Professional Documents
Culture Documents
Installation
Operation
Maintenance
E50001-U229-A303-X-US00
IMPORTANT
The information contained herein is general in nature and not intended for specific
application purposes. It does not relieve the user of responsibility to use sound practices in
application, installation, operation, and maintenance of the equipment purchased. Siemens
reserves the right to make changes in the specifications shown herein or to make
improvements at any time without notice or obligations. Should a conflict arise between the
general information contained in this publication and the contents of drawings or
supplementary material or both, the latter shall take precedence.
QUALIFIED PERSON
For the purpose of this manual and product labels, a qualified person is one who is familiar
with the installation, construction, operation, or maintenance of the equipment and the
hazards involved. In addition, this person has the following qualifications:
(a) is trained and authorized to energize, de-energize, clear, ground, and tag circuits
and equipment in accordance with established safety procedures.
(b) is trained in the proper care and use of protective equipment such as rubber
gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance
with established safety practices.
(c) is trained in rendering first aid.
GENERAL
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 purchasers purposes, the matter
should be referred to the local Siemens sales office.
The contents of this instruction manual shall not become part of or modify any prior or
existing agreement, commitment or relationship. The sales contract contains the entire
obligation of Siemens Power Transmission & Distribution, Inc. The warranty contained in the
contract between the parties is the sole warranty of Siemens Power Transmission &
Distribution, Inc. Any statements contained herein do not create new warranties or modify
the existing warranty.
Contents
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-33
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . 25
Site Preparation and Mounting . . . . . . . . . . . . . . . . . . 25
General Pre-Installation Inspection . . . . . . . . . . . . . . . 25
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Contactor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pre-Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power Cable Termination . . . . . . . . . . . . . . . . . . . . . . . 33
Series 81000 Controllers . . . . . . . . . . . . . . . . . . . . . . . 33
Termination of Lead-Covered Cables . . . . . . . . . . . . . . 33
Termination of Shielded Cables . . . . . . . . . . . . . . . . . . 33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34-36
Pre-Energization Check . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Energizing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Recommended Maintenance and Lubrication . . . . . . . 37
Mechanical and Electrical Operation of the
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37-38
Vacuum Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Shutter Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Racking Mechanism Adjustment . . . . . . . . . . . . . . . 38-39
Adjustments for Controllers With
Handle-Operated Racking . . . . . . . . . . . . . . . . . . . 40
Adjustments for Controllers With
Screw-Operated Racking . . . . . . . . . . . . . . . . . . . . 41
Mechanical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Electrical Joints and Terminals . . . . . . . . . . . . . . . . 42-43
Periodic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Overload Relay Checks . . . . . . . . . . . . . . . . . . . . . . . . . 43
Recommended Torque . . . . . . . . . . . . . . . . . . . . . . . . . 43
Maintenance After a Fault has Occurred . . . . . . . . . 44
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Terminals and Internal Conductors . . . . . . . . . . . . . . . 44
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Overload Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuse Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-47
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Signal Words
Hazardous voltages
Dangerous Procedures
Qualified Person
General Description
General
The Siemens Series 81000 controller is an integrated
system of contactors and components arranged for
convenient access within a common enclosure consisting
of one or more free-standing structural sections. Each
section is normally 36 inches (914mm) wide, 36 inches
(914mm) deep and 90 inches (2286mm) high (100
inches (2540mm) high with the top mounted main bus
up to 2000A and 103 inches (2616mm) high with
3000A main bus). Refer to Figure 1.
In general, each starter unit is divided into mediumvoltage and low-voltage compartments, each with its
own separate door and interior barriers between the
two. The medium-voltage compartment contains the
drawout carriage power cell module upon which the
shutter mechanism, racking mechanism, line and load
connections, mechanical and electrical interlocks are
mounted. The cell module can be either 29.88 inches
(759mm) (upper or middle cells) or 33.50 inches
(851mm) (lower cell) deep.
36.0
(914.4)
LV
90.0
(2286)
MV
LV
LV
LV
LV
SPACE
MV
MV
100.0*
(2540)
MV
LV
LV
MV
MV
MV
LV
LV
1-High 5kV
LV
1-High 7.2kV
MV
LV
LV
2-High 5kV
3-High 5kV
( ) Dimensions in Millimeters
*103.0 (2616mm) with 3000A bus.
General Description
Horizontal Bus
Ground Bus
Horizontal Bus
Ground Bus
10.0*
(254)
Front
Front
90.0
(2286)
( ) Dimensions in Millimeters
*13.0 (330) with 3000A bus
96H35
97H35
5.0
360
200@2.3kV
350@4.0kV
200@4.6kV
60
96H37
97H37
7.2
360
4.2
570@6.6kV
60
Surge Protection
Ratings
The Series 81000 controllers are rated in accordance
with Table 1, and as shown on the nameplate on front
of the enclosure.
Medium-Voltage Contactors
Siemens Types 96H35 or 97H35 (5kV) and Types 96H37
or 97H37 (7.2kV) contactors are used in Series 81000
controllers. The 96H35 or 97H35 contactors can accept
5kV power fuses rated 2R through 24R. The 96H37 or
97H37 contactors can accept 7.2kV fuses rated 2R
through 24R.
Transformer Loads
2300V
4000V 4600V
6600V
Fused
Max. Maximum 3-Phase kVA at Max.
Contactor Syn. Syn.
Syn. Syn.
Syn. Syn.
Motor
Transf.
Distribution Voltage
Type Motors Motors Ind. Motors Motors Ind. Motors Motors Ind. Fuse
Fuse
Motors
Motors
Motors Rating
Rate
0.8PF 1.0PF
0.8PF 1.0PF
0.8PF 1.0PF
2400V 4160V 4800V 6900V
96H35
97H35
96H37
97H37
24R
24R
450E
1500 200E
General Description
Isolation and Automatic Shutter Mechanisms
(Handle-Operated Racking)
Non-load break finger type stab assemblies provide the
means for manual isolation of the power circuit, in
accordance with NEMA requirements.
