AiVIPGARD S - docs.natlswgr.com

Westinghouse i.L 11-202-5

AiVIPGARD S T A R T E R SHIGH VOLTAGE (25L7 AND 50L7) NEMA CLASS E2

DESCRIPTIONcables may be conveniently arranged near the righthand enclosure wall.APPLICATION

The Westinghouse Ampgarc' is a high voltage starterdesigned for starting and controlling AC motors withhorsepower and voltage ratings as indicated in theRating Table below. Check Table and starter nameplatedata against motor nameplate and power system data.

GENERAL DESCRIPTION - (Standard Line Starter)This Ampgard starter uses the type LF50H730 con-tactor, type LFM7 isolation switch, type CLS700 cur-rent limiting fuses, and either type LFC current trans-formers or through type current transformers. Majorcomponents are arranged as shown in Figure (3) T

where a side view cf the starter is shown.The flew of power through the starter can be traced byreferring to Figure © . The line stab assembly mountedat the back cf the enclosure © serves as the starterline terminals. The stabs are engaged by the line fingers0 of the isolation switch, which is mounted on rails

at the top of the enclosure. The movable line fingersare connected to the upper fuse castirg by means of aflexible shunt © . Powder connections to the typeCLS700 power fuses © are through the line fingercluster © and fuss line stab © . The fuse load stabsO engage the fuse load finger cluster © in the

lower fuse support castings mounted on the contactor.Power flow through the contactor, located on rails Inthe bottom of the enclosure, is from the fuse supportcasting, through the bus bar to the contactor lineterminal © . through the blowout coil © , contacts© . shunts © , load finger cluster © . to the con-

tactor load stab © . These are connected by cable tothe current transformers and starter load terminalslocated on the left side of the enclosure.

ENCLOSUREAmpgard starters are supplied in a bas:c NEMA 1 steelfloor mounted enclosure that is 40" wide x 30" deepx 90" high. A 10" high main bus enclosure can beadded at the top which increases the total enclosureheight to 100". Each basic 90" high enclosure can ac-commodate one 25/50L7 Ampgard starter.

INSTALLATIONPrepare a level mounting per standard floor plan(Figure (2) ) or per special drawings supplied sepa-rately. Installation procedures are specified on200P026. a copy of which is supplied with this book'et.These recommended procedures will save you time ifyou follow them, f.n general, the cable connections canbe made by access through the front of the enclo-sure. Alternately, where there is access space behindthe installation, the rear cover of the enclosure can beremoved in order to aid wiring. Sufficient space hasbeen reserved near the left hand enclosure wall forhigh voltage line and load cables while low voltage

RATING TABLE Fig. 1

Contactor 8-HourEnclosed Rating

(VentilatedEnclosure)

— Amperes —

Horsepower Rating*Symmetrica! 3 PhaseAvailable Short Circuit

Capacity in KVA

Freq.Cyc.Starter Type Voltage Synchronous Induction

Motor100% P.F.| 80% P.F.190.000 KVA @ 2200 V216,000 KVA @ 2500 V2200-2500Ampgard 25L7 50-60 2500 2500650 3000

346.000 KVA @ 4000 V432.000 KVA @ 5000 V4000-5000 4500Ampgard 50L7 50-60 650 45C05000

'Typical H.P. Ratings. F.L. Current of Motor Must Not Exceed 650 Amp.

AtfPGARD STARTER - I.L. 11-202-5 .

HIGH VOLTAGECONDUIT S^ACE

(LOAD OtiVf )LON VOLTAGE

CONDUIT SPACE

1—1.5**r 1 62 *. 9.62- 1

\in m T6.25”

“ a— - 7 16- x 7 S * SLOT (3 8“ BOLTS)-'v.- -MAIN BUS

c

30-7c

1e_FRONT f ’T- 5"2"

3- -4I^ .75-TOP VIEW

(witli Main Bu^j

PREFERREDLOAD CONS*-*:!LOCATION

\ ? •* h 10"

8”r--H L— 2",

r- 2“i

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' r - s 7!PREFERRED

LINT CONDUIT" LOCATION : 15 "l

30"I

R{ MOVABLE U- SNGEYEBOLTS St ?- LiEDWIN OR wl*-I'JT —,

MAIN SUS ev.’LLOV» VOLTAGE

fOMHJl!SPACE PREFERREDl v cONtiri

LOCATION

/ MAIN BUS(WMtN SPECIFIED *;! 5nid.5'. -is5‘r'<?r i 1

:FRONT-iHIGH vGlTACiUI.NDIII: -FACELE*L AND L'lAC

r3 *—II A ITO** VIEWft. \iwntl'ou: VJUI Bui)

v.75" lSECTION 3 6(Ail location*. ff'-'juin;Cutting Top hr 5 a • DIA.

