Effective October 2010 Instruction Booklet IM04302004E ...

ContentsPart Description Page

1 GeneralInformation . . . . . . . . . . . . . . . . . 22 Receiving,Handling,andStorage . . . . . . . 43 InstallingControlCenterSections . . . . . . . 54 InstallingConduitandWiring . . . . . . . . . . 95 IncomingLineConnections . . . . . . . . . . 116 OvercurrentProtectionDevices . . . . . . . 157 OverloadRelayHeaterSelection . . . . . . 168 InspectionPriortoEnergizing . . . . . . . . . 209 UnitInstallationandAdjustment . . . . . . . 2210 Maintenance . . . . . . . . . . . . . . . . . . . . . . 2411 PlanViews . . . . . . . . . . . . . . . . . . . . . . . . 2912 RelatedInstructionLeaflets . . . . . . . . . . 31

Thiselectricalcontrolequipmentisdesignedtobeinstalled,operated,andmaintainedbyadequatelytrainedworkmen .Theseinstructionsdonotcoveralldetails,variations,orcombinationsoftheequip-ment,itsstorage,delivery,installation,check-out,safeoperation,ormaintenance .Caremustbeexercisedtocomplywithlocal,state,andnationalregulations,aswellassafetypractices,forthisclassofequipment .Themaximumshortcircuitcapabilityoftheequipmentshouldnotbeexceed-edbyconnectiontoasourcewithhighercapacity .Ifmaintenanceortroubleshootingassistanceisrequired,contactyournearestEatonsalesoffice .

Effective October 2010Supersedes June 2010Instruction Booklet IM04302004E

Freedom 2100 Motor Control CenterInstallation and Maintenance Manual

2

InstructionBookletIM04302004EEffective October 2010


eaton Corporation www.eaton.com

part 1. General informationTheMotorControlCenter

TheEatonFreedom2100MotorControlCentermaybejoinedtoexistingFiveStar,Series2100,andAdvantageinstallationsusingthesplicebarkitscommontoboth .UnitsdesignedfortheFreedom2100canbemountedinFiveStarSeriesandSeries2100sections,buttheoppositeisnotrecommended,becauseFiveStarandSeries2100unitsmaylackterminalblocksandsufficientinterruptingcapaci-ty .TheFreedom2100MCCmaybejoinedtoexistingEatonFreedomUnitrolandF10UnitrolMCC’swithaspecialsplicebarkit,butunitsarenotinterchangable

ControlCenterNomenclature

ThenumbersshowninparenthesesinthefollowingtextrefertotheballoonlegendsinFigure2 .

TheEatonFreedom2100MotorControlCenterconsistsofoneormoretotallyenclosed,deadfront,freestandingstructuralassem-blies90incheshighwhicharecompartmentalizedtohouseindividu-alcontrolunits .(2)Withcontrolunitsmountedinthefrontsideonly,thestructuremaybe16or21inchesdeep .Formountingunitsback-to-back,thestructureis21inchesdeep .Steelcovers(7)enclosethestructureatthetop,sidesandattherearoffront-mounted-onlystructures .

Averticalbussysteminstalledineachverticalsectionisconnectedtothehorizontalbustofeedtheindividualcontrolunits .Theverticalbusisisolatedbyafullheightbarrier .(6)Anoptionallabyrinthbar-rierprovidesbothisolationandinsulation .Anautomaticshutterisincludedwiththelabyrinthbarriersystemtocoverthestabopeningsforeachcontrolunit .

Atthetopofeachsection,adoorprovidesreadyaccesstothetophorizontalwireway(11)andgroundbus .Thehorizontalwirewayisisolatedfromthebussystemsbysteelbarrierswhichcanberemovedforinstallationandmaintenanceoperations .Adequatespaceisprovidedforcontrolwiringandtopcableentry .

Atthebottomofeachsection,adoor(18)providesreadyaccesstothebottomhorizontalwireway,andneutralbus(ifprovided) .Thebottomofeachsectioniscompletelyopentoprovideunrestrictedbottomentryofcableandconduit .Channelsillsmaybeinstalledacrossthebottomofthecontrolcenterifspecified,andanoptionalbottomplatemayalsobespecified .

Averticalwireway8inchesdeep,extendingthefull90inchheightofthecontrolcenterislocatedtotherightofeachunitcompartment .Thiswirewayiscoveredbytwohingeddoors(15)andcontainscablesupportstosecurewirebundlesandcables .Theverticalwirewayjoinsthehorizontalwirewayatthetopandbottomtoprovideunob-structedspaceforinterwiring .

Eachverticalsectionprovidesspacetomountuptosixcontrollerunits(2)withaminimumheightof12inches,inincrementsofsixinches,foratotalof72inchesofusablespace .ControllersthroughNEMASize5aredrawouttype(exceptreduced-voltagestarters) .Thesedrawoutunitassembliesareacompletelyself-containedpack-ageconsistingofasteelenclosure,operatinghandleandelectricalcomponents .Thedrawoutassemblyslidesintothiscompartmentonguiderails(11)toprovideeasywithdrawalandreinsertionandtoensureprecisealignmentoftheunitstabswiththeverticalbus .Eachdrawoutunitisheldinplacebyasinglequarter-turnlatch(4)whichcanonlybeengagedwhentheunitstabsarefullymatedwiththeverticalbus .Eachunithasaseparatedoor,(1)heldclosedbyaminimumoftwoquarter-turnfasteners .

Theoperatinghandleonthecontrollerunit(3)movesvertically .IntheONorTRIPPEDpositions,thehandleinterlockswiththeunitdoortopreventitsopening .Inthisposition,authorizedpersonnelcanopenthedoorbyturningthedefeatermechanismscrew .(21)WiththeunitdooropenandtheoperatinghandleintheONposition,anotherinterlocktothedividerpanpreventsremovaloftheunit .ThissameinterlockpreventsinsertionoftheunitunlessthehandlemechanismisintheOFFposition .Toensurethatunitsarenotener-gizedaccidentallyorbyunauthorizedpersonnel,thehandlemecha-nismcanbepadlockedintheOFFposition .Spaceforaminimumofthreepadlocksisprovidedoneachhandle .Thedevicepanel(5)ismountedonthedrawoutunit .Itwillaccommodateuptosixpilotdevices .Theoverloadresetbuttonismountedontheunitdoor .

Figure1.Nameplate

Ratings

EachFreedom2100MotorControlCenterhasaratingnameplateattachedtothedoorofthetophorizontalwirewayoftheprimarysection .SeeFigure1andFigure2 .Thisnameplateshowsthegen-eralordernumberunderwhichthemotorcontrolcenterwasbuiltanditscontinuouselectricalratings,intermsofincominglinevolt-age,phases,andfrequency,andampereratingsofthehorizontalbusandtheverticalbusforeachsection .Inaddition,thisnameplateshowsthepassiveshort-circuit(withstand)ratingofthehorizontalandverticalbussystem .Theactiveshort-circuit(interrupting)ratingsofthemainandunitshort-circuitprotectivedevicesareshownonlabelsattachedtotheinsideofeachunit .Beforeinstallingamotorcontrolcenter,calculateandrecordthefaultcurrentavailableattheincominglineterminals .Verifythattheshort-circuitwithstandardshort-circuitinterruptingratingsoftheunitsinthemotorcontrolcen-terareappropriateforthefaultcurrentavailable .

QualifiedPersonnel

Individualswhoinstall,operate,ormaintainMCCsmustbetrainedandauthorizedtooperatetheequipmentassociatedwiththeinstallationandmaintenanceofanMCC,aswellastheoperationoftheequipmentthatreceivesitspowerfromcontrollerunitsintheMCC .SuchindividualsmustbetrainedintheproperprocedureswithrespecttodisconnectingandlockingOFFpowertotheMCCandwearingpersonalprotectiveequipment,whichincludesarcflash,insulating,andshieldingmaterials,andalsouseinsulatedtoolsandtestequipment,followingestablishedsafetyproceduresasoutlinedintheNationalElectricalSafetyCode(ANSIC2)andElectricalEquipmentMaintenance(NFPA70E) .

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Figure2.MotorControlCenterNomenclature

(1)Unit Door

(2)DrawoutUnit

(4)

Turn Latch

(3)OperatingHandle

(7)Top & SideCovers

(15)VerticalWireway

Door

(18)BottomWireway Door

(21

)

DefeaterMechanism Screw

(6Vertical Bus arrie

Labyrint(Optional

)B

)h

r (5)Device Paneland Devices

)

Quarter

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part 2. receiving, Handling, and Storage

warningMCC - Heavy equipMent StateMent tHiS MCC Can weigH in exCeSS of 2,000 poundS. refer to SHipping ManifeStS for exaCt weigHt of equipMent. to prevent Seri-ouS injury or deatH, or equipMent daMage, froM unintended MoveMent of equipMent during tranSport, inStallation or any otHer operationS, enSure tHat (1) only Material Handling equip-Ment of adequate CapaCity and rating for tHe load involved iS uSed; (2) only qualified perSonnel are involved; and (3) all lifting/braCing SHipping labelS and MarkingS inStruCtionS SHipped witH tHe MCC MuSt be followed.

Receiving

Beforeandafterunloadingthemotorcontrolcenter,inspecteachsectionandunitexteriorforevidenceofdamagethatmayhavebeenincurredduringshipment .Ifthereisanyindicationthatthecontrolcenterhasbeenmishandledorshippedonitsbackorside,removethedrawoutunitsandmakeacompleteinspectionoftheinternalstructure,busbars,insulators,andunitcomponentsforpossiblehid-dendamage .Reportanydamagefoundtothecarrieratonce .

Handling

Thefollowingguidelinesareprovidedtohelpavoidpersonalinjuryandequipmentdamageduringhandling,andtofacilitatemovingthemotorcontrolcenteratthejobsite .

GeneralHints

1. Handlethemotorcontrolcenterwithcaretoavoiddamagetocomponentsandtotheenclosureoritspaintfinish .

2. Keepthemotorcontrolcenterinanuprightposition .

3. Ensurethatthemovingmeanshasthecapacitytohandletheweightofthemotorcontrolcenter .

4. Thecontrolcentershouldremainsecuredtotheshippingskiduntilthemotorcontrolcenterisinitsfinallocation .

5. Exercisecareduringanymovementandplacementoperationstopreventfallingorunintentionalrollingortipping .

6. Liftinganglesforhandlingbyoverheadcraneareboltedtothetopofeachshippingsection .Handlingbyoverheadcraneispreferable,butwhencranefacilitiesarenotavailable,themotorcontrolcentercanbepositionedwithafork-lifttruckorbyusingrollersundertheshippingskid .

OverheadCrane

1. SeeFigure3forrecommendedliftingconfiguration .

2. Selectoradjusttherigginglengthstocompensateforanyunequalweightdistribution,andtomaintainthemotorcontrolcenterinanuprightposition .

3. Toreducetensionontheriggingandthecompressiveloadontheliftingangles,donotallowtheanglebetweentheliftingcablesandverticaltoexceed45degrees .Useslingswithsafetyhooksorshackles .Donotpassropesorcablesthroughliftingangleholes.

Figure3.CorrectUseofLiftingAngle

4. Afterremovingtheliftingangles,replacethemountinghardwaretopreventtheentranceofdirt,etc .

Fork-lifttruck

Motorcontrolcentersarenormallytopandfrontheavy .Balancetheloadcarefully,andsteady,asnecessary,whilemoving .Alwaysuseasafetystrapwhenhandlingwithafork-lift.

