CR 194 One/Two-High Vacuum Limitamp® AR Control Page 2
Introduction
GE’s Limitamp® AR is the solution for applications where an
extra margin of protection is essential. It meets the IEEE
C37.20.7 Type 2B and IEC 62271-200, TYPE-A standards and is
available in one- and two-high versions of FVNR motor
starters, rated for 2.4-7.2kV-400A, 5kV-800A.
This instruction book is to be used in conjunction with GEH6263 (Two high vacuum equipment), GEH-5306 (vacuum
contactor) and GEH 5396B (800A) instructions.
Figure 1. 36”
wide Two-High
AR FVNR starter
with low-voltage
doors open.
WARNING: Before any adjustments, servicing, parts
replacement or any other act is performed requiring
physical contact with the electrical working components
or wiring of this equipment, all power must be removed
and locked off from all sources and all attached rotating
equipment must have come to a complete stop. User
personnel must be completely familiar with the following
operating and maintenance instructions before attempting
to service this equipment.
WARNING: The vacuum interrupter integrity test should be
performed before the high voltage vacuum contactors are
energized for the first time and each time the contactors
are returned to service after maintenance, adjustment or
repair. Failure to perform this test may result in serious
injury or death.
CAUTION: Product is not intended for nuclear use.
Opening High-Voltage Door
The high-voltage doors on the CR194 Two-High Vacuum
Limitamp AR are mechanically interlocked to prevent the
opening of the doors, when equipment is energized. For
safe opening of high-voltage door, follow the step-by-step
procedure as mentioned below.
Step 1: Push in the handle latch release and rotate the
isolation switch handle to the full “OFF” position. The latch
release must pop back out. See figure 3.
Step 2: Rotate the handle (Black color handle) down with a
rapid positive motion, to bring it to “OFF” Position.
Step 3: Rotate the high-voltage door latch handle (silver color)
90° in the counter-clockwise direction to disengage the multi
latches on the inside of the door.
Step 4: Turn all flange nuts simultaneously until disengaged
from hat brackets.
Step 5: The high-voltage door may then be opened by pulling
out on the latch handle.
Figure 2. 36”
wide Two-High
AR FVNR starter
with high-voltage
doors open.
Figure 3. Push in
the handle latch
WARNING: Confirm that equipment is de-energized before
opening the high-voltage doors.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 3
Figure 4. Rotating
the high-voltage
door latch handle.
Locking Pins in
Unlocked Position
Latch Handle
Locking Pins in
Locked Position
Figure 6. View of locking pins on high-voltage door.
High-Voltage Door Latches
The Limitamp AR design uses special high strength door latch
parts to keep the door closed during an arcing event. All of the
latches must be properly engaged for the product to function
properly. On the outside of the high-voltage door there is a
door latch operating handle. Rotating this handle operates all
of the latch locking pins at one time.
The door latch locking pins are all adjusted prior to shipping
from the factory. If any of the door latch pins are moved or
replaced make sure they are adjusted per the sketch below.
Make sure to tighten the locking stud on the locking pin bridge.
When the door handle is in the locked position adjust locking
pin bridge to provide a 0.150” gap between the bridge and the
welded “U” fork on the door.
Locking Stud
.150
The mating part of the latch system is shown in the Figure 7
below. The enclosure side latch parts are mounted to the
frame using a stud plate that passes through the flange of the
case. The latch parts can be adjusted in all directions using the
slots in the latch parts and special spacers that mount under
the latch parts. The latch parts should be adjusted so the
locking pins on the door engage the open slot on the case side
latch part. The nominal position for the latch part is flush with
the front edge of the enclosure flange.
Latch Plates
Should Be
Flush With
Front Flange
of Enclosure
Figure 5. View to show gap between locking
pin bridge and “U” fork on the door.
CR 194 One/Two-High Vacuum Limitamp
Figure 7. View of enclosure mounted latch parts.
WARNING: Barriers or enclosure door latch parts removed
to service the equipment must be re-installed in the exact
location for safe operation. Not complying with this
instruction could lead to serious injury. Mark the location
of these items with the ink for ease of re-assembly.
®
AR Control Page 4
Isolation Switch Handle to Contactor
Mechanical Interlock
The Limitamp AR two-high vacuum starter is equipped with a
quick-make, quick-break isolation switch in each starter. This
isolation switch is not designed to make or break motor load
current. To insure that the isolation switch handle cannot be
operated when the contactor is energized, a mechanical interlock
mechanism is provided between the contactor and the isolation
switch handle. Operation of this mechanical interlock for each
starter should be checked per the following procedure.
