T EC H N I C A L A P P L I C AT I O N G U I D E

Evolution series E9000

Motor control center
Table of contents

04 – 05 Evolution series E9000 motor

control center

06 – 19 Overview

20 – 39 Structure

40 – 48 Mains, feeders, incoming lines

49 – 64 Starters

65 – 74 Miscellaneous units

75 – 91 Intelligent MCC

92 – 124 Solid-state drives and starters

125 – 158 Components

159 – 185 Application data

186 – 191 Drawings/tests

192 – 221 Typical circuits

222 – 225 Specifications
4 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Evolution series E9000

Motor control center

Safety and flexibility are standard Rugged and reliable

Evolution Series E9000 motor control centers Motor control centers are constructed of
(MCC) provide safe and flexible centralizing of standardized heavy gauge vertical sections
motor starters and related control equipment. It housing vertical and horizontal buses, wiring
combines motor control units, feeder units, channels and compartmented control units.
distribution transformers, lighting panels, relays, Shipping splits are bolted together to form a single
remote and local control, sophisticated line-up assembly. Units are mounted and wired in
communications, metering and other accordance with the wiring class specified. The
miscellaneous devices to be contained in a single motor control center may be powered by incoming
floor-mounted structural assembly fed from a line connection at a single point protected by an
common enclosed main bus. upstream disconnect or provided with a main
protective device within the equipment. Where
possible, motor control centers bear UL section
and unit labels.

—
Figure 1:
E9000 MCC

—
Figure 2:
E9000 MCC with Arc
Flash Mitigation Units

— —
Figure 1 Figure 2
 T E C H N I C A L A P P L I C AT I O N G U I D E 5

E9000 with AFM: Even more protection New level of arc flash mitigation
E9000 MCC with arc flash mitigation (AFM) units The E9000 AFM units are designed to reduce the
is an offering for customers and specific likelihood of exposure to electrical shock and the
applications where additional protection of potential of internal arcing faults from occuring
personnel is essential. The AFM units were during maintenance.
designed around lowering the potential for
electrical shock hazards in motor control centers. The retractable stab mechanism allows for
The AFM unit design includes optional IP20 devices closed-door racking of the unit, providing added
and incidental contact safety barriers in an effort protection to the electrical personnel from the
to prevent accidental contact with energized parts dangers of an arc flash occurrence.
during maintenance.
The introduction of a compact NEMA contactor in
these AFM units will allow a minimum of IP10
—
Figure 3: protection with optional IP20 terminal protection
E9000 arc-resistant
for starters using this contactor. Other IP20
construction
protection options are available in starter units
including IP20 control power transformer fuses and
pilot devices.

Arc-resistant construction
E9000 AR offers a heavy-duty enclosure which is
tested per applicable sections of IEEE/ANSI
C37.20.7 with Type 2 accessibility. Reinforced doors,
latches, and pilot device brackets provide strength
and an optional plenum allows flexibility for
installation.

—
Figure 3
6 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Overview

Product design and features

Design flexibility, performance, personnel and

equipment pro tection, ease of maintenance and
installation are all contained in the Evolution Series
E9000. Evolution Series E9000 features, such as
separate wiring troughs, split-type terminal
boards, isolated bus, drawout starter units,
operating mechanisms, and provisions for starter Easily removable plastic knock-outs are provided in
interchangeability, are designed for a high level of the vertical wireway ladder assembly to allow
reliability, safety and convenience. routing of field wiring into units.
The new Arc Flash Mitigation (AFM) units were
added in order to provide additional safety
features and flexibility for customers.

Enclosure features
These steel-enclosed control centers can be joined
together to centralize, protect and control the most
complex systems of industrial auxiliary drives, or
the simplest of loads such as fan or pump controls.
As the need arises, additional sections can be
added to an existing lineup in the field, often times An incoming-line terminal compartment can be
without the need for a transition section. located at the top or bottom of a vertical section to
allow cable termination with minimum bending.
A paint finish is applied to all un-plated steel The standard 600-ampere incoming line terminal
parts. The powder coating process passes compartment shown is furnished with mechanical
1000 Hr. ASTM117B salt spray tests and type lugs. Other incoming line terminal
provides lasting protection. compartments are available for main
bus ampacities up to 2500 amperes.

All case side wireways are roll-formed to provide a An optional snap-in steel barrier in the wireway
1/2" lip for cross wiring to rest on, thus preventing provides added isolation for low voltage signal
skinned insulation. wiring between units.
T E C H N I C A L A P P L I C AT I O N G U I D E 7

Bus features Windows on the main bus are available when

required. Please contact the factory for
Splicing further information.

Vertical ground bus and unit ground stab

E9000 MCC can be spliced onto existing 7700 Line,

8000 Line and Spectra MCC for 1200A (supplied
with 2" bars) and below without a transition
section. Horizontal bus location in E9000 matches
the existing bus location. Main bus amperage (Optional) Vertical copper ground bus allows direct
1200A and greater with 4" bus bars can be spliced grounding of unit saddles to the equipment ground
together but requires a transition section. bus. A unit ground bus stab engages the vertical
ground bus before the unit power stabs engage
Main bus barrier the vertical bus. A load ground lug is available for
customer cable grounding. Termination points are
located at the rear of the bucket, next to starter.

Insulated and isolated vertical bus

Clear Lexan barriers located in front of the main

horizontal bus isolate the bus from the top
horizontal wireway. Maintenance personnel can
easily gain entrance to the top horizontal wireway
of the control center without danger of contact
with a live bus.

Infrared scanning
A polyester-reinforced “sandwich” insulates and
isolates the vertical bus and helps prevent the
spread of faults from starter and feeder units to
vertical or horizontal bus. Small stab openings
provide access to vertical bus and maintains
effective isolation. 65kA short circuit bracing is
standard for Evolution Series E9000 MCC.
8 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Vertical bus shutters

New doors mounted on the case feature a

removable hinge pin providing easy door removal
and accurate alignment.

AFM doors have a visual stab and shutter indicator

(Optional) For standard E9000 MCC’s, a vertical
feature as well as a remote racking provision.
bus shutter mechanism can be supplied which
covers the vertical bus stab area when a plug-in
starter or feeder is withdrawn. Cap plugs are
standard to close unused stab openings.

(Standard for AFM) For E9000 AFM, a vertical bus

shutter mechanism is supplied as standard. The
shutter will be mechanically closed when the stabs
are retracted, isolating the bus and preventing
contact. When the stab is extended and engaged
with the bus, the shutter will reverse the operation.

New oversized laser-engraved unit nameplates

on 12" units and larger feature 1 to 9 lines of up
to 20 characters 0.18" high or 4 lines of up to 10
characters 0.30" high. Nameplates use Microsoft®
Windows® Arial font. Custom non-English
characters are an option.
The vertical bus shutter for AFM design is different
than the standard E9000 vertical bus shutter
option. The AFM shutter and shutter guide are
shown above.

Unit features

Doors

Device bracket mounts 30mm for compact pilot

devices and bracket swings open to allow easy
access to unit components, wiring and terminal
blocks. Fully insulated – does not require
grounding.
T E C H N I C A L A P P L I C AT I O N G U I D E 9

Stationery stabs

The 600A stab shown uses a two-step engagement

with vertical bus for low insertion/withdrawal
force. Line side cables crimped
directly into spring reinforced tin-plated copper
stabs. No hidden line side cable in rear of units.
Tapered glass polyester stab mounting base gives
positive plug-in alignment with vertical bus.

Safety interlocks

Combination starter and feeder units of plug-in

construction utilize a positive guidance system.
Plug-in stabs are rated 250A and 600A. The 250A
stab connections shown are made with copper unit
power stabs which are under double spring
pressure and engage the vertical bus to provide
positive contact.

Retractable stabs

An interlock release system is provided so that – if

it becomes necessary for maintenance purposes –
the disconnect may be closed with the door open.
A by-pass is provided to allow opening the door
with the disconnect closed.

— Note: Only qualified personnel familiar with

Extended stabs
the equipment should use the interlock
release and by-pass features.

—
Retracted stabs

An interlock release system is provided so

AFM unit stabs are retractable while maintaining a
that – if it becomes necessary for maintenance
closed-door unit. They move in a horizontal motion
purposes – the disconnect may be closed with
to engage and disengage from the bus when
the door open. A by-pass is provided to allow
retracted (below) or extended (above).
opening the door with the disconnect closed.
10 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Padlocks Interchangeable units

Units can be withdrawn to a disconnected position

and padlocked for maintenance. The vertically
mounted integral handle can be locked in the OFF
position. A drilling pattern is furnished, allowing
the handle to be modified for locking in the ON For flexibility, many units can be interchanged. This
position with a single padlock. This modification design allows quick, easy field changes when
should only be made afterthe user determines it is modifications are desired after installation. Front
desirable to lock the disconnect in the ON position. accessible quarter-turn latches provide for ease of
Padlock to have maximum 3/8" shackle. securing and withdrawal of all plug-in units.

—
AFM retrofit kit unit shelves

With the AFM unit, a different unit shelf is required

to support the movement of the unit while it is
being racked in or racked out. When retrofitting an
existing E9000 MCC, a Retrofit Kit will need to be
Lift up handle design to allow full access to fuses ordered with the AFM Retrofit bucket. The Retrofit
and CB rating plug. Position indication Kit will include this AFM shelf.
ON-TRIP-OFF.

Horizontal handles are standard on 6" 150A and 12" AFM units can be ordered to retrofit existing E9000
250A feeder breakers to optimize space. Optional MCC by ordering the AFM Retrofit Kit along with
vertical handles are available, but will increase the the unit.
unit height. Horizontal handles are not available
with AFM units.
T E C H N I C A L A P P L I C AT I O N G U I D E 11

High density two-piece, pull-apart control terminal The E9000 AFM unit is equipped with the C2000
boards feature up to 18 points in 12” high units. contactor as standard configuration. The CR305
External and internal unit connections are made on contactor is available for most configurations.
opposite sides, allowing the unit to be withdrawn Please contact factory if the CR305 contactor is
without disconnecting control wiring. required in an AFM unit.
Accommodates up to (2) #12 AWG wires with ring,
fork or bare terminations. Rated 30 Amps, 600 Vac. IP20 and incidental contact barrier features
Meets NEC Article 430.74.

(Optional) Motor power terminal blocks can be

supplied in Size 1 and 2 to allow disconnecting
motor wires when removing a unit. NEMA Type BT
wiring.

(Optional) IP20 rated fuses are available.

Please contact factory.

The E9000 MCC unit is equipped with the CR305

contactor as standard configuration. The C2000
contactor is available for many configurations to (Optional) CR104P Lights and Push butons are
obtain a compact footprint. available with optional IP20 accessory.
Please contact factory.
12 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Wire and cable

Standard control and power wire includes flame-
retardant, (VW-1) moisture-heat-and oil-resistant
thermoplastic insulation rated 600 volts, with
stranded copper conductors, types MTW and THW.
Standard colors1 are:
• Red – AC Control
• Blue – DC Control
• Black – AC/DC Power and CPT primary
• Green – Ground
(Optional) C2000 Contactor is available with • White – Neutral
optional IP20 accessory. Please contact factory.
Optional wiring available includes SIS heat-
resistant synthetic rubber-covered switchboard
wire and XHHW flame-retardant cross-linked
synthetic polymer, both rated 600 volts with
stranded copper conductors, and a VW-1 flame
rating (no PVC).

Wire is rated 90 degrees Celsius and terminalsare

rated 75 degrees Celsius.

Note: Not all colors are available with

optional wiring.

Nameplates
Unit service designation nameplates are
furnished when specified. Nameplates can be
supplied as blanks suitable for field engraving,
or engraved at the factory. The standard unit
service designation nameplate is of 2-ply
thermoplastic material, black face with white
core, 2 5/32" x 3 1/2", or 1" x 3" depending on the
unit configuration, fastened with non-corrosive
nylon clips. Stainless steel screws are available as
an option. Nameplates are engraved with white
letters on a black background.
(Optional) Clear Lexan incidental contact barriers
are available for CR305 contactor.
T E C H N I C A L A P P L I C AT I O N G U I D E 13

NEMA class of diagrams and wiring The drawings supplied by the manufacturer shall
Motor control centers are classified by NEMA convey the same information as drawings provided
as follows: with Class I and II motor control centers,
additionally modified as specified by the user.
NEMA class I definition(¹)
Class I motor control centers consist essentially When to specify class I
of a mechanical grouping of combination motor Specify NEMA Class I control centers for
control units, feeder tap units and/or other units independently operated motors requiring
arranged in a convenient assembly and connect no interlocking or other interconnection
to the horizontal and vertical common power bus between units.
to the units.
When to specify class II
This class does not include interwiring or When factory interconnections are desired to
interlocking between units or to remotely provide such functions as sequencing and other
mounted devices, nor does it include control interlocking or interconnection, the control centers
system engineering. Diagrams of the individual required are NEMA Class II.
units only are supplied.
When to specify class IS and IIS
NEMA class II dDefinition(¹) When custom drawings are desired to show special
Class II motor control centers consist of a grouping device identification, special terminal numbering,
of combination motor control units, feeder tap or special diagram size, etc. the control centers
units and/or other units designed to form a required are Class IS or IIS.
complete control system. They include the
necessary electrical interlocking and interwiring Wiring type
between units and interlocking provisions to The NEMA classes are sub-divided into A, B and
remotely mounted devices in addition to the C depending on the type wiring furnished, with
connections from the horizontal and vertical type B further having type B-D for customer load
common power bus to the units. wiring direct to the device and B-T for customer
wiring to a load TB (size 1 and 2 starters).
The control manufacturer shall provide a suitable
diagram to illustrate operation of the control Note: For feeders and large starters,
associated with the motor control center. customer must wire direct to unit
device terminals.
NEMA class IS and IIS definition(¹)
Class IS and IIS motor control centers shall be the Note: In addition to NEMA prescribed wiring
same as Class I and II motor control centers except types, ABB offers a NEMA 1A Modified MCC.
custom drawings shall be provided in lieu of This type of MCC will be supplied without
standard drawings. wiring and without control diagrams. ABB
can mount low voltage control devices on
Examples of custom drawings are: the pilot device bracket and supply terminal
• Special identifications for electrical devices boards. This would be considered on OEM
• Special terminal numbering designations product device terminals.
• Special sizes of drawings

1. From NEMA standard 18-2001.

14 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Wiring features by NEMA classification

Type of power or control Class I Class IS Class II Class IIS

termination furnished A B C A B C B C B C
Pull-apart and numbered control terminal
No Yes Yes No Yes Yes Yes Yes Yes Yes
boards on unit starter–Sizes 1, 2, 3 and 4
Stationery and numbered control terminal
No Yes Yes No Yes Yes Yes Yes Yes Yes
boards on unit starter – Sizes 5, 6 and 7
Pull-apart and numbered power terminal oards
on unit starter –Sizes 1 and 2. (On Type A wiring:
No Yes Yes No Yes Yes Yes Yes Yes Yes
Same type of numbered terminals
on starter itself for Sizes 1, 2, 3and 4)
Numbered terminals on starter itself for power
connection with no power terminal boards – Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Sizes, 5, 6 and 7
Stationery master terminal boards (Top,
bottom or rear of section)
No No Yes No No Yes No Yes No Yes
For control – Sizes 1 thru 5 / For power –
izes 1 thru 3 (E9000 Sizes 1 and 2 only)
Unit terminal boards for feeder tap units
No No No No No No No No No No
and distribution panels
Starter-unit-mounted pilot devices internally
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
wired to starter – Sizes 1 thru 7
Terminal board points for remote devices
No Yes Yes No Yes Yes Yes Yes Yes Yes
(Excluding extra tie points)
Master terminal-board wiring connections No Yes Yes No Yes Yes No Yes No Yes
Factory-wired interconnections between units
No No No No No No Yes Yes Yes Yes
in the same motor control center
Type of drawings furnished
Outline and summary sheet
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
(Schedule of units)
Unit elementary wiring diagrams showing
numbered terminal points (Terminal boards Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
not furnished on Type A)
Unit elementary wiring diagrams showing
numbered terminal points and interconnections
No No No No No No Yes Yes Yes Yes
to other units and/or to
the first level of remote devices
Schedule of wires to master terminal blocks No No Yes No No Yes No Yes No Yes
Custom drawings as specified by user No No No Yes Yes Yes No No Yes Yes

A computerized manufacturing process necessitates that the E9000 Line motor control center standard unit numbering system be followed to identify the section and
location of each unit. This is explained in detail in application data (Section J). It greatly simplifies wire tracing of interconnection wires, and is beneficial to the application of
programmable control. The Outline and Summary drawing furnished with the equipment cross references the unit numbers and customer unit designations when specified.
T E C H N I C A L A P P L I C AT I O N G U I D E 15

Codes and Standards Motor control circuits other than such tapped
Motor control centers are manufactured to control circuits (common control transformers
NEMA standard ICS 18 and are eligible to receive or external power source) shall be protected
the Underwriters Laboratories listing mark under against overcurrent in accordance with section
standard UL 845. Vertical sections and units which 725.12 or 725.35, as applicable. This section
have been listed with UL will bear the UL/cUL of NEC also indicates the type power source
listing mark (see right for examples). Since vertical and field wiring conductor sizes. Where a motor
sections and units are listed independently, it is control circuit transformer is provided, the
possible to have combinations of listed and non- transformer should be protected in accordance
listed sections and units within the same control with NEC Article 430.72(c). Transformers other
center. Sections and units which will be shipped than motor control circuit transformers should be
with the UL listing mark are identified in the protected in accordance with NEC Article 450.3(b).
appropriate sections of this publication.
Section label
The National electrical code (NEC) covers
installation of electric conductors and equipment
for installations identified in the NEC Article 90.
The NEC is not intended as a design specification
and acceptance of an installed motor control center
by a local code authority relies on factors
independent of the equipment as shipped from the
factory. In general, equipment which bears the UL
listing mark can be installed to meet the NEC.
Compliance to NEC is the responsibility of the
installer. Where 100 percent UL listed equipment is
mandatory or there are other special code
requirements refer to the factory for verification.

The NEC defines several types of control circuits

and the over-current protection required for each
type. The following paragraphs provide a general
reference to the NEC Article applicable for the more
common control circuits.

NEC Articles 430.72(a) and (b) cover motor control —

circuits tapped from the load side of a motor UL #E33752, Vol. 1, Sec. 5.

branch-circuit short-circuit protective device (unit

Unit label
disconnect). Control circuit conductors from such a
tapped control circuit shall be protected in
accordance with NEC Table 430.72(b), which lists
the maximum fuse or circuit breaker rating vs.
conductor size.
16 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Short circuit considerations High available short-circuit currents of modern

All ratings in this publication are RMS distribution systems require special consideration
symmetrical amperes. so that equipment may be operated within its
rating. The cost and operational acceptability of
Short-circuit current ratings the following should be carefully considered:
The NEMA Motor Control Center Standard
ICS 18-2001 defines the short-circuit rating 1. Use load-center distribution systems with
of a motor control center as follows: smaller transformers which limit the available
“The motor control center short-circuit rating shall short-circuit current.
be the maximum available rms symmetrical current 2. Use a current-limiting busway, reactors or higher-
in amperes permissible at its line terminals. It shall impedance transformers to reduce the available
be computed as the sum of the short-circuit short-circuit current.
current contributions of the motors connected to 3. Use current-limiting fuses, current-limiting
the motor control center and the maximum breakers, or breakers with limiters, in all
available current, including all other short-circuit combination starters and feeders in the
current contributions of the supply system at the control centers.
point of connection to the motor control center.”
Main protective devices
A motor control center requires adequate
Motor control center bus
overcurrent and short-circuit protection. This is the
function of the main protective device. It may be
located in or remote from the control center and
sized per NEC A or 240 for horizontal bus
protection. Wherever located, it must have an
interrupting rating equal to or greater than the
available short-circuit current at the point of its
connection to the system. If located at the control
center, this value would be the system available
—
short-circuit current, Is (Figure 1).
Figure 1.

A motor control center should be protected for all

Figure 1 illustrates simply the basis of determining types of faults from low-level arcing ground faults
the available short-circuit current. The individual to bolted threephase faults which can develop the
short-circuit current ratings of the main bus full available short-circuit current. Line-to-line and
extensions, combination-controller units and line-to-ground arcing faults (ofte produced by
feeder-tap units must equal or exceed available contaminated atmospheres, foreign materials, etc.)
short-circuit current. can be appreciably lower in magnitude than the
available short-circuit current and must be
Is is the short-circuit current available from the assumed not to be selfextinguishing.
system at the point where the motor control center
is connected. Im is the short-circuit current Even low-level arching faults are capable of
contribution of the motors connected to the motor releasing tremendous energy at the point of
control center. If exact information is lacking, the fault and can be highly destructive.
motor contribution can be estimated at four times
(4X) the continuous-current rating of the main
horizontal bus. Isc is the available short-circuit
current to be used as the basis for selection.
Thus: Isc = Is + Im.
T E C H N I C A L A P P L I C AT I O N G U I D E 17

A Spectra (molded case switch) or a non-automatic When switches without a three-phase trip are used,
insulated case circuit breaker must be properly an ITI BGFL ground-fault protection scheme is
coordinated with up stream protective devices. particularly recommended since damaging arcing
faults almost always involve ground. It should
For full protection against all levels of arcing faults operate the trip device on the closest
on grounded systems, a ground-fault relay is line-side three-phase disconnect.
recommended. The ground-fault system is a
protective means that responds to phase-to- Main horizontal bus and vertical bus extensions
ground current, but is not affected by phase- The standard bus short-circuit withstand rating is
tophase current. It is used to protect motor control 65 kAIC symmetrical amperes. Also available as an
centers from extensive damage, which can be option is 100kAIC. The bus rating must equal or
caused by phase-toground arcing faults. exceed the available shortcircuit current. Refer to
"Structure" section for ratings.
Fuses are single-pole interrupters. An arcing fault
may not necessarily be cleared by a single-pole Combination motor control units
interruption, as the fault can be back-fed from The short-circuit rating of a combination controller
the other energized phases. This reduces the fault is based on tests with rated short-circuit current
current, increasing the blowing time of the available at the line terminal of the control center
energized fuses. Because of this delay, severe and at rated voltage. The short-circuit rating must
equipment damage may occur. Single-phasing equal or exceed the available short-circuit current.
is eliminated with fastacting three-pole fused Refer to "Starters" section for ratings.
interrupter switches which open when a single
fuse blows. Feeder tap units
All feeder tap units must have a short-circuit rating
An electrically operated HPC switch with which equals or exceeds the available short-circuit
single-phase detector will meet the three-phase current. Refer to Feeders" section" for ratings.
disconnection (single-phase protection)
recommendations for a main protective device.
18 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Fuse classification UL standard

Characteristic(¹) Class J-TD Class R Class L
UL classifications are the most definitive method
Ampere Range 0-600 0-600 601-6000
of determining fuse characteristics, and are used
250
in this publication. Use UL fuse “Class” when Voltage Ratings 600 600 600
specifying type of fuse. Interrupting Rating RMS
200 K 200 K 200 K
Symmetrical Amperes
UL classifications used in motor control Current-Limiting Yes Yes Yes
centers are: Rejection Type Yes Yes Yes
A. C lass R – current-limiting type fuses with reject
mounting features. Class R fuses are sub-divided 1. Check fuse manufacturers for specific fuse characteristics.

into Classes RK-1 and RK-5, depending on

maximum peak let-through currents. RK fuses
are rated 600 amperes maximum and 250 volts
or 600 volts.
B. Class J-TD – are more current limiting than RKs
and due to their unique dimensions have an
inherent rejection feature. Ratings are 600
amperes maximum, 600 volts. (Time delay
Class J-TD fuse may limit component damage
under fault.)
C. C lass L – are current limiting and due to their
unique mounting dimensions have an inherent
rejection feature. Ratings are 601 amperes
minimum, 600 volts.

Fuses marked with “Time-Delay,” “Dual-Element”

or similar designations are time-delay type fuses
and will generally carry 500 percent rated amperes
for 10 seconds, thus allowing a smaller rated fuse
to be used in most starter applications.

Fuses that are mechanically interchangeable may

not be electrically equivalent. Refer to the fuse
manufacturer for interrupting rating and current-
limiting characteristics.
T E C H N I C A L A P P L I C AT I O N G U I D E 19

Environmental considerations Standard NEMA 3R construction is suitable for

The standard E9000 motor control center wind velocities up to 75 mph. Beyond this, up to 130
is designed for operation in a clean, indoor mph, specially reinforced enclosures are available
environment having a 40°C maximum ambient through Strategic Equipment Packaging Services.
temperature. This special design is also necessary if the NEMA
3R enclosure has to withstand seismic conditions,
The nominal minimum temperature for storage including seismic Zone 4 applications.
is -40°C and for operation, -20°C. Motor control
center space heaters are recommended whenever E9000 motor control center is available for
temperature conditions below 0°C will exist. Where earthquake conditions. It is IBC rated.
extreme cold temperatures are to be encountered Please see DET-463.
for long periods of time. It is recommended that
the motor control center be installed in heated For dusty atmospheres, see "Structure " section.
rooms or enclosures.
The altitude limit for the standard electro-
For ambient temperatures above 40°C, special mechanical motor control center design is 6000
consideration must be given to the need for feet. Applications above this should be referred
ventilation, ambient-compensated breakers and to the Company for recommendations. Some
overload relays, special wire insulation and solid-state components are only rated to 3300
oversized control transformers. Ambient feet and may reduce the altitude limit of the motor
compensated overloads provide essentially control center.
constant trip setting as the control ambient varies.
Fungus-proofing of organic materials is inherent.
For indoor environments subject to falling liquids, Keeping equipment dry and above the dew-point is
NEMA 2 dripproof enclosures are recommended. the best way of avoiding fungus-growth, and the
If water spray and splashing are to be encountered, use of space heaters is recommended for this
NEMA 2 construction should also be used. Space purpose. Heaters should be energized if the motor
heaters may be desirable to prevent condensation control center is to be stored for any length of time.
on internal parts. Where export crating is involved, provisions must
be made on the outside of the crate for access to
For outdoor installations, NEMA 3R non-walk-in space heaters.
weatherproof enclosures are required.
Thermostatically controlled space heaters and
ambient-compensated breakers and overload
relays should be considered for these applications.
Provisions for heating and cooling the entire
outdoor enclosure are also available.
20 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Structure

Enclosure types They are not water-tight. Similar to NEMA 12

Motor control centers are made up of standardized gasketed construction except with catch pan-type
vertical sections housing vertical and horizontal dripshield on top and with open bottom.
bus, wiring channels and compartmented control
units. Sections may be bolted together to form a Dripshield extends four inches beyond front of
single panel assembly powered by line connection motor control center. Standard finish: light gray
at a single point. Normal shipping split is three ANSI 61. Furnished with removable conduit cover
sections maximum. plates unless otherwise specified.

NEMA type 1 – Gasketed – semi dust-tight, indoor NEMA type 3R – Rain-proof, outdoor
Intended to cushion doors and mitigate vibration. Intended for use outdoors to protect the enclosed
Standard finish is light-gray ANSI 61 over a equipment against rain. They are not dust-proof,
phosphate rust inhibitor. All unpainted parts are snow-proof nor sleet proof (ice-proof). Optional
zinc-chromate electroplated or galvanized. lights and receptacles available.
Enclosures are furnished with bolt-on rear covers.
Hinged rear doors are available as an option. Type 12 – Industrial use – Dust-tight
Pan-type doors utilize quarter-turn fasteners. and drip-tight, indoor
Gasketed doors, cover plates, and operating Intended for use indoors to protect the enclosed
handles are available as an option. Two heavy-duty equipment against fibers, flyings, lint, dust and
3" by 1-1/2", 12-gauge floor sills and 1/4" structural dirt, light splashing, seepage, dripping and external
lifting lugs are included. Open bottom is standard. condensation of noncorrosive liquids.

NEMA type 2 – Drip-proof, indoor 1HG

Intended for use indoors to protect the enclosed Similar to NEMA 1 gasketed construction except
equipment against falling noncorrosive liquids and that bottom plates are furnished and all removable
falling dirt. Dripshields on top of the motor control plates are gasketed.
center and neoprene closed-cell gasketing afford
protection from falling and splashing liquids.

Construction Enclosure type Description Voltage (V) Short circuit (kA) Main bus rating
type 480 600 65 100 600 800 1200 1600 2000 2500 3000 3200
Standard NEMA Type 1 Semi Dust-tight,
• • • • • • • • • • • •
Indoor
NEMA Type 1HG Heavy Gasketed • • • • • • • • • • • •
NEMA Type 2 Drip-proof, Indoor • • • • • • • • • • • •
NEMA Type 3R Rain-proof, Outdoor • • • • • • • • • • • •
Type 12 Dust-tight,
• • • • • • • • • •
Drip-tight, Indoor
Arc-resistant NEMA Type 1 Semi Dust-tight,
• • • • • • • •
Indoor
Type 12 Dust-tight,
• • • • • • • •
Drip-tight, Indoor
T E C H N I C A L A P P L I C AT I O N G U I D E 21

Indoor enclosures

Front elevation and mounting locations

(13", 20", 22" and 25" Deep sections)

Note: If anchor bolts are to be inbedded

in the foundation, they must be located
according to the drawing furnished by ABB
for the specific equipment. Locate one in
the center front and one in the center back.
Anchor bolts should be 1/2 inch diameter,
of Grade 2 steel (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.

Note: Seismic IBC testing was performed

use 1/2' - 13 Grade 5 bolts, torqued to 50
foot-pounds, located in each of the four
corners in each section.

Ref. Section depth

Dim. 13" Deep 20" Deep 22" Deep 25" Deep
Width "A" B C B C B C B C
20" 10.00" 8.73" 10.00" 15.73" 10.00° 17.73" 10.00" 20.68"
508.8 mm 254.4 mm 221.7 mm 254.4 mm 399.5 mm 254.4 mm 450.3 mm 254.4 mm 525.3 mm
24" 12.00" 8.73" 12.00" 15.73" 12.00° 17.73" 12.00" 20.68"
609.6 mm 304.8 mm 221.7 mm 304.8 mm 399.5 mm 304.8 mm 450.3 mm 304.8 mm 525.3 mm
30" 15.00" 8.73" 15.00" 15.73" 15.00° 17.73" 15.00" 20.68"
762.0 mm 381.0 mm 221.7 mm 381.0 mm 399.5 mm 381.0 mm 450.3 mm 381.0 mm 525.3 mm
22 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Side elevations 13" deep section

600A to 1200A main bus

Side elevations 20" deep section

600A to 1200A main bus
T E C H N I C A L A P P L I C AT I O N G U I D E 23

Side elevations 25" deep

back-to-back section 1200A main bus

Side elevations 22" deep section

1600A to 2500A main bus
24 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Side elevations 25" deep back-to-back section 1600A to 2500A main bus

Top conduit entry (13", 20", 22" and 25" deep sections)
T E C H N I C A L A P P L I C AT I O N G U I D E 25

Bottom conduit entry 13" deep section

Bottom conduit entry 20" deep section

Ref. dim. 20" wide enclosure 24" wide enclosure 30" wide enclosure
20" 24" 30"
A"
508.8 mm 609.6 mm 762.0 mm
17.56" 21.56" 27.56"
B"
446.0 mm 547.6 mm 700.0 mm
4.85" 8.85" 14.85"
C"
123.2 mm 174.2 mm 377.2 mm
26 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Bottom conduit entry 22" deep section

Bottom conduit entry 25" deep section

Ref. dim. W 24" wide enclosure 30" wide enclosure

20" 24" 30"
A"
508.8 mm 609.6 mm 762.0 mm
17.56" 21.56" 27.56"
B"
446.0 mm 547.6 mm 700.0 mm
4.85" 8.85" 14.85"
C"
123.2 mm 174.2 mm 377.2 mm
T E C H N I C A L A P P L I C AT I O N G U I D E 27

Elevation and mounting 30" deep section

600A to 1200A main bus

Note: If anchor bolts are to be inbedded

in the foundation, they must be located
according to the drawing furnished by ABB
for the specific equipment. Locate one in
the center front and one in the center back.
Anchor bolts should be 1/2 inch diameter,
of Grade 2 steel (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.

Note: Seismic IBC testing was performed

use 1/2' - 13 Grade 5 bolts, torqued to 50
foot-pounds, located in each of the four
corners in each section.

Ref. Section depth

Dim. 13" Deep 20" Deep 22" Deep 25" Deep 30" Deep
Width "A" B C B C B C B C B C
20" 10.00" 8.73" 10.00" 15.73" 10.00" 17.73" 10.00" 20.68" 10.00" 25.69"
508.8 mm 254.4 mm 221.7 mm 254.4 mm 399.5 mm 254.4 mm 450.3 mm 254.4 mm 525.3 mm 254.4 mm 653.5 mm
24" 12.00" 8.73" 12.00" 15.73" 12.00" 17.73" 12.00" 20.68" 12.00" 25.69"
609.6 mm 304.8 mm 221.7 mm 304.8 mm 399.5 mm 304.8 mm 450.3 mm 304.8 mm 525.3 mm 304.8 mm 653.5 mm
30" 15.00" 8.73" 15.00" 15.73" 15.00" 17.73" 15.00" 20.68" 15.00" 25.69"
762.0 mm 381.0 mm 221.7 mm 381.0 mm 399.5 mm 381.0 mm 450.3 mm 381.0 mm 525.3 mm 381.0 mm 653.5 mm
28 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Top conduit entry 30" deep section

Note: Spacer shell allows unit doors, in

spliced section on the right, to open fully.

Bottom conduit entry 30" deep section

Ref. dim. 30" deep section

A" 20.00" 24.00" 30.00"
B" 17.56" 21.56" 27.56"
CW" - 3"
600A - 1200A 13.25" 13.25" 13.25"
D
CW" - 5"
1600A - 2500A 15.25" 15.25" 15.25"
—
CW - Channel width
T E C H N I C A L A P P L I C AT I O N G U I D E 29

Details for auto transformer

Note: Transformer platform is 6" from floor

recommend that cable entry come from
adjoining section.
30 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Drip pan — NEMA II 13" deep section

SEISMIC CORNER BRACE

ARC A
WELD NEMA 3R C
FLOOR SILL END VIEW
2.15
(54.6) .635 BOLT DOWN
HOLE (4)

NEMA 3R
FRONT VIEW
OPEN B

A MCC SECTION
2.15 SIDE
(54.6)

FLOOR SILL
40" OR LESS

6" MIN. 10" MIN.

CE
FRONT 20" WIDE WELD WELD
2.09 2.09
(53.1) (53.1)

ARC WELD DOWN LENGTH OF NEMA 3R EVERY 40" OR LESS FOR 130MPH WINDS AND 2.25G SHOCK (LENGTH & DEPTH PER OUTLINE)
T E C H N I C A L A P P L I C AT I O N G U I D E 31

Drip pan — NEMA II 20", 22", 30" deep sections

Drip pan — NEMA II 25" deep section back-to-back

Ref. dim. 13" Deep 20" Deep 22" Deep 25" Deep 30" Deep
A" 20.00" 20.00" 20.00" 20.00" 20.00"
D" 4.00" 4.00" 4.00" 4.00" 4.00"
E" 9.75" 9.75" 9.75" 9.76" 9.75"
F" NA 18.25" 20.25" NA 28.25"
32 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Type C master terminal

Note: Maxium handle is 6'7", measure from

bottom of sill to top of handle

Used for L and U shaped motor control Back-to-back configuration with

center arrangements wrap-around corner section

Dimensions (in inches)

MCC depth A B
13 20 17 The wrap-around corner section is standard
20 24 24 sections which accommodate plug-in units,
22 24 26 therefore no space is lost in the transition.
T E C H N I C A L A P P L I C AT I O N G U I D E 33

Incoming line terminations

34 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R
T E C H N I C A L A P P L I C AT I O N G U I D E 35

Outdoor enclosures
MCC Depth Front Top
(D) extension (F) cover (G) (H)
UL listed type 3R non-walk-inenclosure (standard) 20" 5 35 25
The standard NEMA 3R enclosure consists of a 22" 5 37 27
specially constructed MCC section with a mating 30" 5 45 35
framework which supports the roof and extended
front. The basic design is similar to switchboard
Note:
construction. The smaller footprint will permit a
1. Doors shown are double door or
broader usage than the optional NEMA 3R
single door module width less than 45".
construction. Meets Seismic Zone 4.
2. Nema 3R module may contain 1, 2 or 3
MCC sections, 3 section shipping split
The standard NEMA 3R enclosure consists of a
limited to (3) 20" wide MCC sections only.
specially constructed MCC section with a mating
3. When 30" deep sections is used, 20" and
framework which supports the roof and extended
22" deep section enclosure are extended
front, designed for bottom entry and exit.
so that they are flush front and rear with
the 30" deep enclosure.
• Three-point door latch;
4. All dimensions are in inches.
• 90° door with wind stop;
• Reinforced roof;
• Crane lifting;
• 2° roof pitch;
• Shipped via flatbed truck;
• 3" floor sills.
36 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Enclosure options Rodent barriers

Metal plates bolted to the bottom of each end
Space heaters section to close the opening between the front and
Space heaters are used to prevent moisture rear floor sills. Not required if the floor sills will be
condensation on the inside of the motor control removed or imbedded in concrete.
center. One heater (62.5 watts at 120 volts AC) is
installed in the bottom of each vertical section. Extra width vertical wireway
UL requires space heaters be controlled by a 24" wide sections can be furnished with 8" wide
thermostat. One thermostat can control up vertical wireway and door.
to 23 heaters and is located in the top
horizontal wireway.
Motor control center construction
Major structural components side
A terminal board for connecting an external sheets,L-H and R-H 0.075"
120-volt power source is standard. The terminal Vertical Bus Mounting Channels 0.090"
board is located in the top horizontal wireway Case Sills, Front/Rear, Top/Bottom,
adjacent to the thermostat(s). Top Horizontal Channel (13 gauge)
Lifting channel (top) 0.187"
This is recommended since it permits the space Floor sills (optional structural type)
heaters to be energized even when the motor see below 0.105" (12 gauge)

control center itself is deenergized. If export Enclosing covers/panels

crating is involved, the space heater circuit can be Rear covers, 13" and 30" deep 0.075" (14 gauge)
wired to an external plug for energizing the heaters Rear covers, 20" and 22" deep 0.060" (16 gauge)
during shipment and storage. Endplates 0.060" (16 gauge)
Top conduit covers 0.060"
When specified, space heater power can be
Bottomplates 0.060"
provided from within the motor control center.
Vertical wiretrough door 0.060"
Include the required distribution transformer with
primary and secondary protection in the motor Other steel
control center. Unit barrier shelves 0.063"
Unit cover doors 0.075"
An enclosed foreignvoltage disconnect switch is Unit saddles 0.090"
available as an option.

Bottom plates
Plates bolt on to the bottom of each motor control
center section. They may be removed
to facilitate installing conduit.

Extended height pull box (top hat)

A pull box can be mounted on top of a vertical
section when specified. The standard height is
12 inches; 6-, 18-, and 24" heights are also available.
Top, front, and end covers are removable for
access.

Special transitions to 8000 line and low-voltage

switchboards are available upon request. Please
consult factory.
 T E C H N I C A L A P P L I C AT I O N G U I D E 37

Note: Arc weld down length of NEMA 3R

every 40" or less for 130 mph winds and
2.25G shock (length and depth per outline)

Note: For all installations, including

Seismic Zone 4, testing was performed
using 1/2"-13 Grade 5 bolts, torqued to
50 foot-pounds, located in each of the
four corners in each section.

Center of gravity
For a uniformly loaded 90" high x 20" deep
lineup, center of gravity is:
• X = center of lineup
• Y = 46 1/2" above bottom of floor sill
• Z = 8" in from front (front-mounted devices
20" deep)

OR: 10" in from front (back-to-back construction)

• Z = 5" in from front (13" deep)
• Z = 8 1/2" in from front (22" deep)
• Z = 11" in from front (25" NEMA 3R)

Typical variations due to uneven loads:

• X = ± 5"
• Y = ± 1"
• Z = ± .5"

20" Y
Z

Material: 3" × 5#/FT CHANNEL B4A10

Finish: F31-HC2 X

—
Optional structural type floor sills 91.5"

Note that bolt down locations for sections with

seismic bracing change from center of structure
(left to right), to four corners with .635 clearance
holes for 1/2" bolts —
CW - Channel width

Mounting requirements for seismic NEMA 3R with

optional heavy base Sections Lbs Kg
90"H × 20"W indoor type 1 and 12 500 272
ORNER BRACE 90"H × 20"W indoor back-to-back type 1 and
ARC
NEMA 3R
ARC WELD ALL FOUR 13 700 318
WELD CORNERS (3/16" BEAD)
FLOOR SILL END VIEW
90"H × 20"W outdoor type 3R 725 329
.635 BOLT DOWN
HOLE (4)

NEMA 3R
FRONT VIEW 6" CHANNEL
OPEN B ANCHORED

A MCC SECTION 10" MIN.

SIDE WELD

FLOOR SILL MIN. 8" H BEAM

40" OR LESS ANCHORED FRONT
AND REAR
6" MIN. 10" MIN.
CEMENT PAD
20" WIDE WELD WELD
2.09
(53.1)

ENGTH OF NEMA 3R EVERY 40" OR LESS FOR 130MPH WINDS AND 2.25G SHOCK (LENGTH & DEPTH PER OUTLINE)
38 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Bus selection This total cannot exceed the vertical bus rating.
All continuous-current rating selections or Tin plated copper vertical bus is standard, with
recommendations are based on the motor silver plating as an option.
control center being located in a maximum 40°C
(104°F) ambient. Refer to "Overview" section for Neutral bus
other environmental considerations. Neutral lugs will be provided as applicable.
Neutral bus is normally sized at 50 percent
Main horizontal bus of the main bus ampacity.
The size of motor control center main bus and
cables feeding the main bus is based on the Ground bus
current-carrying capacity required for motors NEC requires a ground bus in multisection motor
plus other connected loads. control centers. 300 ampere Cu ground bus will
meet minimum size requirements for main busses
The capacity required for motors can be taken as rated through 2000 amperes. A clearance hole for
125 percent of the full-load rating of the largest 3/8" hardware is provided in each section. The
motor plus 100 percent of the full-load rating of all default for incoming ground termination is (3)
other motors to be operated at the same time. #2-1/0 for 300A ground bus and (3) 1/0-500 kcmil
Modified requirements resulting from duty-cycle or for 600A ground bus. Ground bar comes with
demand factor can be taken into account. 6 predrilled holes for ground connectors.

The current-carrying capacity required for other Options

connected loads should be computed on the basis The following UL listed options are available:
of 100 percent of the sum of individual loads except • Shutter mechanism for vertical bus
where a demand factor can properly be applied to stab openings.
reduce this total. Consideration should be given to • Fully-insulated main horizontal bus.
future requirements. • Silver plated horizontal and vertical bus.
• Silver plated ground bus.
Vertical bus extensions
Vertical bus is available in 30" wide enclosures
maximum. The maximum vertical bus loading is
calculated as follows: 80 percent of the feeder trip
or fuse clip rating, plus 100 percent of the starter
full load amps, plus 25 percent of the largest motor
full load amps.
T E C H N I C A L A P P L I C AT I O N G U I D E 39

Bus systems/selection 6

Short-circuit rating in RMS

MCC Bus Continuous current Material symmetrical amperes – (kA) UL Notes
Rating amperes Cu 65 100
600 • • • 1/4" x 2"
800 • • • 3/8" x 2"
1200 • • • 1/2" x 2"
Main Horizontal 1600 • • • (²) 1/2" x 2"
2000 • • • (²) 1/2" x 2"
2500 • • • (²) 1/2" x 2"
2500/3000/3200 • • • (⁶) 3/8" x 1.5"
300 • • • 3/8" x 3/4"
Vertical
600/700*/850 • • • 3/8" x 1 1/2"
800 • •
1200 • •
Neutral
1250 • •
1600 • • (²) 0.5" x 2"
300 • • 1/4" x 1"
Horizontal
600 • • 1/4" x 2"
ground
800 • • 3/8" x 2"
Vertical grounds 150 • • 1/8" x 1"

All values shown based on 1200A/sq.in. density rating. Alternate density ratings are available; if required, consult factory.

1. W hen a size 6 or 7 starter is in the motor control center lineup, use a 1200 ampere microEntelliguard Trip Unit circuit breaker as a main.
2. Requires special section 90" high, 24" wide, 20" deep.
3. Requires special section 90" high, 30" wide, 30" deep.
4. Main breaker must be mounted at top of the section and requires full 20" depth of enclosure.
5. R equires special section 90" high, 30" wide, 30" deep. When section is on the left, allow for a 5" spacer to permit unit doors on the right to open.
6. For UL or service entrance labels provide main breaker in switchboard construction.
7. Consult factory for availability.
8. 2500 Type 12, 3000, 3200 require section 90"H, 36"W, 30"D; Spacer shell (5");
9. 3000/3200 require elevated roof cover (5")
10. 3000A EntelliGuard G will be UL489, 3200A EntelliGuard G will be UL1066. Solidly grounded Wye 3 phase, 4 wire.

Data subject to change without notice.

40 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Mains, feeders, incoming lines

Mains If a single disconnect is furnished as a disconnect

for all load circuits the unit will be marked “Main”.
General In order for the units to be classified as suitable for
Main units consist of an externally operable circuit service entrance, the incoming phase conductors
disconnect, either a fusible switch or a circuit must connect directly to the disconnect device line
breaker. Sizes by ampere rating, short-circuit terminals or to a UL listed main line terminal
rating, type construction and Space units required assembly.
are given in the accompanying lists. Normally,
thermal magnetic circuit breakers or fuses are A grounding electrode conductor terminal
necessary for main protection. The short-circuit connector sized in accordance with the circuit
interrupting rating depends on the type disconnect ampacity is furnished in one section. Three-phase,
furnished. Select a main unit for which the four-wire systems include a neutral bonding jumper
interrupting rating equals or exceeds the maximum for grounding the neutral conductor during
available fault current. For reverse-fed circuit installation. Ground fault protection is required for
breakers, refer to factory for details. disconnects 1000A and above for solidly grounded
wye services, where phase-to-ground is more than
Refer to specific breaker publications for 150 volts (NEC 230.95).
time-current characteristics and programmable
options for the various types of circuit breakers. Main metering/lugs
A list of these publications is given in "Application Current transformers (CTs) can be provided in the
data" section. main compartment for use with a metering unit.
This option may increase space requirement. If
Service entrance crimp type lugs are required, a bus assembly is
UL listed main units containing only circuit fabricated to provide a landing pad for these
breakers or fused switches may be UL classified as terminals. This extends the space required for the
suitable for service entrance. main and must be factory installed. Size will be the
same as NEMA lug option.

Ul listed fused switch mains

Interrupting rating RMS amps

(in thousands)(¹) Construction
Amperes Space units Notes
Volts
240 480 600 Stab-in Bolt-in
Fusible switches
200 100 100 100 • 2
400 MCS 100 100 100 • 4 (⁴)
600 MCS 100 100 100 • 4 (⁴)
High pressure contact (HPC) switch
800 100 100 100 • 6 (²)
1200 100 100 100 • 6 (²)
1600 100 100 100 • 6 (³)
2500 100 100 100 • 6 (³)

1 With Class J, R and L fuses.

2 Requires a 24" wide by 20” deep section. Full depth of enclosure is required.
3 Requires 30" wide by 30" deep section. Must be NEMA 1 Construction, 80% rated only.
4 Class J fuse is 3X.
 T E C H N I C A L A P P L I C AT I O N G U I D E 41

Mains, feeders, incoming lines

IC (kA) Entry
UL (X)
Amperes CB Type Stab-in Bolt-in Space units Notes top/
listed
240V 480V 600V bottom
Spectra thermal magnetic molded case circuit breaker
150 SEL/SEP 65/100 65/100 25 • 1 • T/B
250 SFL/SFP 65/100 65/100 25 • 1.5 • T/B
600 SGL/SGP 65/100 65/100 65 • 2 • T/B
1200 SKL 65 65 42 • 3.5 • (¹)(⁴) T/B
PowerBreak II insulated-case circuit breaker with EntelliGuard G trip unit
800 SSF/SHF 65 65 42 • 6 (24W) • (²) T/B
1200 SSF/SHF 65 65 42 • 6 (24W) • (²) T/B
1600 SSF/SHF 65/100 65/100 42/65 • 6 (30W) • (³) T/B
2000 SSF/SHF 65/100 65/100 42/65 • 6 (30W) • (³)(⁵) T/B
2500 SSF/SHF 65/100 65/100 42/65 • 6 (36W) • (³)(⁵) T/B
800 SSD 65 65 42 • 6 (30W) (⁵)(⁶)(⁷) T/B
1600 SSD 65 65 42 • 6 (30W) (³)(⁵)(⁶)(⁷) T/B
2000 SSD 65 65 42 • 6 (30W) (³)(⁵)(⁶)(⁷) T/B
EntelliGuard G air circuit breaker with EntelliGuard G trip unit
800 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
1200 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
1600 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
2000 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
2500 GA/GB 100 100 100 • 6 (36W) • (⁶)(⁸) T/B Design without fan cooling.
Requires 3" rear clearance
3000 GA/GB 100 100 100 • 6 (36W) • (⁶)(⁸)(⁹)(¹⁰) T/B from wall
Requires 3" rear clearance
3200 GA/GB 100 100 100 • 6 (36W) • (⁶)(⁸)(⁹)(¹⁰) T/B from wall
800 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
1200 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
1600 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
2000 GB 65/100 65/100 • 5.5(24Wx30D) • (⁶)(⁸) T/B
2500 GA/GB 100 100 100 • 6 (36W) • (⁶)(⁸) T/B Design without fan cooling.
Requires 3" rear clearance
3000 GA/GB 100 100 100 • 6 (36W) • (⁶)(⁸)(⁹)(¹⁰) T/B from wall
Requires 3" rear clearance
3200 GA/GB 100 100 100 • 6 (36W) • (⁶)(⁸)(⁹)(¹⁰) T/B from wall

1. W hen a size 6 or 7 starter is in the motor control center lineup, use a 1200 ampere microEntelliguard Trip Unit circuit breaker as a main.
2. Requires special section 90" high, 24" wide, 20" deep.
3. Requires special section 90" high, 30" wide, 30" deep.
4. Main breaker must be mounted at top of the section and requires full 20" depth of enclosure.
5. R equires special section 90" high, 30" wide, 30" deep. When section is on the left, allow for a 5" spacer to permit unit doors on the right to open.
6. For UL or service entrance labels provide main breaker in switchboard construction.
7. Consult factory for availability.
8. 2500 Type 12, 3000, 3200 require section 90"H, 36"W, 30"D; Spacer shell (5");
9. 3000/3200 require elevated roof cover (5")
10. 3000A EntelliGuard G will be UL489, 3200A EntelliGuard G will be UL1066

Data subject to change without notice

42 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Ground-fault protection of equipment per NEC Arc flash mitigation (AFM) main and feeder units
Each main or feeder disconnect rated 1000 The E9000 AFM units are designed to reduce the
amperes or more and installed on a solidly likelihood of exposure to electrical shock and the
grounded wye electrical system of more than potential of internal arcing faults from occurring
150 volts to ground, but not exceeding 600 volts during maintenance. The retractable stab
phase-to-phase, will be provided with ground-fault mechanism allows for closed-door racking of the
protection of equipment. unit, providing added protection to the electrical
Exception No 1: The above is not required if the personnel from the dangers of an arc flash
disconnect is for a continuous industrial process occurrence. The introduction of a compact NEMA
where a non-orderly shutdown will introduce contactor in these AFM units will allow a minimum
additional or increased hazards. of IP10 protection with optional IP20 terminal
Exception No 2: The above is not required protection for starters using this contactor.
for fire pumps. The 300-Line Legacy NEMA contactor is remain
Exception No 3: The above is not required if available with this new design. Other IP20
ground-fault protection is provided ahead of protection options are available in all starter
the equipment. units including IP20 control power transformer
fuses and pilot devices. For more information
Note: The above is paraphrased from NEC see page D2 and GE Publication DEA-593.
section 215.10, 215.95 and 240.13.

AFM circuit breaker mains — standard selection

Interrupting rating RMS Amps

Amperes Circuit breaker (in thousands) Construction
Space units
(up to) type Volts Retractable
480 600 Stab-in Bolt-in
Spectra Thermal Magnetic
150 SEL/SEP 100 65 • 1
150 SELT-L/SEPT-L 65 • 1
250 SFL/SFP 100 65 • 1.5
600 SGL/SGP 100 65 • 2
T E C H N I C A L A P P L I C AT I O N G U I D E 43

Feeders
Feeder units consist of an externally operable
circuit disconnect, either a fusible switch or a
circuit breaker. Thermal magnetic circuit breakers
are required unless the feeder supplies a critical
circuit, such as a fire pump controller.

Select the fuse or circuit breaker trip rating based

on the feeder circuit continuous current rating in
accordance with the NEC. Feeder unit short-circuit
interruption ratings must equal or exceed the
available short-circuit currents.

Fused switch feeders

Interrupting rating
RMS Amps (in thousands) Construction Space UL (X)
Amperes Notes
Volts units(¹) listed
240 480 600 Stab-in Bolt-in
Fusible switches
30 100 100 100 • 1 •
30/30 100 100 100 • 1 • (²)
60 100 100 100 • 1 •
60/60 100 100 100 • 1 • (²)
100 100 100 100 • 1 •
100/30 100 100 100 • 1 •
100/60 100 100 100 • 1 •
100/100 100 100 100 • 1 •
200 100 100 100 • 2 •
400 MCS 100 100 100 • 3 •
600 MCS 100 100 100 • 3 •
High pressure contact (HPC) switch
800 100 100 100 • • (³)
1200 100 100 100 • • (³)
1600(⁴) 100 100 100 • (³)

1. Top/bottom entry.
2. Dual or twin feeder units.
3. Requires a 24" wide by 20" deep section. Full depth of enclosure is required.
4. Requires a 30" wide by 20" deep section. Full depth of enclosure is required.

AFM fused switch feeders – standard selection

Interrupting Construction
Amperes rating(in Retractable Space units
thousands)
Stab-in
Fusible switches
30 100 • 1
60 100 • 1
100 100 • 1
200 100 • 2
44 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Feeders

Circuit breaker feeders – standard selection

Circuit IC (kA) Entry

UL (X)
Amperes breaker Stab-in Bolt-on Space units Notes top/
listed
type 240V 480V 600V bottom
Spectra thermal magnetic molded case circuit breaker
100 SEL/SEP 65/100 65/100 25/25 • 1/2 • T/B
100/100 SEL/SEP 65/100 65/100 25/25 • 1 • T/B
150 SEL/SEP 65/100 65/100 25/25 • 1/2 • T/B
150/150 SEL/SEP 65/100 65/100 25/25 • 1 1/2 • T/B
250 SFL/SFP 65/100 65/100 25/25 • 1 • (²) T/B
250/250 SFL/SFP 65/100 65/100 25/25 • 2 • (²) T/B
600 SGL/SGP 65/100 65/100 65/65 • 2 • T/B
1200 SKL 65 65 42 • 3.5 • (³) (⁴) T
PowerBreak II insulated-case circuit breaker with EntelliGuard G trip unit
800 SSF/SHF 65 65 42 • 6 (24W) • T/B
1200 SSF/SHF 65 65 42 • 6 (24W) • T/B
1600 SSF/SHF 65/100 65/100 42/65 • 6 (30W) • T/B
2000 SSF/SHF 65/100 65/100 42/65 • 6 (30W) • T/B
2500 SSF/SHF 65/100 65/100 42/65 • 6 (36W) • T/B
800 SSD 65 65 42 • 6 (30W) T/B
1600 SSD 65 65 42 • 6 (30W) T/B
2000 SSD 65 65 42 • 6 (30W) T/B
EntelliGuard G air circuit breaker with EntelliGuard G trip unit
800 GB 65/100 • 5.5(24Wx30D) • T/B
1200 GB 65/100 • 5.5(24Wx30D) • T/B
1600 GB 65/100 • 5.5(24Wx30D) • T/B
2000 GB 85/100 • 5.5(30Wx30D) • T/B
2500 GA/GB 100 100 • 5.5(30Wx30D) • (⁵) T/B
800 GB 65/100 • 5.5(24Wx30D) • T/B
1200 GB 65/100 • 5.5(24Wx30D) • T/B
1600 GB 65/100 • 5.5(24Wx30D) • T/B
2000 GB 85/100 • 5.5(24Wx30D) • T/B
2500 GA/GB 100 100 • 5.5(30Wx30D) • (⁵) T/B

1. W
 hen feeder unit accessories are required such as shunt trip, Aux switch, UV release, etc., unit height must be a minimum of 1 space.
2. 1X units are available with horizontal handle.
3. Requires full depth of enclosure; (20" deep minimum).
4. F
 eeder units 1000A and over should have ground fault sensing on three-phase, four-wire systems where line to ground voltage is more than 150V.
5. If used with 3000A or 3200A main bus, an elevated roof (5").

AFM circuit breaker feeders – standard selection

Interrupting rating RMS Amps

Circuit breaker (in thousands) Construction
Amperes (up to) Space units
type Volts Retractable
480 600 Stab-in
Spectra thermal magnetic
150 SEL/SEP 100 25/65 • 1
150 SELT-L/SEPT-L 65 • 1
250 SFL/SFP 100 65 • 1.5
600 SGL/SGP 100 65 • 2
T E C H N I C A L A P P L I C AT I O N G U I D E 45

Accessories

Accessories for mains and feeders

Accessories
Circuit breaker Undervoltage
Bell alarm Auxiliary switch Shunt trip RELT
release
Spectra • Up to 2(⁴) •(⁴) • X(²)
Power Break II •(¹) Up to 12(¹) • • X
HPC • Up to 12(¹) • • X

1. 600VAC not UL Listed.

2. G and K Frame only.
3. Shunt trip requires aux switch (G and K) or bell alarm (EandF) for continuous operation.
4. Aux switch available @ 240V max only.

