Rockwell Automation 2500 User Manual

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Installation Instructions

CENTERLINE 2500 Low Voltage Motor Control Centers

Catalog Numbers 2500

Important User Information

IMPORTANT

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

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.

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

Labels may also be on or inside the equipment to provide specific precautions.

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).

Allen-Bradley, ArcShield, CENTERLINE, E1 Plus, E3 Plus, E300, IntelliCENTE R, POINT I/O, PowerFlex, Rockwell Automation, Rockwell Software, RSLinx, RSLogix, RSNetworx, SMC, Stratix 5700, and Stratix 6000 are trademarks of Rockwell Automation, Inc.

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

Summary of Changes

This manual contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.

New and Updated Information

This table contains the changes made to this revision.

Top ic Pag e

Corrected the kiloamp rating shown for protection 11

Added E300™ relay as an available electronic overload relay 12

Added double-front depth and footnote to Table 3 14

Added dimension and footnote to Figure 2 14

Added note to Figure 5 16

Revised information in Technical Data table 17

Updated nameplate and unit identification labels in Figures 6, 7, and 8 18, 19

Updated humidity information in Environment section 24

Updated torque numbers for horizontal power bus connections 43

Updated environment information in Suggested Maintenance Guidelines table 74

Updated Stratix model number to 5700 in Figure 25 79

Updated artwork to show new large rotary-operator handle Throughout publication

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 3

Summary of Changes

Notes:

4 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Preface

System Overview

Receiving, Handling, and Storage

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Purchased Components and Additional Instruction Sheets . . . . . . . . . . . 9

Chapter 1

ArcShield™ Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

IntelliCENTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

IntelliCENTER Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

IntelliCENTER Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Typical Column Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Nameplate Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Motor Control Center Sequence Numbering. . . . . . . . . . . . . . . . . . . . . . . 19

ArcShield Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Chapter 2

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Install Columns

Chapter 3

Location Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

ArcShield Clearance Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Remove Packing Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Locating Bus Splice Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Removing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Positioning the Motor Control Center . . . . . . . . . . . . . . . . . . . . . . . . . 28

Securing a Motor Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Securing Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Sealing IP54 Enclosures Before Securing . . . . . . . . . . . . . . . . . . . . . . . . 30

Securing Single-front, One-column-wide Shipping Blocks. . . . . . . . 31

Securing Single-front, Two-column-wide Shipping Blocks . . . . . . . 32

Securing Double-front, One-column-wide Shipping Blocks . . . . . . 33

Securing Multiple-column Shipping Blocks . . . . . . . . . . . . . . . . . . . . . 34

Joining Columns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Seismic Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Splicing the Power Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Accessing the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Splicing Power Bus, 800…4000 A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Splicing the Protective Earth (PE) Conductor . . . . . . . . . . . . . . . . . . 42

Control and Network Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 5

Table of Contents

Install Cable

Door Latches, Operator Handles, and Unit Interlocks

Chapter 4

Install ArcShield Protection After Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Lugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Incoming Line Lug Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Main Disconnecting Means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Cable Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Secure Load Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Chapter 5

Height Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Door Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Quarter-turn Door Latches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

ArcShield Door Latches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Small Rotary-operator Handles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Opening the Unit Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Closing the Unit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Opening the Unit Door in the ON/I Position . . . . . . . . . . . . . . . . . . 52

Operator Handles for Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 52

Locking Units in the OFF/O Position. . . . . . . . . . . . . . . . . . . . . . . . . . 53

Locking Units in the ON/I Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Large Rotary-operator Handles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Opening the Unit Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Closing the Unit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Opening the Unit Door in the ON/I Position . . . . . . . . . . . . . . . . . . 55

Operator Handles for Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 56

Locking Units in the OFF/O Position. . . . . . . . . . . . . . . . . . . . . . . . . . 56

Locking Units in the ON/I Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Unit Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Chapter 6

Install and Remove Units

Unit Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Withdrawable Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Operating Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Selecting an Operating Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Safety Guidelines for Installing and Removing Withdrawable Units . . 64

Inserting a Withdrawable Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Removing a Withdrawable Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Removing the Unit Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Multiple Module Unit Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

One Module Unit Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Chapter 7

Commissioning

6 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Pre-Commissioning Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Commissioning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Maintenance

IntelliCENTER Options

Table of Contents

Chapter 8

Establish a Maintenance Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Suggested Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Chapter 9

EtherNet/IP Motor Control Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Connection Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Cable Length Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Cable Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Adding a MCC Unit to an EtherNet/IP System . . . . . . . . . . . . . . . . 80

Ethernet Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Connecting Power Supplies–Remote or in the MCC Lineup. . . . . 81

Network Power Supply and the Protective Earth Circuit. . . . . . . . . 81

Connecting Two Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

System Design Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

EtherNet/IP Software Installation Checklist. . . . . . . . . . . . . . . . . . . . 83

DeviceNet Motor Control Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Preparing a DeviceNet System for Commission . . . . . . . . . . . . . . . . . 83

Terminating Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Joining DeviceNet Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

DeviceNet Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Connecting Power Supplies–Remote or in the MCC Line-Up . . . 87

Network Power Supply and the Protective Earth Circuit. . . . . . . . . 87

Connecting Two Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Electronic Data Sheets (EDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Where to Find EDS Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Installing EDS Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Finding EDS Files for Other Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Uploading EDS Files from the Device . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Worksheets

Glossary

Index

Appendix A

Sample MCC Layout Worksheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 7

Table of Contents

Notes:

8 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Preface

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

CENTERLINE 2500 Receiving Handling and Storage Instructions, publication 2500-IN002

CENTERLINE 2500 EtherNet/IP Motor Control Centers, publication 2500-TD003

EtherNet/IP Network Configuration User Manual, publication ENET-UM001

CENTERLINE 2500 DeviceNet™ Motor Control Centers, publication 2500-TD002

DeviceNet Media Design User Manual, publication

DNET-UM072

IntelliCENTER Software User Guide, publication MCC-UM001 Provides information about installing and using

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1

Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls, publication SGI-1.1

Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and

Provides information about receiving, handling, and storage of CENTERLINE® 2500 MCCs.

Provides information about EtherNet/IP MCCs.

Provides information to design, install, and troubleshoot an EtherNet/IP network system.

Provides information about DeviceNet MCCs.

Provides information to design, install, and troubleshoot a DeviceNet cable system.

IntelliCENTER® software on CENTERLINE MCCs.

Provides general guidelines for installing a Rockwell Automation® industrial system.

Provides general guidelines for installing and maintaining solid state control components.

other certification details.

You can view or download publications at http://www.rockwellautomation.com/

literature/.

To order paper copies of technical documentation, contact your local

Allen-Bradley distributor or Rockwell Automation sales representative.

Purchased Components and Additional Instruction Sheets

Manuals and data sheets for specific components inside the motor control center (for example, transformers, metering devices, electronic overloads, PLCs, soft starters, and drives) are shipped inside the motor control center. These manuals and data sheets must be read and understood before installing and operating the motor control center. Keep these manuals and other documentation for future reference.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 9

Preface

Notes:

10 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Chapter 1

System Overview

CENTERLINE 2500 Motor Control Centers (MCCs) are designed for applications that must comply with international standards and practices for low voltage motor control centers. The CENTERLINE 2500 MCC is ideal for tough, demanding industrial applications where uptime and ease of maintenance is required.

The time-proven CENTERLINE power bus structure distributes line power throughout the MCC via an isolated bus work structure. Standard, center-fed, 300 A rated vertical bus supplies power to the individual units above and below the horizontal bus for an effective 600 A capacity and virtually unrestricted unit arrangement. An optional 600 A vertical bus provides an effective rating of 1200 A.

ArcShield Rating

The CENTERLINE MCC is also available with an ArcShield™ rating. The ArcShield rating includes arc-resistant features for enhanced protection in the event of internal arcing faults.

In addition to standard safety features of the CENTERLINE 2500 MCC, the ArcShield option provides the following:

• Spring latches

• Reinforced structure

• Pressure relief vent system through the top of the enclosure

• Protection up 300 ms at 480V/65 kA

Table 1 - Conformity Ratings for CENTERLINE 2500 MCC with ArcShield

Value Description

Ratings:

Ue lp arc tarc lpc arc

Protection Personal protection and assembly protection suitable for limited continued operation; assembly

Requirements IEC/TR 61641, ed. 2.0 2008-1

480V 65 kA 300 ms 65 kA

protection is limited to outgoing units tested for conditional current under arcing conditions.

An ArcShield label is provided on the MCC with information about the accessibility level and arc fault ratings. See Figure 9 on page 20

for an example of

this rating label and its location.

See Figure 4 on page 16

page 50

for ArcShield door latches.

for the location of ArcShield structure protection and

For more information, refer to guidelines addressed in IEC Standard 60364-5-52.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 11

Chapter 1 System Overview

IntelliCENTER Software

CENTERLINE 2500 MCCs with IntelliCENTER software provides you with an integrated hardware, software, and communication solution. It features preconfigured software that provides real-time data, trending, component history, wiring diagrams, user manuals, and spare parts. IntelliCENTER offers plug-and-play setup, troubleshooting, hardware configuration changes without opening enclosure doors, and convenient change tracking. It also provides intelligent diagnostic and predictive failure information.

IntelliCENTER technology improves the intelligence of your MCC by using built-in networking to capture information used for predictive maintenance, process monitoring, and advanced diagnostics.

IntelliCENTER Features

• Built-in networking – EtherNet/IP or DeviceNet – Media protected behind barriers – Access ports in wireways – Topology lets you add and remove devices without interrupting any

other device on the network

• Intelligent motor controls – PowerFlex® drives – SMC™-3 and SMC-Flex soft starters – E300, E1 Plus™, and E3 Plus™ electronic overload relays

• IntelliCENTER software – Distributed IO – POINT I/O™ system/DSA – Virtual MCC – Parameter editor – Status dashboards – Documentation management – Spare parts information

• Factory configuration – IP address network media validation – IP address node configuration – Communication check – Network commissioning

12 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

System Overview Chapter 1

IntelliCENTER Software

IntelliCENTER MCCs can be provided with pre-configured IntelliCENTER software. The software is capable of viewing, managing, and configuring multiple MCC line-ups. The IntelliCENTER software communication driver lets the software be installed and operated on EtherNet/IP or DeviceNet. The IntelliCENTER software can function as a stand alone software package or as an ActiveX control in a human machine interface (HMI).

Structure

CENTERLINE 2500 MCCs offer units with a full complement of AC drives, soft starters, and other devices. Pluggable power connections on the back of the unit plug into the vertical bus. A mechanical interlock helps prevent the unit door from being opened while the main switch is in the ON/I position. An additional mechanical interlock helps prevent the unit from being withdrawn or inserted when the unit main switch is closed. Separate vertical wireways isolate control and network cables from power wiring. Units are available as fixed or fully withdrawable.

Figure 1 - CENTERLINE 2500 MCC

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 13

Chapter 1 System Overview

All measurements are in mm unless otherwise specified.

Table 2 - Column Width

Total Column Width Unit Width Vertical Wireway Width

600

(1)

(1) Only for full-column, frame mount applications.

600 No vertical wireway

700 500 200

800 300

900 400

1000 500

Table 3 - Column Depth

Single-front Double-front

600 1200

800 1600 or 2000

(1)

(1) 800 mm columns can be mounted in a double-front

arrangement on site. A 400 mm air gap is required between 3200 A and 4000 A double-front columns.

Table 4 - Column Height

Dimension Measurement

Total Height 2300

Available Unit Height 1980

Top Horizontal Wireway 170

Bottom Horizontal Wireway 115

External Mounting Channel 35

170

1980

115

600…1000

600 or 800

2300

200…500

(1)

500 or 600

(1)

(1) Vertical wireway dimensions apply only to 500 mm wide units.

Dimensions

CENTERLINE 2500 MCCs are designed in widths between 600 and 1,000 mm. Each column is 2300 mm high and either 600 mm or 800 mm deep. Double-front columns are also available. See the column tables below for additional options.

Unit size is described in terms of modules. Each module is approximately 80 mm high. Columns can accommodate 24 modules of varying unit combinations.

Figure 2 - Typical Column Dimensions

14 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

System Overview Chapter 1

Lifting Angle

Network Wireway

Top Wi rew ay Endplates

Left Side Plate

Center End Closing Plate

Bottom Wireway Endplates

Mounting Channels

Bottom Plates

Bottom Wireway Cover

Right Unit Support and Ver tic al Wir eway Asse mbly

Vertical Wireway Door

Top Wir ewa y Co ver

Top Wi rew ay Pan

Top Wir ewa y Ba rr ier

Top Plate

Optional ArcShield Center End Closi ng Plate Insulator

Horizontal Power Bus

Single Unit Support Pan

Typical Column Construction

Columns are rigid, free-standing structures with heavy-duty external mounting channels continuous for the width of the shipping block. Columns are secured at the installation site by bolting through clearance holes in the mounting channel or by welding.

