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O&M Manual LRS

O&M for LRS

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sanjay Adhikari
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183 views9 pages

O&M Manual LRS

O&M for LRS

Uploaded by

sanjay Adhikari
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
Streams Rol mip -2 4 RS OPERATION & MAINTENANCE MANUAL FOR ERECTION & COMMISSIONING OF LIQUID ROTOR STARTER AND LIQUID ROTOR CONTROLLER ERS GINE! sTRIAL AREA GOVINDPURA. Mis ENTERPR! PLOT No. 46, & 47, 5 OPAL | (MP) M62 5.502864 FI TEL: 0755- ee ote in, rgbansalz@gmal an E-mail : kgbansale ere Scanned with CamScanner 34.4 34.2 34.3, 344 315, | 316 S47 General Liquid Rotor Resistancos s1 ti larter are designed for inserting External Resistance inthe Rotor Circuit of Si Ip Ring andincreasing the: starting PEATE Motors for reducing the starting current The Liquid Rotor Resistance conform to BS 140 In the Starting posit Resistance nea eee ie Moving Electrodes aro wide apart, inserting full Resistance to all the fake bal of the Motor, As tho Motor picks up Speed, tho motor attains full speed, phases are cut-off Smoothly (Sleoplossly). When the formed. peed, all the three phases aro shorted and a star point is ‘The instructions given below are to be strictly followed. UNPACKING Carefully unpack the Liquid Rotor Resistance and ‘examine all parts to see that nothing is broken or missing. If any damage or loss is suspected during transit, immediately notify the carrier, insurance company & Enterprising Engineers. CONSTRUCTION General Arrangement and Schematic Drawing keptinside the Control Panel/Box ofLRS at the time of dispatch should be referred while reading the following. In type LSHM Electrodes move horizontally Liquid Rotor Resistance consists of Fabricated Tank to accommodate Electrodes & Electrolyte both. It is provided with Tank Cover. Lifting Lugs, Base Channel, Electrolyte Level Gauge, Filling & Over Flow: Sockets and Drain Plug. ase barriers are provided to separate the electrodes from each Polypropylene phi ross current. others and from tank to reduce ¢! .g Electrodes are mounted sulators. Movin: intand are Fixed Electrodes are fixed on Epoxy ins ‘on channels which move on rollers. Moving Electrodes ‘make a star poll earthed through electrolyte and tank. 1d with copper Conductor, which connects Rotor Each Fi 1e is provide’ ch Fixed Electrode Is Pro er MountedontheTank. Terminal Through Polypropylen® ur Gear and Pinion, Sprocket and tes set of SP Pilot Motor, Pulleys, Gear Box 1, Limit Switches, Mechanical Box, accomm' Chain arrangement, H and Declutch Coupling: hich, Moving Elect ough Chain and rodes are fixed is moved thr The Channel on w! Motor Mechanism. _—_——<$<$_—_ Scanned with CamScanner (02) 4.8 Cable Box accommodates Bushings, Copper connections, Shorting Contact 3.4.8 a cable Gland Plate. Box, accommodates Contactors FC, RC, Over-Load Relays OLR, ea Lemp IL-1, 2 & 3 Push Buttons PBS, PBR & PBF, isolating Switchig and Control Selector Switch CSS, Temperature Controller TSH, Water Leva Controller WLC, Phase Failure Relay PFR, Heater H, Thermostat TH, Miniature Circuit Breakers MCB18&2, Current Relay and Timer. 3.1.9 3.1.10 Atthe Run Position of Motor all the three phases of the rotor Circuit of the Motor me romagnetic Contactor SC, is are shorted to make a star point. For Shorting Elect provide. 3.2 Motor Operated Mechanism 3.2.1 The Motor Operated Mechanism of Liquid Rotor Resistance is driven by 415 \V,3 Phase Pilot Motor PM with Reduction Gear. 32.2 The Pilot Motor is operated by two contactors FC & RC. One contactor is for Reversing the Electrodes or inserting the resistance and other contactor for Forwarding the Electrodes or cutting-off the Resistance. t only one Contactor can be 3.2.3 Contactors are electrically Interlocked such thal ‘Switched 'ON' ata time. 3.2.4 Thermal Overload Relay OLR1 is provided for protection of Pilot Motor PM. 3.2.5. Lockable Selector Switch CSS is provided so that Liquid Resistance can be operated either Manually by Push-Buttons or from Auto point The mode of Auto peration is automatic by the Auxiliary Switch ofthe Stator Contactor/ACB/OCE. | 3.26 Ruste PBF & PBR are provided for Manual electrical operations for Revere oe cowering the Electrodes, One Push-Button PBS is provided'ot lop, Limit Switches LSS& ic a Ss LSR are operated at the end positions Indicati . Indicating Lamps IL-1, IL-2 & IL-3 and Miniature Circuit Breakers MCB1 & 23% provided as perthe SchematicDiagram. 