GE Energy Industrial Solutions Evolution Series E9000 Motor Control Centers Installation & Maintenance Guide DEH-40472 Rev.
Evolution Series E9000 Installation & Maintenance Guide Contents 1. 2. 3. 4. 5. 6. 1 Warnings, Cautions & Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Description – Vertical Section Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DEH–40472 Warnings, Cautions & Notes As Used In This Publication WARNINGS Warning notices are used in this publication to emphasize that hazardous voltages, currents, or other conditions that could cause personal injury are present in this equipment or may be associated with its use. Warning notices are also used for situations in which inattention or lack of equipment knowledge could cause either personal injury or damage to equipment.
Evolution Series E9000 Installation & Maintenance Guide Chapter 1 – Introduction This publication provides guidelines for installation and maintenance of Evolution Motor Control Centers, as shown in Figure 1. The information provided does not cover all details or variations in this product offering, nor does it address all possible contingencies to be met in connection with installation, operation, or maintenance.
Evolution Series E9000 Installation & Maintenance Guide General Description – Motor Control Center Buses General Description – Control Center Units The main horizontal power bus is located at the top of the vertical section. The bus bolted joints are accessible from the front by loosening the barrier mounting screws and sliding the Lexan® bus barrier up and forward from the main bus. Figure 2 shows a horizontal power bus with its Lexan barrier. Figure 3 shows the bus barrier mounting slots and screw.
Evolution Series E9000 Installation & Maintenance Guide Chapter 2 – Receiving, Handling & Storage Receiving Before leaving the factory, the motor control center is given a final mechanical and electrical inspection and is packed in accordance with the best practices for electrical equipment. On receipt of any apparatus, make an immediate inspection for any damage or loss of equipment in transit.
Evolution Series E9000 Installation & Maintenance Guide Chapter 3 – Installation Before any installation work is begun, consult all drawings furnished by the General Electric Company as well as all applicable contract drawings for the particular installation. Pay particular attention to the location of units in the motor control center and their relations to existing or planned conduits and busways.
Evolution Series E9000 Installation & Maintenance Guide Surface under motor control center base must be of non-combustible material unless bottom covers are installed in each vertical section. The overall height of the equipment should be considered with respect to headroom, top conduit entry space and alignment with other equipment. Figure 7C. Low bus position of ground and neutral bus (minimum available space for conduit entry) in 13-inch deep section, 6-inch cover. Figure 7D.
Evolution Series E9000 Installation & Maintenance Guide Do not use compressed air to clean the equipment if it contains moisture. Remove all hardware packages, drawings and other items shipped with the equipment. Check all nuts, bolts, and electrical joints for tightness. All cables entering the bottoms of sections should be pulled through conduits to a point where they will be accessible after the equipment is in place. Sections can be moved to their final position and properly leveled. Figure 11.
Evolution Series E9000 Installation & Maintenance Guide Bus Splice Kits as illustrated. Note that for Condition 3, where there is an enclosure on opposite sides of the working space, the clearance for only one working space is required. Table 2. Bus Splice Kits Splicing From / To E9000/E9000 Main Bus Splice Amps Assembly Kit Size Bars/ (in.) Phase (thick x Copper width) SC Rating Splice 600V Max. Instruction (sym.
Evolution Series E9000 Installation & Maintenance Guide Figure 17. Typical top entry of main cables to the incoming-line lug compartment (600A shown) Figure 16. Top conduit entry space for 20-inch and 22-inch sections Table 3. Dimensions for Figures 15 and 16 Width Dimension A Dimension B 20" 20" 17.56" 24" 24" 21.56" 30" 30" 27.56" Equipment Wiring When pulling, bending, and terminating field wiring, avoid scraping, cutting or otherwise damaging cable insulation or strands.
Evolution Series E9000 Installation & Maintenance Guide lugs on the disconnect. Connect the motor leads at the starter terminals if either of these conditions is met: a. The motor control center is furnished as “NEMA B-D wiring” (where D=Device) or b. The starter is NEMA size 6 or smaller. Connect the motor leads to the starter at the T1, T2, and T3 terminals if these conditions are met: a. The equipment is furnished as “NEMA B-T” wiring and b. The starter is NEMA size 2 or smaller.
Evolution Series E9000 Installation & Maintenance Guide Field connections to these control and load terminals should be made at the master terminal boards. Make field connections to all feeders and motor loads for starters larger than NEMA size 2 as described for NEMA Type B motor control centers. Optional grounding lug can be provided in each Plug-in unite if vertical ground bus is specified. Figure 21. Side cutout dimensions on 13", 20", 22" and 25".
Evolution Series E9000 Installation & Maintenance Guide height, order a blank filler door with hinge hardware and a snap shelf. See the renewal parts bulletin for ordering blank doors and gasket materials. The gasket material lines the inner perimeter of the section. Figure 23 shows the gasket material mounted to the outside of the door. Gasket 9. Slide the unit into the vertical section, then push at the top and bottom until the stabs are fully engaged with the vertical bus. 10.
