Instruction Booklet MN043001EN Effective November 2012

XT and XT FlashGard
motor control center installation
and maintenance manual
Contents
Part Description Page
1 General information. . . . . . . . . . . . . . . . . . 2
2 Receiving, handling, and storage . . . . . . . 5
3 Installing control center sections . . . . . . . 6
4 Installing conduit and wiring. . . . . . . . . . 10
5 Incoming line connections . . . . . . . . . . . 12
6 Inspection prior to energizing. . . . . . . . . 16
7 XT MCC unit installation
and adjustment. . . . . . . . . . . . . . . . . . . . 17
8 XT FlashGard® MCC unit installation
and adjustment. . . . . . . . . . . . . . . . . . . . 19
9 Maintenance. . . . . . . . . . . . . . . . . . . . . . 23
10 Plan views. . . . . . . . . . . . . . . . . . . . . . . . 29
11 Related instruction leaflets. . . . . . . . . . . 31

This electrical control equipment is designed

to be installed, operated, and maintained by
adequately trained workmen. These instructions
do not cover all details, variations, or combinations
of the equipment, its storage, delivery, installation,
check-out, safe operation, or maintenance. Care
must be exercised to comply with local, state, and
national regulations, as well as safety practices, for
this class of equipment. The maximum short-circuit
capability of the equipment should not be exceeded
by connection to a source with higher capacity.
If maintenance or troubleshooting assistance is
required, contact your nearest Eaton sales office.
Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual
Part 1. General information The operating handle on the controller unit (3) moves vertically. In the
ON or TRIPPED positions, the handle interlocks with the unit door to
The motor control center prevent its opening. In this position, authorized personnel can open
The Eaton XT and XT FlashGard motor control center may be the door by turning the defeater mechanism screw. (21) With the
joined to existing Freedom, Five Star, Series 2100, and Advantage unit door open and the operating handle in the ON position, another
installations using the splice bar kits common to both. Units interlock to the divider pan prevents removal of the unit. This same
designed for the XT and XT FlashGard can be mounted in Five interlock prevents insertion of the unit unless the handle mechanism
Star Series and Series 2100 sections, but the opposite is not is in the OFF position. To ensure that units are not energized
recommended, because Five Star and Series 2100 units may lack accidentally or by unauthorized personnel, the handle mechanism
terminal blocks and sufficient interrupting capacity. The XT and XT can be padlocked in the OFF position. Space for a minimum of three
FlashGard MCC may be joined to existing Eaton Freedom Unitrol padlocks is provided on each handle. The device panel (5) is mounted
and F10 Unitrol MCCs with a special splice bar kit, but units are not on the drawout unit. The XT pilot device panel will accommodate up
interchangeable. to four devices, and XT FlashGard panels up to six devices.

Control center nomenclature

The numbers shown in parentheses in the following text refer to the
balloon legends in Figure 4.
The Eaton XT and XT FlashGard motor control center consists of
one or more totally enclosed, dead front, freestanding structural
assemblies 90 inches high, which are compartmentalized to house
individual control units. (2) With control units mounted in the front
side only, the structure may be 16 or 21 inches deep. For mounting
units back-to-back, the structure is 21 inches deep. Steel covers
(7) enclose the structure at the top, sides, and at the rear of front-
mounted-only structures.
A vertical bus system installed in each vertical section is connected
to the horizontal bus to feed the individual control units. The vertical
bus is isolated by a full height barrier. (6) An optional labyrinth barrier
provides both isolation and insulation. An automatic shutter is included
with the labyrinth barrier system to cover the stab openings for each
control unit. Figure 1. Nameplate
At the top of each section, a door provides ready access to the
top horizontal wireway (11) and ground bus. The horizontal wireway Ratings
is isolated from the bus systems by steel barriers, which can be
Each XT and XT FlashGard motor control center has a rating
removed for installation and maintenance operations. Adequate
nameplate attached to the door of the top horizontal wireway of the
space is provided for control wiring and top cable entry.
primary section. See Figure 1. This nameplate shows the general
At the bottom of each section, a door (18) provides ready access order number under which the motor control center was built and
to the bottom horizontal wireway, and neutral bus (if provided). The its continuous electrical ratings, in terms of incoming line voltage,
bottom of each section is completely open to provide unrestricted phases, and frequency, and ampere ratings of the horizontal bus
bottom entry of cable and conduit. Channel sills may be installed and the vertical bus for each section. In addition, this nameplate
across the bottom of the control center if specified, and an optional shows the passive short-circuit (withstand) rating of the horizontal
bottom plate may also be specified. and vertical bus system. The active short-circuit (interrupting) ratings
A vertical wireway 8 inches deep, extending the full 90-inch height of of the main and unit short-circuit protective devices are shown on
the control center, is located to the right of each unit compartment. labels attached to the inside of each unit. Before installing a motor
This wireway is covered by two hinged doors (15) and contains cable control center, calculate and record the fault current available at the
supports to secure wire bundle sand cables. The vertical wireway incoming line terminals. Verify that the short-circuit with standard
joins the horizontal wireway at the top and bottom to provide short-circuit interrupting ratings of the units in the motor control
unobstructed space for interwiring. center are appropriate for the fault current available.

Each vertical section provides space to mount up to 12 controller Qualified personnel

units (2) with a minimum height of six inches, in increments of
six inches, for a total of 72 inches of usable space. Controllers Individuals who install, operate, or maintain MCCs must be trained
through NEMA® Size 5 are drawout type (except reduced-voltage and authorized to operate the equipment associated with the
starters). These drawout unit assemblies are a completely self- installation and maintenance of an MCC, as well as the operation
contained package consisting of a steel enclosure, operating handle of the equipment that receives its power from controller units in
and electrical components. The drawout assembly slides into this the MCC. Such individuals must be trained in the proper procedures
compartment on guide rails (11) to provide easy withdrawal and with respect to disconnecting and locking OFF power to the MCC
reinsertion and to ensure precise alignment of the unit stabs with and wearing personal protective equipment, which includes arc
the vertical bus. Each drawout unit is held in place by a single flash, insulating, and shielding materials, and also use insulated
1/4-turn latch (4), which can only be engaged when the unit tools and test equipment, following established safety procedures
stabs are fully mated with the vertical bus. Each unit has a separate as outlined in the National Electrical Safety Code® (ANSI C2) and
door, (1) held closed by a minimum of two 1/4-turn fasteners. Electrical Equipment Maintenance (NFPA® 70E).

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
control center installation and  Effective November 2012
maintenance manual

(11) Top
Wireway Door

24 Vdc Power
Supply Unit

Vertical
Wireway Door

(5) Device Panel

Figure 2. XT FlashGard Motor Control Center

Figure 3. XT Motor Control Center—Typical MCC Unit

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual

(9) (10)
Top Horizontal Horizontal Bus (11)
Wireway Barriers Top Wireway
(7) Door
Top and Side Cover

(3)
Large Operating
Handle
(6)
Vertical Bus Barrier—Labyrinth

(20)
Ground Bus

(4)
1/4 Turn Latch

(2)
Drawout Unit

(1)
Unit Door

(5)
(3) Device Panel
Small Operating Handle

(21)
Defeater Mechanism Screw
(16)
Vertical Wireway
(15)
Door
Vertical Wireway

(17)
Structural Members

(8) (19) (18)

Horizontal Bottom Horizontal Bottom Horizontal
Ground Bus Wireway Wireway Door

Figure 4. XT FlashGard Motor Control Center

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
control center installation and  Effective November 2012
maintenance manual
Part 2. Receiving, handling, and storage Overhead crane

1. See Figure 5 for recommended lifting configuration.

m warning 2. Select or adjust the rigging lengths to compensate for any
MCC—Heavy Equipment Statement unequal weight distribution, and to maintain the motor control
This MCC can weigh in excess of 2000 pounds. Refer to shipping center in an upright position.
manifests for exact weight of equipment. To prevent serious 3. To reduce tension on the rigging and the compressive load
injury or death, or equipment damage, from unintended on the lifting angles, do not allow the angle between the lifting
movement of equipment during transport, installation, or cables and vertical to exceed 45 degrees. Use slings with safety
any other operations, ensure that (1) only material handling hooks or shackles. Do not pass ropes or cables through lifting
equipment of adequate capacity and rating for the load angle holes.
involved is used; (2) only qualified personnel are involved;
and (3) all lifting/bracing shipping labels and markings
instructions shipped with the MCC must be followed.

