laboratories UL 489 Par 2 5 A circuit breaker that does not employ a fusible element and that when operating within its current limiting range limits the let through l tto a value less than the l t of a 12 cycle wave of the symmetrical pro spective current Molded Case Switch A molded case switch is available in the ED2 ED4 ED6 HHED6 CED6 type circuit breakers This device employs the same operating mechanism as the thermal magnetic and magnetic only units A preset instantaneous function is factory installed to allow the switch to trip at a value over 1000A and protect itself against high fault conditions No overload or low fault current protection is provided This protection must be supplied by separate overcurrent devices Catalog information is located on pages 48 51 Interrupting Ratings Symmetrical RMS Amperes kA Based on UL 489 Standards UL File 4E10848 RMS Symmetrical Amperes kA Breaker UW ALR Type AC pc 120 240 277 480 600 125 250 5000 ED2 1 dj emm qued m ED2 2 3 P ENSE EM MONDO MEE I7 NS ED4 1 el af 15 z ED4 2 3 P 65 1 30 2 ED6 2 3 P 6 2 18 a 18 6P HED4 1
47. isolate electrical power inspect the unit and remove any dust or other foreign material present Periodically check all connections for freedom from corrosion and screw tightness particularly if vibration is present The front of the case should be wiped with a dry cloth only Use minimal pressure especially over the viewing window area If necessary wipe the rear case with a dry cloth If a cleaning agent is necessary isopropyl alcohol is the only recommended agent and should be used sparingly Water should not be used If the rear case exterior or terminals should accidentally be contaminated with water the unit must be thoroughly dried before further service Should it be suspected that water might have entered the unit factory inspection and refurbishment is recommended In the unlikely event of a repair being necessary it is recommended that the unit be returned to the factory or nearest Crompton service centre rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 63 tyco Electronics Energy Division Tyco Electronics UK Limited tuco Crompton Instruments due mE Freebournes Road Witham Electronics Essex CMB 3AH UK X Tel 44 1376 509 509 Energy Division Fax 44 1376 509 511 DECLARATION OF CONFORMITY Manufacturer s Name Tyco Electronics UK Limited Crompton Instruments Manufacturer s Address Freebournes Road Witham Essex CM8 3AH UK declares that the products Product N
48. open Undervoltage Trip A With the circuit breaker in the OFF position apply variable voltage supply leads to the accessory terminals marked 1 and 2 Figure 2 B Apply 100 percent of the accessory voltage rating to the undervoltage module C Turn the circuit breaker to the ON position Breaker must remain closed D Reduce test voltage Breaker must trip with voltage level between 70 and 35 percent of marked accessory rating Internal Limit Beh Ga Shunt Trip Coil Terminals 1 Customer Power Source Figure 1 Electrical Data For Shunt Trip Undervoltage Coil Terminals 1 Customer Power Source Figure 2 Electrical Data For Undervoltage UV Trip Coil Nri Selen Catalog Voltage X nated Vantage Number Amperes 60 Cycles AC 24 1 200 817 060 48 0 800 518 060 120 0 395 01ED60 208 0 265 SO2ED60 240 0 165 SOSED60 277 0 190 S15ED60 480 0 145 SO4ED60 600 0 080 SO6ED60 DC 24 2 20 S07ED60 48 1 20 SO9ED60 125 0 50 11ED60 250 0 35 S13ED60 Shunt Trip and Undervoltage Trip Wiring information Tin plated accessory terminals with binding head screws are provided Terminals are suitable for use with No 14 No 22 AWG wire Cu only or 5 16 in wide max insulated crimp type connectors Strip back wire 3 8 in max Ec At Rated Voltage Catalog 9 Amperes 60 Cycles AC 120 0
49. or low load power factor Driver speed droop or belt slip Reactive droop Line drop Defective diodes suppressor or windings CHECK AND REMEDY Reduce load The load on each leg should be evenly balanced and rated current should not be exceeded on any leg Motor starting currents are too large for the generator When starting multiple motors sequence the motors and start the largest motors first Reduce lagging power factor load Check driver If belt driven check belt tension Check under frequency setting on regulator Under frequency voltage roll off may be activated If the generator is equipped for parallel operation some droop is normal as reactive load increases When operating as a single unit the parallel CT can be shorted to eliminate this effect Refer to Regulator manual If voltage is proper at generator terminals but low at load terminals increase external wire size Test the generator using the 12 volt battery test as specified in the testing section If the results indicate generator problems perform insulation continuity and diode tests as specified in the testing section GENERATOR PRODUCES FLUCTUATING VOLTAGE CAUSE Fluctuating engine speed Regulator stability Regulator external rheostat Defective rectifier assembly Loose terminal or load connections Defective regulator CAUSE Faulty metering Incorrect connections Regulator adjustments Leading power factor Incorrect regulator conn
50. plate 4 The motor operator is aligned on top of the spacers and the 4 8 32 screws and installed as shown in Figure 2 5 Rotate cam to the off position See label inside motor operator 6 Close and latch the mechanism cover 7 Complete the desired control connections and electrically test the motor operator system before reenergizing the breaker power terminals in accordance with the electrical operation Motor For Use With Operator Frames 1 Circuit Breakers And Switchtypes MOE6120 ED ED2 ED4 ED6 HED4 MOE6240 HED6 CED6 ED6 A CED6 A Electrical Operation With the breaker and the operating mechanism in the OFF position press the ON button to energize the motor This action will close the breaker When the breaker handle reaches the ON position the motor circuit is disconnected by an internal limit switch Electrical Characteristics Table OFF In Rush Running Time Reset i Amps Amps Hz Amps 10 0 2 0 24 18 10 0 20 24 18 In Rush Running Amps Amps Closing or Opening Time 0 6 seconds With the breaker and the operating mechanism in the ON posi tion press the OFF button to energize the motor This action will open the breaker When the breaker handle reaches the OFF position the motor circuit is disconnected by an internal limit switch When the circuit breaker trips automatically there is no exter nal indication that the breaker
51. shipment or storage before installation Measure insulation resistance see operation Clean and dry the windings as required Never start a motor which has been wet without having it thoroughly dried SAFETY Motors should be installed protected and fused in accordance with latest issue of National Electrical Code NEMA Standard Publication No MG 2 and local codes Eyebolts or lifting lugs are intended for lifting the motor only These lifting provisions should never be used when lifting or handling the motor with other equipment i e pumps gear boxes fans or other driven equipment as a single unit Be sure the eyebolt is fully threaded and tight in its mounting hole Eyebolt lifting capacity ratings is based on a lifting align ment coincident with the eyebolt centerline Eyebolt capacity reduces as deviation from this alignment increases See NEMA MG 2 Frames and accessories of motors should be grounded in accordance with National Electrical Code NEC Article 430 Forgeneralinformation of grounding referto NEC Article 250 Rotating parts such as pulleys couplings external fans and shaft extensions should be permanently guarded LOCATION In selecting a location for the motor consideration should be given to environment and ventilation A motor with the proper enclosure for the expected operating condition should be selected The ambient temperature of the air surrounding the motor Should not exceed 40 C 10
52. supply Versions of the unit are available to suit 100 200V 45 65 Hz a c d c and 12 48V d c supplies 4 2 2 1 High Voltage version Standard supply voltage 100 to 250V a c nominal 15 85V a c absolute minimum to 287V a c absolute maximum or 100V to 250V d c nominal 25 15 85V d c absolute minimum to 312V d c absolute maximum a c supply frequency range 45 to 66 Hz or 360 to 440 Hz Model 0440 a c supply burden 4 2 2 2 Low Voltage version d c supply 12 to 48V d c nominal 25 15 10 2V d c absolute minimum to 60V d c absolute maximum d c supply burden rompton 46 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 4 2 3 Measuring Ranges Values of measured quantities for which errors are defined Voltage 70 120 of nominal Current 5 120 of nominal Frequency 45 66 Hz 360 440 Hz Model 0440 Crest values of voltage and current must remain within 168 of nominal maximum rms values 4 2 4 Accuracy Voltage 0 4 of reading 0 1 of range 1 of range maximum for Model 0440 Current 0 4 of reading 0 1 of range 1 of range maximum for Model 0440 Frequency not 0340 0 15 of mid frequency 1 of mid frequency for Model 0440 Temperature coefficient 0 013 C typical Response time to step input 1 5 seconds approx Screen update time 0 5 second approx 4 2 5 Reference conditions of influence quantities Values that quantities
53. the generator will tend to hunt under steady state conditions The screwdriver adjustable potentiometer adjusts the system stability Adjustment clockwise increases the stability Increasing the stability increases the response time of the generator Conversely decreasing the stability decreases the response time of the generator V HZ ROLL OFF FREQUENCY SELECTION The roll off point is the frequency where the generator voltage starts to decrease This reduces the Kilowatt load to the engine which allows the engine to recover in speed under any load transient condition Use jumper to select 50 HZ or 60 Hz The screwdriver adjustable potentiometer sets the roll off frequency from 54 61 Hz in the 60 Hz setting or from 45 51 Hz in the 50 Hz setting The SE350 has the roll off point preset to 58 Hz in the 60 Hz mode and 48 Hz in the 50 Hz mode To change the roll off point adjust engine speed to the desired rated speed 50 or 60 Hz Set the voltage to the desired setting at rated speed Adjust engine speed to the desired roll off point Turn the potentiometer counterclockwise until the voltage starts to drop off Then adjust the potentiometer clockwise until the voltage returns to rated voltage Re adjust engine speed to rated speed PRELIMINARY SET UP Ensure the voltage regulator is correctly connected to the generator Refer to the specific connection diagram supplied with the generator Set the regulator voltage adjust to full counter clo
54. to Marathon Electric for application assistance OPERATION WARNING Disconnect and lock out before working on motor or driven equipment BEFORE INITIAL STARTING 1 If a motor has become damp in shipment or in storage measure the insulation resistance of the stator winding Minimum Insulation Resistance p Rated Voltage In Megohms 1000 Do not attempt to run the motor if the insulation resistance is below this value 2 If insulation resistance is low dry out the moisture in one of the following ways Bakeinoven attemperature not morethan 90 C 194 F b Enclose motor with canvas or similar covering leavinga hole at the top for moisture to escape andinsert heating units or lamps c Passa current at low voltage rotor locked through the stator winding Increase the current gradually until the winding temperature measured with a thermometer reaches 90 C 194 F Do not exceed this temperature 3 See that voltage and frequency stamped on motor and control nameplates correspond with that of the power line 4 Check all connections to the motor and control with the wiring diagram 5 Be sure rotor turns freely when disconnected from the load Any foreign matter in the air gap should be removed 6 Leave the motor disconnected from the load for the initial start see following caution Check for proper rotation Check for correct voltage within 10 of nameplate value and that it is bala
55. value press The screen will move on to the next Set up screen Section 3 7 Potential Transformer Secondary Value Press f to change the PT Primary voltage Initially all the digits of the present value will be flashing and the decimal point position will be illuminated This is to indicate that initially the multiplier must be selected Press to set the decimal point position Note that the x1000 indicator is on Press to accept the displayed decimal point position The digits stop flashing and the PT Primary Value screen appears Set the display to read the value of the PT Primary voltage using the method described in Section 3 2 Number Entry Procedure The primary voltage that can be set will be restricted to a value such that together with the full scale current value previously set the absolute maximum power 120 of nominal current and voltage cannot exceed 360 Megawatts After the last digit has been accepted the Confirmation screen will appear This example confirmation screen shows a primary voltage setting of 2 2 kV Press gt gt to accept the displayed PT Primary Voltage The next Set up screen will appear Section 3 7 Potential Transformer Secondary Value To change the displayed value press 11 The Decimal Point screen will reappear Crompton INSTRUMENTS tyco Electronics Energy Division 3 7 Potential Transformer Secondary Value 0240 0340 0440 0640 1000
56. which affect measurement errors to a minor degree have to be for the intrinsic headline errors for measured quantities to apply Ambient temperature 23 C Input frequency 50 or 60 Hz 2 Input waveform Sinusoidal distortion factor 0 005 Auxiliary supply voltage Nominal 1 Auxiliary supply frequency Nominal 1 Auxiliary supply distortion factor 0 05 Magnetic field of external origin Terrestrial flux 4 2 6 EMC Standards EMC Immunity EN61326 for Industrial Locations to performance criterion A EMC Emissions EN61326 to Class B Domestic Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 47 tyco Electronics Energy Division 4 2 7 Safety IEC1010 1 BSEN 61010 1 Permanently connected use Normal Condition Installation category Ill pollution degree 2 Basic Insulation 720V RMS maximum Auxiliary circuits 12 48V auxuliary communications relay and analogue outputs where applicable are separated from metering inputs and 100 250V auxiliary circuits by at least basic insulation Such auxiliary circuit terminals are only suitable for connection to equipment which has no user accessible live parts The insulation for such auxiliary circuits must be rated for the highest voltage connected to the instrument and suitable for single fault condition The connection at the remote end of such auxiliary circuits should not be accessible in normal use Depending on application equipment connected to auxili
57. will drop on the main stator core Having the rotor in this position will limit the amount of rotor drop to that of the air gap Visually inspect the bearing bore for damage or wear If worn or damaged replace prior to reassemble Opposite Drive End Bearing Bracket Removal Prior to proceeding with bracket removal disconnect exciter field leads F and F from the automatic voltage regulator and ensure that they are free to move when the bearing bracket is removed Remove the bearing bracket retaining bolts Using a pair of screw drivers wedge the bracket off the frame After approximately 1 8 inch the bracket will clear the locating register on the frame and will drop until the rotor is resting on the main stator core Continue to pull the bracket free from the bearing Visually inspect the bearing bore and o ring if equipped for damage or wear If worn or damaged repair or replace prior to reassembly Drive End Bearing Bracket Removal Two Bearing Units Remove any drive arrangement from the generator shaft extension Remove the bearing lock ring retaining screws There is no o ring in the drive end bearing bracket The shaft extension must be supported before proceeding further A hoist and sling jack or some other means of support with a capacity of 2 tons should be used Remove the bearing bracket retaining cap screws Using a flat bladed screw driver or chisel pry the bracket back from the frame After approximately 1 8 inc
58. 0 5 mA 0 2 Bottom 1 Bottom 0 PF European Convention North American Convention Symmetrical full range import only In the above symmetrical arrangement 0 mA corresponds to unity power factor This is not the case with the following asymmetrical arrangement Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 37 tyco Electronics Energy Division a Import Capacitive Import Capacitive PF Reading PF Reading Inductive Reading 4 Inductive g 1 Top 0 9 PF Top 0 9 PF Reading Reading Bottom Bottom 0 5 PF Output 0 5 PF Top 0 ma European Convention North American Convention Asymmetrical import only mainly inductive In the example above the unit has an analogue output range of 0 to 1 mA all power is imported and the load is inductive The 1 mA Output range covers a reading power factor range of 0 6 from 0 9 capacitive to 0 5 inductive The capacitive overlap is provided in case of over compensation of power factor The Output to Reading correlation is as follows Reading European Convention North American Convention Output Output 0 9 PF cap 0 mA 1mA 0 167 0 833 0 9 PF ind 0 333 mA 0 667 mA 0 8 PF ind 0 500 mA 0 500 mA 0 7 PF ind 0 667 mA 0 333 mA 0 6 PF ind 0 833 mA 0 167 mA 0 5 PF ind 1mA 0 mA rompton INSTRUMENTS 38 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Ener
59. 020 25 25 HED62B025 100 25 HHED62B025 100 65 25 30 HED62B030 100 30 HHED62B030 100 65 25 35 HED62B035 100 35 HHED62B035 100 65 25 40 HED62B040 100 40 HHED62B040 100 65 25 45 HED62B045 100 45 HHED62B045 100 65 25 50 HED62B050 100 50 HHED62B050 100 65 25 60 HED62B060 100 60 HHED62B060 100 65 25 70 HED62B070 100 70 HHED62B070 100 65 25 80 HED62B080 100 80 HHED62B080 100 65 25 90 HED62B090 100 90 HHED62B090 100 65 25 100 HED62B100 100 100 HHED62B100 100 65 25 110 HED62B110 100 110 HHED62B110 100 65 25 125 HED62B125 100 25 18 30 N A 125 HHED62B125 100 65 25 _ SHIPPING 10 per carton Wt 25 Ib Molded Case Switch 100 HHED62S100A 100 65 25 3 Pole 125 HHED628125A 100 65 25 HED63B015 20 HED63B020 100 25 HED63B025 100 3 Pole 30 HED63B030 100 HHED63B015 35 HED63B035 100 20 HHED63B020 100 65 25 40 HED63B040 100 25 HHED63B025 100 65 25 45 HED63B045 100 30 HHED63B030 100 65 25 50 HED63B050 100 35 HHED63B035 100 65 25 60 HED63B060 100 40 HHED63B040 100 65 25 70 HED63B070 100 45 HHED63B045 100 65 25 80 HED63B080 100 50 HHED63B050 100 65 25 90 HED63B090 100 60 HHED63B060 100 65 25 100 HED63B100 100 70 HHED63B070 100 65 25 110 HED63B110 100 80 HHED63B080 100 65 25 125 HED63B125 90 HHED63B090 100 65 25 SHIPPING 10 per carton Wt 25 Ib 100 HHED63B100 100 65 25 HHED63B110 interrupting ratings are listed on page 49 HHED63B125 Includes self protecting instantaneous element Molded Case May be used on a circuit capable of del
60. 04 d Other applicable standards for grounding are 10 5 1 NEC Article 430 Part L on grounding of motors 10 5 2 NEC Article 445 1 on grounding of generators 10 5 3 NEC Article 250 for general information on grounding 11 0 Optional Accessories Several control and protection accessories are provided with the MG sets Below is a description of each Other devices may also be provided to facilitate special testing or operational requirements Consult with Georator Application Engineers 11 1 11 3 Motor Starters Starters used are generally Enclosed Full Voltage Magnetic Non Reversing with IEC Rated contacts Non combination without Input Circuit Breakers starters are offered as a standard Enclosures are NEMA 1 Type Combination Motor Starters and different type enclosures e g dust tight can also be provided All starters are supplied with motor overload Class 10 protection This protection is a solid state relay with wide selection of motor current and manual trip reset Door mounted Start Stop push buttons are also provided Additional auxiliary contacts and or power control transformers can also be made available for control purposes Reduced voltage starters are the general offering for large motors Circuit Breakers Breakers are Thermal Magnetic Trip Molded Case 2 or 3 pole Common Trip circuit breakers A molded circuit breaker is one that is assembled as an integral unit in a supportive and enclosing housing of i
61. 04 03 tyco Electronics Energy Division 4 1 4 Safety IEC1010 1 BSEN 61010 1 Permanently connected use Normal Condition Installation category Ill pollution degree 2 Basic Insulation 300V RMS maximum Auxilary circuits 12 48V auxiliary communications relay and analogue outputs where applicable are separated from metering inputs and 100 250V auxiliary circuits by at least basic insulation Such auxiliary circuit terminals are only suitable for connection to equipment which has no user accessible live parts The insulation for such auxiliary circuits must be rated for the highest voltage connected to the instrument and suitable for single fault condition The connection at the remote end of such auxiliary circuits should not be accessible in normal use Depending on application equipment connected to auxiliary circuits may vary widely The choice of connected equipment or combination of equipment should not diminish the level of user protection specified 4 1 5 Insulation Dielectric voltage withstand test 4 1 6 Environmental Operating temperature Storage temperature Relative humidity Shock Vibration Enclosure integrity front face only 4 1 7 Enclosure Style Material Terminals 3 25kV RMS 50 Hz for 1 minute between all electrical circuits 10 to 60 C 20 to 85 C 0 95 non condensing 30g in 3 planes 10 to 15 Hz 1 5 mm peak peak 15 to 150 Hz 1 0g IP54 ANSI C39 1 Polycarbonate front and bas
62. 1000 1540 Most of the products described in this manual allow the user to specify within a range the secondary voltage of the potential transformer PT with which it is to be used The exception is the Integra 1000 and self contained Integra 1540 which has the PT secondary factory set On the Integra 1000 1540 the user cannot change this value 1 4 Demand Calculation 0240 0340 0440 0640 1000 1540 The maximum power consumption of an installation is an important measurement as most power utilities base their charges on it Many utilities use a thermal maximum demand indicator MDI to measure this peak power consumption An MDI averages the power consumed over a number of minutes reflecting the thermal load that the demand places on the supply system The Integra uses a sliding window algorithm to simulate the characteristics of a thermal MDI instrument with the demand being calculated once per minute The demand period can be reset which allows synchronisation to other equipment When it is reset the values in the Demand and Maximum Demand registers are set to zero Demand Integration Times can be set to 8 15 20 or 30 minutes The number of sub intervals i e the demand time in minutes can be altered either by using the Demand Integration Time set up screen see Section 3 8 or via the RS485 port where available using the Modbus protocol During the initial period when the elapsed ti
63. 110 100 Review all prime mover prestart up instructions and ensure that all recommended steps and procedures have been followed Hz LL re 220 200 Remove any masking materials affixed during painting Inspect the generator prime mover and any accessory equipment to ensure that nameplates and all safety warning caution signs and decals provided with the equipment are in place and clearly visible Note It is strongly recommended that the authority having jurisdiction over the installation site be consulted to determine if any additional warning or caution notices or additional safety devices are required by local codes standards Any such required notices or devices should be installed prior to initial startup START UP The following procedure should be followed when starting the generator set for the first time 1 The generator output must be disconnected from the load Be sure that the main circuit breaker or fused disconnect is in the open position Open the input power to the automatic voltage regulator Remove the fuse or disconnect and insulate one of the regulator input power leads See separate regulator manual Verify that all prime mover start up procedures have been followed If the unit is provided with space heaters ensure that they are de energized In some installations a set of auxiliary contacts on the main circuit breaker or transfer switch will automatically open the space
64. 2 3 14 RS485 Modbus Address 33 3 15 Analogue Output Set Up 34 3 15 1 Introduction 34 3 15 2 Analogue Output Scaling Example 35 3 15 3 Power Factor 36 3 15 4 Phase Angle 39 3 15 5 Parameters available for analogue outputs 40 3 15 6 Reading Parameter Selection A1r or A2r 41 3 15 7 Reading Top 1 or A2rt 42 rompton INSTRUMENTS 2 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Contents Page 3 15 8 Reading Bottom 1 or A2rb 43 3 15 9 Output Top Alot or A2ot 43 3 15 10 Output Bottom 1 or 206 43 4 Specification 44 4 1 Display Only Versions 44 4 1 1 Input 44 4 1 2 Auxiliary Power Supply 44 41 3 EMC Standards 44 4 1 4 Safety 45 4 1 5 Insulation 45 4 1 6 Environmental 45 4 1 7 Enclosure 45 4 2 Display Transducer Combined Versions 45 4 2 1 Inputs 45 4 2 2 Auxiliary Power Supply 46 4 2 3 Measuring Ranges 47 4 2 4 Accuracy 47 4 2 5 Reference conditions of influence quantities 47 4 2 6 Standards 47 4 2 7 Safety 48 4 2 8 Insulation 48 4 2 9 Environmental 48 4 2 10 Enclosure 48 4 3 Display Tranducer Combined 1000 and 1540 48 4 3 1 Inputs 48 4 3 2 Auxiliary Power Supply 49 4 3 3 Accuracy 49 4 3 4 Reference conditions 50 4 3 5 Reference conditions of influence quantities 50 rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 3 tyco Electronics Energy Division Contents Page 4 3 6 Nominal range of use o
65. 250 Volts DC 2000 Type ED4 HED4 480 Volts 60 Hz 250 Volts DC E 1 Type ED6 HED6 600 Volts 60 Hz 500 Volts DC Type ED2 1 Pole 120 Voits 60 Hz 125 Volts DC 000 i 4 H Type ED4 1 Pole 277 Volts 60 Hz 125 Volts DC 1 000 en Type HED4 1 Pole 277 Volts 60 Hz 125 Volts DC 550 800 H Instantaneous Trip Table 800 600 t Rating Fixed Instantaneous 600 500 k Amperes i Trip Amperes 500 LN 15 25 400 700 x Y 30 125 600 1 000 400 300 t Interrupting Rating 300 Breaker Sym Rms Amperes 200 Maximum Single Pole 240V 480 V 600V 125 V 250 V 500V 200 Trip Time at 25 tD2 TOA TORR 250 Seconds 300965 Sec ED4 65kA 18kA 5kA 30 j ED6 65kA 25kA 18kA 18kA 3 P 195 1 d H HED4 100kA 42kA 10k 100 90 LLLA TL HED6 100kA 30KA 25KAG P 29 70i 1 L HHED6 00 65 25 z 70 60 1 r a 1 Single pole test data at 25 C on 125 Ampere Breaker For other ratings refer to NEMA 60 50 t TEE procedures 50 t T H E 2 Sample instantaneous shown for 100A breakers only For other instantaneous trip 40 values see table Instantaneous trip values shown in table are nominal values 40 30 130 MI t 20 4 H 20 I4 is 1 10 10 2 H LL rrr ake FEEF g 7 A E H a g H HERE 8 43 ICH E LO 4 z o a T a z 8 Minimum it 3
66. 30 1 6 208 028 UO2ED60 240 016 UO3ED60 277 013 U16ED60 480 008 UOGED6O 600 _ 008 08 60 DC 24 110 U13ED60 48 060 U14ED60 125 027 U1OED60 250 020 U12ED60 I T E Auxiliary Switch and Bell Alarm Switch Electrical Check Auxiliary Switch Kits Ampere Rating of Switch Catalog Number of Number Switches Volts AC Volts DC 240 480 125 250 AO1ED62 1 5 6 5 25 AO2ED62 2 5 15 5 25 AO1ED64 1 15 15 15 5 25 All switch modules have 3 terminals if single switch unit 3 5 7 or 6 terminals if double switch unit 3 5 7 4 6 8 Auxiliary Switch A Use a buzzer or light attached to switch leads 7 and 5 8 and 6 if double auxiliary switch module With breaker in ON position a light or buzzing noise should not be observed B Move handle to OFF position Indicator light or buzzer should turn on C Attach test to leads 7 and 3 8 and 4 if double auxiliary switch module Light or buzzer should turn off D Move handle to ON position Indicator light or buzzer should turn on Should the indicator not function properly during check procedure check for incorrect installation or wiring Bell Alarm Switch A Check continuity of B and B1 contacts per acces sory label See Bell Alarm Switch information on page 17 for definition of normal position Auxiliary Switch and Bell Alarm Switch Wiring Information Auxiliary and bell alarm s
