Eaton AMPGARD NEMA 3R User manual

Instruction Booklet IB48091 Effective October 2022
Contents
Description Page
Section 1: Introduction .....................2
Section 2: Receiving, handling, and storing .....8
Section 3: Installation .....................10
Section 4: Common configurations...........13
Section 5: Inspection and maintenance .......14
Section 6: Renewal parts ..................14
Read and understand all the markings, labels, and
instructions before attempting installation, opera-
tion, or maintenance of this equipment.
This equipment must be installed and serviced
only by qualified electrical personnel. Retain this
document for future use.
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center

2
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
m WARNING
HAZARD OF ELECTRICAL SHOCK OR BURN.
THE EQUIPMENT MUST BE OPERATED WITHIN ITS NAMEPLATE RATINGS.
OPERATING THE EQUIPMENT OUTSIDE OF ITS RATINGS MAY CAUSE FAIL-
URE RESULTING IN PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR
DEATH.
ALL APPLICABLE SAFETY CODES, SAFETY STANDARDS, AND SAFETY REG-
ULATIONS MUST BE STRICTLY ADHERED TO WHEN INSTALLING, OPERAT-
ING, OR MAINTAINING THIS EQUIPMENT.
m WARNING
SAFETY WARNINGS
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING
INSTALLATION, OPERATION, OR MAINTENANCE OF THE EQUIPMENT.
• OBSERVE NATIONAL ELECTRICAL CODE (NEC), OCCUPATIONAL SAFETY
AND HEALTH ACT (OSHA), AND LOCAL PROCEDURES AND STANDARDS.
THIS INCLUDES VISUAL INSPECTIONS WHILE THE DOOR IS OPEN,
MAKING ANY ADJUSTMENTS INSIDE OR OUTSIDE THE ENCLOSURE,
PERFORMING MAINTENANCE, AND/OR INSTALLING REPLACEMENT
PARTS.
• THE END USER IS RESPONSIBLE FOR CONFORMING TO ALL
APPLICABLE CODE REQUIREMENTS WITH RESPECT TO GROUNDING
THE EQUIPMENT.
• ENSURE THAT YOU ARE WEARING PROPER PERSONAL PROTECTIVE
EQUIPMENT (PPE) TO SAFEGUARD YOURSELF AGAINST THE HAZARDS
PRESENT DUE TO MEDIUM VOLTAGE PROXIMITY.
• DISCONNECT ALL LOW VOLTAGE AND MEDIUM VOLTAGE POWER
SOURCES BEFORE STARTING ANY WORK ON THE EQUIPMENT PER
OSHA AND LOCKOUT PROCEDURES.
• VERIFY THAT THE VOLTAGE HAS BEEN REMOVED.
• DISCONNECT THE ISOLATION SWITCH BY USING THE HANDLE. NEVER
LEAVE THE ISOLATION SWITCH IN AN INTERMEDIATE POSITION.
ALWAYS MOVE THE HANDLE TO THE FULLY OPEN OR FULLY CLOSED
POSITION.
• USE ADEQUATE FALL PROTECTION WHEN WORKING ABOVE GROUND
LEVEL.
Section 1: Introduction
1.1 Purpose
The purpose of this instruction booklet is to address typical consider-
ations for the application and installation of the rain proof enclosure.
Included in this are:
• Equipment ratings;
• Receiving, handling, and storing the equipment; and
• Physical constraints of the job site.
The purpose of NEMA 3R enclosure is to provide protection to
AMPGARD®products in the outdoor locations. It is a rain proof
enclosure which will provide protection to enclosed gear.
The performance of this equipment is greatly influenced by the
installation conditions, protective scheme, grounding method, and
the actions of the operator. Application of AMPGARD equipment
does not supersede the requirement of adequate PPE.
This instruction booklet does not purport to cover all possible contin-
gencies, variations, and details that may arise during installation,
operation, or maintenance of this equipment. If further information
is desired regarding this product, contact your local Eaton sales
office.
1.2 Strategy
NEMA 3R enclosure is required in various applications such as water
and wastewater, agriculture, mining, minerals, oil, and gas to provide
protection to enclosed gear. For various configurations of medium
voltage motor control centers, NEMA 3R enclosure with widths of
20, 26, 32, 44, and 48 inches are available.
Also, the incoming line with the capability to connect with a medium
voltage switch gear and a transformer is available.

