Maintenance

Preventive Maintenance

Read and understand the following precautions before performing any maintenance.

DANGER
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462 or local equivalent. Only qualified personnel familiar with medium voltage equipment are to perform work described in this set of instructions. Workers must understand the hazards involved in working with or near medium voltage circuits. Perform such work only after reading and understanding all of the instructions contained in this bulletin. Turn off all power supplying this equipment before working on or inside the equipment. Always use a properly rated voltage sensing device to confirm power is off. Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding. More than one disconnector switch may be required to de-energize the equipment before servicing. Disconnect the equipment and enable a lockout command prior to performing maintenance on the equipment. Ensure that any stored energy in the capacitors has dissipated before energizing or de-energizing the equipment. Disconnect the controller from the load before measuring insulation resistance (IR). Carefully inspect your work area and remove any tools and objects left inside the equipment. Replace all devices, doors, and covers before turning on power to  this equipment. All instructions in this manual are written with the assumption that the customer has taken these measures before performing installation, maintenance  or testing. Failure to follow these instructions will result in death or serious injury.

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH

Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E, NOM-029-STPS-2011, or CSA Z462 or local equivalent.
Only qualified personnel familiar with medium voltage equipment are to perform work described in this set of instructions. Workers must understand the hazards involved in working with or near medium voltage circuits.
Perform such work only after reading and understanding all of the instructions contained in this bulletin.
Turn off all power supplying this equipment before working on or inside the equipment.
Always use a properly rated voltage sensing device to confirm power is off.
Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of backfeeding. More than one disconnector switch may be required to de-energize the equipment before servicing.
Disconnect the equipment and enable a lockout command prior to performing maintenance on the equipment.
Ensure that any stored energy in the capacitors has dissipated before energizing or de-energizing the equipment.
Disconnect the controller from the load before measuring insulation resistance (IR).
Carefully inspect your work area and remove any tools and objects left inside the equipment.
Replace all devices, doors, and covers before turning on power to  this equipment.
All instructions in this manual are written with the assumption that the customer has taken these measures before performing installation, maintenance  or testing.

Failure to follow these instructions will result in death or serious injury.

Regular preventative maintenance will help ensure that the equipment continues to operate correctly and help prevent injury. The frequency of preventative maintenance depends upon the type of maintenance and the installation environment.

To ensure the motor controller is properly maintained, perform the following inspection procedures:

Preventive Maintenance Frequency and Action to Take

Maintenance Schedule	Recommended Action
During commissioning (prior to putting equipment in operation)	Torque all power connections, including factory-wired equipment. Inspect all of the control wiring for loose connections or damage. If fans are installed, verify proper operation. Verify that the filters and guards are in place.
For the first month of operation	Re-torque all power connections every two weeks. This includes factory-wired equipment. Inspect cooling fans to verify proper operation (if installed). Inspect filter for dirt and debris. Replace filter if clogged.
After the first month of operation	Re-torque all power connections once a year. Remove any accumulated dust using a vacuum cleaner. Wipe clean with a solvent such as denatured alcohol, if necessary. Inspect the cooling fans every three months to verify proper operation (if installed). Clean or replace air vent filters every three months.

NOTE: If mechanical vibrations are present at the installation site, inspect the electrical connections more frequently.

Maintenance Records

Maintaining well documented maintenance records will be helpful in locating possible intermittent problems by identifying a particular area where there are recurring issues within the system.

Vacuum Contactor Maintenance

To remove a contactor, follow these steps:

Review the Preventive Maintenance.
Ensure that the main disconnector is open and the grounding blades are seated (if grounding option is included).
Disconnect all power wires going to the vacuum contactor poles.
Remove any covers on the bottom of the contactor, if necessary.
Remove the control wires from the contactor.
Remove the four mounting bolts and remove the contactor.

To replace a contactor, reverse the steps for removing the contactor. Test the contactor before installing it to verify proper operation. A contactor manual comes with each motor controller. Refer to the contactor manual for more information when disassembling and reassembling the contactor. If required, contact your local field sales office or distributor for the manual.

Interlocks

Interlocks should be checked for proper operation before power is applied to the motor controller equipment. Check the access interlock to verify that:

The power fuses cannot be accessed unless the disconnector switch is open.
The disconnector switch cannot be closed while the power fuses are accessible.

DANGER
HaZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH Properly destroy extra interlock keys (when supplied), or store them in a secure location. Make extra interlock keys accessible only to appropriate personnel. Do not modify or alter interlocks. Failure to follow these instructions will result in death or serious injury.

Before placing the equipment into operation, see Operation, and consult the drawings for proper operating sequence.

The load break interrupter switch is equipped with a mechanical device that blocks access to a closed switch. In addition, the load break interrupter switch must be opened before the medium voltage door can be opened.

Disconnector Switch

Inspect the equipment for visible evidence of damage such as overheating.
Verify that all components are tightened correctly.

Refer to the manufacturer's instruction manual for additional maintenance requirements.

Replacing the Plant Interface Module (PIM) Battery

For ATL configurations using the MotorSeT advanced motor control system, the battery must be replaced if the starter trips on "Battery/clock" after the control power is applied. Refer to the maintenance section in instruction bulletin BRU3897001 for details.