67. 4 F unless the motor has been especially designed for high ambient temperature applica tions The free flow of air around the motor should not be obstructed The motor should never be placed a room with a hazardous process or where flammable gases or combustible material may be present unless it it specifically designed for this type of service 1 Dripproof open motors are intended for use indoors where atmosphere is relatively clean dry andnon corrosive 2 Dripproof open fire pump motors are to be installed ina Type 2 dripproof environment as defined in NEMA 250 3 Totally enclosed motors may be installed where dirt moisture and corrosion are present or in outdoor locations 4 Explosion proof motors are built for use in hazardous locations as indicated by Underwriters label on motor Consult UL NEC and local codes for guidance Refer to Marathon Electric for application assistance FLOOR MOUNTING Motors should be provided with a firm rigid foundation with the plane of four mounting pads flat within 010 for 56 to 210 frame 015 from 250 through 500 frame This may be accomplished by shims under the motor feet For special isolation mounting contact Marathon Electric for assistance V BELT DRIVE 1 Select proper type and number of belts and sheaves Excessive beltload will damage bearings Sheaves should be in accordance to NEMA Spec MG 1 orasapprovedby the manufacturer for a specific application 2
68. 40 1000 1540 This is the reactive energy that has been consumed since the unit was last reset see Section 3 9 Resets The reading shows the energy kVArh in the reactive component of the supply Sys Volts Volts L1 N Reactive Energy kVArh 7 digit reading i e 0000102 Volts L3 N Volts 13 1 Amps L3 Key moves to next screen rompton INSTRUMENTS 16 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 2 15 Demand 0240 0340 0440 0640 1000 1540 This screen displays the present demand i e the maximum power and the maximum current demanded during the defined integration window period See Section 3 8 Demand Integration Time System Total Active Power Demand kWD System Total Current Demand AD Key gt gt moves to the next screen 2 16 Maximum Demand 0240 0340 0440 0640 1000 1540 This screen displays the maximum power and the maximum current that has been demanded since the unit was last reset see Section 3 9 Resets Maximum System Total Active Power Demand kWD Maximum System Total current Demand AD Key gt gt returns to the start of the sequence with the System Screen 2 17 Over Range The displayed values must be in the range 999 x 1000 to 9999 x 1000 Any parameter value outside this range will cause the display to show overrange Thi
69. 5 6 7 8 910 20 30 40 50 60 70 8090 100 200 300 100 90 80 I 70 60 T fa LL te 50 r 1 40 F 1 7 T T Maximum Available 30 Symmetrical 1 2 Cycle Ft 20 4 4 10 t 9 t 8 EE 6 4 5 4 3 2 1 E Jj J 600 VAC 8 L 480 VAC 7 js 6 5 _ da Lot 1 emt 4 4 7 7 g 240 VAC 3 P di asd MAPAS elt Su ber ost T ett get ler 1 2 4 5 6 7 8 910 20 30 40 50 60 70 8090 100 200 300 TD 7101 B REV 2 Available Short Circuit Current RMS Symmetrical Amperes x 10 100 90 80 70 60 50 40 30 20 o D N oo 49 50 Ordering Information Circuit Breaker Catalog Numbers ED2 Non Interchangeable Trip 1 Pole ED4 Non Interchangeable Trip 1 Pole UL Interrupting Ratings kA RMS Symmetrical Amperes Num 5 25V DC ED21B015 5 ED21B020 5 25 ED21B025 5 30 ED21B030 5 35 ED21B035 5 40 ED21B040 5 45 ED21B045 5 50 ED21B050 5 60 ED21B060 5 70 ED21B070 5 80 ED21B080 5 90 ED21B090 5 ED21B100 5 ED22B015 ED22B020 ED22B025 ED22B030 ED22B035 ED22B040 ED22B045 ED22B050 ED22B060 ED22B070 ED22B080 ED22B090 ED22B100 5 5 5 5 5 5 5 5 5 5 5 5 5 Molded Case Switch ED22S100A 100 ED23B015 20 ED23B020 10 N A 25 ED23B025 10 N A 30 ED23B030 10 N A 35 ED23B035 10 N A 40 ED23B040 10 N A 4
70. 5 ED23B045 10 N A 50 ED23B050 10 N A 60 ED23B060 10 N A 70 ED23B070 10 N A 80 ED23B080 10 N A 90 ED23B090 10 N A 100 ED23B100 10 N A Molded Case Switch ED23S100A 10 N A 100 SHIPPING 10 per carton Wt 38 Ib C Approved for frequent switching applications SWD duty Includes self protecting instantaneous element will trip at currents over 1000A May be used on a circuit capable of delivering not more than the indicated fault current when protected by a fuse or circuit breaker at 100 or 125 amperes Complete Breaker j UL Interrupting Ratings kA Unenclosed RMS Symmetrical AUN Catalog Number 120V 277 AC 125V DC ED41B015 5 ED41B020 25 22 5 ED41B025 25 22 5 ED41B030 25 22 5 ED41B035 25 22 5 ED41B040 25 22 5 ED41B045 25 22 5 ED41B050 25 22 5 ED41B060 25 22 5 ED41B070 25 22 5 ED41B080 25 22 5 ED41B090 25 22 5 ED41B100 25 22 5 SHIPPING 30 per carton Wt 38 Ib 2 Pole 15 ED42B015 20 ED42B020 65 18 30 25 ED42B025 65 18 30 30 ED42B030 65 18 30 35 ED42B035 65 18 30 40 ED42B040 65 18 30 45 ED42B045 65 18 30 50 ED42B050 65 18 30 60 ED42B060 65 18 30 70 ED42B070 65 18 30 80 ED42B080 65 18 30 90 ED42B090 65 18 30 100 ED42B100 65 18 30 110 ED42B110 65 18 30 125 ED42B125 65 18 30 Molded Case Switch 100 ED42S100A 65 18 30 125 ED428125A 65 18
71. 7 The Edit screen will reappear To accept the displayed value press The next Set up screen will appear Volts L3 N Volts 13 1 Confirmation rompton INSTRUMENTS 30 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 3 12 RS485 Baud Rate 0240 0340 0440 0640 1000 1540 Option Use this screen to set the Baud Rate of the 5485 Modbus JC NII port The values displayed are in kbaud Where the transducer unit may be separate from the display unit the transducer has two Modbus ports at least one of which may be used for communicating with a display The RS485 Baud Rate option only sets the Baud Rate for a port that is not communicating with a display unit The port characteristics for communication with a display are preset If the JC NII protocol is to be used the baud rate must be set to 9 6 If a display is detected on an RS485 port at start up any user settings for that port will be ignored Press gt gt to accept the currently displayed value The next Set up screen will then appear Sys Volts h A H d M To change the baud rate press f 5 w Use the 11 key to scroll through the available values 2 4 4 8 9 6 a and 19 2 Select the required baud rate and press gt gt to confirm your selection The Confirmation screen will appear Edit Press gt gt to accept the new setting The next Set up screen will app
72. ASSEMBLY REMOVAL The rectifier assembly cannot be removed until the opposite drive end bearing bracket and bearing have been removed see bearing removal procedure Remove the three exciter rotor leads from the heat sinks and the two main rotor leads from the main rotor posts see Figures 4 Remove the Screws securing the rectifier assembly and pull the assembly free from the shaft DIODE REPLACEMENT Prior to installing a replacement diode on the heat sink apply a thin film of conductive heat sink compound around the base of the diode do not coat the threads When installing a diode on the heat sink care should be taken not to over torque the retaining nut which could cause damage to the device Torque to 28 pound inches If not damaged the existing diode lead wire may be unsoldered from the failed diode and resoldered on the replacement MARATHON A Subsidiary of Regal Beloit Corporation 430 FRAME RETURNED GOODS Contact Marathon Electric Manufacturing Corporation for authorization before returning any product We can not be responsible for any items returned without authorization CAUTION Single bearing generators must have their rotor assembly properly secured to prevent damage during transit to the factory or to an authorized service center TROUBLESHOOTING This section is intended to suggest a systematic approach to locating and correcting generator malfunctions The section is arranged according
73. Align sheaves carefully to avoid axial thrust on motor bearing The drive sheave onthe motor should be positioned toward the motor so itis as close as possible to the bearing 3 3 When adjusting belt tension make sure the motor is secured by all mounting bolts before tightening belts 4 Adjust belt tension to belt manufacturers recommenda tions Excessive tension will decrease bearing life 5 For more information see Marathon Electric Publication SB588 DIRECT CONNECTED DRIVE Flexible or solid shaft couplings must be properly aligned for satisfactory operation On flexible couplings the clearance between the ends of the shafts should be in accordance with the coupling manufacturer s recommendations or NEMA standards for end play and limited travel in coupling MISALIGNMENT and RUN OUT between direct con nected shafts will cause increased bearing loads and vibra tion even when the connection is made by means of a flexible coupling Excessive misalignment will decrease bearing life Proper alignment per the specifications of the coupling being used is critical Some large motors are furnished with roller bearings Roller bearings should not be used for direct drive ELECTRICAL CONNECTIONS CAUTION Install and ground per local and national codes Consult qualified personnel with questions or if repairs are required WARNING 1 Disconnect power before working on motor or driven equipment 2 Motors with aut
74. BEARING Typical Generator Cross Section I i I uU wd d Number Number 1 End Bracket under end cover 360 amp 430 frames 11 Main Stator y O Rectifier Assembly 5 Air Intake Screen 280 frame only End Bracket drive end 5 6 ExciterRotor 16 Bearng diveend 8 LinkBoard termnalbock 18 9 X CondutBc 19 ExhaustScreen dripcovernotshown Note Illustration above is a 280 frame MagnaPlus Other Frame sizes are typical Optional PMG not shown The generator model and serial numbers are required when ordering parts MARATH ee 20 504 9 03 A Subsidiary of Regal Beloit Corporation SE350 VOLTAGE REGULATOR INSTRUCTION MANUAL i v w ecuez H7 an gvis 170A Z 1nd 100 VA 005 ZH 09705 OFZ 061 10 6519 4 OSE3S HOLVIn93H 39V110A VST Lt eS NISNOISN I NI NOB 8 5 NOHJAVHVII SAIM NYSA MARATHON A Subsidiary of Regal Beloit Corporation INTRODUCTION The SE350 voltage regulator is an encapsulated electronic voltage regulator that controls the output of a brushless AC generator by regulating the current into the exciter field SPECIFICATION SE350 REGULATOR Sensing amp Power Input 190 240 Vac Burden 500 VA
75. Cap P E 3 Conduit Box TopHolding Serew 13 Rotor Core 23 Inner Bearing Cap Bolt 4 Conduit Box Top M Lifting Eye Bot 1 24 Grease Plug 5 Conduit Box Bottom HoldingBoit 15 Stator Core 25 Bel Bearing P E Bal Bearing O P E 16 Frame 26 Shaft Extention Key 7 PreledingSpring 17 Stator Winding 7 27 Sht 8 Inner Bearing Cap OE 18 Plate Holding Screw 28 Drain Plug grease o Grease Plug 19 Baffie Plate Pe 29 Bracket Screen 10 Inner Bearing Bok 20 Bracket P E Pulley End O P E Opposite Pulley End Bearing Numbers are shown on motor nameplate when requesting information or parts always give complete motor description model and serial numbers Bracket and frame screens are optional WARNING These instructions must be followed to ensure safe and proper installation operation and maintenance of the motor They should be brought tothe attention ofall persons who install operate or maintain this equipment GENERAL INFORMATION Marathon Electric motors are all fully factory tested and inspected before shipping Damage during shipment and storage canoccur Motors not correctly matched to the power supply and or the load will not operate properly These instructions are intended as a guide to identify and eliminate these problems before they are overl
76. Compton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 5 tyco Electronics Energy Division 1 1 Unit Characteristics Integra 0240 Sys Volts e 000 Volts L1 N Volts L1 2 Volts L3 N Volts 13 1 Default display Integra 0440 Sys Volts e Volts L1 N Sys Amps Frequency e Volts L3 N Volts L3 1 Amps L3 Default display rompton INSTRUMENTS 1 1 1 0240 The 0240 will display the following parameters System voltage average of all phases System frequency Hz Voltage line to neutral for each phase 4 wire systems only Voltage line to line for each phase calculated in 4 wire The 0240 has Set up screens for potential transformer primary and secondary voltages 1 1 2 0340 The 0340 will display the following parameters System voltage average of all phases System current average of all phases Voltage line to neutral for each phase 4 wire systems only Voltage line to line for each phase calculated in 4 wire Current in each line The 0340 has Set up screens for Full scale current value Potential transformer primary and secondary voltages 1 1 3 0440 and 0640 The 0440 operates on a mains frequency of 400 Hz nominal and the 0640 at 45 65 Hz The units can measure and display the following parameters System voltage average of all phases System current average of all phases System frequency Hz Voltage
77. Division Contents Page 1 Introduction 5 1 1 Unit Characteristics 6 1 1 1 0240 6 1 1 2 0340 6 1 1 3 0440 and 0640 6 1 1 4 1000 7 1 1 5 1540 8 1 2 Maximum Power 9 1 3 Secondary Voltage 9 1 4 Demand Calculation 9 1 5 RS485 Serial Option 10 1 6 Pulse Output Option 10 1 7 Analogue Output Option 10 2 Display Screens 11 2 1 Layout 11 2 2 Start Up Screens 11 2 3 System Screen 12 2 4 System THD Screen 13 2 5 Line to Neutral Voltages 13 2 6 Line to Neutral Voltage THD 13 2 7 Line to Line Voltages 14 2 8 Line to Line Voltages THD 14 2 9 Line Currents 14 2 10 Line Currents THD 15 2 11 Neutral Current Frequency and Power Factor 15 2 12 Power 15 2 13 Active Energy KWh 16 2 14 Reactive Energy kVArh 16 rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 1 tyco Electronics Energy Division Contents Page 2 15 Demand 17 2 16 Maximum Demand 17 2 17 Over Range 17 2 18 kWh and kVArh Display Range 18 2 19 Error Messages 18 3 Setting up 18 3 1 Introduction 18 3 2 Number Entry Procedure 19 3 3 Access 21 3 8 1 Access with No Password Protection 21 3 3 2 Access with Password Protection 21 3 4 Changing the Password 23 3 5 Full Scale Current 24 3 6 Potential Transformer Primary Voltage 24 3 7 Potential Transformer Secondary Value 26 3 8 Demand Integration Time 27 3 9 Resets 28 3 10 Pulsed Output Pulse Duration 29 3 11 Pulse Rate 30 3 12 RS485 Baud Rate 31 3 13 5485 Parity Selection 3
78. E025 place cable between Wire Connector Installation breaker tab and connector body Figure 1 C Hold in place while tightening set screw 4 with a screw driver or hex wrench on TA1E6125 See Table for proper wire size selection and screw tightening torque Wire Connectors and Tightening Torque Cable Set Connector Contactor Cable Screw Tightening ED Frame Catalog Number R Wire Size Torque Breaker Type ange n Lb 1 piece 15 25A a v 14 10 AWG Cu 14 10 AWG 32 1 2 amp 3 Pole ae 12 10 AWG Al Line amp Load Side SA1E025 10 AWG 20 30 100A 1 piece 8 AWG 36 1 Pole Line Side Only 10 2 AWG 6 4 AWG 45 2 or 3 Pole Line CU AI 3 AWG 50 amp Load Side 2 1 0 AWG 60 All CED6 Line Side Only LN1E100 1 piece 10 AWG 20 30 60A 10 Cu 8 AWG 36 1 Pole Load Side Only 8 4 Cu Al 6 4 AWG 45 CED6 Load Side Only LD1E060 1 piece 4 AWG 45 70 100A 4 Cu 3 1 0 AWG 50 1 Pole Load Side Only 3 1 0 Cu Al 2 1 0 AWG 60 CED6 Load Side Only LD1E100 1 piece 110 125A 3 3 0 Cu 3 3 0 AWG 80 2 or 3 Pole 1 2 0 Al Line amp Load Side TA1E6125 30 125 1 10 1 0 Cu 10 1 0 Cu 100 2 or 3 Pole TC1ED6150 Line amp Load Side T E Compression Connector CCE125 A DANGER Hazardous Voltage Will cause death or severe injury Turn er off supplying switch _ board or panel before installing A SAFETY INSTR
79. ED6 ETI 8 28 9 58 All Other Types 5 02 6 33 Side View X Connecting Rear Studs Y P tHe m 35 16 Silver Finished Brass Nuts Line Side Figure 2 6 00 RS 2641 I pep NN Line Side 1 00 1 00 RS 2641 IBN E Figure 3 Drilling Plan 3 00 Figure 4 14 I T E Plug In Adapters A DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS General A complete plug in installation requires one line end adapter assembly consisting of a mounting block tulip connectors and associated hardware one load end adapter assembly and one switchboard mounting plate The switchboard mounting plate is optional and can be replaced by other mounting means to suit customer s requirements Application Information Switch Breaker No of Line End Load End b did Type Poles Mtg Plate Cat No 2 Pc2637 PC2638 PL2617 GED CEDEET PC2657 PC2658 PL2617 PC2637 PC2638 PL2616 AUGUE Types PC2658 PL2616 PC2657 Mounting Preparation Figures 1 and 2 A If the switchboard mounting plate 1 is to be used provide drilling as shown in Figure 1 B If other mounting means are to be used provide the cutouts and drilling required to mount the adapter blocks as shown in Figure 2 Switchboard Mounting Plate if used Figure 3 A Place sw
80. FRAME SIZE EXCITER RESISTANCE EXCITER FIELD NO LOAD TERMINAL VOLTAGE MODEL GENERATOR RESISTANCE NO LOAD VOLTS WITH 12 VDC FIXED EXCITATION ROTOR 480 V 60HZ HIGHWYE 60HZ HIGH WYE 50 HZ 281PSL1502 320 439 90 58 435 J 361 5_1602 1481 J 9900 141 460 X X 370 Stator resistance measured line to line in a high wye connection DEDICATED GENERATOR RESISTANCE STATOR ROTOR NO LOAD VOLTS 60 HZ 431PSL1811 0248 56 899 f e MARATHON A Subsidiary of Regal Beloit Corporation PARTS LIST SINGLE BEARING Typical Generator Cross Section Im Number Number 1 Bracket under end cover 360 amp 430 frames 11 Main Stator Cid 2 Beain 12 Main Rotors Oring 280 frame only 13 Rotor IntegralKeyway Cd 4 Rectifier Assembly O Z O Z 11 14 Fan O 6 Exciter Rotor Shaft 8 Link Board terminal block 18 DriveDisk SAE _ 9 ConduitBox CEC 19 drip cover not shown Note Illustration above is a 280 frame MagnaPlus Other Frame sizes are typical Optional PMG not shown The generator model and serial numbers are required when ordering parts e JIMARATH 19 ELECTRIC A Subsidiary of Regal Beloit Corporation PARTS LIST DUAL
81. Issue 1 04 03 23 tyco Electronics Energy Division 3 5 Full Scale Current 0240 0340 0440 0640 1000 1540 This parameter is the value of nominal Full Scale Currents that will be displayed as the Line Currents This screen enables the user to display the Line Currents inclusive of any transformer ratios The values displayed represent the current in amps For example setting 800 on this screen will cause the display to indicate 800 amps when the nominal maximum typically 5A or factory build option of 1A current flows through the transducer current inputs The maximum value is as specification Press to accept the present value and move on to the next Set up screen Section 3 6 Potential Transformer Primary Voltage Sys Volts To change the Full Scale Current press and change the current value as detailed in Section 3 2 Number Entry Procedure If the presently displayed current together with the full scale voltage value results in an absolute maximum power 12096 of nominal current and voltage of greater than 360 Megawatts the range of the most significant digit will be restricted The Maximum Power restriction of 360 Megawatts refers to 120 of nominal current and 120 of nominal voltage i e 250 Megawatts nominal system power When the least significant digit has been set pressing the key will advance to the Full Scale Current Confirmation stage The minimum value allowed is 1 The value wil
82. KVA ratings are approximately MARATHON A Subsidiary of Regal Beloit Corporation equal to 50 of the generator s three phase ratings DEDICATED SINGLE PHASE CONNECTION HIGH VOLTAGE SERIES CONNECTED OPERATION PRE START INSPECTION Before starting the generator for the first time the following inspection checks are recommended 1 SHAFT OPERATION OF THE GENERATOR UNTIL ALL LEADS HAVE BEEN CONNECTED AND INSULATED FAILURE TO DO THIS MAY RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE A visual inspection should be made for any loose parts bad connections or foreign materials Bar the set over by hand for at least 2 revolutions to be sure that there is no interference and that the set turns freely If the set does not turn freely check for clearance in the generator and exciter air gap Check all wiring against the proper connection diagrams and ensure that all connections and terminations are tight and properly insulated WARNING MAGNAPLUS GENERATORS MAY HAVE VOLTAGE PRESENT AT THE LEAD TERMINALS WHEN THE IS ROTATING DO NOT PERMIT Verify that all equipment is properly grounded earthed Clear the surrounding area of any materials that could be drawn into the generator Check all fasteners for tightness Check all access plates covers screens and guards If they have been removed for assembly or inspection reinstall and check for security 9 VOLTAGE DEDICATED 120
83. OSSD Shaft is 2 93 Long RHOSVD Shaft is 13 25 Long Installation of Handle CRHOH A Attach the handle 10 and gasket 11 to the enclosure door 12 and secure with four bolts flatwashers lockwashers and nuts supplied 14 Tighten nuts to 75 in Ib Figure 5 B When the enclosure door is closed check if the handle inter locks with the shaft in all handle positions except RESET OPEN To open the enclosure door when the breaker is in the ON position rotate the screw slot on the handle plate counter clockwise This procedure will defeat the interlock C To lock handle in OFF position pull the lockplate 15 from the handle and insert up to three 5 16 inch padlocks Installation Diagrams Drill and Tap 8 32 Circuit Breaker Mounting Holes When Type CED6 D is used C B In Enclosure Door Add Additional Mecca Mtg Holes 3 00 Dia Drilling Plan Dimensions Inches RE A 3 84 Circuit Break Outline i B 69 1 31 Enclosure Outline D 1 0 E 1 81 F 5 0 281 Dia 4 Places G 3 25 H 8 25 175 Dia Thru 4 PL In Enclosure Door Figure 1 a 4 00 1 31 y 2 Enclosure Door 5 97 16 28 5 Lockwasher 4 Places 38 32 x 4 CED6 4 screws Pod 1 Breaker Mounting Surface Operator Shaft Depth Breaker Operator Inst
84. On pressing to confirm the last digit the Confirmation screen will appear provided the password is correct Sys Volts From the Password Confirmation screen there is the option of changing the password as described in Section 3 4 Changing the Password To proceed to the first Set up screen press Password Confirmation If the password is incorrect the Password Request screen will reappear to permit a retry Press 7 to start a retry or gt gt to exit to the Display screens Sys Volts Password Incorrect rompton INSTRUMENTS 22 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 3 4 Changing the Password The option to change the password is only available from the Password Confirmation screen immediately after the user has entered the existing password if applicable Press 11 to start changing the password The password screen for the first digit will appear with the old password on the bottom line Set up the new password on the bottom line as described in Section 3 2 Number Entry Procedure On pressing to confirm the last digit the Password Confirmation screen will appear Press to confirm the new password The first Set up screen Sys Volts will appear Press to try again The first digit screen will appear again New password confirmation rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240
85. RESENT AT BOTH THE GENERATOR AND VOLTAGE REGULATOR ensure that they are clean and free of debris Clogged intake air screens will reduce cooling air flow and result in higher operating temperatures This will reduce TERMINALS DURING THIS PROCEDURE CAUTION MUST BE EXERCISED NOT TO COME INTO generator life and may result in generator damage PERSONAL CONTACT WITH LIVE TERMINALS 2 All MagnaPLUS generators are equipped with double LINKS OR STUDS SERIOUS INJURY OR DEATH shielded ball bearings lubricated for the life of the COULD RESULT bearing Every 1 000 hours check the bearing s for smooth quiet operation For continuous duty generators recommended practice is to replace the 7 Start the set and adjust the terminal voltage to the bearing during major overhauls of the engine desired value by means of the regulator voltage x adjustment If the regulator is equipped with a stability 3 Periodically inspect the unit for any buildup of contamination dirt oil etc on the windings If the wound components have become coated with heavy concentrations of oil and grime the unit should be disassembled and thoroughly cleaned This operation is not one that can be accomplished effectively on site but rather one that should be conducted by an authorized service center equipped with the appropriate apparatus and solvents necessary to properly clean and dry the generator adjustment follow the instructions in the regulator ma
86. Reversing the test leads reverse biased will result in the diode switching off and no electricity will be conducted The results of these tests should indicate one of three conditions 1 Good diode Will have a much greater resistance in one direction than the other Typical reverse biased resistance will be 30 000 ohms or greater while forward biased resistance will be less than 10 ohms The battery light tester will have the light on in one direction and off in the other 2 Shorted condition Ohmmeter reading will be zero or very low in both directions The continuity tester will have the light on in both directions 3 Open condition Ohmmeter will have a maximum infinity reading in both directions Continuity tester light will be off in both directions Diode failure after a 25 hour run in period is generally traceable to external causes such as a lightning strike reverse current line voltage spikes etc All 6 diodes are essentially in the same circuit When a diode is stressed to failure there is no easy method to determine remaining life in the other diodes To avoid possible continued failures it is recommended that the entire rectifier assembly be replaced rather than replacing individual diodes SERVICE GENERAL The service procedures given in this section are those which can reasonably be conducted on site with a minimum number of special tools and equipment All service procedures should be conducted
87. ST 12V BATTERY TEST The generator no load voltage is dependent on exciter input voltage and generator speed With the generator operating at rated speed and 12 volts dc applied to the exciter field the generators terminal voltage will be near rated value 1 Shutdown the generator set and connect a voltmeter on the generator terminals 2 Disconnect the regulators F F1 and F F2 leads and connect them to a 12V battery Caution should be taken to ensure that the battery is not exposed to any potential arcing 3 With no load on the generator main breaker open run the generator at rated speed Measure the generator s terminal voltage and compare this value with values recorded during installation If voltage readings are normal the main generator and excitation are operating properly Troubleshooting should continue with the regulator If readings are not normal the problem is in the generator Continue testing diodes surge suppressor and windings Continuity Resistance Test The generator has four components which can be checked using an ohm meter exciter stator exciter rotor main stator and main rotor Each of these components are comprised of various windings which form a complete electrical path of relatively low resistance Using an ohm meter measure the loop resistance of each component Compare these measured values with the values listed in the specification section of this manual Note that very small resi
88. Tension should be checked after the first 24 to 40 hours of operation Ideal tension is the tension at which the belt will not slip under peak load conditions However note that over tensioning shortens belt and bearing life Avoid the use of belt dressing as this will damage the belts and lead to premature failure While an educated thumb may be acceptable for ordinary drives we recommend the use of a tension gauge which measures the pounds force required to deflect the belt a specified distance Vendors such as TB Woods provided detailed data on upper and lower limits for tension as a function of belt size and length and should be used for precise data see http www tbwoods com index php for their free downloads General data is shown below Belt Type Smaller Sheave Dia Used Belt lbs force New Belt lbs force BX 4 4 5 6 7 1 10 5 BX 5 8 8 6 7 3 10 9 CX 7 0 9 0 14 7 21 8 CX 9 5 16 0 15 9 23 5 D 12 0 16 0 212 31 3 3VX 4 02 6 9 5 3 7 9 5VX 4 4 6 7 8 8 13 2 5VX 7 10 9 14 8 22 1 5VX 11 8 16 0 17 1 255 8V 12 5 17 0 26 8 39 9 BASIC TROUBLE SHOOTING FOR BELT COUPLED MOTOR GENERATOR SETS 1 Check output voltage and output frequency A Output voltage is adjustable using voltage adjusting pot and screw driver voltage adjustment for voltage regulator If there is no voltage adjustment it is likely that the voltage regulator has failed
89. The handle can be padlocked in the OFF position with up to three 54 in padlocks The breaker operator can also be padlocked in the OFF position Drilling of Enclosure A Catalog number RHOSSD standard depth shafts are used for minimum depth enclosures Refer to minimum dimen sion K in Figure 2 Catalog Number RHOSVD variable depth shafts are used for all other enclosure depths Shafts are cut to length L as shown in Figure 3 w Drill and tap circuit breaker mounting holes in breaker mounting surface 1 and handle mounting holes in enclosure door 2 as shown in Figure 1 Installation of Breaker and Breaker Operator A Attach the circuit breaker 3 and breaker operator 4 to the enclosure panel using the four mounting screws and lockwashers 5 as shown in Figure 3 Tighten to 20 in Ib NOTE For Type 4 and 4x applications use Handle Catalog No RHOH4 and appropriate illustrations Installation of Shaft RHOSSD RHOSVD A Shaft length for Variable Depth Operators L K 3 32 in Attach the shaft 6 to the operating arm 7 of the breaker operator and tighten the set screw to 70 in Ib min NOTE The proper orientation of the wings 8 shown in off position at the end of the shaft when the breaker is in the OFF position Figure 4 NOTE It is recommended that the shaft support bracket 9 be installed if the enclosure depth exceeds 10 in Attach as shown in Figure 3 Tighten screw to 45 in Ib NOTE RH
