Rockwell Automation 1512B MV User Manual

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Page 1

User Manual

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

Publication 1500-UM055G-EN-P

Page 2

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.

Page 3

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

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Summary of Changes

Notes:

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

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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

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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

Page 7

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

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Table of Contents

Notes:

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

Page 9

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

Page 10

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

Page 11

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

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Chapter 1 General Information

Notes:

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

Page 13

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

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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.

Page 15

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

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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

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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

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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

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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.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 11

Page 20

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

Page 21

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

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 13

Page 22

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

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

Page 23

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

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 15

Page 24

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

Page 25

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

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 17

Page 26

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

Page 27

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.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 19

Page 28

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

Page 29

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

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 21

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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

Page 31

Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3

IMPORTANT

TIP

6. Reverse the procedure to close the door. Door lock bolts must be adequately tightened (refer to Recommended Torque Values

Chapter 1 for torque values).

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

On all ArcShield starters, the sticker in Figure 22 is attached to each door for your reference.

Figure 22 - Label on Arc Resistant Door

. Do not overtighten the bolts. If the

on page 3 of

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 23 cabinet.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 23

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.

Page 32

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

IMPORTANT

5.25 [133]

31.38 [797]

36.00 [914]

16.17 [411]

30.00 [762]

2.31 [59]

4.62 [117]

9.32 [237]

23.68 [601]

7.50 [191]

4.88 [124]

13.05 [331]

FOR TOP COMPARTMENT.

LOAD CABLE CONDUIT OPENING

MOUNTING HOLES FOR .50 [M12] DIA. ANCHOR BOLTS.

LINE CABLE CONDUIT OPENING.

LOAD CABLE CONDUIT OPENING FOR BOTTOM COMPARTMENT.

5.68 X 9.00 [144 X 229]

3.00 X 5.00 [76 X 127]

CONTROL WIRE CONDUIT OPENING.

BOTH TOP & BOTTOM COMPARTMENTS.

EACH OPENING PROVIDES ACCESS TO

BOLT (REQUIRED FOR SEISMIC APPLICATIONS ONLY)

MOUNTING HOLES FOR 0.50” [M12] DIA. ANCHOR

[144 X 229]

5.68 X 9.00

5.68 X 9.00 [144 X 229]

(Front)

REQUIRED FOR SEISMIC APPLICATIONS.

MINIMUM DISTANCE TO CONCRETE FLOOR CUT-OUT

1.00 [25] X 3.00 [76] NON REMOVABLE SILL CHANNELS.

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.

Figure 23 - Cabinet Floor Plan

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

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.

Page 33

Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3

TIP

Power Bus

cutout holes

must align

Silicone is applied around

power bus cutout area to

prevent gas leakage

between joined cabinets

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. 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 23).

2. When joining ArcShield sections, apply a continuous 3 mm (1/8 in.) wide bead of silicone 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 11 of Chapter 2. When joining the ArcShield sections, use the provided 1/4-20

thread fasteners to secure the perimeter of the horizontal bus opening, ensure all bolts are installed. (Before joining sections together, ensure there is a silicone seal around the bus bar opening.)

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

Figure 24 - Joining Sections

on page 23).

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 25

Page 34

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

Side Bus Access Cover

Center Rear Bus Access Cover

Access to the Power Bus

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

on page 47 of Chapter 5).

Rear Access

1. Remove the hardware securing the center rear bus access cover (see

Figure 25

2. Remove the center rear bus access cover.

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

and ground bus (see Figure 27

Figure 25 - 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.

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

2. Remove the side bus access cover (see Figure 25

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 26 connection must be maintained to ensure unit arc resistant performance.

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

to Figure 28). This

Page 35

Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3

Side Bus Access

Cover G round

Connection

Removable Handle

Figure 26 - Side Bus Access Cover Warning Label

Figure 27 - Side Bus Access Cover Ground Connection

Figure 28 - ArcShield Ground Plate

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 27

Page 36

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

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 that power bar.

2. Open medium voltage power cell door (see Figure 29

Figure 29 - ArcShield Power Cell (Upper)

3. Remove the retaining screw from the cable duct barrier and remove the barrier (see Figure 30

4. Remove the two retaining screws from the cable duct boot and remove the boot (see Figure 30

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

Page 37

Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3

Current Transformers

CT Mounting Plate

Loosen Retaining Screws

Cable Duct Boot

Remove Retaining Screws

Cable Duct Barrier

Remove Bus Access Cover

Figure 30 - Removing Cable Duct Boot and Barrier

5. 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 7 on page 10

Figure 31 - Removing Bus Access Covers

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 29

Page 38

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

Contactor Bus Bars

Mounting Bolts

Trailer Fuse Block

6. 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).

7. Remove the power fuses from the isolation switch.

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

vertically up and out of the mounting slots (see Figure 32

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

Figure 32 - Contactor Bus Bars (Trailer Fuse Block for Clip-on Fuses Shown)

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

11. 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 33

12. Reverse the procedure to reassemble the cabinet. Ensure that the barriers are put back in place.

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

Page 39

Figure 33 - Access to Right Side of Power Bus

Remove self-

tapping screws

Cable Duct Barrier

Cable Duct Boo t

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.

Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3

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 Front Access - Top Exiting Load Cables, 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 34

Figure 34 - Bottom Cable Exit Configuration

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 31

Page 40

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

IMPORTANT

Connect Load Cables to

Current Transformers

Removable Cable Duct Boot

to load cable conduit

opening for cables exiting

from bottom power cell

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.

For ArcShield units, cable size should not exceed 1-500 MCM or 2-350 MCM per phase.

Note: Refer to Dimensional Drawings provided with order documentation for additional details related to cabinet floor plans.

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

Procedure on page 47 of Chapter 5).

2. Follow steps 2 to 6 from Front Access – Access to Power Bus

on page 28

for the procedure to swing out the low voltage panel.

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 35

Figure 35 - Access to Load Cable Conduit Openings (Bottom Exit Cable)

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

Page 41

Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3

TIP

Top of Ca bin et

Load Cable Conduit Opening for Cables from Top Power Cell

Load Cable Conduit

Opening for Cables from

Bottom Power Cell

Current Transformer

Mounting Plate

4. Remove the appropriate load cable conduit openings in the top or bottom of the cabinet (see Figure 36

or Figure 37).

Top Exiting Load Cables

Follow steps 1-4 from previous section.

5. Load cables for the bottom power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 36 Run the cables behind the current transformer mounting plate and into the bottom power cell.

6. For the top power cell, pull the cables into the cabinet through the appropriate opening (see Figure 36

Figure 36 - Load Cable Conduit Openings

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.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 33

Page 42

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

TIP

Load Cable Conduit Opening for

Cables f rom 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 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 37 cables behind the current transformer mounting plate and into the top power cell.

Figure 37 - Load Cable Conduit Openings

). Run the

6. For the bottom power cell, pull the cables into the cabinet through the appropriate opening (see Figure 37

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.

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

Page 43

Common Installation

IMPORTANT

Chapter 4

Bus Splicing

Power Bus

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

1. The power and ground bus splice kit can be found in a package mounted to the front of the shipping skid.

Verify that the structure series numbers on the splice kit package match the structure series number found on the cabinet nameplate (refer to Starter Identification regarding the nameplate).

2. Refer to Access to the Power Bus standard or ArcShield enclosure.

3. For a 1200A power bus, assemble the splice bars as shown in Figure 38 Tighten the nuts to 65 N•m (48 lb•ft). For a 2000A power bus, assemble the splice bars as shown in Figure 39 Tighten the nuts to 65 N•m (48 lb•ft).

on page 26 of Chapter 3 for either

on page 2 of Chapter 1 for details

on page 47 of Chapter 5).

Attach the bus links to the cabinet on the left side first - as viewed from the front of the unit.

Always place the bus clamps on the rear side of each main horizontal bus or splice bar, as viewed from the front of the unit.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 35

Page 44

Chapter 4 Common Installation

Bus Clamp

Flat Washer

Lock Washer

Hex Nut

Power Bus

Splice Bar

Bus Support

Main Horizontal Power Bus

Bus Clamp

Flat Washer

Lock Washer

Hex Nut

Power Bus

Splice Bars

Bus Support

Main Horizontal Power Bus

Figure 38 - Typical 1200A Power Bus Splicing Configuration (Viewed from front of cabinet)

Figure 39 - Typical 2000A Power Bus Splicing Configuration (Viewed from front of cabinet)

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.

