GE Energy Connections
Evolution Series
*
E9000
Motor Control Centers
User Manual
DEH-40472 Rev. 08
Evolution Series E9000 User Manual
Contents
Warnings, Cautions & Notes ............................................................2
1. Introduction ...................................................................3
General Description – Vertical Section Enclosures ....................................... 3
General Description – Arc Resistant .....................................................4
General Description – Motor Control Center Buses ......................................4
General Description – Motor Control Center Units .......................................4
Bus Splicing .............................................................................5
Bus Splice Kits ..........................................................................5
2. Receiving, Handling & Storage ..................................................6
Receiving ............................................................................... 6
Handling ................................................................................6
Storage .................................................................................6
3. Installation ....................................................................7
Indoor Enclosures .......................................................................7
Installation of Bottom Entry Conduits ...................................................9
Installation of Flooring ................................................................. 10
Positioning and Joining Sections ....................................................... 11
NEC Work Space ....................................................................... 11
Installation of Top Entry Conduits ...................................................... 12
Exhaust Fan Installation ................................................................ 13
Main Incoming Power Cables ........................................................... 13
Individual Unit Wiring .................................................................. 14
Wiring NEMA Type A Motor Control Centers ............................................ 14
Wiring NEMA Type B Motor Control Centers ............................................ 15
Wiring NEMA Type C Motor Control Centers ............................................ 15
Wiring Between Sections .............................................................. 16
Terminal Blocks ........................................................................ 16
Installation of Standard Motor Control Center Units .................................... 16
Removal of Draw-out Motor Control Center Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operating Handles, Door Interlocks and Padlocking Provisions .......................... 18
Operating Handle ...................................................................... 19
Pilot Bracket and Door ................................................................. 20
NEMA 3R Outdoor Enclosure Installation ............................................... 20
4. Operation ................................................................... 22
Preparing for Initial Operation .......................................................... 22
Initial Operation of the Motor Control Center ........................................... 22
Door Closing Procedure ................................................................ 23
5. Maintenance ................................................................. 25
Equipment Maintenance ............................................................... 25
Inlet Filter Maintenance ................................................................ 25
Arc Resistant Maintenance ............................................................. 25
Control Power ......................................................................... 25
Control Power Fusing .................................................................. 25
Suggested Maintenance Tools .......................................................... 26
Replacing or Adding Breaker Accessories to Plug-in E or F Frame Circuit Breaker ........ 26
Replacing a Control Power Transformer Mounted Under Disconnect .................... 26
Replace a Compact Starter (1/2 X) ...................................................... 27
Suggested Lifts ........................................................................ 27
Publications Available from GE ......................................................... 27
Renewal Parts ......................................................................... 28
Ordering Additional or Replacement Parts .............................................. 28
Other Information ..................................................................... 28
6. Overload Heaters ............................................................ 29
Heaters for Ther-Mag Circuit Breaker Controllers ....................................... 29
Heaters for Mag-Break Controllers ..................................................... 30
Heaters for Fused Controllers .......................................................... 35
Heaters for NEMA Size 6 and 7 Fused Controllers ....................................... 38
Electr
1
onic Overload for Circuit Breaker and Fused Controllers ........................... 38
DEH–40472
Warnings, Cautions & Notes
As Used In This Publication
WARNINGS
Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions
that could cause personal injury are present in this equipment or may be associated with its use.
Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause
either personal injury or damage to equipment.
CAUTIONS
Caution notices are used for situations in
which equipment might be damaged if care
is not taken.
NOTES
Notes call attention to information that is
especially signicant to understanding and
operating the equipment.
This document is based on information available at the time of its publication. While eorts have been made to ensure accuracy, the information contained herein
does not cover all details or variations in hardware and software, nor does it provide for every possible contingency in connection with installation, operation, and
maintenance. Features may be described herein that are not present in all hardware and software systems. GE Energy Connections assumes no obligation of notice
to holders of this document with respect to changes subsequently made.