3:2. Nv 3.2. & All Electrical equi i lectrical equipments are wired as per the Schematic Diagrams supplied: 3.29 a - Mechanical Operation ‘or Manual - ic ic ec Marwels eral operation ofthe Liquid Resistance the Reduction 628 ee fo the Chain Mechanism, by shifting Declutching Level eee ng wi disengage, and decouple Reduction Gear from . ‘esistance Can be operated by the Hand Wheel Scanned with CamScanner 42 43 44 45 432.40 Local/Manual-Electrica| 32.11 Remote/Automatic- (03) Keep the Selector Switch ogee ation label. Engage tho Goar bes = 'n Local or Manual Position as marked on the Resistance can be Operated’ nee Mechanism by Declutching Lever Now 'REVERS'PBRPush Button "Cally by prossing ‘FORWARD PBF or Electrical Operation a in Remote or Automatic Position as marked on Tee nome: Now Resistance will be Operated automatically See SNe Switch of Stator Switch ic, Contactor/ACB/OCB. As soon as and whan Stator pane the Moving Electrodes will automatically move forward Reversed ant encntch is open the Moving Electrode will be automatically nd reach START position ready fornext operation. Keep the Selector Swi Level. As per the Sci 32.12 Interlocking System : Itis absolutely necessary that full-Resistance should be in Rotor Circuit of the Motor and Shorting Contactor of, before attempting to start the Motor. An Interlocking Circuit is provided as safety Interlock. NO/NC Contacts of ACB/OCB/Contactor of Stator Panel to be connected as show in Schematic Diagram. A Timer is also provided to trip the Stator Switch if there is some mal- operation during cutting of Resistance in closing of Motor. INSTALLATION : The Liquid Resistance should be placed conveniently near the Motor to which itis tobe connected and it should be bolted toa firm foundation. Open the cover and doors and clean all parts and see that everything is visibly in sound condition. echanism and lubricate the moving parts like Bearings Jean all parts of the m Clean all pa ‘SAE 40 or equivalent. Bushes, Rollers, Gears etc. by Machine ol ike i rodes few times manually. In case of Motor operated mene eal Reduction Gear Box should be decoupled, before Trying to operate manually. For this a declutchifg Liver is provided this is set And locked for electrical operation before dispatch from the works. Remove The Locking Pin and move the Declutching lever sideways so that coupling, Between Chain Mechanism and Reduction Gear shaft is disengaged. Lock the Lever in this position by Locking Pin. Operate the Liquid Resistance manually. The operations should be smooth in both directions. See that Nothing is loose or broken and all hardware are properly tightened and locked. ‘oth and proper, proceed for electrical connections of as per the Schematic Diagram. Proper phase ly is very essential for proper operation of Motor If manual operation is smo motor operated mechanist sequence of three phase SUPP Scanned with CamScanner 46 47 48 49 4.10 41 4.42 (04) ASE SEQUENCE oF y, .T PROPER PH NING IT IS IMPORTANT PLY TO THE oO THE ‘One INGOMING THREE, SoerariON, OR DAMAGE rane ER WIS! . orANSM MAY HAPPEN sure Phase Failure Relay PFR i provided for this meas safely As three phase supply to terminal connectors as shown in schema Connect the three Diagram. a , ing Electrodes in middle posi ion. Now remove the | tel a “pelteing Lever and move it sideways, so that Chain | a tnd Reduction Gear-Shaft are engaged. Locked the lever in this | fechal d position by Locking Pin. iquic i ri that Electrodes move from the Liquid Resistance Electrically and see that serpin poston by pressing PBF 'Forward' which indicates proper phase sequence. If not, disconnect the supply immediately and interchange any two phases, Check Again for proper phase Sequence. After ensuring proper phase sequence as explained above press Push Button Forward and check that Pilot Motor is stopped by actuating limit switch 'LSR' and it should get actuated when Moving Electrodes reach to closest to Fixed Electrode, when Full-Resistance is out. Similarly check by Pressing Push Button Reverse that