User Manual Medium Voltage Controllers, 200/400A Two-High Cabinet, Standard and Arc-Resistant Enclosure Publication 1500-UM055G-EN-P
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://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision.
Summary of Changes Notes: iv Rockwell Automation Publication 1500-UM055G-EN-P - May 2013
Table of Contents Chapter 1 General Information Document Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Prepared Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Series Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Incoming Line Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Current Transformer Barrier . . . . . . . . . . . . . . . . . . . . . . . . Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contactor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Chimney Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Appendix B ArcShield Plenum Installation Instructions Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Notes: viii Rockwell Automation Publication 1500-UM055G-EN-P - May 2013
Chapter 1 General Information Document Scope This User Manual pertains to the Rockwell Automation Bulletin 1512B medium voltage controller. The Bulletin 1512B structure includes provisions for two complete MV controller units. The installation section provides instructions for both the standard enclosure type and Rockwell Automation arc resistant type (ArcShield).
Chapter 1 General Information Starter Identification A structure nameplate is attached to the right-side flange of the structure (see Figure 1). Refer to the nameplate for information such as series number, section number, NEMA enclosure type, unit ratings and bus ratings. Figure 1 - Typical Structure Nameplate A unit nameplate is also found in the low voltage compartment with specific unit motor application information (see Figure 2).
General Information Prepared Space Chapter 1 When ordering a starter kit to complete a prepared space(2), provide the following information to ensure the proper components are supplied. Series Number Provide the series number from the structure with the prepared space. The number is stamped on a nameplate on the right-hand flange of the starter (see Figure 1). The series number is also available from the dimension drawings for the starter.
Chapter 1 General Information Notes: 4 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013
Chapter 2 Installation – Standard Enclosure IMPORTANT For information on the installation site preparation, see General Handling Procedures for MV Products, Publication MV-QS050_-EN-P. ATTENTION: 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.
Chapter 2 Installation – Standard Enclosure Opening the Medium Voltage Doors ATTENTION: Medium voltage components are located behind the swing-out low voltage panel (standard cabinets only). Complete the Power Lock-out procedure (refer to Power Lock-out Procedure on page 47 of Chapter 5) before attempting to open the swing-out low voltage panel. Failure to do so may result in severe burns, injury or death.
Installation – Standard Enclosure Chapter 2 4. The door is now released and will swing open. 5. Reverse the procedure to close the door. IMPORTANT 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.
Chapter 2 Installation – Standard Enclosure Figure 5 - Cabinet Floor Plan NOTES FOR SEISMIC APPLICATIONS • For installations on concrete – the minimum depth and radius of concrete supporting the cabinet anchors is dependent on seismic loads. Refer to important information above. • For installations on a metal structure – the metal plate depth and cabinet anchoring method is dependent on seismic loads.
Installation – Standard Enclosure Chapter 2 5. Secure the sections together using the 1/4-20 self-tapping screws. Thread the screw through the 7 mm (0.281 in.) clearance hole to the corresponding 6 mm (0.219 in.) pilot hole. To access the front clearance holes of the left-side 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 Front Access– Access to Power Bus on page 11. 6.
Chapter 2 Installation – Standard Enclosure 3. Once the rear bus cover is removed, you will see the three power bus bars and the ground bus bar (see Figure 8).
Installation – Standard Enclosure Chapter 2 Side Access A side bus access cover is located on each side of the controller. 1. Remove the hardware from the appropriate side bus access cover (see Figure 7). 2. Remove the side bus access cover. 3. Once the side bus access cover is removed, you will see the three power bus bars and the ground bus (see Figure 9).
Chapter 2 Installation – Standard Enclosure 3. Open the low voltage cell doors (refer to Opening the Low Voltage Doors on page 5). 4. Disconnect the control wiring harness from the wire plug at the lower left side of the contactor. 5. Remove the two self-tapping screws from the center vertical channel (see Figure 10). 6. Pull on the center vertical channel to swing out the low voltage panel.