Insulated Power Bus Splicing

If the starter is equipped with insulated power bus, then a splice kit with insulated links, insulating boots and tape will be provided. Refer to the kit for installation instructions.

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

Page 45

Common Installation Chapter 4

Ground Bus Support

Main

Ground

Bus

Hex Nut

Lock Wash er

Flat Washer

Ground Bus Splice Bar

IMPORTANT

Ground Bus

1. See Figure 40 to determine the correct ground splice configuration and assemble as shown.

2. Torque the hardware to 15 N•m ± 1 N•m (12 lb•ft ± 1 lb•ft).

3. Check all hardware for correct tightness and replace all covers and plates.

Figure 40 - Typical Ground Bus Splicing Configuration (Front View)

Incoming Line 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 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.

Incoming cables are connected to the power bus in the last section on the left.

For Non-ArcShield units, cable size should not exceed 1-750 MCM or 2-500 MCM per phase.

For ArcShield units, cable size should not exceed 1-500 MCM or 2-4/0 per phase. For larger cables, an incoming line module must be used.

1. Remove the center-back plate or side plate to access the power bus. If access to the rear of the unit is not possible, refer to Access to the Power Bus

page 9 of Chapter 2 for either standard or ArcShield enclosures.

2. Connect the incoming power lines to the power bus. Torque to specifications (refer to Recommended Torque Values

Chapter 1) (see Figure 41).

on page 3 of

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 37

Page 46

Chapter 4 Common Installation

Power

Cable

Lugs

Ground

Bus Lug

IMPORTANT

Figure 41 - Incoming Line Cable Connections

If line cables require installation by front access, complete the incoming line connection before installing load cables.

3. Connect the ground wire to the ground bus lug.

4. Connect any external control wires to the control panel terminal blocks in

the low voltage compartment. Refer to wiring diagram.

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

Page 47

Common Installation Chapter 4

Current Barrier Transformer

Installation of Current Transformer Barrier

Figure 42 - Current Transformer Barrier

Hi-Pot and Megger Test

ATT EN TI ON : Ensure current transformer barrier is installed before

re-energizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel.

Insulation integrity should be checked before energizing medium voltage electrical equipment. Use a high voltage AC insulation tester or a Megger for this test. If a Megger is used, a 5000 volt type is recommended.

ATT EN TI ON : Exercise caution when performing high voltage tests on the equipment. Failure to do so may result in electric shock causing severe burns, injury or death

ATT EN TI ON : Disconnect power factor correction capacitors (if so equipped) before performing the Hi-Pot test. Failure to do so may result in personal injury or damage to the equipment. See Power Lock-out Procedure (refer to Po wer

Lock-out Procedure on page 47 of Chapter 5) for information on dissipating any

stored power in the capacitors.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 39

Page 48

Chapter 4 Common Installation

ATT EN TI ON : Remove all primary fuses for the control power transformer and/

or the potential transformer. Failure to do so may cause damage to the equipment during the Hi-Pot test.

Insulation can be tested from phase to phase and from phase to ground. The recommended level for AC Hi-Pot testing is (2 X V rated line-to-line voltage of the power system. The leakage current must be less than 20 mA. Record the result for future comparison testing.

If a Megger is used, it should indicate 50,000 megohms or greater if the unit is isolated from the line and the motor. If the unit is connected to a motor, the Megger should indicate 5,000 megohms or greater (phase to ground).

) volts, where VLL is the

Start-up Procedure

Contactor Inspection

See Publication 1502-UM050_-EN-P or 1502-UM052_EN-P for information on pre-energization inspection, vacuum bottle integrity test and insulation resistance test.

Preliminary Checks

Ver if y t he fo llo wi ng :

• Contactor current and voltage ratings are correct for the attached load;

• Control voltage is correct;

• Settings for protective relays;

• Heater elements (if provided) in overload relay are secure and undamaged;

• Equipment grounding;

• External power and control connections match electrical diagrams;

• All hardware is correctly reinstalled and torqued to specifications (refer

to Recommended Torque Values

• All barriers are replaced to correct positions;

• All fuses are correct class, type and rating;

• Mechanical interlocks and isolation switch function properly;

• Ensure that any microprocessor-based protection relay is programmed;

• Interior of cabinet is free from dirt, loose bolts, tools or metal chips.

Vacuum clean if necessary;

• All tools are accounted for. If you cannot locate a tool, do not energize the

unit until it is found.

on page 3 of Chapter 1);

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

Page 49

Common Installation Chapter 4

Testing Contactor Operation

1. Connect the appropriate external power supply (120 or 230V AC) to the test receptacle in the control panel. Turn the selector switch to the TEST position.

ATTENTION: Some control circuit configurations may require control jumpers to let the contactor close during the test procedure. Do not jumper any isolation switch contacts such as ISa or ISb (see Figure 66 on

page 65 for the location of these contacts). Using jumpers for these

contacts may result in equipment damage or injury to personnel.

2. Electrically operate the contactor several times. Inspect the armature plate to verify that it fully contacts the magnetic cores.

3. Turn the selector switch to the OFF position and unplug the test voltage.

4. Remove any metal filings or loose hardware from around the magnetic

cores of the vacuum contactor. The debris is attracted to the coil once it is energized and could prevent the contactor from closing properly.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 41

Page 50

Chapter 4 Common Installation

L1 L3L2 GRD

MTR

ISOLATING SWITCH

DOOR INTERLOCK

CURRENT LIMITING

POWER FUSES

TEST SUPPLY POINT

PRIMARY FUSES

CURRENT LIMITING

50/60Hz

OVERLOAD

592

REMOTE EQUIPMENT

"IEEE" NUMBER FOR PROTECTIVE DEVICE

LOW VOLTAGE DOOR MOUNTED DEVICED

CUSTOMER WIRING

LEGEND

2400V-6900V,3Ø, 50/60Hz

EXTRA AUXILIARY

CONTACTS

YBLK

B Y

MOV

CC-CLOSING COIL HC-HOLDING COIL

MAIN CONTACTOR PILOT RELAY (CR1)

STOP

DSTART

RUN

OFF

MAIN CONTACTOR (M)

ECONOMIZING CONTACTOR (CR2)

KML

HM32G

3534

IJM

CR1

21A

CR2

17C

17A15A 17B15

MOV

MAB

CR1

REC/MOV

CR2CR1 CR2 CR2CR1

CR2 DC

(1) (2)

(3) (4)

NORMAL

OFF

TEST

120V

__EF2__EF2

____

120

500

CPT

(6) (5)

(7) (8)

ISa

CT2

CT1

CT3

ISb

REMOVE JUMPER WHEN CONNECTING REMOTE EQUIPMENT

Typical Wiring Diagrams

Figure 43 - Typical Wiring Diagram: Electrically Held Vacuum Contactor (Relay Control)

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

Page 51

Common Installation Chapter 4

L1 L3L2 GRD

MTR

ISOLATING SWITCH

DOOR INTERLOCK

CURRENT LIMITING

POWER FUSES

TEST SUPPLY POINT

PRIMARY FUSES

CURRENT LIMITING

OVERLOAD

592

REMOTE EQUIPMENT

"IEEE" NUMBER FOR PROTECTIVE DEVICE

LOW VOLTAGE DOOR MOUNTED DEVICE

CUSTOMER WIRING

LEGEND

2400V-6900V,3Ø, 50/60Hz

INTELLIVAC TO BE PROGRAMMED/CONFIGURED BY THE

POWER APPLIED. THE FOLLOWING FACTORY INSTALLED

OUTPUT RELAY CONTACTS SHOWN WITHOUT CONTROL

MODULE STATUS - FAIL SAFE

CONTACTOR STATUS - FAIL SAFE

CUSTOMER BEFORE START-UP.

