Rockwell Automation Allen-Bradley MCP Manual

Instruction Leaflet for Installation of Q-Frame
Motor Circuit Protector, Type MCP (with Electronic Trip Device)
a WARNING
CONTACT WITH ENERGIZED EQUIPMENT CAN
RESULT IN DEATH, SEVERE PERSONAL INJURY,
OR
SUBSTANTIAL PROPERTY DAMAGE. DO NOT
AlTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT
IS
ENERGIZED. ALWAYS VERIFY THAT NO VOLTAGE IS
PRESENT BEFORE PROCEEDING WITH THE TASK,
AND ALWAYS FOLLOW GENERALLY ACCEPTED
SAFETY PROCEDURES.
ALLEN-BRADLEY
IS NOT LIABLE FOR THE
MISAPPLICATION
OR MISINSTALLATION OF ITS
PRODUCTS.
The user is cautioned to observe all recommendations,
warnings,and cautions relatingto the safety of personnel
andequipmentas well as all general and local healthand
safety laws, codes, and procedures.
The recommendationsand informationcontained herein
are basedon Allen-Bradleyexperienceandjudgement,
but should not be consideredto be all
- inclusive or cover -
ing every application or circumstancewhich may arise. If
any questions arise, contact Allen-Bradleyfor further
informationor instructions.
1. INTRODUCTION
to comply with the applicable requirementsof Underwrit-
ers Laboratories,Inc. Standard UL489 and the Interna -
tional ElectrotechnicalCommission Recommendations
The MCP is aUL
- recognizedcomponent. It is
used primarilyto provide short
- circuit protec tion
as part of acombinationcontrollerwhere othercircuit
protectivefunctions are performed by other devices
within the controller.Since the Q
- frame MCP is a non-
sealed device, it is marked LINE and LOADand is not
N
O . IEC947 - 2.
suitablefor reversefeed applications.
I
Fig. 1-1 Q - frame TypeMCP Motor Circuit
Protector
2. INSTALLATION
The installationprocedureconsists of inspectingthe
MCP and, as applicable, installingaccessories, and ter
-
minals; mountingthe MCP; connecting the line and load
conductors;torquing terminals; and attaching terminal
shields.The MCP, accessories, mounting hardware, and
unmountedterminals may be supplied in separate pack
-
ages. To installthe MCP, performthe followingsteps.
Note: Internal accessory installation in any type of
circuit breakershould be done beforethe circuit
breaker is mounted and connected. Refer to individ-
40752-081(1) Effective 2/03
Bul. 140M
in 3-pole frames only. The MCP is designed
of 600A. . The MCP is available as Type MCP
Motor Circuit Protector (MCP) (Fig. 1-1) has a rating
The Q-Frame instantaneous (magnetic-only)
General Information
This instruction leaflet (IL) gives procedures for installa-
tion, operation, and field testing of Q-frame MCPs.
For this publication, the term motor circuit protection
(MCP) shall also include instantaneous (magnetic)
only circuit interrupters.