Installation – Standard Enclosure Chapter 2 7. Remove each glass-polyester barrier located in front of the current transformers (see Figure 11). Figure 11 - Removing Glass-polyester Barrier Current Transformers Remove self-tapping screws from barrier assembly Glass-polyester barrier 8. Remove the retaining screw from the cable duct barrier and remove the barrier (see Figure 12). 9. Remove the two retaining screws from the cable duct boot and remove the boot (see Figure 12).
Chapter 2 Installation – Standard Enclosure Figure 12 - Removing Cable Duct Boot and Barrier Current Transformers CT Mounting Plate Loosen Retaining Screws Cable Duct Boot Remove Retaining Screws Cable Duct Barrier 10. To access the left side of the power bus, locate the two bus access covers at the rear, left side of the power cell. Remove the four self-tapping screws from each cover and remove the covers (see Figure 13).
Installation – Standard Enclosure Chapter 2 11. If access to the right side of the power bus is required, remove the vacuum contactor from the upper power cell (refer to Removing the Contactor on page 52 of Chapter 5). 12. Remove the power fuses from the isolation switch. 13. Remove the interphase barriers from the trailer fuse block by raising them vertically up and out of the mounting slots (see Figure 14). 14. Use a 9/16-in.
Chapter 2 Installation – Standard Enclosure 17. Reverse the procedure to reassemble the cabinet. Ensure that the barriers are put back in place and all parts and tools are accounted for. Figure 15 - Access to Right Side of Power Bus Remove self-tapping screws ATTENTION: Ensure all barriers are replaced before re-energizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel.
Installation – Standard Enclosure Chapter 2 Figure 16 - Bottom Cable Exit Configuration Cable Duct Barrier Cable Duct Boot Load Cable Connections ATTENTION: To avoid shock hazards, lock out incoming power (refer to Power Lock-out Procedure on page 47 of Chapter 5) 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.
Chapter 2 Installation – Standard Enclosure Figure 17 - Access to Load Cable Conduit Openings (Top exit cable configuration shown) (LV panels removed for clarity) Remove Cable Duct Boot to access Load Cable Conduit opening for cables exiting from bottom Power Cell Current Transformer Mounting Plate Connect Load Cables to Current Transformers 4. Remove the appropriate load cable conduit openings in the top or bottom of the cabinet (see Figure 18 or Figure 19).
Installation – Standard Enclosure Chapter 2 Top Exiting Load Cables 5. Load cables for the bottom power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 18). Run the cables behind the current transformer mounting plate and into the bottom power cell.
Chapter 2 Installation – Standard Enclosure Bottom Exiting Load Cables TIP Follow steps 1-4 from the previous section. 5. Load cables for the top power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 19). Run the cables behind the current transformer mounting plate and into the top power cell.
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) This installation section contains information on arc resistant styles of enclosures, referred to in this manual as “ArcShield”. IMPORTANT For information on the installation site preparation, see Publication MV-QS050_-EN-P. ATTENTION: Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death.
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) Opening the Medium Voltage Doors ATTENTION: Complete the Power Lock-out procedure (refer to Power Lock-out Procedure on page 47 of Chapter 5) before beginning any service procedures to the unit. Failure to do so may result in severe burns, injury or death. Medium voltage doors are identified as MV in Figure 21.
Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3 6. Reverse the procedure to close the door. Door lock bolts must be adequately tightened (refer to Recommended Torque Values on page 3 of Chapter 1 for torque values). IMPORTANT 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.
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) 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.
Installation – Arc-Resistant Enclosure (ArcShield) Joining Sections Chapter 3 TIP Joining hardware can be found in a package mounted to the front of the shipping skid. TIP 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 12 mm (1/2 in. [M12]) floor mounting bolts (refer to Anchoring on page 23). 2. When joining ArcShield sections, apply a continuous 3 mm (1/8 in.
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) Access to the Power Bus ATTENTION: This procedure requires contact with medium voltage components. To avoid shock hazards, lock out incoming power before working on the equipment (refer to Power Lock-out Procedure on page 47 of Chapter 5). 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.
Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3 Figure 26 - Side Bus Access Cover Warning Label Figure 27 - Side Bus Access Cover Ground Connection Side Bus Access Cover Ground Connection Figure 28 - ArcShield Ground Plate Removable Handle Rockwell Automation Publication 1500-UM055G-EN-P - May 2013 27
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) Front Access – Access to Power Bus ATTENTION: To avoid shock hazards, lock out incoming power (refer to Power Lock-out Procedure on page 47 of Chapter 5) 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. 1.
Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3 Figure 30 - Removing Cable Duct Boot and Barrier Current Transformers CT Mounting Plate Loosen Retaining Screws Cable Duct Boot Remove Retaining Screws Cable Duct Barrier 5. To access the left side of the power bus, locate the two bus access covers at the rear, left side of the power cell. Remove the four self-tapping screws from each cover and remove the covers (see Figure 7 on page 10).
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) 6. If access to the right side of the power bus is required, remove the vacuum contactor from the upper power cell (refer to Removing the Contactor on page 52 of Chapter 5). 7. Remove the power fuses from the isolation switch. 8. Remove the interphase barriers from the trailer fuse block by raising them vertically up and out of the mounting slots (see Figure 32). 9. Use a 9/16-in.
Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3 Figure 33 - Access to Right Side of Power Bus Remove selftapping screws ATTENTION: Ensure all barriers are replaced before re-energizing the equipment. Failure to do so may result in electrical faults and cause damage to equipment or serious injury to personnel. Front Access – Bottom Exiting Load Cables If the cables in your cabinet exit from the bottom, the procedure to access the power bus is almost identical to the one above.
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) Load Cable Connections ATTENTION: To avoid shock hazards, lock out incoming power (refer to Power Lock-out Procedure on page 47 of Chapter 5) 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. IMPORTANT The current transformers may be positioned for top or bottom cable exit.
Installation – Arc-Resistant Enclosure (ArcShield) Chapter 3 4. Remove the appropriate load cable conduit openings in the top or bottom of the cabinet (see Figure 36 or Figure 37). Top Exiting Load Cables TIP Follow steps 1-4 from previous section. 5. Load cables for the bottom power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 36). Run the cables behind the current transformer mounting plate and into the bottom power cell. 6.
Chapter 3 Installation – Arc-Resistant Enclosure (ArcShield) Bottom Exiting Load Cables TIP Follow steps 1-4 from previous section. 5. Load cables for the top power cell should be routed first. Pull the cables into the cabinet through the appropriate opening (see Figure 37). Run the cables behind the current transformer mounting plate and into the top power cell.
Chapter 4 Common Installation Bus Splicing Power Bus ATTENTION: This procedure requires contact with medium voltage components. To avoid shock hazards, lock out incoming power before working on the equipment (refer to Power Lock-out Procedure on page 47 of Chapter 5). 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.
Chapter 4 Common Installation Figure 38 - Typical 1200A Power Bus Splicing Configuration (Viewed from front of cabinet) Bus Support Bus Clamp Power Bus Splice Bar Main Horizontal Power Bus Flat Washer Hex Nut Lock Washer Figure 39 - Typical 2000A Power Bus Splicing Configuration (Viewed from front of cabinet) Bus Support Bus Clamp Main Horizontal Power Bus Power Bus Splice Bars Flat Washer Hex Nut Lock Washer ATTENTION: Ensure all barriers are replaced before re-energizing the equipment.
Common Installation Chapter 4 Ground Bus 1. See Figure 40 to determine the correct ground splice configuration and assemble as shown. 2. Torque the hardware to 15 N•m ± 1 N•m (12 lb•ft ± 1 lb•ft). 3. Check all hardware for correct tightness and replace all covers and plates.
Chapter 4 Common Installation Figure 41 - Incoming Line Cable Connections Power Cable Lugs Ground Bus Lug IMPORTANT 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 Installation of Current Transformer Barrier Chapter 4 Figure 42 - Current Transformer Barrier Current Barrier Transformer ATTENTION: 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. Hi-Pot and Megger Test Insulation integrity should be checked before energizing medium voltage electrical equipment.
