GE Evolution Series E9000 Installation, Operation And Maintenance Manual Download Page 8 | Manualshive

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E VOLUTI ON S E R I E S E9 0 0 0

M OTO R CO N T R O L C EN T ER

Bus splicing steps for 2500A without fans,
3000A, and 3200A main bus

For 2500 A without fans, 3000 A, and 3200 A main
bus, it is recommended to pre-mount the align and
torque all splices in all phases before you join the
section if possible. If splicing from the left, pre-
mount the splices and pre-torque bolts from right
case side opening. If splicing from the right, slide in
bus bars through left case side opening and access
the bolts for torquing through the vertical wireway.

Step 1:

Mount on left side of section

Transition case and
MAIN/MLO section

Splices mounted on
the left side of section

Step 2:

Connect feeder section with splices

Step 3:

Connect main buses with splices

Connecting Feeder
section with splices
to MAINs/MLOs with
transition case

3 pieces/phase
of splices

Main buses
connected
by splices

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Summary of Contents for Evolution Series E9000

Page 1: ...INSTALLATION OPER ATIONS AND MAINTENANCE MANUAL Evolution series E9000 Motor control center ...

Page 2: ......

Page 3: ...04 Warnings cautions and notes 05 08 Introduction 09 Receiving handling and storage 10 29 Installation 30 32 Operation 33 36 Maintenance 37 49 Overload heaters Table of contents ...

Page 4: ...ated with its use Warning notices are also used for situations in which in attention or lack of equipment knowledge could cause either personal injury or damage to equipment Caution notices are used for situations in which equipment might be damaged if care is not taken Notes call attention to information that is especially significant to understanding and operating the equipment Warnings cautions...

Page 5: ...inuous non removable main horizontal bus Main bus splice bars are provided within each shipping split for field connecting main busses Refer to motor control center outline drawings furnished by ABB for location of shipping splits within each motor control center lineup Hinged doors are provided over horizontal and vertical wireways These doors can be removed by extracting the hinge pins inside th...

Page 6: ...rier Figure 2B shows the 2500 A without fans and the 3000 3200 A main horizontal bus configuration The vertical bus either 300 A or 600 850 A is connected with two bolts per phase to the main bus The phase relationship is A B C from top to bottom and left to right as viewed from the front 2500 A Type 12 construction without fans will be limited to 700A vertical bus A continuous horizontal ground b...

Page 7: ...ing 600 110C1735G1SM 1 1 4 x 2 65K 110C1258 800 110C1735G4SM 1 3 8 x 2 65K 110C1256 1200 110C1735G7SM 1 1 2 x 2 100K 110C1253 1600 2000 110C1735G12SM 2 1 2 x 2 100K 110C1263 2500 110C1735G13SM 2 1 2 x 2 100K 110C1785 2500 3200 110C1735G38SM 3 2 5 x 4 100K 110C2357 N3R and Spacer Shells 600 110C1735G14SM 1 1 4 x 2 65K 110C1258 800 110C1735G15SM 1 3 8 x 2 65K 110C1256 1200 110C1735G16SM 1 1 2 x 2 10...

Page 8: ...lices and pre torque bolts from right case side opening If splicing from the right slide in bus bars through left case side opening and access the bolts for torquing through the vertical wireway Step 1 Mount on left side of section Transition case and MAIN MLO section Splices mounted on the left side of section Step 2 Connect feeder section with splices Step 3 Connect main buses with splices Conne...

Page 9: ...se two or more chains or cables to distribute the weight evenly Pinch bars pipe rollers or slings are useful implements for handling equipment but be careful to maintain distributed loading and to always apply leverage at the floor sills and or lifting eyes Figures 05A and 05B illustrate typical handling techniques Storage If it is necessary to store the equipment for any length of time be sure to...

