11128 STARTER MANUAL.pdf

Operating Manual Oil-cooled drum-type rheostatic rotor starter Type : DOA250/300A

Customer ...........................: F.E.P. International Traders, Inc.

Order-No ............................: 12041400321

Ident.-No.............................: 12000009015-16

CONTENTS / SUMMARY 1. IMPORTANT NOTE IN010 2. RECOMMENDATION FOR OIL 3. TECHNICAL SPECIFICATION 4. SERVICE / SAFETY INSTRUCTIONS L1.1 / FS / FSU 5. OUTLINE DRAWING MZ1630b 6. WIRING DIAGRAM / TERMINAL BLOCK SF1043c-1 7. DESCRIPTION OF WIRING DIAGRAM SF1043c-1 8. CIRCUIT DIAGRAM FOR CONTACT DRUM S1DAW947 9. STROKE ADJUSTMENT T30736a 10. COVER SHEET SPARE PARTS LIST 11. SPARE PARTS LIST

12. CHECKLIST 12000009015

13. CHECKLIST 12000009016

Page 1 of 1

TECHNICAL DOCUMENTATION

Serial No.: 12000009015-16 Type: DOA250/300A

IN 010 1/1

ACHTUNG

Vor Anlegen der Prfspannung an den Widerstandsteil zwecks Isolationsprfung mu der Mekreis mit den Klemmen n und o des Frequenzrelais abgetrennt werden.

IMPORTANT NOTE Before applying test voltage to the starting resistor for checking insulation, make sure you have detached the measuring wires of the frequency relay at terminals n and o.

ATTENTION Avant dappliquer la tension dpreuve la rsistance de dmarrage fin de vrifier lisolation, il faut dconnecter les cbles de mesure du relais de frquence aux bornes n et o.

ATENCION Antes de aplicar la tensin de ensayo a la resistencia de arranque pare comprobar el aislamiento, es preciso desconectar los cables de medicin del rel de frecuencia en los bornes n y o.

ATTENZIONE Prima di applicare la tensione di prova sullelemento di resistenza per controllarne lisolamento si deve staccare il circuito di misura con i morsetti n ed o del rel di frequenza.

of 1

RECOMMENDATION FOR OIL

Normal transformer oil according to VDE 0370/DIN 57370/IEC 296 is

applied, e.g. Shell Diala S2 ZU-I, Esso Univolt 56, BP Energol JS-HA.

Practical examinations have shown that it is not necessary to purify or

renew the oil filling even after a long working period as it is only

required to store heat energy and not to improve insulation.

The make or type of the transformer oil is not decisive, however in no

case may CLOPHEN, PYRANOLE or ASKAREL be filled in.

01/2012

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T E C H N I C A L S P E C I F I C A T I O N

Oil-cooled drum-type rheostatic rotor starter

For three-phase slipring motor, number of steps: 6 number of positions: 7, balanced shorting, starting time ta = appr. 20 s, starting severity f = 1.4, successive starts z = 3 from cold state, periodic starts h = 1, number of starts per hour. Required amount of oil approx. 100 l, approx. weight 125 kg, (without oilfilling), o-a-dim. acc. to MZ 1630b, size 2, class of protection IP 54, painting acc. to RAL 7035. With servo-drive 3x440 V, 60 Hz, incl. all necessary auxiliary switches, emergency handwheel and temperature switch F3/ F31, control voltage 220 V, 60 Hz, wiring according to SF 1043c-1. For rated motor power 250 kW, rotor 525 V, 289 A, MK/MN = 2.2, nN = 900 rpm, mass moment of inertia max. J = 120 kgm, referred to rated motor speed, for a BALL MILL drive. Type: DOA250/300 Serial-No. 12000009015-16A REMARKS:

- Temperature monitoring - Oil level gauge - Step interval monitoring - Locked rotor control

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Service / Safety instructions L1.1 / FS / FSU

Safety instructions for the operation of starters (In conformity with the low voltage directive 73/23/EEC)