Chapter 4 Common Installation ATTENTION: 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 VLL) volts, where VLL 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.
Common Installation Chapter 4 Testing Contactor Operation 1. Connect the appropriate external power supply (120 or 230V AC) to the test receptacle in the control panel. Turn the selector switch to the TEST position. ATTENTION: 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 Figure 66 on page 65 for the location of these contacts).
Chapter 4 Common Installation Typical Wiring Diagrams 2400V-6900V,3Ø, 50/60Hz L1 L2 L3 GRD Figure 43 - Typical Wiring Diagram: Electrically Held Vacuum Contactor (Relay Control) ISOLATING SWITCH IS DOOR INTERLOCK CT1 T1 F1 CT2 T2 F1 CT3 F1 CURRENT LIMITING POWER FUSES MTR T3 M CURRENT LIMITING PRIMARY FUSES F2 __E 47 46 CPT 500 VA 44 V 42 ____ F2 __E 49 OL 592 OVERLOAD 120 V 5 ISa OFF 8 X ISb 6 7 (6) NORMAL X (5) 9 (7) (8) X F3 TEST SUPPLY POINT TS 120V 50/60Hz 10 TEST (
Common Installation Chapter 4 Figure 44 - Typical Wiring Diagram: Electrically Held Vacuum Contactor (with IntelliVAC Control) 2400V-6900V,3Ø, 50/60Hz L1 L2 L3 GRD ISOLATING SWITCH IS DOOR INTERLOCK CT1 T1 F1 CT2 T2 F1 CT3 F1 CURRENT LIMITING POWER FUSES MTR T3 M CURRENT LIMITING PRIMARY FUSES F2 __E F2 __E 47 46 CPT1 500 VA 44 42 ____ V 49 OL 592 OVERLOAD 120 V 5 ISa OFF 8 X ISb 7 (6) (8) X 10 TEST SUPPLY POINT TS 120V 50/60Hz (3) (4) EXTRA AUXILIARY CONTACTS 12 X 36 V 15
Chapter 4 Common Installation Notes: 44 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013
Chapter 5 Maintenance ATTENTION: Use suitable personal protective equipment (PPE) per local codes or regulations. Failure to do so may result in severe burns, injury or death. Tool Requirements IMPORTANT Establish a maintenance and inspection schedule for the equipment. Annual servicing, or every 20,000 operations (whichever comes sooner) is the minimum recommended. Extreme operating conditions may warrant additional attention. IMPORTANT Some components of this product incorporate Imperial hardware.
Chapter 5 Maintenance Door Interlock Circumvention ATTENTION: The door interlock mechanism is designed to prevent access to the medium voltage cell while the unit is energized. When the unit is in operation, do not circumvent this interlocking safety feature. Always disconnect and lock out incoming power (refer to Power Lock-out Procedure on page 47) before proceeding with any adjustments requiring the handle to be moved to the ON (closed) position.
Maintenance Chapter 5 ATTENTION: Always perform the Power Lock-out procedure before servicing the equipment. Failure to do so may result in severe burns, injury or death. Power Lock-out Procedure ATTENTION: 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.
Chapter 5 Maintenance 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 OFF position. Disconnect the external power supply. g. Complete the Power Lock-out procedure 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 47).
Maintenance Chapter 5 6. Check the line and load sides of the contactor with a hot stick or appropriate voltage measuring device for the system voltage, to verify that they are voltage free (see Figure 48). a. Check for line-side voltage at the top vacuum bottle terminals. b. Check for load-side voltage at the bottom vacuum bottle terminals. Figure 48 - Contactor Voltage Checkpoints Check line-side power here Check load-side power here 7.
Chapter 5 Maintenance Fuse Removal and Replacement ATTENTION: Only personnel who have been trained and understand the Bulletin 1500 product line are to work on this equipment. Suitable safety equipment and procedures are to be used at all times. Figure 50 - Medium Voltage Power Fuses Bolt-on Fuses Clip-on Fuse Clip-on Fuse Extractor ATTENTION: Servicing energized industrial control equipment can be hazardous.