Options for mains and feeders Accessories for high pressure contact
(HPC) switches
Terminals for field wiring mains and feeders • Motor operator mechanism
• Remote close
Will accept wire(²) • Undervoltage release
Terminal size
AWG/kcmil(¹) Material • Shunt trip with lockout
Switches • Bell alarm–alarm only
30A QMW 14-8 Cu-Al • Bell alarm with lockout
14-2 Cu • Auxiliary switch module
60A QMW
12-2 Al • Mechanical counter
14-1/0 Cu • Key interlock mounting provision
100A QMW
12-1/0 Al • Push button cover
200A QMW (1) 6-250 Cu-Al • Door interlock
(1) 2-350(³) Cu-Al • Blown fuse protector
400A MCS (molded case switch))
(1) 8-600 Cu-Al
(1) 8-600 Cu-Al Key interlocking
600A MCS (molded case switch) (1) 4-500(³) Cu-Al
Provisions for key interlocking can be provided on
(2) 6-500 Cu-Al
all circuit breakers over 250A and fusible switches
over 100A. The standard key lock is by Superior
HPC Switch 300-750 Cu
— 800-1600A Lock Corporation. However, coordination with
300-800 Al
Kirk key locking will be supplied if necessary.
Circuit breakers
The following information is required when
SE150 15-150A 1 lug 12-3/0 Cu-Al
lock coordination is to be provided with other
SF250 70-225A 1 lug 8-350 Cu-Al
up-stream or down-stream devices remote
SG600 1 lug 6-600 Cu-Al
from the motor control center:
125-600A 2 lugs 2/0-500 Cu-Al
SK1200 3 lugs (800A) 3/0-500 Cu-Al
PURCHASED BY ___________________________
3 lugs 300-750 Cu-Al
ULTIMATE USER ___________________________
300-1200A 4 lugs 250-400 Cu-Al DESTINATION _____________________________
1. C
 onductor #1 and smaller may be noted 60/75°C. LOCK MANUFACTURER _____________________
Conductors #0 and larger must be rated 75°C. LOCK NUMBER____________________________
2. C
 onductor sizes based on 1/Ph unless otherwise indicated.
3. Feeders PURCHASE ORDER NUMBER _________________

Accessories for fused switches Note: Minimum 24" high units are required
Fused switches can be ordered with up to two for key interlocking. UL listed option.
auxiliary contacts which are available in the
following UL listed configurations: 1 normally open,
1 normally closed, 1 normally open/1 normally
closed, or 2 normally open.
46 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Ground fault protection Incoming line terminations

Two types of UL listed ground fault protection The following cable terminal compartments
can be provided as an option with feeder and main are commonly specified for use in motor control
circuit breakers. A shunt trip device is required in center construction where the main AC power
the circuit breaker to trip the breaker if a ground disconnect is located upstream of the motor
fault should occur. ITI BGFL ground break control center. For other custom cable termination
protective relaying is recommended for main arrangements contact an ABB sales representative.
breaker application. Model #252 ground fault The number of cables indicated must not be
relaying is recommended for most feeder exceeded to maintain the short-circuit rating.
applications. See "Components" section for
description of both ground fault relay types.
A minimum of 12" additional space height is
required in addition to the standard space height
shown for each main feeder unit. A separate
120-volt source for the shunt trip circuit will
decrease the additional space required. Refer
to page 179 for application help.

MLO space in inches / Top feed

Incoming line vertical space available Minimum conduit space
cable assemblies Cables/ Cables/ Cable range per width and top bottom
Top Bottom lug(³) phase NEMA Bending(⁷) depth (Figure 1)
18/66 2 2 #2-350 kcmil 20"x13" 5"x13.7" A-B
18/66 3 3 #6-300 kcmil 20"x13" 5"x13.7" A-B
600A Std. Lug(⁴)(⁵) 24/54 2 2 #2-600 kcmil 20"x13" 5"x13.7" A-B
24/54 3 3 #2-500 kcmil 20"x13" 5"x13.7" A-B

30/48 1 2 #2-600 kcmil 20"x13" 5"x13.7" A-B

18/66 1 2 #2-350 kcmil 20"x13" 5"x13.7" A-B
600A NEMA Lug(²)
30/48 1 2 #2-600 kcmil 20"x13" 5"x13.7" A-B
24/60 24/54 4 4 #2-500 kcmil 20"x13" 5"x13.7" A-B
800A/1200A
24/60 24/54 3 3 #2-600 kcmil 20"x13" 5"x13.7" A-B
Std. Lug (¹)(⁴)
30/54 24/54 4 4 #2-600 kcmil 20"x13" 5"x13.7" A-B
800A/1200A 30/48(⁶) 1 4 500-750kcmil 24"x13" 5"x13.7" A-B
NEMA Lug 36/58 36/42 1 4 500-1000kcmil 24"x13" 5"x13.7" A-B
1600A NEMA Lug 72/0 72/0 1 8 500-1000kcmil 30"x30" 13"x17.7" A-C
2000A NEMA
Lug(²)(⁴) 72/0 72/0 1 8 500-1000kcmil 30"x30" 13"x17.7" A-C
2500A NEMA
Lug(²)(⁴) 72/0 72/0 1 10 500-1000kcmil 36"x30" 13"x17.7" A-C
2500A Without
Fans 72/0 72/0 1 12 500-1000kcmil 36"x30" 13"x27.6" A-C
3000A 72/0 72/0 1 12 500-1000kcmil 36"x30" 13"x27.6" A-C
3200A 72/0 72/0 1 12 500-1000kcmil 36"x30" 13"x27.6" A-C

1. Space shown above is for 20" deep design 800A to 1200A MLO.
2. B
 urndy type YA crimp lugs is available as an option. Crimp Lugs require NEMA drilling and NEMA Lug spacing.
3. Mechanical compression Cu/Al Lugs furnished for 75°C cable.
4. C
 u/Al standard. Copper only lugs are available as an option. These may affect number of cables per lug.
5. NEMA wire bending rules reduce cable size if entry is from the side.
6. 13" deep requires full section no vertical bus.
7. Lug cable range may be larger than the NEMA bending allows above.
T E C H N I C A L A P P L I C AT I O N G U I D E 47

The following features apply to ZTSD open-type

switches which are UL listed through 480 volts and
CSA listed through 600VAC. For specific ratings
and additional optional features refer to Zenith.

Zenith ZTSD Utility to Generator time delay MX 250

Module Standard Features:

6P  icroprocessor activated test switch

M
(momentary)
A3 Aux Contact - closed in emergency
(Source 2) Additional available up to 10,
must be specified
— A4 Aux Contact - closed in normal (Source 1)
Figure 1
Additional available up to 10, must be
specified
Busway entrances
CDT Exerciser no load timer
Motor control centers include provisions for
DS Disconnect Switch for source voltage to
connecting a busway. Busway must be braced for
transfer power panel, 600A to
maximum available short circuit current. Minimum
1200A only
enclosure sizes for busway are shown in the
DT Time Delay from Neutral Switch position
adjacent table. Refer to the factory for other type
to Source 1 on retransfer
busway. Include busway requisition number when
DW Time Delay from Neutral Switch position
ordering motor control center.
to Source 2 on retransfer
E Engine Start Relay
Spectra series busway
EL/P Event Log of last 16 events
Max. busway Ampacity K/P Frequency Indication on the controller
Pull Enclosure Cu Al
LNP Center-off position LCD-Indicator
Entry
box size 1000A/ 750A/
L1,2,3,4 LED lights, Source 1and2 position, Source
Std Std
IN² IN² 1and2 available
Top 12" 30"W x 22"D 1600 1500 1350 1000 P1 Engine Start Timer (adj. To 6 sec.)
Bottom 30"W x 22"D 1600 1500 1350 1000 R50 In Phase monitor between Normal (Source
Top 12" 30"W x 22"D 2000 2000 2000 2000 1) and Emergency (Source 2) to allow
Bottom 30"W x 22"D 2000 2000 2000 2000 transfer
Top 12" 36"W x 22"D 2500 2500 2500 2500 S13P Microprocessor activated commit/no
Bottom 36"W x 22"D 2500 2500 2500 2500
commit on transferring to Emergency
(Source 2) (with enable/
disable settings)
Note: Bus bars must be phased front-to-rear in 24"
T Retransfer to Normal (Source1) adjustable
width enclosure. Bottom entry requires full section.
time delay
For busway, refer to factory.
U Engine stop / cool down timer
V1 Voltage imbalance between phases
Automatic Transfer Switches
(3 phase only)
Motor control centers may be furnished with Zenith
W Adjustable time delay on transfer to
transfer switches. The switch is mounted in a
Emergency (Source2)
separate unit and cable-connected to the motor
YEN Bypass transfer timers function (soft key
control center bus. Manual control, pushbuttons,
switch in microprocessor)
pilot lights and switches may be door-or bracket-
mounted within the unit. Up-stream overcurrent
protection must be provided for each power source.
The unit can be UL listed if all components are listed
for use in motor control center equipment.
48 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Withstand current ratings (WCR) for automatic transfer switches(¹)

Available RMS symmetrical Amperes at 480 Volts AC

MCC enclosure When used with class J or L When used with class RK-5 fuses or
Minimum MCC Switch rating
widths (in current-limiting fuses molded-case circuit breakers
Space units(²) (Amps)(³)
inches) Max. fuse size Max. breaker size
WCR (Amps) WCR (Amps)
3 24 40 100,000 50 22,000 150
3 24 80 200,000 100 22,000 150
3 24 100 200,000 125 22,000 150
3 24 150 200,000 200 42,000 400
3 24 260 200,000 350 42,000 400
3 24 400 200,000 600 50,000 400
3 24 600 200,000 750 65,000 800
6 30 800 200,000 1200 65,000 1200
6 30 1000 200,000 1200 65,000 1200
6 30 1200 200,000 1200 65,000 1200

1. 3
 -pole vs. 4-pole transfer switches: Typically, most MCCs do not have the neutral pulled, so a 3-pole switch will suffice. If the
generator neutral is bonded to the frame of the generator and pulled to the MCC to provide a single-phase connection, a
4-pole transfer switch is required to facilitate transferring the neutral from the Utility to the Generator connection.
2. D
 oes not include space for protection; switches must be mounted at bottom of section in order to install vertical bus above switch.
3. L
 arger sizes require special over-size enclosures. Refer to factory.

Transitions
Transitions for connecting control centers to
transformers, low-voltage switchgear or switch-
boards are available and generally the same depth
as the equipment to which they are to be con-
nected. Appropriate overcurrent protection for
the control center must be provided.
 T E C H N I C A L A P P L I C AT I O N G U I D E 49

Starters

General Basic starter units are provided in tables in this

Combination motor control starter units consist of section. Starters are listed by starter function,
an externally operable circuit disconnect, either a line voltage, HP, NEMA size, and combination short-
fusible switch or circuit breaker, and a magnetic circuit rating. Tables in this section also list control
starter with an overload relay in the motor lines. power options and other options including any
additional space requirements for these options.
Unit NEMA sizes listed are based on continuous Typical starter circuits are shown in "Drawings/
horsepower ratings. The maximum horsepower tests" section. Starters can also be used for
rating of each NEMA size controller is reduced for lighting or resistive heat loads ("Application
long accelerating times and for jogging or plugging data" section).
duty. Jogging duty is defined as 5 or more
contactor openings or closings per minute or over Arc flash mitigation (AFM) main and starter units
10 in a 10-minute period. Plugging is rapidly E9000 AFM units are a new offering for customers
stopping or reversing the motor by reversing the and specific applications where additional
phase sequence of the power supplied to the protection of personnel is essential. The AFM units
motor. Refer to the factory anytime accelerating were designed around lowering the electrical shock
times exceed 10 seconds or jogging or plugging hazards for motor control centers. The AFM unit
duty is required. Refer to the factory when `Design design includes optional IP20 devices and
E’ motors are used, not to be confused with Energy incidental contact safety barriers in an effort to
Policy Act (EPAC) motors. prevent accidental contact with energized parts
during maintenance.
The short-circuit interrupting rating depends on
the type disconnect furnished. Select a starter The E9000 AFM units are designed to reduce the
combination for which the interrupting rating likelihood of exposure to electrical shock and the
equals or exceeds the maximum available potential of internal arcing faults from occurring
fault current. during maintenance. The retractable stab
mechanism allows for closed-door racking of the
Basic combination motor starter units consist of: unit, providing added protection to the electrical
1. Externally operable circuit disconnect. personnel from the dangers of an arc flash
2. Magnetic starter with a thermal-magnetic, occurrence. The introduction of a compact NEMA
or electronic overload relay. contactor in these AFM units will allow a minimum
3. External overload reset operator. of IP10 protection with optional IP20 terminal
4. Tapped line voltage, 120-volt CPT control protection for starters using this contactor.
power or external control power.
5. Pull-apart control terminal boards through The 300-Line Legacy NEMA contactor remains
NEMA size 5. available with this new design. Other IP20
6. Pull-apart power terminal boards through protection options are available in all starter units
NEMA size 2 (when BT specified). including IP20 control power transformer fuses and
7. E xtra CPT capacity for operating auxiliary pilot devices.
relays and pilot devices (when specified).
8. Plug-in construction through NEMA size 5 (FVNR)
starters. Bolt-in construction may require
vertical bus modifications.
50 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

A safety interlock prevents customers from Selection tables

opening the unit door and racking out the stab Circuit breaker type
when the unit is energized. The visual indicators on
FVNR AFM
the front of the units provide personnel with a clear
view of the status of the stab and vertical bus C2000 300-line
Circuit
isolation shutter. NEMA size standard standard
breaker type
space units space units

AFM Features: 1 SEL/SEP 1 1.5

• Two-position closed-door retractable unit stabs 2 SEL/SEP 1 1.5

• Automatic operation vertical bus 3 SEL/SEP 1.5 2

isolation shutter 4 SFL/SFP 2 2.5
• Stab and Shutter position indicators on 5 SGL/SGP 4
unit doors
• Padlock for racking screw and FVR AFM
stab-breaker interlock
• Optional IP20 safety features and incidental C2000 300-Line
Circuit
NEMA size standard standard
contact barriers breaker type
space units space units
• Stab and Door Interlock: prevents opening the 1 SEL/SEP 1.5 2
unit door when stab is energized. 2 SEL/SEP 2 2.5
• Stab and Unit Interlock: prevents user from taking 3 SEL/SEP 3 3.5
the unit out when stab is energized,
4 SFL/SFP 3 3.5
or inserting the unit into the bus when stab
is extended.
• Racking Screw and Disconnect Interlock: prevents Selection Tables
the user from racking the stab Fused Switch Type
in/out of the unit with the disconnect in
FVNR AFM
the “ON” position.
Class RK-1, RK-5, J-TD C2000
300-line
For information, please see publication standard
NEMA size Switch standard
DEA-593. Clip Amps Space
Amps Space units
units
1 30 30 1 1.5
2 60 60 1 1.5
3 100 60 2 2.5
3 100 100 3 3.5
3 200 200 3.5 4
4 200 200 3.5 4

FVR AFM

Class RK-1, RK-5, J-TD C2000 300-line

standard standard
NEMA size Switch
Clip Amps space space
Amps units units
1 30 30 1.5 2
2 60 60 2 2.5
3 100 60 4 4.5
T E C H N I C A L A P P L I C AT I O N G U I D E 51

Selection tables
Circuit breaker type

208 Volts, 60 Hertz – combination motor starters

FVNR Part winding

Circuit Circuit
NEMA Space
Max. Hp IC (kA) breaker Notes NEMA size Max. Hp IC (kA) breaker Space units
size units
type type
1 7.5 65/100 SEL/SEP 1 (²) 1 10 65/100 SEL/SEP 2
2 10 65/100 SEL/SEP 1 2 20 65/100 SEL/SEP 2
3 25 65/100 SEL/SEP 1.5 3 40 65/100 SFL/SEP 4.5
4 40 65/100 SFL/SFP 2 4 75 100 SGL 5
5 75 100 SGL 3 5
6 150 65 SKL 4

FVR Y-Delta

Circuit Circuit
NEMA Space NEMA Space
Max. Hp IC (kA) breaker Notes Max. Hp IC (kA) breaker Notes
size units size units
type type
5 75 100 SGL 3 2 20 65/100 SEL/SEP 4
6 150 65 SKL 3.5 3 40 65/100 SEL/SEP 5
1 7.5 65/100 SEL/SEP 2 4 60 100 TGL 5.5
2 10 65/100 SEL/SEP 2 5 150 100 TGL 5.5 (³)
3 25 65/100 SEL/SEP 3.5 6 300 100 TGL 5.5
4 40 65/100 SFL/SFP 4
5 75 100 SGL 5.5
6 150 65 SKL 8.5 (¹)

2S1W, 2S2W

Max. Hp
Circuit
Constant Rev space
NEMA size IC (kA) breaker Space units Notes
variable Constant HP units
type
torque
4 40 30 25 SFL 4.5 7.5
5 75 60 30 SGL 5 10
6 150 100 65 SGL/SKL 8.5 (³)
1 7.5 5 65/100 SEL/SEP 2 2.5
2 10 7.5 65/100 SEL/SEP 2 3
3 25 20 65/100 SEL/SEP 4 4.5
4 40 30 65/100 SFL/SFP 4.5 5.5
5 75 60 100 SGL 5.5 10

RVAT

Circuit Space units Note: The space requirements shown in

NEMA Max.
IC (kA) breaker 13" 20" Notes these tables are minimum. Where layout
size Hp
type Deep Deep dimensions are critical, refer to factory. One
4 40 25 SFL 5 4 space unit or X unit equals 12 inches of
5 75 100 SGL 5 vertical height.
6 150 65 SKL N/A 12 (¹)
1. S
 ize 6 FVR, RVAT, 2S2W require (2) adjacent 24" wide sections,
2 10 65/100 SEL/SEP 4 4 20" deep (2S1W).
3 25 65/100 SEL/SEP 5 4 2. A 1/2X compact starter is available.
3. Refer to factory.
4 40 65/100 SEL/SFP 5.5 4.5
5 75 100 SGL 5 (²)
6 100 65 SKL N/A 12 (¹)
52 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Selection tables
Circuit breaker type

230 Volts, 60 Hertz – combination motor starters

FVNR Part winding

Circuit Circuit
NEMA Space NEMA Space
Max. Hp IC (kA) breaker Notes Max. Hp IC (kA) breaker Notes
size units size units
type type
6 200 65 SKL 5.5 4
1 7.5 65/100 SEL/SEP 1 (⁴) 5 (³)
2 15 65/100 SEL/SEP 1 1 10 65/100 SEL/SEP 2
3 30 65/100 SEL/SEP 2 2 25 65/100 SEL/SEP 2
4 50 65/100 SFL/SFP 2.5 3 50 65/100 SEL/SEP 4.5
5 100 100 SGL 3 4 75 100 SGL 5
6 200 65 SKL 6 (¹) 5 (³)

FVR Y-Delta

Circuit Circuit
NEMA Space NEMA Space
Max. Hp IC (kA) breaker Notes Max. Hp IC (kA) breaker Notes
size units size units
type type
5 100 100 SGL 5.5 (¹) 4 75 100 SGL 5.5 (¹)
6 200 65 SKL 8.5 (²) 5 (³)
1 7.5 65/100 SEL/SEP 2 2 25 65/100 SEL/SEP 4
2 15 65/100 SEL/SEP 2 3 50 65/100 SEL/SEP 5 (¹)
3 30 65/100 SEL/SEP 3 4 75 100 SGL 5.5 (¹)
4 50 65/100 SFL/SFP 3 5 150 100 SGL 5.5 (³)
5 100 100 SGL 5.5 (¹)
6 200 65 SKL 8.5 (²)

2S1W, 2S2W

Max. Hp
Constant Circuit Rev Space
NEMA size IC (kA) Space units Notes
variable Constant HP breaker type units
torque
4 50 40 25 SFL 4.5 5.5
5 100 75 30 SGL 5.5 (²) 10
6 200 150 65 SKL 8.5 (²)
1 7.5 7.5 65/100 SEL/SEP 2 2.5
2 15 20 65/100 SEL/SEP 2 3
3 30 40 65/100 SEL/SEP 4 4.5
4 50 75 65/100 SFL/SFP 4.5 7.5
5 100 150 100 SGL 5.5 (²) 10

RVAT

Circuit Space units 1. Requires 24" wide section.

NEMA Max.
IC (kA) breaker 13" 20" Notes 2. S
 ize 6 FVR, RVNR, 2S2W require (2) adjacent 24" wide sections,
aize Hp 20" deep (2S2W).
type Deep Deep
3. Refer to factory.
5 100 100 SGL N/A 5 4. A 1/2X compact starter is available.

6 200 65 SKL N/A 12 (²)

SEL/ Note: The space requirements shown in
2
15 65/100 SEP 4 4 these tables are minimum. Where layout
SEL/ dimensions are critical, refer to factory.
3 30 65/100 SEP 5 4
One space unit or X unit equals 12 inches
4 50 65/100 SFL/SFP 6 4.5
of vertical height.
5 100 100 SGL N/A 5
T E C H N I C A L A P P L I C AT I O N G U I D E 53

Selection tables
Circuit breaker type

460 Volts, 60 Hertz – combination motor starters

FVNR Part winding

Circuit Circuit
NEMA Space NEMA Space
Max. Hp IC (kA) breaker Notes Max. Hp IC (kA) breaker Notes
size units size units
type type
5 200 100 SGL 3 4 150 10 SGL 4.5
6 400 65 SKL 5.5 5 (⁴)
1 10 65/100 SEL/SEP 1 (⁵) 1 15 65/100 SEL/SEP 2
2 25 65/100 SEL/SEP 1 2 40 65/100 SEL/SEP 2
3 50 65/100 SEL/SEP 1.5 3 75 65/100 SEL/SEP 4.5
4 100 65/100 SFL/SFP 2 4 150 100 SGL 5
5 200 100 SGL 3.0 5 (⁴)
6 400 65 SKL 5.5

FVR Y-Delta, OT

Circuit Circuit
NEMA Space NEMA Space
Max. Hp IC (kA) breaker Notes Max. Hp IC (kA) breaker Notes
size units size units
type type
4 100 25 SFL 3 2 40 25/65 SE 3
5 200 100 SGL 6 (¹) 3 75 25/65 SGL 3.5 (¹)
6 400 65 SKL 12 (²) 4 150 65 SGL 4.5 (¹)
1 10 65/100 SEL/SEP 2 5 300 65 SGL 5
2 25 65/100 SEL/SEP 2
3 50 65/100 SEL/SEP 3
4 100 65/100 SFL/SFP 4
5 200 100 SGL 5.5 (¹)
6 400 65 SKL 8.5 (²)

2S1W, 2S2W

Max. Hp
Constant Circuit Rev space
NEMA size IC (kA) Space units Notes
variable Constant HP breaker type units
torque
4 100 75 25 SFL 4.5 5.5
5 200 150 30 TJC 6 (¹)(²) 10
6 400 300 65 SKL 12 (²)
1 10 7.5 65/100 SEL/SEP 1.5 2.5
2 25 20 65/100 SEL/SEP 2 3
3 50 40 65/100 SEL/SEP 4 4.5
4 100 75 65/100 SFL/SFP 4.5 7.5
5 200 150 100 SGL 6 (¹)(²) 10

RVAT
1. Requires 24" wide section.
Circuit Space units 2. S
 ize 6 FVR, RVAT, 2S2W require (2) adjacent 24" wide sections,
NEMA Max.
IC (kA) breaker 13" 20" Notes 20" deep (2S1W not available).
size Hp
type Deep Deep 3. S
 ize 5 RVAT cannot be mounted in 13" deep enclosure.
4. Refer to factory.
5 200 100 SGL 5 (³) 5. A 1/2X compact starter is available.
6 400 65 SKL N/A 12 (²)
2 25 65/100 SEL/SEP 4 4 Note: The space requirements shown in
3 50 65/100 SEL/SEP 5 4 these tables are minimum. Where layout
4 100 65/100 SEL/SEP 6 4.5 dimensions are critical, refer to factory.
5 200 100 SGL N/A 5 (³) One space unit or X unit equals 12 inches
of vertical height.
54 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Selection tables
Circuit breaker type

575 Volts, 60 Hertz – combination motor starters

FVNR Part winding

Circuit Circuit
NEMA Space NEMA Space
Max. Hp IC (kA) breaker Notes Max. Hp IC (kA) breaker Notes
size units size units
type type
1 10 25 SEL 1 1 15 25 SEL 2
2 25 25 SEL 1 2 40 25 SEL 2
3 50 25 SEL 1.5 3 75 25 SEL 4.5
4 100 25 SFL 2 4 150 10 SGL 5
5 200 65 SGL 3 5 (³)
6 400 42 SKL 6 (¹) 4 150 42 SGL 5
4 100 42 SGL 2 5 (³)
5 200 65 SGL 3.5
6 400 42 SKL 6 Y-Delta, OT

Circuit
FVR NEMA Space
Max. Hp IC (kA) breaker Notes
size units
type
Circuit
NEMA Space 2 40 25 SEL 3
Max. Hp IC (kA) breaker Notes
size units
type 3 75 25 SEL 3.5 (¹)
1 10 25 SEL 2 4 100 25 SEL 4.5 (¹)
2 25 25 SEL 2 4 150 100 SGL 5 (¹)
3 50 25 SEL 3 5 (³)
4 100 25 SFL 3 4 150 42 SGL 5 (¹)
5 200 65 SGL 5.5 (¹)
6 400 42 SKL 8.5 (²)
4 100 42 SGL 3
5 200 100 SGL 5.5 (¹)
6 400 42 SKL 8.5 (¹)

2S1W, 2S2W

Max. Hp
Constant Circuit Rev Space
NEMA size IC (kA) Space units Notes
Variable Constant HP breaker type units
Torque
1 10 7.5 25 SEL 2 2.5
2 25 20 25 SEL 2 3
3 50 40 25 SEL 4 4.5
4 100 75 25 SFL 5 7.5
5 200 150 22 SGL 5.5 (¹)(²) 10
6 400 300 42 SKL 8.5 (²)

RVAT
1. Requires 24" wide section.
Circuit Space units 2. S
 ize 6 FVR, RVAT, 2S2W require (2) adjacent 20 and 24" wide sections,
NEMA Max.
IC (kA) breaker 13" 20" Notes 20" deep (2S1W).
size Hp
type Deep Deep 3. Refer to factory.

2 25 25 SEL 4 4
3 50 25 SEL 5 4
Note: The space requirements shown in
4 100 25 SFL 6 4.5
these tables are minimum. Where layout
dimensions are critical, refer to factory. One
5 200 65 SGL 5 4.5
space unit or X unit equals 12 inches of
6 400 42 SKL N/A 12 (²)
vertical height.
5 200 100 SGL N/A 5
6 400 42 SKL N/A 11 (²)
T E C H N I C A L A P P L I C AT I O N G U I D E 55

Selection tables
Fused switch type

208 Volts, 60 Hertz – combination motor starters(⁵)(⁷)

FVNR Y-Delta, OT

Class RK-1, RK-5, Class RK-1,

NEMA J-TD Space NEMA Max. IC RK-5, J-TD Space
Max. Hp IC (kA) Notes
size Switch Clip units size Hp (kA) Switch Clip units
Amps Amps Amps Amps
1 7.5 100 30 30 1 2 7.5 100 60 30 3 (²)
2 10 100 60 60 1 2 10 100 60 30 3
3 15 65 100 60 2 2 15 100 100 60 3
3 25 65 100 100 2.5 3 20 65 100 100 4 (¹)
3 25 100 200 200 2.5 3 30 100 200 200 5 (¹)
4 40 100 200 200 3.5 4 40 100 200 200 5 (¹)
5 75 100 400 400 5 4 60 100 400 400 6 (⁴)
6 150 600 600

FVR 2S1W, 2S2W

Class RK-1, Class RK-1,

Max. Hp
NEMA Max. IC RK-5, J-TD Space NEMA IC RK-5, J-TD Space
Notes Notes
size Hp (kA) Switch Clip units size CT Constant (kA) Switch Clip units
Amps Amps VT HP Amps Amps
1 7.5 100 30 30 1.5 1 7.5 5 100 30 30 2
2 10 100 60 60 2 2 7.5 100 60 30 2
3 15 65 100 60 3 (⁵) 2 10 100 60 60 2
3 25 65 100 100 3.5 (⁵) 3 15 15 65 100 60 3.5 (⁵)
4 40 100 200 200 5 3 25 20 65 100 100 3.5 (⁵)
5 75 100 400 400 9.5 4 40 100 200 200 5.5
6 (³)(⁶) 5 75 100 400 400 8.5 (³)
1 7.5 5 100 30 30 2
RVAT 2 7.5 100 60 30 2
2 10 100 60 60 2
Class RK-1,
Space units 3 15 15 65 100 60 3.5 (⁵)
NEMA Max. IC RK-5, J-TD
Notes 3 25 20 65 100 100 3.5 (⁵)
size Hp (kA) Switch Clip 13" 20"
Amps Amps Deep Deep 4 40 100 200 200 5.5
2 10 100 60 60 4 4 5 75 100 400 400 8.5 (³)
3 15 65 100 60 5 4 (⁵) 6 100 600 600 8.5 (³)
3 25 65 100 100 5 4 (⁵)
1. Requires 24" wide section.
4 40 100 200 200 6 5 2. Size 1 not available. Use Size 2.
5 75 100 400 400 — 6 (³) 3. S ize 5 FVR, 2S1W, 2S2W with fused switch requires (²)
adjacent sections; left hand section is 24" wide 6X, right hand
6 section is 20" wide with top 31/2X used for disconnect.
4. S ize 4 Wye-Delta with fused switch requires a 24" wide
section when main horizontal bus is rated 1000 ampere
Part winding UL or less. A 30" wide section is required with 1200
ampere UL or higher rated main horizontal bus.
5. Use size 4 spacing for 100k ratings.
Class RK-1, 6. Requires 12" bottom wireway cover to UL Label.
NEMA Max. IC RK-5, J-TD Space 7. A ll 400/600A units are MCS (molded case switches).
Notes
size Hp (kA) Switch Clip units
Amps Amps
1 7.5 100 30 30 2 Note: The space requirements shown in
2 15 100 100 60 2 these tables are minimum. Where layout
3 20 65 100 100 4 (⁵)
dimensions are critical, refer to factory.
3 30 100 200 200 5
One space unit or X unit equals 12 inches
of vertical height.
4 60 100 400 400 5.5
56 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Selection tables
Fused switch type

230 Volts, 60 Hertz – Combination Motor Starters(⁵)(⁷)

FVNR Y-Delta, OT

Class RK-1, Class RK-1,

NEMA Max. IC RK-5, J-TD Space NEMA Max. IC RK-5, J-TD Space
Notes Notes
size Hp (kA) Switch Clip units size Hp (kA) Switch Clip units
Amps Amps Amps Amps
1 7.5 100 30 30 1 2 7.5 100 60 30 4
2 15 100 60 60 1 2 10 100 60 30 4
3 30 65 100 100 2 (⁶) 2 15 100 60 60 4
3 30 100 200 200 2.5 2 20 100 100 100 4
4 50 100 200 200 3.5 3 30 65 100 100 4.5 (¹)(⁶)
5 100 100 400 400 5 4 60 100 400 400 6 (⁴)
6 200 100 600 600 5.5 (¹)

2S1W, 2S2W
FVR

Class RK-1,
Class RK-1, Max. Hp
NEMA IC RK-5, J-TD Space
NEMA Max. IC RK-5, J-TD Space Notes
Notes size CT Constant (kA) Switch Clip units
size Hp (kA) Switch Clip units
VT HP Amps Amps
Amps Amps
1 7.5 5 100 30 30 2
1 7.5 100 30 30 1.5
2 7.5 100 60 30 2
2 15 100 60 60 2
2 15 10 100 60 60 2
3 30 65 100 100 3 (⁶)
3 30 25 65 100 100 4 (⁶)
4 50 100 200 200 5
4 30 100 200 100 5.5
5 100 100 400 400 8.5 (³)(⁶)
4 50 40 100 200 200 5.5
6 200 100 600 600 8.5 (²)
5 100 75 100 400 400 8.5 (³)
1 7.5 5 100 30 30 2
RVAT
2 7.5 100 60 30 2
Class RK-1, 2 15 10 100 60 60 2
Space units
NEMA Max. IC RK-5, J-TD 3 30 25 65 100 100 4 (⁶)
Notes
size Hp (kA) Switch Clip 13" 20"
4 30 100 200 100 5.5
Amps Amps Deep Deep
4 50 40 100 200 200 5.5
2 15 100 60 60 4 4
5 100 75 100 400 400 8.5 (³)
3 30 65 100 100 5 4 (⁶)
6 200 150 100 600 600 8.5 (²)
4 50 100 200 200 6 5
5 100 100 400 400 6
1. Requires 24" wide section.
6 200 100 600 600 N/A 12 (²) 2. S ize 6 FVR, RVNR, 2S1W, 2S2W require (2)
adjacent 24" wide sections, 20" deep.
3. S ize 5 FVR, 2S1W, 2S2W with fused switch requires (2)
Part winding adjacent sections; left hand section is 24" wide 6X, right hand
section is 20” wide with top 31/2 X used for disconnect.
4. S ize 4 Wye-Delta with fused switch requires a 24” wide
Class RK-1, section when main horizontal bus is rated 1000 ampere
NEMA Max. IC RK-5, J-TD Space UL or less. A 30” wide section is required with 1200
Notes
size Hp (kA) Switch Clip units ampere UL or higher rated main horizontal bus.
Amps Amps 5. U se time-delay fuse, maximum rating same as switch amps.
6. Use size 4 spacing for 100k ratings.
1 7.5 100 30 30 2 7. A ll 400/600A units are MCS (molded case switches).
2 15 100 60 60 2
2 20 100 100 100 2 Note: The space requirements shown in
3 30 65 100 100 4 (⁶) these tables are minimum. Where layout
4 60 100 400 400 5.5 dimensions are critical, refer to factory. One
space unit or X unit equals 12 inches of
vertical height.
T E C H N I C A L A P P L I C AT I O N G U I D E 57

Selection tables
Fused switch type

460 Volts, 60 Hertz – Combination Motor Starters(6)

FVNR Part winding

Class RK-1, Class RK-1,

NEMA Max. IC RK-5, J-TD Space NEMA RK-5, J-TD Space
Notes Max. Hp IC (kA)
size Hp (kA) Switch Clip units size Switch Clip units
Amps Amps Amps Amps
1 10 100 30 30 1 1 10 100 30 30 2
2 15 100 60 30 1 1 15 100 60 30 2
2 25 100 60 60 1 2 25 100 60 60 2
3 30 65 100 60 2 2 30 100 100 60 2
3 50 65 100 100 2.5 3 60 100 200 200 5
4 100 100 200 200 3.5 4 150 100 400 200 5.5
5 125 100 400 200 5
5 200 100 400 400 5
Y-Delta, OT
6 250 100 600 400 6 (¹)
6 400 100 600 600 6 (¹) Class RK-1,
NEMA Max. IC RK-5, J-TD Space
Notes
FVR size Hp (kA) Switch Clip units
Amps Amps
Class RK-1, 2 10 100 60 30 3 (³)
NEMA Max. IC RK-5, J-TD Space 2 15 100 60 30 3
Notes
size Hp (kA) Switch Clip units
2 25 100 60 60 3
Amps Amps
2 30 100 100 60 3
1 10 100 30 30 1.5
3 50 65 100 100 4 (¹)
2 15 100 60 30 2
3 60 100 200 200 5 (¹)
2 25 100 60 60 2
4 100 100 200 200 6 (¹)
3 30 65 100 60 3
4 125 100 400 200 6 (⁵)
3 50 65 100 100 3.5
4 100 100 200 200 5
1. Requires 30" wide section.
5 125 100 400 200 8.5 (⁴) 2. S
 ize 6 FVR, RVNR, 2S1W, 2S2W require (2) adjacent 24" wide
sections, 20" deep with 12" bottom wireway cover.
5 200 100 400 400 8.5 (⁴)
3. Size 1 not available. Use Size 2.
6 250 100 600 400 8.5 (²) 4. S ize 5 FVR, 2S1W, 2S2W with fused switch requires (2)
adjacent sections; left hand section is 24" wide 6X, right hand
section is 20" wide with top 3 1/2 X used for disconnect.
RVAT 5. S
 ize 4 Wye-Delta with fused switch requires a 24" wide
section when main horizontal bus is rated 1000 ampere
UL or less. A 30" wide section is required with 1200
Class RK-1,
Space units ampere UL or higher rated main horizontal bus.
NEMA Max. IC RK-5, J-TD 6. A ll 400/600A units are MCS (molded
Notes
size Hp (kA) Switch Clip 13" 20" case switches).
Amps Amps Deep Deep
2 15 100 60 30 4 4 Note: The space requirements shown in
2 25 100 60 60 4 4 these tables are minimum. Where layout
3 30 65 100 60 5 4 dimensions are critical, refer to factory.
3 50 65 100 100 5 4 One space unit or X unit equals 12 inches
4 100 100 200 200 6 5 of vertical height.
5 125 100 400 200 — 6
5 200 100 400 400 — 6
6 250 100 600 400 N/A 12 (²)
6 400 100 600 600 N/A 12 (²)
58 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

2S1W

Class RK-1,
Max. Hp
NEMA IC RK-5, J-TD Space
Notes
size CT Constant (kA) Switch Clip units
VT HP Amps Amps
1 10 7.5 100 30 30 2
2 15 15 100 60 30 2
2 25 20 100 60 60 2
3 30 30 65 100 60 4
3 50 40 65 100 100 4
4 100 75 100 200 200 5.5
5 125 100 100 400 200 8.5 (⁴)
5 200 150 100 400 400 8.5 (⁴)
6 250 250 100 600 400 8.5 (²)
6 400 300 100 600 600 8.5 (²)

2S2W

Class RK-1,
Max. Hp
NEMA IC RK-5, J-TD Space
Notes
size CT Constant (kA) Switch Clip units
VT HP Amps Amps
1 10 7.5 100 30 30 2
2 15 15 100 60 30 2
2 25 20 100 60 60 2
3 30 30 65 100 60 4
3 50 40 65 100 100 4
4 100 75 100 200 200 5.5
5 125 100 100 400 200 8.5 (⁴)
5 200 150 100 400 400 8.5 (⁴)
6 250 250 100 600 400 8.5 (²)
6 400 300 100 600 600 8.5 (²)
T E C H N I C A L A P P L I C AT I O N G U I D E 59

Selection tables
Fused switch type

575 Volts, 60 Hertz – combination motor starters(⁵)(⁶)

FVNR Y-Delta, OT

Class RK-1, Class RK-1,

NEMA RK-5, J-TD Space NEMA Max. IC RK-5, J-TD Space
Max. Hp IC (kA) Notes
size Switch Clip units size Hp (kA) Switch Clip units
Amps Amps Amps Amps
1 10 100 30 30 1 2 10 100 60 30 3 (³)
2 25 100 60 60 1 2 15 100 60 30 3
3 40 100 100 60 2 2 20 100 60 60 3
3 50 100 100 100 2.5 2 25 100 60 60 3
4 100 100 200 200 3.5 3 50 100 200 100 4 (¹)
5 200 100 400 400 5 3 75 100 200 200 4 (¹)
6 400 100 600 600 6 4 100 100 200 200 6 (¹)
4 150 100 400 400 6 (⁵)
FVR
5 (⁶)

Class RK-1,
RK-5, J-TD 2S1W, 2S2W
NEMA Max. IC Space
Notes
size Hp (kA) Switch Clip units
Amps Amps Class RK-1,
Max. Hp
1 10 100 30 30 1.5 NEMA IC RK-5, J-TD Space
Notes
size CT Constant (kA) Switch Clip units
2 25 100 60 60 2
VT HP Amps Amps
3 40 100 100 60 3
1 10 7.5 100 30 30 2
3 50 100 200 100 5
2 25 100 60 60 2
4 100 100 200 200 5
3 40 40 100 200 60 5.5
5 200 100 400 400 8.5 (⁴)
3 50 100 200 100 5.5
6 400 100 600 600 8.5 (²)
4 100 100 200 200 5.5
5 200 100 400 400 8.5 (⁴)
RVAT 6 400 100 600 600 8.5 (²)
1 10 7.5 100 30 30 2
Class RK-1, 2
Space units 25 100 60 60 2
NEMA Max. IC RK-5, J-TD
Notes 3 40 40 100 200 60 5.5
size Hp (kA) Switch Clip 13" 20"
Amps Amps Deep Deep 3 50 100 200 100 5.5
2 25 100 60 60 4 4 4 100 100 200 200 5.5
3 40 100 200 60 6 5 5 200 100 400 400 8.5 (⁴)
3 50 100 200 100 6 5 6 400 100 600 600 8.5 (²)
4 100 100 200 200 6 5 1. Requires 24" wide section.
5 200 100 400 400 6 2. S ize 6 FVR, RVNR, 2S1W, 2S2W require (2) adjacent 24" wide
sections, 20" deep with 12" bottom wireway cover.
6 400 100 600 600 N/A 12 (²) 3. Size 1 not available. Use Size 2.
4. S ize 5 FVR, 2S1W, 2S2W with fused switch requires (2)
adjacent sections; left hand section is 24" wide 6X, right hand
Part winding
section is 20" wide with top 3 1/2 X used for disconnect.
5. S ize 4 Wye-Delta with fused switch requires a 24" wide
section when main horizontal bus is rated 1000 ampere
Class RK-1, UL or less. A 30" wide section is required with 1200
NEMA RK-5, J-TD Space ampere UL or higher rated main horizontal bus.
Max. Hp IC (kA)
size Switch Clip units 6. Refer to factory.
Amps Amps 7. A ll 400/600A units are MCS (molded case switches).

1 10 100 30 30 2
1 15 100 60 30 2 Note: The space requirements shown in
2 25 100 60 60 2 these tables are minimum. Where layout
3 50 100 200 100 5 dimensions are critical, refer to factory.
3 75 100 200 200 5 One space unit or X unit equals 12 inches
4 100 100 200 200 5 of vertical height.
4 150 100 400 400 6
60 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Starter options

Additional Additional
Option Function space Option Function space
required required
Control Provides control power. See Selector CR104P maintained type–use
transformer “Control Transformer” for — switches as permissive start with 2 or 3 —
details on-off wire control.
CPT primary Class CC fuse wired in each Hand-off-auto CR104P maintained type–use
fuses ungrounded transformer to select auto or manual start —
primary conductor. with 2-wire control.
CPT One midget fuse (typical Gould Fast-slow- CR104P maintained type–use
—
secondary Ferraz type TRM) wired in off-auto with 2-speed starters.
—
fuse ungrounded Control Power Fixed control Stationery control terminal
Conductor TB boards in place of split type —
Control power One Class CC fuse wired in terminal boards.
fuse each ungrounded control Power TB Stationery motor lead terminal
power conductor. Use when Yes
boards Size 3 and 4
control power source is remote
Power TB Split ype terminal blocks on
from unit. —
NEMA size 1 and 2
Starter
Control High density pull-apart
overload For more information see —
disconnect TB will provide foreign voltage
protection "Application data" section. —
isolation without disengaging
Pilot lights CR104P type. the unit vertical bus stabs.
Full voltage Red–ON FAST, FWD, UP Control relay C2000 Type (standard) Rated
Amber–DOWN, REV, SLOW — 600V, with 10A contacts. Relays
Green–STOPPED, READY are available with normally
Transformer CR104P with 6V lamp (See full open and normally closed non-
—
voltage lights for lens colors) convertible contacts. Up to
LED CR104P Type transformer type four additional contact blocks
— Yes
with 6V LED Lamp can be added to basic 4 pole
relay. Size 1 and Size 2 FVNR
Push-to-test CR104P, Full-voltage
starters require an additional
transformer type, or LED (See
— half-space unit for three to four
full-voltage lights for lens
relays. Two relays can be added
colors)
with no increase in Space units.
Push buttons CR104P momentary type-use
Timing relays C2000 (standard) .3 to 3
Start-stop with FVNR starters with 3-wire —
pneumatic seconds or 10 to 180 seconds
control.
timing range. 10A contacts. 4 Yes
Stop CR104P momentary type- INST and 2 TD interlocks (NO
provides stop function at MCC — and NC).
with 3-wire control.
Timing relays Time-delay on energization/
Stop CR104P maintained type– electronic de-energization double pole,
provides stop function at MCC double throw contacts rated
with 2/3 wire control. Can be 600V, 10A. Timing ranges 1-10
—
furnished with mushroom or
head and provision for locking 10-300 seconds.
open.
Fwd, Rev, Stop CR104P momentary type-use
—
with FVR starters.
Fast, Slow, CR104P momentary type-use
—
Stop with 2-speed starters.
T E C H N I C A L A P P L I C AT I O N G U I D E 61

Starter options

Additional Additional
Option Function space Option Function space
required required
Motor driven Used for long timing periods. Current Donut type CT located in one
1/2X
Specify timing range. transformer motor phase conductor for
Yes
Accelerating C2000 (standard) timing relay purchasers use. (Also used for
relay for multi-speed motors to door mounted Ammeter.)
provide definite accelerating Amp Integrated CT/Current
time for each speed above first transducer transducer with 4-20 MA
speed. Time interval is ammeter output. (Requires 120V Power).
adjustable .3 to 30 seconds. AC panel-type, single current
Yes
Alternate Electronic Timer. transformer operated five-
Decelerating C2000 (standard) timing relay ampere movement. Scale
relay allows time for motor to coast selected based on 125% motor
stop before permitting restart full-load amperes.
or coast to a lower speed on Elapsed time Mounts on pushbutton
multi-speed motors before meter bracket. Meter Visible from
initiating slow speed operation front of MCC.
(2-speed motors). Time Phase loss/ APVR used primarily to sense
interval is adjustable .3 to 30 unbalance phase loss, unbalance, or
seconds. Alternate Electronic —
voltage reversal, has time delay under-
Timer. sensing voltage.
Compelling On multi-speed starters, Motor The motor winding heater is
relays requires the controller to winding designed for use with 3-phase
progress in sequence from low heater ac motors to guard against
to high speed. One relay is damage caused by
required for each speed over condensation buildup on
one. Requires same space as motor windings which can
C-2000 timing relay. Alternate 1/2X
occur in high humidity
Electronic Timer. environments during motor
Latch relay Once relay closes, mechanical idle periods. Refer to
latch holds relay closed until application data in
electrically reset. "Components" section
Fused switch 2-10A auxiliary interlocks (1X-size 5).
auxiliary operated by disconnect Coil Surge suppressors reduce
—
interlock operator Max. (2NO, or 1NO suppressor undesirable transients in
and 1NC) 120V control circuits by absorbing
CB options SPDT auxiliary interlocks voltage transients generated
(spectra only) mounted in CB. Refer to — by operating coils.
aux. Interlock factory if more than 2 required. Door diagram Circuit diagram mounted on
—
Bell alarm Internal CB alarm switch. — back of unit door.

Shunt trip Electric remote trip. Wire markers Permanent wire number
—
identification on each control
Key interlock Added to disconnect operating —
wire. Tube type standard, heat
above 250A handle to require a shrink optional.
predetermined system —
Provision for Terminals located between
operating sequence. Specify
PFC capacitor contactor and OL relay.
operating sequence.
Ground fault Zero sequence sensing Ground
Fault Relay for equipment
Yes
protection for NEMA size
2-6 starters.
62 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Product information UL required primary transformer protection in

accordance with NEC Article 430.72(c) and Article
Undervoltage protection 450 fuses are furnished in each ungrounded
Standard starters drop out when line voltage drops primary conductor. Motor control circuit power,
below approximately 65 percent rated volts and other than power tapped from the load side of
can be reclosed when voltage returns to 85 percent the starter unit disconnect, should be protected
rated volts. Where momentary contact devices are against overcurrent. The protective device may
used in standard three-wire control circuits, the be located at the source or by the optional fuse(s)
starter will not reclose on momentary loss of located in each unit. Normally, one (Class CC) fuse
voltage until the START button is pushed, thus in the ungrounded conductor will provide the
inherently providing undervoltage protection. needed protection. Where wiring external to the
motor control center is indicated, No. 14 AWG
If a maintained contact device, such as a float copper will be assumed as the minimum conductor
switch, is used to start the motor, the starter will size unlessotherwise specified.
close automatically upon restoration of control
voltage. In some cases, this may not be desirable Long control circuits
for safety reasons, and a reset pushbutton and On exceedingly long control circuits two problems
auxiliary relay should be specified to provide may occur – (1) starter will not close due to line
undervoltage protection. voltage drop and (2) starter may not open due to
capacitive coupling. Table below gives the one-way
Overload relays distances (in feet) from the starter to the
Standard relays are three-leg block bimetallic type pushbutton along the route of the control cable.
with adjustment from 90 to 110 percent of the This table is for 120 volt coils and allows
heater rating. A single calibration adjusts all three for a maximum voltage variation of 10 percent.
legs. A single reset button mounted on the starter The distances are given for #14 and #12 AWG
door permits external reset. Ambient-compensated control wire.
relays are available for ambients from –30°C to
+80°C and have adjustment from 90 to 110 percent Distance in feet with Distance in feet with
NEMA size
#14 wire #12 wire
of normal rating. Improved protection is provided
1 1300 2070
when the motor is in a relatively constant ambient
2 460 730
but control is subject to varying ambient. Relays
3 320 510
are interchangeable with standard type.
4 250 395
1-6(¹) 5000 6000
Optional electronic overload relay and
Motor managment relays 1. Distance based on using an interposing relay, type C2000

Electronic overload relays and electronic overload

relays with basic communication functions Separate source control circuits
are available (see page H-12). Advanced motor A separate control bus is available as an option.
management relays from Multilin are also available This bus can be fed from a separate external
(see page H-5 for MM200 and MM300). source, or from within the motor control center by
a separate distribution transformer or distribution
Control circuit protection panel. A normally open auxiliary contact should be
Motor control circuits tapped from the load side specified on each unit disconnect to open the
of the starter unit disconnect, such as line-to-line control bus circuit when the unit disconnect is
control and line-to-neutral control are protected opened. Unit control circuit fusing should also
by listed, branch circuit rated fuses in each be added.
ungrounded conductor. UL requires rejection type
fuses for equipment rated above 10kA short-circuit In lieu of the auxiliary disconnect contact, pull-
rating. 6 ampere, 600 volt Class CC fuses are apart terminal boards may be specified to provide
furnished as standard. Motor control circuit control voltage isolation for individual starters.
transformers are protected with a fuse in each
ungrounded secondary conductor. Secondary fuses
are UL Recognized supplementary fuses size per
Article 450 of the NEC (20 amperes maximum).
T E C H N I C A L A P P L I C AT I O N G U I D E 63

Pilot devices Control terminals

Pushbuttons, selector switches, pilot lights, etc., The table below lists the maximum number of high
are single-unit, heavy-duty oil-tight type mounted density control terminals available on standard
on the starter unit door. heights units. See standard diagrams in "Typical
circuits" section for number of control terminals
Auxiliary contact ratings required for standard starters. Note total number
of control points are in addition to T1, T2 and T3
NEMA size 1-6
power terminal points.
Amperes
AC Volts Starter Size 1 Size 2 Size 3 Size 4
Continuous Make Break
function CB/FS CB/FS CB/FS CB FS
115 10 60 6.0
FVNR 18 18 18 18 48
230 10 30 3.0
FVR 30 42 48 48 48
460 10 15 1.5
2S1W 24 36 48 48 48
575 10 12 1.2
2S2W 24 36 48 48 48
DC Volts
—
125 10 — 1.1
CB = Circuit breaker; FS = Fused Switch.
250 10 — 0.5

Control transformers
Starter auxiliary contacts (option) Power is tapped from the load side of the starter
Auxiliary contacts rated 10 amperes, 600 volts unit disconnect and the transformer provides 120
are available, either normally open or closed volt power. Two 600 volt primary fuses, plus one
(non-convertible). Quantities of contacts shown 250 volt secondary fuse in the ungrounded
are maximum available and include starter conductor is standard.
requirements for cross-electrical interlocking and
holding circuits. If more contacts are required than Standard control power transformer ratings
shown, a relay must be added. are adequate to handle the starter-coil current and
three pilot lights. If additional burdens are
Total control contacts expected, larger transformers should
available (includes contacts be specified.
required in basic control
Starter type circuit for seal-in,cross
interlocking, etc.) Starter Size CPT Std. VA CPT Max. VA(⁵) UL (X)
Notes
and type(³) 60 Hz 50 Hz 60 Hz 50 Hz Listed
NEMA size Starter
1 2 3 4 5 6 All Size 1 60 150 300 250 • (⁶)

Full-voltage, nonreversing All Size 2 150 150 300 250 •

(FVNR) 5 6(²) 6 6 6 6 All Size 3 300 250 300 250 •
Full voltage, reversing (FVR) All Size 4 300 250 300 250 •
Forward contactor 4 4 4 4 4 4 All Size 5
and 6 100 100 300 250 • (⁴)
Reverse contactor 4 4 4 4 4 4
Two-speed, one winding
(251W)¹ Coil characteristics

Low-speed contactor 4 4 4 4 4 5
Size and Type Inrush Volt–Amp Sealed Volt–Amp
High-speed contactor 3 4 4 4 4 5
Size 1, FVNR, FVR 151* 23*
Two-speed, two winding
(252W) Size 2, FVNR, FVR 528 60
Low-speed contactor 4 4 4 4 4 5 Size 3, FVNR, FVR 1152 83
High-speed contactor 4 4 4 4 4 5 Size 4, FVNR, FVR 1248 87
Part winding Size 5, FVNR 2580 191
Run contactor 5 6 6 6 6 6 Size 6, FVNR 3360 255
Autotransformer, reduced- Size 2, 2S1W 576 75
voltage
Size 3, 2S1W 1248 87
Run contactor 6 6 6 6 6
Size 4, 2S1W 1336 95
Relay for RVAT size 3
and 4 55 9
Relay for FVNR size 5
and 6 55 9

—
* Compact starter inrush 88VA, sealed 9VA
64 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

300 line standard coil data

Amps Amps % Volts Millisec

Size Coil VA Watts Vars PF
120V 480V P/U D/O P/U D/O
Inrush 1.26 .33 151 69.5 134 .46
1 85 63 15 to 30 7 to 15
Holding .2 .55 24 6 23 .25
Inrush 4.4 1.2 528 169 500 .32
2 85 68 20 to 40 7 to 15
Holding .5 .14 60 12.9 57.9 .26
Inrush 9.6 2.6 1152 230 1129 .20
3 85 65 20 to 45 7 to 15
Holding .69 .18 83 18.4 81.5 .19
Inrush 10.4 2.8 1248 262 1220 .21
4 85 65 20 to 45 7 to 15
Holding .73 .2 87 18.8 84.8 .22
Inrush 21.5 5.7 2580 464 2538 .18
5 85 65 30 to 50 15 to 25
Holding 1.6 .42 191 38.8 185 .25
Inrush 28.1 7.6 3360 608 3325 .18
6 85 65 30 to 50 15 to 25
Holding 2.1 .58 255 44 246 .25

1. For constant- or variable-torque motors.

2. Limit 4 with APVR relay.
3. Refer to Company for part-winding and Y-delta starters.
4. Starter coils operated at line voltage. Starters operated by control relay in 120 volt control circuit.Class CC fuses are provided for starter coil circuit.
5. Without increasing standard unit space requirements for size 1 to 4, over size CPT in size 5 will add 6".
6. 1/2X FVNR uses a 100VA CPT.

Thermal magnetic circuit breaker substitution Terminals for field wiring

Substituting a thermal-magnetic circuit breaker in
place of a Mag-Break® circuit breaker may require Will accept wire(¹)
Description
increasing the circuit breaker trip rating to avoid AWG/MCM Material

tripping on starting. See "Appendix" section for Starter Load Terminals

recommended thermal-magnetic circuit breaker Size 1 Starter 14-8 Cu
trip ratings. Size 2 Starter 14-4 Cu
Size 3 Starter 8-1/0 Cu
NEMA Standard Short-circuit rating Size 4 Starter 4-3/0 Cu
size circuit Substitute
starter breaker 230V 460V 575V Size 5 Starter (2) 2/0-400 Cu
25 25 22 Size 6 Contactor (2) 2/0-500 Cu-Al
SELT
1,2,3 SELI 100 100 25 Control Terminal Boards
SELL 100 100 65 Hi Density Pull-Apart (2) 12 Max. Cu
SEL SFLT 65 65 25 Power Terminal Boards
4 SFLT 100 100 25 50 Amp Size 1 and 2 Type C
SFLI Wiring 14-6(²) Cu
100 100 100
5 SGLI SGLT 100 100 65 1. C
 onductors #1 and smaller may be rated 60/75°C. Conductors
#1/0 and larger must be rated 75°C. Conductors wired
directly to OL device terminals must be rated 75°C Cu.
2. #6 only with ring terminal.
 T E C H N I C A L A P P L I C AT I O N G U I D E 65

Miscellaneous units

Operator and metering panels These panels will be UL labeled providing all
Unit spaces can be used to provide metering and/ the components are UL listed for use in motor
or operator’s panels in the motor control center control centers.
itself. Arrangement and dimensions will vary
depending on the quantity and type of the devices Relay panels
required. Normally, fuse blocks, terminal blocks Relay panels can be furnished from 1 space unit to 6
(T.B.s), current and potential transformers, etc., can Space units with full width doors. The amount of
be mounted on a base within the unit space. vertical space required is generally determined by
Meters, pilot lights, pushbuttons, switches, etc., the number of terminal board points required or
can be mounted on the door. Suitable locations and relay type used; when in doubt allow for a double
adequate space should be provided so that wiring vertical row of terminal boards.
is simplified and there is no interference between
door and base mounted components. The following These panels will be UL labeled providing all
devices are often specified: the components are UL listed for use in motor
• Pushbuttons, selector switches, pilot lights; control centers.
• Ammeters, voltmeters and other instruments
(switchboard type); Alternator relay panels
• Instrument and transfer switches; Consists of two motor alternator circuit using two
• Electronic power meter; control relays and a latching relay. Requires
• Control relays; minimum 1 space unit height.
• Timing relays (pneumatic, motor-operated or
electronic);
• Protection relays;
• Alternator relays.

Single vertical row of T.B.s Double vertical row of T.B.s

Horizontal Horizontal
Maximum no. of
width for width for Maximum no. of std.
Space units Maximum no. of std. 4-pole Maximum no.
component component 4-pole relays
T.B. points relays of T.B. points
mounting mounting
Section width 20”W Section width 20”W
1 12 11 1/2" 6 24 6" 3
1 1/2 24 11 1/2" 12 48 6" 6
2 30 11 1/2" 18 60 6" 9
2 1/2 42 11 1/2" 24 84 6" 12
3 48 11 1/2" 36 96 6" 18
3 1/2 60 11 1/2" 42 120 6" 21
4 72 11 1/2" 48 144 6" 24
4 1/2 78 11 1/2" 54 156 6" 27
5 90 11 1/2" 60 180 6" 30
5 1/2 96 11 1/2" 66 192 6" 33
6 108 11 1/2" 72 216 6" 36

—
T.B.s or relays for size estimating only.
66 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Mounting plates
Blank plates are available for customer use when
field mounting a PLC and/or relays. All plates come
with mounting screws and door. Full height dished
plates come with top horizontal bus barrier.