CONFIGURATION/POWER-UP STATES ARE IN EFFECT:

INTELLIVAC NOTES:V

- INTELLIVAC MODULE VACUUM CONTACTOR AUXILIARY INPUTAUX

- INTELLIVAC MODULE EXTERNAL CAPACITOR INPUTEC

- INTELLIVAC MODULE CLOSING COIL OUTPUTCCO

- MAIN CONTACTOR INTELLIVAC MODULEM-IV

- INTELLIVAC MODULE TRIP COIL OUTPUTTCO

REMOVE JUMPER WHEN CONNECTING REMOTE EQUIPMENT

EXTRA AUXILIARY

CONTACTS

MOV

TCO

AUX CCO

STOP

DSTART

RUN

OFF

MAIN CONTACTOR (M)

KML

HM32G

3534

IJM

M-IV

15 16

CONTACTOR

STATUS

321A

M-IV

910

14A

2.0A

171315

ABM

M-IV

(1) (2)

(3) (4)

NORMAL

OFF

TEST

__EF2__EF2

____

120

500

CPT1

(6) (5)

(7) (8)

ISa

CT2

CT1

CT3

ISb

50/60Hz120V

Figure 44 - Typical Wiring Diagram: Electrically Held Vacuum Contactor (with IntelliVAC Control)

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 43

Page 52

Chapter 4 Common Installation

Notes:

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

Page 53

Maintenance

IMPORTANT

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.

Establish a maintenance and inspection schedule for the equipment. Annual servicing, or every 20,000 operations (whichever comes sooner) is the minimum recommended. Extreme operating conditions may warrant additional attention.

Chapter 5

Tool Requirements

Recommended Torque Values

Some components of this product incorporate Imperial hardware. Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedures on these components. If you cannot obtain such tools, contact your area Rockwell Automation sales office for assistance.

• Torque wrench: 0...65 N•m (0...48 lb•ft)

• Sockets: 3/8 in., 7/16 in., 9/16 in., 3/4 in. and 7/8 in.

• Ratchet handle and extension

• Wrenches: 7/16 in., 1/2 in., 9/16 in., 3/4 in. and 7/8 in.

• Feeler gauges: 1.3 mm (0.050 in.), 2 mm (0.080 in.), 0.5 mm (0.020 in.)

• Flat-blade screwdriver

• Nyogel 759G Lubricant, Rockwell Automation part no. 80158-357-51

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

Table 2 - 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)

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 45

Page 54

Chapter 5 Maintenance

Door Interlock Lever

Door Interlock Circumvention

ATT EN TI ON : The door interlock mechanism is designed to prevent access to the

medium voltage cell while the unit is energized. When the unit is in operation, do not circumvent this interlocking safety feature. Always disconnect and lock out incoming power (refer to Power Lock-out Procedure

on page 47) before

proceeding with any adjustments requiring the handle to be moved to the ON (closed) position. Failure to do so may result in electric shock causing severe burns, injury or death.

Some of the following sections may require moving the isolation switch handle to the ON position while the medium voltage door is open. The interlocking safeguards in the mechanism are designed to prevent the handle from moving to the ON position while the cabinet door is open.

• To circumvent this safety feature, use a screwdriver, or other tool, to depress the door interlock lever in a downward movement.

• Hold the lever down while moving the handle to the ON (closed) position.

Figure 45 - Door Interlock Lever

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.

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

Page 55

Maintenance Chapter 5

Control Switch

Auxiliary Power Receptacle

ATT EN TI ON : Always perform the Power Lock-out procedure before servicing the equipment. Failure to do so may result in severe burns, injury or death.

Power Lock-out Procedure

ATT EN TI ON : The following procedure requires moving the isolation switch

handle to the ON position. To avoid shock hazards, disconnect and lock out incoming power before proceeding with servicing the equipment.

Failure to lock out incoming power will result in a live power cell once the isolation switch handle is in the ON position and may cause severe burns, injury or death. Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the following safety procedure prior to servicing the equipment.

1. Disconnect and lock out all feeder power supplies to the starter.

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

3. If the unit is equipped with power factor correction capacitors, stored

energy must be dissipated before entering the power cell. Wait at least five minutes before entering the power cell or dissipate the power using the following procedure:

a. Verify that the isolation switch handle is in the OFF position. b. Open the low voltage door. c. Connect the appropriate power supply (120 or 230V ) into the auxiliary

control power circuit as shown on the electrical drawing (see

Figure 46

d. Move the control switch to the TEST position.

Figure 46 - Control Panel (IntelliVAC Control)

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 47

Page 56

Chapter 5 Maintenance

See Detail A

Grounding Bar

Isolation Switch Blades

must fully engage Grounding Pins of

Grounding bar

(Verify for each phase)

Isolation Switch Shutters

must be closed

(Verify for each phase)

Detail A

Grounding Pins

Isolation Switch

Blades in open

position

Viewed from back with components removed for clarifica tion

e. Electrically operate the contactor by pushing the START button on the

unit or at a remote location.

f. Disengage the contactor and move the control switch to the OFF

position. Disconnect the external power supply.

g. Complete the Power Lock-out procedure

4. Open the medium voltage door.

5. Visually inspect that the isolation switch blades fully engage the grounding

pins on the grounding bar. The isolation switch shutters should be closed (see Figure 47

Figure 47 - Inspecting Isolation Switch in Open Position

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

Page 57

Maintenance Chapter 5

Check line-side power here

Check load-side power here

Isolation Switch Blades must

fully engage Incoming Line Stabs

Check incoming line voltage here

6. Check the line and load sides of the contactor with a hot stick or

appropriate voltage measuring device for the system voltage, to verify that they are voltage free (see Figure 48

). a. Check for line-side voltage at the top vacuum bottle terminals. b. Check for load-side voltage at the bottom vacuum bottle terminals.

Figure 48 - Contactor Voltage Checkpoints

7. Use the Door Interlock Circumvention procedure (refer to Door Interlock

Circumvention on page 46) to move the isolation switch handle to the

ON position.

8. Check the isolation switch blades with a hot stick or appropriate voltage measuring device for the system voltage, to verify that they are voltage free (see Figure 49

Figure 49 - Isolation Switch Voltage Check Points

9. Once all power circuits are verified to be voltage free, move the isolation switch handle back to the OFF position. The unit is now safe to service.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 49

Page 58

Chapter 5 Maintenance

Bolt-on Fuses

Clip-on Fuse

Clip-on Fuse Ex tractor

Fuse Removal and Replacement

ATT EN TI ON : Only personnel who have been trained and understand the

Bulletin 1500 product line are to work on this equipment. Suitable safety equipment and procedures are to be used at all times.

Figure 50 - Medium Voltage Power Fuses

ATT EN TI ON : Servicing energized industrial control equipment can be

hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of control equipment. Hazardous voltages may exist in the cabinet even with the circuit breaker in the OFF position. Recommended practice is to disconnect or lock out control equipment from power sources, and confirm discharge of stored energy in capacitors. If it is necessary to work in the vicinity of energized equipment, the safety related work practices of NFPA 70E, Electrical Safety requirements for Employee Work places, must be followed.

ATT EN TI ON : To prevent electrical shock, ensure the main power has been disconnected and equipment has been tagged and locked out. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.

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

Page 59

Maintenance Chapter 5

TIP

The main power fuse has a pop up indicator pin located at one end of the fuse. When a fuse has opened, the indicator will be in its extended position. The fuse should be oriented in the fuse clip assembly so that the indicator is at the top.

ATT EN TI ON : The fuses may be hot for up to one hour after operating. Verify the temperature before handling and use insulated hand protection if needed. Failure to do so may result in burns.

Bolt-on Fuse Removal/Installation

To ol s r eq ui re d: 3/8-in. drive ratchet, 2-in. extension, 6-in. extension, 12-in. extension, 1/2-in. socket, 3/8-in. drive torque wrench.

The fuse configuration will determine what length of extension will be required to get at the mounting hardware. The fuse configuration will also determine what size of interphase barriers are installed, the lower barriers can be removed to provide better access to the fuse mounting nuts.

1. Remove the two lower mounting nuts, lock and flat washers from the mounting studs.

2. Remove the upper two mounting nuts, lock and flat washers from the mounting studs and remove the fuse from the fuse mounting studs.

3. Install the replacement fuse on the four mounting studs, hold the fuse in place and install the upper two flat washers, lock washers and nuts. Torque nuts to 15 N•m (12 lb•ft).

4. Install the lower two flat washers, lock washers and nuts. Torque nuts to 15 N•m (12 lb•ft).

5. If interphase barriers were previously removed ensure they are properly reinstalled.

Clip-on Fuse Removal/Installation

Recommended tool: Fuse extractor part # 80144-491-02 (optional)

The interphase barriers located at the bottom of the fuse assembly can be removed to ease the removal and installation of the fuse.

1. Place the cup section of the fuse extractor over the top of the fuse.

2. Pull back on fuse extractor with a quick motion to dislodge the upper

portion of the fuse from top fuse clip.

