GE Evolution Series E9000 User manual

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL
Evolution series E9000
Motor control center

04 Warnings, cautions and notes
05 – 08 Introduction
09 Receiving, handling and storage
10 – 29 Installation
30 – 32 Operation
33 – 36 Maintenance
37 – 49 Overload heaters
Table of contents

4EVOLUTION SERIES E9000 MOTOR CONTROL CENTER
Warning notices are used in this publication to
emphasize that hazardous voltages, currents, or
other conditions that could cause personal injury
are present in this equipment or may be associated
with its use.
Warning notices are also used for situations in
which in attention or lack of equipment knowledge
could cause either personal injury or damage to
equipment.
Caution notices are used for situations
in which equipment might be damaged if
care is not taken.
Notes call attention to information that
is especially significant to understanding
and operating the equipment.
Warnings, cautions and notes
As used in this publication

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 5
This publication provides guidelines for installation
and maintenance of Evolution Motor Control
Centers, as shown in Figure 1. The information
provided does not cover all details or variations
in this product offering, nor does it address all
possible contingencies to be met in connection
with installation, operation, or maintenance.
Should further information be desired, contact
Post Sales Support: 1-888-437-3765
Refer to the requisition number found on the front
of the equipment when calling for assistance.
Disconnect equipment from all electrical
services before performing any installation
or maintenance work.
For additional information, including safety
considerations for personnel working on this
product, see NEMA Standard Publication No. ICS
2.3, Instructions on the Handling, Installation,
Operation, and Maintenance of Motor
Control Centers.
General description – vertical section enclosures
Each Evolution MCC vertical section is assembled
with two full-side sheets having openings near the
top and bottom for lateral busing and wiring
between sections. Multiple sections are joined
together at the factory in three-section (maximum)
shipping splits. Each shipping split is provided with
continuous floor sills and a lifting angle. Floor sills
and lifting angles are field removable. Each
shipping split includes a continuous non-removable
main horizontal bus. Main bus splice bars are
provided within each shipping split for field
connecting main busses. Refer to motor control
center outline drawings furnished by ABB for
location of shipping splits within each motor
control center lineup. Hinged doors are provided
over horizontal and vertical wireways. (These doors
can be removed by extracting the hinge pins inside
the doors.)
Vertical sections are normally provided with a
top (12-inch high) horizontal wireway and a bottom
(6-inch high) horizontal wireway. Non-arc resistant
vertical section is provided with a vertical (4-inch
wide) wireway. Each arc-resistant vertical section is
provided with a vertical (3.85-inch wide) wireway.
To open unit doors, rotate the latches 90'
counter-clockwise until the screwdriver
slots or knobs are vertical.
To open wireway doors, rotate the latches
90' clockwise until the screwdriver slots or
knobs are vertical.
Because of the great variety of motor controller
assemblies and components provided within
industrial motor control centers and to satisfy
floor-space limitations at installation sites, a large
variety of vertical section dimensions are provided,
as follows:
• Section Height: 90-inch², 78-inch¹, 66-inch¹ etc.
• Section Width: 20-inch, 24-inch, 30-inch etc.
• Section Depth: 13-inch¹, 20-inch, 22-inch or
deeper for large assemblies.
1. Not available in arc-resistant.
2. Sections with top fans and top vents will add 5" Sections with pull
box and plenum will add 12".
Introduction
—
01
Evolution Series
three-section lineup
—
01
Secure Unit Door Latch shown in secure positionOpen

6EVOLUTION SERIES E9000 MOTOR CONTROL CENTER
General description – arc-resistant
The arc-resistant sections are built with increased
structural capacity. The main enhancements are
thicker gage of steel, latches, hinges, and metallic
PD brackets. In addition, there are two versions
available with and without a plenum. The plenum
option adds 12-inches to the top of the 90-inch
section. The plenumless option should have a 4'
clearance on top of the MCC. The top (12-inch high)
horizontal wireway door and the bottom (6-inch
high) wireway door utilize multi-turn latches to
secure the doors. The remaining latches are ¼ turn
(with options for closed status indication). There is
no variation in the units between arc-resistant and
standard E9000 other than the unit door.
Additionally, the Arc Flash Mitigation units are
compatible in arc-resistant design with arc-
resistant/Arc flash Mitigation door.
General description –
motor control center buses
The main horizontal power bus is located at the top
of the vertical section. The bus bolted joints are
accessible from the front by loosening the barrier
mounting screws and sliding the Lexan® bus barrier
up and forward from the main bus. Figure 2A shows
a horizontal power bus with its Lexan barrier. For
arc-resistant design, uses this same Lexan barrier
with additional Metallic dead front barrier. Figure
2B shows the 2500 A without fans and the
3000/3200 A main horizontal bus configuration.
The vertical bus, either 300 A or 600/850 A, is
connected with two bolts per phase to the main
bus. The phase relationship is A–B–C from top to
bottom and left to right, as viewed from the front.
2500 A Type 12 construction without fans will be
limited to 700A vertical bus.
A continuous horizontal ground bus, sized in
accordance with the National Electrical Code, is
provided near the bottom of all motor control
centers.
An optional vertical ground bus can be provided in
each section providing additional grounding. A
neutral bus is provided, when specified, in the
bottom of the incoming section or in the bottom of
all enclosure(s) as specified.
As shown in Figure 3, the arc-resistant MCC will
include a metallic main bus barrier in addition to
the standard Lexan barrier.
General description –
motor control center units
Consult Publication DET-291 for detailed listings of
Evolution MCC units.
Plug-in units are supplied with stabs rated at either
250 A or 600 A. Arc Flash Mitigation (AFM) units are
supplied with retractable stabs, mechanical
interlocks, racking screw, and visual stab and
shutter indicators. AFM units are available in
plug-in or stab-bolt configuration.
Installation and operation of units, both standard
and AFM, are described on page 18 of this guide.
—
02A
—
02B
—
03
—
02A
Horizontal bus with
Lexan barrier
—
02B
2500A without fans,
3000/3200 A main
horizontal bus
—
03
Metallic horizon-
tal bus barrier for
arc-resistant design

