Lrs Resistencia Liquid Starter

LIQUID RESISTANCE STARTER
Installation & Operation Manual

INDEX
0. SPECIFICATION SHEET
1. GENERAL
2. INSTRUCTIONS FOR INSTALLATION
3. COMMISSIONING THE EPM STARTER
4. MAINTENANCE
SPECIFICATION SHEET
Characteristics Specifications
Maximum ambient temperature Type EPM
Maximum dissipation P= Capacity (litres)
Heat exchanger P= Manufacturer CSE Uniserve
Maximum entering water T= Motor power kW
temperature Rotor volts V
Minimum flow rate F= Rotor current A
IP rating of MV enclosure IP Supply volts V
IP rating of LV enclosure IP VA
General IP rating IP Control supply V
Adjustment of starting time (s) VA
Starting time (s) Electrolyte %
Number of consecutive starts from Type
cold
Number of starts h/max Quantity kg
Starting torque Oil (type)
Safety thermostat setting 85°C
Agitator thermostat °C Quantity
Pump thermostat °C Shorting contactor current A
Immersion heater thermostat setting °C Shorting contactor voltage V
Type
Isolating voltage phase/phase kV
Isolating voltage phase/earth kV
Marking
Auxiliary circuits
Single phase power kVA Painting: standard RAL 7032
Three-phase power kVA Other:
Fixing screws Standard
Stainless
Busbar finish Standard
Nickel
Other treatments
Anti-condensation heater
MV enclosure
LV enclosure
Immersion heater kW
Specifications indicated in the present Installation & Operation

Manual may be changed without priornotice.
EPM 1. General
1. GENERAL
1.1 General Information - Introduction 3

1.2 Characteristics 4
1.3 Safety provisions 5
1.3.1 Conforming to the safety standards 5
1.3.2 Following the instructions supplied with the accompanying documents 5
1.3.3 Explantion of the rating plate 5
1.3.4 Description of the rating plate 5
1.4 Description 6
1.4.1 Electrolytic resistance 6
1.4.1.1 Tank 6
1.4.1.2 Electrodes 7
1.4.1.3 Control 8
1.4.1.4 Electrolyte 9
1.4.2 Enclosures 10
1.5 Special applications 11

1.5.1 Dual starting 11
1.5.2 Slip resistance - speed variation 12
3 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

EPM 1. General
1.1 General Information - Introduction
The EPM range of automatic liquid rotor starters is intended for use on large slip ring
and synchronous induction motors.
The range not only ensures excellent starting characteristics with smooth, stepless
acceleration to full load speed, but it can also be used for speed variation, torque control
and plug braking.
The principle employs an electrolytic resistance utilising moving electrodes in an
electrolyte solution.
A large resistance variation is obtained by displacing the electrodes in this solution.
The resistance is shorted out at the end of starting by a shorting contactor (except in case
of speed variation).
The starter comprises:

- 1 electrolytic resistance matched to the motor rating,
- 1 MV enclosure which contains the shorting contactor,
- 1 LV enclosure containing the controls.
The MV enclosure may be supplied as a separate enclosure depending on the rotor data;
details would be provided with each quotation.
LV enclosure
MV enclosure
Electrolytic
resistance
Emptying
valve
Figure 1: EPM general presentation

1.2 Characteristics
Power: 500 to 20 000 kW according to model:

EPM1: up to 1 600 kW.
• Maximum rotor voltage between sliprings: 3 500 V.

• Standard starting times: 9 to 130 seconds.
• Electrolyte level is monitored by magnetic float switches.
• The temperature of the electrolyte is controlled by thermostats.
• Antifrost control is provided by an optional immersion heater.
• Electrolyte cooling is controlled by natural convection assisted by an agitator.
• Cooling of the electrolyte can also be augmented by utilising an optional heat exchanger.
• Electrodes operate without passing through the wall of the tank.
• Low current density: in the order of 1 A/cm. 2
• Electrodes driven by a worm drive controlled by a geared motor, a servomotor or a
motortogether with an electronic speed controller.
• Motor protection is provided by thermal overload relays or motor circuit breaker.
• Numerous interlocks monitor and control the electrodes during the start cycle.
Short-circuit contactor
According to IEC Publication 60947-4: AC2.
According to IEC Publication 60470: AC2.
Current type
The current flowing through the main circuits is AC with variable frequency according to
the slip. Its frequency should be lower than 50/60 Hz.
Rated impulse withstand voltage

The rated impulse withstand voltage of the main circuits is as follows:
• with an operating voltage ≤ 1 000 V regarding the earth and according to the IEC
Publication 60439-1: 8 kV withstand voltage.
• with an operating voltage > 1 000 V regarding the earth and according to the IEC
Publication 60740:
1 000 V < V < 2 500 V, 6.5 kV AC or 12 kV withstand voltage.
2 500 V < V < 3 600 V, 10 kV AC or 20 kV withstand voltage.
Neutral requirement
Neutral requirement is not applicable for the main circuits. The user may choose the
neutral requirement for the auxiliary circuits.