3
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
1.3 Identification
A rating nameplate is located on the door of each unit. Listed on
this name plate is the factory’s general order number. This number
should be given to the Eaton sales office if a question should arise
concerning the equipment or if the renewal parts are required.
Refer to Figure 1 for the typical location of the rating nameplates.
Figure 1. Rating nameplate on the door.
1.4 Ratings
Table 1. Enclosure rating: NEMA 3R.
Configuration
description Number of contactors
Contactor interrupting
capacity -3 phase symmetrical Amperes
per
contactor Amperes totalE1 -kA E2-kA
2- High 28.5 50 @ 7.2 kV 95 (top)
375 (bottom) 470
2- High 28.5 50 @ 7.2 kV 340 (top)
340 (bottom) 680
1- High 18.5 50 @ 7.2 kV 400 (top) 400
1- High 18.5 50 @ 7.2 kV 400 (bottom) 400
1- High
(800 A starter) 18.5 50 @ 7.2 kV 653 653
Rating
nameplate

4
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
1.5 Product description
NEMA 3R enclosure stands on a sturdy base. The base is fixed to
the ground with four foundation bolts. It facilitates to keep the flood
water from entering the structure and if some water tends to enter
the structure, it can easily drain out. It also provides access for the
low voltage and medium voltage cable entry. The side covers are
securely assembled to the base, starter or incoming line weld cell,
and the roof. Various designs of side covers are made available to
connect with various adjoining structures.
Figure 2. Front view.
The slanted roof provides a slope for the rainwater to run down the
enclosure. Filter and screen in the roof assembly provide a path for
hot air to exit the enclosure with minimum ingression of rainwater.
The full height door of the enclosure is hinged to the side cover.
The three-point latch helps to secure the door at roof, side cover,
and base. The latch handle has the provision for a padlock. Wind
latch on the door facilitates opening of the door up to an angle of 97
degrees. Neoprene gasket on the door provides protection against
dirt and water.
Side
cover
Door
Rain cap

5
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Figure 3. Front view with full height doors open.
Figure 4. Rear view showing the rear cover.
Figure 5. View showing the three-point and wind latch.
Roof
Base
Upper
rear
cover
Lower
rear
cover
Wind
latch
3-point
latch

6
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
1.7 Main bus
The main bus enclosure is mounted on top of the 80-inch tall vertical
sections. Main bus enclosure may consist of a 1,000 A, 1,200 A,
2,000 A, or 3,000 A rated main bus and/or 1,000 A rated variable
frequency drive (VFD) bus. The standard bus is uninsulated and can
be silver or tin plated. Option of insulated bus is available. The main
bus enclosure in a starter section may include vertical bus drops to
connect to the starter(s). The main bus enclosure in an incoming
line section may include vertical bus drops to connect the incoming
line cables.
Only bottom entry cables option is available.
Figure 6. Main bus assembly.
Main bus assembly
Main bus assembly
(Shown with VFD bus option)
VFD vertical
bus drops
Variable frequency drive bus
Main bus
Main bus vertical
bus drops
Support

7
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
1.8 Bus splicing
Connect the bus bars using the splice plate provided with the equipment. Tighten the bolts to 20 ft-lb (27 N m).
Figure 7. Front view of bus splicing in main bus assembly.
Figure 8. Rear view of bus splicing in main bus assembly.
Access to the bus compartment from front to
connect the busbars with splice plates.
Access to the bus compartment from rear side
to connect the busbars with splice plates.
Main bus
splice plate
VFD bus
splice plate

