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

Chapter 4 Maintenance

Bolt-on Fuse Removal/Installation

Tools required:

3/8-in. drive ratchet, 2-in. extension, 6-in. extension, 12-in.

extension, 1/2-in. socket, 3/8-in. drive torque wrench.

1. Remove the two lower mounting nuts, lock and flat washers from the

mounting studs.

2. Remove the upper two mounting nuts, lock and flat washers from the

mounting studs and remove the fuse from the fuse mounting studs.

3. Install the replacement fuse on the four mounting studs, hold the fuse in

place and install the upper two flat washers, lock washers and nuts.
Torque nuts to 14.5 N•m (11 lb•ft).

4. Install the lower two flat washers, lock washers and nuts. Torque nuts to

14.5 N•m (11 lb•ft).

5. If interphase barriers were previously removed ensure they are properly

reinstalled.

Clip-on Fuse Removal/Installation

Recommended tool:

Fuse extractor part # 80144-491-02 (optional)

1. Place the cup section of the fuse extractor over the top of the fuse.
2. Pull back on fuse extractor with a quick motion to dislodge the upper

portion of the fuse from top fuse clip.

3. Set fuse extractor aside.
4. Remove the lower portion of the fuse from fuse clip by pulling up and

slightly rotating the fuse in one entire movement.

5. To install the replacement fuse, place the fuse between the fuse clips.
6. Ensure that the flares on the fuse ferrules are properly located with

respect to the fuse clips.

7. Apply a rapid shove to the bottom portion of the fuse barrel to force the

fuse into the clip.

8. Apply a rapid shove to the top portion of the fuse barrel to force the fuse

into the clip.

9. Grip center of fuse barrel with both hands and apply slight back and

forward force to ensure fuse has been properly seated in the fuse clips.

10. Again check and verify that the flares at the top and bottom of the fuse

are not in the contact area of the fuse clip.

11. If interphase barriers were previously removed ensure they are properly

reinstalled.

ATTENTION:

The fuses may be hot for up to one hour after operating.

Verify the temperature before handling and use insulated hand

protection if needed. Failure to do so may result in burns.

The fuse configuration will determine what length of extension will

be required to get at the mounting hardware. The fuse

configuration will also determine what size of interphase barriers

are installed, the lower barriers can be removed to provide better

access to the fuse mounting nuts.

The interphase barriers located at the bottom of the fuse assembly

can be removed to ease the removal and installation of the fuse.

Содержание 1512B

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

Страница 2: ...assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without w...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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