The shutter mechanism operation is directly
controlled by the position of the racking mechanism,
and the movable insulated shutter is linked to the
racking cams, Figure 3.
As the handle of the racking mechanism is moved
towards the ON position, the insulated shutter uncovers
the line stab assembly just prior to engagement of the
contactor line and load stab fingers, Figure 4.
In the reverse operation, when the handle is moved
towards the OFF position, the insulated shutter covers
the line stab assembly, thus effectively isolating the line
side high voltage parts, Figure 5.
Labels on the stationary shutter clearly indicate if the
isolating means is OPENED (disengaged, i.e., drawout
carriage disengaged from line stabs, and shutter covering
line stabs).
Isolation and Automatic Shutter Mechanism
(Screw-Type Racking) (97H3 and 96H6 only)
Links to
Racking
Cam
General Description
Insulating
Sheet
R.H.
Vertical
Support
Shutter
Retaining
Strips
Movable
Shutter
Stationary
Shutter
Tension
Spring
L.H.
Vertical
Support
Door
Interlock
Lever
For Interlocks
See Detail A
(97H3) or B (96H3)
Handle
Housing
Stationary
Stab Insulators
Handle
Handle
Shaft
Driver
Link
Shutter
Connecting
Links
Clevis
Line Switch
Interlock
Stationary
Terminal (LSI) Connecting
Rod (Long)
Racking
Cams
Locking Nut
Connecting Rod
(Short)
Cam
Locking Nut
Clevis
Racking
Switch
Interlock
(RSI)
Support
Plate
Racking
Shaft
Guide
Plate
Enclosure
Frame
Mechanical
Latch
Detail A - 97H3
Detail B - 96H3
Interlock
Interlock
Cable
General Description
Insulating Sheet
Enclosure Frame
Stationary Stab Insulator
R.H. Vertical
Support
Connecting Rods
with Clevis and
Locking Nuts
Contactor Interlock
L.H. Vertical
Support
Set Screw
Door Interlock
Housing
Contactor
Position
Indicator
Racking
Shaft
Racking
Cams
Mounting
Bracket
Padlock
Provision
Safety Limit Switch
Racking Screw Assembly
Guide Plate
General Description
Racking Mechanism and Mechanical Interlocks
(Handle-Operated Racking) (Refer to Figure 6)
Racking of drawout contactors or fuse carriages is
accomplished using a compound four-bar mechanism
operated by an external, enclosure mounted handle.
The handle can be locked with up to three padlocks in
the OFF position.
General Description
Door Interlock
Lever (1)
Door Interlock
Handle Shaft
Door Handle
Interlock (2)
Flat Profile
Handle
Hazardous voltages.
Will cause death, serious injury, or
property damage.
The door-handle interlock should be defeated
only in the event of a malfunction in the
racking mechanism.
Disconnect, ground, and lockout all power
before attempting to defeat interlock.
Never defeat this interlock if the red
contactor engagement light is on.
Hazardous voltages.
Will cause death, serious injury, or
property damage.
The door-handle interlock should be defeated
only in the event of a malfunction in the
racking mechanism.
Disconnect, ground, and lockout all power
before attempting to defeat interlock.
Never defeat this interlock if the red
contactor engagement light is on.
General Description
Contactor Interlock (Screw-Type Racking)
10
General Description
Test Switch
A test switch is provided to switch from run to test
mode. The switch is located on the back side of the
door, mounted on the low voltage compartment. See
Figure 9. With the contactor racked out and the door
opened, the test mode can be selected by rotating the
switch to the test mode. With the switch in the test
mode, the contactor can be electrically operated in its
racked out position. Once the test has been completed,
the contactor can be placed in operation by switching
to the run mode, closing the door and racking in the
contactor by operating the racking handle.
ON
Red Contactor
Engagement
Warning Light
OFF
Hazardous voltages.
If the handle is moved to OFF and the red light stays on,
the racking mechanism is not operating properly and
the contactor is engaged. Do not attempt to open the
high voltage door. Disconnect and lockout all incoming
power and refer to the Troubleshooting section.