4 HOLES EACH 2DC; FOR MULTIPLE LINEUP

1C”r 3.52"=̂r] ij

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3 AVAILABLE XL V CONTROL SPACEJ •{WHEN USED

12"—lj ' “ pfcSAX.)!- j-3.62"

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LT- B9-9:25"_

i_ 9 5 _

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3 75"-,; -3 25 7.5"I V. V'LIA.JCONDt!: SPACE

7" r— 5.5"i .'UPPER LINETERMINAL?

, 1LINE15.5-.-i - 5.5”SrTERMINALSi23” i :

IIHIGH VCLTACf.. CONDUIT SPACEy//\ 'LINE. AND LOAD

FRONT

72.38"• A TALOAD ITERP.1INALS!93"r i

REMOVABLEREAR COVER

iLINE TERMINALST" /

SECTION A A(Avaii.icio C^ble Spjc*:) i 65”vs.

I ILOADTERMINALS

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IHIGH VOLTAGECONDUIT SPACE

P I F;I FOR THT F'.P"bCa” £B3Vt THE FLOOR JI IITI 56.38** i52 6?”

3”i •-1C * — i i i 1 4" x It 4"GROUND BUS

IWHEN SPECIFIED!- 6 i rIA-JL-. 9" 1”

45" [32.£2”

3 4” DIA.(4 P40UNTING HDI.ES/

1.25- -i

ji iLOW VOLTAGECOMP, DOOR 2338' —X iKiP3 in Max. S-«! Ext.j] for Roll-out 10”! t

14- 44P•’*-LOW VOLTAGECONDUIT SPACE

MAINSMARTER DOOR(HIGH VOLTAGE) I

: ofas is.* *• *7 •: AN-̂NV=^I-Jrti.TH VOL ‘SGL 27" Mj* Sill Hcign:

1of .Roll-cut• — 40”FRONT VIEW

r 30—RIGHT HAND SIDE VIEW1

CONDUIT SMu*1'lift:. AND LOAD

trilOMT

2.12"— FLOOR PLAN ; R.56” TO SWING* lV DOORW

2i .y TC SWIMH.V OOCfi

v* 1G- TO SWINGBLANK COMP ODOR 90

I01AL DOOR SWING I* '

Fig. 2.Mounting and Installation Dimensions of 25L7/ 50L7 AmpgardStarters ( Ret. Dwg. No. 657C727)

2

AMPGARD STARTER-11. 11-202-5

SAFETY INTERLOCKSBefore putting the starter into service, it is recom-mended that the user familiarize himself with the safetyinterlocks.Isolation Switch Handle — (See Figure (4) ). The isola-tion switch is opened by moving the handle through avertical arc from the ON to the OFF position, and fromthe OFF position, is can be rotated 90 counterclock-wise to the HORIZONTAL, cr door open position.In both the ON and OFF positions a portion of thehandle housing extends ever the enclosure door, andthus prevents the high voltage door from being opened.To open this door, the handle must be moved to theHORIZONTAL position.With the handle in the OFF position, either a singlepadlock or up to three padlocks locked in place willprevent the handle from being moved to either the ONor the HORIZONTAL position, thus preventing both un-authorized entry into the high voltage compartmentand accidental closing of the isolation switch whilemaintenance work is being done. From the HORIZON-TAL position, the handle cannot be moved to the ONposition,.without first moving to the OrF position.

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The operating handle has three distinct positions.In the ON position (A), the isolation switch isclosed, the high voltage door is locked shut, and thestarter can be energized.In the OFF position (3), the isolation switch is open,the high voltage door is locked shut and the starteris de-energized and grounded.With the handle rotated 90° counterclockwise (C) tothe HORIZONTAL position (D). the isolation switchis open, the starter is de-energized, grounded, andthe door to the high voltage compartment can beopened.

