medium voltage motor starters - ingersoll rand...

Medium VoltageMotor StartersBulletin 1500, 1900

Specification Guide

SyncPro, SCANport, Centerline and ControlNet are trademarks of Rockwell Automation.DeviceNet is a trademark of the Open DeviceNet Vendors Association (O.D.V.A.).

Table of Contents

Section Description Page

1.0 General.............................................................................................. 1Introduction ........................................................................................ 1

Controllers for the World ............................................................ 1Features........................................................................................ 1Squirrel-Cage, Induction Motor Controllers ............................... 4Wound Rotor Motor Controllers ................................................. 4Brush and Brushless Synchronous Motor Controllers ................ 4

2.0 Scope.................................................................................................. 5

3.0 Codes and Standards....................................................................... 5Environmental Conditions ................................................................. 6Seismic Qualifications ....................................................................... 6

4.0 Obligations of Seller......................................................................... 6Deviations .................................................................................... 6

5.0 Drawings and Manuals.................................................................... 7Information Drawings ........................................................................ 7Approval Drawings ............................................................................ 7Final Drawings and Manuals ............................................................. 7

6.0 Spare Parts....................................................................................... 8Critical Spares .................................................................................... 8Maintenance Spares ........................................................................... 8On-Site Inventory Agreement (Optional) .......................................... 8

7.0 Quality Assurance............................................................................ 8Standard Testing ................................................................................ 9Physical Inspection ............................................................................ 9Factory Inspections ........................................................................... 10

Visual Inspection of Equipment ................................................. 10Witness Testing .......................................................................... 10Custom Testing ........................................................................... 11

8.0 Equipment Design and Selection................................................... 12Structure and Controller .................................................................... 12

Enclosure Types ......................................................................... 13Structure Finish .......................................................................... 14

Power Bus ......................................................................................... 15Horizontal Bus ............................................................................ 15Vertical Bus ................................................................................ 15Bus and Cable Bracing ............................................................... 16Ground Bus ................................................................................. 16

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1500-2.0 – September 1999

ii Table of Contents


8.0 Equipment Design and Selection (cont.)

Main Isolating Switch ....................................................................... 16Interlocking ....................................................................................... 17Power Fuse and Fuse Holders ........................................................... 18Vacuum Contactor Specifications..................................................... 18Control Wire Specification ............................................................... 19

Low Voltage Wireway ............................................................... 19Low Voltage Control Panel .............................................................. 20Control Power Transformer .............................................................. 21

Primary Fuses ............................................................................. 21Secondary Fuses ......................................................................... 21

Current Transformer ......................................................................... 22Power Wire Specification ................................................................. 22Motor Protection Devices ................................................................. 22

Undervoltage Protection ............................................................. 22Prepared Spaces ................................................................................ 23

Starter Prepared Spaces .............................................................. 23Load-Break Switch Prepared Spaces.......................................... 24

Starter Kits ........................................................................................ 25Feeder Kits ........................................................................................ 26

9.0 Transportation and Equipment

Delivery Times .................................................................................. 27Loading Equipment ........................................................................... 27Special Packaging Requirements (Optional) .................................... 27

10.0 Commissioning

Start-Up Commissioning Services (Optional) .................................. 28On-Site Training (Optional) .............................................................. 28

1500-2.0 – September 1999

Table of Contents iii


11.0 Basic Data Sheets

General Specifications ...................................................................... 29Main Horizontal Power Bus .............................................................. 30Vertical Power Bus ........................................................................... 30Ground Bus ....................................................................................... 30Power Fuses and Fuse Holders ......................................................... 31Power Losses..................................................................................... 31Vacuum Contactors ........................................................................... 32Control Wire ..................................................................................... 33Control Relays................................................................................... 33Power Wire ....................................................................................... 34Control Power Transformer .............................................................. 35Potential Transformer ....................................................................... 35Transformer Ratings ......................................................................... 35Current Transformer ......................................................................... 36Bar and Donut Current Transformers ............................................... 36Environmental Ratings ...................................................................... 37Starter Ratings ................................................................................... 37Starter Deratings ............................................................................... 37Structure Styles, Dimensions and Weights ....................................... 38

12.0 References........................................................................................ 39

1500-2.0 – September 1999

iv Table of Contents

1500-2.0 – September 1999

Bulletin 1500/1900 Medium Voltage Motor Starters 1

1.0 General Introduction

At Rockwell Automation, we are committed to providing the products andservices that our customers demand. Over the past seventy years, Allen-Bradley medium voltage Centerline® controllers have set the standard bywhich others are measured. Our unmatched quality and innovative designshave made us the leader in medium voltage motor control productsworldwide.

Controllers for the World

Regardless of where you are located, Rockwell Automation has local salesand support offices prepared to help you with your most demanding mediumvoltage needs. Our distributors and sales offices are located in virtuallyevery industrialized nation around the world. Your local team of expertswill help you select the right solution for your application whether it is ablower, chipper, chiller, compressor, pump, fan, transformer feeder, or otherapplication. Our wide range of full voltage controllers, mechanical or solid-state, reduced voltage controllers, and variable frequency AC drives give youthe flexibiity to select the motor control that will give you the utmost inreliability and process control. The Allen-Bradley Centerline® family ofmedium voltage controllers are available for system voltage ratings from2400 to 6900 volts, and can be applied to motors ranging in size from 75 kW(100 hp) to 7,500 kW (10,000 hp).

At Rockwell Automation, we know that there is more to being a world-classsupplier than just having the right product. That is why we have developeda variety of flexible delivery programs. If speed is critical to your selection,our ezShip delivery program may be just what you require. The ezShip programoffers a variety of controllers, options and accessories to choose from.

From start to finish, whether it is local support, product selection and fastdeliveries, Rockwell Automation has the products and services to help youcontrol any medium voltage challenge.

Features

Low Voltage Compartment

Control Panel

• Separate 120 volt source is required for TEST position control power• Allows testing and troubleshooting of the power cell without exposing

personnel to medium voltage• Prevents backfeeding medium voltage through the control power

transformer in TEST mode

1500-2.0 – September 1999

2 Bulletin 1500/1900 Medium Voltage Motor Starters

1.0 General (cont.) Features (cont.)

Low Voltage Compartment (cont.)

Isolated Compartments

• All low voltage components are located in the low voltage compartment• Low voltage panel interior painted white for better visibility• Power cell, low voltage panel, and bus compartment are isolated from

each other for better fault containment

Power Bus Compartment

Centerline Bus Design

• Designed as an integral part of the structure• Dissipates heat more efficiently• Edge-to-edge configuration maximizes resistance to magnetic forces and

minimizes moisture or dust collection• Molded bus brace reduces maintenance and provides better distribution of

forces during a fault• Accessible without a ladder, for installation and maintenance• Allows for incoming line cables to enter through the top or bottom of the

compartment

Power Cell Compartment

Non-Load-Break Isolation Switch

• Electrical and mechanical interlocks prevent the switch from opening orclosing when the contactor is energized.

• Ensures normal operation only when the switch is fully closed.• Allows for separate source testing when in the "OFF" position.• Blade stabs are grounded in the "OFF" position.

Visible Isolation

• When in the open position, a visible barrier isolates the power cell fromthe power bus compartment.

• Status of the isolation switch can be viewed through a window in thepower cell door.

Handle and Interlock Mechanism

• Simple direct drive mechanism improves reliability and ensures superioroperator safety.

• Mechanical interlock mechanism remains part of the enclosure toeliminate setup adjustment.

• Power cell door is interlocked with the handle mechanism to prevent thedoor from being opened when the cell is energized.

1500-2.0 – September 1999



Power Cell Compartment (cont.)

