GE ReliaGear LV MCC User manual

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL
ReliaGear™ LV MCC
Low voltage motor control center

04 Safety measures and
classifications
05 – 06 Introduction
07 – 09 Receiving, handling and storage
10 – 33 Installation
34 – 35 Testing and inspection
36 – 37 Operation
38 – 39 Maintenance
40 – 41 Reference document numbers
42 – 54 Overload heaters
Table of contents

4RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
Read the following hazard classifications carefully,
and fully inspect the equipment for any identifiable
hazards prior to installation, operation, or
maintenance. The following classifications listed
below will appear throughout this document or
on labels located on the equipment. These are
standard symbols defined by ANSI Z535.4-2011
which were established for recognition of potential
hazards which pose risk to life and property. The
classification is based on the probability and
severity of injury if the hazard is not avoided.
Please follow instructions, warnings, labels, and
codes for proper installation, operation, and
maintenance of equipment and devices. Only
Qualified Persons, as defined by NFPA 70, should
provide installation, operation, and maintenance
on this equipment and devices.
Danger symbol/Warning symbol
The addition of either symbol to a “Danger” or
“Warning” safety label indicates that an electrical
hazard exists that will result in personal injury if
the instructions are not followed.
This document is based on information available
at the time of its publication. While efforts have
been made to ensure accuracy, the information
contained herein does not cover all details or
variations in hardware and software, nor does
it provide for every possible contingency in
connection with installation, operation, and
maintenance. Features may be described herein
that are not present in all hardware and software
systems. ABB assumes no obligation of notice to
holders of this document with respect to changes
subsequently made.
ABB makes no representation or warranty,
expressed, implied, or statutory, with respect to,
and assumes no responsibility for the accuracy,
completeness, sufficiency, or usefulness of the
information contained herein. No warrantees of
merchantability or fitness for purpose shall apply.
This is the safety alert symbol. It is used to alert
you to potential physical injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.
Danger indicates a hazardous situation which, if
not avoided, will result in death or serious injury.
Warning indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
Caution indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.
Notice is used to address practices not related to
physical injury.
Safety instruction (or equivalent) signs indicate
specific safety-related instructions or procedures.
Safety measures and classifications
DANGER
WARNING
CAUTION
NOTICE
SAFETY
INSTRUCTIONS

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' count-
er-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
WARNING
WARNING

6RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
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.
—
02A
—
02B
—
02A
Horizontal bus with
Lexan barrier
—
02B
2500A without fans,
3000/3200 A main
horizontal bus
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.

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 7
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.
Equipment packages
Every package leaving the factory is plainly marked
with the case number and customer's order
number. If the equipment has been split for
shipment, the section numbers of the equipment
enclosed in each shipping package are identified.
Note: To avoid the loss of any parts when
unpacking, the contents of each container should
be carefully checked against the packing list before
discarding the packing material. The contents of
each shipping package are listed on the Master
Packing List. In addition, this list includes the
number of the shipping crate in which
miscellaneous parts needed to install and operate
the equipment (such as hardware, contact
lubricant, touch-up paint, breaker closing devices,
etc.) are located. Normally, such devices are packed
in a cardboard carton and the carton secured in an
empty MCC compartment.
Inspecting for damage
All equipment leaving the factory is carefully
inspected and pakced by personnel experienced
in the proper handling and packing of electrical
equipment. Upon receipt of any equipment,
immediately perform a visual inspection to
ascertain if any damage has been sustained in
shipping or if there are any loose parts. Air Circuit
breakers may be shipped separately in individual
containers with the breaker in the open position.
Air Circuit breakers should be unpacked and visually
inspected for damage or loose parts as soon as
possible after they have been received. Be sure
to inspect all devices mounted or packed inside
compartments of each section to see if any have
been dislodged or damaged.
Filing a claim
If any damage is evident, or indication of rough
handling is visible, file a claim for damage at once
with the transportation company and notify your
ABB sales representative immediately. Information
on damaged parts, part number, case number,
requisition number etc., should accompany the
claim.
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
CAUTION

8RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
MCC enclosure lifting
It is preferable to leave the shipping skids in place
under the MCC until it reaches its final location. The
equipment should be installed in its final location.
The MCC sections are best handled by lifting with a
crane as shown in fig. 03. Removable lifting plates
are provided, as standard equipment, on the top of
each MCC shipping section. To preserve the
external appearance of the equipment, it is
suggested that the lifting plates be left in place
except where adjacent equipment must be bolted
together, i.e. shipping splits, etc.
Utilize Two/four equal length cables and an
overhead crane, each with a minimum load rating of
twice the weight of the MCC. Estimated weights for
shipping splits appear on the Front View drawings.
Note: The angle between the cables and the top of
the equipment must be at least 45 degrees. If this
is not possible because of lack of headspace,
spreader bars must be used. Also, lift cables with
greater load capability may be necessary,
depending upon the angle between the cables and
the crane hook.
Connect a cable from the crane to the Two/four
lifting plates located on the top-front/rear of the
MCC as shown in fig. 03.
Observe the following points when lifting the
equipment:
• Do not pass cables or ropes through support
holes
• Always use load-rated, inspected, and approved
shackles or safety hooks to attach hoisting
equipment to the lifting points.
• Rig slings so that the legs are no less than 45°
from horizontal, as shown in fig. 04.
Take up the slack in the lifting device very carefully
and manually stabilize the MCC to prevent it from
rotating.
The weight of the motor control center can vary.
Chechk the weight of the section against the
capacity of the crane when lifting.
Note: The angle between the cables and the top of
the equipment must be at least 45 degrees. If this
is not possible because of lack of headspace,
spreader bars (not supplied with Equipment) must
be used. Also, lift cables (not supplied with
Equipment) with greater load capability may be
necessary, depending upon the angle between the
cables and the crane hook.
Not furnished with equipment
CAUTION
—
03
—
04
—
03
Using standard lifting
angles or lifting eyes
to hoist the MCC
—
04
Angle 45° between
Equipment Lifting
hook and cables
NOTICE
NOTICE
NOTICE
Spreader
45°
Lifting plate
NOTICE

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 9
Gently lower the MCC section onto the level site
location. If the MCC is roughly handled or jarred, it
is possible to damage or misalign internal
components.
Rollers
If crane facilities are not available, the equipment
may be moved into position by means of
construction rollers placed under the shipping
skids. The MCC may be raised enough for the
placement of rollers by mean of a fork lift or jack.
Ensure adquate number of rollers under the
equipment. Use minimum one roller for each 18
inches of equipment length.
Forklifts
When using a forklift to raise the line-up to position
rollers underneath, proceed as follows:
1. Expand forklift tines to their maximum (widest
extension.
2. Carefully insert tines of forklift below one side of
the MCC line-up at the approximate center of the
panel as shown in fig. 06.
—
05
—
05
Positioning the
MCC with rollers
—
06
Placing forklift tines
under equipment
shipping skids
—
07
Placement of rollers
under shipping skid
Note: Do not attempt to lift or move the equipment
with a forklift positioned in the front or rear of the
equipment.
3. Raise equipment and position one roller under
the skids close to the raised end of the line-up.
4. Carefully lower the gear until it rests on the roller
as shown in fig. 07.
5. Repeat the lifting process at the other end and
place the appropriate number of the rollers under
the skids spacing them evenly across the width
of the line-up.
Note: If shipping skids are removed prior to final
placement of equipment, rollers may only be used
to move the equipment in a direction parallel to the
front.
6. Carefully lower the gear until it rests on the
rollers (fig. 07).
NOTICE
NOTICE
—
06
—
07
7. While carefully pushing the MCC to its final site
position, the rollers that are freed from the rear
of the MCC are then repositioned at the forward
end. This procedure should be continued until the
MCC is in its final location.
8. When the MCC is in its final position, remove all
lug bolts holding the shipping skids to the MCC
line-up.
9. Insert the tines of the forklift at one end of the
line-up, raise slightly, and remove the loose
rollers.
10. Lower the end of the gear carefully to the floor.
11. Raise the other end of the line-up slightly and
remove the remaining roller at that end.