11
General Description
Contactorin
in Connected
Connected (ON)
Contactor
(ON)Position
Position
Contactor Open
Door
Interlock
Lever
Handle
ON
Detent
Lever
Contactor
Interlock
Lever
Drive
Link
OFF
Driver
Link
Connecting Rod
Cam
Short
Connecting
Rod
Figure 11a. 97H3 Racking Mechanism Handle in ON Position (Handle-Operated Racking, Directly Actuated Interlock)
ContactorininDisconnected
Disengaged (OFF)
Position
Contactor
(OFF)
Position
Contactor Closed
Closed Using
Contactor
UsingTest
TestPower
Power
Short
Connecting
Rod
Door
Interlock
Lever
Driver
Link
ON
Contactor
Interlock
Lever
OFF
Handle
Drive
Link
Connecting Rod
Cam
Detent
Lever
21.5
(546mm)
Figure 11b. 97H3 Racking Mechanism Handle in OFF Position (Handle-Operated Racking, Directly Actuated Interlock)
12
General Description
Drawout Carriage in Connected (C) Position
Contactor Closed
Compartment Door Closed
Door Interlock
Lever
Connecting Rod
Contactor Interlock
Indicator in
Connected (C)
Position
Link
Contactor
Interlock Lever
Safety Limit
Switch
Link
Indicator in
Disconnected (D)
Position
Contactor Interlock
Flap in Upper
Position (Racking
Access Not Blocked)
Door Interlock Flap in
Lower Position (Racking
Access Blocked)
13
General Description
Contactor in Engaged (ON) Position
Contactor Open
Door
Interlock
Lever
Interlock
Cable
Handle
ON
Contactor
Interlock
Lever
Drive
Link
Connecting
Rod
Detent
Lever
OFF
Driver
Link
Cam
Short
Connecting
Rod
Figure 13a. 96H Racking Mechanism Handle in ON Position (Handle-Operated Racking, Cable Actuated Interlock)
Short
Connecting
Rod
Interlock
Cable
Door
Interlock
Lever
Driver
Link
ON
Contactor
Interlock
Lever
OFF
Handle
Cam
Drive
Link
Connecting
Rod
Detent
Lever
21.5
Figure 13b. 96H Racking Mechanism Handle in OFF Position (Handle-Operated Racking, Cable Actuated Interlock)
14
General Description
Power Fuses (Current-Limiting)
Maximum Design
Continuous Current Minimum Interrupting Interrupting Rating
Catalog Number Current Designation
Voltage
@ 40C
Rating
50/60Hz
5080
7200
48FM2R-4G
48FM3R-4G
48FM4R-4G
48FM6R-4G
48FM9R-4G
48FM12R-4G
48FM18R-5G
48FM24R-5G
A072F1D0R0-2R
A072F1D0R0-3R
A072F1D0R0-4R
A072F1D0R0-6R
A072F1D0R0-9R
A072F1D0R0-12R
A072B2DAR0-18R
A072B2DAR0-24R
2R (1 Barrel)
3R
4R
6R
9R
12R
18R (2 Barrel)
24R
2R (1 Barrel)
3R
4R
6R
9R
12R
18R (2 Barrel)
24R
70
100
130
170
200
230
390
450
70
100
130
170
200
230
390
450
190
225
330
500
740
955
1440
1910
190
225
330
500
740
955
1440
1910
Single Phase
80kA rms
Asymmetrical
(210MVA @ 2.4kV)
(415MVA @ 4.8kV)
Single Phase
80kA rms
Asymmetrical
(620MVA @ 7.2kV)
90H3
Power Cell
(Compartment)
Type
93H3 or 96H3
94H3 or 97H3
93H3 or 96H3
94H3 or 97H3
15
General Description
Current Characteristic Curves
Total Clearing Times
Type FM Current Limiting Fuses
2400 & 4800 Volts (2R-24R)
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
300
200
100
90
80
70
60
50
40
30
20
10
.8
.7
1
.9
.6
.5
10000
9000
8000
CURRENT IN AMPERES x 10
1000
900
800
1000
900
800
700
700
600
600
500
400
500
400
300
300
200
200
100
90
80
100
70
70
90
80
60
60
50
50
2R
40
30
40
30
3R
20
20
4R
6R
10
9
8
10
9
8
9R
12R
TIME IN SECONDS
18R
3
24R
2
1
.9
.8
1
.9
.8
.7
.7
.6
.6
.5
.5
.4
.4
.3
.3
.2
.2
.1
.09
.08
.1
.09
.08
.07
.07
.06
.06
.05
.05
.04
.04
.03
.03
.02
.02
283121
.01
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
16
400
300
100
70
80
90
50
60
40
30
20
10
.8
.7
1
.9
.5
.6
CURRENT IN AMPERES x 10
200
.01
TIME IN SECONDS
General Description
Current Characteristic Curves
Total Clearing Times
Type A720R Current Limiting Fuses
7200 Volts (2R-24R)
103814
CURRENT IN AMPERES x 10
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
300
200
90
80
100
70
60
50
30
40
20
10
9
8
.9
.8
.7
.5
.6
1000
900
800
1000
900
800
700
700
600
600
500
400
300
500
400
300
200
200
100
90
80
100
70
70
60
60
50
50
90
80
40
40
2R
30
30
3R
20
20
4R
5R
10
9
8
10
9
8
6R
5
4
TIME IN SECONDS
9R
5
4
12R
TIME IN SECONDS
18R
2
24R
1
.9
.8
1
.9
.8
.7
.7
.6
.6
.5
.5
.4
.4
.3
.3
.2
.2
.1
.09
.08
.1
.09
.08
.07
.07
.06
.06
.05
.05
.04
.04
.03
.03
.02
.02
103814
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
300
200
100
60
70
50
40
30
20
10
.8
1
.9
.5
.7
.6
90
80
.01
.01
CURRENT IN AMPERES x 10
17
General Description
Current Characteristic Curves
Minimum Melting Times
Type FM Current Limiting Fuses
2400 & 4800 Volts (2R-24R)
CURRENT IN AMPERES x 10
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
300
200
100
90
80
70
60
50
40
30
20
10
9
8
1
.9
.8
.7
.6
.5
1000
900
800
1000
900
800
700
700
600
600
500
500
400
300
400
300
200
200
100
90
80
100
70
70
90
80
60
60
50
50
2R
40
40
3R
30
30
4R
20
20
6R
9R
10
9
8
10
9
8
12R
TIME IN SECONDS
18R
24R
3
1
.9
.8
1
.9
.8
.7
.7
.6
.6
.5
.5
.4
.4
.3
.3
.2
.2
.1
.09
.08
.1
.09
.08
.07
.07
.06
.06
.05
.05
.04
.04
.03
.03
.02
.02
280121
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
18
300
200
70
80
90
50
60
30
40
20
10
9
1
.9
.8
.6
.7
.5
CURRENT IN AMPERES x 10
100
.01
.01
TIME IN SECONDS
7
6
General Description
Current Characteristic Curves
Minimum Melting Times
Type A720R Current Limiting Fuses
7200 Volts (2R-24R)
CURRENT IN AMPERES x 10
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
300
200
90
80
100
70
50
60
40
30
20
10
9
.9
.8
.7
.6
.5
1000
900
800
1000
900
800
700
700
600
600
500
400
500
400
300
300
200
200
100
90
80
100
70
70
60
60
50
50
90
80
40
40
2R
30
30
3R
20
20
4R
10
9
8
6R
9R
6
5
6
5
12R
TIME IN SECONDS
TIME IN SECONDS
5R
10
9
8
18R
3
24R
2
1
.9
.8
1
.9
.8
.7
.7
.6
.6
.5
.5
.4
.4
.3
.3
.2
.2
.1
.09
.08
.1
.09
.08
.07
.07
.06
.06
.05
.05
.04
.04
.03
.03
.02
.02
103813
7000
6000
5000
4000
3000
2000
1000
900
800
700
600
500
400
300
200
100
90
80
50
60
70
30
40
20
10
1
.9
.8
.5
.7
.6
10000
9000
8000
.01
.01
CURRENT IN AMPERES x 10
19
General Description
Fuse selection guide for type FM and A720R fuses for series 81000
controller with type 3UA overload relay (NEMA Class 10).
