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Motor Control Centres 8PX3
Installation and Maintenance
Instructions
8PX3 Instruction Manual
Note
Authorized and qualified personnel
For the purpose of this manual, a qualified person is one who
is familiar with the installation, construction or operation of the
equipment and the hazards involved. In addition, the person has
the following qualifications:
a) is trained and authorized to de-energize, clear, ground and
tag circuits and equipment in accordance with established
safety practices.
b) is trained in the proper care and use of protective equipment
such as rubber gloves, hard hat and safety glasses.
c) is trained in rendering first aid.
Warning
Serious injury and equipment damage can occur through
accidental contact with live wiring or bus system. Before
beginning work on this or any other electrical equipment,
disconnect and lock out incoming power and control
voltage sources. Check all terminals with a voltmeter
to ensure that the equipment is totally de-energized.
Before power is restored, follow the procedures outlined
in the pre-operation inspection section of this manual.
DANGER
Hazardous Voltage.
Will cause severe
injury or death.
Turn power off supplying
device before installing.
SAFETY INSTRUCTIONS
8PX3 Instruction Manual
Table of Contents:
Nomenclature ................................................................................................................. ii
1.0 General Information
1.1 Introduction ........................................................................................................... 1
1.2 General Description .................................................................................................. 1
1.3 Operating Environment ............................................................................................. 2
2.0 Receiving and Handling
2.1 Receiving .................................................................................................................. 3
2.2 Handling ...................................................................................................................3
2.3 Storage ..................................................................................................................... 4
3.0 Installation
3.1 Site Preparation ......................................................................................................... 5
3.2 Mounting .................................................................................................................. 5
3.3 Top and Bottom Covers .............................................................................................. 6
3.4 Joining Shipping Sections .......................................................................................... 6
3.5 Incoming Power Connections .................................................................................... 7
3.6 Top Conduit to Upper Incoming Cable Compartment ................................................. 8
3.7 Top Conduit to Main Breaker ...................................................................................... 9
3.8 Bottom Conduit to Main Breaker ................................................................................ 9
3.9 Bottom Conduit to Vertical Bus Bars ........................................................................... 10
4.0 Wiring Instructions
4.1 Load and Control Wiring ............................................................................................ 11
4.2 Final Inspection/Checklist ........................................................................................... 12
4.3 Final Testing ..............................................................................................................13
5.0 Maintenance
5.1 Routine Maintenance ................................................................................................. 14
5.2 Field Additions ........................................................................................................... 16
5.3 Drawout Unit Removal and Replacement ................................................................... 16
5.4 Drawout Unit Addition ............................................................................................... 17
5.5 Torque Values ............................................................................................................ 18
5.6 Installation and Adjustment of Motor Circuit Interrupter Protector ............................... 19
6.0 3RU Overload Relays
6.1 Description ................................................................................................................22
6.2 Single-Phase Protection .............................................................................................. 22
6.3 Manual or Automatic Reset ........................................................................................ 22
6.4 Overload Relay Selection Charts ................................................................................. 24
6.5 Contactor Maintenance for SIRIUS Contactors 3RT1036 and larger............................... 27
6.6 Contactors .................................................................................................................29
7.0 Trouble shooting ......................................................................................................... 30
8.0 MCC Optional Equipment .......................................................................................... 32
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8PX3 Instruction Manual
Nomenclature
ITEM DESCRIPTION ITEM DESCRIPTION
1 MCC FRAME F.O.B. 13 MAIN BUS LI
2 MCC BRACE 14 MAIN BUS L2
3 BACK PLATE 500 MM 15 MAIN BUS L3
4 END PLATE 16 NEUTRAL MAIN BUS
5 WIRE WAY U-POST 17 CHANNEL SILL 500 MM
6 B.B.CHANNEL LEFT SIDE 18 TOP COVER PLATE
7 B.B.CHANNEL RIGHT SIDE 19 BOTTOM COVER PLATE
8LOWER B.B. CHANNEL 20 WIRING CHANNEL DOOR 24.5 M
9 UPPER B.B, CHANNEL 21 BUFFER PLATE
10 UPPER & LOWER FACE COVER 22 MAIN BUS COVER
11 VERTICAL BUS BAR 23 VERTICAL BUS SUPPORT
12 STAND-OFF INSULATOR
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8PX3 Instruction Manual
1.0 General Information
1.1 Introduction
This instruction manual describes in detail the Siemens 8PX3 Motor Control Center. It has
been prepared for the purpose of instructing personnel in the proper handling, installation,
operation and maintenance of the control center. The 8PX3 MCC has been engineered
to comply with CSA and EEMAC standards to meet today’s industry requirements. These
publications and this instruction manual should be thoroughly read and understood prior
to beginning any work on the equipment.
1.2 General Description
The Siemens 8PX3 Motor Control Center is an integrated system of protective devices,
electrical bus bars and control units gathered into compartments within a common
enclosure consisting of one or more free-standing, deadfront structural frames. Each
standard section is 500 mm wide, but may be up to 1000 mm wide depending on the
size of the enclosed equipment.
Electrical power is distributed through the main horizontal bus mounted at the top and
extending the length of the motor control centre. Each vertical frame containing provisions
for drawout units is fed by a vertical bus system connected to the horizontal bus. The
horizontal bus system is isolated from the front by a full-length steel barrier; an optional
barrier may be installed to isolate the vertical bus.
Each vertical frame will accommodate up to seven 280 mm high control units in the front
and, if so equipped, six in the rear if no neutral bus is provided. The control unit height may
vary from a minimum of 280 mm up to 1960 mm. Most control unit assemblies through
EEMAC Size 4 are drawout type.
Each control unit contains an operating handle extending through the door to switch the
disconnecting means on and off.
The disconnecting means switched by the operating handle may be either a fusible
disconnect switch or a circuit breaker which is coordinated with a contactor and an
overload relay to form a basic control unit. Other auxiliary devices such as relays,
transformers, switches and lights may be added to the basic unit.
Introduction - General Description - Operating Environment
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8PX3 Instruction Manual
1.3 Operating Environment
The 8PX3 Motor Control Center is designed for indoor applications to function efficiently
under normal operating conditions at 5 to 40° C in a dry environment.
