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125 VOC
CONTROL
BUS

01
TR

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TOil 011-"

II MIl lIAS IlEIJI raEUlI'ED AT SlSSTAHTIAl EXP9ISE.


ITS Cllll100S AIlE TO BI: USED. RPROOO<a> OR D!SQ.OS8IIM
EJIPllDSEIlIlllTlll PfIllIS$IOII Of II. MIl nus lilA.... MIl

H
M

M-RUN
VACUUM
CONTACTOR

MOTES

... FUSE SPEC IAL


MARION DIV.
PIC 384340-8

[A28G]

MARION DIVISION OF
IMORESCO INC. MARION, OHIO

[C22K]

02
TR

NEUTRAL
STARTING
REACTOR

GENERATOR

'~ll----

T --. SWING

SGFE

rECI;F]
F

'MY AM) COIfUKllAl DFORtMnOfil All) es THE EXa.USllE PROPRTY

IMPORTANT NOTE

[C22G]

GENERATOR

T--'CROWO

CGFE

rECIOn

l~CI~ COC,l
~ ~
.,

ONE-LINE
D.C. OR IVES

~.2

r:
*
HOCH!

LHOIST
GENERATOR

HGFE

rECO?F]

01

.,

44-7

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

03

02

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REGULATOR
POWER
SUPPLIES

SHUNT
TRIP

MFT

T
U

WINCH

01

08

07

06

05

04

03

02

BlWRS

ONE-LINE
MTR CNTL CENTER

'2

~~

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

"

10

BLOWERS

09

SWING
MOTOR

~~~} PROP.
-<~~,....-~
MTR.
3G
I 5X

I
8

~J

30./
D
-<.,..--v"""..,....,, S C R O8 W
MOTOR
15X
BLOWER

3A
15X

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I~

'*_.

IIIlRESCO 1It.!1I1 All> HAS IlEEJI 0ClB.OPD AT


11 lIlA1l1IG a ITS COIfIDITS ARE TO BE usm.
lIlM 11 PRIOR EJIPIIESSED IllITlDI PIllIISSI
BE IlEMlIED TO ..

PRCF'RIETAIY AIIO COIFItOTlll DF"()RIM.TIOIf AIIl

IMPORTANr-NOTE

944-7

30

29

28

IOTES

-<~~HOIST
8 CABLE

MARION DIVISION OF
INDRESCO INC. MARION. OHIO

-'V-

---J 11----0

DC MOTOR
2L
-<~[B25H] FIELD
EXCITERS
IX
I
I

HOIST
2E/ "'" '~~MOTOR
~""""~~~O~R
IX

2C/ "'" L --.rv ~ .. If.S.FIL TER


--<.,..--v
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IX

27

II

[A22V] -{-SHUNT
TRIP

All>

(')

[A20V] -Q--UVR

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CPEX 5KVA

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DRV CVT IKVA

2A/ "'" ' L ~ ~J15\FILTER


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IX

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IMPORTANT NOTE

DIM

PROPERTY

SPARE

,.... AII)

---+

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I
I

J
K

WARION DIVISION OF
IMORESCO INC. MARION, OHIO

IW~0\ILE\<I.

I
I 0b'~~'L~g~?

AUTO
LUBE,

2-P 2-P _

I
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"THIS EaAIUC REJl'RESEIfTS PROPIUETARY AlII eotnOTJAllFORMlnOl Me) IS THE


or I&IrRKllI Df'ftSKlN
OF ItdESCO JJC..OIJ NIl HAS 8EDI Em..OPED AT SUBSTMfTlAL
_
1EJ11O 1l lilA.... IIlI ITS lllIlTBITS II<E TO BE llSBl, REPIlOW<D
"0< Oft PART "1IIOUT 1l I'RIOft ElIPRfSSeI) .,T1BI PIlIISSIOl rF II. All)
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in
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MOTES

p
R

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I

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2-P 2-P

I
I
I
I

I
I

10

I.. . -

LIGHTING

~SPARE

2-P 2-P -

W~

ONE-LINE
M ISCELLANE GUS

.. -

LIg~+C~~<I.

I
I
I

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[AIIZl
3-PH 230V
DISTR IBUTIDN
BOARD .2

I
-t------<>-

LIGHTING <I.
OUTLET
,

01

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

03

02

12i 1944-7
=bl

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:I:

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j"
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3 PH
50 HZ
6600 VOL T5

L:~~

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COLLECTOR
RING
JUNCTION BOX

IliI

L'"'~,~i

I
I

I
I

i .

I
I

CABLE REEL

TRAIL
CABLE
JUNCTION BOX

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GC

J
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MARION. OHIO

DOOR

I~CH

IliI

IOTl:S

DISCONNECT SW
SW-TC
ION REAR OF
MACHINE)

MARION DIVISION OF

INDRESCO INC.

I
I

GC2

HL3

HL2

HLI

[B25V]

-7

30

29

28

27

26

25

24

23
GC2

O------@..

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

03

02

01

22

HLl3

HL 12

HL II

AUX. COLLECTOR RING


(TOP OF CENTER JOURNAL!

'{L.H.I

HIGH VOLTAGE
COLLECTOR RINGS
(BETWEEN FRAMES)
{NUMBERED FROM
INNER TO OUTER
W/GND AT CENTERI

HIGH VOL T AGE


LOWER FRAME

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13

20A
(21

3FU

II)

--

BIT

II

L ( ==J

~~

I
~ j")
(23) J'r"61
HI9
H23

K3

3KVA

_. __ .

TEST -NORMAL

GND

BFT

"'11

121

B47

BI2

"f!'

151

...

..,

'"

MOTES

BLOWN
FUSE
.
INDICATOR
1000R MOUNTEDI

'"'

~
B

I
)1(15)1116 )

PFM
~nm

18

fR

~
~

....

RESET
13J 3PB 141

MARION DIVISION OF
INDRESCO INC. MARION, OHIO

lll

a-alSOY

"'n

VM

j2fPURCHASER'S TEST POWER


(20V.

GND

17
[COl]

17

TPI
CPI
I TSW '
1201
(22) (22)
(21)
T 6600/120V
1(7) (8) I
1,
1
H22
~
~
~
1
II'-I~)I(~--,
H20 1
H<:'~~I

BFT

~IMAR ION.ELSH.211944-7.2B

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o

TEST -NORMAL

~ -TKI

(L!l...r.

CPI
I TSW
1/5)
(/9) 1(4) (3)

OJ

IFU

100

IL21~

~I

[COl]

lJJ

-=-

ALL CONTROL
GNDS ARE CONNECTED
VIA TB TO GND BUS

f:~

[AI2Z]

TI

T2

IT3)

spa

K40

1-

SR
TAPS 50-65-80:1.
SET AT 80:1.

HI-VOL TAGE
CABINET RVNR

@]

[A23Z]

IGC2

GROUND
M0llipOR

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

1 1

11944-7

-=-

T~I
P.F. CORRECTION
CAPACITOR
127KVAR
6.6KV

09T

K30

06

05

04

03

02

01

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r-

[B25MJ

l7J

01

..q-

03

..q-

E-STOP

L3
05B

"T

M12 MX MJ3
05C

Pl!_

M14

'-

[55 J

J7

'::;'--'

MX

1P 1

'A'

[ 49J

...

[55 J
( 1 SEC. TORE)

M27

G1 ""1:~
[55J

[55J

"M" MOTOR MRIN


CONTRCTOR
35. 41

FL TR

-:e::J-

15
MX2 NI3 +CRJ'_

[29J

NI4

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17

'::;'--'

MX2

19

NPI

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...

[29J
( 1 SEC. TORE)

..

N27

G'f "'"I',~
[29J

[29J

21
"N" MOTOR NEUTRRL
CONTRCTOR
35. 5K07. 12R69

FL TR

.:0-

23
25

27~
Hr--_ _R-<:T...,D_CR)----------=3-=0--------~--_{~
17.
A
.~
[59J
~

MX2 RUX. RELRY


19.23. 23

(15 SEC.

31

TORE)

29

33

"'->----'-_~---'M 1----'3:c.:l---'---'...;l'Ne-[IIJ

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35

37

39 ~
33

TH

34

7
l

ROJUST TIME DELRY TO


IRTDR + 5 SEC. TDAE)

FU
1A)
E-STOP

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250W

SJ--!iI-tl

43

I.L.

2S0W

45

l7J

(rBI-B]

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37 STDR

3B

EifT 39

'k"

49F
[05J

[35J

40

1.ST

BLOWN FUSE TRIP

STOP
STRRT
41j 4"
~!
43
C~MI__B_,_---'404_--_o_MX MX
RUX. RELRY
2PB
I L---...;;d..L'.c----'O--(5'-"---o~~
05. 07. 1 J. 11
L55K
55M
i
M
I
[12F41J
Fm

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I
I
I
I

LT - I VA
LODTRAK I V
SOLID STATE MOTOR
PROTECTION MODULE

~RTOR RUN TIME DELRY RELRY


29

Fm

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'ETrf-b-

49 0 (
:z:~

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STRRTING RERCTOR
THERMOSTRT

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LT-IVA

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49B
490
[12R39J

411-

MRCHINE HOUR METER

c~

v~n
MRRION.ELSH.211944-7.2C

51

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55

BI006008

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H.V. FUSE CBNT

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o

118 AI

IHlJ

7E

HI

5G

5G

Hl

XO

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X3

6J

TEST

[12AII]

r----'
1 TRIP AT ),

1L

IGOAI

'Rfr

"M------li

....J

'1'100

---'

~I

12U

Ixo

12V

[15A09]

IX2

3 KVA
415,10%V/
55-0-55

'--y-----/

12T

XI

12X

SHi;'i::T CO-[

[15M5]

\'----------v

12W

I~

12Y

12Z

&

W~"'L~~~

4IS'10%V/

LIGHTING
TRANSFORMER

TO CB-AB
AUX. BUS
CKT. BRKR.
MCC UN IT IJ

l.UJl.U.J

b=b t: ,-::::l

[12AOS]

i L........J

AUXIL IARY
CONTROL
TRANSFORMER

01

25

24

23

22

2/

20

19

18

17

16

15

14

13

12

1/

10

09

08

07

06

05

04

03

02

-I

MARION DIVISION OF
INDRESCO INC. MARION.

OHIO

FAULT
CONTROL PANEL

' l3f1 0UNO

PASS NEUTRAL WIRE THROUGH CURRENT SENSOR


TWO TIMES TO GET 80:1 SENSOR RATIO FOR
TRIP AT IN' 1.0 A.

'THIS DRAWING REPRESENTS PROPRIEURY AND CONFIDENTIAL JNFORtl.ATION AND IS TKE EXCLUSIVE PROPERTY
OF MARION DIVISION OF IN.ORESCO IN(.(I.II) AND HAS BEEN DEVELOPED AT SUBSTANTIAL EXPENSE.
THEREFORE, NEITHER THE ~AW\NG NOR iTS CONTENTS ARE TO BE USED, REPRODUCED OR DISCLOSED IN
WHOLE OR IN PART WITHOUT THE PRIOR EXPRESSED WRITTEN PERMISSION OF 1.11. AND THIS DRAWING AND

I\)

N
CJ

.J>.

r-. .......

I 2"1 1 944 - 7

30

29

28

27

r1I.

26

C8-A8
SHUNT
TRIP

[12AI3] - - - -

: __

4?

,J,
3~

I"'~~ X IL~ IAR Y

,IT~ : ~ I::::~"O"
h

o ---------,0
A...-e.
,~"n
,,----F"u-::SA
-

GFRA 0
GROUNO FAUL T
RELAY

GFACT
12.5MA 1'(-;;8-;;0,----HH~~ II
II~
CURRENT
, CT - SE C
_
150;1
TEST
9M,
2(,
I 1<'
TO 4K I
,
TWINDING
1:80

"'"

R- GF A

-..J

to

11K

I 12K
j

J'
CB-AB
UNOERVOL TAGE
RELEASE

~'3K

P~ER

CO~T~OL

RESET

r---------,

AUX. TRANSFORMER
GROUND FAUL T
MONITOR PANEL

13 A.I

;C;;

FU-GFO
_
5J

X3

xo

o--+------'I..-...:o-'-

8F

Xl

_L

XI\
H3

frl

IMPORTANT NOTE

FU-GFA
13AJ

HL53 IH3J

HL5l

lD5E
T-GF
250 VA., I PH.,
50/50 HZ.,
415 TO 110 VOL TS
)

GND

H~~

lkJ

:r:

I~

H~~

AUXIL IARY TRANSFORMER


112.5 KVA., 3 PH., 50 HZ.,
5500 VOL TS DEL TA TO 415 VOL TS WYE
HL51 IHI!
XI

Ul

fTl

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a

::I
::D

[AI2Z]

HLII

FUSED DISCONNECTS
ILOAO BREAKI

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02

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0

03

04

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06

07

08

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U1

09

09
10

II

II

12

12

13

13

14

14

15

15

I
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o;;J

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16

16
17

17

178

18 [12A20l
19

H1lHi

19B

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rn

T-PS
21
1.0KVA
22 310-450V PRIMARY
23 240V SECONDARY
50 HZ
24

18
[I2C23J

Cl2CIIl

[I2C39J

19

21R

21S 21

H5

20
21G

21H

21L

21J

21N

21M

210

X4

X5

~+H3

25

23

1-

24
25

X2

26

26

25C

27
CB-PS
15A

28

27
HI
vvvv

29
30

22

31

HI

H3

H2

vvvv

( 7AI5Jl
[8AI5JJ
[9AI5JJ

"""'

'-AAA..J

HGT
15 KVA

33
34

_XD_
Xl

38G

38

31

Xl

32

SGT
15 KVA

XO

33

XO

XI

X3

1X2

36
37

29
30

rn

GGT
15 KVA

X3

35

H3 28

'---

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rn

H2

HI

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128C

32

H3

H2

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3BJ

38M

38L

<

36

38H

i-

35

38N

38R

380

:I

37
38S3 8

39

39

40

40

10%

230V

43

230V

10%

42

10%

230V

TO CROWD GEN.
FLD. EXC ITER

TO HOIST GEN.
FLD. EXCITER

44

[9A03El

[8A03EJ

[7A03El

43

TO S WI NG GEN.
FLD. EXCI TER

c
a:

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42

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46

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49

50

50

51

51

52

52

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53

53

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54

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55

55

56

56

57

57

58

58

59

59
A

REV,

:5

REV. 2

07-21-95
REY,1

ISSUED

03-27-95
REV.

~~~

!~I;

t=1--6~

~I~;i

~;~~;

60

60

"ADE BY

S. WAMSLEY

rEV.
05-11-95

APPROVALS

!PRINTS TO

fiRST WADE FOR REO.

37796E181
SOFTWARE NO.

GENERAL ELECTRIC
DRiVE SYSTEMS

SALEM. VA. USA

8~

~~~gg

ELEMENTARY DIAGRAM
INCOMING powER

- ~~~~

00-",""-

246B5931AA
CDNT.DNSH.

5J

~~i~

SH. NO.

5A

CODE NO

MAR ION.ELSH.21194 4-7.5A

5A

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~~~~:

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A

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01

02

03

04

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05

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06

07

0
0

112B33F I

MPS
SUPPL Y

08

I 12B3SF I

09

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10

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II

12

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14

16

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100R

17
18

13
14
15
16

PTB2

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18
19
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20

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20

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22

22

23

LJ I +)

24

3 +

23
6

L21-1

24

I C3603R229B

25

25

26

26

27

27

28

28

29

29

30

30

31

31

32

32

33

33

34

34

35

35

36

pm

38

39

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~

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40

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1m

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41
42

FU
OR
SOV

43
44

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111

mrnl

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37

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DIPPER TR I P OVERLOAD

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43

45
46

47

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49

50

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56

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59

XI + I
(JA02B]

60

A
REV, ;,

REV.'"

REV. 2
ISSUED

03-27-95
~

59

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(JA02PI

07-21-95

REV.

r<1

<f)

~
~

WADE BY

S. WAMSLEY

F
REV, I

APPROVALS

05-11-95
IPRINTS TO

FIRST "AOE FOR REO.

37796E181
SOFTWARE NO.

GENERAL ELECTRIC
DRIVE SYSTEMS

SALEM. VA. USA

60

ELEMENTARY DIAGRAM
125VDC SUPPLY II
DIPPER TRIP

246B5931AA
CONT. OH SH.

5JA

~ ~~~~

~n~i:

~~~~i

ISH. NO.
5J

CODE NO.

MAR ION.ELSH.211944 -7.5J

5J

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01
02

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125 VDC

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HRX

TB

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DPTR

2.5 SEC TOAD

03

04
05
06

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14

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15
16

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21
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28
29

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42
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54

51
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53
54

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55

55

56
57
58
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I'PRINTS TO

SOFTWARE NO.

ELEMENTARY DIAGRAM

GEN ERA L ELEe TRIC OIG-PROPEL


TRANSFER

FIRST MADE FOR REO.

37796EIBI

DRIVE SYSTEMS

SALEM. VA.. USA

246B5931AA
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5K

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39
41

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39
41

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25

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SH. NO.

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CROWD GEN. FlD.


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54

SWING GEN. FLO.


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APPROVALS

05-11-95
lPRINTS TO

FIRST ),lADE FOR REO.

37796EIB'
SOFTWARE NO.

GENERAL ELECTRIC
DRIVE SYSTEMS

SALE.... VA. U.S.A.

~~~~~
:>
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ELEMENTARY OIAGRA...
MAGNETICS
246B5931AA
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03-27-95
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07-21-95
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36
37

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29
30

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60

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57
[S ... 29AJ
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24

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59

25

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23

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54
55

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51

19

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46
47

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33

31

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31

31

32

32

33

33
34

34
35

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38

36

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40

40

42
43

44

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HVR/RL Y3
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51
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53
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S

03-27-95

37796E 1BI
SOFTIiIlRENO.

REV,S

S. WAMSLEY

ELEMENTARY 0 IRGRRM

Rl"PRllYRLS

[REV. l

DRIVE SYSTEMS

MAGNETICS

24685931RR
CONT. ON SH.

5N

MARION.ELSH.211944-7.5L

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36

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12

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47
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18
19

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20

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23
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24
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26
27

30

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EVENT BUZZER
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32
33

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51

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[93l-

16E

20

41

[P331

HT.

HMOTX

16

145

[P25J
SMSF

[PS7l

15

42

.Il!,~

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SMOTX

HMSF

CMsF

13

39

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10
12

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40

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29

02

04

28

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CONT.ON-SH.

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59

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~~~~~
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CODE NO.

MAR ION.ELSH.211944-7.5M

5M

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~~~~

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BI006008

BI006008

02

01
02

03

03

01

!l

04

04

05

05

a: "
a:

06

06

IT)

07

07

06

06

09

09

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

1B

1B

19

19

20

20

21

21

22

22

23

23

24

24

25

25

26

26

27

27

2B

2B

29

29

30

30

31

31

32

32
PFEX

33
34
35

120VAC

PFOl

(43) 3S

r-1--_~2A~__l~_24V I
~

ISK04PI

36

-----'
O PWR

L---

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37

36

I--i,2-

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PMF2

39

(Sl46J'

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WEAK FLO SET

XI N( - J

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LlOHTS ON
= NORM

-=3'="BB""'=.:..:.-lf------+--.::.::3""'B""F.:...::::...:=+---1~
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40
41

PMfil

RI

RHI

R2

c!E...

SElX

12

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lOSS

r---,(t-....c:~.JA"""=,-,
........--C:::h-d----1~ COM

42

:~~{ ~-"S",S,,-2=.n"-,.-l-I,

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43E

43

44

36R

rr=~
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I
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F2

FI

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56

SW2B = 2 ON

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46
49
51

54
55

ON

56

PFEX SETUP INST


(j)SET JUMPERS ( SW' S ON
saeA CARD
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GIVE 41A IS4.7MV RT TBI-IS.l6J

57

@WlTH PMFI,2 P.U. AOJ SW2A.B TO


GIVE 24.6A (32.BMV AT TB1-lSol61

56

(DWITH PMFI,2 0.0. AOJ RHI TO


GIVE 13.66A IIB.2MV AT TBI-IS.ISJ

59
60

60
f

REY. :I

REV. 2

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IssuED

REY. S

nRDElll

07-21-95
03-27-9S
S .WAMSlEY

IREV.

OS-I1-9S
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ELEMENTRRY 01 RGRAM
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REF

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SALEM. VA. U.S.A.

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53

55

I-

52

54

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53

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50

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51

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MARION.ELSH.211944-7.5N

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BI006008

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[7]

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2511

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21
23
25
27
29
31
33
35
37

Y (+ )

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43
45

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51

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NON-INVERTED OUTPUTS
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39

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17

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K15. 7F4D
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KD4
HMSF [7] HMS FAULT RELAY
K17. M13. M41
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K29
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K31
SMS-N [7] SMS NEUTRRL RELRY
K04
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TYPICRL
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6311
6511
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K24. K4D. K44
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-- -

MARION.ELSH.211944-7.5P

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IN

PART WITHOUT THE PRIOR EXPRESSED WRITTEN PERI,lJSSJON OF

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THEREFORE. NEITHER THE DRAWING NOR ITS CONTENTS ARE TO BE USED. REPRODUCED OR DISCLOSED IN

"THIS DRAWI~G REPRESENTS PROPRIETARY AND CO~F1DE~T1Al INFORMATIoN AND IS THE EXCLUSIVE PROPERTY
OF MARION DIVISION OF rNDRESCO INC.(t.!1) AND HAS BEEN DEVELOPED AT SUBSTANTIAL EXPENSE.

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03
04

[5A3BG 1I5A3BH 1I5A3BJ I

05
06

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07
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18

NOTE: 6

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20

INTERPRETEO
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21
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l2

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24

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28

26

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03-27-95
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ELEMENTARY DIAGRAM

GENERRL ELECTRIC
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SALEM. VA.. USA

HOIST GEN. FIELD EXCITER

24685931RR
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76

0"

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2

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FIELD
CURRENT

V.I093

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49
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63 BlK

32 [835TI
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54

23

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13

13

14

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15

15

16

16

17

17

18

18

19

19

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07-21-95
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01

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37
3B
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3.9A =

V.1093

'2'
VM2
V .1 095

( - )

:~

C41Cl

BLK
;-I5B

(C42Cl:

4f~T

46

tm.
22

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V.IOZB

HTa
69

26

I +I
PROPEL ARMA TURE
CURRENT

I- I

BLK
51 (B 6Tl IIPIRI

52

70

53 [B BTl
S
6
1
1

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00::

40

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:i~

46
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l

47

lA2
V.I027

ALL =
OA =
mV =
000 COUNTS

I-I

57
5B
59
60
A
REV. ,

REV, 2

07-2t-95
REv, .-

ISSUED

REV. 5

nADEIlT

03-27-95
5. WRMSLEY

F
R(Y.

G
I

If'RINT5TO

F!R5TnADEfORREQ.

31796E I BI
SlIFTNAREHIJ.

ELEMENTARY DIAGRAM

Rf"f'RDVRlS

05-11-95

GENERAL ELECTRIC
ORIVE SYSTEMS
SALEM. VA .. USA

CROWD GEN. FIELD EXCITER

2468S93IRA
COHT.ON5H.

BB

SH.Nt!.

BA

MARION.ELSH.211944-7.8A

LLJ

c::~

45

(+ )

50A
100MV
V.I029

49
50

39

GENERA TOR FIELD


30
CURRENT
WHT
2
L==~
IF2
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CURRENT

(-I

o
:Z

Ll..o

42

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o
:I:

3B

2 1-+~3;nB"'M - - - [E03C I

1901F

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THERM.

VOLTS

L--~,

4I

36
37

1+)

I~

35

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40

56

MODEL NO.
GF20DD
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KW
VDC
I .ODSF
100Y. O. L

26

54

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NOTE: 6

19

55

.,.

15
16

47
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to

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14

16

43

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13

13

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11

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09 I - -

10

23

li

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BI006008

BI006008

02

03

04

04

05

05

06

06

07

07

08

08

09

09

10

10

11

12

12

13

13

14

14

15

15

16

16

17

17

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1B

19

19

20

20

:g

cr:~

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22
23
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30

31

31

32

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53

53

54

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56

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59

59

60

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REV. 2

REV.

ISSUED

07-21-95
<4

03-27-95
REY. S

nADEllT

S. WAMSLEY

rEV.
1
05-16-95

If'RIHTSTlI

Af"PROVRt5

FIRST nADE fllRREtI.

37796E161
SOFTWRRE ND.

"~

ELEnENTRRY DIAGRAM

GENERRL

ELECTRIC

ORIVE SYSTEMS

CROWO/PROPEl
ARMATURE C1RCU I T
2468S931RR
CliNT. OM SH.
BC

e~~

g,~5

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MAR ION.ELSH.211944 -7.88

88

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BI006008

01

rL-

03
05

05

a:
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07

07

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09

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11
13

13

15

15

17

17

19

19

21

21

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23

lIml!J.L

IA33NI-",
25

/'.... 'I'

I
2
3
4
5
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31

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37

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31

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29

37
39

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29

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30
31

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36

41

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20.000 COUNTS

38
40

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37
39

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34

to

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JR. 11SVRC/2BVOC I
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55
56
57

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REV. 2

01-21-95
IssuED

F[RSTnAOEfDRAEO.

31196El B1

GENERRL

ELECTRIC

DRIVE SYSTEMS

SRLEM. VR U.S.R.

REGULRTOR CONT,
REF IGNO FLT INPUT
246B5931RR
CONT.ONSH.

8E

~~~

f-

~;!I

<l
f-

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0

Cl.

:;

ELEMENTARY DIAGRAM

API'ROVALS

IiDFTlIARfHO.

S. WRMSLEY

05-11-95
rlllNTS to

03-21-95
MOE II'

IREV.

~~~

60
F

f0

59

rLJ

~:=r:E5

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~~~~

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80

MAR ION.ELSH.211944 - 7.80

a:

:z: :::e
a
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-

40

54

<!

42

ANALOG
INPUTS

34

....
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22

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21

69

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58

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14

InA. IOVIlC

60

15

K2 RELRY CONTACT RRTINGS:


1 .2R 11SVRC12BVOC I

59

0
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13

58

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a:

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VAA.184

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52

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27

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35

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23

33

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27
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34
35
36
37
38
39
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41
42
43

29
30
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tt---l--+-oriR_SC_ _4_'-t-__--<S} I 5K a4AI

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32
33
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AVAILABLE
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43
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Iri!'

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20

25

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32
33

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19

22
23

CMS/RL Y4

OPERATES WHEN
AOOR. =EE.2~~;1
~R4NO
35
CROWD MS=C OR RET
RS 422
II---+-(~J----I----- I 5L 42GI
R4C
31
tt---I--+o-~----t---- I 5Ll OC I
R4NC
33
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31

16
17

21

AOOR. = EE. 2249-

36
37
38
39

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01.Ll

ii:~

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49
50
51

52
53
54

52
53
54

55
56
57

55
56
57
Rl Y1 THRU Rl Y6 CONTRCT RRTlNGSI

J.\!l iii
= lOW

30

30nVQC

LEVEL SJG WIRE.

REY.2

rRE .... "

ISSUED

REV. S

nAOEII'

03-27-95

...L.-05_-_II_-9-,5=""rl.....;-;;;;;"..."..,,,--_-I
!f'RIHTSTO

fIRST nRDE fOR RED.

37796E I B1
SDf'TIiRREIrIIJ.

S. WAMSLEY

!If'f'ROYRlS

I'RfV.l

L..;;;--,--+-_ _---iho"'7-"'2_1-_95

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59
60

IR tlSVRCI2BVOCI

GE NERR L ELEe TRIC


DRIVE SYSTEMS

SALEM. VA .. U.S.R.

ELEMENTARY DIRGRAM
EXC OVER TEMP/
FRUL T CONTROL

24685931RR
CONT. ON SH.

SF

MARION,ELSH,211944-7,8E

o
:Z

oct
:z: ::;;

45
46
47

50
51

e:r:

L&..o

40
41
42
43
44

45

47
48
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REY. :I

35

44
45
46

58
59
60

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14

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:f;r

COMPL
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29
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22
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10

TL.--JlI:I'!--IV-l_~o-,R2_N_C_ _2-j1

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II

m,
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CD
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07

INPUTS
RLY2
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R2NO 23
~I:}--+-o~-----j
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"

a:
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IA41MJ

16

FAULT-f;>AOD . =EE.216':1

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13

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23
24
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43

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40

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23
24
25
26
27
28
29
30

31
32

36
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49

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44

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35

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NEUTRAL

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17F28C I

29

34

OT2NC

27
28

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120

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15

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18

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53

53

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54

55

55

56

56

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57
58
59
60

11 THRU
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on

57

CONTRCT

C
REV. 2

REV. 4

IssuED

I-

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I0:
0

60

REV, I

07-21-95
03-27-95
REV. 5

I0

59

r",

5 NAnES

REV. ,

58

0.6 R 1IOVDC. 125VAC


2.C A 3DYOC

= STATUS

MROEDY

05-11-95
I"RINTSTD

F!RST nROf FOIfREO.

37796E 161
5DFTIlRRENO.

S. WRMSLEY

RPPROVRLS

GENERAL ELECTRIC
DR I VE SYSTEMS
SALEM. VA .. U.S.A.

T
R
U
S
ELEMENTARY OIAORAM
DID/PROPEL
INPUT/ONO FLT OUTPUT

~ ...... l='

[j;~

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PANEL LAYOUT 01 AGRAM


HO I ST /CROWO/PROPEL

24685931AP
CONT.DHSH.

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EXC LAY 3 104-106 150 155-157 159

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57

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21 NUftBER IN

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31 MOUNT SHRI ON TOP OF SHR2 RHO HERTER COVER


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F1flST nRDE fOR RED.

37796EIBI
5DFTIIRllEHO.

PANEL LAYOUT DIAGRAM

GENERRL ELECTRIC
DRIVE SYSTEMS

SALEn. VA. U.S.A.

OIG-PROPEL TRANSFER

24685931RP
CONT.OHiSH.

ISH.

:0.

FINAL

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10 - NAME

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10 - NAME

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19
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8 - AIR
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-

II - HS GEN
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II - CR GEN
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4 - HOIST
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...... "

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TABLE OF CONTENTS
SH. CODE/NO

- - /1
--/2
- - /3

OA-OC
lA-lD

2A-2D
5A-5P
7A-7GA
8A-8G
9A-9G
12A-12U
14A-14C
15A
29A-29E

SUBJECT
TITLE
TABLE OF CONTENTS
KEY INTERLOCK SYSTE M
LE GE NO
ONE-LINE DIAGRAM
HI-VOL T
MASTER CONTROL
HOIST CONTROL
CROWD CONTROL
SWING CONTROL
MOTOR CONTROL CENTER
AUTO-LUBE CONTROL
LIGHT IN G
CAB INE T OUTL INES

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REEL

TRAIL CABLE
J. BOX

COLLECTOR RINGS

BOTTOM OF UPPER FRAME

MARION DIVISION OF
IMORESCO INC. MARION. OHIO

E
BOLT EXTENDED I
W BOLT W I T H D R A W N '
L.a. LOCKED OPEN
L.C. LOCKED CLOSED
DENOTES DOORS MECHANICALLY
INTERLOCKED WITH LOCAL ISOLATOR

CABLE I

LOWER FRAME
DISCONNECT

DOOR

DOOR

KEY INTERLOCK
SYSTEM

E
.(

DOOR

FUTURE USE
(IF REQD.)
L.C.

~Ilt-

AUXIL IARY
TRANSFORMER

M.G. SET
DRIVE MOTOR

HIGH VOLTAGE CONTACTOR CABINET

DO~

H.V. FUSE CABINET

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MAR ION DIVISION

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SYSTEM

FOR
TYPE

182M SHOVEL
o
z

W
(SI

LEGE N 0

.-J

STANDARD LOCATION SYMBOLS


[j]D.C. CONTROL PANEL .M8A

TRANSFORMER ASSE MBL Y 'M 14A

[IjRESISTOR ASSEMBLY .M7A


[IjMOTOR CONTROL CENTER 'M58A
[]JHIGH VOL TAGE PANEL .MIOA
[]LOWER FRAME

[2] OPERATOR'S

CAB

[ ] ] DIG-PROPEL TRANSFER PANEL .M35C


DMOUNTED REMOTE IE.G. DEVICE ON BOOM,
UPPER FRAME ETC.)

LOCATION/DESTINATION CROSS-REFERENCE
NUMBERS LISTED UNDER NAME OF RELAY (OR STARTER.
CONTACTOR. ETC.) DENOTE LOCATION OF INTERLOCKS
IN THIS GROUP. SPARE INTERLOCKS ARE SHOWN
UNDERLINED NO. INDICATES N.C. CONTACTS.
BRACKETED NUMBERS [
] BELOW INTERLOCKS
DENOTE LOCATION OF THE OPERATING COIL.
BRACKETED NUMBERS [
] AT THE END OF A WIRE
INDICATES WHERE THAT WIRE IS CONTINUED
A NUMBER SHOWN IN PARENTHISIS I
)
INDICATES WHERE THE WIRE CAME FROM.
AND IS THE NAME OF THAT WIRE.

EXAMPLE:

3T_~_F_---<:~_ HOR IZONTAL

[5 K
_

POST ION ON SHEET


_ VERTICAL POSITION ON SHEET
SHEET CODE, ALPHA-NUMERIC.
NUMER IC ONL Y SHEET NO.S ARE NOT USE D.

MRRION.ELSH.212781-4.DR

COilE NO.

OA

BI006008

CONSISTS OF SHEETS 5 ""

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~

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f'--

01

02

02

rL-

03

03

01

04

04

05

05

SHEET NO,

09

06
07
08
09

10

10

06
07

OA

COVER SHEET

08

08

INDEX

II

II

12

12

13

MAGNETICS INTERFACE

17

5L

LOWER FRAME MAGNETICS INTERFACE

18

5M

SYSTEM FAUL T INDICATION CONTROL

19

5N

PROPEL EXCI TER

15

16

INCOMING POWER

a
c

16

17
18
19

20
21

22
23
24

22

7A

HOIST GENERATOR SHUNT FIELD CONNECTION AND EXCITATION


HOIST ARMATURE CIRCUIT AND GROUND DETECTION

25

78
7C

HOIST/PROPEL MTR FIELD CONNECTION AND EXCITATION

26

7D

REGULATOR CONTROL: REF/GND FL T INPUT

27

7E

EXCITER OVERTEMP/FAULT CONTROL

28
29

7F

DIG/PROPEL INPUT/GND FLT OUTPUT

7G

MAGNETICS

23
24
25

26

27

28
29
30

30
31

31

32
33
34

32
8A

CROWD GENERATOR SHUNT FIELD CONNECTION ANO EXCITATION

88

CROWD ARMATURE CIRCUIT AND GROUND DETECTION

35

8C

CROWD/PROPEL MTR FIELD CONNECTION AND EXCITATION

36

8D

REGULATOR CONTROL: REF/GND FLT INPUT

37

8E

EXCITER OVERTEMP/FAULT CONTROL

38

8F

DIG/PROPEL INPUT/GND FLT OUTPUT

39

33

34

36
38

.....

40
41

42
43

9A

SWING GENERATOR SHUNT FIELD CONNECTION AND EXCITATION

42
43

44

98

SWING ARMATURE CIRCUIT AND GROUND DETECTION

45

9C

SWING MOTOR FIELD CONNECTION AND EXCITATION

46

9D

REGULATOR CONTROL: REF/GND FLT INPUT

47

9E

EXCITER OVERTEMP/FAULT CONTROL

48
49

9F

GND FAULT OUTPUT

9G

MAGNETICS

Z""

o.

enD

>~
Cia

zg

44

~~

46

47
48
49
50

51

51

52

52

53

53

STANDARD LOCATION SYMBOLS

NOTE:

54

ID

~ ~~~lrgR~'hM~m~BL

rn

lID

D,C, CONTROL PANEL

[] OPERATOR'S CAB
[ID HOIST-PROPEL TRANSFER PANEL

RESISTOR ASSEM8LY

@] A,C. AUXILIARY CONTROL PANEL

lID

[2J HIGH VOLTAGE PANEL

LOWER FRAME

ALL UNMARKED DEVICES SHOWN ON


THIS ELEMENTARY, EXCEPT ROTATING
EOUIPMENT, ARE LOCATED ON ID
D.C, CONTROL PANEL,

MOUNTED REMOTE (E.G, DEVICE ON


BOOM, UPPER FRAME ETC,)
H

54

55

56
57
58
59

HYDRAULIC CONTROL PANEL

60
P

APPROVALS
REV. 3
REV. 2
IREV. I
ELEMENTARY DIAGRAM
f.,.~,,'-,4~+-_ _-+,~~,;,,1u~~~,--I-.:c9~::-"'-_ _-.L:0:.::~-,-I,--I-.:c9::.c~I'P~.~INT~'~TO=-!~f1.~'~T ~.'~O<~'~O.~.~EO~, - - GENER AL ELECTR IC INDEX
03-27-95
I
37796EI81
DRIVE SYSTEMS
246B5988AA
.wADE BY
SOfTWARE NO.
REV, S

S. WAMSLEY

SALEM, VA" USA

CONT. ON 5H.

OC

MARION.ELSH.212781-4.GE-OB

LLl

~g:;

45

50

Ocr

39

41

o
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37

MAGNETICS

8G

35

40

58
59
60

;""J

15

DIG/PROPEL TRANSFER

21

57

I-

"N

14

125 VOL T SUPPLY AND DIPPER TRIP

20

55
56

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LIMITAMP EQUIPMENT

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2An
A
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BFT
BIL
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C.C
CB
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FSX
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HI.H2.H3
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nov
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DC
OCR
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OTX
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PB
PFC
PFM
PG
PHA .PH ,PHC
PLR
PRO
PST
PT
PTB
R
RC
REC

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Rll
Rn
RS
RTD
RX
S
SC
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SPR
SR
SS
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VFsn
vn
vns
VRn
VRTD
VT
VTO
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WHn
WM
WTD

nlCROPROCESSOR BASED STARTING ( PROTECTION nODULE


AC AnnETER
DC AnnETER
ACCElERAT ING CONTACTOR
AnBER INDICATING LIGHT
AnnETER
AnnETER SW ITCH
AUTOTRANSFORnER
ACCELERATION TInInNG RELAY
BLOWN FUSE INDICATOR
BLOWN FUSE TR IP
BLUE INOICRTING LIGHT
CRPACITOR
CLOSING COil
CIRCUIT BREAKER
CONTACTOR CONTROL nODULE
CALI FORN IA0ISCONNECT
CHOKE
FIELD CURRENT CALIBRATION nODULE
CAPACITOR TRIP DEVICE
CONTROL POWER INTERLOCK
RUX. RElRY TO CPI
CONTROL RElRY
CURRENT TRANS FORnER
CURRENT TEST BLOCK
CURRENT TRANSDUCER
DIODE
DC CURRENT TRRNSFORnER
0IFFE RENT IAl RElRY
DISCONNECT SWI TCH
EXCITER FIELD RElRY
ElRPSEO TInE nETER
EXCITER
EXCITER RHEOSTAT
SYNC. nOTOR FIELD lEADS
FIELD CONTACT OR
AUX. FIELD RELAY
AUX. FIELD RELAY
FIELD DISCHARGE RESISTOR
FIELD GROUND RESISTOR
SYNC, nOTOR FIELD
FIELD lOSS RELAY
FILTER
FIELD RECTIFIER PRNEl
FRST SPEED CONTACTOR
FAST SPEED SHORT ING CONTACTOR
AUX. RELAY TO FS
FEEDER SWITCH
FIXED TAP RESISTOR
FUSE
GROUND CURRENT TRANSFORnER
GROUND FRULT RELAY
AUX. RELAY TO GF
GREEN INDICATING LIGHT
GROUND
GROUND BUS
GROUND SENSOR
OUTGOING TERnINAlS TO TRANSFORnER
HEATER AnnETER
ISOLATING SWITCH
INconPlETE SEQUENCE RELAY
ANT I-K ISS RELAY
lRTE OPENING
INCOnING TERnlNAlS OR AC BUS
LIGHTING ARRESTOR
LIGHT
lOCKOUT RELAY
LIGHT SWITCH
lODTRAK 4 nOTOR PROTECT ION RELAY
lOOTRAK/GROUNO FAULT
lODTRAK/OVERCURRENT -OVERTEnPERATURE
lOOTRAK/OVERlOAO-OVERCURRENT
lOOTRAK/OPEN PHASE-PHASE REVERSAL
lOOTRAK/OPEN PHASE-PHASE UNBAlRNCE
lOOTRAK/OVERTEnPERATURE
lODTRAK/AUX. RELAY
nAIN CONTACTOR
nOTOR
nETEL OXIOE VARiSTOR
CONTRCTOR HOLDING RESISTOR RELAY
nAIN DISCONNECT SWITCH
AUX. RELAY TO n
NEUTRAL CONTACT OR
AUX. RELAY TO N
OPE RAT IONS COUNTER
OVERCURRENT RELAY
OVERLORD RELRY
OVERTEnPERATURE RELAY
AUX. RELAY TO OT
POLAR ITY nARK
PUSH BUTTON
POWER FACTOR CRPRC ITOR
POWER FRCTOR nETER
PLUG
INCOnlNG LINE TERMINRlS
POWER LOSS RELAY
CT PROTECTOR ITHYR ITE )
PHASE SHIFTING TRANSFORnER
POTENT IRl TRRNSFORMER
POTENT IAL TEST BLOCK
RUN OR REVERSE CONTACT OR
RELEASE COIL OR CONTACT
RECTIFIER

UI- 5Httl5 'J & 'JA


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RECEPTACLE
RIl INDICATING LIGHT
RECTIFIER CONTACTOR
RESISTOR
RESISTANCE TEnPERATURE DETECTOR
AUX. RELAY TO R
STRRT CONTACTOR
SURGE CRPACITOR
SLI P-GURRD RELAY
SHUNT
SPACE HEATER RnnETER
SPACE HEATER
STAll PROTECT IVE RElRY
STARTING REACTOR
SLOW SPEED CONTACT DR
SLOW SPEED SHORTING CONTACTOR
SELECTOR SWITCH
STAB
SHORTING TERnlNAl BOARD
AUX. RELAY TO SS
AUX. RELAY TO S
TRANSFORnER
TInE CLOSING
TInE DELAY AFTER DE-ENERGIIATION
TInE DELAY AFTER ENERGIIATION
TInE OPENING
OUTGOING TERnlNAlS TO nOTOR
TERnlNAl BOARD
THERnOSTAT
THYRITE
TIE SWITCH
TEST POWER INTERLOCK
AUX. RELAY TO TPI
TEST POWER SWITCH
TInING RELAY
TRIP RELAY
THERnOSTAT ON AT DR SR
TEST-NORnAl SELECTOR SWITCH
UNLATCH RELAY
UNDER VOLTAGE RELAY
UNDERVOLTAGE TlnlNG RELAY
VOLTAGE CHECK RELAY
VOLTAGE DIVIDER NETWORK
VARIABLE FIELD SUPPLY nODULE
VOLTnETER
VOLTnETER SW ITCH
VARnETER
VAR TRANSDUCER
VARIRBLE AUTOTRANSFORnER
VOLTAGE TRANSDUCER
WATTHOUR DEnANO nETER
WATTHOUR METER
WATTnETER
WATTS TRANSDUCER

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HANDLE IS PUSHED IN. CAN NOT BE OPENED WHEN nA INLI NE
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"" - START AND STOP PUSHBUTTONS ARE WIRED THOUGH TERnINAl AT
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o - AT

A TERnINAl ON "TB" ALOOP IN THE CT SECONDARY CIRCUIT WIRE


PERMITS INSERTION OF AHOOK ON AMMETER FOR nEASURING
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f - DEV ICE FURN ISHED BY OTHERS nOUNTED REMOTE.


TERM INAL BOARD PO INT.

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TO TEST - HANDLE nUST BE IN THE DISCONNECT POSITION I OFF) RND


TEST-NORMAL SELECTOR SWITCH. LOCATED IN THE lOW VOLTAGE
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CONNECT HIS TEST POWER TO THE PROPER TERnINRLS AND NOTE
THAT THE CONTROL CIRCUIT IS NOT GROUNDED WHEN DISCONNECTS ARE OPEN.
BE SURE TO TURN THE TEST -NORnAl SW ITCH TO NORnAL
BEFORE nOVING THE DISCONNECT HANDLE TO THE ( ON ) POSITION.

THIS DIAGRAn SHOWS STARTER WITH THE ISOLATING SWITCH !N


THE DISCONNECT POSITION AND THE TEST POWER INTERLOCK
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CONTROLLER GROUND

NOTE B - TDUV IS WIRED FOR TInE DELAY DROP-OUT ON lOSS


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25

24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

07

06

05

04

,f,'~t'""

LTG
BUS

02
03

08

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30

29

28

27

26

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23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

03

02

OJ

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-....I

WARION DIVISION OF
IMORESCO INC. MARION.

OHIO

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7

30

29

28

27

26

24

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125 VOC
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BUS

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24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

03

02

MARION. OHIO

212781-4
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30

29

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22

21

20

19

18

17

16

15

14

13

12

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10

09

08

07

06

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03

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01

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30

29

28

27

26

25

24

23

22

21

20

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/8

17

16

15

14

13

12

II

10

09

08

07

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30

29

28

27

26

25

24

23

22

21

20

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/8

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15

14

13

12

II

10

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08

07

06

05

04

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31
33

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32
49
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37
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26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

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56

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REv, Z

07-21-95
REV. 4

ISSUED

03-27-95
REV, 5

M'Of BY

S. WAMSLEY

rEV.
I
05-11-95

IPRINTS TO

APPROVALS

FIRST MAO FOR REO.

37796EIBI
SOFTWARE NO.

R
S
T
ELEMENTARY DIAGRAM
GENERAL ELECTRIC INCOMING POWER
M

DRIVE SYSTEMS

SALEM. VA.. USA

246B5988AA
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21
22

22
23

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25

25

26

26

27

27

28

28

29

29

30

30

31

31

32

32

33

33

34

34

35

35

36
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49

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51

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52

53

53

54

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55

55

56

56

57

57

58

58

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IJA02PJ

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rEV. 2
ELEMENTARY DIAGRAM
/;;R"'EV~." -1------hI"~"'i'"~;;:~~'--7:::9-5::..9-5---.J.:::05::..-.:.:rr-'-9::5;,I'P:;;;R1..HT;oS..TO,..j7.~;;;~~"T97.~AU;~;;-:e"'Flo:OR"RE"'0-.- - j GENE:~;s~~:~sTR IC ~~~~~~ ~~~:LY 6
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246B5988AA
REV, ,

REV, I

I s.

APPROVALS

HO.

WAMSLEY

SALEM. VA. USA

CONT. ON

SH.

5JA

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5J

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47

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48

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51

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52

52

53

53

54

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55

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56
57

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ISSUED

03-27-95
REV,

Ow

a::~
<
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45

112A53UJ ~112A57U)

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S. WAMSLEY

WADE

IPR1NTS TO

37796EIBI

ELEMENTARY DIAGAAM

GEN ERA L ELEe TRIC DIG-PROPEL

FIRST MAD fOR REO.


SOFTWARE NO.

TAANSFER
DRIVE SYSTEMS

SALEM. VA., USA

246B5988AA
CONT. ON SH.

5K

SH. NO.

5JA

MAR ION.ELSH.212781-4. SJ A

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g~,\. - 9Mfu.,
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58
59

(L02P]

REV. 2
ISSUEO
WADE BY

S.WAMSLEY

F
jREV. I

APPROVALS

05-11-95
rRIHTSTO

FIRST MAO[ FOR REO.

37796E161
SOFTWARE NO.

GENERAL ELECTRIC
DRIVE SYSTEMS

SALEM, VA. U.S.A.

R
S
T
ELEMENTARY DIAGRAM
MAGNETICS

24685988AA

ISH.HO.

~ ~!~~

- ~~i~
rr-""O-

CONT. ON SH.

sL

~~~~

5K

CODE NO.
Rs4

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51

60

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42

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24. 26. ~

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.....
a
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43
RS6

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40

CDB

", CfLT

:r:

38

CDB-Jl.6.5.J-,

36

~,~,K52

37

2.5K IDW
HDB

35

NOTE' SHEET SP SUPPL! EO BY MAR I ON

[ 9006G]
[L02B]

03-27-95
REV. 5

29
30

[~02P]

07-21-95
REV. "

26
27

DIPPER TRIP CONT.


J37

(5~29Al

24
25

32

[8G23]

CRX FUNCTION
OR

OH~

r---

23

SWING BRAKE
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58
59

20

31

C;,R

57

60

18

31~( 9f I DC]

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55

25

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52

19

28

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0
4Bf

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51

46f

[JAl1]

LE-~ART III

49
50

HOIST BRAKE
~AGNET VALVE

SRX FUNCTION

42H

(PBJ]
45

17

2.5K lOW

HT.
31

1
.

44

HT.

p9H

FINAL CRDWD L.S. FINAL RETRACT L.S.

43

16

HRX FUNCTION
OR
[JAill 1BP [7F 40Al

OH~

RSS

L.s. 30

o (4B]
TE
:
"

2.sK lOW

2.5K lOW

C~X

p9E

(P631

42

lOB

HT.

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3B

INITIAL
HT.
RETRACT L.S. 2.

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40

T ,

INITIAL
CROWD L.S. 2B

38

36f

[JJ9]

13
14

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VALVE

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30

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I 15 IS I
1[5~A331 '

28
29

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24
25

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02

05

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[9f34B I

14G

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(PI9]

17H

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19

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HBPS
170 -~-

17
18

HTB

LINE EXCITATION
07. 12

[7046.531

H~B

14

01

03

LINE EXCITATION AUX.


13,J4AIS,14BII.14CIS

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12

I'-C\J

2.SK lOW

LGX

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[7FOSLl 10F [BfOSLlI 00 [9FOSLl 10H

06

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07
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120 VAC

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MAR ION.ELSH,212781-4.5K

5K

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BI006008

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A

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0
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7A

07

r K04P I

04
05

01

02

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05
06

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[BF04CJ

07
OB

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09

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35

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10

I
I

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10

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12

12E

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15
16

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19
21

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20

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25
26

26
27 [ 04Al

27
FIELO LOSSI
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PROPEL MOTOR
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29E

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30

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29

29
30

31

32

31
32

33

33
34

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36

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1_1

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36

PROPEL MOTOR
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14.-l6.!.-l:!..i3

40

M.s. OFF NEUTAAL

HNS/RL Y4
(7E25 J

43

CNS/RL Y4

44

PNFI

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I
17E IBJ 460 [BdIBJ

46

end
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00

43

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44
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VOLTS> 575
46F

PROPEL MTR. FLO.


CONTROL -2
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OLJ.J
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0::
0

<:z

46

:::::E_

47

[BG46J

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45

47

a::

42

45

41

PROPEL MTR. FLO.


CONTROL -1
N44 .!i..1.2-

IBG53l

3B

40
41

:I:

37
39

42

35

PROPEL MTR.
THERMOSTATS
# I
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37J

39

4B

4B
49

HOC

51

[JA;J
I

SOD

[JAI6J
PCIAUX

52

[JA5IJ
OGL
CR3

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56

[14C37]

57

S30

54
55

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53

49

CDC

50

S7E

[JA53J

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CR3

LFL
CR4

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[14A37]

S7H

[7oo6C) -----<
[Boo6C]

59

60
A
REY. :I

REV. 2

07-21-95
~

ISSUED

03-27-95
REV. S

MROE8T

S. WAMSLEY

E
I~EY.

S7K

AUTO LUBE
FAUL T RELAY

56

21.. !1li

57

SOflllRREHl1,

GENERRL

ELECTRIC

OR]VE SYSTEMS