Page 10: ...eep 20 Deep 22 Deep 25 Deep Width A B C B C B C B C 20 10 00 8 73 10 00 15 73 10 00 17 73 10 00 20 68 508 8 mm 254 4 mm 221 7 mm 254 4 mm 399 5 mm 254 4 mm 450 3 mm 254 4 mm 525 3 mm 24 12 00 8 73 12 00 15 73 12 00 17 73 12 00 20 68 609 6 mm 304 8 mm 221 1 mm 304 8 mm 399 5 mm 304 8 mm 450 3 mm 304 8 mm 525 3 mm 30 15 00 8 73 15 00 15 73 15 00 17 73 15 00 20 68 762 0 mm 381 0 mm 221 7 mm 381 0 mm ...

Page 11: ...ed to 50 foot pounds located in each of the four corners in each section REF DIM Section Depth 13 Deep 20 Deep 22 Deep 25 Deep 30 Deep Width A B C B C B C B C B C 20 10 00 8 73 10 00 15 73 10 00 17 73 10 00 20 68 10 00 25 69 508 8 mm 254 4 mm 221 7 mm 254 4 mm 399 5 mm 254 4 mm 450 3 mm 254 4 mm 525 3 mm 254 4 mm 653 5 mm 24 12 00 8 73 12 00 15 73 12 00 17 73 12 00 20 68 12 00 25 69 609 6 mm 304 8...

Page 12: ... be inbedded in the foundation they must be located according to the drawing for the specific equipment Locate one in the center front and one in the center back Anchor bolts should be 1 2 inch diameter of Grade 2 steel minimum In non Seismic Zone 4 Locations Restricted 12 wireway zone 12 20 Restricted 12 wireway zone Optional zone splice bolt acces Restricted zone splice bolt acces Restricted 6 f...

Page 13: ...it entrance space available at the bottom of standard sections Exceptions to this available space rule are indicated on drawings for specific installations Center the conduit beneath the section vertical wireway to facilitate direct cable entry 6A Bottom conduit entrance details for standard 13 inch deep section low bus position 6A 6B 6C Top conduit entry for all 2500A without fans 3000A and 3200A...

Page 14: ...ition of ground and neutral bus with 12 inch cover compartment at the bottom of MCC 7C Low bus position of ground and neutral bus minimum available space for conduit entry in 13 inch deep section 6 inch cover 7D Upper position of ground and neutral bus maximum space available for conduit entry 6 inch bottom cover 7E Available conduit space for 2500A without fans 3000A and 3200A main bus configurat...

Page 15: ...t should be considered with respect to headroom top conduit entry space and alignment with other equipment Note If anchor bolts are to be imbedded in the foundation they must be located according to the drawing for the specific equipment Locate one in the center front and one in the center back Anchor bolts should be 1 2 in diameter of Grade 2 steel minimum in non seismic locations Bolts must exte...

Page 16: ...onductor and any other conductor of the circuit For example the voltage to ground for a 480 volt ungrounded delta system is 480 volts See Figure 11 for general working clearance requirements Distances are measured from the live parts if the live parts are exposed or from the enclosure front if live parts are enclosed If any assemblies such as switchboards or motor control centers are accessible fr...

Page 17: ...c installations Note Top rear entrance should only be used with full rear accessibility Equipment wiring When pulling bending and terminating field wiring avoid scraping cutting or otherwise damaging cable insulation or strands Always remove top cover plates when drilling holes This prevents small metal chips from falling into the panel and cause serious damage Width Dimension A Dimension B 20 20 ...

Page 18: ...top rear conduit entry space of the appropriate MCC section Installation involves connecting two mated control power harness ends for each fan assembly One harness is located within the fan assembly The corresponding mated harness end is coiled and secured inside the top rear of the section being ventilated Fan Assembly Top Rear Cover Location 13C Filter Assembly UL Type 12 Fan Assembly Arc resist...

