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Rockwell Automation Publication 2100-IN012G-EN-P - August 2016

Chapter 2

Installation Procedures

Bus Torque Specifications 

Tighten all bus splice connections with a torque wrench and socket at intervals 
established by your maintenance policy. See 

Chapter 9 

for suggested 

maintenance. If a torque wrench is not available, tighten until the conical 
spring washer is flat.

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

Summary of Contents for CENTERLINE 2100

Page 1: ...CENTERLINE 2100 Low Voltage Motor Control Centers Bulletin Numbers 2100 Installation Instructions OriginalInstructions ...

Page 2: ...information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Page 3: ...updated information as indicated in the following table Topic Page Addedinstructionstoinstallafixed mount24VDCtwo branchredundantpower unit 64 Added instructions to remove a circuit breaker in a vertical handle unit 113 Added instructions toremove a circuit breaker in horizontal handle and space saving units 119 ...

Page 4: ...4 Rockwell Automation Publication 2100 IN012G EN P August 2016 Summary of Changes Notes ...

Page 5: ... as Manufactured in the United States 17 Series Lettering Units and Sections 20 Receiving Handling and Storage 22 Receiving 22 Handling 23 Storage and Operation 24 Chapter2 Installation Procedures Location Planning 25 Height Considerations 25 ArcShield Clearance Height 26 Securing an MCC 26 Seismic Requirements 38 Joining and Splicing New MCCs 39 Joining and Splicing Existing MCCs 39 Joining and S...

Page 6: ...m a Section 57 Remove the Support Pan 62 Install Fixed mount 24V DC Two branch Redundant Power Unit 64 Chapter5 Arc Flash Protection Marking as Required by the National Electrical Code Flash Protection Marking Requirement 67 110 16 Flash Protection 67 Arc Flash Marking Clarification 68 Rockwell Automation Services 68 Chapter6 Operator Handle and Unit Interlock Defeating the Unit Door Interlock 69 ...

Page 7: ... MCC 99 Disconnect Switch and Contact Lubrication 102 Use Thermal Infrared or Other Temperature Measurement Techniques for Preventive Maintenance 103 Inspect the Units for Signs of Overheating 104 Chapter10 Maintenance after Fault Condition Maintain the MCC after a Fault Condition 105 Chapter11 Renewal Parts Order Information 107 Chapter12 Parts Illustrations Typical Section Construction 109 Typic...

Page 8: ...119 Remove Circuit Breaker 119 Install Circuit Breaker 121 Verify Operation 124 Adjust the Circuit Breaker Position 124 AppendixB Auxiliary Contact Adapters Install External Auxiliary Contact Adapter on G H and J Frame Horizontal Units 125 Required Tools 125 Install the Auxiliary Contact Adapter 126 Install External Auxiliary Contact Adapter on G H J and K Frame Units 127 Required Tools 127 Instal...

Page 9: ...031 Provides information for motor control centers using an EtherNet IP network Arc Flash Resistant Low Voltage Motor Control Center Designs White Paper publication 2100 AP003 Provides information about arc resistant motor control centers Power Factor Correction Capacitors for Bulletin 2100 MCC Starter Units Application Techniques publication 2100 AT001 Provides information about the use of power ...

Page 10: ...es for the application installation and maintenance of solid state control Industrial Automation Wiring and Grounding Guidelines publication 1770 4 1 Provides general guidelines for installing a Rockwell Automation industrial system ProductCertifications website http www rockwellautomation com global certification overview page Provides declarations of conformity certificates andother certificatio...

Page 11: ... with top and bottom horizontal wireways Sections that are designed to accommodate plug in units include a vertical wireway Each 90 in 2286 mm vertical section can accommodate up to 6 0 space factors or 78 in 1981 mm for units Units buckets are designed in increments of 0 5 space factors Each 0 5 space factor is approximately 6 5 in 165 1 mm high Units are designed as either removable plug in or f...

Page 12: ...vide up to Type 2 accessibility per IEEE standard C37 20 7 which helps protect you when you are at the front sides and rear of the enclosure in the unlikely event of an arcing fault A label on the MCC with the ArcShield rating provides information in regard to the accessibility level and arc fault ratings For more information about accessibility levels performance and testing requirements refer to...

Page 13: ...100 IN012G EN P August 2016 13 General Information Chapter 1 Section Number UL and cUL Certification Marking Catalog Number Serial Number Series Letter of Section Bus Bar Voltage and Current Rating UL Registration Number Enclosure Type ...

Page 14: ...tion marking Device type and size Figure 2 Unit Label The catalog number or serial number and series letter are required to properly identify the equipment to sales or factory personnel MCC Sequence Numbering CENTERLINE MCCs are designed so functionality is not affected by the section installation order for example vertical section numbering sequence order All MCC sections carry a serial plate tha...

Page 15: ... the total MCC line up For example the voltage current rating short circuit withstand and NEMA enclosure type IP rating for all sections must match Non sequential numbering cannot create a functional or listing certification issue However install MCCs sin sequential order Installing MCCs in sequential order helps ensure proper installation and ensures that factory supplied documentation matches th...

Page 16: ...the interior of the bottom plate of plug in units or on the interior right hand side plate of frame mounted units Figure 4 UL Label Designation for Units Short circuit Rating Label MCC vertical sections that are UL listed and or CSA cUL certified carry a short circuit rating label The short circuit rating label for a vertical section is on the inside of the vertical wireway door of standard sectio...

Page 17: ...STALLED PER MANUFACTURER S INSTRUCTIONS REFER TO PUBLICATION 2100 IN012 EQUIPMENT WILL NOT FUNCTION AS ARC RESISTANT IF ABOVE GUIDELINES ARE NOT FOLLOWED FAILURE TO FOLLOW THESE GUIDELINES COULD RESULT IN SEVERE INJURY OR DEATH PN 240698 ALLEN BRADLEY BULLETIN 140G FRAME G H J K M or N NOTE 140G N MUST HAVE INSTANTANEOUS TRIP FUNCTION ON AND SET NO HIGHER THAN 12 000A 100 ms Arc Duration Device Li...

