SafeGear MCC IOMM Controller July 2017

2017
SafeGear® Motor Control Center

Controller
Installation, Operation and Maintenance Manual
Controller
Installation, Operation and Maintenance Manual
Table of Contents
1
1. Foreword 1
2
2. Introduction & Safe Practices 2
3
3. Receiving, Handling and Storage 3
4
4. General overview 4
5
5. Normal Service Conditions 4
6
6. Construction 5
7
7. Extraction Truck Assembly 5
8
8. Racking System and Disconnect 6
9
9. Shutter’s Charger Mechanism 7
10
10. Insertion and Removal 8
11
11. Compartment Detail 10
12
12. Maintenance 11
13
13. Accesories 12
14
14. Appendix 13
15
15. End of life of product 24
16
16. Methods of disposal 24
Controller
1. Foreword
This booklet provides information for the Medium Voltage (2.4 kV to 6.9 kV) SafeGear MCC Controller as described below.
All information in this booklet was current at the time of printing. All references in this booklet are determined from viewing the controller from the front.
DRAWOUT (REMOVABLE):
A drawout controller is a controller that may be removed from a cell without the unbolting of any connections or mounting supports. It utilizes specific interlock
devices that function according to ANSI standards, which allow for the safe removal of the device with minimal risk to personnel. It is intended for use in SafeGear®,
ADVANCETM, or abbreviated versions of ABB and OEM switchgear. It also contains plug-in primary and secondary disconnects with two physical ANSI operating
positions within the cell: Connected and Test /Disconnected. In the connected position both primary and secondary contacts shall be engaged. In the Test/
Disconnected position, primary contacts are separated from the bus contacts while the secondary contacts remain engaged to the controller to be tested. The
connection of secondary circuits shall be completely automatic, it shall not depend on operator interaction.
FIXED-MOUNT:
A Fixed-mount controller is intended to be mounted as a stationary device. It does not contain any racking related interlocks and/or primary leads. Primary
connections are hard bussed to the associated gear in which the controller is installed by the consumer. Secondary wiring is terminated on a 5 foot length of wire
from the compartment to secondary plugs that are the same as the draw-out versions. Plugs and associated pins can be purchased for plug in connection or the
wires may be cut to provide direct connections. The fixed mount version must be provided with the plugs in this manner to meet UL listing and to insure proper
testing of the controller. The customer is responsible for any damage to the controller that is due to mis-wiring of the controller.
1 SafeGear® Motor Control Center Controller Installation, Operation and Maintenance Manual
2. Introduction & Safe Practices
Introduction:
The purpose of this manual is to provide instructions for unpacking, storage, installation, operation, and maintenance for the SafeGear® controller. This manual
should be carefully read and used as a guide during installation, initial operation, and maintenance.
The specific ratings of each model controller are listed on the individual nameplates. The SafeGear® controller is a protective device. As such, they are maximum
rated devices. Therefore under no circumstances should they be applied outside of their nameplate MCC ratings. Refer to ANSI and IEEE guidelines referring to
the use of controller applications.
WARNING
THE CONTROLLERS DESCRIBED IN THIS MANUAL ARE DESIGNED AND TESTED TO OPERATE WITHIN THEIR NAMEPLATED RATING. OPERATION
OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL, RESULTING IN PROPERTY DAMAGE, BODILY INJURY AND/OR DEATH. ALL ANSI
AND NEC SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE ADHERED
TO STRICTLY.
SAFE PRACTICES:
The design includes several interlocks and safety features which help ensure safe and proper operating sequences.
To ensure safety of personnel associated with installation, operation, removal, and maintenance of these controllers, the following recommendations must be
followed:
Only qualified persons, as defined in the safety standards applied in the country where are going to be installed the controllers, who are familiar with the installation
and maintenance of medium voltage circuits and equipment should be permitted to work on these controllers.
