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07-21-95
03-27-9S
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5A-5P
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8A-8G
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TITLE
TABLE OF CONTENTS
KEY INTERLOCK SYSTE M
LE GE NO
ONE-LINE DIAGRAM
HI-VOL T
MASTER CONTROL
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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:
[5 K
_
MRRION.ELSH.212781-4.DR
COilE NO.
OA
BI006008
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CO
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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
18
5M
19
5N
15
16
INCOMING POWER
a
c
16
17
18
19
20
21
22
23
24
22
7A
25
78
7C
26
7D
27
7E
28
29
7F
7G
MAGNETICS
23
24
25
26
27
28
29
30
30
31
31
32
33
34
32
8A
88
35
8C
36
8D
37
8E
38
8F
39
33
34
36
38
.....
40
41
42
43
9A
42
43
44
98
45
9C
46
9D
47
9E
48
49
9F
9G
MAGNETICS
Z""
o.
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>~
Cia
zg
44
~~
46
47
48
49
50
51
51
52
52
53
53
NOTE:
54
ID
~ ~~~lrgR~'hM~m~BL
rn
lID
[] OPERATOR'S CAB
[ID HOIST-PROPEL TRANSFER PANEL
RESISTOR ASSEM8LY
lID
LOWER FRAME
54
55
56
57
58
59
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
CONT. ON 5H.
OC
MARION.ELSH.212781-4.GE-OB
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45
50
Ocr
39
41
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37
MAGNETICS
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35
40
58
59
60
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15
DIG/PROPEL TRANSFER
21
57
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14
20
55
56
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5J
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SLOW SPEED CONTACT DR
SLOW SPEED SHORTING CONTACTOR
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AUX. RELAY TO S
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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
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30
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07-21-95
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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
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.
AND STORAGE
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
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.
BI006008
Remove y shipping braces and replace the endshield bolts ( 4), Fig. 2.
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.
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
SYNCHRONOUS
SPEED
RPM
OVERSPEED,
PERCENT OF
SYNCHRONOUS
SPEED
20
25
DIRECT COUPLING
BI006008
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.
BI006008
KV
OPERATION
STEPS
INITIAL START
1. After inspecting the motor carefully, make the
initial start by following the regular sequence of
starting operations in the control instructions.
BI006008
SUBSEQUENT STARTS
For subsequent starts, follow the sequence of
operations given in the control instructions.
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.
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
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.
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.
CLEANING INSULATION
GENERAL
1. General c eanliness
2. Insulation and windings
3. Lubricati n and bearings
BI006008
This method is very effective in cleaning windings when used wlth a low-pressure steam jenny
(maximum steam flow 30 psi and 90 C).
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.
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
REGREASING
TABLE 1
REGREASING INTERVALS
ANTI-FRICTIO
BEARING MAINTENANCE
Type of
Service
Typical Example
Standard
One- or Two-shift
Operation
Severe
Dirty Location
High Ambient Temperature
Relubrication
Interval
1 Year
2 Months
GREASE RECO
CLEANING
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
oF
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
Bearing Disassembly
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
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.
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.
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. )
or
Insulation failure
Motor
What to Check
Misalignment
Uneven air-gap alignment
Settling of foundation
Parts rubbing the rotating
element
Sprung shafting
Balance
Wrong connections
Open circuits
Starting voltage
Excessive line drop
Excessive load
Mechanical obstruction
11
BI006008
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
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
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BI006008
BI006008
MOTOR INSTRUCTIONS
GEH-2301 K
Supersedes GEH-2301.
BI006008
All Enclosures
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.
Avoid conta
that shaft k
energized.
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
INSTALLATION
LOCATION
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.
5/8
3/4
37
90
180
320
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
TABLE I
V-BEL T SHEAVE PITCH DIAMETERS
Horsepower
3600
7 1/2-10
15
20-25
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.
?-.\
15
20
25-30
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.
BI006008
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
MAINTENANCE
INSPECTION
Relubrication with the shaft stationary is recommended for safety and best purging of oldgrease.
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
1 1/2-7 1/2
10-40
50-150
200-350
4 yr
11/2 yr
9 mo
6 mo
Very
Severe
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
fan
the
the
the
MOTOR WINDINGS
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
.-
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
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.
BI006008
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
5
5
5
5
6
6
7
7
7
8
8
8
8
8
8
8
8
9
9
9
9
9
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13
15
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16
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21
21
SUBJECT
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
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
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
PAGE
5
10
10
11
12
36
39
41
41
44
45
48
14
35
47
BI006008
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
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
BI006008
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
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
Type MDV -
Type MDP -
Type MDT -
Horiz ntallyMounted,TotallyEnclosed,
Slow Seed, Waterproof Features.
SuffixAE
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.
BI006008
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.
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
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
4.
10.
16.
17B.
20.
21.
31.
36.
39B.
150.
Insulation
INSPECTION B
ORE STARTING
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.)
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
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.
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
I 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
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)
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
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.
11
BI006008
TABLE 5
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
Newton-Metres
5-7
7-9
13-17
24-30
60-75
7-9
9-12
18-23
33-41
80-100
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.
BI006008
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.
BI006008
COMPONENT
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.
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,.
'"
)~
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
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.)
Check for any unusual noise, vibration, or change from previous observations.
14
BI006008
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
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.
15
BI006008
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.
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.
BI006008
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
17
BI006008
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
18
....
<.0
;:,
en
ell
N
00
;;g
'C
ell
CQ
!!
SHAn.ofl
~__
SPACER RIN"
_ __
1__
..
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AIR DUTLn
-I
-<j,\
I:
~.'.J _
:
i
-=-
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1: __
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'j__
,-,
pc
.>....
..
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-- - -
ORE
-A'M""" C'CKU
SPI" Bf'GBR
II
f (I
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- ~r "~:;~, I::,"'
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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. \ . " .
~ ~.>//;.~>~>
~:.>:J-:",._-------~----\ ~(CRE[NC.OV[R~
if'
""''''''1 --.
(;:--,
> -
I,
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-r--
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-
L-
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:&1
ci-\:~ __ ---_---'~AIN
'-[/__ -COMM
JC'-. l.JVI
"r
/;>-.",
PocE
r~
~j 1J'4l;~]=---~--GOMM COIL
BLOWER
1-1 ~_
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Cil
BI006008
BI006008
Fig. 5 Type MD808 With Top Half Opened For Removal of Armature
20
BI006008
(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.
B)
C)
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
22
BI006008
14
Ref.
No.
Description
Ref.
No.
14
Description
Fig. 7
DEl ILAREA B
SPLIT
ONNECTION
DETAIL AREA A
SPLIT CONNECTION
@32
23
Fig. 7 Drive End Brazed Pole Face Connections
BI006008
Description
Description
DETAIL AREA C
PF CONNECTION SPACER
DETAIL AREA D
PF CONNECTION SPACER
24
Fig. 7A Commutator End Brazed Pole Face Connections
BI006008
10
. . .'-1---13
"==':.:.-=,~==2~
4
5
9
14
11
12
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.
25
26
BI006008
BI006008
(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.
Replacement Be
The bearings of MD8
on the shaft with a hea
bearings with greater
normal (C3 or C4) m
gs
Armored Motors are mounted
interference fit. For this reason,
radial internal clearance than
st be used.
27
00
'-1
-L:':-
~_-.J
PIPE
......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
///
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
PRESS HERE
~
c
(l)
"ti
<
,Cri
Q..
(ti
)::.
$-.
~
~
G)
BI006008
BI006008
COMMUTATOR
END
45
4
Removal of Armature
910
PINION
END
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
DISASSEMBLY -
TICAL MOTOR
29
~
I
/32
39A
36
117
904
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
10
(l)
o
~
:<
"ti
Ql
)::.
~
!-
G)
BI006008
BI006008
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
collar. Pull the collar and inner race from the shaft
together.
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.
BI006008
32
Lift the top half of the frame in place and start, but
do not tighten the frame split bolts.
BI006008
(10) Follow the gene al instructions in the Final Assembly of Horizon Motor section of this Instruction
Book.
WARNING:
chinery can ca
Brushes should
while the machi
(1) Make sure that th pigtail screw is tight, and that the
pigtail does noti terfere with free movement of the
brush.
(2)
(3) Check that the b shes are free in the holders with
the springs posi oned correctly and functioning
properly.
COMMUTATION ADJUSTMENT
33
BI006008
COMMUTATOR MAINTENANCE
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
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
.,.,
.~
H.~
uu
.~.~
UUH
"~.,
,~"
~.
~.~
....
HH
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"
BI006008
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
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
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
on the commutator surface. The number of these markings equals half or oJI the number of poles on the motor.
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
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
M/GCO
Printed In
U.S.A.
BI006008
BI006008
(3)
commutation.
(4) Run at a high en ugh load to allow filming process
to take place (a leastl/2t03/4fullload).
(5) Wipe the comm tator occasionally during the filming process with clean canvas to remove high-resistance or high-fri tion areas.
Commutator Cle
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.
BI006008
38
BI006008
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
~~'~~H~/8"
~~'\'\.'\.'\.~
r
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
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).
ASSEMBLIES
A red insulating coati:lg is applied over the stator end
turns, coils, poles, and 'nternal surfaces of compensated
39
BI006008
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
BI006008
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
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
(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
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.
42
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
WARNING: ~ol'lfen,ts
mabIe. Adequ
vided to minirni
hazards caused b
purposes.
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.
43
BI006008
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
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
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
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
BI006008
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
BI006008
TROUBLESHOOTING GUIDE
Type of Trou pie
or MachinE
Componen
BEARINGS
High Temperatur
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
BRUSHES
Burned Brushes
Brush Breakage,
Chatter or Sque~l
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
47
BI006008
INSULATION
Low Insulation
Resistance
Moisture, dirt or contaminants (dirt, oil, or oil vapors, metal particles, atmospheric
contamination, dust).
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
kilopascals
6.895
degrees F
degrees C
deg. C = 5/9
(deg. F-32)
25.4
16.387
BI006008
49
BI006008
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
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
16~
17 B --i)
0-17 A
L..-.--;-.---J
30se
''('1lj
(~ ~
~J
.
52
..
~~3()SD
305A
Figure 17
BI006008
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
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
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
r '1.
j
153
16~
17B4~c-17A
...,- ----r- .---!
310
""
17B----c@-'- 'e::~17A
~.,.~
56
Figure 19
16
BI006008
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
MDP820
~
310
9A
39B
40
17A
.'
I"
~ \,,_.
'~
I
~\j)l!
(
\"
.
16 \"'"
153
D
,
.0
'\
,,' "\))\~
34
I
42
17B
32A
\
58
Figure 20
BI006008
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
MDP822 MOTORS
........
_.~
15
10"
?~
60
--{'-
Figure 21
BI006008
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
U"153
e-16
17B'@~O
'-.
.--' -17A
42-:~-
34--~.-40
-:;.:,
1
"1,
122
"
1-
'2
.....~
~-39A
'36
@'31
~~6
310
~._.~
.~'''''/~
\17A
\I
~
/
202 A
62
"
\
XlSA
Figure 22
BI006008
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
MDP824 MOTORS
.. ~.... '.
5A
64
Figure 23
BI006008
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
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
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
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.
Commutator
12.
34.
38.
Shaft Cover
32.
29.
30.
Conduit Box
26.
Brushholder Spring
Carbon Brush
23.
Brushholder
24.
22.
Brushholder Yoke
Brushholder Stud
20.
r:?
18.
21.
Bearing Cap
Ball Bearing
Armature Fan
Bearing Bracket
17.
14.
15.
13.
...
7.
5.
11.
Armature Coil
4.
8.
Armature
3.
...
Description
1.
Ref.
N2..:,
35
~
,
,~
"
~
~
'>
0\
'I
!I!
"
"
..................... *UDllf
II
\_1I
0--=:1~
.. /
'"' ~ [:9l"
(}~-"
Fig. 11
lfl
BI006008
BI006008
BI006008
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
DIRECT CURRENT
MOTORS AND GENERATORS
FRAMES CD180AT - CD500AT
INTRODUCTION
Protection from wetness and temperature extremes includes moisture from the surrounding atmosphere con-
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
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
Storage
1.