WARNING: Confirm the equipment is de-energized before
performing this check.
Adjustment Nuts On
the Interlock Assembly
Step 1: Adjust the nuts to shift the connecting rod position as
shown in Figure 10.
Step 2: With the contactor open the connecting rod should be
adjusted up to a point where the pusher will pass through the
round hole in the connecting rod.
Step 3: Once adjusted tighten the two nuts against the block.
Connecting RodPusher Rod
Figure 10. Showing how pusher is unblocked when the contactor
is open.
Figure 8. View of the contactor to isolation switch
mechanical interlock at the vacuum contactor.
Figure 9. Adjusting connecting rod
Pusher Rod
Blocked
Figure 11. Showing how pusher is blocked when the contactor
is closed.
To verify that the interlock is properly adjusted push down on
the top of the contactor moving armature and hold it down.
Now attempt to press the handle latch release (pusher). The
mechanical interlock should prevent the handle release from
going in and prevent the handle from being moved.
CR 194 One/Two-High Vacuum Limitamp
®
AR Control Page 5
High-Voltage Door Defeater Latch
WARNING: The following steps should be taken only as a last
resort to enter a malfunctioning controller. It is imperative
that all power to main bus be removed before proceeding.
IN CASE OF EMERGENCY, remove all power to the controller,
then the high-voltage door may be opened with the contactor
in the closed position and with the isolation switch closed, by
following the procedure listed below.
WARNING: Do not proceed unless all power to the
controller is removed. In this situation, doors must not
be opened with power connected to the bus.
Door Interlock Defeater
Locking Nuts
Step 1: Remove the door interlock defeater locking nuts as
shown in Figure 12.
Step 2: Rotate the door latch operating handle 90° counter-
clockwise to disengage the multiple door latches on the inside
of the high-voltage door.
Step 3: Turn all flange nuts simultaneously until disengaged
from hat brackets.
Step 4: The high-voltage door should be able to be opened by
pulling out on the silver handle. As you pull on the door, the
door interlock defeater will pull away from the door.
WARNING: Defeating high-voltage door interlock leaves
the power fuses and contactor connected to the bus.
The bus power must remain de-energized while the
high-voltage door is open.
Door Interlock Defeater
Figure 12. View showing door interlock defeater locking nuts.Figure 13. View showing door interlock defeater.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 6
Low-Voltage Box Wiring Details
Plenum Installation Guide
Step 1: All low voltage wiring entering and exiting the low
voltage box must be routed through the bushings provided on
the box.
Step 2: Once all wiring is complete fill the bushings with R.T.V
or other equivalent sealant material.
Step 3: Wrap the outside of bushings and wiring with 3M, 130C
tape. Tape must extend down the wire bundle for a minimum
of 6 inches. Refer figure 14 for details.
WARNING: Ensure all wire way openings are properly
sealed before energizing.
Bushing Provided
for Customer Wiring
Purpose
The Limitamp AR design requires the use of a ventilation
plenum to route any arcing gases away from the equipment. Each section requires a plenum and extra extension
plenum parts can be used to exhaust the arcing gases out
of the building. The plenum parts are shipped with the
equipment and it is the end user’s responsibility to install
the plenum part on the equipment.
Store the plenum or extension plenums on a level surface to
avoid distortion. Ensure pleum or extension plenums are kept
in clean and dry condition with ample air circulation.
NOTE: It is recommended NOT to store the plenum outdoors.
At the installation site, remove all separately packaged
components shipped within the Limitamp AR unit. Find the
plenums, cover plates, mounting hardware and place them in
the work area. It is recommended that the plenum parts be
installed in the sequence listed below.
WARNING: Allow at least 12 feet of unobstructed space
for exhaust gases. Serious injury or death may occur.
Step 1: Before plenum installation begins remove all
plastic snap-in clips in top vent flaps to ensure vent flaps
operate properly.
Properly Sealed and
Taped Bushing
Figure 14. Low-voltage box wiring.
Step 2: Apply a strip of sealer around the top perimeter of
the first shell. Sealer should be placed on the outside of the
mounting holes on the shell top.
Step 3: Lift plenum box for the first section with appropriate
means and place it on top of the unit taking care to not
damaging flaps on roof.
Sealer
Figure 15. Apply sealer around the top perimeter of the shell.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 7
Step 4: Align holes on shell top and the plenum. Attach the
plenum using the 3/8“ hardware provided with kit as shown in
Figure 16.