The standard for internal sheet metal parts is G90 galvanized metal for Series C CENTERLINE 2500 Motor Control Centers.

Figure 3 - Typical Column

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 15

Chapter 1 System Overview

Frame-mounted Brackets

See page 46

for more

information.

Door Latch Brackets

See page 46

for more information.

Pressure Relief Plate

See page 23

for more information.

Detail A

Detail B

Detail C

Detail D

Center End Closing

Plate with Insulator

Only on end-of-lineup

columns.

See Figure 3 on page 15

for more details.

Columns Installed in a Single-front Configuration Columns Installed in a Double-front Configuration

NOTE: A 400 mm air gap is required between 3200 A and 4000 A configurations.

Additional bracing is provided for ArcShield columns.

Figure 4 - ArcShield Column Protection Hardware

Figure 5 - Column Configuration

16 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

System Overview Chapter 1

Technical Data

This table provides the technical specifications for the 2500 MCC.

Standards EN 60204-1:2006 Safety of machinery – electrical equipment of machines; Part 1: General requirements

IEC 61439-1 Ed. 2.0 b:2011 Low-voltage switchgear and controlgear assemblies; Part 1: General rules

EC Directives IEC/TR 61641, ed. 2.0 2008-1 Enclosed low-voltage switchgear and controlgear assemblies – guide for testing under conditions of arcing due

to internal fault

2004/108/EC EMC directive

2006/95/EEC Low voltage directive

Certifications and Markings

ABS ABS Shipboard

http://www.rockwellautomation.com/rockwellautomation/certification/marine.page?

C-Tick http://www.rockwellautomation.com/rockwellautomation/certification/c-tick.page?

CE Conformance Marked http://www.rockwellautomation.com/rockwellautomation/certification/ce/page?#Motor

China Compulsor y Certif icate (CCC) http://www.rockwellautomation.com/rockwellautomation/certification/china.page?#motorcontrol

DEKRA http://www.rockwellautomation.com/rockwellautomation/certification/third.page?

GOST-R http://www.rockwellautomation.com/rockwellautomation/certification/gost/page?#/tab1

IBC 2010 http://www.rockwellautomation.com/rockwellautomation/certification/overview.page?

ICC–ES AC156 http://www.rockwellautomation.com/rockwellautomation/certification/overview.page?

IEEE 344 http://www.rockwellautomation.com/rockwellautomation/certification/overview.page?

KEMA http://w ww.rockwellautomation.com/rockwellautomation/certification/third.page?

SEI/ASCE 7-05 and 7-10 http://www.rockwellautomation.com/rockwellautomation/certification/overview.page?

Rated Voltages Rated operating voltage, U

Rated frequency, f

Rated insulation voltage, U

Rated Currents Continuous current rating, I

Short circuit peak withstand, I

Short time withstand rating, I

Up to 690V, 3-phase

50…60 Hz

1000V, 3-phase

Horizontal bus - up to 4000 A Vertical bus - up to 1200 A per column

Horizontal and vertical buses - up to 210 kA

Horizontal and vertical buses - up to 100 kA for 1 second

(3)

Neutral (N) Full or half-rated

Creepage Distances and Clearances

Rated impulse withstand voltage, U

Material group (overvoltage category) IIIa (175 </= CTI < 400)

imp

6, 8, or 12 kV

Pollution degree 3

Bus Material and Plating

Horizontal power bus Copper (optional tin plating)

Vertical distribution bus Copper with tin plating

Protective earth conductor (PE) Copper (optional tin plating)

Degrees of

IEC 60529 IP20, IP42, or IP54

Protection

Forms of Separation IEC 61439-1 Form 2b, 3b, or 4b

Column Dimensions Height See page 14

Widt h

Depth

Units Module size 80 mm high x 500 mm wide = 1 module

Modules per column, max 24 (23 for high density)

Withdrawable unit sizes 1, 2, 4, 6, 8, 10, 12 modules

Structural Surface Treatments

Interior

G90 galvanized metal

Exterior RAL 7032 Pebble Grey paint or Munsell 6.5 paint (additional colors available by request)

(1)

Environment Storage temperature -25…55 °C

(2)

Operating (ambient) temperature -5…40 °C

with up to 95% non-condensing humidity

Altitude Up to 1000 m without derating: derated after 1000 m

(1) Interior painted surfaces available as custom paint requests. (2) The average temperature over a 24-hour period must not exceed 35 °C. (3) Up to 600 A top and bottom, effective 1200 A per column.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 17

Chapter 1 System Overview

Column Number

Catalog Number/Serial Number

Power Bus Voltage and Current Rating

Enclosure Typ e

Catalog Number/Serial Number Unit Location

Device Type and Rating Voltage Rating

Order Number

TIP

Nameplate Data

In compliance with EN 61439-1, each CENTERLINE 2500 MCC column is supplied with a nameplate on the enclosure or vertical wireway door.

Figure 6 - Column Nameplate

Each unit also has an identification label. On withdrawable units, the unit identification label is on the interior of the bottom plate of the unit. On fixed units, the unit identification label is on the interior right side plate.

Figure 7 - Unit Identification Label

The catalog number or serial number and series letter are required to properly identify the equipment to sales or factory personnel.

18 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

System Overview Chapter 1

IMPORTANT

Identifies Column Sequence Numbering

Motor Control Center Sequence Numbering

CENTERLINE 2500 MCCs are designed so functionality is not affected by the column numbering sequence. However, we recommend that columns be installed in sequential order.

Each CENTERLINE 2500 MCC column nameplate identifies column sequence numbering, for example, MCC column 1 of 1 or 1 of 5.

Figure 8 - Column Nameplates

Columns are numbered to match factory-supplied MCC elevation drawings. Numbering each column helps installers and users easily identify MCC columns and units. If there are questions about column numbering during field installation, inspection, or operation, the following instructions can provide guidance.

Leftmost column must be installed in the proper location for the bus to splice. (Both ends of double-front MCCs must be installed as ends for splicing.)

The most important criteria for additions of columns to existing MCCs is matching the horizontal bus, enclosure type, and network capabilities for the complete MCC line up. The voltage, current rating, short circuit withstand, and IP rating for all columns must be consistent.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 19

Chapter 1 System Overview

Detail D

Detail E

Detail C

Top Vie w

Front View – Frame Mount Front View – Withdrawable

Detail B

Detail A

NOTE: All labels

are external except

for horizontal

locations of “D.”

ArcShield Labels

MCC columns with arc proof assembly have a rating label (Detail E in Figure 9) below the nameplate. There are also labels on other parts that must be in place before operating a MCC with ArcShield; see Figure 9

CENTERLINE 2500 MCCs with ArcShield have a back-corner baffle at the end of each lineup and insulation on the center side closing-plate at the end of the lineup; see Figure 4 on page 16

for more details. They also have external vertical

support angles at each end of the lineup.

Figure 9 - ArcShield Label Locations

20 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Chapter 2

Receiving, Handling, and Storage

Refer to Receiving, Handling and Storing CENTERLINE 2500 Motor Control Centers Instructions, publication 2500-IN002 publication is shipped with each MCC, attached to the outside of the MCC within the layer of clear poly wrap.

ATT EN TI ON : To avoid personal injury or structural damage, never attempt to lift or move the motor control center by any means other than the methods outlined in the Receiving, Handling and Storing CENTERLINE 2500 Motor Control Centers Instructions, publication 2500-IN002 front heavy.

, for additional instructions. This

. Motor control centers are top and

Receiving

CENTERLINE 2500 MCCs are shipped upright as one or two column shipping blocks or two or four double front column shipping blocks. Each CENTERLINE 2500 MCC shipping block is provided with a lifting angle. Each column in a shipping block is bolted to the shipping skid with removable shipping angles and covered with clear plastic wrap. Protection is for upright shipping and is not waterproof or watertight. Equipment that extends from the structures is also protected.

Heavy duty/export packaging is similar to standard packaging, but uses a poly wrap suitable for occasional water-spray. In addition, wood framing and sheeting surround the columns. Heavy duty/export packaging is not watertight, waterproof, or intended for long-term storage.

Upon delivery of the MCC, refer to the packing slip shipped with your MCC for sizes and exact shipping weights, as well as the shipment for lost or damaged items. If lost or damaged items are detected, refer to the steps described in publication 2500-IN002

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 21

Chapter 2 Receiving, Handling, and Storage

Handling

Storage

The following are acceptable methods of handling MCC columns within the receiving facility. These methods are described in publication 2500-IN002

• Use of a forklift

• Overhead lifting (crane or hoist)

• Sling lifting

MCC columns must be handled in the upright vertical position. Failure to comply with this method can lead to busbar, unit, and enclosure damage.

The MCC must remain bolted to the shipping skid until delivered to its final installation area.

ATT EN TI ON : MCCs are top and front heavy. To avoid personal injury or structural damage, never attempt to lift or move the MCC by any means other than the methods outlined in Receiving, Handling and Storing Motor Control Centers, publication 2100-IN040

CENTERLINE 2500 MCCs, units and related equipment must be stored in a clean, dry environment with ambient temperatures ranging from -25…55 °C (-13…131 °F). For short periods, not exceeding 24 hours, temperatures of up to 70 °C (158 °F) are allowed. Take care to help prevent damage from exposure to excessive humidity, vibration, and shock.

Store MCCs with the plastic covering in place to prevent dirt and dust from entering the structure. Check periodically for condensation build up and, if necessary, install space heaters. for ordering information.

Contact your Rockwell Automation representative

22 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns

300 mm Minimum Clearance

ArcShield pressure relief plate on top of column.

Chapter 3

Location Planning

When planning the location for your CENTERLINE 2500 MCC, consider:

• Cable entry and exit points

• Busways

• Overall height of installation area

• Alignment with other equipment

• Future needs

• Environment

The area must be level and the environment must be compatible with the degree of protection provided by the enclosure.

ArcShield Clearance Space

You need a minimum 300 mm of clearance space above the MCC. This space is needed to vent the pressure relief plates in case of an arc flash.

ATTENTION: Do not step on pressure relief plate. Stepping on plate could cause it to not work properly during arc flash.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 23

Chapter 3 Install Columns

Environment

CENTERLINE 2500 MCCs are designed to operate under the service conditions described in IEC 61439-1. Be aware that variations in temperature and relative humidity could potentially cause occasional condensation.

Temperature

When operating an MCC, ambient air temperature must remain in the range of

-5…40 °C. The average temperature over a 24-hour period must not exceed 35 °C.

Humidity

Non-condensing humidity is permissible up to 95% at the maximum temperature of 40 °C, with the average temperature not exceeding

Altitude

The CENTERLINE 2500 MCC is designed to operate at installation sites at altitudes up to 1000 m above sea level without derating. If the altitude at your installation site exceeds 1000 m above sea level, contact your Rockwell Automation representative for derating information.

35 °C over a 24-hour period

Pollution Degree

CENTERLINE 2500 MCCs are designed for use in a pollution degree 3 environment. IEC 61439-1 defines pollution degree 3 as, “conductive pollution occurs or dry, non-conductive pollution occurs that become conductive due to condensation.”

24 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

Shipping Angle (4 places)

Packing Box Brackets (4 places)

Detail A

Detail B

Remove Packing Materials

When the MCC has been delivered to the site of installation, remove the packaging material. Save any manuals and data sheets for future reference.

ATT EN TI ON : To avoid personal injury, use caution when the motor control center is not secured. Motor control centers are top and front heavy.

1. Remove the packing box around the horizontal bus if present and remove

the four brackets as shown (Detail A).

2. Remove the bolts securing each shipping angle (Detail B) from the

shipping skid.

ATTENTION: Once the bolts are removed from the shipping angles, the MCC is no longer secured on the skid.

3. Remove the shipping angles from the MCC.

You can now remove the MCC from the shipping skid.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 25

Chapter 3 Install Columns

Locating Bus Splice Kits

Power bus splice kits, if required, are within a wireway or blank unit space. A fluorescent pink, removable label (on the outside of the column) designates the location. PE splice kits are in the bottom horizontal wireway, fastened to the horizontal PE conductor.

Locate the splice kits and set aside for later use.

Figure 10 - Splice Kit Label

26 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

IMPORTANT

Top End

Closing Plates

Horizontal

Wireway Covers

Center End Closing Plate

Insulator (optional)

Bottom End

Closing Plates

Center End

Closing Plates

Horizontal

Wirew ay Covers

Removing the Covers

Follow these procedures for removing the covers on the MCC.

1. Remove the top and bottom horizontal wireway covers from the MCC.

2. If present, remove the top, bottom, and center end closing plates, on the

sides of the two columns that are to be joined.

