May, 1992 Instruction Manual 89981M9101R5/92, Motor Control Center Installation and Maintenance Manual For Equipment Manufactured After May 18,1992 Class 8998 Control Products Service Bulletin for Installation and Maintentance WARNING: Before installation or maintenance this equipment must be de-energized to prevent electrical shock or burn, personal injury or property damage. SQUARE D COMPANY Dedicated to Growth » Committed to Quality‘TABLE OF CONTENTS. ‘GENERAL, SECTION G PAGE INTRODUCTION Gt 3 DESCRIPTION G2 3 PACKAGING 63 3 INSPECTION Ca 3 STORAGE Gs 4 HANDUNG G6 4 INSTALLATION SECTIONT PAGE LOCATION, HW 3 JOINING SECTIONS 2 5 POWER BUS SPLICING HB 2 GROUND BUS SPLICING Ha 10 ‘CONDUCTOR ENTRY 16 " LOAD AND CONTROL WIRING 1168 WL PREOPERATIONAL CHECK LIST t 2 ENERGIZING EQUIPMENT 8 2 PADLOCK PROVISIONS 9) 2 ADVANCE/RETRACT MECHANISM 120 8 STANDARD MOTOR CIRCUIT PROTECTOR (MAG-GARD) CIRCUIT BREAKER. [APPLICATION INFORMATION bas “4 FUSE CLIP LOCATION 124 4 MAINTENANCE SECTION M PAGE ENCLOSURE M2 5 ‘BUS BARS AND INCOMING LINE COMPARTMENTS Ma 15 UNITS wa 7 ‘CONTROL UNIT LOCKOUT Maz 7 UNIT REMOVAL Maz, 18 INSULATION TEST M40) 2 (MAINTENANCE AFTER A FAULT HAS OCCURRED M42 24 EXPANSION SECTIONE PAGE ORDERING INFORMATION, £2 25 INSTALLING ADDITIONAL MOTOR CONTROL CENTER UNITS 3 25 INSTALLING ADDITIONAL MOTOR CONTROL CENTER SECTIONS, E16. 28 ‘APPENDIX, SECTION A PAGE SQUARE D LITERATURE LIST At 23 MOTOR CONTROL TROUBLE-REMEDY TABLE AZ 3031 (CIB STARTER UNITS - MELTING ALLOY OVERLOADS AS 32 iS STARTER UNITS - MELTING ALLOY GVERLOADS Ad 33 ‘CUB STARTER UNITS - BIMETALLIC OVERLOADS AS; 34 FS STARTER UNITS - BIMETALLIC OVERLOADS AS 35 (CIRCUIT BREAKER AND FUSIBLE SWITCH SELECTION TABLES Az 36 ‘OFFSET HORIZONTAL BUS SPLICING INSTRUCTIONS A 7 SPLICING NEMA 3R ENCLOSURES Ag 38 (C78 PART WINDING STARTER UNITS - MELTING ALLOY OVERLOADS Ai0 39 IS PART WINDING STARTER UNITS - MELTING ALLOY OVERLOADS Aa 40 (C18 PART WINDING STARTER UNITS - BIMETALLIC OVERLOADS Anz a IS PART WINDING STARTER UNITS - BIMETALLIC OVERLOADS AB a2 (©1991 Square D All Rights ReveredDANGE EQUIPMENT MUST BE DE-ENERGIZED DURING ALL INSTALLATION AND MAINTENANCE OPERATIONS. FAILURE TO DE-ENERGIZE EQUIPMENT WILL EXPOSE PERSONNEL TO LIVE PARTS WHICH MAY RESULT IN ELECTRICAL SHOCK AND/OR BURN. GENERAL Introduction Gr WARNING: There isa hazard of electrical shock or burn whenever working in or around electrical equipment. Turn off power supplying the equipment before working de motor control centers. ‘The operation of motor contral centers is dependent upon handling, installation, operation and maintenance by qualified personnel, as well as upon proper design and manufacture. Failuretofollow certain fundamental instal- lation and maintenance requirements could lead to per. sonal injury and the failure and loss of the motor control center as well as damage to other propety For the purpose of this guide, a qualified person is one ‘who is familiar with the installation, construction and ‘operation of the equipment and the hazards involved. He should be: 4. Trained and authorized o energize, de-energize, clear, ‘ground, and tag circuits and equipment in accordance ‘with established safety practices. b. He should also be trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance with established safety practices. Description G2 ‘Motor Control Centers provide the most suitable method for grouping electrical motor