Rollers

Rodorpiperollers,withtheaidofpinchbars,provideasimplemethodofmovingthemotorcontrolcenterononefloorlevel,ifthereisnosignificantincline .Rollthemotorcontrolcenterslowly,andsteadytheloadtopreventtipping .

Storage

Whenanmotorcontrolcentercannotbeinstalledandplacedintooperationimmediatelyuponreceipt,takestepstopreventdamagebycondensationorharshenvironmentalconditions .Ifthemotorcon-trolcentercannotbeinstalledinitsfinallocation,storeitinaclean,dry,ventilatedbuilding,heatedtopreventcondensation,andpro-tectedfromdirt,dust,water,andmechanicaldamage .Whenstorageconditionsarelessthanideal,installtemporaryelectricalheating,typicallyintheformoflightbulbs,totaling150wattspersection,hungintheverticalwireway,orbyapplyingpowertoself-containedspaceheatersthatthemotorcontrolcentermaybeequippedwith .Removeallloosepackingandflammablematerialsbeforeenergizinganyoftheheatingelements .

MOTOR CONTROL CENTER

Lift Point

Don’t pass ropes or cablesthrough lift holes. Use slings with safety hooks or shackles.

Lift Hole

Lift Angle

A

Max.45º

The height of the lift point above the spreader should be at least 1/2 of “A”(the distance between eye bolts). Thisensures a maximum angle of 45º as shown.

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part 3. installing Control Center SectionsGeneral

Freedom FlashGardmotorcontrolcenters(MCCs)aredesignedforinstallationinaccordancewithboththeNationalElectricalCodeT(NECT),NFPA70,andtheNationalElectricalSafetyCode(NESC),ANSIC2 .

Cautionif work iS involved in ConneCting tHe Control Center witH exiSting equipMent, enSure tHat inCoMing power iS diSConneCted before work beginS. diSConneCting MeanS SHould be loCked out and/or tagged out of ServiCe. wHere it iS not feaSible to de-energize tHe SySteM, tHe following preCautionS SHould be taken:

A. Personsworkingnearexposedpartsthatareormaybeener-gizedshouldbeinstructedandshouldusepractices(includingappropriatepersonalprotectiveequipment,whichincludesarcflash,insulating,andshieldingmaterials,andinsulatedtoolsandtestequipmentinaccordancewiththeNFPA70E) .

B. Personsworkingonexposedpartsthatareormaybeenergizedshould,inaddition,bequalifiedpersonswhohavebeentrainedtoworkonenergizedcircuits .

Installation

1. Beforeanyinstallationworkbegins,consultalldrawingsfurnishedbyEaton,aswellasallapplicablecontractdrawingsfortheinstallation .Giveparticularattentiontothephysicalloca-tionofunitsinthecontrolcenterandtheirrelationtoexistingorplannedconduit,busways,etc .Provideforfutureconduitentrancepriortocontrolcenterinstallation .

2. Locatethecontrolcenterintheareashownonthebuildingfloorplans .Ifinawetlocationoroutsideofthebuilding,protectthecontrolcenterfromwaterenteringoraccumulationwithintheenclosure .Recommendedclearancesorworkingspacesareasfollows:

a. Clearancefromwalls(wherenotrearaccessible)—aminimumof1/2inchforindoorand6inchesforoutdoororwetlocations .

b. ClearancefromfrontofMCC(workingspace)—minimumof3feetforcontrolcenterswithoutexposedliveparts .SeeNEC110-13 .

otee:N Thisworkingspaceshouldnotbeusedforstorageandshouldhaveadequatelighting .

3. SinceMCCsareassembledatthefactoryonsmoothandlevelsurfacestoensurecorrectalignmentofallparts,MCCsshouldbesecurelymountedonalevelsurface .Thefoundationfurnishedbythepurchasermustbetrueandlevel,orthebottomframesmustbeshimmedtosupporttheentirebaseinatrueplane .Itisrecommendedthatleveledchannelsillsunderboththefrontandrearofthecontrolcenterbeusedtoprovidethislevelbase .DrillandtapthechannelsillsformountingboltsinaccordancewiththeapplicablefloorplandrawingandtheneitherinstalltheMCClevelwith,orontopof,thefinishedfloor .Ifsillsaregroutedinconcrete,themountingboltsshouldbescrewedinplaceandremainuntiltheconcretehashardened .

4. Forbottomentry,positiontheMCCsothattheconduitstubsorflooropeningsarelocatedintheshadedareasshownontheMCCfloorplandrawings(refertopage29andpage30forfloorplandimensions) .Theshadedareasrepresenttheopenspaceavailableforconduitentrythroughthebottomofeachsection .Ashadedareamayberestrictediflargecontrollersorauto-transformersaremountedinthebottomofthesections .Ifoptionalbottomplatesaresupplied,theplatesmayberemovedanddrilledforconduitentry .

5. InstalltheMCCinitsfinalposition,progressivelylevelingeachsectionandboltingtheframestogetheriftheyareseparated .Ifnecessary,securetheMCCtowallsorothersupportingsurfaces .Donotdependonwoodenplugsdrivenintoholesinmasonry,concrete,plaster,orsimilarmaterials .SeeNEC110-13 .

6. Iftwoormoreshippingsectionsaretobejoinedintoanintegralassemblyorashippingsectionistobejoinedtoanexistingsection,refertoparagraphsbelowbeforeproceedingwiththeinstallation .

7. GroundandbondtheMCCasfollows:

a. MCCsusedasserviceequipmentforagroundedsystemorasanincominglinesectionforaseparatelyderived,previ-ouslygroundedsystem:

1. Runagroundingelectrodeconductor(groundwire)havingasizeinaccordancewithNEC250-94fromthegroundingelectrodetotheMCCgroundbusorgroundterminalprovided .SeealsoNEC250-92(A)and92(B) .

2. IfthesystemisgroundedatanypointaheadoftheMCC,thegroundedconductormustberuntotheMCCinaccordancewithNEC250,andconnectedtothegroundbusterminal .

3. Donotmakeanyconnectionstogroundontheloadsideofanyneutraldisconnectinglineoranysensorusedforground-faultprotection .Donotconnectoutgoingground-ingconductorstotheneutral .

b. MCCsusedasserviceequipmentforanungroundedsystemorasanincominglinesectionforaseparatelyderived,previouslyungroundedsystem:

1. Runagroundingelectrodeconductor(groundwire)havingasizeinaccordancewithNEC250-94fromthegroundingelectrodetotheMCCgroundbusterminal .SeeNEC250-92(A)and92(B) .

c. MCCsnotusedasserviceequipmentnorasanincominglinesectionforaseparatelyderivedsystem,andusedoneitheragroundedorungroundedsystem:

1. GroundtheMCCgroundbusbymeansofequipmentgroundingconductorshavingasizeinaccordancewithNEC250-95orbybondingtotheracewayenclosingthemainsupplyconductorsinaccordancewithNEC250-92(B) .

8. Whenallwiringandadjustmentsarecomplete,closeallunitandwirewaydoors .

9. Indampindoorlocations,shieldtheMCCtopreventmoistureandwaterfromenteringandaccumulating .

10. UnlesstheMCChasbeendesignedforunusualserviceconditions,itshouldnotbelocatedwhereitwillbeexposedtoambienttemperaturesabove40°C(104°F),corrosiveorexplosivefumes,dust,vapors,drippingorstandingwater,abnormalvibration,shock,ortilting .

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JoiningCompatibleSections

Iftwomoreshippingsectionsaretobejoinedintoanintegralassembly,orasectionaddedtoanexistinginstallation,splicingofhorizontalbus,groundbus,neutralbus,andjoiningoftheadjacentverticalsectionsmustbeplannedwiththeinstallation .

1. Removethesidesheetsfromadjacentverticalsectionstobejoined .(Thesesheetswillhavebeenremovedfromfactory-assembledsections .)

2. ThehorizontalbusspliceplatesandconnectionhardwarewillbeshippedwiththeMCCattachedtooneendofshippingsection .RefertoFigure4 .

3. Thismethodprovidesthemostconvenientaccesstothebolts,andeliminatestheneedtoremovethehorizontalbusbarriersinthatstructure .Shouldtheexistingbusbeoxidized,sandlightlywithafinealuminumoxidepaper .

Cautiondo not uSe eMery ClotH or any abraSive Containing Metal.

4. Removetheupperhorizontalwirewaydoorfromthestructureontherightsideoftheleft-hand(LH)section,andremovethetwo-piecewirewaybarriertoprovideaccesstotheendsofthebusinthatsection .

5. Movethesectionintoplace,aligningtheuprightstructuralchan-nelsandbottomchannels .Alignmentofthesectionwithfloorsillsandfoundationprovisionswillbefacilitatedbyremovingthebottomhorizontalwirewaydoors .Usingthe“U”typeframeclampsprovided,clampadjacentfrontuprightchannelstogetheratthetop,bottom,andapproximatecenteroftheverticalstructure .“U”clampplacementsmustbeplaced4inches(101 .6mm)aboveorbelowthedrawoutunit—1/4turnlatchandunitinterlockfeatureonthecovercontrolmodule;seedetailsonpage30bottomleft-handcorner .Thisoperationwillbefacilitatedbyremovingtheverticalwirewaydoorsfromtheleft-handstructureandoneormoredrawoutunitsfromtheright-handstructure .SeePart9,page22 .

6. Ifrearaccessisavailable,“U”clampsshouldalsobeusedtoclamptherearuprightchannelstogether .Infront-mounted-onlystructures,thiswillrequireremovaloftheadjacentbacksheets .Inaback-to-back-mountedstructure,removetheverticalwire-waydoorsandoneormoredrawoutunitsasabove .

7. Securethesectionstothefloorsillsormountingboltsasprovidedfortheinstallation .

8. Boltthehorizontalbusspliceplatestothebusintheleft-handstructure,torquingallbusspliceboltsto360pound-inches(30pound-feet) .SeeFigure5 .

9. Replaceallunits,busbarriers,anddoors .

JoiningIncompatibleSections

JoiningaFreedom MCCtootherequipment,suchasTypeWand11-300controlcenters,willusuallyinvolveatransitionsectioninstalledbetweenthetwovarietiesofequipment .ThistransitionsectionwillbedetailedondrawingsprovidedbyEatonandtheapplicablecontractdrawings .Ifprovidedseparately,itshouldbeinstalledfirst .ReviewtheoverallinstallationtasktodeterminewhetherthetransitionsectionshouldbeattachedtotheexistingequipmentortotheFreedomFlashGardsection,beforeitismovedintoplace,andselectthesequencethatwillprovidebestaccesstobussplicingandjoiningofthestructures .

Figure4.SplicePlatesAttachedtoRight-HandSection

Figure5.AccesstoLeft-HandSplicePlateConnections

SplicePlates

EachspliceplatekitconsistsofshortpiecesofbusbarthesamewidthasthemainhorizontalbusoftheMCCthekitisshippedwith,fourboltsperphase,andappropriatequantitiesofrelatedhardware .Forasinglebusbarperphase,thehardwareisusedasshowninFigure6foreither16-or21-inchdeepenclosures .Eachspliceplateispunchedwithrectangularholestoacceptasquareshankcarriageboltthatwillnotrotateasthenutistightened .

