SpaceMaker IIPowerPlugs&RearRackingShaft CarriageRackingHooks DoorHandle& SideShaft •RACKINGSHAFTINTERLOCK INSTALLINGTHEINTERLOCK CARRIAGESTOPSAFETYLEVER CARRIAGEPOSITIONINDICATOR

t §

SIEMENS i fw

SpaceMaker IIMOTOR

CONTROLLER

W A R N I N G

Dangerous voltages are present inside controller compartments.Always use safety precautions when entering.

De-Energize all incoming power if conditions exist which are thecontrary to those described in this instruction book or which areotherwise unusual. ICD 6031-01A20X2850-04

www.nationalswitchgear.comCourtesy of NationalSwitchgear.com

CONTENTSPage PageINTRODUCTION

GENERAL INFORMATION ....WARRANTYGENERAL DESCRIPTION

Door HandleAutomatic Shutter MechanismSeparately Accessible Control Compartment . ...2

RECEIVING .INSPECTIONSTORAGE ..

ADJUSTMENT*•FUSE REPLACEMENT•ARC CHUTES•LSI, GUIDE PLATE, and ANTI-RACKING

MECHANISM•CARRIAGE RACKING MECHANISM ... .

Power Plugs & Rear Racking ShaftCarriage Racking HooksDoor Handle & Side Shaft

•RACKING SHAFT INTERLOCKINSTALLING THE INTERLOCKCARRIAGE STOP SAFETY LEVERCARRIAGE POSITION INDICATOROPERATING CIRCUITSCONTACTOR DROPOUT TIMESERVICE DOLLYCARRIAGE DISCONNECT

FINGER ASSEMBLIES•EMERGENCY ENTRANCE

1 101 1012 112 12

132 133 133 13

1415

INSTALLATIONCUBICLE MOUNTING. ...CONNECTIONS

Control ConnectionsEQUIPMENT CHECKOUT

ElectricalMechanical

153 163 166 1666 166 16

OPERATIONK'ORMAITEST

MAINTENANCEGENERALCARRIAGE RACKING MECHANISMAIR-BREAK CONTACTORTROUBLE SHOOTING CHARTPARTS IDENTIFICATION

99 17

1718-2425-27

*Pay close attention to these pages. This information is very important.

The information contained within i9 intended to assist operating personnel byproviding information on the general characteristics of equipment of this type. Itdoes not relieve the user of responsibility to use sound Practices and SafetyProcedures in the installation, application, operation and maintenance of theparticular equipment purchased.If drawings or other supplementary instructions for specific applications areforwarded with this manual or separately, they take precedence over anyconflicting or incomplete Information in this manual.

\SIEMENS-ALLISP.O. Box 89, Wichita Falls, Texas 76307


INTRODUCTION

GENERAL INFORMATIONThis Manual provides complete instructions on instal -lation , operation and maintenance , and will be of valueonly when read and applied by all personnelresponsible for the equipment.

rear - mounted , isolated , low voltage control devicecompartment.

Two full voltage squirrel -cage motor controllerscan be mounted one above the other in the 36 -in. wide.32 - in. deep, 90 - in . high cubicle. Each controller has afull rating of 1500 hp maximum at 2300 volts or 2500 hpmaximum at 4000- 5000 volts. At unity power factor , themaximum ratings of synchronous motor controllers are1750 hp at 2300 volts and 3000 hp at 4000-5000 volts.With current limiting fuses , each controller has aninterrupting capacity of 200 MVA at 2200- 2500 volts or350 MVA at 4000- 5000 volts.

Mounted in the high voltage compartment are thecurrent transformers, stationary disconnect plugs ,shutter and racking mechanisms, line and load

Pay particular attention to the information aboutinterlocks and their adjustments. These paragraphs arestarred.

WARRANTYSee sales contract .

GENERAL DESCRIPTIONEach SpaceMaker If controller consists of a stationary ,rigid, self-supporting steel enclosure with a fronthinged , high voltage compartment door containing a

inMin* AUI*

•"MfNS *UI1

Fig 1 •Single and two-high SpaceMaker II controller for squirrel-cage motors.


Separately Accessible Control CompartmentThe isolated low voltage control is accessible through ahinged door in the high voltage compartment door.Access to the control compartment is permitted at alltimes for operational inspection by turning the twosiotted -head V\ turn latches. This compartmentcontains all of the control and metering devicesrequired by the particular application and permitted byspace limitations.

connections, mechanical and electrical interlocks, andthe drawout contactor. The contactor itself mounts thecurrent limiting power fuses , the movable disconnectfingers , the control power transformer with two currentlimiting primary fuses and two secondary fuses , adouble - throw (test - normal) knife switch and a discon*necting control terminal block. (A separate manual isavailable with information on the contactor - ICD6030.)

Door HandleRECEIVING — Handle With CareConvenient operation of the racking mechanism is pro-

vided by the externally operated door handle whichrotates 180 degrees from the contactor “Connected” tothe "Open ” position . A coupling on the door handleassembly permits opening the door only in the door“Open” position. An indicator on the handle givespositive indication of the mechanism position: that is ,carriage “Connected” , carriage “Disconnected” , ordoor * ‘Open’ * . The door handle can be locked with up tothree padlocks in either the “Connected ” or “Dis-connected” position.

Before moving or unpacking any units, examine allshipping sections to determine if any damage has oc-curred in transit . If damage is detected , unpack the unitand thoroughly inspect the contents for damage. (SeeInspection.) The contactor carriages and the controllercubicle are shipped in separate packages. Check theentire shipment against the packing list for anyshortages , Determine the extent of the damage orshortage , if any, and notify the carrier and yourSiemens- Allis sales office immediately.

Automatic Shutter Mechanism The cubicles and carriages are shipped on separatewooden bases. Move the cubicles by lifting with a craneusing the lifting angles provided. Lift the carriages asshown in Fig. 3. Do not lift with racking hooks at rear ofcarriage. If no crane facilities are available , rolling orother methods may be used , but apply force only towooden shipping pallet. Do not place carriages intocubicle until the units are at the permanent location , allthe suggested inspections have been made , and the

Installation” Section of this book has been read. Ifunits will not be used immediately, see “Storage”.

An isolating shutter covers the line terminals when theracking mechanism is in the carriage “Disconnected”or the door in the “Open” position. This preventsoperating and maintenance personnel from accidentlycoming into contact with the live line terminals.

4 I

OVERLOADRELAY

i

Fig. 2 - Overload relay mounted in the SpaceMaker IIcontroller front access compartment.

-2-


c. Check that the control transformer primary fuses areproperly positioned in their respective clips and arenot damaged.

d. Operate the contactor manually by pulling down thearmature of the magnet to close the contacts. Uponreleasing , the movable contact assembly should fallfreely.

e. Check the control panel on the side of the contactorto assure that all wire connections are secure andthat the circuit is in good operating condition.

f. Check the condition of the arc chutes.g. When more than one controller is involved in an

installation , make certain that each carriage ismatched with the nameplate in its respective com-partment . A stick -on nameplate , provided on thecarriage and the compartment , gives the followingdata: controller part number, carriage part number,controller rating, control transformer and currenttransformer ratios, fuse ratings, overload relay set -ting and wiring diagram drawing number.

I

^i/ i'M,

M ViTViUBiFig. 4 - Remove this shipping angle only after cubicles have

been mounted and leveled.

INSPECTIONRemove all packaging, blocking, and external bracing.Do Not remove the angle iron brace (See Fig. 4) acrossthe bottom of the front of the cubicle opening until theunits have been leveled and bolted into place. Inspectas follows:a. Check all components for evidence of loose bolts ,

nuts, accessories, freedom from distortion and forgeneral good condition.

b. Inspect the main power fuses for proper mounting.The fuse clips should also be checked for distortion.

STORAGEIf the controller will not be installed in its operatinglocation , store it in a clean , dry place along with thecarriages. Never store the controller and carriages in anenvironment for which they were not designed. If spaceheaters are furnished, keep them energized.

ter INSTALLATIONCAUTION

Controllers must be installed on a flat, level foundation.Slope, if any, must be toward the rear. Slope must not exceed 1/8 inch.