Min. Mounting plate Min. Mounting plate

enclosure dimensions enclosure dimensions
Description (inches) Part number Description (inches) Part number
depth depth
(inches) Width Height (inches) Width Height
12 110C1040MDG1 12 110C1040MDG41
18 110C1040MDG2 18 110C1040MDG42
24 110C1040MDG3 24 110C1040MDG43
15 30 110C1040MDG4 30 110C1040MDG44
Dished
36 110C1040MDG5 mounting 36 110C1040MDG45
42 110C1040MDG6 plate, No 20 20 42 110C1040MDG46
bus, 13.5”
48 110C1040MDG7 48 110C1040MDG47
from door
12 110C1040MDG8 54 110C1040MDG48
18 110C1040MDG9 60 110C1040MDG49
24 110C1040MDG10 66 110C1040MDG50
30 110C1040MDG11 72 110C1040MDG51
36 110C1040MDG12
20 42 110C1040MDG13
48 110C1040MDG14
54 110C1040MDG15
60 110C1040MDG16
66 110C1040MDG17
72 110C1040MDG18
12 110C1040MDG19
Over
vertical 18 110C1040MDG20
13
bus, 9.5" 24 110C1040MDG21
from door
30 110C1040MDG22
36 110C1040MDG23
24 42 110C1040MDG24
48 110C1040MDG25
54 110C1040MDG26
60 110C1040MDG27
66 110C1040MDG28
72 110C1040MDG29
12 110C1040MDG30
18 110C1040MDG31
24 110C1040MDG32
30 110C1040MDG33
36 110C1040MDG34
30 42 110C1040MDG35
48 110C1040MDG36
54 110C1040MDG37
60 110C1040MDG38
66 110C1040MDG39
72 110C1040MDG40
T E C H N I C A L A P P L I C AT I O N G U I D E 67

Min. Mounting plate

enclosure dimensions
Description (inches) Part number
depth
(inches) Width Height
12 110C1040MDG52
18 110C1040MDG53
24 110C1040MDG54
30 110C1040MDG55
36 110C1040MDG56
24 42 110C1040MDG57
48 110C1040MDG58
54 110C1040MDG59
60 110C1040MDG60
Dished 66 110C1040MDG61
mounting 72 110C1040MDG62
plate, no 20
bus, 13.5" 12 110C1040MDG63
from door 18 110C1040MDG64
24 110C1040MDG65
30 110C1040MDG66
36 110C1040MDG67
30 42 110C1040MDG68
48 110C1040MDG69
54 110C1040MDG70
60 110C1040MDG71
66 110C1040MDG72
72 110C1040MDG73
12 110C1040MDG74
18 110C1040MDG75
24 110C1040MDG76
30 110C1040MDG77
36 110C1040MDG78
20 42 110C1040MDG79
48 110C1040MDG80
54 110C1040MDG81
60 110C1040MDG82
Dished 66 110C1040MDG83
Mounting 72 110C1040MDG84
Plate, no 20
Bus, 15.5" 12 110C1040MDG85
from door 18 110C1040MDG86
24 110C1040MDG87
30 110C1040MDG88
36 110C1040MDG89
24 42 110C1040MDG90
48 110C1040MDG91
54 110C1040MDG92
60 110C1040MDG93
66 110C1040MDG94
72 110C1040MDG95
68 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Min. Mounting plate Min. Mounting plate

enclosure dimensions enclosure dimensions
Description (inches) Partnumber Description (inches) Part number
depth depth
(inches) Width Height (inches) Width Height
12 110C1040MDG96 12 110C1040MDG184
18 110C1040MDG97 18 110C1040MDG185
24 110C1040MDG98 24 110C1040MDG186
30 110C1040MDG99 30 110C1040MDG187
Dished
mounting 36 110C1040MDG100 36 110C1040MDG188
plate, no 20 30 42 110C1040MDG101 24 42 110C1040MDG189
bus, 15.5" 48 110C1040MDG102 48 110C1040MDG190
from door
54 110C1040MDG103 54 110C1040MDG191
60 110C1040MDG104 60 110C1040MDG192
66 110C1040MDG105 Dished 66 110C1040MDG193
72 110C1040MDG106 mounting 72 110C1040MDG194
plate, no 20
12 110C1040MDG107 bus, 18.5" 12 110C1040MDG195
18 110C1040MDG108 from door 18 110C1040MDG196
24 110C1040MDG109 24 110C1040MDG197
30 110C1040MDG110 30 110C1040MDG198
36 110C1040MDG111 36 110C1040MDG199
20 42 110C1040MDG112 30 42 110C1040MDG200
48 110C1040MDG113 48 110C1040MDG201
54 110C1040MDG114 54 110C1040MDG202
60 110C1040MDG115 60 110C1040MDG203
66 110C1040MDG116 66 110C1040MDG204
72 110C1040MDG117 72 110C1040MDG205
12 110C1040MDG118 12 110C1040MDG140
18 110C1040MDG119 18 110C1040MDG141
24 110C1040MDG120 24 110C1040MDG142
30 110C1040MDG121 30 110C1040MDG143
Dished
mounting 36 110C1040MDG122 36 110C1040MDG144
plate, no 20 24 42 110C1040MDG123 20 42 110C1040MDG145
bus, 17.5" 48 110C1040MDG124 48 110C1040MDG146
from door
54 110C1040MDG125 54 110C1040MDG147
60 110C1040MDG126 60 110C1040MDG148
66 110C1040MDG127 66 110C1040MDG149
72 110C1040MDG128 72 110C1040MDG150
12 110C1040MDG129 12 110C1040MDG151
18 110C1040MDG130 18 110C1040MDG152
24 110C1040MDG131 24 110C1040MDG153
30 110C1040MDG132 30 110C1040MDG154
Dished
36 110C1040MDG133 mounting 36 110C1040MDG155
30 42 110C1040MDG134 plate, no 22 24 42 110C1040MDG156
48 110C1040MDG135 bus, 21" 48 110C1040MDG157
from door
54 110C1040MDG136 54 110C1040MDG158
60 110C1040MDG137 60 110C1040MDG159
66 110C1040MDG138 66 110C1040MDG160
72 110C1040MDG139 72 110C1040MDG161
12 110C1040MDG173 12 110C1040MDG162
18 110C1040MDG174 18 110C1040MDG163
24 110C1040MDG175 24 110C1040MDG164
30 110C1040MDG176 30 110C1040MDG165
Dished
mounting 36 110C1040MDG177 36 110C1040MDG166
plate, no 20 20 42 110C1040MDG178 30 42 110C1040MDG167
bus, 18.5" 48 110C1040MDG179 48 110C1040MDG168
from door
54 110C1040MDG180 54 110C1040MDG169
60 110C1040MDG181 60 110C1040MDG170
66 110C1040MDG182 66 110C1040MDG171
72 110C1040MDG183 72 110C1040MDG172
T E C H N I C A L A P P L I C AT I O N G U I D E 69

Lighting and distribution panelboards Notes:

The following panelboards are available for • Branch devices are plug-in for Type AL and
mounting in motor control centers. Type AL and bolt-on for AQ, AE and AD panelboards.
AQ Panelboards with main circuit breakers are Maximum of 42 circuits per panel.
normally provided. Type AE and AD panels require • Ground fault CB not available in AL panels.
a feeder unit for the main circuit breaker, which • Lighting panel main bus is rated 1000
then feeds the M.L.O. panel. amps per square inch, alternate 800 amps
per square inch is available.
Branch Interrupting •
System rating rms Notes:
Panel Poles symmetrical
voltage Poles • 65 kAIC rating for panels is obtained
type Type Ampere
(max.) (¹) Amps (in
Rating thousands) through series rating.
THQL 1 15-70 10 • For all panels fed from MCC bus, add
THQL 2 15-100 10
feeder unit to feed panel.
120/240
THHQL 1 15-70 22 MCC Space units
Vac
A Series THHQL 2 15-125 22
Type AL Panel Main
TXQL 1.2 15-30 65 Number of Space units(³) SpaceUnits(³)
Bus Rating
THQL Circuits AL, AQ AE
2.3 15-100 10 (Amps)
240 Vac THHQL 2.3 15-100 22 12 100 2 2
THQL 3 15-30 65 12 225 2 1/2 2
THQB-GF 1.2 15-30 10 18 100 2 1/2 2 1/2
THQB 1 15-70 10 18 225 2 1/2 2 1/2
THQB 2 15-100 10 24 225 2 1/2 2 1/2
120/240
THHQB-GF 1 15-30 22 24 400 4 1/2 3 1/2
Vac
A Series THHQB 1 15-70 22 30 225 3 3
Type AQ THHQB 2 15-100 22 30 400 4 1/2 3 1/2
TXQB 1.2 15-30 65 36 225 3 1/2 3
THQB 1.2 15-100 10 36 400 5 4
240 Vac THHQB 2.3 15-100 22 42 225 3 1/2 3 1/2
TXQB 3 15-30 65 42 400 5 4
120 Vac TEY 1 15-100 65
AD
A Series 240 Vac TEY 2.3 15-100 65
Type AE 277 Vac TEY 1 15-100 14 Panel Main Bus
4 wire Number of Circuits Space units(³)
480/277 Rating (Amps)
TEY
Vac Max. 2.3 15-100 14 12 100 2 1/2
TED 1 15-100 14 12 225 3
277 Vac TED4 1 15-50 14 18 100 3
THED 1 15-30 65 18 225 3 1/2
TED4 2 15-100 14 24 100 3
A Series TED4,6 3 15-150 14
Type AD 24 225 3 1/2
3 wire 480 Vac THED4 2 15-100 25 30 100 3 1/2
THED4 3 110-150 25 30 225 4
THED6 3 15-150 25 36 100 4
TED6 3 15-150 14
600 Vac 36 225 4 1/2
THED6 3 15-150 18 42 100 4
1. Two-pole THED breakers require a 3-pole space. 42 400 1/2
2. E
 quipment rating is equal to the lowest interrupting
rating of any circuit breaker installed.
3. O
 ne space unit (X) equals 12" vertical height. M.L.O. panel
does not include feeder space requirements. (see pg. C4)
70 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

The unit rating is the same as the lighting panel Primary protection only
rating when:
A. T he lighting panel is mounted as a separate Primary Current Primary protection rating

motor control center unit but not connected 125% or next higher standard
9 amps or more
rating per NEC Sect. 240-6
to any power source within the motor control
2 amps to 9 amps 167% maximum
center. This does not reduce or affect motor
Less than 2 amps 300% maximum
control center short-circuit rating. The
lighting/ distribution panel must have a
main breaker. Primary and secondary protection
B. The lighting panel is mounted as a separate
motor control center unit and factory Primary Secondary
Secondary current
protection rating protection rating
connected directly (with no intermediate
125% or next higher
transformer) to motor control center bus 9 amps or more 250% maximum
standard rating
through a feeder. The panel series rating Less than 9 amps 250% maximum 167% maximum
must equal or exceed motor control center
short-circuit rating.
Transformer secondary conductors are wired
C. T he lighting panel is mounted as a separate
to a terminal board in the unit. One leg of 120
motor control center unit and factory
volt secondaries, the center point of 120/240
connected to a transformer unit in the motor
volt secondaries, and the Y-point of 3-phase
control center. This does not reduce or affect
secondaries are grounded unless otherwise
motor control center short-circuit rating.
specified. NEC Article 450-3 covers transformer
protection, other than motor control circuit
Distribution transformers
transformers or special applications.

General
The general requirements are:
Open, dry-type transformers with primary
• The degree of protection required depends
thermal-magnetic circuit breaker or fusible
on the specific application.
switch with NEMA Class R (dual element) fuses
• Select a transformer protective device which
are available in motor control center construction.
provides the required protection.
The accompanying tables give both single- and
• Secondary protection in each ungrounded
three-phase transformers normally mounted
conductor can be provided if specified.
in motor control centers for use in supplying
separate-source control circuits, panelboards
and power external to the motor control center.

Space units shown include space necessary for

the primary disconnect. One space unit equals
12 inches of vertical height. If transformers with
taps are required, refer to the factory. Primary
disconnects stab into the vertical bus.
T E C H N I C A L A P P L I C AT I O N G U I D E 71

Three-phase transformers (Delta-Y, no Taps(⁶))

Fused switch-100kAIC Circuit breaker

Switch Fuse Space UL listed IC rating (kA) Space UL listed

KVA Notes CB Trip Notes
size Amps(⁴) unit (X) 65 100 unit(⁵) (X)

380-120/208 Volts, 50 Hertz

3 30 7 2.5 • QMW 2.5
9 30 17.5 3 • SEL SEP 30 3
30 60 60 6 • (¹)(³) SEL SEP 70 4 • (¹)(⁷)
45 200 90 6 • (³) SEL SEP 150 4.5 • (³)
480-120/208 Volts, 60 Hertz
3 30 5.6 2.5 • QMW 2.5
9 30 15 3 • SEL SEP 20 3 •
15 30 25 4 • SEL SEP 30 3.5 •
30 60 45 4 • (¹)(⁷) SEL SEP 70 3.5 • (¹)(⁷)
45 100 70 4 • (³) SEL SEP 125 3.5 • (¹)(⁷)
600-120/208 Volts, 60 Hertz
3 30 4.5 2.5 • QMW 2.5
9 30 12 3 • SELL 20 3.5 •
30 60 40 4 • (¹)(⁷) SELL 70 3.5 • (¹)(⁷)

1. Requires full depth of motor control center.

2. Requires 24" wide enclosure.
3. Requires 20" deep enclosure 24" wide.
4. S
 ized for primary protection only. (Dual element fuses)
5. Sized for primary and secondary protection.
6. Add 6" for Taps.
7. Requires 30" wide enclosure.

Notes:
• 15-45KVA transformers are TP-1 rated per NEMA
Standard TP-1-1996.
• Low temperature rise and/or copper windings are
available. Refer to factory.
72 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Distribution transformers

Single-phase transformers

Fused switch-100kAIC Circuit breaker

UL IC rating (kA)
Switch Fuse Space CB trip Space UL listed
KVA listed Notes Notes
size Amps(⁴) unit 65 100 (⁵) unit (X)
(X)
240-120/240 Volts, 60 Hertz
0.5 30 3.2 1 • QMW 1
1 30 7 1 • QMW 1
3 30 15 1.5 • SEL SEP 30 1.5 •
5 30 30 2 • SEL 40 2 •
10 60 60 2 • (¹) SEL 70 2 • (¹)
15 200 80 4 • (¹)(⁶) SEL SEP 150 3.5 • (¹)(⁶)
25 200 150 4 • (¹)(⁶) SEL SEP 225 3 • (¹)(⁶)
37.5 200 200 6 • (¹)(⁷) SEL SEP 225 4 • (¹)(⁷)
380-120/240 Volts, 50 Hertz
0.50 30 3.5 1 • QMW 1
1 30 4 1 • QMW 1
3 30 12 1.5 • SEL 15 1.5 •
10 60 35 2 • (¹) SEL 50 2 • (¹)
15 60 50 3 • (¹)(⁶) SEL 90 2.5 • (¹)(⁶)
25 100 90 3 • (³) SEL SEP 150 2.5 • (³)
37.5 200 125 4 • (⁶)(⁷) SEL SEP 125 4 • (⁶)(7)
480-120/240 Volts, 60 Hertz
0.50 30 2.8 1 • SEL 1
1 30 3.5 1 • SEL 1
3 30 10 1.5 • SEL 15 1.5 •
5 30 12 2 • SEL 20 2 •
10 30 25 2 • (¹) SEL 40 2 • (¹)
15 60 40 3 • (¹)(⁶) SEL 50 2.5 • (¹)(⁶)
25 100 70 3 • (³) SEL SEP 125 2.5 • (³)
37.5 100 100 4 • (⁶)(⁷) SEL SEP 125 3.5 • (⁶)(7)
600-120/240 Volts, 60 Hertz
0.50 30 2.5 1 • QMW 1
1 30 4 1 • QMW 1
3 30 8 1.5 • QMW 1.5
10 30 20 2 • (¹) SELL 40 2 • (¹)
15 60 35 3 • (¹)(⁶) 50 2.5 • (¹)(⁶)
25 60 60 3 • (³) 100 2.5 • (³)
37.5 100 80 4 • (⁶)(⁷) 90 3.5 • (⁶)(7)

1. Requires full depth of motor control center.

2. Requires 24" wide enclosure.
3. Requires 20" deep enclosure 24" wide.
4. Sized for primary protection only. (Dual element fuses)
5. Sized for primary and secondary protection.
6. Add 6" for Taps.
7. Requires 30" wide enclosure.

Notes:
• 15-45KVA transformers are TP-1 rated per NEMA
Standard TP-1-1996.
• Low temperature rise and/or copper windings are
available. Refer to factory.
T E C H N I C A L A P P L I C AT I O N G U I D E 73

Power factor correction capacitors

Disconnect
Description means
Motors and other inductive loads require two kinds Short circuit
of electrical current: Current which performs the protective means
actual work and reactive current which produces
Contactor
the magnetic fields necessary for the operation of
inductive devices such as motors. Both types of
Overload relay
currents produce system I2R losses. Capacitors
installed near inductive loads can be used to reduce
the reactive currents which flow through much of Motor
the system, thereby reducing I2R losses.
Capacitor

Low-voltage capacitors are generally three-phase A B

units, delta-connected, and are protected by —
current limiting fuses. The fuses disconnect the *Care should be taken when connecting power factor
correction to the line side of power conversion equipment,
capacitor in the event of an electrical short, such as drives, to avoid component damage.
providing service continuity for the system and
reducing the possibility of rupturing the capacitor
Power factor correction capacitors
case.

Selection of power factor correction capacitors

Capacitors switched with the motor
The following table is provided as a guide.
Capacitors used for power factor correction should
Consult motor manufacturer for actual capacitor
be selected using the motor manufacturer’s
KVAR values.
application data.

Typical capacitor ratings(¹)

When the capacitor is connected ahead of the
overload relay (sketch A and B), the overload current Nameplate Maximum
HP Full load RPM
elements should be selected using the full-load Volts KVAR

motor current and service factor values specified 3 230/460 1750 1.4

on the nameplate of the motor. Capacitors must 5 230/460 1740 1.9

not exceed the maximum KVAR recommended by 7 230/460 1760 3.1

the motor manufacturer for switching with the 10 230/460 1750 3.6
specific motor selected. 15 230/460 1760 4.5
20 230/460 1750 5.1
Power factor correction capacitors should be 25 230/460 1760 7.2
switched by a separate contactor (sketch B) under 30 230/460 1760 9.1
any of the following conditions: 40 230/460 1770 14.9
• High inertia load; 50 230/460 1765 19.1
• Open circuit transition reduced 60 230/460 1775 24.9
voltage starting; 75 230/460 1775 27
• Wye-delta motor; 100 230/460 1780 29.1
• Reversing or frequently jogged motor; 125 460 1780 32.3
• Multispeed motor (2S1W, 2S2W, etc.). 150 460 1785 38.7
200 460 1785 50.5
Power factor correction capacitors should not be
300 460 1785 77.2
connected to the load side of solid state starters
and drives*. It should be noted that two-speed 1. F
 or use with 1800 rpm, 3-phase. 60Hz classification B motors
Type KE to raise full-load power factor to approximately 95 percent.
motor starters and soft starters require separate 2. See J1 for full load amps.
contactors to switch in capacitors after a
time-delay in order to avoid possible motor MCC Space Maximum KVAR
UL Listed
damage while the capacitors discharge. For Units
240V 480V 600V (X)
the same reason, Wye-Delta starters have the Required

capacitors applied after the delta connection 1X 22 1/2 50 45 X

has been made.

74 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

One space unit X equals 12 inches of vertical height. Recommended switching device
Space required is for capacitor only. Add space for
switching device as needed. Molded case
Switch with class J
KVAR circuit breaker
(in Amperes)
(in Amperes)
In front-mounted configurations utilizing the 20" 240 Volts, 60 Hertz
deep enclosure, capacitors may be mounted in the 2 1/2 10 15
rear 10 inches of space behind the vertical bus. Rear 5 20 20
access to the motor control center is required for 7 1/2 30 30
servicing the capacitors.
10 40 40
15 60 60
Optional 240 and 480 volt blown fuse indicating
20 80 80
lights are available. The indicating lights are
27 1/2 125 100
mounted on the unit door.
30 125 110
37 1/2 175 150
All capacitor units are Dry Type.
480 Volts, 60 Hertz
5 10 15
Bus connected power factor capacitors may be
7 1/2 15 15
paralleled to increase kvar ratings. Refer to factory.
10 20 20

Power factor correction capacitors should be 15 30 30

switched by a separate contactor (sketch B) under 20 40 40

any of the following conditions: 25 50 50

• High inertia load; 27 1/2 60 50
• Open circuit transition reduced 30 60 60
voltage starting; 37 1/2 80 70
• Wye-delta motor;
• Reversing or frequently jogged motor; —
For PFCC other than 240V or 480V, 60 Hz, refer to factory for sizing.
• Multispeed motor (2S1W, 2S2W, etc.).

Power factor correction capacitors should not be

connected to the load side of solid state starters
and drives*. It should be noted that two-speed
motor starters and soft starters require separate
contactors to switch in capacitors after a time-
delay in order to avoid possible motor damage
while the capacitors discharge. For the same
reason, Wye-Delta starters have the capacitors
applied after the delta connection has been made.
 T E C H N I C A L A P P L I C AT I O N G U I D E 75

Intelligent MCC

Intelligent E9000 MCC Standard network devices

The Intelligent low-voltage motor control center ABB offers a wide variety of network devices
(MCC) is an extension of the Evolution E9000 MCC to build a customized MCC to meet your needs.
product which utilizes network devices to Overload and motor management relays, intelligent
communicate the status of the system, to enable trip units, variable frequency drives (VFD’s), soft
control of the system devices, or to facilitate starters, and main metering are all available with
advanced diagnostics. communication capabilities. This section will
highlight the intelligent solutions ABB can offer
A motor control center is responsible for by leveraging these network devices.
controlling multiple motor loads throughout your
facility. With the intelligent MCC offering, you can To learn more about these devices, please
remotely monitor and control your system, helping see "Components" section and "Solid-state drives
to increase productivity and personnel safety. and starters" section (for VFD’s and Soft Starters).

— — — —
Multilin’s MM200 motor EntelliGuard trip unit (TU) FC 102 & FC 302 VFD's ASTAT XT soft starters
management relay

— — — —
Multilin’s MM300 motor microEntelliGuard TU ASTAT BP soft starters Multlin’s main metering:
management relay PQMII and EPM series
76 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Intelligent solutions VersaMax Nano and Micro controllers

ABB offers multi-level solutions to help meet the
needs of your motor control center application.
Intelligent E9000 MCC configurations can provide
local monitoring at or near the equipment, remote
control of the network devices, dual protocol
solutions, and complete system integration
with existing equipment.

The following examples demonstrate some of

the different intelligent MCC configurations ABB
can provide using programmable logic controllers,
programmable automation controllers, I/O
systems, human machine interfaces, and envisage*
Pick the palm-sized PLC that’s light
Energy Management software to help transform
on your budget
network devices into an intelligent MCC solution.
For tight spaces, the VersaMax Nano PLC is
Monitoring the perfect solution. Thanks to its all-in-one
construction, installation is a breeze. All you have to
do is snap it onto a DIN-rail or screw it into a panel.
With the VersaMax Nano, you save on initial as well
as life-cycle costs.

Select the big-featured PLC in a compact package

The small footprint VersaMax Micro PLC offers
the flexibility of modular design and a variety of
built-in features, including up to 64 I/O points
(expandable to 176 I/O points), fast cycle times,
a robust instruction set and extensive memory
Monitoring and control
that multiplies your programming options.

Dual communication bus

T E C H N I C A L A P P L I C AT I O N G U I D E 77

Tap the perfect solution for low-end Take advantage of a host of

motion applications communications options
Both the VersaMax Nano and Micro can be used Both the VersaMax Nano and Micro have an RS-232
with either a PWM or a pulse train device. In port that can be used for SNP slave, Modbus RTU
addition, both controllers come with built-in high- or serial I/O commands. The Micro 23 and Micro 28
speed counters that can be used in either Type A or also have an RS-485 port that adds SNP master
Type B configurations. The new Micro 20, Micro 40 and Modbus master commands. With serial I/O
and Micro 64 support four 100Khz high-speed commands, you can interface with such devices as
counters and four 65Khz PWM or pulse train out- pagers, intelligent scales, bar code readers and
puts for high speed motion applications. printers. The new Micro 20, Micro 40 and Micro 64
have a second option port that supports either
The new MicroMotion expansion module (2 axis RS-232, RS-485 or USB communications module.
of Servo or Stepper @ 500Khz pulses/second with The VersaMax Nano and Micro can easily be
encoder inputs) is ideal for either Micro integrated networked to Ethernet utilizing the powerful
motion control or standalone motion control (over VersaMax SE (Serial to Ethernet module).
serial or Ethernet networking). The MicroMotion
expansion module is loaded with features and Program your controllers in record time
supports 2 axis of stepper and servo control. The With Proficy Machine Edition software,
module supports a powerful function set, Home, programming your VersaMax Nano and Micro PLCs
Jog, Registration Input, S-Curve acceleration, is a simple and intuitive process. Mix Relay Ladder
Feedrate Override and more. Up to 256 move Diagram and Instruction List programming within
profiles are stored on the module and backed an application. Develop and save custom view
up with the Portable Memory device (removable tables. View PLC and I/O system fault tables
Flash device) for easy program storage of the on demand. Machine Edition is an automation
motion moves. The Micro 20, Micro 40, and Micro software breakthrough deploying HMI, motion, and
64 support up to 2 Micro-Motion expansion multi-target control in an integrated development
modules for a total of 4 axis high performance environment. This environment provides a common
motion control. user interface, drag-and-drop editing, and a rich
set of development tools. The Micro 20, Micro 40
and Micro 64 support a portable program FLASH
Memory Module that provides a simple cost
effective way of upgrading field controllers.
78 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

VersaMax Nano and Micro controllers

Typical Micro 20, Micro 40 and Micro 64

applications

— —
Material handling, packaging and assembly machines SCADA

Micro 20, Micro 40, Micro 64 Advantages Micro advantages

Flexible motion control to improve machine Flexible Communications from Serial to Ethernet
throughput is built into controller • Modbus master, Modbus slave and Report
• Up to 4 axes of stepper or servo control by exception
(32bit, 65Khz Pulse Train) • Modem and Ethernet SRTP or Modbus
• Up to 4 high speed counters at 100Khz (32bit) TCP (Server) option

Powerful networking to improve data gathering Abundance of data storage capability

• Plug in 10/100M bit Ethernet available • Up to 32Kwords of data storage
• Two built-in communication ports
Powerful instruction set
Simple control for complex applications • Floating point math and PID for process control
• 48K bytes of user program memory and • Write and Read data to internal FLASH
32Kwords of data storage
• Advanced programming instruction set.
Ramping, Jog, Find Home, Go Home, Blended
Move (up to 4 continuous moves)
• Portable program storage device

MicroMotion expansion
• 2 axis of Servo or Stepper @ 500Khz pulses/
second with encoder inputs
• Supports Home, Jog, Registration Input,
S-Curve acceleration, Feedrate Override
and more
• Interfaces with Micro 20, Micro 40, Micro 64
or standalone mode using Serial or Ethernet
• Stores up to 256 motion profiles on module
T E C H N I C A L A P P L I C AT I O N G U I D E 79

VersaMax Nano and Micro controllers

The newest additions to the Micro family – the
Micro 20, Micro 40 and Micro 64 PLCs – feature
expansion to 132, 152 and 176 I/O points
respectively, to fast cycle times, robust instruction
sets, and generous memory to allow more flexible
programming. These new Micros each feature an
optional second port that provides you with an
additional RS-232 port, RS-485, USB, or Ethernet.
The serial expansion ports come with two analog
input channels. A user-friendly memory module is
available to easily download changes to the
controller without the need of a PC.

And it’s all packaged in a sturdy modular design for

easy access and long-term durability. These all-in-
one PLCs give you everything you need to control
a wide variety of applications.

VersaMax Nano and Micro controllers selection guide

Features Nano 10 Micro 14 Micro 23 Micro 28 Micro 20 Micro 40 Micro 64

Built-in
6 in/4out 8 in/6 out 13 in/10 out 16 in/12 out 12 in/8 out 24 in/16 out 40 in/24 out
Discrete I/O
Built-in Analog 1 on some
none 2 in/1 out none none none none
I/O models
I/O Expansion
none Up to 4 units Up to 4 units Up to 4 units Up to 4 units Up to 4 units Up to 4 units
Units
Logic Memory
2K 9K 9K 9K 24K 24K 24K
(Words)
Data Storage
256 256 2K 2K 32K 32K 32K
(Words)
Scan Time
1.3 msec 1.1 msec 1.1 msec 1.1 msec 1.1 msec 1.1 msec 1.1 msec
(msec/K)
Battery Backed Yes and Super Yes and Super Yes and Super Yes and Super Yes and Super
Super Cap only Super Cap only
RAM Cap Cap Cap Cap Cap
Real Time
none none Yes, Included Yes, Included Yes, Included Yes, Included Yes, Included
Clock
1 RS-232 and 1 RS-232 and 1 RS-232 and
second port second port second port
1 RS-232 and 1 RS-232 and optional RS- optional RS- optional RS-
Ports Available 1 RS-232 1 RS-232
1 RS-485 1 RS-485 232, RS-485, 232, RS-485, 232, RS-485,
USB or USB or USB or
Ethernet Ethernet Ethernet
Ethernet Yes, VersaMax Yes, VersaMax Yes, VersaMax Yes, VersaMax Yes on second Yes on second Yes on second
Option SE SE SE SE port port port
High Speed Up to 4 at Up to 4 at Up to 4 at Up to 4 at Up to 4 at Up to 4 at Up to 4 at
Counter 10Khz (16 bit) 10Khz (16 bit) 10Khz (16 bit) 10Khz (16 bit) 100Khz (32 bit) 100Khz (32 bit) 100Khz (32 bit)
Pulse Train/ Up to 4 at 5Khz Up to 4 at 5Khz Up to 4 at 5Khz Up to 4 at 5Khz Up to 4 at Up to 4 at Up to 4 at
PWM (16 bit) (16 bit) (16 bit) (16 bit) 65Khz (32 bit) 65Khz (32 bit) 65Khz (32 bit)
Find Home, Go Find Home, Go Find Home, Go
Home, Jog, Home, Jog, Home, Jog,
Motion Ramp, Blended Ramp, Blended Ramp, Blended
N/A N/A N/A N/A
Commands Move (4 Move (4 Move (4
Consecutive Consecutive Consecutive
Moves) Moves) Moves)
Write Register
Values
No Yes Yes Yes Yes Yes Yes
to Internal
Flush
80 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

VersaMax Nano and Micro controllers – general Standard input circuit – 120/240 Volt isolated AC
I/O Circuits output module (VersaMax IC200MDL331)

Standard input circuit – 120 Volt AC input module Terminals Field Wiring
(VersaMax IC200MDL240) Rated Voltage 120/240 Vac
1 NC Output Voltage Range 85 to 264 Vac
HN
2 ~ Outputs per Module 8 (each output isolated)
3 NC Isolation 1500 volts RMS between
Terminals Field Wiring A1
4 fieldside and logic side
5 NC 500 volts RMS between
A1 Rated Voltage 120 Volts AC HN~
1
A2
6 each output
2 Indicators One Lcd per point 7 NC Output Current (Max.) 2 amps per point,
A3 Inputs per Module 16 (1 group with a
3 8 A2 5 amps per module
A4
4 single common) 9 NC Output Characteristics:
A5
5 Isolation 1500 volts RMS between 10 HN
~ Inrush Current 25 amps maximum
A6
6 field side an logic side 11 NC for one cycle
A7 Current Draw 50 mA (typical) at rated Min. Load Current 100 mA
7 12 A3
A8 voltage from backplane Output Voltage Drop 1.5 volts maximum
8 13 NC
B1 Output Leakag
9 14 HN~ e Current 3 mA maximum at
B2
10 Input Characteristics: 15 NC 120 Vac
B3
11 Max. On-state 70 volts to 132 volts 16 A4 6 mA maximum at
B4
12 Min. Off-state 0 to 20 volts NC 240 Vac
B5 17
13 Min. On-state 6 mA maximum 18 HN
~
On response time 1 ms maximum
B6 Off response time 9 ms maximum
14 Max. Off-state 1.5 mA maximum 19 NC
B7 (1/2 cycle)
15 On response time 1 cycle 20 A5
B8
16 Off response time 2 cycle
17 NC
18 NC
HN
19 ~
20 NC

I/O Configurations
Standard I/O for motor control center consists
of grouped input cards and isolated output cards
(note that the isolated outputs can control NEMA
size 1 to 6 starters).
T E C H N I C A L A P P L I C AT I O N G U I D E 81

Programmable automation controllers Higher performance

The RXi Controller is designed for high
Expanding on traditional PLCs performance distributed IO applications. With
Intelligent Platforms created the concept of the a high performance dual core CPU and Gigabit
Programmable Automation Controller with the PROFINET (with built in MRP redundancy) and
introduction of the PACSystems family of Ethernet ports, every aspect of the RXI has been
automation controllers. Expanding on traditional designed for performance. For even more power,
PLCs, PAC controllers provide a highly reliable, the RXi controller can be combined with the RXi
high-performance advanced control platform for Modular IPC to deliver a unique control and
discrete logic control, motion control, and process computing platform for the factory floor.
control. While ABB offers and supports a wide Integrated highspeed connectors allow instant
variety of communications protocols to support data handling. Operator usability can be enhanced
our customers needs, we have standardized our by pairing the RXi Modular IPC with new RXi panel
control systems on the market-leading industrial displays with new multitouch technology.
network, PROFINET, to provide an extremely high
performance, highly reliable, yet simple to The unique combination of high performance
configure and install distributed IO network. control, integrated PROFINET, intelligent display
module, and compact format truly distinguishes
PACSystems RXi controller the RXi Controller from other offerings.
High Performance Distributed IO
Controller Platform Greater uptime
Systems with distributed architectures are easier
Intelligent Platforms has leveraged its rich to configure and maintain. In addition, RXi
experience in embedded computing and control components are industrial temperature grade,
technology in the design of the innovative which combined with patented thermal monitoring
PACSystems RXi controller platform. The RXi technology and sophisticated passive cooling
Controller incorporates leading-edge CPU techniques delivers reliable control in rugged
technology, the market leading industrial Ethernet environments.
network technology, and a unique user interface for
maintaining the controller to deliver a control Lower total cost of ownership
system unique in the industry. RXi’s compact control and computing platform
allows users to simplify panel design and reduce
The PACSystems RXi controller is PROFINET the overall size of the panel while benefiting from
enabled, delivering a small footprint solution with the performance, maintainability, and
highly flexible distributed I/O capabilities to upgradeability of the PACSystems platform. The
equipment builders and end users. Its unique optional Intelligent Display Module provides a
Intelligent Display Module provides configuration maintenance touchscreen display right on the
and maintenance functions at the controller controller, providing faster interaction with the
without software. As a PACSystems controller, the controller and simpler start-up.
RXi is fully compatible with applications written for
any other PACsystems platform. The result is a high
performance solution designed for distributed
IO applications.
82 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

PACSystems RXi controller

Feature Benefit

Dual core processor for high performance in rugged applications

Rugged technology with wider temperature ranges, higher shock and vibration designs, suitable for
COMExpress CPU technology industrial applications
Carrier and enclosure designs last across multiple CPU lifespans to provide faster
performance enhancements
Provides a Gigabit Ethernet I/O network connection with built-in cable redundancy (MRP) delivering
Integrated redundant PROFINET I/O Interface
IO cabling redundancy with no external switches
Enables truly unique combinations of control and Proficy (or other Microsoft® Windows® or Linux
High-speed interconnect bus
applications)
Built-in data storage Internal industrial grade SSD drive provides local long-term data retention
Interfaces enable program loading, serial communications and data storage via
USB and SD interfaces
standard devices

Specifications

Storage
• 10 MB user memory

Data Retention
• RXi specific Energy Pak provides power during
power failure while data is written to NV RAM

Ethernet
• 2 Port (shared MAC) GB PROFINET – with MRP
• 1 Ethernet (10, 100, 1000 Mbit) port
• 1 Ethernet (1000 Mbit) – internal

USB Interface
• 2 USB 2.0 Standard Size

Others
• SD Card (on Intelligent Display Module or
Intelligence Faceplate)

Power
• Input: 24V DC (±25%) with protection

Environmental
• Operating: -25°C to +55° C (standard)
• Storage: -40°C to +125° C
• Operating humidity: 10% to 90%

Mounting
• Panel Mount
• Dinrail Mount with Optional DIN Mount Plate

Safety
• UL, CE
• Class 1, Div 2 (pending)
T E C H N I C A L A P P L I C AT I O N G U I D E 83

PACSystems RXi controller Features

The PACSystems RX3i controller is an incredibly • High-speed processor and patented technology
powerful Programmable Automation Controller for faster throughput without information
(PAC) in the innovative PACSystems family. bottlenecks
The RX3i features a single control engine and a • Dual backplane bus support per module slot:
universal programming environment to provide - High-speed, PCI-based for fast through put
application portability across multiple hardware of new advanced I/O
platforms and deliver a true convergence - Serial backplane for easy migration of existing
of control. With integrated critical control Series 90-30 I/O
platforms, logic, motion, HMI, process control and • Multiple CPU offerings meeting various
high availability based on our Reflective Memory performance criteria up to and including an
technology, the RX3i provides the performance and Intel® 1 GHz CPU for advanced programming
flexibility to give you an advantage. No matter the and performance with 64 Mbytes memory
challenges your applications bring, PACSystems • Memory for ladder logic documentation and
RX3i lets you take control. machine documentation (Word, Excel, PDF,
CAD and other files) in the controller to reduce
Benefits downtime and improve troubleshooting
The innovative technology of the PACSystems RX3i • Open communications support including
enables users to: Ethernet, GENIUS, PROFIBUS™, HART,
• Address major engineering and business DeviceNet™ and serial
issues, such as higher productivity and tighter • Supports high density discrete I/O, universal
cost control analog (TC, RTD, Strain Gauge, Voltage and
• Boost the overall performance of their Current configurable per channel), isolated
automation systems analog, high-density analog, high-speed
• Reduce engineering and commissioning costs counter, and motion modules
• Easily integrate new technology into installed • Expanded I/O offering with extended features
base systems for faster processing, advanced diagnostics and
• Significantly decrease concerns regarding short- a variety of configurable interrupts
and longterm migration and platform longevity • Hot insertion for both new and migrated modules

High performance control on one platform

The PACSystems RX3i provides logic, motion,
HMI, and process control with open
communications protocols.
• PACMotion modules can control up to 40 high
speed axes in one rack
• PACSystems High Availability solution offers
true dual redundancy data synchronization
and bumpless transfer
• The Control Memory Xchange offers amazing
data transfer at a rate of 2.12 Gbaud

Universal development environment

The common software platform across all
controllers, award-winning Proficy Machine Edition
software provides the universal engineering
development environment for programming,
configuration and diagnostics
for the entire PACSystems family.
• Programming tools such as tag-based
programming, a library of reusable code
and a test edit mode for improved
online troubleshooting
• User-friendly environment that can increase
design flexibility and improve engineering
efficiency and productivity
84 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

PACSystems RXi Controller

Baseplates Expansion Modules

Pneumatic Modules

Discrete I/O Modules

Networks and Distributed I/O

Power Supplies CPUs

—
Motion modules

CPUs Discrete I/O modules

The CMU310 is a High Availability redundant CPU Input modules provide the interface between the
that is configured using the MaxON software. The PLC and external input devices such as proximity
CMU310 has the same functionality as the CPU310. sensors, push buttons, switches, and BCD
Synchronization of the CMU310s is via an thumbwheels. Output modules provide the
Ethernet link. interface between the PLC and external output
devices such as contactors, interposing relays, BCD
Baseplates displays and indicator lamps.
The RX3i Universal baseplates support hot swap
capability to reduce downtime. Expansion bases Analog I/O modules
are available in 5 and 10 slot versions to ABB offers easy-to-use analog modules and HART
maximize flexibility. analog modules for control processes such as flow,
temperature and pressure.
Universal bases power supplies
The RX3i power supply modules simply snap in just Specialty modules
like I/O, and they work with any model CPU. Each The RX3i features a wide range of Specialty
version provides auto-ranging so there is no need Modules to address specific application
to set jumpers for different incoming power levels, requirements.
and they are current limiting so a direct short will These modules include:
shut the power supply down to avoid damage to • Millivolt and Strain Gage I/O
the hardware.at a rate of 2.12 Gbaud. • RTD I/O
• Temperature Control
• Thermocouple I/O
• Resistive I/O
• Power Transducer
T E C H N I C A L A P P L I C AT I O N G U I D E 85

Networks and distributed I/O systems Example PLC connections

The RX3i features a variety of communications
options for distributed control and/or I/O. Choose PLC controlled starters
from Ethernet EGD, PROFIBUS-DP, Genius and A combination motor starter will require a
DeviceNet. These communication modules are easy minimum of one Input and one Output per starter.
to install and quick to configure. As shown in Figure 5, the Output is connected
between the starter coil and the fused, ungrounded
RX3i pneumatic module leg of the control voltage source (terminals 3, 1).
This output module provides 11 pneumatic outputs The Input connection is made between the starter
and five 24 VDC sourcing outputs. For each “Seal contact” and the grounded leg of the control
pneumatic output, the module contains an internal voltage source (Terminals 2, X2). The Input monitors
3-way solenoid-actuated valve and an associated the status of the seal circuit to independently verify
output fitting. Solenoid power is supplied from an that the starter has closed.
external 24 VDC source to the“DC Outputs”
connector on the front panel.

Expansion modules for local and remote I/O

The RX3i supports various expansion options for
local and remote I/O to optimize configurations.
The RX3i can be expanded up to 8 expansion bases
using local remote expansion module. The RX3i also
supports Ethernet remote I/O using the RX3i
Ethernet Network Interface module (IC695NKT001)
Series 90-30 Ethernet Network Interface module
(IC693NIU004) for more distributed I/O. —
Figure 5. Input and output Connection

Motion control
When an H-O-A switch is used with PLC I/O, the
The PACMotion controller is a versatile 4-axis servo
configuration will appear as shown in Figure 6.
motion controller that provides the scalability and
Note: as mentioned previously, the INPUT monitors
flexibility to cover a full range of motion
the status of the starter’s seal circuit in the manual
applications from small material handling
mode as well as the PLC (automatic) mode.
applications to complex multi-axis machines and
electronic line shaft applications. PACMotion
provides real-time synchronization of all axes in an
RX3i rack. A separate RX3i fast logic scan enables
fast deterministic event response and
synchronization, and the demand driven data
exchange model between the RX3i CPU and
PACMotion module many significantly reduce scan
time impact. The 4-axis servo motion controller is
built on a high performance hardware platform,
with a new enhanced motion engine, operating
system, and open standard integrated
programming paradigm. —
Figure 6. H-O-A Connection

Starter units with individual control transformers

For starters having individual control power
transformers all Outputs must be isolated type.
This requirement is necessary due to the separate
voltage sources provided by the individual control
transformers. Inputs may be either isolated or non-
isolated types. Where non-isolated Inputs are used
all X2 terminals must be wired together.
86 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Surge suppressors
In cases where excessive noise is present on the
control line or hard interlocks which will operate
often (in series with PLC Output), surge
suppressors are recommended.

Optional inputs/diagnostic
Additional Input connections can be made to
monitor the specific status of combination starters
and feeders to provide further diagnostic
information to the process operator and
maintenance personnel.
—
1. The status of the overload relay can be Figure 7. Input and Output Connections for Separate-Source Control
monitored. An electricallyisolated, normally-open
auxiliary contact can be ordered with the 300- Isolated versus non-isolated outputs
Line overload relay and an additional PLC Input
can be wired in series with it. Isolated outputs
2. A PLC Input can be connected between terminals Isolated outputs can be used for direct control of
1 and X2 to monitor the availability of control NEMA size 1 through 4 combination starters
power to the starter unit. without the use of an interposing relay. The
contactors of standard NEMA size 5 and larger
Starter units with separate-source starters are operated at line voltage with
control voltage interposing relays operated from the secondary of
Input and Output connections are shown below the control transformer.
(see Figure 7) for units arranged for separate-
source control. Non-isolated outputs
NEMA size 1-2 starters may be operated directly
Input from common PLC output cards. The continuous
A common (non-isolated) Input can be used if all current rating of ABB’s non-isolated output module
X2 terminals are wired together. requires an interposing relay for NEMA size 3 and
larger starters. Check the module ratings for inrush
Output and continuous values.
As required by NEC Article 430-74, if a disconnect
auxiliary contact and/or control circuit fuse (FU) is Distributed I/O and Remote I/O
included with each starter, then the Output must Intelligent Platforms provides high performance
be the isolated type. However, if the auxiliary distributed I/O for demanding control applications.
contact and fuse are omitted, a common Output Our I/O and Controllers are connected by PROFINET
module can be used. With common output – the market leading industrial network. Using this
modules, interposing relays are required with common interface allows users to mix and match
NEMA size 3 and 4 starters. Note: NEC article 430- their preferred controller with the I/O that best
74 can be met with standard split-type control meets the needs of each part of the applica-tion.
terminal boards on all draw-out units, or with Our I/O portfolio has a wide range of packaging
pull-apart terminal boards. options covering the full spectrum of needs from
simple discrete to high speed analog control, and
from factory automation to process industries with
harsh environments. We deliver best in class
flexibility, performance, reliability and connectivity.
T E C H N I C A L A P P L I C AT I O N G U I D E 87

VersaMax I/O and control The perfect match for today’s open systems
Maximum versatility is the guiding principle behind VersaMax gives you the freedom to connect to a
VersaMax from Intelligent Platforms. This compact, wide variety of host controllers, including PLC, DCS
extremely affordable control solution can be used and PC-based control systems by way of Genius,
as a PLC, as I/O, and as distributed control. With its DeviceNet™, PROFIBUS-DP™ and Ethernet
modular and scalable architecture, intuitive networks. VersaMax also fully supports the power
features and ease of use, this innovative control and open architecture of PC Control solutions.
family can save machine builders and end users
considerable time and money. The ultimate in cost-effective control and I/O
With intuitive diagnostics, hot insertion of modules
Offering big PLC power in a small package and quick connect wiring, VersaMax extends
VersaMax CPUs supply a number of features usually uptime, reduces engineering and training needs,
found only in PLCs with larger footprints, including and dramatically reduces project life-cycle costs.
up to 64k of memory for application programs,
floating point math, realtime clock, subroutines, A design that maximizes ease of use
PID control, flash memory, and bumpless program Every aspect of VersaMax has been carefully
store. The serial ports support serial read/write refined to accommodate the user. Snap-together
and Modbus master/slave communications. I/O carriers mean that no tools are required for
module installation or extraction. A convenient
An abundance of useful I/O options rotary switch can be used for setting bus and
ABB offers a broad range of discrete, analog, reducing programming time. With VersaMax, you
mixed, and specialty I/O modules. These modules can even address I/O automatically.
can be freely combined to create stand-alone I/O
stations with up to 256 I/O points and expanded
I/O systems with up to 4,096 I/O points.
88 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

PACSystems RSTi The RSTi line of I/O extendds the capabilities

Ethernet based I/O delivers high performance and of PROFINET enabled solutions with a
system flexibility. comprehensive line of granular slice I/O that
simplifies panel design and reduces the overall
To succeed in an outcome-driven world, businesses size of the control panel while offering the
must operate faster and leaner and be increasingly performance, maintainability and upgradability
connected. At Intelligent Platforms, we understand of the PACSystems platform.
today’s connected business environment, and are
committed to simplifying it. That’s why we’ve Decentralized I/O reduces cost
designed an automation architecture that helps The RSTi decentralized I/O addresses the
you design better machines and plants, operate challenges of high installation overhead cost and
them smarter, and redefine the interaction with lack of granularity of a centralized I/O system. The
your equipment. RSTi provides a high performance distributed I/O
network that reduces the cost of field wiring. The
A pivotal point in this architecture is the I/O. distributed nature of the RSTI enables a machine
Intelligent Platforms leverages industry standards builder to design in sections with distributed I/O
and our experience in embedded technology and drops closer to the field devices.
high-performance automation to deliver I/O that
simplifies system design while reducing costs. Decentralized I/O systems are easily disassembled
and reassembled with a standard, off-the-shelf
With Ethernet-based RSTi I/O, communications are Ethernet cable versus hundreds of wires coming
enhanced through PROFINET, a high-speed, open back to a centralized control cabinet.
protocol that facilitates the massive amounts of
data that devices generate. The RSTI I/O unlocks The compact RSTi I/O line allows the user to “right
the potential of continuity, connectivity, and size” the application, minimizing cost and panel
collaboration for your control systems. space. I/O expansion is simple with the slide and
lock design.
Simplifying system design without
sacrificing performance
Equipment builders are continuously looking to
improve the performance of their equipment while
augmenting usability and reducing size and
complexity. These requirements extend to the I/O
control system. With PACSystems automation
portfolio, ABB provides high-performance control
solutions with best-in-class integration of
distributed (networked) I/O ideally suited
for demanding applications.

Feature Benefit
PROFINET Connectivity High-speed I/O throughout that connects to hundreds of third-party devices
System Diagnostics Increased uptime by isolating system failures quickly
Powerful Integration
Reduced development time with Proficy Machine Edition tools
Tools
Granular design enables “right sizing” the application, resulting in minimum installation cost and panel
“Build as You Go”
space
Rugged Design Rugged “slide and lock” design provides an easy, secure installation
Eight global standard network interfaces supported by the RSTi enables the user to standardize on one
Network Independence
I/O system regardless of the bus requirements
T E C H N I C A L A P P L I C AT I O N G U I D E 89

PACSystems RSTi Over 80 module types available

Distributed I/O delivers high performance and • AC and DC I/O
system flexibility • Relay Outputs
• Analog I/O
Powerful solution • RTD
The RSTi innovative design enables module power, • Thermocouple
communications and field power to be passed from • 2, 4, 8 and 16 point density
one module to the next. Power Distribution, Power
Booster and Field Power Isolation modules are User friendly design
available to simplify installation wiring. The RSTI • Rugged, removable terminal block
compact design (99 mm high x 70 mm deep x 12mm • Tool-less spring clamp wiring
wide for I/O) reduces panel space. • DIN Rail “slide and lock” design
• Color coded identification
Global standards • Easy to read LED status
• CE, UL, CUL approved • Diagnostic test points
• UL Class 1 Div 2 and ATEX Zone 2
• Temperature range -20°C to 60°C Specialty modules
• UL temperature range -20°C to 60°C • Serial communications
• High-speed counters
Flexible network interfaces • SSI interface
• PROFINET RT • PWM and pulse output
• Modbus TCP/IP
• DeviceNet SVDC module power and communications
• CC-Link • Passed from one module to the next
• PROFIBUS DP/V1
• Modbus Serial Field power
• CANOpen • Passed from one module to the next

The high-performance PACSystems RSTi PROFINET enabled family of

I/O modules are part of the Intelligent Platforms High Performance
Platform strategy. The platform leverages industry standards plus the
combination of experience in embedded technology and automation
to deliver long-life and higher performance solutions that are easy to
configure, manage and upgrade. Contact your local representative
for more information about solutions for your I/O requirements.
90 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Human machine interfaces (HMIs)

The QuickPanel view family

The QuickPanel View bundled visualization solution
provides the tools required for today’s application
needs with a combination of bright touch screen
displays, multiple communications options, and
Proficy View – Machine Edition software.

Information delivery
Acting as the bridge between the enterprise
system and the plant floor, QuickPanel View
provides information, not just data, that the
Seamless connectivity
operators need to run the machines, and that
As your need to monitor and collect data grows,
managment needs to run their business.
you may need to connect to a wide variety of
devices. Unless your operator interface has
The QuickPanel View is a critical link to a
seamless connectivity, you may face delays and
well-integrated manufacturing operation.
headaches. That is why QuickPanel View comes
• Built on Microsoft Windows CE
standard with a large number of built-in drivers to
operating system
connect with the the world of automation devices,
• Built-in web server access data and
making it easy to connect to anything.
panel using any standard browser
• Communication drivers over serial and Ethernet
• Communication over fieldbus and vendor specific
Scalable
networks through the addition of a
As your information requirements grow, so will
communication expansion card
your hardware needs. QuickPanel View products
are exceedingly scalable to grow with your needs.
Other advantages
• Broad range of display sizes from 6" to 15"
We invite you to explore the advantages of
• Choice of Monochrome, Color-STN, or
QuickPanel View.
Color-TFT display
• Cost-effective replacement for push buttons
• Expandable memory and communications
and pilot lights
options
• Data collection, trending, system security and
• Easy configuration allows you to run the same
other functions
program on different size models
• Multi-language support
• Migration of applications developed with
QuickDesigner
• Adherence to global standards UL, ATEX, and CE
T E C H N I C A L A P P L I C AT I O N G U I D E 91

envisage Typical monitored values

Energy management system • RMS current
• Current demand
• Peak current
• RMS voltage
• KW and KWh
• Peak KW demand
• Apparent power (KVA) and apparent
energry (KVAh)
• Reactive power (KVA) and reactive
energry (KVARh)
• Power factor
• Frequency
• Event records
• Additional system parameters — water, air, gas,
electric, steam, HVAC, backup power, security
• Switch position and breaker status

Typical connected devices

• Meters
• Trip units
envisage monitoring
• UPS
The envisage Monitoring module displays real-time
• Solar chargers
power and demand data from remote intelligent
• CRAC units
energy devices as well as facility-wide
• ATS
infrastructure systems.
• PSG
• PDU
A birds-eye graphical site diagram provides a
• Generators
model representation of the complete facility and
• VFD
leads quickly to more detail in dynamic one-line
• PLC
schematics for the site location and even individual
• Proactive relays
installed devices and monitored values.
• “Smart” power strips

It keeps you completely and accurately informed

of the system’s status in real-time – both locally
and remotely – through customized views that
aggregate and scale the information you need.
Energy monitoring includes trend data from
meters, relays, and breaker trip units in order to
analyze the power system. It allows you to highlight
and acknowledge unusual activity and alarm
conditions with the real-time and historical
alarm viewers to ensure that problems do not
go unnoticed.

—
Overview of entire network
92 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Solid-state drives and starters

Adjustable frequency AC drives A drive must have short circuit protection. Since a
drive is subjected to higher available short circuit
General application notes currents in an MCC, (vs. a wall mounted unit)
As a vehicle for controlling multiple motor additional components such as current limiting
functions, the Motor Control Center has become fuses and reactors are utilized. See typical one
the logical place to mount variable speed drives. line sketch.
However, the application of these drives is not a
simple selection process, and the following is an A drive can provide significant energy savings.
explanation of some of the variables involved. When a fan or pump is utilized on a system with
variable flow rates, whether measured in gallons
A drive must have ventilation. The basic power per minute or cubic feet of cooling air per minute,
switching components are transistors, which are a variable speed drive is the most efficient means
mounted on finned heat sinks. Although the drive of control. Since a variable torque load requires
may be operating at 95% or greater efficiency, the significantly less energy when operated at lower
5% (±) normal heat loss cannot be enclosed in the speed, the energy savings can be in the 25 to 50%
MCC without exceeding the safe operating range when compared to a full voltage motor using
temperature (50°C). Standard mounting is dampers or valving to reduce its output.
ventilated (NEMA 1 or 1A only). (The amount of savings depends, of course, on
the amount of time the motor can be used at the
A drive is electronically controlled. The new reduced speed.) It will also lower demand charges
generation of PWM drives are all microprocessor due to reduced motor starting current.
based. Although well shielded from stray noise,
they require careful wire routing, and in some cases
shielded wire runs to avoid “nuisance” problems.
Control wires should be run separate from power
leads. If they must cross, try to keep them at right
angles to minimize the induced electric
fields (noise).

A drive creates noise on the power system.

Although we use line reactors to minimize system
disturbances, a drive will create harmonics on
the power/system (both at the motor and at the
transformer). If sensitive computer systems are to
be utilized, they should be isolated from the drive’s
source, or EMI/RFI filters added. Likewise, the
harmonics created at the motor may cause the
motor to run hotter than expected. Standard
motors should be derated 10% when used with a
drive. We recommend high efficiency motors for
drive applications as a minimum. See motor
application data, SH, page G3.
T E C H N I C A L A P P L I C AT I O N G U I D E 93

Line reactors The FC 102 and FC 302 series have an array of

The available power source connected to the Drive functions that provides significant benefits.
is not to exceed 500kVA. If the AC power source is Standard features include: auto-tuning without
greater than 500kVA and the Drives rating (HP) is having to rotate the motor, built in PID control,
less than 10% of the power source's kVA; AC line rotating motor pick up control (catch spinning
reactors will have to be installed in L1, L2, and L3 motor), Standard RS485 (Modbus RTU), Metasys
power leads of the Drive. We provide 3% Line or Apogee FLN P1 Communications, automatic
reactors as standard but they can be deleted as an energy-saving operation (which minimizes drive
option. The drive internally has a DC reactor, which and motor loss at light load) and other functions
will protect the drive components. to combine performance and energy savings.

Load filters The new generation IGBT means reduced electrical

IGBT drives create voltage spikes at the motor. noise and less voltage spiking. On-line-tuning
Motor insulation rating must be higher than these provides a continuous check for variation of motor
peaks. Motor should meet NEMA MGI part 31. If not, characteristics during running of high-precision
load filters may be required. Refer to page G4. speed control. All drives conform with the following
safety standards: UL, cUL, CE and C-Tick.
Adjustable speed drives
FC 102 and FC 302 Series

Adjustable frequency drive

The FC 102 VFD is an AC packaged drive that
provides the functionality required for variable
torque loads such as fans, pumps and
compressors. Forward/Reverse and Simple
commands from the local or remote keypad or
from the facility management system, along with
pre-loaded motor parameters and factory defaults,
allow for quick and readyto- go installation.