EPM 1. General
1.3 Safety provisions
1.3.1 Conforming to safety standards
The unit the followingstandards:

• EN 60439-1 – October 1994: Low voltage switchgear and controlgear assemblies,
part 1.
• EN 60204-1 – February 1993: Electrical equipment of industrial machines, part 1.
• IEC 60470 – January 1974: AC high voltage contactors.
1.3.2 Following the instructions supplied with the accompanying documents
The unit is only to be operated as per the instructions supplied.
The unit is adjusted during cimmissioning and should only be serviced by CSE Uniserve
qualified personnel.
List of the accompanying documents:

• the instruction manual,
• the wiring diagram(s),
• the rating plate.
1.3.3 Explanation of the rating plate
Over each EPM is a rating plate which shows the specifications of the unit.
Note: Some configurations require two rating plates.
1.3.4 Description of the rating plate
AO IP's order Starting M otorrated Statorrated EPM N °

num ber rate pow er voltage R otorvoltage
and current
R
Motor Power kW Sv kV O Rv V
T
O
Starter N ber of starts Hour Day Consecutive R Ra A
o
Mark EPM N :
C ontactor Coil Supply Electrode motor Motor agitator
specifications Contactor V Hz V Hz V Hz
Type
Antifrost
Electrolyte - Kg , % Oil l Time S heater x kW
Tank electrolyte quantity H eaterpow er
Electrode m otor M otoragitator

electricalspecifications Starting electricalspecifications
tim e

1.4 Description
1.4.1 Electrolytic resistance
1.4.1.1 Tank
Manufactured from stainless steel and supplied with lifting eyes.
Protection: IP54.
Capacity and dimensions are a function of the power (See installation manual).
The electrolyte level is monitored by float magnetic system enabling control and
activation of a fault relay with free contacts on the terminal (according to diagrams).
The temperature of the electrolyte is controlled by two or three thermostats:

- Th1: this thermostat prevents starting if the electrolyte temperature is too high. It
also activates the fault relay (according to diagrams).
- Th2: the agitator or pump control thermostat. The agitator is used to improve the
heat dissipation of the starter.
- Th3: this optional thermostat is used to operate the antifrost heater and is activated
in the region of 5°C.

EPM 1. General
1.4.1.2 Electrodes
The three electrodes are arranged in a line and each comprises a fixed and a
moving electrode. Polypropylene compartmentalisation ensures isolation between
the phases.
The electrodes, cast in GS or bronze consist of concentric cylinders which merge

with each other in the minimum resistance position.
The fixed electrodes, situated at the lower end of the isolated compartments, are fed
from an insulated copper bar.
Since this bar does not pass through the wall of the tank, it is impossible for the
electrolyte to leak.
The moving electrodes travel vertically inside an isolated compartment guided by a

nylon slide. The assembly is supported by two strong brass rods mounted on the
moving electrode system.
This assembly, common to all three electrodes, constitutes the neutral point.
The low current density, in the order of 1 A per cm2, ensures an extremely long
electrode life.
Fixed
electrode
connection
Polypropylene Isolating
compartment electrode
guide
Moving
electrode
Fixed
electrode
Figure 2: Electrolytic resistance (electrodes)

1.4.1.3 Control
Displacement of the moving electrode assembly is controlled by a motor driven

worm screw assembly (geared motor, motor together with an electronic speed
controller, servomotor).
A handwheel is used for commissioning and emergency operation.
The standard starting times are factory set: 10, 20, 30, 40, 60, 80 or 130 seconds.
The limit switches which control the operation of the electrode drive motor and also
the closing of the shorting contactor which eliminate the residual resistance at the
end of starting.
The overload relay will trip the electrode control motor if an accidental blockage
occurs.
An electrical interlock prevents a new start if the moving electrodes are not at the
start position.
The return to the start position is automatically effected after the shorting contactor is
closed.
If a power failure occurs during starting, the electrodes return automatically to the
start position. When the supply is restored, a new start cycle is possible.
Handwheel
Limit
switches Geared motor (or motor
or servomotor)
Mechanism
holder Worm screw
Fixed electrode
connection
Connection
protection
Figure 3: Electrode control system

EPM 1. General
1.4.1.4 Electrolyte
The electrolyte generally comprises a solution of sodium carbonate or sodium

borate.
For preparation of the electrolyte, refer to the installation manual.
The cooling of the electrolyte is effected by natural convection and forced circulation
(via the agitator) but in certain applications (permanent slip etc.), it is possible to
augment the heat dissipation by the use of an optional heat exchanger.

1.4.2 Enclosures
Dimensions of the MV enclosure depends on the shorting contactor rating.
Power cable entry is carried out at the base. The cable guide plate of the enclosure
should be drilled during installation. Cables come onthe terminal outputs mounted
on front of the enclosure (see figure 4).
The controls are built-in the LV enclosure. This enclosure lies on the right part of the
MV enclosure. Connecting the control cables is performed at the base through the
back plate to be drilled. Control cables come on the screw terminals (see figure 5).
Protection: IP 54.
R1
R2
R3
AG ITATEUR TH 1 85°C
TH 2 40°C
BP
AG ITATO R
Figure 4: MV enclosure
Figure 5: LV enclosure

EPM 1. General
1.5 Special applications
1.5.1 Dual starting
For starting machines of higher ratings, or to reduce the mechanical stress, it

maysometimes be preferable to use two motors totalling the rated power rather
than asingle unit.
A dual EPM starter is then used, in order to ensure identical acceleration of both
motors.
For this application the EPM starter comprises two resistances whose ohmic values
are equalised between the two tanks. The electrode drive assemblies are
mechanically coupled so as to ensure complete synchronisation of the two electrode
assemblies.
Finally, to ensure that the resistances are short-circuited simultaneously, a single
four or six pole contactor is used to eliminate the two resistances at the end of
starting.
Three control gear housings are fitted; the first one contains the electrical controls
(LV), the second the shorting contactor (MV) and the third enables connection of
cables of one of both motors.
A tunnel links the two housings for interlocking the shorting contactor and the control
circuits.
The cable entries for the two motors are at the base of each enclosure.
EPM 1 and 2 DUO are mounted on a single chassis. EPM 3 and 4 DUO are
delivered in sections for assembly at site.
MV tunnel Contactor
enclosure
Motor 1 and
Coupling Motor 2
Resistance 1 Resistance 2
Cable entry
Cable entry
Motor 2
Motor 1
Link between the two