2.
CAUTION:
BI006008
TABLE 1
APPROXIMATE NET WEIGHTS*
FRAME
SIZE
~ay cause
rust.
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
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
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.
3.
ARMATURE
WEIGHT
kgs.
Ibs.
extensions.
BI006008
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.
Location/Ventilation
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.
BI006008
Mounting
Coupled Drive
coupling.
V-Belt Drives
Alignment
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
BI006008
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
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
Fig.2A
BI006008
10,000.
STANDARD SIZE
ROLLER BEARING
AND STANDARD
SHAFT
FRAME
CD500AT
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
Fig.2B
BI006008
TABLE 2
1.0
1.2
1.5
1.8
2.0
126,000 x HP x ~ lbs
DxRPM
two of operation.
life results, if the belts and sheaves are kept clean and the
Where:
HP
RPM
power occurs.
The curves in Fig. 2 can be used to determine the anticipated LIO life, which is the life in hours that 90% of
Thrust Loads
speed.
the radial load, "W", on the shaft and bearing is there and
minus.
belts and chain drives, the radial load, "W", does vary
somewhat with motor load, and so the motor load duty
10
BI006008
TABLE 3
THRUST CAPACITY IN POUNDS
VERTICAL MOUNTING
------------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
Grouting
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
Flexible Coupling
Before grouting the base, the alignment should be checked
as follows:
1.
Slide the sleeve from the coupling so that the hub faces
are exposed.
2.
single-bearing genera rsconnected with rigid (solid) couplings. With each kin of coupling and each kind of base
11
BI006008
4.
5.
6.
7.
3.
6.
7.
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.
2.
5.
1.
4.
12
BI006008
These inspection pr
DM&G.
or repair.
Bearings and
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.
When DC motors are operated from rectified power supplies, the pulsating v tage and current wave forms effect
fier shall be 230 volts for 240volt DC motor ratings, and 460
volts for 500 or 550 volt DC motor ratings.
13
BI006008
Connections
nection diagram shipped with the machine. Bolted connections must be tight. When fixed termination (terminal
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
ratings.
TABLE 5
LEAD MARKERS
FUNCTION
Field (shunt)
Field (series)
Bbwer Motors,
Type AN tachometer
generator
Tachometer generator,
direct current, to terminal
board
BH 1, BH2, BH3,
BH4, etc.
Thermostat
Resistance Temperature
Detector (RTD)
Armature
Where:
WINDING
14
BI006008
Protective
De~ices
TABLE 6
125 VAC
250 VAC
600 VAC
30VDC
5 AMPS
2.5 AMPS
1 AMP
5AMPS
* Inductive 3 AMPS
1.5AMPS
O.5AMP
1.5AMPS
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.
Thermostats
Space Heater
When furnished, refer to the Print Certification for Electrical Rating or the motor nameplate.
15
BI006008
Ventilation System
rotation.)
Maintenance
HOUSING
Inspection
IMPELLER
BLADES
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
Mounting
When bases are removed on enclosed motors, the enclo-
plug.
16
BI006008
TABLE 7
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
.5 -7.5
Very
Severe
Lubrication Interval
Horizontal Vertical
7 yrs.
3 yrs.
9 mos.
1.5 yrs.
6 mos.
yoke bolts.
Motor windings
TABLE 8
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
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
TABLE 9
COMMUTATING AND MAIN POLE
BOLT TORQUE
FRAME
*
**
CD180AT
CD210AT
CD250AT
CD280AT
CD320AT
CD360AT/CD400AT
CD360AT/CD400AT
CD500AT
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
Bearings
16-20
16-20
16-20
36-45
36-45
23-28
16-20
36-45
TABLE 10
VIBRATION VALUES
Accessory Mounting
Provisions for mounting accessories on the commutator
RPM
MAXIMUM AMPLITUDE
IN INCHES
(PEAK TO PEAK)
.001
.0015
.002
.0025
used.
18
BI006008
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
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.
CD360AT
CD180AT320AT
l ~~~:D~
0.625'-11 tap
1.56' Deep
60 Deg. center
1.00' Dia.
-+-----+
(2)0.375'-16 tap
1.00 Deep
CD500AT
CD400AT
Standard commutator-end bracket
and accessory shaft extension.
Fig.4A
19
BI006008
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.
Fig.4B
Fig.4C
KEYWAY
IIA"
Accessory
mounting face
(2)
WIDTH
DEPTH
.6255
.6250
.1875
.0937
.7505
.7500
.1875
.0937
.5005
.5000
OMIT
.3130
.3125
OMIT
Fig.4D
Fig.4B-D
20
BI006008
GEH-3967~
TABLE 11
RELUBRICATION
INTERVAL IN
HOURS OF
OPERATION
MAINTENANCE
FRAME
SIZE
AVERAGE
RPM
BALL
BEARING
ROLLER
BEARING
CD250AT,
CD280AT &
CD320AT
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
auxiliary devices.
21
BI006008
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.
Replacement of Bearings
Brushes
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
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
Aeroshell No.7
HIGH TEMPERATURE
-20F to 350F
-28C to 176C
D6A2C13
22
BI006008
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.
23
BI006008
Wear Marker
Fig. 5
Frame CD180AT
Fig. 7
Frames CD360AT-500AT
Fig. 6
Frames CD210AT-320AT
Fig. 5, 6, 7
Brushholder Assemblies
1.
2.
3.
BRUSH
Remove brush.
Brush Installation:
1.
2.
3.
.080
.070
~:t;;;;;;=-=t:.:;;;;~===l
.-----------
Connect pigtail
COMMUTATOR
24
BI006008
Brush Seating
Commutator
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.
TABLE 15
CAUTION: Avoi inhaling carbon and seater
dust. Recommen using a dust mask during
sanding, seating d blowing, or vacuuming.
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-
BI006008
Mechanical
lubricated separately.
Insulation
.005" to .040"
2.
.000" to .015"
Waterproof Machines
1.
Contamination
2.
Mechanical factors
3.
High temperatures
most applications.
suggested maximum loads for various operating conditions. Operation within these maximum loads will limit the
26
BI006008
Testing Metho4 s
TABLE 16
Visual Inspection
EFFECT OF TEMPERATURE
ON INSULATION RESISTANCE
WINDING
TEMPERATURE
DEGREE C
80
70
60
50
40
30
20
10
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
2.
3.
Temperature.
4.
5.
Moisture.
10.00
5.50
3.10
1.70
1.00
0.55
0.31
0.17
1.
MULTIPLYING FACTOR
TO OBTAIN INSULATION
RESISTANCE AT
40C (104F)
the original factory test of two times the rated voltage plus
1000 volts.
sulation resistance
incre~ses in
personnel.
27
BI006008
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.
WARNING: Safety glasses and/or other protective equipment should be used to prevent injury
to eyes and respiratory organs.
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.
28
GE Motors BI006008
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
M/GCO
Printed In U.S.A.
BI006008
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.
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.
30
BI006008
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.
31
BI006008
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
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
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
33
BI006008
Per Motor
I.
Brush
2.
Brush Spring
3.
Bearing C.E.
4.
Bearing D.E.
5.
Armature
6.
7.
Coil Main
8.
9.
Access Cover
10.
Brush Rigging
II.
Armature Fan
12.
13.
12
13
'"
Commutator End
Fig. 9
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
BI006008
GE Motors
Instruc ions
Armored
Type MO
alars
114 - MOV810
(Photo MG-5359)
GEH-4246C
(supplements GEH-32 8)
BI006008
SAFETY PRECAUTIONS
WARNING
Use proper care and procedures in handling, lifting,
installing, operating, and maintaining the equipment.
Safe maintenance p
ces with qualified personnel is
ore starting maintenance procedures,
t:
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.
BI006008
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
Introduction
Bolted Joints
TABLE 1
The special features incorporated into these motors involve
bolted joints, bearings. bearing assemblies. tan hubs, and
related parts.
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
Fig. 1 -
Lubrication of Bolts
(Photo MG5320-9)
4
BI006008
TABLE 2
BOLT TIGHTE NING TORQUE VALUES
ME ALLIe PARTS*
Thread
Size (Inches)
(UNC-2A)
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
9-12
18-23
33-40
80-100
160-200
280-350
BI006008
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.
Fig. 2 -
BI006008
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.
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
TABLE 4
BEARING HOUSING DIMENSIONS AND BEARING FITS
HOUSIN( BORE
(Factory T olerance)
mm
FRAME Inches
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
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.
Fig. 3 -
(Photo MG5358-1)
BI006008
GREASE
BEARING CAP
GREASE SEAL
Fig. 4A - Packing of Grease in
Commutator End Bearing Cap
Fig. 4 -
(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
11.
Motor Disassembly
1. Place motor in a horizontal position with the drive end
bearing bracket overhanging the workbench.
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.
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.
BI006008
Removal of F m
Removal of B ushholder
Assembly of ~ otor
Installing Field Coils ( \rmature Removed):
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.
BI006008
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
Frame
MDV804
MDV806
MDV808
MDV810
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
Motor Installation
Pinion Mounting
12
BI006008
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
BI006008
14
BI006008
BI006008
BI006008
SEMotors
comp~n~rie. PA 16531
3001
East Lake
Telex 703531
Telephone
(814) R~~~2217
8
General Electric
11-92 (5M) D
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.
FOUNDATION
APPLICATION
LOCATION
Single-unit Arresters
E~I"c
Co",
ny
lor
.,.s.e whICh ire 001 COyefeo' su1hcIftflity for 1h. purchJlwr', pUfpos..M, lhe mOl"e, shotJLd be f.t.
BI006008
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
CLEARANCE
(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
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
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 the General Electric Company.
BI006008
Direct-current Generators
GEI-99854J
CONTENTS
SUBJECT
PAGE
INTRODUCT ON
RECEIVING,
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
31
36
INSULATIONj
37
LUBRICATIO~
40
43
CABLE CON~ECTIONS
44
47
EXPLODED
46
1EWS
I
BI006008
INTRODUCTION
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.
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.
BI006008
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.
(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.
BI006008
INSTALLATION
(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.
BI006008
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.
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.
(1) Titeseal
BI006008
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.
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
TABLE II
115 VAC
230 VAC
120 VDC
(5) Observe brush condition, brush fit, and brush freedom in the brush box.
240 VDC
3.0 amp.
1.5 amps
2.5
.08 amps
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.
BI006008
(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
(21) Check the directi n of rotation ofthe m-g set and the
polarity of the 0 tput of each unit.
INSPECTIO
AFfER STARTING
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.
BI006008
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
1/2-13
5/8-11
1/4-20
1/2
5/16-18
9/16
3/8-16
3/4
15/16
1 1/8
3/4-10
1 3/16
7/8-9
1 1/2
1-8
1 11/16
1-1/8-7
1 7/8
1-1/4-7
2 1/4
1-1/2-5
7/16
TABLE IV
BOLT TIGHTENING TORQUE VALUES NONMETALLIC PARTS BOLTED TO METALLIC PARTS
DESCRIPTION OF
SPECIAL FEATURES
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
7/16
1/4-20
1/2
5/16-18
9/16
3/8-16
3/4
1/2-13
15/16
5/8-11
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
BI006008
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
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
128
55
57
12
9A
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
BI006008
Direct-current Generators
GEI-99854J
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
BI006008
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
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
BI006008
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
BI006008
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
BI006008
COMPONENT
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.
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
MECHANICAL
Air Filters
If supplied with excavator, keep in good working order. Replace when necessary.
Bolts
18
BI006008
COMPONENT
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
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
(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.
(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
(3) After the bearing has cooled, slide the cartridge over
the bearing. Assemble the snap ring, if one is required.
11 12 13 14 15
1
-~
6
5
4
24
29
13
21
23
20
22
BI006008
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.
(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.
(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.
(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.
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).
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
22
BI006008
(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)
(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.
(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.
Troubleshooting
(1) High vibration in
move the end co
indicate the runo
cate a maximum
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
Commutation Adjustment
24
GEA
BI006008
etching of trailing edge of commutator bar. Pattern is related to number of conductors per slot.