10 RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
Installation
General
This section contains complete instructions for
installing ReliaGear LV Motor Control Center (MCC).
Caution: Personnel installing this equipment must
be thoroughly familiar with this instruction manual
and all articles of the National Electrical Code
applicable to the installation of this MCC. In
addition, all drawings, both mechanical installation
and electrical, must be understood and strictly
followed to prevent damage to the MCC or
equipment being protected by the MCC.
Note: Before installation work is started, it is
important to review all of the drawings provided,
including the equipment arrangement drawings,
site installation drawings, elementary and remote
connection drawings, mechanical connection
drawings, and the summary of euipment list.
All expendable hardware for shipping purposes
only, is painted yellow or tagged with yello adhesive
tape and may be discarded at completion of the
installation phase.
Site location
In general, the location of the MCC equipment will
have been predetermined during the specification
and/or procurement of equipment phases. Indoor
locations with buildings impose certain
requirements which must be met so that the MCC
may operate efficiently with a minimum of
maintenance.
In locating the MCC, adequate aisle space must be
provided at the front and rear of the equipment to
ensure proper ventilation of the euipment and to
allow service and maintenance of the equipment
with the front and rear doors open.
The recommended aisle space is shown on the floor
plan supplied with the equipment drawings.
The MCC equipment should be placed in an area
where clean, dry air is free to circulate around and
above it. Since air is taken into the equipment at
the bottom of each section and exhausted at the
top in some section, a location with good airflow
must be provided for efficient operation as laid out
for each sections.
Refer to NEC Workspace requirements described in
this section.
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.
NOTICE
NOTICE
CAUTION

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 11
Note:
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 1/2 inch diameter, of
Grade 2 steel (minimum) In non-Seismic Zone 4
Locations. Bolts must extend a minimum of 2
11/32 inch above grade to 3/4 inch above the
channel sill. If 13 (330.2mm) deep verical sections
are used, anchor bolts or some form of external
bracing
is required.
2. Seismic Zone 4 IBC testing was performed use
1/2 “ - 13 Grade 5 bolts torqued to 50 foot-
pounds, located in each of the four corners in
each section.
Ref.
Dim.
Section Depth
13° Deep 20° Deep 22° Deep 25° Deep
Width "A" B C B C B C B C
        
        
        
        
        
        
—
08
—
08
Front elevation of
feeder section
—
09
Bottom view: Location
of mounting holes
Indoor enclosures
Front elevation and mounting locations
(13-inch, 20-inch, 22-inch and 25-inch Deep
sections)
—
09
Front
Removable
floor
plates
2.09
[53,1]
2.16
[54,9]
Ø .63 [15,9]
MTG hole
A"
C"
B"
90.00
[2286,0]
12.00
[305,0]
A"
Removable plates cover
wire trough and bus
extension openings
4.40
[111,8]
Front mounted vertical
bus glass polyester
insulted and isolated
full length
Fan is rear when
required
Removable shelves
between units for easy
unit rearrangement
Wiring openings to
rear wiring
compartment
Removable bottom
plate if specified
6 or 12
[292]
cover at
bottom
1.50
[38,1]
NOTICE

12 RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
Note:
1. If anchor bolts are to be inbedded in
the foundation, they must be located according
to the drawing for the specific equipment. Locate
one in the center front and one in the center back.
Anchor bolts should be 1/2 inch diameter, of
Grade 2 steel (minimum) In non-Seismic Zone 4
Locations. Bolts must extend a minimum of 2
11/32 inch above grade to 3/4 inch above the
channel sill. If 13 (330.2mm) deep verical sections
are used, anchor bolts or some form of external
bracing
is required.
2. Seismic IBC testing was performed use 1/2' - 13
Grade 5 bolts, torqued to 50
foot-pounds, located in each of the
four corners in each section.
REF.
DIM.
Section Depth
13° Deep 20° Deep 22° Deep 25° Deep 30° Deep
Width "A" B C B C B C B C B C
          