CUBICLE MOUNTING not equal within 1 /8”. Also examine alignment , perpage 7.The importance of mounting the cubicle on a flat and

level foundation cannot be overstated. All four cornersof the cubicle must be touching, securely bolted , andcontinuously supported across the front and back. Pro-vide an apron extending a minimum of three feet on thesame level as the front of each cubicle for inserting andremoving the carriage . Install the extreme left handunit at least 14” from any obstruction to allow thecompartment floor to swing wide enough for thecarriage movement in or out . Remove all temporaryblocking, packing, ties , retaining tape, etc. from alldevices and mechanisms. Remove the angle iron (Fig.4) across the bottom of the front of the cubicle. This wasonly a temporary shipping brace and can be discarded.If the side lift angles were used , remove these andreplace the hardware furnished in the bolt holes. Touchup any scratches with the spare paint provided. Correctany cubicle distortions, installation or shippingdamage, etc . if diagonal measurements of cubicle are

CONNECTIONS(Refer to Figs. 5- 11 and Tables I , II and III)Make all incoming power , load , and control connectionsin accordance with the information given in these tablesand illustrations. Make all connections as indicated inthe connection diagrams. The cable arrangementsgiven for incoming line connections are maximum sizebased on compartments being free of incoming lineaccessories.

However, a limited number of accessories (e .g.potential transformers , current transformers, lightningarrestors , surge capacitors, etc.) may be used depend -ing on the size of the accessory and the available space.Consult the factory when numerous devices arerequired in incoming line compartments.

For units without bus, the incoming cables are con -nected to the line terminals in each compartment of a

“3—


two-high controller. For a single controller in the lowercompartment, the incoming cables are connected to theline terminals in the lower compartment. In all cases,the outgoing motor leads connect to the currenttransformers, located on the left -side wall of thecompartment.

3 CONOUIT SPACE INFIXED TOP PLATEtI zriinr.z

rafrfr -“BUS 20

DUCT

2-t TOP VIEW36* or 24-

WIDE CUBICLE7/8 ** 1234 1/4 T1 LINEUP CAN BfEXTENDED IN £ ITHER^DIRECTION

ft>

*•fV 7\/ .CONOUIT SPACEIN FLOOR

/

CONOUITSPACE

IN FLOOR

3 FRONT VIEWVERTICAL ENTRY OF CABLE

3 R8 CD«D/ \

NOTESXJ1/ \/ •1- INCOMING LINE CAN ENTER FROMEITHER END Of LINEUP .

* 2-llN{UP CAN BE EXTENDED ONLYON OPPOSITE END Of INC . LINE .

p

1 CONDUIT SPACE INBUS DUCT END COVERI In5 *7-26- 17?4DUCTI l/J FLOOR PLAN «*> FLOOR PLAN(Sin

36 O* 24"» 5 0 1 1 /7-l 5 '8 2 13 3 2 0 2i 1 WIDE CUBICLEI5 14 -S I 4 i96Jjk:p - “rX\C0NDUIT SPACE

IN TOP OFCUBICLE

*2r”-P"-- x LX- J

1 "T 3Tli -f -VISIDE VIEW FRONT VIEW-J L —iI 1

HORIZONTAL ENTRY OF CABLE: r — —I 1---1-_-_x“T- 1 CUTOUT INBOTTOM OFBUS DUCT

1

fig. 7 - Cable Entrances (Refer Table III).TOP VIEW TOP VIEW

4 I*— 36 - - 2 4 - -

i 1E2 4T f ''TVW > f BUS 20DUCTW XT.SEE TABLE I == =Lr — -CONDUIT SPACEIN TOP

FRONT VIEW FRONT v IE wTOP VIEWCABLE ENTRANCE IN

FULL HEIGHTM 36WIDE INCOMINGLINE CUBICLE

CABLE ENTRANCE INFULL HEIGTH 24-WIDE INCOMINGLINE CUBICLE

24 362 24

pFig. 5 •Cable Entrances (Refer Table I). CONDUITSPACE IN BUSDUCT END "COVER

! ((1 >101I 1 .\ \ 116to 7JAJ c :::B

5 OO oSIDE VIEW FRONT VIEWJ 1 h>P. P-4 1i (NON-SHIELDED CABLE)VERTICAL OR HORIZONTAL ENTRY OF CABLEBUS joDUCT JL_„PT 24 36-•ACONDUIT SPACE

IN BOTTOM-'-'"'" ItDI 3tVi 24AtTOP VIEW CONDUITSPACE IN BUS

DUCT END >COVER .

I

20 « - 1 •REMOVABLECOVER PLATE 14~ *r* r% r* -—s\ -1 4t 1 I4 4i i 4 M lH 11U U

(SHIELDED CABLE )VERTICAL OR HORIZONTAL ENTRY OF CABLE

INCOMING LINE TOBUS COMPARTMENTTOP ENTRY WITH TOP HAT

f:O («FRONT VIEWSIDE VIEW

Fig. 8 * Cable Entrances (Refer Table HI).:ig. 6 - Cable Entrances (Refer Table II).— 4 —


MAXIMUM CABLE SIZE PER PHASE

Shltldtd With |Siren Con#si Potheads(4 ) 500 MCM ! (2) Size 750 MCM

Cubic 1«Width Eni!3L Nonshleldtd

Top ( 4 ) 500 MCM36*'Of Of

( 3) 750 MCM 750 MCM: 6' 500 MCM ( 6i 500 MCM ! (2) Size 750 MCM36” BoHorn of Of'4 ', 750 MCM t f 4 * 750 MCM

500 MCM (2) Size 500 MCM24” (3 ) 500 MCMTooOf or

(2i 750 MCM(2) 750 MCM( 2) Size 750 MCM24” Bottom i ( 4 ) 500 MCM ( 4) 500 MCM

oror212186

Fig 9 * Cable connections for incoming line and outgoing motorconnections Shutter removed to make incoming cabie terminalsaccessible

(3 ) 750 MCM(31 750 MCM

TABLE I Figure 5 * 24 or 36 inch auxiliary cubicle.

£

*-*I I Shi »1 dad WithEntry 1 Nonshitldad i Strosi ConesCubicleWidth RemarksMax. of 3bus feed C.T.mounted inbus duct

i

| < 3 > 750 MCM j ( 21 750 MCMBottom : per phase | per phase1C”

I*

_TABLE II Figure 6 * Incoming line through vertical bus duct on

either end of lineup.

"1Shielded WithStress ConesEntry Orifice Nonshielded Remarks

(1) 250 MCM 12” Wide topplate24M W x 10"H top hat

20X 6Vertical

20X16 [ 2 ) 750 MCM (2) 750 MCMVertica I

(1) 250 MCM(2) 500 MCM

Horizontal 20X 6Horizontal 20X16 (2 ) 500 MCM 24” W x 10°

H top hat

TABLE Ml Incoming lines to bus compartment maximum cablesizes per phase. Figures 7 and 8

223015Fig 10 - Line cables internally connected between upper and lowercompartments.

When a nine-plug carriage used on reversing controllers is furnished , stub cables are provided for thecustomer to connect the incoming line to the lineterminals.

When a two* high (Style Y ) controller is furnished ,the interconnections between the upper and lowercompartments are factory installed. When the con-troller is furnished with a bus, interconnections fromthis bus to the line terminals are factory installed. Theinsulated tube furnished only on two- high controllers ,permits pulling motor cables through an energizedcompartment .

l

NOTH: All ' line terminals are energized unless theincoming line is opetied.

If larger size incoming cables or more cables perphase (See Table I ) arc required , a special compart -ment can he supplied. These additional compartmentscan also provide the space requirements for metering ,potheads. current transformers, etc.

— 5 —


Control Connections*4 . Check remote sequence interlocking connections for

correctness of contact and make certain conduitwiring is not grounded. ( Extremely long remote con -trol runs in conduit of a few hundred feet or moremav prevent the control relays from dropping opento stop motor because of capacitance between wiresin the conduit . If this condition exists , use inter -posing DC control relays. Consult factory regardingthis situation. )

5 . Exercise extreme care that all secondary circuits ofcurrent transformers are closed. The open circuitscan occur when instruments are shipped separatelyor are mounted reinotclv.

