Rockwell Automation 1512A MV User Manual

User Manual

Medium Voltage Controllers, 400A One-High Cabinet, Standard and Arc-Resistant Enclosure

Publication 1512A-UM100F-EN-P

Important User Information

IMPORTANT

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/ important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

available from

) describes some

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Identifies information that is critical for successful application and understanding of the product.

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table contains the changes made to this revision.

Top ic Pag e

Converted the document to FrameMaker Throughout

Inserted Arc Flash warning ii

Added Isolation Blade Switch Adjustment section 54

Updated Isolation Switch Blade Assembly 65

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 iii

Summary of Changes

Notes:

iv Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

General Information

Installation – Standard Enclosure

Chapter 1

Document Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Chapter 2

Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Front Access – Top Incoming Line Cables . . . . . . . . . . . . . . . . . . . . . . . 8

Front Access – Bottom Incoming Cables . . . . . . . . . . . . . . . . . . . . . . . 10

Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation – Arc-Resistant (ArcShield)

Common Installation

Chapter 3

Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Opening the Medium Voltage Door . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Front Access – Bottom Incoming Cables (Bottom Entry/Exit). . . 22

Front Access – Top Incoming Cables (Top Entry/Exit) . . . . . . . . . 24

Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chapter 4

Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Insulated Power Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Ground Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Incoming Line Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installation of Current Transformer Barrier . . . . . . . . . . . . . . . . . . . . . . . . 33

Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Contactor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Testing Contactor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 1

Table of Contents

Chapter 5

Maintenance

Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Door Interlock Circumvention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Power Lock-out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Fuse Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

BOLT-ON FUSE Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . 46

CLIP-ON FUSE Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . 46

Contactor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Removing the Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Contactor Interlock Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

To Reduce the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

To Increase the Gap Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Isolation Switch Mechanism Inspection and Lubrication . . . . . . . . . . . . 52

Isolation Blade Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Isolation Switch Mechanism Grounding Adjustment. . . . . . . . . . . . . . . . 57

Auxiliary Contacts Inspection and Replacement . . . . . . . . . . . . . . . . . . . . 58

Auxiliary Contacts Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Adjusting the Normally Open (ISa) Contacts . . . . . . . . . . . . . . . . . . . 59

Adjusting the Normally Closed (ISb) Contacts. . . . . . . . . . . . . . . . . . 60

Adjusting the Change-of-State Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Emergency Circumvention Procedure for Power Cell Entry. . . . . . . . . . 61

Installing Z-clip with Isolation Switch Handle in the

OFF Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Installing Z-clip with Isolation Switch Handle in the

ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Spare Parts

ArcShield Unit Information

ArcShield Plenum Installation Instructions

Chapter 6

Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Appendix A

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

ArcShield Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . . 68

Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Chimney Exhaust Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Appendix B

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

General Plenum Layout for ArcShield Line-up. . . . . . . . . . . . . . . . . . . . . . 74

STEP 1 – Mounting a Single Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

2 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Table of Contents

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Plenum Placement on Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

STEP 2 – Alignment of “Side-by-Side” Plenums . . . . . . . . . . . . . . . . . . . . 77

STEP 3 – Sequence of Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

STEP 4 – Closing the Front of the Plenum Sections . . . . . . . . . . . . . . . . 79

STEP 5 – Extension and Elbow Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 79

STEP 6 – Mounting Extension/Elbow to Plenum “Line-up”. . . . . . . . . 80

STEP 7 – Additional Mounting Support. . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Appendix C

ArcShield Chimney Installation Instructions

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 84

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Chimney Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 3

Table of Contents

Notes:

4 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

General Information

IMPORTANT

Chapter 1

Document Scope

This User Manual pertains to the Rockwell Automation Bulletin 1512A medium voltage controller. The Bulletin 1512A structure provides one complete MV controller unit.

The installation section provides instructions for both the standard enclosure type and the Rockwell Automation arc resistant type (ArcShield).