90. UCTIONS General NOTE This instruction sheet outlines the recommended installation procedure Use of these lugs in some installations may result in less wire bending space than is specified in the National Electric Code Installation of Compression Connector A Turn off power supplying device before installation compres sion lugs B Remove any existing wire connectors from circuit breaker Install circuit breaker D Preform cables to final configuration and strip insulation back 134 in on each conductor Use an appropriate insu lation stripping tool to avoid damaging the conductor See Figure 1 1 Barrell Wire Stripping Figure 1 E Clean aluminum conductor surfaces throughly with a wire brush or other suitable means to remove oxides and other contaminants from the conductor NOTE Copper wires and the compression connector should not be cleaned abrasively F Remove cap from compression connector and insert cable fully into barrel 1 Figure 1 of connector G Insure that connector tang s 2 Figure 1 are in their proper orientation prior to crimping This helps avoid twisting of cables during installation H Select an appropriate tool and die combination from Table 1 and make the required number of crimps within the boundaries stamped on the connector barrel Refer to Figure 2 for sequence of multiple crimps Table 1 Compression Tool and Die Chart For Copper and A
91. accelerated by enclosing the unit with a covering and inserting additional heating units A hole should be left at the top of the covering to permit the escape of moisture Care should be taken not to overheat various accessory equipment mounted with the generator Forced Air Another method to dry the generator is to run the set with no excitation see startup procedure item 2 The natural flow of ambient air through the generator will tend to dry the windings This method can be accelerated by adding a source of heat at the air intake to the generator Heat at point of entry should not exceed 80 C 180 F TESTING Visual Inspection Remove covers and look for any obvious problems burnt windings loose connections broken wires frayed insulation cracked brackets missing hardware etc Check for foreign objects which may have been drawn into the generator Verify that the generator s air gaps main rotor and exciter are free from obstructions If possible rotate the generator manually to ensure free rotation Never bar over the engine generator set using the generator fan WARNING THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR VOLTAGE REGULATOR TERMINALS DURING THIS PROCEDURE CAUTION MUST BE EXERCISED NOT TO COME INTO PERSONAL CONTACT WITH LIVE TERMINALS LINKS OR STUDS SERIOUS INJURY OR DEATH COULD RESULT CONSTANT EXCITATION TE
92. age L1 L2 calculated Volts 21 Voltage L2 L3 calculated Volts 22 Voltage L3 L1 calculated Volts 23 Neutral Current Amps 24 Active Energy Import GWh 25 Reactive Energy Import Gvarh The following parameters are available only on the Integra 1540 26 THD V1 27 THD V2 28 THD V3 29 THD 11 30 THD 12 31 THD I3 32 THD Vmean 33 THD Imean rompton INSTRUMENTS 62 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 7 Maintenance Warning During normal operation voltages hazardous to life may be present at some of the terminals of this unit Installation and servicing should be performed only by qualified properly trained personnel abiding by local regulations Ensure all supplies are de energised before attempting connection or other procedures It is recommended adjustments be made with the supplies de energised but if this is not possible then extreme caution should be exercised Terminals should not be user accessible after installation and external installation provisions must be sufficient to prevent hazards under fault conditions This unit is not intended to function as part of a system providing the sole means of fault protection good engineering practice dictates that any critical function be protected by at least two independent and diverse means In normal use little maintenance is needed As appropriate for service conditions
93. allation Figure 2 Figure 3 1 3 48 32x5 8 1 2 Enclosure ed Door 1 5 Lockplate ae A 7 Breaker 1 0 Handle 9 Operator Arm en LzK 3 32 1 1 Gasket 48 32 x 3 g Thread Cutting Screw 9 Variable Depth 2 ek oiei 1 2 cut 5 97 Min Variable Depth Only enclosure door 16 28 Max Breaker Mounting Surface 1 4 Y Flat Washer t E Q 4 8 Lock Washer 40 52 Nut Variable Depth Side View Handle Figure 4 Figure 5 25 26 Types 1 12 A DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS Standard Depth E2RH1 Drilling of Enclosure A B Drill breaker mounting holes H 1 in the enclosure per drilling plan on outline drawing Figure 1 Place template on breaker mounting surface so that the four centers in the template line up with the breaker mounting holes Make sure ON OFF indications on template are in same direction as ON OFF indications on the breaker To hold template in place punch two holes in template with breaker mounting screws and tighten into breaker mount ing holes Measure distances N and P from walls of enclosure Figure 2 Relocate template on enclosure cover by adding enclosure thickness and cover overhang R to dimensions N and P Figure 3 Remove backing from template an
94. alogue value The table also shows those values that may be signed where the value may go negative 3 15 2 2 Reading Top 1 or A2rt This is the value of the electrical parameter that will cause the analogue output to produce Output Top Example 135 volts 3 15 2 3 Reading Bottom Airb or A2rb This is the value of the electrical parameter that will cause the analogue output to produce Output Bottom Example 95 volts This value may be set to any value between zero and 120 of nominal Or between 120 and 120 of values that may be signed for example VAr 3 15 2 4 Output The two Output values specify the analogue current outputs that will represent the top and bottom Reading values They are included to allow additional versatility where particular requirements prevail or to convert a 0 20mA output to 4 20mA However it is suggested that in most other cases these values should be set to the limits that the hardware can cover The range of the analogue output s for the unit is marked on the product label 3 15 2 5 Output Top A1ot or A2ot This is the value of output that will be reached when the measured electrical parameter is at the reading top value Example 10mA rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 35 tyco Electronics Energy Division 3 15 2 6 Output Bottom 1 or A2ob This is the value of output that will be reached when the measure
95. ames Integra 1540 series Multifunction Digital Metering System Model Numbers INT 0240 INT 0340 INT 0440 INT 0640 INT 0740 INT 1540 conforms to the following standards LVD BS EN 61010 1 1993 Plus Amendment 2 July 1995 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use EMC BS EN 61326 1998A1 Emissions standard for Measurement Control and Laboratory Equipment Class B BS EN 61326 1998A1 Immunity standard for Measurement Control and Laboratory Equipment Annex A Supplementary Information The product complies with the requirements of the following EU directives and carries CE marking accordingly European Low Voltage Directive 73 23 EEC amended by 93 69 EEC by the standards route to compliance e EMC Directive 89 336 EEC amended by 93 68 EEC by the standards route to compliance Signature of authorised person N F Dudley R amp D Manager f Dated 27 March 2003 Registered Office Faraday Road Dorcan rompton Swindon Wiltshire SN3 5HH UK Registered No 550926 VAT No GB 681 471 425 rompton 64 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics j Energy Division Tyco Electronics UK Limited Crompton instruments Freebournes Road Witham Electronics Essex CM8 3AH UK w Tel 44 1376 509 509 Energy Division Fax 44 1376 509 511 DECLARATION OF CONFORMITY Manufacturer s Name Tyco Electronics UK Limited
96. ary circuits may vary widely The choice of connected equipment or combination of equipment should not diminish the level of user protection specified 4 2 8 Insulation Dielectric voltage withstand test 3 25kV RMS 50Hz for 1 minute between all isolated electrical circuits 4 2 9 Environmental Operating temperature Storage temperature Relative humidity Shock Vibration Enclosure integrity front face only Harmonic distortion 4 2 10 Enclosure Style Material Terminals Weight 20 to 70 C 20 to 80 C 0 95 non condensing 30g in 3 planes 10 to 15 Hz 1 5 mm peak peak 15 to 150 Hz 1 0g IP54 max 50 THD up to 15th harmonic ANSI C39 1 Polycarbonate front and base steel case 6 32 UNC slotted barrier type 1 3kg 4 3 Display Tranducer Combined 1000 and 1540 See section 4 3 16 for specifications particular to the 1540 4 3 1 Inputs Nominal input voltage a c rms System PT VT primary values rompton INSTRUMENTS 57 7 to 600V L N single phase 100 to 600V L L 3 wire 57 7 to 346V L N 4 wire 1V to 400KV 48 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Max continuous input voltage Max short duration input voltage Nominal input voltage burden Nominal input current System CT primary values Max continuous input current Max short duration current input Nominal input current burden 4 3 2 Auxiliary Power Supply 120 of
97. assembly breaker operator assembly adjustable door catch and mounting hardware The operator features a trip indicator the ability to padlock in the OFF position with up to three 5 16 padlocks interlocks with I T E DKR2 DKR3 DKL2 and DKL3 door latch mecha nisms and auxiliary switch HAS 1 can be attached to provide remote indication of handle position Preparation 1 Turn OFF and lock out all power that supplies the circuit breaker and other equipment within the enclosure before installing this device 2 Prepare mounting holes in the enclosure flange and the enclosure panel See Table below for hole dimensions and illustrations Figures 1 and 2 8 32 UNC 8 32 UNC Handle Operators ving Breakers FDFBEL FDFBER4 FDFBEL4 Catalog numbers with the suffix 4 are for installation in Types 1 3 3R 4 4X and 12 enclosures Catalog numbers without the suffix 4 are for installation in Types 1 3 3R and 12 enclosures Fixed Depth operators can only be installed 3 Pole ED HED and CED type circuit breakers ED2 ED4 ED6 HED4 HED6 HHED6 CED6 ED6 ET1 CED6 ET1 Handle 281 Dia 2 Holes 28 2 44 4 69 t 25 R 4 PI Enclosure Flange Enclosure Panel F 4 Holes 6 Holes For CED6 and CFD6 Figure 1 Door Catch Bracket Interlock Lever 75
98. atch bracket 15 to the enclosure door and attach the adjustable door catch 16 to the door catch bracket 15 using the 48 32 x 5 16 in mounting screws 17 and 8 external tooth lockwashers 18 Note the H dimen sion for the correct mounting holes Tighten the mounting screws to 25 in lbs Adjusting Door Catch Figure 4 1 Move the handle to the OFF position and close the enclo sure door This action should release the interlock allowing the handle to be turned ON If the handle cannot be turned ON loosen the screws 17 and adjust the door catch 16 downward in its slot retighten the screws 17 and repeat 2 Move the handle to the ON position and attempt to open the enclosure door The door catch 16 should engage the inter lock lever extension and hold the door closed If the door can be opened adjust the door catch 16 downward 3 Repeat steps 1 and 2 to insure that the handle cannot be turned ON unless the door is fully closed and the door can not be opened if the handle is in the ON position NOTE The door can be opened when the handle is in the ON position by rotating the interlock defeater screw 19 located on either side of the handle housing I T E Fixed Depth Handle Operator Types 1 3 3R 4 4X 12 Installing Breaker And Breaker Operator Figures 5 And 6 Adjusting The Breaker Operator Figure 6 Circuit Breaker 20 or 23 Il E m Padlocking Hole Driver Pin
99. ate line up with the breaker mounting holes Make sure ON OFF indications on template are in same direction as ON OFF indications on the breaker To hold template in place punch two holes in template with breaker mounting screws and tighten into breaker mount ing holes Measure distances N and P from walls of enclosure Figure 2 Relocate template on enclosure cover by adding enclosure thickness and cover overhang R to dimensions N and P Figure 3 Remove backing from template and secure template on door Drill holes J 3 in dia and 4 in dia on template Figure 3 Circuit Breaker Rotary Handle Mechanism Mounting A B Mount breaker with handle up by sliding it under the tabs in mounting plate With breaker in OFF position and rotary handle mechan ism in OFF position mount mechanism on breaker using four 8 32 x 4 in screws When mounting ED Frame breakers with any handle operator four spacers must be used as shown in Figure 4 Make sure opening in mechan ism lever engages breaker handle Tighten screws Loosely secure the door rings with three 6 32 x in screws as provided Position the interior ring 2 contains latch tabs and threaded holes as shown in Figure 5 The exterior ring mounts on the outside Figure 6 Close the enclosure door and adjust external ring on door so itis concentric with handle ring Tighten the three screws 4
100. ating the interlock mechanism In the OFF position the interlock can be defeated by pushing the interlock lever extension 10 downward while moving the handle to the ON position Figure 2 With the enclosure door open and the handle in the ON position the interlock can be defeated by tur ning the defeater screw 11 on the operating handle counter clockwise When the enclosure door is closed the door latch mechanism now automatically defeats the interlock C Weld the door catch bracket 12 to the enclosure door Figures 2 and 4 NOTE Holes may be drilled in the door catch bracket using the projections as centers User must provide the mounting hardware D Fasten the door catch 13 to the door catch bracket with two 88 32 x 54g in pan head screws and external tooth lockwashers Figure 2 INSTALLATION DIAGRAMS a 1 640 Min i 060 Min 250 Max F Door Catch Bracket 4 688 Interlock Lever Extension 1 156 Max Min Door Catch NS B Figure 1 Figure 2 Ec 6 8 fe oo 9 9 x a 1 a0 9 M Pad ed 4 N pd M 1 7 3 11 X 2 Bellcrank LL Figure 3 Frame 12 2 438 Figure 4 Assembly Instructions Adjusting Door Catch Mechanism A Close the enclosure door and move the handle into the ON position Adjust the door catch downward if the handle can not be moved
101. b A2ot A2ob At the end of the set up for the second analogue output pressing will exit the set up system and enter the display mode 3 15 1 2 Reverse Operation It is possible to set reading top below reading bottom In the example of Section 3 15 2 setting reading top to 95 volts and reading bottom to 135 volts would cause the output current to decrease from 20mA to 4mA as the measured voltage increased from 95 to 135 volts 3 15 1 3 Reduced output range Note that if the output values are adjusted to reduce output range accuracy may be degraded For example if a 0 20mA capable output is set to operate over 0 1mA then the specified accuracy will be degraded by a factor of 20 rompton INSTRUMENTS 34 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 3 15 2 Analogue Output Scaling Example In this example the Integra has an output current range of 0 to 10mA and it is required that this output range represents a reading range of 95 to 135V Example Output top 10mA 135V Reading top Analogue Output Reading Value current from unit represented by Output Output bottom OmA 95V Reading bottom 3 15 2 1 Reading 1 or A2r The measured electrical parameter that the analogue output will represent Example Volts Ave Average Voltage As shown in Table 2 any continuously variable parameter volts amps watts etc can be selected for output as an an
102. between the display and transducer where applicable 3 Setting up 3 1 Introduction The following sections give step by step procedures for configuring the Integra transducer for a particular installation using an attached display To access the Set up screens press and hold the 4f Adjust key and the gt gt Next keys simultaneously for five seconds This brings up the password entry stage See Section 3 3 Access On completion of the last Set up screen the program exits Set up mode and returns to the last selected Display screen To return to the Display screens at any time during the set up procedures press the 7 and the gt gt keys simultaneously for five seconds rompton INSTRUMENTS 18 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco i Electronics Energy Division 3 2 Number Entry Procedure When setting up the unit many screens require the setting up of a number usually on the middle row of digits In particular on entry to the setting up section a password must be entered The procedure is as follows In general press the 1 adjust key to change something on the current screen Pressing the gt gt next key normally leaves the current screen unchanged and brings up the next screen The example below shows how the number 0000 can be changed to 1234 The digits are set one at a time from left to right The decimal point to the right of the digit in the picture flashes to Sys
103. bit registers The following table details the 3X register address and the values of the address bytes within the message A tick in the column indicates that the parameter is valid for the particular wiring system Any parameter with a cross X will return the value Zero 0000h Some parameters are only available on the Integra 1540 as shown in the table below Each parameter is held in the 3X registers Modbus Function Code 04 is used to access all parameters e g to request Volts 1 Start address 00 No of registers 02 Volts 2 Start address 02 No of registers 02 Each request for data must be restricted 40 parameters or less Exceeding the 40 parameter limit will cause a Modbus exception code to be returned Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 57 tyco Electronics Energy Division Register Parameter Parameter Modbus Start 30 30 10 10 Number Address Hex 4 wire 3 wire 3 wire 2 wire High Byte Low Byte 30001 1 Volts 1 L1 4W or L1 L2 3W 00 00 v v 30003 2 Volts 2 L2 N 4W L2 L3 3W 00 02 v X 30005 3 Volts 3 L3 N 4W or L3 L1 3W 00 04 v x X 30007 4 Current 1 00 06 4 v v 30009 Current 2 00 08 X 30011 6 Current 3 00 0A v v x x 30013 7 Watts Phase 1 I
104. blocks until breaker base bottoms against mounting block Secure breaker in place with 48 32 x 4 06 in mounting screws 16 C If installation requires use of front panel trim provide cutout for breaker escutcheon Figure 7 Installation Diagrams Dimensions In Inches Type CED6 CED6 ETI 12 25 11 25 8 28 All Other Types 9 00 8 00 5 02 Mtg Hardware 266 Dia Hole le 3 38 gt 4 Pls For 266 Dia Hole 4 Pls 38 Rad 4 Pls A Mtg Hardware By Customer 1 2 3 4 5 6 customers Sheet perder fopona 2 00 Drilling Switchboard Drilling and Cutouts Plug In Adapter Mounting Plate for Adapter Block Installation Figure 1 Figure 2 Figure 3 Customer Supplied Bus or Connector Breaker Mounting Location R 7 8 9 2 5 a NE 16 11 12 Sees m Outline Line 2 20 1 4 Side 14 Cutout Front Pod Panel Trim 2 10 159 Load Side Accessory A15 Studs Cutout for Breaker Preparation Warning Labels Final Assembly Front Panel Trim Figure 4 Figure 5 Figure 6 Figure 7 Dimensions in Inches Pole Center Left Right x Y 2 28 1 50 4 50 3 62 15 16 I T E Shunt Trip Undervoltage Trip Auxiliary Switch and Bell Alarm Switch Accessories Installation A DANGER Hazardous Voltage Will cause death or sever
105. by qualified maintenance personnel Replacement parts may be ordered through an authorized service center or directly from the factory FIELD FLASHING Restoring Residual Magnetism not applicable on PMG equipped generators To restore residual magnetism to the generator connect a 12 volt battery to the exciter field while the generator using the following procedure 1 Shutdown the generator set Remove the exciter field leads F and F from the regulator CAUTION Failure to remove the exciter field leads from the automatic voltage regulator during flashing procedures may destroy the regulator 2 Connect the F and F leads to the battery s corresponding positive and negative terminals This should be done using an appropriate length of lead wire to separate the battery from the point of connection batteries may explode when exposed to an electric arc After 3 to 5 seconds remove the F lead An inductive arc should result If no arc is drawn repeat the procedure 3 Reconnect the F and F leads to the regulator Restart the generator and verify that terminal voltage is developed If terminal voltage does not develop repeat the field flashing procedure and or consult the trouble shooting section BEARING REMOVAL Prior to performing this operation it is suggested that the alternator s shaft be rotated until two of the main rotor poles are in a vertical position Once the bearing bracket is backed out the rotor
106. can be padlocked to prevent unauthorized entry into the enclosure Drawings in these installation instructions are oriented for right hand flange installation Left hand flange installation drawings are mirror images of the right hand versions For left hand flange installation substitute clock wise for counterclockwise and vice versa whenever those words appear Installation of the Door Latch Mechanism A Drill mounting holes in the enclosure door observing the minimum dimensions shown in Figure 2 See FHOH Handle Operator instructions for flange drilling pattern NOTE D and E dimensions are determined by the height of the enclosure Refer to Figure 1 for the following steps B Place gasket 1 on handle plate 2 and attach handle plate to enclosure door with two thin wall hex nuts 3 Tighten the nuts to 100 in Ib C Insert lockout screw 4 and handle 5 through holes in the handle plate D Install latch bar post assembly 6 screw sealing washer flat washer and special hex nut 7 if used E Attach top 8 bottom 9 and latch plate rollers 10 to latch bar with retaining pins and E rings NOTE Two point latch does not have bottom roller F Fasten the top and bottom rollers to the enclosure door with locking type flange nuts Tighten the nuts then loosen them 1 turn to allow movement of the roller assemblies G Place bottom spring 11 over the bottom thin wall hex nut inside the enclosure door
107. ce sheaves Belts turn over in grooves Damaged cord section in belts Frayed or gouged belts e Replace belts Excessive vibration e Replace belts if damaged Worn sheaves e Replace sheaves Sheave misalignment e Realign sheaves Belts Squeal High starting load Belts not tensioned properly Excessive overload e Tension drive e Redesign amp replace drive Insufficient arc of contact e Revisecenterline distance Belt Breakage Foreign material in drive e Provide drive guard e Tension belts standard on Georator units Belts damaged during installation Shock or extreme overload e Follow installation instructions Eliminate overload e Redesign drive Excess Vibration Damaged belt cord section e Replace belts Loose belts e Tension drive Belts improperly tensioned e Tension belts evenly CKIMARATHON E LECT 1 ae Standard Induction Motors Installation Operation amp Maintenance Instructions TYPICAL CUTAWAY VIEW OF A MARATHON DESIGNED DRIPPROOF HORIZONTAL INTEGRAL HORSEPOWER MOTOR amp PARTS DESCRIPTION 364 THRU 445 FRAME SIZE DA 9 69 69 G9 G9 9 G9 24 9 1 Frame vent Sereen 11 Bracket ope 21 Bracket Holding gor 2 Conduit Bottom 12 Baffle Plate O P E 22 Inner Bearing
108. ce vibration increase bearing life and ensure minimum coupling wear It may be necessary to shim the generator feet for proper support and alignment Secure the feet of the generator with grade 5 or greater bolts through the holes provided in the mounting feet Consult the coupling manufacturer s instructions for alignment specifications and procedures GENERATOR MOUNTING Two Bearing Units Belt Driven Two bearing MagnaPLUS generators can be belt driven provided belts are sized and applied correctly Please refer to your supplier of belts and sheaves for correct sizing and tensioning specifications A bearing life calculation should be performed Marathon Electric recommends a minimum B 10 life of 40 000 hours If cog type belts are used a vibration may be introduced which could lead to premature failure of the bearings END PLAY TESTING Refer to the engine manual for recommended end play specifications and measurement procedures If end play is not to specification it is an indication that the generator shaft is not moving freely in the assembly and normal life of the thrust bearing could be impaired Probable causes of this problem are 1 Improper seating of drive discs in the flywheel resulting in misalignment 2 Improper mating of generator frame to engine flywheel housing resulting in misalignment 3 Improper G dimension per SAE J620c on either the engine or generator TORSIONAL VIBRATION Torsional vibrations
109. ch Piate Roller 9 Bottom Roller Lockout Plate KR Top Spring Pin 11 Bottom Spring Latch Plate Roller Figure 1 Left Hand Operation Figure 2 aS 10 24 Tap 2 Holes F 1 68 Figure 3 39 40 I T ETELEMAND Electric Motor Operator Catalog Numbers MOE6120 MOE6240 DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing AY SAFETY INSTRUCTIONS INSTALLATION INSTRUCTIONS Description The motor operated mechanism is designed to open close and reset a circuit breaker or switch by remote control The customer must supply the circuit breaker or switch normally ON and OFF pushbuttons external wiring a control power source and all control logic Consult the wiring diagram Figure 3 for a typical control connection The motor operator is hinged for opening to the bottom or load end of the breaker see Figure 2 NOTE For Automatic Reset Operation a separate auxiliary contact must be provided by the customer Installation 1 Turn off and lock out all power supplying circuit breaker and motor operator before installation or servicing 2 Mount the breaker and motor operator with its cover open together on the mounting panel as shown in Figure 2 3 The 4 spacers are placed between the breaker and the motor operator mounting base
110. ckwise minimum voltage level Set the remote voltage adjust if used to the center position Set the stability control full clockwise maximum stability level Connect the positive lead of a 100 V D C voltmeter to Fl and the negative lead of the voltmeter to F2 or use an appropriate AC voltmeter on the generator output leads SYSTEM START UP Start and run the generator at no load and rated speed The generator voltage should build up to a minimum level Actual level is dependent upon connection If it does not build up refer to field flashing section in generator manual Slowly adjust the voltage control until the generator voltage reaches the nominal value If used adjust the remote voltage rheostat to set the generator voltage to the exact value desired Turn the stability adjust counter clockwise until instability is shown on either of the voltmeters mentioned in the PRELIMINARY SET UP section With the system operating in an unstable condition slowly adjust the stability control clockwise until generator stability is reached Interrupt regulator power for a short time approximately 1 2 seconds If the generator remains stable no further adjustment is necessary If the generator does not remain stable increase the stability slightly and interrupt regulator power again This procedure should be repeated until system stability is reached and maintained TROUBLESHOOTING Residual Voltage No Output Acceleration tim
111. connect all loads open main circuit breaker or disconnect prior to shutdown This is especially important if loads can be damaged by low voltage or low frequency conditions during generator coast down e MARATHON A Subsidiary of Regal Beloit Corporation or the rotating rectifier assembly Ensure that RPM is the same as initial test 5 Monitor and record insulation resistance with a 500 volt mega ohm meter The minimum acceptable reading is 2 mega ohms If the reading drops below the minimum the generator should be cleaned and dried at an authorized service shop Consult Marathon Electric for more information DRYING WINDINGS Generators in service may inadvertently have their windings exposed to splashing or sprayed water Units that have been in transit or storage for long periods of time may be subjected to extreme temperature and moisture changes causing excessive condensation Regardless of the source of moisture wet windings should be thoroughly dried out before operating the unit If this precaution is not taken serious damage to the generator can result The following procedures may be utilized in drying the generators windings The method selected will be influenced by winding wetness and situation limitations Space Heaters An electric heater may have been supplied with the generator When energized from a power source other than the generator the heater will gradually dry the generator This process can be