Based on maximum motor accelerating time of 10 seconds.
400
350
24R
300
18R
250
200
12R
9R
150
6R
100
4R
3R
50
2R
0
100
150
200
300
400
500
600
20
1500
2000
3000
General Description
100000
90000
80000
70000
60000
24R
18R
12R
9R
6R
5R
4R
3R
2R
Type A720R
Fuse
(2R-24R)
7.2kV
50000
40000
30000
PS
20000
.
YM
SS
AM
T xR
EN - 2.6
R
R
CU UCE
AK ROD
E
P P
UM N
IX M IT CA
MA IRCU
C
10000
9000
8000
7000
6000
5000
4000
3000
2000
103815
70000
80000
90000
100000
50000
60000
40000
30000
20000
8000
9000
10000
6000
7000
4000
5000
3000
2000
1000
700
800
900
500
600
400
300
200
100
1000
100000
90000
80000
Type FM
Fuse
(2R-24R)
5kV
70000
60000
50000
24R
18R
12R
9R
6R
4R
3R
2R
40000
30000
20000
A
M.
MS
MP
SY
R
6x
T
EN 2.
RR CE U
C U
AK D
PE PRO
UM CAN
XIM UIT
A
M IRC
C
10000
9000
8000
7000
6000
5000
4000
3000
2000
284121
90000
100000
80000
70000
60000
50000
40000
30000
20000
9000
8000
10000
7000
6000
5000
4000
3000
2000
1000
800
900
700
600
500
400
300
200
100
1000
21
General Description
3000
24R
2000
18R
1500
12R
1000
9R
800
600
6R
500
400
4R
300
3R
200
2R
150
5
10
15
20
25
30
35
40
Allowable
Acceleration Time (In Seconds)
Allowable Acceleration Time (In Seconds)
Figure 18. Maximum Allowable Acceleration Times
22
Lift Point
1/2A
45
max
Lifting
Angle
Handling
Series 81000 controllers are shipped in groups of one to
five vertical sections which are mounted on wooden
shipping skids. For 90-inch high controllers, lifting angles
are provided as shown in Figures 19 and 20.
Controllers with top mounted horizontal bus are provided
with side mounted lifting angles, as shown in Figure 22.
Heavy equipment.
Improper lifting can result in death,
serious personal injury or substantial
property damage.
Use extreme care when handling the motor
controller.
23
Skid Removal
Skid removal should be performed just prior to final
placement of the controller and is achieved by removing
the skid lag bolts. If the lifting bracket or angles have been
removed, reinstall them on the top of the controller (Refer
to Recommended Torque Values, Table 10) and attach the
crane rigging to remove all slack without lifting the
equipment. This is a recommended safety measure to
reduce the possibility of tipping. The lag bolts may now be
removed, the controller lifted, the skids removed, the
controller lowered into place, and the anchor bolts secured.
The last operation should be performed with adequate
rigging tension to prevent tipping. After all additional
shipping sections are secured in a similar manner, sections
and bus bars should be joined in accordance with
instructions in the installation section of this manual. Close
doors as soon as possible to eliminate entrance of dirt and
foreign materials into the controller enclosure.
Contactor Removal
Heavy equipment.
Improper lifting can result in death,
serious injury or substantial
property damage.
Use extreme care when handling the motor
controller.
24
Installation
Hazardous voltages.
Will cause death, serious injury or
property damage.
Disconnect, lockout, and ground incoming
power and control voltage sources before
beginning work on this or any other
electrical equipment.
Installation should be performed only by
qualified personnel.
Introduction
Before performing any installation activities:
Test all power terminals to verify that incoming
power has been disconnected. Use only approved
high voltage test equipment to check voltage on
power terminals. Do not attempt to measure highvoltage (over 600 volts) with a volt-ohm meter.
Operating Equipment
The Series 81000 controller conforms with the provisions of
NEMA standards ICS1, clause 6, Altitude Class 2KM (class
1KM for 96H6 contactors refer to Instruction Manual
SGIM-9098B), which defines the usual service condition for
electromagnetic control. It is designed for indoor use where
the temperature inside the controller is higher than the
ambient temperature. The controller is capable of carrying
its rated load when the ambient temperature does not
exceed 40oC (104oF) and the altitude does not exceed 6600
feet (2000m) (3300 feet (1000m) for 96H6 contactors)
above sea level. Where unusual service conditions exist, or
where temperature or altitude limitations are exceeded, the
controller construction, ratings, or protection may require
alteration. Some examples of unusual service conditions are
excessive moisture, vibration, or dust.
Site Preparation and Mounting
Installation shall be in accordance with the National
Electrical Code, (NFPA 70) and NEMA standards. Unless
the controller has been designed for unusual service
conditions, it should not be located where it will be
exposed to ambient temperatures above 40oC (104oF),
corrosive or explosive fumes, dust, vapors, dripping or
standing water, abnormal vibration, shock, tilting, or
other unusual operating conditions.