The E9000 offers expanded horsepower ratings

in 230Vac (1/4 to 50Hp), 460Vac (1/2 to 500Hp)
and 575Vac (1-500Hp) for even greater range of
application. The FC 302 Adjustable Frequency Drive —
FC 102 & FC 302 VFD's
with flux vector and dynamic torque-vector control
using optimized control of voltage and current
vectors provides the enhanced performance that
you are looking for in your application. The FC 302
process control systems will make any task simple
and profitable. In addition, by adding an optional
(encoder) speed feedback device, this drive can be
configured to operate in a flux vector control mode.
The FC 302 provides flexibility across a wide range
of constant torque applications.
94 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Adjustable speed drives

Standard specifications FC 102 and FC 302 (continued)

Process PID differential time 0.0 - 10 s

Process PID differential gain 1.0-50.00
On reference bandwidth 0-200%
Operation Keypad operation: Hand, Off, Auto Digital Input: Programmable for Start/Stop, Forward/Reverse, Jog Timer
Operation method operation: Stop after predetermined time frame. USB Port for programming drive with optional PC Software
Left or Right Arrow buttons on keypad in Manual Mode Speed Potentiometer: 0 to +10 Vdc, 10 to 0 Vdc,
Frequency reference signal
0- 10Vdc analog input 0/4-20ma analog input
Up to 3 Input References can be selected from Analog Input #1 or #2, Frequency Input #1 or #2, Network, or
References
Potentiometer
Signals 6 - Digital Inputs, 24 Vdc PNP or NPN, 1 - Safe Stop Digital Input suitable for category 3 installations to meet
EN-954-1, 2 - Pulse Inputs rated to 110kHz or 1 - Pulse Input and 1 - Encoder Input 24 Vdc rated to 4096 PPR 2 - Analog
Inputs -10 to +10V scalable or 0/4 to 20 mA scalable. Digital Input Settings: No Operation, Reset after drive trip or
alarm, Drive at stop with no holding current, Quick Stop according to Quick Stop Decel Time 1, Stop on input going
low, Start, Maintained Start after signal applied for Minimum of 2ms, Reversing, Start Reverse, Enable Start Forward
Input signals only, Enable Start Reverse only, Jog, Multi-Step Frequency selection (1 to 8 Steps), Hold Drive Frequency, Hold
Reference, Speed Up; activated by Hold Drive Frequency, or Hold Reference, Slow Down; activated by Hold Drive
Frequency or Hold Reference, Drive Parameter Setup Select 1-4 Precise Start or Stop; Activated when drive parameter,
precise start or stop function is selected, Catch Up or Slow Down; Activated by signal to add to or subtract from input
reference to control speed,Pulse Input selectable from 100 - 110000Hz, Accel / Decel Time select. Set Input to Accel /
Decel Times 1 to 4, Digital Potentiometer Input Increase or Decrease, Mechanical Brake Feedback.
2 - Digital Outputs 24 Vdc (Digital Outputs are used in place of 2 of the Digital Inputs), 2 - Form C Relays rated to 2A at
240 Vac, 1 - Analog Output 0/4 to 20mA, Relay Output Settings : No Operation, Control Ready, Drive Ready, Drive Ready
in Remote, Standby No Drive Warnings, Drive Running, Drive Running No Drive Warnings, Drive Running on Remote,
Alarm, Alarm or Warning, At Torque Limit, Out of Current Range, Below Current, Above Current, Out of Speed Range,
Output signals Below Speed, Above Speed, Out of Feedback Range, Below Feedback, Above Feedback, Thermal Overload Warning,
Reverse, Bus OK, Torque Limit and Stopped, Brake and no Warning, Brake Ready and No Faults, Brake Chopper Fault,
External Interlock, Out of External Reference Range, Below External Reference, Above External Reference, Fieldbus
Controlling Drive, No Alarm, Running in Reverse, Local Mode Active, Remote Mode Active, Start Command Active, Hand
Mode Active, Auto Mode Active
Line Phase Loss, DC Overvoltage, DC Undervoltage, Drive Overload, Motor Overtemperature, Motor Thermistor
Overtemperature, Torque Limit, Overcurrent, Ground Fault, Short Circuit, Control Word Timeout, Brake Resistor Short-
Circuited, Brake Chopper Short-Circuited, Brake Check, DC Link Voltage High, DC Link Voltage Low, Internal Fan Fault,
Protective functions External Fan Fault, Power Board Overtemperature, Missing U Phase, Missing V Phase, Missing W Phase, Internal Fault,
Control Voltage Fault, Auto Tune Check - Wrong Motor Parameters, Auto Tune Low Inom - Motor current is too low,
Current Limit, Mechanical Brake Low, Drive Initialized to Default Value, Keypad Error, No Motor, Soft Charge Fault, Auto
Tuning Fault, Serial Comms Bus Fault, Hardware Mismatch, Speed Limit.
LCD Display with 6 Alpha-numeric lines. Multi-Language Support, Hot Pluggable, Remote Mount Option, and CopyCat
Keypad
Feature, IP65 rating when remote mounted on enclosure, LED’s - Green - drive is on, Yellow - indicates a warning, Red -
Keypad features
indicates an alarm, Amber - Indicates active Menu keys and H-O-A keys
Status - shows status of drive, Quick Menu - Enters Quick Start, Parameter Data Check or Trending Modes, Main Menu -
Used for programming all drive parameters, Alarm Log - Used to display Alarm list, Back - Reverts to previous step or
Keypad keys layer in parameter,structure, Cancel - Used to cancel last change or command, Info - Displays information about a
command arameter, or function in any display. Hand/Off/Auto - Used to control drive locally or put drive in remote
mode, Reset - Used to reset Warnings or Alarms.
Password 2 Level Password Protection
Alternate motor parameters Up to 4 Separate complete parameter set-ups are available
Graphical trending Trend Speed, Power, Frequency or any value programmed in status display
RS485 modbus RTU serial
communications
Physical Level EIA/RS485
Transmission distance 1640 ft (500m)
Node address 32
Transmission speed 2400, 4800, 9600, 19200, 38400,or 115200 (bits/s)
Transmission mode Half Duplex
Transmission protocol Modbus RTU
Character code Binary
Character length 8 Bits
Error check CRC
Special AF650 FP modes
Fire override mode Overrides drive’s protective features and keeps motor running
Pump cascade controller Distributes running hours evenly over up to 4 pumps.
Sleep mode Drive detects low or no flow conditions and adjusts output
Dry pump detection Detects pump operation and can set off alarm, shuts off, or other programmed actions
Belt monitoring Drive can detect relationship between current and speed to recognize a broken belt
T E C H N I C A L A P P L I C AT I O N G U I D E 95

FC 102 and FC 302 Standard options

Line reactor 3% Reactor is standard with the drive

DC link reactors Standard with drive
Class AFII RFI Standard with drive
Speed control The unit comes with a Keypad that can be used for Speed adjustment.
Outputs relays Drive come standard with two relays form C rated to 2A at 240 VAC.
Outputs analog Drive comes standard with 1 Analog output 0/4-20mA
Drive comes standard with 2 Digital outputs at 24 VDC (Digital Outputs are used in place of the 2
Outputs digital
Digital inputs.
Communications Drive RS-485, Modbus RTU, Metasys N2, or Apogee FLN P1

FC 102 and FC 302 Additional options

Line reactor 5% Reactor must be requested and priced

Speed control Door mounted potentiometer must be requested and priced.
Communication module Profibus DP internal mounted module for use on FC 102 and FC 302. Supports Profibus DP V1
Profibus communications networks.
DeviceNet DeviceNet internal mounted module for use on FC 302 and FC 102. ODVA certified device.
Ethernet IP internal mounted module for use on FC 302 and FC 102. ODVA certified device. Features
Ethernet IP 2-Port built-in switch. Also includes webserver and email notification. 1Requires I/O and network
slots and cannot be used with any other network or I/O modules
Modbus TCP Modbus TCP internal mounted module for use on FC 302 and FC 102.
ProfiNet RT ProfiNet RT internal mounted module for use on FC 302 and FC 102.
LonWorks internal mounted module for use on FC 102 drives only. Supports LonWorks building
LonWorks
automation communications networks
BacNet internal mounted module for use on FC 102 drives only. Supports BacNet MSTP building
BacNet
automation communications networks.
Relay Output internal mounted module for use on the FC 302 and FC 102. Module adds (3) Form C
Relay output
relay outputs to the drive. Relays are rated at 2A at 240V resistive load.
Analog I/O internal mounted module for use on the FC 102 drive only. Module Includes: 3 - Analog
Analog I/O Inputs 0-10V, 0/4-20mA and 3 - Analog Outputs 0-10V,Battery Back-Up power for
FC 102’s internal Real Time Clock
24V DC External Supply internal mounted module for use on the FC 302 and FC 102 drives. This
module accepts an external 24V DC supply which is used to keep the control board of the drive and
24V DC external supply
other option modules powered in the event of a Line side power outage. Can be used with
Communications and I/O Modules.
General Purpose I/O internal mounted module for use on FC 302 and FC 102 drives.
General purpose I/O Module includes: 3 - 24V Digital Inputs, 2 - PNP/NPN Digital Outputs,
2 - 0-10V Analog Inputs and 1 - 0/4-20mA Analog Output
Encoder internal mounted module for use on the FC 302. Module supports all 5V incremental
Encoder
encoders. Also supports Hyperface SinCos encoders.
Resolver internal mounted module for use on the FC 302 drive. Module supports 4-8Vrms, 2.5kHz -
Resolver
15kHz, 50mA resolvers. Resolution is 10bit at 4Vrms.
Safe PLC I/O internal drive mounted module for use on the FC 302 drive. This module provides a
Safe PLC I/O
safety input based on a single pole 24V DC input.
96 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Adjustable speed drives

Space height and assembly

FC 102 and FC 302 space height, 42 kAIC

Max HP GP/FP CT/VT @ Section 1 Section 2

Function Plug-Ini Disconnect
208V 230/240V 380/415V 440/480V 575/600V Width X height Width X height
• 5/5 5/5 3/3 5/5 SELI, SELT 15 2.5
• 5/7.5 10/10 SELI, SELT 15 3
• 10/15 10/15 15/15 20/25 SELI, SELT 15 4
25/40 25/40 40/60 60/60 SELI, SELT 24 4

Basic ,LR, /75 SELI, SELT 24 5.5

bypass and 40/ 40/ SELI, SELT 30 5.5
isolation
50/60 50/60 SFLI, SFLT 30 5.5
75/ 75/ SELI, SELT 24 5.5 15 1.5
/75 100/125 SFLI, SFLT 24 5.5 15 1.5
100/125 150/200 SGLI. SGLT 30 5.5 24 1.5
200/250 300/ SGLI. SGLT 30 5.5 30 4.5

1. S
 ection 2 will always be on the left and bottom mounted. All Space height is based on all main bus sizes.
2. When line reactors are not required consult factory for dimensions.
3. Pilot devices may impact the X height on certain plug-in HPs

Minimum UL short-circuit rating 42KAIC@ 480V

FC 102 and FC 302 space height, 65 kAIC

Max HP GP/FP CT/VT @ Section 1 Section 2

Function Plug-in Disconnect
208V 230/240V 380/415V 440/480V 575/600V Width X height (³) Width X height (¹)
• 3/3 3/3 3/3 5/5 SELI, SELT 15 2
SELI, SELT,
• 10/10 TECL 15 2
• 10/15 10/15 15/15 20/25 SELI, SELT 15 3
SELI, SELT,
• 20/25 TECL 15 3
• 15/20 15/20 30/30 40/50 SELI, SELT 15 4
SELI, SELT,
• 40/50 TECL 15 4

Basic and 25/40 24/40 40/60 60/75 SELI, SELT 24 4

LR SELI, SELT,
60/75 TECL 24 4
40/ 40/ 75/ SELI, SELT 24 4.5
/75 100/125 SFLI, SFLT 24 4.5
SELI, SELT,
75/100 TECL 24 4.5
100/ 150/ SFLI, SFLT 30 5.5
200/250 300/350 SGLI, SGLT 30 5.5 20 3
350/350 500/500 SKLI, SKLT 30 6 24 6
500/500 SGLI, SGLT 30 6 24 3.5

1. Section 2 will always be on the left and bottom mounted. All Space height is based on all main bus sizes.
2. When line reactors are not required consult factory for dimensions.
3. Pilot devices may impact the X height on certain plug-in HPs

Minimum UL short-circuit rating 65KAIC@ 480V

Minimum UL short-circuit rating 65KAIC @ 600V for all buckets rated 575/600 V
T E C H N I C A L A P P L I C AT I O N G U I D E 97

Adjustable speed drives

Space height and assembly

FC 102 and FC 302 space height, 100 kAIC

Max HP GP/FP CT/VT @ Section 1 Section 2

Function Plug-In Disconnect
208V 230/240V 380/415V 440/480V Width X Height(³) Width X Height(¹)
X 5/5 5/5 3/3 5/5 SEPI, SEPT 15 2.5
X 5/7.5 10/10 SEPI, SEPT 15 3
X 15/20 15/20 30/30 40/50 SEPI, SEPT 15 4
Basic, LR, 40/ 40/ SEPI, SEPT 30 5.5
Bypass
50/60 50/60 SFPI, SFPT 30 5.5
with
J-Fuse (2) 75/ 75/ SEPI, SEPT 24 5.5 15 1.5
100/125 SFPI, SFPT 24 5.5 15 1.5
100/125 150/200 SGPI, SGPT 36 4.5 15 3
200/250 300/350 SGPI, SGPT 36 5.5 30 4.5

1. Section 2 will always be on the left and bottom mounted. All Space height is based on all main bus sizes.
2. When line reactors are not required consult factory for dimensions.
3. Pilot devices may impact the X height on certain plug-in HPs

Minimum UL short-circuit rating 100KAIC@ 480V

Six pulse VFD generic block diagram

Rectifier Intermediate Inverter

(SCR/DIODES) Circuit Section (GBTs)

L1 T1
L2 T2
L3 T3

Power Section

Soft Charge Circuitry

Logic to Power Interface

Control Logic
98 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Adjustable speed drives

Drive configuration in motor control center construction

circuit breaker or fusible switch required for disconnect

STAB (2)

MCC BUS
(1)
CB REACTOR VFD (3) MOTOR
STANDARD VFD *

STAB (2)
MCC BUS

VFD WITH
(1)
LINE ISOLATION CB REACTOR VFD (3) MOTOR
*

STAB (2) OL
MCC BUS

VFD WITH (1)

CB REACTOR VFD (3) MOTOR
BYPASS FEATURE *

STAB (2) OL
MCC BUS

VFD WITH (1)

CB REACTOR VFD (3) MOTOR
LINE ISOLATION *
PLUS BYPASS FEATURE

1. Drawout breaker through 600A

2. J Fuse as required
3. DC link reactor (choke) included in drive

* Load filter option

T E C H N I C A L A P P L I C AT I O N G U I D E 99

Adjustable speed drives GEMActive Dynamic Current Injection Filters for

Harmonic filters harmonic cancellation and power factor correction:
• Reduce harmonics for IEEE 519 (1992) standard
ABB offers two basic filter types in MCC compliance
construction: Matrix and Dynamic Current • Decrease harmonic related overheating of cables,
Injection. Consult factory for sizing. switchgear and transformers
• Reduce downtime caused by nuisance thermal
Matrix Harmonic Filters provide broadband tripping of protective devices
reduction of harmonics. They not only offer better • Increase electrical network reliability and reduce
performance over other broadband filtering and operating costs
12- and 18-pulse harmonic reduction techniques, • Compensate each phase independently
they also are suitable for a wider range of • Are UL approved
applications. Matrix Harmonic Filters can be • Offer parallel connection for easy retrofit and
installed in either variable or constant torque drive installation of multiple units for large networks
applications and can be applied on either a six • Filter to the 50th order harmonic
pulse or half-controlled rectifier. For applications • Filter entire network or specific loads depending
other than variable torque, contact the factory for on installation point
filter selection. • Respond to load fluctuations in 40 microseconds
with 8 milliseconds for full response to step load
Matrix Harmonic Filters enable most AC drive changes
systems to comply with the voltage and current • Feature IGBT based power electronic technology
distortion limits outlined in IEEE 519. A complete • Come in 50, and 100A models for 208-480V,
harmonic analysis and product selection tool is 50/60 Hz, three phase networks that can be
available at www.gedigitalenergy.com. paralleled to match load requirements
Select Digital Energy > HV/MV Equipment >
Capacitors > LV Power Factor Correction > Matrix GEMActive reduces problematic harmonic
Harmonic Filter or simply use this “link”. levels and provides instantaneous power factor
correction. Cost savings result from reduced
Matrix Harmonic Filters are multi-stage low pass downtime and maintenance. In addition, over-
filters specially configured to avoid the attraction sizing of distribution equipment to provide for
of harmonics from other sources on a shared power harmonics and poor power factor can be avoided.
system. They will not cause power system
resonance. However, the configuration of the filter GEMActive dynamically corrects power
requires that only drives or equivalent loads be quality by providing: Active Harmonic Filtration,
loaded on the output. One filter can be used with Resonance Prevention, Power Factor Correction
multiple drives, but if there is a drive bypass circuit, and Dynamic VAR Compensation
there must be one filter per drive and the filter and
drive combination must
be bypassed.
100 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Adjustable speed drives VARIABLE CONSTANT CONSTANT

TORQUE TORQUE HORSEPOWER

TORQUE 100%

TORQUE 100%

TORQUE 100%
Motor application data

Harmonic derating
AC motors have traditionally been applied as SPEED HZ 100% SPEED HZ 100% SPEED HZ 100% 150%
constant speed motors, so there is little published
information on reduced speed efficiencies, HP = Required HP
TXN
especially when operated with a non-sinusoidal (1)HP = T = Torque in lb./ft.
5250
supply such as an inverter. The harmonics present N = Speed in RPM
in the PWM inverter output increase motor losses
and thus motor heating. Energy Saver motors,
Select the proper motor using the data from motor
designed for high efficiency and improved thermal
application brochures, identify the motor full load
characteristics, may be applied at nameplate rating
current and select the inverter which meets or
for variable torque duty, such as centrifugal fans
exceeds the motor full load current requirements.
and pumps, for 4 and 6 pole ratings. Standard AC
motors designed for 60 Hertz operation should be
2. Motor speed range
derated 10% for variable torque duty. For constant
Motor synchronous speed is determined by the
torque applications, Energy Saver and standard
following equation:
design motors should be applied per Figure 7.
For other applications refer to the Company. Frequency
120 X Applied
ENERGY $AVER TYPE KE
Sync. Motor Speed =
100
Number of Motor Poles
STANDARD K
Induction motors operate at a somewhat slower
% TORQUE

speed than synchronous speed due to slip, which

is generally 2-3 percent of synchronous speed.

If the application requirements call for higher or

lower speeds than can be obtained by using
0 100 150 standard motors following these application
% SPEED
— guidelines, gear increasers or reducers should
Figure 7 be considered.

How to select drives

3. Multi motor drives
1. Types of load
Multiple motors can be driven simultaneously by
In selecting inverters, load patterns of machines
one drive unit. In order to select the proper inverter,
should be known in advance. Generally, loads can
total the individual motor full load currents and
be categorized into the three types shown below.
multiply the sum by a factor of 1.1. Select the
Estimate or obtain the point marked 0 as indicated.
inverter than can deliver the total current
This defines maximum torque and the maximum
calculated. Each motor will require individual
or minimum speed requirement of the driven
overload relays, when switched independently RTF.
equipment. Calculate the required motor HP by
substituting the maximum torque and rated
motor base speed in equation (1).
T E C H N I C A L A P P L I C AT I O N G U I D E 101

4. Acceleration time Adjustable speed drives

Acceleration time is programmable. If the
programmed setting calls for a faster acceleration How to select drives (cont.)
than the drive system is capable of, the unit may 5. Deceleration Time
trip due to an overcurrent condition. Therefore, the Deceleration time is programmable. If the
actual time to accelerate the driven load should be programmed setting calls for faster deceleration
calculated using the following equation and the than the drive system is capable of, the unit may
acceleration time setting should be adjusted trip due to an overvoltage or overcurrent condition.
accordingly. Therefore, the actual time required to decelerate
the driven load should be calculated using the
(Wk 2 X ΔN)
TA= following equation and the deceleration time
308 (T X 1.2) setting should be adjusted accordingly.

Where:
TA = T
 ime to accelerate the driven load (Wk 2 X ΔN)
TD=
(in seconds). 308 (T X .2)
ΔN = Change in speed (in RPM)
WK2 = The total system inertia reflected to the
Where:
motor shaft. Includes motor, machine
TD = Time to decelerate the driven load
gears (in ft./lbs.2)
(in seconds).
T = Motor full load torque (lb./ft.)
ΔN = Change in speed (in RPM)
Wk2 = T he total system inertia reflected to the
When using a drive in a conventional constant motor Shaft. Includes motor, machine gears
speed machine application where a full voltage (in ft./lbs.2)
starter has been used, the acceleration time should T = Motor full load torque (lb./ft.)
be set longer than the original machine. This is
because the maximum allowable current that the If faster deceleration is required, refer
FC 302 drive can deliver is 150 percent of rated to the Company.
current, while full voltage starters deliver 600-800
percent. This means that the drive delivers a “soft
start” and thus reduces starting torque over that of
a full voltage starter, which naturally yields a longer
acceleration time.

MOTOR SPEED (MAX.)

MOTOR SPEED
(ZERO)
ACCELERATION TIME TIME

ADJUSTABLE
102 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Cable and motor considerations for drives Max. cable lengths between drive and motor without filters
A primary concern in recent years has been for
Motor insulation
wiring between adjustable speed drives and 1000V 1300V 1600V
level
motors. This is because voltage spiking, seen at FC 302 and FC 984 ft. 984 ft.
the motor terminals at the switching frequency 49 ft. (15M)
102 460V Input (300M) (300M)
can cause damage to the motor insulation. This FC 302 and FC 984 ft. 984 ft. 984 ft.
spiking depends on several factors such as drive 102 230V Input (300M) (300M) (300M)

input voltage level, drive output wave-form dv/dt, • PWM IGBT drives are not typically recommended
length of the cabling from the drive to the motor with 1000Vac insulation Motors
and characteristics of the cabling used, etc. In • Load filters are recommended from 984 ft.
addition, there are secondary effects related to when motor insulation level is 1300V or above
drive/motor wiring that impact performance • Custom motors are available for applications
such as parasitic capacitance. not listed
• Contact motor manufacturer or your
Drive input voltage, motor insulation and cable ABB sales representative
length are beyond the scope of the drive design.
Peak voltage insulation rating (horizontal, 60 Hzonly)
The following guidelines were compiled for
your convenience.
XSD-
Frame ODP-KE TEFC-KE XSD-KS ASD-KAF
IEEE841-KS
System filtering 140 1000V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
The use of a properly sized filter can reduce the 180 1000V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
voltage peaks and rise times seen at the motor. 210 1000V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
The filter must be properly sized and located. If 250 1000V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
the filtering is done with reactors it must be placed 280 1000V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
close to the motor terminals. If the filtering is with 320 1300V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
LRC (Inductance, Resistance and Capacitance) it 360 1300V P-P 1000V P-P 1300V P-P 1600V P-P 1600V P-P
must be placed at the output terminals of the drive.
400 1300V P-P 1300V P-P 1300V P-P 1600V P-P 1600V P-P

440 1300V P-P 1300V P-P 1300V P-P 1600V P-P 1600V P-P
Application consideration for drives:
500 1300V P-P 1300V P-P N/A 1600V P-P 1600V P-P

—
ODP = Open-Dripproof, TEFC = Totally Enclosed Fan-Cooled,
XSD = Extra Saver Duty, ASD = Adjustable Speed Drive

Caution: If existing motors are used,

condition of insulation must be checked
and manufacturers insulation rating as well.
Load filters may be required.
T E C H N I C A L A P P L I C AT I O N G U I D E 103

ASTAT XT Key features

• Ratings up to 1400Amps and up to 690VAC;
Digital soft starters for 3ph standard • Friendly multilanguage interface with two rows,
induction motors sixteen characters each;
ASTAT XT solid state soft starter features • Built-in with three extra power terminals for
microprocessor control digital technology. Setup external bypass;
and adjustment is performed through a six-button • In-Line or Inside-Delta operation modes;
keypad and parameters or messages are displayed • Torque control and pump control
out trough a friendly LCD multilanguage interface advanced features;
with two rows, sixteen alphanumeric characters • Motor protection according IEC 10, 20 and NEMA
each. The design includes isolated I/O and high 10, 20, 30, even if ASTAT XT is in bypass;
level of protection in their circuits to minimize the • Built-in communications RS485 port, and ModBus
disturbance effects while working in the hardest protocol as standard;
industrial environment. • ProfibusDP and DeviceNet optional interfaces for
communications.
ASTAT XT soft starter offers reliable performance
and smooth acceleration for a variety of standard
AC motors up to 1400A and up to 690V, reducing
mechanical shock to the driving system, resulting
in extended component and motor life. For units up to 820A. “U” type.

ASTAT XT offers many traditional features such a

motor overload function, adjustable ramps, current
limit, kick start, but also other high end features
like Inside-Delta operation, Torque control, Pump
control and a reliable motor and unit set of
protections.

— —
ASTAT XT ASTAT XT Control Panel
104 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT
Technical data

Ratings
230 to 500Vac +10%, -15% for QT1xxx units
Main voltage
460 to 600Vac +10%, -15% for QT2xxx units
3ph AC supply
690Vac +10%, -15% for QT3xxx units
Starter current rating
3ph AC motors From 8A up to 1400A
Motor current rating
3ph Induction motors Motor rated current from 50% to 100% of starter current
Control voltage
1ph AC supply 230VAC, +10, -15%, 50/60Hz or 110VAC, +10, -15%, 50/60Hz (optional)
Frequency range
50/60Hz systems Wide from 45Hz to 65Hz. Auto-tracking frequency range
Digital inputs voltage 90-230Vac, +10 -15%, 50/60Hz or 24Vdc, +10%, -15% (optional)
Control specifications
Control system Digital control with microcontroller. Starting ramp, with progressive increase in voltage and current limitation.
Operation mode In-Line (three wires) or Inside-Delta (six wires) of the motor
Run operation Soft Start and Soft stop by multiple choices, including torque control both at start or Stop phases
By LCD display, keypad and Indication
LEDs Display: LCD with two rows, 16 characters each
Operator interface Type: Multilanguage, dip-switch selectable for English, Italian, Spanish and German
Keys: Six keys, Mode, reset, Set, Select and Up / Down
LEDs: ON, Start, Run, Soft Stop, Stop, Save / Slow Speed, Dual Set / Reverse and Fault
Initial voltage 10-50% Un. Up to 80% with expanded settings function
Starting current 100-400% In. Can be extended up to 500%, by using extended settings
Acceleration
ramp time 1-30 sec. Can be extended up to 90 sec, by using extended settings
Deceleration
ramp time 1-30 sec. Can be extended up to 90 sec, by using extended settings
Current limitation 100-400% of motor rated current. Can be extended up to 500% by using extended settings
Bypass By external contactor while motor is full protected by ASTAT XT
Monitoring Motor current, line voltage, motor thermistor resistance, test and maintenance and statistics
Environmental conditions
Operating temperature -10°C up to 60ºC, with current derating by 2.5% per °C, from 50ºC
Storage temperature -20ºC up to 70ºC
Maximum altitude Up to 1000 mts. Ask your dealed for installation at higher altitude
Humidity 95% at 50ºC or 98% at 45ºC
Protection degree IP20 for units up to 72A, IP00 for units from 85A up to 1400A
Pollution degree Class 3
Standards
Global standards CE for the full trange. UL, cUL for specifi ed units up to 820A
EMC emissions EN 61000-6-4 CISPR 11 Class A
EN 61000-6-2 ESD 8KV air, IEC 801-2; Electric RF fi eld 10 V/m, 20-1000Mhz, IEC 801-3;
Immunity
Fast transients 2KV, IEC 801-4
Safety EN 600947-1 Related to safety requirements; UL508C
 T E C H N I C A L A P P L I C AT I O N G U I D E 105

ASTAT XT
Functions

Available Standard Functions

ASTAT XT is provided with a soft start and soft stop features, including fi ve independent acceleration and decelertaion curve
Soft Start and Soft
models. The factory default curve is used for general purpose, other three are used for pump control and the last one for torque
Stop
control.
Specific function for pump control, that avoids overpressure in the system at the end of acceleration phase and suppresses the
Pump Control
hammering at stopping phase.
Provides a smoth time controlled torque ramp acceleration and deceleration, with linear deceleration of the torque resulting in a
Torque Control
close to linear speed deceleration, thus eliminating stall conditions.
ASTAT XT allows either traditional Line operation or Inside Delta operation. When the ASTAT XT is installed to operate Inside Delta,
the individual phases of the starter are connected in series with the individual motor windings (six wiring connections like the
In Line / Inside Delta
Start-Delta starters), thus reducing the current x1.73, and allowing the use of a much smaller starter (x1.5 less than motor rated
current).
ASTAT XT allows bypass operation using an external contactor, controlled ON/OFF by starter function EOR (End Of Ramp).The
Bypass starter is provided with three dedicated power terminals to facilitate wirings to the bypass contactor. ASTAT XT protections to
motor are enabled, even in bypass.
This function allows to start high friction loads that require high starting torque for a short period of time. When this function is
Kick Start enabled, a pulse of 80% Un during an adjustable time from 0 to 1 sec. is given to the motor. After this pulse the output voltage is
ramping down to starting voltage setting, before ramping up again to full voltage.
Detects end of acceleration and outputs a signal by a dry relay contact. This signal can be delayed by an adjustable timer from
End of Ramp
0-120 sec.
Lock-out Allows to control the number of startings into a period of time, then protecting both motor and ASTAT.
By this function, ASTAT XT is able to control a secondary motor dual setting of starting voltage, starting current, durrent limit,
Dual Settings
ramp up, ramp down and motor current parameters can be selected by using one of the programmable ASTAT XT inputs.
Activated when the motor has a light load for extended periods of time, then reducing the output voltage level and decreasing the
Energy Saving
reactive current and motor copper/iron losses. This function can be enabled or disabled by dedicated parameters in ASTAT XT.
Function that allows the motor to run at 1/6 constant rated speed, for a short period of time of maximum 30 sec. This function
Slow Speed
supports forward and reverse operation.
This function allows the ASTAT XT automatic recover after a fault caused by undervoltage, undercurrent or phase lost. Auto-reset
Auto Reset
can be programed up to maximum 10 attempts.
Allows three methods of control for the ASTAT´s built-in cooling fans:
— Continuous operation
Cooling Fan Control
— Controlled by an external input
— Automatically OFF controlled, after five minutes ASTAT XT is stopped
This is a specific function useful when the starter is powered from a diesel generator rather than from commercial power supply.
Generator Supply The function is enabled by an internal dip switch, and helps to minimize the negative effects caused by the generator´s voltage
fluctuations during starting.
This function is enabled by means of starter´s internal dip switch, then locking the keypad. This is usefull to prevent undesired
Keypad Lock
parameter modifications.
Built-in ASTAT XT includes a ModBus RTU communications protocol. Communications are carried out through a half duplex RS485 port,
Communications with maximum baud rate of 9600, supporting up to 247 stations.
ASTAT XT records useful data for maintenance and start up:
— Last 10 trip events.
Statistic Data
— Statistical data like number of starts, number of trip events and elapsed RUN time.
— Last trip data information of motor current, starting current and acceleration time.
106 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT (continued)
Functions

Motor and Starter Protection

Overload Digital control with microcontroller. Starting ramp with progressive increase in voltage and current limitation.
Motor Thermistor In-Line (three wires) or Inside-Delta (six wires) of the motor.
Too Many Starts Soft start and soft stop by multiple choices, including torque control both at start or stop phases.
Long Start Time Trips if output voltage does not reach rated voltage at the preset maximum start time.
Trips under the following conditions:
— Instantaneously when current exceeds 8.5 x ASTAT XT current
O/C JAM Fault
— During starting when current exceeds 8.5 x motor current
— During running when current exceeds 200-850% of motor current, O/C JAM has a programmable triping delay of 0-5 sec.
Undercurrent Trips when line current drops below the preset level for the preset time.
Undervoltage Trips when line voltage drops below the preset level for the preset time.
Overvoltage Trips when line voltage increases above a preset level for a preset time.
Phase loss Trips if 1 or 2 phases are lost.
Frequency loss Trips if frequency is not in the range of 40-66.6 Hz.
Phase sequence Trips if line phase sequence is wrong.
Slow speed time Trips when operating at slow speed for extended periods.
Trips the ASTAT XT when one or more motor phases is not properly connected to ASTAT XT’s load terminals or if there is an internal
Wrong connection
disconnection in the motor winding.
Shorted SCR Trips and prevents starting if any SCR is short-circuited or when motor windings are shorted.
Over temperature Heat-sink over-temperature. Trips the ASTAT XT when the heat-sink temperature rises above 85°C.
External fault Trips the ASTAT XT when a NO contact between terminals 19-21 closes for over two seconds.
Wrong parameters Parameters not transferred from RAM to EEPROM or vice versa.
OC or wrong CON Trips when the ASTAT XT is connected Inside Delta and wrong connection or overcurrent is detected.
T E C H N I C A L A P P L I C AT I O N G U I D E 107

ASTAT XT
I/O Wiring, Basic Scheme

Note: Profibus or DeviceNet options cannot be

ordered separately. For those communication
networks, please order the ASTAT XT with the
required option built-in.
108 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Overload protections
Thermal characteristics

The ASTAT XT allows motor protection

according IEC Class 10 or Class 20 and NEMA 10,
20 or 30. User free selectable by ASTAT internal
dedicated parameter.

IEC Class
IEC 10
Class 10 IEC Class
IEC 20
Class 20
Sec. Sec. Sec. Sec.
10000 10000 10000 10000

1000 1000 1000 1000

100 100 100 100

COLD COLD
COLD COLD
10 10 10 10
HOT HOT HOT HOT

1 1 1 1
1.0 1.5 1.0
2.0 1.5
2.5 2.0
3.0 2.5
3.5 3.0
4.03.5
4.54.0
5.0 4.5
5.55.0
6.05.5
6.56.0
7.06.5 7.0 1.0 1.5 1.0
2.0 1.5
2.5 2.0
3.0 2.5
3.5 3.0
4.03.5
4.54.0
5.0 4.5
5.55.0
6.05.5
6.56.0
7.06.5 7.0
Multiples Multiples
of motor ofFLA
motor
Rating
FLAIn
Rating In Multiples Multiples
of motor ofFLA
motor
Rating
FLAIn
Rating In

10 Light
NEMA NEMA 10 Duty
Light Duty NEMA NEMA
20 20
Sec. Sec. Sec. Sec.
10000 10000 10000 10000

1000 1000 1000 1000

100 100 100 100

COLD COLD
COLD COLD
10 10 10 10

HOT HOT
HOT HOT
1 1 1 1
1.0 1.5 1.0
2.0 1.5
2.5 2.0
3.0 2.5
3.5 3.0
4.03.5
4.54.0
5.0 4.5
5.55.0
6.05.5
6.56.0
7.06.5 7.0 1.0 1.5 1.0
2.0 1.5
2.5 2.0
3.0 2.5
3.5 3.0
4.03.5
4.54.0
5.0 4.5
5.55.0
6.05.5
6.56.0
7.06.5 7.0
Multiples Multiples
of motor ofFLA
motor
Rating
FLAIn
Rating In Multiples Multiples
of motor ofFLA
motor
Rating
FLAIn
Rating In

NEMA NEMA
30 30
Sec. Sec. Maximum Number Starting/Hour
10000 10000

Starting Current Ramp Time

I/In¹ 10s 20s 30s
1000 1000
2 24 12 8

3 16 8 5
100 100
COLD COLD 4 12 6 4

1. In= rated current of ASTAT XT in the specified class IEC/NEMA

10 10

HOT HOT
1 1
1.0 1.5 1.0
2.0 1.5
2.5 2.0
3.0 2.5
3.5 3.0
4.03.5
4.54.0
5.0 4.5
5.55.0
6.05.5
6.56.0
7.06.5 7.0
Multiples Multiples
of motor ofFLA
motor
Rating
FLAIn
Rating In
T E C H N I C A L A P P L I C AT I O N G U I D E 109

ASTAT BP

Digital soft starters for 3ph AC induction motors

The ASTAT BP soft starter delivers reliable
performance and smooth acceleration and
deceleration on 3 phase AC induction motors from
8A-1100A at 208V-400V or 460V-600V. It reduces
mechanical wear and tear on motors and also can
reduce peak energy demands by limiting the
current to motors at startup.

Features
• Offers current and torque control
• Has multiple soft start and stop curves to meet
a variety of applications
• Comes with built in NEMA Class 10, 20, 30 or IEC —
Class 10 or 20 overload ASTAT BP

• Features full text programming

Ratings
• Current ratings
- 8A, 17A, 31A, 44A, 58A, 72A, 85A, 105A, 145A,
170A, 210A, 240A, 310A, 360A, 414A, 477A, 515A,
590A, 720A, 840A, 960A, 1100A
• Line voltage
- 3ph, 208V to 440V, 50/60Hz (QB1x)
3ph, 460V to 600V, 50/60Hz (QB2x)
• Frequency range
- 45Hz-65Hz, auto-tracking frequency range
• Control voltage
- 120V or 240V, +10% / -15%
(specified at through catalog number)

Environmental conditions
• Networks
- Modbus RTU as standard
• Standards
- UL and cUL
• Ambient Temperature
- -10ºC to 50ºC
• Altitude
- 3300ft or 1000m (consult factory)
• Protection degree
- Open Chassis / IP20 to 44A,
Open Chassis / IP00 58A and above
110 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT BP
Technical data

General information
Supply voltage Line to line 208-600V (to be specified) + 10%-15%
Frequency 45 – 65 Hz (fixed or variable frequency source)
Control supply Either 110VAC or 230VAC (to be specified) +10% - 15%
Control inputs Either 90-230VAC - Must be the same as Control Supply
Load Three phases, three/six wires, squirrel cage induction motor
Connection type Standard 3 wire U, V, W connection, or 6 wire Inside Delta (programmable)
Rated insulation voltage 1,000V
Rated impulse voltage 4kV
Form designation Form 1 (Bypassed Controller)
Start-stop parameters
Starter current ASTAT-BP’s rated current according to its nameplate
Motor current Motor Full Load Ampere of Starter Current
Start/stop curve
2 standard starting and stopping curves
0 (standard)
Pump control
6 field selectable curves preventing over-pressure during start and water hammer during stop
curves (1!, 2!, 3!)
2 selectable curves preventing over-pressure during start and water hammer during stop. In addition, these curves may be used
Torque control curve (4)
for torque control starting of constant torque applications
Kick start duration A pulse of 80% Un, for an adj. time 0.1-1 Sec, for starting high friction loads
Starting voltage 10-50% Un (5-80%)
100-400% In. A single current control starting curve. It appears when Starting Voltage is displayed, the up arrow is pressed and
Initial current
Starting Voltage has reached its max.
Current limit 100-700% of Motor Current
Ramp UP time 1-30 Sec (1-90 sec)
Ramp DOWN time 1-30 Sec (1-90 sec)
DUAL settings Secondary start stop characteristic for: Starting Voltage, Starting Current, Current Limit, Ramp UP, Ramp DOWN and Motor
parameters Current
Slow speed torque Torque while motor is at 1/6 nominal speed
Motor protection
Too many starts Maximum number of starts, range: Off or 1-10, during a time period 1-60 min.
Starts inhibit Time period 1-60 min, when starting is prevented, after too many starts fault
Long start time
Maximum allowable starting time 1-30 sec. (1-250 sec)
(stall protection)
Three trip functions:
1. At all time
If I > 850% of Starter Current (Ir) it trips the ASTAT-BP within 1 cycle (overrides the value of the O/C – JAM Delay setting).
Over current (JAM Fault) 2. At starting process
If I > 850% of Motor Current it trips the ASTAT-BP after O/C JAM Delay (see here after)
3. At run time
If I > O/C – JAM Fault setting of Im it trips the ASTAT-BP after O/C JAM Delay
Can be set as IEC Class 10, 20 or NEMA Class 10, 20 or 30.
Electronic overload
Can be set to operate at all times, disabled or operate during Run only.
Under current Trips when current drops below 20-90% of Motor Current, time delay 1-40 sec. Optional auto reset after time delay
Under voltage Trips when main voltage drops below 50-90% of Line Voltage, time delay 1-10 sec. Optional Auto Reset.
Over voltage 4Trips when main voltage increase above 110-125% of Line Voltage, time delay 1-10 sec.
Phase loss,
Trips when one or two phases are missing, or frequency is < 40Hz or > 65Hz. Optional auto reset.
Under/over frequency
Phase sequence Trips when phase sequence is wrong
Long slow speed time Trips if operating at slow speed TRQ for more than 1-30 sec (1-250 sec)
Prevents starting, trips if motor is not connected / incorrectly connected to the ASTAT-BP
Wrong connection
(not active in D.Set: Generator Parameters)
Shorted SCR Trips if one or more SCRs have been shorted (not active in D.Set: Generator Parameters)
Heat sink over
Trips when heat-sink temperature rises above 85°C
temperature
External fault Trips when an external contact closes for 2 sec.
Motor thermistor Trip level setting 1-10K, trips when resistance decreases below the level set
 T E C H N I C A L A P P L I C AT I O N G U I D E 111

ASTAT BP
Technical data (continued)

Control
Displays LCD in 4 – Field selectable languages and 8 LEDs
Keypad 6 keys for easy setting
Aux contact –
1 NO, 8A, 250VAC, 2000VA
programmable
Fault contact 1 NO, 8A, 250VAC, 2000VA
Communication RS 485 with Modbus protocol for full control and supervision
Communication Profibus DPV1 for full control and supervision
(optional) DeviceNett for full control and supervision
Temperatures operating -10° to 60°C; For ambient temperature between 50°C and 60°C, derate the current by 2.5% for each °C that is above 50°C
Storage -20° to 70°C
Standards
Dielectric test 2500VAC
Degree of protection IP 20 for QBx0008 - QBx0044 ; IP 00 for QBx0058 – QTx1100
Pollution degree 3
EMC emissions EN 61000-6-4 CISPR 11 Class A
EN 61000-6-2 ESD 8KV air, IEC 801-2;
Immunity Electric RF field 10 V/m, 20-1000Mhz, IEC 801-3
Fast transients 2KV, IEC 801-4
Safety UL508C
Rated operational current AC:53a:3.5-30: 50-4
Normal service
conditions
Altitude Up to 1000m
Humidity 95% at 50°C or 98% at 45°C
Fan and control
consumption ratings
QBx0008 to QBx0170
Total approximate consumption: 35VA
— No fan
QBx0210 to QBx0477
Total approximate consumption: 85VA
— Fans 50 VA
QBx0515 to QBx0840
Total approximate consumption: 100VA
— Fan 50 VA
QBx0960 to QBx1100
Total approximate consumption: 160VA
— Fans 110 VA
112 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size /current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SELT 2 2 5 5 65 15" 2
0017 SELT 3 5 10 15 65 15" 2
0031 SELT 7.5 10 20 25 65 15" 2
0044 SELT 10 15 30 40 65 15" 2.5
Stab
0058 SELT 15 20 40 50 65 15" 2.5
0072 SELT 20 25 50 60 65 15" 2.5
0085 SELT 25 30 60 75 65 20" 3
ASTAT XT 0105 SELT 30 40 75 100 65 20" 3
with no
features 0145 SFLT 40 50 100 150 65 20" 3
0210 SFLT 50 60 125 150 65 20" 3
0310 SFLT 60 75 150 200 65 20" 3
0390 SGLT 100 100 250 300 65 20" 3
Stationery
0460 SGLT 125 150 300 400 65 20" 3
0580 SGLT 150 150 350 400 65 30" 4.5
0650 SGLT 200 200 400 400 65 30" 4.5
0820 SKLT 200 250 500 500 65 20" + 30" 4.5 + 3
0008 SELT 2 2 5 5 100 15" 2
0017 SELT 3 5 10 15 100 15" 2
0031 SELT 7.5 10 20 25 100 15" 2
0044 SELT 10 15 30 40 100 15" 2.5
Stab
0058 SELT 15 20 40 50 100 15" 2.5
0072 SELT 20 25 50 60 100 15" 2.5
0085 SELT 25 30 60 75 100 20" 3.5
ASTAT XT 0105 SELT 30 40 75 100 100 20" 3.5
with no
features 0145 SFLT 40 50 100 150 100 20" 4
and J fuses 0210 SFLT 50 60 125 150 100 20" 4
0310 SFLT 60 75 150 200 100 20" 4
0390 SGLT 100 100 250 300 100 20" 4
Stationery 0460 SGLT 125 150 300 400 100 20" 4
0580 SGLT 150 150 350 400 100 30" 5.5
0650 SGLT 200 200 400 400 100 30" 5.5
SKLT and L
0820 200 250 500 500 100 20" + 30" 4.5 + 4.5
Fuses

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
 T E C H N I C A L A P P L I C AT I O N G U I D E 113

ASTAT XT – Type 1

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEL*/SEP* 2 5 5 65 15" 2
0017 SEL*/SEP* 5 10 15 65 15" 2
0031 SEL*/SEP* 10 20 25 65 15" 2
Stab
0044 SEL*/SEP* 15 30 40 65 15" 3
0058 SEL*/SEP* 20 40 50 65 15" 3
0072 SEL*/SEP* 25 50 60 65 15" 3
0085 SEL*/SEP* 30 60 75 65 20" 3
ASTAT XT 0105 SEL*/SEP* 40 75 100 65 20" 3
with no
features 0145 SFL*/SFP* 50 100 150 65 20" 3
0170 SFL*/SFP* 60 125 150 65 20" 3
0210 SFL*/SFP* 75 150 200 65 20" 4
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 4
0390 SGL*/SGP* 150 300 400 65 20" 4
0460 SGL*/SGP* 150 350 400 65 30" 4.5
0580 SKL*/SKP* 200 400 400 65 30"+20" 4.5+3
0820 SKL*/SKP* 250 500 500 65 30"+20" 4.5+3
0008 SEL*/SEP* 2 5 5 65 15" 2.5
Stab 0017 SEL*/SEP* 5 10 15 65 15" 2.5
0031 SEL*/SEP* 10 20 25 65 15" 2.5
0044 SEL*/SEP* 15 30 40 65 20" 2.5
0058 SEL*/SEP* 20 40 50 65 20" 2.5
0072 SEL*/SEP* 25 50 60 65 20" 2.5
0085 SEL*/SEP* 30 60 75 65 20" 3.5
ASTAT XT 0105 SEL*/SEP* 40 75 100 65 20" 3.5
with bypass
feature 0145 SFL*/SFP* 50 100 150 65 20" 3.5
Stationery 0170 SFL*/SFP* 60 125 150 65 20" 3.5
0210 SFL*/SFP* 75 150 200 65 20" 5.5
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30"+20" 6+2
0580 SKL*/SKP* 200 400 400 65 30"+20" 6+4
0820 SKL*/SKP* 250 500 500 65 30"+20" 6+4
0008 SEMCS 2 5 5 100 15" 2.5
0017 SEMCS 5 10 15 100 15" 2.5
0031 SEMCS 10 20 25 100 15" 2.5
Stab
0044 SEMCS 15 30 40 100 15" 2.5
0058 SEMCS 20 40 50 100 15" 2.5
0072 SEMCS 25 50 60 100 15" 2.5
ASTAT 0085 SEMCS 30 60 75 100 20" 4
XT with 0105 SEMCS 40 75 100 100 20" 4
bypass and
J or L fuse 0145 SFMCS 50 100 150 100 20" 4
feature 0170 SFMCS 60 125 150 100 20" 4
0210 SFMCS 75 150 200 100 20" 6
Stationery
0310 SFMCS 100 250 300 100 20" 6
0390 SGMCS 150 300 400 100 20" 6
0460 SGMCS 150 350 400 100 30"+20" 6+3
0580 SKMCS 200 400 400 65 30"+20" 6+5.5
0820 SKMCS 250 500 500 65 30"+20" 6+5.5

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
114 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT – Type 1 (continued)

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEL*/SEP* 2 5 5 65 15" 2.5
0017 SEL*/SEP* 5 10 15 65 15" 2.5
0031 SEL*/SEP* 10 20 25 65 15" 2.5
Stab
0044 SEL*/SEP* 15 30 40 65 15" 2.5
0058 SEL*/SEP* 20 40 50 65 15" 2.5
0072 SEL*/SEP* 25 50 60 65 15" 2.5
0085 SEL*/SEP* 30 60 75 65 20" 3.5
ASTAT XT
with ISO 0105 SEL*/SEP* 40 75 100 65 20" 3.5
and bypass 0145 SFL*/SFP* 50 100 150 65 20" 3.5
feature
0170 SFL*/SFP* 60 125 150 65 20" 3.5
0210 SFL*/SFP* 75 150 200 65 20" 5.5
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30"+20" 6+2
0580 SKL*/SKP* 200 400 400 65 30"+20" 6+4
0820 SKL*/SKP* 250 500 500 65 30"+20" 6+4
0008 SEMCS 2 5 5 100 15" 2.5
0017 SEMCS 5 10 15 100 15" 2.5
0031 SEMCS 10 20 25 100 15" 2.5
Stab
0044 SEMCS 15 30 40 100 15" 3
0058 SEMCS 20 40 50 100 15" 3
0072 SEMCS 25 50 60 100 15" 3
ASTAT XT 0085 SEMCS 30 60 75 100 20" 4
with ISO, 0105 SEMCS 40 75 100 100 20" 4
bypass and
J or L fuse 0145 SFMCS 50 100 150 100 20" 4
feature 0170 SFMCS 60 125 150 100 20" 4
0210 SFMCS 75 150 200 100 20" 6
Stationery
0310 SFMCS 100 250 300 100 20" 6
0390 SGMCS 150 300 400 100 20" 6
0460 SGMCS 150 350 400 100 30"+20" 6+3
0580 SKMCS 200 400 400 65 30"+20" 6+5.5
0820 SKMCS 250 500 500 65 30"+20" 6+5.5
0008 SEL*/SEP* 2 5 5 65 15" 2
0017 SEL*/SEP* 5 10 15 65 15" 2
0031 SEL*/SEP* 10 20 25 65 15" 2
Stab
0044 SEL*/SEP* 15 30 40 65 15" 2.5
0058 SEL*/SEP* 20 40 50 65 15" 2.5
0072 SEL*/SEP* 25 50 60 65 15" 2.5
0085 SEL*/SEP* 30 60 75 65 20" 3
ASTAT XT 0105 SEL*/SEP* 40 75 100 65 20" 3
with ISO
feature 0145 SFL*/SFP* 50 100 150 65 20" 3
0170 SFL*/SFP* 60 125 150 65 20" 3
0210 SFL*/SFP* 75 150 200 65 20" 5.5
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30" 5.5
0580 SKL*/SKP* 200 400 400 65 30"+20" 6+3
0820 SKL*/SKP* 250 500 500 65 30"+20" 6+3

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
 T E C H N I C A L A P P L I C AT I O N G U I D E 115

ASTAT XT – Type 1 (continued)

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEMCS 2 5 5 100 15" 2
0017 SEMCS 5 10 15 100 15" 2
0031 SEMCS 10 20 25 100 15" 2
Stab
0044 SEMCS 15 30 40 100 15" 2.5
0058 SEMCS 20 40 50 100 15" 2.5
0072 SEMCS 25 50 60 100 15" 2.5
0085 SEMCS 30 60 75 100 20" 3.5
ASTAT XT
with ISO and 0105 SEMCS 40 75 100 100 20" 3.5
J or L fuse 0145 SFMCS 50 100 150 100 20" 3.5
feature
0170 SFMCS 60 125 150 100 20" 3.5
0210 SFMCS 75 150 200 100 20" 6
Stationery
0310 SFMCS 100 250 300 100 20" 6
0390 SGMCS 150 300 400 100 20" 6
0460 SGMCS 150 350 400 100 30"+20" 5+2.5
0580 SKMCS 200 400 400 65 30"+20" 5+4.5
0820 SKMCS 250 500 500 65 30"+20" 5+4.5
0008 SEMCS 2 5 5 100 15" 2
0017 SEMCS 5 10 15 100 15" 2
0031 SEMCS 10 20 25 100 15" 2
Stab
0044 SEMCS 15 30 40 100 15" 2.5
0058 SEMCS 20 40 50 100 15" 2.5
0072 SEMCS 25 50 60 100 15" 2.5
0085 SEMCS 30 60 75 100 20" 3.5
ASTAT XT 0105 SEMCS 40 75 100 100 20" 3.5
with J or L
fuse feature 0145 SFMCS 50 100 150 100 20" 3.5
0170 SFMCS 60 125 150 100 20" 3.5
0210 SFMCS 75 150 200 100 20" 4
Stationery
0310 SFMCS 100 250 300 100 20" 4
0390 SGMCS 150 300 400 100 20" 4
0460 SGMCS 150 350 400 100 30" 5.5
0580 SKMCS 200 400 400 65 30"+20" 4.5+4.5
0820 SKMCS 250 500 500 65 30"+20" 4.5+4.5

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
116 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT – Type 12

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEL*/SEP* 2 5 5 65 15" 2
0017 SEL*/SEP* 5 10 15 65 15" 2
0031 SEL*/SEP* 10 20 25 65 15" 2
Stab
0044 SEL*/SEP* 15 30 40 65 15" 3
0058 SEL*/SEP* 20 40 50 65 15" 3
0072 SEL*/SEP* 25 50 60 65 15" 3
0085 SEL*/SEP* 30 60 75 65 20" 4
ASTAT XT 0105 SEL*/SEP* 40 75 100 65 20" 4
with no
fFeatures 0145 SFL*/SFP* 50 100 150 65 20" 4
0170 SFL*/SFP* 60 125 150 65 20" 4
0210 SFL*/SFP* 75 150 200 65 20" 5.5
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30" 7.5
0580 SKL*/SKP* 200 400 400 65 30" 7.5
0820 SKL*/SKP* 250 500 500 65 30" 7.5
0008 SEL*/SEP* 2 5 5 65 15" 2.5
0017 SEL*/SEP* 5 10 15 65 15" 2.5
0031 SEL*/SEP* 10 20 25 65 15" 2.5
Stab
0044 SEL*/SEP* 15 30 40 65 20" 3
0058 SEL*/SEP* 20 40 50 65 20" 3
0072 SEL*/SEP* 25 50 60 65 20" 3
0085 SEL*/SEP* 30 60 75 65 20" 3.5
ASTAT XT
0105 SEL*/SEP* 40 75 100 65 20" 3.5
with bypass
feature 0145 SFL*/SFP* 50 100 150 65 20" 3.5
0170 SFL*/SFP* 60 125 150 65 20" 3.5
0210 SFL*/SFP* 75 150 200 65 20" 5.5
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30"+20" 6+2
0580 SKL*/SKP* 200 400 400 65 30"+20" 6+4
0820 SKL*/SKP* 250 500 500 65 30"+20" 6+4
0008 SEMCS 2 5 5 100 15" 2.5
0017 SEMCS 5 10 15 100 15" 2.5
0031 SEMCS 10 20 25 100 15" 2.5
Stab
0044 SEMCS 15 30 40 100 15" 2.5
0058 SEMCS 20 40 50 100 15" 2.5
0072 SEMCS 25 50 60 100 15" 2.5
0085 SEMCS 30 60 75 100 20" 4
ASTAT XT
with bypass 0105 SEMCS 40 75 100 100 20" 4
and J or L 0145 SFMCS 50 100 150 100 20" 4
fuse feature
0170 SFMCS 60 125 150 100 20" 4
0210 SFMCS 75 150 200 100 20" 6
Stationery
0310 SFMCS 100 250 300 100 20" 6
0390 SGMCS 150 300 400 100 20" 6
0460 SGMCS 150 350 400 100 30"+20" 6+3
0580 SKMCS 200 400 400 65 30"+20" 6+5.5
0820 SKMCS 250 500 500 65 30"+20" 6+5.5

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
 T E C H N I C A L A P P L I C AT I O N G U I D E 117

ASTAT XT – Type 12 (continued)

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEL*/SEP* 2 5 5 65 15" 2.5
0017 SEL*/SEP* 5 10 15 65 15" 2.5
0031 SEL*/SEP* 10 20 25 65 15" 2.5
Stab
0044 SEL*/SEP* 15 30 40 65 15" 2.5
0058 SEL*/SEP* 20 40 50 65 15" 2.5
0072 SEL*/SEP* 25 50 60 65 15" 2.5
0085 SEL*/SEP* 30 60 75 65 20" 3.5
ASTAT XT
with ISO 0105 SEL*/SEP* 40 75 100 65 20" 3.5
and bypass 0145 SFL*/SFP* 50 100 150 65 20" 3.5
feature
0170 SFL*/SFP* 60 125 150 65 20" 3.5
0210 SFL*/SFP* 75 150 200 65 20" 5.5
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30"+20" 6+2
0580 SKL*/SKP* 200 400 400 65 30"+20" 6+4
0820 SKL*/SKP* 250 500 500 65 30"+20" 6+4
0008 SEMCS 2 5 5 100 15" 2.5
0017 SEMCS 5 10 15 100 15" 2.5
0031 SEMCS 10 20 25 100 15" 2.5
Stab
0044 SEMCS 15 30 40 100 15" 3
0058 SEMCS 20 40 50 100 15" 3
0072 SEMCS 25 50 60 100 15" 3
ASTAT XT 0085 SEMCS 30 60 75 100 20" 4
with ISO, 0105 SEMCS 40 75 100 100 20" 4
bypass and
J or L fuse 0145 SFMCS 50 100 150 100 20" 4
feature 0170 SFMCS 60 125 150 100 20" 4
0210 SFMCS 75 150 200 100 20" 6
Stationery
0310 SFMCS 100 250 300 100 20" 6
0390 SGMCS 150 300 400 100 20" 6
0460 SGMCS 150 350 400 100 30"+20" 6+3
0580 SKMCS 200 400 400 65 30"+20" 6+5.5
0820 SKMCS 250 500 500 65 30"+20" 6+5.5
0008 SEL*/SEP* 2 5 5 65 15" 2
0017 SEL*/SEP* 5 10 15 65 15" 2
0031 SEL*/SEP* 10 20 25 65 15" 2
Stab
0044 SEL*/SEP* 15 30 40 65 15" 3
0058 SEL*/SEP* 20 40 50 65 15" 3
0072 SEL*/SEP* 25 50 60 65 15" 3
0085 SEL*/SEP* 30 60 75 65 20" 4
ASTAT XT 0105 SEL*/SEP* 40 75 100 65 20" 4
with ISO
feature 0145 SFL*/SFP* 50 100 150 65 20" 4
0170 SFL*/SFP* 60 125 150 65 20" 4
0210 SFL*/SFP* 75 150 200 65 20" 5.5
Stationery
0310 SFL*/SFP* 100 250 300 65 20" 5.5
0390 SGL*/SGP* 150 300 400 65 20" 5.5
0460 SGL*/SGP* 150 350 400 65 30"+20" 7.5+2.5
0580 SKL*/SKP* 200 400 400 65 30"+20" 7.5+3
0820 SKL*/SKP* 250 500 500 65 30"+20" 7.5+3

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
118 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT – Type 12 (continued)

Power unit Circuit Horsepower(¹)

