Rockwell Automation CENTERLINE 2100 Instruction Manual

CENTERLINE 2100 Low Voltage Motor Control Centers

Instruction Manual

2100-xxx

Important User Information

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

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

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

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

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

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

available from your local

) describes some important differences

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.

IMPORTANT

ATTENTION

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

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

SHOCK HAZARD

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

BURN HAZARD

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

CENTERLINE, CENTERLINE 2100, ArcShield, Allen-Bradley, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

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

Summary of Changes

The information below summarizes the changes to this manual since the last printing.

To help you find new and updated information in this release of the manual, we have included change bars as shown to the right of this paragraph.

Topic Page

Addition of ArcShield Throughout document Updated tech support contact information Throughout document Updated product dimensions 26 Updated seismic information 37 Addition of temperature measurement

techniques for preventative maintenance

3Publication 2100-IN012C-EN-P - April 2009 3

Summary of Changes

Notes:

4 Publication 2100-IN012C-EN-P - April 2009

General Information

Preface

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

Purchased Components and Additional Instruction Sheets. . . 10

Chapter 1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

MCC Sequence Numbering . . . . . . . . . . . . . . . . . . . . . . . . . 14

UL/CSA Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Short-circuit Rating Label. . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Series Number and Series ID as Manufactured in the

United States. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Series Lettering - Units and Sections. . . . . . . . . . . . . . . . . . . 20

Receiving, Handling and Storage . . . . . . . . . . . . . . . . . . . . . 22

Receiving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Storage and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Installation Procedures

Installing Conduit and Cable

Chapter 2

Location Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Height Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Securing an MCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Seismic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Joining & Splicing New MCCs . . . . . . . . . . . . . . . . . . . . . . . 38

Joining & Splicing Existing MCCs . . . . . . . . . . . . . . . . . . . . . 38

Installing and Joining Pull Boxes . . . . . . . . . . . . . . . . . . . . . 38

Joining and Splicing NEMA Type 12 MCCs . . . . . . . . . . . . . . 39

Joining & Splicing NEMA Type 3R and Type 4 MCCs . . . . . . 39

Bus Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Chapter 3

Installing Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Bottom Entry Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Top Entry Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Installing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Incoming Line Compartment . . . . . . . . . . . . . . . . . . . . . 43

Main Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Cable Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Incoming Line Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Chapter 4 Installing and Removing Plug-in Units

5Publication 2100-IN012C-EN-P - April 2009 5

Installing Plug-in Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Remove a Plug-in Unit with a Vertical Operating Handle

from a Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Table of Contents

Arc Flash Protection Marking as Required by the National Electrical Code

Operator Handle and Unit Interlock

Remove a Plug-in Unit with a Horizontal Operating Handle

from a Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Remove the Support Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Chapter 5

Flash Protection Marking Requirement . . . . . . . . . . . . . . . . . 59

110.16 Flash Protection . . . . . . . . . . . . . . . . . . . . . . . . . 59

Arc Flash Marking Clarification . . . . . . . . . . . . . . . . . . . . . . 60

Rockwell Automation Services . . . . . . . . . . . . . . . . . . . . . . . 60

Chapter 6

Defeating the Unit Door Interlock . . . . . . . . . . . . . . . . . . . . 61

Open the Door when the Operating Handle is in the

ON/I Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Defeating the Unit Interlock Lever . . . . . . . . . . . . . . . . . . . . 63

Energize a Unit with the Unit Door Open . . . . . . . . . . . . 63

Locking Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Lock Vertical Operating Handles in the OFF/O Position . 64 Lock Horizontal Operating Handles in the OFF/O

Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Lock Units with Operating Handles in the ON/I Position . 66

Unit Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Final Check List Before Energizing

Energizing the Equipment

Maintenance

Maintenance After Fault Condition

Renewal Parts

Chapter 7

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Pre-Energizing Check Procedure . . . . . . . . . . . . . . . . . . . . . 73

Perform the Pre-energizing Check Procedure . . . . . . . . . . . . 74

Chapter 8

Energize the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Chapter 9

Maintain the MCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Disconnect the Switch and Contact Lubrication . . . . . . . . . . 94

Use Thermal Infrared or Other Temperature Measurement

Techniques for Preventive Maintenance . . . . . . . . . . . . . . . . 95

Inspect the Units for Signs of Overheating . . . . . . . . . . . 96

Chapter 10

Maintain the MCC After a Fault Condition . . . . . . . . . . . . . . 99

Chapter 11

Order Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

6 Publication 2100-IN012C-EN-P - April 2009

Parts Illustrations

Table of Contents

Chapter 12

Typical Section Construction . . . . . . . . . . . . . . . . . . . . . . . 103

Typical Construction of a Unit with a Vertical Operating

Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Typical Construction of a Half Space Factor Unit with a Horizontal Operating Handle and Door Mounted Pilot

Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Typical Construction of a Unit with a Horizontal Operating

Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Index

Publication 2100-IN012C-EN-P - April 2009 7

Table of Contents

8 Publication 2100-IN012C-EN-P - April 2009

Preface

Additional Resources

The following publications supplement this manual. For more information and further reference, please use these available publications.

Publication Name Publication No.

Arc-Flash Resistant Low Voltage Motor Control Center Designs White Paper

Power Factor Correction Capacitors for Bulletin 2100 MCC Starter Units Application Techniques

CENTERLINE 2100 Motor Control Centers Joining and Splicing Vertical Sections Instructions

CENTERLINE 2100 Motor Control Centers (MCC) Units with Vertical Operating Handles Installation Instructions

CENTERLINE Motor Control Centers NEMA Type 12 Sealing Instructions

Receiving, Handling, and Storing Motor Control Centers 2100-IN040 MCC Instantaneous Trip Motor Circuit Protectors (MCP) in

Combination NEMA Starter, Soft Starter (SMC), and Variable Frequency AC Drive Units Technical Data

MCC Inverse Time Circuit Breakers in Combination NEMA Starter, Soft Starter (SMC), and Variable Frequency AC Drive Units Technical Data

CENTERLINE Motor Control Centers Power Fuses Product Data 2100-TD003 DeviceNet Motor Control Centers (MCC) Technical Data 2100-TD019

2100-AP003

2100-AT001

2100-IN010

2100-IN014

2100-IN037

2100-TD001

2100-TD002

CENTERLINE 2100 Motor Control Center End Closing Plates Installation Instructions

CENTERLINE 2100 Motor Control Center (MCC) Units with Horizontal Operating Handles Installation Instructions

CENTERLINE Motor Control Centers Mains and Incoming Lines Reference Document Update

CENTERLINE Motor Control Centers Installing a Pull Box on a Bulletin 2100 Vertical Section Instructions

Safety Guidelines for the Application, Installation, and Maintenance of Solid-state Control

2100-IN069

2100-IN060

2100-TD018

2100-IN029

SGI-IN001

You can view or download publications at

http://literature.rockwellautomation.com

. To order paper copies of technical documents, contact your local Rockwell Automation distributor or sales representative.

9Publication 2100-IN012C-EN-P - April 2009 9

Preface

The documents in the following table are referenced in this document and can be obtained from their respective organizations.

Resource Website

National Electrical Manufacturer’s Association (NEMA)

• NEMA ICS 1-2000 Industrial Control and Systems: General Requirements

• NEMA ICS 2.3-1995, Instructions for Handling, Operation and Maintenance of Motor Control Centers Rated Not More Than 600V

National Fire Protection Association (NFPA)

• NFPA 70 - National Electrical Code

• NFPA 70A - Recommended Practice for Electrical Equipment

Maintenance

• NFPA 70E - Standard for Electrical Safety in the Workplace

Institute of Electrical and Electronic Engineers (IEEE) IEEE standard C37.20.7 - IEEE Guide for Testing Metal-Enclosed Switchgear Rated Up to 38 kV for Internal Arcing Faults

www.nema.org

www.nfpa.org

www.ieee.org

Purchased Components and

When equipment such as transformers, metering, PLCs, or drives are supplied with the motor control center (MCC), specific manuals and

Additional Instruction Sheets

data sheets are also supplied. These documents should be read and understood before installing and operating the MCC. Refer to the unit locations of these devices for their manuals and/or data sheets.

10 Publication 2100-IN012C-EN-P - April 2009

General Information

Chapter

General Description

Allen-Bradley CENTERLINE Motor Control Centers (MCCs) consist of one or more vertical sections containing electromagnetic and/or solid state control devices that are prewired and tested within modular (plug-in) or frame mounted (hard-wired) units.

CENTERLINE MCCs are designed in standard widths of 20 in. (508 mm), 25 in. (635 mm), 30 in. (762 mm), 35 in. (789 mm), and 40 in. (1016 mm). The standard front-mounted depths of an MCC are 15 in. (381 mm) and 20 in. (508 mm), in addition back-to-back mounted depths of 30 in. (762 mm) and 40 in. (1016 mm) are also offered. The standard height of an MCC is 90 in. (2286 mm). A 70.5 in. (1791 mm) high section is also available. All MCC sections are supplied with top and bottom horizontal wireways. Sections which are designed to accommodate plug-in units include a vertical wireway. Each 90 in. (2286 mm) vertical section can accommodate up to 6.0 space factors or 78 in. (1981 mm) for units.

Units (buckets) are designed in increments of 0.5 space factors. Each

0.5 space factor is approximately 6.5 in. (165.1 mm) high. Units are designed as either removable (plug-in) or frame-mounted (non-plug-in).

Individual units house a wide variety of power and logic devices. Plug-in units are mounted on unit support pans within the section. Stab assemblies located on the back of the unit plug onto the vertical bus. A mechanical interlock prevents the unit door from being opened when the disconnect is not in the OFF position. An additional mechanical interlock prevents the unit from being plugged-in or unplugged when the disconnect is not in the OFF position.

Line power is distributed throughout the MCC via an isolated bus work structure. The main horizontal bus is located in the center of each section. 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, allowing virtually unrestricted unit arrangement. An optional 600 A vertical bus provides 1200 A effective rating.

11Publication 2100-IN012C-EN-P - April 2009 11

Chapter 1 General Information

The CENTERLINE MCC is also available with ArcShield. ArcShield includes arc resistant features which are intended to help provide enhanced protection to you during internal arcing faults (when compared to MCCs which are only designed to meet UL 845 requirements). Arcing faults can be caused, for example, by accidental touching, closing into faulted lines, or loose connections. Depending on the application, ArcShield can provide up to Type 2 accessibility per IEEE standard C37.20.7, which helps protect you when you are located at the front, sides, and rear of the enclosure in the unlikely event of an arcing fault.

A label on the MCC with ArcShield provides information in regard to the accessibility level and arc fault ratings.

For more information about accessibility levels, performance, and testing requirements, refer to IEEE standard C37.20.7, IEEE Guide for Testing Metal-Enclosed Switchgear Rated up to 38 kV for Internal Arcing Faults.

ArcShield provides a reinforced MCC structure and arc-containment latches on all doors. To help protect you during an arc-fault, arc-containment latches, when closed and latched properly, allow pressure relief and help keep the doors from unlatching or detaching from the structure.

12 Publication 2100-IN012C-EN-P - April 2009

General Information Chapter 1

Nameplate Data

Catalog Number/Serial Number

UL and cUL Certification Marking

Section Number

Each MCC section has a nameplate located on the enclosure or vertical wireway door. The nameplate includes:

• catalog number/serial number.

• series letter of section.

• bus bar voltage and current rating.

• section number.

• UL and cUL certification marking.

• UL registration number.

• enclosure type.

Section Nameplate

Series Letter of Section

Bus Bar Voltage and Current Rating

UL Registration Number

Enclosure Type

Catalog Number / Serial Number

cUL Certification Marking

Each plug-in and frame mounted unit also has an identification label. The unit label is located on the interior of the bottom plate of plug-in units or on the interior right-hand side plate of the frame mounted units. The unit label for each plug-in or frame mounted unit includes:

• catalog number/serial number.

• series letter of the unit.

• voltage rating.

• unit location.

• UL and cUL certification marking.

• device type and size.