conttol and other related devices ina compact, economical, free-standing installa- tion. A motor control center is made of standardized vertical sections consisting ototally enclosed, dead front, free-standing structures bolted together. These sections support and house controt units, a common bus bar for distributing power to the control units and a network of ice trough and conductor entrance areas for aecommo- dating outgoing load and control wires. ‘The control unitsconsistof components suchas combina- tion motor starters, branch feeder devices or lighting panelboards. Each is mounted in an individual, isolated ‘compartment having its own cover. When frontof-board ‘unit arrangements selected, all units are mounted on the front side of the control center. A 15* or 20" deep section is provided for front-of-board mounting. Standard motor ‘control center width is 20" with a 4* wide vertical wire- ‘way. An optional 25" wide section with a9* wide wireway is also available. Larger sections are available for mount- ing larger equipment. ‘When a back-to-back arrangement is selected, the units are mounted on both the front andrearofa31"or41"deep structure. (Note: There is about 1* between back-to-back sections.) The standard height ofall motor control center structures is 91-1/2" Packaging Ga ‘Motor control centers are constructed in shipping blocks of three vertical sections maximum. This allows ior ease in handling during transportation and installation. The ‘main horizontal bus of all shipping blocks is spliced together atthe jobsite wth the use of integral splice bars. Before being packed for shipment from the factory, the ‘motor onirolcenterisinspected visually, electrically and mechanically by a professional Quality Control Analyst. Certification of Quality Control testing is available upon request. ‘After leaving Quality Control, each shipping block is ‘carefully packaged and attached to a skid. Inspection ct Inspect the motor control center for any damage a8 soon asitis received. Delivery ofthe equipment toa cartier at any ofthe Square D Plants or other shipping point consti- tutes delivery tothe purchaser, Tile and al risk of loss or damage in ansit shall pass tothe purchaser at that ime, regardless of freight payment. Al claims for loss and damage must be made by the purchaser to the carrier. The packaging material should be replaced for protection, Luni installation has begun,Storage cs Ifthe motor control center cannot be placed Into service reasonably soon afer its receipt, it should be stored in a clean, dry and ventilated building fee from temperature ‘extremes. Acceptable storage temperatures ae from 0°C 32°F) to 40°C (104°F). Uv the storage area fs cool and/or damp, enough heat should be provided to prevent condensation which may beharm{ultothemotorcontrol center. Contact your local Square D field office for specific requirements NOTE: Outdoor storage is inadequate, even with the protection of a tarpaulin. Handling ‘Adequate equipment for handling the motor control cen- ters such as fork ruck, crane, orrods and piperollers must be available. The table at right, wth approximate weights ‘of single sections full of typical units, is a guide for determining the type of handling equipment needed, Weights vary by enclosure type and depth. A single skid could contain from one to three vertical sections. The following instructions are provided to avoid injury and equipment damage while moving the motor control cen. ters. 1. Caution should be exercised when moving heavy equipment. 