Maintenance TIP Chapter 5 The main power fuse has a pop up indicator pin located at one end of the fuse. When a fuse has opened, the indicator will be in its extended position. The fuse should be oriented in the fuse clip assembly so that the indicator is at the top. ATTENTION: The fuses may be hot for up to one hour after operating. Verify the temperature before handling and use insulated hand protection if needed. Failure to do so may result in burns.
Chapter 5 Maintenance 6. Ensure that the flares on the fuse ferrules are properly located with respect to the fuse clips. 7. Apply a rapid shove to the bottom portion of the fuse barrel to force the fuse into the clip. 8. Apply a rapid shove to the top portion of the fuse barrel to force the fuse into the clip. 9. Grip center of fuse barrel with both hands and apply slight back and forward force to ensure fuse has been properly seated in the fuse clips. 10.
Maintenance Chapter 5 4. Disconnect the control power transformer primary leads from the fuse terminals at the top of the contactor. 5. Use a 9/16-in. socket wrench to disconnect the power cables and bus bars from the rear of the contactor. 6. Remove the nylon contactor bushing retaining screw from the contactor interlock lever. 7. Slide the contactor interlock rod and the nylon contactor bushing out of the groove in the contactor interlock lever (see Figure 53).
Chapter 5 Maintenance 9. Slide the contactor forward slightly to disengage the retaining tabs at the rear of the contactor from the mounting bracket inside the cabinet. 10. Carefully remove the contactor from the cabinet. ATTENTION: The contactor weighs approximately 22 kg (50 lbs) and assistance may be required to safely remove it from the cabinet and transport it. Failure to use caution when moving the contactor may result in equipment damage and/or personal injury. 11.
Maintenance Chapter 5 Figure 54 - Isolation Switch Handle Adjustments Gap: 0.045...0.060 in. (1.1...1.5 mm) Isolation Switch Operating Lever Switch Interlock Lever Stop Bracket Isolation Switch Handle at halfway position Contactor Interlock Rod Contactor Interlock Lever Nyloc Nut To Reduce the Gap Distance 5. Loosen the two screws in the stop bracket and move the stop bracket up against the interlock lever. 6.
Chapter 5 Maintenance 10. Move the stop bracket until it just touches the interlock lever and tighten the screws. 11. Apply Loctite 290 (or equivalent adhesive) to the stop bracket screws and torque the screws to 8 N•m (6 lb•ft). 12. Move the isolation switch handle to the ON position. 13. Manually close the contactor by attaching locking pliers to the contactor interlock lever and pushing down until the armature plate contacts the magnetic cores (see Figure 55).
Maintenance Chapter 5 Figure 56 - Isolation Switch Operating Lever Overlap Overlap minimum 0.125 in. (3 mm) Isolation Switch Operating Lever Interlock Lever 14. Open the contactor. Verify that the interlock lever and the rod move freely and that the return springs move the assembly back to the starting position.
Chapter 5 Maintenance Figure 57 - Isolation Switch Handle Mechanism Lubrication Points Threaded Connecting Rod Clevis Pins and Cotter Pins Isolation Switch Operating Lever Interlock Lever Lubrication Points (at replacement only) Contactor Interlock Rod 5. Inspect the mounting hardware on the isolation switch operating lever and contactor interlock rod (see Figure 57). Tighten any loose hardware. 6. Inspect the isolation switch blades and the incoming line stabs (see Figure 63).
Maintenance Chapter 5 Figure 58 - Isolation Switch Lubrication Points Lubricate Isolation Switch Blades Lubricate Pivot Points Isolation Blade Switch Adjustment The Bulletin 1500 (Series R) Isolation Switch has been updated to improve performance. This procedure ensures the isolation switch linkage assembly operates correctly with the new design change. ATTENTION: Complete the Power Lockout procedure of the main power bus before servicing equipment.