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating Frame
0008 SEMCS 2 5 5 100 15" 2
0017 SEMCS 5 10 15 100 15" 2
0031 SEMCS 10 20 25 100 15" 2
Stab
0044 SEMCS 15 30 40 100 15" 3
0058 SEMCS 20 40 50 100 15" 3
0072 SEMCS 25 50 60 100 15" 3
0085 SEMCS 30 60 75 100 20" 4
ASTAT XT
with ISO and 0105 SEMCS 40 75 100 100 20" 4
J or L fuse 0145 SFMCS 50 100 150 100 20" 4
feature
0170 SFMCS 60 125 150 100 20" 4
0210 SFMCS 75 150 200 100 20" 5.5
Stationery
0310 SFMCS 100 250 300 100 20" 5.5
0390 SGMCS 150 300 400 100 20" 5.5
0460 SGMCS 150 350 400 100 30"+20" 7.5+2.5
0580 SKMCS 200 400 400 65 30"+20" 7.5+4.5
0820 SKMCS 250 500 500 65 30"+20" 7.5+4.5
0008 SEMCS 2 5 5 100 15" 2
0017 SEMCS 5 10 15 100 15" 2
0031 SEMCS 10 20 25 100 15" 2
Stab
0044 SEMCS 15 30 40 100 15" 3
0058 SEMCS 20 40 50 100 15" 3
0072 SEMCS 25 50 60 100 15" 3
0085 SEMCS 30 60 75 100 20" 4
ASTAT XT 0105 SEMCS 40 75 100 100 20" 4
with J or L
fuse feature 0145 SFMCS 50 100 150 100 20" 4
0170 SFMCS 60 125 150 100 20" 4
0210 SFMCS 75 150 200 100 20" 5.5
Stationery
0310 SFMCS 100 250 300 100 20" 5.5
0390 SGMCS 150 300 400 100 20" 5.5
0460 SGMCS 150 350 400 100 30"+20" 7.5+2.5
0580 SKMCS 200 400 400 65 30"+20" 7.5+4.5
0820 SKMCS 250 500 500 65 30"+20" 7.5+4.5

1. All ratings are based on a selection of Normal Duty or Class 20 overloads. See operators guide for more rating options.
 T E C H N I C A L A P P L I C AT I O N G U I D E 119

ASTAT BP

Power unit Circuit Horsepower

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEL*/SEP* 2 5 5 65 15" 1.5
0017 SEL*/SEP* 5 10 15 65 15" 1.5
0031 SEL*/SEP* 10 20 25 65 15" 1.5
0044 SEL*/SEP* 15 30 40 65 15" 1.5
0058 SEL*/SEP* 20 40 50 65 15" 2
Stab
0072 SEL*/SEP* 25 50 60 65 15" 2
0085 SEL*/SEP* 30 60 75 65 15" 2.5
0105 SEL*/SEP* 40 75 100 65 15" 2.5
ASTAT BP 0145 SFL*/SFP* 50 100 125 65 15" 2.5
with no
features 0170 SFL*/SFP* 60 125 150 65 15" 2.5
0210 SGL*/SGP* 75 150 200 65 20" 3.5
0240 SGL*/SGP* 100 200 250 65 20" 3.5
0310 SGL*/SGP* — 250 300 65 20" 3.5
0360 SGL*/SGP* 125 300 350 65 24" 4
Stationery
0414 SGL*/SGP* 150 350 400 65 24" 4
0477 SGL*/SGP* — 400 450 65 24" 4
0515 SKL*/SKP* 200 450 500 65 24" 6
0590 SKL*/SKP* — 500 600 65 24" 6
0008 SEL*/SEP* 2 5 5 65 15" 2
0017 SEL*/SEP* 5 10 15 65 15" 2
0031 SEL*/SEP* 10 20 25 65 15" 2
0044 SEL*/SEP* 15 30 40 65 15" 2
0058 SEL*/SEP* 20 40 50 65 15" 2
Stab
0072 SEL*/SEP* 25 50 60 65 15" 2
0085 SEL*/SEP* 30 60 75 65 15" 2.5
0105 SEL*/SEP* 40 75 100 65 15" 2.5
ASTAT BP 0145 SFL*/SFP* 50 100 125 65 15" 3
with ISO
features 0170 SFL*/SFP* 60 125 150 65 15" 3
0210 SGL*/SGP* 75 150 200 65 20" 5
0240 SGL*/SGP* 100 200 250 65 20" 5
0310 SGL*/SGP* — 250 300 65 20" 5
0360 SGL*/SGP* 125 300 350 65 24" 5
Stationery
0414 SGL*/SGP* 150 350 400 65 24" 5
0477 SGL*/SGP* — 400 450 65 24" 5
0515 SKL*/SKP* 200 450 500 65 24"+20" 5.5+2
0590 SKL*/SKP* — 500 600 65 24"+20" 5.5+2
0008 SEMCS 2 5 5 100 15" 2
0017 SEMCS 5 10 15 100 15" 2
0031 SEMCS 10 20 25 100 15" 2
0044 SEMCS 15 30 40 100 15" 2
0058 SEMCS 20 40 50 100 15" 2
Stab
0072 SEMCS 25 50 60 100 15" 2
0085 SEMCS 30 60 75 100 15" 2.5

ASTAT BP 0105 SEMCS 40 75 100 100 15" 2.5

with ISO and 0145 SFMCS 50 100 125 100 15" 3.5
J or L fuse 0170 SFMCS 60 125 150 100 15" 3.5
features SGMCS 75 150 200 100 20" 6
0210
0240 SGMCS 100 200 250 100 20" 6
0310 SGMCS — 250 300 100 24" 6
0360 SGMCS 125 300 350 100 24" 6
Stationery
0414 SGMCS 150 350 400 100 24" 5.5
0477 SGMCS — 400 450 100 24" 5.5
0515 SKMCS 200 450 500 65 24"+20" 5.5+4.5
0590 SKMCS — 500 600 65 24"+20" 5.5+4.5
120 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT BP (continued)

Power unit Circuit Horsepower

IC (kA) @ Section
Starter type and feature size/current breaker X-height
200V 230V 460V 575V 460V width
rating frame
0008 SEMCS 2 5 5 100 15" 2
0017 SEMCS 5 10 15 100 15" 2
0031 SEMCS 10 20 25 100 15" 2
0044 SEMCS 15 30 40 100 15" 2
0058 SEMCS 20 40 50 100 15" 2
Stab
0072 SEMCS 25 50 60 100 15" 2
0085 SEMCS 30 60 75 100 15" 2.5
0105 SEMCS 40 75 100 100 15" 2.5
ASTAT
BP with J 0145 SFMCS 50 100 125 100 15" 3
or L fuse 0170 SFMCS 60 125 150 100 15" 3
fFeatures
0210 SGMCS 75 150 200 100 20" 5
0240 SGMCS 100 200 250 100 20" 5
0310 SGMCS — 250 300 100 20" 5
0360 SGMCS 125 300 350 100 24" 5
Stationery
0414 SGMCS 150 350 400 100 24" 5
0477 SGMCS — 400 450 100 24" 5
0515 SKMCS 200 450 500 65 24"+20" 5.5+4.5
0590 SKMCS — 500 600 65 24"+20" 5.5+4.5
 T E C H N I C A L A P P L I C AT I O N G U I D E 121

Solid-state starters
Standard reduced-voltage, nonreversing with primary disconnect

ASTAT-BP integrated by-pass space requirement

Power Horsepower
Circuit
unit size IC (kA) @ Section
Starter type and feature breaker X-height
/ current 200V 230V 460V 575V 460V width
frame
rating
0058 SELT 15 20 40 50 42 20" 3
0072 SELT 20 25 50¹ 60 42 20" 3
Stab
0085 SELT 25 25 60¹ 75 42 20" 3
0105 SELT 30 30 75 75 65 20" 3
0145 SFLT 40 50 100 125 65 20" 4
ASTAT-BP
0170 SGLT 50 60 125 150 65 20" 5
0210 SGLT 60 75 150 200 65 24" 5
Stationery
0240 SGLT 75 100 200² 300 65 24"+ 20" 4 + 2.5
0310 SGLT 100 100 250³ 300 65 24"+ 20" 4 + 2.5
0360 SGLT 125 150 300³ 350 65 24"+ 20" 4 + 2.5
0058 SELT 15 20 40 50 100 20" 3.5
0072 SELT 20 25 50¹ 60 100 20" 3.5
Stab
0085 SELT 25 25 60¹ 75 100 20" 3.5
0105 SELT 30 30 75 75 100 20" 3.5
ASTAT-BP 0145 SFLT 40 50 100 125 100 20" 4
with
J fuses 0170 SGLT 50 60 125 150 100 20" 5
0210 SGLT 60 75 150 200 100 24" 5.5
Stationery
0240 SGLT 75 100 200² 300 100 24"+ 20" 5 + 2.5
0310 SGLT 100 100 250³ 300 100 24"+ 20" 5 + 2.5
0360 SGLT 125 150 300³ 350 100 24"+ 20" 5 + 2.5
0058 SELT 15 20 40 50 100 20" 3.5
0072 SELT 20 25 50¹ 60 100 20" 3.5
Stab
0085 SELT 25 25 60¹ 75 100 20" 3.5
0105 SELT 30 30 75 75 100 20" 3.5
ASTAT-BP
with 0145 SFLT 40 50 100 125 100 20" 4.5
isolation 0170 SGLT 50 60 125 150 100 20" 5
and J fuse
0210 SGLT 60 75 150 200 100 24" 5 + 2.5
Stationery
0240 SGLT 75 100 200² 300 100 24"+ 20" 5 + 2.5
0310 SGLT 100 100 250³ 300 100 24"+ 20" 5 + 2.5
0360 SGLT 125 150 300³ 350 100 24"+ 20" 5 + 2.5

1. Use M power unit for 450% for 30 sec. Heavy Duty rating.
2. Use S power unit for 450% for 30 sec. Heavy Duty rating.
3. Standard Duty only

Run C-2000 Contactor

The ASTAT-BP is supplied with a bypass contactor
across the entire product line. Refer to factory if
NEMA contactors are required.
122 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Solid-state starters
Reduced-voltage, 300/450%

ASTAT SS starters standard duty (300/450% selectable)

SSS Cat#
NEMA HP @ HP @ HP @ HP @ Section Section
Function FLA @1.15 Disconnect IC (kA)(²) X-height
size(¹) 200/208 230/240 380/50HZ 460/480 1 width 2 width
SF
QC2GDP
.1-3 .1-3 .1-7.5 .1-10
1 13.9 A
Stab In 25 20” 2X
5-7.5 5-7.5 10 QC2IDP
15 15-20 27.8 A
2 SELT
10 10-15 20-25 25 QC2KDP
15 20 30 30-40 54.8 A
3 20” 2.5X
20-25 25-30 40-50 50 QC2MDP
100
30 60 75 91.3 A
SSS BASIC 4
40 40-50 75 100 QC2QDP SFLT 20” 4X
50-60 60-75 100-125 150 187.0 A 24” 5X
5
75 100 150 200 QC2SDP 30” 20” 3X 5.5X
100 125 200-250 300 321.7A SGT 30” 20” 3X 5.5X
6 350 QC2TDP 30” 5.5X
125-150 150 300 65
400 413.0A 36” 20” 3X 5.5X
QC2UDP
7 200 500 SKT 36” 20” 5.5X 5.5X
547.8A
QC2GDP
.1-3 .1-3 .1-7.5 .1-10
1 13.9 A Stab
20” 2.5X
5-7.5 5-7.5 10 QC2IDP In
15 15-20 27.8 A
2 42
10 10-15 20-25 25 QC2KDP SELT
15 20 30 30-40 54.8 A
3 20” 3X
20-25 25-30 40-50 50 QC2MDP
SSS with 30 60 75 91.3 A
4
isolation 40 40-50 75 100 QC2QDP 24” 5X
50-60 60-75 100-125 150 187.0 A SFLT
5 30” 5X
75 100 150 200 QC2SDP
100 125 200-250 300 321.7A SGT 30” 20” 5X 3.5X
65
125-150 150 300 350 QC2TDP
6 200 400 413.0A
36” 20” 5X 3.5X
QC2UDP SKT
200-250¹ 250-300¹ 400-500¹ 500
547.8A
QC2GDP
.1-3 .1-3 .1-7.5 .1-10
1 13.9 A Stab
20” 2.5X
5-7.5 5-7.5 10 QC2IDP In
15 15-20 27.8 A
2 SELT 42
10 10-15 20-25 25 QC2KDP
15 20 30 30-40 54.8 A
3 20” 3.5X
20-25 25-30 40-50 50 QC2MDP
SSS with 30 60 75 91.3 A
bypass 4
isolation 40 40-50 75 100 QC2QDP SFLT 24” 5X
50-60 60-75 100-125 150 187.0 A 30” 5X
5
75 100 150 200 QC2SDP
SGT 30” 20” 5X 3.5X
100 125 200-250 300 321.7A
65
125-150 150 300 350 QC2TDP
6 200 400 413.0A
36” 20” 5X 3.5X
QC2UDP SKT
200-250¹ 250-300¹ 400-500¹ 500
547.8A

1. Application rated C2000 contactors. NEMA size is used as a reference to horsepower only.
2. 65/85KAIC rating is with fuses.
T E C H N I C A L A P P L I C AT I O N G U I D E 123

Solid-state starters
Standard reduced-voltage, nonreversing
with primary disconnect

Options
1. Solid-state starter with isolation contactor

2. Solid-state starter with bypass contactor

3. Solid-state starter, isolation and bypass

124 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Solid state drives and starters

Arc flash mitigation (AFM)

The E9000 AFM units are designed to reduce the
likelihood of exposure to electrical shock and the
potential of internal arcing faults from occurring
during maintenance. The retractable stab
mechanism allows for closed-door racking of the
unit, providing added protection to the electrical
personnel from the dangers of an arc flash
occurrence.

For more information see page D2 and Publication

DEA-593.

AFM Solid State Drives and Starters

AFM Bucket
Standard
Rating @ Height w/
Unit Type Bucket Height
480V (hp) C2000
(inches)
(inches)

ASTAT-BP 5-30 18 24
(Internal 40-50 24 30
Bypass) 60-100 30 36
ASTAT-XT 5-20 24 30
(External
Bypass) 25-50 30 36

0.25-5 24 30
VFD-GP 5-10 24 36
(Constant
Torque) 10.1-20 36 48
20.1-40 48 60
0.25-5 24 30
VFD-FP 5-10 24 36
(Variable
Torque) 10.1-25 36 48
25.1-50 48 60
 T E C H N I C A L A P P L I C AT I O N G U I D E 125

Components

Spectra RMS Mag-break motor circuit protectors Spectra RMS rating plugs
Use of the same UL Listed interchangeable rating
Interchangeable rating plug plugs for both Mag-break and fully configured
Spectra RMS Mag-Break motor circuit protectors Spectra RMS circuit breakers expands the flexibility
use the same snap-in rating plugs as fully of the entire Spectra RMS family of products. The
configured (long-time trip function) Spectra advantages of interchangeable rating plugs with
RMS circuit breakers. Each rating plug defines Spectra RMS circuit breakers are inherent to
the range of instantaneous-trip settings Spectra RMS Mag-Bbreak units, which permit wider
available to the circuit breaker through its ranges of motor ratings to be protected by a given
trip setting adjustment. breaker frame size.

Trip setting adjustment Spectra RMS Mag-break trip unit characteristics

The solid-state instantaneous-trip circuitry of the Spectra RMS Mag-break motor circuit protectors
Spectra RMS Mag-break motor circuit protectors provid positive, reliable and cost-effective
has a single, multiposition adjustment at the front instantaneous, with tracking short-time
of each breaker. Changes in settings vary the overcurrent protection to those circuits where
instantaneous-trip and tracking short-time long-time overload protection is supplied by
characteristics. The Mag-Break motor circuit thermal or solid-state overload devices.
protectors differ from a fully configured circuit
breaker by only providing an instantaneous and
tracking short-time trip function.

Accessory pockets
Spectra RMS Mag-break motor circuit protectors
have the same accessory pockets and use the same
internal accessories as Spectra RMS circuit
breakers. This important capability allows field
modification of Mag-Break units with shunt
trip,undervoltage release, bell alarm or auxiliary
switch accessories,in any combination, without —
SE150 Spectra RMS Mag-break
affecting the UL Listing status. motor circuit protector
126 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Motor circuit short circuit protection

When a squirrel-cage induction motor is energized,
a high value of magnetizing inrush current flows
for the first few cycles, followed by a substantial
reduction in current flow while the motor
accelerates to its rated speed. When plotted on
a time current curve, the motor current has three
distinct regions – for the first five to eight cycles,
typical magnetizing inrush currents are
approximately ten times the full-load motor current
(but can be much greater for high efficiency
motors). Between 0.10 and 10 seconds, the
magnetizing inrush current drops to approximately
five to six time the full-load motor current. After
approximately 10 seconds, the motor reaches its
—
full speed and the current quickly decreases to the Motor Circuit Protection Using Mag-Break
full-load current of the motor. Motor Circuit Protectors

Optimum motor protection for the first two Spectra RMS Mag-break motor circuit
regions of the motor time current plot would protector ratings
involve a two-tiered protection scheme with a high The table below lists rating plugs available for each
value of current tolerated for a few cycles, followed Mag-Break motor circuit protector frame size.
by a lower,sustained trip setting. Instantaneous trip settings are listed under
electrical data on page 21 and UL interrupting
This is exactly the protection that is offered by ratings are shown on page 28 (per UL 489, motor
the Mag-Break motor circuit protector. This two circuit protectors are not marked with interrupt
tiered protection scheme prevents nuisance ratings). Except for 3 amp and 7 amp plugs, all
tripping due to magnetizing inrush current, other rating plugs are used in both circuit breaker
without compromising superior short circuit and Mag-break motor circuit protectors .
protection during motor acceleration. Protection
for the third region of the motor time current Spectra RMS mag-break motor circuit
protector and rating plug current ratings
plot is accomplished via the motor starter’s
overload relay. Frame Maximum Amperes Available rating Plugs, Amperes
7(¹) 3 and 7
The time current curve below illustrates this motor 30 15, 20, 25 and 30
protection scheme. Curve A and the shaded area SE-frame 60 40, 50 and 60
directly above it represents the region of operation 100 70, 80, 90 and 100
that will produce permanent damage to either the 150 110, 125 and 150
motor, its feeder conductors or both. Curve B SF-frame 250
70, 90, 100, 110, 125, 150, 175, 200,
225 and 250
represents the trip characteristics of the motor
125, 150, 175, 200, 225, 250, 300, 350
starter’s overload relay, which provides both long- SG-frame
400
and 400
term overload and stall protection but does not 600 250, 300, 350, 400, 450, 500 and 600
protect the system from short circuits in either the 800 300, 400, 500, 600, 700 and 800
SK-frame
motor or its feeder conductors. Curve C is a plot of 1200 600, 700, 800, 900, 1000 and 1200

the motor current during a worst-case start (e.g., 1. T

 he 7-amp frame and the 3A and 7A rating plugs are used only
low line voltage, highest load torque, etc.). Curve D with the Spectra RMS Mag-Break motor circuit protector.
represents the trip characteristics of the
Mag-Break motor circuit protector — with this
addition, the motor and its feeder conductors
are now fully protected against short circuits.
T E C H N I C A L A P P L I C AT I O N G U I D E 127

Spectra RMS molded case switches Spectra RMS molded case switch
Construction. The family traditions of ruggedness
and dependability are continued in the Spectra
RMS molded case switch line. These units provide a
circuit disconnect function using the compactness
of molded case circuit breaker construction. The
operating handle actuates all three poles of the
switch using the same common trip bar of Spectra
RMS circuit breakers and Mag-Break units.

Termination Lugs. Snap-in termination lugs

used with SEand SF-Frame Spectra RMS circuit
breakers are used interchangeably in Spectra RMS Spectra RMS molded case switch applications
molded case switches. SG- and SK-Frame molded Molded case switches are inherently horsepower-
case switches use the same bolt-on termination rated. By virtue of the UL489 six-times rated-
lugs used with Spectra RMS circuit breakers. current overload test, they can be used as motor
circuit disconnects where overload and short-
External Accessories. The full range of external circuit protection are provided by other protective
circuit breaker accessories offered for use with devices.
Spectra RMS circuit breakers and Mag-Break motor
circuit protectors, are available for molded case Spectra RMS molded case switches are most
switches. In addition, plug-in bases, commonly used as a disconnect in main, feeder, or
motoroperated mechanisms, mechanical starter applications in combination with fuses.
interlocks, and the full complement of external
handle operators (STDA, TDR and TDM) are All Spectra RMS molded case switches are UL
available for use with Spectra RMS molded Listed and tested per UL Standard 1087 for molded
case switches. case switches.

Fixed-Trip Setting. The Spectra RMS molded case

switches are equipped with a fixed Hi-set
instantaneous trip setting whose values are shown
in the table below.

Spectra RMS molded-case switch fixed-trip setting

Molded case Maximum

Fixed-Trip setting RMS
switch ampere
Amperes nominal ±20%
frame rating
100
SE-frame 2100
150
SF-frame 250 2450
400 5600
SG-frame
600 6000
800 12.600
SK-frame
1200 12.700
128 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Heavy duty fusible disconnects Spectra molded case switch (MCS)

400 and 600 Amp
QMW fusible switch A growing number of industrial applications with
high available short-circuit current has made
switch fuse coordination increasingly important. In
addition, there has been a growing number of
requirements for 400 amp and above applications,
including Ground Fault, Annunciation and Remote
Tripping. The Evolution E9000 MCC supports these
requirements by incorporating Spectra Molded
Case Switches with separate fuse blocks for all
400A and 600A applications. The same accessories
used in the Spectra Circuit Breaker can be used in
the MCS. In addition to ease of accessorizing, the
MCS saves space.

Withstand capability – Safety and reliability depend

on the interrupting capacity of both the switch and
the switch-fuse combination. While switch-fuse
interrupting ability is limited by the maximum
current the fuse will interrupt, it is also determined
by the maximum let-through energy the switch will
withstand as the fuse clears a short circuit.

QMW fusible switch (30-200 Amps) The switch must remain operable after the fuse
The QMW Fusible Switch is a premium heavy-duty has cleared. Switch withstand capability rating is
disconnect switch. It was developed to meet the determined by the maximum energy the switch
most rigorous industrial requirements. It meets can withstand (and remain operable), stated as
or exceeds all industry standards for withstand ampere-squared seconds, l²t.
capability and interrupting ratings, and it is UL
listed for use in Evolution MCC. Interrupting Capacity – In addition, the switch may
have to interrupt a wide range of currents without
assistance from the fuse, including normal
switching-duty currents (up to fullload rating),
overload and motor “jogging” currents (up to 10
times motor full load) or intermediate fault
currents (usually arcing faults–from overload to
near full-system available).

Previously, basic switch design criteria has been

primarily concerned with interrupting normal
switching and motor starting currents. New
applications require a switch capable of
interrupting intermediate fault currents without
assistance from a fuse. For maximum protection,
a switch should be able to interrupt any current on
which it can be closed and reopened before the
fuse blows. This is commonly called
“fuse racing.”
T E C H N I C A L A P P L I C AT I O N G U I D E 129

High pressure contact (HPC) switches

The new generation HPC switch is based on the
time-proven platform of the Power Break II circuit
breaker. Now, it’s ArcWatch-enabled to provide a
better Arc Flash hazard mitigation solution. The
new generation HPC builds on the abilities of the
original HPC by utilizing the features of the Power
Break II (PBII) circuit breaker. In addition, HPC
utilizes the EntelliGuard control unit which
incorporates many of the features of the
EntelliGuard Trip Unit for circuit breakers.

The HPC switch is available in frame ratings of 800,

1200, 1600, 2000 and 2500, both top and bottom
feed, with IC ratings to 200kA with the appropriate
UL Class L fuses. The new generation HPC switch is
available for new installations and for retrofit, to In addition, the HPC utilizes the EntelliGuard
replace the older HPC. By retrofitting with the new control unit which incorporates many of the
generation HPC switch, remote operation of the features of the EntelliGuard Trip Unit for
switch through the motor operators, shunt trips circuit breakers:
with lockouts, RELT and the Adjustable IOC for • Built-in metering, waveform capture and
continuous reduced incident energy can be Modbus communications
added in the same footprint as that of the older • Ground fault protection or alarm,
existing switch. optional GF disable
• WFR Adjustable Selective Instantaneous
Features and benefits protection
• Top or Bottom Feed • RELT Alternate Adjustable fast instantaneous
- 800-4000 Amperes 600 Volts ac Max setting, remote operable and with positive
• High Durability–Safety of Operation status feedback
- High-dielectric strength, glass reinforced • Zone-Selective operation for GF that works with
insulating case all circuit breaker trip platforms and includes four
• High Interrupting Capability different GF curve shapes
- Arc chute of unique construction suppresses • Instantaneous Zone-Selective operation that
arcs and cools gases rapidly, providing quick works with upstream EntelliGuard Trip Units
arc interruption and extended switch life and EntelliGuard control units
• High Transient Voltage Withstand Capability
- Interphase partitions mesh with switch cover RELT Control Schematic
to completely isolate each pole
• Extended Switch Life
- Preloaded constant pressure pivot eliminates
braid whip and fraying on high short-circuit
currents and repeated operations
• Positive “ON-OFF” Indication
- Green (OFF), Red (ON), eliminates any question
about the position of the switch contacts
• Easy Operation Quick Make
• Emergency Open–Quick Break
- Finger-tip “OFF” button instantly opens
the switch contacts
• Fuse Mounting Bolts with Captive Washers
for Ease of Mounting Fuses
• Padlocking Provisions Standard
130 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Power Break II insulated case circuit breakers Standard features for exceptional flexibility
• Highly flexible time current settings
General Description - up to 22 Long Time Delays
Power Break II insulated case circuit breakers offer - up to 22 (fuse shaped) Long Time
the rugged, reliable type of system protection - up to 14 Short Time Delay bands
critical for heavy-duty applications. In Evolution - 3 Short Time slopes (I2T)
Series E9000 MCC, Power Break II circuit breakers • Selective Instantaneous algorithm (WFR)
are rated up to 100,000 amperes RMS symmetrical • Ammeter
interrupting capacity without fuses or current • Large backlit LCD screen
limiters. In Evolution E9000 MCC, the Power Break • Breaker status indication
II design consists of 800, 1600A*, 2000A*, and • Universal rating plugs – less plug inventory
2500A* Amp frame sizes. • Status and event log (10 Events)
• Date and time event stamping
• LED health status indicator
• Free set-up software
• Discrete I/O
• Thermal memory, battery back-up
• Common interface across all versions
• Mechanism self-timing

Optional full-function metering

• Current (Amps, kAmps)
• Voltage (Ph-Ph, Ph-N)
Power Break II is a versatile breaker, designed for a • Energy (kWh, MWh, GWh)
wide variety of applications with features such as • Real power (kW, MW)
temperature insensitive trip units, push-to-open • Total power (kVA, MVA)
and -close buttons, standard padlocking provision, • Frequency (Hz)
maximum three-cycle closing time, field installable • Demand (avg. kW, MW) and peak demand
rating plugs to change ampere ratings, UL listing,
plug in field installable accessories, and easy-to- Options
operate two stage pumphandle, stored-energy • Internal/external ground fault trip or alarm with 4
operating mechanism capable of change curves to select from (I2T, I4T, special selective
after close. GF curve, and definite time slope)
• Switchable ground fault trip / alarm (now
EntelliGuard TU trip unit password protected and UL Listed)
EntelliGuard TU is the trip unit with the built-in • Modbus RTU communications (Profibus also
flexibility required to match your system’s needs, available for EntelliGuard G)
whether for optimum safety, optimum system • Waveform capture for harmonic analysis
reliability or both at the same time. The • Full-function metering
EntelliGuard TU trip unit provides the industry’s • Protective relaying (see list of functions below)
most advanced instantaneous protection without • Zone-Selective-Interlocking for GF, ST,
compromising system selectivity. Instantaneous (I-ZSI)
• Threshold Zone-Selective-Interlocking for ST
and Instantaneous (T-ZSI)
• Built-in Zone-Selective-Interlocking test
capability
• RELT – Reduce Energy Let Through
• RELT and ground fault alarm harness kits
• Test Set GTUTK20
• Digital Test Kit Software, available
December 2013
T E C H N I C A L A P P L I C AT I O N G U I D E 131

Optional protective relaying functions • Spectra RMS Mag-Break instantaneous-only

• Undervoltage motor circuit protectors also use the same
• Overvoltage digital, solid state trip unit and rating plugs as
• Voltage unbalance the circuit breakers. The interchangeable rating
• Current unbalance plug establishes the instantaneous pickup range
• Power reversal (with tracking short-time) but does not change
• Power direction setup the frame ampere rating.
• Spectra RMS molded case switches have a fixed,
1. Some options require 24VDC additional hardware high-set instantaneous trip (without tracking
to enable Metering, Relaying, RELT, ZSI, Modbus short-time function) and have short circuit
to be added to the breaker, equipment cubicle withstand ratings equal to their equiva- lent
and equipment sections. breaker frame size interrupting rating in
* 1600A, 2000A, 2500A PowerBreak II circuit most cases.
breakers are 100% rated in the LV MCC • RMS breakers are ambient insensitive. Trip times
construction. 800A PowerBreak II circuit will not vary over the range 10-50° breaker
breakers are 80% rated ambient .
• Spectra RMS breakers contain no parts that
Spectra RMS circuit breakers -features would support fungus growth and are, therefore,
inherently fungusproof.
Spectra RMS •
SE150, SF250, SG600 and SK1200 circuit breaker Other MCCB features
frames have a digital, solid state, RMS sensing trip • Broad product line to meet virtually any
system with field installable, front-mounted rating application need.
plugs to establish or change the breaker ampere • Reduced downtime. A tripped breaker is easily
rating. Adjustable instantaneous with tracking spotted and can be immediately reset after the
short-time is standard on all frames. The trip unit fault has been corrected.
uses digital sampling to determine the RMS value • Eliminates single phasing. A common trip bar
of sinusoidal and non-sinusoidal currents. See disconnects all poles simultaneously on both
more at: http://www.geindustrial.com/products/ overloads and short circuits.
circuit-breakers/spectra-rms-electronic- • Offers application flexibility through the use
trip#sthash.fmoX8l9f.dpuf. of a wide variety of accessory devices and special
attachments.
A complete circuit breaker consists of a UL Listed • Repetitive operation — no fuses to replace.
circuit breaker frame and a rating plug (UL Listed • Breakers can be repetitively tested. Fuses must
interchangeable trip breaker unit). Terminal lugs be destroyed to confirm calibration accuracy.
for cable connection are available if required.
Reference – GET-7002 for further application information.

• All frames use the same UL listed, field installable

internal accessories (auxiliary switch, shunt trip, The add-on limiter coordinates with the Spectra
undervoltage release and bell alarm). thermal magnetic trip to allow normal tripping
• All frame sizes have maximum UL listed functions at standard ratings with backup
interrupting ratings of 100 kA @ 480 volts AC limiting at high short-circuit levels for
150A frame Spectra circuit breakers
with 600 volts AC ratings to 65 kA depending on
frame size. UL listed current limiting versions are
provided through the SG600 frame for the 65 kA
@480 volts AC and the 100 kA @ 480 volts AC
models, with no increase in physical
frame size.
132 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Spectra RMS Circuit Breakers - Features Optional features

• Ground Fault (Trip or Alarm) pickup and delay
microEntelliGuard Trip Unit bands with multiple slopes, I2t IN/OUT for
The microEntelliGuard trip unit is the newest and optimal system coordination
most advanced trip unit available in the Spectra • Neutral Protection provides overload protection
line of molded case circuit breakers. Based on the on the system neutral
EntelliGuard TU trip platform, the new • Zone Selective Interlocking (ZSI) capability on
microEntelliGuard trip unit allows you to select the Short Time, Ground Fault and Instantaneous
enhanced system protection, coordination, settings for optimal system coordination and
metering and communications options required for selectivity
the application. New features include enhanced • Reduced Energy Let-Through (RELT) setting for
time-current adjustability, Ground Fault Alarm, enhanced equipment and personnel protection
Neutral Protection, Zone Selective Interlock (ST/ • Advanced metering option includes the ability to
GF/INST), and direct Modbus communications. monitor current, voltage, energy, frequency,
Other features that enhance system protection and power factor, power (real/reactive/apparent) and
diagnostics include long-time thermal memory, peak power demand
waveform capture, programmable output contacts, • Modbus communications system with user
and an LED “Health” status indicator. selectable address assignment for
communicationdirectly with EnerVista Viewpoint
Standard features power system monitoring software
• Adjustable Long-Time pickup and delay bands • Waveform capture for enhanced system
with three curve shapes (MVT I2t, CB and Fuse diagnostics
I4t) for optimal system coordination (includes • Protective Relays for enhanced system protection
thermal memory for enhanced system protection) - Voltage Unbalance
• Adjustable Short-Time pickup with multiple delay - Current Unbalance
bands, curve slopes, I2t IN/OUT, and - Under Voltage
OFF setting - Over Voltage
• Adjustable Instantaneous pickup - Power Reversal
• 3-Phase ammeter - Load Alarm
• Backlit LCD display with five-button tactile • Input relay for RELT signal or remote tripping of
keypad and sealable, clear LEXAN cover for the breaker
tamper resistant settings • Two programmable output relays for enhanced
• LED Status Indicator to show “health” of signaling and diagnostics
trip unit • Control Power option provides connection
• Trip Target indication and local pickup capability for +24Vdc control power via the
warning signal distributioncable system
• Interchangeable/universal rating plugs
• Test set jack for GTUTK20 test kit Other features
• True RMS sensing for accurate response to • UL Listed for reverse feed and HACR
high harmonic content waveforms type (standard)
• EMI immunity per ANSI C37.90 • UL Listed Current Limiting (optional
on SG Frame)
• Internal Accessories (Shunt Trip, Undervoltage
Release, Auxiliary Contacts, Bell Alarm) – UL
Listed for field installation and common
across the entire line of Spectra RMS breakers

Note: Spectra molded case circuit breakers

are 80% rated (continuously) in LV MCC
construction as tested by UL845.
T E C H N I C A L A P P L I C AT I O N G U I D E 133

Ground fault current detection systems Contact rating

Model BGFL (Relay)
Trip Currents 5-60, 30-360, or 100-1200A Device input power Inrush Cont.
120 Volts ac 10A 3A

Description 125 Volts dc 1A 1A

48 Volts dc 4A 4A
These Class 1 Model BGFL ground fault relays and
24 Volts dc 8A 8A
sensors form a system for detecting a ground fault
current on a ground ac power system. When a
ground fault exceeds a pre-selected current level
and time delay setting, the relay initiates a trip
signal for a shunt trip disconnect device to open
and clear the fault. This BGFL system provides
protection for electrical equipment,
not for personnel.

Operating range: Trip currents of 5-60, 30-360, or

100-1200A. Time delay from 0.10 to 1 second
(adjustable).
Input power: 2 VA plus shunt coil requirements.
Rated @ 120 Vac.
Input withstand: 200,000 Amperes RMS for 3
cycles, 50/60 Hz.
Nominal input voltage: 120 Volts ac, 125 Volts dc,
24 Volts dc, 48 Volts dc.
Frequency: 50/60 Hz.
Ambient temperature range: -30°C to +60°C
Only for use with GFL sensors.
Approximate weight 1.5 lbs.

• Meets NEC service entrance equipment

standards.
• Available in three basic styles: Standard, Form C
or Zone Interlocking for coordination of single or
multiple ground fault devices in system.
• Integral test panel with Push To Test and Shunt
Trip Bypass pushing for ease in proper
operational testing of the system, with or
without tripping the protective device.
• Power On LED indicator in cover.
• Positive visual trip indicator, manual reset.
• Infinitely adjustable Time Delay.
• Discrete current threshold adjustment.
• Panel or door mounting.
• Rear terminal kit and clear plastic cover standard
with door mounting.
• Electromechanical relay output, positive ON
and OFF.
• Operates with molded case and power circuit
breakers, bolted pressure switches, fusible
Note: Mounting provision on reteangular
disconnect switches.
GFL sensors with 11.1" and 13.2" widths.
134 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Ground fault current detection systems Model number Trip(¹) Current

Model GFM Relay GFM 156 3.8 to 18
2.0 to 65 Amp Trip Currents
Model number Trip(¹) Current
Description GFM 3P208 5 to 20
These Class 1 Model GFM Ground Fault protection
systems are designed to minimize damage or loss 1. Тrip current tolerance is ± 15 percent.

to equipment caused by destructive arcing ground

faults. This GFM system is designed for all
polyphase applications and is ideally suited for
motor control, motor control centers, and medium
voltage starters. Systems can be wye or delta,
grounded or resistance grounded. When the
ground fault current exceeds a preselected
condition (current and time settings) the relay
trips. The relay contacts can be connected in the
control circuit of a motor starter, to the shunt trip
of a circuit breaker or similar disconnecting or Model GFM-252 and 262
alarm devices. The system has an inverse time Contacts rated 10 Amps continuous, 23 Amps
characteristic to prevent nuisance tripping. The inrush, 120 Volts AC
relay tripping current value is field adjustable over
the trip current range of the sensor. The adjustable
0.46"
trip time delay relay is field settable 1.17"

up to 36 cycles. 2.00" 0.50"

.86"
3.30"
Operating range: Trip currents from 2.0-65A. Time
delay from instantaneous to 36 cycles. 1.15"
8
1.18"
Input power: Self-powered 2.50" 3 10

Frequency: 50/60 Hz. 1 12

Ambient temperature range: -30°C to +60°C
0.46" 2.25" 0.35"
Only for use with GFL sensors.
#6-32X.35LG.
TERMINAL SCREWS
Operation
• Positive condition indication
3
• Normal (Reset) - Green (“ON”) 8
To current Sensor X1 1
• Tripped - Red (“OFF”) and X2 all contacts 10
shown with the relay in
• Manual Reset the tripped position 12

3.53" (4) 0.31X0.21

2.75"
OPEN SLOTS Typical circuit
L1 L2 L3
1.77" 1.09" 2.15"
STAB M OL 8CT.
4.6" (3) (5) (6) (5) (6) (5) (6) (H1)
L3 K3 K6 T3
3.00" (2) (3)
CB
(4) (3)
(3) (4) (4)
3.5" OR
0.44" L2 K2 K5 T2
LSW
LABEL GFX2 GFX1 (2) MOTOR
(1) (1) (1) (2) (1) (2)
L1 K1 K4 (FX2) T1
(1) (3) (FX1)
2.0" 3.75" G2
3.65" 2FU
1.56" DIA GFR
H1 (2) (4) G1
(1) (3)
(H1) (H2)
1.83 1FU
10.75" (2) (1) T
1 X1 (X1) (X2) X2
Gnd
1.77"
GFR
(10) (9)

SW PB
Hand Auto
M OL
(13) OFF (14) (A) (B) (7) (8)
1A 3 48 49

M R
(15) (16) (12) (11) (1) (2)
5 2
x=Closed(MC) PB
T E C H N I C A L A P P L I C AT I O N G U I D E 135

C2000 Line Motor Starters Easier installation

C2000 Line motor starters offer greater design • 5-75 hp contactors can be either DIN-rail or
versatility. C2000 Line components are loaded with screw mounted
features that make them easier to install, allow • Mechanical interlocks allow quick, easy
more flexible configurations, and allow for a configuration of reversing contactors
smaller unit footprint. These components conform • Coil information is printed on top of each
to international standards (UL, cUL and IEC-947) contactor for easy reference
and have dual (U.S./European) markings to ensure • On 5-25 hp contactors, pozi-drive screws accept
global acceptance. A single nomenclature system any screwdriver
allows simple sourcing worldwide. AC coils (both • Easy attachment of accessories
50 Hertz and 60 Hertz versions) are available for a
wide range of voltages for flexibility. Flexible, compact configurations
• In the 5-75 hp range, each contactor accepts both
front– and side-mount auxiliary contact blocks
• Pneumatic timers can be used in conjunction with
side-mount auxiliary contact blocks
• Double-clamp terminal accepts two differently
sized wires; both control and power wires can be
inserted
• Surge suppression is built into the electronic
control module inside 100-500 hp contactors
• RT overload relays mount directly on 5-125 hp
contactors to reduce space requirements
Design versatility
• 3-pole AC contactors (non-reversing and
Safety protection
reversing, ranging from 5-500 hp @ 460 volts)
• Contactors in the 5-75 hp range have built-in
• RT overload relays (Class 10 versions for
finger and back-of-hand protection
contactors 5-125 hp range, and Class 10 and Class
30 versions for contactors in the 150-500 hp
range)
• Contactor accessories — front– and side-mount
auxiliary contact blocks, mechanical interlocks,
pneumatic times, and surge suppressors
• Wye-delta starters
• Control relays available in various contact
arrangements
• Up to six front-mount auxiliary contact blocks
and one side-mount auxiliary contact block can
be added to contactors in the 30-75 hp range.
136 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Dimensions (in/mm)

Contactor Width(¹) Height Depth(¹) Contactor

Width Height Depth
CL00 1.77/45 3.19/81 3.35/85 with Overload

CL01 1.77/45 3.19/81 3.35/85 CL00+RT1 1.77/45 5.03/128 4.20/106.7

CL02 1.77/45 3.19/81 3.35/85 CL01+RT1 1.77/45 5.03/128 4.20/106.7

CL25 1.77/45 3.19/81 3.43/87 CL02+RT1 1.77/45 5.03/128 4.20/106.7

CL04 2.17/55 3.43/87 3.86/98 CL25+RT1 1.77/45 5.03/128 4.20/106.7

CL45 2.17/55 3.43/87 3.86/98 CL04+RT1 2.17/55 5.27/133.7 4.06/103

CL06 2.60/66 4.63/117.5 4.57/116 CL45+RT1 2.17/55 5.27/133.7 4.06/103

CL07 2.60/66 4.63/117.5 4.57/116 CL06+RT2 2.60/66 7.25/184 4.57/116

CL08 2.60/66 4.63/117.5 4.57/116 CL07+RT2 2.60/66 7.25/184 4.57/116

CL09 2.95/75 4.63/117.5 4.96/126 CL08+RT2 2.60/66 7.25/184 4.57/116

CL10 2.95/75 4.63/117.5 4.96/126 CL09+RT2 2.95/75 7.43/189 4.96/126

CK75 4.86/123 7.01/178 6.50/165 CL10+RT2 2.95/75 7.43/189 4.96/126

CK08 4.86/123 7.01/178 6.50/165 CK75+RT3 4.86/123 10.39/264 6.50/165

CK09 5.90/150 8.34/212 8.18/208 CK08+RT3 4.86/123 10.39/264 6.50/165

CK95 5.90/150 8.34/212 8.18/208 CK09+RT4 5.90/150 16.53/420 9.12/231.6

CK10 6.29/160 9.00/229 9.05/230 CK95+RT4 5.90/150 16.53/420 9.12/231.6

CK11 6.29/160 9.00/229 9.05/230 CK10+RT5 6.29/160 14.45/367 11.36/289

CK12 9.06/230 9.84/250 10.31/262 CK11+RT5 6.29/160 14.45/367 11.36/289

CK12+RT5 9.06/230 16.18/410.9 11.81/300

1. D
 oes not include front- or side-mount auxiliary contacts required
on CL25, CL45 and CL06-CL10.

300-line motor starters

The 300-line starter is a full-voltage, magnetic
motor starter with encapsulated coil and three-leg
block overload relay with visual trip indicator,
manual reset and manual weld check. It
incorporates all the features and benefits most
asked for by users and has received standard
The molded coil is impervious to moisture, dirt and
specification approval by many major
oil. It is highly resistant to mechanical damage and
manufacturers. In addition to the basic non-
high-humidity failure. Retaining clips engage
reversing form, the 300-Line is available in
detents encapsulated in the coil to hold it securely
reversing, two-speed and combination forms in
in place.
NEMA sizes 00-5.
Staggered Saddle

The 300-Line’s toolless contactor disassembly Clamp Terminals

with Permanent
allows quick access for inspection and Terminal
maintenance. Simply release two coil retainers and Identification

pull the spring clip from the “I” magnet to gain Improved
Auxiliary
access to the magnet, coil and contacts. No need to Contacts
Quick
remove any wiring. Rated
Contact
for Heavy
Inspection
Pilot-Duty
and Coil
Change

Manual Weld
Check

Dual
Overload Trip Bimetal
Adjustment Overload
Optional terminals can be provided to permit the ±10% Protection

easy connection of power factor correction

capacitors for energy conservation. Visual Trip
Indication
Optional N.O. Isolated
High Fidelity Contacts
T E C H N I C A L A P P L I C AT I O N G U I D E 137

300-line motor starters

The overload relay can be manually tripped

deliberately as a convenient way to check against
contact welding. Depressing the manual weld check
— arm trips the relay. Then a welded contact can be
Cover removed
detected with a simple continuity check.
Where it’s essential to monitor performance or
diagnose faults, a 300-Line starter may be ordered
with an additional isolated, highfidelity, normally-
open contact on the overload relay. This contact
may be used for direct input to a programmable
controller or direct interface with a computer.

Overriding is eliminated because overload reset

occurs only when the reset arm is released on the
standard manual-reset form.

A bright yellow visual trip indicator tells operators

at a glance if the overload has tripped. An optional
automatic-reset overload relay is available for
special applications upon request.
All line and load terminals on NEMA size 00, 0 and 1
starters have saddle clamps to accommodate all
types of terminations– ring, spade and stripped-
wire. Terminal numbering is permanently stamped,
and terminals are staggered to help prevent
shorting. NEMA size 2, 3 and 4 starters are also
available with provision for ring terminations
with staggered terminals. Size 5 starters are
available with provision for ring terminations. Overload relay heaters are completely
In-line terminals for spade and stripped-wire interchangeable with heaters for 200- and
connections are standard. 100-Line starters, eliminating the need to
stock different heaters.

On NEMA size 1 starters and larger, contact tips

are weld-resistant with cool operation and
extended life. The contacts have a wedgeshaped
configuration for positive make with minimum
bounce. They can be easily changed from normally
open to normally closed without additional parts
on Sizes 0 and 1. Magnet provides long life and is
specially treated to resist rust.
138 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Relay trip points are factory calibrated at given

currents for high accuracy. For added flexibility, the
trip current of the relay is adjustable +10 percent to
allow tuning the protection to any given motor and
to eliminate nuisance tripping. A single calibration
adjusts all three legs. The overload relay is available
in standard or ambient-compensated forms.

Each auxiliary contact is rated 10 amperes AC,

continuous current (NEMA A600), and is suitable
for either right or left side mounting. All necessary
parts are supplied in the modification kit for easy
installation. An insulating shield is also provided
for use between each auxiliary contact unit and
the starter.

Auxiliary contact kits offered include one with a

basic contact block and one with an adder block.
The basic block is supplied with either a single
circuit (one normally open contact or one normally
closed contact) or a double circuit (one normally
open and one normally closed contact). The adder
block must be used in conjunction with a basic
block. It may be ordered with either one normally
open or one normally closed contact.

Overload Relays

Series RT thermal CR324 thermal CR324X electronic Basic MM200 MM300

Overload relay bimetallic Overload relay communication motor controller motor controller
Overload relay Overload relay
Description RT overload relays The CR324 thermal The CR324X is an The Basic The MM200 The MM300
provide motor bimetallic overload electronic alternative Communication integrates integrates
overload protection relays use to the CR324 overload relay is a protection, control protection, control,
through fixed interchangeable bimetallic overload solid-state overload and multiple automation,
bimetal heaters. match overload relay. The CR324X relay with selectable communication metering,
These relays are relays to motor eliminates the need trip class and wide protocols in a diagnostics and
ambient amps. A ±10 trip for heater elements, current adjustment rugged compact multiple
compensated and adjustment dial is providing a broader range settings. This device for low communication
utilize a differential used to fine tune the amperage robust relay allows voltage motor protocols in a
mechanism for motor overload adjustment range. for either ground applications. Easily rugged compact
single-phase relays. Overload relay Provisions for fault or integrated into new device for low
sensitivity. Overload features include trip increased diagnostic communication and existing control voltage motor
relays may be set for test, manual reset on capabilities permit modules to be side system applications.
4 different upstroke, weld check automation control mounted to the relay. architectures, the Designed for motor
operational modes visible trip indicator via auxiliary contacts MM200 provides control centers, the
— manual reset only, and an optional and remote reset comprehensive low MM300 delivers
automatic reset only, normally open signal open collector. voltage motor superior protection
manual reset/stop, contact. Mounting protection and and control to
or automatic reset/ dimensions are communications for extend equipment
stop. Stop is identical to the all types of motor life and maximize
initiated by pushing CR324 thermal protection process uptime.
the reset button overload relay and applications.
which interrupts the permit fast, simple
holding circuit in the field upgrades.
latter two listed
modes. Overload
relays feature visible
trip indication, reset
on the upstroke,
weld check, and
trip test.
 T E C H N I C A L A P P L I C AT I O N G U I D E 139

Series RT thermal CR324 thermal CR324X electronic Basic MM200 MM300

Overload relay bimetallic overload relay communication motor controller motor controller
overload relay overload relay
Type Thermal Thermal bimetallic Electronic Electronic Electronic Electronic
Protection class 10, 10A, 20, 30 20 10, 20, 30 10, 15, 20, 30 10, 15, 20, 30 10, 15, 20, 30
(selectable) (selectable) (selectable) (selectable)
Ambient Ambient Optional Ambient insensitive Ambient Yes* Yes*
compensation temperature compensated
compensating
Phase loss protection Yes No Yes Yes Yes Yes
Phase unbalance Yes No No Yes Yes Yes
Ground fault No No No Yes* Yes Yes
Self powered Yes Yes Yes Yes No (power from No (power from
starter CPT) starter CPT)
Accuracy ±5% ±5% ±2% 2.5-5% 2% 2%
Repeatability ±3% ±3% ±2% 1%
FLA Adj. range 0.16-850A Up to 135A 0.4-540 A 0.4-540 A 5 to 1000 FLA 5 to 1000 FLA
(Depending on relay (Depending on relay in steps of 1A** in steps of 1A**
chosen) chosen)
Reset mode Manual and Manual (auto Manual Manual and Manual and Manual and
Automatic optional) Automatic Automatic Automatic
Trip test Yes Yes Yes Yes Manual and Manual and
Automatic Automatic
Trip indication Yes Yes Yes Yes LED/User Interface/ LED/User Interface/
SCADA SCADA
Operating –25° to 60°C 0° to 55°C –20° to 70°C –20° to 60°C –20° to 60°C –20° to 60°C **
temp. range (compensated)
Communications No No No Profibus* Modbus RTU Modbus RTU
DeviceNet* Modbus RTU + Modbus RTU +
Ethernet IP* Profibus DP Modbus TCP
Modbus RTU + + Profibus DP
Profibus Modbus RTU +
+ DeviceNet Modbus TCP
+ DeviceNet
Addressable No No No Yes Yes Yes
Heater required Yes Yes No No No No
PFC terminals No Yes (optional Yes (optional No No No
through NEMA through NEMA
Size 2) Size 2)
PLC compatible No No Yes Yes Yes Yes
contacts
Aux. contacts NO and NC NC (NO optional) NO and NC NO and NC 2 NO, 1 C form 2 NO standard,
add on available
Mount Designed to mount Designed to mount Designed to mount Din-Rail Panel Mount Din-Rail Panel Mount Din-Rail Panel Mount
directly to C2000 directly to CR305 directly to CR305
contactor or panel contactor or panel contactor or panel
mount mount mount
Reference publication Control catalog DEP-015 090824 - V17, 131111 - V21,
section 1 GEK-113400E, GEK-113022J,
1601-9034-A6 1601-9023-AA
Notes * Ground fault and *When ordered with *When ordered with
communication RTD Module **1-10 RTD Module
modules cannot be turns are available to ** based on 1"
used at the same accommodate CT around base unit
time turns lower than 5A ***1-10 turns are
available to
accommodate CT
turns lower than 5A

This table reflects standard offering of overload relays; however, other ASTATs and VFDs utilize integral overload protection algorithms.
overload relays can be included if needed. If you have other overload relays External overload relays are only used with ASTATs and VFDs to
you wish to add to your MCC, please contact the factory for assistance. support the motor control in a bypass configuration.
140 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Industrial relays Contact ratings

C2000 Control relays A600 P600 Q600 P300

Continuous
10A 5A 2.5A 5A
thermal current
Max. VA/Amps 7200VA/
138VA 69VA 138VA
making 60A
Max. VA/Amps 720VA/
138VA 69VA 138VA
breaking 6A
Max. operating
600VAC 600VDC 600VDC 300VDC
voltage

Accessories for C2000 contactor and

control relay

The C2000 Control Relay is a compact, industrial Front-mount auxiliary contact blocks
style relay designed for heavy-duty applications
where reliability and versatility are required.

Basic forms: 4 NO; 3NO-1NC; 2NO-2NC; 4 NC Max

front mounted aux. contacts: 4 (NO or NC)
Contact Rating: A600; P600
Aux. Contact Rating: A600; Q600; P300
Timer Contact Rating: A600; P600

Coil data
1NO or 1NC
AC Voltage DC Voltage Front-mount auxiliary contact blocks clip
Burden
into front face of control relay.
Inrush 45 VA 5.5 W
Holding 6 VA 5.5 W
Pneumatic timers
Pickup Voltage (% of Coil Volts) 85-110 80-110
Drop-Out Voltage (% of Coil Volts) 40-55 20-40
Switching Delay (ms)
Switching Delay on
Coil Voltage at +10% to -20% 6-25 35-65
Coil Voltage at Rated Value 8-20 40-45
Switching Delay off
Coil Voltage at +10% to -20% 6-13 30-60
Coil Voltage at Rated Value 6-13 30-60
Maximum Operations per Hour
No Load 9000 3600
Pneumatic timers are adjustable time-delayed aux-
Rated load 1200 1200
iliary contacts. They come equipped with two
time-delayed contacts: 1NO or 1 NC, electrically
Coil rating separated. Setting is scaled over a 350° rotation by
AC Coil Rating DC Coil Rating
means of a knurled knob with timing guide marks.
24V/60 Hz 24V/50 Hz 24VDC To mount a pneumatic timer, simply clip it on front
48V/60 Hz 42V/50 Hz 48VDC face of control relay.
120V/60 Hz 110V/50 Hz 125VDC
208V/60 Hz 190V/50 Hz 250VDC
Type Range Contacts
240V/60 Hz 220V/50 Hz
Time .1-30 sec 1NO-1NC
240V/60 Hz 220V/50 Hz
Delay On 1-60 sec. 1NO-1NC
277V/60 Hz 240V/50 Hz
Time .1-30 sec. 1NO-1NC
— 380V/50 Hz
Delay Off 1-60 sec 1NO-1NC
— 415V/50 Hz
480V/60 Hz 440V/50 Hz
600V/60 Hz 550V/50 Hz
T E C H N I C A L A P P L I C AT I O N G U I D E 141

Surge suppressor

For suppression of disturbances on electronic cir-

cuits due to the coil transient voltage occurring on
opening of the contactor. Limits high voltage tran-
sients that may be produced when coil is de-ener-
gized. Mounts directly on top of the coil.

Control relay - front view AC control relay - side view

1.77
45 5.55
141
4.49
1114
3.35
85

3.19
81 C B

.18
4.5
.195 1.38
TYP.
5 35
142 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

CR104P pilot devices Push-

Type STD Bulb Color
to-test
Description Full Voltage Red
• • #120PSB
Newly-designed nameplates with chrome-plated (120 VAC) Green
octagonal rings project an attractive, quality Amber
Transformer Blue
appearance. Positive feel selector switches give a (6 VAC • • #755
White
quality touch in all illuminated, solid color, spring Secondary)
Clear
return, and maintained units.
Red
White
Standard and illuminated push buttons and Neon • N/A Neon
Amber
selector switches are available. Both push button
Clear
and selector switches are available with key or for Red
conventional operation. The CR104P push-button LED Green
LED
line also includes press-to-test and standard (transformer • •
(6 Volt) Blue
type only)
indicating lights, mushroom-head, joy stick, push- Amber
pull and push-push operators.

Application
Especially adapted to machine-tool service or
any application where oil or coolant is present.
The convenient one-hole mounting makes this line
suitable for general purpose use in equipment of all
kinds where panel mounting is possible. This line is
ideal for applications where oil tightness,
watertightness and long life are essential.

All units are suitable for use in Type 1, 3, 3R, 4, 12

and 13 environments when mounted in enclosures
rated for those same applications.

Features
• Ease of assembly–One screw contact block
Contact ratings
mounting. Octagonal ring provides ease in front
panel mounting and enclosure applications. AC ratings, NEMA A600 heavy pilot duty
• Greater torque–Due to the eight-sided ring
design, greater torque can be developed during Continuous AC Voltamperes @ 60/50 Hz²
Max. Ac
current Amps Make Break
assembly and installation to provide oil tightness.
• Stocking inventories reduced–Forms may be 600 10 7200 720

furnished as complete units or as components,

allowing building block construction from DC ratings, NEMA P600
a minimum of stock.
• Color Coded–Colored knobs and caps are Max. Make or Break Amps

available in kit forms for easy field conversion. 125V 250V 600V
1.1 0.55 0.2

CR104P pilot lights

1. CR104PTP units are suitable for Type 1,12, and 13 applications only.
Pilot lights match appearance of switches 2. M
 aximum make and break currents are 60 and 6 amperes
respectively for voltages of 120 and below.
above. Standard applications use full voltage
or transformer type lights. Optional nameplates
match those used with switches, neon lights are
available (with limited lens colors).
T E C H N I C A L A P P L I C AT I O N G U I D E 143

C2000 pilot devices C2000 pilot devices

Description
C2000 Push Buttons are heavy-duty, 22.5mm
water-tight and oil-tight pilot devices. Four
operator styles – round polished and satin chrome,
round and square engineered plastic – are available.
They just snap onto the mounting flange and all
reflect a sleek, distinctive European style that give
you precisely the look and function you want in
your push buttons. Choose from full-voltage,
resistor and transformer power supplies with
incandescent, LED or neon lamps.

Features
• Installation is quick, labor cost are reduced.
• Ergonomic design adds ease of assembly and
operation.
• Back-tightened locking rings discourage
tampering, accommodate a range of panel Standard for 1/2X compact starter. See Control Catalog.

thickness, and tighten down with either a custom

wrench or any flatbladed screwdriver.
• A removable orientation tab allows universal
mounting in either notched or round 22.5 mm
holes.
• Permanently bonded front gasket provides
superior sealing against contaminants and makes
installation nearly foolproof.
• Markings are easy to read and laser-etched so
they remain permanently legible.
• 4-point contact, flanges snap securely onto the
operator. C2000 double bridge feature
• Ultrasonically welded contact block housings
hold up longer and resist contamination better,
even in the dustiest environments.
• Double bridge sliding contacts provide excellent
performance, even in low-voltage applications.
• Terminals (both screw and quick-connect) can be
wired off the operator, then snapped on.
• Contacts are rated A600, Q300.
14 4 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Solid-state motor winding heater Applications

50 Hertz Applications: The 230/460 volt device can
Description be used at 220/440 volts, 50 Hertz. The 575 volt de-
The motor winding heater is designed for use with vice can be used at 550 volts, 50 Hertz.
3-phase ac motors to guard against damage
caused by condensation build-up on motor Typical wiring diagram
windings, which can occur in high-humidity
environments during motor idle periods. With the
heater connected as indicated in the connection
diagram, and the motor not running, an SCR
controlled current flows in the motor windings,
producing enough heat to maintain the
temperature inside the motor above the ambient
temperature. The motor winding heater is
automatically energized after the starter contacts
(M) open, and de-energized when the starter
contacts close. Fuses are included for SCR
overcurrent protection and protection for wiring.