Figure 6: Duo starter tanks

1.5.2 Slip resistance - speed variation
When permanent slip is required, it is necessary to increase the thermal dissipation

and calorific capacity of the EPM by adding a heat exchanger.
Normally a water-cooled exchanger is used for this purpose and an adequate supply
of water must be available for this purpose. The volume will vary depending on the
power and the temperature of the cooling water.
For certain speed control applications, the EPM is equipped as standard with a
servomotor and a suitably rated heat exchanger.
This type of equipment is generally supplied without a shorting contactor.
In this version of the EPM, the electrodes are in bronze.
Figure 7: EPM with exchanger for use in speed variation

EPM 2. Instructions for installation
2. INSTRUCTIONS FOR INSTALLATION
2.1 Overview 3
2.1.1 Preliminaries 3
2.1.2 Electrical installation 3
2.1.3 Electrical environment 3
2.1.4 Connections 3
2.2 SINGLE EPM 5

2.2.1 General advice 5
2.2.2 Dimensions and weights 5
2.2.3 Operating Environment 6
2.2.4 Spare Space 6
2.2.5 Warning 6
2.3 EPM DUO 7

2.3.1 General Recommendations 7
2.3.2 EPM 3 and EPM 4 DUO assemblies 7
2.3.2.1 Assembling the two tanks and the electrode coupling assembly 8
2.3.2.2 Fitting the electrical interconnections 9
2.3.3 Weights and dimensions 9
2.3.4 Environment 10
2.3.5 Spare Space 11
2.3.6 Warning 11
2.4 EPM WITH HEAT EXCHANGER 12

2.4.1 General recommendations 12
2.4.2 Weighs and dimensions 12
2.4.3 Connecting the cooling circuit of the heat exchanger 14
2.4.4 Environment 14
2.4.5 Spare Space 15
2.4.6 Warning 15

2.1 Overview
2.1.1 Preliminaries
Check as follows that:

• The details on the equipment rating plates suit that of the motor to which the EPM is
associated.
• The control voltage meets the operating voltage of the contactor coils (see rating plate).
2.1.2 Electrical installation
Installation and connection should be carried out with power off and should be
completed and checked bya suitably qualified personnel well acquainted with electrical
safety rules.
2.1.3 Electrical environment
The equipment is specially designed to operate in an electrical environment CAT III,

pollution 3.
2.1.4 Connections
• Open the EPM enclosures and read the connection diagrams delivered with the unit.
• Perform the control connections using the attached diagrams.
• Connect the starter to the motor rotor.
• Performance of the protection sheaths depends on the adaptation of the packing boxes
and their adaptation to the cables.
The user will have to drill and adapt the gland plate following all the safety
procedures and regulations.
• The unit should be earthed using the terminal provided for this purpose which is
marked with the earth symbol. This earth terminal is located on the MV enclosure.
Location of the earth terminal
M V contactor
M V bars
Earth term inal

For the cable size, refer to table 1 issued from the IEC Publication 60439-1.
Size of the phase Min. size of the corresponding

conductors protection conductor
S Sp
mm2 mm2
S ≤ 16 S
16 < S ≤ 35 16
35 < S ≤ 400 S/2
400 < S ≤ 800 200
S > 800 S/4
Table 1
For the EPM DUO, the two tanks should be star connected to the same earth.

2.2 SINGLE EPM
2.2.1 General advice
The EPM starter should be installed on a solid level surface.

When installed, the EPM must be level.
The foundation supporting the EPM must be designed to support the weight of the
starter.
2.2.2 Dimensions and weights
Table 2 below shows the dimensions and weights for each model of the EPM range,
together with the floor fixing details.
A B C E F G Weight Tank
Type mm mm mm mm mm mm without with capacity
electrolyte electrolyte
EPM 1 1 700 2 000 1 230 856 600 1 620 720 kg 1 720 kg 1 000 litres
EPM 2 2 120 2 000 1 360 950 600 2 060 850 kg 2 350 kg 1 500 litres
EPM 3 2 510 2 290 1 660 1 190 600 2 440 1 230 kg 4 230 kg 3 000 litres
EPM 4 2 950 2 500 1 860 1 410 800 2 850 1 550 kg 6 550 kg 5 000 litres
Table 2: Dimensions and weights for SINGLE EPM starters
Figure 1: Dimensions for starters EPM1, 2, 3 and 4 SOLO

Floor fixing holes Ø 22.
Positioning: lifting eyes Ø 48. )
The foundation should be even so that no mechanical stress will be applied to the
EPM starter when it is bolted to the floor.
) Note: The lifting eyes for the EPM 1 are mounted in the floor fixing holes.