Three-Frame Motor Control Center,
front view
Two-Frame Motor Control Center,
rear view, back plate removed
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8PX3 Instruction Manual
2.0 Receiving and Handling
Receiving - Handling - Storage
2.1 Receiving
The 8PX3 Motor Control Centers are normally shipped from the factory completely
assembled, inspected, tested and packed. If any damage which may have occurred
during shipment is found, the receiver should immediately call it to the attention of
the local freight agent handling the shipment. Siemens sales office should be notified.
2.2 Handling
8PX3 Motor Control Centers are shipped in groups of one to five vertical frames which
are mounted on 100 mm x 100 mm wooden shipping blocks. When single frames are
shipped individually, each is additionally mounted on a special pallet for further stability.
Each shipping block is provided with two lifting angles on top for convenient handling.
The following table gives the approximate weights of single vertical frames and will be
helpful in determining the required capacity of the handling means. If a vertical frame
contains power factor correction capacitors, reactors or a large transformer, sufficient
additional weight-handling capacity must be allowed.
Weight Table
Frame Size Weight
500 mm W x 434 mm D Front Only 280 KG
500 mm W x 550 mm Back-to-back 386 KG
Warning
Serious injury and equipment damage can occur if the 8PX3 Motor Control
Center is moved with a wire rope “come along,” pried or otherwise handled
except by attachment to the noted lifting brackets. Always handle the control
center in the vertical position. Restraints may be necessary to prevent tipping
during handling, since the equipment weight is mostly at the top and front of the
unit. Jacks, prybars, dollies, roller lifts and similar devices for lifting, handling,
moving and lowering all require supplemental blocking beneath the MCC and
restraints to prevent tipping. These devices are not recommended due to the
hazards implicit in their use.
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8PX3 Instruction Manual
Due to the high center of gravity, precautions should be taken when moving an MCC
with a forklift, or pipe rollers, to prevent shifting or tipping.
It is recommended that a crane or hoist be used to handle the MCC.
Handling of Motor Control Centre by
a. Crane or Hoist
b. Rollers
c. Forklift
2.3 Storage
If storage is necessary, the equipment should be placed indoors in a clean,
dry and protected location.
Periodic inspection of the storage is required to ensure proper condition of the equipment.
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8PX3 Instruction Manual
3.0 Installation
Site Preparation -Mounting- of Top and Bottom Covers -Joining Shipping Sections -Incoming
Power Connections -Top Conduit to Upper Incoming Cable Compartment -Top Conduit to
Main Breaker- Bottom Conduit to Main Breaker- Bottom Conduit to Vertical Bus Bars
3.1 Site Preparation
8PX3 Motor Control Centers are assembled in a special fixture to assure square
construction and correct alignment of parts. A flat, level concrete surface should
be prepared for the mounting site.
An uneven foundation may cause misalignment of shipping block units and doors.
3.2 Mounting
The coordination between the bolts and the MCC should be verified prior to attempting
installation. Expandable inserts in predrilled holes or imbedded "L" bolts are recommended.
See the following figure for anchor bolt location.
The bolt size should be from 10 mm (3/8") to 12 mm (1/2").
Welding the steel base or sill channels to a steel floor plate is an alternate mounting
method, especially recommended in areas subject to seismic activity.
The motor control center should never be placed on a floor made of flammable material
such as wood (as per CSA C22.2 No. 14).
MCC Anchor Bolt Location
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8PX3 Instruction Manual
3.3 Top and Bottom Covers
Top covers are provided on all motor control centers as an integral part of the enclosure.
Bottom covers are supplied on certain types of construction such as EEMAC 12. These
covers should be removed only for the purpose of piercing holes for conduit or wire entry
and must be immediately replaced to reduce the possibility that falling material, tools or
personnel could unintentionally contact the bus system or other live parts.
3.4 Joining Shipping Sections
If it is necessary to join two or more shipping sections at the job site, the following
procedures are recommended:
1. Position the first shipping section in place on the foundation and level.
2. Remove the front horizontal bus barrier. If rear is accessible, the back cover plates
should be removed from the two mating frames.
3. Position the second shipping section on the foundation and level it. The horizontal
bus should be inspected for proper positioning and alignment at this time.
4. Remove side bracing.
5. Position the right-hand MCC. Join the structures to each other by passing the joining
bolts from the inside of the left-hand MCC wire way through the joining holes, into
the right-hand MCC.
6. Join the ground bus between the two adjacent sections.
7. Assemble the bus bar links to join the horizontal power bus and neutral bus, if
supplied, in the two shipping sections, as shown in the following figure. The horizontal
and neutral buses may differ in size, material or plating; therefore, the links must
be matched to the proper bars. All links and associated mounting hardware are
provided with the MCC.
8. Tighten all bus connections to torques specified in Section 5.5, in the Maintenance
section of this manual.
9. If the motor control center is wired per EEMAC Class II, connect the interunit wiring
terminal blocks between shipping sections.
10. If there are other shipping sections to be joined, repeat steps 1 through 8 above.
11. Secure the motor control center to the foundation.
12. EEMAC 12 enclosure sections should be securely joined and sealed to prohibit intrusion
of dust and moisture.
13. If MCC sections are supplied with insulated bus bars, carefully and securely tape the
joints with electrical insulation tape.
Bus Connections between Shipping Sections
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8PX3 Instruction Manual
3.5 Incoming Power Connections
After all shipping sections are in place, levelled and joined together into a single motor
control center, cables may be pulled and top entry conduit may be installed. Bottom entry
conduit will have been stubbed through the floor at the proper locations prior to placement
of the MCC. The incoming source cables may be connected at this time; however, the
power source disconnecting means must remain open and locked out until all wiring is
completed and the entire system has been checked out. Tighten all screw lugs and bolted
electrical connections to the specified torque listed on page 18.
If crimp lugs are supplied, use only the crimping tool recommended by the lug manufacturer.
Caution
Remove top cover before drilling and cutting holes for conduit to prevent metal
chips from falling into the motor control center.
Warning
Do not connect the motor control center to a source which is capable of
delivering fault currents greater than the interrupting or withstand ratings
of the MCC or its units. Connection to such a source can result in equipment
damage, serious injury or loss of life.
To minimize the length of unsupported cable, the shortest, most direct routing should
be chosen. All cables entering the control center must be adequately supported and
restrained to withstand the maximum fault current capable of being delivered by the
source. The recommended distances between straps for 36 kg rated straps are 150 mm
for 22 kA bracing, 100 mm for 42 kA bracing, 75 mm for 65 kA bracing and 50 mm for
100 kA. Using a strap rated less than 36 kg will require the spacing distances to be reduced.