The product Bulletin numbers covered by this document are:

• 1512A 200/400 A FVNR controller

• 1512AT 200/400 A Transformer Feeder

• 1512AP 200/400 A Prepared Space

This document is to be used for all Bulletin 1512A unit types, including arc resistant (ArcShield™) units. Important information specifically for ArcShield units can be found in Appendix A

ATT EN TI ON : Users must refer to the information in Appendix A, Appendix B and Appendix C Failure to do so may negate the arc resistant benefits provided by ArcShield, exposing personnel to risk of serious injury or death.

to correctly install and maintain ArcShield arc resistant units.

, Appendix B and Appendix C.

Starter Identification

This document may also be used as a reference guide for the following Bulletin numbers:

• 1512DM 200/400 A VFD Input Contactor Units

• 1512DO 200/400 A VFD Output Contactor Units

• 1512M 200/400 A VFD Output Bypass Starter

• 1562E 200/400 A MV SMC Flex Solid-State

(up to 4800 V) Reduced Voltage Starter

• 1591B Incoming Line Unit

• 1592BF Fused Load Break Switch for Feeders

• 1592BP Fused Load Break Switch for Feeders, prepared space

A nameplate is attached to the right-side flange of the structure (see Figure 1). Refer to the nameplate for information such as series number, section number, NEMA enclosure type, unit ratings, and bus ratings.

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 1

Chapter 1 General Information

Figure 1 - Typical Structure Nameplate

A nameplate is also found in the low voltage compartment (see Figure 2) with specific unit motor application information.

Figure 2 - Typical Unit Nameplate

Refer to these nameplates whenever you contact Rockwell Automation for assistance. Be prepared to provide such information as series number, structure series, unit series, diagram schematic and catalog number.

Recommended Torque Values

2 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

When reinstalling components, or when reassembling the cabinet, tighten the following bolt sizes to the specified torque values:

Table 1 - Torque Values for Hardware

1/4 in. hardware 8 N•m (6 lb•ft)

5/16 in . hardware 15 N•m ( 12 lb•ft)

3/8 in. hardware 27 N•m (20 lb•ft)

1/2 in. hardware 65 N•m (48 lb•ft)

Installation – Standard Enclosure

IMPORTANT

Low Voltage Door

Medium Voltage Door

For information on the installation site preparation, see Publication

MV-QS050_-EN-P

ATT EN TI ON : Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death.

Chapter 2

Door Opening Procedure

Opening the Low Voltage Doors

Low voltage doors are identified as LV in Figure 3.

1. To access the low voltage compartment, use a flat-head screwdriver and turn both of the 1/4-turn fasteners, located on the low voltage door, 90° in a counterclockwise direction.

2. The door is now released and will swing open.

3. Reverse the procedure to secure the doors.

Figure 3 - Standard Cabinet

Refer toAccess to the Power Bus on page 7 for the procedure to open the swingout low voltage panel behind the low voltage door.

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 3

Chapter 2 Installation – Standard Enclosure

IMPORTANT

ATT EN TI ON : Medium voltage components may be located behind the swing-

out low voltage panel (standard cabinets only). Complete the power lockout procedure (refer to Power Lock-out Procedure

on page 41 of Chapter 5) before

attempting to open the swing-out low voltage panel. Failure to do so may result in severe burns, injury or death.

ATT EN TI ON : Complete the Power Lockout procedure (refer to Power Lock-out

Procedure on page 41 of Chapter 5) before beginning any service procedures to

the unit. Failure to do so may result in severe burns, injury or death.

Opening the Medium Voltage Doors

Medium voltage door is identified as MV in Figure 3.

The medium voltage door has its own isolation switch handle and interlocking safeguards.

Refer toAccess to the Power Bus

on page 7 for the procedure to open the swing-

out low voltage panel behind the low voltage door (for standard cabinet only).