Page 18: ... Changed to new PCP 100A disconnect December 1988 Size 6 Changed to Bulletin 500 series B starters October 1988 K Size 1 5 CB units and size 1 2 disc units Changed handle operating mechanism and circuit breaker to Cutler Hammer series C 150 A 250 A 400 A frame October 1986 L 21A through 54A Changed to Bulletin 100 line contactors in 21 A 30 A 45 A SMC unitsand original design 24 A 35A 54 ASMC unit...

Page 19: ...ange from SMP overload relay to E1Plus overload relay August 2006 2107 2113 size 2 and 3 Redesign due to starter component series letter change December 2009 Z Changed to Bulletin 140G and 140MG circuit breakers December 2013 1 Replacement and renewal parts are no longer supported For more information contact Rockwell Automation LV MCC Technical Support at 1 440 646 5800 and followthe prompts to A...

Page 20: ... Requires Style 3 Unit Support Pan w Bushing Requires Alternate Top Horizontal Wireway Pan Requires Door Gasketing Kit Requires Retrofit Kit 3 Requires Ground Bus Kit Space Factor Series 2100H UAJ1 2100H UA12100H UJ1 2100H USPA1 2100H USPJ1 2100H NA4A1 2100H NA4J1 2100H NA4A2 2100H NA4J2 2100 GJ10 2100H R1 2100H R2 2100H GS1 NEMA Type 1 Series A D 4 1 0 or larger A E 4 F L 4 5 M or later 6 5 NEMA ...

Page 21: ...oltage Motor Control Centers Post Shipment Support 5 Required only if series F or later 1 0 space factor or larger CENTERLINE 2100 unit is installed in topmost location of series A E vertical sections 6 For more information regarding possible door hinge requirements contact Rockwell Automation LV MCC Technical Support at 1 440 646 5800 and follow the prompts to Allen Bradley Low Voltage Motor Cont...

Page 22: ...If necessary other types of packaging are available Refer to publication 2100 IN040 for receiving handling and storage instructions This publication is shipped with each MCC attached to the outside of the MCC within the layer of clear plastic wrap For additional information about the handling installation operation and maintenance of MCCs rated more than 600V consult NEMA ICS 2 3 1995 ExportPackag...

Page 23: ... 96 244 42 107 43 109 Back to back 4 section block 1800 816 96 244 42 107 43 109 Back to back 6 section block 2200 998 96 244 42 107 63 160 Table 6 Shipping Weights and Dimensions Export Packaging Export Packing below deck 1 1 Export packing for below deck is required for all international shipments The MCC shipping block is mounted on a skid and covered in clear plastic wrap This packaging is not...

Page 24: ...humidity Ambient storage temperature range is 30 65 C 22 149 F In addition MCCs have an altitude class of 2 km 1 km for MCCs that contain variable frequency drives The altitude class of 2 km designates equipment for installation where the altitude does not exceed 2000 m 6600 ft For installation above 2000 m 6600 ft contact Rockwell Automation LV MCC Technical Support at 1 440 646 5800 and follow t...

Page 25: ...ckages shipped with assembled MCCs include an MCC elevation drawing and an MCC floor plan layout Height Considerations If the MCC is equipped with optional external mounting channels or is mounted on a pad the height from the floor to the center of the top handles must be checked for compliance with NFPA 70 National Electrical Code NEC Article 404 8 and UL Standard 845 If the distance from the flo...

Page 26: ...in the top rear of cabinet cable trays must be a minimum of 12 in 305 mm above the top plate Figure 10 ArcShield Planning Dimensions Securing an MCC Anchor bolts 1 2 in 13 mm can be embedded in the foundation prior to installation Two bolts per vertical section fasten the MCC through its internal mounting angle to the foundation corner sections require three bolts and 40 in 1016 mm wide sections r...

Page 27: ...st 2016 27 Installation Procedures Chapter 2 Figure 11 Mounting Dimensions for 15 in and 20 in Sections IMPORTANT The external vertical support angle on MCC sections with 100 ms arc resistant rating add an additional 2 in 50 8 mm to each end of the lineup ...

Page 28: ...rd Ground Bus 7 38 in 187 mm 0 25 in 6 35 mm Dimensions approx 15 in Deep 20 in Deep 20 in Wide in mm 25 in Wide in mm 30 in Wide in mm 35 in Wide in mm 20 in Wide in mm 25 in Wide in mm 30 in Wide in mm 35 in Wide in mm A 20 00 508 25 00 635 30 00 762 35 00 889 20 00 508 25 00 635 30 00 762 35 00 889 B 15 00 381 15 00 381 15 00 381 15 00 381 20 00 508 20 00 508 20 00 508 20 00 508 C 11 56 294 11 ...

Page 29: ...13 in in Slots 14 mm x 29 mm Slots Dimensions approx 20 in Deep 40 in Deep 20 in Wide in mm 25 in Wide in mm 30 in Wide in mm 35 in Wide in mm 20 in Wide in mm 25 in Wide in mm 30 in Wide in mm 35 in Wide in mm A 20 00 508 25 00 635 30 00 762 35 00 889 20 00 508 25 00 635 30 00 762 35 00 889 B 30 00 762 30 00 762 30 00 762 30 00 762 40 00 1016 40 00 1016 40 00 1016 40 00 1016 C 11 56 294 11 56 294...

Page 30: ... 2100 IN012G EN P August 2016 Chapter 2 Installation Procedures Figure 14 Mounting Dimensions for 25 in Wide Section with 9 in 228 6 mm Wireway 90 in 2286 mm high The optional external mounting channels add 1 5 in 38 1 mm to the height ...

Page 31: ...igure 15 Mounting Dimensions for 10 in Wide Section with 10 in 254 mm Incoming Line Section Dimension approx Section Depth 15 in 381 mm Deep in mm 20 in 508 mm Deep in mm A 12 75 324 17 75 451 B 14 75 375 19 75 502 A L1 A L2 A L3 A B 1 25 in 32 mm 7 5 in 191 mm 10 in 254 mm 1 12 in 28 mm Power Wires ...

Page 32: ...32 Rockwell Automation Publication 2100 IN012G EN P August 2016 Chapter 2 Installation Procedures Figure 16 Mounting Dimensions for NEMA 3R and 4 Section 90 in 2866 mm high ...