WheretheMCCisbuiltwithtwohorizontalbusbarsperphase,thespliceplatesareinstalledasshowninFigure7 .ThetopedgeofFigure7throughFigure10representsthebacksideoftheMCC .Thetopportionofeachofthesefiguresappliesto21-inchdeepenclosuresandthelowerportionto16-inchdeepenclosures .Notethatforallbutthesingle-barperphase(Figure6)installation,the16-inchdeepenclosuresrequiretheuseofanutplatethatismountedwiththesamecarriageboltusedtoattachthehorizontalbusbarstothechannel-shapedinsulators .Installthesenutplatesbeforemountingthespliceplates .Tightenthespliceplateboltswithadrivingtorqueof360pound-inches(30pound-feet) .

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Type 3R Enclosures

WheretheMCCissuppliedinaType3Renclosureforanoutdoorapplication,applyroofsplicecapsateachshippingblockjunctiontomaintaintheenclosureintegrity .

Figure6.Single-BarSpliceKit

Figure7.Double-BarSpliceKit

Figure8.Triple-BarSpliceKit

SplicePlate

CarriageBolt

3/8" -16Nut

FlatWasher

LockWasher

FrontFace

21" Deep

16" Deep

NutPlate

FlatWasher

LockWasherHex–Head Bolt

21" Deep

16" Deep

Figure9.Quadruple-BarSpliceKits

Figure10.Six-andEight-BarSpliceKits

21" Deep

21" Deep

16" Deep

Six Bars per Phase—21" Deep

Front FaceEight Bars per Phase—21" Deep

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Joining to a Freedom FlashGard, Freedom Unitrol,orF10Unitrol

ConsulttheassemblyinstructionsuppliedwitheveryFreedomMCCsetupforsplicetoFreedomFlashGard,FreedomUnitrol,orF10Unitrol .

warningSpeCifiC Safety note for inStalling and reMoving MCC unitS—reCoMMend tHe uSe of new aCCeSSory.

Figure11.SplicePlatesAttachedtoFreedom2100HorizontalBusandGroundBusatTop

Figure12.HorizontalBusSpliceFreedomUnitrolonLeft,Freedom2100onRight

Figure13.SplicePlateAttachedtoFreedomFlashGardGroundBusatBottom

Figure14.SplicePlateAttachedtoFreedomFlashGardNeutralBus

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Freedom 2100 Motor Control Center Installation and Maintenance Manual


part 4. installing Conduit and WiringConduit

Installconduitinsuchamannerastopreventwaterfromenteringandaccumulatingintheconduitortheenclosure .Eliminatesagsinconduit .Havetheconduitenterthemotorcontrolcenter(MCC)intheareasdesignatedforconduitentryontheplanviews .Seepage29andpage30ofthisbookletandoutlinedrawingsshippedwiththeMCC .Keepingconduitwithintheshadedareasshownintheplanviewswillavoidcableinterferencewithstructuralmembersandlivebus .SeePart12 .

Wiring

InstallthelineandloadconductorssizedinaccordancewiththeNEC .Usecopperwireonlyforcontrolterminations.Usecopperwireonlyforpowerterminationsunlesstheyaremarked“CU/AL.”Useconductorswithatemperatureratingof167ºF(75°C)orhigher,butregardlessoftheinsulationtemperaturerating,selectthewiresizeonthebasisof167ºF(75°C)wireampacity .Usingahighertemperaturewireampacitytableoftenresultsinasmallercross-sectionofcopperavailableforcarryingheatawayfromterminals .

Installinsulatedwireandcableatatemperaturesufficientlywarmtopreventtheinsulationfromcrackingorsplitting .

Whenmorethanoneconduitisrunfromacommonsourceortoacommonload,besuretohaveeachconduitcarryconductorsfromeachphaseandthesamenumberofconductorsperphase .Ifthephaseconductorsarenotdistributeduniformly,eddycurrentswillbegeneratedinthesteelbetweentheconduits .

LocateconductorswithintheMCCtoavoidphysicaldamageandtoavoidoverheating .Secureincomingpowerlinesinamanneradequatetowithstandtheforcesthatwillacttoseparatetheconductorsundershort-circuitconditions .Usethecabletiesfurnishedinbothhorizontalandverticalwirewaystosupporttheloadandinterconnectionwire .Useashieldedcommunicationscableinsideofflexiblemetalconduittoprotectverylowvoltagesignalstransmittedtoorfromacomputerorprogrammablecontroller .

LugsfurnishedwiththeMCCanditscomponentsareforClassBandClassCstranding .Verifythecompatibilityofwiresize,type,andstrandingwiththelugsfurnished .Wheretheyarenotcompatible,changethewireorlugsaccordingly .Ifcrimplugsareused,crimpwiththetoolsrecommendedbythemanufacturer .

Usecareinstrippinginsulationtoavoidnickingorringingthemetal .Allfieldwiringtocontrolunitsshouldbemadeinaccordancewiththewiringdrawingsthatarefurnishedwiththecontrolcenter .Loadandcontrolwiringcanbebroughtinthroughtheupperand/orlowerhorizontalwireways .Determinethetypeofwiringinstalledinthecontrolcenter(NEMATypeBorC)andproceedperthefollowingappropriateparagraph .

Thephasesequenceofthepowercircuitloadterminals(top-to-bottom:T1,T2,T3)inunitsmountedontherearsideoftheMCCisoppositetothatoftheloadterminalsinunitsmountedonthefrontsideofaback-to-backMCC .Toobtainthesamedirectionofrotationforamotorconnectedtoarear-mountedunitasforoneconnectedtoafront-mountedunit,re-labeltheterminalsintherear-mountedunit:T3,T2,T1,andwireaccordingly .Refertothewarningstickersuppliedwithrear-sideunits .Whenmakingpowerconnectionstothestarterterminals,besuretoleavesufficientslackinthewiressothattheunitcanbewithdrawntothedetentpositionformaintenance .SeeTable8 .

NEMATypeBWiring

Eachcontrolunitisfactoryassembledwithdevicesinter-wiredwithintheunit .Inaddition,allcontrolwiringiscarriedtounitterminalblocksmountedontheright-handsideoftheunit .SeeFigure15 .Bringthefieldwiringofcontrolwiresfromahorizontalwirewayintotheverticalwirewayontheright-handsideoftheapplicablecontrolunitandterminatethemattheunitterminalblocks .

Bringloadwiringfromtheverticalwireway,underthebottomright-handsideoftheunit,toterminationswithintheunit .Ifoptionalloadterminalsareprovided,terminateloadwirestoloadterminalslocatedadjacenttotheverticalwireway .Togainaccesstotheseterminals,placetoolbetweenright-handwrappersideandwirewaypostasshowninFigure15a .

Figure15.UnitTerminalBlocks

Figure15a.Pull-ApartTerminalBlocks

EngagingPull-apartTerminalBlocks

Themaleportionofthepull-apartterminalblockislocatedinaplasticbagtiedtothepivotrodinsidetheunit .Thisterminalblockcanbewiredoutsideoftheverticalwireway .Toengagetheterminalblock,alignthefingersofthemaleconnectorwiththeslotatthebackofthefemaleportionoftheterminalblock .Thenrotatethemaleportionforwardandtotheleftintothefemaleportionoftheterminalblock .Eachmaleportionofthepull-apartterminalblockhastwocavitiesadjacenttothecenterterminalscrewtoacceptthebladeofanelectrician’sscrewdriverusedtocamtheblockintoandoutofengagement .Eachmaleportionalsohasarearslotthatcanengagetheedgeoftheunitframewhereitcanbemountedforeaseintroubleshooting .

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NEMA Type C Wiring

Eachcontrolunitisfactoryassembledwithdevicesinter-wiredwithintheunit .Inaddition,allcontrolwiringiscarriedtounitterminalblocksonthesideoftheunitandfromtheseunitblocks,alongwithloadwiringthroughSize3,tomasterterminalblockslocatedatthetoporbottomofthestructure .SeeFigure16 .Masterterminalblockscanbeeitherfixedordrawoutmounted .Inthedrawoutdesign,theterminalblocksarerackmountedtopermitwithdrawaloftheentireassemblyforeaseofwiringduringinstallationandmaintenance .BringfieldwiringfromthehorizontalwirewaytothemasterterminalblocksexceptforloadwiringlargerthanSize3 .Theselatterloadwiresshouldbecarriedintotheverticalwirewayandunderthebottomright-handsideoftheunittoterminationswithintheunit .

Figure16.MasterTerminalBlock

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part 5. incoming Line Connections OvercurrentProtection

Allungroundedconductorsinamotorcontrolcenter(MCC)installationrequiresomeformofovercurrentprotectioninordertocomplywithSection240-20oftheNEC .SuchovercurrentprotectionfortheincominglinestotheMCCisintheformoffusesoracircuitbreakerlocatedatthetransformersecondarythatsuppliestheMCC .TheconductorsfromthetransformersecondaryconstitutethefeedertotheMCC,andthe“10-footrule”andthe“25-footrule”ofNEC,240-21apply .TheselatterexceptionstothegeneralruleallowthedisconnectmeansandovercurrentprotectiontobelocatedintheMCC,providedthefeedertapsfromthetransformeraresufficientlyshortandotherrequirementsaremet .

AcircuitbreakeroracircuitinterruptercombinedwithfusescontrollingthepowertotheentireMCCmayprovidetheovercurrentprotectionrequiredasdescribedaboveormaybeasupplementarydisconnect(isolation)means .SeeFigure17,Figure18,andFigure19 .

WhentheMCChasamaindisconnect,bringtheincominglines(thefeeders)tothelineterminalsofthecircuitbreakerorcircuitinterrupter .TheloadsideofthecircuitbreakerortheloadsideofthefusesassociatedwiththecircuitinterrupterhasalreadybeenconnectedtotheMCCbusbardistributionsystem .Inthecaseofmaindisconnectsrated400Aorless,thisloadconnectionismadebystabconnectionstoverticalbusbarsthatconnecttothehorizontalbusdistributionsystem .SeeFigure17 .

Figure17.MainDisconnectwithStabLoadConnectionsOvercurrentProtectiontobeLocatedintheMCC,ProvidedtheFeederTapsfromtheTransformerareSufficientlyShortandOtherRequirementsareMet

VerticalWireway

StabConnections

Figure18.MainCircuitBreakerwithReverseFeed

Figure19.MainCircuitBreaker

Note thatwith reverse feed, the bottom terminals of the circuit breaker are still energized when the circuit breaker is turned off!

12




Incoming Line Lugs

WheretheovercurrentprotectionfortheMCCisataremotelocation,theMCCfeederlinesareconnectedtoincominglinelugsattachedtothebusbardistributionsystem .SeeFigure20 .Forhigh-ampereratedhorizontalbusbarsystems,theincominglinelugsaremountedonverticalrisersthatconnecttothehorizontalbusbars .SeeFigure21 .

Figure20.IncomingLineLugConnections

Figure21.IncomingLineCompartment,2000A

13




Short-circuit Bracing

Allincominglinestoeitherincominglinelugsortomaindisconnectsmustbebracedtowithstandthemechanicalforcescreatedbyahighfaultcurrent .WiththeremainderofaFreedom2100MCCratedfornotlessthan65,000A(rmssymmetrical),theinstallingelectricianneedstoanchorthecablesattheincominglineconnectionssuffi-cientlyandtightenthelugscorrectly .

