Download mv motor control centers rvss spec

Specification for Tender
769879218
General Specification for MV Motor
Control Centers – Reduced Voltage Soft
Start
1. General
2. Product
3. Execution
Last update : 2017-05-13
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Specification for Tender
769879218
Table of contents:
1. General ……………………………………………………………………...............................
p. 3
1.1 Section Includes……………………………………………………………………………….. p. 3
1.2 Medium voltage controllers shall be designed, manufactured, assembled and tested in accordance
with the following standards……….………………………………………………………..……. p. 3
1.3 Submittals ……………………………………………………………………............………..
p. 3-4
1.4 Quality Assurance……… ………………………………………………………………….....
p. 4
1.5 Qualifications………. …………………………………………………………………...........
p. 4
1.6 Delivery, storage and handling………………..……………………………………................
p. 4
1.7 Operation and maintenance manuals……………………………………………….................
p. 4
1.8 Extra Products………… ………………………………………………………………...........
p. 4
2. Product.…………………………………………………………..............................................
p. 5
2.1 Manufacturers……… …………………………………………………………………............
p. 5
2.2 Medium voltage motor controller Assembly……………………..…………………………… p. 5-6
2.3 Ratings…… ……………………………………………………………………………...........
p. 6-7
2.4 Components…….…………………………………………… …………….............................
p. 7-8
2.5 Power and earth busbar (Motor Control Center Construction Only)…………………............
p. 8
2.6 Wiring termination ………….………………………………………………..........................
p. 8
2.7 Motor Protection……….. ……………………………………………………………............
p. 8
2.8 Metering…….…………………………………………………………………………...…….
p. 8
2.9 Controllers………..……………………………………………………………………...........
p. 9-15
2.10 Mechanically Latched contactor………………….…………………………....…………… p. 15
2.11 Incoming line sections to MCC…………………………………….……………..…………
p. 15
2.12 Fabrication ………..………………………………………….....................……...................
p. 16
2.13 Factory finishing……….………………………………………………................................
p. 16
2.14 Related Sections……… …………………………………………………………………......
p. 16
3. Execution …………………………………………………………………................................
p. 16
3.1 Examination specified components……………………………………………………............. p. 16
3.2 Installation ……….………………………………………………………………….................
p. 17
3.3 Field Quality Control…………..……………………………………………………………… p. 17
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Specification for Tender
769879218
1. General
1.1 section includes
1.1.1 The Contractor shall furnish and install the medium voltage controllers as specified herein and as
shown on the contract drawings.
1.1.2 Controller application describes Full Voltage Non Reversing starters for Induction Motors.
1.1.3 One-high construction.
1.1.4 Medium voltage motor control equipment shall be compatible with the medium voltage primary
equipment.
1.2 Medium voltage controllers shall be designed, manufactured, assembled and tested in accordance
with the following standards:
1.2.1
IEC 60694
Commons specifications for high-voltage switchgear and
controlgear standards
1.2.2
IEC 62271-200 Ac metal-enclosed switchgear and controlgear for rated voltages above 1 kV
and up to and including 52 kV
1.2.3
IEC 60470
high voltage alternating current contactors and contactor based motor starter
1.2.4
EC 60282-1
high voltage fuses: limiting fuses
1.2.5
IEC 62271-102 alternating current disconnectors and earthing switches
1.2.6
IEC 60255
measurement relay and protection unit
1.2.7
IEC 60044-1
Instrument transformers - Part 1: current transformers
1.2.8
IEC 60044-2
Instrument transformers - Part 2: voltage transformers
1.2.9
IEC 60044-8
Instrument transformers - Part 8: low power current transducers
1.2.10 IEC 61958
High-voltage prefabricated switchgear and controlgear assemblies - Voltage
presence indicating systems
1.2.11 IBC 2000
Seismic Standards
1.2.12
The equipment shall also comply with the following standards:
- NEMA ICS 3 Part 1 & 2 , 1993 (R2000),
- UL 347, EEMAC E14-1. Arc Resistant,
- ANSI C19.7,
- ANSI C:37.20.7, 200X, Arc Resistant.
1.3 SUBMITTALS
1.3.1 FOR REVIEW/APPROVAL
1.3.1.1 The following information shall be submitted to the Engineer:
- Master drawing index.
- Front view elevation.
- Floor plan.
- Top view.
- Schematic diagram.
- Nameplate schedule.
- Component list.
- Conduit entry/exit locations.
- Assembly ratings including:
> Short circuit rating.
> Voltage.
> Continuous current.
> Basic impulse level.
- Major component ratings including:
> Voltage.
> Continuous current.
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Specification for Tender
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> Interrupting ratings.
- Cable terminal sizes.
1.3.1.2 Where applicable the following additional information shall be submitted to the Engineer:
- Connection details between close-coupled assemblies.
- Composite floor plan of close-coupled assemblies.
- Key interlock scheme drawing and sequence of operations.
1.3.1.3 Submit six (6) copies of the above information.
1.3.2 FOR INFORMATION
1.3.2.1 When requested by the Engineer the following product information shall be submitted:
- Product brochures.
- Product datasheets.
1.3.2.2 Test Certificates
1.3.3 FOR CLOSE-OUT
1.3.3.1 The following information shall be submitted for record purposes at time of shipment:
1.3.3.2 Final as-built drawings and information for items listed in Article 1.03A.
1.3.3.3 Wiring diagrams.
1.3.3.4 Installation information.
1.3.3.5 Submit six (6) copies of the above information.
1.4 QUALITY ASSURANCE
1.4.1 In accordance with (customer to specify section)
1.4.2 Manufacturer: Company specializing in medium voltage metal-enclosed motor controller with at least
five years documented experience. The manufacturer of the motor controller must be the same as the
manufacturer of the circuit breaker switchboard.
1.4.3 Type tests shall be carried out in accordance with IEC 62271-200 provided that additional
requirements specified (e.g. busbar insulation) are taken into consideration. Certificates shall be available
upon request. Certificates issued/supported by independent testing laboratories are preferred. Components
installed within the assembly shall be type tested in accordance with the applicable IEC standards.
Certificates obtained from the component Manufacturers shall be made available at the request of the
Principal.