1. General In operation, starters, depending on their degree of protection, may have live, uninsulated and possibly also moving or rotating parts, as well as hot surfaces. In case of inadmissible removal of the required covers, of improper use, wrong installation or maloperation, there is the danger of serious personal injury and damage to property. All operations serving transport, installation and commissioning as well as maintenance are to be carried out by skilled technical personnel (Observe IEC 364 or CENELEC HD 384 or DIN VDE 0105-100 and national accident prevention rules!). For the purposes of these basic safety instructions, "skilled technical personnel" means persons who are familiar with the installation, mounting commissioning and operation of the product and have the qualifications needed for the performance of their functions. 2. Intended use Starters are components designed for inclusion in electrical installations or machinery. In case of installation in machinery, commissioning of the starter (i.e. the starting of normal operation) is prohibited until the machinery has been proved to conform to the provisions of the directive 98/37/EEC (Machinery Safety Directive - MSD). Account is to be taken of EN 60204. Commissioning (I.e. the starting of normal operation) is admissible only where conformity with the EMC directive (89/336/EEC) has been established. The starters meet the requirements of the low voltage directive 73/23/EEC. They are subject to the harmonised Standards of the series prEN 50178/DIN VDE 0160 in conjunction with EN 60439-1/DIN VDE 0660, part 500. The technical data as well as information concerning the supply conditions shall be taken from the rating plate and from the documentation and shall be strictly observed. 3. Transport, storage The instructions for transport, storage and proper use shall be complied with. The climatic conditions shall be in conformity with prEN 50178. 4. Installation The installation and cooling of the appliances shall be in accordance with the degree of protection. It is to take into account a max. ambient temperature of 45C. The starters shall be protected against excessive strains. In particular, no components must be bent or isolating distances altered in the course of transportation or handling. No contact shall be made with electronic components and contacts. Starters contain electrostatic sensitive components which are liable to damage through improper use. Electric components must not be mechanically damaged or destroyed (potential health risks). Oil cooled starters must be filled with acidfree, mineral insulating oil of ambient temperature according to DIN VDE 0370 corresponding IEC 296 (e.g. Shell Diala D, Esso UNIVOLT 52, BP T166 SGF, MOBILECT 37) up to the middle of sight glass prior to commissioning. Air cooled starters are equipped with a air inlet at the bottom and with a air outlet in class of protection IP23 at the side. It is not allowed to cover this outlets. Distance to the walls > 0,5 m.

of 3 5. Electrical connection When working on live starters, the applicable national accident prevention rules (e.g. VBG 4) must be complied with. The electrical installation shall be carried out in accordance with the relevant requirements (e.g. cross sectional areas of conductors, fusing, PE connection). Observance of the limit values required by EMC law is the responsibility of the manufacturer of the installation or machine. Each unit is accompanied by a wiring diagram showing the electrical connections. Watch for good electrical connections on terminals. A correct polarity of the actuating motor is required to ensure proper function. In case the direction of rotation compared with the wiring diagram and the description is not correct, the contact assembly should be brought to a middle position. Polarity of the actuating motor must then be reversed by interchanging two phases (reverse polarity of armature in case of DC or universal motors.) If there are oil pumps, the sense of rotation is as well to check. For this the brass screwed cap on the motor housing is to remove. 6. Operation Installations which include starters shall be equipped with additional control and protective devices in accordance with the relevant applicable safety requirements, e.g. Act respecting technical equipment, accident prevention rules etc. The technical data are found on the rating plate. During operation, all covers and doors shall be kept closed. The starters are provided with notching facilities in each position and can be turned progressively from step to step. Only end limit positions of the starters are suitable for continuous operation. Keeping them in the intermediate positions, even for temporary speed control, would case destruction of the unit. Starters with remote drive are equipped with a pilot motor and a stepping mechanism. One complete revolution will advance the switching gear properly by one step. As the catch roll engages the stepping wheel only during a small angular movement, contact changing takes place rapidly. The individual contacts will always be fully covered, because the stepping wheel acts also as a nothing wheel, and the actuating motor will be only cut off whilst idling with stepping wheel out of mesh. A switching procedure once initiated must not be interfered with by hand. Controlling and locking as well as monitoring and protective functions (thermal motor protection, overcurrent monitoring, thermostat, lock device etc.) may not be put out of operation, not even during trial service. Systems may be mounted and operated only in the documented order. 7. Maintenance and servicing Only carry out all work on the control devices, i.e. installation, connection, opening the device and maintenance, when - the system is free of electrical current, - it cannot be switched on again and - all drives are at a standstill Before starting these works check the system to be without stresses using suitable tools. The contact pressure and the connections should be checked regularly at larger intervals. Heavily worn contacts must be replaced. Bearing and moving parts are to be greased sufficiently. In case of oil cooled starters make sure, that oil is always free of physical pollution. In case of air cooled starters the contacts must be maintained with an acid- and resinfree contact grease. Should the catch roll be left engaged in the stepping wheel due to a supply failure, any attempt to proceed by hand will prove impossible. In this case the motor shaft must be turned out of the mesh.

of 3 8. Spare parts When ordering spare parts, the 6 digit serial number of the equipment on the rating plate should always be indicated to avoid incorrect supplies. 9. Warranty Only in observance of and adherence to the respective valid operating instructions can the manufacturer's warranty be upheld.

KEEP SAFETY INSTRUCTIONS IN A SAFE PLACE ! August 2002 lg.

12000009015-16

DOA250/300A

A1

A2K2

21

22K50

1

2K0

18

15K2

A1

A2K1

21

22S80

21

22K0

21

22S81

31

32K50

A1

A2K3

18

15K3

21X

22XK0

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

+=

Zustand nderung Datum Name NormGepr.