2.2.3 Operating Environment
The equipment is supplied suitable for use in the specified operating conditions, level
of protection, ambient temperature and other detailed environments (see
specification data).
2.2.4 Spare Space
To ensure correct operation, it is necessary to provide a free area around the EPM.
This space is necessary for two reasons:
- access for maintenance,
- the necessity to provide a sufficiently large volume of air to allow good heat
dissipation.
A space of 600 mm is necessary around the EPM starter to provide access to the
tank (for cover removal) and to avoid a reduction in heat dissipation. A
minimum of1 000 mm clear above the equipment is necessary for the same
reason. It is worthnoting that the contactor enclosure must be removed when
inspecting or replacingthe electrodes.
If these distances are reduced, maintenance operations will become

considerably more difficult, (indeed impossible in certain cases, without
moving the starter) likewise, the thermal characteristics of the starters would
be derated.
2.2.5 Warning
Do not place anything on or around the EPM starter.

2.3 EPM DUO
2.3.1 General Recommendations
The EPM DUO should be installed on a solid level surface.

starter.
2.3.2 EPM 3 and EPM 4 DUO assemblies
The EPM 3 and EPM 4 DUO are delivered with the 2 tanks separated, the
mechanical coupling is supplied loose, as well as the electrical connections.
Assembly is required as follows:
- Connect the two tanks and their mechanical couplings.

- Mount the connecting tunnel for the two rotor circuits and make the electrical
connections.
Each starter assembly is marked by a letter, followed by numbers marked assembly

1 and 2.
Tunnel
Side E1 Side E2
R ef.E1 R ef.E2
Figure 2: DUO starter assembly - References E1 and E2

2.3.2.1 Assembling the two tanks and the electrode coupling assembly
The assembly plan supplied must be strictly adhered to in respect to the markings
shown in figures 2 and 3.
3
1
Figure 3: Mechanical coupling
- The tanks must be firmly fixed to their plinths which must be level (see general
installation recommendations).
The electrode control arms are preadjusted to be at the same level. Do

not use the handwheel until the cardans and the tanks have beenconnected
and the mechanical coupling completed.
- Position and bolt down tank E1.

- Align tank E2 with the electrolyte interconnecting pipes on tank E1.
- Fit the sealing ring between the pipes on tanks E1 and E2 so as to ensure a
watertight seal. Tighten the screws.
- Bolt down tank E2 ensuring that it is level.
- Mount the plate 1 .
- On the cardan 2 , fit the spring 3 .
- Fit the cardan with spring and cotter pin on the output shaft transmission of the tank
E1.
- Repeat as above for tank E2.
- Fit the protection cover over the mechanical coupling.

2.3.2.2 Fitting the electrical interconnections
- Always refer to the instructions, fit the tunnel to the underside of the enclosures.
- Proceed with the assembly of the 3 copper busbars which connect the resistance
to the shorting contactor.
- Connect the control circuit in accordance with the wire numbers shown on each
terminal.
- Connect the earth circuit on both starters.
2.3.3 Weights and dimensions
Tables 3 and 4 below indicate the weights and dimensions of each EPM DUO and
the floor fixings.
A B C G Weight Tank
Type mm mm mm mm without with capacity
EPM 1 DUO 2 760 2 000 1 650 2 140 1 500 kg 3 500 kg 2 000 litres
EPM 2 DUO 2 945 2 000 2 030 2 325 1 800 kg 4 800 kg 3 000 litres
Table 3: EPM 1 and 2 DUO - Weights and dimensions
Figure 4: EPM 1 and 2 DUO - Dimensions

A B C E F G Weight Tank
EPM 3 DUO 3 580 2 290 2 510 990 600 2 440 2 450 kg 8 450 kg 6 000 litres
EMP 4 DUO 4 020 2 500 2 950 1 015 800 2 850 2 850 kg 12 850 kg 10 000 litres
Table 4: EPM 3 and 4 DUO - Weights and dimensions
Figure 5: EPM 3 and 4 DUO - Dimensions
Floor fixing holes Ø 22mm.

Positioning: lifting eyes Ø 48mm.
2.3.4 Environment
The equipment is supplied suitable for use in the specified operating conditions, level
of protection, ambient temperature and other detailed environments (see
specification data).

2.3.5 Spare Space
To ensure correct operation, it is necessary to provide a free area around the EPM.
This space is necessary for two reasons:
- access for maintenance,
- the necessity to provide a sufficiently large volume of air to allow good heat
dissipation.
A space of 600 mm is necessary around the EPM starter to provide access to the
tank (for cover removal) and to avoid a reduction in dissipation. A minimum of
1 000 mm clear above the equipment is necessary for the same reason. It is worth
noting that the contactor enclosure must be removed when inspecting or replacing
the electrodes.
If these distances are reduced, maintenance operations will become

considerably more difficult, (indeed impossible in certain cases, without
moving the starter) likewise, the thermal characteristics of the starters would
be derated.
2.3.6 Warning
Do not place anything on or around the EPM starter.

2.4 EPM WITH HEAT EXCHANGER
2.4.1 General recommendations
The EPM starter should be installed on a solid level surface.
starter.
2.4.2 Weighs and dimensions
Tables 5 and 6 below show the weights and dimensions for each EPM and heat
exchanger together with the floor fixing details. Consult the data sheet for details on
the heat exchanger.
A B C D E F Weight Tank
max. electrolyte electrolyte
EPM 1 E 2 000 2 000 1 640 856 600 1 920 870 kg 1 870 kg 1 000 litres
EPM 2 E 2 410 2 000 1 735 950 600 2 350 1 000 kg 2 500 kg 1 500 litres
EPM 3 E 2 840 2 290 2 025 1 190 600 2 770 1 480 kg 4 480 kg 3 000 litres
EPM 4 E 3 270 2 500 2 245 1 410 800 3 180 1 800 kg 6 800 kg 5 000 litres
Table 5: Weights and dimensions for EPM with heat exchanger
Exchanger type 1 2 3 4 5 6 7 8 9 10
I 36 350 350 350 400 400 520 520 520 520
J 420 420 420 420 420 420 420 420 420 420
K 175 337 627 1128 1139 1851 462 661 862 1162
L 429 591 881 1382 1370 2083 835 1035 1235 1535
Ø 140 140 140 140 200 200 285 285 285 285

Tableau 6: Exchanger type
Figure 6: EPM 1, 2, 3, and 4 with exchanger - Dimensions
Floor fixing holes Ø 22mm.