1.5 QUALIFICATIONS
1.5.1 For the equipment specified herein, the manufacturer shall be ISO 9000
1.5.2 The manufacturer of this equipment shall have produced similar electrical equipment for a minimum
period of five (5) years. When requested by the Engineer, an acceptable list of installations with similar
equipment shall be provided demonstrating compliance with this requirement.
1.6 DELIVERY, STORAGE, AND HANDLING
Equipment shall be handled and stored in accordance with manufacturer's instructions. One (1) copy of
these instructions shall be included with the equipment at time of shipment.
1.7 OPERATION AND MAINTENANCE MANUALS
1.7.1 Three (3) copies of the equipment operation and maintenance manuals shall be provided
at time of shipment.
1.7.2 Operation and maintenance manuals shall include the following information:
- Instruction books and/or leaflets.
- Recommended spare parts list.
- Drawings and information required by Article 1.03.
1.8 EXTRA PRODUCTS
Manufacturer shall provide a recommended Spare Parts List, included as part of the Operation and
Maintenance Manuals.
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Specification for Tender
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2. product
2.1 manufacturers
2.1.1 The Medium Voltage Motor Controllers shall be Merlin Gerin type Motorpact or approved equal.
2.1.2 Current limiting fuses shall of suitable manufacture to ensure the coordination and the integrity of the
system. The blown fuse indicator shall be an "Extended Travel” type with a minimum of 25mm of travel.
Fuses shall have a 50,000 Amperes interrupting rating.
2.1.3 Fuses shall be non-disconnect type with provisions for removal and replacement from the front of the
motor controller
2.1.4 Select the appropriate optional Fuselogic description and/or features
2.1.5 {Option} The Medium Voltage Motor Controllers shall be equipped with an optional Fuselogic blown
fuse protection system to automatically open the contactor, when a fuse interrupts. The system shall also
prevent single phasing conditions by blocking the closing of the contactor when a fuse is blown or if a fuse
is not installed.
2.2 Medium Voltage Motor Controller Assembly
2.2.1 Controllers to be supplied in modular one-high, one controller per structure construction. Stacked or
tiered controllers are not acceptable. The equipment shall be factory-assembled (except for necessary
shipping splits) and operationally checked. The width of a standard motor starter shall be 375 mm. The
width of an enclosure with an integrated power factor correction capacitor shall be 750 mm.
2.2.2 The enclosure rating shall be IP3X. {Option:} [IP4X], [IP31], [IP41].
2.2.3 The motor controller shall [consist of a single section] [be a multiple section line-up] [be close coupled
to MetalClad Switchgear], and be of indoor construction
2.2.4 The medium voltage motor controller assembly shall be partitioned into the following distinct
compartments:
-Busbar compartment
- Low Voltage compartment
- Load compartment containing the fuses, contactor, instrument transformers, and customer cable
terminations and cable-earthing switch.
2.2.5 Disconnector and contactor assemblies, including current limiting fuses, shall be of the component-tocomponent type. There shall be no bolted connections between the contactor finger assembly and the
customer load terminals.
2.2.6 The equipment shall be designed for front accessibility only to allow installation against a wall.
Standard rear access shall be provided. A viewing window shall be provided as standard to permit
verification from the rear of the enclosure that an operator is accessing the proper cubicle by ensuring that
the appropriate front door is open.
2.2.7 Cable entry or exit shall be [bottom] [top] [Bottom and top].
2.2.8 {Option} [The enclosure shall be Internal Arc Class as defined in Annex A of 62271-200]. {Option}
[A tunnel shall be provided to divert the hot gasses.] [The tunnel height shall be 440mm]. ****Required
when ceiling height is 2 meters or less above the top of the equipment {top cable entry or exit is not
available}.
2.2.9 In establishing the requirements for the enclosure design, consideration shall be given to such relevant
factors as controlled access, tamper resistance, protection from ingress of rodents and insects.
2.2.10 Motor controller shall not require ventilation openings to aid in cooling of the associated components.
2.2.11 Flexible power conductors shall interconnect the main contactor with the motor load terminals.
Flexible power conductor terminals shall be of the swage 360º radial cold-fused compression type
connections. These connections shall be maintenance free, never requiring torque.
2.2.12 The motor controller shall be low maintenance designed to reduce the requirement for annual/
periodic maintenance of the equipment. Equipment with scheduled maintenance intervals of one or more
years is preferred.
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Specification for Tender
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2.2.13 A low voltage compartment to accommodate control circuit terminal blocks, control components [and
PowerLogic metering]. The low voltage compartment shall be located at the top of each vertical section.
The interior of the Low Voltage compartment shall be painted white.
2.2.14 Shipping splits shall be a maximum of 5 sections (1875 mm) to minimize the number of overlapped
main bus joints and on site labour.
2.2.15 Medium voltage motor control equipment shall be compatible with Merlin Gerin Distribution
Equipment.
2.3 RATINGS
2.3.1 System Voltage: [2.4] [[3.3] [4.16] [6.6] [7.2] [
] kV, three phase, [solidly earthed] [resistor
earthed through a [ ] ohm resistor] [unearthed], [three phase 3 wire] [three phase 4 wire.] Neutral busbar
not available.
2.3.2 Main Busbar Capacity: [630] [1250] [2500] [3150] amperes, continuous.
2.3.3 Medium Voltage Motor Controllers shall have the following ratings with HRC fuses
Motor Controller Ratings
Rated voltage
(kV)
7.2
Rated insulation level
power frequency withstand voltage 50 Hz - 1 min (rms
20
kV)
lightning impulse withstand voltage 1.2/50 µs (kV
60
peak)
Frequency
(Hz)
50/60
Nominal current and maximum short time withstand current (1)
rated current
In
200
Short time withstand current
Ith max.
(kA/3 s) 40
(kA/2 s) 50
Disconnector
0.25 second
50
Equipment (after fuses)
1 second
4.2
30 seconds
1.7
Earthing Switch Fault Close
kA Symmetrical
5kA
kA Peak
14kA
Internal arc withstand (Optional)
second
25kA
0.50 second
40kA
0.25 second
50kA
Altitude Rating
metres
1000
Contactor Rating
rated current
In
Electrical Endurance
Mechanical Endurance
Standard
Latched
Short Circuit Interrupting Amps (RMS Sym.)