Eachincominglinecompartmentisequippedwithtwo-piecesheetsteelbracketsthatformacablebracingsupportbracketthatisapproximately9inchesfromtheconduitentrypoint,forbothtop-andbottom-feedapplications .Usethebracketandappropriatelashingmaterialtotiethecablessecurelytogetherifbundledortoholdapartwhentheyarerequiredtobeseparated .SeeFigure22,whichshowsthetwo-partmounting/bracingbracket,inatopentryincominglugconfiguration .

Figure22.IncomingLineCompartmentShowingTwo-PieceSupportBracket,withOpeningforCables

MakingConnection

Cautionall inCoMing line CoMpartMentS preSent an obviouS Hazard wHen tHe door iS opened or CoverS are reMoved witH power on. wHen working in tHiS area, tHe inCoMing feeder SHould be de-energized.

Beforebeginningworkonincominglineconnections,refertoalldrawingsfurnishedbyEaton,aswellasallapplicablecontractdrawingsfortheparticularinstallation .

Dependingonthelocation,size,andtypeoftheincomingarrange-ment,removeoneormorehorizontalandverticalwirewaydoors,andselectedunitstoprovidecompleteaccess .SeePart9,page22forunitremovalinstructions .

Fortopentry,thetopcoverplatesareeasilyremovedfordrillingorpunchingoperations .

14




MCC with a Magnum or a main lug only incoming line(Figure21)section—cablebracing/lashingfortop-andbottom-feedarrangements

1. Allcablemustbeterminatedwithtwo-holemountedcompres-sionormechanicalset-screwtypelugs .

2. Allnon-current-limitingcircuitbreakersratedabove42kAandwithcircuitsratedfor800AandbelowrequirecablelashingperFigure23 .

3. Circuitbreakerrated42kAand belowrequirenocablelashing .

4. Nocablelashingisrequiredforcurrent-limitingcircuitbreakers .

5. Nocablelashingisrequiredforcircuitsusingmorethanfour(4)cablesof500kcmilorlargersizewireperphase,regardlessofshortcircuitrating .

Figure23.CableLashingInstallationInstructions

Cable Lugs(Note 2)

RopeCable

Instructions:1. Route cable as close together as possible.2. Wrap rope around the cable 6 in (152.4 mm) from lugs (see Note 1).3. The second wrap is to be applied 6 in (152.4 mm) from the first wrap.4. After the second wrap, the cables should be wrapped at 12 in (304.8 mm) increments to the entry or exit point of the switchgear.5. Verify that each set contains 5 loops and that all ropes are pulled as tight as possible.

Note 1: The goal is to bundle all cables together in one bundle, but near the lug landings, so the bundles may need to separate. In this case, the rope between cables should be wrapped to provide support.

Note 2: The center pole cable lugs are shown in-line with outer poles; Figure 21 shows lugs with center pole offset either leading or lagging outer poles, depending on top or bottom feed cables. The six-inch dimension shown in these arrangements is from the closed lug, which is the center pole for top entry and outer poles for bottom entry as shown in Figure 21.

Note 1

Note 1

6.00(152.4)

6.00(152.4)

12.00(304.8)

3/8" diameter

Nylon, twisted

Size = #12

3 strand

Tensile strength = 3340 lbs (1515 kg)

Working load = 278 lbs (126 kg)

Rope Requirements:

15




part 6. overcurrent protection devicesDeviceSelection

Articles240and430oftheNECcontaintherulesforselectingfuses,circuitbreakers,andoverloadrelaysbytypeandbyvoltageandampererating .Followtheserulesforfeedercircuits,andtheinstructionsattachedtotheinsideoftheleft-mostverticalwirewaydoor,formotorbranchcircuits .Selectandinstalloverloadrelaycurrentelements(heaters)basedonthemotorservicefactorandfull-loadcurrent .Ambient-compensatedoverloadrelaysareusedinmotorcontrolcenters(MCCs)tooffsetthetemperaturegradientthatoccursfromtoptobottominaloadedverticalsection .

Heatersmustbeinstalledinthestarteroverloadrelayassembliesbeforethestarterisenergized.

C306ThermalOverloadRelays(Figure24)

C306overloadrelaysareprovidedonFreedomstarters .Foursizesareavailableforoverloadprotectionupto114A .Featuresinclude:• Selectablemanualorautomaticresetoperation• Interchangeableheaterpacksadjustable±24%tomatchmotor

FLAandcalibratedforusewith1 .0and1 .15servicefactormotors .Heaterpacksfor32Aoverloadrelaywillmountin75Aoverloadrelay—usefulinderatingapplicationssuchasjogging

• Class10or20heaterpacks(Figure24) .UseClass10heaterswithfusibleorthermal-magneticbreakerdisconnectsonly

• Bimetallic,ambient-compensatedoperated .Trip-freemechanism• ElectricallyisolatedNOandNCcontacts(pullRESETbutton

totest)• Overloadtripindication• Single-phaseprotection• ULlisted,CSAcertified,andNEMAcompliant

Figure24.C306ThermalOverloadRelayandHeaterPack

C306OverloadRelaySetting

FLADialAdjustment—Formotorshavinga1 .15servicefactor,rotatetheFLAadjustmentdialtocorrespondtothemotor’sFLArating .EstimatethedialpositionwhenthemotorFLAfallsbetweentwolettervaluesasshowninFigure25 .

Formotorshavinga1 .0servicefactor,rotatetheFLAdialone-halfpositioncounterclockwise(CCW) .

Manual/AutomaticReset—Theoverloadrelayisfactoryset“M”formanualresetoperationasshowninFigure25 .Forautomaticresetoperation,turntheresetadjustmentdialtothe“A”position .Automaticresetisnotintendedfortwo-wiredevices .

TestForTripIndication—Totestoverloadrelayfortripindicationwheninmanualreset,pullouttheblueresetbutton .Anorangeflagwillappearindicatingthatthedevicehastripped .Pushresetbuttontoreset .

warningto provide Continued proteCtion againSt fire or SHoCk Hazard, tHe CoMplete overload relay MuSt be replaCed if burnout of tHe Heater eleMent oCCurS.

Figure25.OverloadRelaySettings

CurrentTransformers

Whencurrenttransformersareusedwithoverloadrelays,thecurrentthroughtheoverloadrelayheaterisrelatedtothemotorfull-loadbytheinverseofthecurrenttransformerratio .

warningdo not ever reMove HeaterS froM Size 5 and larger StarterS to CHeCk unit operation. tHeSe StarterS uSe Current tranSforMerS to drop tHe Current to tHe range of tHe Size 1 overload relay. operation witH HeaterS reMoved will not interrupt voltage to tHe Motor and will generate dangerouS voltageS in tHe open SeCondary of tHe Current tranSforMer.

ExampleofSettingforManualReset

FLADialAdjustment ResetAdjustmentDial

1 .0ServiceFactor

1 .15ServiceFactor

A

M

Exampleof12 .0FLASettingforHeaterPackNumberH2011BShowingPosition

for1 .0or1 .15ServiceFactorMotors

16




Motor Circuit Protector (HMCP)

Afterinstallationofthecontrolcenter,eachMCPmustbeadjustedtoactualmotorfull-loadamperes(FLA)sothatitwilltripatanycurrentthatexceedsstartinginrush.Thissettingprovideslow-levelfaultprotection .Thefirsthalf-cycleinrushwillvarywiththemotorcharacteristics .Motorswithlocked-rotorcurrentsof6timesmotorfull-loadampereswillusuallyrequireaninstantaneousmagneticsettingof7to11timesmotorfull-loadamperestopreventtrippingwhenstarting .

Figure26.HMCPMagneticAdjustment

Acamtoacceptasmallnarrow-bladeelectrician’sscrewdriverisnearthelowerleftcornerandaroundthatareeightletteredadjustmentpoints,calibratedintripamperes .SeeFigure26 .Adjustmentshouldneverexceed13timesFLA,whichisinaccordancewithNECrequirementsformagnetic-trip-onlybreakers .Adjustmentshouldbemadeasfollowse:

1. ObtainFLAfrommotornameplate .

2. MultiplyFLAby13 .

3. SetthecamtothehighesttripsettingthatdoesnotexceedthecalculatedfigureofItem2 .Thisisthemaximumsettingthatshouldbeused .

4. Depressandturnthescrewdriveradjustmentcounterclockwiseonesettingatatime,untilthebreakertripsinstartingandthenadjustupwardonesettingposition .Thiswillensurethatthecir-cuitwillopeninstantlyonanycurrentabovethemotorinrush,usually7to11timesFLA .

ThePUSH-TO-TRIPbuttonchecksthetrippingfunctionandisusedtoperiodicallyexercisethebreakeroperatingmechanism .Thebuttonisdesignedtobeoperatedbyusingasmallscrewdriver .

Oncethebreakerhastripped,applyforcewhenmovingtheunitoperatinghandlefromtheTRIPPEDtotheRESETposition,whichisslightlypassedtheOFFposition

Freedom2100MCCsaresuppliedwithTypeHMCPmotorcircuitprotectorshavinganinterruptingratingtomatchtheshort-circuitwithstandratingofthebusbarsystem .ForHMCPsin225,400,and600Aframesizes,themagnetic-tripadjustmentissetforeachpole .Athree-poleHMCPhasthreetripsettingstoadjust .Placeallthreepolesatthesamesetting .

CurrentLimitersforUsewithTypeHMCPandFDBreakers

TheadditionofthecurrentlimiterprovidesinterruptingcapacityabovetherangehandledbytheHMCPinmotorstartersorbyFDthermal-magneticfeederbreakers .

EachHMCPorFDbreakerratedupto150Ahasitsowncurrentlimitertoprovidecoordinatedprotectionagainstfaultsupto100,000A,rmssymmetrical .

Built-intripindicatorsineachphaseimmediatelyshowwhenafaulthasblownthecurrentlimiterandtrippedthecircuitbreaker .Thispro-videsprotectionagainstsinglephasing .Afterinterruptingafault,thecurrentlimiterwillrequirereplacement.Afterthefaulthasbeencleared,thecurrentlimiterisreplacedbytheremovalofthreescrews .Thebreakercanthenberesettoprovideforsubsequenthighovercurrentprotection .

TypeHMCPandFDCircuitBreakerswithTerminalEndCovers

Circuitbreakersinstalledinunitsconnectedto600Vdistributionsystemsrequireaterminalendcaptobeinstalledonthelineside .Replacetheterminalendcapwhenreplacingcircuitbreakersinsuchunits .

17




part 7. overload relay Heater SelectionHeaterSelectionandInstallation

Heatersshouldbeselectedonthebasisoftheactualfullloadcurrentandservicefactorasshownonthemotornameplateorinthemotormanufacturer’spublishedliterature .

Whenmotorandoverloadrelayareinthesameambientandtheservicefactorofthemotoris1 .15to1 .25,selectheatersandsetFLAadjustmentdialfromtheheaterapplicationtable .Iftheservicefactorofthemotoris1.0,orthereisnoservicefactorshown,rotatetheFLAadjustmentdialcounterclockwiseone-half(1/2)position.

Theconductorsattachedtotheterminalsofanoverloadrelayactasaheatsinkandareaconsiderationinestablishingthecurrentratingofeachheaterelement .Topreventnuisancetripping,whichwilloccurifundersizedconductorsareused,selectthewiresizeasiftheconductorshadaninsulationtemperatureratingof167ºF(75°C),eveniftheconductorsactuallyusedhaveatemperatureratinghigherthan167ºF(75°C) .

ProtectheaterandstarteragainstshortcircuitsbyprovidingbranchcircuitprotectioninaccordancewiththeNationalElectricalCode .

otee:N Beforeinstallingheaterpacks,refertothemotornameplateforFLA(fullloadamps)andservicefactor(1 .5or1 .0) .Selecttheheaterpackfromthepropertableonthispage .