Pilot Motor is stopped by actuating Limit switch Start Position 'LSS' and it should get actuated when Moving Electrodes are in Fully -Resistance - In position. If Liquid Resistance ‘works smoothly without any trouble or hesitancy when operated electrically proceed further. Connect the earthing Terminal on the tank control Box with good earth. See the Interlocking Circuit as Per schematic Diagram. This is a Necessa’¥ Rolo, Ren caution 80 that Stator Switch can never be closed unless the Liaud esistanceisin "Start" or"FULL RESTANCE" Position | Check that settin 9 of Limit Swit locked properly, These haan oo and Stopper Lever are not disturbed anda’® e have ° Commissioning the folowing she oo ooKed In the works. However bel? ment of 1 or 2 © operation of o «Electrodes closer to each thon of Limit Limit Switch due to over: ‘shooting. : . Similar SR’), Moving the f aerate avoid breakage mm of Limit Switch plunge Limit Switch (Run Posi" This checking is necess@Y Scanned with CamScanner (b) Check the sett; electrically ater engagr ini s Button is presseq th, a by oper Z| . es © Pil Perating the Electrodes ‘START position. At thig ane = ove, When Revers Push t gap of 1 or 2 mm by clrodes will start m i lart moving to atherpesiion young es ed and there should be a Slop. Similarly check for ish Button, Pressing forward 5 ELECTROLYTE ne Asolution of common Wash used as Electrolyte, Fi ine tone aa hot concentrated solution of act" lear Co3) in water. Add th mmo iS Solutio, well. Lumps of soda must never beat mm carbonate, Naz Co3) in water is Acid free water, Propare separately " Washing soda (sodium carbonate, Naz Meat timo to tho wator in the Tank and ste fise to uneven distribution of ae e410 waterin tho Tank ae nc give uneven distribution of curren u7oN in threo phases and waeuns give rise to elapse before a uniform solitony three phases and a considerable time would soda might also mern® ewlcbe obtained The addition of solid lumps of complex chemical een outstanding properties, its stable re: makes it very suitable for this Purpose. The latter being useful in neutralizing any slight acid impurities that may be Presentin the local water which if not neutralized would resultin rapid corrosion. No exact proportion can be given for the strength of the solution as this varies considerably in different cases. The correct solution must always be obtained by trail. Start can be made with 0.7% solution (7 gram sodium carbonate in one liter ofwater) EALY - abate pedi Fatur othe Phase Seqvonce Reverse cndtionaPhase Failure Relay is provided in Liquid Resistance. please check electrical connection corecly 28 per the Sehemetc Diagram suplad wih Liu Resistance After giving power connection to Liquid Resistance if it does nol operate electrically. then Phase Sequence is wrong, Then Interchange any two Phaseis R to Y and toR. Then electrical operation will operate. E CONTROLLER Te tempt Eas Se eae ome Control (TSH) nas been proviedin Laud Resistance A Temperature Sansor ce ntroller (TSE Tank. Please check the electrical connection as ned Mounted inside the Tank" vpplied with Liquid Resistance, As Soon as the 1 the Schematic Diagram Supe ine set evel it wll give Alarm andfitis so Feet e signal for the stator switch, The Temperature of controlled it ieator, chctoivc “ be indicated on the Dial Indicator. Scanned with CamScanner (06) OLLER een ratte Iype WLCDI has been provided in Liquig Please check electri { Eloctrolyte in the Tank, cal mee Two Sensor Prods are placed in the Tank, ELECTROLYTE LEVE! Adevice Electrolyte Love! i 1 the | Resistance to control Ganection as por Schematic Diagram, ‘One Sensor Prod is placed below the El trolyt i tho correct top Lovel of Elec! i orate vat top Lovol of Electrolyte as soon as the Electrolyte Level goes 'd and as alarm will be given. Then the Wn itwill be sensed by the Sensor Pro so od freo water should be added n the Tank upto the correctlevel. g CURRENT RELAY Current relay is provide Resistance. The secondary cur the Current Relay through Termi 42). Primary voltage of 240 V.A.C. is bein: Relay. d as safety equipment in the Control Panel of Liquid rent of 1 A from Stator CT of Main Motor is fed to inal Nos. 1 & 2 which are connected to TBI (41, ig fed to the PT. Terminal Nos. 586 o ‘The Current Relay