Receiving Lift Point

Before and after unloading the motor control center, inspect each The height of the lift Don’t pass ropes
Max.
section and unit exterior for evidence of damage that may have been point above the
45º
or cables
spreader should be through lift holes.
incurred during shipment. If there is any indication that the control at least 1/2 of “A” Use slings with
center has been mishandled or shipped on its back or side, remove (the distance between
eye bolts). This
safety hooks
or shackles.
the drawout units and make a complete inspection of the internal ensures a maximum A
structure, busbars, insulators, and unit components for possible angle of 45º as shown.
hidden damage. Report any damage found to the carrier at once. Lift Hole
MOTOR CONTROL CENTER Lift Angle
Handling
The following guidelines are provided to help avoid personal injury
Figure 5. Correct Use of Lifting Angle
and equipment damage during handling, and to facilitate moving
the motor control center at the job site.
4. After removing the lifting angles, replace the mounting hardware
General hints to prevent the entrance of dirt, etc.
1. Handle the motor control center with care to avoid damage to Forklift truck
components and to the enclosure or its paint finish.
Motor control centers are normally top and front heavy. Balance the
2. Keep the motor control center in an upright position. load carefully, and steady, as necessary, while moving. Always use
3. Ensure that the moving means has the capacity to handle the a safety strap when handling with a forklift.
weight of the motor control center.
Rollers
4. The control center should remain secured to the shipping skid
until the motor control center is in its final location. Rod or pipe rollers, with the aid of pinch bars, provide a simple
method of moving the motor control center on one floor level, if
5. Exercise care during any movement and placement operations
there is no significant incline. Roll the motor control center slowly,
to prevent falling or unintentional rolling or tipping.
and steady the load to prevent tipping.
6. Lifting angles for handling by overhead crane are bolted to the
top of each shipping section. Handling by overhead crane is Storage
preferable, but when crane facilities are not available, the motor
When a motor control center cannot be installed and placed into
control center can be positioned with a forklift truck or by using
operation immediately upon receipt, take steps to prevent damage
rollers under the shipping skid.
by condensation or harsh environmental conditions. If the motor
control center cannot be installed in its final location, store it in a
clean, dry, ventilated building, heated to prevent condensation, and
protected from dirt, dust, water, and mechanical damage. When
storage conditions are less than ideal, install temporary electrical
heating, typically in the form of light bulbs, totaling 150 watts per
section, hung in the vertical wireway, or by applying power to self-
contained space heaters that the motor control center may be
equipped with. Remove all loose packing and flammable materials
before energizing any of the heating elements.

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Part 3. Installing control center sections 4. For bottom entry, position the MCC so that the conduit stubs
or floor openings are located in the shaded areas shown on
General the MCC floor plan drawings (refer to page 29 and page 30
XT and XT FlashGard motor control centers (MCCs) are designed for floor plan dimensions). The shaded areas represent the open
for installation in accordance with both the National Electrical Code® space available for conduit entry through the bottom of each
(NEC®), NFPA 70, and the National Electrical Safety Code (NESC®), section. A shaded area may be restricted if large controllers or
ANSI C2. auto-transformers are mounted in the bottom of the sections. If
optional bottom plates are supplied, the plates may be removed
and drilled for conduit entry.
m Caution 5. Install the MCC in its final position, progressively leveling each
If work is involved in connecting the control center section and bolting the frames together if they are separated.
with existing equipment, ensure that incoming power is If necessary, secure the MCC to walls or other supporting
disconnected before work begins. Disconnecting means surfaces. Do not depend on wooden plugs driven into holes in
should be locked out and/or tagged out of service. Where masonry, concrete, plaster, or similar materials. See NEC 110.13.
it is not feasible to de-energize the system, the following 6. If two or more shipping sections are to be joined into an integral
precautions should be taken: assembly or a shipping section is to be joined to an existing
section, refer to paragraphs below before proceeding with
A. Persons working near exposed parts that are or may be the installation.
energized should be instructed and should use practices 7. Ground and bond the MCC as follows:
(including appropriate personal protective equipment, which
includes arc flash, insulating, and shielding materials, and a. MCCs used as service equipment for a grounded system
insulated tools and test equipment in accordance with the or as an incoming line section for a separately derived,
NFPA 70E). previously grounded system:

B. Persons working on exposed parts that are or may be energized 1. Run a grounding electrode conductor (ground wire)
should, in addition, be qualified persons who have been trained having a size in accordance with NEC 250.94 from the
to work on energized circuits. grounding electrode to the MCC ground bus or ground
terminal provided. See also NEC 250.92(A) and 92(B).
Installation 2. If the system is grounded at any point ahead of the
MCC, the grounded conductor must be run to the MCC
1. Before any installation work begins, consult all drawings in accordance with NEC 250, and connected to the
furnished by Eaton, as well as all applicable contract drawings ground bus terminal.
for the installation. Give particular attention to the physical
location of units in the control center and their relation to existing 3. Do not make any connections to ground on the load side
or planned conduit, busways, etc. Provide for future conduit of any neutral disconnecting line or any sensor used
entrance prior to control center installation. for ground-fault protection. Do not connect outgoing
grounding conductors to the neutral.
2. Locate the control center in the area shown on the building floor
plans. If in a wet location or outside of the building, protect the b. MCCs used as service equipment for an ungrounded
control center from water entering or accumulation within the system or as an incoming line section for a separately
enclosure. Recommended clearances or working spaces are derived, previously ungrounded system:
as follows: 1. Run a grounding electrode conductor (ground wire)
a. Clearance from walls (where not rear accessible)— having a size in accordance with NEC 250.94 from the
a minimum of 1/2-inch for indoor and 6 inches for outdoor grounding electrode to the MCC ground bus terminal.
or wet locations. See NEC 250.92(A) and 92(B).

b. Clearance from front of MCC (working space)—minimum c. MCCs not used as service equipment nor as an incoming line
of 3 feet for control centers without exposed live parts. section for a separately derived system, and used on either a
See NEC 110.13. grounded or ungrounded system:
NNote: This working space should not be used for storage and should 1. Ground the MCC ground bus by means of equipment
have adequate lighting. grounding conductors having a size in accordance with
NEC 250.95 or by bonding to the raceway enclosing
3. Since MCCs are assembled at the factory on smooth and level the main supply conductors in accordance with
surfaces to ensure correct alignment of all parts, MCCs should NEC 250.92(B).
be securely mounted on a level surface. The foundation furnished
8. When all wiring and adjustments are complete, close all unit and
by the purchaser must be true and level, or the bottom frames
wireway doors.
must be shimmed to support the entire base in a true plane. It is
recommended that leveled channel sills under both the front and 9. In damp indoor locations, shield the MCC to prevent moisture
rear of the control center be used to provide this level base. Drill and water from entering and accumulating.
and tap the channel sills for mounting bolts in accordance with 10. Unless the MCC has been designed for unusual service
the applicable floor plan drawing and then either install the MCC conditions, it should not be located where it will be exposed
level with, or on top of, the finished floor. If sills are grouted in to ambient temperatures above 40°C (104°F), corrosive or
concrete, the mounting bolts should be screwed in place and explosive fumes, dust, vapors, dripping or standing water,
remain until the concrete has hardened. abnormal vibration, shock, or tilting.

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
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maintenance manual
Joining compatible sections
If two more shipping sections are to be joined into an integral
assembly, or a section added to an existing installation, splicing of
horizontal bus, ground bus, neutral bus, and joining of the adjacent
vertical sections must be planned with the installation.

1. Remove the side sheets from adjacent vertical sections to be

joined. (These sheets will have been removed from factory-
assembled sections.)
2. The horizontal bus splice plates and connection hardware will be
shipped with the MCC attached to one end of shipping section.
Refer to Figure 6.
3. This method provides the most convenient access to the bolts,
and eliminates the need to remove the horizontal bus barriers in
that structure. Should the existing bus be oxidized, sand lightly
with a fine aluminum oxide paper.

m Caution
Do not use emery cloth or any abrasive containing metal.

4. Remove the upper horizontal wireway door from the structure

Figure 6. Splice Plates Attached to Right-Hand Section
on the right side of the left-hand (LH) section, and remove the
two-piece wireway barrier to provide access to the ends of the
bus in that section.
5. Move the section into place, aligning the upright structural
channels and bottom channels. Alignment of the section
with floor sills and foundation provisions will be facilitated
by removing the bottom horizontal wireway doors. Using the
“U” type frame clamps provided, clamp adjacent front upright
channels together at the top, bottom, and approximate center
of the vertical structure. “U” clamp placements must be placed
4 inches (101.6 mm) above or below the drawout unit—1/4-turn
latch and unit interlock feature on the cover control module; see
details on page 30 bottom left-hand corner. This operation
will be facilitated by removing the vertical wireway doors from
the left-hand structure and one or more drawout units from the
right-hand structure. See Part 7, page 17.
6. If rear access is available, “U” clamps should also be used to
clamp the rear upright channels together. In front-mounted-only
structures, this will require removal of the adjacent back sheets.
In a back-to-back-mounted structure, remove the vertical wireway
doors and one or more drawout units as above.
7. Secure the sections to the floor sills or mounting bolts as
provided for the installation. Figure 7. Access to Left-Hand Splice Plate Connections
8. Bolt the horizontal bus splice plates to the bus in the left-hand
structure, torquing all bus splice bolts to 360 pound-inches Splice plates
(30 pound-feet). See Figure 7. Each splice plate kit consists of short pieces of busbar the same
9. Replace all units, bus barriers, and doors. width as the main horizontal bus of the MCC the kit is shipped with,
four bolts per phase, and appropriate quantities of related hardware.
Joining incompatible sections For a single busbar per phase, the hardware is used as shown in
Joining an XT and XT FlashGard MCC to other equipment, such as Figure 8 for either 16- or 21-inch deep enclosures. Each splice plate
Type W and 11-300 control centers, will usually involve a transition is punched with rectangular holes to accept a square shank carriage
section installed between the two varieties of equipment. This bolt that will not rotate as the nut is tightened.
transition section will be detailed on drawings provided by Eaton and Where the MCC is built with two horizontal busbars per phase,
the applicable contract drawings. If provided separately, it should the splice plates are installed as shown in Figure 9. The top edge
be installed first. Review the overall installation task to determine of Figure 9 through Figure 12 represents the back side of the
whether the transition section should be attached to the existing MCC. The top portion of each of these figures applies to 21-inch
equipment or to the XT and XT FlashGard section, before it is deep enclosures and the lower portion to 16-inch deep enclosures.
moved into place, and select the sequence that will provide best Note that for all but the single-bar per phase (Figure 8) installation,
access to bus splicing and joining of the structures. the 16-inch deep enclosures require the use of a nut plate that is
mounted with the same carriage bolt used to attach the horizontal
busbars to the channel-shaped insulators. Install these nut plates
before mounting the splice plates. Tighten the splice plate bolts
with a driving torque of 360 pound-inches (30 pound-feet).