3. Set fuse extractor aside.

4. Remove the lower portion of the fuse from fuse clip by pulling up and

slightly rotating the fuse in one entire movement.

5. To install the replacement fuse, place the fuse between the fuse clips.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 51

Page 60

Chapter 5 Maintenance

 



Flares

Blown Fuse Indicator (shown in blown state)

6. Ensure that the flares on the fuse ferrules are properly located with respect to the fuse clips.

7. Apply a rapid shove to the bottom portion of the fuse barrel to force the fuse into the clip.

8. Apply a rapid shove to the top portion of the fuse barrel to force the fuse into the clip.

9. Grip center of fuse barrel with both hands and apply slight back and forward force to ensure fuse has been properly seated in the fuse clips.

10. Again check and verify that the flares at the top and bottom of the fuse are not in the contact area of the fuse clip.

11. If interphase barriers were previously removed ensure they are properly reinstalled.

Figure 51 - Clip-on Style Medium Voltage Power Fuse

Contactor Maintenance

Refer to publication 1502-UM050_-EN-P or 1502-UM052_-EN-P for contactor maintenance instructions.

Removing the Contactor

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

Lock-out Procedure on page 47) 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).

2. Disconnect the control wiring harness from the wire plug at the lower left side of the contactor (See Figure 52

3. Remove the control power transformer primary fuses from the top of the contactor.

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

)

Page 61

Maintenance Chapter 5

Contac tor Operating Level

Contac tor Interlock Rod

Contactor Interlock Rod

Nylon Contactor

Bushing

Retaining Screw

Nylon

Contactor

Bushing

Nyloc Nut

Contactor Operating Lever

Contactor Remaining Tabs

4. Disconnect the control power transformer primary leads from the fuse terminals at the top of the contactor.

5. Use a 9/16-in. socket wrench to disconnect the power cables and bus bars from the rear of the contactor.

6. Remove the nylon contactor bushing retaining screw from the contactor interlock lever.

7. Slide the contactor interlock rod and the nylon contactor bushing out of the groove in the contactor interlock lever (see Figure 53

Figure 52 - Removing the Contactor (Front view)

Figure 53 - Removing the Contactor (Right-side view)

8. Remove the two contactor mounting bolts at the front of the contactor.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 53

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Chapter 5 Maintenance

9. Slide the contactor forward slightly to disengage the retaining tabs at the rear of the contactor from the mounting bracket inside the cabinet.

10. Carefully remove the contactor from the cabinet.

ATT EN TI ON : The contactor weighs approximately 22 kg (50 lbs) and assistance may be required to safely remove it from the cabinet and transport it. Failure to use caution when moving the contactor may result in equipment damage and/or personal injury.

11. If the contactor is being replaced with a new one, move the contactor interlock lever to the new contactor.

ATT EN TI ON : The retaining screw is critical to the mechanical integrity of the isolation switch. It is very important to ensure this screw is replaced during reassembly.

12. Reverse the procedure to reinstall the contactor. Ensure the mounting bolts, power cable hardware and bus bar hardware is properly torqued (refer to Recommended Torque Values

on page 3 of Chapter 1).

Contactor Interlock Rod Adjustment

13. Adjust the contactor interlock rod according to the Contactor Interlock Rod Adjustment procedure (refer to Contactor Interlock Rod Adjustment

on page 54).

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

Lock-out Procedure on page 47) 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).

2. Open the medium voltage door. Use the Door Interlock Circumvention procedure (refer to Door Interlock Circumvention the isolation switch handle halfway between the OFF and ON position (see Figure 54 procedure is completed.

3. With the contactor in the OFF position, insert a 1.5 mm (0.060 in.) feeler gauge in the gap between the interlock lever and the isolation switch operating lever. The gap must be between 1.0 mm to 2.0 mm (0.039 in. to

0.078 in.).

). Keep the handle in this position until the adjustment

on page 46) to move

4. To reduce the gap distance, follow steps 5-7. To increase the gap distance follow steps 8-10.

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

Page 63

Figure 54 - Isolation Switch Handle Adjustments

Isolation Switch Operating Lever

Isolation Switch

Handle at halfway

position

Nyloc Nut

Contactor Interlock Lever

Contactor Interlock Rod

Stop Bracket

Switch Interloc k Lever

Gap: 0.045...0.060 in.

(1.1...1.5 mm)

Maintenance Chapter 5

To Reduce the Gap Distance

To Increase the Gap Distance

5. Loosen the two screws in the stop bracket and move the stop bracket up against the interlock lever.

6. With the feeler gauge positioned in the gap, move the interlock lever and the stop bracket closer to the isolation switch operating lever to reduce the gap space. Tighten the stop bracket screws.

7. Tighten the nyloc nut until it is snug against the contactor interlock lever. Do not overtighten the nyloc nut as it will move the interlock lever and reduce the gap. Proceed to Step 11.

8. Loosen the two screws in the stop bracket and move the stop bracket away from the interlock lever.

9. Loosen the nyloc nut until the gap reaches the desired size.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 55

Page 64

Chapter 5 Maintenance

Contac tor Interlock Rod

Contac tor Plug

Contac tor

Mounting Bolts

Contactor

Operating Lever

10. Move the stop bracket until it just touches the interlock lever and tighten the screws.

11. Apply Loctite 290 (or equivalent adhesive) to the stop bracket screws and torque the screws to 8 N•m (6 lb•ft).

12. Move the isolation switch handle to the ON position.

13. Manually close the contactor by attaching locking pliers to the contactor

interlock lever and pushing down until the armature plate contacts the magnetic cores (see Figure 55

). Verify that the interlock lever overlaps the isolation switch operating lever by at least 3 mm (0.125 in.) (see

Figure 56

Figure 55 - Closing Contactor Manually (Some parts not shown)

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

Page 65

Maintenance Chapter 5

Overlap minimum

0.125 in. (3 mm)

Isolation Switch Operating Lever

Interlock Lever

Figure 56 - Isolation Switch Operating Lever Overlap

14. Open the contactor. Verify that the interlock lever and the rod move freely and that the return springs move the assembly back to the starting position.

Isolation Switch Mechanism Inspection and Lubrication

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

Lock-out Procedure on page 47) 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).

2. Open the medium voltage door.

3. Inspect the condition of the clevis pin and cotter pins shown in Figure 57

Replace any worn parts.

4. If it is necessary to replace the isolation switch operating lever or the interlock lever, apply Dow Corning 55 O-ring lubricant (Rockwell Automation part no. RU-8216, or equivalent) to the pivot points before installing the new components (see Figure 57

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 57

Page 66

Chapter 5 Maintenance

Contactor Interlock Rod

Lubrication Points

(at replacement only)

Interlock Lever

Clevis Pins and Cotter Pins

Threaded Connecting Rod

Isolation Switch Operating Lever

IMPORTANT

Figure 57 - Isolation Switch Handle Mechanism Lubrication Points

5. Inspect the mounting hardware on the isolation switch operating lever and contactor interlock rod (see Figure 57

6. Inspect the isolation switch blades and the incoming line stabs (see

Figure 63

7. Remove any dirt and dried grease.

8. Lubricate the isolation switch blades and the isolation switch blade pivot

points with Nyogel 759G (see Figure 58

). Tighten any loose hardware.

). The mating surfaces must be clean and well lubricated.

Do not scrape or file the parts. This may remove the plating and expose the underlying copper to corrosion.

Lubricate the isolation switch blades a minimum of once per year to avoid excessive wear to the components and to prevent the isolation switch blades from overheating.

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

Page 67

Figure 58 - Isolation Switch Lubrication Points

Lubricate Isolation

Switch Blades

Lubricate Pivot

Point s

Maintenance Chapter 5

Isolation Blade Switch Adjustment

The Bulletin 1500 (Series R) Isolation Switch has been updated to improve performance. This procedure ensures the isolation switch linkage assembly operates correctly with the new design change.

ATT EN TI ON : Complete the Power Lockout procedure of the main power bus before servicing 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.