is so setin our works that if there is nay sudden over current it main motor during starting, then Current Relay will not allow the electrodes to be moved further for decreasing resistance. When motor current reduces to st value, the resistance cutting will continue and electrodes will move further. The Current Relay is provide with tow types of settings :- (1) Current Setting : With the help of current setting, current range of stator is set so that if the current exceeds this limit during starting the resistance cutting stop (2) Differential Setting : With the help of Differential settin, of the relayis setto avoid hunting of the LRS amestcinen ie COMMISSIONING 10.1 Connect the Rotor Circuit of th 1e Motor to the Epoxy Cast Bushing Termit Conductors in calbe box. Cable Gland should be used for supporting cable 10.2 i ate completion, See that all connection are well made as per the Instructior 6 very Carefully before attempting to start the Motor. Resistance. M Bush-Lifting ang Short-Circuit i Brushes are lowered or cicuiling Gear is fitted to the Motor see that arewithdrawn, on to the slip rings and that the Short - Circuiting Contacts Close th it '@ Stator Switch. Motor will start rotating at slow speed. Scanned with CamScanner (07) 6 Ifthe Switching-on 108 ‘he Start" position 0 Al or Closing the Stator Switch, with the Electrodes in Electrolyte fom the tank ost2%2° In" position, fs mor, thon romove some add some clean acid free water. This will increase the resistance of Electrol resistance is obtains oe and reduce tho Starting Currnt, until the required Now move the Movir . towards Fixed eovia Electrodes to"RUN" position. As Moving Electrodes Move sndMotorwitpick ore cee? Gxlemal Resistance in Rotor Circuit wil Reduce 10.8 eae aa kick when Moving Electrodes reach nearest to the Fixed peed final "RUN" position and Short-Circult Contacts touch, cutting of iquid Resistance from the Rotor Circuit, then some move concentrated soda solution till the Starting and Running of Motor is smooth. Note :-Aheavy Current peak at the moment of closing the Stator Circuit Breaker or’ ocB (Stator ‘Switch) with Liquid Resistance in "START" position Indicates too strong a solution. On the other hand, if the solution is too weak Excessive sparking and a me large increase in speed may occur when the Short-Circuiting Contacts touch. | 10.9 In the case of Motors Fitted with Brush-Lifting and Short-Circuit Gears, when Motor attain full speed, gear should be operated to Short-Circuit the slip-rings. | PRECAUTIONS 11.1. Stator Switch should be closed only when moving electrodes of the liquid resistance are in "START" position separated and brushes are firmly placed on slip-rings in case brush-lfting arrangement is provided on the motor. To avoid faulty operation interlocking connection should be done as explained above and in schematic diagram. When motor is running at full speed Moving Electrodes SHOULD NEVER BE MOVED FROM RUN POSITION unless motor is fitted with Brush-Lifting and Short-Circuit Gear. 11.2 tripping the Stator Switch the Moving Electrodes 11.3 When motor is stopped b: sition in readiness for the nextstart. should be putto "START" pos 12 MAINTENANCE be inspected every month for Electrolyte Level And 12.1 The Liquid Resistance should: ory r n of Liquid Resistance are Frequent, to ever year or more frequently. if operatio check the following thoroughly. 122 ELECTROLYTE (@) The level of the Electrolyte should be maintained up to the proper level i.e, Middle of the Liquid Level Gauge mounted on the Tank, Liquid level can be inspected from out-side-without iting the Tank Cover. IfLiquid Levelis lower, add fresh clear water through a pipe provided above the Over-Flow pipe on the back of the Tank. There is no need to add soda while adding fresh water to maintain level. Scanned with CamScanner 12.5 12.6 (08) th sludge formed, the dirty and there is too muct , the Te een a ud Bo drained off. Tank should be thoroughly cleaneg Sema Seni tiat ‘water, Add concentrated solution of washing soda as and filled wi : explained in above. The moving and fixed electrodes should be inspected and if found to be mush Corroded orworn-out, these should be replaced. i id be clean and in proper hort

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