SMCC O, M Manual

NW0244/R05/017
OPERATING, COMMISSIONING
AND MAINTENANCE MANUAL
FOR
SIEMENS
PROJECT REFERENCE NW0244
STATION MOTOR CONTROL CENTRE

FOR HALFAYA
ACTEMIUM REFERENCE IWO 8270
8270 STATION MCC IOM.Doc Page 1 of 40

CONTENTS
Section Description
1 Health & Safety Instructions

First Aid in Case Of Electrical Shock
2 Installation Instructions
3 Part A- Operation
Part B- Maintenance and Fault Finding Procedures
Part C- Test Procedures for Site Electrical Testing of
Motor Control Centre

SECTION 1
HEALTH & SAFETY INSTRUCTIONS
FIRST AID IN CASE OF

ELECTRICAL SHOCK

1.1 HEALTH & SAFETY AT WORK ACT 1974
IMPORTANT HEALTH AND SAFETY NOTICE.
The following information is provided to assist our customers to meet their

obligations under Section 6 of the Health and Safety at Work Act.
Actemium products are designed and manufactured to be safe when properly used for
their intended purpose. It is therefore essential for purchasers to make all
appropriate information readily available to all persons concerned with the use of the
product.
The product should be installed, commissioned, operated, cleaned and maintained by

competent persons, or those under their supervision, in accordance with good
engineering practice and in compliance with:
• IEE Regulations for Electrical Installations Codes of Practice.

• Statutory requirements.
• Instructions specifically advised by Actemium. Clients are asked to note that
Actemium will be pleased to offer additional information and guidance upon
request.
Clients are advised to refer to Actemium in the event of equipment malfunction. This
will ensure that repairs are carried out in a professional manner, without
compromising the inherent safety of the equipment.
1.2 COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL
The purchaser/user is advised to comply with the instructions and information given
in this manual and ensure that all personnel to be associated with the apparatus
supplied under this contract are made familiar with the information contained herein.
1.3 INSTALLATION
The purchaser/user should ensure that the apparatus supplied under this contract is
correctly installed in a suitable location by technically qualified and competent
persons.
Apparatus supplied as loose components, devices or sub-assemblies could, when

energised, constitute a safety hazard. The purchaser/user should ensure that such
apparatus is installed in a secure location and that adequate safety information about
the installation is provided to all personnel to be associated with it.

1.4 OPERATION AND MAINTENANCE
1.4 Guidance Notes for Users on the Safety of Personnel
The rules for ensuring the safety of personnel can be summarised as

follows:
(a) During Normal Use ensure that the plant operators:
- are fully conversant with all controls, particularly those for emergency
shutdown,
- comply with safety warning notices and keep all enclosures shut,
- are trained to recognise signs of mal-operation and know what action to

take in the event of trouble or difficulty.
(b) During Maintenance, Testing etc. ensure that only technically

competent and authorised persons are permitted to carry out work and
that they:
- comply with statutory requirements,
- are fully conversant with the apparatus and the system of which it is part,
and recognise hazards which could arise, e.g. back feed,
- where possible, isolate the apparatus completely before opening

enclosures, and prove it to be dead before starting work. Precautions must
be taken to ensure that the isolated apparatus cannot become live whilst
any work is being carried out,
- comply with any safe working procedures for the safety of themselves and
of others, including the use of temporary barriers and warning notices,
- are conversant with the information provided, particularly on measures

relating to safety,
- recognise the hazards which can arise when working on live apparatus and
take all the necessary precautions,
- functionally check the apparatus and then mechanically and/or electrically

test it in accordance with this manual and good working practice before
putting the apparatus back in service,

- take account of the possibility that the apparatus may have been modified
without proper reference to the manufacturer and take extreme caution at
all times before, during and after any work is carried out.
If there is any doubt as to the correct and safe method of working, then further
assistance should be sought from Actemium.
1.5 SKILLS REQUIRED FOR SPECIFIC TASKS
To ensure that under normal healthy plant operating conditions the plant is safe to
use:
- it has been designed and tested in accordance with relevant British, European
and International Standards,
- information is provided in this manual about the conditions necessary for

safety and about any hazards which are reasonably foreseeable during normal
use, together with precautions to be taken to counteract them.
However, the Purchaser/User should ensure that the apparatus is maintained in

a safe condition and if technically competent and authorised personnel have to
gain access to apparatus which is not made completely safe as recommended,
everyone under whose authority these persons act should ensure that
appropriate safety procedures are generated and are complied with.
Reference to the Apparatus/Task/Skill Level Schedule below enables the user

to select personnel to carry out specified tasks requiring access to the
apparatus.