Page 19: ...tely brace cables for faults of 100K RMS symmetrical amperes based on horizontal bus bracing However cables should always be secured at the first support inside the enclosure and at the support nearest to the incoming terminals Insulated bushings are also recommended at conduit terminations Lashing scheme for connecting cables in 2500A 3000A and 3200A main bus configurations Add 5 wraps for every ...

Page 20: ... cable Install plastic side barrier 3 Pull the control wiring then measure cut strip and terminate it on individual device terminals in the unit 4 When specified an optional ground lug is provided in each draw out combination starter unit for terminating a motor frame grounding wire For larger starters the lug is mounted on the horizontal ground bus 5 Use cord or plastic ties to secure all wiring ...

Page 21: ... environments due to the toxicity of the gases Also 48 inches of space at the end piece is needed as a safe zone The plenum design can vary in height depth and width see table 1 It is used on the flap covers on the top of the section The frontal fap cover of the section is the only one to be removed When the plenum is installed users can cut anywhere in the top of the plenum for incoming cables wi...

Page 22: ...he plenum for cable entry The available space varies per the depth and width of the section Do not make any cuts on top of sections that don t have incoming cables to reduce the chance of arc propagation Arc resistant plenum less equipment Plenum less equipment design uses thin aluminum sheet metal attached to the top of the section with nylon rivet when an arc instance occurs the top side of the ...

Page 23: ... moving parts and to keep it away from heat producing components such as resistors and fuses 6 Verify that the connections on all devices and terminal blocks are tightened to their proper torque values as listed on the label on the vertical wireway door Wiring NEMA type C motor control centers Master terminal boards in NEMA Type C motor control centers are provided in the larger top or bottom hori...

Page 24: ... ordered separately is shipped complete with the door and associated hardware If the space available in the vertical section is greater than the new unit height order a blank filler door with hinge hardware and a snap shelf See the renewal parts bulletin for ordering blank doors and gasket materials The gasket material lines the inner perimeter of the section Figure 25 shows the gasket material mo...

Page 25: ...and rear to ensure that all screw terminals are tight all foreign material and packing are removed and the insulating barriers are secure 7 The unit disconnect must be in the OFF position before the unit can be inserted into the vertical section 8 If necessary rotate the latches at the top and bottom of the unit so that they are horizontal 9 Remove the snap in cover over the vertical bus stab in o...

Page 26: ...nadvertent contact Failure to observe this precaution can result in serious injury or death 5 Turn the latches at the top and bottom of the unit a quarter turn counterclockwise to release the unit These latches are shown in Figure 27 and Figure 28 6 Pull unit out to remove it being extremely careful to support its weight as it is fully withdrawn 7 The door over the withdrawn unit can be latched cl...

Page 27: ...f the way as shown in Figure 33 allowing access to the breaker Final commissioning Verify that all doors are properly latched and interlocked prior to energizing Caution should be used when removing or installing units consider the weight in table above Two persons may be required or the assistance of a lifting devices See page 28 for suggested lifts Caution The friction of Type 12 gasketing can p...

Page 28: ...outdoor enclosure installation The pilot device bracket in is locked in place using the door mounted locking bracket shown in Figure 35A All pilot device brackets for arc resistant MCCs are metallic both standard and AFM units Standard E9000 MCCs utilize a plastic pilot device bracket Figure 34B 34A 34A Grasp the center of the door 34C 34C Pilot device bracket locking bracket in door 34B 34B Arc r...

Page 29: ... Hardware kits shipping with modules 4 Assemble bus splices per splice instructions included in splice kit 5 Install wireway transition channel barrier by sliding it though the 5 x 5 wireway cutout and attaching it using 1 1 4 28 x 3 8 thread rolling Figure 35C 6 Re attach right rear cover by re attaching 1 4 20 x 5 8 sealing screw Figure 35B Detail C 7 Attached center cap using 8 1 4 20 x 5 8 thr...

Page 30: ... pneumatic or motor driven timers for proper time interval settings 8 Manually operate all branch circuit disconnects and verify proper operation of disconnects and door interlocks 9 Where applicable manually trip all circuit breakers to verify that operating handles move freely to the TRIP indicating position With the door closed and latched reset each tripped circuit breaker by pushing the opera...