~~~

!~~ji

'"n.
0

MAGNET 1CS

~~~

<t
f-

ELEnENTRRY a I RGRRM

~8i,
~'g~

f-

59
60

FIRST nllOf fOR REO.

37796E I B1

f-

5B

05-11-95
l'RIHlSTO

II;

54

RPPROVRlS

~Cl~

;a!B?

55

A~R

S9G

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,";j;3~

53

RI L [l]

[57 J

~~

52

R510
2.5K, lOW

[14839J

:-::~

SO
51

RLFR

5B

REV.

co
co
lJ1

16

PROPEL BRAKE
CONTROL RELAY
10.-.12

12

PROPEL BRAKE []
MAGNET VAL VES

~~TI
(SJA32J

22

'PROPEL MOTOR OTEMP"

.v

~~

CONTROL TRANSFER SWITCH


BRAKE SET [l]
HTB DIG PROPEL
10
~rE CGFE "
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20

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03
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05

05
06

06

07

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08

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17

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19

19
20
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lc-Q-2 IS
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20

21
PCA2 ICGF

22
23
24
25

L2

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GNo
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29

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41
43
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07-21-95
03-27-95
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36

41

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54
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34

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05-11-95
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FIR5TnIlOEFDRREQ.

37796EI61
SOFTIIARENO.

ELEMENTARY DIAGRAM

Al'f'ROVflUI

GENERAL ELECTRIC
OR I VE SYSTEMS
SRLEM. VR.. USR

CROWD GEN. FIELD EXCITER

246B59BBAA
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MAR 1ON.ELSH .212781-4 .8A

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12

12

13

13

14

14

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16

16

17

17

18

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19

19

20

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21
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REY.4

ISSUED

REV. 5

nAOEeT

07-21-95
03-27-95
S. WAMSLEY

1
rEV.
05-IB-95

I~R'NT5 TO

Rf'I'RDVAlS
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37796EIBI
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CROWO/PROPEl
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246B59BBAA
tONT.ON SI!.

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BB

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43

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53
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510
70 +24V _

72 -24V _

55
56

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11
13
14
15
16
17
18
19
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73

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31
32
33

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59

60
B
REY, 3

HEV.2

07-21-95
~

ISSUED

REY.S

nAOfllY

s.

rEV.
I
05-11-95

FIRsrnADEFORREQ.
50FtIlRREHO.

GENERRL ELECTRIC
DRIVE SYSTEMS
SALEM, VA .. U,S.A.

24685988RR
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ELEMENTARY DIRGRRM

APPROVALS

37796E 1B1
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03-27-95

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57

37

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VAR.IB2

65 REFN _

4'

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37

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05

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20

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22
23
24
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32
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40
41

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16
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25
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30
31
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36

37

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50

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51

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52

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53

53

54

54

55

55

56

56

57

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8
REV.

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REV. 2

IssuED

03-27-95
REV. 5

f0

f-

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l~RIN'S TO

fIRsrnAOEfDRRECI.

37796E I B1
5DFTWRRfNIJ.

nAOfflT

S. WAMSLEY

Af'rRDYAL:I

05-11-95

GENERRL

ELECTRIC

OR I VE SYSTEMS

SALEM. VA .. U.S.A.

ELEMENTARY OlAGRAM
EXC OVERTEMPI
FAUL T CONTROL

246B59BBRR
eONT.OMSK.

BF

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07-21-95
REV. 4

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LEVEL SlG toIIRE.

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20

27

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25 /"Ii 13

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128

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302

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216
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LEGEND
AS------ARC SUPPRESSOR
CH------CRANKCASE HEATER
CIS-----CONTROL ISOLATOR SWITCH
CFCB----CONDENSER FAN CIRCUIT BREAKER
CMCB----COMPRESSOR MOTOR CIRCUIT BREAKER
CFC-----CONDENSER FAN CONTACTOR
CMC-----COMPRESSOR MOTOR CONTACTOR
EFLCB---EVAP. FAN LOW CIRCUIT BREAKER
EFHCB---EVAP. FAN HIGH CIRCUIT BREAKER
EFHC----EVAP. FAN HIGH CONTACTOR
EFLC----EVAP. FAN LOW CONTACTOR
FSS-----FAN SPEED SWITCH
HPS-----HIGH PRESSURE SWITCH
HTS1----HIGH TEMP. SWITCH 1
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HCL-----HEAT CONTACTOR LOW
HCH-----HEAT CONTACTOR HIGH
LLSV----LIOUID LINE SOLENOID VALVE
LDO-----LEAK DETECTOR OUTLET
LPS-----LOW PRESSURE SWITCH
MCS-----MAIN CONTROL SWITCH
PDR-----PUMP DOWN RELAY
PMCB----PRESSURISER MOTOR CIRCUIT BREAKER
PMC-----PRESSURISER MOTOR CONTACT OR
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VSS-----VENT SELECTOR SWITCH

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II MARK EACH END OF POWER CRBLES WITH R WIRE MARKER.

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COLOR TAPE: WHITE: SA3BR.SNHB
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3J nOUNT SHRl ON TOP OF SHR2 RNO HERTER COVER


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II - HS GEN(C
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BI006008

INSTRUCTIONS

CUSTOM 8000
HORIZONTAL INDUCTION
MOTORS
OPEN, DRIPPROOF OR WEATHER-PROTECTED WITH ANTI-FRICTION BEARINGS

TYPE I

DESCRIPTION
GENERAL
General EI ctric horizontal induction motors,
Fig. 1, are de igned and constructed of high-quality

materials for general use where operating conditions


are not extreme. Properly installed and maintained,
they will give long, trouble-free service.
These motors have received special inspection
during the manufacturing and assembly operations
to assure that all parts have been manufactured in
accordance with strict quality-assurance standards.

VENTILATION
These motors are designed with a self-ventilation
system which circulates ambient air through the
motor. Louvered openings in the end shields provide an entrance for cooling air at both ends of the
motor. The air passes through air deflectors to the
rotor fans. The fans blow a portion of the air
radially across the end turns of the stator coils.
The remainder enters the large ventilation openings in the rotor body and passes through the rotor
ducts, across the air cap, and exhausts from the
stator ducts. At this point, it rejoins the air circulated across the coil end turns and is directed out
of the air e~haust passages at the side of the frame.
Fig. 1.

ellS to II 8000, horizontal, open, dripproof,


or we ther-protected Type I induction
motor , with anti -friction bearings

weather-protected Type I motors are equipped


with a shaft seal on the drive end and have removable screens over all air openings.

RECEIVING, HANDLING, AND STORAGE


RECEI

AND STORAGE

The machine is shipped from the factory as a


complete unit re dy for installation and operation.
Each machine hould be carefully inspected upon
arrival. Any da age should be reported promptly
to the carrier a d to the nearest office of the General Electric Co pany.

Single-bearing machines are shipped from the


factory with spacers in the air gap and bracing on
the rotor to prevent move ment during transit. These
shipping braces and spacers must be removed before installing such machines.
In the event that the machine will not be put into
service immediately, certain protective precautions

The. instructions do or purport to CO"fI' .JI d.ils or tlMi.tion, in ~uipm.nt nor to pro.,idfl for rdry possible conting6ncy to btl met in conn:tion with installation, operation
or ".int.".nctI. Should fu her inform.tion be d.sirtJd or Ihou/~ /Mrricu", probl-.Jms .rl. which .,.. not COt/fired suffic;ttntly for the purclulser's purposes, the msttll' should be Ttlferred
to
Electric do Brezi S.A.

G.".,.,

BI006008

Custom 8000 Horizontal Induction Motors


should be taken to protect the machine while in storage. If at all possible, it should be placed under
cover in a clean, dry location.
However, during storage, windings should be
protected from excess ive moisture absorption by
some safe and reliable heating means.
Space
heaters, if supplied, or some other type of reliable
heating means should be used to always keep the
temperature of the winding a few degrees above the
temperature of the surrounding air. It is recommended that the machines in storage be inspected,
and the windings meggered at periodic intervals
and a log kept of pertinent data. (Refer to the section entitled "Insulation Resistance. ") Any significant drop in insulation resistance should be investigated.
During the time of manufacturing, testing, and
preparation for shipment, basic precautions are
taken by the factory to guard against corrosion in
general.

MENT SUCH AS PUMPS, COMPRESSORS


OR OTHER DRIVEN EQUIPMENT. IN
THE CASE OF ASSEMBLIES ON A COMMON BASE, LUGS OR EYEBOLTS PROVIDED ON THE MOTOR ARE NOT TO
BE USED TO LIFT THE ASSEMBLY
AND BASE BUT, RATHER, THE ASSEMBLY SHOULD BE LIFTED BY A SLING
AROUND THE BASE OR BY OTHER
LIFTING AIEANS PROVIDED ON THE
BASE. IN THE CASE OF UNBALANCED
LOADS (SUCH AS COUPLINGS OR OTHER
ATTACHAIENTS) , ADDITIONAL SLINGS,
OR OTHER EFFECTIVE MEANS SHOULD
BE USED TO PREVENT TIPPING. DO
NOT LIFT WHEN TEMPERATURE IS BELOW THAT ALLOWED BY WARNING
LABEL.
FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN DAMAGE
TO THE EQUIPMENT, INJURY TO PERSONNEL, OR BOTH.

Grease-lubricated machines have the bearings


packed at the factory and no further preventive
maintenance is required on the bearings during
storage.

HANDLING
WARNING:
LIFTING LUGS OR EYEIWLTS ON THE MOTOR ARE DESIGNED
FOR HANDLING THE MOTOR ONLY.
Tlmy ARE NO]' TO HE USED TO LIFT
TIm MOTOR FLUS ADDITIONAL EQUIP-

STORAGE
The machine should be stored in a clean, dry, indoor location. When storing out-of-doors in damp
locations, the machine should be enclosed in a
waterproof covering to prevent the entrance of
moisture.
If the purchaser has specified that the machine
be packaged for long-term storage, the package
should be left intact during the period of storage.

INSlALLAliON
UNPACKING
WARNING: INSTALLA TION SHOULD BE
IN ACCORDANCE WITH THE NATIONA.L
ELECTRICAL CODE AND CONSISTENT
WITH
SOUND
LOCAL
PRACTICE.
COUPLING, BELT AND CHAIN GUARDS
SHOULD BE INSTALLED AS NEEDED
TO PROTECT AGAINST ACCIDENTAL
CONTACT WITH MOVING PARTS. MACHINES ACCESSIBLE TO THE PUBLIC
SHOULD BE FURTHER GUARDED BY
SCREENING, GUARD RAILS, ETC. TO
PREVENT THE PUBLIC FROM COMING
IN CONTACT WITH THE EQUIPMENT.

FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN INJURY TO


PERSONNEL.

WARNING: IF IGNITABLE DUST OR LINT


IS PRESENT THE SURFACE TEMPERATURE OF SPACE HEA TERS, IF SUPPLIED, SHOULD NOT EXCEED 80 PERCENT OF THE IGNITION TEMPERA1'uRE. REFER TO SPACE HEATER
NAMEPLATE OR FACTORY FOR INFORMATION ON SURFACE TEMPERA1'uRE. DUST AND/OR LINT SHOULD
NOT BE ALLOWED TO BUILD UP
AROUND THE SURFACE OF THE SPACE
HEATERS.

FAILURE TO OBSERVE THESE PRECAUTIONS MA Y RESULT IN DAMAGE


TO EQUIPMENT, INJURY TO PERSONNEL, OR BOTH.
If a packaged machine has been exposed to low
temperatures, unpack it only after it has reached

BI006008

Custom 8000 Horizontal Induction Motors


the temperat e of the room in which it will be unpacked or 10 ated; otherwise sweating will occur.

ALIGNMENT AND DOWELING

Remove y shipping braces and replace the endshield bolts ( 4), Fig. 2.

Always align the machine accurately with th4


driven unit. When aligning with an adjustable bas4
for belt drive, allow for movement and locate thl
belt adjusting:"'screw head away from the driven unit

LOCATION
Install the machine in a well-ventilated area.
Make sure th re is clearance around the enclosure
to allow a nor al flow of air.
Avoid loca ions subject to excessive steam vapors, oil vap rs, chemical fumes, moisture, dirt,
dust, or lint.

WARNIN : INSTALLATION OF THE MACHINE


HERE HAZARDOUS. F LAMMABLE, 0
COMBUSTIBLE VAPORS OR
DUSTS
RESENT A POSSIBILITY OF
EXPLOS N OR FIRE SHOULD BE IN
ACCORD NCE WITH THE NATIONAL
ELECTR CAL CODE, ARTICLES 500503, AN
CONSISTENT WITH SOUND
LOCAL
RACTICES. EXTREME CARE
IS REQUI ED FOR MACHINES SUPPLIED
WITH AN EXPLOSION-PROOF OR DUSTIGNITIO
PROOF ACCESSORY DEVICE,
OR CON UIT BOX SINCE ANY NICKS OR
BURRS D RING DISASSEMBLY AND REASSEMB Y MAY DESTROY THE EXPLOSION PROOF OR DUST-IGNITION
PROOF EATURES.
FAILURE TO OBSERVE THESE PRECAUTION
MAY RESULT IN DAMAGE
TO THE QUIPMENT, INJURY TO PERSONNEL, OR BOTH.

MOUNTING
The foundat on of the motor must be sufficiently
rigid to minim ze vibration and to maintain alignment between t e motor and the load. When foundation caps and s Ie plates are used, they are designed
to act as space s between the true foundation and the
motor and must be evenly supported on the foundation.

NOTE: A
with the l

ays align the motor accurately


d.

After accur e alignment of the motor and the load


shafts, the bas should be grouted to the foundation.

After alignment, dowel pins should be inserte(


through the motor base into the foundation to main
tain the position of the motor if it becomes neces
sary to remove it. Dowel holes for this purpose arE
located in diagonally opposite feet. These hole~
should be drilled and reamed together with corres
ponding holes in the foundation and the dowel pim
inserted.

CAUTION: CARE SHOULD BE EXERCISED IN INSTALLING AND OPERA TING


THIS EQUIPMENT TO PREVENT DRIVEN
EQUIPMENT SUCH AS PUMPS, COMPRESSORS, HOISTS, ETC. FROM DRIVING THE MOTOR IN THE REVERSE
DIRECTION AND/OR ABOVE RA TED
SPEED.
WARNING: UNLESS OTHERWISE SPECIFIED, THE MOTOR IS DESIGNED TO
OPERATE CONTINUOUSLY ONLY AT
RA TED SPEED, AND IN AN EMERGENCY
OF SHORT DURATION AT THE FOLLOWING OVERSPEED:

SYNCHRONOUS
SPEED
RPM

OVERSPEED,
PERCENT OF
SYNCHRONOUS
SPEED

1801 and over

20

1800 and below

25

FAILURE TO OBSERVE THESE PRECA UTIONS MA Y RES UL T IN DA MA GE


TO THE EQUIPMENT, INJURY TO PERSONNEL, OR BOTH.

The power may be transmitted from the motor to


the load by direct coupling, belts, or chains. Special considerations should be observed with each
type of drive.

DIRECT COUPLING

Direct-connected motors may be coupled to the


load through flexible couplings. Accurate mechanical line-up is essential for successful operation.
3

BI006008

Custom 8000 Horizontal Induction Motors


Mechanical vibration and roughness during the
operation of the motor may be indications of poor
alignment. In general, line-up by straight edges
across, and a feeler gage between, coupling halves
is not sufficient. It is recommended that the line-up
be checked with dial indicators and checking bars
connected to the motor and load-machine shafts.
Threaded bolt holes (53) for vertical jacking are
provided in the base of the motor for convenience in
alignment. (Jacking bolts should not be used as
permanent supports. )
BElT DRIVE

To avoid overstressing the motor bearings and


belts or chains, use pulley sheaves or sprockets no
smaller than those recommended by the belt or chain
manufacturer and the General Electric Company.
V -belt Drive

Align the sheaves carefully to avoid axial thrust


on the bearings. Belt tension should just prevent
slippage when the motor is running at full load. Excessive belt tensions cause unnecessary loads on the
bearings. This maybe especially true on high-inertia loads where belts may be tightened to prevent
squealing and slipping during acceleration.
On
drives of this type, the belts should be allowed to
slip during acceleration to prevent the possibility of
overloading the motor bearings.
The pulley ratio should not exceed 8 to 1. The
tension ratio should be not less than 7 to 1. The belt
speeds should not exceed 5, ODD-feet per minute unless otherwise recommended by the manufacturer
of tne belt.
Flat-belt Drive

Arrange the motor and the load shafts so that they


are parallel. Belt tension should be just enough to
prevent slippage when the motor is running at full
load.
The distance between centers should be at least
2-1/2 times the diameter of the larger pulley unless
a belt-tightener adjustment is used. The pulley ratio
should not exceed 5 to 1. The tension ratio should
be not less than 4 to 1. The belt speed should not
exceed 5, OOO-feet per minute unless otherwise recommended by the belt manufacturer. If possible,
make the low side of the belt the driving side. Run
the grain, or smooth side, of the belt on the pulley.
Chain Drive

Align the sprockets and adjust the chain just


enough to permit a slight sag on the slack side. The
distance between the shaft centers should be not less
4

than the diameter of the larger sprocket plus the radius of the smaller one. Consult the chain manufacturer for maximum ratio, speed, and lubrication
of the chain.

POSITION OF CONDUIT BOX


If mounting conditions permit, conduit access
plate (47) may be relocated and the conduit box (52)
may be turned so that entrance can be made from
the top, bottom, or from either side.

WIRING AND GROUNDING


WARNING:
MOTOR
AND CONTROL
WIRING,
OVERLOAD
PROTECTION,
AND GROUNDING SHOULD BE IN ACCORDANCE
WITH
THE
NA TIONA L
ELECTRICAL CODE AND CONSISTENT
WITH SOUND LOCAL PRACTICES.

FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN DAMAGE


TO THE EQUIPMENT, INJURY TO PERSONNEL, OR BOTH.

Stator winding connections should be made as


shown on the connection diagram or in accordance
with the wiring diagram attached to the inside of
the conduit box cover.
The motor frame may be grounded by attaching
a ground strap from a known ground point to one of
the conduit -box bolts. One of the bolts is brass and
marked with a decal. Only the identified brass bolt
should be used for grounding.

VOLTAGE AND FREQUENCY


Check the motor nameplate for voltage and frequency values.
The frequency must agree with the value stamped
on the nameplate.
The voltage should correspond with that of the
line or be compatible with the system voltage, 1. e.,
440-volt motors are suitable for use on 480-volt
systems.
ALLOWABLE RANGE

The motors will continue to operate (but with


characteristics somewhat different from nameplate
values) if the voltage and frequency vary within the
following ranges:
Voltage - within plus or minus ten percent (10%)
of the values stamped on the nameplate

BI006008

Custom 8000 Horizontal Induction Nlotors


Frequency within plus or minus five percent
(5%) of the va ue stamped on the nameplate
Voltage and requency Together - within plus or
minus ten perc nt (10%) (providing frequency alone
is within plus or minus five percent (5%) of the
value stamped n the nameplate)

INS LATION RESISTANCE


If a motor as become damp in shipment or in
storage, it is dvisable to measure the insulation
resistance of he stator winding with a megger.

WARNING: BEFORE MEASURING INSULATION


MUST BE
WINDINGS
CONNECT
GROUND
REMOVE
STATIC C

ESISTANCE, THE MACHINE


AT STANDSTILL AND ALL
TO BE TESTED MUST BE
D TO THE FRAME AND TO
OR A TIME SUFFICIENT TO
LL RESIDUAL ELECTROARGE.

FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN INJURY TO


PERSONNE .

In accordan e with established standards, the


recommended
inimum insulation resistance for
the stator windi g is as follows:
R

KV

where R m = recommended mInimUm insulatior


resistance in megohms at 40 C of the entire stator
winding obtained by applying direct potential to the
entire winding for one minute, and
KV = rated machine voltage in kilovolts.

NOTE: See IEEE Recommended Practice


for Testing Insulation Resistance of Rotating Machines, Publication No. 43, for more
complete information.

If the insulation resistance is lower than this


value, it is advisable to eliminate the moisture in
one of the following ways:

1. Bake the motor in an oven at a temperature


not exceeding 90 C until the insulation resistance
becomes practically constant.
2. Enclose the motor with canvas or similar covering, leavin.g a hole at the top for moisture to escape. Insert heating units or lamps and leave them
on until the insulation resistance becomes practically constant.
3. With the rotor locked using approximately 10
percent of rated voltage, pass a current through the
stator windings. Increase the current gradually until the temperature reaches 90 C. Do not exceed
this temperature. Maintain a temperature of 90 C
until the insulation resistance becomes practically
constant.

OPERATION
STEPS

RIOR TO INITIAL START

1. Wherever possible, examine the interior of


the motor for oose objects or debris which may
have accumulat d, and remove any foreign material. (See "Ge eral Cleanliness" under "Maintenance". )

2. If possibl , turn the rotor by hand to be sure


that it rotates f ely.
3. Check all
diagram. Chec
nections for ti
become loosene

onnections against the connection


all accessible factory-made contness to make sure that none has
during shipment or storage.

INITIAL START
1. After inspecting the motor carefully, make the
initial start by following the regular sequence of
starting operations in the control instructions.

2. It is recommended that the motor be initially


started uncoupled from the load. Check the rotation. If it is necessary to change the rotation, interchange any two leads.

3. With the motor connected to the load, check


for satisfactory operation.
5

BI006008

Custom 8000 Horizontal Induction Motors

SUBSEQUENT STARTS
For subsequent starts, follow the sequence of
operations given in the control instructions.

JOGGING AND REPEATED STARTS


CAUTION:

REPEATED STARTS AND/OR


JOGS OF INDUCTION MOTORS GREATLY
REDUCE THE LIFE OF THE WINDING
INSULA TION. THE HEA T PRODUCED
BY EACH ACCELERATION OR JOG IS
MUCH MORE THAN THAT PRODUCED
AND DISSIPATED BY THE MOTOR
UNDER FULL LOAD.
IF IT IS NECESSARY TO REPEATEDLY
START OR JOG A MOTOR, IT IS AD-

VISABLE TO CHECK THE APPLICATION


WITH THE LOCAL GENERAL ELECTRIC
SALES OFFICE.

HEATING
Do not depend on the hand to determine temperature; use a thermometer. If there is any doubt
about the safe operating temperature, take the temperature of the part in question and confer with the
nearest office of the General Electric Company.
Give full details, including all nameplate information.

Overheating of the machine may be caused by


improper ventilation, excessive ambient temperature, dirty conditions, excessive current due to
overload or unbalanced a-c voltage.

REPAIR AND FAILURE PROCEDURES


REPAIR
Hepairs should be made only by qualified personnel using the materials and processes for which the
motor was designed. To protect the warranty during the warranty period, all repairs must be made
in a General Electric Service Shop or approved repair facility. Many repairs can be easily performed
with only assembly operations if General Electric
replacement parts are available. If major repairs
are undertaken (suchas rewinding a stator), proper
facilities should be available and suitable precautions observed.

WARNING: WHEN BURNING OFF OW


INSULATION MA TERIALS OR WHEN
WEWING NEAR INSULA TION DURING
REWINDING, ADEQUA TE VENTILA TION
MUST BE PROVIDED TO A VOID EXPOSING PERSONNEL TO NOXIOUS FUMES.
COMBUSTION OF EXHAUST FUMES
MUST BE COMPLETE AND ADEQUATELY VENTED TO THE OUTSIDE
ATMOSPHERE.
EXPOSURE OF PERSONNEL TO AIRBORNE INORGANIC FIBERS MUST BE
A VOIDED BY ADEQUA TE VENTILA TION
OR BY WETTING THE REMAINING INSULATION COMPONENTS FOLLOWING
THE BURNING OFF OF THE ORGANIC
MATERIALS.

FAILURE TO OBSERVE THESE PRECA UTIONS MA Y RES UL T IN INJUR Y TO


PERSONNEL.

FAILURE
WARNING: AN EXTREME OVERLOAD
OR ELECTRICA L FAILURE MA Y RESULT IN HEATING OR ARCING WHICH
CAN CAUSE THE INSULATION TO GIVE
OFF NOXIOUS FUMES. ALL POWER
SHOULD BE REMOVED FROM THE MOTOR CIRCUIT AS A PRECAUTION EVEN
THOUGH THE CIRCUIT HAS OVERLOAD
PROTECTION.
PERSONNEL SHOUW
NOT APPROACH THE MOTOR UNTIL
ADEQUATE
VENTILA TION OF THE
AREA HAS PURGED THE AIR OF
FUMES. WHEN COVERS OF A MOTOR
ARE REMOVED AFTER A FAILURE,
CARE SHOUW BE OBSERVED TO A VOID
BREA THING FUMES FROM INSIDE THE
MOTOR. PREFERABLY, TIME SHOUW
BE ALLOWED FOR THE MOTOR OR
GENERATOR TO COOL BEFORE ATTEMPTING ANY EXAMINATION OR REPAIR.
FAILURE TO OBSERVE THESE PRECAUTIONS MA Y RESULT IN INJURY TO
PERSONNEL.

BI006008

Custom 8000 Horizontal Induction Motors


WARNIN
WA TER SHOUW
NOT BE
APPLIE TO ANY ELECTRICALLY ENERGIZE EQUIPMENT BECAUSE ELECTRIC SH CK COUW RESULT IN SERIOUS OR FATAL INJURY. IN CASE OF
FIRE,
SCONNECT ALL POWER AND
USE A C RBON DIOXIDE EXTINGUISHER
TO QUE CH THE FLAME.
BEFORE
OPERATNG ANY MOTOR AFTER A
SUSPEC ED FAILURE, IT SHOULD BE
INSPECT V FOR DAMAGE.

GE
WARNIN : BEFORE INITIA TING MAINTENANC
ALL PO
CHINES A
CHINES
pAcIToR
TOR UN
DUCTOR
ALL TER
ING GRO
DUCTOR
HANDLIN
CONNECT
TIVE DE

PROCEDURES, DISCONNECT
ER SOURCES TO THE MAV ACCESSORIES. FOR MAQUIPPED WITH SURGE CADO NOT HANDLE CAPACIL DISCHARGED BY A CONIMULTANEOUSLY TOUCHING
NALS AND LEADS, INCLUDND. THIS DISCHARGE CONHOULD BE INSULA TED FOR
REPLACE GROUNDING
ONS, COVERS, AND PROTECCES.

FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN INJURY TO


PERSONN L.

Maximum e uipment availability and mlnImUm


maintenance c ts result from a carefully planned
program of in pection and maintenance. If it is
necessary to r pair, recondition, or rebuild these
motors, it is r commended that the nearest General
Electric Servic Shop be consulted. Factory trained
personnel, usi g factory methods, shop facilities,
and General El ctric renewal parts, are available to
service the equ pment day or night.

GENERAL CLEANLINESS
The interior and exterior of the machine shoull
be kept free from dirt, oil, and grease. Oily vapor
paper, or textile dusts may build up and block of
ventilation, leading to over heating of windings. Con
ducting dusts shorten creepage distance and pene
trate windings, causing short circuits and grounds
Hard, sharp dusts abrade insulation, and shorten it!
useful life as they are driven past vulnerable sur
faces by ventilation air. Cast-iron dust is a viciou~
enemy of insulation because it is magnetic and il
agitated by stray magnetic fields. Light, compara
tively harmless dusts can be blown out with lowpressure, dry air. Grit, iron dust, carbon, anc
copper dusts should be removed by suction. Vacuumhose tips for either pressure or suction should nol
be made of metal.

INSPECTION
Most motors have a two-piece end shield for
accessibility.
For special applications, such as belt drives, a
one-piece, solid end shield and bearing may be supplied with the machine.
Generally, direct-drive motors are arranged to
permit the removal of the upper half of the end shield
(18) from both ends of the motor for inspection purposes without disturbing the motor line-up.
Remove the bolts (24) holding the upper half of
the end shield to the frame. Remove the bolts (4)
holding the upper half to the bottom half of the end
shield, and the bolts (l) holding the end shield to the
inner bearing cap. Remove the screws (20) holding
the upper air deflector (19) to the ring (22) and disconnect the L-clamps joining the upper and lower
air deflectors. Remove the upper air deflector.
If further accessibility is desired, remove the
screws (23), rotate the ring (22), and lower deflector. Remove the screws (20) holding the lower de.flector to the ring. The lower air deflector can now
be removed.

In addition t the daily observation of the over-all


condition and 0 ration of the motor, it is recommended that a
neral inspection routine be established to check riodically the following items:

CLEANING INSULATION
GENERAL

1. General c eanliness
2. Insulation and windings
3. Lubricati n and bearings

To obtain a long life and satisfactory operation


of insulated windings, they should be kept reasonably
clean from dirt, oil, metal particles, and other contaminants. A variety of satisfactory and acceptable
methods are available for keeping equipment in a
7

BI006008

Custom 8000 Horizontal InductKm Motors


state of cleanliness that will result in longer life and
greater reliability. The choice of method will depend greatly on time, availability of equipment, and,
to some extent, on the insulation system.
WARNING: TO PREVENT INJUR Y TO
EYES AND RESPIRA TORY
ORGANS
SAFETY GLASSES AND SUIT.ABLE VENTILA TION OR OTHER PROTECTIVE
EQUIPMENT SHOUW BE USED.
VACUUM CLEANING

For removal of loose dust, dirt, and particles,


the use of suction is preferable to blowing out with
compressed air since there is less possibility of
damage to the insulation and less chance of getting
conducting or other harmful particles into areas that
may later result in damage during operation.
COMPRESSED-AIR CLEANING

Compressed air is effective and convenient for


removing loose dust and particles in otherwise inaccessible areas such as air ducts and between coils
at the end turns.

It is advisable to dry the windings, preferably in


a circulating-air oven, after the cleaning operation.
(See "Insulation Resistance". ) Other methods, such
as hot-air heaters, etc., are also satisfactory, but
care must be taken so that the temperature is 'within
the limits set in the "Insulation Resistance" section
of this instruction book.

Thorough dry-out is especially important with the


standard unsealed systems. The sealed systems will
normally return to a satisfactory level of insulation
resistance with several hours of air drying. If time
permits, however, it is desirable to bake the stators
to assure turn-to-turn dryness. For extremely dirty
conditions, where the methods mentioned above are
not sufficient, contact the nearest General Electric
Service Shop or the factory.
REVARNISHING WINDINGS

After several cleanings with water and detergent,


it may be necessary to revarnish the windings. The
following General Electric varnish treatments are
recommended for the various Class A and Class B
systems. These varnishes are available from the
General Electric Company Insulation Materials Department or General Electric Service Shop.
Stator, 0 to 6,000 Volts

CAUTION: C'ARE MUST BE TAKEN,


HOWEVER, TO MAKE SURE THA l' THE
AIR SUPPLY IS DRY AND THAT EXCESSIVE AIR PRESSURE IS NOT USED.
GENERALLY A PRESSURE OF NOT
MORE THAN:W PSI IS RECOMMENDED.

All systems, where baking is possible, are to


be treated with varnish No. 9522 or 9700 and baked
at 150 C for four hours. Where baking is not possible, treat with varnish No. 1202 and air dry.
Stator, 6,000 Volts and Up

CLEANING WITH WATER AND DETERGENT

This method is very effective in cleaning windings when used wlth a low-pressure steam jenny
(maximum steam flow 30 psi and 90 C).

Treat with No. 1202 varnish and air dry.

Rotors with Insulated Windings

Treat with No. 1202 varnish and air dry.


CAUTION:

TO MINIMIZE POSSIBLE
DAMAGE TO VARNISH AND INSULATION, A FAIRLY NEUTRAL NON-CONDUCTING TYPE OF DETERGENT, SUCH
AS DUBOIS FLOW, SHOUW BE USED.
A PINT OF DETERGENT TO 20 GA LLONS OF WATER IS RECOMMENDED.

If a steam jenny is not available, the cleaning


solution may be applied with warm water by a spray
gun. Tightly adhering dirt will require additional
agitation by gentle brushing or wiping. After the
cleaning operation, the windings should be rinsed
with water or low-pressure steam.

For special varnish applications, such as acid


resistant, abrasion resistant, exceptionally corrosive atmospheres, etc., contact the nearest General
Electric Service Shop or factory.

BEARING MAINTENANCE
One of the most important features in the successful operation of an induction motor is the
bearings.
The machines covered by these instructions are
supplied with anti-friction bearings.

BI006008

Custom 8000 Horizontal Induction Motors


A conscient ously applied program of preventive
maintenancew' laddyears of useful life to the bearings. For thi reason, the following instructions
are included.

REGREASING

TABLE 1
REGREASING INTERVALS

ANTI-FRICTIO

BEARING MAINTENANCE

Machines wth anti-friction bearings are shipped


from the fact ry with the bearings packed with
grease. li the
chines have been stored for a long
period of time, it is advisable to regrease the bearings before ope ation.
The grease sed as a lubricant in grease-lubricated anti-frict'on bearings does not lose its lubricating ability s ddenly, but over a period of time.
For a given be ring construction and assembly, the
lubricating abil ty of a grease with age depends primarily on the pe of grease, the size of the bearing, the speed t which the bearing operates, and the
severity of ope ating conditions. As a result, it is
not possible to accurately predetermine when new
grease must be dded. Good results can be obtained
if the general r commendations as stated in this instruction book re followed.
The primary function of grease is to supply the
essentiallubric tingoil from the sponge-like reservoir of its soap structure. Grease-lubricated antifriction bearin s consume only a small amount of
lubricant; howe er, this lubricant must always be
present to avoid rapid wear and bearing failure. To
obtain optimum results, the recommended grease
should be used, and regreasing should be in accordance with Table 1.

Type of
Service

Typical Example

Standard

One- or Two-shift
Operation

Severe

Dirty Location
High Ambient Temperature

Relubrication
Interval
1 Year
2 Months

The following procedure should be followed in


regreasing:
1. Wipe all the lubrication fittings clean.
2. Remove the relief plug and free the hole of
hardened grease.
3. With the machine running, add grease slowly
with a hand-operated pressure gun until new grease
is expelled through the relief hole. (li the fittings
are not safely accessible with the machine running,
grease may be added sparingly with the machine
at rest. )
4. Run the machine for about 20 minutes, with
the relief plug removed, to expel excess grease.
5. Clean and replace the relief plug.

GREASE RECO

CLEANING

In order to ssure proper relubrication of the


machine, regr ase with General Electric grease
No. D6A2C5 or grease meeting the following specifications:

Since the method of greasing anti-friction bearings tends to purge the housing of used grease, removal of all grease should be required infrequently.
Whenever the machine is disassembled for general
cleaning, however, the bearings and housings should
be cleaned of old grease by washing with a grease:dissolving solvent.

Worked penetraton
"
265-296
Oil viscosity, S U at 100 F . . . . . . . .. 400-550
Soap type . . ..
.Sodium or lithium
N-H bomb, mini um hours
for 20 psi drop at 210 F . . . .
750
Bleeding, maxi um weight %
in 500 hours at 212 F . . . . . . .
.
"
10
Rust inhibiting
Yes

NOTE: F ambient temperatures below


use a 1 w temperature grease, such
as General lectric grease No. D6A4.

oF

BEARING REPAIR AND REPLACEMENT

Even though high-quality design and workmanship are incorporated in a bearing, it sometimes
becomes necessary to remove it for maintenance.
It is for this reason that the following instructions
are included.
Care must be taken to avoid scratching or nicking the critical surfaces of the balls or rollers.
9

BI006008

Custom 8000 Horizontal Induction Motors

cap for burrs. It is important that these surfaces


be smooth.

Bearing Disassembly

Extreme care is required in the disassembly of a


machine for bearing removal. In addition, the surfaces of the shaft bearing fit and the bearing itself
must be protected during and after disassembly
operations.

NOTE: On motors with accessible or sPlit


end shields, it is not necessary to remove
the upper-half end shield from the lowerhalf end shield.
Bearings may be removed for cleaning or replacement by using the following procedure:
1. Remove the hex head bolts (1 and 3) holding the
inner bearing cap (12).
2. Remove the hex head bolts (24) holding the end
shields (18 and 10) to the frame (34).
3. Remove the end shields.

NOTE: On motors with an outboard slinger


(IS), it is necessary to remove the slinger
before removing the end shield.
4. Remove the bearing lock-nut assembly (14).
5. Remove the bearing (13) by using a puller or
by tapping against the bearing cap (12),
Bearing Reassembly

Cleanliness is important when working with bearings. Before reassembling a bearing, all bearing
and machined surfaces should be thoroughly cleaned
with a suitable solvent. Examine the machined fits
of the end shield, cartridge, slinger, and grease

Reassembly of the bearing should be performed


in the following manner:
1. Inspect the bearing housing and related parts
for foreign material. Clean if necessary.
2. The machined fits and critical surfaces of the
end shield, bearing housing, bearing cap and bearings should be free of all nicks, scratches or burrs.
If any polishing is done, care should be taken to
avoid a deposit of metal dust in and around the bearing assembly.
3. The internal surface of the bearing housing
should be coated with a thin film of the recommended
grease. The shaft and the shaft fit of the grease
housing and grease cap should also receive a very
light coating of the recommended grease. These
precautions, although not absolutely essential, will
guard against corrosion of the critical surfaces.
4. Heat the bearing in oil to a temperature between 50 C and 125 C (122 F to 257 F) and place it
on the shaft. Hold it against the shaft shoulder until
the bearing cools.
5. Replace the bearing nut and washer.
6. Procure a stud, 8 inches long, threaded on
one end (3/8-16 thread). Screw the stud into one of
the holes in the inner bearing cap to facilitate lining
up the bearing-cap holes with the holes in the end
shield.
7. All subsequent reassembly steps will be a reversal of the disassembly procedure.

OPERATIONAL DIFFICULTIES
Frequent careful inspection of machines during
operation is essential to detect any improper operation which may, in time, result in a serious failure.

Some operating difficulties which may occur, and


their causes, are given in Table 2 and shouldbe corrected as soon as discovered.

RENEWAL PARTS
HOW TO ORDER
When ordering parts, give a description and state
the quantity of parts del?ired. All orders for renewal
parts must include the nameplate rating and identification number of the machine. These are required
to identify every part of the motor.
10

STORAGE
OF RENEWAL PARTS
Renewal parts stocks should be stored in a clean,
dry place.

Custom 8000 Horizontal Induction BI006008


Motors

TAILE 2
TROUILE SHOOTING
Affected Part
Bearings
Bearing

Housin~

Insulation

Difficulty
Noisy - Rough

Misalignment
Damaged bearing

Overheating
(Temperature, when measured
by a thermometer at a point
on the bearing housing nearest
the bearing, is in excess of 60 C. )

Worn out or dirty grease


Insufficient grease
Excessive end thrust or
misalignment
Excessive loading condition

Low insulation resistance

Moisture, dirt, metal particles, or other contaminants on the insulated


windings
Power sources
Excessive temperatures
Mechanical damage
Voltage surges
Excessive vibration with
resultant mechanical
damage

or
Insulation failure

Motor

What to Check

Excessive vibration, noise

Misalignment
Uneven air-gap alignment
Settling of foundation
Parts rubbing the rotating
element
Sprung shafting
Balance

Failure of the machine to


accelerate

Wrong connections
Open circuits
Starting voltage
Excessive line drop
Excessive load
Mechanical obstruction

11

BI006008

Custom 8000 Horizontal Induction Motors

1
2
3
4
5

6
7

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27

12

End-shield bearing-cap screw


Greas e fitting
Bearing cap screws
Upper-half end-shield bolt
Drain plug
End-shield screen (when used)
End-turn bracket
End-turn bracket screw
Bearing insulation
Lower-half end shield
Lower-half air deflector
Inner bearing cap
Anti-friction bearing
Bearing locknut assembly
Slinger (when used)
Shaft
Key
Upper -half end shield
Upper -half air deflector
Air-deflector mounting screw
Slinger set screw (when used)
Air-deflector mounting ring
Air-deflector mounting-ring screw
End-shield bolt
Air-deflector mounting-ring bracket
Air-deflector mounting-ring-bracket screw
Rotor key

28

29
30
31
32
33
34
35

36
37
38

39
40
41
42
43
44
45
46
47
48
49
50
52
53
54

Locking nut
Fan set screw
Fan
End-shield gasket (when used)
Rotor winding
Rotor laminations
Stator frame
Dowel pin
Stator laminations
Stator winding
Cover gasket
Cover screw
Cover
Stator screen screw (when supplied)
Stator frame screen (when supplied)
Terminal plate screw
Terminal plate
Conduit-box cover
Conduit access plate screw
Conduit access plate
Conduit-box cover scr~w
Pipe tap for conduit
Conduit-box screw
Conduit box
Tapped hole for jacking
Dowel hole

BI006008

I--..ij...--+-----....
2--+-1------...~

3 - - - 1 - - 4 - -.....

4--1....

13

BI006008

40

38
39

-"

./>.

37
7

36

4342 414445

l\

35

49

----

t=-" ~-.x.

34

I I
5046 52

_.-----------

.~ P.~_~~~:::1r~~

--

33,

,~.

,y

4,

I
53 54

'f
If
~~

JJ'-r

I I I I

~"t, ..'l'0
_.~1 __ .1

I I I

--'.

~"

"

"

~--

~" ..,--~

.~"

~"

'-"--~

"""~,

'~

,,~

~
~,,--~

-""~ ~

[":~~

"

- ~

~~

II

12

13

14

15

--16

'_I

:-

--~17

21

18

19

'--22
'2G

24
-23

_-C:.~~~.-.~.

..,

BI006008

BI006008

GENERAL ELECTRIC DO BRASIL S.A.


SETOR DE EQUIPAMENTOS PESADOS
CAMPINAS - SP

MOTOR INSTRUCTIONS

GEH-2301 K
Supersedes GEH-2301.

BI006008

TRI!CI,AD@ HORIZONTAL, BALL BEARING,


POLYPHASE AND SINGLE-PHASE INDUCTION MOTORS
Frames 213-449

Typical Dripproof Alum num Motor

All Enclosures

Typical TEFC Motor

Typical Wound Rotor Motor

SAFE MOTOR OPERATION


direction of the lift must not exceed a IS-degree
angle with the shank of the eyebolt. Do not use
eyebolt in ambient below OF. At lower temperature, eyebolt could fail resulting in injury to
personnel and/or damage to equipment. Dropforged eyebolts per ASTM A489 or equivalent
must be used.

WARNING:

High voltage an rotating parts of electrical machinery can ca e serious or fatal injury. Its installation' op ation and maintenance should be
performed by q lified personnel only. Familiarization with NE
MG2 Safety Standard for Construction and G ide for Selection, Installation and
Use of Electri Motors and Generators, the National Electrica Code and sound local practices is
recommended.

Do not use motors with automatic-reset thermal


protection where unexpected starting of equipment might be hazardous to personnel.

For equipment overed by these Instructions, it is


important to ob erve safety precautions to protect
personnel from possible injury. Personnel should
be instructed to

Provide proper safeguards for personnel against


possible failure of motor-mounted brake, particularly on applications involving over-hauling
loads.

Avoid contac with energized circuits.

Do not change brushes on wound rotor motors or


any machine with any power connected to machine.

Disconnect a I power sources before attempting


maintenance or repair.

Avoid conta t with the start or run capacitors


in single-p se motors until a safe discharge
procedure s been followed.

Safe maintenance practices and qualified };ersonnel


are imperative. Before initiating maintenance procedures, be sure that all power sources are disconnected from the machine and accessories to
avoid electric shock and personal injury from rotating parts. If a high-potential insulation test is
required, procedures and precautions outlined in
NEMA Standards MGI should be followed.

and in accordance with prescribed


handling, lifting, installing, opintaining the equipment. Do not
lift motor an driven equipment with motor lifting means. rt eyebolts are used for lifting motors, they ust be securely tightened, and the

FAILURE TO PROPERLY GROUND MOTOR MAY


CAUSE SERIOUS INJURY TO PERSONNEL.
GROUNDING SHOULD BE IN ACCORDANCE WITH
THE NATIONAL ELECTRICAL CODE AND CONSISTENT WITH SOUND LOCAL PRACTICE.

Avoid conta
that shaft k
energized.

with rotating parts and be sure


is fully captive before motor is

These instructions do nof purport to cover all details or variations in equipment nor to provide for every possible contingency to be
met in connection
"th installation, operation or maintenance. Should further information be desired or should particular problems arise

which are not cover d sufficiently lor the purchaser's purposes, the molter should be relerred to the General Electric Company.

GENERAL _

ELECTRIC

BI006008

GEH-230J

Horizontal, Ball-Bearing, Polyphase Indudion Motors

INSTALLATION
LOCATION

Dripproof motors are designed for operation in


well-ventilated areas where the atmosphere is reasonably free of dirt and moisture. If stored, keep
motors in a clean, dry place.

under each nut or bolt head to get a secure hold on the


motor feet; or, as an alternate, flanged nuts or bolts
may be used. The recommended tightening torques
(for medium carbon steel bolts, identified by three
radial Hnes at 120 degrees on the head) are:
Bolt Size

MOUNTING

25
60
120
210

3/8
1/2

Totally enclosed motors are designed for operation where motors may be exposed to dirt, moisture
and most outdoor conditions.
Explosion-proof motors bearing the Underwriters' Laboratories label designating the motor
U/L Class and Group as defined in the National Electrical Code are designed for operation in areas
classified by local authorities as hazardous in accordance with standards set forth in that Code.

Recommended Toraue (Ft-Ib)


Minimum
Maximum

5/8
3/4

37

90
180
320

The application of pulleys, sheaves, sprockets


and gears on motor shafts is shown in NEMA MG114.06. The application of the V-belt dimensions to
alternating-current general purpose motors is shown
in MGl-14.43.a (see Table I). V-belt sheave pitch
diameters should not be less than the values shown
in Table I.

Mount motors securely on a firm, flat base.


Grout in larger motors, if necessary. Ball-bearing
motors, except vertical high-thrust motors, can be
sidewall or ceiling mounted. Ball bearing motors,
up to and including 360-frame diameter, can be
vertically mounted. The standard transition and/or
sliding bases are suitable for floor mounting. For
other locations, check the factory for base recommendations .

The power supply must agree with thenameplate


voltage and frequency. Motors will operate satisfactorily on line voltage within 10 percent of nameplate value or frequency within 5percent, anda combined variation not to exceed 10 percent.

Align motors accurately. For direct drive, use


flexible couplings if possible. For drive recommendations, consult drive or equipment manufacturers or the General Electric Company.

Dual-voltage motors can be connected for the


desired voltage by following instructions on the
nameplate or connection diagram inside the conduit
box cover.

Mounting bolts must be carefully tightened to prevent changes in alignment and possible damage to the
equipment. It is recommended that a washer be used

Wiring of motor and control, overloadprotection,


and grounding shall be in accordance with the National Electrical Code and local requirements.

TABLE I
V-BEL T SHEAVE PITCH DIAMETERS
Horsepower

3600
7 1/2-10
15
20-25

SYnchronous Speed RPM


1200
1800
5 - 7 1/2
10
15
20
25
30
40
50
60

3-5
71/2
10
15
20
25
30-40
50

900
2-3
5
7 1/2
10

75
100

12.5

40

75
60
50
100
75

60

125
100
150
125
200

If the wire size is selected from Table II, singlephase motor performance will not be adversely affected by voltage drop in the branch circuit.
?-.\

V-belt Sheave, Minimum


Diameter Inches
Narrow
Conventional
A,B,C,D.E
3V, .5V, 8V t
Pitch Diameter Outside Diameter
3.0
3.8
4.4
4.6
5.0
5.4
6.0
6.8
7.4
8.2
9.0
9.0
9.0
10
10
11.5
11
10.5

15
20
25-30

POWER SUPPLY AND CONNECTIONS

3.0
3.8
4.4
4.4
4.4
5.2
6.0
6.8
7.4
8.2
8.6
8.0
8.4
8.6
10
10.5
10
9.5
9.5
12
13.2

TABLE II
WIRE SIZES
Individual Branch Circuit for Single-Phase Motor

:Max.*
Motor

Minimum
Wire Gage Number for Branch
Circuit Lene:ths Indicated
0-50 Ft*
100 Ft
200 Ft

HP

Volts

Fuse
Amps

230
115

60
110

12
8

10
8

230

90

10

71/2

230

125

10

230

150

Maximum sheave width = 2(N-W)- 1/4". (N-W is approximate usable shaft length.)
tMaxlmum sheave wtdth = N-W.

* Values based on National Electrical Code.

BI006008

Horizontal, Ball-Bearing, Polyphase Induction Motors


THERMAL PROTEC TORS

The words "T~ermally Protected" on thenameplates identify r~otors having built-in protection
against overcurr nt.
(a) Manual re~et protectors are reset after the
motor coo s by pressing the external reset
button.
(b) Automatic reset protectors (no external button) reset automatically as the motor cools.
WARNING: l-r'HERE UNEXPECTED
STARTING WOULD BE HAZARDOUS TO
PERSONNEl, DO NOT USE AUTOMATIC
RESET PROTECTIONo

OPERATION
If the motor has been stored in a damp location,
dry out thorough y before operating. Do not exceed
a temperature of 85 C (185 F) in drying.

GEH-230J

Check the operating current against the nameplate


current. Do not exceed the value of nameplate amperes times service factor (if any) under steady continuous load.

MAINTENANCE
INSPECTION

Inspect motors at regular intervals, depending


upon service. Keep motors clean and ventilation
openings clear.
LUBRICATION

Ball-bearing motors are shipped with sufficient


grease for a long operating period (see Table III).
Relubrication at intervals consistent with the type
of service shown in Table III will provide the oil
and grease to give longer bearing life. Excessive or,
too frequent lubrication may damage the motor.
Relubricate with General Electric D6A2C 5 grease
for the best results, unless special grease is specified on the nameplate.

Operate nO-Iofld to check rotation and for free


running. To reVE rse rotation: three-phase, interchange two line I ~ads; two-phase, interchange leads
T 1 and T3; one-I hase, follow the connection nameplate or label on ~e motor.

Relubrication with the shaft stationary is recommended for safety and best purging of oldgrease.

Operate under load for an initial period of at least


one hour to obse rve whether any unusual noise or hot
spots develop.

WARNING: IF RELUBRICATION IS PERFORMED WITH THE MOTOR RUNNING,


STAY CLEAR OF ROTATING PARTS.

TABLE III
LUBRICA TlON REQUIREMENTS
Type of
Service
Easy

Typical Examples
Valve: ; door openers; portable floor sanders; motor
opera ng infrequently (one'hour per day).

HP
Range

Relubrication Interval
Horizontal
Vertical

1/2-7 1/2
10-40
50-150
200-350

10 yr
7 yr
4 yr
3 yr

Standard Machi ~e tools; air-conditioning apparatus; conveyorf , one or two shifts; garage compressors;
refrig ~ration machinery; laundry machinery;
textile machinery; oil well pumps; water pumps;
wood- working machinery.

1 1/2-7 1/2
10-40
50-150
200-350

7 yr
4 yr
1 1/2 yr
1 yr

3 yr
1 yr
6 mo
3 mo

Severe

Motor ~ for fans, M-G sets, etc., that run 24 hours


per da IY, 365 days per year; coal and mining machiner IY; motors subject to severe vibration; steelmills ~rvice.

1 1/2-7 1/2
10-40
50-150
200-350

4 yr
11/2 yr
9 mo
6 mo

Very
Severe

Dirty, vibrating applications; where end of shaft is


hot(pu mps and fans); high ambient temperatures.

1 1/2-7 1/2
10-40
50-150
200-350

11/2 yr
6 mo
3 mo
11/2 mo
6 mo
3 mo
2 rno
1 mo

9
4
4
3

mo
mo
mo
mo

--..:~

9 yr
3 yr
1 1/2 yr
9 mo

..

BI006008

GEH-2301

Horizontal, Ball-Bearing, Polyphase Induction Motors

Relubricate with the motor warm.


On drive end - Insert the lubrication fitting on motors with pipe plugs. Remove the other plug for
grease relief on all motors. Clean grease relief
opening of any hardened grease. Be sure fittings
are clean and free of dirt. Using a low-pressure
hand-operated grease gun, pump in clean recommended grease until new grease appears at the relief hole. After relubricating, allow the motor to
run for ten minutes before replacing relief plug.
On opposite drive end - For dripproof motors,
follow the same procedure as for the drive end.
For totally enclosed fan-cooled motors:

Frames 213-215- Remove caps on the


cover for access to
grease plugs. Follow
greasing procedure for
drive end.

fan
the
the
the

Frames 254-326 - Remove the hexagonal rod


through the fan cover for the
grease relief. Follow the
procedure for the drive end.
Insert the rod occasionally
to check for appearance of
new grease.
Frames 364-449 - Follow the procedure for
the drive end except that
the grease relief pipe extending through the fan
cover acts as a reservoir
for purged grease and
should be removed occasionally during regreasing.
Run the motor for 20 minutes after regreasing before replacing the pipe.
Motors not having pipe plugs or grease fittings
in bearing housings can be lubricated by removing
the end shields from the motor, cleaning the grease
cavity, and refilling the cavity three-quarters full
with recommended grease.
CAUTION: TO A VOID DAMAGE TO
EQUIPMENT,' REARINGS AND GREASE
MUST BE KEPT FREE OF DIRT.
EXPLOSION-PROOF MOTORS

The Underwriters' Laboratories label signifies


that a motor is designed and manufactured in ac-

cordance with U/L standards which require special


features for operation in hazardous atmospheres.
If these features are altered in any way so as not to
comply with the provisions of the U/L Inspection
and Label Service Manual, the motor should not be
classified as a U/L labeled motor and the label shall
be removed. To maintain explosion-proof features,
it is recommended that repairs be made by a service
shop or factories having the necessary data to maintain and inspect the U/L design features. Therefore,
it is recommended that repairs on such motors be
made in GE Service Shops having the information
and knowledge available to properly inspect the
motor.
NOTE: When thennostats are supplied in
explosion-proof motors, they must be connected in accordance with the connection
diagram furnished with the motor.

MOTOR WINDINGS

To clean, use a soft brush and, if necessary, a


slow-acting solvent in a well-ventilated room.

WOUND ROTOR MOTORS


(TYPES M and MR)
COLLECTOR RINGS

Before putting a wound rotor motor into service,


be sure that the collector rings are clean and have
a polished surface. The brushes should be set down
on the collector surfaces with a good fit.
The brushes should move freely in the holder and
at the same time make firm, even contact with the
collector rings. When installing a new brush, fit it
carefully to the collector ring. Be sure thatthe pigtail conductors are securely fastened to and make
good contact with the brush holders.
'~
MAINTENANCE

Collector rings, brushes, brush holders andbrush


studs should be examined for wear and dust accumulation at regular intervals. Ordinarily, the rings will
require only occasional wiping using a piece of
canvas or non-linting cloth. Do not let dust or dirt,
and particularly carbon dust, accumulate on the
brush holders, rings or the collector shell. Continuously rated wound rotor motors should be inspected every three months and short-time rated
motors every six months.

iENERAL ELECTRIC COMPANY, COMMERCIAL & INDUSTRIAL MOTOR DEPT., HENDERSONVILLE, TN 37075

GENERAL _
85 (3M)

ELECTRIC

BI006008

-.

GEMotors

Instru tions
Armored otors
Type MD 1JO
c

GEH-3258J

BI006008

GEH-3258J, Armored Motors, Type MD800

.-

SAFETY PRECAUTIONS
WARNING
High voltage and rotating parts can cause serious or
fatal injury. The use of
ctric machinery, like an
other utilizations of co
trated power and rotating equipment, can
ardous. Installation, operation, and maintenance of electric machinery
should be performed by qualified personnel, in
accordance with applicable provisions of the National Electrical
0
cal practice.
For equipmentcoveredb
instruction book, itis
important to observe safety precautions
rotect
personnel from po
injury. Among the many
considerations, pe
ould be instructed to:

v
en disconnected
ctrical power sources,
accessory devices associated with the work
have been de-energized.
If high potential insulation test is required, p
d
outlined in NEMAstan
M
"lIed.

Avoid by-passing or
safeguards or

Safe maintenance practices ~ith qualified personnel is imperative. Before starting maintenance procedures, be positive that:

operative any

Use proper care


ocedures in handr
lifting, installing, operating, and maintaining the
equipment.

Failure to pr
ground the frame of this
chine can
rious or fatal injury to personnel.
Grounding
e machine frame and structure
should be in a
ancewith the NationalE1ectrical
Code a
onsistent with sound l~cal practice.

These instructions do not purport to cover all details or variations in equipmentnor to provide for every possible
contingency to be metin connection with installation, operation, or maintenance. Should further information
be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes,
the matter should be referred to GE Motors - DM&G.

7993 General Electric Company

BI006008

Armored Motors, Type MD800, GEH-3258J

CONTENTS
SUBJECT

INTRODUCTION
RECEMNG, HAND ING AND STORAGE
RECEMNG
HANDLING
STORAGE
DESCRIPTION
CLASSIFICATIO S
MOTORBEARIN S
VENTILATION
INSTALLATION
LOCATION
PROTECTION
MOUNTING
ALIGNMENT
COUPLED DRIVE
INSTALLATION
VICE FOR MDT
TABLE MOTO S
OPERATION
INSPECTION BE RE STARTING
Bearings
Insulation
Commutator an Brushes
Connections
Shunt Field Exc tation
Protective Devic s
Space Heaters
Speed Limit De 'ce
Thermostats
Ventilation Syst m
General Mecha ical Inspection
Tightening Bolt dJoints
INSPECTION AFT R STARTING
Bearings
Noise and Vibra 'on
BEFORE PUTTIN MACHINE IN SERVICE
INSPECTION AFT R SHORT TIME
IN SERVICE
MAINTENANCE
PRODUCTIVE
NTENA"l>.JCE
MAINTENANCE PR CEDURES
REPAIR
FAILURE
DISASSEMBLY- H RIZONTAL MOTOR
Removal of Arm ture................................
Removal of Bear ngs
Removal of Shaf From Armature
Removal of Brus holder
Removal of Field Coils

PAGE

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5
5
6
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7
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8
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15
15
16
16
16
16
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21
21

SUBJECT

ASSEMBLY- HORIZONTAL MOTOR


Installing Field Coils (Armature Removed)
Assembly of Brushholder
Pressing New Shaft Into Armature
Replacement Bearings
Assembly of Bearings
Final Assembly of Horizontal Motor
DISASSEMBLY - VERTICAL MOTOR
Removal of Armature
Removal of Commutator End Bearing
Removal of Failed Drive End Bearing
ASSEMBLY - VERTICAL MOTOR
Replacement Bearings
Assembly of Commutator End Bearing
Assembly of Drive End Bearing
Final Assembly of Vertical Motor
BRUSH MAINTENANCE
COMMUTATION ADJUSTMENT
COMMUTATOR MAINTENANCE
Commutator Turning, Stoning, and
Sanding
Commutator Film Care
Commutator Check Chart
Commutator Clean-up by
Air-cure Method
Procedure
PINION AND COUPLINGS
Removal From Armature
Mounting Couplings, Pinions and
Brake Wheels on Shaft
Pinion, Coupling, and Brake Wheel
Mounting
RECONNECTION OF POLE FACE
ASSEMBLIES
INSULATION
TESTING METHODS
Visual Inspection
Insulation-Resistance Measurement..
CLEANING OF WINDINGS
FIELD SERVICE CLEANING
Dry Dusts
Oily Dirt
Drying of Windings
SERVICE SHOP CLEANING
LUBRICATION
Armature Bearings
Frequency of Lubrication
RENEWAL PARTS

PAGE

21
21
21
27
27
27
27
29
29
31
31
31
31
31
32
32
33
33
34
34
36
36A
37
37
37
37
37
38
39
40
41
41
41
42
42
42
42
43
43
44
44
44
46

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

LIST OF ILLUSTRATIONS
FIG. NO.
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig.7A
Fig.7B
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24

PAGE

Shaft and Bearing Seal


Type MD808 Bearing Parts
Type MD820 Through MD826 Section
Type MDP828 Section
Type MD808 With Top Half Opened For Removal of Armature
Compensating Winding Connections At Frame Split
Drive End Brazed Pole Face Connections
Commutator End Brazed Pole Face Connections
Typical Bolted Pole Face Connection
Removal ofInner Race of Bearing With Puller
Shaft Removal
Pressing in New Shaft MD802 Through MD818
Pressing in New Shaft MD820 Through MD828
Typical Section View of Bearing Assembly. Types MDV81 0 Through MDV818 Vertical Motors
Type MDV820 Thru MDV824 Section
Micrometer Depth Gage Being Used To Measure Pinion Advance
MDT Drive End Bearing
MDP804 Through MDP808 Motors, Exploded View - Horizontal
MDV804 Through MDV808 Motors, Exploded View - Vertical
MDP810 Through MDP818 Motors, Exploded View - Horizontal
MDV810 Through MDV818 Motors, Exploded View- Vertical
MDP820, Exploded View - Horizontal
MDP822 Motors, Exploded View - Horizontal
MDV820, MDV822 Motors, Exploded View - Vertical
MDP824 Motors, Exploded View - Horizontal
MDV824 Motors, Exploded View - Vertical

9
17
18
19
20
22
23
24
25
26
28
28
28
29
30
40
45
50
52
54
56
58
60
62
64
66

LIST OF TABLES
TABLE NO.

Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12

Typical Weights
Speed Limit Device - Maximum Current Ratings
Thermostat - Maximum Current Ratings
Bolt Tightening Torque Values - Metallic Parts
Bolt Tightening Torque Values - Non-Metallic Parts to Metallic Parts
Commutator Condition vs. Recommended Remedy
Coupling Hub or Pinion Mounting Data
Coating Material
Effect of Temperature on Insulation Resistance
Bearing Greases
Bearing Lubrication Data
Metric Conversion Factors

Suggested Maintenance Schedule


Grading of Commutation
Troubleshooting Guide

PAGE

5
10
10
11
12
36
39
41
41
44
45
48
14
35
47

BI006008

Armored Motors, Type MDBOO, GEH-3258J

covers the MD800 line ofArmored

installation, operation and maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the
purchasers' purposes, the matter should be referred to
GE Motors - DM&G.

RECEIVING, HANDLING
AND STORAGE
RECEIVING
The equipment should be placed under adequate cover
immediately upon receipt as packing coverings are not
suitable for out-of-doors or unprotected storage. This
includes adequate protection from construction dirt,
during and after installation.
Each shipment should be carefully examined upon
arrival. Any damage should be reported promptly to the
carrier and to the nearest office of GE Motors.

HANDUNG

These instructions do ot purport to cover all details or


variation in equipmen nor to provide for every possible
contingency or hazar to be met in connection with

Motors can be lifted byusing hooks or slings in the lifting


lugs on the frame. These lugs are designed to safely carry
the weight of the whole machine. Blowers should be
protected with spreader bars if necessary. Ventilating
hoods may have to be removed to clear hooks. Do not lift
the machine by the shaft extensions. (Refer to the
Typical Weights, Table 1.)

TABLE 1
TYPICAL WEIGHTS*
FRAME SIZE

802
803
804
806
808
810
812
814
816
818
820
822
822X
824
824X
826
828

POUNDS
MATURE
ONLY
COMPLETE MOTOR
A

160
210
290
370
540
720
960
1440
2030
2630
3040
3850
4240
4650
5430
8050
11060

550
780
960
1300
1820
2480
3310
4620
5840
7730
12100
15200
15940
19100
20600
25000
39100

KILOGRAMS
ARMATURE ONLY
COMPLETE MOTOR

75
95
130
170
245
325
435
655
920
1195
1380
1745
1923
2110
2463
3650
5020

250
355
435
590
825
1125
1500
2100
2650
3500
5490
6700
7230
8660
9344
11340
17740

*Approximate weigh s for typical motors in each frame size.

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

STORAGE
If a machine, or any part of a machine, is not installed
immediately, it should be stored in a clean, dry place and
protected from variations in temperature, high humidity, and dust. Ifpossible, sudden changes in temperature
and humidity should be avoided. If the temperature of
the storage room varies to such an extent that the
windings and coils are exposed to moisture condensation, the machine should be protected by a safe, reliable
heating system such as space heaters, which will keep the
temperature of the machine slightly above that of the
storage room. Brushes should not be allowed to remain
in contact with the commutator during prolonged storage, otherwise corrosion may occur and later result in
flat spots on the commutator, vvith corresponding poor
and destructive commutation.
Ifthe machine has been exposed to low temperatures for
an extended period of time, unpacking it before it has
reached room temperature will cause it to sweat.
The presence of moisture on the internal machine parts
can cause electrical failure ofinsulated windings and/ or
mechanical failure of highly stressed armature glass
banding.
All exposed machined steel parts are coated with a rust
preventive before shipment. These surfaces should be
examined carefully for signs of rust and moisture, and
recoated if necessary. Once started, rust will continue if
the surface is recoated without first removing all rust and
moisture. Rust may be removed by careful use of fine
abrasive paper. Slushing compound can be removed by
using a solvent such as mineral spirits.

B.
C.

in well
Take necessary pnecauu'::ms
fire or explosion hazards.

DESCRIPTION
The Type MD800 mill motor series is a complete line of
motors, ranging in size from 5 HP to 2,000 HP. They are
designed for use as steel mill auxiliaries and for driving
power shovels, cranes, hoists, bridges, etc.
Basically the design is the same for all types and sizes,
requiring only slight modifications for each particular
application. The frames are the horizontal split type with
lifting lugs provided on the top half to facilitate installation and removal. On the smaller sizes, horizontal Types
MD802 to MD812, the top half is hinged to the bottom
half. On the larger sizes of horizontal motors and all
vertical types, the top half must be completely removed
for inspection, removal, or repair of the armature.
The armature is a complete unit assembly which may be
lifted out of the bottom half of the frame, complete with
bearing housing and bearing assembly. This facilitates
the replacement ofa defective armature in the shortest
possible time, in case of failure or breakdown. All standard motors are equipped with a tapered shaft extension
at both ends, with a key, nut, and lock washer at each
end.

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

CLASSIFICATI
The different types 0 motors for each particular horsepower rating are dete mined by the system ofventilation
used and the metho of mounting the motor in service.
The types in general use are:
TypeMD

Horiz ntally Mounted, Enclosed


Horiz ntally Mounted,
Free-Ventilated
Horiz ntally Mounted,
otor-Mounted Blower Unit

Type MDV -

Vertic lly Mounted, Motor-Mounted


B ower Unit

Type MDP -

Horiz ntally Mounted, Protected,


S If-Ventilated
Horiz ntally Mounted, Protected,
Free-Ventilated
Horiz ntally Mounted, Protected,
M tor-Mounted Blower Unit

Type MDT -

Horiz ntallyMounted,TotallyEnclosed,
Slow Seed, Waterproof Features.

SuffixAE

.dth solid cylindrical roller bearth ends.

Suffix AA -

Single idth solid cylindrical roller bearing pi ion end. Single row ball bearing
comm tator end.

MOTOR BEARIN S
Standard horizontal ill motors are furnished with
single width solid cylin rical roller bearings. These bearings are supplied wit a single-lipped inner race and
double-lipped outer r e with the rollers and roller cage
retained with the oute race. Armature endplaywith two
roller bearings ranges from 7/64" to 11/64". If these
motors are to be opera dother than horizontal, a thrust
bearing is required at e commutator end ofthe motor.
Suffix "AA" after the m tor frame size identifies that the
motor is equipped wit a thrust bearing at the commutator end.

VENTILATION
The basic frame desi for each motor size provides the
necessary openings fo self-ventilation, totally enclosed
operation, force-venti tion, or external blower unit
ventilation.
By the addition or om'ssion ofa fan, baffle and covers
over the proper openi s, each motor can be converted
from one type to anot er.

In a totally enclosed operation, all ofthe frame openings


are closed with solid covers and gaskets, to prevent the
entrance of outside air into the motor. The fan continuaUyrecirculates the air inside the motor which is isolated
from the outside atmosphere. This type is used in wet or
dusty locations where the surrounding air would prove
injurious to the motor windings and thus affect the
operation of the motor.
The self-ventilated protected type motor has deflection
hoods assembled over the upper fan end openings to
prevent extraneous objects from dropping into the
motor. Guards or screens are also bolted to the other
openings for the same purpose. Cool air is drawn into
the motor through openings at the commutator end of
the frame by the armature fan. The air passes over and
inside the commutator, circulates between the field
coils, flows over and through the armature, and is finally
expelled by the fan through openings in the frame at the
drive end of the motor.
The MD totally enclosed force-ventilated motor has a
rectangular opening in the bottom of the frame on both
the commutator and drive ends of frames 802 through
818 only. Either ofthese can be used for the air inlet. The
air discharges through the upper end openings (on the
end opposite the air inlet) . These openings are covered
with special deflection hoods which have hinged flaps
inside them. The hinged flaps swing open to allow the air
to escape when the motor is being ventilated, and swing
closed by gravity to keep out dirt when the ventilation is
shut off. All other frame openings are closed with solid
covers.
The MDP protected force-ventilated motor has the same
air inlet as the MD totally enclosed force-ventilated
motor. However, in this enclosure, the frame openings
in the drive end are covered only with guards so that
there are more air outlets.
When air is to be blown into the end opposite the
commutator, the armature fan must be removed since it
will impede proper air flow.
Motors may also befurnished with a blowerunitmounted
on the frame. This blower unit is driven by a separate
motor mounted on the mill motor. Filters can be supplied with the blower unit if desired, and can be added
at any time to a blower supplied without filters. Air
outlets are arranged as described above for either the
MD totally enclosed force-ventilated motor or the MDP
protected force-ventilated motor.

BI006008

GEH-3258J, Armored Motors, Type MD800

INSTALLATION
WARNING: Installation should be in accordance with the National Electrical Code and
consistennvith alllocal codes. Coup'
It,
and chain guardsshould beinstalled
rotec
. accidental contac
vmg parts.
chines accessible to the public
be further guarded byscreening, guard
etc., to prevent the public from coming
contact with the equipment.

WARNING: Disconnect power before touching any internal part. High voltage may be
present even when the machine is not rotatd excitation supply,
ing. If used .vith a r
disconnect all AC line connections to the
excitation source. With other excitation supplies, disconnect all DC field connections.

LOCATION
Motors should be installed where they will be readily
accessible for inspection and maintenance. Clean, dry
air should be available for proper ventilation of machines which are notequipped for operation with filters,
or for separate ventilation from a good source. It is
important for all machines that the external openings
for ventilation are not obstructed in any manner that
might limit the free passage of air.

PROTECTION
CAUTION: Windings, commutators, brush
riggings, and bearings should be carefully protected during installation to avoid damage
from paint spray, weld splatter, welding rod
butts, or metal chips from files and grinders
which would fall onto the motor. Metal particles which lodge in windings can cause either
immediate or premature failures. Paint or oil
on commutators can be detrimental to good
commutation.

MOUNTING
Motors should be mounted on rigid and solid foundations. Hold-down bolts should be inspected regularly
and kept tight. The feet of the machine may be doweled
or blocked to the foundation plates or base when alignment procedures are completed.

ALIGNMENT
CAUTION: Be sure to align or check alignment carefully. Misalignment can cause excessive vibration and damaging forces on shafts
and bearings. Time taken to assure good alignment ",ill be returned in reduced downtime.

COUPLED DRIVE
When a motor and a driven unit together have four or
more bearings, flexible couplings should be used to
facilitate alignment. Three-bearing construction requires
a rigid coupling. Careful alignment of machines when
using either solid (rigid) or flexible couplings is essential to prevent excessive vibration, hot bearings, or shaft
failures.

INSTALLATION ADVICE FOR MDT


TABLE MOTORS
CAUTION: Operatingconditionswhere highressur
erand mill scaledirectlystrike
af
al must be avoided. In
or the bearing assembly
can be proVl
by installing a collar over the
upling hub as shown in Fig. 1. The collar is
esigned to have a close-run'
clearance
with the outside diameter of t
aring cartridge. Physical barriers can also be installed to
provide increased protection for the bearing
assembly. The need for additional protection
is best determined by the mill builder and
customer, who have knowledge of the motor
environment. Precautions taken to protect
e motor bearings from contamination will
dividends in increased bearing life and
downtime for the motor.

OPERATION
WARNING: High voltage electric shock can
cause serious injury. Disconnect power before
touching any internal part. High voltage may
be present even when the machine is not
rotating. Ifused with a rectified power supply,
disconnect all AC line connections to power
supply. "Vith other power supplies, disconnect
DC line and field connections. Also disconnect power from auxiliary devices.

BI006008

Armored Motors, Type MD800, GEH-3258J

FRAME

SIZE
802
21

4,~oo

4.499
~,soo

803
804

.449

S,SCO

806
808
810

31

812

5,449
(.,,'<SC
(",<'40
7,"2, SO
7."2.45
8,000

7,930
8,75"0
8,,~6

4-, $:'0

5$""30
5,S~O
(","2~"

7, '2.<:>0
8()~o
8,l~O

10

"B" 000 DIA.


.010
COLLAR
" "DIA. REF.
RG. CTG.

4.
10.
16.
17B.
20.
21.
31.
36.
39B.
150.

BEARING SEAL - OUTER


SHAFT
PINION NUT
LOCKWASHER
COUPLING - CUSTOMER
COLLAR (INSTALLED OVER CUSTOMER COUPLING)
ROLLER BEARING
BEARING CARTRIDGE
THRUST COLLAR - OUTER
MAGNET FRAME

Fig. 1 Shaft and Bearing Seal


t~ry readings. Persistently low readings may be caused by
dIrt or metal chips imbedded in the sheet insulation or
insulated bolt assemblies.

Insulation

INSPECTION B

ORE STARTING

These inspection pro edures should be followed before


starting the machine D r the first time, after an extended
shutdown, or after a teardown for extensive maintenance or repair.

Bearings
Ball or roller bearings re greased at the factory and will
need no attention u til relubrication is necessary as
suggested in the Main enance section.
Make sure that a grease plugs are tight.
The bearings on the MD828 are insulated from
ground.
To preclude the possi ility of the shaft operating at a
potential above grou d, the bottom bolt on the drive
end bearing assembly' utilized as a grounding bolt. To
check the insulation r sistance, remove the grounding
bolt and measure th shaft to ground resistance. If
readings are less than 2 ,000 ohms, the exposed surfaces
of the insulation may b coated with oil and dirt causing
a short. Cleaning these surfaces should produce satisfac-

Take and record megger readings to determine if moisture or dirt are present on winding surfaces. The readings for indoor storage should be taken monthly. Any
downward trend of the megger readings indicates appropriate maintenance steps are required. (Refer to the
Insulation Resistance Measurement and Cleaning of
Windings section of this Instruction Book.)

Commutator and Brushes


Brushes should be worn in to ,have at least 85 percent
contact over the brush surface and continuous contact
from heel to toe. The commutator surface and undercut
mica should be clean and free from dirt, grease, paint
spots, or brush dust.
Check all brushes to be sure they are free to move in the
holders. All springs should be down and latched. Brush
pigtail connections should be tight and the pigtails
should not interfere with the action of the spring or
brush, and should not contact any object that does not
operate at brushholder potential.

Connections
All terminal connections should be checked against the
motor's connection diagrams to be certain that the
polarity or direction of rotation will be correct.

BI006008

GEH-3258J, Armored Motors, Type MD800

Speed Limit Device

See that bolted connections are tight, adequately insulated, and that proper clearances exist between conductors of different polarity and between conductors and
ground. Bolted connections of flexible cable should be
insulated.

The mechanical speed limit device is factory adjusted to


trip at 115 percent ( 2 percent) of rated top speed and
requires manual resetting.

Shunt Field Excitation

Both normally open and normally closed contacts are


present and have current ratings as in Table 2.

For many MD motor applications, it is common practice


to leave the shunt fields excited while the motor is in a
standby mode.
The shunt fields for the shunt, compound, and stabilized shunt motors have the capability of being energized continuously at standstill with rated voltage without exceeding rated temperature rise. Motors applied
with field forcing must have cooling air supplied when
the fields are overexcited. In the event ofloss of cooling
air, the shunt field excitation must be reduced to rated
or below. It is recommended the air supply be interlocked to provide this protection.
MDP motors used on excavators are normally applied
with field forcing on a duty cycle basis. It is important
that the blowers be on and running in the proper
direction when the fields are energized. Self-ventilated
excavator motors, when at standstill, must have the
excitation reduced to approximately 60 volts on the
nominal 72 volt field.

Protective Devices
WARNING: See that all protective de1ilC<~S
erspeed devices, bearing temperature re, etc.) are connected and ,~ill functi
properly. Be Sure all coupling guards,
protectors, grounding connectors, covers, and
other safety devices are properly attached.

Space Heaters
Space heaters are furnished in machines when ordered.
They should be energized with the correctAC voltage as
shown on the nameplate.
WARNING: The
ace of a space heater
block becomes h
en the heater is energized. The temperature rise above the ambient temperature may be as high as 400C.
Avoid touching heater blocks when heaters
have been recently energized to preventburns.
Also ignitable dust or lint should not be allowed to collect around the surface of the
heaters to prevent fire or explosion.

10

TABLE 2
SPEED LIMIT DEVICE - MAX. CURRENT RATINGS
NORMALLY OPEN OR CLOSED CONTACTS

115 VAC

230 VAC

120 VDC

240 VDC

3.0 amps

1.5 amps

2.5 amps

0.8 amp

Thennostats
The thermostat is a protective device. It is not intended
to limit motor loading or provide normal insulation life.
When supplied, it is mounted in contact with a commutating coil, which is the only accessible part of the
armature circuit. Since factors such as shaft speed, ventilation (blower or shaft fan) , current ripple (SCR phaseback), and short time overload affect the temperature
relationship between the armature and commutating
field, complete protection from all conditions resulting
from overtemperature is not possible. The device is
especially useful in guarding against loss of normal
ventilation air, high ambient temperature, and prolonged operation of self-ventilated motors at very low
speeds.
Thermostats may be used in alarm or relay circuits
within rating limits shown in Table 3.

TABLE 3
THERMOSTAT - MAXIMUM CURRENT RATINGS
NORMALLY OPEN OR CLOSED CONTACTS

LOAD 1125 VAC 1250 VAC 1600 VAC

I 30 VDC

DO NOT USE ABOVE 600 V AC or 30 VDC

5 amps
1amp
Resistive 5 amps 2.5 amps
i*'lnductive 3 amps 1.5 amps 0.5 amps 1.5 amps
*Suitable for Pilot Duty only (Relay coils).

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

TABLE 4
BOLT TIGHTENING TORQUE VALUES - METALLIC PARTS

Wrench
Size

Thread
Sizes
UNC-2A)

Hex Head C1 C5
Medium Carbon
Steel (Elect.
Connections,
Main Pole Bolts)

Hex Head C1 F5A 1


Non-magnetic
Steel
(Comm. Pole Bolts
MD 820-828)
TORQUE

7/16
1/2
9/16
3/4
15/16
1-1/8
1-3/16
1-1/2

1/4-20
5/16-18
3/8-16
1/2-13
5/8-11
3/4-10
7/8-9
1-8

Lb.-Ft.

Newton-Metres

Lb.-Ft.

Newton-Metres

7-9
13-17
24-30
60-75
120-150
210-260
320-400
460-580

9-12
18-23
33-40
80-100
160-200
280-350
430-540
620-790

5-6
9-11
16-20
35-45
72-90
100-125
155-195
210-260

7-8
12-15
22-27
49-61
98-120
135-170
210-265
285-355

Tightening Bolted Joints


WARNING: The mostats automatically reset
after the motor h. s cooled somewhat. In order
to prevent prope ty damage or injury to personnel, the contr I circuit should be designed
to prevent the aut )matic starting of the motor
when the thermo tat resets.

Ventilation System
See that blowers or ce tral systems are ready to supply
cooling air. Air filters s ould be in place. Blowers should
be checked for correct rotation.

General Mechanic. 1 Inspection


Check the inside of th( machine for tools, metal chips,
or any other foreign n aterial that may have accumulated during storage 0 installation. Make sure that all
rotating parts have encugh clearance from any stationary parts. Turn the ma hine over by hand, if possible,
and check for scrapin~ noises or any other signs of
mechanical interferen e. Check the tightness of the
bolts in the feet, coupl ngs, frame split, bearing housings, and any other bol s that may have been disturbed.

CAUTION: Special instructions apply to


boltedjoints from "Z" vintage vertical motors
in frame
through MDV808. For "Z
vintage" motors identified by "Z" in the model
list, refer to Instruction Book GEH-4246. Special instructions also apply to "Z"vintage horizontal excavator MDP806 through 812 motors
per GEH-4287.
Since loose bolts can cause both electrical and mechanical failures, all bolts and nuts must be kept tight. Maintenance schedules must include the checking of bolt
tightness. Table 4 gives the torque values to be used in
this maintenance procedure.
The information in Table 4 applies to all bolted joints
except when non-metallic parts (e.g., fluid bed parts,
polyester glass moldings) are boIted to metallic parts.
Here, lower torque values as listed in Table 5 are recommended to prevent parts from fracturing.

11

BI006008

GEH-3258J, Armored Motors, Type MD800

TABLE 5

(2) After 24 hours of service is complete, all main and


commutating pole bolt torques should be checked.

BOLT TIGHTENING TORQUE VALUES NON-METALLIC PARTS TO METALLIC PARTS

(3) After three months of service, again check all main


and commutating pole bolt torques.

Wrench
Size

Thread
Size

7/16
1/2
9/16
3/4
15/16

1/4-20
5/16-18
3/8-16
1/2-13
5/8-11

Hex Head C1C5 Medium


Carbon Steel (Yokes,
Brush Studs, Coil Supports)
Lb.-Ft.

Newton-Metres

5-7
7-9
13-17
24-30
60-75

7-9
9-12
18-23
33-41
80-100

The following precautions which apply to the tightening


of bolted joints should be observed in maintenance
procedures:
(1) Use a torque wrench for tightening only. When
necessary to loosen bolts, use another type ofwrench.

(4) Then, every six months or as often as experience


dictates, check all main and commutating pole bolt
torques.
NOTE: It may be difficult to use a torque
wrench on some pole bolts due to machine
location or mounted accessories. A good
method of checking the torque on these bolts
is to first get the feel of the desired torque with
a torque wrench on an accessible bolt. Then,
immediately check the difficult bolt using a
normal wrench with approximately the same
lever arm. Most mechanics will come within 10
percent of the desired value.

INSPECTION AFfER STARTING


The following items should be checked after the machine is running:

(2) The pressure bearing surfaces and the threads of


nuts and bolts should be clean, dry, and free from
oil and grease when torqued to the values given.
Oiled threads require that torque values be reduced 10 percent.
(3) When initially tightening a bolted joint, the final
turn must be tightened with the torque "'Tench to
obtain an accurate setting.
(4) In checking the tightness ofboltedjoints, the torque
wrench should be applied at the higher value of
torque given in the Tables to ensure adequate
tightness.
Loose pole bolts will cause serious failures on industrial
equipment. Even though all of these pole bolts are
torqued to the specified values during manufacture,
they must be checked on site periodically. Experience
has shown that bolted joints are subject to loosening
during shipping. Experience has also shown that both
vibration and heating and cooling of boltedjoints cause
them to loosen.
For these reasons, the pole bolts should be checked
according to the recommendations below:
(1) Before start up, make a visual inspection and spot
check ofmain and commutating pole bolt tightness
with a torque wrench.
12

Bearings
Place thermometers on all bearing housings so that
bearing temperatures can be watched for a few hours.
Ball or roller bearing housing temperatures should be
no more than 2S'C (45'F) above room temperature or a
maximum of 6S'C (149F). Higher temperatures than
this indicate trouble. Check alignment and lubrication.
Do not overgrease.

Noise and Vibration


Check for unusual vibration or noises that might indicate rubbing or interference. New machines may smell
warm or have the odor of varnish , but should not smell
scorched.
Vibration of new machines should not exceed 0.002"
(.05 mm.) at the bearing houses. The most likely cause
of vibration in new machines is misalignment due to
improper installation, loose foot bolts, uneven shimming under feet, or damage to the machine during
shipment or installation. Curren t ripple due to rectified
power supply may also be a source ofvibration and audio
noise.

BI006008

Armored Motors, Type MD800, GEH-3258J

GMACHINE
Run at light loads r at no load for a few hours to
determine that no u usual bearing temperatures occur,
that no localized ele trical heating results, and (in the
case ofmachines wi unseated brushes) that the brushes
get the proper fit. Be sure that any carbon dust resulting
from brush seatings i cleaned up before full-load operation. Check for satis actory commutation when load is
first applied.

INSPECTION
IN SERVICE
Mter a machine has een operating for a short time, an
inspection should be made to ascertain that there have
been no changes sine installation. Check for increased
vibration, signs of c nge in alignment or foundation
settling, bolts that ay have loosened, rubbing parts,
loose connections, a d worsened commutation. Take
the proper steps to c rrect the trouble.

that maintenance operations which do not more than


pay for themselves are notjustified. Such a case would be
where more money is spent on the maintenance than
would be saved if the equipment were not maintained
and allowed to fail.
Contact your nearest GE Service Shop or I&SE office to
get printed material describing ways of setting up a
Productive Maintenance system.
Productive Maintenance as applied to MD800 Armored
Motors would mean:
(l) Making good records of machine data and setting
up a means of recording maintenance performed
and measurements taken.
(2) Establishing a routine ofmeasurements to be taken
and inspection operations to be performed. Without other experience to guide you, follow the suggested maintenance schedule given later. Experience can be quickly built up by performing the
inspections and measurements called for. These
records will show you whether or not various components of the machine change quickly or slowly.
Maintenance schedules can then be re-adjusted as
this experience dictates. Making more frequent
and more elaborate inspections at first and carefully recording results will give a feel for the important items and the timing of critical inspection
items. Set up a program to balance between spending more on maintenance and inspection than a
failure would cost.
In some cases, it is less expensive and will do no harm to
repair or replace a part after it wears out rather than
maintain it regularly. Equjpment the size and value ofan
MD800 Armored Motor will justify a certain amoun t of
routine maintenance.
Accurate records will help form your judgment of what
is important and will also show gradual aging of the
insulation, wear of brushes, loosening offastenings, and
roughening of the commutator. These records will also
point out the approaching need for repair or replacement of components.

Productive Maintenan e goes a step beyond preventive


maintenance techni ues. Productive Maintenance
means that maintenan e should pay for itselfin terms of
less downtime, mone saved in repairing equipment,
and more total prod ction for each dollar spent on
maintenance operatio s. Productive Maintenance means

The Suggested Maintenance Schedule on the next page


shows a suggested schedule of routine maintenance
operations and measurements. A time schedule is given
which may be modified as a record of experience is built
with this equipment in particular applications. Motors
on continuous process lines will have more operating
hours than intermittently run machines and will need
more frequent attention.
13

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

SUGGESTED MAINTENANCE SCHEDULE


Adjust this schedule as necessary. Be guided by your records. They will show when more or less attention is justified.

COMPONENT

INSPECTION OR MAINTENANCE OPERATION


MONTIll..Y

BEARINGS

Make sure that grease or oil is not leaking out of the bearing housings. Ifany leakage
is present, correct the condition before continuing to operate.

Ball and Roller

Listen to a few bearings on a sampling basis. Bearings that get progressively noisier
will need replacement at the next shutdown. Regrease if called for under Frequency
of Lubrication.

BRUSHES

Check the brush length. Replace when the brush wear marker on the pigtail reaches
the top of the brush box. Inspect for worn or shiny brush clips, frayed or loose
pigtails, chipped or broken brushes, and check for indications of overheating of the
brush or pigtail at the socket. Remove a few brushes to check the brush-commu tator
contact face. Burned areas indicate commutation troubles. Loosen each brush in its
holder. Blowout the area of the brushholder and brushholder stud insulation with
clean, dry air to get rid of brush dust. Wipe brushholder stud insulation to remove
contamination.
W4

:.

,.,

c,.

'"

rrnid ... r.t

)~

78
V1

'7
.f

.~.

COMMUTATORS

Check the commutator for roughness by carefully feeling the brushes with a fiber
stick.]umping brushes give advance warning ofa commutator going rough. Observe
the commutator for signs of threading. (Refer to the Commutator Check Chart,
CEA-70S3 which is included as part of this Instruction Book.) If threading is getting
worse, take action; threading healed over - OK. Check for excessive commutator
wear rate, streaking, copper drag, pitch bar-marking, and heavy slot bar-marking.
Commutator should not have more than 0.0025" (.06 mm.) total indicator runout
or 0.0002" (.005 mm.) bar-to-bar steps.

INSUlATION

Perform a visual inspection. (Refer to the Insulation section of this Instruction


Book.)

MECHANICAL
Air Filters

If supplied with motor, keep in good working order. Replace when necessary.

Bolts

Perform visual observation for loose bolts, loose parts, or loose electrical connections. Check pole bolt torque. (Refer to Tables 4 & 5 for correct torque values.)

Noise and Vibration

Check for any unusual noise, vibration, or change from previous observations.

EVERY SlX MONTHS


BEARINGS
Ball and Roller

Listen to all bearings.


(Continued on next page)

14

BI006008

Armored Motors, Type MD800, GEH-3258J

S GGESTED MAINTENANCE SCHEDULE (CONT'D)


COMPONENT

INSPECTION OR MAINTENANCE OPERATION


EVERY SIX MONTHS (Cont'd)

COMMUTATORS

Check risers for cracks and dirt. If there are cracks, also check end ofshaft keyway
and shaft fan. (Cracks in this area mean extreme torsional vibration in system.)
Dirt should be cleaned out of the risers to maintain good ventilation.

INSUlATION

Measure one-minute insulation resistance. (Refer to Insulation.) Compare with


records. Wipe deposits from brushholder stud insulation and commutator
creepage path. Remove heavy deposits from around the field coil connections
where grounding might occur. Blow deposits out of the commutator riser area
with clean, dry air. Blowout any blocked ventilation openings in windings. Make
visual inspection for signs of overheating (dry, cracked, "roasted-out" insulation
and varnish).

MECHANICAL
Bolts

Check all electrical connections for tightness. Look for signs ofpoor connections
(arcing, discoloration, heat) .Adjust inspection period to suit experience. Inspect
foundation for signs of cracking, displaced foot shims; check foot bolts for
tightness. Check frame-split bolts, brushholders, brushholder studs, bracket
bolts, etc., on sampling basis. Check all coupling bolts. Check pole bolt torque.
(Refer to Tables 4 and 5 for correct torque values.)

Shaft

Check corners of exposed end of shaft keyway for cracks (due to extreme
torsional vibration). If there are cracks, check fan and commutator risers.
Check for clogged screens, louvres, filters, etc.

Ventilation
Vibration

MAINTEN

Check for excessive vibration (more than 0.002" to 0.003") (.05 mm. to .08 mm.)
thatwiIl indicate change in balance or alignment. (Refer to Noise and Vibration.)

CE PROCEDURES

REPAIR
Repairs should only e made by qualified personnel
using the materials an processes for which the motor
was designed. To prot ct the warranty during the warranty period, all repai must be made in a GE Service
Shop or approved rep 'r facility. Many repairs can be
easily performed with nly assembly operations, if GE
replacement parts are available. If major repairs are
undertaken (such as r winding an armature), proper
facilities should be av Hable and suitable precautions
observed.

WARNING: Exposure ofpersonnel to airborne


inorganic fibers must be avoided by adequate
ventilation or bywetting the remaining insulation components follo'\\'ing the burning off of
the organic materials.

15

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

FAILURE
WARNING: An extreme overload orelectrical
failure may result in heating or arcing, which
can cause the insulation to give off noxious
fum
powe
removed from the
or or gener
it as
caution
though the cIrcuit has over!
protection. Personnel should not approach the
motor or generator until adequate ventilation
of the area has purg the air offumes. 'Wilen
covers of a motor
rator are removed
after a failure, care
ld be observed to
avoid breathing fum
m inside the motor
or generator. Preferably, time should be
allowed for the m
or generator to cool
before attempting an xamination or repair.

WARNING: Water
not be applied to
anyelectricallyenergrze equipment, because
electric shock coul
suIt in serious or fatal
injury. In caseoffir
ectall power and
e a carbon dioxid
isher to quench
the flame. Before
'ng any motor or
generator after a su
d failure, it should
be inspected for
. Remove covers and
make visual inspection of brushes, commutator, connections, andwindings. Electrical tests
of each winding to check for open or short
circuits or grounds should be made. Any arc
damage should be cleaned up and repaired as
necessary. Brushes rna
d reseating before
operation.

DISASSEMBLY - HORIZONTAL MOTOR


Clean exterior before starting disassembly.
Refer to Fig. 2, which is a typical longitudinal section
through the armature and bearings of the horizontaltype motors.
Figs. 3 and 4 show typical longitudinal sections through
the armature and bearings ofthe MD820 through MD828
horizontal-type motors.
In these motors, the armature, (with bearings and bearing housings assembled) forms a complete unit assembly which can be readily removed or installed in the
frame assembly. The correct bearing alignment is maintained by the mounting bolts. The bolts secure the
bearing housings, which have machined surfaces as part
of the frame.
16

Removal of Armature
CAUTION: Safe practices for lifting and handling equipment should be followed. Hoists
and slings should be ofadequate capacity and
in good repair. (Refer to Table of W
Table 1.)
In the smaller sizes, Types MD802 through MD812, the
top half of the frame is hinged to the lower half. Therefore, it is only necessary to open it to remove the armature. (Refer to Fig. 5.) In the larger sizes, the top half
must be disconnected, unbolted, and lifted off before
the armature can be removed. On all units, care should
be taken so that the bearing cartridge does not slide off
the shaft during handling.
(1) Remove the bolts which clamp the two frame halves
together and the bolts which clamp the bearing
housings to the top frame half. Remove the brushes
from the holders to prevent brush breakage.
(2) On motors with hinged frames, hoist the top frame
halfrotating it on the hinge approximately 90, and
secure itin this position. On motors without hinged
frames, disconnect the external cable connections
between the two halves of the frame and hoist the
top frame half directly up and then away from the
motor.
(3) If the armature is to be removed, remove the bolts
which hold the bearing housings to the bottom half
of the frame, loop a rope sling around the two shaft
extensions, and carefully lift the armature avoiding
damage to field coils and other parts. Place the
armature on a support to the shaft, bearing housings, or core to hold it off the floor.
The MD820 through MD828 motors are designed with
compensatingwindings. Before removing the top halfof
the stator frame, it is necessary to disconnect the compensating or pole face connections, bus ring connections, and brush rigging yoke internal to the stator
frame. For a typical view of electrical connections at the
frame split, refer to Fig. 6.

Removal of Bearings (Refer to Fig. 2)


(1) The bearing housing assembly with outer race and

rollers ofthe bearing can be readily pulled offofthe


shaft for inspection or disassembly. Note that these
roller bearings have a double lip on the outer race
and a single lip on the inner race, which must be
assembled on the shaft with the single lip on the
armature side. This permits the roller assembly to
be pulled off of the inner race without any further
disassembly.

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

36

34----4;;..;

39----

.,
31

910
10. SHAFT
16. PINION NUT
17A. LOCKWASHER

31.
34.
36.
39.
910.
150.

BEARING
BEARING CAP
BEARING CARTRIDGE
THRUST COLLAR
CAP SCREW
FRAME

(Photo No. MG5295)

Fig. 2 Type MD808 Bearing Parts


(2) To remove the be ring assembly, pull the bearing
cap and cartridg assembly, including the outer
race and'rollers, f om the shaft.

Care should be taken not to damage the commutator


shell insulation.

Removal of Shaft From Annature


(3) Heat the thrust c llar and the inner race of the
bearing to appro 'mately 100C and remove from
the shaft, using a uller which engages on the end
of the thrust collar (Fig. 8 illustrates the method of
using the puller.)

The armature core and commutator are pressed on the


shaft. Ifit becomes necessary to replace a shaft, remove
the bearings as described earlier. Remove the fan hub in
a similar manner. Then, obtain a steel pipe or sleeve
which will just fit over the shoulder on to the shaft at the
drive end and long enough to press the armature core

17

BI006008

GEH-3258J, Armored Motors, Type MD800

55

32

56.~i
I
EJ\l. '"

53

1r=J

MD826 ONLY
73A
DRIVE END

COMMUTATOR END

32
40

15

1.
2.
4B.
4C.
5A.
6.
6A.
7D.
9A.
10.
12.
12A.
12B.
12C.
15.
16.
17B.
31.
32.
34.
36.
39.
40.
42.
50.

Armature
Armature Coil
Armature Banding End Turns (CE)
Armature Banding End Turns (DE)
Armature Coil Support - Molded (CE)
Armature Core
Armature Core Key
Armature Baffle (MD824 Only)
Equalizer - Molded
Shaft
Commutator
Commutator Segment and Insulation
Commutator Shell
Commutator Banding
Pinion Key
Pinion Nut
Pinion Lockwasher - Bent Type
Bearing
Bearing Bracket
Bearing Cap
Bearing Cartridge
Thrust Collar
Grease Fitting
Pipe Plug
Brush

53.
55.
56.
57.
57B.
57D.
58.
70.
73A.
75.
116.
117.
150.
151.
153.
502.

900.
901.
902.
903.
904.
908.
909.

Brushholder Yoke
Brushholder Stud
Brushholder Stud Insulation
Brushholder
Brushholder Spring
Brushholder Mounting Bolt
Brushholder with Support
Comm Coil and Pole Assembly
Main Field Coil and Pole with Bars
Pole Bolts
Cover, Side Drive End
Cover, Top Comm End
Frame
Frame Split Bolt
Shaft Thimble
Pole Face Connections
(Miscellaneous Parts)
(Not Standard Renewal Parts)
Armature Flange (CE)
Armature Flange (DE)
Armature Flange Key
Armature Lamination
Armature Banding Groove Lamination
Bearing Bracket Split Bolts
Comm Pole Shim

Fig. 3 Type MD820 Through MD826 Section

18

....
<.0

;:,

en
ell

N
00

;;g

'C
ell

CQ

!!

SHAn.ofl

~__

SPACER RIN"

_ __

1__

ARN FLANGE (C.E.)

..

.-,1';

AIR DUTLn

-I

-<j,\

I:

~.'.J _

:
i

-=-

~ -III IR_
1: __
_ -"

'j__

,-,

pc

.>....

..

__

-- - -

ORE

-A'M""" C'CKU

SPI" Bf'GBR

II

f (I

'"BOLT

- ~r "~:;~, I::,"'
,~'"
1J- i 1- --j('''''"'"' ',m
II
r
I!
' 1)~ G~~V~D

.-

Coce

lx--..::r-"' ",""""

-1- 1

. . - .

-- - :

MA
(
MA.. 'N. POLE ;;COll
MAIN pO"L1. \ . " .

':~.. ""' \\ "


,__ fJ~ij?,~i~'-illll~I~>
'-~1'.m ,*" 'i/ ~c,'jil-C,,-------9(~K~
c"~~I'~~([
------;.c--t'---- ~--=-:;::=-.=--=-~r=-= I:;. __ --__~~.(L"
-.: :. --- J---U.. J~
~ ::r:~:VRE

~ ~.>//;.~>~>
~:.>:J-:",._-------~----\ ~(CRE[NC.OV[R~
if'
""''''''1 --.

(;:--,

> -

I,
/ /

-r--

/,
-

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00

--..-

=.

:&1

ci-\:~ __ ---_---'~AIN

'-[/__ -COMM

JC'-. l.JVI

"r

/;>-.",

PocE

r~
~j 1J'4l;~]=---~--GOMM COIL

!__/~ T J.[1 I/;~::~:::;,,,,


POLE

BLOWER

1-1 ~_
ITj~ ~'""""

.. ~ r

1- - -I

}:.

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t..

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Cil

BI006008

BI006008

GEH-3258J, Armored Motors, Type MDBOO

(Photo No. MG5292-1)

Fig. 5 Type MD808 With Top Half Opened For Removal of Armature
20

BI006008

Armored Motors, Type MD800, GEH-3258J


and commutator off of the shaft. Support the armature
on this pipe so that the pressure is exerted on the shaft
at the commutator nd. Protect the end of the shaft
when pressing. (Ref~ r to Fig. 9.)
The pressing tonna~ e for shaft removal will normally
range between 10 tOilS (9000 kilograms) and 200 tons
(180,000 kilograms). It is likely that damage may result
to the commutator ~ nd shaft extension in this operation. Usually the shaf is being replaced so this damage
is of no concern. If equired, the damage to the shaft
threads can be minirr ized by using a shaft nut to distribute the load.
Heating of the arma ure in an oven to approximately
150C before pressin will usually reduce removal tonnage to be ,vithin the above range.

(2) Assemble the pole piece and coil assembly into the
frame and secure it with bolts through the frame. It
is recommended that new lock washers be used on
the pole piece bolts when reassembling the field
coil in the frame. Draw the bolts up tight to seat the
pole piece in the position on the frame. For motors
with compensating windings, Fig. 7 illustrates the
brazed type connections. Fig. 7B illustrates how to
assemble the bolted type pole face connections.
(Refer to the Reconnection of Pole Face Assemblies section for connection and post treatment of
pole face windings.)
(3) Tie all cables into neat sturdy bundles. Tie cable
bundles to cable anchors in the frame so that
bundles are suspended securely in position. Locate
cable bundles away from sharp corners, moving
parts, brush rigging, and hand hole openings.

Removal of Brusl:lholder
Each brushholder is individually bolted to a support
which is bolted to he motor frame. To remove a
brushholder, disconr ect the brush pigtail and loosen
the bolt sufficiently tc remove the brushholder.

(4) Insulate all internal bolted coil connections as


described below:
A)

Apply a small amount of insulating putty as


required to smooth sharp corners and fill all
voids to round out the joint for easier taping.

B)

Apply tape. Several lengths may be used, but


start each length so that one or more full turns
of tape secure previous tape end. Joint insulation taping should completely cover the bolt,
nut, washers, terminals, etc., extending approximately 1/4" to 1/2" (6-13 mm.) onto the
cable and/or lead insulation, resulting in at
least 3 tape thicknesses minimum coverage.

C)

Paint the tape surface with fast-drying insulating varnish.

Removal of Field ~oils


(1) Lift or remove th top halfof the frame as described
under Removal ( f Armature.
(2) Disconnect the cabIes to the coil to be removed,
and take out the Dolts which hold the pole piece to
the frame. Remc ve the complete pole piece and
coil assembly. In order to remove some coil and
pole assemblies, t is necessary to remove the adjacent poles first. he armature must be removed
from the frame fc r proper access to coils and poles
in the bottom fra me half.
(3) When removing cpnnections and coils, take care to
prevent bumpin~ coils and terminals which can
result in damage to the coil coating. Reassemble
bolts, washers, and nuts on coil terminal.
NOTE: Do not di lodge or otherwise damage
insulation washer molded between coil terminals. Do not lose nsulation bolts for field coil
terminations.

ASSEMBLY - HOIUZONTAL MOTOR


Installing Field Co Is (Armature Removed)
(1) Always assemble he bottom center commutating
coil first, since it cannot be installed if the two
adjacent exciting poles are in the frame.

Assembly of Brushholder
(1) Install the brushholder on'the support as high offof
the commutator as possible. Tighten the bolt sufficiently to hold the brushholder in place until after
the frame is closed on the armature. Remove brushes
from the brushholders to prevent brush breakage
when the armature is installed.
(2) Mter the frame halves have been assembled in
place together with the armature, release the bolt
and adjust the brushholder to provide .070" to .080"
(1.8 to 2.0 mm.) clearance between the face of the
brushholder and the commutator surface. An .075"
(1.9 mm.) thick non-metallic shim may be used.
Tighten the bolts securely.

21

BI006008

GEH-3258J, Armored Motors, Type MD800

Fig. 6 Compensating Winding Connections At Frame Split

22

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

DRIVE END BRAZED POLE FACE CONNECTIONS

14

Ref.
No.

Description

POLE FACE CONNECTIONS


0001 CONN,PF
0002 CONN,PF
0003 CONN,PF
0004 CONN,PF
0011 CONN,PF
0012 CONN,PF
0013 CONN,PF
0014 CONN,PF

Ref.
No.

14

Description

SPLIT CONNECTION PARTS


0025 PLATE-END
0026 SPACER
0027 CONNECTOR
0028 BD CONN
0029 PLATE-END
0031 TUBING,INSUL
0032 TUBING,INSUL
0033 SCREW,CAP
0034 SCREW,CAP

Fig. 7

DEl ILAREA B
SPLIT

ONNECTION

DETAIL AREA A
SPLIT CONNECTION

@32

23
Fig. 7 Drive End Brazed Pole Face Connections

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

COMMUTATOR END BRAZED POLE FACE CONNECTIONS


Ref.
No.

Description

POLE FACE CONNECTIONS


0005 CONN,PF
0006 CONN,PF
0007 CONN,PF
0008 CONN,PF
0010 CONN,PF
0011 CONN,PF
0012 CONN,PF
0013 CONN,PF
0014 CONN,PF
0015 CONN,PF
0016 CONN,PF
0017 CONN,PF
0018 CONN,PF
0019 CONN,PF
0020 CONN,PF
0021 CONN,PF
0022 CONN,PF
0023 CONNECTOR
Ref.
No.

Description

PF CONNECTION SPACER PARTS


0035 SPACER,PF
0036 SPACER,PF
0040 TUBING,INSUL
0041 TUBING,INSUL
0042 SCREW, CAP
0043 SCREW, CAP

DETAIL AREA C
PF CONNECTION SPACER

DETAIL AREA D
PF CONNECTION SPACER

24
Fig. 7A Commutator End Brazed Pole Face Connections

BI006008

Armored Motors, Type MD800, GEH-3258J

(Photo No. MG5269-1)

10

. . .'-1---13

"==':.:.-=,~==2~
4

5
9

14

11

12

BOLTED POLE FACE CONNECTOR ASSEMBLY


1
2
3
4
5
6
7

CONNECTORS
INSULATION WASHER
POLE FACE BAR
NUT
STUD
TEE NUT
INSULATION

8
9
10
11
12
13
14

SPRING WASHER
FLAT WASHER
BOLT
LOCK WASHER
NUT
SPACER
TUBE

NOTE: Parts 4,5 and 6 to be tightened to 17 pound foot (23 newton-metre) torque.

Fig. 7B Typical Bolted Pole Face Connection

25

GEH-325BJ, Armored Motors, Type MDBOO

Fig. 8 Removal of Inner Race of Bearing With Puller

26

BI006008

BI006008

Armored Motors, Type MD800, GEH-3258J


(3) After tightenin the bolt, once again check the
spacing to the c mmutator and the alignment of
the brushes with the commutator segments.

(5) Assemble the outer race and rollers in the bearing


cartridge by tapping evenly around the outer race
with a mallet. Tap itinto place so thatitseats evenly
against the shoulder in the bearing cartridge.

(4) Attach pigtails.

Pressing New Sha t Into Armature


Clean the bore ofthe mature core removing any nicks,
burrs, or scoring in the surface. Heat the armature
assembly to approxi ately I50 a C in an oven. Place the
heated assembly in a press with the commutator end
down. (Refer to Figs, 0 and 11.)

(6) Assemble the bearing cap to the cartridge and


secure it with capscrews. Tighten the capscrews
securely. These bolts are not accessible from the
outside of the motor.
(7) Slide the bearing housing assembly into position
on the shaft, over the inner race and thrust collar.
Rotate it on the shaft to be sure that it turns freely
with no binding of the bearing.

For the MD802 throu h MD8I8, rest the armature on a


pipe or sleeve just lar e enough to clear the shaft and
butt against the com utator (Fig. 10).

Final Assembly of Horizontal Motor

For the MD820 throu h MD828, also rest the armature


on a pipe or sleevejust arge enough to clear the shaft but
small enough to fit nder the commutator and butt
against the commutat r mounting bolts. (Refer to Fig.
11.)

(1) With the brushes removed and the top half of the
motor frame opened 90 or removed, lift the armature by means of a sling over the two shaft extensions outside of the bearing housings. Lower the
armature into the bottom half of the motor frame.
Bolt the bearing housings to the frame.

Insert the shaft at roo


assembly and quickly
slot. Press in the new
drive end until the cor
shaft. Use a shaft nut 0
threads from damage.

Replacement Be
The bearings of MD8
on the shaft with a hea
bearings with greater
normal (C3 or C4) m

temperature into the armature


lign the shaft key and core key
haft by applying pressure at the
seats against the shoulder on the
the drive end to protect the shaft

gs
Armored Motors are mounted
interference fit. For this reason,
radial internal clearance than
st be used.

Assembly of Bear' gs (Refer to Fig, 2)


(1) Clean the bearin mounting surfaces on the shaft
and remove any .cks, burrs, or scoring.
(2) Heat the thrust co lar to approximately 100C in an
oven or oil bath nd slide it onto the shaft tight
against the should r. If thrust collar is symmetrical,
it can be placed th either end out.
(3) Heat the inner ra
in an oven oroil b
shaft tight against
on the inner race
use a torch, since

e of the bearing to about 1l0C


th and quickly assemble iton the
e thrust collar. Position the lip
owards the thrust collar. Do not
t can cause local soft spots.

(4) Pack the bearing camber of the bearing cartridge


and rollers of the earing 1/2 to 2/3 full of bearing
grease, such as G grease D6A2C5 as indicated in
Table 11 under L brication.

(2) On motors which have brushholders mounted in


the lower half of the frame, it is necessary to reach
into the housing to measure the spacing of the
brushholders from the commutator. (Refer to Step
6 of this section.)
(3) Lower the upper half of the frame into position
over the armature and secure the two halves together with the clamp bolts. Be careful to avoid
causing damage to the field coils at the frame split.
(4) Replace the bolts holding the bearing housing to
the top half of the frame.
(5) Rotate the armature in the bearing to be sure that
it turns freely without binding.
(6) Remove the commutator covers and check the
spacing between the face of the upper brushholders
and the commutator surface. Adjust this spacing to
provide .070" to .080" (1.8 mm to 2.0 mm.) clearance, by loosening the bolt to permit raising or
lowering of the brushholder to obtain the proper
clearance. An .075" (1.9 mm.) thick non-metallic
shim may be used. Tighten the clamp bolt securely
to hold the brushholder in position.
(7) Replace and tighten any electrical connections
which were loosened or removed in disassembly.
Insulate all bolted electrical connections except
those on the brushholder. For MD820 through
MD828 motors, be sure all pole face compensating
windings are reconnected at the frame split.

27

00

'-1

-L:':-

~_-.J

PIPE

Fig. 9 Shaft Removal

......f - - - -

SLEEVE OR

__"I I IL __ .--l

hillri

i _...,r-----f- ,-~I
r-r---+-t+
..
:I I II
!:

I~ill:'>-~

-'; I

~-

'-~'-l,.
.:

PRESSfERE

-J-L..
O

Fig. 10 Pressing in New Shaft


MD802 Through MD818

///

-9:: :fr~ffi-J SLEEVp~p~R

L.l-L..L._

--,.-r-I-+-~'-I
,
I. I

I __ ,+j~1

,I

~Ll I \'-

!
I I
:
I I I
....J
L_~-ll? I
I

-I

.Jr, - -b'L~~

.,

!L~L_i--T

,-

'i ll

._.=)

PRESr HERE

PIPE

SLEEVE OR

Fig. 11 Pressing in New Shaft


MD820 Through MD828

PRESS HERE

~
c

(l)

"ti

<

,Cri

Q..

(ti

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$-.

~
~

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BI006008

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

vertical motors. This bearing assembly would also be


typical of MD and MDP horizontal motors, which use
vertical type bearings without the vertical mounting
flange.

COMMUTATOR
END
45
4

Refer to Fig. 13, which shows a typical longitudinal


section through the armature and bearings of the
MDV820 through MDV824 vertical type motor. The
MD828 motor is not available as a vertically-mounted
motor.

Removal of Armature
910

PINION
END

For the MDV804 through the MDV818, refer to Figs. 12,


17 & 19.
(1) Remove the motor from its mounting and place it
horizontal on a bench, supported on the frame with
the flange clear. Using a suitable puller, pull the
pinion or coupling from the drive end of the shaft.
Remove the brake wheel or shaft guard from the
commutator end of the shaft.

39A

(2) From the commutator end openings, insert a nonmetallic strip (1/32" to 1/16" - 1 mm. to 2 mm.
thick) in the air gap at the bottom commutating
pole. This strip is to protect the armature glass
bands from damage.

31.
32.
34.
36.
39A.
41.

Bearing
Bearing Bracket (DE
Cap, Bearing
Cartridge, Bearing
Collar, Thrust
Grease Tube

44.
45.
910.
911.
912.

Ring, Split
Ring, Locking
Bolt (Brg. Bracket-Frame)
Screw (Cartridge-Frame)
Screw (Locking Ring)
913. Compression Fitting

Fig. 12 Typica Section View of Bearing


Assembly. Types MDV810 Through MDV818
Vertical Motors. ( or Types MDV804 Through
MDV80 , Refer To Fig. 17.)
(8) Install a set of bushes and tighten the terminal
screws which sec re the pigtails to the brushholder
or connection pI teo If new brushes are used, they
should be seated s described in the Brush Maintenance section of is Instruction Book. Replace the
commutator cov rs.

DISASSEMBLY -

TICAL MOTOR

Only the procedures


vertical motors are c ntained in the following paragraphs. For other pro edures, refer to the Disassembly
- Horizontal Motors s ction of this Instruction Book.
Refer to Fig. 12, whi
bearing assembly of

is a typical section view of the


e types MDV804 to MDV818

(3) Remove the drive end flange-to-frame bolts. Using


a sling and hoist on the drive end shaft extension,
lift the end of the shaft to take up the load on the
flange-to-frame rabbet, so that the flange can be
pulled away from the frame just far enough to clear
the rabbet. Lower so that the armature core rests on
the pole. Switch the hoist to the flange, and take up
the load on the bearing so that the flange with the
bearing cartridge, inner race, and cap can be removed from the shaft as one assembly. Care should
be taken not to damage the lip-type seals during this
operation.
(4) Split the frame by removing the frame split bolts
and the commutator end cartridge cap screws.
(5) Break all external electrical connections across the
frame split. Remove the upper frame half.
(6) Loop a rope sling around the two shaft extensions,
and carefully lift the armature avoiding damage to
field coils and other parts. The armature core
should be placed on a clean, padded surface to
prevent damage to the armature core bands.
For the removal ofMDV820 through MDV824, refer to
Fig. 13.

29

~
I

/32

39A

36

128 "------J 902

117

904

13 Type MDV820 Through MDV824 Section

II I

Armature
Armature Coil
Armature Banding End Turns (CE)
Armature Banding End Turns (DE)
Armature Coil Support (CE)
5B. Armature Coil Support (DE)
6. Armature Core
6A. Armature Core Key
7D. Armature Baffle (MD824 Only)
9A. Equalizer - Molded
10. Shaft
398
12. Commutator
12A. Commutator Segment and Insulation
12B. Commutator Shell
12C. Commutator Banding
15. Pinion Key
31
16. Pinion Nut
17B. Pinion Lockwasher - Bent Type
31. Bearing (CE-Ball ) (DE-Roller)
32. Bearing Bracket
34. Bearing Cap
COMMUTATOR END
36. Bearing Cartridge
39. Thrust Collar
39A. Thrust Coller - Inner
55
53
39B. Thrust Coller- Outer
7.
\ 32
40. Grease Fitting
570
41. Grease Tube Assembly
~
578
42. Pipe Plug
40 44
44. Split Ring
50 15~ 58 34
50. Brush
53. Brushholder Yoke
55. Brushholder Stud
56. Brushholder Stud Insulation
57. Brushholder
57B. Brushholder Spring
57D. Brushholder Mounting Bolt
16
58. Brushholder with Support
70. Comm Coil and Pole Assembly
73A. Main Field Coil and Pole with Bars
75. Pole Bolts
116. Cover, Side Drive End
117. Cover, Top Comm End
I
I "
150. Frame
178
42
Split
Bolt
Frame
151.
153. Shaft Thimble
502. Pole Face Connections
(Miscellaneous Parts)
(Not Standard Renewal Parts)
900. Armature Flange (eE)
901. Armature Flange (DE)
902. Armature Flange Key
903. Armature Lamination
904. Armature Banding Groove Lamination
Fig.
908. Bearing Bracket Split Bolts
909. Comm Pole Shim

1.
2.
4B.
4C.
5A.

116

)-'-31

.".\ !

39A

34

31

I II

41

32

42

42

DRIVE END

MDV 824 ONLY

10

(l)

o
~
:<
"ti

Ql

)::.

~
!-

G)

BI006008

BI006008

Armored Motors, Type MD800, GEH-3258J


Remove the motor fr
and place it in a hori
pinions, couplings, b
the shaft extensions a
the instructions for re
tal type motor.

m its vertical mounting position


ontal position. Carefully remove
ke wheels, and shaft guards from
d remove the armature following
oval of armature from a horizon-

Removal of Com utator End Bearing


For the MDV804 thro gh the MDV818, refer to Figs. 12,
17 & 19.
(1) Take out the ca

screws and remove the bearing


cap from the be ring cartridge.

(2) Remove cap scr s and the circular locking ring.


Take out the split ingwhichfitsin the groove in the
shaft.
(3) Install a suitable
holes in the bea
tridge with the
shaft. This beari
discarded.

uller with the studs through the


ing cartridge, and pull the carall bearing and collar from the
g will be brinelled and must be

(4) Remove the ball bearing from the cartridge by


tapping lightly wi h a mallet on the collar.
For MDV820 through

DV824, refer to Fig. 13.

(1) To remove the baring assembly, first take off the

bearing cap.
(2) Using a suitable uller in the grooves provided in
the shaft collar, r move the collar from the shaft.
(3) Install a suitable puller using studs through the
threaded holes i the bearing cartridge and pull
the cartridge, thr st collar, and ball bearing from
the shaft. The bal bearing may become brinelled
during removal a d should be discarded.
(4) Remove the ball
gently tapping wi
Excessive tappin
further brinell or

bearing from the cartridge by


h a mallet on the thrust collar.
may cause the ball bearing to
ecome disassembled.

Removal of Failed rive End Bearing


(Refer to Figs. 12 d 13.)
(1) The outer race of e drive end roller bearing can
be removed by ta ing off the bearing cap. With a
suitable puller, pu I the outer race and rollers from
their seat in the baring cartridge.
(2) The bearing inner ace is removed from the shaft by
using a suitable p ller engaged behind the thrust

collar. Pull the collar and inner race from the shaft
together.

ASSEMBLY - VERTICAL MOTOR


Only the procedures peculiar to the assembly ofvertical
motors are contained in the following paragraphs. For
other procedures, refer to the instructions on Assembly
- Horizontal Motors.

Replacement Bearings
The bearings ofMD800 Armored Motors are mounted
on the shaft with a heavy interference fit. For this reason,
bearings with greater radial internal clearance than
normal (C3 or C4) must be used.

Assembly of Commutator End Bearing


For the MDV804 through the MDV818, refer to Figs. 12,
17 & 19.
(1) Pack a small amount of sealing grease (D6A2D) in
the labyrinth groove on the inside of the cartridge,
and place the collar in the cartridge. (Refer to
Table 10 for grease sources.)
(2) Assemble the ball bearing into the cartridge by
tapping evenly on the outer race with a mallet until
it seats firmly against the shoulder at the bottom of
the bore. Cool the bearing in a freezer or heat the
cartridge in an oven to lOOC, to make this job
easier and to prevent damage to the bearing or
cartridge.
NOTE: For a bearingwith a seal, assemble the
bearing with the seal down or toward the
center of the armature.
(3) Heat the assembly in an oven to 110C. Place the
cartridge assembly on the shaft and press against
the inner race of the bearing. Press the bearing on
the shaft until the split ringwilljust enter the groove
in the shaft.
(4) Assemble the split ring in the groove in the shaft
and lock it into place by attaching the locking ring
to the split ring by means of the cap screws. The cap
screws are to be lock wired.
(5) Pack around the balls of the bearing with a bearing
grease such as GE grease D6A2C5.
(6) Pack bearing grease in bearing cap until the cap is
1/2 to 2/3 full. Wipe grease on the lip of the seal in
the bearing cap. Assemble the bearing cap to bearing cartridge.
31

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

For the MDV820 through MDV824, refer to Fig. 13.


(1) Pack a small amount of sealing grease in the labyrinth groove on the inside of the bearing cartridge
and place the cartridge on the commutator end
shaft as close to the commutator as possible.
(2) Heat the thrust collar to approximately 110C in an
oven or clean oil bath and quickly assemble it
against the locating shoulder on the commutator
end shaft.
(3) Heat the ball bearing to approximately 110C in an
oven or clean oil bath and quickly assemble it onto
the shaft against the thrust collar with the lip or
thrust shoulder on the outer race toward the thrust
collar.

NOTE: It is important the ball bearing be


assembled with the thrust shoulder on the
outer race toward the armature windings, so
that the armature thrust is properly carried by
the bearings when the motor is mounted in
the vertical position.
(4) Heat the thrust collar to approximately 150C in an
oven or clean oil bath and quickly assemble it on the
shaft against the inner race of the ball bearing.
(5) After the heated parts have cooled, slide the bearing cartridge into position over the thrust collar
and ball bearing un til the outer race of the bearing
seats firmly on the shoulder provided in the cartridge bore.
(6) Using a suitable bearing grease such as GE grease
D6A2C5, pack around the balls of the bearing.
(7) Pack grease into the bearing cap until the cap is
1/2 to 2/3 full. Coat the mating surfaces of the
labyrinth seal between the shaft collar and bearing
cap with a sealing grease. Bolt the bearing cap to the
cartridge.

Assembly of Drive End Bearing (Refer to


Figs. 12 and 13.)
The thrust collar and roller bearing inner race are
assembled on the shaft by heating both pieces to approximately 110C in an oven or oil bath and quickly
assembling first the collar tight against the shoulder and
then the inner race tight against the collar.
The bearing outer race is assembled in the bearing cartridge which is attached to the motor flange as follows:

32

(1) Pack the grease cavity in the bearing cartridge


approximately 1/2 full ofbearing grease such as GE
grease D6A2C5.
(2) Wipe grease around the rollers of the bearing, and
assemble the bearing in the cartridge tapping on
the outer race with a mallet until the bearing seats
firmly against the shoulder at the bottom of the
bore.
(3) Pack the bearing cap 2/3 full of bearing grease and
assemble to the bearing cartridge.

Final Assembly of Vertical Motor


For the MDV804 through the MDV818:
(1) Place the bottom half of the frame, with the coils
and brushholders properly assembled and connected, on a bench support on the frame with
provisions for clearance for the motor flange.
(2) Place a non-metallic protective strip (1/32" to
1/16" - .8 mm. to 1.6 mm. thick) on the lower
commutating pole. This will protect the armature
core bands during assembly. This protective strip
should extend into the commutator area, so that it
can be removed from the commutator end after
assembly.
(3) Place a rope sling over the two shaft extensions of
the armature and lower the assembled armature
into the bottom half ofthe frame. The commutator
end cartridge will rest on the frame cartridge fit,
while the drive end of the core will rest on the poles
in the bottom half. The commutator end cartridge
cap screws should be started, but not tightened, in
the bottom half.
(4) Wipe the seals of the drive end bearing assembly
with grease.
(5)

Lift the top half of the frame in place and start, but
do not tighten the frame split bolts.

(6) Lift and carefully guide the flange and bearing


assembly onto the shaft until the outer race of the
roller bearing is assembled on the inner race far
enough to support the flange.
(7) Lift on the end of the shaft until the flange rabbet
engages with the frame rabbet, and assemble flange
bolts.
(8) Assemble and tighten all cap screws for the commutator end bearing assembly.

BI006008

Armored Motors, Type MD800, GEH-3258J

(9) Tighten all fr

(7) Check spare brush supplies during installation to


be sure that replacement brushes are on hand.

(10) Follow the gene al instructions in the Final Assembly of Horizon Motor section of this Instruction
Book.

ugh MDV824 motor, follow the


sembly of Horizontal Motor.

Good brush perform ce depends, to a large degree, on


the care used in fittin and adjusting the brushes before
the machines are put into service. An initial inspection
and frequent subseq ent inspections are required to
obtain satisfactory pe ormance. The following points
are important with gard to assuring proper brush
service.

WARNING:
chinery can ca
Brushes should
while the machi

Replacement brushes should have their commutator


contact surfaces curved to exactly fit the commutator
surface. This is accomplished by "sanding in" the brushes
in each brushholder separately. Draw a sheet of nonmetallic sandpaper under the brushes with the rough
side toward the brush, while the brushes are pressed
firmly toward the commutator. When sanding brushes,
do not get carbon dust into the windings. The motor
should be thoroughly blown out after sanding the
brushes.

The replacement of brushes can be simplified in two


ways. First, in most cases, up to 20 percent of the brushes
on one stud can be replaced without requiring "sanding
in". Second, the use of brushes with fluted contact faces
simplifies the process of sanding brushes.
The brushes originally supplied with the motor are of
the proper grade for all service conditions and, when
brush replacements are necessary, use the same grade of
brush or a GE recommended substitute.

(1) Make sure that th pigtail screw is tight, and that the
pigtail does noti terfere with free movement of the
brush.

(2)

pigtail cannot touch uninsulated


ine.

(3) Check that the b shes are free in the holders with
the springs posi oned correctly and functioning
properly.

COMMUTATION ADJUSTMENT

(4) The brushholder should be uniformly spaced about


0.07" to 0.080" (1 77-2.03 mm.) from the commutator surface.
(5) Check brush fit a d, if necessary, use a seater stone
while the machi e is running to obtain an acceptable fit.
(6) Running a machi eatnoload (such as during start
up) and the lack f proper filming on a new commutator sometim s leads to a short life for the first
sets of brushes. efore investigating or changing
the brush grade, wait and see how the first set of
replacement bru hes perform.

33

BI006008

GEH-3258J, Armored Motors, Type MD800


All of the machines are adjusted at the factory and
normally do not require additional adjustment.
Any problem that develops due to machine adjustment
should be recognized as soon as possible after start up so
it can be corrected during the warranty period.
Slot bar etching will normally be the first sign of a poorly
adjusted machine. (Refer to the "Commutator Check
Chart", GEA-7053, which is included as part of this
Instruction Book.) This should not be confused with slot
bar marking which is a normal characteristic, especially
during the early stages of commutator film development. A pencil eraser may be used to erase a marked bar.
Ifthe copper is smooth under the erased area, there is no
etching.

(Refer to the Commutator Twn.ing, Stoning and


Sanding section ofthis Instruction Book.) Chamfer
the edges of the segments and remove all mica fins
adhering to the sides of the commutator segments.
Very careful inspection is required to detect the
high side mica fins.
(5) Check clearance between the brushholders and the
commutator surface. This clearance should be
0.070" ( 1.8 mm.).
If trouble is experienced in finding electrical neutral or
if machine adjustment is questionable, contact the local
GE representative.

COMMUTATOR MAINTENANCE

Once a DC machine is correctly adjusted, it will not get


out of adjustment unless something becomes loose or
fails within the machine. Loosening of pole bolts or
electrical connection screws are the most likely cause of
poor adjustmen t. The tightness of these bolts should be
checked periodically.

Commutator Turning, Stoning, and Sanding


If a field coil fails and must be replaced, it is important
that the shims be placed exactly as they were removed.
Never intermix nonmagnetic and magnetic shims.
If an armature of an MD820 through MD828 is replaced
in a motor, set the brush yoke back on the factory mark.
MD820 through MD828 motors are equippedwith brush
yokes with adjustment means for attaining proper circumferential brush spacing. The circumferential brush
spacing ofMD802 through MD818 motors is fixed and
no adjustment is necessary or provided.
The following checks should be made, if commutation
problems develop and especially after any major repair
or replacemen t of parts.
(1) Inspect all electrical connections and make certain
that none are loose.
(2) Check the connections and make certain that the
commutating field or any part of it is not reversed
and that one or more of the main field coils is not
reversed.
(3) Inspect the brushes and see that they move freely in
the holder and that the pigtails do not interfere
with any part of the rigging.
(4) Inspect the surface of the commutator and wipe off
any blackening. Ifit is rough or eccentric, causing
the brushes to chatter or move in the holder, it
should be ground or stoned or perhaps turned.

34

It is preferable to remove the armature from the machine to refinish the commutator.
In many cases, stoning or sanding is done before it is
necessary or where other procedures should be employed (refer to Table 6).
Commutators with slight grooving or threading are
often turned or ground because of nothing more than a
displeasing appearance. Commutators can get a black
color when operating in various atmospheres and with
certain types of brushes. Doing nothing may be the best
procedure in these cases. Wiping with canvas removes
some ofthe high-resistance or high-friction areas offilm.
The frequent use of clean canvas on, a commutator can
help greatly in developing and keeping a uniform film.
This helps to reduce the arcing caused by high-resistance areas.
Usually there is little doubt when it is necessary to grind
or turn a rough commutator. Danger signs are: rough
surface, noise, sparking, rapid brush wear, and even load
or speed fluctuations.
Chips can be drawn into the armature, when itis rotating
due to the fan action ofthe commutator risers, windings,
or armature fan. If resurfacing is to be done, arrange to
tape up or otherwise protect the commutator risers and
commutator-end armature windings.

BI006008

Armored Motors, Type MD800, GEH-3258J

GRADING

DF COMMUTATION
1 BLACK
No Sparking.

1+ BAND LIMITS
The point at which pinpoint sparking first occurs on
one or more brushes. Final bands are normally
called on 1+ sparking unless specified otherwise.
'u
.n..

Iuu

11/4 SLIGHT SPARKING ON A FEW BRUSHES


The point after band limits where sparking begins to
spread. In cases where a generally well spread
sparking occurs at band limits, this grade may not
be present.
~,

.,.,

.~

H.~

uu
.~.~

11/2 SLIGHT SPARKING ON HALF OF BRUSHES


The point where half of the brushes or half of the
total edge of the brushes are covered with yellow
sparks.
uu
.L~.~

UUH

"~.,

,~"

~.

~.~

....

HH

2 SPARKING ON MOST OF BRUSHES


The point where sparking is general on nearly all
brushes. Sparking will be mostly yellow, but a
few brushes may have white spots. There should
be no streamers.
v-v
.~.~

Iu

uuu
.~.'".~.

.~.~.~

H.~.~.

.~

3 DESTRUCTIVE SPARKING
Any sparking with streamers is destructive, and
the machine must never be run with this type of
sparking. Heavy white sparks may also emit
crackling sounds.
~,~,
"",-.L,"

.~.~.~.,

.~. ~'I~'

.~.~.~.,

. ""'u~,
L"AL".L

""~,

.L".L".L"

II IIII II/V IIII IIII III


35

BI006008

GEH-3258J, Armored Motors, Type MD800

TABLE 6
COMMUTATOR CONDITION VS. RECOMMENDED REMEDY

CONDITION

TOOL

FIXED
STONE

ROTATING
STONE

HAND
STONE

SANDPAPER

BRUSH
SEATER

Make Film
Uniform

X
X

Fit Brushes

Remove
Threading

Remove
Grooving

Remove
Streaking

Polish

X
X

Reduce Film

Remove
Roughness

UNTREATED
CANVAS

X
X

Reduce
Chatter

Whether a stone or tool is used should be governed by


the condition of the surface to be trued. An extremely
rough commutator can be resurfaced more quickly with
a tool than with a stone. Mter the surface is concentric,
it is then smoothed with medium-grain and fine-grain
stones.

shorting and grounding. Final clean-up can be done by


"air-curing" the commutator. (Refer to the Commutator
Clean-up by Air-cure Method section of this Instruction
Book.)

Commutator Film Care


A proper commutator film is essential to good commutation and acts to prolong brush life by reducing friction.

A hand stone can be used by a competent person, but


should be avoided by the novice, since an improperly
supported stone can quickly roughen a surface and
increase the eccentricity. A hand stone should be used
only to keep the equipment operating until a shutdown
is possible, and should not be used on extremely rough
surfaces at all.

Various substances in the air such as water vapor, oil


vapor, or chemical fumes affect the appearance of a
commutator film. The appearance of the film is unimportant if brush wear, commutator wear, and machine
performance are satisfactory.

The refinished surface must be smooth and concentric


with the center of rotation.

The best way to establish a good operating commutator


film on a machine that seems to need help is:

The commutator must be carefully cleaned after resurfacing. Segment insulation mica should be undercut if
necessary, and the slots between segments thoroughly
cleaned out. Segment bars should be scarfed. Keep
copper chips out of the rest of the machine to avoid

(1) Have the commutator smooth and concentric.

36

(2) Have the brushes accurately fitted to the commutator surface. Fluted brushes minimize fitting problems and help establish a satisfactory film.

BE Motors

BI006008

Commutator Check Chart


For Comparing Commutator Surface Markings
SATISFACTORY COMMUTATOR SURFACES

COPPER DRAG, an abnor 01 build-up of commutator

PITCH BAR-MARKING produces law or burned spots

HEAVY SLOT BAR-MARKING can involve etching of

material,. forms most often a trailing edge of bar. Con~


dition is rare, but can co us flashover if not checked.

on the commutator surface. The number of these markings equals half or oJI the number of poles on the motor.

trailing edge of commutator bar. Pattern is related to


number of conductors per slot.

CAUSES OF POOR COMMUTATOR CONDITION


Frequent visual inspection of ommutator surfaces can warn you when any of the above conditions are developing so that you can take early corrective action. The chart below
may indicate some possible auses of these conditions, suggesting the proper productive maintenance.
Light
Electrical
Adjustment

Electrical
Overload

Electrical

Load

Armature
Connection

Unbalanced
Shunt
Field

Type of Brush
in Use

Brush
Presure

Vibration

(light)

Abrasive
Brush

Porous
Brush

Gas

Streaking

Threading

Grooving
Copper Drag

X
X

Pitch Bar-Marking
Slot Bar-Marking

GE Motors

Contamination

v
A

X
A

X
X
X

Abrasive

Dust

X
X

HOW TO GET THE MOST VALUE FROM THIS CHART

3001 East Lake R ad


Erie, PA 16531
Phone: 814-875-3 9
FAX: 814-875-342

The purpose of the Commutator Check Chart is to help you spat undesirable cammutotor conditions as
they develop so you con take corrective action before the condition becomes serious. This chart will also
serve as an aid in recognizing satisfactory surfaces.
The box chart above indicates the importance of selecting the correct brush and having the right operating
conditions for optimum brush life and commutator wear.
For additional information or help with carbon brush application or commutation problems, contact your
nearest GE Sales Office or Distr,butor.

GEA-7053A

1992 General Electric Company 1/92 (30M)

M/GCO

Printed In

U.S.A.

BI006008

BI006008

Armored Motors, Type MD800, GEH-3258J

es adjusted electrically for the best

(3)

commutation.
(4) Run at a high en ugh load to allow filming process
to take place (a leastl/2t03/4fullload).

per square cm.)] against the commutator surface.


Hold the hose between one and two inches from
the commutator surface and sweep it back and
forth longitudinally, in the direction of the mica.
(3) Increase the voltage in steps of about 10 percent.

(5) Wipe the comm tator occasionally during the filming process with clean canvas to remove high-resistance or high-fri tion areas.

If these steps still do ot result in satisfactory brush life


and commutator surf ce life, special brushes which can
cope with atmospher c contamination may be needed.
Consult GE Motors - M&G for further help.

Commutator Cle

-up by Air-eure Method

After a commutator as been stoned or turned, or as a


final clean-up after afl shover or severe short-circuit, aircure the commutator by blowing out the slots with the
armature rotating an voltage applied to the commutator (so that there is oltage between bars). The extra
oxygen supplied by th air burns up slivers ofcopper and
carbon. This clean-u method prevents flashovers that
are sometimes cause by dirty commutators.

(4) If the sparks cannot be blown out, shut down and


clean out the commutator slots with a scraper or
engraving tool to remove the dirt, copper whiskers,
etc. Then restart and proceed as before.
(5) Continue the air-curing until top operating voltage
is reached and all sparks disappear.

PINION AND COUPliNGS


Removal From Armature

NOTE: When removing the pinion from a


motor armature, always use a suitable pinion
puller to avoid causing damage to either the
pinion, motor frame, bearings, or armature
shaft. Do not heat the pinion before pulling
and do not use wedges between the pinion and
the bearing cap. In order to prevent damage to
an ti-friction bearings, avoid the use ofa sledge
hammer on the pinion puller.

Procedure
(1) Set up the contr I so that variable voltage may be
applied to the br shes and the machine rotated at
will.
(2) While running he commutator at some convenient speed an applying about 10 percent top
operating volts, u e a 1/2" (13 mm.) hose to direct
ajetofdry,comp essedair [(30 psi max) (2.1 kg.

Mounting Couplings, Pinions, and Brake


Wheels on Shaft
The location of a coupling on the shaft will determine
the load-carrying ability ofthe assembly. When mounted
with the proper interference fit, the motor torque is
transmitted through the shrink fit of the coupling hub
on the motor shaft. Unless specified otherwise by the
coupling manufacturer, a coupling hub should be
mounted with the same advance that applies to a pinion.
37

BI006008

GEH-3258J, Armored Motors, Type MD800

Pinion, Coupling, and Brake


Wheel Mounting
NOTE: Successful operation of the gearing
largely depends on the proper mounting of
the pinion on the armature shaft. Mounting
pinions by heating them in boiling water and
driving them on the shafts by a blow from a
heavy sledge hammer is not recommended,
because it results in uncontrolled advance of
the pinon on the shaft. Too great an advance
can cause breakage of the pinion core, while
insufficient advance can cause pinion slippage
and wear in spite of the presence of the key. In
addition, the application of hammer blows
can injure the finished surfaces of the antifriction bearings.
Pinions must be mounted to a definite advance on the
shaft, without hammer blows. This requires heating the
pinion to a higher temperature than is obtainable with
boiling water, and is based on a difference in temperature between the pinion and the shaft. The following
method for mounting pinions is recommended:
(1) Thoroughly clean the pinion seating surface on the
shaft and the bore ofthe pinion using a solvent such
as mineral spirits.

Remove any scoring from either part. Spot the cold


pinion on the shaft by hand to obtain atleasta 75 percent
fit. Check the fit 'with bluing. Remove pinion.
(2) Break all sharp edges of the key and keyway with a
fine file, so there will be approximately 1/64"
(.4mm.) radius at each edge. Fit the key to the shaft,
taking care to avoid upsetting metal of the shaft
adjacent to the key. If previously upset, file lightly,
checking the fit with bluing until a 75 percent fit
results. Try the pinion on the shaft to make certain
that it does not bind on the key.

38

(3) Mount the pinion cold byplacingiton the shaft and


snappingitin position by hand. Measure the "cold"
position of the pinion, using a micrometer depth
gage. (Fig. 14 illustrates the method of using the
depth gage.) Mark the places where the depth gage
was resting so measurements can be made from the
same positions after the pinion is mounted.
(4) Remove the pinion from the shaft and heat it in a
suitable oven to the temperature specified in the
Pinion Mounting Data, Table 7. If the pinion is
heated in oil, the bore must be thoroughly cleaned
before mounting. To avoid this complication, the
use of an oven is recommended.
The pinion temperature is indicated as a temperature difference between the shaft and pinion. This
temperature difference is only estimated and can
be adjusted to main tain the specified advance. Heat
the pinion in the oven until the temperature is
uniform at the required number of degrees above
the shaft temperature. For example, if the shaft
temperature is 25C (77F) and the estimated difference is 120C (225F), heat the pinion to 150C
(302F) for mounting. Pinion temperature must
never be above 190C (374F).
Some accurate method must be provided for measuring the pinion and shaft temperatures quickly
before mounting the pinion. This can best be done
with a hand pyrometer which may be obtained from
GE Motors - DM&G. When a hand pyrometer is not
available, a cen tigrade thermometer can be used by
placing putty over the bulb to hold it against the
pinion. Heat the pinion a few degrees above the
desired temperature before removing it from the
oven. Wait until the pinion has cooled to the desired temperature. Remove the thermometer and
quickly mount the pinion as described below:
(5) Mter making sure the bore is clean, quickly mount
the hot pinion on the shaft. When the pinion is
nearly engaged with the taper fit (butnotactuallyin
contact), snap it forcibly into place with a quick
push. Itis important that the hot pinion be instantly
snapped into position before it has cooled appreciably. Otherwise, the pinion will immediately
"freeze" to the shaft and cannot be adjusted further.
(6) Check the "hot" or shrunk-on position of the pinion on the shaft, using the micrometer depth gage.
The actual advance is the difference between depth
gage readings at the hot and cold positions. To
control the stresses in the pinion, the advance must
be within the limits specified in Pinion Mounting

BI006008

Armored Motors, Type MD800, GEH-32S8J

TABLE 7
COUPLING HUB OR PINION MOUNTING DATA

Shaft
Dia.

Pinion
IIDII

II

Shrunk On
Pinion Advance

XII

FRAME

in.

mm.

in.

mm.

in.

mm.

in.

MD802
803
804
806
808
810
812
814
816
818
*820
*822+
*824++
*826

1.750
2.000
2.000
2.500
3.000
3.250
3.625
4.250
4.625
5.000
5.875
6.250
7.000
7.845

44.45
50.80
50.80
63.50
76.20
82.55
92.08
107.95
117.48
127.00
149.23
158.75
177.80
199.26

1.7435
1.9935
1.9935
2.4935
2.9935
3.2435
3.6185
4.2435
4.6185
4.9935
5.8685
6.2435
6.9935
7.8385

44.285
50.635
50.635
63.335
76.035
82.385
91.910
107.784
117.310
126.835
149.060
158.585
177.635
199.098

3.0
3.5
3.5
4.0
4.5
4.5
5.0
5.0
5.5
6.0
6.75
7.25
9.25
10.25

76
89
89
102
114
114
127
127
140
152
172
184
235
260

.011 to
.013 to
.013 to
.017 to
.020 to
.027 to
.037 to
.045 to
.055 to
.065 to
.070 to
.075 to
.080 to
.085 to

* Coupling Drive (Dnly


+ 822X Same as 8 2 Data
++ 824X Same as 8 4 Data

~~'~~H~/8"

~~'\'\.'\.'\.~
r

TAPER 11/4" IN CIA. PER 12" IN LENGj


(10.417 mm. PER 100 mm. IN LENGTH)

Estimated
Temperature
Difference
Oe9. (C) De9. (F)

mm.
.014
.018
.018
.022
.025
.032
.045
.055
.065
.075
.080
.085
.090
.095

(3.18

0.28 to
0.33 to
0.33 to
0.43 to
0.51 to
0.69 to
0.94 to
1.14to
1.40 to
1.65 to
1.78 to
1.91 to
2.03 to
2.16 to

0.36
0.46
0.46
0.56
0.64
0.81
1.14
1.40
1.65
1.91
2.03
2.16
2.29
2.41

m~.~ CHAMFER

70
70
70
70
70
80
95
100
115
125
120
120
120
120

125
125
125
125
125
145
170
180
210
225
215
215
215
215

45

3/16" (4.76 mm.) RADIUS

PIHIOH lORt

~'\'\'\\,,'\.'\.'\.\ .\
Data, Table 7. If he advance is not within the limits
given, the pinion should be pulled and remounted.
(7) Assemble the lock washer and nut. Tighten firmly
and lock. For the MD826, bolt the end plate in
place. Tighten b Dlts firmly.
(8) The brake whee mounting is similar to the coupling or pinion mounting. Because it does not
transmit continuous torque, the brake wheel requires only 50% of the advance onto the shaft at
50% of the temp rature difference shown in Table
7 for couplings 0 pinions. For example, an MD802
brake wheel adv nee and temperature difference
are 50% of the ~rable 7 values or .0055" to .007"
(0.14 mm. to 0.18 mm.) at a temperature difference
of 35C (62'soF).

RECONNECTI01~ OF POLE FACE

ASSEMBLIES
A red insulating coati:lg is applied over the stator end
turns, coils, poles, and 'nternal surfaces of compensated

wound machines to cover and seal all exposed copper,


thereby retaining high insulation resistance to prevent
nuisance electrical trips. This coating, applied at the
factory over connected assemblies by electrostatic spray
to achieve full coverage also, as might be expected,
penetrates portions ofthe clamped joints.
Before reconnecting pole face bars or pole face assemblies, for bolted connections remove all coating from
mating surfaces using mechanical methods. To prevent
high resistant joints, the connection surfaces must be
clean and free of coating and foreign materials.
Clean the reconnected parts and adjacent area using the
procedure described in the Cleaning of Windings section of this Instruction Book. Apply two coats of GE
A50CD615A red air dry enamel to the connections and
surrounding area, allowing 30 minutes drying time between coats. The application method preferred is conventional spray; application by brush is acceptable.
(Refer to Table 8 for material description.)

39

BI006008

GEH-3258J, Armored Motors, Type MDBOO

MICROMETER DEPTH GAGE BEING USED TO


MEASURE PINION ADVANCE. (NOTE THAT LINEUP MARKS USED TO LOCATE GAGE, PINION,
AND SHAFT IN IDENTICAL POSITIONS FOR
"HOT" AND "COLD" MEASUREMENT)

Fig. 14 Micrometer Depth Gage Being Used To Measure Pinion Advance

by overspeed) can lead to failures. These failures are


accelerated by high temperatures, which cause the insulation to lose much of its flexibility and strength.

INSUlATION
Many of the troubles which end a machine's useful life
are failures in the insulation system. Insulation failures
are of two general types: shorts to ground and shorts
between the windings in the armature or fields.
Some failures are the result ofmechanical damage to the
insulation system. Chafing (caused by vibration) or
cracks in varnish films (caused by high temperatures or

40

Many more failures are caused by contamination and


moisture. Air-borne contaminants can gradually collect
oli insulation surfaces and penetrate cracks. Oilyvapors
present in many atmospheres deposit on surfaces and
collect other contaminants. Contaminants that are electrical conductors cause leakage currents to ground or to
points of differing electrical potential. Leakage currents
can eventually char insulation surfaces providing even
better paths for greater leakage current; finally causing
failure. Even non-conducting contaminants can become
conducting in the presence of moisture with the same
result.
Try to eliminate sources of contamination and moisture
for maximum insulation life. Air filters for blowers, air
piped from cleaner locations, shielding from water leaks
or spray, proper use of space heaters during downtime,
etc., can all help slow the deterioration of insulation
systems.

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

TABLE 9

TABLE 8
CO)! TING MATERIAL
KNOWN SOL RCE FOR GE A50CD615A
(LYPTAL, INC.
305 EASTERN AVE.
CHEf-SEA, MA 02150
SUPPLIER' DESIGNATION: 1201E

EFFECT OF TEMPERATURE
ON INSULATION RESISTANCE

Winding
Temperature
Degree C

80

70

For greater reliabili v, conducting contaminants and


wetness must be exc uded from the inside of the machine.

60
50
40
30
20

10

Multiplying Factor
To Obtain Insulation
Resistance At 40C (104F)

18.0
8.0
4.0
2.0
1.0
.50
.26
.14

TESTING METE ODS


Visual Inspection
Visual inspection is re ommended as the quickest means
of finding insulation ;ystem troubles. Visual inspection
may not sound like :J test method, but a careful visual
inspection done by a ompeten t person is coming to be
recognized as one of t:Ie most valuable means ofjudging
insulation condition.

(2) Time the test voltage is applied.


(3) Temperature.
(4) Surface condition (contaminants).

In addition to collectin~ con tarninants, insulation shrinks,


cracks, and becomes brittle with heat and age. These
changes allowmovem ntof coils, loose filler strips, loose
ties, chafing and abra ion, all ofwhich can be picked up
by visual inspection.
Experience and judE ment can be gained by careful
observation and comI aring results ofvisual inspections
with insulation-resist; nce measurements. GE Service
Shops have people v ho can inspect equipment and
point out potential tro/-lble areas. Their services can help
build experience and udgment for future visual inspections.

Insulation-Resista IJ.ce Measurement


A method of measu ing the insulation resistance is
described in Report 3, "Recommended Practice for
Testing Insulation Re istance of Rotating Machinery",
published by IEEE, 3 5 E. 47th Street, New York, New
York, 10017. The res'rstance measurements should be
taken with a 500- or 1 OO-volt megger and corrected to
40C (104F).
The insulation resista ce measurements are affected by
the following:
(1) Magnitude of tes voltage.

(5) Moisture.
When a 1OOO-volt megger is used, taking readings of one
minute and converting the data to 40C (104F), the data
will evaluate the other two factors (i.e. the contaminants
and the moisture present).
The insulation resistance varies inversely with the winding temperature. That is, as the temperature decreases,
the insulation resistance increases in accordance with
Table 9.
Note that for a 40C (104F) decrease in temperature,
the insulation resistance is increased by a multiplier of
ten.
The insulation resistance of a machine is affected by its
design. For machines without pole face connections, the
insulation resistance ofthe armature circuit corrected to
40C (104F) should measure at least 1.5 megohms or
cleaning is required. Machines with pole face bars have
multiple creepage paths in parallel and will have lower
armature circuit insulation resistance. Such resistance
corrected to 40C (104F) should measure at least 0.25
megohms or cleaning is required. Main fields should
measure at least 1.5 megohms at 40C (104F).

41

BI006008

GEH-325BJ, Armored Motors, Type MDBOO


If the measurements are less than these limits, the
machine should be dried or cleaned to attempt to
increase the insulation resistance. Regular, periodic
measurements of insulation resistance can give a useful
indication of the rate ofinsulation system deterioration.
External connections should be removed to isolate the
windings to be tested and the megger value logged. A
sudden drop or consistent trend toward low values of
insulation resistance give evidence that the insulation
system is deteriorating and that failure may be eminen t.
High potential tests are not recommended on machines
which have been in use. If such a test is made immediately after installation, the testvoltage should not exceed
85 percent of the original factory test of two times the
rated volts, plus 1000 volts.
NOTE: Surge testing and AC impedance tests
of windings to detect shorts should be performed only by trained personnel.

CLEANING OF WINDINGS
Experience has proven that machines which are used on
most applications are bound to get dirty. Although every
effort is made to minimize the possibility of dirt accumulation, the basic shape and arrangement of parts is
somewhat prone to collect dirt. Therefore, itis necessary
to periodically blow the dirt out of the windings. Failure
to follow an adequate cleaning procedure leads to excessive and uneven dirt accumulations which can produce
excessive unbalance and may seriously inhibit ventilation.
When harmful dirt accumulations are present, a variety
of cleaning techniques are available. The one selected
for a particular machine will depend on:
(l) The extent of the cleaning operation to be undertaken.

(2) The particular machine involved.


(3) The type of dirt to be removed.

FIELD SERVICE CLEANING


(ASSEMBLED MACHINES)
Dry Dusts
Dry dirt, dust, or carbon should first be vacuumed,
without disturbing adjacent areas or redistributing the
contamination. Use a small nozzle or tube connected to
the vacuum cleaner to enter into narrow openings
(i.e between commutator risers). A soft brush on the
vacuum nozzle will loosen and allow removal of dirt
more firmly attached.

42

After the initial cleaning with a vacuum, high-velocity air


may be used to remove remaining dust and dirt.
WARNING: Safety glasses
tective equipment sh
injury to eyes and respiratory organs.
Great clouds ofdust may fill the air during this operation
so, where possible, operate the machine at a low speed
to permit maximum dust removal. Also, continue vacuum
cleaning to prevent contamination of the machine or
adjacent equipment. Compressed air is to be clean and
free from oil and water.

Oily Dirt
The presence of oil makes thorough, effective cleaning
of machines in service virtually impossible and Service
Shop conditioning is recommended. Oil on a surface
forms a "fly paper effect", which attracts and holds firmly
any entrained dust. Neither suction nor compressed air
is effective. Consequently, only accessible areas may be
cleaned. First, remove as much of the dirt as possible by
scraping or brushing the dirty surfaces. Then, wipe away
as much dirt as possible with dry rags. For surfaces not
readily accessible, a rag on a hooked wire can be used to
clean dirt out of holes and crevices. Rags should be
changed frequently for clean ones, so that contamination picked up from one area is not carried to other less
dirty areas.
To simplifY the removal of oily dirt, solvents are commonly prescribed.

BI006008

Armored Motors, Type MD800, GEH-3258J

The caution not to u e liquid solvents when cleaning a


DC machine applies articularly to commutators. Using
solvents to clean any ommutator runs the risk of washing conducting cont inants into the commutator structure and causing sho ts. On a commutator having glass
bands, the commutat I' bar-to-bar voltage acting on the
contaminants can ca se currents to flow with subsequent heating, burni g and possible failure (breaking)
of the glass bands. Bu ned bands may break under their
own built-in tension a standstill. If a band should break
with the machine at igh speed, commutator bars will
lift, causing damage t internal parts, or the commutator may actually fly a art. Band burning, once begun,
cannot be stopped by cleaning and the bands will have
to be replaced.
Without special testin
surgetester,weakness
armature cannot be e
be studied with the m
of the test is question
develop enough elec
weak grounding path

equipment such as the armature


s that could result in shorts in the
posed. Grounding weakness may
gger, but even here acceptability
Ie, because the megger does not
ical energy to expose all of the
.

WARNING: ~ol'lfen,ts
mabIe. Adequ
vided to minirni
hazards caused b
purposes.

using any solvent, consult the Material Safety Data Sheet.


Steam cleaning is not recommended because, as with
liquid solvents, conducting contaminants may be carried deep into inaccessible areas resulting in shorts and
grounds.
FREON TF is a chlorofluorocarbon. Chlorofluorocarbons have been identified as upper atmosphere ozone
depletors. The use ofFreon in industry is expected to be
greatly reduced in the future. The availability of Freon
may be limited, and its use could be prohibited by
regulations.

Drying of Wmdings
Drying of machines is most effectively done by the
application ofheat. The windings and insulation should
be heated so that their temperature does not exceed
125C at any location. (Do not make local hot spots.)
The machine's own frame and the addition of some
covers usually will make an effective enclosure to contain
the heat, if an oven cannot be used. Some flow of air is
desirable to allow moisture to be carried away. Methods
of generating heat include blowing hot air through the
machine, heating with heat lamps, passing current
through the main-field-coil windings, etc.

If temperature as high as 125C can be attained, they


should be limited to six or eight hours duration. Lower
temperatures will cause correspondingly longer drying
times.
Drying-out can be ended when the insulation resistance
to ground (corrected to 40C) is restored to a satisfactory
value as described under the Insulation Resistance section of this Instruction Book. Ifthese values do not reach
a proper level, then a thorough cleaning or complete
reconditioning may be necessary.

SERVICE SHOP CLEANING

FREON TF is the rec


because it is nonflam
and oil, is considere
insulations, and has
Solvent (a high flash
solvency, but is flamm

mmended solvent for cleaning


ble, has good solvency for grease
safe with most varnishes and
low order of toxicity. Stoddard
oint mineral spirits) has good
ble and moderately toxic. Before

**Registered tradema k of the E. 1. Dupont Co.

When the cleaning or drying methods described in


preceding paragraphs do not result in restoration of
acceptable insulation resistance and/ orwhen machines
are extremely dirty or contaminated, it is recommended
that the reconditioning services of a GE Service Shop
be obtained. Service shops are knowledgeable and
equipped for more sophisticated restoration methods,
such as steam, solvent, and abrasive cleaning,
revarnishing, and rewinding if necessary. To facilitate
ease of cleaning the blower/motor impeller, two puller

43

BI006008

GEH-3258J, Armored Motors, Type MD800


holes have been added in the hub for removal of the
impeller from the shaft.

TABLE 10
BEARING GREASES

LUBRICATION
Annature Bearings
Anti-friction type bearings are used to support the armature on all types and models of these motors. All of the
Type MD and MDP motors are equipped with single
width, solid cylindrical roller bearings at both ends,
whereas the Type MDVvertical motors have a single-row
ball bearing at the commutator end and a cylindrical
roller bearing at the pinion end. Convenient fittings are
provided for the addition of grease when necessary.
The lubricant used in these bearings should be a long
life, industrial quality bearing grease, such as GE grease
D6A2C5. The soap and oil in the grease must not
separate at moderate temperatures nor within a reasonable length of time, nor should the grease harden
objectionablywith age or exposure. The grease must not
be corrosive to any metal used in the construction of the
motor. (Refer to Table 10.)
For cold weather areas where temperatures are consistently below-18"C (O"F) for the winter season, GE grease
D6A4 which is a low temperature bearing grease should
be used. (Refer to Table 10.)

CAUTION:
pressure additives
failures. These lubr
tive c
tion
produce
lubricant containin
tives should be use
come

Voids between the rotating shaft and stationary bearing


housing should be packed with GE sealing grease D6A2D.
This includes labyrinth bearing seal arrangements associated with vertical motors or MD820-824 motors. (Refer
to Table 10.)
When repacking bearings with fresh grease, the housings or grease reservoirs should be filled from 1/2
to 2/3 full. An excessive amount ofgrease in the bearing
will cause excessive bearing temperatures. (Refer to
Table 11.)
44

KNOWN SOURCES OF GE GREASE D6A2C5:


Atlantic 54 GE
Shell Alvania No.2
Texaco Regal AFB-2
KNOWN SOURCES OF GE GREASE D6A4
(LOW TEMPERATURE):
Humble Oil Beacon 325
Shell Aeroshell Grease No.7
KNOWN SOURCE OF GE GREASE D6A15A1
(SYNTHETIC HYDROCARBON GREASE
ALL TEMPERATURE):
Mobilegrease 28
KNOWN SOURCE OF GE GREASE D6A2D
(SEALING):
Master Lubriko 7XM

Equivalent and compatible greases may also be


available from other vendors.

Lubricate motor at standstill. Remove grease reliefplug,


and free relief hole from any hardened grease. If grease
gun fittings are used, clean the fitting thoroughly before
adding grease. The addition of grease for each lubrication should be limited to about 1/8 of the maximum
grease tabulated above. A shot of grease 1/4" diameter
xl" long weighs about .03 ounce. (A shot ofgrease 6 mm.
in diameter x 33 mm.longweighsabout 1 gram.) Do not
overgrease. Mter greasing, run the motor for a few
minutes before replacing relief plug.

Frequency of Lubrication
The frequency of lubrication of the anti-friction type
bearings depends on the type and severity ofservice and
the temperature of the surrounding air. Regreasing
periods will vary from approximately 6 manths to 3 years
or more. Applications such as motors on steel mill screwdowns, roll tables, etc., which are subjected to considerable radiant heat, will require more frequent lubrication
than similar motors in lighter or cooler service. Motors

BI006008

Armored Motors, Type MD800, GEH-3258J

TABLE 11
BEARING LUBRICATION DATA
MIN. (GREASE RESERVOIR 1/2 FULl) & MAX. (GREASE RESERVOIR
2/3 FULL OF GREASE) AT EACH BEARING
OUNCES OF

CUBIC CENTIMETERS

FRAME
SIZE

UBIC INCHES
OF GREASE

OF GREASE

MD802
803
804
806
808
810
812
814
816
818
820
822+
824++
826
828

31/2 - 41/2
4 - 5 1/2
5-7
61/2 - 9
8 1/2 - 11 1/2
13 - 17 1/2
17 - 23
20 - 27
24 - 32
24 - 33
29 - 38
34 - 45
42 - 51
58 - 78
67 - 78

55 - 75
65 - 90
80 - 115
110- 150
140 - 190
210 - 290
280 - 380
330 - 440
390 - 520
390 - 540
470 - 620
560 - 740
690 - 840
950-1300
1100 - 1300

GREASE
1 3/4
2
2 1/2
3 1/4
4 1/4
6 1/2
8 1/2
10
12
12
14 1/2
17
21
29
33 1/2

2 1/4
2 3/4
3 1/2
4 1/2
53/4
8 3/4
11 1/2
13 1/2
16
16 1/2
19
22 1/2
25 1/2
39
39

GRAMS
50 55 70 90 120 180 240 280 340 340 410 480 600 820 950 -

65
80
100
130
160
250
330
380
450
470
540
640
720
1100
1100

+ Same for 822X


++ Same for 824X

in dusty orwet enviro ments also require more frequent


greasing.
These instructions
nature, and the bes
conditions. Experien
greasing can safely b

e necessarily of a very general


practice is dependent on local
e may show that the time between
increased.

The bearing housin


with grease, as this c
internal friction whic
bearing. This causes
separate and the exc
the bearing housing.
considerable loss of
failure often results f

should not be completely filled


uses churning of the grease and
results in excessive heating of the
he oil and soap in the grease to
ss grease escapes to the outside of
ver-filling is usually indicated by
rease from the housing. Bearing
om over-greasing.

For MDT drive end earings equipped with shaft rubbing seals (refer to Fi . 15), special greasing techniques
are required. Pack th bearing chamber of the cartridge
100% full of grease, uch as GE grease D6A2C5. Field
experience on relati ely slow speed MDT motors has
shown that fully greas ng the drive end bearing assembly
will increase protec on against contamination from
water and mill seal , thereby significantly increasing
seal and bearing life without resulting in overheated
bearings.

31

31.
34.
36.
37B.
39A.
39B.

Roller Bearing
Bearing Cap
Bearing Cartridge
Rubbing Seal
Thrust Collar
Shaft Collar

Fig. 15 MDT Drive End Bearing


45

BI006008

GEH-3258J, Armored Motors, Type MD800


Conditions where high pressure water and mill scale
can directly strike the shaft and bearing seal must be
avoided. Generally, a close running clearance between
the coupling hub and bearing cartridge on the motor
will provide significant protection to the bearing assembly. Mechanical barriers can also be installed to provide
increased protection. Precautions taken to protect the
motor bearings from contamination will pay dividends
in increased bearing life and reduced downtime for the
motor.

Renewal Parts
Use of genuine GE renewal parts will assure continued
high performance and the full benefits of the long
operating life built into your GE MD800 motor.
Purchase frequently required spare parts at the same
time you order your new equipment. Protective stocks of
brushes, brushholders, armature coils, field coils, and
bearings immediately available for replacement are a
wise investment. The cost ofstocking parts can be repaid
many times in minimizing a single shutdown.
A complete back-up stock of replacement parts is maintained at the factory and some selected GE Service Shop

46

locations for fast off-the-shelf delivery. Contact your


nearest GE sales office for all of your renewal parts
requirements.
Refer to the Renewal Parts exploded views or other
illustrations in this book when ordering renewal parts
for your MD800 motors. Contact the nearest GE sales
office, specify the quantity required, and describe the
parts in detail. For positive identification at the factory,
also include the motor model number and serial number.

Distributor location is available to you at


(814) 875-2387 (toll free at 1-800-458-0451).
Refer major repairs to your nearest GE Apparatus Service Shop. The GE Service Shop is equipped to repair,
overhaul, or rebuild your MD800 motors economically
and quickly. Factory specifications are followed, genuine GE replacement parts are used, and complete testing
offinished work is carried out. "When vital operations are
at stake, contact the GE Service Shop.

BI006008

Armored Motors, Type MD800, GEH-3258J

TROUBLESHOOTING GUIDE
Type of Trou pie
or MachinE
Componen

BEARINGS
High Temperatur

Possible Cause of Trouble

High temperatures are those exceeding 25C (45F) rise above ambient as measured
by thermometer on the bearing housing.
Cause: Overgreasing, heat conducted along shaft, misalignment, extremely high
loads or speeds, grease in poor condition, bearing in poor condition.

Noise

Normal bearing sound is uniform; compare with known good bearing. Roller
bearings are noisier than ball bearings.
Cause: Bearing starting to fail, noise transmitted from somewhere else (coupling,
driven machine, etc.).

Grease Leakage

Overgreasing, grease relief plug not removed when adding grease, grease with motor
running.

Oil Leakage

Wrong grease, overgreasing, high temperature, or loose bearing cover bolts.

BRUSHES

See Commutator Check Chart, GEA-7053.

Burned Brushes

Poor commutation (observe commutation visually to check), brushes off neutral,


excessively high overloads or excessively fast current changes (will cause poor
commutation regardless of adjustment), wrong kind of brushes, vibration upsetting
commutation.

Brush Breakage,
Chatter or Sque~l

Rough commutator, high vibration, wrong kind of brush, high-friction, commutator


film, atmospheric contamination, brushes tight in holders, high mica, incorrect
clearance between brushholders and commutator.

High Brush Wear

Severe sparking, vibration, wrong kind of brush, rough commutator, and contaminants in atmosphere. In some cases, it may be desirable to sacrifice brush life to gain
good commutation and long commutator life.

COMMUTATORS and
COMMUTATIC N
Excessive Sparking or
Burned Brushes

Brushes off neutral, excessively high overloads or excessively fast current changes.

Commutator
Appearance
Threading,
Bar-Marking

See Commutator Check Chart, GEA-7053.

47

BI006008

GEH-3258J, Armored Motors, Type MD800

TROUBLESHOOTING GUIDE (Cant'd.)


Type of Trouble
or Machine
Component

Possible Cause of Trouble

INSULATION
Low Insulation
Resistance

Moisture, dirt or contaminants (dirt, oil, or oil vapors, metal particles, atmospheric
contamination, dust).

Arcing over Insulation


Surface or Behind
Commutator Risers

Same causes as above. Contaminants are usually airborne.

Short Insulation Life

Unusually severe source of contamination, overheating, (overloads, poor ventilation or


high ambient temperature) mechanical vibration or shocks (causes chafing, etc.).

NOISE

Excessive vibration, rubbing of armature or fan, fan noise, (air noise), brush noise, bad
bearing, loose coupling, machine loose on foundation or base, current ripple due to
rectified power supply.

HOT WINDINGS

Improper or restricted ventilation, blocked air passages, (dirt or dust), excessive load,
short circuited coils, punchings shorted. Incorrect blower rotation.

VIBRATION

New machine vibration should be limited to 0.002" (.05 mm.); 0.003" to 0.004" (.08 mm.
to .10 mm.) may not be damaging but greater vibration amplitudes will probably cause
rapid deterioration.
Causes: Misalignment, bent shafts, balance weight missing, settled foundation, loose
hold-down bolts, air gap not uniform, loose bearing cartridge to frame bolts.

TABLE 12
METRIC CONVERSION FACTORS
To convert from

48

To

Multiply by
0.4536

pounds

kilograms

inches

millimetres

cubic inches

cubic centimetres

ounces

grams

28.35

pound-feet

newton-metres

1.356

tons

kilograms

907.2

pounds per square inch

kilopascals

6.895

degrees F

degrees C

deg. C = 5/9
(deg. F-32)

25.4
16.387

BI006008

Armored Motors, Type MD800, GEH-3258J

THIS PAGE INTENTIONALLY LEFT BLANK

49

BI006008

GEH-3258J, Armored Motors, Type MD800

MDP804 THRU MDP808 MOTORS

EXPLODED VIEW -

HORIZONTAL

15

.# /~'''''''
0~

'"""

"""

",,,,/

.. -.-:' ,

12

~:~~:"'-'--

"~~":'.

.'\-

-'"

7
7A

31
44

40

17A
1

16 ~"\

:Q
~

37:~'d

.\~

\ 1\\\'

.~r;;)
\JI::!)
I

''''','I

42

1168

178

50

Figure 16

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

Ref.
No.
1
2
6
6A
7
7A
10
12
15
16
17A
17B
31
34
36
37A
37B
39A
39B
40
42
44
45
50
55
56
57
57B

escription
ARMATURE
ARMATURE COl
ARMATURE CO E
ARMATURE CO EKEY
ARMATURE FA
ARMATURE FA HUB
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK W SHER-SPLIT TYPE
PINION LOCK W SHER-BENT TYPE
BEARING
BEARING CAP
BEARING CART lOGE
BEARING SEAL- NNER
BEARING SEAL- UTER
THRUST COLLA -INNER
THRUST COLLA -OUTER
GREASE FITTIN
PIPE PLUG
SPLIT RING
LOCKING RING
BRUSH
BRUSH HOLDER TUD
BRUSH HOLDER TUD INSULATION
BRUSHHOLDER
BRUSH HOLDER PRING

Figure 16

Ref.
No.
57C
70
73
75
102A
102B
104A
104B
1140
116A
116B
116C
117A
117B
119A
119B
141
151
153
202A
202B
208A
30SA
305B
305C
3050
310

Description
BRUSH HOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
POLE BOLTS
COVER. BOTTOM COMM END-SOLID
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM DRIVE END-SOLID
COVER, BOTTOM DRIVE END-SCREEN
COVER, QUICK ACCESS-COMM
END-SOLID
COVER, SIDE DRIVE END-SOLID
COVER, SIDE DRIVE END-SCREEN
COVER, SIDE DRIVE END-HOOD
COVER, TOP COMM END-SOLID
COVER, TOP COMM END-SCREEN
COVER, TOP DRIVE END-SOLID
COVER, TOP DRIVE END-SCREEN
CABLE BUSHING
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
HEAT SINK-SPACE HEATER
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

51

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

MDV804 THRU MDV808 MOTORS

EXPLODED VIEW - VERTICAL

16~

17 B --i)

0-17 A

L..-.--;-.---J

30se

''('1lj

(~ ~
~J
.

52

..

~~3()SD

305A

Figure 17

BI006008

Armored Motors, Type MD800, GEH-3258J

Ref.
No.
1
2
6
6A
7
7A
10
12
15
16
17A
17B
31
32B
34
36
37A
37B
39A
40
41
42
44
45
50
55A
55B

0 scription
ARMATURE
ARMATURE COIL
ARMATURE COR
ARMATURE COR KEY
ARMATURE FAN
ARMATURE FAN UB
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK WA HER-SPLIT TYPE
PINION LOCK WA HER-BENT TYPE
BEARING
BEARING BRACK T-DRIVE END
BEARING CAP
BEARING CARTRI GE
BEARING SEAL-I NER
BEARING SEAL-O TER
THRUST COLLAR INNER
GREASE FITTING
GREASE TUBE A SEMBLY
PIPE PLUG
SPLIT RING
LOCKING RING
BRUSH
BRUSH HOLDER
UD-RIGHT HAND
BRUSHHOLDER
UD-LEFT HAND

Figure 17

Ref.
No.
56
57
57B
57C
70
73
75
102A
102B
112B
114A
114B
1140
117A
117B
141
151
153
202A
202B
208A
305A
305B
305C
3050
310

Description
BRUSHHOLDER STUD INSULATION
BRUSHHOLDER
BRUSH HOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
POLE BOLTS
COVER, BOTTOM COMM END-SOLID
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM SIDE DRIVE
END-SCREEN
COVER, SIDE COMM END-SOLID
COVER, SIDE COMM END-SCREEN
COVER, QUICK ACCESS-COMM
END-SOLID
COVER, TOP COMM END-SOLID
COVER, TOP COMM END-SCREEN
CABLE BUSHING
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
HEAT SINK-SPACE HEATER
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

53

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

MDP810 THRU MDP818 MOTORS

EXPLODED VIEW - HORIZONTAL

15

71A

31
44

39B 45

\.:

4O~37B~f~
\. ~'\:;)

34\s:

17A ~%I.
I
\~~
~,\,

16 \'" \

'~~

\..;)

/
/
/

.\:OJ I)
.

116B

42

17B

153

570

~.

~
,.,._,.>J':'> . ~.

.....,\,

"

Y"'''
.

54

73

Figure 18

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

Ref.
No.
1
2
6
6A
7
7A
9
10
12
15
16
17A
17B
31
34
36
37A
37B
39A
39B
40
42
44
45
50
55A
55B
56
57
57B

Ref.
No.
ARMATURE
ARMATURE COl
ARMATURE COR
ARMATURE COR KEY
ARMATURE FAN
ARMATURE FAN UB
EQUALIZER COl
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK WA HER-SPLIT TYPE
PINION LOCK WA HER-BENT TYPE
BEARING
BEARING CAP
BEARING CARTR DGE
BEARING SEAL-I NER
BEARING SEAL- UTER
THRUST COLLA INNER
THRUST COLLA OUTER
GREASE FITTING
PIPE PLUG
SPLIT RING
LOCKING RING
BRUSH
BRUSHHOLDER TUD-RIGHT HAND
BRUSH HOLDER TUD-LEFT HAND
BRUSHHOLDER TUD INSULATION
BRUSH HOLDER
BRUSH HOLDER

Figure 18

570
70
73
75
102A
102B
104A
104B
1140
116A
116B
116C
117A
117B
119A
119B
141
151
153
202A
202B
208A
305A
305B
305C
3050
310

Description
BRUSHHOLDER MOUNTING BOLT
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
POLE BOLTS
COVER, BOTTOM COMM END-SOLID
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM DRIVE END-SOLID
COVER, BOTTOM DRIVE END-SCREEN
COVER, QUICK ACCESS-COMM
END-SOLID
COVER, SIDE DRIVE END-SOLID
COVER, SIDE DRIVE END-SCREEN
COVER, SIDE DRIVE END-HOOD
COVER, TOP COMM END-SOLID
COVER, TOP COMM END-SCREEN
COVER, TOP DRIVE END-SOLID
COVER, TOP DRIVE END-SCREEN
CABLE BUSHING
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
HEAT SINK-SPACE HEATER
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

55

BI006008

GEH-3258J, Armored Motors, Type MD800

MDV810 THRU MDV818 MOTORS

EXPLODED VIEW - VERTICAL

r '1.
j

153

16~

17B4~c-17A
...,- ----r- .---!

310

""

17B----c@-'- 'e::~17A
~.,.~

56

Figure 19
16

BI006008

Armored Motors, Type MD800, GEH-3258J

Ref.
No.
1
2
6
6A
7
7A
9
10
12
15
16
17A
17B
31
32B
34
36
37A
37B
39A
40
41
42
44
45
50
55A

escription
ARMATURE
ARMATURE COl
ARMATURE CO E
ARMATURE CO EKEY
ARMATURE FA
ARMATURE FA HUB
EQUAliZER COl
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK W SHER-SPLiT TYPE
PINION LOCK W SHER-BENT TYPE
BEARING
BEARING BRAC ET-DRIVE END
BEARING CAP
BEARING CART lOGE
BEARING SEAL- NNER
BEARING SEAL- UTER
THRUST COLLA -INNER
GREASE FITTIN
GREASE TUBE SSEMBLY
PIPE PLUG
SPLIT RING
LOCKING RING
BRUSH
BRUSH HOLDER STUD-RIGHT HAND

Figure 19

Ref.
No.
55B
56
57
57B
57D
70
73
75
102A
102B
112B
114A
114B
114D
117A
117B
141
151
153
202A
202B
208A
305A
305B
305C
305D
310

Description
BRUSH HOLDER STUD-LEFT HAND
BRUSH HOLDER STUD INSULATION
BRUSH HOLDER
BRUSH HOLDER SPRING
BRUSH HOLDER MOUNTING BOLT
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
POLE BOLTS
COVER, BOTTOM COMM END-SOliD
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM SIDE DRIVE
END-SCREEN
COVER, SIDE COMM END-SOliD
COVER, SIDE COMM END-SCREEN
COVER, QUICK ACCESS-COMM
END-SOLID
COVER,TOP COMM END-SOliD
COVER, TOP COMM END-SCREEN
CABLE BUSHING
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
HEAT SINK-SPACE HEATER
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

57

BI006008

GEH-3258J, Armored Motors, Type MD800

MDP820

EXPLODED VIEW - HORIZONTAL

~
310

9A

39B

40
17A

.'

I"
~ \,,_.

'~

I
~\j)l!
(
\"
.

16 \"'"

153

D
,

.0

'\

,,' "\))\~
34
I

42

17B

32A
\

58

Figure 20

BI006008

Armored Motors, Type MD800, GEH-3258J

Ref.

Ref.
No.
1

2
5A
6
6A

9A
10
12
15
16

17A
17B
31
32A
32B
34
36
39A
39B
40
42A
50
53
55
56

De cription

ARMATURE
ARMATURE COIL
ARMATURE COIL UPPORT-COMM END
ARMATURE CORE
ARMATURE CORE KEY
MOLDED EQUALI ER
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK WAS ER-SPLIT TYPE
PINION LOCK WAS ER-BENT TYPE
BEARING
BEARING BRACKE -COMM END
BEARING BRACKE -DRIVE END
BEARING CAP
BEARING CARTRI GE
THRUST COLLAR-I NER
THRUST COLLAR- UTER
GREASE FITTING
PIPE PLUG
BRUSH
BRUSH HOLDER Y
BRUSHHOLDER S UD
BRUSHHOLDER S UD INSULATION

Figure 20

No.

57
57B
57C
70
73A
75A
75C
750
76
102B
110A
110B
118A
118B
118C
134
151
153
202A
208A
305A
305B
305C
3050
310

Description

BRUSHHOLDER
BRUSHHOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE WITH BARS
COMM POLE BOLT
MAIN FIELD POLE BOLT
MAIN FIELD POLE BOLT-BOTTOM
POLE FACE BARS
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM SIDE COMM END-SOLID
COVER, BOTTOM SIDE COMM
END-SCREEN
COVER, TOP SIDE COMM END-SOLID
COVER, TOP SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-HOOD
COVER, LEAD
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

59

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

MDP822 MOTORS

EXPLODED VIEW - HORIZONTAL


.,'

........

_.~

15

10"

?~

60

--{'-

Figure 21

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

Ref.

Ref.
No.

No.
1
2
5A
6
6A
9A
10
12
15
16
17A
17B
31
32A
32B
34
36
39A
39B
40
42
50
53
55

ARMATURE
ARMATURE COIL
ARMATURE COIL UPPORT-COMM END
ARMATURE CORE
ARMATURE CORE KEY
MOLDED EQUALIZ R
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK WAS ER-SPLIT TYPE
PINION LOCK WAS ER-BENT TYPE
BEARING
BEARING BRACKE -COMM END
BEARING BRACKE -DRIVE END
BEARING CAP
BEARING CARTRI GE
THRUST COLLAR-I NER
THRUST COLLAR- UTER
GREASE FITTING
PIPE PLUG
BRUSH
BRUSH HOLDER Y KE
BRUSHHOLDER S UD

Figure 21

56
57
57B
57C
70
75A
73A
75C
75D
76
102B
110A
110B
118A
118B
118C
134
151
153
202A
208A
305A
305B
305C
3050
310

Description
BRUSH HOLDER STUD INSULATION
BRUSHHOLDER
BRUSHHOLDER SPRING
BRUSH HOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
COMM POLE BOLT
MAIN FIELD COIL & POLE WITH BARS
MAIN FIELD POLE BOLT
MAIN FIELD POLE BOLT-BOTTOM
POLE FACE BARS
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM SIDE COMM END-SOLID
COVER, BOTTOM SIDE COMM
END-SCREEN
COVER, TOP SIDE COMM END-SOLID
COVER, TOP SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-HOOD
COVER, LEAD
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

61

BI006008

GEH-3258J, Armored Motors, Type MD800

MDV820, MDV822 MOTORS

U"153
e-16

17B'@~O

EXPLODED VIEW - VERTICAL

'-.
.--' -17A
42-:~-

34--~.-40

-:;.:,
1
"1,

122

"

1-

'2

.....~

_:,.y_ ... ~._'

~-39A

'36

@'31

~~6
310

~._.~

.~'''''/~

\17A

\I

~
/

202 A

62

"

\
XlSA

Figure 22

BI006008

Armored Motors, Type MD800, GEH-3258J

Ref.
No.
1
2
5A
6
6A
9A
10
12
15
16
17A
17B
31
32A
32B
34
36
39A
39B
40
41
42
44
50

D scription
ARMATURE
ARMATURE COIL
ARMATURE COIL SUPPORT-COMM END
ARMATURE COR
ARMATURE COR KEY
MOLDED EQUALI ER
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK WA HER-SPLIT TYPE
PINION LOCK WA HER-BENT TYPE
BEARING
BEARING BRACK T-COMM END
BEARING BRACK T-DRIVE END
SEARING CAP
BEARING CARTRI GE
THRUST COLLAR INNER
THRUST COLLAR OUTER
GREASE FITTING
GREASE TUBE A SEMBLY
PIPE PLUG
SPLIT RING
BRUSH

Figure 22

Ref.
No.
53
55
56
57
57B
57C
70
73A
75A
75C
76
118A
118B
118C
122
124
134
151
153
202A
208A
305A
305B
305C
305D
310

Description
BRUSHHOLDER YOKE
BRUSHHOLDER STUD
BRUSHHOLDER STUD INSULATION
BRUSHHOLDER
BRUSHHOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE WITH BARS
COMM POLE BOLT
MAIN FIELD POLE BOLT
POLE FACE BARS
COVER, TOP SIDE COMM END-SOLID
COVER, TOP SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-HOOD
COVER, SPACE HEATER ACCESS
COVER, FRAME MOUNTING ACCESS
COVER, LEAD
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

63

BI006008

GEH-3258J, Armored Motors, Type MD800

MDP824 MOTORS

EXPLODED VIEW - HORIZONTAL


,

.. ~.... '.

5A

64

Figure 23

BI006008

Armored Motors, Type MDBOO, GEH-325BJ

Ref.
No.
1
2
5A
6
6A
9A
10
12
15
16
17A
17B
31
32A
32B
34
36
39A
39B
40
42
50
53
55
56

Ref.
No.
ARMATURE
ARMATURE COl
ARMATURE COl SUPPORT-COMM END - MOLDED
ARMATURE CO E
ARMATURE CO E KEY
EQUALIZER-MO DED
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK W SHER-SPLITTYPE
PINION LOCKW SHER-BENTTYPE
BEARING
BEARING BRAC ET-COMM END
BEARING BRAC ET-DRIVE END
BEARING CAP
BEARING CARTR DGE
THRUST COLLA -INNER
THRUST COLLA -OUTER
GREASE FiniNG
PIPE PLUG
BRUSH
BRUSHHOLDER OKE
BRUSHHOLDER TUD
BRUSHHOLDER TUD INSULATION

Figure 23

57
57B
57C
70
73A
75A
75C
750
76
102B
110A
110B
118A
118B
118C
134
151
153
202A
208A
305A
305B
305C
3050
310

Description
BRUSHHOLDER
BRUSHHOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE WITH BARS
COMM POLE BOLT
MAIN FIELD POLE BOLT
MAIN FIELD POLE BOLT-BOTTOM
POLE FACE BARS
COVER, BOTTOM COMM END-SCREEN
COVER, BOTTOM SIDE COMM END-SOLID
COVER, BOTTOM SIDE COMM
END-SCREEN
COVER, TOP SIDE COMM END-SOLID
COVER, TOP SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-HOOD
COVER, LEAD
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

65

BI006008

GEH-325BJ, Armored Motors, Type MDBOO

MDV824 MOTORS

EXPLODED VIEW -

VERTICAL

.-12
'- ,;
1
Q."j

@'5A

..I',.>.-.-:.~.

,-.: .. ,..:.;..-

'--'"i
I. .:

6
~'9A

i..

m
I

73A

~.A;-~_~

66

- II

'.:

11 - 76
I

~
202 A

Figure 24

BI006008

Armored Motors, Type MDBOO, GEH-3258J

Ref.
No.
1
2
5A
5B
6
6A
9A
10
12
15
16
17A
17B
31
32A
32B
34
36
39A
39B
40
41
42
44
50
53

D scription
ARMATURE
ARMATURE COIL
ARMATURE COIL UPPORT-COMM END
ARMATURE COIL UPPORT-DRIVE END
ARMATURE COR
ARMATURE COR
EQUALIZER-MOL
SHAFT
COMMUTATOR
PINION KEY
PINION NUT
PINION LOCK WA HER-SPLIT TYPE
PINION LOCK WA HER-BENT TYPE
BEARING
BEARING BRACK T-COMM END
BEARING BRACK T-DRIVE END
BEARING CAP
BEARING CARTRI GE
THRUST COLLAR INNER
THRUST COLLAR OUTER
GREASE FITTING
GREASE TUBE A SEMBLY
PIPE PLUG
SPLIT RING
BRUSH
BRUSHHOLDER
KE

Figure 24

Ref.
No.
55
56
57
57B
57C
70
73A
75A
75C
76
118A
118B
118C
122
124
134
151
153
202A
208A
305A
305B
305C
3050
310

Description
BRUSHHOLDER STUD
BRUSHHOLDER STUD INSULATION
BRUSHHOLDER
BRUSHHOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE WITH BARS
COMM POLE BOLT
MAIN FIELD POLE BOLT
POLE FACE BARS
COVER, TOP SIDE COMM END-SOLID
COVER, TOP SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-HOOD
COVER, SPACE HEATER ACCESS
COVER, FRAME MOUNTING ACCESS
COVER, LEAD
FRAME SPLIT BOLT
SHAFT THIMBLE
SPACE HEATER ONLY
THERMOSTAT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER MOTOR

67

BI006008

GEMotors
General Electric ;~;::;!tor Operation
Drives Motor an
E' PA 16531
3001 East Lake Road, (fe,
Telephone 814875-3129
Telex 703531
Facsimile 814 875-3595
1993 General Electric Comp~ny USA

GEH-3258J 12/933M;TC Prmte m

BI006008

Instmet; '1lS
Direct-Cu rent
Motors a d Generators
Frames C 1BOAT to CD500AT

GEH-3967M

GEMotors

BI006008

SAFETY PRECAUTIONS

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation, or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the matter
should be referred to GE Motors-DM&G.

1989, 1991, 1993, 1994 General Electric Company

Commutator

12.

(Includes Insulator on CD500AT)

Conduit Box Gasket

Bearing Retaining Ring

34.

38.

SpecifY whether for drive end or commutator end.

(Used on CD360AT-eD500AT Drive End Only)

Shaft Cover

32.

(SpecifY side, bottom or top)

Bearing Bracket Covers

Conduit Box Adaptor

29.

30.

Conduit Box

26.

Brushholder Spring

Carbon Brush

23.

(With Pressure Spring and Clip, if needed)

Brushholder

24.

22.

Brushholder Yoke

Brushholder Stud

20.

r:?

Brush Rigging (Includes Complete Assembly for CD 180AT)

18.

21.

Bearing Cap

Ball Bearing

Armature Fan

Bearing Bracket

17.

14.

15.

13.

...

12A. Balance Ring' (Used on CD180AT-eD320AT)

Slot Insulation (Through CD400AT)

7.

Armature Shaft and Core Assembly

Slot Wedge (Through CD400AT)

5.

11.

Armature Coil

4.

8.

Comm. Coil and Pole ~mbly

Armature

3.

...

Description

Main Coil and Pole Assembly

1.

Ref.
N2..:,

35

~
,

,~

"

... ............ ""--",,

~
~

'>

0\

'I

!I!

CD210AT - CD500AT Frames, Exploded View

"

"

..................... *UDllf

II

\_1I

0--=:1~

.. /

'"' ~ [:9l"

(}~-"

Fig. 11

lfl

Direct Current Motors and G enerators, GEH-3967f.

BI006008

BI006008

BI006008

Direct Current Motors and Generators, GEH-3967/\

CONTENTS
PAGE

SUBJECT
INTRODUCTION

RECEIVING

Storage
Long Term Storag Considerations
Handling

LocationNentilati n
Protection
Mounting
Alignment
Motor-Generator ets
Grouting
Alignment Proced re

Fig. 1
Selecting the Proper Key Length
Fig.2A
Bearing Life-Ball Bearings
Fig.2B
Bearing Life-Roller Bearings
Fig. 3
Correct Arrangement of Blower Housing,
Impeller Blades & Direction of Rotation to
Obtain Proper Pressure & Air Flow
Fig.4A
Accessory Mounting CD180AT-CD500AT
Fig.4B-4D
Accessory Mounting CD180AT-CD500AT
Fig. 5,6,7
Brushholder Assemblies
Fig.8
Correct Spacing of Brushholder to Commutator
Insert
Commutator Check Chart
Fig. 9
CD180AT Frame, Exploded View
Fig. 10
CD210AT- CD500AT Frames, Exploded View

4
5
5

6
6
7
7
11
11
11

12

OPERATION
Inspection Before tarting
Bearings and Cou lings
Commutator and rushes
Rectified Power S pplies
Power Supply Iden ification
Connections
Protective Devices
Thermostats
Speed Limit Devic
Space Heater
Ventilation System
AC Blower Motors
Maintenance
Brake
General Mechanic I Inspection
Accessory Mountin
Inspection After St rting
Bearings
Noise and Vibrati n
Inspection After S ort Time In Service

13
13
13
13
13
14
15
15
15
15
16
16
16
17
17
18
18
18
18
18

180AT-CD210ATI
250AT-CD500ATI

utting Specifications

s
Ie Couplings

s
ng

RENEWAL PARTS
Registered trademar of General Electric Company

7
8
9

16
19
20
24
24
29
34
35

LIST OF TABLES
Table 1
Approximate Net Weights
Table 2
Belt Tension Factors
Table 3
Thrust Capacity in Pounds
Table 4
Power Supply Available
Table 5
Lead Markers
Table 6
Maximum Current Ratings for
Speed Limit Switches & Thermostats
Table 7
Blower Motor Lubrication Guide
Table 8
Grade 5 Hardware Torqve Values
Table 9
Commutating and Main Pole Bolt Torque
Table 10
Vibration Values
Table 11
Recommended Regreasing Periods
Table 12
Sources of Supply for Bearing Greases
Table 13
Standard Ball Bearings for Kinamatic~Motors
Table 14
Minimum Brush Length
Table 15
Commutator Diameters
Table 16
Effect of Temperature on Insulation Resistance
Table 17
Recommended Spare Parts
Table 18
Standard Brush and Brush Spring Part Numbers

21

MAINTENANCE

PAGE

LIST OF ILLUSTRATIONS

INSTALLATION

Bearings (Frames C
Bearings (Frames C
Brushes
Brush Seating
Commutator
Commutator Under
Mechanical
Shaft End Play
Waterproof Machin
Lubrication of Flexi
Insulation
Testing Methods
Cleaning of Windin
Drying of Windings
Service Shop Clean
Repair
Failure

SUBJECT

21
21
22
25
25
25
26
26
26
26
26
27
28
30
30
30
31

31
3

5
10
11
13
14
15
17
17
18
18
21
22
23
23
25
27
32
32

BI006008

'irect Current Motors and Generators, GEH-3967M

DIRECT CURRENT
MOTORS AND GENERATORS
FRAMES CD180AT - CD500AT

INTRODUCTION

Protection from wetness and temperature extremes includes moisture from the surrounding atmosphere con-

'his instruction book covers the CD I 80AT-CD500AT line

densing onto cooler machine surfaces. This condensation


on machine surfaces can result in rusting or corrosion and

of DC motors and generators.

WARNING: High voltage and rotating parts

the electrical windings may suffer serious damage.

can cause serious or fatal injury. The use of

Where wetness and/or cold conditions are present, the

electric machinery, like all other utilizations of


concentrated power and rotating equipment,
can be hazardous. Installation, operation, and
maintenance of electric machinery should be
performed by qualified personnel. Familiarization with NEMA safety standards for construction and guide for selection, installation, and
use of integral HP motors and generators, the
National Electrical Code, and sound local practices is recommended.

machine and its parts must be protected by a safe reliable


heating system which, at all times, will keep the machine
temperature slightly above that of the surrounding atmosphere. If a space heater is included in the machine, it
should be energized per the voltage specified on the motor
nameplate.
Smaller machines shipped in paper cartons are protected
from condensing-type wetness by the insulating characteristics of the carton. To avoid sweating where these have
been exposed to low temperatures for an extended period,
allow a few hours for the machine and carton to attain room
temperature before unpacking.

RECEIVING
[he equipment should be placed under adequate cover
mmediately upon receipt as packing coverings are NOT
mitable for out-of-doors or unprotected storage. Standard
factory packing methods do not allow for stacking of

Brushes should notremain in contact with the commutator


during prolonged storage, because corrosion may occur
and later result in flat spots on the commutator. Release
the brush springs and lift the brushes, when prolonged
storage occurs.

motors.
Each shipment should be carefully examined upon arrival.
i\ny damage should be reported promptly to the carrier
and to the nearest office of GE MotonrDM&G. Shipping

All exposed machined-steel parts are slushed with a rust

damage is not covered under the standard warranty. A


claim must be filed with the carrier.

preventive before shipment. These surfaces should be


examined carefully for signs of rust and moisture, and
reslushed if necessary. Once started, rust will continue if

Storage

the surface is reslushed without first removing all rust and


moisture. Rust may be removed by carefully using fine

During installation orwhen in storage, the machine and its


parts must be protected from the following:

using a suitable solvent such as mineral spirits.

1.

Dirt of all kinds.

2.

Wetness and temperature extremes.

abrasive paper. Slushing compound can be removed by

CAUTION:

Many motors are shipped 'with


drive end grounding brushes. These brushes
and the surfaces they ride on must be free ofany

Protection from dirt can be achieved by covering the

slushing compound before operation.

machine with a tarpaulin or polyethylene sheet or keeping


it where the surrounding area is clean.

BI006008

Direct Current Motors and Generators, GEH-3967/1;


WARNING:~ ineral spirits are flammable and
moderately t< lxic. The usual precautions for
handling che ~icals of this type must be obsexved. These nelude:

TABLE 1
APPROXIMATE NET WEIGHTS*

FRAME
SIZE

1. Avoidexce sive contact with skin.


CDL 182AT
CD186AT
CDL 186AT
CD189AT
CD218AT
CD219AT
CD2110AT
CD258AT
CD259AT
CD287AT
CD288AT
CD289AT
CD2811AT
CD327AT
CD328AT
CD365AT
CD366AT
CD368AT
CD3610AT
CD3612AT
CD407AT
CDL407AT
CD409AT
CDL409AT
CD4012AT
CD504AT
CDL504AT
CD506AT
CDL506AT
CD508AT
CDL508AT
CD5010AT

2. Use in well Iventilated areas.


3. Takeneces :aryprecautions to preventfrre or
explosion I azards.
Extreme care must e exercised in removing rust on shaft
extensions near sha t seals, since it is difficult, and sometimes impossible, to remove rust from these surfaces without damaging or de orming them.
Burrs or bumps on other machined surfaces should be
carefully removed b using a fine file or scraper.
Machines in storage should be inspected, have the insulation resistance chec ed at frequent and regular intexvals,
and a log kept of pe tinent data.
CAUTION: ~ hen stored, it is suggested that
the armature b e rotated a few revolutions every
three months o prevent loss of grease protection on the bea rings and races. Loss ofgrease or
oil protection

~ay cause

rust.

Long Term Sol orage Considerations


l.

Provide blocks, uch as railroad ties, to store the


machine off the ground. This will minimize moisture
pickup from the ground and make inspections easier
to accomplish. I e sure there is sufficient drainage.

every three months. If the megger reading indicates a


decreasing insul tion resistance, move the machine to
a drier location.
Wrap Mylar aro fmd the commutator and tape it to
itself. Do not taF e the Mylar to the commutator.

80
102
128
162
240
250
280
360
400
500
550
660
790
690
770
750
860
1020
1310
1650
1300
1350
1600
1650
3210
1900
2070
2290
2440
2810
2970
4260

36
46
58
74
106
114
127
164
183
225
250
300
360
315
350
340
390
465
595
750
590
610
725
750
1460
860
940
1040
1110
1275
1350
1935

Complete motors or generators can be lifted by usin g


hooks or slings in the lifting lugs on top of the unit. Th e

loss of grease pr t>tection on the bearings and races.


Loss ofgrease pr t>tection causes rust. Note: Rotate the
~ection which

8
11
16
20
23
25
29
35
40
51
59
80
95
72
82
100
120
140
130
240
180
180
225
225
350
265
265
330
330
405
405
545

Handling

4. Rotate the arma ure every three months to prevent

armature in the

17
25
35
45
50
56
63
78
89
113
130
175
210
158
181
220
260
300
400
530
400
400
500
500
780
590
590
720
720
890
890
1200

MOTOR
WEIGHT
Ibs.
kgs.

*Approximate weights for typical motors in


each frame size. Does not include weights of
accessories such as tachometers, blowers,
heat exchangers, etc. For specific weights,
refer to certified outline.

2. Megger the unit before storing and record the values

3.

ARMATURE
WEIGHT
kgs.
Ibs.

lifting lugs are designed to safely carry the weight of th e


individual machine. Do not lift the machine with the shaft

will not snag the

extensions.

Mylar wrapping n the commutator.

BI006008

Direct Current Motors and Generators, GEH-3967M


ventilation or totally enclosed inert-gas-filled
motors (Class I locations only) when installation
and operation conform to certain requirements.

WARNING: Motor-generator sets or units with


heavy attachments such as gear boxes or pumps
must NOT be lifted by using the lifting lugs of
the individual machines.

Motors for Class I locations must have leads


sealed at the frame exit and an explosion proof
conduit box. (Refer to Sections 5014 and 501-5.)

Motor-generator set bases have lifting holes to be used with


spreader bars or hooks. Care must be taken in handling to
avoid twisting bases. (Refer to Table 1 for approximate
weights of armatures and motors.)

Motors for Class II locations must have leads


sealed at the frame exit and a dust-ignition-proof
conduit box. (Refer to Sections 5024 and 502-5.)

INSTALLATION
Installation should be in accordance with the National
Electrical Code and consistent with all local codes. Coupling, belt, and chain guards should be installed as needed
to protect against accidental contact with moving parts.
Machines accessible to the public should be further guarded
by screens, guard rails, etc., to prevent personnel from
coming into contact with the equipment. Fully guarded
covers are supplied on motors and generators. Shaft guards
are supplied on MG sets.

CAUTION: Silicone vapor may be present and


originate from sealing compounds, electrical
cables, and room transformers. These sources
must be eliminated. Silicone vapor interferes
with commutation and high brush wear may
result.
Motors and generators should be installed so that they are
readily accessible for routine inspection and maintenance.
They are suitable for use in ambient temperatures from OC
(32F) to 40C (104F). An adequate supply of clean, dry
room air (at temperatures from OC to 40C) is required for
self-ventilated and blown motors. Where motors must
operate in dirty, wet, or contaminated environments, protection in the form of filters or totally enclosed construction must be used to insure long life with normal maintenance.

Totally enclosed and waterproof motors must have all


covers securely in place with gaskets intact in order to
exclude dirt, oil, and water. It is generally preferred to
remove plugs from drain holes at the bottom of the frame
to insure that condensation does not collect inside the
motor. However, if the installation requires plugs to be
installed, they must be removed periodically to make certain that all water is eliminated.

Do not obstruct ventilating openings.

Location/Ventilation

When filters are supplied, service them regularly. Dirty


filters shut off ventilating air.

e use ofelectrical equipment in


tions is restricted by the National
lectric
e,Article 500. Original equipment
manufacturers and user customers must read,
understand, and apply these rules for installation and use of all equipment in such locations
and consult local code inspection and enforcement agencies as necessary to insure compliance. Motors listed by Underwriters Laboratories, Inc. for use in specific locations have been
designed, tested, and approved for use in such
locations only.

Beware of recirculation. Install motors so that hot exhaust


air will not re-enter the motor.

Protection
CAUTION: Windings, commutator, brush rigging, and bearings should be carefully protected
during installation to avoid damage from paint
spray, weld splatter, welding rod butts, or metal
chips from files and grinders. Metal particals
which lodge in windings can cause either immediate or premature failures. Paint or oil on
commutators can be very detrimental to good
commutation.

Sections 501-8 and 502-8 now permit the use of


totally enclosed motors with positive pressure

BI006008

Direct Current Motors and Generators, GEH-3967M

Mounting

Coupled Drive

Motors and generator should be mounted on rigid and


solid foundations. Lev I the base (or the machine). Hold-

When amotor and a driven unit together have four or more

down bolts should be nspected regularly and kept tight.

alignment. Three-bearing construction requires a rigid

The feet of the machin may be doweled to the foundation

coupling.

bearings, flexible couplings must be used to facilitate

plates or base when ali nment procedures are completed.


Sliding bases, when us d, should be securely anchored to
the foundation.
Motors are suitable fo mounting as ordered. Special assembly ofthe conduit b x, endshields, and covers is provided when the motor is s ordered. Do not rotate commutator-end endshield with respect to the frame, since brush

Motors are balanced in the factory using a half-height key


offulliength. To preserve the original dynamic balance of
the motor, select the coupling hub key length "B" accord-

position is affected. ( efer any questions regarding the


allowable mounting 0 ientations for your motor to GE
Motors-DM&G. )

ing to the formula in Fig. 1.

V-Belt Drives

Alignment

The V-belt system produces a heavy shaft and bearing


loading, making it necessary that these factors be considered carefully for proper application. Since belt drives
impose a bending moment on the motor shaft, it is always
desirable to have the motor sheave located as close to the
motor bearing as possible to minimize both bearing load
and shaft stress. This will result in increased bearing life.
For the load centered 2" in toward the bearing from the
end of the shaft instead of at the end of the shaft, the
bearing load is reduced by 10% and the life increased by
33%. The bearing life curves which follow assume that the
load is centered at the end of the shaft. New improved Vbelts are now on the market that significantly reduce the
number and size of belts required for a given load. These
new belts should always be considered, since the sheave will
be shorter and the load centered closer to the bearing.
It should also be noted that the radial load on the motor

bearing is directly proportional to the diameter of the


sheave. A larger diameter sheave means less radial load on
the shaft.
The standard NEMA shaft extension is designed for belted

A=ACCESSORY BOR
LENGTH
C=KE.YWAY LENGTH
(C+A) PROPER
B= =KE.Y
2
LENG

loads. Dimensions are provided on the standard dimension sheets. A sliding base is available as an accessory to
facilitate belt adjustment.

Bearing Life
Bearing life for belted drives is determined by calculating

Fig. 1

the radial load at the end of the shaft.

Selec' g the Proper Key Length

BI006008

Direct Current Motors and Generators, GEH-3967M

10,000

STANDARD BALL

BEARING AND

4,000.

STANDARD SHAFT

3,000

2,000_-

1'500~
1,000

FRAME

CD500AT

aiiDilliii

CD400AT

500~~.1

400~~~mll

- - - CD320AT
111---- CD287AT, CD288AT
CD258AT, CD259AT
_ - - - CD210AT

200

-11---- CD180AT

~-lJ;:Hlffi:eml----- CD140ATC
3,000

5,000
4,000

L10 BEARING LIFE (HOURS)


10,000_

OVERSIZE BALL

<Ii

BEARING AND

...

OVERSIZE SHAFT

al

:::!..
~

cr:

4,000

\I)

3,000=_

::E:

o
o

...Z

2,000

tr.-.......tttt

=c

~
cr:

1,000

0'

CD400AT

o...

...cr:

CD360AT

1111111~3~m~~~id]jlfi:::::=---

'5

=:
=:

::J

400

CD320AT

300

><
cr:

=:
100
1,000

2,000

3,000

5,000

10,000

20,000 30,000

50,000

100,000

L 10 BEARING LIFE (HOURS)

Fig.2A

Bearing Life at 1750 RPM Average Speed vs. Load, W


(For other Average Speeds, multiply Life by 1750/average speed.)

BI006008

Direct Current Motors and Generators, GEH-3967M

10,000.

STANDARD SIZE
ROLLER BEARING
AND STANDARD
SHAFT

FRAME
CD500AT

CD360AT & CD400AT


CD320AT

300~
200~

100
1,

OVERSIZE
ROLLER BEARING
AND OVERSIZE
SHAFT

10,000

iii
lID

:::!.
~

II.

c(

:z:

5,000
4,000
3,000

FRAME
CD'5010ATZ

2,000

FRAME
CD500AT

1,500

1,000

V)
II.

0
Q

IU

c(

CD320AT

c(

......0
c(

c(
~

;:)

500
400

300

)(
c(

200

100
1,

tjj::r:J:tlt!Jm
2,000 3,000

5,000
4,000

10,000

20,000 30,000
50,000
40,000

100,000

l10 BEARING LIFE (HOURS)

Fig.2B

Bearing Life at 1750 RPM Average Speed vs. Load, W


(For other Average Speeds, multiply Life by 1750/average speed.)

BI006008

Direct Current Motors and Generators, GEH-3967M


If slippage occurs after the belt tension has been correctly

TABLE 2

adjusted, the belts and pulleys have not been chosen

BELT TENSION FACTORS

1.0
1.2
1.5
1.8
2.0

properly for the application.

Chain and Sprocket Drive


Timing Belt
V-Belt, 1:1 Ration
V-Belt, 2:1 Speed Decreased Ratio
Flat Belts

The radial load, "W", produced by the belts, when tight-

There is normally a drop in tension during the first 24 to 48

ened just enough to transmit the load without slipping, is

hours of operation. During this "run-in" period, the belts

given by the relation:

seat themselves in the sheave grooves and initial stretch is


removed. Belt tension should be re-ehecked after a day or

126,000 x HP x ~ lbs
DxRPM

two of operation.

Sheave pitch diameter in inches for V-belt applications.

life results, if the belts and sheaves are kept clean and the

Where:

Matched belts run smoother, and last longer. Longer belt

HP

Maximum ratio of horsepower, including over-

belts are prevented from rubbing against the belt guards or


other obstructions.

RPM

loads, to the minimum speed at which that

Mounting may be either horizontal or vertical for these

power occurs.

bearing life determinations, as long as no axial load other

Belt tension factor from Table 2.

than the weight of the armature is present if vertical.

Special Load Considerations

The curves in Fig. 2 can be used to determine the anticipated LIO life, which is the life in hours that 90% of

Where the load is overhung beyond the motor shaft exten-

bearings with this load would be expected to exceed


without failure. The standard ball bearing and standard

sion or greater bearing life is desired, the application


should be referred to GE Motors-DM&G.

shaft option will be the most economical, if acceptable life

Thrust Loads

is obtained from the curve. A good, commonly used design

Due to the mounting position or type of drive arrange-

figure is 20,000 hours. However, calculated life of as low as

ment, a thrust load may be applied to the motor shaft. The

5,000 hours has sometimes been necessary for special

Kinamatic motor is designed to permit a limited amount of


thrust load. This permissible load will vary by mounting

applications. The curves are drawn for 1750 RPM average


speed. If the application has some other average speed, the

position and direction of the load due to the w~ight of the

life can be adjusted by multiplying by the 1750/average

armature. The permissible load is tabulated in Table 3 by

speed.

frame diameter and mounting position. These apply to


standard size ball bearings only.

It is important to know that the bearing life for V-belt

applications is independent of the motor load. Once the

For vertical mounting, the data is tabulated with a plus or

belts have been tightened just enough to prevent slipping

minus constant. If the force of the load is acting up (against

when the maximum torque is being delivered by the motor,

gravity), then the constant should be plus. If the load is

the radial load, "W", on the shaft and bearing is there and

acting down (with gravity), then the constant should be

remains constant regardless of the motor load. For timing

minus.

belts and chain drives, the radial load, "W", does vary
somewhat with motor load, and so the motor load duty

For applications combining thrust and radial loads or

cycle, as well as the average speed should be considered to

where thrust loads exceed the values shown in the table,

estimate bearing life.

refer all details to GE Motors-DM&G.

For special applications belt tension should be checked


and adjusted following the belt manufacturer's recommendations.

10

BI006008

Direct Current Motors and Generators, GEH-3967M

TABLE 3
THRUST CAPACITY IN POUNDS

VERTICAL MOUNTING

HORI ONTAl MOUNTING


FRAME
CD180AT
CD210AT
CD250AT
CD280AT
CD320AT
CD360AT
CD400AT
CD500AT

------------1

2500

RPM
1750

1150

850

145
190
225
300
355
630
580
890

172
220
265
355
410
740
690
1050

210
270
325
430
500
880
840
1310

240
310
370
490
580
1040
970
1510

Motor-Gener

2500

1750

RPM
1150

850

15017
17517
21417
24017
20064
24064
28564
33064
25093
28593
34593
39093
330135
380135
460135
525135
390190
460190
545190
620335
700335
820335
970335
1110335
700526
820526
970526
1110526
--------------- REFER TO GE MOTORS-DM&G ----------------

or Sets

quired. (Refer to the Alignment Procedure section of this


Instruction Book.)

MG sets are properly ligned before shipment. Check the


alignment before ope ating a set to be sure that shipping,

Grouting

handling, and install tion have not misaligned the units.


(Refer to the Alignm t Procedure section of this Instruction Book.)

On concrete foundations, a minimum of 1" should be


allowed for grouting.
A Iich, non-shrink grout should be used. High-grade grout
mixtures are available commercially. If the grout is to be
prepared at the site, a cement-sand ratio of 1:2 is recommended. Only enough water should be used to give a stiff
mixture. The dean, but rough surface of the foundations
should be wet and the grout forced or puddled under the
base.

Two types ofMG set b ses are used. One is called "non-selfsupporting" and, as th name implies, is not rigid. The nonself-supporting base s designed to act only as a spacer
between the foundati n and the units of the MG set and
must not be trusted
carry any weight unless well supported at all of the m unting pads on its underside. This
type of base should b securely bolted to the foundation
and, if convenient, g uted in after alignment. Grouting
tends to make the b e more solid and less liable to later

Alignment Procedure

vibration troubles. Be areful not to distort the base during


handling or the abili to properly align the MG set will be
destroyed.
The other type of b se is called "self-supporting" and
usually has three pad on it" underside forming a threepoint support. A self- upporting base is rigid enough so
that it needs support nlyat the pads. The entire weight of
the MG set is support don just these three points and the

Flexible Coupling
Before grouting the base, the alignment should be checked
as follows:

foundation must be d signed to take these high loads.

1.

Two kinds of couplin s are used to connect units of MG


sets. Some MG sets . I be made up of two-bearing units

Slide the sleeve from the coupling so that the hub faces
are exposed.

2.

coupled together wit flexible couplings. Others will use

Check that the coupling hub spacing is in accordance


with the outline dimensions with the units in the

single-bearing genera rsconnected with rigid (solid) couplings. With each kin of coupling and each kind of base

mechanical center of their end play.

design, a slightly di erent alignment procedure is re-

11

BI006008

Direct Current Motors and Generators, GEH-3967M


3.

4.

5.

Start with the coupling next to the largest unit (usually


the motor) or near the middle of a long set. Check the
radial alignment by using a straightedge across the
hubs at both vertical and horizontal locations or by
clamping a dial indicator to one hub and indicating
the other hub on its outside diameter. Be sure that the
dial indicator supports do not bend or sag, since this
will give inaccurate readings.
Use a dial indicator at hub faces and rotate both units
together 90,180,270, and 360; or measure the gap
at each position by inserting a feeler gauge. The
reading should not vary more than 0.002 ".
Correct any misalignment by shimming between the
base and the foundation. If shimming between the
base and foundation will not correct misalignment,
the unit has moved during shipment and should be
shifted on the base.

6.

Repeat Steps #2, 3, and 4 on each coupling, working


away from the motor or center unit.

7.

Recheck the couplings on long sets after completing


the above checks, because shimming on subsequent
units may affect those already checked. After the set
has been aligned within the specified limits, the coupling shells may be bolted together.

Startwith the coupling next to the largest unit (usually


the motor) or near the middle of a long set, tap the
coupling flange with a rawhide or similar non-metallic
mallet until the coupling halves separate 0.005" to
0.010".

3.

Correct any misalignment by shimming between the


base and the foundation. If shimming between the
base and the foundation does not correct misalignment, the unit has moved during shipment and should
be shifted on the base.

6.

Repeat Steps #2, 3, and 4 on each coupling, working


away from the motor or center unit.

7.

Recheck the couplings on long sets after completing


the above checks, because shimming on subsequent
units may affect those already checked. After the set
has been aligned within the specified limits, tighten
the coupling bolts.

OPERATION
WARNING: Disconnect power before touching
any internal part. High voltage may be present
even when the machine is not rotating. If used
with a rectified power supply, disconnect all AC
line connections to power supply. With other
power supplies, disconnect all DC line and field
connections. Also disconnect power from auxiliary devices.

Before grouting the base, the alignment should be checked


as follows:

2.

5.

CAUTION: Do not draw the two coupling


halves together unless the variation in measurements is 0.002" or less. If there is a variation
greater than 0.002", excessive vibration and
possible shaft fatigue can occur.

Solid Flanged Couplings

Loosen all coupling bolts enough to assure that the


bolts are not holding the couplings together.

Rotate the coupling 90,180,270, and 360 and take


similar readings. The maximum variation should not
exceed 0.002".

The generators may then be doweled, if desired.

The generators may then be doweled, if desired.

1.

4.

WARNING: Ground the machine properly to


avoid serious injury to personnel. Grounding
must be in accordance with the National Electrical Code and consistent with sound local practices. One of the bolts holding the conduit box
to the unit, accessible from inside the conduit
box, is identified and may be used for attaching
a grounding cable.

Measure the distance between the coupling faces at


four points spaced 90 apart around the coupling rim
with a feeler gauge; measuring to the nearest 0.001 ".
The maximum variation between any two readings
should not exceed 0.002".

12

BI006008

Direct Current Motors and Generators, GEH-3967M


The ratings of DC motors intended for operation from
rectified power supplies are based upon motor tests using
a suitable power supply. The specific characteristics for
three-phase rectified power supplies described below in

Inspection Be ore Starting

the Power Supply Identification section are in common


use. For operation of motors from rectified power supplies

These inspection pr

other than those given in this section, refer to GE Motors-

edures should be followed before

starting the machine or the first time, after an extended


shutdown, or after a t ardown for extensive maintenance

DM&G.

or repair.

A motor may, under some conditions, be operated from a


power supply different from that indicated on the name-

Bearings and

plate. Letters used to identify power supplies in common

Machines with ball

roller bearings are greased at the

use have been chosen in alphabetical order of increasing

factory and will nee

no attention until relubrication is

magnitude of ripple current. Power supply compatibility


can be judged by Table 4.

necessary as sugg sted under the Maintenance


section. (Refer to Tab e 11).
Flexible couplings s

checked to see that they

contain the proper a

The oil suspended in grease may leak out after extended


periods of motor stor ge. Because of this, it is not unusual
to find puddles of oil elow the bearings. If the motor has
been stored for over s x months, the grease drains should
be checked to see the are not plugged with a waxy residue.
After ensuring the 0 enings are clear and free, a small
amount of grease sho ld be pumped through.

Commutator nd Brushes
Brushes should bewo n in to have at least 85% contact over
the brush surface and ontinuous contact from heel to toe.
The commutator su ace and undercut mica should be
clean and free from di t, grease, paint spots, or brush dust.

The nameplates ofDC motors intended for operation from


rectified power supplies will be stamped with a Power
Supply Identification as described below:

Brushes should be fr e to move in the holders and all


springs should be do
and latched. Brush pigtail connections should be tight, nd the pigtails should not interfere
with the action of the pring or brush and should be clear

A. When the power supply used as the basis of rating is


one of the four described below, a single letter "C", "D",
"E", or "K" will be used to identify it on the nameplate.

of any other part of t e machine.

Power Supply Identification Letter "e"

Rectified Pow r Supplies

This designates a three-phase, 60 hertz input, full-wave

When DC motors are operated from rectified power supplies, the pulsating v tage and current wave forms effect

power supply having 6 total (controlled) pulses per cycle.


The power supply has no free wheeling and no series

the motor performan e by increasing motor heating and

inductance added externally to the motor armature circuit

degrading commutat on. Because of these effects, it is

inductance. The input line-to-line AC voltage to the recti-

necessary that the mo rs be designed or specially selected


to suit this type of op ration.

fier shall be 230 volts for 240volt DC motor ratings, and 460
volts for 500 or 550 volt DC motor ratings.

13

BI006008

Direct Current Motors and Generators, GEH-3967M


Power Supply Identification Letter "0"

Connections

This designates a three-phase, 60 hertz input, semi-bridge

Terminal connections should be checked against the con-

power supply having 3 controlled pulses per cycle. The


supply has free wheeling with no series inductance added

nection diagram shipped with the machine. Bolted connections must be tight. When fixed termination (terminal

externally to the motor armature circuit. The input line-to-

boards) is not specified, then the exposed connections

line ACvoltage to the rectifier shall be 230 volts for 240 volt
DC motor ratings and 460 volts for 500 or 550 volt DC motor

should be appropriately insulated. Grounding screws or


studs do not need to be insulated. When more than one

ratings.

terminal is marked with the same identification, they

Power Supply Identification Letter "E"

should be joined in the same connection. (Refer to Table


5 for identification of winding leads.)

This designates a three-phase, single-way (half-wave) power


supply having 3 total pulses per cycle and 3 controlled

When series leads are not being used (example: a stabilizpd


shunt or a compound wound unit being used as a straight

pulses per cycle. The power supply has no free wheeling


and no series inductance added externally to the motor
armature circuit inductance. The input line-to-line AC

shunt), the lead should be individually insulated. Do not


connect together.

voltage to the rectifier shall be 460 volts for 240 volt DC


motor ratings.

TABLE 5
LEAD MARKERS

Power Supply Identification Letter "K"

FUNCTION

This designates a single-phase, full-wave power supply


having 2 total (controlled) pulses per cycle with free
wheeling 60 hertz input with no series inductance added
externally to the motor armature circuit. The input AC
voltage to the rectifier shall be 230 volts for 180 volt DC
ratings.
B. When intended for use on a power supply other than
"C", "D", "E", or "K", the motor will be identified as follows:
M/NF-V-H-L

A1, A2, A3, A4, etc.

Control signal lead


attached to commutating
winding - one lead only.

More than one signal lead

C1, C2, C3, C4, etc.

Field (shunt)

F1, F2, F3, F4, etc.

Field (series)

S1, S2, S3, S4, etc.

Bbwer Motors,
Type AN tachometer
generator

T1, T2, T3, T4, etc.

Tachometer generator,
direct current, to terminal
board

A 1, A2, A3, A4, etc.

free wheeling is used).

Brake coil leads

B1, B2, B3, B4, etc.

3 digits indicating nominalline-to-line AC


voltage to the rectifier.

Heater, brake space


heater

BH 1, BH2, BH3,
BH4, etc.

Brake interlock switch

BS1, BS2, BS3,


BS4, etc.

Heater, space heater in


the machine

H1, H2, H3, H4, etc.

Thermostat

P1, P2, P3, P4, etc.

Resistance Temperature
Detector (RTD)

R1, R2, R3, R4, etc.

M = a digit indicating total pulses per cycle.


N = a digit indicating controlled pulses per
cycle.
F = free wheeling (this letter appears only if

Armature

ACCESSORIES & SPECIAL DEVICE MARKINGS

Where:

WINDING

H = 2 digits indicating input frequency in hertz.


L = 1,2, or 3 digits indicating the series inductance in millihenries (may be zero) to be
added externally to the motor armature
circuit inductance.

14

BI006008

Protective

Direct Current Motors and Generators, GEH-3967M

De~ices

TABLE 6

See that all protective devices (overspeed devices, bearing


temperature relays, e c.) are connected and will function
properly. Be sure all coupling guards, shaft protectors,
grounding connector, covers, and other safety devices are
properly attached.

MAXIMUM CURRENT RATINGS FOR


SPEED LIMIT SWITCHES & THERMOSTATS
ON DRIPPROOF & TOTALLV
ENCLOSED MOTORS
(Normally open or normally closed contacts)
LOAD

CAUTION: Mo or Field Heating - Unless specificallyordered motors are NOT capable of


continuous stan ~still excitation at rated field
current. When tI e motor is shut down for more
than 30 minutes one of the following options
must be used:

125 VAC

250 VAC

600 VAC

30VDC

Do not use above 600 VAC or 30 VDC


Resistive

5 AMPS

2.5 AMPS

1 AMP

5AMPS

* Inductive 3 AMPS

1.5AMPS

O.5AMP

1.5AMPS

* Suitable for pilot duty only (relay coils)

Speed Limit Device


1. De-energize title fields completely.

2. Use field eC(J~omy relays to limit the field


current to a lJ~aximum of 50% of the nameplate rating.

The standard mechanical speed limit device is non-adjustable. Tripping speed is specified by a note on the print
certification for each specific order and on the motor
nameplate.

3. When applic< ble, fields may remain fully energizedifthelJ otorventilationsystem (blower
or customer ( uct) remains in operation.

The speed limit electrical contacts are normally closed and


are usually connected in relay or holding circuits. Current
ratings are the same as Table 6.

Thermostats

WARNING: The contacts of the speed limit


device automatically reclose after the speed has
fallen below the trip value. In order to prevent
property damage or injury to personnel, the
control circuit should be designed to prevent reenergizing the motor until the cause of the
overspeed has been corrected.

The thermostat is a dl"vice that may be used in alarm or


protective relay circui ~ within rating limits shown in Table
6. It is not intended 0 limit motor loading or provide
normal insulation life. When supplied, it is mounted in
contact with a comml tating coil which is the only accessible part ofthe armatl re circuit. Since factors such as shaft