Unit Label

Series Letter of Unit

Device Type and Size

Unit Location

Voltage Rating

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

Publication 2100-IN012C-EN-P - April 2009 13

Chapter 1 General Information

MCC Sequence Numbering

Identifies Vertical Section Sequence Numbering

CENTERLINE MCCs are designed so functionality is not affected by the section installation order, for example, vertical section-numbering sequence order.

All MCC sections carry a serial plate, which identifies vertical section sequence numbering. For example, MCC section 1 of 1, 1 of 5, and so on.

Section Nameplate

Sections are numbered to match factory-supplied MCC elevation drawings. Numbering each section helps installers and users easily identify MCCs, sections, and units. If there are questions about section numbering during field installation, inspection, or operation, the following information can provide guidance on equipment acceptability, listing, and certification.

CENTERLINE MCC sections can be installed or added as follows:

• In non-sequential order

• Addition of a single section (add-on section)

• Addition of multiple sections (add-on lineup of sections)

• Addition of single section or multiple section between MCC

sections

If sections are added to an existing lineup and not installed in sequential order, the installation should not be considered a misapplication or in conflict with Underwriter Laboratories (UL) listing and Canadian Standards Association (CSA) certification.

The paramount criteria for additions of sections to existing MCCs is matching the horizontal bus electrical and ingress protection (enclosure type) ratings for the total MCC line up. For example, the voltage, current rating, short circuit withstand, and NEMA enclosure type (IP rating) for all sections must match.

14 Publication 2100-IN012C-EN-P - April 2009

General Information Chapter 1

Non-sequential numbering may not create a functional or listing/certification issue. However, MCCs should be installed in sequential order. Installing MCCs in sequential order helps ensure proper installation and ensures that factory-supplied documentation matches the equipment.

You can rearrange MCC sections. However, if a section that uses a right-hand side sheet with integral, internal mounting flanges is located on the outside of a lineup, an additional closing kit plate is required. Refer to CENTERLINE 2100 Motor Control Center End Closing Plates Installation Instructions, publication 2100-IN069 that contain contain arc resistant features cannot use a section with integral mounting flanges on the outside of a lineup.

. MCCs

UL/CSA Marking

CENTERLINE MCCs are listed by Underwriter’s Laboratories, Inc. (UL), Standard for Safety UL 845, and certified by the Canadian Standards Associate (CSA), Standard C22-2, No. 14.

Due to standards harmonization, a MCC may also carry the cUL designation. cUL is comparable to CSA certification.

Vertical sections and units are labeled independently. It is possible to have combinations of labeled and non-labeled sections and units in the same MCC.

Vertical sections and structure options that are UL listed and CSA/cUL certified are marked accordingly. All components in a UL or CSA listed section must be UL listed and cUL/CSA certified. The UL and/or CSA/cUL designation is an integral part of the section nameplate as shown on page 14

Units and unit options that are UL listed and CSA/cUL certified are marked accordingly. All options and components in a UL and/or cUL/CSA listed unit must be UL listed or recognized and/or cUL/CSA certified. The UL designation is located on the interior of the bottom plate of plug-in units or on the interior right-hand side plate of frame mounted units.

UL Label Designation for Units

Publication 2100-IN012C-EN-P - April 2009 15

Chapter 1 General Information

Short-circuit Rating Label

MCC vertical sections that are UL listed and/or CSA/cUL certified will carry a short-circuit rating label. The short-circuit rating label for a vertical section is located on the inside of the vertical wireway door of standard sections or on the interior right-hand side plate of a section that contains a unit that occupies the full section and does not contain a vertical wireway.

Short Circuit Label for Sections

MCC units that are UL listed and/or CSA/cUL certified will carry a short-circuit rating label located on the bottom plate of plug-in units or on interior right-hand side plate of frame mounted units.

Short Circuit Label for Units

16 Publication 2100-IN012C-EN-P - April 2009

Series Number and Series

General Information Chapter 1

ID as Manufactured in the United States

Sections

Series Letter

Scope Description of Change Date

(1)

— Original design

All Changed terminal blocks

All Elimination of external mounting channels

All Reverse fed 2192 and 2193

All Redesign gasketing

All Modified top horizontal wireway pan to accept units with handle interlock in topmost space

factor

(1)

42K 42 k bracing-incorporates new bus support & cover

65K 65 k bracing-incorporates new bus support & cover

ATTENTION

Read tables through before adding new sections or units to an existing CENTERLINE MCC.

Implemented in the U.S.

February 1971

November 1976

June 1979

April 1981

October 1982

October 1983

January 1985

July 1985

H All New hinge design January 1986 J All Changed handle, operating mechanism, and circuit breaker to Cutler-Hammer series C, 150 A,

250 A, 400 A frame

October 1986

K All Changed to new unit grounding system May 1990

L All Changed to new 600 A...1200 A circuit breaker operating mechanism February 1996

M All Changed to serpentine DeviceNet cabling system May 2001

(1)

Replacement and renewal parts are no longer supported. For more information, contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

2100 Units

Series Letter

Scope Description of Change Date Implemented

in U.S.

(1)

— Original design

All sizes Changed terminal blocks

All sizes Changed handle mechanism to Cutler-Hammer MCPs

Size 5 Changed from ITE to A-B 400A disconnect

All sizes Changed from Bulletin 709 series K starters to Bulletin 500 line starters

February 1971

November 1976

June 1979

April 1981

Publication 2100-IN012C-EN-P - April 2009 17

Chapter 1 General Information

2100 Units

Series Letter

(1)

Scope Description of Change Date Implemented

in U.S.

All sizes Redesign of gasketing, wraparound and unit support pan for Bulletin 700 line

All sizes Redesign of gasketing, wraparound and unit support pan for Bulletin 500 line

All sizes Changed to new door, circuit breaker mechanism and control station

October 1982

April 1984

Size 5 Changed to Bulletin 500 series L October 1984 Size 3 Changed to new PCP 100A disconnect December 1988 Size 6 Changed to Bulletin 500 series B starters October 1988

Size 1-5 CB

units and size

Changed handle, operating mechanism and circuit breaker to Cutler-Hammer series C, 150 A, 250 A, 400 A frame October 1986

1-2 disc units

21A through

54A

All sizes Changed to new unit grounding system and 600 A, 800 A, 1200 A bolted pressure

All sizes Changed to PCP 200 A and 400 A disconnect, rerated vacuum Bulletin 2112 and

0.5 SF CB units 2103L, 2113,

Changed to Bulletin 100 line contactors in 21 A, 30 A, 45 A SMC units and original design 24 A, 35 A, 54 A SMC units

switch

2113 and new pilot device offerings External auxiliary on circuit breakers

November 1989

May 1990

January 1993

April 1994

2193

All sizes and

ratings

New disconnect external auxiliary contacts and new 600 A...1200 A circuit breaker operating mechanism

May 1996

SMC units Redesign and upgrade of ratings for 24 A...500 A SMC-2 and SMC-PLUS units.

Original design of SMC Dialog Plus units

1200A 2193 Redesign of 1200A, 2193F and 2193M units November 1997

August 1997

800A 2193 Changed circuit breakers to MDL Frame November 1998

225A 2193F Changed circuit breakers from J Frame to F Frame October 1999

2000A 2193 Changed to flange mounted operating handle November 2000

All sizes Changed the Bulletin 800MR and Bulletin 800T-PS pilot devices to Bulletin 800Es November 2000

All 1.5 space

factor units

All except 2100-SD1

Changed unit bottom plate

Changed to new Bulletin 1497 control circuit transformer

November 2000

July 2001

2100-SD1 Changed smoke detector head and base components November 2001

18 Publication 2100-IN012C-EN-P - April 2009

2100 Units

General Information Chapter 1

Series Letter

Scope Description of Change Date Implemented

in U.S.

2162Q, 2163Q, 2164Q, 2165Q

2162R, 2163R,

2164R, 2165R

Redesign of 240-480V PowerFlex 70 and release of 600V PowerFlex 70

Original release of PowerFlex 700

April 2002

July 2002

2154H, 2155H Original release of SMC-3 November 2002

2154J, 2155J Original release of SMC Flex April 2004

2112, size 3, 4

and 5

Redesign to reduced space factor with Class J fuse clip

April 2004

2162T, 2163T Original release of PowerFlex 40 September 2004

2107, 2113,

size 3

Reduced space factor

April 2005

2162Q, 2163Q Reduced space factor, changed CCT with integral fuses April 2005

All sizes 800F pilot devices August 2005

2154J, 2155J,

108 A and 135

Redesign to change units from frame mounted to plug-in

March 2006

(1)

Replacement and renewal parts are no longer supported. For more information contact, Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

2400 Units

Series

Scope Description of Change Date

Letter

A — Original design June 1990 B 18A, 24A, 30A Changed to series B, Bulletin 194R, 30 A disconnect March 1992 C 18A, 24A, 30A Changed to three Bulletin 800E pilot devices on 0.5 space factor units July 1992

All sizes New disconnect external auxiliary contacts and new 600 A...1200 A circuit breaker

operating mechanism

16A-85A Original design of units with a Bulletin 100-C contactor September 1999

Implemented in U.S.

February 1996

Publication 2100-IN012C-EN-P - April 2009 19

Chapter 1 General Information

Series Lettering - Units and

When using sections in conjunction with units of different series letters, consult the table below.

Sections

MCC Modifications for Unit and Structure Compatibility

If Mounted in this Type of

(1),(2)

Section

NEMA Type 1 Series A...D

NEMA Type 1 Series E...J

(4)

NEMA Type 1 Series K or later

NEMA Type 1 w/gasket or Type 12 Series A...D

NEMA Type 1 w/gasket or Type 12

Series E...J

(7)

NEMA Type 1 w/gasket or Type 12 Series K or later

Plug-in Units No

Space Factor

1.0 or

(4)

larger

Series — 2100H-UAJ1 2100H-UA1

A-E

F-L M or

later

(2)

N or

0.5

1.0 or

later

A-E

larger

F-L M or

later

(2)

0.5

N or later

1.0 or

A-L

larger

M or later

1.0 or

A-E

larger

F-L M or

later

(2)

0.5

N or later

1.0 or

A-E

larger

F-L M or

later

(2)

0.5

N or later

1.0 or

A-L

larger

M or later

Additional Parts Required

(4)

—  ——

(6)

———  —— 

(4)

——  ————

——— — — ——

(6)

(4)

——  ————

—  ——

———  —— 

(4)

——  ————

——— — — ——

(4)

——  ————

Requires Style 1 Unit Support Pan

 ——— — ———

Requires Style 3 Unit Support Pan

2100H-UJ1

Requires Style 3 Unit Support Pan w/ Bushing

2100H-USPA1 2100H-USPJ1

Requires Alternate Top Horizontal Wireway Pan

2100H-NA4A1 2100H-NA4J1 2100H-NA4A2 2100H-NA4J2

(5)



(5)



(5)



(5)



Requires Door Gasketing Kit

2100-GJ10 2100H-R1

Requires Retrofit

Kit

2100H-R2

Requires Ground

(3)

Bus Kit

2100H-GS1

———

——

(8)

 ——

 — 

(8)

20 Publication 2100-IN012C-EN-P - April 2009

General Information Chapter 1

(1)

When installing unit in topmost location in vertical sections, care must be taken to comply with the National Electric Code 6.7 ft (2000 mm) unit handle-to-floor height limitation. A unit operating handle extender (catalog number 2100-NE1) is available which provides 3 in. (76.2 mm) added height flexibility.

(2)

When CENTERLINE 2100, 0.5 space factor or Space Saving NEMA Starter plug-in units are ordered unassembled or ordered for existing sections, a centralized wiring diagram holder kit (catalog number 2100H-WDH) should be ordered.

(3)

Permits installation of 0.5 space factor or Space Saving NEMA Starter plug-in units in existing series E...J CENTERLINE 2100 vertical sections.

(4)

Replacement and renewal parts are no longer supported. Contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

(5)

Required only if series F or later, 1.0 space factor or larger CENTERLINE 2100 unit is installed in topmost location of series A...E vertical sections.