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 7
Bus splicing
Main, neutral and ground bus splice bars (with all
associated hardware) are furnished, as necessary,
to join sections together. They are located in the
first section to the right of the joint.
Remove the top Lexan barrier, as shown in Figure
2A and Figure 04, to access the main bus. Refer to
instruction drawings in splice kit. See Table 2.
Arc-resistant design has metallic barrier in addition
to the Lexan barrier which also must be removed to
access the main bus. Arc-resistant shipping splits
will arrive with end caps. When bus splicing, please
remove these end caps to make connection, only
the furthest most left and right end caps shall
remain.
—
04
Horizontal bus barrier
mounting slot and screw
—
04
Amps Main Bus Splice
Assembly Kit
Bars/
Phase
Copper
Size (in.)
(thick x
width)
SC Rating

(sym.amps)
Splice
Instruction
Drawing*
Standard Splicing
      
      
     

     
       

     

      
     
     
      

       

      
Bolt Size Copper Joints Aluminum Joints
lb-ft N-m lb-ft N-m
    
    
    
    
     

Torque values for various bolt sizes and joint types.
Bus splice kits

 When assembling or connecting
to aluminum bus, apply a suitable
joint compound between the
contacting surfaces.
*Included in kits
 Standard plating is tin. Refer to
factory for alternate plating.

8EVOLUTION SERIES E9000 MOTOR CONTROL CENTER
Bus splicing steps for 2500A without fans,
3000A, and 3200A main bus
For 2500 A without fans, 3000 A, and 3200 A main
bus, it is recommended to pre-mount the align and
torque all splices in all phases before you join the
section if possible. If splicing from the left, pre-
mount the splices and pre-torque bolts from right
case side opening. If splicing from the right, slide in
bus bars through left case side opening and access
the bolts for torquing through the vertical wireway.
 Mount on left side of section
Transition case and
MAIN/MLO section
Splices mounted on
the left side of section
Connect feeder section with splices
Connect main buses with splices
Connecting Feeder
section with splices
to MAINs/MLOs with
transition case
3 pieces/phase
of splices
Main buses
connected
by splices

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 9
Receiving
Before leaving the factory, the motor control center
is given a final mechanical and electrical inspection
and is packed in accordance with the best practices
for electrical equipment.
On receipt of any apparatus, make an immediate
inspection for any damage or loss of equipment in
transit. Should damage or missing material
be noted, file a claim immediately with the carrier
and notify the nearest office of ABB. Information
such as a description of the damage, the shipping
crate numbers, the requisition numbers and
the panel catalog number should accompany
the claim.
Handling
Motor control center sections are always shipped in
an upright position, in single or group sections.
Sections must be maintained in an upright position
during all handling.
Never attempt to jack, lift, or move the equipment
at points other than the lifting angle or floor sills.
Use two or more chains or cables to distribute the
weight evenly. Pinch bars, pipe rollers or slings are
useful implements for handling equipment; but be
careful to maintain distributed loading and to
always apply leverage at the floor sills and/or
lifting eyes. Figures 05A and 05B illustrate typical
handling techniques.
Storage
If it is necessary to store the equipment for any
length of time, be sure to observe the following
precautions:
• Uncrate the equipment.
• Store the equipment in a clean, dry, humidity-
controlled area at moderate temperature. Cover
with a suitable canvas or heavy-duty plastic cover
to prevent entrance of foreign material.
• If equipment must be stored in cool or high
humidity areas, in addition to completely
covering the equipment, provide a heat source to
prevent condensation of moisture in the
equipment. Energize space heaters (if furnished
in the equipment) or place a standard 120-volt
lamp rated at 75 watts inside the bottom of each
vertical section.
Receiving, handling and storage
—
05A
Using standard lifting
angles or lifting eyes
to hoist the MCC
—
05A
—
05B
—
05B
Positioning the
MCC with rollers

10 EVOLUTION SERIES E9000 MOTOR CONTROL CENTER
Installation

1. If anchor bolts are to be inbedded in the
foundation, they must be Equipment.
Locate one in the center front and one in
the center back. Anchor bolts should be

(minimum) In non-Seismic Zone 4
Locations. Bolts must extend a minimum
of 2 11/32 inch above grade to 3/4 inch
above the channel sill. If 13 (330.2mm)
deep verical sections are used, anchor
bolts or some form of external bracing
is required.
2. Seismic Zone 4 IBC testing was

torqued to 50 foot-pounds, located in
each of the four corners in each section.
Ref.
Dim.
Section Depth
   
Width "A" B C B C B C B C
        
        
         
        
        
        
—
Bottom view: Location of mounting holes
Indoor enclosures
Front elevation and mounting locations
(13-inch, 20-inch, 22-inch and 25-inch
Deep sections)
Before any installation work is begun, consult
all drawings, as well as all applicable contract
drawings, for the particular installation. Pay
particular attention to the location of units in
the motor control center and their relations to
existing or planned conduits and busways.