MOTOR CONTROLLERS

MOTOR CONTROLLERS
PART 1-GENERAL
1.01 RELATED DOCUMENTS:
A. Drawings and general provisions of Contract, including General and
Supplementary Conditions and Division-l Specification sections, apply to work
of this section.
B. Requirements of the following Division-16 sections apply to work specified in
this section:
1. "Basic Electrical materials and Methods".
2. "Motor Control Centers".
3. "Electrical Cabinets, Boxes and Fittings".
4. "Circuit and Motor Disconnects".
5. "Circuit Breakers".
6. "Wires and Cables".
1.02 SUMMARY:
A. This section includes low-voltage motor controllers (starters) as indicated by
drawings and schedules.
B. Types of motor controllers specified in this section include the following:
„h Fractional HP manual.
„h Across the Line Magnetic.
„h Auto-transformer reduced voltage.
„h Wye-delta reduced voltage.
C. Work of this section includes wires/cables, electrical cabinets, boxes and fittings,
as specified in Division-I6 sections, and used in conjunction with motor
controllers. ,
D. Refer to applicable Division-16 "Wires and Cables", "Electrical Raceways", and
"Electrical Cabinets, 'Boxes and Fittings" Sections for requirements in
connection with motor controllers.
E. Refer to applicable section in Division 15 for requirements in connection with
system control and operation.
1.03 SUBMITTALS:
A. Product Data: submit manufacturer's data and installation instructions on motor
controllers. Include dimensions, ratings and data on features and components.
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B. Shop Drawings: submit shop drawings of motor controllers showing accurately
scaled equipment, locations and spatial relationships to associated motors and
equipment.
C. Wiring Diagrams: submit power and control wiring diagrams for motor
controllers showing connections to electrical power panels, feeders, and
equipment. Differentiate between portions of wiring which are manufacturerinstalled
and portions which are field-installed.
D. Certified Reports: submit field tests and observations specified in "Field Quality
Control" in this Section.
1.04 QUALITY ASSURANCE:
A. Manufacturer's Qualifications: firms regularly engaged in manufacture of motor
controllers of types and sizes required, whose products have been in satisfactory
use in similar service for not less than 5 years.
B. Installer's Qualifications: firm with at least 3 years of successful installation
experience with projects utilizing motor controller work similar to that required
for this project.
C. Codes and Standards:
1. IEC Compliance: comply with IEC 947- 1 & 4 for contactors, IEC 439- 1 Low
Voltage Switch gear and Control Gear Assemblies, and IEC 292 -I, for low
voltage motor starters.
2. Electrical Code Compliance: comply with applicable local Electrical
Regulations or Code requirements of the authority having jurisdiction.
3. NEMA ICS2, "Industrial control devices, controllers and assemblies".
1.05 PRODUCT DELIVERY, STORAGE AND HANDLING:
A. Deliver motor controllers and components properly packaged in factoryfabricated
type containers.
B. Store motor controllers and components in original packaging and in a clean dry
space; protect from weather and construction traffic.
C. Handle motor controllers and components carefully to avoid breakages, impacts,
denting and scoring finishes. Do not install damaged equipment; replace and
return damaged units to equipment manufacturer.
1.06 SEQUENCING AND SCHEDULING:
A. Coordinate with other electrical work including wires/cables, electrical boxes
and fittings, and raceways, to properly interface installation of motor controllers
with other work.
B. Sequence motor controller installation work with other work to minimize
possibility of damage and soiling during remainder of construction period.
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C. Coordinate installation with driven equipment and remote control systems
including any interfacing, if required, with central control and monitoring
system.
1.07 MAINTENANCE:
A. Maintenance Data: submit maintenance data and parts list for each motor
controller and component; including "trouble shooting." maintenance guide.
Include that data, product data and shop drawings in a maintenance manual; in
accordance with requirements of Division I.
B. Maintenance Stock, Fuses: for types and ratings required, furnish additional
fuses, amounting to one unit for every 5 installed units, but not less than 2 units
of each.
PART 2-PRODUCTS
2.01 MANUFACTURERS:
Available Manufacturers: subject to compliance with requirements,
specifications, design drawings and regulations.
