Rockwell Automation 1512B MV User Manual

User Manual

Medium Voltage Controllers, 200/400A Two-High Cabinet, Standard and Arc-Resistant Enclosure

Publication 1500-UM055G-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 59

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 iii

Summary of Changes

Notes:

iv Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

General Information

Installation – Standard Enclosure

Chapter 1

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

Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Prepared Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Series Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Starter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 2

Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Front Access– Access to Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Front Access – Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . 16

Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Top Exiting Load Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation – Arc-Resistant Enclosure (ArcShield)

Common Installation

Chapter 3

Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Front Access – Access to Power Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Front Access – Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . 31

Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Top Exiting Load Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 4

Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Insulated Power Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Ground Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 v

Table of Contents

Incoming Line Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installation of Current Transformer Barrier . . . . . . . . . . . . . . . . . . . . . . . . 39

Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Contactor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Testing Contactor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 5

Maintenance

Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Door Interlock Circumvention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Power Lock-out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Fuse Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Bolt-on Fuse Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Clip-on Fuse Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Contactor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Removing the Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Contactor Interlock Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

To Reduce the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

To Increase the Gap Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Isolation Switch Mechanism Inspection and Lubrication . . . . . . . . . . . . 57

Isolation Blade Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Isolation Switch Mechanism Grounding Adjustment. . . . . . . . . . . . . . . . 62

Auxiliary Contacts Inspection and Replacement . . . . . . . . . . . . . . . . . . . . 63

Isolation Switch Auxiliary Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Adjusting the Normally Open (ISa) Contacts . . . . . . . . . . . . . . . . . . . 64

Adjusting the Normally Closed (ISb) Contacts. . . . . . . . . . . . . . . . . . 65

Adjusting the Change-of-State Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Emergency Circumvention Procedure for Power Cell Entry. . . . . . . . . . 66

Installing Z-clip with Isolation Switch Handle in the

OFF Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Installing Z-clip with Isolation Switch Handle in the

ON Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Chapter 6

Spare Parts

Bulletin 1512 and 1512BT Units Parts List. . . . . . . . . . . . . . . . . . . . . . . . . 69

Appendix A

ArcShield Unit Information

vi Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

ArcShield Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . . 72

Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Table of Contents

Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Chimney Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Appendix B ArcShield Plenum Installation Instructions

ArcShield Chimney Installation Instructions

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 78

STEP 1 – Mounting a Single Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Plenum Placement on Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

STEP 2 – Alignment of “Side-by-Side” Plenums . . . . . . . . . . . . . . . . . . . . 81

STEP 3 – Sequence of Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

STEP 4 – Closing the Front of the Plenum Sections . . . . . . . . . . . . . . . . 83

STEP 5 – Extension and Elbow Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 83

STEP 6 – Mounting Extension/Elbow to Plenum “Line-up”. . . . . . . . . 84

STEP 7 – Additional Mounting Support. . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Appendix C

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 88

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Chimney Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 vii

Table of Contents

Notes:

viii Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

General Information

IMPORTANT

Chapter 1

Document Scope

This User Manual pertains to the Rockwell Automation Bulletin 1512B medium voltage controller. The Bulletin 1512B structure includes provisions for two complete MV controller units.

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

The product Bulletin numbers covered by this document are:

• 1512B 200/400 A FVNR controller

• 1512BT 200/400 A Transformer Feeder

• 1512BP 200/400 A Prepared Space

This document is to be used for all Bulletin 1512B 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.

(1)

, Appendix B and Appendix C.

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 4800V) Reduced Voltage Starter

• 1591B Incoming Line Unit

• 1592BF Fused Load Break Switch for Feeders

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

(1) Not available on arc-resistant designs.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 1

Chapter 1 General Information

Starter Identification

A structure 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.

Figure 1 - Typical Structure Nameplate

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

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.

2 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

General Information Chapter 1

Prepared Space

When ordering a starter kit to complete a prepared space following information to ensure the proper components are supplied.

(2)

, provide the

Series Number

Provide the series number from the structure with the prepared space. The number is stamped on a nameplate on the right-hand flange of the starter (see

Figure 1

the starter.

). The series number is also available from the dimension drawings for

Motor Data

Provide the following motor data:

• Locked rotor current

• Full load current

• Maximum locked rotor time

• Acceleration time

• Motor service factor

• Motor horsepower

Recommended Torque Values

Starter Features

Provide information regarding any special features required for the starter kit. Indicate if these features are different from the motor control features in the existing, complete power cell.