Bearb.Datum

Ur sp r . E r s . f . E r s .d .Pageof

2

1

contac tor forServo - MotorSchtz fr

p i lo t -motors tep- interval -moni torre lay comb. forStufenzeitberwachung

Fernantriebremote-drive

A1

A2

Y1

Z2K4

21

22S69

t ime-adjustmentt i m e r f o r s t a r t i ng-

S c h r i t t - Z e i t r e l a i s

Starter 1

2ON/OFF

A1

A2K0

1X2

2X2

3X2 4

N(L- )(L+)

L1

13

14S61

13

14S64

F10

43

44Q10

2.1E

2.1A

16

13X

14XK1

21

22K1

TB

SF 1043c-1

18.06.13

12

11

14

2.4D

1.2D

1.3D

1.2D

2.4D 1.5D 1.2D

2.8A

1.3D

1.3D

3.5D

18 151.3C

1 23 45 6

2.8B

13X 14X1.4D21 221.3C

18 151.6C 18 153.5B1 21.3B5 62.2B21 221.4B21X 22X1.6C31X 32X3.4B

DOA250/300A12000009015-16

56K0

X3

o

A1

A2n

X2

F5

11

14F5

A1

A2K7

15

18K7

A1

A2K8

21

22S51

11

14K8

X1

X2H2

21

22S50

A1

A2K50

15X2

16X2

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

+=

Zustand nderung Datum Name NormGepr.

Bearb.Datum

Ur sp r . E r s . f . E r s .d .Pageof

t o s t a r t i n g r e s is torzum Anlasswiderstand

remote resetFern-rckstellung

Blockierschutzl ocked rotor cont ro l

Frequency control

1

2

Fernantriebremote-drive

1

2

3

4

5

6K1

L1X1

L2

S81

S50

L3 PE

S35

S301

S60

Hi l f swalze - Schal ter12345 - - - - 1

for handwheeli nter lock ing sw i tchHandradschalter

rachet switchesRastenhebelschalter

s t e p l im i t sw i t chSchr i t tendschalter

p i lo t -motorServo-Motor

S80

aux i l iary cam switches

gle ichzei t ig m i t S81

simultaneously with S81

S50 arbei tet n icht

S50 do not work

n

1 3 5

2 4 6Q10

33

34

43

44

0,15 KW0,67A

S64

S61

S69S302

M3U V W

PEM1

1.8E

1.8A

--

warningmax. 85C

cut offmax. 120C

A1

A2K130

A1

A2K131

>85C

3

1-F3

>120C

3

2-F31

PE

1X3

2X3 3X3

5X34X3

26SF 1043c-1

18.06.13

1.2D

2.2D

2.2D 2.3D

1.3D

1.3D

3.5D

11 142.2C 15 182.3C11 142.3C21 223.5D

11 123.5D21 221.3B31 321.5C

12 1114

3.1B

21 223.5C12 1114

3.2B

21 223.5C

TB DOA250/300A12000009015-16

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

=+

Pageof

Fernantriebremote-driveZustand nderung Datum Name NormGepr.

Bearb.Datum

Urspr. Ers. fr Ers. durch

5X2

6

7X2

warningmax. 85C

8X2

9

10X2

cut off

11

12S302

19X2

20X2

Starterin startposition

11

12S35

17X2

18X2

Starterin endposition

21X2

Trip

11

12S60

18

15K4

21

22K8

22X2

33

34Q10

31X

32XK0

23X2

24X2

Starter

11

12K50

11

12S301

ready for start

max. 120C

21

22K131

21

22K130

12

11

14K130

12

11

14K131

36

Derpa

SF 1043c-1

18.06.13

11

14F10

1.5D

2.3D

2.8A

1.2D

2.4D

2.5D

2.4D

2.4D 2.5D

1.1C

TB DOA250/300A12000009015-16

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

=+

page

Seite Blatt/Pfad

page/path

Anschluconnection

Ziel intern

destination

internally

BezeichnungdesignationBrckenlinks

Klemmennummerterminal-no.