1. Electrically open the contactor by pressing the STOP button on the starter or at the remote control location.

2. Move the isolation switch handle to the OFF position.

3. Unscrew the door locking bolts for the medium voltage door.

4. The door is now released and will swing open.

5. Reverse the procedure to close the door

Ensure that the swing-out low voltage panel is in its original position before attempting to close the MV door. When closing the medium voltage door, ensure all door locking bolts on the right side of the MV door are in place and tightened until the door is flush with the flange Do not overtighten the bolts. If the door is not securely fastened, it will not be possible to move the isolation switch handle to the ON position.

ATTENTION: Complete the Power Lock-out procedure (refer to Power

Lock-out Procedure on page 41 of Chapter 5) before beginning any

service procedures to the unit. Failure to do so may result in severe burns, injury or death.

4 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

TIP

IMPORTANT

Anchoring

Place the controller in the desired installation location. The floor must be flat and level. Use four 12 mm (1/2 in. [M12]) floor mounting bolts to securely fasten the controller to the mounting surface. See Figure 4 the mounting holes in the cabinet.

Refer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan.

Pre-determined cabinets have been designed for Uniform Building Code (UBC) seismic zone 1, 2A, 2B, 3 and 4, and IBC (International Building Code) seismic activity without overturning or lateral movement, provided they are securely mounted according to UBC, IBC and local building codes. This can include concrete pad design, steel floor design and the sizing of cabinet anchors. Concrete floor cutouts must not be adjacent to floor anchor bolts and must be sized to seismic load. Consult factory if floor mounting must be reviewed by an accredited engineer. Many jurisdictions require an engineer from the local area to review the design. Seismic qualification does not indicate that the equipment will function properly after a seismic event.

Figure 4 - Cabinet Floor Plan

as an example of the location of

NOTES FOR SEISMIC APPLICATIONS

• For installations on concrete – the minimum depth and radius of concrete supporting the cabinet anchors is dependent on seismic loads. Refer to important information above.

• For installations on a metal structure – the metal plate depth and cabinet anchoring method is dependent on seismic loads.

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 5

Chapter 2 Installation – Standard Enclosure

TIP

IMPORTANT

Side Bus Access Cover

0.219 Pilot Holes (5x)

0.281 Pilot Holes (5x)

0.219 Pilot Holes (3x)

Joining Sections

Joining hardware can be found in a package mounted to the front of the shipping skid. Refer to publication MV-QS050_-EN-P

for level floor surface

requirements.

For Arc Resistant cabinets, see page 15.

6. Position the left side section on a level surface and secure the section in place with 12 mm (1/2 in. [M12]) floor mounting bolts (refer to Anchoring

on page 5).

7. When joining NEMA/EEMAC Type 12 sections, apply a continuous 3 mm (1/8 in.) wide bead of silicon sealer around the perimeter of one section.

8. Remove the side bus access covers if applicable.

9. Position the right section against the left section. Ensure that the surface is

level.

10. Secure the sections together using the 1/4-20 self-tapping screws. Thread the screw through the 7 mm (0.281 in.) clearance hole to the corresponding 6 mm (0.219 in.) pilot hole. To access the front clearance holes of the left-side cabinet, open the medium voltage doors. To access the rear clearance holes remove the rear covers of the starter. If rear access is not available, refer to Front Access – Top Incoming Line Cables or Front Access – Bottom Incoming Cables

on page 10.

on page 8

11. Secure the right section to the floor using 12 mm (1/2 in. [M12]) floor mounting bolts (refer to Anchoring

Figure 5 - Joining Sections

on page 5).

6 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

Side Bus Access Cover

Center Rear Bus Access Cove r

Access to the Power Bus

ATT EN TI ON : This procedure requires contact with medium voltage

components. To avoid shock hazards, lock out incoming power before working on the equipment (refer to Power Lock-out Procedure

on page 41 of Chapter 5).

Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death.

Rear Access

1. Remove the hardware securing the center rear bus access cover (Figure 6).

2. Remove the center rear bus access cover.

3. Once the rear bus cover is removed you will see the three bus bars

(Figure 7

Figure 6 - Access to Power Bus from Side and Rear of Cabinet

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 7

Figure 7 - Bus Bars from Back Access

Chapter 2 Installation – Standard Enclosure

Side Access

A side bus access cover is located on each side of the controller.