Page 33: ...o height Rear Front A Ground Bus B C Interior Section 0 25in 6 mm 14 06 in 337 mm 2 87 in 73 mm 16 56 in 421 mm 2 Mounting Holes 0 63 in 16 mm Diameter 12 37 in 314 mm Dimension approx Exterior Section Width 20 in 508 mm Wide 1 in mm 1 This measurement is the interior section width 25 in 635 mm Wide 1 in mm 30 in 762 mm Wide 1 in mm A 25 00 635 30 00 762 35 00 889 B 13 75 349 16 25 413 18 75 476 C...

Page 34: ...nal mounting channels add 1 5 in 38 1 mm to the height Dimension approx Section Depth 15 in 381 mm Deep in mm 20 in 635 mm Deep in mm A 25 13 638 30 13 765 B 12 63 321 15 13 384 C 16 81 427 21 81 554 D 17 62 448 22 62 575 B A A B D C D C 0 25 in 6 mm 0 25 in 6 mm 1 41 in 36 mm 1 41 in 36 mm 2 Mounting Holes 0 63 in 16 mm Diameter Ground Bus 2 Mounting Slots 0 56 in x 1 13 in in Slots 14 mm x 29 mm...

Page 35: ... add 1 5 in 38 1 mm to the height Dimensions approx Section Width 1 1 When ahorizontal bus ora disconnecting means switch or circuit breaker is specified reducethe A dimension by 5 in 127 mm 20 in Wide in mm 25 in Wide in mm 30 in Wide in mm 35 in Wide in mm 40 in Wide in mm A 17 25 438 22 25 565 27 25 692 32 25 819 37 25 946 B 16 50 419 21 50 546 26 50 673 31 50 800 36 50 927 C 5 25 133 7 75 197 ...

Page 36: ... 40 in Wide Front mounted Section Rear 10 00 in 254 mm B Front A 10 00 in 254 mm 40 00 in 1016 mm 1 69 in 43 mm 20 00 in 508 mm 7 15 in 102 mm 0 25 in 6 mm Standard Ground Bus 4 Mounting Slots 0 56 in x 1 13 in in Slots 14 mm x 29 mm Slots Dimension approx Section Depth 15 in 381 mm Deep in mm 20 in 508 mm Deep in mm A 15 381 20 508 B 11 56 294 16 56 421 ...

Page 37: ...1 in H reduced height MCC Sections A D C B E 20 in 508 mm 20 in 508 mm 70 48 in 1790 19 mm 70 48 in 1790 19 mm 0 25 in 6 mm 0 25 in 6 mm 71 in High Section 1803 4 mm Dimension approx Section Depth 15 in 381 mm Deep in mm 20 in 635 mm Deep in mm A 15 00 380 20 00 508 B 14 75 374 19 75 500 C 5 12 130 10 12 256 D 4 101 8 203 E 4 40 112 ...

Page 38: ...ctions were not compromised when subjected to a UBC Zone 4 earthquake or the IBC seismic event Per the IEEE 344 standard the equipment was under power and operated before during and after the seismic tests To obtain a UBC or IBC seismic withstandability each individual CENTERLINE 2100 MCC lineup for example both front and back MCCs in back to back applications must be mounted on an adequate seismi...

Page 39: ...led when adding to existing CENTERLINE MCCs When adding to existing MCCs you must identify the series of the MCC that you are adding to If the existing MCC is series A or B you must consult MCC technical support at 1 440 646 5800 and follow the prompts to Allen Bradley Low Voltage Motor Control Centers Post Shipment Support for joining and splicing procedures When the existing MCC is series C or l...

Page 40: ...ublication 2100 IN029 for installing and joining the pull box onto the vertical section Joining and Splicing NEMA Type 12 MCCs NEMA Type 12 MCCs must be properly installed to prevent the ingress of dust and dirt Follow the caulking instructions in the NEMA Type 12 Sealing Instructions publication 2100 IN037 supplied with the NEMA 12 MCC Use caulk to close any mounting holes in the bottom plates an...

Page 41: ...ns 2 or 4 0 25 in 6 mm x 0 50 in 12 7 mm Taptites 2 wireway extensions required for 15 in 381 mm deep 2 wireway extensions required for 20 in 508 mm deep 1 0 25 in 6 mm 20 x 0 70 in 17 78 mm taptite per wireway extension Remove left hand driphood angle and remount after the adjacent driphood has been drilled out Remove right hand driphood angle and discard Drill out 5 0 172 in 4 36 mm diameterhole...

Page 42: ... a torque wrench and socket at intervals established by your maintenance policy See Chapter 9 for suggested maintenance If a torque wrench is not available tighten until the conical spring washer is flat Torque values can be found on the information label on the interior of the vertical wireway door or on the interior right hand side plate of frame mounted units ...

Page 43: ...alignment to incoming connections Bottom Entry Conduit If your conduit is entering from the bottom follow this procedure 1 Prepare the installation site so the foundation is level 2 Before the MCC is installed place and stub up conduit approximately 2 in 51 mm above floor level making sure all incoming conduit is clear of the horizontal ground bus For approximate section base dimensions and ground...

Page 44: ...s clear of the horizontal ground bus For approximate location of the horizontal ground bus mounted in the top horizontal wireway refer to Mains and Incoming Lines Dimension Reference publication 2100 TD018 For space availability for incoming cables refer to the elevation drawings shipped with assembled MCCs Installing Cable Install the cable when the temperature is above freezing 0 C 32 F unless t...

Page 45: ...vailable short circuit current is 42 000 A rms symmetrical or less Use of crimp or compression type lugs is acceptable when the incoming lines available short circuit current does not exceed 100 000 A rms symmetrical Main Disconnect Top entry is straight through to the line side of the main fusible disconnect or main circuit breaker For bottom entry the connection scheme varies depending on the ra...

Page 46: ...bracing incoming and outgoing cables There are many sizes and types of cables as well as different means that the cables can be supported Acceptable methods are shown on the following pages SecuringCableswithGlassTape In this example glass fiber reinforced tape or glass filament tape is used Make sure the taping is continuous from the point the cables enter the MCC to the point the cables are term...

Page 47: ...able slack during wrapping so that individual cables are supported by the rope as a single mass Figure 26 Securing Cables with Nylon Rope SecuringCableswithHardwood In this example a hardwood brace maple hardwood made for the specific application is used Holes are bored approximately the size of the cable diameter Several bolt holes are also bored the breadth of the hardwood brace The brace is cut...