2. Verify the capabilities of the moving equipment to ‘handle the weight. 3. Fork trucks, when available, provide a quick and Convenient method of moving motor control centers. 4. Lifting angles are provided on each shipping block for ‘handling the motor control center by overhead cranes. ‘The followingprecautions shouldbetaken when using, ‘a. Handle in the upright position only. bi. Select rigging lengths to compensate for any un- ‘equal weight distribution. Do not exceed the 45° maximum between the vertical and iting cables. | % em | Atzoe | tm | ease | Acasa | Soo waav | Aeza | 9 asease| en | 0 | stem | E76 zane | sta | 430 | sean | aay | coo Sosa | tre | 99 | Srteze | E77 Bees | Aan | Soo | daase | Aes | foo dea | eB | So | eset | Em Burm | Anza | 500_| tonseo | ‘sess | ooo Saas | Fo. :36 APPENDIX A7 CIRCUIT BREAKER AND FUSIBLE SWITCH SELECTION TABLE Due to the special design of the ADVANCE / RETRACT operating mechanism, itis tecommended thatthe entire disconnect ‘assembly be replaced when replacing a circuit breaker or switch. The disconnect assembly includes the ADVANCE / RETRACT ‘mechantsm and the appropriate circuit breaker or switch. Only three screws need to be removed when replacing the assembly, ‘making ita much simpler and much quicker operation than replacing the individual breaker or switch. ‘Always select replacement devices ofthe same type and ratings as the device being replaced. Use ofa different type disconnect, ‘or of a disconnect with different ratings may alter the short circult ratings ofthe motor control centr. NEMA Size 14 combination starters with MAG-GARD magnetic only circuit breakers, NEMA Size 5 combination starters with KA frame (225 A. maximum) MAG-GARD magnetic only circuit breakers: “eveplce hs Gre brenkar_| Order is dconnect asm | Wo weplce ths Gre Brake |_ Onder his disconnect asonbiy ‘aP3coo3ti MSDSAMCoOBM rAPRCIO010N MsDsAMarDONIEe FARGO MSDSAMCOODHMI Ars6250256 Mebewncasons fapacoisine Msosanconsna aracasonao Msosancastnae rarsconosne MSDSAMCODOMS* rapacasontne ebewcasevat" NEMA Size 1-4 combination starter: with thermal-magnetic circut breakers, NEMA Size 5 combination starters with KA frame (225 A. maximum) thermal-magnetic circuit breakers, main and branch feeder circuit breakers through 225A (TF suffix denotes 9" branch units) Te replace ths ceut beaker, [Orr ths Giconnec asonbir: [To mlace discret bake Over ths diconnedt ase arcs MSDSATMOISM "| raPaGonTE MSDSATMOTON arneoz0. Mspsarwazan-* ‘aPasoncte MsDsAMaBoN*U266 arse MSDsAtC2044-— + U266 aP36000 sDsaTuosoM == raraioyo MSDsArMO20¢ == arouse MSDSATMOBON "L266 apace SDSAIMEIOM + L266 ap3si00 sDsamaoon + arse SDsetowoM-- = U266 kaPseii0 sDsanan + raras0s0 MsDsAraosom tapieias Msosanasys = arasosore MSDSmsoM--* W266 kaPseiso sosatnatson-- + FaPseoeo MSDSAMOSDH | karaer9s MsDsa75M== + Farssocre MSDSAIaGOM + U266 AP36200 asDsamia00M == * ransso70 MSDSATMOTNA.