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

Table 1 - Hardware Torque Values

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)

(2) Not available on arc resistant cabinets.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 3

Chapter 1 General Information

Notes:

4 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Installation – Standard Enclosure

IMPORTANT

LV MV

1/4-turn fasteners for

Upper Low Voltage Door

1/4-turn fasteners for

Lower Low Voltage Door

For information on the installation site preparation, see General Handling Procedures for MV Products, 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 compartments for standard cabinets – use a flat-head screwdriver and turn both of the 1/4-turn fasteners at least 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 - Access to Low Voltage Compartments

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 5

Chapter 2 Installation – Standard Enclosure

LV MV

Door Locking Bolts for Upper Medium Voltage Door

Isolation

Switch

Handles

IMPORTANT

Opening the Medium Voltage Doors

ATT EN TI ON : Medium voltage components are located behind the swing-out

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

Procedure on page 47 of Chapter 5) before beginning any service procedures to

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

Medium voltage doors are identified as MV in Figure 4.

Figure 4 - Access to Medium Voltage Compartments

on page 47 of Chapter 5) before

Each medium voltage door has its own isolation switch handle and interlocking safeguards. Upper and lower power cells are separated by an isolation barrier.

Refer toAccess to the Power Bus on page 9 for the procedure to open the swing-

6 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

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 medium voltage door.

Installation – Standard Enclosure Chapter 2

IMPORTANT

TIP

IMPORTANT

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 bolts. If the door is not securely fastened, it will not be possible to move the isolation switch handle to the ON position.

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

Procedure on page 47 of Chapter 5) before beginning any service procedures to

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

. Do not overtighten the

Anchoring

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 5 cabinet.

as an example of the location of the mounting holes in the

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.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 7

Chapter 2 Installation – Standard Enclosure

TIP

Figure 5 - Cabinet Floor Plan

Joining Sections

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

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

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

3. Remove the side bus access covers if applicable.

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

level.

on page 7).

8 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

Side Bus Access Cover

0.219 Pilot Holes (5x)

0.281 Pilot Holes (5x)

0.219 Pilot Holes (3x)

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 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– Access to Power Bus

on page 11.

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

Figure 6 - Joining Sections

on page 7).

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 Verify with a hot stick or appropriate voltage measuring device that all circuits

on page 47 of Chapter 5).

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 (see

Figure 7

2. Remove the center rear bus access cover.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 9

Chapter 2 Installation – Standard Enclosure

Side Bus Access Cover

Center Rear Bus Access Cove r

3. Once the rear bus cover is removed, you will see the three power bus bars and the ground bus bar (see Figure 8

Figure 7 - Access to Power Bus from Side and Rear of Cabinet

Figure 8 - Bus Bars from Back Access

10 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

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 (see

Figure 7

2. Remove the side bus access cover.

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

bars and the ground bus (see Figure 9

Figure 9 - Side Bus Access Cover Removed

Front Access– Access to Power Bus

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

Lock-out Procedure on page 47 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.

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

Procedure on page 47 of Chapter 5) for both medium voltage power cells

and the power bus.

2. Open the doors and remove the hinge pins.

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Chapter 2 Installation – Standard Enclosure

Remove self-tapping screws from center vertical channel

Control Wiring Harness

3. Open the low voltage cell doors (refer to Opening the Low Voltage Doors

on page 5).

4. Disconnect the control wiring harness from the wire plug at the lower left side of the contactor.

5. Remove the two self-tapping screws from the center vertical channel (see

Figure 10

6. Pull on the center vertical channel to swing out the low voltage panel.

Figure 10 - Center Vertical Channel

12 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

Current Transfo rmers

Remove self-tapping screws

from barrier assembly

Glass-polyester barrier

7. Remove each glass-polyester barrier located in front of the current transformers (see Figure 11

Figure 11 - Removing Glass-polyester Barrier

8. Remove the retaining screw from the cable duct barrier and remove the barrier (see Figure 12

9. Remove the two retaining screws from the cable duct boot and remove the boot (see Figure 12

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Chapter 2 Installation – Standard Enclosure

Current Transformers

CT Mounting Plate

Loosen Retaining Screws

Cable Duct Boot

Remove Retaining Screws

Cable Duct Barrier

Remove four self-

tapping screws from

each Bus Access Cover

Figure 12 - Removing Cable Duct Boot and Barrier

10. To access the left side of the power bus, locate the two bus access covers at the rear, left side of the power cell. Remove the four self-tapping screws from each cover and remove the covers (see Figure 13

Figure 13 - Removing Bus Access Covers

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Installation – Standard Enclosure Chapter 2

Contactor Bus Bars

Mounting Bolts

Trailer Fuse Block

11. If access to the right side of the power bus is required, remove the vacuum contactor from the upper power cell (refer to Removing the Contactor

page 52 of Chapter 5).

12. Remove the power fuses from the isolation switch.

13. Remove the interphase barriers from the trailer fuse block by raising them

vertically up and out of the mounting slots (see Figure 14

14. Use a 9/16-in. socket to remove the contactor bus bars from the isolation switch trainer fuse block.

Figure 14 - Contactor Bus Bars (Trailer Fuse Block for Clip-on Fuses Shown)

15. Disconnect the secondary control wiring from the control power transformer (CPT) and remove the CPT mounting plate. Leave the CPT attached to the plate.