Streaking
Frequent v
faces can
conditions
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
1-85 (5MI
BI006008
BI006008
R MAINTENANCE
TABLE V
RECOMMENDED COMMUTATOR ACTION
SOME COMMUTATOR/
BRUSH CONDITIONS
POSSIBLE
ACTION
Fit Brushes
Threading
Grooving
Roughness
Brush Seater
Etching
BI006008
(4) Do not use a metal fitting on the end of the air hose
beyond any shut-off valve.
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
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.
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.
(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.
29
BI006008
HIGH PRESSURE
PUMP
HIGH PRESSURE
TUBING
ELBOW
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.
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
(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.
30
BI006008
HYDRAULICALLY REMOVABLE
INSULATED COUPLINGS
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.
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).
STEEL PLATE
HIGH PRESSURE
PUMP
HIGH PRESSURE
TUBING
SHAFT
W)"
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.
BI006008
/ ~ (e,,,,
""~~~2
M'>
(.8 MM)
III
,!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 -
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
'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
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 -
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
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
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
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
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
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
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
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
CHECKING ALIGNMENT
OFCOUPUNGS
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.
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
0
Right
Right
Top
Left
Bottom
0
Right
0
Top
0
Left
0
Left
0
Bottom
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
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
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
INSULATION
(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.)
(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.
37
BI006008
TABLE XI
POLE FACE COATING MATERIAL
TABLE XII
EFFECT OF TEMPERATURE
ON INSULATION RESISTANCE
Winding
Temperature
Degree C
80
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
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
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.
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.
Drying-out can be en
ground (correct to 40
as described under I
do not reach a prope
complete reconditio
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
BI006008
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.
BI006008
TABLE XIV
PEDESTAL OIL REQUIREMENTS
6Y2
6Y2
IN GALLONS
6.3
6Y2
3.9
5Y2 X 5Y2
418 X 418
3.8
4.3
(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)
41
BI006008
TABLE XV
OIL SPECIFICATION CHART
For Normal Excavator
Service and for Cold
Climate Service Light Turbine Oil
D6B6A
D6B6B
GE Spec.
*Ambient Temp.
Range For
-18C to 40C
Safe Operation (OF to 104F)
Flash Point, Min.
350F
330F
Viscosity, Saybolt
Seconds
140-170 at 100F
Pour Point, Max.
OC to 50C
(32F to 122F)
270-325 at 100F
20F
25F
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
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
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
43
BI006008
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.
AMP TERMINAL
COIL LEAD
OR BUS BAR
r---,~~~~~~== REGULAR
PLAIN WASHER
BELLEVILLE WASHERS (2)
AMP TERMINAL
REGULAR NUT
FIG. 12
"AMP" TERMINAL
U-J-~:::::::::::~=S
COIL LEAD
OR BUS BAR
~~~~~~fl~=-REGULAR
PLAIN WASHER
FIG. 13
2) Cables Shall Be Assembled To Brushholder Studs In The Following Manner:
REGULAR NUT
BELLEVILLE WASHERS (2)
BRUSH
HOLDER STUD
L--~~~I~~~::::
"AMP"
TERMINAL
STD HEX HEAD BOLT
FIG. 14
44
BI006008
90
80A
tN-~--+--84A
88
~~_-++--t-85
1....~~_!::Lr-ft
r---J-+----I--~85A
'----+-J-+jl--- 858
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
00
PF CONNECTION SPACER
@
PF CONNECTION SPACER
46
BI006008
REF.
NO.
DESCRIPTI N
REF.
NO.
DESCRIPTION
BI006008
BI006008
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
47
BI006008
DETAIL AREA B
SPLIT CONNECTION
DETAIL AREA A
SPLIT CONNECTION
39 40 45@@
BI006008
REF.
NO.
REF.
NO.
DESCRIPTI N
DESCRIPTION
49
BI006008
SA
-75A
I
I
\
\
\
\
88
,~~
88A/
81A
~O
7O
'
50
10
-75C
BI006008
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
BI006008
,t
/, ,-----------/
,
/-75C
151,
,I
I
I
I
I
~
o
If,
I
~.'
BI006008
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
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
~..
,
"- "
'.
. ;,
, \~:\
10
12
Po
<
/
75A
....
h)
3050
"
,.
BI006008
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
10
-56
75C
/~
I'
75A
31
T
53
BI006008
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
()
()
~j
r;G.~
(.~.
\78
= \
50
!D 7
57C
BI006008
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
'r-------~,.
DRIVE END
FRONT END
TYPICAL MAGNET FRAME
CD580ACD680A
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
61
BI006008
NOTES:
BI006008
BI006008
GEMotors
-----------------------
BI006008
18
BI006008
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
. G N _ - TERMINAL
1'::>---- BUSHINGS
i-
MAXIMUM OR
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
BI006008
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.
CABLE
TERMINATOR
FiniNG
Figure 40.
6"-
to po
CABLE INNER
INSULATION
END SEAL
COPPER SHIELDING
-'--".j:'''Pl''---dSTRESS CONE
BRAID-GROUNDED
'
TO STRUCTURE OR ==~~8:t:b
ARMOR.
2"
~~-t
FILL WITH
SEALING COMPOUND'-lI1VA~=H"'N
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 .
CABLE ARMOR
21
BI006008
CABLE INSULATION
IRRASIL'~
3. Heavily-insulated shield
edge protects high stress
area of stress cone.
4. High conductivity semi-
r
5"
-~
'-Z:J
P-I
/~\~
~t
I ". ~O
1.\ .
__ SEMI-
,\'
C ONDUCTOR
\\
I
'2
BI006008
16
BI006008
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
Co
-g
en
;::;:
I:
Co
:::J
(')
I:
to'
5-5/B
26 11 WIDE
5t
:::t
CiJ
C'll
:b
s'
s'
!
,...
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.
BI006008
TOP
VIEW
NOTE
DEPRESSOR
,.
SIDE
VIEW
oa:
u.
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.
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.
31
BI006008
32
BI006008
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
~usting
0
25
BI006008
SEALER
~OF COUPLING
~~/~"
1/2"
13"
;==
0
I
I
1/2" x 13"
[...-1"lg.(5)
~ 3M SEALER
o~
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~
-
FIG. B
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.
26
BI006008
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.
27
BI006008
Figure 53. Interlock defeater bolt - rear view from inside of door.
28
BI006008
Warning: All power must be removed from the main bus before
attempting to adjust the isolating switch mechanism.
Inspection, Maint
Vacuum Contacto
Isolating Mechanis
29
BI006008
---,
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
I
II I
I
II I
~:
r-1j
+-1I
NOTE
III
t-=J-
:1
.!l I
I
L::
LOOKTHROUGH
CUTOUT
~==:I
LATCH ASSEMBLY
FRONT VIEW
CONTROL POWER
INTERLOCK
NOTE
,,
0.60"]
+ '-------'
REF
:0
I
I
I
I
PUSHER ROD
10
f-
I Z
I 0
II:
1 u..
Figure 57. Checking for proper operation of pusher and control power interlock (CPI).
30
'1
BI006008
Control Connections
23
BI006008
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.
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.
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.
BI006008
Ampere Control
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.
orizontal compartment
bolts shown in Figure 30.
14
BI006008
Placement of Enclosure
General
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.
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:
Warning: Remove all power from the equipment before proceeding with disassembly.
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
12
BI006008
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.
SINGLE BARREL
CAT. NO.
55A212942P "A"
ICAUTIONl
CAT. NO.
218A4293P "A"
DOUBLE BARREL
CAT. NO.
55A212942P "A"
CAT. NO.
218A4293P "A"
ICAUTIONI~
Y
Y
3. RETIGHTEN BOTTOM BOLT (B) TO 23-31 FT/LBS WHILE ENSURING THAT FUSE BARREL DOES NOT TURN.
11
BI006008
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
BI006008
BI006008
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..
Figure 12. View of the disc nnect switch in the OPEN position.
Barriers are emoved for clarity.
BI006008
Figure 10. Anti single-phase contact block - wiring removed for clarity.
BI006008
PANEL
DATA
NAMEPLATE
BI006008
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
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.
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
BI006008
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
J N P Q -
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
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
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
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.
BI006008
Description
Ratings
8
8
Mechanical Interlocking
Auxiliary Enclosures
Dimensions
10
10
Power Fuses
Power Fuse Conversion Instructions
11
11
11
Installation
13
General
Receiving
Handling
Placement of Enclosure
Disassembly
13
13
13
13
13
13
14
14
19
20
20
23
24
24
24
Operation
27
General
27
Test-power Circuit
Preparation of Controller for Operation
27
27
Normal Operation
27
27
.4
29
Vacuum Contactor
29
29
31
31
Test Procedure
31
32
BI006008
CR194 Vacuum
Limitamp Control
BI006008
SECTION 2 - Description
Principle of Operation
Construction
General
These instructions co
Contactors. These c
ment used in starting
lOOO-Volts to a maxi
feeders, and other hi
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
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
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
SECTION 4 - Maintenance
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.
CR193B
CR193C
55A212185GI
55A212185GI
55B532539PI
55B532548PI
55B532540PI
55B532547PI
55A212118G2
55A212118G2
55A212152PI
55A212152PI
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
BI006008
CR193 Vacuum
GE . , , , Contactors
Lim/tamp
BI006008
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
5
6
6
7
9
10
10
11
General
11
11
BI006008
CR_'_93_Vi_ac_u_u_m_L_im_'_"ta_m....:.p_'_C_o_n_ta_c_to_TS
_ _ _ _ _ _I
6. Position the new oil into the contactor and start the
three (3) mounting crews. Do not fully tighten these
screws at this time.
BI006008
BI006008
DRIVER STEM
ADJUST NUTS
UNTIL DRIVER STEM
IS AT THIS LEVEL
BEARING
SUPPORT
BI006008
BI006008
BI006008
SECTION 8
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.
10
~
1
BI006008
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
CONTACTOR
"'OYING
ARIolATU~[
:~-------------------------I----
i
:
t
I
J.--~] ~~;t;_:*~J~~~~~
TER"NAL~ l
BLOCK
I
I
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.
BI006008
Book #2
Vendor Publications
Control
-
Table of Contents -
DC Co tactorlC2800Y108 .. ,
GEH-751E
GEH-1496F
, . . . . .. GEH-3057B
GEH-3095
,.. GEH-5305A
GEH-5600
,.. GEF-8016A
2243-I.M61
BI006008
INSTRUCTIONS
BI006008
GEH-3095
Fig. 7.
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-
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
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
ADJUS
ENT
INTERLOCKS
INCH
HANDLE INTERLOCK
ARM
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
BI006008
BI006008
GEH-3095
--e==:::J::;.:.-...
SHA
OPERATING ARM
SPRING
SPACER
TERMINAL
SCREW ---O"l---~
MOVABLE
CONTACT
I
STATIONARY
CONTACT
PLUNGER
N.O. TIP GAP
Fig. 3.
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).
Fig. 5.
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
Fig. 6.
INTERLOCK
INTERLOCK
PLUNGER
~=:::::2:::t--r N.O. TIP WIPE
N.C. TIP GAP---I--+---,
JAM_.rT'"''M
NUT
Fig. 4.
BI006008
BI006008
GEH-3095
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.
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
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.
Fig. 12.
BI006008
BI006008
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
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.
DESCRIPTION
A maximum of eight electrical interlock circuits can be supplied on any form of contactor.
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
ARC
CHUTE
MAIN
STATIONARY
CONTACT
ARMATURE
ARCING
HORN
ARMATURE
PIVOT
BASE PAD
COIL
MOUNTING
BOLTS
Fig. 1.
BASE
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
Size
D-c
1500
2500
IC2800
600 VOLTS
Bus
Connectionst
A-c 60 A
Hertz
1350
Bus
Connectionst
Two 1/4-in. X 4-in.
Copper Bus
Three 1/4-in. X 6-in.
Copper Bus
2500
+;=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
Fig. 2.
-1';;-
7"
'"
Five
"'.diamin
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.
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".
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.
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.