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8PX3 Instruction Manual
3.6 Top Conduit to Upper Incoming Cable Compartment
The following figure illustrates two cables per phase connected directly to the incoming
line lugs. No. 6 through 350 MCM cables, one or two per phase, may be terminated in
this manner. If more than two cables per phase are necessary, additional incoming
compartment space will be provided. A minimum of 400 mm is not usable for control
units at the top in a vertical frame containing an upper cable compartment. The amount
of non-usable space depends on the quantity and size of incoming cables.
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8PX3 Instruction Manual
3.7 Top Conduit to Main Breaker
The following figure illustrates the connection of top incoming cables to a main incoming
breaker. Refer to the lead sheet to determine the location of available control unit spaces
within a frame containing a main breaker assembly. Greater cable support and restraint is
required because of the longer cable.
3.8 Bottom Conduit to Main Breaker
The following figure illustrates a main incoming breaker connected to cables from conduit
stubbed up inside the frame bottom. The cables coming from the bottom should lie
against the rear of the vertical wire space to allow room for the smaller unit cables and
control wires. All cables should be laced securely to each other and to the cable supports
provided to reduce distortion and damage in the event of a fault.
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8PX3 Instruction Manual
3.9 Bottom Conduit to Vertical Bus Bars
The following figure illustrates another bottom entrance option in which the incoming
power cables terminate on a special vertical bus. Unless otherwise specified, pressure
lugs are furnished for cable terminations. A minimum of 400 mm is not usable for control
units at the bottom of a vertical frame containing this type of incoming cables.
NOTE: 1–Y = 400 MM 2 X 500 MCM
2–Y = 480 MM 2 X 750 MCM
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8PX3 Instruction Manual
4.0 Wiring Instructions
Load and Control Wiring - Final Inspection / Checklist - Final Testing
4.1 Load and Control Wiring
All interconnections between devices within each control unit are prewired at the
factory. Field wiring to each control unit should be made in accordance with the wiring
diagram indicated on the lead sheet for that particular unit. When wiring or performing
any maintenance on drawout units, disengage the stabs by withdrawing the unit. Never
attempt to disengage the stabs with the circuit breaker or disconnect switch in the “ON”
position. Wiring done with the pan in this position will ensure adequate cable slack to
allow unit withdrawal to the same position when future maintenance is required. Always
use stranded wire.
Warning
The vertical bus is completely exposed when
the unit is withdrawn if no barrier is present.
The vertical wiring between control units or between a control unit and conduit should be
pulled through the wiring space on the right side of the frame. These wires should then be
tied or laced together and the resulting bundle then securely fastened to the wire supports.
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8PX3 Instruction Manual
4.2 Final Inspection/Checklist
Every motor control center that leaves the Siemens plant is thoroughly inspected and
tested completely before shipment to customer. After the equipment has been installed
in place and all wiring and cables have been connected, the final inspection and test
should be done before the equipment is energized and put in service.
The following points are to be checked:
• All incoming primary cables and buses, including connection according to the wiring
diagrams. Ensure that all electrical spacings and clearances phase-to-phase and
ground-to-phase are maintained in accordance with CSA Standard requirements.
• Equipment must be clean and free from dust and dirt which has accumulated on
the control centers during installation.
• All cables and bus connections should be tight and properly torqued in accordance
with the torque values specified on page 18.
•Remove temporary wiring jumpers used on the secondaries of the current transformer
tied to the external devices. Refer to wiring diagrams for all connections shown.
• Check that proper fuses are installed.
• Check for proper ground connection.
• Check that all bus bars and connections (if applicable) are properly insulated.
• Check that all blocking supports and other temporary ties are removed from the
contactors, relays and other devices.
• Check that all equipment that was removed from the MCC during installation
is replaced and installed.
• Check that interlocks are functioning properly.
• Check that all structural panels and covers are installed.
• Check that all nameplates and operating instruction labels, including the safety labels,
are installed.
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8PX3 Instruction Manual
4.3 Final Testing
The megger test is used to conduct an electrical insulation resistance test to make sure that
equipment is free from short circuit between phases to ground and that no leakage paths
exist at the insulators due to surface dirt or the presence of absorbed moisture.
The test is conducted by applying 1000 volts DC for 1 minute between phase-to-phase
and phase-to-ground. In all cases, the measured resistance must equal or exceed KV + 1
Megohm. For acceptance where KV is the MCC rating in Kilovolt, i.e. MCC rating voltage
is 600 V, megger test voltage = 1000 V DC, minimum insulation resistance for acceptance
= 1.6 Megohm.
High Potential Test
If it is necessary that a high potential test be done on the equipment which, was previously
tested at the factory, the high potential test will be applicable as follows:
Rated 250 volts : 75% of 1500 volts or 1125 volts
Rated 600 volts : 75% of 2200 volts or 1650 volts
Rated 480 volts : 75% of 1960 volts or 1470 volts
Secondaries and control : 75% of 1500 volts or 1125 volts
Caution
Certain control devices may not be subjected to the test voltage of 75% of 1500 V
or 1125 V but 75% of 900 volts or 675 volts. Rated voltages of these devices must
be verified before testing. The test voltages above are for use at altitudes not over
3300 feet above sea level in an ambient temperature not exceeding 40 °C.
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8PX3 Instruction Manual
5.0 Maintenance
Routine Maintenance - Field Additions - Drawout Unit Removal and Replacement -
Drawout Unit Addition Torque Values - Installation and Adjustment of MCP
Severe environmental conditions or equipment usage will require more frequent
inspections and maintenance. The items in Section 5.1 should be included on any
comprehensive maintenance checklist.
Warning
All compartments may contain hazardous voltages.
Use safety precautions when energizing or servicing
this equipment.
5.1 Routine Maintenance
It is recommended that the following maintenance be performed on a regular basis with
the motor control de-energized and incoming power locked out:
1. Feel the doors, enclosure sides and deadfront surfaces over all circuit breakers and
switches with the palm of the hand. Any surface with a temperature which the palm
of the hand cannot stand for about 3 seconds may indicate trouble. Heat detectors
are also available to detect trouble spots.
2. Wipe all bus insulators and vertical bus barriers and vacuum any accumulation of dust.
3. Check the following for tightness:
a. Bus connections (Torque main bus bolts to prescribed limit on page 18).
b. Power cable connections.
c. Control wire connections.