APPARATUS MINIMUM SKILL LEVEL REQUIRED FOR
Degree Of Integral 100% Isolation & Setting, Cleaning & Setting, Cleaning & Special Testing
Grade Isolation Provided For Proving Dead Routine Routine Commissioning
Maintenance Maintenance Fault Finding
WITH POWER OFF WITH POWER ON OR WITH POWER ON

100% ISOLATED & NOT 100% ISOLATED OR NOT 100%
PROVED DEAD ISOLATED
100% Isolation by
1 operation of the C A C C
isolator(s) provided
Partial isolation only
2 by operation of the
isolator(s) provided. C A C C
The Purchaser/User is
responsible for 100%
isolation elsewhere
No isolator provided.
3 The Purchaser/User is
responsible for any C B C C
necessary situation
elsewhere
100% Isolation not
4 possible because
Impracticable Not applicable Not applicable C C
Unreasonable
and/or Undesirable
Apparatus supplied as
5 loose items,
subassemblies etc. for Skill level to be
which the determined by the
C C C
Purchaser/User is Purchaser/User
responsible for wiring,
assembly etc. (See
page 1 paragraph 2)
SKILL LEVELS AS REFERRED TO IN THE SCHEDULE ABOVE
SKILL JOB DESCRIPTIONS

LEVEL Proposed by Supplier User
A Operating and maintenance staff with NO electrical

knowledge but fully conversant with the operation and
maintenance of the apparatus
B Maintenance staff with SOME electrical knowledge and fully

conversant with the operation and maintenance of the
apparatus and the system of which it is part
C Authorised and competent staff (e.g. Electrician,

Commissioning Engineer) with HIGH degree of electrical
expertise; trained to work on live apparatus and fully
conversant with the operation and maintenance of the
apparatus and the system of which it is part
If additional information relating to the apparatus is required, please contact Actemium .

FIRST AID IN CASE OF ELECTRICAL SHOCK
DO NOT TOUCH THE VICTIM IF HE IS STILL IN CONTACT WITH THE ELECTRICAL

SUPPLY. If the supply cannot be isolated, use DRY insulating material, eg scarf, to pull the
victim clear.
RESUSCITATION USING EXPIRED AIR METHOD

(Approved by the Royal Life Saving Society)
1. Lie the patient on his back, with his arms to his sides. If on a sloping surface,
ensure that the patient’s stomach is lower than his head. RESUSCITATION MUST
COMMENCE IMMEDIATELY ⎯ EVERY SECOND COUNTS. If possible, continue
while lying the patient down.
2. Kneel to one side of and level with the patient’s head. Place one hand under his
neck and the other on top of his head. RAISE THE PATIENT’S NECK AND TILT
HIS HEAD BACK AS FAR AS POSSIBLE WITHOUT USING UNDUE FORCE.
3. Keeping the patient’s head tilted, use one hand to seal either the patient’s nose or
his mouth. Open your mouth wide and inflate the victim’s lungs by blowing air into
his mouth or nose. As you blow, observe the rise of the patient’s chest.
4. Remove your mouth and allow air to escape from the patient’s lungs.
5. Repeat steps 3 and 4 until the patient revives or you are relieved by professional
medical personnel. Do not exceed 12 inflations per minute.
6. When the patient shows signs of natural respiration, adjust your inflation rate to
match his breathing rate.
TREATMENT FOR BURNS
IF BREATHING HAS STOPPED, THE VICTIM MUST BE RESUSCITATED BEFORE BEING

TREATED FOR BURNS.
(A) Do not attempt to remove clothing adhering to the burn.
(B) Do not break blisters.
(C) Cover with a dry, sterile dressing and pad with cotton wool. Bandage lightly over
blisters and firmly over unblistered wounds.
DO NOT APPLY OIL OR GREASE IN ANY FORM

SECTION 2
INSTALLATION INSTRUCTIONS

2 INSTALLATION
2.0 SUMMARY OF PROCEDURE
2.0 Read these instructions.

2.1 Shipping Information
2.2 Lifting Methods
2.3 Fix and Level first panel.
2.4 Position next column
Bolt it, a) to the column that has just been erected, then b) to the floor.
2.5 Fit all fishplates and torque up.
2.6 Inspect and test completed panel installation.
2.7 Connect all cables and commission.
Tools Required
Electrical fitters tool kit.