BI006008
GEH-751E, IC2800-1178, -1l80, Y107, Y108, Y127, and Y128 D",c Contactors
TABLE 4
Gap
Contactor
Main Tip
Arc Tip
Touching
(Inches)
3/4
Minimum
Less
Blowout
Assembly
With
Blowout
Assembly
Main Tip
(Inches)
1-1/8
Minimum
3/4
Minimum
3/16
Minimum
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
c)
0.06
(REF. ONLY)
Fig. 12A.
10
~
oo~
M'I~
C0
Fig. 128.
2. With
solenoid in
the needle
O. OlD-inch
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.
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
1.2
OVERCURRENT PROTECTION
GENERAL
'Non-inductive d
"Capable of inte
volts, 30 amper
12 amperes at 6
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
SPACER
A - - -.... '0-----,,1
- - - SPRING SEAT
KEY - - - - "
SPRING
SPACER
TERMINAL
TIP
GAP~=t=+==:l
r---rE~~~B1~~-MOVABLE
L
CONTACT
-~T~;iJ~J
HOUSING
STATIONARY
CONTACT
~:::t-=~-->."c-- OPERATING
TIP GAP
ARM
ASSEMBLE TIP
SUPPORT FLATLY
AGAINST HOUSING
BY RUNNING SCREW
TO SEAT POSITION
BEFORE MAKING ANy
CONNECTIONS
11
BI006008
GEH-751E, IC2800-ll78, -ll80, Y107, Y108, Y127, and Y128 D...c Contactors
INTERLOCK
TRIPPING ARM
POLE
ASSEMBLY
SCREWS (M)
ARMATURE PIVOT
ADJUSTING KNOB
LOCK SCREW
ADJUSTING
KNOB
Fig. 76.
"
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
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
13
BI006008
o..c Contactors
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
TABLE 5
NEMA
Size
For Use On
Contactor
IC2800-
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.
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
:..
INSTRUCTIONS
GEH1496
BI006008
IC2800 DC GENERAL-PURPOSE
CONTACTORS
1C2800-1607 TO 1609 INCLUSIVE
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
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
"
()
"-.-
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
SA.
COILS
:~
BI006008
7"
,"
-TO'6
2
fi
ff
tlRCING
HORN
3"
is
TABLE II
(Power Contacts)
APPROX. DIMENSIONS IN INCHES (See Fig. 5)
DEVICE
1607
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
OPERATING COIL
ARMATURE
C)
ARMATURE SPRING
J \
BI006008
CONTACT FORCE
(See Table II and Fig. 5)
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 .
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
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
BI006008
TABLE IV
(Contact Tip Gap and Wipe)
MAXIINTERLOCK
Per Figs.10
14 and 15
CONTACTS
MINI-
MUM
MUM
INCHES
INCHES
1/8
5/64
3/32
3/64
5/64
3/64
7/64
5/64
3/32
3/64
(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
REPLACING CONTACTS
BI006008
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
SPRING
SPACER
I-r-'''<::~'':''''''f- STATIONARY
CONiACi
OPERAT! NG
PLUN(iR
.. i
BI006008
MECHANICAL INTERLOCKS
RENEWAL PARTS
GENERAL _
Pl12-801
ELECTRIC
BI006008
GEH-1941C
GE Drive Systems
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
......
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
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.
Y100
Y101
Y105
Y102
Y106
Y103
Y104
Y120
Y121
Y25
Y22
Y126
Y123
Y124
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
Arc chute
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
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
When mounting 1C2800-1170 through -1177 contactors, the following requirements must be maintained:
Movable contact
ti p
Fig. 2.
Contactor clearances
.r---
~learances
i6,"
to
3"
i6
Fig. 3.
Contactor clearances
BI006008
GEH-3057B
IC280
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
I"
3"
"---16 to i6
Fig. 3.
Contactor clearances
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.
voltage
voltage
voltage
voltage
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.
BI006008
BI006008
GEH-30578
Old Type
CONTACT
TIP WIP E
PPROXIMATE
IMENSIONS
IN INCHES
CONTACT OR
FORM
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
ARC CHUTES
TABLE IV
INTERLOCK TIP DATA (OLD TYPE)
IC2800 CONTACTOR FORMS 1170 1172 1173 1174
NORMALLY
OPEN
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
,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
TIP
New Type
BI006008
BI006008
-r--,~D
ASSEMBLE TIP
SUPPORT FLATLY
AGAINST HOUSING
BY RUNNING SCREW
TO SEAT POSITION
BEFORE MAKING ANY
CONNECTIONS
L2:44frt~
Fig. 6.
A---.....
A -1--4-+--1-, I
GEH-3057B
TABLE V
INTERLOCK TIP DATA (NEW TYPE)
CONTACTS
Not
Operated
MINIMUM
5/64 in.
3/64 in.
3/64 in.
5/64 in.
ACTUATING LEVER
SPRING
SPACER
KEY -----..
MOVABLE
CONTACT
TERMINAL
HOUSING~:::~:~:~:~=_
-~
_ _+-STATIONARY
CONTACT
TIP GAP
Fig. 7.
OPERATI NG
ARM
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
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
BI006008
BI006008
GEH-3057B
MECHANICAL INTERLOC S
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.
GENERALfj ELECTRIC
."'1.
5-73 110M)
BI006008
BI006008
BI006008
GEH-5600A
(Supersedes GEH-5600J
GE Drive Systems
Instructions
LodTrak IV
Protective Relay Module
BI006008
BI006008
LodTrak IV
Protective Relay Module
GEH-5600A
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
BI006008
GEH-5600
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
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
BI006008
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
. . . . . .
.
.
.
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.
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
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.
Introduction
A-I
A-3
A-5
A-7
A-9
APPENDIX B
SETUP EXAMPLE
BI006008
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.
3-5.
2-9
3-6.
2-10
3-7.
2-11
3-8.
3-1
3-9.
3-2
Page
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.
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.
5-11
5-12
.. 6-3
6-2
" 7-3
7-4
.. 7-6
"
7-7
7-8
7-9
iii
BI006008
1-5600
Notes:
BI006008
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.
Instantaneous overcurrent
Phase unbalance/open phase
Ground fault
Bearing overtemperature
Phase reversal
Loadjam
Undercurrent (load loss)
Overload
Integrated ov rload/overtemperature with
RTDs
Separated ov load/overtemperature with
RTDs
Overload wit no RTDs
1-3.1. Environment
Operating: 0
BI006008
-5600
>1cal: Must be in a low voltage (250 V max) comlent of the electrical equipment
lsure: NEMA 1
Winding temperature measurement: 1 to 6 RTDs
~.
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
k Inputs
rut fault:
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.
2 % of reading
1 digit
BI006008
KVA:
4 % of readir g
GEH-5600
I digit
Trip characteristics:
IS % of curve plotted
RTD inputs: 50 V
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
Notes:
BI006008
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.
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
BI006008
-1-5600
NOTE
(FRONT VIEW)
LCD DISPLAY
I'M OK LED
DECREMENT
KEY (DEC)
TRIP LED
INCREMENT KEY
(INC)
RESET KEY
SCAN/ENTER
KEY
SELECT KEY
BI006008
GEH-5600
2-4. NON-PRO
2-3
BI006008
1-5600
BI006008
GEH-5600
1. Set point S
2.
must be set to 1 - 6.
3.
The LodTrak IV
peak current fault
cable faults. Trip
seconds after faul
2-5
BI006008
-1-5600
BI006008
2-7.14. Phase
GEH-5600
= Trip)
NOTE
0% capacity used
<39 C.
= both temperatures
2-7
BI006008
fI-5600
2.
b.
b.
c.
BI006008
GEH-5600
501 t-t-H+t--1hnr-r...-+-++-++++---+--+-+-J-+-f.+~
401 H-H#--~I-I-t--l--"H--H-Hf++--+--+-++I+~
3OIH-+-HH---H--H--I+--H-++++---+---+-+--+-I-H~
201 t-t-H+t--l-IcHlr-If--++-++++---+--+-+-J-+-f.+~
MAX STALL
9=tm=$ml$ta:a=~~~ff~
SETTINGS:-+-H-H
~
1eeOC
H-f-t-Hf-_-tr---l"~1IJ41~'~~~iH-~":~TIME
~.
~.
4'1 1-++-+++--~~'''-4I\...~'I\~
~~
\ 1,
\'l
"
~-f-ft~--l--+-++~-H-l
\~,
:g , . . \\
I"~ _
'I ~
, \
It.",
~ 1~i~~~~~}~\~~I~J~l~!~"~_~5~AM~P~FL~C~tEfm
~....
~
:,
, '1;"
8 x 30 SEC
6,1......H-#+----+--I-~~~~
5IHH-#+----+--I--...~~-A.
I'
4IHH-#+----+--I---+J"~I\~..-+~~'--- 8 x 20 SEC
.. ~ ~
..' - 6 x 15 SEC
31IHH-#+----+--I-_+_-f\r:+4~~-~--'--+-+--I-J~-I
I,\, ~
, _ 6 x 10 SEC
2H-f-H-if---+-+--I-+-~"'H,flI---+'--l'-HI~H-I-l
,~
.. _
~ 5 S~C -~40:C,
1~
.8
+- 6 ~ 5 S~C - ,12~'~ ,_
.6
I
~ I
I In
J J I
RTD - CONSTANT 40'e
.5
.4
.3H++++---;--+--+-H-++H----+I_+-I+-III_IH-II-H
.2H-J-H-t---_+--+--I--+-~4_++_--+-_l__+__l_+_+_H_I
'lll~~~~~gTW~O~T~IM~EiS~FUL~L~L~O~A~D~C~U~RIRE~NT~~B~
.08
06
.051H-f-~~--+---+-~~'-+-.I--1-"----+-~-I--I-.l-++H
1 I I I I I
.04
.03
OVERTEMPERATURE/OVERLOAD
WITH INTEGRATED RTD INPUT
.01~:-=-~~------~~~~~--:!':~~~+~-+-!
5.6.7.8.91
.. 5678910
20
.. 567891
Fi~re
BI006008
-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
a.
b.
2.
a.
b.
c.
BI006008
GEH-5600
1000
eoo
eoo
soo
400
300
I,,
\'
"
'"I
.
:",
125 UT
I 1 1 85'k% UT
\~,
l\l \\"
200
\\\~ ~"',
100
MAX STALL
TIME SEITINGS:
,
",\ ",,\ , ..
80
,~
40
~'
I.
60
50
20
III
!
w
::E 10
j: 8
"'" "
~
~
~
. . 6 x 45 SEC COLD
", ,"
~
~ .-5~MP FLC
I':
6
5
4
~30
8w
J J
'.
"
, _
I II
6 x 15 SEC COLD
~ ~"6!15JECtO~~\
J J I II
,
.a
.-
'"'+-6x5SECHOT
r r I I
.6
.5
.4
I J
.3
.2
.1
.08
.07
I 1
.06
.05
.04
.03
.02
.01
.5.6.7 8.91
I I II
I I 1111 I
I T1
3
3 45678910
2
20
MULTIPLE OF FULL LOAD CURRENT
45878g1
BI006008
1-5600
300
200
30%
10-35%
10%
I
100
so
so
30
oU
20
LLI
LLI
~
~
I'
\\
\ 1\ 1\'
,.,
,, ,
\
\,
rn
10
,,
rn
.1
,
,\
I'
,,
\\
\'
'\
I'
i\
\,
- --- -
\ \.
.\
.8
\.
-- -,- .. .
~---
.8
..
87.5% FLC
I
OPLC - 95% FLC
I II
OPLC -
.8
<
OPLC -
>
100% FLC
.2
IA 2
.1
.08
.08
.05
.0.
.03
OPLC -
--
-...-
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
2000
in PERCENTAGE of FLC
+ la2 + Ic2
3000
BI006008
GEH-5600
1.0
0.5
(/)
Q
,-
= 1.00 sec.
.'
0
U
(/)
t
&II
:E
0.10
IAo
I I:
I-
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
2-13
BI006008
-1-5600
Notes:
BI006008
GEH-5600
CHAPTER 3
INSTALLATION
3-1 .1. Door-Mounting
3-1. MOUNTING
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.