3. If ArcShield is present, remove the center end closing plate insulators.

When planning MCC cable routing, consider cable replacement in your plans.

For more information, refer to Chapter

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 27

Chapter 3 Install Columns

TIP

IMPORTANT

Positioning the Motor Control Center

Follow these procedures for positioning your MCC.

1. Documentation packages shipped with assembled MCCs include an MCC elevation drawing with a floor plan layout. Locate and use this floor plan layout for positioning your MCC columns.

2. Identify the leftmost column.

The horizontal power bus does not extend past the leftmost MCC column. For sequential columns, the horizontal power bus extends past the MCC.

3. Position the MCC in the location where it is to be installed.

The floor surface must be level.

4. Depending on the installation site, begin with the leftmost or right-most column and install one shipping block at a time.

Refer to Receiving, Handling and Storing CENTERLINE 2500 Motor Control Centers Instructions, publication 2500-IN002 guidelines.

28 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

, for handling

Install Columns Chapter 3

TIP

Mounting holes (2) 18 mm dia.

Securing a Motor Control Center

Documentation packages shipped with assembled MCCs include an MCC elevation drawing showing an MCC floor plan layout. To secure a column to the foundation, refer to the provided floor plan layout and the following procedures.

Refer to Chapter

4 for cable and conduit routing instructions.

Securing Methods

MCC columns or shipping blocks can be bolted or welded to a foundation. Two mounting channels on the bottom of each MCC column are used for either securing method.

Weld Down Method

See Figure 13 on page 35 for welding a MCC column or shipping block to a foundation.

Bolt Down Method

The two mounting channels allow up to four steel M12 bolts (minimum Property Class 8.8) for each MCC column. We recommend that these bolts be pre-located and embedded in the foundation before installing each MCC column. See page 31

through page 33 for mounting bolt locations.

Figure 11 - Mounting Channel Dimensions and Bolt Locations

All dimensions are mm.

MCC Column Width A B

600 597 46 1

700 697 56 1

800 797 66 1

900 897 76 1

1000 997 861

Mounting channel is not flush with the sides of the MCC column.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 29

Chapter 3 Install Columns

TIP

3 mm wide continuous bead of caulking sealer around outside edge of the sideplate being joined.

Do not allow ‘skin’ to form on caulking before joining the sections.

Sealing IP54 Enclosures Before Securing

The following steps do not apply to IP20 or IP42 enclosures.

1. Remove the tube of caulking (mastic) sealer from the splice kit and read the application directions on the tube.

2. Cut the nozzle at the first notch, 3 mm from the end.

3. Apply a continuous bead of caulking, 3 mm wide, around the outside edge

of the sideplate of the fixed motor control center.

4. Slide the columns together.

Verify the cabinets are level and joining holes are aligned.

5. If lifting angles are removed from IP54 enclosures, you must seal the lifting angle bolt holes with the caulking sealer.

30 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

IMPORTANT

600…1000

460…860

542…942

512…712

600…800

438…638

FRONT

REAR

Dimensions are in mm.

Diagram shows top view of 600 and 800 mm column depths.

234

Protective earth (PE) conductor

Securing Single-front, One-column-wide Shipping Blocks

The following instructions are for bolting down the MCC. See Figure 13 on

page 35 for weld down requirements.

Verify there is adequate clearance on the sides of columns to access the rear mounting bolt locations.

Use steel M12 bolts (minimum Property Class 8.8) to secure columns to the foundation.

1. Remove the bottom wireway cover to locate the front mounting channel. See Figure 3 on page 15

2. Secure the front of the MCC to the foundation with the mounting dimensions below and the mounting channel requirements on page 29

3. Replace the bottom wireway cover.

4. Remove the bottom wireway endplate near the back of the unit to locate

the rear mounting channel. See Figure 3 on page 15

for cover location.

for endplate location.

5. Secure the rear of the MCC to the foundation with the mounting dimensions below and the mounting channel requirements on page 29

6. Replace the bottom wireway endplate.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 31

Chapter 3 Install Columns

IMPORTANT

1200…2000

542…942

234

460…860

512…712

600…800

438…638

Protective earth (PE) conductor

FRONT

REAR

542…942

First Column

= Mounting hole location not required.

Dimensions are in mm.

Diagram shows top view of 600 and 800 mm column depths.

Securing Single-front, Two-column-wide Shipping Blocks

The following instructions are for bolting down the MCC. See Figure 13 on

page 35 for weld down requirements.

Verify there is adequate clearance on the exposed sides of columns to access the rear mounting bolt locations.

Use steel M12 bolts (minimum Property Class 8.8) to secure columns to the foundation. Not all bolt locations are used.

1. Remove the bottom wireway cover to locate the front mounting channel. See Figure 3 on page 15

2. Secure the front of the MCC to the foundation with the mounting dimensions below and the mounting channel requirements on page 29

3. Replace the bottom wireway cover.

4. Remove the bottom wireway endplate near the back of the unit to locate

the rear mounting channel. See Figure 3 on page 15

for cover location.

for endplate location.

5. Secure the rear of the MCC to the foundation with the mounting dimensions below and the mounting channel requirements on page 29

6. Replace the bottom wireway endplate.

32 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

IMPORTANT

600…1000

460…860

234

542…942

1196

438…638

234

FRONT OF UNIT 2

FRONT OF UNIT 1

Protective Earth (PE) Conductor

Dimensions are in mm.

Diagram shows top view of 600 mm column depths.

158

= Mounting hole location not required.

Securing Double-front, One-column-wide Shipping Blocks

The following instructions are for bolting down the MCC. See Figure 13 on

page 35 for weld down requirements.

Use steel M12 bolts (minimum Property Class 8.8) to secure columns to the foundation. Not all bolt locations are used.

1. Remove the bottom wireway cover to locate the front mounting channel. See Figure 3 on page 15

2. Secure the front of the MCC to the foundation according to the dimensions below and the mounting channel requirements on page 29

3. Replace the bottom wireway cover.

4. Repeat steps 1 through 3 for the other side of the double-front shipping

block.

for cover location.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 33

Chapter 3 Install Columns

IMPORTANT

Front

First Column Last ColumnSecond Column

Installation sequence, left to right.

Installation sequence, right to left.

First ColumnLast Column

Additional Columns

Second ColumnAdditional Column

Front

ATTENTION: The figure above shows which bolts are required for multiplecolumn shipping blocks. Drawings with specific dimensions are supplied with each multiple-column shipping block.

= Mounting hole locations not required.

Top Vie w

Top View

Securing Multiple-column Shipping Blocks

The following figures are for bolting down a multiple-column shipping block. See Figure 14 on page 36

Verify there is adequate clearance on the exposed sides of columns to access the rear mounting bolt locations.

Use steel M12 bolts (minimum Property Class 8.8) to secure columns to the foundation. Not all bolt locations are used.

Figure 12 - Bolt-down Requirements for Single-front, Multiple-column-wide Shipping Blocks

for weld down requirements.

34 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Figure 13 - Bolt-down Requirements for Double-front, Multiple-column-wide Shipping Blocks

IMPORTANT

Front of Unit 1

Front of Unit 2

Installation sequence, left to right.

Installation sequence, right to left.

First Column Last ColumnSecond Column Additional Columns

First ColumnLast Column Second Colu mnAdditional Columns

Front of Unit 1

Front of Unit 2

ATTENTION: The figure above shows which bolts are required for multiplecolumn shipping blocks. Drawings with specific dimensions are supplied with each multiple-column shipping block.

= Mounting hole locations not required.

Top View

Use steel M12 bolts (minimum Property Class 8.8) to secure columns to the foundation. Not all bolt locations are used.

Install Columns Chapter 3

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 35

Chapter 3 Install Columns

Front

First Column Last ColumnSecond and Additional

Column s

40 mm 40 mm

40 mm40 mm

40 mm 40 mm

40 mm40 mm

Wel ds

External Mounting Channel

First Column Last ColumnSecond and Additional

Columns

40 mm 40 mm

40 mm40 mm

40 mm

40 mm40 mm

40 mm

Weld

Wel d

External Mounting Channel

Floor Lin e

Floor Line

Double-front Configurations

Single-front Configurations

Front

Top Vie w

Wel d

Front

End View

Top Vie w

End View

Weld

Figure 14 - Weld-down Requirements for Various Configurations

36 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

IMPORTANT

336

353

336

353

744

547

573

165

Dimensions are in mm.

336

353

336

353

744

747

773

365

FRONTFRONT

600 mm Deep Column 800 mm Deep Column

Step 1

Step 2

Step 1

Joining Columns

ATTENTION: Joining columns is done after all columns/shipping blocks

have been secured to a foundation.

Do not use the hardware to draw columns together.

1. Starting with the first column, use M6 x 1.0 hardware provided in the power bus splice kit to fasten the six joining holes together (step 1 in the figure below).

2. 800 mm deep columns: use a M6 hex head bolt, washer, and nut provided in the power splice kit to fasten the two joining holes together (step 2 in the figure below).

3. Torque all fastened bolts to 5.6 Nm.

4. Inspect the interior for dust and dirt. Vacuum cleaning is recommended.

Do not clean by using compressed air—it can contain moisture and blow debris into the control equipment.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 37

Chapter 3 Install Columns

Seismic Capabilities

Actual CENTERLINE 2500 MCC units have been seismically qualified by dynamic (triaxial multi-frequency testing) seismic tests by using ICC–ES AC156

(1)

acceptance criterion that covers general equipment and supports the seismic certification of electrical systems such as Motor Control Centers (MCCs). The testing was carried out in accordance with ICC–ES AC156 criteria and supports data for the following qualification requirements:

• 2006 and 2009 International Building Code, International Code Council

• 1997 Uniform Building Code, Structural Engineering Design Provisions,

Zone 4

• ASCE Standards SEI/ASCE 7-05 and SEI/ASCE 7-10, Minimum Design Loads for Buildings and Other Structures

The range of the ICC–ES AC156 testing enveloped (fulfilled and exceeded) is in the following table.

(1)

Test Criteria

ICC-ES-AC156 1.0 1.0 1.6 1.2 1.33 0.67 0.27 2.5 1.0

ICC-ES-AC156 1.5 1.0 2.4 1.8 1.33 1.005 0.402 2.5 1.0

(1) Equipment is qualified for SDS and z/h values shown. Qualifications can be valid for higher SPS where z/h is less than 1.0.

SDS (g)

z/h

(1)

Horizontal Vertical

(1)

ARIG

(1)

AFLEX/ARIG AFLEX

FLEX

(1)

ARIG

(1)

AFLEX/ARIG

Rp/IpA

CENTERLINE 2500 MCC units demonstrated compliance with the following:

• 100% g level of Uniform Building Code 1997 (UBC) Zone 4 (the maximum UBC Zone)

• 100% g level of the International Building Code 2009 (IBC), (SEI/ASCE: S

≥ 1.5 g @ 5 Hz and SD1 ≥ 2 g @ 1 Hz) when subjected to

a UBC Zone 4 earthquake or the IBC seismic event

Throughout the seismic testing, the MCC units were under power and operated before, during, and after the seismic tests.

To obtain a IBC or UBC seismic withstandability, each individual CENTERLINE 2500 MCC line-up (including those in double-front applications) must be mounted on an adequate seismic foundation. Installation must be carried out per the anchoring requirements as indicated in this instruction manual. All columns in the MCC line-up must also be bolted together per instructions in Joining

Columns on page 37.

In the CENTERLINE 2500 MCC line-up, mounting channels are incorporated in the standard design. As an alternative to bolt down anchoring, these mounting channels can be welded to an adequate seismic foundation. For seismic weld down applications, see Figure 13 on page 35

(1) Acceptance Criteria for Seismic Certif ication by Shake-Table of Non-structural components (AC156), International Code of Council

Evaluation Service (ICC-ES), October, 2010.

38 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

IMPORTANT

TIP

Splicing the Power Bus

ATT EN TI ON : To prevent severe injury or death, de-energize all power sources to

the MCC before joining and splicing columns. Follow local codes and guidelines in addition to the requirements of EN 50110.

When splicing the horizontal power bus, always begin splicing from the lowest phase busbar and work from the bottom up.

Using NO-OX-ID – Do not get any busbar corrosion inhibitor on the bus splicing hardware. It keeps the hardware from being properly torqued and damage can occur.

Power bus consists of the main horizontal bus and neutral bus (if present). Based on the current rating of the power bus, the splice kit contains the appropriate splice bars and corresponding hardware. The following procedures describe methods for splicing power buses based on the ampere rating of the busbars.

For additional splicing information related to specific MCCs, refer to the elevation drawing shipped with the MCC in the documentation package.