4. Inspect all wiring for insulation deterioration, wear or cuts. Replace if necessary.
5. Look for wear of the plating on the unit stab fingers and on the vertical bus at the
location where the unit stab fingers engage the vertical bus. The plating is part
of the environmental protection system for the copper. Oxide and/or other films
can form on exposed copper or aluminum, resulting in a poor contact.
These parts must be replaced when the plating is worn to the point where copper
can be seen, because contact resistance becomes higher, increasing the heat
generated at the contact point, which, in turn, may lead to arcing and possible
bus flashover.
6. Check all operating handles and mechanical interlocks for proper operation.
7. Check and replace defective pilot lamps.
8. Inspect starter contacts and replace if over half-eroded. Do not dress silver alloy
contacts. Replace contact springs at the same time the movable contacts are replaced.
9. Look for indications of overheating, arcing or insulation breakdown and replace
defective parts.
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8PX3 Instruction Manual
10.Remove drawout assemblies and check stab and unit wiring. Vacuum any
accumulated dirt.
11.Visually inspect all instruments and check instrument calibrations.
12.Always replace fuses with those of the same type and rating. Even though another
replacement fuse may be physically interchangeable with the original, it may not
have the same short circuit-interrupting capacity and current-limiting ability.
13.Lubricate the stab fingers with Siemens contact lubricant before replacing drawout
assemblies.
14.Operate each switch or circuit breaker several times to ensure that all mechanisms
are free and in proper working order.
15.Check all devices for missing or broken parts, proper spring tension, free movement,
rusting or corrosion, dirt and excessive wear.
16.Look for any moisture or signs of previous wetness or dripping inside the MCC.
Condensation in conduits or dripping from outside sources is a common cause of
control center failure. If evidence of moisture is found, seal all cracks and openings
and eliminate all sources of moisture such as those which cause a dripping on the
MCC enclosure.
17.Refer to component instruction books for periodic maintenance of component
assemblies.
Caution
Do not oil or lubricate the armature or magnet assembly in any contactor or relay.
The lubricant attracts dust and impedes the proper operation of the armature.
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8PX3 Instruction Manual
5.2 Field Additions
Field additions may be made to the control center if the current rating of the main or
vertical bus is not exceeded. The preparation of the floor and conduit is the same as in
a new installation. Any new shipping section will contain all of the necessary hardware
and bus connecting links. De-energize the existing motor control center and remove the
end side plates from the existing vertical frame which is to be joined. After joining the
structures in accordance with the instructions in the Installation section of this manual,
the field inspection and testing must be performed.
Additions to motor control centers fall into two general categories: a) additions of frames
and b) additions or replacement of drawout units. The addition of frames is similar to
the installation of control centers which have been shipped in several sections. When
mounting methods or models of new and existing sections differ, care must be exercised
to ensure proper alignment of horizontal bus.
Field additions of drawout units may be as simple as installing the assembly into a spare
space or as elaborate as replacing two small units with a larger one. In either event, the
procedure is basically the same, and all necessary parts and hardware will be supplied.
See the Drawout Unit Removal and Replacement section for details.
All wiring must be done in agreement with the unit wiring diagram supplied with the
drawout unit and the wiring instructions detailed in the Installation section of this bulletin.
5.3 Drawout Unit Removal and Replacement
The following sequence should be followed when removing a drawout unit:
1. Turn unit off using the STOP button or selector switch.
2. Push the disconnecting means operating handle to the “OFF
”
position.
3. With a screwdriver, turn the quarter-turn door fastener 90° counterclockwise
and open the door.
4. Turn the drawout unit latch by 90°.
5. Separate pull-apart terminals, if supplied, or disconnect wires from terminal blocks,
tag and secure within the MCC.
6. The drawout unit may now be easily removed from the frame.
7. The drawout unit should be protected from abuse, dust and moisture while it is not
mounted in the MCC.
Warning
Insufficient bracing can result in serious injury and equipment damage. Verify
that the available power source fault current has not been increased when adding
frames or drawout units. The existing MCC and new additions may not be properly
braced if the available fault current has been increased.
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8PX3 Instruction Manual
5.4 Drawout Unit Addition
Drawout units may easily be added to the 8PX3 Motor Control Center to fill blank spaces.
Each unit comes complete with horizontal mounting plate, door and hinges. The following
is the installation procedure for these units.
1. Remove the cover(s) over the blank section(s) equal to the drawout unit height.
2. Horizontal mounting plates are installed by fastening the rear into place with three
self-tapping screws and the front with two self-tapping screws in the predrilled
vertical channels.
3. Use the new door as a template to locate the positions of the hinges. Self-tapping
screws in predrilled holes are used to bolt the hinges to the left-hand corner channels.
4. Remove the vertical bus barrier insert.
5. Push the disconnecting means operating handle to the “OFF” position.
6. Install the drawout unit onto the mounting plate and push in the unit without
engaging the stabs.
7. Connect all power cables and control wires in agreement with the unit wiring diagram
and the instructions detailed in the Wiring Instructions section of this manual.
8. Review and perform the procedures for units as listed in the Final Inspection/Checklist
on page 12.
9. Push the drawout unit in towards the bus until the stabs are firmly connected to the
bus. If the unit is twisted during insertion, it will not fully engage onto the vertical bus.
10. Close the door and secure it with the quarter-turn fasteners. If the drawout unit is
not properly inserted, the door will not close. Never force the door to close!
11. Move the handle to the “ON” position. The control unit is now ready for operation.
12. Repeat Steps 1 through 11 for each additional new drawout unit to be added.
Warning
Live bus is exposed through the access hole. Contact with the bus
can result in serious injury, loss of life and equipment damage.
Warning
Do not allow the stab to engage the vertical bus at this time!
Stab engagement will energize terminals exposed to operating
personnel and can result in serious injury.
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8PX3 Instruction Manual
5.5 Torque Values
Tolerance: +5% - 0%
Tolerance
Thread-Forming Screws
Torque in Inch Pounds
Screw Size Up to .187 Over .187
AL CU AL CU
8 – 32 30 50 30 50
10 – 24 30 50 30 50
1/4 – 20 30 72 50 72
5/16 – 18 – – – –
Conversion Tables
Example 1
Grade 5 Bolts with Grade 2 Nuts
Torque in Foot Pounds
Bolt
Size All Thickness AL & CU
1/4 – 20 6
5/16 –18 12
3/8 – 16 20
1/2 – 13 50
Belleville Washer Nuts
Torque in Foot Pounds
Bolt
Size All Thickness AL & CU
1/4 – 20 6
5/16 –18 12
3/8 – 16 20
1/2 – 13 50
Torque Conversion Factors
Units
to Be Imperial Metric International
Converted System – S.I.
