Installation Instructions CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Catalog Number 2500 Topic Page Important User Information 2 Location Planning 3 Environment 3 Removal of Packaging Materials 4 ArcShield Clearance Space 9 Securing a Motor Control Center 10 Securing a Column or Shipping Block 10 Splicing the Power Bus 16 Splicing the Protective Earth Conductor (PE) 21 Control and Network Cables 23 Torque Specifications 23 Additional Resources 24 Allen-Bradley Parts
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 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. WARNING 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. IMPORTANT ATTENTION Identifies information that is critical for successful application and understanding of the product. 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 consequence SHOCK HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present. BURN HAZARD Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 3 Location Planning When planning the location for your CENTERLINE 2500 MCC, consider the following: Cable entry and exit points Busways Overall height of installation area Alignment with other equipment Future needs Environment The area must be level and the environment must be compatible with the degree of protection provided by the enclosure. Environment CENTERLINE 2500 MCCs are designed to operate under the service conditions described in IEC 60439-1. Be aware that variations in temperature and relative humidity could potentially cause occasional condensation. Temperature When operating an MCC, the ambient air temperature must remain in the range of -5 40 C (23 104 F). The average temperature over a 24 hour period must not exceed 35 C (95 F). Humidity Relative humidities must not exceed 50% at the maximum temperature of 40 C (104 F). At lower temperatures, higher relative humidities are permissible. Altitude The CENTERLINE 2500 MCC is designed to operate at installation sites at altitudes up to 1000 m (3300 ft). If the altitude at your installation site exceeds 1000 m, contact your Rockwell Automation representative for derating information. Allen-Bradley Parts
4 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Pollution Degree CENTERLINE 2500 MCCs are designed for use in a pollution degree 3 environment. IEC 60439-1 defines pollution degree 3 as, conductive pollution occurs or dry, non-conductive pollution occurs which becomes conductive due to condensation. Removal of Packaging Materials ATTENTION To avoid personal injury, use caution when the motor control center is not secured. Motor control centers are top and front heavy. When the MCC has been delivered to the site of installation, remove the packaging material. Save any manuals and datasheets for future reference. Follow these procedures for removing packaging materials. 1. Remove the packing box around the horizontal bus if present and remove the four brackets as shown.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 5 2. Remove the two front and two rear bolts per shipping angle from the shipping skid. Shipping Angle (4 places) ATTENTION Once the bolts are removed from the shipping angles, the MCC is no longer secured on the skid. 3. Remove the shipping angles from the MCC. MCC may now be removed from the shipping skid. Allen-Bradley Parts
6 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Locating the Bus Splice Kits Power bus splice kits, if required, are located within a wireway or blank unit space. A fluorescent pink, removable label (on the outside of the column) designates the location. PE splice kits are located in the bottom horizontal wireway, fastened to the horizontal PE conductor. Locate the splice kits and set aside for later use. Splice Kit Label
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 7 Remove the Covers Follow these procedures for removing the covers on the MCC. 1. Remove the top and bottom horizontal wireway covers from the MCC. 2. If present, remove the top, bottom, and center end closing plates, on the sides of the two columns that are to be joined. Removal of Covers and End Closing Plates for Joining End Closing Plates Horizontal Wireway Covers Horizontal Wireway Covers ArcShield Center End Closing Plate Insulator (optional) 3. If ArcShield is present, remove the insulated horizontal bus center end closing plates. IMPORTANT Consider how cables will be routed to the MCC and plan for cable placement. For more information, refer to CENTERLINE 2500 Low Voltage Motor Control Centers Instructions, Chapter 4 - Installing Cable, publication 2500-IN001. Allen-Bradley Parts