Isolated Cable Ducts

• Easy access for cable installation• Ample room for stress cones• Provides isolated load cable compartments between top and bottom

power cells

Swing Out Low Voltage Panel

• Allows for easy access to install load cables• Maximizes low voltage panel space

Current Transformers

• Bar-type current transformers are supplied as standard for overloadprotection and metering

Vacuum Contactors

Modular Construction

• Designed to be interchangeable with other contactors of the same rating• Horsepower rated devices are located elsewhere in the power cell, not on

the contactor• Easily removed for maintenance and repair

Vacuum Bottles

• Designed to industry specifications• Arcing confined inside vacuum bottle for ionized gas protection• Mounted on the front of the contactor for visible inspection• Contact wear indicators located on the bottle eliminates the need for

special tools• Excellent dielectric recovery provides high switching frequency

Long Electrical and Mechanical Life

• 1,000,000 electrical operations (400 A)• 2,500,000 mechanical operations (400 A)

Low Current Chop

• No surge suppression required for most applications• Reduces the chance of cable or motor insulation failure caused by voltage

spikes

1500-2.0 – September 1999



Vacuum Contactors (cont.)

Fixed-Mounted Devices

• Fixed-mounted design eliminates the wories typically associated withdrawout contactors

• Compact design of the contactor eliminates the need for it to be removedfrom the power cell

• No drawout stab and finger assemblies, which require routine maintenance

The medium voltage product line shall provide various starting methods andoptions:

Squirrel-Cage, Induction Motor Controllers Bulletin Numbers

Full Voltage Non-Reversing...........................................................1512Full Voltage Reversing...................................................................1506Multi-Speed, Non-Reversing .........................................................1522Multi-Speed, Reversing.................................................................1526Part-Winding, Non-Reversing .......................................................1532Part-Winding, Reversing...............................................................1536Wye-Delta, Non-Reversing ...........................................................1542Wye-Delta, Reversing ...................................................................1546Reduced Voltage Autotransformer, Non-Reversing.......................1572Reduced Voltage Autotransformer, Reversing...............................1576Reduced Voltage Reactor, Non-Reversing ....................................1582Reduced Voltage Reactor, Reversing ............................................1586

Wound Rotor Motor Controllers

Full Voltage Non-Reversing...........................................................1552Full Voltage Reversing...................................................................1556

Brush & Brushless Synchronous Motor Controllers

Static Exciters ................................................................................1271Full Voltage Non-Reversing...........................................................1912Full Voltage, Reversing..................................................................1906Part-Winding, Non-Reversing .......................................................1932Part-Winding, Reversing...............................................................1936Reduced Voltage Autotransformer, Non-Reversing.......................1972Reduced Voltage Autotransformer, Reversing...............................1976Reduced Voltage Reactor, Non-Reversing ....................................1982Reduced Voltage Reactor, Reversing ............................................1986

We sincerely believe that your exact requirements can be fulfilled.

1500-2.0 – September 1999


2.0 Scope This specification outlines the overall fabrication, performance and func-tional requirements for a medium voltage motor controller for use withpolyphase motors. The complete controller shall meet the overall designrequirements as specified herein.

The starter shall be _____ V, 3 phase, _____ hp or _____ kW rated, andused for the starting of ______ motors (induction, synchronous, woundrotor).

3.0 Codes and Standards The Seller's equipment shall be designed, manufactured and tested to meet orexceed the applicable requirements of the latest standards published by thefollowing organizations:

• Canadian Standards Association (CSA), Industrial Control EquipmentC22.2 No. 14

• American National Standards Institute (ANSI), Instrument TransformersC57.13

• Institute of Electrical & Electronic Engineers (IEEE)

• National Electrical Code (NEC)

• Electrical & Electronic Manufacturers Assoc. of Canada (EEMAC)

• Occupational Safety & Health Act (OSHA)

• Guide for Harmonic Control and Reactive Compensation of Static PowerConverters (IEEE 519-1992)

• National Electrical Manufacturers Association (NEMA), Medium VoltageControllers Rated 1501 to 7200V AC ICS 3-2 (formerly ICS 2-324)

• Underwriters Laboratories, Inc. (UL), High Voltage Industrial ControlEquipment 347

• European Directives for Safety and EMC

Note: It shall be the responsibility of the user and/or installer to know andmeet all local codes, standards, and OSHA requirements.

1500-2.0 – September 1999


3.0 Codes and Standards Environmental Conditions (cont.)

The controller shall accept nominal plant power of 2400V, 3300V, 4200V,6600V or 6900V AC ( ±10%), 3 phase 50/60 Hz (± 3%).

The controller shall operate in an ambient temperature range of 0°C to 40°C(32°F to 104°F) with a relative humidity of up to 95% (non-condensing).

The equipment shall be capable of being stored in an environment with anambient temperature range of -20°C to 75°C (-4°F to 149°F) for electroniccomponents.

The equipment shall operate at altitudes from 0 to 1000 m (3,300 ft) abovesea level, without derating. For applications above 1000 m (3,300 ft), themaximum current and Basic Impulse Levels (B.I.L.) of the controllers shallbe derated, and vacuum contactors shall be compensated for operation atthe specified altitude (see page 37).

Seismic Qualifications

The starter, when bolted down (mounted) per the Seller's recommendedinstallation instructions, shall withstand certain horizontal and verticalaccelerations (seismic zones 1, 2, 3 and 4) without overturning or lateralmovement.

Note: The seismic qualification does not indicate that the equipment willoperate properly during or after a seismic event.

4.0 Obligations of Seller Deviations

Any exceptions or deviations shall be defined in writing at the time of bid.

1500-2.0 – September 1999


5.0 Drawings and Manuals Information Drawings

Orders shall include a submittal of three (3) bond paper prints of the dimen-sion drawing and electrical drawings (two for customer and one for Seller'slocal representative), at the time engineering is finalized. These drawingsshall be suitable for photo copying.

Approval Drawings

If requested at the time of order entry, approval drawings shall be availableat no charge. The approval submittal shall include (3) bond paper prints ofthe dimension drawing and electrical drawings supplied at the published leadtime after order receipt by Seller. Submittal of approval drawings requiresan additional ______ weeks. Approval drawings can be sent electronicallyvia the Internet, as an alternative to sending them by mail.

Note: Seller shall allow the customer two (2) weeks to review the draw-ings. This period starts on the date that the drawings are shipped tocustomer and ends on the date that the drawings must be back to Seller.If drawings are returned earlier than two (2) weeks, then lead-time shallbe adjusted accordingly.

Final Drawings and Manuals

Certified drawings, instruction and maintenance manuals (3 sets) shall be sentwithin 30 days of final product shipment. Final drawings shall be available inDXF format at no charge.

1500-2.0 – September 1999


6.0 Spare Parts Recommended spare parts list and prices shall be supplied with the bid.Also, the address of the manufacturer’s closest parts stocking location tothe user shall be provided.

Critical Spares

These parts are identified as being associated with long lead times and/or arecritical to the unit's operation. They should be held in reserve by the customerto limit unforeseen downtime.

Maintenance Spares

These parts are identified as being required by customers to regularlyperform scheduled maintenance on their equipment. They include, but arenot limited to, consumable spares that are required to be exchanged duringscheduled customer maintenance periods.

Seller shall assist in determining an appropriate level of spare parts inconjunction with the customer’s bill of material (which may include circuitbreakers, full voltage starters, load break switches and other auxiliaryequipment, including variable speed drives) and the customer’s currentinstalled base.

On-site Inventory Agreement (Optional)

Seller shall offer an on-site inventory agreement, in which the Seller willstock and supply as needed all of the spare parts required by the user in theclosest stocking location. The user shall have a controlled/immediateaccess to this inventory 365 days a year.

7.0 Quality Assurance All inspection and testing procedures shall be developed and controlledunder the guidelines of the seller's quality system. This system must beregistered to ISO 9001 and regularly reviewed and audited by a third partyregistrar.

All incoming material shall be inspected and/or tested for conformance toquality assurance specifications.

All sub-assemblies shall be inspected and/or tested for conformance tovendor’s engineering and quality assurance specifications.

All printed circuit boards with active components shall be burned-in for aminimum of 48 hours at 60ºC (140°F).

