Cutler-Hammer GMCP User manual

I.L. 15579B
Effective December 1998 Supersedes I.L. 15579A dated December 1993
Cutler-Hammer
Installation Instructions for GMCP Motor Circuit Protector
DO NOT ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT IS ENER-
GIZED. DEATH, SEVERE PERSONAL INJURY, OR
SUBSTANTIAL PROPERTY DAMAGE CAN RESULT
FROM CONTACT WITH ENERGIZED EQUIPMENT.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT
BEFORE PROCEEDING WITH THE TASK, AND
ALWAYS FOLLOW GENERALLY ACCEPTED SAFE-
TY PROCEDURES.
CUTLER-HAMMER IS NOT LIABLE FOR THE MISAP-
PLICATION OR MISINSTALLATION OF ITS PROD-
UCTS.
1-0 INTRODUCTION
The user is cautioned to observe all recommendations,
warnings, and cautions relating to the safety of person-
nel and equipment, as well as all general and local
health and safety laws, codes, and procedures.
!
WARNING The recommendations and information contained herein
are based on Cutler-Hammer experience and judge-
ment, but should not be considered to be all-inclusive or
covering every application or circumstance which may
arise. If any questions arise, contact Cutler-Hammer for
further information or instructions.
General Information
The G-Frame instantaneous-only (magnetic) motor cir-
cuit protector (MCP) (Figure 1-1) is available in ratings
from 3A to 63A continuous current for motor starter
sizes 0 through 2. The MCP is designed to comply with
the applicable requirements of Underwriters
Laboratories, Inc. Standard UL489 and the International
Electrotechnical Commission Recommendations No.
IEC 157-1.
The MCP is a UL recognized component under file
E7819. It is used primarily to provide short-circuit pro-
tection as part of a combination controller where other
circuit protective functions are performed by other
devices within the controller. The MCP is suitable for
reverse feed applications. For more information, see
T.D. 29-321.
This instruction leaflet (IL) gives procedures for installa-
tion, operation, inspection, and field testing of G-Frame
MCP’s.
2-0 INSTALLATION
The installation procedure consists of inspecting and
mounting the MCP, connecting and torquing the line and
load terminations, and attaching terminal shields when
required. To install the MCP, perform the following steps:
G-Frame MCP’s are factory sealed. UL489 requires
that internal accessories be installed at the factory.
Mounting hardware (where required) is supplied in a
separate package.
2-1. Make sure that the MCP is suitable for the intend-
ed installation by comparing nameplate data with sys-
tem requirements. Inspect the MCP for completeness
and damage before mounting.
Figure 1-1 G-Frame Motor Circuit Protector
NOTICE

I.L. 15579B
Page 2
Effective 12/98
BEFORE MOUNTING THE MCP IN AN ELECTRICAL
SYSTEM, MAKE SURE THE MCP IS SWITCHED TO
THE OFF POSITION AND THAT THERE IS NO VOLT-
AGE PRESENT WHERE WORK IS TO BE PER-
FORMED. THE VOLTAGES IN ENERGIZED EQUIP-
MENT CAN CAUSE DEATH OR SEVERE PERSONAL
INJURY.
2-2. To mount the MCP, perform the following steps:
Depending on the equipment configuration, the
MCP can be mounted using different styles of hard-
ware. The following steps describe how to mount
the MCP using standard hardware. When special
hardware is needed (for example, with handle mech-
anisms), the instruction leaflet describing the acces-
sory also describes the special mounting arrange-
ments.
a. For individual mounting panels, make sure that
mounting panel is predrilled using drilling plan
(Figure 2-1).
b. If MCP includes factory installed internal acces-
sories, make sure accessory wiring can be
reached when the MCP is mounted.
c. Position MCP on mounting surface.
d. Install mounting screws, washers, and nuts.
Tighten screws firmly, but do not exceed 28
pound-inches (3.16 N.m.).
DIN Rail Mounting
An adapter kit (S#1275C79G02) suitable for use with
standard 35 millimeter DIN rail (such as 35 mm x 7.5 or
35 mm x 15 per DIN EN50022), should be preassem-
bled to the rear of the circuit breaker (Figure 2-2).
WHEN ALUMINUM CONDUCTORS ARE USED, THE
APPLICATION OF A SUITABLE JOINT COMPOUND
IS RECOMMENDED TO REDUCE THE POSSIBILITY
OF TERMINAL OVERHEATING. TERMINAL OVER-
HEATING CAN CAUSE DAMAGE TO THE MCP.