          
          
          
          
          
Indoor enclosures
Elevation and Mounting
30-inch Deep Sections 600 A to 1200 A Main Bus
—
11
—
10
—
10
End view standard
30" deep
—
11
Bottom view: Location
of mounting holes
Removable
floor
plates
2.09
[53,1]
2.16
[54,9]
C"
Front
Ø .63 [15,9]
MTG hole
23.80
[604,5]
A"
B"









Front
Fan
when required
NOTICE



INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 13
NOTICE
—
12
—
13
Indoor enclosures
Elevation and mounting
30-inch deep sections 2500A without fans,
3000A, and 3200A main bus configurations.
Note:
1. If anchor bolts are to be inbedded in the
foundation, they must be located according to
the drawing for the specific equipment. Locate
one in the center front and one in the center back.
Anchor bolts should be 1/2 inch diameter, of
Grade 2 steel (minimum) In non-Seismic Zone 4
Locations.
Restricted 12"
wireway zone
12"
20"
Restricted 12"
wireway zone
Optional zone
splice bolt acces
Restricted zone
splice bolt acces
Restricted 6" feeders
wireway zone
3"
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 IBC testing was performed use
1/2' - 13 Grade 5 bolts, torqued to 50
foot-pounds, located in each
—
12
End view: Standard
30-inch deep section
for 2500A without fans,
3000A, and 3200A main
bus configurations
—
13
Restricted zones - No
component can be placed
in restricted zones
as shown in figure.
Front
See Detail D
See Detail D
Removable end plates
cover wire trough and
bus extension openings
Deep 30.0
Side view
End plate cover

14 RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
Note: Spacer shell allows unit doors, in spliced
section on the right, to open fully.
—
15
Installation of bottom entry conduits
Conduits can be stubbed in after the location of the
motor control center lineup has been established.
Conduit should be stubbed approximately 2 inches
(51mm) above the finished floor line. Figure 6 and
Figure 7 show the conduit entrance space available
at the bottom of standard sections.
Exceptions to this available space rule are indicated
on drawings for specific installations. Center the
conduit beneath the section vertical wireway to
facilitate direct cable entry.
—
14
Top conduit entry 30-inch
deep section
—
17
—
18
—
14
—
16
—
16
Top conduit entry for
all 2500A without fans,
3000A, and 3200A
configurations
—
17
Bottom conduit entrance
details for standard
13-inch deep section,
low bus position.
—
18
Bottom conduit entrance
details for standard
13- nch deep section,
bus upper position.
—
15
Top conduit entrance
details for std. 20"
x 30' 3" channel
Note: Bottom rear entrance should only be used
with full rear accessibility.
A" 
Front
Spacer shell transition

deep section
Section
depth

depth


NOTICE
NOTICE
A"
Removable top cover plates
Available
conduit space
B"
Front
23.80
[604,5]
3.30
[83,8]
5.25
[133,4]
15.25
[387,4]
3.10
[78,7]
3.10
Front
17.56"
21.56"
27.56"
33.56"
20"
24"
30"
36"
Removable top
plate
Available
conduit space
5.25 (20" deep)
13.25 (30" deep)
13.00
[330,2]
10.66
[270,7]
Vertical wiring
trough area
10.66 x C"
[270.7 x C mm]
C"
B"
3.10
[78,7]
Conduit entry
low bus position
13.84 x 3.92
[351.5 x 9.6]
6 in cover for top
Area for ground
and neutral bus
(if used) low
bus position
A"
Front
13.00
[330,2]
10.66
[270,7]
Vertical wiring
trough area
10.66 x C"
[270.7 x C mm]
C"
B"
Conduit entry
low bus position
13.84 x 6.85
[351.5 x 173.9]
suggested 12 in cover
Area for ground
and neutral bus
(if used) low
bus position
A"
Front