8 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Positioning the Motor Control Center Follow these procedures for positioning your Motor Control Center. 1. Identify the left most column. TIP The horizontal power bus does not extend past the MCC of the left most column. For sequential columns, the horizontal power bus will extend past the MCC. Refer to CENTERLINE 2500 Low Voltage Motor Control Centers Instructions, Chapter 1 - Motor Control Center Sequence Numbering, publication 2500-IN001. Left Most and Sequential Columns 2. Depending on the installation site, begin with the leftmost or rightmost column and install one shipping block at a time. 3. Position the MCC in the location where it is to be installed. The surface of the floor must be level. Refer to Receiving, Handling and Storing CENTERLINE 2500 Motor Control Centers Instructions, publication 2500-IN002, for handling guidelines.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 9 ArcShield Clearance Space You need to keep clear a minimum of 1 m (3.28 ft) of space above the MCC. This provides space should the pressure relief plates vent in the event of an arc flash. ATTENTION Do not step on pressure relief plate. Stepping on plate could cause it to not work properly during arc flash. 1 m (3.28 ft) Allen-Bradley Parts
10 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Securing a Motor Control Center Documentation packages shipped with assembled MCCs include an MCC elevation drawing showing an MCC floor plan layout. To secure a column to the foundation refer to the provided floor plan layout and the following procedures. Refer to the CENTERLINE 2500 Installation Manual, publication 2500-IN001, for cable and conduit routing instructions. Securing a Column or Shipping Block Each column is arranged to allow four steel M12 bolts (minimum Property Class 8.8) to be used to securely fasten each MCC column through its internal mounting angle to the foundation. Anchor bolts (M12) may be pre-located and embedded in the foundation prior to installation. Although four mounting holes are preferred, at least one bolted connection is required in the front and rear of each MCC column. Follow these procedures for securing the MCC. 1. For IP 54 Enclosures, remove the tube of caulking (mastic) sealer from the splice kit and read the application directions on the tube. TIP For IP20, IP40, or IP42 Enclosures, no additional gasketing is required. 2. Cut the nozzle at the first notch, 3 mm (0.125 in.) from the end. 3. Apply a continuous bead of caulking, 3 mm (0.125 in.) wide, around the outside edge of the sideplate of the fixed motor control center. IP54 Sealing Caulk Location Apply 3 mm (0.125 in.) wide continuous bead of caulking sealer. Do not allow skin to form on caulking before joining the sections.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 11 4. Slide the columns together making sure cabinets are level and joining holes are aligned. 5. If lifting angles are removed from IP54 enclosures, you must seal the lifting angle bolt holes with the caulking sealer. 6. For Front-only Configured Single Column Shipping Blocks, remove the bottom horizontal wireway cover to fasten the front of the MCC to the foundation. If rear access is available, remove the back plate and fasten the rear of the MCC to the foundation as illustrated in Preferred Mounting Arrangement. If rear access is not available, fasten the first column to the foundation before moving adjacent columns into place. Preferred Mounting Arrangement Front-only Configured, Single Column Shipping Blocks 69,0 (2.72) 700,0 (27.56) 561,0 (22.09) Dimensions are in mm and (in.) Diagram illustrates 600,0 and 800,0 mm (23.62 and 31.50 in.) column depth (4) Mounting Holes 18,0 (0.71) 438,0-638,0 (17.24-25.12) 6,0 (0.24) Protective Earth Conductor 513,0-713,0 (20.20-28.07) 600,0-800,0 (23.62-31.50) 234,0 (9.2) 82,0 (3.23) 29,0 (1.14) Front 642,0 (25.28) 44,0 (1.73) 7. For Front-only Configured Two Column Shipping Blocks, remove the bottom horizontal wireway cover to fasten the front of the MCC to the foundation. Allen-Bradley Parts