Anschluconnection

Ziel extern

destination

externally

Bezeichnungdesignation

Kabelbezeichnung extern

cable designation

externally

PageofZustand nderung Datum Name Norm

Gepr.Bearb.Datum


Klemmenplanterminal block

1

X1

L1Q10

12.8A

L2Q10

32.8A

L3Q10

52.8A

PE2.8A

46SF 1043c-1

18.06.13TB DOA250/300A12000009015-16

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

=+

page

Seite Blatt/Pfad

page/path

Anschluconnection

Ziel intern

destination

internally



Anschluconnection

Ziel extern

destination

externally



cable designation

externally


Gepr.Bearb.Datum



2

X2

1F10

E1ON/OFF

11.2B

2K0

A1ON/OFF

21.2C

3F10

E21.1E

4K0

A21 .1E

5K130

123.1B

6K130

143.1B

7K130

113.1C

8K131

123.2B

9K131

143.2B

10K131

113.2C

15K8

14H2

X12.3D

16K8

A2H2

X 22.3D

17S35

113.4B

18S35

123.4B

19S302

113.3B

20S302

123.3B

21K0

31X

3.5A

22Q10

343.5D

23S301

113.5A

24K50

123.5D

56SF 1043c-1

18.06.13TB DOA250/300A12000009015-16

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

=+

page

Seite Blatt/Pfad

page/path

Anschluconnection

Ziel intern

destination

internally



Anschluconnection

Ziel extern

destination

externally



cable designation

externally


Gepr.Bearb.Datum



3

X3

1S50

21-F3

32.4B

2K130

A1-F3

12.4C

3K131

A1-F31

22.5C

4F5

n2.2E

5F5

o2.2E

PE2.5C

66SF 1043c-1

18.06.13TB DOA250/300A12000009015-16

of 3

Description of Wiring Diagram

SF 1043c-1

The wiring diagram represents the internal wiring of the remote drive. The external wiring may be derived from this diagram and can be changed to meet specific safety and other measures the customers want to introduce. The functioning of all equipment is checked by us. Proper operation of the drive can however not be guaranteed unless the internal wiring remains unchanged and the principle of the wiring is adhered too. Watch for correct polarity of the pilot drive(s) when starting the drive. The purposes of the various control members are as follows: F3 temperature switch F3 is included in the stator circuitry. It operates at approx.

850C and prevents a further starting operation, which might initiate emergency shut down via temperature switch F31.

F31 temperature switch F31 will deenergize the main drive in event of excessive

oil-temperature switch at approx. 1200C. S301 an interlocking contact, that is closed only in the initial position of the control

gear thus permitting start of the motor only in this position, i.e. with total starting resistor in circuit.

S302 works same as S301. It can be used for signalling purposes. S35 is closed in the end position with the starting resistance completely shorted

out. It can be used for signalling, supervision etc. as desired.

of 3

S50 is closed in each intermediate position and energizes then the relay K50. Contact 11-12 of the relay K50 makes sure, that the mechanism has snapped

accurately into the position. It is linked in series with S301. Contact 21-22 of the relay K50 opens the closing circuit of the contactor, so

that between the steps no new command will be effective. Mechanical damage of the stepping mechanism, due by incorrect hand operation, is avoided by this it prevents operation, if the drum controller is not properly adjusted to a full step postion.

Contact 31-32 feeds pulses via relay K3 to relay K4. This circuit monitors the performing of step charges.

S60 is closed within the whole operating range. Under emergency control by

handwheel the main line contactor will be tripped in case the initial or the limit position are being exceeded due to maloperation. The latter is not possible under automatic control.

S61 is a limit switch which opens the closing circuit of the control contactor prior to

reaching the limit position. Accurate stopping of the pilot drive by S81 will thus be initiated.

S64 is open in the initial position. With the stator switch dropped out, it effects

travel beyond the limit position to the initial position, where the drive will be stopped via step limit switch S81.

S69 bridges step interval monitoring after a starting procedure has been

completed. S80 is interlocked with the clutch of the handwheel for emergency control. Upon

engaging the clutch for hand operation it opens the closing circuit of control contactor. This prevents trouble by simultaneous hand- and remote-operation.

S81 is a step limit switch which opens the holding circuit of control contactor

momentarily after each completed step. It will, however, not become effective unless the closing circuit of the control contactor has already been opened. The drive will only be stopped accurately via S81 after a completed step, i.e. in a proper drum position with pilot motor out of mesh.

of 3

LOCKED ROTOR CONTROL In order to protect the starting resistor against excessive currents which could occur in event of the driven machine being blocked mechanically, a frequency relay (F5) is installed. F5 supervises rotor frequency which decreases as motor speed increases. If rotor frequency does not decrease within a preset time lag (K7) to a stipulated value, this will cause relay K8 to interrupt power flow by opening the external mains contactor or circuit breaker. (Path Trip). Tripping will be indicated by lamp H2 (extern). Relay K8 remains engaged and thereby prevents switching on the mains contactor KO until having pressed the reset button S51. The metering input circuit of the frequency relay will bear up to 400 V. In case of a higher rotor voltage at standstill, the starting resistor is tapped accordingly. Approximate dial settings: F5 : 90 percent of full rated mains frequency K7 : 20 percent of total starting time

DOA250/300A

1 2 3 4 5 6 7 8

A

B

C

D

E

F

1 2 3 4 5 6 7 8

A

B

C

D

E

F

=+

Page 1

of

Ajustement des doigts decontact

Stroke Adjustment

5-6 4

T 30 736a

Anlasser Typ '2$ Gre 5-8Drehzahlsteller ADK ... / DP ...

Starter type '2$ size 5-8Speed regulator ADK ... / DP ...

Dmarreur type '2$ tailles 5-8Graduateur de vitesse ADK ... / DP ...

Anlasser Typ: O(A)'2$ Gre 0-4StarterType: O(A)D2$ size 0-4DmarreurType: O(A)D2$ tailles 0-4

Regulador del nmero de revolucionesADK ... / DP ...

Tipo: O(A)D2$ tamaos 0-4Arrancador tipo '2$ tamaos 5-8

Kontaktfingereinstellung

Ajuste de los dedos de contacto

1

Arrancador

Ers.d.Ers.f.Urspr.