25
Installation
36.0
(914.4)
34.94
36.0
(867.5)
10.06
1.12
(255.5)
(28.5)
6.06
(914.4)
(153.9)
2.87 (72.9)
21.88
21.88
(555.8)
(555.8)
31.0
(767.4)
31.0
4.42
(787.4)
(112.3)
68.5
4.68
(1739.9)
(118.9)
4.42
(112.3)
32.75
(831.9)
36.0
(914.4)
36.0
(914.4)
4.68
(118.9)
Front
Front
2.13
32.50
(825.5)
(54.1)
3.50
(88.9)
3.50
(88.9)
Top View
Floor Plan
( ) Dimensions in Millimeters
Figure 22. Top View and Typical Floor Plan With Bus Located in Top Compartment
36.0
36.0
(914.4)
(914.4)
34.94
(887.5)
.625 Dia. 2-Holes for Sill
Anchor Bolts when Reqd
(1-front, 1-rear)
10.06
1.12
(255.5)
(28.45)
6.06
(153.9)
2.87 (72.9)
For T1, T2, T3 to Middle
Compartment
18.83
(478.3)
28.78
31.0
(731.0)
4.01
(101.9)
32.75
3.75
(95.3)
68.5
(1739.9)
(105.9)
(787.4)
36.0
(831.9)
4.2
(914.4)
(106.7)
4.2
Conduit for
Control Wire
(106.7)
4.0
(101.6)
Top View
Floor Plan
( ) Dimensions in Millimeters
Figure 23. Top View and Typical Floor Plan With Bus Located in Top Hat Compartment.
26
29.50
(749.3)
2.13
(54.1)
32.50
(825.5)
Compartment
For T1, T2, T3 to Middle
Compartment
Center Line of Conduit
Max. Nominal Rigid
Conduit Size 3.5(88.9)
for Control Wires.
For T1, T2, T3 to Top
Compartment
Center Line of Conduit Max.
Nominal Rigid Conduit Size
3(76.2) for Control Wires.
Installation
Front
Hazard of explosion or fire.
2.12
(53.8)
3.0
(76.2)
3.0
(76.2)
32.75
(831.9)
1.12
(28.4)
36.0
(914.4)
Catalog No.
Power Fuse Type
Contactor Amp Rating
Part No.
Power Fuse Rating
( ) Dimensions in Millimeters
Installation
After it has been
verified that the correct contactor has been selected for a
given medium-voltage compartment, the contactor may
be installed as follows:
1. Open the medium-voltage compartment door
(handle must be in OFF position, red contactor
engagement light must be OFF).
2. Position the contactor in front of the compartment
and align the rear contactor wheels with the inside
edge of the guide plate sides.
Heavy equipment.
Improper lifting device or dolly handling
can cause death, personal injury, or
property damage.
Observe all handling instructions in this
instruction manual to prevent tipping or
dropping equipment.
3. Roll the contactor onto the guide plate and into the
compartment until it stops. Use the handle on the
front of the contactor for this purpose. When the
contactor is fully inserted, the mechanical latch
(see Figure 6) should rotate to prevent it from
rolling back out of the compartment.
4. Connect the control wiring harness to the contactor
by inserting the harness plug into the receptacle on
the left side of the contactor.
5. Close and latch the medium-voltage
compartment door.
27
Installation
Bottom Entry
Top Entry
Front
Typical
Stress
Cone
Steel
Conduits
for Cables
Side View
28
Installation
Top Entry
TA2
TB2
Horizontal Entry
Horizontal Entry
Vertical
Entry
36.0
(914.4)
Vertical
Entry
10.0
(254)
TC2
Vertical
Entry
Horizontal Entry
Type
20.0
(508)
36.0
(914.4)
36.0
(914.4)
Max. Cable/
Max. Cable/
Max. Cable/
(Non-Shielded)
(1) 250 kcmil
(Non-Shielded)
Vertical Entry
(2) 750 kcmil
Horizontal Entry
(2) 500 kcmil
(Shielded)
Vertical Entry
(2) 750 kcmil
Horizontal Entry
(2) 500 kcmil
( ) Dimensions in Millimeters
Figure 26. Incoming Line Arrangement with Bus Located on Top of the Cubicle Top Entry
29
Installation
Bottom Entry
Type
BB2
BA2
18.0
(457.2)
Min.
BC2
36.0
(914.4)
36.0
(914.4)
Max. Cable/
Max. Cable/
Max. Cable/
Max. Cable/
(Non-Shielded)
(3) 750 kcmil
(Shielded)
(2) 750 kcmil
(Non-Shielded)
(6) 500 kcmil
(4) 750 kcmil
(Shielded)
(6) 500 kcmil
(4) 750 kcmil
(Non-Shielded)
(4) 500 kcmil
(3) 750 kcmil
(Shielded)
(4) 500 kcmil
(3) 750 kcmil
(Non-Shielded)
(1) 500 kcmil
(Shielded)
(1) 500 kcmil
Bottom Entry
Type
BE2
CTs
L1 L2 L3
36.0
(914.4)
Max. Cable/
(Non-Shielded)
(4) 500 kcmil
(3) 750 kcmil
(Shielded)
(4) 500 kcmil
(3) 750 kcmil
( ) Dimensions in Millimeters
Figure 27. Incoming Line Arrangement with Bus Located on Top of the Cubicle Bottom Entry
30
BD2
36.0
(914.4)
Installation
Top Entry
Type
TC3
TB3
TA3
TD3
Vertical
Entry
Horizontal Entry
Horizontal Entry
Vertical
Entry
L1
L2
L3
36.0
(914.4)
36.0
(914.4)
CTs
36.0
(914.4)
36.0
(914.4)
Max. Cable/
Max. Cable/
Max. Cable/
Max. Cable/
(Non-Shielded)
(1) 500 kcmil
(Non-Shielded)
Vertical Entry
(2) 750 kcmil
Horizontal Entry
(2) 500 kcmil
(Non-Shielded)
Vertical Entry
(2) 750 kcmil
Horizontal Entry
(2) 500 kcmil
(Non-Shielded)
(1) 500 kcmil
Top Entry
Type
TE3
24.0
(685.8)
Max. Cable/
(Non-Shielded)
(1) 500 kcmil
( ) Dimensions in Millimeters
Figure 28. Incoming Line Arrangement with Bus Located in Rear of Upper Compartment Top Entry
31
Installation
Bottom Entry
Type
BB3
BA3
(Non-Shielded)
(2) 500 kcmil
(Shielded)
(2) 500 kcmil
BD3
24.0
(685.8)
36.0
(914.4)
18.0
(457.2)
Min.