Metric socket set up to 22mm A/F
Torque wrench up to 70NM (52 ft.lbs) - end sensing type e.g. Gedore ‘BZ’
Scissors or Stanley knife - for cutting sealing strip.
Large flat bladed screwdriver - for removing covers.
Petroleum jelly (electrical) - for busbar joints.
Wire wool - for cleaning fishplates.
2.1 Shipping Information

2.2. Lifting Methods
Warning -Mechanical assistance will be required for lifting.
Panels must always be lifted by the lifting positions as provided, or by pallet/forklift

trucks and by NO OTHER MEANS.
Lifting by busbars or busbar supports will damage them and could lead to early
failure in service.
Safety
The panel is fitted with busbars and is hence ECCENTRICALLY LOADED, i.e. top
heavy, so great care must be taken when moving or transporting it. If a panel is
damaged in transit or during installation, contact Actemium immediately, as busbar
integrity cannot be guaranteed without inspection.
Protection
During transit, storage and installation the panel must be protected from damp and
dust and any contamination must be removed before covers are replaced. This also
applies if any drilling or similar work is carried out after the panels have left our
works. Always give the inside of the panel a thorough clean prior to testing.

2.3. Fix and Level First Panel
The plinth has 15 mm Dia clearance holes to permit bolting down to the floor. This
can be done by rag bolts or raw bolts etc, as appropriate.
It will be necessary to remove gland plates to gain access to the fixing down points.
(Alternatively a clamp system can be used as shown in the sketch below)
The plinth should be level and fixed first, with suitable packing. Refer to the General
Arrangement in the book of drawings for the finished layout of the panel to ensure
assembly in the correct order.

2.4 Assembly of next Column
Sealing strip must be fitted between columns to maintain the IP rating, as in the
sketch below.
Columns are bolted together with M8 bolts as shown in the sketch above
When all columns are in place, and bolted together, then the base fixings can also be
tightened.
Note
In order to maintain the degree of

protection (IP level) any openings
between the plinth and the floor should
be closed.

2.5 Fitting of Fishplates
These are fitted from above/front by removing all the top and front covers from the
busbar chamber. Mating surfaces should be cleaned thoroughly and smeared with a
thin layer of petroleum jelly to prevent deterioration of the joint.
Use an end sensing torque wrench e.g. Gedore type ‘BZ’ and do not over tighten
bolts. If bolts are too loose or too tight it can lead to early failure. Bolt tightness and
other connections should be checked prior to testing of the panel, especially if the
panel has been in transit or storage for any length of time. We recommend that after
each bolt is torqued up, it be marked with paint or similar to prevent repetition. It
may be necessary, where large busbars are fitted, to pre-assemble the fishplates in one
column, as they may not fit together after the columns are joined together.

2.6 Tests on completion
This equipment is supplied complete and is fully tested. However, after assembly and
installation of the fishplates, we recommend that the system is undergoes the tests
described in Section 4
Warning
Before carrying out any high voltage testing ensure that all sensitive circuits are
isolated. Refer to individual manufacturer’s instructions for detailed information.
Safety
Ensure all personnel are kept well away from the panel during high voltage testing to
prevent danger of electrical shock.
2.7 Connect & Commission
When all the tests have been completed, then the cables may be connected, all the
covers replaced, and any scratches should be touched up. Seriously damaged panels
and doors can be returned to our works for repair or replacement.
If panels have been installed for some time, return a sample to account for the ageing
of the paint and ensure an exact colour match.

SECTION 3
OPERATION, MAINTENANCE
AND TEST PROCEDURES

3A OPERATION
OPERATING MODES
3A.1 NORMAL
3A.2 TEST/MAINTENANCE
3A.3 FAULT INDICATION
3A.4 SAFETY
3A.5 OTHER NON ESSENTIAL CONTROL
3A.1 NORMAL
All main switches are to be in the ON position.
All control key switches S3 are to be selected to REMOTE, and the key removed.
Control is then done remotely by UCP (TCM)
3A.2 (OPERATION FROM THE MCC-Motor Control Centre)
All main switches are to be in the ON position.
Selector Switch S3 to be in LOCAL position the controls are now done at the MCC
using the Push Buttons at the door
3A.3 FAULT INDICATION
The fault indicator (H3 - amber) is illuminated by the operation the overload trip.
To reset the fault indicator, switch off the compartments main switch. Open the
compartment and press the reset button on the overload. Close the compartment and
turn on compartments main switch.
3A.4 SAFETY
For safety each compartment main switch is door interlocked, and can be isolated in
the OFF position with a padlock facility.
The key operated control switch S3 has the key removable in the REMOTE position
only.
3A.5 OTHER NON ESSENTIAL CONTROL

The main incomer is fitted with three supply available lamps (if requested) to indicate
the presence of the main supply on the live side of the incomer.
The main incomer is fitted with an ammeter and selector switch (if requested) to
monitor the current draw on each phase of the incoming supply.
The main incomer is fitted with a voltmeter and selector switch (if requested) to
monitor the voltage on each phase of the incoming supply.
A thermostat mounted in the top horizontal cableway controls the panel anti-
condensation heaters.