Short Circuit Withstand at Rated Voltage (fused)
kA Symmetrical
kA Peak
Short time withstand current
Ith max.
(1 second)
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7.2
20
60
50/60
400
(kA/3 s) 40
(kA/2 s) 50
50
7.8
3.0
5kA
14kA
25kA
40kA
50kA
1000
200
250,000
2,500,000
250,000
6.3kA
400
250,000
2,500,000
250,000
6.3kA
50
130
50
130
4.0
6.0
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Specification for Tender
769879218
(30 seconds)
Chopping Current
Switching Frequency
Maximum Closing Time
Maximum Opening Time
(Avg. RMS Amps)
(Ops per hour)
(milliseconds)
(milliseconds)
2.4
0.5
1200/300 latched
100 or less
30ms or less
2.4
0.5
1200/300 latched
100 or less
30 or less 350 or
more (delayed)
Maximum Soft Start Controller kW ratings shall be as follows:
200A
kV
2.3
3.3
4.16
6.6
6.9
KW
600
750
925
1865
1865
400 A
kV
2.3
3.3
4.16
6.6
6.9
kW
1100
1675
2000
3700
3700
2.4 COMPONENTS.
2.4.1 The disconnector shall be a two position externally operated manual three-pole device, such that in the
open position it earths and isolates the line side from the load compartment. The switch-operating handle
shall be removable. The operating mechanism shall be rugged, simple and shall have provisions for three
padlocks in the on or off position. [A changeover contact shall be provided for remote position indication of
the disconnector.] [Provide key interlocks to coordinate with….]
- Mechanical Interlocks: interlock shall be provided to prevent the opening of the high voltage access door
with the no-load disconnector closed. To access the medium voltage compartment, the no-load disconnector
must be opened to the earth position. The interlock must be directly attached to the operating mechanism and
should not rely on long cables and linkages.
- All interlocks shall not require adjustments over the life of the equipment. This shall be demonstrated by a
test of 10 times the industry standard’s maximum.
- A viewing port shall be installed in the disconnector enclosure to enable visible verification of the blade
position. {Option} Provide LED light with pushbutton operation for ease of viewing.
2.4.2 {Option:} A cable earthing switch shall be provided. The earthing switch shall be used to earth the load
cables. It is shall be mechanically interlocked with the disconnector and be operated using the same handle.
The earthing switch shall have a spring operated quick make device capable of making 14kApk. The cable
earthing switch shall be mounted in the load box at the motor lead terminals. The earthing switch shall be a
maintenance free device.
2.4.3 Fuses shall be of the current limiting type. The blown fuse indicator shall be an "Extended Travel”
type with a minimum of 25 mm of travel. Fuses shall have a 50,000 Amperes interrupting. The fuses shall
incorporate special time/current characteristics for motor service allowing proper coordination with the
contactor and overload relay for maximum protection. This coordination shall be such that under a low fault
condition the interrupting rating and dropout time of the contactor shall be properly coordinated with all
possible fuse sizes to eliminate contactor racing. The power fuses shall be vertically mounted permitting
easy inspection and replacement without the need for removing the contactor.
- {Option} Provide FuseLogic shunt trip, single phase protection system using DIN style fuses (or equal) to
automatically open the vacuum contactor when a fuse blows or a fuse is not installed. This is intended for
backup protection only to the motor overload relay. The system shall further prevent potential single phasing
conditions by blocking the closing of the contactor when a fuse is blown or a fuse has nor been installed.
(Provide optional changeover contact for trip indication}.
2.4.5 The vacuum contactor shall be with-drawable and magnetically held [mechanically latched] rated [200
A] [400 A] with single-break high-pressure type main contacts. The vacuum contactor contact wear shall be
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Specification for Tender
769879218
easily checked with the use of a “go/no-go” gauge, included with each controller. {Option} A built-in test
circuit shall be included within each controller to permit checking the control and pilot circuits, with the
medium-voltage de-energized and isolated and the contactor in its normal. A viewing window shall be
provided to view the contactor status.
2.4.6 The contactor shall withdraw on a rail system. When the contactor is lowered it will disconnect the
contactor and when raised, it will connect the contactor and lock it in position.
2.4.7 A viewing port shall be provided to view the contactor status.
2.4.8 ACCESSORIES
- The controller mounted control power transformer (CPT) shall be [300VA], [500VA], [750VA], 2kVA],
and be 60kV BIL rated. Fuse holder with two primary current limiting fuses.
- The controller mounted open delta voltage transformer shall be provided for metering and protection.
2.5 POWER AND EARTH BUSBAR (Motor Control Center Construction Only)
2.5.1 When controllers are grouped together in a line-up, the horizontal main busbar shall be located in its
own compartment. To allow for ease of maintenance or extension of line-ups, the main busbar shall be
front, rear, top, and side accessible.
2.5.2 Main power busbar bars shall be tin-plated copper and braced for 50 kA 2-seconds (40 kA 3 seconds).
All busbar shall be braced to withstand, without damage or deformation, maximum let-through current
permitted by the current limiting fuses.
2.5.3 Copper earth busbar shall be continuous and extend from one end of the motor control centre to the
other through each vertical section. Minimum size to be 6.35 mm by 50mm.
2.6 WIRING/TERMINATIONS
2.6.1 Standard control wire shall 1.5mm2.
2.6.2 Current transformer circuits shall utilize 2.5 mm2 wires.
2.6.3 Controllers shall be complete and control wires including terminations for external connections.
2.6.4 Phase sequencing shall have proper identification and all wires shall have suitable markings at all
terminations.
2.7 MOTOR PROTECTION
Provide a microprocessor-based multi-function, motor protective relay that monitors three-phase ac current
and makes separate trip and alarm decisions based on pre-programmed motor current and temperature
conditions. [Sepam Series (20), (40) (80)]
2.8 METERING
2.8.1 Microprocessor-Based Metering Package
Where indicated on the drawings, provide a UL Listed solid-state microprocessor-based metering package
with optional waveform capture. Metering package shall be a PowerLogic circuit monitor.[Each] - -PowerLogic Circuit Monitor, [with digital display][with waveform capture][stand-alone section[s]
containing a controller shall include the following [as shown on the drawings]:
- [CM 3000] [CM 4000]
- [Wired for communications; to other [devices.]