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 15
—
19
—
20
—
22
—
19
Low bus position of
ground and neutral bus
(minimum available
space for conduit
entry) in 13-inch deep
section, 6-inch cover.
—
20
Standard position of
ground and neutral
bus with 12-inch
cover compartment at
the bottom of MCC
—
21
Low bus position of
ground and neutral bus
(minimum available
space for conduit
entry) in 13-inch deep
section, 6-inch cover
—
22
Upper position of
ground and neutral
bus (maximum
space available for
conduit entry), 6-inch
bottom cover
—
23
Available conduit space
for 2500A without fans,
3000A, and 3200A main
bus configurations
—
24
Neutral & Ground bus
positions for 2500A
without fans, 3000A,
and 3200A main bus
configurations
—
23
—
24
Ground bus
1.50
[38,1]
3.00
[76,2]
Neutral bus
If space heater
is specified
with 6" lower
wire way use
top entry only
1.50
[38,1]
3.00
[76,2]
6.00
[152,4]
Neutral bus
Ground bus
Space heater
if specified
Front
—
21
Ground bus
3.00
[76,2]
Neutral bus
If space heater
is specified
with 6" lower
wire way use
top entry only
1.50
[38,1]
9.95
[252,6]
6.55
[166,4]
Front
Space heater if
specified
Front
3.00
[76,2]
6.00
[152,4]
Ground bus
Neutral bus
9.95
[252,6]
1.50
[38,1]
Front
8.20
20"
24"
30"
36"
17.56
21.56
27.56
33.56
3.10
3.51 (20" deep)
13.25 (30" deep)
Available conduit
space
2.00
Neutral bus Ground bus 16.5
25.2
3.00
[76,2]

16 RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
Installation of flooring
For most installations, the MCC floor sills can rest
on the finished floor. The foundation for the
equipment should be level and flat in all planes.
Refer fig. 25 for definition of flat and level.
Although not normally required, the purchaser may
elect to install, level and grout the stel members or
MCC floor sills in the floor, as illustrated in Fig. 26
and Fig. 27.
If the floor sills are removed, lifting and moving the
shipping sections must be done carefully.
—
26
—
25
—
25
Control center floor sills
grouted to the floor
before installation to
provide a level foundation
Surface under motor control center base must be
of non-combustible material unless bottom covers
are installed in each vertical section.
The overall height of the equipment should be
considered with respect to headroom, top conduit
entry space and alignment with other equipment.
Note:
• If anchor bolts are to be imbedded in
the foundation, they must be located according
to the drawing for the specific equipment. Locate
one in the center front and one in the center back.
Anchor bolts should be 1/2" in diameter, of Grade
2 steel (minimum) in non-seismic locations. Bolts
must extend a minimum of 2 11/32" above grade
to 3/4" above the channel sill. If 13" (330.2mm)
deep sections are used, anchor bolts or some
form of external bracing is required.
• Seismic Zone 4/IBC testing was performed using
1/2" – 13 Grade 5 bolts, torqued to 50 foot-
pounds, located in each of the four corners in
each section.
—
27
—
26
Installing steel
floor members
—
27
Installing steel
floor members
If there are vertical sections of varying depths
(such as 13, 20, or 22 inches) in a single lineup, the
fronts of the sections must be lined up for proper
alignment of the main bus bars. Figure 26
illustrates this point.
Note the front alignment of the 13-inch-deep
section.
CAUTION
NOTICE
NOTICE
WARNING
Plane #1
Plumb line Perpendicular
on both
axis to within
25" over
10' span
Plane #2
.062
Surface of pad

