Eaton Ampgard 400 Instruction Manual
Instructional Leaflet IB48041
Effective December 2009
Instructions for AMPGARD 400A
medium voltage starter
DANGER
READ AND UNDERSTAND THIS MANUAL IN ITS
ENTIRETY BEFORE INSTALLING OR OPERATING THE
CONTROLLER. INSTALLATION, ADJUSTMENT, REPAIR,
AND MAINTENANCE OF THESE CONTROLLERS
MUST BE PERFORMED BY QUALIFIED PERSONNEL.
A QUALIFIED PERSON IS ONE WHO IS FAMILIAR
WITH THE CONSTRUCTION AND OPERATION OF
THIS EQUIPMENT AND THE HAZARDS INVOLVED.
Introduction
This instruction book is intended to cover
the handling, installation, operation, and maintenance of AMPGARDT 400A, 7.2 kV starters and
associated equipment. The function of these
controllers is to start, stop, and protect medium
voltage motors, transformers, capacitors, and
other loads. Controllers may be of full voltage,
reduced voltage reactor, reduced voltage
autotransformer, reduced voltage solid-state, or
two-speed type. They may control induction or
synchronous machines, and they may be
non-reversing or reversing.
While this instructional leaflet is dedicated primarily
to full-voltage starting, the other applications listed
are an expansion of the principles identified in this
leaflet. This leaflet does not purport to cover all
possible contingencies, variations, and details that
may arise during operation or maintenance of this
equipment. If further information is desired
regarding this product, contact your local Eaton
sales office.
Identification
A rating nameplate is located on the door of each
controller. Contained on this nameplate are the
controller type and ratings as required by industry
standards. Also contained on this nameplate is the
factory’s general order number. This number should
be given to the Eaton sales office if a question
should arise concerning the equipment or if renewal parts are required. Refer to Figure 1 for typical
location of rating nameplates.
Instructional Leaflet IB48041
Effective December 2009
Low
Voltage
Door
Figure 1. Starter with Rating Nameplate
Instructions for AMPGARD 400A
medium voltage starter
DANGER
EXCEEDING THE NAMEPLATE RATINGS OF AN AMPGARD CONTROLLER
MAY CAUSE EQUIPMENT DAMAGE, SEVERE INJURY, OR DEATH.
Do not apply an AMPGARD controller beyond its nameplate ratings.
Rating
Nameplate
Medium
Voltage
Door
Table 1. Contractor Ratings
Rated Utilization Voltage 2200–2500V 3000–3600V 3800–4800V 6000–6900V
Interrupting rating
NEMAT unfused (E1)
NEMA fused (E2)
Application table
Induction motor
Synchronous motor (0.8 PF)
Synchronous motor (1.0 PF)
Transformer
Capacitor three-phase
8.5 kA
50 kA
200 MVA at 2400V
1750 hp
1750 hp
2000 hp
1500 kVA
1200 kVAR
8.5 kA
50 kA
295 MVA at 3300V
2250 hp
2250 hp
2500 hp
2000 kVA
1650 kVAR
8.5 kA
50 kA
400 MVA at 4600V
3000 hp
3000 hp
3500 hp
2500 kVA
2100 kVAR
8.5 kA
50 kA
570 MVA at 6600V
4500 hp
4500 hp
5500 hp
4000 kVA
3300 kVAR
Maximum insulation voltage: 7200V
Maximum interrupting current
(3 operations)
Rated current
IEC make-break capability-AC1
Make
Break
Short-time current
30 seconds
1 second
8.6 milliseconds (0.5 cycle)
Standard service altitude
Optional service altitude
Mechanical life
Electrical life
BIL
Dielectric strength (60 Hz)
Closing time
(energization to contact touch)
Operating time
Time-rated cycles on 60 Hz base.