If desired, a pilot light can be connected as shown

(“Fuse Condition Indicator”) to visually monitor the Note: Since voltage is present at motor
condition of the fuses. With the starter contacts terminals at all times, cautionary
open, the light will be On if current paths through information sent with the device
FU1 and FU2 are complete. The pilot light should must be observed.
have a line voltage rating.

Specifications
Output Voltage Regulation: Voltage applied to
motor winding will vary +2% maximum for line
voltage variations of +10%, -15%.

Operating Temperature Range: -20°C to +50°C.

Fusing: FU1–Fast-acting semiconductor fuse for

SCR overcurrent protection. FU2–Class RK-5
rejection type fuse with time delay for wiring
protection.

Additional SCR Protection: Metal oxide varistor

protects against voltage surges. RC snubber circuit
limits rate of change of circuit voltage.

Motor Voltage
Motor Horsepower Range
+10%, –15%, 3-Phase 60 Hz
230/460V 15-400 Hp
575V 25-400 Hp

Heater is UL Listed in MCC Construction

T E C H N I C A L A P P L I C AT I O N G U I D E 145

EPM 6000 power meter

High Accuracy Power and Energy Measurement

Overview
EPM 6000 is one of the industry’s highest
performance revenue grade panel meters. Based on
the latest technology and an all-new platform, EPM
6000 has a superior cost to performance ratio and
significantly outperforms othe metering products
many times its price.

Applications
• Continuous metering of electrical loads such as Features
generator panels, feeders, switchgear etc. Monitoring and Metering
• Provides remote status when used with EnerVista • True RMS multifunction measurements including
suite of software voltage, current, power, freq.,
• Low and medium voltage applications energy, etc.
• Replaces multiple analog meters saving space • Meets ANSI C12.20 (0.2%) and IEC 687 (0.2%)
and installation costs accuracy classes
• Future field upgradeable for added functionality
Key benefits without removing installed meter
• High accuracy multifunction power meter • Load percentage graphical bar for instant load
• Superior performance at competitive pricing visualization
• Ultra compact, easy to install, program and use
• 0.2% class revenue certifiable energy and Communications
demand metering • RS485 Modbus and DNP 3.0 Protocol up to 57.6K
• Total harmonic distortion (%THD) Baud (Serial Option)
• Fits both ANSI and DIN cutout • Modbus TCP Protocol through 10/100BaseTX via
• Large 3 line .56” bright LED display for better RJ45 (Ethernet Option)
visibility and longer life • 3 Line .56” Bright Red LED Display
• User programmable for different system voltages • Front IrDA Port laptop communication
and current measurements • Pulse output for accuracy testing and energy
• Standard Modbus and DNP communications
For more information on EPM 6000, please see
• Optional Ethernet port for simplified integration https://www.gedigitalenergy.com/multilin/catalog/ epm6000.htm
into onto new or existing LAN infrastructures and
multi-point connectivity
146 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

EPM 6010 automation power meter

BACnet/IP communications and energy
measurement

Overview
The Multilin EPM 6010 is an industry leading
revenue grade power meter with native BACnet/IP
communications. This meter is designed to
integrate seamlessly into existing and new building
management systems using the popular BACnet
protocol. The meter allows users to gather data on
voltage, current, power and energy usage
throughout a facility. Features
Measuring and Metering
Designed to be the perfect device for • High accuracy multifunction power meter,
environmental initiatives, LEED certified projects 0.2% class revenue certifiable energy and demand
and smart energy projects, the EPM 6010 provides metering.
superior metrology, and revenue • Samples at 400+ times per cycle and has 24 bit
testable 0.2% energy accuracy. The meter is in A/D conversion to measure accurately and reliably
compliance with ANSI and IEC accuracy standards, • Meets ANSI C12.20 (0.2%) and IEC 687 (0.2%)
has advanced DSP technology, samples at high accuracy classes.
rates, and has 24 bit A/D conversion to measure • Total harmonic distortion (%THD)
and analyze power accurately and reliably. • Load percentage graphical bar for instant load
visualization.
Applications • True RMS multifunction measurements including
• LEED projects voltage, current, power, frequency and energy.
• Smart buildings
• Commercial energy management Communications
• HVAC efficiency monitoring • BACnet/IP 100BaseT Ethernet protocol
• Building management systems • 40 pre-defined BACnet objects facilitate rapid
integration
Key benefits • Embedded web-server, allows BACnet/IP
• Rapid integration into BACnet management interface to be remotely configured and BACnet
systems objects can be remotely viewed over the internet
• High accuracy multifunction power meter, with a web browser
0.2% class revenue certifiable energy and • Standard Modbus TCP communications can be
demand metering used to poll the EPM 6010 while BACnet/IP
• Ultra compact and easy to install, fits both ANSI interface is being used
and DIN cutouts
For more information on EPM 6010, please see
• EnerVista software makes metered data and https://www.gedigitalenergy.com/multilin/catalog/ epm6010.htm
power quality status easily accessible
• User programmable for different system voltages
and current measurements
• Standard Modbus and TCP communications
• Easy to read, large 3 line .56” bright LED display
for better visibility and longer life
T E C H N I C A L A P P L I C AT I O N G U I D E 147

EPM 7000 power meter

Power quality and energy cost measurement

Overview
The EPM 7000 meter provides revenue class (0.2%)
three phase power metering with optional
Ethernet, relay, status, and analog output
communication modules. This flexible meter can be
used for a wide range of high accuracy applications
including disturbance recording and power quality
studies.

EPM 7000 can easily be mounted in a panel for Features

generator monitoring, substation automation, Metering
power quality studies, data recording and more. • Meets ANSI C 12.20 and IEC 687 (0.2%) accuracy
The meter can also provide data to RTUs, PLCs and • Ia Ib Ic In
other control devices. • Va Vb Vc Vab Vbc Vca
• Hz W VAR VA
The EPM 7000 is a highly accurate meter providing • Wh VARh VAh
0.1% accuracy for Voltage and Current. The unit’s • Demand: W VAR VA
real-time clock provides time stamping of all logs • Power Factor
as they are created. Up to 4 MB of data can be • Voltage and Current Angles
logged for analysis of historical trends, limit • Load Bar
alarms, I/O changes power quality recording and
sequence of events. Power Quality
• Harmonics to the 40th order
Applications • Total Harmonic Distortion
• Four quadrant energy and power monitoring • Disturbance Recording and Waveform Capture
of distribution feeders, transformers, reactors • Sag and Swell
and generators.
• Power monitoring of LV and MV industrial power Data Logging
control centers and motor control centers. • Up to 4 MB Memory
• Energy monitoring of commercial and • Disturbance Recording
distribution utilities. • Power Quality Studies
• Load Studies
Key benefits
• Four Quadrant Energy and Power Measurement, Communications
complying with ANSI C12.20 (0.2% Accuracy) • Standard RS485 Modbus (DNP 3.0 and Modbus
• Analyze power quality over long periods of time RTU or ASCII)
to improve network reliability through high • Optional Ethernet 100BaseT
resolution event and disturbance recording • IrDA Port
• Ideal for monitoring industrial power centers, • Intuitive faceplate programming
data centers and hospitals due to high accuracy
disturbance recording (up to 512 samples/cycle) Software
• Retrieve archived data, capture past events and • Embedded Web Server
analyze disturbances through high resolution • Communicator
data recording (up to 4MB of data logging) • EnerVista Integrator
• Flexible communication options provide easy • EnerVista Launchpad
to access meter values, simplified configuration
For more information on EPM 7000, please see
and seamless integration into new or existing https://www.gedigitalenergy.com/multilin/catalog/epm7000.htm
automation systems
148 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

PQM II power quality meter Features

Power quality and energy cost management Monitoring and Metering
• Ia Ib Ic In
Overview • Va Vb Vc Vab Vbc Vca
Multilin has set a new standard in metering • V I unbalance
technology with the introduction of the PQM II. • True PF crest and K factor
This meter, designed on the latest industry • Hz W var VA
specifications, provides accurate and reliable • Wh varh VAh W cost
three-phase power metering with an optional • Demand: A W var VA
Ethernet and fiber communications module in • Harmonic analysis through 63rd with
a small and modern package. The PQM II can THD and TIF
be used for a variety of applications including • Event recorder - 150 events
metering of distribution feeders, transformers, • Waveform capture
generators and motors. • Data logger -98,000 events
• Voltage Disturbance Recorder (VDR)
Applications -500 events
• Metering of distribution feeders, transformers,
generators, capacitor banks and motors Communications
• Medium and low voltage systems • Front RS232 serial port (1,200 to 19,200 bps)
• Commercial, industrial, utility • Two rear RS485 serial ports with ModBus and
• Flexible control for demand load shedding, power DNP 3.0 protocol
factor, etc. • Ethernet connectivity provided by MultiNet
• EnerVista software is provided for setup and
Key benefits monitoring functions
• Power quality metering with waveform capture • External dial-in modem capabilities
and historical data logging
• Easy to program and use with keypad and large Protection and Control
illuminated 40 character display • Load shedding
• Multiple communication ports for integration • Power factor control
with DCS and SCADA systems • Pulse input totalizing
• Supports DNP 3.0 and Modbus protocols
For more information on PQM II, please see
• Digital and analog I/Os for control and alarms https://www.gedigitalenergy.com/multilin/catalog/pqmil.htm
• Voltage disturbance recording capability for
electrical sag and swell events
T E C H N I C A L A P P L I C AT I O N G U I D E 149

Three-phase voltage monitors

Model SPVRB

General
UL Listed file No. E103039 The model SPVRB
Voltage Sensing Relay is designed to protect
against single phase, phase loss, phase unbalance,
and phase reversal in a power system. The output
contacts change their normal state only when a
single phase, phase loss, phase unbalance, or phase
reversal occurs for longer than the preset trip delay.
A total power loss or de-energization of the SPVRB
relay will not change the output contacts position.
Recommended for manual reset switches and
breaker applications. The SPVRB is suitable for loss
of phase with motor loads.
¹ Bi-Colored LED Indicator
• Power system condition Normal (Green),
Features
Trip (Red)
• Phase unbalance: 8%
² Electromechanical Diagnostic Indicator
• Adjustable Trip Delay: 1 to 10 seconds after failure
• Phase loss
occurs, prevents nuisance operations
³ Adjustable System Delay
• Output Relay: normally de-energized, form C
• Phase loss
contacts for easy circuit configuration
• Phase unbalance
• Electro-mechanical indicator: retains memory of
• Single phase
fault until manually reset
• Phase reversal
• Door or panel mounting
• Under and over voltage
• Status Indicator: bi-colored LED
- Green: Output relay de-energized (2) 0.24 Dia.
(normal condition) Holes
- Red: Output relay energized (fault condition) Clearance
- Dark: Output relay de-energized (input holes for #12
power off) screws
• Single Phase, Phase Reversal, Phase Unbalance
and Phase Loss Protection: operates the output
relay after a preselected time
• Automatic or Manual mode
- Automatic mode: Upon removal of fault
conditions, relay automatically resets
to normal
- Manual mode: Upon removal of fault conditions,
relay resets to normal after local or remote
reset button has been pressed

SPVRB — XXX

Input Voltage:
120/208/240/480 or
Panel mounting layout
575 Vac, (60 Hz)
380 or 415 Vac, (50 Hz)
Output contact ratings
Available models

Model No. Nominal Vac Hz Voltage Continuous HP

SPVRB–120 120 60 120 Vac 10 A 1/3
SPVRB–208 208 60 240 Vac 10 A 1/2
SPVRB–480 480 60 600 Vac 3A 1/2
SPVRB–575 575 60 10 A, 28 Vdc/120 Vac/240 Vac, 80% pf
SPVRB–380 380 50 3 A, 480 Vac/600 Vac, 80% pf
SPVRB–415 415 50
150 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

High-resistance ground Line and control connections

The line connections are made to the main bus. The
Equipment overview control power and auxiliary device connections are
High Resistance Grounding Equipment coordinates made to the terminal blocks rated 30 amperes, 600
the use of resistors and control devices, creating a volts. Refer to the specific diagrams furnished with
high-resistance ground for a power system. The the equipment for location detail. Setup
grounding equipment has the following features: information is through the operator’s panel.
• Over-voltage reduction: Reduces the transient
over voltages that can occur during arcing faults. Where to use
• Fault detection: Gives immediate warning when The function of high-resistance grounding
the first ground fault occurs. equipment is:
• Fault tracking: Helps locate the fault by 1. To provide a ground for neutral of an ungrounded
producing a tracer signal of current pulses easily threephase power system, utilizing the high-
distinguishable from background noise. resistance method. Using this equipment allows
• Operation protection: Enables the system to the system to operate basically as an ungrounded
continue operation with a single line-to ground system. The equipment is designed to eliminate
fault present. the danger of high-transient overvoltages during
certain types of ground faults.
Operational description – low-voltage
systems (600v max) Note: The use of high-resistance grounding
Typical circuit used in low-voltage is shown on 600 volt maximum systems precludes
on page L22. line-to-neutral loading.

When a ground fault occurs, the resistor acts to 2. To provide an immediate warning when
limit the ground current to a pre-determined low the first ground fault occurs through an
value. Taps are provided on the resistor to adjust alarm system.
the fault current. The voltage appearing across the 3. To provide a method for quickly locating
resistor or the amperage through the resistor is and removing the fault before another fault
sensed by the PulserPlus Pro Controller. A variable develops on another phase, thereby preventing
time delay is entered via the operator’s panel. When circuit outages due to double line-toground
the time delay expires, the red Ground Fault faults. This is done by using the pulsing ground
indicator light will illuminate. Auxiliary contacts are current feature and portable detector.
provided in case a remote indication of the fault is
Approximate dimensions and weights
needed or desired. The red light will stay
illuminated until the ground fault is removed and Without
Equipment With pulsor
WxDxH pulsor in
the system is reset. Optionally, the PulserPlus Pro enclosure in pounds
(inches) pounds
type
can be set for auto-reset. In addition, an audible Wye Delta Wye Delta
alarm will sound when the ground fault occurs. This 20 x 20 x
NEMA 1 600 700 575 675
alarm can be silenced from the 90
operator’s panel.
600 Volt maximum Wye system
PULSING CONTACTOR

Features NGI SW1

• Undervoltage and undercurrent detection NEUTRAL

CURRENT LOOP INPUT

and alarm
VOLTAGE INPUT

A#
CONTROL MODULE
• Adjustable pulser from 10 to 50 per minute CPT LINE
B#

for custom setup FUSES INTERLOCKING

DISCONNECT

• Adjustable trip delay to avoid ALARM CONTACTS

OPERATOR
nuisance downtime INTERFACE

• Alarm contacts for remote monitoring of ground 600 Volt maximum Delta system
fault, high harmonics and loss of ground PULS

• High harmonic filtering and detection

• Third harmonics generator winding protection
• Remote operation and monitoring via RS232,
Modbus or Ethernet communication

PulserPlus Pro is a trademark of Post Glover.

T E C H N I C A L A P P L I C AT I O N G U I D E 151

MM200 motor management system Features

Low voltage motor protection and control Protection and control
• Motor thermal model
Overview • Undercurrent
The MM200 meter integrates protection, control • Current unbalance
and multiple communication protocols in a rugged • Acceleration time
compact device for low volage motor applications. • Sensitive ground fault
Easily integrated into new and existing control • Built-in starter logic
system architectures, the MM200 provides • FVNR, FVR, two-speed
comprehensive low voltage motor protection • Auto / manual control
and communications for all types of motor • Configurable inputs
protection applications. • Power fail restart

Applications Metering and monitoring

• Low Voltage Three-Phase AC Motors • Current, motor loads, thermal capacity
• MCC and standalone Panel Mount Applications • Motor running time, cause of trip, total number of
• IEC NEMA Motor Control Center (MCCs) trips
• Process control applications • 1A / 5A combined CT inputs
• System architecture requiring multiple
simultaneous communications Communications
• FVNR, FVR, two speed • Networking through RS485
• Multiple Protocols - Modbus RTU ODVA Compliant
Key benefits DeviceNet Internally
• Flexible Protection, Control, and Communication powered Profibus
options to suit Low Voltage Motor applications • Simultaneous Communications
• Small footprint designed specifically for IEC and
NEMA MCC applications User Interface
• Integrated pushbuttons and LED indicators • Optional Control Panel with control push buttons
reduce external components and wiring and LED status indicators
• Flexible DIN rail mounting • Includes EnerVista MM200 Setup software for
• Multiple communication protocols allows simple simple programming and retrieval of system or
integration into monitoring and control systems trip information
• Optional control panel provides local control
EnerVista Software
• State of the art software for configuration and
commissioning Multilin products
• Graphical Logic Designer and Logic Monitor to
simplify designing and testing procedures
• Document and software archiving toolset to
ensure reference material and device utilities are
up-to-date

For more information on MM200, please see

https://www.gegridsolutions.com/multilin/catalog/mm200.htm
152 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

MM200 motor management system

Functional block diagram

ANSI device numbers and functions

Device No. Function

37 Undercurrent
46 Current unbalance
49 Thermal overload
50G Ground instantaneous overcurrent
51R Locked/Stalled rotot, mechanical jam

52

BUS

Power Fuse

7 inputs and 3 outputs (standard)

24 V DC

Temperature
Metering
Contactor
Thermistor A

51R 49 37 45
Phase CT 3

51G
Ground CT 1

RS485 - Modbus RTU

Profibus/DeviceNet

MM200
Motor Load
Motor Management System
T E C H N I C A L A P P L I C AT I O N G U I D E 153

MM200 motor management system Dimensions

User interface Side view

Front panel controls

• Integrated device controls

12 LED indicators
• Motor status
• Alarm indication and trip
• Communication status
• Additional user LEDs
• Auto/manual Front view
• % motor load

Top view

Optional FieldbusProtocols 3 Phase CT inputs

(ProfiBus or DeviceNet)

Power supply and digital

RS485 Communications
inputs
and thermistor input
• 24 VDC Power supply
• 7 x 24 VDC inputs (wet)
• 60-300VAC power supply
• 6x AC inputs

• Sensitive ground fault

Optional control • 2 Form A outputs (5 Amps)
panel interface • 1 Form C outputs (5 Amps)
154 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

MM300 motor management system Features

Integrated automation and protection for low Protection and Control
voltage motors • Enhanced Thermal Modeling
• Mechanical Jam / Stalled Rotor
Overview • Undercurrent
The MM300 meter integrates protection, control, • Underpower
automation, metering, diagnostics and multiple • Acceleration Time
communication protocols in a rugged compact • Current Unbalance
device for low volage motor applications. Designed • Ground Fault
for Motor Control Centers, the MM300 delivers • Sensitive Ground Fault
superior protection and control to extend • Phase Overvoltage / Undervoltage
equipment life and maximize process uptime. • Auxiliary undervoltage
• Phase reversal
Applications • VT fuse failure
• Low Voltage three-phase AC motors • Thermistor
• MCC or stand alone panel mount applications • RTD overtemperature
• Reversing and reduced voltage applications
• Motor applications requiring advanced Automation
automation or control such as conveyor systems • Programmable flexlogic option
or well recovery pumps • Starter control
• IEC or NEMA class motors • Process interlocks
• Programmable inputs and outputs
Key benefits • Undervoltage auto-restart
• Full-featured protection for low voltage
AC motors Metering and Monitoring
• Advanced automation capabilities for providing • Metering — Current, Voltage, Power, Energy,
customized protection and integrated Frequency, RTD, Thermistor
process control • Oscillography — Analog Values at 32 Samples/
• Advanced FlexLogic reduces requirement for local cycle and Digital States
PLC’s • Event Recorder — Up to 256 Time Tagged Events
• Reduced installation space requirements through with 1ms re
integration of multiple devices including • Advanced Device Health Diagnostics
protection, control functions, pushbuttons,
status LEDs and Communications
communication interfaces • Networking Interfaces — Two Wire RS485,
• Application flexibility with multiple I/O options RJ45 Ethernet
and programmable logic options (FlexLogic) • Multiple Protocols (Modbus RTU , Modbus TCP/IP,
• Enhanced troubleshooting tools including Internally Powered Profibus, ODVA Compliant
sequence of event records and DeviceNet)
waveform capture • Programming Ports - USB, RS485
• Powerful communications including Serial, • Network Time Protocol (When Ordered
Ethernet, Profibus, and DeviceNet protocols with Ethernet)
• Small form factor and remote display options
designed to fit in MCC buckets
 T E C H N I C A L A P P L I C AT I O N G U I D E 155

User Interface MM300 motor management system

• Control Panel with 12 Status LED’s, Motor Control Functional block diagram - ANSI device numbers
and Function Keys and functions
• Color HMI Display featuring a full color graphical
display, Motor and system status LED’s, USB Device No. Function

programming port and motor control keys 27AUX Undervoltage - Auxiliary Input
27 Undervoltage - Three Phase
37 Undercurrent/Underpower
EnerVista Software
38 Bearing Temperature RTD
• State of the art software for configuration and
46 Current Unbalance
commissioning Multilin products
47 Voltage Phase Reversal
• Graphical Logic Designer and Logic Monitor to
49 Thermal Overload
simplify designing and testing procedures
50G Ground Instantaneous Overcurrent
• Document and software archiving toolset to 51G Ground Time Overcurrent
ensure reference material and device utilities are 51R Locked/Stalled Rotor/Mechanical Jam
up-to-date 59 Overvoltage - Three Phase
66 Starts/Hour and Time Between Starts
For more information on MM300, please see
https://www.gegridsolutions.com/multilin/catalog/mm300.htm

52

BUS

Power Fuse Control PT

Control
fuse
27X
6 inputs and 2 outputs (standard)
Direct voltage inputs
Optional
(690 V AC maximum) three-phase
voltage
27 59 47
card
Metering
Contactor
V, A, W, var, VA, PF, Hz

51R 49 37 66 46
Phase CT 3

Ambient air 50G 51G Expansion module,

Ground CT 1 two cards per module,
Stator RTDs maximum of two modules
RTD 49
Bearing RTDs
• Six inputs and two form-A outputs (max 5 cards)

Temperature 38 • Three RTDs – 100 ohm Platinum (max 2 cards)

• Foour form-C contact outputs (max 4 cards)

Thermistor
• Three-phase voltage card (max 1 card)

Optional
Load RTD
card
Motor

RS485 - Modbus RTU

MM300
Options

Options

Ethernet - Modbus TCP/IP

Motor Management System
Profibus/DeviceNet
156 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

MM300 motor management system

User interface

Dimensions
T E C H N I C A L A P P L I C AT I O N G U I D E 157

Integrated tranquell HE and ME

Surge protective device (SPD) with enhanced
thermal protection

Overview
Surge protective devices (SPD) are engineered
for reliability, flexibility and long life in the most
extreme surge environment. The true maximum
surge current rating has been proven successful
in third-party tests.

These SPD models connect to the panelboard or

switchboard bus bars without adding width or
depth to the panel enclosure, and only occupying
7X of vertical bus space. Third-party tested per
IEEE C62.62 and NEMA LS-1 for the rated 8x20μs
surge current, per mode with fusing included.
Features and benefits
Standard features include a surge counter, audible
• UL 1449 3rd Edition, Type 1 or Type 2
alarm, indicating lights, dry contacts and an
• UL 1283, EMI/RFI noise filter
integral surge rated disconnect. Rating options
• UL 96A, Lightning Protection System
range from 65kA per mode to 300kA per mode.
• cUL, CSA C22.2
• Integral surge rated disconnect
All mode protection is provided with surge
• Compact design requires only 7X height
components (MOVs) connected on the phase to
of space
neutral, phase to ground and neutral to ground
• Tranquell ME device is tested to a minimum of
paths as appropriate for the voltage configuration.
5,000 category C3 impulses (10kA, 20kV)
per mode
Technical specifications
• Tranquell HE device is tested to a minimum of
20,000 category C3 impulses (10kA, 20kV)
Nominal discharge current (in): 20ka
per mode
Short circuit current rating (SCCR): 200kA
• Industrial-sized MOV technology
Operating frequency: 50/60 Hz
• Thermally protected MOVs eliminate the need
Connection: 6 to 2/0 Conductors,
for additional upstream overcurrent protection
Parallel Connected
• Form C dry contacts for remote monitoring
Operating temperature: -40° F to 149° F
• Green status indicating lights, red alarm light
(-40° C to +65° C)
• Audible alarm with test/disable feature
Operating humidity: 0% to 95% Non-Condensing
• LCD surge counter
Weight: 24 lbs. (10.89 kg)
• 5 year limited warranty (standard), 10 year
limited warranty (optional)
158 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Integrated Tranquell HE and ME

Surge protective device (SPD)

Catalog number

MCOV Max. Maximum Surge

System Current Capacity
Nominal Voltage Continuous
(Volts RMS) Voltage
Configuration Operating
Voltage Exposure Per Per (integral to
For all kA ratings
L-N/G (Vrms) Level Mode Phase PP Spectra panel or switchboard)
TPHE 120S 120/240 1 Ph, 3 W + G 150 06 TPME 65kA 130kA for UL Type 2 Locations
TPME 120Y 120Y/208 3 Ph, 4 W + G 150 08 TPME 80kA 160kA For all TPHE devices (125kA -
220Y 220Y/380 3 Ph, 4 W + G 320 10 TPME 100kA 200kA SG 300kA)integral to switchgear
for UL Type 2 Locations
240D 240 Delta 3 Ph, 3 W 270 12 TPHE 125kA 250kA
240H 120/240 Delta HL 3 Ph, 4 W + G 150/270 HL 15 TPHE 150kA 300kA (integral to
For all kA ratings
ME MCC)for UL Type 2 Locations
240Y 240Y/415 3 Ph, 4 W + G 320 20 TPHE 200kA 400kA
277Y 277Y/480 3 Ph, 4 W + G 320 25 TPHE 250kA 500kA (integral to
For all kA ratings
347Y 347Y/600 3 Ph, 4 W + G 420 30 TPHE 300kA 600kA PPT1 Spectra panel or switchboard)
for UL Type 1 Locations
480D 480 Delta 3 Ph, 3 W 550
For all TPHE devices (125kA -
SGT1 300kA)integral to switchgear
for UL Type 1 Locations

(integral to
For all kA ratings
MET1 MCC)for UL Type 1 Locations

Protection ratings

Voltage Code 120S / 120Y 240D 240H 220Y / 240Y / 277Y 347Y 480D
Protection Mode L-N L-G N-G L-L L-G L-L L-N HL-N L-G HL-G N-G L-L HL-L L-N L-G N-G L-L L-N L-G N-G L-L L-G L-L
UL 1449, 3rd edition Voltage
Protection Ratings (VPR) 900 800 700 1200 1200 1800 1000 1200 800 1200 700 2000 2200 1500 1200 1200 2000 1500 1500 1500 2500 1800 3000
(assigned UL rating)
UL 1449, 2nd edition
Suppression Voltage Ratings 400 400 400 700 800 1500 500 700 400 700 400 900 — 800 800 800 1500 1200 1000 1000 2000 1500 3000
(SVR) (assigned UL rating)*
B3 Ring Wave Clamping
470 463 452 752 750 1240 465 — 466 — 476 1025 — 763 836 828 1393 883 1000 1000 1723 1223 1800
Voltage @ 6kV, 500A
C3 Combo Wave Clamping
793 670 680 1007 890 1640 775 — 670 — 680 1163 — 1170 1073 1180 1827 1467 1240 1240 2220 1607 2933
Voltage @ 20kV, 10kA

*Note: SVR Ratings are no longer assigned by UL

and are included in the table above for reference
purposes only.

Dimensions

17.722 0.280
[450.130] 6.964
[ 7.112] HOLE [176.877]
17.382
0.340 (4 PLACES)
[441.494]
[8.636]
9.400
[238.755]
7.202
[182.922]
6.762
[171.751] TYP

2.638
[67.004] TYP

Note: All dimensions

NOTE: All dimensions areandfor
are for reference only reference
are shown only
in inches [millimeters]
See instruction manual for details
and are shown in inches [millimeters]
See instruction manual for details
 T E C H N I C A L A P P L I C AT I O N G U I D E 159

Application data

Approximate motor full-load current ratings

Full-Load Current for EPAC Compliant Motors

Average expected values

For three-phase, 60 Hertz, Type KE (NEMA Design
B) dripproof, normal starting torque, continuous
40°C ambient (1.15 service factor) horizontal
induction motors.

Average expected values Average expected values

Motor Synchronous of full-load currents Motor Synchronous of full-load currents
HP speed, RPM HP speed, RPM
200V 230V 460V 575V 200V 230V 460V 575V
1800 1.6 1.4 0.70 0.56 3600 9.4 8.0 4.0 3.3
1/4¹
1200 1.7 1.5 0.75 0.60 1800 9.9 7.9 3.9 3.4
3
3600 2.0 1.7 0.85 0.68 1200 12.0 8.6 4.3 4.2
1/2¹ 1800 1.7 1.5 0.75 0.60 900 15.4 13.4 6.7 5.4
1200 2.0 1.7 0.85 0.68 3600 15.4 12.2 6.1 5.4
3600 2.0 1.8 0.88 0.70 1800 14.4 12.6 6.3 5.7
5
1800 2.3 2.0 1.0 0.80 1200 19.3 14.0 7.0 6.7
1/2
1200 2.3 2.0 1.0 0.80 900 19.8 17.2 8.6 6.9
900 3.2 2.8 1.4 1.4 3600 21.4 18.0 9.0 7.5
3600 2.8 2.4 1.2 0.96 1800 23.7 18.0 9.3 8.2
7 1/2
1800 3.2 2.8 1.4 1.1 1200 26.0 19.8 9.9 9.0
3/4
1200 3.7 3.2 1.6 1.3 900 28.5 24.0 12.4 9.9
900 4.4 3.8 1.9 1.5 3600 27.4 24.0 12.0 9.5
3600 3.7 3.2 1.6 1.3 1800 27.0 23.8 11.9 10.9
10
1800 4.1 2.2 1.6 1.4 1200 32.7 25.8 12.9 11.4
1
1200 4.4 4.6 2.3 1.5 900 33.1 28.8 14.4 11.5
900 5.5 4.8 2.4 1.9 3600 42.6 36.0 18.0 14.8
3600 5.3 4.8 2.4 1.8 1800 40.3 35.0 17.6 16.2
15
1800 6.0 4.4 2.2 2.1 1200 45.1 33.0 19.1 15.7
1 1/2
1200 6.0 4.6 2.3 2.1 900 47.6 41.4 20.7 16.6
900 7.1 6.2 3.1 2.5 3600 62.3 45.4 22.7 21.7
3600 6.9 6.0 3.0 2.4 1800 53.2 46.2 23.1 20.6
20
1800 7.1 5.8 2.9 2.5 1200 56.6 50.0 25.0 19.7
2
1200 7.6 6.2 3.1 2.6 900 63.9 55.6 27.8 22.2
900 10.6 9.2 4.6 3.7
160 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Average expected values Note: The listed data is based on

Motor Synchronous of full-load currents approximate full-load current ratings of
HP speed, RPM
200V 230V 460V 575V standard, open, 1.15 service factor,
3600 72.0 56.0 28.0 25.0 continuous rated General Electric motors.
1800 71.3 60.0 30.0 24.8 Full-load current ratings of similar motors
25
1200 73.8 63.2 31.6 25.7 of other manufacturers may vary
900 82.6 71.8 35.9 28.7
considerably. Therefore, whenever possible
3600 85.6 67.8 33.9 29.8
use actual full-load current rating given on
1800 81.7 71.2 35.6 29.9
30 motor nameplate. Contact motor
1200 88.6 73.8 36.9 30.8
manufacturer for full-load currents of
900 92.2 80.2 40.1 32.1
single-phase and DC motors.
3600 101 89.0 44.6 39.2
1800 112 97.8 48.9 40.3
40
1200 114 99.6 48.5 39.8
900 122 105.8 52.9 42.3
3600 140 129 64.5 48.9
1800 142 122 61.1 49.4
50
1200 144 125.2 61.0 50.1
900 159 138.2 69.1 55.3
3600 163 145.6 72.8 56.6
1800 172 147.4 73.7 59.9
60
1200 172 149.2 69.8 59.7
900 176 153.4 76.7 61.4
3600 206 181 90.5 71.5
1800 207 180.0 91.6 72.0
75
1200 206 719.2 86.7 71.7
900 221 191.8 95.9 76.7
3600 262 238 119 91.2
1800 281 232 116 97.7
100
1200 283 246 118 98.4
900 296 258 129 103
3600 338 290 139 116
1800 340 296 143 118
125
1200 352 306 149 122
900 370 322 161 129
3600 398 346 164 138
1800 412 348 169 143
150
1200 419 364 177 146
900 435 378 189 151
3600 446 217 178
200 1800 468 226 187
1200 482 239 193
3600 574 287 230
250 1800 590 295 236
1200 594 297 238
3600 676 338 270
300
1800 686 340 274
3600 774 387 310
350
1800 792 396 317
400 3600 890 445 356

1. O
 pen, Type K, general purpose, NEMA SF, solid
base, rolled-steel-shell, induction motors.
 T E C H N I C A L A P P L I C AT I O N G U I D E 161

Mag-break magnetic circuit breaker trip set positions Spectra RMS circuit breaker current ratings
The greatest degree of protection is provided when the
magnetic trip setting is just above the motor starting inrush Instantaneous trip setting,
Max. Rating nominal RMS sym. Amperes
current. It is therefore recommended that the magnetic trip Frame frame plug Trip setting adjustment position
position be adjusted to a setting one position higher than Amps Amps
Min. 2 3 4 5 6 Max.
the setting that carries the motor starting current. For 3 11 13 16 19 24 31 39
7
recommended continuous-current ratings, see overload 7 22 27 35 43 56 71 90
heater tables on pages J-5 through J-12. 15 43 55 69 86 111 143 182
20 58 74 93 116 151 196 254
30
25 73 93 117 147 193 253 332
Cat No. Cont. Trip setting positions
30 87 112 142 179 237 314 415
3 Pole Amperes Lo 2 4 6 8 10 Hi
40 118 150 188 237 308 394 501
TEC36003 3 8 13 18 23 28 33 38
60 50 148 187 236 296 386 498 637
TEC36007 7 18 30 42 54 66 78 90 SE
60 178 224 284 355 464 604 777
TEC36015 15 42 68 94 120 146 172 198
70 206 261 329 411 534 684 863
TEC36030 30 90 140 190 240 290 340 390
80 236 299 377 472 614 787 999
TEC36050 50 180 260 340 420 500 580 660 100
90 267 338 426 532 694 892 1138
TEC36100 100 300 468 636 804 972 1140 1300
100 297 376 475 593 775 998 1280
TEC36150 150 600 950 1300 1650 2000 2350 2700
110 328 415 524 654 857 1105 1426
TFC36225 225 600 780 1020 1200 1400
150 125 374 474 598 745 979 1265 1640
TFC36225A 225 1000 1200 1630 1920 2250
150 450 570 720 897 1181 1528 1991
TJC36400B 400 1200 1400 1850 3250 4000
Min. 2 3 4 5 Max.
TJC36400E 400 330 435 600 860 1100
70 205 260 330 410 535 700
TJC36400F 400 550 720 945 1280 1670
90 265 335 425 530 690 900
TJC36400G 400 1000 1280 1780 2360 3300
100 295 375 470 590 765 1000
TJC36600G 600 1000 1280 1780 2360 3300
110 325 410 520 650 845 1100
TJC36600H 600 1800 2100 2600 3600 6000
125 370 465 570 740 960 1250
SF 250
150 440 560 705 885 1150 1500
175 515 655 825 1035 1345 1750
200 590 750 940 1180 1535 2000
225 665 840 1050 1330 1730 2250
250 740 935 1180 1480 1920 2500
125 380 480 620 765 990 1275
150 455 575 740 920 1185 1530
175 530 670 865 1070 1385 1785
200 605 765 990 1225 1580 2040
400 225 680 860 1115 1375 1780 2295
250 755 955 1235 1530 1975 2550
300 905 1145 1480 1835 2370 3060
350 1060 1340 1730 2140 2765 3570
SG
400 1210 1530 1980 2445 3160 4080
250 765 965 1215 1500 1960 2530
300 915 1155 1455 1800 2355 3035
350 1070 1350 1700 2100 2745 3545
600 400 1200 1540 1940 2400 3135 4050
450 1375 1735 2185 2695 3530 4555
500 1525 1925 2425 2995 3920 5060
600 1830 2310 2910 3595 4705 6075
300 940 1150 1445 1795 2375 3015
400 1255 1535 1930 2395 3165 4015
500 1570 1915 2410 2990 3955 5020
800
600 1875 2290 2895 3610 4740 6195
700 2155 2665 3375 4240 5525 7420
SK 800 2440 3035 3860 4875 6305 8705
600 1825 2310 2905 3685 4730 6110
700 2125 2695 3390 4300 5515 7125
1200 800 2430 3080 3870 4910 6305 8145
1000 3040 3850 4840 6140 8880 10180
1200 3650 4620 5805 7370 9455 12215
162 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Thermal magnetic trip ratings for motor circuits

These selections are based on 2005 National
Electric Code requirements for squirrel-cage
motors without code letters or with code letter
through G. Lower trip ratings may be required for
motor with code letter A and higher trips for
motors with code letters H to V. Local code or
specific application requirements may necessitate
special selection. Thermal-magnetic circuit breaker
combination motor control units are not
recommended for motors with full-load currents of
3.8 amperes or less.

NEMA Motor CB 200/208V 230V 380V 460V 575V NEMA Motor CB 200/208V 230V 380V 460V 575V
size HP type trip trip trip trip trip size HP type trip trip trip trip trip
2 15 15 15 15 15 50 200 / 250
3 20 15 15 15 15 225 /
60 300
1 5 SE 30 30 20 15 15 250
7.5 50 30 30 20 20 300 /
75 350
350
10 30 20 20
225 /
10 50 50 100 400
5 SGL 250
15 70 50 40 30
2 SE 225 / 225 /
20 70 50 40 125 300
250 250
25 70 60 50 300 /
150 300 250
15 70 350
20 100 100 350 /
200 300
25 100 100 400
3 SE 100 500
30 125 100 70 50
40 100 100 70 125 800 800
50 125 125 100 150 SGL/ 800 800
30 125 200 SKL 1000 500
6
40 200 150 250 800 500 400
50 SF 200 300 800 600 500
4 350 800 800
60 SGL 150 150 100 SKL
75 200 200 125 400 1000 800
100 225 150
T E C H N I C A L A P P L I C AT I O N G U I D E 163

Motor selection table for spectra motor circuit protectors

Max HP per system voltage Starter Rating plug

CB sensor CB frame
208V 230V 380V 460V 575V Size Amps CAT#
0.5 0.5 1.0 1.0 1.5 3 SRPE7A3
7
1.0 1.5 3.0 3.0 3.0 7 SRPE7A7
2.0 3.0 5.0 5.0 7.5 15 SRPE30A15
3.0 5.0 10.0 10.0 10.0 1 20 SRPE30A20
30
5.0 25 SRPE30A25
— 7.5 30 SRPE30A30
7.5 40 SRPE60A40 60
15 25 SRPE30A25
30
15 20 30 SRPE30A30
SE 150
15 25 2 40 SRPE60A40
10 10 25 25 50 SRPE60A50 60
15 60 SRPE60A60
25 30 50 SRPE60A50
30 30 40 70 SRPE100A70 100
3-4
25 25 50 60 60 100 SRPE100A100
30 150 SRPE150A150 150
60 100 SRPE150A100
4RVAT(¹) 150
40 50 75 100 100 150 SRPE150A150
60 60 75 150 SRPF250A150
4STD 200 SF 250
40 50 75 100 100 200 SRPF250A200
50 50 100 125 150 250 SRPG400A250
60 60 125 150 300 SRPG400A300
5 400 SG 600
75 75 150 200 350 SRPG400A350
100 200 400 SRPG400A400
250 400 SRPG800A400
600 SG 600
100 200 250 300 500 SRPG800A500
6
150 150 300 350 400 800 SRPK1200A800
1200 SK 1200
200 400 1000 SRPK1200A1000

1. Size 4 RVAT with SF CB requires an additional 6" height extension.

164 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Overload heater tables Size 0 and 1 (standard and ambient comp.)

Heaters for thermal-mag controllers Motor full- Heater Motor full-load Heater
load Amps number Amps 3-Ph, number
For continuous rated motors with a service factor 3-Ph, 3 Heater CR 123 3 Heater CR 123
of 1.15 to 1.25, select heaters from the heater table. .41-.45 C054A 4.96-549 C592A
For continuous rated motors with a service factor .46-.49 C060A 5.50-5.91 C630A
of 1.0, multiply the motor full-load current by 0.9 .50-.53 C066A 5.92-6.47 C695A
and use this value to select heaters. .54-.59 C071A 6.48-7.20 C778A
.60-.65 C078A 7.21-8.22 C867A
Overload relay tripping current in 40°C ambient is .66-.76 C087A 8.23-8.72 C955A
the minimum value of full load current multiplie .77-.84 C097A 8.73-9.67 C104B

by 1.25. .85-.93 C109A 9.68-10.4 C113B

.94-1.04 C118A 10.5-11.0 C125B
1.05-1.15 C131A 11.1-12.4 C137B
Provide short circuit protection in accordance with
1.16-1.27 C148A 12.5-13.2 C151B
the National Electrical Code.
1.28-1.39 C163A 13.3-15.4 C163B
1.40-1.55 C184A 15.5-17.1 C180B
Warning: Opening of the circuit breaker may be an
1.56-1.73 C196A 17.2-18.0 C198B
indication that a fault current has been interrupted. 1.74-1.89 C220A
To provide continued protection against fire or Size 1
1.90-2.05 C239A
shock hazard, all current-carrying parts and other 2.06-2.28 C268A 17.2-18.1 C198B
components of the motor controller should be 2.29-2.47 C301A 18.2-20.0 C214B
examined and replaced if damaged. If heater 2.48-2.79 C326A 20.1-21.5 C228B
burnout occurs, the complete overload relay must 2.80-3.31 C356A 21.6-22.5 C250B
be replaced. 3.32-3.70 C379A 22.6-23.9 C273B
3.71-4.06 C419A 24.0-26.3 C303B
4.07-4.47 C466A 26.4-27.0 C330B
4.48-4.95 C526A
T E C H N I C A L A P P L I C AT I O N G U I D E 165

Size 2 (standard and ambient comp.) Size 4 (standard and ambient comp.)

Motor full- Heater Motor full-load Heater Motor full-load Heater Motor full-load Heater
load Amps number Amps 3-Ph, number Amps 3-Ph, number Amps 3-Ph, number
3-Ph, 3 heater CR 123 3 heater CR 123 3 heater CR 123 3 heater CR 123
27.1-32.2 F357B 28.8-32.0 F357B
5.48-5.85 C630A 16.8-17.9 C180B
32.3-34.0 F395B 32.1-34.2 F395B
5.85-6.47 C695A 18.0-18.7 C198B
34.1-36.8 F430B 34.3-36.7 F430B
6.48-7.35 C778A 18.8-20.4 C214B
36.9-44.6 F487B 36.8-43.9 F487B
7.36-8.06 C867A 20.5-22.7 C228B
44.7-48.4 F567B 44.0-46.6 F567B
8.07-9.03 C955A 22.8-24.7 C250B
48.5-53.9 F614B 46.7-52.6 F614B
9.04-9.61 C104B 24.8-26.3 C273B
54.0-57.4 F658B 52.7-55.6 F658B
9.62-10.5 C113B 26.4-29.5 C303B
57.5-60.0 F719B 55.7-58.7 F719B
10.6-11.6 C125B 29.6-32.5 C330B
60.1-69.5 F772B 58.8-67.1 F772B
11.7-12.5 C137B 32.6-36.7 C366B
69.6-71.7 F848B 67.2-70.6 F848B
12.6-13.6 C151B 36.8-41.9 C400B
71.8-79.9 F914B 70.7-76.3 F914B
13.7-16.7 C163B 42.0-43.2 C440B
80.0-92.3 F104C 76.4-88.7 F104C
43.3-45.0 C460B
92.4-97.0 F114C 88.8-93.4 F114C
97.1-108 F118C 93.5-105 F118C
Size 3 (standard and ambient comp.)
109-118 F133C 106-114 F133C

Motor full- Heater Motor full- Heater 119-131 F149C 115-128 F149C
load Amps number load Amps number 132-135 F161C 129-131 F161C
3-Ph, 3 heater CR 123 3-Ph, 3 heater CR 123 132-135 F174C
19.0-19.3 F233B 17.8-18.4 F233B
19.4-22.1 F243B 18.5-21.1 F243B
Size 5 (standard and ambient comp.)
22.2-23.4 F270B 21.2-22.1 F270B
23.5-27.0 F300B 22.2-26.1 F300B Motor full-load Heater Motor full-load Heater
27.1-29.1 F327B 26.2-28.0 F327B Amps 3-Ph, number Amps 3-Ph, number
3 heater CR 123 3 heater CR 123
29.2-31.8 F357B 28.1-31.3 F357B
109-118 C592A 185-200 C104B
31.9-33.9 F395B 31.4-33.3 F395B
119-128 C630A 201-221 C113B
34.0-37.6 F430B 33.4-34.3 F430B
129-138 C695A 222-237 C125B
37.7-41.9 F487B 34.4-40.9 F487B
139-155 C778A 238-262 C137B
42.0-47.7 F567B 41.0-44.7 F567B
156-168 C867A 263-270 C151B
47.8-52.1 F614B 44.8-51.0 F614B
169-184 C955A
52.2-55.8 F658B 51.1-52.0 F658B
55.9-59.7 F719B 52.1-55.4 F719B
59.8-68.1 F772B 55.5-63.3 F772B
68.2-71.5 F848B 63.4-66.1 F848B
71.6-78.2 F914B 66.2-73.5 F914B
78.3-87.5 F104C 73.6-82.2 F104C
87.6-90.0 F114C 82.3-90.0 F114C
166 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Overload heater tables Size 0 and 1 (standard)

Heaters for mag controllers Motor Mag-break trip setting

Heater
full-load SE rating
The Mag-Break protector is factory adjusted to the number
Amps 3-Ph, plug Rec. Max.
CR 123
minimum trip setting. 3 heater
.65-.74 C087A 3 LO LO
Warning: To maintain overload, short circuit, and .75-.84 C097A 3 LO LO
ground fault protection, use the following .85-.92 C109A 3 LO LO

instructions to select heaters and to adjust the .93-1.02 C118A 3 LO 2

1.03-1.10 C131A 3 LO 2
Mag-Break trip setting.
1.11-1.23 C148A 3 LO 2
1.24-1.38 C163A 3 LO 3
For continuous rated motors with a service factor
1.39-1.49 C184A 3 LO 4
of 1.15 to 1.25, select heaters from the heater table.
1.50-1.67 C196A 3 LO 4
For continuous rated motors with a service factor
1.68-1.79 C220A 3 LO 5
of 1.0, multiply motor fullload current by 0.9 and 1.80-1.98 C239A 3 2 5
use this value to select heaters. 1.99-2.24 C268A 3 3 5
2.25-2.43 C301A 3 3 6
Use the heater table to verify that the Mag-Break 2.44-2.75 C326A 7 LO 3
and current limiter rating is correct for the motor 2.76-3.25 C356A 7 LO 4
full-load current. Then set the Mag-Break trip 3.26-3.43 C379A 7 LO 4
setting to the recommended value. 3.44-4.03 C419A 7 2 4
4.04-4.43 C466A 7 2 5
If the Mag-Break trips when starting the motor, 4.44-4.94 C526A 7 3 5
increase trip setting one step at a time until the 4.95-5.36 C592A 7 3 6

motor can be consistently started. 5.37-5.77 C630A 7 4 6

5.37-5.77 C630A 15 LO 3
5.78-6.35 C695A 15 LO 3
Do not exceed the maximum trip setting shown in
6.36-6.92 C778A 15 LO 4
the heater table.
6.93-7.99 C867A 15 2 4
8.00-8.47 C955A 15 2 5
Overload relay tripping current in 40°C ambient is 8.48-9.19 C104B 15 3 5
the minimum value of heater full-load current 9.20-10.0 C113B 20 2 4
multiplied by 1.25. 10.1-10.7 C125B 20 2 5
10.8-12.0 C137B 20 2 5
Warning: Overload relays with automatic reset may 12.1-12.9 C151B 20 3 5
automatically start a motor connected to a 2-wire 13.0-15.1 C163B 20 4 6
control circuit. When automatic restarting is not 15.2-16.3 C180B 25 3 5
desired, use a 3-wire control circuit. 16.4-17.9 C198B 25 3 6

Warning: Tripping of the Mag-Break may be an Size 1 (standard)

indication that a fault current has been interrupted.
To provide continued protection against fire or Motor Mag-break trip setting
Heater
full-load SE rating
shock hazard, all current-carrying parts and other number
Amps 3-Ph, plug Rec. Max.
CR 123
components of the motor controller should be 3 heater
examined and be replaced if damaged. If heater 18.0-19.7 C214B 30 3 5
burnout occurs, the complete overload relay must 19.8-21.2 C228B 30 3 5
be replaced. 21.3-22.3 C250B 30 3 6
22.4-23.5 C273B 40 2 5
23.6-25.5 C303B 40 3 5
25.6-27.0 C330B 40 3 5
T E C H N I C A L A P P L I C AT I O N G U I D E 167

Size 0 and 1 (Ambient Comp.)

Size 2 (Standard)

Motor Mag-break trip setting Motor

Heater Mag-break trip setting
full-load SE rating Heater
number full-load SE rating
Amps 3-Ph, plug Rec. Max. number
CR 123 Amps 3-Ph, plug Rec. Max.
3 heater CR 123
3 heater
.66-.76 C087A 3 LO LO 8.81-9.27 C104B 15 3 5
.77-.84 C097A 3 LO LO 9.28-9.99 C113B 20 2 4
.85-.93 C109A 3 LO LO 10.0-11.1 C125B 20 2 5
.94-1.04 C118A 3 LO 2 11.2-12.1 C137B 20 3 5
1.05-1.15 C131A 3 LO 2 12.2-13.0 C151B 20 3 5
1.16-1.27 C148A 3 LO 3 13.1-15.5 C163B 20 4 6
1.28-1.39 C163A 3 LO 3 15.6-16.8 C180B 25 3 5
1.40-1.55 C184A 3 LO 4 16.9-18.0 C198B 25 3 6
1.56-1.73 C196A 3 2 4 18.1-19.7 C214B 30 3 5
1.74-1.89 C220A 3 2 5 19.8-21.6 C228B 30 3 5
1.90-2.05 C239A 3 2 5 21.7-23.9 C250B 40 2 5
2.06-2.28 C268A 3 3 5 24.0-25.5 C273B 40 2 5
2.29-2.47 C301A 3 3 6 25.6-28.2 C303B 50 2 5
2.48-2.79 C326A 7 LO 3 28.3-31.6 C330B 50 3 5
2.80-3.31 C356A 7 LO 4 31.7-34.7 C366B 50 3 6
3.32-3.70 C379A 7 2 4 34.8-37.8 C400B 50 3 6
3.71-4.06 C419A 7 2 4 37.9-40.6 C440B 60 3 5
4.07-4.47 C466A 7 2 5 40.7-43.4 C460B 60 3 6
4.48-4.95 C526A 7 3 5
4.96-5.49 C592A 7 3 6 Size 2 (Ambient Comp.)
5.50-5.91 C630A 7 4 6
5.50-5.91 C630A 15 LO 3 Motor Mag-break trip setting
Heater
5.92-6.47 C695A 15 LO 3 full-load SE rating
number
Amps 3-Ph, plug Rec. Max.
6.48-7.20 C778A 15 2 4 CR 123
3 heater
7.21-8.22 C867A 15 2 4
9.04-9.61 C104B 15 3 5
8.23-8.72 C955A 15 2 5
9.62-10.5 C113B 20 3 4
8.73-9.67 C104B 15 3 5
10.6-11.6 C125B 20 2 5
9.68-10.4 C113B 20 2 4
11.7-12.5 C137B 20 3 5
10.5-11.0 C125B 20 2 4
12.6-13.6 C151B 20 3 5
11.1-12.4 C137B 20 2 5
13.7-16.7 C163B 20 4 6
12.5-13.2 C151B 20 3 5
16.8-17.9 C180B 25 3 5
13.3-15.4 C163B 20 4 6
18.0-18.7 C198B 25 3 6
15.5-17.1 C180B 25 3 5
18.8-20.4 C214B 30 3 5
20.5-22.7 C228B 30 3 6
Size 1 (Ambient Comp.)
22.8-24.7 C250B 40 2 5
24.8-26.3 C273B 40 2 5
Motor Mag-break trip setting
full-load
Heater
SE rating 26.4-29.5 C303B 50 2 5
number
Amps 3-Ph, plug Rec. Max. 29.6-32.5 C330B 50 3 5
CR 123
3 heater 32.6-36.7 C366B 50 3 6
17.2-18.1 C198B 25 3 6 36.8-41.9 C400B 50 3 6
18.2-20.0 C214B 30 3 5 42.0-43.2 C440B 60 3 5
20.1-21.5 C228B 30 3 5 43.3-43.4 C460B 60 3 6
21.6-22.5 C250B 30 3 6
22.6-23.9 C273B 40 2 5
24.0-26.0 C303B 40 3 5
26.1-27.0 C330B 40 3 5
168 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Size 3 (standard and ambient comp.) Size 4 (ambient comp.)

Motor Mag-Break Trip Setting Motor Mag-break trip setting

Heater SE Heater SE
full-load full-load
number rating number rating
Amps 3-Ph, CR 123 Rec. Max. Amps 3-Ph, Rec. Max.
plug CR 123 plug
3 heater 3 heater
17.8-18.4 F233B 30 2 5 28.8-32.0 F357B 50 3 5
18.5-21.1 F243B 30 3 5 32.1-34.2 F395B 50 3 5
21.2-22.1 F207B 30 3 5 34.3-36.7 F430B 70 2 5
22.2-26.0 F300B 40 3 5 36.8-43.8 F487B 70 3 5
26.1-28.0 F327B 40 3 5 43.9-46.6 F567B 70 3 5
28.1-31.3 F357B 50 3 5 46.7-52.6 F614B 100 2 4
31.4-33.3 F395B 50 3 5 52.7-55.6 F658B 100 2 5
33.4-34.3 F430B 50 3 5 55.7-58.7 F719B 100 2 5
34.4-40.9 F487B 70 2 5 58.8-67.1 F772B 100 3 5
41.0-44.7 F567B 70 3 5 67.2-70.6 F848B 100 3 6
44.8-51.0 F614B 100 LO 4 70.7-76.3 F914B 150 2 4
51.1-52.0 F658B 100 LO 4 76.4-88.7 F104C 150 2 5
52.1-55.4 F719B 100 2 5 88.8-93.4 F114C 150 3 5
55.5-63.3 F772B 100 3 5 93.5-105.0 F118C 150 3 5
63.4-66.1 F848B 100 3 5 106.0-114.0 F133C 150 3 5
66.2-73.5 F914B 100 3 6 115.0-128.0 F149C 150 4 6
73.6-82.2 F104C 150 2 4 129.0-130.0 F161C 150 4 6
82.3-86.9 F114C 150 2 5

Size 4 (standard) Size 4 (standard)

Motor Mag-Break Trip Setting Motor Mag-break trip setting

Heater SE Heater SF
full-load full-load
number rating number rating
Amps 3-Ph, Rec. Max. Amps 3-Ph, Rec. Max.
CR 123 plug CR 123 plug
3 heater 3 heater
28.8-32.0 F357B 50 3 5 28.8-32.0 F357B 70 2 4
32.1-34.2 F395B 50 3 5 32.1-34.2 F395B 70 2 4
34.3-36.7 F430B 70 2 5 34.3-36.7 F430B 70 2 5
36.8-43.9 F487B 70 3 5 36.8-43.9 F487B 70 2 5
44.0-46.6 F567B 70 3 5 44.0-46.6 F567B 70 3 5
46.7-52.6 F614B 100 2 4 46.7-52.6 F614B 100 2 4
52.7-55.6 F658B 100 2 5 52.7-55.6 F658B 100 2 4
55.7-58.7 F719B 100 2 5 55.7-58.7 F719B 100 2 5
58.8-67.1 F772B 100 3 5 58.8-67.1 F772B 150 LO 4
67.2-70.6 F848B 100 3 6 67.2-70.6 F848B 150 LO 4
70.7-76.3 F914B 150 2 4 70.7-76.3 F914B 150 2 4
76.4-88.7 F104C 150 2 5 76.4-88.7 F104C 200 LO 4
88.8-93.4 F114C 150 3 5 88.8-93.4 F114C 200 LO 4
93.5-102.0 F118C 150 3 5 93.5-102.0 F118C 200 LO 5
103.0-110.0 F133C 150 3 5 103.0-110.0 F133C 200 2 6
111.0-122.0 F149C 150 4 6 111.0-122.0 F149C 200 2 6
123.0-131.0 F161C 150 4 6 123.0-131.0 F161C 200 2 6
T E C H N I C A L A P P L I C AT I O N G U I D E 169

Size 4 (ambient comp.) Size 6 – 600:5 CT (standard and ambient comp.)

Motor Mag-break trip setting Motor Instantaneous

Heater SF Heater SK
full-load full-load trip setting
number rating number rating
Amps 3-Ph, Rec. Max. Amps 3-Ph,
CR 123 plug CR 123 plug Rec. Max.
3 heater 3 heater
28.8-32.0 F357B 70 2 4 181-197 C220A 400 LO 4
32.1-34.2 F395B 70 3 4 198-214 C239A 400 2 4
34.3-36.7 F430B 70 3 5 215-238 C268A 400 3 5
36.8-43.8 F487B 70 3 5 239-258 C301A 500 LO 4
43.9-46.6 F567B 70 3 5 259-290 C326A 500 2 5
46.7-52.6 F614B 100 2 4 291-346 C356A 800 LO 4
52.7-55.6 F658B 100 2 4 347-387 C379A 800 LO 5
55.7-58.7 F719B 100 2 5 388-423 C419A 800 2 5
58.8-67.1 F772B 150 LO 4 424-467 C466A 1000 LO 4
67.2-70.6 F848B 150 LO 4 468-516 C526A 1000 2 4
70.7-76.3 F914B 150 2 4 517-540 C592A 1000 2 5
76.4-88.7 F104C 200 LO 4
88.8-93.4 F114C 200 LO 4
93.5-105.0 F118C 200 LO 5
106.0-114.0 F133C 200 2 6
115.0-128.0 F149C 200 2 6
129.0-130.0 F161C 200 2 6

Size 5 – 300:15 CT (standard and ambient comp.)

