USER MANUAL Bulletin 1512A 400A One-High Cabinet Standard and Arc-Resistant Enclosure

Medium Voltage CONTROLLERS USER MANUAL Bulletin 1512A 400A One-High Cabinet Standard and Arc-Resistant Enclosure

Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid-State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://literature.rockwellautomation.com describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable. In no event will Rockwell Automation, Inc. be responsible or liable for any indirect or consequential damages resulting from the use or application of this equipment. The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use, based on the examples and diagrams. No patent liability is 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 written permission of Rockwell Automation, Inc. is prohibited. Throughout this manual, when necessary we use notes to make you aware of safety considerations. W A R N I N G Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. I M P O R T A N T Identifies information that is critical for successful application and understanding of the product. A T T E N T I O N Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequences. S H O C K H A Z A R D Labels may be on or inside the equipment (for example, drive or motor) to alert people that dangerous voltage may be present. B U R N H A Z A R D Labels may be on or inside the equipment (for example, drive or motor) to alert people that surfaces may reach dangerous temperatures.

Table of Contents General Information Chapter 1 Document Scope... 1-1 Starter Identification... 1-2 Prepared Space... 1-3 Installation Standard Enclosure Chapter 2 Door Opening Procedure... 2-1 Opening the Low Voltage Doors... 2-1 Opening the Medium Voltage Doors... 2-2 Anchoring... 2-4 Joining Sections... 2-5 Access to the Power Bus... 2-6 Rear Access... 2-6 Side Access... 2-7 Front Access Top Exiting Load Cables... 2-8 Front Access Bottom Exiting Load Cables... 2-10 Load Cable Connections... 2-11 Installation Arc Resistant Chapter 3 Door Opening Procedure... 3-1 Opening the Low Voltage Doors... 3-1 Opening the Medium Voltage Doors... 3-2 Anchoring... 3-5 Joining Sections... 3-7 Access to the Power Bus... 3-8 Rear Access... 3-8 Side Access... 3-9 Front Access Bottom Incoming Cable... 3-10 Front Access Top Incoming Load Cables... 3-12 Load Cable Connections... 3-14 Common Installation Chapter 4 Bus Splicing... 4-1 Power Bus... 4-1 Insulated Power Bus Splicing... 4-3 Ground Bus... 4-3

ii Table of Contents Common Installation (cont.) Chapter 4 Incoming Line Cable Connections... 4-4 Installation of Current Transformer Barrier... 4-5 Hi-Pot and Megger Test... 4-6 Start-Up Procedure... 4-6 Contactor Inspection... 4-6 Preliminary Checks... 4-7 Testing Contactor Operation... 4-7 Typical Wiring Diagrams: Electrically Held Vacuum Contactor (Relay Control)... 4-8 Electrically Held Vacuum Contactor (with IntelliVAC Control)... 4-9 Maintenance Chapter 5 Tool Requirements... 5-1 Recommended Torque Values... 5-1 Door Interlock Circumvention... 5-2 Power Lockout Procedure... 5-3 Fuse Removal and Replacement... 5-7 Bolt-on Fuse removal/installation... 5-9 Clip-on Fuse removal/installation... 5-9 Contactor Maintenance... 5-10 Removing the Contactor... 5-11 Contactor Interlock Rod Adjustment... 5-13 To Reduce the Gap Distance... 5-14 To Increase the Gap Distance... 5-14 Isolation Switch Mechanism Inspection and Lubrication... 5-15 Isolation Switch Mechanism Grounding Adjustment... 5-18 Auxiliary Contacts Inspection and Replacement... 5-19 Auxiliary Contacts Adjustment... 5-20 Adjusting the Normally Open (ISa) Contact... 5-21 Adjusting the Normally Closed (ISb) Contact... 5-22 Adjusting the Change-of-State Point... 5-22 Emergency Circumventive Procedure for Power Cell Entry... 5-23 Installing the Z-clip with Isolation Switch Handle in the OFF Position... 5-25 Installing the Z-clip with Isolation Switch Handle in the ON Position... 5-25

Table of Contents iii Spare Parts Chapter 6 Spare Parts List... 6-1 ArcShield Unit Information Appendix A Overview... A-1 ArcShield Design... A-1 Plenum Information... A-2 Plenum Exhaust Consideration... A-3 Additional Notes... A-6 ArcShield Plenum Installation Instructions Appendix B Recommended Torque Values... B-1 Plenum Bracing... B-1 Description of Plenums and Components... B-3 General Plenum Layout for ArcShield Line-up... B-4 Step 1 Mounting a Single Plenum... B-5 Step 2 Alignment of Side-by-Side Plenums... B-7 Step 3 Sequence of Final Assembly... B-8 Step 4 Closing the Font of the Plenum Sections... B-9 Step 5 Extension and Elbow Assembly... B-10 Step 6 Mounting Extension/Elbow to Plenum Line-up... B-11 Step 7 Additional Mounting Support... B-12 ArcShield Chimney Installation Instructions Appendix C Recommended Torque Value... C-1 General Plenum Layout for ArcShield Line-Up... C-2 Cabinet Preparation... C-3

iv Table of Contents

Chapter 1 General Information Document Scope This User Manual pertains to the Rockwell Automation Bulletin 1512A medium voltage controller. The Bulletin 1512A structure provides one complete MV controller unit. The installation section provides instructions for both the standard enclosure type and the Rockwell Automation arc resistant type (ArcShield). The product Bulletin numbers covered by this document are: 1512A 200/400 A FVNR controller 1512AT 200/400 A Transformer Feeder 1512AP 200/400 A Prepared Space I M P O R T A N T This document is to be used for all Bulletin 1512A unit types, including arc resistant (ArcShield ) units. Important information specifically for ArcShield units can be found in Appendix A, B and C. A T T E N T I O N Users must refer to the information in Appendix A, B and C to correctly install and maintain ArcShield arc resistant units. Failure to do so may negate the arc resistant benefits provided by ArcShield, exposing personnel to risk of serious injury or death. This document may also be used as a reference guide for the following Bulletin numbers: 1512DM 200/400 A VFD Input Contactor Units 1512DO 200/400 A VFD Output Contactor units 1512M 200/400 A VFD Output Bypass Starter 1562E 200/400 A MV SMC Flex Solid-State (up to 4800 V) Reduced Voltage Starter 1591B Incoming Line Unit 1592BF Fused Load Break Switch for Feeders 1592BP Fused Load Break Switch for Feeders, prepared space