Page 48: ...t circuit current is less than 42 000 A brace the cables every 12 in 305 mm When the short circuit current is 42 000 A or greater brace the cables every 6 in 153 mm Incoming Line Brace Allen Bradley manufactures an incoming line brace similar to the hardwood clamping type brace To order an incoming line brace contact your local Allen Bradley distributor or Rockwell Automation sales representative ...

Page 49: ...actices Refer to the NFPA 70E Standard for Electrical Safety in the Workplace publication R ATTENTION Review your company safety lockout and tag out procedure De energize all units before installing or removing ATTENTION All covers and doors must bein place before applying power to the MCC If units are removed they must be replaced with the appropriate items such as units doors and unit support pa...

Page 50: ...lide the shaft port cover open 3 Insert the 1 4 in hex tool into the shaft port 4 Rotate the wrench counter clockwise to retract the power stabs The indicator next to the disconnect handle changes from red to green 5 Pull out the power stabs lockout lever You can attach a lock to the lever to prevent the lever from being pushed in and the power stabs being extended 6 Remove the cover from the stat...

Page 51: ...ty in pins 1 and 2 When the stabs are retracted they complete the circuit verifying that all three stabs have retracted completely b Verify that the stab housing shutters are closed by checking continuity in pins 3 and 4 of the status port A limit switch provides feedback to indicate the stab housing shutters are closed 8 Continue following the steps with Remove a Plug in Unit with a Vertical Oper...

Page 52: ...nitwitha Vertical Operating Handle from a Section To remove a unit follow this procedure 1 Make sure the disconnect handle is in the OFF O position 2 For non arc resistant units turn the door latches 1 4 turn for units that are equipped with arc resistant door latches push in the latch and rotate 1 4 turn Arc Containment Latch ...

Page 53: ... remove the unit door to remove a unit from a section However these steps can still be necessary even when the door is not removed For Units With Follow This Step A control station First slide the hinge pin out ofthe hinge and through the tab on the control station wiring ArcShieldunitswith100 msarc duration rating Two hinges are required for each hinge leaf 1 The upper hinge on each door must ber...

Page 54: ...front of the unit one at the top and one at the bottom of the unit Units that are 2 0 space factor and larger have two latches at the top All units with the 100 ms arc resistant rating have two latches at the top 6 Detach the front portion of the pull apart terminal blocks from the unit base and place the wires and terminal blocks in line with the wiring clearance tunnel Wiring Tunnel ...

Page 55: ...at the lower left of the unit and the tab in the upper right of the unit as finger holds Reposition your hands as necessary to properly support the unit while you are removing the unit from the MCC TIP It is not necessary to place wires and terminal blocks into the vertical wireway to remove a plug in unit that includes the wiring clearance tunnel ATTENTION Plug in MCC units can be heavy or awkwar...

Page 56: ...onnect switch units you need to remove the bottom arc latch bracket You can do this by first removing the unit below the dual disconnect unit ATTENTION All covers and doors must bein place before applying power to the MCC If units are removed they must be replaced with the appropriate items such as units doors and unit support pans When installing units for CENTERLINE 2100 Motor Control Centers wi...

Page 57: ...O position 2 For non arc resistant units turn the door latch 1 4 turn for units that are equipped with arc resistant door latches push in the latch and rotate 1 4 turn 3 Open the door completely 4 Remove the unit door if necessary a Remove the door mounted devices and wiring if necessary TIP It is not necessary to remove the unit door to remove a unit from a section However these steps can still b...

Page 58: ...Step A control station First slide the hinge pin out of the hinge and through the tab on the control station wiring ArcShield units with 100 ms arc duration rating Two hinges are required for each hinge leaf 1 Theupperhinge oneachdoormustbe removedfromthe structuretoremovethe uppermost hinge pin 2 Remove the hinge pin through the lower hinge then through the hinge leaf and upper hinge Only top hin...

Page 59: ...on Publication 2100 IN012G EN P August 2016 59 Installing and Removing Plug in Units Chapter 4 c Swing the door to near closed position d Lift the door outward to remove 5 Detach the wiring terminal block from the unit ...

Page 60: ...ard approximately 3 in 7 62 cm out of the MCC You can reposition your hands as necessary to properly support the unit while you are removing the unit from the MCC For the CENTERLINE 2100 MCC units with swing out door latches you need to rotate the latch bracket 90o clockwise to avoid interference with the unit ATTENTION Plug in MCC units can be heavy or awkward to handle Use an assistant or a plat...

Page 61: ...ors and unit support pans ATTENTION All covers and doors must bein place before applying power to the MCC If units are removed they must be replaced with the appropriate items such as units doors and unit support pans When installing units for CENTERLINE 2100 Motor Control Centers with the ArcShieldrating youmust makesure you are installingaunit thathas thesame arc resistance rating as the MCC in ...

Page 62: ...et aside for installation later 2 Pry the plastic retaining clip from the right hand unit support by using a screwdriver This is visible in the vertical wireway For CENTERLINE MCC units with arc resistant latches the unit support pan is secured to the right hand unit support by the screw that retains the arc latch bracket To remove the unit support pan you must remove the arc latch bracket Plastic...

Page 63: ...structure 5 Push back on the left side of the support pan until the support pan is free from the structure Vertical sections can be supplied with plug in stab opening protective caps manual shutters or automatic shutters Refer to the next step if any of these options are supplied 6 Carefully install the protective caps or close the manual shutters after the unit is removed Automatic shutters close...

Page 64: ...th Vertical Operating Handles Installation Instructions publication 2100 IN014 The redundant power unit requires 0 5 space factor and three bolt locations as shown 2 Place the unit into the open space and secure the unit on the right side with two 10 32 self tapping screw and tighten to 32 lb in 3 6 N m by using a 5 16 in socket wrench 3 Secure the unit on the left side with one 1 4 20 self tappin...

Page 65: ... maximum The existing power supply is pre wired at the factory to terminal blocks in the horizontal wireway 4 Move this 24V DC wire connection from the terminal block within the power supply unit to the output terminal block of the two branch redundant unit Terminals PS and PS are for the left 4 A branch and RS and RS are for the right 4 A branch On the incoming side for redundant operation indepe...