If necessary, remove units and unit support pans for the appropriate access to splice the power bus.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 39

Chapter 3 Install Columns

Primary Splice Cover

Secondary Splice Cover

Top Sc rew of

Primary Cover

Top Sc rew of

Secondary Cover

Splice Covers Locati on

Accessing the Power Bus

Follow these procedures to access the power bus.

1. To gain access to the horizontal power bus, open the vertical wireway door to the left of the splice.

2. Identify the primary and secondary splice covers as shown.

3. Loosen the top and bottom screws on the secondary splice cover, slide the

secondary splice cover to the right, and remove the cover.

The screws remain in the wireway.

4. Loosen the top and bottom screws on the primary splice cover, slide the primary splice cover to the left, and remove the cover.

The screws remain in the wireway.

Splicing Power Bus, 800…4000 A

Follow these procedures to splice the power bus.

1. Assemble splice bars and hardware as shown in Figure 15 on page 41

Repeat for each phase of busbar and, if present, the neutral bar.

2. Tighten hardware to torque specifications.

See Torque Requirements for Hardware Connections on page 43

Do not grease or lubricate hardware.

3. Replace the horizontal bus access covers and check that the bolts and nuts are secure.

40 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

Front

800…1250A

Front

1600…2500 A

3200 A 4000 A

4. Replace the units and unit support pans in their respective stations if they were removed.

Figure 15 - Power Bus Splicing Configurations

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 41

Chapter 3 Install Columns

Splice bars are attached.

PE splice bars

Splicing the Protective Earth (PE) Conductor

The PE conductor is in the bottom horizontal wireway of an MCC column. Up to three PE conductors can be present. To access the PE conductor, remove the bottom horizontal wireway cover.

Follow these procedures to splice the Protective Earth Conductor.

1. Locate the PE splice bars.

PE splice bars are secured to the end of the horizontal PE during shipping.

2. Use the PE splice bars to join the horizontal PE of each column and assemble the splice bars and hardware as shown.

3. Tighten hardware to torque specifications. See Torque Specifications

page 43.

Do not grease or lubricate hardware.

4. Replace horizontal wireway cover and check that bolts are secure.

42 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Columns Chapter 3

Control and Network Cables

When finished joining and splicing columns, make sure to connect network and other control cables as required.

Torque Specifications

Refer to Chapter

9 for IntelliCENTER options.

Tighten bus splice connections with a torque wrench according to the table. Torque values can be found on the information label on the interior of the vertical wireway door or on the interior right side plate of fixed units.

Hardware Description Hardware Size Torque

Incoming line lug attachment bolts M12 x 1.75 61 N•m

Horizontal power bus to vertical distribution bus connection

Horizontal power bus splice connection M10 x 1.5 38 N•m

Protective earth conductor (PE) splice connection M6 x 1.0 7.3 N•m

Column joining hardware M6 x 1.0 6.2 N•m

DeviceNet splice cable screws — 0.55 N•m

I/O terminal blocks — 0.45 N•m

(1) The factory-made horizontal power bus to vertical distribution bus connections are tightened by a computer-

controll ed torquing s ystem.

(1)

M10 x 1.5 38 N•m

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 43

Chapter 3 Install Columns

Notes:

44 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Chapter 4

Install Cable

When installing cable, make sure it is installed according to appropriate codes and standards. Multi-conductor cables, cable trays, cable ducts, and conduit are all acceptable methods of routing cable to your MCC.

It is important that all cable is installed so it is compatible with the enclosure rating of the MCC. Cable entry and exit points must be properly sealed so water and moisture cannot enter or accumulate inside the enclosure.

Inside the MCC enclosure, route cable away from the PE conductor to avoid damage. Position cable so bending is minimized and relative vertical alignment to incoming connections is maintained.

Refer to the documentation package shipped with your MCC for the following information:

• Approximate cable entry locations

• Space availability for incoming cables

• PE conductor locations

• Wiring schemes for main fusible disconnects, main circuit breakers and

incoming line compartments

Install cable per manufacturer’s instructions and sized according to appropriate codes and standards.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 45

Chapter 4 Install Cable

TIP

Detail A

Frame Stiffener Bracket Wireway Latch Bracket

Detail B

Detail C

IMPORTANT

TIP

Install ArcShield Protection After Wiring

You can temporarily remove ArcShield latch brackets to maker it easier to connect load cables.

Consider removing a unit if you cannot access the screw on the left side of the bracket.

Follow these procedures for installing the door latch bracket/frame stiffener in the wireway.

1. Open door.

Install door latch bracket and frame stiffener bracket (if latter was removed).

Verify latch bracket is in the correct orientation before installing. See Detail C in figure below.

3. Torque all bracket screws to 3.6 N•m (32 lb•in).

Lugs

Install lugs so proper spacing is used between phases. Hardware must be tightened per the torque specifications.

Refer to Chapter 3

for more information.

Verify the compatibility of wire size, type, and stranding for the power lugs furnished. Use correct lugs in all applications. Crimp compression lugs with manufacturer recommended tools.

Use the MCC electrical schematics and wiring diagrams to verify field wiring connection points.

46 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install Cable Chapter 4

Incoming Line Lug Compartment

Main Disconnecting Means

Cable Bracing

Top or bottom incoming line lug compartments are available. Base the lug selection on the size, number and type of conductor.

The following are guidelines for selecting lugs based on incoming line available short circuit current, I

≤ 50,000 amperes RMS symmetrical use mechanical screw or

crimp/compression type lugs.

> 50,000 amperes RMS symmetrical crimp/compression type lugs are

recommended.

Refer to the documentation package shipped with your MCC for information on incoming terminations.

For main disconnects or circuit breakers, use the lugs provided.

The CENTERLINE 2500 MCC bus work system has been tested and is qualified to withstand forces that exceed the short circuit withstand ratings for the MCC. Incoming line cables and outgoing feeder cables also need to be supported to withstand the same short circuit forces. Follow appropriate codes and standards when bracing incoming and outgoing cables.

There are many sizes and types of cables, as well as different means by which the cables can be supported. Cabling needs to be secured or braced for the weight of the cable and in case of a fault.

Follow the guidelines addressed in IEC Standard 60364-5-52.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 47

Chapter 4 Install Cable

Form 3b Form 4b

Secure Load Wires

Standard internal separation within the MCC is IEC 61439-1 Form 3b. IEC 61439-1 Form 4b is available by enclosing terminals for external conductors in a metal box within the vertical wireway.

48 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Chapter 5

Hei

Door Latches, Operator Handles, and Unit Interlocks

Height Considerations

In accordance with EN 61439-1, operating devices (push buttons and handles) should be no more than 2000 mm above floor level. If the MCC is mounted on an elevated surface, the height from the floor to the center of the top handles must be checked for compliance.

Figure 16 - Operator Handle Height

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 49

Chapter 5 Door Latches, Operator Handles, and Unit Interlocks

IMPORTANT

Head Slot

T-handle

Latches shown in vertical (closed) position.

Door Latches

There are two types of door latches available for the 2500 MCC: quarter-turn door latches and ArcShield door latches. Both latches are available with T-handles.

Quarter-turn Door Latches

Latches are provided on each unit door to hold the door closed and isolate the column. You can rotate the door latches by using a standard slotted screwdriver in the head slot.

Open the door latches as follows.

1. Rotate each door latch a quarter turn (90°) until its head slot is horizontal.

Open the door once all latches are in the open position.

Close and lock the door latches as follows.

1. Close the door.

2. Using a slotted screwdriver, rotate each door latch a

quarter turn (90°) until all slots are vertical.

ArcShield Door Latches

ArcShield door latches are spring-loaded to allow pressure relief and keep the doors from detaching from the structure.

Follow the same procedures in the Quarter-

turn Door Latches to open or close a door

with ArcShield door latches.

ArcShield door latches are spring-loaded. When closing a door, push in each latch as you turn it so it locks correctly for ArcShield protection.

50 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Door Latches, Operator Handles, and Unit Interlocks Chapter 5

Handle in OFF/O Position Handle in ON/I Position Handle in Tripped/T Position

Small Rotary-operator Handles

The following is a brief summary of operating instructions for small rotaryoperator handles. For additional information, see publication 21-361-950-01 which is available online at http://www.rockwellautomation.com/literature

Figure 17 - Small Rotary-operator Handle Positions

Opening the Unit Door

1. Turn the small rotary-operator handle to the OFF/O position.

2. Release the door latches.

3. Grasp the small rotary-operator handle and pull the unit door toward you

to open.

Closing the Unit Door

1. Check that the small rotary-operator handle is in the OFF/O position.

2. Close the unit door.

3. Secure the door latches.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 51

Chapter 5 Door Latches, Operator Handles, and Unit Interlocks

Handle in ON/I Position

Handle in Tripped/T Position

10° maximum

turn clockwise.

Defeater Screw

Opening the Unit Door in the ON/I Position

When the unit door is closed and the small rotary-operator handle is in the ON/I or TRIPPED/T position, a defeater screw must be deliberately operated to open the unit door.

ATTENTION: Follow local codes and guidelines in addition to the requirements of EN 50110 when working on energized equipment.

1. Release the door latches.

2. Locate the defeater screw on the lower right corner of the small rotary-

operator handle.

3. Use a flat blade (number 2) screwdriver to turn the defeater screw 10° (maximum) clockwise.

4. Carefully open the unit door.

Operator Handles for Circuit Breakers

In the event of a circuit breaker fault, the circuit breaker operator handle moves to the TRIPPED/T position. Only reset the circuit breaker after the cause of the

52 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

fault has been determined and corrected.

Follow these procedures to reset the circuit breaker.

1. Turn the small rotary-operator handle to the OFF/O position; see

Figure 17 on page 51

2. After the fault has been corrected, verify that it is safe to re-energize the unit and turn the small rotary-operator handle to the ON/I position.

Door Latches, Operator Handles, and Unit Interlocks Chapter 5

Click

Use screwdriver to push down and release lock.

Use screwdriver to remove ha ndle screw.

Locking Units in the OFF/O Position

ATT EN TI ON : Follow all company safety and lockout procedures, and local codes

when performing this procedure.

Follow these procedures to lock a unit in the OFF/O position.

1. Turn the small rotary-operator handle to the OFF/O position.

2. Push and hold the button on the handle. The lock opening is now visible.

3. Insert and secure the lock.

Up to three 8 mm locks can be inserted.

Locking Units in the ON/I Position

ATTENTION: Locking an operating handle in the ON/I position can conflict with

local codes and emergency shutdown requirements.

Locking units in the ON/I position requires user modification. To modify the operator handle to allow locking in the ON/I position, follow the procedure illustrated in Figure 18

Figure 18 - Modification of the Small Operator Handle to Allow Locking in the ON/I Position

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 53

Chapter 5 Door Latches, Operator Handles, and Unit Interlocks

Release Mechanism

Circuit Breaker Style

Disconnect Style

Release Mechanism

Large Rotary-operator Handles

The following is a brief summary of operating instructions for large rotaryoperator handles available for disconnects or circuit breakers.

For additional disconnect handle information, see publication 40053-127-01 which is available online at http://www.rockwellautomation.com/literature

Figure 19 - Large Rotary-operator Handle Styles

Opening the Unit Door

Follow these procedures for opening the unit door.

1. Verify the large rotary-operator handle is in the OFF/O position.

2. Release the door latches.

3. Hold the large rotary-operator

handle in the OFF/O position while pushing the release mechanism down.

4. Carefully open the unit door.

54 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Door Latches, Operator Handles, and Unit Interlocks Chapter 5

Defeater

Mechanism

Closing the Unit Door

1. Verify the large rotary-operator handle is in the OFF/O position.

2. Slowly close the door until contact with the large rotary-operator handle is

made.

3. Hold the large rotary-operator handle in the OFF/O position while closing.

4. Close the door and secure the door latches.

Opening the Unit Door in the ON/I Position

ATTENTION: Follow local codes and guidelines, and the requirements of EN

50110 when working on energized equipment.

When the unit door is closed and the large rotary-operator handle is in the ON/I position, a defeater mechanism must be deliberately operated to open the unit door (for example, to open the door of an energized unit).

Follow these procedures to open a door with the large rotary-operator handle in the ON/I position.

1. Release the door latches.

2. Locate the defeater mechanism on

the right side of the handle.

3. Use a flat blade screwdriver to push the defeater mechanism in the direction of the arrow.

4. Carefully open the unit door.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 55

Chapter 5 Door Latches, Operator Handles, and Unit Interlocks

Operator Handles for Circuit Breakers

In the event of a circuit breaker fault, the circuit breaker operator handle moves to the TRIP/+ position. Only reset the circuit breaker after the cause of the fault has been determined and corrected.

Follow these procedures to reset the circuit breaker.