1. Remove the hardware from the appropriate side bus access cover.

2. Remove the side bus access cover.

3. Once the side bus access cover is removed, you will see the three bus bars.

(Figure 8

Figure 8 - Side Bus Access Cover Removed

Front Access – Top Incoming Line Cables

1. Complete the Power Lockout Procedure (refer to Power Lock-out

Procedure on page 41 of Chapter 5) for both medium voltage power cells

and the power bus.

2. Open the low voltage cell door (refer to Opening the Low Voltage Doors

on page 3).

3. Open the medium voltage cell doors (refer to Opening the Medium

Vol ta ge D oor s on page 4).

4. Remove the two self-tapping screws from the low voltage panel if installed. (Installed for shipping purposes – see Figure 9

5. Use a flat head screwdriver and turn both of the 1/4-turn fasteners 180 degrees in a counterclockwise direction.

8 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

TIP

Remove selftapping screws

Remove 1/4 turn fasteners

Swing Open Low Volta ge Pan el

Remove selftapping screws from Bus Access Barriers

Bus Access Barriers

Figure 9 - Low Voltage Panel

Figure 10 - Access to Power Bus with Low Voltage Panel Rotated

6. Pull on right-hand side of low voltage panel. Swing low voltage panel to the front and left of cabinet (see Figure 10

The power cell door must be in a fully opened position prior to rotating the low voltage panel.

7. Locate the removable bus access barriers (2).

8. Remove retaining screws from removable bus access barriers to expose

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 9

incoming cable connections to main bus (see Figure 11

9. Install incoming line cables to power bus, torque to specifications (refer to Recommended Torque Values

on page 2 of Chapter 1).

Chapter 2 Installation – Standard Enclosure

TIP

Low Voltag e Panel

Power Bus

10. Reverse procedure after cables have been installed.

Figure 11 - Power Bus with Barrier Removed

ATT EN TI ON : Ensure all barriers are replaced before re-energizing the

equipment. Failure to do so may result in electrical faults and cause damage to equipment or severe injury to personnel.

Front Access – Bottom Incoming Cables

If the incoming cables in your cabinet enter the section from the bottom, follow the same procedure as for Front Access – Top Incoming Line Cables

Access to incoming cable duct in the power cell is also required.

1. Open the power cell door.

2. Locate incoming cable duct at rear left-hand side of power cell (see

Figure 12

3. Remove self-tapping screws from the cable duct access barriers. Remove

barriers.

4. Route and install incoming line cables to power bus. Torque to specifications (refer to Recommended Torque Values

on page 2 of

Chapter 1).

5. Reverse procedure after cables have been installed.

10 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Figure 12 - Access to Bottom Incoming Line Cables

Cable duc t access barrier

Bottom incoming cable duct located in power cell

IMPORTANT

TIP

Installation – Standard Enclosure Chapter 2

Load Cable Connections

ATT EN TI ON : Ensure all barriers are replaced before re-energizing the

equipment. Failure to do so may result in electrical faults and cause damage to equipment or severe injury to personnel.

ATT EN TI ON : To avoid shock hazards, lock out incoming power (refer to Power

Lock-out Procedure on page 41 of Chapter 5) before working on the equipment.

Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death.

The current transformers may be positioned for top or bottom cable exit. Follow the appropriate procedure described for your starter configuration.

Cable size should not exceed 1-750 MCM or 2-500 MCM per phase.

Refer to Dimensional Drawings provided with order documentation for additional details related to cabinet floor plan.

1. Complete the Power Lockout procedure (refer to Power Lock-out

Procedure on page 41 of Chapter 5).

2. Remove the appropriate cable conduit opening plate(s) from the cabinet

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 11

conduit.