(6)

For more information regarding possible door hinge requirements, contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

(7)

Series E...J sections cannot accommodate 0.5 space factor or Space Saving NEMA Starter plug-in units in bottom-most unit location.

(8)

A ground strap can be used to ground units rather then installing a ground bus. Refer to the CENTERLINE 2100 Motor Control Centers (MCC) Units with Vertical Operating Handles Installation Instructions, publication 2100-IN014

Publication 2100-IN012C-EN-P - April 2009 21

Chapter 1 General Information

Receiving, Handling and Storage

Refer to the following sections for information on receiving, handling, and storage of MCC units.

Receiving

As standard, CENTERLINE MCCs are shipped upright in shipping blocks of one to three front-mounted sections or two to six back-to-back sections. Each shipping block of an MCC is provided with a lifting angle. The lifting angle is optional on NEMA Type 3R and Type 4 MCCs. Each vertical section in a shipping block is bolted to the shipping skid and covered with clear plastic wrap. Equipment that extends from the structures is also protected. Protection is for upright shipping and is not waterproof or watertight. If necessary, other types of packaging are available.

Refer to publication 2100-IN040 instructions. This publication is shipped with each MCC, attached to the outside of the MCC within the layer of clear plastic wrap. For additional information about the handling, installation, operation and maintenance of MCCs rated more then not 600V, consult NEMA ICS

2.3-1995.

for receiving, handling, and storage

Export Packaging

A maximum of three vertical sections standing upright can be shipped with export packaging together in one block. The MCC is bolted to a skid and wrapped in poly wrap suitable for occasional water-spray; a wooden frame and chipboard surround the sections. Export packaging is not watertight, waterproof or intended for long-term storage. Extended storage may require space heaters and other considerations. Export packing adds extra weight and dimensions to the shipping block.

Handling and Receiving MCCs

Lifting Angle

Shipping Skid

22 Publication 2100-IN012C-EN-P - April 2009

General Information Chapter 1

Handling

Lifting with a forklift, overhead lifting, sling lifting, and pipe or rod rolling are methods that can be used to handle vertical sections. See the following tables for typical weights and dimensions for standard 20 in. (508 mm) wide and 15 in. (381 mm) or 20 in. (508 mm) deep sections. For sizes not listed consult your local Rockwell Automation Sales Office.

Shipping Weights and Dimensions - Standard Packaging

Standard Packing

(1)

Front mounted 1-section block

Front mounted 2-section block

Front mounted 3-section block

Back-to-back 2-section block

Back-to-back 4-section block

Back-to-back 6-section block

(1)

Standard packing for shipments in the United States and Canada. The MCC shipping block is mounted on a skid and covered in clear plastic wrap. This packaging is not watertight or waterproof.

Weight kg (lb), approx.

Height in. (cm), approx.

Depth in. (cm), approx.

Width in. (cm), approx.

227 (500) 96 (244) 36 (91) 43 (109)

454 (1000) 96 (244) 36 (91) 43 (109)

680 (1500) 96 (244) 36 (91) 63 (160)

454 (1000) 96 (244) 42 (107) 43 (109)

816 (1800) 96 (244) 42 (107) 43 (109)

998 (2200) 96 (244) 42 (107) 63 (160)

Publication 2100-IN012C-EN-P - April 2009 23

Chapter 1 General Information

Shipping Weights and Dimensions - Export Packaging

Export Packing (below deck)

Front mounted 1-section block

Front mounted 2-section block

Front mounted 3-section block

Back-to-back 2-section block

Back-to-back 4-section block

Back-to-back 6-section block

(1)

Export packing for below deck is required for all international shipments. The MCC shipping block is mounted on a skid and covered in clear plastic wrap. This packaging is not watertight or waterproof. Additional packing materials surround the shipping block. The export packing adds extra weight and increases the dimension of the shipping block.

Weight

(1)

kg (lb), approx.

295 (600) 99 (252) 37 (94) 44 (112)

522 (1150) 99 (252) 37 (94) 44 (112)

748 (1650) 99 (252) 37 (94) 64 (163)

544 (1200) 99 (252) 43 (109) 44 (112)

907 (2000) 99 (252) 43 (109) 44 (112)

1111 (2450) 99 (252) 43 (109) 64 (163)

Height in. (cm), approx.

Depth in. (cm), approx.

Width in. (cm), approx.

ATTENTION

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

Storage and Operation

CENTERLINE MCCs conform to NEMA standard ICS 1-2000 for service and storage conditions. All MCCs should operate in an ambient

temperature above 0 95% non-condensing humidity. If the equipment is stored, the ambient

temperature should remain above -30

(149

F). In addition, MCCs have an altitude class of 2 km (1 km for MCCs that contain variable frequency drives). The altitude class of 2 km designates equipment for installation where the altitude does not exceed 2000 m (6600 ft). For installation above 2000 m (6600 ft), contact Rockwell Automation LV MCC Technical Support at

1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

C (32 oF) but not exceeding 40 oC (104 oF) at

C (-22 oF) but not exceed 65 oC

24 Publication 2100-IN012C-EN-P - April 2009

Installation Procedures

Chapter

Location Planning

Height Considerations

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

• Conduits

• Busways

• Overall height of installation area

• Alignment with other equipment

• Future needs

• Ambient temperature

The area must be level and the environment must be compatible with the NEMA enclosure rating of the equipment

Documentation packages shipped with assembled MCCs include an MCC elevation drawing and an MCC floor plan layout.

If the MCC is equipped with optional external mounting channels or is mounted on a pad, the height from the floor to the center of the top handles must be checked for compliance with NFPA 70 National Electrical Code (NEC) Article 404.8 and UL Standard 845. If the distance from the floor to the center of the highest handle is greater then 6.7 ft (2042.16 mm) a unit operating handle extender should be added (catalog number 2100H-NE1).

Height Planning Dimensions

Height of Handle

6.7 ft (2042.16 mm) Maximum

Cement Pad

Floor Line

25Publication 2100-IN012C-EN-P - April 2009 25

Chapter 2 Installation Procedures

Securing an MCC

Anchor bolts [1/2 in. (13 mm)] may be pre-located and embedded in the foundation prior to installation. Two bolts per vertical section fasten the MCC through its internal mounting angle to the foundation [corner sections require three bolts and 40 in. (1016 mm) wide sections require four bolts]. See the following illustrations and tables for general dimensions. Dimensions matching your equipment can be found on the elevation drawings shipped with your MCC.

Mounting Dimensions for 15 in. and 20 in. Sections

26 Publication 2100-IN012C-EN-P - April 2009

Installation Procedures Chapter 2

(2) Mounting Slots

0.56 in. x 1.13 in. in Slots (14 mm x 29 mm) Slots

Standard Ground Bus

Rear

0.25 in. (6.35 mm)

7.38 in. (187 mm)

For seismic bolt-down applications: first section of the MCC lineup.

Front

For seismic bolt-down applications: last section of the MCC lineup, extra bolt-down locations (2 bolts).

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

15 in. Deep 20 in. Deep

Dimensions approx.

20 in.

Wide

in. (mm)

25 in. Wide

in. (mm)

30 in. Wide

in. (mm)

35 in. Wide

in. (mm)

20 in. Wide

in. (mm)

25 in. Wide

in. (mm)

30 in. Wide

in. (mm)

35 in. Wide

in. (mm) A 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) B 15.00 (381) 15.00 (381) 15.00 (381) 15.00 (381) 20.00 (508) 20.00 (508) 20.00 (508) 20.00 (508) C 11.56 (294) 11.56 (294) 11.56 (294) 11.56 (294) 16.56 (421) 16.56 (421) 16.56 (421) 16.56 (421) D 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445) 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445)

(1)

Applies to first and last sections that require seismic ratings.

Publication 2100-IN012C-EN-P - April 2009 27

9.13 (232) 9.13 (232) 9.13 (232) 9.13 (232) 14.13 (359) 14.13 (359) 14.13 (359) 14.13 (359)

Chapter 2 Installation Procedures

Mounting Dimensions for 30 in. and 40 in. Deep Back-to-Back Section

Dimensions approx.

7.38 in. (187 mm)

0.25 in. (6 mm)

7.38 in. (187 mm)

20 in. Wide

in. (mm)

1.69 in. (43 mm)

3.19 in. (81 mm)

Front

Rear Rear

Front

20 in. Deep 40 in. Deep

25 in. Wide

in. (mm)

30 in. Wide

in. (mm)

35 in. Wide

in. (mm)

20 in. Wide

in. (mm)

25 in. Wide

in. (mm)

(4) Mounting Slots

0.56 in. x 1.13 in. in Slots (14 mm x 29 mm) Slots

Standard Ground Bus

30 in. Wide

35 in. Wide

in. (mm)

in. (mm) A 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) 20.00 (508) 25.00 (635) 30.00 (762) 35.00 (889) B 30.00 (762) 30.00 (762) 30.00 (762) 30.00 (762) 40.00 (1016) 40.00 (1016) 40.00 (1016) 40.00 (1016) C 11.56 (294) 11.56 (294) 11.56 (294) 11.56 (294) 16.56 (421) 16.56 (421) 16.56 (421) 16.56 (421) D 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445) 10.00 (254) 12.50 (318) 15.00 (381) 17.50 (445)

28 Publication 2100-IN012C-EN-P - April 2009

Installation Procedures Chapter 2

Mounting Dimensions for 25 in. Wide Section with 9 in. (228.6 mm) Wireway [90 in. (2286 mm) high]

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

Publication 2100-IN012C-EN-P - April 2009 29

Chapter 2 Installation Procedures

Mounting Dimensions for 10 in. Wide Section with 10 in. (254 mm) Incoming Line Section

A (L1)

A (L2)

A (L3)

7.5 in. (191 mm)

1.25 in. (32 mm) 10 in. (254 mm)

Power Wires

Section Depth

Dimension,

approx.

15 in. (381 mm) Deep

20 in. (508 mm) Deep

in. (mm A 12.75 (324) 17.75 (451) B 14.75 (375) 19.75 (502)

in. (mm

1.12 in. (28 mm)

30 Publication 2100-IN012C-EN-P - April 2009

Installation Procedures Chapter 2

Mounting Dimensions for NEMA 3R and 4 Section [90 in. (2866 mm) high]

Publication 2100-IN012C-EN-P - April 2009 31

Chapter 2 Installation Procedures

Mounting Dimensions for NEMA 3R and 4 Section

12.37 in. (314 mm)

Ground Bus

0.25 in. (6 mm)

14.06 in. (337 mm)

Rear

Interior Section

2.87 in. (73 mm)

16.56 in. (421 mm)

Front

(2) Mounting Holes

0.63 in. (16 mm) Diameter

If the optional non-removal lifting angle is supplied, add 3.63 in. (92.2 mm) to height.

Exterior Section Width

Dimension, approx.

A 25.00 (635) 30.00 (762) 35.00 (889) B 13.75 (349) 16.25 (413) 18.75 (476) C 11.25 (286) 13.75 (349) 16.25 (413)

(1)

This measurement is the interior section width.

20 in. (508 mm)

(1)

Wide

in. (mm)

25 in. (635 mm)

(1)

Wide

in. (mm)

30 in. (762 mm)

(1)

Wide

in. (mm)

32 Publication 2100-IN012C-EN-P - April 2009

Installation Procedures Chapter 2

Mounting Dimensions for 15 in. and 20 in. Deep Corner Section [90 in. (2866 mm) high]

1.41 in. (36 mm)

(2) Mounting Slots

0.56 in. x 1.13 in. in Slots (14 mm x 29 mm) Slots

0.25 in. (6 mm)

Ground Bus

1.41 in. (36 mm)

0.25 in. (6 mm)

(2) Mounting Holes

0.63 in. (16 mm) Diameter

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

Dimension,

approx.

15 in. (381 mm) Deep

in. (mm) A 25.13 (638) 30.13 (765) B 12.63 (321) 15.13 (384) C 16.81 (427) 21.81 (554)

Section Depth

20 in.(635 mm) Deep

in. (mm)

D 17.62 (448) 22.62 (575)

Publication 2100-IN012C-EN-P - April 2009 33

Chapter 2 Installation Procedures

Mounting Dimensions for 15 in. and 20 in. Deep x 40 in. Wide Front-mounted Section

The optional external mounting channels add 1.5 in. (38.1 mm) to the height.