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

1. Insert a screwdriver in the Isolation Switch Defeater, push down and hold at the bottom position.

2. Actuate the Isolation Switch Operating Handle from Open (black) to Closed (red) in a continuous movement.

Do not use excessive force or speed in closing the switch. This will cause an incorrect test result.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 59

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Chapter 5 Maintenance

Closed position

Open position

Isolation Switch Operating Handle

Isolation Switch Defeater

Isolation Switch Linkage Assembly (Phase 3)

TIP

Figure 59 - Isolation Switch Defeater

3. Phase 3 (far right linkage) must be measured for overall travel.

All three phases share the same main actuating shaft but the Phase 3 is the easiest to measure.

Figure 60 - Isolation Switch Linkage Assembly Location

4. Rest the customer-supplied digital protractor on the bottom of the isolation switch linkage assembly.

The angle of the linkage must be 180º or slightly higher, with a tolerance of

0/+6 degrees.

If a digital protractor is unavailable, lay a straight edge against the bottom of the steel lever on the operating shaft to check for parallel alignment of the red link.

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

Page 69

Figure 61 - Isolation Switch Linkage Assembly Angle Location

Must have tolerance of 0/+6 degrees

Shaft Assembly

Red Glass Polye ster Switch Link

Isolation Switch Mechanical Threaded Linkage

Maintenance Chapter 5

5. Loosen the lock nuts at each clevis (Note: one is a left-handed thread).

6. Adjust the isolation switch mechanical threaded linkage with a wrench

until the overall travel angle of the switch link is within the required tolerance.

7. Hold the position of the threaded linkage and tighten the lock nuts.

Figure 62 - Isolation Switch Mechanical Threaded Linkage

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 61

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Chapter 5 Maintenance

Ground Bar

Maximum Gap 0.06 in. (1.5 mm) between ground Bar and Isolation Switch in open position

Isolation Switch Blade

Incoming Line Stab

Auxiliary Contact

8. Actuate the Isolation Switch handle to verify the travel angle.

If the angle is incorrect, repeat steps 5 through 7 until desired travel angle is reached.

ATT EN TI ON : All three isolation switch linkage assemblies must meet the angle tolerance requirements.

Isolation Switch Mechanism Grounding Adjustment

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

Lock-out Procedure on page 47) before working on the equipment. Verify with a

hot stick or other 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).

2. Inspect the grounding of the isolation switch blades. When the isolation switch handle is in the OFF position, the isolation switch blades must fully engage the grounding pins and be within 1.5 mm (0.06 in.) of the ground bar (see Figure 63

). When the isolation switch handle is in the ON

position, the blades must fully engage the incoming line stabs.

Figure 63 - Isolation Switch Grounding Adjustment

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

Page 71

Maintenance Chapter 5

CATALOG NO.

700-CPM

SER. A

AMP

CATALOG NO.

700-CPM

SER. A

AMP

CATALOG NO.

700-CPM

SER. A

AMP

CATALOG NO.

700-CPM

SER. A

AMP

CATALOG NO.

700-CPM

SER. A

AMP

CATALOG NO.

700-CPM

SER. A

AMP

D-head Fastener

Correct

Incorrect

3. To adjust the distance from the blades to the bar, disconnect the threaded connecting rod at the handle operating lever (see Figure 57

4. Turn the threaded connecting rod to lengthen or shorten it. This will adjust the position of the isolation switch blades in the ON and OFF position.

Auxiliary Contacts Inspection and Replacement

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

Lock-out Procedure on page 47) 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).

2. Inspect the auxiliary contacts for wear, scorching or heat damage. Replace any damaged contacts. The contacts have a mean time between failure (MTBF) rating of 20 million operations if used within the operating specifications.

3. To remove the contact, turn both of the D-head fasteners until the flat sections are aligned with the edge of the contact (see Figure 64

4. Remove the contact from the housing.

5. Disconnect the wires from the auxiliary contact.

6. Reverse the procedure to replace the auxiliary contact.

7. Ensure the contact is correctly positioned into the contact carrier (see

Figure 64

Figure 64 - Auxiliary Contact Orientation

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 63

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Chapter 5 Maintenance

ISa Auxiliary

Contacts (N.O.)

ISb Auxiliary Contacts (N.C.)

IMPORTANT

Isolation Switch Auxiliary Contacts

The auxiliary contacts are mounted on the left side of the isolation switch, slightly below the cams on the isolation switch shaft.

Normally open contacts (Isolation Switch a Contacts - ISa) are on the outside of the isolation switch housing, and normally closed contacts (Isolation Switch b Contacts - ISb) are on the inside of the housing.

Figure 65 - Location of ISa and ISb Auxiliary Contacts

ISa and ISb contacts are exactly the same (700 CPM). The cam controls the normally open or normally closed status of the contacts.

Refer to Figure 43 on page 42

The Isolation Switch Ground Adjustment procedure (refer to Isolation Switch

Mechanism Grounding Adjustment on page 62) must be completed before

adjusting the auxiliary contacts to ensure proper synchronization of the assembly.

to Figure 44 on page 43 for wiring diagrams.

Adjusting the Normally Open (ISa) Contacts

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

Lock-out Procedure on page 47) before working on the equipment. Verify with a

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

1. Move the isolation switch handle to the OFF (open) position.

2. Loosen the bolt holding the outside cam to the shaft. Do not loosen the

bolt entirely. The cam should not be able to rotate freely on the shaft.

3. Move the isolation switch handle to the ON (closed) position and check that nothing prevents cam from rotating with the shaft.

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

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Maintenance Chapter 5

CATALOG NO.

700-CPM

SER. A

AMP

Cam

Cam Follower

Auxiliary Contact

Gap: 0.25 in. (6.35 mm)

4. Insert a 6.35 mm (0.25 in.) diameter pin into the cam groove between the cam follower and the end of the cam groove.

Figure 66 - Adjusting Auxiliary Contacts (ISa Auxiliary Contact Shown)

5. Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin – 6.35 mm (0.25 in.).

6. Move the isolation switch handle to the OFF (open) position and check that nothing prevents the cam from rotating with the shaft.

7. Tighten the bolt holding the cam to the shaft. Move the isolation switch handle to the ON position and recheck the gap using the pin.

8. Verify that auxiliary contact ISa is open when the isolation switch is open. Verify that ISa contact is closed when isolation switch is closed.

Adjusting the Normally Closed (ISb) Contacts

1. Move the isolation switch handle to the OFF (open) position.

2. Loosen the bolt holding the inside cam to the shaft. Do not loosen the bolt

entirely. The cam should not be able to rotate freely on the shaft.

3. Insert a 6.35 mm (0.25 in.) diameter pin into the cam groove between the cam follower and the end of the cam groove.

4. Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin — 6.35 mm (0.25 in.).

5. Tighten the bolt that holds the cam to the shaft. Move the isolation switch handle to the OFF position and recheck the gap using the pin.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 65

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Chapter 5 Maintenance

IMPORTANT

6. Operate the handle several times, then recheck the 6.35 mm (0.25 in.) clearance between the end of the cam groove and the follower pin for both cams.

7. Verify that auxiliary contact ISb is closed when isolation switch is open. Verify that ISb contact is open when isolation switch is closed.

Adjusting the Change-of-State Point

This procedure sets the secondary electrical interlock. When properly adjusted, the electrical interlock is designed to open the control power circuit before the isolation switch opens as the handle is moved to the OFF position.

1. Once the auxiliaries have been adjusted, move the isolation switch handle to the ON position.

2. Connect a conductivity measuring device across the closed auxiliary contacts.

Emergency Circumvention Procedure for Power Cell Entry

3. Slowly move the isolation switch handle towards the OFF position and observe the point at which the movable isolation switch blades separate from the incoming line stabs. The auxiliary contacts must change state from the closed to open position before the isolation switch blades lose contact with the incoming line stabs. This prevents the isolation switch from being opened while the unit is energized and under load conditions.

ATTENTION: The auxiliary contacts must be properly adjusted to avoid opening the isolation switch under load conditions. Improper adjustment may result in damage to the equipment and/or severe burns, injury or death to personnel.

4. If the auxiliaries do not change state before the isolation switch opens, repeat the auxiliary contacts adjustment procedure (refer to Auxiliary

Contacts Inspection and Replacement on page 63).

The interlocking mechanism of the medium voltage starter is designed to prohibit access to the power cell while the isolation switch handle is in the ON position and the isolation switch is closed.

The following procedure is intended to be used only when the isolation switch cannot be opened as described in the Door Opening Procedure for either standard or ArcShield enclosures.