ATTENTION: The CPT is heavy and assistance may be required to safely remove and transport the unit. Use caution when removing the CPT. Failure to do so may result in personal injury and/or damage to the equipment.

16. To access the right side of the power bus, remove the self-tapping screws from the lower glass-polyester bus access cover and remove the cover (see

Figure 15

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Chapter 2 Installation – Standard Enclosure

Remove self-tapping screws

17. Reverse the procedure to reassemble the cabinet. Ensure that the barriers are put back in place and all parts and tools are accounted for.

Figure 15 - Access to Right Side of Power Bus

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.

Front Access – Bottom Exiting Load Cables

If the cables in your cabinet exit from the bottom, the procedure to access the power bus is almost identical to the one above. Follow the procedure for To p Ex i ti n g L o a d

Cables on page 19, but remove the cable duct barrier and cable duct boot from the

top of the lower power cell, rather than those at the bottom (see Figure 16

16 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Figure 16 - Bottom Cable Exit Configuration

Cable Duct Barrier

Cable Duct Boo t

IMPORTANT

Installation – Standard Enclosure Chapter 2

Load Cable Connections

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

Lock-out Procedure on page 47 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.

Refer to Dimensional Drawings provided with order documentation for additional details.

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

Procedure on page 47 of Chapter 5).

2. Open the MV power cell door.

3. Remove the cable duct boot at the top of the cabinet for top exiting load

cables, or remove the one at the bottom of the cabinet for bottom exiting load cables (see Figure 17

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Chapter 2 Installation – Standard Enclosure

Remove Cable Duct Boot to

access Load Cable Conduit opening for cables exiting

from bottom Power Cell

Current Transformer

Mounting Plate

Connect Load Cables to

Current Transformers

TIP

Figure 17 - Access to Load Cable Conduit Openings (Top exit cable configuration shown)

(LV panels removed for clarity)

4. Remove the appropriate load cable conduit openings in the top or bottom of the cabinet (see Figure 18

or Figure 19).

Refer to Dimensional Drawings provided with order documentation for additional details.

18 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Installation – Standard Enclosure Chapter 2

Ground Lug

Load Ca ble Conduit

opening for cables from

bottom power cell

Load cable Condui t

Opening for cables

from top power cell

Top of Cabinet

Top Exiting Load Cables

5. Load cables for the bottom power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 18 Run the cables behind the current transformer mounting plate and into the bottom power cell.

Figure 18 - Load Cable Conduit Openings (Top Exit Shown)

6. For the top power cell, pull the cables into the cabinet through the appropriate opening (see Figure 18

7. Connect the cables to the current transformers and tighten the connections to 65 N•m (48 lb•ft).

8. Connect cable shields to the ground lug.

9. Reinstall the cable duct boot and reassemble the cabinet.

ATTENTION: 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.

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Chapter 2 Installation – Standard Enclosure

TIP

Load Cable Cond uit Opening

for cables from top power cell

Load Cable Conduit Opening for

cables from bottom power cell

Bottom of Cabinet

Bottom Exiting Load Cables

Follow steps 1-4 from the previous section.

5. Load cables for the top power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 19 cables behind the current transformer mounting plate and into the top power cell.

Figure 19 - Load Cable Conduit Openings (Bottom Exit Shown)

). Run the

6. For the bottom power cell, pull the cables into the cabinet through the appropriate opening (see Figure 19

7. Connect the cables to the current transformers and tighten the connections to 65 N•m (48 lb•ft).

8. Connect cable shields to the ground lug.

9. Reinstall the cable duct boot and reassemble the cabinet.

ATTENTION: 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.

20 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

Chapter 3

IMPORTANT

Chimney

Upper Low Voltage

Door handle

Lower Low Voltage

Door handle

Plenum

Upper Low Voltage Door handle

Lower Low Volt age Door handle

Installation – Arc-Resistant Enclosure (ArcShield)

This installation section contains information on arc resistant styles of enclosures, referred to in this manual 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 on page 18.

1. To access the compartments for ArcShield cabinets – turn the release handle counter-clockwise 90º.

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

3. Reverse the procedure to secure the door.

Figure 20 - Access to Low Voltage Compartments

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Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

Chimney

Upper Low Voltage

Door handle

Lower Low Voltage

Door handle

Plenum

Upper Low Voltage Door handle

Lower Low Volt age Door handle

IMPORTANT

Opening the Medium Voltage Doors

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

Procedure on page 47 of Chapter 5) before beginning any service procedures to

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

Medium voltage doors are identified as MV in Figure 21.

Figure 21 - Access to Medium Voltage Compartments

Each medium voltage door has its own isolation switch handle and interlocking safeguards. Upper and lower power cells are separated by an isolation barrier.

Refer toAccess to the Power Bus on page 26 for the procedure to open the swingout 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 (see Figure 22

3. Turn the release handle counter-clockwise 90 degrees.

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

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

22 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013

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