Fig. 4Isolation switch operation

Fig. 3Section view of a non-reversing line starter in de-energizedposition (Numbers are referred to in text)

AMPGARD STARTER - 1.L. 11-202-5

Door interlocks — With the isolation switch handle Inthe HORIZONTAL position, the high voltage compart-merit door can he opened. As soon as the dcor opens,a mechanical interlock becomes effective. It is de-signed to prevent the user from accidentally operatingthe isolation switch handle and closing the starter onto the line with the enclosure door open.

This interlock is a spring loaded plunger located justbehind the door. When the door is ooen. it extendsand prevents the handle from being accidentally movedto the OFF position. If the user wishes to observe theoperation oi the isolation switch during installation ormaintenance, this interlock must be deliberatelycheated to move the handle to the OFF position. Thisis done by depressing the plunger with a screwdriverwhite moving the handle.Caution — Tills action allows the user to close theswitch on to the line stabs. He should be fully aware ofthe hazarcs. familiar with the operation of the switch,and take all appropriate safety precautions. Thehandle must be returnee to the HORIZONTAL positionto close the high voltage ooor. Moving the handle fromthe vertical OFF position to the HORIZONTAL positionautomatical!', resets the interlock.Contactor — [sodat ten Switch Meehan ?(see Figure (5) ). Tne type LFM 7 isolating switch func-tions only r i? a disconnect • - h must never close on toor interrupt a rower loa.1. To prevent this, i mechani-cal interlock between contactor and isolating switchis orevideo*, if the coniac

••Tiar'ock —

s ciusod. the interlocklever on the contactor aoratere actuates a mechanicallinkage that locks the handle operating mechanism ofhe switch. This is a positive interlock - - it cannot be

cheated without disassemble of the interlock.

Fig. 5Contac?oi-iiCU-*!-.-:‘ s-.viic* - I- ICCk (Photo 69-0272)!*

soia^on Switch Insulating Shutter — As the isolationswitch is opened, an insulating shutter slides acrossthe insulating rear barrier to prevent any accidentalaccess to the lice bus. Tibs shuf - v-r is mechanicallydriven and thus is positive in action. As the shutterslides across the openings to rho line stabs, warningstripes appear. When the isolation switch is fullyopened, the line fingers are retracted from the linestabs and connected to the ground bar. grounding thefuses.T'nr: shutter and grounding fingers nrv vir,ih! ~ from theiron* of the enclosure, crd should bo checked as a

prora - :V;r..

i

insuiatj: vformer. 7» .c above the trans-

;upp!ies 115 VACto the ungrounded cor,tail rircuis tnrouch 10-amperefuses mount • 1 or* the ;:>d f. ! r •m‘actor frame. (Insome cases the secondly w .iinur? .5 230 volts.)

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^ o-. -.ntrol transformer, theTo energize the primary o!contactor must be pushed ir:Sp ih.;; enclosure, the main

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power fuses must be ir.staMo.-1. urv: the isolation switchmust bo ON.

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Test-Run ?ii;^ — For coir..:;.* t -no. * curing maintenance,when it may odosiradio iu *.the control circuit orly. a c, piug with 2 test

nvdod. T- * •

C :Ze the contactor orCONTROL PANEL AND LOW VOLTAGE COMPONENTScomponents Comprised r > f livg interpos-

ing relay, protective relays and rectifier are mountedon a fixed panel located on the right hand side of the

o The control power transformer, nominally4Of, VA. single phase, is bulled to the L.H.

contactor frame and comer; out wild the* contactor.7hc> primary r - f the control transformer is connected tothe f ine through the isolation swi'ch and power fuses,

and rs protected by too current limiting fuses mounted

T: positionplug from iis socket. (und< *r die r - — vol transformer onthe contactor), and plug « t i.- rsingle phase c-xton-Jon <:u»d.provided when specifier, b,- : r .,:

• •:« v disconnect thei< J // < >• *

a 60 cycle, 115 voltc.'./-voial plugs may be: s

r.- r!o'V ,*

.- ary circuit and re-•. contactor before

Caution - Disconnect th: -. r - v?

store the plug l% > iis $ •?>..returning the ;rii? to so.'/: i :

4

AMPGARD STARTER ~ 11. 11-202-5

SHORT CIRCUIT AND OVERLOAD PROTECTION 7) AM possible safety precautions have been taken,and the installation checked for conformancewith applicable safety codes.