1. Turn the circuit breaker handle from the TRIP/+ position to the OFF/O position.

2. Turn the circuit breaker handle from the OFF/O position to the RESET position.

3. Locate and correct the fault.

4. Verify it is safe to re-energize the unit.

5. Turn the handle from the RESET position to the ON/I position.

Locking Units in the OFF/O Position

ATT EN TI ON : Follow all company safety and lockout procedures, and local codes

when performing this procedure.

1. The large rotary-operator handle must be in the OFF/O position.

2. Pull the middle section of the operator handle toward you.

The lock opening is now visible.

3. Insert and secure the lock.

Up to three 8 mm locks can be inserted.

56 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Door Latches, Operator Handles, and Unit Interlocks Chapter 5

For Cat. No. 140U-PB and 140U-PY Rotary Handles

For Cat. No. 140U-HM4 and 140U-HM4E Rotary Handles

123

Locking Units in the ON/I Position

Locking units in the ON/I position requires user modification.

ATTENTION: Locking an operating handle in the ON/I position can conflict with local codes and emergency shutdown requirements.

To modify the operator handle so you can lock it in the ON/I position, you must first remove at least one tab accessible from the handle backside and inside door.

See Figure 20

Figure 20 - Locking Rotary Handles in the On/I Position

for the appropriate instructions.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 57

Chapter 5 Door Latches, Operator Handles, and Unit Interlocks

Unit Interlocks

ATTENTION: Do not attempt to install or remove a unit while the unit main

switch is in the ON/I position.

A unit interlock is provided with each plug-in unit. Unit interlocks help prevent units from being removed from or inserted into a column while the operator handle is in the ON/I position.

58 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install and Remove Units

One Module Unit Four Module Unit

Chapter 6

Unit Size

Unit size is described in terms of modules. One module is 80 mm high by 500 mm wide. Withdrawable units are available is the following sizes: 1, 2, 4, 6, 8, 10, and 12 modules. Fixed units range in size from 4…24 modules.

Any unit size above one module must be in even increments. Therefore, you cannot have a unit that is 11 modules high.

CENTERLINE 2500 MCCs are available with many combinations of withdrawable and fixed units. This table lists the maximum ampere rating of each unit size.

Number of Modules Ampere Rating (max)

132 A

2…12 225 A

Figure 21 - Unit Types

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 59

Chapter 6 Install and Remove Units

Protective Earth Conductor (PE)

ControlNetwork

LoadLine

Isolated Control and Network Wirew ay

Customer Load Connection

Load

Line

Control

Network

Withdrawable Units

Withdrawable units are characterized by withdrawable line, load, control, network, and PE connections. Outgoing load and control connections from these units are made in the vertical wireway. Withdrawable units use a sliding track and a mechanical lever for ease of insertion and removal. Additional features include a separate unit door and optional door mounted pilot devices. The unit door can be closed and latched, providing isolation when the unit is removed. Pilot devices are housed in removable control stations. An optional closing plate is available to help provide isolation if the control station is removed.

Figure 22 - Connections for Multiple Module Withdrawable Units

Figure 23 - Withdrawable Unit Connections – Two or More Modules

60 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Figure 24 - Withdrawable Unit Connections – One Module

Network Control

Guide Pins (2)

Line and Load

Network

Control

Line and Load

Guide Pins

Install and Remove Units Chapter 6

Figure 25 - Subplate Connections for One Module Withdrawable Units

Operating Positions

Withdrawable units have four operating positions: Connected, Te s t , Disconnected, and Released. Detents are present to confirm that the unit is in

one of the four positions. An interlock helps prevent the unit from being inserted or removed while the branch circuit device is in the ON/I position. Stabs are provided to make the line and load connections. A first make, last break PE contact is also provided. Control and network connections plug into an isolated vertical wireway on the left side of the column. See the following descriptions for additional information about the features of each position.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 61

Chapter 6 Install and Remove Units

Locking Mechanism Withdraw Lever

Selecting an Operating Position

1. Grasp the withdraw lever with one hand.

2. Slide the locking mechanism toward the withdraw lever.

3. Rotate the withdraw lever to the desired position.

Mechanical detents are used to confirm that a position is selected.

62 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

4. Release the locking mechanism and withdraw lever.

Connected Position

In the Connected position, the line, load, control, network, and PE connections are engaged. Closing the unit door helps to keep the withdraw lever in the connected position. To engage the interlock or turn the branch circuit device to the ON/I position, the unit door must be fully closed.

Install and Remove Units Chapter 6

Test Position

In the Te s t position, the control, network, and PE connections are engaged. Line and load connections are isolated. This helps allow the control and network wiring of the units to be verified. Units can be locked in this position.

Disconnected Position

In the Disconnected position, the unit remains in the column but connections are not present. This is an isolated position. Units can be locked in the disconnected position.

Released Position

Withdrawable units can be completely removed from the columns. The lever must be moved out of the Disconnected position into the Released position before the unit can be withdrawn. When units are removed from the MCC, they are fully isolated from connections.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 63

Chapter 6 Install and Remove Units

IMPORTANT

Screw locations on right side

Screw location on left side

Front side of unit support pan

Safety Guidelines for Installing and Removing Withdrawable Units

ATTENTION: De-energize, lock out, and tag out all sources of power to the MCC

when installing or removing MCC units. If MCC units are installed or removed with power applied to the main power bus, follow established electrical safety work practices. Refer to the publication, NFPA 70E: Standard for Electrical Safety in the Workplace®, for further information.

WARNING: If power sources are connected to the motor control center, use extreme caution when inserting units. All busbars and the line sides of the inserted units are energized and contact with these parts can cause injury or death.

ATT EN TI ON : To insure operator safety and prevent equipment damage, we recommend that two people install or remove units that are in the upper six modules or over 1600 mm above floor level.

Units with door-mounted operator handles, switches, and disconnects must be in the OFF/O position before units are inserted or removed.

Do not attempt to install or remove a unit when the unit main switch is in the ON/I position.

Inserting a Withdrawable Unit

The unit support pan below the unit compartment must be in place before installing the unit.

Follow these procedures to insert a withdrawable unit.

1. Open the unit door completely and verify the unit support pan has been installed.

The unit support pan is secured with two screws on the right side and one screw on the left side.

64 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Install and Remove Units Chapter 6

For one module units, verify the subplate is installed. The subplate is attached to the column with two mounting screws.

2. Rotate the unit withdraw lever to the Released position.

3. Slowly slide the unit into the column along the tracks on the unit support pan until it locks in the Disconnected position.

4. Slide the locking mechanism toward the withdraw lever, rotate the

withdraw lever to the Te s t position, and continue to insert the unit into the column.

The unit locks in the Te s t position.

5. Slide the locking mechanism toward the withdraw lever again, and rotate the withdraw lever to the Connected position.

Vertical bus shutters automatically opens as the unit is inserted.

6. Insert the unit until it locks in the Connected position.

The unit is now installed in the column.

7. Connect any door mounted devices.

Removing a Withdrawable Unit

8. Close the unit door and secure the door latches.

Refer to

information on the withdraw lever.

1. Open the unit door completely.

2. Unplug or remove door mounted pilot devices.

3. Slide the locking mechanism on the withdraw lever to the left and rotate the withdraw lever to the Te s t position.

4. Slide the locking mechanism toward the withdraw lever and rotate the withdraw lever to the Disconnected position.

5. Slide the locking mechanism toward the withdraw lever again and rotate

the withdraw lever to the Released position.

Continue to slide the unit out of the column. The unit can now be completely removed from the column.

Shutters close automatically as the unit is removed.

6. Close the unit door and secure the door latches.

Selecting an Operating Position on page 62 for additional

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 65

Chapter 6 Install and Remove Units

IMPORTANT

Removing the Unit Door

It is not necessary to remove the unit door to install or remove a unit from a column. However, if a unit door must be removed, use one of the following procedures.

If present, door-mounted control stations can be removed from the door and kept with the unit.

Before performing work on units or unit doors, make sure the unit main switch is in the OFF/O position.

Multiple Module Unit Doors

Follow this procedure to remove multiple module unit doors.

1. Make sure the unit main switch is in the OFF/O position.

2. Release each door latch.

3. Open the unit door completely.

4. Remove and/or disconnect door-mounted devices and wiring.

5. Slide the hinge pins upward to remove.

6. Swing door to near closed position and lift outward to remove.

7. To install the unit door, reverse this procedure.

One Module Unit Doors

Follow this procedure to remove one module unit doors.

Remove the unit from the column before removing its door. Follow unit removal procedures on page 65

1. Make sure the unit main switch is in the OFF/O position.

2. Release each door latch.

3. Open the unit door completely.

4. If a control station is provided with a plug for control wires, unplug this

connection before removing the unit.

5. Remove and/or disconnect door-mounted devices and wiring.

6. Remove the two screws that fasten the hinge to the column.

7. Remove the unit door and hinge assembly from the column.

8. To install the unit door, reverse this procedure.

66 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Commissioning

Chapter 7

Introduction

Pre-commissioning Checklist

This chapter provides guidance for the startup of a newly installed MCC.

We recommend that you make an itemized list that includes the following:

• Serial number

• Number of columns

• Number of units and their corresponding voltage

• Current ratings

• Kilowatt ratings

• Types of circuits

• Fuse sizes

• Circuit breaker ratings and trip settings

• Other important data

This itemized list should be saved in a file along with other data for the MCC such as, component manuals, MCC manuals, overload relay instructions and wiring diagrams.

ATT EN TI ON : Follow applicable company safety procedures.

ATT EN TI ON : To protect the safety of personnel performing the pre-energizing

check, verify remote MCC power sources are disconnected and locked in the OFF/O position. Follow local codes and guidelines in addition to the requirements of EN 50110.

Use a voltmeter to verify that the remote MCC power sources are disconnected.

ATT EN TI ON : Power factor correction capacitors (PFCCs) must be applied correctly. When PFCCs are connected to the motor circuit and the start-up procedure requires the respective motors to be jogged, inched or bumped (rotation direction check), temporarily disconnect PFCCs.

For additional assistance, contact your Rockwell Automation representative.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 67

Chapter 7 Commissioning

TIP

ATT EN TI ON : Verify that motor acceleration times are within specific

application specifications.

Excessive starting currents and/or acceleration times can cause inverse time circuit breakers, power fuses, overload relays, and other components to overheat and/or shut down equipment.

The following procedures should be executed only by a ‘skilled person’ as defined by IEV 195-04-01 and 3.52 of IEC 60204-1, as follows:

‘Skilled person Person with relevant education and experience to enable him or her to perceive risks and to avoid hazards that operation or maintenance of a product can create.’

Follow these procedures for completing the pre-commissioning checklist.

1. Check and verify that the MCC is installed per instructions.

See Chapter 3, Install Columns

2. Inspect and verify that the MCC is level and secured.

3. Inspect the enclosure and units for damage and verify that electrical

clearances have been maintained based on the voltage and impulse rating of the equipment.

4. Remove all blocks or temporary holding means used for shipping component devices in the MCC.

5. Check the integrity of the bus splice connections.

Recommended torque values can be found on the information label on the interior of the vertical wireway door or on the interior right side plate of fixed units.

See Chapter 3, Install Columns

for splicing information.

The factory-made horizontal power bus to vertical distribution bus connections are tightened by a computer-controlled torquing system. Therefore, these components do not need torquing by the customer.

6. Check and verify that all PE connections are made, based on applicable codes and standards.

If the PE conductor is not provided or has been removed, verify MCC columns are connected with joining hardware to provide a continuous PE path. See Joining Columns

on page 37 for more information.

7. Perform the following for field wiring: a. Check the field wiring for proper conductor sizing. b. Verify all incoming and outgoing power wiring is secure, well

supported, and braced to withstand the effects of a fault current as detailed in Chapter 4, Install Cable

68 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Commissioning Chapter 7

IMPORTANT

TIP

For incoming line compartments of 8 modules or less: the incoming cables should be firmly secured halfway between the top of the column and the incoming line compartment terminals.

For full-line (24 modules) incoming line compartments: the cables should be braced every 300 mm if the system’s available short circuit current is less than 42,000 amperes rms symmetrical. If the system’s available short circuit current is greater than or equal to 42,000 amperes rms symmetrical, current bracing should occur every 150 mm.

c. Check the integrity of all field connections.

Recommended torque values not found on individual devices can be found on the unit wiring diagrams.

d. Check field wired connections made to the MCC.

Refer to wiring diagrams and verify that proper clearances between adjacent phases and/or phases to PE are being maintained.

8. Verify the voltage and kilowatt ratings on the motor correspond with the MCC unit ratings.

9. Verify that proper overload relays are installed and/or adjusted to relative full load current shown on the motor rating nameplate.

10. For applications requiring power fuses, install fuses in fusible switches in accordance with application requirements.

Do not apply grease or NO-OX-ID to fuse ferrules.

11. For circuit breaker applications, verify that the circuit breakers are in accordance with application requirements, and have correct amperage and trip settings.