Ozf-in Ibf-in Ibf-ft gf-cm kgf-cm kgf-m mN-m cN-m N-m
1 ozf-in = 1 0.0625 0.005 72 0.072 0.0007 7.062 0.706 0.007
1 Ibf-in = 16 1 0.083 1152.1 1.152 0.0115 113 11.3 0.113
1 Ibf-ft = 192 12 1 13.826 13.83 0.138 1356 135.6 1.356
1 gf-cm = 0.014 0.0009 0.000 07 1 0.001 0.000 01 0.098 0.01 0.0001
1 kgf-cm= 13.89 0.868 0.072 1000 1 0.01 98.07 9.807 0.098
1 kgf-m= 1389 86.8 7.233 100 000 100 1 9807 980.7 9.807
1 mN-m= 0.142 0.009 0.0007 10.2 0.01 0.0001 1 0.1 0.001
1 cN-m= 1.416 0.088 0.007 102 0.102 0.001 10 1 0.01
1 N-m= 141.6 8.851 0.738 10.197 10.20 0.102 1000 100 1
▼
cN-m
Convert 10 lbf-ft into cN-m
lbf-ft
10 x 135.6 = 1356 cN-m 135.6
Example 2
lbf-ft
Convert 14 kgf-m into lbf-ft
kgf-m
14 x 7.233 = 101.26 lbf-ft 7.233
Read down
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8PX3 Instruction Manual
5.6 Installation and Adjustment of Motor Circuit Interrupter Protector
Siemens Instantaneous Trip Motor Circuit Interrupter Type ED63A and CED63A 600 VAC
For Use With: Combination Motor Controllers
Note: This instruction outlines the recommended installation procedure.
Mounting Procedure for Motor Circuit Interrupter Protector:
1. Turn off power supplying this device before setting trip range or servicing.
2. Prior to mounting motor circuit interrupter, manually exercise handle from “OFF”
position to “ON”. Then push the trip button.
This operation procedure will ensure mechanical operation of the motor circuit
interrupter.
3. Use four mounting screws for Type ED63A or six for Type CED63A and associated flats
from kit catalogue number MSE6 to bolt the motor circuit interrupter onto the customer-
supplied mounting plate assembly.
19
DANGER
Hazardous Voltage.
Will cause severe
injury or death.
Turn power off supplying
device before installing.
SAFETY INSTRUCTIONS
8PX3 Instruction Manual
Adjustment Procedures for ETI Motor Circuit Interrupter Protector:
1. Motor circuit interrupter continuous current rating should not be less than 115% of
Motor Full Load Current (MFLC). The MFLC is obtained from the motor nameplate.
2. The instantaneous setting is determined by multiplying the MFLC by 11. Select the closest
setting, but it must be under 13 x MFLC. In order to comply with the Canadian Electrical
code, Part 1,*adjust the instantaneous button by rotating to the current determined in
the previous step.
Example:
20 HP 460 V AC = 27 ampere MFLC x 115%
= 31 amps continuous current rating
= 40 ampere interrupter
27 x 11 = position 4 setting
A convenient conversion table is supplied below. This chart does not cover all application
or motor current values, but does cover most commonly used three-phase motors.
Note:
Conversion current rating -1.15 times MFLC.
Setting based on 11 times MFLC (or a setting just above peak in-rush current).
Motor circuit interrupter instantaneous value tolerance levels are determined by
UL 489 Standards +/- 20% of marked settings.
Handle operating forces:
“ON” to “OFF” : 8-10 Ibs.
“OFF” to “ON” : 8-10 Ibs.
Relatch : 14 Ibs.
*CSA allows 215% of the motor locked rotor current where indication is given.
C22-1-28-210
Motor HP Rating Contin. Amps Trip Range Setting
208V 460V 575V LO 2 3 4 HI 208V 460V 575V
– 1/4 1/4 1 2.6 4.5 6 7.5 9 – 3 2
1/4 1/2 1/2 2 7 11 15 19 22 2 2 2
1/3 3/4 3/4 2 4 3 2
––1 2 ––3
3/4 1.5 1.5 5 16 26 36 46 54 3 2 2
122 5 432
1-1/2 3 3 10 30 50 70 85 100 3 2 2
255 10 444
37-1/2 7-1/2 25 55 90 125 155 180 3 3 2
––10 25 – – 3
51015 30 80135 185 235 270 3 2 3
–15– 30 – 4 –
7-1/2 20 20 40 115 185 255 325 375 3 4 3
––25 40 4
Conversion Tables
20
8PX3 Instruction Manual
Screw Replacement
Trip Adjustment
21
8PX3 Instruction Manual
6.0 3RU Overload Relay
Description - Single Phase Protection - Manual or Automatic Reset - Overload Relay
Selection Chart - Contactor Maintenance - Contactor Selection Chart
6.1 Description
The 3RU three-phase thermal overload relay is an EEMAC Class 10, directly heated, front
adjustable, ambient temperature-compensated bimetallic device. The relay is supplied
with one normally closed contact for opening the control circuit in case of thermal trip
and one normally open contact to provide a remote alarm indicator.
6.2 Single-Phase Protection
In addition to motor overload protection, the internal trip mechanism provides motor
single-phase protection. See page 23: Curve 1 shows the normal three-phase
time-current tripping relationship. The relay senses a loss of phase condition and shifts
the time-current tripping response curve to the left, as shown by Curve 2. As a result of
this curve shift and the higher single-phase current, the tripping time of the overload
relay will be reduced.
6.3 Manual or Automatic Reset
The 3RU overload relay is set for HAND reset operation when shipped from the factory.
The relay may be set for AUTO operation by depressing and turning the blue reset button
counterclockwise to the position marked “A.” See photo on page 23.
Calibrated for Service Factor of 1.15
A large percentage of today’s motors are rated for a service factor of 1.15.
To assure optimal protection, simply adjust the dial as shown below.
Warning
Automatic reset should not be used with two-wire control or
where automatic resetting of the overload relay would restore
power to the motor, endangering either personnel or equipment.