Figure 16. View of hardware to mount plenum to the shell.
Step 5: Apply sealer around perimeter of plenum side that will
be closed.
Sealer
Figure 17. Apply sealer on closed end of plenum.
Step 6: Mount plenum end cover using 3/8” hardware. Refer to
Table 1 for torque details.
3/8” Hardware
Torque Recommendations.
Table 1
Bolt SizeSAE Grade 5 Bolt Torque (Ft-lb)
1/4 - 204
5/16 - 189
3/18 - 1616
1/2 - 1339
3/8” Hardware
Figure 18. Mount end cover plate on plenum.
CR 194 One/Two-High Vacuum Limitamp
®
AR Control Page 8
Step 7: Apply sealer around perimeter of the other side of the
plenum and on the top of the second shell.
Sealer
Figure 19. Application of sealer to plenum and shell.
Step 8: Lift second plenum and position to align holes. Bolt the
second plenum in place. Install 3/8” hardware in all holes
between the plenums and to the top of the shell.
Bolts Installed
to Seal Joint
Step 9: Apply a layer of sealer on the bottom plate of the first
extension plenum. Attach bottom plate to the plenum.
Sealer
Figure 21. Mount extension plenum bottom plate in place.
Figure 20. Bolting the plenums together
Step 10: Apply a layer of sealer to the open end of the plenum
that is mounted on the end of the lineup. Lift the extension
plenum and hold it in place until bolts can be mounted to
attach the two plenums together. Extension plenum should be
supported by additional supports from the roof of the building.
Sealer
Figure 22. Assemble the extension plenum using
3/8” Hardware.
CR 194 One/Two-High Vacuum Limitamp
®
AR Control Page 9
Step 11: Continue the assembly of extension plenums following
the same procedure. At the end of the extension plenum the
end duct assembly must be installed.
Figure 23. Assembly of end duct to the last segment
of the plenum.
End Duct
3/8” Hardware
If customer chooses to install their own version of end duct
segment then the duct must allow a minimum open exhaust
area of 428 in2.
Step 12: Once all the plenums are in place and bolted together
apply gasket around the perimeter of each plenum frame and
mount the cover plates using 3/8” hardware.
At the installation site, remove all separately packaged
components shipped within the Limitamp AR unit. Find the
Turned Plenum, mounting hardware and place them in the
work area.
Step 1: Remove top cover plate on existing extension plenum
for assembly. Apply sealer around perimeter of existing
extension plenum side flanges, where turned plenum (Front/
Rear) will be attached.
Sealer
Figure 25. How to apply sealer around perimeter of plenum.
Step 2: Install 3/8” diameter mounting bolts to attach turned
plenum (Front/Rear) to the extension plenum.
Figure 24. Mount top covers using 3/8” diameter bolts.
Figure 26. Use 3/8” hardware to mount turned plenum
(Front/Rear).
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 10
3/8” Hardware
Step 3: Apply sealer around perimeter of turned plenum
(Front/Rear) flanges where extension plenum will be attached.
Sealer
Figure 27. Apply sealer around perimeter of turned plenum
(Front/Rear).
Step 4: Install 3/8” diameter mounting bolts to attach
extension plenum to turned plenum.
Step 5: Once all the plenums are in place and bolted together
apply sealer around the perimeter of each plenum frame and
mount the cover plates using 3/8” hardware.
Sealer
Figure 29. Assemble top covers using 3/8” diameter bolts.
Figure 28. Use 3/8” hardware to mount extension plenum.
At the installation site, remove all separately packaged
components shipped within the Limitamp AR unit. Find the
Turned Plenum, mounting hardware and place them in the
work area.
Step 1: Remove top covers on existing extension plenum for
assembly. Apply sealer around perimeter of existing extension
plenum side flanges where turned plenum (up/down) will
be attached.
Sealer
Figure 30. Apply sealer around perimeter of plenum.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 11
Step 2: Install 3/8” diameter mounting bolts to attach turned
plenum (top/bottom) to the extension plenum.
3/8” Hardware
Figure 31. Use 3/8” hardware to mount turned plenum.
Step 3: Apply sealer around perimeter of turned plenum (top/
bottom) flanges where extension plenum will be attached.
Sealer
Step 4: Install 3/8” diameter mounting bolts to attach
extension plenum to turned plenum
3/8” Hardware
Figure 33. Mount extension plenum on turned plenum
(up/down).
