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Rockwell Automation Publication 1500-UM055I-EN-P - December 2021

Preface

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Resource

Description

Medium Voltage 450 A Contactor, Series G User Manual,

publication

1502-UM060

Provides information on handling, installing, maintaining, and troubleshooting 450 A medium

voltage contactors.

EtherNet/IP Network Devices User Manual,

ENET-UM006

Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP

network.

Ethernet Reference Manual,

ENET-RM002

Describes basic Ethernet concepts, infrastructure components, and infrastructure features.

System Security Design Guidelines Reference Manual,

SECURE-RM001

Provides guidance on how to conduct security assessments, implement Rockwell

Automation products in a secure system, harden the control system, manage user access,

and dispose of equipment.

Industrial Components Preventive Maintenance, Enclosures, and Contact

Ratings Specifications, publication

IC-TD002

Provides a quick reference tool for Allen-Bradley industrial automation controls and

assemblies.

Safety Guidelines for the Application, Installation, and Maintenance of

Solid-state Control, publication

SGI-1.1

Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides

general guidelines for the application, installation, and maintenance of solid-state control in

the form of individual devices or packaged assemblies incorporating solid-state

components.

Industrial Automation Wiring and Grounding Guidelines, publication

1770-4.1

Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website,

rok.auto/certifications

Provides declarations of conformity, certificates, and other certification details.

Summary of Contents for 1512B

Page 1: ...CENTERLINE 200 400 A Two High Cabinet Standard and Arc Resistant Enclosure BulletinNumbers1512B 1512BT 1512BP 1512DM 1512DO 1512M 1562E 1591B 1592BF 1592BP User Manual Original Instructions...

Page 2: ...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 w...

Page 3: ...2 Opening the Medium Voltage Doors 12 Anchoring 14 Joining Sections 15 Access to the Power Bus 16 Rear Access 16 Side Access 17 Front Access Access to Power Bus 18 Front Access Bottom Exiting Load Cab...

Page 4: ...57 Clip on Fuse Removal Installation 57 Contactor Maintenance 58 Removing the Contactor 58 Contactor Interlock Rod Adjustment 60 To Reduce the Gap Distance 61 To Increase the Gap Distance 61 Isolation...

Page 5: ...of Side by Side Plenums 87 STEP 3 Sequence of Final Assembly 88 STEP 4 Closing the Front of the Plenum Sections 88 STEP 5 Extension and Elbow Assembly 89 STEP 6 Mounting Extension Elbow to Plenum Line...

Page 6: ...6 Rockwell Automation Publication 1500 UM055I EN P December 2021 Notes...

Page 7: ...200 400 A VFD Output Contactor Units 1512M 200 400 A VFD Output Bypass Starter 1562F 200 400 A MV SMC 50 Solid State up to 4800V Reduced Voltage Starter 1591B Incoming Line Unit 1592BF Fused Load Brea...

Page 8: ...es System Security Design Guidelines Reference Manual SECURE RM001 Provides guidance on how to conduct security assessments implement Rockwell Automation products in a secure system harden the control...

Page 9: ...es number section number NEMA enclosure type unit ratings and bus ratings Figure 1 Typical Structure Nameplate A unit nameplate is also found in the low voltage compartment with specific unit motor ap...

Page 10: ...rter kit to complete a prepared space a provide the following information to ensure the proper components are supplied Series Number Provide the series number from the structure with the prepared spac...

Page 11: ...40 85 C 40 185 F If storage temperature fluctuates or if humidity exceeds 85 space heaters must be used to prevent condensation The equipment must be stored in a heated building having adequate air ci...

Page 12: ...Opening the Medium Voltage Doors Medium voltage doors are identified as MV in Figure 4 LV MV LV MV LV MV LV MV 1 4 turn fasteners for Upper Low Voltage Door 1 4 turn fasteners for Lower Low Voltage D...

Page 13: ...ium Voltage Door Door Locking Bolts for Upper Medium Voltage Door Isolation Switch Handles IMPORTANT Each medium voltage door has its own isolation switch handle and interlocking safeguards Upper and...

Page 14: ...and IBC International Building Code seismic activity without overturning or lateral movement provided they are securely mounted according to UBC IBC and local building codes This can include concrete...

Page 15: ...20 self tapping screws 12 lb ft 15 N m Thread the screw through the 7 mm 0 281 in clearance hole to the corresponding 6 mm 0 219 in pilot hole To access the front clearance holes of the left side cabi...

Page 16: ...three power bus bars and the ground bus bar see Figure 8 Figure 7 Access to Power Bus from Side and Rear of Cabinet ATTENTION This procedure requires contact with medium voltage components To avoid sh...