MAINTENANCE
AND
FAULT FINDING
PROCEDURES

3B TYPES OF FAULT
Faults are generally found to be within the following categories:-
3B.1 Starter will not operate

3B.2 Starter closes but motor will not run
3B.3 Noisy Contactor or relay
3B.4 Coil burnout
3B.5 Nuisance tripping
3B.6 Contacts overheating and burning
3B.7 Motor burnout
3B.8 Starter will not open
A multi-range universal test meter is considered an almost essential piece of

equipment for all but the most elementary diagnosis. Other useful pieces of
equipment are a pair of test wires with shielded clips at one end and protected prods at
the other for shorting out and bypassing elements of a control circuit.
If after initial inspection and check of voltage availability, etc., the cause of a problem
is not apparent it is frequently advantageous to isolate the apparatus concerned from
the system, except where the operation of it is essential for the diagnosis. This can
frequently be done by removing the main fuses or isolating the MCCB and energising
the control circuit from a separate supply. Another way is to remove the outgoing
main connections to the controlled apparatus.
FAULT TRACING GENERAL POINTS
The appropriate schematic diagram must be used for circuit checking.
When checking a control circuit in particular it is best to adopt the 50/50 method of
elimination. For instance, with an open circuit system, it is best to check by bridging
from the supply terminal to approximately the midpoint of the control circuit. If this
fails to actuate the Contactor then the fault must be in the other half, which in turn is
bridged. By progressing in this way the fault should be found quite quickly.

3B.1 STARTER WILL NOT OPERATE
i) Check that the overload relay reset button has been depressed and that all remote
control switches, etc., are connected and in a closed position. If a self-resetting
overload relay is involved, check that enough time has elapsed after a trip for the
unit to reset.
ii) Check that the supply is available across all phases and also between the feed
terminals of the control circuit. The latter is connected from one phase to neutral.
Lack of a supply may be due to:-
a) A supply failure.
b) Main or control circuit fuses blown or circuit breaker tripped; before

replacing fuses check the system for short-circuits and earth faults.
c) Broken or loose connections, particularly in the control circuit.
d) Isolating switch open.
e) Incorrectly connected; check schematic wiring diagram.
iii) Check the following parts of the control circuit for continuity (which may have
become affected by dirt, foreign bodies or corrosion) by short-circuiting their
terminals progressively or, in the case of a coil, by measuring its resistance with a
test meter.
a) Any switch in the control circuit having normally closed contacts e.g.
initiating pushbuttons, limit, level, pressure switches, thermostats and remote
stop pushbuttons. The initiating circuit can be checked by manually operating
the moving contact carrier of the Contactor or relay, but this needs care. If a
push-button operated device will pull in and hold under these conditions a
faulty starting circuit is indicated.
b) Any interlocking devices with other equipment. These are frequently

isolated by auxiliary contacts on an isolating switch.
c) Overload relay trip switch; this may mean a replacement of the overload
relay. It should be remembered that thermal overload relays require long
cooling periods before they can be reset.
d) Contactor coil. Most Contactor coils have a resistance of several hundred

ohms.

iv) Check that the Contactor coil is the correct voltage and frequency rating.
Specifications require that coils operate satisfactorily over the range - 15% to +
10% nominal volts. A frequent occurrence here is the fitting of a line-to-line
rated coil on a phase-to-neutral connected control circuit. A coil that is
connected to a supply higher than its rating will develop shorted turns and
quickly becomes overheated and faulty.
v) Check that the moving contact carrier mechanism has not become jammed by
something coming loose, transit packing or a foreign body.
3B.2 STARTER CLOSED BUT MOTOR WILL NOT RUN
i) Inspect motor for signs of distress. A loud humming can be caused by:-
a) A single-phasing condition. This usually means that the motor is only