Page 31: ...ntrol center 5 Close the main disconnects if any at the motor control center 6 Close each branch circuit disconnect or feeder at the motor control center For AFM Units ensure that all visual indicators are showing RED to indicate ENGAGED stab position and OPEN shutter position 7 Operate each motor starter individually to verify satisfactory operation including the following parameters Motor rotati...

Page 32: ...the door completely and turn the 1 4 turn latches 1 4 Turn Latch Door closing procedure of pilot device bracket extension bubble door for some GP FP drives E9000 MCC units Variable Frequency Drive Extension Bubble 36 36 Door pilot device bracket and extension bubble in open position 37 37 Partially close the pilot device bracket and extension bubble as shown PD Bracket Extension Bubble Door Door C...

Page 33: ...eck meters and instruments Check critical instrument calibrations 9 Check all unit door interlocks for proper operation 10 Check all indicating lights and replace as required 11 If fuse replacement is necessary always install the same type and rating as the fuses furnished with the motor control center Fuse designs may be mechanically equivalent but not electrically equivalent They may not have th...

Page 34: ...ding the breaker assembly not required for accessories only 6 Remove three front breaker screws from assembly 7 Slide the breaker down and out 8 Install the new breaker by following this procedure in the reverse order Torque all electrical connections Rearrangement of units must follow the following loading rules 80 of the feeder trip or fuse clip rating plus 100 of the starters full load current ...

Page 35: ...height 58 Lowered height 3 1 8Æ 20 X 20 deck size 10 load center 2 X 6 molded on rubber casters The following instructions are available 300 Line starter GEH 5190 NEMA Size 1 FVNR GEH 4774 NEMA Size 2 FVNR GEH 4806 NEMA Size 3 FVNR GEH 4807 NEMA Size 4 FVNR GEH 4839 NEMA Size 5 FVNR GEH 5198 NEMA Size 6 FVNR GEH 5190 NEMA Size 1 FVR and 2 Speed GEH 4775 NEMA Size 2 FVR and 2 Speed GEH 4806 NEMA Si...

Page 36: ...g unit all data on that unit s nameplate located on the right side of the unit 3 NEMA control center class I or II 4 NEMA wiring type A B or C 5 NEMA enclosure type 1 1 Gasketed 1 HG heavy gasketed 2 3R or 12 6 Power supply characteristics Voltage Number of phases Frequency in Hz 7 Control power voltage and frequency in Hz 8 Nameplate designation and title 9 Motor characteristics Horsepower rating...

Page 37: ...e complete overload relay must be replaced Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 41 45 C054A 4 96 549 C592A 46 49 C060A 5 50 5 91 C630A 50 53 C066A 5 92 6 47 C695A 54 59 C071A 6 48 7 20 C778A 60 65 C078A 7 21 8 22 C867A 66 76 C087A 8 23 8 72 C955A 77 84 C097A 8 73 9 67 C104B 85 93 C109A 9 68 10 4 C113B 94 1 04 C118A 10 5 11 0 ...

Page 38: ...52 1 F614B 44 8 51 0 F614B 52 2 55 8 F658B 51 1 52 0 F658B 55 9 59 7 F719B 52 1 55 4 F719B 59 8 68 1 F772B 55 5 63 3 F772B 68 2 71 5 F848B 63 4 66 1 F848B 71 6 78 2 F914B 66 2 73 5 F914B 78 3 87 5 F104C 73 6 82 2 F104C 87 6 90 0 F114C 82 3 90 0 F114C Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 27 1 32 2 F357B 28 8 32 0 F357B 32 3 34...