04.06.86TB

NormGepr.Bearb.Datum

TBDatum Name

25.6.97Original neunderungZustand

Fingerklotz: 17 NmFingerhead

Fingerklotz: 17 NmFingerheadPatin du doigtCabeza del dego

Patin du doigtCabeza del dego

SegmentoSegmentSegmentSegment: 12 Nm

SegmentoSegmentSegmentSegment: 9 Nm

12000009015-16

Seite/Page 1 von/of 4

ERSATZTEILE-LISTE

SPARE PARTS LIST Gerte-Nr. / Serial No.: 12000009015-16 Typ / Type: DOA250/300A

STEUERUNG / CONTROL UNIT Seite/Page 2 von/of 4Gerte-Nr. / Serial No.: 12000009015-16 Typ / Type : DOA250/300APos.-Nr. Eingeb. Empf. Beschreibung / Typ Material-Sach-Nr. Lieferzeit Preis Bemerkungen

Stck Stck in Wochen EUR / StckPos. No. Qty. Qty. Description / Type Material No. Deliv. Time Price Remarks

instal. recom. weeks EUR / piece

Verstellmotor Gr. 1-4U BG06-31/DU04 PE 301 20 1931 4 W M11 Pilot motor size 1-4U (46,2UpM/rpm) (440V, 60Hz)

Mitnehmer P 090 017 2 W (M1)1 Drive arm

Temperaturschalter 85C / 120C PE 301 30 164 3 W F3 / F311 Temperature switch 2 no contacts

Hilfsschalter T 6881N PE 301 00 011 1 W S81, S50, S60, S64/3017 Auxiliary switch S61/35, S69, S302

Hilfsschalter T 6881V PE 301 00 012 1 W S801 Auxiliary switch

Nockenscheibe, einzeln, gefrst P 070 0012 1 WCam disk (single, milled )

Taster E-215-16-11F PE 301 10 78 3 W S511 Pushbutton

Steuerschtz AF09-30-01-13 PE 301 10 0702110 3 W K0, K12 Auxiliary contactor 100-250 V AC/DC

Hilfsschalterblock CA4-10 PE 301 10 070311 3 W K11 Snap on switch

Hilfsschalterblock CA4-01 PE 301 10 070322 3 W K02 Snap on switch

Zeitrelais CT-ERS.12S PE 301 10 07086 3 W K2, K72 Timing relay 0,05s-300h; 1We, 1c/o

Zeitrelais CT-WBS.22S PE 301 10 07104 3 W K31 Timing relay 0,05s-300h; 2We, 2c/o

Zeitrelais CT-AHS.22S PE 301 10 07096 3 W K41 Timing relay 0,05s-300h; 2We, 2c/o

Relais CR-M, kompl., 3 We, 230V AC PE 301 10 07360 3 W K8, K50, K130, K1314 Relay CR-M, compl., 3c/o, 230 V AC

Frequenzrelais SL 9837 PE 301 10 092 4 W F51 Frequency relay 220 V

Motorschutzschalter MS 116-1,0 PE 301 10 0729 3 W Q101 Manual motor starter 0,63-1 A

Hilfsschalter HK1-20 PE 301 10 07231 3 W (Q10)1 Auxiliary contact 2S; 2no

Sicherungsautomat S 201-C4 PE 301 10 07901 3 W F101 circuit breaker 4 A

Hilfsschalter S2C-H6R PE 301 10 07904 3 W (F10)1 Auxiliary contact 1We; 1 c/o

SCHALTTEIL / DRUM CONTROLLER PART Seite/Page 3 von/of 4Gerte-Nr. / Serial No.: 12000009015-16Pos.-Nr. Eingeb. Empf. Beschreibung / Typ Material-Sach-Nr. Lieferzeit Preis Bemerkungen


instal. recom. weeks EUR / pieceHandrad Kunststoff, Gr. 1-4 PE 303 40 08 1 W 250 mm

1 Handwheel plastic, size 1-4 250 mm

Rastenhebel P 150 001 1 W1 Ratchet lever

Rastenfeder Gr. 3 - 4 PE 302 50 28 2 W1 Ratchet spring size 3 - 4

Druckfeder fr Kontaktfinger PE 302 50 21 1 W21 Pressure spring for contact finger

Kontaktfingerklotz P 060 001 1 W21 Contact finger head

Kontaktfingerklotz 1-8 vorne plattiert P 060 0035 2 WCont. finger head 1-8 front side tippedKontaktfingerklotz 1-8 hinten plattiert P 060 0036 2 WCont. finger head 1-8 back side tippedKontaktfingerklotz beidseitig plattiert P 060 004 2 WContact finger head tipped both sidesSegment 1 - 4 P 060 005 1 W

21 Segment 1 - 4Segment 1 - 4 vorne plattiert P 060 007 2 WSegment 1 - 4 tipped front sideSegment 1 - 4 beidseitig plattiert P 060 008 2 WSegment 1 - 4 tipped both sides