Toinstalle:

Figure27.HeaterPack

A. Insertthree(3)identicallynumberedheaterpacksintotheover-loadrelaywithanFLAratingthatincludesthemotornameplateFLA(fullloadamps) .

B. Tightentheheaterpackmountingscrewssecurelyperrecom-mendedtorquevalueslistedbelow .

Heater pack numbers recommended torque

H2001B thru H2017BH2018 thru H2024

9 lb-in (1 Nm)24-30 lb-in (2.7–3.4 Nm)

C. Adjust the FLA adjustment dial to the motor nameplate FLA (full load amps).

Theoverloadisnowsetfor1.15servicefactor.

D. If the motor nameplate is 1.0 service factor, rotate the FLA adjustment dial counterclockwise one-half (1/2) position.

E. The overload is factory set for M(MANUAL) reset operation. If automatic reset is required, turn the reset adjustment dial to A(AUTO). Automatic reset is not intended for two-wire control devices.

ToRemoveHeaterPacks

Loosentwo(2)heaterpackmountingscrewsandremoveheaterpackfromoverloadrelay .

OverloadRelaySetting

Thisbimetallicambient-compensatedoverloadrelayisadjustablewithintheFLArangeoftheheaterpack .EachheaterpackismarkedwithitsFLAratings .Withproperheaterselection,theoverloadrelaywillultimatelytripat125%FLAfora1 .15servicefactormotorandat115%FLAfora1 .0servicefactormotor .

HeaterSelection/installation

SelecttheappropriateheaterpacknumberthatcorrespondstothemotorFLAratingforyourapplication .Inserteachheaterintotheoverloadrelayandtightenheatermountingscrewssecurelypertablebelow .

otee:N Atotalofthreeindividualheatersmustbeinstalledinorderfortheoverloadrelaytoworkproperly .

Heater pack numbers torque

H2001B thru H2017BH2018 thru H2024

9 lb-in24–30 lb-in

FLADialAdjustment

Formotorshavinga1 .15servicefactor,rotatetheFLAadjustmentdialtocorrespondtothemotor’sFLArating .Estimatethedialposi-tionwhenthemotorFLAfallsbetweentwolettervaluesasshownintheexample .Formotorshaving1 .0servicefactor,rotatetheFLAdialone-half(1/2)positioncounterclockwise(CCW) .

FLA 1 .0ADJUSTMENT SERVICEDIAL FACTOR

Exampleofa12 .0FLAsettingforaheaterpacknumberH2011Bshowingpositionfor1 .0or1 .15servicefactormotor .

A D

B C

1.15 ServiceFactor

A D

B C

1.0 ServiceFactor

A

M

HeaterPackMountingScrew

18




Manual/automatic Reset

Theoverloadrelayisfactorysetat“M”formanualresetoperationasshownintheillustration .Forautomaticresetoperation,turntheresetadjustmentdialtothe“A”position .Automaticresetisnotintendedfortwo-wirecontroldevices .

RESETADJUSTMENTDIAL

Exampleofsettingformanualreset .

TestforTripIndication

Totestoverloadrelayfortripindicationwheninmanualreset,pullouttheblueResetbutton .Anorangeflagwillappearindicatingthatthedevicehastripped .PushResetbuttonintoreset .

Formoreinformation,gotowww .1800oldunit .comorcall1-800-OLD-UNIT .

Table1. NEMASize0and1HeaterPackSelectionTable

Motor FLa rating FLa Dial positions

Size FStandard tripClass 20A B C D

0.254 0.375 0.560 0.814 1.20

0.306 0.452 0.676 0.983 1.45

0.359 0.530 0.7911.15 1.71

0.411 0.607 0.907 1.321.96

H2001BH2002BH2003BH2004BH2005B

1.79 2.15 3.23 4.55 6.75

2.16 2.603.90 5.50 8.17

2.53 3.04 4.56 6.45 9.58

2.90 3.49 5.23 7.4011.0

H2006BH2007BH2008BH2009BH2010B

9.14 14.0 18.723.5

10.8 16.9 22.7 28.5

12.4 19.9 26.7 33.5

14.0 22.8 30.7—

H2011BH2012BH2013B aH2014B a

aAfter the above referenced settings have been made, rotate the FLA dial one position clockwise for these heaters (see table). If less than one position is available, rotate dial maximum. This does not apply when these heaters are used with adapter base. Catalog No. C306TB1. Exception: does not apply to AN16DN0.

otee:N Formaximumratings,seetablebelow .Use75°Ccopperconductorsonly .Maximumwiresize—8AWG .

neMa Size amperes Size amperes

0 18 — —

1 27 F 32

warningto provide Continued proteCtion againSt fire or SHoCk Hazard, tHe CoMplete overload relay MuSt be replaCed if burnout of tHe Heater eleMent oCCurS.

A

M

Table2. NEMASize2HeaterPackSelectionTable

Motor FLa rating aFLa Dial positions Size J and K

Standard tripClass 20a B C D

3.23 4.55 6.75 9.14 14.0

3.90 5.50 8.17 10.8 16.9

4.56 6.45 9.58 12.4 19.9

5.23 7.40 11.0 14.0 22.8

H2008BH2009BH2010BH2011BH2012B

18.7 23.5 29.0 39.6 53.9

22.7 28.5 34.0 45.5 60.9

26.7 33.5 39.1 51.5 67.9

30.7 38.5 44.1 57.474.9

H2013BH2014BH2015BH2016B bH2017B b

aFor motor FLA values not listed, turn the dial clockwise for higher or counterclockwise for lower ratings.

bAfter the above reference settings have been made, rotate the FLA dial one position clockwise for these heaters (see table). If less than one position is available, rotate dial to maximum. This note does not apply when these heaters are used with adapter base. Catalog No. C306TB1.

otee:N Formaximumratings,seetablebelow .Use167ºF(75°C)copperconductorsonly .Maximumwiresize—3AWG .


2 45 J 60

— — K 73

Table3. NEMASize3and4HeaterPackSelectionTable

Motor FLa rating aFLa Dial positions Size n

Standard tripClass 20A B C D

18.0 24.6 33.5 45.7

20.2 27.6 37.5 51.2

22.3 30.5 41.5 56.7

24.5 33.4 45.6 62.1

H2018H2019H2020H2021

62.2 84.7 106.0

69.7 94.9 118.0

77.1 105.0 131.0

84.6 115.0 144.0

H2022H2023H2024

aFor motor FLA values not listed, turn the dial clockwise for higher or counterclockwise for lower ratings.

otee:N Formaximumratings,seetablebelow .Minimumwiresize—6AWG .


3 90 N 14

4 135 — —

19





Motor FLa rating aFLa Dial positions


34 49 72

41 59 87

48 69 103

54 79 118

H2003BH2004BH2005B

107 129 194

130 156 234

152 182 274

174 209 —

H2006BH2007BH2008B

aFLA rating marked on heater pack multiplied by a transformation ratio. For motor FLA values not listed, turn the dial clockwise for higher or counterclockwise for lower ratings.

otee:N Formaximumratings,seetablebelow .Minimumwiresize—2AWG .

neMa Size amperes

5 270


Motor FLa rating aFLa Dial positions


144 215

174 259

205 304

235 348

H2005BH2006B

258 388

312 468

365 547

419 —

H2007BH2008B

aFLA rating marked on heater pack multiplied by a transformation ratio. For motor FLA values not listed, turn the dial clockwise for higher or counterclockwise for lower ratings.

otee:N Formaximumratings,seetablebelow .

neMa Size amperes

6 540

Table6. MagneticReduced-VoltageStarterClassesF600,F700,F890withC306ThermalOverloadRelay

Starter type Class

Multiply actual Motor Full Load Current by Factor Below and refer to adjusted Full Load Current Column in tables

Quantity of Heaters required per Starter

Autotransformer F600 1 3

Part-winding F700 0.5 6

Star-delta F800 0.575 3

20




part 8. inspection prior to energizing

1. Beforeenergizingthemotorcontrolcenter(MCC),conductathoroughinspectiontomakecertainthatallforeignmaterials,suchastools,scrapsofwire,andotherdebris,areremovedfromallunitsandthestructure .Removeanyaccumulationofdustanddirtwithavacuumcleaner .

2. Allcircuitconnectionsaretightenedattimeofassemblybypower-driventoolswithcontrolledtorque .However,thevibrationsexperiencedintransitmayloosensomeoftheseconnections .Checkatleast10%ofthetotalconnectionsforatightconnection .Shouldthisspot-checkrevealsomelooseconnections,itwillbenecessarytocheckallconnectionpoints.Theconnectionstobecheckedincludebushardware,circuitbreakerandswitchterminals,contactorandrelayterminals,andterminalblocks .Alwayschecktheincominglineconnections .TightentothetorquevaluesshowninTable7 .

3. RemoveallblocksorothertemporaryholdingmeansusedforshipmentfromallcomponentdevicesintheMCCinterior .

4. Checktheenclosuretoseethatithasnotbeendamagedsoastoreduceelectricalspacings .

5. CompareallcircuitsforagreementwiththewiringdiagramsthataccompanytheMCC .Besurethateachmotorisconnectedtoitsintendedstarter .

6. Makecertainthatfieldwiringisclearoflivebussesandphysicallysecuredtowithstandtheeffectsoffaultcurrent .

7. Checktodeterminethatallgroundingconnectionsaremadeproperly .

8. Checkalldevicesfordamage .Makeallnecessaryrepairsorreplacements,priortoenergizing .

9. Manuallyexerciseallswitches,circuitbreakers,andotheroperatingmechanismstomakecertainthattheyareproperlyalignedandoperatefreely .

10. Testanyground-faultprotectionsystemsthatwerefurnished .

11. Setanyadjustablecurrentandvoltagetripmechanismstothepropervalues .

12. Ensurethatoverloadrelayheaterelementsareinstalledandselectedtothefull-loadcurrentshownonthenameplateofeachmotor .

13. InstallpowercircuitfusesinthefusibleswitchesinaccordancewithNECapplicationrequirements .Makesurethatfusesarecompletelyinsertedintheclipsprovided .Donotattempttodefeattherejectionfeatureonthefuseclip,whenprovided .

14. Donotoperateacurrenttransformerwithitssecondarycircuitopen .Ensurecurrenttransformerisconnectedtoaload,orasecondaryshortingbarisinstalled .

15. Topreventpossibledamagetoequipmentorinjurytopersonnel,checktoensurethatallpartsandbarriersthatmayhavebeenremovedduringwiringandinstallationhavebeenproperlyreinstalled .

16. ConductanelectricalinsulationresistancetesttomakesurethattheMCCandfieldwiringarefreefromshortcircuitsandgrounds .Dothistestphase-to-phase,phase-to-ground,andphase-to-neutral,withtheswitchesorcircuitbreakersopened .

17. IftheMCCcontainsalabyrinthverticalbusbarriersystem,verifytheoperationoftheautomaticshutters .SeePart9foradjustmentsofthismechanism .