Page 39: ... 22 4 23 5 C273B 2 8 23 6 25 5 C303B 3 8 23 6 25 5 C303B LO 3 25 6 27 0 C330B LO 3 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 TEC and TECL Rating Mag Break Trip Setting Rec Max 66 76 C087A 3 LO LO 77 84 C097A 3 LO LO 85 93 C109A 3 LO 1 94 1 04 C118A 3 LO 1 1 05 1 15 C131A 3 LO 2 1 16 1 27 C148A 3 LO 2 1 28 1 39 C163A 3 LO 3 1 40 1 55 C184A 3 LO 4 1 56 1 73 C196A 3 1 4 1 74 1 89 C220A 3...

Page 40: ... 52 0 F658B 100 1 4 52 1 55 4 F719B 100 1 4 55 5 63 3 F772B 100 1 5 63 4 66 1 F848B 100 2 6 66 2 73 5 F914B 100 2 6 73 6 82 2 F104C 100 2 7 82 3 86 9 F114C 100 3 9 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 TEC and TECL Rating Mag Break Trip Setting Rec Max 28 8 32 0 F357B 50 1 4 32 1 34 2 F395B 50 2 5 34 3 36 7 F430B 50 2 6 36 8 43 4 F487B 50 3 7 43 5 43 9 F487B 100 1 3 44 0 46 6 F567...

Page 41: ...1 98 C239A 3 2 5 1 99 2 24 C268A 3 3 5 2 25 2 43 C301A 3 3 6 2 44 2 75 C326A 7 LO 3 2 76 3 25 C356A 7 LO 4 3 26 3 43 C379A 7 LO 4 3 44 4 03 C419A 7 2 4 4 04 4 43 C466A 7 2 5 4 44 4 94 C526A 7 3 5 4 95 5 36 C592A 7 3 6 5 37 5 77 C630A 7 4 6 5 37 5 77 C630A 15 LO 3 5 78 6 35 C695A 15 LO 3 6 36 6 92 C778A 15 LO 4 6 93 7 99 C867A 15 2 4 8 00 8 47 C955A 15 2 5 8 48 9 19 C104B 15 3 5 9 20 10 0 C113B 20 ...

Page 42: ...SE Rating Plug Mag Break Trip Setting Rec Max 8 81 9 27 C104B 15 3 5 9 28 9 99 C113B 20 2 4 10 0 11 1 C125B 20 2 5 11 2 12 1 C137B 20 3 5 12 2 13 0 C151B 20 3 5 13 1 15 5 C163B 20 4 6 15 6 16 8 C180B 25 3 5 16 9 18 0 C198B 25 3 6 18 1 19 7 C214B 30 3 5 19 8 21 6 C228B 30 3 5 21 7 23 9 C250B 40 2 5 24 0 25 5 C273B 40 2 5 25 6 28 2 C303B 50 2 5 28 3 31 6 C330B 50 3 5 31 7 34 7 C366B 50 3 6 34 8 37 8...

Page 43: ...0 7 76 3 F914B 150 2 4 76 4 88 7 F104C 150 2 5 88 8 93 4 F114C 150 3 5 93 5 102 0 F118C 150 3 5 103 0 110 0 F133C 150 3 5 111 0 122 0 F149C 150 4 6 123 0 131 0 F161C 150 4 6 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 SE Rating Plug Mag Break Trip Setting Rec Max 28 8 32 0 F357B 50 3 5 32 1 34 2 F395B 50 3 5 34 3 36 7 F430B 70 2 5 36 8 43 8 F487B 70 3 5 43 9 46 6 F567B 70 3 5 46 7 52 6 ...

Page 44: ...3 Ph 3 Heater Heater Number CR123 SG Rating Plug Instantaneous Trip Setting Rec Max 181 197 C220A 400 MIN 4 198 214 C239A 400 2 5 215 238 C268A 500 MIN 4 239 258 C301A 500 MIN 4 259 290 C326A 500 2 5 291 346 C356A 600 MIN 5 347 387 C379A 600 2 5 388 424 C419A 600 3 MAX Heaters for fused controllers For continuous rated motors with a service factor of 1 15 to 1 25 select the appropriate heaters for...