1500-2.0 – September 1999


7.0 Quality Assurance (cont.) Standard Testing

The following tests shall be carried out in accordance with applicablerequirements and/or specifications of Canadian Standards Association(CSA), Underwriters Laboratories (UL), National Electrical ManufacturersAssociation (NEMA), European Standard (EN), and InternationalElectrotechnical Commission (IEC).

Functional checks shall be performed wherever possible; otherwise, inspec-tion and continuity checks shall be made.

A "HI-POT" dielectric withstand test shall be performed on all buswork andcables from phase to phase and phase to ground (except solid-statecomponents, low voltage controls and instrument transformers). Thevoltage level used for this test depends on the product's nominal ACvoltage.

Component devices shall be functionally operated in circuits as shown onelectrical diagrams or as called for by specific test instructions.

Instruments, meters, protective devices and associated controls shall befunctionally tested by applying the specified control signals, current and/orvoltages.

Medium Voltage starters shall be inspected for the following:• Electrical interlocking• Motor protection and ground fault, if applicable

Physical Inspection

The product must meet all applicable engineering and workmanship stand-ards and specifications. All components shall be verified against engineeringdocumentation to be present and correctly installed.

Warning plates, isolation barriers, and mechanical interlocks must providesufficient safety/isolation for personnel and equipment.

• Warning labels and nameplates must be present and in their specifiedpositions to advise personnel of possible hazards.

• Isolation barriers must be in place within the cabinet. Such barriersprotect personnel from touching live medium voltage components in anarea that otherwise does not have power supplied to it.

• Operation of isolation switch handle and door interlocks must be verified.The interlocking prevents the opening of any medium voltage door on amedium voltage cabinet when the isolation switch handle has beenmoved to the full ON position.

All bus and bus connections shall be checked for proper clearance,creepage, phasing, and torque.

1500-2.0 – September 1999


7.0 Quality Assurance (cont.) Factory Inspections (Optional)

Visual Inspection of Equipment

If requested, a review of the electrical and mechanical drawings for thepurchased equipment will be done with the Applications Engineer orProject Manager prior to commencing the inspection.

The visual inspection consists of a customer visit to the factory, with priornotification and coordination with the Customer Service Coordinator orthe Project Manager, with the intent to view the customer-specific equipmentat the various stages of build during the visit. There is no preparation ofthe equipment in any way for this inspection and is a means to allow thecustomer to verify the progress of the order without any disruption to themanufacturing cycle.

Witness Testing

Medium Voltage Starters

A review of the electrical and mechanical drawings for the purchasedequipment will be done with the Applications Engineer or Project Managerprior to commencing the tests. Any questions or clarifications prior tocommencing the test will be addressed at this time. The Test Facility willthen host the customer for the duration of the actual testing. At theconclusion of the test the customer will reconvene with the ApplicationsEngineer or Project Manager to discuss any concerns or issues that aroseduring the test. The Project Manager or Applications Engineer will respondback to the customer at the earliest possible time with an outline of thefinancial and/or schedule impact of the changes

The Medium Voltage starter testing consists of demonstrating an AC highpot test to the customer. Control power at the rated voltage is then appliedto the equipment, and a functional demonstration of customer purchasedoptions and control devices is completed. This is completed with the starterin the TEST position. The operation of the vacuum contactor is alsodemonstrated. The starter is then placed into the NORMAL position andoperation is demonstrated. There will be no medium voltage applied, andthe testing will be conducted in the low voltage test bay.

1500-2.0 – September 1999


7.0 Quality Assurance (cont.) Factory Inspections (Optional)

Witness Testing (cont.)

Synchronous Starters

A review of the electrical and mechanical drawings for the purchasedequipment will be done with the Applications Engineer or Project Managerprior to commencing the tests. Any questions or clarifications prior tocommencing the test will be addressed at this time. The Test Facility willthen host the customer for the duration of the actual testing. At theconclusion of the test, the customer will reconvene with the ApplicationsEngineer or Project Manager to discuss any concerns or issues that aroseduring the test. The Project Manager or Applications Engineer will respondto the customer at the earliest possible time with an outline of the financialand/or schedule impact of the changes.

The Medium Voltage synchronous starter testing consists of demonstratingan AC high pot test to the customer. Control power at the rated voltage isthen applied to the equipment, and a functional demonstration of customerpurchased options and control devices is completed. This is completed withthe starter in the TEST position. The operation of the vacuum contactor isalso demonstrated. The starter is then placed into the NORMAL postionand operation is demonstrated. Voltage is then injected into the powercircuit within the starter at the secondary, and operation is demonstratedutilizing a resistive load. There will be no medium voltage applied, and thetesting will be conducted in the low voltage test bay.

Custom Testing

The Seller shall be prepared to provide custom testing of the equipment. Thecustomer specifications for the customer test must be provided to the Sellerat least two months prior to the testing date at which time the Seller willprovide a cost and schedule impact for completing the testing requirements.

1500-2.0 – September 1999


8.0 Equipment Design Structure and Controller and Selection

The medium voltage motor controllers shall consist of a single structure or aline-up of structures containing the following:

• An isolated compartment for horizontal power and ground bus• A terminal provision to feed the bus• Removable backplates• An allowance for top or bottom entry of the power and/or control cables• An allowance for top or bottom exit of the load cables from the controller

through isolated metal wireway(s)• Viewing window in the power cell door• Removable lifting angles or brackets• Non-removable sill channels• Hybrid epoxy electrostatic powder paint finish• Appropriate starter units to meet the application requirements

The motor control center(s) (MCC) shall have provisions to enable them tobe bolted together to form a rigid, free-standing assembly, and shall bedesigned to permit bus extension for future controller additions to the leftand/or the right.

The controller shall be manufactured by a single vendor.

Each structure shall have two (2) non-removable base sill channels andremovable lifting angles or brackets for ease of handling and installation.

The medium voltage controllers shall be designed in two basic styles:

• 1-High: One (1) medium voltage controller in one (1) vertical section• 2-High: Two (2) medium voltage controllers in one (1) vertical section

The structure shall be divided into three (3) isolated compartments:

• Main power and ground bus compartment• Power cell compartment• Low voltage compartment

Metal or glastic barriers shall be provided between each vertical section,between the low voltage compartment and the power cell and/or mainpower bus compartment, and between the power cell and main power buscompartment. Personnel shall have access to the low voltage compartment,with the controller energized, without being exposed to any medium voltage.

The medium voltage motor controllers shall be for 3-phase, 3-wire, 50/60Hz applications, rated 2400, 3300, 4160, 4800, 6600 and 6900 volts.

1500-2.0 – September 1999


8.0 Equipment Design Structure and Controller (cont.) and Selection (cont.)

The medium voltage motor controller shall consist of a metal-enclosed,free-standing, dead front, vertical steel structure. Each structure shallcontain the following items:

• Tin-plated copper horizontal power bus (optional)• A continuous bare copper ground bus• A main non-load-break isolating switch and operating handle• A vacuum contactor• Three (3) current limiting power fuses for NEMA Class E2 operation• Three (3) current transformers• A control power transformer• A low voltage control panel• Space for necessary auxiliary control and metering devices• Top and bottom plates to accommodate entry cable connectors

Enclosure Types

The medium voltage product line shall be available in a NEMA Type 1(IEC IP40) general purpose enclosure as standard. Optional enclosures areNEMA Type 1 with door gasketing (IEC IP30), NEMA Type 12 dust tightand drip proof (IEC IP54) or NEMA Type 3R outdoor (IEC IP34) non-walk-in styles. Each enclosure shall be properly sized to dissipate the heatgenerated by the controller within the limits of the specified environmentaloperating conditions.

1500-2.0 – September 1999


8.0 Equipment Design Structure and Controller (cont.) and Selection (cont.)

Structure Finish

As standard, all exterior and interior metal parts (except for the power cellback plates and low voltage panel) shall be painted ANSI 49 medium lightgray (3R shall be ANSI 61). All metal back plates in the power cell andlow voltage compartments shall be painted high gloss white for highvisibility. Optional field touch-up spray can(s), matching the enclosure color,shall be supplied when requested.