Kontaktfinger 1 - 4 P 060 011 1 WContact finger 1 - 4Kontaktfinger 1-4 vorne plattiert P 060 0131 2 WContact finger 1-4 front side tippedKontaktfinger 1-4 hinten plattiert P 060 0132 2 WContact finger 1-4 back side tippedDoppel-Kontaktfinger 1 - 4 P 060 017 1 WTwin contact finger 1 - 4D.-Kontaktfinger 1-4 vorne plattiert P 060 0191 2 WTwin contact finger 1-4 front side tippedD.-Kontaktfinger 1-4 hinten plattiert P 060 0192 2 WTwin contact finger 1-4 back side tipped

Typ / Type : DOA250/300A

WIDERSTANDSTEIL / RESISTOR PART Seite/Page 4 von/of 4Gerte-Nr. / Serial No.: 12000009015-16 Typ / Type : DOA250/300APos.-Nr. Eingeb. Empf. Beschreibung / Typ Material-Sach-Nr. Lieferzeit Preis Bemerkungen


instal. recom. weeks EUR / pieceWiderstandselement E10 A 002 074 2 W

3 Resistor grid E10Widerstandselement E14 A 002 075 2 WResistor grid E14Widerstandselement E20 A 076 694 2 W

3 Resistor grid E20Widerstandselement E28 A 002 077 2 WResistor grid E28Widerstandselement E40 A 002 078 2 W

6 Resistor grid E40Widerstandselement E55 A 002 079 2 WResistor grid E55Widerstandselement E80 A 002 080 2 WResistor grid E80Widerstandselement E55dv A 001 778 2 W

6 Resistor grid E55dVWiderstandselement E80dv A 001 779 2 W

6 Resistor grid E80dVWiderstandselement E110 A 076 695 2 W

3 Resistor grid E110Widerstandselement E175 A 001 781 2 WResistor grid E175Widerstandselement E230 A 001 782 2 WResistor grid E230Widerstandselement E340 A 001 783 2 WResistor grid E340Widerstandselement E470 A 001 784 2 WResistor grid E470Widerstandselement E670 A 001 785 2 WResistor grid E670

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12000009015

HELMKE ORBIS GmbH P.O. Box 1203, - 31152 Sarstedt/Germany

Tel. No. 05066/90333-0 FAX No. 05066/90333-145 E Mail: [email protected] Internet: www.helmke.de

Check List NOTE: The check list has to be filled in before commissioning and should then be returned to: HELMKE ORBIS GmbH, Ludwig-Erhard-Ring 7-9, 31152 Sarstedt Requirement: The starter may only be put into operation by qualified personnel. Remarks: Prior to attaching rotor cables to terminals K, L, M and before having linked

the slipring (wound rotor) motor to the power supply functional off load tests on the rotor starter may be performed without having filled transformer oil into the starter tank in order to facilitate handling and inspection. If thereby the starter has proved faultless transformer oil may be filled in before connecting up rotor cables (for further details see item 3).

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Type of device: Oil cooled drum type rheostatic rotor starter assigned the designation Serial No.: For starting a slipring motor, motor power 250 kW rotor voltage at standstill: 525 V rotor current at full rated speed and at full load torque: 289 A Type of driven machine: BALL MILL Circuit diagram of pilot drive unit: 3phase power supply voltage: 440 V, 60 Hz 1phase control voltage: 220 V, 60 Hz Outline drawing: Degree of protection: IP 54 Will the run up procedure take place under the conditions and technical data for which the starter has been calculated and designed? (Please confirm) Have steps been taken to prevent overload? (Please confirm) 1. Measuring Resistance Values Prior to applying power to the stator side of the slipring motor and before having attached rotor cable(s) to starter terminals K,L,M test the rotor starter:

1.1 Press down the handwheel and measure the ohmic values between terminals K and L, K and M, L and M in each starter position.

(The handwheel can be fixed in the down position by use of a clip on the end of shaft).

yes

yes

DOA250/300A12000009015

SF 1043c-1

MZ 1630b, size 2

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Note down the values in the table below:

Position K-L K-M L-M

In initial position the ohmic values between any two of the three rotor terminals should be approx. 0.98 Ohms ( 10%). The minimum ohmic value should read approx. zero Ohms and be in final working position. If the result is not satisfactory please contact HELMKE ORBIS immediately. 2. Functional Test of the Pilot Drive Unit 2.1 Attach the control wires to the terminal strip of the pilot drive unit. Apply power to the pilot drive unit only. If the handwheel still is fixed in down position, release it. Make sure the power supply to the stator side of the slipring motor continues

to remain interrupted, also in event of switching ON the slipring motor. 2.1.1 Does the starting resistance change from max. value 10% to approx. zero within the run up time stated on the rating plate of the starter? (Cross out what doesnt apply) (If not, continue at item 5)

yes/no

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2.1.2 To check the step interval monitoring system keep the handwheel pressed down for approx. 5 seconds at the beginning of a simulated run up procedure.

After this time has run off, monitor system must trip. After having released the handwheel the drum controller must automatically return to first starting position with maximum resistance in circuit. Has the energy cut off signal been produced? (Cross out what doesnt apply) (If the answer is no then continue at item 5) Wiper relay K3 is and remains set to approx. 0.3 seconds on principle. (For starters with step interval monitoring system only.) 2.1.3 In case of starters having a run up control system using rotor frequency

(locked rotor control) the corresponding relay settings must also be checked.