2-3. After mounting the MCP, line and load cables and
accessory leads should be connected. (See accessory
schematic diagram on side of MCP.)
If terminal shield on MCP cover with mounting
screws provided.
2-4. If required, install terminal shield on MCP cover
with mounting screws provided.
2-5. After the MCP is installed, check all mounting hard-
ware and terminal connecting hardware for correct
!
WARNING
NOTICE
Figure 2-1 GMCP Mounting Bolt Drilling Plan
Line
End
1.937
(49.20)
.969 (24.61)
C
LCircuit Breaker Handle 3.218
(81.74)
.688 (17.48)
.138-32 Tap Holes
(M4 x .7)
1.000
(25.40)
Load
End
Figure 2-2
Screwdriver
Line end
Load end
Device
DIN
rail
DIN rail
adapter
Device
Line end
Load end
DIN
rail
DIN rail
adapter
Installation
1. Hook load end to DIN rail.
2. Push line end in direction shown
until DIN rail adapter snaps onto
DIN rail.
Removal
1. Place screwdriver tip into DIN
rail adapter and against device
as shown
2. Pull screwdriver in direction
shown to release device from
DIN rail.
!
CAUTION
NOTICE

I.L. 15579B Page 3
Effective 12/98
torque loading. Torque values for line/load terminals
are given in Tables 2.1 and 2.2 and on the MCP name-
plate.
3-0 MANUAL OPERATION
The MCP is manually operated by the handle or the
PUSH-TO-TRIP button. The MCP handle has three
indicating positions, two of which are shown with handle
lettering to indicate ON and OFF. Trip status is indicat-
ed by white strip on handle.
Circuit Breaker Reset
After tripping, the MCP is reset by moving the MCP han-
dle to the extreme OFF position.
PUSH-TO-TRIP Button
The PUSH-TO-TRIP button checks the tripping function
and is used to periodically exercise the operating mech-
anism. The button is designed to be operated by using
a small screwdriver.
Adjustment of Trip Setting
The trip setting adjusting mechanism permits the MCP
to be fine tuned to provide more precise protection. The
mechanism consists of a cam with six positions for dif-
ferent trip levels. The trip levels are labeled A through
F; actual trip values are shown on the MCP cover name-
plate and in Tables 3.1. Adjustments is made only in
one direction as indicated in Figure 3-1. A rotation stop
prevents the adjustment wheel from being rotated
against indicated adjustment direction. The MCP can
be damaged if adjustment is forced against indicated
adjustment direction. Once the F setting has been
reached, continue adjusting in the same direction to
return to the A setting. To adjust the trip level, perform
the following steps:
3-1. Determine the motor full load current from the
motor nameplate. Refer to Table 3.1 and select appro-
priate MCP trip setting. Using a small screwdriver,
rotate wheel in direction indicated (See Figure 3-1) to
the appropriate setting.
3-2. For closest protection, turn the adjustment wheel to
successively lower settings until the MCP trips when the
motor is started. Only adjust in direction indicated (See
Figure 3-1). When this setting has been determined,
turn the adjustment wheel to the next highest setting.
The MCP is now adjusted for normal operation.
3-3. If the MCP does not trip at the lowest setting (A),
leave the adjustment wheel at this position.
4-0 INSPECTION AND FIELD TESTING
G-Frame MCPs are designed to provide years of almost
maintenance-free operation. The following procedure
describes how to inspect and test a MCP in service.
Inspection
MCPs in service should be inspected periodically. The
inspection should include the following checks:
Circuit Terminal Screw Wire AWG Wire Metric
Breaker Type Head Type Range Wire ➀
Amps. Material Type Range (mm2)
3-20 Clamp Slotted Cu/Al #14-10 1.5-4
(Plated Steel)
25-63 Pressure Slotted Cu/Al #10-1/0 4-50
(Aluminum Body)
➀Not UL Listed sizes.
Table 2.1 Terminal Types
For line and load-side. Terminals are UL Listed as suit-
able for wire type and size given below.
AWG Wire Torque Torque
Range Value lb-in Value N.m.
#14-10 20 2.26
#8 40 4.52
#6-1/0 45 5.09
Table 2.2 Terminal Torque Values Figure 3-1 MCP Manual Controls
Handle
Trip Indicator:
White Color
When Tripped
ON
TRIP
OFF
RESET
Push to Trip
Button Trip Setting Adjustment Mechanism
Adjust Only In
Direction Shown By
Arrow

Cutler-Hammer
Pittsburgh, Pennsylvania U.S.A.
Effective 12/98 (ISI)
Style 8703C84H03
Printed in U.S.A.