connected to two of the three supply phases, due to an open circuit, a high
resistance Contactor contact or at worst an open circuit in one of the motor
phase windings. This is best checked by a tong-test ammeter. The current
should be approximately the same in each phase. A voltage reading can
sometimes be misleading due to high resistance. A motor will rarely start
under the single phasing condition.
b) Excess load torque. Some drives for example have a clutch, or a manually or
automatically operated unloading device - compressors are a typical example -
to relieve the motor during starting. If fitted check to see that it is operating
satisfactorily. A jammed pump impeller due to the presence of foreign matter
is a typical example.
The starting torque of a squirrel cage motor switched direct on line is normally
between 1.3 and 2 x FLT and in the star connection of a star delta starter it is
reduced to about one-third of this figure. A particular case of this condition, of
course, is when the drive has stalled due to some mechanical defect - a seized
bearing or jams are typical examples.
c) A reversed phase, particularly with star/delta starters.
d) A defective motor. This is outside the scope of this manual.
ii) Check that full voltage is available across all three phases of the input terminals
and the output terminals of the starter after it is operated. If affirmative, check the
motor terminals. Most motors require heavier cabling than their full load current
would indicate, to hold down the volt drop that occurs due to the starting current -
typically for direct on line started machines of 5 to 8 x FLC.
In the case of low voltages it should not be forgotten that the torque is
proportional to the square of the voltage, e.g. 15% reduction in terminal voltage
leads to a 27% reduction in starting torque.

In the cases of single-phasing, confusion can arise from the fact that the control
circuit of the starter is connected between one of the phases that are energised
and the neutral. The starter will operate but the motor will not run.
iii) Check that the brake, if fitted, is releasing correctly.

3B.3 NOISY CONTACTOR OR RELAY
A.C. Contactors are rarely absolutely silent, but extreme noise should not be ignored
since doing so frequently leads to the burnout condition described in Section 3B.4.
i) Check that the correct rating of coil is fitted for the control circuit voltage and
frequency applied. Care should be taken with low control circuit voltages and
long remote connections that excess volt drop is not occurring.
ii) Check that the magnet faces are clean and dry. If this is not the case they should
be cleaned with a fluid such as a trichlor-ethylene. It is best to use a lint-free
cloth for the purpose. Abrasives can sometimes cause trouble because the correct
mating of the magnet faces is so important from the noise point of view.
iii) Intermittent contacts in the control circuit can, of course, cause noise.
Sometimes these are most difficult to trace. The continuity checks as detailed in
3B.1 (iii) will frequently isolate the cause of trouble. It is sometimes necessary to
bridge the contacts of auxiliary devices such as thermostats and limit switches
with the plant in operation to locate those intermittent contacts caused by
vibration.
iv) Check magnet alignment and freedom of movement.
v) Ensure that no foreign matter is preventing the two halves of the magnet coming
together satisfactorily.

3B.4 COIL BURNOUT
This can usually be detected very easily visually and by smell.
i) Check that the correct rating coil is fitted for the control circuit voltage and
frequency applied. See 3B.1 (iv).
ii) Coils can overheat due to the voltage applied to them being too high or too low.
In both cases the trouble is usually preceded by an excessive coil current and a
noisy condition. In the low voltage case the trouble is caused by the fact that the
magnet has not sealed the system inductance and therefore, its impedance is low
and the current high.
iii) Each of the other points mentioned in 3B.3 should be examined in order to
properly diagnose the cause of the coil burnout.

3B.5 NUISANCE TRIPPING
This is caused by a variety of problems:-
i) Check to see if the overload relay has tripped. If affirmative, it can be that the
load is too high - check the nameplate current of the drive with the set current on
the overload relay. In some cases it may be necessary to have a recording
ammeter in service to test for occasional overloads that cannot be observed over a
short period.
ii) Check that the currents in each of the three phases are balanced. Most motors
have phase currents within 10% of each other. If they are not, the condition can
sometimes be due to a high resistance contact or terminal in the system or to an
overload heater coil becoming partially open circuited. It is not generally
realised that an imbalance of 2% in voltage can lead to over 10% imbalance in
motor current.
iii) Check for occasional high resistance in the control circuit which can sometimes
be caused by the lack of contact pressure, dirt or by vibration causing poor
contact on limit switches or pushbuttons, etc. If this is found to be the case, an
improved type of switch or relocation to isolate the device from the vibration may
become necessary.
iv) Temporary voltage fluctuations, particularly drops, can cause the tripping of
starters. The possibility of the starting current - (up to 8 x FLC) of an adjacent
motor causing drops should be considered.
v) In the case of star delta starters it occasionally happens that the timer contact
stays in the 'timed out' mode, and the starter goes straight into the delta
connection. If the drive is not designed for this sort of operation a trip can result.
vi) Incorrect HRC main fuses or circuit-breaker settings can be the cause of trouble.
It should be born in mind that most motors take 5-8 times normal FLC on starting
and a check should be made on manufacturers' ratings for their devices. It is a
requirement of the British Standard that back-up protection recommendations and
the class of protection afforded is given for overload relays.
vii) Check overload relays for faulty normally closed tripping contacts or
calibration. In the latter case reference should be made to the operating curve or
to the manufacturer so that a check can be made with the specified tripping
characteristic.
viii) Many star delta starters have their overload relay heaters connected in the phase
circuits of motors. They may be calibrated in terms of phase current or line
current so in the event of nuisance tripping a check should be made on the
method employed.