GE Energy Connections makes no representation or warranty, expressed, implied, or statutory, with respect to, and assumes no responsibility for the accuracy,
completeness, suciency, or usefulness of the information contained herein. No warrantees of merchantability or tness for purpose shall apply.
© Copyright 2017 General Electric Company
All Rights Reserved
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Evolution Series E9000 User Manual
Chapter 1 – Introduction
This publication provides guidelines for installation and
maintenance of Evolution Motor Control Centers, as
shown in Figure 1. The information provided does not
cover all details or variations in this product oering,
nor does it address all possible contingencies to be
met in connection with installation, operation, or
maintenance. Should further information be desired,
contact GE Field Service Administration:
Call GE–RESOLve
1-888-437-3765
Refer to the GE requisition number found on the front
of the equipment when calling for assistance.
Disconnect equipment from all electrical
services before performing any installation
or maintenance work.
For additional information, including safety considerations
for personnel working on this product, see NEMA Standard
Publication No. ICS 2.3, Instructions on the Handling,
Installation, Operation, and Maintenance of Motor
Control Centers.
General Description –
Vertical Section Enclosures
Each Evolution MCC vertical section is assembled with
two full-side sheets having openings near the top and
bottom for lateral busing and wiring between sections.
Multiple sections are joined together at the factory in
three-section (maximum) shipping splits. Each shipping
split is provided with continuous oor sills and a lifting
angle. Floor sills and lifting angles are eld removable.
Each shipping split includes a continuous non-removable
main horizontal bus. Main bus splice bars are provided
within each shipping split for eld connecting main
busses. Refer to motor control center outline drawings
furnished by the General Electric Company for location
of shipping splits within each motor control center
lineup. Hinged doors are provided over horizontal and
vertical wireways. (These doors can be removed by
extracting the hinge pins inside the doors.)
Vertical sections are normally provided with a top (12"
high) horizontal wireway and a bottom (6” high) horizontal
wireway. Each Arc Resistant vertical section is provided
with a vertical (3.85" wide) wireway.
Figure 1. Evolution Series three-section lineup
To open unit doors, rotate the latches 90'
counter-clockwise until the screwdriver slots
or knobs are vertical.
To open wireway doors, rotate the latches 90'
clockwise until the screwdriver slots or knobs
are vertical.
Secure Open
Unit Door Latch shown
in secure position
Because of the great variety of motor controller
assemblies and components provided within industrial
motor control centers and to satisfy oor-space limitations
at installation sites, a large variety of vertical section
dimensions are provided, as follows:
1
• Section Height: 90", 78"
, 66"1 etc.
• Section Width: 20", 24", 30" etc.
1
• Section Depth: 13"
, 20", 22" or deeper
for large assemblies.
1
Not available in Arc Resistant
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Evolution Series E9000 User Manual
General Description –
Arc Resistant
The Arc Resistant sections are built with increased
structural capacity. The main enhancements are thicker
gage of steel, latches, hinges, and metallic PD brackets.
In addition, there are two versions available with and
without a plenum. The plenum option adds 12" to the
top of the 90" section. The plenumless option should
have a 4' clearance on top of the MCC. The top (12"
high) horizontal wireway door and the bottom (6" high)
wireway door utilize multi-turn latches to secure the
doors. The remaining latches are ¼ turn (with options
for closed status indication). There is no variation in the
units between Arc Resistant and standard E9000 other
than the unit door. Additionally, the Arc Flash Mitigation
units are compatible in Arc Resistant design with
Arc Resistant/Arc Flash Mitigation door.
Figure 2. Horizontal bus with Lexan barrier
General Description –
Motor Control Center Buses
The main horizontal power bus is located at the top of
the vertical section. The bus bolted joints are accessible
from the front by loosening the barrier mounting screws
®
and sliding the Lexan
the main bus. Figure 2 shows a horizontal power bus
with its Lexan barrier. For Arc Resistant design, uses
this same Lexan barrier with additional Metallic dead
front barrier.
