GE ReliaGear LV MCC Installation, Operation And Maintenance Manual Download Page 3

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Safety measures and

classifications

– 06

Introduction

– 09

Receiving, handling and storage

– 33

Installation

– 35

Testing and inspection

– 37

Operation

– 39

Maintenance

– 41

Reference document numbers

– 54

Overload heaters

Table of contents

Summary of Contents for ReliaGear LV MCC

Page 1: ...INSTALLATION OPER ATIONS AND MAINTENANCE MANUAL ReliaGear LV MCC Low voltage motor control center ...

Page 2: ......

Page 3: ...lassifications 05 06 Introduction 07 09 Receiving handling and storage 10 33 Installation 34 35 Testing and inspection 36 37 Operation 38 39 Maintenance 40 41 Reference document numbers 42 54 Overload heaters Table of contents ...

Page 4: ...ontained herein does not cover all details or variations in hardware and software nor does it provide for every possible contingency in connection with installation operation and maintenance Features may be described herein that are not present in all hardware and software systems ABB assumes no obligation of notice to holders of this document with respect to changes subsequently made ABB makes no...

Page 5: ...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 the doors...

Page 6: ...horizontal ground bus sized in accordance with the National Electrical Code is provided near the bottom of all motor control centers 02A 02B 02A Horizontal bus with Lexan barrier 02B 2500A without fans 3000 3200 A main horizontal bus An optional vertical ground bus can be provided in each section providing additional grounding A neutral bus is provided when specified in the bottom of the incoming ...

Page 7: ...ardboard carton and the carton secured in an empty MCC compartment Inspecting for damage All equipment leaving the factory is carefully inspected and pakced by personnel experienced in the proper handling and packing of electrical equipment Upon receipt of any equipment immediately perform a visual inspection to ascertain if any damage has been sustained in shipping or if there are any loose parts...

Page 8: ...ables and the crane hook Connect a cable from the crane to the Two four lifting plates located on the top front rear of the MCC as shown in fig 03 Observe the following points when lifting the equipment Do not pass cables or ropes through support holes Always use load rated inspected and approved shackles or safety hooks to attach hoisting equipment to the lifting points Rig slings so that the leg...

Page 9: ... equipment with a forklift positioned in the front or rear of the equipment 3 Raise equipment and position one roller under the skids close to the raised end of the line up 4 Carefully lower the gear until it rests on the roller as shown in fig 07 5 Repeat the lifting process at the other end and place the appropriate number of the rollers under the skids spacing them evenly across the width of th...

Page 10: ... will have been predetermined during the specification and or procurement of equipment phases Indoor locations with buildings impose certain requirements which must be met so that the MCC may operate efficiently with a minimum of maintenance In locating the MCC adequate aisle space must be provided at the front and rear of the equipment to ensure proper ventilation of the euipment and to allow ser...

Page 11: ... 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 399 5 mm 381 0 mm 450 3 mm 381 0 mm 525 3 mm 08 08 Front elevation of feeder section 09 Bottom view Location of mountin...

Page 12: ... 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 mm 221 1 mm 304 8 mm 399 5 mm 304 8 mm 450 3 mm 304 8 mm 525 3 mm 304 8 mm 653 5 mm 30 15 00 ...

Page 13: ...y zone Optional zone splice bolt acces Restricted zone splice bolt acces Restricted 6 feeders wireway zone 3 Bolts must extend a minimum of 2 11 32 inch above grade to 3 4 inch above the channel sill If 13 330 2mm deep verical sections are used anchor bolts or some form of external bracing is required 2 Seismic IBC testing was performed use 1 2 13 Grade 5 bolts torqued to 50 foot pounds located in...

Page 14: ...ow bus position 18 Bottom conduit entrance details for standard 13 nch deep section bus upper position 15 Top conduit entrance details for std 20 x 30 3 channel Note Bottom rear entrance should only be used with full rear accessibility A 5 129 Front Spacer shell transition from 30 to 20 22 25 deep section Section depth 20 22 25 depth 30 00 762 0 NOTICE NOTICE A Removable top cover plates Available...

Page 15: ...500A without fans 3000A and 3200A main bus configurations 24 Neutral Ground bus positions for 2500A without fans 3000A and 3200A main bus configurations 23 24 Ground bus 1 50 38 1 3 00 76 2 Neutral bus If space heater is specified with 6 lower wire way use top entry only 1 50 38 1 3 00 76 2 6 00 152 4 Neutral bus Ground bus Space heater if specified Front 21 Ground bus 3 00 76 2 Neutral bus If spa...

Page 16: ...ment 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 extend a minimum of 2 11 32 above grade to 3 4 above the channel sill If 13 330 2mm d...

Page 17: ...distance from the face of the equipment Table 110 26 a provides requirements for clearances away from the equipment based on the circuit voltage to ground and whether there are grounded or ungrounded objects in the step back space or if there are exposed live parts across from each other The voltages to ground consist of two groups 0 to 150 and 151 to 600 inclusive Remember where an ungrounded sys...

