Rockwell Automation Allen-Bradley CENTERLINE 2500 User manual

CENTERLINE
®
2500
Low Voltage
Motor Control
Centers
Instruction Manual

Important User Information
Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application, Installation and
Maintenance of Solid State Controls (Publication SGI-1.1 available from your local
Rockwell Automation sales office or online at http://www.ab.com/manuals/gi)
describes some important differences between solid state equipment and hard-wired
electromechanical devices. Because of this difference, and also because of the wide
variety of uses for solid state equipment, all persons responsible for applying this
equipment must satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes.
Because of the many variables and requirements associated with any particular
installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of
information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written
permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
WARNING Identifies information about practices or circumstances that can
cause an explosion in a hazardous environment, which may lead
to personal injury or death, property damage, or economic loss.
IMPORTANT Identifies information that is critical for successful application
and understanding of the product.
ATTENTION Identifies information about practices or circumstances that can
lead to personal injury or death, property damage, or economic
loss. Attentions help you:
•identify a hazard
•avoid a hazard
•recognize the consequence
SHOCK HAZARD Labels may be located on or inside the equipment (e.g. drive or
motor) to alert people that dangerous voltage may be present.
BURN HAZARD Labels may be located on or inside the equipment (e.g. drive or
motor) to alert people that surfaces may be dangerous
temperatures.

Instruction Manual
CENTERLINE ®2500 Motor Control Centers

iPublication 2500-IN001A-EN-P - May 2006
Table of Contents
Preface
Recommended Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Purchased Components and Additional Instruction Sheets . . . . . . . . . i
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Chapter 1
General Information
General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Typical Column Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Motor Control Center Sequence Numbering . . . . . . . . . . . . . . . . . . . 1-7
Chapter 2
Transporting Motor Control
Centers
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Shipping Weights and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Receiving, Handling and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Chapter 3
Installation of Columns
Location Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Securing a Motor Control Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Joining and Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Chapter 4
Installing Cable
Considerations for Installing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chapter 5
Commissioning
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Pre-Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Commissioning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Chapter 6
Unit Information
Module Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Unit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operating Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Chapter 7
Door Latches, Operator Handles
and Unit Interlocks
Height Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Door Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Small Rotary Operator Handles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Large Rotary Operator Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Unit Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12

Publication 2500-IN001A-EN-P - May 2006
ii
Chapter 8
Unit Installation and Removal
Withdrawable Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Removing the Unit Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Chapter 9
Motor Control Center Options
DeviceNet Motor Control Centers . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Chapter 10
Maintenance
Suggested Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Chapter 11
Maintenance After Fault Condition
Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Chapter 12
Renewal Parts
Order Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

iPublication 2500-IN001A-EN-P—May 2006
Preface
Recommended
Publications
The following publications supplement this manual. For more information
and further reference, please use these available publications. These
publications are available online at
www.rockwellautomation.com/literature or from your local Rockwell
Automation representative.
Purchased Components and
Additional Instruction
Sheets
Manuals and datasheets for specific components inside the motor control
center (transformers, metering devices, electronic overloads, PLCs, soft
starters, drives, etc.) are shipped inside the motor control center. These
manuals and data sheets must be read and understood before installing and
operating the motor control center. Keep these manuals and other
documentation for future reference.
Definitions
Column –Vertical segment of a motor control center. Columns consist of the
bus system, units and wireways. Sometimes referred to as cubicle.
Conduit – Metal tube that encloses electric wires and cables.
Control station –Door mounted assembly that houses pushbuttons, indicator
lights and other small control devices.
Control unit – Unit that contains any type of power control or metering
device including starters, contactors, AC drives and soft starters.
Disconnected position – Plug-in unit operating position in which line, load,
control, network, and Protective Earth (PE) connections are disengaged, but
the unit is still housed in the column. For more information refer to Chapter 6 –
Unit Information.
Double-front – Configuration in which columns are installed back-to-back.
Columns with double-front construction contain separate power bus systems
that are spliced together. (Figure 1.5)
Feeder unit – Unit containing a disconnection means used to distribute power
to a remote device. Available in two types: circuit breaker or fused disconnect.
Publication Title Publication Number(1)
(1) Some publication numbers contain a revision character’x.’ This character will increase
alphabetically with successive revisions. Always order and use the latest revision available.
CENTERLINE 2500 Receiving Handling and Storage Instructions 2500-IN002x…
CENTERLINE 2500 DeviceNet Motor Control Centers 2500-TD002x…