8
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
1.9 Modifications to equipment
Any modifications to the equipment outside of the assembly instruc-
tions in Eaton documentation may compromises compliance with UL
standard. Please contact the factory with any related questions.
1.10 Documentation reference
Any modifications to the equipment outside of the assembly instruc-
tions in Eaton documentation may compromises compliance with UL
standard. Please contact the factory with any related questions.
IB48041: AMPGARD®400A Motor Starters;
IB48043: AMPGARD®800A Motor Starters; and
IB020003: AMPGARD®RVSS Soft Starters.
For further information on installation and application, refer to the
applicable technical data, publications, and/or industry standards.
Download Eaton electronic information from
www.eaton.com/AMPGARD.
1.11 Eaton contact information
For the location of your nearest Eaton sales office or distributor, call
toll-free 1-800-525-2000 or log onto www.eaton.com/AMPGARD.
Eaton Services and Systems (EESS) can be reached at 1-800-498-
2678.
m CAUTION
THE OUTDOOR RATING OF THE EQUIPMENT IS ONLY VALID WHEN ALL THE
COVERS AND DOORS ARE PROPERLY SECURED OVER THE ENTIRE LENGTH
OF ANY GIVEN LINEUP.
WWHEN WORKING ON MEDIUM VOLTAGE EQUIPMENT, PERSONNEL
MUST WEAR APPROPRIATE PPE.
m CAUTION
BEFORE ENERGIZING THE EQUIPMENT ENSURE THAT:
• THE EQUIPMENT IS SECURED ON A TRUE AND LEVEL SURFACE.
• CONFIRM THAT ALL THE HARDWARE IS IN PLACE AND TORQUED PER
SPECIFIED VALUES.
• CONFIRM NO TOOLS OR OBJECTS ARE LEFT INSIDE THE ENCLOSURE.
• CONFIRM ALL COVERS, DEVICES, DOORS, PANELS ETC. ARE SECURED.
Figure 9. Location of lifting angles.
Section 2: Receiving, handling, and storing
2.1 Receiving
The equipment is shipped assembled in shipping sections/splits.
Depending on the length of the lineup, it may be necessary to
ship the equipment in several shipping sections/splits to facilitate
handling. Each shipping section/split is shipped bolted to a wooden
skid and covered with protective material.
A box(s) labeled “Installation Parts or Ship Loose Parts” is also
included. This box contains the packing list. The packing list identi-
fies all cartons and skids. Each carton and skid are labeled with the
shop order number and a shipping weight. Only accept items from
the shipping carrier if all the items described on the packing list have
been received. If the equipment has been damaged, file a claim
as soon as possible with the carrier and notify the nearest Eaton
representative.
2.2 Handling
The unit is equipped with insulated components for medium voltage
and must be protected against damage during handling. The control-
ler should always remain upright. Exercise extreme care during
any movement and placement operations to prevent dropping or
unintentional rolling or tipping. The preferred method of lifting and
maneuvering the shipping sections/splits into their final position is
with an overhead crane. Lifting angle of appropriate length is bolted
to the top of each shipping section. Lifting clip assemblies are used
to bolt the angle to the roof of enclosure units. Attach a 2-leg sling
with hooks to the lifting angle to lift or move the sections. Do not
allow the angle between the lifting cables and vertical to exceed 45
degrees. If a crane is not available, shipping sections/splits/skids
can be moved by use of rollers. However, safeguards need to be
put in place to assure that the equipment is not deformed during
maneuvering.
Each controller is properly adjusted at the factory before shipment.
However, vibration and mechanical stresses imposed by transit and
installation can adversely affect mechanical interlocks. Therefore, a
final inspection is essential before energizing.
ote:N The assembly will tilt at a slight angle due to the variation in the center
of gravity.