- =| kaviez3s MSDSAII2SI NEMA Size 1-4 combination starters with fusible switches To veplace tis size swith: | Oner itis comet assembly; | To replace tis size wich | Over his connect asonbly 0 AMP "MSDSAFSOROM === 100 AN ‘MSOSAF Stoo So ANP MSDSAFSOGOM “+4 200 AP MSDSAFS200M = ‘Main and branch feeder fusible switches through 200A (U266 denotes 9° branch fusible units) "epee ti ne switchs | Onder hs daconnent aeriy- | To replace this ae wich | One this connect aonb Replacement ofthe operating mechanism is nat requized for NEMA Size 5 combination starters with LA frame (400 A. max.) circult breakers, NEMA Size 5 fusible starters, NEMA Size 6 stares, main and branch circuit breakers over 225 Amps, of for ‘main and branch switches aver 200 Amps: Order a replacement circuit breaker or automatic molded case switch ofthe same type as the original device, ‘ToorderaFH/ KH high interrupting rating breaker instead ofthe standard FA/KA type breaker, add form Y532tothe disconnect assembly number Example: To replace an FHP36100, order an MSDSATM100M - - *Y532. These modifications may also be added to disconnect assemblies when required: 74. Single pole interlock on operating mechanism Y301 Guent limiting module (lor starter units size 1-3) Y¥303._ Current limiting module (for 15-100. branch feeders) Y312 Class R fuse clips + Voltage form must be added 532 High interrupting circult breaker U212 0-250 Volt 1U203. Disconnect for NEMA 12 units 10213 above 250 VoltAPPENDIX A& OFFSET HORIZONTAL BUS SPLICING INSTRUCTIONS Gace (FOR SPLICING ONLY ON LEFT SIDE OF STRUCTURE) Equipment must be de-energized during installation and maintenance operations. Failure to de-energize equipment will expose personnel to live parts, which may result in electrical shock and/or burn. NOTE: Inall structures with offset horizontal bus splice bars are provided as a kit shipped in a carton. This canton is shipped in the structure and contains all needed splice bars and mounting hardware for specified horizontal bus spicing. NOTE: The provided splice kit will only be used ifsplicing isto bbe done on the eft while facing the suructure. If splice is not on the left, kt must be removed before energizing, and retained for future expansion, I structure isto be spliced to another structure on the right, follow splicing instructions provided for that structure application, NOTE: In all splice connections there is always one (1) more splice bar than laminations of horizontal bus. (See iMustration,) SPLICING INSTRUCTIONS |. Position structures to be spliced together with fronts being, flush, This will assure proper alignment of horizontal bus. 2, Position rear splice bar (bar with clinch nuts) against backface (of rear horizontal bus bar. (See illustration.) 3. natal a plain splice bar between each lamination of horizon- rem tal bus with the last bar installed against the front face of the ee horizontal bus. (See illustration.) 4.Line up mounting holesin splice busand horizontal bus.(Four (4) holes in each splice) 5. Install 3/8" mounting hardware (Four (4) bolts per splice) ‘making sure thatraised surface of washers positionedtoward the bolt head. ae NOTE: Install all hardware before torquing 6. Torque all bolts to 370-385 pound.inches. 7. The above instructions will be repeated forall three (3) phases, of horizontal bus. £8. Before energizing equipment replace all covers and barriers that were removed to accomplish this splicing operation. 