1-2 General Information Starter Identification A nameplate is attached to the right-side flange of the structure (see Figure 1.1). Refer to the nameplate for information such as series number, section number, NEMA enclosure type, unit ratings, and bus ratings. Figure 1.1 Typical Structure Nameplate A nameplate is also found in the low voltage compartment (see Figure 1.2) with specific unit motor application information. Figure 1.2 Typical Unit Nameplate Refer to these nameplates whenever you contact Rockwell Automation for assistance. Be prepared to provide such information as series number, structure series, unit series, diagram schematic and catalog number.

General Information 1-3 Recommended Torque Values When reinstalling components, or when reassembling the cabinet, tighten the following bolt sizes to the specified torque values: 1/4 in. hardware 6 ft lb (8 N m) 5/16 in. hardware 12 ft lb (15 N m) 3/8 in. hardware 20 ft lb (27 N m) 1/2 in. hardware 48 ft lb (65 N m) Table 1.A Torque Values for Hardware

1-4 General Information

Chapter 2 Installation Standard Enclosure I M P O R T A N T For information on the installation site preparation, see General Handling Procedures for MV Products, Publication MV-QS050_-EN-P. A T T E N T I O N Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death. Door Opening Procedure Opening the Low Voltage Doors Low voltage doors are identified as LV in Figure 2.1. 1) To access the low voltage compartment, use a flat-head screwdriver and turn both of the 1/4-turn fasteners, located on the low voltage door, 90 in a counterclockwise direction. 2) The door is now released and will swing open. 3) Reverse the procedure to secure the doors.. LV.. MV. Standard Cabinet Figure 2.1 Access to Low Voltage Compartments

2-2 Installation - Standard Enclosure Door Opening Procedure (cont.) See Access to the Power Bus, page 2-6, for the procedure to open the swing-out low voltage panel behind the low voltage door. A T T E N T I O N Medium voltage components may be located behind the swing-out low voltage panel (standard cabinets only). Complete the power lockout procedure on page 5-3 before attempting to open the swing-out low voltage panel. Failure to do so may result in severe burns, injury or death. A T T E N T I O N Complete the Power Lockout procedure on page 5-3 before beginning any service procedures to the unit. Failure to do so may result in severe burns, injury or death. Opening the Medium Voltage Doors Medium voltage door is identified as MV in Figure 2.2.. LV.. MV. Standard Cabinet Figure 2.2 Access to Medium Voltage Compartments I M P O R T A N T The medium voltage door has its own isolation switch handle and interlocking safeguards. See Access to the Power Bus, page 2-6, for the procedure to open the swing-out low voltage panel behind the low voltage door (for standard cabinet only).

Installation - Standard Enclosure 2-3 1) Electrically open the contactor by pressing the STOP button on the starter or at the remote control location. 2) Move the isolation switch handle to the OFF position. 3) Unscrew the door locking bolts for the medium voltage door. 4) The door is now released and will swing open. 5) Reverse the procedure to close the door. I M P O R T A N T Ensure that the swing-out low voltage panel is in its original position before attempting to close the MV door. When closing the medium voltage door, ensure all door locking bolts on the right side of the MV door are in place and tightened until the door is flush with the flange. Do not overtighten the bolts. If the door is not securely fastened, it will not be possible to move the isolation switch handle to the ON position. A T T E N T I O N Complete the Power Lock-out procedure on page 5-3 before beginning any service procedures to the unit. Failure to do so may result in severe burns, injury or death.

2-4 Installation - Standard Enclosure Anchoring Place the controller in the desired installation location. The floor must be flat and level. Use 4 ½ in. (M12) floor mounting bolts to securely fasten the controller to the mounting surface. See Figure 2.3 as an example of the location of the mounting holes in the cabinet. Note: Refer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan. I M P O R T A N T Pre-determined cabinets have been designed for Uniform Building Code (UBC) seismic zone 1, 2A, 2B, 3 and 4, 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 pad design, steel floor design and the sizing of cabinet anchors. Concrete floor cutouts must not be adjacent to floor anchor bolts and must be sized to seismic load. Consult factory if floor mounting must be reviewed by an accredited engineer. Many jurisdictions require an engineer from the local area to review the design. Seismic qualification does not indicate that the equipment will function properly after a seismic event. Figure 2.3 Cabinet Floor Plan NOTES FOR SEISMIC APPLICATIONS For installations on concrete the minimum depth and radius of concrete supporting the cabinet anchors is dependant on seismic loads. Refer to important information above. For installations on a metal structure the metal plate depth and cabinet anchoring method is dependant on seismic loads.