9
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Table 2. Typical section weights.
Equipment
type Actual starter width
Full
stucture
width
Main
bus
rating
Typical
structure
weight
in. (mm) in. (mm) Amperes lbs (kg)
400 A starter/
feeder 36 (914)
44 [1118] 1,000 2,644 [1199]
1,200 2,662 [1207]
2,000 2,696 [1223]
3,000 2,761 [1252]
800 A starter/
feeder 36 (914)
44 [1118] 1,000 2,758 [1251]
1,200 2,789 [1265]
2,000 2,823 [1280]
3,000 2,888 [1310]
Incoming line
18 (457)
26 [660] 1,000 1,387 [629]
1,200 1,395 [633]
2,000 1,419 [644]
3,000 1,471 [667]
18 (457)
with throat
26 [660] 1,000 1,445 [655]
1,200 1,453 [659]
2,000 1,477 [670]
3,000 1,529 [693]
24 (610)
32 [813] 1,000 1,608 [729]
1,200 1,318 [598]
2,000 1,342 [609]
3,000 1,390 [630]
4 in. transition
line
4 (102) 4 (102) -63 (29)
2.3 Storing equipment
Equipment contains insulating materials, electrical contacts, and
operating mechanisms which must be protected against dirt, mois-
ture, dust, foreign materials, corrosive atmospheres, and extreme
temperature changes.
If it is necessary to store the equipment before installation, it would
be advisable to place the equipment indoors in a controlled environ-
ment on a true and level surface to reduce strain and distortion in
the equipment.
m WARNING
WARNING FOR OUTDOOR STORAGE
IN THE EVENT OF STORING THE EQUIPMENT OUTDOORS, ENSURE THAT
THE EQUIPMENT STAYS COVERED SO THAT WATER DOES NOT ENTER THE
GAP BETWEEN TWO UNITS WITHOUT THE RAIN CAP. ALSO, USE SPACE
HEATERS TO AVOID CONDENSATION IN THE ENCLOSURE.

10
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Section 3: Installation
3.1 Procedure of bolting the enclosure to ground
Refer to the following figures and tables for information.
Figure 10. Footprint and lag-down bolt locations.
a These are the locations of 0.88-inch (25.4 mm) diameter mount-
ing holes for securing the equipment enclosure to a finished
foundation. Use 0.50-inch (12 mm) diameter SAE Grade 5 hard-
ware tightened to 70 ft-lb (94 N m) is recommended.
Use of other post-installed mechanical anchor systems, bonded/
adhesive type systems, pre-installed cast-in-place systems such
as shear lugs, L-bolts and J-bolts, or plug welding the equipment
vertical section at the mounting hole locations to cast-in-place
structural steel materials or to a steel house foundation is sole
responsibility of others. Alternative mounting systems must
have equal or greater average ultimate tensile and shear load
capabilities as SAE Grade 5 hardware. In addition to the load
capabilities of the mounting system, the bearing strength and
bearing surface area at each unit vertical section mounting hole
location must be considered. Consult a licensed structural or
civil engineer prior to selecting a mounting system if a system
other than that recommended is preferred.
b This is a medium-voltage cable conduit entry location when
entering from the floor. See shop order floor plan for recom-
mended conduit locations. Conduit projection must not exceed
2.00 inches (50.8 mm).
c Location of low-voltage control conduit wiring opening. Conduits
are limited to a projection of 1.00 inch (25.4 mm) above the
finished floor. Maximum conduit size is 1.25 inches (31.8 mm).
d This is a medium-voltage cable conduit entry location in an
incoming line vertical section when entering from the floor.
See shop order floor plan for recommended conduit locations.
Conduit projection must not exceed 2.00 inches (50.8 mm).