Evolution Series E9000 Installation & Maintenance Guide 5. Turn the latches at the top and bottom of the unit a quarter turn counterclockwise to release the unit. These latches are shown in Figure 25 and Figure 26. 6. Pull unit out to remove it, being extremely careful to support its weight as it is fully withdrawn. 7. The door over the withdrawn unit can be latched closed. 8. If desired, a blank door can be ordered to cover the unused opening.
Evolution Series E9000 Installation & Maintenance Guide Table 3. Weight and heights of CB basic with CPT Plug-in units Estimated weight Minimum height no door (lbs) (inches) NEMA Size 1 FVNR 35 12 NEMA Size 2 FVNR 37 12 NEMA Size 3 FVNR 53 18 NEMA Size 4 FVNR 62 24 NEMA Size 5 FVNR 125 36 Figure 28. Concealed screw used to defeat the door interlock. CAUTION should be used when removing or installing units consider the weight in table above.
Evolution Series E9000 Installation & Maintenance Guide NEMA 3R Outdoor Enclosure Installation Figure 32. Rotating the operating handle to access the breaker. Pilot Bracket and Door The pilot device door can be removed by lifting straight off per Figure 33. Also, the metal bracket can be removed by loosening mounting screws and removing bracket. NEMA 3R Installation Instructions Figure 33. Grasp the center of the door. 1. Remove left rear cover on right shipping module (Figure 1.
Evolution Series E9000 Installation & Maintenance Guide 17
Evolution Series E9000 Installation & Maintenance Guide Chapter 4 – Operation Preparing for Initial Operation In addition to the normal circuit checking after wiring is completed, the following specific actions should be taken before energizing the equipment: 1. Check and tighten any electrical connections, such as lugs and bus splices that may have loosened during shipment, handling and installation. Torque values are provided on or adjacent to components or lugs.
Evolution Series E9000 Installation & Maintenance Guide 5. Close the main disconnects, if any, at the motor control center. 6. Close each branch-circuit disconnect or feeder at the motor control center. 7.
Evolution Series E9000 Installation & Maintenance Guide Chapter 5 – Maintenance Equipment Maintenance De-energize all equipment before performing any maintenance operation. There may be voltage present within the equipment from remote sources, even though all main- and branch-circuit disconnects have been opened at the equipment. Failure to observe this precaution can result in serious injury or death.
Evolution Series E9000 Installation & Maintenance Guide 7. Slide the breaker down and out. 8. Install the new breaker by following this procedure in the reverse order. Torque all electrical connections. Replacing a Control Power Transformer Mounted Under Disconnect Figure 42. Pilot light and pushbutton removal tool, catalog number GEN-1684A. Figure 43. EntelliGuard Trip Unit Digital Test Kit, catalog number GTUK20.
Evolution Series E9000 Installation & Maintenance Guide Publications Available from GE Order any of the following publications from your nearest GE Energy representative, authorized distributor, or from the following address: GE Energy Distribution Services PO Box 2913 Bloomington IL 61702-2913 Phone: 309-664-1513 Fax: 309-662-6990 The following instructions are available.
Evolution Series E9000 Installation & Maintenance Guide Ordering Additional or Replacement Parts Other Information The following information is needed for supplying the proper equipment: 1. All data on the motor control center master nameplate 2. If the unit is to be a duplicate of an existing unit, all data on that unit’s nameplate, located on the right side of the unit 3. NEMA control center class: I or II 4. NEMA wiring type: A, B or C 5. NEMA enclosure type: 1, 1 Gasketed, 2, 3R or 12 6.
Evolution Series E9000 Installation & Maintenance Guide Chapter 6 – Overload Heaters Heaters for Ther-Mag Circuit Breaker Controllers For continuous-rated motors with a service factor of 1.15 to 1.25, select the appropriate heaters for the motor full-load current. For continuous-rated motors with a service factor of 1.0, multiply the motor full-load current by 0.9 and use this value to select heaters. Overload relay tripping current in 40°C ambient is the minimum value of full-load current multiplied by 1.
Evolution Series E9000 Installation & Maintenance Guide Size 5 (Standard and Ambient Comp.) Motor FullLoad Amps 3-Ph, 3 Heater 109-118 119-128 129-138 139-155 156-168 169-184 Heater Number CR 123 C592A C630A C695A C778A C867A C955A Motor FullLoad Amps 3-Ph, 3 Heater 185-200 201-221 222-237 238-262 263-270 Circuit breaker tripping may be an indication that a fault current has been interrupted.
Evolution Series E9000 Installation & Maintenance Guide Size 0 and 1 (Ambient Comp.) Motor FullLoad Amps 3-Ph, 3 Heater .66-.76 .77-.84 .85-.93 .94-1.04 1.05-1.15 1.16-1.27 1.28-1.39 1.40-1.55 1.56-1.73 1.74-1.89 1.90-2.05 2.06-2.28 2.29-2.47 2.29-2.47 2.48-2.79 2.80-3.31 3.32-3.70 3.71-4.06 4.07-4.47 4.48-4.95 4.96-5.49 4.96-5.49 5.50-5.91 5.50-5.91 5.92-6.47 6.48-7.20 7.21-8.22 8.23-8.72 8.73-9.67 9.68-10.4 10.5-11.0 11.1-12.4 11.1-12.4 12.5-13.2 13.3-15.4 15.5-17.