ix) Check that all heaters of an overload relay are in circuit. When controlling
single-phase motors it is desirable to have all three phases of an overload relay
energised by looping. In this way the power of all three bi-metals or elements is
employed to overcome the friction and any sticking of the device's mechanism.
With overload relays providing single-phasing protection it is absolutely
essential. Failure to do so in a frequent source of frustration.

3B.6 CONTACTS OVERHEATING & BURNING
High temperatures in the contact area can rapidly become serious. They can be caused
by:-
i) Badly worn contacts. Any large blobs of contact material which may have
formed should be removed, but it should be emphasised that it is not necessary to
file contacts to a smooth finish. It should be remembered that the roughened
surface formed on the contacts by arcing has very good current carrying
properties, far superior to that of a smooth surface. The black film which forms
on silver and silver alloy contacts is not detrimental and should not be removed.
ii) Low contact spring pressures. It is necessary to check that the pressures are not
seriously below the original values. They can be checked with a spring balance
against the manufacturers' recommendations. Contact springs should always be
changed when contacts are replaced.
iii) High contact resistance. Sometimes contacts not opened or closed for long
periods develop an oxide film which produces a high resistance. In many cases it
is only necessary to operate the device for a few times to correct this.

3B.7 MOTOR BURNOUT
The burnout of a motor usually means that the overload relay has not fulfilled its
function in disconnecting the motor. Some reasons are detailed in paragraph i)
however, they can burn out for other reasons and some of these are mentioned in
paragraph ii) of this section.
i) Some reasons for the failure of the starter to trip properly are:-
a) Overload relays incorrectly selected or set in relation to the full load current
of the load. Most overload relays are calibrated in full-load current and allow
a margin for overload and normal starting conditions to prevent nuisance
tripping. It is not necessary for any further allowance to be made otherwise
the small safety margin of the modern continuous maximum rated motor is
likely to be exceeded.
b) Faulty overload relay. Check the operation of the trip switch manually if
possible. Ultimately it may be necessary to check the operation against the
manufacturers' characteristic curves usually found in catalogues.
c) Solenoid overload relays with their piston movements are so retarded by the
deterioration of the dashpot oil and so forth that they fail to operate.
d) The incidence of a single-phasing fault with an overload relay not designed

to cope with this trouble i.e. without a differential tripping feature.
e) A sticking Contactor. To overcome remnant magnetism a Contactor has a

permanent air gap in the magnetic system. If this is lost due to mechanical
wear of the surface in contact, and the contact and throw-off springs are weak,
a unit can sometimes fail to open even though de-energised by the overload
trip switch. On starters operating very frequently it is advisable to check the
air gap which is usually in the centre limb of the magnet, against
manufacturers' recommendations from time to time. Another cause of sticking
is the Contactor unit becoming physically sluggish because of lack of
clearance, foreign bodies and the ingress of high viscosity liquids etc.
f) Faulty or wrong control circuit wiring making the overload relay trip switch
inoperative. Check the operation of the Contactor by manually operating the
overload relay if possible.
ii) Motor can also burn out due to:-
a) Blocked internal or external cooling passages and vents.

b) Ambient temperature too high. Most motors are designed for a maximum
ambient of 40 degrees C.
c) The ingress of moisture or chemicals causing deterioration in the insulation.
d) Weak or faulty motor insulation sometimes caused by insecure location of

the windings themselves.
e) A breakdown of motor insulation due to mains borne voltage spikes as a

result of switching or lightning surges.
f) Poor motor design or manufacture.
g) Wrong motor connections. Check against motor diagram and ensure a

balanced three-phase current.
h) Some motors will not withstand the 20% overload for 2H from a hot
condition allowed for overload relays for BS4941-1:1979 and IEC 292. In
order to avoid repeat burnouts consideration can be given to the insertion of
thermistors at the rewind stage to give improved protection by use of a
thermistor relay.