Chapter 5 Maintenance Figure 59 - Isolation Switch Defeater Closed position Isolation Switch Operating Handle Isolation Switch Defeater Open position 3. Phase 3 (far right linkage) must be measured for overall travel. All three phases share the same main actuating shaft but the Phase 3 is the easiest to measure. Figure 60 - Isolation Switch Linkage Assembly Location Isolation Switch Linkage Assembly (Phase 3) 4.
Maintenance Chapter 5 Figure 61 - Isolation Switch Linkage Assembly Angle Location Must have tolerance of 0/+6 degrees Shaft Assembly Red Glass Polyester Switch Link 5. Loosen the lock nuts at each clevis (Note: one is a left-handed thread). 6. Adjust the isolation switch mechanical threaded linkage with a wrench until the overall travel angle of the switch link is within the required tolerance. 7. Hold the position of the threaded linkage and tighten the lock nuts.
Chapter 5 Maintenance 8. Actuate the Isolation Switch handle to verify the travel angle. If the angle is incorrect, repeat steps 5 through 7 until desired travel angle is reached. ATTENTION: All three isolation switch linkage assemblies must meet the angle tolerance requirements. Isolation Switch Mechanism Grounding Adjustment ATTENTION: To avoid shock hazards, lock out incoming power (refer to Power Lock-out Procedure on page 47) before working on the equipment.
Maintenance Chapter 5 3. To adjust the distance from the blades to the bar, disconnect the threaded connecting rod at the handle operating lever (see Figure 57). 4. Turn the threaded connecting rod to lengthen or shorten it. This will adjust the position of the isolation switch blades in the ON and OFF position. Auxiliary Contacts Inspection and Replacement ATTENTION: To avoid shock hazard, lock out incoming power (refer to Power Lock-out Procedure on page 47) before working on the equipment.
Chapter 5 Maintenance Isolation Switch Auxiliary Contacts The auxiliary contacts are mounted on the left side of the isolation switch, slightly below the cams on the isolation switch shaft. Normally open contacts (Isolation Switch a Contacts - ISa) are on the outside of the isolation switch housing, and normally closed contacts (Isolation Switch b Contacts - ISb) are on the inside of the housing. Figure 65 - Location of ISa and ISb Auxiliary Contacts ISa Auxiliary Contacts (N.O.
Maintenance Chapter 5 4. Insert a 6.35 mm (0.25 in.) diameter pin into the cam groove between the cam follower and the end of the cam groove. Figure 66 - Adjusting Auxiliary Contacts (ISa Auxiliary Contact Shown) Gap: 0.25 in. (6.35 mm) Cam Cam Follower 20 AMP SER. A 700-CPM CATAL OG NO. Auxiliary Contact 5. Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin – 6.35 mm (0.25 in.). 6.
Chapter 5 Maintenance 6. Operate the handle several times, then recheck the 6.35 mm (0.25 in.) clearance between the end of the cam groove and the follower pin for both cams. 7. Verify that auxiliary contact ISb is closed when isolation switch is open. Verify that ISb contact is open when isolation switch is closed. Adjusting the Change-of-State Point IMPORTANT This procedure sets the secondary electrical interlock.
Maintenance Chapter 5 ATTENTION: This procedure may expose personnel to energized medium voltage components. Whenever possible, lock out incoming power before beginning this procedure. If you are unable to lock out incoming power, use the appropriate protective equipment and work practices to avoid shock hazards. Failure to do so may result in severe burns, injury or death. 1. Remove the two 1/4-20 self-tapping screws from the Z-clip and remove the Z-clip.
Chapter 5 Maintenance If it is possible to move the isolation switch handle to the OFF position for reassembly, follow steps 5-10. If it is not possible to move the isolation switch handle to the OFF position for reassembly, follow steps 11-13. ATTENTION: The Z-clip assembly must be reassembled to ensure the interlocking mechanism functions properly. Failure to do so will let personnel access live medium voltage parts and may cause severe burns, injury or death.
Chapter 6 Spare Parts The following list of spare parts is valid for typical Bulletin 1512 and 1512BT units. Please contact your local Rockwell Automation office to ensure that the following part numbers are valid for your system.