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual
Type 3R enclosures
Where the MCC is supplied in a Type 3R enclosure for an outdoor
application, apply roof splice caps at each shipping block junction to
maintain the enclosure integrity.

Carriage Splice
Bolt Plate

21" Deep

3/8" -16 Flat Lock Front

Nut Washer Washer Face

Figure 8. Single-Bar Splice Kit

21" Deep 21" Deep

Nut
Plate
16" Deep

16" Deep

Flat Lock
Hex–Head Bolt Washer Washer Figure 11. Quadruple-Bar Splice Kits

Figure 9. Double-Bar Splice Kit

21" Deep

Six Bars per Phase—21" Deep

16" Deep

Figure 10. Triple-Bar Splice Kit

Front Face
Eight Bars per Phase—21" Deep

Figure 12. Six- and Eight-Bar Splice Kits

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
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maintenance manual
Joining to an XT and XT FlashGard, Freedom Unitrol,
or F10 Unitrol
Consult the assembly instruction supplied with every XT and
XT FlashGard MCC set up for splice to XT and XT FlashGard,
Freedom Unitrol, or F10 Unitrol.

m WARNING
Specific safety note for installing and removing MCC units—
recommend the use of new accessory.

Figure 15. Splice Plate Attached to XT and XT FlashGard

Ground Bus at Bottom

Figure 13. Splice Plates Attached to XT and XT FlashGard

Horizontal Bus and Ground Bus at Top

Figure 16. Splice Plate Attached to XT and XT FlashGard

Neutral Bus

Figure 14. Horizontal Bus Splice Freedom Unitrol on Left,

XT and XT FlashGard on Right

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
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maintenance manual
Part 4. Installing conduit and wiring NEMA Type B wiring
Conduit Each control unit is factory assembled with devices inter-wired
within the unit. In addition, all control wiring is carried to unit
Install conduit in such a manner as to prevent water from entering terminal blocks mounted on the right-hand side of the unit.
and accumulating in the conduit or the enclosure. Eliminate sags See Figure 17 and Figure 27. Bring the field wiring of control
in conduit. Have the conduit enter the motor control center (MCC) wires from a horizontal wireway into the vertical wireway on the
in the areas designated for conduit entry on the plan views. right-hand side of the applicable control unit and terminate them
See page 29 and page 30 of this booklet and outline drawings at the unit terminal blocks.
shipped with the MCC. Keeping conduit within the shaded areas
shown in the plan views will avoid cable interference with structural Bring load wire from the vertical wireway and terminate at the
members and live bus. See Part 10. motor load terminal block, shown in Figure 17a.

Wiring
Install the line and load conductors sized in accordance with the NEC.
Use copper wire only for control terminations. Use copper wire
only for power terminations unless they are marked “CU/AL.”
Use conductors with a temperature rating of 167ºF (75ºC) or higher,
but regardless of the insulation temperature rating, select the wire
size on the basis of 167ºF (75ºC) wire ampacity. Using a higher
temperature wire ampacity table often results in a smaller cross-
section of copper available for carrying heat away from terminals.
Install insulated wire and cable at a temperature sufficiently warm to
prevent the insulation from cracking or splitting.
When more than one conduit is run from a common source or to a
common load, be sure to have each conduit carry conductors from
each phase and the same number of conductors per phase. If the
phase conductors are not distributed uniformly, eddy currents will
be generated in the steel between the conduits.
Locate conductors within the MCC to avoid physical damage and
to avoid overheating. Secure incoming power lines in a manner
adequate to withstand the forces that will act to separate the
conductors under short-circuit conditions. Use the cable ties
furnished in both horizontal and vertical wireways to support the
load and interconnection wire. Use a shielded communications cable Figure 17. Unit Terminal Blocks
inside of flexible metal conduit to protect very low voltage signals
transmitted to or from a computer or programmable controller.
Lugs furnished with the MCC and its components are for Class B
and Class C stranding. Verify the compatibility of wire size, type, and
stranding with the lugs furnished. Where they are not compatible,
change the wire or lugs accordingly. If crimp lugs are used, crimp
with the tools recommended by the manufacturer.
Use care in stripping insulation to avoid nicking or ringing the metal.
All field wiring to control units should be made in accordance with
the wiring drawings that are furnished with the control center. Load
and control wiring can be brought in through the upper and/or lower
horizontal wireways. Determine the type of wiring installed in the
control center (NEMA Type B or C) and proceed per the following
appropriate paragraph.
The phase sequence of the power circuit load terminals (top-to-
bottom: T1, T2, T3) in units mounted on the rear side of the MCC is
opposite to that of the load terminals in units mounted on the front
side of a back-to-back MCC. To obtain the same direction of rotation
for a motor connected to a rear-mounted unit as for one connected
to a front-mounted unit, re-label the terminals in the rear-mounted
unit: T3, T2, T1, and wire accordingly. Refer to the warning sticker
supplied with rear-side units. When making power connections
to the starter terminals, be sure to leave sufficient slack in the
wires so that the unit can be withdrawn to the detent position Figure 17a. Pull-Apart Terminal Blocks
for maintenance. See Table 2 on page 16.

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
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maintenance manual
Engaging pull-apart terminal blocks
The male portion of the pull-apart white terminal blocks used
on XT units are located in plastic bags attached to each unit. This
terminal block can be accessed in the vertical wireway adjacent to
unit. Align the terminal block with connector mounted on unit side
and plug together as shown in Figure 17. These are used in XT
FlashGard units. The XT units use the black compact terminal
blocks, shown in Figure 17a and Figure 27, which come installed on
the unit outside in the vertical wireway.

NEMA Type C wiring

Each control unit is factory assembled with devices inter-wired
within the unit. In addition, all control wiring is carried to unit
terminal blocks on the side of the unit and from these unit blocks,
along with load wiring through Size 3, to master terminal blocks
located at the top or bottom of the structure. See Figure 18.
Master terminal blocks can be either fixed or drawout mounted.
In the drawout design, the terminal blocks are rack-mounted to
permit withdrawal of the entire assembly for ease of wiring during Figure 18. Master Terminal Block
installation and maintenance. Bring field wiring from the horizontal
wireway to the master terminal blocks except for load wiring
larger than Size 3. These latter load wires should be carried into
the vertical wireway and under the bottom right-hand side of the
unit to terminations within the unit.

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Effective November 2012 control center installation and 
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Part 5. Incoming line connections
Overcurrent protection
All ungrounded conductors in a motor control center (MCC)
installation require some form of overcurrent protection in order to
comply with Section 240.20 of the NEC. Such overcurrent protection
for the incoming lines to the MCC is in the form of fuses or a circuit
breaker located at the transformer secondary that supplies the MCC. Note that
with reverse
The conductors from the transformer secondary constitute the feed, the
feeder to the MCC, and the “10-foot rule” and the “25-foot rule” bottom
of NEC 240.21 apply. These latter exceptions to the general rule terminals of
allow the disconnect means and overcurrent protection to be the circuit
located in the MCC, provided the feeder taps from the transformer breaker are
still energized
are sufficiently short and other requirements are met. when the
A circuit breaker or a circuit interrupter combined with fuses circuit breaker
controlling the power to the entire MCC may provide the is turned off!
overcurrent protection required as described above or may
be a supplementary disconnect (isolation) means. See Figure 19,
Figure 20, and Figure 21.
When the MCC has a main disconnect, bring the incoming lines
(the feeders) to the line terminals of the circuit breaker or circuit
interrupter. The load side of the circuit breaker or the load side of
the fuses associated with the circuit interrupter has already been
connected to the MCC busbar distribution system. In the case of
main disconnects rated 400A or less, this load connection is made
by stab connections to vertical busbars that connect to the
horizontal bus distribution system. See Figure 19.
Figure 20. Main Circuit Breaker with Reverse Feed

Vertical
Wireway

Stab
Connections

Figure 19. Main Disconnect with Stab Load Connections Figure 21. Main Circuit Breaker
Overcurrent Protection to be Located in the MCC, Provided
the Feeder Taps from the Transformer are Sufficiently Short
and Other Requirements are Met

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
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maintenance manual
Incoming line lugs
Where the overcurrent protection for the MCC is at a remote
location, the MCC feeder lines are connected to incoming line lugs
attached to the busbar distribution system. See Figure 22. For high-
ampere rated horizontal busbar systems, the incoming line lugs are
mounted on vertical risers that connect to the horizontal busbars.
See Figure 23.