Publication 2500-IN001A-EN-P - May 2006
ii
Fixed unit – Unit that is permanently mounted in a column. These units
typically house components that are large and/or require more current
capacity than a plug-in unit can provide. Sometimes referred to as a
frame-mounted unit.
Inserted position – Plug-in unit operating position in which the line, load,
control, network, and Protective Earth (PE) connections are engaged. For
more information refer to Chapter 6 – Unit Information.
Locking mechanism – Part of the withdraw lever. This mechanism must be
engaged to select unit operating positions. (Figure 6.10)
Main switch – Disconnecting means for a Motor Control Center. Available in
two types: circuit breaker or fused disconnect.
Module space – Grid size used to determine space distribution within the
motor control center. Height of one module is approximately 80 mm. Module
width is 500 mm.
Motor Control Center (MCC) – One or more columns operating with a
common power bus.
PFCC – Power factor correction capacitor.
Plating – Type of surface treatment that distributes a layer of protective
coating on structural parts.
Plug-in units – Replacable units with line connections made via unit bus line
stabs. Plug-in units include withdrawable units. Sometimes referred to as
withdrawable or removable units.
Protective earth conductor (PE) – Protective circuit busbar. Sometimes
referred to as earth bar.
Shipping block – Also referred to as shipping splits. Two double-front or 700
mm columns joined together at the manufacturing site for ease of
transportation. Shipping blocks cannot be separated at the installation site. A
shipping block can also be one section.
Skilled person – “Person with relevant education and experience to enable
him or her to perceive risks and to avoid hazards which operation or
maintenance of a product can create.” IEC 60204-1, 3.52 and IEV 195-04-01.
Stabs – Assembly located on the back of a unit that is used to make line and
load connections. (Figures 6.3 and 6.4)
Test position – Plug-in unit operating position in which the control, network,
and Protective Earth (PE) connections are engaged, and line and load
connections are isolated. For more information refer to Chapter 6 – Unit
Information.

Publication 2500-IN001A-EN-P - May 2006
iii
Trunk line – Main DeviceNet communication cable within the motor control
center.
Unit – An arrangement of power and/or control devices that are housed
together and inserted into a column. A unit may be used to distribute power or
control a remote device. The size of units is described by module space.
Unit main switch – Disconnecting means for a unit within a motor control
center. Available in two types: circuit breaker or fused disconnect.
Withdraw lever – Mechanism used to insert and remove withdrawable units.
The withdraw lever is used to select an operating position (inserted, test,
disconnected, and withdrawn) and has mechanical detents to ensure that the
lever is securely in position. (Figure 6.10)
Withdrawable unit – Unit where line, load, control, network and PE
connections are made using stabs or connectors. Withdrawable units are
inserted and removed using the withdraw lever.
Withdrawn position – Plug-in unit operating position in which line, load,
control, network, and Protective Earth (PE) connections are disengaged and
the unit is removed from the column. For more information refer to Chapter 6
– Unit Information.

Publication 2500-IN001A-EN-P - May 2006
iv
Notes:

1Publication 2500-IN001A-EN-P—May 2006
Chapter 1
General Information
General Description
Allen-Bradley CENTERLINE 2500 Motor Control Centers (MCCs) are
designed for applications that need to comply with international standards and
practices for low voltage motor control centers. The CENTERLINE 2500
MCC is ideal for tough, demanding industrial applications where uptime and
ease of maintenance is required.
The time-proven CENTERLINE power bus structure is used to distribute line
power throughout the MCC via an isolated bus work structure. Standard,
center-fed, 300 ampere rated vertical bus supplies power to the individual units
above and below the horizontal bus for an effective 600 ampere capacity,
allowing virtually unrestricted unit arrangement. An optional 600 ampere
vertical bus provides an effective rating of 1200 amperes.
CENTERLINE 2500 MCCs utilize units with a full complement of AC drives,
soft starters, and other devices. Withdrawable units are mounted on unit
support pans within the column. Stab assemblies located on the back of the
unit plug into the vertical bus. A mechanical interlock helps prevent the unit
door from being opened while the main switch is in the ON/I position. An
additional mechanical interlock helps prevent the unit from being withdrawn
or inserted when the unit main switch is closed. Separate vertical wireways
isolate control and network cables from power wiring.
Figure 1.1 CENTERLINE 2500 MCC
CENTERLINE 2500 MCCs are designed in a standard width of 700 mm.
Each column is 2300 mm high and 600 mm deep. Double-front columns are
also available. See Tables 1.1, 1.2 and 1.3 for additional options.
One Module Unit
Eight Module Unit