Description....................... Hybrid epoxy powder paint - high gloss.Standard color .................. ANSI 49 medium light gray

(optional ANSI 61 light gray)Procedure........................ Continuous paint line. All parts are painted

before assembly.Preparation ...................... Alkaline wash/rinse/iron phosphate rinse/iron-

chrome sealer rinse/recirculated de-ionizedwater rinse and virgin de-ionized water rinse.

Painting............................ Air-atomized electrostatic spray.Total paint thickness - 0.002”(0.051 mm) minimum

Baking.............................. Natural gas oven at 179°C (355°F) minimum.

Notes:1. When optional custom paint color is specified (including ANSI 61),

all external surfaces shall be painted to the custom color requirement,except for the external isolating switch handle assembly, lifting anglesand lifting brackets .

2. All unpainted steel parts shall be plated with a zinc plate/bronze chromateprocess for corrosion resistance.

1500-2.0 – September 1999


8.0 Equipment Design Power Bus and Selection (cont.)

Horizontal Bus

The main horizontal power bus shall be located in the center, at the back ofthe structure, to provide optimum heat distribution, ease of maintenance andsplicing. The power bus shall be mounted on the edge to a molded bussupport insulator in a common vertical plane. This mounting methodprovides superior short-circuit withstandability and protection against theaccumulation of dust and tracking between phases. The power bus shall bemade of tin-plated copper and be available in one of the followingcontinuous current ratings: 1200, 2000 or 3000 amps. Optional silver-platedpower bus shall be available.

Access shall be provided to the bus compartment from the front or the rearof the structure to allow for installation and regular maintenance of thepower and ground bus splice connections.

The horizontal bus work, the cabling/bus from the main power cell shall bebraced and tested in accordance with NEMA ICS 2-3 and UL 347.

When optional insulated power bus is specified for the main horizontal bus, asleeve-type, heat shrink insulating material with good flame resistance andself-extinguishing properties shall be used. This material shall have aminimum wall thickness of 1.4 mm (0.055 in).

Vertical Bus

Vertical power bus risers shall be provided from the main horizontal powerbus to the isolating switch line terminals.

1500-2.0 – September 1999


8.0 Equipment Design Power Bus (cont.) and Selection (cont.)

Bus and Cable Bracing

The horizontal/vertical bus work and the cabling/bus in the main power cell(s)shall be braced and tested in accordance with NEMA ICS 3-2 and UL 347.

These standards require that the bus work withstand the let through energyallowed by the largest fuse during the short-circuit test for the maximumstarter interrupting rating. These short-circuit ratings are 400 MVAsymmetrical at 5000 volts and 200 MVA at 2500 volts, as defined byNEMA and UL. (These interrupting ratings are essentially the fuseinterruption ratings of 50,000 amps symmetrical.) These tests areconducted with the short-circuit at the load side of the controller, and themaximum current is limited by the current limiting fuse.

The bus work and cabling shall be braced to withstand the let-throughenergy allowed by the largest fuse during a short-circuit fault.

Ground Bus

A continuous bare copper ground bus shall be provided along the entirelength of the motor controller lineup. A mechanical lug for #8 - #1/0 AWGor #6 - 250 MCM cable shall be supplied at the incoming end of the lineup.The standard ground bus shall be 6 x 52 mm (1/4 in x 2 in) bare copper.Optional tin plating shall be available for corrosive environments.

Main Isolating Switch

The main power cell shall have an externally operated, 3-pole, gangoperated, fixed mounted non-load-break isolating switch providing thefollowing features:

• The isolating switch shall isolate the power bus compartment from thepower cell by means of a positively driven shutter mechanism to preventaccidental contact with line terminals in the power bus compartment.

• The main power cell door shall have a viewing window through which theoperator can verify that the isolating switch is open.

• The isolating switch shall only have the ability to interrupt the no-load(magnetizing) current of the control power transformer(s) (CPT) and/orpotential transformers (PT) supplied inside the controller power cell.

1500-2.0 – September 1999


8.0 Equipment Design Main Isolating Switch (cont.) and Selection (cont.)

• In the OFF position, the isolating switch shall provide a means of groundingappropriate medium voltage power cell components, bleeding off hazardousstored energy, thus providing safe operation and maintenance.

• Three rating sizes shall be available: 400 amp, 600 amp, 800 amp.

• One or more N-O and N-C auxiliary contacts shall be arranged to openthe secondary circuit of the CPT and/or PT, de-energizing the controlcircuit. This is to ensure there is no load on the isolating switch when it isopened or closed. The contacts shall also prevent backfeeding throughthe CPT and/or PT, and isolate the power cell when the control circuit isin the TEST mode. It shall only be possible to operate the TEST controlcircuit when the isolating switch is in the open position. The auxiliarycontacts shall have a NEMA contact rating of 2 x A600 and 2 x P600.

• The isolating switch shall remain connected to the external operatinghandle at all times. The isolating switch shall also be mechanically andelectrically interlocked with the main contactor.

• The external isolating switch operating handle shall have provisions to bepadlocked, with up to three (3) padlocks in the open position, and one (1)padlock in the closed position. The closed position shall be located andmarked, but shall be drilled out by the USER to allow insertion of thepadlock.

• The power cell door on each controller shall be interlocked with theisolating switch such that the door(s) cannot be opened when the isolatingswitch is fully closed, and the isolating switch cannot be closed with thedoor(s) open (without defeating the interlock with a tool).

Interlocking

Mechanical interlocking, including cable interlocks, horizontal and verticalram interlocks, shall be provided to prevent the opening of any power celldoor or medium voltage compartment until the non-load-break isolatingswitch is fully in the open position and power is removed (the externaloperating handle must be in the "OFF" position).

Optional key interlocks, configured to operate with the operating handle orpower cell door, shall be available when interlocking is required with anotherspecified device, i.e. main breaker, load-break switch, starter, etc.

1500-2.0 – September 1999


8.0 Equipment Design Power Fuses and Fuse Holders and Selection (cont.)

Depending on the type of load, R-rated or E-rated current limiting powerfuses shall be provided. R-rated fuses shall be used for the short-circuitprotection of medium voltage motors and motor controllers. E-rated fusesare general purpose fuses and shall be used in combination with an overloadrelay, under certain conditions, for the short-circuit protection of non-motorloads (when possible), i.e. primary protection of power transformers.

The medium voltage product shall have fixed power fuse holders that areseparately mounted in the power cell, not on the contactor, and be locatedto allow easy inspection and replacement without any disassembly. Thepower fuses shall provide visual condition indication by way of a spring-actuated blown fuse indicator. The power fuse size shall be selected whenmotor data and the protective device characteristics are known.

Vacuum Contactor Specifications

The electrically (magnetically) held or mechanically latched style mediumvoltage contactor shall be the Allen-Bradley Bulletin 1502 vacuum type.

The following current ratings shall be available:

• 400 amp• 800 amp

The contactor shall have visual contact wear indicators. No special toolsare required for checking contact wear.

The maintenance of vacuum bottles and coil maintenance shall be facilitatedwhile the contactor is mounted within a power cell. Removal of contactoris not required.

The contactor shall be fixed mounted inside the power cell. Fixedmounting provides solid, continuous contact while lowering maintenancerequirements considerably. The contactor shall be interlocked with thenon-load-break isolating switch, both electrically and mechanically and, as aconsequence, shall provide the following safety features:

• Prevent the isolating switch from being opened or closed when thecontactor is in the closed position.

• Prevent the opening of the medium voltage door when the isolatingswitch is in the closed position.

• Prevent the closing of the isolating switch when the medium voltage doorof the controller is open.

• Remove control power from the CPT, PT or external power source to thecontrol circuit when the isolating switch and contactor are in the open position.