Section Width

Dimensions approx.

20 in. Wide

in. (mm)

25 in. Wide

in. (mm)

30 in. Wide

in. (mm) A 17.25 (438) 22.25 (565) 27.25 (692) 32.25 (819) 37.25 (946) B 16.50 (419) 21.50 (546) 26.50 (673) 31.50 (800) 36.50 (927) C 5.25 (133) 7.75 (197) 10.25 (260) 12.75 (324) 15.25 (387)

(1)

When a horizontal bus or a disconnecting means (switch or circuit breaker) is specified, reduce the ‘A’ dimension by 5 in. (127 mm).

34 Publication 2100-IN012C-EN-P - April 2009

(1)

35 in. Wide

in. (mm)

40 in. Wide

in. (mm)

Installation Procedures Chapter 2

Mounting Dimensions for 15 in. and 20 in. Deep x 40 in. Wide Front-Mounted Section

40.00 in. (1016 mm)

10.00 in. (254 mm)

1.69 in. (43 mm)

0.25 in. (6 mm)

7.15 in. (102 mm)

Standard Ground Bus

Dimension,

approx.

A 15 (381) 20 (508) B 11.56 (294) 16.56 (421)

20.00 in. (508 mm)

Section Depth

15 in. (381 mm) Deep

in. (mm)

Rear

Front

20 in. (508 mm) Deep

in. (mm)

(4) Mounting Slots

0.56 in. x 1.13 in. in Slots (14 mm x 29 mm) Slots

Publication 2100-IN012C-EN-P - April 2009 35

Chapter 2 Installation Procedures

Mounting Dimensions for 71 in. H (reduced height) MCC Sections

0.25 in. (6 mm)

70.48 in. (1790.19 mm)

20 in. (508 mm)

0.25 in. (6 mm)

70.48 in. (1790.19 mm)

20 in. (508 mm)

71 in. High Section (1803.4 mm)

Section Depth

Dimension,

approx.

15 in. (381 mm) Deep

in. (mm)

20 in.(635 mm) Deep

in. (mm) A 15.00 (380) 20.00 (508) B 14.75 (374) 19.75 (500)

C 5.12 (130) 10.12 (256)

D 4 (101) 8 (203)

E — 4.40 (112)

36 Publication 2100-IN012C-EN-P - April 2009

Installation Procedures Chapter 2

Seismic Requirements

To demonstrate the seismic withstand of various CENTERLINE MCCs [20 in. deep (508 mm), 30 in. deep (762 mm) back-to-back, and 40 in. deep (1016 mm) back-to-back], the MCC design construction has been qualified by seismic calculations per the Uniform Building Code (UBC). CENTERLINE 2100 MCC samples have been seismically qualified by dynamic (triaxial multi-frequency testing) seismic tests per IEEE 344 Seismic Test Standards. The results of the MCC seismic testing demonstrated compliance with the 100% g level of Uniform Building Code 1997 (UBC) zone 4 (the maximum UBC zone) and 100% g level of The International Building Code 2006 (IBC), for example, the MCC structure, the MCC units, and the MCC components or electrical functions were not compromised when subjected to a UBC Zone 4 earthquake, or the IBC seismic event. Per the IEEE 344 standard, the equipment was under power and operated before, during, and after the seismic tests.

IMPORTANT

Variable frequency drive units using ‘rollout’ drive configurations are not seismically tested.

In order to obtain a UBC or IBC seismic withstandability, each individual CENTERLINE 2100 MCC lineup (for example, both front and back MCCs in ‘back-to-back applications), must be mounted on an adequate seismic foundation and installed per the seismic anchoring requirements as shown in the following illustrations.

In seismic application dimensions ‘E’ applies to the first and last sections of the MCC lineup. See Mounting Dimensions for 15 in. and

20 in. Sections for dimensions.

Seismic Bolt Down Requirements

EERear

The hardware required is 1/2 in.-13 Grade 5 or HSL-3 M12 or better bolts embedded in the foundation.

FrontFirst Section Last Section

Second Section and Additional Sections

MCC Lineup

Publication 2100-IN012C-EN-P - April 2009 37

Chapter 2 Installation Procedures

Seismic Weld Down Requirements

0.25 in. (6 mm)

First Section Last Section

Rear

Second Section and Additional Sections

Joining & Splicing New MCCs

1.50 in. (38 mm)

Rear

Front

1.50 in. (38 mm)

MCC Lineup

Optional Location for Rear Welds

Left-hand Side View

1.50 in. (38 mm)

Front

Floor Line

1.50 in. (38 mm)

A main horizontal bus splice kit must be installed between shipping blocks of new MCCs to connect the main horizontal bus. In addition, the neutral bus splice kit (if required) and the ground bus splice kit must be installed between shipping blocks. Refer to CENTERLINE 2100 Motor Control Centers Joining & Splicing Vertical Sections Instructions, publication 2100-IN010

Joining & Splicing Existing

A main horizontal bus, a neutral bus (if required), and a ground bus splice kit must be installed when adding to existing CENTERLINE

MCCs

MCCs. When adding to existing MCCs, you must identify the series of the MCC that you will be adding to. If the existing MCC is series A or B, you must consult MCC technical support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support for joining and splicing procedures. When the existing MCC is series C or later, refer to CENTERLINE 2100 Motor Control Centers Joining & Splicing Vertical Sections Instructions, publication 2100-IN010

Be sure to also connect DeviceNet cables and other control cables as required.

Installing and Joining Pull Boxes

38 Publication 2100-IN012C-EN-P - April 2009

When pull boxes are supplied with your MCC, refer to Installing a Pull Box on a Bulletin 2100 Vertical Section, publication 2100-IN029

, for

installing and joining the pull box onto the vertical section.

Installation Procedures Chapter 2

Joining and Splicing NEMA

NEMA Type 12 MCCs must be properly installed to prevent the ingress of dust and dirt. Follow the caulking instructions in the NEMA Type 12

Type 12 MCCs

Sealing Instructions, publication 2100-IN037 12 MCC. Using caulk, close any mounting holes in the bottom plates and bolt holes between shipping splits.

It is necessary that all door latches and wireway doors be fully latched to prevent dust and dirt from entering the enclosure and to meet NEMA Type 12 requirements.

Joining & Splicing NEMA

A main horizontal bus, a neutral bus (if required) and a ground bus splice kit must be installed between the internal sections for new and

Type 3R and Type 4 MCCs

existing NEMA Type 3R and Type 4 MCCs. Refer to CENTERLINE 2100 Motor Control Centers Joining & Splicing Vertical Sections Instructions, publication 2100-IN010 sections.

Joining Instructions for NEMA Type 3R and 4 Sections

Cabinet Spacer (2) 0.25 in. (6 mm) x 0.50 in. (12.7 mm) Taptites

, supplied with the NEMA

, for splicing Type 3R and Type 4 internal

(2) wireway extensions required for 15 in. (381 mm) deep. (2) wireway extensions required for 20 in. (508 mm) deep. (1) 0.25 in. (6 mm) -20 x 0.70 in. (17.78 mm) taptite per wireway extension.

Remove right-hand driphood angle and discard. Drill out (5) 0.172 in. (4.36 mm) diameter holes to 0.25 in. (6 mm) diameter in driphood.

Remove the right-hand and left-hand side plates before joining sections. The gasket is across the top of the driphood and down the backplate on one of the adjoining sections.

MCC MCC MCC

Gasket

Cabinet Spacer (2) 0.25 in. (6 mm) x 0.50 in. (12.7 mm) Taptites

Remove left-hand driphood angle and remount after the adjacent driphood has been drilled out.

(2) 0.25 in. (6 mm) x 0.50 in. (12.7 mm) Taptit

Wireway Extensions (2) or (4) 0.25 in. (6 mm) x 0.50 in. (12.7 mm) Taptites

Gasket

Cabinet Spacer (2) 0.25 in. (6 mm)

0.50 in. (12.7 mm) Taptites

Publication 2100-IN012C-EN-P - April 2009 39

Chapter 2 Installation Procedures

Bus Torque Specifications

Tighten all bus splice connections with a torque wrench and socket at intervals established by your maintenance policy. See Chapter 9 suggested maintenance. If a torque wrench is not available, tighten until the conical spring washer is flat.

Torque values can be found on the information label on the interior of the vertical wireway door or on the interior right-hand side plate of frame mounted units.

for

40 Publication 2100-IN012C-EN-P - April 2009

Installing Conduit and Cable

Chapter

Installing Conduit

When installing conduit, make sure it is installed according to local codes - to assure water and moisture cannot enter or accumulate in the MCC enclosure. Conduit must be installed so they are compatible with the NEMA rating of the MCC. The conduit should be placed away from the horizontal ground bus to avoid damage. We recommend that the conduit be positioned to minimize cable bending and maintain relative vertical alignment to incoming connections.

Bottom Entry Conduit

Follow this procedure if your conduit is entering from the bottom.

1. Prepare the installation site so the foundation is level.

2. Before the MCC is installed, place and stub up conduit

approximately 2 in. (51 mm) above floor level, making sure all incoming conduit is clear of the horizontal ground bus.

For approximate section base dimensions and ground bus locations, refer to Installation Procedures, Chapter 2 elevation and floor plan drawings shipped with MCC.

, or

For approximate bottom entry locations and wiring schemes for main fusible disconnects, main circuit breakers, and incoming line compartments, refer to Mains and Incoming Lines Dimension Reference, publication 2100-TD018

Top Entry Conduit

Follow this procedure if your conduit is entering from the top.

1. After the MCC is in place, leveled, and the sections are joined

and spliced, bring conduit into the top of the incoming section.

For approximate top entry locations and wiring schemes for main fusible disconnects, main circuit breakers and incoming line compartments, refer to Mains and Incoming Lines Dimension Reference, publication 2100-TD018

41Publication 2100-IN012C-EN-P - April 2009 41

Chapter 3 Installing Conduit and Cable

2. Remove the lifting angle and top plate.

3. Modify the top plate for necessary conduit entries.

This method helps guard against metal chips falling into the MCC, which can cause serious damage to the components.

4. Replace the top plate and lifting angle bolts to guard against

dust or dirt from entering the top horizontal wireway.

5. Make sure that all incoming conduit is clear of the horizontal

ground bus.

For approximate location of the horizontal ground bus mounted in the top horizontal wireway, refer to Mains and Incoming Lines Dimension Reference, publication 2100-TD018

For space availability for incoming cables, refer to the elevation drawings shipped with assembled MCCs.

Installing Cable

Install the cable when the temperature is above freezing 0 °C (32 °F), unless the cable is suitable for installation at temperatures below freezing. This will help prevent cable insulation from cracking or splitting.

MCCs are rated for use with 75 °C (167 °F) cable. Cable must be sized by using a 75 °C (167 °F) column in NEC Table 310–16 (NEC 2005 Edition). The temperature rating of the lugs is not relevant.

ATTENTION

Properly connect all line and load cables to avoid a bolted fault and equipment damage.

Lugs

Follow this procedure to install the lugs.

1. Verify the compatibility of wire size, type, and stranding versus

the power lugs furnished.

Use correct lugs in all applications.

2. Crimp compression lugs with manufacturer recommended tools.

42 Publication 2100-IN012C-EN-P - April 2009

Installing Conduit and Cable Chapter 3

3. Use the MCC electrical schematics to verify field wiring

connection points.

Incoming Line Compartment

Top or bottom entry to the incoming line-section bus is straight through to the connection terminals. The vertical bus provides pads for the incoming lugs. The lug selection should be based on the size, number, and type of conductor.

• Use of mechanical screw-type lugs is acceptable only when the incoming lines’ available short-circuit current is 42,000 A rms symmetrical or less.

• Use of crimp or compression type lugs is acceptable when the incoming lines’ available short-circuit current does not exceed 100,000 A rms symmetrical.