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 17
Positioning and joining sections
If groups of sections are to be joined together in a
final lineup, remove the end cover plates and the
plug buttons, from the sides of the sections to be
joined. Figure 10A shows the side views, with the
end cover plates removed, for 20-inch-deep
sections with 2-inch (50.8 mm) and 4-inch
(101.6 mm) bus bars.
Carefully check and remove dirt, dust or bits of
packing material from the interior of all sections.
Use a brush, soft cloth or vacuum cleaner.
Do not use compressed air to clean the equipment
if it contains moisture. Remove all hardware
packages, drawings and other items shipped with
the equipment. Check all nuts, bolts, and electrical
joints for tightness.
All cables entering the bottoms of sections should
be pulled through conduits to a point where they
will be accessible after the equipment is in place.
Sections can be moved to their final position and
properly leveled.
For Type 12 and arc-resistant enclosure, see Figure
29 for proper gasket in between the section splits.
For additional gasket material order part number
245A1888P5.
NEC work space
NEC Work Space is defined in Table 110.26(a)
Working Spaces. Included in these clearance
requirements is the step-back distance from the
face of the equipment.
Table 110.26(a) provides requirements for
clearances away from the equipment, based on the
circuit voltage to ground, and whether there are
grounded or ungrounded objects in the step-back
space, or if there are exposed live parts across from
each other.
The voltages to ground consist of two groups: 0 to
150 and 151 to 600, inclusive. Remember, where an
ungrounded system is utilized, the voltage to
ground will be the greatest voltage between the
given conductor and any other conductor of the
circuit. For example, the voltage to ground for a
480-volt ungrounded delta system is 480 volts.
See Figure 30 for general working clearance
requirements. Distances are measured from the
live parts if the live parts are exposed, or from the
enclosure front if live parts are enclosed. If any
assemblies, such as switchboards or motor control
centers, are accessible from the back and expose
live parts, the working clearance dimensions would
be required at the rear of the equipment, as
illustrated.
Note that for Condition 3, where there is an
enclosure on opposite sides of the working space,
the clearance for only one working space is
required.
—
28
—
28
Side view of a 20-inch-
deep section showing
the cover plates,
plug bottoms and
joining points
—
29
—
29
Type 12 and arc-resistant
gasket material between
section splits
Gaskets
End cover plate
Three-phase bus
Plug buttons
Neutral or ground bus
(when specified)
Wire way
A
A
B
B
C
C
CAUTION

18 RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
(Effectively
insulated)
(Grounded parts,
concrete etc. )
3 ft
3 ft
Exposed live
parts
Exposed live
parts
Electric
equipment 150V
nominal, or less
Electric
equipment 150V
nominal, or less
Condition 1: Minimum 3 ft. for 151-600V
Condition 2: Space would increase to 3 ft. 6 in for 151-600V
Condition 3: Space would increase to 4 ft. for 151-600V
—
30
—
30
General Working
Clearance Requirements
—
31
—
31
Top conduit entry space
for 13-inch sections
—
32
—
32
Top conduit entry
space for 20-inch and
22-inch sections
Table 3: Dimensions for figures 31 and 32
Installation of top entry conduits
After the motor control center is in place and
leveled, and the sections are joined together,
conduits can be brought into the tops of sections
as required. Figure 31 and Figure 32 show the
conduit entry space available at the tops of
standard sections. Refer to drawings for
deviations on specific installations.
Note: Top rear entrance should only be used with
full rear accessibility
Always remove top cover plates when drilling holes.
This prevents small metal chips from falling into
the panel and cause serious damage.
Width Dimension A Dimension B
  
  
  
3 ft
Exposed live
parts
Electric
equipment 150V
nominal, or less
Electric
equipment 150V
nominal, or less
NOTICE
CAUTION
13.00
[330,2]
A"
B"
Front
5.25
[133,4]
13.80
[350,5]
Removable top
cover plates
Available
conduit space
5.25
[133,4]
3.30
[83,8]
6.14
[156]
3.10
[78,7]
A"
B"
Front
Equipment wiring
When pulling, bending, and terminating field
wiring, avoid scraping, cutting or otherwise
damaging cable insulation or strands.
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. See Figures 13,
14 and 15 for approximate dimensions for main,
neutral, and ground bus.
CAUTION