7APPENDIX 9 SPLICING OF NEMA 3R ENCLOSURES FOR MODEL 5 STEP 1, Remove backplate from structure being addedtoline- STEP 5. Re-attach mid deflector, insuring that both top plate ‘up. addition sa mult-section shippingspit,only the flanges are covered. See figure 1. seinen eater eeeaie STEP 6, Using the six 10-32 serews that were supplied in the STEP 2. Remove mid deflector cap from right side of existing cloth bag, secure the right front vertical channel ofthe BR, See figure 1. ‘existing 3R to the left front vertical channel of the additional 3R. See figure 3. STEP 3, After placing structures sce by side, splice together as shown in the installation manual NOTE: Procedure shown is used when adding to right hand side of existing 3R. Follow same procedure when STEP 4. Re-attach the back plate to the structure using the Adding to let hand side of existing 38. additional hardware supplied in cloth bag. The left side of the back plate will install as before. The right side will attach to the mult-section back bracket, See figure 2 MID DEFLECTOR FIGURE 1 EXISTING 38 ADDITIONAL 3. RIGHT FRONT LEFT FRONT. EXISTING 38. ADDITIONAL 38 VERTICAL CHANNEL ‘VERTICAL CHANNEL MULTLSECTION BACK BRACKET FIGURE 2 FIGURE 3 38Select proper thermal overload from applicable starter size table below. (See starter nameplate) APPENDIX A10 MELTING ALLOY OVERLOAD SELECTION TABLES. FOR CIRCUIT BREAKER PART WINDING COMBINATION STARTER UNITS re = ro fees |e |e Sera oes) ea care | Pee | maaan | ee coon | emt | aoa | ae aoa ianaet | So eet | idee: | emt |e | ea mone | eee | ay ee eerie | as Sores era oeeerlirete eg) tee | eee See | cean | meme cer eee eel etc wee | eae | ae cas EES | HS | soon sa ems | eee | cone ee a ae 436-407 cus 1030437 carr fone bolic eae 468505 cc 368 sms cco fas | oi Se ee ee ee ee es Sees | ee es tag | tees | mee aes eee | cee | ee seer eevee (mea | ene eet eie | eee eon | ee foes | ele foe ins wes | 3 | gems | aoe ee | ig — — mee | te felons | cee [ote] rca Bas | ge Sua | eee | eee | Pee td A on ore tee fer Become oe see Sa jee | we ee ap fee | ace mere fee | ene | eee | ee ree my Soes sarees | ecu] aero | ea omer | Peart | ea ae iment |e ioaue | vst eae Sn} nae as 8929.95 B20 248279 : 2 ee ae | a8 a a 882 m8359 828 eiitiono | remwe | rutcionn | THERMAL shan eu | cane waar” | tee | tin | ie ae wo} oe | ee | ed [eas anes ees eee Seen |e | oie | ee | Sarena | ewe ass Sel ee | ee | See | eee | ate Se) em) mer ae eae jee | i | ee ne See eee ae ee 39WARNING: APPENDIX A11 MELTING ALLOY OVERLOAD SELECTION TABLES FOR FUSIBLE SWITCH PART WINDING COMBINATION STARTER UNITS Select proper thermal overload from applicable starter size table below. (See starter nameplate.) Do not exceed maximum fuse rating shown opposite the thermal unit selection. Fuses may need tobe of the time delay type to permit motor starting. Class RKS fuses are recommended. swe size 3 wore mae] nore norm Tax] nore wa ‘amet | “uw | eanvc | ‘comer ‘carr | "owt | eae |‘Commr | "ox | etic ‘ty | wer | “ee_| Sot tau | ee | “dwn | Sin | mer | "aur Wie | bose | tao | Sone fonizs | ce isa | ion | amy | cee | to aa daears | ceaes | so | trams | come | iooa sein | one | oso Yeas | ceie | 0 tn Vo | swe aay 3 are | oie | 235 | nosuss E85 | E33] 3 | noses auze| ee | as Seeia | cose | Sao | sems| Cees | wo! Hise | 8H | 22 | mosis Sissaa | SoBe | feo | maas| ce aco | So] Bs Sars | e200 | 32 | eacias zeuis| ees | | us Mea | ogee | 33) | tacinae sroaa | cease | too cena | wo| us ‘eae Steet | ce set | 0 Si | o| us asoaas| ean | 40 eS | m3 cea: | io] as 2eher | 8350 | 38 | soaaes Sein | so] Sees | 84m | és | Bape Bn size 4 jonsas | ox [oT o0] — |‘Stemwr | “unm | sane ssanes | 832 | 30 | 38 ae | aaa [cea iesoa | B40 | 30 | 40 wma [coms | hese | os [3] % te: |cems | wnat | cees | us Dawe | coo | ious | ee’ | io ibs | com | 0 SWE 2 ysas69 | CC 121 ws itcion| reer | Gis | rtctono ass wes | cere | amo canes | star | “ary | “tae my zai | cc | 30 Tassel 2 ba 0 Hae | cee | 3 seas | too | oo | danas 3, iene 58 ‘etenos| 5m | toe tigen73| 8 102 120 | 360399 4900 SIZES Trewss| gus | ts fame | "mr | extn He | me | exes: «0 ‘aan | nonce | “Coy ‘ams ne ian | bom | 20 Rene no zen | bo ue | ies 00, Sea | bo two | io Hoan | doe | 30 feet | Bot | 0 3eoan | Bo tes | 500 Seta | Bo wo | 00 ears | D0 30 | ‘00 ‘Seaey | Bo 500 | S00 40APPENDIX A12 AMBIENT COMPENSATED BIMETALLIC OVERLOAD SELECTION TABLES FOR CIRCUIT BREAKER PART WINDING COMBINATION STARTER UNITS Select proper thermal overload for Form B and Y59 from applicable starter size table below. {See starter nameplate.) size 1 size 4 MOTOR MOTOR orOR fcummexr | “unm! | ‘cuter | Ont ‘coment | ost ‘awn | wonee | Sawn | nome tan | te iat ‘aR ins | —e9az8 AR 38 oosn9 | £08 sn | Aris | Seana me oe Seoeos | E59 ssoens | E52 usin | agize | ssninss | xez7 teu sess | fogomge | ARas mors | 93 teen atts | toouss | Ake mene | £9 zuan | meus | msenes | anue roses | E57 iia! | Mtzoe | eeu | Mme Sosa | £50 Bhan | M220 | gmun | Ana snows | £38 296317 ARI 792207 AR 154 eee a ven | gar sem | mp | [itBBo [em He ee asta ae ve ae ra =e Ae Beate | mame | eB | agen a er Ltr Ml el ae media iee gu | gm | gs ka | BEE | aS veers | otue | sear | ate peer ett erase ee me | Oe | Se | Be wee | vee | ow | am SE | ER | ae | 8 ae =e Bea» | mame | BR | mene a [te ea i aus) 18 clas 7 sons | im gem | 1BAPPENDIX A13 AMBIENT COMPENSATED BIMETALLIC OVERLOAD SELECTION TABLES. FOR FUSIBLE SWITCH PART WINDING COMBINATION STARTER UNITS Select proper thermal overload from Form B and Y59 from applicable starter size table below. (See starter nameplate) um fuse rating shown opposite the thermal unit selection. Fuses may need to be of the time delay type to permit motor starting. Class K5 or Class R fuses are recommended. size suze 4 woror wx | noe ‘a ro ma tioto | wena | Mb | rntiono| rica | He ritionp | rewat | st ‘cant | “owt | sate |'Zomnr | Mon’ | ettwc tae | “Ow | sate tan” | stor | “an | Stn | store | “Aun ‘tan | stwrre | “dy ves | aces | rasp eon | ass | 7 oss] an | 300 linia | tie | tas [Secon | Met | 6 mos] ES | 33 vases | artas | te [ssnmse| az | sows! Em | do ie |] |G] a |e mois) 63) | oo tisen | Ariss |"? itouss| Aes | 2 Anus | ext | 0 iia | ae | We |'Bsei] 83 |g mows | fan | 400 fan | Ma | 38 [ease] Ata |e soos | 3 | 2oea7 | ARI ‘42 | 1792207) AR 154 20 eee bisa 2 size 5 aoa | Saas esses | as’ | 0 | 30) [tice we staraas | A390 foeses| AB | Jo [30 [Ska ite 4g6ss3 | AR 437 3 aaeaes | ar 30 | 30 | 35 = — sees | Attao | i | Beis] M8 | 3/4) [pone 2B ae : = 266297 250 size2 33 ritBin| mana | A | Sto] mea | Me ‘0 comme | “owe | sarc |‘cosmour | “owt | wane awry [_wosser | “wry | Sian | twee | "any wens | _Akas | 9 | waoa | Anas | 5 Stern | akss | i | dea | rao | 40 townos| Aor | to | caer | At |S jazevasl Aewa| 2 | Soosss| ARs | 50 wsern| arise | 15 | sees] arco | 60 areas | ann | 25 | moms | anv | 60 mons| Ans | 30 | eam] Aree | 60 SIZE 3 ution | meezwat | fst |rottionn | mena | _fose ‘coment | “uxt | wane |'cumvt | ox | ect tt | otacn | "an | Son | aanace |“ wale | 2 on] 2a soens | Em ” eed Boao | em | so |mgass) Em || 243® SQUARE D COMPANY Deaicated to Growth + Committed to Quality Order Ne. 9981510185 /92 eches omeona? ajar 9900 som 10M NG Printed in USA.