Evolution Series E9000 Installation & Maintenance Guide Size 3 (Standard and Ambient Comp.) cont. Motor FullLoad Amps 3-Ph, 3 Heater 55.5-63.3 63.4-66.1 66.2-73.5 73.6-82.2 82.3-86.9 Heater Number CR 123 F772B F848B F914B F104C F114C TEC & TECL Rating 100 100 100 100 100 Mag-Break Trip Setting Rec. Max.
Evolution Series E9000 Installation & Maintenance Guide Size 0 and 1 (Ambient Comp.) Motor FullLoad Amps 3-Ph, 3 Heater .66-.76 .77-.84 .85-.93 .94-1.04 1.05-1.15 1.16-1.27 1.28-1.39 1.40-1.55 1.56-1.73 1.74-1.89 1.90-2.05 2.06-2.28 2.29-2.47 2.48-2.79 2.80-3.31 3.32-3.70 3.71-4.06 4.07-4.47 4.48-4.95 4.96-5.49 5.50-5.91 5.50-5.91 5.92-6.47 6.48-7.20 7.21-8.22 8.23-8.72 8.73-9.67 9.68-10.4 10.5-11.0 11.1-12.4 12.5-13.2 13.3-15.4 15.5-17.
Evolution Series E9000 Installation & Maintenance Guide Size 4 (Standard) Motor FullLoad Amps 3-Ph, 3 Heater 28.8-32.0 32.1-34.2 34.3-36.7 36.8-43.9 44.0-46.6 46.7-52.6 52.7-55.6 55.7-58.7 58.8-67.1 67.2-70.6 70.7-76.3 76.4-88.7 88.8-93.4 93.5-102.0 103.0-110.0 111.0-122.0 123.0-131.
Evolution Series E9000 Installation & Maintenance Guide Size 5 – 300:15 CT (Standard and Ambient Comp.) Motor FullLoad Amps 3-Ph, 3 Heater 106-115 116-125 126-135 136-151 152-164 165-179 180-195 196-215 216-231 232-255 256-270 Heater Number CR123 C592A C630A C695A C778A C867A C955A C104B C113B C125B C137B C151B SG Rating Plug 250 250 250 250 300 300 350 350 400 400 400 Instantaneous Trip Setting Rec. Max. LO 3 LO 4 2 4 2 5 2 4 2 5 2 4 2 5 2 4 2 5 3 5 Size 6 – 600:5 CT (Standard and Ambient Comp.
Evolution Series E9000 Installation & Maintenance Guide Size 0 and 1 (Standard and Ambient Comp.) Motor FullLoad Amps 3-Ph., 3-Heater .41-.45 .46-.49 .50-.53 .54-.59 .60-.65 .66-.76 .77-.84 .85-.93 .94-1.04 1.05-1.15 1.16-1.27 1.28-1.39 1.40-1.55 1.56-1.73 1.74-1.89 1.90-2.05 2.06-2.28 2.29-2.47 2.48-2.79 2.80-3.31 3.32-3.70 3.71-4.06 4.07-4.47 4.48-4.95 4.96-5.49 5.50-5.91 5.92-6.47 6.48-7.20 7.21-8.22 8.23-8.72 8.73-9.67 9.68-10.4 10.5-11.0 11.1-12.4 12.5-13.2 13.3-15.4 15.5-17.1 17.2-18.
Evolution Series E9000 Installation & Maintenance Guide Size 5 – 300:15CT (Standard and Ambient Comp.) Size 3 (Ambient Comp.) Motor FullLoad Amps 3-Ph., 3-Heater 17.8-18.4 18.5-21.1 21.2-22.1 22.2-26.1 26.2-28.0 28.1-31.3 31.4-33.3 33.4-34.3 34.4-40.9 41.0-44.7 44.8-51.0 51.1-52.0 52.1-55.4 55.5-63.3 63.4-66.1 66.2-73.5 73.6-82.2 82.3-90.
Evolution Series E9000 Installation & Maintenance Guide Heaters for NEMA Size 6 and 7 Fused Controllers For continuous-rated motors with a service factor of 1.15 to 1.25, select the appropriate heaters for the motor full-load current. For continuous-rated motors with a service factor of 1.0, multiply the motor full-load current by 0.9 and use this value to select heaters. Overload relay tripping current in 40° C ambient is the minimum value of full-load current multiplied by 1.25.
Catalog numbers of electronic overloads for various sizes of NEMA starters and current ranges. NEMA Size 1 1 1 1 1 2 2 2 3 3 3 4 4 4 5➀ 5➀ 5➀ FLA Range in Amps 0.8 to 1.59 1.6 to 3.19 3.2 to 6.49 6.5 to 12.8 13 to 27 13 to 25.6 26 to 49.9 50 to 100 17 to 34.9 35 to 64.9 65 to 90 17 to 34.9 35 to 64.9 65 to 135 32 to 64.0 65 to 129.
These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency that may be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the GE Company. GE Energy 41 Woodford Avenue, Plainville, CT 06062 www.geelectrical.