speed, ventilation (blower or shaft fan), current ripple
(SCR phase-back), anI short-time overload affect the temperature relationship IJetween the armature and commutating field, complete I rotection from all conditions resulting from over-temper ture is not possible. The device is
especially useful in gu rding against loss of normal ventilation air, high ambient temperature, and prolonged operation of self-ventilated motors at very low speeds.

Space Heater
When furnished, refer to the Print Certification for Electrical Rating or the motor nameplate.

WARNING: The surface ofaspace heater block


becomes hot when the heater is energized. The
temperature rise above the ambient temperature may be as high as 4000C. Avoid touching
heater blocks which have recently been energized to prevent burns. Also, to prevent fire or
explosion, ignitable dust or lint should not be
allowed to collect around the surface of the
heaters.

WARNING: Thermostats automatically reset


after the motor I as cooled somewhat. In order
to prevent prope ty damage or injury to personnel, the control ircuit should be designed to
prevent the aut matic starting of the motor
when the therm< stat resets.

15

BI006008

Direct Current Motors and Generators, GEH-3967M

Ventilation System

Power Supply and Connections

Blowers or central systems must be in operation to supply


cooling air before loading force-ventilated machines. Air

The nameplate voltage and frequency should agree with


power supply. Motors will operate satisfactorily on line
voltage within + -10% of the nameplate value or frequency

filters should be in place. Blowers should be checked for


correct rotation. (Refer to Fig. 3 for correct direction of

within + - 5% combined variation not to exceed +- 10%.

rotation.)

Dual voltage motors can be connected for the desired


voltage using instructions on the nameplate or connection
diagram.
Wiring ofmotor, control, overload protection, and grounding should meet the National Electrical Code and local
building codes.
AIR INLET

Maintenance

HOUSING

Inspection

IMPELLER
BLADES

Inspect the motor at regular intervals. Keep motor clean


and ventilating openings clear.

INTERNAL
BAFFLE

Lubrication

AIR FLOW
AIR FLOW
V18N LOOKING AT AIR INLET,
NP36M24875
BLOWER MOTOR IS ON FAR SIDE

Ball bearing motors are adequately lubricated at the factory. Motors, if equipped with grease fittings, should be
relubricated at intervals consistent with type of service
(refer to Table 7) to provide maximum bearing life. Excessive or too frequent lubrication may damage the motor.

Fig. 3

Correct Arrangement of Blower


Housing, Impeller Blades and Direction ofRotation to Obtain Proper
Pressure and Air Flow

Relubricate the motor with GE-D6-A2C5 grease unless


special grease is specified on the nameplate. For best
purging of old grease, relubricate while the motor is warm
and the shaft stationary.

AC Blower Motors (If Equipped)


Remove caps on the fan cover for access to the grease plugs.
On the drive end and opposite drive end of motors with
pipe plugs, insert a lubrication fitting. Remove the other
plug for grease relief of all motors. Clean grease relief
opening of any hardened grease. Be sure fittings are clean
and free of dirt. Using a low pressure, hand operated

Mounting
When bases are removed on enclosed motors, the enclo-

grease gun, pump in clean recommended grease until new

sure must be maintained by plugging the bolt holes with

grease appears at the relief hole. After relubricating, allow


the motor to run for ten minutes before replacing relief

the plastic plugs from Kit No. 182lBPKl.

plug.

16

BI006008

Direct Current Motors and Generators, GEH-3967M

General Mechanical Inspection

TABLE 7

Check the inside of the machine for tools, metal chips, or

BLOWERMO OR LUBRICATION GUIDE


Type of
Service

Typic I
Examp es

HP
Range

S
T
A
D
A
R
D

1 or 2 S ifts

.5 -7.5

Severe

Continuou Duty
and/ r
Severe Vi ration

.5 -7.5

Dirt and Vi ration


and/ r
High Am ient

.5 -7.5

Very
Severe

any other foreign material that may have accumulated


during storage or installation. Make sure that all rotating

Lubrication Interval
Horizontal Vertical
7 yrs.

parts have clearance from any stationary parts. Turn the


machine over by hand, if possible, and check for scraping

3 yrs.

noises or any other signs of mechanical interference.


Check the tightness of the bolts in the feet, couplings,
bearing housings, and any other bolts that may have been
disturbed. Also check the torque of the yoke bolts. (Refer
to Table 8.)
4 yrs.

9 mos.

1.5 yrs.

Check the tightness of the main and commutating pole


bolts (as listed in Table 9) at start-up. Loose pole bolts
could be a source of objectionable noise when motors are
supplied from rectified power. Also check the torque ofthe

6 mos.

yoke bolts.

Motor windings
TABLE 8

To clean motors, use soft brush and, if necessary, a slow


acting solvent in a we 1ventilated room.

GRADE 5 HARDWARE TORQUE VALUES

BOLT
THREAD
SIZE (inches)
1/4
5/16
3/8
1/2
5/8
3/4
1

Brake
Flange-mounted bra
rabbet. Since the acc
with a brake, the sta
extension should be
Standard brakes are
ing only. When moto

es may be mounted on the accessory


ssory stub shaft is not suitable for use
dard NEMA commutator end shaft
ordered when such use is planned.
esigned for horizontal floor mounts are sidewall or ceiling mounted, the

brake must be reasse bled to maintain its relation to the


horizontal. Where m tors are to be mounted with the shaft
vertical up or down, special brakes should be specified.
Brakes used on sever applications, such as outdoor gantry
cranes, have many s ecial features.

17

- 20
18
16
13
11
10
- 8

HEX
HEAD
DIMENSION
7/16
1/2
9/16
3/4
15/16
1 1/8
1 1/2

TORQUE
LB. FT.
7
13
24
60
120
210
460

TO
9
TO 17
TO 30
TO 75
TO 150
TO 260
TO 580

BI006008

Direct Current Motors and Generators, GEH-3967M


ing adapter, which can be machined for various accessories, can be ordered separately.

TABLE 9
COMMUTATING AND MAIN POLE
BOLT TORQUE
FRAME

*
**

CD180AT
CD210AT
CD250AT
CD280AT
CD320AT
CD360AT/CD400AT
CD360AT/CD400AT
CD500AT

Inspection After Starting

BOLT
SIZE

TORQUE lib-ttl
A
B

3/8-16
3/8-16
3/8-16
1/2-13
1/2-13
3/8-16
3/8-16
1/2-13

24-30
24-30
24-30
60-75
60-75
35-42
24-30
60-75

The following items should be checked after the machine


is running:

Bearings

16-20
16-20
16-20
36-45
36-45
23-28
16-20
36-45

Ball-bearing or roller-bearing housing temperature should


not be more than 80C (176F). Check alignment and
lubrication if temperature exceeds this limit. Do not overgrease. (Refer to the Regreasing Procedure section of this
Instruction Book.)

Noise and Vibration

A. For steel bolts when assembled without lubricant


(dry threads)
B. Forsteel bolts when assembled with lubricatedthreads
* 6 radial slashes on bolt head. (Grade 8)
** 3 radial slashes on bolt head. (Grade 5)

Check for unusual vibration or noises that might indicate


rubbing or interference.
Vibration of new machines at the bearing housings, as
measured by a vibration meter, should not exceed the
values shown in Table 10. (The motor is mounted alone on

CAUTION: Standard motors, as shipped, are


assembled with bolts without lubricant (dry

rubber per NEMA method.)

threads). Bolts may be replaced when necessary


with bolts with dry threads, or with bolts lubricated with a motor oil or other suitable thread
lubricant. When lubricated threads are used,

The most likely cause of vibration 10 new machines is


misalignment due to improper installation, loose foot
bolts, uneven shimming under feet, or damage to machine
during shipment or installation. Current ripple due to
rectified power supply may also be a source ofvibration and
audio noise.

the lower torque values in column B will apply.


The higher torque values in column A, when
applied to bolts with lubricated threads, can
cause excessive bolt tension and possible bolt
breakage.

TABLE 10
VIBRATION VALUES

Accessory Mounting
Provisions for mounting accessories on the commutator

RPM

end shield is a standard feature on frames CD210AT and


above. The rabbet has NEMA Type FC face mounting

3000 - 4000 inc!.


1500 - 2999 inc!.
1000 - 1499 inc!.
999 and below

dimensions, including the mounting bolt holes as shown in


Fig. 4. The standard stub shaft also permits coupling
certain accessories.
WARNING: To prevent injury from rotating
shaft, the stub shaft cover must be maintained in
position when the accessory mounting is not

MAXIMUM AMPLITUDE
IN INCHES
(PEAK TO PEAK)

.001
.0015
.002
.0025

Inspection After Short Time in


Service

used.

New machines may smell warm or have the odor ofvarnish,


but should not smell scorched.

Standard accessories are available as kits. These include a


variety of tachometers and speed limit switches. A mount-

Mter a machine has been operating for a short time, an


inspection should be made to ascertain that there have

18

BI006008

Direct Current Motors and Generators, GEH-39671

NOTE: Max permissible thread


engagement in these
holes is 1.00'.

Accessory mounting face


See machine
outline for
location

0.24'

NOTES:
Accessories shaft as shown furnished on all machines not having commutator end shaft extensions.

8.500'
8.498' Dia.
0.40"

Accessories shaft is suitable for driving tachometer and speed limit switch.
For brake application a keyed commutator end
shaft extension is required.

0.50'-13 tap
(4) Holes
equally spaced

Furnished on CD180AT only when specifically ordered.

2.1250"
2.1245' Dia.

1.1250"
1.1245' Dia.
CD180AT and CD21 OAT do not
have shoulders as shown.
Furnished on CD180AT only
when specifically ordered.

0.500'-13 tap 1.25 Deep


60 Deg. center 0.75' Dia.

CD360AT

CD180AT320AT

l ~~~:D~

0.625'-11 tap
1.56' Deep
60 Deg. center
1.00' Dia.

-+-----+

0.500'-13 tap 1.25' Deep


60 Deg. cent r 0.75' Dia.

(2)0.375'-16 tap
1.00 Deep

CD500AT

CD400AT
Standard commutator-end bracket
and accessory shaft extension.

Fig.4A

Accessory Mounting CD180AT - CD500AT

19

BI006008

Jirect Current Motors and Generators, GEH-3967M

0.462 Dia.
(4) Holes equally spaced

Accessory
mounting face

Ir

Accessory
mounting face

0.2S20tap
(4) Holes equally spaced

~3.96.

4.24

4.502
4.501 Dia.

Form -yo Tachometer adapter


mounts on bracket shown in Fig. SA

BC42/BC46 Tachometer adapter


mounts on bracket shown in Fig. SA

Fig.4B

Fig.4C

KEYWAY

IIA"

Accessory
mounting face

(2)

No. 10-32 tap


90 Deg. apart

Adapter, Scr_ & Dowel used on CD21 OAT-320AT only.


Coupling bolts directly to shaft on CD360-SOOAT.

WIDTH

DEPTH

.6255
.6250

.1875

.0937

.7505
.7500

.1875

.0937

.5005
.5000

OMIT

.3130
.3125

OMIT

T orsionaJly rigid coupling rated at


.17 HP per 100 RPM.

Fig.4D
Fig.4B-D

Accessory Mounting CD180AT - CD500AT

20

BI006008

Direct Current Motors and Generators,

GEH-3967~

been no changes sin e installation. Re-torque all main and

Motors operating in ambient temperatures above 40"(

commutating pole bolts. (Refer to Table 9.) Also check the

should reduce interval listed in Table 11 by half.

torque of the yoke bolts. (Refer to Table 8.) Check for


increased vibration, signs of change in alignment or foun-

TABLE 11

dation settling, bol ~ that may have loosened, rubbing


parts, loose connecqms, and worsened commutation, and

RECOMMENDED REGREASING PERIODS

RELUBRICATION
INTERVAL IN
HOURS OF
OPERATION

take the proper steT s to correct the trouble. Also, check


condition of air filte s on blower ventilated machines. The
amount ofdirt in the air varies widely between installations.

MAINTENANCE

FRAME
SIZE

WARNING: I- igh voltage electric shock may

AVERAGE
RPM

BALL
BEARING

ROLLER
BEARING

cause serious a fatal i~ury. Disconnect power


before touchin any internal part. High voltage

CD250AT,
CD280AT &
CD320AT

may be presen even when the machine is not


rotating. If use ~ with a rectified power supply,
disconnect all V\C line connections to power

500
1150
1750
3000

36000
15000
10000
5000

18000
7500
5000
2500

CD360AT &
CD400AT

500
1150
1750
3000

30000
12000
6000
2500

15000
6000
3000
1250

CD500AT &
CD5010AT

500
1150
1750
2000

25000
8000
4000
2600

12500
4000
2000
1300

supply. With at her power supplies, disconnect


all DC line and field connections. Also, disconnect power fro

auxiliary devices.

WARNING: Grpund the machine properly to


avoid serious iI ~ury to personnel. Grounding
must be in acco dance with the National Electrical Code and c nsistent with sound local practices.

For best lubrication results, regrease with GE grease No


D6A2C5 or an equivalent lithium base ball bearing grease
(Refer to Table 12.) Avoid mixing different kinds ofgrease
Lubricate motor at standstill. Make sure the grease fitting
is clean and free from dirt. Remove lower grease relief plug
(reliefpipe on fan-eooled motor). Free the reliefhole from
any hardened grease. Use a hand-operated grease gun

WARNING: Replace covers and protective devices before op< rating.

Bearings (Frarnes CD180AT-CD210AT)

only. Pump in grease until new grease appears at lower


grease hole. (Insert pipe occasionally on fan-eooled motors
to check for appearance of new grease.) Mter greasing

Double shielded bear ngs are standard in these frame sizes.


The bearings are lub Iicated by the bearing manufacturer
and are not regreas ble. These bearings should be re-

allow motor to run about ten minutes before replacing


grease relief plug (or pipe) to permit excess grease to drain
out.

placed whenever the motor is disassembled for servicing.

Bearings (Frarnes CD250AT-CD500AT)


Bearing housings an packed with grease at the factory.
Greasing is not reqt: ired before the motor is put into
service. Since the oil n the grease will ultimately become
depleted, itis necessaI vto relubricate bearings periodically
depending on the fra ne size of the motor, average operating speed, and the ty e of bearing (ball or roller). (Refer
to Table 11.)

21

BI006008

)irect Current Motors and Generators, GEH-3967M


bearing. Discard the old bearing. The new bearing and all
mating parts should be kept extremely clean during reassembly. (Refer to Table 13 when selecting replacement
bearings.)

CAUTION:lfalargeamountofgreaseispumped
into the motor and none appears at the drain,
then remove the handhole covers and visually
inspect the area where the shaft protrudes thru
the cap and endshield for grease leakage. This
would indicate that the drain is plugged up. If
this occurs, then remove bearing cap and clean
all dried grease out ofthe cavity and drain hole.
Refill 1/3 full. Be sure to wipe away any grease
leakage before reassembling the handhole covers. Repeat cleaning after 12-24 hours of operation.

To install a new bearing, heat the bearing to 116-127C


(240-260F) in oil or in an oven. Then slip or press the
bearing on the shaft. The bearing should be mounted
tightly against the shoulder on the shaft.
Mter the bearing has cooled, re-install the retaining ring
where used. Fill the grease reservoir in the inner bearing
cap or cartridge 1/3 to 1/2 full of grease. Butter the
bearings and fill the grease reservoir in the bearing bracket
1/3 to 1/2 full of grease.

Replacement of Bearings

Brushes

Mter the bearing brackets have been removed, a bearing


puller may be used to pull the bearings from the shaft.
Protect the shaft center while using the puller. On frames
CD360AT through CD500AT, it may be necessary to remove the bearing retaining snap ring before pulling the

(Refer to Figs. 5, 6, and 7.)

Good brush performance is dependent on the care used in


fitting and adjusting the brushes before the machines are
put into service. An initial inspection of brush condition

WARNING: Extreme pressure (EP) greases should not be used in DC machines. Insulation deterioration and
increased brush wear may result from the presence of silicones.
TABLE 12
SOURCES OF SUPPLY FOR BEARING GREASES
Temperature
STANDARD TEMPERATURE
15F to 212F
-10C to 100C

GE Designation
D6A2C5

Supplier

Supplier's Designation

GE Supply
158 Gaither Drive
Mt. Laurel, NJ 08054
1-800-341-1010

GE Ball Bearing Grease


(supplied in small
tubes and cans

Shell Oil Company


P.O. Box 2463
One Shell Plaza
Houston, TX 77002
(713) 241-4201

Alvania No.2

Texaco, Inc.
200 Westchester Avenue
White Plains, NY 10650
(914) 253-4000

Regal AFB-2

LOW TEMPERATURE
-60F to 200F
-51C to 93C

D6A4

Shell Oil Company


P.O. Box 2463
One Shell Plaza
Houston, TX 77002
(713) 241-4201

Aeroshell No.7

HIGH TEMPERATURE
-20F to 350F
-28C to 176C

D6A2C13

Standard Oil Company


225 Bush Street
San Francisco, CA 94120
(415) 894-7700

Chevron "SRI II"

22

BI006008

Direct Current Motors and Generators,


!

GEH-3967~

TABLE 13
STANDARD BALL BEARINGS FOR KINAMATIC MOTORS*

NEMA
FRAME DIAM ETER

STANDARD
COMM END
BEARING

180AT
210AT
250AT
280AT
320AT
360AT
361 OAT
3612AT
400AT
4012AT
500AT
501 OAT

6206
6206
6207
6209
6210
6211
6211
6213
6213
6214
6216
6218

AFBMA#

STANDARD
DRIVE END
BEARING

AFBMA#

30BC02JPP3
30BC02JPP3
35BC02X3
45BC02X3
50BC02X3
55BC02X3
55BC02X3
65BC02X3
65BC02X3
70BC02X3
80BC02X3
90BC02X3

6206
6207
6209
6210
6211
6213
6214
6214
6214
6217
6218
6222

30BC02JPP3
35BC02JPP3
45BC02X3
50BC02X3
55BC02X3
65BC02X3
70BC02X3
70BC02X3
70BC02X3
85BC02X3
90BC02X3
110BC02X3

* Motors sometin~es have oversize ball bearing and roller bearing options
TABLE 14

CAUTION: DC motors and generators operated for long periods of time at light loads or in
contaminated atmospheres may be subject to
abnormal brush and commutatorwear. This can
result in the need for excessive maintenance
and/or commutator damage. If the application
requires operation under these conditions, GE
Motors-DM&Gwill be pleased tosuggesta change
in brush grade or other measures to minimize
the problem.

MINIMUM B ~USH LENGTH (in inches)


FRAME
CD180AT
CD210AT-250AT
CD280AT-320AT
CD360AT
CD400AT
CD500AT

MINIMUM BRUSH LENGTH*


.68
.70
.90
1.10
1.50
1.60

*Refer to Figs. 5, E, 7 for drawing


WARNING: High voltage and rotating machinery can cause serious or fatal injury. Brushesmay
not be touched or replaced while the machine is
energized or rotating.

and another inspectio ~ after the first two months ofservice


is recommended to d termine how often subsequent inspections are needed. Wear markers are provided on the
brush pigtail. (Refer t Figs. 6 and 7.) When the crimped
marker approaches entry into the brushholder, brush
replacement should b investigated. For future ordering,
record the brush part number which is stamped on the
brush. (Refer to TablE 18.)

CAUTION: The presence of silicone in DC


motors, particularly totally enclosed constructions, will cause rapid brush wear. Sources of
silicone include oils, R1V compounds, hand
creams, mold release agents, grease, and some
insulating varnishes. These silicone substances
must be avoided to insure proper motor performance.

23

BI006008

Jirect Current Motors and Generators, GEH-3967M

Wear Marker

Fig. 5
Frame CD180AT

Fig. 7
Frames CD360AT-500AT

Fig. 6
Frames CD210AT-320AT

Measure Brush Length Here:

Fig. 5, 6, 7

Brushholder Assemblies

With Machines Stopped and Power Off:


(Refer to Figs. 5, 6, and 7.)

1.

Unfasten pigtail (Refer to <D).

2.

Release spring by pushing in slightly to disengage


locking tab (Refer to @), then pull spring back.

3.

BRUSH

Remove brush.

Brush Installation:

1.

Place brush in holder with bevel towards spring. Brushes


should move freely in holder.

2.

CD180AT - Release spring to original position against


brush. CD210AT-CD500AT - Push spring into position
until lock tab (Refer to @) engages slot and locks.

3.

.080
.070

~:t;;;;;;=-=t:.:;;;;~===l

.-----------

Connect pigtail

COMMUTATOR

NOTE: If the brushholders have been disassembled, it may


be necessary to readjust the height of the holder from the
commutator surface. Loosen the brush stud to holder
screw and adjust the holder until a gap of .070" to .080" is
Fig. 8

obtained. Retighten the screw and recheck the gap. (Refer


to Fig. 8.)

24

Correct Spacing of Brushholder


to Commutator

BI006008

Direct Current Motors and Generators, GEH-3967M

Brush Seating

Commutator

Brushes should have heir commutator contact surfaces

Keep the commutator dean. Ordinarily, the commutator


will require only occasional wiping with a piece ofcanvas or
other nonlinting cloth. Do not use lubricant or solvent on
the commutator. Check the commutator for roughness
while running by feeling the brushes with a fibre stick,
avoiding contact with live electrical or moving mechani-eal
parts.Jumping brushes give advance warning of deterioration of commutator surface. (Refer to the Commutator
Check Chart, GEA-7053 for commutator surface marking
and causes of poor commutator condition.) Commutator
runout over .003" T.I.R. (Total Indicator Reading) and bar
to bar readings over .0003" indicate need for repair. (Refer
to Table 15.)

curved to exactly fit th commutator surface. This is accomplished by "sanding i "the brushes in each brushholder
separately. Draw a she t of coarse non-metallic sandpaper
(l00-150 grit) under the brushes with the rough side
toward the brush, wh Ie the brushes are pressed firmly
toward the commutat r. Do not use emery cloth. When
sanding brushes, do n t get carbon dust into the windings.
The motor should be horoughly blown out after sanding
the brushes. This can b accomplished by cleaning the dust
from the commutator brushholders, and adjacent parts
with a vacuum deane air blast, or other suitable means.
Mter the rough sand ng, the brushes should be finely
ground to fit using a bush seater. Rotate motor at around
nameplate RPM. Mak sure there is no load on the machine (armature curr t is nil). Carefully and lightly rub
the brush seater acros the entire commutator surface for
10 or 15 seconds. Re at between each and every set of
brush studs. Reverse otor rotation and repeat. Stop
motor and cut all powe to the motor and check brush face.
Continue seating unti brush face is 85% seated. Again,
motor must be thorou hly blown out after brush seating,
the same as with sandi g.

CAUTION: The presence of silicone in DC


motors, particularly totally enclosed constructions, will cause rapid brush wear. Sources of
silicone include oils, R1V compounds, hand
creams, mold release agents, grease, and some
insulating varnishes. These silicone substances
must be avoided to insure proper motor performance.

TABLE 15
CAUTION: Avoi inhaling carbon and seater
dust. Recommen using a dust mask during
sanding, seating d blowing, or vacuuming.

COMMUTATOR DIAMETERS (IN INCHES)

WARNING: High oltage and rotating parts can


cause serious or fatal injury. The use of all
electric machine ,like all other utilization of
concentrated po er and rotating equipment,
can be hazardous Installation, operation, and
maintenance of ectric machinery should be
performed by qu ified personnel. Familiarization with NEMA
ety standards for construction and guide for lection, installation and use
ofintegral HP rno ors and generators, National
Electrical Code,
recommended.

FRAME

NEW

MINIMUM

CD180AT
CD21 OAT
CD250AT
CD280AT
CD320AT
CD360AT
CD400AT
CD500AT

2.76
4.50
5.00
5.78
6.50
7.50
8.32
10.25

2.62
4.27
4.75
5.49
6.17
7.13
7.92
9.75

Commutator Undercutting
Specifications
If the commutator is resurfaced, or during inspection or
overhaul, insure the mica segments are undercut below the
commutator surface. Commutator undercutting should be
made to a depth of .040 - .050". Following commutator re-

nd sound local practices is

surfacing (stoning/turning), the segments should be


"scarfed" by lightly breaking the sharp corners of the
copper segments with a knife or tool made for that purpose. Scarfing segments will reduce carbon brush dust
buildup and improve brush life.

CAUTION: Do n t use liquid solvents of any


kind. Solvents will ot remove carbon dust accumulations, but wil spread and wash them into
critical areas.
25

BI006008

Direct Current Motors and Generators, GEH-3967M

Mechanical

lubricant supply for each half, so that both halves must be

Check the condition of air filters and replace them if they


are dirty. Check for unusual noises which were not present

lubricated separately.

Insulation

when the unit was originally installed. Check all electrical


connections for tightness. Clean out any dirt from screens,
louvers, etc. which would interfere with flow of cooling air.

Shaft End Play


Standard endplay should be measured with a dial indicator. The limits are:
1.

CD180AT thru CD320AT

.005" to .040"

2.

CD360AT thru CD500AT

.000" to .015"

Premature failure of insulation is due to:


Some designs may use a wavy washer (preload spring) to
eliminate endplay. The above limits do not include the
axial endplay of the bearing itself which is approx..002".

Waterproof Machines

1.

Contamination

2.

Mechanical factors

3.

High temperatures

Contamination includes excessive moisture, oily vapors,


conducting and non-conducting dust, chips, and chemical
fumes. Contamination is best avoided by proper enclosure
and ventilation. Filters, ventilation from a remote clean air
source, unit coolers, and a totally enclosed construction are
all possible means of protecting DC machines in adverse
environments. Space heaters protect against moisture damage by maintaining the machine above dew-point during
storage or when idle. They should be arranged so that they
are automatically energized whenever power is removed
from the motor. Space heaters do not supply enough heat
for drying out windings which have been water-soaked.

Waterproof machines require the use of sealing devices to


exclude water from the bearings and from entering openings in the magnet frame. When a waterproof machine has
been disassembled, it will be necessary to remove the old
sealing compound from around the mating surfaces of the
bearing brackets and magnet frame; from underneath the
field pole bolt heads and bearing cap to bearing bracket
bolt heads; and from around the conduit box adapter
threads to the magnet frame. Reapply new sealant (use
Titeseal T20-66, light weight, GE part # 905A999AC009) to
these areas and wipe excess sealant with a clean rag slightly
dampened with mineral spirits. When accessories such as
brakes and tachometers are disassembled, it will be necessary to reseal at the accessory mounting face. Prior to
reassembly, inspect for damage at gaskets around enclo-

Mechanical factors include shock, vibration, overspeed,


etc. Maintaining machines in good mechanical repair,
including isolation from excessive external shock and maintenance of smooth running conditions, will contribute to
long insulation life.

sure covers and at shaft rubbing seals located in the bearing


caps.

The insulation system III these machines is capable of


withstanding some short time periods of operation at

Lubrication of Flexible Couplings


Flexible couplings are normally lubricated with a semi-

temperatures higher than that used for the basis of ma-

fluid grease or an oil. The coupling manufacturer's in-

chine rating. Prolonged or excessively high temperature


will cause the insulation to become brittle and crack,

structions should be followed in choosing a lubricant and


setting relubrication intervals. GE ball bearing grease

leading to premature failure. Application data is available

D6A2C5 is a suitable lubricant for flexible couplings in

from GE Motors-DM&G for any particular machine giving

most applications.

suggested maximum loads for various operating conditions. Operation within these maximum loads will limit the

Flexible couplings which join a small machine to a large

temperature to suitable values.

one may have two different size coupling halves joined by


an adapter plate. Couplings of this type have a separate

26

BI006008

Direct Current Motors and Generators, GEH-3967M

Testing Metho4 s

TABLE 16

Visual Inspection
EFFECT OF TEMPERATURE
ON INSULATION RESISTANCE

Visual inspection is recc mmended as the quickest means of


finding insulation systems troubles. Visual inspection may

WINDING
TEMPERATURE
DEGREE C

not sound like a test me hod, but a careful visual inspection


done by a competent I erson is one of the most valuable
means ofjudging insul- tion condition.
In addition to collectin contaminants, insulation shrinks,
cracks, and becomes

80
70
60
50
40
30
20
10

rittle with heat and age. These

changes allow movemen.t of coils, loose filler strips, loose


ties, chafing, and abrasi n, all ofwhich can be picked up by
visual inspection.
Experience and judgm< nt can be gained by careful observation and comparing results of visual inspections with
insulation resistance ml
personnel who can ins]
tential trouble areas. Tl
ence and judgment for

asurement. GE service shops have


ect equipment and point out poeir services can help build experiuture visual inspections.

The insulation resistance of a machine is affected by its


design. The insulation resistance of the armature cirCUIt
corrected to 104F (40C) should measure at least 1.5
megohms or cleaning is required.

A method of measuring the insulation resistance is described in Report 43, "RiPcommended Practice for Testing
Insulation Resistance 0 Rotating Machinery", published
by IEEE, 345 E. 47th ~ treet, New York, NY 10017. The
resistance measuremen~ should be taken with a 500- or

If the measurements are less than this limit, the machine


should be dried or cleaned to attempt to increase the
insulation resistance. Regular, periodic measurements of
insulation resistance can give a useful indication of the rate
of insulation system deterioration. External connections
should be removed to isolate the windings to be tested and

1000-volt megger and c I>rrected to 104F (40C).


The insulation resistan e measurements are affected by
the following:
Magnitude of test v )ltage.

2.

Time the test volta~ e is applied.

3.

Temperature.

4.

Surface condition ( ontaminants).

5.

Moisture.

10.00
5.50
3.10
1.70
1.00
0.55
0.31
0.17

Note that for a 104F (40C) decrease in temperature, the


insulation resistance is increased by a multiplier of ten.

Insulation Resistance Measurement

1.

MULTIPLYING FACTOR
TO OBTAIN INSULATION
RESISTANCE AT
40C (104F)

megger value logged. A sudden drop or consistent trend


toward low values of insulation resistance, although POSSIbly caused by moisture or contamination, generally gives
evidence that the insulation system is deteriorating and
that failure may be eminent.
High-potential tests are not recommended on machines
which have been in use. If such a test is made immediately
after installation, the test voltage should not exceed 85% of

When a 1000-volt megg r is used, taking readings of one


minute and converting the data to 40C (l04F), the data
will evaluate the other two factors, i.e., the contaminants

the original factory test of two times the rated voltage plus

and the moisture presel t.

1000 volts.

The insulation resistanc varies inversely with the winding


temperature. That is, as he temperature decreases, the in-

NOTE: Surge testing and AC impedance tests of windings

sulation resistance

incre~ses in

to detect shorts should be perfonned only by trained

accordance with Table 16.

personnel.

27

BI006008

'Jirect Current Motors and Generators, GEH-3967M

Cleaning of Windings

CAUTION: Liquid solvents should not be directly applied to the commutator, armature,
field coils, or any part of a DC machine. Liquid
solvents carry conducting contaminants (metal
dust, carbon, etc.) deep into hidden areas to
produce shorts and grounds, thus causing ma-

If windings become contaminated, suitable cleaning methods can be used to alleviate the problem.
The machine should be de-energized and slowly rotated by
hand to permit maximum dust removal. Dry dirt, dust, or
carbon should first be vacuumed - without disturbing
adjacent areas or redistributing the contamination. Use a
small nozzle or tube connected to the vacuum cleaner to
enter into narrow openings (i.e., between commutator
risers). A soft brush on the vacuum nozzle will loosen and
allow removal of dirt more firmly attached.

chine failure. Mechanical components may be


cleaned by a wiping rag barely moistened (not
wet) with a solvent.

WARNING: Solvents may be flammable and


moderately toxic. The usual precautions for
handling chemicals of this type must be observed. These include:

This vacuum cleaning may be supplemented by blowing


with compressed air (air pressure should be in accordance
with OSHA standards), which has passed through a dryer
to remove moisture before entering the motor.

1. Avoid excessive contact with skin.

2. Use in well-ventilated areas.

Dirt can collect on the inside surface of the drive-end coil


support and on the underside of the armature coils. This
dirt can be easily removed with compressed air or a vacuum.
Dirt may also accumulate in the axial vent holes which pass
all the way through the armature core and commutator. It
usually will be necessary to use compressed air to blow this
dirt out. The commutator vent holes can best be cleaned by
directing air from the commutator end.

3. Take necessary precautions to preventfire or


explosion hazards.

WARNING: Safety glasses and/or other protective equipment should be used to prevent injury
to eyes and respiratory organs.

It is important to realize that when blowing out a machine,


dirt may settle in a previously cleaned area and it may be
necessary to repeat the cleaning process to ensure that a
thorough job is done.

Oily Dirt
The presence of oil makes thorough, effective cleaning of
machines in service virtually impossible and service shop
conditioning is recommended. Oil on a surface forms a "fly
paper effect", which attracts and holds firmly any en trained
dust. Neither suction nor compressed air is effective. Consequently, only accessible areas may be cleaned. First,
remove as much of the dirt as possible by scraping or
brushing the dirty surfaces. Then, wipe away as much dirt
as possible with dry rags. For surfaces not readily accessible,
a rag on a hook wire can be used to clean dirt out of holes
and crevices. Rags should be changed frequently for clean
ones so that contamination picked up from one area is not
carried to other less dirty areas.

Dirt can be removed from stationary parts of the machine


by either compressed air or a vacuum nozzle or a combination of both. Air should be directed between the stator
coils, into the pocket corners of bearing brackets, around
the cables, and onto the brush rigging. Special care should
be taken to keep the commutator clean. The commutator
should be wiped with a clean lint-free cloth after blowing
out.
High voltage electric shock can
or fatal injury. Electrical circuits
de-energized prior to cleaning or other
ance activities. Ground electrical cirto cleaning or maintenance to disacitors. Failure to observe these prey result in injury to personnel.

To simplify removal of oily dirt, solvents are commonly


prescribed.

28

GE Motors BI006008

LIGHT TAN FILM over e tire commu-

MOTTLED SURFACE with random film

SLOT BAR-MARKING, a slightly darker

HEAVY FILM can appear over entire

tator surface is one of man normal conditions often seen on a we I-functioning


machine.

pattern is probably the most frequently

film, appears on bars in a definite pattern

area of efficient and normal commutator

observed condition of commutators in


industry.

related to number of conductors per slot.

and, if uniform, is quite acceptable.

WATCH FOR THESE DANGER SIGNS

COPPER DRAG, an abnor 01 build-up of commutator

PITCH BAR-MARKING produces low or burned spots

HEAVY SLOT BAR-MARKING can involve etching of

material, forms most often

t trailing edge of bar. Con-

on the commutator surface. The number of these mark-

dition is rare, but can caus flashover if not checked.

ings equals half or all the number of poles on the motor.

trailing edge of commutator bar. Pattern is related to


number of conductors per slot.

CAUSES OF POOR COMMUTATOR CONDITION


Frequent visual inspection of commutator surfaces can warn you when any of the above conditions are developing so that you can take early corrective action. The chart below
may indicate some possible causes of these conditions, suggesting the proper productive maintenance.
Light
Electrical
Adjustment

Electrical
Overload

Electrical

Load

Armature
Connection

Unbalanced
Shunt
Field

Type of Brush
In Use

Brush
Presure

Vibration

(light)

Abrasive
Brush

Porous
Brush

Contamination

Gas

Abrasive

Dust

Streaking
Threading
Grooving
Copper Drag
Pitch Bar-Marking
Slot Bar-Marking

GE Motors
3001 East Lake oad
Erie, PA 16531
Phone: 814-875-3 29
FAX: 814-875-342
GEA-7053A

HOW TO GET THE MOST VALUE FROM THIS CHART


The purpose of the Commutator Check Chart is to help you spot undesirable commutator conditions as
they develop so you can take corrective action before the condition becomes serious. This chart will also

serve as an aid in recognizing satisfactory surfaces.


The box chart above indicates the importance of selecting the correct brush and having the right operating
conditions for optimum brush life and commutator wear.
For additional information or help with carbon brush application or commutation problems, contact your
nearest GE Sales Office or Distributor.

1992 General Electric Company 1/92 (30M)

M/GCO

Printed In U.S.A.

BI006008

Direct Current Motors and Generators, GEH-3967M


Drying out can be ended when the insulation resistance to
ground (corrected to 4DC) is restored to a satisfactory
value as described in the Insulation Resistance section. If
these values do not reach a proper level, then a thorough
cleaning or complete reconditioning may be necessary.

WARNING: WhileFREONTF is considered to


be non-flammable and has a relatively low order
of toxicity, it should be used only in well-ventilated areas that are free from open flames. Avoid
prolonged exposure to vapors. Failure to observe these precautions may result in injury to
personneL

Service Shop Cleaning


When the cleaning or drying methods described in preceding paragraphs do not result in restoration of acceptable insulation resistance and/or when machines are
extremely dirty or contaminated, it is recommended that
the reconditioning services of a GE service shop be obtained. Service shops are knowledgeable and equipped for
more sophisticated restoration methods, such as hot water
detergent wash, solvent and abrasive cleaning, revarnishing, and rewinding if necessary.

FREON TF is the recommended solvent for cleaning because it is nonflammable, has good solvency for grease and
oil, is considered safe with most varnishes and insulations,
and has a low order of toxicity. Stoddard Solvent has good
solvency, but is flammable and moderately toxic. Before
using any solvent, consult the Material Safety Data Sheet.
Steam cleaning is not recommended because, as with
liquid solvents, conducting contaminants may be carried
deep into inaccessible areas resulting in shorts and grounds.

Repair
Repairs should be made only by qualified personnel using
the materials and processes for which the motor was
designed. To protect the warranty during the warranty
period, all repairs must be made in a GE service shop or
approved repair facility. Many repairs can be easily performed with only assembly operations, ifGE replacement
parts are available. If major repairs are undertaken (such
as rewinding an armature), proper facilities should be
available and suitable precautions observed.

FREON TF is a chlorofluorocarbon. Chlorofluorocarbons


have been identified as upper atmosphere ozone depletors.
The use of Freon in industry is expected to be greatly
reduced in the future. The availability of Freon may be
limited, and its use could be prohibited by regulations.
CAUTION: Carbon brush performance may be
ruined by absorbed solvents. Remove brushes
prior to solvent wiping.

WARNING: When burning off old insulation


materials or when welding near insulation during rewinding, adequate ventilation must be
provided to avoid exposing personnel to noxious fumes. Combustion ofexhaust fumes must
be complete and adequately vented to the outside atmosphere.

Drying of Windings
Drying of machines is most effectively done by application
of heat. The windings and insulation should be heated so
that their temperature does not exceed 225F (l25C) at
any location. (Do not make local hotspots.) The machine's
own frame and the addition of some covers usually will
make an effective enclosure to con tain the heat, if an oven
cannot be used. Some flow of air is desirable to allow
moisture to be carried away. Methods of generating heat
include blowing hot air through the machine, heating with
heat lamps, passing current through the main-field-eoil
windings, etc.

WARNING: Exposure ofpersonnel to airborne


inorganic fibers must be avoided by adequate
ventilation or by wetting the remaining insulation components following the burning off of
the organic materials.

If temperatures as high as 225F (125C) can be attained,


they should be limited to six or eight hours duration. Lower
temperatures will cause correspondingly longer drying
times.
Registered trademark of the E.!. Dupont Co.

30

BI006008

Direct Current Motors and Generators, GEH-3967M

Failure

RENEWAL PARTS
Using genuine GE renewal parts assures continued high
performance and the full benefits of the long operating life
designed into your GE motor.

WARNING: An xtreme overload or electrical


failure may resu t in heating or arcing, which
can cause the i sulation to give off noxious
fumes. All powe should be removed from the
motor circuit as precaution, even though the
circuit has overlo d protection. Personnel should
not approach th motor until adequate ventilation of the area has purged the air of fumes.
When covers of a totally enclosed motor are
removed after a : 'lure, care should be observed

Downtime can be minimized by having a protective stock of


parts available for replacement. (Refer to Table 17.)
The permanently attached nameplate on your GE motor
displays the model and serial number, providing all the
information you need for ordering. Parts are available
directly from authorized GE-DM&G parts distributors. Direct electronic access to the factory database of motor
information and warehouse inventories enables the distributor to quickly identifY part numbers, delivery times,
and order status.

to avoid breathin fumes from inside the motor.


Preferably, time hould be allowed for the motor to cool befor attempting any examination
or repair.

WARNING: Wat rshouldnotbeapplied to any


electricallyener 'zed equipment because electric shock could suIt in serious or fatal injury.
In case of fire,
nnect all power and use a
carbon dioxide tinguisherto quench to flame.

Distributor location is available to you at


(814) 875-2387 (and toll free outside
Pennsylvania at 1-800-458-0451).

Before operatin any motor after a suspected


failure, it should be inspected for damage. Remove covers and ake visual inspections of the
brushes, commu tor, connections, and windings. Electrical te ts ofeach winding to check for
open or short rcuit or grounds should be
made. Any arc
mage should be cleaned up
and repaired as n cessary. Brushes may need reseating before 0 eration.

For your convenience, Table 18 outlines standard brush


and brush spring part numbers to assist in ordering renewal
parts.

31

BI006008

Direct Current Motors and Generators, GEH-3967M

SPARE PARTS
TABLE 17
RECOMMENDED SPARE PARTS

As insurance against costly downtime, it is strongly recommended that spare parts be kept on hand in
accordance with the chart below:
NUMBER OF DUPLICATE MOTORS IN SERVICE
DESCRIPTION

2-4

5-10

11-20

More than 20

WITH OR WITHOUT ELECTRICAL SHOP FACILITIES

Complete Machine
Drive End Ball Bearing
Front End Ball Bearing
Brushes (Sets)
Brushholders (Sets)
Brushholder Springs (Sets)
Main Field Coil and Pole
Commutating Field Coil and Pole
Armature Complete*
Blower Vent, motors
Blower motors

1
1
2

1
1
4
1/2
1
1
1
1

1
1
6
1/2
1
1
1
1

1
2
2
8
1
2
2
2
2

2
3
3
10
1
2
3
3
2

1
2

1
3

1/2

WITH ELECTRICAL SHOP FACILITIES

Shaft**
Armature Rewinding Supplies

* If shop facilities are available, the quantity of armatures may be reduced by stocking the armature parts
listed in the second group.
** Shaft not replaceable in CD180AT thru CD250AT.

TABLE 18
STANDARD BRUSH AND BRUSH SPRING PART NUMBERS

FRAME SIZE
CD180AT
CD210AT
CD250AT
CD280AT
CD320AT
CD360AT
CD400AT
CD500AT

STANDARD BRUSH
PART NUMBER*

BRUSH SPRING
PART NUMBER

36A167400AAOO 1
36A 167401 AA008
36A 16740 1AA008
36A167402AA004
36A167402AA004
36A164456AA021
36A164451AB018
36A 164452AA021

36B467022AB001
36B467020AAOO 1
36B467020AA001
36B467021AA001
36B467021AA001
36B465486AA001
36B465481AD001
36B465482AAOO 1

* Brush part numbers are for most applications. Special applications such as papermills, pump motors,
diesel-driven generators and others may require special brush grades. Before ordering brushes, check
the part number stamped on the brush to ensure the correct brush replacement.

32

BI006008

Direct Current Motors and Generators, GEH-3967M

This page left intentionally blank.


Exploded views found on pages 34 & 35

33

BI006008

Direct Current Motors and Generators, GEH-3967M


Qty.
Name

Per Motor

I.

Brush

2.

Brush Spring

3.

Bearing C.E.

4.

Bearing D.E.

5.

Armature

6.

Coil & Pole Comm.

7.

Coil Main

8.

Bearing Bracket (CE)

9.

Access Cover

10.

Brush Rigging

II.

Armature Fan

12.

Bearing Bracket (DE)

13.

Wound Frame Assembly

12

13

'"

Commutator End

Fig. 9

CDl80AT Frame, Exploded View

34

Drive End

BI006008

BI006008

GEMotors
General Electric Company
. Motor and Generator
17-2- 3001 East Lake Road
E Pennsylvania 16531
:'h,e, . '814) 875-3129- Telex: 703531
none."
FAX: (814) 875-3421

~Z~~fng

991 1993, 1994 General Ele.etrie Company


@1989,1 6',ImA
25MlHoAPrintedmUSA
GEH-3967M
""

BI006008

GE Motors

Instruc ions
Armored
Type MO

alars
114 - MOV810

(Photo MG-5359)

GEH-4246C
(supplements GEH-32 8)

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810

SAFETY PRECAUTIONS
WARNING
Use proper care and procedures in handling, lifting,
installing, operating, and maintaining the equipment.

High voltage and rotating parts can cause serious or


fatal injury. The use ofelectric machinery, like all other
utilizations of concentrated power and rotating equipment, can be hazardous. Installation, operation, and
maintenance ofelectric machineryshould be performed
by qualified personnel, in accordance with applicable
provisions of the National Electrical Code and
local practice.

Safe maintenance p
ces with qualified personnel is
ore starting maintenance procedures,
t:

Equipment connected to the shaft will not cause


m
rotation,

For equipment covered by this instruction book, it is


important to observe safetyprecautions to
sonnel from possible injury. Among the many c
erations, personnel should be instructed to:

ine windings have been disconnected


d from all electrical power sources, and

Avoid contact with energized circuits or rotating


parts,

ry devices associated with the work area


en de-energized.

Avoid by-passing or rendering inoperative any safeguards or protection devices,

Ifhigh potential insulation test is required, procedures


and precautions outlined in NEMA standards MG-I
should be followed.

Avoid extended exposure in close proximity to


machinery with high noise levels, and

Failure to properly ground the frame of this machine


can cause serious or fatal injury to personnel. Grounding of the machine frame and structure should be in
accordance with the National Electrical Code and consistent with sound local practice.

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met
in connection with installation, operation. or maintenance. Should further information be desired or should particular problems arise
which are not covered sufficiently for the purchaser's purposes, the matter should be referred to GE Motors.

1986, 1992 General Electric Company

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810

CONTENTS
PAGE

SUBJECT

Introduction
BoltedJoints
Bearings and Bea 'ng Assemblies
Drive End Bearin Assembly
Commutator End earing Assembly
Lubrication
Fans and Fan Hub
Fan Hub Removal and Replacement
Fan Assembly
Motor Disassembl
Removal of Bearin s
Removal of Fan
Removal of Brush older
Removal of Field oils
Assembly of Moto
Pinion Mounting
Motor Installation

4
4
5
5
6
7
7
7
9
10
10
11
11
11
11
12
12

List of Illustrations
Fig. 1
Fig. 2
Fig.3
Fig. 4
Fig. 4A
Fig. 5
Fig.6
Fig.7
Fig.8
Fig. 9
Fig. 10
Fig. 11

Lubricatio of Bolts
Method of eating Frozen Bearing in the Flange
Proper Ins allation of Lock Wire
Installatio of Commutator End Bearing
Packing of rease in Commutator End Bearing Cap
Fan Assem ly
MDV804 - DV810 ("Z" Vintage)
MDV804 - DV810 Exploded View - Vertical
MDV804
MDV806
MDV808
MDV810

4
6
8
9
9
9
13
15
16
17
18
19

List of Tables
Table
Table
Table
Table

1
2
3
4

Washer P rt Numbers
Bolt Tigh ening Torque Values Metallic Parts
Acceptab e Bearings for MDV804-MDV810 Motors
Bearing ousing Dimensions and Bearing Fits
3

4
5
6
7

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810

Introduction

Bolted Joints

This instruction book is a supplement to GEH-3258, and


covers vertical motors in frame sizes MDV804-MDV810,
which have been designed for use in applications \\-ith severe
shock and vibration. The motors described can be identified
bv a letter "Z" in the model number - such as
5~1D080Z129673SE. These motors have features and procedures not used in the rest of the MD800 line. These features
must be considered when making repairs or using the
motors. This instruction book should be used as a supplement to Instruction Book GEH-3258, which covers the entire
MD800 line of motors.

Special Tools and Materials


Torque Wrenches ... 10-250 lb-ft (13-340 newton-metres)
Lubricant ... Single or multi-viscosity automotive motor
oil (Example SAE 30. 10W-40).
With severe shock and \ibration. bolted parts tend to
become loose. To prevent this. special care must be taken
in the design and assembly of bolted joints to insure that
they are tight when assembled and stay tight in senice.
Assembly techniques also are critical in making a good
bolted joint and should be given utmost attention during
the assembly ofa motor. (Refer to Figs. 8, 9, 10 and 11 for
all critical b;lted joints.) The threads and bearing surface
beneath the head ofthe bolt should be lubricated according to these figures.

WARNING: High voltage and rotating parts


can cause serious or fatal injury. The use of
electric machinery, like all other utilization of
concentrated power and rotating equipment,
can be hazardous. Installation, operation, and
maintenance of electric machinery should be
performed by qualified personnel.'Familiat1zation with NEMA safetystandard for constructlon
and guide for selection, installation, and use of
integral HP motors and generators, the .National Electrical Code and sound local practlces
is recommended.

(Refer to Fig. 1, which


lubricant to a bolt.)

shows proper application of

Avoid contaminating electrical parts with the lubricant.


A hardened (Rockwell C45) and ground steel washer
should be used beneath all bolt heads on critical joints.
(Refer to Table 1 for washer part numbers.) The surface
on which the washer bears should be smooth and free of
dirt and paint. Torque the bolts to the values on the
assembly drawings with a hand-held torque wrench. (Refer to Figs. 8, 9, 10 and 11.) This insures that the parts are
clamped together correctly.

Installation of the machine where hazardous,


inflammable, or combustible vapors or dusts
present a possibility of explosion or fire should
be in accordance with the National Electrical
Code, Articles 500-503, and be consistent with
sound local practices.

TABLE 1
The special features incorporated into these motors involve
bolted joints, bearings. bearing assemblies. tan hubs, and
related parts.

WASHER PART NUMBERS


BOLT
SIZE (Inches)

(Refer to Figs. 6 and 7 to find the location of various parts


described in this instruction book.

GEM
PART NO.

GE TSBO
PART NO.*

3/8

124A8476AA 003

189V657 001

1/2

124A8476AA 004

189V173 001

5/8

124A8476AA 008

189V513 001

3/4

124A8476AA 009

V8805547 001

*Shops which repair GE traction motors or motorized wheels may


identih' washers by these numbers,

Fig. 1 -

Lubrication of Bolts

(Photo MG5320-9)
4

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810


All other bolts in the notor should be assembled without
lubricant and tighten d as indicated in Table 2.

Occasionally, the bearing housing mav be damaged and the


bore v.~ll have to be built up or sleeved to return it to its
original dimensions. With the tighter fits on the outer race,
tighter tolerances had to be held in the factolJ' for this bore.
(Refer to Table 4.)

(Refer to the Motor }~sembly section of this instruction


book for more information on assembling bolted parts.)

TABLE 2
BOLT TIGHTE NING TORQUE VALUES
ME ALLIe PARTS*

Thread
Size (Inches)
(UNC-2A)

If it is not possible to hold these tolerances in the repair


facility, it is still possible to obtain the correct fit for a
particular bearing. If the bearing which v.~ll be used is
available, it may be measured at the outside diameter with a
micrometer and the bore made to obtain the correct fit
according to Table 4. Essentially, what is done here is to
ignore the bearing manufacturer's tolerance and give the
leeway to the machinist making the bore. The next time a
bearing is replaced, this fit will again have to be checked ifthe
bore is outside ,factory tolerance.

Hex Head CIC5


Medium Carbon
Steel (Electrical
Connections)
TORQUE
Lb.-Ft.

1/4-20
5/16-18
3/8-16
1/2-13
5/8-11
3/4-10

7-9
13-17
24-30
60-75
120-150
210-260

Newton-Metres

Drive End Bearing Assembly

9-12
18-23
33-40
80-100
160-200
280-350

The bearings on MDV804-MDV8I 0 motors are mounted on


the shaft with a heavy interference fit. Thev also have tight
housing fits sometimes, depending on bearing and housing
dimensions (tolerances). For this reason, bearings with
greater radial internal clearance than normal (C4) must be
used. (Refer to Table 3 for acceptable bearings.)

(*NOT for use with lu xicated bolts. For lubricated bolt


torques, refer to Figs. 8, 9, 10 and 11.)

Bearings should be assembled as follows:

Bearings and flearing Assemblies

I. Clean bearing moun ting surfaces on the shaft and remove


any nicks, burrs, or scoring.

Shock and vibration c n cause bearings to move in their


housings causing wear to bearing and housing parts and
eventual bearing failu e. The MDV804-MDV8IO motors
have been designed w th housings that fit tighter to the
outer race of the bear ng to prevent this movement and
wear. This requires tha C4 internal clearance bearings be
used in both ends of the motor (i.e., the ball and roller
bearings) to insure ac equate internal clearance in the
bearing after assembly

2. Heat the thrust collar to 100C in an oven or oil bath and


slide it on the shaft tight against the shoulder. Thrust collars
for these motors are svmmetrical and can be placed on either
end. The bearing side of the thrust collar must run true
within .001" TIR.
3. Heat the inner race of the bearing to 110C in an oven or
oil bath and quickly assemble it on the shaft: tight against the
thrust collar. Position the lip of the inner race towards the
thrust collar. Do not use a torch since it can cause local soft
spots.

CAUTION: Jibe mngswith insufficient internal clearance ar p used, premature bearing


failures may resu t.

4. Install the inboard (Part 37A, Fig. 6) rubbing seal in the


bearing bracket with the "lip" of the seal facing the proper
direction. (Refer to Fig. 6.) If installed backwards, the seal
may be damaged when assembling the bracket to the motor
frame and be rendered useless. Grease the lip v.~th a small
amount ofbearing grease such as GE Grease D6A2C5 (D6A4
for low temperature).

Roller bearing part numbers for various vendors are listed


in Table 3. Ball bearing are tabulated by the Anti-Friction
Bearing Manufacturer Association number, which is understood by all bearin vendors. Bearings are also available through GE Moto s Renewal Parts.

5. Assemble the roller bearing outer race and rollers in the


bearing bracket by tapping evenly on the outer race with a
clean soft mallet until it seats firmly against the shoulder at
the bottom of the bore. Cooling the bearing in a freezer will
make this job easier and prevent damage to the bearing or
bracket. (Refer to Fig. 2.)

When assembling the baring outer races into housings, it


is helpful to chill the b arings in a freezer (which shrinks
the outside diameter) )r to heat the housing in an oven
(which expands the tore) to make them fit together
easier. The bearing she uld be "tapped" into place with a
clean soft mallet. If th bearing has been chilled, it may
condense water from he air. As the bearing warms to
room temperature, thi should be blown off with an air
hose until dry. (Fig. 2 hows the installation of a chilled
bearing in a drive end )earing bracket.)

6. Assemble the bracket with bearing and seal to the motor


frame. (Refer to the Motor Assembly section of this instruction book.)
5

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810

TABLE 3
ACCEPTABLE BEARINGS FOR MDV804-MDV810 MOTORS
Frame
Roller
Bearings
Hyatt
SKF
MRC
Railway
NTN
GE*
-- SHIELDED
-- UNSHIELDED

MDV804

MDV806

MDV808

MDV810

NJ313-C4

NJ315-J/4
R315G3
L-1315-U
NJ315-C4

R-1317-WB
NJ317-J/4
R317G2
L-1317-U
NJ317-C4

R-1319-WB
NJ319-J/4
R319G9
L-1319-U
NJ319-C4

M-8832705 004
894A605BU 021

M-8832705 005
894A605BU 032

M-8832705 006
894A605BU 010

M-8832705 007
894A605BU 090

R-1313-WB-CA
NJ313-J/4
R313G3

Ball Bearings
MDV804

MDV806

MDV808

MDV810

AFBMA
No.

65BC03XA4
65BC03XP4
65BC03XW4
65BC03XY4

75BC03XA4
75BC03XP4
75BC03XW4
75BC03XY4

85BC03XA4
85BC03XP4
85BC03 XW4
85BC03XY4

95BC03XA4
95BC03XP4
95BC03XW4
95BC03XY4

GE No.

M-8832706 009

M-8832706-00 1

M-8832706-002

M-8832706-003

*NOTE: Shielded bearings are to be used in motors which do not have rubbing seals. Unshielded bearings are to be used
in machines which have an inboard and outboard rubbing seal.
7. Assemble the outboard rubbing seal (Part37B in Fig. 6)
into the cap with the lip in the proper direction.

10. The bolts should be lock-wired according to the assem


bly drawings, Figs. 3, 8, 9, 10 and 11.

8. Fill bearing cap grease cavity approximately one-halfto


two-thirds full ofbearing grease such as GE Grease D6A2C5
(D6A4 for low temperature). "Butter" the bearing with
grease. Apply a small amount ofgrease to the lip of the seal.

Commutator End Bearing Assembly


1. Pack a small amount of sealing grease (D6A2D) in the
labyrin th groove on the inside of the cartridge and place
the thrust collar (Refer to Part 39A in Fig. 6 in the
cartridge. )

9. Assemble the cap to the bracket and fasten using


lubricated bolts (see Boltedjoints) and torque according
to the assembly drawings, Figs. 8, 9, 10 and 11.

2. Assemble the ball bearing into the cartridge by tapping


evenly on the outer race with a mallet until it seats firmly
against the shoulder at the bottom of the bore. Cool the
bearing in a freezer or heat the cartridge in an oven to
make this job easier and to preven t damage to the bearing
or cartridge. (Refer to Fig. 4.)

3. Heat the assemblv in an oven to 110e. Place the


cartridge assembly on" the shaft and press against the inner
race of the bearing. Press the bearing on the shaft until the
split ring just enters the groove in the shaft.

Fig. 2 -

4. Assemble the split ring in the groove in the shaft and


lock it into place by attaching the locking ring to the split
ring by means of flat-head Nylok screws and tighten with
an Allen wrench. A long wrench with a "T" handle makes
this job quicker, but is not required.

Method of Seating Frozen Bearing in the Flange


(Photo MG-5320-8)
6

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810


.5. Pack the cage betw en the balls of the bearing full of
grease such as GE D6P 2C5. (D6A4 grease should be used
for low temperature.)

fit. This alone should be adequate to keep the fan and hub
mounted securely. If, however, the fan hub is overbored
slightly or the shaft is slightly undersize, it is possible for
the hub to work its way down the motor shaft and cause
damage to the motor. To preven t this, a spacer ring called
a fan ring (Part 7C, Fig. 6) is fitted to the shaft after the hub
is mounted. This ring supports the fan hub against the
thrust collar and roller bearing inner race, which also has
the shrink-fit to the shaft, in case the fan hub is loose on the
shaft. The spacer ring is also mounted with a light shrink
fit to the shaft.

6. Assemble the armature and drive end bearing bracket


(Part 32B, Fig. 6) with t earingandseal to the motor frame.
(Refer to the Motor l\ssembly section, Steps 8 through
14.)
7. Pack bearing grease into the bearing cap grease cavity
until it is full. (The ca\~ty is filled with grease as shown in
Fig. 4A.) Wipe grease ( n the lip of the seal in the bearing
cap.

Fan Hub Removal and Replacement

8. Assemble the bear'ng cap to the bearing cartridge.


Lubricate bolts and th ead into bearing cartridge, but do
not tighten. Bolts shou ld not protrude from back side of
bearing cartridge, or tf eywill interfere with assembly into
frame.

The fan hub is not normally removed from the shaft. lffor
some reason it must be removed, its position circumferentially should be marked relative to the armature. The
armature balance weights are in the hub and remounting
in the same position eliminates the need to rebalance the
armature, unless the armature winding is replaced.

Lubrication

The fan hub may be removed as follows:

Type MDV vertical mot )rs have a single-row ball bearing at


the commutator end ar d a cylindrical roller bearing at the
pinion end. Convenient fittings are provided for the
addition of grease whe [1 necessary.

1. On MDV808 and MDV810 motors, remove the drive


end bearing parts including the thrust collar. On MDV806
and MDV804 motors, the fan ring should be removed and
used as a pulling means for the drive end bearing parts.
Tapped holes are provided on the fan ring for this. On
MDV808 and MDV81 0 motors, the fan ring is pulled along
with the fan hub. (Refer to Fig. 6 for position of fan hub
and fan ring.)

For lubrication inform' tion, refer to the Instruction Book


GEH-3258.

Fans and Fan fubs


The MDV804-MDV81C motors use a cast iron fan hub,
which is attached to tht motor shaft bv means of a shrink

2. Mount a puller to the fan hub using the holes provided


in the hub.

TABLE 4
BEARING HOUSING DIMENSIONS AND BEARING FITS
HOUSIN( BORE
(Factory T olerance)
mm
FRAME Inches

DESIRED BEARING TO HOUSING FIT


Inches
mm

MDV804

MDV806

MDV808

MDV810

5.5117
--5.5111

139.99

--139.98

.0007l* to .0007T*

6.2990
---

159.99

---

.0008l* to .0008T*

6.2984

159.98

7.0864

179.99

.0008l* to .0008T*

7.0858

---

179.98

7.8738

199.99

.0008l* to .0008T*

---

7.8730
*l = loose

--199.98

.02l* to .02T*

.02l* to .02T*

DEPTH OF BORE
Drive End
Comm End
Inches
mm
Inches
mm

--

1.130

28.70
-28.58

1.110

1.125

--

--

1.255
-

--

31.88

1.234
-

31.34
-

1.380

35.05
-

1.360

34.54
-

1.250

.02l* to .02T*

1.375
.02l* to .02T*

*T = Tight

1.505
-1.500

31.75

1.105

1.229

34.92

1.355

38.23

1.970

--

38.10

-1.965

28.19
28.07

31.22

34.42
50.10

--

49.91

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810


The hub should be replaced as follows:

CAUTION: Care should be taken not to damage


the armature shaft with the pulling apparatus.

1. Clean the shaftand bore of the hub to make sure itisfre(


of dirt, burrs. and varnish.

2. Heat the hub and fan ring to 100C in an oven.

3. Heat may be applied to the hub near its bore to expand


the hub and make pulling easier.

3. Quicklv slide the fan hub onto the shaft aligned with the
markings made before removaL Make sure the hub seats
against the shaft shoulder.

CAUTION: Excessive heat applied with atorch


can damage the motor shaft or melt the lead
armature balance weights. Keep the heat distributed evenly and near the bore.

4. Mount the fan ring securely against the fan hub.

CAUTION: The fan ring must not overhang


the shoulder on the shaft that will later locate
the thrust collar. If it does, the fan hub and fan
ring must be removed and the cause determined.

Apply force on the puller while heating. Once the hub


(and fan ring on MDV808 and MDV8l 0 motors) begins to
move, continue pulling until it is free of the shaft.

Fig. 3 -

Proper Installation of Lock Wire

(Photo MG5358-1)

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810

GREASE

BEARING CAP
GREASE SEAL
Fig. 4A - Packing of Grease in
Commutator End Bearing Cap

Fig. 4 -

Installation of Commutator End Bearing

(Photo MG5320-4)

Fan Assembly
On MDV804-MDV81O motors, a cast aluminum fan is
mounted to the hub using bolts. The assembly of the
hardware in thisjoint is shown in Figs. 8, 9, 10 and 11. A
special locknut is used. The fan should be assembled as
follows:
1. On MDV804, MDV808, and MDV810 motors, place the
fan on the hub with the bolt holes aligned. The fan may
require tapping with a soft mallet to engage the rabbet. On
MDV806 motors, hold the fan loosely in place, but do not
mount on the rabbet. (Refer to Fig. 5.)
2. Lubricate bolts with bolt lubricant. (Refer to the Bolted
joints section.) Assemble through holes with hardened
washer beneath the bolt-head (except the MDV804 which
uses a flat-head screw). Assemble the other hardened
washer and start the nut.
(Photo MG5320-12)
9

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810


11. Lift the top half of the motor with a crane.

12. If the armature is to be removed, loop a rope sling


around the two shaft extensions and carefully lift the
armature, avoiding damage to the field coils and other
parts. Place the armature on a support to the shaft or on
the bearing housings, or place the core on a soft material.

3. Tighten the bolt while holding the nut with a wrench.


An offset box wrench used through the fan blades is best
for MDV806 motors. The nut is a prevailing torque type
which cannot be finger-tightened.
4. Torque the bolt to the values shown in Figs. 8. 9,10 and

11.

Motor Disassembly
1. Place motor in a horizontal position with the drive end
bearing bracket overhanging the workbench.

2. Clean the exterior before starting disassembly.

Removal of Bearings

3. Commutator end covers and brushes should be removed and the brushholders adjusted as far away from
the commutator as possible.

Commutator End:
1. Remove the bearing cap.

4. Remove the shaft extension cover, if one is used.

2. Remove the split ring from the armature shaft.

5. Loosen the bolts holding the drive end bearing bracket


to the magnet frame. These bolts may be loosened with an
open-end or box wrench without removing the pipe plugs
in the bearing bracket. If this is done, the bolts will remain
captive in the bearing bracket. The pipe plugs may also be
removed, and the bolts will be free to be completely
removed.

3. Using a suitable puller and, using the holes in the


bearing cartridge, pull the cartridge thrust collar and
bearing as a unit. This operation will produce flat spots on
the balls and races of the bearing and ruin the bearing.
Since the bearing must be scrapped, it is acceptable to use
heat from a torch on the bearing as long as it is not
excessive and damaging to the shaft.

6. Support the drive end bearing bracket on a crane before


removing.

4. Remove the bearing from the cartridge by pushing on


the thrust collar. The bearing may be tight in the cartridge
and require the use of a small press or it may be tapped out
with a mallet, if care is taken not to damage the thrust
collar.

WARNING: If the bearing bracket is not adequately supported, it may fall to the floor
upon removal, causing personal injury.

Drive End:
The bracket is mounted to the magnet frame with a rabbet
fit, which may be tight. The bracket can be removed by
using mallet blows to disengage the rabbet or by loosening
the frame split bolts. The bracket will come off as a unit,
including the bearing outer race and rollers and bearing
cap.

1. The drive end bearing bracket should be removed as


described in the Motor Disassembly section.
2. On MDV808 and MDV810 motors, use a puller that
engages the thrust collar. On MDV804 and MDV806 motors, use the fan ring which has holes provided for pulling.

7. Remove bolts holding the commutator end bearing


housing to the frame.

Heat may be used on the bearing inner race and thrust


collar if the bearing is to be scrapped. Heat from a torch
will cause local soft spots in the inner race and ruin it.

8. Loosen the bolts holding the commutator end bearing


cap to the bearing housing and back-out the bolts approximately one-half inch (13 mm).

3. Remove the safety wire, bearing cap bolts, and the


bearing cap.

9. Remove the frame split bolts.

4. Remove the bearing outer race and rollers. The outer


race may be tight in its housing and require the use of a
press or may be tapped out with a mallet. To accomplish

10. Disconnect the electrical connections at the frame


split.
10

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV81 0


this, it may help to ass( mble the bearing inner race in the
bearing and use the th tustcollar to push on the inner race.

4. Insulate all internal bolted coil connections as


described below:

Removal of F m

A. Applv tape. Several lengths may be used, but start each


length so that one or more full turns of tape secure
previous tape end. Joint insulation taping is to completely cover the bolt, nut, washer, terminals, etc.,
extending approximately 1/4" to 1 12" (6 mm -13 mm)
onto the cable andlor lead insulation, resulting in at
least three tape thicknesses minimum coverage.

1. The fan, if used, car be removed by removing its bolts.


The nuts are a prevail ng torque type and must be held
while turning the bolt. An offset box end wrench works
best for this on MDV8 6 motors.

Removal of B ushholder

B. Paint the tape surface with fast-drying insulating varnish.

Each brushholder is ndividually bolted to a support,


which is bolted to th motor frame. Loosen the bolt
sufficiently to remove brushholder.

5. If the fan ring has been removed, heat to 100C in an


oven and place on shaft tight against the fan hub. This ring
should not overhang the shaft shoulder which locates the
thrust collar. (Refer to the Fan Hub Removal and Replacement section.)

Removal of FO eld Coils


1. Lift or remove the op half of the frame as described
under the Motor DisaJ sembly section.

6. Assemble bearings. (Refer to the Bearing Assembly


section.)

2. Disconnect the cab es to the coil to be removed, and


take out the bolts whic 1 hold the pole piece to the frame.
Remove the complete pole piece and coil assembly. In
order to remove SOIT e coil and pole assemblies, it is
necessary to remove th adjacent poles first. The armature
must be ;emoved from he frame for proper access to coils
and poles in the botto In frame half.

7. Assemble fan to hub (if used). (Refer to the Fan Hub


Removal and Replacement section.)
8. Lift the armature using two rope slings around the shaft
extensions and place the armature into frame.

3. ''''nen removing cor.nections and coils, take care to


prevent bumping coils and terminals, which can result in
damage to the coil coat ng. Reassemble bolts, washers, and
nuts on coil terminal.

9. If brush rigging has been removed completely or in


part, complete the following steps which are appropriate:
A. Assemble the insulating blocks into the frame using bolts
which have been lubricated according to the Bolted
Joints and Hardened Washers section. Torque according to lie assembly drawing, Figs. 8, 9,10 and I!.

NOTE: Do not d slodge or otherwise damage


insulated washer molded between coil terminals. Do not lose insulated bolts for field coil
termination.

B. Assemble the brush studs to the insulating blocks and


torque bolts according to the assembly drawing, Figs.
8,9, 10, and 11. Do not use lubricants because it will
contaminate the insulating block surfaces.

Assembly of ~ otor
Installing Field Coils ( \rmature Removed):

C. Install the brushholder on the stud as high off of the


commutator as possible. Tighten the bolt sufficient to
hold the brushholder in place until after the frame is
closed on the armature. Remove brushes from the
brushholders to prevent brush breakage when armature is installed.

1. Alwavs assemble tht bottom center commutating coil


first, si~ce it cannot be installed if the two adjacent exciting poles are in the fr" lIne.
2. Assemble the pole piece and coil assembly into the
frame and secure it w th bolts through the frame. The
bolts should be lubri ated (refer to the Bolted Joints
section) and should be orqued according to the assembly
drawing, Figs. 8, 9, 10 nd 11. A hardened steel washer is
to be used beneath thl bolt-heads.

10. Remove the pipe plugs from the drive end bearing
bracket, if this has not been done previously.
11. Coat the frame split with sealer material. (Refer to
assembly drawing, Figs. 8, 9, 10 and I!.) . Lift the top half
of the frame into place, being careful not to damage
armature or field coils.

3. Tie all cables into neat, sturdy bundles. Tie cable


bundles to cable anchc rs in the frame so that the bundles
are suspended securel, in position. Locate cable bundles
away from sharp corne s, moving parts, brush rigging, and
handhold openings.

12. Install frame split bolts. Bolts should be lubricated and


a hardened washer should be used. Torque according to
the assembly drawing, Figs. 8, 9,10 and I!.
11

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810


13. Using a crane, lift the drive end bearing bracket complete
with bearing into place. Once the bearing begins to go
together, lift the bracket and consequently the drive end of
the armature slightly higher to engage the bracket to frame
rabbet. Lubricate the bolts, and then install the bolts and
hardened washers through the pipe plug holes. Torque bolts
according to the assembly drawing, Fig. 8, 9,10 and 11.

lose its initial stretch and clamping force. The following


washers (or similar washers) are recommended:
Frame
MDV804
MDV806
MDV808
MDV810

14. Coat the pipe plugs with sealer material and install
according to the assembly drawing, Figs. 8, 9,10 and 11.

Washer
I 24.A.8476AA 009
124A8476AA 010
124A8476AA 007
124A8476AA 007

5. The mounting bolts should be Grade 5 and should be


torqued as follows when lubricated with an automotive
motor oil on the threads and under the bolt-head:

15. Lubricate commutator end bearing housing to frame


bolts and install with a hardened washer. Torque according to the assembly drawing, Figs. 8, 9,10 and 11.

Frame
MDV804
MDV806
MDV808
MDV810

16. Torque commutator bearing cap to bearing cartridge


bolts according to the assembly drawing, Figs. 8, 9, 10 and 11.
17. To set up the brushholders, release the brush box to
stud bolts in place and adjust the brushholder to provide
.070 to .080 in. (1.8 - 2 mm) clearance between the face of
the brushholder and the commutator surface. A nonmetallic shim may be used to obtain this spacing (a wooden
tongue depressor works well). Tighten the bolts securely.

Bolt Size
3/4-10
3/4-10
1-8
1-8

Torque
2301b-ft 310
2301b-ft 310
4901b-ft 670
4901b-ft 670

Nm
Nm
Nm
Nm

It is not possible to get a torque wrench on all the bolts due


to mechanical interference with parts of the motor or
parts of the drill or excavator. Tightening of bolts should
be done as follows:
A "Snug up" all bolts with a hand wrench. Very little
clamping force will be obtained by this operation, but
the bolts will be tightened enough to remove all clearance between the bolt-head and hardened washers.

18. After tightening the bolt, again check the spacing to


the commutator and the alignment of the brushes with the
commutator segments.

Refer to the Instruction Book GEH-3258.

B. Note the position of the head of the bolts that can be


torqued. Torque these bolts with a torque wrench an<
note how far they turn.

Motor Installation

C. Tighten the other bolts with a wrench by turning the


heads an equal amount to those torqued.

Pinion Mounting

Proper installation of the motor is as important to its


performance as proper assembly ofthe motor. The method
for installation recommended bv GE Motors is as follows:
1. Make sure the mounting surface of the motor and the
gearbox are free of nicks, burrs, and irregularities. This is
especially true for the mounting rabbet. The mounting
surface should be free of dirt.
2. A non-hardening gasket sealer, such as a Permatex
No.2, Titeseal, Permatex Gel Gasket, Locktite Gasket
Eliminator, or any number of products that would squeeze
out when bolts are initially tightened should be used to
seal against oil leaks. No paper or similar gaskets should be
used because they allow mounting bolts to become loose.
3. A lubricant should be used on the bolt threads and the
bearing surface ofthe bolt-head. The lubricant GE Motors
uses is a single or multi-viscosity automotive motor oil
(example SAE 30, 10W-40).
4. A hardened washer should be used beneath the bolthead. This prevents the bolt-head from digging into the
steel of the motor flange, which would allow the bolt to

12

BI006008

GEH-4246C, Armored Motors, Type MDV804-MDV810

41

153

Figure 6

Ref.
No.

Description

1
2A
4B
4C
5B
6
6A
7
7A
7C
10
12
12A
12B
15
16
17B
31
32B
34
36
37A
37B
39A
40
41
42
44
50

ARMA URE
ARMA UREWINDING
ARM-B NDING-END TURN (CE)
ARM-B NDING-END TURN (DE)
ARMA URE COIL SUPPORT (DE)
ARMA URE CORE
ARMA URE CORE KEY
ARMA URE FAN
ARMA URE FAN HUB
ARMA URE FAN RING
SHAFT
COMM TATOR
COMM TATOR SEGMENT & INSULATION
COMM TATOR SHELL
PINIO KEY
PINIO NUT
PINIO LOCK WASHER-BENT TYPE
BEAR I G
BEARI G BRACKET-DRIVE END
BEAR I GCAP
BEARI GCARTRIDGE
BEAR I G SEAL-INNER
BEARI G SEAL-OUTER
THRU T COLLAR-INNER
GREA E FITTING
GREA E TUBE ASSEMBLY
GREA E PLUG
SPLIT ING
BRUS ES

Ref.
No.
55
56
57
57B
57D
58
70
73
75
114D

Description

BRUSH HOLDER STUD


BRUSH HOLDER STUD INSULATION
BRUSH HOLDER
BRUSH HOLDER SPRING
BRUSH HOLDER MOUNTING BOLT
BRUSH HOLDER WITH SUPPORT
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
POLE BOLTS
COVER-QUICK ACCESS-COMM
END-SOLID
150 FRAME
FRAME SPLIT BOLT
151
153 SHAFT THIMBLE
900 ARMATURE FLANGE (CE)
903 ARMATURE LAMINATION
904 ARMATURE BANDING GROOVE
LAMINATION
909 COMM POLE SHtM
910 BOLT-BRG BRACKET TO FRAME
914 HARDENED WASHER
915 BOLT-BEARING CAP
915A BOLT-BEARING CAP-WIRED
916 BOLT-BEARING CARTRIDGE
917 BOLT-BRUSH HOLDER ASSEMBLY
918 BOLT-FAN
919 LOCKNUT
920 BALANCE WT.

Fig. 6 - MDV804 - MDV810 ("Z" Vintage)


13

BI006008

14

BI006008

Insert page 1 from file BI006008-00_2b.pdf here

BI006008

BI006008

SEMotors
comp~n~rie. PA 16531

3001
East Lake
Telex 703531
Telephone
(814) R~~~2217
8

General Electric

11-92 (5M) D

Facsimile (814) 875-6692

BI006008

GEH-424'

INSTRUCTIONS

Superse<1e&

GEH42<

TRANQUELL@
STATION SURGE ARRESTERS*
MODEL SERIES 9L11, 2.7-360KV
MODEL SERIES 9L16, ABOVE 360KV
MODEL SERIES 9L26, 9L29, (SPECIALS)
CAUTION: THE EQ IPMENT COVERED BY THESE INSTRUCTIONS SHOULD BE INSTALLED AND SERVICED ONL)
BY COMPETENT P RSONNEL FAMILIAR WITH GOOD SAFETY PRACTICES. THIS INSTRUCTION IS WRITTEN FOF
SUCH PERSONNEL AND IS NOT INTENDED AS A SUBSTITUTE FOR ADEQUATE TRAINING AND EXPERIENCE I"
SAFE PROCEDURE _FOR THIS TYPE OF EQUIPMENT.

./

TRANQUELL Sta ion Surge Arresters are of singlephase design, suita Ie for outdoor service. Three arresters
are required for thr e-phase installations. Smaller, lowerrated models are sipped assembled, while larger, high
rated models consi t of two to five individual units which
must be assembled. The arresters require no testing before
being placed in serv'ce and are completely self-supporting.

Company, complete nameplate data should be furnish!


order to expedite replies.

Each TRA~Q ELL arrester contains a number of


verticaJly stacked z nc-oxide valve elements and, for some
higher arrester rat ngs, shunt gap elements permanently
sealed in porcelain housing(sl. Each housing is provided
with a means of pr ssure-relief in the remote event of an
arrester failure. l etal end fittings, cemented to the
housing, provide a means for bolting the arrester units
together and to a foundation. An outline drawing is
included with ever arrester and should be reviewed for
details.

FOUNDATION

APPLICATION

Arresters are d signed to limit surge voltages to a safe


value by dischargi g the surge current to ground. This
ability to discha ge surges, and the application of
arresters to power s stems are described in GE publication
GET-6951. In case f doubt concerning application, consult
your local General lectric Company representative.
INSTALLATION
INITIAL INSPECTI N

TRANQUELL nesters are designed to withstand


severe shipping sh ks. In addition, each unit is shipped in
a carefuJly designe container. If the crate or carton shows
signs of rough ha dling upon receipt, the porcelain
housing should be i spected for chips or cracks. If damage
is apparent, the ar ester should not be installed. Claims
for such damage s ould be registered immediately with
the common carrie
The model nu ber, rating and maximum continuous
voltage capability f each complete arrester are identified
on the nameplate which is attached to the lower end
fittings. The name lale information should be checked
against the shippi g memorandum. If at any time it is
necessary to cor espond with the General Electric

LOCATION

Install the arrester electrically as close as practic


to the apparatus being protected. Keep line and gr<
connections short and direct.

The footings of all outdoor piers or supports sh


extend below the frost line and be elevated above
ground line sufficiently to meet personnel sa
requirements.
It is permissible to mount some low-vol t
TRANQUELL arresters horizontally. However,
factory should be consulted for each application to be
that horizontal mounting is permissible for a partie
arrester. When mounted horizontally, the pressure r
vents must be pointing downward. For other mour
orientations consult your General Electric repre~
ative (or approved mounting configurations.
ASSEMBLY

Single-unit Arresters

Each arrester is shipped completely assembled.


Install the arrester vertically on the foundation, \.I
care to see that it is perpendicular, shimming unde
but one foot if necessary. It is important that all feet
solidly on the foundation before the foundation bolt~
drawn down to avoid unnecessary stresses in the
fittings. Tighten the bolts firmly. The pressure-relier,
should be oriented to minimize damage to adja
equipment by incandescent gases in the remote eve
arrester failure.

Also applies 10 CAP UELLe vatls!ors


Thew ins"uCI~S do

or m nlen.nt.e ShoCk.Ild IUri

'0 the Ceoneral

E~I"c

Co",

t PlJfpofl 10 cove' ~II del ls 01 y.u~Hons ,n e<:l\.lIpmeni 1\01 10 pt'oy~e

r Inlorm..lIon be de$11ed Of snoulO p.arUcul.r ptob1em,

ny

lor

~yer)' POSSlbi~ conllt\Qe~)' 10 be mel In connechon

with inSlall.uon. Oper~

.,.s.e whICh ire 001 COyefeo' su1hcIftflity for 1h. purchJlwr', pUfpos..M, lhe mOl"e, shotJLd be f.t.

BI006008

GEH-4249 TRANQU ELL ~ Surge Arresters


Multi-unit Arresters
IMPORTANT: Multi-unit TRANQUELL arresters consist
of units with identical serial numbers to be erected in the
e:wct order specijied on the outline drawing shipped with
each arrester. The serial and model numbers of the unit are
given on the unit nameplate attached to each lower end
jitting. The base unit ALSO bears the complete arrester
nameplate, which lists the unit assembly sequence top to

base.
Special arresters consisting of two or more parallel
units must have identical serial numbers and are not
interchangeable with units having different serial
numbers.
Install the base unit vertically on the foundation using
care to see that it is perpendicular, shimming under all
but one foot if necessary. It is important that all feet rest
solidly on the foundation before the foundation bolts are
drawn down to a void unnecessary stresses in the end
fittings. Tighten the bolts firmly. The pressure-relief vents
should be oriented to minimize damage to adjacent
equipment by incandescent gases in the remote event of
arrester failure.
. Select the next unit carefully by reference to the serial
number, unit model number and the outline drawing; then
mount it on top of the base unit and secure it loosely with
bolts. Use stilTening washers where the outline drawing
indicates they should be used. It must be checked
carefully to determine that it is vertical, and shimmed
under all but one foot if necessary. It can then be bolted
securely to the base unit. This procedure should be
repeated as necessary for arresters composed of more than
two units.
The line terminal cap can be used as a lifting aid to
erections by bolting it temporarily to each unit in turn.
Be sure to install the grading rings at the points called
for on the outline drawing.
LINE AND GROUND CONNECTIONS

Connect the arrester ground to the apparatus ground


the main station ground, utilizing a reliable common
ground network of low resistance.
Connection to the line should be made through a
suitable line connector. Line connections should be made
in such a manner that no excessive mechanical stress is
placed on the arrester.
CAUTION: ALWAYS BE CERTAIN THAT THE
GROUND CONNECTION IS FIRMLY MADE BEFORE
CONNECTING THE ARRESTER TO AN ENERGIZED
LINE. IF AN INSULATING UNIT IS USED AT THE
GROUND END TO PERMIT USE OF A DISCHARGE
COUNTER, THE DISCHARGE COUNTER MUST BE
CONi',mCTED (OR THE INSULATING UNIT SHORTED
OUT) BEFORE CONNECTING THE ARRESTER TO AN
ENERGIZED LINE.
a~d

CLEARANCE

clearances apply for con ve ntiona I au tdoor s ubsta tions.


These values should be used only after it has been determined that any local codes or standard practices do T'~I
require larger clearances. Arresters rated 96 kV
below may be enclosed completely using the sa
clearance values. The values shown are suitable for
altitudes up to 3300 feet (l000 meter~). At higher
altitudes, add 3 percent for each additional 1000 feet of
elevation. The arrangement of the foundation plans if
shown on the outlines can be modified if proper clearances
are maintained.
ALTITUDE AND TEMPERATURE

TRANQUELL arresters, 9L11, 9L16, 9L26 and 9L29


series can be used from 0-10000 feet (0-3050 meters)
altitude.
These arresters can be used in locations where the
maximum temperature does not exceed 60 C and where
the average temperature does not exceed 45 C.
PERIODIC INSPECTION AND MAINTENANCE

Before inspecting or handling, disconnect the arrester


from line and, as a safety precaution, ground the line end.
Remove this temporary ground before reconnecting the
arrester to the line.

.' TRANQUELL arresters require no special care. They


may be hot-washed, subject to the usual care and
;echniques used in hot-washing insulation to avoid
external f1ashover.
These arresters do not require testing, and no test
which applies power voltage in excess of maximum
arrester voltage rating should be made without consul~:
the ~neral Electric Company. There is no single field
which will indicate the complete operating characterist. ~
of the arrester.
STORAGE

As all Tranquell aresters are designed for outdoor use,


they may be stored outdoors if suitable precautions are
taken to prevent deterioration of the packing material.
The arresters may be covered with a polyethylene or other
waterproof covering to keep them dry, clean, and free from
Jitter until used. In climates where outdoor temperature
and humidity extremes rapidly deteriorate the cardboard
packing material, it is recommended that arresters to be
stored outdoors be removed from their packing and be
bolted (vertically) to a skid. [(the arresters units are stored
in a horizontal position, the pressure relief vents must be
pointing downward.
PORCELAIN TOP UNITS

Porcelain top arresters with center line terminals are


available and are particularly suited for use in metal
cubicles. These arresters can be mounted in any position
when installed in a reasonably clean and dry indoor
location.
DISCHARGE COUNTERS

The term "clearance" means the actual distance


between any parts of the arrester at line potential and any
object at ground potential or other phase potential.
Clearances listed on the appropriate outline print
packed with each arrester are the minimum recommended
and were determined such that the operation and capability of the arrester is not significantly affected. These

An insulating base is required when installing a


discharge counter with arresters. Both of these are
accessories and are described in Handbook Section 59 r '
Install the discharge counter and insulating base as sh
on the outline drawing furnished with the counter.

GENERAL ELECTRIC COMPANY


PITTSFIELD, MA. 01201
10/89

(5!'!)

Pnnted ,n U.S.A.

GEI-56128D

BI006008

GEMotors
Motor Installation and Maintenance
All Enclosures - Frames 143 - 449 - Single and Polyphase - Ball Bearing
Warning

Safe Motor Operation

High voltage and rotati g parts of electrical machinery can cause serious or fatal injury. Its installation, operation and
maintenance should be performed by qualified personnel only. Familiarization with NEMA MG2 Safety Standard for
Construction and Guid for Selection, Installation and Use of Fractional and Integral Motors, the National Electrical
Code and sound local ractices is recommended. For equipment covered by these instructions, it is important to
observe safety precauti ns to protect personnel from possible injury. Personnel should be instructed to:
Avoid contact with nergized circuits. Disconnect all power sources before attempting maintenance or repair.
Avoid contact with rotating parts and be sure that shaft key is fully captive before motor is energized.
Avoid contact with the start or run capacitors in single-phase motors until a safe discharge procedure has
been followed.
Act with care and' accordance with prescribed procedures in handling, fitting, installing, operating and
maintaining the e uipment.
Do not lift motor nd driven equipment with motor lifting means. If eyebolts are used for lifting motors,
they must be secu ely tightened and the direction of the lift must not exceed a 15 degree angle with the
shank of the eyeb It.
Do not use motor with automatic thermal protection where unexpected starting of equipment might be
hazardous to pers nnel. Provide proper safeguards for personnel against possible failure of motor mounted
brake, particularl on applications involving overhauling loads.
Safe maintenanc
be sure that all p
personal injury f
outlined in NE

practices and qualified personnel are imperative. Before initiating maintenance procedures,
wer sources are disconnected from the machine and accessories to avoid electrical shock and
om rotating parts. If a high potential insulation test is required, procedures and precautions
Standards MGl should be followed.

Failure to properly gro nd motor may cause serious injury to personnel. Grounding should be in accordance with'
the National Electrical Code and consistent with sound local practice.

Installation
I. Location
a)
b)
c)
d)

Dripproof otors are used in a well ventilated place reasonably free of dirt and moisture.
Standard en losed motors are used where they are exposed to dirt, moisture and most outdoor conditions.
Severe-duty nclosed motors are used in highly corrosive or excessively moist areas.
Explosion-p oof motors bearing the Undenvriters' Laboratories label designating the motor U/L Class and
Group as d med in the National Electrical Code are designed for operation in areas classified by locaL
authorities s hazardous in accordance with standards set forth in that Code.

BI006008

BI006008

- - - 1 - - - - - - - - - - -

GE Motors

InslnJcti

flS

Direct-Cull ent Generators


Type COS rames 320-8000
MPC and CF Frames 500-900
For Excav. tor Motor-Generators

BI006008

GEI-99854J Direct-current Generators

SAFETY PRECAUTIONS

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met
in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise
which are not covered sufficiently for the purchaser's purposes, the matter should be referred to the General Electric Company.

BI006008

Direct-current Generators

GEI-99854J

CONTENTS
SUBJECT

PAGE

INTRODUCT ON
RECEIVING,

DLING, AND STORAGE

INSTALLATI N
INSPECTION

TER STARTING

DESCRIPTIO

OF SPECIAL FEATURES

SUGGESTED

NTENANCE SCHEDULE

MAINTENAN~E

.4

PROCEDURES

10
18

19

COMMUTATcpR MAINTENANCE

27

HYDRAULIC~LYREMOVABLEKEYLESS COUPLINGS

29

HYDRAULIc1LLYREMOVABLE INSULATED COUPLINGS

31

CHECKING 4IGNMENT OF COUPLINGS

36

INSULATIONj

37

LUBRICATIO~

40

NOISE AND "1IBRATION

43

CABLE CON~ECTIONS

44

POLE FACE CpNNECTIONS

47

EXPLODED

46

1EWS
I

BI006008

GEI-99854J Direct-current Generators

INTRODUCTION

purposes, the matter should be referred to the General


Electric Company.

This instruction book covers General Electric Kinamatic@


Types CDS, MPC, and MCF generators which are designed
to meet the specific requirements of electric-powered
shovels and draglines. These generators have been designed
with maximum accessibility and minimum size combined
with rugged construction and ease of maintenance. Although
each generator is designed to suit the characteristic of a
particular MD motor, and each motor-generator set is
designed for the particular shovel and dragline on which it is
used, all parts are made of standardized components,
wherever possible for maximum duplication and interchangeability of spare parts.

RECEIVING, HANDLING,
AND STORAGE
Receiving
Immediately upon receipt, the unit should be carefully
unpacked and examined for any damage sustained in
transit. If damage or evidence of rough handling is observed, an effort to establish the responsibility for the
damage should be made and the damage should be
reported promptly to the carrier and to the nearest General Electric Company.

Frame sizes range from CDS320 to CDS8000 for bracket


type construction, and MPC500 to MCF900 for pedestal
type construction. Within the bracket type frame sizes,
there are several divisions in design continuity. The smallest
group includes frames CDS320 to CDS500, the mic1dle
group includes frames CDS580 to CDS680, and the largest
group includes frames CDS5000 to CDS8000. In addition
to the size groupings, there is also a division of large 1200
RPM sleeve bearing sets and smaller 1800 RPM ball
bearing sets, although there is a wide overlapping between
these two divisions. Speeds noted are the normal 60 hertz
rated motor-generator set speeds. Other speeds will result
from different driving motor line frequencies. Typical
motor-generator sets are shown on the cover.

Unless specifically called for on the requisition, the


equipment is not suitably packed for long-term out-of~
doors storage. If it is necessary to store the equipment for
an extended period, it should be adequately protected as
described below.
Handling
Safe practices and careful handling are importan t to avoid
injury to personnel and damage to windings, commutators,
brush riggings, and other mechanical parts. Individual
generators and motors are provided with lifting lugs to
which cables or chain hooks may be attached for lifting
individual units. (See Typical Generator Weights, Table I,
Page 5.)

WARNING: High
and rotating parts
can cause serIOUS
injury. The use of
electric machinery, like all other utilization of
concentrated power and rotating equipment,
can be hazardous. Installation, operation, and
maintenance of electric machinery should be
fiedpersonneL Familiarsafety standard for construction and guide for selection, installation
and use ofintegral HP motors and generators,
National Electrical Code, and sound local
practices is recommended.

CAUTION: Motor-generator sets should' not


be lifted by using the lifting lugs of individual
machines.
Lifting holes are provided in the base for lifting and
handling the entire motor-generator set. Itis recommended
that a spreader bar be used in conjunction with a lifting bar
through the holes in the base. Extreme care should be
taken to prevent a lifting chain from bearing against a
winding or bearing part. Armatures should be lifted by
means of a rope sling around the core, shaft, or coupling.
Never place the sling around the commutator or end
winding when lifting an armature. A tapped hole is provided
in the commutator end shaft extension, which is intended
specifically for lifting and handling the armature. Exercise
particular care to prevent bumping the armature coils,
commutator, or bearingjournals or scratching or damaging
the glass end turn bands or core bands. Serious damage

These instructions do not purport to cover all details or


variations in equipment nor to provide for every possible
contingency or hazard to be met in connection with
installation, operation, and maintenance. Should further
information be desired or should particular problems
arise which are not covered sufficiently for the purchaser's
4

BI006008

Direct-current Generators GEI-99854J

TABLE I
TYPICAL GENERATOR WEIGHTS IN POUNDS AND KILOGRAMS
FRAMES SIZES
CD250
CD280
CD320
CD360
CD400
CD440
CD500
CDS580
CDS680
CDS5000
MPC500
CDS6000
MCF600
CDS7000
MCF700
CDS8000
MCF800
MCF900

ARMATURE ONLY
POUNDS
KILOGRAMS
60
100
140
200
260
350
550
800
1050
2350
1700
2800
2900
4000
4000
5850
5850
5454

GENERATOR COMPLETE
POUNDS
KILOGRAMS
240
360
520
720
950
1320
1890
2900
4400
6600
5600
10100
10100
13650
12300
14850
17500
16565

30
50
60
90
120
160
250
360
480
1070
770
1270
1320
1810
1810
2650
2650
2470

110
170
240
330
440
600
860
1320
2000
3000
2540
4580
4580
6190
5580
6740
7940
7510

'These weights are approximate and do not necessarily reflect specific generator ratings.

degrees warmer than the surrounding air. They should


be energized with the correctAC voltage as shown on
the nameplate.

and premature electric I failure can result from careless


handling.
Storage
The motor-generator s ts for excavators often arrive at the
erection site before t ey can be placed on board the
excavator. Care must e taken to protect them whether
they are stored in a bu' ding or outdoors. In either case,
the excavator erector a d mine personnel must take the
special precautions des ribed below:
Outdoor storage
(1) Inspect equipmen for damage during shipment.
(2) Prepare the erecti n site with adequate drainage. A
crushed rock surf ce is suggested.

(6) The brushes should be separated from the commutator and collector ring surfaces during storage. Either
use the mylar sheet provided or remove the brushes
from the holders. The brushes, if allowed to rest on
the commutator or collector rings, could cause corrosion ofthe surface which later results in flat spots. The
result is destructive sparking when the equipment is
operated.

(3) Store the motor- enerator sets off the ground on


blocks such as railr ad ties. This will minimize moisture
pick-up from the g ound and make inspections easier
to accomplish.
(4) Do not enclose th machines in polyethylene so that
air cannot circulat . A small amount ofcirculating air
is necessary to pr vent the humidity reaching the
level at which sw ating occurs. The moisture can
cause the electri al failure of insulated windings
and/ or the mec anical failure of highly stressed
armature glass ba ding.
(5) The machines sh
the room air by sa
are most suitable
heaters are install
ordered, and thes

(7) Take and record megger readings to determine if


moisture or dirt are present on winding surfaces. The
readings during indoor storage should be taken
monthly. Any downward trend ofthe megger readings
indicates appropriate maintenance steps are required.
(See Insulation Resistance Measurements, Page 38
and Drying of Windings, Page 39.)

uld be kept slightly warmer than


, reliable heaters. Electric heaters
for this purpose. Electric space
d in the base under the units when
heaters keep the machine several

(8) If the packaging is disturbed or the heat source


interrupted for any reason during the indoor storage,
they must be re-established to provide protection
5

BI006008

GEI-99854J Direct-current Generators


Indoor Storage
(1) The equipment should be stored in a clean, dry room
which is not subject to sudden changes in temperature. Varying temperatures in the storage room may
cause the machines to sweat and result in corrosion of
parts or even damage from freezing.

during the storage period.


(9) Shaft journals and shaft extensions are preCISIOn
ground and should be checked by experienced personnel. Care must be taken when cleaning to avoid
damaging such surfaces. Extreme care must be exercised to prevent these parts from rusting since it is
difficult, and sometimes impossible, to remove rust
from these surfaces without damaging or deforming
the surface. If burrs or bumps result from careless
handling, carefully remove them, using a fine file or
scraper.

(2) Steps (3) through (12) which are described in the


Outdoor Storage section (Pages 5 and 6) should be
applied to Indoor Storage.

INSTALLATION

(10) All exposed machined-steel parts are slushed with a


rust prevention before shipment, including steel collector rings. These surfaces should be examined
carefully for signs ofrust and moisture, and reslushed
if necessary. Once started, rust will continue if the
surface is reslushed without first removing all rust
and moisture. Reslushing is to be done with Tectyl
#506 or equivalent. Rust may be removed by careful
use of fine abrasive paper. Slushing compound can
be removed by use of a suitable solvent such as
mineral spirits.

Installation should be in accordance with the National


Electrical Code and consistent with sound practices and all
legal codes.
Inspection
Before installation, the motor-generator set should be
carefully inspected. Windings, commutators, brush riggings, and bearings should be carefully protected during
installation to avoid damage from paint spray, weld splatter,
welding rod butts, or metal chips from files and grinders
which could fall onto the generator. Metal particles which
lodge in windings can cause either immediate or premature failures. Paint or oil on commutators can be very
detrimental to good commutation.
Mounting
Bases for shovel sets are designed to be self-supporting.
They are usually supported at three or four points. Any
base should be supported only at these designed supports.
With the three-point bases, all three points will always line
up in a single plane. Four-point bases should be bolted
down in such a manner that no base distortion is created.
This can be accomplished by resting the set on the two
designed points at one end and raising the other end by
use of a jack located directly under the centerline of the
shaft on a cross-member of the base. Slowly lower the
raised end until the third point touches; then, shim under
the fourth point before tightening all four pad bolts.

(11) The lubrication may drain from the top half of antifriction bearings when equipment is stored for long
periods of time, thereby permitting rust to form on
the unprotected bearing half. Rotate the motorgenerator set occasionally to prevent rust of this type.
Be sure the brushes are not riding on the mylar sheet
which separates them from the commutator and
collector ring surfaces when rotating the set. Brushes
must be lifted from the commutator and collector
rings.

Alignment
The alignment of all couplings on pedestal type sets
should be checked before the set is operated. A careful
and systematic procedure for measuring and recording
the coupling alignment is recommended to ensure accurate results. This procedure is described in the Maintenance
Procedure section.

(12) On motor-generator sets with sleeve bearings, the


bearing journals are wrapped for protection during
storage and these sets should not be rotated during
storage.

Flexible couplings used on bracket type sets need not be


checked before the set is operated unless there is some
evidence of damage prior to startup. These sets may be
started and vibration measurements made. (See "Noise and
6

BI006008

Direct-current Generators GEI-99854J


ceed 200 megohms.
To remove a journal bearing, remove the pedestal cap,
cradle caps, and top bearing half. Also remove any oil
piping and temperature-indicating bulbs in the lower
bearing half. The coupling bolts must be loosened to
prevent bending a shaft or coupling. Then,jack the shaft
just enough to relieve the weight on the lower bearing half
and roll this half around the journal and remove.

Preparation for Initial


t
These inspection proce ures should be followed before
starting the machine fo the first time, after an extended
shut-down, or after a tea -down for extensive maintenance
or repair.

Air passages and air gap should be checked in both rotors


and stators, to make sur that these passages are free from
all foreign objects, such as dirt, lint, old rags, wood chips,
metal particles, or rode t nests. Also, check around the
brush boxes for extran ous nails, bolts, or other foreign
objects. If necessary, th windings should be blown out
with clean dry air.

The sleeve bearing housing or pedestal to cradle insulation resistance can be checked while the shaft is raised and
the bearing out of place. The insulation resistance should
exceed 200 megohms. This insulation prevents damaging
shaft currents, which are caused by slight flux unbalances
in the motor magnetic circuit. These current~, if allowed
to flow through either sleeve or anti-friction bearings, can
cause enough damage to make bearing replacement
necessary.
Fill the bearing housing with a suitable oil (see Sleeve
Bearing Lubrication, Page 41) to the center of the oil level
gage.
To prevent oil seepage through the housing split, apply a
thin continuous layer of a non-hardening oil-sealing
compound. Experience has shown two methods have
been successful in sealing the pedestal cap to the pedestal.

Steel Collector Rings


Before starting the mac ine, complete the following:

(1) Remove the prote


age"), using a solv
Spirits). Grooves s
a thin rope or nyl
protective coating

tive coating (see "Outdoor Stornt such as GE D5B8 (i.e. Mineral


ould be cleaned thoroughly. Use
n toothbrush to help remove the
rom the grooves.

First, the housing split can be sealed by using Titeseal.


"Butter" a continuous strip of Titeseal one inch wide and
a few mils thick on the pedestal surface. Then proceed to
assemble the pedestal cap.

(2) If there is any rust n the ring surfaces, remove it by


rubbing lightly wit fine sandpaper.

Second, the housing split can also be sealed by using


silicone bathtub sealant. The silicone sealant is applied in
a continuous bead about .06 inch (1.6 mm) in diameter
around the pedestal's mating surface.

(3) Lower the brushes

Even though the gasketing material is non-hardening, it is


recommended that the mating surfaces be cleaned and
new material be applied each time the pedestal cap is
removed. Titeseal can be cleaned off by use of a solvent
Toluene or Acetone. The silicone sealant should be cleaned
off by scraping.

Bearings
Machines with ball or oller bearings are greased at the
factory and will need 0 attention until relubrication is
necessary as suggested n the Maintenance section.

Machines equipped wi
nals wrapped and treat
The bearing must be 0
the journal cleaned an
removed as described i
bearing and bearing
foreign matter that m
ment.

The sealing materials can be obtained in the United States


from:

h sleeve bearings have their jourd for protection during shipment.


ened, the wrapping removed, and
flushed. Each bearing should be
the following paragraph, and the
ousing cleaned to remove any
y have accumulated during ship-

Flexible couplings should be checked to see that they


contain the proper amount of lubricant.

Remove the thrust bea ng shipping spacers and check its


insulation resistance. egger between the inner thrust
plate and adapter. Th insulation resistance should ex-

Conunutator and Brushes


Brushes should be worn in to have at least 85 percent

(1) Titeseal

Radiator Specialty Company


1410 W. Independence Blvd.
Charlotte, NC 28201

(2) Silicone sealant -

at most hardware stores

BI006008

GEI-99854J Direct-current Generators


contact over the brush surface and continuous contact
from heel to toe: The commutator surface and undercut
mica should be clean and free from dirt, grease, paint
spots, brush dust, or high mica fins.

Insulation
If the equipment has been stored for any period of time, or
has been exposed to the weather during erection, the
insulation resistance of all windings must be checked.
Measure and record the insulation resistance of each
machine. These readings can be used to compare with later
readings.

Brushes should be free to move in the holders and all


springs should be down and latched. Brush pigtail connections should be tight and the pigtails should not
interfere with the action of the spring or brush and should
not contact any object that does not operate at brushholder
potential.

Surge Capacitors
Some AC motors, especially those of higher horsepower
and/ or voltage, are equipped with surge capacitors. These
capacitors have relatively long discharge time and there
may be danger of touching these terminals before this
discharge has taken place. Each capacitor is equipped with
an internal discharge resistor, which will reduce the voltage to less than 50 volts in 5 minutes.

Connections
Check all terminal connections for accuracy, according to
the diagram of connections, and for tightness. Polarity
and direction of rotation should be checked. Bolted
connectors on flexible cables that can be bent to touch a
ground must be insulated.
Protective Devices

Start-up Inspection Check List


This Inspection Check List summarizes the information
pertinent to start-ups contained in this book. Refer to the
material described in the Inspection Prior to Initial Start
and Inspection Mter Starting sections and to the other
sections referenced.

Speed Limit Device


The mechanical speed-limit device is factory adjusted to
trip at a predetermined overspeed and requires 'manual
resetting. Qualified General Electric personnel should be
contacted for readjustment.

Before Starting M-G Set:


(l) Check all internal bolted connections for proper
torque (see Tightening Bolted Joints, Page 10).

Both normally open and normally closed contacts are


present and have current ratings as in Table II.

(2) Inspect the internal cable condition, ascertain cable


ties are adequate, and check cable clearances to rotor.
(3) Inspect for foreign objects in air passages and air gaps.

TABLE II

(4) Check brush box spacing (.070 to .080 inch (1.8 mm


to 2.0 mm) from commutator) and that brushes are
running on the brush tracks.

SPEED LIMIT DEVICE-MAXIMUM CURRENT RATINGS


NORMALLY OPEN OR CLOSED CONTACTS

115 VAC

230 VAC

120 VDC

(5) Observe brush condition, brush fit, and brush freedom in the brush box.

240 VDC

(6) Inspect the condition of the brush springs.

3.0 amp.

1.5 amps

2.5

.08 amps

(7) Observe commutator surface condition and report


any copper or glass band damage to the local General
Electric representative. Light brush seating may be
required to correct brush fit.

Belt Drives
Belt drives which are applied to motor-generator sets must
maintain a tightness to keep the belts from slipping. A
good practice is to tighten them such as to barely avoid belt
slippage under the most severe load conditions. Do not
overtighten as bearing or shaft damage may occur. Qualified General Electric personnel should be contacted concerning any questions dealing with the adjustment of
these drives.

(8) Megger all circuits and record data (see Insulation


Resistance Measurements, Page 38).
(9) Check all pole and foot bolts for proper tightness.
Sledge the foot bolts tight.
(10) Check coupling alignment on sets with pedestal type
construction (see Checking Alignment of Couplings,
Page 36).
8

BI006008

Direct-current Generators GEI-99854J


Noise and Vibration
When the m-g set is first run, check for unusual noise,
which indicates rubbing ofparts or the presence offoreign
objects. At this time, a defective bearing or unlubricated
bearing may be detected by unusual noise.

(11) Check coupling bplts by sledging them tight.


(12) Check flexible co plings to make sure they have been
lubricated.
(13) Remove the pape
the sleeve bearin
tals with proper 0
Page 41). Be sure
centered axially.

from the sleeve bearings. Inspect


,shaftjournals, and fill the pedesI (see Sleeve Bearing Lubrication,
ch sleeve bearing is approximately

Tightening Bolted Joints


Since loose bolts can cause both electrical and mechancial
failures, all bolts and nuts must be kepttight. The Suggested
Maintenance Schedules (Pages 18 and 19) include the
checking of bolt tightness. Table III gives the torque values to be used in this maintenance procedure.

(14) Seal the pedestal pEts (see Bearings, Page 7).


(15) Anti-friction bear ngs are greased at the factory and
do not require r greasing at start up. Regreasing
schedules are as ecommended under the Ball and
Roller Bearing L brication section, Page 40).

The information in Table III applied to all bolted joints,


except when non-metallic parts (e.g. fluid bed parts,
polyester glass moldings) are bolted to metallic parts.
Here, lower torque values, as listed in Table IV, are recommended to prevent parts from fracturing.

(16) Prepare the thru t bearing (see Thrust Bearing Assembly and Disas embly, Page 22).
(17) Megger pedestal nsulation on pedestal bearing m-g
sets and record d tao

The following precautions which apply to the tightening


of bolted joints should be observed in maintenance procedures:

(18) Check pedestal b lts by sledging them tight.


(19) For AC motors
connections are

ith dual voltage, check that the


ade for the mine voltage supply.

(1) Use a torque wrench for tightening only. When


necessary to loosen bolts, use another type of wrench.

(20) Bump the m-g stand check for rubbing or other


unusual noises. so, on pedestal bearing, check that
the oil rings are rning.

(2) The values given are for dry bolts.


(3) In initially tightening a bolted joint, the final turn
must be tightened with the torque wrench to obtain
an accurate setting.

(21) Check the directi n of rotation ofthe m-g set and the
polarity of the 0 tput of each unit.

(4) In checking the tightenss of bolted joints, the torque


wrench should be applied at the higher value of
torque given in the Tables to insure adequate tightness.

(22) Be sure that the protective devices are functioning


properly.

INSPECTIO

AFfER STARTING

Loose pole bolts will cause serious failures on excavator


equipment. Even though all these pole bolts are torqued
to the specified values during manufacture, they must be
checked on site periodically. Experience has shown that
bolted joints are subject to loosening during shipment.
Experience also has shown that both vibration and the
heating and cooling of boltedjoints cause them to loosen.

Bearings
Sleeve bearing oil rin s should be turning and delivering
oil to the shaft. Bulb-t e or digital-type thermometers can
be placed 1 inch (25 m) below the oil level to monitor
bearing temperature .
Sleeve bearing housi g temperatures should not be more
than 30C (86F) abo e room temperature or a maximum
of 70C (158F) in a 4 C ambient. Bearing Temperature
Relays (BTR's) or esistance Temperature Detectors
(RTD's) are sometim s used as protective devices to alarm
excessive rises in bear ng temperatures. These devices are
normally set to regis r internal bearing temperatures of
lOOC (212F) maxi urn. The normal acceptable internal operating temper ture is approximately 80C (176F) .
Ball or roller bearing ousing temperatures should not be
more than 25C (77 F) above room temperature or a
maximum of 75C ( 67F) in a 50C (122F) ambient.
Higher temperature indicate trouble. Check alignment
and lubrication imm diately.

For these reasons, the pole bolts should be checked


according to the recommendations below:
(I) Before start up, make a visual inspection and spot
check the main and commutating pole bolt tightness
with a torque wrench.
(2) After 24 hours of operation, all main and commutating pole bolt torques should be checked.
(3) After 3 months of oepration, again check all main
and commutating pole bolt torques.
(4) Then, every 6 months or as often as experience
dictates, check all main and commutating pole bolt
torques.

Under severe load co ditions, the housing temperature of


an anti-friction thrus bearing may run 35C (95F) above
room temperature 0 a maximum of 85C (185F) above
a 50C ambient.

BI006008

GEI-99854J Direct-current Generators

TABLE III
BOLT TIGHTENING TORQUE VALUES

Hex Head C1 C5
Medium Carbon Steel
Socket Head (Hexagonal) C1A7 Hex Head C1 E1
(Hold Down, Elect, Connections
High Strength Alloy Steel Silicon Bronze Material
Main Pole, Frame Eye Bolts, Etc.)
(Coupling Bolts)
(Comm. Pole Bolts)
Wrench
Size

Thread Sizes (UNC-2A)

Torque Lb-Ft (newton metre)


8-10 (11-14 Nom)

13-17 (18-23 Nom)

16-20 (22-27 Nom)

9-11 (12-15 Nom)

24-30 (33-40 Nom)

28-35 (38-47 Nom)

16-20 (22-27 Nom)

1/2-13

60-75 (80-100 Nom)

72-90 (98-120 Nom)

32-40 (43-54 Nom)

35-45 (49-61 Nom)

5/8-11

120-150 (160-200 Nom)

140-180 (190-240 Nom)

70-86 (95-120 Nom)

72-90 (98-120 Nom)

255-320 (350-430 Nom)

90-115 (120-160 Nom)

100-125 (135-170 Nom)

400-500 (540-680 Nom)

145-178 (197-241 Nom)

155-195 (210-265 Nom)

615-770 (830-1040 Nom)

865-1080 (1170-1460 Nom)

210-260 (285-355 Nom)


-

1220-1520 (1660-2060 Nom)

2130-2660 (2890-3610 Nom)

1/4-20

7-9 (10-12 Nom)

1/2

5/16-18

9/16

3/8-16

3/4
15/16
1 1/8

3/4-10

210-260 (280-350 Nom)

1 3/16

7/8-9

320-400 (430-540 Nom)

1 1/2

1-8

460-580 (620-790 Nom)

1 11/16

1-1/8-7

640-800 (870-1080 Nom)

1 7/8

1-1/4-7

900-1120 (1220-1520 Nom)

2 1/4

1-1/2-5

1540-1940 (2090-2630 Nom)

7/16

Hex Head C1 F5A 1


Non-Magnetic Steel

5-6 (7-8 Nom)

TABLE IV
BOLT TIGHTENING TORQUE VALUES NONMETALLIC PARTS BOLTED TO METALLIC PARTS

DESCRIPTION OF
SPECIAL FEATURES

Hex Hand C1C6 Medium Carbon Steel


(Yokes, Brush Studs, Coil Supports)

General
Excavator generators are designed for ruggedness, maximum accessibility, minimum length, and ease of maintenance. In the range of frame sizes, there are three general
groups which differ somewhat in appearance and features,
but in general have the same basic design. The large size
group includes frames CDS5000 to CDS8000 for
bracket-type construction and frames, and MPC500
through MCF900 for pedestal-type construction. There is
a definite correlation between the pedestal and bracket
construction in that MPC500 refers to the same size generator as CDS5000. Correspondingly, MPC600 is the same
as CDS6000, MCF700 the same as CDS7000, and MCF800
the same as CDS8000. The nomenclature MPC and MCF
refers to pedestal construction in noncompensated and
compensated design respectively. The middle-size group
includes frames CDS580 and CDS680. The small-size group
includes frames CDS320 through CDS500. Figures 1, 2, 3,
4 and 5 on the pages following show typical cross-section
assembly views of each of the groups.

WRENCH
SIZE

Thread Size (UNC-2A)

7/16

1/4-20

5-7 (7-9 Nom)

1/2

5/16-18

7-9 (9-12 Nom)

9/16

3/8-16

13-17 (18-23 Nom)

3/4

1/2-13

24-30 (33-41 Nom)

15/16

5/8-11

60-75 (81-100 Nom)

Torque Lb-Ft (newton metre)

removing the whole generator or disturbing its alignment on


the motor-generator set. Split magnet frames are usually held together by six bolts and aligned by four dowel
pins. The top half has lifting lugs suitable for lifting either
the whole generator or the top half of the magnet frame.
These lifting lugs should not be used to lift the entire
motor-generator set.
Magnet frames of the small-size group, CDS320 through
CDS500, are solid rather than split. These small-size generators are lighter weight and can readily be handled as
complete units.

Magnet Frames
Magnet frames of the large and middle-size groups, CDS580
through CDS8000 and MPC500 through MCF900, are
split, which permits the top half to be removed separately.
This feature allows the removal of an armature without

Bearinli!S

Generators in frames CDS5000 through CDS8000, and


MPC500 through MCF 900 are furnished with either ball
10

BI006008

Direct-current Generators GEI-99854J


bearings or sleeve be rings. As a general rule, sleeve
bearings are used on t e large 1200 RPM sets (1000 RPM
for 50-hertz power); ba I bearings are used on the smaller
1800 RPM sets (1500
M for 50-hertz power).

Couplings
On DS-l machines, th drive end coupling is separately
machined and then sh nk on the shaft. The commutator
end coupling is assem led with the same interference fit.
However, this couplin is hydraulically removable using a
hydraulic pump with ydraulic oil and a suitable puller.
The pressures involve in pulling couplings reach 25,000
psi (170 MPa). A pu p is usually furnished with each
excavator and should e used for coupling removal only.
Tables VII, VIII, and give the coupling numbers for the
various frame sizes and coupling sizes along with assembly
and finishing recomm ndations. Refer to the RemovalAlternate Method sec ion for removing drive end and
keyed flexible couplin s.
Thrust Bearing
End play of a motor-g
single bearing in one
expansion of the shaft
tional thrust on other
locked bearing is locat
locking the outer rac
other motor bearing
in their housings. Th
adequate to take both

nerator set is limited by locking a


fthe units. This allows for thermal
and rotors without imposing addiearings. On ball bearing sets, this
d in the AC motor. Thus, by axially
of one of the motor bearings, the
d all generator bearings can float
capacity of the locked bearing is
thrust and radial loads.

On sleeve bearing sets the thrust of the set is usually taken


in a separate anti-fri tion bearing. This thrust bearing
assembly includes a baring, stub shaft, and housing. It is
mounted on the ped stal of one of the end generators.
This bearing assembl is specially designed to take only
thrust load and not rial load (see Fig. 6).

Ventilation
Frames CDS320 throu h CDS680 have shaft fans and axial
vent holes, but not rial ducts. The air is drawn in the
commutator end, thr ugh the generator, and discharges
out the coupling end.
On frames CDS500 through CDS8000 and MPC500
through MCF900, the spider or quill construction permits
air to circulate unde the core and through the radial
ducts in the core. T e radial duct acts as a fan creating
positive air flow thro gh the generator. The air flow path
is in the drive end of t e unit and out the commutator end.

11

BI006008

GEI-99854J Direct-current Generators

128

55

57

12

9A

TYPICAL CDS7000 - 8000


ARMATURE

AIR OUTLET

REF.
NO.
1E
1F
2
4A
4B
4C
SA
5B
6
6B
9A
10
12
12B
12C
31
32
34

DESCRIPTION
Armature Spider
Armature Balance Weight
Armature Coil
Armature Banding - Core
Armature Banding - End Turns (CE)
Armature Banding - End Turns (DE)
Armature Coil Support (CE)
Armature Coil Support (DE)
Armature Core
Armature Core - Radial Air Ducts
Equalizer - Molded
Shaft
Commutator
Commutator Shell
Commutator Banding
Bearing
Bearing Bracket
Bearing Cap

36
42
46
50
53
55
56
57
70
73A
75
150
502
909
921
922
923
924

Bearing Cartridge
Pipe Plug
Grease Metering Plate
Brush
Brushholder Yoke
Brushholder Stud
Brushholder Stud Insulation
Brushholder
Comm. Coil & Pole Assembly
Main Field Coil & Pole with Bars
Pole Bolts
Frame
Pole Face Connections
Comm. Pole Shim
Main Pole Shim
Cable Clamp
Solid Coupling
Air Baffle

FIG. 1 Typical Cross-Sectional Assembly, CDS 5000-9000


12

BI006008

Direct-current Generators

GEI-99854J

CROSS-SECTIONAL VIEW OF ARMATURE FOR MCF700, 800, 900

ARMAT~RE SHOWN FOR MPC 500, 600 ONLY.

REF.
NO.
1E
1F
2
4A
4B
4C
SA
5B
6
6B
9A
10
12
12B
12C
50
53

DESCR PTION
Armatu e Spider
Armatu e Balance Weight
Armatu e Coil
Armatu e Banding - Core
Armatu e Banding - End Turns (CE)
Armatu e Banding - End Turns (DE)
Armatu e Coil Support (CE)
Armatu e Coil Support (DE)
Armatu e Core
Armatu e Core - Radial Air Ducts
Equaliz r - Molded
Shaft
Comm tator
Comm tator Shell
Comm tator Banding
Brush
Brush older Yoke

55
56
57
70
73A
75
80
82
91
122
150
502
503A
909
921
923

Brushholder Stud
Brushholder Stud Insulation
Brushholder
Comm. Coil & Pole Assembly
Main Field Coil & Pole with Bars
Pole Bolts
Pedestal with Cap
Oil Sight Gage
Oil Drain
Cover, Space Heater Access
Frame
Pole Face Connections
Line Adapter
Comm. Pole Shim
Main Pole Shim
Solid Coupling

IG. 2 Typical Cross-Sectional Assembly, MPC-MCF 500-900


13

BI006008

GEI-99854J Direct-current Generators


AIR OUTLET
6
7R

6C

4C

31
46
10 ...............

42

AIR INLET
922

REF.
NO.
2
4A
4B
4C
5B
6
6C
7
7R
9
10
12
12B
12C
31
32
34

DESCRIPTION
Armature Coil
Armature Banding - Core
Armature Banding - End Turns (CE)
Armature Banding - End Turns (DE)
Armature Coil Support (DE)
Armature Core
Armature Core - Axial Air Ducts
Armature Fan
Armature Fan Guard
Equalizer Coil
Shaft
Commutator
Commutator Shell
Commutator Banding
Bearing
Bearing Bracket
Bearing Cap

36
42
46
50
53
55
56
57
570
70
73
75
150
909
921
922
923

Bearing Cartridge
Pipe Plug
Grease Metering Plate
Brush
Brushholder Yoke
Brushholder Stud
Brushholder Stud Insulation
Brushholder
Brushholder Mounting Bolt
Comm. Coil & Pole Assembly
Main Field Coil & Pole
Pole Bolts
Frame
Comm. Pole Shim
Main Pole Shim
Cable Clamp
Solid Coupling

FIG. 3 Typical Cross-Sectional Assembly, CDS580-680


14

BI006008

Direct-current Generators

GEI-99854J

7R

57E
32

50
34

12E
128
12F
AIR OUTLET
CD400 THRU CD500
922

REF.
NO.
1G
2
4A
4B
4C
5B
6
6A
6C
6D
6E
7
7R
7S
9
10
12
12B
12D
12E

150

DESC IPTION
Armat re Adapter
Armat re Coil
Armat re Banding - Core
Armat re Banding - End Turns (CE)
Armat re Banding - End Turns (DE)
Armat re Coil Support (DE)
Armat re Core
Armat re Core Key
Armat re Core - Axial Air Ducts
Armat re Core - End Plate
Armat re Core - Rivet
Armat re Fan
Armat re Fan Guard
Armat re Fan Key
Equali er Coil
Shaft
Com utator
Com utator Shell
Com utator Vee Ring
Com utator Nut

12F
31
32
34
42
50
53
55
57
57D
57E
70
73
75
150
909
921
922
923
925

Commutator Key
Bearing
Bearing Bracket
Bearing Cap
Pipe Plug
Brush
Brushholder Yoke
Brushholder Stud
Brushholder
Brushholder Mounting Bolt
Brushholder Stud - Bellville Washer
Comm. Coil & Pole Assembly
Main Field Coil & Pole
Pole Bolts
Frame
Comm. Pole Shim
Main Pole Shim
Cable Clamp
Solid Coupling
Eye Bolt

F G. 4 Typical Cross-Sectional Assembly, OS-1, COS320-500


15

BI006008

GEI-99854J Direct-current Generators


75

925

150

140

REF.
NO. DESCRIPTION
1G Armature Adapter
2 Armature Coil
4A Armature Banding - Core
4B Armature Banding - End Turns (CE)
4C Armature Banding - End Turns (DE)
5B Armature Coil Support (DE)
6 Armature Core
6A Armature Core - Key
6C Armature Core - Axial Air Ducts
6D Armature Core - End Plate
6E Armature Core - Rivet
7 Armature Fan
7S Armature Fan Key
9 Equalizer Coil
10 Shaft
12 Commutator
12B Commutator Shell
12D Commutator Vee Ring
12E Commutator Nut
12F Commutator Key

15
31
32
34
42
50
53
55
57
57D
57E
70
73
75
140
150
909
921
925

Pinion Key
Bearing
Bearing Bracket
Bearing Cap
Pipe Plug
Brush
Brushholder Yoke
Brushholder Stud
Brushholder
Brushholder Mounting Bolt
Brushholder Stud - Bellville Washer
Comm. Coil & Pole Assembly
Main Field Coil & Pole
Pole Bolts
Conduit Box
Frame
Comm. Pole Shim
Main Pole Shim
Eye Bolt

FIG. 5 Typical Cross-Sectional Assembly, OS-2 COS-320-500


16

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Direct-current Generators

GEI-99854J

Failure

Repair
Repairs should be made only by qualified personnel using
the materials and proc sses for which the motor or generator was designed. T protect the warranty during the
warranty period, all re airs must be made in a General
Electric Service Shop r approved repair facility. Many
repairs can be easily per armed with only assembly operations, if General Electri replacement parts are available.
If major repairs are u dertaken (such as rewinding an
armature), proper facil ties should be available and suitable precautions obse ed.

Annature Removal

Type CDS, MPC, and MCF shovel generators are designed


to allow easy removal ofthe armature from the set line-up.
In replacing an armature, there are certain precautions
which should be taken and a definite order of steps to be
followed for best results. The following procedure is recommended:
(1) If the unit to be replaced is a middle unit of the set,
mark the top of the mating coupling halves on both
ends of the armature to be removed. This marking
makes it possible to maintain the same angular arrangement of rotors between the ends of the set.

(2) Remove the coupling end magnet frame cover from


both the generator whose armature is to be removed
and from the unit adjacent to its commutator end.
On pedestal bearing sets, this step is not necessary.
17

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GEI-99854J Direct-current Generators

SUGGESTED MAINTENANCE SCHEDULE


Adjust this schedule as necessary. Be guided by your records. They will show when more or less attention is justified.

COMPONENT

INSPECTION OR MAINTENANCE OPERATION


MONTHLY
(For 24-hour a day operation, this should be biweekly.)

BEARINGS

Make sure that grease or oil is not leaking out of the bearing housings. If any leakage is present,
correct the condition before continuing to operate.

Ball and Roller

Listen to a few bearings on a sample basis. Bearings that get progressively noisier will need
replacement at next shutdown (see Lubrication, Page 40).

Sleeve

Check oil level. The oil level is to be midway between the two lines on the oil gage when the
excavator is at standstill. Check oil color through sight gage. Slightly cloudy oil is OK. Black oil is
a danger sign. Slight foaming is not unusual.

BRUSHES

Check the brush length. Replace when brush wear marker on pigtail reaches top of brush box.
Inspect for worn or shiny brush clips, frayed or loose pigtails, chipped or broken brushes, and
check for indication of overheating of the brush or pigtail at the socket. Remove a few brushes to
check the brush-commutator contact face. Burned areas indicate commutation troubles. Loosen
each brush in its holder. Blowout the area of the brushholder and brushholder stud insulation
with clean, dry air to get rid of brush dust. Wipe brushholder stud insulation to remove
contamination.

COMMUTATORS

Check the commutator for roughness by feeling the brushes with a fiber stick.

Bouncing brushes give advance warning of a commutator going rough. Observe the commutatOi
for signs ofthreading (see Commutator Chart, GEA-7053). If the threading is getting worse - take
action; threading healed over - OK. Check for excessive commutator commutation wear rate,
streaking, copper drag, pitch bar-marking, and heavy slot bar-marking. Commutator should have
not more than 0.0025 inch (.06 mm) total indicator runout or .0002 inch (.005) bar-to-bar steps.
Remove dust or dirt that may have accumulated on glass band surfaces, using vacuum followed
by low pressure (20 psi) clean, dry air.

INSULATION

Visual Inspection (see Insulation, Page 37).

MECHANICAL
Air Filters

If supplied with excavator, keep in good working order. Replace when necessary.

Bolts

Visual observation for loose bolts, parts, or electrical connections.

Noise and Vibration

Any unusual noise, vibration, or change from previous observations.

18

BI006008

Direct-current Generators GEI-99854J

SUGGESTED MAINTENANCE SCHEDULE

COMPONENT

INSPECTION OR MAINTENANCE OPERATION


EVERY SIX MONTHS

BEARINGS
Ball and Roller

Listen to all bearings. Pull back bearing cap to inspect grease condition on a few representative
machines. (Check one bearing on a motor-generator set, etc.)

Sleeve

Remove pedestal cap and cradle caps. Lift top half of bearing. Inspect bearing surface and rings
for wear. If excessive wear or sludge in bottom of housing, roll out bottom half of bearing for
inspection.

COMMUTATORS

Check risers for cracks and dirt. If there are cracks, also check end of shaft keyway and shaft fan.
(Cracks here may mean extreme torsional vibration in the system.) Dirt should be cleaned out of
the risers to maintain good ventilation. Remove dust or dirt that may have accumulated on glass
band surfaces using vacuum followed by low pressurized (20 psi) clean, dry air.

INSULATION

Measure insulation resistance. (See Insulation, Page 37). Compare with records. Wipe deposits
from brushholder stud insulation and commutator creepage path. Remove heavy deposits from
around field coil connections where grounding might occur. Use vacuum followed by clean, dry
pressurized air (do not exceed 30 psi) to blow deposits out of the commutator riser area and to
remove any block ventilation openings in windings. Make visual inspection for signs ofoverheating.

MECHANICAL
Bolts

Check all electrical connections for tightness, look for signs of poor connections (arcing,
discoloration, heat). Adjust inspection period to suit experience. Inspect foundation for signs of
cracking, displaced foot shims, and check foot bolts for tightness. Check frame-split bolts,
brushholders, brushholder studs, main and commutating pole bolts, bracket bolts, etc., on
sampling basis. Check all coupling bolts (see Tables III, and IV, Page 10 for bolt torque values.)

Shaft

Check corners of exposed end of shaft keyway for cracks (due to extreme torsional vibration). If
there are cracks, check fan and commutator risers.

Ventilation

Check for clogged screens, louvres, filters, etc.

Vibration

Check for excessive vibration (see Noise and Vibration, Page 43).
YEARLY

BEARINGS
Sleeve

Drain housings. Remove pedestal cap and cradle caps. Lift top of bearing. Inspect bearing surface
and rings for wear. Ifexcessive wear or sludge in bottom ofhousing, roll out bottom halfofbearing
for inspection. Clean and flush if necessary and refill (see Sleeve Bearing Lubrication). Use oilsealing compound to seal housing split when reassembling bearing.

19

BI006008

GEI-99854J Direct-current Generators


the commutator.

(3) Remove the top half ofthe commutator end bearing


bracket. To accomplish this, remove the bolts that
hold the top half bracket to the magnet frame, the
bolts that hold the split bracket together, and the
brush yoke clamping bolts. On ball bearing machines,
the top half of the outer bearing cover must first be
removed to allow the magnet frame rabbet to disengage. Take care to protect the bearing from dirt and
damage. On pedestal bearing sets, this step is not
necessary.

(3) Variation in manufacture may result in the condition


that a slight brush shift from the factory setting as
described in Paragraph 1 is required. In most cases,
the factory setting will work for all replacements.
Commutation under load should be observed following the replacement. Any unusuaL sparking, abnormal commutator film, or bar burning should be
detected and corrected in accordance with the
Commutation Adjustment section of this instruction
book.

(4) Remove all electrical connections between the top


and bottom halves of the frame.

(4) When an armature is replaced, refinement of the MG


set balance may be required to meet the limits shown
in Table XVII, Page 43.

(5) Remove all the brushes from the brushholders and


protect the commutator surface with a wrap of heavy
paper.
(6) Remove the top half of the brush rigging. On sleeve
bearing generators, remove the top half of the bearing housing or the pedestal cap, and cradle caps, then
remove the top half of the bearing and the oil rings.

Anti-friction Bearing Removal


The procedure for removing an anti-friction bearing varies slightly due to differences in construction between
small and large machines. In general, the same technique
applies. For best results, the following procedures should
be followed:

(7) Remove the top half of the magnet frame.


(8) If the armature to be removed is not an end unit,
place fiber strips or wedges of suitable material into
the air gaps of the machine adjacent to the commutator end. For ball bearing sets, the bearing housing
bolts of this adjacent unit should also be loosened to
prevent damage to the bearing.

(1) Clean the exterior of the housing to prevent dirt from


getting into the bearing or coupling.
(2) Remove the coupling hub, if the unit has one. If the
unit has a hydraulically removable coupling, it should
be removed according to the procedures given in the
Hydraulically Removable Keyless Coupling section of
this instruction book.

(9) Remove the bolts holding both couplings together.


(10) Release the thrust bearing, if present, for axial movement.

(3)

(11) Place a sling around the shaft extensions using suitable protection for the bearingjournal. Do not lift the
armature by placing the sling around the end turns or
commutator. Spread the couplings until both rabbets
disengage. Carefully lift the armature clear.
Removal of Shaft from Armature
The shaft is designed to be removed from the armature
core and commutator assembly. Proper removal procedures must be followed to support the assembled armature
while removing the shaft. Contact your nearest General
Electric Authorized Service Apparatus Shop for the correct procedure for removing the shaft from the armature.

Next, remove the outer bearing cover. On frame sizes


CDS320 through CDSSOO, this outer cover is an
integral part of the bearing bracket which requires
that the enitre bracket be removed. On the larger
frame sizes CDSS80 through CDS8000, the outer
cover is removable as split halves, exposing a grease
metering plate which must be removed to expose the
bearing. If a snap ring or bearing lock nut is used, it
should be removed.

(4) The next step is to insert a split spacer ring around the
shaft between the inner race of the bearing and the
inner lip of the bearing cover. On frame sizes CDS320
through CDSSOO, this is accomplished by simply sliding the inner cover back toward the commutator,
exposing the shaft, and allowing the spacer ring to
slip into place around the shaft. For frame sizes
CDSS80 through CDS8000, the entire cartridge must
be slid toward the commutator until the cartridge
clears the bearing. Then the spacer ring can be
slipped into place as before and the cartridge slid
back over the bearing. In either case, the cover or the
cartridge is used to pull the bearing. A suitable puller
is attached and the bearing can be pulled. If a puller
which presses against the end of the shaft is used, care
should be exercised not to damage the shaft center.

Armature Installation
A new or repaired armature is installed in the generator in
the reverse order given for armature removal. The following precautions are necessary for proper assembly:
(1) The chisel marks on the brushholder yoke should be
set on the factory setting.
(2) Brushholders must be adjusted to have a .070 to .080
inch (1.8 to 2.0 mm) radial spacing to the commutator. A .075 inch (1.9 mm) thick non-metallic shim
may be used. When installing a replacement armature which has a commutator diameter larger than
the former one, it may be necessary to move the
brushholders outward radially to prevent damage to

(5) Ifa bearing is pulled without a split spacer ring and all
the pulling force is exerted on the outer race, assume
that the bearing is damaged and that it must be
replaced.

20

BI006008

Direct-current Generators GEI-99854J


Assembly of Ball Beari g
The following proced re should be followed in assembling a ball or roller baring:

(3) After the bearing has cooled, slide the cartridge over
the bearing. Assemble the snap ring, if one is required.

(1) Fill the grease ca ty in the cartridge 1/2-2/3 full of


the recommende grease and slide the cartridge
onto the shaft as r as it will go.

(4) "Butter" the bearing with grease, replace the grease


metering plate (CDS5S0 thru CDSSOOO frame sizes),
fill the bearing cap full of the recommended grease,
and assemble.

(2) Heat the bearing in oil in an oven to 116-127C


(240-260F), an slide the bearing onto the shaft.
The inner race sh uld be mounted tightly against the
shoulder adjacen to the bearing fit.
9 10

(5) Run the machine for several minutes to purge the


excessive grease before replacing the plugs.

11 12 13 14 15

1
-~

6
5
4

24

29

13

New Oil Sight


Gage as Shown

21

23

20

22

1. Oil Sight Gaug~


2. Bolt (Stub Shafr to Shaft)
3. Stub Shaft
1
4. Bearing Retain r (Inner Race)
5. Screw (Bearin Retainer to Stub Shaft)
6. Bearing Retain r (Outer Race)
7. Screw (Bearin Retainer to Bearing Housing)
8. Bearing Housi g
9. Screw (Outer T rust Plate to Inner Thrust Plate)
10. Pipe Plug
11. Outer Thrust Pate
12. Cover
13. Inner Thrust PI te
14. Gasket
15. Adapter (Thrus Bearing)

16. Ball Bearing


17. Oil Slinger
18. Screw (Adapter to Pedestal)
19. Pedestal
20. Dowel Pin (Adapter to Pedestal)
21. Pipe Plug
22. Screw (Cover to Adapter)
23. Pipe Plug (Drain)
24. Insulating Washer
25. Screw (Inner Thrust Plate to Adapter)
26. Hardened Steel Washer
27. Insulating Tube
28. Steel Shims (Inner Thrust Plate to Adaptel
29. Insulating Shim

FIG 6 Assembly For Insulated Style Anti-Friction Thrust Bearing


21

BI006008

GEI-99854J Direct-current Generators


Thrust Bearing Assembly and Disassembly
Essentially, the thrust bearing on an motor-generator set
consists of a stub shaft, a duplex mounting of angular
contact ball bearings, and a housing. Thrust in both
directions is trans-mitted through the shaft and bearings
to the housing.

mm). This clearance should be measured with a


feeler gauge at the three point where the inner thrust
plate bolts to the adapter.
(12) Megger between the inner thrust plate and adapter.
The insulation resistance should exceed 200 megohms.

The alignment of this thrust bearing is critical in achieving


good performance. It is important to follow the listed
procedure for assembly and disassembly. Note that the
instructions to be followed at start-up are listed separately
(see Fig. 6).

(13) Assemble outer thrust plate to inner thrust plate.


Install dowel pin in outer thrust plate to bearing
housing. The outer thrust plate has a machined
groove with a maximum depth of .881 inch (22.4
mm) and a minimum depth of .879 inch (22.3 mm).
The bearing housing has a machined thrust section
with a maximum thickness of .867 inch (22.0 mm)
and a minimum thickness of .865 inch (21.9 mm).
This limits the end play from a minimum of.O 12 inch
(.30 mm) to a maximum of .016 inch (.40 mm).
Therefore, the end play is not adjustable.

Assembly
(1) Check to see that the endplay of the m-g set is centered. Magnetic cores of all units should be centered
within .25inch (6.4mm). Individual bearingendplay
centered within .06 inch (1.6 mm). If necessary,
center the rotating element to meet these limits.

(14) Assemble housing cover and other hardware.

(2) Check the end of the shaft for squareness and trueness and remove all burrs, dirt, and upset caused by
metal stamps.

(15) Fill with oil to a level even with the center of the oil
sight gage. A high quality turbine grade mineral oil
that is corrosion and oxidation inhibiting, having a
viscosity as shown in Table XV should be used. This
normally should be the same oil that is in the sleeve
bearings.

(3) Mount the stub shaft and bolt. The Allen wrench
should be sledged tight until it rings. (When assembling thrust bearing to MPC500, proceed with Step
#4 before Step #3.)
(4) Mount the thrust bearing adapter to the face of the
pedestal or sleeve bearing housing and dowel.

Disassembly
(1) Drain oil.

(5) Indicate runout of the stub shaft OD .25 inch (6.4


mm) from the end. This runout not to exceed .001
inch (.025 mm) TIR. Rotating the stub shaft to a
different angular position with respect to the m-g set
shaft may improve runout, if it is excessive.

(2) Remove housing cover.

(6) Check radial clearance between the stub shaft and


the adapter. It should be equal all around within
.01O inch (.25 mm).

(6) Loosen inner thrust plate and remove metal (T-shaped) shims. Remove inner thrust plate and insulating
shims. Keep insulating tubing, insulating washers,
and hardened steel washers with inner thrust plate.

(3) Remover outer thrust plate.


(4) Remove inner race retainer ring.
(5) Remove the bearing housing and bearings as a unit.

(7) Mount the inner thrust plate to the adapter with the
insulating shim. Leave out the metal (T-shaped)
shims at this time. Be sure to include tubing, insulating washer, and hardened steel washer when assembling.

(7) Ifit is desired to remove the stub shaft, the oil slinger
and thrust bearing adapter must be removed first.
(8) It if is desired to replace the bearings only, omit
disassembly Steps #6 and #7. Remove the outer race
retainer ring and remove bearings from bearing
housing. To assemble new bearings, return to assembly Step #8 and follow assembly instructions.

(8) Assemble thrust bearings into bearing housing and


clamp outer races with outer race retainer ring. (It
may be necessary to tap outer races of bearings lightly
with mallet to assemble). The bearings are to be
mounted back-to-back with stamped surfaces of outer
races adjacent to each other.

Checking Assembly
(1) Check to see that the endplay of the m-g set is
centered. At the factory during assembly of the m-g
set, magnetic cores of all units are centered and the
endplay of each bearing is centered within .06 inch
(1.6 mm). Check the sleeve bearing by the collector
ring of the synchronous motor to determine that it is
centered in the shaft journal within .06 inch (1.6
mm).

(9) Assemble oil slinger and bearing assembly onto stub


shaft.
(10) Clamp inner races of bearings with inner race retainer ring.
(11) Insert metal (T-shaped) shims between the insulat-

ing shim and adapter in three places until the clearance between the inner thrust plate and bearing
housing is between .002 inch and .005 inch (.05 mm
and .13 mm) and the difference between the largest
and smallest measurement is not over .001 inch (.025

(2) Remove the housing cover.


(3) Loosen the bolts holding the outer thrust plate and
remove and discard the shipping spacers between
outer and inner thrust plate.

22

BI006008

Direct-current Generators GEI-99854J


tion and frequent subsequent inspections are required to
obtain satisfactory performance. The following points are
important in regard to assuring proper brush service:

(4) Remove the outer hrust plate. Verify that the dowel
pin is installed.
(5) Tighten the bolts h Iding inner race bearing retainer
to 60-75 ft-Ib (80-1 0 Nem) torque.
(6)

Check the cleara ce between the bearing housing


and the inner thr st plate with a feeler gage at the
location of the thr e pairs of inner thrust plate bolts.
Each of the thre measurements must be between
.002 inch and .005 inch (.05 mm and .13 mm) and the
difference between the largest and smallest measurement is not over. 01 inch (.025 mm). Axial movement of the sh ft assembly and/or changes in
shimming behind the inner thrust plate may be
necessary to acco plish this. Keep in mind that the
requirements in St p #1 must also be met.

(1) Make sure the pigtail screwis tight and that the pigtail
does not interfere with free movement of the brush.
(2) Be certain the pigtail cannot touch uninsulated parts
of the machine.
(3) Check that the brushes are free in the holders with
the springs positioned correctly and functioning
properly.

(7) Megger between t e inner thrust plate and adapter.


The insulation re stance should exceed 200 megohms.

(4) The brushholders should be uniformly spaced about


.070 to .080 inch (1.8-2.0 mm) from the commutator
surface.

(8) Assemble outer t rust plate to inner thrust plate.


Torque bolts to 6 -75 ft-Ib (80-100 Nem).
(9) Assemble housing over and other hardware. Torque
bolts to 24-30 ft-Ib (33-40 Nem).

(5) Check brush fit and, if necessary, use seater stone


while the m-g set is running to obtain an acceptable
fit (85% contact).

(10) Fill with oil to a Ie el even with the center of the oil
sight gage. A high quality turbine grade mineral oil
that is corrosion nd oxidation inhibiting, having a
viscosity as shown 'n Table XV should be used. This
normally should e the same oil that is in the sleeve
bearing.

(6) Running a machine at no load (such as during start


up) and the lack of proper filming on a new commutator sometimes leads to short life for the first set of
brushes. Before investigating or changing the brush
grade, wait and see how the first set of replacement
brushes perform.

NOTE: Alignment of hrust bearing must be checked,


whenever coupling ali c nment is checked or corrected.

Troubleshooting
(1) High vibration in
move the end co
indicate the runo
cate a maximum

(7) Check spare brush supplies during installation to be


sure that replacement brushes are on hand.
Replacement brushes should have their commutator contact surfaces curved to exactly fit the commutator surface.
This is accomplished by "sanding in" the brushes in each
brushholder separately. Draw a sheet of non-metallic
sandpaper under the brushes with the rough side toward
the brush, while the brushes are pressed firmly toward the
commutator. When sanding brushes, do not get carbon
dust into the windings. The generator should be thoroughly blown out after sanding the brushes.

icates bearing misalignment. Reer and inner retainer ring, and


t of the stub shaft. It should indif .001 inch (.03 mm) TIR.

(2) Excessive endplay indicates either loose hardware or


internalloosenes in the bearings. Remove housing
cover and check ti htness of all exposed bolts, including the stub shaft olt. If these bolts are tight, loosen
outer thrust plat so that it is possible to see the
bearing housing. Move the motor-generator set rotors toward the t rust bearing end of set, until the
bearing housing does not touch the inner thrust
plate. Recheck th tightness of the bolts holding the
inner and outer earing retainer and the stub shaft
bolt. If these bol are tight, remove the outer thrust
plate and check t e inner thrust plate bolts. If these
bolts are not loos , use an indicator to check for axial
movement of th bearing housing. Any movement
indicates internal looseness in the bearings, and they
should be replac d.

The replacement ofbrushes can be simplified in two ways.


First, in most cases, up to 20% of the brushes on one stud
can be replaced without requiring "sanding in". Second,
the use of brushes with fluted contact faces simplifies the
process of sanding brushes.

Brush Maintenance
Good brush performa ce is dependent to a large degree
on the care used in Itting and adjusting the brushes
before the machines e put in service. An initial inspec-

23

BI006008

GEI-99854J Direct-current Generators


(1) Inspect all electrical connections and make certain
that none are loose.

Commutation Adjustment

(2) Check the connections and make certain that the


commutating field or any part of it is not reversed,
and that one or more of the main field coils is not
reversed.
(3) Inspect the brushes and see that they move freely in
the holder, and that the pigtails do not interfere with
any part of the rigging.
(4) Check the brush spacing and alignment with paper
tape. The brush spacing should always be checked
with reference to the toe of the brush. Machines of
certain designs are very sensitive to circumferential
brush spacing and a variation of over .06 inch (1.6
mm) should be corrected. In general, the more
accurate the brush spacing, the better will be the
commutation.

All of the generators are adjusted at the factory and


normally do not require additional adjustment.

(5) Inspect the surface of the commutator and wipe off


any blackening. Ifit is rough or eccen tric, causing the
brushes to chatter or move in the holder, it should be
ground or stoned or perhaps turned (see Commutator
Turning, Stoning and Sanding). Chamfer the edges
of the segments and remove all mica fins adher-ing to
the sides of the commutator segments. Very careful
inspection is required to detect the high side mica
fins.

Any problem that develops due to machine adjustment


should be recognized as soon as possible after start up, so
it can be corrected during the warranty period.
Slot bar etching will normally be the first sign of a poorly
adjusted machine (see the Commutator Check Chart on
Page 25). This should not be confused with slot bar marking, which is a normal characteristic especially during the
early stages of commutator film development. A pencil
eraser may be used to erase a marked bar. If the copper is
smooth under the erased area, there is no etching.

(6) Check clearance between the brushholders and the


commutator surface. This clearance should be .070
to .080 inch (1.8-2.0 mm).

Once a DC machine is correctly adjusted, it will not get out


of adjustment unless something becomes loose or fails
within the machine. Loosening of pole bolts or electrical
connection screws are the most likely cause of poor adjustment. The tightness of these bolts should be checked
periodically.

If trouble is experienced in finding electrical neutral or if


machine adjustment is questionable, please contact the
local General Electric representative.

Split Output Generator Adjustments


This type of generator is normally used on loader shovels
to supply the power for two separate swing motors.

Ifafield coil fails and must be replaced, it is important that


the shims be placed exactly as they were removed. Never
intermix nonmagentic and magnetic shims.

In order to obtain two separate outputs from a single


generator, the armature is wound without equalizers.
Because of this special winding, it is necessary to balance
the voltage between like polarity brush studs. This is done
externally to the armature to allow the generator to commutate properly.

If an armature is replaced in a machine, set the brush yoke


back on the factory mark. If commutation is poor after the
brushes have been seated and run in for a few hours, it may
be necessary to shift the yoke slightly. Shift the brush yoke
no more than .13 inch (3.2 mm) and observe commutation
only after the machine has operated for at least 5 minutes
under normal loading so the brushes will be reseated.

After any disassembly or major realignment of such a


generator, it is necessary to check the voltage between like
polarity brush studs and between the two output circuits.

If commutation is better, shift slightly each way from this


point waiting until the machine has operated under load
at least 5 minutes each time to find optimum commutation.

Excite the generator open circuit, between 350 and 450


volts, to take the measurements.
The voltage difference between like polarity brush studs
should not exceed 5 volts.

If commutation was worse after the original change, shift


to the other side of the factory mark by no more than .13
inch (3.2 mm) and repeat the process.

The voltage difference between the two output circuits


should not exceed 3 volts. Any adjustment required to
bring the generator into the above limits is quite complicated. It requires changes in the main pole air gaps.
Because of the compleXity of the adjustments, it is recommended they be performed by a qualified General Electric
Service Engineer.

The electrical kick and AC method of finding neutral, as


described in some literature, will not find the correct
neutral on many of the excavator generators. Shading coils
and pole face teeth affect these types of neutral settings.
The following checks should be made if commutation
problems develop and especially after any major repair or
replacement of parts:

24

GEA

BI006008

SATISFACTORY COMMUTATOR SURFACES

PITCH BAR-MARKING produces low or burned spots

HEAVY SLOT BAR-MARKING con involve

on the commutator surface. The number of these mark-

etching of trailing edge of commutator bar. Pattern is related to number of conductors per slot.

ings equals half or all the number of poles on the motor.

How to Get the Most Value from This Chart

OF POOR COMMUTATOR CONDITION

Streaking

Frequent v

vat inspection of commutator sur-

faces can
conditions

orn you when any of the above


ra developing so that you can toke

He<tr;,,,1

El&c!,;,ol

Adjust",,,nl

Ov....." ..d

Arma'"'.
Conn"dien

early corrective aclion. The chart below may indicate some possible causes of these conditions,
suggesting the proper productive maintenance.

Unbalanced
Shunt Fi"ld

llru.hPreu,.
(light)

Al>ra.;..
B,ulh

Po v.
a..on

The purpose of the Commutator Check Chart is to help you spot undesirable commutator conditions os they develop so you con toke
corrective action before the condition becomes serious. This chort will
also serve as an aid in recognizing sotisfactory surfaces.
Abrasivo

Du.!

The bOJ( chart at the left indicates the importance of selecting the
correct brush and having the right operating conditions for optimum
brush life and commutator wear. General Electric offers a complete
line of carbon brushes designed to meet all operating conditions and
requirements of integral horsepower machines.

Cappe,D,"Il

For additional information or help with carbon brush application


or commutation problems, contact your nearest General Electric
Sales Office or Distributor.

1-85 (5MI

BI006008

BI006008

Direct-current Generators GEI-99854J

R MAINTENANCE

The rotating stone requires an elaborate set-up but, as with


all turning devices, the stone must not chatter or vibrate.
If a rotating stone is used, avoid multiples of synchronous
speeds between the stone and the commutator rotation.
A hand stone can be used by a competent person, but
should be avoided by the novice, since an improperly
supported stone can quickly roughen a surface and increase
the eccentricity. A hand stone should be useli only to keep
the equipment operating until a shut-down is possible,
and should not be used on extremely rough surfaces at all
(see Table V) .

Commutators with sli ht grooving or threading are often


turned or ground be ause of nothing more than a displeasing appearance. ommutators can get a black color
when operating in var ous atmospheres and with certain
types ofbrushes. Doin nothing may be the best procedure
in these cases. Wipin with untreated canvas removes
some of the high-resis ance or high-friction areas of film.
The frequent use of cl an, untreated canvas on a commutator can help greatlyi developing and keeping a uniform
film. This helps to r duce the arcing caused by highresistance areas.

The refinished surface must be smooth and concentric


with the center of rotation.
The commutator must be carefully cleaned after resurfacing. Segment insulation mica should be undercut, if
necessary, and the slots between segments thoroughly
cleaned out. Segment bars should be scarfed. Keep copper
chips out of the rest of the machine to avoid shorting and
grounding. Final clean-up can be done by "air-curing" the
commutator (see Commutator Clean-up By Air-cure
Method, Page 29).

In most cases, there is little doubt when it is necessary to


grind or turn a roug commutator. Danger signs are:
rough surface, noise, s arking, rapid brush wear, and even
load or speed fluctua ions. Turning or grinding can be
done in the machine y rigging a commutator surfacing
fixture to a suitable support. On a split bracket type
machine, removing t e top half of the bracket exposes a
suitable flat surface. n pedestal machines, a mounting
must be provided.

TABLE V
RECOMMENDED COMMUTATOR ACTION

If circumstances permi , it is usually preferable to remove


the armature and resur ace a commutator in a lathe, rather
than attempt resurfaci in the machine.
Chips can be drawn i to the armature when it is rotating
due to the fan action f the commutator risers, windings,
or armature fan. If res rfacing is done, arrange to tape up
or otherwise protect e commutator risers and commutator-end armature ndings.

SOME COMMUTATOR/
BRUSH CONDITIONS

POSSIBLE
ACTION

Fit Brushes

Sand Paper, Brush Seater

Threading

Fixed or Hand Stone

Grooving

Fixed or Hand Stone

Roughness

Tool, Fixed or Hand Stone

Slot Bar Marking

Brush Seater

Etching

Fixed or Hand Stone

Commutator Film Care


The color of a commutator film is not important as long as
brush life and commutator maintenance is satisfactory.
A proper commutator film is made up ofcopper oxide and
some products of the brush and its treatment, and is
lubricated by the moisture in the air. The copper oxide
film and the moisture for lubrication are both essential for
good commutation and for long brush life.
The lackofmoisture in air blowing on the commutator will
cause high friction losses ofthe brushes. This can cause the
film to be stripped away.

Whether you use a st ne or tool should be governed by


commu tator condit" on (see Suggested Maintenance
Schedule, Page 18). he commutator can be resurfaced
more accurately with a tool than with a stone. Mter the
surface is concentric it is then smoothed with medium
and fine-grain stones

The presence ofoil fumes or drops ofoil on the commutator


acts as follows: Oil fumes coat the copper vapor produced
during the process of commutation. The copper vapor
cannot make direct contact with the air. Thus, itcannot be
oxidized into a stable copper oxide commutator film.
Condensed copper (copper particles) and oil are mixed
together producing a mechanically unstable commutator
film.

Where machines hav to be resurfaced at high peripheral


speeds, itis simpler to se the fixed stone or rotating stone.

Lubricating oil used for bearings will not produce enough


fumes to be detrimental to commutation. A drop of
27

BI006008

GEI-99854J Direct-current Generators


lubricating oil falling on a commutator can cause trouble.

(2) When using a wiper, make sure there are no loose


ends of canvas that can catch on rotating parts.

Fumes from high temperature gear and rope lubrican ts or


from cleaning fluids are detrimental to commutation and
cause the following kinds of problems:

(3) High voltage may be present. Do not contact internal


parts of the machine.

(1) Commutator surface streaking.

(4) Do not use a metal fitting on the end of the air hose
beyond any shut-off valve.

(2) Commutator film tearing.

(5) Workmen should wear goggles and rubber insulating


gloves and stand on dry planking.

(3) Copper drag.


(4) Film stripping and, on higher current rated machines,
brush powdering and grooving in a single track.

(6) The person operating the controls should remain at


the controls until all work is complete.

A drop of water or an insect hitting the commutator can


tear or strip the film off a portion of the commutator
almost instantly. Abrasive dust such as taconite will cause
rapid brush wear and mechanical grooving of all tracks.
Corrective action for the above types of problems include:
(1) A cover over the top of the commutator will help
protect it from drops of water and oil, insects, abrasive dust, and dry air blasts from the house fans.

If a single brush track has been stripped of film, it will be


necessary to use seater stone to remove the film from all of
the brush tracks so all brush contact drops will be equal. If
this is not done, the contact drop of the affected path will
be low and will not film correctly. The machine should be
run at no voltage or very low voltage, while seater stone is
applied. Blowout the brush carbon after applying seater
stone.

(2) Experiment with the house ventilation system and


doors to determine the best way to keep heated gear
lubricant fumes from getting on the commutators. It
may be necessary to erect a shield or baffle between
the point of application of the gear lubricant and the
affected commutators.
(3) Check the location ofthe gear lubricant heating pot.
Make sure these fumes are kept away from the commutators.
(4) Use cleaning fluids such as kerosene for cleaning the
floor plates and machinery sparingly and only when
the machinery is shut down and cool. Do not restart
the m-g sets until the fumes have dissipated. Fumes
can be rapidly dissipated with the house ventilation
fans. Never allow any cleaning fluid to contact a
commutator.
(5) Make sure the commutator is smooth and round.
Copper drag and film tearing and stripping is aggravated by vibration of the brushes. Refinish commutator if necessary.
(6) Use a good commutating high temperature brush
grade to minimize the effects of oil or dry air.

FIG. 7 Canvas or ethylene glycol Wiper


In very dry climates, it may be necessary to use ethylene
glycol to establish a commutator film or to stop "brush
singing". (Brush singing is due to increased friction because
of the absence of atmospheric moisture for lubrication,
and is an indication that film stripping is about to begin.)
Ethylene glycol will cause an artificial film to develop and
will act as a lubricant. In most cases, a copper oxide film
will develop before the artificial film wears out. A canvas
wiper barely moistened (not wet) with ethylene glycol may
be used to wipe the commutator periodically.

(7) Make sure the generator does not have excessive


vibration. Realign or balance if necessary.
The following corrective actions following "WARNING"
and "CAUTION" require working on the machine while it
is rotating:

A canvas wiper may be made by securely fastening layers of


untreated canvas to a wooden stick (Fig. 7). Multiple layers
of 6 to 8 ounce duck or canvas are recommended. The
worn or dirty outer layers can be removed and the next
layer exposed.

(1) When using the seater stone, the machine should be


run without voltage to prevent flashover.
28

BI006008

Direct-current Generators
A commutator that has xperienced copper drag must be
cleaned up (see Co mutator Clean-Up By Air-Cure
Method).

GEI-99854J

(5) Continue the air curing until top operating voltage is


reached and all sparks disappear.

If you are in doubt as 0 the problem or the corrective


action necessary, pleas contact your local General Electric representative.

HYDRAULICALLY REMOVABLE
KEYLESS COUPLINGS
Assembly
This type of coupling is heated uniformly in an oil bath or
controlled oven (uneven heating with any kind oftorch is
NOT recommended) to a temperature of 200C (392F),
and shrunk onto a cylindrical shaft extension with no key
or keyway. The amount of interference fit is sufficient to
give an adequate driving torque with adequate safety
factor, without the use of a key.

Commutator Clean-Up By Air-Cure Method


After a commutator has been stoned or turned, or as a final
clean up after a flasho er or severe short circuit, air-cure
the commutator by blo ing out the slots with the armature
rotating and voltage a plied to the commutator (so that
there is voltage betwee bars). The extra oxygen supplied
by the air burns up sl vers of copper and carbon. This
clean-up method prev nts flashovers that are sometimes
caused by dirty comm tators.

When reinstalling a coupling half that has been removed,


it should be located in the original axial and angular
position. In general, the axial position is such that the end
of the hub is flush with the end of the shaft. The pressure
hole in the shaft should be spaced as far as possible from
the pull-off holes. The face, rabbet diameter, and OD of
the solid coupling halves must run true with the rotor
bearingjournals. These fits should be trued in a lathe with
the rotor accurately aligned such that the journal runout
is less than .001 inch (.03 mm). Refer to Tables VI, VII,
VIII and IX for the finished rabbet diameter. Used coupling halves frequently require careful peaning before
machining to bring the rabbet diameter to the correct size.
Checking and truing operations must be performed with
the shaft accurately aligned in a lathe.
Removal - Hydraulic
A typical cutaway section of the hydraulically removable
keyless coupling ready for removal is shown in Fig. 8. The
procedure for removing the coupling is as follows:

Procedure
i
(1) Set up the contrr so that variable voltage may be
applied to the br shes and the machine rotated at
will.

(1) Position the armature so that the oil hole in the end
of the shaft is on top. The adjacent two coupling
pulling holes are to be horizontal.

(2) Running at rated speed and about 10 percent top


operating volts an using a 1/2 inch hose, direct ajet
of dry, compress d air, 30 psi maximum (210kPa)
against the com utator surface. Hold the hose between one and tw inches (25 and 51 mm) from the
commutator sur ce and sweep it back and forth
longitudinally, in the direction of the mica.

(2) Assemble the high pressure nipple, the elbow, and


the high pressure tubing. The nipple must be long
enough so that the coupling hub can be pulled clear
of the shaft extension without interfering with the
tubing or elbow.

(3) Increase the volt ge in steps of about 10 percent.

(3) Assemble the hydraulicjack pump, Enerpac Model P228 or equivalent and a pressure gage to the high
pressure tubing. The pump should develop a maximum of 40,000 psi (280MPa). The tubing is rigid and
requires that the pump be properly located at the
height of the armature shaft and perpendicular to it.
The pump should be supported solidly so it remains
in place when it is operated.

(4) If the sparks can ot be blown out, shut down, clean


out the commuta or slots with a scraper or engraving
tool to remove t e dirt, copperwhiskers, etc. Then
restart and proce d as before.

(4) Pump up the high pressure pump to approximately

29

BI006008

GEI-99854J Direct-current Generators


15,000 psi (lOOMPa) oil pressure to expand the
coupling. The pressure should be reapplied several
times during the next operation of assembly and
alignment of the coupling puller. If, each time pressure is rebuilt, the handle is left in the top position of
the pumping stroke, then the reduction of pressure
in the system is shown by the falling of the handle.
When the handle falls, oil pressure should be rebuilt.

HIGH PRESSURE
PUMP
HIGH PRESSURE
TUBING

ELBOW

(6) Itis necessary to have equal force on both sides of the


coupling. Thejack mounting must be repositioned as
necessary so that the pulling force is even. It is
necessary to measure the distance from the coupling
face to the puller surface. This distance should differ
by less than .016 inch (.4 mm) on the two sides
throughout the pulling process. If required, the distances should be re-measured and appropriate adjustment made.
(7) Oil pressure on the coupling is maintained so that the
oil can penetrate under the coupling. The oil pressure
should result in slight leakage at the back of the
coupling indicating penetration of the oil. Oil leakage at the coupling face should be minimum. If
leakage is excessive, the oil pressure will not build to
the approximately 15,000 psi (l00 MPa) required for
removal. The leakage may be reduced by peaning the
coupling face adjacent to the leak to permit building
up pressure.

COUPLING

NIPPLE
RIGID COUPLING

(8) The proper setup makes the pulling operation relatively simple. The oil pressure from the hydraulic
pump must be maintained to expand the coupling.
The pressure on the pull-off jack is now increased.
The coupling should be floated off, not forced off. To
accomplish this, hold minimum pressure on the pulloffjack while expanding the coupling.

FIG. 8 Cutaway section of a hydraulically removable


coupling with pump assembled
COUPL I NG
FLANGE

HYffiAUL I C
JACK

(9) In some cases, the coupling does not move when the
pulling force is applied. Maintain the oil pressure to
the coupling and the force on the pullingjack. Then
strike the coupling with several sharp blows of a rawhide mallet. When applied with the coupling expanded by oil pressure and with the pulling force on
the coupling, often the blows will release the coupling
and permit its removal.

SHAFT

SPACER

BAA

PlJo1P

(10) In especially stubborn cases, it may be necessary to


torch heat the flange of the coupling, in addition to
the oil pressure under the coupling and the jacking
force (refer to Removal- Alternate Method).

FIG. 9 Hydraulically removable coupling with pump,


pUll-studs and hydraulic jack assembled
(5) Assemble the pull-off studs and a jack or other suitable pull (see Fig. 9). The pull-off studs are screwed
into the proper holes in the coupling.

(11) The coupling slides offwith relative ease until the oil
groove is exposed and the floating pressure lost. The
remaining.5 inch (13 mm) or so will release, because
the mating surfaces have been lubricated by the
wetting of the coupling bore, as it moves across the
groove in the shaft. The pulling force may not be
adequate to complete this last stage ofremoval. Sharp
blows with a rawhide mallet are often helpful in using
a minimum pull force and reducing damage during
this final step of removal.

Then the hydraulic jack is mounted on the pull-off


studs. A hoist is recommended for holding and leveling the jack. A steel bar with parallel ends must be
positioned between the shaft center and the jack.
During this alignment procedure, maintain light
pressure on the jack to hold the steel bar in position.

30

BI006008

Direct-current Generators GEI-99854J

HYDRAULICALLY REMOVABLE
INSULATED COUPLINGS

Removal - Alternate ethod


Keyless couplings are ounted to the shaft with a heavy
interference fit. Somet mes it is not possible to build up
sufficient hydraulic pre sure to relieve the fit and pull the
coupling, due to hydra lie oil leakage at the fit. In addition, most opposite co mutator-end couplings and keyed
couplings have no pr vision for hydraulic removal. In
these cases, the followi g method may be used:

Assembly
This type of coupling must be heated uniformly in a
controlled oven to a temperature of200C (392F) .Do not
induction heat the coupling. (This causes uneven heating of the coupling.) Mter removing the insulated coupling from the controlled oven, quickly assemble on shaft.
The inner insulated sleeve of the coupling will cool at a
faster rate than the outside of the coupling. The interference fit between the coupling and the sleeve is momentarily lost. During this brief period (approximately
30 seconds), Do not allow the sleeve and coupling to lose
their special relationship to one another. The exterior
face of the coupling and sleeve assembly is to be in the
same plane as the end of the shaft.

(1) Ifthe coupling is a ydraulictype, oil pressure (40,000


psi/280 MPa max' um) should be applied and the
puller assembled s in the Removal-Hydraulic section. Even if there s too much leakage and the coupling cannot be pul ed by the hydraulic method, some
oil will penetrate t e fit and lubricate during pulling.

Removal
This type of coupling consists of removing two joined
parts: a solid coupling and an inner insulated sleeve.
Adequate support (steel-type plate) opposite the flange
end is required during removal. This will support the
insulated sleeve to be removed in conjunction with the
solid portion of the coupling (see Fig. 10).

(2) Using a minimum ftwo acetylene torches with large


flames ("rosebud' or other non-cutting tip) heat
should be applie to the outside diameter of the
coupling body. T flames should be played over the
coupling for even heating.

STEEL PLATE

HIGH PRESSURE
PUMP
HIGH PRESSURE
TUBING

SHAFT

W)"

Ummi PIPE TAP

RIGID COUPLING

The heat will cause the oupling to expand and will relieve
the fit to facilitate pull ng. If the heat is not applied at a
rapid enough rate, the eat will also be conducted into the
shaft so the coupling a d shaft expand together and the fit
is not relieved. If thi happens, the assembly must be
allowed to cool to roo temperature and the procedure
repeated.

INSULATED SLEEVE

FIG. 10
The procedure described in the Removal - Hydraulic
section should be followed. Should some difficulty develop during removal, a slight application of heat can be
played over the outside of the coupling (refer to Removal
- Alternate Method, Step 2). Do not overheat. An excessive amount of overheating will damage the insulated
portion of the coupling.

(3) While the coupli g is being heated, pressure on the


pull-off jack sho ld be increased. When the fit is
relieved sufficien ly, the coupling will break loose.

Coupling Finishing and Recommended Fits


Unless otherwise specified, replacement couplings are
furnished with a finished bore and with .016 inch (.4 mm)
of material on the coupling face and rabbet diameter,
which must be removed after assembly on the shaft.

(4) Once the coupli g begins to move, pulling should


continue and he t be applied until the coupling is
free of the shaft.

To assemble a coupling with a straight bore (both those


with key and keyway and those without), it is necessary to
heat the coupling uniformly in an oil bath or controlled
oven (heating with any kind of torch is not recommended)
to a temperature of 200C (392F). Couplings with keys

(5) In some cases, es ecially if hydraulic oil is not used,


some slight scrat hing of the shaft may occur. This
should be hand olished out before replacing the
coupling.
31

BI006008

GEI-99854J Direct-current Generators


normally have an interference fit which may vary from 0.5
mil to 1.0 mil per inch (.01 mm to .03 mm) of diameter.
Keyless couplings should have an interference fit ofl.O mil
per inch (.03 mm per 25.4 mm) of diameter.

/ ~ (e,,,,
""~~~2

M'>

(.8 MM)

III

The rabbet diameter should be measured and finish


machined according to Tables VI, VII, VIII and IX.
Ifthe measured dimensions is not given in these tables, the
rabbet may be machined to match the mating halfcoupling
using a fit of from line-to-line to 0.001 inch (.025 mm)
interference. Also, see Fig. 11.

,!25(J2MM)
.OJ2 (.8 MM)
COLLECTOR OR
COMMUTATOR END

"A" Dla.

.OJ2~
M'~) I

(.8

Bore

"B"
Dia.

Female

Dia.

"B"

Male

Dla.

Bore Dla.

FIG. 11

TABLE VI
HYDRAULICALLY REMOVABLE COUPLING -

MALE HALF FINISHING AND RECOMMENDED FITS

DIMENSIONS IN INCHES AND MILLIMETERS


"B" Dia. Rabbet Fil "B" Dia. Rabbet Fil
Inches

Drawing
No..
36B465278AA004
36B465278AA005
36B465119AA002
36B465278AA006
36B465119AA003
36B465278AA007
36B465119AA004
36B465278AA009
36B465278AA010
36B465278AA012
36B465278AA013
36B465278AA014
36B465346AA005
36B465346AA008
36B465347AA004
36B465348AA003
....36B465119BB001
36B465348AA004
....36B465119BB002
36B465348AA005
....36B465119BB003
36B465348AA006

....36B469511AA001.

"A"
"A"
Dia.
Dia.
Cplg. Cplg.
O.D.
aD
Inches mm

Shaft
Dia.
Inches
+0.0005
-D.0005

Shaft
Dia.
mm
+0.013
-D.013

Cplg.
Bore
Inches
+0.0005
-D.0005

Cplg.
Bore
mm
+0.013
-D.013

11 3/4

368
368
368
368
368
368
368
368
368
368
368
368
225
225
257
298
298
298
298
298
298
298

6.3570
6.7500
6.7500
6.7500
67500
5.3750
5.3750
5.7500
4.8750
4.1880
7.5000
4.5000
4.5000
4.1880
4.1880
4.5000
4.5000
5.3750
53750
6.7500
6.7500
4.1880

161.925
171.450
171.450
171.450
171.450
136.525
136.525
146.050
123.825
106375
190.500
114.300
114.300
106.375
106.375
114.300
114.300
136.525
136.525
171.450
171.450
106.375

63681
67427
6.7427
6.7427
6.7427
5.3691
5.3691
5.7437
4.8696
4.1833
7.4920
4.4950
4.4950
4.1833
4.1833
4.4950
4.4950
5.3691
5.3691
67427
6.7427
4.1833

161.749
171.264
171.264
171.264
171.264
136375
136375
145.889
123.687
106.255
190296
114.173
114.173
106.255
106255
114.173
114.173
136.375
136.375
171.264
171.264
106.255

9.781
9.781
9781
9781
9.781
9.781
9.781
9.781
9.781
9.781
9.781
9.781
5781
5.781
7.031
8.656
8.656
8.656
8.656
8.656
8.656
8.656

14'/2

368

67500

171.450

6.7409

171.219

9.781

14 1/2
14'/2
14'/2
14'/2
14'/2
141/2

14'/2
14'/2
141/2
14'/2
14'/2
14'/2
87/8

87/8
10'/8

11'14
11'14
11

/4

11'/4

11'14
11

3
/4

Before
After
Asm
Asm
+0.001 +0.0005
-D001 -DOOOO

mm
Before
Asm
+0.025
-D.025

After
Asm
+0.013
-D.OOO

9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
9.7500
5.7500
5.7500
7.0000
8.6250
8.6250
8.6250
8.6250
8.6250
8.6250
8.6250

248.437
248.437
248.437
248.437
248.437
248.437
248.437
248.437
248.437
248.437
248.437
248.437
146.837
146.837
175.587
219.862
219.862
219.862
219.862
219.862
219.862
219.862

247.650
247.650
247.650
247.650
247.650
247.650
247.650
247.650
247.650
247.650
247.650
247.650
146.050
146050
177.800
219.075
219.075
219.075
219.075
219.075
219.075
219.075

9.7500

248.437 247.650

Lenglh
of
Hub
Inches

63/4

Length
of
Coupling
Hub
Bolls
mm UNC-2A

4 1/4

108
108
108

1-8 x 3'/4
1-8 x 3'/4
1-8 X 3'/4
1-8 x 3'/4
1-8 x 3'/4
1-8 x 3'/4
1 ~8 x 3'/4
1-8 X 3'/4
1-8 x 3'/4
1-8 x 3'/4
1-8 x 3'/4
1-8 x 3'/4
3/4~1 0 x 2'/2
3/4 -10 x 2'/2
'/4-10 x 2'/2
'/4-10 x 2'/2
'/4-10 x 2'/2
'/4-10 x 2'/2
'14-10 x 2'/2
'/4-10x2'/2
'/4-10 x 2'/2
'/4-10 x 2'/2

6'/4

159

1-8 x 3'/4

6'/4
6'/4
4'/4
4'/4
4'/4
4'/4

53/4
43/4
4'/4
4'/4
4'/4

4'/4
4 1/4
4'/4

33/4
33/4
4'/4
4'/4
4'/4
4'/4

171
159
159
108
108
108
108
146
120
108
190
108
108
108
108
95
95
108

108

No. of
Bolls
Req'd

Application'"

8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8

TS990 Molar
CDS8000 (Slv. Brg.) & MCF800
CDS8000 (Slv. Brg.) & MCF800
CDS7000 (Slv. Brg.) & MCF700
CDS7000 (Slv. Brg.) & MCF700
CDS6000 (Slv. Brg.)
CDS6000 (Slv. Brg.)
TS980 Motor
TS970 Molar
K8200 Motor
TS9279
CDS6000 (Bail Brg.)
CDS6000 (Ball Brg.)
K8200 Motor
K8200 Motor
CDS5000 (Slv. Brg.) MPC500 &
CDS6000 (Ball Brg.)
CDS5000 (Slv. Brg.) MPC500 &
CDS6000 (Bail Brg.)
CDS6000 (Slv. Brg.}""
CDS6000 (Slv. Brg.)""
CDS7000, MCF700, CDS8000,
K8200 Molar

MCF900 (Slv. Brg.)

'Machines coupled to CDS320 & CDS400 should have 2 inch (50 mm) long bolts.
"And MPC 600
'''Couplings are stamped with a number consisting of a portion of the drawing number (i.e. 278AA4 for drawing number 36B465278AA004)
....1984 coupling bores & shaft 0.0. with dimensions over 4 inches had a tolerance change requiring these new coupling drawings for MPC500-600 & MCF700-800
....1.2 mils/inch of shaft diameter interterence fit.

32

BI006008

Direct-current Generators GEI-99854J

TABLE VII
SOLID DF IVE END COUPLING - FEMALE HALF FINISHING AND RECOMMENDED FITS
DIMENSIONS IN INCHES AND MILLIMETERS
"B" Dia. Rabbet Fit "B" Dia. Rabbet Fit
Inches
mm
"A"
[ ia.
Dia.
C Ig.
Cplg
CD.
O.D.
Inches
m

Drawing
No:"
36B465278AA011
36B465346AA002
36B465346AA003
36B465346AA004
36B465346AA007
36B465347AA002
36B465347AA003
36B465348AA002

14\/2
87/6
87/8
8 7/8
87/8
10'/8
10'/8
11'1,

68
25
25
25
25
57
57
98

Shaft
Dia.
Inches
+0.0000
-0.0005

Shaft
Dia.
mm
+0.000
-0.013

Cplg.
Bore
Inches
+0.0005
-0.0000

Cplg.
Bore
mm
+0.013
-0.000

3.8750
2.8750
3.2500
38750
2.6250
3.2500
3.7500
3.8750

98.425
73025
82.550
98.425
66.675
82.550
92250
98.425

3.8706
2.8716
32463
38706
2.6219
3.2463
37457
3.8706

98.313
72.938
82.456
98313
66.596
82.456
95.140
98.313

Before
After
Asm
Asm
+0.001 +0.0005
-0.001 -0.0000
9.781
5781
5.781
5.781
5.781
7.031
7.031
8656

9.7500
5.7500
5.7500
5.7500
5.7500
7.0000
7.0000
86250

Before
Asm
+0.025
-0.025

After
Asm
+0.013
-0.000

Length
of
Hub
Inches

248.437
146.837
146.837
146.837
146.837
178.587
178587
219.862

247.650
146.050
146.050
146.050
146.050
177.800
177.800
219.075

4'/4
3
3

3 3/4
2 3/4

3 3/4
3 3/4

Length
Coupling
of
Hub
Bolts
mm UNC-2A
108
76
76
95
70
76
95
95

<;8-1 x 3'/4
3/4 -10 x
2'/2*
3/4 -10

x 2'12

3/4 -10

x 2'12

x 2'12
x 2'/2
3/4 -10 x 2'12
3/4~10 x 2'/2

3/4 -10
3/4 -10

No. of
Bolts
Req'd
8
6
6
6
6
6
6
8

Application'"
TS970 Motor
CDS580 (Ball Brg)
CDS680 (Ball Brg.)
CDS5000 (Ball Brg.)
CDS500 (Ball Brg.)
CDS680 (Ball Brg.)
K6340 Motor
CDS5000 (Ball Brg)

Table VII has prior to 1984 coupling bores & shaft O.D. tolerances for dimensions under 4 inches.

TABLE VIII
SOLID DI ~IVE END COUPLING -

FEMALE HALF FINISHING AND RECOMMENDED FITS

DIMENSIONS IN INCHES AND MILLIMETERS


"B" Dia. Rabbet Fit "B" Dia. Rabbet Fit
Inches

Drawing
No:"
36B465278AA001
....36B465119BA001
36B465278AA002
....36B465119BA002
36B465278AA003
....36B465119BA003
36B465347AA001
36B465348AA001
....36B465119BC001
36B469510AA001

"A"

A"

Dia.

ia.

Cplg. Cpig.
o.D.
.D.
Inches
nm

Shaft
Dia.
Inches
+0.0005
-0.0005

Shaft
Dia.
mm
+0.013
-0.013

Cplg.
Bore
Inches
+0.0005
-0.0005

Cplg.
Bore
mm
+0.013
-0.013

68
68
68
68
68
68
57
98
98
68

7.7500
7.7500
6.7500
6.7500
5.3750
5.3750
4.0000
5.0000
50000
82500

196850
196.850
171.450
171.450
136.525
136.525
101600
127.000
127.000
209.550

7.7417
7.7417
6.7427
6.7427
5.3691
5.3691
3.9955
4.9945
4.9545
8.2407

196.639
196.639
171.264
171264
136.375
136.375
101.485
126860
126.860
209.314

14'/2
14'/2
14'/2
14'/2
14'/2
14'/2
10'/8
113/4
11 3/4

141/2

Before
After
Asm
Asm
+0.001 +0.0000
-0.001 -0.0005
9.719
9.719
9.719
9.719
9.719
9.719
6969
8.594
8.594
9.719

97500
9.7500
97500
9.7500
9.7500
9.7500
7.0000
86250
8.6250
9.7500

mm
Before
Asm
+0.025
-0.025

After
Asm
+0.000
-0.013

246.863
246.863
246863
246.863
246.863
246.863
177.013
218.288
218.288
246.863

247.650
247.650
247.650
247650
247.650
247.650
177.800
219.075
219.075
247.650

Length
of
Hub
Inches
5'/4

5'/4
4'/4
4'/4
4 1/4
4'/4

2 3/4
3'/2

3'/2

53/4

Length
of
Coupling
Bolts
Hub
mm UNC-2A
133
133
108
108
108
108
70
89
89
146

1-8 x 3'/4
1-8 x 3'/4
1-8 x 3'/4
1-8 x 3'/,
1-8 x 3'/,
1-8 x 3'/4
3/4 -10 x 2'12
3/4 -10 x 2'/2
3/4 -10 x 2'12
1-8 x 3'/,

No. of
Bolts
Req'd
8
8
8
8
8
8
6
8
8
8

Application'"
CDS8000 (Slv. Brg.) &
CDS8000 (Slv Brg) &
CDS7000 (Slv. Brg.) &
CDS7000 (Slv. Brg) &
CDS6000 (Slv. Brg.)"
CDS6000 (Slv. Brg.)"
CDS680 (Ball Brg.)
CDS5000 (Slv. Brg.) &
CDS5000 (Slv. Brg.) &
MCF900 (Slv Brg.)

MCF800
MCF800
MCF700
MCF700

MPC500
MPC500

" And MPC 600


~
"'Couplings are stamped with a n mber consisting of a portionn of the drawing number (i.e. 278AA1 for drawing number 36B465278AA001)
....1984 coupling bores & shaft O. . with dimensions over 4 inches had a tolerance change requiring these new coupling drawings for MPC500-600, MCF700-800.
I

TABLE IX
"B" Dia. Rabbet Fit "B" Dia. Rabbet Fit
Inches

Drawing
No:"

"A"
Dia.
Cplg.
aD.
Inches

"A"
Jia.
pig.
J.D.
~m

Shaft
Dia.
Inches
+0.0000
-0.0005

Shaft
Dia.
mm
+0.010
-0.013

Cplg.
Bore
Inches
+0.0005
-0.0000

Cplg
Bore
mm
+0.013
-0.000

36B465346AA001
36B465346A006
36B465346AB001
36B465346AB002

87/8
87/6
87/8
87/8

~25
~25

37500
35000
2.2500
3.0000

95250
88.900
57.150
76.200

3.7457
3.4960
2.2473
2.9965

95.140
88.798
57.081
76.111

~25

225

Before
After
Asm
Asm
+0.001 +0.0000
-0.001 -0.0005
5.719
5.719
5.719
5.719

5.7500
5.7500
5.7500
5.7500

Table IX has prior to 1984 coupling bores & shaft 0.0. tolerances for dimensions under 4 inches.

33

mm
Before
Asm
+0.025
-0.025

After
Asm
+0.000
-0013

Length
of
Hub
Inches

145.263
145263
145.263
145.263

146.050
146.050
146.050
146.050

23/4
2 3/4

2'/4
2'/4

Length
Coupling
of
Hub
Bolts
mm UNC-2A
70
70
57
57

3/4-10 X 2'/2
1
3/4 -10 x 2 12
3/4 -10 x 2
3/4-10 x 2

No. of
Bolts
Req'd
6
6
6
6

Application'"
CDS580
CDS500
CDS320
CDS400

(Ball
(Ball
(Ball
(Ball

Brg)
Brg)
Brg.)
Brg.)

.p..

1/8

1200RPM
1200RPM
1200RPM

1000RPM
1000RPM
1000RPM
1000RPM
1000RPM
1000RPM
1000RPM
1000RPM
1000RPM
1000RPM

161/161KW
161/161KW
161/161KW
235KW
235KW
235KW
297KW
297KW
297KW
397KW
397KW
397KW
397KW
397KW
397KW

161/161KW
161/161KW
161/161KW
235KW
235KW
235KW

157/157KW
641KW
641KW
641KW

MPC646D
OR
CDS6583

MPC644D
OR
CDS6513

MPC664C
OR
CDS6402

MPC664D
OR
CDS6452

MPC664E
MPC664E
MPC664E

CDS6663
CDS6663
CDS6663

MPC644E
OR
CDS6583

MPC644E

MCF766D
OR
CDS7582

1000RPM
1000RPM
1000RPM

1200RPM
1200RPM
1200RPM

1200RPM
1200RPM
1200RPM

1200RPM
1200RPM
1200RPM

1200RPM
1200RPM

204KW
204KW

MPC544C
OR CDS5423

204KW
204KW

1000RPM
1000RPM

I COMM

Rating (475V)

SHAFT

MPC44D
OR CDS5453

Frame

ICPLGI

BRG
SHLDR

~ B~

II

36A160411AA
36A160411AA
36A160411AA

36A163378BB

36A163378BA
36A163378BA
36A163378BA

36A 163378AA
36A163378AA
36A163378AA

36A162933AA
36A162933AA
36A162933AA

36A162123AA
36A162123AA
36A161123AA

36A161467AA
36A161467AA
36A161467AA

36A 160429BA
36A160429BA
36A160429BA

36A160429AA
36A160429AA
36A160429AA

36A162238AA
36A 162238AA

36A160414AA
36A160414AA

Basic No.

CORE

FIG. A WITH CE COUPLING

36B465119BA002
36B465119BA002
36B465119BA002

36B4651198BA003

36B465119BA003
36B465119BA003
36B465119BA003

36B465119BA003
36B465119BA003
36B4651196A003

36B465119BA003
36B465119BA003
36B465119BA003

36B465119BA003
36B465119BA003
36B465119BA003

36B465119BA003
36B465119BA003
36B465119BA003

36B465119BA003
36B465119BA003
36B465119BA003

36B465119BA003
36B465119BA003
36B465119AA004(600)

36B465119BC001
36B465119BC001

36B465119BC001
36B465119BC001

DE Coupling

SHAFT

36B465119BB003(500)
36B465119AA003(600-700)

36B465119BB002(500)
36B465119AA004(600)

36B465119BB002(500)
36B465119AA004(600)

36B465119BB002(500)
36B465119AA004(600)

36B465119BB002(500)
36B465119AA004(600)

366465 19AA004(600)

36B465~!lBB002(500)

36B465119BB002(500)
36B465119AA004(600)

36B465119B002(500)

36B465119BB001

36B465119BBOO 1

CE Coupling

1984 & AFTER

3/16

G31
G54
G64

G11

G11
G56
G66

Gl1
G56
G66

G11

G11
G56
G66

G11
G56
G66

G11
G56
G66

G11
G56

G11
G56

G11
G56

BRG
SHLDR

B~

+0

13'1,

12'1,

11'/2

B- 1/64

COMM

61'/'

60'12

60'/2

64'1,

58

54

51 1/4

56'/2

60'12

50'1,

52'1,

+1/64
C-{)

62

60'1,

60'1,

64'1,

58'1,

54'1,

51'1,

56'1,

60'1'

50'1'

52'1,

+1/64
D-{)

CORE

FIG. B WITHOUT CE COUPLING

EXCAVATOR ARMATURE MACHINING

3/16

G)

~.

Cil

ti'l
0-

CD

:::J

CD

G)

~
CD

c:::

()

7-

()

tJ

t..

CO
CO

QJ

BI006008

(J'1

1/8

1200RPM
1200RPM

1000RPM
1000RPM
1000RPM
1000RPM
1000RPM

641KW
641KW
641KW
506KW
506KW
506KW
1045KW
1045KW
1045KW
1254KW
1254KW
450KW(500V)
450KW(500V)
450KW(500V)
836KW
836KW
836KW
1045KW
1045KW
1045KW
1254KW
1254KW

MPF766C
OR
CDS7512

MCF764B
MCF764B
MCF764B

MCF868C
OR
CDS8584

MCF968B
MCF968B

MCF864C
OR
MCF8482

MCF866C
OR
CDS8582

MCF868D
MCF868D
MCF868D

MCF968C
MCF968C

36B465119BB003(500)
36B465119AA002(600-800)

36B465119BB003(500)
36B465119AA002(600-800)

36B465119BA001
36B465119BA001
36B465119AA002
36B465119BA001
36B465119BA001
36B465119BA001
36B465119BA001
36B465119BA001
36B465119BA001

36A161327BA
36A161327BA
36A161327BA
36A161327CA
36A161327CA
36A161327CA
36A161 896AA
36A161 896AA
36A161 896AA

1200RPM
1200RPM
1200RPM
1000RPM
1000RPM
1000RPM

36A180023AA
36A180023AA

36B46951 OAAOO 1
36B46951 OAAOO 1

36B469511AA001 (600-900)

36B469510AA001
36B469510AA001

36A180045AA
36A180045AA

36B469511AA001 (600-900)

36B465119BB003(500)
36B465119AA003(600-800)

36B465119BB003(500)
36B465119AA002(600-800)

36A161327AA
36A161327AA
36A161327AA

36B465119BA001
36B465119BA001
36B465119BA001

1200RPM
1200RPM.
1200RPM

36B465119BB003(500)
36B465119AA003(600-700)

36A163705AA
36A163705AA
36A163705AA

36B465119BA002
36B465119BA002
36B465119BA002

36A162117AA
36A162117AA
36A162117AA

36B465119BB003(500)
36B465119AA003(600-700)

36B465119BB003(500)
36B465119AA003(600-700)

36B465119BA002
36B465119BA002
36B465119BA002

"'-.

36A161852AB
36A161852AB
36A161852AB

CE Coupling

BRG

SHLDR

-I

36B465119BB003(500)
36B465119AA003(600-700)

DE Coupling

1984 & AFTER

I'

SHAFT

36B465119BA002
36B465119BA002
36B465119BA002

36A161852AA
36A 161852AA
36A 161852AA

Basic No.

3/16

I'

63

71'/.

71'/.

G31
G54
G64
G01
G03

58'/.

67'/.

67'/.

G31
G54
G64

G01
G03

G31
G54
G64

51'/6

G31
G54
G64-

54'/6

54'/6

+1/64
C--{)

58'/6

15'/6

13'/6

+0
B- 1/ 64

G31
G54
G64

G31
G54
G64

G31
G54
G64

COMM

CORE

FIG. B WITHOUT CE COUPLING

36B465119BA002
36B465119BA002
36B465119BA002

1200RPM
1200RPM
1200RPM

1200RPM
1200RPM
1200RPM

1000RPM
1000RPM
1000RPM

506KW
506KW
506KW

MCF764C
MCF764C
MCF764C

1200RPM
1200RPM
1200RPM

330KW
330KW
330KW

Rating (475V)

COMM

CORE

MCF764C
MCF764C
MCF764C

Frame

SHAFT

SHLDR

BRG

FIG. A WITH CE COUPLING

EXCAVATOR ARMATURE MACHINING

71'16

71'/6

63'/6

58'/6

67'/6

67'/8

51'1.

58'/2

54'/.

54'/.

+1/64
D--{)

-I

3/16

<0

QJ

G)

iil

ii1
0-

:J
CD

G)
CD

.....

:J

(1)

c::

()

()

...

CJ
~.

BI006008

BI006008

GEI-99854J Direct-current Generators

CHECKING ALIGNMENT
OFCOUPUNGS

using a feeler gage, measuring to the nearest 0.001


inch (.03 mm). The maximum variations between
any two readings should not exceed 0.002 inch (.05
mm).

When checking coupling alignment, the base of the motor-generator set should always be bolted securely to the
deck of the excavator in the position in which it will be
expected to operate. It is important to follow the step-bystep procedures and accurately record all readings. When
checking more than one coupling of a motor-generator
set, always start at the coupling neare~t the two-bearing
unit (usually the motor).

(5) Rotate the coupling 90, 180,270 and 360 degrees and
take similar readings. Note that the 360 degree
readings repeat the first set of readings to show the
data is reliable. The maximum variation should not
exceed 0.002 inch (.05 mm) between the four readings taken at each coupling position.
(6) Correct horizontal misalignment by loosening foot
bolts, removing dowel pins, and bumping the pedestal or frame into position. Correct vertical misalignment by shimming under the feet. Check and maintain all internal clearances (such as air gaps, bearing
covers, fan, and baffle clearances) equally around the
circumference. To be adequately centered, the air
gaps between the poles and armature should be
within plus or minus ten percent of the average air
gap. Abuse in shipment and handling may cause
misalignment and even distort dowel pins to the
extent that redoweling may be necessary.

Solidly Coupled Sets


The procedure for solidly coupled sets is as follows:
(1) Loosen all coupling bolts enough to insure that they
are not holding the couplings together.
(2) Tum the set over to minimize sag and bindings in the
couplings.
(3) Start with a coupling next to the two-bearing unit
(usually the motor) or near the middle of a long set.
Two diametrically-opposite bolts should be carefully
adjusted to be loose and yet not allow the coupling
rabbet to disengage. Spread the coupling about 0.005
inch to 0.015 inch (.13 mm to .38 mm) using two
jacking screws or by rapping the flange with a fiber
mallet.

(7) Repeat Steps #2, 3, 4, and 5 for each coupling,


working out away from the two-bearing unit.
(8) Recheck the couplings of sets with more than two
units on either side of the two bearing unit after
completing the previously mentioned checks, because shimming on subsequent units may affect those

(4) Measure the gap between the coupling faces at four


points spaced 90 degrees around the coupling rim

TABLE X
COUPLING ALIGNMENT (REPRESENTATIVE READINGS)
ALL READINGS IN MILS OR THOUSANDS OF AN INCH
Coupling Position

Coupling Position

Feeler
Position

0
Right

0
Top

0
Left

0
Bottom

Feeler
Position

Right
Top
Left
Bottom

12(.30)
12(.30)
13(.33)
13(.33)

14(.35)
13(.33)
14(.35)
13(.33)

13(.33)
14(.35)
13(.33)
14(.35)

14(.35)
14(.35)
15(.38)
15(.38)

Right
Top
Left
Bottom

Coupling in line. Gradually changing readings indicate coupling is


opening slightly with rotation.

0
Right

Right
Top
Left
Bottom

0
Right

0
Top

0
Left

0
Left

0
Bottom

12*(.30*) 14*(.35*) 14*(.35*) 16*(.41 *)


15 (.38) 17 (.43) 17 (.43) 19 (.48)
18*(.46*) 21 *(.53*) 20 (.51) 23*(.58*)
15 (.38) 18 (.46) 17 (.43) 20 (.51)

Coupling out of line sideways. Note that right and left readings'
showconstantdifferenceof6to 7thousandths (.15to .18 mm);topand
bottom readings all right.

Coupling Position
Feeler
Position

0
Top

Coupling Position
Feeler
Position

0
Bottom

14 (.35) 14 (.35) 16 (.41) 17 (.43)


10*(.25*) 10*(.25*) 11*(.28*) 12*(.30*)
15 (.38) 14 (.35) 17 (.43)
17 (.43)
19*(.48*) 19*(.48*) 22*(.56*) 22*(.56*)

Right
Top
Left
Bottom

Coupling out of line vertically. Note that top and bottom readings'
show constant difference of 9 to 10 thousandths (.23 to .25 mm); left
and right readings all right.

0
Right

0
Top

0
Left

0
Bottom

14 (.35) 11 *(.28*) 16*(.41 *) 20*(.51 *)


18*(.46*) 15 (.38) 11*(.28*) 16 (.41)
14 (.35) 19*(.48*) 15 (.38) 12*(.30*)
10*(.25*) 16 (.41) 20*(.51 *) 15 (.38)

Bad coupling face or bent shaft indicated. Notw how tight and loose
spots' travel with rotation of coupling. Necessary to remove both
rotors and true-up coupling faces or replace the rotor with bent shaft.

36

BI006008

Direct-current Generators GEI-99854J


already checked.
the specified lim
sledging. Experi
sledged tight will
to specified value

INSULATION

ter the set has been aligned within


ts, tighten all coupling bolts by
nee shows that coupling bolts
ot loosen, whereas those torqued
do loosen.

Many of the troubles which end a machine's useful life are


failures in the insulation system. Insulation failures are of
two general types: shorts to ground and shorts between the
windings in the armature or fields.
Some failures are the result of mechanical damage to the
insulation system. Chafing caused by vibration or cracks in
varnish films caused by high temperatures or by overspeed
can lead to failures. These failures are accelerated by high
temperatures which cause the insulation to lose most ofits
flexibility and strength.

Table X shows typica readings of a properly aligned


coupling and an exa pIe of each of the three possible
cases of misalignment.
Flexibly Coupled Sets
The procedure for fle ibly coupled sets is as follows:

Failures are also caused by contamination and moisture.


Air-borne contaminants can gradually collect on insulation
surfaces and penetrate cracks. Oily vapors present in many
atmospheres deposit on surfaces and collect other contaminants. Contaminants that are electrical conductors
cause leakage currents to ground or to points of differing
electrical potential. Leakage currents can eventually char
insulation surfaces providing even better paths for greater
leakage current, finally causing failure. Even non-conducting contaminants can become conducting in the
presence of moisture with the same result.

(1) Remove all the c upling bolts and slide the shells
back so that the h b faces are exposed.
(2) Check the coupli g hub spacing in accordance with
the outline dime sions with the units in the mechanical center 0 their end play.
(3) To check parallel misalignment, start with the coupling next to the I rgest unit or near the middle of the
set. Use a straight dge across the top of the two hubs
and measure and cord the gap that appears between
one hub and the traight edge. Rotate the two units
together so that t e previously measured spot on the
hubs is at 90 and easure and record the gap again.
Repeat after rotat' g to 180,270 and 360. The fifth
measurement at 3 0 is a check of the accuracy of the
method and sho s if the data is reliable. The difference in gap mea urements should not exceed .01
inch (.25mm). ( dial indicator clamped to one hub
can also be used 0 measure parallel misalignment.
Both hubs must otate together to cancel out inaccuracies in hub ontour. Dial indicator supports
must be very rigid so that sag or bending will not give
inaccurate readi s.)

Try to eliminate sources of contamination and moisture


for maximum insulation life. Air filters for blowers, air
piped from cleaner locations, shielding from water and oil
leaks or spray, proper use of space heaters during downtime, etc., can all help slow the deterioration of insulation
systems.

(4) A feeler gage and spacer block or dial indicator can


be used to meas re angular misalignment. Rotate
both units toget er 90, 180, 270 and 360, measuring the axial s paration of the hubs at each position. Measure onl at one spot on the hubs as before.
The difference i gap measurements should not
exceed .01 inch ( 25 mm).
(5) Correct the verti
the units and hori
Abuses in shipm
dowels on the bas
be necessary.

Reconnection of Pole Face Assemblies


A red insulating coating is applied over the stator end
turns, coils, poles, and internal surfaces of compensated
wound machines to cover and seal all exposed copper,
thereby retaining high insulation resistance to prevent
nuisance electrical trips. This coating, applied at the
factory over connected assemblies by electrostatic spray so
as to achieve full coverage, also as might be expected,
penetrates portions of the clamped joints.

al alignment by shimming under


ontal alignment by shifting frames.
nt and handling may distort the
to the extent that redoweling may

(6) Repeat Steps # 2, ,and 4 on each coupling, working


out away from th motor or center unit.

Before reconnecting pole face bars or pole face assemblies,


remove all coating from mating surfaces using mechanical
methods. To prevent high resistance joints, the connection surfaces must be clean and free ofcoating and foreign
materials.

(7) Recheck the cou lings on sets with more than two
units on either s de of the two bearing units after
completing the bove checks, because shimming
when checking bsequent units may affect those
already checked. ter the set has been aligned within
the specified limi s, the coupling shells may be bolted
together.

Clean the reconnected parts and adjacent areas (see Field


Service Cleaning (Assembled Machines) Page 39). Apply
two coats of GE A50CD500A red air dry enamel to the
connections and surrounding area, allowing 15 minutes
drying time between coats. The application method pre-

37

BI006008

GEI-99854J Direct-current Generators


ferred is electrostatic, since this method provides uniform
coverage, but conven tional spray including use of aerosol
containers or application by brush is acceptable (see
Table XI for material description.)

10021. A 500 volt megohm meter is best for checking


generator insulation. If trouble is suspected in the armature, it is best to lift the brushes and check the armature to
ground. Use the 500 volt megohm meter first and, if the
insulation reading is good, then recheck with a 1000 volt
megohm meter to insure the integrity of the armature.
Insulation resistance measurements are affected by the
following:
(l) Magnitude of test voltage
(2) Time the test voltage is applied
(3) Temperature
(4) Surface condition (contaminants)
(5) Moisture
When a 1000 volt megger is used, taking readings of one
minute and converting the data to 40C (l04F), the data
will evaluate the other two factors, i.e., the contaminants
and the moisture present.

TABLE XI
POLE FACE COATING MATERIAL

The insulation resistance varies inversely with the winding


temperature. That is, as the temperature decreases, the
insulation resistance increases in accordance with the
following Table:

Known source for GE A50CD500A, packaged bulk:


"Synthite ER-41"
John C. Dolph Co.
P.O. Box 267
Manmouth Junction, NJ 08852

TABLE XII
EFFECT OF TEMPERATURE

Known source for GE A50CD500A, packaged in aerosol


spray containers:
Synthite ER-41
"OMNIPAK" for Lacquer type LA-12
Sherwin-Williams
Local Distributors

ON INSULATION RESISTANCE

Winding
Temperature
Degree C
80

Testing Methods/Visual Inspection


Visual inspection is recommended as the quickest means
of finding insulation system troubles. Visual inspection
may not sound like a test method, but a careful visual
inspection done by a competent person is one of the most
valuable means ofjudging insulation condition.
In addition to collecting contaminants, insulation shrinks,
cracks, and becomes brittle with heat and age. These
changes allow movement of coils, loose filler strips, loose
ties, chafing, and abrasion, all of which can be picked up
by visual inspection.

Multiplying Factor
To obtain Insulation
Resistance At 40C (104F)
18.0

70

8.0

60

4.0

50

2.0

40

1.0

30

.50

20

.26

10

.14

The insulation resistance of a machine is affected by its


design. For machines without pole face connections, the
insulation resistance of the armature circuit corrected to
40C (104F) should measure at least 1.5 megohms or
cleaning is required. Machines with pole face bars have
multiple creepage paths in parallel and will have lower
armature circuit insulation resistance. Such resistance
corrected to 40C (l04F) should measure at least .25
megohms or cleaning is required. The shunt field insulation resistance corrected 40C (104F) should be at least
1.5 megohms or cleaning is required.

Experience and judgment can be gained by careful observation and comparing results of visual inspections
with insulation-resistance measurements. General Electric
Service Shops have personnel who can inspect equipment
and point out potential trouble areas. Their services can
help build experience and judgment for future visual
inspections.
Insulation Resistance Measurements
A method of measuring the insulation resistance is described in Report 43, "Recommended Guide for Testing
Insul~tion Resistance of Rotating Machinery," published
by IEEE, BoxA, Lennox Hill Station, New York, New York,

If the measurements are less than these limits, the machine should be dried or cleaned to attempt to increase
the insulation resistance. Regular, periodic measurements
38

..

BI006008

Direct-current Generators GEI-99854J


without disturbing adjacent areas or redistributing the
contamination. A brush of appropriate size and stiffness
attached to a vacuum nozzle, can be used to loosen and
remove dirt more firmly attached. If dirty surfaces require
brushing or scraping to loosen the dirt, care should be
used to avoid damage to insulated parts.

of insulations resistan e can give a useful indication of the


rate of insulation syst m deterioration. External connections should be rem ved to isolate the windings to be
tested and the megg value logged. A sudden drop or
consistent trend towar low values of insulation resistance
provides evidence that he insulation system is deteriorating
and that failure may
eminent.
High Potential and S
High potential tests a
which have been in us
after installation, the
of the original factory
1000 volts for one mi

ge Tests
e not recommended on machines
. If such a test is made immediately
est voltage should not exceed 85%
est of two times the rated volts, plus
ute.

Surge testing and A


detect shorts should
sonnel. Special test eq
will expose weaknesse
armature shorts.

impedance tests of windings to


e performed only by trained peripment for armature surge testing
in the armature that could resultin

After the initial cleaning with vacuum, high-velocity, clean,


compressed air may be used to remove the remaining dust
and dirt.

Clouds of dust may fill the air during this operation. When
possible, the vacuum cleaner should be used to minimize
the spreading of the dust. Before using compressed air, it
should be checked to be sure it is clean and free from oil
and moisture.
The pressure of the compressed air is critical. It should be
30 psi maximum (210 kPa) to be both effective and safe to
handle. Observe practices normally employed when handling compressed air hoses and equipmen t. The air nozzle
should be designed to be easy to handle and flexible
enough to bend into the vent holes behind the generator
couplings. All covers should be removed from the generator. These should include the drive and cover, commutator end bracket hand hole covers, and the end cover
over the commutator end bearing housing.

Drying of Windings
Drying of machines is most effectively done by the application of heat. The 'ndings and insulation should be
heated so that theirte perature does not exceed 125C at
any location. (Do not ake local hot spots.) The machine's
own frame and the a dition of some covers usually will
make an effective encl sure to contain the heat, if an oven
cannot be used. So e flow of air is desirable to allow
moisture to be carrie away. Methods of generating heat
include: blowing hot air through the machine, heating
with heat lamps, passi g current through the main-fieldcoil windings, etc.

Likely places where dirt will accumulate are:


Behind risers

If temperatures as hi h as 125C can be attained, they


should be limited to ix or eight hours duration. Lower
temperatures will ca se correspondingly longer drying
times.

Axial Vent holes

Drying-out can be en
ground (correct to 40
as described under I
do not reach a prope
complete reconditio

Commutator or Drive End Coil Supports


Inside Commutator Coils

d when the insulation resistance to

Radial Vent Ducts

C) is restored to a satisfactory value

Under the Commutator Shell

ulation Resistance. If these values


level, then a thorough cleaning or
ing may be necessary.

Behind Pole Face Bars and Pole Face Winding


Connections
There is no substitute for common sense in the care of
electrical equipment. A little ingenuity will pay rewarding
dividends in the time required to clean a generator and
the effectiveness of the cleaning program.

Service Shop Cleanin


When the cleaning 0 drying methods described in preceding paragraphs d not result in restoration of acceptable insulation resis ance and or when machines are
extremely dirty or co taminated, it is recommended that
the reconditioning s rvices of a General Electric Service
Shop be obtained. Se 'ce shops are knowledgeable and
equipped on more ophisticated restoration methods,
such as steam and a rasive cleaning, revarnishing, and
rewinding, if necessa

Oily Dirt
The presence of oil makes thorough, effective cleaning of
machines in service virtually impossible, and Service Shop
conditioning is recommended. Oil on a surface forms a
"fly paper", which attracts and holds firmly any entrained
dust. Neither suction nor compressed air is effective.
Consequently, only accessible areas may be cleaned. First,
remove as much of the dirt as possible by scraping or
brushing the dirty surfaces. Then, wipe away as much dirt
as possible with dry rags. For surfaces not readily accessible, a rag on a hooked wire can be used to clean dirt out

Field Service Cleanin (Assembled Machines)


Dry Dusts
Dry dirt, dust, and c rbon should first be vacuumed 39

BI006008

GEI-99854J Direct-current Generators


FREON TF (E.!. DuPont Co.) is the recommended solvent
for wiping clean because it is nonflammable, has good
solvency for grease and oil, is considered safe with most
varnishes and insulation, and has a low order of intoxicity.
Stoddard Solvent (a high flashpoint mineral spirits) has good
solvency, but is flammable and moderately toxic. Before using
any solvent, consult the Material Safety Data S!)eet. Steam
cleaning is not recommended for field service cleaning
because, as with solvents, conducting contaminants may be
carried deep into inaccessible areas resulting in shorts and
grounds.

of holes and crevices. Rags should be changed frequently


for clean ones so that contamination picked up from one
area is not carried to other less dirty areas.
To simplify removal of oily dirt, solvents are often prescribed. However, such solvents should never be applied
in liquid form.

FREON TF is chlorofluorocarbon. Chloroflurocarbons have


been identified as upper atmosphere ozone depletors. The use
of Freon in industry is expected to be greatly reduced in the
future. The availability of Freon may be limited, and its use
could be prohibited by regulations.

LUBRICATION
Ball and Roller Bearing Lubrication
Ball and roller bearings use the oil from the grease at a rate
that is dependent on bearing operating temperature,
operating time and speed, and bearing load. Machines
exposed to high temperatures use up grease (oil) faster.
Machines operating at high speeds use up grease faster
and continuous operation uses grease faster than intermittent operation.

The caution not to use liquid solvents when cleaning a DC


machine applies particularly to commutators. Using solvents to clean any commutator runs the risk of washing
conducting contaminants into the commutator structure
and causing shorts. On a commutator having glass bands,
the commutator bar-to-bar voltage acting on the contaminants can cause currents to flow with subsequent
heating, burning, and possible failure (breaking) of the
glass bands. Burned bands may break under their own
built-in tension at standstill. If a band should break with
the machine at high speed, commutator bars will lift,
causing damage to internal parts, or the commutator may
actually fly apart. Band burning, once begun, cannot be
stopped by cleaning, and the bands will have to be replaced.

Motors and generators are shipped with enough grease to


run for a least six months without relubrication. For most
equipment, GE grease D6A2C5, which is a high quality ball
bearing grease, should be used. It is suitable for excavator
service except in cold weather areas. For the cold weather
areas where temperatures are consistently below OaF (18C) for the winter season, GE grease D6A4, which is a
low temperature ball bearing grease, should be used.

The recommended regreasing period for CDS320-680


frame size generators is 6 months and 3 months for the
40

BI006008

Direct-current Generators GEI-99854J


CDS5000-9000 frame si es.

as the oil delivery to the bearing will not be adequate and


the bearing failure may result.

Be sure grease fittings ar clean. Remove grease-reliefplug


and clean out reliefhole. Pump in new grease wi th a handoperated grease gun, u til the new grease comes out the
relief hole. Then, run t~e machine for a few minutes to
purge excessIve grease Defore replacing the plugs.

TABLE XIV
PEDESTAL OIL REQUIREMENTS

Grease condition on CI S580-9000 frames can be checked


by removing a bearin cap. Remove the bolts in the
bearing cap and slide th cap back along shaft. Remove the
two 1/4 inch screws hiding the metering plate to the
bearing cartridge and I ull the metering plate back. The
grease near the bearing should have some free oil, should
not be much darker in olor or much different inconsistency when compared tp new grease. Dry, crumbly grease
is definitely beyond all' use.

BEARING SIZE CAPACITY

6Y2
6Y2

IN GALLONS

6.3

6Y2

3.9

5Y2 X 5Y2
418 X 418

3.8

4.3

For excavator machines, the recommended oil is either


light or medium turbine oil as shown in Table XV. The ligh
turbine oil is recommended for climates where the ambi
enttemperaturerangesfrom-18C (OF) to 40C (104F)
The medium turbine oil is recommended for climates
where the ambient temperature ranges from OC (32F) to
50 0 e (122F). If the ambient temperature is outside those
listed or ifthere are unusual operating conditions, consul
your General Electric representative for lubrication speci
fication.

Old grease can be clean d out of the bearing and bearing


cap by wiping with a c ean cloth. An oil can filled with
solvent may be used to Oush the bearing, if desired. New
grease can be added b "buttering" the bearing lightly,
replacing the grease mptering plate and then filling the
bearing cap full of new grease.
ABLE XIII
BEA ~ING GREASES

An opening is provided in the pedestal cap for the purpose


of adding oil and for inspection of the oil rings. Oil should
be added only when the shaft is at standstill and the
excavator is level, so that the level in the sight gage
properly shows the immersion of the oil rings in the oil
When the oil level is below the bottom mark on the sight
gage and the machine is run, the inner surface of the oil
ring is not wetted and oil is not delivered to the bearing
When the machine is running, the opening in the pedesta
cap allows viewing of the oil rings to be sure they are
turning freely. The outer surfaces of the oil rings throw off
a lot of oil, even when the level is dangerously low. Thus
observing the oil spray is not indicative that oil is being
supplied to the bearing.

Known Sourc~ s of GE Grease D6A2C5:


A lantic 54 GE
ShE II Alvania No.2
Tex, co Regal AFB-2
Known Sour es of GE Grease D6A4:
(Lo NTemperature)
Humb e Oil Beacon 325
Shell Ae oshell Grease No.7

All pedestals since mid 1976 should be equipped with .25


inch (6.35 mm) thick leather seals to prevent pedestal oil
leaks. If oil leaks should continue after the installation of
the leather seal, the following steps should be taken to stop
the leakage:

Known Sourc~ of GE Grease D6A15A1:


(Synthetic Hydrocarbon Grease
All Temperature)
M bil Grease 28

(1) Remove bearing and inspect the size of the drain slot
in the bottom half ofthe bearing. The effective width
of the drain slot must be at least .25 inch (6.35 mm)

Equivalent nd compatible greases


may also be a\ ailable from other vendors.

(2) Install a new leather seal on the pedestal. Be sure the


leather seal fits tightly between the pedestal and shaft
to insure that the leather seal will rub on the shaft.

Sleeve Bearing Lubric tion


Machines equipped wi h sleeve bearings are shipped from
the factory without oil ip the bearing pedestals. Oil should
be added so that the Ie el is in the center of the two marks
on the sight glass. Wi h the bull's eye type gage, the oil
should be maintained at the center of the gage. Oil level
measurements must ;; lways be taken with the shaft at
standstill and the exc~vator level. To maintain proper
lubrication, it is prefen ed to operate with oil level between
the top mark and the c nter of the two marks. Never allow
the oil level to fall belor,v the bottom mark for any reason,

An optional feature that can be provided for climates


where winter temperatures are constantly below -18C
(OF) is pedestal oil heaters. These heaters are located
below the oil sump. The heaters are controlled so that the
oil sump temperature is always above -18C (OF). The
light turbine oil is recommended for all applications
where the pedestal oil heaters are used.

41

BI006008

GEI-99854J Direct-current Generators


time required to heat the oil depends on the ambient
temperature. At - 40C (-40F), the oil should be heated
for about three hours before starting the m-g set.

TABLE XV
OIL SPECIFICATION CHART
For Normal Excavator
Service and for Cold
Climate Service Light Turbine Oil

For Warm Climate


Service-Medium
Turbine Oil

D6B6A

D6B6B

GE Spec.

In starting an motor-generator set during cold weather,


the sleeve bearings can wipe due to lack of lubrication.
During a shut down, all the oil drains from the bearing
leaving metal-to-metal contact. The start up of the m-g set
will not damage the bearings, if the relubrication is established under the following conditions:
(1)

*Ambient Temp.
Range For
-18C to 40C
Safe Operation (OF to 104F)
Flash Point, Min.

(2) Have the proper oil level.


(3) Have the oil temperature above the minimum recommended ambient temperature in Table XV. In cold
climates, the pedestal oil heaters are recommended.

350F

330F

Viscosity, Saybolt
Seconds
140-170 at 100F
Pour Point, Max.

OC to 50C
(32F to 122F)

270-325 at 100F

20F

Use the proper type of oil. For cold climate service,


this is light turbine oil.

(4) Start the motor -generator set.

25F

*The use of pedestal oil heaters is recommended, if the


winter temperatures are consistently below -20C (-4F).

Lubrication of Flexible Couplings


Flexible couplings are normally lubricated with a semifluid grease or oil. The coupling manufacturers' instructions should be followed in choosing a lubricant and
settingrelubrication intervals. General Electric ball-bearing
grease D6A2C5 is a suitable lubricant for flexible couplings
in most applications. For cold weather areas where temperatures are consistently below OaF (-18C) for the winter
season, GE grease D6A4, which is a low temperature ball
bearing grease, should be used.

Known sources of GE material 06B6A:


Amoco Nonpareil Medium
Atlantic Ideal S150
Chevron OC Turbine Oil 32
Citgo Pacemaker T-32
Gulfcrest 32
Mobil DTE No. 797

Flexible couplings, which join a small machine to a large


one may, have two different size coupling halves joined by
an adapter plate. Couplings of this type have a separate
lubricant supply for each half, so that both halves must be
lubricated separately.

Shell Turbo Oil 32


Sunvis 916
Texaco Regal (R & 0) 32
Known Sources of GE material 06B6B:
Atlantic Ideal S315
Chevron OC Tubrine Oil 68
Citgo Pacemaker T-68
Gulf Harmony 68
Mobil DTE Heavy Medium
Shell Turbo Oil 68
Sunvis 931
Texaco Regal (R & 0) 68

During cold weather when the machine has been idle, the
oil in the sump cools and is viscous. The colder the oil, the
more viscous or resistant to flow it becomes. On start up
under these conditions, the oil may not flow to wet the
inner surface of the oil ring, especially if the oil level is
below the bottom mark. This can cause lack oflubrication
of the bearing, resulting in a bearing failure.
If the power to the excavator has been off, the sump oil
temperature may fall below -18C (OF). When power is
restored, the pedestal heaters should be energized and
the oil should be heated so that its temperature is above18C (OF) before starting the motor-generator set. The
42

BI006008

Direct-current Generators GEI-99854J

TABLE XVII
VIBRATION

ABLE XVI
METRIC CC NVERSION FACTORS
To Convert From:

To:

pounds

kilograms

inches

millimeters

cubic inches
ounces
pound-feet

28.35

kilo pascal

degree F

degrees C

1200

150CY

1800

Displacement 90

80

60

50 microns

3.6

3.0

2.4

2.0 mils

(4.8)

(4.8)

(4.8)

.19

.19

.19

.19 in/sec

16.387

n 3wton meters

pounds per
square inch

1000

25.4

grams
kilograms

RPM

0.4536

cu ic centimeters

tons

NEW EQUIPMENT

MUltiply By:

Velocity

1.356

(4.8) mm/sec

907.2

OLD EQUIPMENT

6.89
deg. C

= deg. F-32

Displacement 120

100

80

70 microns

4.8

4.0

3.2

2.6 mils

(6.4)

(6.4)

(6.4)

.25

.25

.25

1.8
Velocity

(6.4) mm/sec
.25 in/sec

MAINTENANCE REQUIRED

NOISE AlN'D VIBRATION


The vibration of the m g set should be measured at each
bearing on either the pearing cartridge for anti-friction
bearings or the pedesta for sleeve bearings. The vibration
data should be taken ,,~th all the generators running no
load and should inclukie horizontal, vertical, and axial
readings. The guidel'lnes that are recommended for
evaluation of allowable ~bration on excavator m-g sets are
listed in Table XVII.

Displacement 240

200

160

130 microns

9.6

8.0

6.4

5.3 mils

(13)

(13)

(13)

(13) mm/sec

.51

.51

.51

.51 in/sec

Velocity

Note: 25.4 microns = 1 mil


Micron displacements above are rounded to the nearest ten.
Excessive vibration can be caused by a number of reasons.
The most likely causes of excessive vibration is a new m-g
set are as follows:
(1) Coupling misalignment.

(2) Damage in shipment.


(3) Loose couplmg bolts.
(4) Loose foot bolts or base tie-down bolts.
It should be noted that:
When vibration peak-to-peak amplitude readings at
operating speed are within the acceptable limits in
Table XVII, no further action is needed.
If the amplitude readings are in excess of the acceptable limits, first check possible causes (1) thru (4). With
a new motor-generator set, dirt accumulation should
not be a source of unbalance.
Ifvibration amplitude is still excessive, it is necessary to
go from simple surveillance using only amplitude
readings, to diagnostic techniques with more sophisticated instruments. Refer to GE Motors - DM&G or
Installation and Service Engineering Division.

43

BI006008

GEI-99854J Direct-current Generators

CABLE CONNECTIONS
Armature Circuit Connections
1) Cables Shall Be Assembled To Coil Leads Or Bus Bars In The Following Manner:
A) "AMP" Terminals Shall Be Assembled As Shown In Fig. 1 & 2. All Connections Made Above Horizontal Centerline Shall
Have The Head Of The Screw Located On The Magnet Frame Side Of The Connection Joint.

STD HEX HEAD SCREW

AMP TERMINAL

REGULAR PLAIN WASHER

COIL LEAD
OR BUS BAR

r---,~~~~~~== REGULAR

PLAIN WASHER
BELLEVILLE WASHERS (2)

AMP TERMINAL

REGULAR NUT

FIG. 12
"AMP" TERMINAL

STD HEX HEAD SCREW

U-J-~:::::::::::~=S
COIL LEAD
OR BUS BAR

REGULAR PLAIN WASHER