Read these instructions carefully before attempting any installation, operation, or maintenance of these power controllers.
DO NOT work on an energized controller.
DO NOT work on a controller unless all components are disconnected by means of a visible controller and securely grounded.
DO NOT work on a controller with power supplied to the secondary control circuit.
DO NOT defeat safety interlocks. This may result in bodily injury, death and/or equipment damage.
DO NOT work on a closed controller.
DO NOT work on a controller with charged energy.
DO NOT use a controller by itself as the sole means of isolating a medium or high voltage circuit.
DO NOT leave a controller in an intermediate position in a cell. Always place the controller in the Disconnect/Test or Connect position without hesitation between
positions.
NOTICE
FAILURE TO OBSERVE THE REQUIREMENTS OF U.S. OSHA STANDARD 1910.269 CAN CAUSE DEATH OR SEVERE BURNS AND DISFIGUREMENT. THIS
STANDARD SPECIFICALLY PROHIBITS THE WEARING OF POLYESTER, ACETATE, NYLON, OR RAYON CLOTHING BY EMPLOYEES WORKING WITH
EXPOSURE TO ELECTRIC ARCS OR FLAMES.
SafeGear® Motor Control Center Controller Installation, Operation and Maintenance Manual 2
3. Receiving, Handling and Storage
SafeGear® MCC controllers are subject to complete factory production tests and inspection prior to packaging and shipment. The shipping package is designed to
provide reasonable protection during shipment and to provide convenient handling. Accessories such as racking handles are shipped separately from the controller.
Receiving:
Immediately upon receipt of the controller(s), examine the shipping container to determine if any damage or loss was sustained during transit. If damage or indication
of rough handling is evident, take photos and file a damage claim at once with the carrier and promptly notify your ABB representative. ABB is not responsible for
damage of goods after delivery to the carrier. However, ABB will lend assistance if notified of claims. Use care in unpacking to avoid damaging any controller parts.
Unpack controllers immediately upon receipt. If unpacking is delayed, difficulty may be experienced in making a claim for damages not evident upon receipt. Check
the contents of each carton against the packing list before discarding any packing material. If any discrepancy is discovered, promptly notify the nearest district
office. Information specifying the purchase order number, controller serial number, and part numbers of damaged or missing parts should accompany the claim.
Handling:
SafeGear® MCC controller shipping crates are designed to be handled by fork lift.
See the Accessories section for information regarding the lifting accessories available for use with the SafeGear® MCC controller.
Once removed from the shipping container, the controller wheels are designed to move the controller across a clean smooth, paved even surface.
Care must be taken not to damage the secondary locking tab (Figure 2) when transporting, rolling, or handling the SafeGear® MCC controller.
DO NOT pull the controller by the front handles with the controller in any position other than full Disconnect.
DO NOT move the controller by pushing on the embedded pole assemblies or primary leads of the embedded poles. Damage and misalignment of the pole
assemblies will occur if force is applied to them.
Storage:
Controllers should be installed in their permanent location as soon as possible. If the controllers are not placed in service for some time, it is advisable to store in a
covered, well-ventilated, dry, dust-free, non-corrosive ambient, away from any flammable materials and at a temperature between 23 °F and 104 °F. In any case,
avoid any accidental impacts or positioning which stresses the structure of the apparatus.
This may be done by keeping the controller in its original shipping container and storing it in a warm, dry, and uncontaminated atmosphere. The controllers should
be stored to minimize condensation. Moisture can cause deterioration of metal parts and high voltage insulation.
Prior to storage of the controller, verification should be made that it is free from shipping damage and is in satisfactory operating condition.
CAUTION
Do not stack controllers.