(see Figure 13

to Figure 15). The plate may be punched or cut to mount

Chapter 2 Installation – Standard Enclosure

3. Load cables for the power cell should be routed before control cables. Pull the cables into the cabinet through the appropriate opening (see Figure 13 to Figure 15

4. Remove current transformer barriers.

5. Connect the cables to the current transformers and tighten the

connections to 65 N•m (48 lb•ft).

6. Connect cable shields (if present) to the ground lug.

7. Reinstall the current transformer barrier and reassemble the cabinet.

Figure 13 - Access to Load Cable Conduit Openings (Bottom Entry)

Figure 14 - Load Cable Conduit Openings, Bottom Exit

12 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Figure 15 - Routing of Load Cables (Top exit shown)

Curren t Transformer

Route Cables through Access Hole

Installation – Standard Enclosure Chapter 2

ATT EN TI ON : Ensure all barriers are replaced before re-energizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel.

Figure 16 - Load Cable Conduit Openings, Top Exit

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 13

Chapter 2 Installation – Standard Enclosure

Notes:

14 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Chapter 3

IMPORTANT

Low Voltag e

Door

Medium

Voltage Door

Chimney

Installation – Arc-Resistant (ArcShield)

This installation section contains information related only to the Rockwell Automation arc resistant enclosures, referred to now as “ArcShield”.

For information on the installation site preparation, see Publication

MV-QS050_-EN-P

ATT EN TI ON : Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death.

Door Opening Procedure

Opening the Low Voltage Doors

Low voltage doors are identified as LV in Figure 17.

1. To access the low voltage compartments for ArcShield cabinets, turn the release handle counter-clockwise.

2. The door is now released and will swing open.

3. Reverse the procedure to secure the low voltage doors.

Figure 17 - Access to Low Voltage Compartments

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 15

Chapter 3 Installation – Arc-Resistant (ArcShield)

IMPORTANT

TIP

ATT EN TI ON : Complete the Power Lockout procedure (refer to Power Lock-out

Procedure on page 41 of Chapter 5) before beginning any service procedures to

the unit. Failure to do so may result in severe burns, injury or death.

Opening the Medium Voltage Door

Figure 18 - Access to Medium Voltage Compartments

The medium voltage door has its own isolation switch handle and interlocking safeguards. The low voltage panel compartment and power cell are separated by an isolation barrier.

A Medium Voltage door is shown in Figure 17.

Failure to follow the MV door opening procedure could damage or jam the mechanical door interlocks. This could result in the mechanical interlocks not operating as intended and could result in the door becoming jammed in the closed position.

1. Electrically open the contactor by pressing the STOP button on the starter or at the remote control location.

2. Move the isolation switch handle to the OFF position.

3. Unbolt the door locking bolts for the medium voltage door.

4. Turn the black release handle counter clockwise 90 º (Figure 19

5. The door is now released and will swing open (the door is heavy and does take some force to swing open).

6. Reverse the procedure to close the door. This sequence must be followed. Door lock bolts must be adequately tightened (refer to Recommended

To r qu e Va lu es on page 2 of Chapter 1).

On all ArcShield starters, the sticker in Figure 19 is attached to each door for your reference.

16 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Figure 19 - Label on Arc Resistant Door

IMPORTANT

TIP

Installation – Arc-Resistant (ArcShield) Chapter 3

Anchoring

The last step in closing the medium voltage door, ensure all door locking bolts on the right side of the MV door are in place and tightened until the door is flush with the flange securely fastened, it will not be possible to move the isolation switch handle to the ON position. Do not attempt to rotate the arc latching handle until the locking bolts are tightened (refer to Figure 19

ATT EN TI ON : Complete the Power Lock-out procedure (refer to Power Lock-out

Procedure on page 41 of Chapter 5) before beginning any service procedures to

the unit. Failure to do so may result in severe burns, injury or death.

Place the controller in the desired installation location. Use 12 mm (1/2 in. [M12]) floor mounting bolts to securely fasten the controller to the mounting surface. See Figure 20 mounting holes in the cabinet.

and Figure 21 as an example of the location of the

Refer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan.