High efficiency motors can have higher locked rotor and inrush currents, which require higher magnetic trip settings.

ATTENTION: Rockwell Automation AC drives and soft starter units are shipped with preset factory settings such as ramp speed, current limits, switch positions, and readouts. Preset factory settings are not suitable for some applications. Refer to instruction manuals, supplied with the MCC, for specific start-up guidance.

12. Set and verify adjustable current, voltage and other settings, according to device instructions or wiring diagrams.

Refer to the device instruction sheets or manuals supplied with the MCC for specific start-up guidance.

Component devices in MCC units (such as transfer switches, power factor correction capacitors, transducers, motor protectors, line monitors, over and under-voltage relays, and motor windings heaters) can require unique start-up procedures.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 69

Chapter 7 Commissioning

TIP

13. Manually exercise all switches, control auxiliary switches, circuit breakers, their respective operators, unit interlocks, trip mechanisms (test by pushing the Push to Trip button) and any other operating mechanisms to verify proper operation.

14. Check timing relay settings as required.

15. Verify vents are free from obstructions.

16. Check that fans used for forced air cooling have:

a. Shafts that rotate freely b. Blades with no dust or debris build-up

17. Check that all filters are in place and clean.

We recommend that you set up an inhouse program for scheduled cleaning or replacement.

18. Check all current transformers for proper polarity.

Verify transformer secondaries are NOT open, and are either connected to their respective devices or shorted. Reference individual unit wiring diagrams and schematics for proper installation.

ATTENTION: Current transformer secondaries should not be “open.” To avoid possible injury and electrical shock to personnel, do not energize a current transformer with its secondary open.

19. Ver i f y all barriers and parts removed during the installation process have been reinstalled.

We recommend that a barrier checklist is developed including such items as, unit location, and barrier location. This checklist should be saved for future reference.

20. Before closing the enclosure and/or individual units, remove all tools, metal chips, scrap wire, and other debris from the MCC interior.

If there is an accumulation of dust or dirt, clean out the MCC by using a brush, vacuum cleaner, or a clean, lint-free rag. DO NOT use compressed

air—it redistributes contaminates on other surfaces.

21. Verify all withdrawable units are in the Connected position.

Close and latch unit and wireway doors, ensuring that wires are not pinched. Column closing plates must be in place.

ATTENTION: When conducting an electrical insulation resistance test, isolate equipment sensitive to high test voltages, such as meters, solid state devices, motor winding heaters, capacitor units, and transformers.

70 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Commissioning Chapter 7

22. Conduct an electrical insulation resistance test to verify MCC wiring integrity. Conduct this test with an insulation resistance (megger) tester with a potential of 500…1000 volts.

ATTENTION: Verify all switches or circuit breakers are in the OPEN/I or Off/O positions before conducting an electrical resistance test.

Conduct this megger test phase-to-phase, phase-to-PE and, when applicable, phase-to-neutral on the MCC buswork. Typical insulation resistance values are 50 megohms or greater.

Insulation resistance values are affected by temperature, humidity, or dampness, which can cause a considerably lower insulation resistance reading. If the insulation resistance values are less than one megohm (due to dampness, temperature or humidity) or the MCC has been stored in a damp or humid area, it is recommended the equipment be dried out. Dry out motor cables by injecting a low voltage current or by using space heaters.

Once the equipment is dry, repeat the insulation resistance test. The minimum value for insulation resistance on a new installation at startup or energizing is 1 megohm. These readings can be recorded in Megger

Reading Recording Table on page 94.

Commissioning Procedure

Next, check the field wiring, for example, motor cables and/or incoming line cables.

ATT EN TI ON : Commissioning a motor control center must be done only by skilled personnel with proper personal protective equipment. Energizing a MCC for the first time is potentially dangerous. Serious damage and/or personal injury can occur. Follow local codes and guidelines in addition to the requirements of EN 50110.

ATT EN TI ON : This procedure is provided as a general guideline for energizing a newly installed CENTERLINE 2500 MCC and should be used only after the

Pre-commissioning Checklist has been completed.

Read this procedure in its entirety before beginning the commissioning procedure. If you have any questions or concerns, contact your Rockwell Automation representative.

1. Review other instructions supplied for the proper operation of special units such as AC drives and soft starters, with appropriate and skilled personnel.

2. Verify that main and unit main switches are in the OFF/O position so there is no load on the MCC.

Also, verify that associated remote devices are de-energized.

3. Latch doors and secure covers.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 71

Chapter 7 Commissioning

TIP

4. Energize the MCC remote power source.

If the MCC has a main circuit breaker or disconnect switch that can be operated from a remote location, energizing from the remote location is strongly recommended.

If the MCC main circuit breaker or disconnect switch cannot be energized from a remote location, follow the procedure below.

• De-energize the remote power source

• Close MCC main disconnect or circuit breaker switch.

• Re-energize the MCC remote power source.

ATTENTION: Main switch handles should be operated with a firm, direct motion into the closed (ON/I) position.

5. Energize from the source of the system, working toward the loads.

Energize one unit at a time, beginning with control units then feeder units.

6. Fully withdrawable units can be commissioned in the Test position.

This position helps allow control and network connections to be tested without engaging three phase power.

See Chapter 6, Install and Remove Units

for more information on

operating positions.

7. After the disconnect devices have been closed, loads such as lighting circuits, motor starters, and contactors can be energized.

a. When power factor correction capacitors are energized with the motor

windings and the start-up procedure requires that the respective motors be jogged or inched, temporarily disconnect the power factor correction capacitors. For more information on power factor capacitors and MCC units, contact your local Rockwell Automation Representative.

b. Verify that acceleration times are within application specifications.

Excessive starting currents and/or acceleration times can cause inverse time circuit breakers, power fuses, overload relays and other components to overheat and/or shut down equipment.

8. Verify meters, including voltmeters and ammeters, are working properly.

9. Reset device settings that were adjusted during installation and

commissioning to appropriate operational settings.

For commissioning MCCs with the DeviceNet network and/or IntelliCENTER software, refer to the CENTERLINE 2500 DeviceNet Motor Control Centers Technical Data, publication 2500-TD002 CENTERLINE 2500 Motor Control Centers with EtherNet/IP Network Technical Data, publication 2500-TD003

72 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

, or

Maintenance

ATTENTION: Only skilled personnel should oversee the maintenance

and servicing of motor control centers.

De-energize all power sources before performing maintenance or service work on columns or units.

Follow local codes and guidelines in addition to the requirements of EN 50110 when working on energized equipment.

Replace and secure all barriers, covers, shields and doors, and perform the

Pre-commissioning Checklist

equipment.

Chapter 8

on page 67 before re-energizing the

Establish a Maintenance Program

A periodic preventative maintenance program must be established for MCCs to help avoid unnecessary downtime. At a minimum, checks must be made once a year. If equipment within the MCC is subject to heavy duty or highly repetitive operation, more frequent maintenance can be necessary. Use the following suggested maintenance guidelines to establish a maintenance program.

Keep a log of service and maintenance work performed on your MCC. Record the following information.

• Date test and maintenance work is performed

• List of checks and tests performed

• Condition of the equipment

• Any repairs and/or adjustments made to equipment

For maintenance regarding specific components, such as circuit breakers, contactors, AC drives, relays, and meters, reference the specific component instruction manual for each device.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 73

Chapter 8 Maintenance

Suggested Maintenance

This table provides some suggested guidelines for maintaining your MCC.

Guidelines

Suggested Maintenance Guidelines Date Remarks Initials

1. Environment • Verify operating (ambient) conditions.

2. Enclosure Exterior • Clean surfaces. Retouch painted surfaces if necessary.

3. Contaminants

4. Bus System ATT EN TI ON : De-energize all power sources

– Room temperature range: -5…40 °C – Non-condensing humidity, max: 95% at 40 °C

• Check that door latches are functioning and secure.

•

Inspect for signs of excessive heat in the following locations:

– Doors – Enclosure sides

If severe corrosion or discoloration is evident, replace the damaged components. Identify the cause of damage and

make necessary repairs.

ATTENTION:

in addition to the requirements of EN 50110 when working on energized equipment.

• Check for contaminants (moisture, dirt, dust) inside the enclosure. Contaminants must be removed and the source eliminated.

• Check for contaminants in the following locations: – Cable entr y and exit points, seams and openings – Devices (push buttons, relays, and disconnect switches)

Make sure the source or cause of wetness or moisture is identified and eliminated.

before performing maintenance or service work on columns or units.

Follow local codes and guidelines

(1)

• Check the bus support and insulation for cracks and/or damage.

• Inspect bus splice connections for discoloration.

• Verify the integrity of bus splice connections. Re-torque

connections. See label inside vertical wireway door for recommended torque values.

• Use a vacuum or a lint free cloth to clean the bus and supports.

• Conduct an electrical insulation resistance (megger) test. Record and save the results.

See Pre-commissioning Checklist

5. Operating Handles • Verify that operator handles move freely (no sticking or

6. Locking Devices Check locking and interlocking devices for proper working

7. Current Carrying Components

8. Contacts • Check for excessive wear and dirt accumulation.

binding).

• Check functions of the operator handles.

• Check the defeater mechanisms on operator handles.

• Replace broken, deformed, malfunctioning or badly worn

parts/assemblies.

condition. Replace as necessary.

• Inspect for discoloration, corrosion, wear, excessive heat and other signs of possible failure.

• Current carryin g devices can include fuse clips, line, and load terminals.

–

Vacuum or wipe contacts w ith a soft cloth to remove dirt. Note: Applicable only for Allen-Bradley® 100-D size contactors (95-860A).

• Replace contacts in complete sets to avoid misalignment and uneven contact pressure.

• Discoloration and/or slight pitting of the contacts is normal.

• Do not file contacts or use spray cleaners.

on page 67.

74 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Maintenance Chapter 8

Suggested Maintenance Guidelines Date Remarks Initials

9. Coils • Check contactor and relay coils for signs of overheating (cracking, melting or burnt insulation).

– If signs of overheating are present, replace the coil.

• Correct the overvoltage or undervoltage conditions that

caused coil failure.

• Clean any residue of melted coil insulation from other parts of the device or replace such parts.

10.Terminals • Check for loose wire connections and tighten as necessary.

• Check schematics/component documentation for torque values.

– Power terminals – Co ntrol circuit terminals

• Replace damaged parts or wiring.

11.Pilot Lights Replace damaged lamps and lenses.

12.Fuses • Check fuses and fuse clips. – When replacing fuses, install the same type and rated

fuse that was originally furnished with the MCC.

13.Fans and Cooling

Devices

• Inspect blowers and fans for operation and damage. – Replace blowers and fans that have bent, chipped or

missing blades, or if the shaft does not turn freely.

• Clean or change air filters for fans.

• Clean heat exchanger fins.

14.Solid State Devices • Perform a visual inspection. Components or circuit boards must be replaced if the following are found:

– Discoloration – Charred or burned components

• Check printed circuit boards for: – Proper seating in the edge board connectors – Locking tabs in place

15.Unit Stabs

•

Inspect stabs for wear and/or corrosion. Replace if necessar y. – If the line stab assembly is severely pitted, inspect the

vertical bus for wear and pitting. Replace as necessary.

• Lightly lubricate line and load stabs with NO-OX-ID grease before installing the unit into the column.

16.Control and Network Plugs

• Inspect for bent or damaged pins. – If necessary, clean the contacts.

• Verify the connector mechanism is functioning properly.

17.Withdrawable Units • Remove dust and grease from the guide rail.

• Check that the withdraw lever and locking mechanism

operate freely.

• Check for easy movement of withdrawable units within the column.

• Test the unit interlock function.

18.Final Check • Verify all withdrawable units are in the correct operating position (Connected, Test, Disconnected, Withdrawn).

• Verify enclosure doors and wireway covers have been closed and are secure.

• After performing maintenance or repair, test the control system for proper functioning under controlled conditions.

(1) The average temperature over a 24-hour period must not exceed 35 °C.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 75

Chapter 8 Maintenance

Notes:

76 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

IntelliCENTER Options

IMPORTANT

Chapter 9

EtherNet/IP Motor Control Centers

Basic information is provided in the following sections. For additional information, refer to CENTERLINE 2500 Motor Control Centers with EtherNet/IP Network, publication 2500-TD003

Connection Count

The EtherNet/IP network can accommodate a vast number of nodes. The EtherNet/IP network does not have a specific maximum number of nodes like other fieldbus networks. The limit is based on the number of connections the EtherNet/IP scanner can make.

To estimate the number of connections a network uses, visit

http://www.rockwellautomation.com/solutions/integrated architecture/ resources3.html for our EtherNet/IP Capacity Tool.