6. Check all control devices for any foreign matter.All devices must be free to function normally.

4

7 . Check all fuses for continuity and proper rating.(See page 10 for fuse replacement . )

8. Check settings on all protective relays using appro-priate instruction manuals.

Remote control or metering connections are made tothe terminal blocks located on the left -side wall of thecompartment and are accessible from the low voltagecontrol compartment . If the control devices are locatedin a separate compartment , the remote connections willnormally be made to terminal blocks located in thatcompartment. Be sure to remove any temporaryjumpers when connecting the remote devices.

EQUIPMENT CHECKOUTCheckout all equipment systematically prior to engi -neering and placing in service . This checkout can beperformed by the installer or operator or contact yourSiemens Allis sales representative for a quotation forthe services of a serviceman. The following is arecommended check list sequence :Electrical1. Check all high voltage cable ( including factory in -

stalled) for rght and proper connections. Make sureall proper mechanical and electrical clearances havebeen maintained.

2. Check all power connections behind protectivebarriers or shutters.

3. Check all external power and control connectionsagainst wiring diagrams.

Mechanical1. Match the fused carriage with the corresponding

cubicle. Check the rating data of the label on thefront left - hand side of the carriage with the inside ofthe compartment door.

SHUTTER

MECHANICAL*̂ 4jy'lNTERL0CKi J \l iMAIN LEAbSTATIONARY

PLUGS

CONTACTOR /GUIDE TRACKS

ELECTRICALINTERLOCK

Fig 12 - Note Label “FRONT"Fig 11 - Layout ( f SpaceMaker 2-high (Style Y ) controller compartments.—6 —


REAR SHUTTER SHAFTRACKING PINS

ACUBICLEREAR SHEET

MECHANICAL RACKINGINTERLOCK

1—a11-1 'Bi r * - s ir -GUIDE PLATE/ (MUST BE LEVEL)

SHIMMING WASHERSNOTES 1 ADJUSTMENT TO BE MADE WITH SHUTTER MEOIANISM IN FULLY CLOSEO

POSITION (SIDE SHAFT FLAT UPWARD)2 CARRIAGE GUIOE RAIL ON GUIDE PLATE SHOULD BE PERPENDICULARTO THE R E A R SHUTTER SHAFT3 LSI SHOULD BE PERPENDICULAR TOGUlDE PLATE TO ADJUST. ADD

SHIMMING WASHERS 00 NOT BEND THE SUPPORT BRACKET ORTHE SPRl^C CONTACT

Fig. 14. •Line switch interlock and racking interlock dimensions.

4»F0R 9- PLUGCONTACTOR 7[1] Guide Plate or Support Plate\2\ Guide Rail(3) Hold down bolts(4] Anti-racking Interlock|5] Line Switch Interlock |LSI)[6| Shutter Panel[7) Racking Pins[8) Side Shaft (note flat spot 8A|[9) Rear Shaft

o

RACKINGSHAFT

ITT O3Doz

1*STATIONARYPLUG TERMINALS f(£>£ OTOP or SUPPORT

PLATEFig. 13 * SpaceMaker II Controller Cubicle.

i .\2. Check arc chutes in carriage for proper placement.Examine chutes to make certain they are not crackedor have pieces broken off. If any pieces are missing,check contactor carefully for any fragments that mayhave fallen into the mechanism. Any foreignmaterial that prevents contactor operation could endin extensive damage. (See page 10 for arc chuteplacement.)

3. Check contactor and fuse interphase barriers. (SeeFig. 12. ) Barriers must be in place with the edgeslabeled “front” as shown.

4. Check racking interlock manually to assure freemovement. Check spring for proper placement . (Seepage 11 for adjustment.)

With the spring in place and the plunger stillnot operating freely, check for binding of the inter -lock mechanism.

Some special controllers , such as reversers .have two-high and / or side by side units with inter -compartmental linkage between anti- racking inter -locks that prevent opening any one compartmentdoor when any of the contactors in the other com-

SIDE VIEW

Fig. 15 * Alignment of stationary plug terminals on rear compartment wallshould be checked before inserting carriage.

partments are closed . Consult factory for adjustmentof these multi- linkage interlocks.

At this point , check the guide plate (supportplate). This plate , the LSI and the interlocks havebeen factory adjusted. Check dimensions as shownin Fig. 14. (See page 11 for adjustment . )

5. Rotate the side shaft of the cubicle to make certainthat the shutters move freely. Check alignment ofthe stationary power plugs on the rear compartmentwall according to the dimensions shown in Fig. 15.(Illustration shows a nine plug carriage.) The dimen-sions to the centers of the plug terminals are meas-ured from the top of the plate which supports thecarriage wheels. (See page 13 for adjustment.)Leave the side shaft in a position with the flat sidehorizontal and facing upward so it will mate withdoor handle coupling. (See page 12 for adjustment.)— 7 —


STOP BRACKET

ANGLE SEAL

&r .**Tig. t6 Stop bracket and angle seal (Angle seal only on special NEMA

enclosures) .Fig 17 - Locking pin holds dolly safely to controller frame.

(Refer page 28}

6. Clean guide plate and compartment floor thoroughly.Assemble stop bracket (See Fig . 16) to guide plateper Fig. 37.

NOTE: Some NEMA special purpose enclosures havean angle at the bottom of the compartment(Fig. 16) to form a seal with a gasket on thelower inside of the compartment door. Removethis angle only to roll carriages in or out of com-partments. When carriage has been installedand completely checked for proper operation ,replace this angle.

i

For upper compartments , use the transferdolly. The carriages can be safely lifted onto thedolly with a rope sling and chain hoist . Place therope sling under the four ends of the carriage sideplates, as shown in Fig. 3, but not across the knifeswitch or fuses. Do not lift with racking hooks. Besure that the locking bars are in place while the car-riage is on the dolly and that the dolly is level andproperly adjusted to the height of the upper com -partments.

Fig. 18 - Transfer dolly permits safe removal of carriage from uppercompartment (Refer page 28)

8. Remove control circuit plug from clamp on left sideof compartment and plug into mate on carriage. (SeeFig. 19.) Tighten the two fasteners and check thatall'leads are secure to plug - in block. CONTROLLERTEST. The controller can be tested in this position.See the instruction label posted to the carriage nextto the knife switch for test procedure. (See Fig. 20.)After a successful test , MOVE THE CARRIAGESWITCH INTO THE NORMAL (UP) POSITION,turn the external racking door handle upwards , sothe pointer indicates open , arid close the compart -ment door. The door handle bearing must mate withthe shaft when the flat spot on the shaft is facingupward. (See Fig. 13.) If the handle does not fit ,adjust as shown on page 13.

Position the dolly in front of the proper com -partment and insert the dolly locking pin. (See Fig.17 & 18.) Make sure no cord or wire is in the pathof carriage wheels.

7. Roll the carriage into the compartment (with thegrooved left wheels straddling the guide rail ) as faras the racking shait safety interlock will allow . Thisinterlock pijevents ramming the carriage completelyinto the compartment while thestop bracket to butt against guide rail .

Idoor is open. Turn

-8-


*

DISCONNECTINGTERMINALBLOCK

/ OCEDURE1.%

Fig. 19 - The disconnecting terminal block connects all secondary wiring tothe carriage.

9. Rack in carriage by turning handle 180°clockwise until the handle is vertical and the pointerindicates the carriage is "Connected’ \ A snappingaction will be noticed as the racking mechanismlocks in near the end of the racking travel.-

Fig 20 - Knife switch used to test controller.

not rack in easily , adjust the racking hooksas shown on page 13. Also check the gear meshas shown on page 12.

counter

Tf all of the above steps have been checked , and adjust -ments are correct , the rnoior controller is ready foroperation. Proceed to the section on Operation.NOTE: DO NOT USE FORCE. If the carriage does

OPERATION

The- standard SpaceMaker II circuit for a full-voltage, squirrel-cage motor controller is shown in Fig. 21.

TEST

Leave the control disconnect block attached to the carriage andmove the carriage several feet from the compartment. The controlcircuit will not operate because the primary and secondary of thecontrol power transformer are open.

