GE Evolution Series E9000 User manual

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL

Evolution series E9000

Motor control center

04 Warnings, cautions and notes

05 – 08 Introduction

09 Receiving, handling and storage

10 – 29 Installation

30 – 32 Operation

33 – 36 Maintenance

37 – 49 Overload heaters

Table of contents

4EVOLUTION SERIES E9000 MOTOR CONTROL CENTER

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 in attention or lack of equipment knowledge

could cause either personal injury or damage to

equipment.

Caution notices are used for situations

in which equipment might be damaged if

care is not taken.

Notes call attention to information that

is especially significant to understanding

and operating the equipment.

Warnings, cautions and notes

As used in this publication

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 5

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.

Should further information be desired, contact

Post Sales Support: 1-888-437-3765

Refer to the requisition number found on the front

of the equipment when calling for assistance.

Disconnect equipment from all electrical

services before performing any installation

or maintenance work.

For additional information, including safety

considerations for personnel working on this

product, see NEMA Standard Publication No. ICS

2.3, Instructions on the Handling, Installation,

Operation, and Maintenance of Motor

Control Centers.

General description – vertical section enclosures

Each Evolution MCC vertical section is assembled

with two full-side sheets having openings near the

top and bottom for lateral busing and wiring

between sections. Multiple sections are joined

together at the factory in three-section (maximum)

shipping splits. Each shipping split is provided with

continuous floor sills and a lifting angle. Floor sills

and lifting angles are field removable. Each

shipping split includes a continuous non-removable

main horizontal bus. Main bus splice bars are

provided within each shipping split for field

connecting main busses. Refer to motor control

center outline drawings furnished by ABB for

location of shipping splits within each motor

control center lineup. Hinged doors are provided

over horizontal and vertical wireways. (These doors

can be removed by extracting the hinge pins inside

the doors.)

Vertical sections are normally provided with a

top (12-inch high) horizontal wireway and a bottom

(6-inch high) horizontal wireway. Non-arc resistant

vertical section is provided with a vertical (4-inch

wide) wireway. Each arc-resistant vertical section is

provided with a vertical (3.85-inch wide) wireway.

To open unit doors, rotate the latches 90'

counter-clockwise until the screwdriver

slots or knobs are vertical.

To open wireway doors, rotate the latches

90' clockwise until the screwdriver slots or

knobs are vertical.

Because of the great variety of motor controller

assemblies and components provided within

industrial motor control centers and to satisfy

floor-space limitations at installation sites, a large

variety of vertical section dimensions are provided,

as follows:

• Section Height: 90-inch², 78-inch¹, 66-inch¹ etc.

• Section Width: 20-inch, 24-inch, 30-inch etc.

• Section Depth: 13-inch¹, 20-inch, 22-inch or

deeper for large assemblies.

1. Not available in arc-resistant.

2. Sections with top fans and top vents will add 5" Sections with pull

box and plenum will add 12".

Introduction

—

Evolution Series

three-section lineup

—

Secure Unit Door Latch shown in secure positionOpen

6EVOLUTION SERIES E9000 MOTOR CONTROL CENTER

General description – arc-resistant

The arc-resistant sections are built with increased

structural capacity. The main enhancements are

thicker gage of steel, latches, hinges, and metallic

PD brackets. In addition, there are two versions

available with and without a plenum. The plenum

option adds 12-inches to the top of the 90-inch

section. The plenumless option should have a 4'

clearance on top of the MCC. The top (12-inch high)

horizontal wireway door and the bottom (6-inch

high) wireway door utilize multi-turn latches to

secure the doors. The remaining latches are ¼ turn

(with options for closed status indication). There is

no variation in the units between arc-resistant and

standard E9000 other than the unit door.

Additionally, the Arc Flash Mitigation units are

compatible in arc-resistant design with arc-

resistant/Arc flash Mitigation door.

General description –

motor control center buses

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 2A shows

a horizontal power bus with its Lexan barrier. For

arc-resistant design, uses this same Lexan barrier

with additional Metallic dead front barrier. Figure

2B shows the 2500 A without fans and the

3000/3200 A main horizontal bus configuration.

The vertical bus, either 300 A or 600/850 A, is

connected with two bolts per phase to the main

bus. The phase relationship is A–B–C from top to

bottom and left to right, as viewed from the front.

2500 A Type 12 construction without fans will be

limited to 700A vertical bus.

A continuous horizontal ground bus, sized in

accordance with the National Electrical Code, is

provided near the bottom of all motor control

centers.

An optional vertical ground bus can be provided in

each section providing additional grounding. A

neutral bus is provided, when specified, in the

bottom of the incoming section or in the bottom of

all enclosure(s) as specified.

As shown in Figure 3, the arc-resistant MCC will

include a metallic main bus barrier in addition to

the standard Lexan barrier.

General description –

motor control center units

Consult Publication DET-291 for detailed listings of

Evolution MCC units.