18. Installcovers,closedoors,andmakecertainthatnowiresarepinchedandthatallenclosurepartsareproperlyalignedandtightened .

19. TurnallcircuitbreakersandfusibleswitchestotheOFFpositionbeforeenergizingthebus .

Table7. DrivingTorque

Description lb-in

Control wiring

Coil leadsRelaysPushbuttonsControl fuse blocksAuxiliary contacts

8 lb-in8 lb-in8 lb-in8 lb-in8 lb-in

Control wiring terminal blocks

Side-mounted lug/compressionRail-mounted lug typeRail-mounted compression type

9 lb-in12 lb-in18 lb-in

21




Table8. PowerWiringe:Starters

For Freedom Starters with C306 overload & Freedom Contactors tightening torque Conductors

Size 1 Contactor 20 lb-in Use 75°C copper conductorsSize 2 Contactor Wire size (AWG) Torque (lb-in)

14–10 35

8 40

6–4 45

3–2 50

Size 3 and Freedom Compact Size 4 (CN15MN)

Wire size (AWG) Torque (lb-in)

Slotted head screw

8 40

6–4 45

3–1/0 50

Socket head screw

Socket size (in) Torque (lb-in)

3/16 120

1/4 200

5/16 250

Size 4 275 lb-in

Size 5 500 lb-in

Starter with C440 Solid State overload

Wire size (AWG) Torque (lb-in)

NEMA 1 & 2 12-10 23

8-6 28

NEMA 3 6-1 28

Table9. FusedSwitches

Description lb-in

30A fuse assembly60A fuse assembly100A fuse assembly


200A fuse assembly400A fuse assembly600A fuse assembly


Breakers—Refertotorquevaluesonbreakercase .

Table10. IncomingLineLugs

Description lb-in

#2/0–350 MCM#2/0–650 MCM

360 lb-in360 lb-in

#2/0–750 MCM500–1000 MCM

500 lb-in600 lb-in

Table11. BusBolts

Description lb-in

All 276 lb-in (23 lb-ft)

22




part 9. Unit installation and adjustment DoorRemovalandInstallation

All doors on the control center are mounted on pin hinges to facilitate removal for installation and maintenance opera-tions. With the operating handle on the OFF position, rotate the quarter-turn latches, open the door, remove the hinge pins as shown in Figure 28, partially close the door and lift it from the structure. Reverse this procedure for installation.

UnitRemovalandInstallation

Afteropeningand/orremovingtheunitdoor,thecontrolunitisexposed .Withascrewdriver,pushinonthelatchatthetopcenteroftheunitandrotate¼turncounterclockwise .

CautionunitS 18” or More HigH Have a retaining braCe at tHe lower edge of eaCH Side of tHe unit fraMe to add Stability in SHipping. tHe SHipping braCeS May be retained or reMoved after inStallation; unSCrew prior to unit witHdrawal.

Pull-apartterminalblocksintheverticalwirewaymustbedisengaged(seeFigure29andpage9)andwiringfromtheunittootherunits,tomasterterminalblocksortoloaddevicesmustbedisconnectedbeforetheunitisremoved .GrasptheunitasshowninFigure30andpullitoutward .Thefirstinchoftravelpullsthestabsfreefromtheverticalbus,andthegroundingcliponthesideoftheunitframeisalsodisengaged .

Toreplaceacontrolunit,positionthemountingpointsontheunitframewiththematingguiderails .Slidetheunitinwarduntilallfourmountingpointsareengaged,thenmoveitinwardwithaquickpush .Thismovementeasilyovercomesthecompressionofthestabsastheyengagetheverticalbus .Withtheunitinitscorrectposition,thequarter-turnlatchiseasilyengagedbypushinginwardandrotating¼turnclockwise .

Figure28.HingePInRemoval

Figure29.DisengagingPull-ApartTerminalBlocks

Figure30.WithdrawingaUnit

23




Detent Position

Formaintenanceandtestpurposes,theunitcanbepartiallywith-drawn(approximately1½inches)untilthestabsarefreeofthebus .Inthisposition,thequarter-turnlatchcanberotatedclockwisetoengagethedetentpositionslot;thiswillsecuretheunittoensurethestabsremaindisengagedduringmaintenance .SeeFigure31 .Thelatchcanbepadlockedinthisposition .

Operating Handle Linkage Adjustment

Movementoftheoperatinghandleintheverticalplaneshouldnotberestrictedbythehandlecavityateitherthetoporbottomtoitstravel .Shouldrestrictionoccur,eliminateitadjustingthelengthoftheoperatinglinkageasshowninFigure32 .Dependingonthetypeofprimarydisconnectdevicecontainedinthecontrolunit,itmaybenecessarytolengthenorshortenthelinkage .

Automatic Shutter Travel Adjustment

Whentheoptionallabyrinthverticalbusbarrierisinstalledinthecontrolcenter,ashutterisprovidedtoautomaticallycoverthestabopeningswhenacontrolunitiswithdrawn .Theshutterisopenedbyengagementoftheleft-handsideofthecontrolunitwiththeshutterarmlinkageattachedtotheleft-handverticalstructuralmembers .Whentheunitiswithdrawnfreeofthelinkage,aspringautomati-callymovestheshuttertoitsclosedposition .SeeFigure33andFigure4 .

Withthecontrolunitremoved,theshuttershouldcompletelycomerthestabopenings .Ifitdoesnotcovertheopenings,useanadjust-ablewrenchtobendthelinkarmtotherightuntiltheshuttercoversthestabopenings .

If,onre-insertionofthecontrolunit,interferenceisfeltbetweenthestabassemblyattherearoftheunitandtheshutter,theengage-mentofthecontrolunitwiththeshutterarmlinkageisinsufficienttofullyopentheshutter .Useanadjustablewrenchtobendthelink-agearminwardtowardtheunittoincreaseitsengagementwiththeunit .Aninwardbendofapproximately¼inchwillprovidesufficientadditionalshuttertravel

InstallingPilotDevices

The device panel can accommodate up to six pilot devices such asoil-tightpushbuttons,indicatinglights,selectorswitchesandminia-turemeters .Ifunusedspaceisavailableandtheadditionofotherdevicesisdesired,observethefollowingprocedure .

Afteropeningtheunitdoor,loosenthetwoscrewsatthetopofthedevicepanel .Slidethepanel½inchlefttopermitittoswingdownforaccess .SeeFigure34 .Withthepeenendofaball-peenhammerorwithadriftorchisel,removethedesiredknockout .

Figure31.UnitLockedinDetentPosition

Figure32.OperatingHandleLinkageAdjustment

Figure33.ShutterArmLinkage

24




CautionbraCe tHe panel Solidly to avoid breaking tHe Hinge pintS. uSe a knife or SMall file to reMove reMaining plaStid burrS. inStall and wire tHe new deviCe and re-attaCH teH top of tHe deviCe panel to tHe unit.

Figure34.UnitDevicePanel

InstallingaNewUnit

Itisrecommendedthatanewunitbeinstalledinaunitspaceatthetopofaverticalcompartmentordirectlybelowanexistingunit .Materialprovidedwiththenewunitbythefactoryincludes:Adivid-erpanwithintegralguiderails,aunitdoor,hinges,catchesandhard-ware .Observethefollowingsequenceofoperationsforinstallation .

1 . Removetheexistingblankdoor .

2 . Positionthenewunitdoorovertheopenspacetoensurethehingesandlatchesarealigned .Ifthespacesdiffer,thehingesandlatchesonthestructuremustbere-locatedtomatchtheunitdoorhingesandlatches .Mountthedoor,usingthehingepinsprovided .

3 . Installthenewdividerpaninthenotchesprovidedintherearbarriersothatitisalignedwiththebottomofthenewdoor .Attachthepantotheverticalstructurechannelswithonethread-formingscrewoneachside .

4 . Removefromtheverticalbusbarriertheflatplatewhichcoversthestabholesthatwillalignwiththestabsonthenewunit .Ifanoptionallabyrinthverticalbusbarrierisinplace,installanauto-maticshutteroverthestabcutouts .Followtheinstructionsheetprovidedwiththeshutterkit .

part 10. MaintenancePreventiveMaintenance

Preventivemaintenanceshouldbeaprogram,ascheduledperiodicactionthatbeginswiththeinstallationoftheequipment .Atthattime,specificmanufacturer’sinstructionliteratureshouldbeconsulted,thenstoredforfuturereference .Follow-upmaintenanceshouldbeatregularintervals,asfrequentlyastheseverityofdutyjustifies .Timeintervalsofoneweek,oronemonth,oroneyearmaybeappropriate,dependingontheduty .Itisalsodesirabletoestablishspecificchecklistsforeachcontrol,aswellasalogbooktorecordthehistoryofincidents .Asupplyofrenewalpartsshouldbeobtainedandstored .

Thiscontrolequipmentisdesignedtobeinstalled,operated,andmaintainedbyadequatelytrainedworkmen .Theseinstructionsdonotcoveralldetails,variations,orcombinationsoftheequipment,itsstorage,delivery,installation,check-out,safeoperation,ormaintenance .Caremustbeexercisedtocomplywithlocal,state,andnationalregulations,aswellassafetypractices,forthisclassofequipment .

Authorizedpersonnelmayopenaunitdoorofamotorcontrolcenter(MCC)whilethestarterunitisenergized .Thisisaccomplishedbydefeatingthemechanicalinterlockbetweentheoperatingmechanismandtheunitdoor .Aclockwisequarterturnoftheslottedheadscrewlocatedabovetheoperatinghandlewillallowthedoortoopen .SeeFigure355 .

Whenservicingandadjustingtheelectricalequipment,refertotheapplicabledrawingscoveringthespecificmotorcontrolcenterMCCandanyotherrelatedinterconnectiondrawings .Followanyinstruc-tionsthatmaybegivenforeachdevice .Alistofinstructionleafletscoveringstandardcomponentsisshownonpage31ofthismanual .AnyoftheseleafletsmaybeobtainedbycontactingyournearestEatonrepresentative .

GeneralGuidelines—Thewholepurposeofmaintainingelectricalequipmentcanbesummarizedintworules:

1. Keepthoseportionsconductingthatareintendedtobeconducting .

2. Keepthoseportionsinsulatedthatareintendedtobeinsulated .

Goodconductionrequiresclean,tightjoints,freeofcontaminantssuchasdirtandoxides .

Goodinsulationrequirestheabsenceofcarbontrackingandtheabsenceofcontaminants,suchassaltanddustthatbecomehydroscopicandprovideanunintendedcircuitbetweenpointsofoppositepolarity .

Figure35.DefeaterMechanism

25




CautionMaintenanCe of tHe Control CoMponentS requireS tHat all power to tHeSe CoMponentS be turned off by opening tHe branCH CirCuit diSConneCt MeanS and witHdrawing tHe unit to tHe detent poSition (See figure 31) or reMoving tHe unit entirely froM tHe MCC. wHen unitS are fully inSerted into tHe MCC, tHe line Side of eaCH diSConneCt iS energized. do not work on fixed unitS unleSS tHe Main diSConneCt for tHe MCC iS off..

WhenworkingonportionsofabranchcircuitremotefromtheMCC,lockthedisconnectmeansforthatcircuitintheOFFposition .TopositivelylocktheoperatingmechanismintheOFFposition,ametallockingbarrecessedinthehandlemaybeextendedandpadlockedwithfromonetothreepadlocks .SeeFigure36 .

Figure36.LockingOutaDisconnect

WiththedooropenandthedisconnectdeviceOFF,theoperatinghandleismechanicallyinterlockedtopreventinadvertentlybeingpushedON .Todefeatthisinterlock,thebaronthetopofthemecha-nismshouldbepushedinslightly,allowingthehandletomoveupwardtotheONposition .

warningif fully inSerted, tHe power and Control CirCuitS will be energized. padloCking to prevent tHiS Handle MoveMent May be aCCoMpliSHed by tHe SaMe MetHod aS deSCribed above.