Max. Cable/
BC3
36.0
(914.4)
Max. Cable/
Max. Cable/
Max. Cable/
(Non-Shielded)
(1) 500 kcmil
(Non-Shielded)
(4) 500 kcmil
(3) 750 kcmil
(Shielded)
(4) 500 kcmil
(3) 750 kcmil
(Non-Shielded)
(4) 500 kcmil
(3) 750 kcmil
(Shielded)
(4) 500 kcmil
(3) 750 kcmil
Bottom Entry
Type
BE3
CTs
36.0
(914.4)
Max. Cable/
(Non-Shielded)
(2) 500 kcmil
(1) 750 kcmil
(Shielded)
(2) 500 kcmil
(1) 750 kcmil
( ) Dimensions in Millimeters
Figure 29. Incoming Line Arrangement with Bus Located in Rear of Upper Compartment Bottom Entry
32
Installation
Power Cable Termination
A Leakage Distance
Terminal Lug
Rubber Jacket
Ground Strap
Final Layer Electrical Tape
33
Operation
12. Test the ground fault protection system (if furnished)
in accordance with the manufacturer's instructions.
Hazardous voltages.
Will cause death, serious injury or
property damage.
Disconnect, lockout, and ground incoming power
and control voltage sources before beginning
work on this or any other electrical equipment.
All pre-energization checks outlined in this
instruction manual must be performed before the
equipment is energized. This equipment should
be energized by qualified personnel only.
Pre-Energization Check
After installation, field additions, or maintenance, the
following checklist should be followed:
1. Remove all blocks or other temporary holding means
used for shipment from all component devices in the
controller interior. If the retaining bracket used for
shipment of the contactors has not been removed,
remove the retaining bracket which secures the left
front contactor wheel to the guide plate.
2. Retighten all accessible connections in accordance
with the torque values provided in Table 7 of the
maintenance section of this manual.
3. Check the integrity of the bus supports.
4. Check the enclosure to see that it has not been
damaged and that electrical spacing has not
been reduced.
5. Compare all circuits for agreement with the wiring
diagrams which accompany the controller.
6. Make certain that external wiring is clear of bus,
and all power wiring is physically secured to
withstand the effects of the largest fault current
which the supply system is capable of delivering.
7. Verify that all ground connections have been made
properly. If sections of the controller were shipped
separately, they must be connected in a manner to
assure a continuous ground path.
8. Check all devices for damage. Make necessary
repairs or replacement prior to energizing.
9. Be sure that each motor is connected to its
intended starter. Ensure that fuse rating is in
agreement with the rating specified in the
contactor catalog number.
10. Manually exercise all operating mechanisms,
contactors, magnetic devices, and other devices to
make certain that they are properly aligned and
operate freely.
11. With all loads disconnected, exercise all electrically
operated devices with test power to determine that
they operate properly. Refer to the wiring diagrams
for the required control voltage, frequency, and test
power terminal designations required to test the
contactor. For the contactor, this should also
include tests at the lower limits of pickup voltage as
shown in the instruction manual for the contactor.
34
Operation
Pre-Energization Check
Energizing Equipment
Hazardous voltages.
Hazardous voltages.
35
Installation
RUN
TEST
A
B
115V. or 230V.
CPT
LSI
X2
X1
52
53
RUN
X= Contacts Closed
20
L2
RL
TEST
55
Push to Test
CXFU
L1
RSI
54
TFU
6
Legend
CPT . . . .Control Power Transformer
CXFU . .Fuse for CPT Sec.
LSI . . . . .Line Switch Interlock
LM . . . . .Main Contactor
REC . . . .Rectifier
RL . . . . .High Voltage Light
RSI . . . . .Racking Switch Interlock
T . . . . . .Trip Coil
TFU . . . .Fuse for Test Power
TX . . . . .Trip Aux. Relay
LM CC . .Main Contactor Magnet Coil
RMI . . . .Racking Motor Interlock
J3
115V. or 230V.
Test Power
LM7
A1
A2
TX
43
44
(+)
TRIP
11 F
AC
Rec.
-1
AC
E2
E1
TX
(-)
TX
T
44
43 13
14
CLOSE
RMI
22
Optional
For Screw-Type
Racking Only
LM4
14
84
LM6
83
12
21
13
LM8
22
16
32
17
31
D 10
LM
DC Drive Unit
A1
LM
CC
W1
A2
2
Mech. Trip
LM
CC
18
19
Figure 31. Typical Control Circuit Diagram with Type 96H3 or 97H3 Contactor (Latched Contactor with Electrical Trip)
36
Maintenance
Hazardous voltages.
Will cause death, serious injury or
property damage.
Disconnect, lockout, and ground incoming
power and control voltage sources before
beginning work on this or any other
electrical equipment.
Introduction
Before performing any maintenance:
Test all power terminals to verify that incoming power
has been disconnected. Use only approved high voltage
test equipment to check voltage on power terminals.