Installation - Standard Enclosure 2-5 Joining Sections (For Arc Resistant cabinets Refer to Chapter 3) Note: Joining hardware can be found in a package mounted to the front of the shipping skid. Refer to publication MV-QS050_-EN-P for level floor surface requirements. 1) Position the left side section on a level surface and secure the section in place with ½ in. (M12) floor mounting bolts (Refer to Anchoring, page 2-4). 2) When joining NEMA/EEMAC Type 12 sections, apply a continuous 1/8-in.- (3-mm-) wide bead of silicon sealer around the perimeter of one section. 3) Remove the side bus access covers if applicable. 4) Position the right section against the left section. Ensure that the surface is level. 5) Secure the sections together using the 1/4-20 self-tapping screws. Thread the screw through the 0.281 in. clearance hole to the corresponding 0.219 in. pilot hole. To access the front clearance holes of the left-side cabinet, open the medium voltage doors. To access the rear clearance holes remove the rear covers of the starter. If rear access is not available, refer to Access to the Power Bus Front Access, page 2-9. 6) Secure the right section to the floor using ½ in. (M12) floor mounting bolts (refer to Anchoring, page 2-4). Side Bus Access Cover Front Front 0.281 Clearance Holes (QTY. 3) 0.219 Pilot Holes (QTY. 5) (All dimensions in inches) Figure 2.4 Joining Sections 0.219 Pilot Holes (QTY. 3) 0.281 Clearance Holes (QTY. 5)

2-6 Installation - Standard Enclosure Access to the Power Bus A T T E N T I O N This procedure requires contact with medium voltage components. To avoid shock hazards, lock out incoming power before working on the equipment. (See Power Lockout Procedure, page 5-3). Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death. Rear Access 1) Remove the hardware securing the center rear bus access cover (Figure 2.5). 2) Remove the center rear bus access cover. 3) Once the rear bus cover is removed you will see the three bus bars (Figure 2.6). Side Bus Access Cover Center Rear Bus Access Cover Figure 2.5 Access to Power Bus from Side and Rear of Cabinet (N o n A rcshie ld) Figure 2.6 Bus Bars from Back Access

Installation - Standard Enclosure 2-7 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) Remove the side bus access cover 3) Once the side bus access cover is removed, you will see the three bus bars. (Figure 2.7) Figure 2.7 Side Bus Access Cover Removed

2-8 Installation - Standard Enclosure Access to the Power Bus (cont.) Front Access Top Incoming Line Cables 1) Complete the Power Lockout Procedure (see page 5-3) for both medium voltage power cells and the power bus. 2) Open the low voltage cell door (see page 2-1). 3) Open the medium voltage cell doors (see page 2-2). 4) Remove the two self-tapping screws from the low voltage panel if installed. (Installed for shipping purposes see Figure 2.8). 5) Use a flat head screwdriver and turn both of the ¼ turn fasteners 180 degrees in a counterclockwise direction. Turn 1/4 turn fasteners Remove Self-tapping screws Figure 2.8 Low Voltage Panel Remove self-tapping screws from bus access barriers Swing Open Low Voltage Panel Bus access barriers Figure 2.9 Access to Power Bus with Low Voltage Panel Rotated 6) Pull on right-hand side of low voltage panel. Swing low voltage panel to the front and left of cabinet (see Figure 2.9).

Installation - Standard Enclosure 2-9 Note: The power cell door must be in a fully opened position prior to rotating the low voltage panel. 7) Locate the removable bus access barriers (2). 8) Remove retaining screws from removable bus access barriers to expose incoming cable connections to main bus (see Figure 2.10). 9) Install incoming line cables to power bus, torque to specifications (see page 1-3). 10) Reverse procedure after cables have been installed. Swingout Low Voltage Panel Power Bus Figure 2.10 Power Bus with Barrier Removed A T T E N T I O N Ensure all barriers are replaced before reenergizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or severe injury to personnel.

2-10 Installation - Standard Enclosure Access to the Power Bus (cont.) Front Access Bottom Incoming Cables If the incoming cables in your cabinet enter the section from the bottom, follow the same procedure as for Front Access Top Incoming Cables. Note: Access to incoming cable duct in the power cell is also required. 1) Open the power cell door. 2) Locate incoming cable duct at rear left-hand side of power cell (see Figure 2.11). 3) Remove self-tapping screws from the cable duct access barriers. Remove barriers. 4) Route and install incoming line cables to power bus. Torque to specifications (see page 1-3). 5) Reverse procedure after cables have been installed. Cable duct access barrier Bottom incoming cable duct located in power cell Figure 2.11 Access to Bottom Incoming Line Cables A T T E N T I O N Ensure all barriers are replaced before reenergizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or severe injury to personnel.

Installation - Standard Enclosure 2-11 Load Cable Connections A T T E N T I O N To avoid shock hazards, lock out incoming power (see page 5-3) before working on the equipment. Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death. I M P O R T A N T I M P O R T A N T The current transformers may be positioned for top or bottom cable exit. Follow the appropriate procedure described for your starter configuration. Cable size should not exceed 1-750 MCM or 2-500 MCM per phase. Note: Refer to Dimensional Drawings provided with order documentation for additional details related to cabinet floor plan. 1) Complete the Power Lockout procedure (see page 5-3). 2) Remove the appropriate cable conduit opening plate(s) from the cabinet (see Figures 2.12 to 2.14). The plate may be punched or cut to mount conduit. 3) Load cables for the power cell should be routed before control cables. Pull the cables into the cabinet through the appropriate opening (see Figures 2.12 to 2.14). 4) Remove current transformer barriers. 5) Connect the cables to the current transformers and tighten the connections to 48 ft.lb (65 N.m). 6) Connect cable shields (if present) to the ground lug. 7) Reinstall the current transformer barrier and reassemble the cabinet.