Main Disconnect

Top entry is straight through to the line side of the main fusible disconnect or main circuit breaker. For bottom entry, the connection scheme varies depending on the rating of the main device. In some cases, the bottom entry connects to the top or line side of the main fusible disconnect or main circuit breaker. In other cases the connection is reverse-fed, the bottom entry cables connect to the bottom of the main fusible disconnect or main circuit breaker. For further information refer to Mains and Incoming Lines Dimension Reference, publication 2100-TD018

Mechanical screw-type lugs are supplied as standard with all main fusible disconnects or main circuit breakers. Crimp or compression lugs are optional.

Cable Bracing

The CENTERLINE MCC bus work system has been tested and is qualified to withstand maximum short-circuit forces exceeding 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 NEC and local codes 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. Acceptable methods are shown on the following pages.

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Chapter 3 Installing Conduit and Cable

Securing Cables with Glass Tape

In this example, glass fiber-reinforced tape or glass filament tape is used. The taping should be continuous from the point the cables enter the MCC to the point the cables are terminated. It is important that cables are wrapped several times for additional strength. Cable slack should be drawn up during wrapping so that individual cables are supported by the tape as a single mass.

Securing Cables with Glass Tape

Securing Cables with Nylon Rope

In this example, cables are lashed in a ‘figure 8’-type configuration by using nylon rope. The rope lashing should be continuous from the point the cables enter the MCC to the point the cables are terminated. Other types of rope lashing may be acceptable. Cable slack should be drawn up during wrapping so that individual cables are supported by the rope as a single mass.

Securing Cables with Nylon Rope

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Installing Conduit and Cable Chapter 3

Securing Cables with Hardwood

In this example, a hardwood brace (maple hardwood) made for the specific application is used. Holes are bored approximately the size of the cable diameter. Several bolt holes are also bored the breadth of the hardwood brace. The brace is cut in two pieces and is used as a clamp to secure the cables. Through bolts are inserted into the brace and tightened so that cables are held tightly in place.

Securing Cables with Hardwood

A second form of hardwood brace (not shown) is a yolk type in which the cables are passed through. Holes should be small enough to provide a snug fit for the cables. The connectors or lugs are attached to the cables and cables are bolted to the terminals.

When using the hardwood bracing method and the short circuit current is less then 42,000 A, cables should be braced every 12 in. (305 mm). When the short circuit current is 42,000 A or greater, cables should be braced every 6 in. (153 mm).

Incoming Line Brace

Allen-Bradley manufactures an incoming line brace similar to the hardwood clamping-type brace. To order an incoming line brace, contact your local Allen-Bradley sales office and reference assembly number 40113–848.

IMPORTANT

Lugs should be installed so they are in line with each other and proper spacing is used between phases. Hardware must be torqued per the torque tables found on the enclosure door.

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Chapter 3 Installing Conduit and Cable

Notes:

46 Publication 2100-IN012C-EN-P - April 2009

Chapter

Installing and Removing Plug-in Units

Installing Plug-in Units

ATTENTION

For unit installation, refer to CENTERLINE 2100 Motor Control Centers (MCC) Units with Vertical Operating Handles Installation Instructions, publication 2100-IN014 (MCC) Units with Horizontal Operating Handles Installation Instructions, publication 2100-IN060

When installing or removing MCC units, when possible, de-energize, lockout, and tag-out all sources of power to the MCC. If the MCC units will be installed or removed with power applied to the main power bus, follow established electrical safety work practices. Refer to the NFPA 70E Standard for Electrical Safety in the Workplace publication.

Review your company safety lockout and tag-out procedure. De-energize all units before installing or removing.

All covers and doors must be in place before applying power to the MCC. If units are removed, they must be replaced with the appropriate items such as units, doors, and unit support pans.

, and CENTERLINE 2100 Motor Control Center

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Chapter 4 Installing and Removing Plug-in Units

Remove a Plug-in Unit with a Vertical Operating Handle from a Section

1. Make sure the disconnect handle is in the OFF/O position.

2. For non-arc resistant units, turn the door latches 1/4 turn; for

units that are equipped with arc-resistant door latches, push in the latch and rotate 1/4 turn.

Arc Containment Latch

3. Open the door completely.

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Installing and Removing Plug-in Units Chapter 4

TIP

It is not necessary to remove the unit door to remove a unit from a section. However, steps a and b below may still be necessary even when the door is not removed.

a. Remove the door-mounted devices and wiring, if necessary. b. Remove the hinge pins by sliding upward with a flathead

screwdriver.

The control station can be hung on the front of the unit by using square holes adjacent to the top unit latch.

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Chapter 4 Installing and Removing Plug-in Units

4. Swing the door to near closed position.

5. Lift the door outward to remove.

Wiring Tunnel

6. Disengage the captive latches located at the front of the unit,

one at the top and one at the bottom of the unit.

Units that are 2.0 space factor and larger have two latches at the top.

7. Detach the front portion of the pull-apart terminal blocks from

the unit base and place the wires and terminal blocks in line with the wiring clearance tunnel.

8. Remove other cables or devices that would prevent the unit

from being withdrawn.

TIP

It is not necessary to place wires and terminal blocks into the vertical wireway to remove a plug-in unit that includes the wiring clearance tunnel.

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Installing and Removing Plug-in Units Chapter 4

9. Pull the unit forward (outward) approximately 3 in. (7.62 cm)

out of the MCC, using the handle provided at the lower left of the unit and the tab in the upper right of the unit as finger holds.

You may need to reposition your hands as necessary to properly support the unit while you are removing the unit from the MCC.

ATTENTION

Plug-in MCC units may be heavy or awkward to handle. Use an assistant or a platform lift device if necessary to help you handle the unit.

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Chapter 4 Installing and Removing Plug-in Units

For the CENTERLINE 2100 MCC units with arc-resistant door latches, you may need to tilt the top of the unit slightly to the rear to avoid interference with the top arc latch bracket before removing the unit. If you do not have enough clearance, you will need to loosen the latch bracket screw (approximately two turns) to remove the unit.

Latch Bracket

TIP

For dual-mounted, fusible-feeder disconnect switch units, you will need to remove the bottom arc latch bracket. You can do this by first removing the unit located below the dual disconnect unit.

10. Remove the unit from the MCC.

11. Carefully install protective caps or close manual shutters after

the unit is removed.

Automatic shutters will close as units are removed.

ATTENTION

All covers and doors must be in place before applying power to the MCC. If units are removed, they must be replaced with the appropriate items such as units, doors, and unit support pans.

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Remove a Plug-in Unit with a Horizontal Operating Handle from a Section

Installing and Removing Plug-in Units Chapter 4

1. Make sure the disconnect handle is in the OFF/O position.

2. For non-arc resistant units, turn the door latch 1/4 turn; for units

that are equipped with arc-resistant door latches, push in the latch and rotate 1/4 turn.

Arc Containment Latch

3. Open the door completely.

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Chapter 4 Installing and Removing Plug-in Units

TIP

It is not necessary to remove the unit door in order to remove a unit from a section.

4. Remove the door-mounted devices and wiring, if necessary.

5. Remove the hinge pins by sliding upward with a flathead

screwdriver.

6. Swing the door to near closed position.

7. Lift the door outward to remove.

8. Detach the wiring/terminal block from the unit.

9. Place the wiring/terminal block in the vertical wireway to the

right of unit.

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Installing and Removing Plug-in Units Chapter 4

10. Push the latch mechanism to the left with your right hand.

11. Pull the unit forward (outward) approximately 3 in. (7.62 cm)

out of the MCC.

You may need to reposition your hands as necessary to properly support the unit while you are removing the unit from the MCC.

For the CENTERLINE 2100 MCC units with arc-resistant door latches, you will need to rotate the arc latch bracket 90

clockwise to avoid interference with the unit.

Arc Latch Bracket

ATTENTION

Plug-in MCC units may be heavy or awkward to handle. Use an assistant or a platform lift device if necessary to help you handle the unit.

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Chapter 4 Installing and Removing Plug-in Units

12. Remove the unit from the MCC.

13. Carefully install protective caps or close the manual shutters

after unit is removed.

ATTENTION

All covers and doors must be in place before applying power to the MCC. If units are removed, they must be replaced with the appropriate items such as units, doors, and unit support pans.

14. See the next section for additional information.

Automatic shutters will close as units are removed.

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Remove the Support Pan

Installing and Removing Plug-in Units Chapter 4

Plastic

Retaining

Clip

1. Pry the plastic retaining clip from the right-hand unit support by

using a screwdriver.

This is visible in the vertical wireway.

For CENTERLINE MCC units with arc resistant latches, the unit support pan is secured to the right-hand unit support by the screw that retains the arc latch bracket. In order to remove the unit support pan, you must remove the arc latch bracket.

Arc Latch Bracket

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Chapter 4 Installing and Removing Plug-in Units

2. Lift the right side of the support pan approximately 4 in.

(102 mm).

3. Pull the right side of the support pan forward to release from the

left rear slot on the structure.

4. Push back on the left side of the support pan until the support

pan is free from the structure.

Vertical sections may be supplied with plug-in stab opening protective caps, manual shutters, or automatic shutters. Refer to the next step if any of these options are supplied.

5. Carefully install the protective caps or close the manual shutters

after the unit is removed.

Automatic shutters will close as the units are removed.

ATTENTION

All covers and doors must be in place before applying power to the MCC. If units are removed, they must be replaced with the appropriate items such as units, doors, and unit support pans.

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Chapter

Arc Flash Protection Marking as Required by the National Electrical Code

Flash Protection Marking Requirement

The flash protection marking requirement was initially established in 2000 by The National Fire Protection Association (NFPA 70E), Standard for Electrical Safety Requirements for Employee Workplaces. NFPA 70E applies to workers who install, maintain, or repair electrical systems.

In 2002, NFPA 70, The National Electrical Code (NEC) added the Article 110.16, and reinforced the flash protection marking of equipment. The 2002 version of the article is stated below.

110.16 Flash Protection

Switchboards, panelboards, industrial control panels, and MCCs that are in other than dwelling occupancies and are likely to require examination, adjustment, servicing, or maintenance while energized shall be field marked to warn qualified persons of potential electric arc flash hazards. The marking shall be located so as to be clearly visible to qualified persons before examination, adjustment, servicing, or maintenance of the equipment.

FPN No. 1: NFPA 70E-2000, Electrical Safety Requirements for Employee Workplaces, provides assistance in determining severity of potential exposure, planning safe work practices, and selecting personal protective equipment.

FPN No. 2: ANSI Z535.4-1998, Product Safety Signs and Labels, provides guidelines for the design of safety signs and labels for application to products.

As Arc Flash Technology emerges, new developments have caused changes to arc flash criteria. For example, in 2004, the NFPA 70E was reissued in a completely new format along with changes reflecting new developments. The NEC is revised every three years and the NFPA 70E is revised every four years. The latest editions of the NEC and NFPA 70E should be used in establishing potential electric arc flash hazards and arc flash marking.

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Chapter 5 Arc Flash Protection Marking as Required by the National Electrical Code

Arc Flash Marking Clarification

The flash protection marking per NEC Article 110.16 is a field marking requirement and is to be applied by the MCC end-user for each specific application. The marking is similar to other NEC marking requirements, for example, voltage, voltage hazard labels, and circuits. However, flash protection markings must be based on application information and calculations from the installation site. The intent of the marking is to identify the presence of a potential flash hazard and to provide assistance in determining necessary protective clothing and personal protective equipment (PPE) that should be worn by qualified electrical persons when servicing electrical equipment. You must establish field marking requirements based upon:

• the level of the on-site personnel safety training.

• the level of required clothing and required PPE.

• consistency for the level of marking of various equipment, for

example, switchboards, panelboards, industrial control panels, and MCCs.

• the available flash energy on each piece of equipment. This energy is determined from available fault current, arc flash duration due to the type and degree of short circuit protection equipment.

Rockwell Automation Services

Rockwell Automation understands the importance of you fulfilling the field arc-flash hazard marking requirements as defined by Article

116.10 in the NEC. Rockwell Automation may assist you in determining the necessary arc flash marking as required by NFPA 70E.