NORMAL

With the control knife switch in the normal position, the carriageracked to the "Connected" position and the incoming line ener-gized , pressing the start button energizes the master relay coil( MR ). A contact of MR energizes the contactor rectifier and coilcircuit, and another MR contact provides half of the start buttonseal. An M contact completes the seal when M closes to apply powerto the motor. The start button can then be released.

The main contactor may be supplied with a coil circuit requiringeither 115 volts or 230 volts A C. Depending on the type of coilfurnished, perform the following steps to test the controller:

230VAC Contactor - Connect a single-phase, 230 volt , 60HZpower source to points 13 and 14 on the compartment terminalboard. If the control circuit includes 115V devices, then the testpower must be from a three-wire 230/115V source connected toterminals 13, 14 and 15 with point 15 grounded.

Pressing the stop button de-energizes the master relay. The con-tacts of MR open, de-energizing the main contactor and breakingthe start button seal. The M contact in the seal circuit opens whenthe main contactor drops out.

115VAC Contactor - Connect a single-phase, 115 volt. 60HZpower source to points 9 and 13 on the compartment terminalboard. Ground , if any. must he connected to terminal 9

In the case of an overload, the normally closed overload contact( OL) in series with the master relay coil will open, and the sequ-ence will be the same as a normal stop. After returning the circuitto the start conditions, the motor may be pul back on line throughthe normal start sequence.

After connecting test power, move the knife switch to the testposition. The control circuit will now function in the normal man-ner. Always return the knife switch to the normal position whentesting is completed.

—9 —


/

fINCOMING LINEe * ‘‘

uTT u.sUJc/1 FUSEFUSEDu.

ControlTransformer

AW ControlTransformernnX X X ramocrr

1 .nr tnF“V?I F 9 ^ouOL *? &ML ir, 'T3 01l I OL CUST. TEST SOURCE115V \ct CTCT CUST TEST SOURCE230 V »D

START

MR M

9*T2 11T3T1 Elnd.Motor MR MiMRriMR

SP SP,Tsp

“ LEGEND — HH YYCT .... Current TransformerK5 .... Knife SwitchLSI .... Line Switch Inter lock

Main ContactorMaster RelayOver load Relay

REC .... Rect i f ierSurge Protec tor

»*v> Oo o cAC'ACAC RR»R S M

1 1 (Ms 1 M TR S M»-Q IVM

MR S M4*OL LWLW

21B • 115VAC CONTACTOR OPERATIONSP 21 A • 230VAC CONTACTOR OPERATION

ADJUSTMENTThis section describes and illustrates all adjustmentsfor the carriage and compartment.

CAUTIONMake sure the arc chute is properly inserted* rearend to back, as shown in Fig. 23. Failure to insertthe arc chute properly will result in damage to thecontroller.

•FUSE REPLACEMENT (See Fig. 22)Remove fuse barriers if necessary. Place fuses in theholders so that the target button on the end of the fuseis toward the front of the carriage. If the fuse blows , thetarget will extend 3/8 to 1/2 in. Remove fuses from theholders by lifting one end and withdrawing the otherend from the fuse clip . If difficulty is encountered inremoving the fuse, a screwdriver handle or wrench maybe placed under the fuse , between the fuse and the fusetongue, and a prying motion used . Replacement fusesshould fit tightly against the semi-circular stop locatedat the bottom of the fuse holder.

To remove arc chutes , lift the back end of the chuteuntil it releases and then lift the entire chute upward ,slide forward and out.

1 f*< * r v '.. M t/ ;a ;Jr - - . 1 f.'i% 1i '3

r i- v, f. \

:i

v*ARC CHUTESTo insert arc chutes, slide in rear of chutes first , thenpush down on front and back of chutes, making surethat the arc runners are properly seated over thestationary contacts. Arc chutes are properly seatedwhen a positive click is felt on both ends of the chuteand the groove on the side of the arc chutes is horizon -tally even with the blowout plates.

vT

n• '•«

Fiq. 22 - No special tools required for fuse installation.—10-


spring to prevent over bending when carriage is rackedin.

DO NOT CHANGE THE LENGTH OF THEMATING CONTACT STUDS (See Fig. 24). These studshave been factory set with an assembly Fixture. Thissetting must be maintained to allow interchangingcarriages in various compartments. Remember thatsubstitution of carriages requires matching data withcompartment door labels.

SHIM TO SUITWITH *10WASHERS

LEAFn SWING

3Fig. 23 Inserting arc chuteGUIDEPLATE

tzr:TOP VIEWSiUE VIEW

Fig. 25 - Adjust LSI with washers as shownNormally, when the carriage is in the racked in

position, the leaf spring will be 50% compressed. (SeeFig. 26 and Instructions page 12.)

STUDS24 - Mating contact studs for LSI

*LSI , GUIDE PLATE, AND ANTI-RACKINGMECHANISM

(Refer to Fig. 13, 14, and 24 thru 28)Check dimensions as shown in Fig. 14.If the plumb line dimensions check indicates both inter -locks have shifted the same amount and in the samedirection , loosen the four bolts that hold down theentire guide plate (Fig. 13). Shift the guide plate untilthe proper dimensions are obtained. (Guide plate clear -ance holes are oversized to permit adjustment.) Tightenthe four bolts securely.

If adjustment of the LSI only is required , observethe following: Adjust any obvious distortions to the leafspring. A stefci backing plate is located behind the Fig. 26 • Handle shows line switch interlock relationship.

1 1


Adjust LSI by adding washers .as shown in Fig. 25. Afurther check of the LSI is as follows:

If adjustment of the anti-rack interlock is required,observe the following:

1. Connect a buzzer and battery to terminals 9 and 11.(If there is power to the unit , connect a 300 voltmeter to terminals 9 and 11.)

1. Loosen the two mounting nuts. (See Fig. 27.)2. Shift the interlock assembly to the front or rear as

required.2. Rack the carriage in until buzzer sounds or VM indi -

cates contact. 3. Use the dimensions shown in Fig. 14. The plungermust clear the interference post on the carriage by/4" maximum at B when the carriage is racked in.

(See Fig. 28)3. Rack carriage out slowly. Contact should be broken

at 35° to 45° of handle rotation. (See Fig . 26 . )

PLUNGERCARRIAGE RACKING MECHANISM

The gear meshing of the side and back racking shaftscannot be off one tooth in either direction for properoperation. Proper meshing can be checked by makingthe checking Fixture showm in Fig. 29 , and using it asfollow's:

r1/4 000oio

“"XT)+ . V« APPROX0 943 Ii

APPROX .M.F. 1/4 or 5/16 C R. STEEL

‘ -VFig. 29 - Gear mesh checking fixture.ADJUSTMENT NUTS

r

Fig. 27 - Anti-racking interlock.

PADDLE

INTERFERENCE POST

Fig. 30 • Fixture placement for checking gear mesh.Fig. 20 - Interference post on carriage.

-12—


•Carriage Racking HooksThe carriage must be drawn into proper electrical con -tact with even pul! on the racking hooks . If any inter -ference occurs , adjust the hooks forward or back untilthe carriage rolls freely. The hooks may also requireadjustment up or down to obtain proper carriage lock -ing. The point indicated in Fig . 32 should be 28 3, 4 in.from the floor to the top of the slot in the racking hook .

*Door Handle and Side ShaftRemove the screw that fastens the handle to the squareshaft of the coupling. Remove the handle , pointer andlock plate , spring washer and indicating plate , carefullynoting the assembly sequence. Loosen but do notremove the three bearing screws which are nowexposed.Fig 31 - Front side snaft support.

Close the door and position the coupling and bear -ing for proper mating to the side shaft . The door latch ,which is mounted on the inside flange of the cubicle ,may need adjustment to clear the coupling. With thedoor closed and the coupling in its proper position ,tighten the three bearing alignment screws. Re-assemble the door handle in the proper sequence anddouble check for proper indication and handle position.(See Fig. 33. )

With the side shaft turned so that the flat ishorizontal and the stop pin is against the stop on thefront bearing support , place the checking fixture on theshutter drive arm pin on the racking cam t Fig . 30). Theedge of the fixture should be flush with the side shaftwith the shutter completely closed. With the side shafthorizontal , adjust the front and rear side shaft supportsfor free mechanism movement and minimal end plav.