Publication 2500-IN001A-EN-P - May 2006
1-2 General Information
Units are either withdrawable or fixed. Unit size is described in terms of
modules. Each module is approximately 80 mm high. Columns can
accommodate 24 modules of varying unit combinations.
Figure 1.2 Typical Column Dimensions (Dimensions are in mm)
Table 1.1 Column Width
Total Column Width Unit Width Vertical Wireway Width
700 mm (standard) 500 mm 200 mm
800 mm 500 mm 300 mm
900 mm 500 mm 400 mm
1000 mm 500 mm 500 mm
Table 1.2 Column Depth
Front Only Double-Front
600 mm 1200 mm
800 mm 1600 mm
Table 1.3 Column Height
Dimension Measurement
Total Height 2300 mm
Available Unit Height 1980 mm
Top Horizontal Wireway 170 mm
Bottom Horizontal Wireway 115 mm
External Mounting Channel 35 mm
170
1980
115
2300
700-1000
600
500 200-500
35

Publication 2500-IN001A-EN-P - May 2006
General Information 1-3
Typical Column
Construction
Figure 1.3 Typical Column
Lifting Angle
Control and Network Wireway
Top Horizintal Wireway
Closing Plates
Left Side Plate
Horizontal Power Bus
Center End
Closing Plate
Bottom Horizontal Wireway
Closing Plates
Mounting Channels
Bottom Plates
Bottom Horizontal
Wireway Cover
Right Unit Support and Vertical
Wireway Assembly
Vertical Wireway Door
Top Horizontal
Wireway Cover
Top Horizontal Wireway Pan
Top Horizontal Wireway Barrier
Removable Top Plate

Publication 2500-IN001A-EN-P - May 2006
1-4 General Information
Figure 1.4 Columns Installed in a Front Mounted Configuration
Figure 1.5 Columns Installed in a Double-Front Configuration

Publication 2500-IN001A-EN-P - May 2006
General Information 1-5
Technical Data
Table 1.4 CENTERLINE 2500 Specifications
Standards
EN 60439-1:1999 + A1:2004
EN 60204-1:1997
Low-voltage switchgear and controlgear assemblies
Part 1: Type-tested and partially type-tested assemblies
Safety of machinery – Electrical equipment of machines
Part 1: General requirements
EC Directives
73/23/EEC
89/336/EEC
Low Voltage Directive as amended by 93/68/EEC
EMC Directive as amended by 92/31/EEC and 93/68/EEC
Rated Voltages
Rated Operating Voltage, Ue
Rated Frequency, fn
Rated Insulation Voltage, Ui
Up to 690 V, 3-Phase
50 – 60 Hz
1000 V, 3-Phase
Rated Currents
Continuous Current Rating, Ie
Short Circuit Peak Withstand, Ipk
Short Time Withstand Rating, Icw
Horizontal Bus
Up to 2500 A
Up to 176 kA
Up to 80 kA, 1 s
Vertical Bus
Up to 1200 A
Up to 110 kA
Up to 50 kA, 1 s
Creepage Distances and Clearances
Rated Impulse Withstand Voltage, Uimp
Material Group (Overvoltage Category)
Pollution Degree
6, 8, or 12 kV
IIIa (175 </= CTI < 400)
3
Bus Material and Plating
Horizontal Power Bus
Vertical Distribution Bus
Protective Earth Conductor (PE)
Copper (optional tin plating)
Copper with tin plating
Copper (optional tin plating)
Degrees of Protection
IEC 60529 IP 20, 30 or 41
Forms of Separation
IEC 60439-1 Form 3b or 4b
Column Dimensions
Height
Width
Depth
2300 mm
700, 800, 900 or 1000 mm
600 mm (1200 mm, double-front)
Units
Module Size
Modules per Column
Withdrawable Unit Sizes
80 mm high x 500 mm wide = 1 module
24
1, 2, 4, 6, 8, 10, 12 modules
Structural Surface Treatments
Interior
Exterior
High Visibility White Paint (Additional colors available by request.)
RAL 7032 Pebble Grey Paint or Munsell 6.5 Paint (Additional colors available by
request.)
Environment
Storage Temperature
Operating (Ambient) Temperature
Humidity
Altitude
-25°C to +55°C
-5°C to +40°C
Up to 50% at +40°C
Up to 1000 m

Publication 2500-IN001A-EN-P - May 2006
1-6 General Information
Nameplate Data
Each CENTERLINE 2500 MCC column is supplied with a nameplate located
on the enclosure or vertical wireway door, in compliance with IEC 60439-1, 5.1.
See Figure 1.6. for column nameplate information.
Figure 1.6 Column Nameplate
Each unit also has an identification label. On withdrawable units, the unit
identification label is located on the interior of the bottom plate of the unit.
On fixed units, the unit identification label is placed on the interior right side
plate. See Figure 1.7 for unit identification label information.
Figure 1.7 Unit Label
NOTE: The catalog number or serial number and series letter are required to
properly identify the equipment to sales or factory personnel.
Column Number
Catalog Number / Serial Number Series Letter of Column
Power Bus Voltage
and Current Rating
Enclosure Type
Order Number
Catalog Number / Serial Number Unit Location
Device Type and Rating Voltage Rating
Series Letter of Unit