Shipping boxes can and will collapse causing damage to the controllers and or personnel and equipment.
4. General overview
The SafeGear® Controller is a magnetically actuated and latched controller
capable of a very high number of operations due to its robust design.
Controller’s ratings are 400 A and 720 A and NEMA Class E2. It conforms
to latest international standards such as UL 347, ICS3 part 2.
Controller Features
·· Fuse status indicator

·· Position indicator
·· Operation counter
·· Controller status
·· Local trip on the front side
·· Blown Fuse Mechanism
·· Extraction truck
Fig. 1 SafeGear® MCC Controller
5. Normal Service Conditions
Normal operation conditions

Minimum ambient temperature -5°C
Maximum ambient temperature 40°C
Maximum 24 hours ambient relative humidity 85% Non-condensing
Normal operational altitude above sea level 1000m
Normal non-corrosive and non-contaminated atmosphere
Table 2
If the contactor is to be used in conditions other than those specified above, please consult the factory.
Controller Weight Approximate

Controller 400 A 720 A
Maximum Weight approximate - lbs (kg) 375 (170) 750 (240)
Table 3
The table shows approximated values for controller weight with 500VA CPT.
Storage
Place the equipment on the shipping base. Store all equipment indoors in a well-ventilated area. The location where the contactor is to be installed should be free
from dust, corrosive gas and moisture. When it is to be used in a chemical plant or in outdoor applications, take necessary precautions against corrosion, water
seepage and condensation.
The storage building should have a well-drained paved floor. The temperature should be between 23°F (-5°C) and 104°F (40°C). The air should be dry (50%
maximum humidity).
6. Construction
4 4 4
5 3
1. Extraction Truck
2. Fuse Box
3. Contact Fingers (They are different between 720 A and 400 A)
4. Shutter’s charge mechanism
5. Vacuum bottles
6. CPT (Control Power Transformer)
7. Extraction Truck Assembly

ABB’s extraction truck assembly for MCC is integral to the controller itself, in lieu of being inside the MCC controller cell.
Vacuum controller, power fuses, control power transformer (CPT) and all auxiliary contacts are mounted on a truck assembly and are completely removable from
the cell to allow maintenance outside the cell and away from energized primary and secondary circuits.
Fig. 2 Extraction truck assembly
8. Racking System and Disconnect
A racking system is integral to the controller. Racking is only possible with the door closed. The racking system has two positions (Connected and Test /
Disconnected). In the connected position both primary and secondary contacts shall be engaged. In the test/disconnected position, primary contacts are separated
from the bus contacts while the secondary contacts remain engaged to the controller to be tested.
Interlocks
The truck has three different mechanical interlocks in the controller construction:
1.
1 The first makes it impossible to rack the controller in with the door open. (Highlighted in green).
2
1. The second interlock does not allow opening of the door with the controller in connected position. (Highlighted in green).
1.
3 The third and last interlock mechanism, is a padlock upon the principal screw (worm gear) to prevent racking when the controller is in connected or
disconnected position. (Highlighted in green).
9. Shutter’s Charger Mechanism
When the controller is removed, the shutter’s position cover the primary contacts in the controller compartment. When charged the springs and the controller is
inserted, the shutter’s charge mechanism provides the energy required to actívate the opening of the shutter’s charge mechanism and to permit the conection
with the primary contacts.
Procedure
Before placing the contactor inside the module, is necessary to manually charge the springs showns.
Fig. 3 Spring before being charged
Steps for charging the springs manually:
1.
1 The spring is in its normal position.
2.
2 Charge the spring manually (as shown in the picture).
3.
3 In this position, the spring is charged. (Note: When the spring is charged, it maintains its position as shown in the picture).
1 2 3
10. Insertion and Removal
This section describes the necessary steps for inserting and removing a controller to and from the “Disconnect” position. Racking the controller to and from
Disconnect/Test and Connected (Control circuit checkout) positions is covered in the next section. The following rules should always be observed when inserting
a controller into the MCC compartment.
• NOTE: ABB has specific accessories to be used with ABB controllers.

• ALWAYS compare the controller ratings nameplate with the MCC ratings nameplate. Verify controller secondary control voltage ratings are in
agreement with the MCC control voltage ratings.
• DO NOT attempt to insert the controller prior to a complete inspection of both controller and MCC compartment controller and compartment
must be free of tools, obstructions or foreign objects.
• DO NOT attempt to insert or rack a closed controller.
• DO NOT force a controller into or out of the cell.
WARNING
Do not attempt to remove the controller from the controller compartment without the required ramp, dolly or lift truck. Refer to the
specific MCC comp Installation, Operation and Maintenance manual for details.
Before placing the controller inside the compartment, is necessary to charge the springs of the shutter’s charge mechanism.
CAUTION
Use of any other racking device not approved by ABB will void the warranty!!
Approved device shown below.
INSERTION:
(Refer to Figure 4 for compartment detail and Appendix A for controller detail)
1. Open MCC controller compartment door to its fully opened position.