Replacement Door-Mounting
Adaptor Plate
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
2. ESTlW>.TED WEIGHT:
6 LBS.
3-1
BI006008
1-5600
2. Base-Mounting
171B6843G3
171 B6843G4
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
BI006008
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
MOUNTING HOLE
RTD CALIBRATION
POTS
===
===
===
===
===
===
o
MOUNTING HOLE
SCREW TO REMOVE
FRONT COVER
3-3
BI006008
-1-5600
o
TERMINAL BOARD TB3
(RTD CONNECTIONS)
(]
MANUFACTURER'S
TEST CONNECTOR
(GE FACTORY USE ONLY)
CT COVER
r;e>~r:=""iT'==~~1
SNAPS OVER
CT'S ------------ >
e>
e>
BI006008
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
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
{96
PROGRAMMING
LOCK
N.C. 100
3-5
BI006008
1-5600
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
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
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
BI006008
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
3-7
BI006008
1-5600
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
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.
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.
BI006008
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
3-9
BI006008
[-5600
WARNING
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
BI006008
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
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
3-11
BI006008
1-5600
BI006008
GEH-5600
CHAPTER 4
START-UP
4-1. PRELIMINARY CHECKS
( AUTION
WARNING
messa~ es
CAUTION
BI006008
-1-5600
, APPLICATION CONSIDERATIONS
,1. RTD Inputs
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
Motor
HPNoits
175 0
165 0
BI006008
GEH-5600
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
fI-5600
Notes:
BI006008
GEH-5600
CHAPTER 5
OPERATING INSTRUCTIONS
5-1. OPERATING
5-1.1. Running Mo
5-1
BI006008
1-5600
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.
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.
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
GEH-5600
5-3
BI006008
1-5600
Display Type
No.
Display
Model
Display Type
No.
Display
Present
Values
PVO
PRESENT VALUES
PUSH INC FOR 1ST
4E
Since Start
Values
SSO
PV1
SS1
PV2
CAPACITY USED
XXX PERCENT
SS2
PV3
CURRENT 11 =XXXX
12 = XXXX 13 = XXXX
SS3
MAX UNBALANCE
% OF FLC XXX
PV4
SS4
PV5
SS5
PV6
SS6
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
BI006008
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
AT3
ST4
OVERLOAD TRIPS
AT4
ST5
WINDING RTD
TRIPS XX
AT5
AT TRIP UNBALANCE
% OF 1 FLC=XXX
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
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
-1-5600
Key Pushad
New Display
Comments
:SENT VALUES
SH INC FOR 1ST
~VO display) *
INC
DEC
SCAN/ENTER
SELECT
RESET
PV1 display
PV14 display
PRESENT VALUE displays
SSO display
INC
DEC
SCAN/ENTER
SELECT
RESET
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) * *
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
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
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
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
(or)
RESETTING
module resets
(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
module resets
1st Present Value line
BI006008
GEH-5600
Table 5-4. Trip Mode Displays and Key Operation - Models 4A, 4C, and 4 (Continued)
Present Display
Key Pushed
New Display
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 =
(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
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
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
INC
DEC
SCAN/ENTER
SELECT
RESET
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
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
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
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
fI-5600
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
SP4
NOM. SECONDARY
VOLTS
XXX
"50" to 120 V
All
SP26
OVERLOAD
TYPE XXXXXX
SP5
UNDERVOLTAGE
ALARM
XXX
"NO" or YES
All
SP27
"10" to 175
SP6
UNDERVOLTAGE
ALARM %V XX
"55" TO 95
All
SP28
"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
SP11
OVERVOLTAGE
ALARM %V XXX
"105" to 130
4E
SP33
SP12
OVERVOLTAGE
TRIP XXX
"NO" or YES
All
SP34
"10" to 175
SP13
OVERVOLTAGE
TRIP %V XXX
"110" to 135
4E
SP35
"10"to175
SP14
OVERVOLTAGE
DELY SEC XX. X
0.2 to 30
"15"
All
SP36
"20" to 185
SP15
PHASE LOSS
BY VOLTS XXX
"NO" or YES
4E
SP37
"20" to 185
SP16
PHASE REVERSAL
BY VOLTS XXX
"NO" or YES
All
SP38
"2.00" to 5.00
SP17
CT PRIMARY AMPS
TO 5 AMP XXX X
50 TO 9000
"500"
All
SP39
"3.0" to 12.0
SP18
"TODF" or
NTDF
All
SP40
STALL TIME
XX
SEC
"1" to 90
SP19
"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)
BI006008
Table
GEH-5600
Model
SP No.
Displ y
Units
(" " = defeult)
Model
SP
No.
Display
Units
(" " = default)
All
SP46
"5 to 30
4C,4E
SP55
MAX STARTS/HOUR
XXX
USED
"NO" or YES
All
SP47
"NO or YES
4C,4E
SP56
MAX STARTS/HOUR
INTERVAL X
"1 to 5
All
SP48
"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
Notes:
BI006008
GEH-5600
CHAPTER 6
MAINTENANCE
6-1. PERIODIC MA NTENANCE
Decade Resistance
ox to simulate RTD
Time Testing
6-2.4. Undercurrent and Load Jam Testing
6-3. CALIBRATION
o=
6-1
BI006008
H-5600
6-4.2. Relay
CAUTION
6-4.3. Fuse
6-5. TROUBLESHOOTING
PARTS REPLACEMENT
.1. CT Cover
BI006008
GEH-5600
Probable Cause
Corrective Action
No display, 1M OK LEe
blinks
Internal failure
General:
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.
SAMPLE STALL
INTERNAL FAILURE
TRIP RELAY ERROR
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
INTERNAL FAILURE
AUX RELAY ERROR
OPEN RTD
Reading wrong
Connection problem
6-3
BI006008
H-5600
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
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.
NOTE
BI006008
fI-5600
ill
3. Message Values
BI006008
Protective Relay
Mo~
ule
GEH-5600
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
= 1 DC
= 1 DC
= FlC
= FLC
(Index 7)/2.9
=%
1 amp
= 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
= volts
MOTOR VOLTS PH
Valid
Valid
21.231
=1V
MOTOR VOLTS PH
Valid
Valid
21.231
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
= 1 DC
= 1 DC
= amps
NOTE
Models 4A ,and 4C do not display any voltages, watts, or external relay values.
7-3
BI006008
[-5600
Index
LoByte
HiByte
Scale
:ONTRAST
34
Valid
Valid
1 = 1
= darkest, 32 = lightest
35
Valid
None
= enable, 2 = disabled
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
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
)VERVOLT TRIP?
46
Valid
None
1 = enabled, 2
= disabled
JVERVOLT TRIP %
47
Valid
1 = 1% of nominal
IOLTS LOSS?
48
Valid
None
= enabled,
= disabled
49
Valid
None
= enabled,
= disabled
:T PRIMARY AMPS
75
Valid
1 = 1 amp
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
65
Valid
None
= remote, 2
90
Valid
None
= enabled, 2
= disabled
50
Valid
None
= enabled, 2
= disabled
67
Valid
Valid
1 = 1
1 to 6
51
Valid
Valid
None
)VERLOAD TYPE
66
Valid
None
1 = RTO, 2 = No RTO
69
Valid
Valid
10.24 = 1 C
68
Valid
Valid
10.24
52
Valid
None
70
Valid
53
Valid
None
1 = 1 of 2, 2
54
Valid
Valid
None
55
Valid
Valid
None
Valid
=1
=1
C
1 = enabled, 2
= disabled
1 to 4
1 of 4
BI006008
GEH-5600
Index
LoByte
HiByte
Scale
72
Valid
Valid
10.24
74
Valid
Valid
10.24
=1
71
Valid
Valid
10.24
=1
73
Valid
Valid
10.24
=1
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
80
Valid
None
83
Valid
273
81
Valid
None
82
Valid
273
PHASE REVERSAL
84
Valid
None
= enabled,
= disabled
GROUND FAULT
58
Valid
None
= enabled,
= disabled
94
Valid
None
= enabled,
= disabled
96
Valid
Valid
290
1 amp
(Index 96l/2.9
% 1 amp
95
Valid
Valid
290
1 amp
(Index 95l/2.9
% 1 amp
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
61
88
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
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
H-5600
Index
LoByte
HiByte
Scale
Factors
CAPACITY USED
123
Valid
Valid
PH 1 CURRENT
116
Valid
Valid
= 1%
273 = FLC'
= amps'
PH 2 CURRENT
117
Valid
Valid
273
PH 3 CURRENT
118
Valid
Valid
= amps
= amps
115
Valid
Valid
= FLC
273 = FLC
10.24 = 1 DC
UNBALANCE % FLC
125
Valid
Valid
273
= 100%
(Index 125)/2.73
124
Valid
Valid
290
= 1 amp
(Index 124)/2.9
PH 1 VOLTS
119
Valid
Valid
21.231
= 1 volt
PH 2 VOLTS
120
Valid
Valid
21.231
1 volt
PH 3 VOLTS
121
Valid
Valid
21.231
= 1 volt
112
Valid
Valid
10.24
= 1 DC
113
Valid
Valid
10.24
114
Valid
Valid
10.24
= 1 DC
= 1 DC
= amps
NOTE
% unbalance
% 1 amp
BI006008
GEH-5600
Models 4C and 4E
Display
Index
LaByte
HiByte
Scale
STARTS A TTEMPTE D
142
Valid
Valid
STARTS COMPLETED
143
Valid
Valid
144
Valid
Valid
OVERLOAD TRIPS
145
Valid
Valid
146
Valid
Valid
147
Valid
Valid
148
Valid
Valid
149
Valid
Valid
GROUND FAULT TR PS
150
Valid
Valid
151
Valid
Valid
UNDERVOLT TRIPS
152
Valid
Valid
OVERVOLT TRIPS
153
Valid
Valid
UNDERCURRENT TR PS
154
Valid
Valid
155
Valid
Valid
156
Valid
Valid
157
Valid
Valid
Factors
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
=1
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
161
Valid
Valid
MAX UNBALANCE
162
Valid
Valid
(Index 1621/2.73
= % Unbal
165
Valid
Valid
= 100%
10.24 = 1 DC
273 = 100%
290 = 1 amp
164
Valid
Valid
10.24
166
Valid
Valid
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
= kV
169
Valid
Valid
21.231
= 1 volt
= kV
160
Valid
Valid
= 65536 kW
141
Valid
Valid
= 1 kW
DC
7-7
BI006008
fI-5600
Flag
Index
LoByte
Bit
External Relay
106
Valid
Ground Fault
106
Valid
Ground Fault
109
Valid
106
109
106
109
106
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)
102
102
Valid
102
Valid
102
Valid
101
Valid
101
Valid
101
Valid
101
Valid
= RTD3 Open,
= RTD4 Open,
101
Valid
= RTD5 Open, 0
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
= 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
GEH-5600
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
7-9
BI006008
H-5600
Notes:
BI006008
GEH-5600
CHAPTER 8
RENEWAL PARTS
8-1. INTRODUCTI
fuse
Part Description
Part Number
CT cover
Relay
Fuse (2 a 125 V)
323AI729Pl
305A6647Pl
218A4989P3
NOTE
8-1
BI006008
H-5600
Notes:
BI006008
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
= 64.8 A
A-I
BI006008
H-5600
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
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
If SP23 = YES
SP24
SP25
SP26
SP27
SP28
SP29
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
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
SP Number
B-1
BI006008
1-5600
;P Number
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
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
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
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
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
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
C-1
BI006008
-1-5600
Date
ter No.
ling
Description of Drive
SP
No.
SP1
SP17
SP
No.
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
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
SP52
"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
"1" to 90
SP63
SP41
"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)
"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
GEH-5600
Notes:
C-3
BI006008
[-5600
Ition
Date
ter No.
ing
Description of Drive
SP
No.
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
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
SP32
SP33
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
SP35
SP36
SP37
SP38
SP39
SP40
Setting
SP
No.