Figure 22. Incoming Line Lug Connections

Figure 23. Incoming Line Compartment, 2000A

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual
Short-circuit bracing Making connection
All incoming lines to either incoming line lugs or to main disconnects
must be braced to withstand the mechanical forces created by a m Caution
high fault current. With the remainder of an XT and XT FlashGard
MCC rated for not less than 65,000A (rms symmetrical), the All incoming line compartments present an obvious hazard
installing electrician needs to anchor the cables at the incoming line when the door is opened or covers are removed with power
connections sufficiently and tighten the lugs correctly. on. When working in this area, the incoming feeder should be
de-energized.
Each incoming line compartment is equipped with two-piece sheet
steel brackets that form a cable bracing support bracket that is Before beginning work on incoming line connections, refer to all
approximately 9 inches from the conduit entry point, for both top- drawings furnished by Eaton, as well as all applicable contract
and bottom-feed applications. Use the bracket and appropriate drawings for the particular installation.
lashing material to tie the cables securely together if bundled or to
hold apart when they are required to be separated. See Figure 24, Depending on the location, size, and type of the incoming
which shows the two-part mounting/bracing bracket, in a top entry arrangement, remove one or more horizontal and vertical wireway
incoming lug configuration. doors, and selected units to provide complete access. See Part 7,
page 17, for unit removal instructions.
For top entry, the top cover plates are easily removed for drilling or
punching operations.

Figure 24. Incoming Line Compartment Showing Two-Piece

Support Bracket, with Opening for Cables

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maintenance manual
MCC with a Magnum® or a main lug only incoming line
(Figure 23) section—cable bracing/lashing for top- and
bottom-feed arrangements

1. All cable must be terminated with two-hole mounted

compression or mechanical set-screw type lugs.
2. All non-current-limiting circuit breakers rated above 42 kA and
with circuits rated for 800A and below require cable lashing
per Figure 25.
3. Circuit breaker rated 42 kA and below require no cable lashing.
4. No cable lashing is required for current-limiting circuit breakers.
5. No cable lashing is required for circuits using more than four
cables of 500 kcmil or larger size wire per phase, regardless of
short circuit rating.

Rope Requirements:
3/8" diameter
Nylon, twisted
Size = #12
3 strand
Tensile strength = 3340 lbs (1515 kg)
Working load = 278 lbs (126 kg)

Cable
Rope

Note 1

Cable
Lugs
(Note 2)
Note 1

6.00 6.00 12.00

(152.4) (152.4) (304.8)

Instructions:
1. Route cable as close together as possible.
2. Wrap rope around the cable 6 in (152.4 mm) from lugs (see Note 1).
3. The second wrap is to be applied 6 in (152.4 mm) from the first wrap.
4. After the second wrap, the cables should be wrapped at 12 in (304.8 mm) increments to the entry or exit point of the switchgear.
5. Verify that each set contains 5 loops and that all ropes are pulled as tight as possible.

Note 1: The goal is to bundle all cables together in one bundle, but near the lug landings, so the bundles may need to separate.
In this case, the rope between cables should be wrapped to provide support.

Note 2: The center pole cable lugs are shown in-line with outer poles; Figure 21 shows lugs with center pole offset either leading
or lagging outer poles, depending on top or bottom feed cables. The six-inch dimension shown in these arrangements is from the closed lug,
which is the center pole for top entry and outer poles for bottom entry as shown in Figure 21.

Figure 25. Cable Lashing Installation Instructions

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Part 6. Inspection prior to energizing Table 1. Driving Torque

Description lb-in
1. Before energizing the motor control center (MCC), conduct a
thorough inspection to make certain that all foreign materials, Control Wiring
such as tools, scraps of wire, and other debris, are removed Coil leads 8 lb-in
from all units and the structure. Remove any accumulation of Relays 8 lb-in
dust and dirt with a vacuum cleaner.
Pushbuttons 8 lb-in
2. All circuit connections are tightened at time of assembly Control fuse blocks 8 lb-in
by power-driven tools with controlled torque. However, the
vibrations experienced in transit may loosen some of these Auxiliary contacts 8 lb-in
connections. Check at least 10% of the total connections for a Control Wiring Terminal Blocks
tight connection. Should this spot-check reveal some loose Side-mounted lug/compression 4.5 lb-in
connections, it will be necessary to check all connection Rail-mounted lug type 12 lb-in
points. The connections to be checked include bus hardware,
Rail-mounted compression type 18 lb-in
circuit breaker and switch terminals, contactor and relay
terminals, and terminal blocks. Always check the incoming line Unit Load Terminal Block
connections. Tighten to the torque values shown in Table 1. 100A load block 110 lb-in
3. Remove all blocks or other temporary holding means used for 180A load block 150 lb-in
shipment from all component devices in the MCC interior.
4. Check the enclosure to see that it has not been damaged so as
to reduce electrical spacings. Table 2. Power Wiring—Starters
5. Compare all circuits for agreement with the wiring diagrams that Tightening Torque Load Side
XT Contactor
accompany the MCC. Be sure that each motor is connected to Catalog Number Slotted Torque (lb-in) Conductors
its intended starter.
Power wire (AWG) Use 75°C
6. Make certain that field wiring is clear of live busses and NEMA size 1 14–6 25 copper
physically secured to withstand the effects of fault current. conductors
NEMA size 2 12–2 35
7. Check to determine that all grounding connections are NEMA size 3 8–250 kcmil 120
made properly.
NEMA size 4 9–250 kcmil 120
8. Check all devices for damage. Make all necessary repairs or NEMA size 5 1/0–250 200
replacements, prior to energizing.
XT contactor/starter Control wire (AWG)
9. Manually exercise all switches, circuit breakers, and other
#16–14 10
operating mechanisms to make certain that they are properly
aligned and operate freely.
10. Test any ground-fault protection systems that were furnished.
11. Set any adjustable current and voltage trip mechanisms to the Table 3. C440 Solid-State Overload Relay
proper values. Terminal Wire Size (AWG) Torque lb-in
12. Ensure that overload relay heater elements are installed and Control 2 x (18–12) 9
selected to the full-load current shown on the nameplate of
NEMA size 1 and 2 1 x (12–100) 23
each motor.
1 x (8–6) 28
13. Install power circuit fuses in the fusible switches in accordance
NEMA size 3 1 x (6–1) 28
with NEC application requirements. Make sure that fuses are
completely inserted in the clips provided. Do not attempt to
defeat the rejection feature on the fuse clip, when provided.
Breakers—Refer to torque values on breaker case.
14. Do not operate a current transformer with its secondary circuit
open. Ensure current transformer is connected to a load, or a
secondary shorting bar is installed. Table 4. Incoming Line Lugs
Description lb-in
15. To prevent possible damage to equipment or injury to personnel,
check to ensure that all parts and barriers that may have #2/0–350 kcmil 360 lb-in
been removed during wiring and installation have been #2/0–650 kcmil 360 lb-in
properly reinstalled. #2/0–750 kcmil 500 lb-in
16. Conduct an electrical insulation resistance test to make sure 500–1000 kcmil 600 lb-in
that the MCC and field wiring are free from short circuits and
grounds. Do this test phase-to-phase, phase-to-ground, and
phase-to-neutral, with the switches or circuit breakers opened.
Table 5. Bus Bolts
17. If the MCC contains a labyrinth vertical bus barrier system,
verify the operation of the automatic shutters. See Part 7 for Description lb-in
adjustments of this mechanism. All 360 lb-in
18. Install covers, close doors, and make certain that no wires
are pinched and that all enclosure parts are properly aligned
and tightened.
19. Turn all circuit breakers and fusible switches to the OFF position
before energizing the bus.

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
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maintenance manual
Part 7. XT MCC unit installation
and adjustment
Door removal and installation
All doors on the control center are mounted on pin hinges
to facilitate removal for installation and maintenance operations.
With the operating handle on the OFF position, rotate the
1/4-turn latches, open the door, remove the hinge pins as shown
in Figure 26, partially close the door and lift it from the structure.
Reverse this procedure for installation.

Unit removal and installation

After opening and/or removing the unit door, the control unit is
exposed. With a screwdriver, rotate latch located to the left of the
operator handle 1/4-turn counterclockwise.

m caution
Units 18” or more high have a retaining brace at the lower edge
of each side of the unit frame to add stability in shipping. The
shipping braces may be retained or removed after installation;
unscrew prior to unit withdrawal.

Pull-apart terminal blocks in the vertical wireway must be

disengaged (see Figure 27 and page 10) and wiring from the unit
to other units, to master terminal blocks or to load devices must be
disconnected before the unit is removed. Grasp the unit as shown in
Figure 28 and pull it outward. The first inch of travel pulls the stabs
free from the vertical bus, and the grounding clip on the side of the
unit frame is also disengaged.
To replace a control unit, position the mounting points on the unit
frame with the mating guide rails. Slide the unit inward until unit is
halfway in, then move it inward with a quick push. This movement Figure 27. Disengaging Pull-Apart Terminal Blocks
easily overcomes the compression of the stabs as they engage the
vertical bus. With the unit in its correct position, the 1/4-turn latch
is easily engaged by rotating 1/4-turn clockwise. If the latch will not
rotate, the unit is not fully inserted.