Cable Length Limitations

The EtherNet/IP network uses fiber or copper twisted-pair wiring. The maximum length of copper twisted-pair wiring is 100 m between devices. There is no cumulative length for the entire network. Fiber cable length varies by cable design. Inside the MCC, all cables are copper twisted-pair.

The 100 m maximum length must account for Ethernet cable inside the column. To help determine cable lengths for your application, each MCC is shipped with documentation identifying the cable length used within the MCC. This cable length must be added to the length between the Grace port and the externally-connected device.

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Chapter 9 IntelliCENTER Options

IMPORTANT

Cable Routing

Each EtherNet/IP network has one or two Stratix 6000™ switches typically mounted in the top horizontal wireway in the standard configuration. The number of switches depends on the number of units in the column. Cables connected to the switch are then routed to EtherNet/IP devices in the column. Up to 12 EtherNet/IP ports can be provided in each CENTERLINE 2500 column.

In a standard MCC column, the vertical network wireway has EtherNet/IP connections equal to the number of units (up to 12) for that column. Devices that require 24V DC to power up must have it supplied through pins B4 and B5 in the control plug.

Pins B4 and B5 in the control plug are reserved for 24V DC power; avoid using for other reasons.

Connection to the EtherNet/IP network and the control plug is made when a unit is in the Connected or Test position.

Adding or removing a unit from the EtherNet/IP system does not interrupt the operation of other units in the system.

78 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Figure 26 - EtherNet/IP Network Connections in 2500 MCC Units

Ethernet cable enters and leaves through wireways on each side of column.

Removable horizontal wireway cover at top of MCC column.

NOTE: Examples above depict typical 2500 MCC configurations with EtherNet/IP communication. Refer to 2500-TD003

for more information on EtherNet/IP communication for 2500 MCC units.

Refer to 1783-UM004 for more information on Stratix 5700 Ethernet-managed switches.

Ethernet cable routing through

typical single MCC column.

Stratix 5700

Ethernet Ports

(6 port

model shown)

Ethernet cable routing through typical two MCC columns.

Stratix 5700 switch behind top horizontal wireway cover.

IntelliCENTER Options Chapter 9

Determining Cable Lengths

To help determine cable lengths for your application, each MCC is shipped with documentation identifying the cable length used within the MCC.

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Chapter 9 IntelliCENTER Options

87654321

MCC Cable Types

ATT EN TI ON : Do not apply high voltage to any installed EtherNet/IP cable system or its connectors.

The CENTERLINE 2500 MCCs use a high voltage 600V Ethernet cable designed to perform above TIA 568-B.2 and ODVA Ethernet standards. These cables have the following features:

• Foil and braided shield, PVC, eight conductor (four pair)

• 600V PVC cable designed to support high voltage applications

• On-machine rated cable for use in a cable tray shared with high voltage

power cables

• RJ45 insulation displacement connector available for field terminations

• Wide thermal operating range

Table 5 - EtherNet/IP Cable Specifications for MCCs

Certifications UL and cUL Listed

Outside diameter 0.32 ± 0.015 in. (8.13 ± 0.38 mm)

Operating temperature -20…80 °C

Cable rating UL, cUL TYPE CMG; UL PLTC or UL AWM 2570 80C 600V, TIA 568B

Figure 27 - EtherNet/IP Cable Pin-out

Pin No. Cable Color Description

1 White/Orange TxData + 2 Orange TxData 3 White/Green Recv Data + 4Blue Unused 5 White/Blue Unused 6Green Recv Data 7White/BrownUnused 8Brown Unused

Adding a MCC Unit to an EtherNet/IP System

Use this section to add Bulletin 2500 units to an EtherNet/IP MCC. Each EtherNet/IP component is factory wired within the unit and has a communication cable that plugs into the device on one end and generally into a vertical wireway EtherNet/IP port on the other end.

No. of Conductors

8 Teal 600V PVC Foil and braided

Jacket Material Cable Type Cable Rating Cat. No.

Red 600V PVC 1585J-M8EBJM-2

shield

(UL) CMX, CMR; c(UL) CMG; (UL) PLTC or AWM 2570 80 °C 600V; TIA-568-B

(1)

1585J-M8HBJM-2

80 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

(1) Replace -2 (2 m) with -5 (5 m), or -10 (10 m) for additional standard cable lengths.

IntelliCENTER Options Chapter 9

IMPORTANT

Ethernet Power Supply

Many EtherNet/IP components require 24V DC power source to operate. The power supply must be EtherNet/IP compatible as specified in the ODVA requirements.

Power supplies that do not satisfy both points listed above can result in damage to the EtherNet/IP signal and components, as well as failure to comply with local codes and inspection.

A power supply unit that meets EtherNet/IP requirements can be supplied with the MCC. A cable connects the output of the power supply to pins C3 and C4 of the control plug in the network wireway. This cable is already connected when the power supply unit ships installed in the MCC. Redundant configurations are also available.

Connecting Power Supplies–Remote or in the MCC Lineup

Connect power supplies according to guidelines to minimize voltage drops in the EtherNet/IP system while providing proper supply voltage to system devices. Refer to the Converged Plant-wide Ethernet Design and Implementation Guide,

ENET-TD001

, for detailed connecting instructions.

Network Power Supply and the Protective Earth Circuit

The EtherNet/IP network is grounded at the various components via the component ground. Therefore, no further grounding needs to be connected to the Ethernet cables.

Do not connect the 24V DC common in the power supply bucket to the PE. Doing so violates the grounding guidelines for the various EtherNet/IP components.

Connecting Two Power Supplies

Install an additional 24V DC Class 1 power supply for MCC lineups with 14 or more columns. When using two supplies, provide a break between the two 24V DC networks. Locate the appropriate break for the two networks and verify the terminal blocks are not connected between these two columns.

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Chapter 9 IntelliCENTER Options

EtherNet/IP Network

24V DC Connection -24V DC Connected

+24V DC Not Connected

24V DC Connection

Figure 28 - Connecting Two Power Supplies

Position each power supply so it feeds a maximum of seven columns to the left or right (refer to the sample lineup above).

System Design Installation Checklist

When installing an EtherNet/IP MCC, verify the following before applying power to the network:

• Only one power supply is connected for each 14 sections of MCC.

• The power supply for the system is 24V DC.

• The PE is connected.

• Connections are inspected to detect and correct any loose wires, opens, or

shorts.

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IntelliCENTER Options Chapter 9

IMPORTANT

EtherNet/IP Software Installation Checklist

The following steps, along with references for more information, are provided to assist with the EtherNet/IP software installation process.

1. Install the communication card in your personal computer.

2. Load the Windows hardware drivers for the communication card.

3. Load RSLinx® software.

4. Configure the RSLinx driver.

Within the RSWho function, make sure no unrecognized devices (the ‘?’ symbols) appear for any devices. If an unrecognized device appears, load the electronic data sheet (EDS) file.

DeviceNet Motor Control Centers

Refer to the Electronic Data Sheets (EDS) details.

Do not leave the RSWho constantly browsing. Close the RSWho screen or disable Autobrowse.

5. Use the device web pages or RSLogix™ 5000 software to program and configure devices (for example, full load current, acceleration rate).

6. Write the PLC program.

7. If IntelliCENTER software is provided, load per the IntelliCENTER

Software User Guide, publication MCC-UM001

This section explains how to connect the terminating resistors and join the DeviceNet cables.

section below for additional

Preparing a DeviceNet System for Commission

If your CENTERLINE 2500 MCC is equipped with DeviceNet, terminating resistors must be installed prior to commissioning. If your MCC consists of more than one shipping block, DeviceNet splicing cables need to be installed as columns are joined together.

Basic information is provided in the following sections. For additional information, refer to DeviceNet Motor Control Centers (MCCs), publication

2500-TD002

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Chapter 9 IntelliCENTER Options

IMPORTANT

Terminating Resistors

The DeviceNet network only operates correctly when there are exactly two terminating resistors, one at each end of the network trunk line.

Terminating resistors are necessary at the ends of trunk lines to reduce reflections of the communication signals on the network.

Refer to Figure 29

for more information.

Follow these procedures to install terminating resistors.

1. Locate the terminating resistor kit.

Terminating resistor kits are shipped in the top horizontal wireway. A removable white label indicates the location of the kit.

2. Remove the top horizontal wireway cover from each column in the network.

3. Plug the first terminating resistor into the left port in the top horizontal wireway of the left end column in the network and torque the connector screws to 0.55 N•m.

4. Plug the second terminating resistor into the right port in the top horizontal wireway of the right end column of the network and torque the connector screws to 0.55 N•m.

5. Do not replace the horizontal wireway covers until all shipping blocks in the network have been spliced together.

Refer to

Joining DeviceNet Cables on page 86.

84 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Ter m in at i ng

Resistor

DeviceNet cable is spliced between MCC columns.

Ter m in at i ng

Resistor

Removable horizontal wireway cover at top of MCC column.

DeviceNet Linking

3-phase Horizontal Power Bus

NOTE: Examples at right depict typical 2500 MCC configurations with one DeviceNet network.

Refer to 2500-TD002

for examples of typical 2500 MCC

configurations with two DeviceNet networks.

Tru nk l ine in t he control and network wireway.

DeviceNet ports are supplied for each required unit.

DeviceNet trunk cable routing

through typical MCC column.

DeviceNet

Scanner

DeviceNet

Scanner

Power

Flex

Drive

MCC configuration with a remote DeviceNet scanner.

Configuration wi th remote D eviceNet scanner and divided MCC line-up.

Each DeviceNet trunk line must start and end with a terminating resistor.

MCC configuration with DeviceNet scanner installed in a fixed unit.

MCC configuration with remote DeviceNet scanner and remote device.

DeviceNet port behind top horizontal wireway cover.

Remote

DeviceNet

Scanner

IntelliCENTER Options Chapter 9

Figure 29 - Installing Terminating Resistors and DeviceNet Splicing Cables

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Chapter 9 IntelliCENTER Options

IMPORTANT

Joining DeviceNet Cables

After the terminating resistors have been installed, DeviceNet cables in each column of the network must be spliced together.

Follow these procedures to join the DeviceNet cables.

1. Locate the DeviceNet splicing cable in the top horizontal wireway.

One end of the splicing cable is plugged into the right DeviceNet port in the column to the left of the splice.

2. Route the cable through the top horizontal wireway into the column to the right of the splice.

3. Plug the free end of the DeviceNet splicing cable into the left port in the top horizontal wireway of the column to the right of the splice.

4. Torque connector screws on the splicing cable plugs to 0.55 N•m.

5. Verify the horizontal wireway is free of tools and debris.

6. Replace horizontal wireway covers.

DeviceNet Power Supply

The DeviceNet cable system requires a 24V DC power source to operate. The power supply must be DeviceNet compatible as specified in the ODVA requirements.

Power supplies that do not satisfy both points above can result in damage to the DeviceNet signal and components, as well as failure to comply with local codes and inspection.

A power supply unit that meets DeviceNet requirements can be supplied with the MCC. A cable connects the output of the power supply to a DeviceNet port in the control and network wireway. This cable is already connected when the power supply unit ships installed in the MCC. Redundant configurations are also available.

Remote power supplies should meet the following requirements, per ODVA:

• Rated 24V DC (±1%)

• Rise time of less than 250 milliseconds to within 5% of 24V DC at full

load of 8 A

• Current limit protection of 8 amps continuous and 10 amps for the first 250 ms

• Sized correctly to provide each device with its required power—each device typically requires 90…165 mA

• Derated for temperature with the manufacturer’s guidelines

86 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

IntelliCENTER Options Chapter 9

Power S upply

Power Supply

Red V+

White CAN_H

Blue CAN_L

Black V- (common)

BREAK

Connecting Power Supplies–Remote or in the MCC Line-Up

Connect power supplies according to these guidelines to minimize voltage drops in the DeviceNet system and ensure proper supply voltage to system devices. Refer to the Media Design Installation Guide, DNET-UM072

, for detailed

connecting instructions.

Network Power Supply and the Protective Earth Circuit

The DeviceNet cable must be connected to the PE circuit at only one location. The ideal choice is at the power supply. Connect the power supply and 24V DC common (black wire) to the PE circuit by using #8 AWG wire.

Best PE Practice

• If the power supply comes installed in the MCC, the black 24V DC common terminal is connected to the PE within the unit.

• To improve the connection, use #8 AWG green wire and ground the black 24V DC common terminal to a very stable PE external to the MCC or to an optional true earth (TE) connection inside the MCC.

• If the power supply is external, the same recommendations apply.

Connecting Two Power Supplies

An additional 24V DC Class 1 power supply must be installed for MCC line-ups with more than 14 columns. When using two supplies, the red conductor between the power supplies must be broken. Locate a linking connector between columns and disconnect the red conductor.

Connect only ONE of the two power supplies to the PE.