Electrical protection is provided by the Type CLS 700power fuses and the overload relay. The CLS 700 cur-rent limiting power fuses have a special time/currentcharacteristic for motor service, and this characteristicis coordinated with the characteristic of the overloadrelay. Currents greater than full lead motor current, upthrough locked rotor current, will operate the overloadrelay and trip the contactor before the fuses blew. Thisprevents unnecessary blowing of the fuses. Since theinterrupting capacity of the contactor is 75.000 KVA, thepower fuses must operate faster than the overloadrelay when current exceeds this value, in order toprevent damage to the contactor. In all faults above75,000 KVA and within the rating of the equipment, theCLS fuses will operate first.The current transformers, overload relay heaters, andpower fuses are coordinated with specific motor char-acteristics. Therefore the starter must be used with themotor for which it was designed. Motors with specialcharacteristics or loads requiring special protectionoften require other or additional protective relays. Con-sult the instruction leaflet for the particular relaybefore attempting any adjustment or service.

Isolation Switch — Be sure that:1) The power fuses have been properly Installed.

See the permanent operating instructions on theinside of the high voltage door.

2 ) The mechanical interlocks operate freely andare properly adjusted in order to provide theintended protection. See maintenance and repairsection of this instruction leaflet for adjustmentprocedures.

Contactor — Be sure that:1) The blowout irons are forward and down. If the

arc boxes won't go into place, the blowout ironis probably in the wrong position.

2) The arc boxes are in their proper operating po-sition. Push them firmly into place to be surethat the knife blades engage the knife jawsmounted in front of and behind the main contacts.

3) THE FOUR CONTACTOR PHASE BARRIERS AREINSTALLED.

START-UP PRECAUTIONS4) The drawout latch on the lower left hand side of

the contactor is encaged.5) The magnet armature and moving contact system

move freely.

Before attempting to put a newly installed starter intoservice, study the wiring diagram 2nd available in-struction literature.

General Precautions — Be sure that: Control Circuit — Be sure that:1) The corresponding starter and motor are con-

nected as shown on the Westinghouse drawings.This is particularly essential in this class ofmotor starter as the fuse ratings, current trans-formers. and overload heater elements are basedon the characteristics of the particular motor tobe controlled.

2) The starter is connected to a suitable powersupply with characteristics agreeing with motorand starter nameplate data.

3) The motor and machine it drives are properlylined up. bolted down, lubricated, free of ob-structions. and ready to go.

4) Connections are r.eat, tight, of proDer capacity,and in agreement with the wiring diagram.

5) Equipment has been cleaned of dirt, scraps ofwire, tools, and all other foreign material.

6) THE INSULATION LEVEL OF THE STARTERSHOULD BE CHECKED BEFORE THE STARTERIS ENERGIZED. Refer to the maintenance andrepair section of this instruction for additionalinformation regarding the checking of insulationlevel.

1) The high voltage and low voitage control fusesare properly installed.

2) The female low voltage control plug from thelow voltage control pane! has been pushed intothe male control socket on the contactor.

3) The test-run plug on the contactor is pluggedinto the receptacle on the control transformerpanel.

Close the high voltage door, the low voltage door,and then tighten the door latches. Move the isolatingswitch handle from the HORIZONTAL to the OFF posi-tion. The Ampgard starter is now ready tc be energized.

AMPGARD STARTER - I.L 11-202-5

MAINTENANCE AND REPAIRTo do this:

1) Remove the power fuses.2) Lift the contactor latch on the left hand side of

the contactor, and pry the contactor from its stabconnections, using a “Jiffy Bar”, as outlined inthe installation instruction.

3) Carefully pull the contactor toward you. to thedetent position, which is about 3/4 of the way out.It will again be stopped by the contactor latch.In this drawout position, all routine maintenancecan be carried out. For major overhaul, the con-tactor can be completely removed from the en-closure by taking two more steps:

4) Remove the low voltage control plug from theR.H. side of the contactor.

5) Press down on the contactor stop latch and rollthe contactor out of the enclosure onto the floorusing a “Jiffy Bar’ *, as shown in the installationinstruction.