Motor Instantaneous
Heater SG
full-load trip setting
number rating
Amps 3-Ph,
CR 123 plug Rec. Max.
3 heater
106-115 C592A 250 LO 3
116-125 C630A 250 LO 4
126-135 C695A 250 2 4
136-151 C778A 250 2 5
152-164 C867A 300 2 4
165-179 C955A 300 2 5
180-195 C104B 350 2 4
196-215 C113B 350 2 5
216-231 C125B 400 2 4
232-255 C137B 400 2 5
256-270 C151B 400 3 5

Size 6 – 600:5 CT (standard and ambient comp.)

Motor Instantaneous
Heater SG
full-load trip setting
number rating
Amps 3-Ph,
CR 123 plug Rec. Max.
3 heater
181-197 C220A 400 MIN 4
198-214 C239A 400 2 5
215-238 C268A 500 MIN 4
239-258 C301A 500 MIN 4
259-290 C326A 500 2 5
291-346 C356A 600 MIN 5
347-387 C379A 600 2 5
388-424 C419A 600 3 MAX
170 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Overload heater tables

Overload relays

Electronic overloads for circuit breaker controllers

Tripping current is 120% of Dial setting. Motors
with 1.15-1.25 service factor, set dial to motor FLA
Motors with 1.0 service factor, set dial to 0.9
motor FLA. Overload relays for compact 6" starter
CL45A310MJ, NEMA size 1

FLA FLA range

Class 10 Class 20
NEMA Catalog catalog catalog Breaker frame and type
range in Breaker frame and type in Amps
size number number number
Amps
0.4-.65 RTN1D E Mag. and thermal mag.
1 0.8 to 1.7 CR324CXD E Mag. and Thermal Mag.
0.65-1.1 RTN1F E Mag. and thermal mag.
1 1.8 to 3.4 CR324CXE E Mag. and Thermal Mag.
1-1.5 RTN1G E Mag. and thermal mag.
1 3.2 to 6.8 CR324CXF E Mag. and Thermal Mag.
6.5 to 1.3-1.9 RTN1H E Mag. and thermal mag.
1 CR324CXG E Mag. and Thermal Mag.
13.5 1.8-2.7 RTN1J E Mag. and thermal mag.
1 13 to 27 CR324CXH E Mag. and Thermal Mag. 2.5-4.1 RTNIK RT12K E Mag. and thermal mag.
6.5 to 4.0-6.3 RTNIL RT12L E Mag. and thermal mag.
2 CR324DXG E Mag. and Thermal Mag.
13.5
5.5-8.5 RTNIM RT12M E Mag. and thermal mag.
2 13 to 27 CR324DXH E Mag. and Thermal Mag.
8.0-12 RTNIN RT12N E Mag. and thermal mag.
2 25 to 50 CR324DXJ E Mag. and Thermal Mag.
10.0-16 RTNIP RT12P E Mag. and thermal mag.
3 17 to 35 CR324FXK E Mag. and Thermal Mag.
14.5-18 RTNIS RT12S E Mag. and thermal mag.
3 35 to 70 CR324FXL E Mag. and Thermal Mag.
17.5-22 RTNIT RT12T E Mag. and thermal mag.
3 65 to 135 CR324FXM E Mag. and Thermal Mag.
21-26 RTNIU RT12U E Mag. and thermal mag.
E,FandG Mag. and Thermal
4 17 to 35 CR324FXK
Mag.
E,FandG Mag. and Thermal
4 35 to 70 CR324FXL
Mag.
E,FandG Mag. and Thermal
4 65 to 135 CR324FXM
Mag.
5¹ 35 to 70 CR324GXN E Mag. and Thermal Mag.
5¹ 65 to 135 CR324GXP E Mag. and Thermal Mag.
130 to
5¹ CR324GXQ E Mag. and Thermal Mag.
270
130 to
6² CR324HXS G,K Mag. and Thermal Mag.
270
260 to
6² CR324HXT E Mag. and Thermal Mag.
540

1. 300:15 CT’s
2. 800:5 CT’s
T E C H N I C A L A P P L I C AT I O N G U I D E 171

Overload heater tables Size 0 and 1 (standard and ambient comp.)

Heaters for fused controllers Motor full-load

Heater number Maximum
Amps 3-Ph.,
The Mag-Break protector is factory adjusted to CR123 fuse rating
3-heater
the minimum trip setting. .41-.45 C054A 3
.46-.49 C060A 3
For continuous rated motors with a service factor .50-.53 C066A 3
of 1.15 to 1.25, select heaters from the heater table. .54-.59 C071A 3
For continuous rated motors with a service factor .60-.65 C078A 3
of 1.0, multiply the motor full-load current by 0.9 .66-.76 C087A 3
and use this value to select heaters. .77-.84 C097A 3
.85-.93 C109A 3

Table 1 – Maximum fuse and short-circuit rating .94-1.04 C118A 3

1.05-1.15 C131A 3
Class RK fuse Class J fuse Class K-1, K-5 fuse 1.16-1.27 C148A 3
NEMA Max. RMS 1.28-1.39 C163A 3
size Max. Max. Max. RMS Max. RMS
Sym. Max. clip 1.40-1.55 C184A 6
Clip Clip sym. Amps sym. Amps
Amps
1.56-1.73 C196A 6
1 30A 100.000 60A 100.000 5.000
1.74-1.89 C220A 6
2 60 100.000 100 100.000 Fuse per 5.000
overload 1.90-2.05 C239A 6
3 100 100.000 200 100.000 5.000
heater 2.06-2.28 C268A 6
4 200 100.000 400 100.000 table 10.000
2.29-2.47 C301A 6
5 400 100.000 600 100.000 10.000
2.48-2.79 C326A 10
2.80-3.31 C356A 10
3.32-3.70 C379A 12
Warning: Opening of the fuse(s) may be an
3.71-4.06 C419A 15
indication that a fault current has been interrupted.
4.07-4.47 C466A 15
To provide continued protection against fire or
4.48-4.95 C526A 15
shock hazard, all current-carrying parts and other
4.96-5.49 C592A 20
components of the motor controller should be 5.50-5.91 C630A 20
examined and replaced if damaged. If heater 5.92-6.47 C695A 25
burnout occurs, the complete overload relay must 6.48-7.20 C778A 25
be replaced. 7.21-8.22 C867A 30
8.23-8.72 C955A 30
8.73-9.67 C104B 35¹
9.68-10.4 C113B 35¹
10.5-11.0 C125B 40¹
11.1-12.4 C137B 45¹
12.5-13.2 C151B 50¹
13.3-15.4 C163B 60¹
15.5-17.1 C180B 60¹
172 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Overload relay tripping current in 40°C ambient is Size 3 (standard)

the minimum value of full-load current multiplied
Motor full-load
by 1.25. Heater number Maximum
Amps 3-Ph.,
CR123 fuse rating
3-heater
Provide short-circuit protection in accordance with 19.0-19.3 F233B 70
the National Electrical Code, except Fuses are not 19.4-22.1 F243B 80
to exceed the value shown in the table. 22.2-23.4 F270B 80
23.5-27.0 F300B 90
Suitable for use in a circuit capable of delivering 27.1-29.1 F327B 100
not more than the maximum RMS symmetrical am- 29.2-31.8 F357B 110(¹)

peres indicated in the table below, 600-volts maxi- 31.9-33.9 F395B 125(¹)

mum, when protected by an appropriate fuse hav- 34.0-37.6 F430B 125(¹)

37.7-41.9 F487B 150(¹)
ing an interrupting rating not less than the
42.0-47.7 F567B 175(¹)
available short-circuit current.
47.8-52.1 F614B 175(¹)
52.2-55.8 F658B 200(¹)
Motor full-load 55.9-59.7 F719B 200(¹)
Heater number Maximum
Amps 3-Ph.,
CR123 fuse rating 59.8-68.1 F772B 200(¹)
3-heater
68.2-71.5 F848B 200(¹)
Size 1
71.6-78.2 F914B 200(¹)
17.2-18.1 C198B 60(¹)
78.3-87.5 F104C 200(¹)
18.2-20.0 C214B 60(¹)
87.6-90.0 F114C 200(¹)
20.1-21.5 C228B 60(¹)
21.6-22.5 C250B 60(¹)
Size 3 (ambient comp.)
22.6-23.9 C273B 60(¹)
24.0-26.3 C303B 60¹
Motor full-load
26.4-27.0 C330B 60(¹) Heater number Maximum
Amps 3-Ph.,
CR123 fuse rating
3-heater

Size 2 (standard and ambient comp.) 17.8-18.4 F233B 70

18.5-21.1 F243B 80
Motor full-load 21.2-22.1 F270B 80
Heater number Maximum
Amps 3-Ph., 22.2-26.1 F300B 90
CR123 fuse rating
3-heater
26.2-28.0 F327B 100
5.48-5.85 C630A 20
28.1-31.3 F357B 110(¹)
5.86-6.47 C695A 20
31.4-33.3 F395B 125(¹)
6.48-7.35 C778A 25
33.4-34.3 F430B 125(¹)
7.36-8.06 C867A 30
34.4-40.9 F487B 150(¹)
8.07-9.03 C955A 30
41.0-44.7 F567B 150(¹)
9.04-9.61 C104B 35
44.8-51.0 F614B 175(¹)
9.62-10.5 C113B 35
51.1-52.0 F658B 200(¹)
10.6-11.6 C125B 40
52.1-55.4 F719B 200(¹)
11.7-12.5 C137B 45
55.5-63.3 F772B 200(¹)
12.6-13.6 C151B 50
63.4-66.1 F848B 200(¹)
13.7-16.7 C163B 60
66.2-73.5 F914B 200(¹)
16.8-17.9 C180B 60
73.6-82.2 F104C 200(¹)
18.0-18.7 C198B 70(¹)
82.3-90.0 F114C 200(¹)
18.8-20.4 C214B 80(¹)
20.5-22.7 C228B 80(¹)
22.8-24.7 C250B 90(¹)
24.8-26.3 C273B 90(¹)
26.4-29.5 C303B 100(¹)
29.6-32.5 C330B 100(¹)
32.6-36.7 C366B 100(¹)
36.8-41.9 C400B 100(¹)
42.0-43.2 C440B 100(¹)
43.3-45.0 C460B 100(¹)

1. See Table 1 for maximum fuse and short-circuit rating.

T E C H N I C A L A P P L I C AT I O N G U I D E 173

Size 4 (standard) Size 5 – 300:15CT (standard and ambient comp.)

Motor full-load Motor full-load

Heater number Maximum Heater number Maximum
Amps 3-Ph., Amps 3-Ph.,
CR123 fuse rating CR123 fuse rating
3-heater 3-heater
27.1-32.2 F357B 110 109-118 C592A 600
32.3-34.0 F395B 125 119-128 C630A 600
34.1-36.8 F430B 125 129-138 C695A 600
36.9-44.6 F487B 150 139-155 C778A 600
44.7-48.4 F567B 175 156-168 C867A 600
48.5-53.9 F614B 175 169-184 C955A 600
54.0-57.4 F658B 200 185-200 C104B 600
57.5-60.0 F719B 225¹ 201-221 C113B 600
60.1-69.5 F772B 225¹ 222-237 C125B 600
69.6-71.7 F848B 250¹ 238-262 C137B 600
71.8-79.9 F914B 275¹ 263-270 C151B 600
80.0-92.3 F104C 300¹
92.4-97.0 F114C 350¹
Electronic overload table for fusible controllers
97.1-108 F118C 400¹
Tripping current is 120% of Dial setting. Motors
109-118 F133C 400¹
119-131 F149C 400¹
with 1.15-1.25 service factor, set dial to motor FLA
132-135 F161C 400¹
Motors with 1.0 service factor, set dial to
0.9 motor FLA.
1. See Table 1 (page J-17) for maximum fuse and short-circuit rating.
FLA range Catalog
NEMA size Max. fuse in Amps
Size 4 (ambient comp.) in Amps number
1 0.8 to 1.7 CR324CXD Class R 30 Class J 60
Motor full-load
Heater number Maximum 1 1.8 to 3.4 CR324CXE
Amps 3-Ph.,
CR123 fuse rating 1 3.2 to 6.8 CR324CXF
3-heater
28.8-32.0 F357B 110 1 6.5 to 13.5 CR324CXG

32.1-34.2 F395B 125 1 13 to 27 CR324CXH

34.3-36.7 F430B 125 2 6.5 to 13.5 CR324DXG 60 100

36.8-43.9 F487B 150 2 13 to 27 CR324DXH

44.0-46.6 F567B 175 2 25 to 50 CR324DXJ

46.7-52.6 F614B 175 3 17 to 35 CR324FXK 100 200

52.7-55.6 F658B 200 3 35 to 70 CR324FXL

55.7-58.7 F719B 225¹ 3 65 to 135 CR324FXM

4 17 to 35 CR324FXK 200 400
58.8-67.1 F772B 225¹
4 35 to 70 CR324FXL
67.2-70.6 F848B 250¹
4 65 to 135 CR324FXM
70.7-76.3 F914B 275¹
5(¹) 35 to 70 CR324GXN 400 600
76.4-88.7 F104C 300¹
5(¹) 65 to 135 CR324GXP
88.8-93.4 F114C 350¹
5(¹) 130 to 270 CR324GXQ
93.5-105 F118C 350¹
Class L
106-114 F133C 400¹ 6(²) 130 to 270 CR324HXS 600
1200
115-128 F149C 400¹
6(²) 260 to 540 CR324HXT
129-131 F161C 400¹
132-135 F174C 400¹ 1. 300:15 CT’s
2. 800:5 CT’s
174 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Starter fuse selection

The following tables are furnished as a guide.

Check vendor fuse characteristics before making
final selection.

200 and 208 Volts

UL Class J Time-Delay RK-5

Typical Switch
Size Hp Time delay No time delay BMC
FLA Amp CSC FRN Clip TR Clip
CSC# AJT Clip CSC# A4J Clip
1/2 2.3 30 3 30 10 30 2.8 30 3.5 30
3/4 3.2 30 5 30 10 30 4 30 4.5 30
1 3.9 30 6 30 15 30 5 30 6.25 30
1 1/2 5.3 30 8 30 20 30 7 30 8 30
1
2 7.1 30 10 30 25 30 9 30 12 30
3 10.6 30 15 30 30 30 12 30 15 30
5 16.3 30 25 30 45 60 20 30 25 30
7 1/2 25.3 30 30 30 60 60 30 30 30 30
2 10 31.3 60 50 60 90 100 40 60 40 60
15 45.1 100 60 60 110 200 60 60 60 60
3 20 591 100 90 100 150 200 70 100 90 100
25 731 100 100 100 175 200 90 100 100 100
30 881 200 125 200 200 200 100 100 125 200
4
40 120 200 175 200 225 400 150 200 175 200
50 150 400 225 400 300 400 175 200 225 400
5 60 174 400 250 400 350 400 200 200 225 400
75 210 400 300 400 450 600 250 400 300 400
BMC–Bussman Fuse
CSC–Chase Shawmut Fuse

230 Volts

UL Class J Time-Delay RK-5

Typical Switch
Size Hp Time delay No time delay
FLA Amp BMC FRN Clip TR CSC Clip
CSC# AJT Clip CSC# A4J Clip
1/2 2.0 30 3 30 10 30 2.5 30 3 30
3/4 2.8 30 4 30 15 30 3.5 30 4 30
1 3.4 30 6 30 15 30 4 30 5.6 30
1 1/2 4.6 30 8 30 30 30 6.25 30 8 30
1
2 6.2 30 10 30 25 30 8 30 10 30
3 9.2 30 15 30 30 30 12 30 15 30
5 14.2 30 25 30 45 60 17.5 30 25 30
7 1/2 22.0 30 30 30 60 60 25 30 30 30
10 27.2 60 40 60 90 100 35 60 40 60
2 15 39.2 60 60 60 — — 50 60 60 60
15 39.2 100 60 60 110 200 — — — —
20 51.4 100 80 100 150 200 60 60 80 100
3 25 63.6 100 100 100 175 200 80 100 100 100
30 76.6 100 100 100 200 200 100 100 100 100
40 104 200 150 200 225 400 125 200 150 200
4
50 130 200 200 200 300 400 150 200 200 200
60 151 400 225 400 350 400 175 200 225 400
5 75 183 400 300 400 400 400 225 400 300 400
100 240 400 350 400 600 600 300 400 350 400
125 296 600 450 600 600 600 350 400 450 600
6 150 348 600 500 600 450 600 500 600
200 468 600 500 600 600 600
T E C H N I C A L A P P L I C AT I O N G U I D E 175

460 Volts

UL Class J Time-Delay K-5

Typical Switch
Size Hp Time delay No time delay
FLA Amp BMC FRS Clip CSC TRS Clip
CSC# AJT Clip CSC# A4J Clip
1/2 1.0 30 1.5 30 3 30 1.25 30 1.4 30
3/4 1.4 30 2 30 3 30 1.6 30 2 30
1 1.7 30 3 30 6 30 2 30 2.5 30
1 1/2 2.3 30 4 30 6 30 2.8 30 4 30
1 2 3.1 30 5 30 10 30 3.5 30 5 30
3 4.6 30 8 30 15 30 5 30 7 30
5 7.1 30 10 30 25 30 9 30 10 30
7 1/2 11.0 30 15 30 35 60 15 30 15 30
10 13.6 30 20 30 40 60 17.5 30 20 30
15 19.6 60 30 30 50 60 25 30 30 30
2 20 25.7 60 40 60 90 100 35 60 40 60
25 31.8 60 50 60 100 100 40 60 50 60
30 38.3 100 60 60 110 200 45 60 60 60
3 40 52.0 100 80 100 125 200 60 60 75 100
50 65.0 100 100 100 150 200 80 100 100 100
60 75.5 200 110 200 175 200 90 100 110 200
4 75 91.5 200 150 200 225 400 110 200 150 200
100 120 200 175 200 225 400 150 200 175 200
125 148 400 225 400 300 400 200 200 225 400
5 150 172 400 250 400 350 400 225 400 250 400
200 224 400 300 400 500 600 300 400 350 400
250 295 600 450 600 600 600 350 400 400 400
300 343 600 500 600 400 400 500 600
6
350 396 600 600 600 450 600 600 600
400 453 600 500 600 600 600

575 Volts

UL Class J Time-Delay K-5

Typical Switch
Size Hp Time delay No time delay
FLA Amp BMC FRS Clip CSC TRS Clip
CSC# AJT Clip CSC# A4J Clip
3/4 1.1 30 2 30 3 30 1.25 30 1.6 30
1 1.4 30 2 30 6 30 1.6 30 2 30
1 1/2 1.8 30 3 30 6 30 2.25 30 3 30
2 2.5 30 4 30 10 30 2.8 30 4 30
1
3 3.7 30 6 30 15 30 4.5 30 6 30
5 5.7 30 10 30 20 30 7 30 9 30
7 1/2 8.8 30 15 30 30 30 10 30 15 30
10 10.9 30 15 30 35 60 15 30 15 30
15 15.7 60 25 30 45 60 20 30 25 30
2 20 20.6 60 35 60 60 60 25 30 35 60
25 25.4 60 40 60 80 100 35 60 40 60
30 30.6 100 45 60 100 100 40 60 45 60
3 40 41.6 100 60 60 110 200 45 60 60 60
50 52.0 100 80 100 125 200 60 60 80 100
60 60.4 200 90 100 150 200 70 100 90 100
4 75 73.2 200 125 200 175 200 90 100 125 200
100 96.0 200 150 200 225 400 110 200 150 200
125 118 400 175 200 225 400 150 200 175 200
5 150 138 400 225 400 300 400 175 200 225 400
200 179 400 300 400 400 400 225 400 300 400
250 236 600 350 400 500 600 300 400 350 400
300 274 600 450 600 600 600 350 400 450 600
6
350 317 600 500 600 400 400 500 600
400 363 600 600 600 450 600 600 600
176 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Control transformer fusing Heat loss considerations

Secondary
Volts 250V
In determining the heat loss of a motor control
600V Type ATMR or Equivalent
Type TRM or center for air conditioning requirements, 250 watts
Equivalent
per foot of lineup is a reasonable assumption.
200- 380- 440- 575- 110- 220-
XFMR 240V 416V
230V 400V 480V 600V 120V 240V
VA 60HZ 50HZ
60HZ 50HZ 60HZ 60HZ 50HZ 50HZ Actual heat loss will vary due to section loading and
60 1 1 3/4 6/10 1/2 1/2 6/10 3/10 diversity factors. A typical motor control center
75 1-1/2 1-1/2 8/10 8/10 3/4 6/10 8/10 1/2
may operate normally at 60 percent of maximum
100 2 2 1-1/4 1 1 3/4 1 6/10
possible loading.
150 3-1/2 3 1-1/2 1-1/2 1-1/2 1-1/4 1-6/10 8/10
200 4 4 2 2 2 1-1/2 2 1
Fully rated circuit breaker starters with CPT’s,
250 5 5 2 2 2 2 2-8/10 1-1/2
approximate losses are:
300 6 6 3-1/2 3-1/2 2 2 3-2/10 1-6/10
Size 1– 27 Watts
500 6 6 6 6 5 4 5 2-8/10
Size 2– 57 Watts
Size 3–130 Watts
Control fusing for non-CPT applications Size 4–200 Watts
Size 5–300 Watts
Type control Fuse Amps (class CC) Size 6–650 Watts
Line to line 10
Line to neutral 10
Heat losses for feeders and mains vary depending
Common control 6
on frame size, loading and type of trip with
Separate source 6
electronic trips having lower losses. The following
table provides a general guide for estimating
Typical CPT ratings (480V/120V Shown) losses assuming 80 percent loading. For critical
Open circuit
applications refer to the Company.
VA %R %X secondary
Volts
Type Frame Loss (Watts)
60 9.05 1.03 131.9
SE150 15
100 6.39 1.18 129.4
SF250 20
150 5.02 1.01 127.3 Molded case circuit
SG600 25
200 5.09 1.06 126.2 breaker frame
SK800 40
250 6.81 .88 127.8
SK1200 50
300 5.15 .73 126.4
800A 80
500 5.84 1.45 128.7
Insulated case 1600A 210
power break 2000A 305
2500A 375
2500A - fixed 195
Air circuit breaker 2500A - drawout 438
(EntelliGuard G) 3200A - fixed 318
3200A - drawout 558

Typical losses for transformers:

1kVA, 1-Ph 75 Watts
5 kVA, 1-Ph 190 Watts
9 kVA, 3-Ph 295 Watts
15 kVA, 3-Ph 460 Watts
30 kVA, 3-Ph 1000 Watts

Horizontal and vertical bus losses, when loaded to

capacity are approximately 100 watts per section.

Solid State Starters or VFDs will typically generate

3 watts per ampere of load during operation.
 T E C H N I C A L A P P L I C AT I O N G U I D E 17 7

Motor Loads Non-motor load ratings are based on the use of

two poles to control single-phase loads and three
NEMA contactor ratings
poles to control three-phase loads.
Normal starting duty HP/
Description KW rating by NEMA size Capacitor switching, requires special
1 2 3 4 5 6 considerations. A discharged capacitor acts
Single 115V 2 3 7.5 essentially like a short circuit, and the inrush
phase 230V 3 7.5 15 current is limited by the impedance connected in
7.5/ 10/ 25/ 40/ 75/ 150/ series with the capacitor which includes
200V
5.5 7.5 18.5 30 55 110
connecting cables. Therefore, the maximum
7.5/ 15/ 30/ 50/ 100/ 200/
230V capacitance which can be switched by a contactor
5.5 11 22 37 75 150
Three 380/ 10/ 25/ 50/ 75/ 150/ 300/ will increase with higher series impedance.
phase 415V 7.5 18.5 37 55 110 260 Switching more than one capacitor or capacitor
10/ 25/ 50/ 100/ 200/ 400/ bank in close electrical proximity to each other
460V
7.5 18.5 37 75 150 260
should be avoided as the energized capacitor bank
10/ 25/ 50/ 100/ 200/ 400/
575V
7.5 18.5 37 75 150 260 can increase the inrush current to the second bank
when it is energized. Reactors or resistors may be
required between the two capacitor banks to limit
Non-Motor Loads
inrush currents.
When selecting contactors for non-motor loads,
the following load characteristics should be con-
NEMA Standards require shunt capacitors to
sidered:
operate satisfactorily at 135 percent of rated KVAR
1. Voltage and maximum continuous current.
due to manufacturing tolerances and other
2. Maximum peak inrush current and duration.
variations. The higher inrush and steady state
3. RMS current and duration of maximum current on
currents associated with these capacitors should
cyclic loads.
be taken into consideration.
4.Frequency of operation.
5.Maximum interrupting current, voltage, power
NEMA Publication ICS2-210 covers
factor and wave form.
non-motor loads.
6.Available short-circuit current.

NEMA contactor ratings

Max. Transformer primary switching (kVA)

inrush Tung Transformers having inrush currents Transformers having inrush currents
Size of Cont. Resistive of not more than 20 times FLA of over 20 through 40 times FLA
current ten(¹)
Contactor Amps Loads(²)
(Amps Lamps Single-phase Volts Three-phase Volts Single-phase Volts Three-phase Volts
Peak) 120 240 480 600 208 240 480 600 120 240 480 600 208 240 480 600
0 18 140 10 18 0.6 1.2 2.4 3 1.8 2.1 4.2 5.2 0.3 0.6 1.2 1.5 0.9 1.0 2.1 2.6
1 27 288 15 27 1.2 2.4 4.9 6.2 3.6 4.3 8.5 11 0.6 1.2 2.5 3.1 1.8 2.1 4.3 5.3
2 45 483 30 45 2.1 4.1 8.3 10 6.3 7.2 14 18 1.0 2.1 4.2 5.2 3.1 3.6 7.2 8.9
3 90 947 60 90 4.1 8.1 16 20 12 14 28 35 2.0 4.1 8.1 10 6.1 7.0 14 18
4 135 1581 120 135 6.8 14 27 34 20 23 47 59 3.4 6.8 14 17 10 12 23 29
5 270 3163 240 270 14 27 54 68 41 47 94 117 6.8 14 27 34 20 24 47 59
6 540 6326 480 540 27 54 108 135 81 94 188 234 14 27 54 68 41 47 94 117

1. 300-volts maximum, Tungsten lamp loads include infrared lamps having Tungsten filaments.
2. Resistive loads include electric discharge lamps such as fluorescent, mercury, vapor, etc.
178 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Non-motor loads

NEMA contactor ratings for single capacitor or capacitor bank switching

Continuous Three-phase rating of capacitor

Size of
ratings rms Maximum size of three-phase capacitor in kVAR or available current in Amperes RMS sym.
controller
amperes 3000 5000 10.000 14.000 18.000 22.000
At 230 Volts, 60 Hertz
2 45 12 8 4 3 2 2
3 90 27 27 15 11 9 7
4 135 40 40 40 30 24 20
5 270 80 80 80 80 80 75
6 540 160 160 160 160 160 160
At 460 Volts, 60 Hertz
2 45 25 16 8 6 4 4
3 90 53 53 31 23 18 15
4 135 80 80 80 61 49 41
5 270 160 160 160 160 160 149
6 540 320 320 320 320 320 320
At 575 Volts, 60 Hertz
2 45 31 20 10 7 6 5
3 90 67 67 39 29 23 19
4 135 100 100 100 77 61 51
5 270 200 200 200 200 200 189
6 540 400 400 400 400 400 400

Disconnect minimums: thermal magnetic breakers rated 135%, fused switch rated 165%.

NEMA contactor for heating loads

Continuous Maximum kW ratings(²)

current 575 Volts 460 Volts 230 Volts 115 Volts
NEMA size
rating 3-Pole 3-Pole 3-Pole
amps 2-Pole 1-Ph 2-Pole 1-Ph 2-Pole 1-Ph 2-Pole 1-Ph 3-Pole 3-Ph
3-Ph 3-Ph 3-Ph
00 9 5 9 4 7 2 3.5 1 1.75
0 18 10 18 8 14 4 7 2 3.5
1 27 15 25 12 20 6 10 3 5
2 45 24 43 20 34 10 17 5 8.5
3 90 50 86 40 68 20 34 10 17
4 135 75 130 60 105 30 52 15 26
5 270 150 260 120 210 60 105 30 52
6 540 300 515 240 415 120 210 60 105
7 810 450 775 360 625 180 315 90 155
8 1215 700 1200 540 960 270 480 135 240
9 2250 1290 2200 1020 1740 510 880 255 440

1. A
 vailable at capacitor terminals.
2. A
 pplicable only to resistive loads having inrush currents Application of starters for heating and
not exceeding 1.5 times the continuous current rating.
lighting loads
3. S
 pectra CB will permit deletion of overload heaters for these loads.
1. No Tungsten lamp loads, No transformer loads.
2. Contactor loading must meet table above.
3. Overload heaters may be sized for maximum³.
4. Disconnect must be thermal magnetic or fused
switch rated per NEC @ 125% of load amps.
T E C H N I C A L A P P L I C AT I O N G U I D E 179

Non-motor loads

Application rated

Maximum kVA of transformer for primary switching (50/60Hz)

Max. Inrush = 20 x Normal Inrush = 40 x Normal

Catalog Peak
Phase
number closing 120V 208V 240V 480V 600V 120V 208V 240V 480V 600V
current
450 1 0.6 1 1.2 1.7 2.1 0.3 0.5 0.6 0.8 1
CL00
Amps 3 1.1 1.9 2.2 3.1 3.8 0.5 0.9 1.1 1.5 1.9

450 1 0.8 1.4 1.7 2.4 3.0 0.4 0.7 0.8 1.2 1.5
CL01
Amps 3 1.5 2.6 3.0 4.2 5.2 0.7 1.3 1.5 2.1 2.6

450 1 1.2 2.0 2.5 3.5 4.4 0.6 1.0 1.2 1.7 2.2
CL02
Amps 3 2.2 3.8 4.5 6.3 7.7 1.1 1.9 2.2 3.1 3.8

550 1 1.8 3.1 3.7 5.2 6.4 0.9 1.5 1.8 2.6 3.2
CL25
Amps 3 3.2 5.5 6.5 9.1 11.2 1.6 2.7 3.2 4.5 5.6

550 1 2.2 3.8 4.5 6.3 7.8 1.1 1.9 2.2 3.1 3.9
CL04
Amps 3 4.0 7.0 8.0 11.2 13.7 2.0 3.5 4.0 5.6 6.8

550 1 2.8 4.8 5.7 8.0 9.7 1.4 2.4 2.8 4.0 4.8
CL45
Amps 3 5 8.6 10 14.0 17 2.5 4.3 5 7.0 8.5

1000 1 3.4 5.9 6.8 9.5 12 1.7 2.9 3.4 4.7 6

CL06
Amps 3 6 10.4 12 16.8 21 3 5.2 6 8.4 10.5

1000 1 4.2 7.2 8.5 12 14.2 2.1 3.6 4.2 6.0 7.1
CL07
Amps 3 7.5 13 15 21 25 3.7 6.5 7.5 10.5 12.5

1000 1 5.7 10 11.4 16 20 2.8 5.0 5.7 8.0 10

CL08
Amps 3 10 17.3 20 28 35 5 8.6 10 14 16

1280 1 7.1 12.3 14.2 20 22.8 3.5 6.1 7.1 10 11.4

CL09
Amps 3 12.5 21.6 25 35 40 6.2 10.8 12.5 17.5 20

1280 1 8.5 14.7 17.1 24 28.5 4.2 7.3 8.5 12 14.2

CL10
Amps 3 15 26 30 42 50 7.5 13 15 21 25

1850 1 10 17.2 20 28 31.3 5 8.6 10 14 15.6

CK75
Amps 3 17.5 30.3 35 49 55 8.75 15.1 17.5 24.5 27.5

1850 1 11.4 19.7 22.8 32 34.2 5.7 9.8 11.4 16 17.1

CK08
Amps 3 20 34.6 40 56 60 10 17.3 20 28 30

2500 1 14.2 24.6 28.5 40 48.5 7.1 12.3 14.2 20 24.2

CK09
Amps 3 25 43.3 50 70 85 12.5 21.6 25 35 42.5

3700 1 18.5 32.0 37.1 52 62.8 9.2 16.0 18.5 26 31.4

CK95
Amps 3 32 55.4 65 91 110 16 27.7 32 45 55

7000 1 22.8 39.5 45.7 64 85.7 11.4 19.7 22.8 32 42.8

CK10
Amps 3 40 69.3 80 112 150 20 34.6 40 56 75

7000 1 28.5 49.4 57.1 80 97.1 14.2 24.7 28.5 40 48.5

CK11
Amps 3 50 86.6 100 140 170 25 43.3 50 70 85

8400 1 45.7 79.2 91.4 128 160 22.8 39.6 45.7 65 80

CK12
Amps 3 80 138.6 160 224 280 40 69.3 80 112 140
180 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Maximum three-phase kVAR rating for switching capacitors

10,000 Amps RMS 22,000 Amp RMS

Catalog
Maximum available fault current Maximum Available Fault Current
number
200V 230V 460V 575V 200V 230V 460V 575V
CL00 3 3 5 5.7 1.5 1.5 2.5 2.8
CL01 435 4.5 9.5 11 2.2 2.2 4.5 5.5
CL02 6.5 6.5 11 12.5 3.2 3.2 5.5 6.2
CL25 9 9 15 17.5 4.5 4.5 7.5 8.2
CL04 12.5 12.5 21 24 6.2 6.2 10.5 12
CL45 17 17 30 35 8.5 8.5 15 17.5
CL06 22 22 40 50 11 11 20 25
CL07 25 25 45 65 12.5 12.5 22.5 32.5
CL08 30 30 50 70 15 15 25 35
CL09 40 40 65 95 20 20 32.5 47.5
CL10 50 50 80 120 25 25 40 60
CK75 60 60 100 150 60 60 100 150
CK08 70 70 130 175 70 70 130 175
CK09 95 95 165 230 95 95 165 230
CK95 105 105 190 288 105 105 190 288
CL10 135 135 260 370 135 135 260 370
CL11 190 190 325 450 190 190 325 450
CK12 250 250 400 600 250 250 400 600

Utilization in category AC-1, general use

CL Contactors CK Contactors
3-pole contactors
00 01 02 25 04 45 06 07 08 09 10 75 08 09 95 10 11 12

Max. operational current 40°C A 25 25 32 32 54 55 80 100 102 120 120 150 175 200 310 500 600 650
at ambient temperature 55°C A 25 25 32 32 54 55 80 100 102 120 120 150 175 200 310 425 510 546
of: (for all voltages) 70°C A 20 20 25 25 41 44 62 78 81 80 80 130 155 175 270 335 432 468

CL Contactors CK Contactors
4-pole contactors
01 02 03 04 06 07 08 09 08 09 95 10 11 12

Max. operational current 40°C A 25 32 40 54 70 100 110 120 175 200 310 500 550 650
at ambient temperature 55°C A 25 32 40 54 70 100 110 120 175 200 310 425 462 543
of: (for all voltages) 70°C A 20 25 28 41 52 78 88 80 155 175 270 335 462 468
T E C H N I C A L A P P L I C AT I O N G U I D E 181

Horsepower/kilowatt ratings are shown below

General 1 Phase-HP A 3 Phase-HP A Power In

Catalog
purpose Max. FLA
number 115V 230V 200V 230V 460V 575V 380/400V kW A
ratings
CL00 25 10 .5 (9.8) 1.5 (10) 3 (11) 3 (9.6) 5 (7.6) 7.5 (9) 4 (9)

CL01 25 13.8 .75 (13.8) 2 (12) 3 (11) 3 (9.6) 7.5 (11) 10 (11) 5.5 (12)

CL02 32 17.5 1 (16) 3 (17) 5 (17.5) 5 (15.2) 10 (14) !5 (17) 7.5 (18)

CL25 32 22,22,17¹ 1.5 (20) 3 (17) 5 (17.5) 7.5 (22) 15. (21) 15 (17) 11 (25)

CL04 54 32A 2 (24) 5 (28) 10 (32) 10 (28) 20 (27) 25 (27) 16 (32)

CL45 55 34,34,27¹ 3 (34) 5 (28) 10 (32) 10 (28) 25 (34) 25 (27) 18.5 (40)

CL06 80 48 3 (34) 7.5 (40) 15 (48) 15 (42) 30 (40) 40 (41) 22 (50)

CL07 100 62 5 (56) 10 (50) 20 (62) 20 (54) 40 (52) 50 (52) 30 (65)

CL08 110(O) 102 (E) 68 5 (56) 15 (68) 20 (62) 25 (68) 50 (65) 60 (62) 37 (80)

CL09 140 (O) 120 (E) 80 7.5 (80) 15 (68) 25 (78) 30 (80) 60 (77) 75 (77) 45 (95)

CL10 140 (O) 120 (E) 104,96,80¹ 10 (100) 20 (88) 30 (92) 40 (104) 75 (96) 75 (77) 55 (105)

CK75 150 140 10 (100) 25 (110) 40 (120) 50 (130) 100 (124) 125 (125) 75 (154)

CK08 175 156 15 (135) 30 (136) 50 (149.5) 60 (145) 125 (156) 125 (125) 90 (185)

CK09 200 192 60 (169.4) 75 (192) 150 (180) 150 (144) 132 (250)

CK95 310 302 100 (285) 100 (248) 250 (302) 300 (289) 160 (310)

CK10 500 398 125 (358) 150 (360) 300 (361) 400 (382) 220 (420)

CK11 600 480 150 (414) 200 (480) 400 (477) 500 (472) 280 (550)

CK12 650(E) 750 (O) 602 200 (552) 250 (602) 500 (590) 600 (574) 375 (700)
182 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Publication references

Construction equipment and components

Publication Description Stockinglocation

GEP-1100 Buylog Catalog–Covers Full Line of Products Bloomington
Molded case circuit breakers
Application and Selection Guide for Molded Case Circuit
GET-2779 Bloomington
Breakers
GEZ-7000 Bloomington
MCCB Time-Current Curves
GET-7002 Bloomington
Spectra RMS Molded Case Circuit Breakers
Power break insulated
case circuit breakers
GET-6211 Selection and Application Bloomington
GEZ-7001 Time-Current Curves Bloomington
Low Voltage Power Circuit Breakers
GEI-86150 Installation and Operation Instructions Bloomington
GEK-7310 Maintenance Manual Bloomington
GEZ-7002 Type AKR Time-Current Curves Bloomington
GES-6227 Type AKR MicroVersaTrip RMS-9 Time Current Curves Bloomington
GES-6228 MicroVersaTrip Ground Fault Time-Current Curves Bloomington
Disconnect switches
GET-6205 Type HPC High-Pressure Contact Switches, Technical Bloomington
GEZ-7003 Type HPC Time-Current Curves Bloomington
Ground fault protective products
GET-2964 Ground Break Systems Bloomington
GEZ-7003 Ground Break Time-Current Curves Bloomington
Panelboards
GET-6592 “A” series Tech. Specifications Bloomington
GEA-11316 A Series Bloomington

Factory automation products

Publication(¹) Description Stocking location

Fanuc programmable logic control
GFW-0067 Automation Solutions Catalog Charlottesville
Fanuc I/O
GEK-90486 Genius I/O System User’s Manual Charlottesville
GFA-089 Genius I/O System Charlottesville
GEI-86150 Installation and Operation Instructions Bloomington
GFA-150 Field Control™ Charlottesville
GFT-298 VersaMax I/O Charlottesville
GFA-180 VersaMax Charlottesville

Motor control center equipment

Publication Description Stocking Location

Spectra series and 8000-line MCC
DEA-036 Spectra Series Product Brochure Bloomington
GEF-4628 8000-Line Renewal Parts Bulletin Bloomington
GEH-4961 Installation and Maintenance (Instructions) Bloomington

1. For more information visit our website at www.gefanuc.com/default2.htm

T E C H N I C A L A P P L I C AT I O N G U I D E 183

General purpose controls

Publication Description Stocking location

GEP-1260 Control catalog–covers full line of products Bloomington
Magnetic motor starters
GEA-10928 300-Line magnetic motor starters, descriptive Bloomington
GEH-5190 300-Line Instructions, NEMA size 1, FVNR Bloomington
GEH-4774 300-Line Instructions, NEMA size 2, FVNR Bloomington
GEH-4806 300-Line Instructions, NEMA size 3, FVNR Bloomington
GEH-4807 300-Line Instructions, NEMA size 4, FVNR Bloomington
GEH-4869 300-Line Instructions, NEMA size 5, FVNR Bloomington
GEH-5198 300-Line Instructions, NEMA size 6, FVNR Bloomington
GEH-5190 300-Line Instructions, NEMA size 1, FVR and 2-Speed Bloomington
GEH-4775 300-Line Instructions, NEMA size 2, FVR and 2-Speed Bloomington
GEH-4806 300-Line Instructions, NEMA size 3, FVR and 2-Speed Bloomington
GEH-4807 300-Line Instructions, NEMA size 4, FVR and 2-Speed Bloomington
GEH-4839 300-Line Instructions, NEMA size 5, FVR and 2-Speed Bloomington
Pilot devices
GEA-10877 Bloomington
Relays and timers
GEA-10639 Bloomington
GEH-4115 Bloomington
GEH-4120 Bloomington
GEH-4147 Bloomington
GEH-4139 Bloomington
GEH-6435 Bloomington
DET-069 Bloomington
Variable speed drives(¹)
GEI-100364 Fort Wayne
GEI-100363 Fort Wayne
Solid state starters
DEH-40397 Bloomington
GEH-6533 Bloomington
DEH-40396 Bloomington
DEH-40417 Bloomington

MCC's shipped after October 2019 will likely include a VFD from Danfoss FC102 and/or FC302.
184 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Electrical data KW= HPx.746 or 75x.746

Eff. .902 =62
Motor horsepower output may also be calculated .238 X 62 = 14.8 kVAR (use 15 kVAR)
as follows:
Defining the load
V x A x Pf x EFF
HP=
746
Rotating motion Linear motion
horsepower
Rules of thumb (approximation)
TxN FxV
At 1800 RPM, a motor develops a 3 lb. – ft. per HP. HP= HP=
5250 33.000
At 1200 RPM, a motor develops 4.5 lb – ft. per HP.
At 460 volts, a 3-phase motor draws 1.25 amp Where: T = Torque (lb-ft) Where: F = Force or
per HP. At 230 volts, a 3-phase motor draws 2.5 Tension (lb)
amp per HP. N = Speed (RPM) V = Velocity (FPM)
TxN FxV
Conversion formulas HP= HP=
63.000 396.000
To find Alternating current three-phase
Amperes when HP x 746 Where: T = Torque (lb-in) Where: F = Force or
Horsepower is known 1.73 x V x Eff x fp Tension (lb)
Amperes when Kw x 1000 N = Speed (RPM) V = Velocity (in/min)
Kilowatts is known 1.73 x V x pf
Amperes when Kva x 1000
Kva is known 1.73 x V Accelerating torque/force
1.73 x A x V x pf
Kilowatts
1000 WK² x N WxV
TA= 308t FA= 1933t
1.73 x A x V
Kva
1000
Horsepower - 1.73 x A x V x Eff x pf Where: TA = Where: FA = Accelerating
(Output) 746
Accelerating Force (lb-ft)
KW (alternating current) = KVA x Power Factor
torque (lb ft) W = Weight (lb)
KW (direct current) = V x A x .001
WK² = Total system V = Change in
KWH = KW x Hours
inertia that must velocity (FPM)
HP = KW
Motor Efficiency
be accelerated. t = Time (sec.)
This includes motor
Values Ohms Law rotor, speed reducer (if
V=Volts I=E/R used), and load. (lb-ft²)
A or I = Amperes (amps) R=E/I
Work/P = Watts/Power E=IXR Torque
KW=Kilowatts P=IXE T=FxR
KwH=Kilowatt Hours P=IXIXR
KVA=Kilovolt Amperes Where: T = Torque (lb-ft)
Pf=Power Factor, Table F = Force (lb)
Ph= Phase Factor, Table R = Radius (ft)

kVAR calculation when motor operating

WK 2 – reflected
characteristics are known
If motor HP, full-load power factor (PF) and
Reflected WK² = WK² of Load
efficiency (eff) are known, its easy to calculate
(Reduction Ratio)²
the correct kVAR necessary to improve PF to
This is for either belt or gear reductions.
any value.

FPM to RPM
Example: 75HP, 3600 RPN, NEMA B motor with
RPM = FPM
full-load PF of 87% and eff. of 92% corrected
.262 x (diameter in inches)
to 95%PF
Original PF = .87 Cos: Tan: = .567
Desired PF = .95 = Cos: Tan: = .329
Difference = .238
T E C H N I C A L A P P L I C AT I O N G U I D E 185

Electrical data Other useful formulas

Centrifugal loads Gear ratio - most favorable

Flow rate: Flow ₁= RPM₁ WK² + Tf² + Tf

GR=
Flow ₂= RPM₂ WKM² TM² TM

Where: WK² = WK² of the load

Torque: Torque ₁= RPM₁
WK²M = WK² of the motor
Torque ₂= RPM₂
Tf = Friction torque of the laod
TM = Average motor torque
²
Pressure: Pres₁= RPM₁ during acceleration
Pres₂= RPM₂
If friction torque is low compared to accelerating
BHP₁ = RPM₁ ³ torque this can be reduced to:
Horsepower:
BHP₂ = RPM₂₂
WK²
GR=
Fans and blowers: BHP = CFM x PSF WK²
3300 x (fan efficiency)
Duty cycle calculations
BH = CFM x PIW
6350 x (fan efficiency) HP HP²₁t + HP²₂t + HP₃t² + etc
RMS = t₁ + t₂ + t₃ + etc

BHP = CFM x PSI

229 x (fan efficiency)
GPM x TH x
(specific gravity)
Pumps: BHP =
3960 x (pump efficiency)

GPM x PSI x
(specific gravity)
BHP =
1713 x (pump efficiency)

Where: BHP = Brake horsepower

PSF = Pounds per square foot
PIW = P
 ressure in inches of
water guage
PSI = Pounds per square inch
GPM = Gallons per minute
TH = Total head (including friction)
186 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Drawings/tests

E9000 MCC unit numbering system The outline summary drawing furnished with the
The General Electric Engineering Documentation equipment cross-references the unit location and
System will accept a 3-character unit address the service designation specified for each unit.
designation consisting of a combination of
letters and/or numbers (such as: 12J, ABC, A1D, Motor control center no. 1
2AD, etc.). The recommended unit addressing A B C D

system is illustrated and described in the

following paragraphs. A
B
C
Note: Should customer’s (3-character maximum) 1AD
D
unit numbering system differ from the following
E
unit addressing system, then both can appear
F
when requested on the CAD-generated motor G
control center unit summary drawings issued from H
the factory. I
J
Benefits K
When ordering NEMA Class I or II motor control L
centers where factory interconnections are M
required, this system produces a uniform N

numbering format for engineering documentation. O

The unit numbering system produces a unique

unit address designation. When wiremarkers are Number the front view arrangement from
specified, it ensures consistency and ease of wire left-to-right 1, 2, 3 … or A, B, C … Line off the
tracing/troubleshooting between factory-wired space required for the top and bottom horizontal
units and other devices within the motor control wireways. Then line off the interconnecting vertical
center lineup such as programmable control wireway in each vertical section. Note that some
I/O racks. units (including large starters, transformers,
panelboards, etc.) may require full width of section
General and that no separate vertical wireway door will be
1 A D
Typical 3-Character designation adjacent to these units.
Motor control center number/character
Vertical section number/character Example:
Unit location (line number/character) Assume that the top horizontal wireway is to be 12
inches high. In the first section a full-voltage non-
Note: The motor control center number/character reversing NEMA size 1 combination starter is to be
assignment may be a number (1, 2, 3, 4, etc.) installed in the first available position below the
provided the number of MCC lineups on an order top horizontal wireway. Assuming conventional unit
does not exceed 9. If 10 or greater, then the motor sizing (FVNR-1 equals 1X or 12-inch unit height), the
control center character should be a letter of the unit location assignment becomes: 1 A D
alphabet (A, B, C, D, etc.). Likewise, the vertical
1 A D
section character should be an alphabetic entry for
lineups exceeding 9 sections. Motor control center
Vertical section
Unit location
T E C H N I C A L A P P L I C AT I O N G U I D E 187

Continue lining off the unit space requirements for This computer-based system is used to translate
various units and future spaces as required until equipment functional requirements into detailed
the lineup is complete and all spaces have been equipment designs and material lists. These
addressed. Notice that every unit location has a computerized drawings are used in the
unique unit location designation. This unit manufacturing process to increase product
designation will not be repeated again within the assembly accuracy, repeatability and consistency.
order. Since every motor control center lineup also Standardization of production procedures and
has a unique panel catalog number, then the unit methods has been improved such that given
nameplate and catalog number will never devices are consistently located in the same
be duplicated. position on or within the equipment. Unit wiring is
handled in the same manner, resulting in improved
15XXXXXXX - 1AD
wiring accuracy and productivity. The following
Example: drawing elements are included in the standard
MCC Cat Number documentation package.
Unit Location
1) Lead Sheet Figure 1
2) Outline Figure 2
A reminder about future spaces: If a 2X future space 3) Summary Tables Figure 3
is to be arranged into two 1X compartments, then 4) Unit Elementaries Drawings/tests section
the outline sketch must be lined off into 1X
compartments with individual unit addresses. This 1. Lead Sheet – Contains special Customer notes
will ensure that the necessary unit doors A B C D and manufacturing or test instructions.
and shelves will be provided by the factory. 2. Outline – Presents front view plan drawings
showing the physical arrangement of units and
E9000 MCC unit numbering system associated equipment within the motor control
CAD documentation system permits the engineer center lineup.
to perform virtually all design functions without 3. Summary Tables – Provides all necessary
the need of traditional drafting tools and functional detail of each unit including nameplate
associated equipment. inscriptions.

—
Figure 1
188 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

> < INCLINE

UL UL UL UL 600

FVNR FVNR FDRCB/

1 1.5 ACC ADC
FDRCB/ SPACE
FRONT AAD ABD ACD ADD
VIEW
FVNR FVNR FDRCB/ SPACE
1.5 1.5 ACE
FDRCB/
AAF ABF ACF ADF
FVNR FVNR FDRCB/ SPACE
1.5 1.5 ACG
FDRCB/
AAH ABH ACH ADH
FVNR FVNR FDRCB/ FDRCB/
1.5 1 ACI ADI
SECT. HEIGHT 90 INCHES FDRCB/ FDRCB/
AAJ ABJ ACJ ADJ
FVNR FVNR FDRCB/ SPACE
1.5 1 ACK
FDRCB/
AAL ABL ACL ADL
FVNR FVNR FDRCB/ SPACE
1.5 1 ACM
FDRCB/ ADN
AAN ABN ACN
UL SECT. NO.
X=SHIPPING
LENGTH
>=SPLICE 001 002

1 2 3 4
MOD SHEET
SECT. WXD FRONT 20X20 FRONT 20X20 FRONT 20X20 FRONT 20X20
VERT. BUS A
300 300 300 600/300

—
Figure 2

UNIT SUMMARY EVOLUTION SERIES MCC

REQ. NO. ENG. NAME JBC DWG. FOR INSTALLATAION
PANEL CAT. NO. ISSUED 01/16/1996 REV. ABB DWG. NO. SH F01A
FRONT REV NO. 0 MEBANE, NC USA CONT. ON SH F01B
CAT# 273A7916P3FC D TOTAL NOT LABELED
UNIT CUST R HP TRIP
W S OL OL AUX
UNIT ELEM CONN. I CB FUSES
MOD UNIT S FUNCTION KW FLA RPM SF HEATER RELAY FUSE/ SC CPT CATALOG
NAMEPLATE I Z INILK UL CSA
LOC E SW BY
Z K-KW CR123 TYPE CLIP MARKER VA NUMBER
SH NO E 0 0 LABEL LABEL
AAD 6-MILL 200A 1 1 1.8 1000 1.150 C220A AMBIENT SELI 3 3 0 UL 157 150
100 FVNR IA52-102437
FEED END
JACKING PUMP
RED RUN PTT LT
AAF 6-MILL 200A 1 1.5 2.4 1000 1.150 C301A 3 0 157
100 FVNR AMBIENT SELI 3 UL 150 IA52-102438
FEED END
JACKING PUMP
RED RUN PTT LT
AAH 6-MILL 1.5 1000 3 0 157
100 200A FVNR 1 2.4 1.150 C301A AMBIENT SELI 3 UL 150 IA52-102438
FEED END
FILTRATION PUMP
RED RUN PTT LT
AAJ 6-MILL 200A 1 1.5 2.4 1000 1.150 C301A AMBIENT SELI 3 3 0 UL 157 150
100 FVNR IA52-102438
DISCHARGE END
JACKING PUMP
RED RUN PTT LT
AAL 6-MILL 1.5 3 0 157
100 200A FVNR 1 2.4 1000 1.150 C301A AMBIENT SELI 3 UL 150 IA52-102439
DISCHARGE END
EXT. LUBE PUMP
RED RUN PTT LT
AAN 6-MILL 200A 1 1.5 2.4 1000 1.150 C301A 3 0 157
100 FVNR AMBIENT SELI 3 UL 150 IA52-102439
DISCHARGE END
FILTRATION PUMP
RED RUN PTT LT
ABD 7-MILL 200A 1 1.5 2.4 1000 1.150 C301A 3 0 157
100 FVNR AMBIENT SELI 3 UL 150 IA52-102438
FEED END
JACKING PUMP
RED RUN PTT LT
ABF 7-MILL 100 200A 1 1.5 2.4 1000 1.150 C301A AMBIENT SELI 3 3 0 UL 157 150
FVNR IA52-102438
FEED END
EXT. LUBE PUMP
RED RUN PTT LT
ABH 7-MILL 100 200A 1 1.5 2.4 1000 1.150 C301A AMBIENT SELI 3 3 0 UL 157 150
FVNR IA52-102438
FEED END
FILTRATION PUMP
RED RUN PTT LT
ABJ 7-MILL 100 200A 1 1 1.8 1000 1.150 C220A AMBIENT SELI 3 3 0 UL 157 150
FVNR IA52-102437
DISCHARGE END
JACKING PUMP
RED RUN PTT LT

—
Figure 3
T E C H N I C A L A P P L I C AT I O N G U I D E 189

Paint finish Packaging and storage

Indoor equipment Domestic packaging

The standard Mebane paint system consists of the Normally a motor control center Lineup is shipped
following two processes. in groups of three vertical sections for ease of
handling. Each shipping split is mounted on a
Phase I – Cleaning hardwood skid to facilitate moving by rollers or
In a 7-stage spray washer, steel parts are cleaned fork-lift truck. Lifting eyes are also provided for
and sprayed in the controlled cleaning solutions. moving by crane. Shipping blocks are placed on the
face of the sections to protect handles and devices.
The shipping splits are wrapped in clear stretch
Stage Temperature Chemical solution(s)
polyfilm to protect the equipment from the usual
1–Cleaning 115-120° Ferro clean
dust and dirt encountered during shipment.
2–Rinse 105-118° None
Necessary bus splice bars are included for
3–Iron phosphate 90-105° Secure low foam
connecting the shipping splits together.
4–Rinse Ambient None
5–Non chrome
Ambient Non chrome final seal Export crating
sealer
The sections are bolted to a skid with a solid floor.
6–Rinse Ambient None
The equipment is then enclosed in a 3/8" plywood
7–Deionized rinse Ambient None
crate with 2 x 4 reinforcing at the top and corners.
Three 1 1/4" steel bands are placed horizontally
Cleaned steel parts enter a drying oven at 300-
around the crate for additional reinforcing.
350°F. The preceding operating parameters have
been determined to produce an Iron Phosphate
All equipment should be protected against
coating of a minimum of 150 milligrams per square
moisture and temperature extremes during
foot to meet MIL Spec. TT-C-490.
shipment and storage. See Environmental
Considerations in "Overview" section. For
Phase II – Painting by electro-static
prolonged shipping periods where export crating
powder process
is involved, it is recommended the equipment
Primed metal parts are electrostatically coated
space heaters (when specified) be wired for
with a powder paint consisting of the following:
connecting to an external power source while
670-011 ANSI-61 Polyester Paint (Light Gray)
in transit, to minimize condensation.