Separatecontrolsourcesofpowermustalsobedisconnected .Ifcontrolpowerisusedduringmaintenance,takestepstopreventfeedbackofahazardousvoltagethroughacontroltransformer .Bealerttopowerfactorcorrectioncapacitorsthatmaybecharged .Dischargethembeforeworkingonanypartoftheassociatedpowercircuit .

Cleaning.Soot,smoke,orstainedareas(otherthaninsidearcchutes),orotherunusualdeposits,shouldbeinvestigatedandthesourcedeterminedbeforecleaningisundertaken .Vacuumorwipecleanallexposedsurfacesofthecontrolcomponentandtheinsideofitsenclosure .Equipmentmaybeblowncleanwithcompressedairthatisdryandfreefromoil .(Bealerttobuilt-inoilersinfactorycompressedairlines!)Ifairblowingtechniquesareused,removearccoversfromcontactorsandsealopeningstocontrolcircuitcontacts

thatarepresent .Itisessentialthattheforeigndebrisberemovedfromthecontrolcenter,notmerelyrearranged .Controlequipmentshouldbecleananddry .Removedustanddirtinsideandoutsidethecabinetwithoutusingliquidcleaner .Removeforeignmaterialfromtheoutsidetopandinsidebottomoftheenclosure,includ-inghardwareanddebris,sothatfutureexaminationwillrevealanypartsthathavefallenoffordroppedontotheequipment .Ifthereareliquidsspreadinside,determinethesourceandcorrectbysealingconduit,addingspaceheaters,orotheractionasapplicable .

MechanicalChecks.Tightenallelectricalconnections .Lookforsignsofoverheatedjoints,charredinsulation,discoloredterminals,andthelike .Mechanicallycleantoabrightfinish(don’tuseemerypaper)orreplacethoseterminationsthathavebecomediscolored .Determinethecauseoftheloosejointandcorrect .Beparticularlycarefulwithaluminumwireconnections .Aluminumwireisbestterminatedwithacrimptypelugthatisattachedtothecontrolcomponent .Whenscrewtypelugs(markedCU/AL)areusedwithaluminumwire,thejointshouldbecheckedfortightnessevery200operationsofthedevice .

Wiresandcablesshouldbeexaminedtoeliminateanychafingagainstmetaledgescausedbyvibration,thatcouldprogresstoaninsulationfailure .Anytemporarywiringshouldberemovedorpermanentlysecuredanddiagramsmarkedaccordingly .

Theintendedmovementofmechanicalparts,suchasthearmatureandcontactsofelectromechanicalcontactors,andmechan-icalinterlocksshouldbecheckedforfreedomofmotionandfunctionaloperation .

Wrap-up.Checkallindicatinglamps,mechanicalflags,doors,latches,andsimilarauxiliariesandrepair,ifrequired .

Logchangesandobservationsintorecordbookbeforereturningequipmentintoservice .Donotremoveanylabelsornameplates .Restoreanythataredamaged .

ContactWearandReplacement

Contactorsaresubjecttobothmechanicalandelectricalwearduringtheiroperation .Inmostcases,mechanicalwearisinsignificant .Theerosionofthecontactsisduetoelectricalwear .Duringarcing,materialfromeachcontactis vaporizedandblownawayfromtheusefulcontactingsurface .

Acriticalexaminationoftheappearanceofthecontactsurfacesandameasurementoftheremainingcontactover-travelwillgivetheusertheinformationrequiredtogetthemaximumcontactlife .

Over-travelMeasurement

Contactlifehasendedwhentheover-travelofthecontactshasbeenreducedto0 .02inch .

Over-travelofthecontactassemblyisthatpartofthestrokethatthemovingcontactswouldtravelaftertouchingthefixedcontactsiftheywerenotblockedfrommovementbythefixedcontacts .

Amethodofmeasuringover-travelisasfollows:

A. Placea0 .02-inchfeelergaugebetweenthearmatureandmagnet,withthearmatureheldtightlyagainstthemagnet .

B. Checkcontinuallyineachphase,i .e .,determineifcircuitfromterminal-to-terminalforeachpoleisopenundertheseconditions .

C. Ifthereiscontinuitythroughallphases,theremainingover-travelissufficient .Ifthereisnotcontinuitythroughallphases,replaceallstationaryandmovingcontactsplusmovingcontactover-travelsprings .Afterreplacingparts,manuallyoperatecontactortobesurebindingdoesnotoccur .

26




Table12. ContactorTroubleshootingChart

Defect Cause remedy

Short contact life Low contact force Adjust over-travel, replace contacts, and replace contact springs as required to correct contact force.

Contact bounce on opening or closing

Correct improper voltage applied to coil. Correct any mechanical defects or misalignment.

Abrasive dust on contacts

Do not use emery cloth to dress contacts.

Load current is too high

Reduce load. Use larger contactor.

Jogging cycle is too severe

Reduce jogging cycle. Check factory for more durable contact material. Use larger contactor.

Overheating Load current too high Install arc box.

Loose connections Replace broken or eroded insulating parts, arc horns, and grid plates. Clean or replace insulating parts having a heavy coating of foreign conducting material.

Over-travel and/or contact force too low

Remove contaminating materials that may have accumulated on arc horns and steel-grid plates.

Ambient temperature is too high

Reduce load. Provide better ventilation. Relocate starter. Use larger contactor.

Line and/or load cables are too small

Install terminal block and run larger conductors between contactor and terminal block.

Welding of contacts Over-travel and/or contact force is too low

Adjust over-travel, replace contacts, and replace contact springs as required to correct contact force.

Magnet armature stalls or hesitates at contact touch point

Correct low voltage at coil terminals as coil draws inrush current.

Contactor drops open to contact-touch position because of voltage dip

Maintain voltage at coil terminals. Install low voltage protective device, sometimes called “Brownout Protector.”

Excessive contact bounce on closing

Correct coil overvoltage condition.

MaintenanceofMotorControllersafteraFault

otee:N ReproducedbypermissionoftheNationalElectricalManufacturersAssociationfromNEMAStandardsPublicationNo .ICS2-2000(R2005),IndustrialControlDevices,ControllersandAssemblies,copyright2000byNEMA .

Inamotorbranchcircuitthathasbeenproperlyinstalled,coordinated,andinservicepriortothefault,openingofthebranch-circuitshort-circuitprotectivedevice(fuse,circuitbreaker,motorshort-circuitprotector,andsoon)indicatesafaultconditioninexcessofoperatingoverload .Thisfaultconditionmustbecorrectedandthenecessaryrepairorreplacementsmadebeforere-energizingthebranchcircuit .

Itisrecommendedthatthefollowinggeneralproceduresbeobservedbyqualifiedpersonnelintheinspectionandrepairofthemotorcontrollerinvolvedinthefault .

Procedure

Cautionall inSpeCtionS and teStS are to be Made on ControllerS and equipMent tHat are de-energized, diSConneCted, and iSolated So tHat aCCidental ContaCt Cannot be Made witH live partS and So tHat all plant Safety proCedureS will be obServed.

Enclosure.Substantialdamagetotheunitdoororframe,suchasdeformation,displacementofparts,orburning,requiresreplacementoftheentireunit .

CircuitBreaker.Examinetheunitinteriorandthecircuitbreakerforevidenceofpossibledamage .Ifevidenceofdamageisnotapparent,thebreakermayberesetandturnedON .Ifitissuspectedthatthecircuitbreakerhasopenedseveralshort-circuitfaultsorifsignsofcircuitbreakerdeteriorationappearwithintheenclosure,thecircuitbreakershouldbereplaced .

DisconnectSwitch.Theexternaloperatinghandleofthedisconnectswitchmustbecapableofopeningtheswitch .Ifthehandlefailstoopentheswitchorifvisualinspectionafteropeningindicatesdeteriorationbeyondnormalwearandtear,suchasoverheating,con-tactblade,orjawpitting,insulationbreakageorcharring,theswitchmustbereplaced .

FuseHolders.Deteriorationoffuseholdersortheirinsulatingmountsrequirestheirreplacement .

TerminalsandInternalConductors.Indicationsofarcingdamageand/oroverheating,suchasdiscolorationandmeltingofinsulation,requirethereplacementofdamagedparts .

Contactor.Contactsshowingheatdamage,displacementofmetal,orlossofadequatewearallowancerequirereplacementofthecontactsandthecontactsprings .Ifdeteriorationextendsbeyondthecontacts,suchasbindingintheguidesorevidenceofinsula-tiondamage,thedamagedpartsortheentirecontactormustbereplaced .

OverloadRelays.Ifburnoutofthecurrentelementofanoverloadrelayhasoccurred,thecompleteoverloadrelaymustbereplaced .Anyindicationthatanarchasstruckand/oranyindicationofburningoftheinsulationoftheoverloadrelayalsorequiresreplacementoftheoverloadrelay .

Ifthereisnovisualindicationofdamagethatwouldrequirereplacementoftheoverloadrelay,therelaymustbeelectricallyormechanicallytrippedtoverifytheproperfunctioningoftheoverloadrelaycontact(s) .

ReturntoService.Beforereturningthecontrollertoservice,checksmustbemadeforthetightnessofelectricalconnectionsandfortheabsenceofshortcircuits,grounds,andleakage .

Allequipmentenclosuresmustbeclosedandsecuredbeforethebranchcircuitisenergized .

27




Figure37.NormalServiceWear

Contact Tip

Contact Plate(Brass or Copper)

NewStillServiceable

Figure38.EndofServiceLife

Corner of ContactWorn Away

Replace

Figure39.NEMA3RMCC-AllFiltersRequireCleaningonRegularBasis

CLEAN FILTER ON A REGULAR BASIS.

ACCESS FILTER FROM THE OUTSIDE OF THE ENCLOSURE.

CLEAN FILTER ON A REGULAR BASIS.

ACCESS FILTER FROM THE OUTSIDE OF THE ENCLOSURE.