The vertical bus, either 300A or 600/850 A, is connected
with two bolts per phase to the main bus. The phase
relationship is A–B–C from top to bottom and left to
right, as viewed from the front.
A continuous horizontal ground bus, sized in accordance
with the National Electrical Code, is provided near the
bottom of all motor control centers.
An optional vertical ground bus can be provided in each
section providing additional grounding. A neutral bus is
provided, when specied, in the bottom of the incoming
section or in the bottom of all enclosure(s) as specied.
bus barrier up and forward from
Figure 3. Metallic horizontal bus barrier for Arc Resistant design
General Description –
Motor Control Center Units
Consult Publication DET-291 for detailed listings of
Evolution MCC units.
Plug-in units are supplied with stabs rated at either
250 A or 600 A. Arc Flash Mitigation (AFM) units are
supplied with retractable stabs, mechanical interlocks,
racking screw, and visual stab and shutter indicators. AFM
units are available in plug-in or stab-bolt conguration.
Installation and operation of units, both standard and
AFM, are described on page 14 of this guide.
As shown in Figure 3, the Arc Resistant MCC will include
a metallic main bus barrier in addition to the standard
Lexan barrier.
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Evolution Series E9000 User Manual
Bus Splicing
Main, neutral and ground bus splice bars (with all
associatedhardware) are furnished, as necessary, to
join sections together. They are located in the rst
section tothe right of the joint. See Figures 13, 14 and
15 for approximatedimensions for main, neutral, and
ground bus.
Remove the top Lexan barrier, as shown in Figure 11 and
Figure 12, to access the main bus. Refer to instruction
drawings in splice kit. See Table 2.
Arc Resistant design has metallic barrier in addition to
the Lexan barrier which also must be removed to
access the main bus. Arc Resistant shipping splits will
arrive with end caps. When bus splicing, please remove
these end caps to make connection, only the furthest
most left and right end caps shall remain.
Figure 11. Horizontal bus with Lexan barrier
Table 1. Torque values for various bolt sizes and joint types
Bolt Size
5/16-18 5–9 7–12 6.5–9 9–12
3/8-16 12–16 16–22 10–15 14–20
1/2-13 30–39 41–53 25–35 34–47
5/8-11 65–80 88–108 35–45 47–61
3/4-10 125–150 169–203 50–75 68–102
Note: When assembling or connecting to aluminum bus, apply a suitable joint
compound between the contacting surfaces.
Copper Joints Aluminum Joints
lb-ft N-m lb-ft N-m
Bus Splice Kits
Table 2. Bus Splice Kits
Splicing From / To E9000/E9000
Size
Main Bus Splice
Amps
Standard Splicing
1200 110C1735G7SM 1 1/2 x 2 100K 110C1253TG1
1600/
2000
2500 110C1735G13SM 2 1/2 x 2 100K 110C1785TG1
N3R and Spacer Shells
1200 110C1735G16SM 1 1/2 x 2 100K 110C1253TG1
1600/
2000
2500 110C1735G13SM 2 1/2 x 2 100K 110C1263TG1
*Included in kits
Note: Standard plating is tin. Refer to factory for alternate plating.
Assembly Kit
600 110C1735G1SM 1 1/4 x 2 65K 110C1258TG1
800 110C1735G4SM 1 3/8 x 2 65K 110C1256TG1
110C1735G12SM 2 1/2 x 2 100K 110C1263TG1
600 110C1735G14SM 1 1/4 x 2 65K 110C1258TG1
800 110C1735G15SM 1 3/8 x 2 65K 110C1256TG1
110C1735G17SM 2 1/2 x 2 100K 110C1263TG1
Bars/
Phase
Copper
(thick x
width)
(in.)
SC Rating
600V Max.