~~~~~~fl~=-REGULAR

PLAIN WASHER

BELLEVILLE WASHERS (2)


REGULAR NUT

FIG. 13
2) Cables Shall Be Assembled To Brushholder Studs In The Following Manner:

REGULAR NUT
BELLEVILLE WASHERS (2)

BRUSH
HOLDER STUD

L--~~~I~~~::::

REGULAR PLAIN WASHER

"AMP"
TERMINAL
STD HEX HEAD BOLT

REGULAR PLAIN WASHER

FIG. 14
44

BI006008

Direct-current Generators GEI-99854J

90

80A

tN-~--+--84A

88

~~_-++--t-85
1....~~_!::Lr-ft

r---J-+----I--~85A

'----+-J-+jl--- 858

FIG. 15 Cross-Sectional View of Pedestal

768
75C

78

90
78

78A

768

FIG. 16 Typical Polef ce Gang Connection Part #76A Tightened To 17 Pound-Foot (23 Newton-Metre) Torque
45

BI006008

GEI-99854J Direct-current Generators

00
PF CONNECTION SPACER
@

PF CONNECTION SPACER

FIG. 17 Commutator End Brazed Pole Face Connections

46

BI006008

Direct-current Generators GEI-99854J

REF.
NO.

DESCRIPTI N

POLE FACE CONN CTIONS


0006 CONN, PF
0007 CONN, PF
0008 CONN, PF
0009 CONN, PF
0010 CONN, PF
0011 CONN, PF
0012 CONN, PF
0014 CONN, PF
0015 CONN, PF
0016 CONN, PF
0017 CONN, PF
0018 CONN, PF
0019 CONN, PF
0020 CONN, PF
0021 CONN, PF
0024 CONN, PF
0025 CONN, PF
0026 CONN, PF
0027 CONN, PF
0028 CONN, PF
0029 CONN, PF
0030 CONN, PF
0031 CONN, PF
0032 CONN, PF
0034 CONN, PF

REF.
NO.

DESCRIPTION

SPLIT CONNECTION PARTS


0036 PLATE
0037 SPACER
0038 CONNECTOR
0039 PLATE
0040 WASHER
0043 TUBING
0045 SCREW, CAP
0054 CONNECTOR
0055 BLOCK, TERM
PF CONNECTION SPACER PARTS
0046 SPACER, PF
0050 TUBING
0051 TUBING
0052 SCREW, CAP
0053 SCREW, CAP

BI006008

GEI-99854J Direct-current Generators

BI006008

Direct-current Generators GEI-99854J

REF.
NO.
POLE
0006
0007
0008
0009
0010
0011
0012
0014
0015
0016
0017
0018
0019
0020
0021
0024
0025
0026
0027
0028
0029
0030
0031
0032
0034

REF.
NO.

DESCRIPTIO
FACE CONNE TIONS
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF
CONN, PF

DESCRIPTION

SPLIT CONNECTION PARTS


0036 PLATE
0037 SPACER
0038 CONNECTOR
0039 PLATE
0040 WASHER
0043 TUBING
0045 SCREW, CAP
0054 CONNECTOR
0055 BLOCK, TERM
PF CONNECTION SPACER PARTS
0046 SPACER, PF
0050 TUBING
0051 TUBING
0052 SCREW, CAP
0053 SCREW, CAP

47

BI006008

GEI-99854J Direct-current Generators

DETAIL AREA B
SPLIT CONNECTION

DETAIL AREA A
SPLIT CONNECTION

39 40 45@@

FIG. 18 Drive End Brazed Pole Face Connections


48

BI006008

Direct-current Generators GEI-99854J

REF.
NO.

REF.
NO.

DESCRIPTI N

POLE FACE CONNE TIONS


0001 CONN, PF
0002 CONN, PF
0003 CONN, PF
0004 CONN, PF
0005 CONN, PF
0008 CONN, PF
0009 CONN, PF
0010 CONN, PF
0011 CONN, PF
0012 CONN, PF
0013 CONN, PF
0022 CONN, PF
0023 CONN, PF

DESCRIPTION

PF CONNECTION SPACER PARTS


0046 SPACER, PF
0050 TUBING
0051 TUBING
0052 SCREW, CAP
0053 SCREW, CAP

SPLIT CONNECTIO PARTS


0036 PLATE
0037 SPACER
0039 PLATE
0040 WASHER
0041 TUBING
0042 TUBING
0043 TUBING
0044 SCREW, CA
0045 SCREW, CA
0054 CONNECTO

49

BI006008

GEI-99854J Direct-current G enerators

SA

-75A

I
I

\
\

\
\

88

,~~

88A/

81A

~O

7O

'

FIG. 19 MCF700-900 Generators Exploded V'lew

50

10

-75C

BI006008

Direct-current Generators GEI-99854J

REF.
NO.

DESCRIPTI N

1D
2
5A
5B
6
6A
9A
10
12
50
53
55
56
57
57B
57C
70
73A
75A
75C

ARMATURE COUPLINGS
ARMATURE OIL SET
ARMATURE OIL SUPPORT-COMM END
ARMATURE OIL SUPPORT-DRIVE END
ARMATURE ORE
ARMATURE ORE KEY
EQUALIZER MOLDED
SHAFT
COMMUTAT R
BRUSH
BRUSHHOL ER YOKE
BRUSHHOL ER STUD
BRUSHHOL ER STUD INSULATION
BRUSHHOL ER
BRUSHHOL ER SPRING
BRUSHHOL ER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD OIL & POLE WITH BARS
COMM POL BOLT
MAIN FIELD OLE BOLT

51

REF.
NO.

DESCRIPTION

76
80A
81
81A
82
83
84
84A
85
85A
85B
87
88
88A
89
90
93
131
151

POLE FACE BARS


PEDESTAL CAP
OIL RING
OIL RING WEAR PADS
SIGHT GAUGE
CRADLE BOTTOM
CRADLE CAP
CRADLE CAP DOWEL PIN
INSULATING BOLT
INSULATING SHIM
INSULATING WASHER-CRADLE CAP
SLEEVE BEARING
OIL SEALS-LEATHER
OIL SEAL RING
OIL TEMPERATURE GAUGE
FILLER CAP
SPACE HEATER, PEDESTAL
COVER, HOOD COMM END
FRAME SPLIT BOLT

BI006008

GEI-99854J Oirect-cu.:..:rr..:e.:...:n.:....t.: G. :e.:. .:n:. er,:. :8:.:tO:.:.r,:. S

,t
/, ,-----------/
,

/-75C

151,

,I
I

I
I
I

~
o

FIG. 20 MPC500-600 Generators Exploded View


52

If,

I
~.'

BI006008

Direct-current Generators GEI-99854J

REF.
NO.

DESCRIPTI N

REF.
NO.

DESCRIPTION

1D
2
5A
5B
6
6A
9A
10
12
50
53
55
56
57
57B
57C
70
73
75A

ARMATURE
ARMATURE
ARMATURE
ARMATURE
ARMATURE
ARMATURE
EQUALIZER
SHAFT
COMMUTAT
BRUSH
BRUSHHOL
BRUSHHOL
BRUSHHOL
BRUSHHOL
BRUSHHOL
BRUSHHOL
COMM COl
MAIN FIELD
COMM POL

75C
80A
81
81A
82
83
84
84A
85
85A
85B
87
88
88A
89
90
93
131
151

MAIN FIELD POLE BOLT


PEDESTAL CAP
OIL RING
OIL RING WEAR PADS
SIGHT GAUGE
CRADLE BOTTOM
CRADLE CAP
CRADLE CAP DOWEL PIN
INSULATING BOLT
INSULATING SHIM
INSULATING WASHER-CRADLE CAP
SLEEVE BEARING
OIL SEALS-LEATHER
OIL SEAL RING
OIL TEMPERATURE GAUGE
FILLER CAP
SPACER HEATER, PEDESTAL
COVER, HOOD COMM END
FRAME SPLIT BOLT

COUPLINGS
OIL SET
OIL SUPPORT-COMM END
OIL SUPPORT-DRIVE END
ORE
ORE KEY
MOLDED
R
ER YOKE
ER STUD
ER STUD INSULATION
ER
ER SPRING
ER MOUNTING CLIP
& POLE ASSEMBLY
OIL & POLE
BOLT

53

BI006008

GEI-99854J Direct-current Generators

~..
,

"- "

'.

. ;,

, \~:\

10

12

Po
<

/
75A

....

h)

3050

FI G . 21 CDS50006000 Excavator Generator Ex ploded View


54

"

,.

BI006008

Direct-current Generators GEI-99854J

REF.
NO.
1D

2
5A
5B

6
6A
9A
10

12
31

32
34
36
40
42
46
50
53

55

REF.
NO.

DESCRIPTIO

56

ARMATURE COUPLINGS
ARMATURE OIL SET
ARMATURE OIL SUPPORT-COMM END
ARMATURE OIL SUPPORT-DRIVE END
ARMATURE ORE
ARMATURE ORE KEY
EQUALIZER- OLDED
SHAFT
COMMUTAT R
BEARING
BEARING BR CKET
BEARINGC
BEARING C
TRIDGE
GREASE FIT ING
PIPE PLUG
GREASE ME ERING PLATE
BRUSH
BRUSHHOL ER YOKE
BRUSHHOL ER STUD

57
57B
57C
70
73
75A
75C

76
110B
118A
133
151
305A
035B
305C
305D
305E
310

55

DESCRIPTION
BRUSH HOLDER STUD INSULATION
BRUSH HOLDER
BRUSH HOLDER SPRING
BRUSH HOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
COMM POLE BOLT
MAIN FIELD POLE BOLT
POLE FACE BARS
COVER, BOTTOM SIDE COMM END-SCREEf\
COVER, TOP SIDE COMM END-SOLID
COVER, DRIVE END
FRAME SPLIT BOLT
BLOWER HOUSING
BLOWER IMPELLER
AIR INLET SCREEN
AIR INLET HOOD WITH SCREEN
BLOWER BRACKET
BLOWER MOTOR

BI006008

GEI-99854J Direct-current Generators

10

-56

75C

/~

I'

75A
31

T
53

FIG. 22 CDS580-680 Excavator Generator Exploded Vlew


56

BI006008

Direct-current Generators GEI-99854J

REF.
NO.

10

2
5B

6
7
9

10

12
31

32
34
36
40
42
46

REF.
NO.

DESCRIPTIO
ARMATURE
ARMATURE
ARMATURE
ARMATURE
ARMATURE
EQUALIZER
SHAFT
COMMUTAT
BEARING
BEARING B
BEARINGC
BEARING C
GREASE FIT
PIPE PLUG
GREASE ME

COUPLINGS
OIL SET
OIL SUPPORT-DRIVE END
ORE
AN
OIL

50
53
55

56
57
57B

57C
R

70
73

CKET
P
RTRIDGE
ING

75A

75C
110B
118A

133
ERING PLATE

57

DESCRIPTION
BRUSH
BRUSHHOLDER YOKE
BRUSH HOLDER STUD
BRUSH HOLDER STUD INSULATION
BRUSH HOLDER
BRUSHHOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
COMM POLE BOLT
MAIN FIELD POLE BOLT
COVER, BOTTOM SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-SOLID
COVER, DRIVE END

BI006008

GEI-99854J Direct-current Generators

()

()

~j

r;G.~
(.~.

\78

= \
50
!D 7

57C

FIG. 23 CDS320-500 Excavator Generator Exploded View


58

BI006008

Direct-current Generators GEI-99854J

REF.
NO.

10

2
6
6A
7
9
10

12
31

32
34

40
42

REF.
NO.

DESCRIPTIO

50
53
55

ARMATURE
ARMATURE
ARMATURE
ARMATURE
ARMATURE
EQUALIZER
SHAFT
COMMUTAT
BEARING
BEARING BR CKET
BEARINGCA
GREASE FIT ING
PIPE PLUG

57
57B
57C

70
73
75A
75C
110B
118A

133

59

DESCRIPTION
BRUSH
BRUSH HOLDER YOKE
BRUSH HOLDER STUD
BRUSH HOLDER
BRUSHHOLDER SPRING
BRUSHHOLDER MOUNTING CLIP
COMM COIL & POLE ASSEMBLY
MAIN FIELD COIL & POLE
COMM POLE BOLT
MAIN FIELD POLE BOLT
COVER, BOTTOM SIDE COMM END-SCREEN
COVER, TOP SIDE COMM END-SOLID
COVER, DRIVE END

BI006008

GEI-99854J Direct-current Generators

VIEW OF BAFFLE AND


CARTRIDGE USED ON
FRAMES 580A TO 680A
(BOTH ENDS)
VIEW OF FAN AND HUBS NOW USED
FRAMES 580A TO 685A NEW AND
REPLACEMENT DESIGN

VIEW OF FAN AND FAN HUB USED


FRAMES 580A TO 680A OBSOLETE
DESIGN

'r-------~,.

DRIVE END

VIEW OF SHAFT BEARING


AND RETAINING RING USED
ON FRAMES 580A TO 680A

FRONT END
TYPICAL MAGNET FRAME
CD580ACD680A

VIEW OF BRUSH RIGGING USED


ON FRAMES 580A TO 680A

FIG. 24 Type CD, Frames 186A to 685A Kinamatic Direct Current Motors and Generators
60

BI006008

Direct-current Generators

GEI-99854J

REF.
NO.

DESCRIPTIO~

REF.
NO.

DESCRIPTION

1
2
7
7A
10
46
31A,B
32A,B
34
35
36
51
53

ARMATURE!
ARMATURE
ARMATURE
ARMATURE
ARMATURE HAFT
GREASE ME ERING PLATE
BEARING
BEARING BR CKET
BEARINGCA
BEARINGCA GASKET
BEARINGCA TRIDGE
BRUSH RIGG NG
BRUSH HOLD RYOKE

55
57A
57B
50
70
12
140
140B
140C
118A
73
45

BRUSH HOLDER STUD


BRUSH HOLDER
BRUSH HOLDER SPRING
BRUSH
COMM COIL AND POLE ASSEMBLY
COMMUTATOR
CONDUIT BOX
CONDUIT BOX ADAPTER
CONDUIT BOX ADAPTER GASKET
COVER, TOPSIDE COMM END-SOLID
FIELD COIL & POLE
LOCKING RING

61

BI006008

GEI-99854J Direct-current Generators

NOTES:

BI006008

BI006008

GEMotors

-----------------------

General Electric Company


Drives Motor and Generator Operation
3001 East Lake Road Erie, PA 16531
Telephone (814) 875-3129 Telex 703531 Facsimile (814) 875-3595
9/90 (1M) D

BI006008

Figure 34. Lower incoming line barrier.

Figure 33. Isolator switch arrier showing bolts to be removed.

18

Figure 35; Main bus compartment with all barriers


removed and incoming line cables terminated.

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control

Figure 28. Unbolt the cables from the bottom


of the fuse assembly.

Figure 30. Remove the bolts shown and slide the


horizontal barrier out of the enclosure.

Figure 29. Remove the three load-side connecting bolts.


(do not adjust the R.T.V. covered bolts)
Remove the two retaining nuts.

Figure 31. Remove the horizontal main bus barrier


bolts shown and remove the barrier.

17

!
!

I
I

BI006008

_ _ _ _ _--1~---------------C-R-'94-v.-a-CU-U-m-Li-m-it-am-1J4OO_A_m...,:1J_e_re_Co_n_t"_ol
I

Motor Connections
Motor cables may enter from the top or bottom of the
enclosure. In the one-high enclosure, the motor terminals are located on the inside lower left wall as shown in
Figure 36. The incoming leads should be trained for
maximum space between phases and ground. The
connections may be made before or after energizing the
main bus and without shutting down adjacent equipment. Also see Figure 60.
Warning: If the main bus in energized while load cables are being installed, all barriers must be in place and the disconnect
switch must be in the offposition and the blades must be visually checked to ensure that they are completely disconnected from
the vertical bus.

The motor terminals can accommodate up to one 500MCM per phase with stress cones in the standard 26-inch
wide enclosure. If larger cable entries are required, an
optional 34-inch wide cabinet is available.
Figure 36. Load ter inals located on the left wall of the highvoltage compartment. he lower incoming line barrier and isolator
switch barrier hav been removed. Phase A is at the top.

19

BI006008

CRI94 Vacuum Limitamp 400Ampere Control


Extra-width Enclosure
A special 34-inch-wide enclosure is available for terminating shielded cable with stress cones, or for terminating
more than one large cable per phase. The enclosure
design permits space for termination of two 500-MCM
cables per phase with stress cones* for motor and power
leads. Figures 35 and 38 show the space available in this
extra-width enclosure. Design is basically the same as the
26-inch-wide one-high, and all data and information in
these instructions applicable to the 26-inch one-high
design apply to the 34-inch-wide enclosure.

Power Cable Tennination


In any installation, the cable should be prepared for
termination in accordance with the instructions of the
cable manufacturer. However, the following general
recommendations are given for proper cable tennination in Vacuum Limitamp equipment.

Figure 38. Motor cable terminations in


26-inch or 34-inch wide enclosures.

I. Pull in the cables in accordance with the panel


outline diagram and position them for maximum
clearance between phase, ground and other cable or
wire runs. Refer to Figure 60 of these instructions for
recommended location of incoming cables in a standard
Limitarnp controller.

. G N _ - TERMINAL

1'::>---- BUSHINGS

i-

MAXIMUM OR

Uo--- POTHEAD BODY


7/8" MAXIMUM OUTSIDE DIAMETER

THROUGHTYPE POTHEAD
WIPING SLEEVE OR STUFFING BOX
WIPING SLEEVE OR STUFFING BOX
LEAD CABLE
LEAD SHEATH
27/8" MAXIMUM OUTSIDE DIAMETER

INCOMING
CABLE

INCOMING
CABLE

TERMINALTYPE POTHEAD

THROUGHTYPE POTHEAD

Figure 39. Termination of cable in potheads.

*General Electric Terrni-Kit stress cones.


~o

BI006008

CRI94 Vacuum Limitamp 400Ampere Control


2. Prepare the cabl for termination in accordance with
the manufacturer's i structions. For suggested terminating methods, see pa es 20 through 23 and Figures 39
through 45.
3. Bolt the cable ter inals to the bus or other point of
termination.

COPPER LUG
OUTER LAYER
IRRASIL TAPE
NOTE:
FOR DETAILS OF END
SEAL SEE FIG. 40 FOR
RUBBER CABLE AND
FIG. 41 FOR VARNISHED
CAMBRIC CABLE.

GE NO. 8380 TAPE


INSIDE FOR RUBBER OR
NO. 992 VC TAPE FOR VARNISHED
CAMBRIC IS RECOMMENDED.
ALTERNATE: BUILD ENTIRE END
SEAL WITH GE IRRASIL@ TAPE.

I~~~j FILL WITH SEALING


COMPOUND

CABLE
TERMINATOR
FiniNG

Figure 40.

tion of rubber-insulated, non-shielded,


-covered, 5000-volt cable.

Figure 42. Termination of interlocked-armor,


non-shielded, 5OOO-volt cable.

6"-

Irtasil No. 42005

to po

CABLE INNER
INSULATION
END SEAL

1. Cut cable to pr per length leaving conductor sufficiently


long to extend into he terminal lug.
2. Remove braid, ape, and inner insulation and expose the
conductor end for
distance of one inch plus the length of
conductor to go int the terminal lug.
3. Attach termin I to conductor.

COPPER SHIELDING
-'--".j:'''Pl''---dSTRESS CONE
BRAID-GROUNDED
'
TO STRUCTURE OR ==~~8:t:b
ARMOR.
2"

~~-t

FILL WITH
SEALING COMPOUND'-lI1VA~=H"'N

4. Taper the insu at ion as shown.


5. Remove the b id and tape, if any, six inches from the
lug, exposing the i sulation. Leave one-half inch of original
cable tape extendin beyond the cutback braid.
6. Apply the end eal using GE Irrasil'" electrical tape. Obtain a smooth wra ping but do not stretch tape more than
necessary.

CABLE TERMINATOR
FiniNG

7. Bind down end of braid and tape, if any, with Irrasil tape
as shown on drawin .
8. Apply two laye s half-lap of GE Irrasil'" tape over-all from
lug to exposed brai .

Figure 41. Termi ation of vamished-cambric-insulated,


non-shielded, non-lead-covered, 5000-volt cable.

CABLE ARMOR

Figure 43. Termination of interlocked-armor,


shielded, 5OOO-volt cable.

21

BI006008

CRI94 Vacuum Limitamp 4lXJ Ampere Control


1. If contact between the cable and an adjacent bus
:annot be avoided, as may be the case with the two 500\1CM cables per phase, tape the bus in the immediate
ricinity of the cable contact point so that the surface
:reepage distance from the cable to the bare bus bar is at
east three inches. Thus, the surface creepage from the
)are bus where the cable terminates, to the bare part of
:he bus where the cable touches, will be at least seven
nches. The thickness of tape on the bus should be
tpproximately %2 inch. General Electric No. 8380 tape is
'ecommended for most of the buildup and General
~lectric No. 42005 Irrasil tape is recommended over-all.
J. Where more than two 500-MCM cables per phase are
'equired, they should be brought into different sections,

GE NO. 8380 TAPE INSIDE FOR RUBBER OR


NO. 992 VC TAPE FOR VARNISHED CAMBRIC
IS RECOMMENDED. ALTERNATE; BUILD ENTIRE
END SEAL WITH GE IRRASIL@ NO. 42005 TAPE

CABLE INSULATION

or an incoming line compartment must be provided. If


the two 500-MCM cables must be terminated with stress
cones, a cable entrance compartment must be ordered.
6. Run all the low-voltage wires so as to avoid any
possible contact with high-voltage lines.

Tennination of Lead-covered Cable


Termination of lead-covered cable requires the use of
potheads (see Figure 39.) The pothead manufacturer's
instructions should be followed in terminating the cable
at the pothead. Standard Limitamp starters have space
for locating one pothead of the pull-through type which
accommodates up to and including 2/0, three-conductor, 5000-volt cable. In this type of pothead, the three
conductors of the cable are fanned out within the
pothead and pass completely through it, with the
pothead sealing and terminating the lead covering. For
larger cables, potheads with terminating bushings are
required. In this case, or when more than one pullthrough type is required, special cable entrance
compartments are available.
Through-type potheads are satisfactory for varnishedcambric cable indoors. Paper-insulated cables are more
hygroscopic and, since the only thing protecting the
individual conductors from moisture is tape on the
surface, high humidity might cause difficulty. Terminaltype potheads are required for paper-insulated cable.

GE NO. 8380 TAPE


NO. 19 AWG
TINNED COPPER WIRE
GE IRRASIL' NO. 42005 TAPE
SHIELDING TAPE
GE NO. 8380 TAPE
GE

IRRASIL'~

NO. 42005 TAPE

Tennination of Pothead Cable


Figure 44. Termination of shielded, 5000-volt cable
showing stress-cone construction.

1. Maintains tight fit under


load cycling and all cable
operating conditions.

2. Track-proof insulating EPDM


rubber.

3. Heavily-insulated shield
edge protects high stress
area of stress cone.
4. High conductivity semi-

conducting rubber relieves


electrical stress.
5. Internal step positions
stress cone properly on
cable shield.

6. Ground clamp provides


positive ground.

r
5"

-~

Tennination on Non-shielded, Non-Ieadcovered Cable

'-Z:J

P-I

/~\~

~t
I ". ~O

1.\ .

__ SEMI-

,\'

C ONDUCTOR

\\
I

Figure 45. TERMI-MATIC preformed stress cones (5 kV).

'2

The instructions for terminating lead-covered cable by


using potheads apply as well to those terminations of
other types of cable where potheads may be desired.

This cable is generally run through rigid conduit or


cable raceways and brought into the enclosure by the use
of conventional cable clamps and conduit fittings. Refer
to Figures 40 and 41 for termination details.

Tennination of Interlocked-annor Cable


Interlocked-armor cable is terminated by means of
specially designed cable fittings. These terminators
consist generally of mounting bracket, armor clamp, and
supporting base and bushing, with various modifications
available for special types of sealing.

BI006008

CRI94 Vacuum Umita

Figure 26. Unplug the umbilical cord assembly.

Figure 25. View howing armature interlock.

16

Figure 27. Unbolt the cables from the bottom


of the fuse assembly.

BI006008

CR194 Vacuum Limitamp 400 Ampere Control

Figure 23-1. Depress STOP push button.

Figure 23-3. Handle OFF - Pusher bar OUT.

Figure 23-2. Place isolator handle in the OFF position by


depressing pusher bar and rotating handle rapidly down.

Figure 23-4. Turn door latches and open door.

15

"T1

Ll

("

!I'

o
iii

:::T

:i"

LI

*-

6-1/2
L2-6-1/2
L3

5-5/B

t;- 1300

0-1/0-1

~'i

~,.l
~
*

...1

----r=

+--4=
T2

17
L--.l.:

18-1/0

7FT 6

FRONT

TOP VIEW

.-.

7FT 6

FRONT
TOP VIEW

AUXILIARY

7FT 6

REV.) 1I1193

J
E

"

AUXILIARY

1-1/21

1-1/2

J
r"".. . "10'"1 ~

}--VARIAlILE WJDTH....j
FRONT VIEW

FRONT
FLOOR PL~
2-3116

FRONT
FLOOR PL~

2-3116

.1r-J

25-5/8 3Il

ib TIlh
I"': 25-5/8 3Il

JUT

~-diz---J1T----J.I

l-l:-

1-1/21

rVllR1.... 1~1-1/2
i .. ~~;:.~ ....

}- VARJABLE WlDTH..j
FRONT VIEW

AUXILIARY

1 1 1

jo---- 30----l
FRONT VIEW

2- 11116
VAW)" I-HI

t-t= ~/2P*

9-1/29-1/2

:-6

' '
:'~l3
1--5

1-3/B
TOP VIEW

*_/1 : ~L2

9-1/29-1/2

34 11 WIDE

NOTE:
B - INCOMING POWER TERMINAL CONNECTION
INDICATES TERMINAL LOCATION - APPROX. FOR CABLE LENGTH
B1 - AC POWER BUS
!'. - APPROXIMATE UNCRATED WEIGHT
C - CONTROL LEAD TERMINAL BOARD
- ADD 5 PERCENT FOR DOMESTIC SHIPPING WEIGHT
D - MOTOR LEAD TERMINAL CONNECTION
- ADD 20 PERCENT FOR EXPORT SHIPPING WEIGHT
E - GROUND BUS TERMINAL CONNECTION
F - GROUND TERMINAL CONNECTION
G - SPACE REQUIRED TO OPEN DOORS 90 DEGREES
J - MOUNTING HOLES FOR 1/2 IN. DIA. ANCHOR BOLTS
K - SPACE AVAILABLE FOR INCOMING CONDUIT
M - RECOMMENDED POSITION FOR INCOMING MOTOR CONDUIT
N - RECOMMENDED POSITION FOR INCOMING CONTROL CONDUIT
P - RECOMMENDED POSITION FOR INCOMING POWER CONDUIT

FRONT 2-3/16
3-1/2
FLOOR Pl~

6l2-1--l

1
$!.J-l .~

: 15 I

25-5/B 30

2-3116

"t~l:Erh

H5l2

1-1/2~ k 2 3
: r l k 1-1/2
1-1/2

:--

"""'~ i

(Q

t;- 1000

9-lIB

7-3/16

3-1/2-1 LO:

1-3/8
TOP VIEW

FRONT

5-s/sf"-I:@j

: I!l>:Tf

6-1/2
L2-6-112
L3

:.~----,

I-I/O

M5-1/0

10-1

::
--L:
: 27-3/8I
,,<3-1/2

0-1/2

2-0{

I:

3
o

CD
III
:::J
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-g

en

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I:

Co

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26 11 WIDE

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s'

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,...

Q1=

BI006008

BI006008

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the
matter should be referred to the GE Company.

GEH-5305A 0594 PSA

GE Electrical Distribution & Control


General Electric Company
P.D. Box 489, 6807 Industrial Dr, Mebane, NG. 27302
7994 General Electric Company

BI006008

CR194 Vacuum Limitamp 400Ampere Control

TOP
VIEW

NOTE

1. Adjust depressor bracket(s) by bending to


depress interlock plungers equally with
handle in OFF position.

DEPRESSOR

2. Loosen screws "A", depress interlock


plungers (2 or 3) all the way, then move
depressor back 0.04 to 0.06 inch for slack
and tighten screws.

,.

SIDE
VIEW

___ TO HAN OLE


IZ

MAIN DISCONNECT ROD ASSEMBLY

oa:
u.

Figure 58. Checking test power interlock (TPI) adjustments.

Checking Proced es Mechanical Inter ock & Manual Isolator (See


Figures 56-58)
1. Check the door echanical interlock for proper
interference. See Fi ure 56.
2. Check for proper operation of pusher rod and
Control Power Inter ck (CPI) operation. See Figure 57.
3. Check the Test P wer Interlock (TPI) adjustment.
See Figure 58.

Warning: The vacuum interrupter integrity test should be performed before the high-voltage contactor is energized for the first
time and each time it is returned to service after maintenance,
adjustment, or repair (See GEH-5306). Otherwise the vacuum
interrupter integrity test should be performed annually.
Caution should be exercised during this test since high voltage
testing is potentially hazardous. First open the controller
isolating switch then completely isolate the contactor by disconnecting the bolted connections at the contactor load terminals
prior to performing the high potential test. Also remove CPT
primary fuses.
Failure to perform these tests may cause serious injury or death.

Vacuum Interrup er Integrity Test


Warning: The control isolation switch (QMQB) must be
placed in the offpositio and the motor load must have come to
a complete stop before a tempting to perform the vacuum interrupter integrity test.
Caution: X-ray emissi
high voltage is applied
terrupter. Do not appl
tactor that is higher th

n may be produced if an abnormally


cross the open contacts of a vacuum ina voltage across the 400A CR193B conn 20.0 kV RMS.

High potential test instruments can be purchased to


perform the vacuum interrupter integrity test. The
following is a recommended test instrument:
Hipotronics Model 7BT 60A
Use of a DC Hipot is not recommended because results
may indicate a problem with a good interrupter. If you
wish to use DC Hipot, set for 28kV, but if interrupter
fails, confirm failed interrupter using above AC Hipot.

Test Procedure
General
This test determines the internal dielectric condition
and vacuum integri of the vacuum interrupters. Prior
to performing this te t the outside surfaces of the
vacuum interrupters should be wiped clean of any
contaminants with a on-linting cloth or industrial type
wiper. During this t st each interrupter should be
checked separately.

Note: Before performing vacuum integrity test, confirm that


both the armature gap setting and contact wear adjustment
(GEH-5306, Sections 5 & 6) are proper.

1. Disconnect load side power leads from contactor and


CPT primary fuses.
2. With the contactor in the open position connect the
test leads to the contactor power terminals as shown in
Figure 59. Apply the recommended test voltage (per
above) and hold for a minimum of five (5) seconds.

31

BI006008

CR194 Vacuum Limitamp 400 Ampere Control


In these routine inspections, four basic categories of
deteriorating influences should be kept in mind:
1a. The effect of foreign material: Dirt and dust from
the environment such as wood fibers, coal dust, cement,
lamp black, lint.
1b. The effect of chemicals in the atmosphere: such as
sulfur dioxide, chlorine, some hydrocarbons and salt
water.
2. Mechanical wear and fatigue on all moving parts.
3. Heat.
4. Loose joints and connections.
5. Perform vacuum interrupter integrity test as described in these instructions.

Figure 59. Method of connecting test leads to interrupter


for vacuum integrity test.

Follow directions in these instructions for obtaining


access to all sections of the controller including highvoltage door interlocking. Also, refer to GEH-5306 for
directions relative to inspection of the high-voltage
contactor.
The following are some specific recommendations:

3. Reverse the leads and repeat the test.


4. If no breakdown occurs the interrupter is in acceptable condition. If a breakdown occurs the interrupter
should be replaced. Refer to the "Interrupter Replacement" section in GEH-5306.
Note: No attempt should be made to try to compare the condition of one vacuum interrupter with another nor to correlate the
condition of any interrupter to low valu'es ofDC leakage current. There is no significant correlation.
5. Mter the high potential voltage is removed from the
interrupters, the metal end caps of the interrupters
should be discharged with a grounding stick to remove
any residual electrical charge.
6. Make sure that all connections are tightened properly
to 16 lb.-ft. Reconnect load cables and replace CPT fuses.

Preventive Maintenance Guide


Warning: Before performing any preventive maintenance on the
Vacuum Limitamp controller all power must be removed from
the equipment and all rotating equipment must have coasted to
a complete stop.
Maximum trouble-free service from Vacuum Limitamp
controllers requires periodic inspection, preventive
maintenance, and periodic cleaning. A definite schedule should be maintained for inspection, the frequency
depending upon operating conditions. Preventive
maintenance activity should then be established as the
result of periodic inspection.

32

1. Check for cleanliness generally, but particularly for


accumulation of any foreign material on insulators.
Voltage failures can result from tracking across insulation surfaces when they are dirty. The primary circuit
insulation on the controller may be checked phase to
phase and phase to ground using a 2500 volt megger.
2. Check for abrasive material accumulated in the
isolating mechanism and mechanical interlock bearing
and cam surfaces.
3. Check for buildup of dust or dirt which would reduce
any air or surface voltage clearances.
4. Excessive heat can cause wire and cable insulation
breakdown. Therefore, check for any evidence of
melting, discoloring, deterioration of wire and cable.
5. The isolating mechanism has a life expectancy of
approximately 6000 operations. If the application is
such that the mechanism is operated more than twice
each day, then the mechanism should be checked at the
end of each 1000 operations, otherwise a yearly inspection is recommended.
6. Periodic checks of dimensions of the isolating mechanism and mechanical interlocks is strongly recommended. Follow the section in these instructions
entitled "ISOLATING MECHANISM AND MECHANICAL INTERLOCK".
7. When any part of the isolating mechanism and
mechanical interlock is replaced, all dimensions and
checking procedures referred to under No.6 above
should be followed to be sure the system is in normal
working order.

BI006008

CRI94 Vacuum Umitamp 400 Ampere Control


3. Push in the latch r lease (B) and move the handle
(C) mechanism from the ON to OFF position, again in a
rapid, positive motio
Near the bottom of th
again be heard and th
open. Inspection may
viindow provided in th
release (B), Figure 49,
the handle travel (See

handle travel a sharp snap should


disconnect contacts should be fully
e made by viewing through the
fixed barrier. The handle latch
hould pop fully out at the bottom of
igure 57).

4. Repeat steps I an 2 until the disconnect switch is


again in the closed p sition. Simulate the contactor
being energized by d pressing the contactor armature
downward until the c ntactor is in the fully closed
position. While hold ng the contactor in the closed
position, attempt to ush in the latch release (B). The
release should move orward only slightly and the handle
should not rotate. N w, release the contactor armature
and depress the latch release. Attempt to close the
contactor armature. he armature should move slightly
and stop, preventing he contactor from moving to the
closed position.
5. Repeat steps I an 2 above. When the handle (C) is
rotated to the ON po ition, the door latch (G) should
drop to within I % to inches from the bottom of the
handle assembly (H)
6. If the mechanism
checks, an adjustme
assembly as shown in
to ensure that the in
the contactor can be
the disconnect switc
diate position, the in

ails to meet any of the above


t must be made to the interlock
Figure 50. This adjustment is made
rlock slider is moving properly. If
ade to turn ON manually when
operating handle is in an intermeerlock needs to be adjusted.

A Door-operated release (Not visible) G Door Latch


B Handle latch release (Pusher)
H Handle Assembly
C Handle
Figure 49. Operating handle parts.

Caution: Before makin any adjustments, be sure that the contactor is in the fully off osition and the disconnect switch
handle is in an interm iate pDsition with the handle latch release (B), Figure 49, fu ly depressed.
A. Loosen the botto
holding the top a
Also loosen the

lacking nut (X), Figure 50, while


nut (W) firmly in position.
retaining nuts at the top of the rod.

~usting
0

B. Turn the adjustin nut until the interlock slider is just


slightly below the andle latch release rod (0.06 inches).
C. When the proper position has been reached hold the
top adjusting nut (W) and tighten the lower locking
nut (X) to hold t e adjustment. Finally tighten the
two locking nuts t the top of the rod.
D. Test the interloc mechanism again by following
Steps 1 through 6 above.
If the controller fails to meet any of the above checks
DO NOT ENERGIZ THE CONTROLLER. Contact
your nearest Genera Electric sales office.

W Top adjusting nut


X Bottom locking nut

Y Armature interlock rod


Z Contactor armature

Figure 50. Adjusting the interlock mechanism.

7. Return the disco nect handle to the OFF position.

25

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control

SEALER

~OF COUPLING

~~/~"

1/2"

13"

x 13" x 11/4" Ig. (12)


Add gussets to joints of
roof channel supports on
walk-in type. Add coupling
to roof joints. Use 3M
sealer in all cracks. ~
k2: Ig. (6/;1
J_
ENC L. JOINTS ~<;II

;==
0

I
I

1/2" x 13"
[...-1"lg.(5)

~ 3M SEALER

o~

TOP BRAc'E ANGLl


~

ADD ALL PARTS


NOTED HERE

0.50'

0.25"

~"\J0.5~
to- SEALER

I>-

/'

['SEALER

0.50 "

O. 25"
On sides of single cases
and sides of cases on ends
of lineups, use sealer
around cutouts under all
cover plates. Also use
sealer in all bolt holes.
Purpose of sealer is to
have weathertight seal between exposed joints of
enclosures.
O. 50"
Where to apply:

l'

BonOM BRACE
0

ANGLES
I
FLAT HEAD

!==

.
FRONT CUTAWAY VIEW
OF EXISTING EQUIPMENT

O. 50"

[:;

1=7

SIDE VIEW
FIG. A

~L~
-

R.H. END VIEW (AFTER A)


SHOWING PARTS TO BE ADDED

SPECIAL NOTE FOR FIELD


INSTALLATION BY
CUSTOMER:

Apply to one side of one


case at each junction of
lineup of cases.

FIG. B

In addition to other instructions shown, hardware should be removed


and used to bolt new
enclosures to existing
enclosures. The end-plate
assembly and gaskets
should be removed and
discarded. After enclosures
are in place, install roof
coupling furnished with
new enclosures.

Method of Application:
Place the extruded
sealer strip with slight
pressure 1/2-inch in from
front and rear edge of side
of case except 1I4-inch in
at cutouts. Use two (2)
strips side by side the full
height of case. Also apply
across the top of the side
of the case 1/2-inch down.
See Fig. "A".
Material:
Extruded 3M sealer formula EC1126, 1/4-inch
diameter extruded bead x
30-inch long strips. Product
of Minnesota Mining and
Manufacturing Co., 700
Grand Avenue, Ridgefield,
New Jersey.
The approximate total
length of sealer required at
each junction will be 42
feet, for non walkin and 70
feet for walk-in.

Figure 51. Assembly of outdoor enclosure.

26

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control


Operation
General
A test-power interloc~ (TPI) (See Figure 14) circuit and
Test-Normal Selector Switch (TSW) (See Figure 9) is
provided to check ou the control circuit of the complete
unit without applyin power to the motor. Mter all
control-circuit conne tions are made, the controller
should be put throu, h its complete operating sequence,
in the test position, a a final check.
A wiring diagram wh' ch shows the circuit and connections
that apply to the con roller is included with the controller
when it is shipped fr m the factory. All external wiring
from the controller ust be made in accordance with
the connection diagr m supplied with the controller.

Mter all connections have been properly made, all parts


properly assembled, and all components thoroughly
inspected and adjusted, the controller is ready for operation.

Normal Operation
1. Mter all power and control connections are made,
AND WITH THE ISOLATING DEVICE OPEN, megger
between phases at the motor terminals, and between
each phase and ground stud or bus, to ascertain that no
short circuits are present.
2. Close the compartment doors and apply power to the
controller.

Test Power Circ


A complete operation I check of the controller can be made
without applying vol e to the motor or to the bus as follows:

1. The isolating-devi e handle must be in the open


position. In the ope position, contacts of the mechanically operated test-p weI' interlock (TPI) will open the
secondary circuit of he control-power transformer,
thereby isolating it. he Test-Normal Selector Switch
(TSW) must be in th "Test" position to close the circuit
to the test-power tel' inals on the control terminal board.
2. Refer to the clem
the required control
terminal designatio
to terminals provide
voltage control com
to the low-voltage co
for proper operatio

make a good contact when closed. The relay and contactors


are carefully adjusted at the factory; however, should an
adjustment of these devices be necessary, these adjustments
are explained in the individual instructions for each device.

ntary and connection diagrams for


voltage, frequency, and test-power
. Connect the required test-power
on the terminal board in the lowartment. Power may then be applied
trol circuit and the circuit tested
.

If the operating handle of the isolating mechanism


cannot be moved to the closed position, it may be that
the mechanical interlock device is preventing this
movement. To move the handle to the closed position,
the high-voltage door must be fully closed and the
contactor must be open.
3. Close the isolating-device handle by moving the
handle with a rapid, positive motion to the extreme
upper position until it latches into position. Unless the
latch ( pusher) snaps out when the handle is moved to
the extreme positions, either in the open or closed
position, the contact marked CPI (control-power interlock) will not close and the operation is not complete.
4. Operate the controller in the normal manner with
the pilot devices (usually, push buttons) provided.
5. Mter the preliminary operation check is made, check
the motor for proper rotation.

Preparation of C ntroller for Operation


Once the panel is in
the inside with a brus
Make certain that an
which may interfere
devices, are removed

lace and the cable terminated, clean


, soft cloth, or dry compressed air.
dirt, dust or bits of packing material,
'th successful operation of the panel
rom the panel.

Caution: Care should be taken during the cleaning operation to


prevent any dirt from eing blown into the inaccessible spaces of
the devices.
Before the controlle can be operated, even for a tryout
without power, all d vices must be placed in full operating
condition. Also, ch ck to ascertain that no tools or loose
wires have been left ithin the panel during installation.
Operate each device y hand to see that the moving parts
operate freely and wi hout binding. Make sure that all
electrical contact tips are clean, free of grease and dirt, and

Door Opening Procedure


General
To open the high-voltage doors to gain access to the
contactor or motor terminals, the contactor must be in the
de-energized position. If the contactor is energized, the
latch on the disconnect handle cannot be pushed in, the
handle cannot be operated, nor can the door be opened.
Depressing the stop button de-energizes the contactor.
The latch release on the disconnect handle can then be
depressed, which opens an electrical interlock in the
secondary of the control-power transformer. When the
latch release has been depressed, the isolating switch
handle may be moved to the lower or open position.
With the disconnect handle in the lower position, the
high-voltage door may be opened by turning the Y4 turn
latches.

27

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control

Figure 52. Door interlock defeater bolts.

Figure 54. Interference latch may be operated by opening the


high-voltage door and pulling latch down.

Figure 53. Interlock defeater bolt - rear view from inside of door.

Figure 55. Isolating mechanism and electrical interlocks


mounted in enclosure.

28

BI006008

CRI94 Vacuum Umitamp 400 Ampere Control


Door-Defeater Latfh

Warning: All power must be removed from the main bus before
attempting to adjust the isolating switch mechanism.

Warning: The followin steps should only be taken as a last


resort to enter a malfunc ioning controller. It is imperative that
all power to the main bu be removed before proceeding.

IN CASE OF EMERG NCY, remove all power to the


controller; then the h gh-voltage door may be opened
with the contactor in he closed position and with the
isolating switch closed by using the hex-head bolts,
located to the lower I ft of the isolating-switch handle, as
follows:
Warning: Do not procee unless all power to the controller is
removed. Doors must no be opened with the power connected to
the bus.

1. Turn the door latc es 1;4 turn counterclockwise.


2. Remove the right- and hex-head bolt, as shown in
Figure 52.
3. Turn the left-hand olt 1;4 turn counterclockwise.
Figure 53 shows the b lts from the inside. The door may
then be opened.
Warning: Defeating the oor interlock leaves the controller
connected to the bus. T bus power must be removed.

On some one-high en losures, the low-voltage control


panel serves as a barri r to isolate the high-voltage
control-power transfo mer and fuses. An interference
pin, shown in Figure 4, prevents swinging this lowvoltage panel out unti the high-voltage door is opened.

Inspection, Maint

1. Mter removing all power to the controller, and as


described in steps 1 & 2 of the Mechanical Operation
Check, rotate the isolating switch handle to the ON
position. Then remove the fixed barrier (Figure 33) by
removing the retaining screws that hold it in place.
Retain the hardware for reassembly.
Some of the barrier mounting hardware is nylon type
hardware. Note the location of these parts so they may
be reassembled properly.
2. Near the end of each switch blade assembly, an
adjusting nut is located along with a Belleville washer
type spring. To adjust the blade pressure the nut must
be adjusted. Loosen the small set screw located on each
of the retaining nuts to enable adjustment.
3. Loosen the adjusting nut at the top of the blades.
With your fingers retighten the nut until all the slack is
out between the blades, stationary contact, spring washer
& nut, then tighten an additional 18 (one-eighth) turn.
This procedure provides the necessary 0.005 inch spring
compression of the blades.
4. Tighten the set screw on the nut to lock the adjustment in position. Use caution to prevent turning the
nut on the main screw while tightening the set screw.
5. When the adjustment is complete for all three phases,
rotate the isolating switch handle to the OFF position.
Then, apply a thin coating of Mobil Temp SHG32
grease to the contact surfaces of the male stab portion of
the disconnect.

Vacuum Contacto

To properly adjust the pivot point Belleville washer type


spring, return the isolating switch handle to the ON
position per step 1 above. Then, follow the steps below:

Complete maintenanc and adjustment instructions for the


high-voltage contactors are presented in GEH-5306. Refer
to that instruction for I problems of servicing and adjusting; and to the proper re ewal parts bulletin for renewal parts.

1. On each phase, loosen the set screw on the pivot


point adjusting nut.

Contactor tip life dep nds on the severity of the service,


but in any case, it is re ommended that the contactor tip
wear be checked at Ie st once a year or in very high duty
cycle operations, after every 250,000 operations.

Isolating Mechanis

and Mechanical Interlock

Warning: Under no circ mstances should the isolation switch


be inspected or adjusted ith power applied to the main bus.

The quick-make quic break isolation switch assembly is


adjusted and tested at the factory. Under normal
circumstances the swi h does not need adjustment,
however, if conditions require it the switch may be
adjusted in the field. 0 adjust the isolating switch the
following steps should be followed:

2. Loosen the adjusting nut and then retighten using


your fingers until the nut is just snug and no side play of
the parts is evident.
3. Using wrenches tighten the adjusting nut an additional one-half (Y2) turn and tighten the set screw to hold
the adjustment in place.
4. Rotate the isolating switch handle to the OFF
position, then reinstall the isolator switch barrier. If
necessary the viewing window may be cleaned before
reinstallation of the barrier. Use a soft cloth and a mild
soap and water solution or a commercial cleaner such as
Windex or other similar cleaner.
Warning: Severe injury or death may result if the equipment is
energized with the mechanical interlocks defeated. Remove all
power from the equipment before defeating any of the mechanical
interlocking mechanisms.

29

BI006008

CRl94 Vacuum Umitamp 400 Ampere Control

---,

WARNING: Defeating the door interlock


leaves the controller connected to the bus.
The bus power must be removed.

81
I
I

1----1 I
I C-~ I
DOOR INTERLOCK BAR

APPROXO.50"~

tll ':

m
I

.J-...,.,4-'1 L
I

~r-~L~L'~~t

1<9> '\ I~-

ADJUST STOP NUT


~ 1:---- 1 J
BEHIND DOOR SO THAT I
I-J
LATCH MAY PIVOT
I
I
FREELY.
I
I

To check if sufficient (or safe) interlocking


between door and door interlock bar exists,
the following should be done:

I
II I
I
II I

~:

r-1j

+-1I

NOTE

III

t-=J-

A. Open high-voltage door.

B. With the door open, close the isolator


switch by manually depressing the door
operated release. See Figure 49.

:1

.!l I
I

L::

LOOKTHROUGH
CUTOUT

~==:I

LATCH ASSEMBLY

C. Close door against interlock bar.

D. Look through door cutout below handle

and visually determine if there is a


minimum of 0.50-inch overlap (see sketch).

E. For a final check, close the door, close the

disconnect switch, and try to pull the door


open. The door should not open.

FRONT VIEW

Figure 56. Checking procedures for mechanical door interlock.

WARNING: Defeating the door interlock


leaves the controller connected to the bus.
The bus power must be removed.

CONTROL POWER
INTERLOCK

NOTE

,,

0.60"]

+ '-------'

REF

:0
I
I

I
I

PUSHER ROD

10

f-

I Z
I 0
II:
1 u..

1. Set 0.12-inch gap (as shown) with pusher


extended (out position). See 0.60-inch
reference.
2. Then, check the interlock operation with
the pusher depressed.

3. Both contacts must be open and have a


contact gap of at least %4 inch.
4. Insure the pusher pops out fully (see 0.60inch reference) in both the down (off) and
up (on) positions.

HANDLE LATCH RELEASE


(PUSHER)

Figure 57. Checking for proper operation of pusher and control power interlock (CPI).

30

'1

BI006008

CRI94 Vacuum Umitamp 400 Ampere Control


Interlocked-armor, Non-shielded Cable

Control Connections

RUBBER-COVERED - Refer to Figure 42 for general


information concerni g termination. For details, refer
to Figure 40. Note tha rubber-covered cable requires
only taping near the t rminal and not back to the
terminator fitting. Ho ever, if there is a possibility of oil
coming in contact wit the rubber insulation, it would be
well to use a layer ofIr asil No. 42005 tape all the way
back to the terminator fitting.

Conduit for control wires should be brought in the areas


as shown in the outlines. There is room in both the
bottom and top for the control conduits to be brought
into the enclosure. In all Vacuum Limitamp controllers,
the control connections are made through a terminal
board on the left side of the low-voltage control compartment. Refer to Figures 46 and 47 for details.

VARNISHED-CAMBR - Refer to Figure 42 for general


information concerni g termination. Note that varnished-cambric cable equires taping back to the
terminator fitting, sin e the individual conductors or
"singles" have no brai

Interlocked-armor, Shielded Cable


Interlocked-armor, ru ber-covered, and varnishedcambric insulated cabl s are sometimes shielded at
ratings of 5 kV and be ow. If they should be, proceed to
terminate as detailed I' other types of shielded cables.
Refer to Figure 43.

Termination of Sh elded Cable


It is recommended th t when shielded cable is used,
"stress-relief cones" be built up at the cable terminations,
or else General Electr' c Termi-Matic stress cones be
used as shown in Figu e 44 and Figure 45. This will
relieve the electrical s ress which occurs in the area
around the terminati n of the ground shield. Whenever
possible, the conduit ould be brought in through the
bottom. A maximum f one 500-MCM cable per phase
may be terminated in ne full-voltage starter section.
When making shielde -cable terminations to Limitamp,
the following procedu e is recommended:

Figure 46. Low-voltage compartment showing low-voltage


terminal strip on left side of panel.

Use GE Termi-Matic s stem per Figure 45, or else build


stress cones with tape s follows:
1. Mark the cable at last 10 inches from the terminal
point.
2. Remove all shieldi g from the terminal end to this
point, leaving sufficie t ground strip to reach the nearest
ground connection.
3. Proceed to build st ess cones as prescribed by the
cable manufacturer. efer to Figure 43 and 44 for details.
4. Tie all of the grou
to ground bus (if ord
enclosing case. (See
"Wire and Cable Entr

d strips together and fasten them


red) or to a large stud on the
ote on grounding under item on
nee".)

If the foregoing reco mendations, along with the cable


manufacturer's reco mendations, are followed, the
cable terminations sh uld be satisfactory and reliable.
These instructions ap Iy to both rubber-covered and
varnished-cambric ins lated shielded cables.

Figure 47. High-voltage compartment showing low-voltage


wiring trough. Low-voltage cables entering from the
floor should be routed through this channel.

23

BI006008

CR194 Vacuum Limitamp 400 Ampere Control

Control wires coming up through the floor should be


run just behind the door hinges inside the channel (see
Figure 47) provided for this purpose and the wires
should be terminated on the terminal board in the lowvoltage compartment. Control wires entering from the
top of the enclosure should also be run in the channel
provided just behind the low-voltage door hinges and
terminated on the terminal block.

Reassembly
Mter all power and control-wire connections are made,
the Vacuum Limitamp controller must be reassembled
by following the sequence on pages 13 and 14 in reverse
order. If the controller is enclosed in a NEMA type 3
enclosure, refer to Figure 51 for assembly instructions.
Note: Do not attempt to operate without all barriers reassembled.

Replacing Contactor In Enclosure


When replacing the contactor in the enclosure, the
following procedures should be followed:

400-Ampere Contactor
1. Before installing the contactor, ensure that the cables
attached to the line side of the contactor are properly
tightened to 35 lb-ft.
Figure 48. Line connection bolts for 4OO-ampere contactor.

2. Remove the three bus bar bolts that were placed in


position during contactor removal and slide the
contactor onto its mounting base and ensure that the
retaining studs protrude through the front of the
contactor side bars. Also ensure that the armature
interlock is properly engaged in the interlock pawl on
the lower-right side wall. (See Figures 17 and 25)
Note: This mechanism transmits the contactor armature motion
to the mechanical interlock and it is vital that this mechanism
function properly.
3. Install and tighten the three load-side connection
bolts. See Figure 29.
Caution: Be absolutely certain that these bolts are properly installed and tightened. These are current carrying connections
and must be tight or damage will result. These connections
must be tightened to 16 lbjt. See Figure 29.
4. Install the mounting nuts on the retaining studs on
each side of the contactor and tighten.
5. Attach the line cables to the bottom of the fuse
assembly. Be absolutely certain that these connections
are properly tightened to 9 lb-ft. See Figure 48.
6. Manually operate the contactor armature and observe
that the mechanical interlock functions properly. If so,
the contactor is properly installed.
7. Reconnect the control umbilical cord to the
contactor and be sure the retaining wing nuts are tight.
Installation of the contactor is now complete.

24

Warning: Make certain that all barriers are replaced and bolted
tightly into position. Make sure the line and load side terminations of the contactor are tightened properly. Failure to perform
these operations could result in failure of the unit to operate
safely and reliably.

Mechanical Operation Check


All Power Off
With the main incoming power removed, operation of
the isolating switch should be checked. This may be
accomplished as follows:
1. With the high-voltage door open (and power disconnected) push in the door-operated release (A), Figure
49, with your left hand. This is not a normal function
and should only be used for initial equipment check out.
2. Push in the handle latch release (B), Figure 49, with
the thumb of your right hand and lift the handle (C) in
a rapid, positive motion from the OFF to the ON position. The door operated release (A) can now be
released. Near the top of the handle movement a sharp
snap should be heard and the isolator switch contacts
should be in the closed position. The contacts may be
viewed by looking through the window supplied in the
main fixed barrier. The contacts should be fully seated
on all three phases. The handle latch release (B),
Figure 49, should pop fully out at the top of the handle
travel (See Figure 57).

BI006008

CRI94 Vacuum Umitamp

Ampere Control

b. Loosen the line side cable bolts at the bottom of


the fuse assembly an save the hardware. Be sure
the cables are free 0 their mounts and that they
can be freely remov d. See Figure 27.
c. Remove the three 10 d side connection bolts in the

bottom of the conta tor. These bolts are accessed


through the openin s at the bottom of the
contactor from the font. A socket wrench with an
extension may be us d to remove these bolts. Save
this hardware for re se. See Figure 29.
Note: Do not loosen R. T. V. overed bolts.
d. There are two retain ng nuts at both sides on the
lower front of the co tactor. These nuts must be
removed. See arrow in Figure 29.

Grounding
All controller enclosures must be grounded. A stud is
welded to the lower back of the enclosure in the incoming-line compartment area for connection to the
grounding system. This connection must be made
before making any power connection.
If ground bus is ordered, the ground stud is connected
to the ground bus at the factory and the system ground
can be connected to the ground bus instead.
The control and instrumentation circuits are grounded
to the enclosure at the terminal board. This is normally
the only grounding point. It can be temporarily removed for test purposes; but it must be regrounded
before the control is returned to operation.

e. Slide the contactor ut of the mounting base and


lift it and the line si e cables out of the enclosure.
f. Replace the three b Its removed from the load side
connections in their holes and thread them in a
few turns. These bo ts will prevent reinstalling the
contactor until rem ved again. This serves as a
reminder that the b Its are there and need to be
reinstalled when the contactor is being replaced.

4. Prepare to remove the


barrier by removing the

orizontal compartment
bolts shown in Figure 30.

5. Remove the horizontal barrier, Figure 30. (If a


hinged low-voltage panel i used, swing it to the left and
out of the enclosure.)
6. Remove the horizontal bus barrier bolts as shown in
Figure 31, and then lift th barrier out of the enclosure.
The horizontal bus is the exposed as shown in Figure 32.
7. Detach the switch barri r with the viewing window by
removing the ten bolts, Fi ure 33. Pull the barrier out of
the enclosure.
8. Remove the front cove
barrier, Figure 34, (if in co
from the floor) or remove
(if cables are to be routed i

of the lower incoming line


ing cables are to be routed
the top incoming line barrier
to the enclosure from the top).

After the preceding steps ave been completed, all


power termination points nd bus connections are
accessible. See Figure 35.

14

Incoming Power Connections


Incoming power connections to the bus may be made in
anyone of the enclosures in a lineup. Space for one
500- MCM cable with stress cones per phase is available
in the standard 26-inch wide enclosure. A 34-inch wide
enclosure is also optionally available when larger cable
capacities are required. The 34-inch enclosure is
standard with synchronous controllers and 7200 volt
controllers. If shielded cable is used, refer to the
information on Page 23 of this manual.
In the one-high enclosure with horizontal power bus,
incoming power connections are made on the left end of
the bus bars. When the barriers are removed from the
enclosure, both ends of the power bus and the ground
bus are accessible from the inside of the enclosure. To
add additional units to a line-up of enclosures, the new
enclosure can be located in position and, with the bus
splices furnished with the equipment, the bus connections can be made to either side of the existing
equipment. Figures 32 and 35 show the accessibility of
both ends of the bus bars with the barriers removed and
the low-voltage panel swung out. The splices must be
bolted in place with the ~-inch hardware supplied with
the splice kit. Torque splice bolts to 35 lb.-ft.

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control


Installation

Placement of Enclosure

General

It is essential that the controller be securely fastened in


an upright position on a level surface to allow proper
functioning of the internal devices. While there are no
roll-out components, access will be improved if the
controller is located at floor level with plenty of room
allowed for doors to swing fully open as shown on the
drawings supplied with the equipment.

This section contains information on receiving and


handling, disassembly, power-cable termination, grounding, and reassembly to make the equipment ready for
operation.

Receiving
Vacuum Limitamp controllers are fabricated as rigid,
floor-mounted, self-supporting steel sections requiring
no floor sills. They are crated and shipped in an upright
position and, when received, should be kept upright.
Some components may be shipped separately, such as
top-mounted resistors or potential transformers. These
components are identified by catalog number coinciding
with that of the section on which they are to be
mounted.
Plastic film wrap or corrugated cardboard is normally
used for domestic crating with the steel enclosure
sections bolted to a wooden skid. See Figure 19. After
receiving, the packing may be removed and the equipment handled on the wooden skid. See Figure 20.

After the controller has been placed in position, the


floor mounting bolts may be installed and tightened.
The location of these bolts is shown on the outline
drawing furnished with each controller. These bolts are
Y2-inch bolts and are usually located in each corner of
the controller base.

Disassembly
After the equipment has been set in place where it is to
be permanently connected, some internal disassembly is
required to make the necessary external power-cable and
control-wire connections. Disassembly should be done
in a definite sequence by following Figure 23 through
Figure 34, and as described below:

Disassembly Sequence of Operation


Handling
It is always preferable to handle Limitamp controllers by
the lifting means provided. Figure 21 shows the recommended method of lifting a single section, while Figure
22 shows the recommended method of lifting a lineup.

Note that the lineup in figure 22 is suspended from an


equalizing bar. A lineup should be supported at as many
points as possible. If there is not enough headroom to
lift the panel by its lifting beam, then a trackjack can be
used. The controller can be raised by placing a track
jack under the shipping skid. Rollers can then be placed
under the skid for rolling the equipment to its final
location. The panel should then be raised by its lifting
beam, the shipping skid removed, and the panel set into
place.
The use of fork-lift trucks is not recommended, since the
forks may damage the enclosure or interior parts of the
equipment, and the equipment becomes very unstable
when lifted from the bottom. If no other method of
handling is available, the forks must go under the skid
bottom to avoid damaging the equipment, and the
assembly lifted only slightly to allow the skid to be slid
along a flat, level surface. However, the recommended
method is by crane as pictured.

Warning: Remove all power from the equipment before proceeding with disassembly.

1. Move the manual isolator handle to the OFF position.


Refer to the nameplate attached to the high-voltage door
near the handle. Figure 23-2 shows the method of first
depressing the pusher with one hand and moving the
handle with the other. Refer to page 27 and 29 for
normal and emergency door opening procedures.
2. Open both the top (low-voltage) and bottom (highvoltage) doors.

Contactor Removal
Normally it is not necessary to remove the contactor from
its mount in order to make external power-cable and
control-wire connections. If the contactor is not to be
removed proceed to Step 4. Otherwise, follow the steps
outlined below to remove the contactor from the controller.
3. Contactor removal.
a. Remove"the wing nuts holding the contactor
umbilical cord and connectors in place and save
the hardware. This hardware will be reused to
remount the connector when the contactor is
reinstalled. Unplug the connector and place the
bracket in the lower front channel to the left of the
contactor for safe keeping. See Figure 24.

13

BI006008

CR194 Vacuum Limitam4!-400_A_m_'P_eli_e_c_o_n_t"_ol

Figure 19. Vacuum Li itamp controller wrapped in


plastic film wr p ready for shipment.

Figure 21. Recommended method of lifting single panel.

Figure 20. Vacuum Limitam controller with outside packaging


material remove and read9 for handling.

Figure 22. Recommended method of lifting a Vacuum Limitamp


lineup. Note that the lineup is suspended from an equalizing bar.

12

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control


Power Fuses

Power Fuse Conversion Instructions

Bolted EJ-2 type current-limiting power fuses are supplied as standard with Vacuum Limitamp controllers.
These standard fuses are bolt-in type because the blown
fuse indicator and the trip bar that operates the antisingle phase contact block require precise alignment of
the striker pin at the top of the fuse with the operators.
Clip-in fuses are available as an option in 400 ampere to
cover requirements for EJ-I type fuses, but the "antisingle phase" indication/trip functions are not available
with clip fuses. Coordination information for EJ-2 type
fuses is available in GES-5000, and for EJ-I type fuses,
GES-5002. Interrupting ratings are shown on page 5 of
these instructions. Figure 18 shows the top of the bolted
power fuse assembly with the blown fuse indicators in
the normal position.

Bolt-in fuses used on Vacuum Limitamp and Air-break


Limitamp may be field converted from one to the other
by carefully following the instructions below.

SINGLE BARREL

CAT. NO.
55A212942P "A"

ICAUTIONl

CAT. NO.
218A4293P "A"

Starting Autotransfonners & Reactors


Reduced voltage controllers include a reactor or autotransformer designed for starting duty in accordance
with NEMA ICS2-214. The duty cycle generally furnished is for medium-duty applications which consist of
three 30-second starts spaced 30-seconds apart followed
by a one-hour rest. To prevent overheating and possible
damage when applied on more severe duty (heavy duty)
applications, special reactors or autotransformers must
be specified. Thermostats are mounted on the reactor
and transformer cores to offer protection against overheating. These thermostats must be manually reset if
tripped by high temperature.

DOUBLE BARREL

CAT. NO.
55A212942P "A"

CAT. NO.
218A4293P "A"

ICAUTIONI~

Y
Y

BY CAREFULLY FOLLOWING THESE INSTRUCTIONS, THE ABOVE FUSE VERSIONS MAY BE


FIELD CONVERTED FROM ONE TO THE
OTHER.

BY CAREFULLY FOLLOWING THESE INSTRUCTIONS, THE ABOVE FUSE VERSIONS MAY BE


FIELD CONVERTED FROM ONE TO THE
OTHER.

1. LOOSEN BOTTOM BOLT (Y) WHILE INSURING FUSE BARREL


DOES NOT ROTATE (SEE CAUTION).

1. LOOSEN AND REMOVE BOTH BOTTOM BOLTS (Y) WHILE IN


SURING FUSE BARREL DOES NOT ROTATE (SEE CAUTION).

2. ROTATE BOTTOM STRAP (X) 180 DEGREES.

2. ROTATE BOTTOM STRAP (X) 180 DEGREES.

3. RETIGHTEN BOTTOM BOLT (B) TO 23-31 FT/LBS WHILE ENSURING THAT FUSE BARREL DOES NOT TURN.

3. REINSTALL BOTTOM BOLTS (Y) AND SPECIAL SPRING


WASHER (BELLEVILLE). RED PAINTED STRIPE ON WASHER
TO FACE TOWARD BOLT HEAD.

CAUTION:DO NOT LOOSEN TOP BOLT OF


FUSE. THIS WILL DAMAGE INTERNAL
ELEMENTS OF FUSE.

4. TIGHTEN BOTTOM BOLTS (B) TO 23-31 FT/LBS WHILE INSUR


ING THAT FUSE BARREL DOES NOT TURN.

CAUTION: DO NOT LOOSEN TOP BOLT OF


FUSE. THIS WILL DAMAGE INTERNAL
ELEMENTS OF FUSE.

11

BI006008

CRI94 Vacuum Limitam


Warning: There is no emergency condition that can justify forcible operation of the manual isolator with the main contactor
closed. The isolator must be operated only with the contactor open.
All high-voltage doors are interlocked by mechanical
interference mechanism that lock high-voltage doors
closed until the disconnect switch is in the OPEN
position. This is done to prevent exposure to high-voltage.
In one-high controllers the bottom door covers the highvoltage compartment. Other high-voltage doors may be
full height to cover high-voltage parts located in auxiliary
sections. These devices may include reactors, autotransformers or control power transformers, etc.
Key interlocking is frequently used in lieu of mechanical
interference mechanisms to lock high-voltage doors
closed until power inside has been removed. Nonloadbreak switches are also key interlocked to prevent
operation under load. In all cases of key interlocking, it
is important to follow the operating sequence as described on the drawings furnished with the equipment.
On some one-high enclosure designs, a low-voltage
control panel mounted by hinges to the left side of the
enclosure serves as a barrier to isolate the high-voltage
control power transformer and fuses. An interference
latch, shown in Figure 54, prevents swinging this panel
out until the high-voltage door is opened, thus ensuring
that high-voltage power to the Control Power Transformer is disconnected.

Auxiliary Enclosures
Many sizes of enclosures are furnished in Vacuum
Limitamp control lineups for various purposes. Some
are tabulated below:
Wound rotor, secondary contactor and resistor
compartments
Bus transitions to switchgear
Bus transitions to transformers
Cable entrance compartments
Rectifier exciter compartments
Starting reactor or autotransformer
compartments
Relay and metering compartments
Instrument transformer compartments
Manual switch compartments
Refer to Figure 60 for details.

Dimensions
Figure 18. Blown fuse indic tor shown in the NORMAL position.

10

Vacuum Limitamp controllers are normally 30-inches


deep and gO-inches high. Width varies for one-high
controllers, induction motors, synchronous motors,
other special applications, or cable space requirements.
Refer to Figure 60 for typical outline dimensions.

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control

Figure 13. Disconnect switch shown with barrier in place.


Switch shown in CLOSED position.

Figure 15. View of quick-make quick-break operator.

Figure 14. View of handle assembly area showing


test power interlocks.

Figure 16. The operating handle for the disconnect may be


padlocked to prevent operation.

BI006008

CRI94 Vacuum Umitam

Vacuum Limitamp Contr I is supplied standard with


bolt-in type fuses. The fu e holders will accommodate
2400-volt through 7200-v lt fuses. The length of these
types of fuses vary and th lower fuse mount can be
adjusted to the proper Ie gth by unbolting the mount
from the back rail and re ounting it in the proper
location. For 7200-volt a plications, the fuses require a
slightly different lower m unting strap and the top fuse
mounting strap must be c anged. This requires that the
disconnect switch be disa sembled. See Figure 8.
The vacuum contactors s pplied with Vacuum Limitamp
Control are magnetically perated by a de coil fed by an
integral rectifier and tim d holding circuit. A base
mounted contactor timin module (CTM) applies full
voltage to the contactor c il for a time sufficient to fully
close the contactor. A se ies capacitor is then switched
in to hold the contactor c osed without overheating the
coil.

Manual Disconnect (Isolating Mechanism)


Vacuum Limitamp controllers, following the NEMA
definition, provide a means for manually isolating the
power circuit by operation of a disconnecting device.
The disconnecting mechanism consists of a quick-make
quick-break, non-load break disconnect switch (see
Figures 11 through 13) which is controlled by the
operating handle (see Figure 6). A fixed barrier (Figure
13), with a viewing window, is supplied to provide
isolation from the energized bus parts. There are no
moving shutters that require maintenance. The quickmake, quick-break, operating mechanism is shown in
Figure 15.
Load current must not be interrupted by the disconnect
switch. A mechanical interlock is provided to ensure
that the contactor is in the open position before the
operating handle can be actuated. Also, the contactor
cannot be operated while the operating handle is being
moved from one position to another.

Blown Fuse Indicator'


Blown fuse indication is a tivated by a trip bar located at
the rear of the top fuse hider. The blown fuse indicator requires bolt-in type f ses. When one or more of the
fuses blow, a small indica or moves upward from the top
center of the fuse to indi ate which fuse has blown. The
right end of the trip bar as a cam that operates an antisingle phase contact whic is wired to trip the controller
off-line to prevent single hasing of the connected load.
See Figure 10.

The mechanical isolator will accept up to four padlocks


to prevent operation. See Figure 16.

Mechanical Interlocking
Vacuum Limitamp equipment is designed so the highvoltage contactor performs all normal load current
interrupting. The current-limiting fuses generally
interrupt the fault currents.
Note: The quick-make quick-break manual isolator will not
interrupt any load or fault current..

A mechanical interference system is included with all


Vacuum Limitamp controllers (mechanical interlock),
which prevents opening of the manually operated
isolating contacts unless the high-voltage contactor itself
is demonstrated by magnet position to be already open.
This is to ensure that the contactor has opened the
power circuit and interrupted the current before the
disconnect switch may be operated. See Figure 17.
Warning: The manual isolator should never be forcibly
operated. Its mechanical interference interlock should be
defeated only by knowledgeable and qualified electrical maintenance personnel who have de-energized all power feeding the
controller.

Figure 12. View of the disc nnect switch in the OPEN position.
Barriers are emoved for clarity.

BI006008

CR794 Vacuum Limitamp 400 Ampere Control

Figure 8. High-voltage compartment showing fuse assembly.

Figure 10. Anti single-phase contact block - wiring removed for clarity.

Figure 9. View of various low-voltage components on swing panel.

Figure 11. View of disconnect switch in the CLOSED


position. Barriers are removed for clarity.

BI006008

CRI94 Vacuum Umitam 400 Ampere Control

PANEL
DATA
NAMEPLATE

Figure 6. Panel data nameplate.

Figure 5. 34-inch wide


ampere FVNR synchronous starter
high-voltage section sh wing the 400-ampere contactor.

Figure 7. The 800 and 400 ampere vacuum contactors.

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control


Interrupting Ratings At Utilization Voltage Shown
Maximum
Volts

Maximum
Continuous
Amperes (RMS)

2500

Three-phase Symmetrical
System MVA
Class E1
Unfused

Class E2
Fused

400

29

200

5000

400

50

400

7200

400

50

600

Basic Impulse Level (BIL)


The standard BIL rating of Vacuum Limitamp controllers is 60kV crest (design rating). This rating excludes
dry-type control transformers and starting reactors or
autotransformers.

Dielectric Test Voltage


2 1/4 x nameplate voltage plus 2000 volts.

High-voltage Vacuum Contactors


Figure 3. 26-inch wide 400-ampere FVNR starter.

Ratings
Refer to the panel data nameplate (see Figure 6) on
front of the enclosure for detailed ratings applicable to a
particular controller. Equipment basic ratings equal or
exceed NEMA ICS2-324 for Class E2 Controllers, and are
summarized below.

The vacuum contactors used in Vacuum Limitamp


controllers are available in two different ratings: 400
and 800 amperes. This publication covers only the 400
ampere rating. The contactors are similar in operation
but very different in size and rating. For this reason they
are not directly interchangeable mechanically. See
Figure 7.
The contactors are easily removable from the controller
assembly by removing a few bolts that hold the contactor
in position and by disconnecting the line and load power
connections. The auxiliary contacts and the coil terminals are connected by means of a removable connector
that is retained by two wing nuts. By removing these
wing nuts, the wiring harness is easily disconnected from
the contactor. Refer to the information beginning on
Page 13 of this publication that details the correct
method for contactor removal.

Approximate Maximum Horsepower,


Current & Voltage Ratings
2200-2400 Volts
Continuous Current
(RMS) (Amperes)

Induction
Motors

400 Max.

1600

4000-4800 Volts

Synchronous Motors
0.8PF
1600

I
I

1.0PF

Induction
Motors

2000

3450

7200 Volts

Synchronous Motors
0.8PF
3450

I
I

1.0PF

Induction
Motors

3725

4800

Synchronous Motors
0.8PF

1.0PF

4800

6000

Note: Above ratings apply to controllers in Nt"MA 1, vented


enclosures, at 4(f' C ambient.

BI006008

CRI94 Vacuum Limitam 400 Ampere Control

Description
Equipment Identific tionCR Number Designa .on
Basic type designation fo all Vacuum Limitamp Control
equipment is CR194 wit significant alpha-numeric
suffixes used to define ring, function, contactor type
and enclosure type.

_J
CR194

Starting and Speed Fun1tions


A
B
C
D
E
G
H

J N P Q -

Single-speed, full oltage


Single-speed, redu ed voltage reactor type
Single-speed, redu ed voltage autotransformer type
Single-speed, part winding start
Single-speed, redu ed voltage primary resistor
2 speed, 1 winding full voltage
2 speed, 1 winding reactor reduced voltage
2 speed, 1 winding autotransformer reduced voltage
2 speed, 2 winding full voltage
2 speed, 2 winding reactor reduced voltage
2 speed, 2 winding autotransformer reduced voltage

L.-

NEMATYPE
1 = NEMA E1 (Unfused)
2 = NEMA E2 (Fused)

Enclosure
A - 26" 1-HI
B - 34" 1-HI
System Voltage
7
8
2

2400 Volts
4200 Volts
7200 Volts
Other

Controlled Apparatus
Rotation and Braking
1
2
4
5
7

Non reversing/no braking


Reversing/non br king
Non reversing/dy amic braking
Reversing/dynami braking
Reversing/pluggin

General
The basic Vacuum Limit mp controller is a frontconnected assembly of c mponents and conductors for
motor starting, arranged for convenient access, in an
enclosure which allows s ace and facilities for cable
termination, plus safety i terlocking of doors and
isolator to prevent inadv rtent entrance to high-voltage
parts. No back access is equired. This equipment may
be rated up to 7.2 kV de ending on the contactor and
fuse ratings. Installation operation, and service should
be performed only by ex erienced personnel trained in
this class of equipment.

o
1

2
3
4

5
6

Synchronous Motor (brushless type)


Induction Motor
Synchronous Motor (ring type)
Wound Rotor Motor
Transformer Feeder
Capacitor Feeder
Other

In general, the unit enclosures are divided into highvoltage and low-voltage compartments, each with its own
separate door and with interior barriers between the two.
See Figures 3, 4, and 5. To open the high-voltage
compartment door, the power must be disconnected by a
sequence of manual operations which requires deenergizing the high-voltage contactor, operating the
isolating switch handle, and unlatching the door. Lowvoltage doors may be entered without disconnecting the
power; however, this should be done with extreme care
and caution
The upper compartment of one-high controllers may
contain a low-voltage panel, hinged on the left side,
which acts as a barrier to the high-voltage control power
transformer mounted on the upper rear cover.

BI006008

CRI94 Vacuum Limitamp 400 Ampere Control


Warning: Before any adjustments, servicing, parts replacement
or any other act is performed requiring physical contact with the
electrical working components or wiring of this equipment,
power must be removed from all sources and all attached
rotating equipment must have come to a complete stop.
User personnel must be completely familiar with the following
operating and maintenance instructions before attempting to
service this equipment.
Warning: The vacuum interrupter integrity test should be
performed before the high-voltage, vacuum contactor is energized
for the first time and each time the contactor is returned to
service after maintenance, adjustment, or repair.
Failure to perform this test may result in serious injury or death.

Introduction
Vacuum Limitamp controllers are designed to meet
NEMA ICS2-324 HAC General Purpose High-voltage Class
E Controllers" and UL 347 requirements, and may be
described as metal-enclosed high-interrupting capacity,
vacuum-contactor-type starter equipments with manual
isolation. Individual starters and controllers are designed for specific applications; the components and
functions being dictated by the Purchaser specifications
and needs. Controllers may be fused or unfused.

Figure 1. 26-inch wide one-high controller.

The essential control functions for all types of a-c motors


consist of starting, stopping, and overload protection.
Vacuum Limitamp controllers also include short-circuit
protection, but other functions are provided in each
controller as they are applicable to the type of motor
being controlled (such as synchronous and wound-rotor
motors). Also, special functions are provided in great
variety as may be required for particular applications.
These instructions were prepared as a guide to handling,
installation, operation and maintenance of all one-high,
400 Amp types of Vacuum Limitamp controllers. This
includes the 26-inch wide one-high and the 34-inch wide
one-high controller. Figure 1 shows a 26-inch wide
controller and Figure 2 shows a 34-inch wide synchronous controller.
The intent of these instructions is to give the Purchaser
the necessary general information to identify his controller as to type and function, to describe suggested
methods of installation, and to demonstrate some
techniques of operation and maintenance. The Purchaser should interpret these instructions for
applicability to his particular controller by referring to
the nameplate data on the controller and to the electrical diagrams supplied with the controller.
If the controller is for a synchronous motor, these
instructions should be used with GEH-5201. For applications questions refer to GET-6840. For details on
high-voltage contactor refer to GEH-5306.

Figure 2. 34-inch wide synchronous controller.

BI006008

CRI94 Vacuum Limita 11 400 Ampere Control


Table of Contents
Introduction

Description

Equipment Identification-CR Number Designation


General

Ratings

Basic Impulse Level (BIL)

Dielectric Test Voltage

High Voltage Vacuum Contactors

Blown Fuse Indicator


Manual Disconnect (Isolating Mechanism)

8
8

Mechanical Interlocking

Auxiliary Enclosures
Dimensions

10
10

Power Fuses
Power Fuse Conversion Instructions

11
11

Starting Autotransformers & Reactors

11

Installation

13

General
Receiving
Handling
Placement of Enclosure
Disassembly

13
13
13
13
13

Disassembly Sequence of Operation


Grounding
Incoming Power Connections
Motor Connections
Extra-width Enclosure
Power Cable Termination

13
14
14
19
20
20

Con trol Connections


Reassembly

23
24

Replacing Contactor In Enclosure

24

Mechanical Operation Check

24

Operation

27

General

27

Test-power Circuit
Preparation of Controller for Operation

27
27

Normal Operation

27

Door Opening Procedure

27

Inspection, Maintenance, & Servicing

.4

29

Vacuum Contactor

29

Isolating Mechanism and Mechanical In terlock

29

Checking Procedures, Mechanical Interlock & Manual Isolator

31

Vacuum Interrupter Integrity Test

31

Test Procedure

31

Preventive Maintenance Guide

32

BI006008

CR194 Vacuum
Limitamp Control

One-High Controllers with Stationary Mount


Vacuum Contactors
Caution: Product is not intended for nuclear use.

Utilization Voltage - 2.4 through 7.2 kVac


26-wide and 34-wide, One-High, 400 Amp
(For 48-wide, 800 Amp see GEH-5396)

BI006008

CRI93 Vacuum Limitamp" Contactors


SECTION 1 - In oduction

SECTION 2 - Description

Warning: Before any a


or any other act is perfo
electrical working comp
power supply must be di

'ustments, servicing, parts replacement


ed requiring physical contact with the
ents or wiring of this equipment, the
connected.

Principle of Operation

Warning: The vacuum


section 9) should be per
contactor is energized fo
contactor is returned to
or repair. Otherwise, th

interrupter integrity test (as described in


rmed before the high-voltage vacuum
the first time and each time the
ervice after maintenance, adjustment,
s test should be performed annually.

Failure to perform this t st may result in serious injury or death.

These contactors are magnetically operated by means of a


dc coil. Energization of this coil causes the contacts inside
the sealed vacuum interrupter to close and establish the
power circuit. When this coil is de-energized two armature
return springs force the moving armature to open the
vacuum interrupter contact tips. As these tips open, the
current in the power circuit is interrupted at the first
current zero. This extremely quick interruption reduces
the arc energy and results in low contact wear.

Construction
General
These instructions co
Contactors. These c
ment used in starting
lOOO-Volts to a maxi
feeders, and other hi

er vacuum Limitamp High-voltage


tactors are designed for equipac motors with line voltages from
um of nOD-Volts, transformer
h-voltage control equipment.

These contactors are esigned to provide long, troublefree service with only ~ minimal amount of maintenance.
These contactors can be identified by their catalog
number. An outline f the catalog number nomenclature is shown in Tabl 1.
Table 1. Vacuum co tactor catalog number system.
BASIC NUMBER: CR 193
1. CURRENT
RATING:

123456

A~'

200A, 3.6KV
400A, 7.2KV
BOOA, 5.0KV

B
C
2. COIL VOLTAGE:

OO!
11

=
NO COIL
=110/115
VDC OR
RECTIFIED AC

3. LATCH
MECHANISM:

LO = NO LATCH
L1 = LATCH ELECTRICAL
CLOSE AND OPEN
L2
LATCH ELECTRICAL
CLOSE AND OPEN
AND MANUAL OPEN

4. NORMALLY OPEN 00 = 0 N.O. CONTACTS


(N.O.) AUXIL05 = 5 N.O. CONTACTS
IARY CONTACTS 10 = 10 N.O. CONTACTS
15 = 15 N.O. CONTACTS
SEE NOTE
20 = 20 N.O. CONTACTS
5. NORMALLY
CLOSED (N.C.)
AUXILIARY
CONTACTS
SEE NOTE
6. LATE OPENING
NORMALLY
CLOSED
(L.O.N.C.)
AUXILIARY
CONTACTS
SEE NOTE

00
05
10
15
20

=
=
=
=
=

0 N.O. CONTACTS
5 N.C. CONTACTS
10 N.C. CONTACTS
15 N.C. CONTACTS
20 N.C. CONTACTS

o L.O.N.C. CONTACTS
1
2
3
4
5

L.O.N.C.
L.O.N.C.
L.O.N.C.
L.O.N.C.
L.O.N.C.

CONTACTS
CONTACTS
CONTACTS
CONTACTS
CONTACTS

Note: Sum ofNO., NG. nd lateapeningnormally cwsed (L.ONG.)


interwcks cannot exceed 2 . Interlock bwck assembly has 5 contacts/
assembly. Maximum of ur (4) block assemblies per contactor can
be provided. Other combi ations ofNO., N. G., L. o.N. G. are
possible. Change argu
ts to meet arrangement required.

The main components of these contactors are as follows:


a one-piece, molded-glass, polyester case; a molded-glass,
polyester moving armature; three vacuum interrupters; a
coil and magnet; and a molded-glass, polyester terminal
support bar.
These contactors can be fitted with up to twenty auxiliary
contacts in any combination of normally open and
normally closed. These contacts are housed in a clear,
plastic housing for easy contact inspection.
Vacuum limitamp Contactors are built with metric hardware,
so that the contactor line can be used throughout the world.

SECTION 3 - Installation
General
All Vacuum Limitamp Contactors are suqjected to thorough
inspection and testing prior to packaging for shipment.
Observe the following precautions before applying
power to a contactor for the first time.
1. Remove all packing materials that were used to
protect the contactor in transit.
2. Carefully inspect all parts of the contactor for damage.
3. Remove any protective grease or oil which may be on
the magnet pole faces, as the grease could collect dust
and dirt, thus causing a sticking of the ~agnet.
4. Ensure that all parts of the contactor are clean.
Accumulations of dust and dirt on high-voltage equipment can cause failures.
5. Manually operate the moving armature of the
contactor to see that all parts operate freely.
6. Operate the contactor electrically under no load
conditions by applying rated coil voltage to the coil terminals. Note that these contactors use dc operated coils. When
the contactor has completely closed, the voltage applied to
the coil must be reduced to approximately 25 percent of the
rated voltage to prevent over-heating of the coil windings.
7. Perform a check on each vacuum interrupter as described
in Section 9 entitled "Vacuum Interrupter Integrity Test."
3

BI006008

CRI93 Vacuum Limitamp'" Contactors

SECTION 4 - Maintenance

Warning: Disconnect the contactorfrom the power supply before


making any inspections or adjustments as specified in sections 4
through 10.

General
Vacuum Limitamp Contactors will provide long troublefree service if given the benefit of inspection,
preventative maintenance, and periodic cleaning. The
frequency of the inspection periods will depend upon
the operating conditions for the contactor.
Table 2 below lists the adjustment tools and gages that
are required to perform the inspection and adjustments
as described in the following sections. See Figure 1.

Caution: Do not deviate from the instructions outlined. Do not


force movement of the armature. OVeJctravel of the contacts
beyond the limits specified could cause damage to the vacuum
interrupter bellows. Do not twist the movable terminal of the
interrupter. Rotational twisting can cause permanent damage
to the interrupter bellows. Exercise care when replacing interrupters to prevent damage which can reduce the life of the
equipment, and cause serious injury or death due to current
leakage in the interrupter.

Table 2. Contactor Gages and Adjustment Tools


TOOL DESCRIPTION

CR193B

CR193C

Contact Wear Gage

55A212185GI

55A212185GI

Interrupter Adjustment Wrench

55B532539PI

55B532548PI

Armature Setting Gage

55B532540PI

55B532547PI

Contactor Closing ToolsCD

55A212118G2

55A212118G2

Interlock Set Gage

55A212152PI

55A212152PI

CD Quantity of two required.

Contactor gages and adjustment tools are available from


the factory. Prices for the gages and tools are in GE
Apparatus Handbook, Section 2072, page 4.

Inspection
During routine inspections check for the following
items.
1. Loose screws, nuts, and bolts.
2. Accumulation of dust or foreign material such as coal
dust, cement dust, or lamp black. These materials must
be periodically removed from the contactor if inspection
shows any accumulation.
The outside surfaces of the vacuum interrupters must be
wiped clean, as dust collects moisture which can cause a
voltage breakdown around the outside of the interrupter.
3. Check the magnet and coil air gap setting. Refer to
Section 5 "Coil Adjustment and Replacement".
4. Check each of the vacuum interrupters for contact
wear. Refer to Section 6 "Contact Wear Check and
Interrupter Reset".
5. Check auxiliary interlock adjustment and contact
wear. Refer to Section 8 "Auxiliary Interlock Adjustment
and Replacement".
6. Perform a check on each vacuum interrupter as
outlined in Section 9 "Vacuum Interrupter Integrity
Test".
7. Check the contactor latch mechanism if applicable.
Refer to Section 10 "Latch Mechanism".
f

Figure 1. Tools for inspection and adjustment.

BI006008

CR193 Vacuum
GE . , , , Contactors
Lim/tamp

BI006008

CRI93 Vacuum Limitamp,. Contactors

Table of Contents
Section 1 - Introduction
General
Section 2 - Description

3
3

Principle of Operation

Construction

Section 3 - Installation
General
Section 4 - Maintenance

3
3
4

General

Inspection

Section 5 - Coil Adjustment and Replacement


Procedure for all Contactor Sizes
Section 6 - Contact Wear Check and Interrupter Reset
CR193B and CR193C Contactor Procedure
Section 7 - Interrupter Replacement

5
6

6
7

CR193B and CR193C Contactor Procedure

Section 8 - Auxiliary Interlock Adjustment & Replacement

Procedure for all Contactor Sizes


Section 9- Vacuum Interrupter Integrity Test
General
Section 10 - Latch Mechanism

9
10
10
11

General

11

CR193B and CR193C Contactor Acljustment Procedure

11

BI006008

CR_'_93_Vi_ac_u_u_m_L_im_'_"ta_m....:.p_'_C_o_n_ta_c_to_TS

_ _ _ _ _ _I

SECTION 5 - C9il Adjustment and Replacement


Procedure for

alll Contactor Sizes.

1. If the contactor as no latch proceed directly to Step


2. If the contactor i fitted with a latch, disconnect the
unlatch coil control ires and remove the two (2) latch
mounting screws an lift the latch mechanism from the
contactor.
2. If the contactor c il requires replacement due to
overheating or othe damage follow Steps 3 through 11.
If the coil does not eed replacement follow Steps 9
through 11.

7. Close contactor manually using the contactor closing


tools. See Item A, Figure 6. Ensure that the pole faces
of the coil mate with the moving armature.
8. Tighten the three (3) coil mounting screws fully.
Open contactor by removing closing tools.
9. With the contactor in the open position check the
magnet and coil air gap using the armature setting gage.
Insert the gage fully between the armature and the coil
pole faces. The gage should be a close sliding fit. See
Figure 4. If adjustment is necessary follow Steps 10 and
11. If adjustment is not required then no other checks
of the coil are necessary. Proceed directly to step 11.

5. Lift coil assembly out of contactor. See Figure 3.

10. Remove the two (2) barrel nuts at top of push-off


spring rods (See Figure 4, Item C) and adjust the two (2)
plastic stop nuts until the close sliding fit is obtained at
the gage. Reassemble the two (2) barrel nuts and
tighten them against the plastic stop nuts.

6. Position the new oil into the contactor and start the
three (3) mounting crews. Do not fully tighten these
screws at this time.

11. If the contactor is fitted with a latch mechanism,


reassemble the latch and adjust as discussed in Section
10 "Latch Mechanism".

3. Disconnect coil t rminal wires. See Figure 2.


4. Remove the thre
Figure 2.

(3) coil mounting screws. See

Figure 2. Coil t rminal wires and mounting screws.

Figure 3. Removal of coil assembly.

BI006008

CRI93 Vacuum Limitamp ~ Contactors

SECTION 5 - Coil Adjustment and Replacement

CR193B (400-Ampere) and CR193C


(BOO-Ampere) Contactor Procedure
1. Close the contactor using the contactor closing tools
(Item A, Figure 6). Do not overtighten. A single sheet
of ordinary paper inserted between the armature and
closing coil may be used as a helpful feeler gage to
determine when the armature has just closed against the
face of the coil poles.
2. Check for contact wear by inserting the "RESET" end
of the contact wear gage between the locknuts and the
spacer sleeve as shown in Figure 6. If the "RESET" end
of the gage CANNOT be inserted then the interrupter
needs to be reset. Follow Steps 3 through 7. If reset is
not required go to Step 7. Each interrupter should be
checked and reset as required.
3. Loosen the two (2) clamp block screws (Item D,
Figure 7) until the interrupter alignment ball is free to
rotate.
4. Using the interrupter adjustment wrench turn the
alignment ball to raise the interrupter until the "INI
TIAL" end of the gage can be inserted as shown in
Figure 6.

Figure 4. Insertion of armature setting gage.

SECTION 6 - Contact Wear Check and


Interrupter Reset

5. Retighten the two (2) clamp block screws (8 lb-ft.) to


lock the alignment ball in place. Mter the clamp block
screws are tightened check to see that the fit at the wear
gage is tight; if not re-adjust the interrupter position as
described in Step 4.
6. Adjacent to the interrupter is an interrupter reset
indicator label. This label indicates the number of times
each interrupter has been reset. Remove the appropriate portion of the peel-off label. See Figure 5. If the
interrupter has previously been reset two (2) times then
the indicator label will show blue and red marking in the
areas where the peel-off portions of the label have been
removed during previous resets. If this is the case the
interrupter must be replaced. Refer to Section 7 "Interrupter Replacement".
7. Remove the contact wear gage and the contactor
closing tools.

Figure 5. Appropriate removal of peel-off label.

BI006008

CR193 Vacuum Limitamp'" Contactors


SECTION 7 - Interrupter Replacement
CR193B (400-Ampere) and CR193C
(800-Ampere) Contactor Procedure
The procedures below describe the steps required to
replace a single interrupter. Repeat steps for each
interrupter that requires replacement.
1. Remove the two (2) nuts and the spacer sleeve from
the top of the interrupter driver stem. Items A and B,
Figure 9.
2. Remove the six (6) screws which attach the flexible
braid assemblies to the terminal support bar. Item C,
Figure 10.
3. Remove the four (4) screws that attach the terminal
support bar to the contact box. Item D, Figure 10. Lift
the terminal support bar out of the contact box.
4. Remove the two (2) clamp block screws and the
clamp block from the bottom of the interrupter assembly. Items E and F, Figure 10.
5. Withdraw the interrupter assembly downwards from
the contactor. See Figure 11.
6. Remove the alignment ball, contact pressure spring,
and guide bearing (Items G, H, and I, Figure 12) from
the interrupter. Assemble parts on new interrupter
assembly.
7. Insert new interrupter assembly into the contactor.
Make sure that the brass guide bearing on the interrupter is fully-seated in the spherical bearing on the
contactor moving armature.
8. Reassemble the spacer sleeve and one nut to the top
of the interrupter driver stem. With the contactor in the
open position adjust the nut on the driver stern until the
top of the driver stem is level with the top of the bearing
support. See Figure 8. Assemble the second nut to the
driver stern and lock it against the first nut.

DRIVER STEM

ADJUST NUTS
UNTIL DRIVER STEM
IS AT THIS LEVEL

Figure 7. Loo ening the clamp block screws.

BEARING
SUPPORT

Figure 8. Interrupter reassembly.

BI006008

CR193 Vacuum Limitamp," Contactors


SECTION 7 - Interrupter Replacement
9. Manually close the contactor using the contactor
closing tools. Do not overtighten. A single sheet of
ordinary paper inserted between the armature and
closing coil may be used as a helpful feeler gage to
determine when the armature has just closed against the
face of the coil poles.
10. Reassemble the clamp block and the clamp block
screws over the alignment ball. Make sure the alignment
ball is fully seated in the clamp block. Do not fully
tighten the clamp block screws at this time.
11. Using the interrupter adjustment wrench to turn the
alignment ball, raise or lower the interrupter until the
"INITIAL" end of the contact wear gage can be inserted
between the spacer sleeve and the nuts on the driver
stem. See Figure 6.

Figure 9. Removal of the nuts and spacer sleeve from


interrupter driver stem.

Figure 11. Downward removal of interrupter assembly.

Figure 10. Removal of screws attaching the flexible braid


assemblies with the terminal support bar.

BI006008

CR193 Vacuum Limitamp" Contactors


12. Tighten the two
lock the alignment
screws are tightene
gage is tight; if not
discussed in Step 11

(2) clamp block screws (8 lb-ft.) to


all in place. Mter the clamp block
check to see that the fit at the wear
-adjust the interrupter position as

13. Remove the old interrupter reset indicator label that


is adjacent to the in errupter and apply new label
supplied. See Figur 5.

SECTION 8 - Auxiliary Interlock Adjustment


and Replacement
Procedure for All Contactor Sizes
The procedures below describe the steps required to
replace an interlock block assembly. Interlock blocks
should be replaced when the following conditions exist:
The contacts are badly pitted or burned.

14. Reassemble the erminal support bar to the contact


box and attach each of the flexible braid assemblies to
the support bar.
15. Remove the co tact wear gage and contactor closing
tools.

The contact tips are worn to a point where


the silver facing on the tips has worn by 0.02
inches.
NOTE: Tarnish on the silver facings does not have to be
removed because the tarnish breaks down into products
that are conductive when power is applied.
1. Tag all the wires that connect to the interlock terminals and then remove. See Figure 13.
2. Remove the nut from top of interlock driver stem on
the top side of the armature molding (or extension
arm). Item A, Figure 13.

Figure 12. Interru ter alignment ball, contact pressure


sp ng and guide bearing.

Figure 13. Replacement of interlock block assembly.

BI006008

CRI93 Vacuum Limitamp ~ Contactors

SECTION 8

SECTION 9 - Vacuum Interrupter Integrity Test

3. Remove the two (2) interlock mounting screws and


remove the interlock from the contactor. Item B, Figure
13. Remove any extension rods, nuts, and washers that
might be connected to the interlock and assemble these
parts to the new interlock assembly.

Caution: X-Ray emissions may be produced if an abnormally


high voltage is applied across the open contacts of a vacuum interrupter. Do not apply a voltage that is higher than the values
recommended in the test instructions.

4. Assemble the new interlock assembly to the contactor


using its two (2) mounting screws. Install the nut on the
top of the interlock driver stem but do not tighten at this
time.
5. Insert the interlock set gage into the bottom of the
interlock as shown in Figure 14.
5. Adjust the nuts at the armature molding (extension
arm) until the moving contact carrier inside the interlock block just touches the top of the interlock set gage.
See Figure 14.
7. Tighten the nuts on both the top and bottom sides of
the armature molding (or extension arm). Make sure
that the interlock clevis and contact carrier are not
twisted as the nuts are tightened.
8. Reattach all wire to their appropriate terminal.

General
This test determines the internal dielectric condition
and vacuum integrity of the vacuum interrupters. Prior
to performing this test the outside of the vacuum
interrupters should be wiped clean of any contaminants
with a non-linting cloth or industrial type wiper. During
this test each vacuum interrupter should be checked
individually.
Warning: The vacuum interrupter integrity test should be performed before the high voltage vacuum contactor is energized for
the first time, and each time it is returned to service after maintenance, adjustment, or repair. Otherwise, this test should be
performed annually.
Caution should be exercised during this test since high-voltage
testing is potentially hazardous.
Failure to perform the vacuum interrupter integrity test may
cause serious injury or death.
High-potential test instruments can be purchased to perform the
vacuum interrupter integrity test. The following is a recommended test instrument:
Hipotronics Model 7BT50A
Use of a DC Hipot is not recommended because results
may indicate a problem with a good interrupter. If you
wish to use a DC Hipot, set at 28kV, but if interrupter
fails, confirm failed interrupter using above AC Hipot.
Warning: Caution should be exercised during this test since
high-voltage testing is potentially hazardous.
Note: Before performing vacuum integrity test, confirm that
both the armature gap setting (Section 5) and contact wear adjustment (Section 6) are proper.
1. With the contactor in the open position connect the
test leads to the contactor power terminals as shown in
Figure 15. Apply 20-kV rms, 50-Hertz power for 400
ampere and 800 ampere contactors, and hold for a
minimum of five seconds.
2. Reverse the leads and repeat the test.

Figure 14. New interlock adjustment.

10

3. If no breakdown occurs the interrupter is in an


acceptable condition. If a breakdown occurs, the
interrupter should be replaced. Refer to Section 7
"Interrupter Replacement".

~
1

BI006008

CRI93 Vacuum Limitamp" Contactors


I

Note: No attempt ShOUfje made to try to compare the condition of one vacuum int
pter with another nor to correlate the
condition of any interr ter to low values ofDC leakage current.
There is no significant orrelation.
4. After the HIGH P
from the interrupter
rupters should be dis
remove any residual

TENTIAL VOLTAGE is removed


the metal end caps of the interharged with a grounding rod to
lectrical charge.

CR193B (400-Ampere) and CR193C


(800-Ampere) Contactor Adjustment Procedure
I. Steps 2 through 4 describe the steps necessary to mount
the latch mechanism to the contactor. If the latch mechanism is already assembled on the contactor, proceed
directly to Step 5 for adjustment procedure for the latch.
2. Mount the latch mechanism to the contactor using the
two (2) latch-mounting screws supplied. The latch mounts
directly to the center mounting post of the contactor coil.
The latch-mounting plate is provided with a clearance hole
for the center-mounting screw on the contactor coil.
3. Assemble the catch (see Figure 16) to the contactor
moving armature using one each 0.010", 0.030" and
0.060" shims and the hardware provided.
4. Connect the control wires to the unlatch coil terminal block on the side of the latch mechanism support
bracket (see Figure 16).

Figure 15. T sting the vacuum interrupter.

SECTION 10 - L tch Mechanism


General
The mechanicallatc mechanisms that are used on
Vacuum Limitamp C ntactors are mounted directly to
the contactors.

The purpose of the I tch is to hold the contactor closed


without the need for continuous coil power. The
contactor can be clo d (latched) by energizing the
main contactor closi g coil. Once the contactor is
latched the power to the main closing coil should be
removed to prevent oil overheating. To open (unlatch)
the contactor, power is applied to the unlatch coil on the
latch mechanism. 0 ce the contactor is open the power
to the unlatch coil should be removed to prevent coil
overheating.

5. Close the contactor electrically and allow to latch


closed. Note that both the main closing coil and the
unlatch coil have to be deenergized after operation to
prevent coil overheating. With main coil deenergized,
measure gap between centerline of contactor moving
armature and the main coil pole faces. Desired range
for this separation between pole faces is 0.009" to 0.013".
If outside this range, manually unlatch contactor, then
add or remove shims as required to meet desired range
(see Figure 16) and repeat measurement.
6. With contactor still latched closed, energize main
coil. Set nut and release knob (see Figure 16) so that
dimension "X" is equal to 0.060" +/- 0.005".
Deenergized main coil.
7. Manually operate the latch by pulling the release
knob. The latch mechanism should move freely and the
contactor should move to the fully open position.
8. Electrically operate the latch and unlatch coils to
insure that these operate properly.

CONTACTOR

"'OYING

ARIolATU~[

:~-------------------------I----

The latch mechanis can also be unlatched manually by


operating the manu release mechanism if a contactor
with the "L2" latch 0 tion is specified.

i
:
t
I

J.--~] ~~;t;_:*~J~~~~~

TER"NAL~ l

BLOCK

I
I

Figure 16. Cross-sectional view of CR193B and CR193C latch.

11

BI006008

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the
matter should be referred to the GE Company.

GE Electrical Distribution & Control


General Electric Company
Po. Box 489,6807 Industrial Dr, Mebane. NC 27302
GEH-5306A 0694 PSA

7994 General Electric Company

BI006008

Book #2
Vendor Publications

Control
-

Table of Contents -

DC Co tactorlC2800Y108 .. ,

GEH-751E

Gener I Purpose Contactors

GEH-1496F

Magn ic Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. GEH-1941 C


DC Co tactor IC2800Y100
Manua Magnetic Disconnect Switch IC2801

, . . . . .. GEH-3057B
GEH-3095

CR194 Vacuum Limitamp Control Controllers with Contactor


C ntrol Module

,.. GEH-5305A

CR193 Vacuum Limitamp Contactors . . . . . . . . . . . . .. GEH-5306A


LODT AK IV Protective Relay Module
& W Drawout Limitamp Contactors

GEH-5600
,.. GEF-8016A

uty DC Contactor DS303 . . . . . . . . . . . . . . . .. GEK-83756A


Itage Disconnect, Lower Frame Brown Boveri. 2.1.3-1 C
Limita p Equipment Outline ... ",.,............ 327B9530

2243-I.M61

BI006008

INSTRUCTIONS

BI006008

GEH-3095

MANUAL-MAGNETIC DISCONNECT SWITCH


IC2801

Before any adjustme


or any other act is per
with the electrical w
this equipment the
DISCONNECTED.

ts, servicing, parts replacement


armed requiring physical contact
rking components or wiring of
OWER SUPPLY MUST BE

The 1C2801 manu I-magnetic disconnect switch


Fig. 1) isusedasasafetydisconnect on cranes:
and other applicatio s requiring a similar mainline disconnect. A 0- or three-pole contactor is
used, depending upon whether the switch is used on
a-c or d-c applicati ns. D-c power switches will
have d-c magnets.
-c power switches will have
either a-c magnets r rectified d-c magnets, depending upon contacto rating.
(see

On crane applicati ns, the manual handle is moved


to the 0:\ position hen the operator enters the
crane area. This h ndle movement closes electrical interlocks so t at the contactor can be energized from the or; pu hbutton located in the operatorI scab.
Before leaving the operator's cab, the operator
pushes the OFF push utton which deenergizes the
contactor and remov s power to the crane. The
operator should alwa s move the manual handle to
the OFF position whe leaving the crane area. This
prevents energizing the contactor from the ON
pushbutton in the cab, until the manual handle is returned to the ON posit on.
Under normal oper ting conditions, the operator
can open the switch b pushing the OFF pushbutton.
However, should a fau t condition weld the contactor
tips, the switch is so d signed that moving the manual
handle to the OFF po ition will break the weld and
mechanically open the switch.
Provision for the 0 erator to padlock the switch
in the OFF position is standard on all switches.

These instructions do not

Fig. 7.

IC2807 manual-magnetic disconnect switch

INSTALLATION
On crane applications, it is recommended that
the switch be mounted on the footwalk leading to the
crane, and located in such a manner that the operator will have easy access to the switch handle.
Before applying power to the switch, operate all
moving parts manually to make sure they move
freely. Also, see that the magnet faces are clean
and free from any foreign material which may have
resulted from shipment.
Remove the fastenings which hold the arc chutes
and armature during shipment. Never operate the
switch with power on the contacts unless all arc
chutes are in place.

lJrporf to cover ell details or variations in equipment nor to provide for every possible contingency to be met in connection

with instollotion, operation r maintenonce. Shovld fvrther information be desired or shovld particvlar problems arise which are not covered sufficientty
for the pvrchasers purpose the matter should be referred to the General Electric Company.

GENERAL

ELECTRIC

BI006008

BI006008

GEH-3095

Manual-

agnetic Disconnect Switch

TABLE I
CONT CT GAP AND TIP WIPE AND CONTACT RATING
CONTACT RATING (AMPERES)
Contacts

Maximum

Minimum

7 /64"
5/64"

5/64"
3/64"

Tip Gap
Tip Wipe

Not Op rated

CONTACT TIP GAP AND WIPE


Interrupt
Numbe
D-c Inductive*
A-c**
of
Interlo ks Carry Make 125V 250V 600V 110V 220V 440V 600V
6

One Se

10

60

1.8

0.5

0.2

Two Se s
in Seri s

10

60

4.0

1.2

0.35

1.5

1.2

*Non- nductive d-c interrupting rating is 1. 5 times inductive.


**Capa Ie of interrupting inrush current of 60amperes at 110 volts,
30 a peres at 220 volts, 15 amperes at 440 volts, and 12 amat 600 volts a limited number of times.

ADJUS

ENT

The manual-magnetic witch is basically a mechanical/electrical form f a magnetic contactor.


This instruction covers ad ustments other than contactor adjustments, since eparate instructions are
provided for the contact rs. Table II on page 5
lists instruction book an renewal parts bulletin
references for the vario s contactors by ampere
ratings.

ating arm at "A" in the direction needed. Do not


adjust the spacer nut and jam nut. The operating
arm plungers must clear the interlock plungers by
l/8-inch minimum (see Fig. 4).

INTERLOCKS

INCH

HANDLE INTERLOCK

The operation of the


checked as follows:

ARM

andle interlock may be

1. The interlock plun er and operating-arm


plunger must line up ve tically and horizontally
within 1/16 inch (see Fig. ).
2. To correct the hori
the shaft bolts that mount
the operator in the direct
the vertical alignment, 10
thread-cutting screw that
its bracket, and rotate the
desired (see Fig. 3).

ontal alignment, loosen


the ope rator, and slide
on desired. To correct
sen, by one thread, the
ounts the interlock on
interlock up or down as

3. Misalignment or an lar position of the operating arm should be correc ed by twisting the oper2

INTERLOCKS

Le
-r-

1/16 INCH

Fig. 2.

INTERLOCK
PLUNGER

Alignment of interlock plungers and


operating arm plungers

BI006008

BI006008

Manual-Magnetic Disconnect Switch


ACTUATING ARM

GEH-3095

--e==:::J::;.:.-...

1/8 INCH WIDE


CLEARANCE
~---SPRING SEAT

SHA
OPERATING ARM

SPRING
SPACER
TERMINAL
SCREW ---O"l---~

POINT " A"


SPACER NUT
PANEL

MOVABLE
CONTACT
I

SPRING - - - - + - I - - ; ' " " i


f==~~=j
HOUSING

STATIONARY
CONTACT
PLUNGER
N.O. TIP GAP

Fig. 3.

Interlock and operating arm assembly, handle


in ON positi n

4.
in the OFF position, the interlocks should hav a minimum tip gap of 5/64inch and a minimum ip wipe of 3/64-inch measured
at locations shown in Figs. 5 and 6.
5. With the handl
interlock plungers s
travel and there sh
tween the spacer n
Fig. 3).

in the ON position (Fig. 7) the


ould be at the bottom of their
uld be a gap of l/16-inch bet and the operating arm (see

Fig. 5.

Interlock block with normally open contacts


in OFF position of handle

6. If it becomes necessary to change the interlock contacts from normally open to normally closed
or vice versa, reassemble the contacts, springs,
and other internal parts as shown in Figs. 5, 6, and
7. The spring ends must not project into the holes
or keys or otherwise interfere with the movement
of the operating arm.

SPRING SPACER

ASSEMBLE TIP SUPPORT


FLATLY AGAINST HOUSING
BY RUNNING SCREW TO
SEAT POSITION BEFORE
MAKING ANY CONNECTIONS
TIP WIPE

Fig. 6.
INTERLOCK

Interlock block with normally closed contacts


in OFF position of handle
SPRING
SPACER

INTERLOCK
PLUNGER
~=:::::2:::t--r N.O. TIP WIPE
N.C. TIP GAP---I--+---,

JAM_.rT'"''M
NUT

Fig. 4.

Adjustment of operating arm plungers and


interlock plun ers

Fig. 7. Interlock block with one set of normally open


contacts and one set of normally closed contacts
with handle in ON position

BI006008

BI006008

GEH-3095

Manual-Magnetic Disconnect Switch


LINKAGE
SLOT
1/64 INCH TO

ARMATURE
PIN

~21NCH

ARMATURE
PIN

Fig. 9.

Fig. 8.

7. Contact
cuits require
center spring i
circuit- rear ran
supplied with al

~21NCH

Handle in ON posifion
and confacfor closed

ocks with two normally closed cirspring spacer to assure that the
properly in place. Because of the
ement feature, a spring spacer is
two-circuit contact blocks.

8. When cir uits are rearranged to obtain one


normally open nd one normally closed circuit, the
contacts should be assembled as shown in Fig. 7.

Fig. 10. Handle in ON position


and confacfor opened

DOOR INTERLOCK (IF USED)


With the interlock plunger at the bottom of its
travel, there must be a 1/64-inch gap between the
top of the plunger and the top of the interlock mounting bracket.
The cabinet door will rest against the top of the
interlock mounting bracket. The flanged door activates the plunger, when the door is closed (see Fig.
11) .

MECHANICAL LI KAGE (ALL FORMS)


CURRENT-LIMIT FUSE SWITCH (IF USED)

1. With the

andle in OFF position and the contactor in the fu y opened position, adjust the turnbuckle to allow 1/64-inch to 1/32-inch clearance
between the arm ture pin and the top ofthe slot (see
Fig. 8).
2. With the andle in ON position and the contactor in the fu ly closed position, adjust the turnbuckle to allow 1/32-inch minimum travel of the
armature pin
the top of the slot (see Fig. 9).
3. With the h ndle in ON position and the contactor in the fully pen position, adjust the turnbuckle
to allow 1/32-i ch minimum clearance between the
armature pin an the bottom ofthe slot (see Fig. 10).

1. With a 11/32-inch spacer shim "A", and interlock operator "B", the interlock plunger must
have l/32-inch to 1/16-inch approximate travel remaining (see Fig. 12). The shaft must be moved all
the way up vertically in its pivot holes for this adjustment.
3. With the parts and shim located per Item 1
above, the contacts of the interlock must have 5/32inch minimum tip gap.
3. With the insulation operator of the interlock
laying on the ferrule of one fuse, maximum clearance to the ferrules of the other fuses should not
exceed 1/64 inch.

INTERLOCK OPERATOR

"s" SHAFT SUPPORT


MOUNTING
SLOTS

INTERLOCK
MOUNTING
BRACKET

SHA FT "S"
r-r:::~~=:;::r-;~:-J
(ROUND OR
f-----...... RECTANGULAR)

I
I
I

SPACER
SHIM "A"

INTERLOCK BLOCK
NOTE- FOR ADJ STMENT OF
INTERLOCK NOT PERATED,
SEE TABLE

Fig. 11.

80ff m view of door inferlock assembly

FERRULE AND SHIM SPACER


EDGES MUST SE IN LINE
FERRULE GUIDE (WITH
EJECTOR PIN)

Fig. 12.

Currenf-limif fuse switch assembly

BI006008

BI006008

Manual-Magnetic Disconnect Switch


4. Shaft "S" should have 1/32- to 3/64-inch end
play in its supports. The shaft can be located at
any point in its pi~ot holes for this adjustment.
5. The interlo k should be located approximately
horizontal.

REr~EWAL PARTS
When ordering renewal parts, address the nearest General Elect ic Sales Office, specify the quantity required, an< give the catalog numbers or describe the requirE d parts in detail. Table II of this
instruction book ists renewal parts bulletins for
all switch rating~. For any other parts not described by this bu letin, give the complete nameplate
information from he switch. This nameplate is located on the contartor's insulated base.

GEH-3095

TABLE 1/
INSTRUCTIONS AND RENEWAL PARTS
REFERENCES
Rating in Amperes
(2- or 3-Pole Switches)
100
150
300
600
900
1500
2500

Instructions
GEH-3069
GEH-3069
GEH-306~

GEH-3058
GEH-3058
GEH-751
GEH-751

Renewal
Parts
GEF-4036A
GEF-4036A
GEF-4036A
GEF-4308
GEF-4307
GEF-4324
GEF-4325

BI006008

BI006008

BI006008

INDUSTRY

CONTROL

GENERAL

fJ ELECTRIC

SALEM.

-68

(2M)

DEPARTMENT

VA.

24153

GEH751E

INSTRUCTIONS

BI006008

D-C CONTACTORS
IC2800-1178, 1180, Y107, Y108,
Y127, AND Y128

Before any adju


ment or any oth
cal contact with
or wiring of thi
MUST BE DISC

The devices
primarily NE
tactors having
single pole, no
have two opera
parallel connect

tments, servzcmg, parts replaceact is performed requiring physihe electrical workin{! components
equipment the POWER SUPPLY
NNECTED.

Forms of the IC2800-1178 and 1180 contactors


are available that can be mechanically tied together
for use in applications where two pole and three
pole contactors are required. Refer to the General
Electric Company for details.

DESCRIPTION

A maximum of eight electrical interlock circuits can be supplied on any form of contactor.

described in this instruction are


Sizes 8 and 9, d-c mill type cond-c operating magnet. They are
mally open, shunt contactors and
ing coils that can be series or
d.

All contactor have one set of a~cing tips with


a series blowou coil. The IC2800-1178, Y107 and
Y127 contactor have one set of main currentcarrying tips a d the IC2800-1180, Y108 and Y128
contactors have two parallel sets of main currentcarrying tips. he arcing tips and the blowout coil
are shorted out w en the main tips are fully sealed in.
The IC2800-1
connected devic
by the user in
All forms must

78 and 1180 are unmounted, backs that are assembled and adjusted
ccordance with these instructions.
e mounted on an insulated panel.

The IC2800Yl
connected contac
sulated base of
mounted on eithe
are completely
the factory.

7 and Y108 are unit mounted, frontors. They are assembled on an inthe dead-back type which can be
steel or insulated panel. All forms
ssembled, adjusted and tested at

The IC2800Yl 7 and Y128 are unit mounted forms


of the IC2800-1 78 and 1180. Special forms are
available where the lower connection terminal is
front-connected. All forms are completely assembled, adjust
and tested at the factory. They
are assembled n an insulated base which can be
mounted on eith r a steel or insulated panel having
a cutout that all ws the back connection terminals
to protrude thro gh the panel.
Special forms of these contactors are available
for use in a-c
plications. These forms can be
identified by the aminated pole pieces in the blowout coil assembl

Contactors can be mechanically interlocked when


necessary.
Direct current must be supplied to the coils for
both a-c and d-c applications. A rectifier can be
used with a-c control power if d-c is not available.
Refer to Section labeled "Coil Connections."
MOUNTING BOLT - - -_ _

ARC
CHUTE

MAIN
STATIONARY
CONTACT

ARMATURE

ARCING
HORN

ARMATURE
PIVOT
BASE PAD

COIL
MOUNTING
BOLTS

Fig. 1.

BASE

IC2BOO- YlOB d-c contactor


with IC2B20-E401 relay.

These instructions d not purport to cover 01/ details or variations in equipment nor to provide for every possible contmgency to be met in connection
with installation, oper tion or maintenance. Should further information he desired or should particular problems arise which ore not covered sufficiently
for the purchaser's pu oses, the matter should be referred to the General Electric Company.

BI006008

GEH-75JE, IC2800-JJ78, -"80, YJ07, YJ08, YJ27, and Yi28 D-c Contactors

TABLE 1
CONTACTOR

CONTACTOR RATINGS

NEMA

8 HR. OPEN AMPERE RATING

Size

D-c

1178, Y107, Y127

1500

1180, Y108, Y127

2500

IC2800

600 VOLTS

Bus
Connectionst

A-c 60 A
Hertz

One 1/4-in. X 4-in.


Copper Bus
Three 1/4-in. X 4-in.
Copper Bus

1350

Bus
Connectionst
Two 1/4-in. X 4-in.
Copper Bus
Three 1/4-in. X 6-in.
Copper Bus

2500

t These are minimum requirements; the equivalent cable may be substituted.


AFar special a-c forms.

+;=14"
1''1'-

.t...::..

r
I"

-$
I

~-

12"

4 1 ....

-II"

-$

I"

I"

9iE;

9j6

For
bus
con7

'- e-I

-2

1*

1
11

-~

: ti I

Five

I'J!16 in

I .2 I

I ~
1.=
I
I

I
I
I
I
L __ J

$I

-',,,
2
~--l

For
bus
conn?

diam
mtg
0les

7"

lis

II

I,.

I
I
15"
4 16 I .JC
(.) I
I .2 I
I ... I
1 ~
c 1
I
I
I
I
L __ J

-~

mtg
holes
3 11
10il

101-

\-,--$-

t ~:"~m.

5-

-+_2

-r
j

$For
bus

conn~

I- 3"+-52."_
a

....._--'
FRONT VIEW

f-3"+-4f-

IC2800-YI08. unit-mounted.

IC2800-YI07, unit-mounted.
Depth (including bose): 11- 7/16 inches
Weight: 170 pounds
... Location of

specially

adjusted

Depth (including bose): 12 -15/16 inches


Weight: 190 pounds

interlocks used to insert holding resistor.

Fig. 2.

-1';;-

7"

'"

Five

"'.diamin

Typical outline and drilling plans.

BI006008

IC2800-U78, -U80; YJ07, YJ08, YJ27, and YJ28 D-c Contactors, GEH-75JE
NSTALLATION
When mountOng these contactors, the proper
NEMA standard or electrical clearance and creepage to conductin parts and to ground must be maintained. Note tha the complete magnet structure is
at the same pote tial as the power tips.
To obtain th maximum interruption rating of
the interlocksm ntedawayfrom the magnet-frame,
an air gap of 3/ -inch must be maintained between
the open face of the interlocks and any conducting
part or ground.
Maintain the following mInImUm arcing clearances for inter uption at maximum current and
voltage:
a. Above co tactor arc chutes to other devices 8 inches.
b. Above co tactor arc chutes to enclosure not
lined wit insulation - 8 inches.
c. In front f contactor arc chutes to enclosure
not lined with insulation - 8 inches.
d. Above c ntactor arc chutes to enclosure
lined wit insulation - 4 inches.
e. In front f contactor arc chutes to enclosure
lined wit insulation - 4 inches.
CAUTION:

EVER OPERATE THE CONTACTOR W TH POWER ON THE CONTACTS UNL SS THE ARC CHUTES ARE
IN PLACE.

MOUNTED CON ACTORS

UNMOUNTED CONTACTORS
Contactors IC2800-1178 and IC2800-1180 are for
assembly directly on the purchaser's insulation
base or panel of 1-1/2 to 2-inch thickness. Drill
the base in accordance with the outline and drilling
plan supplied with the contactor. For estimating
purposes, Fig. 3 gives typical outline and drilling
plans which include mounting electrical interlocks.
Then, referring to Figs. 4 and 5, assemble and adjust the contactor as follows:
1. Mount the arcing stationary tip and blowout
assembly (See Fig. 4). The stationary contact tip
must be assembled as shown in Fig. 4A. The tip
must be flush with surface "J" and line "K".

2. Mount the main tip assembly, spacer and


shims per Fig. 4B. Initially, the spacer contained
a tapped hole into which a stud was inserted. Now,
the stud is brazed to the spacer to make the stud
and spacer a single unit.
3. Connect the blowout coil and the main stationary-tip assembly with the connection strap. The
spacer with the tapped hole must be under the main
stationary-tip assembly where this connection is
made. The connection strap does not rest against
the panel. The bracket for the connection strap
must be as shown in Fig. 5.
4. Mount the frame and armature assembly as
a unit (Fig. 4) although they are two separate pieces.
Make sure that the armature fits into its pivot (Fig.
5), the base pads are in place on both sides of the
panel, and the grounding strap is in place on the
back of the panel.

Mount the IC 800Y107 and IC2800Y108 in a vertical position - ee Fig. 1. Attach them to the main
base or panel th mounting bolts in accordance with
the outline and drilling plan supplied with the contactor.

5. Operate the armature and measure the wipe


of the ma:in contacts. (See Fig. 6 - measurement C).
The term "wipe" as used here may be more
familiar as "allowance for erosion of tip material." Accurate measurements cannot be made
by operating the armature manually. The coils
should be energized to check adjustments.

For estimati g purposes, Fig. 2 gives typical


outline and dri ling plans showing the upper bus
connections to t e right and horizontal to the base.
When mounting the contactor on a non- insulating
base, make sur that the sheet of insulation supplied with the ontactor is in place between the
contactor base nd the main base or panel.

Install shims, as needed, between the spacer


assembly and the panel, as shown in Fig.4B, to obtain a wipe of 19/64-inch ~ 1/32-inch. Loosen hardware at the back of the panel to allow adding of
the shims.

Mount the I 2800Y127 and IC2800Y128 as described above. When mounting the contactor on a
non-insulating b se or panel, the cutout that allows
the back-connec ion terminals to protrude through
the panel must
of such size that the proper NEMA
standard for ele trical clearance and creepage between the panel nd all live parts on the back of the
contactor base i maintained.

Manually operate the armature until the arc ing


tips just touch, then a gap of at least 3/16-inch
must exist between the main tips. (See Fig. 6measurement F). Vary wipe C within its limits to
maintain this dimension.
With these dimensions held, a minimum allowable main tip gap of 3/4-inch must be maintained.
(See Fig. 6 - measurement D).
3

BI006008

GEH-751E, IC2800-1178, -1l80, Y107, Y108, Y127, and Y128 D",c Contactors

TIP GAP AND WIPE DATA

TABLE 4

LATCH ASSEMBLY ADJUSTMENTS


Wipe t

Gap

Contactor

Arc Tip "A"


(Inches)

Main Tip
Arc Tip
Touching
(Inches)

Arc Tip "B"


(Inches)

3/4
Minimum

Less
Blowout
Assembly
With
Blowout
Assembly

Main Tip
(Inches)

1-1/8
Minimum

3/4
Minimum

3/16
Minimum

t Electrical wipe is measured with the contactor


coils energized, and the armature not held-in
with the latches.

1 +1/16

2" -1/32

Electrical
Main Tip "C"
(Inches)

Mechanical
Main Tip ''D''
(Inches)

19/64 1/32

17/64 1/64

19/64 1/32

17/64
Minimum

Mechanical wipe is measured with control voltage


removed from the contactor coils, and the armature held-in with the latches.

NOTE: It is recommended that the electrical wipe be set at approximately 21/64


inch (upper limit of "G" tolerance); then,
release control voltage so that the contactor
is held-in by the latches. Adjust latches
for a mechanical wipe of 17/64-inch minimum. This allows for 1/16-inch clearance between the needle bearings and the
latches, which is a sufficient clearance for
the latches to drop into position when the
contactor is operated manually or electrically. See Fig. 12a.

b) To equalize the mechanical wipe, adjust


the latch block and tighten jam nuts.
All latches must be supporting the armature(s) in the latched position. To
check this, carefully do the follOlting:
(1) In the latched position, raise each
latch block slightly and observe the
needle bearing.
(2) If the needle bearing moves, then the
latch is holding.
(3) Repeat for each latching block.
(4)Adjust if necessary.

a) When two contactors are mechanically


joined together, it is imperative that
the dimensions listed in this section be
as close to equal as possible for each
of the contactors. If the adjustments
are not equal for each contactor, mechanical binding will result.

c)

WIzen the handle for manual operation


is used, the motion of the handle must
be free and veryfluid. If ajerky motion
is experienced, re-adjust per Figs. 4a
and 4b.

The solenoid mounted on each latched contactor


should be set for a gap of approximately 1/4 to 3/8
inch. Adjust by moving the solenoid bracket up or
down as required.

0.06
(REF. ONLY)
Fig. 12A.

10

~
oo~
M'I~
C0
Fig. 128.

1. When two contactors are joined together, the


solenoid coils will be connected in series. Again,
the gap of the plunger must be the same for each
solenoid.

2. With
solenoid in
the needle
O. OlD-inch

the contactor(s) de-energized and the


the energized position, the gap between
bearing and the latch block should be
minimum. See Fig. 12b.

BI006008

IC2800-1l78, -1l80, Y107, Y108, Y127, and Y128 D-c Contactors, GEH-751E
After ALL djustments have been made, it is desirable to dril and pin the operating arms to the
shaft to preve t their changing relationships.

ELE TRICAL INTERLOCKS


CONTACT TIP

AP AND WIPE

Not
Operated

Maximum

Minimum

7/64 in.
5/64 in.

5/64 in.
3/64 in.

Tip Gap
Tip Wipe

Contact Rating (A
Number
of
Carry
Interlocks

Interrupt
1ake

D-c Inductive'
A-c"
125V 250V 600V 110V 220V 440V 600V

One Set

10

60

1.8

0.5

0.2

Two Sets
in Series

10

60

4.0

1.2

0.35

1.5

When circuits are rearranged to obtain one


normally open and one normally closed circuit, reassemble parts as shown in Fig. 14 to assure proper
electrical creepage between the two circuits.
The interlock should be positioned on its bracket
so that with the contactor in its energized position,
the interlock plunger, Fig. 14, should not bottom,
and with the contactor in its de-energized position,
there should be some clearance (C) between the interlock plunger and the interlock operating arm,
Fig. 14.
_ Tip gaps and wipes, when new, should be as
shown in the following table. Replace contact tips
when wipe reaches one half of minimum specified.

1.2

OVERCURRENT PROTECTION
GENERAL

'Non-inductive d
"Capable of inte
volts, 30 amper
12 amperes at 6

c interrupting rating is 1.5 times inductive.


rupting inrush current of 60 amperes at 110
s at 220 volts, 15 amperes at 440 volts, and
0 volts a limited number of times.

These inter
ternal parts w
ferent contact
sary the parts
with Figs. 13,

ocks use a contact block having inich can be rearranged to give difrrangements. Should this be neceshould be reassembled in accordance
4, or 15.

Spring ends must not protrude into holes (A),


slots (B), or k ys (C), which serve as guides for
operating arm ee Fig. 15).
Contact bloc s with circuits as shown in Fig. 15
require a spri g spacer (D) to assure that the
center spring i properly in place. Because of the
circuit rearran ement feature, a spring spacer is
supplied with I other two circuit contact blocks,
as shown in Fig. 13 and 14.

SPRING
SPACER

If a-c overcurrent protection is reqUired for a-c


applications of the IC2800-1178, -1180, - Y107, or
-Y108 contactors, an instantaneous overload relay,
mounted separately, may be used.
If d-c overcurrent protection is reqUired, an
IC2820-E400 or IC2820-E401 instantaneous overload relay may be used. These d-c overload relays
are designed specifically for use on the IC28201178, -1180, -Y107, and -Y108 contactors. Ordinarily, these relays are mounted on the contactors
and shipped as part of the contactor. This method
is recommended because it eliminates the pOSSlbili ty of relay adjustments being changed in mounting.

IC2820-1091 relays which were used in the past


for d-c overcurrent protection are obsolete with
renewal parts only available. They have different
electrical interlocks from those of the IC2820-E400

ACTUATING LEVER ----e=~-~CLEARANCE

A - - -.... '0-----,,1

- - - SPRING SEAT

KEY - - - - "

SPRING
SPACER
TERMINAL
TIP

GAP~=t=+==:l

r---rE~~~B1~~-MOVABLE
L
CONTACT

Lp::j:::FF=- TIP WIPE


SPRING

-~T~;iJ~J

HOUSING

Fig. 13. Interlock lock with one set


of norma Iy open contacts
and one set of normally
closed c ntacts in deposition of con-

STATIONARY
CONTACT

~:::t-=~-->."c-- OPERATING
TIP GAP

ARM

Fig. 14. Interlock. block with normally closed contacts in


energized position of contactor

ASSEMBLE TIP
SUPPORT FLATLY
AGAINST HOUSING
BY RUNNING SCREW
TO SEAT POSITION
BEFORE MAKING ANy
CONNECTIONS

Fig. 15. Interlock block with normally open contacts in


energized position of contactor

11

BI006008

GEH-751E, IC2800-ll78, -ll80, Y107, Y108, Y127, and Y128 D...c Contactors

MOUNTING (SEE FIGS. 16 AND 171

INTERLOCK
TRIPPING ARM

These instructions apply only to d-c overcurrent


relays shipped as separate items for mounting on
contactors in the field. These d-c overcurrent relays are completely adjusted and calibrated before
shipment. Each relay will require some disassembly
and reassembly in the field, which can change the
calibration. However, if care is taken in mounting,
the adjustments and calibration should not change.
Under no circumstances should the relay air gaps
(Gaps A and B, Fig. 19) be changed from the original factory setting. Before mounting the relay,
first measure and record the air gap dimensions,
which should not differ widely from those given in
Table 5. Then measure the gaps again after mounting, to make sure they are exactly the same as
originally measured.

POLE

ASSEMBLY
SCREWS (M)
ARMATURE PIVOT
ADJUSTING KNOB
LOCK SCREW
ADJUSTING
KNOB

Fig. 76.

IC2820-E400 overload relay {electrical


interlock not shown}.

and -E401 relays. However, minimum tip gap and


tip replacement instructions of the latter will apply. The IC2820-1091 relays have a slightly different operating mechanism with different air gaps.
(Gaps A and B, Fig. 19.) As on the IC2820-E400
and -E401 relays, the air gaps should not be changed
from the original factory setting. Operating mechanism adjustments on the IC2820-1091 relay, when
aUowed by parts, are the same as for other d-c
overcurrent relays.

The IC2820-E400 mounts with a U-bracket around


the lower connection-bus assembly of the IC28001178 or -1180 contactor. It attaches to the bus assembly on the back of the base, but the relay proper
is on the front of the base and all adjustments are
made from the front.
The IC2820-E400 requires additional drilling
(see panel layout, Fig. 18). Before attempting to
mount this relay, first completely mount and adjust
the IC2800-1178 or IC2800-1180 contactor. Remove

"

J!.

ctOF LOWER
CONTACT UNIT

OIA

16 'L\

r,'- 4(?~t.(.

L~

"

21
13"

i6

~180IA.~
;t

-+--:

i$--:
--4t---"
19
L=t"f=i~~~$-'::.J i6
I

_I

I
:,

TIT;

+(2REO'O)

7"

7"

I-'~T'~~

-1

3!{'

116
//.:] I ~- 5"---I-3{
L 205(NO.50RILL)
".d:>.l
(2 REO'O)
~k OIA . ..rv
IC2820-E400
IC2800-YI07A OR-Y IOBA CONT ACTOR

--Tl-- 1
5

II"

16

I
LATCH ADJUSTMENT

LATCH

I------....i
FOR BUS CONNECTION

Fig. J 7.

12

IC2820E40J overload relay (electrical


interlock not shown).

Fig. 78. Panel layout (front view).

BI006008

..

IC2800-lJ78 j ":1180, Yl07, Yl08, Y127, and YI28 D-c Contadors, GEH-751E

LATCH
ADJUSTMENT

POLE
PIECES

THIS LINE
APPROX.LEVEL

LATCH
LATCH

THIS PORTION OF
ARMATURE STOP
MUST BE STRAIGHT

PIVOT

ARMATURE
STOP

Fig. 19. Relay adjustments.

the assembly sc ews (M) which faste~ the U-bracket


to the pole piec s. Mount the U-bracket to the bus
assembly on th back of the base. Pick up the remainder of the elay as a unit and, from the front
of the panel, in ert the pole pieces through the two
1-1/8 inch dia eter holes located just below the
lower shunt con ection.
Take care n t to apply too much force, or to
twist the pole p eces, because this will upset the
relay adjustmen s and calibration. Replace the assembly screws M) and mount the electrical interlock with its b acket in the 0.205-inch diameter
holes. The elect ical-interlock bracket has slotted
mounting holes 0 permit adjustment. If care has
been taken in m unting this relay, the only necessary adjustment are to the electrical interlock.
However, check the other adjustments as given in
the following sec ion.
The IC2820-E 01 is completely front connected
and is mounted y sliding it over the lower connection-bus asse bly of the IC2800-Y10? or IC2800Y108 contactors. No additional drilling is required.
Mount the electr cal interlock in the holes already
provided in the contactor sub-base. Adjust the
electrical interl ck and check the other adjustments as given n the sections on Adjustments and
Testing in this in truction.

ADJUSTMENTS IS E FIG. 191


1. The air ga s (Gap A and Gap B of Fig. 19.
between the arm ture and the pole pieces, with the
armature droppe out against the armature stop,
are given in Tab e 5. These air gaps are given as
reference inform tion only as air gaps must be

identically maintained as originally shipped. (See


mounting instructions above.) These gaps are obtained by bending the armature stop and adjusting
the pivot within the limits of its screw clearance
holes. Take care when bending the armature stop
that the portion alongside which the latch moves is
not deformed. Make sure that the latch operates
freely after the armature gaps are set. Also, take
care that the armature stop remains approximately
level where the armature hits it.
2. The armature fits through two windows which
position it and also act as guides for it. Both windows
are in parts having slotted-screw clearance holes
to permit any adjustment necessary in aligning the
windows with respect to the armature.
The support nearest the pivot should be approximately centered. Then, center the armature stop
about the armature. The result should leave an
equal amount of clearance on either side of the
armature to the sides of the windows. Points "a"
of Fig. 19).
Check that the amount of side-to-side movement of the armature, which is permitted by the
window nearest the pivot, is not enough to allow the
armature to rest against, or rUb, either side of the
window in the armature stop. Rubbing of armature
against armature stop window will cause erratic
trips.
3. The latch and latch adjustment (see Fig. 19)
must be set to meet the following requirements:
a. The latch must drop into place easily when
the armature is operat~f.l slowly by hand.

13

BI006008

GEH-751E, IC2800-1178, -lI80, Y107, Y108, Y127, and Yl28

o..c Contactors

b. With the armature dropped back against the


latch, Gap A (see Fig. 19) should be 1/16
inch or less.

sary to readjust the spring pressure by means of


the adjusting knob if the relay did not trip at the
desired current.

4. The electrical interlock must be adjusted to


meet the following requirements:

After setting the tripping point at the desired


current, lock the adjusting knob with the lock-screw
provided for that purpose.

a. With the armature resting against the armature stop, there should be a minimum clearance of 3/32 inch between the interlock
tripping arm and the interlock plunger (see
Fig. 13).
b. With the armature dropped back against the
latch, the gap on the normally closed contacts should be approximately 1/16 inch
(see Fig. 15).
TESTING

Using the adjusting knob, set the pointer at the


value of current desired. If possible, raise the current slowly until the relay trips. It may be neces-

TABLE 5

NEMA
Size

For Use On
Contactor
IC2800-

Also, the armature should not step pick-up.


That is, it must not pick up where it hits the interlock plunger and then hesitates before it operates
the interlock. If this happens, readjust the electrical
interlock and the latch adjustment to permit the
armature to travel further before engaging the interlock plunger.

RENEWAL PARTS
Order replacement coils by the catalog number
stamped on the existing coil. Request the renewal
parts bulletin for identification of other parts or
identify by description and complete contactor IC
number.

IC2820-E400, -E401 OVERLOAD RELAYS


Air Gap in
Inches*

Calibration
Range
in Amperes

IC2820
Form

Gap A

Gap B

Automatic

800-2500
1500-6000

E400E3
E400E2

13/64
9/32

3/64
1/16

Hand

800-2500
1500-6000

E400F3
E400F2

13/64
9/32

3/64
1/16

Automatic

800-2500
1500-6000

E401A3
E401A2

5/16
7/16

3/64
1/16

Hand

800-2500
1500-6000

E40lB3
E40lB2

5/16
7/16

3/64
1/16

Automatic

800-2500
1500-6000

E400C3
E400C2

13/64
9/32

3/64
1/16

Hand

800-2500
1500-6000

E400D3
E400D2

13/64
9/32

3/64
1/16

Automatic

800-2500
1500-6000

E401C3
E401C2

5/16
7/16

3/64
1/16

Hand

800-2500
1500-6000

E401D3
E401D2

5/16
7/16

3/64
1/16

Type of
Reset

1178
8
Y107

1180

9
Y108

* These

dimensions are given for reference only. Do not change the relay air gaps as the nameplate
calibration is with the gaps set and any change will affect the calibration.
'

14

...

t'
I

(
f

BI006008

"

BI006008
1

GENERAL ELECTRIC COMPANY

DRIVE SYSTEMS DEPARTMENT


SALEM VA. 24153
l

GENERAL. ELECTRIC

:..

INSTRUCTIONS

GEH1496

BI006008

IC2800 DC GENERAL-PURPOSE
CONTACTORS
1C2800-1607 TO 1609 INCLUSIVE

IC2800-1617 TO 1619 INCLUSIVE

IC2800-1612 TO 1614 INCLUSIVE

IC2800-1620 TO 1623 INCLUSIVE

IC2800-1625 AND IC2800-1627

Bef01'e any adj tments, se1'vicing, pm'ts replacement or any otJ l' act is pe110rmed requi1'ing plzysical contact wit the elect1'ical w01'king components
or wiring of th equipment, the POWER SUPPLY
MUST BE DIS ON."'TECTED.

GENERAL
These conta tors are self-contained front-connected units an are suitable for mounting on either
steel or insula' on bases (see Fig. 1, 2, 4, 6, 7, 8,
and 9). They e available either with or without
blowouts. A ch ice of blowout ratings are available
for each contactor covered in this instruction. For
those contacto s having more than one pole it is

WING NUT

possible to have a mixture of blowout ratings which


might include one or more poles with no blowout.
The pole arrangements and ratings are given in
Table 1.
lC2800-1627 contactors have both a pickup and a
drop-out coil which have a common connection point.
These coils are in the same coil assembly and on
the same core. Both are intermittent coils requiring power removal with a separate device after the
contactor has operated. The contactor is held in
the picked-up position by a permanent magnet.

TABLE I

RETAINER

DEVICE
IC28001607
1608
1609
1612
1613
1614
1617
1618
1619
1620
1621
1622
1623
1625
1627

MAIN POLES
MAX. CONTIl\"UOUS
POLE
POWER RATING
AMPERES
ARRANGEMENT
1 N.O.
1 N.C.
1 N.O. - 1 N.C.
2 N.O.
2 N.O. - 1 N.C.
2 N.O. - 2 N.C.
1 N.O.
1 N.C.
1 N.O. - 1 N.C.
1 N.C.
1 N.O.
2 N.O.
2 N.O. - 1 N.C.
1 N.O. - 1 N.C.
2 N.O. - 1 N.C.

25
25
25
50
50
50
50
50
50
100
100
100
100
100
100

*The ratings given are the maximum continuous amperes for one pole and are correct only for a no
blowout pole or a pole with the highest blowout
available with the contactor.

Fig. 1.

Th.n instructi n, do not purporl 10 cor olf deloi" or .arialioM in equipment nor Ie pro.ide 'or e"rr pouible conlingency 10 be mel in colllleClion
wilh in"olfolion. ope,olion 0' maintenonce. Should furlhe, in'ormolion be de,;red 0' .hould porlicular problem, ari'e which are nol co.ered .uHicienl/y
Ihe purcho. " purpo"'. Ihe maHe, .hould be re'erred 10 lhe General Eleelric Compony.

'0'

GENERAL _

ELECTRIC

BI006008

GEH-1496, 1C2800 Dc General-purpose Confocfors

"

()
"-.-

Fig. 4. IC28001617 contactor, with universal interlock

MAINTENANCE
ARC CHUTES
Fig. 2. IC28001609 contoctor

AC OPERATION
If the contactor is to be energized from the output of a metallic rectifier, a full-wave bridge circuit of the type illustrated in Fig. 3 is often used.
Whenever this type of connection is used, the ac
side only should be opened or both the ac and dc
sides should be opened simultaneously. The dc circuit only should not be opened unless the rectifier is
rated for full ac voltage, which 'Would be evident
from the omission of the resistor on the ac side.
Contactors IC2800-1612, 1613, 1614, 1620, 1621,
1622, 1623, 1625 and 1627 may be de-energized by
opening both ac and dc circuits simultaneously, to
prevent time delay dropout and to prolong rectifier
life.

l-_--_AC

All poles which have blowouts also have arc


chutes. These arc chutes in all cases are clamped
in position in one of three ways. Either a retainer
and wing nut, a wire spring clamp or a wrap-around
coil spring are used. To remove the arc chute
simply loosen the wing nut and swing the retainer
aside (Fig. 1) or unhook the wire spring clamp
(Fig. 7). On devices with the coil spring, the spring
will stretch enough to allow the arc chute to be removed without unhooking the spring (Fig. 8). Take
care to replace the arc chute in the same manner
in which it was removed. The retainer or spring
clamp should go back into place without any undue
forcing. If you encounter trouble recheck to make
sure the arc chute is in place properly.
ARCING HORNS

Clearance to contacts must be as shown in Fig.


SUPPLY - - - - - I

SA.
COILS

Fig. 3. Full.wove rectifier for ac operation


2

To replace coils, remove the molded block which


supports the front connections and lift the entire
armature assembly off the frame. For the IC28001608, 1609. 1618, and 1619 it is not necessary to
unhook the armature spring. For these contactors,
remove the two screws (H in Fig. 2) and lift the
armature assembly off as a unit.

:~

BI006008

IC2800 Dc General-purpose Contaetors, GEH-1496

7"
,"
-TO'6
2

fi
ff

tlRCING
HORN

3"

is

Fig. 5. Normall open contacts (left) and normally closed


contacts (right)

For all the


struction, you
(Fig. 6). Do n
the spring ten
set in a partie

Fig. 5A. Arcing horn clearance to contocts

quire resetting the springpressure, after reassembling the contactor.

ther contactors covered by this inustfirstunhook the armature spring


t loosen or otherwise tamper with
ion adjustments, because they are
ar manner and therefore would re-

After removing the armature assembly, take out


the coil retainer which fits into a groove in the

TABLE II
(Power Contacts)
APPROX. DIMENSIONS IN INCHES (See Fig. 5)
DEVICE

1607

CONT ACT WIPE


AW"
B
MINI UM
MINIMUM
1/ 6

BW"

17/64

1/32

1608

CONTACT GAP
D
C
MINIMUM MINIMUM

1/16

1/32

1/16

1/32

1/ 6

1/32

1612

1/ 6

1/32

1613

1/ 6

1/32

1/16

1/32

1/4

1614

1/ 6

1/32

1/16

1/32

1/4

1617

1/ 6

1/32

1619

1/32

1620

15/64

17/64

3/32

1/16

3-3/4

2-3/4

3-3/4

7-1/2

14

5/16

7-1/2

14

5/16

7-1/2

14

7-1/2

14
5

5
18-1/2

7
23

5/16

1/32
1/32

2-3/4
8

11/32
1/16

3-1/2

11/32

1/16
1/ 6

3-1/2
17/64

1609

1618

APPROX. CONTACT
FORCE IN OUNCES
N.O. CONTACTS N.C. CONTACTS
INITIAL FINAL INITIAL FINAL
Ff IN
Fi IN
Ff in
Fi IN
FIG. 5
FIG. 5 FIG. 5 FIG. 5

1/4

5/16

7-1/2

14

13/32

1/16

13/32

18-1/2

23

1622

3/ 2
3/ 2

1/16

13/32

18-1/2

23

1623

3/ 2

1/16

3/32

1/16

13/32

13/32

18-1/2

23

18-1/2

23

1625

3/ 2

1/16

3/32

1/16

13/32

13/32

18-1/2

23

18-1/2

23

1627

3/ 2

1/16

3/32

1/16

13/32

13/32

18-1/2

23

18-1/2

23

1621

"When A meas res AW or B measures BW, it is recommended that the contacts be renewed.
3

BI006008

GEH-1496, 1C2800 Dc General-purpose Contaetors

OPERATING COIL

ARMATURE

should be as listed in Table II. The most common


use of the holding coils is in special circuits where
the holding coil. when energized. will prevent the
normally open tips from closing. Therefore make
all adjustments with the holding coil de-energized.

C)

On contactors with normally open poles only, the


armature spring should be adjusted to hold the
armature firmly against its stop. However, not so
firmly that the cold operating coil will not completely pick up and wipe the tips at 65 percent of
full rated volts with the coil at room temperature
or approximately 25 C. With cold coils, 1C2800-1627
contactors must pick up and wipe the tips at 70
percent of full-rated pickup volts. They must drop
out completely at 70 percent of full-rated drop-out
volts. 1C2800-1627 contactors use a pickup and a
drop-out coil which have a common connection.
These adjustments are made at the factory and
should not need to be changed. It will be found,
however. necessary to readjust or at least to recheck the adjustments after replacing a part.
CARE OF POWER CONTACTS
In general, contacts do not require attention
during their normal life. When they have worn so
that the A dimension is reduced to AW or the B dimension to BW (see Fig. 5 and refer to Table TI),
HOLDING COIL

ARMATURE SPRING

Fig. 6. IC28001613 con/odor

core. Replace the coil. making sure that the spring


washer and any spacers are also replaced in the
same order in which they were removed. Take
care also. that the armature is replaced in the
same manner as it was removed. Rehook the armature spring and as an added precaution check the
contact wipes and gaps - as given in Table IT. Also
check the armature spring adjustments and pickup
as given in the paragraph on Armature Spring
Adjustments in this instruction. Having been careful not to disturb the spring adjustments and having
reassembled the contactor properly. there should
not be a need to make any adjustments.

J \

ARMATURE SPRING ADJUSTMENTS


(See Fig. 6)
The contactors which have normally closed poles
have their armature springs adjusted so that with
the coils de-energized, the normally closed tip wipe
(B in Fig. 5) should be a minimum of one-half the
value listed in Table IT. By manually pressing the
armature against the holding coil core. the wipe
4

SPRING CLAMP (SHOWN UNHOOKED)

Fig. 7. IC28001620 conloc/or

BI006008

1C2800 Dc General-purpose Contaetors, GEH-1496


it is recomm nded that they be replaced. The B
dimension mu t be measured with the armature
manually held down against the holding coil core.
This is becau e the normally closed tips are set
with as little as one-half of the B dimension in their
normal or de- nergized position (see paragraph on
Armature Spri g Setting in this instruction).

CONTACT FORCE
(See Table II and Fig. 5)

Check contact force using a pull scale. Pull in


the direction perpendicular to the plane of the movable contact as shown in Fig. 5. Do not try to adjust
the contact force. If it is not within the limits as
given in Table n, replace the contact spring (Fig.
9).

ELECTRICAL INTERLOCKS
Two designs of electrical interlocks have been
furnished. \Vhen replacing contacts or rearranging
circuits, care should be taken to determine which
interlock design is on the contactor. (See Fig. 10.
12,13,14, and 15 and Table III.) The universal
electrical interlock as shovm in Fig. la, 14, and 15
is of the most recent design .

"""07: When adding or ,'eplacing a complete interlock assembly, the insulation


as shoum in Fig. 4 must be in place between the inte1'lock block and the coil.

TABLE 1/1 IN TE RL0 (K RAT I NGS

Fig. 8.

7 contoctor with

coi/.spring.type arc-chute

Number
of
Carry Make
Contacts
One Set
10
60
Two Sets
10
60
in Series

n Amp er es)

Interrupt

I
Ac"
125V 250V 600V 111 OVl220V HOV 600V
1.8 0.5 0.2 I 6 I 3
1.5 1.2
Dc Inductive*

4.0

retainer
CONTACT SPRINGS

(I

1.2

0. 35 1

* Non-inductive dc interrupting rating is 1. 5 times inductive.


**Capable of interrupting inrush current of 60 amperes at 11 0
volts. 30 amperes at 220 volts. 15 amperes at 440 volts. and
12 amperes at 600 volts a limited number of times.

SPRING
SPACER

'==+==1=::'

N
TIPc.GAP-

L~=~=~_NO.
TIP WIPE

Fig. 70. Universal electrical interlock with one set of norm oily
open contads, and one set of normally closed
contacts in the operated position
INSPECTION AND CARE

The interlock should be positioned on its bracket


so that with the contactor in its energized position,
5

BI006008

GEH-1496, 1C2800 Dc General-purpose Contactors


the interlock plunger, Fig. 15. should not bottom.
With the contactor in its de-energized position,
there should be some clearance (C) between the interlock plunger and the interlock operating arm
(Fig. 11).
Tip gaps and wipes, when new, should be as
shown in Table IV. Replace contact tips when wipe
reaches one-half of minimum specified.
A universal interlock. per Fig. 10. having one
set of normally open contacts and one set of normally closed contacts must be adjusted so that with
one set of contacts just touching, there is at least
1/64 inches of gap between the other set of contacts.

TABLE IV
(Contact Tip Gap and Wipe)
MAXIINTERLOCK

Per Figs.10
14 and 15

CONTACTS

MINI-

To replace removable contacts on interlock


blocks illustrated in Fig. 10. 14. and 15. lift the
spring seat with the thumb and forefinger and remove the operating plunger which supports the
movable contacts. Snap off the U-shaped keys and
the movable contacts can be removed and replaced.
Care should be taken not to lose any parts or pieces
during this operation. To replace a stationary
contact, remove the terminal screw and lift the
contact assembly off the housing. Replace by pressing the new contact assembly into the molded insert
and run the terminal screw to its seal position.
Care should be taken to avoid changing the shape of
this contact assembly in handling. Also, the shape
should not change during operation.

MUM

MUM

INCHES

INCHES

1/8

5/64

3/32

3/64

5/64

3/64

7/64

5/64

CHANGING CIRCUIT ARRANGEMENT

3/32
3/64

To change an interlock from normally open to


normally closed or vice-versa, disassemble the
movable contacts in the manner described above
and turn the contact over. The contact, spring,
spring spacer and keys should be reassembled as
shown in Fig. 10, 14, and 15. The stationary contacts should then be removed, inverted and replaced
as outlined in the above paragraph.

(N.O.)
Tip Gap
Not
Operated (N.C.)
TipWipe
(N.O.)
TipWipe
Operated (N.C.)
Tip Gap

Not
Per Figs.
Operated Tip Gap
Tip Wipe
and
1 2 an d 13
Operated

INTt:RLOeK
OPERATING ARM

/
1 - - - _......
.1--1CLEARANCE

Ie)

INTERLOCK
PLUNGER

Fig. 71. Contoetor in its de-energized position

REPLACING CONTACTS

To replace the contacts on interlocks illustrated


in Fig. 12 and 13, grasp the spring retainer (R)
6

with the thumb and forefinger of the right hand and


hold the interlock and plunger with the left hand.
Slide the spring retainer and spring to the rear and
lift up until the spring retainer is free of the slot
so it can be removed. (Care should be taken that
the operating spring is not lost during this operation.) Remove the plunger by lifting the rear of
the plunger with a screwdriver. and at the same
time pushing it to the rear until it is disengaged
from the slot. Note that on the interlock with a
normally open contact to the front, it may be necessary to remove the stationary contacts before the
plunger can be removed.

When circuits are rearranged to obtain one


normally open and one normally closed circuit, the
normally closed circuit must be located at the bottom
as shown in Fig. 10 or electrical creepages will not
be maintained. (Note that Fig. 10 is shown in the
operated position. )
Spring ends must not protrude into holes (A),
slots (B), or keys (C), which serve as guides for
the operating arm. See Fig. 14.
Contact blocks with two normally closed circuits
require a spring spacer (D) as shown in Fig. 14 to
assure that the center spring is properly in place.
Because of the circuit rearrangement feature, a
spring spacer is supplied with all other two-circuit
contact blocks, as shown in Fig. 10 and 15.