2.02 MOTOR CONTROLLERS -GENERAL:
A. Except as otherwise indicated, provide motor controllers and ancillary
components which comply with manufacturers standard materials, design and
construction in accordance with published product information, and as required,
for a complete installation.
B. Coordinate the features of each motor controller with the ratings and
characteristics of the supply circuit, the motor, the required control sequence, the
duty cycle of the motor, drive, and load, and the pilot device, and control circuit
affecting controller functions. Provide controllers that are horsepower , rated to
suit the motor controlled in accordance with the standards.
C. Contacts shall open each unearthed connection to the motor.
D. Overload Relays: ambient-compensated type with inverse-time-current
characteristic and fitted with differential element for single phasing protection.
Provide with heaters or sensors in each phase matched to nameplate full-load
current of the specific motor to which connected with appropriate adjustment ,
for duty cycle.
E. Under .Voltage Protection: provide on all 3-phase motors, and where indicated.
otherwise.
F. Earth fault protection provide on motor circuits with adjustable current and time
setting.
G. Motor Protection: in general where no other reference~ is indicated use the
"IEEE Guide Protection", (ANSI/IEEE C.37.96).
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H. Enclosures: for individually mounted motor controllers and control devices,
comply with Section ¡§Electrical Cabinets, Boxes and Fittings" and with IEC439,
IEC947-1. Provide enclosures suitable for the environmental conditions at the
controller location. As a minimum, provide IP42 to IEC 529 to an approved
manufacturer's standard colour and finish, except as otherwise required.
I. Interlock is to be provided between disconnector or circuit breaker such that the
cover or door to any controller unit cannot be opened unless the switch or circuit
breaker are placed in the off position, before accessing the internal components
of a controller or combination starter.
J. Padlocks: provide operating handle of disconnect devices with padlockable
means suitable for at least 2 padlocks.
2.03 MANUAL MOTOR CONTROLLERS :
A. Fractional HP Manual Controllers: where indicated, provide single-phase twopole
manual starters for fractional HP motors as shown on drawings. Manually
operated controller are to be equipped with quick-make, quick-break toggle
mechanisms; and with one-piece thermal bi-metal type overload element per
phase. Controller to become inoperative when thermal unit is removed. Provide
controllers with double break silver alloy contacts, and with green pilot lights,
for indicating ¡§on" position, controller should be capable of being padlocked in
OFF position.
2.04 MAGNETIC MOTOR CONTROLLERS (D.O.L)
A. Description: provide full-voltage, nonreversing, across-the-line, magnetic
controller for ratings up to 5HP , except where otherwise indicated (Refer to
Drawings and Schedules).
Provide single-pole or 3-pole manually resettable overload element for phase or
three-phase motors, respectively. Contactors are to be suitably selected in
accordance with IEC for type of duty cycles.
B. Control Circuit: 120 V. Provide control power transformer integral with
controller where no other supply of 120 V control power to controller is
indicated. Provide control power transformer with adequate capacity to operate
connected pilot lights, indicating and control devices, plus 100 percent spare
capacity. Provide Local/automatic / off selector switch where indicated Land
start-stop push buttons for local control.
C. Combination Controller: switch type; non fused; quick-make, quick-break
mechanism; factory assembled with controller and arranged to disconnect it.
D. Combination Controller. motor circuit protector or circuit-breaker type, factory
assembled with the controller, calibrated to coordinate with the actual
locked-rotor current of the connected motor and the controller overload relays.
Provide. motor-circuit protectors. with field-adjustable trip elements as
specified in Division 16 Section "L V Circuit Breakers".
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2.05 REDUCED VOLTAGE MOTOR CONTROLLERS
A. Wye-Delta Controllers: provide automatic wye-delta magnetic type controllers
for motors over 5 HP up to 20 HP, of sizes, ratings and electrical characteristics
indicated. Provide controllers of the closed-circuit transition type, including
three 3-pole contactors as required, resistances, adjustable pneumatic timer, and
3-pole overload protection relay in the winding circuit. "' Equip with START
-STOP push button for local control.
B. Auto-Transformer Reduced Voltage Controllers: provide auto-transformer type
reduced voltage controllers, for motors over 50HP of sizes, ratings and electrical
characteristics indicated, using type with closed-circuit transition feature.