Page 66: ...6 XL module that connects to that power source turn off which indicates input power was lost However the V out light on that same 1606 XL module remains on which indicates the second power supply is still providing 24V DC power Therefore the devices on that circuit remain on This process can be repeated by alternating the power supplies that were left on or turned off TIP UsetheEthernetPowerSupply...

Page 67: ...ce while energized shall be field marked to warn qualified persons of potential electric arc flash hazards The marking shall be located so as to be clearly visible to qualified persons before examination adjustment servicing or maintenance of the equipment FPN No 1 NFPA 70E 2000 Electrical Safety Requirements for Employee Workplaces provides assistance in determining severity of potential exposure...

Page 68: ...el of the on site personnel safety training The level of required clothing and required PPE Consistency for the level of marking of various equipment for example switchboards panelboards industrial control panels and MCCs The available flash energy on each piece of equipment This energy is determined from available fault current arc flash duration due to the type and degree of short circuit protec...

Page 69: ... just below on units with a vertically mounted operator handle or just to the right on units with a horizontally mounted operator handle of the pivot point of the operator handle To operate the defeater mechanism and defeat the door interlock while the operator handle is in the ON I position use a flat head screwdriver to turn the defeater screw clockwise one eighth to one quarter turn ATTENTION W...

Page 70: ...ion Publication 2100 IN012G EN P August 2016 Chapter 6 Operator Handle and Unit Interlock Figure 28 Operating Handle Defeater for Vertical Operator Handle Figure 29 Operating Handle Defeater for Horizontal Operator Handle ...

Page 71: ...or horizontal handles to move the operator handle to the ON I position and energize the unit Figure 30 Defeater Lever for Vertical Operator Handle ATTENTION When working on or near energized electrical equipment followestablishedelectricalsafety relatedworkpractices RefertoNFPA70E Standard for Electrical Safety in the Workplace Personal protective equipment PPE is not shown for clarity ATTENTION W...

Page 72: ...ition To lock the small medium and large operator handle in the OFF O position put the shackle of the lock through the opening in the operator handle assembly The opening can accommodate up to three padlocks Figure 32 Locking Vertical Handles in OFF O Position ATTENTION When working on or near energized electrical equipment followestablishedelectricalsafety relatedworkpractices RefertoNFPA70E Stan...

Page 73: ...the ON I Position Follow this procedure to lock the operator handle in the ON I position 1 Drill out the hole to 3 8 in 9 5 mm diameter maximum 2 Insert the shackle of the lock The following instructions assume that the handle is in the ON I position For units with small handles the hole is in the upper portion of the operator handle assembly For units with medium and large operator handles the ho...

Page 74: ...ication 2100 IN012G EN P August 2016 Chapter 6 Operator Handle and Unit Interlock Figure 34 Locking Small Handle in ON I POSITION Vertical Operating Handle Figure 35 Locking the Medium Handle in ON I Position Drill Out Drill Out ...

Page 75: ... Publication 2100 IN012G EN P August 2016 75 Operator Handle and Unit Interlock Chapter 6 Figure 36 Locking Large Handle in ON I Position Figure 37 Locking Horizontal Handle in ON I Position Drill Out Drill Out Drill Out ...

Page 76: ... interlock can also be used with the unit installed in the section but partially removed from the section In this position the unit is partially removed from the MCC and the slot in the interlock plate is in line with the flange of the unit support pan above this unit When the unit is locked in this position the unit power and ground stabs are disengaged This position can be used to prevent insert...

Page 77: ...n When the unit is locked in this position the unit power and ground stabs are disengaged This position can be used to prevent insertion of a unit into the MCC Figure 40 Unit Interlock to Prevent Insertion Horizontal Operating Handle ATTENTION When working on or near energized electrical equipment followestablishedelectricalsafety relatedworkpractices RefertoNFPA70E Standard for Electrical Safety ...

Page 78: ...78 Rockwell Automation Publication 2100 IN012G EN P August 2016 Chapter 6 Operator Handle and Unit Interlock Figure 41 Unit Interlock to Prevent Insertion Unit Completely Withdrawn ...

Page 79: ...g with other data for the MCC such as component manuals heater element instructions MCC manuals and wiring diagrams Blank sample forms are provided at the end of this chapter Pre energizing Check Procedure Allow only a qualified person to conduct the pre energizing check A qualified person is defined by NEMA Standards Publication No ICS 2 3 Instructions for the Handling Installation Operation and ...

Page 80: ...k that clearance height is at least 12 in 305 mm 5 Check the integrity of the bus splice connections ATTENTION To ensure the safety of personnel performing the pre energizing check make sure the MCC remote power sources are disconnected and locked in the OFF O position Use a voltmeter to verify that the MCC remote power sources are disconnected ATTENTION Power factor correction capacitors PFCCs mu...

Page 81: ...CC field conductors b Check that all barriers and parts that have been removed during installation have been reinstalled Some barriers can be required to be removed for field wiring c Check that all incoming and outgoing power wiring is secure and braced to withstand the effects of a fault current as detailed in Chapter 3 d Check that conduit and cabling are well supported For incoming line compar...

Page 82: ... on the unit wiring diagram Verify that all fuses fit each application 11 For circuit breaker applications verify that the circuit breakers are in accordance with NEC application requirements and have correct ampacity and trip settings Refer to MCC Instantaneous Trip Motor Circuit Protectors MCP in Combination NEMA Starter Soft Starter SMC and Variable Frequency AC Drive Units Technical Data publi...

Page 83: ...ng or replacement If you have an MCC with arc resistant design features if a unit has been provided with arc resistant baffles over door vents and fans these baffles must be fastened securely in place to maintain the arc resistant capabilities of the MCC Do not install any type of filter in place of or in addition to the arc resistant baffles 16 Check all current transformers for proper polarity a...

Page 84: ...ables by injecting a low voltage current or by using space heaters Once the equipment is dry repeat the insulation resistance test The minimum value for insulation resistance on a new installation at startup or energizing is 1 MΩ Record these readings in the Insulation Resistance Reading Recording Table Use this table to record additional insulation resistance readings during regular maintenance p...

Page 85: ...t Before Energizing Chapter 7 Door Latch Position Diagrams Figure 42 Vertical Wireway Door Figure 43 0 5 Space Factor and Units with Horizontal Disconnect Handles Standard Latches Arc Resistant Latches Standard Latches ArcResistantLatches 0 5 Space Factor 1 Space Factor or Larger ...