Page 17: ...s from Back Access Side Access A side bus access cover is located on each side of the controller 1 Remove the hardware from the appropriate side bus access cover see Figure 7 2 Remove the side bus acc...

Page 18: ...ol wiring harness from the wire plug at the lower left side of the contactor 4 Remove the two 1 4 20 self tapping screws from the center vertical channel see Figure 10 5 Pull on the center vertical ch...

Page 19: ...021 19 Chapter 1 Installation Standard Enclosure Figure 10 Center Vertical Channel 6 Remove each glass polyester barrier located in front of the current transformers see Figure 11 Remove self tapping...

Page 20: ...ing Glass polyester Barrier 7 Remove the 1 4 20 retaining screw from the cable duct barrier and remove the barrier see Figure 12 8 Remove the two 1 4 20 retaining screws from the cable duct boot and r...

Page 21: ...ove the four 1 4 20 self tapping screws from each cover and remove the covers see Figure 13 Figure 13 Removing Bus Access Covers 10 If access to the right side of the power bus is required remove the...

Page 22: ...ry control wiring from the control power transformer CPT and remove the CPT mounting plate Leave the CPT attached to the plate 15 To access the right side of the power bus remove the 1 4 20 self tappi...

Page 23: ...s the power bus is almost identical to the one above Follow the procedure for Top Exiting Load Cables on page 25 but remove the cable duct barrier and cable duct boot from the top of the lower power c...

Page 24: ...t incoming power see Power Lock out Procedure on page 53 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to d...

Page 25: ...re 19 Top Exiting Load Cables 4 Load cables for the bottom power cell should be routed first Pull the cables into the cabinet through the appropriate opening see Figure 18 Run the cables behind the cu...

Page 26: ...nal assembly and tighten the 1 2 13 hardware to 45 lb ft 61 N m 7 Connect cable shields to the ground lug 8 Reinstall the cable duct boot and reassemble the cabinet Ground Lug Load Cable Conduit openi...

Page 27: ...l pull the cables into the cabinet through the appropriate opening see Figure 19 3 Connect the cables to the current transformers and tighten the connections to 65 N m 48 lb ft 4 Connect cable shields...

Page 28: ...28 Rockwell Automation Publication 1500 UM055I EN P December 2021 Chapter 1 Installation Standard Enclosure Notes...

Page 29: ...Shield cabinets turn the release handle counter clockwise 90 2 The door is now released and will swing open 3 Reverse the procedure to secure the door Figure 20 Access to Low Voltage Compartments IMPO...

Page 30: ...r is now released and will swing open 5 Reverse the procedure to close the door Tighten the 3 8 1 75 door lock bolts by hand until threads are engaged 6 Door lock bolts must be adequately tightened se...

Page 31: ...efer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan IMPORTANT Pre determined cabinets have been designed for Uniform Building Code UBC seis...

Page 32: ...ss covers if applicable 4 Position the right section against the left section Ensure that the surface is level 5 25 133 31 38 797 36 00 914 36 00 914 16 17 411 30 00 762 2 31 59 4 62 117 9 32 237 23 6...

Page 33: ...bus opening ensure all bolts are installed Before joining sections together ensure there is a silicone seal around the bus bar opening 8 Secure the right section to the floor using M12 1 2 in floor m...

Page 34: ...Access to Power Bus from Side and Rear of Cabinet Side Access A side bus access cover is located on each side of the controller 1 Remove the hardware from the appropriate side bus access cover 2 Remo...

Page 35: ...ation 1500 UM055I EN P December 2021 35 Chapter 2 Installation Arc Resistant Enclosure Figure 27 Side Bus Access Cover Ground Connection Figure 28 ArcShield Ground Plate Side Bus Access Cover Ground C...

Page 36: ...the two 1 4 20 retaining screws 12 lb ft 15N m from the cable duct boot and remove the boot see Figure 30 Figure 30 Removing Cable Duct Boot and Barrier ATTENTION To avoid shock hazards lock out inco...

Page 37: ...see Figure 31 on page 37 Figure 31 Removing Bus Access Covers 5 If access to the right side of the power bus is required remove the vacuum contactor from the upper power cell see Removing the Contact...

Page 38: ...er bus remove the 1 4 20 self tapping screws 12 lb ft 15N m from the lower glass polyester bus access cover and remove the cover see Figure 33 11 Reverse the procedure to reassemble the cabinet Ensure...

Page 39: ...fore re energizing the equipment Failure to do so will defeat the structure s arc resistant capabilities and result in electrical faults and cause damage to equipment or serious injury to personnel Ca...