Chapter 6 Spare Parts Notes: 70 Rockwell Automation Publication 1500-UM055G-EN-P - May 2013
Appendix A ArcShield Unit Information Overview ArcShield units have a robust arc resistant enclosure design that has been tested per IEEE C37.20.7 (2001). Each ArcShield structure was tested to withstand the effects of an arc flash at 40 kA for 0.5 seconds. ArcShield units provide Type 2B Accessibility. ArcShield Design ArcShield units typically include a pressure relief vent on the roof of the structure (some incoming units may not have a pressure relief vent if top cable entry is required).
Appendix A ArcShield Unit Information Exhaust Systems: Chimney or Plenum Information Plenum Option A plenum can be provided for each unit, and is to be field-mounted on the top of the unit structure (some incoming units may not have a plenum if top cable entry is required). The purpose of the plenum is to direct the hazardous flames and gases away from the top of the arc resistant enclosure.
ArcShield Unit Information Appendix A Figure 70 - Cross-section of Plenum Extension, dimensions in inches [mm] 23 [584] 25 [633] Plenum Exhaust Considerations The following options for locating the plenum exhaust are presented: 1. Plenum ducted to an area of the control room where arc gases are permitted to escape, with plenum extensions (see Figure 71, Figure 72 and Figure 73). 2. Plenum duct to outside of control room (see Figure 71 and Figure 72). Plan the location where the plenum will exhaust.
Appendix A ArcShield Unit Information Figure 71 - Plenum Exit Left with Extensions to Internal Controlled Access Area (Top View) Y L Personnel Access Barrier X Figure 72 - Plenum Exit Left with Extension(s) to Internal Controlled Access Area (Front View) H L Personnel Access Barrier Minimum H = 3.5 m (138 inches) Minimum L = 1.
ArcShield Unit Information Appendix A Figure 73 - Chimney Exhaust Space Requirements H H1 Minimum H1: 1.7 m (67 inches) Minimum H: 1 m (39 inches) Additional Notes • The walls of the plenum exit area must be capable of withstanding the pressure generated. • Any painted surfaces which face direct contact with the arc products may ignite. Flame suppression is recommended. • The exit point can also be outside the building. Ensure exit area can not be blocked by ice, snow, or vermin nests.
Appendix A ArcShield Unit Information Chimney Information A chimney can be provided for each unit, and is to be field mounted on top of the unit structure. The purpose of the chimney is to direct the hazardous flames and gases away from the top of the resistant enclosure. The chimney is secured to the top of each unit structure. Refer to Appendix C for chimney installation instructions. Each ArcShield line-up includes a chimney exhaust section that extends vertically directly above the enclosure.
Appendix B ArcShield Plenum Installation Instructions The following instructions are provided to ensure the proper installation and function of plenum components supplied with ArcShield enclosures. Refer to Appendix A for additional information related to ArcShield plenums before attempting to follow these instructions. Recommended Torque Values 1/4-20 Thread Fasteners – 7.
Appendix B ArcShield Plenum Installation Instructions Figure 75 - Description of Plenums and Components General Plenum Layout for ArcShield Line-up 78 18" wide Plenum Fastened directly over the 0.5 m (18 in.) wide cabinet 26" wide Plenum Fastened directly over the 0.7 m (26 in.) wide cabinet 36" wide Plenum Fastened directly over the 0.9 m (36 in.
ArcShield Plenum Installation Instructions Appendix B Figure 76 - ArcShield Line-up 36 in. Exhaust extension Sealed end Exhaust end Plenum exhaust can be on the left or right hand end of the line up. Pictures and figures in this procedure are shown for a right hand exhaust exit direction. Also shown is an optional vertical (top) direction exhaust extension (see Figure 88).
Appendix B ArcShield Plenum Installation Instructions Cabinet Preparation In preparation for mounting Plenum, remove 1/4-20 fasteners from the Relief vent on the top of the MV enclosure. Leave the (4) corner fasteners in place (see Figure 79). Figure 78 - Relief Vent Fasteners (top view) Figure 79 - Relief Vent Corner fasteners Relief vent Relief fasteners The Plenums are designed to fit over the fastener heads at the (4) corners of the Relief vent.