Construct controllers with 3-pole contactors, 3-phase starting auto-transformer,
adjustable pneumatic timer, and 3-pole block type overload relay. Construct
auto-transformer with voltage taps at 50 percent, 65 percent and 80 percent of
full line voltage, and with thermal overload protection device on each phase to
protect against overheating. Duty cycle of starters for motors up to 200 HP is to
be 15 second operation out of each 4 minutes for one hour, repeated after two
hours. For motors over 200 HP, starter duty cycle is to be 3 periods of 30 second
on, 30 seconds off, repeated after 1 hour.
C. Combination Controller: provide moulded case circuit breaker as disconnecting
and over-current protection in common enclosure with controller.
2.06 AUXILIARY CONTROL DEVICES
A. General: factory installed in controller enclosure except as otherwise indicated,.
Where separately mounted, provide suitably protected enclosure to standards
applicable, except as otherwise indicated.
B. Pushbutton Stations, Pilot Lights, and Selector Switches: heavy-duty type.
C. Stop and Lockout Pushbutton Station: momentary-break pushbutton station with
a factory-applied has arranged so a padlock can be used to lock the pushbutton in
the depressed position with the control circuit open.
D. Control Relays: auxiliary and adjustable time-delay relays.
E. Ammeters, Voltmeters, and Frequency Meters: panel type, 75 mm minimum
size with 90-deg or 120-deg scale and plus or minus 2-percent accuracy, Where
indicated, provide transfer device with an off position.
F. Current Sensors: rated to suit application.
G. Phase-Failure and Undervoltage Relays: solid-state sensing circuit with isolated
output contacts for hard-wired connection. Provide adjustable undervoltage
setting.
H. Current-Sensing, Phase-Failure Relay: solid-state sensing circuit with isolated
contacts for hard-wired connection. Arranged to operate on phase failure, phase
reversal, current unbalance of from 30 to 40 percent, or loss of supply. voltage.
Provide adjustable response delay.
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PART 3- EXECUTION
3.01 APPLICATION
A. Manual Controllers: use for single-phase motors except as indicated.
B. Pushbutton Stations: except as otherwise indicated, provide momentary- contact
start-stop units. Provide in covers of magnetic controllers for manually started
motors where indicated, and connect start contact in parallel with sealing
auxiliary contact for low-voltage protection.
C. Manual-Off-Automatic 'Selector Switches: except as otherwise indicated, install
in covers of magnetic controllers of motors started and stopped by automatic
controls or interlocks with other equipment. Make control connections so that
only the manual and automatic control devices that have no safety functions will
be bypassed when the switch is in the manual position. Connect motor-control
circuit in both hand and automatic positions for safety type control devices such
as low- and high-pressure cut-outs; high-temperature cut-outs, and motoroverload
and over current protectors. Make control-circuit connections to a
manual-off-automatic switch or to more than one automatic control device in
accordance with a wiring diagram that is Manufacturer and Engineer approved.
3.02 INSTALLATION
A. General: install independently mounted motor control devices in accordance
with manufacturer's written instructions.
B. Manufacturer's Field Services: ( arrange and pay for the services of a factoryauthorized
service representative to inspect the field assembly and connection of
components, and supervise the pre testing and adjustment of solid-state
controllers.
C. Location: locate controllers as indicated and within sight of motors controlled.
D. D. Mounting: for control equipment at walls, bolt units to wall or mount on
light- weight structural steel channels bolted to the wall. For controllers not at
walls, provide free standing racks fabricated of structural steel. members and
light- weight slotted structural steel channels. Use feet consisting of 1,0 mm
(3/8- inch) thick steel plates, 150 mm ( 6- inches) square, bolted to the floor. Use
feet for welded attachment of(40 mm (1-I/2-inch )by 40 mm (1-I/2-inch ) by 6
mm (1/4-inch) vertical angle posts not over three feet on centers. Connect the
posts with horizontal lightweight slotted steel channels and bolt the control
equipment to the channels.
E. Motor-Controller overcurrent Devices: conform to requirements of Division 16
Sections "L V Circuit Breakers".