BI006008

IC2800 Dc General-purpose Contactors, GEH-1496

CIRCUITS CLOSED

CIRCUITS OPEN

STATIONARY CONTACTS

SPRING
INTERLOCK OPERATING SPRING

Fig. 12. Two circuit electrical interlocks showing location of contact springs
ond "u" shaped keys - when chonging interlocks from normally open
to normally closed, or vice verso
CIRCUITS OPEN

CIRCUITS CLOSED

TIP WIPE

1lI0VA8lE CONTACTS

~~~t-7

INTERLOCK
SPR IN G

Fig. 13. Three-circuit electrical interlocks showing the somE' information as Fig. 7.

_ - - - SPRING SEAT
KEY

--r"'=~!=~-A

MOVABLE
CONTACT

TERMINAL

A-II----+-+--liIh

A
N.C TIP WIPE

ASSEMBLE TIP
SUPPORT FLATLY
AGAINST HOUSING
BY RUNNING SCREW
TO SEAT POSITION
BEFORE MAKING ANY
CONNECTIONS

Fig. 14. Univers I electrical interlock with normally closed


contact in unoperoted position

SPRING
SPACER

I-r-'''<::~'':''''''f- STATIONARY

CONiACi

"N.O. ilP GAP

OPERAT! NG
PLUN(iR

Fig. 15. Universal electrical interlock with normally open


contacts in unoperated position
7

.. i
BI006008

GEH-1496, IC2800 Dc General-purpose Contactors

MECHANICAL INTERLOCKS

RENEWAL PARTS

Single-pole forms of these devices are arranged


for horizontal mechanical interlocking in pairs to
keep one device from closing while the other is
closed. When one contactor is completely closed
and the other open. there should be a slight amount
of free motion of the interlock arm. Double-throw
forms cannot be mechanically interlocked.

Renewal parts may be ordered from the renewal


parts bulletin by spec ifying the quantity required
and the catalog number, or by describing the parts
in detail and giving the complete nameplate rating
of the equipment.

GENERAL ElECTRIC COMPANY


COMPONENT AND DEVICES SALES
DRIVE SYSTEMS DEPARTMENT
SALEM, VA 24153

GENERAL _

Pl12-801

ELECTRIC

BI006008

GEH-1941C

GE Drive Systems

11AGNETIC RELAYS FOR INSTANTANEOUS


OR TIME-DELAY DROPOUT
DS2820AIOO AND DS2820B200

B rore any adJustments, serJicing, parts replacent or an)' other act is performed requiring physical
co tact with the electrical working components or
wi 'ng oj this equipment, the POWER SUPPLY
M 'ST BE DISCONNECTED.
7

e DS2820A 100 and DS2820B200 relays are


se f-contained, front-connected, dc operated
m gnetic relays. Either form relay may be
a plied in instantaneous pick-up applications,
h wever, drop-out characteristics differ bet\\" en the two forms.
e DS2820AIOO relay can be a,pplied as an
tantaneous pick-up, time-delay drop-out
'ice; or as an instantaneous pick-up, instaneous drop-out device. Maximum time delay
up to approximately 2.0 seconds may be
tained depending upon the number of inter10 ks and the thickness of shims. This relay is
ca able of controlling from two to rv,'elve circu ts. Time-delay dropout may be obtained
wi relays controlling up to four circuits.
in
d
ta
o
o

e DS2820B200 Relay may be applied as an


in tantaneous pick-up, time-delay drop-out
d 'ice with a maximum time delay up to appr ximately 5.0 seconds.
Se 'es or shunt coils permit the use of these
re ays as current or voltage relays with adjustab e pickup or dropout.
If de source of power is not available, the de
o tput of a metallic rectilier may be used as a
so rce of power to energize the relay coils.

......

ese relays can be mounted as a unit on


er steel or insulated bases.

Fig. 1. DS2820A100A Two-circuit ck magnttic


time relay.

OPERATION
Vihen the relay is used as a time-delay device,
timing is initiated either by opening the coil
circuit with a sv,'itch similar to S in Fig. 4 or by
short-circuiting the relay coil as by sv.;tch S in
Fig. 3. If the timing is initiated by shortcircuiting the relay coil, the current in the coil
and the flux in the magnetic circuit decays
slowly, producing a time-delay dropout of the
relay armature as shown in Fig. 3.

BI006008

\
(

GE Drive Systems
General Electric Company
1501 Roanoke Boulevard
Salem. Virginia 24153
(703) 387-7000

BI006008

INSTRUCTIONS

GEH-3057B

IC2800 D-C MILL-TYPE CONTACTORS


600 VOLTS MAXIMUM

1170BS, BT, BU, BY, BW, CA, CB, CC


1172AY, AW, BA, HB, BC, BE 1173N, P
1174AH, Al, AK, AL, AM, AN 1175R, S
Before any adju tments, servzcmg, parts replacement or any ot er act is performed requiring
physical contact wit the electrical working components or wiring
this equipment the POWER
SUPPLY MUST BE ISCONNECTED.

ODUCTION
These 1C2800 c ntactors are single-pole, d-c
operated, mill-type with a maximum voltage rating
of 600 volts. The current ratings are listed in
Table I. Forms are vailable with and without blowout coils.
Forms without lowout coils are intended primarily for dynami -braking duty. They have only
make and carry r tings and must not be used to
interrupt current.

TABLE I CONTACT OR CURRENT RATINGS


CONTACTOR
FORM
1C28001170
1172
1173
1174
1175
1176
1177

Y100
Y101
Y105
Y102
Y106
Y103
Y104

Y120
Y121
Y25
Y22
Y126
Y123
Y124

*The ratings give


amperes for one po
blowout pole or a
out coil available w

POLE
NGEMENT
1
1
1
1
1
1
1

N.O.
N.O.
N.C.
N.O.
N.C.
N.O.
N.O.

MAXIM:UM
CONTINUOUS
AMPERES*
100
150
150
300
300
600
900

-1176AQ, AR, AW, BE l177A, B


Yl00 THROUGH Yl06 ALL FORMS
-Y120 THROUGH Y126 ALL FORMS

completely assembled, adjusted, and tested at the


factory. They are assembled on an insulated base
of the dead-back type which can be mounted on
either a steel or insulated panel.
The 1C2800-Y120 through - Y126 are self-contained contactors. The upper connection to the blowout coil is back connected and the lower connection
to the movable shunt may be either front or back
connected. All forms are completely assembled, adjusted, and tested at the factory. They are assembled on an insulated base which can be mounted on
either a steel or an insulated panel having a cutout
that allows the back-connection terminals to protrude through the panel.
Contactors with d-c magnets may be operated
directly from a d-c supply or through rectifiers
from an a-c supply. Whenever this type of connection scheme is employed, both the a-c and d-c
sides of the rectifier must be opened simultaneously by use of an auxiliary contactor, so the main
contactor will not experience a time-delay dropout lJecause of coil discharge through the rectifier.
Coils used with rectifiers are designed .to allow
for a drop in voltage due to rectification, and are
different from coils of the same nominal voltage
for q-c supplies.

Arc chute

are the maximum continuous


e and are correct only for a no
Ie with the highest rated blowth the contactor.

The 1C2800-117 through -1177 are unmounted


contactors that can be assembled and adjusted by
the user in accorda ce with these instructions. They
are principally back connected, although some forms
are front connected All forms must be mounted on
an insulated panel.

Armature

Operating coil-~rt1==::::,~

The 1C2800-Y1 0 through -Y106 are self-contained, front-conn ted contactors. All forms are

Fig. 1.

Stationary
fulcrum
plate for
armature

Typical IC2800 d-c mill-type contactor

These instructions do t purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection
with installation, operoti n or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently
for the purchaser's purp ses, the matter should be referred to the General flectric Company.

GENERAL

ELECTRIC

BI006008

GEH-30578

IC2800 D-C Mil/- Type Contactors


INSTALLATION

All contactors should be inspected for proper


operation and clearances, as described below, when
first installed and occasionally thereafter.
MOUNTING

When mounting 1C2800-1170 through -1177 contactors, the following requirements must be maintained:

1. The rectangular fiber spacer for the bus-bar


connection to the blowout coil should be mounted
behind the panel to properly position this connection.

Movable contact
ti p

Fig. 2.

Contactor clearances

2. Since the frame assembly is electrically


alive, the proper NEMA standard for electrical
clearance and creepage to conducting parts and to
ground must be maintained.
When an 1C2800-YI00 through -YI06 is mounted
on a steel panel, the sheet of insulation supplied
with the contactor must be in place between the
contactor sub-base and the main base or panel.

.r---

When an 1C2800-Y120 through -Y126 is mounted


on a steel panel, the cut-out required must be of
such size that the proper NEMA standard for electrical clearance and creepage exists between the
steel panel and all live parts on the back of the
contactor base.
The movable contact, of all contactors, should
pivot freely on the rocker bearing at the lower end
of the contact and should strike the stationary contact squarely. The armature should pivot freely on
its fulcrum, and should not rise off the fulcrum
when the contactor is energized and fully picked up.
CLEARANCES

For proper contactor interruption, the following


must be maintained:

~learances

1C2800-1170, -1172, -YlOO, -YI20, -YI0l, -Y121


contactors - With the movable contact tip in its
de-energized position, maintain a gap of 1/16 in.
to 1/4 in. between the arcing horn and the movable contact tip. (Fig. 2)
1C2800-1174, -1176, -1177, -YI02, -YI22, -YI03,
-YI23, -YI04, -Y124 contactors - Withthemovable contact tip in its de-energized position,
maintain a gap of 1/16 in. to3/16in. between the
arcing horn and the movable contact tip. (Fig. 3)
A gap of 13/16 in. between the arcing horn and
the burning strip mounted on the stationary contact bracket must also be maintained. (Fig. 3)

i6,"

to

3"
i6

Movob Ie contact tip

Fig. 3.

Contactor clearances

The arc chute should rest freely on the stationary


contact bracket without interfering mechanically
with any of the moving parts. With the movable
contact in its energized position, a minimum gap of
0.06 in. must be maintained between the edges of
the contact and the arc chute.
To obtain the maximum interruption rating of
the electrical interlocks mounted on these contactors, an air gap of 3/4 in. must be maintained between the open face of the interlock and any conducting part or ground.
When mounting any contactor described in these
instructions, the NEMA standard for electrical
clearances and creepages between all electrical
live points (power connections, control connections,
etc.) to conducting parts or to ground must be maintained.
The mInImUm arcing clearances, for forms of
contactors containing blowout coils, are listed in
Table II. These clearances must be maintained in
front and above the contactor arc chute when the

BI006008

GEH-3057B

IC280

D-C Mill- Type Contadors

INSTAL ATION
All contactors shoul be inspected for proper
operation and clearances as described below, when
first installed and occasi nally thereafter.
MOUNTING

When mounting IC280 -1170 through -1177 contactors, the following re uirements must be maintained:
1. The rectangular fi er spacer for the bus-bar
connection to the blowo t coil should be mounted
behind the panel to prope ly position this connection.

Fig. 2.

Contactor clearances

2. Since the frame assembly is electrically


alive, the proper NEM standard for electrical
clearance and creepage to conducting parts and to
ground must be maintain d.
When an IC2800-YlO through - Y106 is mounted
on a steel panel, the s eet of insulation supplied
with the contactor mu be in place between the
contactor sub-base and t e main base or panel.

I"

Movob Ie contact tip

When an IC2800-Y12 through -Y126 is mounted


on a steel panel, the c t-out required must be of
such size that the prope NEMA standard for electrical clearance and c eepage exists between the
steel panel and all li e parts on the back of the
contactor base.
The movable contac, of all contactors, should
pivot freely on the rock r bearing at the lower end
of the contact and shoul strike the stationary contact squarely. The arm ture should pivot freely on
its fulcrum, and shoul not rise off the fulcrum
when the contactor is en rgized and fully picked up.
CLEARANCES

For proper contacto interruption, the following


clearances must be mai tained:
IC2800-1170, -1172, contactors - With the
de-energized position,
to 1/4 in. between the
able contact tip. (Fig.

100, -Y120, -Y101, -Y121


movable contact tip in its
maintain a gap of 1/16 in.
arcing horn and the mov)

IC2800-1174, -1176, - 177, -Y102, -Y122, -Y103,


-Y123, -Y104, -Y124 ontactors - Withthemovable} contact tip in i s de-energized position,
maintain a gap of 1/16 in. t03/16in. between the
arcing horn and the m vable contact tip. (Fig. 3)
A gap of 13/16 in. b tween the arcing horn and
the burning strip mou ted on the stationary contact bracket must als be maintained. (Fig. 3)
2

3"

"---16 to i6

Fig. 3.

Contactor clearances

The arc chute should rest freely on the stationary


contact bracket without interfering mechanically
with any of the moving parts. With the movable
contact in its energized position, a minimum gap of
0.06 in. must be maintained between the edges of
the contact and the arc chute.
To obtain the maximum interruption rating of
the electrical interlocks mounted on these contactors, an air gap of 3/4 in. must be maintained between the open face of the interlock and any conducting part or ground.
When mounting any contactor described in these
instructions, the NEMA standard for electrical
clearances and creepages between all electrical
live points (power connections, control connections,
etc.) to conducting parts or to ground must be maintained.
The mInimUm arcing clearances, for forms of
contactors containing blowout coils, are listed in
Table n. These clearances must be maintained in
front and above the contactor arc chute when the

BI006008

BI006008

GEH-30578
contactor is used on a 600-volt-maximum motor
circuit.

TABLE II
CONTACTOR ARCING CLEARANCES
NCLOSURE ENCLOSURE NOT
INED WITH
LINED WITH
SULATION
INSULATION

CONTACTOR
IC28001170
1172
1174
1176
1177

YIOO
YIOl
YI02
YI03
YI04

Y120
Y121
Y122
Y123
Y124

2 in.
2 in.
2.5 in.
3 in.

3.5 in.

3.5 in.
4 in.
5 in.
6 in.
6.5 in.

To replace the contact, first make sure the


spring is in position between the bracket and the
shunt. Insert the lower end of the contact between
the shunt and the bracket, and push in until the
notch in the contact seats on the rocker bearing on
the bracket. Position the top edge of the shunt
against the shoulder on the back of the contact;
insert the holding screw through the shunt and into
the contact and tighten.
The stationary contact may be removed by
loosening the holding screw a few turns. This contact has a slotted mounting hole, making it unnecessary to remove the screw entirely. To replace the contact, slide it into position against the
bracket and tighten the holding screw.
CONTACT FORCE

PICKUP AND WIPE

All contactors sh uld pick up and fully wipe with


cold coil as follows:
a. Rectified a-c ontrol 70%* of a-c
b. Rectified a-c ontrol with
holding resi tor . 75%* of a-c
c. D-c control. . ... 63%t of coil
d. D-c control w th holding
resistor .. .. 75%t of coil
. *85% with hot co

IC2800 D-C Mill- Type Contactors

voltage
voltage
voltage
voltage

t80% with hot coil

D SCRIPTION
CONTACTS
It is seldom ne essary to clean the surfaces of
the contacts, but if hey should become unduly oxidized from unusual conditions such as very infrequent operation, the may be dressed with a medium
flat file without re oval from the contactor. Care
should be taken not 0 gouge the surface of the contact and to maintain an even surface.

When the contac s have worn sufficiently to reduce the wipe to th values indicated in Table III,
they should be rep aced. To replace the contacts
remove the arc ch te and, in the case of the normally open contacto , loosen the arcing horn slightly
and push it to one si e. Next, remove the cap screw
holding the movabl contact and shunt together. To
remove the movabl contact push the upper part of
the contact toward he base and at the same time,
pull it up and out f the contactor. This will raise
the lower part of the contact off the fulcrum so
that the contact can e removed easily.
If it should be n cessary to remove the contact
spring, the contact should first be removed in the
manner described a ove.

If for any reason it is necessary to check contact force (see Table III), pass a loop of fine wire
around the movable contact as shown in Fig. 4.
Pull on this with a spring balance held in such a
direction that the line pull is approximately perpendicular to the contact surface on the movable
contact. Initial contact force is indicated when the
movable contact is just pulled away from its stop
at the top of its supporting bracket. It is usually
convenient to see this by placing a piece of paper
between the contact and the stop, and pulling on
the spring balance until this paper can just be
withdrawn. Final contact force is indicated by energizing the magnet on normally open contactors,
and pulling on the spring balance until the movable
contact begins to leave contact with the stationary
contact. Notice that in order to check final contact
force with values given in the table, this test
should be made with new contacts:

I_.-,1

Fig. 4.

rtdJMethod of checking contact force


3

BI006008

BI006008

IC2800 D-C MiII- Type Contactors

GEH-30578

Old Type

CONTACT

TIP WIP E
PPROXIMATE
IMENSIONS
IN INCHES

CONTACT OR
FORM

IC2800-1170, Y100& Y120


IC2800--t172, Y101 & Y121
IC2800-1173, Y105 & Y125
IC2800-1174, Y102 & Y122
IC2800-1175, Y106& Y126
IC2800-1176, Y103& Y123
IC2800-1177, Y104& Y124

1 /32
/8
/4
2 32
1 64
2 32
2 32

9/64
1/8
5/32
7/32
7/32
9/32
9/32

1/16
1/16
3/32
7/64
1/8
1/8
1/8

CONTACT FORCE
IN POUNDS
t: 15%)
INITIAL

FINAL

21/4
3 1/4
4
61/2
7 1/4
13 1/2
13 1/2

4
61/2
8
13
141/2
27
27

*When B measures BW it is recommended that the contacts be


renewed.

The older type of electrical interlock was used


only on the IC2800-1170 through -1177 contactors.
It uses a molded block to mount the movable contacts on the contactor armature. The stationary
element consists of two stud assemblies designed
so that the contact tips can be changed from the
normally open to the normally closed position \vithout additional parts. The movable and stationary
contacts must be reversed togetl;1er when such a
change is being made.
The normally closed electrical interlock should
be adjusted so that it is always closed when the
contactor is de-energized, even when the armature
is moved sideways the maximum distance permitted by the armature retainer. Adjust both normally open and normally closed interlocks in accordance with Table IV and Fig. 5.

ARC CHUTES

The arc chute is e tirely removable from the


contactor. The arc chu e is seated on the stationary
contact bracket and bet een the pole pieces. On the
larger size contactors provision is made for securing the arc chute wi h a mounting screw.
Never operate the ontactor with power on the
contacts unless the arc chute is securely in place.

TABLE IV
INTERLOCK TIP DATA (OLD TYPE)
IC2800 CONTACTOR FORMS 1170 1172 1173 1174

1175 1176 1177

TIP WIPE (A)


3/16 5/32 3/16 7/32
IN INCHES

7/32 3/16 3/16

NORMALLY
OPEN

TIP GAP (B)


IN INCHES

1/16 7/64 1/8

TIP WIPE (A)


7/32 1/8
IN INCHES

COILS

To change the mai coil on any of these contactors, the cap screw olding the coretothe frame
should be removed. T e core and coil can then be
dropped out and the coi slipped off the core. Notice
that the end of the cor which is in contact with the
frame is shouldered t assure that binding of the
screw will not make i difficult to remove. In replacing the core, be s re that this shouldered section drops into the ho e in the frame. On the normally closed contacto s the frame is stepped to
make it easy to slid the shouldered end of the
core into the frame.
Coils for these co tactors have one flange or
boss with a square e ge. This fits against the
frame to prevent the oil from turning. The coilretaining washer, use to keep the coil tight, is
placed between the hea of the core and the coil.

NORMALLY
TIP GAP (B)
CLOSED
IN INCHES

7/64 3/16

1/8 7/32 7/32

3/32 3/32 3/16 3/16

13/16 3/16 3/16

NOTE: Adjust lower interlock tip to gap "B," then


adjust upper tip so that both make contact at the
same time (Within 1/64 in.)

,J"ll UPPER
lUl)J
TIP
CENTER LINE
OF TIPS MJST
BE IN LINE
WITHIN 1. IN.

32

IN ALL
DIRECTIONS

8
1rITnmLOWER

Wi

Fig. 5.

ELECTRICAL INTERLOCK

Two designs of ele trical interlocks have been


furnished. The older t e interlock was designated
by numbers containin an X (such as X2 or X5)
while the newer type i designated by letters (such
as B or E).

11/64 1/8 7/32 7/32

TIP

Interlock tips (old type)

New Type

The new-type electrical interlock is used on all


the -YIOO and Y-120 series contactors as well as
-1170 series. It consists of a contact block having
two electrical circuits. The internal parts can be
4

BI006008

BI006008

IC2800 D-C MilI- Type Contactors


rearranged to give di ferent contact arrangements.
Should this be neces ary, the parts should be reassembled in accord nce with Figs. 6, 7, or 8.
Spring ends must not protrude into holes (A), slots
(B), or keys (C), w ich serve as guides for the
operating arm. See Fi . 6.

-r--,~D

ASSEMBLE TIP
SUPPORT FLATLY
AGAINST HOUSING
BY RUNNING SCREW
TO SEAT POSITION
BEFORE MAKING ANY
CONNECTIONS

L2:44frt~

Fig. 6.

Contact blocks with two normally closed circuits


require a spring spacer, (D) in Fig. 6, to assure
that the center spring is properly in place. Because
of the circuit rearrangement feature, a spring
spacer is supplied with all other two-circuit contact
blocks, as shown in Figs. 7 and 8.
The interlock should be positioned on its bracket
so that with the contactor in its energized position
the operating arm (Fig. 8) should not bottom, and
with the contactor in its de-energized position there
should be some clearance between the operating arm
and the actuator on the armature (see Fig. 7).

A---.....

A -1--4-+--1-, I

GEH-3057B

Interlock block with normally closed contacts in


unoperated po ition

Tip gaps and wipes should be as shown in the


following table. Replace the contact tips when the
wipe reaches one-half the minimum specified.

TABLE V
INTERLOCK TIP DATA (NEW TYPE)
CONTACTS
Not
Operated

MINIMUM

(N.O.) Tip Gap

5/64 in.

(N.C.) Tip Wipe

3/64 in.

(N.O.) Tip Wipe

3/64 in.

(N.C.) Tip Gap

5/64 in.

ACTUATING LEVER
SPRING
SPACER

KEY -----..

MOVABLE
CONTACT

TERMINAL

HOUSING~:::~:~:~:~=_
-~

_ _+-STATIONARY
CONTACT

TIP GAP

Fig. 7.

OPERATI NG
ARM

Interlock block with normally open contacts in


unoperated po ition

SPRING
SPACER

0
l=~~~~ L~~~r=~-N.
TIP WIPE

NC
TIP GAP"::

Fig. 8.

TABLE VI
INTERLOCK RATINGS (In Amperes)
Interrupt
Number
A-c**
of
Carry Make D-c Inductive*
Contacts
125V 250V 600V 110V 220V 440V 600V

SPRING---+-!--_-bI

Operated

Interlock block with one set of normally open


contacts and 0 e set of normally closed contacts in opera d position

One Set

10

60

1.8

0.5

0.2

Two Sets
in Serie~

10

60

4.0

1.2

0.35

1.5

1.2

* Non-inductive d-c interrupting rating is 1.5 times


inductive.
**Capable of interrupting inrush current of 60 amperes at 110 volts, 30 amperes at 220 volts, 15
amperes at 440 volts, and 12 amperes at 600 volts
a limited number of times.

To remove the movable contacts lift the spring


seat, tilt the operating arm forward, and lift out the
entire movable contact assembly. Snap off the "U"
shaped keys and slide the contacts off the operating
arm. Care should be taken not to lose the operating
spring during this operation.
To remove the stationary contact tip assembly,
remove the terminal screw, then lift the contact tip
off the housing. To replace the tip, press it onto the
molded insert and run the terminal screw to its
seat position. The shape of this contact assembly
should not be changed by handling or during operation.

BI006008

BI006008

GEH-3057B

IC28 0 D-C Mill- Type Contactors

To change an interl ck from normally open to


normally closed, or v' e-versa, disassemble the
movable and stationar contacts in the manner
described above, invert and reassemble.
An interlock block
ving one normally open
and one normally close circuit must be assembled
with the normally close contact on the bottom (see
Fig. 8) or electrical cr epage distances will not be
maintained.

MECHANICAL INTERLOC S

Mechanical interloc s on a pair of contactors


must keep one of the pa r from making contact when
the other is just makin contact and both contactors
have new contacts. Whe one contactor is completely
closed, and the other 0 en, there should be a slight
amount of free motio of the interlock arm (approximately 1/16-inch) If adjustment is required,
it can usually be lna e by means of clearance
either at the screws hiding the mechanical-interlock bracket to the c ntactors or at the stud on
which the molded arm otates. Adjustment can also

be made by aligning the two contactor frames in the


clearances of their mounting holes on the panel.
NORMALLY CLOSED CONTACTORS

The above instructions apply to both the normally open and normally closed contactors. In addition, these precautions apply to the normally
closed devices. The main operating spring should
work freely without binding on its guides. Since the
coils for the normally closed contactors are intermittently rated, they should not be energized more
than 50 percent of the time, and not more than 15
minutes at one time. However, if a coil is energized
only once every three hours or longer, it may be
energized for 30 minutes at one time.

RENEWAL PARTS
When ordering renewal parts, address the nearest
General Electric sales office, specify the quantity
required, and give the catalog numbers or describe
the required parts in detail. Also be sure to give
the complete nameplate rating of the equipment.

GENERAL ELECTRIC COMPANY


INDUSTRIAL CONTROL PRODUCTS DEPARTMENT
SALEM, VA. 24153

GENERALfj ELECTRIC

."'1.

5-73 110M)

BI006008

BI006008

Insert page 2-5 from file BI006008-00_2b.pdf here

BI006008

GEH-5600A
(Supersedes GEH-5600J

GE Drive Systems

Instructions

LodTrak IV
Protective Relay Module

BI006008

BI006008

LodTrak IV
Protective Relay Module

GEH-5600A

Original Issue Date: October 1989


Revision A: April 1995

These instructions d
contingency to be m
should particular pr
referred to GE Driv

not purport to cover all details or variations in equipment, nor to provide for every possible
t during installation, operation, and maintenance. Should further information be desired or
lems arise that are not covered sufficiently for the purchaser's purpose, the matter should be
Systems, Salem, Virginia, U.S.A.

This document cont ins proprietary information of General Electric Company, U.S.A. and is furnished to its
customers solely to sist that customer in the installation, testing, and/or maintenance of the equipment described.
This document shall ot be reproduced in whole or in part nor shall its contents be disclosed to any third party
without the written a proval of GE Drive Systems, 1501 Roanoke Boulevard, Salem, Virginia 24153, U.S.A.

BI006008

Ie

1989 by General Electric Company, U.S.A.


All rights reserved.
Printed in the United States of America.

Trak is a trademark of General Electric Company. U.S.A.

BI006008

Protective Relay M dule

GEH-5600

Safety Symbol legend

WARNING

Commands a tention to an operating procedure, practice, condition or statement, which, if not strictly
observed, co ld result in personal injury or death.

CAUTION

Commands at ention to an operating procedure, practice, condition or statement, which, if not strictly
observed, cou d result in damage to or destruction of equipment.

NOTE

Commands att ntion to an essential operating or maintenance procedure, condition, or statement that must
be highlighted

BI006008

1-5600

Protective Relay Module

WARNING

This equipment contains a potential hazard of electrical shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the equipment and the instructions should install,
operate, or maintain this equipment.
Isolation of test equipment from the equipment under test presents potential electrical hazards. If
the test equipment cannot be grounded to the equipment under test, the test equipment's case
must be shielded to prevent contact by personnel.
To minimize hazard of electrical shock or burn, approved grounding practices and procedures
must be strictly followed.

WARNING

To prevent personal injury or equipment damage caused by equipment malfunction, only


adequately trained persons should modify any programmable machine.

BI006008

Protective Relay M dule

GEH-5600

TABLE OF CONTENTS

Chapter/Paragraph

Chapter/Paragraph

CHAPTER 1

2-7.8.
2-7.9.
2-7.10.
2-7.11.
2-7.12.
2-7.13.
2-7.14.
2-7.15.

1-1.
1-2.
1-2.1.
1-3.
1-3.1.
1.3.2.
1-3.3.
1-3.4.
1-3.4.1.
1-3.4.2.
1-3.4.3.
1-3.5.
1-3.6.
1-3.7.
1-3.8.
1-3.9.

Introduction . . . . . . . . . .
Equipment escription
Module Ty s
General Spe ifications
Environmen
Control Po er Source . . . .
Output Cont cts
Inputs
RTDs
Voltage Inp t (Model 4E)
External ReI y Input (Model
Measured V ues
Published C rYes
Noise Isolati n
Voltage Rati g . . . . . . . .
Maximum C Fault Current

CHAPTER 2

2-1.
2-1.1.
2-1.2.
2-1.3.
2-1.4.
2-2.
2-3.
2-4.
2-4.1.
2-5.
2-6.
2-6.1.
2-6.2.
2-6.3.
2-7.
2-7.1.
2-7.2.
2-7.3.
2-7.4.
2-7.5.
2-7.6.
2-7.7.

. . . . . . . .
.
.
.
.
. . . . . . . .
.
.
.
.
4E)
.
.
.
.
. . . . . . . .
.

I-I
1-1
1-1
1-1
I-I
1-2
1-2
1-2
1-2
1-2
1-2
1-2
1-3
1-3
1-3
1-3

DES RIPTION OF OPERATION

Operator Int rface . . . . . . . .


Readouts
Annunciator
Diagnostics
Display of easured/Calculated
RTD Measu ment/Open RTD
Current Me urement . . . . . .
Non-Protecti e Mode
Trip Relay
eration Test . . .
Protective M de .. . . . . . . .
Reset Modes
Manual Rese Mode . . . . . . .
Automatic R set Mode
Remote Rese Mode . . . . . . .
Protective F ctions
Integrated 0 erload/
Overtemperat re with RTDs
Overload Wi out RTDs
Separated Ov rload/
Overtemperat re with RTDs
Instantaneous Overcurrent
Phase Unbal ce/Open Phase
Ground Fault
Bearing Ove emperature . . . .

. . . . . .
.
.
.
Values .
.
. . . . . .
.
. . . . . .
. . . . . .
.
. . . . . .
.
. . . . . .
.

2-1
2-1
2-1
2-1
2-1
2-1
2-2
2-3
2-3
2-3
2-3
2-3
2-3
2-3
2-3

. 2-3
. 2-4
.
.
.
.
. . . . . .

2-4
2-5
2-5
2-5
2-5

2-7.16.

Phase Reversal .. . . . . . . . . . . . . . . 2-5


Undercurrent (Load Loss)
2-6
Load Jam
2-6
Undervoltage (Model 4E)
2-6
Overvoltage (Model 4E)
2-6
Phase Loss by Volts (Model 4E)
2-6
Phase Reversal by Volts (Model 4E)
2-7
Maximum Number of Starts in
One Hour (Model 4E)
2-7
Capacity Used Value
(> 99 % = Trip) . . . . . . . . . . . . . . . 2-7

CHAPTER 3

3-1.
3-1.1.
3-1.2.
3-2.
3-2.1.
3-2-2.
3-2.3.
3-2.4.
3-2.5.
3-2.6.
3-2.6.1.
3-2.6.2.
3-2.6.3.
3-2.7.
3-2.8.
3-2.9.

Mounting
3-1
Door Mounting
3-1
Base Mounting
3-2
Wiring
3-3
Control Power Wiring
3-10
Phase Current CT Wiring
3-10
Ground Fault CT Wiring . . . . . . . . . 3-10
RTD Input Wiring
3-10
Grounding Wiring . . . . . . . . . . . . . 3-11
Output Relay Wiring
3-11
Alarm Relay
3-11
Trip Relay
3-11
Auxiliary Relay
3-11
Voltage Input Wiring (Model 4E)
3-11
External Relay (Model 4E)
3-12
RS-422 Communication
(Model 4C & 4E)
3-12

CHAPTER 4

4-1.
4-1.1.
4-2.
4-3.
4-3.1.
4-3.2.
4-3.3.
4-3.4.
4-2.5.
4-3.6.
4-3.7.

INSTALLATION

START-UP

Preliminary Checks
4-1
Trip Relay Operation Test
4-1
Initial Motor Start . . . . . . . . . . . . . 4-1
Application Considerations . . . . . . . . 4-2
RTD Inputs
4-2
Current Transformer Inputs
4-2
Stall Time Setting (SP40)
4-2
Instantaneous Overcurrent
Setting (SP41 and SP42)
4-2
Phase Unbalance Setting (SP48)
4-3
Undercurrent Alarm/Trip
(SP57 and SP60) . . . . . . . . . . . . . . 4-3
Load Jam (SP61-SP63)
4-3

BI006008

5600

Protective Relay Module

TABLE OF CONTENTS - CONTINUED

ter/Paragraph

Chapter/Paragraph

;)TER 5

CHAPTER 7
DEFINITION

.1.
.2.
.3.
.4.
.5.

.1.
.1.

OPERATING INSTRUCTIONS

Operating Modes . . . . . . . . . . .
Running Mode
Present Values
Since Start Values (Model 4E)
Starts/Trips/Hrs (Model 4C & 4E)
Values At Trip
Set Point Values
Alarm Mode
Trip Mode
Resetting
Set Point Mode (Set Point Inputs)
Notes On Set Points . . . . . . . . .
Displays and Key Operation . . . .
Running Mode . . . . . . . . . . . .
Set Point Mode . . . . . . . . . . . .

PTER 6

. . . 5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-2
5-2
5-2
5-2
. . . 5-3
. . . 5-3
. . . 5-3
. . . 5-3

7-1.
7-2 .
7-2.1.
7-2.2.
7-2.2.1.
7-2.2.2.
7-2.3.
7-2.3.1.
7-2.3.2.
7-2.4 .

Introduction . . . . . . . . . . . . . . . . . 7-1
Message Definition
7-1
Packets
7-1
Message Contents
7-1
Master To LodTrak Module
7-1
Lodtrak Module To Master
7-2
Message Values
7-2
Commands Received
7-2
Data Sent
7-2
Status Messages
7-2

CHAPTER 8

8-1.
8-2.

RS-422 COMMUNICATION

RENEWAL PARTS

Introductions. . . . . . . . . . . . . . . . 8-1
Parts List
8-1

MAINTENANCE
APPENDIX A

Periodic Maintenance . . . . . . . . . . .
Module Testing
Overload Trip Time Testing . . . . . . .
Phase Unbalance Trip Time Testing ..
Instantaneous Overcurrent Testing ...
Undercurrent and Load Jam Testing ..
Calibration
RTD Calibration
Current Calibration
Parts Replacement . . . . . . . . . . . . .
CT Cover
. . . . . . . . . . . . . . .
Relay
Fuse
Troubleshooting

6-1
6-1
6-1
6-1
6-1
6-1
6-1
6-2
6-2
6-2
6-2
6-2
6-2
6-2

A-I.

SET POINT RECORDS

Introduction

A-I

LodTrak IV Module System/Motor Protection


Settings - Models DS3820LT4A & -4C

A-3

LodTrak IV Module System/Motor Protection


Settings - Model DS3820LT4E

A-5

Module Systems/Motor Protection Settings


Replacing LodTrak II with LodTrak IV
Module

A-7

Module System/Motor Protection Settings


Replacing LodTrak III with LodTrak IV
Module

A-9

APPENDIX B

SETUP EXAMPLE

Setpoint Selection for LodTrak Model LT4A .. B-2

BI006008

Protective Relay Mo ule

GEH-5600

LIST OF FIGURES
Number

Page

Number

2-1.
2-2.

2-2

3-3.

2-8

3-4.

2-3.

2-4.
2-5.
3-1.
3-2.

LodTrak IV M dule Operator Interface ..


Typical Curves for Various Stall
Time Settings t Different RTD
Temperatures . ................
Typical Curves for Various Stall
Time Settings t Balanced Currents
with No RTD ias ..............
Typical Phase nbalance
Characteristics ................
Typical Groun
Characteristics ................
Outline Drawi and Door
Mounting Diag am ..............
LodTrak IV M dule Base Mounting
Outline for 171 6843G5 ..........

3-5.
2-9
3-6.
2-10
3-7.
2-11
3-8.
3-1
3-9.
3-2

Page

TB1 Tenninal Board Connections,


and Ground Fault and Phase
Current CT Connections ...........
TB2 and TB3 Terminal Board
Connections
.................
Wiring for Model 4A, 2-wire RTDs,
3-conductor Shielded ............
Wiring for Model 4A, 3-wire RTDs,
2-conductor Shielded ............
Wiring for Model 4C, 2-wire RTDs,
2-conductor Shielded ............
Wiring for Model 4C, 3-wire RTDs,
3-conductor Shielded ............
Wiring for Model 4E, 3-wire RTDs,
3-conductor Shielded ............

3-3
3-4
3-5
3-6
3-7
3-8
3-9

LIST OF TABLES
Number

1-1.
4-1.
5-1.
5-2.
5-3.
5-4.
5-5.

RTD Characte . tics


Recommended TD Trip
Temperatures.
LodTrak IV M dule Displays
(Models 4A, 4 ,& 4E) . . . . . . . . . ..
Running Mode isplays and Key
Operation (Mo 1 4E)
Alarm Mode Di plays and Key
Operation (Mod Is 4A, 4C, & 4E)
Trip Mode Dis lays and Key
Operation (Mod Is 4A, 4C, & 4E)
Set Point Mode Displays and Key
Operation (Mod Is 4A & 4C) . . . . . . ..

Number

1-3

5-6.

4-2

5-7.

5-4

6-1.
6-2.
7-1.
7-2.
7-3.
7-4.

5-6
5-7
5-8

7-5.
5-10
7-6.

Set Point Mode Displays and Key


Operation (Model 4E)
Set Point Mode Display Wording
(Models 4A, 4C, & 4E)
Troubleshooting The LodTrak Module
RTD Resistance vs. Temperature
Present Values List Indexes
Set Point List Indexes
Values At Trip List Indexes. . . . . . .
Starts/Trips/Hours List Indexes
(Models 4A & 4C) '"
Since Start Values Indexes
(ModeI4E)
Status Flag Indexes, Bits 1-8 .,

5-11
5-12
.. 6-3
6-2
" 7-3
7-4
.. 7-6
"

7-7
7-8
7-9

iii

BI006008

Protective Relay Module

1-5600

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 1
OVERVIEW
1-1. INTRODUCTI N

This manual contains i stallation and operating instructions for the model D 3820LT4 LodTrak IV Protective Relay Module.
The LodTrak IV mod e is a solid-state relay module
used to protect a 3-ph e ac motor/system and certain
system parameters ag . st damaging conditions.
The user of this manu
motor protection plus
systems. Additionally,
sections require experi
technology.

should have knowledge of ac


xperience with industrial control
the testing and troubleshooting
nce in electrical/electronic

Instantaneous overcurrent
Phase unbalance/open phase
Ground fault
Bearing overtemperature
Phase reversal
Loadjam
Undercurrent (load loss)

LodTrak IV modules can operate with four types of


RTDs, CT ratios up to 9000:5 ratio, and two control
power input levels.
One model also includes voltage inputs for additional
protective features and power monitoring.

Before installing or op rating the LodTrak IV module,


personnel should study the application sections, noting
the WARNINGs and
UTlONs included for personal
and system protection. Before attempting to maintain or
repair the module, a te hnician should thoroughly
understand the entire anual.

There are three LodTrak IV module types with the


following model numbers:

DS3820LT4A - Basic LodTrak IV


module

1-2. EQUIPMENT 0 SCRIPTION

DS3820LT4C - Similar to model 4A plus a


communication link

DS3820LT4E - Similar to model 4C plus voltage


input and power monitoring

The LodTrak IV modu e is more than a relay - it is a


microcomputer-based e ectronics module with interfacing for inputs and outp ts. The microcomputer allows
field adjustment for in ividual motor/system conditions.
Each module is custo zed (programmed) to meet each
system's requirements y storing motor/system data for
the specific application in a non-volatile memory.
The LodTrak IV modul
temperature inputs fro
(CTs) and resistance te
Using this information,
tive functions:

monitors motor current and


external current transformers
perature detectors (RTDs).
it provides the following protec-

Overload
Integrated ov rload/overtemperature with
RTDs
Separated ov load/overtemperature with
RTDs
Overload wit no RTDs

1-2.1. Module Types

1-3. GENERAL SPECIFICATIONS

The following specifications are of a general nature.


For specific information about a particular installation,
refer to the system specifications provided by the
switchgear or the controller manufacturer, or the motor
application engineer.

1-3.1. Environment

Operating: 0

to 60C (Celsius) at back of module

Storage: -40 C to 70C


Relative humidity: 0-90% noncondensing, operating,
and storage
1-1

BI006008

Protective Relay Module

-5600

>1cal: Must be in a low voltage (250 V max) comlent of the electrical equipment

1-3.4.1. RTDS. Maximum nns current in an RID:


1.2 rnA for 10 ohm copper type; 0.12 rnA for other
types

lsure: NEMA 1
Winding temperature measurement: 1 to 6 RTDs
~.

Control Power Source

'ard: 115 Vac + 15%, -30%; 47 - 63 Hz or


I dc + 12%, -16%
A. maximum

'cal ride through" for a drop to 0 from nominal


1.5 cycles (0.024 seconds)

Motor bearing temperature measurement: 1 to 2 RTDs


Load bearing temperature measurement: 1 to 2 RTDs
1-3.4.2. VOLTAGE INPUT (MODEL 4E). Source:
Must be from 120 V secondary PTs connected in an
open delta configuration with the secondary grounded
and polarities opposite. Refer to Figure 3-9.

Maximum burden at 120 Vac: 10 VA


3. Output Contacts

nuous: 8 A, 1500 VA or 240 W max


upt as follows:
Voltage

Resistive

Inductive

28 V dc
115 V ac
125 V dc
230 V ac

8A
8A
0.35 A
6A

6A
6A
0.2 A
0.2 A

1-3.4.3. EXTERNAL RELAY INPUT (MODEL 4E).


Terminals are provided to accept an external contact
from devices such as a differential relay. This permits
all trip functions to be combined in the LodTrak which
will trip and display the external trip message, if the
external contact closes.

Closed (Tripped): Low Level signal with 50 ohms maximum resistance


Open: Must be greater than 10 K ohms

1-3.5. Measured Values


*ac: 0.5 power factor
*dc: LlR = 40 msec

k Inputs

mt transformers (one per phase): 5 A secondary


~, 50/60 Hz

rut fault:

1 A or 5 A, secondary rating, 50/60 Hz

of phase CTs: Should provide 2 A to 5 A


dary current at primary full load current level for
, secondary. See Figure 2-2 for maximum in
on to stall time and locked rotor current.
mum burden on CT secondary: 0.00202 ohms and
f .00235 ohms @ 60 Hz

NOTE
Accuracy is dependent upon CT and PI'
accuracy. The use of high accuracy devices
may improve current and voltage accuracy
to 1%, kVA to 2%, and kw to near
2% at PF=l.O.

Phase currents: 2 %, + 1 digit resolution of


secondary current times the CT ratio from 1.25 A to
10 A secondary on a 5 A CT
Minimum measured current is 10% of full load current
set
Groundfault current: 4% of reading from 0.1 A to
1 A secondary current
Minimum measured current is 50 % of alarm current set
Maximum measured CT secondary current is 2.5 A
Voltage:

2 % of reading

1 digit

BI006008

Protective Relay Mo ~ule

KVA:

4 % of readir g

GEH-5600

I digit

than that produced by the noise generator described in


ICS 2-230.43 and 2-230.44. This may require filters or
surge supressors applied to electromagnetic devices
operating with logic system components to limit the
magnitude and duration of transient voltages conducted
or radiated into the logic system. "

KW: 8% (improves as PF approaches 1.0)


RTD temperature: ~ C of reading with proper
connection. Measures IS to 205C, which is
equivalent to a shortee RTD or to an open RTD
respectively.

To avoid possible problems from a potential noise


source, use MOVs (metal oxide varistors) or other
suitable suppression across relay coils in the low
voltage compartment.

1-3.6. Published C ryes

Trip characteristics:

The LodTrak IV module meets the surge withstand


capability of ANSI/lEE C37.90-1978 Section 9.

IS % of curve plotted

Repeatability of curve: I % when initial conditions


are the same each tim( measurement is made.
1-3.8. Voltage Rating
1-3.7. Noise Isolati ~n

RTD inputs: 50 V

The LodTrak IV mod\: Ie is highly tolerant of electrical


noise and exceeds the equirements of electrical noise
test described in NEM A.. Standards Publication No. ICS
2, Part ICS 2-230. However, this module must be
installed, wired, and Ie cated with some degree of
concern for electrical roise, which could produce
erratic operation.

All other inputs/outputs: 250 V


Accepted RTD Characteristics: (See Table I-I.)

1-3.9. Maximum Module CT Fault Current

Maximum CT fault current: 200 A for I second


According to NEMA ~ tandard ICS 2, Part ICS 2-230,
page 10, "Logic system components should be wired,
enclosed, and isolated rom sources of potential noise so
that any noise received by the logic components is less

Current levels and stall time entered are prevented from


exceeding this limit under normal operating conditions.
These are limits shown in Figure 2-2.

Table 1-1. RTD Characteristics


RTD Type

Ohms at DC

Cop er

10 @ 25

15

PT

100@ 0

NI

120@ 0

NI

100@ 0

Edison
Characteristic #

DIN Spec.

43760

British
Standard

1904

1-3

BI006008

1-5600

Protective Relay Module

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 2
DESCRIPTION OF OPERATION
2-1.3. Diagnostics

The LodTrak IV
information throu readouts, annunciation, and
diagnostic display, and allows the operator to
respond using inp t keys. Figure 2-1 shows these
interface devices.

The LodTrak IV module performs internal


diagnostics when control power is first applied and
while power is on. It automatically displays
diagnostic information for operator use. This can
provide shutdown of the module if an internal
problem exists.

2-1 .1. Readout

The module provi s a readout of all measured


inputs by scanning and displaying the ones used on
its 16-character by 2-line LCD display. This
display updates ev ry three seconds. The operator
can read individual phase currents in motor amps,
RTDs in C, and round fault current in percentage
of trip level.

The LodTrak IV m dule uses its display and two


LEDs to annunciat faults and errors, as follows:

LCD display. nnunciates all alarms and trips


when they occ r. Alarm annunciation returns to
the display onc every minute if the display has
been selected t another list to evaluate status
of the alarm. T 'p annunciation always returns
to the display om the At Trip Values list if
the trip has not been reset. Overtemperature
by winding RT s is annunciated separately
from overload
unciation, which is overtemperature by calculated copper temperature.

Trip LED. Ann


flashes during t
Annunciates tri
on until the tri

nciates alarms by flashing, and


e power-up selftest (once).
s by being on steady, and stays
is reset.

I'M OK LED.
unciates the status of the
internal power upply and processor. Flashes
during power-u and selftest when control
power is applie and when in the Set Point
Mode. On stea y for normal operation. Goes
off with loss of control power or processor
malfunction.

2-1.4. Display of Measured/Calculated


Values

The LodTrak IV module updates its display every


three seconds for each measured/calculated value.
Therefore, a rapidly changing input can cause an
alarm or trip before the display shows it. All values
are plus or minus one digit in the least significant
digit.

2-2. RTD MEASUREMENT/OPEN RTD

For lead length compensation, a 3-wire


measurement with one wire common to each group
of RTDs is used. The common wires connect to
TB3-19 and TB3-20 which internally connects to
system ground via TB3-13. TB3-19 and -20 are the
returns for the multiplexed current source. The hot
side of the current source is TB3-1, -4, -7, -10, 13, and -16 for winding RTDs, with TB3-2, -5, -8,
-11, -14, and -17 the feedback side. The hot side of
the current source for bearing RTDs is TB3-21, 24, -27, and -30, with TB3-22, -25, -28, and -31
the feedback side. The sense point for lead length
compensation is where the common and feedback
are tied together.
An open RTD is detected when the current source
goes to its compliance voltage because of too much
resistance in the loop. With no RTDs connected to
the LodTrak module and with RTD protection
enabled, the OPEN RTD message appears in the
display for the first open detected. Open common
wires are not open RTDs, and cause only incorrect
readings.

2-1

BI006008

Protective Relay Module

-1-5600

Because the LodTrak module updates its display of


measured values every 3 seconds, the displayed
current may vary for motors/systems with pulsating
loads. If values are read from the communication
output, values should be averaged by the computer
that is displaying these values to an operator.

NOTE

A significant difference in the common


lead ohms and other lead ohms causes a
III TEMP reading.

2-3. CURRENT MEASUREMENT


The LodTrak module measures phase currents as
RMS, based on the characterization of the last 33
samples of the waveform over a 2-cycle period
(.032 seconds at 60 Hz). The maximum input
current measurable is 75 A. Recognition of
instantaneous faults are anticipated by evaluation of
the change in current since the last sample,
allowing an instantaneous event to be recognized in
0.003 - 0.005 seconds.

Ground fault current levels are measured in the


same manner as phase currents. The maximum
measurable input level is 2.5 A, which is 2.5 times
the maximum setable trip level.

(FRONT VIEW)

LCD DISPLAY

I'M OK LED

DECREMENT
KEY (DEC)

TRIP LED

INCREMENT KEY
(INC)
RESET KEY

SCAN/ENTER
KEY

SELECT KEY

Figure 2-1. LodTrak IV Module Operator Interface

BI006008

GEH-5600

2-4. NON-PRO

2-6.2. Automatic Reset Mode

(All Models.) Th normal trip relay state is


determined by SP 8 and can be NTDF (picks up
for a trip) or TO F (drops out for a trip or a
detectable fault).
the non-protective mode, the
trip relay is dropp d out for either NTDF or TODF
selection.

The LodTrak module automatically resets any


temperature-related trip when the temperature has
cooled 15 below the alarm set point. All other
trips must be reset in the Manual Reset Mode.

2-6.3. Remote Reset Mode

Non-protective M de occurs for either of two


conditions: (1) if e SAVEIN jumper, which
connects TB2-7 d -8, is in place (Set Point
Mode, see section 5-1.4), or (2) a power or
LadTrak module alfunction. If control power is
lost, both the trip d alarm relays drop out.

This is only possible with models 4C or 4E, which


use RS-422 communication signals (see sections 51.3.1 and Chapter 7).

2-7. PROTECTIVE FUNCTIONS


Operation Test

This test should b


models of the Lad
the trip relay open
occurs. Chapter 3,

done at initial installation for all


rak IV module. It checks that
the main contactor after a trip
Installation, describes this test.

The protective functions provided by the LodTrak


module (listed in section 1-2) are enabled or
disabled and necessary values set when the module
is programmed for the particular motor/system.
Table 5-7 lists the set points, their default values,
and limits. The following paragraphs describe these
protective functions.

2-5. PROTECTI E MODE

The LodTrak mod


as long as control
jumper (TB2-7 an
malfunction of the
have proper data t
Improper set point
that may not prote
false alarms and t

Ie is in this mode of operation


ower is applied, the SAVEIN
-8) is removed, and there is no
module. All set points should
protect the motor/system.
data may default to set points
t or that may give nuisance or
s.

With the SAVEIN 'umper removed, the module


comes on in the Pr tective Mode after a control
power interruption However, full motor protection
is not valid until t e LodTrak module has had time
to establish the pro er temperatures by RTD
measurement and/o current input. This takes from
1 to 5 minutes, de ending on the state of the motor
at the time of cont 1 power interruption.

2-6.1. Manual R set Mode

. All trips must be r set at the LodTrak module,


which must be in t e Values At Trip list to reset a
trip using the RES T key. Section 5-1.3.1
describes how to m ually reset the module.

2-7.1. Integrated Overload/Overtemperature


with RTDs

The LodTrak IV module protects a motor from


thermal damage caused by prolonged overload,
mechanical stall, too frequent starts, and severe
duty cyclic loading. This protection is based on the
thermal tracking analysis presented in GE
publication GER-2897.
The RTDs embedded in the stator windings protect
against extended periods of light overloads (less
that 200% current). Under heavier overload, the
RTDs cannot follow the rate of temperature
change. For this case, the current calculations are
required.
The LodTrak IV module provides two trip/alarm
points for overload protection. One point is set by
the maximum RTD trip temperature (see Table 41); the other is a fixed maximum copper
temperature trip of 180C. The alarm points for
both are adjustable with SP27 the RTD alarm and
SP44 the copper temperature alarm.
Figure 2-2 shows typical curves for various stall
time settings at different RTD temperatures. These
curves represent trip times via the copper

2-3

BI006008

Protective Relay Module

1-5600

temperature limit. Therefore, the RTD temperature


defines the areas below 2.0 times full-load current.
Note the decrease in trip time as RTD temperature
increases. This represents the LodTrak module's
thermal tracking capability.
The trip time is a function of the motor heating
characteristics and ambient conditions under which
the motor is being operated.
This protective function uses both maximum phase
current and maximum RTD temperature to
calculate copper temperature under all conditions.
The maximum RTD and copper temperature are
initialized to 40C and 80 C, respectively, when
control power is applied. These temperatures then
integrate to the levels measured from module
inputs.
The LodTrak IV module maintains copper
temperature above the maximum RTD temperature
at all times that current is in the motor. The
:lifference depends upon current level up to 1.95
per unit (PU) current, with locked rotor current
plus stall time included beyond that point. Cooling
:lepends on the maximum RTD temperature
measured once copper temperature has cooled to
the level of maximum phase current.
fo enable the integrated overload/overtemperature
Jrotective function:
I.

Set point SP23 (Winding RTDs are Used) must


be set to YES.

Set point SP24 (Number of Winding RTDs)


must be a value of 1 - 6.

Set point SP26 (Overload Type) must be set to


RTD.

minutes.) These curves represent trip times via the


copper temperature limit. Alarm (SP44) is
adjustable. Trip times decrease if current unbalance
causes heating above the multiple shown on the
curve. The overload protective function uses only
phase currents to calculate the stator temperature
and the copper temperature. It measures each phase
current to calculate equivalent motor heating
current caused by current unbalance. Thus,
negative sequence current heating causes faster trip
times than balanced current.
With locked rotor current levels high and with a
stall time below 10 seconds, overload and phase
unbalance trips can occur at about the same time if
a start is attempted with an open phase.
In this protective mode, the minimum stator and
copper temperature is 40C with initialization to
40 C and 80C, respectively, when control power
is applied. The LodTrak IV module calculates
stator temperature up to the ultimate trip level (set
point SP43) whenever the current is in the motor.
Beyond this level, motor heating current controls
the calculated copper temperature, with the starting
point set by the calculated stator temperature at that
time. This causes faster trip times if the motor was
running before the current exceeded the ultimate
trip level, calculated stator temperature keeps the
copper temperature from cooling too fast. When
current goes to zero, the cooling rate of the
calculated stator temperature is one-third of its
heating rate.
To enable the overload (without RTDs) protective
function:
1. Set point SP23 (Winding RTDs Are Used)
must be set to NO.
2.

2-7.2. Overload Without RTDs

fhe LodTrak IV module protects a motor from


hermal damage caused by mechanical stall, hot
;tarts, prolonged overloads, and the heating from
legative sequence currents.
Figure 2-3 shows typical curves at balanced
:urrents for various stall time settings for both a
:old start (40C) and a hot start (110 0C). (Hot
;tart is the temperature reached with balanced
:urrents after running at 1.0 PU current for 60 - 80

Set point SP43 (ultimate trip) must be set to the


value required by the application (see section 51.4.1).

2-7.3. Separated Overload/Overtemperature


with RTDs

This motor protection is the same as for an


overload without RTDs (above), except that a trip
also occurs when the maximum RTD temperature
reaches the RTD trip temperature set point. This
gives two trip/alarm points for overload, but does
not provide thermal tracking capability because

BI006008

GEH-5600

measured RTD t mperature is not included in the


overload characte istics.
This protective nction uses either the overload
protection or a m asured maximum RTD
temperature trip oint that is independent of the
overload trip ch acteristic.
ated overload/overtemperature

1. Set point S

3 must be set to YES.

2.

must be set to 1 - 6.

3.

must be set to NO RTD.

current unbalance. The LodTrak IV module


calculates an operating load current (OPLC) by
averaging the squares of the 3-phase currents. The
set point SP48 (Phase Unbalance Trip) value is the
percentage unbalance allowed at 1 per unit OPLC
that will cause a trip.
As OPLC falls below 1 per unit OPLC, the allowed
percentage unbalance increases based on the actual
OPLC. At OPLC levels below 0.875 PU, a
maximum of 35 % unbalance is allowed. If all 3phase currents exceed 1.5 PU, this protection is
disabled, allowing greater unbalance during
starting.

2-7.6. Ground Fault


eous Overcurrent

The LodTrak IV
peak current fault
cable faults. Trip
seconds after faul

odule provides protection against


caused by shorted windings or
ime is approximately 0.032
level is detected.

Instantaneous ove current protection is a peak


sensing function, hich requires that dc offsets be
considered. The aximum measurable level for CT
secondary current is 75 amps, which cannot be
exceeded by the 11 load current entered (SP38)
times the instant eous current multiplier entered
(SP42). Trip time equals 0.024 to 0.032 seconds.
SP38 is in RMS, d SP42 must include -/2 for
peak sensing (SP4 = SP39 x multiple (typically =
2) x 1.414).

For ground fault detection, the module uses a zero


sequence CT with all three load current phases
(power cables) running through the same window.
The ratio of the CT to the module setting
determines the maximum primary current allowed
for a ground fault. Set point SP51 sets the alarm
point. The delay (SP54) prevents nuisance trips on
starting and permits coordination with other
devices.
Figure 2-5 shows typical trip characteristics. This
protective function is a low-level current
measurement from 0 to 2.5 amps. The LodTrak IV
module digitally filters the measured current. When
the current average exceeds the alarm/trip levels
for the appropriate timing, the ground fault
alarm/trip occurs.

2-7.5. Phase U balance/Open Phase

2-7.7. Bearing Overtemperature

For current unbal ce protection, the worst case is


open phase. Both arm and trip set points are in
percentage of full oad current. When running at
less than full load current, more unbalance is
allowed because t e motor can withstand more
negative sequence losses. This protection does not
operate when all 3 phase currents exceed 1.5 times
full load current.

The LodTrak IV module monitors bearing RTDs.


Models 4A and 4C have one grouping for all four
RTDs. Model4E permits the splitting of RTDs
into two groups of two. This allows for different
RTD types or different alarm or trip set points. The
alarm/trip points are for the hottest of the group(s)
selected.

Figure 2-4 shows ypical trip characteristics. The


operating load cu ent (OPLC) is the square root of
the average of the sum of each current squared.

The bearing overtemperature alarm/trips are based


on the maximum of the RTD inputs to the group.
Reset of a trip can be automatic or manual via set
point SP64, with reset allowed when measured
temperature is 15C below the alarm point.

This protective fu ction determines the loss caused


by negative seque ce currents, which result from

2-5

BI006008

Protective Relay Module

-1-5600

2-7.8. Phase Reversal

2-7.10. load Jam

The module's phase reversal function is system


protection against damage/hazard caused by a
change in the motor rotation direction if a phase
sequence change is made. This function requires
that minimum current be 150% of full load current
to detect phase reversal.

The LodTrak IV module's load jam function


protects the system from abnormal loading. These
abnormal loads may result from system mechanical
failures, or from trying to operate the motor at
loads above the normal operating load. This
function is disabled during starting.

Phase reversal is sequence-sensitive to CT


secondary currents that exceed 1.5 PU current as
set in set point SP38 (secondary full load amps).
Phase reversal is enabled only during the start
inrush transition of 0 to greater than 150% of full
load current; it is disabled once current falls below
the 150% level.

Load jam protection is disabled/enabled the same


way as the undercurrent protection. For alarm/trip
points, both load protection functions use the
average of the 3-phase currents over an 8-10 cycle
period. This prevents transient changes in load
currents from causing nuisance trips. This protection is trip only because the alarm and trip relays
operate at the same time.

To enable the phase reversal trip function, set point


SP49 must be set to YES.

Set points SP61 thru SP63 must be set to the


appropriate levels for this function to operate.

2-7.9. Undercurrent (load loss)


2-7.11. Undervoltage (Model 4E)

The LodTrak IV module's undercurrent function


protects the system against loss of motor drive
capability caused by loss of coupling means (such
as breakage, chain breakage, pump loss of prime).
This function is disabled during starting and when
below 10 % full load current.
The undercurrent protective function is disabled
until current exceeds 1.5 PU and returns to below
that level, remaining there for 15 seconds. Once
this sequence completes, the function is enabled
(even if control power is interrupted momentarily)
until current falls below 0.10 PU. After falling
below 0.10 PU, a start cycle of current must
complete or normal motor currents sensed for a
time period to reenable the load loss protective
function.
To enable the function, set points SP57
(Undercurrent Used), SPS8 (Undercurrent trip
used), SP59 (Undercurrent level), and SP60
(Undercurrent delay) must be set to appropriate
values.
NOTE

If SP57 is "YES" and SP58 is "NO",


the undercurrent function will only

produce an alann signal.

Model 4E of the LodTrak IV module includes


protection against low line volts with either an
alarm only or an alarm and trip. Undervoltage
protection operates on an 8-cycle average voltage
level, and is always present if selected.
The delay set point (SP9) affects both the alarm
and trip so that both can be prevented during motor
accelerating time. The nominal secondary voltage
set point (SP4) determines the 100% voltage level.

2-7.12. Overvoltage (Model 4E)

Model 4E of the LodTrak IV module includes


protection against high line volts with either an
alarm only or an alarm and a trip. Overvoltage
protection operates on an 8-cycle average voltage
level, and is always present if selected.
The delay set point (SPI4) affects both the alarm
and trip so that transient overvoltage are ignored.
The nominal secondary voltage set point (SP4)
determines the 100% voltage level.

BI006008

Protective Relay Mo ule

2-7.13. Phase oss by Volts (Model 4E)

This feature prote ts against attempting a start if


one or more phas volts are below 50 % of the
nominal voltage s t point. The LodTrak module's
display annunciate this protection as PHASE LOSS
in the Starts/Trips Hours list, and PHASE
UNBALANCE el where. This is a trip-only
protection, with t alarm and the relays operating
at the same time.
Set point SP15 m t be set to YES to enable this
function. This fun tion is disabled if phase
unbalance protecti n (paragraph 2-7.5) is enabled
and minimum mot r current is above 0.1 PU.
(Volts must be pre ent for current flow.)

2-7.14. Phase

eversal by Volts (Model 4E)

GEH-5600

An emergency restart can be accomplished by


resetting the 60-minute period, as follows:
1. Press the RESET key twice. The LodTrak
module displays the amount of time until reset
is allowed.
2. With the display showing this time, hold in the
DEC and SCAN/ENTER keys and press the
RESET key. This sets the time to O.

2-7.16. Capacity Used Value (>99%

= Trip)

This value indicates how close a motor is to being


tripped off line. The value is either the greatest
percentage calculated for winding temperature
versus user set trip temperature, or calculated
motor temperature versus 180C trip temperature.

This feature is a p otection against attempting a


start if the line vol age sequence is not per the
connection sequen into the LodTrak IV module
(see section 3-2.7) This is a trip-only protection
with the alarm and trip relays operating at the same
time.

NOTE

0% capacity used
<39 C.

= both temperatures

2-8. USING CURVES (FIGURES 22 AND 2-3)

Set point SP16 mu


function. Protectio
current level as 10
exceeds 50 % of no

t be set to YES to enable this


is present regardless of the
as the minimum voltage
.nal.

2-7.15. Maximu Number of Starts in 1


Hour (Models 4C and 4E)

Models 4C and 4E of the LodTrak IV module


include protection gainst too many start
attempts/completio s in a 6O-minute period after
the first start is att pted/completed. This
protection holds th LodTrak module in the Trip
Mode when the mo or stops after the number of
start attempts/comp etions within 6O-minute period
equals the number' the set point list. The
LodTrak module c be reset when the 6O-minute
period completes.
Set points SP55 mu t be set to YES and SP56 to
the appropriate val e for this function to operate.

These curves are used to determine overload trip


times and to aid in the initial selection of the CT
ratio.
Figure 2-2 is used when the overload/overtemperature function is integrated with the RTD
temperature function. This figure shows three sets
of curves:

Some limit conditions

A family of curves (6 x 5 sec)

Several different cold curves

The three upper most curves labeled 2.0, 3.5, and


5 amp FLC represent limit cases when long stall
time settings are required. The 5 amp FLC curve
shows that if rated FLC produces 5 amps in the CT
secondary, the locked rotor multiple of FLC can be
no more than 4. This is the point where the 5 amp
FLC curve intercepts the 90 second line. If the
rated locked rotor multiple must be larger than this,
the CT's must be selected to provide a CT
secondary current lower than 5.0 amps for rated
FLC. If secondary FLC is 3.5 amps, the 3.5 amp

2-7

BI006008

Protective Relay Module

fI-5600

FLC curve shows that stall time can be set at 90


seconds with a locked rotor multiple setting as high
as 6. The 2.0 amp FLC curve shows that the 90
second stall time can be used with multiples up to
10. Notice that as the required stall time decreases,
the allowable locked rotor multiple can be larger.
For example, if FLC is 5.0 amps and stall time is
set at 30 seconds, the locked rotor multiple setpoint
can be as high as 7.
The three lowest curves are the 6 x 5 sec family.
The 6 x 5 sec 40C curve is the cold or set up
curve. The set up data is specific for a particular
motor/application as determined by a motor
application engineer. The actual position of this
curve is set by SP39 (rated locked rotor amps as a
multiple of full load amps [the 6]) and SP40 (rated
stall time [the 5 sec]). The 40C indicates the cold
rating curve. Notice that the 6 x 5 sec 40 C curve
passes through the point where the 5 second line
intersects the multiple of 6 line. The two curves
below it show how the trip characteristics shift as
motor temperature increases.
The other curves labeled 6 x 10 sec, 6 x 15 sec,
6 x 20 sec, and 6 x 30 sec show the cold curve for
several different motors, each having the 6 times
multiple of stall amps but with different stall time
ratings. Any of these curves can be used to aid in
constructing a new curve for a specific motor.

To create specific curves for a particular locked


rotor multiple, and stall time set points, use the
following procedure:
1.

2.

Cold motor curve


a.

Place a point on the graph where the


specified multiple intersects the
specified stall time.

b.

Construct a curve, paralleling the


closest existing curve, through the
point placed in Step 1. This is the cold
or 40C curve.

Curves for 80 to 120C can also be


constructed
a.

On a convenient multiple line, measure


the vertical distance between the 6 x 5
sec 40C and the 6 x 5 sec 80 C
(and/or 120C) curves.

b.

On the same multiple line used in Step


1, measure downward from the cold
curve (drawn in Step Ib) above the
distance found in Step I, and place a
point.

c.

Construct a curve, paralleling the


closest existing curve, through the
point placed in Step 2. This is the new
hot curve.

BI006008

GEH-5600

Protective Relay M41ule

501 t-t-H+t--1hnr-r...-+-++-++++---+--+-+-J-+-f.+~
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MULTIPLE OF FULL LOAD CURRENT

Fi~re

2-2. Typical Curves for Various Stall Time Settings


at Different RTD Temperatures
2-9

BI006008

Protective Relay Module

-1-5600

Figure 2-3 is used when the overlaod/overtemperature function does not use RTDs or when
the RTD function is separate from overload. This
figure shows:

Limit conditions

Several families of curves

How the ultimate trip setting affects trip


times.

The three curves labeled 2.0, 3.5, and 5 amp FLC


represent limit cases when long stall time settings
are required. This is described above.
The two lowest curves are one family. The 6 x 5
sec cold curve is the cold or set up curve. The set
up data is specific for a particular motor/application
as determined by a motor application engineer. The
actual position of this curve is set by SP39 (rated
locked rotor amps as a multiple of full load amps
[the 6]) and SP40 (rated stall time [the 5 sec]).
Notice that the 6 x 5 sec cold passes through the
point where the 5 second line intersects the multiple
of 6 line. The 6 x 5 sec hot curve below it shows
how the trip characteristics shift when the motor
reaches normal full load operating temperature.
There are two more families of curves labeled 6 x
15 sec cold and hot and 6 x 45 sec cold and hot.
Any of these curves can be used to aid in
constructing a new curve for a specific motor.
The ultimate trip setpoint modifies the shape of the
trip curve. This effect is shown on the 6 x 45 sec
cold curve as dotted lines in the 1 to 4 multiple
area. This setpoint is nonnally determined from
motor service factor. This current value (in pu)
becomes the asymptote for the curves.

To create specific curves for a particular locked


rotor multiple and stall time set points, use the
following procedure:
1.

Cold motor curve

a.

Place a point on the graph where the


specified multiple intersects the specified stall
time.

b.

Construct a curve, paralleling the closest


existing curve, through the point placed in
Step 1. This is the cold curve.

2.

Hot motor curve

a.

On a convenient multiple line, measure the


vertical distance between the cold and hot
curves of the family nearest the cold curve
drawn in Step Ib above.

b.

On the same multiple line used in Step I,


measure downward from the cold curve
(drawn in Step Ib above) the distance found
in Step I, and place a point.

c.

Construct a curve, paralleling the closest


existing curve, through the point placed in
Step 2. This is the new hot curve.

BI006008

GEH-5600

Protective Relay Mo( ule

1000

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Fi ure 2-3. Typical Curves for Various Stall Time Settings


At Balanced Currents with No RTD Bias
2-11

BI006008

Protective Relay Module

1-5600

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- --- -

\ \.

.\

.8

\.

-- -,- .. .

~---

.8

..

87.5% FLC

I
OPLC - 95% FLC

I II

OPLC - 97.5% FLC

OPLC -

.8

<

OPLC -

>

100% FLC

.2

IA 2
.1
.08
.08
.05

.0.
.03

OPLC -

--

- ... TWO PHASES = 1 MAX


ONE PHASE = 1 MIN

-...-

PHASE UNBALANCE
MAX - MIN CURRENT In PERCENT OF FLC
vs TRIP TIME, 10% & 30% S.P.
vs OPERATING LOAD CURRENT
(CURRENTS LESS THAN 1.5 FLA)

.0 1

10

20

30 40

80 80 100

IMAX -

IMIN

200

400

800 800 1000

2000

in PERCENTAGE of FLC

Figure 2-4. Typical Phase Unbalance Characteristics

+ la2 + Ic2

3000

BI006008

GEH-5600

Protective Relay Mo( ule

TYPICAL GROUND FAULT


TRIP CHARACTERISTICS
CURRENT STEP FROM
1----1--+---4---+--- ZERO CURRENT -

1.0

Ground Fault Delay

0.5
(/)
Q

,-

= 1.00 sec.

.'

Ground Fault Delay = 0.50 sec.

0
U

(/)
t

&II

:E

Ground Fault Delay = 0.10 sec.

0.10

IAo
I I:

I-

Ground Fault Delay

0.05

= 0.05 sec.

BASED ON A "100:5 CT

0.01 H---+---t----+--r---+---+--I---.J--~

1.0

2.0

3.0

4.0

5.0

8.0

7.0

8.0

MULTIPLE OF TRIP LEVEL

Figure 2-5. Typical Ground Fault Trip Characteristics

2-13

BI006008

-1-5600

Protective Relay Module

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 3
INSTALLATION
3-1 .1. Door-Mounting

3-1. MOUNTING

The LodTrak IV mod


meets the environmen
The location should b
to facilitate inspectio

Ie can be mounted anywhere that


al specifications of section 1-3.1.
easily accessible and well-lighted
and servicing.

AUTION
The LodTrak
module must be mounted
vertically to pr ide necessary ventilation.
Heat producing devices must be located at
a sufficient dist nee from the module to
ensure that the 0 C maximum module
ambient tempe ture is not exceeded. The
bottom of the m dule should be at least 2
inches above an barrier that could impede
airflow through the module from bottom to
top.

The LodTrak IV module is normally mounted through a


cut-out in the door of a starter. This requires a
minimum clearance of 4.30 inches behind the door.
Figure 3-1 shows the door cut-out dimensions and
mounting-hole drill pattern.

Replacement Door-Mounting

Adaptor Plate

LodTrak IV module replacing:


- Lodtrak I module
- LodTrak II or III module

323A1502G2
323AI502GI

;.f<~~
3~e

Ir:':~
===
===
===
===
===

ALL MATERIAL
IS CONDUCTIVE

TOP VIEW

f----I-

CIIJ ITIJ

11~.

[[ [} ITIJ

11.563

OJ

5 '~2

1---2 Y. - -2 y.--l
L----::- S'l: ~
5.75

DRIll. PlAN

OR

P~El

R DOOR

M UNT\NG

IC~lt
:~: - J ;;.F
SIDE VIEW

f--

FRONT VIEW

NOTES:
1.

~L

DIMENSIONS AAE IN INCHES

2. ESTlW>.TED WEIGHT:

Figure 3-1. Outline Drawing and Door Mounting Diagram

6 LBS.

3-1

BI006008

Protective Relay Module

1-5600

2. Base-Mounting

Replacement Base Mounting

Plate Part No.

LodTrak IV module can be base-mounted initially,


can replace a LodTrak II or LodTrak III module in
idsting base mount.

LodTrak IV module replacing:


- LodTrak II module
- LodTrak III module

171B6843G3
171 B6843G4

base mount adaptor for initial LodTrak IV module


lIation is part number 171 B6843G5. Figure 3-2
IS the mounting dimensions for this adaptor.

SIX (6) MOUNTING HOLES


FOR 1/4" DIA. HARDWARE

NOTES:
ALL DIMENSIONS ARE IN INCHES

<)1
__ -I

1
I

I
I

.J

1.00

1<>++_-.L__

CD IT]
CD IT]

16.25
16.75

~96

-,

<)1

15.20

r-1

2~6

--...,
I

I <>++--1..

0.50

-t
- - - - - - 6.79

-------..,.1

SIDE VIEW

I.

FRONT VIEW

Figure 3-2. LodTrak IV Module Base Mounting Outline for 17186843G5

BI006008

Protective Relay Mo ule

GEH-5600

3-2. WIRING
Before wiring the Lod rak module to the input and
output sources, review the power specifications in
Chapter 1. Note that t ese specifications include noise
isolation requirements.
All wiring connects to the terminal boards located on
the module's sides (se Figures 3-3 and 3-4), or to CT
input connections, loc ted at the rear of the module (see
Figure 3-3).
Control terminal boar TBI is for relay and control
power connections. It ontains binding head screws, and
accepts either ring or ade terminals for up to #14

AWG wire. Terminal board TB2 is for communication


connections, program lock inputs, and external relay
inputs. Terminal board TB3 is for RTD connections.
For TB2 and TB3, which are clamp-type terminal
boards, wires need to be stripped of insulation for 0.25
inches, then installed into the correct terminal board
point. When using stranded wires, use particular care
that all strands enter the terminal. Flared strands can
cause shorts between adjacent terminals.
Figures 3-5 thm 3-9 show all LodTrak IV module
wiring connections. The five figures show wiring
variations for the different models with either 2-wire or
3-wire RTDs.

(RIGHTHAND SIDE & BACK VIEW)

Note: See Figures 3-5 thru 3-9


for wiring details.
SCREW TO REMOVE
FRONT COVER
SCREW TO REMOVE
BACK COVER

MOUNTING HOLE

RTD CALIBRATION
POTS

TERMI AL BOARD TB1


(RELA & CONTROL
POWE CONNECTIONS)

===
===
===
===
===
===
o
MOUNTING HOLE
SCREW TO REMOVE
FRONT COVER

PHASE CURRENT & GROUND


FAULT CT CONNECTIONS
(CT COVER REMOVED)
SCREW TO REMOVE
BACK COVER

Figure 3-3. TBt Terminal Board Connections, and


Ground Fault and Phase Current CT Connections

3-3

BI006008

-1-5600

Protective Relay Module

(LEFTHAND SIDE & BACK VIEW)

Note: See Figures 3-5 thru 3-9


for wiring details.

o
TERMINAL BOARD TB3
(RTD CONNECTIONS)

(]

TERMINAL BOARD TB2


(RS-422 & SAVEIN
JUMPER CONNECTIONS)

MANUFACTURER'S
TEST CONNECTOR
(GE FACTORY USE ONLY)

CT COVER
r;e>~r:=""iT'==~~1
SNAPS OVER
CT'S ------------ >

e>

e> e> e>

e>

Figure 3-4. TB2 and TB3 Terminal Board Connections

BI006008

Protective Relay Mo ule

GEH-5600

r--I

INTERNAL ------j
CONNECTIONS

WINDING

rat

~}

MODEL 4A
RTD WIRING
-WIRE RTD'S
.3-CO DUCTOR SHIELDED

~
1

M
17

~}

010
115VAC OR t25VOC

r-

REO

4o-+--+--+RTD2

TRIP
RELAY

N.C.

~
7
8o-t--+-+9

10 o-+--+--+RI04 1 1 o-+--+--+12
13 o-+-+--+RTD5 14 o-t--+-+15

t 1}

16 o-t--+-+--------4-<> 12 ~g~I~OL
RI06 17 o-+-+-++<>~1,3 GROUND
18

STARTER
GROUND

014

N.C.
RIO -19
COM
BEARING 21 O-+---+-

RTD7 22 O-+--+-

23
L

L2

24 o-+-+--+RI08 25 o-t--+-+26

l3

MOTOR
STARTER

3
ALARM
RELAY

~}
AUXILIARY
1
RELAY
RIO,3

TB,3

lo-t---+RIO 1 2o-+---+-

TO TRIP
CIRCUIT AS
REQUIRED

MOTOR
INTERNAL
CONNECTIONS

27o-+-+-~

RI09 28o-t--+-+29

30 o-t--+-+RTD 10 ,31 o-t--t--t-

32

I
I
I
I
I
I
I
I

RIO
COM -20
TB2
N.C.

11'

20
N.C.

.31'
40

N.C.

51'
60

SAVE
IN

{71'
80

THE SAME SIZE WIRE MUST BE


USED FOR ALL RTD WIRING.

{96

PROGRAMMING

LOCK

N.C. 100

Fi ure 3-5. Wiring For Model4A, 2-Wire RTDs, 3-Conductor Shielded

3-5

BI006008

1-5600

Protective Relay Module

I--INTERNAL
----lI
I
CONNECTIONS

MOTOR
INTERNAL
CONNECTIONS

TB3

~}

MODEL 4A
RTD WIRING
3-WIRE RTD'S
2-CONDUCTOR SHIELDED

,...----A-----.

WINDING

TBl

~
1

1?}
tJ

10-t---fRID 1 20-t----+-

REO

3
ALARM
RELAY

40-t---fRTD2

70-t---f80-t----+9

100-t---fRTD4 11 0-t----+12

130-t---fRTD5 14 0-t----+15

115V_A_C_O_R_1_25_V_DC_-+<> 11} CONTROL


160-t---f12
POWER
RTD6 17 0 - t - - - f r+<~13 GROUND
18

AUXILIARY
RELAY
RID3

17

TO TRIP
CIRCUIT AS
REQUIRED

~}
~

STARTER
GROUND

TRIP
RELAY

N.C.

010

N.C.

014

RTD _ 19
COM

o-+------;----J

BEARING 21 0-t----+-

RTD7 22 0-t----+23

L1

L2

u
MOTOR
STARTER

I
I

24 0-t----+RTD8 25 0 - t - - - f 26

270-t----+RID9 280-t---f29

I
I

30
RID10 31
32

o-+---!-

<:>--t----S-.---~

RTD
COM -20
TB2
N.C.

19

20
N.C.

39

THE SAME SIZE WIRE MUST BE


USED FOR ALL RID WIRING.

40
u.

~ ~ ~

'-'~~~

MOTOR

I
N.C.

SAVE
IN

N.C.
MUST BE KEPT AT LEAST
18" FROM HIGH CURRENT
BUS OR WIRING.

50,
60

{7 0I
86

PROGRAMMING
LOCK

9b
{100

Figure 3-6. Wiring For Model4A, 3-Wire RTDs, 2-Conductor Shielded

BI006008

Protective Relay Mo ule

GEH-5600

INTERNAL --J
Ir--- CONNECTIONS
I

WINDING

TBI

~
~
1

ODEL 4C
TO WIRING
2 WIRE RTD'S
2-CON UCTOR SHIELDED

RTDI

ALARM
RELAY

f;L}
1

AUXILIARY
RELAY
RTD3

17

TO TRIP
CIRCUIT AS
REQUIRED

~}
J,.tl
010

115VAC OR 125VDC

TB3

10-+---+-20--+--+

REO

40-+---+RTD2

t:j

MOTOR
INTERNAL
CONNECTIONS

70--+--+
80-+---t9

100-+--+
RTD4 11 o--+---t12

TRIP
RELAY

130--+--+
RTD5 14 0--+--+
15

N.C.

------_+_<J :2' }

...STARTER
GROUND

CONTROL
160--+--+
POWER
RTD6 17 0 - + - - +
+>-1;.:3 GROUND
18

014

N.C.

RTD - 19 0 - - + - - - - - - '
COM

BEARING 21 O-+---+-

RTD7 220--+---t23

L1

l2

240-+---tRTD8 25 o--t---+26

l3

I
I

270--t---tRTD9 280-+---t29

MOTOR
STARTER
CT
A

30 o--+---+-RTD10310--+---t32
RTD
COM -200--+------'

TB2
TRANSMIT

RECEIVE

{~~

",I ---.Lr---,-----.,j"'r----,--

{ NP~31
[4

L..

<.:>

~ ~ ~
Cl. Cl. Cl.

SAVE
2222
IN
MUST BE KEP AT LEAST
18" FROM HIG CURRENT
BUS OR WIRIN .

{7 0
80

90

N.C. {

100

THE SAME SIZE WIRE MUST BE


USED FOR ALL RTD WIRING.
FROM "MASTER" TO LAST LT4C
SHIELD MUST BE CONTINUOUS

F. ure 3-7. Wiring For Model4C, 2-Wire RTDs, 2-Conductor Shielded

3-7

BI006008

1-5600

Protective Relay Module

INTERNAL--J
II--.. -CONNECTIONS
I

WINDING

TBl

~}

MODEL 4C
RIO WIRING
3-WIRE RIO'S
3-CONDUCTOR SHIELDED

~
1

4o--t--+--tRTD2

~
1

~}
B

RED

3
ALARM
RELAY

I?}
AUXILIARY
1
RELAY
RTD3
{

,----A----.,

TB3

lo--t---tRTD 1 2 o--I---t-

TO TRIP
CIRCUIT AS
REQUIRED

MOTOR
INTERNAL
CONNECTIONS

7o--t--+--tao--t--+--t9

10 o-+--+-+RTD4 11 o-+--+-+12

TRIP
RELAY

13o-+--++RTD5 14 o-+--++15

115V_A_C_O_R_l_Z_5V_D_C_-+ ' ' } CONTROL


16 O--I--++12
POWER
RTD6 17 o-+--+-+13 GROUND
-+0-:-::
18

N.C.

010

.--

STARTER
GROUND

N.C.

014

RTD -19
COM

BEARING 21 o--t---t-

RTD7 22o--t---t23
L1

L2

24 o--+---+---+RTD8 25 o--+---+---+26

L3

27 o--+---+---+RT09 28o--+---+--+29

MOTOR
STARTER

30
RT010 31
32
RTD
COM -20
TB2
TRANSMIT

RECEIVE

{P 1
N Z

L..

J:

<.:> ll.

CD
J:
!l.

<
J:

[4

ll.

MUST BE KEPT AT LEAST


18" FROM HIGH CURRENT
BUS OR WIRING.

2 2

1 1

{'~' I
N

N.C.

0I
{90
100

SAVE {7
IN
8

~~

XMIT}
RCV

TO NEXT
LT4C

SHIELD MUST
BE CONTINUOUS
FROM "MASTER"
TO LAST LT4C
THE SAME SIZE WIRE MUST BE
USED FOR ALL RTD WIRING.

Figure 3-8. Wiring For Model4C, 3-Wire RTDs, 3-Conductor Shielded

BI006008

Protective Relay Mo ule

GEH-5600

ilNTERNAL
CONNECTIONS

WINDING

TBI
I

ODEL 4E
TO WIRING
3 WIRE RTO'S
3-CON UCTOR SHIELDED

17

RELAY

19

010

1 15VAC OR 125VDC

N.C.

CONTROL
POWER

12
13

STARTER
GROUND

RTD2

4
5
6

RTD3

RELAY

GROUND

014

ffi3

RTDI

14

!J}'"""""
9} m"
"}

MOTOR
INTERNAL
CONNECTIONS

1
2
3

} MAR'
RELAY

16

TO TRIP
CIRCUIT AS
REQUIRED

~
REO

7
9

10
RTD4 11
12

13
RT05 14
15

16
RTD6 17
18

N.C.

RTD -19
COM

15
}
16

VOLTS
INPUT

I
I
I
I

BEARING 21

Ll

L2

RTD7 22
23

L3

24
RTD8 25
26

MOTOR
STARTER

27
RTD9 28
29
30
RTD10 31
32

LJ

RTD
COM -20
TB2
TRANSMIT

{IIc::
SAVE {7
IN
80

RECEIVE

....
0

I
CL

lD
I

ll.

{P I I
N 2

ll.

MUST BE KE
18" FROM HI H CURRENT
BUS OR WIRI G.

?
I

EXT. {9
RELAY 10

FROM "MASTER" TO LAST LT 4E


SHIELD MUST BE CONTINUOUS
THE SAME SIZE WIRE MUST BE
USED FOR All RTO WIRING.

[Jure 3-9. Wiring For Model 4, 3-Wire RTDs, 3-Conductor Shielded

3-9

BI006008

Protective Relay Module

[-5600

1. Control Power Wiring

'rak IV modules operate on either ac or dc power.


specifications, see section 1-3.) This input power
ects to input terminals TB1-11 and TB1-12, which
ot polarity sensitive. Separate wires should be run
tly from the control power source to TBl-ll and
12, with no connections to any other device or to
)ther point on the LodTrak IV terminal board. An
nal 1 amp fuse is recommended.

seconds, shielded wire is sometimes needed to prevent


nuisance tripping on starting. The ground connection on
the secondary should be at the same point as the phase
CTs.
3-2.4. RTD Input Wiring

If either winding or bearing RTDs are used (SP23 or


SP29 = YES) and no RTDs are connected, the LCD
display annunciates an OPEN RTD message. The TRIP
LED then flashes to indicate an alarm, and the alarm
relay is dropped out. This does not affect the trip relay.

2. Phase Current CT Wiring

Figures 3-5 thru 3-9). For proper phase reversal


Ition (section 2-7.8), the output sequence from the
econdaries must provide PHA-l to PHB-1 to PHCation into the LodTrak IV module. Wiring from
T secondaries should be routed so that other
llctors carrying high current do not induce false
nt. One side of each CT secondary must be
lded externally to the module, and multiple
lds must be avoided.

WARNING

Extremely hazardous voltages can appear


across the CT secondaries if the secondary
circuit is open circuited. To avoid electric
shock or burn, do not service these leads
with the motor energized.

3. Ground Fault CT Wiring

a single window-type CT of desired current ratio.


a 100/5 GE type JCH-O transformer is used.
e motor load conductors through the CT window.
t

The maximum "loop" resistance for RTD wires must


not exceed 25% of the "cold" RTD resistance.
Example: Use at least #14 AWG (3-conductor shielded)
wires for a 500 ft. run (one way) from the module to a
10 ohm copper RTD at the motor. Here, 1000 ft. (loop
distance) of #14 AWG wire has a resistance of about
2.5 ohms. This corresponds to 25% of the RTD
resistance.

CAUTION
Before connecting any RTD leads to the
module/starter, remove any ground connections at the motor to prevent possible
damage to the module.
Winding RTDs must be connected in sequence, RTD 1
(TB3-1, -2, and -19 with shield to -3). Bearing RTDs
must be connected in sequence beginning with RTD 7
(TB3-21, -22, and 20 with shield to -23). Reference
Figures 3-5 thru 3-9.

~ally

:se conductors are shielded and the shields pass


Igh the ground fault CT, the shield-to-ground
lding wires must pass back through the ground
CT. The CT secondary is not polarity sensitive
the LodTrak module.
Ilg from the CT secondary to the LodTrak module
not pass near conductors carrying high current. If
~ip level is low and the trip delay is below 0.5

The LodTrak IV module is configured to accept either


2- or 3-conductor shielded cable between the motor
junction box and TB3. It is also arranged so that either
2- or 3-wire RTDs may be connected. For typical
connections, see Figures 3-5 thm 3-9.
NOTE

RTDs must not be grounded at the motor.


Verify that the type of RTD set point (listed in Table 57) is set to the type of RTD that is connected to that
group of RTDs (such as winding to 10 ohm CU,
bearing GR 1 to 100 PT, GR 2 to 120 NI).

BI006008

Protective Relay Mo< ule

3-2.5. Grounding V"iring

V~ARNING
To prevent shoe ~ or burn to personnel, the
LodTrak IV mo ule and the RTD shields
must be ground d as specified to prevent
dangerous voltal es on the module if an
RTD short or C [' open circuit occurs.

GEH-5600

Trip on Detectable Failure; TODF means Trip on


Detectable Failure). When in NTDF Mode, the N.O.
contact closes on a trip condition. It de-energizes when
the module is reset. When in TODF Mode, the
N.C.contact closes on a trip condition, a module
failure, or loss of control power. For connection points,
refer to Figures 3-5 thru 3-9.

I_C_A_U_T_I_O_N_I
The trip relay should not be wired to cause
interruption of the control power to the
LodTrak module. To do so causes motor
status to be lost upon interruption of control power.

(~AUTION

Multiple grounrn in the RID wiring may


damage the mod~.J1e if common mode voltages exceed 5 vo 15.
The lead from TBI-13 provides proper module
grounding. This grounj connection must provide a
proper "noise" connec ion to the system ground.
Connections in this pa h must be to bare metal (star
washer) with braided connections across the hinges, if
required.
A short green jumper wire connects the module's back
cover to its side frame Do not remove this jumper.

3-2.6. Output Rela) Wiring


The LodTrak IV modu e contains a trip relay, an alarm
relay, and an auxiliary relay output. Each relay contains
one single-pole double throw (Form 4C) contact for
wiring at terminal boat d TB I to appropriate external
alarm and/or shutdown circuits.

3-2.6.1. ALARM RELAY. The alarm relay may be


used for both the moto and the module status alarm.
The normal operating Hate is energized, so the
normally open (N.O.) ontacts are closed. The normally
closed (N .C.) contacts rlose for any alarm condition
and automatically open when the condition is cleared
prior to a trip. Note th~t only the undercurrent alarm
requires a reset via the RESET key when current either
drops to zero or exceec s undercurrent level. For
connection points, refe to Figures 3-5 thru 3-9.
3-2.6.2. TRIP RELA '{. The trip relay is normally
de-energized (NTDF lY ode, N.C. contact closed) or
normally energized (TC DF Mode, N.C. contact open),
as determined by set p< int SPI8. (NTDF means No

No trip or alarm contact wiring should be connected to


LodTrak module's control power terminals TBI-ll and
TBI-12 (see section 3-2.1).

3-2.6.3. AUXILIARY RELAY. The auxiliary relay


can be set to follow either the alarm or the trip relay,
or set as TODF only. The TODF setting opens the
N.O. and closes the N.C. contact to provide an output
that indicates loss of protection only. The TODF state
keeps the N.O. contact closed until any of the following
conditions occur:

Control power is lost


The SAVEIN jumper is in
The LodTrak module malfunctions
An open RTD is not detected here, rather, it
operates the alann relay.

For connection points, refer to Figures 3-5 thru 3-9.

3-2.7. Voltage Input Wiring (Model 4E)


This wiring must be from an open delta PT connection
with a 120 V maximum nominal secondary. The transformers used must be of an instrument class to provide
specified accuracies.
The wiring requirements (refer to Figure 3-9) are based
on the Ll-L2-L3 rotation of line volts. Therefore,
polarity must be observed when making connections. Ll
connects to TBI-I5 and L3 connects to TBI-16. Tie the
ground to the common connection equivalent to L2.
Primaries and secondaries must have opposite polarity
at the common point, such as H2 to HI and X2 to Xl.

3-11

BI006008

1-5600

Protective Relay Module

8. External Relay InputlModel 4E)

3-2.9. RS-422 Communication (Models 4C & 4E)

e external relay is in the same compartment as the


rrak module, use twisted wire from the N. O. relay
lct to the LodTrak module. If the external relay
lct is outside the compartment containing the
rrak module, use twisted-pair shielded wire.
ate the shield at the contact and tie opposite end of
d to TB2-10.

The module's RS-422 connections are at TB2-1 thm -6


(refer to Figures 3-7 thm 3-9). Use 4-conductor (two
twisted-pair) shielded cable for the differential transmit
and receive lines. Daisychain the modules together with
this cable. The maximum distance from the last module
in the chain to the master device is 1000 feet. Shields
must be continuous and terminated only on the master
module in the chain.

:onnection points, refer to Figure 3-9.


To properly terminate the receive pair, connect TB2-S
to TB2-6 on the last module of the chain. Connect the
shield to a proper ground at the master device.
Maximum wire size should be #18 AWG, since two
wires must go into each TB point on every LodTrak
module, except the last one in the chain.
Chapter 7 covers RS-422 communication for the
LodTrak IV module.

BI006008

Protective Relay Mod ule

GEH-5600

CHAPTER 4
START-UP
4-1. PRELIMINARY CHECKS

4-1 .1. Trip Relay Operation Test

( AUTION

WARNING

To ensure that thl LodTrak IV module


protects the moto /system, the preliminary
checks listed in th s section must be made
before starting thl motor.

Do not use the trip relay test if there is either


danger to personnel or possible damage to the
system caused by the motor stopping
suddenly when the trip relay operates.

When ready to start up the LodTrak IV module and


motor/system, conduct the following preliminary
checks:

The following Trip Relay Operation Test should be


done for all models at initial installation. This test
ensures that the trip relay opens the main contactor if a
trip occurs.

I. With no control po .ver to the LodTrak IV module,


check that wiring n atches the installation
instructions in Chat ter 3.
2. Apply control pOWl r to the module.

3. Verify the followin :


a. No error

messa~ es

are on the display.

b. The I'M OK (I !Un okay) indicator is flashing or


on.
4. Check that all set pints contain the right values for
the motor/system u ed. (Refer to section 5-1.4, if
needed.)

To test the relay:


I. Disconnect the motor, then close the main contactor.
2. Place the module in the Set Point Mode by
installing the SAVEIN jumper (TB2-7 and -8). If
the trip relay is set for TODF, the main contactor
should drop out if the trip circuit is wired properly.

3. If the trip relay is set for NTDF, go to set point


SPI8 and enter TODF. Remove the SAVEIN
jumper. The contactor should drop out if the trip
circuit is wired properly. Return set point SPI8 to
NTDF.

5. Call each connected RTD to the display (see Table


5-2) to verify that a 1 the RTDs read the proper
temperature.

CAUTION

6. Check that the Lad' rak IV module is left in the


Protective Mode: the I'M OK indicating light is
steadily on with the alarm relay picked up and the
trip relay in the pro per state.

Be sure that the trip relay set point (SP18) is


left with the proper value and the
SAVEIN jumper is removed after all data is
verified.

4-2. INITIAL MOTOR START


If the phase rotation on the CT secondaries is not
known, disable the phase reversal function (SP49) until
both the motor rotation and the CT secondary phase
rotation is verified to be PHAI-PHBI-PHCl. With
4-1

BI006008

Protective Relay Module

-1-5600

er off, the rotation can be changed by reconnecting


e #1 terminals on the LodTrak module.
,ing the undercurrent function (SP57), make sure
it is either disabled or set low enough (SP59)
ag the motor/system checkout to prevent unwanted
/alarms.

, APPLICATION CONSIDERATIONS
,1. RTD Inputs

luse the LodTrak IV mouule protection is based on


lOttest RTD, at least three RTD inputs should be
, one for each of the three stator windings.
type of protection used with RTD inputs depends
le motor and the system being protected. The
\rated overload/overtemperature protection is
itive to both current and measured temperature,
\rated with each other. The separated
load/overtemperature protection is sensitive either
lrrent, regardless of measured temperature, or to
mred temperature, regardless of current. For
rated overload/overtemperature, the ultimate trip
ag (SP43) is used and must include the motor
lce factor for full utilization of the motor capability.

e 4-1 shows recommended RTD trip temperatures.


able 4-1. Recommended RTD Trip Temperatures
NEMA MG 1-20.40
- Insulation Class B
F

than 1500 HP

110

) HP or greater:
kV or less
reater than 7 kV

105 0
100 0

130

125 0
120 0

155

150 0
145 0

H
180

Phase current CTs must provide 2.00-5.00 amps (5A


secondary) at the motor full-load current level. Refer to
Figure 2-2 for additional limitations. For instance, if
CT secondary FLA = 3.5A and a 90-second stall time
is desired, the maximum multiple is 6. To use 90second stall times with higher multiples of current a
higher CT ratio is required to yield a lower FL CT
secondary current.
The ground fault CT should be chosen according to the
maximum allowable primary current to cause a trip.
This current level must provide 0.1-1.00 amp on the
CT secondary. A 100:5 window type CT is
recommended, which gives a 2-20 amp trip adjustment
on the primary.

4-3.3. Stall Time Setting (SP40)

The stall time setting is the amount of time that locked


rotor current is allowed to flow at a 40 C temperature.
Allowable stall time is normally set at the 40 C stall
time, with the LodTrak module thermal model
providing shorter times for hot conditions.
For motors with a longer acceleration time than
allowable stall time, the motor manufacturer must
provide the allowed maximum acceleration time. The
LodTrak module's stall time setting must be based on
this allowable acceleration time. Additional protection
equipment for the zero speed condition is required.

ultimate trip (SP43) affects the overload trip by


~nt only. For maximum utilization of motors with
= 1.0, set ultimate trip to 110%; for SF = 1.15,
lltimate 1ft to 125 %. Settings below 110% limit
>r utiliz~ ,on and would be determined by the
ication engineer for a particular application.

Motor
HPNoits

4-3.2. Current Transformer Inputs

175 0
165 0

Severely rotor-limited motors (hot and cold stall times


nearly equal) require special protection consideration by
an application engineer. The LodTrak IV module can
only protect at the hot stall condition, meaning additional equipment is required for cold stall protection.

4-3.4. Instantaneous Overcurrent Setting (SP41


and SP42)

For the LodTrak IV module to provide instantaneous


overcurrent protection (see section 2-7.4), two
conditions must be met: (1) the main contactor must be
able to interrupt the set current level and (2) the fuses
must carry the current for the total time that it takes to
interrupt the fault current.

BI006008

Protective Relay Mo ule

GEH-5600

To prevent trips caus d by dc offsets that occur on the


starting current's first 1-3 cycles, the module's setting
(SP42) should be at I ast:

The delay time before an alann-plus-trip prevents


nuisance trips caused by a transient decrease in normal
load.

..[2 x 2 x (locked otor current multiple, SP59)

If this function is enabled, the user must detennine the


overall effect on the system operation.

The set point is in m tiples of FLA.


4-3.7. Load Jam (SP61 - SP63)
4-3.5. Phase Unba ance Setting (SP48)

The phase unbalance tip (see section 2-7.5) should be


set in the 10-20% ran e.
NOTE

Open phase prot tion is lost if this function


is disabled.

4-3.6. Undercurren AlarmlTrip (SP57 and SP60)

To set the load loss al


and trip function (see section
2-7.9), the user shoul detennine the nonnal operating
load and consider the riticality of a drop in nonnal
operating load.

Load jam protection (see section 2-7.10) sets the maximum average load current allowed in the motor once it
is started. The value of this function should depend on
two factors: (1) the protection desired for driven
machinery and (2) the effect on other operations if an
abnonnal increase in nonnal operating load current trips
the motor, although the current is still within the motor
capability.
The load jam trip function should always be set below
the locked rotor value. This wiIl then take the motor off
line before the nonnal locked rotor and stall time
setting does.

4-3

BI006008

Protective Relay Module

fI-5600

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 5
OPERATING INSTRUCTIONS
5-1. OPERATING

The LodTrak IV mod Ie has four operating modes:

Running Mode. Th module is operating in the


normal state.

Alarm Mode. The odule is in the alarm state,


caused by an input condition that has exceeded an
alarm set point.

Trip Mode. The m dule has tripped the motor


because one or rna e of the set points has been
exceeded.

Set Point Mode.


mode. Set Point M
attached at the bac
only be entered an

The following paragra


modes.

e module is not in a protective


de is entered when a jumper is
of the module. Set points can
changed in this mode.
s describe these operating

5-1.1. Running Mo

The LodTrak module i


SAVEIN jumper is re
alarm condition has not
access the five lists of
using the SELECT ke
to the display.

in the Running Mode when the


ved from TB2-7 and -8 and an
occurred. The operator can
alues described below by
to bring the proper list name

Table 5-2 explains typi al key operations in the


Running Mode.
5-1.1.1. PRESENT ALUES. Accessible in all
modes, except the Set oint Mode. Operator can
individually view each alue that has been enabled by
pushing the INC or DE key, or display them in
automatic sequence by ushing the SCAN/ENTER key.
To stop the scan or to access other keys once in the
scan, the operator m t press the SCANIENTER key
again.

At power-up and Trip r set, the LodTrak module enters


the Running Mode and isplays the first value of this
list. See Table 5-1 for t e possible value displays.

5-1.1.2. SINCE START VALUES (MODEL 4E).


Accessible in all modes, except the Set Point Mode,
operable only after a start complete has been detected.

When this list is enabled, some of the maximum values


recorded are higher than normal operating values, such
as motor temperature. The operator can access these
values using the INC or DEC keys, or can view them
using the SCAN key. The operator can update this
list any time after the motor is running by using the
SELECT key to display the top of the list, holding
the RESET key in, and then pressing the DEC key.
All values go to zero when the motor stops (below 0.10
PU current). See Table 5-1 for the displays possible.

5-1.1.3. STARTS/TRIPS/HRS (MODELS 4C AND


4E). This list is accessible in all modes, except the Set
Point Mode. This list of values resides in the nonvolatile portion of memory. The LodTrak module
records the starts and trips in the non-volatile memory
as they occur, but records the motor running hours
every 12 hours, if the module has control power. This
means that control power interruptions to the module
may cause an error of 12 to 24 hours in this record,
depending on when and how the interrupts occurred.
The operator should zero this list after
"commissioning" the system to provide proper data
under operating conditions. This is done in the same
way as the Since Start List zeroing. See Table 5-1.

5-1 .1 .4. VALUES AT TRIP. This list is accessible


in all modes, except the Set Point Mode. This list
records the values of all measured inputs when a trip is
detected. This occurs just before the main interrupter
shuts down the motor. Because of the fast trip time on
Instantaneous Overcurrent, current values recorded are
not valid (may be zero). Values in this list are updated
each time a trip occurs, and stored only in volatile
memory. Loss of control power causes all values to go
to zero when the module is powered back up. See Table
5-1 for the displays possible.

5-1.1.5. SET POINT VALUES. This list is


accessible in all modes, but the values can be changed
only in the Set Point Mode. In all other modes, the
operator can view set point values by using the INC,
DEC, or SCAN keys.

5-1

BI006008

1-5600

:n using INC or DEC in the Running Mode, the


al display is SP23 (WINDING RTDS USED). This
ns that the DEC key accesses system values set and
[NC key accesses motor values from the initial
lay. Table 5-7 lists the possible set points.

.2. Alarm Mode

y for alarm prior to trip.) In the Alarm Mode, the


Trak module's alarm relay output operates because
or more of the alarm set points have been
eded. While in this mode, the Trip indicating
t flashes and an alarm message appears in the
lay. The alarm message indicates the type of alarm
the magnitude of the current for an overload only.
e alarm is caused by any other condition, the
lay indicates the alarm type. In this case, the
ator needs to view the actual value in the Present
Le display list by pushing the SELECT key.
3.larms automatically reset when values fall below
l1arm set point level, as long as a trip has not
rred. There is some hysteresis in the reset to
ent the LodTrak module from going in and out of
mode unnecessarily. No records are made of the
ns. The alarm message is lost if any key is pressed,
ceappears 60 seconds after the last key is pressed.
)pen RTD causes the module to stay in this mode
the open is cleared.
.larm Mode, the operator can access the five lists of
es described under section 5-1.1. Table 5-3 explains
lisplays and key operations in the Alarm Mode.

Protective Relay Module

displaying the trip type and value. (Note that IOC may
not display the true value). The operator must then push
the RESET key at least twice: the first time to display
the value causing the trip, and the second time to either
reset the trip if okay to do so, or to monitor value
changes until it is okay to reset. The operator can also
display other values after pushing RESET the second
time .
Except for Temperature and Phase Unbalance, all trips
can be reset as soon as the fault is cleared. Temperature
trips cannot be reset until the temperature cools to 15
below the alarm set point. The Phase Unbalance trip
cannot be reset until the percentage decreases to below
the alarm set point.
The Auto Reset Mode automatically resets trips initiated
by a temperature limit on.ly (overload and RTD
temperatures). If a trip occurs while in the Auto Reset
Mode, the operator should still push the RESET key as
described above to check the value at which the trip
occurred and to monitor the temperature cooldown until
the reset occurs automatically.
The display automatically returns to the first values in
the Present Value list when a reset is completed. Table
5-4 is an example of key operation during a reset.

5-1.4. Set Point Mode (Set Point Inputs)


In the Set Point Mode, the set point values can be
entered or changed as required. The operator puts the
module in this mode by placing a jumper across the two
SAVEIN terminal points, TB2-7, and -8, on terminal
board TB2.

3. Trip Mode
module is in the Trip Mode when one or more
ts exceed trip set point values. When the module
, the output Trip relay changes state. The relay
:r picks up or drops out, as defined by SP18.
:n the module is in the Trip Mode, the Trip
~ating light remains steady on. The display tells
:ause of the trip and indicates that the RESET key
ushed.
rip Mode, the operator can access the five lists of
es, described under section 5-1.1.

3.1 RESETTING. To manually reset a trip, the


ator must first bring the VALUES AT TRIP list to
Iisplay. This ensures that no trip is reset without

CAUTION
Because data points are being changed while
in the Set Point Mode, the motor is not
protected. This mode may also cause a trip.
In this mode, the IMOK light flashes and the Alarm and
Trip relays are dropped out (see section 3-2.6.2).
The display shows the set point items in sequential
order. Table 5-7 shows the list of the set point values as
they appear. Note that while in this mode, the operator
can access and change set point values, but cannot
access the other lists of values.

BI006008

Protective Relay Mo ule

GEH-5600

The Set Point Mode c anges key operation from the


Running Mode per the example in Table 5-6. To select
the next higher set poi t, push the SELECT key; to
select the next lower s t point, push the RESET key.
To increase or decreas the value of the selected set
point, hold in the INC or DEC key until that value is
reached. Note that the alue only goes as far as the
minimum or maximu allowed. To enter a value into
volatile memory, press the SCAN/ENTER key twice.
The first time this key is pushed, the display asks if the
operator is sure. Press' g the RESET key at this point
returns the display to t e set point value displayed
before the SCAN/ENT R key was pushed.

The choice of a local or remote reset is remote only via


the RS-422 communication and does not allow remote
reset of trips caused by current faults. The Remote ID
letter must be set to a unique alpha for each module on
the RS-422 communication line. (See Chapter 7 for
more RS-422 information.)

When all set points ar set to the correct values,


remove the SAVEIN j mper from TB-2. This enters all
values into non-volatil memory, and places the
LodTrak module in th Running mode. This display
shows "SAVING DA ", then "INITIALIZING". The
I'M OK LED flashes til all data is saved, then
changes to a steady on. The Alarm relay picks up and
the Trip relay assumes its selected state.

SELECT - changes the display between the title of


each list.

INC - moves the display up the list of data points.

DEC - moves the display down the list of data


points.

RESET - when pressed with the DEC key, zeros


the STARTS/TRIPSIHRS list (4C and 4E) and the
SINCE START list (4E).

SCAN/ENTER - start/stops a scan in any selected


list.

5-1.4.1. NOTES 0 SET POINTS. All modules are


shipped with the defau values in non-volatile memory.
The set points that hav NO as a value cause no more
values of that type to b displayed. For example, if
WINDING RTDS US D is set to NO, none of the set
points related to windi g RTDs are displayed.

5-2. DISPLAYS AND KEY OPERATION


5-2.1. Running Mode

In the Running Mode, the following keys are used:

Table 5-2 shows examples of their use.


Both PT and CT Prim
set points are the primary
ratings of the external ansformers, not the system
voltage or current.

5-2.2. Set Point Mode

The ultimate trip (SP43 affects an overload trip by


current only. For maxi urn utilization of motors with
SF = 1.0, set the ulti ate trip to 110%; for SF = 1.15
set to 125 %. Settings blow 110 % limit motor
utilization and are dete .ned by the particular
application.

In the Set Point Mode, the following keys are used:

The frequency set point must be set to the proper line


frequency.
The relay settings are
DF for Trip on Detectable
Failure and NTDF for 0 Trip on Detectable Failure.
Note that an open RTD is not considered a detectable
failure since motor prot ction should have at least three
winding and two bearin inputs. The LodTrak module
ignores open RTDs in i s overload and bearing
p~otection. The Alarm
lay indicates open RTDs.

SELECT - moves the display up the list of set


points.

INC - increases the value of a set point.

DEC - decreases the value of a set point.

RESET - moves the display down the list of set


points, or returns the display to the same set point if
the ARE YOU SURE message is in the display.

SCAN/ENTER - enters set point values to RAM


when pressed twice.

Tables 5-5 and 5-6 show examples of their use.

Table 5-7 provides a lis of set points and default


settings.

5-3

BI006008

Protective Relay Module

1-5600

Table 5-1. LodTrak IV Module Displays - Models 4A, 4C, and 4


tiel

Display Type

No.

Display

Model

Display Type

No.

Display

Present
Values

PVO

PRESENT VALUES
PUSH INC FOR 1ST

4E

Since Start
Values

SSO

SINCE START VALUE


PUSH INC FOR 1ST

PV1

MOTOR AMPS =XXXX


MOTOR TEMP = XXXC

SS1

MAX PERCENT FULL


LOAD XXX

PV2

CAPACITY USED
XXX PERCENT

SS2

MAX MOTOR TEMP


DEG C XXX

PV3

CURRENT 11 =XXXX
12 = XXXX 13 = XXXX

SS3

MAX UNBALANCE
% OF FLC XXX

PV4

MAX WINDING RTD


Y=XXX DEG C

SS4

MAX GROUND FAULT


% OF 1A XXX

PV5

STATOR RTD1 =XXXC


RTD2=XXX 3=XXXC

SS5

MAX WINDING RTD


Y=XXX DEG C

PV6

STATOR RTD4 = XXXC


RTD5=XXX 6=XXXC

SS6

MAX BEARING RTD


YY=XXX DEG C

PV7

BEARING RTD
7 =XXXC 8=XXXC

SS7

MAX VOLTAGE
XX.XX

PV8

BEARING RTD
9=XXXC 10=XXXC

SS8

MIN VOLTAGE
XX.XX

PV9

GROUND FAULT
% OF 1 AMP XXXX

SS9

MAX KILOWATTS =
XXXX.XXX

PV10

KVOLTS V1 =XX.XX
V2=XX.XX
V3=XX.XX

PV11

AVERAGEKVA
XXXX.XXX

PV12

AVERAGE KW
XXXXX

Present
Values

PV13

NO OR REMAINING
START/HR X

Present
Values

PV14

EXTERNAL RELAY
XXXXXXX

Present
Values

4E

(Table 5-1 is continued on the following page.)

BI006008

Protective Relay Mo ule

GEH-5600

Tabl 5-1. LodTrak IV Module Displays - Models 4A, 4C, and 4 (Continued)
Model

Display Typ

No.

Display

Model

Display Type

No.

Display

4C &
4E

Starts/Trips
Hrs Values

STO

STARTSITRIPS/HRS
PUSH INC FOR 1ST

All

Values
At Trip

ATO

VALUES AT TRIP
PUSH INC FOR 1ST

ST1

STARTS ATTEMPTED
XX

An

A T TRIP CAPACITY
USED XXX

ST2

STARTS COMPLETED
XX

AT2

AT TRIP 11 =XXXX
12=XXXX

ST3

MOTOR HOURS RUN


XXXX

AT3

AT TRIP WND RTD


Y=XXX DEG C

ST4

OVERLOAD TRIPS

AT4

AT TRIP BRG RTD


YY=XXX DEG C

ST5

WINDING RTD
TRIPS XX

AT5

AT TRIP UNBALANCE
% OF 1 FLC=XXX

BEARING RTD TRIPS


XX

AT6

AT TRIP GNDFAULT
% OF 1 AMP XXX

ST6

ST7

ST8

ST9

PHASE UNBALANCE
TRIPS XX

4E

An

AT TRIP V1 =XX.XX
V2 = XX.XX V3 = XX.XX

PHASE REVERSAL
TRIPS XX

4E

ATB

AT TRIP EXTERNAL
RELAY XXXXXXX

GROUND FAULT
TRIPS XX

All

AT9

A T TRIP STARTS THIS


HR X

ST10

INST OVERCURRENT
TRIPS XX

ST11

UNDERVOLTAGE
TRIPS XX

ST12

OVERVOLTAGE
TRIP XX

ST13

UNDERCURRENT
TRIPS XX

ST14

LOAD JAM
TRIPS XX

ST15

MAX STARTS/HOUR
TRIPS XX

ST16

EXTERNAL RELAY
TRIPS XX

5-5

BI006008

Protective Relay Module

-1-5600

Table 5-2. Running Mode Displays and Key Operation - Model4E


sent Display

Key Pushad

New Display

Comments

:SENT VALUES
SH INC FOR 1ST
~VO display) *

INC
DEC
SCAN/ENTER
SELECT
RESET

MOTOR AMPS = XXXX


EXTERNAL RELAY
(scans PV1PV14)
SINCE START VALUE
(no change)

PV1 display
PV14 display
PRESENT VALUE displays
SSO display

ICE START VAL


SH INC FOR 1ST
SSO display) *

INC
DEC
SCAN/ENTER
SELECT
RESET

MAX PERCENT FULL


MAX KILOWATTS =
(scans SS1 - SS9)
STARTSITRIPS/HRS
(no change)

SS1 display
SS9 display
SINCE START displays
STO display

I\,RTSITRIPS HRS
SH INC FOR 1ST
STO display) *

INC
DEC
SCAN/ENTER
SELECT
RESET

STARTS ATTEMPTED
EXTERNAL RELAY TRIP
(scans ST1 - ST16)
VALUES AT TRIP
(no change)

ST1 display
ST16 display
STARTS/TRIPS displays
ATO display

LUES AT TRIP
SH INC FOR 1ST
I\,TO display) *

INC
DEC
SCAN/ENTER
SELECT
RESET

AT TRIP CAPACITY
AT TRIP STARTS
(scans A T1 - AT9)
SET POINT VALUES
(no change unless in
Trip Mode)

AT1 display
AT9 display
AT TRIP displays
SPO display

r POINT

INC
DEC
SCAN/ENTER
SELECT
RESET

WINDING RTDS
EXTERNAL RELAY
(scans SP1 - SP65)
PRESENT VALUES
(no change)

SP23 display
SP22 display
SET POINT displays
PVO display

VALUES
SH INC FOR 1ST
SPO display) * *

fer to Table 5-1 for a complete listing of displays.


efer to Tables 5-6 and 57 for a complete listing of displays.

NOTE
Models 4A and 4C do not include all lists of values available with model 4E. Therefore, results will be
different than those shown in this table. However, the same procedures apply for all models.

BI006008

Protective Relay Mo( ule

GEH-5600

Tablf 5-3. Alarm Mode Displays and Key Operation - Models 4A, 4C, and 4
Present Display

Key Pushed

New Display

XXXXX ALARM
PUSH SELECT
(TRIP light flash)

INC
DEC
SCAN/ENTER
SELECT"

(no change)
(no change)
(no change)
PRESENT VALUES
PUSH INC FOR 1ST
(resets to ALARM display
after 1 min.)
(no change)

RESET
OVERLOAD ALARM
MOTOR AMPS =
(tracks amps)
(TRIP light flash)

INC
DEC
SCAN/ENTER
SELECT"

RESET

(no change)
(no change)
(no change)
PRESENT VALUES
PUSH INC FOR 1ST
(resets to ALARM display
after 1 min)
(no change)

Comments

PVO DISPLAY

PVO DISPLAY

* Once SELECT is pushe ,the operator can call any list to the display via the SELECT key.

5-7

BI006008

-1-5600

Protective Relay Module

Table 5-4. Trip Mode Displays and Key Operation - Models 4A, 4C, and 4
'sent Display

Key Pushed

New Display

ERTEMP TRIP
SH RESET
liP light on)

INC
DEC
SCAN/ENTER
SELECT
RESET

(no change)
(no change)
(no change)
(no change)
AT TRIP WND RTD
Y = XXX DEG C

then push
SELECT

VALUES AT TRIP
PUSH INC FOR 1ST

Comments

AT3 display

1st At Trip display


from here all values At Trip
can be seen with INC,
DEC, or SCAN buttons

or push
RESET
(second push)

XXXX TRIP
PUSH RESET
(or)'
NO RESET
RTD Y = XXX

ERLOAD TRIP
;H RESET
IP light on)

INC
DEC
SCAN/ENTER
SELECT
RESET

then push
SELECT

or push
RESET
(second push)

if second fault

motor not cool enough

(or)
RESETTING

module resets

MOTOR AMPS = XXXX

first Present Value line

(no change)
(no change)
(no change)
(no change)
AT TRIP 11 =XXXX
12 = XXXX 13 = XXXX

VALUES AT TRIP
PUSH INC FOR 1ST

AT2 display

1st At Trip display


Trip relay not reset
Trip relay can only be
reset when the display is
in the At Trip list

(if second trip)


OVERTEMP TRIP
PUSH RESET

Trip relay not reset

(if no second trip)


NO RESET
MOTOR TEMP =

motor not cool enough

(if motor cooled)


RESETTING
MOTOR AMPS = XXXX
MOTOR TEMP =

module resets
1st Present Value line

BI006008

Protective Relay Mo ule

GEH-5600

Table 5-4. Trip Mode Displays and Key Operation - Models 4A, 4C, and 4 (Continued)
Present Display

Key Pushed

New Display

GND FAULT TRIP


PUSH RESET
(TRIP light on)

INC
DEC
SCAN/ENTER
SELECT
RESET

(no change)
(no change)
(no change)
(no change)
AT TRIP GNDFAULT
% 1AMP = XXXX

then push
SELECT

or push
RESET
(second push)

INC
DEC
SCAN/ENTER
SELECT
RESET

then push
SELECT

or push
RESET
(second push)

AT6 display

VALUES AT TRIP
PUSH INC FOR 1ST

1 st At Trip display

XXXXXXXX TRIP
PUSH RESET

if second fault
Trip relay not reset

(or)
NO RESET
XXXXX =

motor not cool (2nd fault)

(or)
RESETTING
MOTOR AMPS = XXXX
XXXX TRIP
PUSH RESET

Comments

(no change)
(no change)
(no change)
(no change)
AT TRIP XXXXX
XXXXXXX = XXX X

module resets
first Present Value line

At Trip display

VALUES AT TRIP
PUSH INC FOR 1ST

1st At Trip display

YYYYY TRIP
PUSH RESET

if second fault
Trip relay not reset

(or)
RESETTING
MOTOR AMPS = XXXX

module resets
first Present Value line

5-9

BI006008

H-5600

Protective Relay Module

Table 5-5. Set Point Mode Displays and Key Operation - Models 4A and 4C

Isent Display

Key Pushed

INTRAST =

INC
DEC
SCAN/ENTER
SELECT
RESET

. . . 17

E YOU SURE?
>pears after
TER key pushed)

INC
DEC
SCAN/ENTER

SELECT
RESET
PRIMARY AMPS

5 A . . . 500

iP RELAY STATE
. . .TODF

New Display

18
16
ARE YOU SURE
CT PRIMARY AMPS
FREQUENCY
(no effect)
(no effect)
(blank)
then displays
CT PRIMARY AMPS
(no effect)
CT PRIMARY AMPS

501
500

Comments
Increases value
decreases value
see next step in displays
moves to next set point
previous set point

stores value of display


next set point
this set point

INC
DEC
SCAN/ENTER
SELECT
RESET

ARE YOU SURE?


TRIP RELAY STATE
CT PRIMARY AMPS

toggles value
toggles value
see ARE YOU SURE display
moves to next set point
previous set point

INC
DEC
SCAN/ENTER
SELECT
RESET

NTDF
TODF
ARE YOU SURE?
ANY RELAY STATE
TRIP RELAY STATE

increases value
decreases value
see ARE YOU SURE display
moves to next set point
previous set point

BI006008

Protective Relay Module

GEH-5600

'rrable 5-6. Set Point Mode Displays and Key Operation - Model 4
Present Display

Key Pushed

New Display

Comments

CONTRAST =
(SP1 display)

INC
DEC
SCAN/ENTER
SELECT
RESET

18
16
ARE YOU SURE?
PT VOLTAGE INPUT
FREQUENCY

increases value
decreases value
see next step in displays
moves to next set point
previous set point

ARE YOU SURE?


(appears after
ENTER key pushed)

INC
DEC
SCAN/ENTER

SELECT
RESET

(no effect)
(no effect)
(blank)
then displays
PT VOLTAGE INPUT
(no effect)
PT VOLTAGE INPUT

PT VOLTAGE INPUT
. . . . . NO
(SP2 display)

INC
DEC
SCAN/ENTER
SELECT
RESET

YES
YES
ARE YOU SURE?
PT PRIMARY KVOLT
CONTRAST

toggles value
toggles value
see ARE YOU SURE display
moves to next set point
previous set point

PT PRIMARY KVOLT
TO 120v . . . NO
(SP3 display)

INC
DEC
SCAN/ENTER
SELECT
RESET

4.21
4.19
ARE YOU SURE?
NOM SECONDARY
PT VOLTAGE INPUT

increases value
decreases value
see ARE YOU SURE display
moves to next set point
previous set point

NOM SECONDARY
VOLTS . . 50
(SP4 display)

INC
DEC
SCAN/ENTER
SELECT
RESET

51
49
ARE YOU SURE?
UNDERVOLTAGE
PT PRIMARY KVOLT

toggles value
toggles value
see ARE YOU SURE display
moves to next set point
previous set point

. . . . . 17

stores value of display


next set point
this set point

NOTE

Models 4A and 4C operate the same as model 4E, except that the next point after entering the value for
contrast is CT PRlMARY AMPS.

5-11

BI006008

Protective Relay Module

fI-5600

Table 5-7. Set Point Mode Display Wording


clel

Models 4A, 4C, and 4

SP
No.

Display

SPl

CONTRAST =
XX

1 to 32

"17"

All

SP23

WINDING RTDS
XXX
USED

"NO" or YES

SP2

PT VOLTAGE INPUT
XXX

"NO" OR YES

All

SP24

WINDING RTDS
aTY
XXX

"1" to 6

SP3

PT PRIMARY KVOLT
to 120V XX.XX

00.24 to 69.00
"4.20"

All

SP25

WINDING RTDS
TYPE XXXXX

"10 CU" 100 PT


100 NI 120 NI

SP4

NOM. SECONDARY
VOLTS
XXX

"50" to 120 V

All

SP26

OVERLOAD
TYPE XXXXXX

"NO RTD" or RTD

SP5

UNDERVOLTAGE
ALARM
XXX

"NO" or YES

All

SP27

MAX WINDING RTD


ALARM
XXX

"10" to 175

SP6

UNDERVOLTAGE
ALARM %V XX

"55" TO 95

All

SP28

MAX WINDING RTD


XXX
TRIP

"20" to 185

SP7

UNDERVOLTAG E
TRIP
XXX

"NO" or YES

All

SP29

BEARING RTDS
USED
XXX

"NO" or YES

SP8

UNDERVOLTAGE
TRIP %V XX

"50" to 90

All

SP30

BEARING RTD
aTY
X

"1" to 4

SP9

UNDERVOLTAGE
DELY SEC XX.X

0.2 TO 30
"15"

4E

SP31

BEARING RTD
GROUPS XGR W/X

"1 GR W/4"
2 GR W/2

SP10

OVERVOLTAGE
ALARM
XXX

"NO" or YES

All

SP32

BEARING RTD GRl


TYPE XXXXX

"10 CU" 100 PT


100 NI120 NI

SP11

OVERVOLTAGE
ALARM %V XXX

"105" to 130

4E

SP33

BEARING RTD GR2


TYPE XXXXX

"10 CU" 100 PT


100 NI 120 NI

SP12

OVERVOLTAGE
TRIP XXX

"NO" or YES

All

SP34

BEARING RTD GRl


ALARM XXX

"10" to 175

SP13

OVERVOLTAGE
TRIP %V XXX

"110" to 135

4E

SP35

BEARING RTD GR2


ALARM XXX

"10"to175

SP14

OVERVOLTAGE
DELY SEC XX. X

0.2 to 30
"15"

All

SP36

BEARING RTD GR1


TRIP XXX

"20" to 185

SP15

PHASE LOSS
BY VOLTS XXX

"NO" or YES

4E

SP37

BEARING RTD GR2


TRIP XXX

"20" to 185

SP16

PHASE REVERSAL
BY VOLTS XXX

"NO" or YES

All

SP38

CT SEC FULL LOD


X.XX
AMPS =

"2.00" to 5.00

SP17

CT PRIMARY AMPS
TO 5 AMP XXX X

50 TO 9000
"500"

All

SP39

LOCK ROTOR AMPS


TIMES FL XX.X

"3.0" to 12.0

SP18

TRIP RELAY STATE


XXXX

"TODF" or
NTDF

All

SP40

STALL TIME
XX
SEC

"1" to 90

SP19

AUX RELAY STATE


XXXXX

"TODF" or TRIP or
ALARM

All

SP41

INST OVERCURRENT
USED XXX

"NO" or YES

4E

SP20

RESET OF A TEMP.
TRIP
XXXXXX

"LOCAL" or REMOTE

All

SP42

INST OVERCURRENT
TIMES FL XX

"6" to 37

4E

SP21

REMOTE 10 LEITER
X

A to Z

"7"

All

SP43

ULTIMA TE TRIP IS
% OF FLC XXX

"85" to 125

SP22

EXTERNAL RELAY
USED
XXX

"NO" or YES

All

SP44

OVERLOAD TEMP
XXX
ALARM

"80" to 170

All

SP45

PHASE UNBALANCE
XXX
USED

"NO" or YES

Units

Model

SP No.

Display

Units
(" " = default)

(" " = default)

BI006008

Protective Relay Mo ule

Table

GEH-5600

-7. Set Point Mode display Wording

Models 4A, 4C, and 4 (Continued)

Model

SP No.

Displ y

Units
(" " = defeult)

Model

SP
No.

Display

Units
(" " = default)

All

SP46

PHA E UNBAL ALARM


XX
%0 FLC

"5 to 30

4C,4E

SP55

MAX STARTS/HOUR
XXX
USED

"NO" or YES

All

SP47

PHA E UNBAL TRIP


USE
XXX

"NO or YES

4C,4E

SP56

MAX STARTS/HOUR
INTERVAL X

"1 to 5

All

SP48

PHA E UNBAL TRIP


%0 FLC XX

"10t035

All

SP57

UNDERCURRENT
USED
XXX

NO or YES

All

SP49

PHA E REVERSAL
TRIP
XXX

"NO or YES

All

SP58

UNDERCURNT TRIP
USED
XXX

"NO or YES

All

SP50

GRO NO FAULT
USE
XXX

"NO or YES

All

SP59

UNEDRCURNT
LEVEL
% OF FLC XX

"15 to 90

All

SP51

All

SP60

UNDERCURRENT
DELAY SEC XX

"1" to 20

All

SP52

All

SP61

LOAD JAM
USED XXX

"NO" or YES

All

SP62

LOAD JAM
TIMES FL XX.X

0.7 to "2.0"

All

SP63

LOAD JAM
DELY SEC XX

"1" to 10

All

SP64

RESET OF A TEMP.
TRIP XXXXXX

"MANUAL"
AUTO

All

SP65

FREOUENCY IS
HERTZ XX Hz

50 or "60

All

All

SP53

SP54

AULT ALARM
MP XXX

5 to 70 "30"

AULT TRIP
XXX

"NO or YES

AULT TRIP
MP XXX

10 TO 100 "50

GRO NO FAULT
DELY SEC X.XX

0.05 to 1.00
"0.10

5-13

BI006008

,H-5600

Protective Relay Module

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 6
MAINTENANCE
6-1. PERIODIC MA NTENANCE

6-2.2. Phase Unbalance Trip Time Testing

The LodTrak IV mod Ie does not require routine


calibration. However, aintenance should include
periodic cleaning of th outer surfaces to prevent
excessive dust and dirt from getting into the module.

The plotted phase unbalance trip times (see Figure 2-4)


are based on a step change of one phase from a
balanced condition. Once the LodTrak module detects a
current unbalance, the trip times become less than
shown. Use the following steps to assure that a
balanced current exists before a trip time test:
I. Turn off test current after setting current level.

The following equipm nt is needed for testing the


LodTrak IV module:

2. Turn off control power, then turn it back on.

Decade Resistance

3. Apply the unbalanced currents set prior to step #1.

Ac current source, -10 amps at 1 volt

ox to simulate RTD

A complete module te requires RTD simulation


resistors with at least ne of them adjustable within 0.1
ohms, and a 3-phase c rrent source with a minimum
capability of 10 amps t 1 volt. A single-phase source
can be used for all fun tions except phase reversal. The
phase unbalance test r uires separate control of onephase current input to he LodTrak module.

6-2.1. Overload Tri

4. Measure the time from the current application to the


trip relay operation. Note that the operating load
current is based on the RMS of the three inputs.

6-2.3. Instantaneous Overcurrent Testing

When testing instantaneous overcurrent levels, overload


trips occur if current is left on after the trip has
occurred.

Time Testing
6-2.4. Undercurrent and Load Jam Testing

Overload trip time test


conditions. Note that b
2-2 and 2-3) depend 0
the application of over
temperature in the first
40 for a cold curve,
repeatable trip times, i
each time current is ap
less than 5 seconds, th
may become a signific

require proper inputs and initial


th overload curves (see Figures
the initial temperature prior to
ad current. The initial
Present Value display must be
a 40 constant RTD curve. For
put current must be the same
lied. When testing trip times of
current source's rate of rise
t factor.

To test undercurrent and load jam and see values in the


Since Start list (model 4E only), the Start Disable must
be defeated or a start cycle simulated. To defeat Start
Disable, apply phase currents greater than 10% of full
load current before applying control power. Note that
the alarm/trip levels for these two protections are based
on the average of the three input currents.

6-3. CALIBRATION

Use a single-phase cu nt source for testing overload


with no RTD. This is ecause unbalanced currents
cause a faster trip time for the same average multiple of
full load current. Overl ad with RTD uses the highest
of the three phases as t e multiple of full load current.

Internal calibration of the RTDs and all current


measurements may be checked/adjusted by placing the
module in the Set Point Mode, pressing ENTER once,
then pressing INC and DEC at the same time. The
display reads:

o=

x.xx and 148 - 0 = xxx. xx.

6-1

BI006008

Protective Relay Module

H-5600

.1. RTD Calibration

6-4.2. Relay

: Figure 3-3.) Adjust the top potentiometer for 0 and


bottom for" 148 - 0". The two interact with each
:r, so one must go back and forth to adjust to 0.00
148.00 within .10. RTDs are now calibrated.
ceed to section 6-3.2 (Current Calibration) or
love and restore control power to return to the
Point Mode.

There are three identical relays that can be replaced: the


Alarm (top), Auxiliary (center), and Trip (bottom).

Ie 6-2, provides data on RTD resistance versus


perature.

.2. Current Calibration

CAUTION

All set point data goes to default values if the


following step is executed. Proper values must
be recorded before internal calibration of
current measurements, or motor/system
damage may occur.
Insure that all CT currents are 0 before
calibrating.
mal calibration of all current measurements is done
Jressing SELECT, which updates offsets. Control
ler must be removed and reapplied to restore the
Iule to the Set Point Mode.

To replace these relays:


1. Remove the back cover by removing the four
screws that secure it to the module (Figure 3-3).
Each relay is socket-mounted on the upper left side
of the printed wiring board at the rear of the
module.
2. Pull aside the wire clamp that secures the selected
relay in its socket, then carefully unplug the relay.
3. Insert the new relay and secure it with the wire
clamp.
4. Replace and secure the module's back cover, being
sure to re-install the green wire jumper.

6-4.3. Fuse

There is one plug-in power fuse rated 2 amps, 125


volts. It can be accessed by disconnecting all power
sources and removing the back cover (refer to
Figure 3-3). The fuse is located near TBI terminal 11.
Be sure to replace the green jumper wire when
installing the cover.

6-5. TROUBLESHOOTING
PARTS REPLACEMENT

re are only three replacement parts for the LodTrak


nodule: the relays, fuse, and CT cover. Chapter 8
rides part numbers and ordering information.
NOTE

Because of the module's construction and


circuitry, printed wiring boards should not be
replaced in the field .

.1. CT Cover

CT cover snaps into place over the CT terminals,


.ted at the back of the LodTrak module (Figure 3-4).

The GE factory tests and verifies that all equipment is


working correctly before shipping it to the customer
site. However, if problems occur with the LodTrak
module after installation, Table 6-1 is a troubleshooting
guide for the most common problems.
The module includes self diagnostics that display error
messages and/or cause the I'M OK LED to blink when
it detects problems. Table 6-1 includes corrective
actions for these errors.

BI006008

Protective Relay Mod ule

GEH-5600

Table 6-1. Troubleshooting the LodTrak Module


Symptom

Probable Cause

Corrective Action

Module is dead: No d splay, IMOK LED off

Power not getting to unit

1. Check incoming power. If okay, go to step 2.


2. Check fuse. If bad, replace per section 6-4.3.
3. If unit is still dead, return module to factory for repair.

No display, 1M OK LEe
blinks

Internal failure

1. Return module to factory for Jepair.

During setup (Models 4C


& 4El. module not aCI essible from keyboard, ( isplay reads REMOTE CPMMAND

SP20 set to REMOTE

1. Set SP20 to LOCAL.

General:

Error message on dis,:. lay:


USED STD DATA

Lost or incorrect set point data 1. Power down, then back up.
2. Check and re-enter data (see section 5-1.4).
3. Power down, then back up.
4. If display shows same error, return module to factory
for repair.

EEPROM ERR ALARr~

Failure in EEPROM write cycle. 1. Press SELECT button.


2. If display shows same error, return module to factory
for repair.

SAMPLE STALL

1. Power down, then back up.


2. If display shows same error, return module to factory
for repair.

INTERNAL FAILURE
TRIP RELAY ERROR

Trip relay defective

1. Power down.
2. Replace relay. See 6-4.2. (Bottom relay)
3. Power up.
4. If display shows same error, return module to factory
for repair.

INTERNAL FAILURE
ALRM RELAY ERROF

Alarm relay defective

1. Follow steps used for trip relay (above).


See 6-4.2. (Top relay)

INTERNAL FAILURE
AUX RELAY ERROR

Auxiliary relay defective

1. Follow steps used for trip relay (above).


See 6-4.2. (Center relay)

OPEN RTD

RTD defective or RTD wiring

1. Check RTD and its wiring (see section 3-2.4l.

RTD always reads -1 5

RTD wiring defect

1. Check for reversed RTD (red & white) wires.


2. Check for shorted RTD wires.
3. Make sure RTD is not grounded at the motor.

Reading wrong

Connection problem

1. Check for correct wiring per section 3-2.4.


2. Check for excess resistance in connection path (section 3-2.4).

Wrong selection of RTD TYPE

1. Check that RTD TYPE is set correctly (see Table 5-7).

Calibration performed with


current in one or all CTs

1. Repeat calibration procedure (see section 6-3.), making


sure that all CTs have 0 primary current.

RTD reading errors:

Current reading errors:


Offset errors

6-3

BI006008

Protective Relay Module

H-5600

Table 6-2. RTD Resistance vs. Temperature

Temperature
in C

Copper
10 at 25 DC

Platinum
100 at 0 DC

Nickel
120 at 0 DC

Nickel
100 at 0 DC

9.04

100.0

120.0

100.0

10

9.43

103.9

128.1

106.8

20

9.81

107.7

136.2

113.5

25

10.00

109.7

140.2

116.8

30

10.20

111.6

144.2

120.2

40

10.58

115.4

152.3

126.9

50

10.97

119.3

160.4

133.7

60

11.35

123.2

168.5

140.4

70

11.74

127.0

176.5

147.1

80

12.12

130.9

184.6

153.8

90

12.51

134.7

192.7

160.6

100

12.89

138.6

200.8

167.3

110

13.28

142.5

208.8

174.0

120

13.66

146.3

216.9

180.1

130

14.05

150.2

225.0

187.5

140

14.43

154.0

233.1

194.3

150

14.82

157.9

241.1

200.9

160

15.20

161.8

249.2

207.7

170

15.57

165.7

257.3

214.5

180

15.95

169.6

265.4

221.3

185

16.14

171.6

269.4

224.7

200

16.71

177.4

281.5

234.9

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 7
RS-422 COMMUNICATION DEFINITION
7-1. INTRODUCTI N

Models 4C and 4E of
hardware and softwar
baud), full duplex, m
(LAN). There can be
same LAN.

he LodTrak IV module contain


to support a low speed (1200
Itidrop local area network
p to 26 LodTrak modules on the

Each LodTrak module


controller. This maste
accept the differential
accept an RS-232 sign
RS-422. The master c
1200 baud, NO parity

becomes a slave to the master


can be any controller that can
S-422 signal directly, or can
that has been converted from
ntroller port is normally set for
8 bits, and 2 stop bits.

Each request packet from the Master to the LodTrak


module is identified by an < id > character. This is the
ASCII A to Z character entered in SP21 (REMOTE ID
LETTER). A question mark (?) in this location can
never be accessed by the RS-422 communication.
Each response packet from the LodTrak module to the
Master has an identification < lid>. This is the ones
complement of the < id > character described above.
Each request or response packet has its message
[ < >. . . < >] between the < id > or < lid> and the
<eot>. The <id> code ranges from A (41H, 65D)
to Z (5AH, 9OD), while the <lid> code ranges from
IA (BEH, 190D) to IZ (A5H, 165D).

7-2. MESSAGE DE INITION

Each message is defin d as a "packet", which is based


on ASCII coding. The e messages have no traffic
control. Therefore, an request packet from the Master
must receive a respons packet from a LodTrak module
before another request packet can be sent. If a LodTrak
module does not begin sending a response within 0.2
seconds after a request packet is received, the LodTrak
module cancels the re est.
NOTE

NOTE

The < esc > character must precede the two


special case data bytes if they are in the
message sent to the LoadTrak module.
Packet examples:
Master to LodTrak module:
< esc> < id > [ < >. . . < > ] < eot >
LodTrak module to Master:
<esc> </id>[ < > . . . < >] <eot>

Request of values flags from a function that is


disabled results i invalid and confusing data.
7-2.2. Message Contents
7-2.1. Packets

7-2.2.1. MASTER TO LODTRAK MODULE. The

Each packet has two s ecial case data bytes:

LodTrak module only accepts two types of request


messages from the Master controller:

The byte that flags the beginning of a packet. This


is the ASCII < esc character, or 1BH
(hexadecimal) .
The byte that flags the end of a packet. This is the
ASCII <eot> ch acter, or 04H.

If either of these chara ters appear as part of a


message, an ASCII < sc> character precedes it when
the message is from th LoadTrak module and must
precede it for message sent to the LoadTrak module.

Read request. The first byte in the message is an

ASCII < R > followed by a single byte binary


number defined as the index for a variable to be
read. The LodTrak module responds to any invalid
request as an error: -1 = access denied; -2 =
request failed. Read requests for disabled set points
respond with data that may be misleading. Do not
request data unless the set point is enabled.
A seperate request is needed for each desired data
index.
7-1

BI006008

Protective Relay Module

fI-5600

Command requests. The first byte in the message is

ASCII < W > followed by a single byte binary


lUmber defined as the index for that command. If
he command is valid and completed, the LodTrak
nodule returns an "Acknowledge" status message
:+ I). If the command is invalid or cannot be
~xecuted, the LodTrak module responds with an
~rror message (-lor -2, as above).

ill

,2.2. LODTRAK MODULE TO MASTER. The


Irak module responds to the master only after it
ives a valid request message. The response message
ther of two types:

Jata message. This type of message is indicated by


leading zero binary byte, followed by the value's
linary index, then the value's low byte followed by
t's high byte. A checksum byte is the message's
ast byte. This checksum makes the 8-bit sum of the
'alue bytes zero.

itatus message. This is a single binary byte that


eports the status of a command request or reports
:rrors.

3. Message Values

3.1. COMMANDS RECEIVED. There are only


command values that the LodTrak module accepts:
~

"0" requests reset of an overload trip.

interpreted or calculated by the Master to obtain the


meanings.
Tables 7-1 thru 7-5 define all useful indexes for Present
Value, Set Point, At Trip, Starts/TripslHour~ and
Since Start value displays. In each table, the scale is
decimal counts = value defined.

7-2.4. Status Messages

The motor status is a count in the high byte of index


104, and is the only status message that is a "count".
The status of the module, alarms, and trips are in
messages that require evaluation of each bit in each byte
read. All of the status messages should be scanned to
determine the present state of the motor and LodTrak
module. Table 7-6 defines the flags and their associated
indexes, bytes, bits and values.

The following is a sample dialogue between master


controller and LodTrak module:
Condition:
Master wants to read index 4 (Motor voltage
phase I) from the module designated as "B" .
The messages are composed of 8-bit bytes,
shown in hexadecimal notation. Commas are
used for clarity only and are not part of the
message. Notice that because the selected index
(04) has the same value as the code for <eat>
it must be prefaced by the (esc) character.

"I" requests reset of an overtemperature trip,


ither winding or bearing.
NOTE
~II

other types of trips must be manually


eset.
3.2. DATA SENT. The LodTrak module sends
It (2-byte) data values, which are identified by
[ numbers. The index numbers specify the memory
ions of this data, which is of three types:

Request from Master control:


IBH, 42H, 52H, IBH, 04H, 04H
Where IBH=esc, 42H=B, 52H=R, IBH=esc,
04H=4,04H=eot
Response from LodTrak module:
IBH, BDH, OOH, IBH, 04H, LBH (lobyte
value), HBH (hibyte value), C5H (chksum
value),04H

.n integer, in which both bytes are valid.


'wo independent characters in the same index.

Where IBH=esc, BDH=/B, OOH=O,


IBH=esc, 04H=4, LBH=LBH, HBH=HBH,
CSH=CSH,04H = esc

Ine-half of a long integer.


values are per the LodTrak module's measured
s and/or flags. These values and flags must be

If (lobyte value) = IIH and (hibyte value) =


11H then (chksum value) = DEH

BI006008

Protective Relay

Mo~

ule

GEH-5600

Table 7-1. Present Value List Indexes


Display

Index

LoByte

HiByte

AVERAGE KW

122

Valid

Valid

AVERAGE KW

159

Valid

Valid

BEARING RTD 7

14

Valid

Valid

BEARING RTD 8

15

Valid

Valid

= 1 kW
10.24 = 1 DC
10.24 = 1 DC

BEARING RTD 9

16

Valid

Valid

10.24

BEARING RTD 10

17

Valid

Valid

10.24

CAPACITY USED

128

Valid

Valid

Valid

Valid

= 1%
290 = 1 amp

21

Valid

Valid

273

Valid

Valid

273

GROUND FAULT %
MOTOR AMPS (AVC)

MOTOR AMPS PH 1

Scale

Factors

= 65536 kW

Both bytes = Hi word


Both bytes = La word

= 1 DC
= 1 DC

= FlC
= FLC

(Index 7)/2.9

=%

1 amp

(Index 21 x FLC)/273 = amps *


(Index 1 x FLC)/273

= amps
= amps
= amps

MOTOR AMPS PH 2

Valid

Valid

273 = FLC

(Index 2 x FLC)/273

MOTOR AMPS PH 3

Valid

Valid

273

= FLC

(Index 3 x FLC)/273

133

Valid

Valid

10.24 = 1 DC

MOTOR VOLTS PH

Valid

Valid

21.231

=1V

(Index 36)/.12) x Index 4

= volts

MOTOR VOLTS PH

Valid

Valid

21.231

=1V

(Index 36)/.12) x Index 5

MOTOR VOLTS PH

Valid

Valid

21.231

(Index 36)/.12) x Index 6

STATOR RTD 1

Valid

Valid

10.24

=1V
= 1 DC

= volts
= volts

STATOR RTD 2

Valid

Valid

10.24

= 1 DC

STATOR RTD 3

10

Valid

Valid

10.24

STATOR RTD 4

11

Valid

Valid

10.24

= 1 DC
= 1 DC

STATOR RTD 5

12

Valid

Valid

10.24

STATOR RTD 6

13

Valid

Valid

10.24

MOTOR TEMP

* FLC can be calculate d from (indexes 33 X 75)/5

= 1 DC
= 1 DC

= amps

NOTE

Models 4A ,and 4C do not display any voltages, watts, or external relay values.

7-3

BI006008

Protective Relay Module

[-5600

Table 7-2. Set Point List Indexes


)isplay

Index

LoByte

HiByte

Scale

:ONTRAST

34

Valid

Valid

1 = 1

= darkest, 32 = lightest

'T VOLTAGE INPUT

35

Valid

None

= enable, 2 = disabled

'T PRIMARY KVOLT

36

Valid

Valid

(Index 36)/100

~OMINAL SEC.

37

Valid

Valid

21.231 =lV

Valid

None

VOLT

Factors

1 = enable, 2 = disabled

JNDERVOLT?

38

JNDERVOLT ALARM

39

Valid

Valid

1 = 1% of nominal

JNDERVOLT DELAY

40

Valid

Valid

10 = 1 second

(Index 40)11 0 = sec

JNOERVOLT TRIP?

41

Valid

None

1 = enabled, 2 = disabled

JNOERVOLT % NOM

42

Valid

1 = 1% nominal

)VERVOLTS?

43

Valid

None

JVERVOLT ALARM

44

Valid

Valid

1 = 1% of nominal

)VERVOLT DELAY

45

Valid

Valid

10 = 1 second

(Index 45)/10 = sec

)VERVOLT TRIP?

46

Valid

None

1 = enabled, 2

= disabled

JVERVOLT TRIP %

47

Valid

1 = 1% of nominal

IOLTS LOSS?

48

Valid

None

= enabled,

= disabled

'HASE REV. BY VOLT

49

Valid

None

= enabled,

= disabled

:T PRIMARY AMPS

75

Valid

1 = 1 amp

"RIP RELAY STATE

92

Valid

None

= TOOF, 2 = NTOF

~UX

93

Valid

None

= alarm, 2

RELAY STATE

Valid

Valid

Valid

Valid

1 = enabled, 2

= disabled

= trip,

3 = TOOF

= local

IESET TEMP TRIP

65

Valid

None

= remote, 2

eXT RELAY USED?

90

Valid

None

= enabled, 2

= disabled

"lINGS RTOS USED

50

Valid

None

= enabled, 2

= disabled

"lINGS RTOS aTY

67

Valid

Valid

1 = 1

1 to 6

"lINGS RTDS TYPE

51

Valid

Valid

None

1:1 OC,2: 120N,3: 100P,4:1 OON

)VERLOAD TYPE

66

Valid

None

1 = RTO, 2 = No RTO

MX WOG RTD ALARM

69

Valid

Valid

10.24 = 1 C

MX WDG RTO TRIP

68

Valid

Valid

10.24

IRG RTDS USED?

52

Valid

None

IRG RTDS aTY

70

Valid

lAG RTDS GROUPS

53

Valid

None

1 = 1 of 2, 2

IRG RTC GRl TYPE

54

Valid

Valid

None

1:1 OC,2: 120N,3:1 00P,4:1 OON

IRt RTO GR2 TYPE

55

Valid

Valid

None

1:1 OC,2:120N,3: 100P,4:1 OON

Valid

=1

=1

C
1 = enabled, 2

= disabled

1 to 4

1 of 4

BI006008

Protective Relay Mo ule

GEH-5600

Table 7-2. Set Point List Indexes (Continued)


Display

Index

LoByte

HiByte

Scale

BRG RTD GR1 ALA M

72

Valid

Valid

10.24

BRG RTD GR2 ALA M

74

Valid

Valid

10.24

=1

BRG RTD GR1 TRIP

71

Valid

Valid

10.24

=1

BRG RTD GR2 TRIP

73

Valid

Valid

10.24

=1

CT SEC FULL LOAD

33

Valid

Valid

100

= 1 amp

(Index 33)/100

= amps

LOCKER ROTOR XF C

76

Valid

Valid

273

= 1 per unit

(Index 76)/273

= xFLC

STALL TIME-SEC

77

Valid

Valid

INSTANT OVERCUF ?

56

Valid

None

INST OVERCURREN

79

Valid

Valid

273

OVERLOAD ALARM

57

Valid

Valid

10.24

ULTIMATE TRIP

78

Valid

Valid

273

PHASE UNBAL USE

80

Valid

None

PHASE UNBAL ALA M

83

Valid

273

PHASE UNBAL TRIP

81

Valid

None

PHASE UNBAL TRIP

82

Valid

273

PHASE REVERSAL

84

Valid

None

= enabled,

= disabled

GROUND FAULT

58

Valid

None

= enabled,

= disabled

GND FAULT TRIP

94

Valid

None

= enabled,

= disabled

GND FAULT ALARM

96

Valid

Valid

290

1 amp

(Index 96l/2.9

% 1 amp

GND FAULT TRIP

95

Valid

Valid

290

1 amp

(Index 95l/2.9

% 1 amp

GND FAULT DELAY

97

Valid

Valid

MAX STARTS/HOUF

59

Valid

None

MAX STARTS/HOUF

91

Valid

UNDERCURRENT US D

60

Valid

UNDERCURRENT TR P

85

UNDERCURRENT LE EL

86

UNDERCURRENT DE AY

87

LOAD JAM USED

61

LOAD JAM TRIP

88

LOAD JAM DELAY

89

RESET OF A TRIP
FREQUENCY IS

Valid

Valid

Factors
1 C

1 second
1

=
=

1 per unit

=1

= xFLC

(Index 781/273

=%

1 per unit

= 1 per unit
1 per unit

10 milliseconds

= enabled,
= enabled,

% FLC

= disabled

=%

(Index 82)/2.73

(Index 97)/1 0

FLC

= disabled

(Index 83)/2.73
1

= disabled

(Index 79)/273

= enabled,

FLC

= milliseconds

= enabled,

= disabled

None

= enabled,

= disabled

Valid

None

= enabled,

= disabled

Valid

Valid

273 - 1 per unit

Valid

Valid

Valid

None

Valid

Valid

273

Valid

Valid

62

Valid

None

= automatic,

63

Valid

None

= 60 Hz,

Valid

=1

(Index 86l/2.73

% FLC

1 second
1

1 per unit

= enabled,

(Index 88)/273

= disabled
= xFLC

1 second

= manual
50 Hz

NOTE
Models A and 4C do not display voltage or external relay messages.

7-5

BI006008

Protective Relay Module

H-5600

Table 7-3. Values At Trip List Indexes


Display

Index

LoByte

HiByte

Scale

Factors

CAPACITY USED

123

Valid

Valid

PH 1 CURRENT

116

Valid

Valid

= 1%
273 = FLC'

(Index 116 x FLC)/273

= amps'

PH 2 CURRENT

117

Valid

Valid

273

(Index 117 x FLC)/273

PH 3 CURRENT

118

Valid

Valid

= amps
= amps

MAX WINDING RTD TEMP

115

Valid

Valid

= FLC
273 = FLC
10.24 = 1 DC

UNBALANCE % FLC

125

Valid

Valid

273

= 100%

(Index 125)/2.73

GND FAULT % 1 AMP

124

Valid

Valid

290

= 1 amp

(Index 124)/2.9

PH 1 VOLTS

119

Valid

Valid

21.231

= 1 volt

(Index 119) x (Index 36)/.12


volts

PH 2 VOLTS

120

Valid

Valid

21.231

1 volt

(Index 120) x (Index 36)/.12


volts

PH 3 VOLTS

121

Valid

Valid

21.231

= 1 volt

(Index 121) x (Index 36)/.12


volts

MAX BRG RTD (ALL)

112

Valid

Valid

10.24

= 1 DC

MAX BRG RTD (7&8)

113

Valid

Valid

10.24

MAX BRG RTD (9& 10)

114

Valid

Valid

10.24

= 1 DC
= 1 DC

FLC can be calculated from (Indexes 33 x 75)/5

= amps

NOTE

Models 4A and 4C do not display any voltage trips.

(Index 118 x FLC)/273

% unbalance

% 1 amp

BI006008

Protective Relay Mo( ule

GEH-5600

Table 7-4. Starts/Trips/Hours List Indexes -

Models 4C and 4E

Display

Index

LaByte

HiByte

Scale

STARTS A TTEMPTE D

142

Valid

Valid

STARTS COMPLETED

143

Valid

Valid

MOTOR HOURS RUr

144

Valid

Valid

OVERLOAD TRIPS

145

Valid

Valid

WINDING RTD TRIP

146

Valid

Valid

BEARING RTD TRIP~

147

Valid

Valid

PHASE UNBAL TRIP

148

Valid

Valid

PHASE REV TRIPS

149

Valid

Valid

GROUND FAULT TR PS

150

Valid

Valid

INST OVRCUR TRIP'

151

Valid

Valid

UNDERVOLT TRIPS

152

Valid

Valid

OVERVOLT TRIPS

153

Valid

Valid

UNDERCURRENT TR PS

154

Valid

Valid

LOAD JAM TRIPS

155

Valid

Valid

MAX START TRIPS

156

Valid

Valid

EXT. RELAY TRIPS

157

Valid

Valid

Factors

=1
=1
=1

1 COUNT FOR EACH TRY


1 COUNT FOR EACH RUN
1 COUNT FOR EACH
HOUR

=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1

1 COUNT FOR EACH TRIP


1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP
1 COUNT FOR EACH TRIP

NOTE
Model 4C does not display any voltage trips.
Table 7-5. Since Start Values Indexes - Model 4E
Display

Index

LoByte

HiByt8

Scale

Factors

MAX % FLC

163

Valid

Valid

(Index 1631/2.73

= % FLC

MAX MOTOR TEMP

161

Valid

Valid

MAX UNBALANCE

162

Valid

Valid

(Index 1621/2.73

= % Unbal

MAX GROUND FAUL

165

Valid

Valid

= 100%
10.24 = 1 DC
273 = 100%
290 = 1 amp

MAX WNDG RTD

164

Valid

Valid

10.24

MAX BRG RTD (7&8)

166

Valid

Valid

MAX BRG RTD (9& 1

167

Valid

MAX KVOLTS

168

MIN KVOLTS

273

(Index 165)/2.9

=%

1 amp

DC

10.24

=1
=1

Valid

10.24

=1

DC

Valid

Valid

21.231

= 1 volt

(Index 168) x (Index 36)/120

= kV

169

Valid

Valid

21.231

= 1 volt

(Index 169) X (Index 36)1120

= kV

MAX KWATTS "

160

Valid

Valid

= 65536 kW

Upper two bytes

MAX KWATTS "

141

Valid

Valid

= 1 kW

Lower two bytes

DC

* KWATTS are evaluat d as a -long integer

Example: KWatts =(Lo 141)+(Hi 141)"256+(Lo 160)"65535+(Hi 160)"16.777216 e6

7-7

BI006008

Protective Relay Module

fI-5600

Table 7-6. Status Flag Indexes, Bits 1 - 8

Flag

Index

LoByte

Bit

External Relay

106

Valid

Ground Fault

106

Valid

Ground Fault

109

Valid

Group 1 Bearing RTD

106

Group 1 Bearing RTD

109

Group 2 Bearing RTD

106

Group 2 Bearing RTD

109

Group 3 Bearing RTD

106

Group 3 Bearing RTD

109

Valid

Load Jam

106

Valid

Max Starts/hr

106

Module Status

103

Valid

Module Status

110

Valid

Module Status

110

Valid

Motor Status

104

All

Valid

HiByte

Valid
6
Valid

2
7

Valid

Valid

Valid

Valid

Bit Value

o = False, 1 = Trip
o = False, 1 = Trip
o = False, 1 = Alarm
o = False, 1 = Trip - RTDs 7 - 10
o = False, 1 = Alarm- RTDs 7 - 10
o = False, 1 = Trip - RTDs 7 & 8
o = False, 1 = Alarm- RTDs 7 & 8
o = False, 1 = Trip - RTDs 9 & 10
o = False, 1 = Alarm- RTDs 9 & 10
o = False, 1 = Trip
o = False, 1 = Trip
o = Run Mode, 1 = SP Mode
o = Normal, 1 = Relay Error
o = Normal, 1 = Processor Error
1 = Start, 2 = Stop, 3 = Running
(Byte value)

= RTD7 Open, 0 = Okay


= RTD8 Open, 0 = Okay
= RTD9 Open, 0 = Okay

Open Bearing RTDs

102

Open Bearing RTDs

102

Valid

Open Bearing RTDs

102

Valid

Open Bearing RTDs

102

Valid

Open Winding RTDs

101

Valid

Open Winding RTDs

101

Valid

= RTD2 Open, 0 = Okay

Open Winding RTDs

101

Valid

Open Winding RTDs

101

Valid

= RTD3 Open,
= RTD4 Open,

Open Winding RTDs

101

Valid

= RTD5 Open, 0

Open Winding RTDs

101

Valid

Inst Overcurrent

106

Valid

Overload

109

Valid

Overload

106

Valid

Overtemperature

106

Valid

Overtemperature

109

Valid

Overvoltage

106

Valid

Overvoltage

109

Valid

Valid

= RTD10 Open, 0 = Okay


= RTDl Open, 0 = Okay
0
0

= RTD6 Open, 0
o = False, 1 = Trip

o = False,
o = False,
o = False,
o = False,
o = False,
o = False,

= Okay
= Okay
= Okay
= Okay

= Alarm

= Trip

= Trip
= Alarm

1
1
1

= Trip
= Alarm

BI006008

Protective Relay Mo ~ule

GEH-5600

Table 7-6. Status Flag Indexes, Bits 1 - 8 (Continued)

Flag

Index

Phase Reversal

107

Unbalance

106

Unbalance

109

Undercurrent

LoByte

Bit

HiByte

Bit Value

Valid

o = False, 1 = Trip
o = False, 1 = Trip
o = False, 1 = Alarm
o = False, 1 = Trip
o = False, 1 = Alarm
o = False, 1 = Trip
o = False, 1 = Alarm
o = False, 1 = Trip
o = False, 1 = Trip

Valid

106

Valid

Undercurrent

109

Valid

Undervoltage

106

Valid

Undervoltage

109

Valid

Voltage Loss

106

Valid

Voltage Sequence

107

Valid

Valid

NOTE

All disabled functions always have false flag states.

7-9

BI006008

Protective Relay Module

H-5600

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

CHAPTER 8
RENEWAL PARTS
8-1. INTRODUCTI

8-2. PARTS LIST

There are only three newal (replacement) parts


available for the Lod rak IV module:

The following list contains the description and part


(catalog) number for the replacement parts for the
LodTrak IV module.

A socket-mounte relay (three per module)

A snap-on plastic cover for the CT connections

When ordering, address the nearest GE Sales Office. Be


sure to include both the description and complete part
number.

fuse

Part Description

Part Number

CT cover
Relay
Fuse (2 a 125 V)

323AI729Pl
305A6647Pl
218A4989P3

NOTE

Because of the odule's construction and


circuitry. printe wiring boards should not
be replaced in th field.
To minimize system d wntime, GE recommends that
the customer keep sp e parts in stock.

8-1

BI006008

Protective Relay Module

H-5600

Notes:

BI006008

Protective Relay Mo ule

GEH-5600

APPENDIX A
SETUP EXAMPLE
Example Specification
Data:
Motor Ratings:
1000 hp, 3-ph 41
V ac, 60 Hz, 900 rpm
Full load cu ent = 108 A
Locked roto current = 920 A
Stall time ra 'ng = 30 sec at 40 degrees Celsius
Insulation cl s F
6- 10 ohm copper inding RTDs
2- 100 ohm nickel bearing RTDs
Motor CTs 200:5
Ground fault CT 1
Load:
Belt-driven fan, m imum load

100 A, minimum load

= 64.8 A

Protection type/levels esired:


Integrated overloa /overtemperature with RTDs, see section 2
Max. ground fault current = 8 A
Max. current unbalance = 15% at full load (91.8 A min)
Max. bearin temperature = 90 DC
Phase-revers detection
Trip on load oss = 50% of full load motor current for 10 sec
Trip on Inst taneous overcurrent
Set points for this exa pIe are shown in the following table:

A-I

BI006008

Protective Relay Module

H-5600

Set Point Selection for LodTrak Model LT4A


for
Example on Previous Page

SP#

Value

1
17
18
19
23
24
25
26
27
28
29
30
32
34
36
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
57
58
59
60
61
62
63
64
65

aIr
200
NTDF
TRIP
YES
6
10 CU
RTD
145
155
YES
2
100NI
80
90
2.7
8.5
30
YES
24
100
145
YES
10
YES
15
YES
YES
30
YES
40
.1
YES
YES
60%
10
YES
.92
10
MANUAL
60

Derivation = Notes
As required for best viewing
CT linecurrent primary rating to 5amp
Trip relay normal state TODF or NTDF (see Pg. 2-3 and 3-11)
Aux relay function (see Pg. 3-11)
Use winding RTDs
Use all six winding RTDs, best for hot spot detection
Winding RTD type- 10 ohm copper
Type of overload protection (see Section 2)
RTD alarm temperature, typically 10 DC below trip point
Trip temperature per NEMA MG 1-20.40 (see Pg. 4-2)
Bearing RTDs used
Number of bearing RTDs
Bearing RTD type- 100 ohm nickel
Bearing alarm temperature, typically 10 DC below trip point
Bearing trip temperature, from bearing specifications
CT sec full load amps = (108)x(5/200)
Locked rotor multiple of full load, (920/108)=8.518use 8.5
Stall time from motor specifications
Instantaneous overcurrent is used (see Pg. 25)
10C multiple = (920/1 08)x(2)x(sqrt 2)
Ult trip not used in this configuration (see Section 2)
Overload alarm temperature, typically 10 DC below trip point
Phase unbalance is used
Phase unbalance alarm point, set below trip value
Phase unbalance trip is used
Phase unbalance trip value from specifications
Phase reversal is used
Ground fault is used
GF alarm % 1 amp, typically 10% below trip point
GF trip is used
GF trip %1 amp = (8)x(5/1 OO)x(l 00%)
GF delay, to be coordinated with other system devices
Undercurrent (load loss) is used (see Pg. 2-6 and 4-3)
UC trip is used
UC trip level = < (1 08)x(64.8/1 08)x(1 00%)
UC trip delay time from specification
Load jam is used (see Pg. 2-6 and 4-3)
Load jam multiple of full load = (100/108) = .925 use .92
Load jam time delay from specification
Reset for temperature trips (see Pg. 5-2)
Power line frequency

BI006008

Protective Relay Mod ule

GEH-5600

APPENDIX B
MODULE SYSTEM/MOTOR PROTECTION SETTINGS
Replacing Lodtrak II With Lodtrak IV Module

~ et Point Name

Setting Should Be

SP1
SP17
SP18
SP19
SP23

( ONTRAST
( T PRIMARY AMPS TO 5 A
RIP RELA Y STATE
I UX RELAY STATE
\ VINDING RTDS USED

SET FOR BEST READABILITY


PRIMARY RATING FROM CT
NTDF
AS DESIRED- ADDITIONAL RELAY (SEE PG. 3-11)
NO IF FUNC 15 = 0, OTHERWISE SET YES

If SP23 = YES
SP24
SP25
SP26
SP27
SP28
SP29

WINDING RTD aTY


WINDING RTD TYPE
( VERLOAD TYPE
~~AX WINDING RTD ALARM
~~AX WINDING RTD TRIP
E EARING RTDS USED

SAME AS FUNC 15
SELECT APPROPRIATE RTD TYPE
RTD
SET 10 BELOW FUNC 17
SAME AS FUNC 17
NO IF FUNC 16 = 0, OTHERWISE SET YES

If SP29 = YES
SP30
SP32
SP34
SP36
SP38
SP39
SP40
SP41
SP42
SP43
SP44
SP45

E EARING RTD aTY


E EARING RTD GR1 TYPE
EEARING RTD GR 1 ALARM
EEARING RTD GR1 TRIP
CT SEC FULL LOAD AMP
lPCK ROTOR AMPS TIMES FLA
ETALL TIME SEC
I ~ST OVERCURRENT USED
I ~ST OVERCURRENT TIMES FL
l LT TRIP IS % FLC
CVERLOAD TEMP ALARM
FHASE UNBAL USED

SAME AS FUNC 16
SELECT APPROPRIATE RTD TYPE
SET 10 BELOW FUNC 18
SAME AS FUNC 18
SET = FUNC 19 X 5/1 00
SET SAME AS FUNC 20
SAME AS FUNC 21
YES
SET = FUNC 22 X 1.414
110 FOR SF = 1, 125 FOR SF = 1.15 (SEE PG 5-3)
SET 10 BELOW FUNC 17 OR 170 (SEE PG 2-3)
NO IF FUNC 23 = 99, OTHERWISE YES

If SP45 = YES
SP46
SP47
SP48
SP49
SP50
SP51
SP52
SP53
SP54
SP57
SP61
SP64

PHASE UNBAL ALARM % UNBAL


PMASE UNBAL TRIP USED
pHASE UNBAL TRIP % UNBAL
P~ASE REVERSAL TRIP
<: ROUND FAULT USED
<: ND FAULT ALARM % 1 A
<: ND FAULT TRIP USED
<: ND FAULT TRIP % 1 A
<: ND FAULT DELAY SEC
L NDERCURRENT USED
LDAD JAM USED
R SET OF TEMP TRIP

SET = FUNC 23 X .67


YES
SAME AS FUNC 23
NO IF FUNC 26 = 1, YES IF FUNC 26 = 2
YES
SET = FUNC 24 X .67
YES
SAME AS FUNC 24
SAME AS FUNC 25
NO
NO
MAN IF FUNC 28 = 51, AUTO IF FUNC 28 = 85

SP Number

B-1

BI006008

Protective Relay Module

1-5600

Replacing LodTrak III with LodTrak IV Module

;P Number

Set Point Name

Settings Should Be

;P1
;P17
;P18
;P19
;P23
f SP23 =
SP24
SP25
SP26
SP27
SP28
;P29
f SP2,; =
SP30
SP32
SP34
SP36
;P38
;P39
;P40
;P41
f SP41 =
SP42
;P43
;P44
,P45
f SP45 =
SP46
SP47
SP48
,P49
iP50
: SP50 =
SP51
SP52
SP53
SP54
;P57
: SP57 =
SP58
SP59
SP60
P61
: SP61 =
SP62
SP63
P64

CONTRAST
CT PRIMARY AMPS TO 5 A
TRIP RELAY STATE
AUX RELAY STATE
WINDING RTDS USED

SET FOR BEST READABILITY


SAME AS FUNC 20
NTDF
AS DESIRED - ADDITIONAL RELAY (SEE PG. 3-11)
NO IF FUNC 15 = 0, OTHERWISE SET YES

WINDING RTD aTY


WINDING RTD TYPE
OVERLOAD TYPE
MAX WINDING RTD ALARM
MAX WINDING RTD TRIP
BEARING RTDS USED

SAME AS FUNC 15
SELECT APPROPRIATE RTD TYPE
NO RTD IF FUNC 14 = 999, OTHERWISE SET TO RTD
SET 10 BELOW FUNC 17
SAME AS FUNC 17
NO IF FUNC 16 = 0, OTHERWISE SET YES

BEARING RTD aTY


BEARING RTD GR2 TYPE
BEARING RTD GR2 ALARM
BEARING RTD GR2 TRIP
CT SEC FULL LOAD AMP
LOCK ROTOR AMPS TIMES FLA
STALL TIME SEC
INST OVERCURRENT USED

SAME AS FUNC 16
SELECT APPROPRIATE RTD TYPE
SET 10 BELOW FUNC 18
SAME AS FUNC 18
SAME AS FUNC 19
SAME AS FUNC 21
SAME AS FUNC 22
NO IF FUNC 23 = 999, OTHERWISE YES

INST OVERCURRENT TIMES FL


ULT TRIP IS % FLC
OVERLOAD TEMP ALARM
PHASE UNBAL USED

SAME AS FUNC 23
SAME AS FUNC 28 (SEE PG. 5-3)
SET 10 BELOW FUNC 17 OR 170 (SEE PG. 2-3)
NO IF FUNC 24 = 999, OTHERWISE YES

PHASE UNBAL ALARM % UNBAL


PHASE UNBALANCE TRIP USED
PHASE UNBAL TRIP % UNBAL
PHASE REVERSAL TRIP
GROUND FAULT USED

SET = FUNC 24 X .67


YES
SAME AS FUNC 24
NO IF FUNC 27 = 999, OTHERWISE YES
NO IF FUNC 25 = 999, OTHERWISE YES

GND FAULT ALARM % 1 A


GND FAULT TRIP USED
GND FAULT TRIP % 1 A
GND FAULT DELAY SEC
UNDERCURRENT USED

SET = FUNC 25 X .67


YES
SAME AS FUNC 25
SAME AS FUNC 26
NO IF FUNC 29 = 999, OTHERWISE YES

UNDERCURRENT TRIP USED


UNDERCURRENT LEVEL % FLC
UNDERCURRENT DELAY
LOAD JAM USED

NO IF FUNC 30 = 999, OTHERWISE YES


SAME AS FUNC 29
IF SP58 = YES SAME AS FUNC 30, OTHERWISE 5
NO IF FUNC 31 = 999, OTHERWISE YES

LOAD JAM TIMES FL


LOAD JAM DELAY SEC
RESET OF TEMP TRIP

SAME AS FUNC 31
SAME AS FUNC 32
MANU IF FUNC 33 = 051, AUTO IF FUNC 33

YES

YES

YES

YES

YES

YES

YES

085

BI006008

GEH-5600

Protective Relay Mo ule

APPENDIX C
SET POINT RECORDS
This appendix includes forms to record set point values
for the following:

A-1. INTRODUCTI
GE recommends that
point values progr
module. This section
These forms list each
models, along with th

e user record and file the set


ed into each LodTrak IV
rovides forms for that purpose.
et point used for the different
default value for easy reference.

LodTrak models DS3820LT4A and -4C (page C-3)

LodTrak model DS3820LT4E (page C-5)

The forms can be removed from this book, if desired.


However, it is a good practice to keep the module's
instructions together with the recorded set point values
so that an operator or technician can have them both
readily available.

C-1

BI006008

Protective Relay Module

-1-5600

LodTrak IV Module System/Motor Protection Settings


(Models DS3820LT4A & -4CI
ation

Date

ter No.
ling

Description of Drive

SP
No.

Set Point Name

SP1
SP17

SP
No.

Set Point Name

(" " = default)


CONTRAST

1 to 32 "17"

SP44

50 to 9000 "500"

SP45

SP18

CT PRIMARY AMPS
TO 5 AMP
TRIP RELAY STATE

"TODF" or NTDF

SP46

SP19

AUX RELAY STATE

SP47

SP20*

RESET OF A TEMP
TRIP
REMOTE ID LETTER

"TODF or TRIP or
ALARM
"LOCAL" or
REMOTE
A to Z "?"

OVERLOAD TEMP
ALARM
PHASE UNBAL
USED
PHASE UNBAL
ALRM % OF FLC
PHASE UNBAL
TRIP USED
PHASE UNBAL
TRIP % OF FLC
PHASE REVERSAL
TRIP
GROUND FAULT
USED
GND FLT ALARM
%1A
GND FAULT TRIP
USED
GND FLT TRIP % 1
A
GND FLT DELY
SEC
MAX STARTS/HR
INTRVL
MAX STARTS/HR
INTRVL
UNDERCURRENT
USED
UNDRCUR TRIP
USED
UNDRCUR LEVEL
% OF FLC
UNDRCUR DELY
SEC
LOAD JAM USED

SP21*
SP23
SP24
SP25

Units

WINDING RTDS
"NO" or YES
USED
WINDING RTDS QTY "1" to 6

Setting

SP48
SP49
SP50
SP51

WINDINGS RTDS
TYPE
OVERLOAD TYPE

"10 CUM 100 PT


100 NI 120 NI
"NO RTD" or RTD

SP52

MAX WINDING RTD


ALARM
MAX WINDING RTD
TRIP
BEARING RTDS
USED
BEARING RTD QTY

"10" to 175

SP54

"20 to 185

SP55*

NO" or YES

SP56*

"1" to 4

SP57

"10CU" 100 PT
100NI120NI
"10" to 175

SP58

"20" to 185

SP60

"2.00" to 5.00

SP61

"3.0" to 12.0

SP62

SP40

BEARING RTD GR1


TYPE
BEARING RTD GR1
ALARM
BEARING RTD GR1
TRIP
CT SEC FULL LOAD
A
LOCK ROTOR AMPS
TIMES FL
STALL TIME SEC

"1" to 90

SP63

SP41

INST OVRCUR USED

"NO or YES

SP64

SP42

INST OVERCUR
TIMES FL
ULT TRIP IS % OF
FLC

"6" to 37

SP65

SP26
SP27
SP28
SP29
SP30
SP32
SP34
SP36
SP38
SP39

SP43

jel 4C only.

"85" to 125

SP53

SP59

Units
(n " = default)

LOAD JAM TIMES


FL
LOAD JAM DELY
SEC
RESET OF A TEMP
TRIP
FREQUENCY IS
HERTZ

"80" to 170
"NO or YES
"5 to 30
"NO or YES
"10"t035
"NO" or YES
"NO" or YES
5 to 70 "30"
"NO" or YES
10 to 100 "50"
.05 to 1.00 "0.10"
"NO" or YES
"1" to 5
"NO or YES
"NO" or YES
"15" to 90
"1" to 20
"NO or YES
0.7 to "2.S"
"1" to 10
"MANUAL" or
"AUTO
50 or "60"

BI006008

Protective Relay Mo ule

GEH-5600

Notes:

C-3

BI006008

[-5600

Protective Relay Module

LodTrak IV Module System/Motor Protection Settings (Model DS3820LT4E)

Ition

Date

ter No.

ing

Description of Drive

SP
No.

Set Point Name

Units
(. = default)

SP1
SP2
SP3
SP4
SP5
SP6
SP7
SP8
SP9
SP10
SP11
SP12
SP13
SP14
SP15
SP16
SP17
SP18
SP19

CONTRAST
PT VOLTAGE INPUT
PT PRIMARY KVOLT TO
120V
NOM SECONDARY V
UNDERVOLTAGE TRIP
UNDRVOLT ALARM % V
UNDERVOLTAGE TRIP
UNDRVLT TRIP % V
UNDRVLT DELY SEC
OVERVOLTAGE ALARM
OVRVOLT ALARM % V
OVERVOLTAGE TRIP
OVERVOLTAGE TRIP % V
OVRVOLT DELY SEC
PHASE LOSS BY VLTS
PHASE REV BY VLTS
CT PRIM A TO 5 A
TRIP RELAY STATE
AUX RELAY STATE

SP20

RESET OF A TEMP TRIP

SP21
SP22
SP23
c.;P24
SP25

REMOTE 10 LETTER
EXTERNAL RELAY USED
WINDING RTDS USED
WINDING RTDS OTY
WINDING RTDS TYPE

SP26

OVERLOAD TYPE

SP27
SP28
SP29
SP30
SP31

MAX WNDG RTD ALARM


MAX WINDING RTD TRIP
BEARING RTDS USED
BEARING RTD OTY
BEARING RTD GROUPS

SP32

BEARING RTD GRl TYPE

SP33

BEARING RTD GR2 TYPE

1 to 32 "17"
"NO" or YES
00.24 to
69.00 "4.20"
"50" to 120 V
"NO" or YES
"55" to 95
"NO" or YES
"50" to 90
0.2 to 30 "15"
"NO" or YES
"105" to 130
"NO" or YES
"110"to 135
0.2 to 30 "15"
"NO" or YES
"NO" or YES
50 to 9000 "500"
"TODF" or NTDF
"TODF" or TRIP or
ALARM
"LOCAL" or
REMOTE
A to Z "?"
"NO" or YES
"NO" or YES
"1" to 6
"1 CU" 100 PT
100 NI 120 NI
"NO RTD" or RTD
10"to175
"20" to 185
"NO" or YES
"1" to 4
"1 GR W/4
2 GR W/2
"10 CU" 100 PT
100 NI 120 NI
"10 CU" 100 PT
100 NI 120 NI

SP34

BEARING RTD GRl


ALARM
BEARING RTD GR2
ALARM
BEARING RTD GR 1 TRIP
BEARING RTD GR2 TRIP
CT SEC FULL LOAD
LOCK ROTOR AMPS
TIMES FL
STALL TIME SEC

SP35
SP36
SP37
SP38
SP39
SP40

Setting

SP
No.

Set Point Name

Units
(. .. = default)

SP41

INST OVRCUR USED

"NO or YES

SP42

"6" to 37

SP53

INST OVRCUR TIMES


FL
ULT TRIP IS % OF
FLC
OVERLOAD TEMP
ALARM
PHASE UNBAL USED
PHASE UNBAL ALRM
% OF FLC
PHASE UNBLA TRIP
USED
PHASE UNBAL TRIP
OF % FLC
PHASE REVERSAL
TRIP
GROUND FAULT
USED
GND FLT ALRM %
1A
GND FAULT TRIP
USED
GND FLT TRIP % 1 A

SP54

GND FLT DELY SEC

SP55

MAX STARTS/HR
USED
MAX STRTS/HR
INTRVL
UNDERCURRENT
USED
UNDRCUR TRIP
USED
UNDERCURRENT
LEVEL % OF FLC
UNDRCUR DELY SEC
LOAD JAM USED
LOAD JAM TIMES FL
LOAD JAM DELY
SEC
RESET OF A TEMP
TRIP
FREOUENCY IS
HERTZ

SP43
SP44
SP45
SP46
SP47
SP48
SP49
SP50
SP51
SP52

SP56
SP57
SP58
SP59
SP60
SP61
SP62
SP63

"10"to175
SP64
"10" to 175
SP65
"20" to 185
"20" to 185
"2.00" to 5.00
"3.0" to 12.0
"1" to 90

"85" to 125
"80" to 170
"NO" or YES
"5" to 30
"NO" or YES
"10"t035
"NO" or YES
"NO" or YES
5 to 70 "30"
"NO" or YES
10 to 100
"50"
10 to 100
"0.10"
"NO" or YES
"1" to 5
"NO" or YES
"NO" or YES
"15" to 90
"1" to 20
"NO" or YES
0.7 to "2.0"
"1" to 10
"MANUAL" or
AUTO
50 or "60"

BI006008

Protective Relay Module

GEH-5600

Notes:

GE Drive Systems
General Electric Company
1501 Roanoke Boulevard
Salem. Virginia 24153

BI006008

BI006008

GEF-8016A

RENEWAL PARTS BULLETIN

CR1938, C & 0

Vacuum limitamp Contactors

BI006008

CR193B, C & D Rsnswal Parts Bulls/in

Table Of Contents
General information
400 and 800 Amp Contactors
Wire Harnesses
Coil Assemblies
Vacuum Bottle Assemblies
Guide Assemblies
Top Assemblies
Adjustment Tool Kits
Mechanical Latch
Auxiliary Interlocks
Bottle Guide Assemblies
Bottom Terminal Assemblies
Drawout Contactor Parts

Page

.
..
.
.
.
..
.
.
..
.
..
.
..

3
4
5
5
5
5
6

6
6
7
8
8
8

These instructions do not purport to cover all details or variations in equipment for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the
Purchaser's purposes, the matter should be referred to the nearest GE Sales Office.

GEF-8016A

BI006008

CR1938, C & D RBnBwaJ Parts Bul/Btin

Generallnfor
This renewal p rts bulletin will provide the
proper identifi ation of standard parts
which may be equired for the maintenance
of CR193B & 0 400A) and CR193C (800A)
Vacuum Limita p contactors.
Both the comp ete contactors and required
renewal parts re shown as catalog numbers and are s pported by photographs.
Catalog numbe s identified in this bulletin
may not be the same as those parts on the
original equip ent. The renewal part
catalog numbe s are shown in kit form.
It is the intent f this bulletin to give our
customers a q ick and accurate way to
identify parts r quired for normal maintenance of the V cuum Limitamp contactors.
Unless otherwi e stated, all of the parts
shown in the b lIetin are compatible with
the contactors anufactured since 1985.

Since contactors are supplied to meet


specific customer control and distribution
requirements, certain replacement parts not
listed in this publication may occasionally be
required. Please refer to the factory for
these requests.
In these situations, please provide a complete description of the part, along with the
complete data shown on the contactor
nameplate that is affixed to the top of the
conta ctor.
For pricing and availability of parts shown in
this bulletin, contact your nearest GE sales
office.

Attention shoul be given to forecasting


your particular renewal parts requirements
to ensure on-si e availability ofthe specific
parts as requir d for normal maintenance
and proper op ration of your equipment.
To maintain ma imum operating efficiency
and reliability 0 your equipment, genuine
GE renewal pa ts are recommended.

GEF-8016A

BI006008

CRI9jB, C & 0 RenewalPam Bulletin

400A and BOOA Vacuum Contactor

Fig. 1

Contactors can be identified


by their catalog number,
located on the nameplate
on the top of the contactor.

1-_-- 2
Note: 400A contactor shown in photo

400 Amp Contactor

BOO Amp Contactor

CR193B & 0 Vacuum contactors are designed for


equipment used in starting AC motors with line voltages
from 1ODD-Volts to a maximum of 7200-Volts, transformer
feeders, and other medium voltage control equipment.
Item

CR193C Vacuum contactors are designed for equipment used in starting AC motors with line voltages
from 1000-Volts to a maximum of SOOO-Volts, transformer feeders, and other medium voltage control
equipment.

Description
Contactor Bracket and Pin Assembly
Control Wire Harness

See Fig. 2

Plug Bracket and Socket Assembly (not shown)

55B533224G4

Part Number

55B533223G4

Contactor Catalog N um ber System

CR193B & 0

(400A)
(BOOA)
+

CR193C

LATCH VOLTAGE
NO LATCH
110/115 VDC
24 VD C
48 VD C
230/250 VDC
NOLATCH
WITH MECH

110
910
924
948
950

LATCH

+ Voltage for contactor main coil is always 110/115 VDC

* The sum of normally open, normally closed, and late opening normally closed
contacts must be a multiple offive (5). Each interlock block contains five (51
contacts. A contactor may contain a maximum of four (4) blocks, two (2) being
the maximum on either side. Only five (5) late opening normally closed contacts
are available on a contactor.

NORMALLY OPEN AUX CONTACTS


NORMALLY CLOSED AUX CONTACTS
LATE OPENING NORMALLY CLOSED
AUX CONTACTS
AUX INTERLOCK LOCATION
ANY SIDE
RIGHT SIDE ONLY
LEFT SIDE ONLY

Typical contactor number: CR193B110L010032U


400A contactor

wlo mechanical latch


110/115 VDC main coil
10 normally open aux contacts
3 normally closed aux contacts
2 late opening normally closed aux contacts

GEF-8016A

BI006008

CRI!J.lB, C & 0 RenewalPads Bulletin


Fig. 3

Fig. 2

Coil Assembly

Wire H mess Assembly


Description
Single Block Harn ss
Double Block Har ess
Triple Block Harn ss
Four Block Harne s

Part Number
VCPl
VCP2
VCP3
VCP4

Note:
Single block harness s own in photo

Description
CR193B & D, 400 amp contactor
CR193C, 800 amp contactor

Part Number
55D781008G3R
55D781014G3R

Note:
400A coil shown in photo

Fig. 4

Fig. 5

0:0-::
<MIi1!I

Vacuum Bottle Assembly


Description
CR193B & D, 400 mp contactor
CR193C, 800 amp ontactor

Part Number
55C679806G 1RP
55C679810G 1RP

Note:
Above part numbers In lude three (3) vacuum bottles and necessary
hardware.
400A contactor parts s own in photo

GEF-8016A

Guide Assembly
Description
CR193B & D, 400 amp contactor
CR193C, 800 amp contactor

Part Number
55D781008G2R
55D781014G2R

Note:
400A contactor guide parts shown in photo

BI006008

CRI9jB, C & 0 RenewalParis Bulletin


Fig. 7

Fig. 6

Contactor Adjustment Tool Kit

Contactor Top Assembly


Description
CR1938 & 0, 400 amp contactor
CR193C, 800 amp contactor

Part Number
55D781008G 1R
55D781014G1R

Description
CR1938 & 0, 400 amp contactor
CR193C, 800 amp contactor

Note:
400A top assembly shown in photo

Part Number
302A3900D CG 1
302A3900DCG2

Note:
400A tool kit shown in photo

Fig. 8

Mechanical Latch Assembly


Description
110/115 VDC
24VDC
48VDC
230/250 VDC

Part Number
55C679819G3RA
55C679819G3R8
55C679819G3RC
55C679819G3RD

GEF-8016A

BI006008

CRI!J.1/l C & 0 RenewalParis Bulletin

Fig. 9

800 Amp
Block

400 Amp
Block

Auxiliary Interlocks
The table below lists all possible combinations of auxiliary interlocks within a single block.
Sel ct the contact arrangement desired and add the suffix letters to the appropriate part
nu ber (i.e.. 55C679809G2RP).

C ntactor
C 1938 & 0,400 Amp contactor
C 193C, 800 Amp contactor

Suffix
G1RP
G2RP
G3RP
G4RP
G5RP
G6RP
G7RP
G8RP
G9RP
10RP
11 RP

NO
5
4
3

NC

Part Number
55C679809
55C679814~

LONC

2
3
4

5
4
3
2

2
3
4

Suffix
G12RP
G13RP
G14RP
G15RP
G16RP
G17RP
G18RP
G19RP
G20RP
G21RP

NO
3
2
1
2
1

NC

LONC
2

1
2
3

2
2
2
3
3
3
4
4
5

1
2

1
1

N te:
N = Normally open contacts
N = Normally closed contacts
LO C = Late opening normally closed contacts

GEF-8016A

BI006008

CR/BolD, C & 0 RenewalParis Bulletin


Fig. 11

Fig. 10
Bottle
Guide

Bottom Terminal Assembly

Bottle Guide Assembly


Description
CR193B & D, 400 amp contactor
CR193C, 800 amp contactor

Description
CR193B, 400 amp contactor
CR193D, 400 amp drawout contactor
CR193C, 800 amp contactor

Part Number
55D781011G1R
55D781017G1R

Note:
400A top assembly shown in photo

Note:
400A terminal parts shown in photo

=
=

r-+ r=

h
r

II

f-----

~""'~

0
I~
0

~Q
r-....
2

~ r---....

Part Number
55D781008G4R
55D781008G5R
55D781014G4R

=""'=
..........

""'A

L.~

~ "'"
0

I==<
f-

0
0

l~

p.....i

0
0

~U
0

1==

Jl--.
F=

Io=d

L-

0
'--

i-----'

Fig. 12
Drawout Contactor (CR193D) Parts
Item
1
2
3
4

Description
Line Side Stab T' Block
Load Side Stab T' Block
Phase Divider
Phase Barrier

Part Number
55B532563P3
55B532563P2
55C679821 P2
55C679821 P3

GEF-8016A

BI006008

CR/DB, C& 0 RenewalPam Bulletin

( Blank Page)

GEF-8016A

BI006008

GEF-8016A

GE EIBctrical Distribution & Control


0795

General Electric Company


P.O. Box 489, 6801 Industrial Dr. , Mebane, N.C. 27302

BI006008

GEK-83756A

GE Drive Systems

DS303 HEAVY DUTY DC CONTACTORS


SIZES 1 THROUGH 5

B
a
w
th
ne

ore adjustments, serJuing, parts replacement, or


other act is performed requiring physical contact
the electrical working components or wiring of
equipment, the power supply must be disconted.

ese contactors are self-contained, frontco nected, and suitable for mounting on steel
b es, with insulation bases recommended for
co taminated environments. The insulation
a arc extinguishing systems are designed for
6 0 and 1000 Vdc with no arc excursion beyo d the contactor. All contactors, in addition
to having fully-rated blowout coils, also have
bl wout coils with lower current rating to impr ve interruption characteristics at low curre t. For 600 V contactors, the minimum inte ption capacity is 10% of the blowout coil
ra ing, and the maximum interruption capacity is 1000% of the contactor frame size rating
wi UR = 15 ms. For contactors with more
th n one pole, it is possible to have a mixture
of blowout ratings that might include poles
wi no blowout.
er to Table 1 for a listing of basic contactor
s and nominal ratings.

Figure 1. DS303B1A Contactor - interlock added.


roits simultaneously, to prevent time delay
dropout and to prolong rectifier life.

If he contactor is to be energized from the


ou put of a rectifier, a full-wave bridge circuit
of the type shown in Figure 2 is often used.
\ enever this type of connection is used, only
th ac side should be opened, or both the ae
an dc sides should be opened simultaneously.
Th dc circuit alone should not be opened
un ess the rectifier is rated for full ac voltage,
wh ch would be evident from the omission of
th resistor on the ac side. Contaetors may be
de energiz.ed by opening both ae and de cir-

MAINTENANCE
ARC CHUTES (See Figure 3)

All poles with blowout coils also have arc


chutes. To remove the arc chute, loosen the
captive screw "A" and slide the arc chute off in
the horizontal direction. With the Size 4 and 5
contactors, it is also necessary to release the arc
chute latch "B". This may be effectively done

BI006008

GEK-S3756

DS303 Heay)' Duty DC Conlaclors

--,

with a screw driver used to release the latch and slide


the arc chute in the same motion.

In normal service, the arc chute is good for the life of


the contactor and requires no maintenance. Operation
beyond rating may cause excessive erosion of plastic or
ceramic. Replacement is necessary only if there is
evidence of ceramic or plastic walls wearing through,
or if there is extreme ceramic melting caused by an
overload.

ARC CHUTE
LATCH'S'

Replace the arc chute by sliding it over the arc runner


and between the pole pieces. Tighten captive screw
"A" and ensure that latch ~'B" is engaged. There must
be electrical contact at arc chute support "C", Figure 4.
COILS (See Figure 4)
To replace coils, remove the arc chutes, remove the
two screws supporting the lower terminal block, and
unhook the armature tension spring. Do not loosen or
otherwise change the adjustments of the armature
tension spring because this is. factory adjusted for
proper pick up.
Remove the armature assembly and the Coring retaining the coil. Remove the coil.
Replace the coil and reassemble in reverse order.
Spring washer clips and locking screws are used on
some contactors to prevent coil shifting. Reassemble
and adjust if necessary to hold the coils firmly in place.
Adjust the armature spring if loosened or otherwise
disturbed.

Figure 3. DS303B5E Contador.

CONTACT WIPE AND GAP, POWER CONTACT CARE (See Figures 4 & 7)
contact wipe and gap per Table 1. Some adjustment
can be made using shims under the plastic movable tip
carrier.
On contactors 'with normally closed contacts, normally
closed contact wipe is zero ",'ith holding coils, and 1/2
of the Table 1 wipe when no holding coil is used. With
the armature held in the fully open or closed position,
however, gaps and "''ipes must be according to Table 1.

Power contacts do not require maintenance (dressing,


filing, or adjusting) for the life of the contacts. Contacts must be replaced when either contact has worn
through to the copper support or when the wipe is
reduced to .016 inch (see Figures 4 & 7).
In the event of extensive contactor disassembly or
exchange of parts (power contacts excluded), check

l"'---

AC SUPPLY - - - - - - - l

Figure 2. Full wave rectifier for ac operation.

BI006008

DS303 Heavy Duty DC Contactors

GEK-8375I

TABLE!
MAIN CONTACT GAP, WIPE & FORCE
Device
DS303"#t
Size
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
3
3
3
3
3
3
3
3
3
3
3
4
4
4
4
4
4
4
4
4
5
5
5
5
5
5
5
5
5

Pole
ArT: ngement

Holding
Coil

Max. Continuous
Amps. Der:ate for
Smaller Blow-out
Coils

25
25
25
25
25
50
50
50
50
50
50
50
50
50
50
50
100
100
100
100
100
100
100
100
100
100
100
150
150
150
150
150
150
150
150
150
300
300
300
300
300
300
300
300
300

Form
A

no

B
D
G
J

INC
n OlNC
INC
n OlNC

no

B
C
D
E
F
G
H
J

INC

2?' 0
nO-INC
21 OINC
2? 02NC
INC
2?' 0
n OINC
2101NC
2? 0-2NC

no

B
C
D
E
F
G
H
J

INC

2?' 0
n O-lNC
21 OlNC
220-2NC
INC
2~0
120-1NC
21 OlNC
2102NC

no

B
C
D
E
G
H
J

INC
210
11 0-lNC
2J 0-1NC
1NC
210
1 0-lNC
2 OlNC
1 0
1NC
210
1 ~0.1NC
2~0-INC
INC
210
2 ~0.1NC
2 ~O.lNC

K
A

B
C
D
E
G
H
J

YES
YES

..
..
YES
'YES
YES
'YES
YES

YES
YES
YES
)'ES
YES

--

)'ES
YES
YES
YES

YES
YES
YES
YES

Contact Wipe
N.O. &N.C.
Max.
.064
.064
.064
.064
.064
.064
.064
.072
.064
.072
.072
.064
.072
.064
.072
.072
.072
.072
.072
.072
.072
.072
.072
.072
.072
.072
.072
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081
.081

Min.
.044
.044
.044
.044
.044
.044
.044
.052
.044
.052
.052
.044
.052
.044
.052
.052
.052
.052
.052
.052
.052
.052
.052
.052
.052
.052
.052
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051
.051

ALLDESIGN~ : i.e. k 600V; B: 1000V, etc.


# Size
t Form

N.O. Contact
Gap

N.C. Contact
Gap

Min.
.28

Min.

.37
.37
.37
.37

.25

.25
.28

.40
.25
.40
.40

.40

.25
.40
.40
.57

.37

,.

.37
.40
.40
.37

.37
.40
.40

.40

N.O. Contact
Force Oosed,
Oz.
Min.
5.5

N.C. Contac
Force Oosed
Oz.
Min.

3.0
3.0
5.5
5.5

5.5

5.5
5.5

20.0
5.5
20.0
20.0

3.0

3.0
6.5
6.5
5.5

20.0
5.5
20.0
20.0
20.0

5.5
20.0
20.0

6.5

6.5
6.5
6.5
20.0

20.0
20.0
20.0
20.0

20.0
20.0
20.0

20.0
20.0

.42

32.0

.42
.42
.42

32.0
32.0
32.0

32.0
32.0
32.0
32.0

.40
.35
.40
.40

.40
.35
.40
.40
.62
.42
.42
.42
.42
.42
.42
.62

.40
.40
.40
.40
.40
.40

.42
.42

.'

.42

.42.

.42
.42

.42
.42
.42

32.0
32.0
32.0

.42
.42
.42

32.0
32.0
32.0

.42
.42

21.0

21.0
21.0
32.0

32.0
32.0

21.0

21.0
21.0
32.0

32.0
32.0

BI006008

GEK-83756

DS303 Heavy Dut)' DC Contactors

ARMATURE SPRING ADJUSTMENT

the normally open contacts pointed up and the


normally dosed contacts pointed dmm. This is
the only acceptable mounting position.

The annature spring is factory adjusted and does not


require re-adjustment during routine maintenance. If
the annature spring is disturbed or the contactor is
completely disassembled, the annature spring may be
adjusted as follows:

2. The woven shunt must be fonned so that it is in


a neutral position with the contacts just touching; otheruise, the shunt acts as a spring and
impairs pickup.

On contactors with only nonnally open poles,


the annature spring must be adjusted to firmly
open the annature against its stop and yet pick
up between 45 and 65% of the maximum coil
nameplate voltage \\;th the coil at room temperature.
On contactors with normally closed poles but
without a holding coil, the annature spring
must be adjusted to obtain at least 1/2 of the
nonnally closed contact wipe in Table 1. Verify
that pickup is still within 45 to 56% voltage as
above.
On contactors with nonnally closed poles and
with a holding coil, the nonnally closed contacts
do not wipe using the annature return spring
because these contactors use a larger contact
spring. Adjust the armature return spring to
obtain pick up between 45 and 65% voltage as
above.

CONTACT FORCE
Contact force can be checked according to the minimum values of Table 1 by closing the annature by
hand and then measuring the force required to part
the contacts according to Figure 7. Contact force below
minimum can be corrected only by replacing the
contact spring.

Notes:

OPERATlNG
COIL

1. Pick up measurements are always made with


the contactor mounted on a vertical panel 'with

.....r.-..,...,

AAWATURE

ASSOoIBlY

TER W'HAl. IllOCIt


- - - SCREWS 121

ARWATURE TENSION

SPRING

Figure 4. DS303B3A Contactor - arc chute half removed to


show detail.

Figure 5. DS303B3j ContactoT.

BI006008

DS303 Heavy

uty DC Contactors

GEK-83756

TABLE 2
INTERLOCK RATINGS (In Am cres)

Number
of
ContaclS

C ry

Make

Interru t
Dc Inductive
125V

One Set

o
o

60
60

1.8

600 V

250 V
0.5

0.2
0.35

1I0V
6

220 V
3

440 V

1.5

600 V
1.2

Two SelS
4.0
1.2
in Series
'Noninductiv de interrupting rating is 1.5 times inductive.
.... Capable of int rrupting inrush current of 60 amperes at 110 VOllS, 30 amperes at 220 VOllS. 15 amperes at 440 VOllS, and
12 amperes at 600 VOllS a limited number of times.

ELECTRI
Nole:

and 11. The stationary contacts should then be removed, inverted and replaced as outlined in the preceding paragraph.

ing or replacing a complete interlock


assembl)', he insulation as shown in Figure 3 must
e between the interlock and the coil.

vVhen circuits are rearranged to obtain one normally


open and one normally closed circuit, the normally
closed circuit must be located at the bottom, as shown
in Figure 9. Othelwise, electrical creepages 'will not be
maintained. (Note that Figure 9 is shown in the
operated position).

DCARE

The interlock s ould be positioned on its bracket so


that with the co tactor in its energized position, the
interlock plunge (Figure 8) should not bottom. With
the contactor in i de-energized position, there should
be some clearan e (C) between the interlock plunger
and the interloc operating arm (Figure 8).
Tip gaps and ~-i es, when new, should be as shown in
Table 3. Repla e contact tips when wipe reaches
one-half of mini urn specified.
A universal inte lock (Figure 9) having one set of
normally open c ntacts and one set of normally closed
contacts must b adjusted so that ,",-ith one set of
contacts just tou ing, there is at least 1/64 inch of gap
between the oth r set of contacts.

Spring ends must not protrude into holes (A), slots (B),
or keys (C), which serve as guides for the operating
arm. See Figure 10.
Contact blocks with two normally closed circuits require a spring spacer (D) as shown in Figure 10 to
ensure that the center spring is properly in place.
Because of the circuit rearrangement feature, a spring
spacer is supplied with all other twO'-circuit contact
blocks, as shown in Figures 9 and 11.

To replace remo able contacts, lift the spring seat with


the thumb and fi refinger, and remove the operating
plunger that sup orts the movable contacts. Snap off
the U-shaped ke s, and the removable contacts can be
removed and re laced. Care should be taken not to
lose any parts
pieces during this operation. To
replace a stationa . contact, remove the terminal screw
and lift the conta t off the housing. Replace by pressing the new con ct assembly into the molded insert
and run the te inal screw to its seal position. Care
should be taken 0 avoid changing the shape of this
contact assembly in handling. Also, the shape should
not change durin operation.
CHANGING CI CUlT ARRANGEMENT
To change an in erlock from normally open to normally closed or ice-versa, disassemble the movable
contacts in the m nner described above and turn the
contact over. Th contact, spring, spring spacer, and
keys should be re ssembled as shown in Figures 9, 10,

Figure 6. DS303B3D Contactor.


5

:;EK-83756

DS303 Heavy Duty DC Cootaetors

INTERLOCK
OPERATING ARM
CONT"CT GAP:
Mea",re the minimum

L - ....
I

~\

CLEARANCE
(C)
INTERLOCK
PLUNGER

Figure 8. Contactor in its de-energized position.

r-- -----l
I

1/,/11,1'1'1' ,

I
I

)==~._,~

HOLDING COIL
\lFUSED)

SPRING
SPACER
CONT"CT WIPE:
Measure at the front edge
of the plastic housing

'"==+=+==, 4-':::=+=::'::=- NO
TIP WIPE

N
.c.GAPTIP

CONT"CT FORCE
ME,t.SUREMENT
LOCATION

POST OR CORE (POST SHOWN)

Figure 9. Universal electrnal interlock with one set of


normally open contacts and one set of normally
closed contacts in the operated position.

Figure 7. Tjpical contact gap and wipe measurements.

TABLE 3
INTERLOCK CONTACT GAP AND WIPE
(Per Figures 9, 10, & 11)
CONTACTS

Not
Operated

(N.O.)
Tip Gap
(N.C.)
Tip Wipe

MAXIMUM
INCHES

MECHANICAL INTERLOCKS
Contactors are arranged for horizontal mechanical
interlocking in pairs to keep one device from closing
while the other is closed. \Vhen one contactor is
completely closed and the other open, there should be
a slight amount of free motion of the interlock arm.
Double-throw forms cannot be mechanically interlocked.

MINIMUM
INCHES

lIS

5/64

3/32

3/64

RENEWAL PARTS
Operated

(N.O.)
Tip Wipe
(N.C.)
Tip Gap

5/64

3/64

7/64

5/64

Renewal parts may be ordered from the renewal parts


bulletin by specifying the quantity required and the
catalog number, or by describing the parts in detail
and giving the complete nameplate rating of the
equipment.

BI006008

BI006008

GEK83756

r----SPR1NG SEAT
KEY----....

SPRING
SPACER
MOVABLE
CONTACT

TERMINAL

A-!--+-t--~

A
N.C:

IP WIPE

ASSEMBLE TIP
SUPPORT FLATLY
AGAINST HOUSING
BY RUNNING SCREW
TO SEAT POSITION
BEFORE MAKING ANY
CONNECTIONS

I-'-~...r--"=-_-+-STATIONARY

CONTACT

'--N.O. TIP GAP

OPERATI NG
PLUNGER

Figure 11. Universal electrical interlock with nonnally open


contacts in unoperated position.

Figure 10. Uni- mal electrical interlock with normally


close contacts in unoperated position.

Thtse instructions not purport to cover aU details or variations in equipment, nor to provide for e-.;ery possible contingemy to be 1Mt during
installation, operati ,and maintenance. Should further information be desired or should particular problems arise that are not covered
suffidently for the p rchaser's purpose, tJu matter should be referred to GE Drive S)'stems, Salem, Virginia, U.S.A.

BI006008

WARRANTY SERVICE

Should a defect covered by our warranty occur, the part shall be repaired or replaced only upon receipt of the failed
part by Drive Systems Product Service. General Electric sales offices will provide return tags and shipping
instructions.

GE Drive Systems
General Electric Company
1501 Roanoke Boulevard
Salem. Virginia 24153
(703) 3877000

BI006008

BI006008

; General 'Description

:,'

,."

'.

'

::ig. 1, 8.25 KV, 600 ampere, Versa-Rupter Switch

The Versa-Rupter Switch is a


:lroduct of BBC Brown Boveri
Norld-wide technology. Our ex:lerience in the design and
Tlanufacture of load-interrupter

switches now goes back over 50


years.
Classified as a general purpose
load-interrupter switch, the VersaRupter Switch is suitable for ap-

plication in all types of metalenclosed switchgear. A variety of


ratings are available for system
voltages from 4.16 up to 34.5 KV,
nominal. Continuous current

'-',

BI006008

of the ANSI requirements. This


means that normal phase spacings can be maintained without
the need for separate laminate
sheet barriers. The 38KV rating
employs skirted epoxy insulators
with generous phase spacing
making barriers unnecessary at
this voltage as well.
The interrupting system employed
in the Versa-Rupter Switch has
been used successfully for over
20 years. The interrupting
medium is a dual arc extinguishing system utilizing an
auto-pneumatic air-blast and hard
gas nozzle principle. The well
balanced utilization of this dual
system results in a very reliable
and durable arc extinguishing
system.

Fig. 2, 15 KV, 600 am ere, Versa-Rupter Switch

ratings include 200, 6 0, and


1200 amperes.
The switch is three-po e, twoposition and gang-ope ated. The
three pole assemblies, a storedenergy operating mec anism and
the drive linkage are ounted on
a steel frame, with co plete factory alignment and adj stment
and ready for installati n.
The support insulators of the
ratings through 27.0KV are a
specially formulated gl ssreinforced polyester pr viding
high impact resistance
mechanical strength, nd electrical properties including high
track-resistance and fl me retardance. The unique esign of
these insulators also i eludes
built-in "barriers" whic provide
dielectric performance in excess

Fig. 3, 38 KV, 600 ampere, Versa-Rupter Switch

BI006008

Construction Features
Stored energy spring
mechanism zinc plated spring
and cadmium plated iridite dip
parts.

Main drive shaft


Steel frame painted
with epoxy enamel

Current interrupting system


based on auto-pneumatic air
blast and gas extinguishing
arc-chute. Cylinder and piston
for air blast interruption.

Arc-chute
~~~~"*:--- Insulated drive link
....,...~--