A frequently adopted way of control setting will cut off energy if the drive unit doesnt gain 10 percent of full speed beginning at standstill within 20 percent of total run up time, i.e. timer K7 would be set to 20% of run up time and frequency relay F5 would be set to 90% of mains frequency. Locked rotor control: Frequency relay F5: 54 Hz Scale 15 Hyst 7.5% Timer K7: 4 s Timer K7 - Range:: 10 s Timer K7 Setting: 4 Are the settings unchanged? (Please confirm)

yes/no

yes

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3. General Testing Functional test temperature switch F3 /F31 85 C/120C. F4 ./. C. Have all earthing points been properly connected? (Please confirm) Have all mechanical and electrical safety regulations and other laws that are in force at site been observed? (Please confirm) Has normal, acidless mineral transformer oil having ambient temperature been used? (With oil being at ambient temperature the oil tank may only be filled up to the centre of the oil sight glass.) (Please confirm) Has the oil filling been allowed to settle for about 2 or 3 hours? (Please confirm) Have rotor cables been connected? (Please confirm) Handwheel unlocked? (Please confirm) Does power supply provide either full rated voltages or else voltages within particularly acknowledged limits for operating the starter? (Please confirm) In case of deviations beyond 5% of the specified range make sure to first contact HELMKE ORBIS.

yes

yes

yes

yes

yes

yes

yes

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4. Measuring Insulation Resistance Measuring insulation resistance between the 3 rotor terminals K,L,M and the oil tank. The result should be approx. 10 megohms. please enter the value: .......................megohms, (measured with 500 V or 1000 V) Final bench tests on starters in dry state yield values of approx. 80 to 100 megohms. With long storage periods and under the effect of moisture values can drop to below 10 megohms. A field requirement would be to achieve at least 1000 Ohm / V; (related to rotor Volts at standstill). 5. Readjustments If there has been a change in operating characteristics or mistuning which necessitates readjustment proceed as below: Change of run up time A change of run up time will have to comply with instructions stipulated by HELMKE ORBIS, achieved by adjustment of step intervals with relay K2. This must always be verified by checking the complete run up time. After having changed run up time it will also be necessary to reset the step interval monitor! Tuning the step interval monitor by resetting relay K4: General rule: Setting of K4 = maximum step interval + 1 to 2 seconds (where 1 or 2 seconds is the tripping time) For easy tuning of the step interval monitor the maximum period of time between two consecutive pulses of K3 must be measured (LED lamps are on the relay). Time setting on relay K2 plus a time lag caused by the speed of the pilot motor and tripping time 1 to 2 seconds add up to the required setting of K4. The sensitivity of control settings on K4 necessitates practical testing. On starters where the first step interval is longer than the following intervals tuning only refers to the first step. This is achieved by pressing down the handwheel before starting the pilot drive unit. Time then is measured from start to trip.

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After having completed all changes run through the complete list once more checking each detail!! If serious deviations are found in any section of checking procedure the starter may only be put to work on receipt of written approval by HELMKE ORBIS. Company: ....................................................................................................... Place, date: ..................................................................................................... Signature: ........................................................................................................ Please return this check list to: HELMKE ORBIS GmbH Ludwig-Erhard-Ring 7-9 31152 Sarstedt GERMANY

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12000009016

HELMKE ORBIS GmbH P.O. Box 1203, - 31152 Sarstedt/Germany

Tel. No. 05066/90333-0 FAX No. 05066/90333-145 E Mail: [email protected] Internet: www.helmke.de

Check List NOTE: The check list has to be filled in before commissioning and should then be returned to: HELMKE ORBIS GmbH, Ludwig-Erhard-Ring 7-9, 31152 Sarstedt Requirement: The starter may only be put into operation by qualified personnel. Remarks: Prior to attaching rotor cables to terminals K, L, M and before having linked

the slipring (wound rotor) motor to the power supply functional off load tests on the rotor starter may be performed without having filled transformer oil into the starter tank in order to facilitate handling and inspection. If thereby the starter has proved faultless transformer oil may be filled in before connecting up rotor cables (for further details see item 3).

of 7

Type of device: Oil cooled drum type rheostatic rotor starter assigned the designation DOA250/300ASerial No.: For starting a slipring motor, motor power 250 kW rotor voltage at standstill: 525 V rotor current at full rated speed and at full load torque: 289 A Type of driven machine: BALL MILL Circuit diagram of pilot drive unit: SF 1043c-1 3phase power supply voltage: 440 V, 60 Hz 1phase control voltage: 220 V, 60 Hz Outline drawing: MZ 1630b, size 2 Degree of protection: IP 54 Will the run up procedure take place under the conditions and technical data for which the starter has been calculated and designed? (Please confirm) Have steps been taken to prevent overload? (Please confirm) 1. Measuring Resistance Values Prior to applying power to the stator side of the slipring motor and before having attached rotor cable(s) to starter terminals K,L,M test the rotor starter:

1.1 Press down the handwheel and measure the ohmic values between terminals K and L, K and M, L and M in each starter position.