112. d Plate Adjustment operating handle 2 up for ON and down for OFF If the breaker does not switch ON loosen the cable mounting nuts 27 at the fixed plate tab 26 hold the operating handle in the maximum ON position and move the cable 14 toward the top of the breaker Retighten the mounting nuts 27 to secure Trip the circuit breaker by pressing the PUSH TO TRIP but ton on the front of the circuit breaker Check that circuit breaker resets by moving the operating handle 2 from ON to OFF and back to ON If the breaker resets tighten the spring adjuster 29 one additional turn Attach the lockwasher and 10 32 locknut to the end of the cable rod 24 and tighten the locknut Ifthe circuit breaker does not reset after Step B tighten the spring adjuster 29 one turn and repeat Step B Continue this procedure until the breaker does reset then tighten the adjuster spring one additional turn Secure with the lock washer and locknut 30 Spring Adjustment I T E Fixed Depth Handle Operator Types 1 3 3R 4 4X 12 A DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing A SAFETY INSTRUCTIONS GENERAL INFORMATION Description The Fixed Depth Handle Operator is designed to function with Siemens ED Frame molded case circuit breakers and switches A complete handle operator consists of a handle assembly frame
113. d Relubrication Amounts table for volume of grease required Wipe off excess grease and replace filler and drain plugs see following warning Motor is ready for operation WARNING If motor is nameplated for hazardous locations do not run motor without all of the grease or drain plugs installed RELUBRICATION TIME INTERVAL For motors with regreasing provisions NEMA FRAME SIZE sexe 1800 RPM Over 1800 1800 RPM Over 1800 1800 RPM and less RPM and less RPM and less tires ON Service Over 1800 RPM See Note 2 NOTE 1 For motors nameplated as belted duty only divide the above intervals by 3 2 Lubricate at the beginning of the season Then follow service schedule above SEASONAL SERVICE The motor remains idle for a period of 6 months or more STANDARD SERVICE Up to 16 hours of operation per day indoors 100 F maximum ambient SEVERE SERVICE Greater than 16 hours of operation per day Continuous operation under high ambient temperatures 100 to 150 F and or any of the following dirty moistlocations high vibration above NEMA standards heavy shock loading or where shaft extension end is hot RELUBRICATION AMOUNTS For motors with regreasing provisions NEMAFRAMESIZE VOLUME cu in fluid oz TROUBLESHOOTING WARNING 1 Disconnect power before working on motor or driven equipment 2 Motors with automatic thermal p
114. d electrical parameter is at the reading bottom value Example 0mA 3 15 2 7 Summary In the above example the analogue output will be 0 mA when the average voltage is 95 volts 5 mA at 115 volts and 10 mA at 135 volts 3 15 3 Power Factor When analogue output current is used to represent power factor it can indicate the power factor for an inductive or capacitive load on imported or exported power This can be shown in two dimensions as follows Imported Power PF 1 0 5 Import to Import to 05 capacitive load inductive load Imported Imported VAr reactive VAr reactive 0 0 Exported Exported VAr reactive VAr reactive Export to Export to inductive load capacitive load 0 5 0 5 PF 1 Exported Power Power factor The polarity of the power factor reading indicates the direction of power flow Positive PF relates to imported power Negative PF relates exported power This assumes that the unit is connected for a predominantly import application See Installation sheet for further details Crompton INSTRUMENTS 36 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division When setting up the analogue output for a power factor reading the Reading Top value must be in one of the left hand quadrants and the Reading Bottom value must be in one of the right hand quadrants PF 1 Reading Reading Top Bottom 1 Hence if the Reading Top value is
115. d in accordance with ANSIB15 1 Welded steel guards are provided on all MG sets Belt guard screens are welded in the front end of the belt guards for ventilation and should not be obstructed Excessive Vibration may be the result of 8 1 Un even mounting surface 8 2 Non rigid mounting surface or loose mounting bolt s 8 3 Forcoupled in line units coupling misalignment 8 4 Belt tension and alignment please refer to the belt tensioning and maintenance section of the service manual 8 5 Inherent vibration in either motor or generator or both This vibration may occur as a result of worn bearings or an unbalanced rotor 8 6 For belted units improper balance on the either or both sheaves Audible Noise Belted motor generator sets are typically louder than coupled in line motor generator sets Indoor installation sites requires consideration for the noise level that the set is likely to produce As far as speech interference is concerned maximum levels recommended for offices are 60 65 dB For belted units an estimate for Georator s MG sets sound pressure level is dB 75 85 dB at 3 feet This level may vary under given operating and environment conditions and is expected to be maximum when the MG set is operating under full load condition and near a corner with poor sound absorbing reflective surfaces It will be even higher than the above levels with abnormal vibration conditions caused by loose belts A rigid sealed enclosure w
116. d secure template on door Drill holes J in dia and 474 in dia on template Figure 3 Circuit Breaker Rotary Handle Mechanism Mounting A Mount breaker with handle up by sliding it under the tabs in the mounting plate B With breaker in OFF position and rotary handle mechan ism in OFF position mount mechanism on breaker using four 48 32 x 4 in screws When mounting ED Frame breakers with any handle operator four spacers must be used as shown in Figure 4 Make sure opening in mechanism lever engages breaker handle Tighten screws C Loosely secure the door rings with the three 46 32 x v4 in screws provided Position the interior ring 2 contains latch tabs and threaded holes as shown in Figure 5 The exterior ring mounts on the outside of the door with the small flange to the inside Figure 6 D Close the enclosure door and adjust external ring on door so it is concentric with handle ring Tighten the three screws 4 E Check the door operation Latch on mechanism should engage latch tab 3 interior ring when breaker is ON and disengage latch tab when handle is rotated to OPEN DOOR position Repeat Step C if a slight adjustment is necessary F Enclosure door may be opened when breaker is ON by turn ing defeater screw 5 on rotary handle face place Figure 4 in a clockwise direction Installation Diagrams Top of Line End Add Additional Mtg Holes When Type CED6 I
117. d the metal pin has been exposed The circuit breaker is ready for mounting the accessory unit Caution Do not use excessive force or the internal mech anism of the circuit breaker may be damaged D Before assembling accessory unit to the breaker make cer tain that all exposed accessory actuator slots are in line with the locating tabs 1 and the circuit breaker handle 2 is in the tripped position Figure 1 Accessory Mounting Instructions Caution Turn off and lock out all power before removing circuit breaker for modification Breaker must be completely disconnected and removed from any electrical equipment before accessory is attached Never attempt to add more than one accessory module to the circuit breaker Combinations must be ordered within a single module Trip Button on 1 pole circuit breaker trip button is on handle pole 4 Circuit Breaker 2 Handle In Tripped Position tocang eireut Breaker abs uator Slots x Ble e 6 Washer Lockwashers Eu A 3 Cutting Screws a Unit Assembly Figure 1 Trip Latch Pin Knock Out Contactor Pin Knock Out Cradle Pin Knock Out Knock Out Groove Single Pole Knock Outs Figure 2 fue NOTE Accessory module is used on all ED Frame circuit breakers Accessory can not be used with obsolete breaker types E2 E4 HE4 HE6 CLE
118. d with the regulator Part A 527066 It can be located on the rear face of the voltage regulator EXCITER POWER CIRCUIT Connect the regulator wire F to the generator F or Fl field terminal Connect the regulator wire F to the generator F or F2 field terminal See Figure 2 for typical connection diagram SENSING POWER INPUT CIRCUIT Input power and sensing is achieved through terminals 3 and 4 The voltage input requirement of the SE350 is 190 to 240 Vac See Figure 2 INTERCONNECTION DIAGRAM FOR 416 480 VOLT OR 208 240 VOLT WYE CONNECTED GENERATOR T9 T1 GEN 77 T2 T3 FUSE OPTIONAL REMOTE 3 280V 4AMP VOLTAGE ADJUST F2 REMOVABLE JUMPER 7 FOR REMOTE VOLTAGE ADJUST MOVABLE Ne 1 2 WATT F1 JUMPER 3 FeF 7 6 40 FIGURE 2 3F F 7 6 46 VOLTAGE ADJUST The screwdriver adjustable potentiometer adjusts the generator output voltage Adjustment clockwise increases the generator output voltage When using a remote voltage adjust rheostat remove the jumper wire across terminals 6 and 7 and install a 2000 ohm 1 2 watt minimum rheostat This will give 10 voltage variation from the nominal For 5 voltage variation use a 1000 ohm 1 2 watt rheostat See Figure 2 STABILITY ADJUST System stability is the ability of the generator to respond to load transients Decreasing the stability makes the generator less sluggish and faster to respond to toad transients If the stability of the regulator is decreased too much
119. e steel case Screw clamp style 4 2 Display Transducer Combined 0240 0340 0440 0640 For Model 1000 and 1540 specification refer to Section 4 3 4 2 1 Inputs Three phase three wire voltage range ELV Three phase four wire voltage range Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 45 100 120V L L LOV 121 240V L L MIV 241 480V L L HIV 481 600V L L ELV 100 120V L L 57 7 70V L N rompton INSTRUMENTS tyco Electronics Energy Division LOV 121 240V L L 70 1 139V L N MIV 241 480V L L 140 277V L N HIV 481 600V L L 277 346V L N Voltage range is defined by factory build option Nominal input voltage a c rms 57 7 to 346V L N 100 to 600V L L System PT VT primary values 1V to 400 kV Max continuous input voltage 120 of nominal up to 720 V max Max short duration input voltage Twice nominal 1s application repeated 10 times at 10s intervals Nominal input voltage burden 0 2 VA approx per phase Nominal input current 1 or 5 A a c rms System CT primary values Standard values up to 9999 Amps 5 A secondaries 1 A on application Max continuous input current 120 of nominal Max short duration current input 20 times nominal 1s application repeated 5 times at 5 min intervals Nominal input current burden 0 6 VA approx per phase 4 2 2 Auxiliary Power Supply The unit can be powered from an auxiliary a c or d c supply that is separate from the metered
120. e from 0 to 15 degrees downward from the vertical Optional weather protection enclosures may be provided for outdoor installation See paragraph 12 below for a description of optional enclosures 4 0 5 0 6 0 7 0 8 0 9 0 Ambient temperature of the air surrounding the MG Set should not exceed 40 C 104 F for standard rated motors and generators De rating may be necessary if the ambient temperature exceeds 40 C Consult Georator engineering for recommendations For estimated values of heat generated by the MG set under full load conditions BTU hr please consult Georator engineering Eyebolts or lifting lugs on the motor or the generator are intended only for lifting the motor or generator These lifting provisions should never be used to handle the entire MG Set Please use the holes provided in the base for lifting the entire assembly The MG Set base should be mounted on level solid foundation Georator recommends using the 4 mounting holes in the base for mounting the base directly on a rigid foundation If these holes are used 5 8 bolts will be required for mounting For mounting the unit on a concrete foundation anchored bolts can be used with a maximum nut torque of approx 30 lb ft Anchored bolts can pull loose if the concrete is overstressed by too much bolt tension If grouting is used always check for cracks and gaps All rotating parts such as couplings pulleys and unused shaft extensions are guarde
121. e injury Turn power off supplying switch board or panel before installing A Position accessory unit 3 against the side of the cir cuit breaker 4 carefully to determine that all accessory actuator blades are engaged into the actuator slots of the circuit breaker 5 NOTE Fiber washer 6 must be placed between the circuit breaker and the accessory unit as shown in Figure 1 B Secure accessory unit to the circuit breaker using two 6 20 x 1 38 in thread cutting screws and split lockwashers 7 A SAFETY INSTRUCTIONS For this publication the term circuit breaker also includes molded case switches and motor circuit interrupters Circuit Breaker Preparation A thru D for 1 pole circuit breakers D for 2 and 3 pole circuit breakers A For circuit breakers requiring knockouts align accessory to circuit breaker as shown in Figure 1 Mark only the breaker knock outs which correspond to the actuator blades protruding from the accessory package B Place the circuit breaker on a flat surface with the marked knock outs facing you as shown in Figure 2 C Using a sharp object such as a knife blade point place point in groove of knock out and tap on handle until groove is pierced Move around the groove until the knock out can be removed NOTE It is important that the slotted pin is completely exposed and that all plastic has been trimmed and removed until the edge of the knock out has been cleaned an
122. e operating handle to the extreme OFF position The circuit breaker is now ready for reclosing The overcenter toggle mechanism is trip free of the operating handle The circuit breaker therefore cannot be held closed by means of the handle should a tripping condition exist After automatic operation the handle assumes an intermediate posi tion between ON and OFF thus displaying a clear indication of tripping Maintenance Experience has shown that properly applied molded case cir cuit breakers normally do not require maintenance However some industrial users may choose to establish an inspection and maintenance procedure to be carried out on a regular basis For detailed information consult applicable NEMA publications or your local Siemens sales office Breaker Outline Wiring Diagram for 500V dc 3 Pole Ungrounded Systems Only Figure 1 I T E ED Frame Outline Drawings 1 Pole Types ED2 ED4 HED4 ELM gu 50 25 End View i Side View rag ll C Handle Operating Forces Operation Ib OFF to ON 4 ON to OFF 2 TRIPPED to RESET 6 drawing dimensions are shown inches See detail drawings on page 9 ED Frame Outline Drawings 2 Pole Types ED2 ED4 ED6 HED4 HED6 HHED6 Breaker 19 Dia Mounting Holes 38 Dia x 13 Deep Counter 36 Thick 4 00
123. e sole warranty of Siemens Energy amp Automation Inc Any state ments contained herein do not create new warranties or modify the existing warranty _ Information and Instructions General Information General ED Frame Sentron Series circuit breakers as shown on pages 5 9 are for use in individual enclosures switchboards panelboards and load centers They are available as thermal magnetic trip types ED2 ED4 ED6 HED4 HED6 HHED6 CED6 current limiting type CED6 instantaneous magnetic trip only motor circuit protection types ED6 ETI CED6 ETI and molded case switches types ED2 ED4 ED6 HHED6 CED6 CED6 type Sentron Series circuit breakers combine thermal magnetic construction for overload protection and an additional set of patented blow apart contacts in conjunction with the ED Frame s standard patented blow apart contacts This arrangement provides for current limiting protection under high fault interrupting conditions as outlined in the National Elec tric Code Article 240 1 and UL 489 standards CED6 type ED Frame circuit breakers are fuseless and therefore require no blown fuses to be located and replaced should a high cur rent fault occur The common trip feature of the circuit breaker is completely retained so that all poles of the circuit breaker open when caused to trip due to an overload or short circuit Pressure wire connectors suitable for use with aluminum or copper wire are
124. e to rated speed too long Field leads Fl F2 not connected Power input leads not connected Blown or missing fuse Defective regulator Defective generator Output Voltage Low Incorrect connections Voltages adjust turned down Remote voltage adjust is turned down Defective regulator Output Voltage High Voltages adjust turned too high Remote voltage adjust is turned too high Residual voltage at regulator power input wires 3 amp 4 below 10 V ac Check wiring diagram for proper connections Flash generator field Refer to field flashing section in generator manual Reduce acceleration time Interrupt power input to regulator after achieving rated speed Connect field leads Fl F2 Connect power input leads 3 4 Replace fuse Replace regulator Consult generator manual Check wiring diagram for proper connections Rotate voltages adjust CW until desired voltage is reached Rotate remote voltages adjust CW until desired voltage is reached Replace regulator Rotate voltages adjust CCW until desired voltage is reached Rotate remote voltages adjust CCW until desired voltage is reached Output Voltage High Defective regulator Replace regulator No Adjustment Remote Voltage Adjust Voltages adjust wire backwards Reverse the wiring of the Operates Backwards remote voltage adjust Generator Output Voltage Hunting Stability adjusts not set properly Rotate t
125. eading 0 1 of range 1 9 of reading 0 1 of range 0 9 of reading 0 1 of range 1 Class IEC 1036 Active PF 0 8 1 0 8 importing 2 Reactive PF 0 8 1 0 8 importing 0 013 C typical 1 5 seconds approx Twice the error allowed for the reference condition applied in the test Crompton INSTRUMENTS tyco Electronics Energy Division of IEC688 1992 Error in measurement when a measurand is within its measuring range but outside its reference range 4 3 4 Reference conditions Twice the error allowed at the end of the reference range adjacent to the section of the measuring range where the measurand is currently operating or being tested Reference conditions of measurands and where applicable components of the measurand Values of measured quantities and of components of measured quantities where the intrinsic headline errors for the measured quantities apply Voltage Current Frequency Active power Watt Voltage Current Active power factor Reactive power VAr Voltage Current Reactive power factor Apparent Power VA Voltage Current Power factor Voltage Current 50 100 of nominal 10 100 of nominal Nominal 10 10 100 of nominal Nominal 2 10 10026 of nominal 1 0 8 leading or lagging 10 100 of nominal Nominal 2 10 100 of nominal 1 0 8 leading or lagging 10 10026 of nominal Nominal 2 10 10026 of nominal 1 0 8 leading or lag
126. ear Sys Volts To change the value again press 11 The Edit screen will reappear Volts L3 N Volts 13 1 Amps L3 Confirmation rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 31 tyco Electronics Energy Division 3 13 RS485 Parity Selection 0240 0340 0440 0640 1000 1540 Option This screen allows setting of the parity and number of stop bits of the RS485 Modbus JC II port Where the transducer unit is separate from the display unit the transducer has two Modbus ports one of which may be used for communicating with a display The RS485 Parity Selection option only sets the parity for a port that is not communicating with a display unit The port characteristics for communication with a display are preset If the JC NII protocol is to be used this parameter must be set to No parity and One stop bit Press gt gt to accept the currently displayed value The next Set up screen will then appear Sys Volts D To change the parity press Use the 11 key to scroll through the available values odd odd parity with one stop bit E even parity with one stop bit no 1 no parity one stop bit no 2 no parity two stop bits Select the required setting and press to confirm your selection The Confirmation screen will appear Press to accept the new setting The next Set up screen will appear Press 11 to return to the Edit scr
127. ecautions Should a conflict arise between the general information contained in this publication and the con tents of drawings or supplementary material or both the latter shall take precedence Siemens Energy amp Automation Inc reserves the right to make changes in specifications shown herein or add improvements at any time without notice or obligation NOTE Authorized and qualified personnel For the purpose of this manual a qualified person is one who is familiar with the installation construction or operation of the equipment and the hazards involved In addition he has the following qualifications a is trained and authorized to de energize clear ground and tag cir cuits and equipment in accordance with established safety practices 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 is trained in rendering first aid SUMMARY These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contin referred to the sales office listed on back of h The contents of this instruction manual should ify any prior existing agreement commitm or relationship The ict ns the entire obligation of Siemens Energy amp Automation Inc The warranty contained in the contract between the par ties is th
128. ection Defective regulator e MARATHON A Subsidiary of Regal Beloit Corporation CHECK AND REMEDY Check engine and governor systems for malfunctions Check load for fluctuation Adjust Regulator stability Refer to Regulator manual Replace defective or worn rheostat Use shielded cable to minimize electrical noise Check assembly for loose connections Test the diodes as specified in the test section Improve connections both mechanically and electrically Replace regulator GENERATOR PRODUCES HIGH VOLTAGE CHECK AND REMEDY Check voltage with separate meter at generator terminals Verify generator connections Refer to drawings supplied with the generator or connection diagrams in this manual Adjust regulator Consult regulator manual Check the power factor of the load If power factor is leading change load configuration Excessive leading power factor capacitors can cause voltage to climb out of control Verify regulator voltage sensing is connected correctly Consult regulator manual Replace regulator GENERATOR BUILDS VOLTAGE FROM STARTUP THEN GOES TO LOW RESIDUAL VOLTAGE CAUSE CHECK AND REMEDY Regulator protective circuit Check indicators on regulator Correct problems and adjust regulator as is required operating Refer to regulator manual GENERATOR IS OVERHEATING CAUSE CHECK AND REMEDY Generator is overloaded Reduce load Check with ammeter and compare with nameplate rating Clogged ventilating
129. ed in series 6 or 7 panelboards I T E Single Pole Mounting Bracket E2BMB A Place short tab 1 in circuit breaker case slot and then slide C Fasten mounting bracket to circuit breaker with self tapping both tabs toward matching holes in side of circuit breaker screw 3 provided 6 in Ib max torque case Figure 1 D Mount breaker to enclosure surface with two 10 32 x 14 in B Long tab 2 must be snapped into place It can be removed mounting screws provided by prying up with screwdriver and sliding it off This bracket is used for single pole mounting with or without accessory module 10 32 x 4 mounting screw 3 Installation Diagram Figure 1 25 6 750 190 x 312 slotted hole 2 pics x 4 375 463 A y 75 7 25 lt M 130 Dia 439 Installation Dimensions Figure 2 43 44 I T E Enclosures Types 1 3R 4 4x Type 1 E2N1S E2N1F CLE6N1S CLE6NIFO General purpose indoor sheet steel enclosure for use in normal atmosphere listed as service entrance equipment 875 1 125 1 375 1 75 2 00 K O s 6 Places 875 1 125 1 375 1 75 2 00 Ld K O s 2 Required Type 3R E2N3R CLE6N3R An outdoor sheet steel enclosure providing protection against driving rain sleet or snow Listed as service entrance equip
130. een Confirmation rompton INSTRUMENTS 32 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 3 14 RS485 Modbus Address 0240 0340 0440 0640 1000 1540 Option This screen allows setting of the Modbus JC NII device address for the instrument Where the transducer unit is separate from the display unit the transducer has two RS485 ports one of which may be used for communicating with a display The Address option only sets the address for a port that is not communicating with a display unit The port characteristics for communication with a display are preset Press gt gt to accept the currently displayed value The next Set up screen will then appear To change the address press 4f Set the three digit address using the method described in Section 3 2 Number Entry Procedure The range of the allowable addresses is 1 to 247 The range of selectable digits is restricted so that no higher number can be set Press gt gt to confirm your selection The Confirmation screen will appear If the new address is correct press gt gt Depending on the model this may take you out of the Set up screens and back to the last selected Display screen If the new address is not correct press 7 to return to the Edit screen Confirmation rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 33 tyco Electro
131. emand period being updated every minute The demand period can be reset which allows synchronisation to other equipment When it is reset the values in the Demand and Maximum Demand registers are set to zero rompton INSTRUMENTS 54 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Time Integration Periods can be set to 8 15 20 or 30 minutes Note During the initial period when the sliding window does not yet contain a full set of readings i e the elapsed time since the demands were last reset or the elapsed time since Integra was switched on is less than the selected demand period then maximum demands may not be true due to the absence of immediate historical data The Time Integration Period can be user set either from the Integra 1540 Display or by using the communications option Total Harmonic Distortion 1540 only The calculation used for the Total Harmonic Distortion is THD RMS of total waveform RMS of fundamental RMS of total waveform x 100 This is often referred to as THD R The figure is limited to the range 0 to 100 and is subject to the range of use limits The instrument may give erratic or incorrect readings where the THD is very high and the fundamental is essentially suppressed For low signal levels the noise contributions from the signal may represent a significant portion of the RMS of total waveform and may thus generate unexpectedly
132. emporarily If the motor is too large for the generator the generator s voltage dips greater than 30 percent This may result in the motor starter de energizing or the motor stalling MagnaPlus generators generally supply 3 to 4 MARATHON A Subsidiary of Regal Beloit Corporation e horsepower per generator KW in motor starting capability For specific data contact Marathon Electric PARALLEL OPERATION All MagnaPlus generators are built with 2 3 pitch main stator windings and full amortisseur damper windings These features make the MagnaPlus generators suitable for parallel operation when equipped with the proper voltage regulators and voltage regulator accessories Consult with the factory for further information relative to parallel operations NONLINEAR LOADING Solid state electronic control devices variable frequency drives precision motor controls battery chargers etc utilize electronic switching circuits thyristors SCRs Diodes etc These switching circuits introduce high frequency harmonics which distort the normal wave form of the generator This creates additional heat in the generator windings and may cause the generator to over heat Problems which can occur are not limited to the generator Poor wave shape may adversely effect various loads connected to the generator Consult Marathon Electric for further information relative to nonlinear loads INSTALLATION PREPARATION FOR USE Although the ge