Arcing blade
Main blade

~---

(2) Main blades, jaw and hinge contacts completely


silver plated

Open blade
position

Reinforced glass polyester insulators


Front View

Optional Features
rhe Versa-Rupter Switch is
iesigned to accommodate a
rariety of options and
lccessories:
, Operating Handles - For
operation from the front or side
or a cubicle, with a removable
or non-removable handle. The
front mounted handles use a
ruggedly constructed precision
gear and pipe drive linkage.
The non-removable handles
have provision for KirJ< Key interlocks and for padlocking.
Integral Fuse Mountings - A
variety of types and brands of
fuses can be accommodated.

Left Side View

Shunt Trip - The spring


operating mechanism can be
provided with a latch and a
solenoid release. A variety of
voltages are available: 24, 48,
125 Volts DC and 120 and 240
Volts AC.
Motor Operation - Two styles
of operators are available, one
that mounts directly to the side
of the spring operating
mechanism, and one that can
be mounted remotely on either
the side or front of the cubicle.
A variety of operating voltages
are available.
Ground Switches - For mount-

ing directly to the Versa-Rupter


Switch, all have fault closing,
momentary and 2-second
ratings. They can be mechanically interlocked to prevent
closing the Ground Switch
when the Versa-Rupter Switch
is closed, or closing the VersaRupter Switch when the
Ground Switch is closed.
Auxiliary Switches - A six pole
(3 NO and 3 NC contacts) Auxiliary Switch is driven directly
from the switch operating
linkage.

BI006008

SYSTEM RATING
KV, NOMINAL

VERSARUPTER SWITCH RATINGS


CURRENT

VOLTAGE
Rated
Max.
Voltage
(KV)

4.16 THRU 7.2

Rated
Dielectric
B1L Impulse
(KV)

8.25

12.0 THRU 13.8

75

15.0

12.0 THRU 16.5

22.9 THRU 24.9

36

110

27.0

34.5

26

95

17.0

50

125

38.0

Low
Frequency
Withstand
(KV)

60

150

80

Load

Rated

Cont.

Interrupting

Current
(Amperes)

(Amperes)

200

200

600
1200

600
1200

200

200

600

600

1200

1200

200

200

600

600

1200

1200

200

200

600

600

1200

1200

600

600

Capacity

Rated
Mon. Cur.
Asym.RMS
(KA)

LIFE EXPECTANCY
Fault
2 Second
Mechanical
Closlng
Shortlime Endurance
rrentAsym Current Sym. WIO Mainl
RMS (KA)
RMS (KA)
(No. Opr.)

Load Cur.
Endurance
W/O Malnl
(No. Opr.)

40

40

25

1000

100

40

40

25

1000

100

40

40

25

1000

100

40

40

25

1000

100

40

30

25

500

50

'These values are based on the requirements of ANSI STD. C37 581 and represent actual design tests. These numbers are intended to
give the user guidance for nspection and maintenance.

8.25

INCH

6.54

1260

MM

166

320

14.25

15.51

362

394

3.54
90

16.61

422

16.85
428

20.08
510

12.20
310

2.48

16.22

4.80

6.46

591

63

412

122

1&4

150

14.76

13.78

0.59

375

350

15

0.98

0.59

2.95

25

15

75

1.30

8.11

1.22

3.3

206

31

'When left-hand shaft extens on used

BI006008

,.
19B

UNIT

A.

A,

A,'

H,

H,

K.

N"

N,

T,

T,

INCH

886

14,76

16.46

20.12

386

21,02

22.72

2362

17.36

3.43

17.79

480

6.46

669

19.69

1555

0.59

098

0.59

354

0.71

'.
a

"c>
890

Sc

..11>~~,~
1.22

MM

225

375

418

511

98

534

577

600

441

87

452

122

164

170

500

395

15

25

15

90

18

226

31

INCH

886

14.76

16.46

20.12

388

21.02

22.72

23.62

17.36

3.43

2291

732

795

9.25

19.69

2067

0.59

098

0.59

354

0.71

11.46

1.22

98

534

577

600

441

87

582

188

202

235

500

525

15

25

15

90

18

291

31

23.62

17.36

3.43

26.06

732

7.95

1083

1969

23.82

0.59

0.98

0.59

354

0.71

13.03

1.22

600

441

87

862

186

202

275

500

605

15

25

15

90

18

331

31

MM

225

375

418

511

INCH

886

14.76

16.46

20.12

386

21.02

22.72

MM

225

375

418

511

98

534

577

hen leh-hand shah extension used

BI006008

Max.
Voltage
KV

UNIT

A,

A,

A,

H,

N'

N,

INCH

14.57

20.87

26.57

3346

4.84

2756

29.37

2618

36.54

10.08

10.08

14.17

25.59

3425

0.55

6.47

0.98

18.27

1.57

2.40

1.22

MM

370

530

675

850

123

700

746

665

928

256

256

360

650

870

14

163

25

464

40

61

3'

380

'When left-hand shaft

tension used

BI006008

!
~

8
IPARfS
'nEM;

HO. ,

1.
2.
3.

4.
5.
6.
7.
8,
9.

:lD.
.U.

,12.

13.
Ill.
IS.

16.
17.
18,
19.
~Q.

PART',
'~O' ,

lIS f ( .H. MOUNTHI~)

'QTY.

PARTS LIsr (R.H,M9urnIN~)_


ITEM

DESCR I PTI Ul'..

I--.-':'.:..';~.::II:::O:-. ~P..'.A:.::R.:..T ::;..N..:.O:..,.- cf-_ _-'D:..::E..:.S.:...C'i.:...1 PTI.. :O:. : N

~
SPROC ET g'HuBIISSY.
SE TSCI E" (,250-20 x .~O LG)
CHAIN CJARD (,625 UIA, x 22.25 LG),
;
2 COTTE PIN <'094 X 1.00 LG)
4 SCRCW, II.H. (, 375-16 x .750 LG)
4 LocKw SHER' (,375)
1 OPERA I ':G HANDLE Assy.
1 CLOSE INDI CATOR PLATE
1 OPEN I l DICATOR PLATE
2 CHAIN ( 1/2 PITCH)
2 OFFSET LINK Assy.
~76936GRB
4 REMO'I LE LI NK Assy.
159-798-~01_" 2 Tu~~~. KLE As;y.
715602-C
: .2 WIRE 032DIA. x- 10.00 LG)
244-044-501
1 i.. H. lAF-r EXTENSION' KIT (P-150MH)
,(P-170MH)
244-044-502
1
(,,17JMH) :
244-()q4 -505
1
(P-235MHl
244-044-504
1
(P-360MH) ,
244-()q4-506
1
'. (P:'210MH)
' 244-044-5Q~,
l'

186-088-301
G50107-E
232-740-001
53117-C
54390-C03
53103-H
321-105 - 302
201-663-002
201-663 -001
296012GRIl
576987GRB

BI006008

1
1
1

2.
3.

2 2

4.

4 4

5.
6,
7.
8.
g,

41 4

1,1

1 1 1 1
1
4
2
8
2
2
1

NO:

.. .

1.

1
1 1
1 1

1
2 10.

1 1
3 2
2 2
6,4
2'2
2 2
1 1
1
1 1

2 11.
4
2
2
1
1

12.
13.
l'L
20.
21,
22.
23.
24.
25.
26.
27.

1
3 3

3
3 3
6 6
1

3 3
6 6

28.

186-088-301 SPROCKET & hUB Assy.


650107-E
SETSCREW <. 250-20 X .50 LG)
232-740-001 CH/\IN GUARU <'625 DIA. X 22,25 LG)
53117-C
COfTER PIN <'094 DIA. X 1.00 LG)
54390-C03
SCREW, II, H. (.375-16 X ,750 LG)
53103-H
,'LOCKWASIiER <'375)
321-105-302 OP'.RATi% HMDLE Assy.
201-663-002 CLOSED INDICATOR PLATE
201-663-001 OP. ! INDICATOR PLATE
CHAIN' j2 PITCH) (83 LINKS)
296012GRB
576987GRE
OFFSET LI NK Assy
576986GRB
,REMOVA.Bi.E LINK Assy.
159-798-301 TURNBUCKLE Assy.
..
715502-C
WIRE (,032 DIA. X 10.00 LG), ..
244-051-001 ANGLE BRACKET (8.00' LG)
244-052-001 ANGLE (12. 63 LG)
244-05~301 AN0LE Assy. (30.31 LG)
244-054-302 ANGLE Assy. (25.31 LG)
54390-C04
SCREW, H. H. (,375-16 X 1.00 LG)
650403-B
LOCKNUT (. 375-16)
54500-H
FLATWASHcR (,406 10 X .812 00)
244-052-004 Alj'iLE (I7, 63 LG)
. .. _0----'244-052-005 JI'j,.LE <3L75 ,LG)

j".

_.~_

II".

",,"n",", """"

'"4-037-510
29.625 '" 34.00
'KIT No. 244-037-511.A:lJUSTMENr LENGTH 34.625 TO 39. 00
KIT No. 244-037-512 ADJUSTMENT .LENGTH 39.625 TO 44.00
KIT NO. 244-037-514 Ar;JUSTMENT LENGTH = 61.625 TO 66.0

SPUN

'NOTES:---'

'

:T"WHEN IIlSTALLlNG CHAIN ~ND OPERATING H~NDLE,


SWITCH CLOSED AND IIANDLE
THE
POSITlON.

ill

,Of 5'

"* ItANDlE

>P~OCKET,

PLfAiL

liE

2. A.'iLE Assy. ([TEM N? 22 OR 23) ARE USED WITH


- ~,"uLE (IHI-IJ, ~1 Ci1'~7};.U5E SUIl/ED HULES- '/O-ADJUSr--,
fO REQUIRED LENGTH. USE rop OR BOTTOM .HOLE ON
~,
AIIGLE BRACKET liTEM No, 2C) ro FURTHE~ ,ADJUST FO~~_
C"BlcLE DEPTH.' :'

.-

3. SEE DWG. S-20135 FOR INSTALLATION OF L.H. SHAFT


EXTENSION KIT

4. TURNBUCKLES TO BE NO CLOSER THAN 2.:. TO EITHER


SPROCKET IN SWITCH CLOSED POSITION WITH HANDLE
IN THE UP POSITION. IF NECESSARY TO MOUNT SW"CH
S?ROCKET' OUT OF LllfE WITH HANDLE SPROCKET, DO NOT
EXCEED LMISALIGNMENT.
I
CAUTIO~: MAKE. SURE CHi>.IN HAS SUFFICIENT
CLEARANCE FROM. FNGER 12ED PARTS OUTS I DE
,
OF SWITCH BARRiER.

~v-ARIAJiLE\f'BOml ADJUSJI'U:IH~

'5
: "

1
j

AJJUS T CHA I N BE TWEEN Sw I TCH AND HANDLE UNT I L TOP


AND BOTTOM LENGTH OF CMAIN ARE SNUG. OPEN AND CLOSE"
SAITCH 10 TIMES WITH HANDLE, THEN MAKE FINAL
ADJUsrME~ rs ON BOTH TURNBUCKLES. WITH PROPER
AD.JUSTMEIIT, THE HANDLE SHOuLD BE APPROX. 3/4' TO
l.J.r. FROM HANDLE STOP IN EITHER POSITION WHEN

~ t..... SWI TCH ,RIPS.


._. ,- __ . _._
~
,ANGLE AS5Y."M~S;: BE INSTALLED PRIOR to

SPRUI.I
SHAfT

__ _

__"

MAKING THIs 'CHAIN ~JUS1;IE;H.

'riETAIL@
LYOF CIIAIN & TURNBUCKLE'

3'-7 3/4" (27.0 KY OIlLT)


,(R,H,."O!iJ,Y).

,SWITCH
,SPROCKET,

,u...oo 'o...llI.lol<l ''''0 OIifOIll " " . .


~~~::::..~"':=:"'~~u.:::."~ ~":: ~,.~

..

OO"t .. s.o".......

IfIfC04'

.. ..:.:: ..:::::::"::'.=-..:.~"..:..;;;'_'--.....:.;..";.;..:.;;<;..''------:---1 A'

DRIVE HANDLE KITS IL.H. AND R.H. ASSY.)


I

VERSA-RUPTER

0,

'i'l :Uf,-P37

0..

-+_-1.

--;;-'. --_. - - -

,..

-~

BI006008

BI006008
!

- -

MICROPROCESSOR BASEr STARl1N;:) & PROTECTlON MODUi....~

AC RHMET['='

Z n

DC AMMETER

F\CCELERATlNG CONTACTOF

~c

AMBER INDICATING LlGH,

A 5
A,
A

PtMME1ER S~!TCH

B I

BLOWN FUSE INDICATOR


BLOWN FUSE TRIP
BLUE INDICATI~G UGH:

B ,

B L
C

C
C
C
C
C
C
C
C

I
IX

C
C B
C D

CT

DW
ER
E M
E C
E C RHEO
FI .F2
F
F X

~iJ~s
l;RS
D
R
IR

~I

SX
S~

TRS
U

CI
F

FX
IL
ND
RB
5
J ,HZ.H3
AM
S~

XR
X

,D.
J .LZ.L3
A

OR
S~

I-Ill
llGF
1/0C-Ol

1I0L -DC
I/OP-PR
I/OP-PU
1101
lAR

C
CR
L

1
IX
M
B

FC
FM
G
HA. PHB,PHC
LR
RO
PST

P,

P1B
R
RC
REC
RECP
RIL
RM
RS
RID
RX
5
SC
S-GR

~R.,'V;:,"-+R'V.5
REV.S

'-

- -

"

--

5NU~'T

SI-'
SHAl'"

SPACE: HERTER RMMETER

SP HiP

SPACE HEATER
STALL PROTECT IVE RELA'

STARTING REACTOR
SLOW SPEED CON1AClDR
SeD>' SPEED SHORTING CON1ACTOR

SP

RELA~

SS~

SELECTOR SIol!TCH

5'
ST8
55x
5\

SiMB

SHORTING TERMINAL BOARD


RUX. RELA~ TO SS

AUx. REun TO S
lRf'NSFORMER
TIME CLOSING
TIME DELAY AFTER DE-ENERGIZATION
lIME DELAY AFTER ENERGIZATION
TIME OPENING
OU1GOING TERMINALS 10 MOTOR

Ie
TDA,
lDAE
TO
TI.T2.13
T8
lH
lHY
TIE
lPI
lPlx

CLOSING COlc
CIRCUIT BREAKER
CONTACTOR CONTROL MODULE
CALIFORNIA DI5CONNEC1
CHOKE
FIELD CURRENT CALIBRATION MODULE
CAPACITOR TRIP DEVICE
CONTROL POWER INTERLOCK
AUX. RELAY 10 CPI
CON1ROL RELAY
CURRENI lRANSFORMER
CURREN! lESI BLOCK
CURRENI lRAN5DUCER
DIODE
DC CURREN! lRAN5FORMER
DIFFERENTIAL RELAY
DI5CONNECI 5WnCH
EXCIIER FIELD RELAY
ELAPSED TIME MEIER
EXCIIER
EXCITER RHEOSTAI
SYNC MOTOR FIELD LEADS
FIELD CONTAClDR
AUX. FIELD RELAY
AUX. FIELD RELAY
FIELD DISCHARGE RESISTOR
FIELD GROUND RESISTOR
SYNC. MO, DR FIELD
FIELD LOSS RELAY
FIL TER
FIELD RECTIFIER PANEL
FAST SPEED CONTACTOR
FAST SPEED SHOR1ING CONTACTOR
AUX. RELAY 10 F5
FEEDER S~nCH
FIXED lAP RESISTOR
FUSE
GROUND CURRENT lRAN5FORMER
GROUND FAUL T RELAY
AUX. RELAY TO GF
GRHN INDICA1ING UGHT
GROUND
GROUND BUS
GROUND SENSOR
OUTGOING TERMINALS TO lRANSFORMER
HEATER AMMETER
ISOLAIlNG S~nCH
INCOMPLETE SEQUENCE RELAY
ANTI -KISS RELAY
LATE OPENING
INCOMING TERMINALS OR AC BUS
LIGHTNING ARRESTOR
LlGHI
LOCKOUT RELAY
UGHT ~ITCH
LODTRAK III
LODT~AK/GROUND FAULl
LODTRAK 10VERCURRENT -OVERT EMPERATURE
LODTRAK IDVERLOAD-OVERCURRENT
LODTRAK 10PEN PHASE-PHASE REVERSAL
LODTRAK 10PEN PHASE -PHASE UNBALANCE
LODTRAK 10VERTEMPERATURE
LODTRAK AUX. RELAY
MAIN CONTACTOR
MOTOR
METEL OXIDt VARISTOR
CONTACTOR HOLDING RESISTOR RELAY
MAIN DISCONNECT ~ITCH
AUX. RELAY TO M
NEUTRAL CONTACTOR
AUX. RELAY TO N
OPERATlDNS COUNTER
OVERCURRENT RELAY
OVERLOAD RELAY
OVERTEMPERATURE RELAY
AUX. RELAY TO OT
POLARITY MARK
PUSH BUTTON
PO~ER FACTOR CAPACITOR
POWER FACTOR METER
PLUG
INCOMING UNE TERMINALS
PO~ER LOSS RELAY
CT PROTECTOR [THYRITE)
PHASE SHIFIlNG IRANSFORMER
POTENTIAL TRANSFORMER
P01EN1lAL TEST BLOCK
RUN DR REVERSE CONTACTOR
RELEASE COIL OR CONTACT
RECTIFIER
RECEPTACLE
RIL INDICATING LIGHI
RECTIFIER CONTACTOR
RESISTOR
RESISTANCE TEMPERATURE DETECTOR
AUX. RELAY TO R
START CONTACTOR
SURGE CAPACIIOR
SLIP-GUARD RELAY

'R'V.2

~,

S5
55:

AUTOTRAN5FORME"

+I'""=v.-;I

5P,

AMMETER

CAPAC I TOR

C C.

NOt--1ENC_hTURE

NMENCLATUR::'
e.t Pn

ACCELERATIOr.; TlMING

--

-,

TERM] NML BOftRD

THERMOS1AT
iHYRnE
TIE SWITCH
TEST POWER INHRLOCK
AUX. RELAY TO lPI
TESI POWER ~ITCH
TIMING RELAY
lRIP RELAY
THERMOSTAI ON AT OR SR
TEST-NORMAL SELEC10R SWITCH
UNLA1CH RELAY
UNDERVOL lAGE RELAY
UNDERVOL lAGE TIMING RELAY
VOL lAGE CHECK RELAY
VOL lAGE DIVIDER NET~ORK
VARIABLE FIELD SUPPLY MODULE
VOL mETER
VOL lMETER S~ITCH
VARMETER
VAR lRANSDUCER
VARIABLE AUT01RANSFORMER
VOL lAGE lRANSDUCER
WATT HOUR DEMAND METER
WATT HOUR METER
WATTMETER
WATTS lRANSDUCER

TP~

lR
IRP
1ST
1~

UL
UV
UV1R
vCR
VDN
VFSM
VM
VMS
VRM
VR1D
VI
VTD
~HDt1

WHM
WM

W10

NOH A - PURCHASER 10 REMOVE JUMPER AFiER CONNECIING REMOTE DEVI


NOH B - IDUV IS WIRED FOR TIME DELAY OROP-OUI ON LOSS
OF VOLIAGE. THE MAIN CON1ACTOR WILL OPEN. THEN RECLOSE
IF VOLIAGE IS RESTORED ~ITHIN lHE liME RANGE OF TDUv.
FOR INS1ANEOUS DROP-QUI, PURCHASER SHALL RECONNECI
JUMPER PER ELEMEN1ARY.

iHIS DIAGRAM SHOWS S1AR1ER WlIH lHE ISOLATING SWlICH IN


lHE DISCONNECI POSlIION AND lHE lESI PDWER IN1ERLDCK
IN lHE HST POSIIIDN.
10 HSI - HANDLE MUSI BE IN lHE DISCONNECT POSITION [ OFF lAND
lEST-NORMAL SELECIOR S~lICH. LOCA1ED IN iHE LO~ VOL lAGE
COMPARTMENI. MUSI BE IN lHE [ lESI 1 POSITION. PURCHASER IS 10
CONNECI HIS lEST POWER lD lHE PROPER HRMINALS AND N01E
lHAI lHE CON1ROL CIRCUli IS NOI GROUNDED wHEN DISCONNECTS ARE Of
BE SURE TO !URN lHE TES1-NORMAL S~lICH TO NORMAL
BEFORE MOVING lHE DISCONNECI HANDLE TO iHE [ ON I POSITION.
CPI - OPENS ONLY WHEN CPI RELEASE ON ISOLATING S~ITCH
HANDLE IS PUSHED IN. CAN NOI BE OPENED WHEN MAIN UNE
CONTACTOR IS CLOSED.
(:, - STARI AND SlOP PUSHBUnONS ARE ~IRED lHOUGH TERMINAL AI
'IB' IN ORDER THAI REM01E SIART-Sl0P BunONS CAN BE READILY
CONNECIED INTO THE CIRCUIT WHEN REQUIRED.

0-

AI A lERMINAL ON 'IB' A LOOP IN THE C1 SECONDARY CIRCUli


PERMlIS INSERIION OF A HOOK ON AMMElER FOR MEASURING
LINE CURREN!.

t - DEVICE FURNISHED BY 01HERS MOUN!ED REM01E.

f5 - lERMINAL BOARD POIN1,

ND1E:

DEVICE lERMINAL

CON1ROLLER GROUND
~IRE

NO.

SYS1EM GROUND

LIMITAMP
REQ. NO.
MIL NO,
CUSTOM"ER

EQUIPMENT FOR :

37795E182
0997X0397
MARION POWER SHOVEL DIV.

f,,"',.llEiCOc.;~c..:G~L~A~CK"'E~Y _ ___b-"'-V"--5..:.M:....::.G....:L::.A::.cK....:E::.y_1
-\\1lN
+-:...\\.I ME BANE OPE RA TI ON
155"'0 B/7/95

~IF

REO.

37795E 182

MEBANE, NC USA

GE

Dl~At1

NO.

32789=
CONT. ON SH.

no

ISH.

He

BI006008

BI006008

KEY lNTERLOCK SYSTU1


KEY INTERCHANGE

Al I -

MOUNTED ON HANDLE OF MAIN DISCONNECT S"JTCH lR01AllI]


PREvENTS OPENING OF UPSTREAM DISCONNECT
UNTIL HANDLE OF MAIN DISCONNECT ~!TCH lR0JA01) IS OPEN.
ONE KEY REQUIRED FOR SYSTEM OPERATION
CUSTOMER MUST PROVIDE REMOTE LOCK TO
CO-ORDINATE "ITH EQUIPMENT HANDLE
ORDER ON GE-MEBANE P.D PM6641RH.

R01A01

..

L-O

L-D

REV.lt

REV.l

REV.S

REV.2

REv.S

REv.3

> HANDLE

OF SWITCH IS LOCKED OPEN.

HADE Br

APPfK)VAL.S

M G LACKEY
I''''"'''' BI7/95
TECH

REO.
CR

M G LACKEY

1),

KEY CAN BE REMOVED

M G LACKEY

37795E182
CR19L+

L YII\I MEBANE OPERATION

MEBANE. NC USA

GE

DIAGRAf'1 NO.

327895

COOT. ON SH.

OC

ISH.

HOC

BI006008

BI006008
!i

aue

SET PO}NT
I

- -,

;'-"--

i Li~:

DISPLP'

i CONTRAST

.- ::;

..

S~---

is

i
I

3.

tBRN RTD 7.8

3S

IBRN

3E

tBRN RTI' 7.8 TRIP DEG.

37

iBRN RTD 9.J~ TRIP DEG.:-

38

39

INST .' OVERCURRENT IS USED -

-2

_3

CT PRIMARy TO 0 AMP -

18

TRIP RELAY STATE -

19

AUX. RELAY STATE -

TDDF

_6

PHASE UNBAlANCE ALM % OF FLC PHASE UNBALANCE TRIP -

PHASE UNBAL flNC E AL M

IPHASE UNBALANCE

'

8~

_9

PHASE REVERSAL TRIP


GROUND FALL T IS USED'

01

GND FAUL T ALM % DF I AMP ..

TO

J7~

Yi: NO OR YES

5 TO 29

~NO

OR YES

10 TO 30

TRIP % DF FLC -

50

IGROUND

I TO 911

110 !'8S TO l25

_7

52

10

NOli NO OR YES
LiUls TO 3'
~

TO 0.00

OVERLOAD ALM DEG. C -

TODF DR TRIP
OR ALARM

..----,

ICAlC

_0

TO 180

1'2.0~

~i3.~ TO 12.('

INST OVERCURRENT TIMES FLC

~r-

3.30

IULTIMATE TRJP IS Yo OF FLC -

TDOF OR NTDF

112~

SHILL TIME SE:

~i:l'T[l 185
I,

TIMES FL.': ..

_0

TO 175

~IWTO 175

LOAD AMPS ..

-I

_8

J7

In SEC FULL
iLRe CL'lRENT

!I I~

DEG. C

~M

RTD 9.10 ALM DEG.

! UNITS

D!SPLA~

15ET POINT

TO 32

=r~G,S

ND OR YES

FAUL T TRIP -

53

GND FAUL T TRIP % OF ) AMP -

5_

GND FALLT DELAY SEC.

I TD 6

57

UNDERCURRENT IS USED -

10CU 100PT
J00NI J20NJ

58

UNDERCURRENT TRIP USED -

~ NO

GU 5

OR YES

'"

TO 69

:~too

10 TO 100

0.10

0.05 TO 1.00

22
23

~INDING

RTDS ARE USED -

2_

~INDING

RTO on.

20

~INDING

RTD TYPE

NO

26

OVERLOAD TYPE -

27

~INDING

ALARM DEG. C -

28

~INDING

TRIP DEG. C -

29

BEARI NG RTDS ARE USED -

ND OR YES

&0 RTDI NO RTO OR RTD

59

UNDERCURRENT LEVEL % OF FLC -

10 TO 175

60

UNDERCURRENT DELAY SEC. -

TO 185

61

LDAD JAM USED

YES

62

LOAD JAM TRIP TIMES FLC -

63

LOAD JAM DELAY SEC.

1 GR W/ij
2 GR U!2
10CU J00PT

6_

RESET OF A TEMP TRIP -

lOON! 120NI

65

FREQUENCY IS

CJ
CJ 20

! NO I NO OR
) TO _

30

BEARING RTD

31

BEARING RTD GROUPS'

32

BEARING RTD [7.BI TYPE

33

BEARING RTD 19.101 TYPE -

~NO

25 TO 90

CJ

I TD 20

~ ND

OR YES

NO OR YES

OR YES

0.7 TO 10

~I

TO 10
MANUAL DR AUTO

50

50 OR 60

10Cu J00PT
J00NI 120NI

CUSTOMER NOTE:
CUSTOMER TO READ GEH-5600 AND VERIFY ALL SETTINGS BEFORE ENERGIZING EQUIPMENT.

099ttX0397R01A01
REv.~

RH.J

IW\IlE

REV.5

REV.2

ISSID

REV.6

REV.3

Tt.CH

or

APf'froVFt.S

M G LACKEY
REO.

B17195
CR NO.

M G LACKEY

"NW

M G LACKEY.

37795E 182
CR19tt

MEBANE OPERATION
MEBANE. NC USA

GE

DIA6RAt1 NO.

327895:
CONT. ON SH.

ISH. "'OC

BI006008

"

' -

6HL

DETAILS ON
SHZ
FIG!

"..L-

~-

--

--

~-

It~

---

.---_. - ---

lh J '.Jll B j l,:'fJ/

I-Hillll

SlhHP
LAT. NO.

-._-_ ..

---

--

R!J1f1.11 _____

kUIAUI

:>C.l!t!ll

-------

-----~_.~-

~--.-----

--

-------

3- Jr

J:!..~

-----~.

EL EM
CONt,
SHT.

120

AC

'---------

-----------

1----

------~_._--

.~-----------------

IND
HP

11

II

GEH

5~

--f----

f---

PH FRED P.F.

GEH-53~5

- - - - ---

B0~

LOAO TIPE

-- --

------------ +--- f-------

------------- -

---

OC

CONTROL VOL TS

---------- .._--- ----

5~of1Z!Z9'13F ~ ____

----

FUSE
CATALOG NO.

P(J~JER

32789530

DETAILS or,
SH 2
FIG Z

R01hll

-l-

~--

-----~

~- 5F~~

--f~75iN~

.GIN.

R01h01

r
I.

30

-----~"--------

7F J

---_..--

; ,~',":,',',:', '," 0'J~:,~~,~ ~i- ,~":~,~, -~3i':~": ::~:

--._--------

VOL TS

-_._-~-

AMPS

66~0

AC
DC

VOL TS

56~0

t ILl

GEH

SECONDARY

53~6

\...)I'J.l. I

AMPS

66

AC

DC

76

CONTINUOUS
CURRENT RATING
RMS AMPS

CAT

69~0

366

CAT

CAT

CAT

CAT

CAT

GEH-3~9!

TIN

GEH-53~5

YES.

FINISH

TIN

FINISH

TIN

55AZ I Z951 PI

IA

FINISH

TAPED MAIN BUS

NONE

SPECIAL NOTES

CAT

MAX.
INTVOLTS RATING
MVA

..l
..l
CAT

OTY.

161868

CAT099~X0397R01A01
CAT099~X0397R01AII

STAMP NP

NONE

NONE

ENCL. NEMA

JUI 111111\ I

RMS SYMMETRICAL

ALUM.

AMPS

ALUM.

~~~

AMPS

ALUM.

!~~~

I. FOR INSTALLATION. REFER TO

NOTES

5~KA

BIL RATING [KVI

BUS BRACING:

COPPER

D.C. BUS RATING

COPPER

GRND. BUS RATING

COPPER

CLASS E2

MAIN BUS RATING

NEMA

UUIL.lI~L

OTY.

GEH-5396

NO

SILVER

SILVER

SIL VER

>-

'"

:ox:

co

U
<I:
...J

i'i

'fi

~ ~

~"-

CD

In

(T)

f'f'-

>-

x:

co

<I:
...J

'"

alU

In 0::

N=J-

CDal

I~ II'~

<!...J

~ijI

'"

1;;

I~
fJ

en

q:1:

wgj
ZW

ow
Z

Q..

o::u
Z

q:::J

f-'"

>-< <I:

!(T)

.1'--- oj
'ON i5N

m ~-

Lnii

CS)
(T)

BI006008

BI006008

~.

__

\:,fj

.,~

5/8 ---

l/2

~,

0 1/2

Ij/ll}

I,'

II

3]4

1 __ .._ -~

130~'

30--oj
L.H. SIDE VIE~

f-- --

([,J

9 1/8

~.-

~i.:

7-3/1&

'~

,t zo
'"u.

:;

::

:I

:~ '

..

~~

. --+~

1/2

14 1/2

r
I

4 1/4

r@

JJ

F I () 1
::

S - 1/4
1- 114

::

~l3

i --icc

17

1t1/2
10-2-11/1&

II~

+:~.

VIE~

i l-1/2

----I

J'FT&

\!Y

3-1/2

FLOOR PLAN

-v-'

2-3/1&

NY~ li
_~i-..J:}---l
~t:(;;)np.JT

',,[@ir~'lr' i

'~:*,,";'r' l "1'' ' 1

FRONT

34

jlBCUUM....u!

J__ L I----

18-1/4

9'lt/2~~*=

tTl

~~&-917;9--;;;=
~

: ~ l2

\LLI
, '

iJ--
, '

VIE~

31/2~T-1

fOP

1- 1/4

-'---FRo~fF- f--

.- :@:l.
7-1/2,(fjj'

~3-1/2

27

t1
~-I;~-~Jf~-tJ
,-- -1/2

IIII IJI1!111) f'IJfIER [If<1111If,L CCJII/IECTIOI.


f,C PO,IEk BUS
[IF ORDEREDJ
f - COIllROI IEhD IEPMIllhL BOhRD
D - I1fJllJk LEhfJ TERI1!11hl COIHIECTlfJij
f
(,f<IJIJlI[J [JUS TEf<11I1ihL COlHllC! IIJij ( IF CJRDEREDJ
fJ
~,H,rE f<[I)iJlRED 10 Of'EIl Dfj[Jf<S '.10 CJ[GREES
II
411. fdSIE FOR (JJlllhCTOR R[l1uVhL
J
11IJIJlIIIIII) HULES HA' 1/2 ilL DIFI. hllCHOR [jUL IS
~,f'f,rE h'/fdl flBi l FOl< ltlCOl1111G COtrDllII

lJ
lJj

1.

l6

l2

17

f FRONT T
FLOOR PLAN
2-3/1&

VIE~

AUXILIARY

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BI006008

BI006008

Book #2
VendorPubucailons

Support Devices
-

Table of Contents -

Meter jTransformers

4555K10-001

Limit witch, 1C9446-A & -C (Crowd)

GEF-4199A

Instru ent Transformers

GEH-230AF

Relay, Machine Tool

GEH-2385G

Relay, CR120A

GEH-2466E

Time

elay Relays CD 122A . . . . . . . . . . . . . . . . . . . .. GEH-2468G

Switc boards

GEH-2621 C

Capa itors

GEH-2743A

Relay, Ground Fault & Differential. . . . . . . . . . . . . . . .. GEH-3071 B


Magn tic Starters Size 1 . . . . . . . . . . . . . . . . . . . . . . .. GEH-3247F
Magn tic Reversing Starter Size 1

GEH-3620B

Relay, 100V, CR120B

GEH-4115C

Instru tions, CR120BD, CR120BC Series A

GEH-4143C

Overl ad Relays CR 124C & CR124D

GEH-4729A

Groun

GEI-86126H

Break System

IIlumin ted Pushbuttons and Lights . . . . . . . . . . . . . .. GEJ-2836C


Dry Ty e Control Transformers

GEJ-3775B

Dry Ty e GP Transformers . . . . . . . . . . . . . . . . . . . . .. GEK-33276D


Dry Ty e GP Transformers . . . . . . . . . . . . . . . . . . . . .. GEK-33277C
Circuit Breakers, Molded Case. . . . . . . . . . . . . . . . . .. GET-2779
Break, Ground Fault Detection System . . . . .. GET-2946
2243-I.M61

BI006008

INSTALLAliON

198BI006008
4555K10-001G
Supersedes 4555K10-001F

TYPES A8-16, -40, -41,


08-16, -30, -40, -41
AMMETERS AND VOLTMETERS
(TAUT-BAND SUSPENSION)
(THIS PUBLICATION FORMERLY IDENTIFIED AS GEH-1564)
The Types AB-16, -40, -41 and Types DB-16, -30, -40, and -41 are switchboard
instruments whose oving systems are supported by thin metallic bands which practically eliminate friction and make the instrument resistant to shock.
PANEL MOUNTING
All drilling and wiring should be completed before mounting the instruments.
The instruments
st be mounted in a level position. If the panels are over 3/8"
thick, use adapte mounting studs as shown in Fig. 8.
It is advisa le to keep wires carrying heavy current as far as possible from
all indicating in truments. When the instrument is mounted in a level position,
any deviation fro zero should be corrected by means of the zero adjustment.
Connect the
WARNING

nstrument as shown in the appropriate diagram.


DO NOT REMOVE COVER WHILE THE INSTRUMENT IS ENERGIZED. SCALE
PLATE, POINTER, AND ELEMENT ASSEMBLY MAY BE AT HAZARDOUS VOLTAGE LEVELS.

GROUNDING CASES 0 A-C INSTRUMENTS


If transform rs are used on circuits of over 150 volts, connect the grounded
side of the secon ary circuits to the instrument case. Use No.12 Awg copper wire.
Ground connection in accordance with the National Electric Code.
AB)
When the cir uit exceeds 30 amperes or 650 volts, a current transformer of the
ratio indicated 0 the nameplate must be used, and instrument scale will be marked
in primary ampere
D-C AMMETERS

DB)

D-c ammeters for current measurement above 60 amperes must be shunted externallYe Shunt leads an be provided. When leads are supplied by the purChaser, their
resistance shoul agree with the value stamped on the instrument nameplate, otherwise an error in the reading will result.
WARNING

TIAL.

ALL SHUNTS SHOULD BE CONNECTED IN THE GROUNDED SIDE OF THE LINE


WHEN POSSIBLE. WHEN THIS IS NOT POSSIBLE, OR THE CIRCUIT CAN
NOT BE GROUNDED, AVOID REMOVING THE COVER SINCE THE INSTRUMENT
WTIDINGS, AS WELL AS THE SCALE AND POINTER, ARE AT LINE POTENTO AVOID CONTACTING THIS POTENTIAL.

These instructions 0 not purport to cover all details or variations in equipment nor to provide for every
possible contingency 0 be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser~s
purposes, the maHer should be referred to the General Eledric Company.

GENERAL. ELECTRIC

BI006008

BI006008

Page 3
4555KlO-OOl

TYPES AB & DB AMMETERS AND VOLTMETERS

TERilIHAL SCREWS
4 MOUHTICG STUDS

USE ON VOLTMETERS ONLY

10-32 THREA

f-

21 THIlEAO

PANEL

USE ON DOUBLE RATED AMMETERS ONLY

Fig.

Dimensions, Type AB-40 Ammeters and Voltmeters.

It. II

1.1'

DIA.

1.$1

THIS TtMIIlAL fOA USE


~JTH

DOUBLE RATED

1NSTRl.t\EJITS ONLY

Fig. 3.

Dimensions, Types DB-30 and -40 Ammeters and Voltmeters.


TERMINAL STUDS 1/4 - 28 THREAD --,

OUNTING STUDS 1/4-28 THREAD

PANEL'

-.Ii
3

I~

32

Fig. 4.

~3ii--i
4

DIA

-'-~

?z]i:~~L
I 8

23.

31

32

!10

I
I

32 - - - ,

THIS TERMINAL fOR USE WITH


DOU8LE RATED INSTRUMENTS
ONLY

Dimensions, Type DB-4l Ammeters and Voltmeters.

BI006008

BI006008

Page 4

4555KIO-OOl

TYPES AB & DB AMMETERS AND VOLTMETERS


MOUNTING STUDS " ... 28 THREAD

.I\'WU

.~~

7S----~

Fig. S.

~7

VIEW OF BACK SH9W1NG


TERMINAL LOCATION
THIS TERMINAL FOR USE
WITH DOUBLE RAlE!?
INSTRUMENTS ONLY

Dimensions of Type DB-l6 Ammeters and Voltmeters.


TERMINAL SCREWS 1G-32 THREAD
MOUNTING STUDS " ...28 THREAD

USE ON VOLTMETERS
THESE TERMINAlS 'O~ Uf.i ~lrH
DOUBLE RATED A~~I"'" QIWLY

..

.: .

\"""--I---4---....J A I III FOR

,... ~TERS
A ~ . till FOA
VOLT"ETERS

VIEW OF BACK SHOWING


TERMINAL LOCATIONS
.11Tll

Fig. 6.

If

Dimensions of Type AB-l6 Ammeters and Voltmeters.

ADAI'TER MOUNTING ~TUD


FOR I'A~eLSoVE.R 9/16" THICK
SPECIFY 'ANEL THICKNESS
WHEN ORDUlI.NG

Cut-out and panel


g dimensions.

Fig. 8.

Adapter mounting stud.

BI006008

Page 5
.I}555KIO-00l

BI006008

TYPES AB & DB AMMETERS AND VOLTMETERS

WARNING

~Maintenance:

SINCE DANGEROUS VOLTAGE WILL DEVELOP IN THE OPEN-CIRCUIT SECONDARY WINDINGS OF ENERGIZED CURRENT TRANSFORMERS, DEENERGIZE
THE TRANSFORMERS BY SHORT-CIRCUITING THE SECONDARY WINDlNGS BEFORE DlSCONNECTING OR CONNECTING INSTRUMENT TO TRANSFORMERS.

o clean Type AB-16, -41, and Type 08-16, -30, -41 plastic
indows, wash with soap and water, not chemical cleaners.

SOURCE

LOAD

HIGH RATING
SELF

LOAD

CONTAINED

LOAD
SOURCE

...

HIGH RATING

J:

SOURCE
SOURCE

T.
LOW RATING
LOAD
LOAD

SOURCE

Fig. 11. External


connections of
double-rated a-c
ammeters with
current transformer.

Fig. 10. External connections of doublerated a-c ammeters.

Fig. 9. External connections of a-c


ammeters.

-SOURCE

LOW RAT! NG

SOURCE

LOAD

CONTAINED

Fig. 12.

Extern 1 connections of d-c


ammete s.

LOAD WITH EXTERNAL SHUNT

LOAD

HIGH RATING

LOAD

Fig. 13. External connections of double~


rated d-c ammeter (DB-40, -41 only).

SOURCE
FUSES
SOURCE

HI

NSlS

SOURCE

XI

P.T.

LOAD
LOAD

LOAD
SOURCE
FUSES

SOURCE

SOURCE

LOAD

LOAD
LOAD
WITH EXTERNAL RESISTANCE

Fig. 14.
t-;nnQ

Fig. 15. External connect";t'\n~

~_,..

,,.n''''m;:2lt-~-r~ ~;"h

WITH

POTENTIAL

TRANSFORMER

Fig. 16. External conno" ... ;nnro

~_

1-..,

........

BI006008

BI006008

Page 6
4555KIO-OOl

TYPES AB & DB AMMETERS AND VOLTMETERS

SOURCE

SOURCE
+

FUSES

SOURCE

FUSES
LOAD

SELF

SOURCE
-

LOW RATING

LOAD

FUSES

SOURCE

FUSES

LO~D

EXTERNAL
RESiSTOR

FUSES

LOAD

EXT. RES.
LOAD

HIGH RATING

Fig. 19
External
connections of d-c
ground detectors.

Fig. 18
External connections of double-rated
d-c voltmeters.

Fig. 17
Exte
connections 0
d-c voltmeter

c1ii"-l

50

~--'-----98

iI

~2

IO-~12 THD~:
!

e;;1~--I-- 2 ~r------ -~--+-IOO!1!h-7-"- -@---1-

16

I TUBE

,"

8" - - - - \ 1.

98

Fig. 20.

--.L

3"

~"

'3'4

~-FC;/
32

~~

32

Form-3 resistor, single tube.


750VAC, l5/30VAC, 300/60OVAC

29"

,"""'-1-32
I

1IlO!ll+-1-..- - .....
, --;---

2 TUBES
3"

f---------

Fig. 21.

INSTRUMENT

4/81

69" - - - -....

Form-3 resistor, two tubes.


l50/600VAC

RODUCTS OPERATION, GENERAL ELECTRIC CO}WANY, LYNN, MASSo

Printed in U.S.A.

BI006008

GEF-41
Superades GE

BI006008

,RENEWAL PARTS

IC9446-A, -B AND -C LIMIT SWITCHES

NOTE:-When ord ring parts for a form of the switch not covered by this bulletin, give reference number,
description of part complete nameplate reading, and above bulletin (GEF) number. Do not use catalog number
when form for which he parts are needed is not covered by the bulletin.

IC9446A limit switch


18
14

,b~l

_y,,?~'''J0~~-'
""
,,\ 'i-.~'. '"

'.\\\.'\~\t.

IC9446-B limit switch

IC9446-C limit switch

When ordering r newal parts, give quantity, catalog number, ~,elcription of each item required, and complete name plat. reading.

GENERAL. ELECTRIC

\,

BI006008

IC9446-A, -8, AND -C LIMIT SWITCHES

GEF-4199A

IC9446
Form

Ref. No.1
Camshaft
and Hub
1 req'd
Cat. No.

A100AA
A100BA
A100CA
A101AA
A10lBA
A101CA
A102AA
A102BA
A102CA
A103AA
A103BA
A103CA
A104AA
A104BA
A104CA
A105AA
A105BA
A105CA
A200DA
A200EA
A200FA
A20lDA
A201EA
A201FA
A202DA
A202EA
A202FA
A203DA
A203EA
A203FA
A204DA
A204EA
A204FA
A205DA
A205EA
A205FA
A300GA
A300HA
A300JA
A301GA
A301HA
A30lJA
A302GA
A302HA
A302JA
A303GA
A303HA
A303JA
A304GA
A304HA
A304JA
A305GA
A305HA
A305JA
MOOKA
A400LA
A400MA
A401KA
A401LA
A401MA
M02KA
M02LA
A402MA
A403KA
A403LA
M03MA
A404KA
A404LA
A404MA
A405KA
A405LA
A405MA

477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389G5
477C389G5
477C389G5
477C389G5
477C389G5
477C389G5
477C389G2
477C389G2.
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G6
477C389G6
477C389G6
477C389G6
477C389G6
477C389G6
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G7
477C389G7
477C389G7
477C389G7
477C389G7
477C389G7
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G8
477C389G8
477C389G8
477C389G8
477C389G8
477C3B9G8

Ref. No.2
Contact
Unit

Ref. No.4
Operating
Cam

Ref. No.5
Cam
Follower

Ref. No.6
Screw for Vernier Adjustment

Cat. No.

No.
ReQ'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
72lB773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
72lB773G1
721B773G1
721B773G1
721B773G1
721B773G1
72lB773G1
721B773G1
721B773G1
721B773G1
72lB773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
72lB773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
72lB773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1

1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12

N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C 6
N144P15008C6
N144P15008C6
N144P15008C 6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C 6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P1500BC6
N144P15008C6
N144P1500BC6
N144P1500BC6
N144P1500BC6
N144P1500BC6
N144P1500BC6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P1500OC6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P1500BC 6

2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
14
16
1B
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24

147A4787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147A4787P1
147M776P1
147A4776P1
147M776P1
147A4787P1
147A4787P1
147M787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147M787P1
147A4787P1
147A4787P1
147A4776P1
147M776P1
147M776P1
147A4787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A47B7P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147M787P1
147A4776P1
147A4776P1
147A4776P1
147M787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147A4787P1
147A4776P1
147A4776P1
147A4776P1

2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24

106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B70B5G1
106B7085G1
106B70B5G1
106B7085G1
106B70B5G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B7085G1
106B70B5G1

1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
B
9
7
8
9
7
8
9
7
8
9
7
8
9
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12

147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147M789P1
147M789P1
147A4789P1
147A4789P1
147M789P1
147M789P1
147A4789P1
147A4789P1
147M789P1
147A4789P1
147A4789P1
147A4789P1
147M789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147M789P1
147M789P1
147M789P1
147M789P1
147A4789P1
147M789P1
147M7B9P1
147A4789P1
147M789P1
147A47B9P1
147M7B9P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147M789P1
147A4789P1
147M789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147M789P1
147M789P1
147M789P1
147A4789P1
147M789P1
147M789P1
147M789P1
147M789P1
147A47B9P1
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147M789P1
147A47B9P1

1
2
3
1
2
3
1
2
3

Recommended {or normal stock.


2

Ref. No.3
Screw {or
Contact Unit

t
2
3
1
2
3
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12

.)

BI006008

.
IC9446-A, -8, AND -C LIMIT SWITCHES

rC9446
Form

Ref. N .7
Attaching crew
for C m
Cat. No.

AlOOAA
AlOOBA
AlOOCA
AlOlAA
AlOlBA
AlOlCA
AlO2AA
Al02BA
Al02CA
Al03AA
Al03BA
Al03CA
AlO4AA
Al04BA
Al04CA
Al05AA
Al05BA
AlO5CA
A200DA
A200EA
A200FA
A20lDA
A20lEA
A20lFA
A202DA
A202EA
A202FA
A203DA
A203EA
A203FA
A204DA
A204EA
A204FA
A205DA
A205EA
A205FA
A300GA
A300HA
A300JA
A301GA
A301HA
A30lJA
A302GA
A302HA
A302JA
A303GA
A303HA
A303JA
A304GA
A304HA
A304JA
A305GA
A305HA
A305JA
A400KA
A400LA
A400MA
A401KA
A401LA
A401MA
A402KA
A402LA
A402MA
A403KA
A403LA
A403MA
A404KA
A404LA
A404MA
A405KA
A405LA
A405MA

N22P2l008B
N22P2l008B
N22P2l008B
N22P2l008B
N22P2l008B
N22P21008B
N22P2l008B
N22P2l008B
N22P2l008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P2l008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P2l008B
N22P2l008B
N22P2l008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P2l008B
N22P2l008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P2l008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B
N22P21008B

Ref. No.8
Bearing
Flangette

Ref. No.9
Screw for
Flangette

Ref. No. 10
Filler
Strip

GEF-4l99A

Ref. No. 11
Screw for
Filler Strip

Seal Plate Seal Plate


Left Side Right Side
1 Req'd
1 Req'd

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

Cat. No.

2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24

577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A204Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

N22P230l2B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P23012B6
N22P230l2B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6

4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4

l47A4768Gl
l47A4768Gl
l47A4768Gl
l47A4768Gl
147A4768Gl
l47A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
l47A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
l47A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

N22P230l2B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P23012B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P230l2B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P230l2B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

(Not used
on these
forms)

(Not used
on these
forms)

BI006008

IC9446-A, -8, AND -C LIMIT SWITCHES

GEF-4199A

IC9446
Form

Ref. No.1
Camshaft
and Hub
1 Req'd
Cat. No.

B100AA
B100BA
BlOOCA
BI01AA
B101BA
B101CA
B102AA
B102BA
B102CA
BI03AA
BI03BA
B103CA
BlO4AA
B104BA
BlO4CA
B105AA
BI05BA
B105CA
B200DA
B200EA
B200FA
B20lDA
B201EA
B201FA
B202DA
B202EA
B202FA
B203DA
B203EA
B203FA
B204DA
B204EA
B204FA
B205DA
B205EA
B205FA
B300GA
B300HA
B300JA
B301GA
B301HA
B30lJA
B302GA
B302HA
B302JA
B303GA
B303HA
B303JA
B304GA
B304HA
B304JA
B305GA
B305HA
B30SJA
B400KA
B400LA
B400WiA
B401KJ.
B4011.A
B401MP
B402KA
B402LA
B402MA
B403KA
B403LA
B403MA
B404KA
B404LA
B404MA
B405KA
B405LA
B405MA
4

477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389Gl
477C389G1
477C389G1
477C389G1
477C389G1
477C389G1
477C389Gl
477C389G5
477C389G5
477C389G5
477C389G5
477C389G5
477C389G5
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G2
477C389G6
477C389G6
477C389G6
477C389G6
477C389G6
477C389G6
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
'477C389G3
477C389G3
477C389G3
477C389G3
477C389G3
4'17C389G7
477C389G7
477C389G7
4nC389G7
i77C389G7
477C389G7
477C389G4
477C389G4
4'17C389G4
4nC389G4
477G389G4
477C389G4
477C389G4
4'17C389G4
477C389G4
477C389G4
477C389G4
477C389G4
477C389G8
477C389G8
477C389G8
477C389G8
477C389G8
477C389G8

Ref. No.3
Screw for
Contact Unit

Ref. No.2
*Contact
Unit

Ref. No.4
Operating
Cam

Ref. No.5
Cam
Follower

Ref. No.6
Screw for Vernier Adjustment

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773G1
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
'121B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl

1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2

N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144PI5008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144PI5008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
Nl44P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15006C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6

2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24

147A4787P1
147A4787Pl
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787Pl
147A4787Pl
147A4787Pl
147A4776Pl
147A4776P1
147A4776Pl
147A4787Pl
147A4787Pl
147A4787P1
147A4776P1
147A4776P1
147A4776P1
147A4787P1
147A4787P1
147A4787Pl
147A4776P1
147A4776P1
147A4776Pl
147A4787Pl
147A4787P1
147A4787Pl
147A4776P1
147A4776Pl
147A4776P1
147A4787Pl
147A4787Pl
147A4787Pl
147A4776P1
147A4776Pl
147A4776P1
147A4787Pl
147A4787Pl
147A4787PI
147A4776Pl
147A4776Pl
147A4776P1
147A4787Pl
147A4787Pl
147A4787Pl
147A4776P1
147A4776P1
147A4776Pl
147A4787Pl
147A4787PI
147A4787Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4776Pl
147A4776P1
147A4776Pl
147A4787Pl
147A4787Pl
147A4767Pl
147A4776P1
147A4776Pl
147A4776Pl
147A4787P1
147A4787Pl
147A4787PI
147A4776Pl
147A4776Pl
147A4776Pl

2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
14
16
18
14
16
18
14
16
18
14
16
1&
14
16
18
14
16
18
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24
20
22
24

106B7085G5
106B'l085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B.7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5

1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12

147A4789Pl.
147A4789Pl
147A4789P1
147A4789P1
147A4789Pl
147A4789Pl
147A4789P1
147A4789Pl
147A4789P1
147A4789P1
147A4789Pl
147A4789P1
147A4789P1
147A4789Pl
147A4789P1
147A4789Pi
147A4789P1
147A4789Pl
147A4789P1
147A4789P1
147A4789Pl
147A4789Pl
147A4789P1
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789PI
147A4789Pl
147A4789Pl
147A4789Pl
147A4789P1
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4'/89Pl
147A4789Pl
147/,1789Pl

1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12

*Recommended for normal stock.

:J

6
4
5
6
4
5
6
4
5
6
4
5
6
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12
10
11
12

BI006008

GEF4199A

IC9446-A, -B, AND -C LIMIT SWITCHES

IC9446
Form

B100AA
B100BA
B100CA
B101AA
B101BA
B101CA
B102AA
B102BA
B102CA
B103AA
B103BA
B103CA
B104AA
B104BA
B104CA
B105AA
B105BA
B105CA
B200DA
B200EA
B200FA
B201DA
B201EA
B201FA
B202DA
B202EA
B202FA
B203DA
B203EA
B203FA
B204DA
B204EA
B204FA
B205DA
B205EA
B205FA
B300GA
B300HA
B300JA
B301GA
B301HA
B301JA
B302GA
B302HA
B302JA
B303GA
B303HA
B303JA
B304GA
B304HA
B304JA
B305GA
B305HA
B30SJA
B400KA
B400LA
B400MA
B401KA
B401LA
B401MA
B402KA
B402LA
B402MA
B403KA
B403LA
B403MA
B404KA
B404LA
B404MA
B405KA
B405LA
B405MA

Ref. ~o. 7
Attachi J( Screw
for "am

Ref. No.8
Bearing
Flangette

Ref. No.9
Screw for
Flangette

Ref. No. 10
Filler
Strip

Ref. No. 11
Screw for
Filler Strip

Seal Plate Seal Plate


Left Side Right Side

1-_ _-+_T""C:-;-+------r~=__I_---___._;_;::__t_---___._;_;:_iI_----._~_+....:1:-:..:R=eq~':::..d+....:1:-.:.:R:.:.eq;:..'-=Cat. No
~~;d Cat. No. :~;d Cat. No. ~~;d
Cat. No. R~~;d
Cat. No.
~~;d Cat. No. Cat. No.
N22P2100 136
N22P2100EB6
N22P2100EB6
N22P2100e~6
N22P2100e!B6
N22P2100eIB6
N22P2100e!B6
N22P2100e[B6
N22P2100e!B6
N22P2100e!B6
N22P21008!B6
N22P2100e 136
N22P2100e ~6
N22P21008~6

N22P21008~6

N22P21008136

N22P21008~6
N22P21008~6
N22P21008~6

N22P21008136

N22P2l008~6

N22P21008~6

N22P21008~6

N22P21008136
N22P21008136
N22P21008136
N22P21008 6
N22P21008~6

N22P21008S6
N22P210081'6
N22P21008 6
N22P21008B6
N22P21008 S6
N22P21008 6
N22P21008~6

N22P21008B6
N22P21008~6

N22P21008 6
N22P21008~6

N22P21008 6
N22P21008~6

N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P21008 6
N22P210081 6
N22P210081 6
N22P2100816
N22P210081 6
N22P210081 6
N22P210081 6
N22P210081 6

2
4
6

2
4
6

2
4

6
2
4
6
2
4
6

2
4
6

8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
8
10
12
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
14
16
18
20

22
24
20

22
24
20

22
24
20
22
24
20
22
24
20

22
24

577A304Pl
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304Pl
577A304P1
577A304P1
577A304P1
577A304Pl
577A304P1
577A304Pl
577A304Pl
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304Pl
577A3Mpl
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1
577A304P1

2
2

2
2
2

2
2
2
2
2

2
2
2
2
2
2
2
2
2
2
2
2
2
2

2
2
2
2
2
2
2

2
2
2

2
2
2
2

2
2
2
2
2

2
2
2
2
2
2
2

2
2
2
2
2

2
2
2
2

2
2
2
2
2
2
2
2
2

2
2
2

N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6

4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4

147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768G1
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147 A47ii8Gl
147A4768G1
147A4768Gl
147A4768G1
147A4768G1
147A4768Gl
147A4768G1
147A4768G1
147A4768Gl
147A4768Gl
147A4768Gl
147A4768G1
147A4768Gl
147A4768Gl
147A4768G1
147A4768G1
147A4768Gl
147A4768G1
147A4768Gl
147A4768Gl
147A4768Gl
147A4768G1
147A4768Gl
147A4768Gl
147A4768G1
147A4768G1
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768Gl
147A4768G1
147A4768Gl
147A4768Gl
147A4768G1
147A4768G1
147A4768G1
147A4768Gl
147A4768G1
147A4768Gl
147A4768G1
147A4768Gl
147A4768G1
147A4768G1
147A4768Gl
147A4768G1
147A4768G1
147A4768G1
147A4768G1
147A4768G1
147A4768G1
147A4768Gl
147A4768G1
147A4768Gl
147A4768G1
147A4768Gl
147A4768G1
147A4768Gl
147A4768G1
147A4768G1
147A4768G1

2
2
2
2

2
2
2
2

2
2
2
2

2
2
2
2

2
2
2
2
2
2

2
2
2
2

2
2

2
2
2
2
2
2

2
2
2
2
2
2
2
2
2
2
2
2

2
2
2
2
2
2
2

2
2
2
2
2

2
2

2
2
2
2
2
2
2
2

2
2

N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6

2
2
2
2
2
2
2
2

2
2

2
2
2
2
2
2

2
2
2
2
2
2
2
2
2
2
2
2

2
2
2

2
2
2

2
2
2
2

(Not used
on these
forms)

(Not used
on these
forms)

2
2
2
2

2
2
2
2
2
2
2

2
2
2
2
2

2
2
2

2
2
2

2
2
2

2
2
2

2
2
2

2
2
2

BI006008

IC9446-A, -8, AND -C LIMIT SWITCHES

GEF-4199A

IC9446
Form

Ref. No.1
Camshaft
and Hub
1 Req'd
Cat. No.

C200AA
C200BA
C200CA
C200DA
C200EA
C200FA
C20lAA
C201BA
C201CA
C20lDA
C201EA
C201FA
C202AA
C202BA
C202CA
C202DA
C202EA
C202FA
C203AA
C203BA
C203CA
C203DA
C203EA
C203FA
C204AA
C204BA
C204CA
C204DA
C204EA
C204FA
C205AA
C205BA
C205CA
C205DA
C205EA
C205FA
C400GA
C400HA
C400JA
C400KA
C400LA
C400MA
C401GA
C401HA
C40lJA
C401KA
C401LA
C401MA
C402GA
C402HA
C402JA
C402KA
C402LA
C402MA
C403GA
C403HA
C403JA
C403KA
C403LA
C403MA
C404GA
C404HA
C404JA
C404KA
C404LA
C404MA
C405GA
C405HA
C405JA
C405KA
C405LA
C405MA
6

477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G13
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G15
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G14
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16
477C389G16

Ref. No.2
*Contact
Unit

Ref. No.4
Operating
Cam

Ref. No.3
Screw for
Contact Unit

Ref. No.5
Cam
Follower

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773G1
721B773G1
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773G1
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl
721B773Gl

1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12

N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C 6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C 6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
NI44P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C 6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
NI44PI5008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6
N144P15008C6

2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24

147A4787P1
147A4787P1
147A4787Pl
147A4787PI
147A4787P1
147A4787Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776P1
147A4787Pl
147A4787Pl
147A4787P1
147A4787Pl
147A4787Pl
147A4787Pl
147A4776Pl
147A4776Pl
147 A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4776Pl
147 A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787PI
147A4787Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4787Pl
147A4776Pl
147A4776Pl
147 A4776Pl
147A4776Pl
147A4776Pl
147A4776Pl

2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24

*Recommended for normal stock.

Cat. No.
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5
106B7085G5

Ref. No.6
Screw for Vernier Adjustment

No.
Req'd

Cat. No.

No.
Req'd

1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12

147A4789P1
147A4789Pl
147A4789P1
147A4789P1
147A4789Pl
147A4789P1
147A4789Pl
147A4789Pl
147A4789Pl
147A4789P1
147A4789P1
147A4789P1
147A4789P1
147A4789Pl
147A4789Pl
147A4789P1
147A4789PI
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147 A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789Pl
147A4789PI
147 A4789Pl
147 A4789Pl
147A4789Pl

1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12
7
8
9
10
11
12

()
IC9446
Form

r~

,,_.I

.J

C200AA
C200BA
C200CA
C200DA
C200EA
C200FA
C201AA
C201BA
C201CA
C20lDA
C201EA
C201FA
C202AA
C202BA
C202CA
C202DA
C202EA
C202FA
C203AA
C203BA
C203CA
C203DA
C203EA
C203FA
C204AA
C204BA
C204CA
C204DA
C204EA
C204FA
C205AA
C205BA
C20SCA
C205DA
C205EA
C205FA
C400GA
C400HA
C400JA
C400KA
C400LA
C400MA
C401GA
C401HA
C40lJA
C401KA
C401LA
C401MA
C402GA
C402HA
C402JA
C402KA
C402LA
C402MA
C403GA
C403HA
C403JA
C403KA
C403LA
C403MA
C404GA
C404HA
C404JA
C404KA
C404LA
C404MA
C405GA
C405HA
C405JA
C405KA
C405LA
C405MA

BI006008

GEF-4199A

IC9446-A, -8, AND -C LIMIT SWITCHES

Ref. o. 7
Attachin Screw
for ( am

Ref. No.8
Bearing
Flangette

Ref. No.9
Screw for
Flangette

Ref. No. 10
Filler
Strip

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

Cat. No.

No.
Req'd

N22P21008 ~6
N22P21008 136
N22P21008 66
N22P21008 66
N22P21008 66
N22P21008 66
N22P21008 ~6
N22P21008 ~6
N22P21008 136
N22P21008 ~6
N22P21008 136
N22P21008 ~6
N22P21008 ~6
N22P21008 136
N22P21008 ~6
N22P21008 ~6
N22P21008 136
N22P21008,",6
N22P21008 ~6
N22P21008 ~6
N22P21008 86
N22P2100B jB6
N22P2100f 1E6
N22P2100f 1E6
N22P2100f 1E6
N22P2100f 1E6
N22P2100f jB6
N22P2100f 1E6
N22P2100f 1Il6
N22P2100f jB6
N22P2100f jB6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6
N22P2100 B6

2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
2
4
6
8
10
12
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24
14
16
18
20
22
24

577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A30API
577 A304Pl
577A304Pl
577A304Pl
"577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
"577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl
577A304Pl

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1

N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6
N62P23012B6

4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
2
2
2
2
2
2
2
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
2
2
2
2
2
2
2
2
2
2
2
2

Cat. No.

No.
Req'd

147A4768Gl
2
147A4768Gl " 2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
2
147A4768Gl
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
2
147A4768Gl
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A476BGI
2
147A4768Gl
2
147A476BGI
2
147A476BGI
2
147A476BGI
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A476BGI
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A476BGI
1
147A4768Gl
2
147A476BGI
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
2
147A476BGI
147A476BGI
2
2
147A4768Gl
147A476BGI
2
147A4768Gl
2
147A476BGI
2
147A476BGI
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl
2
147A4768Gl 1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A476BGI
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1
147A4768Gl
1

Ref. No. 11
Screw for
Filler Strip

Seal Plate
Left Side
1 Req'd

Seal Plate
Right Side
1 Req'd

Cat. No.

No.
Req'd

Cat. No.

Cat. No.

N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6
N22P23012B6

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1

118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B709BP5
106B7098P5
118B3612G3
llBB3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
llBB3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
llBB3612G3
118B3612G3
118B3612G3
106B709BP5
106B709BP5
106B709BP5
106B709BP5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
106B7098P5
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
llBB3612G3
118B3612G3

118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B7098P5
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
llBB3612G3
118B3612G3
118B3612G3
118B3612G2
118B3612G2
11BB3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
106B7098P5
106B7098P5
106B7098P5
106B709BP5
106B709BP5
106B7098P5
106B7098P5
106B7098P5
106B709BP5
106B7098P5
106B709BP5
106B7098P5
llBB3612G3
llBB3612G3
llBB3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G3
llBB3612G3
118B3612G3
118B3612G3
118B3612G3
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2
118B3612G2

BI006008

GEF-4199A

IC9446-A, -8, AND -C LIMIT SWITCHES


OTHER PARTS
Number Required for IC9446-

Ref.
No.

12
12
12
12
13
13
13
13
14
14
15
15
16
17
18

19
19
19
19
20
21
21
21
21
21
21
21
21
21
21
22
22
22
22
23
23

...<
0
0

0
0

0
0

CO)

-1
-

-4

tIl

tIl

tIl

()

0
0
<l'
()

1
-

- - - - 2
- - - - 2
- - - - 2
- - - - - - - - - - - - 1
- - - 1
- 1 - - - - 1 - - - - 1 -

1
2
-

CO)

2
2
2

2
2
2

2
-

- - - - - - - - - - - - - - - - -

- - - - - - - - - -

0
0

2
2
2

- - - 9 11
- - - 9 11
- - - 1 1
- - - - 1
- - 1 - 1 - - - - 1 - 1

1
-

0
0
<l'

-- - - - - - - - - - - - - 1
- - - - 1 - - - - 1 - - - - 1 - - - - 1
- - - 1 - - - - 1
- - - - -

- - - - - - - 1
- - - 1 - - - 1 - - - 1
- - - - - - - - - - 2 - - - - 2 2
- - - 2
-4 -4 24 -4 4- -4

0
0

1
4

0
0

...tIl

< < <

0
0

0
0
<l'

- - - - - - - - - - - - -

- - - - - - - - - - - - - - 1
- - 1 - - 1
- - - 2 - - 2
4

2
4

- - 2
- 2 - - - 1 - - - 1
- - 1 - - - 1
- - 2 2
- - 4 4
- - 2 2
- - 1 1
- - 1 1
- - 2 2
- - 4 4

Catalog
Number

118B3604Gl
118B3604G2
118B3604G3
118B3604G4
118B7333Gl
118B7333G2
118B7333G3
118B7333G4
50lD131P6
501Dl33P6
501Dl31P5
501Dl33P5
N57 P21010B6
577A331P1
577A331P2
577A331P3
N93P21016
577A122P3
577A317P1
118B3603G1
118B3603G2
118B3603G3
118B3603G4
N22P21006B6
477C388Pl
477C388P2
477C388P3
477C388P4
975C104G1
975CI04G2
975C104G3
975C104G4
477C388P2
477C388P4
118B3606P1
118B3606P2
118B3606P3
118B3606P4
N22P21006B6
N529P55
N529P58
577A101P22
577A101P7
6960053G26
6960053G27
577A180P6
N89P21016B6
577A290P2
161A8277P2
161A8277Pl
N70P2112C6
N22P25008B6

Used on IC9446-C204, -C205, -C404, and -C405 only.


8

Description

Cover
Cover
Cover
Cover
Cover

Cover
Cover
Cover
Cover
Cover
Box
Box
Screw for cover (1/4 in. -20,
5/8 in. pan hd., pro. fin.
Screw for cover, 1/4 in. turn
Screw retainer
Screw fastener
Screw fastening cover to box
(1/4 in. - 20, 1 in. fill. hd.)
Retaining ring for screw
Gasket for cover
Cam follower support
Cam follower support
Cam follower support
Cam follower support
Screw fastening cam follower support
to base (1/4 in. -20, 3/8 in. hex.
hd., pro. fin.)
Base
Base
Base
Base
Base
Base
Base
Base
Base
Base
Contact bracket
Contact bracket
Contact bracket
Contact bracket
Screw fastening contact bracket to base
(1/4 in. -20, 3/8 in. hex. hd., pro. fin.)
Plug
Plug
Plug, right-side
Plug, right-side
Plug, left-side
Plug, left-side
Grommet
Screw fastening seal plate to base (1/4 in.
- 20, 1 in., pro. fin.)
"0" ring for seal plate
Collar for shaft extension, right-hand
Key for shaft, right-hand shaft extension
Set screw for collar (1/4 in. -20, 3/4 in.
hex. soc. hd., cup point, pro. fin.)
Bolt fastening switch to box (3/8 in. -16,
1/2 in. hex. hd., pro. fin.)

()

BI006008

GEF-4199A

IC9446A, -8, AND C LIMIT SWITCHES

SPEED REDUCER, BASE AND COUPLING (WHEN USED)


NO E:- IC9446C202FA identifies a switch without a speed reducer and IC9446C202FA102
identifies a switch with base, speed reducer and coupling. The three suffix
digits 102 are the key to ordering these additional parts. The first of these
three digits indicates the proper column below and the second and third digits
must be added to the Cat. No. for the speed reducer (Ref. 28) below.
Example:- IC9446C202FA102 indicates the sixth column below,
using Cat. No. 147A4786P02 Speed Reducer.
Number Required for IC9446-

Catalog
Number

Ref.
No.

24
24
24
24
24
24
24
24
24
25

1
1

118B3659G1
118B3659G2
118B3659G3
118B3659G4
118B3675G1
119B1368G1
118B3675G3
118B3675G4
118B3675G2
4908763Gll

26

4908763G7

27

1
1

1
1

1
1

1
1

1
1

1
1

1
1

1
1

1
1

1
1

1
1

1
1

2293297P2
N70P2104B6

N70P2105B6

577A142P34

28

28

1
1
1
1

1
1
1
1

147A4786P--

167A8927P--

Description

Base
Base
Base
Base
Base
Base
Base
Base
Base
Coupling,
switch end
Coupling, gear
box end
Coupling disc
Set screw for
coupling,
switch end
(1/4 in. -20,
1/2 in., pro.
fin. )
Set screw for
coupling,
switch end
(1/4 in. -20,
5/16 in.,
pro. fin.)
Spacer for
gear box
Speed reducer
(to complete
the Cat. No.
see NOTE
above)
speed reducer
(to complete
the Cat. No.
see NOTE
above)

BI006008

GEF-4199A

IC9446-A, -8, AND -C LIMIT SWITCHES


SPEED REDUCER, BASE AND COUPLING (WHEN USED) (cont'd)
Number Required for IC9446-

Ref.
No.

Catalog
Number

28

167A5716P--

28

168A2615P--

N509P1624B6

N3402P6032

NUTS
Catalog
Number
N200P21
N245P23B6
N245P25B6

Speed reducer
(to complete
the Cat. No.
see NOTE
on page 9)
Speed reducer
(to complete
the Cat. No.
see NOTE
on page 9)
Pin for coupling, gear
box end
(5/32 x 1-1/2
in., pro. fin.)
Key for coupling, switch
end (3/16 in.
square x
2 in. 19.)

LOCK WASHERS
Catalog
Number

Description
1/4 -20 hex. std., brass
5/16 -18 hex. std., steel
3/8 -16 hex. std., steel

N405P41B6
N405P42B6
N405P43C6
N418P41

Description
For
For
For
For

1/4 in. screw, steel


5/16 in. screw, Steel
3/8 in. screw, steel
1/4 in. screw, stainless steel

PLAIN WASHER
Catalog
Number
N402PllB6

10

Description

Description
For 1/4 in. screw, steel

BI006008
GEF-4199A

IC9446-A, -8, AND -C LIMIT SWITCHES

~J

INDEX OF CATALOG NUMBERS


Catalog identifica ion. in this index are arranged in order, reading from left to right, firat alphabetically according to the prefix
letter or letter., i used, and second numerically.
mbers with a letter prefix will precede thOle without prefixes.
In this index all
The number of Ie ten or digits does not affect placement in the table, thus A1999999 will precede A2, and ZZ9999999 will precede
r without a prefix). Lettera take precedence over numbers so that Cat. No. 26Fl will precede Cat. No. 261.

Cat. No.1 (num

Catalog
Number

Page

N144P15008C6N22P21006B6 N22P21008B6 N22P23012B6 N22P25008B6 N3402P6032 --N509P1624B6-N529P55 -----N529P58 -----N57P21010B6 N62P23012B6 N70P2104B6
N70P2105B6 -N70P2112C6 -N89P21016B6 N93P21016 ---106B7085Gl--l06B7085G5 --106B7098P5 --118B3603G1--118B3603G2 --118B3603G3 --118B3603G4 --118B3604G1--118B3604G2 ---

2,4,6
8
3,5,7
3,5,7
8
10
10
8
8
8
7
9
9
8
8
8
2
4,6
7
8
8
8
8
8
8

Catalog
Number

Page

118B3604G3 ---8
118B3604G4 ---8
118B3606P1 ---8
118B3606P2 ---8
118B3606P3 ---8
118B3606P4 ---8
7
118B3612G2 ---7
118B3612G3 ---9
118B3659Gl ---118B3659G2 ---9
9
118B3659G3 ---118B3659G4 ---9
9
118B3675Gl ---9
118B3675G2 ---9
118B3675G3 ---9
118B3675G4 ---7
118B7098P5 ---118B7333Gl ---8
118B7333G2 ---8
118B7333G3 ---8
118B7333G4 ---8
119B1368G1 ---9
147A4768G1 ---- 3,5,7
147A4776P1 ---- 2,4,6
9
147A4768P -----

Catalog
Number
147A4787P1---147A4789P1---161A8277P1---161A8277P2---167A5716P ---167A8927P ---168A2615P ---2293297P2 ----477C388P1----477C388P2----477C388P3----477C388P4----477C389G1----477C389G13
477C389Gl4 --477C389G15 --477C389G16 --477C389G2----477C389G3----477C389G4----477C389G5----477C389G6----477C389G7----477C389G8-----

Page
2,4,6
2,4,6
8
8
10
9
10
9
8
8
8
8
2,4
6
6
6
6
2,4
2,4
2,4
2,4
2,4
2,4
2

Catalog
Number

Page

4908763G11----9
4908763G7-----9
8
501Dl31P5 ----501Dl31P6 ----8
501Dl33P5 ----8
501Dl33P6 ----8
577AIOIP22 ---8
577AIOIP7 ----8
577A122P3 ----8
9
577A142P34 ---577A180P6 ----8
577A290P2 ----8
577A304P1 ----- 3,5,7
577A317Pl ----8
577A331Pl ----8
577A331P2 ----8
577A331P3 ----8
6960053G26 ---8
6960053G27 ---8
721B773G1 ----- 2,4,6
8
975CI04G1 ----975C104G2 ----8
975C104G3 ----8
975C104G4 ----8

11

GENERAL ELECTRIC SALES OFFICES


READY TO ASSIST YOU . When You Hove Electrical Problem' N~d Furth., Informotion Require O,dr,ing Inll~dion,
.-----------------,
SALES OFFICE CODE KEY
IndustrIal Equipment (Including Agent and
Dlst,lbuto,) Sel..
t EI ,I< Utility Equipment Sal..
i Marin. and D.-I." Equipment Sal..
t Component Sal.. Operation
ALABAMA
Birmingham 5 .. 2151 Highland Ave.

I Mabile 13 ... 704 Gove,nment St.

ARIZONA
Phoenix 12 . 3550 N. Cent,al Ave.
Tucson
151 S. Tucson Blvd.
ARKANSAS

North lillie Rode 1900 E. Washing Ian


t
Pine Bluff
P. O. 80x 1033
CAlifORNIA

fresno 21 321 Palle,.on Bldg.


t < Las Angeles 54 ... 212 N. Vign.. 51.
Los Angele. 5 3325 Wilshire 8lvd.

Oakland 12 ... 409 Thi,leenih St.


Secramento 16 ... 2407 "J" 51.
San Bernordino .337 tot RiversideAve., Riolto,Col.

Son Diego 3 .... " 1240 7th Ave.


t
Son f,ancisco 6 .. 235 Manlgome,y 51.

San Jose . 2155 So. Fint St.


COLORADO
" t : Denve, 6 201 University Blvd.
CONNECTICUT
" t ~ Hartfa,d 5
764 Asylum Ave.
t
New Haven 6 . 129 Church 51.
DISTRICT OF COLUMBIA
t
W a .h!nglan5
777-UlhSI N.W.
Wash,ngton 5 . 806-15th 51 N. W.
flORIDA
t
Jacksonville 6 ....... 1901 Hill St.
t
Miami 32. .. 25 S.E. Second Ave.
Miami 66 .... 5353 N. W. 361h 51.
t
Pensocala .... 207 S. Baylen St.
Tompo 1 . Hend enon Blvd. at lois Ave.
t Tampa 6 ......... 1206 N. "A" 51.
GEORGIA
t f
Allanla 9 .. 1860 Peach.ree Rd N. W.

Macon ....... 682 Cherry 51.


t
Savannah
40 Easl Bay 51.
IDAHO
Boi.e ..... 1524 Idaho St.
ILLINOIS
t
80
840 S. Conal St.
t : Chicago
Pea,ia 2
2008 N.E. Perry Ave.
t
Rackfa,d . " .... 4223 Ea.1 Stale 51.
t
Sp,ingfield .. 607 E. Adams St.
INDIANA
t t
Evansvme 5
2709 Washing Ian Ave.
fort Wayne 6
1635 Broadway
t t
Indianapali. 8 .... 3750 N. Me,idian 51.

:
Saulh Bend 1.
610 N. Michigan St.
IOWA
Ceda, Rapid .......... 210 Second 51 S.E.
t
Davenport .. 1039 Stote St., Bettendorf, Iowa
t :
Des Moines 12 .. 2116 W. Grond Ave.
t
KANSAS
t
Wichita 2 ..... 200 E. first St.
KENTUCKY
t
Lexinglon ....... 628 E. Main 51.
t t
Louisville 18 ........ 2300 Meadow 0,.
LOUISIANA
t
Alexand,ia .. 720 Murray St.

Boton Rouge 6 3170 florida Blvd.


lake Charles . A22 Seventh St.

t : New Orleans 12 ... 837 Gravier St.


t
Sh,evepart ..... 206 Beck Bldg.
West Man,ae ...... 701 N. Sevenlh 51.

t f
t

t:

t:

MAINE

Augu.,a .............. 152 Slale St.


Bongor .................. n Centrol St.

MARYLAND

Baltimore 1 ........... 111 Pork Av..


t
Hogentown ....... 1095 Jefferson Blvd.

* t:

BI006008

t :

Cleveland 4 ........ 4966 Woodland Ave


,Calumbu.15 ........... 395 E Broad 51
Dayton 2 ...._ ... 11 'i/o Manu'ment Bldg:
Dayton .............. 118 W. Firs' St
Man.field
137 Park Ave Wesi
+
Toledo A ... . .(20 Madison Ave.
Youngstown 7 ...... 272 E. Indianola Ave.

t:
t t

MASSACHusms
t : Basion 16
31 51. James Av
t
Springfield 5 ......... 120 Maple 51.

Worcelter 5 .... 288 Grove St.

OKLAHOMA
t
Oklahoma City 2 ..... 119 N. Robin.on 51
t
Tulsa 4 ... Columbia Bldg 2651 E. 21.t 51:

MICHIGAN
Detroit 2 ...... 700 Anloinelle 51.
"
flint 2 ......... 653 S. Saginaw 5

f
Grand Rapid. 8 . 2821 Madison Ave S.E.
t
Jackson ...... 210 W. Franklin 51.

Koloma%oq ......... 927 S. Burdick St.


t
lonling: 8 ... 81.( Michigan Notional Tower

Saginaw ... Second Hational Bonk Bldg.

" t
t

t f.

MINNESOTA
Dululh 2 .. , . U W. Supe,ia, 51.
Fe,gus Falls .. ; ... Norby Bldg Room 4
Minneapali. 3 ... 12 S. Sixlh St.

t
t

t:

MISSISSIPPI
t
Gulfport ... 207 Jaf,an Bldg.
t
Jackson 1 .. 203 W. Capilal 51.
MISSOURI
t
Joplin
220'11 W. Fourth 51.
Kan.a. City 5 ...... 106 W. fourteenth 51.
St. Louis 1 ........... 818 Olive St.

t:
t:

MONTANA

Billings. ....... 303 N. Broadway


t
8ulle
103 N. Wyoming St.
NEIIRASKA
t t Omaha 2 ....... 409 S. Sevente.nlh St.
NEVADA

las Vegas

1711 S. 8.h St.

NEW HAMPSHIRE
t
Manchesle,... 1662 Elm St.
NEW JERSEY
t t Newark 2

520 Broad St.

NEW YORK
t
Albany 3 ......... 8 Colvin Ave.
t
Binghamton ......... 19 Chenango St.
Buffalo 2
625 Delawar. Ave.
:
Elmira ......... Main and Woodland Ave.
t
Hew York 22 ....... 570 lexington Ave.
Niagara falls
falls St.

Rochester <4 ........... 89 E. Ave.


t:t
Syracule 6 ......... 3532 James St.
*
Utica 2 ............. 509 Kent St.

t:

t:

NORTH CAROLINA
129 W. T'ade 51.
Charlotte 1.
t
Greensboro
801 Summit Ave.
Raleigh ........ 16 W. Ma,tin 51.

PENNSYLV ANIA
Allenlawn .... 732 No,lh 16th 51.
E,ie 2 .......... 1001 Stale 51.
Johnstown ............ U lOok St.
Philadelphia 2
3 Penn Center Plaza
Pittsbu,gh 22 .. The Olive, Bldg Mellon Sq.
"
yPillrksbU,gh 28 . 733 Wa.hingtan Rd.

a ..... 5~6 N. Harrison 51.

: t
t
t :

t:

SOUTH CAROLINA
: t
CGolumbifl1. 1 ... 1310 Lady 51.
reenvi e ... 08 W. Washington St.
TENNESSEE
t : ChattanaOOa 2 832 Georgia Ave.

Kingsport ............ 322 Commerce St.


t
Knoxville 16 .... 1301 Hannah Ave NoW.
*t
Memphis .( .......... 1.20 Union Ave.
Na.hville 3 .... 1717 W. End Ave.
Oak Ridge ....... 253 Main St Ea.t

t:

TEXAS

Abilene ...... " . 442 Ceda' St.


Ama,illa ............ 303 Polk 51.
Beaumont ....... 1385 Calder Ave.
Corpul Christi ........ 205 N. Chaparral
Dallcs 7 ..... 8101 Stemmons freeway
EI Pa.a
215 N. StenIon St.
FO,I Wo,th 2 ......... 408 W. Seventh 5:.
Houston 27 ........ <4219 Richmond Ave.
Lubbock ....... 3302 Avenue "AU
Midland ........ 704 S. Johnson 51.
San Antonio 5 ..... 43<4 S. Main Ave.

l :

t
t

Salt Lake Cily 10

200 S. Main 51.

VERMONT
t
Rutland .. 38'11 Cente' 51.
VIRGINIA

t
t

NewportNews,P.O.Box 1038,Newpor' News,Va.


Richmond 17 ...... 5001 W. Broad 51.
Roanoke 16 ...... 920 S. Jeffe"an St.

WASHINGTON
t
Pasco ........ 824 W.Lewis 51.
Seallle4 ......... 710 Second Ave.
Seallle4 ......... 550 W. IdahO St.
t
Spokane 4 ....... S. 162 Po.t St.

t:

<418 Rouer Ave.

WEST VIRGINIA

Bluefield ........... 704 Bland St.


Cha,leston 28 .. 306 MacCarkl. Ave S.E.

t
fairmont ........ 310 Jocobs Bldg.
Wheeling ...... <40 fourteenth St.

Akron 3 ......... 665 W. Market St.


Conlon 4 ......... 1226 Ma,kel Ave N.
Cincinnali 6 ......... 2621 Viclory Pkwy.

WISCONSIN
t
i Appleton ....... 510 W. College Ave.
t
Madi.on 5 ... 5317 Old Middleton Rd.

Milwaukee 3 ..... 940 W. 51. Paul Ave.

NORTH DAKOTA
t
Bismarck

t:

Eugene ....... 1170 Pearl 51.


Medfo,d ......... 107 E. Main St
Porlland 10 ... 2929 N.W. 291h Ave:

t:

UTAH

NEW MEXICO
t
Albuquerque . 120 Madeira Drive, H.E.

OHIO
t
t

OREGON

CANADA: Canadian General Electric Company, Ltd., Toronto

t:

HAWAII: American Factors, Ltd., P.O. Box 3230, Honolulu 1

GENERAL ELECTRIC SERVICE SHOPS


WHEN YOU NEED SERVICE These G.E s.,vic. shops will repai,. recondition.
and r.bulld your "act,le apparatus. Th. facUities are available day and night,
~even days a week, for work in 'he shops or on your pr.mises. Lates. factory
ALABAMA
Bi,mingham P.O. Box 3687. 7-18th 51 S. W.
ARIZONA
(Phoenix) Glendale .. 4911 W ..I Colter 51.
CALIfORNIA
Las Angel.. 1 ... 6900 Slanfa,d Ave.
*( los An"eles) Ontario
.
... . Ontario International Airport
Oakland ..... 3400 Wood 51.
Sac'amenlo U .... 99 Na,th 17th 51.
Son Francisco 3
1098 Harrison St.
COLORADO
Denver 5 .
3353 larimer St.
CONNECTICUT
(Southington) Plantsville . 370 Atwater St.
flORIDA
Jacksonville"
.
.. P.O. 80x 2932. 2020 W. Beave, St.
lMiami} Hialeah ....... 1062 E. 281h 51.
Tampa 1 .......... P.O. Box 1245
GEORGIA
lAllanta} Chamblee ..............
. 5035 Peachtree Industrial Blvd.
IUINOIS
Chicago 32 ...... 4360 W. 471h St.
INDIANA
Fl. Wayne ......... 1731 Ed.on Ave.
Indianapolis 22 ...... 17,(0 W. Vermont St.
IOWA
(Davenport) Bettendorf ...............
............ 1039 Slole St.
KANSAS
"(SI,other) Arkan.a. Cily. G.E. Co P.O. Box 797
0

methods and genuine G-E renewal parts ore used to maintain peak performance
0'service
your equipment. For full Information about the.e ,.rvices, contact your neores'
shop or
office.
*Denates Aircraft Service Shops
101...

KENTUCKY
louisville 9
3900 Crittenden Drive
LOUISIANA
New O,lean.... 2815 N. Robert.an 51.
MARYlAND
Baltimore 30.... " .920 E. Fori Ave.
MASSACHUSmS
lBaston) Medford 55 ..............
MICHIGAN ... 3960 Mystic Valley Parkway
Delrait 2
5950 Third 51.
MINNESOTA
Minneapolis 12
2025-A9th Ave., N.
MISSOURI
Kansas City 20 .... 3525 Gordner Ave.
51. Laui. 10 .......... 1115 East Road
NEW YORK
Albony............... 1097 Centrol Ave.
Buffalo 11 ............ 318 Urban St.
"'(New York) linden, H. J..............
........... 1611 W. Elizabelh Ave.
(New York) North Be,gen, N. J........
................ 6001 Tonnelle Ave.
Schenectady (lnstrlJmentation Service) ......
................ 1 River Rood
NORTH CAROLINA
Charlotte 8 232B Thrift Road
OHIO
Cincinnoti 2 ............
W. Third St.
260 W. Mitchell Ave.
*Cincinnati 32
Cleveland <4 .......... 966 Woodland Ave.
Columbu. 23 .. P.O. Bo. 6198, 212B Eakin Rd.

u.

Toledo 5 .. <405 Dearborn Ave


Youngstown 7 . 272 Eo Indianola Ave.

OREGON
Porlland 10 ... 2727 N.W. 29th Ave.
PENNSYlVANIA
Allenlawn ....... 668 E. Highland St.
Johnstown ....... Ul Oak St.
Philad.lphia 24 ....... 1040 E. Erie Ave
(Pittsburgh) Homestead ............
.. Box 308, RD 1, Buttermilk Hollow Rd.
York ....... . 5A N. Harrison St.
TEXAS
Corpus Christi. ....... 115 Waco St.
Dalla. 35 .......... 3202 Mana' Way
Houston 20 ...... 553,( Harvey Wilson Drive
Midland ......... 704 S. John.ton 51.
UTAH
Salt Lake City 4 ..... 301 S.71h We.' St
VIRGINIA
Richmond 2<4 ....... 1 A03 Ingram Ave.
Roanoke .............. P.O. Box 1327
115 Albermorle Ave., S.E
WASHINGTON
Seattle <4 ........... 3422 first Ave., S.
.Seattle 8 ............... 220 Dowson St.
Spokane 3 ....... South 155 Sherman St.
WEST VIRGINIA
Charleston 28 ......... 306 MacCorkle Ave.
WISCONSIN
Appleton .......... Midway Industrial Area
P.O. Box 83 County Trunk P
Milwaukee 3 ........ 9.0 W. St. Paul Ave.

INDUSTRY CONTROL DEPARTMENT, GENERAL ELECTRIC COMPANY, SALEM r VA.


6-63

(2M)

INSTRUCTIONS

GEH-230AF

BI006008Supersedes GEH-230AE

INSTRUMENT TRANSFORMERS
MOLDED AND OTHER DRY TYPES -

IN RODUCTION
These instructi ns apply to indoor and outdoor
instrument transfo m~rs of molded and other drytype constructions. For information on the installation and care of t ansformers with unusual ratings
of frequency. yalta e or current, or on installations
where unusual can itions exist (refer to Requirements for Instru ent Transformers, ANSI/IEEE
C5? .13-19,8. Sect on 4), consult the nearest sales
office of the Gener Electric Company. When special information i requested, give the complete
nameplate data to .dentify the transformer.

"It is recommended that field tests of insulation


should not be in excess of 75 percent of the factory
test voltage: that for old apparatus rebuilt in the
field, tests should not be in excess of 75 percent of
the factory test voltage; and that periodic insulation
tests in the field should not be in excess of 65 percent of the factory test voltage. Tests made by the
user for design approval may be made at 100 percent. These recommendations relate to dielectric
tests applied between windings and ground and to
induced voltage tests. "

All other test methods are described in ANSI


C57.13 and the Electrical Metermen's Handbook.

E INSTALLATION
INSPECTION

Demognetizing

Before installa ion. transformers should be inspected for physic 1damage that may have occurred
during shipment r handling. During. shipping,
transformers usua ly are supported only by the base
or mounting suppa ts, except that certain molded
types may be ship ed from the factory supported by
insulation surface . Transformers should be dry
and the surface of he bushings should be Clean. All
insulation surface should be considered the same
as the surface of
porcelain bushing in regard to
cleanliness and dr 'ness.

Current transformer cores may become magnetized as a result of the application of direct current
to a winding (for example, while measuring winding
resistance or checking continuity) or in other ways.
If a current transformer becomes magnetized, it
should be demagnetized before being used for precision work. Current transformers should always
be demagnetized before accuracy test.

DRYING OUT

Molded transfo mers, particularly designs for


outdoor use. are r latively impervious to moisture.
If. due to unusual circumstances, insulation tests
indicate the possi ility of the entrance of moisture
into a molded tran former, refer to the nearest GE
Sales Office for detailed information on proper
procedure.
\Vet asphalt-im
transformers may
to the nearest GE
tion on proper pro

regnated or varnish-impregnated
be dried by self-heating. Refer
a les Office for detailed informaedure.

Low-turn Winding

Current
Source I
60Hz

111~W~'d;"
I

Cu r rent Transformer
to be Demagnetized

TESTING

NOTE: The high-turn winding ofa CT


is the winding with the lower rated current.

Generol

Tests should b made in accordancewith C57.131978. Section 8. Note that 8.8.2 states, in part:
j,"Jese ,r';"U,'IO:"lj de
in5'01.'0'lo,,: oDe'o~;on 0
femilJor .. ,.~ good so/~
e,pe',er::e ,r 50'e pro,
s""u'(le"",! ;0' ~hE' Pu'C

One method of demagnetizing is shown in Fig. 1.


Connect the transformer in the test circuit as shown,
with a low resistance across the high-turn winding.
Pass rated current through the low-turn winding
(usually HI - H2). Increase the resistance (R) in
the high-turn winding (usually Xl - X2) circuit until
the transformer core is saturated: then, slowly reduce resistance to zero and disconnect the current
source. Sa turation of the core is indicated by a reduction of current in the high-turn winding circuit.

Fig. 1. Circllit f01' demagnetizing CIOTelzt


transformers

no' purport to co . . er 011 details or \'oriotions in equipmen~ nor to prowide for every pOHjble contingency 10 be met in connect;on with
mOlntenence. The equipment covered by these operoling instructions should be opereted end ser . . iced only by competent technicians
y practices, end these instructions ore wriHen for such perjonnel ond are no' intended as a substjtu1e for ocequote 'raining and
ovres for this type of f'quipment. Should fvrther information be desired or should porticulor problems arise which are not co"'ered
C5e's pu,p05es, the motter should be referred
the Generof Ele,'ric Company.

'0

BI006008

GEH-230, Instrument Transformers

Insulated-neutral and Grounded-neutral


Terminal-type Voltage Transformers

WARNING: A CONTINUOUSLY FARlABLE


RESISTANCE MUST BE USED TO A FOlD
OPENLI-.,Y; THE HIGH-TURN WINDLVG
CIRCUIT WHEN RESISTANCE 1'ALUES
ARE CHANGED. AS THE RESISTANCE
IS INCREASED, THE FOLTAGE ACROSS
THE RESISTANCE WILL APPROACH
OPEN-CIRCUIT FA LUE.

Certain voltage transformers are designed with


one fully insulated primary terminal, with the neutral end of the primary winding insulated for a lower
level or connected to the case, frame, or base. In
some designs, this connection to the case, etc.,
can be removed for primary-applied potential testing. In such General Electric designs. the customer
should consider the required factory primaryapplied potential test level to be 19 kV on outdoor
types and 10 kV on indoor types. These levels
correspond to C57.13-1978 requirements for insulated-neutral terminal types.

Demagnetizing JAR-O Auxiliary Transformers

Due to the wide range of current ratios available


in the Type JAR -0 current transformer, the following method is necessary to prevent voltages which
are damaging to the transformer. See Fig. 2.

VOdObl.H;gha~glll Low-turn Winding


Voltage/
Source,
60Hz

INSTALLATION
SAFETY PRECAUTIONS

1. AIII'G)'s consider an instrument trans/onner


as a part of the circuit to which it is connected, and
do not touch the leads and terminals or other parts
of the transformer unless they are ImOIC/1 to be adequately grounded.

JAR-O CT
NOTE: The high- turn winding of aCT
is the winding with the lower rated current.

2. The insulation sU1jace ofmolded transformers


should be conside1'ed the same as the swjace of a
porcelain bushing, since a voltage stress exists
across the enti,'e insulation sU1facef1'om terminals
to grounded metal parts.

Fig. 2. Schematic dingram for demagnetizing


JAR -0 f1'ansfonners
Key to Fig. 2:
I

= ammeter

3. Always ground the metallic cases, frames,


bases, etc., of instrument t,'ansforme,'s. The
secondaries should be grounded close to the transfO"mers. However, when secondaries of h'ansformers are inte,'connected, thC"e should be only
one g,'ounded point in this circuit to p1"eVent accidental pm'a II eling with sys tem grounding wires,

for reading demagnetizing cu:-rent.

Vd = voltmeter for reading demagnetizing voltage,

The Id reading shall not exceed:


Rated current of the winding energized

50

The Vd reading shall not exceed:


160
Rated current of the winding energized

4, Do not open the seconda1'y ci,'cuit of a current


transfonne1' while the tmnsfonner is energized and
do not ene"gize lchile the secondary ci"cuit is open.
Cun'ent tmnsformC"s may develop open -circuit
secondary l'oltages lchich may be hazm'dous 10 personnel or damaging to the transformer or equipment connected in the secondary circuit.

For example, for demagnetizing by energizing


any 5-ampere JAR-O winding, do not exceed 32 volts
and 0.1 ampere. The core will be adequately demagnetized when either the voltage or the current
is increased to over 80 percent of the maximum
value shown in the applicable formula (see above l,
and then gradually reduced to zero.

5. The application of pou"e," fuses in the primary


ci,'cuits of t'oltage tmnsfonne,'s is recognized and
recommended ope,'atingpractice OnpOll'e1' systems.
TOP1'ol:ide the 7naxilllllmp,'otectionp1"aclical against
damage to other equipment 01' injll1'y to pe,'sonnel in
the event of a I'oltage transformer /ailm'e, it is
usually lIeceSSa1)' to use the smallest fuse ampere
rating u)lich 7cill not result in nuisance blO1ring.
Inc1'easing the fuse ampere rating to redllce nuisance blolci7lg is uS71aZZy accompanied by slower
clearing and incTeased possibility of damage to
01lle1' equipJJlent 01' i7ljm)' to pe,'so717lcl.

WARNING: ONE OR MORE WINDINGS ARE


OPEN-CIRCUITED DURISG THIS OPERA TIO.\'.
THESE WINDINGS JlAY DEl'ELOP I'OLTAGES WHICH ARE HAZARDOUS TO PERSO,VNEL. OBSER1'E
SAFETY PRECAUTIONS.
2

.,
\.

BI006008

Instrument Transformers, GEH-230

SAFETY PRECAUTION

(CONT'Dl

Tapped-secondary current transformers, including multi-ratio current transformers with more than
one secondary tap, are adequately short-circuited
when the short is across at least 50 percent of the
secondary turns. When a suitable secondary burden
has been connected to two terminals of a tappedsecondary current transformer, and normal operation is desired, all unused terminals must be left
open to avoid short-circuiting a portion of the secondary winding and producing large errors. Only
one ratio can be used at a time.

6. ]\'eue,. sllOrt-c rCl/it the sccondm.... terminals


oj a voltage h-a71sj01' ne,.. A seco71dan short ci1'cuit
will cause the !ll/it 0 oveJ'heat alld .rail in a t'ery
S1101't peJ'wd oj time

MOUNTING

....;

Instrument trans ormers should be mounted so


that connections ca be made to the power or distribution lines in su h a manner as to avoid placing
appreciable strains upon the terminals of the transformers.

On double-secondary or multiple-secondary
current transformers, that is, transformers with
two or more separate secondary windings (each
having an independent core), all secondary windings
not connected to a suitable burden must be shorted.

For high-curre t transformer ratings, 2000


amperes and above, there may be some interference from the elect ic field of the return bus unless
the bus centers ar kept at a minimum distance of
15 inches apart; f r ratings above 5000 amperes,
this distance shoul be not less than 24 inches. If
this type transfo er is used 'with more than one
primary turn, the oop should be at least 24 inches
in dianleter. Mak sure that the secondary leads
are tv.'isted closely ogether and carried out without
passing through the ield of the primary conductors.
It is not necessary hat the bus exactly fill the "Iindow, but the bus
buses should be centralized.
For ratings of 10 0 amperes or less, these precautions are gener y wmecessary.

Before a burden is disconnected from a current


transformer, the secondary terminals should be
short-circuited.
PRIMARY BY-PASS PROTECTION

Thyrite primary by-pass protectors are recommended for the proper protection of current
transformers which are so located as' to be e},,-posed
to the effect of surge currents. Th~y are especially
recommended for low primary-current ratings, as
these ratings have a relatively high winding impedance.
Thyrite primary by-pass protectors consist of
one or more Thyrite disks which are connected in
parallel with the primary winding of the transformer. When high-frequency current surges occur,
an appreciable part of the surge current is bypassed through the prote ctor, reducing the voltage
built up across the winding. Under normal operating conditions, the current bypassed has a negligible effect on accuracy.

SECONDARY CON

The resistance f all primary and secondCiry connections should be kept as low as possible to prevent overheating a the terminals, and to prevent
an increase in the econdary burden.
The resistance of the secondary leads should be
included in calcul ling the secondary burden carried
by current transfo mers. The total burden should
be kept within Ii its suited to the transformers
used. The voltage drop in the primary and secondary leads of volt ge transformers will reduce the
voltage at the me uring device.

On SUPER/B UTE
current transformers
(Types JKW-150 through JKW-350), internal gaps
are prOVided on low current ratings. If high voltages occur across the primary coil, these gaps fire
and bypass the current around most of the primary
impedance. The gaps fire at voltages well below
the internal turn-to-turn dielectric strength of the
primary winding.

Short-circuiting of Current Transformers

Many current t ansformers are provided with a


device for short-c rcuiting the secondary terminals,
and are normally hipped from the factory with this
device in the sho t-circuiting position. Check the
position of the sh rting device. The secondary terminals should be sort-circuited by the shorting device, or equivale t, until a suitable burden (such as
an ammeter, wa tmeter, watthour meter, relay,
etc. ) has been co ected to the secondary terminals.

SECONDARY PROTECTORS

Thyrite secondary protectors are designed for


connection across the secondary windings of current transformers to reduce high open -secondary
voltages, which might be dangerous to personnel or
cause an insulation breakdown. If the secondary
circuit to the intended burden is interrupted, the
secondary current will flow through the Thyrite
3

BI006008

Instrument Transformers, GEH-230

HI

HI
H2 Primary Current
--:-..--l......,\..A.A.A ~
----..

l
!

X2

XI

XI

Primary
Voltage

Secondary
Cur rent

'------( A

Secondary
Yoltoge

H2

Voltage Transformer

Current Transformer

Fig. 3. Elementary connections of ins17'umcnt transformers

disks and an adjacent heater coil. The resultant


heating causes a thermostatic switch to shortcircuit the current transformer secondary, allowingthe disks and heater coil to cool, thus permitting
the switch to open. This cycling is repeated until
normal secondary connections are restored. Under
normal operating conditions, the current that is
bypassed has a negligible effect on accuracy.

When the secondary of an instrument transformer


is connected to an instrument (such as a voltmeter
or ammeter) which measures only the magnitude of
the primary voltage or current. polarity is not significant.

PRIMARY FUSES FOR VT'S


The function of voltage transformer primary fuses is to protect the power system by de-energizing
failed voltage transformers. (Although the function
of the fuses is nottoprotect the voltage transformer.
the fuses selected will often protect the voltage
transformer promptly in the event of a short in the
external secondary circuitry, if the short is electrically close to the secondary terminals. )

POLARITY

When wiring instrument transformer circuits, it


is necessary to maintain the correct polarity relationship between the line and the devices connected to the secondaries. For this reason, the
relative instantaneous polarity of each winding of a
transfGrmer is indicated by a marker HI (or a white
spot) on or near one primary terminal, and a marker Xl (or a white spot) near one secondary terminal. See Fig. 3.

To provide the maximum protection practical


against damage to other equipment or injury to per- .
sonnel in event of a voltage transformer failure, it
is usually necessary to use the smallest fuse current rating which will not result in nuisance blowing.
Fuses are rarely available which will fully protect the
volta~e transformer from overloads, or immediately
clear the system of a failed voltage transformer.
Increasing the fuse ampere rating to reduce nuisance
blowing is usually accompanied by slower clearing
and increased possibility of other damage.

Where taps are present, all terminals are


marked in order. The primary terminals are HI,
H2, H3, etc.; the secondary terminals Xl, X2, X3,
etc. (and YI, Y2, Y3, etc., if another secondary
is used). The marker HI always indicates the same
instantaneous polarity as Xl and YI.
When connection is made to a secondary terminal
having a polarity marking similar to a given primary terminal, the polarity will be the same as if
the primary service conductor itself were detached
from the transformer and connected directly to the
secondary conductor. In other words, at the instant when the current is flowing toward the transformer in a primary lead of a certain polarity, current will flow away from the transformer in the
secondary lead of similar polarity during most of
each half cycle.

The use of a fuse in the connection of a vol tage


transformer terminal to ground is not recommended.
For grounded wye connections, it is preferred practice to connect one primary lead from each voltage
transformer directly to the grounded neutral, using
a fuse only in the line side of the primary. With
this connection, a transformer can never be "alive"
from the line side with a blown fuse on the grounded
side.

When connecting instrument transformers with


meters or instruments, refer to the instructions
furnished with the meters or instruments involved.

The fuses on certain molded transformers for


system voltages of 2400 volts or less are provided
with molded fuse holders. The fuses and holders
4

BI006008

GEH-230, Instrument ronsformers


levels of the associated system equipment to avoid
inducing destructive voltages during fuse operation.

are secured to the trans ormer by the spring action


of the fuse clips. Wh n replacing the fuse and
holder, be sure that th plastic insulating piece,
which is fastened under the transformer fuse clip,
is inserted between the nd of the fuse and the open
end of the fuse holder. _ en press the holder firmly
onto the transformer to eat the fuse in both clips.

One permissible exception to the general rules


above is the use of the 2400-vol t, Size A, T}-pe EJ-1
fuse, on 2400/4160-\'011- solidly grounded wye
systems.
In selecting primary-fuse ampere ratings for use
with voltage transformers, the objective is to use
the smallest ampere rating that will not result in
nuisance blowing during normal energization of the
voltage transformer.

WARNING: THE H LDERS SHOULD NOT

BE USED TO CON."'" CT OR DISCO.\WECT


FUSES WHILE TH PRIMARY CIRCUIT
IS ENERGIZED.

The fuses of some 0 der dry-ty-pe transformers


for system voltages of 400 volts or less, are supported by ahingedcer ic cover. If it is necessary
to replace a fuse while t e transformer is connected
to an operating circuit, the cover should be opened
by use of an insulatin hook of sufficient length to
prevent the operator fr m being injured in case an
abnormality exists in t e transformer or the connected circuits. .

When delayed clearing of a failed voltage transformer may result in damage to other equipment or
injury to personnel, "Class II" connection (where a
fuse must pass the magnetizing inrush current of
two transformers) should be avoided if this connection requires a higher fuse ampere rating than the
"Class I" connection (where a fuse passes the inrush
current of one transformer).

In testing fuses fo continuity of circuit, not


more than 0.25 ampere should be used.

MAINTENANCE
After instrument transformers for indoor use
have been installed, they should need no care other
than keeping them clean and dry. Transformers for
outdoor installations should receive the same care
in operation as power transformers of similar design and of s~milar voltage rating.

APPLICATION OF GE TY E EJ FUSES

System maxinium 0 erating line-to-line voltage


should be in the range of 70 to 100 percent of the
rated voltage of the fus This range of application
voltage is recommende because the current-limiting action of the fuse is haracterized by the generation of transient recov ry voltages above normal
circuit voltage values. he ma."crnitude ofthese overvoltages increases no inearly as available shortcircuit current increas s. The maximum voltage
permitted at rated inte
pting current is specified
in ANSI C37.46-1969.

CLEANING

Molded transformers may be cleaned by scrubbing the insulation surface with detergent and a stiff
brush to remove accumulated dirt or oil film. Remove the detergent by washing with clean water.
Then, apply a light grade of silicone oil to the surface if restoration of original surface appearance is
desired.

Therefore, it is imp rtant that the voltage rating


of high-voltage fuses be oordinated with the voltage

BI006008

GENERAL ELECTRIC COMPANY


METER BUSINESS DEPARTMENT .
SOMERSWORTH, N. H. 03878

GENERAL _ELECTRIC

8-83120"11

BI006008

GEH-2385G

._c_o_"_tr_o_l_
"r:-MA TYPE AlB. M . VOLTAGE RATING 600
~TINUOUS AC CURR NT RATING 10 AMP

INSTRUCTION

machine to I relays
CR2811-121 to 1218 open and enclosed
CR2810-11 (open)

CAUTION: Before installing in a nuclear applicati


determine that the product is intended for such U!

(Also usable for CR28U AUO thru AU6)

The CR28IQ-AI4 and the R281I-A2IO


to -A2I8 relays are multi-c rcuit a-c control relays. Because of their long mechanical life they are particular y adapted for
use on machine tool panel. These relays
have added flexibility whic permits contacts to be easily changed rom normally
open to normally closed.
The CR28IQ-AI4 relay i a sturdy device, with four, six, eight or twelve sets of
contacts for a-e circuits of 0 amperes or
less. A typical four-pole rei y is shown in
Fig. I, a six-pole relay in Fig. 2, and a
twelve-pole relay in Fig. 4. The CR28IlA210 to -A2Ia relay is an enclosed
CR28IQ-A14 magnetic rei y with either
four, six or eight sets of c ntacts; or DC
operated with four thru eig t contacts.

kept clean.
.The silver contacts require no attention
but must be replaced before the silver is
completely gone. Filing or otherwise dressing the contacts results only in loss of
silver and reduces normal contact life.

REMOVAL OF COIL
Take. out screws (A) and (B), Fig. I, remove and disassemble complete magnet
assembly. To remove, if space is limited
below the device, hold movable contact
support all the way in, and tilt bottom of
magnet assembly out. When reassembling
make certain that the tapped hole for
screw (B) is to the rear. When replacing,
tighten the screws securely.

INSTALLATION
1. Remove all packing.
2. Clean the magnet su
1.

3. Operate the armature by hand to be


sure that all moving parts ove freely.

MAINTENANCE
The sealing surfaces (C), Fig. I, on the
magnet frame and armat re should be

MOLDED SUPPORT FOR MOVA

CONTACTS

MOLDED SUPPORT FOR


MOVABLE CONTACTS

MOLDED SUPPORT FO
STATIONARY CONTAC

Fig. 2. Typica1 CR2810 machine tool


relay with six sets of contacts

2. Removal of Inner (or all) Movable Con


tacts
To remove the inner (or all) contacts 0
a four- or six-pole contactor, removi
screws (A), Fig. I, draw the magnet assem
bly and movable contact assembly fron
the. contador. To remove open contacts
grasp the movable contact assembly witl
the thumb and forefinger as shown in Fig
3. Rotate toward the center of the mov
able contact support, depress and pull ou
through the rectangular opening in thl
front side of the movable contact support
Closed contacts may be removed directl:
from the stationary contact supports witl
a sideways motion.
To remove the inner (or all) contacts of
the lower head of an eightpole or twelve
pole contactor, remove the screw whicl
holds the upper movable contact assembl:
to the push rod and remove the two screw:
(A), Fig. 1. Withdraw the complete magne
assembly, including the lower movabl.
contact assembly, from the contactor. Re
move the movable contacts as describec
above.
To remove the inner (or all) contacts 0
the upper head of an eightpole or twelve
pole contactor, firsf remove the screv
which holds the upper movable contac
assembly to the push rod. Then remove thl
four screws on the back of the base platt
holding the upper stationary contact sup
port. Remove the upper stationary contac
support and withdraw the upper rnovabh
contact support. Remove the contacts a~
described in the first paragraph unde
"Removal of Movable Contacts."

REMOVAL OF MOVABLE CONTACTS


B
A

E
C

Fig. 1. Typical CR2810 mac ine tool relay


with four sets of co tacts

1. Removal of Outer Movable Contacts


To remove the outer normally open con
tacts, grasp the front side of the movable
contact with needle-nose pliers. Depress
the spring, turn the contacts approximately 75 degrees toward the center and move
the contacts forward until the contact
guide projection emerges through the rectangular opening in the front side of the
movable contact support. Pull the contact
out.
To remove the outer normally closed
contacts, grasp the movable contact with
needle-nose pliers and depress the spring
until the contact is disengaged from the
movable contact support. Pull the contact
out.

Fig. 3. Method of removing or replacing


movable contacts

GENERALe ELECTRI

BI006008

::H-2385
the rear stationary contacts. Pull the contact assembly forward to unseat, then
push downward on the terminal causing
the contact assembly to rotate approximately 30 degrees. Grasp the contact end
of the assembly with the other hand and
withdraw with a rotating motion.
To remove the stationary contacts of
eight pole or twelve-pole contactor, first
remove the screw which holds the upper
movable contact assembly to the push
rod. Then remove the four screws on the
back of the base plate holding the upper
stationary contact support and withdraw
the upper movable contact support. Then
proceed as outlined above. In reassembling, it is necessary to adjust the position
of the stationary contact support as explained in "Changing or Replacing Stationary Contact Support" below.

In reassembling, it is necessary to adjust


the position of the stationary contact as
explained in "Changing or Replacing Stationary Contact Support" below.

INSERTING MOVABLE CONTACTS


To insert the movable contact in the
movable contact support (normally open
contacts), grasp the contact assembly
with the thumb and forefinger (or needlenose pliers) as shown in Fig. 3. First locate
the end of the spring in the rectangular
opening in the front side of the support.
Then insert the end of the contact in the
opening above the spring. Rotate the movable contact approximately 75 degrees toward the center, depress and push forward, making sure that the projections on
the movable contact engage in the slots
of the contact support. Make sure the
spring is properly seated against the movable contact support.
To insert the movable contact in the
stationary contact support (normally
closed contacts), locate the free end of
the spring over the projection on the
molded support. Depress the spring and
insert the movable contact so that it rests
against the stationary contacts. Center the
projections on the movable contact, so
that they will engage the slots in the movable support. Make sure the projections
are properly engaged in the slots of the
movable contact support when reassembling.

CHANGING THE CONTACTS FROM NOR


MALLY OPEN TO NORMALLY CLOSED
The outer contacts are most readily
changed, since they do not involve any
disassembling. On an eight-pole or twelvepole contactor, the upper inner contacts
are the most difficult to change, because
they necessitate removing the upper stationary contact support which requires
adjusting when reassembling.
To change a contact from open to
closed (or vice-versa), remove the contact
as described under "Removal of Movable
Contacts." Insert the contact as described
under "Inserting Movable Contacts."

REMOVAL OF STATIONARY CONTACTS

CHANGING OR REPLACING STATIONARY


CONTACT SUPPORT

To remove the stationary contacts of a


four- or six pole contactor, first remove
screws (A), Fig. I, and draw the magnet
assembly and movable contact assembly
from the contactor. Remove the screws
holding the front stationary contacts. Remove the terminal screws on the rear contact assembly. Remove the screws holding

If, for any reason, the stationary contact support is removed from the contactor
base plate, reassemble as tlJllows: Fasten
the stationary contact support to the base
plate with the four screws tightened
slightly. Place a 1/16-inch spacer in the

PRINCIPAL RENEWAL PARTS


DESCRIPTION
Set Sta. & Moy. Contacts
With Springs & Screws
For One (1) Pole
Coil
Molded Support For Sta.
Contacts For Four (4)
Pole Form
Molded Support For Sta.
Contacts For Six (6)
Pole Form
MOlded Moy. Contact Arm
For Four (4) Pole Form
Molded Moy. Contact Arm
For Six (6) Pole Form

CAT NO.
6960047G26

A
2

22D135G
(See Table)
9004179G1

" " "

1B7D339G1

Sot

USE
USE
USE
USE
USE
USE
USE
USE
USE

COLUMN
COLUMN
COLUMN
COLUMN
COLUMN
COLUMN
COLUMN
COLUMN
COLUMN

A
B
C
0
E
F
G
H
J

USE
USE
USE
USE

COLUMN A
COLUMN B
COLUMN C
COLUMN 0

46BC447P1

115V 200/208V 230V


3
2
23
103
102
123
203
202
223

460V
4
104
204

575V
5
105
205

380V
4
104

440V
9
109

550V
10
110

110V
7
107

AA,AH,AR
AB, AJ, AS, BA,
AC, AK, AT, BB, BG
AD,AL,AV,BC,BH,BM
AE, AM, AW, BD, BJ, BN, BS
AF,AN.AX, BE.BK. BP,BT,BW
AG,AP,AY,BF,BL,BR,BV,BX,BY
DE,DF,DG,DH,OJ,DK,DL
EE,EF,EG, EH,EJ,EK, EL, EM, EN, EP, ER,ES, ET
CR2811

90041BOP1

Frequency
Hz
50"

Fig. 4. Typical CR2810 Machine Tool relay


with twelve sets of contacts
CR2810-A14

QUANTITY PER FORM


B C
E F G H J
3 4 5 6 7 8 6 12

COIL SUFFIX TABLE ., t,


Indicates Yoltage and frequency of operating coil
Frequency
Hz
60"
60t
60t

armature gap (C), Fig. 1. Push up on the


movable armature (D), loosen the screws
holding the contact support to the base
plate and adjust the stationary contact
support so that the normally open contacts just touch the stationary contacts.
Then tighten the screws.
For an eight-pole or twelve-pole contactor, follow the same procedure on each
stationary contact support, as the "wipe"
on the contacts of the upper and lower
contact supports are adjusted independently of each other.
On the contactors which have all normally closed contacts, insert a 9/64-inch
spacer in the armature gap (C), Fig. I, and
adjust the contact support so that the contact faces just break contact.

220V
8
108

GENERAL ELECTRIC COMPANY


GENERAL PURPOSE CONTROL DEPARTMENT
BLOOMINGTON, ILLINOIS 61701

115/
600V 125VDC
6
106
441"
206

230/
250VDC
442"

541t

542t

641t

642t

600V
11

111

A110A, B, C, D
A111A, B,C,D,E,F,G,H
Al12A,B,C,D,E,F,G,H,J,K
Al13A, B,C, 0, E, F,G, H,J
Al14A, B,C,D, E, F,G, H,J, K,AE,
AF,AG,AH,AJ,AK,AL
Al15A, B,C, 0, E, F,G, H,J, K,L, R,S, T, V
Al16A, B, C, 0, E, F,G, H,J, K, L, R,S,T,
W,X,Y,AA
A210A,B,C
A211A, B, C,
A212A, B,C, 0, E
A214A,B,C,D,E,F,G
A216A, B,C,D,E, F,G,H,J

USE COLUMN
USE COLUMN

E
F

USE
USE
USE
USE
USE
USE

G
A
B

COLUMN
COLUMN
COLUMN
COLUMN
COLUMN
COLUMN

r
l

GENERAL. ELECTRIC

11/78
Printed In U.S.A.