Rockwell Automation offers services that can provide assistance in the following areas:

• Arc-flash hazard analysis

• Providing input on the specific Bulletin 2100 MCC design being

used

• The zone determination for the NFPA 70E Hazard/Risk levels

• Your required NEC field marking

For information regarding arc-flash hazard analysis, contact your local Rockwell Automation sales office or distributor.

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Chapter

Operator Handle and Unit Interlock

The operator handle is an integral part of each MCC unit. Adjustment of the handle is not required. The operator handle is interlocked with each unit door as outlined by UL 845.

Defeating the Unit Door Interlock

Refer to the following information for defeating the unit door lock.

Open the Door when the Operating Handle is in the ON/I Position

ATTENTION

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

The defeater screw is located just below (on units with a vertically mounted operator handle) or just to the right (on units with a horizontally mounted operator handle) of the pivot point of the operator handle. To operate the defeater mechanism and defeat the door interlock while the operator handle is in the ON/I position, use a flat-head screwdriver to turn the defeater screw clockwise one-eighth to one-quarter turn.

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

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Chapter 6 Operator Handle and Unit Interlock

ATTENTION

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

Personal protective equipment (PPE) is not shown for clarity.

Operating Handle Defeater for Vertical Operator Handle

Operating Handle Defeater for Horizontal Operator Handle

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Operator Handle and Unit Interlock Chapter 6

Defeating the Unit Interlock

Refer to the following information for defeating the unit interlock lever.

Lever

Energize a Unit with the Unit Door Open

When the unit door is open and the operator handle is in the OFF/O position, the defeater lever must be deliberately lifted on the vertical handles or pushed to the left for horizontal handles, to move the operator handle to the ON/I position, and energize the unit.

Defeater Lever for Vertical Operator Handle

ATTENTION

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

Personal protective equipment (PPE) is not shown for clarity.

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Chapter 6 Operator Handle and Unit Interlock

ATTENTION

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

Personal protective equipment (PPE) is not shown for clarity.

Defeater Lever for Horizontal Operating Handle

Locking Provisions

Refer to the following sections for locking provisions.

Lock Vertical Operating Handles in the OFF/O Position

ATTENTION

To lock the small, medium, and large operator handle in the OFF/O position, put the shackle of the lock through the opening in the operator handle assembly. The opening can accommodate up to three padlocks.

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

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Operator Handle and Unit Interlock Chapter 6

Locking Vertical Handles in OFF/O Position

Small and Medium Vertical Handle Large Handle

Lock Horizontal Operating Handles in the OFF/O Position

Some units use a horizontal operating handle. The horizontal operating handle can be locked in the OFF/O position by putting the shackle of the lock through the open slotted area to the left of the operator handle.

Locking a Horizontally Mounted Operating Handle in OFF/O Position

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Chapter 6 Operator Handle and Unit Interlock

Lock Units with Operating Handles in the ON/I Position

ATTENTION

Locking an operating handle in the ON/I position may be in conflict with local codes and emergency shut down requirements.

Follow this procedure to lock the operator handle in the ON/I position.

1. Drill out the pre-located hole to 3/8 in. (9.5 mm) diameter

maximum.

2. Insert the shackle of the lock.

The following instructions assume that the handle is in the ON/I position:

• For units with small handles, the pre-located hole is in the upper portion of the operator handle assembly.

• For units with medium and large operator handles, the pre-located hole is underneath the operator handle on the handle assembly.

• For units with a horizontally mounted handle, the pre-located hole is on the left-hand side of the handle assembly.

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Operator Handle and Unit Interlock Chapter 6

Locking Small Handle in ON/I POSITION, Vertical Operating Handle

Drill Out

Locking the Medium Handle in ON/I Position

Drill Out

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Chapter 6 Operator Handle and Unit Interlock

Locking Large Handle in ON/I Position

Drill OutDrill Out

Locking Horizontal Handle in ON/I Position

Drill Out

Unit Interlocks

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

Units can also be locked out with a padlock preventing installation of the unit into a vertical section. The lockout feature of the unit interlock can be used with the operator handle in the ON/I or OFF/O position.

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Operator Handle and Unit Interlock Chapter 6

In this position, the unit is partially removed from the MCC and the slot in the interlock plate is in line with the flange of the unit support pan located above this unit. When the unit is locked in this position, the unit power and ground stabs are disengaged. This position can be used to prevent insertion of a unit into the MCC.

Unit Interlock to Prevent Insertion - Vertical Operating Handler

ATTENTION

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

We recommend that maintenance performed on the MCC units be performed away from the MCC in a suitable work area, when possible.

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Chapter 6 Operator Handle and Unit Interlock

Unit Interlock to Prevent Insertion - Unit Completely Withdrawn

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Operator Handle and Unit Interlock Chapter 6

In this position, the unit is partially removed from the MCC and the intermediate slot in the interlock plate is in line with the bushing located in the unit support pan. When the unit is locked in this position, the unit power and ground stabs are disengaged. This position can be used to prevent insertion of a unit into the MCC.

Unit Interlock to Prevent Insertion - Horizontal Operating Handle

ATTENTION

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

We recommend that maintenance performed on the MCC units be performed away from the MCC in a suitable work area, when possible.

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Chapter 6 Operator Handle and Unit Interlock

Unit Interlock to Prevent Insertion - Unit Completely Withdrawn

72 Publication 2100-IN012C-EN-P - April 2009

Chapter

Final Check List Before Energizing

Introduction

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

We recommend making an itemized list including:

• serial number.

• number of sections.

• number of units and their corresponding voltage.

• current ratings.

• horsepower ratings

• types of circuits.

• fuse sizes.

• circuit breaker ratings and trip settings.

• heater elements requirements.

• other important data.

The itemized list could be modeled after the MCC layout drawings supplied with each MCC. This itemized list should be saved in a file along with other data for the MCC such as, component manuals, heater element instructions, MCC manuals, and wiring diagrams. Blank sample forms are provided at the end of this chapter.

Pre-Energizing Check Procedure

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The following procedures should be executed by a ‘qualified person’ as defined by NEMA Standards Publication / No. ICS 2.3, Instructions for the Handling, Installation, Operation and Maintenance of Motor Control Centers, Section 1 as follows:

1.4 Qualified Person

For the purpose of this guide, a qualified person is one who is familiar with the installation, construction and operation of the equipment and the hazards involved. In addition, he or she has the following qualifications:

1.4.1

Is trained and authorized to energize, de-energize, clear, ground and tag circuits and equipment in accordance with established safety practices.

Chapter 7 Final Check List Before Energizing

Perform the Pre-energizing Check Procedure

1.4.2 Is trained in the proper care and usage of protective equipment such as rubber gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance with established safety practices.

ATTENTION

To ensure the safety of personnel performing the pre-energizing check, make sure the MCC remote power sources are disconnected and locked in the OFF/O position.

Using a voltmeter, verify that the MCC remote power sources are disconnected.

ATTENTION

Power factor correction capacitors (PFCCs) should be applied correctly. For application instructions refer to

Correction Capacitors for Bulletin 2100 MCC Starter Units Application Techniques,

publication 2100-AT001. When PFCCs are connected

Power Factor

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 more information contact, Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

Verify that motor acceleration times are within specific application specifications.

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

1. Remove all blocks or temporary holding means used for

shipping all component devices in the MCC.

2. Inspect the enclosure and units for damage.

If structural damage is present, contact MCC technical support at

1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support. If no

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Final Check List Before Energizing Chapter 7

structural damage is visible, the electrical spacings should be intact. Refer to the tables starting on page 84

for the required

minimum electrical spacings.

3. Check and verify that the MCC is properly installed, as described

in Chapter 2

, and inspect and verify that it is level, supported,

and anchored.

4. Check the integrity of the bus splice connections.

Recommended torque values can be found on the information label located on the interior of the vertical wireway door or on the interior right-hand side plate of frame mounted units. See Joining and Splicing Vertical Sections, publication 2100-IN010

for splicing information.

The factory-made power bus connections are tightened by a computer-controlled torquing system. The following connections do not require re-torquing:

• vertical to horizontal bus connections

• power conductor to horizontal bus connections.

These factory-made horizontal to vertical bus connections do not require servicing for the life of the MCC.

5. Check and verify that all ground connections are made properly,

based on local standards.

If ground bus is not provided or has been removed, check that the MCC sections are connected to provide a continuous ground path.

6. Check the field wiring.

a. Check the field wiring for proper conductor sizing.

MCC field conductors should be sized by using the National Electrical Code (NEC) 75 °C (167 °F) wire tables.

b. Removal of barrier or barriers may have been required for

field wiring. Check that all barriers and parts that may

have been removed during installation 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.

c. Check that all incoming and outgoing power wiring is secure

and braced to withstand the effects of a fault current as detailed in Chapter 3

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Chapter 7 Final Check List Before Energizing

d. Check that conduit and cabling are well supported.

For incoming line compartments, 2.0 space factors, 26 in. (660.4 mm) or less, the incoming cables should be firmly secured halfway between the top of the section and the incoming line compartment terminals. In a full section (6.0 space factor) incoming line compartments the cables should be braced every 12 in. (305 mm); if the system’s available short circuit current is above 42,000 A but less then 65,000 A rms symmetrical. Above 65,000 A rms symmetrical available current bracing should occur every 6.5 in. (165 mm). This bracing is in accordance with the Underwriters Laboratories (UL) listing and is necessary to withstand forces resulting from high fault currents. For information on cable bracing methods, see Chapter 3

of this publication.

e. Check the integrity of all field connections.

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

f. Check field wired connections made to the MCC for

agreement with wiring diagrams and verify that proper spacings between adjacent phases and/or phases to ground are being used. Refer to page 84

for the minimum electrical

spacing requirements.

7. Check that the voltage and horsepower ratings on the motor

correspond with the MCC unit ratings.

8. Check that the overload relays or heater elements are selected,

installed and/or adjusted to relative full load current shown on the motor rating nameplate.

9. For applications requiring power fuses, install the fuses in the

fusible switches in accordance with the NEC application requirements.

Refer to CENTERLINE Motor Control Centers Power Fuses Product Data,

publication 2100-TD003 for fuse information. Do

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

must be completely inserted in the fuse clips. Recommended torque values for fuse clamp screws can be found on the unit wiring diagram. Verify that all fuses fit each application.

10. For circuit breaker applications, verify that the circuit breakers

are in accordance with NEC application requirements, and have correct ampacity and trip settings.

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Final Check List Before Energizing Chapter 7

Refer to MCC Instantaneous Trip Motor Circuit Protectors (MCP) in Combination NEMA Starter, Soft Starter (SMC), and Variable Frequency AC Drive Units Technical Data,

2100-TD001

, and MCC Inverse Time Circuit Breakers in

publication

Combination NEMA Starter, Soft Starter (SMC), and Variable Frequency AC Drive Units Technical Data,

2100-TD002 for circuit

breaker information in MCC units.

IMPORTANT

High efficiency motors may have higher locked rotor and inrush currents, therefore, higher magnetic trip settings than those required equivalent standard motors may be required.

11. 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, PFCCs, transducers, motor protectors, line monitors, over and under-voltage relays, and motor windings heaters may require unique start-up procedures. Set and verify adjustable current, voltage, and other settings, according to device instructions or wiring diagrams.

Allen-Bradley 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 may not be suitable for many applications. Refer to instruction manuals, supplied with the MCC for specific startup guidance.

ATTENTION

Verify that the parameters of configurable devices, such as drives, soft starters, and overload relays, are suitable for the specific application and change them as needed for the specific application.

12. 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.

13. Check timing relay settings as required.

14. Check the vents and fans.

a. Check all vents to ensure they are free from obstructions. b. Check all fans, used for forced air cooling to ensure the shaft

rotates without obstructions.

c. Check that filters are in place and clean, and set up an

in-house program for scheduled cleaning or replacement.