Metal parts will enter drying oven at 375-400°F and

Storage
remain for 20 minutes. The standard color is ANSI-
If it is necessary to store the equipment for
61 light gray with a gloss of 60±5, and a thickness
any length of time, the following precautions
of 1.5 mils. This system will withstand a minimum
should be taken:
of 1000 hour humidity test, plus 600 hours salt
1. Uncrate equipment.
spray test.
2. Store in a clean, dry area at moderate
temperature. Cover with a suitable canvas or
heavy-duty plastic cover to prevent entrance of
foreign material.
3. If equipment must be stored in cool or damp
areas, not only should the equipment be
completely covered, but heat should be provided
to prevent condensation of moisture in the
equipment. Energize space heaters (if furnished
in the equipment) or place a standard 120-volt
lamp rated 75 watts inside the bottom of each
vertical section.
190 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Standard commercial tests and inspection Mechanical operations test

Mechanical operating tests shall be performed to
General insure proper
The following summary description defines the functioning of operating mechanisms and
standard factory tests and inspections performed interchangeability.
during manufacture. All motor control center a. The operation of shutters, mechanical interlocks,
equipment is tested and inspected for circuitbreaker-door interlocks, operating
conformance with NEMA ICS 18-2001. Production handles, trip mechanisms, solenoid armature
tests and inspections encompass the verification travels, contact wipes, electromechanical
of physical configuration of assembly and interlocks, physical clearances for mechanical
workmanship, the mechanical adjustments of parts and electrical isolation including any additional
and components, and the sequencing and mechanically related operating functions shall be
functional operations of the control systems. These verified.
tests and inspections are performed on b. The interchangeability of removable units
manufactured products to verify conformance of designed to be interchangeable shall be verified
the equipment to a previously qualified design. The as well as the rejection functions of non-
tests do not include type testing or other interchangeable units.
destructive tests on equipment to be shipped to a
customer. Any additional factory tests beyond Continuity tests – control wiring and
those listed in the following paragraphs must be power cables
referred to Mebane to verify availability of test The correctness of the individual circuit wiring
facilities and qualified manpower. Additional contained in each assembly and the assembly
testing beyond the scope of the following standard wiring interfaces shall be verified as in accordance
commercial tests will affect normal shipment with the connection diagram, wiring table, or
schedules. elementary drawing. The continuity of each circuit
shall be checked.
Production tests
The following list of inspection activities shall be Functional operations test
performed to assure proper and correct materials, All equipments shall be subjected to an operational
workmanship and for any damage conditions in test. The test shall verify the functional operation
accordance with the manufacturing documentation of the control and power circuits and related
and drawings: components, devices and subassemblies- modules
• Components, parts and material. under simulated operating conditions (excluding
• Physical condition of components, parts, loading of the power circuits).
wire insulation.
• Location and orientation of components Devices
and parts. All devices, including subassemblies-modules, shall
• Finish–plating–painting. be operated, set and checked for their functional
• Wire/cable type, size, insulating and characteristics in accordance with the instructions
clamping support. for each and any additional characteristics peculiar
• Wire terminations, insulation removal and to a device:
crimping of terminals. • Pick-up
• Tightness of electrical connections and torque of • Drop-out
bus bar bolts. • Contact wipe
• Wire markers and terminal markers • Amperes
(where specified). • In-rush current
• Labeling of components, parts, etc. • Time-delay
• Tightness torque of assembly bolts
and hardware.
• Welds (spot only).
• Mechanical clearance.
• Electrical clearance (potential hazards).
T E C H N I C A L A P P L I C AT I O N G U I D E 191

Contactors must pick-up and hold-in at or below The test voltages include the standard test voltage
the following percentage or rated coil voltage: (two times rated plus 1000), times 120 percent (for
one-second application).
Device
Voltage source Pick-up (percentage) Rated circuit High potential
type Duration of test
Voltage AC or DC test voltage
DC DC 63
120 1500 1 second
AC AC 85(¹)
240 1800 1 second
DC AC with rectifier 70 with holding resistor
480/600 2700 1 second
75 with holding and
DC AC with rectifier
pick-up resistor
The frequency of the test voltage shall not be less
1. If a control power transformer is used, apply 90
percent voltage to primary of transformer.
than the rated frequency of the equipment tested
and shall be essentially sinusoidal in wave shape.
Sequence and timing circuits
Assemblies and systems involving sequential Note: Consideration shall be made for low-
operation of devices and time delays shall be voltage devices, semiconductors, meters,
tested to assure that the devices in the sequence instruments, transformers, grounding
function properly and in the order intended. circuits, etc., in preparation for the
dielectric tests.
Polarity – phase-sensitive circuits
The polarity of direct-current circuits and phase Option – insulation resistance (megger) tests
connections of alternating-current circuits shall be Insulation resistance tests measure the amount
verified by application of power and measurement of circuit resistance to current leakage. This test
of the relative polarities and phase sequence. is performed when this resistance measurement
is desired and so specified. A nominal charge will
Grounding be assessed.
The grounding circuits and buses shall be verified.
The test voltage and minimum insulation resistance
shall be selected as specified by the contract.
Standard commercial tests and inspection
Standard test values are:
High Potential – Insulation Tests
a. 500 volts DC with 10 megohms minimum
b. 1000 volts DC with 1 megohm minimum
Control wiring insulation tests
A dielectric test (hi-pot) shall be performed on Motor Control Center

circuit wiring to confirm the insulation resistance Monterrey Quality

MCC Certified Test Report
to withstand breakdown to a selected test voltage. ABB ELECTRICAL CONTROL SYSTEMS S DE RL DE CV
Camino a Ojo de Agua 203, CP 66600
Apodaca, Nuevo León, Mexico

The test voltage – amplitude and waveshape, Customer: Customer's Job Name PO: S12345678

method of application and duration of time applied Requisition:

Sales Order:
987654321

151234567
Tag

Item:
Customer's Tag

10

– shall be specified in Wiring Diagrams: 377B4946

The above equipment has been passed the below listed manufacturer’s tests and conforms to the latest applicable ANSI,

NEMA ICS 18-2001. NEMA and IEEE standards and special contractual requirements.

QUALITY
1. WIRE CHECK
Power Circuit. PASS
PASS

Power cable insulation and isolation test

Control Circuit.

2. AC DEVICES
Pickup and Noise Tested at 85 % Voltage. PASS

Power cables and buses shall be tested, phase-to- 3. DC DEVICES

90 % of Rated Voltage with CPT. PASS

phase and phase-to-ground for insulation

Pickup and Noise Tested at N/A % Voltage. N/A
Overvoltage set at N/A Volts. N/A
DC Test when requested by engineering order.

breakdown resistance and circuit isolation as 4. SEQUENCE OPERATION

At Rated Voltage. PASS

specified in NEMA ICS 18-2001.

5. HIGH POTENCIAL TEST
(HI-POT) Power Circuit 2700 Volts for 1 Sec. PASS
Control Circuit N/A Volts for 1 Sec. N/A
Circuit Test include Devices and Components.
When apply, to Control Circuits due Electronic Protection.

6. INSULATION RESISTANCE

Note: These test conditions are as specified for (MEGGER) When Apply. Phases to Ground, Phases to Phases.
Voltage 500/1000V DC according to the order.
N/A

newly constructed equipment and performed in a

7. VISUAL INSPECTION PASS
Appearance, Workmanship, Components assembly,
Mechanical Tolerances, Electrical Clearances and
Mechanical Operations.

clean, temperature- and humidity-controlled 8. OTHERS

factory environment.
N/A N/A

Acknowledgement of final inspection and operation of unit listed per this final test report:

Quality Assurance Representative: Gabriel Martínez Date: January 1, 2020

Page 1 of 1

—
Example of standard test report available
on request for a nominal charge.
192 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Typical circuits

FVNR size 1-4

Typical circuit diagrams

L1 L2 L3
TB
61
Stab 60
M OL 51
(3) (5) (6) (5) (6) (5) (6) 50
L3 (H-O-A Only) 5
K3 K6 T3 4
CB 3
(2) (3) (4) (3) (3) 2
(4) (4) 1A
OR
L2 K2 K5 1
T2 X2
LSW T3
(1) (1) (2) (1) (2) (1) (2) MOTOR T2
T1
L1 K1 K4 T1
(1) (3)
2FU
(15)M (16)
50 51
(2) (4)
H1 H2 (13)M(14)
(H1) (H2) 60 61

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) X2 1 X1 (X1) (X2) X2
GND GND

No Pilot Devices Red Ind. Light

M OL M
(A) (B) (7) (8) OL
(A) (B) (7) (8)
3 40 3 40

M M R
(12) (11) (12) (11) (1) (2)
2 2

(2) IFU (1)

1 X1 (X1) (X2) X2
IFU GND
(2) (1)
1 X1 (X1) (X2) X2
Red/Green Ind. Lights
GND

Start/Stop PB's
M
(A) (B) (7)OL(8)
3 40
STOP START M OL
(13) (14) (3) (10) (A) (B) (7) (8)
1A 2 3 40 M R
(12) (11) (1) (2)
2
M
(12) (11)
M
2 (13) (14) G
(5) (6)
4

(2) IFU (1)

(2) IFU (1) 1 X1 (X1) (X2) X2
1 X1 (X1) (X2) X2 GND
GND
Start/Stop PB's
Red Ind. Light
Hand-Off-Auto-SW

SW
START(10) M
Hand Auto
M (13)STOP(14) (3) (A) (B) (7)OL(8)
(13) OFF OL
(14) (A) (B) (7) (8) 1A 2 3 40
1A 3 40
M R
(12) (11) (1) (2)
(15) (16) M
(11) (12)
x=Closed(MC) 5 2

(2) IFU (1)

1 X1 (X1) (X2) X2
GND
(2) IFU (1)
Start/Stop PB's
1 X1 (X1) (X2) X2 Red/Green Ind. Lights
GND

On/Off Switch START(10) M

(13)STOP(14) (3) (A) (B) (7)OL(8)
1A 2 3 40
SSW
M
(13) Off On (14) (A) (B) (7)OL(8) M R
3 40 (12) (11) (1) (2)
x=Closed(MC) 1A

M
(11) (12)
2
M
(13) (14) G
(5) (6)
4
T E C H N I C A L A P P L I C AT I O N G U I D E 193

FVNR size 1-4

Typical circuit diagrams

L1 L2 L3
TB
61
Stab 60
M 51
(3) (5) (6) (5) (6) (5)OL (6) 50
L3 (H-O-A Only) 5
K3 K6 T3 4
CB 3
(2) (3) (4) (3) (3) 2
(4) (4) 1A
OR
L2 K2 K5 1
T2 X2
LSW T3
(1) (1) (2) (1) (2) (1) (2) MOTOR T2
T1
L1 K1 K4 T1
(1) (3)
2FU
(15)M (16)
50 51
(2) (4)
H1 H2 (13)M(14)
(H1) (H2) 60 61

ASW
(2) IFU (1) (2) IFU (1) (1B) (X1) To Remote
1 X1 (X1) (X2) X2 1 XB X1 Control Source X2
GND
Hand-Off-Auto-SW
Red Light
SW
Hand Auto
OFF M OL M
(13) (14) (A) (B) (7) (8) (A) (B) (7)OL(8)
1A 3 40 1A 3 40

TB
(15) (16) M R M X1
(11) (12) (1) (2) (12) (11)
x=Closed(MC) 5 2 5 2 61
60
51
(2) IFU (1) 50
1 X1 (X1) (X2) X2 5
GND 4
Hand-Off-Auto-SW
3
Red/Green Lights 2
SW
1A
Hand Auto 1
(13) OFF
(14) (A)
M
(B)
OL
(7) (8) X2
1A 3 40

(15) (16) M R
(11) (12) (1) (2)
x=Closed(MC) 5 2

M
(13) (14) G
(5) (6)
4

(2) IFU (1)

1 X1 (X1) (X2) X2
GND
On/Off SW
Red Light

SSW
M OL
(13) Off On (14) (A) (B) (7) (8)
1A 3 40
x=Closed(MC)

M R
(11) (12) (1) (2)
2

(2) IFU (1)

1 X1 (X1) (X2) X2
GND
On/Off SW
Red/Green Light

SSW
M
(13) Off On (14) (A) (B) (7)OL(8)
1A 3 40
x=Closed(MC)

M R
(11) (12) (1) (2)
2

M
(13) (14) G
(5) (6)
4
194 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

FVNR size 5-6

Typical circuit diagrams

S-5
OL OL
(1) (2)
20 23 TB
61
(3) (4) 60
21 51
50
L1 L2 L3 L1 L2 L3 (5) (6)
(H-O-A Only) 5
22 4
3
(5) (6)
M
(5) (6) (5) (6)
M
(5) (6) (1) (2)
2
1A
L3 K3 T3 L3 K3 3CT T3 1
CB CB
(3) (4) (3) (4) (3) (4) (3) (4) (1) (2)
X2
OR OR
L2 K2 T2 L2 K2 2CT T2
LSW LSW
(1) (2) (1) (2) MOTOR (1) (2) (1) (2) (1) MOTOR
(2)
L1 K1 T1 L1 K1 T1
ICT

3FU 3FU 2FU 2FU GND

(2) (2) (1) (3) (4)
(1) (3) (4)
H1 K1 K2 H2 H1 K1 K2 H2

CR M
(1) (2) (A) (B) M
CR
(3) (4) (A) (B)
41 (15)M (16)
41 50 51

(13)M(14)
2FU 2FU 2FU 2FU 60 61
(1) (2) (H1) (H2) (4) (3)
(1) (2) (H1) (H2) (4) (3)
H1 H2

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) X2 1 X1 (X1) (X2) X2
GND GND

No Pilot Devices Red Ind. Light

CR
CR
(A) (B) (7)OL(8) (A) (B) (7)OL(8)
40 3 40
3

M R
M (12) (11) (1) (2)
(12) (11)
2 2

(2) IFU (1)

(2) IFU (1) 1 X1 (X1) (X2) X2
1 X1 (X1) (X2) GND
X2
GND
Red/Green Ind. Lights
Start/Stop PB's

CR
(A) (B) (7)OL(8)
START CR 3
(13)STOP(14) (9) (10) (A) (B) (7)OL(8)
40
1A 2 3 40
M R
(12) (11) (1) (2)
M 2
(12) (11)

M
(13) (14) G
(5) (6)
4
(2) IFU (1)
1 X1 (X1) (X2) X2 (2) IFU (1)
GND 1 X1 (X1) (X2) X2
GND
Hand-Off-Auto-SW
Start/Stop PB's
SW Red Ind. Light
Hand Auto
OFF CR
(13) (14) (A) (B) (7)OL(8)
1A START(10) CR
3 40 (13)STOP(14) (9) (A) (B) (7)OL(8)
1A 2 3 40
(15) (16) M
(11) (12)
5 2 M R
x=Closed(MC) (12) (11) (1) (2)

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) X2 1 X1 (X1) (X2) X2
GND GND
Start/Stop PB's
On/Off Switch Red/Green Ind. Lights
SSW
CR START(10) CR
(13) Off On (14) (A) (B) (7)OL(8) (13)STOP(14) (9) (A) (B) (7)OL(8)
1A 3 40 1A 2 3 40
x=Closed(MC)

M M R
(11) (12) (12) (11) (1) (2)
2

M
(13) (14) G
(5) (6)
T E C H N I C A L A P P L I C AT I O N G U I D E 195

FVNR size 5-6

Typical circuit diagrams

S-5
OL OL
(1) (2)
20 23 TB
61
(3) (4) 60
21 51
50
L1 L2 L3 L1 L2 L3 (5) (6)
(H-O-A Only) 5
22 4
3
(5) (6)
M
(5) (6) (5) (6)
M
(5) (6) (1) (2)
2
1A
L3 K3 T3 L3 K3 3CT T3 1
CB CB
(3) (4) (3) (4) (3) (4) (3) (4) (1) (2)
X2
OR OR
L2 K2 T2 L2 K2 2CT T2
LSW LSW
(1) (2) (1) (2) MOTOR (1) (2) (1) (2) (1) MOTOR
(2)
L1 K1 T1 L1 K1 T1
ICT

3FU 3FU 3FU 3FU GND

(2) (2) (1) (3) (4)
(1) (3) (4)
H1 K1 K2 H2 H1 K1 K2 H2

CR M
(1) (2) (A) (B) M
CR
(3) (4) (A) (B)
41 (15)M (16)
41 50 51

(13)M(14)
2FU 2FU 2FU 2FU 60 61
(H1) (H2) (1) (2) (H1) (H2) (4) (3)
(1) (2) (4) (3)
H1 H2

(2) IFU (1)

1 X1 (X1) (X2) X2
GND
Hand-Off-Auto-SW
Red Light
SW
Hand Auto
OFF CR
(13) (14) (A) (B) (7)OL(8)
1A 3 40

(15) (16) M R
(11) (12) (1) (2)
x=Closed(MC) 5 2

(2) IFU (1)

1 X1 (X1) (X2) X2
GND
Hand-Off-Auto-SW
Red/Green Lights
SW
Hand Auto
OFF CR
(13) (14) (A) (B) (7)OL(8)
1A 3 40

(15) (16) M R
(11) (12) (1) (2)
x=Closed(MC) 5 2

M
(13) (14) G
(5) (6)
4

(2) IFU (1)

1 X1 (X1) (X2) X2
GND

On/Off SW Red Light

SSW
CR OL
(13) Off On (14) (A) (B) (7) (8)
1A 3 40
x=Closed(MC)
M R
(11) (12) (1) (2)
2

(2) IFU (1)

1 X1 (X1) (X2) X2
GND
On/Off SW
Red/Green Lights

SSW
CR OL
(13) Off On (14) (A) (B) (7) (8)
1A 3 40
x=Closed(MC)
M R
(11) (12) (1) (2)
2

M
(13) (14) G
(5) (6)
4
196 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

FVNR with voltage indicator module

Typical circuit diagrams

T E C H N I C A L A P P L I C AT I O N G U I D E 197

FVR size 1-4

Typical circuit diagrams

L1 L2 L3
R
(5) (6)
Stab
(5) F OL
(3) (6) (5) (6) TB
(5) (6) F
9 (17) (18)
L3 K3 K6 T3 50 51
(3) (4) 8
CB 5
(3) 3 (17) R(18)
(2) (4) (3) (4) (3) (4) 52 53
OR 1A
L2 K2 K5 1
(1) (2) T2
X2 (15) F (16)
LSW 60 61
T3
(1) (2)
(1) (1) (2) (1) (2) MOTOR T2 (15) R (16)
T1 62 63
L1 K1 K4 T1
(1) (3)
2FU

(2) (4)
H1 H2
(H1) (H2)

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) X2
1 X1 (X1) (X2) X2
GND GND
Amber/Red/Green/
No Pilot Devices
Ind. Lights

¨
F
(12) R(11)(A) (B)
R F OL OL
(12) (11)(A) (B) (7) (8) (7) (8)
3 6 40 3 6 40

¨
F F R
(14) (13) (14) (13) (1) (2)
8 8

¨
(12) F(11)(A) R(B) F R
(12) (11)(A) (B)
5 7 5 7

¨
R R A
(14) (13 (14) (13) (17) (18)
9 9
F R G
(15) (16) (15) (16) (9) (10)
16 13

(2) IFU (1)

(2) IFU (1)
1 X1 (X1) (X2) X2
1 X1 (X1) (X2) X2
GND
GND
Rev/Fwd/Stop PB
Fwd/Rev/Stop PB Amber/Red/Green Lights

STOP FWD R F OL
STOP FWD F (13) (14) (8) (6) (12) (11)(A) (B) (7) (8)
(13) (14) (8) (6) (12) R (11)(A) (B) OL
(7) (8) 1A 3 6 40
1A 3 6 40

F R
(14) (13) (11) (12)
(14) F (13)
8
8

REV F R
REV F R (21) (22) (12) (11)(A) (B)
(21) (22) (12) (11)(A) (B) 5 7
5 7

(14)R (13) A
R (17) (18)
(14) (13)
9
9
F R G
(15) (16) (15) (16) (9) (10)
16 13

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) X2 1 X1 (X1) (X2) X2
GND GND
Rev-Off-Fwd SW
Rev-Off-Fwd SW Amber/Red/Green Light
SW

SW R O F F
R O F (13) (14) (12) R (11) (A) (B) (7)OL(8)
F
(12) R (11)(A) (B) (7) (8)
OL 1A 3 6 40
(13) (14)
1A 3 6 40
F R
(14) (13) (1) (2)
F 8
(13) (14)
8
F R
(15) (16) (12) (11) (A) (B)
F R X=Closed
(MC) 5 7
(15) (16) (12) (11)(A) (B)
X=Closed
(MC) 5 7
R A
(14) (13) (17) (18)
9
R
(13) (14) F R G
(15) (16) (15) (16) (9) (10)
9
¨ Polarity sensitive (all options). 16 13
198 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

RVAT size 2-6

Typical circuit diagrams

Size 2, 3-65, 80% Taps
Size 4, 5, 6-50, 65, 80% Taps

optional

Power Factor Capacitor

L1 L2 L3
TB
IS AT 53
(5) (6) 52
R (FC) (3C) (1C) (0C) OL 51
* (5) (6) (5) (6) (2C) 0C
(4) T3
50
(H-O-A Only) 5
L3 K3 (3) (4)
CB 2S
(6) 4
FB (FB) (3B) (1B) (0B) (3) 2S 3
* (3)
OR
(4) (3) (4) (2B) 0B
(1)
(5) 2
1A
L2 K2 (1) (2) 2S T2
(2) 1
LSW FA (FA) (3A) (1A) (0A) X2
* (1) (2) (1) (2) (2A) 0A MOTOR
T3
L1 K1 T1 T2
Size 2-4 T1
Size 5 and 6 CT Operated

(2) 3FU (1) (3)

3FU (4)

H1 K1 K2 H2

* Stab-in up to 5
TR 1S 2S R
(C) (NO) (5) TR (3) (13) (14) (A) (B) (13) (14)
43 TO 44 45 46
Inst.

1S
(A) (B)

(15) R (16)
2S R 50 51
(5) TR (1) (13) (14) (A) (B)
TC 47 48 (21) R(22)
52 53

2FU 2FU
(1) (2) (4) (3)
(H1) (H2)

(2) IFU (1) T

T
(2) IFU (1)
1 X1 (X1) (X2) X2 1 X1 (X1) (X2) X2
GND
GND
Start/Stop PB's
Red/Green Ind. Lights On/Off Switch

OTT SSW
START(10) TR
(13)STOP(14) (3) L1 L2 (7)OL(8) (1) (2) TR OL OTT
1A (13) Off On (14) L1 L2 (7) (8) (11) (12)
2 3 40 39
TDAE 1A 3 TDAE 40 39
(10 Sec.) x=Closed(MC)
IS R (10 Sec.)
(11) (12) (1) (2) IS
(12) (11)
R 2
(11) (12) R
(12) (11)
R
(15) (16) G
(5) (6)
T
4 (2) IFU (1)
1 X1 (X1) (X2) X2
(2) IFU (1) T
GND
1 X1 (X1) (X2) X2 On/Off SW
GND Red/Green Lights
Hand – Off – Auto SW
Red/Green Lights SSW
TR OL OTT
SW (13) Off On (14) L1 L2 (7) (8) (11) (12)
Hand Auto OTT
OFF TR OL 1A 3 TDAE 40 39
(13) (14) L1 L2 (7) (8) (1) (2) x=Closed(MC) (10 Sec.)
1A 3 40 39
TDAE IS R
(10 Sec.) (11) (12) (1) (2)
(15) (16)
IS R 2
(11) (12) (1) (2)
R
x=Closed(MC) 5 (11) (12)
R
(11) (12) R
(15) (16) G
(5) (6)
R 4
(15) (16) G
(5) (6)
4

T
(2) IFU (1) T (2) IFU (1)
1 X1 (X1) (X2) 1 X1 (X1) (X2) X2
X2
GND GND
Hand – Off – Auto SW On/Off SW
Red Light Red Light

SW SSW
Hand Auto OTT OTT
TR TR OL
(13) OFF
(14) L1 L2 (7)OL(8) (1) (2) (13) Off On (14) L1 L2 (7) (8) (11) (12)
1A 3 40 39 1A 3 TDAE 40 39
TDAE
x=Closed(MC) (10 Sec.)
(10 Sec.)
(15) (16)
IS R IS R
(11) (12) (1) (2) (11) (12) (1) (2)
x=Closed(MC) 5 2
R R
(11) (12) (11) (12)
T E C H N I C A L A P P L I C AT I O N G U I D E 199

2S2W-C.T., V.T., C.H. Size 1-4

Typical circuit diagrams

TB
9 FS
Note: See GEM-1000A SS SOL 8 (17) (18)
(5) (6) (5) (6)
K6 T3 5 50 51
3 FS
(3) (4) (3) (4) 1A (15) (16)
60 61
K5 T2 1
X2 SS
(17) (18)
(1) (2) (1) (2) T13 52 53
L1 L2 L3
K4 T1 T12
STAB MOTOR T11 (15)SS (16)
(3) (5) (6)
FS
(5) (6) (5)
FOL(6) T3 62 63
T13
T2
L3 K3 K9 T1
CB
(2) (3) (4) (3) (4) (3) (4)
OR
L2 K2 K8 T12
LSW
(1) (1) (2) (1) (2) (1) (2)
L1 K1 K7 T11
(1) (2)
2FU

H1 (3) (4) H2
(H1) (H2)

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) X2 1 X1 (X1) (X2) X2
GND GND
Amb/Red/Grn Ind.
No Pilot Devices
Lights
1
FS SS SOL FOL SOL FOL
FS SS
(12) (11)(A) (B) (7) (8) (7) (8) (12) (11)(A) (B) (7) (8)(7) (8)
3 6 40 39 3 6 40 39
1
SS SS A
(13) (14) (13) (14) (1) (2)
8 8

SS FS SS FS
(12) (11) (A) (B) (12) (11) (A) (B)
5 7 5 7
1
FS FS R
(13) (14) (13) (14) (17) (18)
9 9
SS FS G
(15) (16)(15) (16) (9) (10)
16 13

(2) IFU (1)

(2) IFU (1) 1 X1 (X1) (X2)
X2
1 X1 (X1) (X2) GND
X2
GND Fast-Slow-Off-Auto
SW
Fast/Slow/Stop PB
SW
(13) F S O A (14) FS SS SOL FOL
(7) (8) (7) (8)
FS (12) (11)(A) (B)
STOP SLOW SS SOL FOL 1A 3 6 40 39
(13) (14) (5) (6) (12) (11)(A) (B) (7) (8) (7) (8)
1A 3 6 40 39
SS
(14) (13)
SS 8
(13) (14)
8
(15) (16) (12)IS (11)(A)FS(B)
FAST SS FS 5 7
(21) (22) (12) (11)(A) (B)
5 7
FS
(25) (26) (14) (13)
FS 14 9
(13) (14)
9
(27) (28)

x=Closed (MC)

(2) IFU (1) (2) IFU (1)

1 X1 (X1) (X2) 1 X1 (X1) (X2)
X2 Fast - Slow- Auto-SW X2
SW GND GND
AMB/Red/Grn Ind.
F S O A FS SOL FOL Fast/Slow/Stop PBs
(13) (14) SS
(12) (11)(A) (B) (7) (8) (7) (8)
39 Amb/Red/Grn Lights
1A 3 6 40

SS R STOP SLOW FS SS SOL FOL

(14) (13) (1) (2) (13) (14) (5) (6) (12) (11)(A) (B) (7) (8) (7) (8)
8 3 6 40
1A

IS FS SS A
(15) (16) (11) (12)(A) (B) (13) (14) (1) (2)
5 7 8

FS FAST SS FS
(25) (26) (14) (13) R (21) (22) (12) (11) (A) (B)
(17) (18)
9 5 7

FS R
(27) (28) (13) (14) (17) (18)
SS FS 3
SS FS G (15) (16) (15) (16) G
x=Closed(MC) (9) (10) (9) (10)
(15) (16) (15) (16) (16) (13)
(16) (13)
200 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

2S1W-C.T., V.T., C.H. Size 1-4

Typical circuit diagrams

Note: See GEM-1000A SS SOL TB
(5) (6) (5) (6) FS FOL
K6 T3 (5) (6) (5) (6) 9
K6 T5 8
(3) (4) (3) (4)
(3) (4) (3) (4)
5
K5 T2 3
Constant HP Constant or K5 T4 1A
(1) (2) (1) (2) Variable Torque
(1) (2) (1) (2) 1
K4 T1 X2
K4 T6 T6
(7) (8) T4
(7) (8) T2 T5
T3
T4
L1 L2 L3 (9) (10)
MOTOR
MOTOR T3
L1 L2 L3 (9) (10) T2
STAB
FS T1 T1
(3) (5) FOL(6) STAB
(6) (5) (6) (5) SS SOL(6)
(3) (5) (6) (5) (6) (5)
L3 K3 K9 T5
CB L3 K3 K9 T3 FS
(2) (3) (4) (3) (4) (3) (4) CB (17) (18)
OR (2) (3) (4) (3) (4) (3) (4) 50 51
L2 K2 K8 T4 OR
LSW L2 K2 K8 T2 FS
(1) (1) (2) (1) (2) (1) (2) LSW (15) (16)
(1) (1) (2) (1) (2) (1) (2) 60 61
L1 K1 K7 T6
(1) (3) L1 K1 K7 T1 SS
2FU (1) (3) (17) (18)
2FU 52 53
H1 (2) (4) H2
(H1) (H2) H1 (2) (4) H2 (15)SS (16)
(H1) (H2) 62 63

(2) IFU (1) (2) IFU (1)

X1 (X1) (X2) 1 X1 (X1) (X2) X2
1 X2
GND GND
Amb/Red/Grn Ind.
No Pilot Devices Lights
1 1
FS FS SS SOL FOL
SS SOL FOL (12) (11)(A) (B) (7) (8)(7) (8)
(12) (11)(A) (B) (7) (8) (7) (8)
3 6 40 39
3 6 40 39
1 1
SS A
SS (13) (14) (1) (2)
(13) (14)
8
8
1 1
SS FS
SS FS (12) (11)(A) (B)
(12) (11) (A) (B) 7
5
5 7
1
1
FS R
FS (13) (14) (17) (18)
(13) (14)
9
9 SS FS G
(15) (16) (15) (16) (9) (10)
(2) IFU (1) 16 13
1 X1 (X1) (X2) X2 (2) IFU (1)
GND
1 X1 (X1) (X2) Fast-Slow-Off-Auto SW
Fast/Slow/Stop PB's X2
AMB/Red/Grn Lights SW GND AMB/Red/Grn Ind.
(13) F S O A (14) FS SS SOL FOL
(12) (11) (A) (B) (7) (8) (7) (8)
STOP SLOW FS SS SOL FOL 1A 3 6 40 39
(13) (14) (5) (6) (12) (11)(A) (B) (7) (8) (7) (8)
1A 3 6 40
SS A
(14) (13) (1) (2)
SS A 8
(13) (14) (1) (2)
8
(15) (16) (12)SS (11) (A)FS(B)
FAST SS FS 5 7
(21) (22) (12) (11)(A) (B)
5 7
FS R
(25) (26) (14) (13) (17) (18)
FS R 14 9
(13) (14) (17) (18)
9
SS FS
G (27) (28)
(15) (16) (15) (16) (9) (10)
16 13
x=Closed (MC)

1 (2) IFU (1) SS FS G

X1 (X1) (X2) (15) (16) (15) (16) (9) (10)
X2 Fast - Slow- Off - 16 13
GND
Auto-SW

SW (2) IFU (1)

F S O A FS 1 X1 (X1) (X2) X2
(13) (14) SS SOL FOL
(12) (11) (A) (B) (7) (8) (7) (8) GND
1A 3 6 39
40
Fast/Slow/Stop PB
SS
(14) (13)
8 FS SOL FOL
STOP SLOW SS
(13) (14) (5) (6) (12) (11)(A) (B) (7) (8) (7) (8)
SS FS 3 6 40 39
(15) (16) (11) (A) (B) 1A
(12)
5 7
SS
(13) (14)
FS 8
(25) (26) (14) (13)
14 9 FAST SS
(21) (22) FS
(12) (11) (A) (B)
5 7
(27) (28)
FS
(13) (14)
x=Closed(MC)
3
1Polarity sensitive (all options).
T E C H N I C A L A P P L I C AT I O N G U I D E 201

2S2W with MM200

Typical circuit diagrams

202 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

2S-PW size 1-5

Typical circuit diagrams

M2 OL2
(5) (6) (5) (6)
K9 T9

(3) (4) (3) (4)

K8 T8

L1 L2 L3 (1) (2) (1) (2) For 9 Leads - WYE

K7 T7 Connect Term. 4.5.6
STAB MOTOR
together at motor
M1 OL1 (6)
(3) (5) (6) (5) (6) (5) Terminal Box
L3 K3 K6 T3
CB For 9 Leads - Delta
(2) (3)
OR
(4) (3) (4) (3) (4) Connect Term. 4 & 8, 5 & 9,
L2 LSW
K2 K5 T2 6 & 7 together in three
separate pairs at motor
(1) (2)
(1) (1) (2) (1) (2) terminal box
L1 K1 K4 T1
Size 5 CT Operated Overload

61
(2)3FU (1) (3)3FU (4)
60
H1 K1 K2 H2
51
50
M1 7
TR
(13) (14) (A) (B)
4
43 3
2
1A
M2
(67) TR (68) (B)
1
(A)
X2
TC 44
T9
T8
T7
T3
(1)2FU (2) (4)2FU (3)
T2
H1A (H1) (H2) H2A T1
T
(2) IFU (1)
TB
1 X1 (X1) (X2)
X2
Gnd

SW PB

TR OL1 OL2 M2
Off On
(13) (14) (A1) (A2) (7) (8) (7) (8) (21) (22)

JPR 40 38 50 51
3
1A
X-Closed (MC)

M1 R M2
(11) (12) (1) (2) (15) (16)
2 60 61
PB
M2
(11) (12)
7

M2 G
(13) (14) (5) (6)
4
PB
T E C H N I C A L A P P L I C AT I O N G U I D E 203

Wye-Delta open transition

WYE - Delta 2M
(1) (2)
Open Transition
K9 T6
per GEM – 2034E S
Fig. 16 (2) (1)
K10
(3) (4)
K8 T4

(4) (3)

(5) (6)
K7 T5
L1 L2 L3
(6) (5)

STAB 1M MOTOR
(3) (5) 1OL
(6) (5) (6) (5) (6)
L3 K3 K6 T3
CB
(2) (3) (4) (3) (4) (3) (4)
OR
LSW K2 K5
L2 T2

(1) (1) (2) (1) (2) (1) (2)

L1 K1 K4 T1
Size 5CT Operated

(2) 3FU (1) (3) 3FU (4)

H1 K1 K2 H2

CR 1M
(13) (14) (A) (B)
44

TR
(A1) (A2) 61
TDAE 60
(10 sec.) (H-O-A only) 5
TR S
(55) (56) (A) (B) 4
TD 45 3
2M
2
TR S
(67) (68) (11) (12) (A) (B) 1A
TC 46 47 1
X2
(1)2FU (2) (4)2FU (3) TB
(H1) (H2)
H1A H2A T6
(2) IFU (1)
T T5
1 X1 (X1) (X2) T4
X2
T3
Gnd
T2
T1

Start CR 1OL 2OL 1M

(13) Stop (14) (9) (10) (A1) (A2) (7) (8)(7) (8) (13) (14)
1A JPR 2 PB 3 40 39 60 61
PB

1M
(12) (11)

Note: Control circuit options similar to the FVNR size 5

NOTE: Control circuit options similar to the FVNR Size 5

204 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Wye-Delta closed transition

2M
(1) (2)
K11 T6
RC 2S IS
(R1) (R4) (2) (1) (2) (1)
WYE - Delta
K7 K10
Closed Transition
(3) (4)
per GEM – 2034E
K12 T4
Fig. 16
RC
(R2) (R5) (4) (3) (4) (3)
K8
(5) (6)
K13 T5
RC
(R3) (R6) (6) (5) (6) (5)
K9
L1 L2 L3

STAB 1M MOTOR
(3) (5) 1OL
(6) (5) (6) (5) (6)
L3 K3 K6 T3
CB
(2) (3) (4) (3) (4) (3) (4)
OR
LSW K2 K5
L2 T2

(1) (1) (2) (1) (2) (1) (2)

L1 K1 K4 T1
Size 5CT Operated

(2) 3FU (1) (3) 3FU (4)

H1 K1 K2 H2

CR 2S 2M 1S
(13) (14) (13) (14) (11) (12) (A) (B)
41 42 43
1S 1M
(13) (14) (A) (B)

44
TR
(A1) (A2) 61
TDAE 60
1M
(10 sec.) (H-O-A only) 5
1S 2M
(15) (16) (11) (12) (A) (B) 4
45 3
2S
2
2M
(67) TR (68) (15) (16) (A) (B) 1A
TC 46
1
47
X2
(1)2FU (2) (4)2FU (3) TB
(H1) (H2)
H1A H2A T6
(2) IFU (1)
T T5
1 X1 (X1) (X2) T4
X2
T3
Gnd
T2
T1

Start CR 1OL 2OL 1M

(13) Stop (14) (9) (10) (A1) (A2) (7) (8)(7) (8) (13) (14)
PB 1A JPR 2 PB 3 40 39 60 61

1M
(12) (11)

Note: Control circuit options similar to the FVNR size 5

NOTE: Control circuit options similar to the FVNR Size 5

T E C H N I C A L A P P L I C AT I O N G U I D E 205

Distribution transformers

Typical circuit diagrams

Single-Phase Single-Phase
480/120-240V 240/120V

L1 L2 L3 L1 L2 L3

STAB STAB
(5) (6) (5) (6)
L3 L3
CB CB
(3) (3)
OR OR
L2 LSW L2 LSW

(1) (2) T (1) (2) T

L1 (H1) (H2) (H3) (H4) L1 (H1) (H2) (H3) (H4)

(X4) (X3) (X2) (X1) (X4) (X3) (X2) (X1)

GND GND

Three-Phase
480/208-120V
L1 L2 L3

STAB
(5) (6)
L3 K3
CB
(3)
OR (4)
L2 LSW K2
(H
4)
(H

(1) (2) 1) (
)

H
H3

T2
K1
2)
L1
T1
2) (

(H
3)
(H
1)

(H
(H

4)

(H4) (H3) (H2) (H1)

T3

(X T1
3)
(X
1)

1) (X
(X

4)
(X
3)
2)

2)
(X
(X

4)

N
T2
(X

K4 K5
GND

(X4) (X2)
T3
(X3) (X1)

K6
206 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Single-phase panelboard

Typical circuit diagrams

L1
MCC Bus (if power is furnished from bus)
L2

L3

STAB

Feeder & Transformer Unit

CB
480V/120-240V

GND
BUS

Panelboard Unit
CB

(N)
(L1) (L2)

1 2
A A

3 4
A A

5 6
A A

7 8
A A

9 10
A A

11 12
A A
T E C H N I C A L A P P L I C AT I O N G U I D E 207

Three-phase panelboard

Typical circuit diagrams

L1 MCC Bus (if power is furnished from bus)

L2

L3

STAB

Feeder & Transformer Unit

T2
T1

T3
480V/120-240V
T1

T3

N
Gnd Bus
T2

Panelboard Unit

CB

Gnd (if required)

A A

A A
208 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

FVNR with PLC

Typical circuit diagrams

L1 L2 L3

STAB M OL
(3) (5) (6) (5) (6) (5) (6)
L3 K3 K6 T3
CB
(2) (3) (4) (3) (4) (3) (4)
OR
L2 K2 K5 T2
LSW
(1) (1) (2) (1) (2) (1) (2) MOTOR
L1 K1 K4 T1
(1) (3)
2FU
TB
(2) (4) 4
(H1) (H2) 3
2
1FU T 1
(2) (1)
X2
1 X1 (X1) (X2) X2 T3
Gnd T2
T1

M OL
(A) (B) (7) (8)
[ Output ]
3 40

M
(12) (11)
2

[ Input ]

L1 L2 L3
R
(5) (6)
STAB F OL
(3) (5) (6) (5) (6) (5) (6)
L3 K3 (3) (4) K6 T3
CB
(2) (3) (4) (3) (4) (3) (4)
OR
L2 K2 (1) (2) K5 T2
LSW
(1) (1) (2) (1) (2) (1) (2) MOTOR
L1 K1 K4 T1
(1) (3)
2FU TB
9
(2) (4) 8
5
(H1) (H2) 3
1FU T 1
(2) (1) X2
1 X1 (X1) (X2) X2 T3
T2
Gnd T1

¿
R F OL
(12) (11) (A) (B) (7) (8)
[ Output ]
3 6 40

¿
F
(14) (13)
8

[ Input ]
¿ F R
(12) (11) (A) (B)
[ Output ]
5 7

¿
R
(14) (13)
¿ Polarity sensitive. 9

[ Input ]
T E C H N I C A L A P P L I C AT I O N G U I D E 209

RVNR-AT with PLC

Typical circuit diagrams

Starting Autotransformer Autotransformer

1 2 Taps Line Volts
Connection
3 1 50%
Size 4 - Tap 2
2 65%
F
0 3 90%
Size 4
L1 L2 L3 AT
1S
(5) (6)
STAB R FC(FC) (3C) (1C)(9C) 0C OL
(3) (5) (6) (5) (6) (2C) (5) (6)
L3 K3 (3) (4) (4)2S K6 T3
(3) (6)
CB FB(FB) (3B) (1B)(9B) 2S
(2) (3) (4) (3) (4) (2B) 0B (5) (3) (4)
OR (1) 2S
L2 K2 (1) (2) K5 T2
LSW FA (FA) (3A) (1A)(2A) (2)
(1) (1) (2) (1) (2) (2A) 0A (1) (2) MOTOR
L1 K1 K4 T1

3FU 3FU
(2) (1) (3) (4)
H1 K1 K2 H2

TR 1S 2S R
(13) (14) (65) TR (66) (13) (14) (A) (B) (13) (14)
43 TO 44 45 46
Inst.
1S
(A) (B) TB
3
2
1
2S R
(57) TR (58) (13) (14) (A) (B) X2
T3
TC 47 48 T2
T1

(H1) (H2)
1FU
(2) (1) T
1 X1 (X1) (X2) X2
Gnd

TR OL OTT
(A1) (A2) (7) (8) (1) (2)
[ Output ]
3 40 39
TDAE
(10 sec)
1S
(11) (12)
2
R
(11) (12)

[ Input ]
210 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

2S2W with PLC

Typical circuit diagrams

2S2W SOL
SS
Ref GEN 1000A Fig 5 (5) (6) (5) (6)
K9 T3

(3) (4) (3) (4)

K8 T2

L1 L2 L3 (1) (2) (1) (2)

K7 T1
STAB FS MOTOR
(3) (5) (6) (5) (6) (5)FOL(6)
L3 K3 K6 T13
CB
(2) (3) OR (4) (3) (4) (3) (4)
L2 K2 K5 T12
LSW
TB
(1) (1) (2) (1) (2) (1) (2) 9
L1 K1 K4 T11 8
5
2FU 3
1
X2
(H1) (H2)
T13
(2)1FU (1) T T12
X1 (X1) (X2) T11
1 X2
T3
Gnd
T2
T1

¿
FS SS SOL FOL
(11) (12)(A) (B) (7) (8) (7) (8)
[ Output ]
3 6 4Ø 39

¿
SS
(14) (13)
8

[ Input ]
¿
SS FS
(11) (12)(A) (B)
[ Output ]
5 7

¿
FS
(14) (13)
9

[ Input ]
¿
Polarity sensitive.
T E C H N I C A L A P P L I C AT I O N G U I D E 211

ASTAT XT

Typical circuit diagrams

212 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT Bypass

Typical Circuit Diagrams

T E C H N I C A L A P P L I C AT I O N G U I D E 213

ASTAT XT isolation bypass

Typical circuit diagrams

214 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT XT bypass emergency bypass

Typical circuit diagrams

T E C H N I C A L A P P L I C AT I O N G U I D E 215

ASTAT XT isolation bypass emergency bypass

Typical circuit diagrams

216 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

ASTAT BP

Typical circuit diagrams

T E C H N I C A L A P P L I C AT I O N G U I D E 217

ASTAT BP isolation

Typical circuit diagrams

218 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Adjustable speed drives

FC 102 and FC 302 drives

L1 L2 L3

STAB CB
[3]
L3 [5] [6] K3
[2]
L2 [3] [4] K2
[1]
L1 [1] [2] K1

[E104A]

[A1] [B1] [C1]

REA
[A2] [B2] [C3]

R S T
AF6

[91] [92] [93]

[L1] [L2] [L3]
4–20mA
OR RED C1 [54] LFTR
0–10VDC [C1] [C2]
BLK 11 [55]
REMOTE SHLD [98] W T3
GND [53] [B1] [B2]
[97] V T2
[50]
[A1] [A2]
MOTOR
[88] [96] U T1
DC
[89] Bus
[99]

[95] RELAY 2
GND (RUN)
[06]

[05] 4
RUN
[14] [13] [START] [04] 1
CM FWD [18]
[REVERSE]
[18]
[03] 71
[+24V OUT]
[12] [02] 72
[+24V OUT]
[13]
[01] 70

[20]
Analog [39]
[COAST/LOW] Output
[27] 4-20mA [42]

[JOG] SETTINGS
[29] RS-485 [68]
F01 – [2] ANALOG INPUT 54
Interface F02 – [0] LINKED TO HAND/AUTO
[69] E24 RELAY 1 – [9] ALARM
[32] E24 RELAY 2 – [5] RUNNING
[61] E01 – [8] START
E03 – [0] NO OPERATION
[33] Brake
Resistor [82]

[81]

K1 K2
[1] [3]

[2] [4]

H1 H2
[H1] [H2]
1FU T
[2] [1]
1 X1 [X1] [X2] X2
72
GND 71
70
21
RUN 20
[A1] [A2] 18
5
JPR 18 3 JPRX2 3
1
X2
X2
11
5 C1
TB DTB

AF6
[RUN] RUNX
[04] [05] [A1] [A2]
4
FAN2
[1] [2]

DRCNN FAN1 DRCNN

[MLE] [FML] [1] [2] [MLE] [FML]

RUNX
[13] [14]
20

RUNX
[21] [22]
21
T E C H N I C A L A P P L I C AT I O N G U I D E 219

High-resistance ground

Typical circuit diagrams

T1 35
SW1

37 T2 TB1
31 10 L1
F1 TO 240-600V
T3 36 40 11 TB2
F6 L2 SOURCE
30 32 L3
F7 SYMBOL DESCRIPTION
14
TB3
13 13 33 32
AS ARC SUPPRESSOR
F2

TB6

TB7

TB8
AS 15 CPT CONTROL POWER TRANSFORMER
34 11
F4
F(X) LINE FUSE

51

17

18
52

50
G 32

F3 GND GROUND BUS

TB17
12 NGR NEUTRAL GRD RESISTOR
Pulse External Com
Silence
Reset PB1 TEST PUSHBUTTON
System Normal Gnd Fault Alarm Future Relay Horn
External Control PX
TR PX PULSING CONTACTOR
19 SW1 DISCONNECT SWITCH
Neutral Voltage Neutral Current TB14
Ctrl Power TB12 24
Neutral Ground Neutral Ground Line Com
TR TEST RELAY

TB13
TB15

Display Cable
GND T(X) TRANSFORMER
NGR TEST RESISTOR
UVR UNDER VOLTAGE RELAY
13
14 12 GND
OPTIONAL EQUIPMENT
GND
TEST RESISTOR
UVR CONTROL POWER TRANSFORMER
17 G

14

Operator Interface
18 16 TR
UVR
SYSTEM TEST
PB1
UNDER VOLTAGE RELAY NOTES
1. ALL INTERNAL CONTROL WIRING TO BE 600V,
#14 AWG TERMINATED W/PREINSULATED SHANK
RING & COMPRESSION TERMINAL. RESISTOR WIRING
TO BE #8 TEFLON WIRE. EQUIPMENT & DEVICE
GROUND WIRE SHALL BE INDEPENDENTLY
TERMINATED ON THE GROUND BUS.

15 2. DASHED CONNECTIONS TO BE MADE BY CUSTOMER.

L1 L2 L3 T2
T1 T3
(240-600/120V) (240-600/120V) (240-600/120V)
T1 T2
L1 L2

CUSTOMER CONNECTIONS TB L1 L2 L3
TB17 12 PX 24 TB15 31 H1 40 H1 30 H1
16 SW1
18 1 SW1-L1 X1 37 X1 35 X1 36
240-600V(L-L) H2 H2 H2
2 SW1-L2
(50 OR 60 Hz) H3 H3 H3
SYSTEM TEST 3 SW1-L3 G 10 11 32 X2 35 X2 36 X2 37
PB1 4 14 H4 14 H4 14 H4
5 PULSING CONTACTOR DISCONNECT SWITCH
GROUND FAULT NO 6 52
ALARM CONTACTS COM 7 50
17
(SYSTEM NORMAL) NC 8 51 20
10 11 32 32 32 11 19
9 6 5 4 3
10 F1 F6 F7 F2 F3 F4 0
2 4 3 16
11 .8A 3.5A .8A
12 GND 6 8 7 G
1
TO GROUND BUS 31 40 30 33 20 34
13 GND
TR 13 33 7 8 1 2
TO TEST RESISTOR 14 19
TO RESISTOR (PULSE LEVEL) 15 24 FUSES G 34
PX-L1 GND 13
16 CPT 14
UVR
TO RESISTOR(FAULT LEVEL) 17 12 FUSES
PX-T1
TERMINAL
STRIP NGR F1 F6 F7

1-7A 2.5A 2.5A 2.5A

1-10A 3.5A 3.5A 3.5A

Top view
TOP BANK

17 1/2"
RIGHT SIDE VIEW
15 3/4"
LC660 LC660 2"
N1
3"
LC300 LC300
TEST
3"
LC300
GND
(4) 7/8" X
5/8" DIA. SLOTS
BOTTOM BANK
17 1/2" 12"
15 3/4"
2 banks, each 17 1/2
LC440 LC210 2" (1) 10 coils/bank. (1) 5 coils/bank. 2727-5p
N2 N3
Endframes. Turn flanges in. Terminals up.
LC88 LC132 3"
N5 N4 Furnish jumpers.
LC63 LC75
N6 N7 3"
LC75 LC75
(4) 7/8" X
LC75 LC75 5/8" DIA. SLOTS
GND

FRONT VIEW

12"

6"
220 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

MM200

Typical circuit diagrams

T E C H N I C A L A P P L I C AT I O N G U I D E 221

MM300

Typical circuit diagrams

222 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Specifications

Specification for motor control centers Removable bottom channel sills shall be mounted
600 Volts and below front and rear of the vertical sections and shall
extend the width of the lineup. Motor control
1.0 General center vertical sections shall be nominally 90-
This specification covers low voltage motor inch high and 20-inch deep. Alternate section
control centers with combination starter units. heights shall be 78" or 66". Alternate section
widths shall be 24-inches or 30-inches wide when
1.1 Standards required.
The motor control centers shall be manufactured
and tested in accordance with NEMA ICS 2-3 and 2.1 Horizontal wireway
UL Standard 845. Vertical sections and individual Each vertical section shall contain a minimum 12-
units shall be UL Labeled where possible. inch high top horizontal wireway and a 6” bottom
wireway. When loads exit the bottom a 12”
1.2 Service bottom wireway shall be provided. The
Each motor control center shall be suitable for horizontal wireway shall be covered by a
use on a _______ volt, three phase, _____ wire, removable hinged door.
______ Hertz power system having a short circuit
availability of _____________ amperes 2.2 vertical wiring trough
RMS symmetrical. A separate vertical wiring trough shall be
furnished in each vertical section adjacent to
1.3 Wiring plug-in unit. The wire trough shall permit the
Wiring shall be NEMA Class [ I ] [ II ], Type [ A ] [ BD installation of field wiring and shall isolate this
] [ BT ] [ C ]. Where Type C wiring is required, the wiring from the adjacent unit. No terminal blocks
master terminal blocks shall be located at the shall be located in the vertical wireway. Cable tie
[top] [bottom] of the vertical section. supports shall be furnished in the vertical
Combination starter units shall be wired out to wireway to hold cable and wiring in place. The
split type terminal blocks for easy removal of the vertical wiring trough shall be covered by a
starter unit without disturbing either factory or removable hinged door. [A low-level signal
field installed wiring. All control terminal boards raceway shall be provided.]
shall be accessible from the front.
3.0 Incoming power/Main protective device
2.0 Construction Incoming power to the motor control center shall
Indoor enclosures shall be NEMA Type [1- be [cable] [bus duct]. [Incoming power cables
Gasketed] [2] [12 ]. Indoor enclosures shall be shall enter the [top] [bottom] of the motor control
suitable for front mounting. Outdoor enclosures center.] [Incoming cables shall be of the size and
when specified, shall be NEMA [3R Non-Walk-In] number shown on the plans.] [Incoming bus duct
or [3R Walk-in]. The motor control center shall be shall enter the top of the motor control center
seismic rated for UBC/CBC Zone 4. and shall have a current rating as shown on the
plans.] The motor control center main protective
Each motor control center shall consist of the device shall be a [molded case circuit breaker]
required number of vertical sections of heavy [insulated case circuit breaker] [fused switch].
gauge sheet steel bolted together to form a rigid The main device shall be of the ampere rating
self-supporting assembly.A removable lifting shown on the plans and shall have an interrupting
angle shall be mounted to the motor control rating equal to or greater than the available short
center at the top. circuit current.
T E C H N I C A L A P P L I C AT I O N G U I D E 223

4.0 Bus System The ground bus shall be drilled and lugs furnished
as specified. [There shall be a vertical copper
4.1 Main horizontal bus ground bus in each section. This ground bus shall
Power shall be distributed by means of a be accessible to a bus stab mounted in the unit
continuous horizontal bus with a current rating of compartment area and arranged so that the unit
[600] [800] [1200] [1600] [2000] [2500] amperes. ground stab engages before the power stabs
The main bus shall be [tin-plated .0003 inch thick] engage the vertical bus]. [A motor load ground lug
[standard silver-plated .0002 inch thick] [heavy shall be mounted in the unit and used for
silverplated .0005 inch thick] copper. The main bus terminating the ground of multi-conductor cables.]
shall be braced for [65,000][100,000] amperes RMS
symmetrical. The main bus shall be isolated by 4.4 Neutral bus
barriers from wire troughs, starters, and other A neutral bus shall be furnished when shown on the
areas. There shall be double bolt connections on plans. The neutral bus shall be [300] [600] [800]
main bus joints and splice connections. Main bus [1000] [1200] [1250]. The neutral bus shall [be in the
splicing between shipping splits shall be incoming section only] [extend the full-width] of
accomplished from the front with no structural the motor control center. When a neutral bus is
disassembly. The main bus shall be fully rated and specified, bottom plates shall be furnished. Lugs of
arranged for future extension. the proper ampacity shall be furnished.

4.2 Vertical bus 5.0 Units

The vertical bus in each section shall be rated [300] Combination motor controller and feeder units
[600] [850]*amperes and shall be [tin-plated] shall employ [molded case circuit breakers] [fusible
[silver-plated]. *(1200A Main bus or greater) switches with clips for J or R type fuses] for branch
circuit protection. Circuit breaker disconnects for
The vertical bus shall be braced for [65KAIC] combination motor starters shall be
[100KAIC]. The vertical bus shall have a flame- [thermalmagnetic] [magnetic only].
retardant polyester-glass insulation / isolation
system. This system shall insulate the vertical bus All combination starter and feeder units of plug-in
front and rear. In addition, the barrier shall isolate construction shall utilize a positive guidance
each phase bus. Openings in the vertical bus system to insure positive connection of the unit
insulation/isolation system shall permit the entry stabs to the section vertical bus. Insertion and
of unit stabs. Unused openings shall have plugs or removal of each unit shall not require the use of
covers to prevent the entry of foreign objects. special tools. Unit shelves shall be of a lift out
[The openings in the vertical bus used for starter design. Connection from the power stabs to the
connections shall be covered by an automatic unit disconnect shall be a direct connection. Each
shutter mechanism. The shutters shall circuit breaker starter unit size 1 through size 5
automatically cover the openings when the shall be of plug-in construction. Each circuit
starter is removed].The vertical bus bracing AIC breaker feeder 600A or less shall be plug-in.
rating shall be the same as the main horizontal bus.
Each unit compartment shall be equipped with a
4.3 Ground Bus flange-formed pan type door. The door shall be
A copper ground bus shall extend the full width of mounted on the vertical section with
the motor control center. The ground bus shall be removable hinges.
rated [300] [600] amperes.
224 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R

Each unit shall be equipped with an operating Overload relays shall be:
handle. The handle shall be connected to the • {select one}
disconnect operator using a direct drive and • [Bimetallic, ambient compensated]
requiring no adjustment of linkage. The handle • [Bimetallic, non-ambient compensated]
shall be mechanically interlocked with the door, • [Solid-state, ambient insensitive, self powered,
preventing door opening with disconnect closed. adjustable FLA, adjustable phase unbalance,
The interlock shall also prevent disconnect being phase loss protection, and selectable overload
closed with the door open and prevent the unit class (10, 20, 30) with 2% accuracy and
from being removed or installed with disconnect repeatability, built-in thermal memory to prevent
ON. The interlock shall be capable of being hot motor starts, isolated 1NO and 1 NC auxiliary
defeated, allowing the door to be opened with contacts]
disconnect closed or disconnect closed with the • [Advanced microprocessor based motor
door open. The unit handle shall have provision for protection, Dip switch selectable Phase loss
padlocking in the off position. On circuit breaker protection/Phase Unbalance, adjustable FLA,
units the handle shall have a “tripped” position in Selectable overload class (10, 20, 30)]
addition to OFF/ON. • [Ground fault protection]

Each unit shall be capable of being padlocked in a Provisions to Communicate over the following
partially withdrawn position. In this position, the Protocol:
unit power stabs are disengaged from the vertical [DeviceNet] [Modbus RTU]
bus and no power can enter the unit.
The following minimum information shall be
Combination starter units specified with Type B or available over the Network.
C wiring shall be supplied with split-type terminal • Metering (Average Phase Current in Amps,
blocks. These terminal blocks shall be mounted in Control Voltage, Motor Run Time)
front of the unit and shall allow the removal of the • Starter Status and Configuration Notification
unit without disconnecting any of the control (Run, Overload, Ground Fault, Phase Unbalance,
wiring. Combination starter units up to size 5 shall Commanded Trip, Class setting)
be plug-in construction and shall be capable of • Information (Voltage, Internal failure, 100% Motor
being removed without disconnecting any control Load Warning)
leads from their terminal blocks. • Remote Control (On, Off, Trip, Reset)

[Provide a Display Module for accessing at the unit

all Network data] [Door mounted] [Hand held using
phone jack on the door].
T E C H N I C A L A P P L I C AT I O N G U I D E 225

Control power for starter units shall be from:

{select one}
[Individual control power transformers furnished in
each starter unit. One secondary lead shall be
furnished with a fuse and the other lead shall be
grounded. Control power primary fuses
are required].
[Line voltage. Control circuits on all starter units
with line voltage control power shall be provided
with current limiting fuses mounted in both legs of
the control circuit].
[Separate source (common control)] Two wired
terminal points shall be provided. One leg shall be
wired through a normally open auxiliary contact in
each disconnect and a control power fuse rated 1
amp shall be provided.]

Starter units shall be provided with the following

auxiliary devices:
• [auxiliary starter interlocks,
______ N/O, ______N/C].
• [control / timing relays (as shown on
the drawings)]
• [door mounted pilot devices: Start-stop
pushbutton, H-O-A selector switch, Indicating
lights (quantity and color)].

Miscellaneous units
The following units shall be included in the motor
control center(s) as indicated on the drawings:
• [Lighting and Power transformers]
• [Lighting panelboards]
• [Power metering and associated instrument
transformers, where required]
• [Power factor correction capacitors]
• [Reduced Voltage Solid State]
• [Variable Frequency Drives]
• [PLC’s]
226 E VO L U T I O N S E R I E S E 9 0 0 0 M OTO R C O N T R O L C E N T E R
T E C H N I C A L A P P L I C AT I O N G U I D E 227
—
ABB Inc.
305 Gregson Drive
Cary, NC 27511 USA

abb.com/contacts

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Manufactured by ABB Inc. under license
from General Electric Company.

The information contained in this document is for

general information purposes only. While ABB strives to
keep the information up to date and correct, it makes no
representations or warranties of any kind, express or
DET-291 Rev I August 2020

implied, about the completeness, accuracy, reliability,

suitability or availability with respect to the information,
products, services, or related graphics contained in the
document for any purpose. Any reliance placed on such
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at any time.

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