- PowerLogic digital meter. [PM620] [PM 650] [PM820] [PM 850]
- Other: [..]
2.8.2 Auxiliary Devices
{Option} Provide fixed mounted potential transformer, fused type, 3 phase open delta as indicated on the
contract drawings. These shall be used for the MPR [and meter].
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Specification for Tender
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2.9 CONTROLLERS
2.9.1 The controllers shall be designed to accommodate motors of the size and type as shown on the
drawings.
2.9.2 The controllers shall be provided by a single manufacturer with a complete product offering (refer to
Article 1.01B) of controllers to accommodate the following motor types and starting methods:
- Induction Motor Full Voltage Start.
2.9.3 Provide the following equipment for type controller indicated in Article 2.07.A., and the contract
drawings.
2.9.3.1 Each Induction Motor Full Voltage Non Reversing Controller shall include:
> Medium Voltage Compartment:
- One - three-pole non-load break isolating disconnector.
- Three - Current limiting power fuses.
- One - Draw-out three-pole vacuum contactor assembly.
- {Option} One - Control circuit transformer [300VA] [500VA] [750VA] [2kVA]
- {Option} Two - Control circuit primary current limiting fuses.
- Set - Electrical and Mechanical interlocks.
- Three - Load terminals. An anti-rotational terminal pad shall have provision for two hole cable lugs.
- Current Transformer Options: (Max 3)
- Each section containing a contactor shall include the following [as shown on the drawings]:
- [one] three phase donut Type Low Power Current Transformer [use with SEPAM relay] Current
transformer accuracy shall be equal to or higher than ANSI metering class.
- [one] [two] three phase donut type current transformers []: 5A. or [_____]: 1A
- [one] Zero Sequence CT [2000:1] [50:5]
- {Option} Provide two sets of thermal sensing optical probes for instant temperature detection placed in
which have been determined to have the most significant temperature rise. The probes shall be designed to
withstand constraints related to the medium voltage environments. The optical technology shall provide
reliable measurements and give the system a long service life. The probes shall be factory-built assemblies
comprised of 6 sensors attached to the power circuit, optical connections and a module connector. The
connector shall incorporate an opto-electrical conversion unit eliminating any optical connections.
> Low-Voltage Compartment Door:
- {Option} One - Motor protection relay (MPR) Sepam Series [20][40][80]where specified
- {Option} One - Microprocessor metering package where specified.
- Mounting space for any additional low voltage control, protection, or metering specified.
- Components to be directly mounted on door - size of door cut-outs to match size of mounted component.
> Low-Voltage Compartment:
- Two - Control relays.
- One - Control circuit secondary fuse.
- Set of control circuit terminal blocks.
- Customer terminal blocks with screw compression type connections.
- Mounting space for any additional low voltage control, protection, or metering specified.
> Operator panel
- Disconnector operator mechanism
- Mechanical open-close indication
-Disconnector Viewing Window
- two – 22 mm pushbuttons
- two 22 mm indicating lights
- {Option}Elapsed time meter
- {Option} Key Interlocks: shall be provided for the disconnector operating mechanism as indicated on the
drawings].
> Soft Starter Module
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Specification for Tender
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- Solid state reduced voltage motor starters shall be Square D type RVSS (sized as indicated), or preapproved equal modified to meet the requirements of this specification. The starter shall be complete with
the following standard features and adjustments. Motor and Load Protection shall be integral to the starter
assembly. Motor protection shall be based upon modelling of the thermal characteristics of the motor as
programmed by the user and measured by the starter. All current referenced protection features shall be
calculated from the motor nameplate FLA, and automatically adjusted for the Service Factor, NEMA
Design, Insulation Class, Line Voltage and Line Frequency as entered by the user. All time based protection
features shall be based on a Real Time Clock, remaining active through any power loss. Starter shall provide
the following functions:
- Thermal Overload shall be provided by the on-board microprocessor control. Basic protection shall be
inverse time-current trip curves as defined by NEMA trip curve Classes. The trip curve classes shall be
programmable from between Class 5 and Class 30 and the starter shall be UL listed to provide each
individual class. As the most important protection feature of a starter, the overload protection shall be based
on a Dynamic Thermal Register retained in memory and provide the following features:
- Retentive Thermal Memory shall be used to ensure that the Dynamic Thermal Register does not
loose track of motor temperature after the power is lost or shut down. Upon reapplication of power, the
microprocessor shall be automatically updated as to the motor temperature and adjusted for real time cooling
while the power is off.
- Dynamic Reset Capacity shall retain a snapshot of the thermal capacity necessary to restart the
motor. The starter shall determine these requirements by recording and averaging the previous 3 successful
start-ups. After an overload trip has occurred the protection shall prevent resetting until enough cooling time
has passed and sufficient motor thermal capacity is available.
- True Thermal Modelling shall be a feature of the overload and reset calculations. Once established
at setup, the Dynamic Thermal Register shall be biased according to the following input information when
available: Cold Stall Time, Hot Stall Time, Stopped Cool Down Time, Running Cool Down Time, and all of
the real time information from the RTD Option if ordered.
- Separate Trip Curves shall be provided for Start and Run, allowing a higher level curve to avoid
nuisance tripping during acceleration, but dropping to another level for accurate motor protection while at
full speed. To maximize flexibility, each trip curve shall be programmable as follows:
Basic, using the NEMA Class ranges described above.
Locked Rotor programmable between 400 – 800% of FLA, and a trip time from 1 – 30 seconds.
Measured Start Capacity (I²t curve area) taken from the previous successful start (only applicable to the Start
Curve).
- Overload Alarm shall be provided to warn users of an impending overload trip. The Alarm level
shall be programmable between 40 – 95% of the Dynamic Thermal Register value. It shall provide an
adjustable delay of 1 – 20 seconds.
- Manual or Automatic Reset shall be selectable in programming to provide for automatic reset in
unattended remote applications.