Do not attempt to measure high voltage (over 600
volts) with a volt-ohm meter.
General
For the safety of maintenance personnel as well as
others who might be exposed to hazards associated
with maintenance activities, the safety related work
practices of NFPA70E, parts II and III should always be
followed when working on electrical equipment.
Maintenance personnel should be trained in the safety
practices, procedures and requirements that pertain to
their respective job assignments. This manual should be
reviewed and retained in a location readily accessible
for reference during maintenance of this equipment.
The user must establish a periodic maintenance program
to ensure trouble-free and safe operation. The frequency
of inspection, periodic cleaning and preventive
maintenance will depend upon the operating conditions.
NFPA Publication 70B Electrical Equipment Maintenance
may be used as a guide to establish such a program.
A preventive maintenance program is not intended to
cover reconditioning or major repair, but should be
designed to reveal, if possible, the need for such actions
in time to prevent malfunctions during operation.
Recommended Maintenance and Lubrication
Periodic maintenance and lubrication should include all
of the tasks shown in Table 5. Recommended procedures
for each of the listed tasks are provided in this section of
the manual, or in the references cited in this manual.
Mechanical interlocks
check
Electrical interlock check
Check of terminals
and joints
Periodic cleaning
Dielectric test
Overload relay checks
37
Maintenance
3. Check all devices for missing or broken parts, proper
spring tension, free movement, rusting or corrosion,
dirt and excessive wear.
4. Examine all readily accessible insulating parts for
cracks or breakage and for arc splatter, sooty
deposits, or oil. Clean off arc splatter, oil and sooty
deposits, replace if any signs of burning, charring or
carbon tracking are found. Make sure that the
dielectric integrity of the affected parts is maintained.
5. Measure resistance across each contactor pole from
the line to the load terminal as indicated in Figure
32. If the resistance exceeds the values indicated in
Table 6, loosen connections and perform the
following procedure:
a. Examine all joints for plating wear, replace
if necessary.
b. Clean all surfaces. Replace parts if oxide films
have formed.
c. Examine spring pressure by comparing it to other
similar springs, replace if necessary.
Vacuum Contactors
Maintenance instructions for medium-voltage contactors
are presented in E50001-U279-A304-X-US00.
Shutter Mechanism
Hazardous voltages.
Energized parts located behind
shutter mechanism
Will cause death, serious injury, or
property damage.
Disconnect, ground, and lockout incoming
power before performing any maintenance or
inspection of the shutter mechanism.
96H37
97H37
Fuse R
Rating
None
2R
3R
4R
6R
9R
12R
18R
24R
None
2R
3R
4R
6R
9R
12R
18R
24R
Maximum Resistance
(Main Contacts Closed)
Milliohms at 20C
1.0
11.9
7.3
5.6
4.1
3.1
2.7
2.0
1.8
1.0
11.0
7.3
5.7
4.1
3.1
2.6
2.0
1.8
Hazardous voltages.
Will cause death, serious injury or
property damage.
Disconnect, lockout, and ground incoming
power and control voltage sources before
beginning work on this or any other
electrical equipment.
P1
C1
C2
Kelvin Bridge
Ohmmeter
38
Maintenance
3. Rack the contactor in by moving the handle to the
ON position. If the controller is equipped with
Screw-Type Racking move contactor in the
connected position (C). The racking block will be in
the rear end position. Continuity should be
indicated on the power stab and the LSI.
65 80
23
ON
15
Line Switch
Opens
Power Stabs
Disengage
OFF
20
Middle or Top Compartment
50 65
23
ON
15
Line Switch
Opens
Power Stabs
Disengage
OFF
Dim A
0.07 (1.8)
0.21 (5.3)
Dim B
0.57 (14.5)
0.43 (10.9)
( ) Dimensions in Millimeters
Power
Connection
A
Bottom Compartment
20
Power Connection
LSI Model 2003
53
43
38
C
D
110.0
Power Stabs
Disengage
Line Switch
Opens
LSI
B
1980 to 2005:
Finger Assembly:
25-317-053-804
2003 to 2005:
Kit:
25-317-053-803
Figure 34. Check for Proper Stab Finger and LSI Connection
39
Maintenance
Adjustments for Controllers with HandleOperated Racking.
If the controller is equipped with Handle-Operated
Racking and the proper amount of engagement of the
power stab fingers and/or the LSI cannot be obtained,
perform the following adjustment procedure:
1. Disconnect all incoming power to the controller, open
the medium-voltage compartment door, rack out and
remove the contactor from the compartment.
2. Loosen the locknuts on each end of the long
connecting rod and adjust the length of the rod
by rotating it until the dimensions shown in
Figure 11b or Figure 13b is obtained. Retighten
the locknuts.
3. Defeat the door interlock lever by pushing it in with a
screwdriver and move the handle to the ON position.
Be sure the driver link pin engages the notch in the
detent lever.
Door
Interlock
Lever
Handle
Interlock
Lever
ON
0.06
Detent
Lever
Contactor
Interlock
Lever
Connecting
Rod
OFF
Cell in Top or
Middle
Compartment
Interlock
Lever
Driver
Link
Cam
Short
Connecting
Rod
0.25
Drive
Link
40
Interlock
Cam
Rotated to
Racked-In
Position
Cell in
Bottom
Compartment
Interlock
Cam
Rotated to
Racked-In
Position
Maintenance
Adjustments for Controllers with Screw-Type Racking
If the controller is equipped with Screw-Type Racking and
the proper amount of engagement of the power stab
fingers and/or the LSI cannot be obtained, perform the
following adjustment procedure:
1. Disconnect all incoming power to the controller, open
the medium-voltage compartment door, rack out and
remove the contactor from the compartment.