133. er allows the automatic voltage regulator to function The regulator provides voltage to the exciter resulting in a build up of generator terminal voltage This system of using residual magnetism eliminates the need for a special field flashing circuit in the regulator After the generator has established the initial residual voltage the regulator provides a controlled DC field voltage to the exciter stator resulting in a controlled generator terminal voltage Voltage Regulation In the standard configuration shunt excited the automatic voltage regulator receives both its input power and voltage sensing from the generators output terminals See Figure 1 With the optional PMG configuration the regulator receives input power from the PMG The regulator automatically monitors the generator s output voltage against an internal reference set point and provides the necessary DC output voltage to the exciter field required to maintain constant generator terminal voltage The generator s terminal voltage is changed by adjusting the regulator s reference set point Consult the regulator manual for specific adjustment and operating instructions MOTOR STARTING When a motor is started a large surge of current is drawn by the motor This starting current is equivalent to the motors locked rotor or stall current and is 5 to 10 times normal full load current When the generator supplies this in rush of starting current the generator voltage dips t
134. ess the 11 key to return to restart the number entry The first digit entry screen will appear If a rejection screen appears press the 11 key to restart the entry procedure Rejection INSTRUMENTS 20 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 3 3 Access To access the Set up screens press the 11 and gt gt keys simultaneously for five seconds until the Password Introduction screen appears Password protection can be enabled to prevent unauthorised access to Set up screens Password protection is not normally enabled when a product is shipped The unit is protected if the password is set to any four digit number other than 0000 Setting a password of 0000 disables the password protection 3 3 1 Access with No Password Protection Press gt gt from the Password Introduction screen The 0000 password confirmation screen will appear non Li Li LI Press again to proceed to the first Set up screen 3 3 2 Access with Password Protection If the unit is protected by a password proceed as follows Password introduction rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 21 tyco Electronics Energy Division Enter the four digit password using the method described in Section 3 2 Number Entry Procedure Sys Volts Volts L1 N Volts L3 N Volts 13 1 Amps L3
135. etween the drive discs and the shaft to achieve the proper shaft extension G dimension per SAE J620c Holes are provided in the periphery of the coupling discs which correspond to tapped holes in the prime mover s flywheel The outside diameter of the drive discs fit in a rabbet in the flywheel so that concentricity is assured Grade 8 place bolts and hardened washers are recommended to mount the drive discs to the flywheel DO NOT USE SPLIT TYPE LOCK WASHERS Split lock washers when biting into the drive disc cause stress risers which may result in the disc fracturing The SAE flywheel housing adapter ring and the engine flywheel housing are designed to match each other with no further alignment necessary Use grade 5 or greater mounting bolts MagnaPLUS generator frames are constructed with two or three bolt holes per foot The feet should be shimmed where necessary to obtain solid contact with the sub base With the frame securely bolted to the engine flywheel housing there is no side thrust or pull on the generator frame thus no real need to secure the feet with more than one bolt per foot GENERATOR MOUNTING Two Bearing Generators Direct Drive Two bearing generators are provided with a keyed shaft extension For direct drive generators the assembler furnishes a flexible coupling which is installed between the 5 driver and the generator s shaft Aligning the generator and its driver as accurately as possible will redu
136. ey gt gt moves to next screen Crompton INSTRUMENTS 14 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 2 10 Line Currents THD 0240 0340 0440 0640 1000 1540 Line 1 Current THD Line 2 Current THD Line 3 Current THD Key gt gt moves to next screen 2 11 Neutral Current Frequency and Power Factor 0240 0340 0440 0640 1000 1540 Neutral Current Amps 4 wire and single phase 3 wire system only Frequency Hz 0 ons Power Factor 0 to 1 on 1000 and combined 1540 sign prefix on 1540 two part prefix C indicates Capacitive load and L Inductive Key gt gt moves to next screen 2 12 Power 0240 0340 0440 0640 1000 1540 Sys Volts Reactive Power kVAr Apparent Power kVA Active Power kW Key gt gt moves to next screen Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 15 tyco Electronics j Energy Division 2 13 Active Energy kWh 0240 0340 0440 0640 1000 1540 This is the energy that has been consumed since the unit was last reset see Section 3 9 Resets nnrn m Li LI Active Energy kWh 7 digit reading i e 0001243 Key moves to next screen 2 14 Reactive Energy kVArh 0240 0340 0440 06
137. f influence 51 quantities for measurands 4 8 7 Functional ranges 51 4 3 8 Screen 51 4 3 9 Standards 51 4 3 10 Safety 52 4 3 11 Insulation 52 4 3 12 Environmental 52 4 3 13 Enclosure 52 4 3 14 Serial Communications Option 52 4 3 15 Active Energy Pulsed Output Option 53 4 3 16 Integra 1540 Only 53 5 Basis of measurement and calculations 54 6 Serial Communications 56 6 1 RS485 Port Modbus or JC N2 56 6 2 Modbus Implementation 56 6 3 RS485 Implementation of Johnson Controls Metasys 60 7 Maintenance 63 8 Appendix A CE Declaration of Conformity 64 rompton INSTRUMENTS 4 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 1 Introduction This manual provides operating instructions for the Crompton Switchboard Integra series of Digital Metering Systems Some versions of the Integra incorporate the metering transducer that provides the interface for the measurement of power supply parameters such as voltage current power frequency etc In other versions the display and transducer are separate interconnected units The display allows the user to set up metering transducer parameters and to monitor the measurements Some Integra models can be supplied as either an integral or display only version while others are only available in one format This manual provides user instructions A separate leaflet provides installation instructions Table1 lists the various models of Integra and s
138. from the ON position B With the handle in the ON position try to open the enclosure door without turning the defeater screw in the handle If the door opens readjust the door catch and repeat Steps A and B Mounting Breaker Operator The circuit breaker can be mounted remotely from the handle within a range that is limited by the length of the operating cable 14 Figure 7 and the depth of the enclosure Table 2 and Figure 5 show the horizontal range E of the circuit breaker in 8 to 30 in enclosures Table 1 Circuit Breaker Mounting Dimensions Breaker A B C D G Tap Size CED6 CED6 ETI All Other Types Table 2 Maximum E Dimensions Enclosure Depth Inches FHOECOS 6 36 e 10 12 t6 18 20 24 30 13 8 13 5 13 0 10 7 87 53 Maximum E dimension only if F 4 6 Table 3 F Dimensions 36 Cable 48 Cable Enclosure Depth Min Min 8 4 2 15 5 16 0 10 5 2 15 0 16 5 12 6 0 14 7 17 0 16 4 5 14 2 16 5 18 3 4 12 8 16 0 20 0 6 10 0 15 5 24 14 0 30 8 7 Caution When installed the cable bend radius should not be less than 3 in This minimum wire bending require ment must be met to insure operating safety The mounting procedure is as follows A Determine the desired circuit breaker mounting location using Tables 1 2 and Figure 5 B
139. ge Mount Handle Operator 31 32 I T E Max Flex Flange Mount Handle Operator Types 1 3 3R 4 4X 12 INSTALLATION Mounting Max Flex Handle Operator to Enclosure Frame Assembly A Drill the mounting holes in the enclosure flange and file all burrs Figures 1 and 2 Note the maximum and minimum drill hole distances in Figure 2 B Push the rubber gasket 1 down in the groove of the han dle assembly 2 Figure 3 C The handle and the interlock mechanism are supplied pre assembled from the factory NOTE For ease of assembly move the operating handle to the ON position up toward the top of the enclosure Mount the frame 4 and handle assembly 2 to the enclosure flange 5 with two 74 20 x 1 in socket head cap screws and lockwashers Tighten cap screws from within the enclosure Figure 3 Secure E Ring Connection A Rotate the bellcrank 6 clockwise to engage the return spring 7 Hold the bellcrank in position and place the plastic washer and connecting link onto the bellcrank pin 8 Using pliers secure the connection with an E ring 9 Figure 3 B Mountthe interlock lever extension 10 to the interlock lever 3 using two 26 32 x 3 8 in machine screws and lockwashers Screws mount through the threaded lever extension into the lever Figure 3 Operating Note With the enclosure door open the operating handle cannot be moved from the OFF to ON position without deliberately defe
140. generator s fan as a fulcrum to accomplish this Use the engine manufacturer s recommended practice to manually turn over the engine To prevent possible injury to personnel and damage to the equipment ensure that the engine cannot start during this procedure Remove the two main rotor leads and the three exciter rotor leads from the rectifier assembly figure 4 The rectifier assembly is now electrically isolated from the generator The diodes remain mounted and the diode leads remain connected to the terminal posts Using an ohmmeter or a battery light continuity tester place one test probe on the diode lead terminal post In succession touch the other test probe to the lead screw hole in each heat sink Reverse the probes and repeat the procedure You have now tested the three diodes connected to this terminal post in both the forward and reverse direction Repeat the procedure using the other diode terminal post Forward Reverse Terminal End O Anode Cathode O 4 C FIGURE 3 DIODE POLARITY e MARATHON A Subsidiary of Regal Beloit Corporation 12 When the positive test probe is connected to the diode s anode and the negative test probe is connected to the diode s cathode forward biased the diode will switch on and conduct electricity figure 3 This is observed by a low resistance reading when using an ohm meter or the lighting of the bulb when using a battery light continuity tester
141. ging Nominal 2 40 100 of nominal 4 3 5 Reference conditions of influence quantities Values that quantities which affect measurement errors to a minor degree have to be for the intrinsic headline errors for measured quantities to apply Ambient temperature Input frequency Input waveform Auxiliary supply voltage Auxiliary supply frequency Auxiliary supply distortion factor Magnetic field of external origin rompton INSTRUMENTS 23 C 50 or 60 Hz 2 Sinusoidal distortion factor 0 005 Nominal 1 Nominal 1 0 05 Terrestrial flux Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 4 3 6 Nominal range of use of influence quantities for measurands Values of quantities which affect measurement errors to a minor degree for which the magnitude of the measurement error is defined in this specification Voltage 50 120 of nominal Current 5 120 of nominal Frequency Nominal 10 Power factor active reactive 0 5 lagging 1 0 8 leading importing as appropriate Temperature 20 C to 70 C Input waveform distortion 20 3rd Harmonic distortion Auxiliary supply voltage Nominal 10 Auxiliary supply frequency Nominal 10 Magnetic field of external origin 400A m 4 3 7 Functional ranges Crest values of voltage and current must remain within 168 of nominal maximum rms values The functional ranges of measurands and of influence quant
142. gy Division Imported Power Imported Power PF Reading PF Reading 1 1 Import Import Import Inductive Capacitive Capacitive Import Inductive OPF 0 75 mA 0 5 Output Top Export Export Export Export Inductive Capacitive Inductive 1 mA Capacitive Reading Reading Reading Reading Top 1 PF Bottom 1 PF Top 1PF Bottom 1 PF European Convention North American Convention Symmetrical full range import export In this example the unit is set to represent the full range of inductive and capacitive loads on imported and exported power The unit has an analogue output range of 1 to 1 mA Both Reading Top and Reading Bottom are set to 1 power factor 3 15 4 Phase Angle The Phase Angle analogue outputs are treated in a similar manner to Power Factor with values specified in degrees The following figure shows the relationship between phase angle in degrees and power factor Degrees 1 oda 0 9 9 98 0 98 factor 0 1 84 2 0 1 0 90 a 0 0 1 7 957 7 T 04 107 4 Power 0 9 Power 0 9 factor 0 98 0 98 factor Degrees Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 39 tyco Electronics Energy Division 3 15 5 Parameters available for analogue outputs Table 2 Analogue output parameter selection
143. h the bracket will clear the locating register on the frame Lower the shaft extension until the rotor is resting on the main stator core Continue to pull the bracket free from the bearing Visually inspect the bearing bore for damage or wear If worn or damaged sleeve or replace prior to reassembly Reassembly note Before the bearing bracket is seated against the frame a threaded rod may be used to help align the inner bearing cap with the bearing bracket BEARING REPLACEMENT Using a bearing puller remove the existing bearing It is strongly recommended that the bearing be replaced any time the it is removed from the shaft ALWAYS install the same type and size bearing that was supplied as original equipment Order by part number from the parts list and include the unit serial number and part number when ordering Heat the bearing to a maximum of 1009C 2129F in an oven Apply a thin coat of clean lubricating oil to the press fit area of the rotor shaft Using suitable heat resistant gloves install the bearing over the end of the shaft until it seats against the shaft shoulder The bearing should slide on the shaft and be seated without excessive force Should the bearing bind on the shaft prior to being seated against the shoulder a piece of tubing slightly larger than the press fit area can be used to drive the bearing to its final position Using light taps with a soft mallet apply pressure to the inner race only RECTIFIER
144. h Street Wausau WI 54402 8003 Phone 715 675 3311 FAX 715 675 6361 Ge This manual is printed on recycled stock SB 181 6 2001 MAGNAPLUS GENERATOR 280 430 Frame I nstallation Operation and Maintenance Manual Marathon Electric Mfg Corp A Subsidiary of Regal Beloit Corp P O Box 8003 Oo MARATHON oo 715 675 3359 i 6 Fax 715 675 8026 A Subsidiary of Regal Beloit Corporation www marathonelectric com CONTENTS Safety 2 Receiving and Storage 2 Principles of Operation 3 4 Installation 4 6 Wiring Connections 6 9 Operation 9 10 Maintenance 10 11 Testing 11 12 Service 12 14 Troubleshooting 14 17 Specifications 18 Parts List amp Recommended Spare Parts 19 20 SAFETY PLEASE REMEMBER SAFETY FIRST If you are not sure of the instructions or procedures contained herein seek qualified help before continuing This service manual emphasizes the safety precautions necessary during the installation operation maintenance of your MagnaPLUS generator Each section of this manual has caution and warning messages These messages are for your safety and the safety of the equipment involved If any of these cautions or warnings are not readily understood seek clarification from qualified personnel before proceeding Before any service work is done disconnect all power sources and lock out all controls to prevent an unexpected start up of the generator set driver P
145. he Modbus output option allows remote monitoring from a Modbus master Neutral referenced parameters are only available when used with 4 wire and single phase configured transducers 2 energy and demand measurements importing only unless connected as exporting unit rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 7 tyco Electronics Energy Division Default display Neutral referenced parameters are only available when used with 4 wire and single phase configured transducers All energy and demand measurements are importing only unless connected as exporting unit rompton INSTRUMENTS 1 1 5 1540 The1540 is available either as a display unit operating in conjunction with a 15xx measurement transducer or as a self contained unit incorporating a transducer The unit can measure and display the following System voltage average of all phases System current average of all phases System frequency Hz Voltage line to neutral for each phase 4 wire systems only Voltage line to line for each phase calculated in 4 wire Current in each line Neutral current Power Factor e Active Power kW e Reactive Power kVAr Apparent Power kVA e Active Energy kWh Reactive Energy kVArh Total System Current Demand Admd Total System Active Power Demand kWD Maximum Total System Current Demand AD Maximum Total Sy
146. he same as for setting the Reading Top screens as described in Section 3 15 7 These screens show A1ob or A2ob for Analogue output 2 on the top line rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 43 tyco Electronics Energy Division 4 Specification The parameters listed in this section apply only to those models that can measure those parameters 4 1 Display Only Versions 4 1 1 Input RS485 Dedicated to Crompton Integra transducers 4 1 2 Auxiliary Power Supply The unit can be powered from an auxiliary a c or d c supply that is separate from the metered supply Versions of the unit are available to suit 100 250V 45 65 Hz a c d c and 12 48V d c supplies 4 1 2 1 High Voltage version Standard nominal supply voltages 100 250V a c nominal 15 85V a c absolute minimum to 287V a c absolute maximum or 100 250V d c nominal 15 25 85V d c absolute minimum to 312V d c absolute maximum A C supply frequency range 45 to 66 Hz or 360 to 440 Hz Model 0440 A C supply burden 4VA approx 4 1 2 2 Low Voltage version D C supply 12 48V d c 15 25 10 2V d c absolute minimum to 60V d c absolute maximum D C supply burden 4VA approx 4 1 3 EMC Standards EMC Immunity EN61326 for Industrial Locations to performance criterion A EMC Emissions EN61326 to Class A Industrial rompton INSTRUMENTS 44 Integra 1540 1000 0640 0440 0340 0240 Issue 1
147. he stability adjusts in a CW direction until hunting stops Poor Regulation Defective regulator Replace regulator SIEMENS ED Frame Information and Instruction Guide I I E Molded Case Circuit Breakers DANGER Hazardous voltages are present inside the enclosures or panels in which the circuit breakers are installed Death serious injury and or equipment damage will result if circuit breakers are improperly applied or precaution is not used De energize all incoming power prior to installation of circuit breakers or associated accessories Only qualified personnel should work on or around this equipment Position of circuit breaker handles shown in this booklet is for illustration pur poses only Circuit breakers are to be installed in OFF or TRIPPED position only I T E ED Frame Circuit Breakers 1 2 and 3 Pole 15 125 Amperes Types ED2 ED4 ED6 HED4 HED6 HHED6 CED6 ED6 ETI CED6 ETI Table of Contents Important Notices General Information Dimensional Reference Drawings Pressure Wire Connectors Compression Conne tar Handle Blocking Device Padlocking Device Rear Connecting Studs i Plug In Adapters ae Accessories in n Shunt Trip Undervoltage Ti Switch and Bell Alarm Swit Shunt Trip and Unde Electrical Check Accessories Cont Rotary Handle Operators CRHOESD CRHOEVD Rotary Handle Operator E2RH1 Rotary Handle Operator E2RHV9 Max Flex
148. heater circuit when the generator is connected to the load Start the prime mover and adjust it for proper speed See generator nameplate e MARATHON A Subsidiary of Regal Beloit Corporation Isolate all conditions that could apply voltage to the generator terminals while the generator is at rest Failure to comply could result in personnel injury or equipment damage 6 The purpose of this initial test with the regulator out of 2 the circuit is to detect any wiring mistakes without exposing the unit to undue risk Check all line to line and line to neutral voltages for balanced voltage If voltages are balanced shut down the set and reconnect the regulator If voltages are unbalanced shut down 3 the equipment and check for improper wiring If the problem persists consult the factory If the unit is equipped with space heaters verify that the heater circuit is energized With the regulator de energized the residual voltage should be 10 25 of rated value It is recommended that this residual voltage and driver RPM be recorded for use as a future troubleshooting benchmark MAINTENANCE The following maintenance procedures should be followed to ensure long equipment life and satisfactory performance Maintenance intervals will depend upon operating WARNING conditions THE FOLLOWING TEST MUST BE CONDUCTED BY 1 Routinely check intake and exhaust air screens to QUALIFIED ELECTRICAL PERSONNEL LETHAL VOLTAGE MAY BE P
149. high values of THD To avoid indicating large figures of THD for low signal levels the product will produce a display of 0 zero Typically display of THD will only produce the 0 zero value when the THD calculation has been suppressed due to a low signal level being detected It should also be noted that spurious signals for example switching spikes if coincident with the waveform sampling period will be included in the RMS of the total waveform and will be used in the calculation of THD The display of THD may be seen to fluctuate under these conditions Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 55 tyco Electronics Energy Division 6 Serial Communications 6 1 RS485 Port Modbus or JC N2 0240 0340 0440 0640 1000 1540 Option INTEGRA 1000 and 1540 offer the option of an RS485 communication port for direct connection to SCADA systems This port can be used for either an RS485 Modbus RTU slave or as a Johnson Controls N2 protocol slave Choice of reply protocol is made by the Integra on the basis of the format of request so that a Modbus request receives a Modbus reply and an N2 protocol request receives an N2 protocol reply 6 2 Modbus Implementation This section provides basic information for the integration of the product to a Modbus network If background information or more details of the Integra implementation is required please refer to ou
150. hows their distinctive characteristics Table 1 Summary of Integra models Model V A F PF kW kWh THD Analogue Serial Pulse Freq 0240 V F 45 65 Hz 0340 V A 45 65 Hz 0440 V A F 360 400 Hz 0640 V A F 45 65 Hz 1000 V A F PF kW kWh RS485 Pulse 45 65 Hz option option 1540 V A F PF kW kWh THD Analogue RS485 Pulse option option option 45 65 Hz When used with an 1560 80 transducer that includes analogue options Voltage and current readings are true RMS up to the 15th harmonic 31st for 1560 80 transducer The unit can be powered from an auxiliary a c or d c supply that is separate from the metered supply Versions of each model are available to suit 100 250V 45 65 Hz a c d c and 12 48V d c nominal supplies In this manual the graphic 0240 0340 0440 0640 1000 1540 is used to show the models to which a screen applies Boxes are greyed out to show models that do not have that type of screen 0240 0340 0440 0640 1000 1540 This example indicates that the screen only applies to Models 1000 and 1540 0240 0340 0440 0640 1000 1540 Option This indicates that the screen is an option on models 1000 and 1540 Important safety information is contained in the accompanying installation instructions Installers must familarise themselves with this information before installation
151. ing new brushes fit them carefully to the collector rings Be sure that the copper pigtail conductors are securely fastened to and make good contact with the brushholders ALLOWABLE VOLTAGE AND FREQUENCY RANGE if voltage and frequency are within the following range motors will operate but with somewhat different characteris tics than obtained with correct nameplate values 1 Voltage Within 10 above or below the value stamped on the nameplate On three phase systems the voltage should be balanced within 1 A small voltage unbalance will cause a significant current unbalance 2 Frequency Within 5 above or below the value stamped on the nameplate 3 Voltage and Frequency together Within 10 providing frequency above is less than 5 above or below values stamped on the nameplate CLEANLINESS Keep both the interior and exterior of the motor free from dirt water oiland grease Motors operating in dirty places should be periodically disassembled and thoroughly cleaned CONDENSATION DRAIN PLUGS All explosion proof and some totally enclosed motors are equipped with automatic drain plugs they should be free of oil grease paint grit and dirt so they don t clog up The drain system is designed for normal floor feet down mounting For other mounting positions modification of the drain system may be required consult Marathon Electric SERVICE WARNING Disconnect power before working on motor or driven equ
152. ions in speed WARNING HIGH VOLTAGES MAY BE PRESENT AT THE GENERATOR S TERMINALS WHEN THE UNIT IS RUNNING SOME ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE POWER SOURCE WHEN THE UNIT IS AT REST TOOLS EQUIPMENT CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF ROTATING PARTS AND ELECTRICAL CONNECTIONS SPECIAL PRECAUTIONS MUST BE TAKEN DURING TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO GAIN ACCESS AND PERFORM TESTS BE CAREFUL SERIOUS PERSONAL INJURY OR DEATH CAN RESULT FROM THESE HAZARDS CONSULT QUALIFIED PERSONNEL WITH ANY QUESTIONS CAUSE Voltmeter off or defective Incorrect or defective connections Loss of residual Defective diodes suppressor or windings Regulator protection operating Regulator inoperative GENERATOR PRODUCES NO VOLTAGE CHECK AND REMEDY Check voltage with a separate meter at the generator terminals Verify generator connections See drawings supplied with the generator or lead connection diagrams in this manual Inspect all wiring for loose connections open circuits grounds and short circuits Flash the field Refer to field flashing in the service section If the generator is equipped with a PMG field flashing is not necessary check regulator fuse and input power from the PMG Test the generator using the 12 volt battery test as specified in the testing section If the results indicate generator problems perform ins
153. ipment Motors with automatic thermal protectors willautomatically restart when the protector cools Do not use motors with automatic thermal protectors in applications where automatic restart will be hazardous to personnel or equipment It CAUTION Overgreasing bearings can cause premature bearing and or motor failure The amount of grease added should be carefully controlled NOTE If lubrication instructions are shown on the motor nameplate they will supersede this general instruction Marathon Electric motors are pregreased with a polyurea mineral oil NGLI grade 2 type grease unless stated otherwise on the motor nameplate Some compatible brands of polyurea mineral base type grease are Chevron SRI 2 Rykon Premium 2 Exxon Polyrex EM or Texaco Polystar RB Motors are properly lubricated at the time of manufacture is not necessary to lubricate at the time of installation unless the motor has been in storage for a period of 12 months or longer refer to lubrication procedure that follows LUBRICATION PROCEDURES 1 5 2 3 4 Condition pese qw eal qv atl ren Stop motor Disconnect and lock out of service Remove contaminants from grease inlet area Remove filler and drain plugs Check filler and drain holes for blockage and clean as necessary Add proper type and amount of grease See the Relubrication Time Intervals table for service schedule an
154. it breaker can be turned ON If the breaker will not turn ON adjust the interlock defeater lever downward to engage the lever on the handle operator D To open the door insert a screwdriver into the handle screw and turn the screw and handle counterclockwise The door will only open partially if the operating handle is in the ON position If the door fully opens with the handle in the ON position adjust the interlock defeater lever upward and repeat Steps C and D NOTE To open the door when the handle is in the ON posi tion turn the latch defeaterr screw located on the side of the operating handle Minimum Dimensions In Inches C 1 922 Q 2 594 H 9 375 R 1 875 1 50 S 1 625 J 2 688 T 250 K B 1 859 U 688 L 1 797 281 Dia M 391 Dia Ww 703 Dia N 2 297 X 2 484 P 19 Y 219 Dia OThe last letter and number designate right or left hand 2 or 3 point latches Installation Diagrams 34 16 x 1 42 Button Head Cap Screw Flatwasher l Washer L Sealing 8 Top Roller 7 Special Hex Nut E Ring 6 Latch Bar Post Assembly Locking Type Flange Nut 17 Door Catch 15 interlock Defeater Lever 4 Lockout Screw D 10 24 x RS 4 Screws Lockwasher 13 Top Spring Ha S 16 Latch Bar x 1 1 Supplied By Customer 14 Lockout Plate 1 Gasket 5 Handle M 10 Lat