Page 40: ...in the top or bottom of the cabinet see Figure 36 or Figure 37 Top Exiting Load Cables 1 Load cables for the bottom power cell should be routed first Pull the cables into the cabinet through the appro...

Page 41: ...ound lug 6 Reinstall the cable duct boot and reassemble the cabinet Top of Cabinet Load Cable Conduit Opening for Cables from Top Power Cell Load Cable Conduit Opening for Cables from Bottom Power Cel...

Page 42: ...ppropriate opening see Figure 37 3 Connect the cables to the current transformers and tighten the connections to 65 N m 48 lb ft 4 Connect cable shields to the ground lug 5 Reinstall the cable duct bo...

Page 43: ...1 N m 45 lb ft ATTENTION This procedure requires contact with medium voltage components To avoid shock hazards lock out incoming power before working on the equipment see Power Lock out Procedure on p...

Page 44: ...Configuration Viewed from Front Figure 40 Typical 3000 A Power Bus Splicing Configuration Viewed from Front Bus Clamp Flat Washer Lock Washer Hex Nut Power Bus Splice Bar Bus Support Main Horizontal...

Page 45: ...4 5 N m 1 N m 11 lb ft 1 lb ft 3 Check all hardware for correct tightness and replace all covers and plates Figure 41 Typical Ground Bus Splicing Configuration Front View ATTENTION Ensure all barriers...

Page 46: ...ntrol panel terminal blocks in the low voltage compartment Refer to wiring diagram ATTENTION To avoid shock hazards lock out incoming power see Power Lock out Procedure on page 53 before working on th...

Page 47: ...TION Ensure current transformer barrier is installed before re energizing the equipment Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel Cu...

Page 48: ...Mechanical interlocks and isolation switch function properly Ensure that any microprocessor based protection relay is programmed Interior of cabinet is free from dirt loose bolts tools or metal chips...

Page 49: ...REC MOV CR2 CR1 CR2 CR2 CR1 M CR2 D C 1 2 3 4 X X 47 46 44 42 OL 49 120V TS F3 __E F2 __E F2 ____ 120 500 CPT M 6 5 7 8 12 ISa 5 IS T2 T1 CT2 CT1 T3 CT3 12 11 6 10 F1 F1 F1 7 8 9 ISb Customer wiring L...

Page 50: ...z 120V Main Contactor M Extra Auxiliary Contacts Current Limiting Primary Fuses Current Limiting Power Fuses Test Supply Point Isolating Switch Door Interlock Off Test Normal Stop Start Run Off Contac...

Page 51: ...ctive equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death IMPORTANT Establish a maintenance and inspection schedule for the equipment Annual servic...

Page 52: ...nterlock Lever ATTENTION The door interlock mechanism is designed to prevent access to the medium voltage cell while the unit is energized When the unit is in operation do not circumvent this interloc...

Page 53: ...operate the contactor by pushing the START button on the unit or at a remote location f Disengage the contactor and move the control switch to the OFF position Disconnect the external power supply g C...

Page 54: ...that they are voltage free see Figure 49 a Check for line side voltage at the top vacuum bottle terminals b Check for load side voltage at the bottom vacuum bottle terminals See Detail A Grounding Bar...

Page 55: ...lation switch blades with a hot stick or appropriate voltage measuring device for the system voltage to verify that they are voltage free see Figure 50 Figure 50 Isolation Switch Voltage Check Points...

Page 56: ...the OFF position Recommended practice is to disconnect or lock out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity...

Page 57: ...lling up and slightly rotating the fuse in one entire movement 5 To install the replacement fuse place the fuse between the fuse clips 6 Ensure that the flares on the fuse ferrules are properly locate...

Page 58: ...er primary leads from the fuse terminals at the top of the contactor 5 Use a 9 16 in socket wrench to disconnect the power cables and bus bars from the rear of the contactor 6 Remove the nylon contact...

Page 59: ...ar of the contactor from the mounting bracket inside the cabinet 10 Carefully remove the contactor from the cabinet Contactor Operating Level Contactor Interlock Rod Contactor Interlock Rod Nylon Cont...

Page 60: ...Circumvention on page 52 to move the isolation switch handle halfway between the OFF and ON position see Figure 55 Keep the handle in this position until the adjustment procedure is completed 3 With...

Page 61: ...not overtighten the nyloc nut as it will move the interlock lever and reduce the gap Proceed to Step 11 To Increase the Gap Distance 9 Loosen the two screws in the stop bracket and move the stop brac...