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Chapter 7 Final Check List Before Energizing

If you have an MCC with arc-resistant design features, if a unit has been provided with arc resistant baffles over door vents and fans, these baffles must be fastened securely in place in order to maintain the arc resistant capabilities of the MCC. Do not install any type of filter in place of, or in addition to, the arc resistant baffles.

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.

15. Check all current transformers for proper polarity and ensure their secondaries are not ‘open’, but are either connected to their respective devices or ‘shorted.’

16. Recheck that all barriers and parts that may have been removed during installation have been reinstalled. Refer to

the barrier checklist.

17. 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 using a brush, vacuum cleaner or clean, lint-free rag. Do not

use compressed air - it will redistribute contaminates on other surfaces.

ATTENTION

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

18. Conduct an electrical insulation resistance test to verify the MCC wiring integrity.

Conduct this test using an insulation resistance tester (megger) with a potential of 500...1000V. This megger test should be conducted phase-to-phase, phase-to-ground, and when applicable, phase-to-neutral on the MCC buswork. The test should be conducted with all of the switches or circuit breakers in the open or OFF/O positions. Typical insulation resistance values are 50 MΩ or greater.

Next, check the field wiring; for example, motor cables and incoming line cables. Insulation resistance values are affected by

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Final Check List Before Energizing Chapter 7

temperature, humidity, or dampness which may cause a considerably lower insulation resistance reading. If the insulation resistance values are below 1 MΩ (for example, affected by dampness, temperature, or humidity) or the MCC has been stored in a damp or humid area, we recommend that the equipment be dried out. Dry out the 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 MΩ. These readings may be recorded in the Megger Reading Recording Table

. This table allows for additional megger readings to be recorded during regular maintenance periods.

19. Check that all unit latches are secure.

20. Close and latch all doors, making certain that no wires are

pinched.

21. Check that all section closing plates are in place.

Certain applications may have latch requirements different from those provided. If you have questions regarding proper latching, contact Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support. Refer to the following illustrations for various latch placements.

Publication 2100-IN012C-EN-P - April 2009 79

Chapter 7 Final Check List Before Energizing

Vertical Wireway Door

0.5 Space Factor

1 Space Factor or Larger

Standard Latches Arc Resistant Latches

0.5 Space Factor and Units with Horizontal Disconnect Handles

Standard Latches Arc Resistant Latches

80 Publication 2100-IN012C-EN-P - April 2009

1 Space Factor to 2.5 Space Factor

2.5 Space Factor or Larger

Final Check List Before Energizing Chapter 7

1.0 Space Factor and Units with Vertical Disconnect Handles

An arc resistant latch is used for the center latch only for main incoming power units.

Standard Latches Arc Resistant Latches

For most units, the center latch is a standard quarter-turn latch. For some units a multi-turn latch is used. Torque the latch to 20 lb•in +/- 2 lb•in.

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Chapter 7 Final Check List Before Energizing

6 Space Factor (full section) Units

An arc resistant latch is used for the second and fourth positions. Other latches are standard quarter turn.

Arc Resistant LatchesStandard Latches

When properly latched, the slots on all arc resistant latches are vertical and the latch springs are compressed. The spacing of the spring coils are decreased.

Spring Compression

Uncompressed Spring Compressed Spring

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Final Check List Before Energizing Chapter 7

ATTENTION

Arc resistant MCCs are provided with an insulating sheet for each center-end closing plate. This insulation sheet must be in place in order to maintain the arc resistant capabilities of the MCC.

Arc Resistant MCC with Insulating Sheet (15 in. deep, right side visible)

Insulation Sheet

End Closing Plate

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Chapter 7 Final Check List Before Energizing

General Spacing Requirements for MCCs

(1) (2) (3)

Min Spacing, in. (mm)

Between Live Parts of Opposite Polarity Between Live Parts and

Grounded Metal Parts,

Through Air and Over

Voltage

SurfaceThrough Air Over Surface

125 or less 1/2 in. (12.7 mm) 3/4 in. (19.1 mm) 1/2 in. (12.7 mm)

126...250 3/4 in. (19.1 mm) 1.25 in. (31.8 mm) 1/2 in. (12.7 mm)

251...600 1 in. (25.4 mm) 2 in. (50.8 mm)

(1)

Reference Underwriters Laboratories, Inc. Standards for Motor Control Centers, UL 845, Tables 16.1 and 16.3.

(2)

Spacings at all horizontal and vertical buses, at incoming terminals, at the plug-in portion of all units and at feeder units consisting of fusible disconnect switches or circuit breakers only, having other than horsepower ratings, shall be as specified above. (See 17.2.2 from UL 345.)

(3)

An isolated dead metal part, such as a screw head or a washer, interposed between uninsulated live parts of opposite polarity or between an uninsulated live part and grounded dead metal is considered to reduce the spacing by an amount equal to the dimension of the interposed part along the path of measurement.

(4)

A through-air spacing of not less than 1/2 in. (12.7 mm) is acceptable at a circuit breaker or fusible disconnecting means and between grounded dead metal and the neutral of a 277/480V, three-phase, four-wire MCC.

1 in. (25.4 mm)

(4)

Spacing Requirements within MCC Units

(1) (2) (3)

Min Spacing, mm (in.)

Between Uninsulated Live

Parts and the Walls of a

Metal Enclosure

(3)

, Including

Fittings for Conduit or

Armored Cable

Voltage

125 or less

Between Uninsulated Live Parts of Opposite

Polarity and Between an Uninsulated Live

Part and an Exposed or Uninsulated Dead

Metal Part other than the Enclosure

Through Air Over Surface Shortest Distance

1/8 in. (3.2 mm)

(2)

1/4 in. (6.4 mm) 1/2 in. (12.7 mm)

126...250 1/4 in. (6.4 mm) 3.8 in. (9.5 mm) 1/2 in. (12.7 mm)

251...600 3.8 in. (9.5 mm) 1/2 in. (12.7 mm) 1/2 in. (12.7 mm)

(1)

Reference Underwriters Laboratories, Inc. Standards for Motor Control Centers, UL 845, Tables 16.1 and 16.3.

(2)

The spacing between wiring terminals of opposite polarity shall not be less than 1/4 in. (6.4 mm) if the terminals are in the same plane.

(3)

The enclosure refers to the section enclosure.

A metal piece attached to the enclosure is considered a part of the enclosure for the purpose of this note if deformation of the enclosure is likely to reduce the spacing between the metal piece and a live part.

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Sample MCC Layout Worksheet

Horizontal Wireway

Final Check List Before Energizing Chapter 7

Unit Data

1.0 S.F. 113 in. (330 mm)

Horizontal Wireway

Vertical Wireway

Location of Sample Units within above MCC Layout

Full Width Section

Wiring

Unit Location

Cat. No.

Diagram

Size or Amp Rating

Description

Full Load Current

Horsepower

Overload or

Heater Elements

Kilowatts

Circuit Breaker Trip Setting

Power Fuse Rating

1A 2113B-EDB-48CA CSXXXXXXXX 4 FVNR 77 60 W73 — C — 1E 2112A-BDBD-24J-38-7FEC1A Y-XXXXXX 1 FVNR 4.8 3 7FECIA — — 10 1G 2100-NJ30 N/A — Blank — — — — — — 2A 2113B-2PAB-56WT Y-XXXXXX 450A FVNR(V) 364 250 W43 — 6 —

Publication 2100-IN012C-EN-P - April 2009 85

Chapter 7 Final Check List Before Energizing

Unit Description

Unit Type Code Code Description

CN2DN ControlNet to DeviceNet DNC DeviceNet Connector DNPS DeviceNet Power Supply EN2DN Ethernet ro DeviceNet FCBX Insert with Circuit Breaker FDSX Insert with Fusible Disconnect FVLC Full Voltage Lighting Contactor FVR Full Voltage Reversing FVNR (V) Full Voltage Non-Reversing (Vacuum) INSRT Unit Insert LPAN Lighting Panel (M)BPS MAIN Bolted Pressure Switch (M)CB MAIN Circuit Breaker (M)FDS MAIN Fusible Disconnect Switch (M)LUG MAIN Line Lugs METER Metering Unit NCP Neutral Connection Plate NLD ControlNet to DeviceNet PLC Programmable Logic Controller RVAT Reduced Voltage Autotransformer SMC Solid State Motor Controller SPD Surge Protection Device TERM Terminal Unit TS1W (R) Two-Speed One Winding (Reversing) TS2W (R) Two-Speed Two Winding (Reversing) VFD (VT) Variable Frequency Drive (Variable Torque) VFD (CT) Variable Frequency Drive (Constant Torque) VFDR Variable Frequency Drive Supplemental Unit XFMR Transformer

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MCC Layout Worksheet

Final Check List Before Energizing Chapter 7

MCC Name / Number

Unit Data

Cat. No. Wiring Diagram

Unit Location

___________________________________________________________

Size or Ampere Rating

Description

Full Load Current

Horsepower

Overload or Heater Elements

Kilowatts

Circuit Breaker Trip Setting

Power Fuse Rating

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Chapter 7 Final Check List Before Energizing

Megger Reading Recording Table

MCC Name / Number

Circuit / Unit

Date

Name / Number

___________________________________________________________

Phase-to-Phase Phase-to-Ground Phase-to-Neutral

A - B B - C C - A A - Grd. B - Grd. C - Grd. A - Neut. B - Neut. C - Neut.

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Energizing the Equipment

Chapter

ATTENTION

This procedure is provided as a general guidance for energizing a newly installed CENTERLINE MCC and should be used after the Final Check procedure has been completed. See Final

Check List Before Energizing for more information.

Energizing a MCC for the first time is potentially dangerous. Serious damage and or personal injury can result when power is applied. Therefore, only qualified personnel should energize the equipment.

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

Energize the Equipment

89Publication 2100-IN012C-EN-P - April 2009 89

1. Review any additional instructions supplied for the proper

operation of special units such as variable frequency drives and soft starters with appropriate and qualified personnel.

2. Check that there is no load on the MCC when it is energized.

3. De-energize all main and unit disconnect devices.

4. Check to see if any associated remote devices are de-energized.

5. Energize the MCC remote power source.

Chapter 8 Energizing the Equipment

ATTENTION

Disconnecting device handles should be operated with a firm, direct motion and should not be ‘teased’ into the closed (ON/I) position.

6. Energize the main devices followed by the feeder devices and

the branch circuit devices.

Always energize from the source of the system, working towards the loads.

7. After all of the disconnects have been closed, loads such as

lighting circuits, motor starters, and contactors may 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, refer to the Power Factor Correction Capacitors for Bulletin 2100 Motor Control Center Starter Units Application Techniques, publication 2100-AT001

b. Verify that any acceleration times are within application

specifications.

Excessive starting currents and acceleration times may cause inverse time circuit breakers, power fuses, overload relays, and other components to overheat and shutdown the equipment.

90 Publication 2100-IN012C-EN-P - April 2009

Chapter

Maintenance

A periodic maintenance program should be established for MCCs to avoid unnecessary downtime. The frequency of service to MCCs will depend upon the equipment usage and the environment in which it operates. The following is a suggested checklist and can be used to establish a maintenance program.

Maintain the MCC

ATTENTION

1. Inspect the MCCs once per year or per established maintenance

program.

2. Carefully inspect doors and enclosure sides for evidence of

excessive heat.

3. Check for moisture or any signs of dampness or drippings inside

the MCC.

IMPORTANT

a. Seal off conduit, cracks, and openings that have allowed

and/or could allow moisture to enter the MCC enclosure.

b. Dry or replace and clean insulating material that is damp or

wet or shows signs of moisture.

c. Check devices such as contactors, circuit breakers, disconnect

switches, relays, and push buttons for wetness or signs of moisture, corrosion, or contamination.

d. Replace damaged or malfunctioning parts.

De-energize the MCC before servicing.

Condensation in conduit or dripping from an outside source is a common cause of MCC failure. Eliminate any source of moisture.

4. Check the integrity of bus splice connections.

Bus splices can be easily identified by the label located on the interior of the vertical wireway door or on the interior right-hand side plate of frame mounted units. Recommended torque values

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Chapter 9 Maintenance

can be found on the information label located on the interior of the vertical wireway door or on the interior right-hand side plate of frame mounted units.