Positioning: lifting eyes Ø 48mm.
The foundation should be even so that no mechanical stress will be applied to the
EPM starter when it is bolted to the floor.

EPM 3. Commissioning the EPM starter
3. COMMISSIONING THE EPM STARTER
3.1 Preparing for use 3

3.2 Operating anomalies 8
3.2.1 Overheating of the tank 8
3.2.2 Failure of the moving electrode mechanism (electrode drive motor) 9

3.1 Preparing for use
NOTE: The commissioning commences after the EPM has been installed (see
installation instructions). For the DUO, in particular, all the operations described are
carried out only when the assembly of the starter is complete.
1) Check that the details on the rating plate correspond with those on the motor for which
the starter is to be used.
2) Power connections
Connect the cables from the rotor of the motor to the terminals marked R1, R2 and
R3 on the shorting contactor.
Check tightness of the bolts on the copper connections.
3) Control connections
Consult the diagram supplied with the starter.

Check the control voltage.
Provide a three-phase supply for the agitator motor (or the pump) and the electrode
drive motor. The voltage is indicated on the diagrams supplied with the instrument.
Note: In case an antifrost device is present, it should be switched on even if
the EPM is switched off.
4) Earthing
The equipment should be earthed via the terminal provided for this purpose.

5) Before energising the electrode drive motor
The electrode drive motor may be, depending on the application, either a geared
motor, servomotor, or a motor whose speed is controlled by an inverter.
a) Set the handwheel in position.
b) Remove the wooden blocks which support the electrodes.
Handwheel
Figure 1
Blocks Moving electrode
carrier
Use the handwheel on the top of the electrode drive motor to bring the moving
electrode carrier to the intermediate position.
6) Energising the electrode drive motor:

Check the direction of rotation. The moving assembly should rise, if not, reverse two
of the motor supply cables.

7) Before filling the tank, carry out the following operations carefully:
Ensure that the drain tap is fully closed.
If the EPM is fitted with a heat exchanger:
- Check that the electrolyte circulation valves are open on the heat exchanger.
- Check the cooling water circulation in the heat exchanger.
8) Preparation of the electrolyte
IMPORTANT: These products should be handled with care (see below).
Precautions
Handling and storage
Use a well-ventilated room, away from reactive substances, such as acid, zinc,
quicklime, aluminium.
Protections
- Protect against inhalation (use a mask for protection from dust).
- Hands should be protected using gloves made of Neoprene or Rubber.
- Eyes should be protected by wearing goggles.
- Skin should be protected by wearing suitable clothes.
The user must follow the legislative, regulation and administrative procedures
related tosafety and protection concerning the human health and environment.
The electrolyte generally consists of solution of SODIUM CARBONATE (SC) or

SODIUM BORATE (SB) in distilled water (preferably demineralised).Do not use
recycled water.
Concentration of chlorine should be ≤ 2 %.
The chemical is supplied in powder form, contained in plastic sachets of 5 kg for SC,
and 2.5 kg for SB.
Consult the rating plate of the starter to determine the quantity of chemical to be
used: marked “INSTALLATION DOSE”.
Also supplied with the starter is an additional quantity of chemical labelled
“ADJUSTMENT DOSE”, which can be used in order to adjust the starting torque to
the optimum value (see 10).

9) Filling the tank and preparing the electrolyte
Operation 1: filling the tank half way
a) Untighten the fixing screws and remove the long cover. This operation
requires two operators to remove the long cover.
b) Close the emptying valve at the bottom of the tank.
c) Fill the tank to approximately half way up the isolating compartments. Use
distilled water above 20°C (the electrolyte dissolves better in warm solution).
d) Set the agitator in use.
Operation 2: preparing the electrolyte
e) Fill a plastic container (polyvinyl) with 15 litres of warm water (30°C to 40°C).
f) Pour the plastic sachet of 5 kg of SC electrolyte (or 2.5 kg of SB electrolyte) in

the tank and mix the solution. The electrolyte should not accumulate at the
bottom of the container.
g) Shake the content of the container to complete dissolution of the electrolyte.
h) Pour the electrolytic solution into the starter tank.
i) Repeat from e to h up to the electrolyte dose is empty. Do not use the

adjustment dose.
Operation 3: filling the tank
j) The electrolytic solution being poured in the tank, complete C orrectlevel
the level of the tank with distilled water (observe the level
attached to the tank). During this operation, set the agitator
in service to ensure that the electrolyte is dissolved
completely.
k) Add the anti-evaporation oil in the following quantities :

EPM 1: 8 litres.
EPM 2: 15 litres.
EPM 3: 20 litres.
EPM 4: 30 litres.