To change the gear mesh , remove the front and rearside shaft supports . (See Fig. 31 . ) Disengage the gear -ing and rotate the side shaft to the proper meshposition. Reinstall the front and rear supports and alignas described above.

BEARINGSCREWS

r 'r .v -• - '-- -A*.:-- - - "~-

•Power Plugs and Rear Racking ShaftCheck dimensions as shown in Fig. 15. If the shaftheight is off , adjust the channel support . If anindividual set of plugs is out of position, adjust the indi -vidual insulator support independently.

ADJUSTMENTBOLTS

Fig 33 - Disassembled door handle showing the bearing alignmentscrews

RACKING SHAFT SAFETY INTERLOCKA safetv interlock is provided on the SpaceMakercompartment racking shaft mechanism . The shaft lock( Figure 34 ) consists of a lock bracket ( 48) and com -ptession spring (49 ) mounted on the racking shaft at thefiom bearing support . 1 he lock bracket prevents rota -tion ol the racking shall through inteifrrence with thestop pin when the compartment door is open. Thepm pose ol this safetv feature is to lock the line.shuttersdosed when the compartment door is open.

GUIDE PLATEFig 32 - Racking hook dimension.

-1 3-


49

tI l I[ \ I':rri i£"SIDE VIEW D 43

Fig 35 - Interlock with Door Closed and Shutter Open.

2726 49nT1\ H-

'11r H 1

SIDE VIEW 7 ° 4350Fig 34 - SpaceMaker II Shaft Interlock Installation CLEARANCEWithout this interlock , the racking mechanism can beoperated freely by hand or other externally appliedforce to open the shutters and expose the energized lineterminals . With the interlock the shutters can beopened for inspection purposes by bypassing the inter-lock. This is done by pressing the lock bracket inward tothe point where the pin clears the bracket and thenrotating the shaft 180° by hand ( Figure 35).

Fig. 36 * Interlock with Door Closed and Shutter Closedarc of 180°. The new mechanism is not adaptable to theolder SpaceMaker model which employed a reversibleratchet type racking handle which rotates through 320°.The new shaft lock mechanism can be simply installedon SpaceMaker II units without the need for machiningany of the exist ing parts . If this safety feature is to beadded on existing controllers , one lock bracket 25-204 *209-001 and one compression spring 25- 120 - 212 * 001 arerequired for each SpaceMaker II racking compartment .Proceed as follows to install the lock bracket and springin the field. Refer to Figures 34 and 44.

WARNINGPerform this operation with extreme care. High voltageexists on the terminals.

CAUTION CAUTIONPerform this inspection only with the carriage removedfrom the compartment. Be sure to rotate the shaft backto its original position so the shutters are closed afterthe inspection (Figure 36).

Throughout this installation , carriage must be removedfrom cubicle and unit must be disconnected from theline to de-energize the line stabs located behind theshutter .

In normal racking operation, the interlock is releasedonly when the compartment door is fully closed. As thedooi is closed , the racking handle coupling (23) engagesthe front edge of the lock bracket (48) and pushes itback to provide clearance for the stop pin (50) as theracking shaft (26) rotates. The lock bracket is held inthe disengaged posit ion with spring compressed duringall racking functions. The compression spring will drivethe lock bracket forward to lock the shaft only when thecarriage is disconnected , the operating handle is in the“open posit ion and the door is open . High voltagecompartment door must be pushed and held fullyclosed against the spring pressure before handle can berotated .

1. Drive out roll pin (5U ) from collar (28) and rackingshaft (26).

2. Unbolt and remove rear bearing ( 29 ) and bearingbracket ( 27 ) from cubicle.

3. Pull bearing bracket ( 27) and collar ( 28) from rackingshaft .

4. Reassemble parts on shaft (26) in the following order:back half of the bracket (48). collar (28), bearingbracket (27) , spring ( 49) , and front half of bracket (48).

5. Reinstall the front and rear supports , making surethat shutters are closed when the shaft has the flatside horizontal and facing up. (See Carriage RackingMechanism , page 12.)

6. With shutters closed and shaft with flat side up,reinsert roll pin and drive through collar and shaft .The pin should be flush with top of collar and onthe right side ( when facing unit ) of the bearingbracket s lower lip.

7 . Disassemble and remove door mechanical interlockwhich connects from door to guide plate.

INSTALLING THE INTERLOCK ON EXISTINGCONTROLLERS

be field -The shaft ir j ierlock safety mechanism caninstalled on j existing early model ( Pre - 1971 ) Space -Maker II controllers : these are equipped with theformed square tube handle which rotates through an


The racking shaft safety interlock mechanism describedabove includes all of the safety functions that wereprovided by the door operated mechanical interlock.This mechanism consisted of an interference cammounted on floor plate at left hand side of carriage andactuated by curved connecting rod attached at lowerleft hand corner of compartment door. The mechanismblocks complete entry of the SpaceMaker carriage intothe compartment when door is open and permits entryonly when compartment door is about 4" from beingfully closed. The door -operated mechanical safetyinterlock is now superseded by the new shaft interlockmechanism.

GUIDEPLATE

GUIDE RAIL

STOP LEVER14 171 633 002

O

Fig. 38 Location of Stop Lever in Shipping Position

(Figure 38). After the SpaceMaker unit has been set inits final location , remove and discard the temporaryshipping angle (Figure 4). The carriage stop lever in itsshipping position will block entry of carriage. The leverthus must be unbolted from its temporary position andinstalled on the threaded stud as showm in Figure 40.The friction nut provided to hold the bracket in placemust be turned down on the stud to the point where thelever can still be moved freely by hand.

| ; CAUTIONMake certain that the stop lever is properlyinstalled at its operating location in eachSpaceMaker carriage disconnect compart *'ment . An instruction label (Figures 37 and40) is provided showing the relocation of thestop lever from its temporary shipping posi *tion to its permanent position.

IMPORTANT INSTRUCTIONSBEFORE CARRIAGE IS PLACED INTO COMPARTMENTSTOP LEVER MUST BE REMOVED FROM SHIPPINGPOSITION & ASSEMBLED AS SHOWN.

NUT TO BETIGHTENED TOALLOW FREE

Q QJ MOVEMENT OFSTOP LEVER

!\vx OT \O \O

\STOP LEVERGyiDE PLATE

25-118-524-002Fig. 37 - Stop Lever Assembly instruction Label

CARRIAGE STOP SAFETY LEVERA change has been made in the design and in the ship-ping installation of the carriage stop lever shown in itsoperating location in Figure 37. This lever is mountedon the floor plate at the front left corner. When thecarriage is inserted , the lever blocks the left frontcarriage wheel with the carriage in the “disconnectedposition . The stop lever must be rotated parallel to theguide rail by hand before the carriage can becompletely inserted in the compartment. When thecompartment door is closed , the door flange rotates thelever counterclockwise thus blocking the carriage wheelbehind the interference end of the stop lever (Fie . 40).When the door is closed , the interference end of thelever should contact the guide rail and thus preventmotion of the carriage. Bend the tab on the end of thelever that contacts the door if necessary, so that thiscondition exists. When the door is opened , manuallyrotate the lev^r clockwise so it is parallel to the guiderail and the carriage can then be removed. The inter -ference end of the lock lever has been redesigned toprovide greater interference and added strength.A somewhat different arrangement for the carriagestop lever exists for NEMA special gasketed enclosuretypes where formed steel sealing strips are boltedacross the bottom of the SpaceMaker compartments .See Figure 16. The purpose of these strips is to providea scaling edge to bear against the gasket material onthe inside of the door. Where these sealing strips areinstalled , the operating end of the lever has beenshortened and will be in position to block the carriagewith the strip in place. The formed strip must be tem -porarily removed when the carriage is initially installedin its compartment or when the carriage is to beremoved from ^ ts compartment . The sealing strip must^ . be in position at all other times in order to provide aneffective seal fpr the SpaceMaker compartment .A new temporary location is provided for the carriageguide rail on the left hand side of the compartment floor

SPACEMAKER CARRIAGE POSITION INDICATORA carriage position indicator plate (Figure 39) is nowrstandard^ , equipment in each SpaceMaker carriagecompartment . The indicator plate (part number 25*118-524-003) is mounted at the right front on thecompartment floor ( Figure 40) and is readily visible assoon as the compartment door is opened. This indicatorsupplements the carriage position indication providedby the racking handle when compartment door isclosed. A large arrow on the indicator plate indicatesthe normal location of the carriage in theconnected” position. The plate can readily be installedon existing units without any machining operation .