Page 4 I.L. 15579B
BEFORE INSPECTING THE MCP IN AN ELECTRICAL
SYSTEM, MAKE SURE THE MCP IS SWITCHED TO
THE OFF POSITION AND THAT THERE IS NO VOLT-
AGE PRESENT WHERE WORK IS TO BE PERFORMED.
THE VOLTAGES IN ENERGIZED EQUIPMENT CAN
CAUSE DEATH OR SEVERE PERSONAL INJURY.
MAKE SURE THAT CLEANING AGENTS OR SOL-
VENTS USED TO CLEAN THE MCP ARE SUITABLE
FOR THE JOB. SOME COMMERCIAL CLEANING
AGENTS WILL DAMAGE THE NAMEPLATES OR
MOLDED PARTS.
4-1. Remove dust, dirt, soot, grease, or moisture from the
surface of the MCP using a lint-free dry cloth, brush, or vac-
uum cleaner. Do not blow debris into MCP. If contamina-
tion is found, look for the source and eliminate the problem.
4.2 Switch MCP to ON and OFF several times to be sure
that the mechanical linkages are free and do not bind. If
mechanical linkages are not free, replace MCP.
4-3. Press the PUSH-TO-TRIP button to mechanically trip
the MCP. Trip, reset, and switch MCP ON several times. If
mechanism does not reset each time the MCP is tripped,
replace the MCP.
4-4. Check base, cover and operating handle for cracks,
chipping, and discoloration. MCPs should be replaced if
cracks or severe discoloration is found.
4-5. Check terminals and connectors for looseness or signs
of overheating. Overheating will show as discoloration,
melting, of blistering of conductor insulation, or a pitting or
melting of conductor surfaces due to arcing. If there is no
evidence of overheating or looseness, do not disturb or
tighten the connections. If there is evidence of overheating,
terminations should be cleaned. Before reenergizing the
MCP, all terminations and cable should be refurbished to
the condition when originally installed.
4-6. Check MCP mounting hardware; tighten if necessary.
!
WARNING
!
CAUTION Cam Motor NEMA Continuous GMCP GMCP
Setting Full Load Starter Amps ➁Catalog Trip
Current Size Number Setting
Amperes ➀
A 1.1 - 1.2 15
B 1.3 - 1.5 18
C 1.6 - 1.7 0 3 GMCP003A0 21
D 1.8 - 1.9 24
E 2.0 - 2.2 27
F 2.3 - 2.5 30
A 2.6 - 3.1 35
B 3.2 - 3.6 42
C 3.7 - 3.9 0 7 GMCP007C0 49
D 4.3 - 4.7 56
E 4.8 - 5.2 63
F 5.3 - 5.7 70
A 5.7 - 6.8 75
B 6.9 - 7.9 90
C 8.0 - 9.1 0 15 GMCP015E0 105
D 9.2 - 10.3 120
E 10.4 - 11.4 135
F 11.5 - 12.6 150
A 11.5 - 13.7 150
B 13.8 - 16.0 180
C 16.1 - 18.3 1 30 GMCP030H1 210
D 18.4 - 20.6 240
E 20.7 - 22.9 270
F 23.0 - 25.2 300
A 19.3 - 22.9 250
B 23.0 - 26.8 300
C 26.9 - 30.6 2 50 GMCP050K2 350
D 30.7 - 34.5 400
E 34.6 - 38.3 450
F 38.4 - 42.1 500
A 23.1 - 27.5 300
B 27.7 - 32.2 360
C 32.3 - 36.7 2 60 GMCP060J2 420
D 36.9 - 41.4 480
E 41.5 - 46.0 540
F 46.2 - 50.5 600
A 24.2 - 32.1 315
B 29.1 - 34.8 380
C 33.9 - 39.4 2 63 GMCP063M2 440
D 38.8 - 46.4 500
E 43.6 - 48.9 570
F 48.5 - 53.7 630
➀Motor FLA ranges are typical. The corresponding trip setting is at 13 times the minimum
FLA value shown. Where a 13 times setting is required for an intermediate FLA value,
alternate cam settings and/or MCP ratings should be used.
➁N.E.C. Article 430-110(a) requires the ampere rating of the disconnecting means to be not
less than 115% of the motor full load ampere rating.
Table 3.1 GMCP Trip Settings
4-7. Check area where MCP is installed for any safety haz-
ards including personal safety and fire hazards. Exposure
to certain types of chemicals can cause deterioration of
electrical connections.
Field Testing
Any field testing should be done in accordance with NEMA
Standards Publication AB4-1991.