155. itchboard mounting plate 1 in position at location previously prepared in Step A above Secure in place with 1 4 in hardware furnished by customer Mounting Block Figure 3 A Align mounting block 2 with cutouts in switchboard mount ing plate or customer s mounting means as previously pre pared in Step B above and secure in place with 1 4 in screws 3 washers 4 and 5 and hexnuts 6 furnished Breaker Preparation Figure 4 A Remove pressure wire connectors from breaker if present Select line side breaker stud and insulator 11 and 12 assemble to terminals from back of breaker and secure to breaker terminals with 12 24 screws and washers 7 8 9 as shown in Figure 4 Recommended tightening torque for these screws is 212 3 ft Ib to assure a good electrical connection Repeat this procedure for the remaining line and load connections breaker studs and insulations B Insert line end shields 10 into slots provided at line end of breaker C Affix accessory warning labels 13 14 to top of breaker as indicated in Figure 5 Final Assembly Figure 6 A Make bus and or cable connection to rear of mounting block studs using hex nuts 15 furnished to secure this connection Caution Make certain that breaker operating handle is in the OFF position before proceeding with the next step B Align breaker with mounting blocks and force female tulip clips over male studs 11 in mounting
156. ith baffles reduces noise levels typically by 15 25 dB Although typical sound attenuating enclosures offered by Georator are not sealed at the bottom careful design of the enclosure baffles and 10 0 inclusion of acoustical absorbing materials substantially reduce the audible noise of the MG by typically 25 30 dB at 3 feet Electrical Considerations 10 1 10 2 10 3 10 4 10 5 Apply the correct input voltage to the Motor Starter terminals Motors may operate within 10 of their nameplate however performance characteristics will differ from nameplate data Maximum frequency variation may not exceed 5 rated frequency Good electrical systems and operating practice limit the voltage at the motor under load to not more than 5 of nameplate Also note that starting motors at lower input voltages will reduce the starting torque thereby prolonging the acceleration time of the motor from stand still locked rotor to rated speed With MG Sets the motor is already started under some load which is the generator s inertia For full voltage starting the maximum allowable time for small frame motors up to 286T is 10 seconds for medium frames 324T 326T is 15 seconds and for large frames 364T 449T is 15 seconds To prevent nuisance tripping when starting the unit ensure that an appropriately sized circuit breaker is used with the instantaneous trip set at least at 800 of the Full Load Amp of the motor per NEC Table 430
157. ities for measurands Values of measured quantities components of measured quantities and quantities which affect measurement errors to a minor degree for which the product gives meaningful readings Voltage Current Frequency Power Factor Temperature Active power Watt Reactive power VAr Apparent power VA 4 3 8 Screen Update 4 3 9 Standards Terms Definitions and Test Methods EMC Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 51 5 120 of nominal below 5 of nominal voltage current indication is only approximate 0 120 of nominal 2 120 of nominal for Power Factor 45 66 Hz 1 0 leading or lagging importing active reactive as appropriate 20 C to 70 C 0 120 of nominal 360 MW Max 0 120 of nominal 360 MVAr Max 0 120 of nominal 360 MVA Max 0 5 second approx IEC688 BSEN 60688 IEC1036 BSEN 61036 IEC 61326 rompton INSTRUMENTS tyco Electronics Energy Division 4 3 10 Safety IEC1010 1 BSEN 61010 1 Permanently connected use Normal Condition Installation category III pollution degree 2 Basic Insulation 720V RMS maximum Auxiliary circuits 12 48V auxuliary communications relay and analogue outputs where applicable are separated from metering inputs and 100 250V auxiliary circuits by at least basic insulation Such auxiliary circuit terminals are only suitable for connection to equipment which has no user accessible live
158. ivering not more than the indicated fault current when protected by a fuse or circuit breaker at 100 or 125 amperes Note All tolerance ranges are within UL 489 standards Switch HHED63S100A HHED638125A 100 Ordering Information Circuit Breaker Catalog Numbers CED6 Non Interchangeable Trip 2 Pole 3 Pole Complete Breaker UL Interrupting Ratings kA Complete Breaker UL Interrupting Ratings kA Ampere Unenclosed RMS Symmetrical Amperes Ampere Unenclosed RMS Symmetrical Amperes Rating Catalog Volts AC Rating Catalog Volts AC Volts DC Number 240 480 600 Number 240 480 600 250 500 15 CED62B015 200 200 100 15 CED63B015 200 200 100 N A 50 20 CED62B020 200 200 100 20 CED63B020 200 200 100 N A 50 30 CED62B030 200 200 100 30 CED63B030 200 200 100 N A 50 40 CED62B040 200 200 100 40 CED63B040 200 200 100 N A 50 50 CED62B050 200 200 100 50 CED63B050 200 200 100 N A 50 60 CED62B060 200 200 100 60 CED63B060 200 200 100 N A 50 70 CED62B070 200 200 100 70 CED63B070 200 200 100 N A 50 80 CED62B080 200 200 100 80 CED63B080 200 200 100 N A 50 90 CED62B090 200 200 100 90 CED63B090 200 200 100 N A 50 100 CED62B100 200 200 100 100 CED63B100 200 200 100 N A 50 125 CED62B125 200 200 100 125 CED63B125 200 200 100 N A 50 M
159. l be forced to 1 if the display contains zero when the gt gt key is pressed 3 6 Potential Transformer Primary Voltage 0240 0340 0440 0640 1000 1540 This value is the nominal full scale voltage which will be displayed as L1 N L2 N and L3 N for a four wire system L1 2 L2 3 and L3 1 in a three wire system or system volts for single phase This screen enables the user to display the line to neutral and line to line voltages inclusive of any transformer ratios The values displayed represent the voltage in kilovolts note the x1000 indicator For example on a 2 2kV system with 110V potential transformer secondary set 2 200 at this screen If there is no potential transformer PT in the system i e the voltage terminals are connected directly to the metered voltage leave this value unchanged and skip this set up step If the PT primary and secondary values are changed and it is desired to revert to a set up with no PT then set both PT primary and secondary values to the nominal maximum voltage for the Integra transducer rompton INSTRUMENTS 24 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division To set up the PT primary proceed as follows x1000 Amps KVAr kWh kVArh V 8 be xio00 7 I Decimal Point Sys Volts Digit Edit Confirmation Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 25 To accept the currently displayed
160. layed pulse duration press The next screen will appear Depending on the model this may take you out of the Set up screens and back to the last selected Display screen Confirmation rompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 29 tyco Electronics Energy Division 3 11 Pulse Rate 0240 0340 0440 0640 1000 1540 Option This applies to the Relay Pulsed Output option only Units with this option provide pulses to indicate power consumption kWh This screen allows setting of the kWh pulse rate divisor On a two part DIS 1540 Integra 1560 this screen will set the pulse rate for the kvarh pulse relay where fitted also By default the unit produces one pulse per kWh Changing this divisor changes the output pulse rate as follows Divisor One pulse per 1 1 kWh 10 10 kWh 100 100 kWh 1000 1000 kWh DIS1540 with 1560 1580 only Press to accept the currently displayed value The next Set up screen will then appear ERE To change the pulse rate divisor press 11 Use the key to scroll the value through the available values 1 10 100 1 000 If the maximum power is greater than 3 6 megawatts the range of divisors will be restricted to force an upper limit to the number of pulses hour of 3600 Select the required divisor and press to confirm your selection The Confirmation screen will appear To change the value again press
161. lectrical troubles be sure that Theline voltage and frequency correspond to the voltage and frequency stamped on the nameplate of the motor The voltage is actually available at motor terminals The fuses and other protective devices are in proper condition All connections and contacts are properly made in the circuits between the control apparatus and motor These instructions do not cover all details or variations in equipment nor provide for every possible condition to be met in connection with installation operation or maintenance Should additional information be desired for the purchaser s purposes the matter should be referred to the nearest Marathon Electric Manufacturing Corp sales office listed on the back page MOTOR TROUBLE SHOOTING CHART Your motor service and any trouble shooting must be handled by qualified persons who have proper tools and equipment TROUBLE CAUSE WHAT TO DO Motor fails to start Replace fuses with proper type and rating Overload trips Check and reset overload in starter Improper power supply heck to see that power supplied agrees with motor nameplate and load factor Improper line connections Check connections with diagram supplied with motor Open circuit in winding or control switch Indicated by humming sound when switch is closed Check for loose wiring connections Also see that all control contacts are closing Mechanical failure Check to see if mo
162. line to neutral for each phase 4 wire systems only Voltage line to line for each phase calculated in 4 wire Current in each line The 0440 and 0640 have Set up screens for Full scale current value Potential transformer primary and secondary voltages 6 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 1 1 4 1000 Integra 1000 RS The 1000 will display the following parameters ton Ame Ct System voltage average of all phases System current average of all phases PE System frequency Hz Volts L3 N ID Voltage line to neutral for each phase 4 wire systems only Voltage line to line for each phase calculated in 4 wire Current in each line e Neutral current Default display Power Factor Active Power kW e Reactive Power kVAr Apparent Power kVA Active Energy kWh Reactive Energy kVArh Total System Current Demand AD Total System Active Power Demand kWD Maximum Total System Current Demand AD Maximum Total System Active Power Demand kWD The 1000 has Set up screens for Full scale current value Potential transformer primary voltages Demand integration time and energy demand resets Pulse output duration and rate divisor option e RS485 serial Modbus parameters option A pulsed relay output indicating kWh and an RS485 Modbus output are available as optional extras T
163. ll square assembly If M dimension is the minimum as shown on dimensional chart tighten pipe clamps with support pipe seated fully into both flange collars If M dimension is other than minimum adjust support pipe so that approximately the same amount of pipe is in each of the upper and lower flange collars A minimum of 1 2 in pipe must be in each flange collar Tighten pipe clamps I I E Max Flex Flange Mount Handle Operator Types 1 3 3R 4 4X 12 A DANGER Hazardous Voitage Will cause death or severe injury Turn power off supplying switch board or panel before installing amp SAFETY INSTRUCTIONS GENERAL INFORMATION Description The I T E Max Flex Flange Mount Handle Operator is a flexi ble cable control device used for the remote switching of a circuit breaker within an enclosure The flexible cable is con nected directly to the breaker switch handle at one end and a factory installed switch handle operator at the other end The remote operator handle located on the enclosure flange is used to perform mechanical open close switching operations This is accomplished through the cable s sliding center race enclosed within the cable Function The advanced design concept of the Max Flex Handle Operator provides for greater flexibility when locating a circuit breaker within an enclosure The circuit breaker can be mounted almost anywhere at any angle and on almost any conve
164. log Number A01ED62 A01ED62 A01ED62 01 064 A01ED64 N A A01ED62 A01ED62 A01ED62 A01ED62 1 Shunt Trip and 1 Auxiliary Switch Catalog Number 48 Undervoltage Trip Control Voltage 1 Alarm Switch and 1 Alarm Switch and 1 Auxiliary Switch 2 Auxiliary Switches 2 Auxiliary Switches Catalog Number Catalog Number Catalog Number A01ED62B AO2ED62 A02ED62B A01ED62B AO2ED62 A02ED62B AO1ED62B AO2ED62 AO2ED62B A01ED64B N A N A A01ED64B N A N A N A N A N A A01ED62B AO2ED62 AO2ED62B A01ED62B 02 062 A02ED62B A01ED62B A02ED62 AO2ED62B A01ED62B AO2ED62 AO2ED62B S17ED60 N A N A 518 060 N A N A 501 060 S01ED62A S01ED62AB SO2ED60 SO2ED62A 502 062 SO3ED60 SOSED62A SOSED62AB S15ED60 S15ED64A S15ED64AB SO4ED60 SO4ED64A SO4ED64AB SO6ED60 N A N A S07ED60 S07ED62A S07ED62AB SO9ED60 SO9ED62A SO9ED62AB 11ED60 S11ED62A 511 062 S13ED60 S13ED62A S13ED62AB 1 Undervoltage Trip Bell Alarm Switch Control Voltage 1 Alarm Switch AC 120 208 240 277 480 600 DC Catalog Number 1 Undervoltage Trip and 1 Auxiliary Switch 1 Shunt Trip 1 Auxiliary Switch and 1 Alarm Switch Catalog Number Catalog Number 1 Undervoltage Trip 1 Auxiliary Switch and 1 Alarm Switch 1 Shunt Trip and 1
165. lowing connection diagrams shown below may be either grounded earthed or left above ground potential floating See national and local codes and or the system distribution wiring schematic diagram for the proper connection of the neutral The following connection diagrams are shown for twelve lead generators Ten lead generators have the same terminal designations except for leads T10 T11 and T12 These three leads are internally connected inside the generator and brought out as a single lead TO Ten lead generators can only be connected in a wye configuration HIGH SERIES WYE CONNECTION e MARATHON A Subsidiary of Regal Beloit Corporation VOLTAGE HIGH WYE LOW PARALLEL WYE CONNECTION a VOLTAGE LOW WYE 190 50 208 200 190 VOLTAGE HIGH DELTA Hz 240 120 50 240 120 220 110 200 100 7 Subsidiary Regal Beloit Corporation e DOUBLE DELTA SINGLE PHASE CONNECTION VOLTAGE DOUBLE DELTA hz 240 120 Note Single phase KW KVA ratings are approximately equal to 50 of the generator s three phase ratings VOLTAGE LOW ZIGZAG LL LN Hz 240 120 oe Lone 220 110 200 100 Note Single phase KW KVA ratings are approximately equal to 50 of the generator s three phase ratings Note Single phase KW
166. luminum Conductors No of Wire Size Tool Mfgr Tool No Die No Crimps UT 5 TW TY 2 20 Homer UT 15 58 60 2 2 0 Burndy Y 35 58 60 2 TBN 6 TW TY 2 29 TEB TBN 15 58 60 2 14 210 Square D VC 6 1 z Connector Crimps Figure 2 Remove any inhibitor compound expelled during the crimp ing operation from the connector body and the cable insulation J Slip insulating cover over connector tang and then over con nector barrel so that only the connector tang is exposed Figure 3 Warning Short spacings will result if Step J is not followed Socket Head Cap Screw Insulating Cover Breaker Terminal Installation Figure 3 K Position connector tang on top of the circuit breaker termi nal pad and secure with 14 28 x 1 in socket head cap screw and conical spring washer Conical spring washer is to be installed with convex side of washer toward underside of screw head Figure 3 Torque screw to 50 in Ib T1 12 I T E Handle Locking Devices Ha o IH u a M M I v ATTACHING I T E HANDLE BLOCKING DEVICE E2HBL To Block Handle ON Turn breaker ON Assemble blocking device to breaker by posi tioning it below handle Figure 1 Insert tabs 1 into slots 2 on either side of pad To Block Handle OFF Turn breaker OFF
167. me since the demands were last reset or since the Integra was switched on is less than one minute the maximum demands current MaxAD and power MaxkWD will remain at zero and not follow the instantaneous demands Maximum Demand is the maximum power or current demand that has occurred since the unit was last reset as detailed in Section 3 9 Resets Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 9 tyco Electronics Energy Division 1 5 RS485 Serial Option 0240 0340 0440 0640 1000 1540 Option This option is available on two part separate transducer and display units and on 1000 and self contained 1540 units This option uses an RS485 serial port with Modbus or JC NII protocol to provide a means of remotely monitoring and controlling the Integra unit Both protocols are supplied in the same unit Communications automatically configure according to the protocol that is recognized when the master sends a message Where the installation comprises separate display and transducer units the display communicates with the transducer using a modified Modbus protocol via the RS485 port Such a transducer may have two such ports either or both of which can be used for connection to a display Where a port is available it can be connected to a PC for control and monitoring purposes Set up screens are provided for setting up the Modbus port See Sections 3 12 to 3 14 These sc
168. n ded coil ru Check to make sure that all leads are well connected Locate and repair Motor vibrates Strengthen base Groun Balancing weights shifted Rebalance motor Polyphase motor running single phase Check for open circuit Excessive end play Adjust bearing or add shim Unequal terminal volts Check leads and connections Unbalanced line current on polyphase Single phase operation Check for open contacts motors during normal Unbalanced voltage Correct unbalanced power supply operation Scraping noise Fan rubbing air shield Fan striking insulation Loose on bedplate Tighten holding bolts Noisy operation Check and correct bracket fits or bearing Rotor unbalance Bent or sprung shaft Straighten or replace shaft Excessive belt pull Decrease belt tension Pulleys too far awa Move pulley closer to motor bearing Pulley diameter too small Use larger pulleys Misalignment orrect by realignment of drive Hot bearings ball Insufficient grease Maintain proper quantity of grease in bearing Deterioration of grease or lubircant Remove old grease wash bearings thoroughly in kerosene and replace contaminated with new grease Excess lubricant ity of Overloaded bearing Broken ball or rough races Hot bearings general Check alignment side and end thrust Replace bearing first clean housing thoroughly Marathon Electric Mfg Corp P O Box 8003 100 E Randolp
169. n handle is in OFF position but will open when handle is between OFF and RESET OPEN positions Tighten screws and operate han dle ON and OFF to see that circuit breaker operates satisfactorily Installation Diagrams 2 00 48 32 Top or Line End of Circuit Breaker 4d Mtg Lx n iy ae tg Holes y 5 64 5 00 1 1 7 TL wet NRI vea Breaker Mtg Tapped Surtace Mtg Holes 1 3 25 CED6 Add Additional Pod Mtg Holes when CED6 Type CED6 is used Pod 4A ps 1 Standard Depth Drilling Plan Front View Load End View Figure 1 2 938 Note Drill Only the Y Holes 7 469 the Z Holes Ze Dia 54 Dia 2 938 4J 1 469 e X 2 Dia Drilling for Handle Figure 2 Figure 2a G 16 625 F Variable Depth Load End View Shaft Figure 3 Figure 3a 23 24 Types 1 12 A DANGER Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS I T E Rotary Handle Enclosure Mechanism Standard Depth CRHOESD Variable Depth CRHOEVD General Information When properly installed the rotary handle operator provides single point latching of the enclosure door For maximum pro tection against unauthorized entry into the enclosure addi tional latching means should be provided
170. nced within 1 at the motor terminals After the machine is coupled to the load check that the nameplate amps are not exceeded Recheck the voltage level and balance under load per the above guidelines Shut down the motor if the above parameters are not met or if any other noise or vibration disturbances are present Consult NEMA guidelines or the equipment manufacturer if any questions exist before operating equipment CAUTION For motors nameplated as belted duty only do not run motor without belts properly installed COLLECTOR RINGS Wound Rotor Motors Only The collector rings are sometimes treated at the factory to protect them while in stock and during shipment The brushes have been fastened in a raised position Before putting the motor into service the collector rings should be cleaned to remove this treatment Use a cleaning fluid that is made for degreasing electrical equipment All of the brushes must be released and lowered to the collector surface Keep the rings clean and maintain their polished surfaces Ordinarily the rings will require only occasional wiping with a piece of canvas or non linting cloth Do notlet dust or dirtaccumulate between the collector rings BRUSHES Wound Rotor Motors Only Seethatthe brushes move freely in the holders and at the same time make firm even contact with the collector rings The pressure should be between 2 and 3 pounds per square inch of brush surface When install
171. nerator has been carefully inspected and tested in operation prior to shipment from the factory it is recommended that the generator be thoroughly inspected Check all bolts for tightness and examine the insulation on lead wires for chafing prior to proceeding with installation Remove all shipping tapes bags skids and rotor support blocking For two bearing units rotate the shaft by hand to ensure that it rotates smoothly without binding WARNING DISABLE AND LOCKOUT ANY ENGINE CRANKING DEVICES BEFORE ATTEMPTING TO INSTALL OR SERVICE THE GENERATOR FOR ELECTRIC START SETS DISCONNECT THE CRANKING BATTERY FOR AIR START DISCONNECT THE AIR SUPPLY FOR MOTOR GENERATOR SETS OPEN THE POWER SUPPLY TO THE DRIVE MOTOR FAILURE TO COMPLY WITH THESE SAFETY IN SEVERE PROCEDURES COULD RESULT PERSONAL INJURY OR EQUIPMENT DAMAGE NEVER BAR OVER THE ENGINE GENERATOR SET USING THE GENERATOR S FAN THE FAN IS NOT DESIGNED FOR THIS PURPOSE BARRING OVER THE SET WITH THE FAN COULD DAMAGE THE FAN AND RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE GENERATOR MOUNTING Single Bearing Units Single bearing units are provided with an SAE flywheel housing adapter flange and flexible drive discs Coupling the generator s shaft to the engine flywheel is accomplished with special steel drive discs bolted to the shaft In addition to the drive discs there may be a hub spacer spacer discs or a combination of hub spacer and spacer discs inserted b
172. ng Instructions A Drill and tap breaker mounting holes as shown in Figure 1 B Measure distances A and B from mounting holes to walls of the enclosure Figure 2 C Find handle center dimensions D and E by adding enclosure thickness and cover overhang and C2 to A 1 2 and B 3 985 Drill hole X 2 in dia and drill either holes Y or Z She in dia depending on handle orientation required Figure 2a D If installing variable depth kit measure distance F from breaker mounting surface to outside of cover Figure 3 If distance F is less than 8 in remove shaft guide bracket Find length G by subtracting F from 165 in Mark length G from end of operating shaft and cut shaft squarely at mark Figure 3a Breaker must be tripped during installation Push red but ton marked PUSH TO TRIP Using screws supplied with kit attach mechanism plate to breaker and mount in enclosure in position shown Insert end of operating shaft into square socket in cast oper ating arm so that top of shaft has proper relationship to han dle Tighten set screw in operating arm recommended torque 75 in Ib Place handle and cork gasket on outside of cover and place handle mounting bracket on inside of cover fasten together loosely through cover with the two short screws provided Adjust handle so that cover will not open whe
173. nics Energy Division 3 15 Analogue Output Set Up 0240 0340 0440 0640 1000 1540 Option This is an option on Models 1540 that have separate 1560 or 1580 transducers 3 15 1 Introduction This applies to the analogue output option only allowing the parameter to be selected and the upper and lower limits adjusted for either one or two channels For each analogue output fitted provision is made for five values to be user selected These are Air Parameter from Table 2 This is the measured input that is to be represented by the analogue output for example Watts or Frequency 1 Reading Top This is the value of the electrical parameter that will cause the analogue output to produce Output Top A rb Reading Bottom This is the value of the electrical parameter that will cause the analogue output to produce Output Bottom Alot Output Top This is the value of output that will be reached when the measured electrical parameter is at the reading top value A1ob Output Bottom This is the value of output that will be reached when the measured electrical parameter is at the reading bottom value To aid understanding a simple example is shown in Section 3 15 2 3 15 1 1 Second Channel The screens following show the set up for the first analogue channel Set up of the second analogue output is identical except that screens show A2 instead of A1 i e A2r A2rt A2r
174. nient surface The same flexibility applies when locating the switch handle operator on the flange section of the enclosure Application The Max Flex Operator is designed to work with I T E circuit breakers having current ratings through 600A The Max Flex unit meets all the industrial criteria such as UL and Automo tive Industry Standards Design The new Max Flex Handle Operator provides maximum flexi bility in design and assembly of electrical equipment Since there are no linkages to assemble the Max Flex system can save time during installation The cable design is flexible and rugged It is similar to those cables used in aircraft control systems The flexible cable comes in standard 3 or 4 ft lengths However specific lengths can be special ordered up to 20 ft Operation When properly installed the Max Flex Handle Operator is used to perform remote switching operations from outside of the enclosure Switching is accomplished by pushing the Max Flex Handle Operator up for ON and down for OFF The mechani cal advantage gained with this device simplifies switching oper ations when compared with local switching at the breaker This unique design offers breaker trip indication as a standard feature Interlocking provisions are included and described below All switching functions are standard to accepted practices G Accessory can be used on 3 pole circuit breakers only m L Unassembled Max Flex Flan
175. nominal up to 720V max 2 nominal 1s application repeated 10 times at 10s intervals 0 2VA approx per phase 1 or 5A a c rms Std values up to 4kA 1 or 5 Amp secondaries 12096 of nominal 20 nominal 1s application repeated 5 times at 5 min intervals 0 6VA approx per phase The unit can be powered from an auxiliary a c or d c supply that is separate from the metered supply Versions of the unit are available to suit 100 200V 45 65 Hz a c d c and 12 48V d c supplies Standard supply voltage a c supply frequency range a c supply burden d c supply d c supply burden 4 3 3 Accuracy Voltage Current Neutral current Frequency Power factor Active power W Reactive power VAr Apparent power VA Active energy W h Reactive energy VAr h Temperature coefficient Response time to step input Error change due to variation of an influence quantity in the manner described in section 6 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 49 100 to 250V a c nominal 1596 85V a c absolute minimum to 287V a c absolute maximum or 100V to 250V d c nominal 25 15 85V d c absolute minimum to 312V d c absolute maximum 45 to 66 Hz or 360 to 440 Hz Model 0440 3W 12 to 48V d c nominal 25 15 10 2V d c absolute minimum to 60V d c absolute maximum 3W 0 4 of reading 0 1 of range 0 4 of reading 0 1 of range 4 of range 0 15 of mid frequency 1 of Unity 0 9 of r
176. not circuit breaker footprint 33 I T E Max Flex Flange Mount Handle Operator Types 1 3 3R 4 4X 12 Tighten Detent Screws Securing Operating Cable to Circuit Breaker WARNING Before attaching the cable to the circuit breaker installers must confirm that the power from the supply source has been de energized A Move the circuit breaker handle to the ON position B Remove the soft plastic cap from the end of the threaded cable rod 24 and slide the rod through the hole in the slid ing plate tab 25 of the circuit breaker operating mechan ism 17 Figure 8 C Move the flange mount operating handle 2 to its maximum ON position and hold it in place D Place the cable mounting threads 24 into the slot on the fixed plate tab 26 so that the two mounting nuts 27 are on both sides of the tab Adjust the two mounting nuts so Making Cable Adjustments that the 10 32 nut on the cable rod just touches the slid A Check that circuit breaker turns OFF and ON by moving the Max Flex Handle Operator Assembled to Breaker Figure 8 34 ing plate tab 25 Tighten the mounting nuts 27 to secure the cable Figure 8 E Continue holding the operating handle in the ON position and place the spring 28 over the end of the rod Screw on the spring adjuster 29 and tighten until it begins to com press the spring Do not overtighten D Side View of Max Flex Handle Operator Fixe