Page 62: ...he isolation switch operating lever by at least 3 mm 0 125 in see Figure 57 Figure 56 Closing Contactor Manually Some parts not shown Figure 57 Isolation Switch Operating Lever Overlap 15 Open the con...

Page 63: ...isolation switch operating lever and contactor interlock rod see Figure 58 Tighten any loose hardware 6 If an infrared window is available complete the following steps during normal equipment run mod...

Page 64: ...the incoming line stabs Pitting can indicate incorrect adjustment of the isolation switch auxiliary switches Contact technical support for assistance Isolation Blade Switch Adjustment 1 Insert a scre...

Page 65: ...kage Assembly Location 4 Rest the customer supplied digital protractor on the bottom of the isolation switch linkage assembly The angle of the linkage must be 180 or slightly higher with a tolerance o...

Page 66: ...ch mechanical threaded linkage with a wrench until the overall travel angle of the switch link is within the required tolerance 7 Hold the position of the threaded linkage and tighten the lock nuts Fi...

Page 67: ...3 Isolation Switch Grounding Adjustment 3 To adjust the distance from the blades to the bar disconnect the threaded connecting rod at the handle operating lever 4 Turn the threaded connecting rod to l...

Page 68: ...move the contact from the housing 5 Disconnect the wires from the auxiliary contact 6 Reverse the procedure to replace the auxiliary contact 7 Ensure the contact is correctly positioned into the conta...

Page 69: ...o the OFF open position 2 Loosen the bolt holding the outside cam to the shaft Do not loosen the bolt entirely The cam should not be able to rotate freely on the shaft 3 Move the isolation switch hand...

Page 70: ...isolation switch handle to the OFF open position 2 Loosen the bolt holding the inside cam to the shaft Do not loosen the bolt entirely The cam should not be able to rotate freely on the shaft 3 Insert...

Page 71: ...ibit access to the power cell while the isolation switch handle is in the ON position and the isolation switch is closed 1 Remove the two 10 32 self tapping screws 2 7 lb ft 3 6 N m from the Z clip an...

Page 72: ...68 Defeater Pin If it is possible to move the isolation switch handle to the OFF position for reassembly follow steps 5 10 If it is not possible to move the isolation switch handle to the OFF position...

Page 73: ...in Open the door and tighten the 10 32 bolts 2 7 lb ft 3 6 N m 9 Close the door and move the handle to the ON position Verify that the handle pin overlaps the Z clip and prevents the door from opening...

Page 74: ...74 Rockwell Automation Publication 1500 UM055I EN P December 2021 Chapter 4 Maintenance Notes...

Page 75: ...cal Latch 1 1503VC BMC5 IntelliVAC Electrically Held and Mechanical Latch 4 4 For starters with IntelliVAC control 1 80174 902 14 R Internal IntelliVAC fuse 6 3A 250 V Littlefuse 21506 3 1 Engineering...

Page 76: ...76 Rockwell Automation Publication 1500 UM055I EN P December 2021 Chapter 5 Spare Parts Notes...

Page 77: ...his type of configuration could pose electrical safety risks to site personnel and nullify some safety labeling already applied to the different styles of equipment ATTENTION To ensure Arc resistant i...

Page 78: ...arc resistant enclosure Unit plenums are secured to the top of the unit structure and to adjacent plenums creating a continuous conduit for release of the arc flash energy Refer to Appendix B for ple...

Page 79: ...rmitted to escape with plenum extensions see Figure 71 Figure 72 and Figure 73 2 Plenum duct to outside of control room see Figure 71 and Figure 72 Plan the location where the plenum will exhaust Ensu...

Page 80: ...ensions to Internal Controlled Access Area Top View Figure 72 Plenum Exit Left with Extension s to Internal Controlled Access Area Front View Minimum H 3 5 m 138 inches Minimum L 1 2 m 47 inches Minim...

Page 81: ...ests Access barriers are recommended as a means of restricting access by personnel while the equipment is energized Chain link fencing is a suitable barrier material Equipment that consists of more th...

Page 82: ...ere needs to be a minimum distance of 1 7 m 67 in from the top of the chimney to the ceiling and 1 m 39 in on each side 2 No obstructions eg piping can be in the path of the exhaust within this 2 m 78...

Page 83: ...as the distance from the end of the cabinets to the exit vent A flange is available for installing hangers to support the plenum weight The plenum extension has holes for mechanical support Weight per...

Page 84: ...18 in wide Plenum Fastened directly over the 0 5 m 18 in wide cabinet 26 in wide Plenum Fastened directly over the 0 7 m 26 in wide cabinet 36 in wide Plenum Fastened directly over the 0 9 m 36 in wi...