Page 45: ...79 C326A 10 2 80 3 31 C356A 10 3 32 3 70 C379A 12 3 71 4 06 C419A 15 4 07 4 47 C466A 15 4 48 4 95 C526A 15 4 96 5 49 C592A 20 5 50 5 91 C630A 20 5 92 6 47 C695A 25 6 48 7 20 C778A 25 7 21 8 22 C867A 30 8 23 8 72 C955A 30 8 73 9 67 C104B 35 9 68 10 4 C113B 35 10 5 11 0 C125B 40 11 1 12 4 C137B 45 12 5 13 2 C151B 50 13 3 15 4 C163B 60 15 5 17 1 C180B 60 17 2 18 0 C198B 60 Motor Full Load Amps 3 Ph 3...

Page 46: ...2B 225 69 6 71 7 F848B 250 71 8 79 9 F914B 275 80 0 92 3 F104C 300 92 4 97 0 F114C 350 97 1 108 F118C 400 109 118 F133C 400 119 131 F149C 400 132 135 F161C 400 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Maximum Fuse Rating 28 8 32 0 F357B 110 32 1 34 2 F395B 125 34 3 36 7 F430B 125 36 8 43 9 F487B 150 44 0 46 6 F567B 175 46 7 52 6 F614B 175 52 7 55 6 F658B 200 55 7 58 7 F719B 225 58 8 ...

Page 47: ...Amps Heater Number CR 123 181 197 1 51 1 64 C220A 198 214 1 65 1 78 C239A 215 238 1 79 1 98 C268A 239 258 1 99 2 15 C301A 259 290 2 16 2 42 C326A 291 346 2 43 2 88 C356A 347 387 2 89 3 22 C379A 388 423 3 23 3 53 C419A 424 467 3 54 3 89 C466A 468 516 3 90 4 30 C526A 517 540 4 31 4 50 C592A Maximum Motor Full Load Current Current Transformer Secondary Amps Heater Number CR 123 346 387 2 16 2 42 C326...

Page 48: ...nd G Mag and Thermal Mag 4 65 to 135 CR324FXM E F and G Mag and Thermal Mag 5 32 to 64 0 CR324GXN G Mag and Thermal Mag 5 65 to 129 9 CR324GXP G Mag and Thermal Mag 5 130 to 270 CR324GXQ G Mag and Thermal Mag 6 130 to 259 9 CR324HXS E F and G Mag and Thermal Mag 6 260 to 540 CR324HXT K Mag and Thermal Mag Current Range Max CB Cat No Class Cat No Class Lug Wire Size Torque in lbs 0 4 65 15 RTN1D 10...

Page 49: ...ss 20 LAR08AJ RTN2B NA 15 1 19 10 3 AWG 50 LAR10AJ RTN2C NA 19 1 25 10 3 AWG 50 RTN2D RT22D 25 1 32 10 3 AWG 50 RTN2E RT22E 32 1 43 10 3 AWG 50 RTN2G RT22G 43 1 55 10 3 AWG 50 RTN2H RT22H 55 1 65 10 3 AWG 50 RTN2J RT22H 65 1 82 10 3 AWG 50 RTN2L RT22L 82 1 97 10 1 AWG 50 RTN2M RT22M 97 1 110 10 1 AWG 50 KAR08CJ RTN3B NA 55 80 6 250 MCM 275 RTN3C RT32C 80 1 90 6 250 MCM 275 RTN3D RT32D 90 1 120 6 2...

Page 50: ...50 EVOLUTION SERIES E9000 MOTOR CONTROL CENTER ...

Page 51: ......

Page 52: ...es to keep the information up to date and correct it makes no representations or warranties of any kind express or implied about the completeness accuracy reliability suitability or availability with respect to the information products services or related graphics contained in the document for any purpose Any reliance placed on such information is therefore strictly at your own risk ABB reserves t...

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