3B.8 STARTER WILL NOT OPEN
i) See 3B.7 i) e).
ii) Control switch not open-circuiting properly. Check for lack of continuity.
iii) Excess capacities in very long remote connections. This normally becomes a
problem only when distances in excess of 150m are involved. It is caused by the
capacitance current of the remote control connection being sufficient to keep a
magnet energised even though the remote stop circuit is opened. Often a change
to a lower control circuit voltage will cure this simply reducing the capacitance
leakage current involved. Most manufacturers will give advice on this subject for
their particular equipment if asked.
iv) Check for inadvertent back feed on coil circuit particularly when this is
connected phase to phase. A circuit may be present due to a pilot light or an
earth fault in the control circuit.

TEST PROCEDURES
FOR
SITE ELECTRICAL TESTING OF
MOTOR CONTROL CENTRE

Test No. Description
Pre Test
Test 1 Dielectric Withstand Test
Test 2 CT Primary Injection Tests
Test 3 Thermal Relay Injection Tests
Test 4 Functional Test

PRE-TEST
1. All compartments are to be suction cleaned and checked for correct contents.
All deficiencies or faulty equipment due to theft or damage, are to be made good.
Paintwork is to be touched-up where scratched.
2. Hard hats are to be worn in the test area.
3. Danger signs are to be posted on the unit, and in sight of personnel entering
the test area.
4. The test area is to be secured when test personnel are absent.
5. The input power connections and the neutral link are to be isolated from the
unit under test.
6. The input power leads are to be shorted out, a sign placed at the first break-
point down the line warning of the short and the results should power be switched
through. This break-point must be fully secured and the warning highlighted by a
red pennant, visible outside the unit.
NB: The neutral must be isolated from all others.
7. A suitable fire extinguisher bottle must be available at each exit.
8. No unauthorised person is to be allowed access to the test area until all testing
is completed.
9. All test equipment must be certified accurate and copies of the certificates
made available and included in the test report.
10. A 230Vac, 13Amp double output supply must be made available for test use.
11. The test area is to be well lit by shadowless lighting.
12. All relevant, up to date circuit diagrams, specifications and modification

information must be available on site, to the test engineer and the witness.
13. A suitable step ladder must be available on site to enable a full visual
inspection of the unit to take place.

TEST 1
DIELECTRIC WITHSTAND TEST
Test Equipment:
1000V Insulation resistance meter
3KV Dielectric withstand test equipment
1. Short out all phase and neutral lines at the unit input isolator.
2. Short out the control supply transformer secondary to earth and ensure that all CT's
are treated in the same way. Mark all shorts with red pennants.
3. Switch on all switch/fuse units.
4. Apply 1000V pressure to earth with an insulation resistance meter and note result
on Test Record Sheet.
5. Test lines as required by the form, as amended, to take into account the unit
wiring.
6. Repeat 4 & 5 using the dielectric withstand test equipment and apply 2000Vac,
50Hz for 1 minute at each test, again noting the results on Test Record Sheet.
7. Repeat 4 & 5 using the 1000V insulation resistance meter, noting the results on
Test Record Sheet.
8. Remove all shorting links.

TEST 2
CT PRIMARY INJECTION TESTS
Test Equipment
CT Supply Unit
low range
medium range
high range
1. Connect a suitable test supply into the CT primary circuit, noting injected amperes
and indicator reading on Test Record Sheet.
2. Ensure that the forms raised cover all the CT's fitted.

TEST 3
THERMAL RELAY INJECTION TESTS
Test Equipment:
Primary Current Injection Unit
Stop Watch
1. Take all thermal overload relays out of the circuit to enable input connections to be
made.
2. Connect relays up to simulate a 3 phase current flow and apply:
a) 110% of set FL - No trip
b) 150% of set FL - Time trip and note reset action.
NB: Trip times should be correct in accordance with relay graphs.
3. Connect the relays in single phase mode and carry our test 2 again.
4. Carry out tests 2 & 3 for all overload protection relays, noting the results on Test
Record Sheet.
5. Ensure that Test Record Sheets are raised for all overload relays.
6. Replace all relays back in circuit.
NB: See functional check (test 5) for circuit recheck.