Step 5: Once all the plenums are in place and bolted together
apply sealer around the perimeter of each plenum frame and
mount the cover plates using 3/8” hardware.
Figure 32. Apply sealer around perimeter of turned plenum.
Sealer
Figure 34. Use 3/8” hardware to mount cover plates.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 12
Limitamp AR Extension Plenum
Limitamp AR Extension Plenum - Straight
D”
H”
2”
L”
Extension
Plenum Type
12” straight55B528942ENG412244290
22” straight55B528942ENG1222442135
24” straight55B528942ENG5242442140
36” straight55B528942ENG2362442195
40” straight55B528942ENG3402442215
48” straight55B528942ENG6482442250
Note: 2 inch bottom cover plate has ø 0.635 holes to support the extension plenum
Part numberL (in) H (in) D (in)
Approx.
Weight (lbs)
Limitamp AR Extension Plenum – Elbow – Up/ Down
24”
D”
H”
L”
Extension
Plenum Type
Up/Down Elbow55B528942GJG142.542.541.5300
Note: Rotate the extension plenum suitably to create up/down elbow
Part numberL (in) H (in) D (in)
Approx.
Weight (lbs)
Limitamp AR Extension Plenum – End Duct
24”
Limitamp AR Extension Plenum – Elbow – Front/Rear
H”
2”
D”
Extension
Plenum Type
Front /Rear Elbow55B528942FZG1442444260
Note: Rotate the extension plenum suitably to create Front/Rear elbow
Part numberL (in) H (in) D (in)
L”
Approx.
Weight (lbs)
L”
D”
H”
Extension
Plenum Type
End Duck55C682150ALG115244260
Note: End duct will be provided along with a Rodent screen
Part numberL (in) H (in) D (in)
Approx.
Weight (lbs)
CR 194 One/Two-High Vacuum Limitamp
®
AR Control Page 13
Extension Plenum – General guidelines
1. Support the Extension plenum minimum 40 inches span
throughout the straight length.
2. Straight lengths can be used along with Front/Rear
and/or Up/Down elbows to fit the customer layout.
3. Use the bottom cover plate with ø 0.635 holes for
supporting the extension plenum.
4. Optionally, Contact GE factory to order collars which
can be installed on the plenum for supporting the straight
extension plenum from the top.
5. Extension plenums are constructed using 12 gauge
sheet metal.
6. Allow minimum 76 inches straight length between turns
when designing the layout of the extension plenum.
7. Customer can install his own version of End duct or if
there is a local code requirement with a minimum exhaust
area of 428 in
2
.
8. Refer installation section to assemble extension plenums.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 14
Plenum Flange details to connect the plenum extension or End Duct
Straight extension plenum with Collar installed (Side View)
CollarCollar
Bottom Cover plate
Collar
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 15
Cable Entry From Top or Bottom
Removable cable entry plates are provided on the top and
bottom of the equipment.
Step 1: Remove cable entry cover plates. Cut an appropriate
size hole for required conduit bushing.
Step 2: Install a conduit bushing(s) capable of sealing against
20-psig minimum pressure on all cables entering or exiting the
arc resistant unit.
WARNING: Conduit bushings capable of sealing against
20-psig minimum should be installed on all cables
entering or exiting the enclosure. If these bushings are not
installed, hot arc gases can escape thru open area around
cables. Serious injury or death may result.
Plenum
Conduit Cutout Cover Plates
Figure 35. Conduit cover plate in plenum for top
cable entry.
Conduit
Bushing
Figure 37. Assembly of conduit bushing on the bottom
conduit plates for bottom cable entry.
Dimensions
Vacuum Limitamp AR controllers are normally 42-inches deep
and 90-inches high. The width of the CR 194 Two-High
Vacuum Limitamp AR is 36 inches (40 inches optional).
Refer Figure 38 (Bottom cable entry) and Figure 39 (Top cable
entry) for dimensional details.
The width of the 800A CR 194 One-High Vacuum Limitamp AR
is 48 inches. Refer to Figure 40.
Conduit
Bushing
Figure 36. Assembly of conduit bushing on to the
plenum top cover for top cable entry.
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 16
CR194 AR 400A, Stationary or Draw-out,
Outline Dimensions, Two-High, Bottom Cable Entry.