GEH-24E

BI006008

. . . . .c_o_n_tr_o_l_
INSTRUCTION~

CR120A ind slrial relay

SERIES A

RATINGS

3. Check the operation of the movable contact arm by sliding the


indicating tab to the opposite side of the slot.
Max. Voltage
Rating

Continuous AC
Current Rating

300

10ampmax.

The CR120A 300 Vo relay is a small multi'circuit AC control


relay. Because of their mall size and long mechanical life they
are particularly applicable for use on machine control panels. Added
flexibility permits contac s to be changed from the front to either
normally open or normall closed on all convertible tip forms. Non'
convertible contact forms are also available in all pole arrangements.
Two standard forms f the CR120 relay are available with two
or four main poles. A t 0 pole adder is available for mounting on
either the right or left ide of the 4 pole form giving four, six, or
eight sets of contacts for C circuits of 10 amperes or less.

MAINTENANCE
DO NOT OIL OR GREASE the magnet mating surfaces.
The surfaces of the contacts should be kept clean.
The silver contacts require no further attention but must be replaced before the silver is completely gone. Filing or dressing the
contacts only results in loss of silver and reduces normal contact
life.

REMOVAL OF COIL
1. To remove white retainer, place thumbs against one side of the
retainer and apply pressure.
2. Slide out movable contact arm. (Figure 2)

A 4 pole adder is also available for mounting on the front of the


4 pole relay. Other additi ns to the line consist of a pneumatic time
delay relay available in ti e delay energization and time delay deenergization forms and a I tched form.

FIGURE 2

FIGURE 1- Typical CR120A industrial relay (4 pole form)

INSTALLATION
1. Remove all packing fro

the device.

2. Mount the relay perpe dicular to the panel (2/16' apart) with indicator tab to the right, ft or down.

'"

NOTE: Captive /;'8 - 32


each relay for panel m
a clean American Natio
reQuire a .147 diamet
with 1725 inch pound

elf, threading screws are furnished with


unting the device. These screws will cut
al thread through a Is" thick panel. They
r (/;'26 drill) hole and should be driven
torque.

FIGURE 3

GENE RAL ~. ELEe TRI

iEH-2466E

BI006008

3. Loosen coil terminal screws (terminals without contacts attached)


and remove wiring.

the contact. Slide the terminal tip assembly out of relay.

4. Place screwdriver under one coil terminal screw head, and using
barrier as a fulcrum, pry coil out of relay. (Figure 3)

4. If contacts are to be converted - Exchange position of the two


terminals removed, slide into place, replace wiring, and tighten
screws.

5. Replace coil and wiring, tighten screws and replace movable contact carrier.

5. If terminal tip assembly requires change, follow steps 1 through


3 above and replace with new assembly.

6. To replace retainer, place one side of retainer in holding slots,


making sure indicating tab fits through hole provided in retainer;
then apply pressure to the ends of the opposite side of the retainer with your thumbs.

6. Turn cover on movable contact arm 90 in direction of the arrow


(Figure 5).

(MOVABLE CONTACTS)

CHANGING OR CONVERTING OF CONTACTS


(STATIONARY CONTACTS)
1. Follow steps 1 and 2 under removal of coil.
2. Loosen both terminal screws on opposite sides of pole to be
changed at least three turns. Remove wiring.
3. Grasping the screwdriver by the blade shaft, (Figure 4) place the
thumb over the top (or bottom) of the terminal and the blade
edge of the screwdriver against the inside of the terminal against

FIGURE 5
7. If contacts are to be converted, lift out contact to be changed
and rotate 180. Replace contact in carrier and replace cover on
carrier.
8. If contacts are to be changed, lift out existing contact and replace new contact in same position.
9. Replace contact arm in relay making sure notch in bottom of carrier fits over tab of operating magnet.
10. Replace movable contact arm retainer making sure indicating tab
fits through slot provided in retainer.
NOTE: 6 through 8 pole relays requiring 5 or more NC contacts
should be ordered by nomenclature from the factory. These relays
req uire a different kick - off spring.

FOR COMPLETE RENEWAL PARTS


FIGURE 4

GENERAL ELECTRIC COMPANY


GENERAL PURPOSE CONTROL DEPARTMENT
BLOOMINGTON, ILLINOIS 61701
11/70

REFrR TO GEF 4247

GENERAL. ELECTRIC

GEH-2468

Instructions

BI006008

Time-delay
Relays
CR122A Series

Caution:

Before ins ailing in a nuclear application, determine


that the product is inten ed for such use.

Warning:

Disconne t power before installing or servicing.

Ratings
Maximum Volta e
Rating

Continuous AC
Current Rating

300

10 ampere maximum

Application
The pneumatic time-del
relay is designed for use in control circuits, to introduce a tim interval between the operation of an electrical contact and the ac ual initiation of the controlled function.
Typical applications are achine tool and automation circuits where
an adjustable time delay of from 1/5 to 60 seconds is desired.

Operation
The timer may be adjusted by means of the adjusting screw on the
front of the timing head. Turn counterclockwise to increase time
delay and clockwise to shorten time delay. The rate of change of
timing is greater for long time delays than for short time delays. It
will be noted that a considerably greater adjustment is required at
the "F" (FAST) end that is required at the "S" (SLOW) end to produce an equal effect.
The time setting is adjustable from 1/5 to 60 seconds with approximately 15% repetitive accuracy. The nominal setting may be obtained by averaging 3 readings after a 3 operation "run-in" at each
new time setting.
Where frequent operations introduce mechanical wear, periodic rechecks of the time setting are advisable.
ADJUSTMENT SCREW

Description
The unit (see Figure 1) onsists of a bellows type timer with adjustable orifice and two t ming contacts, all operated by a standard
CR120A industrial relay. Time-delay relays are supplied as either
time delay on energizati n or time delay on de-energization, with the
coil of the basic relay pr viding the operating power.
Tip locations are shown ith the relay de-energized (see Figure 2).
On time delay energize rms, timer is ready to time; on time delay
de-energize forms, timer is timed out.

Installation

Before connecting relay 0 power supply:


1. Remove device from

arton.

2. To check the timer 0 eration on the time delay energize forms,


move the indicating t b on the relay to the right and hold in the
"ON" position until t e timer has timed out. Release the tab of
the relay with a snap action so as to reset the timer mechanism.
To check operation 0 time delay de-energized forms, move indicator on the relay t the left (ON) and release. Timer will then
time out. Do not man ally operate indicator on movable contact
arm on timer attachm nt at any time.
3. Mount time-delay rela on vertical panel (preferred mounting:
timer on left-relay on right) with 1116-inch allowance to next adjacent unit. May be mo nted with the relay indicator tab to the
right, left, or down.

Mounting Data
Captive #8-32 self-threa ing screws are furnished with each relay for
panel mounting the devi e. These screws will cut a clean American
National thread through 1/s-inch thick panel. They require a .147
diameter (#26 drill) hole nd should be driven with 17-25 inch
pounds torque.

Figure 1. Basic device.

TIME DELAY ENERGIZE (No power applied)

E-{ :~-:+-:+~~
TIME DELAY DE-ENERGIZE (No power applied)

Figure 2. Tip locations.

GENERALfj) ELECTRIC

BI006008

Change Of Mode

Changing Or Converting Contacts

Time-delay relays without normally closed instantaneous contacts


may be converted from time-delay energize to time-delay deenergize, or vice versa. Time-delay relays with normally closed instantaneous contacts may not be converted.

Note: Time-delay relays shipped with all normally open instantaneous contacts must not be converted to normally closed. Timedelay relays shipped with one or more normally closed contacts may
be converted to up to four normally closed contacts.

1. Loosen screws "A" and "B" slightly and remove screw "C".
Separate the timer and relay units (see Figure 3).

Stationary Contacts
1. Follow steps 1 and 2 under Removal Of Coil.
2.

Loosen both terminal screws (on opposite side of pole to be


changed) at least three turns. Remove wiring.

3. Grasping the screwdriver by the blade shaft, place the thumb


over the top (or bottom) of the terminal and the blade edge of
the screwdriver against the inside of the terminal against the
contact. Slide the terminal tip assembly out of the relay.

TIMER

RELAY
(HAS BEEN ROTATED)

Figure 3. Change of mode.

2. Remove screw "D" and nut "E".


3. Rotate relay unit 180 0 and reassemble to time-delay unit.
4. With left side of timer facing down and relay above, insert screw
"C" to join relay and timer and tighten. With timer and relay in
this position, screw "C" will be guided into proper position.
Figure 4.

5. Retighten screws A, B, and C equally.


6. With timer facing up and relay down insert screw "D" in outside
hole of relay and secure in position with nut "E".

4.

If contacts are to be converted:


Exchange position of the two terminals removed, slide into
place, replace wiring, and tighten screws.

Maintenance

5.

If terminal tip assembly requires change, follow steps 1 through


3 above and replace with new assembly

The surfaces of the contacts should be kept clean.


The silver contacts require no further attention, but must be replaced
before the silver is completely gone. DO NOT FILE the contacts.
Filing or dressing the contacts only results in loss of silver and
reduces normal life.

Movable Assembly
6. Turn cover on movable contact arm 90 0 in direction of the
arrow (see Figure 4).
7.

If contacts are to be converted, lift out contact to be converted


and rotate 180 0 (see Figure 4). Replace contact in arm and
replace cover on arm.

1. To remove white retainer, place thumbs against one side of the


retainer and apply pressure.

8.

If contacts are to be changed, lift out existing contact and


replace with new contact in same position.

2. Slide out movable contact arm.

9.

Replace contact arm in relay making sure notch in bottom of


arm fits over tab of operating magnet.

10.

Replace movable contact arm retainer making sure indicating


tab fits through slot provided in retainer.

Removal Of Coil

3. Loosen coil terminal screws (terminals without contacts attached)


and remove wiring.
4. Place small screwdriver under one coil terminal screw head, and
using barrier as a fulcrum, pry coil out of relay.
5. Replace coil and wiring, tighten screws, and replace movable
contact arm.
6. To replace retainer, place one side of retainer in holding slots,
making sure indicating tab fits through hole provided in retainer;
then apply pressure to the ends of the opposite side of the retainer with your thumbs.

For complete Renewal Parts


Refer to GEF-4247

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation,
operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the Purchaser's purposes, the
matter should be referred to the nearest General Electric sales office.

For further information


call or write your local
General Electric sales office
or distributor.
Or write ...

IEH-2468G

6/87

(2M)

General Electric Company


General Purpose
Control Components
P. O. Box 2913
Bloomington, IL 61702-2913

GENERAL~ ELECTRIC
Printed In U.S.A.

GEH-2621C

Installation and Maintenance Instructions


BI006008

AVIBVLine@
Switchboards

TYPICAL AV-L1NE<!l SWITCHBOARD

BI006008

Table of Contents
DESCRIPTION
Switchboard Construction
Receiving, Handling and Storage
Installing the Bus Busway Stub
For GE LVD Busway Stubs
For GE Armor Clad:ID Busway Stubs
Short Circuit Cable Bracing
MAIN CABLE
Class 1, 2, and 5 Switchboards
utilizing cord for Short Circuit Protection.
Class 3 and 4 Switchboards
utilizing cord for Short Circuit Protection.
LOAD CABLE
Class 3 and 4 Switchboards
utilizing cord for Short Circuit Protection.
Installing the Switchboard
Switchboard Maintenance

PAGE
3
4
5
5
5
6

8
9, 10, 11
11, 12

BI006008

Switchb
Constru
These instructions do n t purport to cover all details or variations in eq ipment nor do they provide for every possible ontingency to be met in
connection with installat on, operation or maintenance. Should further in ormation be desired, or
should particular probl ms arise which are not
covered sufficiently for t e purchaser's purpose,
the matter should be re rred to your supplier.

FIGURE 2
Typical individually
mounted distribution
construction.

--- ---

BI006008

Receiving, Handling and Storage


RECEIVING
Before leaving the factory, the switchboard is given a final inspection and packed by workmen experienced in the proper
handling and packing of electrical equipment. Upon receipt of
any apparatus, an immediate inspection should be made for any
damage sustained in transit. If damage is noted, or indication of
rough handling is visible, a claim for damage should be filed with
the carrier. Information as to damaged parts, part number, case
number, requisition number, etc., should accompany the claim.

45 MINIMUM

In regard to claims for damaged shipments, shortages and incorrect material, the following is an excerpt from the published
Supplemental Terms and Conditions of Sale for products of the
Company.
"Title and risk of loss shall pass upon delivery of the products to
the carrier at the f.o.b. point and invoices shall be payable without deduction for losses in shipment. It is the Purchaser's responsibility to file claims witli the carrier for loss or damage in
transit."
"Claims for shortages or incorrect material must be made in
writing within 30 days after receipt of the shipment by the Purchaser, and the failure to give the Company such written notice
within the 30-day period shall be unqualified acceptance of the
products and a waiver by the Purchaser of all claims for shortages or incorrect materia!."

HANDLING
Equipment may be moved into position by means of construction
rollers under the shipping skids. Remove all outer packaging.
Lifting by crane or other hoisting methods done as shown in
Figures 3 and 4.
To remove the switchboard from the skids after taking out the
shipping bolts, carefully slide the equipment so that the rear
side is off the skids, resting on the floor (see Fig. 5). Tilt the
entire equipment slightly to the rear to release the skids. Caution is advised in sliding and tilting this equipment due to its
height and weight. It can become top heavy if tilted too far.
Slide the switchboard into place by pushing on the frame. Blow
out any dust or loose particles of packing material which may
have>
)lIected on the device parts. Remove all protective
bloci. :J on relays, devices or breakers.

FIGURE 3
Using lifting slings, spreader
and blocking are not furnished
with equipment.

FIGURE4
Using lifting plates, angles or
beams which are furnished
with equipment.

LIFTING INSTRUCTIONS
1. Do not pass cables or ropes through support holes.
2. Always use load rated shackles or safety hooks in support
holes.
3. Rig so that legs of sling (Figs. 3 and 4) are no less than 45
from horizontal.

STORAGE
If it is necessary to store the equipment for any length of time, the
following precautions should be taken to prevent corrosion or
breakage:
1. Uncrate equipment.
2. Store in a clean, dry, rodent-free area in moderate temperature. Cover with a suitable canvas to prevent deposits of dirt
or other foreign material on movable parts and electrical contact surfaces. (Heavy duty plastic covers are recommended.)
3. If stored in cool or damp areas, heat should be provided to
keep the equipment dry. On outdoor switchboards this may
be accomplished by making a temporary power connection
to the heaters installed in the equipment. On indoor switchboards, two standard 120 volt lamps rated at 100 watts can be
used inside each vertical section.
CAUTION: Remove all cartons and other miscellaneous packing material from inside the units before energizing any heaters.

REMOVE

t
FIGURES
Remove lag bolts. Slide unit off skid and remove skid.

BI006008

The Bus Stub


STUB
FLANGE
ADAPTER

STUB
COVER

REMOVABLE
FRAME
MEMBER
REMOVE
REAR
COVER

For G

FIGURE 6
LVD busway stubs.

lIi""l1:-----{S

FIGURE 7
For GE Armor-Clad busway stubs.

INSTALLATION P OCEDURES
If access to switchboard bus at point of connection to busway
stub is limited by wall or 0 her obstruction, stub must be installed
before board is placed in final location.

G) Remove shipping scr

ws holding bus stub flange adapter to


stub cover. Slide ada er apart to allow stub to enter through
slot in cover. When sp ce is limited, the top rear frame member may be removed 0 that the stub with stub cover may be
installed horizontally i stead of vertically.

Slide flange adapters together to close up slot.


Loosely fasten bus stub flange to stub cover with hardware
furnished with stub.

@ Bolt stub bus to switchboard bus (see Fig. 7A).

Bolt neutral splice bus (if required) to stub neutral with hardware furnished with the neutral splice bus.
After stub and switchboard bus is properly aligned and
bolted, tighten down flange screws.

SWITCHBOARD
BUSBAR
~_~_-

BUS STUB
FLAT WASHER
112-13 BOLT

OPEN SLOT
LOCK WASHER

DO NOT
FILL IN OPEN SLOT
WITH HARDWARE

FIGURE 7A
For GE Ar or-Clad busway stubs.

BI006008

WARNING: Short Circuit Cable Bracing Required


MAIN CABLE BRACING

LOAD CABLE BRACING

Main cable bracing is required when five cables per phase or less
feed a switchboard at available short circuit currents of 100,000
and 150,000 rms symmetrical amperes, and eight cables per
phase or less at an available short circuit current of 200,000 rms
symmetrical amperes.

Load cable short circuit bracing is required for each component


installed in a class 3 or 4 switchboard section with available
short circuit currents of 65,000 rms symmetrical amperes and
above.

Assembly, purchasing and maintenance instructions for main


cable short circuit bracing can be found on pages 6 and 7.

Assembly, purchasing and maintenance instructions for load


cable short circuit bracing can be found on page 8.

Installing The Main Cable


CLASS 1, 2, AND 5 SWITCHBOARDS UTILIZING CORD FOR SHORT CIRCUIT PROTECTION

PRIOR TO INSTALLATION
Before any installation work is performed, study all drawings
furnished by the supplier for the particular installation. These
include arrangement drawings (front, end and plan view), connection diagrams and schedule of equipment. Any material external to the equipment which may be required to meet any local codes (railings, etc.) is not furnished.
CABLE BRACE

"A" and "B" phase main cables and 6 revolutions around the
"B" and "C" phase main cables. Now, with the remaining cord,
wrap the main cable lashing to the cable braces in between
phases with 4 to 5 revolutions, tying a knot to the cable braces
as you complete your last revolution. All revolutions should be
made as tight as possible so as to prevent whipping during short
circuits.

INSPECTION AFTER MAIN CABLE


INSTALLATION
To prevent heating, there should be no closed loop of steel
around a single conductor or group of conductors which does not
include all the conductors (including the neutral) of the circuit. If
the conductors must pass through separate holes in a piece of
steel, slots should be cut between the holes. Do not allow cables
carrying heavy current to come near instruments or meters as
this may affect their accuracy. Use the minimum amount of cable
necessary to accomplish the connections. The increased resistance of longer cables generates unnecessary heat. Main cable
lashing should be checked annually.

REAR ACCESS
MAIN CABLE TERMINALS
FIGURE 78

INSTALLATION PROCEDURES FOR


MAIN CABLE WITH SHORT CIRCUIT
PROTECTION
Align conduit holes in a linear orientation directly over or as close
as possible to the braces. Consideration should be given to
installing conduits or sleeves which might be required for future
connections.
Run and bend the main cable in a most convenient orientation,
making sure the main cable has been located directly up against
the cable braces before it connects to the main cable terminals.
Lash the main cable according to Figure 7B above, using a %"
nominal nylon rope, or a polyester braided rope having a tensile
strength of 2000 Ibs. minimum, making 6 revolutions around the

Some switchboards may require ac, _'S to field wiring terminals


from the rear. Do not install these sWiichboards against the back
wall.

The Main Cable (Cont'd)

BI006008

BOARDS UTILIZING CORD FOR SHORT CIRCUIT PROTECTION

CABLE BRACE

FIGURE7C

PRIOR TO INSTA LATION


Before any installation ork is performed, study all drawings
furnished by the supplie for the particular installation. These
include arrangement dra ings (front, end and plan view). connection diagrams and sc edule of equipment. Any material external to the equipment hich may be required to meet any local codes (railings, etc.) s not furnished.

INSTALLATION P OCEDURES FOR


; MAIN CABLE WIT SHORT CIRCUIT
PROTECTION
Align conduit holes in a Ii ear orientation a distance equal to the
radius bend of the cable. Consideration should be given to installing conduits or sleev s which might be required for future
connections (see Figure D). Run and bend the main cable in a
most convenient orientat on, making sure the main cable has
been located directly up a ainst cable braces before it connects
to the main cable terminal (see Figure 7C). Lash the main cable
according to Figure 7C a ove, using a %" nominal nylon rope,
or a polyester braided rop having a tensile strength of 2000 Ibs.
minimum, making 6 revol tions around the "A" and "B" phase
main cables and 6 revol tions around the "B" and "COO phase
main cables. Now with th remaining cord, wrap the main cable
lashing to the cable brace in between phases with 4 to 5 revolutions, and tie a knot to the able brace as you complete your last
revolution. All revolutions should be made as tight as possible
so as to prevent whipping during short circuits.

FIGURE 70

INSPECTION AFTER MAIN CABLE


INSTALLATION
To prevent heating, there should be no closed loop of steel
around a single conductor or group of conductors which does not
include all the conductors (including the neutral) of the circuit. If
the conductors must pass through separate holes in a piece of
steel, slots should be cut between the holes. Do not allow cables
carrying heavy current to come near instruments or meters as
this may affect their accuracy. Use the minimum amount of cable
necessary to accomplish the connection~ The increased resistance of longer cables generates unnecessary heat. Main cable
lashing should be checked annually.

REAR ACCESS
DO not install these switchboards against the back wall. Rear access is required for field wiring and maintenance.

BI006008

Installing The Load Cable


CLASS 3, 4 SWITCHBOARDS UTILIZING CORD FOR SHORT CIRCUIT PROTECTION

CABLE BRACE

=
FIGURE7E

PRIOR TO INSTALLATION
Before any installation work is performed, study all drawings
furnished by the supplier for the particular installation. These
include arrangement drawings (front, end and plan view), connection diagrams and schedule of equipment. Any material external to the equipment which may be required to meet any local codes (railings, etc.) is not furnished.

INSTALLATION PROCEDURES FOR


LOAD CABLE WITH SHORT CIRCUIT
PROTECTION
Locate the load cable braces which can be found every 18" on
the back of the switchboard. Run and bend the load cable in the
most convenient manner, making sure that the load cable is up
against the load cable brace closest to the component's load
terminals (see Figure 7E) and to every load cable brace above or
below, depending if the load cable will exit the switchboard on top
or bottom (see Figure 7F).
After running the load cable up against the load cable braces
and using a %" nominal nylon rope, or a polyester braided rope
having a tensile strength of 2000 Ibs. minimum, lash the load cable to the load cable brace, making 4 revolutions around the cable and the brace. Tie a knot to the cable brace after completion
"f the last revolution. All revolutions should be made as tight as
possible so as to prevent whipping during short circuits.

FIGURE7F

INSPECTION AFTER LOAD CABLE


INSTALLATION
To prevent heating, there should be no closed loop of steel
around a single conductoror group of conductors which does not
include all the conductors (including the neutral) of the circuit. If
the conductors must pass through separate holes in a piece of
steel, slots should be cut between the holes. Do not allow cables
carrying heavy current to come near instruments or meters as
this may affect their accuracy. Use the minimum amount of cable
necessary to accomplish the connections. The increased resistance of longer cables generates unnecessary heat. Load cable
lashing should be checked annually.

REAR ACCESS
Do not install these switchboards against the back wall. Rear access is required for field wiring and maintenance.

BI006008

Installin The Switchboard


PRIOR TO INSTA LATION
Before any installation work is performed, study all drawings
furnished by the suppli r for the particular installation. These
include arrangement dr wings (front, end, and plan view), connection diagrams and s hedule of equipment. Any material external to the equipment which may be required to meet any local codes, (mats, scree s, railings, etc.), is not furnished.

LOCATION
In locating the switchbo rd, consideration should be given to the
aisle space required. Th space at the front must be sufficient to
permit the opening of drs, and the insertion and withdrawal of
removable breakers. Th space at the rear must be sufficient for
opening of doors as wei as the cables, inspection, and maintenance. Check local cod s for special aisle space requirements.

FIGURE 8
Bolting the switchboard directly to the floorindoor construction.

FOUNDATION R QUIREMENTS
Indoor Equipment-T
enough to prevent sagg
structure. If the found
mounting must be provi
tions to the equipment.

e floor or foundation must be strong


ng from the weight of the switchboard
tion is SUbject to vibrations, special
ed to prevent the transmittal of vibra-

Because of its high stru tural strength, the switchboard may be


bolted directly to the fl r (see Fig. 8). The floor must be entirely level without any igh spots which might cause misalignment. If the floor is not I vel it is recommended that floor channels be used.
The steel floor channel
level concrete slab with t
the finished floor. To avo
tial that the steel chann
prior to the final anchori
struction and method of
tion is shown in Fig.
installation.

when used should be embedded in a


e top surface of the channels flush with
d distortion of the structure, it is essenIs be level and aligned with each other
g. The recommended foundation conounting the switchboard tothe founda. Channels should be grouted after

FIGURE 9
Switchboard mounted on floor channels-indoor construction.
FRONT

PAD WIO

SILL~

Outdoor Equipment
utdoor equipment is usually installed
on a concrete pad with level and smooth surface. When optional channel sills are upplied with the switchboard (three),
they should set on the ad and be filled with grout. See Figs.
10 and 11. Tamper-pro rodent guards are provided with sills.
Conduits-At the time he foundation channels are being installed, any conduits or leeves required for power and control
cables that are to enter t e equipment from underneath should
be located and installed ithin the available space shown on the
floor plan drawings. Con ideration should be given to installing
conduits or sleeves whi h might be required for future connections. Conduit stubs sho Id extend above the floor just enough to
prevent the entrance of ater. Consideration should be given to
the location of compone ts in the switchboard and space should
be allowed for swinging abies after they leave the conduit. The
lowest live metal part in t e switchboard will be approximately 8"
minimum above the bot om of the switchboard (not including
floor sills). It should be n ted that the switchboard must be lifted
over the conduit stubs. he conduits should terminate at the
switchboard with the ap ropriate conduit connectors. Conduits
may require grounding r electrical connection to the switchboard enclosure.

FIGURE 10
Non-walk in type switchboard-outdoor construction.
FRONT

PAD WIO Sill

Jc~~~~~

PAD
WITH SILLS
FIGURE 11
Walk-in type switchboard-outdoor construction.

BI006008

Installing the Switchboard (Cont'd)


FIELD CONNECTIONS AND TESTING OF
GROUND-FAULT PROTECTION SYSTEMS

3) In the service-entrance section, the neutral conductor shall


be bonded to the switchboard ground bus by a "main bonding jumper" (ground strap) (NEC 250-5). This grounding
point on the neutral conductor shall be located on the supply side of any ground-fault sensors involving the neutral
conductor. Grounding connections shall not be made to the
neutral conductor on the load side of the service disconnecting means (NEC 250-23a).

~ On load feeders, run all phase conductors (and neutral if

IGi"

INTEGRAL GROUND

FAULT PROTEeTlc .....

used) through the sensor window(s), with all in the same


direction with respect to sensor polarity.

~ Do not run equipment ground conductors through groundfault sensors. Connect them directly to the switchboard
ground bus (not to the neutral bus).

~ Connect the service grounding electrode (water pipe, etc.)


to the lug provided on the switchboard ground bus for this
purpose (NEC 250-26c).

Whenever a service is derived from a grounded neutral sup-

ply, the grounded neutral conductor must be brought into the


service-entrance equipment, even if the grounded conductor
is not needed for the load supplied by the service (NEC 25023b). This is required to provide a low-impedance groundfault current return path to the neutral to assure operation of
the overcurrent device, for safety to personnel and property.

Refer to GE publication GE1-48907 for instructions for conducting performance tests of new installations of groundfault protection systems, as required by NEC 230-95(c).

~
,

:1

'I

lI

lI

J
I

GJ

~
, , ,

il

}PHASE _4 WIRE LOAD

3 PH,),SE

3 W'RE LOAD

TYPICAL SINGLE-SOURCE
GROUND FAULT PROTECTION
USING INTEGRAL GROUND FAULT TRIPS

FIGURE 13

FUSE SELECTION
The proper fuses for each circuit should be selected based on load
characteristics (see Ambient Temperatures and Circuit Loading) and
available short-circuit current at the line terminals of the switchboard.
Select a fuse for which the rating of the combination fuse and switch
equals or exceeds the available short-circuit current. Removable linktype fuses are not recommended.

TESTING AND INSPECTION

ALTERNATE SENSOR
ARRANGEMENTS

(j)

G)

FOR MAIN BflE,l,KL:r1 GFP

"

et+H>-

,\LTEf"lNATE SUJSOHS

~\-----l

Z["O

SEQuO,CE
,

Hxt>-

- - - - ZERO-SEOUENCE OR
RESIDUAL SENSOR
NEuTRAL

~j

cH>#

Sus

GFR

After the equipment has been installed and all connections made, it should
be tested and inspected BEFORE ENERGIZING. Although the equipment
and devices have been inspected at the factory, a final field test should be
made to be certain thatthe equipment has been properly installed and that
all connections are correct and have not become loose in transportation. It
is recommended that the switchboard be completely wire checked, and all
he
and terminals dou~le checked for tightness. Check all Kirk key
Jcking schemes to insure desired performance. The incoming line
~, ~-.Jld be completely de-energized while the tests are in progress.
In addition to these mechanical checks ,he switchboard should be
meggered. Meggering should be performed with all switchboard devices
in the open position and all instrumentation and control fuses removed. A
megger (megohmmeter) developing 500 volts should be used. As a guide,
switchboards tested when leaving the factory have shown typical
minimum values of 100 megohms. Any switchboards job tested under the
above conditions showing values considerably below this should be
inspected for possible tracking on insulation or insulation breakdown.

RESIDUAL

All scraps of wire. plaster, dust and other foreign material must be
removed. Vacuum cleaning is the recommended method of removal.

GROUND FAULT RELAY

After thorough cleaning and inspection, if the megger reading is still low,
it may still be safe to energize the equipment. When restoring flooded or
wet equipment to service, for example, it is accepted maintenance practice to require a minimum of one megohm before energizing. Under
damp or humid conditions it is considered good practice to operate the
equipment at lower-than-rated voltage for a short time, if possible, to
improve the low megger reading.
Instructions for inspection and testing of low voltage power circuit
breakers are given in the applicable individual instruction book. Directions for testing devices such as relays, instruments and meters are
given in the instruction book furnished for each device. Protective relays
must be coordinated with other relays in the system, therefore these
relays are to be set by the purchaser. General instructions on setting the
relays are given in the relay instruction books.

FIGURE 12

BI006008

GROUND FAUL PROTECTION

When ground fault protection is furnished, it is important that all field connections shall be made
correctly so that t e ground fault protection system will function properly. Observe the following rules,
illustrated in Figs. 2,13.

BOLTING

ELECTRICAL CLEARANCES

Switchboards are fur ished with medium carbon steel hardware having a high t nsile strength. '1." to Va" bolts have a
tensile strength of 1 0,000 psi, and W' to %" bolts have a
strength of 60,000 p i. Similar hardware should be used for
any additional bolting. The use of a torque wrench is recommended to assure th following torques. These torques apply
to aluminum or copp r connections. When torquing bolts the
following values are n minal:

Thefollowing minimum clearances should be maintained exce;


at terminals of circuit breakers and switches:

V4" 5/ 16 " -

3fs" 1/2" 5/a" -

20 bo ts
18 bo ts
16 bol s
13 bol s
16 bol s

8-10 lb.
, .16-19Ib.
23-27 lb.
35-40 lb.
.45-50 lb.

ft.
ft.
ft.
ft.
ft.

Flat washers and sprin washers should be used for all connections. Washers should ot be included under the heads of carriage bolts.

0-125V 126-250V 251-600


Between live parts of opposite
polarity:
Through air
Over surface
Between live parts and
grounded metal through air or
over surface

112"

1"

3/4 "

2"

112"

1"

GROUNDING
The ground bus is bolted to the uprights of the rear fram
structure. It is arranged so that connections to the statio
ground can be made in any unit. A ground lug is included i
each complete equipment for tying the switchboard to the st"
tion ground. IT IS VERY IMPORTANT THAT THE EQUIF
MENT BE ADEQUATELY GROUNDED, TO INSURE THA
ALL PARTS OF THE EQUIPMENT, OTHER THAN L1VI
PARTS, ARE AT GROUND POTENTIAL. Ground sensor re
lays are recommended for protection of the switchboard.

Switchb ard Maintenance


CAUTION! De-ener ize this equipment before performing any work.
A periodic maintenance schedule should be established to obtain the best service fro the switchboard. An annual check and
overall maintenance pr edure for the switchboard devices and
all connections, should e followed as a minimum requirement.
Equipment SUbject to h ghly repetitive operation may require
more frequent maintena ceo
A permanent record of al
record should include a
the date they were mad
any repairs or adjust me
employees should folio
as those'contained in th
company or other safety

maintenance work should be kept. The


ist of periodic checks and tests made,
,the condition of the equipment, and
ts that were performed. Maintenance
all recognized safety practices, such
National Electrical Code, OSHA and in
regulations during maintenance.

For specific information egarding the maintenance of devices,


such as circuit breakers, relays, meters, etc., refer to the separate instruction book fur ished for each device.
1. Periodically inspect s itchboard, while under load to determine if there is any ind cation of overheating. If overheating or
any other unsatisfact ry condition is found, completely deenergize switchboar and investigate. Particularly look for
loose bolts and conn ctions, or overloading. Remove any
accumulation of dirt 0 other foreign matter in enclosure. Do
not touch live parts wile switchboard is energized
2. Plated parts may bec me dark over a period of time due to
oxidation. Do NOT re ove this discoloration, as it will reduce
the thickness of the pi ting.
3. Retighten lugs and joi ts to eliminate possible heating points
Transmittalofvibratio through building structure and conduit
to switchboard may I osen lugs and joints. Turning load off
and on causes expan ion and contraction between lug and
cable tending to loose lug.
4. Do not open sealed br aker or trip units as calibration may be
disturbed. Return to f ctory for any replacement.

AMBIENT TEMPERATURES AND


CIRCUIT LOADING
Switchboards are designed for installation where average ambient temperature will not exceed 40C (104F). For higher temperatures, derating may be required. The conductor
temperatures within the enclosure may be as high as 80C
(176F). Some parts of breakers, switches and fuses may run
hotter. In accordance with NEC Art. 384-16(c) it is recommended
that thermal-magnetic molded-case breakers in switchboards
not be loaded in excess of 80% of rating where load will continue
for three hours or more, even with ambient-compensated
breai,ers.

SHORT CIRCUITS
Normally, the overcurrent protective device on the circuit will
prevent any electrical damage except at the actual point of shortcircuit. A thorough inspection of the entire system after any large
fault current should be made to insure that there has been no
mechanical damage to conductors, insulation or equipment.
In addition, the individual overcurrent protective device or devices which performed the short-circuit interruption must be inspected for possible arcing damage to contacts, arc chutes
and/or insulation. Do not open sealed devices such as breaker
trip units or 150A frame breakers. If there is any possibility that
sealed units may have been damaged, they should be replaced.
For additional details on the particular device involved, refer to
the applicable individual instruction book.

ARCING DAMAGE TO INSULATION


Some organic insulating materials carbonize when subjected to
the heat of an electrical arc and lose their insulating qualities.
Any insulation found to be carbon-tracked must be replaced
before applying power.
(Continued on Page 12)

Switchboard Maintenance (Cont' d)


WATER-SOAKED EQUIPMENT
1. Completely de-energize switchboard.
2. Carefully clean and dry all parts of the switchboard. When
using heaters, do not exceed 180 degrees F.

3. Replace all fuses.


4. Individual devices should be inspected for the possible entrance of water, dirt or foreign matter.
5. Do not open sealed devices such as breaker trip units or
150A. frame breaker. Replace them.
6. Prior to re-energizingthe switchboard it should be meggered.
Refer to testing and inspection section on page 7.
7. If assistance or guidance is required contact your local service engineer. Your supplier's service shops have facilities
for reconditioning.

SPARE PARTS
A spare parts stock for the components of the switchboard,
such as bus, insulators, etc. is not recommended. When components need to be reordered, please refer to the nameplate
marking, shop drawing number, and order by description. A
spare parts stock of devices such as circuit breakers, meters,
switches, etc. will vary due to the variety of installations. Your
supplier sales engineer will be glad to assist you in the proper
selection for a device stock list.

GE Electrical Distribution & Control


General Electric Company
41 Woodford Ave., Plainville, CT 06062
GEH2621C 0989 PS

1989 General Electric Company

BI006008

BI006008 CH21"3A

INSTRUCTIONS

Outdoor Dielektrolill
Power C~pacitor Units

GENERAL SAFETY INSTRUCTIONS

nal resistors. W,th these types of units. the d;5con~cting.


shontng and g'oundmg procedures indtcated abolle must be
followed and should be accomplished by utt/iling an e"ter
nal d':,;charge res'stor of at least the 'res;stance 'n ohms
equal to the mal(imum cha'ge voltage that may have been
on the capacilor. The shQrting con~tion between ter
monaIs should be left on until the un't ;s recQflnected 'n the
c"cuit.

The objecttv of these instructions is to help ma"-e


capacttor use's a a'e of appltcat.on and handltng practices
wh'ch w.lI atd th m in the use 01 power capactlors. The
guides cover go
practices in recetving. handlIng. installa
t;on. fustng. fteld testing and d.sposal of power capacItor
untts. The guides 0 not address themselves to the requ"e
ments of nat,onal ndlor local codes. nor to requirements of
insurance under iters. which may be appltcable to any
given capacItor a Ilcation. Compliance Wtth codes and tn
surance unde,wftt 'so ,equtfements demand IndIvidual con
siderahon on tlte an of cilpac;tor users for each part.cular
situal'on and shou d not be assumed 10 have been achIeved
s,mply by compl tn9 with the suggest,ons contaIned In
these tnstructions

EXPlOSION HAZARD
The COffect applicat;Qfl of capacitor fuses will greatlv
minim.,e the posslbiltty of case ruplure; but s'nce con
s,derable stored energy may be available upon the occur
rence of a fault 'nSlde a capacitor .t IS possib~ to get e.
p'os,ve case rupture ,n any apPlieation. even with proper
fusing. for three phase capac'tors fused only on two ter
m,nals or Stnglephase twobushing unIts on onlv one ler
m.nal. and aPD'.ed on della or ungrounded wye systems. all
tnternal ground fault from the unfused phase to case mIght
result "1 case rupture. These remOle poss;bil,hes must be
conSIdered when locattng the capaC'IofS or eqUlpments

PROTECTION AGAINST SHOCK


CAUTION:
WfR MUST BE SWITCHED OFF
. BEFORE DO G ANY WORK ON CAPACITORS
OR EOUIPiIIf NTS 10 BE CERTAIN THA T THE
CAPACITOR
HAVE BEEN DISCONNECTED
FROM THE
WER SOURCE. IT IS NECESSARY
TO MAKE
VISUAL CHECK FOR AN OPEN
CONTACT D SCONNECT.

If capacitors or equ'pments are not suooloed with fuses.


follow the fus,nq gUIdes recommended in NEMA Standa,d
CPI: ANSI Standard C55. I: the General Electuc Hand
boo"- Seclton 6212. or refer to the nearest General Electltc
Sales OffIce.

After be'ng isconnected. th~ capacitors or equip.


ments should tlten be shorted and grounded as follows:
Capacilo's fo shunt or series application on power
systems have .nte nal discharge resistors Iso ,ndlc~ted on
the nameplatel wi .ch are deslg~d 10 reduce the voltage.
after the power is switched off. to 50 volts or less in ten
mmutes If an un rglound or submersible type. in I,ve
n"nutes for all ot ers rated over 600 volts. and on one
mmute for all othe s rated 600 volts or less. Afler the in
dicated time. the c pac'tor or equipment shQuld be shorted
and grounded by tilu,ng an insulated groundtng stic"- or
equivalent and the the cap~c;tor teH"onals should be con
nected together a
to the case and grounded before han
df;ng.
Other types
f capacitor un'ts such as dc energy
storage. dc filter an pulse forming applieat,ons. and ce,tatn
types of .nduction
at,ng capacitor unIts do not have ,nter

HANDLING OF FAILED CAPACITORS

Some faIled capacilors may be found considerably


bulged due to internal pressure from gassing prior to CtfCud
clear'ng. Such unIts should be handled very carefullv A
latled capactlor should be sholled with su;table .nsulated
shorllng st.d<s. to dtscharge any res,dua' charge. It is fUf
ther recommended that a bulged capacitor be permitted to
cool before handlmg. This w,lllower the interna' pressure.
reducong the poss,bilitv of case rupture w,th lea"-aye of
gasses and lIqUId during subsequent handling.
WARNtNG: AVOID liQUID CONTACT WITH THE
SKIN AND EYES AND EXPOSURE TO FUMES IN
AN UNVEN TIL A TED AREA.

GENERAL. ELECTRIC

BI006008

GEH-2743, Outdoor Dielektrollll Power Capacitor Units


COMBUSTIBLE IMPREGNANT FIRE HAZARD
These capacitors contain a Class IlI.B combustible
liquid which could possibly ignite if there is a case puncture
or rupture in the presence of en electrical arc. Capacitors
should be suitably protected from mechanic.' damage end
located where possible fire would not result in damage or
haJ:ard (0 the surrounding are.

DISPOSAL OF CAPACITORS OR
IMPREGNANT
The impregnating liquid used in this capacitor is Dielektrol III, a biodegradable material. Incineration. or other
disposal should be in accordance with Federal. State and
local Regulations.

APPLICATION
The General Electric power capacitor is designed for
use on power systems to supply leading kilovars. These
leading kilovars reduce line thermal loading and system
losses and raise the voltage level at the point of application.
The capacitor units may be mounted indoors or outdoors.
either singly or in banks.

RECEIVING
Check the capacitor when received to mak.e sure that
no damage occurred during shipment. Minor damage such
as small dents will not harm the unit's performance, but.
units with large dents, leaks or broken bushings should not
be install~d. See the section on "Maintenance" for the
method of handling units with leaks. In case of major
damage. file a claim against the. carrier and also notify the
nearest Sales Office of the General Electric Company for instructions regarding the d.sposition of the capacitor.
Check the capacitor nameplate to make certain that the
capacitor voltage rating is the same as the applied voltage.
According to NEMA Standard CP-l the recommended mal<'
imum continuous-work.ing voltage to be applied to tht:
capacitor shall be 110 percent of the nameplate rating. The
peak continuous work.ing voltage, including all harmonics.
shall be 1.1 x V2 x the nameplate voltage rating. Any lower
voltage is permissible.

Capacitors may be installed indoors or outdoors.


Capacitor units may be stored and operated in any position;
but for most efficient heat dissipation during operation, one
of the large sides should be vertical and. preferably. the
bushings should be vertical. Minimum spacing between
large sides of adjacent units should be 1"1. inches.
When capacitors are mounted in hangers, it is recom
mended that both the capacitor case and the hanger {" it is
metal) be grounded to eliminate the minor shock which may

"'~UuC(.onJ do nol pU'PO"

10

co""~, 4JJ d<1.'/~

TWO-bushing capacitors are generally furnished with


parallel groove connectors and associated Belleville
washers. Single-bushing capacitors are generally furnished
with one Belleville washer plus a nut for use with bus bars.
The parallel groove connectors will accommodate from one
No. 10 Awg solid to two No.2 Awg stranded-copper conductors, as well as equivalent sizes of aluminum. When attaching conductors to the connectors. back 011 the nut to
the top of the terminal stud; then. slip the conductors in
from the side. There is room to do this for combinations of
all eKcept two conductors of the largest size, where it wilt
be necessary to remove the nut (unless the second conductor terminates at the terminal and can be slipped in from the
end!. Bus bars may be used for interconnecting capacitors.
To attach bus bars. all that is required is one Bel/eyille
washer and the nut placed over the bus bar.
The connectors are plated to keep corrosion to a
minimum. However. when aluminum conductors are used.
especially in a salt or corrosive atmosphere, the slow
galvanic action caused by the contact of different metals
can be avoided if an oKidation preventative such as
Penotrox A (Burndy Co.l Of No-ox-id (Dearborn Chemical
Co.l is used to coat the aluminum conductor at the point of
connection.
When tightening the terminal nuts, it is necessary only
to flatten the Belleville washers_ This provides yisual indication of sullicient tightening and results in follow-up
pressure on the conductors of approximately 1000 pounds.
Tightening to more than 25 foot-pounds is not required or
recommended.

AMBIENT TEMPERATURE
High operating temperatures wilt reduce the life of a
capacitor. For single- tier. open installations outdoor's with
unrestricted air circulation. maximum permissible ambient
temperature is 46 C (115 Fl. Installing capacitor units in
tiers. one above another, reduces the maKimum permissible
ambient by 3 C (6 Fl per tier. Non-standard arrangement or
applications where higher ambients will be encountered
should b", referred to the nearest Sales Office of the General
Electric Company for recommendations.
For capacitors mounted indoors. the maKimum permissible ambient temperature is 40 C (104 Fl. Units should
be located so as to minimize the transfer of heat into the
capacitors from adjacent equipment. and free circulation of
air around the capacitors should be provided.

INSTALLATION

'''<st!

be obtained from the small charging current between the


line terminals and the case. Stainless-steel cases have an
unpainted surface under the moonting bracket so that contact is made between the capacitor case and hanger. thus
facilitating grounding by means of a single conductor to the
hanger.

01

Capacitors may operate continuously at any low


temperature. However. if the internal temperature of an
unenergized capacitor drops to less than - 40 C (- 40 Fl.
the unit should not be energized. The unit then must be
brought to at least - 14 C (7 Fl before it may be energized
without possibility of damage. For this reason, if extremely
low temperatures are anticipated, it is advisable to switch
capacitors onto the line to keep their internal temperature
above the critical point.

.,.".(to,,~1m ~qu'pm-et11 n~ 10 p'o',df!: 10' ttvt!fy POSj,bJc COt1(;ng-ency to ~ ~(." conn<ct~ ""th,.,,.

J/.a.I#Qn. O~'4I.on. 01 nJ4.nn4n<;t! Should I~(lkf mlo,m41lOn b< cJff:su~d (.II should P41tlCul.r p'ot:llcm~ .f;S."
Ch4S<'"J p.ulPO$~j. t/k rrJ4Utr' ~ftoukJ b< ,ltCu~d to f" Gtr~,.J Ekc-,,,< COtTIp4ny.

_IKn ..ft! not cov.. ,tt</ $U(hc""ttly'~thtr~.

Outdoor Dielektrollll Power Capacitor Units,


GEH-2743
BI006008

FUSING A 0 LIGHTNING PROTECTION


Capacito s should be fused either individually or in
groups to is late failed units from the system and to
minimi~e oc urrence of case rupture in the event of
capacitor fail reo Types of fuses and ratings for specific applications are listed in Section 6212 of the General Electric
Handbook, 0 information may be obtained at any General
Electric Sales Office.
Cutouts
as possible t

sed for switching should be opened as rapidly


minimj~e arcing.

mmended that capacitors be protected by


suitable 'ight ing arresters connected to the terminal with
as short a lea as possible and with all grounds connected
together. As a general rule, arrester average sparK-over
voltage with a 1.2 x 50 wave should be less than two-thirds
the BIL rating f the capacitor. Ratings of recommended ar
resters are lis ed in Section 6212 of the General Electric
Handbook, or information may be obtained at ar'Y General
Electric Sales Wce.

MAINTENANCE
al service conditions, once a capacitor is installed no furt r maintenance is required during the life of
the unit. Re inting of the units may be desired for appearance, a
periodic cleaning of the bushings may be
necessary in ontaminated atmospheres to prevent arcover.
Capacitor
they are opera
used, the cap
energj~ing (ref
mediately feel
warm.

may be inspected periodically to see that


ing. If indicating protective devices are not
citor can be checked most easily by derence Protection Against Shockl and 'img the case liide. An operating unit will be

If a leak ccurs in the capacitor, the hole should be


sealed with sol er, using alcohol-rosin flux. When this is im-

pos~ible or if a bushing is broken, or if a large quantity of liq-

UId ,mpregnant is lost, cover the ho4e to prevent the entrance of dirt and further loss of liquid. The poss'bdity o( factory repair is dependent upon the extent of the damage:
therefore, contact the nearest General Electric Sales Ofrice
for recommendations regarding disposition.
Units with large dents may be checked for operation as
described under "Testifl\j." If such testing is impo,ssible or II
results are unsatisfactory, contact the nearest General Elec
tric Sales Office regardi~ the possibility of factory test and
repair.

TESTING
field tests may be made to evaluate the operating con
ditions of the capacitor. Such tests are warranted only if
trouble is indicated or if the unit has been damaged. for further tests or details, see NEMA Standard Publication
CP1-1976 (or latest issue).
1. Open circuits, internal short circuits, and \(VA
capacity can be tested by measuring the current taken by
the capacitor when coonected to a suitably protected cir
cuit of rated valtage end good weve form.
2. For two-bushing units only, the insulation between
terminals and case can be tested by applying rated voltage
between short-circuited termiOills and case. from a suitably
protected test source.

WARRANTY
The following basic intorfTl<ltion must be provided with
respect to warranty claims:
Serial number, date in service. date failed. type of in,
stallation (i.e. pole type. stack rack): fiKed or switChed, conditions at the time of failure. 00 not scrap an in-warranty
capacitor unless authorized by manofacturer.

BI006008

GENERAL ELECTRIC COMPANY CAPACITOR PRODUCTS DEPARTMENT HUDSON FALLS N.Y. 12839

GENERAL. ELECTRIC

GEH30711
Supersedes GEH3071"
and GEH-307.

BI006008

INSTRUCTIONS

GROUND-FAULT AND DIFFERENTIAL RELAYS


IC2820Al02

Before any adjust ents, servu:tng, parts replacet is performed requiring physical contact with th electrical working components
or wiring of this quipment, the POWER SUPPLY
MUST BE DISCO ECTED.

GENERAL
The IC2820AIO ground fault Relay is designed
to be used as a f st-acting. manually reset relay
to interrupt contr I power of a line contactor upon
sensing a ground c rrent in the lines to an ac motor
load or other ac e uipment. If a ground fault can
be removed with'n a few cycles of its initiation.
damage to a mot r or other ac equipment can be
WINDOW-TYPE
CURRENT
TRANSFORMER
PRJ.

minimized. For example, on a large induction or


synchronous motor when an insulation failure occurs to ground, the fault current will be removed
before damage is done to the laminations; thus
making it possible to repair the motor at a minimum
of expense and down-time.
The IC2820AI02 differential relay detects any
difference in current going in and out of each phase
of a wye-connected motor. This current difference
will trip the differential relay and shut down the
motor by opening the motor line contactor. Separate
relays and current transformers are connected in
each phase to the motor.

DESCRIPTION
As shown in the elementary diagram (see Fig. 1
.rnd 2) the ground-fault and differential relays are
designed for use with a window-type current transformer. The IC2820AI02 ground-fault relay and the
IC2820AI02 differential relay are identical in construction and differ only in application.
LI

LINES TO MOTOR
L2
L:3

D
WYE POINT OF
MOTOR WINDING

ELEM NTARY DIAGRAM

:3 WINDOW-TYPE
CURRENT
TRANSFORMERS
:3 RELAYS

ELEMENTARY DIAGRAM

[E
A

oB oC
oC

RELAY

Fig. 1.

Elementary
cuit,/C282

RELAY TERMINALS

of ground.fault relay cir-

Fig. 2.

Elementary diagram of diHerential-relay circuit,


IC2820A 102. One relay and current transformer
are connected in each motor phose.

These instructions do 01 purport to COYer all details or variations in equipment nor to provide for every possible contingency to be met in connection
with installation, operoti n or maintenance. Should further information be desired or should porticulor problems arise which are not covered sufficiently
es, the matter should be referred to the General Electric Company.
for the purchoser's pur

GENERAL

fj ELECTRIC

BI006008

GEH-307JB IC2820AJ02 Relays

'

ARMATURE STOP
SCREW

.. 1

'P"NOV'~~.

ARMATURE

OPENON'

'/

A,
LATCH

SHIMS

..

~ ~ -,"~.

CORE
HEAD

SPRING
SEAT

Fig. 4.

Fig. 3.

Reset lever in TRIPPED position

When a ground fault occurs, the vector sum of the


currents in the cables through the 'Window 'Will not
equal zero and this sum 'Will cause a current in the
secondary of the current transformer that 'Will
energize the relay coiL This current 'Will actuate
the relay to TRIPPED, This tripping time is approximately 13 milliseconds. When the relay trips, the
normally-open contacts short out the rectifier and
coiL
Also actuated at this time are a second set of
contacts that may be either normally open or
normally closed, The trip lever holds the relay in
the TRIPPED position until the lever is moved in
a counterclock'Wise direction to the RESET position,
Figure 3 shows the resetlever in the TRIPPED position and Fig, 4 shows it in the RESET position,

CONNECTIONS
The secondary of the current transformer should
be connected to terminals A and D on the relay.
Those connections for use of the normally open or
normally closed contacts to be used in the control
circuit are made at terminals B and C on the contact block.
2

Reset lever in RESET position

MOUNTING
The relay should be mounted on a vertical surface
'With the armature fulcrum at the top and the contacts at the bottom.
When mounting the relay, the proper NEMA
standard for electrical clearance and creepage to
conducting parts and to ground must be maintained.

ADJUSTMENTS
The following adjustments are made at the factory
and should not need to be changed. It 'Will be necessary, however, to readjust or at least to recheck
the adjustments after replacing parts.
1. ARMATURE GAP - Adjust the armature stop
screw, see Fig. 4, so that the armature gap, measured between the armature shim and edge of core
head, Point A, Fig. 4, adjacent to the contact block,
is 0.072 to 0.078.

2. RELAY LATCH - The lever should turn


freely to the fully latched position when the relay
is slowly closed manually and must not bind in any
position of the lever arm. While holding the relay
closed and armature assembly against the core
head, there should be approximately 1/64 in.
clearance between the shim and latch. The latch
must be easily returned to the RESET position.
See Fig. 4.

BI006008

IC2820AJ02 Relays GEH-3071B

SPRING
SPACER

'"=::::+=+:t:::;

N.C.
TIP GAP-

Fig. 5.

U~::;R=~- N.O.
TIP WIPE

Universal lectrical interlock with one set of


normally 0 en contacts, and one set of normally
closed cont cts in the operated position

3. CONTACT GAPS AND WIPES - With the


armature closed nd resting against the latch, the
contacts should h ve a gap of 1/16 in. minimum or
a wipe of 1/32 in. minimum. See Fig. 5.
4. ARMATUR OPENING SPRING - The armature opening spri g (see Fig. 3) is adjusted so that
the relay will pi up cleanly with 10 amperes in the
primary of cur ent transformer JCH-O (ratio
300:5) or 11 a eres in the primary of current
tranSformer JCS- (ratio 100:5).

AINTENANCE

COILS
To replace coi s, first remove the armature assembly and latchi g mechanism as a unit by remov-

ing the two screws "B" as shown in Fig. 3. This


eliminates the possibility of disturbing any adjustments. Then, remove the two fiat-head screws
that secure the core head to the core. After replacing the coil, replace the core head making certain
that the fiat-head screws are tightened so that the
heads of the screws are below the surface of the
core head. Replace the armature and latching
mechanism. Perform the necessary checks as
described under ADJUSTMENTS.

CONTACTS
To replace contacts, lift the spring seat, (Fig.4)
with the thumb and forefinger and remove the entire
movable contact assembly. Snap off the "U"shaped keys and the movable contacts can be removed. Care should be taken that the operating
spring and spring spacer, if removed, are not
lost during this operation.

To remove the stationary contact tip assembly,


remove the terminal screw and lift the contact tip
off the housing. To replace the tip assembly, press
it onto the brass insert molded into the block and
tighten the terminal screw. Care should be taken to
avoid changing the shape of this contact assembly
in handling.

CONTACT RATIN S (in Amperes)


Interrupt
*Dc Inductive

Carry

10

60

tAc

125V

250V

600V

110V

220V

440V

600V

1.8

0.5

0.2

1.5

1.2

*Noninductive dc . terrupting rating is 1. 5 times inductive.


t Capable of inter upting inrush currents of 60 amperes at 110 volts, 30 amperes at 220 volts, 15 amperes
at 440 volts and 2 amperes at 600 volts a limited number of times.

,~

BI006008 -\.
I

GENERAL ELECTRIC COMPANY, U.S.A.


INDUSTRIAL CONTROL DEPARTMENT

GENERAL" ELECTRIC

VI7-771

Instructians Fa

BI006008

GEH-324

NEMA Size 1

8200-Line
CR20S/CR206
Magnetic Contactors
& Starters
Caution: Before in tailing in a nuclear
application, determine hat the product is intended for such use.
Warning: Disconn ct power before installing or servicing.

Description
General Electric 200-Li e full-voltage magnetic motor starters inc ude an open or enclosed magnetic conta tor and a three-leg
block overload relay, p oviding motor protection against running an stalled motor overloads. Separate motor ranch circuit overcurrent protection agai st electrical faults
should be supplied in ccordance with the
National Electrical Cod .

MAGNET
ASSEMBLY
WELD CHECK
OPERATOR

OVERLOAD
RELAY

ADJUSTMENT DIAL

Figur

SLOTS

1.

Ratings
Max.
Voltage

Contactor

600

30 Amp
(open)
27 Amp
(enclosed)

AC
olts

Maximum

Current
Rating

115
200
230
4 0-575

Maximum HP
For AC Motors
Single
Phase

Polyphase

71/2

71/2
10

Installation
Three-point mounting,
wiring saves time, mak
Before connecting star
1. Remove all packing.
2. Clean magnet matin
foreign matter.
3. Install overload relay
overloading the start
heaters for a motor
given on the starter

traighHhrough
s installation easy.
r to power supply:
surfaces of any dirt
heater(s). To prevent
r, do not select
f a larger rating than
ameplate. Select

heater(s) in accordance with heater table,


which accompanies each starter unit.
4. Operate movable magnet and operating
arm by pressing on the nameplate to assure free movement.
5. Mount starter on a sturdy vertical support.
6. Make electrical connections, which are
quick and convenient, due to 12 knockouts provided in NEMA 1 enclosures,
straight through wiring and pressure terminals.
7. The three-leg block overload relay, included on the starter, is furnished from
the factory adjusted for manual reset.
(shift lever is in upper slot). The relay
may be adjusted for automatic reset by
positioning lever in lower slot.
Caution: Overload relays, when adjusted
for automatic reset, should not be used with
two-wire, maintained contact pilot devices
such as pressure, float and limit switches,
as inadvertent restarting of the motor can
occur.

Coil Removal

(Refer To Figure 3)

The encapsulated coil is impervious to


moisture, contaminants and oil. It resists
mechanical damage and failures due to high
humidity. No tools are required to remove
coil.
1. Remove power from device.
2. Press against coil while pulling up slightly
on coil retainers (A-Figure 1) and move
retainers away from coil.
3. Withdraw magnet assembly, coil, molded
cover and movable arm from device.
4. Withdraw spring clip (B-Figure 1) and remove armature from movable arm.
5. Remove coil from magnet.
6. Reassemble device by reversing procedure.

Contact Removal
Movable contacts can be inspected and
replaced in seconds-without tools.
1. Perform steps 1 through 5 under Coil
Removal.
2. Remove magnet from molded cover and
movable arm.
3. Remove return spring from center of
movable arm.
4. Remove molded cover from movable arm.
5. Depress and slide movable contact,
spring and spring seat from movable arm.
6. Remove screws holding stationary contacts in place and remove stationary

contacts.
7. Reassemble device by reversing procedure.

CONTACT

SPRING

Figure 2

Note: For starters with one or more normally closed contacts, perform steps 1 and
2 shown under Coil Removal. Withdraw
spring clip (B-Figure 1) and remove armature, coil and magnet from device.
Remove return spring from center of
movable arm. Remove molded cover and
stationary contacts before lifting movable
arm from device.

Normally Closed Contacts


The contact on this device may be converted from normally open to normally
closed with no additional parts. Perform
steps 1 through 4 shown under Coil Removal.
Lift coil and magnet from movable arm.
Remove return spring from center of
movable arm. Remove molded cover from
movable arm. Depress movable contact
spring and spring seat against movable
contact and rotate these parts 1h-turn
without removing them from window.
Remove the stationary contacts. Install the
movable arm in the device. Install the stationary contacts so that their silver pads
face the movable contact silver pads.
Reassemble the Ijevice. To change contacts from normally closed to normally
open, reverse thE! above procedure.

GENERALfj ELECTRII

BI006008

Check For Welded Contacts


In Overload Relay
This feature permits the maintenance man to check for welded contacts by simply depressing the brown operator located at the top of
the overload relay contact housing. When the relay is in a reset condition, an audible click will be heard when the operator is depressed,
indicating that the contacts are operating normally. A continuity
check can also be made by disconnecting the control wiring from the
terminals of the relay and placing a bell set or a resistance measuring instrument in the circuit. Connecting either of these across the
relay terminals will indicate the relay contact is closed until the
contact-check operator is depressed, interrupting the circuit.
The exclusive manual contact-operation check gives positive
assurance that contacts have not welded due to short circuits in the
control wiring.

Simple Maintenance

tip support is exposed. DO NOT FILE the contacts. Filing or otherwise dressing the contacts only results in lost tip material and
reduces contactor or starter life.
5. The ultimate tripping current of the installed relay heater can
be adjusted the 10% by using the adjustment dial shown in
Figure 1.

Coil Data

Order 15D21G plus number per table below.

Frequency

115V

2001
208V

230V

460V

575V

600V

60 Hertz

002

023

003

004

005

006

Frequency

110V

220V

380V

440V

550V

600V

50 Hertz

007

008

004

009

010

011

Use 022 for 120V, 60 Hertz/110V, 50 Hertz coil.

Accessory Kits

200-Line starters and contactors require virtually no corrective


maintenance. Preventive maintenance will assure many years of
dependable on-line service.
1. Always remove power from device before performing any maintenance.
2. Keep magnet mating surfaces free of accumulated dirt or dust.
3. DO NOT OIL OR GREASE the magnet mating surfaces.
4. Contacts are carefully designed for maximum life. They need only
be replaced when nearly all the silver tip is gone and the contact

1 st NO aux cant for CR205, CR206


1 st NC aux. cant for CR205, CR206
1 st NO-NC aux. cant for CR205. CR206
Additional NO aux. cant for all forms.
Additional NC aux cont for all forms
Pushbutton
Selector swifCh. H-O-A
Selector switch, OFF-ON
Indicafing light
Fifth pole
Control circuit fuse

CR205X1 OOA
CR205X100B
CR205X1 OOC
CR205X100D
CR205X100E
CR205X120N
CR205X130N
CR205X130P
CR205X150N
CR205X111 B
.CR205X141A, B, C, D

When reassembling, note that the magnet and movable arm assembly
(Items 4 through 9) will fit ONL Y ONE WAY The magnet, Item 7, and
movable arm, Item 6, will fit either way but will be quieter if reassembled the same way they were taken apart.

Principal Renewal Parts


Quantity Required

Ref.
No.

Catalog Number

Description
Coil retainer assembly

1
2
3
4
5
6
7
8
9

Overload relay (3-heater, non-compensated form)


Set of stationary and movable contacts with springs and screws for 4 polos
Molded cover for stationary and movable contacts

Return spring for movable contact support


Molded movable contact support 2, 3. 4 pole
Armature and frame (magnet)
Operating coil
Spring retainer for armature

546A301 G008
CR224C310F
546A301G002
546A301 G012
541 A278POOI
187D350P001
546A301 G005
15D21G* * *
546A588P001

CR205

CR206

2
1
1
1
1
1
1
1
1

1
1
1
1
1
1
1

* * * Add suffix number for particular coil rating required. See Coil Data above.
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with instalfation, operation or maintenance.
Should further information be desired or should particular problems arise which are not covered sufficiently for the Purchaser's purposes, the matter should be referred to the nearest General

Electric Sales Office.

GEH3247F

For further information


call or write your local
General Electric
sales office or distributor.
Or write ...

General Electric Company


General Purpose
Control Department
P. O. Box 2913
Bloomington, IL 61701

GENERALfj ELECTRIC
3/83

(10M)

Printed In U.S.A.

GEH<
BI006008

. . ._c_o_"__tr_o_l_
CAUTION: Before installing in a
nuclear application, determine that the
product is intended for such use.

NEMA SIZE 1

CR209 rna netic reversing controller


DESCRIPTION
The various forms of
Magnetic Reversing C
two CR205 mechanicall
terlocked contactors eith
bination with a three-Ie
providing motor protect
and stalled motor overl
branch circuit over against electrical faults
in accordance with th
Code.

the CR209 Size 1


trollers consist of
and electrically inr alone or in comblock overload relay,
n against running
ds. Separate motor
current protection
hould be supplied
National Electrical

CROSS

EASE OF INSTALLAT ON
Three- point mountin , straight - through
installation easy.
wiring saves time, mak
to power supply:
Before connecting start

RELAY

1. Remove all packing.

MOVABLE PORTiON OF MAGNET ASSEMBLY

2. Clean magnet mati g surfaces of any


dust or foreign matter
3. Install overload relay heater(s). To prevent overloading the tarter, do not select
heaters for a motor of a larger rating than
given on the starter nameplate. Select
heater(s) in accordan e with heater table,
which accompanies ea h device.
4. Operate movable ma net and operating
arm by pressing on t e nameplate to assure free movement.
5. Mount starter on a stu dy vertical support.
6. Make electrical conn ctions, which are
quick and convenien due to 12 knockouts, straight throug wiring and pressure terminals.

SIMPLE MAINTENAN E
200- Line starters and
virtually no corrective
ventive maintenance will
ov dependable on -line se

contactors require
maintenance. Preassure many years
ice.

1. Always remove powe from device before


performing any maint nance.
2. Keep magnet mating urfaces free of accumulated dirt or dus .
3. DO NOT OIL OR G EASE the magnet
mating surfaces.

FIGURE 1- Typical CR209 Magnetic Reversing Controller


4. Contacts are carefully designed for maximum life. They need only be replaced
when nearly all the silver tip is gone and
the contact tip support is exposed. DO
NOT FILE the contacts. Filing or otherwise dressing the contacts only results
in lost tip material and reduces contactor
or starter life.
5. The ultimate tripping current of the installed relay heater can be adjusted :!:10'70
by using adjustment dial.
6. The mechanical interlock has been factory
adjusted and normally should never have
to be re-adjusted. If re-adjustment is
ever needed, the following steps should
be followed:
6A- Close one contactor by hand by
pushing down on armature.
68 - Using the other hand, loosen the
nut on opposite contactor interlock
arm and slide it towards the top of
the elongated slot until all gap is
taken up between the two arms.
Follow the same procedure with the
opposite contactor and interlock arm.
6C - Best adjustment is usually obtained

when both mechanical interlock arm


assemblies are as far up in theelongated slots as possible.
6D - With both arms adjusted, there
should be a very slight gap (1/16'
approximately) between the arms
with both contactors open. Neither
arm should overlap each other with
both contactors open.

CAUTION: Before adjusting or operating reverser, make sure the mechanical interlock
arm is engaged with movable contact arm.

EASY COIL REMOVAL


The totally encapsulated coil is impervious
to moisture, contaminates and oil. It resists
mechanical damage and failures due to high
humidity. No tools are required to remove coil.

1. Remove power from device.


2. Press against coil while pulling up slightlyon coil retainers (A - Figure 1) and move
retainers away from coil.
3. Withdraw magnet assembly, coil, molded
cover and movable arm from device.
4. Withdraw spring clip (B - Figure 1) and
remove armature from movable arm.

GENERAL. ELECTR

-3620

BI006008

5. Remove coil from magnet.


7. Reassemble
cedure.

device

arm. Remove molded cover from movable arm.


Depress movable contact spring and spring
seat against movable contact and rotate these
parts 112 turn without removing them from
window. Remove the stationary contacts. Install the movable arm in the device. Install
the stationary contacts so that their silver
pads face the movable contact silver pads.

tacts in place and remove stationary contacts.

6. Replace coil.

7. Reassemble
cedure.

by reversing pro-

device

by reversing pro-

NOTE: For starters with one or more normally


closed contacts, perform steps 1 and 2 shown
under "Removal of Coil". Withdraw spring clip
(8- Figure 1) and remove armature, coil and magnet from device. Remove return spring from
center of movable arm. Remove molded cover.
Remove stationary contacts before lifting
movable arm from device.

QUICK CONTACT REMOVAL


Movable contacts can be inspected and replaced in seconds - without tools.

1. Perform steps 1 through 5 under "Removal of coil".


2. Remove magnet from molded cover and
movable arm.

Reassemble the device. To change contacts


from normally closed to normally open, reverse the above procedure.

RATINGS

NORMALLY CLOSED CONTACTS

3. Remove return spring from center of


movable arm.

Max
Voltage

The contacts on this device may be converted from normally open to normally closed
with no additional parts. Perform steps 1
through 4 shown under "Removal of Coil".
Lift coil and magnet from movable arm. Remove return spring from center of movable

4. Remove molded cover from movable arm.


5. Depress and slide movable contact,spring
and spring seat from movable arm.
6. Remove screws holding stationary con-

REPLACEMENT CONTACTS AND COIL


Complete set of stationary and movable contacts with

600

Max h-p

Confactor

Max

A-c

Current
Rating

Volts

30 amp

115
230
460-575

Poly phase

Single.
phase

(open)

27

for a - c motors

amp

2
3
5

7'1>

10

(enclosed)

COILS
Order Coil by Cot. number plus number in table.
EXAMPlE:CaI.15D21G2 is rated 115V 60 Hz.

springs and screws:-

For I Pole.
For 4 Pales
Coil 12 req'd!

. .. Col. 540A301 G I
Col. 541,A301 G2
. Cot. 15D21 G I:see table'l

Freq (Hz)
60

115V
2

230V
3

460V
4

575V
5

600V
6

Freq (Hz)
50
25

110V
7
17

220V
8
18

440V
9
19

550V
10
20

600V
II
21

Accessory Kits
1 st addltonal NO aux. cant. for all forms.
1 st additional NC aux. cant. for all forms.
2 nd additional NO-NC aux. cant for all forms except 2-speed single-winding controllers.
Control circuit fuse ..

CR205X100D
. .. CR205Xl00E
. CR205X1 OOZ
.CR205X141A. B.C. D

2.

10

PRINCIPAL RENEWAL PARTS


Ref.
No_
1
2
3
4
5
6
7
8
9
10

Description

Coil retainer ossemblv

Overload relay
Set of stationary and movable contacts with springs for one (1) pole
Molded cover for stationary and movable contacts
Return spring for movable contact support
Molded movable contact support 2, 3, 4 pole
Armature and frame (magnet)
Operating coil
Spring retainer for armature
Overload relay-2 speed single winding controller

* 2,

3 and 4 pole contactors require the same quantity of contact sets as the numof poles.

GENERAL ELECTRIC COMPANY


GENERAL PURPOSE CONTROL DEPARTMENT
BLOOMINGTON,ILLINOIS61701
3/83

Quantity Required

Port
Number

546A301 G8
CR224C210F
546A301Gl
546A301 GI2
541 A278Pl
187D350Pl
546A301 G5
15D21G
546A588Pl
CR224G210G

Left Cantactor

Right Cantactor

2
16

1
I

I
1
I
I
1

t
1
1
I
1
1

1
-

t Quantity 1 for multi-speed controller.


/\ Omitted on 2-speed single-winding controller.

GENERAL. ELECTRIC
Printed in U.S.A.

BI006008

GE Overload Relays
CR124C and CR124D
AC or DC Thermal Overload Relays

Caution:

Before installi
the product is intended for

Warning:

in a nuclear application, determine that


ch use.

Disconnect p wer before installing or servicing.

General
GE's CR124C and D overlo d relays incorporate a dial for 15% field
adjustment of tripping curre t, so that it is no longer necessary to
change heaters to eliminate uch problems as nuisance tripping in hot
weather.
The ultimate tripping current of the installed relay heater can be adjusted 15% by using the djustment dial. Turn dial clockwise to
reduce ultimate tripping curr nt and counterclockwise to increase
ultimate tripping current.

Operation
The motor current is carried through a heater element of a resistance
material (See Figure 1). The overloaded motor increases the current
through the heater and gen rates sufficient heat to deflect the bimetal
strip. The deflected strip ca ses the relay contacts (normally connected
in the control circuit of the agnetic contactor or starter with which the
relay is used) to open, de-e ergizing the control circuit, thereby disconnecting the motor from t e line. The average time-current curves are
shown in Figure 2.
.

Heater Selection
The heaters are of the interchangeable type. A sufficient number of
sizes are available to permit selection of the proper heater for any valUE
of motor full-load current within the range indicated in the heater table.
For continuous rated motors with service factor of 1.15 to 1.25, select
heater with maximum motor amperes equal to or immediately greater
than the motor full load current (provides a maximum of 125% protection). For continuous rated motors with no service factor, multiply the
full load current by 0.90 and use this .value to select heater.

Application And Installaton


The relay, and the controller with which it is used, should be protected
from excessive currents that might result from short circuit by the use a
fuses, the rating of which should not exceEld a maximum fuse size and
rating listed in the heater table. In place of fuses, other branch circuit
protective devices can be used in accordance with the Nationar
Electrical Code.
Heaters should not be selected for motor ratings in excess of the rating
of the controller with which the relay is USEld.
The heaters will ultimately trip the relay in a 40C ambient on a current
which is approximately the minimum value of motor full load current
listed in heater table multiplied by 1.25. Select heaters from this instruction unless a special heater table is supplied with the starter.

I
i

1\

fRIP\

1\

RANGE

\:

\
'\

I
i

"(
,\
,

I\J

i
\

I\:
,

'\

N-

N
l'

Figure 1. CR124C overload elay with cover removed and heater installed.
Figure 2. Average time-current characteristics for
CR124C and CR124D overload relay in 40C ambient.

'he relay contact will carry ten amperes continuously and momentarily
nake 30 amperes, but should not be used to interrupt currents in exess of those listed below.
DC (Inductive)

AC
Volts

Amperes

Volts

Amperes

115
230
460
575

15
10
5
4

125
250

0.35
0.17

The relay should be installed in the vertical position as shown in Figure


1 with the reset button at the bottom. The relay should preferably be
located so that the ambient temperature will be the same as that in
which the motor with which it is used is operating. Heaters for these
relays are ordinarily shipped separately and should be mounted in accordance with the instructions on the heater carton. The two heater
screws indicated in Figure 1 should be removed before mounting the
heater and securely tightened once the heater is mounted.

;eater Tables for Open Starters and


)pen or Enclosed Panel Mounted Overloads

Clamp-type terminals are provided for the heater circuit and are suitable
for use with #8 or smaller wire on the Size 1 relay and with #4 or
smaller wire on the Size 2 relay. The insulation must be stripped from
the end of the wire.

For CR124C
Maximum
Motor
Amperes

Heater
Cat. No.
CR123

Maximum
Fuse
Rating

Maximum
Motor
Amperes

Heater
Cat. No.
CR123

Maximum
Fuse
Rating

.33
.37
.41
.46
.52
.57
.61
.67
.75
.84
.94
1.03
1.14
1.30
1.42
1.61
1.72
1.93
2.10
2.34
2.64
2.86
3.13
3.32
3.68
4.08
4.61
5.21
5.62
6.12
683
7.70
8.48
9.19
9.92

C036A
C039A
C043A
C048A
C054A
C060A
C066A
C071A
C078A
C087A
C097A
C109A
C118A
C131A
C148A
C163A
C184A
C196A
C220A
C239A
C268A
C301A
C326A
C356A
C379A
C419A
C466A
C526A
C592A
C630A
C695A
C778A
C867A
C955A
C104B

3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
6
6
6
6
10
10
10
10
10
15
15
20
20
20
25
25
30
30
30

11.1
12.2
13.5
14.6
16.1
17.9
19.3
20.6
22.6
24.8
27.0

C113B
C125B
C137B
C151B
C163B
C180B
C198B
C214B
C228B
C250B
C273B

35
40
45
45
50
60
60
70
70
80
90

BI006008
The relays are shipped from the factory arranged for hand reset but
may be changed to automatic reset by moving the end of the reset
spring from the upper position to the lower position by lifting out and
down. The two positions are indicated in Figure 3. Automatic reset
should not be used if the control circuit is such that resetting of the
relay will automatically cause power to be reapplied to the motor.

Adjustments should not be attempted on the relay other than that of


changing heaters. The bimetal strip should not be tampered with under
any circumstance. With the exception of heaters, which should be
ordered by Catalog Number, it is not recommended that renewal parts
be supplied.

For CR124D
6.63
7.59
8.39
9.20
9.93
11.2
12.5
14.1
15.5
17.4
19.8
21.2
22.7
24.9
27.3
29.7
33.2
39.0
45.0

C695A
C778A
C867A
C955A
C104B
C113B
C125B
C137B
C151B
C163B
C180B
C198B
C214B
C228B
C250B
C273B
C303B
C330B
C366B

20
20
25
30
30
35
40
40
50
50
60
70
70
80
80
90
100
110
125
Figure 3. View of CR124C overload relay showing automatic and
hand reset spring detent positions.

-leater Tables for Enclosed Starters


For CR124D

For CR124C
Maximum
Motor
Amperes

Heater
Cat. No.
CR123

Maximum
Fuse
Rating

Maximum
Motor
Amperes

Heater
Cat. No.
CR123

Maximum
Fuse
Rating

Maximum
Motor
Amperes

Heater
Cat. No.
CR123

Maximum
Fuse
Rating

.31
.34
.38
.43
.47
52
.56
.62
.69
.77
.87
.94
1.04
1.18
1.30
1.47
1.56
1.75
1.90
2.13
2.40
2.60
2.84
3.02

C036A
C039A
C043A
C048A
C054A
C060A
C066A
C071A
C078A
C087A
C097A
C019A
C118A
C131A
C148A
C163A
C184A
C196A
C220A
C239A
C268A
C301A
C326A
C356A

3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
6
6
6
6
6
10
10
10
10

3.34
3.72
4.20
4.73
5.02
5.55
6.21
6.92
7.64
8.31
9.04
9.99
10.9
12.0
13.0
14.3
15.8
17.0
18.1
19.9
21.8
24.2
26.3
270

C379A
C419A
C466A
C526A
C592A
C630A
C695A
C778A
C867A
C955A
C104B
C113B
C125B
C137B
C151B
C163B
C180B
C198B
C214B
C228B
C250B
C273B
C303B
C330B

10
10
15
20
20
20
25
25
30
30
30
35
40
45
45
50
60
60
70
70
80
90
90
90

6.89
7.76
8.63
9.53
10.7
11.7
12.8
14.3
16.1
17.9
19.3
21.4
226
24.6
26.7
30.0
34.8
40.1
43.3
45.0

C778A
C867A
C955A
C104B
C113B
C125B
C137B
C151B
C163B
C180B
C198B
C214B
C228B
C250B
C273B
C303B
C330B
C366B
C400B
C440B

20
25
30
30
35
40
40
50
50
60
70
70
80
80
90
100
110
125
150
150

These instructions do not purport to cover all


details or variations in equipment nor to provide for every possible contingency to be met
in connection with installation, operation, or
maintenance. Should further information be desired or should particular problems arise which
are not covered sufficiently for the Purchaser's
purposes, the matter should be referred to the
nearest GE Electrical Distribution & Control
sales office.

GE Electrical Distribution & Control


,EH-4729A 0390 BLB

General Electric Company


41 Woodford Avenue. Plainville. CT 06062

BI006008

GEH-41'

. . . ._c_o_n_tr_o_1_

INSTRUCTION
CAUTION: Before installing in a nuclear applil
tion, determine that the product is intended
such use.

CR120B 6

o yolt industrial relay-sERIES A


magnet back into position under retaining clip. Magnet must be centered in
housing window in order for it to seat
properly.

DESCRIPTION
The CR120B Series A
volt multicircuit industrial relay line i cludes the basic
magnetic relay, timer a tachments and
latch attachment. These units plus contact modules and moun ing accessories
provide for maximum flex' i1ity.

CONTACT REMOVAL/CONVERSION

RATINGS
Ac-NEMA A600
M

Max. Currant

Max.

aga

Currant

Maka

Maka

B..ak

10

7200

60

v:~ c Contlnuoua ~_......~-+

600

A II
__
arn..;g_....

Dc-NEMA P300
Max.
Currant Aatlng
125V
1.1

250V

Figure 1.

.55

6. Slide magnet back through coil and


center with housing window. Insert
blade of screwdriver through window,
perpendicular to magnet. Using blade
of screwdriver, push retaining clip
away from magnet and apply pressure
on magnet from opposite side. Snap

138

INSTALLATION
1. Disconnect power fro
2. Remove all packing.
3. Operate the magnet an operating arm
by pulling the manu I operator to
assure free movement.
4. Mount the relay on a ve tical panel.
5. Make all electrical con ections.
Normally open contac s are indicated
bygold and normally cl sed by white.

Contact modllies may be removed, inspected, converted or replaced using only


a screwdriver.
1. Disconnect power from the device.
2. Loosen cover screws or screws above
the appropriate deck and remove.
3. Lift out contact module. Contacts may
be inspected through gold transparent
side of module.
4. To convert contact from normally open
to normally closed or normally closed
to normally open:
a. Remove contact module terminal
screws and reassemble on opposite
side.
b. Replace contact module in deck.
5. Reassemble.

COIL REMOVAL
1. Disconnect power fro
2. Remove from panel, if
3. Insert a screwdriver blade between
magnet and magnet retaining clip.
Twist blade to force re ining clip away
from magnet. Push own on screwdriver, dislodging mag et; then applying firm pressure w th screwdriver,
push magnet through coil to position
shown in Figure 1.
4. Grasp the coil terminal and pull out.

Yake Assembly and Post

TO REASSEMBLE:
5. Insert coil and center i housing.

Figure 2.

Figure 3.

These instructions do not pu port to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with
installation, operation or mai tenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the
Purchaser's purposes, the m lIer should be referred to the nearest General Electric Sales Office.

GENERAL" ELECTRII

EH-4115C

BI006008

INSTALLING ADDER DECK


Additional decks of contact modules
may be added to the relay making a relay
with up to 12 poles and a maximum of
eight poles that can be normally closed.
To install adder decks:
1. Remove power from the {ievice.
2. Loosen cover screws and remove
cover.
3. Unscrew steel post and replace with
the longer post supplied with the adder
deck. If adding two decks, only the extra long post supplied with the second
adder deck should be used.
4. Add deck to the relay using the screws
provided.
5. Slip the T-shaped yoke over the steel
post.
6. Add the contact modules. For normally
open contact, assemble with gold tabs
up. A normally closed contact should
have the white side up. Make sure the
screws are on the top side of each
module.
7. If a second adder deck is being used,
repeat steps 4, 5, and 6.
8. Reassemble the cover.

INSTALLING
INDICATING LIGHT ATTACHMENT

INSTALLING
OVERLAPPING CONTACTS

RENEWAL PARTS

Standard contacts are non-overlapping,


Le., during pickup and dropout there is a
period where all contacts are open. If over
lapping contacts are required, contact
modules CR120BX1A may be used. These
contacts will overlap with each other but
not necessarily with standard contacts.
Normally open and normally closed overlapping contacts will all be closed for a
period of time during pickup and dropout.
For installing the contact modules, see
section on Contact Removal/Conversion.

CONTACT MODULE
IDENTIFICATION
The type of contact module can beiden
tified even after installation by the terminal color. Standard modules have a
brass terminal, overlapping modules have
a gray color, and gold-plated contact
modules have red on the terminal.

Colis
(Order 55-513696Go plus suffix number
per table below).
Voltage

F*JU8ncy

Suffix No.

24
115
120
200

60
60
60
60

025
002
0221
023

230
460
575
600

60
60
60
60

003
004
005
006

110
220
380
440
550

50
50
50
50
50

007

008
004
009
010

t Collis dual rated 12OV, 60 Hz/110V, 50 Hz.


Instantaneous Contacts
Standard Contact Modules .... CR120BX1
Overlapping Contact Modules CR120BX1A
Goldplated Contact Modules CR120BX1 B

ACCESSORY KITS
Slllndanl Cont.ct Module. CR12OBX1
Overlepplng Modul

CR12OBX1A

Gold-plated Contact Modula CR120BX1B


First Adder Deck (Can accommodate up to eight
total contact modules)
Includes one contact module
CR12OBX3
Second Adder Deck (Use with llrat adder deck or
elghtpol.. relay to accommodate up to 12 total
contact modules)
Includes four contact modules .... CR12OBX14
Mounting Track-(40 Inches long for 16 relays)
Breakaway type
CR12OBX4
Non breakaway type
CR12OBX16

Figure 4.

1. Remove one of the cover screws.


2. Using screw supplied with indicating
light kit, install the light as shown.
3. Wire to coil terminals or any other
source of the proper voltage.

INSTALLING SURGE SUPPRESSOR

Indicating Light
115V 50160 Hz
230V 50160 Hz
460V 50160 Hz

CR12OBX5
CR12OBX6
CR12OBX7

Surge Suppraaaor
115V5Ol6O Hz

CR12OBX2

Wiring TroUllh Covers


1Yz In. wide x 6 ft.
21n. wide x 61t
2Yz In. wide x 6 ft

CR12OX15A
CR12OX16A
CR12OX171'

NEMA 1 Enclo.ure
(For up to fourpole relay)
(For up to elghtpole relays

CR120BX19
CR12OBX15

Retaining Shleld.-6 ft. long for use:


with mounting track
without mounting treck

CR12OBX9
CR12OBX8

Retaining Shield Br8Cket. (Pkg. of eight) for use:


CR12OBX13
with mounting track
without mounting track
CR12OBX12
Latch and TIm.o.lay Kh.-Latch relays and
timedelay relays are also available as either kits
or complete relays. See General Purpose Con
trol Catalog GEP1260 for Ordering and Pricing
Information.

"
Figure 5.

1. Remove coil terminal screws.


2. Install surge suppressor and lead to
coil terminals as shown.

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _1
3ENERAL ELECTRIC COMPANY
3ENERAL PURPOSE CONTROL DEPARTMENT
3LOOMINGTON,ILLINOIS61701
180

GENERAL" ELECTRIC
Printed In U.S.A.

BI006008

GEH4

Instruction!
CR120BD, CR120BC Series
600 Volt Industrial Relay

CAUTION: Before inst Iling in a nuclear


application, determine hat the product is
intended for such use.

DESCRIPTION

4. Mount the relay on a vertical panel.

The General Electric C 120BD Series A industrial relay is the d form of the standard CR120B relay. T is dc relay is furnished with a dual w nding coil and a
special contact is sup lied in the coil circuit to make available he higher current
needed during the fir
part of the armature stroke. This con act should be replaced only with a C 120BX1A contact
module. Because of th higher watts used
during pickup, the rei y should not be
operated continuously ore than 80 operations per minute.

5. Make
all
electrical
connections.
Normally open contacts are indicated
by gold and normally closed by white.

The CR120BC catalog umbers designate


the latch forms of th dc relay. Since
these relays have an int rmittent rating on
the unlatch coil it shoul be limited to a 25
percent duty cycle.
CAUTION- The center post on the latch
relay has been fact ry adjusted and
should not be turned or ampered with.

magnet back into position under retaining clip. Magnet must be centered in
housing window in order for it to seat
properly.

3. Operate the magnet and operating arm


by pulling the manual operator to assure free movement.

COIL REMOVAL

CONTACT REMOVAl/CONVERSION
SEE REVERSE SIDE FOR LATCH RELAY
INSTRUCTIONS-CONTACT
REMOVAl/CONVERSION

SEE REVERSE SI DE FOR


INSTRUCTIONS-UNLATCH COIL
1. Disconnect power.
2. Disconnect all wires.
3. Remove from panel.
4. Insert a screwdriver blade between
magnet and magnet retaining clip.
Twist blade to force retaining clip away
from magnet. Push down on screwdriver, dislodging magnet; then applying firm pressure with screwdriver,
push magnet through coil to position
shown in Figure 2.
5. Grasp the coil terminals and pullout.

RATINGS
Ac-NEMA A600
Max. Ac
Voltoge

Max.

Max. V Itomp
Rot ng

Max. Curront
Rotlng

c~~~~':tuI-M-Ok-o-'+-B':'re-o-k+-M-o-ke-'--=Br-o-ok-l
Flguro 3.

600

10 Amp

7200

720

60

Dc-NEMA P300

1.

Disconnect power.

2.

Loosen cover screws or screws above


the appropriate deck and remove.

Lift out contact module. Contacts may


be inspected through gold transparent
side of module.
4. To convert from normally open to
normally closed, or vice versa:

3.

a. Remove contact module terminal


screws and reassemble on opposite side.

Flguro 2.

TO REASSEMBLE:
6. Insert coil and center in housings.

INSTALLATION
1. Disconnect power fr
2. Remove all packing.

7. Slide magnet back through coil and


center with housing window. Insert
blade of screwdriver through window,
perpendicular to magnet. Using blade
of screwdriver, push retaining clip
away from magnet and apply pressure
on magnet from opposite side. Snap

b. Replace contact module in back.


5.

Reassemble.

INSTALLING ADDER BLOCKS


Additional decks of contact modules may
be added to the relay making a relay with
up to eleven poles. Up to seven poles may
be normally closed.
To install additional adder decks:

These instructions do not urport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with
installation, operation or m intenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the
Purchaser's purposes, the atter should be referred to the nearest General Electric Sales Office.

GENERAL. ELECTRI

BI006008

4143C

1. Disconnect power.
2. Loosen cover screws and remove
cover.
3. Unscrew steel post and replace with
the longer post supplied with the adder
deck. If adding two decks, only the extra long post supplied with the second
adder deck should be used.
4. Add the deck to the relay using the
screws provided.

Normally open and normally closed overlapping contacts will all be closed for a
period of time during pickup and dropout.
For installing the contact modules, see
section on CONTACT REMOVAL/CONVERSION.

CONTACT MODULE
IDENTIFICATION
The type of contact module can be identified by the terminal color, even after installation. Standard modules have a brass
terminal, overlapping modules have a gray
color, and gold-plated contact modules
have red on the terminal.

LATCH RELAY

Deck As..mbly

Yoke Assembly end Post


Figure 4.

5. Slip the T-shaped yoke over the steel


post.
6. Add the contact modules. For a
normally open contact, assemble with
gold tabs up. A normally closed contact should have the white side up.
Make sure the screws are on the top
side of each module.
7. If another adder deck is being used,
repeat steps 4, 5, and 6.
8. Reassemble the cover.

INSTALLING OVERLAPPING
CONTACTS
Standard contacts are non-overlapping,
i.e., during pickup and dropout there is a
period where all contacts are open. If
overlapping contacts are required, contact
modules CR120BX1A may be used. These
contacts will overlap with each other but
not necessarily with standard contacts.

COIL REMOVAL-UNLATCH COIL


1. Disconnect power.
2. Remove four screws and cover of
latch.
3. Lift out spring washer and core
assembly.
4. Remove coil.
5. To install, reverse procedure.

ACCESSORY KITS
Standard Contact Modules

CR120BX1

Oyerlapplng Modules

CR120BX1A

Goldplated Contact Modules

CR120BX1 B

First Adder Deck (Can accommodate up to eight


total contact modules)
Includes one contact module
CR120BX3
Second Adder Deck (Use with lirst adder deck on
eight pole relay to accommodate up to 12 total
contact modules)
Includes four contact modules ..... CR120BX14
Mounting Track (40 in. long lor 16 relays)
Breakaway Type
.. CR120BX4
NonBreakaway Type. .
. .. CR120BX18
Indicating Light
115V 50/60 Hz..
230V 50/60 Hz. . . . . . .
460V 50/60 Hz
Surge Suppressor
115V 50/60 Hz

CR120BX5
CR120BX6
CR120BX7

...... CR120BX2

Wiring Trough Coyers


1 V, in. wide X 6 It. . . .
2 in. wide X 6 ft. .
2V, in.wideX6ft

. .. CR120X15A
. .. CR120X16A
CR120X17A

NEMA 1 Enclosure
(For up to threepole relays)
(For up to seYen-pole relays)

CR120BX19
CR120BX15

CONTACT REMOVAl/CONVERSION
1. Disconnect power.

Retaining Shlelds-6 It. long lor use:


with mounting track. . . . . .
.
without mounting track. . .
.

2. Loosen the two screws above the


appropriate deck.
3. Pull the release lever of the latch
attachment toward the coil and pull the
top portion of the relay off the post.
4. Lift out contact module. Contacts may
be inspected through gold transparent
side of module.
5. To convert contact from normally open
to normally closed, or vice versa:
a. Remove contact module terminal
screws & reassemble on opposite
side.
b. Replace contact module in deck.
6. To reassemble, pull the release lever
toward the coil and slip the top portion
of relay over the post.
7. Secure to the relay with the two
screws.

Retaining Shield Brackets


(pkg. 01 eight) lor use:
with mounting track. . . .
without mounting track

TIME DELAY RELAYS


Time-delay relays are available as complete relays or timer attachments. See
General Purpose Control Catalog,
GEP-1260, for Ordering and Pricing Information.

CR120BX9
CR120BX8

. . CR120BX13
CR120BX12

RENEWAL PARTS
Coils
(Order Relay Coils 55-513696G*** plus
suffix number per table below).
(Order Unlatch Coils 55-520208G* * * plus
suffix number per table below).
Dc Voltage

Suffix No. * **

12
18
24
32
36

044
043
048
046
047

48
64
72
90
125

049
045
050
051
041

Instantaneous Contacts
Standard Contact Modules
Overlapping Contact Modules
Gold-plated Contact Modules

CR120BX1
CR120BX1A
CR120BX1 B

'lERAL ELECTRIC COMPANY


'lERALPURPOSECONTROLDEPARTMENT
)OMINGTON, ILLINOIS 61701
)

GENERAL. ELECTRIC
Printed In U.S.A.

BI006008
GEI86126 H

Installation
Instructions

Ground Break
System
For Ground Fault
Protection

SYSTEM TEST WITH SERVICE


INTERRUPTION
1. Push red Test bunon. Ground Fault
lamp should light.

<

2. Release red Test bunon. breakerl


interrupter should open.
.<
3. Push and release yellow:< Reset
<<.< bunon.
~.
4. Reset and close breaker/inter:rupler.
H"'2"23

'-'-=---'--'-'--'----+-------------_. ~'--' "--

For additional information, see GET2964

GENERAL _

ElECTRIC

BI006008

BI006008

SENSORS (Figure 1)
G E Type TGS or Type T M sensors must be used with the
Ground-Break system. Al sensors are electrically identical. Select each sensor s that conductors will have the
required electrical and rna netic spacings to the edge of the
sensor window. See Tabl I for a listing of the available
sensors. Type TGM sen ors must be used with Type
TGMR relays only.

o.

-l
C

8 SO

850

Mtg holes for


TGS0432

MIg holes fer


TGS0418
TGS0424

ROUND-BREAKTM SENSORS

TABLE I -

Type Core

Cal. No.

2Y, in. 1.0.

TGMOOO2!TGSOOO2
TGMOOO5!TGSOOO5
TGM0008!TGSOOO8

Figure 2A

WI.

Solid
Solid
Solid

5 in. 1.0.
8 in. 1.0.

3 lb.
4 lb.
7 lb.

>--- 12.50

-j 22S r- J8~ r-

4
4
4
4
4
8
8
8
8
8
8
8
8
11

x
x
x
x
x
x
x
x
x
x
x
x
x
x

8
18
24
29
32
8
8
8
10
18
24
32
38
13

in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.

Splil
Split
Split
Split
Split
Split
Split
Solid
Split
Splil
Splil
Split
Split
Split

17
18
21
23
25
25
20
20
22
31
37
50
57
30

lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.

----1

r- -22:il

500

~ lJUmpe~I~O 0'-t:

RE TANGULAR (Splil Core)


TGS0408
TGS0418
TGS0424
TGS0429
TGS0432
TGS0808
TGS0808A
TGS0808S
TGS0810
TGS0818
TGS0824
TGS0832
TGS0838
TGS1113

,C

II

Strap

8.50

800

No clearance
required to
these surfaces

-t-

-t

-L

8.50

1-

850

8.50

-'-j_'--...J

(3) Terminal
Screws

850

4.00

Mtg. holes for


TGS0832
TGS0838

vC

1.00 C Mtg. holes for


TGS0818
TGS0824

Figure 2B

SENSOR OU LINE DIMENSIONS (Inches)


Round Sensor Dimensions

Cal. No.

2.56
3.94
5..44

5.12
7.88
10.88

5.75
8.50
11.50

5.62
8.50
11.50

0.50
0.50
0.62

.50
.00

TGMOO02!TGSOOO2 6.62
TGMOOO5!TGSOOO5 9.50
TGMOOO8!TGSOOO8 12.75

.00

(21034 loll; Hoi,

B
075 F
I

r 01.-1 2 nI

CLEARANCES

Maintain a minimum of 1 inch


dearance between conductor
bundles and inside surface
of sensor window except as
noted in Figure 28 and below:

t t~~t

--t0t-+--+- 1
1

12

-1

02
12+

o
.75

1-----

12.00 - - -

TGMOOO2!TGSOO02 0 inch
TGMOOO5!TGSOOO5

'h inch

Cat. No. TGS0408

Figure 2C

Figure 2

SENSOR OUTLINE

IMENSIONS (Inches)

Reclangulor Sen. r Dimensions

Cal. No.

No. of
Mfg.
Hoi ..

TGS0418
TGS0424
TGS0432
TGSOSOS
TGS081S
TGS0824
TGSOS32
TGS0838
TGS080SA

6
6
10
6
6
6
10
10
6

B
23 .
29.
37.
S
23.
29.
37.
43.
S

* Additional sizes ovaila

5
18.00
2.12
5
UOO
5.12
5
32.00
0.62
e Outline Drowing
18 00
2.12
.
51
24.00
5.12
5
5
32.00
0.62
5
38.00
3.62
e Ovtline Drawing

Fig.
No.
20
20
20
2b
2c
2c
2c
2c
2b

1.87

'''134 Mil ~es

TerminI! Screws

Cat No. TGS1113

Ie. Con.ult factory.


Figure 2D

BI006008

BI006008

RELAYS (Figures 3, 4, 5 and 6)

r--- --

-r

r- 394
TT\6t---- ,_J..:J++~~

General

Used in conjunction with a circuit protective device having


a shunt trip, this relay, with its sensor, will detect ground
currents and cause the circuit protecting devices to open
(or activate a signalling device) when these currents reach
preselected values of current and time. Optional Type Z
zone selective interlocking provides instantaneous tripping
in each protected zone, and time delay back-up protection
between zones for a fully coordinated and selective system.
Three sizes of relays are available: Continuously adjustable
range of 2-12 amperes, 5-60 amperes and 100-1200 amperes. All relays except Type TGMR5 have a continuously
adjustable time delay range of Instantaneous (0.03) to 1.0
seconds. On Type TG MRS relays time delay range is .03 to
5.0 sec. The time delay characteristic is flat, as shown in
Fig. 4. Once settings have been selected, adjusting knobs
can be clamped in position by means of the clamping bar on
the face of the relay. (Fig. 5).

j'r

!2.56

, ,-~
1

II I
15 941
1850

: I

I~

256
1

L-:-J

f-

11.88
Cat. No. TGS0810

Figure 2E

----j 275

.50

1275

1
1606

8.00

13.75

llrl-'" ~=Ju..:..mp=er=St=rap*==+~~
T1~

1.16

I-- 525 --+- 3 8


1300 --+--1

f---

r-

Cat. No. TGS0808

Figure 2F

(4) .341.0

Time Current Curve GES6135

Mtg. Holes
,:"

'

...

..

..

I J I!

III

8.38

1162

111,:

,
I

I!:

I I

'I

II!

1,1

:~

r+-.----+----r--',' __ .1
,

225

't--'-----+----'---l.J, - f

Figure 2G

Cat. No. TGS0808S

SENSOR MOUNTING INST UCTIONS


1. Bolt the two halves of t e split core sensors together,
using the hardware provi ed, and torque bolts to 70
inch Ibs.
2. Attach jumper strap wit hardware provided to both
halves of split core sen or. Torque strap mounting
screws to 20 inch Ibs.

3. Attach sensor to supportin brackets with a minimum of


four bolts for the rectang lar sensors and two bolts for
the round sensors. Bolt orque should not exceed 45
inch Ibs.

" }','l-."l'
.

II

"L

,\

! II

III

II

I:

0:

~_ll
I I

I,
I

:~q~:

.,1 II!I

I I

I I

,I i .'ol..":} " <. .

,I

, ,

, I

I
I

'I

!i!I!!.. ,,!I,

! I

.'

I I

,I

'I I

TT,I,I,,;!., .1.1.l wlI !"

10"12" x 15" Translucent Poper available for systems coordination studies.


Order from GE Distribution Unit, Hoerle Bldg., Ploinvitle, CT 06062,

Figure 4
3

BI006008

BI006008

UL RECOGNIZED RA INGS

2. Zone Selective Interlocking

System Inp t Ratings

Primary A ps
100-1200 Amp Rei y

2-12 Amp Relay

3S,OOO
12,000
600

Min. Withstand Time

200,000
60,000
4,000

s-oo

.1 Seconds
1.0 Seconds
Continuous

Amp Relay
60.000
-4,000

* Through

fault

current,

1.0 Seconds
Continuous

p ase-te-phase

or

phoseto.

ground.

** below.
Except

05

reduced by sen or continuous current ratings

Sensor Single Phas

Sensor

Thermal Ratings

Continuous Current Rating

TGS0-408 ond TGS0808


TGSoooS
TGS0002
All other sensors

4000
2S00
1600
3000
600
600
600

Amperes
Amperes
Amperes
Amperes
Amperes
Amperes
Amperes

Zone Se lectivity can be obtained with interlocking connections between Ground-Break relays. Type Z. (Cat. No.
Suffix Z). See wiring diagram Figure II. Time delay settings should be determined in the same way as for Time
Delay Selectivity. However. each such relay will operate
instantaneously if a ground-fault occurs in its zone of protection.
If interruption is not completed in normal time, for any
reason. then an interlocked upstream relay, still sensing the
ground-fault, will operate at the expiration of its selected
time delay.
CAUTION
All relays in a zone selective system must operate from a
single source of control voltage unless otherwise approved
by the factory.

RELAYS -Ambient Range -35 0 C thru 80 0 TABLE II

ut Ratings

Max. Time

Adjustable
Trip Reng.

Mox. Volts
2"OVAC / 12SVOC

Control Power
The Ground-Break system ill function with a choice of
control voltages for the rela and for the shunt trip coil.
(See Table II.)
Monitor panels are available 0 match the selection of control voltage. However, a s urce of 120YAC, at least
200Y.A. in size, is needed to test the system by connection
to the test tap provided with e ch sensor.

Selectivity
Selectivity between upstrea
and downstream GroundBreak relays can be accompli ed by either of two methods:
1. Time Delay Selectivity
2. Zone Selective Interloc

R.10y and
Shunt Trip

Lo

Hi

Voltog.

2A.
2A.
2A.
2,0..
2A.
SA.
SA.
SA.
SA.
SA.
l00A.
100A.
lOOA.
l00A.
l00A.

12A.
12A.
12A.
12A.
12,0..
60A.
6OA.
6OA.
60A.
6OA.
1200A.
1200A.
1200A.
1200A.
1200A.

120/240 VAC
125 VOC
4S VOC
32 VOC
2" VOC
120/2"OVACti'
12SVOC
"SVOC
36VOC
24VOC
120/240VAC
12SVOC
"SVOC
36VOC
2"VOC

Cot. No.
Cot. No. with
without Zan.
Type Z '!'
S.lectivity
Selectivity

.....
.....
. ....

TGMRI
TGMRI
TGMR18
TGMRIC
TGMRID
TGSR06
TGSR06
TGSR06B
TGSROOC
TGSR060
TGSR12
TGSR12
TGSR12B
TGSRI2C
TGSR120

.....
.....

TGSR06Z
TGSR06Z
TGSR06BZ
TGSR06CZ
TGSR060Z
TGSRI2Z
TGSRI2Z
TGSRI2BZ
TGSR12CZ
TGSR120Z

(1;. Shunt trip can operate at 120 or 240VAC, but relay operates from 120VAC

in either cese.
G; A downstream relay, while sensing a ground fault above its pickup letting,
will block an upstream Type
which the Type Z relay is set.

relay only far the length of time-delay for

RELAY OUTLINE DIMENSIONS (Inches)


1. Time Delay Selectivity

-_._-

Time Delay Selectivity can


obtained by using GroundBreak relays without interloc ing connections between relays. Using the preferred tim delay steps shown in Figure
4, set each relay at least one step above the relays immediately downstream.
For any overcurrent protecti e devices which require more
than .04 seconds of c1earin time, the time delay steps
should be increased by at I ast as much as the clearing
time exceeds the .04 secon

!.~4

hrc.&-32 Set"
Te't"'''nol

'><--+--'-i

~.I'

3Z38

04

GENERAL

ELECTRIC

Figure 6

SYSTEM OPERATION
Recommended Relay SeHlngs
0.5
0.6
0.8

0.7

TIME DELAY SECS


t

Figure 5

10

Ground-Break relay settings of pick-up current and timedelay for main, feeder and branch circuits should be
selected so as to provide optimum ground-fault protection
and coordination with the conventional overcurrent devices
in the distribution system. Since the ratings of the conventional devices will vary with application, no general
statement can be made. However, the following recommendations are basic for satisfactory performance of most
systems:

BI006008

BI006008

Pick.up Current

Relay pick-up curre


setting should be preferably 20%
of circuit rating. Co sideration should be given to higher
settings for the purp se of having ground faults interrupted
downstream by phas overcurrent devices so as to affect
only the faulted circ it. Motor branch circuits may justify
settings much lower.
Time Delay

The instantaneous (
be used only for mo
preferred time deja
other relay at least
downstream.

OJ seconds) setting generally should


or or branch circuits. Using the other
steps shown in Figure 4, set each
e step above any relays immediately

For any overcurrent


than .04 seconds of
shoujd be increased
time exceed~ .04 sec

rotective devices which require more


clearing time, the time delay steps
by at least as much as the clearing
nds.

Application Voltages

Monitor
Panels
(Cat. Nos.)

Relay

Shunt Trip

TGSMP
TGSMPA
TGSMPB
TGSMPC
TGSMPD

120YAC
125VDC
4BVDC
36VDC
24VDC

120 to 240VAC
125VDC
4SVDC
36VDC
24VDC

TGSMA

120VAC

120 to 240VAC

A pilot light is pro ided to indicate presence of control


power. If the pilot I ght is "out", control power fuses and
circuit should be ch cked.
There are two push uttons provided - red marked "Test"
and yellow marked 'Reset". The ground-fault lamp (red)
lights or a mechani al indicator "pops out" to show that
the Ground-Break r lay has operated to trip a breaker!
interrupter. The res t button must be pushed to reset the
relay after the fault has been located before the breaker!
interrupter can be re losed, or the mechanical indicator can
be manually reset.
The monitor panel has the ability to test the complete
ground-break syste
with or without tripping the circuit
protective device. nstructions for performing tests are
printed on the face late.
During the few seco ds of each test operation, the monitor
panel energizes the ensor test windings. This energy requirement dictates t e use of a J 20 VAC. test power source
of at least 200 V.A. he test signal simulates a ground-fault
of approximately J 6 0 amperes. (See Table III)

lamp
lamp
lamp
lamp
lamp
Mechanical
Indicator

MONITOR PANEL OUnlNE DIMENSIONS (Inches>


(4) MtO Holes for No 8-:32
Screws With Nuts
..l-rC------~'-

T'i---------l
I

A flush mounted mo itor panel is a component part of the


Ground-Break syste . It proviaes the functions of monitoring and testing the round-Break system.

Ground
Fault
Indicator

525

.25

Cut-out Line

Il---- j

I
I
I
I

4.25

i275l

----.,

I
.

0.25

I
I

475

I
____ ..JI
0

Il.t= :3~5~ 1

025

~425~
Figure 8

INSlALLAliON
Mounting the Components
RELAY - See outline dimensions Figure 6. Should be sur-

face mounted in such a position that the settings are acces


sible for adjustment by the operator without risk of
electrical shock. Avoid mounting locations with excessive
vibration or mechanical shock.
MONITOR PANEL - See outline' dimensions Figure 8.Designed to be flush mounted in such a position that the
fault indication will be readily visible and pushbuttons can
be operated conveniently.
SENSORS

See outline dimensions page 1 and 2.

For Ground Strap Application

For the main circuit only, the Ground Strap Application


is desirable if the neutral connection to ground of the
service entrance is available. The sensor should be mounted
to encircle only this neutral connection to ground.
For Zero Sequence Application

Sensors should be so mounted that all phase (and neutral


when used) conductors pass through the sensor window.
Equipment ground conductor must not pass through the
window. * The service neutral must be grounded only on

the line side of the sensor window. To minimize saturation


effects, a J -inch clearance should be maintained between
phase/neutral conductors and the inside of the sensor window (except as noted on sensor outline drawings).
Figure 7

Unless it aho passes through window in opposite direction.

BI006008

BI006008

OPERATION OF SYSTEM

TABLE

If a ground-fault occurs whic exceeds the pick-up and


time delay settings of the rela , it will energize the shunt
trip or other load. The relay ill remain ON (closed) to
continue energlzmg any gro nd-fault signaling devices.
The relay should not be res t until the cause of the
ground-fault indication has be n investigated and cleared.
Only after the relay is reset,
operating the reset pushbutton, or by operating switch S I, Figures 9 and 10, will
it be possible to rec10se the beaker/interrupter.

Wirewound Test Resistors


The simulated GroundFault Signal should be at least 20% higher
than the pick.up setting of the GroundBreak Relay.
Simulated
Ground Fault
Current in
Amperes
Type
Type
TGM
TGS
Sensors Sensors
183
137
114
91

TESTING THE SYSTEM

With Monitor Panel

Add
Rl

~9

600

The reliability of the groun -break system is excellent.


However, since testing is so c venient, it is recommended
that a test be performed mont Iy, or after the breaker has
experienced a fault of any kin

400
200
100
60
40
20

Complete instructions or tes ng the ground-fault system


are printed on the face of th monitor panel, Figure 7.

CAUTION

Min.
Watts

Ohms
Nane
20
30
50
90
150
350
750
1400
2000
4000

1600
1200
1000
800

46
23
11.4
6.9
4.6
2.3

ithout Monitor Pan,1

Nane
50
50
50
25
25
25
20
12
B
5

Total
Rl
Ohms

Min.
Walts

50
70
BO
100
140
200
400
800
1400
2000
4000

100
100
100
50
50
25
25
20
12
8
5

Min. V.A.
f120 VAC
Tesl Power
Source
Volt/Amps

Sensors should have a shorting jumper between terminals


C and M whenever the sensor is disconnected from the
ground-break relay circuit, to prevent a possible shock
hazard to personnel if a ground-fault should occur.

For wiring diagrams, see Fig res 9, 10, 11, 12 and 13.
Reduction of the simulated gr und-fault signal below 1600
Amps (see Table III) is c mpletely optional, but can
substantially reduce the V. . requirements of the test
power source in some cases.

Control Wiring Insulation tests

High voltage tests are not recommended for Ground-Break


control wiring. However, if it is required, temporarily
remove ground connections of control power and sensors,
bond all Ground-Break relay terminals together, and apply
test voltage between the bonded terminals and ground.

**The function of S3 is to inactivate the Trip Coil, if desired. during the Test function and until after Reset has
been accomplished
S3 **
(Optional)

***Other values of Rl. if used. will simulate ground faults


as shown in Table III
Note:
All switches should
be momentary, spring.
return type.

52
Test Function
(Optional)

50 Ohms
100 Watts, Min.

Control
Voltage
Source

Reset
Function

GROUNDBREAK
RELAY

L.-----..--4I--~:........_+-y_--t-Ll

L--------~~-~~-

'- - I

Ground Fault
Indicating Lamp or
other continuously rated
loads (same voltage
as Control Power)

Shunt Trip
or
Electric Trip

II

--,

CS

T -r
l -

~ Connect

SI

I
_1._

.....

120 VAC 208 VAC


N
or
240 VAC
t L2

_4I~

....J

to N for 120 VAC Trip Coil

or to L2 for 208 or 240 VAC Trip Coil


'Wires, #14 AW min., routed together for 100 ft. max.
run. Wires shoul not be harnessed with power conductors.
Wiring Diagram for Ground-BreaK without Monitor Panel
using AC Control Voltage

200
150
150
100
75
50
25
25
25
25
25

Figure 9

BI006008

BI006008

S2
Test Functi n
(Optional)

Rl ***
Reset
Function

Ll -------III--If---i
Test Circuit
120 VAC

~_I

N-.--,.-----f---+---t----'

Control Circuit
24 VDC, 36 VDC

51

T -,-

48

vae c, 125 vac


(Grounding of either
polarity is permissible)

Ground Fault
Indicating Lamp or
other csntinuously rat d
loads (same voltage
as Control Power)

Shunt Trip

GROUNDBREAK
RELAY

0)

Note:
All switches should
be momentary, spring
return type.

OT

Electric Trip

CD

*Wires, #14 WG min., routed together for 100 ft. max.


run. Wires sh uld not be harnessed with power conductors.

**The function of S3 is to inactivate the Trip Coil, if de


sired, during the Test function and until after Reset has
been accomplished.

***Other val es of Rl, if used, will simulate ground faults


as shown in able ill.
Wiring Diagram for GroundBreak without Monitor Panel
using DC Control Voltage

Figure 10

Rl, if any (see Table ill)

..... --.

1--I
I

Monitor
Panel
Cat. TGSMP and
TGSMA

I
I
I
I
I

I
I
I
I

Control
Voltage
Source

I
I

'-- - -,

:--0-- -------,'

-I

Remote indicating lamp or


other continuously rate loads

.J Connect to N for 120 VAC Trip Coil

II

CS

_L_

-r
L-

or to L2 for 208 or 240 VAC Trip Coil

...!I

'Wires, #14 AWG min., routed together for 100 ft. max.
run. Wires should ot be harnessed with power conductors.
Wiring diagram for GroundBreak Relay and Monitor Panel
using AC control voltage

Figure 11

BI006008

BI006008
MAIN RELAY

CD CD CD 0 CD
FEEDER RELAY #2

FEEOER REL Y#1

CD D CD CD CD

}p( P

~ 0~ CD

CD CD CD

q{cpcp

CD

0)

CD

1 I
I

J
SUB-FEEDER RELAY #2A

SUB-FEEOE RELAUIA

CD D CD CD CD

0)

CD

Wires #22 AWG. min.,


twisted pair, with 1000 ft.
max. run. Wires should not
be grounded or harnessed
with power wiring.

CD CD CD

1 ~

J "-

L-----J

Optional Jumper Wire to add time


delay to relay trip. Useful on furthest
downstream reIJ)'s. Also makes any

Type Z relay act like a standard reo


lay with relard to time delay.

Typic.1 Zint Stltclin Interllckinc Clnnttlilas Ilf I SJStelll hninc i lUi, prlttttin ~"iee Ind twl IHdm, witll

Figure 12

IIch Itlder hnillli sub-ItI~er.

Control
and Trin
Circuits

(Grounding 01 either
polarity is permissible)

24. 36,48
or 125VDC

RlilWjl,"h".llIi

-"1_/'-..,-----:-.:.c-t--c-t-----~,-=..:---;:-;-;:::::;-N
....,{(tl-Jl0I2..Jf~----...
Te:;! Circuit
I

...

....

120 VAC

, - - - - - -... u

-I'

( _

CS _..1._

v--*

1"")-------,

'\. I

.f

'tIl

1/.....

'-- ...J1V..UJ 1T

etr-~

(;)

"

G OUNDBREAK RELAY

-T-

CD

, - - 0Y"~,

i ..
" ...... /

' - -_ _)--_ _---1

(j)
i

Remote indicating lamp or


other continuously rated loads.

L.-.f--H 4
L..;---+---t{ 5

..... .....

r '--G.

1L-

: 52**

fTC
- -

MONITOR
PANEL
Cat. Nos.
TGSMPA
TGSMPB
TGSMPC
or
TGSMPD

J;'\ .(0\ GF

/.....

CD

'\!...j-"'I r--j

~~ I

*Wir s, #14 AWG min.. routed together lor 100 It. max,
run. Wires should not be harnessed With power conductors,

.. 10\

I cpr-...;.1-:~R:--...J
1
1

~I--

---J

L....

--'

**Same voltage rating as


DC control cirCUit

Wirinc di,cr.m for GroundBruk Rel.y .nd Monitor Pinel


usinC DC control yolt'Ce

These instructions do not purport t cover all details or variations in equipment nor
to provide for every possible conting ncy to be met in connection with installation
operation or maintenance. Should fur her information be desired or should particular
problems arise which are not covered s Ificiently for the purchaser's purposes, the mat
ter should be referred to the General E ctric Company. These instructions are intend
ed for use by qualified personnel only.

r, ~CP
1-0 11T

Shunt Trip
or,
_ _ JElect"c Trip

'oJ IR
~.

For further information


call or write your local
General Electric
Sales Office or ...

Figure 13

Distribution Equipment
Division
41 Woodford Avenue
Plainville, CT 06062

GENERAte ELECTRIC
8

BI006008

INS aUCTIONS

GEJ-2836C
BI006008

CR2940UW ILLUMINATED OIL-TIGHT PUSH BUTTON


CR2940UX OIL-TIGHT PUSH TO TEST INDICATING LIGHT
CAUTION: Before installing in a nuclear application, determine that the product is intended for such use.
N.D.CONTACT TERMINALS

Tips on Use
The CR2940 UW Illumi ated Oiltight Push Button eliminates he necessity for a separate push b tton unit
and indicating light becaus , in one
unit, it offers the function of both.
All component parts are hown in
figure 1. To prevent accide tal pushing of the button, simply use the guard
in place of the standard c llar.
The push to test indica ing light
provides a simple method 0 checking
the bulb, if not lighted und l' normal
conditions, to determine if t e bulb is
burned out or the circuit i actually
dead.
New G.E. #12 lamps ar used in
these units. They are design
to withstand greater vibration, pro ide better
electrical contact, make easie assembly
and maintenance, and last ar longer
than conventional lamps. Thi is a plugin bulb and no attempt shoul be made
to turn it.
All units are available
front or back mounting in th following
six colors: red, green, am er, white,
blue, and clear.

Installation
1. Mount the unit in accor
the instructions on the carto
2. If mounting an Illumi
tight Push Button, connect
in Figure 2.
. 3. The push to test indic
should be connected in accor
Figure 3. Note that thB jum
on this form only and is
shown in Figure 1.

ance with
.
ated Oilas shown
ting light
ance with
er is used
pplied as

N.CCONTACT TERMINALS
COLLAR

(for' push to test)

COLOR LENS

(for' pU5htotest)

G.E. '*12 LAMP

STANDARD
CONTACT

BLOCK

~~~"
\ "~i NG

.JUMPER

(fer- push to
test" only1

COLLAR
(for- standard

~~UT

forms)

POSITIONING RING
(at' nameplate)

COLOR CAP
AND BUTTON

(for standard
or guarded
forms)

RUBBER GASK.ET
GUARD
Fig. 1 Component parts of CR2940UW and CR2940UX Oil-tight units

__

--------_~_----_~.

.,--,---.

OTHER FORMS

Non-Illuminated Pushbuttons
The CR2940-UW202 and UW203
series are used to match the il1uminated
buttons in appearance and are used
where the indicating light is not required. On these forms, the transformer
and lamp socket assembly are omitted.

Full Voltage (6V.)


(48V.) Forms

and

Resistor

These forms are identical to the


standard forms except the transformer
is replaced by a terminal block with
or without a resistor .

"Building Block" Construction


Color cap assemblies, operator bodies,
and transformers or terminal blocks
with socket assemblies are available for

assembling complete units from basic


parts using the standard CR2940U202
contact block.
When such "building blocks" are
used, first remove the mounting plate
from the contact block. Then insert the
lamp socket through the center hole of
the plate and fasten the transformer
or terminal block to the bracket. The
lamp socket will not fit into place unless you first remove the contact block.
Then screw the contact block back into
place.
When a second contact block is assembled in tandem behind the first
block, using the CR2940U207A adaptor
kit, assemble in accordance with the
instructions in the kit omitting the
screws holding the back plate to the
transformer.

SIGNAL VOLT AGE

--------0
NO

--------0

CONTACT BLOCK
LINE VOLTAGE

1~_ CONTACT

NC

BLOCK

NC

TRANSFORMER
/

/ ' TRANSFORMER
G-E it 12 LAM P

-J~---'O' J
Fig. 2 Elementary Diagram For Illuminated
OilTig t Pushbutton

CQMMON

L2

G-E
; 12
LAMP

tl

---------------------------'

Fig. 3 Elementary Wiring Diagram For Push


To Test Indicating Light

Th instructions do , purport to cover all detail. or variations in equipment nor to provide for every pouibl. contingency to be ".., in connection with installation, operotion 01' maintenance. Shoul further information be d.sired or should particular problem. adJ. which or. not covered sufficiently lor th. pwcfteuer', purpo..., the IftGtfer "ould he
r.,.,red to the General E 'ric Company.

GENEItAL PUIltCHI CONTROL DEPAITMENT. ANERAL ELECTRIC COMPANY, BLOOMINGTON, ILL

BI006008

BI006008

GEJ-3775-B

INSTALLATiON & OPERATING


INSTRUCTIONS FOR
DRY TYPE CONTROL TRANSFORMERS

RECEIVI G - Upon receipt of shipment examine the package for damage


that may have been sustained in transit. If the shipping container must
be opened outdoors, take proper precautions to prevent the entrance of
moisture. While unpacking, examine the product for broken or loose
parts or other damage. If injury from outside sources is evident, file
a damag claim with the transportation company and notify the nearest
General lectric Apparatus Sales Office. Tighten any parts which may
have beco e loose during shipment.
HANDLI G - In general, units having a net weight in excess of 50 lbs.
will have provision for lifting. Damage to the finish and parts may be
avoided y using a spreader on lifting chains. Very large units, in addition to li ting holes or lugs, may have provision for rolling, skidding
or jackin .
STORAG - The storage room should be clean and dry and, when possible witho t extreme temperature variations. Before placing a dry-type
transform r in service after a period of storage, be sure that it is clean
and dry b observing the instructions under" Installation."
INSTAL ATION - The only foundation necessary is a flat surface strong
enough t support the weight of the unit. Regardless of the type of
mounting surface, permanent and effective grounding of the metal case
is recom ended as a safety precaution for personnel. The metal encased
transform rs are suitable for outdoor use, when mounted in an upright
position. he open frame (core and coil) transformers are for indoor use
and shou d be placed in locations not subject to exposure to high humidity. Bec use free circulation of air is essential for the proper operation
of all dr -type transformers, they should not be located in areas where
heavy du t or corrosive fumes are present.
Any ccumulations of dirt or dust may be removed by brushing or by
blowing ry air on the unit. If moisture is evident by the appearance of
rust or
ildew, the unit should be dried out by placing it in an oven or
by blowi g heated air over it. In either case the temperature should
not excee 110 C.
Make only those connections authorized by the nameplate or connection diag am, and do not change connections while the unit is energized.
MAINTENANCE - In general, dry-type transformer products have no
moving arts. The only maintenance required is periodic inspection of
connectio s and removal of accumulated dust, dirt and lint.
RENEW L PARTS - Because of the unit structure of small transformers,
field rep irs are usually uneconomical and no spare and renewal parts
are reco mended. On large and more complicated equipments where
compone t replacement may be desirable, contact the nearest General
Electric A paratus Sales Office for information.
CONTR L TRANSFORMERS - General Electric control transformers
are enca sulated construction and whether of the open frame type for
panel mo nting, or encased for general use, the exterior surface transfers
the heat generated within the unit. They will perform satisfactorily
when the surrounding air temperature doe~ not exceed 40' Centigrade
(140 F hrenheit) and free air circulation is provided by maintaining at

BI006008

least one inch spacing on all sides except the .mounting surface. They
are designed to reach rated temperature when operating continuously at
rated voltage, frequency and load. Serious overheating may result if
operated for sustained periods at over-voltage, above rated current
(rated current equals rated volt-amperes divided by rated voltage), or
less than rated frequency. Generally, within the power frequency range
of 25 to 100 cycles per second, a control transformer may be operated
safely at a frequency higher than rated frequency. Transformers rated
50/60 cycles can be used at 400 cycles if proper allowance is made for
increased regulation caused by the larger reactance voltage drop.
Standard control transformers are designed for step-down service.
The secondary or low voltage is over wound to compensate for resistance drop in order to provide rated output voltage at rated load. If
they are reversed for step-up service, the voltage ratio will be incorrect
and the output voltage will be low. This is particularly significant in
ratings of less than '75 volt ampers. Because of the added turns on the
secondary coil care should be used in applying small transformers when
the load is less than rated load, to make sure that the resultant voltage
is not excessive for the desired loading.
When a control transformer is operating, the temperature of the outside surfaces is generally higher than can be handled comfortably. This
should be no cause for concern since these transformers are designed
to operate at high temperatures to provide the benefits of small size and
light weight.
Surface temperatures generally meet the requirements
established by Underwriters' Laboratories, Inc. to assure safe operation.
Standard control transformers or'identical model numbers may be
connected in parallel, or they may be used in three phase banks. They
may also be connected as autotransformers for boosting or bucking
voltage. However the use of autotransformers is subject to precautions
and in some areas local codes prohibit their use. Be sure to check local
codes before using autotransformers.
NOTE - These instructions do npt purport to cover all details or variations in equipment, nor to pro'vide for every possible contingency to be
met in connection with installation, operation and maintenance. Should
further information be desired or should problems arise which are not
covered sufficiently for the purchaser's purpose, the matter should be
referred to the General Electric Company.

SPECIALTY TRANSFORMER DEPT. GEN'ERAL" ELECTRIC


FORT WAYNE, INDIANA 46804
4/84

Printed in USA

..-

"

GEK-33276D

&I

-.;?..

'"I

GE Dry Type General Purpose


Transformers
Type QL Single and Three Phase,
15-1500 KVA
GENERALINFOR
Type QL transformers ha
tion suitable for indoor se
tected outdoor service. All
floor or platform mountin
mounted on rubber isolati
transmission of vibration.

TION
e a ventilated, encased construcice only, unless converted for proencased models are designed for
. The core and coil structure is
n pads at the base to minimize

Rainshield conversion kits are available to convert standard


indoor Type QL NEMA ype 2 enclosures to NEMA Type
3R enclosures suitable for rotected outdoor installation. The
transformer nameplate sp cifies the proper kit to match the
indoor enclosure and tran former. When these parts are
properly installed, the enc osure is listed by UL and certified
by CSA for NEMA Type R protected outdoor installation,
Conversion kits include ta per proof hardware with a special
tool to replace factory ins lled screws. Complete installation
instructions are supplied. ost type QL transformers can be
ordered from the factory ith the proper NEMA 3R conversion kit.
In addition, vent guards a e available to deter'rodents or debris from entering ventilat on openings. See following caution
statement under Installati n.
General purpose transfor ers are rated 600 volts and below
for supplying appliance, r hting, and power loads from electrical disujbution systems. Standard distribution voltages are
600, 480 and 240 volts; st ndard load voltages are 480, 240,
and 120 volts. The transt
er is used to match the load voltage to the distribution vol ge. Since no vaults are required
for installation, these tran formers can be located at the load
to provide the correct vol age for the application~

INSULATION SYSTEMS CLASSIFICATION


Ambient
40 C
40 C
40 C
40 C

+ Winding Rise + Hot Spot


55
80
115
150

C
C
C
C

10
30
30
30

C
C
C
C

Temp.
Class

105
150
185
220

C
C
C
C

All standard, general purpose Type QL transformers meet


applicable IEEE, ANSI, NEMA, UL, and CSA standards.
Type QL transformers are designed using a 220 C insulation
system with a standard 150 C temperature rise. Transformers for applications requiring lower temperature rises, generally 115 and 80 C, are readily available.
The design life of transformers having different insulation
systems is the same, since the allowable temperature rise of an
insulation material system is predicated on a specified life for
all insulation. The lower temperature systems are designed
for the same life as higher temperature systems.
Consideration should be given to the specific application of
the transformer such as the type of the load to be served, the
space available for the installation, and any weight restrictions
before specifying the class of insulation system to be used.
In addition, note that type QL units with a standard 150 C
winding temperature rise, operating at full load will have a
maximum 50 C/122 F temperature rise on the surface areas
of the enclosure. With a 40 C ambient, the measured enclosure surface temperature would be approximately
90 C/194 F.

HANDLING
Provisions for lifting are provided. Because transformers are
surprisingly heavy, check the weight shown on the outline
drawing or the shipping label to assure adequate capacity of
lifting equipment. For safety, spreaders should be used with
lifting equipment. Lifting holes are provided on the top core
clamps, accessible by removing the top cover. The unit may
also be lifted by forks or skidded at the base.

RECEIVING

APPLICATION
Industry standards classif insulation systems in accordance
with the following rating ystem:

BI006008
Application,
Operation and , .' ,
, Maintenance .
,_

Ins~allation,

Upon receipt of shipment, examine the package for damage


that may have been sustained in transit. If the shipping container must be opened outdoors, take proper precautions to
prevent the entrance of moisture. While unpacking, examine
the product for broken, bent, or loose parts or other damage.
If damage from shipment is evident, file a damage claim with
the transportation company and notify the nearest sales
office.

Ambient temperatures higher or lower than the basis for


ating

Short term loading in excess of nameplate kilovoltampere


with normal life expectancy

Loading that results in reduced life expectancy

The following additional tests are recommended if the unit BI006008


has been repaired or may be made if desired as periodic tests:
1. Resistance measurements of windings

2. Voltage ratio
3. No load losses and excitation current

PACT LOADING

4. Polarity and phase relation

-OFF switching of loads, such as full voltage starting of


tors can place severe mechanical stresses on the winding
ductors and support components. Where this type of loadis anticipated, special design measures may be necessary
estrain the mechanical forces.

5. Induced-voltage test

EREXCITATION

~ration

at voltages in excess of rating may cause core satuIn and excessive core losses. This can result in overheatand abnormally high noise levels. Special care should be
:n where overexcitation is anticipated.

leral purpose transformers are designed to reach rated


perature rise above ambient air temperature when operatcontinuously at rated voltage, frequency, and load. Serioverheating with resultant fire damage may result if the
is operated for sustained periods above rated voltage,
'or above rated current.
:d current equals volt-amperes divided by rated voltage
,ingle-phase units; or for three-phase units, rated voltleres divided by rated line-to-line volts, the quo~ient of
:h is divided by the square root of three (1.732).
Single-phase
_ Rated Volt Amps
Ra te d C urrent- Ra d V I
0 tage
te

..

Three-phase
Rated Volt Amps
Ra ted C urrent = --=:-------""--v'3 x Rated Line Voltage

RALLEL OPERATION
~ral purpose transformers of identical design will operate
factorily when connected in parallel or in three-phase
.s. (Tapped units must be connected on the same voltage
Single-phase units may also be connected as autotranslers for boosting or bucking voltage. However, the use of
transformers is subject to precautions: secondary circuits
,lied by autotransformers may be subjected to exceptionievere short circuits unless protected by current-limiting
IS. It is recommended that suitable current-limiting debe installed, where necessary, to limit the short-circuit
:nt to 25 times the rated current. In all cases, the NaI Electrical Code regulations should be followed.

INTENANCE

APPLIED VOLTAGE TEST-HIPOT


Initial installation tests using ac test equipment should be limited to 75% of NEMA factory test value and routine ac maintenance tests to 65% of factory test value. If dc equipment is
used, the test voltage should not exceed factory rms test
voltage.
PERIODIC INSPECTION AND MAINTENANCE
Like other electric equipment, transformers require maintenance from time to time to assure successful operation. Inspection should be made at regular intervals and corrective
measures taken when necessary to assure the most satisfactory
service from this equipment. Evidence of rusting, corrosion,
and deterioration of the insulation, varnish or paint should be
checked, and corrective measures taken when necessary. Auxiliary devices should be inspected and serviced during these
inspection periods. Terminals, connections, and cabling
should be inspected and accumulated dust, dirt and lint
removed.
Additional information related to the installation and maintenance of general purpose transformers can be found in
American National Standards Institute publication C57-94,
"Guide for Installation and Maintenance of Dry-type Transformers."

STORAGE
Condensation and moistu~e absorption must be prevented
during storage. Ventilated and nonventilated dry transformers should be stored in a warm, dry location. Openings
should be covered to keep out dust. If outdoor storage cannot
be avoided, the transformers must be protected to prevent the
entrance of water, moisture, and other foreign material.

RENEWAL PARTS
The vacuum impregnated unit structure of the core and coil
assembly precludes replacement parts. In most cases, field repairs are not recommended, are not economical and can be
dangerous.
Renewal parts are available for all enclosure parts surrounding the core and coil assembly. Rainshield and vent guards
can be added to any transformer enclosure.
If the conditions of use at the site dictate the need for standbv
equipment, a complete spare unit is recommended.
'

[ODIC TESTS
'ecommended that the following tests be made as prevennaintenance tests before reinstalling a dry-type transfor:hat has been out of service.
lsulation resistance test
pplied-voltage test-Hi pot

These instructions do not purport to cover all details or


variations in eyuipment nor to provide for even' possible
contingcncv to he met in connection with installation operation or maintenance. Should further information be
desired or should particular 'problems arise which are not
covered sufficiently for the purchaser's purposes. the matter should be referred to the GE Companv.

GE Electrical Distribution & Control


General Electric Company
41 Woodford Ave., Plainville. CT 06062
/2760 1088

1988 General Electric Company

GEK-:j3277C

INSTALLATION AND OPERATING INSTRUCTIONS


BI006008

DRY-TYPE GENERAL PURPOSE


TRANSFORMERS
TYPE ML, QM AND QMS

ECEIVING
Upon receipt ex
that may have occur
tainer must be opene
to prevent the entra
former for broken, b
If damage from outs
claim with the tran
nearest General Elect

mine the package for any damage


ed in shipment. If the shipping conoutdoors, take proper precautions
ce of moisture. Examine the transnt or loose parts, or other damage.
de sources is evident, me a damage
ortation company and notify the
c- sales representative.

All general purpose dry type transformers are cooled


by free circulation of surrounding air over their surfaces.
In the totally enclosed, non ventilated designs all heat is
transferred by the exterior surfaces. These transformers
will perform satisfactorily at their rated output when surrounding air does not exceed 40C (104F) and adjacent
structures do not impede free movement of air.

CONNECTIONS

HANDLI G AND STORAGE


Units having ant weight in excess of approximately
50 pounds have a p ovision for lifting. For lifting type
QMS transformers
0
one-inch diameter holes are
provided at the top f the mounting bracket. For level
lifting, a third point ay be established by inserting the
removable lifting bra et which is provided.
The storage roo s should be clean and dry and without extreme tempera ure variations. Before placing the
transformer in servic after a period of storage, be sure
that it is clean and dry by observing the instructions
under" Installation".

PREPARATION
Any accumulatio
brushing or by blow
is evident by feel or
by placing it in an 0
until dry. In either ca
110C (230F).

of dirt or dust may be removed by


ng dry air on the unit. If moisture
ppearance, the unit should be dried
n or by blowing heated air over it
e the temperature should not exceed

MOUNTING
The only found tion necessary is a flat vertical
surface or wall stro g enough to support the weight of
the unit. Regardless of the type of mounting surface,
permanent and effect ve grounding of the metal case is
recommended as a s fety precaution. Free circulation of
air is essential for t e proper operation of all dry type
transformers; therefo e, a minimum distance to adjacent
structures of one inch is required. Both type QM and type
QMS transformers
ust be mounted upright with the
wiring compartment t the bottom. The type ML transformer may be moun d either upright or horizontally.

Reference should be made to the wmng diagram


and/or nameplate when making electrical connections to
the transformer. Do not change connections while the unit
is energized. To minimize circulating currents in the
enclosure all leads to the same load must pass through
one knockout and all supply leads must pass through
one knockout.
Make certain that all connections are electrically tight
so that current-carrying parts are joined under adequate
pressure. If aluminum cable is used, adequate preparation
of the aluminum cable and protection of the joint is
essential.
Type ML general purpose transformers meet Underwriters Laboratories requirement for use with 75C
connecting cables, while QM and QMS transformers meet
the requirements for use with 90C connecting cables.
To protect dry-type transformers from voltage surges
imposed upon the lines by lightning, switching, or other
sources, adequate surge protection devices should be
connected near any transformer exposed to such
overvoltages.
General purpose transformers of identical model
numbers will operate satisfactorily when connected in
parallel or in three-phase banks. They may also be
connected as autotransformers for boosting or bucking
voltage. However the use of autotransformers in subject
to precautions: secondary circuits supplied by autotransformers may be subject to exceptionally severe short
circuit currents unless protected by current-limiting means.
It is recommended that suitable current-limiting devices
be installed, where necessary, to limit the short-circuit
current to 25 times the rated current. In all cases the
National Electrical Code regulations should be followed.

Th~se instruc~ions d not purport to cover all details or variations in equipment nor to provide for every possibie contingency to be met in cannedian witD lnstoilation,
operation or mOlntenan e. Should further information be des'lred or should port1culo:r problems orise which are not covered sufficiently for the pur,-::hc~e,',: purposes, the

matter should be referre to the General Electric Company.

BI006008

MAINTENANCE

DESCRIPTION

Dry-type transformers have no moving parts. The


only maintenance required is periodic inspection of connections and removal of accumulated dust and dirt.
Additional information relating to the installation and
maintenance of general purpose transformers can be
found in the American National Standards Institute
publication C57-94. "Guide for Installation and Maintenance of Dry-Type Transformers".

Type QM, QMS, and Type ML general purpose transformers reflect different types of construction per Figs 1.
2 and 3 below. All units are designed for wall mounting
and for ratings of 600 volts or below. They are suitable
for outdoor as well as indoor service.

RENEWAL PARTS
Because of the unit structure of these transformers,
field repairs are usually uneconomical and no spare parts
and renewal parts are recommended. If conditions of
operation dictate the need for standby equipment, a complete spare unit is recommended.

Fig. 1 Type OMS, enclosed


construction with single~hase ratings, 5-25kVA
(Supersedes previous
Type OM)

GENERAL ELECTRIC COMPANY


SPECIALTY TRANSFORMER DEPARTMENT
FORT WAYNE, INDIANA 46804
1/83

1M

General purpose transformers are designed to reach


rated temperature rise above ambient air temperature
when operating continuously at rated voltage, frequency
and load. Serious overheating with possible fire damage
may result if the unit is operated for sustained periods at
"above" rated voltage, "above" rated current,* or at
"lower" than rated frequency.
*Rated current equals volt-amperes divided by rated
voltage for single-phase units; or for three-phase units,
rated volt-amperes divided by rated line-to-line volts, the
total of which is divided by the square root of three ....
1.732.

Fig. 2 Type OM finned aluminum


construction with singlephase ratings, 5-25kVA
(Superseded by Type OMS)

Fig. 3 Type ML exposed core


construction with threephase ratings, 3-15kVA

GENERALg ELECTRIC
Printed in U.S.A.

BI006008

BI006008

Table of Contents
Page
.
.
Descnptlon
. . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 -;::>...
Trip Units General
,
. . .. 6
Thermal Magnetic
7, 15-16
MicroVersaTrip RMS-9
8-12
MicroVersaTrip 4
13
Current Limiting
. . . . . . . . . . . . . . . . . .. 14
17
Mag-Break Motor Circuit Protectors
18-27
Accessories
Applicati<?n Data General
28-29
Rating Selection
30-40
Time Current Curves
41-76
Inspection and Testing . . . . . . . . . . . . . . . . . . . . . . . . .. 77
78-106
Outline Dra"wings

Refer to GE publications GEA-11884 and


GET-7002 for information on new, solid-state,
RMS sensing Spectra RMS molded case circuit
breakers.

The Gf Faml y of Molded Case Circuit Breakers


From 10-1200

Q-LIXE

peres

T Y

El50

APPLICATIO . FLEXIBILITY

In switchboards, owr control centers and lighting


and in power pan lboards, General Electric molded
case circuit breake 'increasingly are being used to
provide reliable ci cuit protection. Molded case circuit breakers in in ividual enclosures are also being
usedin numerous applications.

J600

Kl200

ACCESSORY FUNCTIONS
Application flexibility of molded case circuit breakers
are enhanced bv a breaker accessorY line.Remote dosing or opening,'voltage-drop protection, indication of
"tripped" condition at a remote iocation, electrical or
mechanical interlocking, automatic redosing,.and
primary or sequential operation are some of the functions practical with accessories.

MINIMUM D WNTIME
Downtime is redu ed and fuse replacement is eliminated with circuit reakers. In case of overload or
shorr circuit, the beaker trips, opening the circuit
and protecting the conductors. When normal conditions are restored, he breaker can be dosed (':0::\")
again.

TRIP-FREE M
The breaker's trip- ee mechanism opens the breaker
contactS under ove load or short circuit conditions,
even with the brea er handle held in the OK position,

ELIMINATES INGLE-PHASING
Circuit breakers eli inate single-phasing. When an
overload or short c rcuit occurs on any one conductor, a common trip ar simultaneously disconnects all
three conductors 0 a three-phase circuit.

EASY SYSTEM UPGRADING


With General Elect 'c circuit breakers, the circuit can
be uprated, even af er the breaker has been installed.
Interchangeable tri s provide a v.,'ide range of ratings
within the same fra e size.

BI006008

SPACE SAVINGS
Space savings can be an important factor in selecting
Genera! Electric molded case circuit breakers as
equipment components. Higher rated breakers in
particular, offer major space economies over fused
switches.

LN"TERRUPTING ABILITY
Interrupting ratings of General Electric molded case
circuit breakers are based on actual short circuit tests.
Breakers are rated for RMS symmetrical ac amperes
and for maximum de amperes.

STANDARDS AND SPECIFICATIONS


General Electric molded case circuit breakers meet
standards established bv Cnderwriters' Laboratories.
National Electrical Manufacturers Association. Federal Specifications. Institute of Electrical and Electronic Engineers. National Electrical Code and
General Electric Company's own high quality
standards,

BI006008

Rugged, Dependable Construction


1. Molded case is ruggedly constructed insulating ma-

teriaL
2. Trip indication is sho'wn by handle position mid'\'ay
between 0:\ and OFF. To reset the trip mechanism.
move the handle to extreme OFF. then to ON position.
3.

Quick-make~quick-break, trip-free mechanism


minimizes arcing during breaker operation. Contacts cannot be "teased" into position. Trip-free
mechanism is independent of manual handle control. The breaker trips under shoTt circuit or overload. even though the operating handle is held in
0:\ position.

4. Front-adjustable magnetic trip provides instantaneoustrip in event of short circuit. Any current
surge above the trip setting produces a magnetic
field ,\'hich instantl\' actuates the trip mechanism
and opens the circUit.
.
5. VERIFIER'" "Twist-to-Trip" mechanically simulates over-current tripping through
actuation of linkages not operated by
1CRIP.... th" ON-OFF handk. Experienc" has
shown that thermal magnetic circuit
breakers in industrial applications
better maintain their original protective characteristics'when regularly
exercised.

~
~

6. Thermal trip provides protection against sustained


overloads. A bi-metallic element. not shown. reactS
time-wise in inverse proportion to the current. If a
circuit is overloaded. heat resulting from excessive
current flow causes the bi-metal to bend. actuating
the trip mechanism to open the circuit.
7. Common-trip har assumes instant disconnect of all
conductors when an overload or shoTt circuit occurs
on anv one conductor in the circuit. or an accessor>'
trip device operates.
.
,

8. Interchangeable trip units (for frames over 150 am-.


pere rating) simplify stocking and reduce inventory
requirements. Field interchangeability assures ma."Ximum flexibility.
9. Silver alloy contacts combine the conductive properties of silver with other elements for dean. positive electrical contacting. Pitting and burning are
minimized for longer contact life.
10. Arc chutes of heat-absorbing insulating material
and metal grid plates quickly "extinguish" arcs.
11. UL listed lugs for copper or aluminum cable. at full
f~:ne

rating. Easy access. and simple straight-in


wrnng.

12. Front adjustable programming functions provide a


high degree of flexibility and convenience in making and checking settings.
13. Long time pick up light is illuminated whenever the
breaker is experiencing an overload condition. The
light is extinguished by removing the overload or
tripping the breaker.
14. Glass epoxy printed circuit boards, not shown, with
epoxy conformal coding over all assembled components provide long life with error free operation.
15.

S~-itch contacts and board interconnectors, not


shown, provide corrosion resistance and long
product life.

16. Neutral current sensor connections located between the breaker lugs aIlo'w panelboard mounting
of breakers without special fillers or increased panel
space.
17. Fault trip indicators for overload. shon circuit and
ground fault are available for local indication.

BI006008

10
1

~-9

'----3

~~---8

13---

17

16

BI006008

Thermal Magnetic and Solid State Trips


THERMAL MAGNETIC AND SOLID
STATE TRIP lJNITS
Thermal magnetic trip units are available in all GE
molded case circuit breakers from Q Line through K
frame. Solid state trip units may be alternately selected
for J and K frame circuit breakers. Additionally, nonautomatic circuit interrupters, or molded case switches,
are available. These interrupters have no automatic
overload or shon circuit trip elements. They are used for
rnanual switching and isolation.

ADJUSTABLE MAGNETIC TRIP-F225,


J600, K1200 and TEC, TEML, TFC, 1JC,
TKC, TFL, THLC-2, THLC-4, TLB4
An electromagnet which partially surrounds the bimetal
is used to provide instantaneous trip in the event of a
shon circuit. The high current creates a strong magnetic
field attracting the armature and releasing the trip latch
in the same.manner as the bimetal does onoverIoad.
For shon circuit protection. the adjustable magnetic trip
provides high, low and inte1"mediate trip settings.

ENCLOSURE COMPENSATED THERM.AL


TRIP: 40C

SOLID STATE TRIP: - 20 TO +55C

An enclosure compensated thermal trip is constructed to


permit an enclosed circuit breaker in a 23"C room ambient to carry 100% of its nameplate current intermittently
and 80% of its nameplate current continuously when cabled ''''ith conductor sized per the UL 489 standard (see
Table 1, page 30).

Solid state MicroVersaTri p S:RMS-9 trip units meet the


same standards as thermal trip units. Complete circuit
breakers equipped with MicroVersaTrip~ trip units are
rated to carry 100% of their current sensor rating intermittentlvand 80% continuously in a 40"C breaker ambient. Some MicroVersaTrip<&: R\'lS-9 equipped breakers
are rated to carry 100% continuously and are so marked.

The thermal trip action is accomplished by a bimetallic


strip. The movement of the bimetal and thus tripping is
proponional to current-high current fast response,
low current slow response. This action provides a time
delay which prevents service interruptions from normal
inrush currents or temporary overloads. Continuous
overloads will cause the bimetal to deflect sufficientlv to
release the latch and open the breaker contacts. Ho{",ever, the bimetal is also sensitive to ambient temperatures. If the room ambient is above or below 25"C, or the
enclosure is warmer than normal. the breaker rating will
vary inversely to the temperature; higher ambient-lower
current. lower ambient-higher current. Endosurecompensation is furnished on Q-Line TEB, TEY, TB-l,
TED '277 volt and TED 480 volt circuit breakers.

AMBIENT TEMPERATURE
COMPENSATING THERMAL TRIP:
10 e TO 50C

In addition to the protection of conductors as required


bv codes and standards. Micr6VersaTrip~RMS-9 can be
s~t to provide protection for equipment such as motors,
generators or transformers and provide improved distribution system selectivity.

OFF

Be"fETAL

Overload Protection

An ambient compensating or-Ambient Compensated,"


thermal trip is the same as an enclosure compensated
trip with one notable exception. It has a reduced sensitivity to changes in ambient temperature. In an ambient
compensating thermal trip an additional bimetal is
added to the circuit breaker. This bimetal responds to
breaker ambient and modifies the characteristics of the
current sensing bimetal to compensate for ambient temperature changes.
Ambient compensating thermal trips are provided as
standard in all 600 volt thermal-magnetic molded case
circuit breakers.
Figure 6.1 Operation of Thermal-Mag Trip Units

BI006008

TABLE 7.1 BR1~ARER TRIP TYPES

Trip Type
Q-LINE
Non-Interchangeable
Non-Interchangeable
E-150
Non-Interchangeable
Non-Interchangeable
Non-Interchangeable
F-225
Interchangeable
Interchangeable
Non-Interchangeable
'III
T]K
Interchangeable
TH.1K Hi-Break
Interchangeable
t
J-6oo
T]4V
Non-Interchangeable
I
Non-Interchangeable
T]H4V Hi-Break
T]L4V Hi-I.e.
Non-Interchangeable
Interchangeable (Rating Plug)<D
TJH Hi-Break RMS-9
l]L Hi-I.e. RMS-9
Interchangeable (Rating Plug<D)
TKM-800
Interchangeable
TKM-1200
Interchangeable
THKM
Hi-Break
Interchangeable
K-1200
TK4V
Kon-Interchangeable
TKL4V Hi-I.e.
Non-Interchangeable
TKH Hi-Break RMS-9
Interchangeable (Rating Plug<D)
TKL Hi-I.e. RMS-9
Interchangeable (RatingPlug)
TEY
?'\on-Interchangeable
TELTEML
Non-Interchangeable
Hi-I.e.
TFL
Non-Interchangeable
TLB-2 (Obsolete)
Non-Interchangeable
TLB-4
Non-Interchangeable
THLC-1
N'on-Interchangeable
Current Limitir g
THLC-2
Non-Interchangeable
THLC-4
N'on-Inten::hangeable
TB-l
Non-Interchangeable
TB-4
Non-Interchangeable
Tri-Break (fuse 1)
TB-6
Non-Interchangeable
TB-8
?'\on-Interchangeaole
CD MicroVersaTrip RMS-9 incorporates programmers with minimum downtime. See Table 7.2 for rating
\Vith field replaceab e rating plugs providing ease of
plug selection.
changing ratings w"thin frame size and sensor rating,
Breaker Type
All
TEB
TED
THED Hi-Break
TF]
TFK
THFK Hi-Break

TABLE 7.2 JlR R:\TING PLUG SELECTION


Frame
Type

J400

150

60
80

Sensor Rating
(Amps)

125
150

J600

600

250
300

K800

800

K1200

1200

100
150

J400

300

.1 400

400

200

__ J
9')-

150
200
__ J
99-

250
300
400

Current Rating
{AJnps)

300
400
450

500
600

300
400
500
600
800

600
700
800
1000
1200

BI006008

Tripping Functions MicroVersa Trip RMS-9


MlcroVersaTrip R:v1$-9 is a trip device developed for j
and K frame circuit breakers. It incorporates the newest
technological advancements in over-current protection
for improved reliability, long life. and flexibility. Operation is fully automatic and normany no external logic or
control power inputs are required. The ::VIicroVersaTrip
svstem for molded case circuit breakers consists of three
parts, a plug-in protection programmer. a flux shift trip
device, and current sensor package.

PROGR.-\M:M..4..BLE MICROELECTRONIC
PROCESSOR
This forms the basis of the MicroVersaTrip protection
programmer. This miniaturization of circuitry provides
the increased flexibilit:-: required to incorporate nine adjustable time-current functions, three mechanical fault
indicators (local). a long-time pickup LED indicator (local) and zone selective interlocking. AU adjustable programmer functions are automatic and self-contained.
This compilation offunctions provides the basis for the

most flexible and useful breaker design presently available anywhere.

SPECIALLY TREATED PRINTED


CIRCUIT CARDS
Each primed circuit card is given a protective conformal
epoxy coating to prevent moisture absorption, fungus
growth and signal leakage. All electronics are housed
'within a metallic enclosure designed to protect against
hi-fault interruption arcs. magnetic interference, dust
and other contaminants.

FLUX"SHIIT TRIP DEVICE


A low energy. positive action tripping device is automati-

cally powered and controlled by the protection programmer.


Current Sensor Package

Three-phase current sensors are incorporated into a single package providing greater flexibility and reliability.

TABLE 8.1 MICROVERSATRIP RMS-9;'" PROGR.A...J\.fMER FU::,\CTIO::,\S


U
UTI j UGT2 j UGT2Z1
LSITI
lSIGT2 I ISIGT2Z11 ISIGT2Z2
Adjustable Current Setting
XXx
x
x
x
I X j x
LongTime
I
XXX
j
,Adjustable Long Time Delay!
x
x
x
X
x

IAdjustable Pick-Up

Short Time/Adjustable Delay

Ir;: Switch
c '- p
A lJustable I nstantaneous PiktJ
Ground
Fault

,
Targets
Zone

.x

Adjustable Pick-Up

,i

Adjustable Delay

1Ft Switch

I
!

OLSC-GF

I
I

,;

GF

I Interlock !GFST

X-

I
I

I
i

OLSC

.x
X

I
I

X
X

X
X-

I
I

I
I

I
I

X-

I
I

I
i
!

I
X-

1
X-

x
X
X

I,

X-

I
I

MICROVERSATRIP0!-RMS-9 FUNCTIO::,\ PROGRA:.\fMER CHAR.-\CTERISTICS


Sensor
Rating

Frame
Type

Long-Time .

(Multiple
of Rating
Plug Amp)

(Amps)

Short-Tnne

~'il':i

ofYC:=

Delay
(Seconds)

i
U400

150.300.400

J600
600
KSOO I 800
IK1200, 1200

I
\2.4.4.9.9.8.20
1.0, .95,
I at 6009<: of ! 1.5. 2.0. 2.5,
.90.. 85.
.80..70. current setting: 3.0, 4.0, 5.0,
I at lower limit I 7.0.9.0
.60..50
I of each band j

<l;Time delay shown at lower iimit of each band, Pick up


toierances
10%, Ground fault pick up not to exceed 1200 amps.
J600 frame with 600-amp sensor for high Ie 65k:\ rating (TJL) limited to lOX.
@Pick up fixed at l.05C.

(Seconds)

Settirig)
(C)

(X)

De1av

r.?T in.@
,40

Adjustable
Instantaneous
PickUp
(Multiple of
Rating Plug
Amp)

(Multiple
of Sensor
Amp Rating)

(X)

(5)

1.5, 2.0. 3.0,


5.0.7.0,9.0,
10.0 without
shon-time

Ground Fault

PickUp

.2..25.3.
.35. .4. .45.
,
.5 ..6

I~T out. CD
1.5. 2.0, 3.0.
9 13- 1
0-090
I
10
..- ::>,
110.0. 13.0. 15.0
i
I with shon-time I

;)'.1

,
i

X-

Current
Setting

FT.in.
.40

FT out.G)
,.10..21. .35
j

@Time dela" at 6001f of current setting at lower limit of band.


Time dela~' at 200% of pick up setting at lower limit of band.
X = rating plug amps
S = sensor amp rating
C = current setting

BI006008

CURRENT SET'~ING (STANDARD)

The adjustable current setting determines the nominal


long time current set ~ng with a = 10% band width. With
a 1.0 setting the brea~er will carry indefinitely withom
tripping the rating p ug rating. Changing the setting
changes the nominal current rating for the breaker.

CURRENT SETTtNG
.7>:

.ax

;~::
1.0X

SETTING(C)

LONG-TIME

DE~AY

(STANDARD)
LONG TIME DELAY

This long-time delay djustment varies the time it ivill


take the breaker to tr p under sustained overload conditions. It provides the unaion of i\'ithstanding momentary overloads such a motor starting. welding, or other
overcurrem conditior s 'withom interrupting the service.

Z 3

'~'
I
I

II
,

DELAY
I

LONG-TIME PI(~UP LIGHT


(STANDARD)
RATING PLUG

The long-time pickup light provides visual indication


that the breaker is eXt~riencing an overload condition.
Indication is provided by a light-emitting diode (LED).
Light flashes when CUJ ent value is 95% of pickup and is
on continuously at IO( % of pickup. Saves test and system start up time.

CAT.NO.~

X~200A

TEST

S~200A ~~O
PICKUP

SHORT-TIME PI<~KUP (OPTIONAL)


This short-time pickup adjustment controls the level of
high current the breakpr can carry for short periods of
time without tripping. Permits downstream breakers to
clear short circuit fault 'without tripping Out the upstream protective devi< I?

SHORT TIME PICKUP


Z.5C 3C

0.
~~f1/

l.se

5C

7C

9C

SHORT-TIME
PICKUP

BI006008

Tripping Functions MicfoVersaTrip RMS-9


SHORT-TIME DELAY (OPTIONAL)
The shon-time delay adjustment is used in conjunction
with the short-time pickup setting to provide a further
refinement of coordination between circuit breakers. It
establishes the time interval the breaker 'will ' ....ait before
responding to the short-circuit current level selected on
the short-time trip point adjustment.

SHORT TIME DELAY

1'"1 IN

rT OUT
MAX MAX

:~:
DELAY

ADJUSTABLE INSTANTANEOUS PICKUP


(STANDARD)
The instantaneous trip point determines the level at
which the breaker will trip \~'ithout intentional time delay (0.025 seconds or less). This immediate interruption
occurs onlv as a result of a severe overcurrent condition.
thereby minimizing damage to the electrical system and
equipment.

INSTANTANEOUS PICKUP
3X SX

2X@:7X
&

1.SX

9X

~ox

ISX 13>:

INSTANTANEOUS
PICKUP

hII

BI006008

GROL~D

FAU' T PICKUP AXD GROUXD


FAULT DELAY (OPTIOXAL)

The ground fault pi kup adjustment controls the level


of ground fault eurr nt at which circuit interruption ,... ill
occur. To comply wi h the National Electrical Code
(:'\EC 230-95). no t' point exceeds 1200 amperes. The
common square kne of the curve can be replaced with
an f't function to fa ilitate coordination with downstream devices such s thermal-magnetic breakers and
fuses whose time-cUl rent curves do not easilv relate to
the square-shape se sing characteristics common to
solid state trip devic s. The ground fault delay adjustment is used to add pre-determined delay in time to
the trip point once e ground fault pickup level has
been reached. This rovides tripping selectivity between
main and feeder or ther downstream breakers. The
gTound fault unit als includes as standard an inverse h
ramp to substantially improve coordination with downstream protective de 'ices such as fuses and thermal
magnetic circuit bre ers.

GROUND FAULT PICKUP


.35 .35S

.4$

.2SS~

.2S

.4SS

.SS
.6$

GROUND FAULT
PICKUP

GROUND FAULT DELAY

12T IN

I"T OUT

MAX MAX

:~:
GROUND FAULT
DELAY

MEMORY CIRe -IT


Because of the highl; intermittent and erratic nature of
arcing ground faults. a memory circuit has been incorporated in all Micro\ ersaTrip ground fault sensing circuits as standard. Th memory circuit integrates arcing
fault current ",..ith ti e, essentially summing the intermittent ground curre t spikes. In the diagrams. it can be
seen how the memo' function works.

Diagram C shows response of ~:ficroVersaTrip ground


fault circuits to the same ground fault: the circuit's memory carries through the missing cycles and generates a
trip signal after the preset time delay.

Diagram A. sho'ws a ty ieal ground fault "'. . it11 half-cycles,


'\'hole cycles and mul 'ple cycles missing, as normally
occurs.
Diagram B sho''''s trip esponse of a typical ground fault
function which does otinclude memorv.The breaker
never trips because t e time delay circuits are reset with
every missing cycle.

FAULT TRIP INDICATORS

(OPTIO~A..L)

Indicators are design dto reduce system downtime by


analyzing any overcu ent fault and identifying its cause.
Mechanical pop-our t 'pe indicators are available on the
programmers for ide tify-ing overload or shoTt circuit
overcurrent faults wh n breakers are ordered without
integral ground fault rotection. Indicators are available
to identify overload, S OTt circuit and ground fault
trips-for breakers s pplied 'with integral ground fault
protection.

OVERLOAD

SHORT CIRCUIT

GROUND FAULT


TAl?

INDICATOR
PUSH TO

RESET

BI006008

Tripping Functions MicroVersaTrip RMS-9


ZONE SELECTIVE 11\"TERLOCKING
The standard means of obtaining selectivity between
main and feeder breakers is by incorporating programmers with time-coordinated trip characteristics. This
consists of setting the farthest dOl-vnstream breaker with
a small time deJay, and progressively increasing the time
delay as you get closer to the main protective device. The
disadvantage in this method is that the system must nOl-v
endure the stress ofthe high current fault untiItime-out
occurs.
The Zone Selective Interlock module. Figure 12.1. receives a signal from a downstream MicroVersaTrip programmer (Logic 0) which causes the module to transmit
a low-level interlock signal to a MicroVersaTrip programmer upstream. The interlock signal activates the
LED portion of an LED-Transistor Opto-isolator in the
upstream programmer causing the fixed delay band to
shift from "ME," to the programmer delay band setting.
Both the Short-Time and Ground Fault functions are
capable of being interlocked.
Zone Selective Interlocking is available for both the
shon-time function and the ground fault function, or
the ground fault function oniy. If no shon..time function
is supplied.

SOURCE

-.-J........

T IM':;1.

-----f
20:-':0

CBI

'\

----r
-----1-

~-S==~::

zo:" I

CB2

fMl ..... ;
'v,
f.--D:..i.
,

20:\' 2

CB3

r--: T ...1.. . . . . - - - - - _

20:\'3

CB4

~ ~:l:::J
';.\1

:v

.iZS~\~:~
...
.:>

HT

MOTOR

\J

~---Ol'TPClfRO:'l PROGRA\!MER
;VI

:T

l.- -I:\,PL1

TO PROGR.A,.M.\lER

r--

----: ZSI\l
DOW:-:STRA;.\l
. l"PSTREA\!
CO:-::-:EC-TIO:\,S
CO:\'NECTIO:\'S
-

BCS

- - WIRING

Figure 12.1 Multi-Zone Interlocking

TEST JACK
The Test Jack located on the front of the rating plug accepts a test cable supplied 'with a portable, battery operated test kit separately available. The test kit will test the
circuit breaker while the circuit breaker is carrying load,
and provides either a trip or no trip test. The test kit ".-ill
simulate a time-over current condition for the long-time,
short-time and ground fault functions. It will also read
trip unit switch settings. and provide a report on the trip
unit self-test feature.

RATING PLUG (STANDARD)


Various ratings plugs are available to fix the ampere rating equal to or lower than the sensor ampere rating as in
Table 7.2.

BI006008

Tripping Fun tions Micro VersaTrip@ 4


MicroVersaTrip-4 is a trip dev-lce developed for GEJ&K
Frame circuit break . It incorporates technological
advancements in ov rcurrent protection for improved
reliability, long life, nd flexibility.

Setting and Instantaneous Pickup or optional Short-time


Pickup with fixed instantaneous, plus Ground Fault
Delay and Ground Fault Pick Up which are optional.

Operation is fully au omatic and normally no external


logic or control pow r inputs are required. The MicroVersaTrip system fa molded case circuit breakers consists of three pans. a plug-in protection programmer, a
flux shift trip device, and a current sensor package.

A 10\v energy positive action tripping device is automatically powered and controlled by the protection programmer.

PROTECTION ROGRA.MMER

CLRRENTSENSORPAC~~GE

FLux-SHIFf TRIP DEVICE

The current sensor-p wered solid-state logic unit incorporates rotary adjust ent knobs for up to four functions. The four funct' ns available are standard Current

Three phase current sensors are incorporated into a single packa;se providing maximum flexibility and reliability.

Ct.:RRENT SEITING
-STANDARD
AD]. INSTANTANEOCS PICK-UP
-STANDARD
LONG-TLME TIMING LIGHT
-STANDARD

TABLE 13.1

J600

~n

600

IK12001
(DTime delay shown at
Time delay shown at I
All pick-up tolerances
Ground Fault pick-up
When optional ad:justa

AD]. GROt.:ND FAULT DEL-\.Y


-OPTIONAL

ROVERSATRIP-4 PROGR.~MMERCHARACTERISTICS

Fixed
at I.1C

12.5

1.5.2.2.5.
3.4.5.7.

9 (C)

0.4

1.5.2.2.5.
3.4.6. S.
10 (X)

0% of current setting at lower limit of each band.


wer limit of each band.
re == 10%.
ot to exceed 1200 amperes.
Ie shon-time pick-up is provided. instantaneous is fixed at l5X.

<) <)
"
._;)- ::>.

.35. A . .45.
.5..6 (X)

lO.1O.0.22.
0.36

= Sensor Current Rating


C = Current Setting

BI006008

Current-Limiting Circuit Breakers


To meet increased demands for electrical service bv residentiaL commercial, and industrial users, and to reduce
system power losses and cost, larger low-impedance
transformers are being installed by power com panies.
The result is systems with higher available short circuit
currents. Traditional branch circuit equipment cannot
handle the fault currents available in these svstems
which can reach 200,000 TInS symmetrical a~peres or
more.
THLC current-limiting circuit breakers (CLB) react far
more quickly to high-level shon circuits than com'entional breakers. In fact, the higher the short circuit current,
thefaster the THLC operates, because of its magnetic repulsion design.
Example: if a 200,000 RMS symmetrical ampere shon
circuit at 480 volts ac were to threaten vour svstem, the
THLC1 would interrupt it in just 3 milfiseconds. At the
same time, the THLC 1 would limit peak let-through
current to less than 42,000 amperes-only 13% of t.'!Je
destructive energy that would flow through ,vithout
THLC 1 protection, and a small enough current to be
controlled by standard series-connected circuit breakers.
But a fast break isn't enough; a CLB must control arc
voltage quickly and efficiently, too.
GE THLC current limiting breakers force the arc into
patented. U-shaped arc plates where sufficient voltage is
developed to "dominate"the shon circuitfas!;. During a
480 volt interruption, for example, the THLCI quickly
counters the driving voltage ,vith a peak arc-voltage in
the range 0800 volts-sufficient voltage to quench the

shoTt circuit without causing unwanted dielectric breakdown elsewhere down the line.
And for long, reliable life, the THLC is also equipped
with special baffles to vent hot gases out of the breaker
during the arc-quenching process.
The THLC current-limiting circuit breaker is designed
to protect standard circuit breakers with ratings as low as
10,000 AIC on systems ",ith available currents up to
200,000 RMS symmetrical amps at 240 Vac or at 480
Vac. It's available in amp ratings ranging from 15 to 400
amps.
II

II

II
lU

II

II

II

II

UL-listed and CSA. certified IC ratings of200kAIC at


240 and 480 volrs and 30kAIC at 600 volts
(13-50A rated 480Vac maximum).
Patended arc plates provide fast, efficient control of
short-circuit conditions
Resettable, fuse-free construction minimizes do,'mtime
J.\1agnetic repulsion contact design interrupts short-circuit
currents of up to 200,000 amperes at 480 volts in less
than 3 milliseconds-tIle higher the current, the
faster the breaker operates
Standard circuit breaker protection with ratings as low as
10,000 AIC on systems ''oith available currents up to
200,000 symmetrical rms amperes
150-ampereframe size with ampere ratings ranging
from 15 to 150 amperes
225-ampereframe size with ampere ratings ranging
from 125-225 amperes
400-ampere frame size with ampere ratings ranging
from 230-400 ampe:-es

BI006008

Trip Unit RafJngs Molded Case Circuit Breakers


TABLE 15.1 TR~P UNIT RATINGS
.

T~

'type

Q-Line
(THQB, LC)

Fixed

TEY

Fixed

E150 Line

Fixed

TEL

Fixed

THLC-l

Fixed

TB-l

Fixed

TQD

Fixed
Fixed and Interchangeable

II

I
I
r

TFL

Fixed

THLC-2
1JD

Fixed
Fi.xed

J-400

Fixed and Interchangeable

J-600

Interchangeable

TLB-4
THLC-4

Fixed
Fixed

TB-4

Interchangeable
,

TB-6

i.

Interchangeable

K-800 Line

Interchangeable

K-1200 Line
TB-8

I
I

Interchangeable
Interchangeable

T_~

OI.ype

Fixed
15,20,30,40.50, 60,

Fixed

70, 80, 90, 100

10,15,20,25,30,35,40,
45,50,60,70,80,90, 110,
125, 150
15,20.25,30,35,40,
50,60. 70. 80,90, 100,
125, 150
15,20,30,40,50,60,70,80,
90, 100, 125, 130
15,20,25,30,35,40,45, 50,
60,70.80,90,100
100,125,150,175,200,225
70,80,90,100,110, 125,
150,175,200,225
70.80,90,100,125,
150,175,200,225
125,150,175,200,225
250,300,350.400
125, 130,173.200,223,
250,300,350.400
250,300,350,400,
450,500,600
250.300,330,400
230.300,350,400
125,150,175,200,225,
250,300,350,400
300,350,400,500,600
300,350,400.450.500,
600,700,800
600,700,800,1000,1200
600, 700, 800

Fixed

Fixed

,
Fixed
Fixed
Fixed
Adjustable
Adjustable
A<Uustable
Fixed
Adjustable

Adjustable
Adjustable
Aqjustable
Adjustable
Adjustable
Adjustable

Aqjustable
Aqjustable

BI006008

Adjustable Magnetic Ratings-Molded Case


Circuit Breakers
TABLE 16.1 ADJUSTABLE MAGNETIC RA.N"GESG) (in rIDS symmetrical amperes, nominal'

lEiOO
Trip
Unit

Hi
70

600

80
90
100

600
600
600

110

600

125

600

150
175
200
__.J

'>9~

_.J
900 1')900 150
900 175
200
1250 __
1250 , 99-.J
1250 i 250

700 1500
800 1750
900 , 2000
1000 12250

300
350
400

375
450

1250
1500
.J_.J
1750
600 2000
675 2250
750 2500
900 3000
1050 3500
1200 4000
~')-

250
750 ' 2500 II 300
900 3000 : 350
300
350 . 1050 3500 400
400 11200 4000 450
450 1350 14500 500
500 1500 5000 600
600 1800 6000 700
800

900
1050
1200
1350
1500
1800

3000
3500
4000
4500
5000
6000

2100 6400
2400 6400

THLC2

Trip
Unit.

1.0

125
150
175
200

600
700
800
900
1000

__ :J
99-

Hi

1250
1500
1750
2000
2250

250
300
350
400

1100
1400
1600
1800

2500
3000
3500
4000

375
450
-9a-a
600

675
750
300
330
400
300
600

<D Consult published trip-time curves for tolerances.

900
1030
1200
1500
1800

1250
1500
1750
2000
2250
2500
3000
3500
3500
3000 TB..6
3000TB-6

600
700
800
1000
1200

1800
2100
2400
3000
3600

6000
6400 1
6400 1
10.000
10,000

BI006008

Mag-Break Motor Circuit Protectors


.\lag-Break provides accurate and fast clearin of
faults on motor eirc itsincluding Jo-w level
faults-the type mo t
prevalent in motor i stallations. Mag-Break s rves
to minimize damage to
motors and motor c trol
apparatus in additio to
protecting motor b nch
circuit conductors. C ntinuous current ratings nd
adjustable instantane us
trip ranges have bee designed to meet l'\ECequirements concerni g
motor full load and I eked
rotor current. The Mg'Break instantaneous rip
point can be set !o',,' d
precisely Gust above
motor inrush) assuri
fault protection and liminating nuisance tripp ng.
Each pole of the~lag
Break breaker contai s a
current sensing elem nt to
trip the breaker insta taneously when the pre elected current setting .
exceeded. Mag-Break s
unique magnetic syst m
permits independent
factory calibration of th
the Hi and Lo ends 0 the
trip range. This provies
field adjustability with accuracy and repeatabiE y at
I;
all Mag-Break
trip scale
positions.
2

10

STANDARD

I~TERRlJPTING DEVICES

0::::::.

TEC
3-150

TFC
__0

AMPERES

AMPERES

..".,..... ..

Ii

~~
800_.~0
0
.
1200 .
.
.
..
AMPERES
.

TKC . 0
9';-

.--:.,.: ..

LIMITER ASSISTED DEVICES


lIji--Af;-

TEC&:
TECL
3-150
A\fPERES

TBC4
400
Al\lPERES

TBC6

TBCS
800
AMPERES

600
AMPERES

Table 17.1 TRIP SET POSITIONS TO TRIP AMPERES

I TEC36003. TEML36003 i

I TEC36007. TE.\TL3600i I
TEC36015, TEML36015
TEC36030, TEML36030
TEC36050, TEML36050
TEC36100. TEML36 100
TEC36150. TE.\fL36150

Cat. No.
3-Po}e

In addition to the two .ndependent factory cali rations, Mag-Break is fie d


adjustable by scre'wdri 'er
adjustments on the fr t
of each breaker. The eld
adjustable setting is co .tinuous over the entir
range from Hi to Lo. a d
each breaker rating la 1
contains
a table
conve in cr:::>

.
settmg posmon to amperes. An overcurrent
any pole will cause all
three poles to trip sim
neously, thus preventi
costly single phasing
problems.

TFC36225
225
TFC36225A
225
TjC36400B
400
TjC36400E
400
TjC36400F
400
TjC36400G
400
TjC36600G
600
TJC36600H
600
TKC36800LG)
800
800
TKC36800:\f G)
TKC361200UD
1200
TKC361200MG)
1200
UMITER ASSISTED DEVICES
TBC43225Fl4F
225
TBC43400Fl4G
400
TBC63600j 14L
600
SOO
TBC83S00K18
<DFor motors aDove 350 Hp

uSC

600
1000
1200
330
550
1000
1000
1800
3000
5000
3000
5000

780
1200
1400
435
720
1280
1280
2100
3600
6000
3600
6000

550
1000
3000
2400

720
1280
3600

MicroVersaTrip t-"qtzipped breakers.

iOOO

1200
1920
3250
860
1280
2360
2360
3600
5100
8400
5100
8400

1400
2250
4000
1100
1670
3300
3300
6000
6000
10000
6000
10000

945
li80
4300

1280
2360
5100

1670
3300
6000
6000

1020
1630
18.50
600
94~O
1780

li80
2600
4300
7000
4300

~ToJerance is

=20% of nominal value.

BI006008

Accessories
MOLDED CASE CIRCUIT BREA.KERS
Undervoltage Protection

The Undervoltage Release


instantaneously trips the
breaker when voltage
drops to 35-70% of normal rating. The device retrips the breaker if it is
closed before normal volt~
age is restored.
Standard dutv and heavv
duty types ar~ available.'

Auxiliary Switch

An auxiliarY s"..-itch can be


used to.operate otheraccessories, indicating lights,
relavs. for automatic reset,
etc. 'A~ailable with one to
four SPDT elements for
flexibility. Switches open
and dose as the breaker is
either manuallv or remotely operat~d.

Time delay Unit For


use with 'lTVR
This unit prevents nuisance tripping due to momentary loss of voltage.

A separate, externa.lly
mounted unit has 120 volt
ac input and 125 volt dc
output with delay adjustable from .1 to .5 seconds.
It is used in conjunction
with 125 volt dc undervoltage release, which must be
ordered separately.

Mechanical Interlocking

The Mechanical Interlock


is a walking beam type e-xternallink between two
breakers mounted in a
switchboard structure.

The interlock permits only


one breaker to be on at a
time: however, both breakers can be OFF at the same
time.

Shunt Trip for


Remote Tripping

Motor Operator for


Remote "On-off"

Bell Alarm

A bell alarm actuates a


warning signal or other
circuitn'when the breaker
is tripp~d under overload,
shoTt circuit, shunt trip,
undervoltage trip, and 3
coil shunt trip conditions.
Not actuated during normal ON-OFF operation.

A motor-operated mechanism can open, dose or reset a breaker. remotely.


This convenient attachment mounts integrally
with the breaker, without
modification to the
breaker or its handle. Just
lift the cover of the accessory mechanism to operate
the breaker manually.
Breaker ON-OFF is indicated in the operating
mechanism cover.

Standard
A Shunt Trip Device can
be used to trip and open a
breaker bv remote control.
When the' breaker opens,
the shunt trip coil circuit is
de-energized by means of
an auxiIiarv switch. Thev
meet VL requirements for
operation at 55% of rated
voltage foruse on ground
fault systems.
Three-coil (not illustrated)
This provides single-phase
protection for fused circuit
breaker combinations,
factory installed only.
It mounts in right pole for
TEB, TED, and in left
pole for TFK TJK, TKM.
Installed internally similar
to standard shunt 'trip with
leads connected across the
fuses. It trips breaker
when a fuse blows or if the
breaker is closed under
load with a fuse open and
fits all breaker types
including molded case
switches. Suitable for system voltages 208 to 600
volts ac.

BI006008

Accessory Availability

Bel Alarm Switch

Breaker T:l"pe

b-Line

GEH-

Combination .
Accessories
Total Number of

GEB-J

I!

i CL

IGEH-

I!

lone

l TED. THED.
CL

CL

4576
5402

i2-pole circuit

breaker-any
one
3-001e circuit
breaker-any
two except
l'VR and 3coil shun! trip

1341~ Au.\:

0)

CL

ITBI. THLC-1

,3416 S.T.
CL 15403 Aux
5401 S.T.

3417

CL

5400

3434

F225 TFC.
TIJ. TFK.
THFK. TIL.
TLB-2
\THLC-2. TLB-4
! THLC-4

n.

CL

3320

CL

3321 Auxi
CL 3435 S.T. ,

lJ600 TJC. TJD.


i TJJ. TJK.
THJK
TB4. TBC4@

4653
5406

CL

CL

4653
5406

CL

5407

VL

L~'1v two

4622

I.

Any two plus bell

3346

j alarm

K1200 TKC.
TKM.THKM

13321 Aux

ITB6.TBC6.

4305

mS. TBC8
jMicroVersaT rip

CL

,
,{L

4626
4663

5408

CL 13344 S.T. ,

14 and R?>fS-9.
TJ4V. THJ4V.
TJL4V. TK4V.
TKL4V. TJH.
TJL. TKH.

II

4620
L'L 5406

only

lOne only

IIEJ50TEB. TEC.

Blown Fuse
Trip De"ice

Mo;::ng :~'Mo;:g =tIM~~ ~=t ~~=

I R I GEH-

GEH-l L

/TQD. THQD

. TEL. TE?>IL

l:ndervohage
Release

Inst. Mounting I lnst.


Sheet
POle' Sheet

Me unting
Pole

I~~~~@

14623
CL 14623

TKL

VL

IAnv two plus bell


! alarm'

3346

,Any one plus bell'


IICLalarm
Listed for

Auxl

S.TI

CL

CL

4623

4624

CL

4.3"3 I field
. - ; inStallation
except bell
alarm

.... _Purple

(Accessory Lead
jColor Coding

~-Yellow

'--.t1-Brown

B lJ Alarm
S,,'itch

Shunt Trip
Black
...... Black

e:-

:Blue
Blue

,;;;.",_R<-'d
'"'- Brown/whitel
~Blue

l:ndervoltage
Release

Q) Left pole mounting not a 'ailabJe for 2 pole TEB. TED.


@CL Ih"ted at 200.000 AIC without internal accessories, 100.000 AlC
with internallv mounted ccessori<;.'$.
@600 volts AC ~uxiliarv sw ,chcs are not CL listed.
@Formeriy green.
.
:'\Ot available with lead ex t from the back of breaker,

White

r-: Yellow

Same as
individual
accessories

All aecessorv
contaCts shown
with the cireuit
breaker in
jtripped po:,ition.

Black

CL listed inteIT'<.lpting capacity with acc<--s.-<orit.'S: 10K AIC at 6<J0


volts AC. 22K AIC at 4SO volts Ae. 22K AIC at 240 volts AC.
0.\faximum available shon circuit application is 85.000 S:ID rms A.
Acccssorv mountS in a one-inch frame and increases over;ul breaker
size b~ o~e pole added to left side.
Leads are #18 AWG 125"C Vullene" insulated,

BI006008

Accessories Electrical Data


a-tine
THQL, THQB,
THQC, TQD, THQD

Auxiliarv Switch

. . --l;-------.-u-.~---,----Ra-s"'-~-~-g----i

r---~-""-::~'--"--I-""":=--:TQB. THQL,
THQB.
TQL,

'I'

TQC. THQC

TQD, THQD

TQh."59_.~~l

TQC:AS2Al

TQDAS2ABIRS

1-5P5T (A)

6 amperes-120 V.A.C.
3 amperes-24 V.A.C.

l-SPST (A)
1-SPDT (AB)

6 amperes-120 V.A.c
3 amperes-24 V.A.c.
6 amperes-240 V.A.C
liz ampere-I23 V.D.C
ll, ampere-250 V.D.C.

Shunt Trip

TQB, THQB,
TQL THQL

TQC, THQC

TQD. THQD

TQST 1
TQST 2
TQST 7
TQST8
TQCST 1
TQCST 7
TQCST8
TQDSTI
TQDST2
TQDST 7
TQDST8
TQDST9

120
240
12
24-48
120-240
12

24
120

Amperes (Inrush)
ac
de
2
3
4
2.4
2
4
2.4
.9

.8

240
24

7.5
4.8

48

2.4

12

j
i

[I

BI006008

E150

TED, THED, TE,


TEe, THLC-I, BI,
TEL,TEML

Auxiliary S"witch (Installation Instructions GEH-3418 or GEH-5403)

Catalog
Num.ber<D

Kumber of
I"
Switches..

Switch Ratings

6 amperes.. '/~ horsepower. 120.. 240 volts ac


5 amperes.. 120 volts ac "Lamp Load.. .
y~ampere. 125 volts de
2
~:, ampere. 250 volts dc
<DFor TEL TE:YIL breakers substitute TEL for TED in catalog number (second installation
instruction noted applies).

I TEDAS2AB I R
I TEDAS2AB2

Shunt Trip (Installation Instructions GEH-3416 or GEH-5401)

TEDST12
120-240
125
I
1..0-1.9
1.0
TEDST13
480-600
I
1.5-1.9
TEDST 7
12
7.5
TEDST S
24
4.6
TEDST 9
48
2.4
TEDSTI I
250
!
0.4
0) For TEL, TE:YIL breakers substitute TEL for TED in catalog number (second installation
instruction noted applies).

lJndervoltage Release (Installation Instructions GEH-5400


or GEH-3417)
Catalog Number<D
Heavy Duty/Std. Duty
TEDxeVAR I TEDxeVBR lev I
TEDXCVCR ICV 2
TV 4
lev 6
TEDxeVDR rev 7
TEDxeVER 1l.'V 8
Il."\' 9
TEDxeVFR
TDXCVGR /CVlO
TEDXCYHR lev I I

100
IS
18
18
18
200
100
50
33
18
IS

24
120
240
480
600

7.500
20.000
30.000
12
24
4S
60
125
250

7.500

<D For TEL. TEML breakers substitute TEL for TED in catalog number (second installation
instruction noted applies).
For TEL TEML breakers standard duty only.

Bell Alarm (Installation Instructions GEH-4576 or GEH-5402)


Catalog Number<D
'rED1:>AR

S~itch

Mounting
Right Pole
Lef, Pole

Raring

:5 amperes.. 240 volts ae

.5 amperes resistin:. 2~~ ampere,


inductive al 21'> volts de
<D For TEL, TEML breakers substitute TEL for TED in catalog number (second installation
instruction noted applies).
TEDBAL

Motor Operators (Installation Instructions GEH-5007)

~~~
n

'.