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

Page 75

Maintenance Chapter 5

Remove 1/4-20

self-tapping screws

Handle Pin

Remove Z-clip

Defeater Pin

ATT EN TI ON : This procedure may expose personnel to energized medium voltage components. Whenever possible, lock out incoming power before beginning this procedure. If you are unable to lock out incoming power, use the appropriate protective equipment and work practices to avoid shock hazards. Failure to do so may result in severe burns, injury or death.

1. Remove the two 1/4-20 self-tapping screws from the Z-clip and remove the Z-clip.

Figure 67 - Removing Z-clip

2. Remove the two door locking bolts.

3. Use a flat-headed screwdriver to turn the defeater pin on the right side of

the isolation switch handle (see Figure 67

4. Open the power cell door.

Figure 68 - Defeater Pin

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 67

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Chapter 5 Maintenance

If it is possible to move the isolation switch handle to the OFF position for reassembly, follow steps 5-10.

If it is not possible to move the isolation switch handle to the OFF position for reassembly, follow steps 11-13.

ATTENTION: The Z-clip assembly must be reassembled to ensure the interlocking mechanism functions properly. Failure to do so will let personnel access live medium voltage parts and may cause severe burns, injury or death.

Installing Z-clip with Isolation Switch Handle in the OFF Position

5. Reattach the Z-clip using the self-tapping screws, but do not completely tighten them.

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

7. Swing the door closed and inspect the position of the Z-clip with respect

to the handle pin.

8. Set the Z-clip so that it is just above the handle pin. Do not set the Z-clip more than 3 mm (0.125 in.) above the pin. Open the door and tighten the screws.

9. Close the door and move the handle to the ON position. Verify that the handle pin overlaps the Z-clip and prevents the door from opening.

10. Move the handle to the OFF position and tighten the door locking bolts.

Installing Z-clip with Isolation Switch Handle in the ON Position

11. Close the door and tighten the door locking bolts.

12. Position the Z-clip as shown in Figure 68

the top portion of the Z-clip.

13. Use the self-tapping screws to reattach the Z-clip.

14. Complete steps 5-10 at the earliest opportunity to confirm that the Z-clip

assembly is correctly installed.

. Ensure the handle pin overlaps

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

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Chapter 6

Spare Parts

The following list of spare parts is valid for typical Bulletin 1512 and 1512BT units. Please contact your local Rockwell Automation office to ensure that the following part numbers are valid for your system.

Bulletin 1512 and 1512BT Units Parts List

Table 3 - Spare Parts List

Part Number Description Recommended Stocking Quantity

(2)(5)

80154-991-59 LV Control Panel

80154-991-61 LV Control Panel

1503VC-BMC5 IntelliVAC (Electrically Held and Mechanical Latch)

1503VC-BMC5-EM1 IntelliVAC Plus (Electrically Held and Mechanical Latch)

80174-902-14-R Internal IntelliVAC fuse – 6.3A, 250 V (Littlefuse 21506.3)

(1)

Engineering Data

40266-515-03 20 Amp Isolation Switch Auxiliary Contact Cartridge (700 CPM) 2

80178-707-53 Isolation Switch Blade Assembly 400A 3

80158-357-51 Nyogel 759G Lubricant 3

RU-8216 Dow Corning 55 O-ring Lubricant 1

80144-491-02 Fuse Extractor (For clip-on fuses only) 1

(1) Consult spare parts list in service manuals that are provided following delivery of equipment. (2) The following is included with the LV Control Panel: CR1 relay, CR2 relay, rectifier, MOV assembly, test switch, test plug. Note: For

mechanical latch assemblies, an additional CR1 relay is substituted for the CR2 relay. (3) For starter s with IntelliVAC control. (4) Power fuses are R rated for motor loads or E rated for non-motor loads. Power fuses are sized to the motor or transformer load data

provided at the time the starter is ordered. Refer to dimensional drawings for specific fuse type and size. Bolt- on or clip-on fuses are

available for various load sizes. Contact Rockwell Automation for details. (5) For starters with electro-mechanical control. (6) For starters with IntelliVAC Plus control.

Power Fu ses

(1)

Primary Fuses (CPT/PT) 2

(1)

LV Control Circu it Fuses 2

(1)

Heater Elements (if used) 3

(Electrically Held)

(2)(5)

(Mechanical Latch) 1

(4)

(6)

(3)

(4)(6)

For 400A contactor spare parts, refer to publication 1502-UM050_-EN-P or Publication 1502-UM052_-EN-P

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 69

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Chapter 6 Spare Parts

Notes:

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

Page 79

ArcShield Unit Information

Appendix A

Overview

ArcShield Design

ArcShield units have a robust arc resistant enclosure design that has been tested per IEEE C37.20.7 (2001). Each ArcShield structure was tested to withstand the effects of an arc flash at 40 kA for 0.5 seconds. ArcShield units provide Type 2B Accessibility.

ArcShield units typically include a pressure relief vent on the roof of the structure (some incoming units may not have a pressure relief vent if top cable entry is required). Under arc flash conditions the pressure relief vent will open allowing hazardous flames and gases to exit the enclosure via the plenum. The low voltage panel area is sealed to prevent flames and gases from entering; however, appropriate personal protective equipment (PPE) must be used whenever working on live circuits. (Refer to NFPA-70E) or (SA-Z462 in North America).

ATT EN TI ON : To ensure Arc resistant integrity, it is important to ensure that the following rules are followed:

• The pressure relief vent may not be tampered with, and it is not to be used as a step.

• No alterations can be made to the ArcShield structure.

• All covers and plates removed for installation or maintenance purposes must be

re-installed and properly secured. Failure to do so voids the arc resistance integrity.

• Power cable entry points are to be treated as the boundary between a hazardous location and sealed accordingly. Failure to do so voids the arc resistant integrity.

• A plenum or chimney must be used to direct the arc flash energy to a suitable location. Failure to do so voids the arc resistant integrity. Refer to Appendix B for plenum installation instructions. Refer to Appendix C for chimney installation instructions.

• All wiring between the low voltage panel and the power cell must be routed through a suitable gland to ensure flames and gases are not transmitted into this area (as fitted from factory).

• The medium voltage power cell doors must be properly secured, using both the handle mechanism and the door bolts (refer to instruction label on the power cell door and refer to Opening the Medium Voltage Doors

Chapter 3). Failure to do so voids the arc resistance integrity.

on page 22 of

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 71

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Appendix A ArcShield Unit Information

Exhaust Systems: Chimney or Plenum Option

Plenum Information

A plenum can be provided for each unit, and is to be field-mounted on the top of the unit structure (some incoming units may not have a plenum if top cable entry is required). The purpose of the plenum is to direct the hazardous flames and gases away from the top of the arc resistant enclosure. Unit plenums are secured to the top of the unit structure and to adjacent plenums, creating a continuous conduit for release of the arc flash energy. Refer to Appendix B installation instructions.

Each ArcShield line-up includes a plenum exhaust section that extends beyond either the left or right ends of the line-up. The other end of the plenum is capped with an end cover. Extensions can be added to the plenum to allow the arc flash energy to be directed further away from the ArcShield line-up to an area where safe venting of the plasma gases can occur.

Figure 69 - Elements of ArcShield Plenum

for plenum

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

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ArcShield Unit Information Appendix A

23 [584]

25 [633]

IMPORTANT

Figure 70 - Cross-section of Plenum Extension, dimensions in inches [mm]

Plenum Exhaust Considerations

The following options for locating the plenum exhaust are presented:

1. Plenum ducted to an area of the control room where arc gases are permitted to escape, with plenum extensions (see Figure 71

2. Plenum duct to outside of control room (see Figure 71

Plan the location where the plenum will exhaust. Ensure that:

• There is no access to personnel while equipment is energized.

• Area is free of flammable material or vapors

Ensure that adequate space is provided around the plenum exhaust, as outlined in

Figure 71

through Figure 73.

Be aware that equipment in the area of the plenum exhaust point will be damaged or destroyed.

, Figure 72 and Figure 73).

and Figure 72).

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 73

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Appendix A ArcShield Unit Information

Pers onnel Access Barrier

Pers onnel

Access Barrier

Figure 71 - Plenum Exit Left with Extensions to Internal Controlled Access Area (Top View)

Figure 72 - Plenum Exit Left with Extension(s) to Internal Controlled Access Area (Front View)

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

Minimum H = 3.5 m (138 inches) Minimum L = 1.2 m (47 inches) Minimum Volume of space required for safe pressure relief: X * Y * H = 11 m3 (390 cubic feet)

Page 83

Figure 73 - Chimney Exhaust Space Requirements

ArcShield Unit Information Appendix A

Minimum H1: 1.7 m (67 inches) Minimum H: 1 m (39 inches)

Additional Notes

• The walls of the plenum exit area must be capable of withstanding the pressure generated.