3.03 IDENTIFICATION
A. Identify motor. control components and control wiring in accordance with,
Division 16 Section "Electrical Identification.
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3.04 CONTROL WIRING INSTALLATION
A. Install wiring between motor control devices and control/indicating devices as
specified in Division 16 Sections "L V Wires and Cables" for hard-wired
connections.
B. Install wiring in enclosures neatly bundled, trained, and supported.
3.05 CONNECTIONS
A. Tighten connectors, terminals, bus joints, and mountings. Tighten field
connected connectors and terminals, including screws and bolt, in accordance
with equipment manufacturer's published torque tightening values. Where
manufacturer's torquing requirements are not indicated, comply with applicable
standards for tightening torques.
3.06 FIELD QUALITY CONTROL
A. Independent Testing Organization: arrange and pay for the services of an
independent electrical testing organization to perform tests and observations on
motor control devices.
B. Reports: prepare written reports certified by testing organization of tests and
observations. Report defective materials and workmanship and unsatisfactory
test results. Include records of repairs and adjustments made.
C. Labeling: on satisfactory completion of tests and related effort, apply a label to
tested components indicating test results, date, and responsible organization and
person.
D. Schedule visual and mechanical inspections and electrical tests with at least one
week's advance notification.
E. Pretesting: on completing installation of the system, perform the following
preparations for tests:
1. Make insulation resistance tests of conducting parts of motor control
components; and of connecting supply, feeder, and control circuits. For
devices containing solid-state components, use test equipment and methods
recommended by the manufacturer.
2. Make continuity tests of circuits.
3. Provide set of Contract Documents to test personnel. Include full updating
on final system configuration and parameters where they supplement or
differ from those indicated in original Contract Documents.
4. Provide manufacturer's instructions for installation and testing of motor
control devices to test personnel.
F. Visual and Mechanical Inspection: include the following inspections and related
work.
1. Motor-Control Device Ratings and Settings: verify that ratings and settings
as installed are appropriate for final loads and final system arrangement and
parameters. Recommend final protective-device ratings and settings where
differences are found. Use accepted revised ratings or settings to make the
final system adjustments. Prepare and submit the load current and overload
relay or relay heater list.
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2. Inspect for defects and physical damage, labeling, and nameplate
compliance with current project drawings.
3. Exercise and perform 'operational tests of mechanical components and other
operable devices in accordance with manufacturer's instructions.
4. Check tightness of electrical connections of devices with calibrated torque
wrench. Use manufacturer's recommended torque values.
5. Clean devices using manufacturer's approved methods and materials.
6. Verify proper fuse types and ratings in fusible devices.
G. Electrical Tests: perform the following in accordance with manufacturer's
instructions:
1. Insulation resistance test of motor control devices conducting parts to the
extent permitted by the manufacturer's instructions. Insulation resistance
less than 100 megohms is not acceptable.
2. Use primary current injection to check performance characteristics of
motor-circuit protectors and for overload relays of controllers for motors.
Trip characteristics not within manufacturer's published time-current
tolerances are not acceptable.
3. Make adjustments for final settings of adjustable-trip devices.
4. Test auxiliary protective features such as loss of phase, phase unbalance and
under voltage to verify operation.
5. Check for improper voltages at terminals in controllers that have external
-control wiring when controller disconnect is opened. Any voltage over 30
V is unacceptable.
H. Correct deficiencies and retest motor control devices. Verify by the system tests
that specified requirements are met.
3.07 CLEANING
A. Remove paint splatters and other. Spots, dirt, and debris. .Touch up scratches
and mars of finish to match original finish, Clean devices internally using,
methods and materials as recommended by manufacturer.
3.08 DEMONSTRATION
A. Training: arrange and pay for the services of a factory-authorized service
representative to demonstrate solid-state and variable-speed controllers and train
Owner's maintenance personnel.
B. Conduct a minimum of 4 hours of training in operation and maintenance as
specified under "Instructions to .Owner's Employees" .in Division I .Section
¡§Project Closeout.¡¨Include training relating to equipment operation and
maintenance procedures.
C. Schedule training with at least seven days' advance notification.
END OF SECTION 16481