1.0 Motor nameplate F.L.A. x 0.92
1.15 Motor nameplate RL.A
Motor service factor Adjustment
22
8PX3 Instruction Manual
3RU OLR Time-Current Tripping Curves
1. Equipment designation label
2. Manual/automatic RESET selector switch
3. STOP button
4. Complete order number on the front of the device
5. Transparent cover, sealable
(secures adjuster knob for rated motor current.
TEST function and Manual/Automatic RESET setting)
6. Switching position indication and TEST function
7. Adjuster knob for rated motor current
8. Repeat coil terminal
(for mounting onto contactors)
9. Auxiliary switch repeat terminal
(for mounting onto contactors)
1
2
3
4
5
6
7
8
9
23
3RU Curves
8PX3 Instruction Manual
Motor service factor equal to or greater than 1.15 1.00
Motor Temperature rise less than or equal to 40°C 1.00
All other motors 0.92
Motor Service Factor Maximum Setting
Characteristic Multiply Motor FLA by:
Maximum Settings of Overload Relays
6.4 Overload Relay Selection Chart
Type 3RU bimetallic type overload relays are supplied with built-in heater elements.
They provide, as a standard:
• three-pole overload protection
• ambient temperature compensation
• phase-failure (single phasing) protection
• alarm contact 1 N.O.
• field adjustability
• overload test button
• The overload relay calibration is based on a motor service factor (S.F.) of 1.15. If the
service factor is 1.0, multiply motor Full Load Current by x 0.92 before making selection.
Selection and Adjustment Procedure:
1. Establish the starter size or contactor type the overload relay is to be fitted to.
2. Determine motor full load current and service factor* from motor nameplate.
3. Place the motor full load current within the corresponding setting range listed below
and simply select the overload relay type number shown opposite in the correct starter,
size column.
4. Once the overload relay is installed, adjust the setting dial to:
- motor full load current if S.F. 1.15.
- motor full load current x 0.92 if S.F. 1.0 or is unmarked.
*See Overload Selection Table on pages 25 and 26.
24
8PX3 Instruction Manual
Overload Relay
SIRIUS 3RU11 Bimetallic Class 10 Overload Relays with Screw Terminals
Description
Class 10, ambient compensated bimetallic
Overload relays for direct mounting to 3RT10
Contactors. For separate mounting when
Used in conjuction with 3RU19 separate
Mount kits.
Features
1NO & NC auxiliary contacts
Manual/automatic RESET
Trip indicator
STOP button
Test function
Sealable cover
CSA, UL
For Contactor Type Setting Range Amps Catalogue No.
3RU111-for direct mounting to 3RT101 contactors
3RT1015 0.11–0.16 3RU1116-0AB0
3RT1016 0.14–0.2 3RU1116-0BB0
3RT1017 0.18–0.25 3RU1116-0CB0
0.22–0.32 3RU1116-0DB0
0.28–0.4 3RU1116-0EB0
0.35–0.5 3RU1116-0FB0
0.45–0.63 3RU1116-0GB0
0.55–0.l8 3RU1116-0HB0
0.7–1.0 3RU1116-0JB0
0.9–1.25 3RU1116-0KB0
1.1–1.6 3RU1116-1AB0
1.4–2 3RU1116-1BB0
1.8–2.5 3RU1116-1CB0
2.2–3.2 3RU1116-1DB0
2.8–4 3RU1116-1EB0
3.5–5 3RU1116-1FB0
4.5–6.3 3RU1116-1GB0
5.5–8 3RU1116-1HB0
7–10 3RU1116-1JB0
9–12 3RU1116-1KB0
3RU112-for direct mounting to 3RT102 contactors
3RT1023 1.8–2.5 3RU1126-1CB0
3RT1024 2.2–3.2 3RU1126-1DB0
3RT1025 2.8–43RU1126-1EB0
3RT1026 3.5–53RU1126-1FB0
4.5–6.3 3RU1126-1GB0
5.5–83RU1126-1HB0
7–10 3RU1126-1JB0
9–12.5 3RU1126-1KB0
11–16 3RU1126-4AB0
14–20 3RU1126-4BB0
17–22 3RU1126-4CB0
20–25 3RU1126-4DB0
3RU113-for direct mounting to 3RT103 contactors
3RT1033 5.5–83RU1136-1HB0
3RT1034 7–10 3RU1136-1JB0
3RT1035 9–12.5 3RU1136-1KB0
3RT1036 11–16 3RU1136-4AB0
14–20 3RU1136-4BB0
18–25 3RU1136-4DB0
22–32 3RU1136-4EB0
28–40 3RU1136-4FB0
36–45 3RU1136-4GB0
40–50 3RU1136-4HB0
3RU114-for direct mounting to 3RT104 contactors
3RT1044 18–25 3RU1146-4DB0
3RT1045 22–32 3RU1146-4EB0
3RT1046 28–40 3RU1146-4FB0
36–50 3RU1146-4HB0
35–63 3RU1146-4JB0
57–75 3RU1146-4KB0
70–90 3RU1146-4LB0
80–100 3RU1146-4MB0
25
8PX3 Instruction Manual
Solid-State Overload Relays
SIRIUS 3RB10 Solid State Overload Relays
ForSetting Manual / Automatic Reset Manual Reset Only
Contactor Range Class 10 Class 20 Class 10 Class 20
Type Amps Catalogue No. Catalogue No. Catalogue No. Catalogue No.