INSTALLATION, OPERATIONS AND MAINTENANCE MANUAL 19
Note: When assembling or connecting to
aluminium bus, apply a suitable joint compound
between the contacting surfaces.
Note: Standard plating is tin. Refer to factory for
alternate plating.
Remove the top Lexan barrier, as shown in Figure
2A and Figure 33, to access the main bus. Refer to
instruction drawings in splice kit. See table 2.
Bus splice kits
—
33
—
33
Horizontal bus barrier
mounting slot and screw
Bolt size Copper joints Aluminium joints
lb-ft N-m lb-ft N-m
    
    
    
    
     
Amps
Main bus splice
assembly kit
Bars/
phase
copper
Size (in.)
(thick x
width)
SC
rating

max
(sym.
amps)
Splice
instruction
drawing
Standard splicing
    
    
    

    
     

    

    
    
    

    
     

     
Table 1: Torque values for various bolt sizes and joint types
*included in kits
Table 2: Bus splice kits splicing from / to ReliaGear
NOTICE
NOTICE
Bus splicing steps for 2500A without fans, and
3200A main bus
For 2500A without fans, and 3200A 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
splice 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.
Step 1: Mount on left side of section
Transition case and
MAIN/MLO section
Splices mounted on
the left side of section
Step 2: Connect feeder section with splices
Connecting Feeder
section with splices
to MAINs/MLOs with
transition case
Step 3: Connect main buses with splices
3 pieces/phase
of splices
Main buses
connected
by splices

20 RELIAGEAR LV MCC LOW VOLTAGE MOTOR CONTROL CENTER
NEMA 3R outdoor enclosure installation
NEMA 3R Installation Instructions
1. Remove left rear cover on right shipping module
(Figure 35A, previous page.) Save the screws for
later reassembly of the cover. Note that the left
module right rear cover has a flange that will be
underneath the removed covered with it is
replaced. This provides an overlapping
connection in the rear of the two spliced
modules (Detail C in Figure 35B).
2. Slide adjoining shipping modules as close
together as possible while carefully aligning the
modules front-to-back.
3. Join shipping modules together using (4 sets)
1/2 hardware (front only). Hardware kits shipping
with modules.
4. Assemble bus splices per splice instructions
(included in splice kit).
5. Install wireway transition channel barrier by
sliding it though the 5 x 5 wireway cutout and
attaching it using (1) 1/4-28 x 3/8 thread rolling
(Figure 35C).
6. Re-attach right, rear cover by re-attaching
1/4-20 x 5/8 sealing screw (Figure 35B, Detail C).
7. Attached center cap using (8) 1/4-20 x 5/8 thread
rolling screws (Figure 35A).
—
34
—
35
Notes:
1. 3-inch floor members can be installed similarly
to standard MCC floor members (Figure 35D).
2. Module doors can be removed by removing
1/4-20 x 3/8 thread rolling screws from door
hinge bracket (Detail D in Figure 35B).
—
34
NEMA 3R outdoor
enclosure installation
—
35
Assembly module line-up
NOTICE
Front left post
Hinge bracket
Piano hinge
Detail D
See detail C
Section A-A
See detail D
B
B
Detail C
1/4-20 x 5/8
thread rolling
washer screw
Right rear
cover
Left rear
cover
Section B-B
35.20 for 20" DP or MCC depth (+) 15.20
105.43
with roof
fan
105.34
w/o roof
fan
MCC depth
5.01 frame exit
A A
3rd module2nd module
Total length of NEMA-3R
1st module
Fasten with
1.4-20 THD.
forming
screws TYP
on top rear
cap
Center cap
Joining 1/2" hardware
fasten 4 plcs
Overlapping
flange
Left rear
cover
Left module Right module