1500-2.0 – September 1999


8.0 Equipment Design Control Wire Specification and Selection (cont.)

The control wire shall be insulated (with a flame retarding thermoplasticcompound), flexible, stranded, bare copper wire supported and neatlybundled. Red wire shall indicate AC control, blue wire shall indicate DCcontrol, and green wire shall indicate ground. Other colors or combinationsmay be used for specific applications. The control wire shall be isolatedfrom high voltage components in the power cell (whenever possible), andwire tube markers which are numbered according to the electrical diagram,shall be provided at each end of the wire.

All of the control wire terminations shall be a screw-type, coppercompression-type terminal block or connector which firmly grips theconductor. Non-insulated, locking-type, fork tongue lugs shall be providedon the control wire terminating on the control power transformer(s) andcurrent transformers.

Low Voltage Wireway

An optional low voltage wireway shall be available across the roof of thestructure. There are two (2) sizes of low voltage wireway available:• 51 mm x 102 mm (2 in x 4 in)• 152 mm x 152 mm (6 in x 6 in)

The low voltage wireway shall allow a convenient method of interconnectingcontrol wire from one controller to another, when interfacing with a masterpanel or with programmable controller circuits.

1500-2.0 – September 1999


8.0 Equipment Design Low Voltage Control Panel and Selection (cont.)

Each controller shall have a separate, front accessible, low voltage controlcompartment. The compartment shall be completely isolated, using metalbarriers between the low voltage compartment and the power cell and/ormain power bus compartments for utmost safety.

Meters, protective relays, selector switches, operators, indicating lights, etc.,shall be mounted on the front of the low voltage control panel, and arrangedin a logical and symmetrical manner. The low voltage panel shall providethe following features:

• Space shall be provided for low voltage control devices, transducers andmetering

• There shall be necessary terminal blocks

• There shall be front access without turning the controller OFF whenopening the low voltage panel door.

• All remote low voltage cable shall be able to enter from the top or bottomof the structure. Access to the wireways shall be by means of removableentry plates on the top and bottom of the structure.

• As standard, the controllers shall incorporate a swing-out low voltage panelwhich provides easier access to the power cell to make bus splicing andload cable connections. All products shall have a swing-out low voltagepanel, which is interlocked with the power cell compartment (the panelshall not have the ability to swing open until the power cell is OFF andisolated from the main power bus) to allow easy access to extra mediumvoltage equipment, i.e. an extra control power transformer and primaryfuses, power factor correction capacitor, or other similar equipment.

• Pilot control relays shall be used to operate and economize the vacuumcontactor.

• The control panel supply voltage shall be 120 or 230 V AC. It shall berectified to provide a DC operating voltage for the vacuum contacor coilsand economizing relay.

• There shall be a 2-pole, 3-conductor (with a grounding prong) male plugto provide a means of connecting a 2-pole, 3-conductor receptacle from aremote 120 V AC, 60 Hz supply to operate the control circuit when it is inthe TEST position.

1500-2.0 – September 1999


8.0 Equipment Design Control Power Transformer and Selection (cont.)

The control power shall be 120 V or 230 V AC and shall be obtained from acontrol power transformer (CPT) located in each controller power cell, orfrom a separate control source. As standard, the dry-type CPT shall be 500VA in size, providing 350 VA extra capacity for the customer's use when thestandard control circuit is supplied. Appropriately sized primary and second-ary fuses will be supplied. Optional sizes of 1000 VA, 2000 VA and 3000VA control power transformers shall also be available.

The secondary circuit of the transformer(s) shall be disconnected from thecontrol circuit by means of the isolating switch auxiliary contacts. This is toensure the isolating switch does not make or break load current, to preventbackfeeding through the transformer(s) and to isolate the power cell whenthe control circuit is in the "TEST" mode.

The standard control power transformers used in the controller shall be acompensated type with an output accuracy of approximately 4% overnominal at no load. They shall be designed to maintain voltage at in-rushesof up to 600%, which results in a 2% overvoltage at full load.

Notes:

1. The control power transformers may be used for metering, ONLY IFthe accuracy of the application does not require conformance to anypotential transformer accuracy ratings.

2. The maximum quantity/size of the CPT(s) available in a 2-high FVNRcontroller rated 7200 volts is (2) - 500 VA (with bolt-on power fuses),or (1) - 1000 VA and (1) 500 VA (with clip-on power fuses).

Primary Fuses

The primary side of the control power transformers and/or potentialtransformers shall be protected by current limiting fuses sized according torequirements. The interrupting rating of the primary fuses shall be 50 kAsymmetrical.

Secondary Fuses

The secondary side of the control power transformer and/or potentialtransformers shall be fused appropriately to protect the transformer(s) fromoverloads. The standard control circuit shall have one leg of the secondarygrounded.

1500-2.0 – September 1999


8.0 Equipment Design Current Transformer and Selection (cont.)

The medium voltage power cell shall include three (3) current transformersof sufficient VA capacity to meet the requirements of all the devicesconnected to them.

Each current transformer shall have the primary rating sized appropriatelyin relation to the full load current rating of the motor or feeder. Thesecondary of the current transformers shall have a 5 A output and anaccuracy suitable for the type and quantity of protection or meteringdevices connected to it. All current transformer control wiring shall beterminated on the current transformer with locking-type, fork tongue lugs.

An appropriate load termination location shall be provided to accommodatelugs with single or two-hole mounting, for connection of the load cables,when either bar or donut-type current transformers are supplied.

The power cell shall have provisions to locate a toroid (donut) style, groundfault sensing current transformer, when the zero sequence ground faultprotection feature is required.

Power Wire Specification

As standard, the power cell shall be wired with the appropriate size ofpower wire based on the controller size at the maximum voltage (5.0 kV or7.2 kV design).

Motor Protection Devices

For each starter unit, a thermal electromechanical or solid-state motorprotection overload relay shall be supplied. The overload protection relayshall be connected to the secondary of the three (3) current transformers.

Note: Alternate motor protection relay shall also be made available.

Undervoltage Protection

Optional undervoltage protection devices or circuits serve to protect themotor by not permitting the starter to remain energized in an undervoltagecondition.

Instantaneous undervoltage protection is supplied as standard. The coil ofthe main power contactor pilot relay (CR1) shall be designed to ensure thelevel of control voltage is sufficient to operate the main power contactorproperly. This is accomplished by the pilot relay requiring a higher voltagefor both pick-up and drop-out than the main power contactor it is controlling.This indirectly provides for a measure of motor protection.

1500-2.0 – September 1999


8.0 Equipment Design Prepared Spaces and Selection (cont.)

When specified, a controller shall be factory constructed with a preparedspace to enable the addition of a FVNR controller, or to complete a fusedload-break switch feeder (200 or 400 amp) in the future, on site, using astarter/transformer kit or a load-break switch feeder kit.

Note: The 2-unit structure is the most common structure offering thisprepared space feature. However, it shall also be available for the 1-high,400 amp FVNR structure.

Starter Prepared Spaces

When a prepared space (for a future controller) is ordered for a 1 or 2-highstructure, the following items shall be supplied:

• The main non-load-break isolating switch and external operating handle.A mechanical interlock shall be installed to keep the switch in the openposition (a label is included with each prepared space to indicate this).

• The electrical and mechanical interlocks, including the contactor interlockrod assembly and hardware.

• Appropriate barriers and wire duct for load cables.

• The power cell door with door screws and viewing window. The clip onthe power cell that interlocks with the operating handle is removed. Thisprevents the switch from closing whether the power cell door is open orclosed.

• A blank low voltage door.

1500-2.0 – September 1999


8.0 Equipment Design Prepared Spaces (cont.) and Selection (cont.)

Load-Break Switch Prepared Spaces

When a prepared space for a fused load-break switch feeder is ordered fora 2-unit structure, the following items shall be supplied:

• The 400 A load-break switch (shipped in the open position) includinginterphase barriers and lexan cover connected to the external operatinghandle.

Note: A mechanical interlock shall be installed to keep the switch in theopen position (a label is included with each prepared space to indicate this).

• The top glastic power fuse support assembly, less the fuse clips.