- Phase Monitoring shall be standard and based on motor current. In order to protect against disconnected
motor leads, this feature will function even if the line voltage remains normal. All features shall be as
follows and capable of being disabled if not needed:
- Phase Loss shall shut down the starter if current through any leg drops to 20% of unit FLA or less.
This protection shall be implemented via hardware and shall be non-adjustable. It shall provide an adjustable
trip delay of 1 – 20 seconds.
- Phase Imbalance Protection shall be provided with programmable sensitivity to provide both Alarm
and Trip points. The sensitivity shall be adjustable for phase-to-phase imbalances of between 5% and 30%.
Each point shall provide an adjustable delay of 1 – 20 seconds.
- Phase Rotation protection shall be self-learning and field programmable. If phase rotation varies
from the initial set pattern, the starter shall trip immediately. If phase rotation is correct, the starter can be retaught to recognize the new rotation.
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Specification for Tender
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- Short Circuit Detection with dual mode protection for starting and running operation shall be standard. This
circuit MUST be provided to protect the starter from load failures. This protection shall be implemented via
hardware and shall be non-adjustable.
- In the starting mode the starter shall employ a ¼ second pre-check routine to determine if the load
circuit has a fault condition and disable the ramping prior to reaching the Initial Voltage setting. This is to
avoid additional equipment damage after a fault that may have occurred while the starter was off.
- In the running mode, this feature will shut down the starter if current through any leg exceeds 10
times unit FLA for 12.5 milliseconds.
- Over Current Protection shall be provided separate from the above to be used as a Shear Pin trip. It shall be
adjustable at lower levels for protecting mechanical components from undue shock when rapid unexpected
load changes occur.
- Adjustment level shall be from 100% to 300% of the programmed motor FLA.
- A time delay of up to 20 seconds shall avoid nuisance tripping from short duration transients.
- Under Current Protection shall alarm the starter on an adjustable condition. This Load Loss sensor shall be
programmable from 10% to 90% of the programmed motor FLA, and, with a time delay of up to 20 seconds
shall avoid nuisance tripping from short duration transients.
- {Optional} Ground Fault protection shall be provided to protect the motor from damage using the Residual
Current method. An Alarm and 2 trip levels, each adjustable from 5 – 90% shall be available with separate
trip times as follows:
- ALARM level preset at 5% with a 0.5 – 20 second delay.
- LOSET Trip level preset at 7% with a 1 – 20 second delay.
- HISET Trip level preset at 10% with an 8 – 250 millisecond delay.
- Line Frequency Window shall be programmable from a 1 – 6Hz variance from the nominal line frequency
as entered by the user. It shall provide an adjustable trip delay of 1 – 20 seconds.
- Coast Down Lockout shall be provided to prevent restarting of the motor during backspin or other
dangerous mechanical conditions after shutting off. The coast down lockout time shall be programmable
between 0 and 60 minutes following a Stop command.
- Starts-per-Hour Lockout shall be provided to prevent damage to the motor from rapid cycling of start
commands for any reason. The maximum starts-per-hour shall be programmable between 1 and 10 starts.
- Time Between Starts Lockout shall also be programmable to work with the above. A minimum time
of between 0 and 60 minutes between start attempts shall prevent restarting too rapidly for the motor and
load conditions as determined by the user.
2.9.3.2 Acceleration Control shall be fully adjustable in programming to match any application. As a
minimum, starter shall come complete with the following settings:
- Ramp Type: To ensure maximum flexibility in matching the load conditions in the field, the starter shall
provide all of the following methods of closed loop acceleration ramp control: Voltage Ramp, Voltage Ramp
with Current Limit, Current Limit Only (Current Step), Current Ramp (Torque Ramp) or up to 3 Custom
Ramp profiles that can be programmed by the user.
- Starting Torque: Initial torque output shall be programmable as either Current or Voltage output, and
adjustable between 0-100% of maximum Locked Rotor Torque (600% current) available from the motor.
- Maximum Current Limit: To ensure reliability of starting under any circumstance that the motor can
function in, Current Limit shall be adjustable between 200 and 600% of the unit rating. This will allow
locked rotor current to be delivered to the motor if necessary. Lighter duty starters with lower current limit
settings will not be acceptable.
- Ramp Time: The time between Initial Torque and Full Output shall be adjustable between 1 and 120
seconds.
- Dual Ramps: To accommodate changing load conditions, the starter shall provide 2 separately adjustable
ramp profiles, selectable via a dry contact closure. Each ramp will provide all of the above features.
- Custom Ramp Curves shall be available that can be configured by the user to match any load or starting
condition. Each of the 3 available custom curves can be profiled by entering 8 torque and time points. The
starter shall create a smooth acceleration curve from these plotted axis points.
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- Kick Start: To provide for starting difficult loads, the starter shall include a Kick Start feature that will
apply a high output for a short time on initial start command. The Kick-Start voltage level shall be adjustable
from 10 – 100% voltage, for 0.1-2 seconds max.
- Jog: For checking rotation at start-up or other testing procedures, the starter shall provide a programmable
Jog feature, adjustable from 5 – 75% of line voltage.
2.9.3.3 Deceleration Control (Ramp Down) shall be completely independent of any Accel Ramp settings and
provide a fully adjustable Decel profile in order to avoid possible motor damage. Pre-programmed Decel
“algorithm” systems that do not allow contouring to match load conditions are not acceptable.
- Step Down Voltage: adjustable from 100 to 0% of line voltage, allowing the motor torque to drop off
immediately to a level that affects output without waiting for a linear ramp.
- Deceleration Ramp Time: adjustable from 0 – 60 seconds to allow gentle controlled deceleration in excess
of the natural coast-to-stop time of the load.
- Stop Voltage Level: adjustable from 100 – 0% of line voltage to automatically turn off the starter when the
output torque has reached a desired level. Programming shall not allow the Stop level to be set higher than
the Step Down Level. External timers shall not be needed to turn off the starter.
- Selectable Operation During Overload shall be available to allow the user to decide if the motor shall turn
off or continue to Decelerate when an overload condition is detected.