(The handwheel can be fixed in the down position by use of a clip on the end of shaft).

yes

yes

12000009016

of 7

Note down the values in the table below:

Position K-L K-M L-M

In initial position the ohmic values between any two of the three rotor terminals should be approx. 0.98 Ohms ( 10%). The minimum ohmic value should read approx. zero Ohms and be in final working position. If the result is not satisfactory please contact HELMKE ORBIS immediately. 2. Functional Test of the Pilot Drive Unit 2.1 Attach the control wires to the terminal strip of the pilot drive unit. Apply power to the pilot drive unit only. If the handwheel still is fixed in down position, release it. Make sure the power supply to the stator side of the slipring motor continues

to remain interrupted, also in event of switching ON the slipring motor. 2.1.1 Does the starting resistance change from max. value 10% to approx. zero within the run up time stated on the rating plate of the starter? (Cross out what doesnt apply) (If not, continue at item 5)

yes/no

of 7

2.1.2 To check the step interval monitoring system keep the handwheel pressed down for approx. 5 seconds at the beginning of a simulated run up procedure.

After this time has run off, monitor system must trip. After having released the handwheel the drum controller must automatically return to first starting position with maximum resistance in circuit. Has the energy cut off signal been produced? (Cross out what doesnt apply) (If the answer is no then continue at item 5) Wiper relay K3 is and remains set to approx. 0.3 seconds on principle. (For starters with step interval monitoring system only.) 2.1.3 In case of starters having a run up control system using rotor frequency

(locked rotor control) the corresponding relay settings must also be checked.

A frequently adopted way of control setting will cut off energy if the drive unit doesnt gain 10 percent of full speed beginning at standstill within 20 percent of total run up time, i.e. timer K7 would be set to 20% of run up time and frequency relay F5 would be set to 90% of mains frequency. Locked rotor control: Frequency relay F5: 54 Hz Scale 15 Hyst 7.5% Timer K7: 4 s Timer K7 - Range:: 10 s Timer K7 Setting: 4 Are the settings unchanged? (Please confirm)

yes/no

yes

of 7

3. General Testing Functional test temperature switch F3 /F31 85 C/120C. F4 ./. C. Have all earthing points been properly connected? (Please confirm) Have all mechanical and electrical safety regulations and other laws that are in force at site been observed? (Please confirm) Has normal, acidless mineral transformer oil having ambient temperature been used? (With oil being at ambient temperature the oil tank may only be filled up to the centre of the oil sight glass.) (Please confirm) Has the oil filling been allowed to settle for about 2 or 3 hours? (Please confirm) Have rotor cables been connected? (Please confirm) Handwheel unlocked? (Please confirm) Does power supply provide either full rated voltages or else voltages within particularly acknowledged limits for operating the starter? (Please confirm) In case of deviations beyond 5% of the specified range make sure to first contact HELMKE ORBIS.

yes

yes

yes

yes

yes

yes

yes

of 7

4. Measuring Insulation Resistance Measuring insulation resistance between the 3 rotor terminals K,L,M and the oil tank. The result should be approx. 10 megohms. please enter the value: .......................megohms, (measured with 500 V or 1000 V) Final bench tests on starters in dry state yield values of approx. 80 to 100 megohms. With long storage periods and under the effect of moisture values can drop to below 10 megohms. A field requirement would be to achieve at least 1000 Ohm / V; (related to rotor Volts at standstill). 5. Readjustments If there has been a change in operating characteristics or mistuning which necessitates readjustment proceed as below: Change of run up time A change of run up time will have to comply with instructions stipulated by HELMKE ORBIS, achieved by adjustment of step intervals with relay K2. This must always be verified by checking the complete run up time. After having changed run up time it will also be necessary to reset the step interval monitor! Tuning the step interval monitor by resetting relay K4: General rule: Setting of K4 = maximum step interval + 1 to 2 seconds (where 1 or 2 seconds is the tripping time) For easy tuning of the step interval monitor the maximum period of time between two consecutive pulses of K3 must be measured (LED lamps are on the relay). Time setting on relay K2 plus a time lag caused by the speed of the pilot motor and tripping time 1 to 2 seconds add up to the required setting of K4. The sensitivity of control settings on K4 necessitates practical testing. On starters where the first step interval is longer than the following intervals tuning only refers to the first step. This is achieved by pressing down the handwheel before starting the pilot drive unit. Time then is measured from start to trip.

of 7

After having completed all changes run through the complete list once more checking each detail!! If serious deviations are found in any section of checking procedure the starter may only be put to work on receipt of written approval by HELMKE ORBIS. Company: ....................................................................................................... Place, date: ..................................................................................................... Signature: ........................................................................................................ Please return this check list to: HELMKE ORBIS GmbH Ludwig-Erhard-Ring 7-9 31152 Sarstedt GERMANY

11128 STARTER MANUAL.pdf

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Transcript of 11128 STARTER MANUAL.pdf