• Appropriate barriers and wire duct for load cables.

• The power cell door with door screws and viewing window. The clip onthe cell that interlocks with the operating handle is removed. This preventsthe switch from closing whether the power cell door is open or closed.

Notes:

1. A circuit diagram shall be sent with each prepared space compartment.

2. No structural modifications shall be required when installing the starterkit or fused load-break switch feeder kit.

3. The prepared space shall be required when installing the starter kit orfused load-break switch feeder kit.

4. The prepared space shall be located in the top power cell when the loadcables exit through the bottom of the structure.

1500-2.0 – September 1999


8.0 Equipment Design Starter Kits and Selection (cont.)

When a starter/transformer controller kit is ordered to convert a preparedspace power cell into a functioning medium voltage controller for motor ortransformer loads, the following parts shall be provided:

• The main power fuse clips, bottom glastic fuse support, interphase barriersand main current limiting power fuses.

• The control power transformer including current limiting power fuses.

• The main current transformers complete with barrier plates and hardwarefor the mounting.

• All of the necessary power and control wiring.

• The low voltage door complete with optional controls, meters and wiring.

• The low voltage panel with the interconnecting control wiring, labels,relays and terminal blocks.

• The main vacuum contactor mounted on a base plate, allowing for easyinstallation in the power cell. The contactor shall include the mechanicalinterlocking plate, ready for connection of the interlock rod assembly.

• The clip for the power cell door. This allows the external operating handleto work properly.

• Instructions and identification nameplates.

The power circuit to and from the vacuum contactor shall be connected inaccordance with the circuit diagram provided with the starter kit.

1500-2.0 – September 1999


8.0 Equipment Design Feeder Kits and Selection (cont.)

When a feeder kit is ordered to convert a load-break switch prepared spacepower cell into a functioning medium voltage 400 A fused load-break switch,the following parts shall be provided:

• The main power fuse clips, bottom glastic fuse support, interphase barriersand main current limiting power fuses.

• The load terminal or CT assembly complete with mounting/barrier platesand hardware for the mounting.

• All of the necessary power and control wiring.

• The clip for the power cell door. This allows the external operating handleto work properly.

• Instructions and identification nameplates.

1500-2.0 – September 1999


9.0 Transportation and Delivery TimesEquipment

Estimated drawing and shipment delivery times are based on receipt of allinformation at time of order.

Shipment of equipment will commence approximately ____ weeks after theSeller receives a written purchase order. Actual on-site delivery will dependon the site location.

Unless specified, transportation is determined by the Seller based on ship-ment by the lowest cost carrier.

Loading Equipment

As standard the Seller must utilize tractors and trailers equipped with air-ridefeatures, reducing the chance of damage and the need for extra packaging.All trailers shall have logistic posts allowing the most secure loading.

Special Packaging Requirements (optional)

The Seller must use custom-designed crates to reduce the possibility of air orsea transit damage, and offer vacuum shrink-wrap to eliminate moisture orhumidity damages.

1500-2.0 – September 1999


10.0 Commissioning Start-Up Commissioning Services (Optional)

Start-up will be performed at the User's site.

The Seller will provide the following:

• A pre-installation meeting with the User to review:– The start-up plan– The start-up schedule– The starter's installation requirements

• Inspect the starter's mechanical and electrical devices enclosed• Perform a tug test on all internal connections within the starter and

verify wiring.• Verify critical mechanical connections for proper torque requirements.• Verify and adjust mechanical interlocks for permanent location.• Confirm all sectional wiring is connected properly.• Re-verify control wiring from any external control devices.• Set up auxiliary equipment with customer supplied parameters.• Exercise the starter in Test Mode (combination controllers).• Confirm cabling of starter to Motor and Line Feed.• Apply Medium Voltage to the starter and perform operational checks.• Run the starter motor system throughout the operational range to verify

proper performance.• User's personnel shall be required on-site and to participate in the start-

up of the system.

Start-up service is to be quoted at a per diem rate with an estimate of timerequired for commissioning.

On-site Training (Optional)

The Seller shall provide a qualified instructor to provide personnel withtraining that is specific to the Starter system installed at the user's facility.The training session will be one (1) day in duration and will be customizedfor the user's needs. Manuals and documentation are provided for eachparticipant, to a maximum of eight participants per class.

The training will cover the following topics:

• Basic motor theory• Starter hardware• Contactor hardware• Hardware replacement procedures• Power device replacement procedures• Fault analysis and troubleshooting• Preventative maintenance procedures

Time will be spent on lecture and hands-on training if user's equipment isavailable. Demos are not provided.

1500-2.0 – September 1999


11.0 Basic Data Sheets Specifications

Description SpecificationsMaximum Rated Voltage 5.0 or 7.2 kV

Nominal Voltage Ratings 2400 V, 3300 V, 4160 V,4800 V, 6600 V, 6900 V

Removable Lifting Provisions Provided YesQuantity Two (2)

Mounting Sill ChannelsRemovable No

Weight of One Motor Controller kg (lb) uMaximum Power Cell Door Swing cm (in) u

2400 to 5000 V 13.25 kVDielectric Voltage Withstand Rating(Insulation Test) for 60 seconds 7200 V 18.2 kVBasic Impulse Level (B.I.L.) Rating 60 kV vEnclosed Controller Current Rating v

Fault Withstand Current Rating50 kA RMS SYM

(80 kA RMS ASYM)2400 V 200 MVA SYM3300 V4160 V 350 MVA SYM4600 V 400 MVA SYM4800 V6600 V 570 MVA SYM

Fault Withstand MVA RatingsAs Fused NEMA Class E2 Controller

6900 VMinimum Insulation Creepage to Groundand Between Phases

89 mm (3.5 in.)

u Refer to page 38 – Structure, Dimensions and Weights.

v The BIL rating must be derated for altitudes above 1000 m (3300 ft.).See page 37 – Starter Deratings, for applicable derating values.

1500-2.0 – September 1999


11.0 Basic Data Sheets Specifications (cont.) (cont.)

Description SpecificationsMain Horizontal Power Bus

Standard Bus Bar Material Tin-plated copper

Optional Bus Bar Material Silver-plated copper

Continuous Current Rating at 40°C (104°F) 1200, 2000 and 3000 A

Maximum Full Load Temperature Rise 65°C (149°F)

Maximum Full Load Temperature 105°C (221°F)

Fault Withstand Current Rating (4.5 Cycles) 60 kA RMS SYM(96 kA ASYM)

Type of Bus Bracing Molded glass polyesterAnti-hygroscopic

Dimensions per Phase

1200 A

2000 A

3000 A

Qty 1 – 6 x 100 mm (1/4 x 4 in)

Qty 2 – 6 x 100 mm (1/4 x 4 in)

Qty 2 – 9.5 x 127 mm (3/8 x 5 in)

Cross Sectional Area per Phase

1200 A

2000 A

3000 A

65 mm2 (1.0 in2) total

129 mm2 (2.0 in2) total

242 mm2 (3.75 in2) total

Insulating Material Between Phases and Ground Air (Standard)

Type : Sleeve, heat shrink

Material : Polyolefin

Thickness : 1.4 mm (0.055 in)

Anti-hygroscopic : 0.5 to 1%

Optional Insulation Material for Main Horizontal Bus

Electrical Strength : 900 V/mil

Vertical Power Bus

Bus Bar Material Tin-plated copper

Continuous Current Rating at 40°C (104°F) 400, 600 and 800 A

Fault Withstand Current Rating (½ cycle) 50 kA RMS SYM(80 kA ASYM)

Type : Sleeve, heat shrink

Material : Polyolefin

Thickness : 1.14 mm (0.045 in)

Anti-hygroscopic : 0.5 to 1%

Insulation Material for Vertical Bus

Electrical Strength : 900 V/mil

Ground Bus

Ground Bus Material Bare copper

Optional Ground Bus Material Tin-plated copper

Continuous Current Rating at 40°C (104°F) 600 A

Dimensions per Phase 600 A 6 x 51 mm (1/4 x 2 in)

Cross Sectional Area 600 A 32 mm2 (0.5 in2) total

1500-2.0 – September 1999



Description SpecificationsPower Fuses and Fuse Holders

This section details the power fuse and fuse holder technical information to which each medium voltageproduct conforms. It includes information on E-rated and R-rated fuses, as well as mounting dimensions.