Figure 28. Withdrawing a Unit

Figure 26. Door Removal and Installation

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
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Automatic shutter travel adjustment 1/4-turn unit interlock
When the optional labyrinth vertical bus barrier is installed in the The 1/4-turn unit interlock is used to secure the unit into the
control center, a shutter is provided to automatically cover the stab structure. It also serves as the interlock to insure that a unit is not
openings when a control unit is withdrawn. The shutter is opened removed or inserted while the disconnect is in the on position. If a
by engagement of the left-hand side of the control unit with the unit disconnect cannot be turned on verify that the unit interlock is
shutter arm linkage attached to the left-hand vertical structural in the engaged or locked position. This position is when the slot is
members. When the unit is withdrawn free of the linkage, a parallel to the floor. If a unit cannot be withdrawn verify that the
spring automatically moves the shutter to its closed position. unit inter lock is fully in the unlocked or disengaged position. The
See Figure 29. interlock is fully disengaged when the slot is rotated 1/4-turn
With the control unit removed, the shutter should completely counter clockwise from parallel to the floor.
cover the stab openings. If it does not cover the openings, use an
Installing a new unit
adjustable wrench to bend the link arm to the right until the shutter
covers the stab openings. It is recommended that a new unit be installed in a unit space
If, on re-insertion of the control unit, interference is felt between at the top of a vertical compartment or directly below an existing
the stab assembly at the rear of the unit and the shutter, the unit. Material provided with the new unit by the factory includes:
engagement of the control unit with the shutter arm linkage is A divider pan with integral guide rails, a unit door, hinges, catches
insufficient to fully open the shutter. Use an adjustable wrench and hardware. Observe the following sequence of operations
to bend the linkage arm inward toward the unit to increase its for installation.
engagement with the unit. An inward bend of approximately 1. Remove the existing blank door.
1/4 inch will provide sufficient additional shutter travel.
2. Position the new unit door over the open space to ensure the
hinges and latches are aligned. If the spaces differ, the hinges
and latches on the structure must be re-located to match the
unit door hinges and latches. Mount the door, using the hinge
pins provided.
3. Install the new divider pan in the notches provided in the rear
barrier so that it is aligned with the bottom of the new door.
Attach the pan to the vertical structure channels with one
thread-forming screw on each side.
4. Remove from the vertical bus barrier the flat plate which covers
the stab holes that will align with the stabs on the new unit.
If an optional labyrinth vertical bus barrier is in place, install an
automatic shutter over the stab cutouts. Follow the instruction
sheet provided with the shutter kit.
5. If the unit is a communicating unit, set the new unit’s address
Figure 29. Shutter Arm Linkage using the dip switched located at the right hand edge of the
handle mechanism housing. Insure that another unit on the
same network is not using the new unit’s address. To avoid
address conflicts and to preserve your current I/O mapping it is
recommended that the new unit be assigned the next address
higher than the highest address currently on the network, even
if skipped addresses exist.
6. Insert unit.

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maintenance manual
Part 8. XT FlashGard MCC unit installation
and adjustment
XT FlashGard MCC unit removal and installation
Preparation to remove plug-in units:

m caution
Units 18 inches or more high have a retaining screw at the
lower edge of each side of the unit frame to add stability in
shipping. The shipping screws may be retained and reused or
removed after installation; unscrew prior to unit withdrawal.

Removing a unit

1. Turn unit operator OFF and keep unit door closed. At this point,
the Stab Position Indicator should show RED, indicating that the
stabs are fully extended and connected to the vertical bus. The
Shutter Position Indicator should show RED, also indicating that
the shutters are open.
2. To disconnect the stabs from the vertical bus, a 3/8-inch square
drive should be inserted into the Racking Receiver. The 3/8-inch
square drive can either be a manual tool or a remote racking
device. Please see IL04300001E for instructions on proper Figure 30. Disengaging Pull-Apart Terminal Blocks
installation of the remote racking device. Rotate the square drive
counterclockwise to begin to remove the stabs. If you happen
to rotate clockwise, the unit should spin freely and prevent the
stabs from being forced any further on the vertical bus. The Stab
Position Indicator flag and the Shutter Position Indicator flag
should begin to rotate to show the position of the stabs and
internal shutter. It takes approximately 30 full rotations to move
the stabs from the CONNECTED to the DISCONNECT position,
at the end of the transition a CLICKING sound is audible. The
DISCONNECT position will be illustrated when the Stab Position
Indicator and the Shutter Indicator are both showing GREEN.
Open the vertical wireway door to remove any plug-in terminal
blocks that might be connected to the unit (Figure 30). Please
look for any additional wiring that might be terminated inside
the unit. These connections will need to be removed prior to
removal of the unit from the structure.
3. Turn the Unit Latch, which is located left of the unit operator
(Figure 31), counterclockwise approximately 1/4-turn.
4. Open unit door and remove any interconnection wiring between
units, master terminal block, or external point of the motor
control center (MCC). For units that contain a motor load stab,
disconnection of the motor leads is not required in order to
remove the unit from the structure. Figure 31. Defeater Mechanism
5. Inspect the unit for any other material, accessories, or cable that
might interfere with the removal of the unit.
6. Pull the unit toward you. Guide rails that assist in the removal of
the bucket will support the bucket. Visually verify that the shutter
in the structure for the bucket has closed over the opening to
the vertical bus. If the shutter did not close, please shut down
power to the MCC prior to replacement or repair of the shutter.
7. Close unit door by securing the door 1/4-turn latches on the right
side of the door to reduce access to the unit.

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
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XT and XT FlashGard MCC units are designed for installation in 3. Press the unit in the structure until the front of the unit is
accordance with both the National Electrical Code (NEC), NFPA 70, approximately flush with the divider pan. You might feel a little
and the National Electrical Safety Code (NESC), ANSI C2. resistance when sliding in the structure. This is due to the
physical connection between the motor load stabs and motor
load terminal block on the lower right-hand side of the unit.
m caution
4. Open vertical wireway door to install any plug-in terminal blocks
If work is involved in removing, installing, or adjusting MCC or terminal and interconnection wiring inside the unit. Close and
units, ensure that incoming power is disconnected before secure wireway door.
work begins. Disconnecting means should be locked out
and/or tagged out of service. 5. Turn unit latch located to the left of the unit operator clockwise
until it is horizontal.
Where it is not feasible to de-energize the system, the following
precautions should be taken.
Handle
A. Persons working near exposed parts that are or may be Mechanism
energized should be instructed and should use safe work Racking Tool
practices (including appropriate personal protective equipment, Bucket Receiver Internal Shutter
which includes arc flash, insulating, and shielding materials, Position: Position: Open
and insulated tools and test equipment in accordance with Connected Unit and Closed
the NFPA 70E). Withdrawn Latch

B. Persons working on exposed parts that are or may be energized

should, in addition, be qualified persons who have been trained
to work on energized circuits.

Starter

Device Island/Panel
Breaker Start, Stop,
Auto, Manual

Figure 33. XT and XT FlashGard Components

Figure 32. Featuring the RotoTract™ Remote Racking Accessory

Stab Indicator Window
GREEN Indicates DISCONNECTED Position
Installation of a unit Racking Receiver

1. Prior to installation of the unit, verify that the unit stabs are fully
withdrawn and the internal shutters are closed (Figure 33). The
unit latch at the top of the bucket needs to be flush with the top
of the bucket to prevent interference with the divider pan when
installing the bucket. The unit operator needs to be in the OFF
position and the unit latch should be turned down so the metal
tab on the left side of the unit is inside the unit. This will prevent
any interference with the structure frame when installing in
the structure.
2. Open the unit door and slide the bucket into the structure.
The unit uses two guide rails that are located on the left and
right side bottom of the divider pan. The top wrapper of the
unit has grooves on the left and right side that sit into the
guide rail (Figure 36).
Figure 34. Stabs in DISCONNECTED Position

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maintenance manual
Automatic shutter travel adjustment
Stab Indicator Window
RED Indicates CONNECTED Position Labyrinth vertical bus barrier with a shutter is provided to
Racking Receiver automatically cover the stab openings when a control unit is
withdrawn. The shutter is opened by engagement of the right-hand
side of the control unit with the shutter arm linkage attached to the
right-hand guide rail. When the unit is withdrawn free of the linkage,
a spring automatically moves the shutter to its closed position.
See Figure 36.
With the control unit removed, the shutter should completely
cover the stab openings. If it does not cover the openings, use an
adjustable wrench to bend the link arm to the right until the shutter
covers the stab openings.
If, on re-insertion of the control unit, interference is felt between
the stab assembly at the rear of the unit and the shutter, the
engagement of the control unit with the shutter arm linkage is
insufficient to fully open the shutter. Use an adjustable wrench
Figure 35. Stabs in CONNECTED Position to bend the linkage arm inward toward the unit to increase its
engagement with the unit. An inward bend of approximately
1/4-inch will provide sufficient additional shutter travel.