2.9.3.4 Starter Protection shall be provided to maintain reliability of both the equipment and the circuit
components, with the following features:
- Shorted SCR Detection shall be standard. This function must automatically prevent a “start” sequence
when at least one SCR is shorted. A means of having qualified service personnel defeat the lockout of this
circuit MUST be provided to allow for “Must Run” situations.
- Shunt Trip Circuit shall be standard. This feature will instantly energize a dry relay contact that can be
wired to a “Shunt Trip” coil of the circuit breaker in order to protect the motor from damage. This protection
shall only operate if there is current flowing through any phase of the starter when in the “Off” condition,
such as when there are multiple shorted SCRs or a bypass contactor stuck on. This feature shall be
independent of the above Shorted SCR protection so that it cannot be defeated.
- Starter Over-temperature Trip shall be built-in and protect the SCRs from excessive heat build-up in the
enclosure or heat sinks. Thermal sensors on the heat sinks shall be pre-wired to one of the programmable
inputs that has been factory preset as the Over Temp input.
2.9.3.5 Inputs shall be provided for the control and option selection of the starter as follows.
- Digital Inputs: All input and control devices shall be rated for 120VAC control or shall require dry contact
closures without the need for external power supplies or interposing relays.
- On-Off Control shall be 120VAC to avoid potential problems with voltage drop in long control wire
runs. The starter shall provide for 2-wire or 3-wire control schemes. Seal-In relay contact for the 3-wire
control scheme shall be internal, dedicated to that use and not counted as an output contact. Terminals shall
be provided for use in interlocking with programmable output relays or external devices.
- User Inputs: 4 programmable digital inputs shall be provided. Each input shall accept dry contact
closures from external user supplied devices, and can be named for display on the DCU when energized. 2
of these inputs shall be preset as Temperature and Dual Ramp Select, but can be changed by the user. Inputs
can be programmed as N.O. or N.C., and programmed with a de-bounce timer of 0 – 60 seconds. Each input
can be assigned to operate any of the Programmable Outputs.
- Analogue Input shall be provided for optional Tach Feedback Starting. This input shall accept 420ma with adjustable offset and gain.
2.9.3.6 Outputs shall be provided for the following functions in addition to the seal-in relay used in 3-wire
control schemes as mentioned above.
- Digital Outputs shall be eight (8) Form “C” contact relay outputs, rated for 240VAC, 5AMPS, 1200VA
max., with each relay being programmable for any one of the following functions;
- Indicator Relay programmable to change state on any of the following conditions: Run / Stop, Start
/ End of Decel, Timed Output, At Speed / Stop, At Speed / End of Decel, Dual Ramp Selected, Self Test
Fail.
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- Fault Trip Relay programmable for each of the following fault conditions: Overload, Phase
Imbalance / Loss / Reversal, Lock Out Inhibits, External Inputs, Short Circuit, Over Current / Shear Pin,
Ground Fault HISET / LOSET, Over / Under Frequency, I²t Start Curve, Shorted SCR, Shunt Trip, Over
Temp, Under Current / Load Loss.
- Alarm Relay including the following conditions: Overload Warning, Overcurrent Warning, Ground
Fault Warning, Under Current Warning, Imbalance Warning, Thermal Register Warning.
- RTD Relay (when RTD Input option is ordered) including Stator or Non-Stator Trip and/or
Warning, and RTD Failure.
- Analogue Outputs (2) shall be included for providing information to external controls and be
programmable as RMS Current or Percentage of Motor FLA.
- If the Tachometer Feedback Starting option is used, the Analogue outputs can be programmed as
RPM.
- If the RTD input option is used, the Analogue outputs can be programmed as Hottest RTD
Temperature for Stator or Non-Stator RTDs.
2.9.3.7 Operator Interface Panel that provides simple to use adjustment and status indication on a dead-front
shroud of the starter shall be provided.
- Adjustments shall be made by keypad with tactile feedback keys for high noise environments. To prevent
confusion, no binary coded dip switches shall be used for programming. Pass code protection shall be
available to prevent unauthorized changes to the programming.
- Alpha-Numeric Display shall be Backlit LCD with 2 lines by 20 characters.
- Indicators using long life LED devices shall provide additional quick annunciation of Power, Run Alarm
and Trip operation, as well as the status of the eight output relays.
- Password Protection shall be provided, allowing 3 levels of access to program information, 2 of these
levels requiring separate Passwords.
2.9.3.8 Metering functions shall be provided through the Alpha-Numeric Display for indicating the
following:
- Output Current for each individual phase or avg. of all 3. Indicating range to be 0.0 – 9999.9 amps.
- Ground Fault Current
- Motor Load % of FLA
- Line Frequency
- Phase Order
- Remaining Thermal Capacity to indicate heating effect and cooling rate of the motor. Range shall be 0 –
100% of the remaining capacity and count up towards 100% while cooling.
- Thermal Capacity to Start indicating the required value that will be added to the thermal register as learned
and averaged from the previous 3 successful starts.
- Average Start Time learned from previous 3 successful starts
- Average Start Current learned from previous 3 successful starts
- I²t to Start measured from the previous start.
- Last Start Time measured from Start Command to At-Speed.
- RTD Metering (when RTD Option is ordered) for up to 12 Stator and Non Stator RTDs, displayed in
degrees C and degrees F. Metering includes Hottest RTD, each RTD Temp, each RTD Max Temp Since
Clear, Measured Run Cool Time in minutes, and Measured Stop Cool Time in minutes.
- Starter Status including Ready, Starting, Running, Last Trip Cause
- Remaining time for O/L Trip, Thermal Inhibit, Coast Down Lock Out, Time Between Starts and Starts per
Hour.
- Event Recorder (last 60 events) with Phase and GF currents record at each event.
- Last Trip including Cause, Phase and GF currents, Unbalance %, Hz, Hottest Stator and Non Stator RTD
recorded.
- Statistics including Elapsed Run Time, Total Trips, Trips on Short Circuit, Start O/L, Run O/L, Frequency,
Overcurrent, Stator RTD, Non-Stator RTD, G/F LOSET and HISET, Acceleration Time, Start Under Curve,
Start Over Curve, I²t Start, Fail Shunt Trip, Phase Loss, Tach Accel, and 4 External Inputs Learned Start
Curve. When enabled, the starter will record a start curve with 100 data points of current and time between
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Start and At-Speed. This data can be exported via the Comm. Port to be plotted on a graph or spreadsheet for
baseline measurement and maintenance analysis.