Units
(. .. = default)
SP41
"NO or YES
SP42
"6" to 37
SP53
SP54
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
GEH-5600
Notes:
GE Drive Systems
General Electric Company
1501 Roanoke Boulevard
Salem. Virginia 24153
BI006008
BI006008
GEF-8016A
CR1938, C & 0
BI006008
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
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.
GEF-8016A
BI006008
Fig. 1
1-_-- 2
Note: 400A contactor shown in photo
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
55B533224G4
Part Number
55B533223G4
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
* 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.
GEF-8016A
BI006008
Fig. 2
Coil Assembly
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
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
Fig. 6
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
Part Number
55C679819G3RA
55C679819G3R8
55C679819G3RC
55C679819G3RD
GEF-8016A
BI006008
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
Fig. 10
Bottle
Guide
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
( Blank Page)
GEF-8016A
BI006008
GEF-8016A
BI006008
GEK-83756A
GE Drive Systems
B
a
w
th
ne
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.
MAINTENANCE
ARC CHUTES (See Figure 3)
BI006008
GEK-S3756
--,
ARC CHUTE
LATCH'S'
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.
l"'---
AC SUPPLY - - - - - - - l
BI006008
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
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
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
.....r.-..,...,
AAWATURE
ASSOoIBlY
ARWATURE TENSION
SPRING
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.
DCARE
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.
:;EK-83756
INTERLOCK
OPERATING ARM
CONT"CT GAP:
Mea",re the minimum
L - ....
I
~\
CLEARANCE
(C)
INTERLOCK
PLUNGER
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
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
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
OPERATI NG
PLUNGER
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
:,'
,."
'.
'
'-',
BI006008
BI006008
Construction Features
Stored energy spring
mechanism zinc plated spring
and cadmium plated iridite dip
parts.
Arc-chute
~~~~"*:--- Insulated drive link
....,...~--
Arcing blade
Main blade
~---
Open blade
position
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.
BI006008
SYSTEM RATING
KV, NOMINAL
VOLTAGE
Rated
Max.
Voltage
(KV)
Rated
Dielectric
B1L Impulse
(KV)
8.25
75
15.0
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
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
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
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' ,
'QTY.
~
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.
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:---'
'
ill
,Of 5'
"* ItANDlE
>P~OCKET,
PLfAiL
liE
.-
~v-ARIAJiLE\f'BOml ADJUSJI'U:IH~
'5
: "
1
j
SPRUI.I
SHAfT
__ _
__"
'riETAIL@
LYOF CIIAIN & TURNBUCKLE'
,SWITCH
,SPROCKET,
..
OO"t .. s.o".......
IfIfC04'
VERSA-RUPTER
0,
'i'l :Uf,-P37
0..
-+_-1.
--;;-'. --_. - - -
,..
-~
BI006008
BI006008
!
- -
AC RHMET['='
Z n
DC AMMETER
F\CCELERATlNG CONTACTOF
~c
A 5
A,
A
PtMME1ER S~!TCH
B I
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'"
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
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
--
-,
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
0-
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
Al I -
R01A01
..
L-O
L-D
REV.lt
REV.l
REV.S
REV.2
REv.S
REv.3
> HANDLE
HADE Br
APPfK)VAL.S
M G LACKEY
I''''"'''' BI7/95
TECH
REO.
CR
M G LACKEY
1),
M G LACKEY
37795E182
CR19L+
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.
3S
IBRN
3E
37
38
39
-2
_3
CT PRIMARy TO 0 AMP -
18
19
TDDF
_6
IPHASE UNBALANCE
'
8~
_9
01
TO
J7~
Yi: NO OR YES
5 TO 29
~NO
OR YES
10 TO 30
TRIP % DF FLC -
50
IGROUND
I TO 911
_7
52
10
NOli NO OR YES
LiUls TO 3'
~
TO 0.00
TODF DR TRIP
OR ALARM
..----,
ICAlC
_0
TO 180
1'2.0~
~i3.~ TO 12.('
~r-
3.30
TDOF OR NTDF
112~
~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
! UNITS
D!SPLA~
15ET POINT
TO 32
=r~G,S
ND OR YES
FAUL T TRIP -
53
5_
I TD 6
57
UNDERCURRENT IS USED -
10CU 100PT
J00NI J20NJ
58
~ NO
GU 5
OR YES
'"
TO 69
:~too
10 TO 100
0.10
0.05 TO 1.00
22
23
~INDING
2_
~INDING
RTO on.
20
~INDING
RTD TYPE
NO
26
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VendorPubucailons
Support Devices
-
Table of Contents -
Meter jTransformers
4555K10-001
GEF-4199A
GEH-230AF
GEH-2385G
Relay, CR120A
GEH-2466E
Time
Switc boards
GEH-2621 C
Capa itors
GEH-2743A
GEH-3620B
GEH-4115C
GEH-4143C
GEH-4729A
Groun
GEI-86126H
Break System
GEJ-3775B
BI006008
INSTALLAliON
198BI006008
4555K10-001G
Supersedes 4555K10-001F
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.
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
TERilIHAL SCREWS
4 MOUHTICG STUDS
10-32 THREA
f-
21 THIlEAO
PANEL
Fig.
It. II
1.1'
DIA.
1.$1
DOUBLE RATED
1NSTRl.t\EJITS ONLY
Fig. 3.
PANEL'
-.Ii
3
I~
32
Fig. 4.
~3ii--i
4
DIA
-'-~
?z]i:~~L
I 8
23.
31
32
!10
I
I
32 - - - ,
BI006008
BI006008
Page 4
4555KIO-OOl
.I\'WU
.~~
7S----~
Fig. S.
~7
USE ON VOLTMETERS
THESE TERMINAlS 'O~ Uf.i ~lrH
DOUBLE RATED A~~I"'" QIWLY
..
.: .
,... ~TERS
A ~ . till FOA
VOLT"ETERS
Fig. 6.
If
Fig. 8.
BI006008
Page 5
.I}555KIO-00l
BI006008
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
-SOURCE
LOW RAT! NG
SOURCE
LOAD
CONTAINED
Fig. 12.
LOAD
HIGH RATING
LOAD
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
~_,..
,,.n''''m;:2lt-~-r~ ~;"h
WITH
POTENTIAL
TRANSFORMER
~_
1-..,
........
BI006008
BI006008
Page 6
4555KIO-OOl
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~:
!
16
I TUBE
,"
8" - - - - \ 1.
98
Fig. 20.
--.L
3"
~"
'3'4
~-FC;/
32
~~
32
29"
,"""'-1-32
I
1IlO!ll+-1-..- - .....
, --;---
2 TUBES
3"
f---------
Fig. 21.
INSTRUMENT
4/81
69" - - - -....
Printed in U.S.A.
BI006008
GEF-41
Superades GE
BI006008
,RENEWAL PARTS
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.
,b~l
_y,,?~'''J0~~-'
""
,,\ 'i-.~'. '"
'.\\\.'\~\t.
When ordering r newal parts, give quantity, catalog number, ~,elcription of each item required, and complete name plat. reading.
GENERAL. ELECTRIC
\,
BI006008
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
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
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
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
: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
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
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
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
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
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
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
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
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
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
PLAIN WASHER
Catalog
Number
N402PllB6
10
Description
Description
For 1/4 in. screw, steel
BI006008
GEF-4199A
~J
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
ARIZONA
Phoenix 12 . 3550 N. Cent,al Ave.
Tucson
151 S. Tucson Blvd.
ARKANSAS
:
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.
t f
t
t:
t:
MAINE
MARYLAND
* t:
BI006008
t :
t:
t t
MASSACHusms
t : Basion 16
31 51. James Av
t
Springfield 5 ......... 120 Maple 51.
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.
" 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
las Vegas
NEW HAMPSHIRE
t
Manchesle,... 1662 Elm St.
NEW JERSEY
t t Newark 2
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.
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.
: 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.
t:
TEXAS
l :
t
t
VERMONT
t
Rutland .. 38'11 Cente' 51.
VIRGINIA
t
t
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:
WEST VIRGINIA
t
fairmont ........ 310 Jocobs Bldg.
Wheeling ...... <40 fourteenth St.
WISCONSIN
t
i Appleton ....... 510 W. College Ave.
t
Madi.on 5 ... 5317 Old Middleton Rd.
NORTH DAKOTA
t
Bismarck
t:
t:
UTAH
NEW MEXICO
t
Albuquerque . 120 Madeira Drive, H.E.
OHIO
t
t
OREGON
t:
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.
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.
(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.
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
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
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
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
INSTALLATION
SAFETY PRECAUTIONS
JAR-O CT
NOTE: The high- turn winding of aCT
is the winding with the lower rated current.
= ammeter
50
.,
\.
BI006008
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.
MOUNTING
....;
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.
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.
SECONDARY PROTECTORS
BI006008
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
POLARITY
BI006008
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).
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
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.
BI006008
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)
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.
MAINTENANCE
The sealing surfaces (C), Fig. I, on the
magnet frame and armat re should be
CONTACTS
MOLDED SUPPORT FO
STATIONARY CONTAC
E
C
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.
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
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
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"
220V
8
108
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~
SERIES A
RATINGS
Continuous AC
Current Rating
300
10ampmax.
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)
FIGURE 2
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.
'"
FIGURE 3
iEH-2466E
BI006008
4. Place screwdriver under one coil terminal screw head, and using
barrier as a fulcrum, pry coil out of relay. (Figure 3)
5. Replace coil and wiring, tighten screws and replace movable contact carrier.
(MOVABLE CONTACTS)
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.
GENERAL. ELECTRIC
GEH-2468
Instructions
BI006008
Time-delay
Relays
CR122A Series
Caution:
Warning:
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
arton.
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.
E-{ :~-:+-:+~~
TIME DELAY DE-ENERGIZE (No power applied)
GENERALfj) ELECTRIC
BI006008
Change Of Mode
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.
TIMER
RELAY
(HAS BEEN ROTATED)
4.
Maintenance
5.
Movable Assembly
6. Turn cover on movable contact arm 90 0 in direction of the
arrow (see Figure 4).
7.
8.
9.
10.
Removal Of Coil
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.
IEH-2468G
6/87
(2M)
GENERAL~ ELECTRIC
Printed In U.S.A.
GEH-2621C
AVIBVLine@
Switchboards
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
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
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.
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
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.
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.
REAR ACCESS
MAIN CABLE TERMINALS
FIGURE 78
BI006008
CABLE BRACE
FIGURE7C
FIGURE 70
REAR ACCESS
DO not install these switchboards against the back wall. Rear access is required for field wiring and maintenance.
BI006008
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.
FIGURE7F
REAR ACCESS
Do not install these switchboards against the back wall. Rear access is required for field wiring and maintenance.
BI006008
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.
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
Jc~~~~~
PAD
WITH SILLS
FIGURE 11
Walk-in type switchboard-outdoor construction.
BI006008
IGi"
INTEGRAL GROUND
~ Do not run equipment ground conductors through groundfault sensors. Connect them directly to the switchboard
ground bus (not to the neutral bus).
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
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.
ALTERNATE SENSOR
ARRANGEMENTS
(j)
G)
"
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.
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
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:
V4" 5/ 16 " -
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.
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.
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.
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.
BI006008
BI006008 CH21"3A
INSTRUCTIONS
Outdoor Dielektrolill
Power C~pacitor Units
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
GENERAL. ELECTRIC
BI006008
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.
10
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!
01
.,.".(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.
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.
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
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.
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
:3 WINDOW-TYPE
CURRENT
TRANSFORMERS
:3 RELAYS
ELEMENTARY DIAGRAM
[E
A
oB oC
oC
RELAY
Fig. 1.
Elementary
cuit,/C282
RELAY TERMINALS
Fig. 2.
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
'
ARMATURE STOP
SCREW
.. 1
'P"NOV'~~.
ARMATURE
OPENON'
'/
A,
LATCH
SHIMS
..
~ ~ -,"~.
CORE
HEAD
SPRING
SEAT
Fig. 4.
Fig. 3.
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
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.
BI006008
SPRING
SPACER
'"=::::+=+:t:::;
N.C.
TIP GAP-
Fig. 5.
U~::;R=~- N.O.
