Rockwell Automation 1512B MV User Manual

0 (0)

User Manual

Medium Voltage Controllers, 200/400A Two-High Cabinet,

Standard and Arc-Resistant Enclosure

Publication 1500-UM055G-EN-P

Important User Information

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 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some 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.

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).

IMPORTANT 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.

Summary of Changes

New and Updated

Information

This manual contains new and updated information.

This table contains the changes made to this revision.

Topic	Page

Converted the document to FrameMaker	Throughout

Inserted Arc Flash warning	ii

Added Isolation Blade Switch Adjustment section	59

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

iii

Summary of Changes

Notes:

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

		Table of Contents
	Chapter 1
General Information	Document Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . . 1
	Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 2
	Prepared Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 3
	Series Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 3
	Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 3
	Starter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 3
	Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . . 3
	Chapter 2
Installation – Standard Enclosure	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-ResistantEnclosure (ArcShield)

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
Common Installation	Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	35
	Insulated Power Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	36
	Ground Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	37

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

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	Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
	ArcShield Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	71
	Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . .	72
	Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	72
	Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	73
	Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	75

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

Table of Contents

ArcShield Plenum Installation

Instructions

ArcShield Chimney Installation

Instructions

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

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

Appendix B

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

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Table of Contents

Notes:

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

Chapter 1

General Information

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(1)

IMPORTANT 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, Appendix B and Appendix C.

ATTENTION: Users must refer to the information in Appendix A, Appendix B and Appendix C to correctly install and maintain ArcShield arc resistant units. Failure to do so may negate the arc resistant benefits provided by ArcShield, exposing personnel to risk of serious injury or death.

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

Chapter 1 General Information

Starter Identification

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

Figure 1 - Typical Structure Nameplate

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

Figure 2 - Typical Unit Nameplate

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

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

General Information	Chapter 1

Prepared Space

Recommended Torque

Values

When ordering a starter kit to complete a prepared space(2), provide the following information to ensure the proper components are supplied.

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 series number is also available from the dimension drawings for the starter.

Motor Data

Provide the following motor data:

•Locked rotor current

•Full load current

•Maximum locked rotor time

•Acceleration time

•Motor service factor

•Motor horsepower

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

Chapter 1 General Information

Notes:

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

Chapter 2

Installation – Standard Enclosure

IMPORTANT For information on the installation site preparation, see General Handling

Procedures for MV Products, Publication MV-QS050_-EN-P.

ATTENTION: 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 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

1/4-turn fasteners for

Upper Low Voltage Door

1/4-turn fasteners for

Lower Low Voltage Door

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

Chapter 2 Installation – Standard Enclosure

Opening the Medium Voltage Doors

ATTENTION: 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 on page 47 of Chapter 5) before attempting to open the swing-out low voltage panel. Failure to do so may result in severe burns, injury or death.

ATTENTION: 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

Isolation

Switch

Handles

. .

LV MV

Door Locking Bolts for Upper Medium Voltage Door

LV MV

Door Locking Bolts for Upper Medium Voltage Door

IMPORTANT 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 to Access to the Power Bus on page 9 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.

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

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

Anchoring

Installation – Standard Enclosure

Chapter 2

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

5.Reverse the procedure to close the door.

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

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

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

IMPORTANT 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

Chapter 2 Installation – Standard Enclosure

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.

TIP	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 on page 7).

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.

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

0.219 Pilot

Holes (5x)

0.281 Pilot

Holes (5x)

Fr o nt

Installation – Standard Enclosure

Chapter 2

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 on page 7).

Figure 6 - Joining Sections

Side Bus

Access Cover

0.281 Pilot

Holes (5x)

0.219 Pilot

Holes (3x)

t n ro F

Access to the Power Bus

ATTENTION: This procedure requires contact with medium voltage components. To avoid shock hazards, lock out incoming power before working on the equipment (refer to Power Lock-out Procedure on page 47 of Chapter 5). Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death.

Rear Access

1.Remove the hardware securing the center rear bus access cover (see Figure 7).

2.Remove the center rear bus access cover.

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

Chapter 2 Installation – Standard Enclosure

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

Center Rear Bus

Access Cover

Side Bus

Access Cover

Figure 8 - Bus Bars from Back Access

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

Installation – Standard Enclosure	Chapter 2

Side Access

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

1.Remove the hardware from the appropriate side bus access cover (see Figure 7).

2.Remove the side bus access cover.

3.Once the side bus access cover is removed, you will see the three power bus bars and the ground bus (see Figure 9).

Figure 9 - Side Bus Access Cover Removed

Front Access– Access to Power Bus

ATTENTION: 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

Chapter 2 Installation – Standard Enclosure

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

Remove self-tapping screws from center vertical channel

Control Wiring Harness

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Installation – Standard Enclosure	Chapter 2

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

Figure 11 - Removing Glass-polyester Barrier

Current Transformers

Remove self-tapping screws from barrier assembly

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

Chapter 2 Installation – Standard Enclosure

Current Transformers

CT Mounting Plate

Loosen Retaining Screws

Cable Duct Boot

Remove Retaining Screws

Cable Duct Barrier

Remove four selftapping screws from each Bus Access Cover

Figure 12 - Removing Cable Duct Boot and Barrier

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

Figure 13 - Removing Bus Access Covers

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Installation – Standard Enclosure	Chapter 2

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 on 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)

Trailer Fuse Block

Mounting Bolts

Contactor Bus Bars

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

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

16.To access the right side of the power bus, remove the self-tapping screws from the lower glass-polyester bus access cover and remove the cover (see Figure 15).

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Chapter 2 Installation – Standard Enclosure

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

Remove self-tapping screws

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.

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 Top Exiting Load 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).

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Installation – Standard Enclosure	Chapter 2

Figure 16 - Bottom Cable Exit Configuration

Cable Duct Barrier

Cable Duct Boot

Load Cable Connections

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

IMPORTANT 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

Chapter 2 Installation – Standard Enclosure

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

(LV panels removed for clarity)

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

4.Remove the appropriate load cable conduit openings in the top or bottom of the cabinet (see Figure 18 or Figure 19).

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

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Installation – Standard Enclosure	Chapter 2

Top of Cabinet

Load cable Conduit Opening for cables from top power cell

Load Cable Conduit opening for cables from bottom power cell

Ground Lug

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

Chapter 2 Installation – Standard Enclosure

Bottom Exiting Load Cables

TIP	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). Run the cables behind the current transformer mounting plate and into the top power cell.

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

Load Cable Conduit Opening for cables from top power cell

Load Cable Conduit Opening for cables from bottom power cell

Bottom of Cabinet

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.

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Chapter 3

Installation – Arc-Resistant Enclosure (ArcShield)

This installation section contains information on arc resistant styles of enclosures, referred to in this manual as “ArcShield”.

IMPORTANT For information on the installation site preparation, see Publication

MV-QS050_-EN-P.

ATTENTION: 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

Chimney

Upper Low Voltage
Door handle	LV	MV
	LV	MV

Lower Low Voltage

Door handle

Plenum

Upper Low Voltage Door handle

Lower Low Voltage Door handle

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

Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield)

Opening the Medium Voltage Doors

Medium voltage doors are identified as MV in Figure 21.

Figure 21 - Access to Medium Voltage Compartments

Chimney
Upper Low Voltage
Door handle
LV	MV
Lower Low Voltage
Door handle

Plenum

Upper Low Voltage Door handle

Lower Low Voltage Door handle

IMPORTANT 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 to Access 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.

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