Tank capacities, reminder

EPM 1: 1 000 litres.
10) Start tests. Electrolyte fine adjustment
a) Replace the cover without the fixing screws.
b) Carry out a start test.
c) If the starting torque is too weak: add electrolytic solution using the electrolyte
ADJUSTMENT DOSE, operation 2 from item 9.
d) If the starting torque is too high: empty some of the electrolyte and top up to the
level mark with water.
When the correct adjustment is obtained, tighten the fixing screws of the cover.
NOTE: A low electrolyte temperature reduces the starting torque. Ahigh

electrolyte temperature increases the starting torque. The electrolyte
concentration has been computed for an average room temperature and this should
be taken into account during adjustments.

3.2 Operating anomalies
3.2.1 Overheating of the tank
a) Check the operation of the agitator (or pump) which should operate at 40°C as
specified in the technical brochure.
b) Check the thermostat setting and the overload relay for the agitator (or pump)
motor.
c) Check the impeller drive and, if necessary the tightness of the connection
between the motor shaft and the impeller rod. If the EPM is fitted with a heat
exchanger, check the motor/pump drive and the effective circulation of the cooling
water.
d) If the EPM is fitted with an antifrost heater, check the setting of the thermostat and
its operation. The operating point is at + 5°C.
e) Exceeding the starting duty: the starting frequency is shown on the rating plate.
f) Check that the starting time is the same as that shown on the rating plate.
g) Ensure that the shorting contactor is operating properly: check each pole of the
contactor.
h) Check the tightness of all connections on the busbars and cables to the rotor of
the motor.
NOTE: The electrolyte overheat thermostat is factory set at 85°C and must not be
altered.

3.2.2 Failure of the moving electrode descent mechanism (electrode drive motor)
a) Check the connections of the motor windings and the supply voltage.
b) Check the connections to the motor terminals and the overload relay.
c) Check the mechanical coupling between the electrode drive motor and the worm
drive of the moving electrodes.
d) Check:
- continuity of the control circuit,
- control circuit supply voltage is present,
- the coil supply voltage.
NOTE: The starting sequence of the motor is correct if the moving electrodes are in
the raised position when the starter is energised.

EPM 4. Maintenance
4. MAINTENANCE
4.1 Safety recommendations 3

4.2 Preventive maintenance 3
4.3 Replacement of components due to wear and tear 4
4.4 Changing the electrodes 8
4.4.1 Emptying the electrolyte from the tank 8
4.4.2 Intervening on the starter 9
4.4.2.1 Sequence of disassembly of the electrical components 9
4.4.2.2 Dismantling order for the mechanical components 10
4.4.2.3 Emptying and rinsing the tank and the 3 isolating tanks before disassembly 11
4.4.2.4 Disassembling the moving electrodes 11
4.4.2.5 Disassembling the fixed electrodes 12
4.4.2.6 Emptying and rinsing the tanks 12
4.4.2.7 EPM 1 starter 12
4.4.3 Fitting the new cast electrodes 12
4.4.4 Testing the starter interlocks 13
4.4.5 Filling the tank, electrolyte dissolution. 13
4.5 EPM DUO 14

EPM 4. Maintenance
4.1 Safety recommendations
All maintenance operations relating to the electrical systems (MV contactor housing, LV
enclosure or motors) or moving mechanical parts (electrode system) should be carried out
with the supply disconnected. Particularly, opening of the MV and LV enclosure doors
should only be carried out with the security interlocks in place and operational.
Switch off the supply to the starter.

Switch off the MV isolator.
Switch off the LV supply:
- Three phase supply.
- Control circuit supply.
- Signalling circuit.
In the presence of the person responsible for electrical services:
- Padlock the circuit breakers or isolators in the “Off” position.
- Set padlocks to ensure locking and isolation between the different circuits.
4.2 Preventive maintenance

a Ensure that the electrolyte level is within 2 cm of the level mark. If necessary, top up
with water with a chlorine level of ≤ 2 %.
b Grease the electrode drive worm screw.
c Check the tightness of all the connections: copper, cables and control circuits.
d Ensure that the short circuit contactor operates correctly. Check each pole of the
contactor: both fixed and moving contacts and the braids.
e Check the tightness of each mechanical part and the metalwork.

4.3 Replacement of components due to wear and tear
a Electrode drive motor :
- Disconnect the motor 22 .

- Undo the bolts A and B from the geared motor support plate 30 , servomotor,
motor.
- Lift off the assembly.
The electrode drive motor is greased for 100 000 operations.
22
60
30
61
60 Geared motor plate gland plate
C
61 Motor screw coupling
B C Top ball thrust bearing
D End ball thrust bearing

17 25
4 27
Figure 1: Motor

EPM 4. Maintenance
b Agitator (except EPM exchanger):
- Disconnect the motor 20 .

- Undo the fixing bolts A .
- Lift out the assembly.
- Uncouple the motor from the propeller support axis by untightening the screws.
20
A
Agitator
support 55
plate
Plate se
62
Motor/propeller axis
coupling
28
Guide
29
Figure 2: Agitator

c Pump/pump motor assembly (for EPM exchanger):
- Isolate with valves up and downstream.

- Disconnect the pipework.
- Disconnect the motor from the pump.
- Undo the fixing bolts.
- Lift off the pump motor assembly.
Break
valves Electrical
connection
Pump motor
assembly
Connection
rings Assembly
fixing devices
Figure 3: Pump motor assembly

EPM 4. Maintenance
d Level switch:
- Accessed inside the LV enclosure.

- Disconnect the switch.
- Undo the fixing screws.
Note: Magnetic float switch 220 V, 60 VA. Consult CSE Uniserve if a replacement
is required.
e Thermostats:
- Accessed inside the LV enclosure.