* »

dis -* i

EABtCARRIAGE BASEANY CARRIAGE POSITION IN

FROM ARROW INDICATES UNSAFECONDITIONS CONTRARY TO

INSTRUCTIONS 20 X 2850.CARRIAGE MAY BE ENERGIZED"OISCONNECT INCOMING POWER

BEFORE ENTERING

DANGERKEEP OUT

IF FRONT EDGE OFCARRIAGE BASE IS

NOT AT ARROW WHEN"DISCONNECTED"

75 H8 574 UOJ

Fig. 39 - Carriage Position Indicator Plate


SPACEMAKER OPERATING CIRCUITS service dolly will not accommodate an upper com -partment. The construction of a lightweight portableplatform is normally recommended to service bottomcompartment carriages when SpaceMaker units areinstalled on a pad above aisle elevation. The factoryshould be consulted where service dollies are requiredfor heights above 52".

Certain controllers are now furnished without the masterrelay. The circuit shown in Figure 21 is modified to usepilot devices to directly energize the contactor rectifier.

TYPE 456 CONTACTOR Choice of Dropout TimeA choice of opening time after de -energization of theSpaceMaker type 456 contactor is available. This isaccomplished by alternate connections between ter -minals R and S in the DC operating coil circuit asindicated in the circuit diagram (Figure 21). Carriageterminals R and S correspond to compartmentterminals 25 and 26 for most SpaceMaker controllers.

CARRIAGE DISCONNECT FINGER ASSEMBLIESAn increase in the contact pressure has been made inthe power disconnect finger assemblies item 1. Figure41 , part number 71 - 240-055* 501 . An increase inpressure of contact fingers was initiated for improvedperformance in corrosive environments such as papermills and chemical plants. The original music wiresprings had a 15 pound rating and were zinc plated anddichromate treated. Disconnect finger assemblies nowbeing supplied are equipped with stainless steelsprings rated at 25 pounds and have an orange color foreasy identification.

Standard circuits are arranged to provide an inherentdropout time of 400- 500 milli seconds for the type 456contactor on deenergizing its coil circuit . Thisoperation is provided by opening the AC input to theoperating rectifier only. The dropout delay has provenextremely beneficial in maintaining uninterruptedmotor operation on power systems experiencing severevoltage dips of short duration. The operating circuit ofthe type 456 contactor also remains sealed at approxi-mately 40 % normal voltage .

SpaceMaker carriages equipped with the new, higherpressure disconnect finger assemblies with orangesprings require a slightly higher racking force. Contactfinger of stationary terminals are factory coated with athin film of high temperature lubricant in order tominimize racking forces and to provide increased life ofsilver plating . The presence of thin lubricating film willincrease the wear life of silver plating by a factor of 10or more. Lubricant such as AC contact lubricant (8.0 oz.tube , 15-171- 370-002) should be applied thinly on thecontact surfaces cf disconnect fingers and stationarycontacts.

Certain special controller applications require a muchfaster dropout time where contactors are used for faultinterruption within 50 MV'A capability or where thefaster dropout time is needed for close up streamprotective coordination. A dropout time of 70-80 milli-seconds can readily be obtained. This is accomplishedby simultaneously opening the AC input and DC outputcircuits of the contactor operating rectifier. The fastdropout circuit would thus be provided by the additionof a master relay (MR) normally open contact betweenterminals R and S in the output circuit of the rectifier.In practice , this is normally accomplished by removingthe jumper between terminals 25-26 on the compart -ment terminal blocks and connecting in the relaycontact as described. The quick dropout feature may bealready provided in the original factory SpaceMakercontrollers to correlate with specific applicationrequirements.

‘EMERGENCY ENTRANCETo gain access to the high voltage compartment:

WARNINGAFTER IT HAS BEEN DEFINITELY DETER-MINEDTHAT A MALFUNCTION HAS OCCURED,THE FOLLOWING PROCEDURES ARE TO BEPERFORMED BY AUTHORIZED PERSONNELONLY. ALL POWER TO THE CONTROL MUSTBE REMOVED BEFORE THESE PROCEDURESARE ATTEMPTED, AND POWER MUST REMAINOFF UNTIL THE CONTROLLER IS IN OPER-ATING CONDITION.

SERVICE DOLLYThe service

Fig. 40 - Installation and Adjustment of Stop Lever

MAINTENANCEInspect the air - break contactor at least once a

month , or more often if the contactor operates on arapid or heavy- duty cycle. Examine the contacts foralignment and wear. With the contactor closed , alignthe movable contacts with the stationary contacts sothat the contact surfaces bear with firm and uniformpressure. Replace badly pitted or burned contacts im-mediately. If contact surfaces are only roughened ,smooth down with a fine file. See contactor instructionmanual for maintenance instructions.

GENERALThe importance of regular and thorough inspection andcleaning prodecures cannot be overemphasized. A rou -tine inspection once a week will suffice when the controlis operating under normal conditions. Under severeoperating conditions , such as dusty or contaminatedatmospheres , it is suggested that a more frequentcheck be made .

CARRIAGE RACKING MECHANISMThe carriage racking mechanism must operate smooth-ly. Onlv a light coating of grease is required on thebearing points of the mechanism and on the gears tokeep the movement operating smoothly. section’s Equipment Checkout

can be used for a maintenance inspection . For isolatedirregularities in equipment operation , use the “TroubleShooting chart ”. The pages following that chart includespare parts indentification . Order spare parts throughyour Siemens- Allis representative .

The “Installation i *

AIR-BREAK CONTACTORW A R N I N G

MAKE CERTAIN THAT THE CONTACTOR ANDITS OPERATING MECHANISM ARE DISCON-NECTED FROM ALL POWER SOURCES BEFOREATTEMPTING INSPECTION OR REPAIR OPER-ATIONS.

-17 —


TROUBLE SHOOTING CHARTTROUBLE REMEDYCAU5E

Compartment doornot square withcubicle opening.

Cubicle not bolted down, tightly onperfectly level surface.

Using a level , add shims as necessaryat mounting bolts and fasten mountinghardware securely .

Cubicle sprung out of shape. Straighten or repair cubicle.Door hinges not properly adjusted. Add spacer washers as shims between

hinge flange and cubicle flange at topor bottom hinge as required tocompensate for error.

Handle improperly assembled. See section on “ Adjustment ”.

Cubicle or door sprung. Straighten or repair.Door will notclose completely;door handlemechanism doesnot line up withoperating shaftwhen door isclosed.

Cubicle not level . Check level , shim and tighten mount -ing bolts .

Door handle assembly out of adjustment. See section on “ Adjustment”.

Vertical position of compartment door outof position .

Remove door hinge pins and add or re-move adjusting washers between hingebracket and bearing tube until correctheight adjustment is obtained.

Side shaft may have been manuallyrotated and not returned to normal'position.

DANGER: High voltage ter-minals may be exposed, inn. shaftby hand counterclockwise until frontstop pin hits stop with flat of shaft endup and horizontal.

Right - hand ^ideof carriage rubsagainst shaftbracket or doorhandle couplingrubs againstcarriage.

Cubicle sprung or not level . Straighten and level .

Loosen four mounting nuts and shiftplate for correct position.

Guide plate for carriage platform out ofposition.

Door not fully closed to allow properengagement between shaft and handlesocket.

Close door firmly and correct anyinterference that prevents door fromreaching fully closed position.

Removewheeis and check for interfer-ence between wheel and carriageframe. Look for and remove anyforeign material or rust in wheelbearing or shaft.

Locked carriage wheels.SpaceMaker car-riage will notrack in withoperating handle.

Foreign objects or materials on compart -ment guide plate in path of carriagewheels.