ArcShield Plenum Installation Instructions Appendix B Figure 80 - Plenum Placement Use recommended torque value for 1/4-20 fasteners TIP STEP 2 – Alignment of “Sideby-Side” Plenums Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place. Plenums mounted side-by-side must be fastened together through the aligning holes using 5/16-in. supplied hardware (see Figure 81).
Appendix B ArcShield Plenum Installation Instructions Figure 81 - Aligning “Side-by-Side” Plenums IMPORTANT STEP 3 – Sequence of Final Assembly Any unused holes must be filled with thread forming screws. i.e.: “Lifting Lug holes”. All Gaps must be sealed and filled with silicone. All Plenums in a Line-up must be mounted to the top of each enclosure and to the Plenum directly beside it before the front duct sections are re-attached (see Figure 77).
ArcShield Plenum Installation Instructions Appendix B The “End Cover Plate” must be mounted on the closed end of the Line-up at this time during the assembly using 5/16-in. hardware (see Figure 82 Left side). STEP 4 – Closing the Front of the Plenum Sections After the first stage of the Plenum assemblies have been mounted, the Plenums can then be “closed-up” by replacing the front duct sections as shown in Figure 83.
Appendix B ArcShield Plenum Installation Instructions Figure 84 - 90° Elbow Section Assembly, Step 5A (Front View) Figure 85 - 90° Elbow Section Assembly, Step 5B (Front View) 36 in. extensions Screen Cover Plate 2-piece 90° elbow section Figure 86 - 90° Elbow Section Assembly, Step 5C (Front View) The Extension components are attached to the Elbow Section using 5/16-in. Hardware. Figure 86 illustrates what the Extension/Elbow Assembly should resemble when finished. Screen Cover Plate 36 in.
ArcShield Plenum Installation Instructions Appendix B Figure 87 - Optional Extension/Elbow with Vertical Extension (Right side exit) Last Plenum in line-up remains open for installation of extension assembly After the Extension/Elbow assembly is attached through the fastener holes on the inside flange of the Plenum, the front duct section can be replaced and fastened through the holes on the outside flanges.
Appendix B ArcShield Plenum Installation Instructions STEP 7 – Additional Mounting Support The Extension/Elbow Assembly must have additional mounting support. 90° Elbow Section: Approximate weight 64 kg (142 lbs) 36" Extension Assembly: Approximate weight 51 kg (112 lbs) Figure 88 shows an example of how the Extension/Elbow Sections can be supported by suspension from a high ceiling. Points A, B & C show where chains or high tension cables may be connected.
Appendix C ArcShield Chimney Installation Instructions The following instructions are provided to ensure the proper installation and function of chimney supplied with ArcShield enclosures. Refer to Appendix A for additional information related to ArcShield chimney before attempting to follow these instructions. Recommended Torque Values 1/4 -20 Thread Fasteners – 7.
Appendix C ArcShield Chimney Installation Instructions General Plenum Layout for ArcShield Line-up An example of a general chimney assembly configuration is shown in Figure 90. Chimneys of varying widths are mounted directly over the MV enclosures of the corresponding width.
ArcShield Chimney Installation Instructions Appendix C Cabinet Preparation In preparation for mounting a chimney, remove 1/4-20 fasteners from the Relief vent on the top of the MV enclosure. Leave the (4) corner fasteners in place (see Figure 79 on page 80). Figure 91 - Relief Vent Fasteners (top view) Figure 92 - Relief Vent Corner fasteners Relief vent Relief fasteners The chimneys are designed to fit over the fastener heads at the (4) corners of the Relief vent.
Appendix C ArcShield Chimney Installation Instructions Chimney Placement on Structure Once the Chimney has been lifted in place directly over the relief vent (shown in Figure 80 on page 81), all 1/4-20 fasteners, removed in Cabinet Preparation on page 89, are replaced to attach the chimney to the top of the enclosure.
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