- Disconnect the thermostat.
- Undo the 4 fixing screws on the thermostat support plate.
f Moving electrode control screw (figures 1 and 4)
- Untighten the fixing screws from the worm drive cover 5 or unlock the bolts.
- Using the handwheel, bring the electrode control arm 17 to the low position.
- Block the assembly using 2 blocks.
- Remove the electrode drive motor 22 .
- Untighten the locking rings from the top and end ball thrust bearings C and D
(figure 1).
- Uncouple the worm drive nut 25 from the moving electrode control arm 17 .
- Lift the worm screw 27 vertically by turning to uncouple the worm drive nut.
- To remantle, operate as above in the reverse way.
Note: Do not alter adjustment of the "LIMIT SWITCHES".
A Handwheel 22 63 64 17
5
8
Figure 4

4.4 Changing the electrodes
Changing the electrode system is an important operation. It is necessary to shut down and
immobilise the starter for several days.
The procedure is as follows:
4.4.1 Emptying the electrolyte from the tank
Remember the different tank capacities:
EPM 1 1 000 litres Electrolytes employed:

EPM 2 1 500 litres Sodium carbonate Sodium borate
EPM 3 3 000 litres CO3 Na2 B4 O7 Na2 10 H2O
EPM 4 5 000 litres Concentration: Concentration:
0.5 to 5 %. 0.5 to 5 %.
EPM 1 DUO 2 000 litres Electrolytes employed:

EPM 2 DUO 3 000 litres Sodium carbonate Sodium borate
EPM 3 DUO 6 000 litres CO3 Na2 B4 O7 Na2 10 H2O
EPM 4 DUO 10 000 litres Concentration: Concentration:
0.5 to 5 %. 0.5 to 5 %.
IMPORTANT RECOMMENDATION FOR DUAL EPM STARTERS

Do not uncouple the moving electrode assembly for the 2 tanks.
The synchronisation of the 2 starters will be compromised.
Check all cable markings before dismantling:
- Mark the copper connections and terminals.
- Disconnect the tunnels linking both starters.
In the case where the electrolyte is not reused, it is necessary to neutralise it, either
in the tank or by sending it to a specialist. Emptying is carried out by opening the
valve at the base of the tank. It is necessary to use a pump to remove the electrolyte
from the 3 isolated tanks.

EPM 4. Maintenance
4.4.2 Intervening on the starter
Note: To disassemble the fixed and moving electrodes it is necessary to raise the electrical
enclosures by 300 mm. A wedge should be used between the bases of the enclosures and
the top of the tank to hold them in this position.
4.4.2.1 Sequence of disassembly of the electrical components
Warning: Mark each cable and wire before disconnecting them.
Medium voltage enclosure

- Remove cables coming from the motor rotor.
Low voltage enclosure

- Remove control circuit cables, three-phase circuit, signalling circuit, thermostats,
level detector, optional probe, geared motor, motor, servomotor.
- Remove thermostat sheath, level detector plate, optional probe.
- Untighten PE nuts A located inside the worm drive cover (figure 4), connection
between LV enclosure and mechanism cover.
Geared motor, motor, servomotor (see figure 1)

- Undo the fixing screws on the plate supporting the geared motor, motor or
servomotor.
- Remove the bolts.
- Remove the electrode motor.
Agitator (except EPM exchanger) (see figure 2)

- Disconnect the cables.
- Undo the fixing screws on the agitator mounting plate.
- Lift out the motor-agitator assembly.
Antifrost heater if fitted

- Disconnect the cables.
- Undo the fixing screws on the heater support.
- Remove the assembly:
EPM 1 and EPM 2: 1 immersion heater.
EPM 3 and EPM 4: 2 immersion heaters.

4.4.2.2 Dismantling order for the mechanical components
1 Remove covers 5 6 7 and 8 , (figure 4).
2 Dismantle mechanism cover: remove worm drive cover which is fixed either with
clips or screws.
We access the worm screw ensuring electrode moving. Dismantle the 4 electrode
cover plates made of PVC 63 and 64 by untightening the screws (figure 4).
3 MV and LV enclosures.
Remove the fixing devices from the enclosure inside the MV enclosure, access via
the doors or removable panels.
Remove the fixing devices from the isolating tubes 31 (figure 5).
Remove the connections supplying the current 65 (figure 5).
Lift the enclosure of 3 cm towards the front.
Lift the assembly of 300 mm and raise the electrode motor. Proceed to the
enclosure bottom and top blockings.
Remove the connection shrouds.
37
31
R1
R2
R3
65
Current supply
Enclosure fixing devices
Figure 5

EPM 4. Maintenance
4.4.2.3 Emptying and rinsing the tank and the 3 isolating tanks before disassembly
4.4.2.4 Disassembling the moving electrodes

(Figure 6)
Move the electrodes to low position and insert a block between each moving and
fixed electrode.
- In the worm drive cover, undo the 6 screws B located in the U iron neutral point
support.
- Untighten the 6 hexagonal rods 24 from the moving electrodes.
- Undo fixing of the moving electrode guide support 44 . Undo the 6 nuts.
- Remove the guide support 32 , electrodes in place. Undo the 3 screws located
inside the U iron.
- Remove the moving electrode guides. Remove the moving electrodes.
B 37 17
Sheath
Neutral
point
support
24
31
44
39
32
16
15
C
A 23 33 34 35
Figure 6: Electrode device