28




Table13. RenewalContactKits,Coils,andOverloadRelays

Description Coil Suffix

part number

neMa Size 1Series B1

neMa Size 2Series B1 neMa Size 3 neMa Size 4

neMa Size 5Series B1

Renewal Parts Pub. 22177 22177 20426 20428 20429

Contact kits

2-Pole3-Pole4-Pole5-Pole

6-656-65-26-65-96-65-10

6-65-76-65-86-65-156-65-16

6-43-56-43-6——

6-446-44-2——

6-456-45-2——

Magnet Coils

120V 60 Hz or 110V 50 Hz240V 60 Hz or 220V 50 Hz480V 60 Hz or 440V 50 Hz600V 60 Hz or 550V 50 Hz

ABCD

9-2703-19-2703-29-2703-39-2703-4

9-2703-19-2703-29-2703-39-2703-4

9-2756-19-2756-29-2756-39-2756-4

9-1891-19-1891-29-1891-39-1891-4

9-1891-19-1891-29-1891-39-1891-4

208V 60 Hz277V 60 Hz208/240V 60 Hz240V 50 Hz

EHJK

9-2703-99-2703-7—9-2703-14

9-2703-99-2703-7—9-2703-14

9-2756-59-2756-9—9-2756-13

9-1891-139-1891-26—9-1891-20

9-1891-139-1891-26—9-1891-20

380–415V 50 Hz380V 50 Hz415V 50 Hz550V 50 Hz

LLMN

9-2703-8———

9-2703-8———

—9-2756-129-2756-89-2756-14

—9-1891-149-1891-219-1891-8

—9-1891-149-1891-219-1891-8

Overload Relays For replacement on existing starters three-pole— ambient-compensated bimetallic

C306GN3B C306GN3B C306KN3 C306NN3 C306DN3B

Table14. StarterType

Description

Unit Catalog number Designation (Class)

Disconnect Means

Fusible Circuit Breaker Circuit Breaker with Current Limiter

Full voltage, non-reversing F204 F206 F207

Full voltage, reversing F214 F216 F217

Reduced voltage, autotransformer type F604 F606 F607

Reduced voltage, part-winding type F704 F706 F707

Reduced voltage, closed transition star-delta F894 F896 F897

Full voltage, non-reversing, two-speed, two windings F954 F956 F957

Full voltage, non-reversing, two-speed, one winding F944 F946 F947

29




part 11. plan Views

Figure40.20InchesWide,16InchesDeep,FrontMountedOnly(4710A30)


5.41(137.4)

2.20 (55.9)

1.25 (31.7)

Top Conduit Space

17.50(444.5)20.00

(508.0)

Top View

Vertical Wireway Door

16.00(406.4)

1.25 (31.7)

Cross Section

4.81 (122.2)

7.31(185.7)

Wire TieBrackets

VerticalWirewayBottom View

17.50(444.5)

6.81 (172.9)

5.41 (137.4)

See Note 5

1.58 (40.1)16.00

(406.4)

Removable BottomFrame MembersSee Note 413.97

(354.8)

Removable Top Cover

0.70 (17.8)

1.25 (31.7)1.25 (31.7)

Bottom Conduit SpaceSee Notes 2 and 3

0.53 (13.5) Dia. See Notes 1 and 1A0.53 (13.5) Dia.See Notes 1 and 1B

Cross Section

5.41(137.4)

2.20 (55.9)

Top Conduit Space

1.25 (31.7)21.50

(546.1)24.00 (609.6)

1.25 (31.7)

Top View


16.00(406.4)

Removable Top Cover

8.81 (233.7)

7.31(185.7)

Vertical Wireway

Wire TieBrackets

1.25(31.7)

1.25(31.7)

21.50(546.1)

0.53 (13.5) Dia.See Notes 1 and 1B

5.41 (137.4)

See Note 5

6.81 (172.9)

1.58 (40.1)


Removable BottomFrame MembersSee Note 5

Bottom View

0.70 (17.8)20.00

(508.0)0.53 (13.5) Dia. See Notes 1 and 1A

2.00 (50.8)

13.97(354.8)



5.41(137.4)

2.20 (55.9)1.25 (31.7)

Top Conduit Space

17.50(444.5)20.00

(508.0)

Top View


20.38(517.7)

1.25 (31.7)

Cross Section

4.81 (122.2)

7.31(185.7)

Wire TieBrackets

VerticalWireway

Bottom View17.50

(444.5)

5.78 (146.8)

5.41 (137.4)

5.41 (137.4)

See Note 5

1.58 (40.1)16.00

(406.4)


18.35(466.1

Removable Top Cover

0.70 (17.8)

1.25(31.7)

1.25(31.7)


0.53 (13.5) Dia. See Notes 1 and 1A

2.00 (50.8)0.53 (13.5) Dia.See Notes 1 and 1B

Removable BottomFrame MembersSee Note 518.35

(466.1)

0.70 (17.8)


5.78 (146.8)

5.41 (137.4)

5.41 (137.4)See Note 5

1.58 (40.1)

Bottom View21.50

(546.1) 1.25 (31.7)1.25 (31.7)

20.00(508.0)

0.53 (13.5) Dia. See Notes 1 and 1A0.53 (13.5) Dia.See Notes 1 and 1B

2.00 (50.8)

5.41(137.4)

2.20 (55.9)

1.25 (31.7)

Top Conduit Space

21.50(546.1)24.00

(609.6)

Top View


20.38(517.7)

1.25 (31.7)

Removable Top Cover

Cross Section7.31

(185.7)

Wire TieBrackets

VerticalWireway

8.81 (223.8)

otese:N 1 . Minimumlengthofanchorboltis2 .00(50 .8)(0 .38-16grade5torqued at31lb-ft) . A . Fornon-seismic,mountwithtwocenterboltsperenclosure . B . Forseismic,mountwithminimumfourcornerboltsperenclosure .2 .Recommendedmaximumconduitheightabovefloorlineis3 .50inches (88 .9mm) .3 .Maximumconduitspacewithchannelsillsis17 .50x9 .73inches (444 .5x247 .1mm) .4 .Formultiplestructureassemblies,eitheroneorbothofthesemembers isremovedtoprovidemaximumunrestrictedconduitspaceatthe bottomoftheMCC .5 .Thisconduitspaceisnotrecommendedwhenaneutralbusand/oraspace heaterisrequired .Otherwisethisspaceisavailableforconduit .SeeFigure4646forverticaldimensions .

30




Figure44.20InchesWide,21InchesDeep,FrontandRearMounted(4710A32)

Figure45.10InchesWide,16or21InchesDeep,TransitionStructure(4710A35/6)

otese:N 1 . Minimumlengthofanchorboltis2 .00(50 .8)(0 .38-16grade5torqued at31lb-ft) . A . Fornon-seismic,mountwithtwocenterboltsperenclosure . B . Forseismic,mountwithminimumfourcornerboltsperenclosure .2 .Recommendedmaximumconduitheightabovefloorlineis3 .50inches (88 .9mm) .3 .Maximumconduitspacewithchannelsillsis17 .50x9 .73inches (444 .5x247 .1mm) .4 .Formultiplestructureassemblies,eitheroneorbothofthesemembers isremovedtoprovidemaximumunrestrictedconduitspaceatthe bottomoftheMCC .

2.20 (55.9)

3.22 (81.8)

5.41 (137.4)

2.20 (55.9)1.25 (31.7)

Top Conduit Space 21.00

(533.4)

Removable Top Cover

Top View


1.25 (31.7)17.50(444.5)20.00

(508.0)

Cross Section Rear Vertical Wireway

Vertical Wireway

Wire TieBrackets

7.31 (185.7)

7.31 (185.7)

17.50(444.5)

5.78 (146.8)

0.53 (13.5) Dia.See Notes 1 and 1B

5.41 (137.4)

See Note 5

5.41 (137.4)

16.00(406.4)

2.00(50.8)



Bottom View

1.32 (33.5)

18.35(466.1)

0.53 (13.5) Dia. See Notes 1 and 1A

4.81 (122.2)

4.81 (122.2)

1.25 (31.7) 1.25 (31.7)

5.41(137.4)

2.20(55.9)

1.25(31.7)

10.00(254.0) 7.50

(190.5)

20.38(517.6)

or16.00

(406.4)

RemovableCover

Top ConduitSpace

1.25(31.7)

Top View

Floor Line

Neutral Bus Location When Specified

Ground BusLocation

Horizontal BusLocation

12.12 (307.8)

3.12 (79.2)4.62 (117.3)4.62 (117.3)

Removable BusBarrier

Flat CoverSupplied onRear of FrontMounted OnlyStructure

HorizontalWireway7.16 (181.9)Deep

2.25(57.2)

Vertical View

5.00(127.0)

3.00 (76.2)ChannelSills SuppliedOnly WhenSpecified

3.0(76.2)

10.50(266.7)

1.00 (25.4)

Bottom View

1.25(31.7)

7.50(190.5)

1.25(31.7)

5.41 (137.4)

5.78 (146.8)

5.41 (137.4)

See Note 5

0.53 (13.5)Dia. (2)See Note 1

Bottom Conduit Space See Notes 2 and 3

1.58 (40.1) 0.70 (17.8)

5.00 (127.0)

18.35 (466.1)

9.73 (247.1)

or 14.11 (358.4)

15.73 (399.5) or20.11 (510.8)

Removable Bottom Frame Members See Note 4. (Not to be removed for seismic)

Figure46.SideViewA

Figure47.SideViewB

5 .Thisconduitspaceisnotrecommendedwhenaneutralbusand/oraspace heaterisrequired .Otherwise,thisspaceisavailableforconduit .SeeFigure4747forverticaldimensions .7 . MasterTerminalBlock(MTB)assemblyisfurnishedforTypeCwiring onlywhenlocationnotspecified .MTBsuppliedatthebottom .8 .Rearhorizontalbusbarriernotsuppliedwithfrontmountedonlystructure .9 .Standardstructurearrangement: A . Infront WithoutMTB:AandB=9 .00(228 .6mm) WithMTBatbottom:AandB=9 .00(228 .6mm) WithMTBattop:AandB=3 .00(76 .2mm) B . Inrear WithoutMTB:C=0,D=72(1828 .8mm),E=3 .00(76 .2mm) WithMTBatbottom:C=0,D=66 .00(1676 .4mm), E=9 .00(228 .6mm)" WithMTBattop:C=12,D=60(1524 .0mm),E=3 .00(76 .2mm)

10.50(266.7)

12.12(307.8) Horizontal Bus Location

Vertical Bus Location

3.12 (79.2)

4.62 (117.3)

4.62 (117.3)

Removable Bus BarrierSee Note 8

Flat Cover Supplied on Rear of FrontMounted Only Structure

Minimum Rated VerticalBus Supplied as Standard in Front Mounted Only Structure

Ground Bus Location

2.25(57.2)

A

See Note 9A

Horizontal Wireway7.16 (181.9) Deep

See Note 7

See Note 7

See Note 9A

BFloor Line

1.00(25.4)

3.00 (76.2) ChannelSills Supplied Only When Specified

5.00(127.0)

3.00 (76.2)

9.73 (247.1) or 14.11 (358.4)

15.73 (399.5) or 20.11 (510.8)10.50

(266.7) Neutral Bus Location When Specified

10.50(266.7)

12.12(307.8)

Horizontal Bus Location See Note 9

Vertical Bus Location

3.12 (79.2)

4.62 (117.3)

4.62 (117.3)

Ground Bus Location

2.25(57.2)

A

See Note 9A

Horizontal Wireway7.16 (181.9) Deep

See Note 7

See Note 7

See Note 9A

BFloor Line

1.00(25.4)

3.00 (76.2) ChannelSills Supplied Only When Specified

5.00(127.0)

3.00 (76.2)14.11(358.4)20.11

(510.8)

10.50(266.7)

Neutral Bus Location When Specified

Removable Bus Barrier

15.00(381.0)

Rear Horizontal Wireway4.97 (126.3) Deep

See Note 7

C

D

See Note 7

E

31




part 12. related instructional Leaflets

publication publication no.

Starters

Size 5, Non-Reversing and Reversing, vacuum IL17087

Contactors



Circuit breakers

Magnum DS I.B. 2C12060H08

RotoTract Remote Racking Operating Manual IL04300001E

Series C, F-Frame IL01219018E

Series C, F-Frame IL29C101

Series C, J-Frame IL01204004E

Series C, J-Frame IL29C103

Series C, K-Frame IL29C104C

Series C, L-Frame IL01207002E

Series C, L-Frame IL29C105

Series C, N-Frame IL01209003E

Series C, N-Frame IL29C106

Series C, R-Frame IL29C613B

Series C, R-Frame IL29C107

Series G, EG-Frame IL29C515C

Series G, JG-Frame IL01207009E

Series G, LG-Frame IL01207001E

Transfer Switches IL14477

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