8500A
400A enclosed
4000A
3200A
2400A
6000A
63 kA peak
–1000 to +2000 meters
–3500 to –1001 meters
+2001 to +5000 meters
2.5 million operations
300,000 operations
60 kV (1.2 x 50 microseconds)
20 kV (1 minute)
90 milliseconds
30 to 330 milliseconds
(selectable)
Arcing time
Pickup voltage
Dropout voltage
Control voltages
AC
DC
Control circuit burden
Closing (AC/DC)
Holding (AC/DC)
Auxiliary contact rating
Voltage (maximum)
Continuous current
Making capacity (AC)
Making capacity (DC)
Breaking capacity (AC)
Breaking capacity (DC)
Latch (when specified)
Mechanical life
Trip voltages (DC)
Trip voltages (DC)
Minimum trip voltage
Trip burden
(24 Vdc)
(125 Vdc)
(110/125 Vac)
Trip Time
Weight
12 milliseconds (3/4 cycle) or less
90% rated coil voltage
60% rated coil voltage
110/120/220/240 (50/60 Hz)
125
—
30 VA
600V
10A
7200 VA
125 VA
720 VA
125 VA
250,000 operations
24/120V
110/120V
90% rated coil voltage
—
—
—
30 milliseconds
60 lbs (27 kg) (rollout)
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Instructions for AMPGARD 400A
medium voltage starter
Description
Controller
The AMPGARD 400A, 7.2 kV controller consists of a non-loadbreak
isolation switch, medium voltage current-limiting fuses, one or
more Type SL vacuum-break contactors, a set of current transformers, plus control and protection devices. The isolating switch has a
limited make and break rating, suitable only for closing and opening
limited transformer magnetizing currents. The controller is designed
to start, stop, and protect a three-phase medium voltage motor
within the ratings shown in Table 1. The controller may also be used
to switch transformer windings or capacitor loads as shown. For
applications other than those indicated, consult the factory. Each
AMPGARD controller occupies all or a portion of a steel structure
that may also enclose a horizontal bus system to distribute power to
two or more sections and a vertical bus system to connect individual
starters to the horizontal bus. The controllers are configured for fullvoltage or reduced-voltage starting, reversing or non-reversing, in
single-speed or two-speed applications.
Starters are available with bolt-in or clip-in main fuses. Contactors
may have bolted connections or stab-in connections to the
starter cell.
The flow of current through a starter with bolted fuses and a
stab-in contactor can be described as follows: The line finger
assembly mounted at the back of the enclosure serves to connect
the isolation switch moving stabs to the controller line terminals
when the switch is closed. Power flows from the switch moving
stabs through a flexible shunt to the upper fuse mountings. The
fuses are connected to the lower fuse mountings that contain the
line-side stab connections to the line finger assemblies for the main
contactor. With the main contactor energized, power flows through
the contactor’s vacuum interrupters to the contactor load fingers,
which are engaged on to the contactor load-side stabs. Medium
voltage cables connect the load-side stabs to the motor load
connections. The contactor is held in place by a set of rails
mounted in the lower part of the cell. Current transformers are
typically mounted immediately behind the main contactor, under the
load-side stabs. The motor load connections are mounted to the left
of the main fuses in the rear of the compartment, facing forward.
Instructional Leaflet IB48041
Effective December 2009
Isolation Switch
Position View
Window
Figure 3. Low Voltage Compartment
Isolation switch
The controller isolation switch is a non-loadbreak device.
Mechanical and electrical interlocks are provided to ensure that
the main contactor is de-energized before the switch can be
operated. In the open position, the switch isolates medium voltage
from the main controller compartment, allowing access to the
controller for inspection and maintenance. For standard applications,
the isolation switch includes ground fingers that ground the line side
of the power fuses when the switch is in the open position. The
isolation switch has a mechanical endurance rating of 10,000
operations. Isolation switches in starters with double-barrel fuses
are supplied with additional phase barriers that must be installed to
maintain the proper dielectric rating of the starter.
DANGER
AMPGARD CONTROLLERS ARE SOMETIMES ENERGIZED BY A BACK-FED
CONDITION THAT ALLOWS THE MEDIUM VOLTAGE COMPARTMENT TO BE
ENERGIZED WITH THE ISOLATION SWITCH IN THE OPEN POSITION. STUDY
THE PLANT SINGLE LINE DIAGRAMS TO MAKE CERTAIN THAT NO BACKFEED SITUATION EXISTS BEFORE ENTERING THE MEDIUM VOLTAGE
COMPARTMENT.
Figure 2. Medium Voltage Compartment
Low voltage components
The low voltage components consisting of a protective relay,
interposing relay, test power circuit, terminal blocks, and optional
equipment are mounted in the low voltage control compartment
located on the front of the controller medium voltage door. The low
voltage compartment is fabricated from steel sheets to provide isolation from the medium voltage components mounted behind the
low voltage compartment. A window is provided in the low voltage
compartment to allow the user to view the position of the isolation
switch before entering the medium voltage compartment. See the
“Isolation Switch” section for further details.