TIP WIPE
AINTENANCE
COILS
To replace coi s, first remove the armature assembly and latchi g mechanism as a unit by remov-
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.
Carry
10
60
tAc
125V
250V
600V
110V
220V
440V
600V
1.8
0.5
0.2
1.5
1.2
,~
BI006008 -\.
I
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
Coil Removal
(Refer To Figure 3)
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.
GENERALfj ELECTRII
BI006008
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
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
Accessory Kits
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.
Ref.
No.
Catalog Number
Description
Coil retainer assembly
1
2
3
4
5
6
7
8
9
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
GEH3247F
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
CROSS
EASE OF INSTALLAT ON
Three- point mountin , straight - through
installation easy.
wiring saves time, mak
to power supply:
Before connecting start
RELAY
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.
CAUTION: Before adjusting or operating reverser, make sure the mechanical interlock
arm is engaged with movable contact arm.
GENERAL. ELECTR
-3620
BI006008
device
6. Replace coil.
7. Reassemble
cedure.
by reversing pro-
device
by reversing pro-
RATINGS
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
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.
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
Description
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.
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
-
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:
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.
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
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.
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.
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
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
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
600
A II
__
arn..;g_....
Dc-NEMA P300
Max.
Currant Aatlng
125V
1.1
250V
Figure 1.
.55
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.
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.
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
INDICATING LIGHT ATTACHMENT
INSTALLING
OVERLAPPING CONTACTS
RENEWAL PARTS
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
ACCESSORY KITS
Slllndanl Cont.ct Module. CR12OBX1
Overlepplng Modul
CR12OBX1A
Figure 4.
Indicating Light
115V 50160 Hz
230V 50160 Hz
460V 50160 Hz
CR12OBX5
CR12OBX6
CR12OBX7
Surge Suppraaaor
115V5Ol6O Hz
CR12OBX2
CR12OX15A
CR12OX16A
CR12OX171'
NEMA 1 Enclo.ure
(For up to fourpole relay)
(For up to elghtpole relays
CR120BX19
CR12OBX15
CR12OBX9
CR12OBX8
"
Figure 5.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _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
DESCRIPTION
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.
magnet back into position under retaining clip. Magnet must be centered in
housing window in order for it to seat
properly.
COIL REMOVAL
CONTACT REMOVAl/CONVERSION
SEE REVERSE SIDE FOR LATCH RELAY
INSTRUCTIONS-CONTACT
REMOVAl/CONVERSION
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.
3.
Flguro 2.
TO REASSEMBLE:
6. Insert coil and center in housings.
INSTALLATION
1. Disconnect power fr
2. Remove all packing.
Reassemble.
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
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.
ACCESSORY KITS
Standard Contact Modules
CR120BX1
Oyerlapplng Modules
CR120BX1A
CR120BX1 B
CR120BX5
CR120BX6
CR120BX7
...... CR120BX2
. .. 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.
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
GENERAL. ELECTRIC
Printed In U.S.A.
BI006008
GEI86126 H
Installation
Instructions
Ground Break
System
For Ground Fault
Protection
<
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
ROUND-BREAKTM SENSORS
TABLE I -
Type Core
Cal. No.
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:
,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
vC
Figure 2B
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
B
075 F
I
r 01.-1 2 nI
CLEARANCES
t t~~t
--t0t-+--+- 1
1
12
-1
02
12+
o
.75
1-----
12.00 - - -
TGMOOO2!TGSOO02 0 inch
TGMOOO5!TGSOOO5
'h inch
Figure 2C
Figure 2
SENSOR OUTLINE
IMENSIONS (Inches)
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
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
TerminI! Screws
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r--- --
-r
r- 394
TT\6t---- ,_J..:J++~~
General
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
f---
r-
Figure 2F
(4) .341.0
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
" }','l-."l'
.
II
"L
,\
! II
III
II
I:
0:
~_ll
I I
I,
I
:~q~:
.,1 II!I
I I
I I
,I
, ,
, I
I
I
'I
!i!I!!.. ,,!I,
! I
.'
I I
,I
'I I
Figure 4
3
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UL RECOGNIZED RA INGS
Primary A ps
100-1200 Amp Rei y
3S,OOO
12,000
600
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
Sensor
Thermal Ratings
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.
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.
-_._-
!.~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
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:
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Pick.up Current
The instantaneous (
be used only for mo
preferred time deja
other relay at least
downstream.
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
lamp
lamp
lamp
lamp
lamp
Mechanical
Indicator
T'i---------l
I
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-
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OPERATION OF SYSTEM
TABLE
Add
Rl
~9
600
400
200
100
60
40
20
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
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
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.
**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)
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._
.....
_4I~
....J
200
150
150
100
75
50
25
25
25
25
25
Figure 9
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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
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
Figure 10
..... --.
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
II
CS
_L_
-r
L-
...!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
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MAIN RELAY
CD CD CD 0 CD
FEEDER RELAY #2
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
CD CD CD
1 ~
J "-
L-----J
Typic.1 Zint Stltclin Interllckinc Clnnttlilas Ilf I SJStelll hninc i lUi, prlttttin ~"iee Ind twl IHdm, witll
Figure 12
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 ..
" ...... /
(j)
i
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....
--'
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
~.
Figure 13
Distribution Equipment
Division
41 Woodford Avenue
Plainville, CT 06062
GENERAte ELECTRIC
8
BI006008
INS aUCTIONS
GEJ-2836C
BI006008
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
COLOR LENS
(for' pU5htotest)
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.
and
Resistor
--------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
---------------------------'
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.
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GEJ-3775-B
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.
Printed in USA
..-
"
GEK-33276D
&I
-.;?..
'"I
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
C
C
C
C
10
30
30
30
C
C
C
C
Temp.
Class
105
150
185
220
C
C
C
C
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:
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Application,
Operation and , .' ,
, Maintenance .
,_
Ins~allation,
2. Voltage ratio
3. No load losses and excitation current
PACT LOADING
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.
..
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
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
GEK-:j3277C
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
CONNECTIONS
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).
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.
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
BI006008
MAINTENANCE
DESCRIPTION
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.
1M
GENERALg ELECTRIC
Printed in U.S.A.
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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
Q-LIXE
peres
T Y
El50
APPLICATIO . FLEXIBILITY
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.
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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.
BI006008
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.
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.
~
~
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.
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10
1
~-9
'----3
~~---8
13---
17
16
BI006008
AMBIENT TEMPERATURE
COMPENSATING THERMAL TRIP:
10 e TO 50C
OFF
Be"fETAL
Overload Protection
BI006008
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
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
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
Three-phase current sensors are incorporated into a single package providing greater flexibility and reliability.
IAdjustable Pick-Up
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
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
(Seconds)
Settirig)
(C)
(X)
De1av
r.?T in.@
,40
Adjustable
Instantaneous
PickUp
(Multiple of
Rating Plug
Amp)
(Multiple
of Sensor
Amp Rating)
(X)
(5)
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
BI006008
CURRENT SETTtNG
.7>:
.ax
;~::
1.0X
SETTING(C)
LONG-TIME
DE~AY
(STANDARD)
LONG TIME DELAY
Z 3
'~'
I
I
II
,
DELAY
I
CAT.NO.~
X~200A
TEST
S~200A ~~O
PICKUP
0.
~~f1/
l.se
5C
7C
9C
SHORT-TIME
PICKUP
BI006008
1'"1 IN
rT OUT
MAX MAX
:~:
DELAY
INSTANTANEOUS PICKUP
3X SX
2X@:7X
&
1.SX
9X
~ox
ISX 13>:
INSTANTANEOUS
PICKUP
hII
BI006008
GROL~D
.4$
.2SS~
.2S
.4SS
.SS
.6$
GROUND FAULT
PICKUP
12T IN
I"T OUT
MAX MAX
:~:
GROUND FAULT
DELAY
(OPTIO~A..L)
OVERLOAD
SHORT CIRCUIT
GROUND FAULT
TAl?
INDICATOR
PUSH TO
RESET
BI006008
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
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.
BI006008
A 10\v energy positive action tripping device is automatically powered and controlled by the protection programmer.
PROTECTION ROGRA.MMER
CLRRENTSENSORPAC~~GE
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
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)
<) <)
"
._;)- ::>.
.35. A . .45.
.5..6 (X)
lO.1O.0.22.
0.36
BI006008
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
BI006008
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
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
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
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
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
10
STANDARD
I~TERRlJPTING DEVICES
0::::::.
TEC
3-150
TFC
__0
AMPERES
AMPERES
..".,..... ..
Ii
~~
800_.~0
0
.
1200 .
.
.
..
AMPERES
.
TKC . 0
9';-
.--:.,.: ..
TEC&:
TECL
3-150
A\fPERES
TBC4
400
Al\lPERES
TBC6
TBCS
800
AMPERES
600
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
.
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
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
BI006008
Accessories
MOLDED CASE CIRCUIT BREA.KERS
Undervoltage Protection
Auxiliary Switch
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
Bell Alarm
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
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. ,
4653
5406
CL
CL
4653
5406
CL
5407
VL
L~'1v two
4622
I.
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
I R I GEH-
GEH-l L
/TQD. THQD
. TEL. TE?>IL
l:ndervohage
Release
Me unting
Pole
I~~~~@
14623
CL 14623
TKL
VL
3346
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
White
r-: Yellow
Same as
individual
accessories
All aecessorv
contaCts shown
with the cireuit
breaker in
jtripped po:,ition.
Black
BI006008
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
Catalog
Num.ber<D
Kumber of
I"
Switches..
Switch Ratings
I TEDAS2AB I R
I TEDAS2AB2
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).
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.
S~itch
Mounting
Right Pole
Lef, Pole
Raring
~~~
n
'.
Voltage
Timing (Secouds)
I Inrush~ning 1 Closing
,".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
A~iary
~~c)gN~@
NtIinbcbr~fS~clt.es
TFK:\SA2AB2.
TFKA.sA2A.B4
s~4tc:hRatixlgS
2
4
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).
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).
.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,
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
..
. . $~.;;;..
."
i
.~
'V.
TJKASA2ABl
TJKASA2AB2
TJKASA2AB3
1]KASA2AB4
3
4
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
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
Hea~J
TJMDVAS
TJMDVBS
TJMDVCS
TJMD"VDS
TJ:vfDVES
TJy!DVFS
100
IS
18
200
24
120
240
7.500
100
12
24
33
60
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
I Ampere
(rime Delay)
2 Ampere
(Time Delay)
.35
~o.
286A755SG8.
BI006008
CatalogNl1mber
TKMAAS2ABl
TK~lAAS2AB2
TKMA.A.s2AB3
TK:'IAAS2AB4
Switch Ratings
6 amperes.
5 amperes.
% ampere.
lh ampere.
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
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
Center Pole
TKMABA.:\L
~_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
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
j TVDVSR
CENTER POLE
MOUNTING ON
TVeV9R
TVTVI0R
TVGV11R
j 24
48 I
1251
250 I
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
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
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)
-'
,~
"
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
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
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
Base,
with
Optional
Mounting
Plate
MECHAl~ISMS
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
F225
70 thru 225 Amperes
J600
K1200
Underwriters' Laboratories
UL 489 Branch Circuit and Service Circuit
Breakers-Order from UL Publications Stock,
333 Pfingsten Road, Northbrook, Illinois 60062.
18
E15D
10 thru 150 Amperes
(NEMA)
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.
BI006008
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
Voltag~ (ac)
120/240
240
9-_II
!
120
240
......
~t B:r~er Type
P()les
Voltage.
f
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
BI006008
c.
.;0 c>
- ""
.::~
g '"
lo-~
1:1 c
+50%
+25%
0/
- 25%
-
50%
I
rated
conouc,or
'
...
200%ot rated
conductor size
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.
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
$: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
3000
350 kcmi1
500 kcmil
500 kcmi1
4/0 A WG
410 A we
4000
<):\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
(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
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 .
<DThe correct size \\'ire should be usee with everv circuit breaker.
The values shown above
be useful in unde~tandingthe
J9-:>
Q-LI7\E
1.0
TQD. THQD
1.0
75
1.0
60/75
1.0
90
75
1.0
90
TD TJK-4. THjk4.