Page 2
Terminal
Cat. No.
Terminal Screw
Material Head
Body TY Pe
ualaccessory instructionleafletsfor specific instal -
lation instructions onfield installable accessories.
2 - 1. Compare nameplate data with existing equipment
ratingsand system requirementsto makesure that
the MCP is suitablefor the intended installation.
Priorto mounting,confirm that the MCP has not
been damaged during transit or initial handling.
2
- 2. To installinternalaccessories, removecover screws
and cover.
Note: The MCP handle must be inthetripped or OFF
positionto remove the cover.
2 - 3. If not already installed, mountaccessories (if
required) in MCP.
Note: When required to be removed or replaced, sta -
tionary interphase barriers can only be installedor
removed with circuit breaker inthe tripped or open
position.
AWG Wire
Range
2
- 4.
2
- 5.
MetricWire Wire
Range (MM') Type
After any internal accessories are installed, and
with the MCP inthe tripped position, makesure that
stationary interphase barriers are properly installed
in base. Installcover and secure with panhead
screws. Torque to 20
- 22 Ib - in. (2.26 - 2.49 N.m).
If not already installed, mountwire connecting ter -
minalsas shown in Fig.2 - 1. Securetheterminals to
the MCP usingtwo panhead slotted screws and
lockwashers. Torque to 6
- 8 Ib - ft. (8.14 - 10.85 N.m).
With the MCP mountedand beforethe conductors
are installedand conductor clamping screws
inserted,the terminal mountingscrews may be
checked for correct torque.
Table 2 - 1. Terminal Types 000
Aluminum Socket
Aluminum Socket
Copper Socket
A WARNING
250 - 350
400 - 500 0
250 - 350 0
THE VOLTAGES INENERGIZED EQUIPMENT CAN
CAUSE DEATH
OR SEVERE PERSONAL INJURY.
BEFORE MOUNTINGTHE MCP INAN ELECTRICAL
SYSTEM, MAKESURE THERE IS NO VOLTAGE
PRESENTWHERE WORK ISTO BE PERFORMED.
Note: Dependingontheequipmentconfiguration, the
MCP can be mounted usingdifferent styles of hard
-
ware. Thefollowing steps describe howtomountthe
MCP usingstandard hardware.When special hard
-
ware isneeded(for example, with the motor opera -
tor), the instructionleaflet describing the accessory
also describes the special mounting arrangements.
2 - 6. To mount the MCP, performthe following steps:
120
- 1 50
185 - 240
120
- 1 50
120 - 300
a.
b.
For individualsurface mounting,drill mounting
panel using the drilling plan shown in Fig. 2
- 2.
For panelboard mounting,only load end support
mounting holes are required. For dead front
cover applications,cut out cover to correct
escutcheon dimensions,see Fig. 2-3.
If MCP includesfactory or field installed internal
accessories, make sure accessory wiring is
accessiblewhen the MCP is mounted.
Note: Labels with accessory connection schematic
diagrams are provided onthe side of the MCP.
c. PositionMCP on mounting surface.
Torque Value
Ib
- in. (N.m)
Cu
275 (31.l)
275 (31.l)
275 (31.l)
400 (45.2)
0 The maximumwidth nonstandardwire connector (tang - type) or bus bar connectorthat can be usedwithout reducing
electrical clearance and creepage distances between phases is 1.690 inches.
0 No hardwareor connector should be installed in a mannerto reducethe electrical clearance betweenthe underneath side
of the phasetermination (line or load) and ground without the addition of supplementary insulation.
0 The metric conductor sizes indicatedare the minimum/maximum sizes that can be inserted inthe terminal. Largersize
conductors may be requiredto satisfy ampacity requirementsfor local installation rules.
40752-081(1) Effective 2/03
140U-QTLA2
140U-Q-TLC2
Aluminum Socket
Aluminum Socket 4-4/0 25-120 Cu/Al
Cu/Al
Cu/Al
Cu/Al
4
4
Contact Allen-Bradley for availability.
4
4
4
4/0-600 275 (31.1)

Page 3
d. InstallMCP mounting screws and washers.
Tighten screws firmly, but
do not exceed28 Ib - in.
(3 N.m).
a CAUTION
WHEN ALUMINUM CONDUCTORSARE USED,THE
APPLICATION
OF A SUITABLEJOINT COMPOUND IS
RECOMMENDEDTO REDUCETHE POSSIBILITY OF
TERMINAL OVERHEATING.OVERHEATINGCAN
CAUSE NUISANCETRIPPING AND DAMAGETO THE
MCP.
2 - 7. Connect line and loadconductors and accessory
leads.
2
- 8. After the MCP is installed,check all mounting hard -
ware and terminal connecting hardwarefor correct
torque loading.Torque valuesfor line/loadterminals
are given inTable 2
- 1 and on the MCP nameplate.
2
- 9. Installlineterminal cover on MCPcoverwith mount -
ing screws provided.Torqueto 20 - 22 Ib - in. (2.26-
2.49 N.m).
2-10. When step - type terminals are used
terminal shields(suppliedwith terminals) must
be installed on the MCP (Fig. 2
- 4) and secured
using retainerand screws includedwith theterminal
shield kit. Warning labelsupplied with the kit must
be attachedto the MCP cover.
A WARNING
HAZARDOUSVOLTAGE CONDITIONSCAN CAUSE
DEATH
OR SEVERE PERSONAL INJURY. MAINTAIN
ORIGINAL ELECTRICALCLEARANCEAND
CREEPAGE SPACINGS AT TERMINATIONS.
Panhead Screws
Panhead 140U-Q-TLC2 and Lockwashers
Screws or (Installed before
and 140U-Q-TLA2 Cable Clamping
Terminal Lug Lockwashers Terminal Lug Screws)
Fig. 2 - 1 TerminalInstallation
Line End
0.250-20
(M6 - 1 .O) Tap
(4 Holes)
3 - Pole MCP
Load End
Dimensions in Inches
(Millimeters)
Fig. 2 - 2 3 - Pole MCP Mounting Bolt DrillingPlans
40752-081(1) Effective2/03