2-12 Installation - Standard Enclosure Load Cable Connections (cont.) Current Transformer Power Cell Load Cable conduit opening (bottom entry) (some parts removed for clarity) Control cable conduit opening Figure 2.12 Access to Load Cable Conduit Openings (Bottom Entry) Figure 2.13 Load Cable Conduit Openings, Bottom Exit

Installation - Standard Enclosure 2-13 Route cables through access hole Power Cell Current Transformer Figure 2.14 Routing of Load Cables (Top exit shown) A T T E N T I O N Ensure all barriers are replaced before reenergizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel. ROOF PLAN 6.62 [168] 5.41 [137] Line cable conduit opening 5.68 x 9.00 [144 x 229] Load cable conduit opening 5.68 x 9.00 [144 x 229] Control wire conduit opening 3.00 x 5.00 [76 x 127] 30.00 [762] 16.04 [407] 4.65 [118] 5.68 x 9.00 [144 x 229] 5.68 x 9.00 [114 x 229] 3.00 x 3.00 [76 x 76] All dimensions are in inches [mm] 3.62 [92] Front Figure 2.15 Load Cable Conduit Openings, Top Exit

2-14 Installation - Standard Enclosure

Chapter 3 Installation Arc-Resistant (ArcShield) This installation section contains information related only to the Rockwell Automation arc resistant enclosures, referred to now as ArcShield. I M P O R T A N T For information on the installation site preparation, see General Handling Procedures for MV Products, Publication MV-QS050_-EN-P. A T T E N T I O N Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death. Door Opening Procedure Opening the Low Voltage Doors Low voltage doors are identified as LV in Figure 3.1. 1) To access the low voltage compartments for ArcShield cabinets, turn the release handle counter-clockwise. 2) The door is now released and will swing open. 3) Reverse the procedure to secure the low voltage doors. Chimney LV Low Voltage Door LV. MV Medium Voltage Door MV. Figure 3.1 Access to Low Voltage Compartments

3-2 Installation Arc-Resistant (ArcShield) Door Opening Procedure (cont.) A T T E N T I O N Complete the Power Lockout procedure on page 5-3 before beginning any service procedures to the unit. Failure to do so may result in severe burns, injury or death. Opening the Medium Voltage Door Chimney LV Low Voltage Door LV. MV Medium Voltage Door MV. Figure 3.2 Access to Medium Voltage Compartments

Installation Arc-Resistant (ArcShield) 3-3 I M P O R T A N T The medium voltage door has its own isolation switch handle and interlocking safeguards. The low voltage panel compartment and power cell are separated by an isolation barrier. A Medium Voltage door is identified as MV on the examples shown in Figure 3.2. I M P O R T A N T Failure to follow the MV door opening procedure could damage or jam the mechanical door interlocks. This could result in the mechanical interlocks not operating as intended and could result in the door becoming jammed in the closed position. 1) Electrically open the contactor by pressing the STOP button on the starter or at the remote control location. 2) Move the isolation switch handle to the OFF position. 3) Unbolt the door locking bolts for the medium voltage door. 4) Turn the black release handle counter clockwise 90 degrees (see Figure 3.3). 5) The door is now released and will swing open (The door is heavy and does take some force to swing open). 6) Reverse the procedure to close the door. This sequence must be followed. Door lock bolts must be adequately tightened. (Refer to page 1-3 for Torque Values). Note: On all ArcShield starters, the sticker in Figure 3.3 is attached to each door for your reference.

3-4 Installation Arc-Resistant (ArcShield) Door Opening Procedure (cont.) Figure 3.3 Label on Arc Resistant Door I M P O R T A N T The last step in closing the medium voltage door, ensure all door locking bolts on the right side of the MV door are in place and tightened until the door is flush with the flange. Do not overtighten the bolts. If the door is not securely fastened, it will not be possible to move the isolation switch handle to the ON position. Do not attempt to rotate the arc latching handle until the locking bolts are tightened (refer to Figure 3.3) A T T E N T I O N Complete the Power Lock-out procedure on page 5-3 before beginning any service procedures to the unit. Failure to do so may result in severe burns, injury or death.

Installation Arc-Resistant (ArcShield) 3-5 Anchoring Place the controller in the desired installation location. Use ½ in. (M12) floor mounting bolts to securely fasten the controller to the mounting surface. See Figure 3.4 and 3.5 as an example of the location of the mounting holes in the cabinet. Note: Refer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan. I M P O R T A N T Pre-determined cabinets have been designed for Uniform Building Code (UBC) seismic zone 1, 2A, 2B, 3 and 4, 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 pad design, steel floor design and the sizing of cabinet anchors. Concrete floor cutouts must not be adjacent to floor anchor bolts and must be sized to seismic load. Consult factory if floor mounting must be reviewed by an accredited engineer. Many jurisdictions require an engineer from the local area to review the design. Seismic qualification does not indicate that the equipment will function properly after a seismic event. Figure 3.4 Cabinet Floor Plan Top Entry/Exit Units

3-6 Installation Arc-Resistant (ArcShield) Anchoring (cont.) Figure 3.5 Cabinet Floor Plan Bottom Entry/Exit Units NOTES FOR SEISMIC APPLICATIONS For installations on concrete the minimum depth and radius of concrete supporting the cabinet anchors is dependant on seismic loads. Refer to important information above. For installations on a metal structure the metal plate depth and cabinet anchoring method is dependant on seismic loads.