(sym.
amps)
Splice
Instruction
Drawing*
Loosen screw, lift and
pull barrier forward
Figure 12. Horizontal bus barrier mounting slot and screw
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Evolution Series E9000 User Manual
Chapter 2 – Receiving, Handling & Storage
Receiving
Before leaving the factory, the motor control center is
given a nal mechanical and electrical inspection and
is packed in accordance with the best practices for
electrical equipment.
On receipt of any apparatus, make an immediate
inspection for any damage or loss of equipment in
transit. Should damage or missing material be noted,
le a claim immediately with the carrier and notify
the nearest oce of the General Electric Company.
Information such as a description of the damage, the
shipping crate numbers, the requisition numbers and
the panel catalog number should accompany the claim.
Handling
Motor control center sections are always shipped in an
upright position, in single or group sections. Sections
must be maintained in an upright position during all
handling.
Figure 5. Positioning the MCC with rollers
Storage
If it is necessary to store the equipment for any length
of time, be sure to observe the following precautions:
• Uncrate the equipment.
• Store the equipment in a clean, dry, humidity-controlled
area at moderate temperature. Cover with a suitable
canvas or heavy-duty plastic cover to prevent entrance
of foreign material.
Never attempt to jack, lift, or move the equipment at
points other than the lifting angle or oor sills. Use two
or more chains or cables to distribute the weight evenly.
Pinch bars, pipe rollers or slings are useful implements
for handling equipment; but be careful to maintain
distributed loading and to always apply leverage at the
oor sills and/or lifting eyes. Figures 4 and 5 illustrate
typical handling techniques.
Figure 4. Using standard lifting angles
or lifting eyes to hoist the MCC
• If equipment must be stored in cool or high humidity
areas, in addition to completely covering the equipment,
provide a heat source to prevent condensation of
moisture in the equipment. Energize space heaters (if
furnished in the equipment) or place a standard 120volt lamp rated at 75 watts inside the bottom of each
vertical section.
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Evolution Series E9000 User Manual
Chapter 3 – Installation
Before any installation work is begun, consult all
drawings furnished by the GE as well as all applicable
contract drawings for the particular installation.
Pay particular attention to the location of units in the
motor control center and their relations to existing or
planned conduits and busways.
Indoor Enclosures
Front Elevation and Mounting Locations
(13", 20", 22" & 25" Deep Sections)
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Evolution Series E9000 User Manual
Indoor Enclosures
Elevation and Mounting
30" Deep Sections 600A to 1200A Main Bus
Top Conduit Entry 30" Deep Section
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Evolution Series E9000 User Manual
Installation of Bottom Entry Conduits
Conduits can be stubbed in after the location of the
motor control center lineup has been established. Conduit
should be stubbed approximately 2 inches (51mm)
above the nished oor line. Figure 6 and Figure 7 show
the conduit entrance space available at the bottom of
standard sections. Exceptions to this available space rule
are indicated on drawings furnished by GE for specic
installations. Center the conduit beneath the section
vertical wireway to facilitate direct cable entry. Note:
Bottom rear entrance should only be used with full
rear accessibility.
Figure 6C (Arc Resistant). Bottom conduit entrance for standard
20-inch deep section, low bus position, 6-inch bottom cover
Figure 6A. Bottom conduit entrance details for standard 13-inch
deep section, low bus position
Figure 6B. Bottom conduit entrance details for standard 13-inch
deep section, bus upper position
Figure 6D (Arc Resistant). Bottom conduit entrance details for
standard 20-inch deep section, bus upper position
Figure 7A. Low bus position of ground and neutral bus (minimum
available space for conduit entry) in 13-inch deep section, 6-inch cover
9
Figure 7B. Standard position of ground and neutral bus with 12-inch
cover compartment at the bottom of MCC
Evolution Series E9000 User Manual
Figure 7C. Low bus position of ground and neutral bus (minimum
available space for conduit entry) in 13-inch deep section, 6-inch cover
Surface under motor control center base must
be of non-combustible material unless bottom
covers are installed in each vertical section.