GENERALAmpgard starters should be operated by authorizedpersonnel only. Personnel authorized to operate theisolation switch and those authorized to inspect, adjust,or replace equipment inside the enclosure should havea complete understanding of the operation of thestarter, and must have thorough training in the safetyprecautions to be followed when working with all highvoltage equipment.A maintenance program should be established as soonas the starter has been installed and put into operation.After the starter has been inspected a number of timesat monthly intervals and the conditions noted, thefrequency of inspection can be increased or decreasedto suit the conditions found, since this will dependupon the severity o* the duty.Before attempting maintenance, consult the specificdiagram and the general 2nd specific device instructionleaflets. These are listed at the end of this leaflet.The photos in the installation instruction (200P026) willaid you in understanding this section.Insulation Level — After installation, and before ener-gizing the starter for the first time, the insulation re-sistance between poles, and from each pole to groundshould be measured and recorded. It is not practicalto specify an absolute value for this reading since it isdependent on other connected apparatus and con-ditions of service. However, any unusually lew readingor abrupt reduction in a reading would indicate apossible source of trouble, and the cause should beinvestigated and corrected.Fuses — The Type CLS700 current limiting fuses shouldbe inspected after each fault-clearing operation, sincethis is the most severe service to which they will besubjected. Check the fuse resistance, and comparethis value with a new fuse. Visual indication of a blownfuse is provided by a colored indicator in the top ofthe fuse. This indicator pops up and is visible whenthe fuse is blown.Blown fuses may be removed and replaced by usingthe fuse puller mounted cn the L.H. upright, just insidethe high voltage door.The correct procedure for replacing fuses is describedcn the instruction sheet (N'P 20CPC27H01) 'which ispermanently fastened inside the high voltage door. Thisinstruction sheet also lists the correct fuse rating andfuse part number for that particular starter. The sametype, rating and part number cf power fuses must beused for replacement in all cases.If for any reason, there is doubt about the conditionof a fuse, a simple test is to check its electrical con-tinuity and resistance.

Contactor — The Type LF50H730 contactor contactscan be easily examined by simply pulling the arcchutes forward to rotate them out of the operatingposition. To make a more detailed examination, toreplace contacts, or to carry out any maintenance work,the contactor can be withdrawn from the enclosure toa drawout position.

TYPE LFM-7 ISOLATION SWITCHRemoval — Any maintenance beyond visual examina-tion should be carried out with the switch removedfrom the enclosure. This will avoid the possible hazardof closing the switch on to an energized line when themechanical interlock has been cheated manually.

To remove the isolation switch from the cabinet:1) De-energize main power feeder, or take pre-

caution noted below.

2) Open the isolation switch.3) Remove the Tyoe CLS 700 power fuses.4) If more accessibility is desired, remove the Type

LF contactor.5) Remove the two bolts located on top of the brace

supporting the isolation switch front casting.6) Slide the isolation switch cut cf the cabinet.

Caution — While it is safe to remove the contactorand isolation switch from the enclosure with the mainline bus energized, once the isolation switch has beenremoved, the fine stab assembly at the back of theenclosure is uncovered, is energized, and is thus ahazard. Be sure to close and !atch the doors, anddisplay a DANGER - HIGH VOLTAGE sign on theenclosure.

Examination (See Figures (3) and (6) ) — With theisolation switch on a table or bench, check the followingpoints:

1) Move the operating handle through its full rangeof operation from the HORIZONTAL position,through OFF to CN (the doer interlock has to becheated manually). The handle and all of theoperating mechanism of the switch should movefreely, without binding. This includes the inter-lock mechanism behind the handle, the linefingers and carrier, the insulating shutter at the

6

AMPGARD STARTER - I.L. 11-202-5

loosening the adjusting clevis © . Make surethe cotter pin is reinstalled in the clevis pinafter this adjustment.

4) Adjust the position of the ground bar © sothat the grounding fingers - © are deflected bythe guide rail © and the phase barriers arepushed tight against the rear insulating barrierof the switch.

5) With the handle rn the OFF pcsition, move thecam follower mounting bracket attached to theguide rail ® toward the operating handleuntil the tip of the shutter operator extendingthrough the shutter just touches the left endof the slot in the rear barrier.NOTE — Make sure the cam follower is centeredvertically on the shutter cam. and its line oftravel parallel with the shutter cam. Tighten allbolts.