-18) Learned Start Curve. When enabled, the starter will record a start curve with 100 data points of current
and time between Start and At-Speed. This data can be exported via the Comm. Port to be plotted on a graph
or spreadsheet for baseline measurement and maintenance analysis.
2.9.3.9 Available control or protection options shall include the following:
- {Optional} Tach Feedback Starting. An optional input card shall be available to allow linear speed
acceleration based on closed loop feedback from a tachometer.
- {Optional} RTD Inputs. Allowing biasing and adjustment of the Dynamic Thermal Register based on realworld temperature readings from up to 12 RTDs, with the following features:
- Programmable RTD Type, shall accept 100 ohm platinum, 100 ohm nickel, 120 ohm nickel and/or
10 ohm copper RTDs
- Configurable RTDs allowing for up to 6 RTDs to be used for the Stator. All RTDs can have names
assigned in programming for clear indication on the display.
- RTD Voting providing for the requirement of at least 2 RTDs to be exceeding the set points for Trip
or Alarm. This feature shall be programmable as Enabled or Disabled..
2.9.3.10 Serial Communications shall be built-in as a standard feature without the need for separate modules.
- Communications protocol shall be RS-232 to a windows based program for data entry, and/or Modbus
RTU protocol via RS485 signals.
- Units shall be capable of being connected to an intelligent communication device in a network of up to 247
devices with unique addresses.
2.9.4 Design Specifications
2.9.4.1 SCR Modules
- PIV Ratings: SCRs will be connected as inverse parallel pairs in series circuits to attain the following Peak
Inverse Voltage ratings as a minimum for each phase:
- System Voltage: 1500 / 2300V
Pairs:
1
PIV Rating. 6500V
- System Voltage: 3300 / 4160V
Series Pairs: 2
PIV Rating. 13000V
- Protection: RC snubber network circuits on each phase assembly. To avoid possible component damage,
MOV protective devices shall be used only on the gate firing circuitry.
- Efficiency: 99.7% through SCRs, 99.97% in bypass mode.
- Control Method: To ensure reliable gate firing even when powered with on-site generators, firing circuits
shall use individual phase transformer coupling method for maximum isolation and rapid rise of firing pulse.
- Noise Immunity: The gate firing circuitry shall be protected from electrical noise and transients to ensure
reliable starting and firing of the SCRs under all power conditions, regardless of the available fault current or
motor lead length.
- They shall be amplified and isolated from the control voltages by means of rugged encapsulated
ring transformers that provide separate power sources for each set of SCR gate drives. The design shall
allow for a “back-porch” DC carry-over of the firing pulse to prevent the SCRs from falsely turning off due
to ringing of the output current or line notching caused by other connected equipment. The gate drive shall
be maintained for 240 electrical degrees from the zero cross point to avoid motor switching transients.
- For additional reliability and to protect against EMI/RFI interface generated by the internal
components, connections to the Digital Control Unit shall be fibre optic.
- When at all possible, the starter shall not require line reactors in the Medium Voltage power section.
Those that do shall include them within the same enclosure as the starter and shall be UL listed in this
configuration.
2.9.4.2 Ambient Conditions
- Temperature: As a standard of unit design quality, starter shall be documented to show the design has been
tested for 0 – 50° C (-32 to 122° F) operation, and Overload Capacity shall be rated at this temperature.
- Altitude: 3300 ft (1000 m) maximum without de-rating.
- Humidity: 0 – 95% RH, non-condensing.
- Thermal: Heat sink temperature switches designed to trip at 85° C.
2.9.4.3 Electronics
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- Non-Volatile Memory will be used throughout the control and protection systems. To prevent the
possibility of loosing protection values, stored programs or statistical data, battery back-up memory systems
will not be allowed.
- The starter shall store all factory defaults in a preset replaceable EPROM memory chip.
- User Programming and statistical data shall be stored in EEPROM memory for ready alteration.
Loss of power shall not affect memory status.
- For fast updates and operation, running programs shall use DRAM memory. The starter shall store
the DRAM memory contents to the EEPROM upon power failure, and restore it upon return to normal.
- Data Sampling
- Critical operating data such as instantaneous current for Short Circuit, Ground Fault and Immediate
Overload calculations shall be sampled every 2 milliseconds to prevent lagging operation.
- Non-Critical data shall be obtained from a true RMS calculation circuit, and sampled in a 350
millisecond moving window of individual phase currents.
- Real Time Clock with automatic leap-year updating shall be provided. This clock alone shall use a battery
back-up with a Lithium-Ion battery rated for at least 10 years of continuous operation without power applied.
The clock shall be capable of being reset in the field after changing the battery, without affecting any other
stored information.
2.9.5 {Option} Provide [compression lugs] for terminating cables onto the motor controller terminal pads.
2.9.6 {Option} Anti-condensation space heaters rated 220 VAC, 250W shall be supplied in each section.
Control power shall be supplied [supplied by owner] [by internal controller mounted CPT] {and shall be
supplied with} [thermostats] [humidistat.]
2.9.7 {Option} Cable earthing switch. To facilitate cable testing in the high voltage compartment, the
earthing switch can be returned to the open position with the MV compartment door open. In this position
interlocks are to be provided to prevent replacement of the high voltage access panel and prevent closure of
the load interrupter switch.
2.9.8 {Option} Voltage Presence Indication System shall be provided on the mechanism compartment and
shall be an easily removable module containing three neon indicators powered from voltage dividers.
2.9.9 {Option:} Surge Arresters (metal-oxide type): [Distribution] [Intermediate] class, rated [3, 6, 9] kV,
one per phase.
2.9.10 {Option} Main busbar live line indicators shall be provided as required and shall be mounted in the
low voltage compartment.]
2.9.11 {Option} Power factor correction capacitor shall be provided. The capacitor shall be a 3 phase unit
connected to the load side of the connector. The rating of the capacitor shall be [100], [150], [200], [250],
[300], [350], [400] kVAR.