3RB101-for direct mounting to 3RT101 contactors
3RT1015 0.1–0.4 3RB1016-1RB0 3RB1016-2RB0 3RB1015-1RB0 3RB1015-2RB0
3RT1016 0.4–1.6 3RB1016-1NB0 3RB1016-2NB0 3RB1015-1NB0 3RB1015-2NB0
3RT1017 1.3–6 3RB1016-1PB0 3RB1016-2PB0 3RB1015-1PB0 3RB1015-2PB0
3–12 3RB1016-1SB0 3RB1016-2SB0 3RB1015-1SB0 3RB1015-2SB0
3RB102-for direct mounting to 3RT102 contactors
3RT1023 0.1–0.4 3RB1026-1RB0 3RB1026-2RB0 3RB1025-1RB0 3RB1025-2RB0
3RT1024 0.4–1.6 3RB1026-1NB0 3RB1026-2NB0 3RB1025-1NB0 3RB1025-2NB0
3RT1025 1.5–6 3RB1026-1PB0 3RB1026-2PB0 3RB1025-1PB0 2RB1025-2PB0
3RT1026 3–12 3RB1026-1SB0 3RB1026-2SB0 3RB1025-1SB0 3RB1025-2SB0
6–25 3RB1026-1QB0 3RB1026-2QB0 3RB1025-1QB0 3RB1025-2QB0
3RB103-for direct mounting to 3RT103 contactors
3RT1033 6–25 3RB1036-1QB0 3RB1036-2QB0 3RB1035-1QB0 3RB1035-2QB0
3RT1034 13–50 3RB1036-1UB0 3RB1036-2UB0 3RB1035-1UB0 3RB1035-2UB0
3RT1035
3RT1037
3RB104 -for direct mounting 3RT104 contactors
3RT1044 13–50 3RB1046-1UB0 3RB1046-2UB0 3RB1045-1UB0 3RB1045-2UB0
3RT1045 25–100 3RB1046-1EB0 3RB1046-2EB0 3RB1045-1EBO 3RB1045-2EB0
3RT1046
3RB105-for direct mounting to 3RT105 contactors
3RT1054 50–20013RB1056-1FW013RB1056-2FW013RB1055-1FW013RB1055-2FW01
3RT1055 50–20023RB1056-1FG023RB1056-2FG023RB1055-1FGO23RB1055-2FG02
3RT1056
3RB106-for direct mounting to 3RT106 and 3RT107 contactors2
3RB106 55–250 3RB1066-1GG0 3RB1066-2GG0 3RB1065-1GG0 3RB1065-2GG0
3RB107 200–540 3RB1066-1KG0 3RB1066-2KG0 3RB1065-1KG0 3RB1065-2KG0
300–630 3RB1066-1LG0 3RB1066-2LG0 3RB1065-1LG0 3RB1065-2LG0
1Overload contains pass-through windows.
2Overload has busbar connections.
26
8PX3 Instruction Manual
6.5 Contactor Maintenance for SIRIUS Contactors 3RT1036 and larger
1. Maintenance
Inspect all connections periodically and tighten if necessary. To inspect main contacts
of the contactor, remove arc-chute by turning arc-chute to expose contacts.
Discolouration and slight pitting indicate normal operation. Do not file contacts.
Replacement is necessary only when contact material has worn thin. Always install
arc-chute before re-energizing equipment. Overload relays are factory-sealed units
and do not require any servicing.
2. Coil Change
1. Loosen the two captive coil-cover-fastening screws on opposite sides of the contactor.
2. Remove the upper part of the contactor body. It may be necessary to remove connec-
tions from the contactor in order to complete this procedure.
3. Remove the coil from the magnet.
4. Replace the coil following the foregoing steps in reverse. Note that the upper and
lower part of contactor housing are keyed.
3. Replacing the Main Contacts
Fixed Contacts: Undo the fixing bolt. Remove the contact complete with its bolt and
firmly tighten the replacement contact.
Moving Contacts: Take hold of the contact, press it gently against the spring, turn it
through 90° and pull it out. Insert the replacement contact in the reverse order, lifting
the spring disc slightly.
27
8PX3 Instruction Manual
Contactors
SIRIUS 3RT 10-Pole with AC Coil, 3RT101 to 3RT104
Coil Voltage Codes**
ACV 60Hz ACV 50Hz Code
24 24 C21
120 110 K6
208 208 M2
240 220 P6
277 – U6
480 – V6
600 – T6
Enclosed Single-Phase Auxiliary
AmpRatings HP-Rating Three-Phase HP Ratings Contacts Screw Terminals Cage Clamp Terminals
AC-3 AC-1 115V 230V 200V 230V 460V 575V NO NC Catalogue No. Catalogue No.
3RT101
1–3RT1015-1A**1 3RT1015-2A**1
718––1
1
/2235– 13RT1015-1A**2 3RT1015-2A**2
1–3RT1016-1A**1 3RT1016-2A**1
922
1
/312357
1
/2–13RT1016-1A**2 3RT1016-2A**2
1–3RT1017-1A**1 3RT1017-2A**1
12 22 – 2 3 3 71
/210 – 1 3RT1017-1A**2 3RT1017-2A**2
3RT102
940
1
/312357
1
/2––3RT1023-1A**0 3RT1023-3A**0
12 40 – 2 3 3 71
/210 – – 3RT1024-1A**0 3RT1024-3A**0
17 40 1 3 5 5 10 15 – – 3RT1025-1A**0 3RT1025-3A**0
25 40 2 3 71
/271
/215 20 – – 3RT1026-1A**0 3RT1026-3A**0
3RT103
28 50 2 5 71
/210 20 25 – – 3RT1033-1A**0 3RT1033-3A**0
32 50 2 5 10 10 25 30 – – 3RT1034-1A**0 3RT1034-3A**0
40 50 3 71
/210 15 30 40 – – 3RT1035-1A**0 3RT1035-3A**0
50 55 3 10 15 15 40 50 – – 3RT1036-1A**0 3RT1036-3A**0
3RT104
65 100 5 15 20 25 50 60 – – 3RT1044-1A**0 3RT1044-3A**0
80 120 71
/215 25 30 60 75 – – 3RT1045-1A**0 3RT1045-3A**0
95 120 10 – 30 30 75 100 – – 3RT1046-1A**0 3RT1046-3A**0
28
Replace the ** in the contactor catalogue number with a coil from the table above.
1 For 3RT101 use B0.
8PX3 Instruction Manual
Enclosed Three-Phase Auxiliary Catalogue
Amp Ratings HP Ratings Contacts Number
AC-3 AC-1 200V 230V 460V 575V NO NC AC Coil
Contactors are supplied without lugs
115 160 40 50 100 125 2 2 3RT1054-6A**6
150 185 50 60 125 150 2 2 2RT1055-6A**6
185 215 60 75 150 200 2 2 3RT1056-6A**6
225 275 75 75 150 200 2 2 3RT1064-6A**6
265 330 75 100 200 250 2 2 3RT1065-6A**6
300 330 100 125 250 300 2 2 3RT1066-6A**6
400 430 125 150 300 400 2 2 3RT1075-6A**6
500 610 150 200 400 500 2 2 3RT1076-6A**6
Vacuum contactors
225 330 75 75 150 200 2 2 3RT1264-6A**6
265 330 75 100 200 250 2 2 3RT1265-6A**6
300 330 100 125 250 300 2 2 3RT1266-6A**6
400 610 125 150 300 400 2 2 3RT1275-6A**6
500 610 150 200 400 500 2 2 3RT1276-6A**6
Description Contactor Wire Size Catalogue No
3RT1.54 6 AWG to 2/0, max. two 1/0 3RT1955-4G
1 Kit = Terminal block. 1 kit 3RT1.5 6 AWG to 3/0, max. one 3/0 & (1) 4 AWG 3RT1956-4G
necessary for each line and load. 3RT1.6/3RT1.7 2/0 to 600 kcmil, max. one 500kcmil 3RT1966-4G2
and one 600kcmil
29
1Standard coil voltage range
2Control power take-off included.