Installation Arc-Resistant (ArcShield) 3-7 Joining Sections Note: Joining hardware can be found in a package mounted to the front of the shipping skid. Refer to publication MV-QS050_-EN-P for level floor surface requirements. 1) Remove the side bus access covers if applicable. 2) Position the left side section on a level surface and secure the section in place with ½ in. (M12) floor mounting bolts (Refer to Anchoring: ArcShield, page 3-5). 3) When joining ArcShield sections, apply a continuous 1/8-in- (3mm) wide bead of silicon sealer around the entire outer perimeter of one section AND around the cutout for the power bus. 4) Position the right section against the left section. Ensure that the surface is level. 5) Secure the sections together using the 1/4-20 self-tapping screws. Thread the screw through the 0.281 in. clearance hole to the corresponding 0.219 in. pilot hole. To access the front clearance holes of the left-side cabinet, open the medium voltage doors. To access the rear clearance holes remove the rear covers of the starter. If rear access is not available, refer to Access to the Power Bus Front Access, page 3-12. 6) Use the provided ¼-20 thread fasteners to secure the entire perimeter of the horizontal bus. Ensure there is a continuous bead of silicone seal around the bus bar opening on one cabinet. 7) Secure the right section to the floor using ½ in. (M12) floor mounting bolts (refer to Anchoring, page 3-5). Note: ArcShield units at the end of a line-up have a ground connection to the outside side bus access cover (see Figures 3.9 and 3.10). This connection must be maintained to ensure unit arc resistant performance. Figure 3.6 Joining Sections

3-8 Installation Arc-Resistant (ArcShield) Access to the Power Bus A T T E N T I O N This procedure requires contact with medium voltage components. To avoid shock hazards, lock out incoming power before working on the equipment. (See Power Lockout Procedure, page 5-3). Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death. Rear Access 1) Remove the hardware securing the center rear bus access cover (Figure 3.7). A T T E N T I O N The rear cover plates are made from 12 gauge metal and are mounted in board of the main structure. The covers will drop inside if care is not taken as you remove the mounting bolts. 2) Remove the center rear bus access cover. 3) Once the center rear bus cover is removed you will see the three bus bars (Figure 3.9). Side Bus Access Cover Center Rear Bus Access Cover (ArcShield) Figure 3.7 Access to Power Bus from Side and Rear of Cabinet

Installation Arc-Resistant (ArcShield) 3-9 Side Access A side bus access cover is located on each side of the controller, when required. 1) Remove the hardware from the appropriate side bus access cover. 2) Remove the side bus access cover (Figure 3.7) 3) ArcShield units at the end of a line-up have a ground connection to the inner plate of the side bus access cover (see Figure 3.9 and 3.10). This connection must be maintained to ensure unit arc resistant performance. Figure 3.8 ArcShield Side Bus Access Cover Warning Label Side Bus Access Cover Ground Connection Figure 3.9 Side Bus Access Cover Ground Connection (Rear Access Cover removed to show connection point)

3-10 Installation Arc-Resistant (ArcShield) Access to the Power Bus (cont) Removable Handle Figure 3.10 ArcShield Ground Plate Front Access Bottom Incoming Cables (Bottom Entry/Exit) 1) Complete the Power Lock-out Procedure (see page 5-3) for both the medium voltage power cell and the power bus. 2) Open the low voltage cell door (see page 3-1). 3) Open the medium voltage door (see page 3-2). 4) Remove the two self-tapping screws from the low voltage panel, and swing open the LV panel. (Refer to Figure 3.11). Access Door Swing Open low voltage panel Remove bolts securing this access door Figure 3.11 Removal of Access Door with Low Voltage Panel Rotated

Installation Arc-Resistant (ArcShield) 3-11 5) Remove the 24 bolts that secure the access door to the frame remove the panel (see Figure 3.11). 6) Remove the two screens at the back of the low voltage compartment (see Figure 3.12). Low Voltage Barriers Remove four screws from each low voltage barrier panel Figure 3.12 Removal of Low Voltage Barriers to Access Power Bus 7) Install incoming line cables to power bus. Torque to specifications (see page 1-3), (Figure 3.13). 8) Reverse procedure after cables have been installed. Power Bus Figure 3.13 Power Bus with Bottom Access Barrier Removed

3-12 Installation Arc-Resistant (ArcShield) Access to Power Bus (cont.) Front Access Top Incoming Cables (Top Entry/Exit) Top entry one high ArcSheild units are 36 wide versus bottom Entry units which are 26 wide. 1) Complete the Power Lock-out Procedure (see page 5-3) for both the medium voltage and the power bus. 2) Open the top medium voltage cell door (see page 3-2). 3) Open the bottom empty cell door (see page 3-2). 4) Remove retaining screws from removable bus access barriers to expose incoming cable connection to main bus (Figure 3.14 and 3.15). Retaining Screws Bus Access Barriers Figure 3.14 Removal of Low Voltage Barriers to Access Power Bus

Installation Arc-Resistant (ArcShield) 3-13 5) Install incoming line cables to power bus. Torque to specifications (see page 1-3). 6) Reverse procedure after cables have been installed. Power Bus Figure 3.15 Power Bus with Top access Barrier Removed

3-14 Installation Arc-Resistant (ArcShield) Load Cable Connections A T T E N T I O N To avoid shock hazards, lock out incoming power (see page 5-3) before working on the equipment. Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death. I M P O R T A N T The current transformers may be positioned for top or bottom cable exit. Follow the appropriate procedure described for your starter configuration. I M P O R T A N T Cable size should not exceed 1-500 MCM or 2-4/0 per phase. For larger cables, an incoming line module must be used. Note: Refer to Dimensional Drawings provided with order Documentation for additional details related to cabinet Floor plan. 1) Complete the Power Lockout procedure (see page 5-3). 2) Remove the appropriate cable conduit opening plate(s) from the cabinet (see Figures 3.16 and 3.17). The plate may be punched or cut to mount conduit. 3) Load cables for the power cell should be routed before control cables. Pull the cables into the cabinet through the appropriate opening (see Figures 3.16 and 3.17). 4) Remove current transformer barriers. 5) Connect the cables to the current transformers and tighten the connections to 48 ft.lb (65 N.m). 6) Connect cable shields (if present) to the ground lug. 7) Reinstall the current transformer barrier and reassemble the cabinet. A T T E N T I O N Ensure all barriers are replaced before reenergizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel.