TEST 4
FUNCTIONAL TEST
Test Equipment:
240Vac 13Amp Single Phase Variable Transformer (Variac)
Phase Direction and Voltage Indicator
Voltmeter
Nominal supply voltage.
1. Remove input short.
2. Connect input leads and remake neutral link.
3. Ensure that the isolator is off.
4. Switch on power to unit under test.
5. Isolate the control supply.
6. Disconnect the normal control supply output and connect a variable control
supply.
7. Check that when the isolator is closed and the individual fuseswitch is made the
correct phase and voltages are available at the output terminals.
8. Motor control circuitry:

Test as per tests 1 to 7 using the motor control switching. Note that the motor
control Contactors function properly at both 85% and 100% voltage. Also note that
telemetry and other indications are available at the furthest part of their circuits.
9. Motor control circuitry:

Test as per test 8, noting that when selected the motor output is reversed.
10. Record all function tests on motor circuits on Test Record Sheet.
If the nominal supply voltage is not available, the control action must be checked
by continuity tester).
11. All 'Test' push/switches are to be exercised to ensure action.
12. Note all voltmeter readings against a test meter and record on Test Record Sheet.
13. Switch off isolator.
14. Reconnect the control supply.

15. Carry out a percentage check on output units.
NB If the nominal supply voltage has not been available during this test, then test
15 must be carried out once supply is available. The input voltmeter should
also be functioned at this stage.

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NW0244/R05/017

PROJECT REFERENCE NW0244

STATION MOTOR CONTROL CENTRE

ACTEMIUM REFERENCE IWO 8270

8270 STATION MCC IOM.Doc Page 1 of 40

1 Health & Safety Instructions

8270 STATION MCC IOM.Doc Page 2 of 40

FIRST AID IN CASE OF

8270 STATION MCC IOM.Doc Page 3 of 40

IMPORTANT HEALTH AND SAFETY NOTICE.

The following information is provided to assist our customers to meet their

The product should be installed, commissioned, operated, cleaned and maintained by

• IEE Regulations for Electrical Installations Codes of Practice.

1.2 COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL

Apparatus supplied as loose components, devices or sub-assemblies could, when

8270 STATION MCC IOM.Doc Page 4 of 40

1.4 Guidance Notes for Users on the Safety of Personnel

The rules for ensuring the safety of personnel can be summarised as

(a) During Normal Use ensure that the plant operators:

- are trained to recognise signs of mal-operation and know what action to

(b) During Maintenance, Testing etc. ensure that only technically

- comply with statutory requirements,

- where possible, isolate the apparatus completely before opening

- are conversant with the information provided, particularly on measures

- functionally check the apparatus and then mechanically and/or electrically

8270 STATION MCC IOM.Doc Page 5 of 40

1.5 SKILLS REQUIRED FOR SPECIFIC TASKS

- information is provided in this manual about the conditions necessary for

However, the Purchaser/User should ensure that the apparatus is maintained in

Reference to the Apparatus/Task/Skill Level Schedule below enables the user

8270 STATION MCC IOM.Doc Page 6 of 40

WITH POWER OFF WITH POWER ON OR WITH POWER ON

SKILL LEVELS AS REFERRED TO IN THE SCHEDULE ABOVE

SKILL JOB DESCRIPTIONS

A Operating and maintenance staff with NO electrical

B Maintenance staff with SOME electrical knowledge and fully

C Authorised and competent staff (e.g. Electrician,

If additional information relating to the apparatus is required, please contact Actemium .

8270 STATION MCC IOM.Doc Page 7 of 40

DO NOT TOUCH THE VICTIM IF HE IS STILL IN CONTACT WITH THE ELECTRICAL

RESUSCITATION USING EXPIRED AIR METHOD

TREATMENT FOR BURNS

IF BREATHING HAS STOPPED, THE VICTIM MUST BE RESUSCITATED BEFORE BEING

(A) Do not attempt to remove clothing adhering to the burn.

(B) Do not break blisters.

DO NOT APPLY OIL OR GREASE IN ANY FORM

8270 STATION MCC IOM.Doc Page 8 of 40

8270 STATION MCC IOM.Doc Page 9 of 40

2.0 SUMMARY OF PROCEDURE

2.0 Read these instructions.

Electrical fitters tool kit.

2.1 Shipping Information

8270 STATION MCC IOM.Doc Page 10 of 40

Warning -Mechanical assistance will be required for lifting.

Panels must always be lifted by the lifting positions as provided, or by pallet/forklift

8270 STATION MCC IOM.Doc Page 11 of 40

8270 STATION MCC IOM.Doc Page 12 of 40

In order to maintain the degree of

8270 STATION MCC IOM.Doc Page 13 of 40

8270 STATION MCC IOM.Doc Page 14 of 40

2.7 Connect & Commission

8270 STATION MCC IOM.Doc Page 16 of 40