Fuse Types

R Rated : 2R to 24R

2R to 24R

19R, 38R

Interrupting Ratings : 2.4 kV to 7.2 kV

Gould A480R – 5.0/2.4 kV

Gould A072 – 7.2 kV

Gould A051B – 5.0/2.4 kV

50 kA RMS SYM (80 kA RMS ASYM)

E Rated : 15E to 450E

20E to 200E

Interrupting Ratings : 5.5 kV, 8.25 kV

Gould A055 – 5.5 kV

Gould A825X – 8.25 kV

50 kA RMS SYM (80 kA RMS ASYM)

Mounting (Center) Dimensions

Clip-On 304.8 mm (12.0 in)

Bolt-On 454.2 mm (17.88 in)

Power Losses

Current (A) Fuse SizeLosses (kW)

± 10%90 6R .125

180 12R .35240 18R .51360 24R 1.0600 57X 1.5

Power Cell Losses (approximate)

800 76X 2.0

Bus Rating (A)

Fully Loaded BusLosses per 915 mm

(36 in.) Section(Watts) ±%

1200 1502000 200

Power Bus Losses (approximate)

3000 200

Control Power Transformer LossesThe losses from a 500 VA control powertransformer fully loaded is approximately

50 W per controller.

Low Voltage Panel Losses The losses from the standard control circuitis approximately 25 W per controller.

1500-2.0 – September 1999



Description SpecificationsVacuum Contactors

The following specification outlines the minimum requirements of the 400 Amp and 800 Amp vacuumcontactor design used in the medium voltage product line.

Contactor Ratings

400 A 800 A

Rated Open Continuous Current (Amps) 400 800

Maximum Rated Voltage (kV) 7.2 7.2

2400 V (RMS SYM Amps) 6300 12000

5000 V (RMS SYM Amps) 6300 12000Short-Circuit InterruptingCurrent Rating

7200 V (RMS SYM Amps) 6000 12000

2400 V (SYM MVA) 25 50

5000 V (SYM MVA) 50 100Short-Circuit InterruptingMVA Rating

7200 V (SYM MVA) 75 150

Short-Circuit Withstand atRated Voltage

Current Peak ½ cycle (kA) 60 85

Dielectric Voltage WithstandRating For 60 seconds (kV) 18.2 18.2

Make and Break Capability at Rated Voltage (kA) 4.0 8.0

For 1 second (kA) 6.0 12.0Short Time Current RatingCapability For 30 seconds (kA) 2.4 4.8

Basic Impulse Level (B.I.L.)Withstand

Phase to Ground,Phase to Phase (kV) 60 60

Electrically Held 1000 200Mechanical Life(Operations) x 1000 Mechanical Latch 100 100

Electrical Life (Operations) x 1000 1000 200

(Meters) 1000 Ê 1000 ËStandard Altitude Rating

(Feet) 3300 Ê 3300 Ë

Chopping Current (Average RMS Amps) 0.5 0.5

Electrically Held 600 600Switching Frequency(Operations per hour) Mechanical Latch 300 300

Electrically Held 7.3 12.8Coil Inrush Current at120 V AC (Amps) Mechanical Latch 11.5 12.8

Coil Continuous (Economized) Current at 120 V AC (Amps) 0.13 0.31

Coil Pick-Up Voltage (V AC) 102 Ì 102 Ì

Coil Drop-Out Voltage (V AC) 75 75

u The maximum altitude rating is 5000 m (16,500 ft) with factory-installed spring options.

v The maximum altitude rating is 5000 m (16,500 ft.) with field adjustable spring adjustment.

Ì The AC control voltage is rectified for the contactor coils.

2500

1500-2.0 – September 1999



SpecificationsDescription

400 A 800 A

Vacuum Contactors (cont.)

(60 Hz) (Cycles) 13 13Maximum Closing Time

(50 Hz) (Cycles) 11 11

(60 Hz) (Cycles) 10 15Maximum Opening Time(Normal Drop Out) (50 Hz) (Cycles) 8 12.5

(mm) 4.8 6.3Contact Gap Ë

(inches) 0.190 0.25

(kg) 21.8 42Contactor Weight

(lb) 48 93

Normally Open 2 2Auxiliary Contacts on theVacuum Contactor Normally Closed 2 2

Auxiliary Contact Rating A600 2 x A600 u

u Master contacts rated at 20 amps, 600 V.

Ë Some earlier designs had different specifications.

Description Specifications

Control Wire

All Medium Voltage structures shall be equipped with control wire which meets the following specifications:

Type TEW, Stranded Copper Wire

AWG Size (Control Circuit) #14 AWG

AWG Size (Current Transformer Circuit) #12 AWG

Number of Strands 19

Maximum Voltage Rating 600 V

Maximum Rated Temperature 105°C (221°F)

Control Relays

Control Relays used in the medium voltage produce line shall conform to the following design standards :

CR1 20 msecPick-up Time

CR2 30 msec

CR1 20 msecDrop-Out Time

CR2 75 msec

CR1 0.60 AC ampsPick-Up Current

CR2 0.10 DC amps

CR1 0.07 AC ampsSealed Current

CR2 0.10 DC amps

1500-2.0 – September 1999



Description SpecificationsPower Wire

Power wire used to feed the primary of the control power transformer or potential transformers is as follows:

AWG Size #8 AWG

Type Belden EPDM 37508

Insulation Rating Ê 8.0 kV

Maximum Temperature Rating 150°C (302°F)

The controller shall be wired with the following non-shielded, stranded wire type, based on the currentratings:

Controller Rating(Amps) AWG Size Type Insulation

Rating ËMaximum

Temperature Rating

200 #2 EP-CSPE MV90 8.0 kV 90°C (194°F)

400 #4/0 EP-CSPE MV90 8.0 kV 90°C (194°F)

600 (2) x #4/9 EP-CSPE MV90 8.0 kV 90°C (194°F)

800 (2) x 350 kcmil EP-CSPE MV90 8.0 kV 90°C (194°F)

Ê For 7.2 kV rated controllers, #8 AWG – 8.0 kV EP-CSPE MV90, non-shielded stranded cable is used.

Ë For 7.2 kV rated controllers, #2 AWG, #4/0 AWG or 350 kcmil MCM – 8.0 kV EP-CSPE MV90, non-shieldedstranded cable is used.

1500-2.0 – September 1999




Control Power Transformer

Type DryVoltage Class 5.0 and 7.2 kVFrequency 50/60 HzStandard Capacity VA Rating 500 Va

Optional VA Ratings1000 VA2000 VA3000 VA

Primary Voltage, Single Phase Ê2400 V AC 4800 V AC3300 V AC 7200 V AC4160 V AC

Rated Secondary Voltage 120 V ACOptional Dual Secondary Voltage 120/240 V ACBasic Impulse Level (B.I.L.) Rating 25 kVPrimary FusesManufacturer Gauld-Shawmut

Type (Current Limiting)A480T – 4.8 kVA720T – 7.2 kV

Maximum Continuous Current Sized According to Requirements

Interrupting Rating50 kA RMS SYM

(80 kA RMS ASYM)Secondary FusesManufacturer Gould-ShawmutType ATMMaximum Continuous Current Sized According to Requirements

Potential Transformer

Type I/M – 50Voltage Class 5.0 and 7.2 kVFrequency 50/60 HzStandard Capacity VA Rating 500 VAOptional VA Ratings None

Primary Voltage Single Phase Ê2400 V AC 4800 V AC3300 V AC 7200 V AC4160 V AC

Rated Secondary Voltage 120 V ACBasic Impulse Level (B.I.L.) Rating 50 kVMetering Accuracy 0.3 WX0.6Y

Ê Primary voltages above 5000 V are supplied according to the application.