Page 86: ...nect Handles Standard Latches Arc Resistant Latches 1 Space Factor to 2 5 Space Factor 2 5 Space Factor or Larger An arc resistant latch is used for the center latch only for main incoming power units and 100 ms arc resistant rating Formostunits the centerlatchisastandardquarter turnlatch For someunits a multi turn latch is used Torque the latch to 20 lb in 2 lb in ...

Page 87: ...nt latches are vertical and the latch springs are compressed The spacing of the spring coils are decreased Figure 46 Spring Compression An arc resistant latch is used for the second and fourth positions Other latches are standard quarter turn All center latches are arc resistantlatchesforunitswith 100 ms arc resistant rating Arc Resistant Latches Standard Latches Uncompressed Spring Compressed Spr...

Page 88: ...Sheet 15 in deep right side visible ATTENTION Arc resistant CENTERLINE 2100 MCCs are provided with certain components to achieve the arc resistant rating These components must be in place prior to using the MCC to maintain the arc resistant capabilities TIP Notallofthecomponentsandfeaturesnecessaryforthearc resistantrating are shown in these images End Closing Plate Insulation Sheet ...

Page 89: ...IVE DEVICE UL LISTED FUSES CLASS L FERRAZ SHAWMUT A4BQ 1200 A CLASS R ANY FUSE 600 A CLASS J ANY FUSE 600 A UL LISTED MOLDED CASE CIRCUIT BREAKERS ALLEN BRADLEY BULLETIN 140U FRAME I JD or K CUTLER HAMMER SERIES C FRAME F J K L M or N WARNING PER IEEE C37 20 7 2007 ARC FLASH HAZARD THE ARC CONTAINMENT CAPABILITY OF THE MOTOR CONTROL CENTER IS DEPENDENT UPON THE MAIN PROTECTIVE DEVICE PROTECT ONLY ...

Page 90: ...ed in 2 Verify the disconnect handle is OFF O 3 Insert the tool in the shaft port and rotate the tool to the right The status indicator changes from green to red Stab Lockout Status Port Shaft Port Status Indicator ATTENTION SecureConnect units are shipped inside the unit location with stabs in the disconnected position Prior to powering your horizontal bus you need to place all SecureConnect unit...

Page 91: ...ng required is 1 5 in 38 mm over surface spacing required is 2 0 in 50 mm Table 8 Spacing Requirements within MCC Units Voltage Min Spacing in mm Between Uninsulated Live Parts of Opposite Polarity and Between an Uninsulated Live Part and an Exposed or Uninsulated Dead Metal Part other than the Enclosure Between Uninsulated Live Parts and the Walls of a Metal Enclosure 1 Including Fittings for Con...

Page 92: ...ion Vertical Wireway Horizontal Wireway Horizontal Wireway 1 0 S F 113 in 330 mm Unit Location Unit Data Cat No Wiring Diagram Size or Amp Rating Description Full Load Current Horsepower Overload or Heater Elements Kilowatts Circuit Breaker Trip Setting Power Fuse Rating 1A 2113B EDB 48CA CSXXXXXXXX 4 FVNR 77 60 W73 C 1E 2112A BDBD 24J 38 7FEC1A Y XXXXXX 1 FVNR 4 8 3 7FECIA 10 1G 2100 NJ30 N A Bla...

Page 93: ...versing Vacuum INSRT Unit Insert LPAN Lighting Panel M BPS MAIN Bolted Pressure Switch M CB MAIN Circuit Breaker M FDS MAIN Fusible Disconnect Switch M LUG MAIN Line Lugs METER Metering Unit NCP Neutral Connection Plate NLD ControlNetto DeviceNet PLC Programmable Logic Controller RVAT Reduced Voltage Autotransformer SMC Solid State Motor Controller SPD Surge Protection Device TERM Terminal Unit TS...

Page 94: ...zing Table 11 MCC Layout Worksheet MCC Name Number ___________________________________________________________ Unit Location Unit Data Cat No Wiring Diagram Size or Ampere Rating Description Full Load Current Horsepower Overload or Heater Elements Kilowatts Circuit Breaker Trip Setting Power Fuse Rating ...

Page 95: ...ore Energizing Chapter 7 Table 12 Insulation Resistance Reading Recording Table MCC Name Number ___________________________________________________________ Date Circuit Unit Name Number Phase to Phase Phase to Ground Phase to Neutral A B B C C A A Grd B Grd C Grd A Neut B Neut C Neut ...

Page 96: ...96 Rockwell Automation Publication 2100 IN012G EN P August 2016 Chapter 7 Final Checklist Before Energizing Notes ...

Page 97: ... the branch circuit devices Always energize from the source of the system working towards the loads ATTENTION Thisprocedureisprovidedasgeneralguidanceforenergizinga newly installed CENTERLINE MCC after the Final Check procedure has been completed See Final Checklist Before Energizing for more information ATTENTION Energizing a MCC for the first time is potentially dangerous Serious damage and or p...

Page 98: ...e motors be jogged or inched temporarily disconnect the power factor correction capacitors For more information on power factor capacitors and MCC units refer to the Power Factor Correction Capacitors for Bulletin 2100 Motor Control Center Starter Units Application Techniques publication 2100 AT001 b Verify that any acceleration times are within application specifications Excessive starting curren...

Page 99: ...ould let moisture enter the MCC enclosure b Dry or replace and clean insulating material that is damp or wet or shows signs of moisture c Check devices such as contactors circuit breakers disconnect switches relays and push buttons for wetness or signs of moisture corrosion or contamination d Replace damaged or malfunctioning parts 4 Check the integrity of bus splice connections Bus splices can be...

Page 100: ...leading to failure Replace bus stabs if wear or corrosion is excessive Lubricate bus stabs with NO OX ID grease catalog number 2100H N18 or 2100H N18T before installing the unit into the section 9 Inspect current carrying parts such as fuse clips knife blades of disconnects and line and load terminals of devices for discoloration corrosion or other signs of wear or possible failure 10 Check lockin...

Page 101: ...ng faults that could lead to equipment malfunction or failure Replace any damaged parts or wiring 14 Check contactor and relay coils for evidence of overheating such as cracking melting or burning of insulation If there is evidence of overheating the coil must be replaced When replacing a coil check and correct the overvoltage or undervoltage conditions that can cause the coil failure Be sure to c...