2. Loosen the locknuts on each end of the long
connecting rod and adjust the length of the rod
by rotating it. The dimension A shown in Figure
12a is 22.3" for the lower compartment and 18.5"
for the middle and upper compartment. Retighten
the locknuts.
3. Defeat the door interlock by pushing it in with a
screwdriver. Move the racking mechanism to the
connected position (racking block at rearmost
position). Verify that the contactor position
.37
.54
Detail Z
Link
Contactor
Interlock
Racking Block
Set Screws
Adjust
Position of
RMI Switch
Mounting
Screws of
RMI Switch
.25
Drive
Link
RMI Switch
Lever
Detail Y
41
Maintenance
Mechanical Interlocks
Hazardous voltages.
Can cause death, serious injury, or
property damage.
Do not attempt to use excessive force or leverage
to defeat the mechanical interlocking system and
gain access to the high-voltage compartment.
Interlock
Lever at
Horizontal
View A
0.12
Min.
Dim.
See View A
Interlock Cam
Shown with
Handle at
ON Position
42
Maintenance
5. Examine all joints for plating wear, replace if the
plating is worn out. Special attention should be paid
to the stab fingers under such adverse environmental
conditions where sulfur dioxide, chlorine, some
hydrocarbons and salt water exists in the
atmosphere. Replace if evidence of copper oxide or
other films have formed. Use Siemens contact
lubricant number 15-172-791-233 to protect the stab
finger joint from deterioration. Worn plating on the
stabs can result in overheating and may lead to
flashover. Plating wear-through can be expected after
approximately 1500 racking operations.
6. Examine insulation on conductor for overheating or
chafing against metal edges that could progress
into an insulation failure. Replace any damaged
conductors, and ensure replacement conductors
are braced or shielded if needed to avoid similar
damage in future operations.
Dielectric Test
Perform test as discussed in the Dielectric Test section
of this manual.
Overload Relay Checks
Perform operational checks: consult manual for the
specific device for periodic checks and tests.
Recommended Torque
When making bolted assemblies, the following
considerations should be generally followed. The
recommended torque is determined by the size and
type of hardware used. Refer to Table 7.
1. Metal-to-Metal Apply standard torque as listed.
2. Metal-to-Insert molded in compound part
Apply approximately 2/3 of standard torque.
Periodic Cleaning
Thread Size
Standard Torque
Metal-to-Metal
(in-lbs/Nm)
8-32
14-20/1.6-2.3
10-14/1.0-1.6
7-10/0.8-1.2
7-10/0.8-1.2
10-32
20-30/2.3-3.4
13-20/1.6-2.3
10-15/1.2-1.8
10-15/1.2-1.8
1/4-20
40-60/4.5-6.8
26-40/3.2-4.5
20-30/2.3-3.4
20-30/2.3-3.4
5/16-18
168-228/19-25.8
110-150/12.4-17
84-114/9.5-13
84-114/9.5-13
3/8-16
240-360/27-41
160-240/18-27
120-180/13.5-20.5
120-180/13.5-20.5
1/2-13
480-600/54-68
320-400/36-45
240-300/27-34
240-300/27-34
43
Introduction
Before performing any maintenance:
Contactor
Refer to the instruction manual for the vacuum
contactors. Manual E50001-U229-A304-X-US00 applies
to the type 96H3 and 97H3 contactors, while manual
SGIM-9098B applies to type 96H6 contactors.
Overload Relays
The complete overload relay must be replaced if
burnout of the heater element has occurred. Any
indications of an arc striking or burning the overload
relay also requires replacement.
General
The excessive currents occurring during a fault may
result in structure, component and/or conductor
damage due to mechanical distortion, thermal
damage, metal deposits, or smoke. After a fault, repair
the cause of the fault, inspect all equipment per NEMA
Standards Publication No. ICS-2, Annex A, and make
any necessary repairs or replacements prior to placing
the equipment into service again. Be sure that all
replacements (if any) are of the proper rating and are
suitable for the application. If in doubt, consult your
Siemens representative.
Inspection
The following areas should be inspected after a fault
has occurred:
Enclosures
External evidence of enclosure deformation usually is
indicative of damage within. Extensive damage will
require replacement of the enclosure parts and the
enclosed equipment. Insure that door mounted
equipment and safety interlocks function properly.
Verify that hinge and latch integrity is maintained.
44
Fuse Holders
Fuses
Always replace all three fuses in a three phase circuit
even though only one or two are open circuited since
internal damage suffered by fuses not replaced could
result in nuisance shutdown later.
Perform Pre-Energization Check procedures detailed in
this manual before restoring the equipment to service.
Troubleshooting
General
In the event that operating problems are encountered,
use the following troubleshooting chart Table 8 to
isolate the cause of the problem and find the remedy. If
the corrective action given in the chart fails to correct
the difficulty, consult your Siemens representative.
The following information is required if it is necessary
to contact Siemens relative to the equipment problem.
Problem
Possible Causes
Remedy
Defective rectifier.
High altitude.
Consult Siemens.
Binding of racking or
shutter mechanism or
mechanical interlocks.
Contactor chatter.
45
Troubleshooting
Table 8. Troubleshooting Chart (continued)
Problem
Possible Causes
Remedy
Motor overloaded.
The starting of high inertia loads may not permit the use
of standard overload relay applications. For accelerating
times of 10 seconds or more, special overload relay
bypass devices and circuits would usually be required.
Contact the factory regarding such problems and supply
complete data on locked-rotor starting current and total
accelerating time under maximum load conditions.
Contact factory.
Replace relay.
46
Troubleshooting
Table 8. Troubleshooting Chart (continued)
Problem
Possible Causes
Remedy
Blowing of motor
power fuses.
Blowing of primary
control transformer fuses.
Blowing of secondary
control transformer
fuses.
Replace fuse.
47
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