Plate must be free of all foreign parti-cles , including gravel , hardware andso forth.

Check elevation of carriage fingers andstationary plug terminals , setting ele -vations in accordance with instructionbook.

Interference between carriage disconnectfingers and compartment stationaryplugs.

—18—


REMEDYTROUBLE CAUSE(corn’d .) Shutter may be binding or operating links

connected to rear racking shaft may be offor broken .

Check insulated shutter hardware forbreakage.

Improper mesh between side pinion gearand rear racking gear.

See section on “Adjustment ” .

Replace entire shaft.Broken or bent racking shaft .

See section on “Adjustment”.Mechanical interlock interference. Inter*locks out of adjustment or improperly set.

Carriage racking hooks hit racking shaftpins. Check height position of shaft locationand position of racking hooks on

SpaceMaker carriage in accordancewith instruction book. Adjust so thatedges of hooks will pass over theracking pins with shutters down.

•Inner phase barriers in SpaceMaker car-riage installed backwards.

Check each fuse barrier and contactorbarrier to make certain that each is inproper direction and properly seated.

Check for signs of scraping or rubbingon carriage and other moving parts;check for freedom of operation ofracking mechanism by operating shaftby hand and making ctrcessary adjust -ments or corrections.

Carriage racks inbut requires un-usual and abnor -mal racking force.

Partial interference or improper rackingmechanism.

Adjust both carriage hooks evenly atcorrect position in accordance with“Adjustment” section.

Racking pins not engaging carriage hooksat proper position.

Carriage disconnect fingers and/or sta-tionary power plugs in need of lubrication. See Page 16 for lubrication procedure.

Carriage will notrack out withracking handle.

SpaceMaker contactors in controller maybe energized. Operate stop button to stop motor be-fore attempting to rack out carriages.Racking mechanism may be broken ordefective. Disconnect incoming power, obtainentrance to compartment by removing

door handle assembly and removedoor-operated mechanical safety inter-lock screws in lower left -hand corner ofdoor; remove sufficient mechanism toallow carriage to be withdrawn andmake necessary repairs or adjustments.

Mechanical jamming of contactor inclosed position, causing contactor to beblocked in by mechanical safety interlock.

Disconnect incoming power, removedoor interlock hardware at lower left -hand corner of door and removehandle assembly to gain entrance tocompartment. Remove the carriageand check the contactor thoroughly todetermine cause for jamming in the

—19—


TROUBLE CAUSE REMEDY

closed position. Such causes might bewelded contacts , broken arc chute ,foreign material in contactor mechan -ism , loose or broken contactor parts ,excessive rust , corrosion or dust , etc.Refer to Type 456 high voltageair - break contactor instruction manualICD6030 for this maintenance. Contac-tor should be completely restored tonormal before returning it to service .

Carriage will notrack out withracking handle,(cont ' d.)

Jamming of mechanical interlock al -though contactor open. Rack carriage all the way back in with

racking handle. This should reducefriction at the point of contact betweenthe plunger of the anti- rack interlockmechanism and the interference plateon the carriage. If this is not success-ful , remove door interlock hardwareand handle assembly to gain access tocompartment. Disconnect incomingpower. Mechanical interlock , locatedon right -hand side sheet , must be setforward to allow' 1 /16 to 1 /8- in.clearance between interference plung-er and stop plate on contactor whencontactor is closed. If position is satis-factory , check for broken spring orbinding in mechanical interlock assem -bly. In -.eilock should release abruptlywhen operated by hand.

SpaceMaker car-riage can beracked out butrequires abnormalracking force.

Friction or binding in racking mechan-ism.

Correct alignment and free slidingshutter mechanism.

Racking hooks on carriage not adjustedequally.

See section on “Adjustment ”.

Adjust and align compartment guideplate, mechanical interlocks , rackingshafts, shutter mechanism , carriagehooks and other details in strict ac-cordance w'ith instruction book.

Entire compartment and carriage out ofadjustment and alignment.

SpaceMaker car-riage forces shut-ters open When itis pushed intocompartment.

Carriage striking movable shutter duringracking operation.

Set alignment and proper mesh ofside shaft and rear shaft . Replace orrepair movable shutter driving arms.

Binding of safetyshutter mechan-ism or breakingof insulated shut -ter hardware. Add additional insulated spacer wash -

ers between shutter sections to provideadditional clearance, or replace shutterassembly if warpage is severe ordamage has occurred.

Warpage of safety shutters.

I

-20-


TROUBLE CAUSE REMEDY(cont ’d.) Rough handling during transportation

and installation.Adjust shutter assembly and replacebroken insulated hardware.

Apparent absenceof control powerwith carriageracked in.

Incoming power line not energized. Close feeder circuit breaker or tieswitch.

Electrical interlock switch ‘ LSI” notadjusted properly.

See section on “ Adjustment” , specifi-cally the LSI.

Check three main motor power fuses,control transformer primary fuses , andcontrol transformer secondary fusesand replace if blown.

Blown fuses.

Control cable not plugged into Space-Maker carriage.

This is the disconnect type terminalblock that must be connected in orderto provide circuitry between compart -ment and carriage. The mating halvesof the terminal block must be engaged,and clamp screw's at top and bottomtightened to hold halves together. Con-trol wire connections in the block aremade through slide - type terminals.See that all terminals are securely inposition.

Switch 9' I d be in “normal” positionfor operation from control transformerpower. When carriage is racked out ,switch can be placed in test position tooperate contactor through normal se-quence , with auxiliary power connectedto compartment terminal block. Placeswitch in “normal” position beforeracking carriage in to operate motor.

Test -normal control switch on left - handside of carriage not in proper position.

Overload relays or other protective relaysin operated or “trip” position.

Reset relays to close contacts and com-plete control circuit .

Check wiring and connection diagramcarefully to make certain that all ex -ternal or alternate connections havebeen made satisfactorily. This is es-pecially true where remote protectiveor control devices are used. Whereremote AC ammeters or wattmetersare used , shorting jumpers in theSpaceMaker compartment must beremoved when external connectionsare made. Check all terminal con -nections to make certain that they aretight and are making metal- to- metalcontact .

Missing jumpers , loose connections ,remote connections , etc.

-21-


TROUBLE CAU5E REMEDYSequence of control circuit being inter-rupted.

Check for and correct remote deviceconnections, tripped protective con-tacts , burned out coils on relays and

contactors, faulty rectifiers , blownfuses , mechanical interference in theoperation of relays and contactors,burned contacts , broken contactsprings , excessive dust or other foreignmaterials in mechanism and betweencontacts.

Motor will notstart , althoughnormal controlvoltage avail -able.

Contactor doesnot pick up, al -though controlcircuit voltageavailable .

Contactor held open by mechanical inter -lock .

Rack in contactor completely. Resetinterlock on guide plate if not incorrect position. Check interlock forfreedom of operation.

Arc chutes or phase barriers not properlyinstalled in contactor.

Make certain that phase barriers are inproper direction and in proper positionand that arc chutes are in proper direc -tion , with arc runners properly seated.

Check coil and rectifier. Make certainthat the long wipe normally closed con -tact is in proper working condition andis open in the closed magnet positionto reduce seal current ( refer to Type456 high voltage air- break contactor in-struction book , ( ICD 6030). Check formechanical interference or f reignmaterials in contactor mechanism andin magnet air gap. Make certain allcontactor parts are in satiifactoryoperating condition and are properlylightened.

Burned out coil or rectifier on Type 456contactor.

Burnout of Type456 contactorrectifier.

Faulty operation of normally closed longwipe contact.

Replace or correct normally closed con -tact assembly or operating finger ifnecessary . Normally closed contactmust open as magnet reaches fullyoperated position to reduce coil sealcurrent .

Voltage surges from power line. Check protective surge suppressoracross DC terminals of rectifier.

Burnout of operating magnet coil . Replace magnet coil and check circuitfor shorted terminals , etc .Limit starting load and running load tomotor capabilities.

Motor overloaded .Overload relaystrip during start -ing or soon aftermotor is up tospeed.

Motor being started too frequently atclose intervals.

Jogging and starting operations mustbe limited to capabilities of the motor .Check starting limitations in motor in -struction manual before repeatedstarts.