Page 102: ...on 2 Remove the line guard from the disconnect 3 For access to the disconnect s stationary contacts remove the arc hood 4 Generously apply the NO OX ID compound sufficient enough to cover with a noticeable film to both sides of the movable contact blades and to the adjacent insides stationary contacts and the hinge 5 Reinstall the arc hood that was removed in step 3 6 Reinstall the line guard cove...

Page 103: ...s so that energized parts are not shorted If care is not taken electrical shock severe injury or death can result When working on or near energized electrical equipment follow established electricalsafety relatedworkpractices RefertoNFPA70EStandardforElectrical Safety in the Workplace Table 13 Temperature Guidance Category Temperature Differential 1 Temperature Rise 2 Repair Service C F C F Servic...

Page 104: ...n sulfide and silver plating On fuses and fuse clips service by polishing with a Scotch Brite cleansing pad Do not lubricate the fuses or the fuse clips 3 If overheating has occurred as indicated by severe tarnishing infrared test results crystallization of insulation on conductors discoloration of the components darkening of the molding materials brittle conductor insulation or deformation and me...

Page 105: ...1 De energize the MCC 2 Investigate the cause of the fault and inspect all equipment thoroughly per NEMA Standards publication ICS 2 3 1995 Instructions for the handling installation operator and maintenance of MCCs not rated more than 600V Section 11 Maintenance after a Fault has Occurred 3 Make necessary repairs to units components and structures as required prior to reenergizing the equipment B...

Page 106: ...106 Rockwell Automation Publication 2100 IN012G EN P August 2016 Chapter 10 Maintenance after Fault Condition Notes ...

Page 107: ...ration inherent design limitations and environmental considerations The total number of similar devices supplied as original equipment within the MCC Individual user policies governing spare parts Consider stocking complete units when the job site is in an area remote from a distributor or district sales office or when it is critical to maintain continuous operation of a system Order Information T...

Page 108: ...108 Rockwell Automation Publication 2100 IN012G EN P August 2016 Chapter 11 Renewal Parts Notes ...

Page 109: ...meplate Vertical Wireway Door VerticaltoHorizontalBusConnection Access Cover Vertical Bus Support Cover Unit Support Pan Sealing Strap Top and Bottom Bottom Support Angle Bottom Horizontal Wireway Cover Left Hand Bottom End Closing Plate Horizontal Ground Bus Top or Bottom Left Hand Side Plate Assembly Vertical Plug in Ground Bus Left Hand Center End Plate Horizontal Power Bus Vertical Power Bus H...

Page 110: ...ation Nameplate Diagram Pocket Captive Latch Starter or Contactor Control Circuit Fuses and Fuse Block Auxiliary Contacts Control Transformer Fusing and Fuse Block ControlCircuitTransformer not shown Power and Control Terminal Blocks Short Circuit Rating Label UL Label Captive Latch Control Station Pilot Devices Reset Button Unit Support Pan Plastic Retaining Pin Overload Handle Cutout Unit Door D...

Page 111: ...g Handle and Door Mounted Pilot Devices Unit Support Pan Bushing Unit Support Pan Plastic Retaining Pin Unit Latch Interlock Pilot Devices ControlCircuitFuseblock and Fuses Control Terminal Block Handle Mechanism Circuit Breaker shown or Fusible Disconnect Control Circuit Transformer Unit Stab Assembly Overload Relay Contactor or Starter Starter Unit Nameplate Unit Door ...

Page 112: ...upport Pan Bushing Unit Support Pan Plastic Retaining Pin Unit Latch Interlock Pilot Devices Control Circuit Fuse block and Fuses Control Terminal Block Handle Mechanism Circuit Breaker shown or Fusible Disconnect Control Circuit Transformer Unit Stab Assembly Overload Relay Contactor or Starter Auxiliary Contacts Unit Nameplate Unit Door Bulletin 2413 IEC Style Shown ...

Page 113: ...Some items of the unit are not shown in the illustrations for clarity Required Tools You need a screwdriver a Phillips screwdriver a socket set with extension and a torque wrench to complete the installation Remove Circuit Breaker To remove a circuit breaker follow these steps 1 See Chapter 4 for instruction to remove a unit from the MCC 2 Place the unit on a clean flat surface IMPORTANT Use cauti...

Page 114: ...d Remove the linkage from the bale 4 Disconnect the circuit breaker wiring a Remove terminal cover mounting screw and slide the terminal cover forward click when pulling b To remove the line side connection top wires use an allen wrench G and H frame 5 mm hex J frame 6 mm Make note of the phasing of the cables c To remove the load side connection bottom wires use an allen wrench G and H frame 5 mm...

Page 115: ... vertical handle unit follow these steps 1 Attach the handle assembly to the mounting plate by using 10 32 x 0 38 thread forming screws and tighten to 20 40 lb in 2 25 4 50 N m 2 If optional external auxiliary contacts are used attach the external auxiliary bracket not included in the kit to the circuit breaker base 3 Position the base on the mounting plate Use the vertical mounting holes 2100V 4 ...

Page 116: ...se The bale snaps into place on both sides of the circuit breaker base If the bale does not snap in easily check the orientation of the bale TIP The wires from internal accessories on the right side of the circuit breaker are routed under the circuit breaker in the trough in the base so they exit on the left Mounting Plate Base Circuit Breaker bale SuppliedwithCircuitBreaker 10 lb in 1 13 N m 8 32...

Page 117: ... kit 16 Insert the terminal cover screw not provided with the kit and tighten to 8 lb in 0 90 N m 17 Attach the load side wiring and tighten to 53 lb in 6 N m for G and H frame units tighten to 71 lb in 8 N m for J frame units 18 Install the load side phase separators on the load side not supplied with the kit Verify that the phase separators are pushed down completely so that they are flush with ...

Page 118: ...just the circuit breaker position follow these steps 1 Loosen the two circuit breaker mounting screws 2 Turn the adjustment screw on the top of the base assembly to the right clockwise to move the circuit breaker higher in the unit Turn the adjustment screw on the top of the base assembly to the left to lower the circuit breaker in the unit 3 If optional external auxiliary contacts are used after ...