All power sources must be isolated and locked out before
servicing the equipment.
For applications where the controller is back fed, the grounding
fingers should be removed from the isolation switch.
The switch consists of a fixed rear portion and a removable front
portion. Refer to Figures 5 and 6. The fixed portion includes the
controller line fingers and a moveable shutter that isolates the line
fingers when the switch is in the open position. The removable
portion is operated by a handle mechanism that extends through the
controller medium voltage door. With the handle in the up position,
the switch is closed and medium voltage is available for connection
to the controller load. With the handle in the down position, the
switch is open and medium voltage is isolated from the controller
and the controller load.
An isolation switch viewing window is provided in the upper rear
corner of the low voltage control compartment. After opening the
isolation switch and before opening the medium voltage door, the
switch should be visually examined through the viewing window to
verify that it is in the open position. Three green and white “barber
poles” will be visible when the switch is in the open position and
the shutter assembly is in the isolating position. See Figure 4 for
location of barber poles. The use of a flashlight will help in verifying
the position of the barber poles.
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3
Instructional Leaflet IB48041
Effective December 2009
Barber Poles
Indicating
Shutter
Closed
Phase
Barriers (4)
for DoubleBarrel Fuses
Figure 4. Shutter Closed
DANGER
DO NOT ENTER THE MEDIUM VOLTAGE STARTER COMPARTMENT WITHOUT VISUALLY VERIFYING THAT THE ISOLATION SWITCH IS OPEN AND
THE ISOLATING SHUTTER IS IN PLACE. ENTERING A COMPARTMENT
WITHOUT THE ISOLATING SHUTTER IN PLACE MAY RESULT IN SEVERE
INJURY OR DEATH.
Instructions for AMPGARD 400A
medium voltage starter
Vacuum contactor
400A AMPGARD medium voltage controllers are supplied with 400A
vacuum contactors. The contactors are supplied with one of two
interrupting ratings: The standard contactor has an interrupting rating
of 4500A, while the high-interrupting contactor has an interrupting
rating of 8500A. The standard contactors are typically supplied on
controllers with single-barrel main fuses (<188 FLA). They are also
supplied when auxiliary contactors are required, such as start and
run contactors on autotransformer starters and run contactors on
reactor starters. High-interrupting contactors are supplied on
controllers with double-barrel fuses. A code plate is provided in
cells originally equipped with high-interrupting contactors to prevent
the inadvertent installation of standard interrupting contactors into
those cells.
Figure 5. Fixed Portion—ISO Switch
Figure 6. Removable Portion—ISO Switch
Power fuses
AMPGARD controllers are supplied with Eaton Type CLS, CLE,
or HLE current-limiting power fuses. Fuses may be either bolt-in
type or clip-in type. All fuses include an indicator that pops up when
the fuse has blown. An optional blown fuse trip bar may be supplied
with bolt-in fuses. The mechanism is mounted on the controller
isolation switch and may be wired to trip the controller off-line in
the event of a blown fuse.
Figure 7. SL Vacuum Contactor
Contactors are typically three-pole devices except in the case of the
start contactor on autotransformer starters, which are normally twopole devices.
Refer to Instruction Book IB48018N for further details on the
operation and maintenance of the vacuum contactors.
Controllers supplied as transformer feeders, or for other specialized
applications, are sometimes supplied with contactors that include
a mechanical latch device. Refer to Instruction Book IB48020
for further details on the operation and maintenance of the
latch mechanism.
Safety interlocks
AMPGARD controllers are manufactured with several built-in interlock provisions and safety features to reduce hazards and provide
proper operating sequences:
•
A mechanical interlock prevents opening the medium voltage door
with the switch in the closed position. Ensure that the medium
voltage door is fully closed and latched using the two latches on
the right side of the door to prevent damage to the interlock
bracket on the back of the door
•
An additional interlock prevents closing of the switch unless the
medium voltage door is closed (see MV door interlock plunger in
Figure 8). On controllers that require two structures (reduced
voltage starters, for example), the door to the second structure
will also be interlocked with the switch-operating mechanism. The
second door must be closed before the main door is closed. Both
doors must be closed before the switch operator can be moved
to the closed position
ote:N Attempting to close the switch with the door open can cause damage
to the operating mechanism.
4
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