Installation Arc-Resistant (ArcShield) 3-15 A B C D E F G Line cable conduit opening Load cable conduit opening Control wire conduit opening. Plenum is removed and shipped separately. Customer must install. Mounting holes for 0.50 [12] dia. anchor bolts Removable lifting angles (2 ) 1.00 [25] x 3.00 [76] non-removable sill channels. Dimensions = inches [mm] Figure3.16 Load Cable Conduit Openings (Top Exit cable configuration shown, with plenum) A B C D E F G Line cable conduit opening Load cable conduit opening Control wire conduit opening. Plenum is removed and shipped separately. Customer must install. Mounting holes for 0.50 [12] dia. anchor bolts Removable lifting angles (2 ) 1.00 [25] x 3.00 [76] non-removable sill channels. Dimensions = inches [mm] Figure 3.17 Load Cable Conduit Openings (Bottom Exit cable configuration shown)

3-16 Installation Arc-Resistant (ArcShield)

Chapter 4 Common Installation Bus Splicing Power Bus A T T E N T I O N This procedure requires contact with medium voltage components. To avoid shock hazards, lock out incoming power before working on the equipment. (See Power Lockout Procedure, page 5-3). Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death. 1) The power and ground bus splice kit can be found in a package mounted to the front of the shipping skid. I M P O R T A N T Verify that the structure series numbers on the splice kit package match the structure series number found on the cabinet nameplate (see page 1-2 for details regarding the nameplate). 2) Refer to Access to the Power Bus, page 2-6 for Standard Enclosure and Page 3-8 for ArcShield Enclosure. 3) For a 1200A power bus, assemble the splice bars as shown in Figure 4.1. Tighten the nuts to 48 ft lb (65 N m). For a 2000A power bus, assemble the splice bars as shown in Figure 4.2. Tighten the nuts to 48 ft lb (65 N m). I M P O R T A N T I M P O R T A N T Attach the bus links to the cabinet on the left side first - as viewed from the front of the unit. Always place the bus clamps on the rear side of each main horizontal bus or splice bar, as viewed from the front of the unit. (See Figure 4.1 or 4.2).

4-2 Common Installation Bus Splicing (cont.) Bus Support Main Horizontal Power Bus Bus Clamp Power Bus Splice Bar Flat Washer Lockwasher Hex Nut Figure 4.1 Typical 1200A Power Bus Splicing Configuration (Viewed from front of cabinet) Bus Support Main Horizontal Power Bus Bus Clamp Power Bus Splice Bars Flat Washer Lockwasher Hex Nut Figure 4.2 Typical 2000A Power Bus Splicing Configuration (Viewed from front of cabinet) A T T E N T I O N Ensure all barriers are replaced before reenergizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or severe injury to personnel.

Common Installation 4-3 Insulated Power Bus Splicing If the starter is equipped with insulated power bus, then a splice kit with insulated links, insulating boots and tape will be provided. Refer to the kit for installation instructions. Ground Bus 1) See Figure 4.3 to determine the correct ground splice configuration and assemble as shown. 2) Torque the hardware to 12 ft lb ± 1 ft. lb (15 N m ± 1 N m). 3) Check all hardware for correct tightness and replace all covers and plates. Hex Nut Lockwasher Flat Washer Ground Bus Splice Bar Main Ground Bus Ground Bus Support Figure 4.3 Typical Ground Bus Splicing Configuration (Front View) A T T E N T I O N Ensure all barriers are replaced before reenergizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or severe injury to personnel.

4-4 Common Installation Incoming Line Cable Connections A T T E N T I O N To avoid shock hazards, lock out incoming power (see page 5-3) before working on the equipment. Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury or death. Incoming cables are connected to the power bus in the last section on the left. I M P O R T A N T For Non-ArcShield units, cable size should not exceed 1-750 MCM or 2-500 MCM per phase. For ArcShield units, cable size should not exceed 1-500 MCM or 2-4/0 per phase. For larger cables, an incoming line module must be used. 1) Remove the center-back plate or side plate to access the power bus. If access to the rear of the unit is not possible, refer to Accessing the Power Bus for either Standard or ArcShield enclosure. 2) Connect the incoming power lines to the power bus. Torque to specifications (see page 1-3) (Figure 4.4). Power Cable Lugs Figure 4.4 Incoming Line Cable Connections Ground Bus Lug I M P O R T A N T If line cables require installation by front access, complete the incoming line connection before installing load cables. 3) Connect the ground wire to the ground bus lug. 4) Connect any external control wires to the control panel terminal blocks in the low voltage compartment. Refer to wiring diagram.

Common Installation 4-5 Installation of Current Transformer Barrier Current Transformer Barrier Figure 4.5 Current Transformer Barrier A T T E N T I O N 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.