12 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 8. Then remove the rear bottom horizontal wireway end closing plate and fasten the rear of the MCC to the foundation. Alternative Mounting Arrangement, Three-point Configuration Front-only configured, Two Column Shipping Blocks Dimensions are in mm and (in.) 1400,0 (55.12) Diagram illustrates 600,0 and 800,0 mm (23.62 and 31.50 in.) column depth. 29,0 (1.14) 642,0 (25.28) 58,0 (2.28) 642,0 (25.28) (6) Mounting Holes 18,0 (0.71) 438,0-638,0 (17.24-25.12) 6,0 (0.24) Protective Earth Conductor 513,0-713,0 (20.20-28.07) 600,0-800,0 (23.62-31.50) 234,0 (9.21) 82,0 (3.23) 69,0 (2.72) 561,0 (22.09) Front 138,0 (5.43) 561,0 (22.09) 44,0 (1.73)
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 13 9. For Double-front Configured, remove the bottom horizontal wireway end closing plates and fasten the MCC to the foundation using the mounting hole arrangement illustrated. Double-front Mounting Arrangement Dimensions are in mm and (in.) Diagram illustrates 600,0 (23.62 in.) column depth. 700,0 (27.56) (8) Mounting Holes 69,0 561,0 (2.72) (22.09) 18,0 (0.71) 234,0 (9.21) 438,0-638,0 (17.24-25.12) 6,0 (0.24) Protective Earth Conductor 513,0-713,0 (20.20-28.07) 1196,0-1596,0 (47.08-62.83) 156,0 (6.14) 82,0 (3.23) 438,0-638,0 (17.24-25.12) 6,0 (0.24) Protective Earth Conductor 513,0-713,0 (20.20-28.07) 234,0 (9.21) 82,0 (3.23) 29,0 (1.14) 642,0 (25.28) Front 44,0 (1.73) Allen-Bradley Parts
14 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 10. For 600 mm Deep Columns, working from the left, use the M6 x 1.0 hardware provided in the power bus splice kit to fasten the six joining holes together. IMPORTANT Do not use hardware to draw cabinets together. Joining Hole Locations 600 mm Deep M6 M6 M6 353,0 (13.90) 336,0 (13.23) Front 744,0 (29.29) M6 M6 M6 165,0 (6.50) 547,0 (21.54) 573,0 (22.56) 353,0 (13.90) 336,0 (13.23) 89,0 (3.50)
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 15 11. For 800 mm Deep Columns, first complete step 9; then, working from the left, use the M6 hex head bolt, lock washer and nut hardware provided in the power bus splice kit to fasten the two additional joining holes together. Ensure cabinets are tightly pushed together. IMPORTANT Do not use hardware to draw cabinets together. Joining Hole Locations 800 mm Deep M6 M6 M6 M6 Hex 353,0 (13.90) 336,0 (13.23) 744,0 (29.29) Front M6 M6 M6 365,0 (14.37) 747,0 (29.41) 773,0 (30.43) M6 Hex 353,0 (13.90) 336,0 (13.23) 89,0 (3.50) Refer to Torque Requirements for Hardware Connections on page 23 for torque requirements. 12. Inspect the interior for dust and dirt. Vacuum cleaning is recommended. IMPORTANT Do not clean using compressed air. It may contain moisture and may blow debris into the control equipment. Allen-Bradley Parts
16 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Splicing the Power Bus ATTENTION To prevent severe injury or death, de-energize all power sources to the MCC before joining and splicing columns. Follow local codes and guidelines in addition to the requirements of EN 50110. IMPORTANT When splicing the horizontal power bus, always begin splicing from the lowest phase busbar and work from the bottom up. IMPORTANT NOTE for NO-OX-ID Do not get any busbar corrosion inhibitor on the bus splicing hardware. It will not allow the hardware to be properly torqued. Damage may occur. Power bus consists of the main horizontal bus and neutral bus (if present). Based on the current rating of the power bus, the splice kit contains the appropriate splice bars and corresponding hardware. The following procedures describe methods for splicing power bus based on the ampere rating of the busbars. For additional splicing information related to specific MCCs, refer to the elevation drawing shipped with the MCC in the documentation package. TIP You might have to remove units and unit support pans to provide access to splice the power bus. Accessing the Power Bus Follow these procedures to access the power bus. 1. To gain access to the horizontal power bus, open the vertical wireway door to the left of the splice. 2. Identify the primary and secondary splice covers as shown.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 17 Primary and Secondary Splice Covers Primary Splice Cover Secondary Splice Cover 3. Loosen the top and bottom screws on the secondary splice cover, slide the secondary splice cover to the right, and remove the cover. The screws will remain in the wireway. Allen-Bradley Parts