177. nsulating material The circuit breakers offered by Georator are provided for the output generator and are wired to the generator terminals and mounted on the generator connection box They are supplied complete with line and load terminals and in the case of FD Frames 250 Amp frames and above the Breaker is UL listed for reverse feed applications For FD Frames and up an adjustable magnetic trip unit is provided In addition to providing short circuit protection through the magnetic trip unit and an overload protection through the thermal trip unit the circuit breakers are often used as convenient switches to apply the Load to the Generator terminals Several accessories and modifications may optionally be provided with the circuit breakers such as Shunt trip devices under voltage release and auxiliary switches For Safety and Installation Instructions the user should consult the appropriate section of the service manual For general information on application and performance refer to NEMA Standards Publications AB 1 and AB 3 For Guidelines for Inspection and preventive maintenance consult NEMA AB 4 Power Monitor The power monitor is a solid state digital triple display multi function power monitoring system The power monitor simultaneously displays every metered electrical power function including 11 3 1 Volts 11 3 2 Amps 11 3 3 Frequency 11 3 4 KW or KVA 12 0 The Meter is featured with a large bright digi
178. nt of pickup 20 second maxumum With the control source energized push test button on face of relay module The breaker should trip immediately Reset by moving breaker handle to the fully OFF position then to the ON position Repeat the trip and reset procedure The assem bly is now fully operational Periodic retesting is recommended to verify continued protection Testing Circuit Momentary PUSH TO TRIP switch on face of relay initiates a simulated fault current through blue sensor leads when ener gized at 120V ac NOTE Circuit leakage from the load may add to or subtract from the test current depending on circuit phase rela tionships In the event of test difficulty check control voltage and load circuit leakage Some installation may require reversing the blue sensor lead connections for proper test circuit operation NOTE Accessory module is used on all ED Frame circuit breakers Accessory can not be used with obsolete breaker types E2 E4 E6 HE4 HE6 CLE Installation Diagrams Customer Supplied Circuit For Shunt Trip Function Red Black Pair Momentary Ohmite No F20J1KO or Equivalent E Contact Device 1 562 4 min cs RU 2 Power Resistor 10000 20W 1 3 1 max Sensor No 64232 Customer Supplied Relay Catalog Numbers Sensitivity GFO1E60 No Bell Alarm GFO1E60BO Normally Open Bell Alarm Contact
179. ntegra 1540 only 00 oc X A 30015 8 Watts Phase 2 Integra 1540 only 00 A X A X 30017 9 Watts Phase 3 Integra 1540 only 00 10 x x X 30019 10 VA Phase 1 Integra 1540 only 00 12 A X v 30021 11 VA Phase 2 Integra 1540 only 00 14 X X 30023 12 VA Phase 3 Integra 1540 only 00 16 A X X X 30025 13 var Phase 1 Integra 1540 only 00 18 s X v 30027 14 var Phase 2 Integra 1540 only 00 1A v X A X 30029 15 var Phase 3 Integra 1540 only 00 1C A X X X 30031 16 Power Factor Phase 1 Integra 1540 only 00 1E A X A A 30033 17 Power Factor Phase 2 Integra 1540 only 00 20 v X A X 30035 18 Power Factor Phase 3 Integra 1540 only 00 22 A X X X 30037 19 Phase Angle Phase 1 Integra 1540 only 00 24 A X 30039 20 Phase Angle Phase 2 Integra 1540 only 00 26 v X v X 30041 21 Phase Angle Phase 3 Integra 1540 only 00 28 X X X 30043 22 Volts Ave 00 2A v A A 30047 24 Current Ave 00 2E v A A A 30049 25 Current Sum Integra 1540 only 00 30 4 v 30053 27 Watts Sum 00 34 M v 30057 29 VA Sum 00 38 30061 31 5 00 3C v A v 30063 32 Power Factor Ave 00 3E A A v A 30067 34 Average Phase Angle Integra 1540 only 00 42 A A v A 30071 36 Frequency 00 46 i v v 30073 37 Wh Import 00 48 v v v v 30077 39 varh Import 00 4C oS v v 30085 43 W Demand Import 00 54 A 30087 44 W Max Demand Import 00 56 v A v 30105 53 00 68 30107 54 Max Demand 00 6A v
180. nto service See the maintenance section of this manual for further information If the unit has been stored an area where it has been subject to vibration it is recommended that the bearing s be inspected and replaced as necessary PRINCIPLES OF OPERATION PMG optional Rotating Assembly PMG Field Exciter Field Exciter Armature Main Field Main Armature rotor stator rotor rotor stator L iN i 3 Phase AC out 3 Phase AC out i PMG i Armature i i stator Rotating Rectifier Assembly p A i 3 Phase Full Bridge Input Power Single Phase shunt powered regulator Automatic WILLE Voltage Regulator Exciter Field Power DC PMG Input Power optional 1 phase 300 250 hertz Sensing Input Single Phase 3 phase optional FIGURE 1 MagnaPLUS Circuit Diagram Main Stator Main Stator Main Rotor AC Output i Cooling Fan Rectifier we Assembly md AL BUE ye Disc Optional PMG CH g 1 cm At PMG Rotor field 5 5 ens Tel b a PMG Stator armatu
181. nual to adjust the stability Again check all line to line and line to neutral voltages for balance It is recommended practice to record the no load excitation DC voltage to the exciter stator generator terminal voltage and driver speed as a benchmark for future troubleshooting 8 Close the main circuit breaker to the load 9 Monitor the generator output current to verify that it is at or below nameplate value WARNING THE FOLLOWING TEST MUST BE CONDUCTED BY QUALIFIED ELECTRICAL PERSONNEL LETHAL VOLTAGE MAY BE PRESENT AT BOTH THE GENERATOR VOLTAGE REGULATOR 10 Check generator speed frequency under load Adjust as necessary Refer to prime mover or governor manuals TERMINALS DURING THIS PROCEDURE CAUTION MUST BE EXERCISED NOT TO COME INTO PERSONAL CONTACT WITH LIVE TERMINALS LINKS OR STUDS SERIOUS INJURY OR DEATH COULD RESULT SHUTDOWN PROCEDURE There are no specific instructions for shutting down the generator however several good practices should be observed to prolong equipment life 4 Every 2 000 operating hours or in conjunction with scheduled engine maintenance check the DC no load excitation voltage per item 7 in the startup procedure Compare this voltage with the value recorded during initial startup If this value of no load excitation voltage is markedly higher than the bench mark reading it is an indication of problems in either the exciter main field 1 It is advisable to dis
182. oint Position Value Entry rompton INSTRUMENTS This screen allows a negative value to be specified as the top reading It will only be available if the parameter selected on the previous screen can be negative For these parameters the column of Table 2 has a tick v To accept the current value for negative no symbol for positive press gt gt to advance to the Alrb screen Use 7 to select the sign for a negative Reading or no symbol for a positive Reading Press gt gt to accept the current sign and advance to the next screen Use this screen to set the position of the decimal point This screen will not appear when the selected parameter is frequency as there is no choice of decimal point position Pressing the 11 key will advance the decimal point position to the right illuminating the x1000 indicator as necessary and wrapping the decimal point position when the highest available position for the currently selected reading has been exceeded Maximum resolution is 3 digits of the metered value Select the required decimal point position and press gt gt to confirm your selection The next screen will appear Use this screen to set the value of the Reading Top Set the three digit Reading Top value using the method described in Section 3 2 Number Entry Procedure Press gt gt to confirm your selection The Confirmation screen will appear 42 Integra 1540 1000 0640 0440 0340
183. olded Case Molded Case Switch Switch 100 CED62S100A 200 200 100 100 CED63S100A 200 200 100 N A N A 125 CED628125A 200 200 100 125 CED638125A 200 200 100 NA N A SHIPPING 5 per carton Wt 20 Ib SHIPPING 5 per carton Wt 30 Ib Instantaneous Trip Motor Circuit Protectors Rating Complete Breaker Ampere Unenclosed Catalog Number tees eT 30 1 ED63A001 2 ED63A002 3 ED63A003 5 ED63A005 10 ED63A010 25 ED63A025 30 ED63A030 40 ED63A040 50 ED63A050 100 ED63A100 125 ED63A125 SHIPPING 1 per carton Wt 3 8 Ib CED63A001 CED63A002 CED63A003 CED63A005 CED63A010 CED63A025 CED63A030 CED63A040 CED63A050 CED63A100 CED63A125 1 per carton Wt 6 Ib interrupting ratings are listed on page 49 Includes self protecting instantaneous element May be used on a circuit capable of delivering not more than the indicated fault current when protected by a fuse or circuit breaker at 100 or 125 amperes Note All tolerance ranges are within UL 489 standards instantaneous Trip Setting Amperes All Values are Nominal 180 270 375 600 1000 1250 53 54 Ordering Information Accessory Combinations Auxiliary Switch Control Voltage 120 208 240 277 480 600 Shunt Trip Control Voltage 24 125 250 Catalog Number 1 Auxiliary Switch Cata
184. omatic thermal protectors will automatically restart when the protector temperature drops sufficiently Do not use motors with automatic thermal protectors in applications where automatic restart will be hazardous to personnel or equipment 3 Motors with manual thermal protectors may start unexpectedly after protectortrips If manual protector trips disconnect motor from power line After protector cools five minutes or more it can be reset and power may be applied to motor 4 Discharge all capacitors before servicing motor 5 Always keep hands and clothing away from moving parts 6 Neverattempt to measure the temperature rise of amotor by touch Temperature rise must be measured by thermometer resistance imbedded detector or thermocouple 7 Electrical repairs should be performed by trained and qualified personnel only 8 Failure to follow instructions and safe electrical procedures could result in serious injury or death 9 If safety guards are required be sure the guards are in use 1 All wiring fusing and grounding must comply with National Electrical Codes and local codes 2 To determine proper wiring rotation and voltage connections refer to the information and diagram on the nameplate separate connection plate or decal If the plate or decal has been removed contact Marathon Electric for assistance 3 Use the proper size of line current protection and motor controls as required by the National
185. ooked or cause further damage ACCEPTANCE Check carefully for any damage that may have occurred in transit If any damage or shortage is discovered do not accept until an appropriate notation on the freight bill is made Any damage discovered after receipt of equipment should be immediately reported to the carrier STORAGE A Keep motors clean 1 Storeindoors 2 Keep covered to eliminate airborne dust and dirt Cover openings for ventilation conduit connections etc to prevent entry of rodents snakes birds and insects etc B Keep motors dry 1 Store in a dry area indoors 2 Temperature swings should be minimal to prevent condensation 3 Space heaters are recommended to prevent condensa tion 4 Treat unpainted flanges shafts and fittings with a rust inhibitor 5 Check insulation resistance before putting motor into service Consult manufacturer for guidelines C Keep Bearings Lubricated 1 Once per month rotate shaft several turns to distribute grease in bearings 2 Ifunit has been stored more than one year add grease before start up Refer to lubrication procedure INSTALLATION UNCRATING AND INSPECTION After uncrating check for any damage which may have been incurred in handling The motor shaft should turn freely by hand Repair or replace any loose or broken parts before attempting to use the motor Check to be sure that motor has not been exposed to dirt grit or excessive moisture in
186. p and Under voltage Trip catalog numbers having an suffix and Auxiliary Switch catalog numbers 02 062 and 02 0628 7 8 Common 5 e e 6 Normally open when circuit breaker is tripped 3 4 Normally closed when circuit breaker is tripped End View of Bell Alarm Switch Figure 1 19 20 I T E Ground Fault Sensor A DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS General Information The ground fault circuit sensor relay module kit functions to de energize a circuit or portion of a circuit within an established period of time when the current to ground exceeds a predeter mined value less than that required to operate the circuit breaker It performs this operation by detecting 5mA 1 or 30mA 6 current difference between two or more load con ductors passing through the sensor and actuating the relay to trip the circuit breaker This current difference normally occurs from a low level ground fault in the load circuit when load is supplied from a grounded power system The relay electronics operates from a 120V ac 66 132v abso lute limits 60 Hz control power source not necessarily related to the load circuit monitored by the sensor The relay module trip mechanism includes an auxiliary switch contact to de energi
187. parts The insulation for such auxiliary circuits must be rated for the highest voltage connected to the instrument and suitable for single fault condition The connection at the remote end of such auxiliary circuits should not be accessible in normal use Depending on application equipment connected to auxiliary circuits may vary widely The choice of connected equipment or combination of equipment should not diminish the level of user protection specified 4 3 11 Insulation Dielectric voltage withstand test 3 25kV RMS 50Hz for 1 minute between all isolated electrical circuits 4 3 12 Environmental Operating temperature 20 C to 70 C Storage temperature 20 C to 80 C Relative humidity 0 95 non condensing Warm up time 1 minute Shock 30g in 3 planes Vibration 10 to 15 Hz 1 5 mm peak peak 15 to 150 Hz 1 0g Enclosure code front IP54 Harmonic distortion max 50 THD up to 15th harmonic 4 3 13 Enclosure Style ANSI C39 1 or JIS C 1102 Material Polycarbonate Front Steel case Terminals 6 32 UNC slotted barrier style Weight 1 3kg 4 3 14 Serial Communications Option Protocol MODBUS RS485 Baud rate 19200 9600 4800 or 2400 programmable Parity Odd or Even with 1 stop bit or None with 1 or 2 stop bits rompton INSTRUMENTS 52 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 4 3 15 Active Energy Pulsed Output Option Rated Default pulse rate Pulse
188. r Guide to RS485 Communications and the Modbus Protocol available on our CD catalogue or from any recognised supplier The Modbus protocol establishes the format for the master s query by placing into it the device address a function code defining the requested action any data to be sent and an error checking field The slave s response message is also constructed using Modbus protocol It contains fields confirming the action taken any data to be returned and an error checking field If an error occurs in receipt of the message or if the slave is unable to perform the requested action the slave will construct an error message and send it as it s response Framing errors receive no response from the Integra The electrical interface is 2 wire RS485 via 3 screw terminals Connection should be made using twisted pair screened cable Typically 22 gauge Belden 8761 or equivalent All A and B connections are daisy chained together The screens should also be connected to the Gnd terminal To avoid the possibility of loop currents an Earth connection should be made at only one point on the network Line topology may or may not require terminating loads depending on the type and length of cable used Loop ring topology does not require any termination load The impedance of the termination load should match the impedance of the cable and be at both ends of the line The cable should be terminated at each end with a 120 ohm 0 25 Wat
189. r are sent most significant bytes first In reversed register mode the two registers that make up a floating point number are sent least significant bytes first To set the mode write the value 2141 0 into this register the instrument will detect the order used to send this value and set that order for all Modbus transactions involving floating point numbers Secondary Volts indicates the voltage on the VT secondary when the voltage on the Primary is equal to the value of System Volts The value of this register can be set to between the minimum and maximum instrument input voltage 6 3 RS485 Implementation of Johnson Controls Metasys These notes explain Metasys and Crompton Instruments Integra 1000 1540 integration Use these notes with the Metasys Technical Manual which provides information on installing and commissioning Metasys N2 Vendor devices Application details The Integra 1000 1540 is a N2 Vendor device that connects directly with the Metasys N2 Bus This implementation assigns 33 key electrical parameters to ADF points each with override capability Components requirements Integra 1000 1540 with RS485 option N2 Bus cable Metasys release requirements Metasys OWS software release 7 0 or higher Metasys NCM311 NCM360 rompton INSTRUMENTS 60 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Support for Metasys Integration Johnson Control Systems
190. r auxiliary contacts only Reset the breaker then turn it to the ON position While observing the blade turn the breaker OFF and ON several times The slot in the blade actuator should nearly align with its locating tab when the breaker is in the OFF position When the breaker is in the ON position the slot should travel clockwise approximately 40 Figure 3 Recommended Combinations Maximum Installable Accessory Combinations Shunt Undervoltage Trip Trip Bellalarm Switch Auxiliary Switch Accessory combinations available only when ordered together Additional accessories cannot be added to the combination at a later time Always attach to left pole Circuit Breaker with Shunt Trip Attached 10 Trip Button 9 Trip Latch Actuator 11 Cradle Actuator 8 Blade Actuator Mechanical Testing Figure 3 17 18 I T E Shunt Trip and Undervoltage Trip Electrical Check Shunt Trip A Reset and turn the circuit breaker handle to ON position B Connect test circuit to accessory terminals 1 and 2 Figure 1 C Preset test circuit voltage to 55 percent of the shunt trip vol tage rating D Apply the 55 percent voltage rating value to the shunt trip device t must trip E Remove test leads from terminals 1 and 2 Apply a continuity tester or ohm meter to the 1 and 2 terminals Assure that coil limit contacts are
191. rate divisors Pulse duration 4 3 16 Integra 1540 Only Measuring Range Total Harmonic Distortion Accuracy Reference conditions of measurands Reference conditions of measurands Reference conditions of measurands Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 53 SPNO 100V dc 0 5A Max 1 per kWhr 1 10 yielding 1 pulse per 10 kWhr 100 yielding 1 pulse per 100 kWhr 60ms 100ms or 200ms 3600 Pulses per hour max Up to 15th Harmonic 096 5096 Total Harmonic Distortion 196 Voltage 6096 to 10096 of nominal for THD Total Harmonic Distortion 20 to 100 of nominal for THD Total Harmonic Distortion 0 3096 rompton INSTRUMENTS tyco Electronics Energy Division 5 Basis of measurement and calculations Reactive and Apparent Power Active powers are calculated directly by multiplication of voltage and current Reactive powers are calculated using frequency corrected quarter phase time delay method Apparent power is calculated as the square root of sum of squares of active and reactive powers For 4 wire products overall powers are the sum of the per phase powers For 3 phase 3 wire products the two wattmeter method is used for overall powers Energy resolution Cumulative energy counts are reported using the standard IEEE floating point format Reported energy values in excess of 16MWh may show a small non cumulative error due to the limitations of the number format Internally the coun
192. re L Exciter Stator T field Exciter Rotor armature FIGURE 2 Typical MagnaPLUS Layout Diagram DIMARATION 3 A Subsidiary of Regal Beloit Corporation PRINCIPLE OF OPERATION MagnaPLUS generators are a brushless self excited externally voltage regulated synchronous AC generator The generator is made up of six major components main stator armature main rotor field exciter stator field exciter rotor armature rectifier assembly and voltage regulator In understanding the above terminology note the following stators are stationary rotors rotate a field is an electrical input and an armature is an electrical output These system components are electrically interconnected as shown in figure 1 and physically located as shown in figure 2 The generator s exciter consists of a stationary field and a rotating armature The stationary field exciter stator is designed to be the primary source of the generator s residual magnetism This residual magnetism allows the exciter rotor armature to produce AC voltage even when the exciter stator field is not powered This AC voltage is rectified to DC by the rotating rectifier assembly and fed directly to the main rotor field As the generator shaft continues to rotate the main rotor field induces a voltage into the generator s main stator armature At rated speed the main stators voltage produced by the residual magnetism of the excit
193. reaker The circuit breaker will TRIP and the operating handle will move to an intermediate TRIP position Move the operating handle from TRIP position to OFF and back to ON The circuit breaker should RESET then turn ON If the breaker does not RESET loosen the breaker operator mounting screws 21 or 24 and adjust the breaker opera tor downward 1 16 inch and retighten the screws per step 5 Repeat if required Padlocking Figure 5 Move the handle to OFF position and attach padlock s at the indicated padlocking hole 37 38 I T E Door Latch Mechanism DKR2 DKR3 DKL2 DKL3 DANGER Hazardous Voltage Will cause death or severe injury Turn power off supplying switch board or panel before installing SAFETY INSTRUCTIONS GENERAL INFORMATION Description These door latch mechanisms are for use in standard or custom built enclosures The door latch post assemblies and the door catch are supplied with the kits Users must supply their own 14 in x in steel latch bar Enclosures with an overall height less than 40 in require the two point door latch mechanism When the overall height is greater than 40 in the three point latch mechanism is used The door latch mechanism can be used with or without the type FHOH Flange Mount Handle Operator These instructions apply when the door latch mechanism is mounted adjacent to and interlocks with the FHOH Handle Operator The door handle
194. reens are not applicable for setting up a port connected to a display unit as the characteristics of such a port are preset On a two port unit communications settings made from an Integra display affect the other communications port unless the second port is also connected to a display in which case the changes have no effect 1 6 Pulse Output Option 0240 0340 0440 0640 1000 1540 Option This option provides a relay pulse output indication of measured active energy kWh The unit can produce one pulse for every 1 10 or 100kW of energy consumed Two part 1540 display units operating with 1560 or 1580 transducers can also produce a pulse for every 1000 kW of energy consumed The pulse divisor can be set from the Set up screen as detailed in Section 3 11 Pulse Rate The pulse width duration can be set as detailed in Section 3 10 Pulsed Output Pulse Duration On two part units two pulsed outputs are available with common pulse rate divisions and pulse widths 1 7 Analogue Output Option 0240 0340 0640 1000 1540 Option This option is available on two part separate transducer and display units and provides an analogue current output that indicates the value of a chosen parameter The parameter can be chosen and set up via the set up screen as described in Section 3 15 Analogue Output Set Up rompton INSTRUMENTS 10 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03
195. roper grounding earthing of the generator frame and distribution system in compliance with local and national electrical codes and specific site requirements must be provided These safety precautions are necessary to prevent potential serious personal injury or even death The hazards associated with lifting or moving your MagnaPLUS generator are pointed out in the installation and maintenance sections Incorrect lifting or moving can result in personal injury or damage to the unit Prior to start up of the unit ensure that all generator leads are properly connected to the generator link board located inside the connection box Always assume that there will be voltage present at the generator terminals whenever the generator s shaft is rotating and proceed accordingly Residual voltage is present at the generator terminals and at the automatic voltage regulator panel connections even with the regulator fuse removed Caution must be exercised or serious injury or death can result This manual is not intended to be a substitute for properly trained personnel Installation and repairs should only be attempted by qualified trained people The cautions and warnings point out known conditions and situations that are potentially hazardous Each installation may well create its own set of hazards MARATHON A Subsidiary of Regal Beloit Corporation When in doubt ask Questions are much easier to handle than mistakes caused by a mi
196. rotectors will automatically restart when the protector temperature drops sufficiently Do not use motors with automatic thermal protectors in applications where automatic restart wil be hazardous to personnel or equipment 3 Motors with manual thermal protectors may start unexpectedly after protector trips If manual protector trips disconnect motor from power line After protector cools five minutes or more it can be reset and power may be applied to motor 4 Discharge all capacitors before servicing motor 5 Always keep hands and clothing away from moving parts 6 Never attemptto measure the temperature rise of amotor by touch Temperature rise must be measured by thermometer resistance imbedded detector or thermocouple 7 Electrical repairs should be performed by trained and qualified personnel only 8 Failure to follow instructions and safe electrical procedures could result in serious injury or death 9 If safety guards are required be sure the guards are in use Iftroubleis experienced in the operation of the motor make sure that A D gt e The bearings are in good condition and operating properly There is no mechanical obstruction to prevent rotation in the motor or in the driven load The air gap is uniform Consult manufacturer for specifications All bolts and nuts are tightened securely Proper connection to drive machine or load has been made In checking for e
197. s Used f _ i Drilling Plan hea o 1 Dimensions inches A 1 4 0 B 525 1 5 D 564 Latch is Part of Supplied Plate E d 50 amp F d 2 56 d G 5 M Robe B H Tapped for d IL 8 32 threads Breaker Mtg it Lt K 4 125 kbs Surface 14 1 M 69 xol Front View Load End View Figure 1 Spacer CED6 Pod Breaker Mounting Mounting Handle 5 Deteater Surface Enclosure Cover to Breaker Screw Figure 2 Figure 3 Figure 4 3 Latch 4 Ring Tab i n 3 Screws 2 Interior Ring Breaker Mtg Screws CED6 Pod Enclosure Interior Enclosure Exterior Figure 5 Figure 6 27 28 I T E Rotary Handle Enclosure Mechanism Types 1 12 A DANGER Hazardous Voltage Will cause death or severe injury Turn power off a supplying switch board or panel before Installing SAFETY INSTRUCTIONS Variable Depth E2RHV 3 5 7 or 9 INSTALLATION INSTRUCTIONS Drilling of Enclosure A B Drill breaker mounting holes H 1 in the enclosure per drilling plan on outline drawing Figure 1 Place template on breaker mounting surface so that the four centers in the templ
198. s situation will be indicated by displaying four bars in the appropriate line The value on the middle line is over range Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 17 tyco Electronics Energy Division 2 18 kWh and kVArh Display Range 0240 0340 0440 0640 1000 1540 The kWh and kVArh display range is limited to 9999999 If the unit is allowed to increment beyond this value the count will either wrap back to zero if the 1560 1580 transducer is set to 7 digit mode or continue to be updated in the 1560 1580 transducer but the display will change to seven bars The value will continue to be available via the Modbus output Sys Volts Volts 13 1 Amps L3 2 19 Error Messages The display repeatedly requests new values from the measurement processor If there is a problem obtaining these values the display will continue to retry but will alert the user by displaying the message Err1 This message may be seen briefly during conditions of extreme electromagnetic interference with the normal display returning once the interference has ceased If the Err1 message persists try interrupting for ten seconds the auxiliary supply or supplies to the Integra display and transducer This may restore normal operation Also check that auxiliary power is reaching the transducer and is within specification Check that there are no problems with the communications cable
