CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch

Instructions CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch CENTERLINE 2100 Motor Control Centers Introduction The intent of this publication is to provide field instructions for connection, operation, and service of the 600A, 800A, or 1200A Bolted Pressure Contact Switch (BPS) used in the CENTERLINE 2100 motor control center (MCC) sections. The BPS is supplied from the factory in a frame mounted design construction as an MCC main fused disconnect, an MCC main non-fused isolation switch, a motor control unit disconnect, or a feeder disconnect. Being a factory frame mounted design, the BPS unit is not intended to be field installed within an MCC section, nor is there a plug-in design available. Also, the BPS is either a top cable design (cables entering or exiting from the top of the BPS) or bottom cable design (cables entering or exiting from the bottom of the BPS). The following publications may be useful: CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012, which is supplied with the MCC. The unit wiring diagram supplied with the MCC unit. To prevent injury or death to personnel installing or servicing the switch, disconnect the motor control center remote power source(s) so that no power is present. 1

2 CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch Instructions Installing Cable 1. Refer to the CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012 supplied with the MCC and turn to the section entitled, Installing Conduit and Cable. The cables, cable connectors, and cable bracing should be matched for the application (e.g., conductor size and type, temperature requirements, short circuit requirements, bracing requirements, code requirements, etc.). 2. Remove the terminal guard assembly as follows: For top cable design See Figure 1. Loosen the three top guard screws (do not remove these screws). Lift the assembly off. Be careful that the assembly is not damaged because it must be replaced and is essential for proper operation of the switch. Top guard screws Arc chutes Bottom guard screws (reference only; not shown) Figure 1 BPS front view (guard screw locations) For bottom cable design Reference Figure 1. Remove the two bottom screws holding the terminal guard assembly (do not lose these screws they will be needed later). Unhook and lift off the assembly. Be careful that the assembly is not damaged because it must be replaced and is essential for proper operation of the switch.

CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch 3 3. Remove the connectors from the switch. For compression lugs: following the cable connector manufacturer s instructions, install the connectors onto the cables. For mechanical lugs: follow the torque specification supplied on the wiring diagram. Note: Guidance is also provided in the CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012. The terminal connector hole pattern is per the NEMA hole spacing standard or 44.5 mm (1.75 in.). 4. Support, position, and form the cables to line up with the terminals of the BPS. IMPORTANT The cables must be properly aligned and should not cause BPS terminals to be skewed. If the cables are not supported or aligned, the weight/force from the cables can act as a lever, causing the terminals to be twisted out of alignment. Proper alignment of BPS terminals is critical for the operation of the switch. IMPORTANT Be careful not to disturb or dislodge the arc chutes. This could cause interference with the operation of the contact blades. See Figure 1. 5. Install the connectors using the hardware supplied. Tighten the hardware to the specified torque requirement as listed on the unit wiring diagram. Note: Guidance is also provided in the CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012. TIP In order to access the hardware for tightening, it may be necessary to use a crow s foot attachment in conjunction with the torque wrench. If a crow s foot attachment is used, no torque value adjustment is required for the small increase in length due to the crow s foot (i.e., use the torque values provided). An example of this operation is shown in Figure 2.

4 CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch Figure 2 Use of crow s foot crow s foot TIP Individually mark each piece of hardware once its torque has been checked. 6. Replace the terminal guard assembly (reverse the instructions in step 2). To prevent injury or death to personnel operating the switch, make sure that the terminal guard assembly is installed. The terminal guard or hood must be in place for proper operation of the switch. 7. Inspect the BPS and the cable installation. Operate the switch two or three times to check that it is functioning properly and has not been adversely affected by the installation. 8. Install fuses (if required) using the hardware supplied. Remember to individually mark each piece of hardware once its torque has been checked. Consult the unit wiring diagram for the hardware torque requirements. Door Interlock Check The door interlock catch was adjusted at the factory and should not require adjustment. However, due to shipping, handling, or installation of the MCC, this catch may need to be adjusted. A quick check should be conducted to see if the door interlock is operating properly (i.e., with the switch closed, the door must be able to close and once the door is closed, the interlock must prevent the door from being opened). Carry out the door interlock check as follows:

CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch 5 1. With the door open, close the switch. 2. Slowly close the door. The door should close fully and without difficulty (there will be an indication of the interlock operation just as the door becomes fully closed). If the door closes without difficulty, the interlock catch is adjusted properly for closing. If the door will not close due to interference, the door interlock catch is out of adjustment and must be readjusted. The door interlock catch is a small bracket mounted on the inside of the door and held on by two screws. To adjust, loosen the screws and slide the door interlock catch downward a small amount, until the door can be closed. Retighten the two screws. Torque to 7.4 Nm (55 lb.-in.). 3. With the BPS in the ON position and the door closed, attempt to open the door (do not use force or jerk the door). The door interlock should prevent the door from opening (the door will open only a slight crack). If the door is prevented from opening, the interlock catch is adjusted properly. If the door can be opened, the door interlock catch must be readjusted. To adjust the catch, angle similar to step 2 above, but slightly slide the door catch upward until the door is prevented from opening. Inspection after Installation Refer to the CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012, supplied with the MCC. Look specifically at the sections entitled, Final Checklist before Energizing and Energizing Equipment. The remote power source(s) to the motor control center may be reconnected and the BPS can be placed into service. Inspect the BPS and the installation. Points of inspection should include the following: Terminal guard assembly has been replaced and the three terminal guard screws have been tightened. All connector hardware has been tightened to the required torque specifications. BPS terminals are aligned with contact blades. Contact blades mate and close correctly. The arc chutes have not been inadvertently moved and do not interfere with the operation of the contact blades. Door interlock functions properly. Start-up checks have been performed.

6 CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch Switch Operation Refer to the CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012, supplied with the MCC, especially the section entitled, Operator Handle and Unit Interlock. Operation, locking off, and other details are similar for all CENTERLINE 2100 disconnects and for the BPS. This information can be found in the aforementioned MCC instruction manual. In addition to the position of the handle, a separate indicator shows the condition of the BPS. This indicator appears behind a window just below the handle bearing. See Figure 3. Figure 3 BPS indicator If the indicator shows ON/I, the BPS contacts are closed. If the indicator shows OFF/O, the contacts are open. However, should the handle be in the OFF/O position and the indicator shows ON/ I or visa versa, the BPS may be incorrectly installed or a malfunction has occurred. IMPORTANT If false or inconsistent contact indications occur, remove the power feeding the BPS. Check for voltage. Carry out cautionary steps (e.g., checking the contact position, operation, and condition of the switches). To prevent injury or death to personnel servicing the switch, disconnect the motor control center remote power source(s) so that no power is present.

CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch 7 On some BPS designs, there is a viewing window feature on the unit door so that by looking through the door window, the BPS contact status can be verified by checking the position of the visible contact blades. See Figure 4. Figure 4 BPS viewing window Switch Service Service the switch by following these maintenance and lubrication guidelines. Maintenance information Inspection of the BPS is recommended at least once a year. In general, most electrical equipment maintenance literature recommends establishing a maintenance inspection period. This period depends on operating conditions (e.g., what the electrical equipment is servicing [critical, process, harmonics etc.]; the duty cycle [number of operations, load, type of load, etc.]; and the environment [high temperature, dirty conditions, chemical atmosphere, etc.]). For example, an inspection period may start out on an annual basis, but, over time, the period may need to be shortened or lengthened, depending on the operating conditions and the resulting condition of the equipment. If the BPS has been operating in a dirty, highly corrosive, or caustic environment, the switch may become overheated or damaged. If the disconnect is overheating or operated beyond its operational life, mechanical as well as electrical wear and damage may occur. In either case, it may be necessary to replace the BPS. Minimum operational life expectancies per NEMA and Underwriters Laboratories standards are as follows:

8 CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch 600A BPS = 5,000 operations 800A BPS = 3,500 operations 1200A BPS = 2,500 operations Note: For more information on BPS temperature analysis, refer to Service and Repair Guidance for CENTERLINE Low Voltage Motor Control Center Units, publication 2100-TD028. Follow NFPA 70E safety guidelines when working on energized equipment. To prevent injury or death to personnel lubricating disconnect switch contacts, make sure the motor control center power source(s) is disconnected and the respective disconnect(s) is locked in the OFF/O position. For plug-in units, remove the unit from the motor control center. To prevent personal injury or damage to equipment, make sure that the unit handle operator is in the OFF/O position before removing the unit. A complete inspection of the device should always be made: After the BPS has interrupted a ground fault, or has been involved in an incident that caused one or more of the fuses to blow. If overheating is observed. Verify that the switch blades and crossbar close fully and that the joint has been bolted properly. Verify that the switch and the connecting bus (or cable) are properly sized for the load current. For switches requiring ventilation, verify that the vents are open and adequate in size. In some cases, overheating can be a result of severe conditions not easily observed, such as harmonics. A knowledgeable electrical professional may be needed to identify the cause of the problem and offer solutions. At regular inspection periods, the BPS should be operated without power connected. Check for proper function and freedom of movement (no sticking or binding) for the disconnect handle operating and defeater mechanisms. Replace broken, deformed, malfunctioning or badly worn parts or assemblies. Check to see that the blades close and open fully. The blades should be vertical when the switch is closed, and rotate approximately 45 degrees upon opening. Clear separation between the blades and jaw contacts should be observed when the switch is open. Also observe the rotation of the crossbar to verify that it travels completely. On most switches, the crossbar rotates approximately 90 degrees.

CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch 9 When the switch is closed, the crossbar should be in a vertical position, near or touching the blades. When the switch is open, the crossbar should be in a horizontal position. Arc quenchers should be inspected for cracks in the molded sides and excessive erosion of the steel plates. A damaged BPS switch may need to be replaced. Switch lubrication Should it be determined that the BPS needs lubrication, the following instructions apply: 1. Turn off the power source(s) to the MCC. To prevent injury or death to personnel servicing the switch, disconnect the motor control center remote power source(s) so that no power is present. 2. Obtain NO-OX-ID compound lubricant, catalog number 2100H-N18 for a 0.47 liter (1 pint) can or 2100H-N18T for a 29.5 ml (1 ounce) tube. To obtain lubricant, contact your local Rockwell Automation sales office or Allen-Bradley distributor. Use only NO-OX-ID lubricant. Do not use a substitute lubricant. The switch may malfunction or arc if an electrically conductive grease (e.g., graphite grease conductor termination compound) is used. 3. Turn off the BPS. 4. Remove the terminal guard assembly. Follow the instructions in step 2 of Installing Cable. 5. Remove the BPS clear cover by removing the eight cover screws. Refer to Figure 5. IMPORTANT Be careful not to lose these screws because this clear cover must be replaced and is essential for proper operation of the switch.

10 CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch Figure 5 Cover screw locations 6. See Figure 6. The contact blades can be swung down for better access. To swing the contact blades down, rotate the contact lever as shown by arrow 1 in Figure 6. Swing the contact down as indicated by arrow 2. IMPORTANT Be careful not to disturb or dislodge the arc chutes this may cause interference with the operation of the contact blades. Refer to Figure 1. Figure 6 Contact rotated for servicing 7. Inspect the contact blades and the stationary contact. Use a dry, clean cloth and Scotch Brite pad to remove old lubricant and clean off dirt and grime. Do not use compressed air to clean the switch. If the contact blades or stationary contacts are damaged or show signs of overheating, the BPS should be replaced.

CENTERLINE 2100 Motor Control Centers 600A, 800A, and 1200A Bolted Pressure Contact Switch 11 Brass nut with Allen screw Figure 7 Contact (center pole), rotated for inspection and servicing 8. Generously apply the NO-OX-ID compound (enough to cover with a noticeable film) to the cleaned inside movable contact blades and the cleaned sides of the stationary contacts. Also apply the compound to the hinge area (between the blades and the stationary hinge). Work the compound into the hinge point by rotating the contact blades several times. Do not loosen or disassemble any of the large brass contact blade nuts. Do not readjust these nuts or loosen the small Allen head set screw. Refer to Figure 7. The brass contact nuts are factory adjusted and must not be loosened or tampered with. If the brass nut is tampered with, the switch can malfunction and cause these nuts to be out of adjustment. 9. Lubricate the BPS Linkages (they operate the bolts on the Movable Blades) with light machine oil. Do not mix the light machine oil with the previously applied NO-OX-ID compound. Do not apply the light machine over the previously applied NO-OX-ID compound. 10. Refer to Figure 6. Return the contact blades to their original operating positions by rotating the contact blades (reverse the procedure in step 6 of this section). An audible click will be heard when the contacts have been returned to their original positions. 11. Re-install the BPS clear cover with the eight cover screws that were removed in step 5 of this section.

IMPORTANT This cover must be in place for proper operation of the BPS. The BPS cover must be in place for proper operation of the switch. Should the switch be operated without this cover in place, a phase-to-phase fault may occur. 12. Replace the terminal guard assembly (reverse the operation in step 2 of Installing Cable on page 2). To prevent injury or death to personnel, make sure that the terminal guard or terminal guard hood is installed. The terminal guard or hood must be in place for proper operation of the switch. 13. Inspect the BPS. With power off, operate the switch two or three times to check that it is functioning properly and has not been adversely affected by the switch maintenance. Points of inspection: BPS cover has been replaced and the eight screws have been properly tightened. Terminal guard assembly has been replaced and the three terminal guard screws have been tightened. Contact blades mate, close, and bolt correctly. The arc chutes have not inadvertently been moved and do not interfere with the operation of the contact blades. 14. Refer to the CENTERLINE 2100 Low Voltage Motor Control Centers Instruction Manual, publication 2100-IN012, supplied with the MCC. Look specifically at the sections entitled, Final Checklist before Energizing and Energizing Equipment. The remote power source(s) to the motor control center may be reconnected and the BPS can be placed into service. Allen-Bradley, CENTERLINE, CENTERLINE 2100 and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. PN-25164 12 Supersedes Publication 2100-IN049A-EN-P - May 2001 Copyright 2008 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.