— 22—


TROUBLE CAUSE REMEDYExcessive acceleration time. The starting of high inertia loads may not

permit the use of standard overload relayapplication. Where accelerating timeapproaches 12 seconds or more , specialoverload relay by pass devices andcircuits would usually be required. Con-tact the factory regarding such problemsand supplv complete data on Iocked -rotor starting current and total acceler -ating time under maximum load condi-tions.

(corn 'd . )

Low line voltage. Line voltage should be maintained be-tween + 10 % and -10 % of motor name -plate voltage.

Overload relaystrip during motoroperation.

Reduce load or correct conditions causingoverload.

Motor being overloaded.

Overload relay not adjusted to motorcapabilities.

Adjust relay setting in accordance withinstructions for the overload relay. Ad-justment should correspond to thermalrating of the motor, including tempera-ture rise, duty and service factor.

Incorrect relay installed. Contact factory .

Sec in accordance with relay instructions.Relays set incorrectly.

Relay tripping mechanism jammed. Replace relay .Overload relaysfail to trip onoverloadcurrent.

Check relay selection and adjustment peroverload relay instructions.

Incorrect relay or relay set incorrectly.

Current transformers with improper ratioor with short -circuited secondary ter -minals.

Current transformers must have a step-down ratio to correspond to full loadmotor current and relay selection. Pro-tective jumpers may be provided at cur -rent transformer secondary terminals oron terminal block connections to guardagainst open transformer secondary cir -cuit . and jumpers must be removedbefore placing equipment in operation.

Use Megger and other test instruments tolocate fault and correct .

Blow ing ofmotor powerfuses.

Short circuit on the load side of the motorfuses.

Jogging or too frequent starting. On frequent starting, fuses accumulateabnormal heat and cool more slowly thando overload relays. Since fuses moreclosely follow' cooling and heating ofmotor windings , successive starting oper -ations must be limited to the safe capacityof the motor to prevent fuse blowing from

-23-


TROUBLE CAU5E REMEDYthis cause . Check size radix on fusenameplate against data lahe! on carriageand data label in Space.\hikrr compart -ment. All three* must ngiee . Fuses arcselected on the basis ot motor full loadcurrent , locked - rotor current and startingtime. Approximate sizes can be deter -mined from Siemens - Albs price booksection .

(cont ’d . ) (corn d . )

Fuses internally damaged because ofimproper handling .

Motor power fuses are made up of multi -ple strands ot fine silver ribbon whichmay be broken if fuses are dropped orroughlystrands can be broken without the triptarget indicating a blown fuse. Handlefuses carefully , installing them in clips ontop of the SpaceMaker carriage , withtarget indicator toward the front .

handled . Several individual

Blowing of pri -mary controltransformer fuses.

Replace or repair transformer .Shorted primary winding in controltransformer.

Fuse ma\ be “open ” due to roughhandling before installing .

Replace fuse.

Secondary fuses not properly coordi -nated.

Melting characteristic of secondary fuseshould not intersect melting characteris -tic of primary fuse. Rating of standardNFC fuse should not exceed twice thesecondary current rating.

Blowing of sec-ondary controltransformer fuses.

Abnormal current or short circuit incontrol .

Check for faulty operation of long wipeeconomizing contacts , shorted magnetcoils , shorted rectifiers, grounds, loose orbent connections , mechanical binding inrelay and contactor mechanisms, ex -cessive operations and incorrect secondary terminal connections.

Overheating ofcarriage dis-connect fingers.

Improper alignment and overtravel onstationary terminals.

Adjust position and alignment of sta -tionary terminals in hack of compartmentin accordance with instruction hook.

Loose mounting hardware or brokensegment springs.

All mounting hardware must he secure ,and all current carrying surfaces must heclean before boiling. Contact springs foreach pair of fingers must he in place andhave original temper. Contact surfaces onfingeis and stationary terminals must hefree of deep voids , corrosion , oxidationand foreign materials, such as dust . etc .Imperfect finger assemblies are a serioushazard and should be replaced . Makesure that the finger retainer shims are inplace.

I

-24-


©©

©

©©

© ©©©

Fig. 41 - SpaceMaker II Carriage

CONTACTOR CARRIAGE- PARTS LIS^Item Description Part No. Qty.No.

Disconnect Fingers w/RetainerFuse ClampOuter ClipInner ClipFuse Block 2-Pole**Fuse Block 1-Polc*Knife Switch 2-Polc * *Knife Switch 1-Polc *Control Power Fuse ClipWheel AssemblyDisconnect BlockElectrical Interlock AssemblyControl Transformer Primary FuseControl Circuit FuseMain Power FuseControl Power TransformerRacking Hook R.H.Racking Hook L.H.Fuse Barrier (inner )Fuse Barrier (outer )Phase Barrier ( inner )Phase Barrier (outer )

1 71-240-055-50114-234-755-00114-234-753-00114-234-754-00100-871-237-10700-871-237-10114-147-049-00125-131-277-00125-127-701-00114-147-042-50114-231-983-50114-170-239-501

62 63 6i4 65 15A 16 16A 17 48 49 110 1] See RecommendedInitial Stock ofReplacement Parts11 212 1* or 2**13 314 115 14-232- 744-50214-232-744-50114-231-648-00214-231-648-00314-133- 795-00114-147-023-001

116 117 218 219 220 2iSee contactor Instruction Manual for all other parts ( ICD6030)

* — 115VAC Contactor Operating Voltage* * — 230VAC Contactor Operating Voltage — 25 —


v*

."li-v 'v -s *.

Fig. 42 * Ooor handle Fig. 43 - Rear view of door handle assembly

OOOR HANDLE ASSEMBLY- PARTS KIT

Item Part Identification Parts Kit No Qty.No.HandleIndicator and Lock PlateSpring WasherSpacer WasherIndicating PlateSpace WasherPadlock PlateBearingCoupling

•IS*16*17*18*19 25-103-302-801*20212223

•NOTE: Items 15 through 20 are in sequential order .

i

— 26 —


(38)

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Fig 44 - Inside view SoaceMaker Jl compartment'-PAGEMAKER II COMPARTMENT-PARTS LIST

Item Description Part No. Qty.No.24 Unc Switch Interlock

Wiring Harness with Plug {230V Contactor)Wiring Harness with Plug* ( 230V Contactor)Wiring Harness with Plug {115V Contactor )Wiring Harness with Plug* (115V Contactor)Racking Shaft AssemblyRearing BracketCollar ( Behind bearing bracket )Rear BearingDoor LatchMechanical Interlock AssemblyCiuide PlateShutter Shaft AssemblyStationary ShutterMovable ShutterScrewWasherWasher ( Phenolic)Spacer ( Nylon)Rivet ( Nylon )Shutter Actuating ArmShoulder Screw ( Nylon )Hex Nut ( Nylon )Washers (Phenolic )Terminal InsulatorTerminalTerminalTerminalShaft Lock BracketSpringRoll Pin

14*170-240-50125-104-745-50125-104-745-50225-104-745-50625-104-745-50725- 201-574-50125-103-256-00114-171-914-00114-174-843 00114-171-772- 00114-323- 199-50114- 233-126-50125-201-587-50114- 231-663-00114-231-662-00100- 6 17-481-U0200-653-109 - 14614-423-344-01625-102-615-00100 -671-501-06014-170-748-00114-171- 239-00200-639 039 -11614-423-344-01414-323-043-50114-1 71 -874-00114- 171 -874 - 00214-147-037-00125-204-209-00125-120- 212-00100-671-177-386

125125A

25 B25C

111261271281i 291301311321

i33

1341351363“ *3* *

36A37

5383

«

394402412422434442452461473481491501

Used on one-high 90” controller (Style Z ) with carnage in lower and low voltagecontrol in upper compartment.Order both items for replacement.•* 97 —


SpaceMaker IIPowerPlugs&RearRackingShaft CarriageRackingHooks DoorHandle& SideShaft •RACKINGSHAFTINTERLOCK INSTALLINGTHEINTERLOCK CARRIAGESTOPSAFETYLEVER CARRIAGEPOSITIONINDICATOR

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