199. screens Clean air passages High room temperature or altitude Improve ventilation or reduce load Insufficient circulation of cooling air Generator location and enclosure design must provide adequate air flow and minimize recirculation of hot air Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed rated current on any one leg GENERATOR PRODUCES MECHANICAL NOISE CAUSE CHECK AND REMEDY Defective bearing Replace bearing Loose or misaligned coupling Tighten realign or replace coupling Belt slap or loose guards Check belt tensioning Check belt guard fasteners EQUIPMENT RUNS NORMALLY ON UTILITY POWER BUT WILL NOT RUN ON GENERATOR SET CAUSE CHECK AND REMEDY Distorted voltage waveform Analyze load Excessive SCR thyristor loading will cause distortion Some equipment may be sensitive to distorted waveforms Refer to Marathon Electric Improper generator voltage or Check name plates of devices comprising the load Compare required voltage and frequency frequency with that of the generator Adjust driver speed and or generator voltage as necessary to match generator output to load requirements CAUTION Compare required voltage frequency and KVA with generator nameplate to ensure adequate generator capacity If in doubt consult Marathon Electric for information regarding generator capacity MARATHON A Subsidiary of Regal Beloit Corporation SPECIFICATIONS MODEL
200. set to 0 5 this will be a power factor of 0 5 for power exported to an inductive load bottom left hand quadrant Conversely the Reading Bottom value must be in one of the two right hand quadrants If the Reading Bottom value is set to 0 5 this will be a power factor of 0 5 for power exported to a capacitive load bottom right hand quadrant Thus a power factor of 1 for true power imported to a resistive load is always included in the analogue output range In specifying the Output Top and Output Bottom values there are two conventions one for European areas of influence and one for North American areas The two conventions are Europe Output Top greater or more positive than Output Bottom USA Output Top less or more negative than Output Bottom The examples below show cases where power is only imported and the load may be either capacitive or inductive The Reading Top and Reading Bottom values of zero ensure that the whole range of possible import power factor readings is covered The unit in the left hand example has an analogue output range of 1 to 1 mA and since the Output Top value 1 mA is more positive than the Output Bottom value 1 mA this arrangement complies with the European convention The right hand example shows the North American convention Import Import PF Reading PF Reading 1 1 Capacitive Inductive Inductive ij 0 5 Q5 mA 0 5 mA Reading Reading Reading Bottom 0 PF Top 0 PF
201. sive particles generated by the flow of cooling air through the generator Consult the factory for appropriate filters and generator deratings required WIRING CONNECTIONS Wiring of the generator and accessories should be done in accordance with good electrical practices Follow government industry and association standards The generator conduit box construction allows cable entry from multiple sides A hole saw or other appropriate tool may be used to provide for conduit entrance Protect the interior of the generator from shavings when drilling or sawing An approved connector must be used in conjunction with the conduit To minimize the transmission of vibration it is essential that flexible conduit be used for all electrical entrance to the generator conduit box All MagnaPLUS generators are equipped with link boards terminal strips for both internal and external connections All connections made to the studs of the link board should be made with high quality ring terminals Ring terminal sizes are 6 mm 280 Series Frames and 10 mm 360 and 430 Series Frames Torque link board connections to the following specifications 280 frame 5 4 NM 4 Ft Lb 360 amp 430 frame 27 NM 20 Ft Lb Refer to the connection diagram supplied with the generator and or the proper diagrams shown in this manual Install all inter component and external wiring in accordance with national and local electrical codes The neutral in the fol
202. stance values require precision equipment to make accurate measurements however a standard ohm meter will provide a good indication of winding continuity e MARATHON A Subsidiary of Regal Beloit Corporation Insulation Test Insulation resistance is a measure of the integrity of the insulating materials that separate the electrical windings from the generators steel core This resistance can degrade over time or be degraded by contaminants dust dirt oil grease and especially moisture Most winding failures are due to a breakdown in the insulation system In many cases low insulation resistance is caused by moisture collected when the generator is shutdown Insulation resistance is measured with a megger mega ohm meter A megger measures insulation resistance by placing 500 volts between the winding and the frame of the generator Caution must be taken to remove all electronic devices regulators diodes surge protectors capacitors protective relays etc from the winding circuit before checking the insulation Winding insulation can be checked on the main stator main rotor exciter stator and exciter rotor Minimum resistance is 2 mega ohms If the winding resistance is low it must be dried see maintenance section or repaired DIODE TESTING If the generator is close coupled to an engine it may be necessary to bar over the engine in order to gain access to a given area of the rectifier assembly NEVER use the
203. stem Active Power Demand kWD The 1540 has Set up screens for e Full scale current value Potential transformer primary and secondary voltages Dis 1540 and Integra 15xx Potential transformer primary voltages self contained Demand integration time and energy demand resets Pulse output duration and rate divisor option e RS485 serial Modbus parameters option Analogue current output option with separate transducer only A pulsed relay output indicating kWhr and Kvarh on the two part Dis 1540 and Integra 15xx combination and an RS485 Modbus output are available as optional extras The Modbus output option allows remote monitoring from another display not self contained or a Modbus master The Analogue current output option provides a current output that indicates the value of a chosen parameter 8 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 1 2 Maximum Power Products covered in this manual are limited to a maximum power of 360 MW During set up primary voltage and current setting are checked and the unit will not accept entries that breach the 360 MW limit This is covered in more detail in the sections that show primary voltage and current set up The Maximum Power restriction of 360 MW refer to 120 of nominal current and 120 of nominal voltage i e 250 MW nominal system power 1 3 Secondary Voltage 0240 0340 0440 0640
204. sue 1 04 03 11 tyco Electronics Energy Division The second screen indicates the firmware installed in the display unit This example states that the version is 0 008 The version on a particular unit will differ in line with ongoing development and improvements After a short delay the default Display screen will appear Use the gt gt Next key to move from one screen to the next in the sequence The sequence depends on the supply configuration single phase 2 or 3 wire 3 phase 3 or 4 wire 2 3 System Screen 0240 0340 0440 0640 1000 1540 The following sections show 3 and 4 wire systems Single phase 2 and 3 wire systems have similar display screens The system screen is the default display It appears when the unit is energised after the start up screens Section 1 1 shows the default system screens for the various models System Average Voltage Volts System Average Line Current Amps System Total Active Power kW Pressing key gt gt moves to the next screen Line to Line for 3 wire systems Line to Neutral for 4 wire and single phase 3 wire systems rompton INSTRUMENTS 12 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division 2 4 System THD Screen 0240 0340 0440 0640 1000 1540 Average Total Harmonic Distortion for System Voltages Average Total Harmonic Dis
205. sunderstanding of the information presented in this manual RECEIVING AND STORAGE RECEIVING AND STORAGE Upon receipt of the generator it is recommended that it be carefully examined for possible shipping damage The generator was given to the freight carrier in good condition thus the carrier is responsible for the product from the factory dock to the destination Any damage should be noted on the freight bill before accepting the shipment Any claims for damage must be promptly filed with the delivering carrier UNPACKING AND HANDLING Carefully read all instruction tags shipped with the unit When lifting attach an overhead crane to the lifting lug s on the generator frame Apply lifting forces in a vertical direction When transporting single bearing generators the generator s rotor must be adequately supported to prevent damage WARNING THE LIFTING LUG S ON THE GENERATOR ARE DESIGNED TO SUPPORT THE GENERATOR ONLY DO NOT LIFT A COMPLETE GENERATOR AND DRIVER ASSEMBLY BY MEANS OF LIFTING LUG S ON THE GENERATOR PERSONAL INJURY OR EQUIPMENT DAMAGE MAY RESULT STORAGE In the event that the generator is not immediately installed on its prime mover it is recommended that the unit be stored indoors in a clean dry area which is not subject to rapid changes in temperature and humidity If the generator is stored for a long period of time the generator should be tested cleaned and dried as required before being put i
206. t Yellow Close Motor Operator Shown in the Open Position Motor Operator Mounting Base Plate 4 8 32 Round Head Screws 4 Spacers Line Side Mounting Panel Y HE it E Flat Washer Lock Washer and Nut Use When Mounting Panel Cannot Be Tapped Breaker and Motor Operator Motor Operated Mechanism Red Open White Common 2 1 2 Amp Slow Blow For Trip Indication Use Circuit Breaker with Internal Bell Alarm Switch Indicating Lights This Line Automatic Reset Only Pushbutton Control Station Note When using Automatic Reset the On Pushbutton Must Be Spot Type and Wired as Shown Maintain Contact for 1 2 Second Minimum For Automatic Reset and On Off lights Use Circuit Breaker with Internal Auxiliary Switch Wiring Diagram Motor Operated Mechanism All Switch Contacts Shown with Circuit Breaker in the ON Position Figure 3 4 42 FT E Panelboard Connector Straps 281 Dia 1 000 3 500 i 500 500 1 000 gt Eee x 375 Outside Connector Strap Catalog Number CS3600R CS3602R 10 32 Tap 2 Insulating Tubing Te t nus ax L 937 Inside Connector Strap Catalog y gt Number CS3601R 2 234 1 5 CS3603R 3 796 3 0 These straps are not us
207. t is maintained with greater precision The reporting error is less than 1 part per million and will be automatically corrected when the count increases Power Factor The magnitude of Per Phase Power Factor is derived from the per phase active power and per phase apparent power The power factor value sign is set to negative for an inductive load and positive for a capacitive load The magnitude of the System Power Factor is derived from the sum of the per phase active power and per phase apparent power The system power factor value sign is set to negative for an inductive load and positive for a capacitive load The load type capacitive or inductive is determined from the signs of the sums of the relevant active powers and reactive powers If both signs are the same then the load is inductive if the signs are different then the load is capacitive The magnitude of the phase angle is the ArcCos of the power factor It s sign is taken as the opposite of the var s sign Maximum Demand The maximum power consumption of an installation is an important measurement as power utilities often levy related charges Many utilities use a thermal maximum demand indicator MDI to measure this peak power consumption An MDI averages the power consumed over a number of minutes such that short surges do not give an artificially high reading Integra uses a sliding window algorithm to simulate the characteristics of a thermal MDI instrument with the d
208. t min resistor A total maximum length of 3900 feet 1200 metres is allowed for the RS485 network A maximum of 32 electrical nodes can be connected including the controller The address of each Integra 1000 1540 can be set to any value between 1 and 247 Broadcast mode address 0 is not supported The maximum latency time of an Integra 1000 1540 is 150ms i e this is the amount of time that can pass before the first response character is output The supervisory programme must allow this period of time to elapse before assuming that the Integra is not going to respond rompton 56 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division The data format in RTU mode is Coding System 8 bit per byte Data Format 4 bytes 2 registers per parameter Floating point format to IEEE 754 Most significant register first Default The default may be changed if required See Holding Register Register Order parameter Error Check Field 2 byte Cyclical Redundancy Check CRC Framing 1 start bit 8 data bits least significant bit sent first 1 bit for even odd parity or no parity 1 stop bit if parity is used 1 or 2 bits if no parity Data Transmission speed is selectable between 2400 4800 9600 and 19200 baud Input Registers Input registers are used to indicate the present values of the measured and calculated electrical quantities Each parameter is held in two consecutive 16
209. t the option required and press gt gt to confirm your i selection The appropriate confirmation screen will appear The confirmation screen will not appear if None has been Reset All selected rompton INSTRUMENTS 28 Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 tyco Electronics Energy Division Press 11 to return to the Reset screen Press gt gt to reset the selected reading s The next screen will appear Sys Volts Confirmation 3 10 Pulsed Output Pulse Duration 0240 0340 0440 0640 1000 1540 Option This applies to the Relay Pulsed Output option only Units with this option provide pulses to indicate power consumption kWh See Section 1 6 pulse output option This screen allows the user to set the duration of the relay output pulse The value displayed represents the pulse duration in milliseconds ms On a two part DIS 1540 Integra 1560 this screen will set the pulse duration for the Kvarh pulse relay where fitted also To retain the current setting press gt gt The next Set up screen will appear Sys Volts To change the pulse duration press 11 Use the 11 key to scroll through the available values of 60 100 and 200 Select the value required and press to confirm your selection The confirmation screen will appear To change the value again press 7 The Edit screen will reappear Sys Volts To accept the disp
210. tal display and a smart keypad for programming and calibration The meter can also be supplied with digital communications interface port such as RS232 or RS485 that allows it to interface with other equipment and allow remote monitoring of the MG operation Full details on the power monitors features and functions calibration and service can be found in the service manual Optional Enclosures These notes pertain to weather as well as sound attenuating enclosures 12 1 12 2 12 3 The enclosure is constructed in aluminum is provided with 12 1 1 Access Door for belts or couplings service 12 1 2 Circulating fan 12 1 3 Thermostat switch 12 1 4 Access for circuit breaker voltage adjustment power monitoring and input and output wiring Access for input and output wiring is normally provided through input and output connection boxes to which electrical connections are made by the user Connections from the motor or motor starter to the input box and from the generator or output circuit breaker to the output box are made by Georator The enclosures are either mounted bolted on the MG steel base or are drop over type The latter will be supplied as a separate item and final electrical connection for the fan and thermostat switch is carried out by the user TENSIONING GUIDE FOR V BELT DRIVES Although belts are tensioned properly before shipment loosening may occur during the first weeks of operation
211. tes of demand data up to a maximum of the demand period setting For example with 15 minute demand period from reset the value will increment from zero every minute until it reaches 15 It will remain at this value until a subsequent reset occurs Demand Period The value written must be one of the following 8 15 20 or 30 minutes otherwise an error will be returned System Type The System type address will display 1 for single phase 2 wire 2 for 3 Phase 3 Wire 3 for 3 Phase 4 Wire or 4 for single phase 3 wire Crompton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 59 tyco Electronics Energy Division Relay Pulse Width is the width of the relay pulse in multiples of 20 ms However only values of 3 60 ms 5 100 ms or 10 200 ms are supported Writing any other value will cause an error to be returned Reset Energy is used to reset the Energy readings A value of zero must be written to this register to accomplish this Writing any other value will cause an error to be returned Pulse Rate Divisor supports only values of 1 10 100 or 1000 Writing any other value will cause an error to be returned System Power is the maximum system power based on the values of system type system volts and system current Register Order the instrument can receive or send floating point numbers in normal or reversed register order In normal mode the two registers that make up a floating point numbe
212. to the symptoms of the problem The steps have been arranged in an attempt to do the easy checks first and prevent further damage when troubleshooting a disabled machine 9 MARATHON A Subsidiary of Regal Beloit Corporation 280 360 FRAME A Exciter Rotor Lead B Main Rotor Lead C Red Suppressor Lead D Black Suppressor Lead FIGURE 4 ROTATING RECTIFIER ASSEMBLY The first step of troubleshooting is to gather as much information as is possible from operating personnel and individuals present during the failure Typical information includes how long the unit had been operating what loads were on line weather conditions protective equipment that did or did not function In addition information as to the operating condition of the generator s prime mover is vital Has the prime mover been maintaining constant speed If not have there been extended periods of under speed operation Has the prime mover experienced an over speed condition If yes what was the maximum speed and how long did the unit operate at that elevated speed The generator speed should be maintained at rated nameplate value during all operating tests The frequency of the generator depends upon rotational speed Most regulators used with MagnaPLUS generators have built in under frequency protection such that if the speed is reduced more than 5 the voltage will drop off rather rapidly with further reduct
213. tor and drive turn freely Check bearings and lubrication Short circuited stator Indicated by blown fuses Motor must be rewound Poor stator coil connection Remove end bells locate with test lamp Rotor defective Look for broken bars or end rings Motor may be overloaded Reduce load Motor stalls One phase may be open Check lines for open phase Wrong application Change type or size Consult manufacturer Motor runs and then Check for loose connections to line to fuses and to control dies down Motor does not come Not applied properly Consult supplier for proper type up to speed Voltage too low at motor terminals because Use higher voltage on transformer terminals or reduce load of line drop Check connections Check conductors for proper size Check load motor is supposed to carry at start Broken rotor bars or loose rotor Look for cracks near the rings A new rotor may be required as repairs are usually temporary Open primary circuit Locate fault with testing device and repair Excessive load Check for high resistance Adequate wire size Get power company to increase power tap Motor takes too long to accelerate and or draws high amp Motor overheats while running under load Frame or bracket vents may be clogged with Open vent holes and check for a continuous stream of air from the motor dirt and prevent proper ventialation of motor Motor may have one phase ope
214. tortion for System Currents Key gt gt moves to next screen 2 5 Line to Neutral Voltages 0240 0340 0440 0640 1000 1540 Three phase four wire systems only Sys Volts Voltage Line 1 to Neutral Volts Voltage Line 2 to Neutral Volts TETAS D Voltage Line 3 to Neutral Volts mps Key gt gt moves to next screen 2 6 Line to Neutral Voltage THD 0240 0340 0440 0640 1000 1540 Three phase four wire systems only THD of Line 1 Voltage to Neutral THD of Line 2 Voltage to Neutral THD of Line 3 Voltage to Neutral Key gt gt moves to next screen Compton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 13 Electronics Energy Division 2 7 Line to Line Voltages 0240 0340 0440 0640 1000 1540 Voltage Line 1 to Line 2 Volts Voltage Line 2 to Line 3 Volts Voltage Line 3 to Line 1 Volts Key moves to next screen 2 8 Line to Line Voltages THD 0240 0340 0440 0640 1000 1540 Three phase three wire systems only Line 1 to Line 2 Voltage THD Line 2 to Line 3 Voltage THD Line 3 to Line 1 Voltage THD Key gt gt moves to next screen 2 9 Line Currents 0240 0340 0440 0640 1000 1540 Line 1 Current Amps Line 2 Current Amps Line 3 Current Amps K
215. ts 1 4 4 v 119 THD Volts 2 4 v 120 THD Volts 3 4 121 THD Current 1 d P4 y 122 THD Current 2 4 s 123 THD Current 3 4 P4 125 THD Voltage Mean v v 126 THD Current Mean F4 s v 3 15 6 Reading Parameter Selection 1 A2r Use this screen to choose the parameter that the analogue Output current will represent The number displayed on the screen is the Parameter Number shown in Table 2 If the displayed Parameter Number is already correct press gt gt to move on to the next Set up screen To change the Parameter Number press 7 and set the three digit number using the method described in Section 3 2 Number Entry Procedure Parameter Selection Press to confirm your selection The Confirmation screen will appear If the new Parameter Number is correct press The next Set up screen will appear Ve If not press 4f You will be returned to the Parameter Selection screen Confirmation Compton INSTRUMENTS Integra 1540 1000 0640 0440 0340 0240 Issue 1 04 03 41 tyco Electronics Energy Division 3 15 7 Reading Top 1 or A2rt The top reading is limited to 12096 of the nominal maximum value of the parameter For example a 230V nominal can be adjusted from 0 to 276V The minimum is zero or 120 if the parameter is signed Sys Volts Volts L1 N Volts 11 2 Amps L1 Sign edit Sys Volts Decimal P
216. uit breaker at 100 or 125 amperes IEC 157 1 P1 Interrupting Ratings kA Circuit Breaker Type 3 P Only Volts 50 60 Hz l 220 240 380 415 HED4 Non Interchangeable Trip 1 Pole 125 HED41 18015 HED41B020 HED41B025 HED41B030 HED41B035 HED41B040 HED41B045 HED41B050 HED41B060 HED41B070 HED41B080 HED41B090 HED41B100 HED42B015 HED42B020 HED42B025 HED42B030 HED42B035 HED42B040 HED42B045 HED42B050 HED42B060 HED42B070 HED42B080 HED42B090 HED42B100 HED42B110 HED42B125 L Interrupting Ratings kA RMS Symmetrical Amperes 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 125V DC SHIPPING 10 per carton Wt 25 Ib 3 Pole HED43B015 HED43B020 HED43B025 HED43B030 HED43B035 HED43B040 HED43B045 HED43B050 HED43B060 HED43B070 HED43B080 HED43B090 HED43B100 HED43B110 HED43B125 N A N A N A N A N A N A N A N A N A N A N A N A N A N A 51 52 Ordering Information Circuit Breaker Catalog Numbers HED6 Non interchangeable Trip HHED6 Non Interchangeable Trip 2 Pole 2 Pole Ampere Rating HED62B015 HHED62B015 HED62B020 HHED62B
217. ulation continuity and diode tests as specified in the testing section Adjust regulator Consult regulator manual Adjust or replace regulator Consult regulator manual GENERATOR PRODUCES LOW VOLTAGE NO LOAD CAUSE Underspeed operation Voltmeter off or defective Incorrect or defective connections Loss of regulator power Regulator adjustment Regulator incorrectly connected Defective diodes suppressor or windings Regulator inoperative CHECK AND REMEDY Check speed using a tachometer or frequency meter Check voltage with a separate meter at the generator terminals Verify generator connections See drawings supplied with the generator or lead connection diagrams in this manual Inspect all wiring for grounds open circuits and short circuits Check regulator fuse and input power Input power is produced by the generator s residual voltage or from an optional PMG Adjust regulator settings Consult regulator manual Review the generator connection diagram or reference the regulator manual Test the generator using the 12 volt battery test as specified in the testing section If the results indicate generator problems perform insulation continuity and diode tests as specified in the testing section Adjust or replace regulator Consult regulator manual e z MARATHON A Subsidiary of Regal Beloit Corporation GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED CAUSE Excessive load Large motor starting
218. witches are three wire 3W devices except for catalog number AO2ED62B where the bell alarm Switch is a two wire 2W device using terminals 1 and 2 Ter minal connections and function are indicated on the accessory label Auxiliary switch contacts are either Type A or Type B Bell alarm switch contacts on three wire 3W devices can be open or closed in the normal posit on On two wire 2W bell alarm Switches the contact is open in the normal position The nor mal position refers to the deenergized state or OFF position of the circuit breaker Auxiliary switch contacts are actuated when the circuit breaker closes Type A contacts are OPEN when the breaker is OPEN Type contacts are CLOSED when the breaker is OPEN Bell alarm switch contacts are actu ated when the circuit breaker TRIPS Tin plated accessory terminals with binding head screws are provided Terminals are suitable for use with No 14 No 22 AWG wire Cu only or 5 16 in wide max insulated crimp type connectors Strip back wire 3 8 in max Auxiliary and Bell Alarm Switch Terminal Number and Contact Position Diagram Breaker Condition Accessory TRIP OFF ON Auxiliary O4 3 O43 3 Switch Second 4 4 4 O44 4 Auxiliar Switch E 6 E g 8 046 Alarm O O Switch ste o 8 ra 8 B Alarm Switch Catalog Numb ADZEDS2B ar Q Q Only Used for devices containing two auxiliary switches all Shunt Tri
219. ze the electronics when the relay module trips the attached circuit breaker NOTES Never attempt to add more than one accessory module to the circuit breaker This device is not intended for personnel protection against electrical shocks These sensors are to be used for equipment protec tion application only Installation Test Procedure A Refer to Breaker Preparation pages 16 17 for breaker preparation module mounting mechanical testing see Shunt Trip and or Undervoltage Trip and electrical testing of bellalarm contacts if required B The ground fault relay module can be used only with I E Sensor 64232 Mounting hardware for sensor is supplied 10 32 x 3 in screws and lockwashers Mount circuit breaker relay assembly and sensor as required C Sensor comes pre assembled with leads terminals and mounting feet Sensor will accommodate four 1 AWG or smaller type TW conductors or equivalent Connect con trol source sensing leads PUSH TO TEST leads and bell alarm contacts if required to terminals on bottom of relay See Figure 1 for the proper terminal connections D Connect load circuit wiring Figure 2 E Control power for relay must be 120V ac 66V 132V 60 Hz Continuous 010A at 120V ac Inrush trip 8A pk max at 120V ac Response Time Threshold Level approximately 2 seconds 115 percent of pickup 70 second maximum 150 percent of pickup 30 second maximum 250 perce

belt coupled motor – generator sets

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belt coupled motor &ndash; generator sets

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belt coupled motor – generator sets