Voltage

Timing (Secouds)

I Inrush~ning 1 Closing

i. .:r};\IO). IAI I120 volt, ae 1


ITED:\10?\IA2 240 volt, ae
ITED\10).1A81 24 voiL,

,".0
2.2
2.0

1.6

.57

1.0

1.5

I ~::g

1.5

LiS
1.75

1.5

1.75

Reeon:U:nended

Fuse
0.5 Ampere

(Time Ddav)

BI006008

Accessories Electrical Data


F225

TFJ, TFC, TFK,


THFK, THLC-2,
THLC-4, TFL, TLB-4

A~iary

Switch (Installation Instructions GEH-4653 or GEH-5406)

~~c)gN~@

NtIinbcbr~fS~clt.es

TFK:\SA2AB2.
TFKA.sA2A.B4

s~4tc:hRatixlgS

2
4

5 amperes. 240 volts a c l


5 amperes resistive, 2Y2 amperes
inductive at 28 volts dc
<DFor TFL breakers substitute TFL for TFK in catalog number (second installation instruction
noted applies).

Shunt Trip (Installation Instructions GEH-4653 or GEH-5406)

120-240
480-600

TFKSTA12
TFKSTA13
TFKSTA 7
TFKSTA 8
TFKSTA 9
TFKSTAll

9_.1

.9-1.9
1.5-1.9

7.5

12
24
48
250

4.2
1.0
0.4

CD For TFL breakers substitute TFL for TFK in catalog number (second installation instruction
noted applies).

Undervoltage Release (Installation Instructions GEH-4653


or GEH-5406)

TFKVVA 1
TFKVVA 2.
TFKVVA 4
TFKCVA 6
TFKVVA 7
TFKCVA 8
TFKVVA 9
TFKUVAlO

120

IS
IS
18
18
200
100

240

7,500
20.000
30.000

480
600

50
18

CD For TFL breakers substitute TFL for TFK in catalog number (second installation instruction
noted applies).

Bell Alarm (Installation Instructions GEH-4620 or GEH-5406)

.Catalog

Number<D!

Switch Rating
~ amperes. 24~ v?lts ac
,
TFKBA..- \R @
,
,:) amperes, reSlsuve
I
2 1/2 amperes inductive at 28 volts de
<DFor TFL breakers substitute TFL for TFK in catalog number (second installation instruction
noted applies).
Changes circuit breaker interrupting capacity to: lOKA @ 600 Vac. 22KA @ 480 Vac, 22KA.
@ 240 Vac.
@) UL listed for field installation v,ith model 4 frames and trips.
I,

Motor Operators@ (Installation Instructions GEH-4581)


j runing (Seconds)
INnning
120 Vac I
5.5
9.5
iTFK:'l0YlAI
125 Vdc I
7.0
4.5
9 _.;)
240 Vac
5.0
lTFKMO\lA2 250 Vdc
4.0
6.0
!
16
iTFKMOMA8i 24 Vdc i 24
lTFKMO\1A9! 48 Vde i 14
9
@) ~ot Available For THLC-2. THLC-4.
I

II}I

9-

0_,

I,
;

0.25

0.45

0.50

0.25

0.25

I Ampere
(Time Delay)
2 Ampere
(Time Delay)

BI006008

J600

TJC, TJJ, TJK,


THJK, TJD, TB ,
TBC4

..

Auxilia..rySwitch (Installation Instructions GEH-3321)

. . $~.;;;..
."
i
.~

'V.

6 amperes. 1/2 horsepower. 120.240 volts ae


5 amperes, 120 volts ae "Lamp Load"
lh ampere. 125 volts de
1/4 ampere, 250 volts de

TJKASA2ABl
TJKASA2AB2
TJKASA2AB3
1]KASA2AB4

3
4

Shunt Trip (Installation Instructions GEH-3433)


-----.,.--.,.--.,.---.,.--~

TJKSTA12
TJKSTA13

19~
_:J

120-240

TJKSTAi

1.0

.9-1.9
1.5-1.9

480-600

i.5
4.6
2.4
0.4

12
24

TJKSTAS
TJKSTA9
1]KSTA I I

48
250

Undervoltage Release (Installation Instructions GEH-3407)

T.JUVIR
TJUV2R
TJUV4R
TJUV6R
TJCV7R
TJCVSR
TJUV9R
TJCVlOR
T.fCVllR

18
1S
IS
18
200
100
50
18
18

120
240
480
600

i.500
20.000
30.000

12
24
48
125
250

7.500

Bell Alarm (Installation Instructions GEH-3320)

Hea~J

Duty Undervoltage Release (Installation Instructions


GEH-5409)

TJMDVAS
TJMDVBS
TJMDVCS
TJMD"VDS
TJ:vfDVES
TJy!DVFS

100
IS
18
200

24
120
240

7.500

100

12
24

33

60

Motor Operators (Installation Instructions GEH-4676)


Timing (Seconds)

TjKMO~IAII' 120 volts ae

J.

125 volts de t
TjKMOyfA21240 volts ae i
, 250 volts de 1
ITjKMO:\:IASI 24 volts de
IT.JKMO:\IA91 48 volts de,

9.5
10.0
5.0
5.5
22.0
14.0

5.5
3.5
3.0
2.5
15.0
10.0

<DTj4V. TJH-S breaker requires mounting plate Cat.

I Ampere
(rime Delay)
2 Ampere
(Time Delay)

.35
~o.

286A755SG8.

BI006008

Accessories Electrical Data


KI200
TKC, TKMA,
THKMA,TB6,
TBC6, TB8, TBe8

Auxiliary Switch (Installation Instructions GEH-3321 )


Ntu:r:tber of SWitChes
1
2
3

CatalogNl1mber
TKMAAS2ABl
TK~lAAS2AB2

TKMA.A.s2AB3
TK:'IAAS2AB4

Switch Ratings

6 amperes.
5 amperes.
% ampere.
lh ampere.

lh horsepower. 120, 240 volt:> ae


120 volt:> ae "Lamp Load"
250 volts de
125 volts de

Shunt Trip (Installation Instructions GEH-3344)


Volts

Catalog
Number
TKMASTA12
TK:"lASTA13
TKMASTA 7
TKMASTA S
TKMASTA 91
TKMASTAllj

ac

de

12~240

125

Amperes (Jnrush)
ae
de
.9-1.9
1.0

1.5-1.9

480-600

4,3

12
24
48
250

7,5

2.4
.4

Undervoltage Release (Installation Instructions GEH-5408)


Catalog
Number

Dropping (25 watt)


Resistor

TKCV 1
TKCV 2
TKCV 4
TKCV 6
TKCV 7
TKVV S
TKVV 9
TKCVIO
TKCVll

IS
18
IS
18
200
100
50
IS
18

120
240
480
600

7.500
20,000
30,000

12
24
48
_0
l er
250

7.500

Bell Alarm
Switch Rating

. Catalog Nl1mber

5 amperes. 240 volts ac. 5 amperes resistive.

Center Pole

TKMABA.:\L

2V:: amperes inductive at 28 volts de

Heavy Duty Undervoltage Release (Installation Instructions


GEH-5410)
1
I

~_umber_t:al_og

-:-__Current
__
DLi_A.

TKy[DVAS
TKy[DVBS
TKMDVCS
TK:'1DVDS
TKy[DVES

-+-I~-_-_-_a~e_~-_V__...,Ol-+-1-ts_-_~-d_-c,--_-_-=,--_lli__OP_P_Ring_esISt__(25_O:_watt)_-;

100)
18,
18
200
100
33

TKyfD\'FS

24
120
240

7.500

12
24
60

Motor Operators (Installation Instructions GEH-4675)


<::atalog Number

CoJit:rcjI

Ttming (Seconds)

All Kl200<D
TKMMOMAI

Im~~~ I l~g

TK\ly!OMA2

240 Vac
250 Vdc

5.0
4.5,

~.~ I} 0.30
3.0
3.0

TK\-DJOMA8
24 Vde I 22
I 15
! 0.60
0.35
TK:.,p,lOMA9 j 48 Vdc I 14
! 10
0040
0.30
G)TK4V. TKH-S breaker requires mounting plate Cat. :-':0. 286A7558G7.

I 1 Ampere

; (Time Delav)

I
.
I 2 Ampere

I (Time Delay)

BI006008

J600&KI200
MICROVERSA
ACCESSORIES
RIGHT POLE
MOUNTING

Auxiliary Switch
Catalog Number
TVAS2AB2R

No. of Switch

Ele,mettts

TVAS2.-\B4R

TVAS6AB2RG)

TVAS6AB4RG)

6 amperes-240 volts ae
Y2 amperes-125 volts de
v., amperes-250 volts de
GEH-4623

6 amperes-'600 volts ac
Y2 amperes-125 volts de
v., amperes-250 volts de

(DXot CL listed

Voltage

Shunt Trip
Catalog Number

ac

de
12
24
48
250
125

TVST7R
TVST8R
TVST9R
TVSTllR
TVST12R

120
240

TVSTlSR

480
600

v(V0~)el

Undervoltage

N.~2.~

Current (Inrush)
(Amperes)

(Volts)

ac

de
<) -

-~

Installation
Instructions

Coil
Resistance
1.6

4.6

1.0
1.9

2.4
0.4
1.0

1.5

46.0
1250.0

GEH-4623

130.0
313.0

1.9

.External

Current

f InstaHation

r----:~...,..-..;..-.;...-a..;.;c(mA...,..~d);.,..e.......j ReSiC:nce :~ f--_R_esISt_...-_or_---l I~nsuc~


ae
de 1
Ohms I Watts
'"'"
TVGV1R
I 120 I I 18
7100
None
I
TVTV2RI 240 I
! 18
7100
7,100! 12\\7
TVn-3R
I 380 I
18
7100
YES
15,000 ; 25W
TVeV4R
480 r
18 I
7100
20,000 i 25W
TVDV6R
I 6001
IS !
7100
30,000 I 25\N
I TVDV7R I I 12
! 200
60
1

j TVDVSR

CENTER POLE

MOUNTING ON

TVeV9R
TVTVI0R
TVGV11R

j 24

48 I
1251
250 I

Bell Alarm Switch


Catalog Number
l]VBALS
TKVBALS

I 100 I

240

50 I
18
IS]

960
7100
7100

NO

NONE

7.500

Single-Pole Dotible-Thr'ow
Switch Rating

5 amperes-240 volts ae
2.5 amperes- 28 volts ae

12'\\7

htsta1latioii
InstructionS
GEH4626
GEA.-4663

BI006008

Accessories-Bectrical Data
J600&K1200

MICROVERSATRIP
ACCESSORIES
RIGHTPOLE
MOUNTING
TV6AB2STIR
TV6AB2ST8R
. TV6AB2ST9R
! TV6AB2ST11R

TV2AB2ST7R
TV2AB2ST8R
TV2AB2ST9R
1 TV2AB2ST1lR

TV6AB2ST13R

TV2AB2ST13R

Installation
Instructions

Same
as
Auxiliar"V
Switches

GEH-4623

12
24

TV6AB2ST12R ) TV2AB2ST12R

Switch
Rating

48
120
240

Same
as
Shunt
Trips

250
125

480
600

Combination Undervoltage/Two Aux. Switches


Installation :
Instructions I

Catalog NlUD
600 Volt.Am:
, TV6AB2UVIR

! TV2AB2UV1R

120
240
TV6AB2UV3R I TV2AB:!CV3R
380
TV6AB2UV4R 1 TV2AB2UV4R
480
ItTV6AB2VV6R
TV2AB2UV6R
600
-------+-------+---4---....;
TB6AB2UV7R
TV2AB2UV7R
1--+-+_ _-'-_ 12
_....;
I TV6A"B2VV8R
TV2AB2UVSR
24
1-------+-----"----4----4---....;
TV6AB2CV9R
TV2AB2UV9R
48
, TV6AB2CVlOR , TV2AB21JVIOR I
TV6:\B2UVllR I TV2AB2UVllR 1
250

!TV6AB2UV2R I TV2AB2UV2R

Same
as
UnderVoltage
Release

Same
as
Auxilian'
I $witche;

GEH-4623

Motor Operator All j600 Frames (Installation Instructions GEH-4676)

TJKy!OMAl!120voltsae
9.5
5.5
l125 volts de
10.0
3.5
.
,TJK:\fOyIA2 240 volts ae
5.0
3.0
i
250 voltS de
5.5
2.5
TJK:\10:\IA8 24 voltS de
22 X)
15.0
1]K:'v!OMA91 48 voltS de
14.0
10.0
@Requires mounting plate Cat. )<0. 286A7758GS.

:}30 }30
.60
.35

I Ampere
(Time Delay)

.35
.30

2 Ampere
(rime Delav)

Motor Operator An K1200 Frames (Installation Instructions GEH-4675)


~

-'

,~

"

Opening

All

120 Vac
125 Vde

TKM:\10:\IAl

240 Vae
250 Vde

TKM:\1OMA2
TKMMOMA~

TKM:YI0MA9

Inrush
9.0
r 10.5
I 5.0
4.5
i

24 Vdc!
48 Vdc

Requires mounting plate Cat.

22
14
)<0.

-Reset

<>

6.0
4.5
3.0
3.0
15
10

286A7558G7.

i}ow

Recomrnendt:d

Fuse

0.30

I Ampere
(Time Delay)

0.35
0.30

; 2 Ampere
(rime Delay)

0.60
0.40

BI006008

Accessories- echanicaJ Data


Back Connections

Plug-in Mounting

Base

Front-connected Cu-. I
lugs allow easy cable d.
The lug mounts dire y to
the mounting surface \'ith
screws and lockwashe .

Back-eonnected studs
need to be supponed by a
sub-base, but make positive contact 'with each line
and load terminal. Studs
stay in place while the
breaker can be removed
or installed.

PERATING
TDR Rotary
Operating Ranell

The Rotary-Operating n:egral Handle mounts d rectIv to the breaker. an


:>pe;ates through the d or
)f the enclosure. A me:hanical interlock preve
'.mauthonzed opening
:he enclosure when the
~andle is in the 0:\ posi
:ion. The locking hasp a :ommodates up to three
Jadlocks. Suitable for h r'zomallv or verticallv
:nount~d breakers. For
\EMA 12K and :\EMA
12 enclosures.

Base,
with
Optional
Mounting
Plate

A plug.;in base assembly


provides for quick
changeout of breakers.
The assembly backplate
mounts to angle-iron
cross-pieces.

Breaker plug-in terminals


align "..ith one-piece backplate assembly.

MECHAl~ISMS

STDA Flange Handle


and Variable Depth
Operating
Mechanism

Tne STDA Flange Handle


is for use with 150-1200
ampere frame circuit breakers. It is designed to meet
automotive dmy specifications, and ?\EM.A 12 and
:\EMA. 4/4X. UL recognized components are
used. The mechanism is of
the Quick-:\1ak.e, QuickBreak ty-pe 'with an integral
mounting plate and low
operating force. Mounting
dimensions fit standard
flange enclosures 8'-24'
deep. Detailed installation
instructions are provided.

TDM Adjustable
Depth Handles

TD:M Door-Mounting
Handles are available in
shallow mounting types
and extended shaft type
for vertical or horizontal
breaker mounting. The
mechanism provides
interlocking. The doormounted handle accommodates up to three padlocks. Suitable for :\E:vIA
12K and :\E:MA 12 enclosures.

NOTE: A pendulum-type
handle designated Cat.
:\0. THCH 45 is also
available for :\EMA 4,
:\EMA 4X and 2) enclosures.

27

BI006008

Application Data-Molded Case Circuit Breakers


Molded case circuit breakers are circuit protective devices that primarily perform two functions: (1) manual
switching operation to open and close a circuit by means
of a toggle handle and (2) automatic opening of the circuit under sustained overload and/or shorr circuit conditions. Circuit breakers inherently provide the automatic
protective function of opening the circuit under abnormal sustained overload. or short circuit conditions, ",ithout the use of fuses. \Vhen a circuit breaker opens to
clear a fault, the toggle handle goes to a TRIPPED position mid-way between the 01\ and OFF positions, thus
clearly indicating that a circuit breaker has opened.
'When the cause of the fault has been removed, the circuit breaker can again be dosed simply by moving the
toggle handle to the RESET position, and then moving
the handle to the ON position.
Circuit breakers have an advantage over fusible elements. A fault on one pole of a multi-pole breaker
actuates a common trip bar that opens all poles simultaneously, thus avoiding single phasing a motor circuit, as
could occur in a fusible device. Molded case circuit
breakers are "trip free" in construction. This means that
the circuit breaker contacts cannot be held dosed against
a fault condition. Molded case circuitbreakers are designed to protect insulated conductors against unsafe
overheating that would ultimately damage the insulation
and conductor.
Thermal-magnetic molded case circuit breakers are not
designed to provide motor running overload protection.
This function is normally performed by overload relays
supplied in manual or magnetic motor starters. However, for infrequently starred motors, MicroVersaTrip
equipped molded case circuit breakers can be used to
provide motor overload, overcurrentand ground fault
protection.
Molded case circuit breakers meet applicable UL Standard 489 covering "Branch Circuit and Service Circuit
Breakers" and meet NEMA Standard A.B-I-Molded
Case Circuit Breakers.
UL Standard 489 makes provision for two classes of
products-UL Standard rated and UL 100 percent
rated. The basis of these ratings for molded case and Insulated case circuit breakers is as follows:

F225
70 thru 225 Amperes

J600

K1200

125 thru 600 Amperes

300 thru 1200 Amperes

B. IOO-percent rated under VI. 489


1. Circuit breakers are rated to carry 100 percent of

their nameplate current continuously in an enclosure


\\ith ventilation and volume as specified on the device
in a room ambient of 25C when cabled as specified
in Table on page 32 using 90C insulation.
2. Room ambient temperatures other than 25C, cable
other than specified in Table on page 32, or enclosure volume and/or ventilation other than specified
on the devices may require derating of the system.

Standards and References

A. Standard rated under tTL 489

Underwriters' Laboratories
UL 489 Branch Circuit and Service Circuit
Breakers-Order from UL Publications Stock,
333 Pfingsten Road, Northbrook, Illinois 60062.

1. Circuit breakers are rated to carry 100 percent of

National Electrical Manufacturers .o\ssociation

their nameplate current continuously in free air at


25C when cabled per Table on page 32.

18

E15D
10 thru 150 Amperes

(NEMA)

A.B-I Standards Publication-Molded Case Circuit


Breakers Order from NEMA Publications, 155
East 44th Street, New York, New York 10017

2. Enclosed circuit breakers are rated to carry 100 percent of their nameplate current intermittently (up to
3 hours maximum) and 80 percent continuously,
with the enclosure in a 25C ambient, and cabled per
Table on page 32.

Federal Specifications
WC-375 Circuit Breaker, Molded Case; Branch Circuit and Service

3. Group mounted circuit breakers may require derating of the circuit breaker and cable in room ambient
temperatures other than 25C and ,\ith cable other
than specified in Table on page 32.

National Electrical Code <I'i"'EC)


Latest Issue
Order from National Fire Protection Association,
Bauerymarch Park, Quincy, Ma. 02269.

BI006008

FEDER..,u SPEC IFICA.TIONS


WC375a

Federal Class
la
Ib
2a
2b
2c
2d
2e
2f
3a
3b
3c
3d
4a
4b
4c
5a
5b
6

W-Q375b
FecieralClass
WaeD
lOb
lla
llb
12a
12beD

I2c
I3a
I3b
HaeD
14b
15aCD
ISb
16a@
I6b@
Iia@
l8a
I9a
20a
2Ia
22a
23a
24a
25a
26a
);ot defined

Circll.it~~erT~

Poles
1 pole
2 and 3 pole
1 pole
1 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole
2 and 3 pole

THQL, THQAL, THQB, THQC


THQL, THQAL, THQB, THQC
TED,TEY
THQL, THQAL, THQB, THQC
THQL, THQAL, THQB, THQC
TED
TBI
THED
TFj, TFK
THFK
TB4
TJJ, TJK
TB4
TJJ, TJK
THJK
TJK6, TKM8
THJK6, THKM8
TB6

Voltag~ (ac)

120/240
240
9-_II
!

120
240

600 volts max

......

~t B:r~er Type

P()les

Voltage.
f

{ THQB, THQL, THQC, THHQB,


THHQL, THHQC, THQBGF, THQLGF,
THQCGF, THHQLGF, THHQBGF
TEB, TED, TEY
TQD, THQD, THQL, THQG, THQC,
TEY,TED4
TEY,TED4
TEY,TED4
TED4, 15-50 amps
TEY, TED-4, 15-100 amps
THHQL, THHQB, THHQC, TEY
THQP, TJD, TEY
TXQL, TXQB, TXQC, TEY
TEY. THFK
TBI. TB4
TBl, TB4, TB6
TB4, TB6, TB8
TED6 15-100 amps
TI], TFK
TFJ, TFK
T1L1JK TKM.1J4V, TK4V
THED 15-100 amps
THJK, THKM, THJ4V, TJH
TPMM, TP, TC, TKH
THPMM, THP, THC
TPMM, TP, TC 3000 & 4000 amp only
TB-l, TB-4, TB-6, TB-8
TED 4, TED 6 llO-150 amps
THED 4, THED 6110-150 amps
TEL, TFL, TLB, THLC

G:>Single unit or duplex con truction must be specified.


@800 amp frame not inelu<ed.
@Thisclass may incorporat a current limiting device within the breaker case.

1 or 2
2or3

120/240 volts
240 volts

2 and 3 poles

240 volts

I pole
I pole
I pole
1,2, & 3 poles
I and 2 poles
2 and 3 poles
1 and 2 poles
2 and 3 poles
2 and 3 poles
2 and 3 poles
2 and 3 poles

277 volts
2/i volts
480 volts
277/480 volts
120/240 volts
240 volts
120/240 volts
240 volts
480 volts
600 volts
600 volts

,I
I

2 and 3 poles

3 poles
3 poles

600 volts max

BI006008

Application Data-Molded Case Circuit Breakers


CURRENT RATINGS
Molded case circuit breakers are designed to protect insulated cable, therefore the characteristics of breakers
are closely tied to the Underwriters' Laboratories specified size and type of wire for each rating as well as the
load characteristics. The following items should be considered when applying and using molded case circuit
breakers:

or binding due to differential contraction of pans. In


general the effect of ambient temperature on an ambient compensating breaker calibration looks like
Fig. 31.1.
?\otice that the above curve specifies the ambient
temperature of the air surrounding the breaker not
room temperature. To conven this information to
room ambient it is necessary to knO\v the temperature rise of the equipment housing the circuit
breaker. This must include factors for group mounting of devices. ventilation, solar insulation or other
radiant heat sources, etc. The above curve also applies onI-v to devices connected with the DL sized conductor. .

A. Cable size must be equal to, or greater than that


specified by Undenvriters' Laboratories Inc. Standard for Safety 489. Thermal current measuring systems (bimetals and fuses) incorporate a resistance
element which generates heat at a rate proponional
to the square of the current. The cable is used as a
heat sink to control the temperature of the bimetal;
reducing the size of the conductor raises the temperature and the breaker will carry less current. In general the effect of cable size on breaker thermal
calibration is iUustratedin Fig. 30.1.

c.

B. Ambient temperatures have an even wider effect on


the rating of the breaker-cable system. High ambient
temperatures not only affect the calibration of the
breaker but may cause internal temperatures to exceed the temperature limits of the insulating materials. Cable may be adapted through the use of higher
rated materials such as glass or mineral. but this is
not possible with switching devices due to mechanical requirements and fabrication techniques. Low
temperatures. on the other hand, substantially increase the current carrying ability of the system until
other limiting factors occur, such as lubricant failure

System operating frequency also has a m;:yor effect


on the rating and performance of molded case circuit breakers. Most circuit breakers mav be direetIv
applied at their published ratings on 50 or 60 Hertz
svstems. but molded case circuit breakers should not
be applied at other frequencies without the concurrenee of the General ElectricCompanyexcept as described on page 36, "FACTOR C-FREQUE?\CY
RATING".
Two separate effects occur at frequencies above 60
Hertz depending on the method of current sensing.
In thermal magnetic devices, the bimetal, which pro
vides overload protection, responds accurately to the
applied current. However, the instantaneous element, which is a solenoid constructed of copper and
steeL becomes hot. This raises the temperature of

% Change in current car1)'ing ability

.;0 c>

- ""
.::~
g '"

lo-~

1:1 c

+50%
+25%

0/

- 25%
-

50%

I
rated
conouc,or
'

...

200%ot rated

conductor size

Figure 30.1 Breaker current rating and conductor size are a


matched pair; any insulation type may be used
but the cross section must remain constant.

30

BI006008

the breaker, ther y reducing the continuous current rating of the evice. The instantaneous trip solenoid becomes h t because of the nature of its
construction and aterials. In addition to adding
heat to the breake , the instantaneous trip does not
respond to curren correctly and the higher the frequency, the less a
rate the response.
At nominal system frequencies less than 50 henz but
above direct curre t, solid-state trip devices become
inoperative due to sensor saturation. Thermal trip
devices remain ac rate while instantaneous trip solenoids lose accura '.. On direct current svstems,
solid-state trip uni 'are completeiy inope'rative,
thermal trip units alibrateaccurate1y and instantaneous trip solenoi s mayor may not be accurate depending on the sp mc construction technique used.
D. Another factor to e considered is the aLtitude at
which the bl-eaker ~ll be applied. The design altitude for molded
e circuit breakers is 0 to 6000
feet. At altitudes a ve 6000 feet the thin atmosphere affects the at transfer of the breaker as well
as its ability to iute
pt shon circuits. So an additional derating of 4 percent is applied at altitudes
from 6000 to 10,00 feet.

E. Load type and duty cycle must also be considered in


the appLication of oided case circuit breakers.
Loads such as capa tors and electromagnets require
a substantial, contin ous current derating factor if
the breaker is no
ly used to s"\'\'itch the load.
Group mounted de ices require additional derating
due to the lack of fr e air circulation around the
devices.
With loads such as r sistance welders, the breaker
continuous current ring must be no less than 125
percent of the weld 100 percent duty-eyde rating.
In general, ,,,,'here 10 d protection in addition to cable protection is desi ed, the load characteristics and
protection requirem ntS must be fully evaluated.

F. The final factor which needs to be considered is a


safet" factor. If the circuit breaker is run at the current level derived from factors A-E continuously, it
will be within its rating and the conductor ratinis~
but it will be on the verge of tripping, and any perturbation from nominal could cause the circuit
breaker to trip. A safety factor of at least 10 percent
should be applied to prevent possible nuisance tripping. Other conditions such as excessive load break
operations, overload tripping or severe load cycling
can affect breaker life and should be factored into
the rating.
The above information is summarized and tabulated in
the following pages for your convenience.
The trip time characteristics of GE solid state trip systems which use rating plugs, like MicroVersaTrip
R.vIS-9, do not change over ambient temperature
variations which are inside the operating temperature range of the trip unit. The operating temperature range for .\1VT RMS-9 molded case circuit
breakers is -20C to +55C. The operating range for
the trip unit is -20C to +85C, Accordingly, for
breakers \\:ith ;\1\:T RMS-9, the items above should be
used only for the purposes ofdetermining if a larger
frame is required. Rating plugs should be selected
based solely on the load current in order to provide
the tightest overload protection.
Selecting the rating plug based solely on the actual
R.\lS current also permits use of smaller conductors.
Referring to Example #2 on page 35, it can be seen
that if a non-interchangeable trip thermal magnetic
breaker had been selected, it would have been rated
400 amperes and (2)3/0 AWG conductors per phase
would have been required (see Table 32.1). using
the solid state trip breaker with interchangeable rating plug, a 300 ampere rating plug \\"3$ appropriate
for the load and the conductor size is reduced to (1)
350kcmil.

Curre.'rt rating % of nominal

1
I

100%

-40

o
Breaker ambient temperature C

Figure 31.1 The effect of ambient temperature on thecontinuous current carrying ability of the breaker and
cable system is shown on page 35, "'FACTOR
B-A.\fl3IEl'iT TEMPERATURE."

31

BI006008

Application Data-Molded Case Circuit Breakers


CURREl\'T R4..TING SELECTION
Circuit breaker ampere rating (11') = I, x A x B x C x D x Ex F x G
where I~ = Actual fun~load current or RMS current
D = Altitude rating factor
A = \fire size factor
E = Load class rating factor
B = Ambient temperature rating factor
F = Safetv factor
C = Frequency rating factor
G = 1.0 for intermittent load or 1.25 for continuous load

TABLE 32.1 WIRE ANDCA..BLE SIZE BY AMPERE RATING


Circuit breakers are calibrated and rated for use with the following wire sizes by
ampere rating

$:j

~ . . C~Jlldtlct(>r
o

! Paralleled I

Rating

Size

Copper,.clad

Paralleled

<y
-;)

30
35
40
45
50
60
70

SO
90

8 A\VG
8 A\VG
8 A\\'G
SAWG
6 A\VG

400
450
500
550
600
700
800
1000

4AWG

3 A\VG

1200

4AWG
3AWG

2 Awe
2AWG@

A we
kcmil
kcmi1
kcmil
kcmi1
kcmil

2000

2iOAwe
3/0 A we
4/OAWG
1250 kcmil

1/0 A WG

4/0
250
300
3:;0
4(JO
500

1400
1600

1 Awe@
IiO AWe

2/0A\VG
3iO A \VG

225
250
275
300
325
350

I Rating IParalleled

Size

12AWG
10AWG
IOAWG
S Ai,VG
SAWe
8 AWe
6 A\Ve
6AWG
4AWG

3 AWG
2 A\VG
I AWGeD

100
110
125
150
175
200

two
two

2500

' 300 kcmil

3000

350 kcmi1
500 kcmil
500 kcmi1
4/0 A WG
410 A we

4000

1 Type RH. RH\\". ReH. THW. TRW:\. or XHHW copper


conductor rna:' be used if the circuit breaker is so marked.

<):\0.

~;;::;':::{I

Copper Conductor
Aluminum Conductor:
Ampere :--'-'---...,...-----;--'-------,..---'---""'""i

Aluminum Conductor

14 AWG
12 AWG
10 AWG
IOAWG

15 or less
20

=:rl

,Aluminum or

two
two
twO
twO

t'vO
twO
three
three

Size

! Paralleled

310 A we
4iOAWG
250 kcmil
300 kcmil
350kcmil
500 kcmi1
300 kcmil
400 kcmi1

two
two
two
two
two
three
three
four or
three
four

250
300
350
500
SOO
$SO
400
350
600
500

five
six

500 kcmil
600 kcmil

or
kcmil
kcmil
or
kcmil
or
600 kcmil

350
600
500
400
600
400

four
three
four
five
four
six
five
eight
seven
six
nine
eight
seven
twelve
eleven
ten

400.
500. or
600 kcmil
400.
500. or
600 kcmil
400.
; 500. or
! 60() kcmil

Size

kcmil
kcmil
kcmi1
kcmi1
kcmil
kcmil
kcmiI
or
kcmil
kcmil

SL,

1600 kcmi1

eight
seven
nine
ten
nine
eight
thirteen
twelve
eleven

600.
750. or
500 kcmil
i 500.
i 600. or
750 kcmil
500.
600. or
750 kcmil

1 RH. RHH. RHW. THW. THW:\. or XHHW aluminum


conductor may be used if the circuit breaker is so marked.

(3) :\0.

TABLE 32.2 PROPERTIES OF CONDUCTORS RATED FOR USE "\VITH M~OLDED CASE
CIRCUIT BREAKERS
Concentric Lay
Stranded Condnctors
Size
AWG,'KC.'\f

No Wires

Diam.
Each W"ue
Inches

Inches

Diam.

<DArea
Square
Inches

Dc Resistance Ohms/M Ft.


At25"'c, 7n.
Copper
I
Bare
Tm'd.
Aluminum
Conductor
Conductor,

Solid
Solid

J>403
.0508

.0403
.050S

.0013
.0020

6.51
4.10

6.79
4.26

Solid
Solid
Solid
Solid

.0032
J>051
.0081
.0130

2.57
1.62
l.OIS
.6404

.184
.232
.260
.292
.332

.027
.042
.053
.067
.087

.410
.259
.205
.162
.129

0
00
000
0000

105600
133100
167800
211600

19
19
19
19

.0641
.0808
.1019
.1285
.0612
.0772
.0867
.0974
.0664
.0745
.OS:37
.0940
.1055

.0641
.080S
.1019
.1285

1620
2580
4110
6530
10380
16510
26240
41740
52620
66360
83690

.372
A1S
.470
.528

.109
.137
.173
.219

.102
.0811
.0642
.0509

2.68
1.68
1.06
.659
.4<)_/
.269
.213
.169
.134
,106
.OM3
.0668
.0525

IS
16
14
12
10

6
4
3
2

,2

Area

Gr. Mils

Bare Conductors

7
7
7
7
19

10.7
,6.72
4.22
2.66
1.67
1.05
.674
.424
.336
.266
.211
.168
. 13:~
.105
.0836

BI006008

TABLE 33.1 PRO ERTIES OF CONDUCTORS R.'\TED FOR USE WITH MOLDED CASE
CIRCUIT BREA RS (CONT.)
SiZe
AWG;KCM
250
300
350
400
500
600
700
750
800
900
1000
1250
1500
1750
2000

2500
3000
3500
4000
5000
600
7000
7500
8000
9000
10000
12500
15000
17500
20000

37
37
37
37
37
61
61
61
61
61
61
91
91
19_I127

0
0
0
0
0
0
0

.0822
.0900
.0973
.1040
.1162
.0992
.1071
.1109
.1145
.1215
.1280
.1172
.1284
.1174
.1255

.0431
.0360
.0308
.0270
.0216
.0180
.0154
.0144
.0135
.0120
.0108
.00863
.00719
.00616
.00539

.260
.312
.364
.416
519
.626
.730
.782
.833
.933
1.039
1.305
1.561
1.829
2.087

.893
.964
.998
1.030
1.090
1.150
1.289
1.410
1.526
1.630

.0708
.0590
.0505
.0442
.0354
.0295
.0253
.0236
.0221
.0197
.0177
.0142
.0118
.0101
.00885

.0187
.0159
.0148
.0139
.0123
.0IlI
.00888
.00740
.00634
.00555

(i::Area. gi~'en is that of a ord having a diameter equal to the over-all diameter of a stranded conductor.
The valu(.'"$ given in the table e those given in Handbook 100 of the
7\ational Bureau of Standard:; except that those shown in the 8th
column are those given in S cmcation B33 of the American Society
for Testing and Materials. an those shown in the 9th column are .

those given in Standard 7\0. $019"83 of the Insulated Power Cable


Engineers Association and Standard 7\0. WCS of the 7\arional Electrieal )'fanufacrurers Association.

TABLE 33.2 FAC


Applied Wire
Crossectional Area as
a Percent of Rated
Crossectional Area
Factor A
response of the breaker in some misapplications or in applications
where ca!>lcampacity is not r<.'qUired to match breaker ampacity.

<DThe correct size \\'ire should be usee with everv circuit breaker.
The values shown above
be useful in unde~tandingthe

TABLE 33.3 FACTRB-CIRCUIT BREAKER ,"~BIEl\'T TEMPER..4TURECD

J9-:>

Q-LI7\E

1.0

TQD. THQD

1.0

75

1.0

60/75

1.0

90

75

1.0

90

TEB. TED. TEY.


TB-l JOOA
TED. THED. TELJ50>\ THLC-1
TF]. TIK. THFK.

TFL. TLB-2. THLC-2

TD TJK-4. THjk4.

TB4. TLB-4. THLC-4


TJI\.6. THJK6
TI\.:-'lA8. THK:vlAS.
TE-S. TB-6

1.0

I 1.0
I

1.0

1.0

75

is

I
I

is

I 1.0

I, 1.0 I

75

75

T]4V.THJ4V. TJIAV. J 1.0


T]H. TJL
I
TK4V, TKL4V. TKH,
TKL

I 1.0

I
I

75

1.0

1.0

I
! 1.0
" 1.0

90

90

90

90

105

I 1.0 I
I 1.0 I

90

75

105
I

DThis is the air temoerature ar und the outside of the breaker


molded case. but i;side the er
'~un:.

1"-:>

11.14
i
,

19_:>-

91_:J

105

I 1.0 I
11.0
I
I 1.0 I

105

11.14 1

19_::>-

105

L051

J05

I I

105

J05

I LOS i

105

11.21

105

105

105

LOS 1

I 1.0 i

I 1.0
I 1.0 I

J05

I, 1.2J

J05

)1.0

105
I

11.05 1

105

105

I'

1.14

Ius I

105
'9,_:J

I 1.3S I
I 1.25 1
I

1.33

I 1.25

19_:>-

I-

I- I

105

I-

I-

II

('\Yire size.

no\'\'c"'\-'cr. rr':USt

based on 75C arrmaciry

be

ILl5

I'l_::>

105

19-::>"

105

i 1.25 1
- I

105

19-:>:

11

TK:VIAJ2. THKMA12! 1.0

,
1.0 I

1"-:>

i
I

NOTE: All temperatures are C

33

BI006008

Application Data-Molded Case Circuit Breakers


TABLE 34.1 FACTOR C-FREQUENCY RATING
......

ICilrcuit

J.JF ,',

Dc

!: ~
'Rmno- ;::'A~V'" at
50/00 Hz 100/120 Hz 150/180 Hz~;:'=OO:':':!2:'::':4';::O::"'Hi-""'30--0-/3-60-Hz""",-""'400-,-1-41-5":"Hz--l

1.03
1.00

1.04
1.00

1.05
I
1.00'

Q-LINE
TEB, TED, THED,
TEY,.TEL,
THLC-l

LO
1.0

1.0
1.0

1.01
1.00

1.02
1.00

TFJ, TFK, THFK,


TFL,TLB-2,
THLC-2

1.0

1.0

1.02

1.05

1.09

LIS

1.18

TFC

1.0

TJJ, TJK, THJK,

1.0

1.0
1.0

1.02
1.02

1.04

1.06

1.15

1.15

1.0
1.0

1.02
1.02

1.04

1.15

1.35

1.35

1.0

1.02

1.0
1.0

1.02
1.02

1.04

1.06

1.15

1.15

1.04

1.15

1.35

1.35

TLB-4,
THLC-4

1]C

1.0

iTKM8, THKMA8,

1.0

!
TKMAI2,
THK.l\.fAI2
TKC

1.0

TJ4V, THJ4V,
1]L4V, T]H, TJL
TK4V, TKL4V,
TKH, TKL

I
i

1.0

1.02

Factor D-Altitude Rating


l.00 for-lOO to +6000 feet
1.04 for 6001 to 10000 feet
l.OS for 10001 to 15000 feet

TABLE 34.2 FACTOR E-LOAD CLASS RATING TOTALG)

1.35
1.25
equals the product ofthe load class rating factors which apply to
the circuit in question.

(1) E

Refcr to N'EC ArJcle 430. Pan B. for conductor and


circuit breaker sizing.

Factor F-Safety Factor 2:: L 1

TABLE 34.3 FACTOR G-D'GTY FACTOR


Continuous duty
(operation at essentially
constant load for three
hours or more)
1.25

34

or

Intermittent
shorttime duty (constant load
for less than three hours
or intermittent load)
1.00

BI006008

;ELECTION OF C RCUIT BRRA.KER


:::URREt\"T Rt\TL G
:ircuit breakers are pri arily used to provide overload
end shon circuit prote on for insulated conductors. In
his regard. the ::'\ationa Electrical Code Article 240-3
equires that conductors be protected in accordance with
heir ampacities, as give in NEC Tables 310-12 through
,10-13. Exceptions are I sted in the article for certain
pecific applications or c nditions including protection
or conductors in mowr circuits.

Ifwe use an F frame (225 amperes) we must calculate


the RMS current during the ,vorst 22.5 minute period
which is 0.1 minute START. 9.9 minute RUN, 5 minute
OFF~ 0.1 minute START. 7.4 minute RUS.

l'he size and type of con uctors required for a given ciruit is usually calculated by the consulting engineer or
>ther specifying authori y, and specified on the job
>Ians. It is in these insta ces. relatively simple to select a
tandard circuit breaker ating that matches the ampactv of the conductor. \Vh re standard circuit breaker rat~gs do not correspond t the ampacity of the
onductor. the ::'\EC aHo vs the next higher rating to be
lsed where rating is 800 amperes or less.

Step 2. Using the ACTUAL CURRENT, or RMS current determined in STEP 1.. estimate the breaker frame
size required by your application. Retain this "estimated" frame size to complete STEP 3.

:or applications where 0 ly load currents are known,


.nd motor circuits, ambi nt temperature, special duty
ydes, frequency and alti ude are involved, the following
ormula for selection of tandard circuit breaker ratings
, used:
i,-cuu Brake Ampere Rating = Act .. Load Curren: x:\ x B X Cx D X ): f x G.

['he procedure for using his formula is explained in the


oHo'wing steps.
;tep L Determine the. CTuAL CuRRE::'\T of the
ircwt by adding the con inuous load amperes for each
:>ad on the circuit. If the load is intermittent, the actual
Jad current is equal to e RMS current over a time peiod equal to one-tenth 0 the frame ampere rating in
ninutes-lOO ampere f me= 10 minutes, 225 ampere
rame- 22.5 minutes, et .
~ple#l:

\.n air-conditioning com ressor cvdes on and off at a


tlaximum rate of four p hour a'nd has the foHowing
haracteristics:
-62 full load ampe s
-248 locked rotor a peres
-6 second starting
e
-5 minute off-time tween starts
fwe use an E frame br 'er (150 ampere maximum)
ie must calculate the RM current during the worst 10
oinute period, which is S ART and RC' in this
xample.
h~s =

(l srartf (f s
\i ~_--:""":""-+-=:-~---'--':"_:""-:'

;(24Sf (0.1 minu e) + (62f (9.9 minutes)

\'
'>ls=66.5 amyeres

_'(248)2(.1) + (62f(9.9)+ (248)2(.1) -'-(62f(7.4)


V
22.5

R,IS-

= 59.2 amps

Step 3. Select the appropriate multiplying factors A to


F for the application conditions involved, and substitute
in the formula. For applications under the jurisdiction of
the ::'\ational Electrical Code the product of B through F
must be equal to or greater than 1.25 for continuous
loads on standard rated devices and equal to or greater
than 1.0 for 100 percent rated devices.
Step 4. ::'\owcompute the proper ampere rating and
the proper General Electric circuit breaker for the application by multiplying the ACTUAL CuRRENT by each
of the four factors determined under STEP 3.
Ampere Rati."'lg = Aella! Currem x Ax Bx C :< D x Ex Fx C = amperes

Select a breaker having a raring equal to or next above


your answer.
Example #2:
To illustrate: Assume a 480 v three phase load of 260 amperes
continuous such as an air-handling fan motor. The a,-ailable
short circuit current is 57 k.A. The protective de,ice is individually mounted in a S'...i tchboard.

The conductors supplying the load \\-i1I be selected to be


equal to 1.25 times the load current.
Ambient temperatures inside the box \\-ill not exceed 40C.
A solid state breaker \\ith a rating plug and long time, short
time, ground fault and instantaneous protection is required.
There are no appreciable harmonics associated \vith the load
and the instantaneous inrush is 7.8 times motor full load
amperes.
The mounting location ""ill be at 7200 ft.
Circuit Breaker Ampere Rating = I continuousxAx Ex C x D x Ex Fx C.
Rating =260 x 1.0 x l.0 x 1.0 x 1.04 X LO x l.J x 1.25 =371.8 arnp<'7'es.

10 minutes
Select a 400A frame MicroVersaTrip RvlS9, 1]L4S with a
TS20LS1GT2 programmer. Since the rating plug is not affected by load characteristics other than the actual R\fS current
value. select a 300A rating plug rather than a 400A plug.

35

BI006008

Application Data-Molded Case Circuit Breakers


Il\iTERRUPTING RATINGS
Circuit breakers must not onlv carrV' the circuit current
at all times under normal condition's, and trip open under overload conditions, but must have sufficient interrupting capacity to successfully interrupt the shon
circuit current that ...illfiow under the worst faultconditions that can occur.

BASIS OF INTERRUPTING RATINGS


Short-Circuit Current Interrupting ratings depend
upon kno...i ng the magnitude of the shon-circuit current that may flow through the circuit breaker or
molded case switch. Devices rated in accordance with L L
Standard 489 list their interrupting capacity of withstand capability in terms of rms symmetrical amps.

Figure 36.1 shows a symmetrical ac current waveform


that 'would occur if a purely resistive circuit was shortcircuited (or even a circuit containing reactance if the
short circuit occurred at precisely the right point in the
voltage \\'aveform-which is unlikely).
Figure 36.2 shows the current trace of a short circuited
ac circuit where displacement about the zero axis exists
as a consequence of when the short circuit is applied an(
the amount of reactance in the short-circuited circuit,
compared to its resistance.

::'hteiq::es of :)eal<s
of s:~e \..:a~t8 .c:-e

The procedures for calculating short-circuit current and


the XJRratios are described in detail in GE Publication
GET3550.

a:o:;;:
:t,eze;c ax;s.

sr~:~e~ca;

Generally, electrical power system engineers calculate


the XJR ratios rather than the power factors of protected
circuits during their short-circuit studies. The magnitude of the momentary peak current to be interrupted-or ...ithstood-isa function of thema:mnum
peak current displacement from the zero current axis.
That displacement isa function of the X/Rratio(or
power factor) of the faulted circuit. The higher the X/R
ratio, the lower the power factor, and the greater the
magnitude of peak current displacement.

Fzgure 36.1 Symmetrical Ac Waveform

Listed interrupting ratings (Table 37.1) are subject to


derating where circuit power factors are below listed
values. Table 38.2 lists rating factors versus X/R ratios
and power factors to allow the user to compensate the
interrupting rating of a circuit breaker for circuit power
factor, where necessary.

t:;veio:>es d-peaks are ~c~


S'f~me-:r}caLa:Cl::ze:cax;s.

Frequency Frequency has an effect upon the interrupting capability of a molded case circuit breaker- Exhaustive testing has been conducted at the two worldwide
standard frequencies, 50 Hz and 60 Hz. Less testing has
been conducted on industrial circuit breakers at 25 Hz
and 400 Hz. Table 38.3 lists suggested application
guidelines for circuit breakers in 400 Hz circuits.
The data shown takes into account the lack of world test
facilities to verify 400 Hz performance, but does represent the existing best engineering judgment ofGeneral
Electric.
Power Factor, or X/R Ratio Interrupting ratings of
molded case circuit breakers are based upon a specific
ratio of reacrance-to-resistance, or a specific power factor. Since practical ac circuits contain some reactance,
there is some displacement between current and voltage
waveforms. Because a short-circuit can literally occur
during any point of the voltage wave, an actual trace of
short-circuit current may display considerable initial displacement from the zero a.xis.

36

Fzgure 36.2 Asymmetrical Ac Waveform

II\~ER.ltUPTING RATINGS

There is a simple relationship between the power facto


of a short-circuited circuit and its XIR ratio. It is:
Power Factor (in Percent) = ~ x 100

Z=VR2 +X2
R
therefore PF = V 2
x 100
R +X 2

and:

BI006008

lIC ratings not UL list dare based on tests per ?\EMA


Standard AB-l "Mold d Case Circuit Breakers." The basic rating is given in R vIS symmetrica1amperes. the pre-

ferred basis fOT selection and application.


Values for dc, UL listed interrupting ratings are maximum amperes.

The following interru t>ting ratings are CL listed except


where footnoted.

TABLE 37.1-AC Il\lERRUPTING RATINGS-UL LISTED


Circuit
Breaker

Type

Voltage
Max.
120/2-}
240
277
480
I
600
Am~lere
ac
Ratilng Voltage MUlti-II Pol Mnlti- I Pole
277/480
277j MUlti-II P lei Multi- I P I
Multi-Pole 1 Pole Pole
Pole.
e Pole
0
Pole
() e
M3~

(2P)

iTHQB. C L
,
lTHHQB.c. L
I

!TXQB. C. L
TQD
ITQDL
JTHQD
IjTHQDL
TEB
!TIB
!TEY
ITED
ITED
TED

!I~i and

1120/240 10000

10
7
10

5000 I 22000

8660

50001 65000
5000! 10000
5000\
22000 50001 22000
120/240 22000 5000 \
120
10000 i
240
10000
277i480 65000 650001 65000
480
I
277
480
18000

8600
8660

120/240 22000

7
3

22
20
22
20(
10(
IO(
IO(

10(
10(
10)(

i~

(3P)

50001

65000
10000
10000

8660
8660
866M)

~gg

14000

l4000
10000
14000

II

TEC
TICL
15C
600
15C
600
TED
ITHED
3C
277
15C
600
!THED
I TEL
150
600
ITHIL
150
600
,THLC-l
150
480
I TFJ. TFK@.TFC225600
THFK@
225
600
TIL
225
TLB-2
225
480
THLC-2
225
480
TJD
400
240
TJ<D@
600
600
THj<D@
600
600
TLB-4
400
480
TJH
600
600
TJL
600
600
THLC-4
400
480
TB-4
400
600
TB-6
600
600
TK@
1200
600
THKMA@
1200
600
TKH
1200
600
TKL@
1200
600
TB-8
800
600
CD Includes J. K. C. 4V suffixe
Indudes C. MA and 4V su ~xcs.
@Includes 4V suffixes.

8660

12~gg ~~g

1100000
I 18000

8660
8660

14000
200000
10000
100000
14000

8660
8660 2000001 8660
8660 10000 i 8660
8660 100000 I' 8660
8660 14000 8660

25000
65000
65000
150000
22000
25000
65000
50000
150000

8660

65000
42000 8660
100000 8660
i. .~~ 8660
200000 8660
1
1250008660
65000 8660
I 100000 8660
I 85000 8660
1200000 8660
22000 10000 22000 8660
I 42000 8660
65000 8660
i 85000 8660
i 65000 8660
i 100000 8660
I 200000 8660
I 200000 8660
: 200000 8660
I 42000 12120
65000 12120
65000 12120
,100000 12120
200000 8660
II

30000
35000
50000
35000
65000
150000
200000
200000
30000
35000
50000
65000
200000

8660

Isoooi

8660
8660
8660

8660

25000
25000
50000
18000
18000
25000

8660
8660
8600

8660
8660

50000

8660

22000
25000

8660
8660

8660
8660
8660
8660

8660

8660

8660

8660
8660 25000 8660
8660 30000 8660
8660 50000 8660
8660 200000 8660
8660 200000 8660
12120 22000 12120
12120 25000 12120
12120 25000 12120
12120 42000 12120
8660 200000 8660

@Interchangeable thermal-magnetic trip circuit breakers are not l:.L. listed for reverse feed.
Single pole limit.
@Ifmodel is rated for 600 volts.

NOTE: The single pole interrupting ratings shown are


the CL listed values for three pole devices and are not
necessarilv the maximu:n capabiIitv of the device. Single
pole interrupting capab'lity must be considered when
.

molded case circuit breakers are used on ungrounded or


resistance grounded distribution systems.
NOTE F '
d"
th
. .
.
b k: orfsenes-co;mecte TatlnlgEslwI . meam CIrCUIt
rea 'ers or uses. reter to c~enera ectnc ,ompany.

3?

BI006008

Application Data-Molded Case Switches


TABLE 38.1 DC I~'TERRUPTING R.>\TINGS-ULLISTED EXCEPT AS NOTED BY (*)

Circuit
Breaker
Type

125
250 Volts
SOOVoits
Voltsj
1 Pole 1 Pole .2 Pole 1 Pole .2 Pole

400 Volts

1 Pole 2 Pole

:;,WV Ol1 s
6W volts
n_.~
rvl<O.2 Pole 3 Pole@ [1 Pole .2 Pole I Pole 2 Pol

iTED4. TEC. TED6


10000
14000*
10000
;THED
20000*
22000*
20000*
20000*
TFJ. TFK. TFC
10000
10000
10000
20000*
20000*
20000*
jTHFK
20000*
20000
ITJJ.1J:K4. TJC. TJD 10000 10000 10000
20000*
20000* 10000 22000*
20000*
20000*
iTHJK4. THJK6
20000*
TKY1AS. TKCSOO
10000 WOOO 10000 10000*
22000
22000-" 122000* 23000* 10000* 23000* 10000* 23000*
23000*
jTKC361200L
iTHKMAS
20000* 20000* 20000* 10000* 20000* 10000* 20000* 10000* 20000*
*Xot UL Listed. G)UL listed for 500 volts 3 poles in series ungTOundcd battcry applications 600 volts

23000*

NOTES:
1. Direct current interrupting ratings are based on a system fault time constant of 8 ms (milliseconds) or less.
2. Multi-pole ratings (2 or 3) are based on midpoint
grounded systems with one pole in positive leg and
one pole in negative leg, or end grounded systems

TABLE 38.2
INTERRtJPTING RATING MULTIPLYING FACTORS FOR
POWER FACTORS LO"'"ER THA.1'.t (OR X/R RATIOS HIGHER
THA;.~ TEST

VALu"ES

..

11 to 20 kA

R.azio

Maltiplier

MuItiplicr

Mudtiplic<-

24.9S0
19.974
16.637
12.460

0.61
0.62
0.63
0.64
0.65

0.72
0.74
0.75
0.76
O.7i

0.81
0.82
0.830.84
0.85

12
IS

1l.0Q6
9.9;>0
9.036
$.273
i.627

0.66
0.67
0.6$
0.69
0.69

0.7S
0.79
0.$0
0.81
0.$2

0.9!

1415
16
17
18

7.072
6.591
6.169
5.797
5.465

0.,0

0.83
0.84
0.85
0.S6
O$i

0.93
0.9-1
0.95
0.96
0.97

19
20
21
2'2
23

5.167
4.899
...656
...434
4;:.'>31

0,75

o.&.~

0.76
0.77
0:;;
0.78

0.$9
0.90
0.91
0.9"2

V.9S
1.000
1.000
1.000
1.000

24

4.045
3.873
3.714
3.566
3.429

0.79

0.94
0.95
0.96
0.97
0.9$

1.000
1.000
1.000
1.000
1.000

V.99

1.000
1.000
1.000
1.000

1.000
1.000
1.000
l.OO(}
1.000

.
6
7
8

14.251

9
10

:1

25
26
27

2S

0.71

0.72
0.73
0.74

o.so
O.Sl
0.82
0.8:,

0.$7

0.88
0.$9
0.90

O.SS
0.84

0.8$
0.S8
0.$9
0.90
0.91

1.000
1.000
1.0(1)

1.000
1.000
1.000

37
3S

2.766
2.675
2.592
2..511
2.434

Looo

J.OOO

1.000

1.000

39
40
41
42
43

2.361
2.291
2.225
2.161
2.100

0.91
0.92
0.93
0.54
0.95

1.000
1.000
1.000
1.000
1.000

1.000
l.000
1.000
1.000
1.000

44
4.3

2.041
1.98;
1.9$0
1.$7S
1.828

0.95
0.%
0.97
0.97
0.9$

1.000
1.000
1.000
1.000
1.000

1.000
1.000
l.000
1.000

1.779
:',32

0.99
1.000

:.000
1.000

1.000
1.000

32

33
34

35
3$

46
4,
4S
~9

50

0.85
0.86
0.$7

~ired

in series in the un-

3. Single pole ratings are for application in ungrounded


systems.

TABLE 38.3
ESTIMATED 400-415 HZ L~'TERRUPTINGRA'I1l'<GS IN
A.\fPERES-NOT tJL USTD

21 kA2Dd Higlxr

3.300
3.180
3.067
2.961
2.861

29
30
31

.8

1 to io kA0

(P""""",")

\\ith two or three poles


grounded leg.

G)k.-\= Ki10amps (1 k.-\ is 1.000 amps) rms. symmetrical.

1.000

THQLB.C
THHQLB.C
TXQLB.C
TQD. TQDL
THQD.THQDL
TEY
TEB
TED 4
TED 6
THED
TFL TEL
TFJ, TFK
THFK
,
THLC-l
TJD
TJJ. TJK
TJ<D
THJG>
TJH
TJL
TKG>
THK0
TKH
TKL
G>Includes solid statc

6500
1000
1800
1800
6500
10000
2500
6500
20000
4200
4200
6500
6500
10000
4200
6500
6500
10000

1000
2200
6500
1000
2200
6500
1000
1800
1800
6500
10000
2500
6500
20000
2200
4200
4200
6500
6500
10000
4200
6500
6500
10000

1400
1400
1400
2500
6500
2200
2500
15000
2200
3000
3000
3500
3500
6500
3000
5000
5000
6500

1400
1800
2500
2200
2200
5000
2200
2200
2500
2500
3000

2200
2500
2500
4200

trips.

40Q..Her..z interrupting ratings arc ba..'.cd on engineeringjudgcment,


taking into consideration thc operating characteristics of molded case
circuit breakers and the worldwide lack of test facilities to verify performance.

BI006008

~ABLE 39.1 Q-LL -E AND TEB MOLDED


RT CIRCUIT
:ASE SWITCH S
VITHSTA.~DRA INGG)
Short Circuit
Withstand R~

MoidedCase
Switch Catalog Number

Amps rIDS Sym.

Amps

TABLE 39.2 MOLDED CASE S\'lITCH


SHORT CIRCUIT WITHSTAND R..:\TING
.'.'RaJiDgs,

60
100

10.000
10.000

100 jTED1l3YI00

TQL. 1'QB. 1'QC22Y6D


TQL. TQB. TQC22YlOO

240
240

roo

60

10.000
10.000

100
i50

TQL. TQB. 1'QC32Y60


TQL. TQB. 1'QC32YI00

'40

60
100

10.000
'0.000

r.t.Bl 1lYlOO

10.000
10.000
10.000

100
100
100

rE.B132Y100

1~134YlOO

TED136Y150

-=

1TFJ236Y225

QQ-_:>

,1'QD32Y225

Q-Line and TEE molded


sw 'cnes have a 10.000 amp symmetricai shor::
circuit withstand rating when pr eaed by a fuse or circuit breaker rated
10.000 amps IC or greater and w osc ampere rating does no. exceed the
ampere rating of the switch.
Protective device rou,: be on line >ide of molded case s,,itch.
Three-pole. 600 vol: switches CO\ 2-pole. 600 volt a...,d 2- and
3-pole. 4S0 volt switches.
With ~icroVersaTrip~ 4-functio prograrn..'ne".

TJJ436Y400

100
i50
150

14.000
14.000
14.000

4S0
600
4S0

14.000
14.000
l4.000

II

14.000

1~~sTFuse

--" i

400
400

22.000
50.000

QQ-

IS.000
22.000
22.000
I 30.000

KM.c\S36YSOO I:JK. THJK.


TJ4V. THJ4V.
'
ITHJ9V. THJ9VV
TK?>1.THKM.
TK4V.1'HK4V.
THK9V. THK9VV
Class L Fu.<e
TKM.~Y1200

i,

240

ITQD

THJ4V.
1'J4V.TI;JK.
THJ9V. THJ9VV
ClassJ Fuse
I1'JK. THJK.
TJ4Y.THJ4V.
THJ9V1'HJ9VV

150

iO.OOO

<)<)-

rJJ

I 1200

breake:- rated
iO.OOOA NOV
TED i34 iOO
TEDI36i50
,TED 134150

TJJ. THJK.
TJ4V. THJ4V.
THJ9V.1'HJ9VV
CI=JFuse

600 [TJK636Y600

100

-_:>

400

TJK. THJK.
TJ4V.THJ4V.
THJ9V. THJ9VV
1'KM. THK.\f.
TK4V.THK4V
THJ9V. THJ9VV
Class L Fuse

<)<)-

--"

ITFJ. TFK. THFK

800

Any fuse or circuit

!TED.THED
!1'FJ. TFK. THFK
lClass J Fuse

400 I1'JD432Y400
400

.Ratini,

I
<)<)-

~~ IY~

I'M~"A-'"

<:ataIOs
Nr.rmber

0/240
0/240

fEB 122Y100

'",

'O".CC'

ii

~I

TQL. TQB. 1'QC21Y690


TQL. TQB. TQC2lYlOO

~40

.i

;''.C>C

I)

400

I
f

600
600
600
240
240 !i
240

600
4S0
600
-iSO

400

50.000

600

400

22.000
30.000

600
4S0
600
600
480

600

!}
}
}

600

50.000
22.000
30.000

600

22.000
30.000

480

800

22.000
30.000

480

800

50.000

600
600

600

22.000
30.000

I}
!}

1200

1200

22.000
I 30.000
I
I

50.000

600

600

.,SO

f 600
48{)

I
II

600 I

lectrical Fonnula For Obtaining kW, kVA, Horsepower a.."1d A.mperes


= Volts; I = Amperes; % Eff. = Percent Efficiency; PF = Power Factor
Direct

C WTe11t

II

ilowatts

IIxE
I

orsepower

.
kV-A
nAI

gEff,x PF
746

x JOOO
E

746

kV-A x 1000
2 x E
kW

746

I-E-X-='A'':::~+-ff'-.':':X''--P-F-

1000

x E x l. 73

1000
I x E x :2 x % Iff. x PF I I x E x 1.73 x g

1000

I2 x E x PF

mperes from kW
mperes from Hp

I2

I, I1000
x E
IlLL
1000

I I x E x I .73 x PF

II

IIxEx:2
1000

JA

mperes from

x Ex :2 x PF
1000

Ho x 746
x E x % Eff.x PF

Erf. x PF i I x E x c;;. Eff.

746

746

. kV-A x JOOO
1.73 x E

I kV-A ~

!kW x

k\\' x 1000
x E x PF

I 1.73

i 1.73

x E x % Eff. x PF

1000

1000

Hp x 746

i Ex % Eff.

..c. SHORT erRCD

T DETERMINATION-For methods of calculation of short-circuit currents for


.dustrial and commercial power systems. a simplified method and curves request a copy of GET-3550

39

BI006008

Application Data
TABLE 40.1 HORSEPOw'ER RATINGS
Horsepower Ratings
480 Volt
Single- Threephase
phase
phas~

240 Volt
Single- Three-

phase

TEBl22YIOO

TEBl32YlOO
TEDl24YIOO

3
2

100
100

TED 134YTlOO
TED I 26YlOO

3
2

100
100

3
3

100
150

TED136xIIOO

i TED136xl150

2~0 '<ac

100

2;:>0
240
480
250
480
600
250
600
600

TFj226Y225
TFK226Y225
! TFJ236Y225
I TFK236Y22::

Catal<>g

Number
T]J426Y225
T]j426Y400
TJK426Y400
T]J436Y225
TJJ436Y400
TJK436Y400
TjD522Y400
TJD432Y400

Catal<>g
Number

40

600
600
600
600

3
3

99--::>

400
400
99-_::>

400
400
400
400

600
600
600
600
600
600
240
240

30

20
20

30

20
30

30
50

40

240 Volt

50
50
50
50
30
50

40
40

75

40
50

75
100

SO
SO

100
150

50

I TjK626Y600

600

I TJK636Y600

600

600 Vac
250 Vdc
600 Vac

Catal<>g
Number

No. of
Poles

Am~res

VoltS

TKMA2YIOOO
TKMA3YlOOO
TK:'>JA2YI200
TKMA3Y1200

2
3
2

1000
lOOO
1200
1200

600
600
600
600

Single-I Threephase
phase
50
50

I, -'~_(O)
,

50
50

Horsepower Ratings
480 Voh
I

50
50
50
50
50
50

75
150
150

240 Volt

No. of
Poles

20
20

Horsepower Ratings
240 Volt
480 Volt
Single- Three- Single- Threephase
phase
phase i phase
50
I 50
50
:
50
50
75
150
50
50
75
50
150

No. of
Poles

,J

phase

600 Volt

2
2

2
:2
2
3
3
3
2
3

Three-

20

.1

vdc
Vac '
Vac i
Vdc
Vac
Vac I
Vdc I
Vac :
Vac I

No. of
Poles

000 Volt

Ii

200

50

"_;:;0

50
50
50
50

y:'-

250

150
300
300

50
500

500
500

200
200

600 Volt

50
50
50
50
50
50

Horsepower Ratings
! 480 Volt
I

50
50
50
50

600 Volt

50
50

Ii

200
400
400

50
50
50
50

I
500

500
500

BI006008

TIME CURREN 1 CURVES-INDEX


BREAKER
TYPE
Q-Line 15-50
Q-Linc 60-100
TQD, THQD
lJD
TEE 15-50
TEB 60-80
TEE 90-100
TED 15-50
TED 60-80
TED 90-100
TED6 & THED6 15-50
TED6 & THED6 60-80
TED6 & THED6 90-150
TEY 1550
TE'Y 60
TEY 100
TEL (15-40 Amps) TCC

TIME CURREJIo'T
CURVE NUMBER

r=t

Ip
TEL (50~ Amps) TCC
(90-150 Amps) TCC
(50-150 Amps) It-r
Ip
TIL (70225 Amps) TCC

Pi'
Ip

TIl, TFK.. THFK


TJJ. TJK THJK
TLB-4
TKMA, THKMA
lJ4V, THJ4V, lJL4V
TK4V, TKL4V-M'\'T-4
lJ4V, THJ4V, 1JL4V
TK4V.TKL4V-Mv'T-4 Gro
lJH, 1JL, TKH,
TKL-R.\!S-9
TJH, 1JL TKH,
TKL-R.\1S-9 Ground

PAGE

GES-6202A
GES-6203A
GES-6lOSC
GES-6112A
GES-6122B
GES-6123B
GES-6124A
GES-6113C
GES-6Il4C
GES-6Il5B
GES-6119C
GES-61WC
GES-6121B
GES-6237
GES-6238
GES-6239
GES-6229A
GES-9620
GES-9621
GES-6230A
GES-6231A
GES-9622
GES-9623
GES-6236
GES-9628
GES-9629
GES-6103E
GES-6104C
GES-6225B
GES-6111C
GES-6198C

42
42
43
43
45
45
46
46
47
47
48
48
49
49
50
50
51
51
52
-<>
::l53
54
54
55
53
55
56
57
57

GES-6195B

58

GES-6235A

58

GES-6228C

59

44
44

TIME CURRE!\'T

A. Circuit breaker conne ed with a minimum of four feet of


rated conductor per te

B. Circuit breaker in ope air at ambient temperature indicated.


C. All tests initiated from the no current condition (cold
start).
Information provided on t e time current curve includes the
following:
1. Product family type

2. Specific device type


3. Ampere ratings covere
4. Overcurrem characteri tics-Iong-time, shon-time. instantaneous. etc.
~la.'Ximum

total c1earin

6. Maximum and minim


i. Frequency ratings
8. Voltage ratings

~~

THLC-4 (250-400A) TCC

i~

TB-1 15-30
TB-l 40~100
TB-4:
TB-6
TB-S
TEC,TECL
TEC, TECL Ip
12t
TEML (3-30 Ampere) TCC

i;

TEML 50-150 Ampere TCC


TIC
lJC400
1JC 600
TKC800
TKC 1200
TBC225
TBC400
TBC 600
TBC800

TL'fECt.iRREl\'T
Ct.i"RVE !IoI'l.JMBER
GES-6219A
GES-6220B
GES-6218B
GES,9603B
GES-9604B
GES-6221B
GES-9608A
G5-9609A
GES-6226B
G5-96lOA
G5-96llA
K215-71C
K215-72C
K215-73D
K215-74D
K215-75D
K215-100A
GES-9600
G5-9601
G5-6232
G5-9625
G5-9624
G5-6233
G5-9627
G5-9626
K215-101
GES-6141
GES-6142
G5-6146
GES-6147
GES-6136A
G5-6137
GES-6138
G5-6139

PAGE
59
60
60
61
61
62
62
63
63
64
64
65
65
66
66
67
67
68
6S
69
70
69
70
71
71
72
72
73
73
74
74
75
75
76

RIPPING CHARACTERISTICS

Molded case circuit break r time current CU1"Ves are the engineering documents which efine technical performance characteristics of the devices.
e test parameters for the
generation of these cun; are as follows:

5.

BREAKER
TYPE
THLC-l 15-40
THLC-l 5O-S0
THLC-190-150
THLC-l (15-150) I ;
I
THLC-2 (125-225A) TCC

temperature limits

9. Specific trip unit ratings


10. Trip unit adjustment ranges
11. Tolerances

Multiples of circuit breaker trip rating are sho\.\"I1 on the top


and bottom horizontal a.-cis. "","ith time in seconds on the vertical
a.'ris. Approximate minimum and maximum clearing time is
readilv determined from the characteristics curves. For example, a'TEDI34100WL 100 ampere, 3 phase. 480 volt breaker.
(reference curve GES-6115B. page 46), under a sustained
overload of 200 amperes (2 times trip rating) reading up to
curve from the horizontal axis. will clear \.\"ithin 80 to 350
seconds. Curve also shows that this breaker mav trip instantaneous]y at current values v.."ithin a band rangi~g from 7.5
to 20 times breaker trip rating but rna\" take up to 14 seconds
to trip. Beyond 20 times breaker rating it will always dear instantaneously. This instantaneous dearing time with no intentionally introduced time delay. ranges up to 0.018 seconds as
shown on curve.
Tripping characteristics meet National Electrical Manufacturers Association and 'Cnderwriters' Laboratories, Inc. standards
for rating and calibration.

41

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BI006008

Time Current Curves

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Time Current Curves

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Inspection an Testing
The need for preve tive maintenance on molded case circuit breakers will vary depending on operating conditions.
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breakers.

IN MAKING C NNECTIONS V\'ITH ALCMINUM \-"IRE REFER TO GEH3445.


GEJ-4654
TCALI2, 12A, 1 ,TC012
Mounting Lugs r E150 Line
Lugs must be secure
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GEJ-4639
TCAL24, TC024, TCAL26,
TC026, TCAL27
Mounting Lugs for F225 Line

ps.
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Suggested method . I' attachment or removal is


illustrated.

Suggested method for attachment or removal is illustrated.

GEJ-4655
TCAL43, TCAL6 , TC043, TC063,
TCAL47,
Mounting Lugs [. r J600 Line
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GEJ-4656
TCAL41, TCAL61, TCAL8l, TCAL91,
TCAL121, TCAL131, TCAL122, TC04I,
TC061, TC081A, TC0121, TC0131,
TC091
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Lugs must be securely fastened to terminal straps,
Lugs, when factory installed,
are torqued to 200 inchpounds minimum.

200 INCHPOUND
MINIMUM

Suggested method for attachment or removal is illustrated.

CABLE CONNE TOR (WIRING LUG)


TORQUEVALU
All Type THQP. TH L, THQB. THQC (including
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THED and TB 1 circu t breakers and molded case
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K1200 Line

BI006008

Back Connect d Studs

FOR INSULATED BASE OVER "THK AND


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NOTE:-WHEN ASSEMBUNG STUDS TO

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A SHORT AND A lONG STUD

AIR GAP SETWEEN


SKR AND CUSTOMER'S
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DRlU.ING FOR BACK


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NOTE:-QMIT CENTER
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THEREFORE. WHEN ORDERING
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cat I Rating & Length

TEF 1

'15-SOA Short

TEF 2

15-SOA Long

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I 6O-1SOA Short

TEF 4

160-1SOA Long

TFK 1

I 225A Short

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225A Long

150 and F225 Line

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Max

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1
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BI006008

Outline Drawings
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Cat. No.
TKM9"
TKM10"
TKM11
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400
600
800 to
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5.5

5.5
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"B" Stud THO'S

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1.125x16
1.125x16

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BI006008

Motor Operate Mechanisms


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BI006008

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TDR Handle

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BI006008

BI006008

GET2964D

'~-

Groun Break
Equipm nt Ground Fault
Detecti n Systems

BI006008

Table of Contents

-.-

The Need for Arcing Ground Fault Protection

Grounding Practices

4-9

ill

Ground Break Systems

10-19

General

Sensors
Relays
Coordination
Operation
Monitor Panels
Specifications

~.'-".

...... _..

Relays
Sensors
Monitor Panels
Ground Break Connection Diagrams

Application Tips

20-23

Solid Ground System


Double Ended Equipment
Medium Voltage Equipment

lZI

Testing

24

Guide Form Specifications

25

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~

BI006008

I The Need For Equipment Arcing


Ground Fault Protection
Grounding of the 3-Phase, 3-Wire System

-).

-,

The early 3-phase, 3- ire low voltage systems, (240, 480


and 600 V), were hist rically ungrounded. Freedom from
unscheduled equipme t shutdowns in the event of a single
ground fault was the basic reason for the use of ungrounded systems. Fa It locating was not only cumbersome but at times was neglected at the risk of developing
a second ground fault More severe faults and unscheduled outages on a la ger scale were consequently experienced.
When disastrous mul iple insulation failures began to
emerge and were prov n to be caused by transient overvoltages due to interm Hent ground faults or the resonant
effects in series indu tive-capacitive circuits, this early
practice of not groun ing power systems rapidly lost its
popularity. Analytical tudies further showed that solid
grounding of the syst m neutral provided a simple and
effective means to sup ress the damaging transient lineto-ground overvoltages
As a result, low voltag
exceptions, operated
properly designed 10
ground fault, in mag nit
current, is usually rapi
protective devices thus
rate ground fault prot
advantage. of solidly g
a circuit will be shut
ground fault.

industrial systems are now, with


ith solidly grounded neutrals. On
voltage systems, a solid line-tode approaching the 3-phase fault
Iy removed by phase overcurrent
often negating the need for sepaction. The major operational disounded systems, however, is that
own when it develops a line-to-

Where electrical service continuity is considered to be an


overriding consideration, high resistance neutral grounding is considered an acceptable compromise. By limiting
the neutral resistor current to a magnitude no less than
the capacitive charging current of the low voltage system,
generally between.5 and 10A, several types of severe
transient overvoltages can be limited to safe values. The
resultant small magnitude of ground fault current is relatively harmless until a second ground fault occurs which
may increase the fault current to much greater magnitudes, causing phase overcurrent devices to operate.
Therefore, the success and effectiveness of high-resistance grounded systems depend largely on the early location and removal of the initial ground fault. To aid in the
location of ground faults, the neutral resistor, is arranged
to provide a pulsating ground fault, generally from 1 ampere to 20 amperes. Now. a simple portable fault locator
can more easily pin-point the fault location against
"noise," usually introduced by stray ground currents.
Note that low resistance grounding, so popular in medium
voltage systems, has not found wide acceptance in low
voltage systems. The need for a complete and separate
series of coordinated ground responsive trips on sprawling multi-circuit low Voltage systems made this mode of
grounding unattractive. Mining service systems however,
have long been grounded through a high resistance because of unique protection problems.

Grounding of the 3-Phase, 4-Wire System


On 3-phase, 4-wire low oltage system, the code requires
the neutral conductor 0 the service entrance to be solidly
grounded and all ele trical equipment be electrically
bonded to ground.
It is important to note t
ated on a 208 wye/120
gradually made the 480
tractive distribution volt

at the early 4-wire systems opervoltage. Increasing load densities


wye/277 volt system the more atge.

The operational record of these systems was generally


considered to be excel ent until reports of severe burndowns of equpiments b came more frequent, especially

on 480 wye/277 volt systems. Studies and tests orought


to light that these severe burndowns were caused by
"arcing faults" as opposed to "bolted faults," the latter
being the usual criterion used to size interrupters. In
nearly all instances these severe burndowns were associated with systems having primary fuses on the transformer
or in service entrance facilities. The growing number of
arcing fault incidents further appeared to coincide with
a corresponding growth of the 480 wye/277 volt systems
(replacing the 208 wye/120 volt systems) and a corresponding increase in the use of higher rated circuit protectors.

Grounding for Safety of Personnel


This form of groundin has been receiving increasing
attention. In essence, th objective is to limit the flow of
accidental ground curre ts in both time duration and magnitude, to levels of a fe milli-amperes, considered to be
non-lethal to the huma body. National standards have
been finalized for non-I thai boundaries. The following
limits have been sugge ed: 5 ma for 7 second? with a
constant J2t value at ot er current levels, and less than

5 ma as a permanent sustained current value limit.


Such a low level of ground fault current can not be
measured in the usual low-voltage system, where just the
normal capacitive charging ground current can easily exceed 100 milli-amps.
The subject is discussed in detail in General Electric
publication GEA-9739.

BI006008

Grounding Practices

~
.......
:~

~ackground

he concern about arcing faults has arisen from reports


f equipment burn downs due to such faults occurring in
variety of distribution equipment - load-center unit
ubstations, switchboards, busway, panelboards, servicentrance equipment, motor-control centers, cable in conuit, to name only a few. The reported incidents have
lVolved both industrial plant and commercial building
istribution equipment, without regard to manufacturer,
eographical location, operating environment, or the
resence or absence of electrical system grounding. In
great many instances, complete and devastating detruction of equipment has occurred. A particularly good
ocumentation of such a case appeared in a reference
rticle, and involved a modern apartment-building comlex whose single 10,000 ampere service entrance was
'om a utility 480Y/277-volt network. The entire main
witchboard was completely gutted by the arcing fault,
Ihich burned for over an hour and seriously inconveninced some 10,000 residents of the development.
.Ithough this documented example is startling because
f the duration and extent of the fault, many other case
istories have been reported in which the service outage
las just as extensive or serious when measured against
1e total installation or the critical nature of the loads
wolved. Personnel fatalities or serious injury, contingent
re damage, complete destruction of electrical equipment,
)SS of vital services, shutdowns of critical loads, and loss
If service or product revenue can be, at one time or
.nother, the awesome and costly effects of arcing-fault
lurndowns. It is obvious, then, that engineers responsible
::>r electrical power system layout and operation should
Ie anxious first, to minimize the probability of arcing
aults in electrical systems, and secondly, to alleviate or
nitigate by means of arcing-fault protection, the destrucive effects of such faults if they should inadvertently
Iccur despite careful system design and use of quality

.-

,. .

In order to minimiZe the probability of an arcing fault


occurrence we must consider the likely causes;
- the presence of vermin, rodents and insects in equipment
- the intrusion of conducting objects such as fish tapes
and tools into bare bus systems
- Loose connection arising from poor installation, heat
cycling and high current surges
- Insulation deterioration as a result of mechanical
damage, voltage surges, heat aging, or moisture, dust
and other contaminants.
Remember that one or more of the above causes of arcing
faults is occurring in every piece of electrical equipment.

No matter what preventive measures may be taken


against arcing faults, their complete elimination is not
possible in practical distribution systems. Arcing faults in
equipment can be expected to occur, and the engineering
of distribution systems protection should take this into
~
account.
-~
--=---.-_-:-..-.-- -=:.=-..=-

~quipment.

.....

BI006008

Solutions to Protection Problem

..,
,"./

Characteristics of Arcing Faults


Once an arcing fault is stablished, it may be quickly selfextinguishing, or, on the other hand, it may continue to
be self-sustaining as d scribed earlier. If initiated singlephase among metal-e closed bar buses, the arc will
rapidly escalate into
three-phase fault. In grounded
systems, ground will us ally be involved in the fault. When
the bus system is insula ed and the fault is initiated singlephase it may be expec ed to remain that way, provided
the current is interrupte promptly.
If the arc is self-sustain
mendous energy at the
even at low current level
ment. It is th is characte
at the point of fault, wh
structive. The bolted fa
throughout the distribu
and does not produce
ergy release of the arci

ng, it is capable of releasingtreoint of fault. This energy release,


, is sufficient to burn down equipistic, energy liberation in the arc
ch makes the arcing fault so deIt, in contrast, dissipates energy
ion system resistance elements,
he concentrated devastating eng fault.

Another characteristic f the arcing fault is its possible


low current level in com arison to the bolted fault. Under
favorable conditions th probable minimum value of rms
line-to-ground arcing-fa It current is only 38 percent of the
bolted line to ground c rrent* value. Under adverse conditions, such as single-p ase operation in the arcing-fault
circuit, or possibly the presence of a highly inductive
ground-return circuit, a further reduction of arcing-fault
current may occur. The ower limit of arcing-fault current
is therefore unpredicta Ie, but analytical considerations
and field experience bo h show that it can have values
which will not operate the instantaneous trips on lowvoltage circuit protectiv devices.

Arcing-fault Prate tion

It is seen from the prece ing paragraphs that the peculiarities of arcing faults - hi h rates of energy release, and
possible low fault curre t levels - make it very desirable
that arcing-fault protecti n be characterized by two important features: a high egree of sensitivity to detect low
level arcing-fault current and fast speed of operation to
limit the destructive effe ts of the arc. The requirements
of selective operation of circuit protective devices, however, to secure maxim m power service reliability for
important loads, may for e a reduction in both the maximum speed of ope ratio and maximum sensitivity available in arcing-fault prote tion. Nevertheless, the adequate
arcing-fault protection sy tem must be relatively sensitive
and fast, and the avail ble solutions to the protection
problem should be mea ured against these criteria.

Since phase-overcurrent devices of either the circuit


breaker or fuse type are almost universally used in lowvoltage distribution systems, it is natural to suggest that
these alone may provide adequate protection against
arcing faults. Unfortunately, fuses and circuit breakers are
useless for currents less than their continuous current
ratings, yet such currents may occur in arcing faults.
Single-phase devices, when used alone in polyphase systems, without supplemental aids to provide polyphase
circuit disconnection, furnish only single-pole interruption
of fault current. Case histories and analyses have shown
that such single-pole interruption may not extinguish
the fault, but often permit it to be backfed with red uced
current from the other energized phases. If the fault
is an arcing one, the protectors in the other phases
may not operate on the reduced current, or may operate
only after a prolonged period. In either case severe
equipment burndowns may occur. For the reasons cited,
fuses alone are not considered self-sufficient agents for
arcing-fault protection. It may be noted, however, that
certain fast-operating shunt-tripped fusible switches,
which provide three-pole circuit disconnection promptly
on the occurrence of a single blown fuse, may be coupled
with supplementary relaying to furnish protection against
arcing ground faults. Appropriate supplementary relaying
woul.d be any of the "GSR" type.
The direct-acting trips on molded-case and low-voltage
power circuit breakers will provide time-delay or instantaneous tripping of the circuit breaker on overcurrents
which exceed their settings. In practice, circuit breaker
instantaneous trips must be set above the offset value of
transformer or motor-inrush currents to avoid unnecessary
tripping. As a result, it has become a widespread but illadvised practice to set breaker instantaneous trips as high
as their range permits, perhaps checking only that such
settings do not exceed the maximum fault currents available (three-phase bolted short circuits). In view of the
possible low levels of arcing-fault currents, these high
instantaneous-trip settings cannot provide assured detection and interruption of destructive arcing faults. It is
nevertheless true that improvement in system protection
can be secured by instantaneous-trip settings no higher
than required to avoid nuisance tripping under normal
conditions. Setting of instantaneous trips on this basis
should become' a general practice in distribution systems.
In addition, the use of short-time trips to supplement
instantaneous tripping wherever possible is a recommended practice. Despite these precautions, however,
arcing-fault currents may have values less than the minimum permissible settings of the instantaneous or shorttime trips; in fact, such currents may be less than the
normal load current in the circuit. Even where the fault
current value may be sufficient to operate the long-time
delay element of the circuit breaker trip, the operating
time of these elements is generally so long that circuit
interruption will not be accomplished before extensive arc
damage has occurred.

Bolted line to ground current is c Iculated using all ground return Impedences
including such objects as fish tap s, Insects or carbonized insulation.

Because of the inadequacies of fuses and conventional


circuit breaker trips in handling arcing ground-fault currents, recourse to supplementary relaying is necessary to
secure adequate protection.

BI006008

iround-overcurrent Relaying
A B

he defects of phase-overcurrent devices in detecting lowvel arcing faults have already been cited. This suggests
lat the ideal solution to the problem would be sensitive to
'cing-fault current alone. Since arcing faults in grounded
{stems almost invariably involve ground this fact permits
near-perfect approach to the ideal solution.

rI

Window

CT

a normal, healthy power distribution system there is no


gnificant flow of current in the ground path or no "zero:quence" current. The presence of appreciable current
I the ground circuit is directly indicative of an electric
ircuit fault. Arcing faults involving ground will produce a
istinct ground-fault current. Therefore, monitoring the
round or zero-sequence circuit provides an effectual
leans of detecting the existence of arcing faults.
I

n excellent method of monitoring the presence of groundlult currents (zero-sequence currents) is provided by the
lw-voltage ground sensor relay (GSR) combination. This
; a window or ring-type CT in combination with an over:ment relay (Fig. 2-1). All of the phase conductors of the
ircuit to be monitored (plus the neutral conductor, if
sed) are passed through the window of the CT. With this
rrangement only circuit faults involving ground will prouce a current in the CT secondary to pick up the relay.
Inder other circuit conditions - balanced, unbalanced, or
ingle-phase load currents, or single- or three-phase short
ircuits not involving ground - the net flux produced in
1e CT core will be nearly zero. (Because of conductor
pacing and geometry some net flux will exist which
:presents an error in the zero sequence summing of
urrents. The error can be minimized by centrally locating
nd/or bundling conductors. The error can also be mini1ized by using CT's with heavy cores.)

ly careful application of the basic GSR scheme shown in


~ig. 2-1 a sensitive, fast ground-fault relaying design be:omes available for protection of all or part of a low'oltage power distribution system.

I
L

Relay trips circuit


protective device
at source

Ph Ph

Figure 2-1: Window current transformer


and overcurrent relay (GSR) combina
tion monitoring ground-fault currents.

.~

<.J

Phase Conductors

Source

GSR

"though the GSR as discussed here is for application as


rcing-fault protection it is, properly speaking, a ground3ult relay, and will operate on all circuit faults involving
[round, whether arcing or bolted.

Load
"'--=-....--U--~-----o:,..J I

_.\ Fault to
Ground
Ground
Return
Current

Jumper

combinali~L

__ J

Note: Conduit is insulated


from ground for five
feet each side of
insulated coupling

Figure 22: Detection of ground-fault


current in return circuit of conductor
enclosure.

BI006008

Susway feeder

""". ~l

i--;--~}

r ---T--I

I
I

Equipme t
ground us

L-:- _) Feeder CS I
Trip I
I

I
I

L_~-,

J
GSR-1

I)..ceeder

Trip

I
L __

I CT
J_

I
I
I
I
J

cs

GSR-1

Station ground

Feeder
Conduit
Feeder GSR relays may be
instantaneous or time-delay.
Main GSR relay is time-delay

Figure 2-3: Gr und-sensor relaying of


unit substation nd outgoing feeders.

Busway or Conduit
to load

Susway
Feeder from source

I-

--

GSR-2 Eq ipment
-,
Gr und Sus
~--

Main ,)

I
I

....

~-r--+.----r--

) .... J

Trip

tor Control Center (MCC)


GSR-1 Protects feeder
circuit to load
GSR-2 Protects Switchboard
or MCC and is selective
with GSR-1

Ground Sus

Substation "A"

Suswayor
Conduit

Switchboard or MCC

"s"

GSR Protects only equipment


"s" and load-side
,..----+-------,
circuits

Switchboard or MCC "S"


Substation "A"
GSR Protects equipment
"A", "S", busway, and circuits
beyond "S"
pplication of ground-senFigure 2-4:
ith various arrangements
sor relaying
of equipment

Application of GSR Relaying


Feeder Protection
Where feeder ground fault protection is desired, the arrangements in Fig. 2-3 are applicable. The GSR relays on
the feeder circuits operate to trip their individual breakers
on external ground faults. If selectivity with downstream
protective devices on ground faults is not necessary, such
as in a branch circuit, the feeder breaker GSR relay may
be the instantaneous type, and have a sensitivity in the
order of 15-amperes ground fault current. If a degree of
selectivity is necessary with other GSR relays or with
smaller phase-overcurrent devices downstream, it may be
obtained with a time-delay GSR relay, through the proper
combination of relay pickup and time-delay settings, or
through zone selective interlocking.
To protect against equipment internal arcing faults to
ground (I.e., those involving the main bus), a main breaker
and time-delay GSR device in the transformer-neutral connection are required, as shown in Fig. 2-3. The main
breaker GSR is set one-step slower than the slowest
feeder breaker GSR. Thus, for external faults the main
GSR relay waits for the feeder breaker GSR to clear the
fault before tripping its breaker, and will provide back-Up
protection if for any reason the feeder breaker fails to
clear the circuit.
On internal faults to ground, all of the ground fault current flows from the equipment enclosure through the main
breaker GSR to the transformer neutral. After a timing-out
interval the main breaker is tripped to extinguish the
fault. In the absence of a secondary main breal<er, the
GSR can transfer-trip the primary metal-clad breaker.
Application FleXibility
To illustrate the flexibility in application which is available
with low-voltage ground fault relaying, Fig. 2-4 has been
included. This shows the use of one or two steps of GSR
relaying to secure protection for individual or multiple
sections of power distribution equipment. In each case, of
course, a means of electrically tripping the associated
circuit-protective device - as with a shunt-trip or undervoltage device - will be necessary. Also, from earlier comments regarding the desirability of prompt extinction of
arcing faults, it should be apparent in all cases that effective application of the GSR relay requires the protective
device to be fast-operating - such as a circuit breaker or
shunt-tripped fusible switch - so as to provide faultcurrent interruption within a few cycles after receiving a
trip signal from the relay.

BI006008

;electivity
hrough the use of "standard" GSR relay combinations
lith minimum pickup values and operating times in the
rder of 300-400 amperes and .1 to .2 Secs. respectively,
1herent selectivity with the smaller branch circuit fuses
nd circuit breakers (such as those used in lighting panel'oards) may be obtained. Fig. 2-5 illustrates this.
\ 350-ampere low-voltage circuit breaker supplying a
lanelboard with 20-amp and 100-amp molded-case circuit
Ireakers is shown in Fig. 2-5a. The time-current characterstics of the three circuit breakers are presented as curves
~, Band C in Fig. 2-5b. Several observations of interest
nay be made.

20 100 350
1000r---'-1-;-;-----';-r--,J-,-----------.
A

I) 350A
--,

100

GSR

0Q)

10

C/)

;irst, at high short-circuit currents - above approximately


1800 amp - the instantaneous-trip characteristic of breaker
\ overlaps that of breakers 'B' and'c: For short circuits belond breakers'B'and C; supply breaker '1\ may be tripped
mnecessarily. It is recognized that the use of a low set
;hort-time delay rather than an instantaneous-tripping elenent on breaker Awould avoid this nuisance-tripping probem, and in many cases would also significantly improve,
lven without supplemental ground fault relaying, the proection provided by breaker A on the occurrence of ground
aults. Nevertheless, the characteristic curves in Fig. 2-5b
ire representative of those frequently encountered in cir~uits of this type, and serve to illustrate the combined
:ffect of GSR relaying and circuit breaker instantaneousrip elements.
3econdly, in the absence of any ground fault protection
1t location A, arcing faults 3800 amperes or less in the
Janel board or closer to breaker A will be removed only
1fter a considerable time delay by breaker W. Extensive
1rcing fault damage to equipment, of course, can occur
.
n the interval before breaker 'P\ operates.
;inally, the addition of a low-set GSR relay combination
1t location A to furnish ground fault protection very
narkedly reduces the risk of arcing fault burndown in this
:ircuit. The operatir.g band of the GSR relay, including
he breaker's tripping and clearing time, is labeled in Fig.
~-5b. The combined characteristic of the GSR relay and
he breaker instantaneous trip is shown by the shaded
:lrea.
Nith a relay-pickup setting of 300 amp (less than the con:inuous rating of breaker A), selectivity with the 20-amp
~ircuit breakers is secured for arcing line-to-ground faults
'rom 300 amp to 3800 amp, above which level the breaker
a,' instantaneous trip takes over. But most important, for
:lrcing ground faults in this range the fault-clearing time
:>f breaker 'ft.' is reduced from minutes to cycles, tremenjously diminishing the arcing damage that would be in::urred for such faults.

c:i

E 1.0

i=
0.1

0.01
Current, amperes
(b)

Figure 2-5: Protective characteristics


with low-set GSR relay, showing selective co-ordination with 20-ampere panel
board breakers.

0'~<;

Sensitivity
The application of GSR ground fault protection will require a decision as to how sensitive the relay-pickup
setting shall be, since maximum sensitivity may make it
nonsele'ctive with downstream phase-overcurrent devices
on low-level ground faults, resulting in nuisance tripping.
In Fig. 2-5, for example, the low-set GSR relay will not be
selective with 100-amp circuit breaker'B'for ground fault
currents between 300 and 1400 amperes. Ground fault
current of this magnitude beyond breaker 'B' will cause
breaker A to trip via a signal from the GSR relay. Adding
ground-sensor relaying at breaker'B: of course, will avoid
this nuisance tripping but may not be economically acceptable. Then the possible courses of action are to
accept the non-selective operation (presently done for
phase-overcurrent devices in many systems today) or to
raise the GSR relay-pickup values. This latter procedure
has been put into effect in Fig. 2-6.
In this figure, the decreased sensitivity of the GSR relay
makes it completely selective with the phase-over-current
trip devices on breakers'S' and'C'for ground faults beyond
their terminals. Now, however, in contrast to the situation
in Fig. 2-5b, the ground fault currents between 300 and
1400 amperes occurring beyond breaker 'B' will not be
quickly removed, but must wait for the operation of the
long-time-delay (thermal) element of breaker 'B' allowing
severe damage to occur.

BI006008

A Choice of Alternatives
Figures 2-5 and 2-6 illustrate that raising the relay-pickup
settings to avoid undesired tripping on low-current ground
faults sacrifices the maximum protection these relays can
provide against low-level arcing ground faults in their
area of action. Thus, a choice of alternatives must be
made when ground-sensor arcing fault protection is only
partially applied throughout the distribution system:
choosing GSR relay maximum sensitivity and minimum
operating time provides maximum protection but may result in undesired tripping for low-level ground faults;
selecting less-sensitive' relay settings and increased operating time improves system service continuity but m~y
lead to aggravated burning damage and possibly a more
prolonged downtime should an arcing ground fault occur.
Ideally, of course, ground fault relaying should be applied
at each circuit interrupter throughout the distribution system. Circuit and equipment protection and service continuity would be optimized since relay-pickup values and
operating time would be set no higher than required for
selective operation on ground faults. It will be a rare case,
however, in which justification of complete system groundfault protection can be shown. In particular, out at the
outer fringes of the distribution system, where circuit
ratings and protective devices are usually small, and where
continuity of service generally is much less vital than at
the main switchboards and substations, the risk of an
occasional burndown due to an arcing ground fault may
be accepted because the alternative of protecting every
branch circuit is unacceptably costly. Of course, new
product developments such as insulated case circuit
breakers with Versatrip Solid State tripping (GE Publication GET-6202) will make the desired protection economically more feasible. For the present, it can be expected
that only the more vital and important of branch circuits
will be equipped with instantaneous ground fault protection. The remaining branch circuits will rely on only their
phase-overcurrent devices, such as circuit breaker, directacting trips or fuses.
Closer to the source, at the bulk power centers~ where
continuity of service is essential and the risk of burndowns must be minimized, time-delay ground fault relaying on the feeder circuits will be imperative.
A Recommendation
As a practical matter (as explained above), electrical distribution systems will have only partially complete ground
fault relaying, and the system designer will generally have
to choose between the alternatives noted in a preceding
paragraph. Only the system designer thoroughly familiar
with the electrical system in question and the loads it supplies can make the "correct" decision between these
tempting alternatives, weighing service continuity against
protection, and the risks of false tripping against the hazards and costs of equipment burndowns. Naturally, no
single suggestion can be made to cover all situations, but
the recommendation can be offered that in choosing alternatives it is better to favor sensitive relay settings and
the occasional problem of undesired tripping, rather than
high-set relay pickups and the risk of total equipment
burnout.

BI006008

~round Break

iystems

GROUND BREAK' SYSTEM


MONITOR PANEL CIRCUIT NO._

IF UMP UGlfTS

'. ' e..


_

eneral Description
1e General Electric Ground Break system provides proction for systems in addition to that provided by the
lnventional phase over-current protective devices. The
round Break system can be set to operate at lower
agnitudes of ground fault current and shorter time deys than conventional overcurrent protective devices by
sponding only to ground currents, thus providing a
eater degree of protection than would otherwise be
)ssible.
1e Ground Break System also includes a Monitor Panel
1ich provides the functions of ground fault indication,
'stem testing and system reset.

GROUND FAUL'T HAS OCCURRED


t. I..dcftl' InddUr gi"IUIlS ..... candIDarL

~=::=-c:.:=~

C\

'HNf"Al~ IU~TRIC

SOLID STATE

GROUND BREAJ(,- RELAY


.

"5!alJllS!tll.~IJI_.'"~

)II

,t

:'

. . .
J!: l'r l'i II I
U
U

..

",."'.. ".."

,"

T"'l Dh'"SU:S

Figure 3-1:

Ground Break Components

In a typical application, a ground fault produces a signal


in a special window-type current transformer called a
GROUND BREAK SENSOR. Sensor can be applied so as
to measure the main circuit ground fault current directly
as it returns to the power source by encircling only the
equipment ground conductor. This application is called
ground strap method. To measure the ground fault current of any circuit indirectly as the vectorial unbalance of
current in the phase and neutral conductors, encircle all
the phase and neutral conductors, but not the equipment
ground conductor. This application is called zero se
quence method.
The output signal of the sensor is fed to a GROUND
BREAK RELAY which is adjustable for current picK-up
and time delay. The relay integrates the signal from the
sensor. If the signal is greater than the preselected settings (current and time) the relay completes a control
power circuit to a shunt trip installed in the circuit protective device, thereby tripping that device.
The relay will remain ON (latched) to continue energizing
any ground fault signaling devices. The relay should not
be reset until the cause of the ground fault has been investigated and cleared. Only after the relay is reset, by
operating the Monitor Panel reset pushbutton, will it be
possible to successfully reclose the breaker/interrupter.
The Ground Break Monitor Panel is an integral part of any
complete Ground Break system. In addition to the functions of ground fault indication, control power indication
and reset after ground fault trip, it is provided with circuitry which can test the complete Ground Break system
with or without tripping the protective device. This test
feature is easy to use, uncomplicated and foolproof. The
Mqnitor Panel test is not just a test of the electronics but a
true test of the response of the system to a ground fault.'

'Ground Break Monilor Panel produces a 1600 ampere ground fault In


tesl mode.

If)

~/

Q;

GROUND BREA

TIME COORDINATION

RELAY

0.
_-"'-,--

GROUND BA[J,K- SYSTEM


MO""CWt 'ANn CtJIICln MO._

u.- UCMtIo

QI(JgD..".,
MAl 0CC.IlAID
2. .....
,.__
_
t. e . - _ ~ . -

......

.....-.-.

The Ground Break s ries of relays are hybrid devices.


They combine the pre ision, speed, reliability and intelligence of solid state lectronic sensing with the isolated
switching capabilities of electromechanical devices.
Relays are used in c njunction with a circuit protective
device having a shunt trip. The relay, with its sensor, will
detect ground current and cause the circuit protecting
device to open (or acti ate a signalling device) when these
currents reach presele ted values. Optional zone selective
interlocking provides nstantaneous tripping in each protected zone, and time delay back-up protection between
zones for a fully coor inated and selective system. Three
pick-up current range are available: continuously adjustable ranges of 2-12, -60; or 100-1200 amperes. The relays also have a conti uously adjustable time delay range
of Instantaneous (0.0 ) to 1.0 seconds. The time delay
characteristic is show on page 26. Once settings have
been selected, adjusti g knobs can be clamped in position by means of the tamping bar on the face of the relay. (Fig. 3-3).
Because of the highly intermittent and erratic nature of
arcing ground faults, a memory circuit has been incorporated in the Ground reak relay which integrates intermittent faults with time.
In the following diagra s it can be seen how the memory
function works. Diagra 3-4A shows a typical ground fault
with half cycle, whole ycles and multiple cycles missing
as normally occurs. Di gram 3-4B shows trip response of
a typical ground fault relay which does not include a
memory function. The elay never trips because the time
delay circuits are reset with every missing cycle. Diagram
3-4C shows response f the Ground Break relay to the
same ground fault, th relay's memory carries thru the
missing cycles and gen rates a trip signal after the preset
time delay.
Trip line ~-r-r--.-h---,r--r-r....,

Figure 3-4A
Ground

BI006008

The standard means of obtaining ground fault selectivity


between main and feeder breakers is by incorporating
time-coordinated GROUND BREAK relays in the system.
This consists of setting the furthest downstream Ground
Break Relay with a small time delay, progressively increasing the time delay, as you get closer to the main protective device. Tr.e main device must have the longest time
delay in the ground fault system. See chart for recommended settings for devices with clearing time of less
than .04 sec.

aull

T-

Zone Selective Interlocking


Type Z Coordination
Another means of obtaining selectivity that offers advantages over time coordination is Zone Selective Interlocking. (Type Z) The main purpose of ground fault protection
is to detect low level arcing faults. However, one disadvantage of the time coordination method is that for minor
ground faults "downstream", the main device may trip.
To preclude this, a time delay is normally introduced, but
at a sacrifice in the degree of protection, except in the
Zone Selective System.
In the Zone Selective Interlock system, the relay farthest
downstream (farthest from the power source) which senses
the fault initiates tripping of its protective device and
sends a signal to all "upstream" relays to block them from
tripping. The "upstream" (closer to the power source) relays respond to a fault in a "downstream" zone by timed
tripping. Timed tripping provides backup protection for
the downstream devices.
For ground faults in their own zones, Ground Break Zone
Selective relays respond by tripping instantaneously to
minimize equipment damage. See Fig. 3-5.
Zone Selective Interlocking can be illustrated by considering a system with two zones. The main breaker is set to
trip after a time delay as a backup to feeder breakers. The
main breaker will trip instantaneously, however, for a
ground fault in its zone regardless of its time dial setting.

~
T
I
M
E

-~
9

a:

'"

c=

--

Figure 3-5

'"<:l

--"

~ Delay Settings

--/

'"<:l

Instantaneous

i ___
No trip

Ground Fault Current

Figure 348
Ground Fault wi hout memory

Trip line ~-r-r--.-h---,r--r""7lO::T7ITrip signal

Figure 3-4C
Ground Bre k Relay
response w th memory

T_

BI006008

;YSTEM OPERATION
tecommended Settings for Standard or Type "z" Relays
Iround Break relay settings of pick-up current and timeelay for main, feeder and branch circuits should be se~cted so as to provide optimum ground fault protection
nd coordination with the conventional overcurrent devices
'1 the distribution system. Since the ratings of the conentional devices will vary with application, no general
tatement can be made. However, the following recom1endations are basic for satisfactory performance of most
ystems.
lecommended ground fault current pick-up values are
hown in Table 3-6 for various equipments or locations
vithin a system. Maximum relay operating times should
Ie in the area of maximum 0.2 sec. (12 cycles) to 0.4 sec.
24 cycles) to minimize damage. The longer times should
lnly be used where necessary for selectivity with down,tream devices or ground relays. Note that with Zone Seective Interlocking,. time settings on a main device apply
lnly to backup protection, as this relay picks up instananeously for a fault in its own zone.
rhe standard GROUND BREAK relay has time and current
)ickup settings that can be adjusted to provide selectivity
)etween GROUND BREAK relays at different levels in the
lame system. These relays are designated GSR-1, GSR-2,
md GSR-3, with higher suffix numbers indicating increasng time-delay. The instantaneous GSR is designated
3SR-0. For larger feeders or mains the suggested minimum
lick-up for a GSR-1 is 400 amperes. This provides seectivity on ground faults between the GSR system and 20
3.mpere lighting and appliance branch circuits.

Table 3-7
TABLE OF PICK-UP SETIfNGS AND TIMES
FOR FIGURE 3-9
Device
Main A

GSR3

D GSR2

PickUp *Time

PickU~

E GSR-1

F GSRO

'Time Pick-Up Time Pick-Up Time

SODA 0.3

Feeder B

500A 0.2

SubFeeder C

400A 0.1
25A 0.03t

Branch H
Relay Operating Time in Seconds
t Ins!. Setting

Table 3-8
RECOMMENDED GROUND SENSOR RELAYS
Desired
Location
of GSR

Recommended GSR

GSR-1
GSR-2
GSR3

M
M+F
M+ F +SF
M=Main

F=Feeder

'E...

SF

GSR-1
GSR-2

GSR-1

SF=Sub-feeder
I

_ f

I I I ""I

I I J

111111,000

Table 3-6
RECOMMENDED CURRENT PICK-UP VALUES
Area

Current Magnitude

Individual Motor Circuits

5-60 A

Panelboards, Motor
Control Centers, Feeder
Circuits to Busway
Risers, Multiple Panels or
Other Feeders

200-800 A

Main Services

400-1200 A

)ne of the steps necessary to assure selectivity between


3SR-1, 2 and 3, is to increase the pick-up values of the
'elays a minimum of 100 amperes (5 amperes, for 5 to 60A
'elay) per step. For example, a GSR-1 set at 400A pick-up
should be backed up with a GSR-2 set at 500 amp pick-up,
Nith an appropriate time setting to obtain selectivity.
rhe coordination curves between GSR-1 J GSR-2, GSR-3
3.nd GSR-O for a particular system plus recommended
pick-up and time settings are shown in Fig. 3-9, and Table
3-7. Table 3-8 gives the recommended GSR designations
ror desired location in any given system.

._I

.... '

..10
,

101

I
1,000

CURRENT IN AMPERES

Figure 39: Typical system showing


device coordinating curves, and GSR
selectivity, using GROUND BREAK.

.1

BI006008

CONTROL VOLT GE

MONITOR PANELS

Ground Break Systems are designed for 24, 36, 48, 125V
de and 120, 120/208-12 /240Vac.
All Ground Break Rela s are provided with two normally
open contacts as stand rd. One of these contacts is tied
to one control power te minal on the relay, the second is
totally isolated so that i may be used for electrical interlocking of relays or for ther control voltages. Both contacts are rated 5 amp res continuous and 30 amperes
inrush at any of the abo e voltages.

A flush mounted monitor panel is a component part of the


Ground Break system. It provides the functions of monitoring and testing the Ground Break system.
A pilot light is provided to indicate presence of control
power. If the pilot light is "out", control power fuses and
circuit should be checked.
There are two pushbuttons provided - red, marked "Test
and yellow, marked "Reset". The ground fault lamp (red)
lights or the mechanical indicator pops out, to show that
the Ground Break relay has operated to trip a breaker/
interrupter. The reset button must be pushed to reset the
relay after the fault has been located before the breaker/
interrupter can be successfully reclosed.
The monitor panel has the ability to test the complete
ground break system with or without tripping the circuit
protective device. Instructions for performing tests are
printed on the face plate.
During the few seconds of each test operation, the monitor
panel energizes the sensor test windings. This energy requirement dictates the use of a control power source of
at least 250 VA. The test signal simulates a ground fault
of approximately 1600 amperes. (For other test currents
see section on System Testing.)

GRC)UNriiiREAK~-SYsiEM--

10

IIONJTOR PANEL caRCUlT


F UIIP UGHT&

~
~

,10"

GROUND FAULT lIAS 0CCtIMED


t . ..--. ...
CGdtioft.
2. PIIIIl
Duttan_o.rt,......

c-...,..,.....

reac-""

1. ...... anddll'a~/~.

.....ocMp-.,,,...- ..._
l.-t~_.

...tt__.......

2..~"-_._f
~I.._

.,---,._--, ._---_.
1 . . - -----

H:r,S OCClla::ll::)

-.

.l P ....", ...d1'''atl;trflooUllo

.-..t

.l A
b

la otrt............
"""""

"

t::~===,

. t =:='1ff1".~
I, Z"':==-~~"";.ll !
~-=
...

~,-""

:01

JfO._

'"i:;lIClorOR PROTRUi)ES

e;:tCUN:) 'F''\ULT

Diagram of relay terminals and


line drawin of contacts and
electronics.

..

l. : . : : : : . . : - :.....

"'---- I~_----.
.=---'

.. ~ . k

__
"':::-;-_.

@ _

~!.
_

GMERALe ELECTRIC

CIIIClA'JIIIII:!K1'.'lIllf'l'CZIllP'NfftOT.'UM'LlJ..c:c....,

GfouniJ BleaK

BI006008

Component Specifications
GROUND BREAK RELAYS

ROUND BREAK SENSORS


ment Transformer Ratio - 800:1 Except Type TGM
tegral Test Winding Ratio -1 :700 Except Type TGM
lermal RatingTGM Sensors - 600 Amperes
TGS0002 -1600 Amperes
TGS0005 - 2500 Amperes
TGS0408 and TGS0808 - 4000 Amperes
All other sensors - 3000 Amperes
lermal rating is the maximum continuous,
rrent which can exist without overheating the sensor)
SYSTEM WITHSTAND RATINGS
ximum Primary Short .
cuit Current rating (thru
It current Sym)
ximum Ground Fault
nnt Ratings

TGSTGSR

TGMTGMR

200,000 A

50,000 A

200,000 A 0.1 sec.


60,000 A 1.0 sec.

35,000 A 0.1 sec.


12,000 A 1.0 sec.
5,000 A 5.0 sec.

electric
Windings to mtg. bushings -1.5 kV
Windings to CT window surface - 2.2 kV
Mounting bushings to CT window surface - 2.2 kV
lulation - Cast Epoxy all sizes
nsor Construction
Model
TGS0002
TGS0005
TGS0008
TGS0808
TGS0810
TGS0818
TGS0808A
TGS0808S
TGS1113
TGS0824
TGS0832
TGS0838
TGS0418
TGS0424
TGS0432
TGS0408

Inside Dimensions
2.5" dia.
5" dia.
8" dia.
8" x 8"
8 3h" x 103h"
8" x 18"
8" x 8
3
8 h" x 8%"
11" x 13"
8" x 24"
8" x 32"
8" x 38"
4" x 18"
4" x 24"
4" x 32"
4" x 8"

Type
Solid Core
Solid Core
Solid Core
Split Core
Split Core
Split Core
Split Core
Solid Core
Split Core
Split Core
Split Core
Split Core
Split Core
Split Core
Split Core
Split Core

~nsors

may be used 1 per phase or any other combinam. For this type of use all outputs except "T" should be
mnected in parallel. When sensors are used more than
per circuit the thermal rating (current) must not be less
an the maximum phase current.
msors For Use With TGMR Relays Only
Model
TGM0002
TGM0005
TGM0008

Inside Dimensions
2.5" dia.
5" dia.
8" dia.
Sensor Turns Ratio 160:1
Test Winding 80 Turns

Type
Solid Core
Solid Core
Solid Core

~ONITOR PANELS
unction - Control power indicator light
Ground fault trip indicator
Ground Break System Reset Button
Ground Break System Test Button
Test - Control power 120V ac, 250 Va during
'unction
short test period is required. Simulates
1600 amperes ground fault during test
(TGSR relays) and 190 amperes (TGMR relays).

120V a-c & 125V doc, 5 A Output


Adjustable
Trip Range
Amperes

LO

HI

2
2
2

5
5
5

12
12
12
12
12
60
60
60
60
60

100
100
100
100
100

1200
1200
1200
1200
1200

2
2
5
5

Relay
and
Shunt Trip
Voltage

Cat. No.
Without
Zone
Selectivity

120/240 VAC
125 VDC
48VDC
32 VDC
24 VDC
120/240 VAC
125 VDC
48 VDC
32 VDC
24 VDC
120/240 VAC
125 VDC
48 VDC
32 VDC
24 VDC

TGMR1
TGMR1
TGMR18
TGMR1C
TGMRlD
TGSR06
TGSR06
TGSR068
TGSR06C
TGSR06D
TGSR12
TGSR12
TGSR128
TGSR12C
TGSR12D

Cat. No.
With
Type Z
Zone
Selectivity

.....
....

.....
....
....

TGSR06Z
TGSR06Z
TGSR068Z
TGSR06CZ
TGSR06DZ
TGSRl2Z
TGSR12Z
TGSR128Z
TGSR12CZ
TGSR12DZ

Tolerance: 10%, but not exceeding 1200A.


Time Delay: Adj. lnst. to 1.0 sec. max.
Calibration: 10% Refer to GES-6135
Ambient Temperature Range: -35C to 80C
Control Power (Nom.)
120Vac
120/208V ac, 120/240V ac
24,36,48, 125V dc
Nom. power dissipation - 1 watt
Maximum power dissipation (Relay tripped)
(excluding aux. devices) - 2 watts
Output - 2 normally open contacts each rated
Continuous

Inrush

5A
5A

30A
3QA

240V ac Max.
125V dc Max.

Open Contact Breakdown Voltage-2000 VAC RMS


Dielectric (all relay terminals shorted)
terminals to ground 1500V rms
Relay Reset by disconnecting control power
Zone Selective Interlocking
Type ZInstantaneous trip, convertible to time delay trip by signal from a downstream Type Z relay.
Other All Ground Break relays incorporate a memory function
which permits the relay to properly interpret the cumulative effect of an intermittent ground fault. Memory time
constant 7 sec.
Ground Break System Control Voltage
Monitor Panel
Wilh GF
Mechanical
Indicator

Relay Control Voltage

TGSMP

TGSMA

TGSMPA
TGSMPB
TGSMPC
TGSMPD

....
....
....
....

120V ae, 1201208V ae


1201240Vae
125V de
48V de
36V de
24V de

With GF
Indicator
Light

BI006008

MINIMUM
GROUND
BREAK
,
SYSTEM PERFORMANCEON XJ TO ~ OR 3:"~'
THROUGH FAULTS
-

18

)
fz
w
a:
a:
:::J
OCf)
f-w
...Ja:
:::J w
Q..

16

14

u..~

w
Cf)u..
:20
Q..Cf) 12
('1')0

?"';\
~SJ

a: z
0
wCf)
Cf):::J
0
II
Q..f- 10

z
ofI

Cf)

I
Q..

10000
9000

8000

'"~

7000

6000

'"

5000
4000

Co

.
0::.
'Q.

':o

3000

::

2000
1000

TGMR RELAYS
WITH TGM SENSORS

GROUND BREAK SENSOR


CONDUCTOR LOCATION FOR
DETERMINING LOWER LIMITS
OF CURVE

2 4 6 8 10 12 14
Error Sig. Amperes

200

400

600

800

1000

1200

ZERO SEQUENCE ERROR SIGNAL


IN AMPERES

15

BI006008

:elay and Monitor Panel


0.600

0.218 MIg. Hole

(4) MIg. Holes foe No. 832

3.54---

10.25

0.3_1(~"~m~~~~~~--!_+-+-NO_' s_cr_ew~:+---J--1
~

32
Terminal ,.
8,r'_

0.95

3,.1

5.14

Screws W,lh Nuts

!
I

5.25

5.64

1750 J:.;t-040

2.944

2i5-,

I
I

I
I
I

Cul-oot line

.37

0.25

r---------l

I
J 1Il
I

-1

'i
j

4.25

475

I
I
I
____ ...1I

-----ll

3.00
>---- 3.50 ~

0.25

Monitor Panel (Flush.mounted)

Relay

ensors

41a

0.25

MIg. holes for

-n-I

1.12+-l

.50

f- 3.88 +

Round Sensor Dimensions (inches)


B

6.62
9.50
'GMOOOS/TGSOOOS 12.75

"GMOO02/TGSOO02
'GMOO05/TGSOO05

2.50
5.00
8.00

5.25

2.56 5.12
3.94 7.88
5.44 10.8S

5.75
8.50
11.50

4-'
1.16

5.62
8.50
11.50

CaL

No.

FIg.
No.

CaL

No.

\No. 0
Mfg.
Holel

0.50
0.50
0.62

2.87

16.06

1
8.50

FIg.
A

~21S1

2.50

Rectangular Sensor Dimensions (inches)


No. 0
Mfg.
Holel

1.16

--i' 1,lL

8.00

TGS0424

50'

'. --r'.

Cat. No.

MIg. holes for


TGS0418

TGS0432

6 23.25 18.00
rGS0418
6 23.25,18.001 2.12 1a TGS081S
1
4.OO
rGS0424
6 29.2r
6 29.25i24.0015.12 1a TGS0824
rGS0432 10 37.25,32.00 0.62 1a TGS0832 10 37.2532.00
rGS0808
6 See Outline Dwg. 1b TGS0838 10 43.2538.00

No.

2.12
5.12
0.62
3.62

10
10
10
10

41c
8.50

(3JTermiral

S.rews

Mli holts for

TGS0832
TGS0838

BI006008

Cat. No.
TGS0002
TGSOOOS
TGS0008
TGM0002
TGMOOOS
TGM0008

2% in.LO.
S in.LO.
8 in. 1.0.
2Y.z in. 1.0.
Sin.LD.
8 in. 1.0.

31bs
41bs
71bs
31bs
41bs
71bs

o
RECTANGU AR (Split Core)
TGS0408
TGS0418
TGS0424
TGS0432
TGS080e
TGS0808S
TGS0810
TG~0818

TGS0824
TGS0832
TGS0838
TGS1113
TGS0808A

4 x 8 in.
4 x 18 in.
4 x 24 in.
4 x 32 in.
8 x 8 in.
8'li x 8'li in
8'li x 10'li in.
8 x 18 in.
8 x 24 in.
8 x 32 in.
8 x 38 in.
11 x 13 in.
8 x 8 in.

Rectangular Sensor

Cat. No.

No. of
Mfg.
Holes

TGS0408
TGS0808S
TGS0810
TGS1113

4
4
4
4

Split
Split
Split
Split
Split
Solid
Split
Split
Split
Split
Split
Split
Split

.75
lSlbs
181bs
21 Ibs
2S Ibs
2SIbs
20lbs
2SIbs
31 Ibs
371bs
SO Ibs
S71bs
2SIbs
20lbs

1----

12.00---...

41 d

8.38
10.38

imensions (Inches)

Fig.
No.

1d

f---11.88 - - - - ;

1f
19

41 I

41 9

n Diagrams

o
:-..1

Control
and Trip
Circuits
24,36,48
or 125 VDC

Rl. if any (see Table ill)

(Grounding of either
polarity is permissible)

Iw,'iJ~~---+---;:::::==~-I---~~~~
_
Test Circuit N
:::

120VAC

~----"'Ll

I
I
I
I

MONITOR
PANEL
Cat. Nos.
TGSMPA
TGSMPB
TGSMPC
or
TGSMPD

I
I

I
I

----0-J

I
I
I
L--4-------1f-'

Remote indicating lamp or


other continuously rated loads.

*Wires,

run. Wir

14 AWG min. routed together for 100 It. max.


should not be harnessed with power conductors.

** Same voltage rating as


DC control circuit

Wiring diagram for Ground Break


Relay and Monitor Panel using d c control voltage
Figure 4-2

Connection Diagrams

.....
e
:"-'"

RI. if any See Fig. 61

+:=r-:...:-:.,..,::J-,

1--I
I

Monitor
Panel
Cat. TGSMP and
TGSMA

I
I
I

Control
Voltage
Source

CD CD
I

---0----------/

I TC

Shunt
TriprI52
o
Electric Trip I_a_ L.-

Remote .10 d'Ica t'109 Iamp or


other continuously rated loads

- ' -_ _===_

"Wires, #14 AWG min.. routed together for 100 It. max.
run. Wires should not be harnessed with power conductors.

Wiring diagram for Ground Break Relay and


Monitor Panel using ac control voltage
Figure 4-3

MAIN RELAY

FEEDER RELAY #2

FEEDER RELAY # I
,,~-"

.,-.~,,,

;;

-:~.~'"

..,'

(D ..

.',

<D0000

CD
SUB-FEEDER RELAY #2A

SUB-FEEDER RELAY #IA

<D. 0:0) 0jt


.. ..
.,~~

.....~:~~~

...~-

'

:~$I~ll

Wires #22 AWG, min., twin


or twisted pair, with 1000
ft. max. run. Wires should
not be grounded or har
nessed with power wiring.

<D0000

1"-"

..J

Optional Jumper Wire to add time


delay to relay trip. Useful on furthest
downstream relays. Also makes any
Type Z relay act like a standard reo
lay with regard to time delay.

Typical Zone Selective Interlocking Connections for


a system having a main protective device and two
feeders, with each feeder having a sub-feeder.
Figure 4-4

BI006008

-+

L.--t-

(continued)

Connection Diagrams

(continued)

*Wires, ;14 AWG min., routed together for 100 ft.


max. run. Wires should not be harnessed with power
conductors.
S3 **
IOp!lonall

S2
Test Function
(Optional)

R1***
50 Ohms
100 Watts. Min.

BI006008

**The function of S3 is to
inactivate the Trip Coil, if
desired during the Test function and until after Reset has
been accomplished.
***Other values of R1, if
used, will simulate ground
faults as shown in Fig. 6-1.
Note:
All switches should be momentary spring-return type.
Control
Voltage
Source

Reset
Function

Sl
'- - - - ,
CS _.1.._
I
I
T
-rI
l

-I

Ground Fault
Indicating Lamp or
other continuously rated
loads (same voltage
as Control Power)

Sl

--! Connect to N for 120 VAC Trip Coil


or to L2 for 208 or 240 VAC Trip Coil

Figure 45

Wiring Diagram for Ground Break without


Monitor Panel using ae Control Voltage.

,~
<,J

S2
Test Functio
(Optional)

---I ~-!---{

R1 ***
Reset
Function

11 ...
Test Circuit
120 VAC

CS

Ground Fault
Indicating Lamp or
other continuously rat d
loads (same voltage
as Control Power)

r==

N---r----+---+---_+_~

Control Circuit
24 VDC. 36 VDC
48 VDC. or J25 VDC

Sl

!Grounding of either
polarity is permissible)
Shunt Trip
or
Electric Trip

CD

I 52
I TC

L..-_ _- ' \

I_ _
*Wires, # 14 WG min., routed together for 100 ft. max.
run. Wires sho Id not be harnessed with power conductors.

-a-,
52

Note:
All switches should
be momentary, springreturn type.

**The function of S3 is to inactivate the Trip Coil, if desired, during the Test function and until after Reset has
been accomplished.

***Other valu s of RI, if used. will simulate ground faults


See Fig. 6-1

Wiring Diagram for Ground Break without


Monitor Panel using de Control Voltage.

Figure 4-6

BI006008

Incoming Power
Neutral

- - - - - - - - - Neutral

,-I
I

,I

...
,.....

....--..(-----t--r'c:--- Neutral Bus

'"'~---~

Main

'~. )I

Zero sequence sensing

Main protection by
ground return sensing

Only main protected

~ _-

Branches

""'--

""'

Only main protected

Main

Feeders

limited selectivity

""'-.......

limited Selectivity

Figure 5-1

rI. rI. Incoming !"ower


'#
'#
Neutral

Branches

r-'

r--"
I

...

.
"'"'
I
I

Branches

Main
GSR.'
Main and feeders protected
by zero sequence system

"

" "'._--- ..--=,....,~-

Neutral

GSR'

Main protection by ground return sensing


Branches by zero sequence

Time Delay Selectivity

"'"'---

Time Delay selectivity

Main

'"""-Ph
N

Figure 52
Incoming Power

~ ~ Neutral

Figure 53

______

GSR2

r--

~~ te..':~~ ~t~~~
,.--.---~------, I

G::;R~'

!.

I..
Zone Selective Interlock

-----.--t"-,.-

Other Relays

GSR.':

I
,

I
I

ro

..
1

.-

~sRrr~-I~~c-'-1
j : rr;-~

.z-~:_-+-I

~~

GSR.'

I ..

I~

:=_:
~

~_,

-:

'I

'

L__ ~~~i~~~~~~~~~~

I
I

-=-

GSR

j
I

-GSR:;'

Main ground return sensing

Selectivity through zone selective interlocking

Ii

Zone
Selective
Interlock

A_., !I

+--1====:tI:t=i=,:. :

,-...
'----7
Ma '-in---....

Sranches Zero sequence

I.......

., I GSR.'

_:y

Ph

Main trips instanlly for a ground fault on t h e sw bd . buss but delays for
a ground fault on downstream equipment.

Main and feeder fUlly selective


using zone selectIve Interlocked relays

I GSR.O

'"""

"'_I
I

BI006008

~.:

..

...

~J::./

-/

Double B s,Double Breaker Emergency Power Systems

91

1 - ~--------------+----

Neutral

)
GSR
,--

Emergency

1m

Optional j" -

,
I

A~-+-f---...--+--+-_~-t--.--+-+--

_L

)ir --I

);?.. --:

BIB
~f- '-...

.l.. "--<

(~->LJ

~~

-1

1.

(f-.>!

GSR

r1
C.-7GSR

'--<

GSR
Load

Load

To other
Feeders

Load

..

Ring Bus (T"ransformer, Generator or both)

..-

-.

.......,

(TR1

.....,..,

'I'

\:R2

,....,...

'I

/~

\TR3

'"""
I

tG'
M1 )

f\
T 1-2

G2

Iu..J--I

)M2

N
S 1

~ )
II I
\.AA./

N
G1 Trips M1, \-2' T - -

/-J.I"

G2 Trips M2, \-2' T _S 2

tG'
M3
I

,-.... II

f\
T 2-3

T3-1 U\..J\.-

N
G3 Trips M3, T 2 _S ' T S _1

BI006008

APPLICATION TIPS (continued)

'-- .

Double-ended unit substations or switchboards


(Fig. 5-7) present a special case, which is one of
obtaining selectivity between the tie and main
protective devices and between the two mains
under arcing fault conditions.
Selectivity is obtained by grounding the neutral
at only one point, at the center of the switchboard,
and placing a sensor on a ground strap between
this point and the switchboard ground bus. The
GROUND BREAK relay associated with this sensor trips the tie device. Sensors for tripping each
main device are located on the neutral, on each
side of the point where the ground strap is connected. All feeder neutral connections are made
on the source side of these sensors.
The GROUND BREAK relays are interlocked to
trip the tie device first, if it is closed. When the
tie is open, ground fault current returns to the
transformer that is energizing the fault by flowing
from the switchboard enclosure and ground bus
throu9h the single ground strap to the neutral bus,
and through one neutral sensor back to the transformer neutral point.
Since only one neutral sensor sees the fault current, only one main device trips and unnecessary
disruption of service is prevented. The main
breaker relays will not operate when load current
flows in the neutral because their control voltage
is obtained through a normally open contact of
the tie breaker relay.

Referring to Fig. 5-7, additional GROUND BREAK


relays may be added to selected feeders for
ground fault protection downstream.

Figure 57

Source ;;:1
3 4 W-WYE

u-L

Ground relays are


interlocked to trip
tie first if it is
closed

Load Feeders

Source ;;:2
3 p 4 W-WYE

I
vJ....u

Load Feeders

SWBD., Grd. Bus


-

Service Ground

CT Ground Sensor
G Ground Break Relay
'':.,,-;,,~:'':'.'

: .... -.....,' ...._.:.".

;.,

.. -...

.... :~:... : ... - ..- ... :;

':.,'

BI006008

Double-ended Eq ipment
Relays G1 and G2 may e selectively coordinated with the
ground-fault protection elays applied on the feeder breakers by the selection 0 suitable current and time-delay
settings. With relays
1 and G2 connected as shown,
maintaining proper pola ity markings, there will be no current flow through the r lay coils for three-phase, phaseto-phase, or phase-to- eutral currents. Furthermore, the
line-to-g round fault cur ent may return over either of the
ground paths and the n utral conductor, or it may be divided between the two in any proportion, without upsetting the proper flow of t e current through the relay coils.
Also, the line-to-neutral load caused by unbalanced lineto-neutral current on
feeder circuit has two parallel
paths by which it may turn to its source at one or both
of the transformers. On path is by means of the neutral
conductor, the other is partially by the neutral conductor
to the ground point n ar one transformer and then by
ground to the neutral 0 the source transformer. With the
current transformers nd relays connected as shown,
these extraneous curre ts flowing in the neutral conductors will cause no adve se action on either of the relays.
That is, it will not add to or subtract from the required
ground fault current flo in the relay coils, nor will it introduce any current flo in the relay coils for non-ground
fault conditions. These conditions are true for any combination of breaker po itions (open or closed) of (M1),
(M2) and (T).

This summation scheme can be applied with the proper


modifications on multi-feed systems; namely, three or
more transformers and/or generators each with its own
ground connections, feeding a switchgear or switchboard line-up and each switchgear or switchboard
grounded on the line side of the main protector and intertied through tie breakers. Consult factory if sensor
leads must exceed 100 feet.
Tran . na.1

'II'I

Tran . na.2

r-

II'

)
~

HI,

'I I-

~ J J ~ < ~ J~, u II

J J J. ~f

1
G

All

arn
6)) )
roti an

CT'

) 0 1)

....

,),)

e) )

A
B

I
I

C
N

I) I) ,)

(3),) ,) ,)

Relays G1 & G2 must trip the tie CB as well as their respective mains.

Medium Voltage
4160

3WIRE

3 PH

-1f-<~)>--4!~-"!-~!t--

61011

400 AMP

GSR

o.~' GSR_2~,
Q~ GSR.~21
Q~ GSR-2

f3

200 A
.1 sec.

T 200 A
.4 sec.

200 A

.1 sec.

200 A

.2 sec.

.,..,.

I
I

AJ..

--.

I---~~~I

AIl,m."

l.,.J

~ 300 A ~ GSR-11

I
30~3:eci
t
I
I x~ ~ ... ~z
..
I ~W~
! ! !
'0".
II
~
I
c0
~
L
' __ J
4160 V

)+,)+,).,

-:

'\.

~-

200A

200A

15"Aj

3 PH 3 WIRE

~ ~l
GSR

GSR-O

GSR-<l

200 A

200 A

200 A

'''l

I
MCC

Figure 59
",

..

"

. .

.' '.

.'

.~.

'.

'. " ; ' '., . : . . . .

"

. . .,

....

BI006008

Testing

Ground Break Test Resistors (Wirewound)


It is recommended a resistor be selected to give simulated
ground fault signals at least 20% higher than pick-up
setting of Ground Break relay.

TESTING
The reliability of the ground break system is excellent. However, since testing is so convenient,
it is recommended that a test be performed
monthly, or after the breaker has experienced a
fault of any kind.

TGM
Sensors
Sim.
Ground
fault
Current

TGS
Sensors
Sim.
Ground
fault
Current

190
130
120
96
68
48
24
12
6.6
4.8
2.4

1600A
1200A

ON-SITE TESTS

If Monitor Panel
Figure 62 Wirewound

Rl

No Monitor Panel
Wirewound

Rl

Resistor,

Added
Resistor

Min.
Wattage

no ad it ion
20n
SOW
30n
sow
son
sow
90n
2SW
IS0n
2SW
350n
25W
7S0n
20W
1400n
12W
2000n
8W
4000n
SW

1000A
800A
600A
400A
200A

100A
60A

40A
201\

Resistor,

Resistor
Figure 42

Min.
Wattage

son
70n
80n
lOon
140n
200n
400n
800n
1400n
2000n
4000n

100W
100W
100W
sow
sow
2SW
2SW
20W
12W
8W
SW
,IT:

The complete Ground Break System consisting of Sensor,


Relay and Monitor Panel incorporates all the testing facilities which would be normally required by any planned
maintenanceltest program.

Figure 61

The system provides the following two types of tests.


I. System test without interruption of service. This test
subjects the Ground Break System to a 1600 ampere
ground fault at the sensor providing a test of the sensor, sensor wiring, relay, relay to Monitor Panel wiring,
and Monitor Panel but disconnects the shunt trip from
the circuit thereby preventing the protective device
from tripping.

... il:l.rl~(5.ttiacleIID
'-+--+------~~

r--

: '---:1---"+--+--=+---,

II. System test with interruption of service. Same as above


but without disconnecting shunt trip, thereby providing
a test of the complete system including the shunt trip
wiring, shunt trip and circuit protective device.

Monitor

I
I
I
I

P""I
C.1t. TGSMP ,nd
TGSMA

I
I
i
I

,
I

" '--..-:=f=:---i---'

If a simulated current of other than 1600 amperes is desired, a resistor chosen from the chart below should be
added to the test circuit and connected to terminal "T" on
the current sensor.

~--yt(
---------_/
~
RmoIrindicJltneqor

athrr ~tin\lOusly ratfd loads

11C
Shu'::,lrip 1 51

[ltdri( Trip:

I.J_

J Contlftt
Of

T-r-

10 N for 120 VA:; Ttc

10 L2 for 20a or 2.0 VJ,[,

T~

Coil
Coil

Wires. #H Awe min.. rou1td tocrtl'ler let )00 ft. mu.


Wires shoukS not be barnmed with power conductOfl.

RIl

Wiring diagram for Ground Break Relay


and Monitor Panel using a c control \'ollage
and Optional Resistor

Figure 6-2

BI006008

Guide Form Specifications

Furnish and install UL recognized ground sensor relay


(GSR) system with Ground Break components for each of
the protective devices indicated on the plans. Each unit
shall consist of a coordinated ground sensor (CT) with integral test winding, solid state relay to operate the shunt
trip circuit on the circuit protective device and Monitor
panel.
The relay shall be of the (standard time delay) (Zone
selective interlock) type and have continuously adjustable
current pick-up settings of (5-60 amperes) (100-1200
amperes) and continuously adjustable time delay setting
from Inst. (.03 sec.)to 1.0 second. It shall provide two independent output contacts each rated 5 amperes continuous and 30 amperes inrush at (24, 36, 48, 125V dc or
120, 120/208, 120/240V ac). The Relay shall include a
memory function to recognize and initiate tripping on
intermittent ground faults. The Monitor Panel shall indicate relay operation and provide means for testing the
system with or without interruption of service and must
not permit the ground fault system to be inadvertently
left in an inactive or OFF state.
The ground sensor shall be installed for ground return or
zero sequence arrangement as required on the main service device. On feeder and branch devices, furnish zero
sequence sensor arrangements.
Double-ended switchboards or switchgear shall be furnished with a combination of ground return and neutral
mounted sensors for coordinated tripping of tie and main
device. Interlocking of the relays for selective tripping of
the tie and main breaker shall be accomplished without additional components other than the Ground Break relays.

BI006008

Time Current Curves


,toO

.,. t I

toO
lOG

'10
10

7 I

MULTIPLES OF PICKUP SETTING


H .. l..... 1
! ! ! !I!:::'1'
.

!'I

:It

_/

..

.OO

...

I
I

I I

I, I,

"

..,

'10

to
I

to

I,

I
I

..

I i

~ I

1.0 Sec.

0.5 Sec.

I, I
,

I
I

.,

0.31 Ser

"

~
,-,

..."
...

........

-;,. ~

.OJ

..,.,

.",~'

~-;

.OJ

0.1 Sec. ,

.. " .

I I

~"

."

I I

I I

J I

"'

." ."", ........ "

,'>-

...,~

,,
,
I

(0.03 Sec.)

,
I

I I

I
.,.1"

Inst.

" "" ..

II
,

.",

0.2, Sy

~I

.~

I
.~

J.

'10

"

10

44

51 at """:

000

GROUND FAULT CURRENT


IN MULTIPLES OF PICKUP SEniNG

GENERAl$ElECTRIC

GROUND BREAK"'SYSTEM

Relay Rang .. (Amp....)


Time Delay Range:
IMt. fO.OJ Sed to '.0 SeC'.

System Voltage Rating


600 ".o.c.
Frequency Rating

50

10

60

H.rt;r

Ground Fault Pickup Settings


and DeJay TIme-Current Curves
fCwrwes

apply fta"" -20C to +55C ombi.nr)

GENERAL ELECTRIC CO., CIRCUIT PROTECTIVE DEVICES

GES-6135
Adjurtmenr.

Type TGSR

51060.... and 100 to 1200

Pick-vp Unit: ConrinwouJy oct,vtfobl..


Time Oeloy: Continuov.Jy oGf'I,tobJ..

Pick-up (",rtn' dOlt, not ..c....d 1200A at ony


W"inV

DEPT.. PLAINVillE, CONN.

~...

I
,
....

.,

... .s

I
I,

0.7 Sec.

.3

"

,.

.
."
70

I I

i= ,

...

I oo

'00

"

I
,

..

I I

...

:Eo

....00'00

II

,I

I I

w ,

, I,
,

,
I

ou

I
I

,oo

en
C

....00'00

..
.3

.2

""
"
"

..

OJ

"

r1\
'-

BI006008

The ( ircuit Diagrams included in this manual are for illustration of typical applicatio s and are not intended as constructional information. Although reasonable
care ras been taken in their preparation to assure their technical correctness, no
responsibility is assumed by the General Electric Company for any consequences
of their use.
The evices and arrangements disclosed herein may be covered by patents of
Gene al Electric Company or others. Neither the disclosure of any information
herei ~ nor the sale of devices by Genera! Electric Company conveys any license
unde patent claims covering combinations of devices with other devices or
elem nts.
In thE absence of an express written agreement to the contrary, General Electric
Com any assumes no liability for patent infringement arising out of any use of the
devic es with other devices or elements by any purchaser of devices or others.

BI006008

molded case circuit breakers


Q-Line Molded Case CircuIT Breakers
THQE Circuit Breakers and Terminations
Application and Selection Molded Case Circuit Breakers
VersaTrip~ for Molded Case CircuIT Breakers
Mag Break~ Motor Circuit Protectors
Tri-Break Integrally Fused CirCUIT Breakers
Mine Duty CircuIT Breakers
Testing and Maintenance of Molded Case CircuIT Breakers

GEA-8481
GEA-9755
GET-2779
GET-6202
GEA-7498
GEA-7477
GET-6207
GET-2963

~
\._j

insulated case circuit breakers


Power-Break Insulated Case Circuit Breakers. Product Information
Power-Break' Insulated Case CircuIT Breakers. Technical Information
VersaTrip~ for Insulated Case Circuit Breakers

GEA9752
GET9732
GET-6202

low voltage power circuit breakers

".'.-

Application and Selection for Type AK Low Voitage Power Circuit Breakers
Power Sensor~ Test Set
Power Sensor Testing Instructions
SST ECS Test Set
Type AK Breaker Installation and Operation Instructions

GEA-8733
GEK-7301
GEK7309
GEK-64454
GEK-7302

Maintenance Manuals
AK-25
AK-SO. -75. -100
AKR-30. -SO

GEI-50299
GEK7303
GEK-7310

Renewal Ports Bulletins


Renewal Ports Price Bulletin
AK-25
AK-50
AK-75
AK-100
AKR-30. -50

GEp1675
GEF-4149
GEF-4150
GEF-4395
GEF-4396
GEF-4527

:)

ground fault protective products


CB3 Ground Fault CirCUIT Breakers
GTR"" Ground Trip Receptacles
Ground-Break@ Systems

r---::-'

GEA9739
GEA-9746
GET2964

safety switches
Spec-Setter"" Safety Switches
Mill Duty Satety Switches
Safety Switch Renewal Ports

GEA-6756
GEA-9747
GEF-4452

disconnect switches
Fusible Disconnects. Operating Handles. and Accessories
Type HPC High Pressure Contact Switches

GET-2954
GET-6205

panelboard components
Fusible Panelboard UnITs

GEA-7490

circuit breaker load centers


PowerMark +~Circuit Breaker Load Centers-thru 600 amp
PowerMark +<!'Riser Panels. Parallel Type
PowerMark +~ Riser Panels. Series Type
Lightning Protector
Meter Mod II and Mini Mod II Modular Metering
Load Center Renewal Ports

GEA-7484
GEA-7494
GIZ236217
GEA-9756
GEA9757
GEF-4453

For further information. contact your local General Electric Sales Office.
ar wrITe Marketing Communications.
Circuit Protective Devices Deportment. 41 VVoodford Ave.. Plainville. CT 06062

,.;.r'\
'..

GENERAL. ELECTRIC
Printed in U.S..!

BI006008

BI006008

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