Page 119: ...set with extension and a torque wrench to complete the installation Remove Circuit Breaker To remove a circuit breaker follow these steps 1 See Chapter 4 for instruction to remove a unit from the MCC 2 Place the unit on a clean flat surface 3 Remove the white mounting screw from under the handle assembly 4 Disconnect any terminal blocks if necessary 5 For space saving design remove the auxiliary b...

Page 120: ... rotate the screwdriver 9 Disconnect the circuit breaker wiring a Remove terminal cover mounting screw and slide the terminal cover forward click when pulling b To remove the line side connection use an allen wrench G and H frame 5 mm hex J frame 6 mm Make note of the phasing of the cables c To remove the load side connection use an allen wrench G and H frame 5 mm hex J frame 6 mm 10 To remove the...

Page 121: ... 32 x 0 81 Pan head screw H and J frame units Use the horizontal mounting holes 2100H 2 Tighten to 18 lb in 2 03 N m 3 Mount the circuit breaker to the base by using screws included with the circuit breaker split lock washers and flat washers use washers from the existing unit and tighten to 10 lb in 1 13 N m 4 Put the circuit breaker ON OFF switch to the ON position Mounting Plate Base Circuit Br...

Page 122: ... J Frame units 7 Add the line terminal cover to the line side not included in the kit 8 Insert the terminal cover screw and washer not provided with the kit and tighten to 8 lb in 0 90 N m 9 Attach the load side wiring and tighten to 53 lb in 6 N m for G and H frame units tighten to 71 lb in 8 N m for J frame units 10 Install the load side phase separators on the load side not supplied with the ki...

Page 123: ...le in the OFF position align the tab on the bale with the slot in the mounting plate and secure with a 10 32 x 0 38 hex head thread forming screw 13 With the handle and the circuit breaker in the OFF position engage the linkage to the notch in the bale 14 Attach the external auxiliary contacts to the bracket Handle Linkage Stud Notch in bale Handle Assembly 10 32 x 0 38 hex head 24 40 lb in 2 7 4 ...

Page 124: ...st the circuit breaker position 1 Loosen the two circuit breaker mounting screws 2 Turn the adjustment screw on the top of the base assembly to the right clockwise to move the circuit breaker higher in the unit Turn the adjustment screw on the top of the base assembly to the left to lower the circuit breaker in the unit 3 After the external contacts have been snapped on adjust the auxiliary bracke...

Page 125: ... J frame horizontal units These kits contain parts to install external auxiliary contacts in units that are the following types Units with horizontal operating handles Have one of the following circuit breakers Bulletin 140G 140MG Bulletin 2100 Series Z and later Required Tools You need a screwdriver a Phillips screwdriver and a hexalobular T 15 screwdriver to complete the installation ATTENTION D...

Page 126: ...dle auliliary bracket to the unit by using two 8 32 x 0 38 thread forming screws 5 Tighten to these values 32 lb in 3 62 N m for 8 screws 18 lb in 2 0 N m for 6 screws 6 Turn the operator handle to the ON I position to verify that the auxiliary contacts change state 7 Check continuity to verify proper operation of the auxiliary contacts Figure 50 Horizontal Units TIP These external auxiliary conta...

Page 127: ...wdriver a 1 4 wrench or socket a 5 16 wrench or socket and a torque wrench Installation Refer to Figure 51 and use the following steps to install external auxiliary contact adapter 1 Make sure that all of the power has been disconnected 2 Verify the parts list 3 Install auxiliary contacts 4 Attach the external auxiliary contact assembly to the mounting plate by using one 8 32 x 0 38 inch thread ro...

Page 128: ...J and K Frame Units 140G G H and J Frames 140G K Frames Parts List 1 Auxiliary Contact Assembly 1 Handle Bracket 2 8 32 x 0 38 screws or 2 6 20 x 0 56 screws Auxiliary Contact Normally Open or Auxiliary Contact Normally Closed Handle Bracket 6 20 x0 56 screw AuxiliaryContactNormallyOpen or Auxiliary Contact Normally Closed Handle Bracket 8 32 x 0 38 screw ...

Page 129: ...nd turn the operator handle to the OFF O position 2 Verify the parts list see Assembly of External Auxiliary Contact Parts 3 Attach the external auxiliary contact assembly to the mounting plate by using two 1 4 20 thread rolling screws and tighten to 55 lb in 6 2 N m Refer to Assembly of External Auxiliary Contact Parts 4 Attach the actuator to the circuit breaker bail by using two 1 4 20 thread r...

Page 130: ...ers Figure 52 Assembly of External Auxiliary Contact Parts Mounting Plate 1 4 20 Screws External Auxiliary Contact Assembly Parts List 1 External Auxiliary Contact Assembly 1 Actuator Arm 2 1 4 20 Screws 2 8 32 Screws Wheel for Auxiliary Contact 8 32 Screws Auxiliary Contact Auxiliary Contact Bracket ...

Page 131: ...g 81 circuit breakers 82 conduit 81 contactor and relay coils 101 disconnect handle 100 fuses 101 interlocking devices 100 locking devices 100 moisture 99 pilot lights 101 power contacts 101 wiring 81 check list 79 circuit breaker 82 113 adjust position 118 horizontal handle unit 119 install 115 121 install auxiliary contact adapters 125 removal 119 space saving design 119 conduit 43 bottom entry ...

Page 132: ...dimensions 23 energizing 79 97 joining and splicing exisiting motor control centers 39 joining and splicing NEMA Type 12 motor control centers 40 joiningandsplicingNEMAType3RandType 4 units 40 joining and splicing new motor control centers 39 maintenance 99 mounting 26 mounting dimensions 25 operation 24 product construction 109 section installation 15 securing 26 seismic requirements 38 storage 2...

Page 133: ...ering 20 number and series ID 17 shipping weights 23 export 23 standard 23 short circuit rating label 16 sections 16 units 16 shutters 56 61 space factor 11 space saving design circuit breaker install 121 circuit breaker removal 119 spacing requirements within the MCC 91 storage 24 support 104 support pan removal 62 ArcShield 62 swing out door latches 60 switch lubrication 102 T temperature guidan...

Page 134: ...134 Rockwell Automation Publication 2100 IN012G EN P August 2016 Index Notes ...

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Page 136: ...t Dial Code for your product Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Gethelp determining how products ...

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