GE Limitamp® AR Medium Voltage Motor Control
Enclosures
Enclosure Outline dimensions 2400-7200 Volts
CR194 AR 400A, 2 High, 36" Wide
(Stationary or Draw-out)-BTM CABLE ENTRY
PLENUM
13
12
16
E
L1
L2
L3
13
68
16
1
6
2
11
L2
L3
3
11
14
16
13
52
5
16
7
42
8
T1
*
T2
*
T3
*
B1
1
6
2
B2
T1
D
42
L.H.SIDE VIEW
Notes:
B1 — AC Power Bus, 1200A
B2 — AC Power Bus, 3000A
C — Control Lead Terminal Board
D — Motor Lead Terminal Connection
E — Ground Bus Terminal Connection
G — Space Required to Open Doors 135°
H — Four-foot Aisle for Contactor Removal
J — Mounting Holes for 1/2" Diameter
Anchor Bolts
M — Recommended Position for Incoming
Motor Conduit
N — Recommended Position for Incoming Control Conduit
Enclosure Outline dimensions 2400-7200 Volts
CR194 AR 400A, 2 High, 40" Wide
(Stationary or Draw-out)-BTM CABLE ENTRY
13
16
E
1
6
2
PLENUM
3
14
16
B2
13
5
16
L.H.SIDE VIEW
3
18
16
1
7
2
D
T1
T2
T3
B1
6
D
42
C
*
*
*
1
2
T1
1
18
1
16
6
2
L1
1
16
2
FRONT
1
7
2
C
H
T3
*
*
48
*
G
T2
36
3
10
4
-2450 lbs
1112 Kg
4
16
15
61
13
16
76
16
69
11
19
15
BTM CABLE ENTRY
2
1
6
24
C
90
1
43
4
C
15
20
16
2-HI
13
68
16
12
L1
11
L2
L2
L3
11
L3
52
7
42
8
Notes:
B1 — AC Power Bus, 1200A
B2 — AC Power Bus, 3000A
C — Control Lead Terminal Board
D — Motor Lead Terminal Connection
E — Ground Bus Terminal Connection
G — Space Required to Open Doors 135°
REV: 01
H — Four-foot Aisle for Contactor Removal
J — Mounting Holes for 1/2" Diameter
Anchor Bolts
M — Recommended Position for Incoming
Motor Conduit
N — Recommended Position for Incoming Control Conduit
CR 194 One/Two-High Vacuum Limitamp® AR Control Page 17
CR194 AR 400A, Stationary or Draw-out,
13
16
Enclosure Outline dimensions 2400-7200 Volts
CR194 AR 400A, 2 High, 36" Wide
(Stationary or Draw-out)-TOP CABLE ENTRY
GE Limitamp
Enclosures
E4A
Outline Dimensions, Two-High, Top Cable Entry.
®
AR Medium Voltage Motor Control
6
3
17
8
13
6
16
5
2
8
LOWER UNIT
M
UPPER UNIT
6
M
N
1
5
2
2
2
16
FRONT
6
TOP VIEW
GE Limitamp® AR Medium Voltage Motor Control
Enclosures
Enclosure Outline dimensions 2400-7200 Volts
CR194 AR 400A, 2 High, 40" Wide
(Stationary or Draw-out)-TOP CABLE ENTRY
6
6
3
17
8
N
13
6
16
5
2
8
M
M
10
TOP VIEW
LOWER UNIT
UPPER UNIT
1
2
2
5
2
16
FRONT
PLENUM
13
12
16
E
L1
L2
L3
1
6
2
11
L2
L3
3
11
14
16
13
5
16
52
7
42
8
1
6
2
T1
*
D
T2
B1
B2
T1
*
T2
*
T3
*
42
L.H.SIDE VIEW
Notes:
B1 — AC Power Bus, 1200A
B2 — AC Power Bus, 3000A
C — Control Lead Terminal Board
D — Motor Lead Terminal Connection
E — Ground Bus Terminal Connection
G — Space Required to Open Doors 135°
H — Four-foot Aisle for Contactor Removal
J — Mounting Holes for 1/2" Diameter
Anchor Bolts
M — Recommended Position for Incoming
Motor Conduit
N — Recommended Position for Incoming Control Conduit
Notes:
B1 — AC Power Bus, 1200A
B2 — AC Power Bus, 3000A
C — Control Lead Terminal Board
D — Motor Lead Terminal Connection
E — Ground Bus Terminal Connection
G — Space Required to Open Doors 135°
H — Four-foot Aisle for Contactor Removal
J — Mounting Holes for 1/2" Diameter
Anchor Bolts
M — Recommended Position for Incoming
Motor Conduit
N — Recommended Position for Incoming Control Conduit