4.4.2.5 Disassembling the fixed electrodes
(Figure 6)
- Undo the 4 Nylon locking nuts A and the 4 nuts C from the bottom of each
isolating block 33 , 34 and 35 .
- Remove the EPM assembly.
4.4.2.6 Emptying and rinsing the tanks
4.4.2.7 EPM 1 starter
To replace the steel electrodes with cast electrodes, it is necessary to perform a

modification on the mechanism support, see diagram X/DF 60251-000 in appendix.
4.4.3 Fitting the new cast electrodes

(Figure 6)
a Fit connection bars 37 and fixed electrodes 15 to the support 31 using bolts and
Nylon locking nuts.
b Proceed to sheathing of fixed electrode connections 37 .
c On the EPM 3 and EPM 4, fit the extension connection shrouds 39 .
d Fit the fixed electrode assemblies in the blocks using nuts and locking nuts.
e Paste extension connection shrouds using silicone AS 310 LOCTITE, CSE Uniserve
partnumber: C 00029-000.
f Mount the hexagonal rods 24 on the moving electrodes.
g Fit the moving electrodes 16 .
h Fit the moving electrode guides 32 .
i Fit the moving electrode guide support cross bar 18 .
j Fit the guide support and the 2 cross bars.
k Mount the moving electrodes on the U iron neutral point support 17 .
l Using the handwheel, raise or lower the moving electrodes manually. Penetration of
the electrodes should be of 40 mm approximately.

EPM 4. Maintenance
m Check tightening from d to k.
n Fit the enclosure.
o Fit the covers.
p Fit the 3 connection shrouds 31 .
q Connect current supply entries 65 , figure 5.
r Connect cables coming from the rotor-motor.
s Assemble the thermostat sheath, the level detector plate and the optional probe.
t Connect the control circuit cable, three-phase circuit, signalling circuit, thermostat,
level detector, optional probe and geared motor or motor or servomotor.
u Tighten the nuts of the geared motor, motor or servomotor plate.
v Tighten the PE nuts inside the mechanism cover, link between LV enclosure and
mechanism cover.
w Mount the agitator connection (except exchanger).
x Mount heater connection (if this option is present).
4.4.4 Testing the starter interlocks
a Movement of the electrodes: with the help of the handwheel situated on the top of
the geared motor bring the moving electrode carrier to the intermediate position.
When the supply is energised, the moving assembly should return to the up
position, if not reverse two phases.
b Mounting of the 4 PVC plates on the mechanism top.
c Mounting of the cover of the mechanism top.
d Agitator or motor-pump group: Direction of rotation. RPM.
e Security controls: thermostats, level detectors, top and bottom limit switches.
4.4.5 Filling the tank, electrolyte dissolution.
4.5 EPM DUO
Maintenance explained above also applies to EPM DUO with the differences following:
- Never uncouple the electrode mechanical drive system.

- Dismantle tunnel(s) by unwiring the terminals and uncouple the 3 power connections.

Lrs Resistencia Liquid Starter

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LIQUID RESISTANCE STARTER

Installation & Operation Manual

2. INSTRUCTIONS FOR INSTALLATION

3. COMMISSIONING THE EPM STARTER

Specifications indicated in the present Installation & Operation

1.1 General Information - Introduction 3

1.5 Special applications 11

3 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

1.1 General Information - Introduction

The starter comprises:

Figure 1: EPM general presentation

4 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

Power: 500 to 20 000 kW according to model:

• Maximum rotor voltage between sliprings: 3 500 V.

Rated impulse withstand voltage

5 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

1.3 Safety provisions

1.3.1 Conforming to safety standards

The unit the followingstandards:

1.3.2 Following the instructions supplied with the accompanying documents

The unit is only to be operated as per the instructions supplied.

List of the accompanying documents:

1.3.3 Explanation of the rating plate

1.3.4 Description of the rating plate

AO IP's order Starting M otorrated Statorrated EPM N °

Electrode m otor M otoragitator

6 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

1.4.1 Electrolytic resistance

Manufactured from stainless steel and supplied with lifting eyes.

The temperature of the electrolyte is controlled by two or three thermostats:

7 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

The electrodes, cast in GS or bronze consist of concentric cylinders which merge

The moving electrodes travel vertically inside an isolated compartment guided by a

Figure 2: Electrolytic resistance (electrodes)

8 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

Displacement of the moving electrode assembly is controlled by a motor driven

Figure 3: Electrode control system

9 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

The electrolyte generally comprises a solution of sodium carbonate or sodium

For preparation of the electrolyte, refer to the installation manual.

10 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

Dimensions of the MV enclosure depends on the shorting contactor rating.

11 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

1.5 Special applications

1.5.1 Dual starting

For starting machines of higher ratings, or to reduce the mechanical stress, it

Link between the two

12 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

When permanent slip is required, it is necessary to increase the thermal dissipation

This type of equipment is generally supplied without a shorting contactor.

In this version of the EPM, the electrodes are in bronze.

Figure 7: EPM with exchanger for use in speed variation

13 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

2. INSTRUCTIONS FOR INSTALLATION

2.2 SINGLE EPM 5

2.3 EPM DUO 7

2.4 EPM WITH HEAT EXCHANGER 12

14 Phone: 1800 987 616 Email: service@cse-uniserve.com.au Web: www.cse-uniserve.com.au

Check as follows that:

2.1.2 Electrical installation

The equipment is specially designed to operate in an electrical environment CAT III,

Location of the earth terminal

Earth term inal

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