4-6 Common Installation Hi-Pot and Megger Test Insulation integrity should be checked before energizing medium voltage electrical equipment. Use a high voltage AC insulation tester or a Megger for this test. If a Megger is used, a 5000 volt type is recommended. A T T E N T I O N Exercise caution when performing high voltage tests on the equipment. Failure to do so may result in electric shock causing severe burns, injury or death A T T E N T I O N Disconnect power factor correction capacitors (if so equipped) before performing the Hi-Pot test. Failure to do so may result in personal injury or damage to the equipment. See Power Lockout Procedure, page 5-3, for information on dissipating any stored power in the capacitors. A T T E N T I O N Remove all primary fuses for the control power transformer and/or the potential transformer. Failure to do so may cause damage to the equipment during the Hi-pot test. Insulation can be tested from phase to phase and from phase to ground. The recommended level for AC Hi-Pot testing is (2 X V LL ) volts, where V LL is the rated line-to-line voltage of the power system. The leakage current must be less than 20 ma. Record the result for future comparison testing. If a Megger is used, it should indicate 50,000 megohms or greater if the unit is isolated from the line and the motor. If the unit is connected to a motor, the Megger should indicate 5,000 megohms or greater (phase to ground). Start-up Procedure Contactor Inspection See Chapter 2 in Medium Voltage Contactor 400A, Publication 1502-UM050_-EN-P or 1502-UM052_EN-P for information on pre-energization inspection, vacuum bottle integrity test and insulation resistance test.

Common Installation 4-7 Preliminary Checks Verify the following: Contactor current and voltage ratings are correct for the attached load; Control voltage is correct; Settings for protective relays; Heater elements (if provided) in overload relay are secure and undamaged; Equipment grounding; External power and control connections match electrical diagrams; All hardware is correctly reinstalled and torqued to specifications (see page 1-3); All barriers are replaced to correct positions; All fuses are correct class, type and rating; 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. Vacuum clean if necessary; All tools are accounted for. If you cannot locate a tool, do not energize the unit until it is found. Testing Contactor Operation 1) Connect the appropriate external power supply (120 or 230 V AC) to the test receptacle in the control panel. Turn the selector switch to the TEST position. A T T E N T I O N Some control circuit configurations may require control jumpers to let the contactor close during the test procedure. Do not jumper any isolation switch contacts such as ISa or ISb (see page 5-20, figure 5.17, for the location of these contacts). Using jumpers for these contacts may result in equipment damage or injury to personnel. 2) Electrically operate the contactor several times. Inspect the armature plate to verify that it fully contacts the magnetic cores. 3) Turn the selector switch to the OFF position and unplug the test voltage. 4) Remove any metal filings or loose hardware from around the magnetic cores of the vacuum contactor. The debris is attracted to the coil once it is energized and could prevent the contactor from closing properly.

4-8 Common Installation 2400V-6900V,3Ø, 50/60Hz L1 L2 L3 GRD ISOLATING SWITCH IS DOOR INTERLOCK F1 CT1 T1 F1 CT2 T2 MTR F1 CURRENTLIMITING POWERFUSES M CT3 T3 CURRENTLIMITING PRIMARYFUSES F2 E F2 E V 500 CPT1 VA 49 OL 592 OVERLOAD 42 44 46 47 5 120 V ISa 8 X (6) (5) 7 6 OFF NORMAL TEST X (1) (2) ISb 9 (7) (8) X 10 TESTSUPPLYPOINT TS 120V 50/60Hz 11 (3) (4) X 12 32 EXTRA AUXILIARY CONTACTS G M H 33 F3 1 1 1 14 30 34 E I M M F J 2.0A F7 31 35 14A A 15 M V M-IV 1-4 EC TCO 2 + 3 B N 13 17 11 6 AUX CCO 12 5 20 L1 G STOP D 1A 2 START D M-IV 15 16 V CONTACTOR STATUS 3 M MOV C M V M-IV OL 4 9 + - 10 CLOSE D RUN D OFF 12 12 MAIN CONTACTOR(M) 36 K M L 37 LEGEND CUSTOMERWIRING D LOW VOLTAGE DOOR MOUNTEDDEVICE REMOVEJUMPER WHEN CONNECTINGREMOTE EQUIPMENT "IEEE" NUMBER FOR PROTECTI VEDEVICE REMOTEEQUIPMENT V INTELLIVACNOTES: OUTPUT RELAY CONTACTS SHO WN WITHOUT CONTROL POWERAPPLIED. THE FOLLOWING FACTORY INSTALLED CONFIGURATION/POWER-UP STATES ARE IN EFFECT: CONTACTOR STATUS-FAILSAFE MODULE STATUS -FAIL SAFE INTELLIVACTO BE PROGRAMMED/CONF IGUREDBY THE CUSTOMERBEFORESTART-UP. AUX - INTELLIVACMODULE VACUUMCONTACTOR AUXILIARY INPUT CCO - INTELLIVACMODULE CLOSINGCOIL OUTPUT EC - INTELLIVACMODULE EXTERNAL CAPACITOR INPUT M-IV - MAIN CONTACTORINTELLIVAC MODULE TCO - INTELLIVACMODULE TRIP COIL OUTPUT Figure 4.6 Typical Wiring Diagram: Electrically Held Vacuum Contactor (with IntelliVAC Control)

Common Installation 4-9 2400V-6900V,3Ø, 50/60Hz L1 L2 L3 GRD ISOLATING SWITCH IS DOOR INTERLOCK F1 CT1 T1 F1 CT2 T2 MTR F1 CURRENT LIMITING POWER FUSES M CT3 T3 CURRENT LIMITING PRIMARY FUSES F2 E F2 E V CPT 500 VA 49 OL 592 OVERLOAD 42 44 46 47 5 120 V ISa 8 X (6) (5) 7 6 OFF NORMAL TEST X (1) (2) ISb 9 (7) (8) X 10 TEST SUPPLY POINT TS 120V 50/60Hz 11 (3) (4) X 12 F3 1 REC/MOV MOV 15 + - CR1 CR1 CR2 CR2 CR2 CR2 C 15A 17A 17B 17C 19 N 17 M MOV CC BLK HC B Y Y 12 M D 20 MAIN CONTACTOR (M) CC-CLOSING COIL HC-HOLDING COIL EXTRA AUXILIARY CONTACTS A M B 13 CR2 ECONOMIZING CONTACTOR (CR2) 32 36 G M H K M L 33 37 1 1 30 34 E I M M F J 31 35 STOP D 1A 2 START D 3 CR1 OL 4 CR1 D RUN D OFF 12 MAIN CONTACTOR PILOT RELAY (CR1) D LEGEND CUSTOMER WIRING LOW VOLTAGE DOOR MOUNTED DEVICE REMOVE JUMPER WHEN CONNECTING REMOTE EQUIPMENT "IEEE" NUMBER FOR PROTECTIVE DEVICE REMOTE EQUIPMENT Figure 4.7 Typical Wiring Diagram: Electrically Held Vacuum Contactor (Relay Control)