Page 4
Line End
% 3 - Pole MCP
I
3.438
(87.33)-w
1.719
* (43.66)
T 5-
3.281
(83.34)
I
I
2.292
(58.22)
I
Load End
4
Fig.2 - 3 MCP Escutcheon CutoutDimensions for 3 - pole
MCP
3. REPLACEMENT OF EXISTING MOTOR CIRCUIT
PROTECTORS
Panel EscutcheonCutout Sizes
Existingcutouts must be modifiedto agree with
requirementsshown in Fig.
2 - 3.
Existing handle mechanisms may needto be
modifiedor replaced.Consult Allen-Bradley for
additional information.
Only Q
- Frame accessories may be
used.
Motoroperators must be replaced.
Key interlock mountingbrackets must be
replaced.
Consult Allen-Bradley for replacementstyles.
Terminals must be replaced, see Table
2 - 1 for
replacementtypes.
Unless noted above, all other physicalcharacter
-
isticsare the same.
HandleThrow Positions
InternalAccessories
ExternalAccessories
Terminal Wire Connectors
Other
a WARNING
CONTACT WITH ENERGIZED EQUIPMENT CAN
RESULT IN DEATH, SEVERE PERSONAL INJURY,
OR
SUBSTANTIAL PROPERTY DAMAGE. DO NOT
ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT
IS
ENERGIZED. ALWAYS VERIFY THAT NO VOLTAGE IS
PRESENT BEFORE PROCEEDING WITH THE TASK,
AND ALWAYS FOLLOW GENERALLY ACCEPTED
SAFETY PROCEDURES.
Note:When replacingan existing MCP or circuit
breaker
of the types listed above, make sure the volt -
age, continuous current, and interrupting rating of
the new MCP are suitable.
40752-081(1) Effective 2/03