• Any painted surfaces which face direct contact with the arc products may ignite. Flame suppression is recommended.

• The exit point can also be outside the building. Ensure exit area can not be blocked by ice, snow, or vermin nests.

• Access barriers are recommended as a means of restricting access by personnel while the equipment is energized. Chain link fencing is a suitable barrier material.

• Equipment that consists of more than 4 vertical sections bolted together may require additional plenum exits. Rockwell Automation will provide guidance on requirements for additional plenum exits when required.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 75

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Appendix A ArcShield Unit Information

Chimney Information

A chimney can be provided for each unit, and is to be field mounted on top of the unit structure. The purpose of the chimney is to direct the hazardous flames and gases away from the top of the resistant enclosure. The chimney is secured to the top of each unit structure. Refer to Appendix C instructions.

Each ArcShield line-up includes a chimney exhaust section that extends vertically directly above the enclosure.

for chimney installation

Chimney Exhaust Considerations

1. From the outlet of the chimney, there needs to be a minimum distance of

1.7 m (67 inches) from the top of the chimney to the ceiling, and 1 m (39 inches) on each side.

2. No obstructions (eg. Piping) can be in the path of the exhaust within this 2 m (78 inches) height requirement.

Plan the location where the chimney will exhaust. Ensure that:

• There is no access to personnel while equipment is energized.

• Area is free of flammable material or vapors.

• Ensure that adequate space is provided around the chimney exhaust as

outlined in Figure 73

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

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Appendix B

IMPORTANT

ARC FLASH HAZARD

PRESSURE RELIEF EXIT

AREAS TO BE:

- INACCESSIBLE TO PERSONNEL WHILE EQUIPMENT ENERGIZED.

- FREE OF OBST RUCTIONS (REFER TO USER MANUAL).

SEVERE INJURY OR DEATH MAY RESULT.

SORTIE DE L’ÉVENT

RÉGION ÊTRE:

- INACCESSIBLE AUX PERSONNEL PENDANT QUE L’ÉQUIPEMENT EST SOUS TENSION.

- DÉMUNI D’OBSTRUCT IONS (RÉFÉRER AU MANUEL)

RISQUE DE BLESSURES CORPORELLES GRAVES OU MÊME LA MORT.

DANGER

HAZARD D’ARC ÉLECTRIQUE

ArcShield Plenum Installation Instructions

The following instructions are provided to ensure the proper installation and function of plenum components supplied with ArcShield enclosures. Refer to

Appendix A

attempting to follow these instructions.

for additional information related to ArcShield plenums before

Recommended Torque Values

Plenum Bracing

1/4-20 Thread Fasteners – 7.5 N•m (6 lb•ft) 5/16-18 Thread Fasteners – 14 N•m (11 lb•ft)

Bracing of the plenum must be able to withstand the dynamic forces of the arc fault as well as any other vibration or seismic effects associated with the installation. Most of this force will be in the direction opposite to where the relief vent exits. The amount of bracing will depend on how the plenum is supported at its exit as well as the distance from the end of the cabinets to the exit vent.

• A flange is available for installing hangers to support the plenum weight.

• The plenum extension has holes for mechanical support.

• Weight per unit length of Rockwell supplied plenum = 28 kg/m (19 lb/ft).

• Installer is responsible for ensuring that the plenum extension has

sufficient support to resist the effect of vibrations and seismic effects.

Plan the location where the plenum will exhaust (refer to Appendix A). Equipment in the area of the plenum exhaust will be damaged or destroyed. Mark the plenum exhaust area as a Hazardous Zone (Figure 74

Figure 74 - Plenum Exhaust Label

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Appendix B ArcShield Plenum Installation Instructions

Figure 75 - Description of Plenums and Components

18" wide Plenum

Fastened directly over the 0.5 m (18 in.)

wide cabinet

18" long Extension

Connected to the last Plenum on the

exhaust end of the “line-up”

Screen Cover Plate

Fastened at the opening of the last

component on the exhaust end

26" wide Plenum

Fastened directly over the 0.7 m (26 in.)

wide cabinet

26" long Extension

Connected to the last Plen um on the

exhaust end of the “line-up”

End Cover Plate

Fastened at the opening of the last

Plenum in the “line-up” opposite the

exhaust end to seal Plenum end

36" wide Plenum

Fastened directly over the 0.9 m (36 in.)

wide cabinet

36" long Extension

Connected to the last Plenum on the

exhaust end of the “line-up”

90° Elbow Section

Connected at the exhaust end of the

Plenum (or Extension)

General Plenum Layout for ArcShield Line-up

An example of a general Plenum assembly configuration is shown in Figure 76. Plenums of varying widths are mounted directly over the MV enclosures of the corresponding width. A 0.9 m (36 in.) Exhaust extension assembly is shown mounted on the extreme right side Plenum of the equipment “Line-up” (can alternatively exhaust to the left).

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

Page 87

Figure 76 - ArcShield Line-up

Sealed end

36 in. Exhaust extension

Exhaust end

IMPORTANT

Front Duc t Section

Components

ArcShield Plenum Installation Instructions Appendix B

STEP 1 – Mounting a Single Plenum

Plenum exhaust can be on the left or right hand end of the line up. Pictures and figures in this procedure are shown for a right hand exhaust exit direction. Also shown is an optional vertical (top) direction exhaust extension (see Figure 88

Plenum components not directly mounted to the tops of the MV enclosures, must have additional mounting support. This includes the Extension components and 90° Elbow Sections (refer to STEP 7 – Additional Mounting

Support on page 86).

Before mounting a single Plenum over an MV enclosure, the front duct section must first be removed. This is shown in Figure 77

Figure 77 - Removing Front Duct Section

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 79

Page 88

Appendix B ArcShield Plenum Installation Instructions

Relief vent

Relief fasteners

Corner fasteners

Cabinet Preparation

In preparation for mounting Plenum, remove 1/4-20 fasteners from the Relief vent on the top of the MV enclosure. Leave the (4) corner fasteners in place

Figure 79

Figure 78 - Relief Vent Fasteners (top view) Figure 79 - Relief Vent

(see

The Plenums are designed to fit over the fastener heads at the (4) corners of the Relief vent. The corner fasteners are required to secure the Relief vent during installation.

Plenum Placement on Structure

Once the Plenum has been lifted in place directly over the relief vent (shown in

Figure 80

replaced to attach the Plenum to the top of the enclosure. Use hand tools only.

), all 1/4-20 fasteners, removed in Cabinet Preparation above, are

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

Page 89

Figure 80 - Plenum Placement

Use recommended torque value for 1/4-20 fasteners

TIP

ArcShield Plenum Installation Instructions Appendix B

STEP 2 – Alignment of “Sideby-Side” Plenums

Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place.

Plenums mounted side-by-side must be fastened together through the aligning holes using 5/16-in. supplied hardware (see Figure 81

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 81

Page 90

Appendix B ArcShield Plenum Installation Instructions

IMPORTANT

End Cover Plate

Figure 81 - Aligning “Side-by-Side” Plenums

Any unused holes must be filled with thread forming screws. i.e.: “Lifting Lug holes”.

All Gaps must be sealed and filled with silicone.

STEP 3 – Sequence of Final Assembly

All Plenums in a Line-up must be mounted to the top of each enclosure and to the Plenum directly beside it before the front duct sections are re-attached (see

Figure 77

Figure 82 - Sequence of Final Assembly

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

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ArcShield Plenum Installation Instructions Appendix B

IMPORTANT

TIP

The “End Cover Plate” must be mounted on the closed end of the Line-up at this time during the assembly using 5/16-in. hardware (see Figure 82

Left side).

STEP 4 – Closing the Front of the Plenum Sections

After the first stage of the Plenum assemblies have been mounted, the Plenums can then be “closed-up” by replacing the front duct sections as shown in

Figure 83

Figure 83 - Plenum Sections

STEP 5 – Extension and Elbow Assembly

Do not re-install the front duct section of the last Plenum on the exhaust side of the Line-up at this time (refer to STEP 6 – Mounting Extension/Elbow to

Plenum “Line-up” on page 84 for more information).

Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place.

The 36" Extension components and 90° Elbow Section are to be attached using 5/16-in. hardware in the following sequence:

Step 5A – See Figure 84

Step 5B – See Figure 85

Step 5C – See Figure 86

The Screen Cover Plate is attached in Figure 85.

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Appendix B ArcShield Plenum Installation Instructions

36 in. extensions

2-piece 90°

elbow section

Screen Cover Plate

illustrates what the

Screen Cover Plate

36 in. extensions

TIP

Figure 84 - 90° Elbow Section Assembly, Step 5A (Front View) Figure 85 - 90° Elbow Section Assembly, Step 5B (Front View)

Figure 86 - 90° Elbow Section Assembly, Step 5C (Front View)

Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place.

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

As referred to in STEP 4 – Closing the Front of the Plenum Sections on page 83, the last Plenum at the exhaust side of the line-up has the front duct section removed. This allows access to fastener holes in order to mount the Extension/ Elbow components (see Figure 87

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

Page 93

ArcShield Plenum Installation Instructions Appendix B

Last Plenum in line-up remains open for installation of extension assembly

Figure 87 - Optional Extension/Elbow with Vertical Extension (Right side exit)

After the Extension/Elbow assembly is attached through the fastener holes on the inside flange of the Plenum, the front duct section can be replaced and fastened through the holes on the outside flanges.

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Appendix B ArcShield Plenum Installation Instructions

TIP

STEP 7 – Additional Mounting Support

The Extension/Elbow Assembly must have additional mounting support.

90° Elbow Section: Approximate weight 64 kg (142 lbs)

36" Extension Assembly: Approximate weight 51 kg (112 lbs)

Figure 88

shows an example of how the Extension/Elbow Sections can be supported by suspension from a high ceiling. Points A, B & C show where chains or high tension cables may be connected.

Figure 88 - Completed Assembly for optional vertical exit Plenum (Right hand exit)

During an arc fault, the plenum will be subjected to a brief high pressure shock wave. The Extension/Elbow assembly may experience dynamic loading. It is important to account for dynamic loading when selecting supporting means and materials.

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

Page 95

Appendix C

ARC FLASH HAZARD

PRESSURE RELIEF EXIT

AREAS TO BE:

- INACCESSIBLE TO PERSONNEL WHILE EQUIPMENT ENERGIZED.

- FREE OF OBSTRUCTIONS (REFER TO USER MANUAL).

SEVERE INJURY OR DEATH MAY RESULT.

SORTIE DE L’ÉVENT

RÉGION ÊTRE:

- INACCESSIBLE AUX PERSONNEL PENDANT QUE L’ÉQUIPEMENT EST SOUS TENSION.

- DÉMUNI D’OBSTRUCTIONS (RÉFÉRER AU MANUEL)

RISQUE DE BLESSURES CORPORELLES GRAVES OU MÊME LA MORT.

DANGER

HAZARD D’ARC ÉLECTRIQUE

ArcShield Chimney Installation Instructions

The following instructions are provided to ensure the proper installation and function of chimney supplied with ArcShield enclosures. Refer to Appendix A for additional information related to ArcShield chimney before attempting to follow these instructions.

Recommended Torque Values

1/4 -20 Thread Fasteners – 7.5 N•m (6 lb•ft) 5/16 -18 Thread Fasteners – 14 N•m (11 lb•ft)

Figure 89 - Chimney Exhaust Label

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Page 96

Appendix C ArcShield Chimney Installation Instructions

General Plenum Layout for ArcShield Line-up

An example of a general chimney assembly configuration is shown in Figure 90. Chimneys of varying widths are mounted directly over the MV enclosures of the corresponding width.

Figure 90 - ArcShield Line-up with Arc Chimneys

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

Page 97

Cabinet Preparation

Relief vent

Relief fasteners

Corner fasteners

In preparation for mounting a chimney, remove 1/4-20 fasteners from the Relief vent on the top of the MV enclosure. Leave the (4) corner fasteners in place

Figure 79 on page 80

Figure 91 - Relief Vent Fasteners (top view) Figure 92 - Relief Vent

ArcShield Chimney Installation Instructions Appendix C

(see

The chimneys are designed to fit over the fastener heads at the (4) corners of the Relief vent. The corner fasteners are required to secure the Relief vent during installation.

Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 89

Page 98

Appendix C ArcShield Chimney Installation Instructions

Use recommended torque value for 1/4-20 fasteners

TIP

Chimney Placement on Structure

Once the Chimney has been lifted in place directly over the relief vent (shown in

Figure 80 on page 81 page 89, are replaced to attach the chimney to the top of the enclosure.

Figure 93 - Chimney Placement

), all 1/4-20 fasteners, removed in Cabinet Preparation on

Use silicone caulking generously to fill any air gaps once the chimney has been securely mounted in place.

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

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Page 100

Rockwell Automation Support

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools. You can also visit our Knowledgebase at http://www.rockwellautomation.com/knowledgebase information, support chat and forums, software updates, and to sign up for product notification updates.

, you can find technical manuals, technical and application notes, sample

for FAQs, technical

For an additional level of technical phone support for installation, configuration, and troubleshooting, we offer

Te c h C o n n e c t representative, or visit http://www.rockwellautomation.com/support/

support programs. For more information, contact your local distributor or Rockwell Automation

Installation Assistance

If you experience a problem within the first 24 hours of installation, review the information that is contained in this manual. You can contact Customer Support for initial help in getting your product up and running.

United States or Canada 1.440.646.3434

Outside United States or Canada Use the Wor ldwi de Lo cato r at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local

Rockwell Automation representative.

New Product Satisfaction Return

Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

United States Contact your distributor. You must provide a Customer Support case number (call the phone number above to obtain one) to your

Outside United States Please contact your local Rockwell Automation representative for the return procedure.

distributor to complete the return process.

Documentation Feedback

Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete this form, publication RA-DU002

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

Publication 1500-UM055G-EN-P - May 2013

, available at http://www.rockwellautomation.com/literature/.

Rockwell Automation 1512B MV User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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

Summary of Changes

Table of Contents

Document Scope

Starter Identification

Prepared Space

Series Number

Motor Data

Recommended Torque Values

Starter Features

Door Opening Procedure

Opening the Low Voltage Doors

Opening the Medium Voltage Doors

Anchoring

Joining Sections

Access to the Power Bus

Rear Access

Side Access

Front Access– Access to Power Bus

Front Access – Bottom Exiting Load Cables

Load Cable Connections

Top Exiting Load Cables

Bottom Exiting Load Cables

Door Opening Procedure

Opening the Low Voltage Doors

Opening the Medium Voltage Doors

Anchoring

Joining Sections

Access to the Power Bus

Rear Access

Side Access

Front Access – Access to Power Bus

Front Access – Bottom Exiting Load Cables

Load Cable Connections

Top Exiting Load Cables

Bottom Exiting Load Cables

Bus Splicing

Power Bus

Insulated Power Bus Splicing

Ground Bus

Incoming Line Cable Connections

Installation of Current Transformer Barrier

Hi-Pot and Megger Test

Start-up Procedure

Contactor Inspection

Preliminary Checks

Testing Contactor Operation

Typical Wiring Diagrams

Tool Requirements

Recommended Torque Values

Door Interlock Circumvention

Power Lock-out Procedure

Fuse Removal and Replacement

Bolt-on Fuse Removal/Installation

Clip-on Fuse Removal/Installation

Contactor Maintenance

Removing the Contactor

Contactor Interlock Rod Adjustment

To Reduce the Gap Distance

To Increase the Gap Distance

Isolation Switch Mechanism Inspection and Lubrication

Isolation Blade Switch Adjustment

Isolation Switch Mechanism Grounding Adjustment

Auxiliary Contacts Inspection and Replacement

Isolation Switch Auxiliary Contacts

Adjusting the Normally Open (ISa) Contacts

Adjusting the Normally Closed (ISb) Contacts

Adjusting the Change-of-State Point

Emergency Circumvention Procedure for Power Cell Entry

Installing Z-clip with Isolation Switch Handle in the OFF Position

Installing Z-clip with Isolation Switch Handle in the ON Position

Bulletin 1512 and 1512BT Units Parts List

Overview

ArcShield Design

Exhaust Systems: Chimney or Plenum Option

Plenum Information