Page 18: ...f standard sections Refer to drawings for deviations on specific installations Note Top rear entrance should only be used with full rear accessibility 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 17 56 24 24 21 56 30 30 27 56 3 ft Exposed live parts Electric equipment 150V...

Page 19: ...35G38SM 3 2 5x4 100K 110C2357 N3R and spacer shells 600 110C1735G14SM 1 1 4x2 65K 110C1258 800 110C1735G15SM 1 3 8x2 65K 110C1256 1200 110C1735G16SM 1 1 2x2 100K 110C1253 1600 2000 110C1735G17SM 2 1 2x2 100K 110C1263 2500 110C1735G13SM 2 1 2x2 100K 110C1763 2500 3200 110C1735G39SM 3 2 5x4 100K 110C2357 Table 1 Torque values for various bolt sizes and joint types included in kits Table 2 Bus splice...

Page 20: ...out 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 thread rolling screws Figure 35A 34 35 Notes 1 3 inch floor members can be installed similarly to standard MCC floor members Figure 35D 2 Module doors can be removed by removing 1 4 20 x 3 8 thread...

Page 21: ...n for UL type 12 enclosure NOTICE Note For details on inlet filter maintenance see filter maintenance in Chapter 5 Filter Assembly UL Type 12 Fan Assembly Arc resistant VFD Fan Shield Exhaust fan installation for UL type 12 enclosure venten fan shields 40 Fan Assembly Top Rear Cover Location Exhaust fans if required are delivered to the installation site as a separate shipping item Fans must be un...

Page 22: ...ntal 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 Warning The equipment must be adequately grounded so that all parts of the equipment other than live parts are at ground potential Failure to observe this precaution can result in seri...

Page 23: ...ection is available cables can be brought into the space behind the vertical bus and brought forward into the front wire trough area through any of the modular openings in the right hand steel support plate Wiring NEMA type A motor control centers Use the following procedure to wire NEMA Type A MCCs 1 Remove black plastic barrier closest to unit connection points and remove knockouts as required 2...

Page 24: ...pecified 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 Route the wiring to avoid interference with moving parts and to keep it away from heat producing components such as resistors and fuses 6 Verify that the...

Page 25: ...inch 19 9 15 0 24 3 2 4 Three phase split bus 48 If rear access is used a rear main bus barrier is a required option If 2500A without fans 2500A Type 12 3000A or 3200A main bus configurations are used 3 of clearance between back of MCC and wall is required CAUTION WARNING Terminal blocks The terminal blocks are mounted on a metal rail located at the bottom of the unit as shown in Figure 49 The ter...

Page 26: ... 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 ...

Page 27: ...rtent 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 52 and Figure 53 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 closed ...

Page 28: ... in Figure 57 The handle can then be rotated up and out of 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 26 for sugges...

Page 29: ...lly close the door as shown The pilot device bracket in is locked in place using the door mounted locking bracket shown in Figure 61 Pilot device brackets and standard buckets for ReliaGear LV MCCs utilize a plastic Wpilot device bracket Door closing procedure of pilot device bracket extension bubble door for some ACS 580 drives ReliaGear MCC units Variable Frequency Drive Extension Bubble 62 63 P...

Page 30: ...er to its intended compartment location observe the following precautions Precautions 1 Check the compartment to ensure that it is free of foreign objects 2 Verify that the breaker is the correct type for that compartment 3 Ensure that the breaker is OPEN 4 Apply a thin fresh coat of lubricating grease to the breaker s primary disconnects 5 Ensure that the position indicator on the circuit breaker...

Page 31: ...s Description ELD3E242 3 E2 2 or E4 2 lifting beam TDOLB 3 PB II lifting beam WARNING 8 Move the breaker into the compartment to the DISCONNECT position If an incorrect breaker has been instaled the interference pins on the breaker will interfere with the rejection pins in disconnect position 9 Slide rails back into compartment Close the compartment door and rotate latch 4 turn counter clockwise 1...

Page 32: ...o move to the DISCONNECT position if the breaker s mechanism s spring is in the Charged state To discharge the energy 4 Attach the breaker lifting plates the lifting beam and lifting device securely and raise breaker off draw out rails 5 Push the draw out rails back into the compartment 6 Pull the breaker forward until the primary disconnects clear the compartment 7 Lower the breaker onto a flat s...

Page 33: ... catalog number TRTOOL 72 Pilot light and pushbutton removal tool catalog number GEN 1684A 73 EntelliGuard trip unit digital test kit catalog number GTUTK20 74 Ekip TT testing power supply kit 75 Ekip T P kit 76 Manual racking handle catalog number 110C2073G1 77 Remote racking device catalog number 190B3523G1 71 72 73 74 75 76 77 Rearrangement of units must follow the following loading rules 80 of...

Page 34: ...n accordance with the owner s established procedures Refer to the key interlock schematic included in the summary furnished with the equipment to determine the sequence of operation and the correct number of operating keys required This precaution is necesarry since the improper use of spare keys will defeat the interlocking scheme Breaker operation test All compartments housing PBII Emax 2 circui...