18 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Remove Secondary Splice Cover Loosen the screws on the secondary splice cover. Slide the secondary splice cover to the right. Remove the cover. 4. Loosen the top and bottom screws on the primary splice cover, slide the primary splice cover to the left, and remove the cover. The screws will remain in the wireway. Remove Primary Splice Cover Loosen the screws on the primary splice cover. Slide the primary splice cover to the left. Remove the cover.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 19 Splicing Power Bus, 800 4000 A Follow these procedures to splice the power bus. 1. Assemble splice bars and hardware as shown in illustrations on pages 19 through 21. Repeat for each phase of busbar and, if present, the neutral bar. 2. Tighten hardware to torque specifications. See Torque Requirements for Hardware Connections on page 23. Do not grease or lubricate hardware. 3. Replace the horizontal bus access covers and check that the bolts and nuts are secure. 4. Replace the units and unit support pans in their respective stations if they were removed. Power Bus Splicing Configuration, 800 1250 A Standard Front Optional Four Hole Splice Allen-Bradley Parts
20 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Power Bus Splicing Configuration, 1600 2500 A Front Power Bus Splicing Configuration, 3200 A Front
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 21 Power Bus Splicing Configuration, 4000 A Front Splicing the Protective Earth Conductor (PE) The PE conductor is located in the bottom horizontal wireway of an MCC column. Up to three PE conductors may be present. To access the PE conductor, remove the bottom horizontal wireway cover. Follow these procedures to splice the Protective Earth Conductor. 1. Locate the PE splice bars. The PE splice bars are secured to the end of the horizontal PE during shipping. Allen-Bradley Parts
22 CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns Locating the PE Splice Bar Splice bars are attached. 2. Use the PE splice bars to join the horizontal PE of each column and assemble the splice bars and hardware as shown. Splicing the PE Conductor 3. Tighten hardware to torque specifications. See Torque Requirements for Hardware Connections on page 23. Do not grease or lubricate hardware. 4. Replace horizontal wireway cover and check that bolts are secure.
CENTERLINE 2500 Motor Control Centers Installing, Joining and Splicing Columns 23 Control and Network Cables When finished joining and splicing columns, make sure to connect DeviceNet and other control cables as required. Refer to CENTERLINE 2500 Low Voltage Motor Control Centers, Chapter 9 - Motor Control Center Options, publication 2500-IN001 for more information. Torque Specifications Tighten bus splice connections with a torque wrench according to the table. Torque values can be found on the information label located on the interior of the vertical wireway door or on the interior right-hand side plate of fixed units. Torque Requirements for Hardware Connections Hardware Description Incoming Line Lug Attachment Bolts M12 x 1.75 Horizontal Power Bus to Vertical Distribution Bus Connection (1) M10 x 1.5 Horizontal Power Bus Splice Connection M10 x 1.5 Protective Earth Conductor (PE) Splice Connection M6 x 1.0 Column Joining Hardware M6 x 1.0 DeviceNet Splice Cable Screws Torque 61 N m 50 N m 50 N m 7.3 N m 6.2 N m 0.55 N m (1) The factory-made horizontal power bus to vertical distribution bus connections are tightened by a computer-controlled torquing system. Allen-Bradley Parts
Additional Resources These documents contain additional information concerning related Rockwell Automation products. Resource CENTERLINE 2500 Low Voltage Motor Control Centers Instruction Manual, publication 2500-IN001 CENTERLINE 2500 Receiving Handling and Storage Instructions, publication 2500-IN002 CENTERLINE 2500 DeviceNet Motor Control Centers, publication 2500-TD002 Description Provides details about installing the CENTERLINE 2500 MCCs. Provides details about receiving, handling, and storage of CENTERLINE 2500 MCCs. Provides details about DeviceNet MCCs. You can view or download publications at http://literature.rockwellautomation.com. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. CENTERLINE, Allen-Bradley, and Rockwell Automation are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. 24 Supersedes Publication 2100-IN049A-EN-P - May 2001 PN-35320 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.