Transformer Ratings

Burden VA Burden PF

W 12.5 0.1

X 25 0.7

Y 75 0.85

YY 150 0.85

Z 200 0.85

Gould-Shawmut

1500-2.0 – September 1999




Current TransformerBar Wound Primary

TypeDonut ToroidBar 7.2 kV

Voltage ClassDonut 600 VBar 60 kV

Basic Impulse Level (BIL) RatingDonut 10 kV Ê

Momentary (Short-Circuit) Current Rating Withstands the Let-Through of the fuseSecondary Current Rating 5.0 A

Maximum Continuous Secondary Current7.5 A (Bar and Donut)

(Most ratios)Type Metering Relaying

Bar

0.3 – BO.10.6 – BO.50.6 – BO.91.2 – B1.8

10T20Accuracy

Donut Ë

Bar and Donut Current Transformers

Continuous Current Rating Factor1.5 A at 30°C (86°F)

(Most ratios) Ambient Ì

Rated Short-Circuit Time Thermal Current 18 kA RMS for 1 sec Ì

Rated Short Time Mechanical Current 40 kA RMS for 1 sec ÌÊ B.I.L. rating of 60 kV when used with 5.0 kV or 8.0 kV power cable.

Ë Accuracy depends on the C.T. Ratio.

Ì The maximum rating depends on the C.T. ratio.

1500-2.0 – September 1999



Environmental Ratings UL/CSA/NEMA IECOperating Temperature Range 0°C to 40°C (32°F to 104°F)Storage and TransportationTemperature Range

-20°C to +75°C (-4°F to 149°F)

Altitude 1000 meters (3,300 feet)Humidity 5% to 95% (non condensing)Pollution Degree 2Seismic (UBCRating) Ê 1, 2, 3, 4

Ê Some units may require special bracing. Contact factory for more information.

Starter RatingsNEMA Type 1 Enclosure NEMA Type 1A, 12, 3R Enclosure

Horsepower v Max. Continuous Horsepower vStarter

Size andType

Max. ContinuousCurrent (amps) w 2400 V 4160 V 6900 V Current (amps) w 2400 V 4160 V 6900 V

360 1500 2500 4000 360 1500 2500 40001-unit, 400 A

400 1750 3000 4500 400 1750 3000 4500260 Top Cell 1000 1750 3000 260 Top Cell 1000 1750 3000

300 Bottom Cell 1250 2250 3500 300 Bottom Cell 1250 2250 35002-unit structurewith standardblank doors 560 Total/Structure 2250 4000 6500 560 Total/Structure 2250 4000 6500

300 Top Cell 1250 2250 3500 N/A — — —360 Bottom Cell 1500 2500 4500 N/A — — —

2-unit structurewith vented door

Option u 660 Total/Structure 2750 4750 8000 N/A — — —600 A 600 2500 4500 7000 540 2250 4000 7000800 A 720 3000 5500 9000x 720 3000 5500 9000x

800 3500 6000 9000x N/A — — —800 A with

vented doorOption u

u The power cell doors are vented. Specify unit modification “-100T” to configure.v The horsepower values are based on assumed Full Load Current and a Service Factor of 1.0 motor data. The actual Full Load Current and Service

Factor ratings determine the limits.w The standard current and basic impulse level (B.I.L.) ratings are valid up to an altitude of 1000 m (3300 ft). For applications above 1000 m (3300 ft),

the maximum continuous current and B.I.L. withstand ratings shall be reduced per Table C.x The largest power fuse size available limits the maximum continuous current to 700 amps.

Starter DeratingsPower Cell Rating

Altitude Range180 A 360 A 600 A 800 A

Reduce B.I.L.Withstand Rating By:

Reduce Max. Continuous Current Rating By:

1000 to 2000 m(3,300 to 6,600 ft.) 5 A 10 A 15 A 20 A 6.0 kV

2001 to 3000 m(6,601 to 9900 ft.)

10 A 20 A 30 A 40 A 12.0 kV

3001 to 4000 m(9,901 to 13,200 ft.) 15 A 30 A 45 A 60 A 18.0 kV

4001 to 5000 m(13,201 to 16,500 ft.) 20 A 40 A 60 A 80 A 24.0 kV

1500-2.0 – September 1999



Structure Styles, Dimensions

The structures shown below are the standard configurations. For otherstructure types and complete dimension details, consult the factory forassistance.

Structure Styles

LV – Low Voltage CompartmentMV – Medium Voltage Compartment/Power Cell

1 2 3 4 5 6.

.

.

.

LV

M V

(1.2)

.

.

.

. .

.

.

.

LV M V

LV M V

(1.10)

.

.

.

.

LV

M V

.

.

.

.

M V

M V

(1.12)

LVA M VA

.

.

.

. .

.

.

.

M VBLVB

(2.3)

.

.

.

.

M V

M V

(24.1 )

.

.

.

.

M V

M V

(24.3)

Structure, Dimensions and Weights

Item No. Bulletin No. Description Dimensions(W x H x D) Weight Power Cell Door

Swing

1 1512A 1-High, 400 A FVNR Starter661 mm x 2315 mm x 915 mm

(26 in. x 91 in. x 36 in.)490 kg

(1075 lbs)597 mm(23.5 in.)


(36 in. x 91 in. x 36 in.)614 kg

(1350 lbs)508 mm(20.0 in.)


(56 in. x 91 in. x 36 in.)816 kg

(1800 lbs)597 mm(23.5 in.)

4 1512B 2-High, 400 A FVNR915 mm x 2315 mm x 915 mm

(36 in. x 91 in. x 36 in.)802 kg

(1770 lbs)508 mm(20.0 in.)

5 1591A 457 mm (18 in.) wide Incoming Line Unit457 mm x 2315 mm x 915 mm

(18 in. x 91 in. x 36 in.)272 kg

(600 lbs)394 mm(15.5 in.)

6 1591A 915 mm (36 in.) wide Incoming Line Unit915 mm x 2315 mm x 915 mm

(36 in. x 91 in. x 36 in.)363 kg

(800 lbs)857 mm

(33.75 in.)

1500-2.0 – September 1999


12.0 References PublicationNumber Title

1500-1.0 Product Brochure • 1500/1900 Products

1500-1.7 Product Profile • Medium Voltage Contactor, 400 Amp

1500-1.8 Product Profile • Medium Voltage Contactor, 800 Amp

1500-2.13 Vacuum Contactor Switches, Surge Phenomenon and itsEffects

1500-2.20 Test Procedures for Medium Voltage Products

1500-2.21 Application of Surge Protection to Vacuum Contactors

1500-2.7 Medium Voltage Bus Support

1500-2.8 Copper Power Bus • Tin vs. Silver Plate

1500-5.5 User Manual • Centerline Medium Voltage Controller,400A, Series B, Two-High

1502-5.0 User Manual • Medium Voltage Contactor, 400 A

1502-5.1 User Manual • Medium Voltage Contactor, 800 A

1512-1.0 Product Profile • Full-Voltage Non-Reversing 1512A,400, 600 and 800 A

1572-1.0 Product Profile • Reduced Voltage Autotransformer 1572,400 A

1592BF-1.0 Product Profile • Fused Load-Break Switch 1592BF,Two-High, 400 A

1901-1.0 Product Profile • Synchronous Motor Starter

1901-5.0 Instruction Manual • 1901 SyncPro

6222 Rockwell Automation Quality System

6500 Terms and Conditions

Internet www.ab.com/mvb

1500-2.0 – September 1999


Medium Voltage Business, 135 Dundas Street, Cambridge, ON N1R 5X1 Canada, Tel: (1) 519 623-1810, Fax: (1) 519 623-8930Web Site: www.ab.com/mvb

Publication 1500-2.0 – September 1999 © 1999 Rockwell International Corporation. All rights reserved. Printed in Canada.Supersedes Publication 1500-2.0 – April 1998

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