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Chapter 9 IntelliCENTER Options

Power SupplyPower Supply

MCC Line-Up With More Than 14 Columns

Break Red Conductor

Position each power supply to ensure that it feeds a maximum of seven columns to the left or right (see the sample line-up below).

MCC line-ups with more than 14 columns could exceed the 75 m trunk length limit to support 500 kbps communications. When the trunk length exceeds this limit, 250 kbps communications should be specified.

Electronic Data Sheets (EDS)

This section applies to any MCC with IntelliCENTER software installed on a DeviceNet or EtherNet/IP network.

After IntelliCENTER software is installed, an electronic data sheet (EDS) must be registered for each unique device in the MCC. This section details how to perform that task.

Overview

EDS files are simple text files used by network configuration tools—such as RSNetWorx™, RSLogix 5000, or IntelliCENTER software—to help identify products and easily commission them on a network. EDS files describe a product’s device type, version, and configurable parameters on a DeviceNet or EtherNet/IP network.

Where to Find EDS Files

The IntelliCENTER data CD has a directory (<cdrom>:\<order>\<item>\EDS) that contains the EDS files necessary for the devices in your IntelliCENTER MCC. The EDS files are automatically registered by the installation program.

An “EDS file” CD is provided that contains EDS files for all DeviceNet and EtherNet/IP products found in MCCs.

88 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

IntelliCENTER Options Chapter 9

Installing EDS Files

EDS files are installed with a program from Rockwell Software® called ‘RSHWare.exe’. This program is included on the IntelliCENTER data CD and in the same directory as the EDS files.

Follow these steps to install EDS files for a DeviceNet or EtherNet/IP network.

1. Ru n t he pr og ra m ‘ R SH War e. ex e’.

2. Click Add/Remove.

3. Select Register an EDS file and click Next.

4. Select Register a directory of EDS files.

5. Browse to the EDS directory on the data CD.

6. Click Next.

The Installer displays the test results.

7. Click Next to continue.

The Installer lets you to change the graphic image for each device.

8. Click Next to continue.

The Installer displays the final task summary.

9. Click Next to continue.

10. Click Finish when completed.

Finding EDS Files for Other Devices

EDS files can be obtained at

http://www.rockwellautomation.com/resources/eds/

Uploading EDS Files from the Device

RSNetWorx for EtherNet/IP or RSNetWorx for DeviceNet software can be used to upload an EDS file directly from a device. If an EDS file cannot be found by other methods, refer to the RSNetWorx help file for steps to upload an EDS file.

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Chapter 9 IntelliCENTER Options

Notes:

90 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Worksheets

Ver tic al Wir eway

80 mm

Bottom Horizontal Wireway

Ver tic al Wir eway

Top Horizontal Wireway

Appendix A

Sample MCC Layout Worksheet

Figure 30 - Sample MCC Layout Worksheet

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 91

Appendix A Work she ets

Unit Data

Serial Number Wiring Diagram

Table 6 - Location of Sample Units within above MCC Layout

Unit Location

1A Y-359039 1200A MLUG

1J Y-359043 DOL 185

2A Y-359042 DOL 110

2N Y-359041 DOL 22

2S Y-359045 XFMR

Size or Amp Rating

Description

Full Load Current

Overload

Kilowatts

Circuit Breaker Trip Setting

Power Fuse Rating

92 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Work she ets Appendix A

Table 7 - Motor Control Center Layout Worksheet

MCC Name / Number ___________________________________________________________

Unit Data

Serial Number Wiring Diagram

Unit Location

Size or Amp Rating

Description

Full Load Current

Overload

Kilowatts

Circuit Breaker Trip Setting

Power Fuse Rating

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 93

Appendix A Work she ets

Table 8 - Megger Reading Recording Table

MCC Name / Number ___________________________________________________________

Date Circuit / Unit

Name / Number

Phase-to-Phase Phase-to-PE Phase-to-Neutral

A - B B - C C - A A - PE B - PE C - PE A - Neut. B - Neut. C - Neut.

94 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Glossary

The following terms and abbreviations are used throughout this manual. For definitions of terms not listed here, refer to the Allen-Bradley Industrial Automation Glossary, publication AG-7.1

Column Vertical segment of a motor control center. Columns consist of the bus system,

units and wireways. Sometimes referred to as cubicle.

Conduit Metal tube that encloses electric wires and cables.

Connected position Plug-in unit operating position in which the line, load, control, network, and

protective earth (PE) connections are engaged. For more information, refer to

Chapter 6, Install and Remove Units

Control station Door mounted assembly that houses push buttons, indicator lights and other

small control devices.

Control unit Unit that contains any type of power control or metering device including

starters, contactors, AC drives and soft starters.

Disconnected position Plug-in unit operating position in which line, load, control, network, and

protective earth (PE) connections are disengaged, but the unit is still housed in the column. For more information, refer to Chapter 6, Install and Remove Units

Double-front Configuration in which columns are installed back-to-back. Columns with

double-front construction contain separate power bus systems that are spliced together.

Feeder unit Unit containing a disconnection means used to distribute power to a remote

device.

Fixed unit Unit that is permanently mounted in a column. These units typically house

components that are large and/or require more current capacity than a plug-in unit can provide. Sometimes referred to as a frame-mounted unit.

Locking mechanism Part of the withdraw lever. This mechanism must be engaged to select unit

operating positions. (See Selecting an Operating Position

Main switch Disconnecting means for a motor control center. Available in two types: circuit

breaker or disconnect switch.

Module space Grid size used to determine space distribution within the motor control center.

Height of one module is approximately 80 mm. Module width is 500 mm.

on page 62).

Motor control center (MCC) One or more columns operating with a common power bus.

Plating Type of surface treatment that distributes a layer of protective coating on

structural parts.

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 95

Glossary

Plug-in units Removable units with line connections made via unit bus line stabs. Plug-in units

include withdrawable units. Sometimes referred to as withdrawable or removable units.

Protective earth conductor (PE) Protective circuit busbar. Sometimes referred to as earth bar.

Released position Plug-in unit operating position in which line, load, control, network, and

protective earth (PE) connections are disengaged and the unit is removed from the column. For more information refer to Chapter 6, Install and Remove Units

Shipping block A single column packaged for transport or multiple columns joined and

packaged together at the manufacturing site for ease of transportation. Shipping blocks cannot be separated at the installation site. Sometimes referred to as shipping splits.

Skilled person “Person with relevant education and experience to enable him or her to perceive

risks and to avoid hazards that operation or maintenance of a product can create.” IEC 60204-1, 3.52 and IEV 195-04-01.

Stabs Assembly on the back of a unit that is used to make line and load connections.

(See Withdrawable Units

on page 60).

Test position Plug-in unit operating position in which the control, network, and protective

earth (PE) connections are engaged, and line and load connections are isolated. For more information refer to Chapter 6, Install and Remove Units

Tr unk li ne Main DeviceNet communication cable within the motor control center.

Un it An arrangement of power and/or control devices that are housed together and

inserted into a column. A unit can be used to distribute power or control a remote device. The size of units is described by module space.

Unit main switch Disconnecting means for a unit within a motor control center. Available in two

types: circuit breaker or fused disconnect.

Withdraw lever Mechanism used to insert and remove withdrawable units. The withdraw lever is

used to select an operating position (inserted, test, disconnected, and withdrawn) and has mechanical detents so the lever is securely in position. (See Selecting an

Operating Position on page 62).

Withdrawable unit Unit where line, load, control, network and PE connections are made with stabs

or connectors. Withdrawable units are inserted and removed by using the withdraw lever.

96 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Index

altitude 24 ArcShield

clearance space door latches install latch bracket stiffener pressure relief plate 16

bus splice kits

locating

cables

bracing control

DeviceNet 77, 83 incoming line lug install

install considerations 45 joining DeviceNet lugs

main disconnect switch 47 network

secure load wires

circuit breakers

operator handles

clearance space closing unit door column

construction dimensions front mounted configuration install 23 joining location planning nameplate splicing

commissioning

pre commissioning checklist procedure 71

control cables

covers

51, 55

DeviceNet 83

cable system joining cables terminating resistors

door latches

ArcShield normal

77, 83

52, 56

environment

altitude

humidity

pollution degree 24 temperature

handling 22 humidity

incoming line lug 47 install

cables lugs

joining DeviceNet cables 86

large rotary operator handles 54 location planning locking units

in off position in on position in the on position 57

lugs

53, 56 53

main disconnect switch 47 maintenance

MCC

megger reading recording table module space mounting arrangement

suggested guidelines

DeviceNet handling layout worksheet options 77 packaging positioning seismic requirements sequence number storage unit descriptions unit types withdrawable units

alternative double-front preferred

Rockwell Automation Publication 2500-IN001C-EN-P - April 2014 97

Index

nameplate

column sequence number unit label

nameplate data network cables

opening door

handle in on position unit

operating device height considerations 49 operating position

operating positions

operator handles for circuit breakers options

51, 54

selecting

connected disconnected released 63 test

52, 55

52, 56

packaging

export

heavy duty horizontal bus box 26 removal shipping skid standard 21

pollution degree positioning MCC power bus

access splice splicing

pre commissioning checklist

removing covers 27 removing doors

multiple module unit one module unit

unit

sealing caulk 30 secure load wires securing

column shipping block

seismic requirements

bolt down

selecting an operating position 62 small rotary operator handles splice

power bus protective earth conductor

storage

39, 40

temperature 24 terminal resistors torque specifications

units

closing door closing the door descriptions 59 information inserting withdrawable install 59 interlocks label lock in on position 53 locking in off position locking in on position opening door 54 opening door with handle in on position opening the door removal 59 removing door removing multiple module doors removing one module doors removing withdrawable types

53, 56

withdrawable units 60

connected disconnected insert operating positions 61 released removing test

98 Rockwell Automation Publication 2500-IN001C-EN-P - April 2014

Rockwell Automation Support

Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400

Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support software service packs. You can also visit our Support Center at https://rockwellautomation.custhelp.com/ updates, support chats and forums, technical information, FAQs, and to sign up for product notification updates.

In addition, we offer multiple support programs for installation, configuration, and troubleshooting. For more information, contact your local distributor or Rockwell Automation representative, or visit

http://www.rockwellautomation.com/services/online-phone

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 ldw ide L ocat or

Rockwell Automation representative.

at http://www.rockwellautomation.com/rockwellautomation/support/overview.page, or contact your local

New Product Satisfaction Return

you can find technical and application notes, sample code, and links to

for software

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

Rockwell Automation maintains current product environmental information on its website at

http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page

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

Publication 2500-IN001C-EN-P - April 2014 PN-252150

Rockwell Automation 2500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CENTERLINE 2500 Low Voltage Motor Control Centers

Important User Information

Summary of Changes

New and Updated Information

Table of Contents

Preface

Additional Resources

Purchased Components and Additional Instruction Sheets

ArcShield Rating

IntelliCENTER Software

IntelliCENTER Features

IntelliCENTER Software

Structure

Dimensions

Typical Column Construction

Technical Data

Nameplate Data

Motor Control Center Sequence Numbering

ArcShield Labels

Receiving

Handling

Storage

Location Planning

ArcShield Clearance Space

Environment

Remove Packing Materials

Locating Bus Splice Kits

Removing the Covers

Positioning the Motor Control Center

Securing a Motor Control Center

Securing Methods

Sealing IP54 Enclosures Before Securing

Securing Single-front, One-column-wide Shipping Blocks

Securing Single-front, Two-column-wide Shipping Blocks

Securing Double-front, One-column-wide Shipping Blocks

Securing Multiple-column Shipping Blocks

Joining Columns

Seismic Capabilities

Splicing the Power Bus

Accessing the Power Bus

Splicing Power Bus, 800…4000 A

Splicing the Protective Earth (PE) Conductor

Control and Network Cables

Torque Specifications

Install ArcShield Protection After Wiring

Lugs

Incoming Line Lug Compartment

Main Disconnecting Means

Cable Bracing

Secure Load Wires

Height Considerations

Door Latches

Quarter-turn Door Latches

ArcShield Door Latches

Small Rotary-operator Handles

Opening the Unit Door

Closing the Unit Door

Opening the Unit Door in the ON/I Position

Operator Handles for Circuit Breakers

Locking Units in the OFF/O Position

Locking Units in the ON/I Position

Large Rotary-operator Handles

Opening the Unit Door

Closing the Unit Door

Opening the Unit Door in the ON/I Position

Operator Handles for Circuit Breakers

Locking Units in the OFF/O Position

Locking Units in the ON/I Position

Unit Interlocks

Unit Size

Withdrawable Units

Operating Positions

Selecting an Operating Position

Safety Guidelines for Installing and Removing Withdrawable Units

Inserting a Withdrawable Unit

Removing a Withdrawable Unit