Page 35: ...nnection and testing When ground fault protection is provided all field connections must be made correctly to insure proper functioning of the ground fault protection system Observe the following rules when connecting and testing ground fault protection systems as illustrated in Figures 45A 45B 45C 45D NOTICE As per NEC 230 95 C the ground fault protection system shall be performance tested when f...

Page 36: ...owing information regarding instantaneous trip settings on magneticonly circuit breakers 7 Check all 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 indicati...

Page 37: ...ming 8 Adjust instantaneous settings on magnetic only circuit breakers and or fuse sizes and overload heater selections to achieve proper motor and branch circuit protection See NEC Article 430 52 Since the adjustable trip setting on magnetic only circuit breakers is factory set at the minimum trip position nuisance tripping may occur on initial motor starting Increase the trip setting in incremen...

Page 38: ...unit wiring for deterioration of insulation and tighten all connections 8 Visually check 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 design...

Page 39: ...g procedure to replace the starter 1 Turn the power off 2 Remove the saddle unit for the motor control center 3 Remove the pilot device bracket it is not required to remove control wiring 4 Remove overload relay 5 Use DIN rail release to gain access to line side wiring of contactor remove line wires 6 Reverse to install new starter Arcing damage to insulation Some organic insulating materials carb...

Page 40: ...ACS580 04 drive modules hardware manual R10 R11 3AXD50000044838 ACS580 01 drives frames R1 to R5 quick installation and start up guide 3AXD50000009286 Quick installation guide ACS580 04 drive module R10 R11 3AUA0000085685 AXx Ap x Assistant control panels user s manual 3AUA0000094606 Drive composer PC tool user s manual 3AFE68615500 FCAN 01 CAN open adapter module user s manual 3AUA0000141650 FCNA...

Page 41: ...ternational building code CBC 2019 California building code Renewal parts Because of the variety of components furnished in the ReliaGear LV MCC motor control center the suggested spare parts will vary You should consider maintaining an adequate supply of the following components as spares Overload heaters Power and control circuit fuses Replacement starter contact kits Starter coils Pilot lights ...

Page 42: ...aced 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 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Motor Full Load Amps 3 Ph 3 Heater ...

Page 43: ...614B 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 0 F39...

Page 44: ...7 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 ...

Page 45: ...1 1 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 F...

Page 46: ...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 47: ...3 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...

Page 48: ...70 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 49: ... 2 5 291 346 C356A 800 LO 4 347 387 C379A 800 LO 5 388 423 C419A 800 2 5 424 467 C466A 1000 LO 4 468 516 C526A 1000 2 4 517 540 C592A 1000 2 5 Motor Full Load Amps 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 C379...

Page 50: ...25 7 21 8 22 C867A 30 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Maximum Fuse Rating 17 2 18 1 C198B 60 18 2 20 0 C214B 60 20 1 21 5 C228B 60 21 6 22 5 C250B 60 22 6 23 9 C273B 60 24 0 26 3 C303B 60 26 4 27 0 C330B 60 Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Maximum Fuse Rating 5 48 5 85 C630A 20 5 86 6 47 C695A 20 6 48 7 35 C778A 25 7 36 8 06 C867A 30 8 07 9 03 C955A 30 ...

Page 51: ... 0 F658B 200 52 1 55 4 F719B 200 55 5 63 3 F772B 200 63 4 66 1 F848B 200 66 2 73 5 F914B 200 73 6 82 2 F104C 200 82 3 90 0 F114C 200 Size 1 Standard and Ambient Comp Size 3 Ambient Comp Motor Full Load Amps 3 Ph 3 Heater Heater Number CR123 Maximum Fuse Rating 27 1 32 2 F357B 110 32 3 34 0 F395B 125 34 1 36 8 F430B 125 36 9 44 6 F487B 150 44 7 48 4 F567B 175 48 5 53 9 F614B 175 54 0 57 4 F658B 200...

Page 52: ... C151B 600 Maximum Motor Full Load Current Current Transformer Secondary 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 NEMA Size FLA Range in Amps Catalog N...

Page 53: ...urnout occurs the complete overload relay must be replaced Catalog numbers of electronic overloads for various sizes of NEMA starters and current ranges NEMA Size FLA Range in Amps Catalog Number Breaker Frame and Type 1 0 8 to 1 59 CR324CXD E Mag and Thermal Mag 1 1 6 to 3 19 CR324CXE E Mag and Thermal Mag 1 3 2 to 6 49 CR324CXF E Mag and Thermal Mag 1 6 5 to 12 8 CR324CXG E Mag and Thermal Mag 1...

Page 54: ...o 135 CR324FXM 5 32 to 64 0 CR324GXN 400 600 5 65 to 129 9 CR324GXP 5 130 to 270 CR324GXQ 6 130 to 259 9 CR324HXS 600 Class L 1200 IEC style overload relays C2000 contactor CLNCJ type RT overload relay for 1 2X starter Current Range Max CB Cat No Class Cat No Class Lug Wire Size Torque in lbs 0 4 65 15 RTN1D 10 RT12D 20 14 8 14 20 0 65 1 1 15 RTN1F 10 RT12F 20 14 8 14 20 1 1 5 15 RTN1G 10 RT12G 20...

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Page 56: ...rives 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 reserve...

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