Figure 36. Shutter Arm Linkage

6. Close unit door and secure unit latches located on the right side
of the door.
7. To connect the stabs to the vertical bus, a 3/8-inch square
drive should be inserted into the Racking Receiver. The 3/8-inch
square drive can either be a manual tool or a remote racking
device. Please see IL04300001E for instructions on proper
installation of the remote racking device. Rotate the square
drive clockwise to begin to insert the stabs. If you happen to
rotate counterclockwise, the unit should spin freely and prevent
the stabs from being withdrawn any further. The Stab Position
Indicator flag and the Shutter Position Indicator flag should begin
to rotate to show the position of the stabs and internal shutter. It
takes approximately 30 full rotations to move the stabs from the
DISCONNECTED to the CONNECTED position, at the end of
the transition a CLICKING sound is audible. The CONNECT
position will be illustrated when the Stab Position Indicator
and the Shutter Position Indicator are both showing RED.
8. At this point, the operator handle can be turned ON to energize Figure 37. Door Hinge Pin
the unit.

Door removal and installation

The unit FlashGard isolator must be DISCONNECTED prior to
maintenance and/or installation operations being performed and
the operating handle must be in the OFF position.
All doors on the control center are mounted on pin hinges to
facilitate removal. Rotate the 1/4-turn latches, open the door, remove
the hinge pins as shown in Figure 37, partially close the door, and
lift it from the structure. Reverse this procedure for installation.

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
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Installing a new unit
It is recommended that a new unit be installed in a unit space at
the top of a vertical compartment or directly below an existing
unit. Material provided with the new unit by the factory includes:
a divider pan with integral guide rails, a unit door, hinges, catches,
and hardware. Observe the following sequence of operations
for installation.

1. Remove the existing blank door.

2. Position the new unit door over the open space to ensure that
the hinges and latches are aligned. If the spaces differ, the hinges
and latches on the structure must be re-located to match the
unit door hinges and latches. Mount the door, using the hinge
pins provided.
3. Install the new divider pan in the notches provided in the rear
barrier so that it is aligned with the bottom of the new door.
Attach the pan to the vertical structure channels with one
thread-forming screw on each side.
4. Remove from the vertical bus barrier the flat plate that covers
Figure 38. Withdrawing a Unit the stab holes that will align with the stabs on the new unit.
Install an automatic shutter over the stab cutouts. Follow the
1/4-turn unit interlock instruction sheet provided with the shutter kit.

The 1/4-turn unit interlock is used to secure the unit into the 5. Insert unit.
structure. It also serves as the interlock to ensure that a unit is not
removed or inserted while the disconnect is in the ON position. If a
unit disconnect cannot be turned on, verify that the unit interlock is
in the engaged or locked position. This position is when the slot
is parallel to the floor. If a unit cannot be withdrawn, verify that the
unit interlock is fully in the unlocked or disengaged position.
The interlock is fully disengaged when the slot is rotated 1/4-turn
counterclockwise from parallel to the floor.

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maintenance manual
Part 9. Maintenance
Preventive maintenance
Preventive maintenance should be a program, a scheduled periodic
action that begins with the installation of the equipment. At that
time, specific manufacturer’s instruction literature should be
consulted, then stored for future reference. Follow-up maintenance
should be at regular intervals, as frequently as the severity of duty
justifies. Time intervals of one week, or one month, or one year
may be appropriate, depending on the duty. It is also desirable to
establish specific check lists for each control, as well as a logbook
to record the history of incidents. A supply of renewal parts should
be obtained and stored.
This control equipment is designed to be installed, operated, and
maintained by adequately trained workmen. These instructions do
not cover all details, variations, or combinations of the equipment,
its storage, delivery, installation, check-out, safe operation, or
maintenance. Care must be exercised to comply with local, state,
and national regulations, as well as safety practices, for this class
Figure 39. Defeater Mechanism
of equipment.
Authorized personnel may open a unit door of a motor control center
(MCC) while the starter unit is energized. This is accomplished
by defeating the mechanical interlock between the operating
mechanism and the unit door. A counterclockwise 1/4-turn of the
slotted head screw located to the right of the operating handle will
allow the door to open. See Figure 39.
When servicing and adjusting the electrical equipment, refer to
the applicable drawings covering the specific MCC and any other
related interconnection drawings. Follow any instructions that
may be given for each device. A list of instruction leaflets covering
standard components is shown on page 31 of this manual. Any
of these leaflets may be obtained by contacting your nearest
Eaton representative.
General Guidelines—The whole purpose of maintaining electrical
equipment can be summarized in two rules:

1. Keep those portions conducting that are intended to

be conducting.
2. Keep those portions insulated that are intended to be insulated.

Good conduction requires clean, tight joints, free of contaminants

such as dirt and oxides.
Good insulation requires the absence of carbon tracking and the
absence of contaminants, such as salt and dust that become
hydroscopic and provide an unintended circuit between points of Figure 40. Locking Out a Disconnect
opposite polarity.

m caution
Maintenance of the control components requires that all
power to these components be turned OFF by opening the
branch circuit disconnect means and withdrawing the unit to
the DISCONNECTED position in the Freedom FlashGard MCC unit.

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual
When using a padlock and multiple padlock adaptor as shown in
Figure 40 and Figure 41, bar size must be a minimum of 0.25 in
(6.35 mm) in diameter to properly securely lock the operator.

m caution
When using multiple padlocks with an adaptor, beware of
locking bars that are an asymmetrical shape. Fully inspect
and check effectiveness of arrangement being applied.

Figure 43. FlashGard Isolator Padlocking Shown with Padlock

Applied in DISCONNECTED Position

m warning
IF FULLY INSERTED, THE POWER AND CONTROL CIRCUITS WILL BE
ENERGIZED. Padlocking to prevent this handle movement
may be accomplished by the same method as described above.

Separate control sources of power must also be disconnected.

If control power is used during maintenance, take steps to prevent
Figure 41. Typical Multiple Padlock Adaptor Application feedback of a hazardous voltage through a control transformer.
Be alert to power factor correction capacitors that may be charged.
With the door open and the disconnect device OFF, the operating Discharge them before working on any part of the associated
handle is mechanically interlocked to prevent inadvertently being power circuit.
pushed ON. To defeat this interlock, the bar on the top of the
mechanism should be pushed in slightly, allowing the handle to Cleaning. Soot, smoke, or stained areas (other than inside arc
move upward to the ON position. chutes), or other unusual deposits, should be investigated and the
source determined before cleaning is undertaken. Vacuum or wipe
FlashGard isolator padlocking—kit 86-7228 clean all exposed surfaces of the control component and the inside
of its enclosure. Equipment may be blown clean with compressed
The FlashGard padlocking mechanism is designed to mount to the air that is dry and free from oil. (Be alert to built-in oilers in factory
front panel of the racking device. Its main function is to provide the compressed air lines!) If air blowing techniques are used, remove arc
user with the ability to lockout access to the 3/8-inch square drive covers from contactors and seal openings to control circuit contacts
screw within the FlashGard racking mechanism. The FlashGard that are present. It is essential that the foreign debris be removed
racking mechanism can be locked out in any position, CONNECTED, from the control center, not merely rearranged. Control equipment
DISCONNECTED (ISOLATED), and TEST positions, to ensure that should be clean and dry. Remove dust and dirt inside and outside
only authorized personnel can operate the racking mechanism. The the cabinet without using liquid cleaner. Remove foreign material
FlashGard padlocking device is designed to allow up to three 3/8-inch from the outside top and inside bottom of the enclosure, including
diameter padlocks. hardware and debris, so that future examination will reveal any parts
that have fallen off or dropped onto the equipment. If there are
liquids spread inside, determine the source and correct by sealing
conduit, adding space heaters, or other action as applicable.