11
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
3.2 Procedure of coupling of two units together
AMPGARD product enclosed in NEMA 3R enclosure can be close
coupled to another gear or incoming line in a single lineup.
Follow the instructions below for coupling of the product enclosed in
NEMA 3 enclosure.
1. Position the units adjacent to each other. Ensure the two
structures are level relative to each other and are mated together
firmly.
Figure 11. Coupling of two units together.
2. Fix the units to each other with the help of 8 coupling holes on
side covers.
3. Install 1/2” hardware with lock washers and 1/2” extra-wide
(1.5” O.D.) feeder washers into each of the threaded holes,
8 places total.
4. Fix the rain cap on the roof. Use the mid rain cap for units in the
centre of the line up. Use the end rain cap at the end of the line
up.
DETAIL B
8 PLACES
DETAIL A
8 PLACES
A
B
REMOVE REAR SHEETS, IN ORDER TO
BOLT THE GEAR TOGETHER.
USE 25A4361G15 KIT
FOR HARDWARE
USE 25A4361G15 KIT
FOR HARDWARE
Detail B
8 places
Detail A
8 places
Use 25A4361G15 kit
for hardware
Use 25A4361G15 kit
for hardware
Remove rear sheets, in order to
bolt the gear full together.

12
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Figure 12. 44W starter coupled with incoming line.
ote:N Remove the lifting angles from top of the units and discard them.
1
1
2
2
3
3
4
4
A A
B B
C C
D D
END RAIN CAP
(906-6515-1)
32.00 44.00
MID RAIN CAP
(904-6212-1)
Mid rain cap
(904-6212-1)
End rain cap
(906-6515-1)

13
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Section 4: Common congurations
Following configurations of the units can be considered.
Figure 13. Incoming line with throat connection + main unit (26-inch width incoming unit + 44-inch width gear).
4.1 Procedure of coupling incoming line with throat connec-
tion with adjacent transformer/switchgear
Follow the instructions below for coupling incoming line with throat
connection with transformer/adjacent switchgear.
1. Remove the sealing ring (marked in Figure 13) from the throat
assembly of incoming line.
2. Position the incoming line and transformer/switchgear adjacent
to each other. Ensure the two structures are level relative to
each other and are mated together firmly.
3. Bolt the throat assembly with the transformer/switchgear.
4. Place the sealing ring on the throat after the assembly is
completed.
1
1
2
2
3
3
4
4
A A
B B
C C
D D
42.32
44.00
26.00
13.28
65.00
102.22

14
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Section 5: Inspection and maintenance
If any self-tapping screws are stripped out, install a ¼-20 nut
with locking hardware on the backside of the screw and torque.
Periodically inspect the air filter in the roof, if present, and replace if
soiled or clogged.
Figure 14. Filter in the roof.
Section 6: Renewal parts
When ordering renewal or spare parts, include as much information
as possible. In many cases, the style number of the new part can
be obtained from identification on the old part. Always include a
description of the part. Specify the rating, structure number, and
shop order number, located on the nameplate of each section.
Filter

15
Instruction Booklet IB48091
Effective October 2022
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
EATON www.eaton.com
Notes:

Eaton
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Cleveland, OH 44122
United States
Eaton.com
© 2022 Eaton
All Rights Reserved
Printed in USA
Publication No. IB48091 / TBG 001596
October 2022
Eaton is a registered trademark.
All other trademarks are property
of their respective owners.
Instructions for Eaton’s AMPGARD®
NEMA 3R motor control center
Instruction Booklet IB48091
Effective October 2022
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety nota-
tions in this document are based on Eaton Corporation’s (“Eaton”)
experience and judgment and may not cover all contingencies.
If further information is required, an Eaton sales office should be
consulted. Sale of the product shown in this literature is subject
to the terms and conditions outlined in appropriate Eaton selling
policies or other contractual agreement between Eaton and the
purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF
FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY,
OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING
CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT
STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF
THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY
ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in
contract, in tort (including negligence), strict liability or other-wise
for any special, indirect, incidental or consequential damage or loss
whatsoever, including but not limited to damage or loss of use of
equipment, plant or power system, cost of capital, loss of power,
additional expenses in the use of existing power facilities, or claims
against the purchaser or user by its customers resulting from the
use of the information, recommendations and descriptions contained
herein. The information contained in this manual is subject to change
without notice.