The factory-made power bus connections are tightened by a computer-controlled torquing system. The following connections do not require re-torquing, vertical to horizontal bus connections and power conductor to horizontal bus connections. These factory-made connections do not require servicing for the life of the MCC.

5. Periodically clean or replace the air filters depending on the

environmental conditions.

6. Check for the proper function and freedom of movement (no

sticking or binding) for the disconnect handle operating and defeater mechanisms.

7. Replace broken, deformed, malfunctioning, or badly worn parts

or assemblies.

8. Inspect unit bus-stab connections for wear or corrosion.

Wear and/or corrosion can increase resistance and cause an increased temperature of the contact point, leading to failure. Replace bus stabs if wear or corrosion is excessive. Lubricate bus stabs with NO-OX-ID grease (catalog number 2100H-N18 or 2100H-N18T) before installing the unit into the section.

ATTENTION

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

To prevent injury or death to personnel lubricating disconnect switch contacts, make sure the MCC power source(s) is disconnected and the respective disconnect(s) is locked in the OFF/O position. For plug-in units, remove the unit from the MCC.

To prevent personal injury or damage to equipment, make sure that the unit handle operator is in the OFF/O position before removing the unit.

9. Inspect current carrying parts such as fuse clips, knife blades of

disconnects, and line and load terminals of devices for discoloration, corrosion, or other signs of wear or possible failure.

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Maintenance Chapter 9

10. Check locking or interlocking devices for proper working

condition.

11. Adjust, repair, or replace any device if necessary.

12. Check power contacts for excessive wear and dirt accumulation

and vacuum or wipe contacts with a soft cloth to remove dirt as needed.

Contacts are not harmed by discoloration and slight pitting. Contacts should never be filed, as this could reduce the life of the contacts. Contact spray cleaners should not be used, as they cause sticking on magnetic pole faces or in operating mechanisms, interfering with the electrical continuity of the contacts. Contacts should be replaced only after the silver has become badly worn. Always replace contacts in complete sets to avoid misalignment and uneven contact pressure.

13. Check for loose wire connections on power and control circuit

terminals.

Loose connections can cause overheating, hot spots, or arcing faults that could lead to equipment malfunction or failure. Replace any damaged parts or wiring.

14. Check contactor and relay coils for evidence of overheating,

such as cracking, melting, or burning of insulation.

If there is evidence of overheating, the coil must be replaced. When replacing a coil, check and correct the overvoltage or undervoltage conditions that may have caused the coil failure. Be sure to clean any residue of melted coil insulation from other parts of the device and replace as necessary.

15. Check all pilot lights and replace lamps and damaged lenses as

necessary.

16. Check all fuses.

If replacing fuses, install the same type and rated fuse that was originally furnished with the MCC.

17. Remove accumulated dust and dirt from structure and individual

units by vacuuming.

Do not use compressed air, as it may contain moisture and blow debris within the enclosure.

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Chapter 9 Maintenance

Disconnect the Switch and Contact Lubrication

18. Refer to individual user policies, NFPA 70B, Recommended

Practice for Electrical Equipment Maintenance for MCC Servicing Guidelines.

ATTENTION

Follow NFPA 70E safety guidelines when working on energized equipment.

To prevent personal injury or damage to equipment, make sure that the unit handle operator is in the OFF/O position before removing the unit.

If a switch that is used frequently becomes difficult to operate or is located in a highly corrosive or caustic environment, it may require lubrication. The lubricant to be used is NO-OX-ID Compound (catalog number 2100H-N18 for a 1 pt can or catalog number 2100H-N18T for a 1 oz tube). To obtain the lubricant, contact your local Rockwell Automation Sales Office, distributor or Rockwell Automation.

1. Determine your unit type.

Plug-in Units

If a disconnect switch requires lubrication and is housed in a plug-in unit, remove the plug-in unit from the MCC (For removal of unit, refer to Chapter 4 Units, before lubricating the switch).

Frame Mounted Units

If a disconnect switch requires lubrication and is housed in a frame mounted unit, turn off the power sources to the MCC so the switch can be lubricated.

, Installing and Removing Plug-in

ATTENTION

94 Publication 2100-IN012C-EN-P - April 2009

To prevent injury or death to personnel lubricating disconnect switch contacts, make sure that the MCC remote power sources are disconnected and the respective disconnects are locked in the OFF/O position.

Maintenance Chapter 9

Save all parts for reinstallation.

2. Remove the line guard from the disconnect.

3. For access to the disconnect's stationary contacts, remove the arc

hood.

4. Generously apply the NO-OX-ID compound (sufficient enough

to cover with a noticeable film) to both sides of the movable contact blades and to the adjacent insides stationary contacts and the hinge.

If the unit requires lubrication because of corrosion (for example, a sulfuric environment), replacing the unit disconnect may be required to avoid overheating conditions. Lubrication may temporarily resolve overheating, however replacing the disconnect switch would be the ideal, long-term solution.

Use Thermal Infrared or Other Temperature Measurement Techniques for Preventive Maintenance

5. Reinstall the arc hood that was removed in step 3

6. Reinstall the line guard cover that was removed in step 2

7. If the lubricated disconnect switch is housed in a plug-in unit,

reinstall the unit.

For installation of unit, refer to Installing Units with Vertical Operating Handles, publication 2100-IN014

ATTENTION

Temperature measuring techniques are often performed with the units fully energized and the doors and covers open.

Use extreme caution when performing these measurements so that energized parts are not shorted.

If care is not taken, electrical shock, severe injury or death will result.

When working on or near energized electrical equipment, follow established electrical safety-related work practices. Refer to NFPA 70E Standard for Electrical Safety in the Workplace.

Use the following procedure when using thermal infrared or other temperature measurement techniques as part of a periodic preventative maintenance program on CENTERLINE 2100 Low Voltage MCCs.

Publication 2100-IN012C-EN-P - April 2009 95

Chapter 9 Maintenance

Temperature Guidance

1. Use test equipment to determine the temperature differential

and the temperature rise of accessible components within the unit.

2. Determine the services and repair recommendations based on

the temperature category in the following guidance chart.

Category Temperature

Differential

(1)

Temperature

(2)

Rise

Repair/Service

°C °F °C °F Service Interval Recommended Action

1 < 10° < 18° < 70° < 126° No service or repair required. See step 1 below. 2 10°...25° 18°...45° 70°...100° 126°...180° Service or repair the unit at next maintenance

See step 2 below. schedule (not greater than six months but continue monitoring as a part of preventive maintenance.)

3 25°...50° 45°...90° 100°...115° 180°...207° Service or repair the unit within the next two weeks

and monitor the unit at the next maintenance interval.

4 > 50° > 90° > 115° > 207° Shutdown the unit and repair. Verify that the

temperature is reduced after re-energization.

(1)

Temperature (measured or rise) differential between adjacent phases or like elements. Load between phases must be balanced with a normal variation not exceeding seven percent.

(2)

Measured temperature less ambient. Due to difficulty obtaining accurate infrared temperature measurements from highly reflective surfaces, we recommend using temperature differential readings in determining the Service/Repair guidelines, for example, emissivity of tin or silver plated material.

Inspect the Units for Signs of Overheating

1. If there are no signs of overheating and thermal infrared tests

indicate service is not necessary, document the units as acceptable.

Use this information for reviewing the mean time to maintenance for preventative maintenance for the specific facility.

ATTENTION

To service the units, make sure that the MCC remote power sources are disconnected and that the respective disconnects are locked in the OFF/O position.

96 Publication 2100-IN012C-EN-P - April 2009

Maintenance Chapter 9

ATTENTION

If servicing a plug-in unit, remove it from the MCC to facilitate servicing. Refer to Chapter 2

of this publication

for unit removal guidelines. When plugging units back in, refer to

Motor Control Centers (MCC) Units with Vertical Operating Handles Installation Instructions,

and

CENTERLINE 2100 Motor Control Center (MCC) Units

with Horizontal Operating Handles Installation Instructions,

CENTERLINE 2100

publication 2100-IN014,

publication 2100-IN060.

2. If there are no signs of overheating, but thermal infrared tests

indicate service is required, check the power connections for proper torque.

a. On disconnect switches, service the knife blades with a

Scotch-Brite cleansing pad.

b. Remove all hardened grease.

Care should be taken not to distort the disconnect jaw (stationary contact).

c. Lubricate with a fine film of NO-OX-ID (catalog number

2100H-N18 for a 0.47 L (1 pt) can, or catalog number 2100H-N18T for a 29.5 ml (1 oz) tube).

Should the disconnect be subject to environmental conditions causing chronic tarnishing, it may be necessary to determine if there is an incompatibility in the plating material, for example, hydrogen sulfide and silver plating.

On fuses and fuse clips, service by polishing with a Scotch-Brite cleansing pad. Do not lubricate the fuses or the fuse clips.

3. If overheating has occurred as indicated by severe tarnishing,

infrared test results, crystallization of insulation on conductors, discoloration of the components, darkening of the molding materials, brittle conductor insulation, or deformation and melting of parts, replace the components that are suspect.

For more information contact, Rockwell Automation LV MCC Technical Support at 1.440.646.5800 and follow the prompts to Allen-Bradley>Low Voltage Motor Control Centers>Post Shipment Support.

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Chapter 9 Maintenance

Notes:

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Maintain the MCC After a Fault Condition

Chapter

Maintenance After Fault Condition

ATTENTION

The opening of the short circuit protective device (such as fuses or circuit breakers) in a properly coordinated motor branch circuit is an indication of a fault condition in excess of operating overload and must be corrected.

Make sure that the MCC remote power sources are disconnected and that the respective disconnects are locked in the OFF/O position.

Fault conditions can cause damage to control equipment. When a fault occurs, follow this procedure.

1. De-energize the MCC.

2. Investigate the cause of the fault and inspect all equipment

thoroughly per NEMA Standards publication ICS 2.3-1995, Instructions for the handling installation operator and maintenance of MCCs not rated more than 600V, Section 11, Maintenance after a Fault has Occurred.

3. Make necessary repairs to units, components and structures as

required, prior to reenergizing the equipment.

Be sure that replacement parts are suitably rated for the application.

An insulation resistance test (megger) may be required. Refer to

Chapter 7

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Chapter 10 Maintenance After Fault Condition

Notes:

100 Publication 2100-IN012C-EN-P - April 2009

Rockwell Automation CENTERLINE 2100 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

Table of Contents

Preface

Additional Resources

General Description

Nameplate Data

MCC Sequence Numbering

UL/CSA Marking

Short-circuit Rating Label

Receiving, Handling and Storage

Receiving

Handling

Storage and Operation

Location Planning

Height Considerations

Securing an MCC

Seismic Requirements

Joining & Splicing New MCCs

Installing and Joining Pull Boxes

Bus Torque Specifications

Installing Conduit

Bottom Entry Conduit

Top Entry Conduit

Installing Cable

Lugs

Incoming Line Compartment

Main Disconnect

Cable Bracing

Incoming Line Brace

Installing Plug-in Units

Remove a Plug-in Unit with a Vertical Operating Handle from a Section

Remove a Plug-in Unit with a Horizontal Operating Handle from a Section

Remove the Support Pan

Flash Protection Marking Requirement

110.16 Flash Protection

Arc Flash Marking Clarification

Rockwell Automation Services

Defeating the Unit Door Interlock

Open the Door when the Operating Handle is in the ON/I Position

Energize a Unit with the Unit Door Open

Locking Provisions

Lock Vertical Operating Handles in the OFF/O Position

Lock Horizontal Operating Handles in the OFF/O Position

Lock Units with Operating Handles in the ON/I Position

Unit Interlocks

Introduction

Pre-Energizing Check Procedure

Perform the Pre-energizing Check Procedure

Energize the Equipment

Maintain the MCC

Disconnect the Switch and Contact Lubrication

Use Thermal Infrared or Other Temperature Measurement Techniques for Preventive Maintenance

Inspect the Units for Signs of Overheating

Maintain the MCC After a Fault Condition