6) With the starter incoming power line de-ener-gized. install the isolating switch in the enclosure.With the interlock link pulled up against the inter-lock stop bracket (see Fig. (5) ). check that thelatch clearance in step (3) above, is maintained.If not. adjust the length of the link to suit.CAUTION — Since this is an interlock adjustmentprocedure, the adjuster should be sure that theincoming power line to the starter is not ener-gized. as the Interlocks will not provide 2nyprotection.As a final check, install the contactor along withthe isolating switch. With the incoming power linede-enercized, check that: a) the isolation switchcan be operated normally when the contactor isopen, b) the isolation switch handle cannot bemoved from either the ON or OFF position whenthe contactor is closed. The contactor can beblocked closed mechanically or energized froma separate control supply, through the test prug.

back of the switch, and the shutter operator.Make sure the Fiex-Loc nut fastening the carrierlink © has full thread engagement, but allowsthe link to pivot freely.

2) With the handle in the ON position, the ends ofthe tine fingers should project through theopenings in the shutter and rear barrier.

3) When the isolation switch interlock extension rod(see Fig. (?) ) is pushed toward the front of theswitch( wthe mechanical interlock mjst lock thehandle mechanism, preventing handle movementin either the OFF or ON position. In the OFF po-sition. it is norma! for the shutter to openslightiy when an attempt is made to force theinterlocked handle. The shutter should nevercome in contact with the line fingers.

Isolation Switch Adjustment — Normally, the isolationswitch wit! not require any adjustment ; however, if forany reason parts are removed or replaced, it may benecessary to make seme adjustments in the switchmechanism. The adjustment procedure is as follows:

i) (Nos. in text refer to figures (3) & (6) ). Removee bolt and Fiex-loc nut fastening the carrier

to the carrier © . With the handle in‘ V -i i

©linkthe ON position, turn the carrier link in or out ofthe handle clevis © until the line fingers ©

beyond she rear barrier by 2.IS r1 .12icenofi. Tighten the Fiex-loc nut only enough tooncone a!' its threads.

i .

Fr.k © ar>d Q'uide rail© to obtain 1.62 • .12 inches from the top of

the line fjngc-rs to the inside rim of the rearinsulating barrier, ( see Figure (5) ). Tighten theboits fastening these two pieces.

t oe : T:S a:

3) Adjust the rocker latch © so that when thehandle moves from tha OFF to the ON position,the rocker iatch clears the handle clevis © by.03 to .05 inches. This is cone by tightening cr

Opening the High Voltage Door Under AbnormalConditions — In the unlikely event th2 t either the isola-tion switch line fingers cr the contactor contacts shouldweld closed, cr if any other event should occur suchthat the isolation switch handle cannot be moved fromthe ON to the OFF position, provision has been madeso that the high voltage door can be opened in anemergency, i he doer can be opened by using thefollowing emergency procedure.

1) Make sure that the incoming power line to thestarter is de-energized, to avoid a hazardoussituation when the door is opened.

2) Remove the four screws holding the rectangularhandle housing cf the isofation switch to thefront casting.

3) The complete handle housing can now be pushedup far enough to provide clearance for the door.The door can be opened and any emergencymaintenance carried out. The handle housingcannot be removed — it is held by a retainingscrew installed from the rear of the front casting.

Contactor Adjustments — All adjustments pertainingto the contactor are described in the contactor in-struction leaflet !L 16-200-7.See page 8 of this instruction for list of publications ofdevices used in this starter.

;•- •• *-•»_

' .

Fig. 6Type* LFM-7 (solution Switch Interlock Mechanism

fPhoic 69-0274 )

f

AMPGARD STARTER - I.L. 11-202-5

LIST OF PUBLICATIONS APPLYINGTO DEVICES USED IN THESE STARTERS

Device Instruction Leaflet No, Renewal Parts Data No.Type LFM7 Isolation SwitchType LF-25H730 & LF-50H730 ContactorsSlipsyn Synchronous Motor ControlAmpgard Installation Instruction

This InstructionIL 16-200-7IL 14-000-1B200P026

LFM-716-200A7

Westinghouse Electric CorporationGeneral Control Division3uffalo, New York 14240

Printed in U.S.A.7-69