The overall height of the equipment should be considered
with respect to headroom, top conduit entry space and
alignment with other equipment.
Note:
• If anchor bolts are to be imbedded in the foundation,
they must be located according to the drawing furnished
by GE for the specic equipment. Locate one in the
center front and one in the center back. Anchor bolts
should be 1/2" in diameter, of Grade 2 steel (minimum)
in non-seismic locations. Bolts must extend a minimum
of 2 11/32" above grade to 3/4" above the channel
sill. If 13" (330.2mm) deep sections are used, anchor
bolts or some form of external bracing is required.
• Seismic Zone 4/IBC testing was performed using 1/2" –
13 Grade 5 bolts, torqued to 70 foot-pounds, located in
each of the four corners in each section.
Figure 7D. Upper position of ground and neutral bus (maximum
space available for conduit entry), 6-inch bottom cover
Installation of Flooring
For most installations, the MCC oor sills can rest on the
nished oor. The foundation for the equipment should
be level and even. Although not normally required, the
purchaser may elect to install, level and grout the steel
members or MCC oor sills in the oor, as illustrated in
Figure 8 and Figure 9. If the oor sills are removed, lifting
and moving the shipping sections must be done carefully.
If there are vertical sections of varying depths
(such as 13, 20, or 22 inches) in a single lineup,
the fronts of the sections must be lined up for
proper alignment of the main bus bars.
Figure 9 illustrates this point..
Figure 9. Installing steel oor members
Note the front alignment of the 13-inch-deep section
Figure 8. Control center oor sills grouted to the oor before
installation to provide a level foundation
Note: Cannot be rolled (as in Figure 5) without oor sills
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Evolution Series E9000 User Manual
Positioning and Joining Sections
If groups of sections are to be joined together in a nal
lineup, remove the end cover plates and the plug buttons,
from the sides of the sections to be joined. Figure 10
shows the side views, with the end cover plates removed,
for 20-inch-deep sections with 2-inch (50.8 mm) and
4-inch (101.6 mm) bus bars.
Carefully check and remove dirt, dust or bits of packing
material from the interior of all sections. Use a brush,
soft cloth or vacuum cleaner.
Do not use compressed air to clean the equipment
if it contains moisture. Remove all hardware
packages, drawings and other items shipped with
the equipment. Check all nuts, bolts, and electrical
joints for tightness.
All cables entering the bottoms of sections should be
pulled through conduits to a point where they will be
accessible after the equipment is in place. Sections can
be moved to their nal position and properly leveled.
For Arc Resistant plenum-less design, the cables can
enter either through the front or rear aluminum ap on
top of the section.
For Type 12 and Arc Resistant enclosure, see Figure
10A for proper gasket in between the section splits. For
additional gasket material order part number 245A1888P5.
Gaskets
Figure 10A. Type 12 and Arc Resistant
gasket material between section splits
NEC Work Space
NEC Work Space is dened in Table 110.26(a) Working
Spaces. Included in these clearance requirements is the
step-back distance from the face of the equipment.
Table 110.26(a) provides requirements for clearances
away from the equipment, based on the circuit voltage
to ground, and whether there are grounded or ungrounded objects in the step-back space, or if there are exposed
live parts across from each other. The voltages to ground
consist of two groups: 0 to 150 and 151 to 600, inclusive.
Remember, where an ungrounded system is utilized, the
voltage to ground will be the greatest voltage between
the given conductor and any other conductor of the
circuit. For example, the voltage to ground for a 480-volt
ungrounded delta system is 480 volts.
Figure 10. Side view of a 20-inch-deep section showing the cover
plates, plug bottoms and joining points
11
See Figure 14 for general working clearance requirements.