Plug-in units are supplied with stabs rated at either

250 A or 600 A. Arc Flash Mitigation (AFM) units are

supplied with retractable stabs, mechanical

interlocks, racking screw, and visual stab and

shutter indicators. AFM units are available in

plug-in or stab-bolt configuration.

Installation and operation of units, both standard

and AFM, are described on page 18 of this guide.

—

02A

—

02B

—

02A

Horizontal bus with

Lexan barrier

—

02B

2500A without fans,

3000/3200 A main

horizontal bus

—

Metallic horizon-

tal bus barrier for

arc-resistant design

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 7

Bus splicing

Main, neutral and ground bus splice bars (with all

associated hardware) are furnished, as necessary,

to join sections together. They are located in the

first section to the right of the joint.

Remove the top Lexan barrier, as shown in Figure

2A and Figure 04, to access the main bus. Refer to

instruction drawings in splice kit. See Table 2.

Arc-resistant design has metallic barrier in addition

to the Lexan barrier which also must be removed to

access the main bus. Arc-resistant shipping splits

will arrive with end caps. When bus splicing, please

remove these end caps to make connection, only

the furthest most left and right end caps shall

remain.

—

Horizontal bus barrier

mounting slot and screw

—

Amps Main Bus Splice

Assembly Kit

Bars/

Phase

Copper

Size (in.)

(thick x

width)

SC Rating



(sym.amps)

Splice

Instruction

Drawing*

Standard Splicing

      

      

     



     

       



     



      

     

     

      



       



      

Bolt Size Copper Joints Aluminum Joints

lb-ft N-m lb-ft N-m

    

    

    

    

     



Torque values for various bolt sizes and joint types.

Bus splice kits



 When assembling or connecting

to aluminum bus, apply a suitable

joint compound between the

contacting surfaces.

*Included in kits

 Standard plating is tin. Refer to

factory for alternate plating.

8EVOLUTION SERIES E9000 MOTOR CONTROL CENTER

Bus splicing steps for 2500A without fans,

3000A, and 3200A main bus

For 2500 A without fans, 3000 A, and 3200 A main

bus, it is recommended to pre-mount the align and

torque all splices in all phases before you join the

section if possible. If splicing from the left, pre-

mount the splices and pre-torque bolts from right

case side opening. If splicing from the right, slide in

bus bars through left case side opening and access

the bolts for torquing through the vertical wireway.

 Mount on left side of section

Transition case and

MAIN/MLO section

Splices mounted on

the left side of section

Connect feeder section with splices

Connect main buses with splices

Connecting Feeder

section with splices

to MAINs/MLOs with

transition case

3 pieces/phase

of splices

Main buses

connected

by splices

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 9

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. Should damage or missing material

be noted, file a claim immediately with the carrier

and notify the nearest office of ABB. Information

such as a description of the damage, the shipping

crate numbers, the requisition numbers and

the panel catalog number should accompany

the claim.

Handling

Motor control center sections are always shipped in

an upright position, in single or group sections.

Sections must be maintained in an upright position

during all handling.

Never attempt to jack, lift, or move the equipment

at points other than the lifting angle or floor sills.

Use two or more chains or cables to distribute the

weight evenly. Pinch bars, pipe rollers or slings are

useful implements for handling equipment; but be

careful to maintain distributed loading and to

always apply leverage at the floor sills and/or

lifting eyes. Figures 05A and 05B illustrate typical

handling techniques.

Storage

If it is necessary to store the equipment for any

length of time, be sure to observe the following

precautions:

• Uncrate the equipment.

• Store the equipment in a clean, dry, humidity-

controlled area at moderate temperature. Cover

with a suitable canvas or heavy-duty plastic cover

to prevent entrance of foreign material.

• If equipment must be stored in cool or high

humidity areas, in addition to completely

covering the equipment, provide a heat source to

prevent condensation of moisture in the

equipment. Energize space heaters (if furnished

in the equipment) or place a standard 120-volt

lamp rated at 75 watts inside the bottom of each

vertical section.

Receiving, handling and storage

—

05A

Using standard lifting

angles or lifting eyes

to hoist the MCC

—

05A

—

05B

—

05B

Positioning the

MCC with rollers

10 EVOLUTION SERIES E9000 MOTOR CONTROL CENTER

Installation



1. If anchor bolts are to be inbedded in the

foundation, they must be Equipment.

Locate one in the center front and one in

the center back. Anchor bolts should be



(minimum) In non-Seismic Zone 4

Locations. Bolts must extend a minimum

of 2 11/32 inch above grade to 3/4 inch

above the channel sill. If 13 (330.2mm)

deep verical sections are used, anchor

bolts or some form of external bracing

is required.

2. Seismic Zone 4 IBC testing was



torqued to 50 foot-pounds, located in

each of the four corners in each section.

Ref.

Dim.

Section Depth

   

Width "A" B C B C B C B C

        

        

         

        

        

        

—

Bottom view: Location of mounting holes

Indoor enclosures

Front elevation and mounting locations

(13-inch, 20-inch, 22-inch and 25-inch

Deep sections)

Before any installation work is begun, consult

all drawings, 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.

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