4-10 Common Installation

Chapter 5 Maintenance Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death. I M P O R T A N T Establish a maintenance and inspection schedule for the equipment. Annual servicing, or every 20,000 operations (whichever occurs first) is the minimum recommended. Extreme operating conditions may warrant additional attention. Tool Requirements I M P O R T A N T Some components of this product incorporate Imperial hardware. Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedures on these components. If you cannot obtain such tools, contact your area Rockwell Automation sales office for assistance. Torque wrench: 0-48 ft lb (0-65 N m) Sockets: 3/8 in., 7/16 in., 9/16 in. Ratchet handle and extension Wrenches: 7/16 in., 1/2 in., 9/16 in. Feeler gauges: 0.050 in. (1.3mm) 0.080 in. (2 mm), 0.020 in. (0.5 mm) Flat-blade screwdriver Nyogel 759G Lubricant, Allen-Bradley part no. 80158-357-51 Recommended Torque Values When reinstalling components, or when reassembling the cabinet, tighten the following bolt sizes to the specified torque values: 1/4 in. hardware 6 ft. lb (8 N.m) 5/16 in. hardware 12 ft.lb (15 N.m) 3/8 in. hardware 20 ft.lb (27 N.m) 1/2 in. hardware 48 ft.lb (65 N.m) Table 5.A Torque Values for Hardware

5-2 Maintenance Door Interlock Circumvention 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 interlocking safety feature. Always disconnect and lock out incoming power (see Power Lockout Procedure, page 5-3) before proceeding with any adjustments requiring the handle to be moved to the ON (closed) position. Failure to do so may result in electric shock causing severe burns, injury or death. Some of the following sections may require moving the isolation switch handle to the ON position while the medium voltage door is open. The interlocking safeguards in the mechanism are designed to prevent the handle from moving to the ON position while the cabinet door is open. To circumvent this safety feature, use a screwdriver, or other tool, to depress the door interlock lever in the switch. Hold the lever down while moving the handle to the ON (closed) position. Door Interlock Lever Figure 5.1 - Door Interlock Lever

Maintenance 5-3 Power Lock-out Procedure Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death. Always perform the power lockout procedure before servicing the equipment. Failure to do so may result in severe burns, injury or death. The following procedure requires moving the isolation switch handle to the ON position. To avoid shock hazards, disconnect and lock out incoming power before proceeding with servicing the equipment. Failure to lock out incoming power will result in a live power cell once the isolation switch handle is in the ON position and may cause severe burns, injury or death. Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the following safety procedure prior to servicing the equipment. 1) Disconnect and lock out all feeder power supplies to the starter. 2) Move the isolation switch handle to the OFF position. 3) If the unit is equipped with power factor correction capacitors, stored energy must be dissipated before entering the power cell. Wait at least five minutes before entering the power cell or dissipate the power using the following procedure: a) Verify that the isolation switch handle is in the OFF position. b) Open the low voltage door. c) Plug the appropriate power supply (120 or 230V) into the auxiliary power receptacle on the control panel (see Figure 5.2). d) Move the control switch to the TEST position. e) Electrically 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 NORMAL position. Disconnect the external power supply. g) Complete the Power Lockout procedure

5-4 Maintenance Power Lock-out Procedure (cont.) Control Switch Auxiliary Power Receptacle Figure 5.2 Relay Control Panel (IntelliVAC control) 4) Open the medium voltage door. 5) Visually inspect that the isolation switch blades fully engage the grounding pins on the grounding bar. The isolation switch shutters should be closed (see Figure 5.3).

Maintenance 5-5 (See Detail A ) Grounding Bar Isolation Switch Blades must fully engage Grounding Pins of Grounding Bar. (Verify for each phase) Isolation Switch Shutters must be closed. (Verify for each phase) Detail A Grounding Pins Isolation Switch Blades in open position (Viewed from the back with components removed for clarification) Figure 5.3 Inspecting Isolation Switch in Open Position 6) Check the line and load sides of the contactor with a hot stick or appropriate voltage measuring device to verify that they are voltage free (see Figure 5.4). a) Check for line-side voltage at the top vacuum bottle terminals. b) Check for load-side voltage at the bottom vacuum bottle terminals.

5-6 Maintenance Power Lock-out Procedure (cont.) Check line-side power here Check load-side power here Figure 5.4 Contactor Voltage Checkpoints 7) Use the Door Interlock Circumvention procedure described on page 5-2 to move the isolation switch handle to the ON position 8) Check the isolation switch blades with a hot stick or appropriate voltage measuring device to verify that they are voltage free (see Figure 5.5). Isolation Switch Blades must fully engage Incoming Line Stabs Check incoming line voltage here Figure 5.5 Isolation Switch Voltage Check Points 9) Once all power circuits are verified to be voltage free, move the isolation switch handle back to the OFF position. The unit is now safe to service.