1.0
I 1.0
I
1.0
1.0
75
is
I
I
is
I 1.0
I, 1.0 I
75
75
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
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
be
ILl5
I'l_::>
105
19-::>"
105
i 1.25 1
- I
105
19-:>:
11
,
1.0 I
1"-:>
i
I
33
BI006008
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
1.0
1.0
1.02
1.05
1.09
LIS
1.18
TFC
1.0
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
1.35
1.25
equals the product ofthe load class rating factors which apply to
the circuit in question.
(1) E
34
or
Intermittent
shorttime duty (constant load
for less than three hours
or intermittent load)
1.00
BI006008
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.
(l srartf (f s
\i ~_--:""":""-+-=:-~---'--':"_:""-:'
\'
'>ls=66.5 amyeres
R,IS-
= 59.2 amps
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
::'hteiq::es of :)eal<s
of s:~e \..:a~t8 .c:-e
a:o:;;:
:t,eze;c ax;s.
sr~:~e~ca;
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
II\~ER.ltUPTING RATINGS
Z=VR2 +X2
R
therefore PF = V 2
x 100
R +X 2
and:
BI006008
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.
3?
BI006008
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
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
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""""",")
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.
BI006008
MoidedCase
Switch Catalog Number
Amps
60
100
10.000
10.000
100 jTED1l3YI00
240
240
roo
60
10.000
10.000
100
i50
'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
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
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
<)<)-
--"
800
!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
~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
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
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.
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 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
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
total c1earin
~~
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;
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
41
I~
.~:
'"
..,
~(""~'
W,
!o'$h'II~'"
I fI
'
MtlU!l
1\
,-
1'1
I ,I
k\"
;,.
I , IIUII
"
'
I~
:':'-
0'
~;.
\1
. 1 I ' IIUI,
linD
.<_~.
"Q"
)It' .. ,
.~_
l"<\.'I".-",,".i
"",S;'Jltlla,,U
11
:; g
:: !
,:I
1I1 :~
".
I IIHiif'
GES6202/l
,~H['-
(fJd(\<t'!t
b1it'j..~.. t
'H,f'<if-M
I:,;
'
,,
,
"
I-h""
.. 1
.'.
J I IIUI,
MULTIPlS OF CURRN1 RAil NO
HII
I,
I-!
\1 \
Tlmeturrent CON.I
(,..-.,,1 ..'..... ,..>.i\\..ut.,;'-' w+'-"' )'~ .,t;.. " ........t .. ~\
__
~t~~_,,~_~~~
fftql.ttMy fttt"tf
t.,h.;.'.U)Y;~lk
,/1 .f\
~
171)
(lur'-;II",.
I.. ,
I,o-~l:::"
_. .. ...."LLlJLlL
LI1LL:.:J.A
n
"Jt
(UUINI _AUtiO
" 1 . I
MU"lfll~ (>l'
JI~~ilmm ~f&TI111111l1l--:ICIJmIIIUlI'~
H..j!4I'_"'~~U
"<.l}fhIH~l'\,IAIk
Wlf9f'ftt'~'
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Cw-ttnl Rtl~'
a~)
, .. " ,
tlt<lfk.tOi,f,;kt~\
~ f(!<ttr"
ttf
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hi'
~ ::
g"
tc
'el':I':~o'
=_.~-'.'~1"::I:i
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,... -- '1V
T ~
Q"IJNJi>-1550
,',
~d
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',A',
"
.-
'
1-,,-
fJJ
t.i _ .
-, :'
~~,,;"
'
.;.,..;,
..
r.r:I:ll'
IP. . -.1....-..,
~~"'.'.'
H~._I.
',--
.,........
", ~
,.0
_.
"
1'- -'-I"I'ij'
--, ..
1=,I;;ie,:t.
1--
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t."",,>::+-,
IV_""''-''v_i~'"'
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..-/:::-:
~IIJ"")
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l=:I~I~[ElW+HII
=flti:rr
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'S1:::p
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lTffFH1R'5
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s: ~ l:IHt81111~EHE.
I
1::::tIJ]'
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(II"t,.hfll.
~'~:
I--
.........'1"---
1,-
ffff-
I 1'1111I
111.,III~I~~I~ml.1Ijl~1
/': ..fl'llki'"
.M;.;;:'::i;,:,
:: . =f
-=:.']". J
.'
"~----
.~~~I"~
:,::=~:
...
I
:;:f~~l:~E1"~-,:1:
1=""
t:.:
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'
"I'f :t:..
lI ""IT
u_l
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QaL1NE---()OlOO
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~
S
Cb
BI006008
<>r)N
,;,~"
~7,.~.I.:;'
""
'"
.. 1'..'
",-,-",
'
I-J,OlJlUU
f"
(\.I"W' ""I~O
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r"
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r=:::
..
f;~ J ,,~.
(I"lf(i~f>M
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t-(('~:~'>'#'I
r'fq<J.rCl'
W.H1 0tAtl''''2'
I"'} I'"
(:w""tAIl.... -at
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",'H
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K1200 Line
BI006008
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TEF 2
15-SOA Long
TEF 3
I 6O-1SOA Short
TEF 4
160-1SOA Long
TFK 1
I 225A Short
TFK 2
225A Long
Min
Max
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1
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Outline Drawings
Back Connected Studs
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Cat. No.
TKM9"
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400
600
800 to
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5.5
5.5
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BUS CLAMPING
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Outline Drawings
E150 Line
lH_E.
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BI006008
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BI006008
Outline Drawings
TDM Handle Operators
CAT. NO.
WITH HA."lDLE
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cat. NB. I A
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1.78 3.001 6.50
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2.7212.7516.75
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10.88
8.62
14.62
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23.12
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6.251
11.38 113.381 6.75/
1.30 111.81
1.30 17.75 10.33'
1.00 118.75
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BI006008
Outline Drawings
:Mechanical Interlocks
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BI006008
BI006008
BI006008
GET2964D
'~-
Groun Break
Equipm nt Ground Fault
Detecti n Systems
BI006008
Table of Contents
-.-
Grounding Practices
4-9
ill
10-19
General
Sensors
Relays
Coordination
Operation
Monitor Panels
Specifications
~.'-".
...... _..
Relays
Sensors
Monitor Panels
Ground Break Connection Diagrams
Application Tips
20-23
lZI
Testing
24
25
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BI006008
-).
-,
BI006008
Grounding Practices
~
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.-
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~quipment.
.....
BI006008
..,
,"./
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.
Bolted line to ground current is c Iculated using all ground return Impedences
including such objects as fish tap s, Insects or carbonized insulation.
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
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.)
I
L
Ph Ph
.~
<.J
Phase Conductors
Source
GSR
Load
"'--=-....--U--~-----o:,..J I
_.\ Fault to
Ground
Ground
Return
Current
Jumper
combinali~L
__ J
BI006008
Susway feeder
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ground us
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Trip I
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GSR-1
I)..ceeder
Trip
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I CT
J_
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GSR-1
Station ground
Feeder
Conduit
Feeder GSR relays may be
instantaneous or time-delay.
Main GSR relay is time-delay
Busway or Conduit
to load
Susway
Feeder from source
I-
--
GSR-2 Eq ipment
-,
Gr und Sus
~--
Main ,)
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) .... J
Trip
Ground Sus
Substation "A"
Suswayor
Conduit
Switchboard or MCC
"s"
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/)
c:i
E 1.0
i=
0.1
0.01
Current, amperes
(b)
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
IF UMP UGlfTS
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.
~=::=-c:.:=~
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If)
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GROUND BREA
TIME COORDINATION
RELAY
0.
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Ground
BI006008
aull
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'"<:l
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i ___
No trip
Figure 348
Ground Fault wi hout memory
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
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
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
._I
.... '
..10
,
101
I
1,000
CURRENT IN AMPERES
.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.
GRC)UNriiiREAK~-SYsiEM--
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BI006008
Component Specifications
GROUND BREAK RELAYS
TGSTGSR
TGMTGMR
200,000 A
50,000 A
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).
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
Inrush
5A
5A
30A
3QA
240V ac Max.
125V dc Max.
TGSMP
TGSMA
TGSMPA
TGSMPB
TGSMPC
TGSMPD
....
....
....
....
With GF
Indicator
Light
BI006008
MINIMUM
GROUND
BREAK
,
SYSTEM PERFORMANCEON XJ TO ~ OR 3:"~'
THROUGH FAULTS
-
18
)
fz
w
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16
14
u..~
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Cf)u..
:20
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('1')0
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a: z
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Cf):::J
0
II
Q..f- 10
z
ofI
Cf)
I
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10000
9000
8000
'"~
7000
6000
'"
5000
4000
Co
.
0::.
'Q.
':o
3000
::
2000
1000
TGMR RELAYS
WITH TGM SENSORS
2 4 6 8 10 12 14
Error Sig. Amperes
200
400
600
800
1000
1200
15
BI006008
3.54---
10.25
0.3_1(~"~m~~~~~~--!_+-+-NO_' s_cr_ew~:+---J--1
~
32
Terminal ,.
8,r'_
0.95
3,.1
5.14
!
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
Relay
ensors
41a
0.25
-n-I
1.12+-l
.50
f- 3.88 +
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
1.16
--i' 1,lL
8.00
TGS0424
50'
'. --r'.
Cat. No.
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
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
(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-'
*Wires,
run. Wir
Connection Diagrams
.....
e
:"-'"
+:=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.-
- ' -_ _===_
"Wires, #14 AWG min.. routed together for 100 It. max.
run. Wires should not be harnessed with power conductors.
MAIN RELAY
FEEDER RELAY #2
FEEDER RELAY # I
,,~-"
.,-.~,,,
;;
-:~.~'"
..,'
(D ..
.',
<D0000
CD
SUB-FEEDER RELAY #2A
.....~:~~~
...~-
'
:~$I~ll
<D0000
1"-"
..J
BI006008
-+
L.--t-
(continued)
Connection Diagrams
(continued)
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
Figure 45
,~
<,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.
Figure 4-6
BI006008
Incoming Power
Neutral
- - - - - - - - - Neutral
,-I
I
,I
...
,.....
'"'~---~
Main
'~. )I
Main protection by
ground return sensing
~ _-
Branches
""'--
""'
Main
Feeders
limited selectivity
""'-.......
limited Selectivity
Figure 5-1
Branches
r-'
r--"
I
...
.
"'"'
I
I
Branches
Main
GSR.'
Main and feeders protected
by zero sequence system
"
Neutral
GSR'
"'"'---
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:;'
Ii
Zone
Selective
Interlock
A_., !I
+--1====:tI:t=i=,:. :
,-...
'----7
Ma '-in---....
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.
I GSR.O
'"""
"'_I
I
BI006008
~.:
..
...
~J::./
-/
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
..
..-
-.
.......,
(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"
tG'
M3
I
,-.... II
f\
T 2-3
T3-1 U\..J\.-
N
G3 Trips M3, T 2 _S ' T S _1
BI006008
'-- .
Figure 57
Source ;;:1
3 4 W-WYE
u-L
Load Feeders
Source ;;:2
3 p 4 W-WYE
I
vJ....u
Load Feeders
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).
'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
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:
Figure 61
... il:l.rl~(5.ttiacleIID
'-+--+------~~
r--
: '---:1---"+--+--=+---,
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
11C
Shu'::,lrip 1 51
[ltdri( Trip:
I.J_
J Contlftt
Of
T-r-
T~
Coil
Coil
RIl
Figure 6-2
BI006008
BI006008
.,. t I
toO
lOG
'10
10
7 I
!'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
GENERAl$ElECTRIC
GROUND BREAK"'SYSTEM
50
10
60
H.rt;r
GES-6135
Adjurtmenr.
Type TGSR
~...
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
""
"
"
..
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"
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'-
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
GEA-8481
GEA-9755
GET-2779
GET-6202
GEA-7498
GEA-7477
GET-6207
GET-2963
~
\._j
GEA9752
GET9732
GET-6202
".'.-
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
GEp1675
GEF-4149
GEF-4150
GEF-4395
GEF-4396
GEF-4527
:)
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
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