Figure 42. FlashGard Isolator Padlocking Shown Mounted

to the MCC Unit

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
control center installation and  Effective November 2012
maintenance manual
Mechanical checks. Tighten all electrical connections. Look for Table 6. Contactor Troubleshooting Chart
signs of overheated joints, charred insulation, discolored terminals, Defect Cause Remedy
and the like. Mechanically clean to a bright finish (don’t use emery
paper) or replace those terminations that have become discolored. Short contact life Low contact force Adjust over-travel, replace contacts,
and replace contact springs as
Determine the cause of the loose joint and correct. Be particularly required to correct contact force.
careful with aluminum wire connections. Aluminum wire is best
terminated with a crimp type lug that is attached to the control Contact bounce on Correct improper voltage applied to
opening or closing coil. Correct any mechanical defects
component. When screw type lugs (marked CU/AL) are used with or misalignment.
aluminum wire, the joint should be checked for tightness every 200
operations of the device. Abrasive dust Do not use emery cloth to
on contacts dress contacts.
Wires and cables should be examined to eliminate any chafing Load current is Reduce load. Use larger contactor.
against metal edges caused by vibration, that could progress to too high
an insulation failure. Any temporary wiring should be removed or Jogging cycle is Reduce jogging cycle. Check factory
permanently secured and diagrams marked accordingly. too severe for more durable contact material.
The intended movement of mechanical parts, such as the Use larger contactor.
armature and contacts of electromechanical contactors, and Overheating Load current too high Install arc box.
mechanical interlocks should be checked for freedom of motion Loose connections Replace broken or eroded insulating
and functional operation. parts, arc horns, and grid plates.
Clean or replace insulating parts
Wrap-up. Check all indicating lamps, mechanical flags, doors, having a heavy coating of foreign
latches, and similar auxiliaries and repair, if required. conducting material.
Log changes and observations into record book before returning Over-travel and/or Remove contaminating materials
equipment into service. Do not remove any labels or nameplates. contact force too low that may have accumulated on arc
horns and steel-grid plates.
Restore any that are damaged.
Ambient temperature Reduce load. Provide better
Contact wear and replacement is too high ventilation. Relocate starter.
Use larger contactor.
Contactors are subject to both mechanical and electrical wear Line and/or load Install terminal block and run larger
during their operation. In most cases, mechanical wear is cables are too small conductors between contactor and
insignificant. The erosion of the contacts is due to electrical wear. terminal block.
During arcing, material from each contact is vaporized and blown Welding of contacts Over-travel and/or Adjust over-travel, replace contacts,
away from the useful contacting surface. contact force is too low and replace contact springs as
required to correct contact force.
A critical examination of the appearance of the contact surfaces
and a measurement of the remaining contact over-travel will give Magnet armature stalls Correct low voltage at coil terminals
or hesitates at contact as coil draws inrush current.
the user the information required to get the maximum contact life. touch point
Over-travel measurement Contactor drops open to Maintain voltage at coil terminals.
contact-touch position Install low voltage protective
Contact life has ended when the over-travel of the contacts because of voltage dip device, sometimes called
has been reduced to 0.02-inch. “Brownout Protector.”
Excessive contact Correct coil overvoltage condition.
Over-travel of the contact assembly is that part of the stroke that bounce on closing
the moving contacts would travel after touching the fixed contacts
if they were not blocked from movement by the fixed contacts.
A method of measuring over-travel is as follows: Maintenance of motor controllers after a fault
A. Place a 0.02-inch feeler gauge between the armature and NNote: Reproduced by permission of the National Electrical Manufacturers
magnet, with the armature held tightly against the magnet. Association from NEMA Standards Publication No. ICS2-2000 (R2005),
Industrial Control Devices, Controllers and Assemblies, copyright 2000
B. Check continually in each phase, i.e., determine if circuit from by NEMA.
terminal-to-terminal for each pole is open under these conditions.
In a motor branch circuit that has been properly installed,
C. If there is continuity through all phases, the remaining over-travel coordinated, and in service prior to the fault, opening of the
is sufficient. If there is not continuity through all phases, replace branch-circuit short-circuit protective device (fuse, circuit breaker,
all stationary and moving contacts plus moving contact over- motor short-circuit protector, and so on) indicates a fault condition
travel springs. After replacing parts, manually operate contactor in excess of operating overload. This fault condition must be
to be sure binding does not occur. corrected and the necessary repair or replacements made before
re-energizing the branch circuit.
It is recommended that the following general procedures be
observed by qualified personnel in the inspection and repair
of the motor controller involved in the fault.

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual
Procedure
Contact Tip

m caution
All inspections and tests are to be made on controllers and
equipment that are de-energized, disconnected, and isolated
so that accidental contact cannot be made with live parts
Contact Plate
and so that all plant safety procedures will be observed. (Brass or Copper)

Enclosure. Substantial damage to the unit door or frame, such as

deformation, displacement of parts, or burning, requires replacement
of the entire unit.
Circuit breaker. Examine the unit interior and the circuit breaker
for evidence of possible damage. If evidence of damage is not
apparent, the breaker may be reset and turned ON. If it is suspected
that the circuit breaker has opened several short-circuit faults or if
signs of circuit breaker deterioration appear within the enclosure, Still
the circuit breaker should be replaced. New Serviceable

Disconnect switch. The external operating handle of the disconnect

switch must be capable of opening the switch. If the handle fails Figure 44. Normal Service Wear
to open the switch or if visual inspection after opening indicates
deterioration beyond normal wear and tear, such as overheating,
contact blade, or jaw pitting, insulation breakage or charring, the
switch must be replaced.
Fuse holders. Deterioration of fuse holders or their insulating
mounts requires their replacement.
Terminals and internal conductors. Indications of arcing damage
and/or overheating, such as discoloration and melting of insulation, Corner of Contact
require the replacement of damaged parts. Worn Away

Contactor. Contacts showing heat damage, displacement of metal,

or loss of adequate wear allowance require replacement of the
contacts and the contact springs. If deterioration extends beyond
the contacts, such as binding in the guides or evidence of insulation
damage, the damaged parts or the entire contactor must be
replaced.
Overload relays. If burnout of the current element of an overload
relay has occurred, the complete overload relay must be replaced.
Any indication that an arc has struck and/or any indication of burning Replace
of the insulation of the overload relay also requires replacement of
the overload relay. Figure 45. End of Service Life
If there is no visual indication of damage that would require
replacement of the overload relay, the relay must be electrically or
mechanically tripped to verify the proper functioning of the overload
relay contact(s).
Return to service. Before returning the controller to service, checks
must be made for the tightness of electrical connections and for the
absence of short circuits, grounds, and leakage.
All equipment enclosures must be closed and secured before the
branch circuit is energized.

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
control center installation and  Effective November 2012
maintenance manual

RotoTract Insertion Point

Door Interlock 3/8-inch Square
Unit Guides
(Included with
the Unit Wrapper)

Bucket Position: Internal Shutter

Connected/Disconnected Position:
Open/Closed

Door
Defeater Screw Cable Assemblies

Breaker Operator
Handle

Unit Terminal Blocks

Device Panel

Unit Disconnect Device

1/4-Turn Latch and Unit

Interlock (Included with
the Cover Control Module)

Figure 46. Motor Control Center FlashGard XT Unit

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual

Breaker Operating Handle

Device Panel

Unit Disconnect Device Device Panel

Breaker Operating Handle

Unit Terminal
Blocks

Unit Disconnect Device

Figure 46a. Motor Control Center XT Unit

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
control center installation and  Effective November 2012
maintenance manual
Part 10. Plan views

Removable Top Cover Removable Top Cover

Top Conduit
Space
16.00 Top Conduit
(406.4) Top View Space 20.38
5.41 (517.7) Top View
(137.4)
5.41
Vertical (137.4)
2.20 (55.9) 17.50 Wireway Door Vertical
(444.5) 2.20 (55.9) Wireway Door
1.25 (31.7) 1.25 (31.7) 17.50
20.00 1.25 (31.7) (444.5) 1.25 (31.7)
(508.0) Wire Tie 20.00
Brackets (508.0)
Wire Tie
Cross Section Cross Section Brackets
7.31
Bottom View
(185.7) 7.31
1.25 17.50 1.25
4.81 (122.2) Vertical (31.7) (444.5) (185.7)
Bottom View Wireway (31.7)
17.50 See Note 5 4.81 (122.2)
1.25 (31.7) (444.5) 1.25 (31.7)
5.41 (137.4) Vertical
See Note 5 Removable Bottom Wireway
Removable Bottom 18.35 Frame Members
5.41 (137.4) Frame Members 5.78 (146.8) See Note 4
(466.1
13.97 See Note 4
6.81 (172.9) (354.8) 5.41 (137.4)
Bottom Bottom
Conduit Space Conduit Space
1.58 (40.1) 0.70 (17.8) See Notes 2 and 3
1.58 (40.1) 0.70 (17.8) See Notes 2 and 3 16.00
0.53 (13.5) Dia. 2.00 (50.8)
16.00 (406.4)
0.53 (13.5) Dia. (406.4) See Notes 1 and 1B
See Notes 1 and 1B 0.53 (13.5) Dia. See Notes 1 and 1A 0.53 (13.5) Dia. See Notes 1 and 1A

Figure 47. 20 Inches Wide, 16 Inches Deep, Figure 49. 20 Inches Wide, 21 Inches Deep,
Front-Mounted Only (4710A30) Front-Mounted Only (4710A31)

Removable Top Cover Removable Top Cover

Top Conduit
Top Conduit Space
Space
16.00 20.38
(406.4) Top View Top View
5.41 (517.7)
(137.4) 5.41
(137.4)
Vertical
2.20 (55.9) Wireway Door Vertical
21.50 2.20 (55.9) 21.50 Wireway Door
1.25 (31.7) (546.1) 1.25 (31.7) (546.1) 1.25 (31.7)
24.00 (609.6) 1.25 (31.7) 24.00
Wire Tie (609.6)
Brackets Wire Tie
Brackets
Cross Section
7.31 Cross Section
7.31
(185.7)
(185.7)
Bottom View 8.81 (233.7) Vertical Bottom View
Wireway Vertical
21.50 Wireway
1.25 21.50 1.25 1.25 (31.7) (546.1) 1.25 (31.7)
(31.7) (546.1) (31.7) See Note 5 8.81 (223.8)
See Note 5 Removable Bottom Removable Bottom
Frame Members 5.41 (137.4)
5.41 (137.4) Frame Members
See Note 5 18.35 See Note 5
13.97 5.78 (146.8)
(354.8) (466.1)
6.81 (172.9) Bottom Conduit Space Bottom
See Notes 2 and 3 5.41 (137.4) Conduit Space
See Notes 2 and 3
1.58 (40.1) 0.70 (17.8) 1.58 (40.1) 0.70 (17.8)
20.00 20.00
0.53 (13.5) Dia. (508.0) 2.00 (50.8) 0.53 (13.5) Dia. (508.0) 2.00 (50.8)
See Notes 1 and 1B 0.53 (13.5) Dia. See Notes 1 and 1A See Notes 1 and 1B 0.53 (13.5) Dia. See Notes 1 and 1A