Publication 2500-IN001A-EN-P - May 2006
General Information 1-7
Motor Control Center
Sequence Numbering
Each CENTERLINE 2500 MCC column nameplate identifies column
sequence numbering, e.g. MCC column 1 of 1, 1 of 5, etc. (Figure 1.8)
Figure 1.8 Column Nameplates
Columns are numbered to match factory-supplied MCC elevation drawings.
Numbering each column helps installers and users easily identify MCC
columns and units. If there are questions about column numbering during field
installation, inspection or operation, the following instructions can provide
guidance.
CENTERLINE 2500 MCC columns can be installed or added as follows:
•In non-sequential order
•Addition of a single column (add-on column)
•Addition of multiple columns (add-on lineup of columns)
•Addition of a single column or multiple columns between existing MCC
columns.
CENTERLINE 2500 MCCs are designed so functionality is not affected by
the column numbering sequence. However, it is recommended that
columns be installed in sequential order.
The most important criteria for additions of columns to existing MCCs is
matching the horizontal bus, enclosure type, and network capabilities for the
complete MCC line up, i.e. the voltage, current rating, short circuit withstand
and IP rating for all columns must be consistent.
Identifies Column
Sequence Numbering

Publication 2500-IN001A-EN-P - May 2006
1-8 General Information
Notes:

1Publication 2500-IN001A-EN-P—May 2006
Chapter 2
Transporting Motor Control Centers
Packaging
Standard Packaging
Standard packaging is not waterproof or watertight. Standard packaged
CENTERLINE 2500 MCCs are shipped upright as one or two column
shipping blocks or two or four double-front column shipping blocks. Each
CENTERLINE 2500 MCC shipping block is provided with a lifting angle.
Each column in a shipping block is bolted to the shipping skid with removable
shipping angles and covered with clear plastic wrap. Equipment that extends
from the structures is also protected.
Heavy Duty / Export Packaging
Heavy duty/export packaging is similar to standard packaging, but uses a poly
wrap suitable for occasional water-spray. In addition, wood framing and
sheeting surround the columns. Heavy duty/export packaging is not
watertight, waterproof or intended for long-term storage.
Shipping Weights and
Dimensions
The dimensions and approximate weights provided in the following tables are
for typical MCCs. Refer to the packing slip shipped with your MCC for sizes
not listed and exact shipping weights.
Table 2.1 Standard Packaging
Standard
Packaging
Column
Width (mm) Weight(1)
(kg)
(1) Weights are for an average motor control center with 6 units. Refer to the packing slip shipped with your MCC
for an exact shipping weight.
Height
(mm)
Width
(mm)
Depth
(mm)
Front Mounted
1-Column
700 400 2430 800 800
Front Mounted
1-Column
800 425 2430 900 800
Front Mounted
1-Column
900 450 2430 1000 800
Front Mounted
1-Column
1000 475 2430 1100 800
Front Mounted
2-Column
700 + 700 800 2430 1500 800
Double-Front
2-Column Block
700 800 2430 800 1480
Double-Front
4-Column Block
700 + 700 1600 2430 1500 1480

Publication 2500-IN001A-EN-P - May 2006
2-2 Transporting Motor Control Centers
Table 2.2 Heavy Duty / Export Packaging
Receiving, Handling and
Storage
Refer to publication 2500-IN002x…, Receiving, Handling and Storing
CENTERLINE 2500 Motor Control Centers, for additional instructions. This
publication is shipped with each MCC, attached to the outside of the MCC
within the layer of clear poly wrap.
Receiving
Upon delivery of the MCC, locate the packing slip and inspect the shipment
for lost or damaged items. If lost or damaged items are detected, refer to the
steps described in publication 2500-IN002x….
Standard
Packaging
Column
Width (mm) Weight(1)
(kg)
(1) Weights are for an average motor control center with 6 units. Refer to the packing slip shipped with your MCC
for an exact shipping weight.
Height
(mm)
Width
(mm)
Depth
(mm)
Front Mounted
1-Column
700 500 2563 800 800
Front Mounted
1-Column
800 525 2563 900 800
Front Mounted
1-Column
900 550 2563 1000 800
Front Mounted
1-Column
1000 575 2563 1100 800
Front Mounted
2-Column
700 + 700 1000 2563 1500 800
Double-Front
2-Column Block
700 1000 2563 800 1480
Double-Front
4-Column Block
700 + 700 2000 2563 1500 1480
ATTENTION To avoid personal injury or structural damage, never
attempt to lift or move the motor control center by any
means other than the methods outlined in publication
2500-IN002x…, Receiving, Handling and Storing
CENTERLINE 2500 Motor Control Centers. Motor control
centers are top and front heavy.