2.10 MECHANICALLY LATCHED CONTACTOR
2.10.1 Mechanically-latched contactors shall be provided when specified for transformer disconnect circuits,
and other uses when it is required to have contactor remain closed, regardless of voltage condition.
2.10.2 Mechanically-latched contactor shall be closed electrically from a local or remote ”close“ pushbutton, and an electrically operated solenoid shall be supplied to open the contactor from a remote location
2.10.3 A mechanical opening device shall be provided to mechanically open the contactor.
2.11 INCOMING LINE SECTIONS TO MCC
2.11.1 Each incoming line section shall be [500mm wide {bottom entry only}] [750mm wide {top or bottom
entry and shall be connected to an adjacent controller.
2.11.2 Terminations shall accommodate up to quantity and size or ratings of cables as indicated on the
drawings.
2.11.3 Incoming Line section shall have a rating of [630] [1250] [2500] [3150] amperes.
2.11.4 {Option} Provide a Voltage Presence Indication System connected by a capacitive circuit to the main
bus. The system lights will indicate voltage when the equipment is energized.
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2.11.5 {Option:} Surge Arresters (metal-oxide type): [Distribution] [Intermediate] class, rated [3, 6, 9] kV,
one per phase.
2.11.6 {Option} The section shall contain a top mounted pull box [432 mm high] to ease in cable pulling and
for additional shielded cable bending space.
2.11.7 SPECIFIED COMPONENTS
- Standard push buttons shall be Harmony type 9001 ZB4, 600 V rated.
- Standard pilot lights shall be Harmony type 9001 XB4, 600 V rated LED long life.
- Standard control relays shall be type CA2DN.
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2.12 FABRICATION
2.12.1 Construction: Each cubicle shall be a separately constructed cubicle assembled to form a rigid
freestanding unit. Adjacent cubicles shall be securely bolted together to form an integrated rigid structure.
Each individual unit shall be braced to prevent distortion.
2.12.2 All busbar joints shall use Belleville washers. Torqued bolts that are used for busbar joints or for
insulators and direct support of any current carrying parts shall be marked with a bead of highly visible
bright orange "torque seal", that will readily show when a bolt has loosened.
2.12.3 Height: 2300mm, maximum including auxiliary support members on top and bottom.
2.12.4 Main busbar shall be copper, [non-insulated] [insulated] rated [630] [1250] [2500] [3150] amps, and
shall be supported directly by the disconnector.
2.12.5 [For single cubicles, include an earth pad with lug.] [For multiple cubicle line-ups, include continuous
earth busbar through the motor controller assembly, securely connected to the steel frame of each cubicle.]
2.12.6 Main busbar and earth busbar connections shall be designed for easy future extensions. Cut-out areas
with removable bolted on covers shall allow for future extension of the main busbar. A knockout shall be
removable for the extension of the earth busbar.
2.13 FACTORY FINISHING
2.13.1 All non-painted steel parts shall be zinc plated.
2.13.2 All All painted steel parts shall be cleaned and a zinc-phosphate pre-treatment applied prior to paint
application.
2.13.3 All Paint Colour shall be RAL9002 White Frosted TGIC polyester powder, applied electrostatically
through air. Following paint application, parts shall be baked to produce a hard durable finish. The average
thickness of the paint film shall be 2.0 mils. Paint film shall be uniform in colour and free from blisters,
sags, flaking and peeling.
2.13.4 All Adequacy of paint finish to inhibit the build-up of rust on ferrous metal materials shall be tested
and evaluated per paragraphs 5.2.8.1-7 of ANSI C37.20.3-1987. Salt spray withstand tests in accordance
with paragraph 5.2.8.4 shall be performed on a periodic basis to provide conformance to this corrosion
resistance standard of at least 600 hours minimum.
2.14 RELATED SECTIONS
- [Section 16290-3]-Power Monitoring And Control Systems
- [Section 16290-6.1]-Medium Voltage Protective Relay
- [Section 16290-7]-Web Enabled Power Distribution Equipment
3. EXECUTION
The following paragraphs in this section represent work that is to be performed by the installing contractor.
If this specification is written for the motor controller manufacturer only, eliminate these sections.
3.1 EXAMINATION SPECIFIED COMPONENTS
3.1.1 Visually inspect motor controller for evidence of damage and verify that surfaces are ready
to receive work.
3.1.2 Visually inspect to confirm that all items and accessories are in accordance with
specifications and drawings.
3.1.3 Verify field measurements are as [shown on Drawings] [shown on shop drawings] [instructed by
manufacturer.]
3.1.4 Verify that required utilities (e.g., control voltage for heater circuits on outdoor motor controller) are
available, in proper location, and ready for use.
3.1.5 Beginning of installation means installer accepts existing surface conditions.
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3.2 INSTALLATION
3.2.1 Install in accordance with manufacturer's instructions and in accordance with recognized industry
practices.
3.2.2 [Connect the primary surge arresters if not connected. If required, use jumper cables, as provided by
the motor controller manufacturer.]
3.2.3 Bending of high-voltage cables should be avoided or minimized. All necessary bends should meet at
least the minimum radii specified by the cable manufacturer.
3.3 FIELD QUALITY CONTROL
3.3.1 Field inspection and testing will be performed by [the installing contractor] [a separate contractor
furnished by the owner.
3.3.2 Visually inspect for physical damage.
3.3.3 Perform mechanical operator tests in accordance with manufacturer's instructions.
3.3.4 Check torque of all bolted connections, including cable terminations, either by observing the bead of
indicating compound to confirm that it is still intact, or with a torque wrench to confirm the joint is tightened
to the manufacturer's specifications.
3.3.5 Touch-up paint all chips and scratches with manufacturer-supplied paint and leave remaining paint
with Owner.
3.3.6 Verify key interlock operation if applicable.
G. Perform insulation resistance test on each phase to earth and each phase to each other phase. Record
results.
3.3.7 Perform low frequency withstand tests according to applicable IEC standards.
3.3.8 Perform contact resistance test across each disconnector blade; report any contact resistance in excess
of 50 micro-ohms.
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