3RT1 Terminal Blocks
Replace the** in the contactor catalogue. Number with a coil code from the table above.
SIRIUS 3RT10 3-Pole with AC/DC Coil, 3RTI05 to 3RT12
Coil Voltage Codes AC/DC**
AC (40Hz to 60 Hz) and DC Code
23 to 261B3
42 to 48 D3
110 to 1271F3
200 to 220 M3
220 to 2401P3
240 to 277 U3
380 to 420 V3
440 to 4801R3
500 to 550 S3
575 to 600 T3
8PX3 Instruction Manual
7.0 Troubleshooting
The following table lists troubles encountered with motor control centers, their causes and solutions. This table is of a gen-
eral nature and covers only the main causes of trouble.
Misapplication of a device can be a cause of serious trouble. It should be noted here that misapplication is a major cause
of motor control trouble and should always be considered when a device is not functioning properly.
Actual physical damage or broken parts can usually be found quickly and replaced. Damage due to water or flood
conditions requires special treatment. Contact your local Siemens office.
Trouble Cause Solution
Contact Chatter 1. Poor contact in control circuit. 1. Replace the contact device or use holding
(also see “Noisy Magnet”) circuit interlock (three-wire control).
2. Low voltage. 2. Check coil terminal voltage and voltage dips
during starting.
Welding or Freezing 1. Abnormal inrush of current. 1. Check for grounds, shorts or excessive
motor load current, or use larger contactor.
2. Rapid jogging. 2. Install larger device rated for jogging service.
3. Insufficient tip pressure. 3. Replace contacts and springs; check contact
carrier for deformation or damage.
4. Low voltage preventing magnet from 4. Check coil terminal voltage and voltage dips
sealing. during starting.
5. Foreign matter preventing contacts 5. Clean contacts with contact cleaner. Contacts,
from closing. starters and control accessories used with very
small current or low voltage should also be
cleaned with the proper contact cleaner.
6. Short circuit or ground fault. 6. Remove fault and check to be sure fuse or
breaker size is correct.
Short Tip Life or 1. Filing or dressing. 1. Do not file silver tips. Rough spots or
Overheating of Tips discolouration will not harm tips or impair
their efficiency.
2. Interrupting excessively high 2. Install larger device or check for grounds,
currents. shorts or excessive motor currents.
3. Excessive jogging. 3. Install larger device rated for jogging service.
4. Weak tip pressure. 4. Replace contacts and springs; check contact
carrier for deformation or damage.
5. Dirt or foreign matter on 5. Clean contacts with contact cleaner. Take steps
contact surface to reduce entry of foreign matter into enclosure.
6. Short circuits or ground fault. 6. Remove fault and check to be sure fuse
or breaker size is correct.
7. Loose connection in power circuit. 7. Clear and tighten.
8. Sustained overload. 8. Check for excessive motor load current
or install larger device.
Coils
Open Circuit 1. Mechanical damage. 1. Handle and store coils carefully.
Contacts
30
8PX3 Instruction Manual
Trouble Cause Solution
31
Overheated Coil 1. Over-voltage or high ambient 1. Check coil terminal voltage, which should
temperature. not exceed 110% of coil rating.
2. Incorrect coil. 2. Install correct coil.
3. Shorted turns caused by mechanical 3. Replace coil.
damage or corrosion.
4. Under-voltage; failure of magnet 4. Check coil terminal voltage, which should
to seal in. be at least 80% of coil rating.
5. Dirt or rust on pole faces. 5. Clean pole faces.
6. Mechanical obstruction. 6. WITH POWER OFF, check for free
movement of contact and armature assembly.
Overload Relays
Tripping 1. Sustained overload. 1. Check for excessive motor currents or
current unbalance, and correct cause.
2. Loose or corroded connection 2. a) Clean and tighten.
b) Replace all insulators showing deterioration
or deposit.
3. Excessive coil voltage. 3. Voltage should not exceed 110% of coil rating.
Failure to Trip 1. Mechanical binding, dirt, corrosion, etc. 1. Replace relay and thermal units.
2. Relay previously damaged by short 2. Replace relay and thermal units.
circuit.
3. Relay contact welded or not in series 3. Check circuit for a fault and correct condition.
with contactor coil. Replace contact or entire relay as necessary.
Magnetic and Mechanical Parts
Noisy Magnet 1. Broken shading coil. 1. Replace magnet and armature.
2. Dirt or rust on magnet faces. 2. Clean.
3. Low voltage. 3. Check coil terminal voltage and voltage dips
during starting.
Failure to Pick up 1. No control voltage. 1. Check and control circuit for loose
and Seal connection or poor continuity of contacts.
2. Low voltage. 2. Check coil terminal voltage and voltage dips
during starting.
3. Mechanical obstruction. 3. WITH POWER OFF, check for free movement
of contact and armature assembly.
4. Coil open or overheated. 4. Replace.
5. Wrong coil. 5. Replace.
Failure to Drop Out 1. Gummy substance on pole faces. 1. Clean pole faces.
2. Voltage not removed. 2. Check coil terminal voltage and control circuit.
3. Worn or corroded parts 3. Replace parts.
causing binding.
4. Residual magnetism due to lack of air 4. Replace magnet and armature.
gap in magnet path.
5. Contacts welded. 5. Replace contactor.
Limit Switches
Broken Parts 1. Over-travel of actuator. 1. Use resilient actuator or operate within tolerance
of the device.
Manual Starters
Failure to Reset 1. Latching mechanism worn or broken. 1. Replace starter.
8PX3 Instruction Manual
8.0 MCC Optional Equipment
Also available with Siemens Motor Control Center:
Samm’s Unit
Soft Start
Variable Frequency Drive
Programmable Logical Center
Electronic Metering
For more information, contact your local Siemens office.
32