Page 85: ...ection exhaust extension see Figure 88 STEP 1 Mounting a Single Plenum Before mounting a single Plenum over an MV enclosure the front duct section must first be removed This is shown in Figure 77 Figu...

Page 86: ...ener heads at the 4 corners of the relief vent The corner fasteners are required to secure the relief vent during installation Plenum Placement on Structure Once the plenum has been lifted in place di...

Page 87: ...lignment of Side by Side Plenums Plenums mounted side by side must be fastened together through the aligning holes using 5 16 in supplied hardware see Figure 81 Figure 81 Aligning Side by Side Plenums...

Page 88: ...uence of Final Assembly The End Cover Plate must be mounted on the closed end of the Line up at this time during the assembly using 5 16 in hardware see Figure 82 Left side STEP 4 Closing the Front of...

Page 89: ...Plate Bottom Plate Front Closing Plate IMPORTANT Do not re install the front duct section of the last Plenum on the exhaust side of the Line up at this time refer to STEP 6 Mounting Extension Elbow to...

Page 90: ...88 the last Plenum at the exhaust side of the line up has the front duct section removed This allows access to fastener holes in order to mount the Extension Elbow components see Figure 87 The Extens...

Page 91: ...al Extension Elbow with Vertical Extension Right Side Exit After the Extension Elbow assembly is attached through the fastener holes on the inside flange of the Plenum the front duct section can be re...

Page 92: ...g 112 lbs Figure 88 shows an example of how the Extension Elbow Sections can be supported by suspension from a high ceiling Points A B C show where chains or high tension cables may be connected Figur...

Page 93: ...e instructions Recommended Torque Values 1 4 20 Thread Fasteners 15 N m 12 lb ft 5 16 18 Thread Fasteners 14 5 N m 11 lb ft Figure 89 Chimney Exhaust Label ARC FLASH HAZARD PRESSURE RELIEF EXIT AREAS...

Page 94: ...y Installation Instructions General Plenum Layout for ArcShield Line up An example of a general chimney assembly configuration is shown in Figure 90 Chimneys of varying widths are mounted directly ove...

Page 95: ...s at the four corners of the relief vent The corner fasteners are required to secure the relief vent during installation Chimney Placement on Structure Once the chimney has been lifted in place direct...

Page 96: ...December 2021 Appendix C ArcShield Chimney Installation Instructions Figure 93 Chimney Placement Use recommended torque value for 1 4 20 fasteners Use silicone caulking generously to fill any air gaps...

Page 97: ...ort circuit currents within its capabilities from both feeding directions within the motor controller without any latching mechanism It is applied to safely ground earth the load connections to three...

Page 98: ...ng window on the medium voltage compartment door The IPMG device is mounted on the controller floor plate or on the top of the main medium voltage vacuum contactor for 600 800 A controllers It is conn...

Page 99: ...imately 180 counterclockwise until the switch flips into its CLOSED position there is a significant sound as the IPMG device engages 3 Remove the handle 4 Verify the CLOSED position of the IPMG device...

Page 100: ...ndle to accommodate at least 180 of clockwise motion The hexagon shaped shaft must mate with the connection of the IPMG operating shaft 2 Rotate the operating handle in one motion approximately 180 cl...

Page 101: ...OSED or GROUNDED position when the blades are in a vertical position If the blades are not readily visible and or if they are in a more horizontal position the IPMG device is in the OPEN position Ther...

Page 102: ...electrical position of the IPMG device OPEN ungrounded load connections or CLOSED grounded load connections These auxiliary switches can be incorporated into the controller s control circuit Their ele...

Page 103: ...age withstand 20 kV Rated short time withstand current 31 5 kA rms Short time withstand duration 4 s Rate peak current 80 kA rms Mechanical duration grade M1 Mechanical endurance operations 2000 Torsi...

Page 104: ...ment that is caused by the mechanical interlocks and interfacing to the main contactor and isolation switch The grounding earthing process is achieved through the movable blades and the fixed terminal...

Page 105: ...tion 1500 UM055H EN P February 2015 Topic Replaced Typical Structure and Typical Nameplate graphics Added Environmental Conditions Transposed step 3 and 4 Added Attention table Added step to procedure...

Page 106: ...106 Rockwell Automation Publication 1500 UM055I EN P December 2021 Appendix E History of Changes Notes...

Page 107: ...Rockwell Automation Publication 1500 UM055I EN P December 2021 107 CENTERLINE 200 400 A Two High Cabinet Standard and Arc Resistant Enclosure User Manual...

Page 108: ...ase Access Knowledgebase articles rok auto knowledgebase Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation i...

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