Distances are measured from the live parts if the live
parts are exposed, or from the enclosure front if live
parts are enclosed. If any assemblies, such as switchboards or motor control centers, are accessible from the
back and expose live parts, the working clearance
dimensions would be required at the rear of the equipment,
as illustrated. Note that for Condition 3, where there is
an enclosure on opposite sides of the working space,
the clearance for only one working space is required.
Evolution Series E9000 User Manual
plenum the conduit can be assembled on top of the
plenum. GE oers an additional pull box for higher conduit
space requirement. The Pull box can be assembled on
top of the incoming section.
Always remove top cover plates when drilling holes.
This prevents small metal chips from falling into the
panel and cause serious damage.
Figure 14. General Working Clearance Requirements
Installation of Top Entry Conduits
After the motor control center is in place and leveled, and
the sections are joined together, conduits can be brought
into the tops of sections as required. Figure 15 and
Figure 16 show the conduit entry space available at the
tops of standard sections. Refer to drawings furnished by
GE for deviations on specic installations. Note: Top rear
entrance should only be used with full rear accessibility.
Figure 15A. Top conduit entry space for 13-inch sections
Figure 15B. Top conduit entry space for 20-inch and 22-inch sections
Table 3. Dimensions for Figures 15 and 16
Width Dimension A Dimension B
20" 20" 17.56"
24" 24" 21.56"
30" 30" 27.56"
Equipment Wiring
For plenum-less Arc Resistant design, the conduits can
be brought into the tops of the sections through front
or rear aps as required. For Arc Resistant sections with
When pulling, bending, and terminating eld wiring,
avoid scraping, cutting or otherwise damaging
cable insulation or strands.
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Evolution Series E9000 User Manual
Exhaust Fan Installation for NEMA 1 Enclosure
Fan Assembly
Top Rear Cover Location
Figure 16A. Exhaust fan for NEMA 1 enclosure
High heat loss main bus splice joints and/or components,
including certain solid state power devices, may require
removal of excess heat to the MCC exterior environment.
This is accomplished by the utilization of exhaust fans.
Exhaust Fan Installation for UL Type 12 Enclosure
and Arc Resistant Vented Fan Shields
UL Type 12 Fan Assembly
Filter Assembly
Figure 16B. Exhaust fan for UL Type 12 enclosure
Arc Resistant
VFD Fan Shield
Exhaust fans, if required, are delivered to the installation
site as a separate shipping item. Fans must be unpacked,
checked for collateral damage, and installed over the top
rear conduit entry space of the appropriate MCC section.
Installation involves connecting two mated control power
harness ends for each fan assembly. One harness is
located within the fan assembly. The corresponding
mated harness end is coiled and secured inside the top
rear of the section being ventilated.
If, upon delivery, it is found that standard rear top section
covers are in place on the section requiring ventilation,
the covers must be removed and discarded. The exhaust
fan assembly can then be installed as shown in Figure 15A.
Note: For details on inlet lter maintenance, see Filter
Maintenance in Chapter 5.
High heat loss components, including certain solid state
power devices, may require removal of excess heat to the
MCC exterior environment. This is accomplished by the
utilization of exhaust fans mounted on unit doors along
with lters. These fans and lters are factory installed.
Note: In addition to using Type 12 exhaust fans and
lters, Arc Resistant design will also have a vented fan
shield on the exterior of the door. For details on inlet
lter maintenance, see Filter Maintenance in Chapter 5.
Main Incoming Power Cables
Refer to the motor control center drawings provided by GE
for the location of the main disconnect or incoming line
terminals and the direction (top or bottom) of cable entry.
Cable-bending room provided within the vertical section
will meet or exceed National Electrical Code requirements.
Incoming line sections are provided with cable supports.
Incoming cables must be rmly secured to withstand
the signicant forces that may be generated during a
short circuit .
13
Cables secured at each support, as illustrated in Figure
17 and Figure 18 (600A example), will adequately brace
cables for faults of 100K RMS symmetrical amperes,
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