Figure 48. 24 Inches Wide, 16 Inches Deep, Figure 50. 24 Inches Wide, 21 Inches Deep,
Front-Mounted Only (4710A33) Front-Mounted Only (4710A34)

NNotes:
1. Minimum length of anchor bolt is 2.00 (50.8) (0.38-16 grade 5 torqued at 31 lb-ft).
A. For non-seismic, mount with two center bolts per enclosure.
B. For seismic, mount with minimum four corner bolts per enclosure.
2. Recommended maximum conduit height above floor line is 3.50 inches (88.9 mm).
3. Maximum conduit space with channel sills is 17.50 x 9.73 inches (444.5 x 247.1 mm).
4. For multiple structure assemblies, either one or both of these members is removed to provide
maximum unrestricted conduit space at the bottom of the MCC.
5. This conduit space is not recommended when a neutral bus and/or a space heater is required.
Otherwise this space is available for conduit. See Figure 53 for vertical dimensions.

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual

2.20 (55.9) Removable

3.22 (81.8) Top Cover 12.12
(307.8) Horizontal Bus Location
Ground Bus 10.50
Top Conduit Location Vertical Bus Location
21.00 (266.7)
Space Top View
(533.4) 3.12 (79.2)
5.41 (137.4) 2.25 A 4.62 (117.3)
(57.2)
Vertical 4.62 (117.3)
2.20 (55.9) Wireway Door
17.50 See Note 9A
1.25 (31.7) 1.25 (31.7)
(444.5) Removable Bus Barrier
20.00 Horizontal Wireway See Note 8
(508.0) 4.81 (122.2) 7.16 (181.9) Deep
7.31 See Note 7 Flat Cover Supplied
(185.7) Wire Tie on Rear of Front-
Brackets Mounted-Only Structure
Cross Section Rear Vertical
Wireway
7.31 Minimum Rated Vertical
(185.7) Bus Supplied as Standard in
Vertical See Note 7 Front-Mounted-Only Structure
4.81 (122.2)
Wireway
1.25 (31.7) 17.50 1.25 (31.7) See Note 9A
(444.5) Removable Bottom
See Note 5 Frame Members
5.41 (137.4) See Note 5
B 5.00
18.35 3.00 (76.2) Channel
5.78 (146.8) Bottom View Floor Line (127.0) Sills Supplied Only
(466.1)
When Specified
5.41 (137.4) Bottom Conduit Space 1.00 3.00 (76.2)
See Notes 2 and 3 (25.4)
1.32 (33.5) 9.73 (247.1) or 15.73 (399.5) or 20.11 (510.8)
0.53 (13.5) Dia. 16.00 2.00 14.11 (358.4) 10.50
(266.7) Neutral Bus Location When Specified
See Notes 1 and 1B (406.4) (50.8)
0.53 (13.5) Dia. See Notes 1 and 1A

Figure 51. 20 Inches Wide, 21 Inches Deep, Figure 53. Side View A
Front- and Rear-Mounted (4710A32)

Removable
Cover Ground Bus 12.12 (307.8) Horizontal Bus
Location Location 12.12 Horizontal Bus Location See Note 9
Top (307.8)
Conduit 3.12 (79.2) Ground Bus Vertical Bus Location
20.38 2.25 10.50
Space (517.6) 4.62 (117.3) Location (266.7) Removable Bus Barrier
(57.2)
or 4.62 (117.3)
16.00 3.12 (79.2)
5.41 Horizontal
(406.4) Wireway Removable Bus 2.25 A
(137.4) Barrier (57.2) 15.00 4.62 (117.3)
7.16 (181.9) (381.0)
2.20 Deep Flat Cover 4.62 (117.3)
(55.9) Supplied on See Note 9A
1.25 1.25 Rear of Front-
(31.7) (31.7) Vertical View Horizontal Wireway
Mounted-Only 7.16 (181.9) Deep
10.00 Structure C Rear Horizontal Wireway
(254.0) 7.50 See Note 7 4.97 (126.3) Deep
3.00 (76.2)
(190.5) 9.73 Channel
Top View (247.1) Sills Supplied
or Only When See Note 7
Removable Bottom 14.11 Specified
Frame Members (358.4)
See Note 4. (Not to 5.00
be removed for D
Floor Line (127.0)
seismic)
7.50 See Note 7
1.00 (25.4) 3.0 See Note 7
(190.5) (76.2)
1.25 1.25 See Note 9A
(31.7) (31.7) 15.73 (399.5) or
10.50 20.11 (510.8)
See Note 5 B 5.00 E
(266.7) Neutral Bus Location 3.00 (76.2) Channel
When Specified Floor Line (127.0)
5.41 (137.4) Sills Supplied Only
18.35 (466.1) When Specified
5.78 (146.8) Bottom Conduit Space 14.11
1.00 (358.4) 3.00 (76.2)
5.41 (137.4) See Notes 2 and 3 (25.4)
20.11
0.70 (510.8)
1.58 (40.1)
(17.8) 10.50
0.53 (13.5) Bottom View Neutral Bus Location When Specified
5.00 (266.7)
Dia. (2)
See Note 1 (127.0)

Figure 52. 10 Inches Wide, 16 or 21 Inches Deep, Figure 54. Side View B
Transition Structure (4710A35/6)

NNotes: 6. Master Terminal Block (MTB) assembly is furnished for Type C wiring only
1. Minimum length of anchor bolt is 2.00 (50.8) (0.38-16 grade 5 torqued when location not specified. MTB supplied at the bottom.
at 31 lb-ft). 7. Rear horizontal bus barrier not supplied with front-mounted-only structure.
A. For non-seismic, mount with two center bolts per enclosure. 8. Standard structure arrangement:
B. For seismic, mount with minimum four corner bolts per enclosure. A. In front
2. Recommended maximum conduit height above floor line is Without MTB: A and B = 9.00 (228.6 mm)
3.50 inches (88.9 mm). With MTB at bottom: A and B = 9.00 (228.6 mm)
3. Maximum conduit space with channel sills is 17.50 x 9.73 inches With MTB at top: A and B = 3.00 (76.2 mm)
(444.5 x 247.1 mm). B. In rear
4. For multiple structure assemblies, either one or both of these members Without MTB: C = 0, D = 72 (1828.8 mm), E = 3.00 (76.2 mm)
is removed to provide maximum unrestricted conduit space at the bottom With MTB at bottom: C = 0, D = 66.00 (1676.4 mm),
of the MCC. E = 9.00 (228.6 mm)”
5. This conduit space is not recommended when a neutral bus and/or a With MTB at top: C = 12, D = 60 (1524.0 mm), E = 3.00 (76.2 mm)
space heater is required. Otherwise, this space is available for conduit.
See Figure 54 for vertical dimensions.

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XT and XT FlashGard motor  Instruction Booklet MN043001EN
control center installation and  Effective November 2012
maintenance manual
Part 11. Related instructional leaflets
Publication Publication No.
Circuit Breakers
Magnum DS I.B. 2C12060H08
RotoTract Remote Racking Operating Manual IL04300001E
Series C, F-Frame IL01219018E
Series C, F-Frame IL29C101
Series C, J-Frame IL01204004E
Series C, J-Frame IL29C103
Series C, K-Frame IL29C104C
Series C, L-Frame IL01207002E
Series C, L-Frame IL29C105
Series G, EG-Frame IL29C515C
Series G, JG-Frame IL01207009E
Series G, LG-Frame IL01207001E
Series G, N-Frame IL01209003E
Series G, R-Frame IL29C107N
Transfer Switches IL14477
Contactors
Size 5, Non-Reversing and Reversing, Vacuum IL16999
Size 5, Non-Reversing and Reversing, Vacuum IL17088
Communication Module
C441V MN04200002E
Solid-State Overload Relay
C440 IL04201001E
Starters
Size 5, Non-Reversing and Reversing, Vacuum IL17087
XT Contactors
NEMA 1 L03407147Z
NEMA 2 L03407148Z
NEMA 3/4 L03407149Z
NEMA 5 L03407150Z

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Instruction Booklet MN043001EN XT and XT FlashGard motor 
Effective November 2012 control center installation and 
maintenance manual

Eaton Corporation
Electrical Sector
1111 Superior Avenue
Cleveland, OH 44114 USA
[Link]

© 2012 Eaton Corporation Eaton is a registered trademark

All Rights Reserved of Eaton Corporation.
Printed in USA
Publication No. MN043001EN / Z12628 All other trademarks are property
November 2012 of their respective owners.