Page 5
4. MANUAL OPERATIONAND TRIP UNIT
ADJUSTMENT
ManualOperation
Manualoperation of the circuit breaker is controlled by
the MCP handle and the PUSH
- TO - TRIP button in the
trip unit. The MCP handle has three positions,two of
which are shown on the cover with raised letteringto indi
-
cate ON and OFF. On the handle, ON, OFF, and TRIP
are also shown by a color
- coded strip for each MCP han -
dle position: red for ON, white for TRIP, and greenfor
OFF (see Fig. 4
- 1).
MCP Reset
After a trip operation, the MCP is reset by movingthe
MCP handleto the Reset (extreme OFF) position.
Note: Inthe event of an automatictripping operation,
no MCP should be reclosed until the cause of trip is
known and the situation rectified.
PUSH
- TO - TRIPButton
The PUSH - TO - TRIP buttonoperatesthe MCP tripping
function and may be usedto periodicallyexercisethe
operating mechanism.The rating plug in electronictrip
unitscontains the PUSH
- TO - TRIPbuttonwhich is oper -
ated by finger pressure.
ElectronicTrip Unit Adjustment
The instantaneoustrip level of the trip unit can be
adjusted by rotatingthe adjustment switchon the front
face of the trip unit with a screwdriver. The switch has
several settings as indicatedon the nameplatewith let -
ters A through H (Fig.4 - 1). The ampere settings are
shownonthe MCP nameplateand in Table4
- 1. To adjust
the setting, rotatethe switch clockwise until arrow on
switch pointsto desired setting.
Trip Units
For additional informationon electronictrip units, referto
5. INSPECTIONAND FIELDTESTING
MCPs are designedto provideyears of almost
maintenance
- freeoperation.The following procedure
describes how to do a limited amount of field inspection
and testing of an MCP.
Inspection
MCPs in service should be inspectedperiodically.The
inspectionshould includethe followingchecks 5
- 1
through
5 - 8.
a WARNING
THE VOLTAGES IN ENERGIZEDEQUIPMENTCAN
CAUSE SEVERE PERSONAL INJURY
OR DEATH.
BEFORE INSPECTINGTHE MCP IN AN ELECTRICAL
SYSTEM, MAKE SURE THE MCP
IS SWITCHEDTO
THE
OFF POSITIONAND THAT THERE IS NO
VOLTAGE PRESENTWHERE WORK
IS TO BE
PERFORMED.
A
A CAUTION
SOME COMMERCIAL CLEANING AGENTS WILL
DAMAGETHE NAMEPLATES
OR MOLDED PARTS.
MAKE SURE THAT CLEANINGAGENTS
OR
SOLVENTS USEDTO CLEANTHE MCP ARE
SUITABLE FOR THE JOB.
5-1.
5-2.
5-3.
5-4.
5-5.
Remove dust, dirt, soot, grease, or moisturefrom
the surfaceof the MCP using a lint
- free dry cloth,
brush, or vacuum cleaner.
Do not blow debris into
MCP. If contamination is found, look for the source
and eliminatethe problem.
Switch MCPto
ON and OFF several times to be
sure that the mechanical linkagesoperatefreely
and do not bind. If mechanicallinkagesdo not oper
-
ate freely, replace MCP.
With the MCP in the
ON position, pressthe PUSH-
TO - TRIP buttonto mechanicallytrip the MCP. Trip,
reset,and switch MCP
ON several times. If mecha -
nism does not reset each time the MCP is tripped,
replacethe MCP.
Check base,cover, operating handle,and handle
barrierfor cracks, chipping, and discoloration. MCP
should be replaced
if cracksor severe discoloration
is found.
Checkwireconnectingterminals andothertype bus
bar connectors for loosenessor signs of overheat
-
ing.Overheatingwill show as discoloration,melting,
or blisteringof conductor insulation,or as pitting or
meltingof conductorsurfacesdue to arcing. If there
is no evidenceof overheatingor looseness,do not
disturb or tighten the connections. If there is evi-
40752-081(1) Effective2/03
Instruction Leaflet 40752-072

Page 6
5-6.
5-7.
5-8.
dence of overheating,terminations should be
cleaned or replaced.Before re
- energizingthe MCP,
all terminations and cablesshould be refurbishedto
the originally installedcondition.
Check MCP mounting hardware, and tighten
if nec -
essary.
Exposureto certain types of chemicals can cause
deteriorationof electrical connections. Check area
where MCP is installedfor any safety hazards,
includingpersonalsafety and fire hazardsand take
requiredprecautionary actions.
The operationof MCPswith electronictrip unitscan
be field tested periodically using the electronic test
kit. Contact Allen-Bradley for details.
FieldTesting
Any field testing should be done in accordancewith appli -
cable NEMA Standard.
Table 4 - 1. InstantaneousTrip Settings(Amperes)
Cam
Setting
A
B
C
D
E
F
G
H
MCP Catalog Number
1800
2400
3000
3600
4200
4800
5400
6000
1000
1250
1500
2000
2500
3000
3500
4000
500
600
800
1000
1250
1500
2000
2500
Handle
Position
Indicator
International
Symbols
-
u -ON
Color: Red - ON
0 - OFF
White
- TRIP
Green
- OFF (Reset)
I
lnstahtaneous I
Trip PUSH - TO - TRIP
/ Adjustment Button
Electronic Switch
Trip Unit
Fig. 4 - 1 MCP Manual Controls
4 40752-081(1) Effective 2/03
140M-Q8P-D60 140M-Q8P-D40 140M-Q8P-D25

Page 7
NOTES
40752-081(1) EffectiveJ2/03

Page 8
40752-081(1) Effective: 2/03
Printed in USA/TQC