. Do not overtighten the bolts. If the door is not

)

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 17

Chapter 3 Installation – Arc-Resistant (ArcShield)

IMPORTANT

Figure 20 - Cabinet Floor Plan – Top Entry/Exit Units

Figure 21 - Cabinet Floor Plan – Bottom Entry/Exit Units

18 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Installation – Arc-Resistant (ArcShield) Chapter 3

TIP

NOTES FOR SEISMIC APPLICATIONS

• For installations on concrete – the minimum depth and radius of concrete supporting the cabinet anchors is dependent on seismic loads. Refer to important information above.

• For installations on a metal structure – the metal plate depth and cabinet anchoring method is dependent on seismic loads.

Joining Sections

Joining hardware can be found in a package mounted to the front of the shipping skid. Refer to publication MV-QS050_-EN-P for level floor surface requirements.

1. Remove the side bus access covers if applicable.

2. Position the left side section on a level surface and secure the section in

place with 12 mm (1/2 in. [M12]) floor mounting bolts (refer to Anchoring

3. When joining ArcShield sections, apply a continuous 3 mm (1/8 in.) wide bead of silicon sealer around the entire outer perimeter of one section AND around the cutout for the power bus.

4. Position the right section against the left section. Ensure that the surface is level.

5. Secure the sections together using the 1/4-20 self-tapping screws. Thread the screw through the 7 mm (0.281 in.) clearance hole to the corresponding 6 mm (0.219 in.) pilot hole. To access the rear clearance holes remove the rear covers of the starter. If rear access is not available, refer to Front Access – Bottom Incoming Cables (Bottom Entry/Exit)

page 22 or Front Access – Top Incoming Cables (Top Entry/Exit) on page 24.

6. Use the provided 1/4-20 thread fasteners to secure the entire perimeter of the horizontal bus. Ensure there is a continuous bead of silicone seal around the bus bar opening on one cabinet.

on page 17).

7. Secure the right section to the floor using 12 mm (1/2 in. [M12]) floor mounting bolts (refer to Anchoring

ArcShield units at the end of a line-up have a ground connection to the outside side bus access cover (see Figure 25 connection must be maintained to ensure unit arc resistant performance.

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 19

on page 17).

and Figure 26). This

Chapter 3 Installation – Arc-Resistant (ArcShield)

Power Bus

cutout holes

must align

Silicone is applied around

power bus cutout area to

prevent gas leakage

between joined cabinets

Figure 22 - Joining Sections

Access to the Power Bus

ATT EN TI ON : This procedure requires contact with medium voltage

components. To avoid shock hazards, lock out incoming power before working on the equipment (refer to Power Lock-out Procedure

on page 41 of Chapter 5).

Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death.

Rear Access

1. Remove the hardware securing the center rear bus access cover (Figure 23).

ATTENTION: The rear cover plates are made from 12 gauge metal and are mounted in board of the main structure. The covers will drop inside if care is not taken as you remove the mounting bolts.

2. Remove the center rear bus access cover.

3. Once the center rear bus cover is removed you will see the three bus bars

(Figure 25

20 Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013

Installation – Arc-Resistant (ArcShield) Chapter 3

Side Bus Access Cover

Center Rear Bus Access Cover

Figure 23 - Access to Power Bus from Side and Rear of Cabinet

Side Access

A side bus access cover is located on each side of the controller, when required.

1. Remove the hardware from the appropriate side bus access cover.

2. Remove the side bus access cover (Figure 23

3. ArcShield units at the end of a line-up have a ground connection to the

inner plate of the side bus access cover (see Figure 25 connection must be maintained to ensure unit arc resistant performance.

Figure 24 - ArcShield Side Bus Access Cover Warning Label

and Figure 26). This

Rockwell Automation Publication 1512A-UM100F-EN-P - May 2013 21

+ 67 hidden pages