2. Align lift truck
3. Raise platform for easy insertion of platform guides, then lower lift truck until platform guides are fully engaged and hooked into MCC compartment cell.
4. Pull back on lift truck to insure platform is fully engaged and level.
5. Grasp lower truck handles on both sides of controller and pull handles inward to unlatch the controller from the lift truck platform.
6. Push controller into controller compartment, pulling handles inward, before front of controller truck reaches front of MCC frame or damage to cell interlock
tabs will occur. Interlocks may prevent or restrict insertion.
7. Align cell interlock tabs with controller compartment and push handles out to fully engage tabs into slots (controller truck will be flush with MCC frame).
CAUTION
Always keep in mind the recommended safety procedures when working in medium voltage equipment.
For the safety of personnel extracting the controller of the MCC, all components should be electrically disconnected by means of a visible break, securely
grounded, locked out and tagged in accordance with personnel precautions.
REMOVAL:
(Refer to Figure 4 for compartment detail and Appendix A for controller detail).
1. Confirm (through window) that controller has been opened and racked to the disconnect position.
2. Open MCC controller compartment door to its fully opened position. The interlocking system prohibits racking while the door is open.
3. Align lift truck left and right platform guides with MCC latch openings.
4. Raise platform for easy insertion of platform guides, then lower lift truck until platform guides are fully engaged and hooked into MCC compartment cell.
5. Pull back on lift truck to insure platform is fully engaged and level.
6. Grasp lower truck handles on both sides of controller and pull handles outward to unlatch the controller from the MCC frame.
7. Pull controller from compartment onto lift platform insuring cell interlock tabs are engaged into the platform slots.
RACKING:
The racking system is unique and features two-positions:
“Test/Disconnect” position, primary contacts are separated from the bus contacts while the secondary contacts remain engaged to the controller to be tested.
Shutters shall be interlocked in the closed position
“Connected” position, both primary and secondary contacts shall be engaged.
CONTROL CIRCUIT CHECKOUT:

The preferred method to check the control circuit is to furnish a separate temporary control power source of the required control voltage rating. The temporary
source must have a properly coordinated backup protective device in the circuit.
Set the device to clear any faults that might occur. Initially all controllers should be racked out (“DISCONNECTED” position) and the main circuit deenergized and
grounded. When AC control power is from control power transformers in the MCC, remove all fuses in the transformer circuits.
1. Make sure all controller are open (OPEN).

2. Rack the controllers out to the open position (DISCONN.).
3. Open all control power source contacts, if supplied.
4. Check each control switch or push-button. Make sure that they are open position (OPEN).
5. Connect a temporary control power source to the circuit load terminals in the MCC. Energize the control circuit from the temporary control power source.
6. Rack the controller to the connected position (CONN.). Open and close the controller to verify the correct connection in the secondary plug. Repeat the same
operation for every controller assembly, one at a time
7. Test the controllers for closing and tripping, operated on manual and electrically through the control circuit, while they are in the “DISCONN.” position.
8. De-energize the control circuit. If AC control power is from transformers in the MCC, remove the separated temporary control power source. Reinstall all fuses
in the transformer circuit.
9. Set all relays, regulators and other devices for proper operation of loads. The factory does not set the relays.
NOTE: Verify the proper phasing of all main circuits according to diagram.
11. Compartment Detail
2
4
Fig. 4 Basic Cell
1. Compartment Slots for engaging the lift trucle

2. Ground Bus
3. Interference Blocking Plate
4. Secondary Disconnects
5. Wheel Rails
6. Shutter
7. TOC Switch
12. Maintenance
Extraction Truck Assembly
The extraction truck assembly requires visual inspection of hardware, lubrication and operations during routine maintenance.
With the controller outside the cell, verify all visible hardware tightness, including handles (8) and wheels (6). Wheels should rotate freely by hand movement. Replace
or tighten any missing or loose hardware.
With the controller outside the cell, rotate the racking screw as though racking the controller to the connect position. This process will expose surfaces inside the
truck that need to be inspected and lubricated. Apply grease “Moykote 33” to entire racking screw, pin and bushing surfaces. Inspect the position Release Shaft
(3), cell locking tabs (7) and secondary Locking Tab (1) for any damage. Return truck to disconnect position. As a precaution, do not operate the controller outside
the cell unless the truck is in the full disconnect position.
11
7 2 6
8 5
9
10
Fig. 5 Truck shown with controller removed
1. Secondary Locking Tab 7. Cell Locking Tabs

2. Racking Screw 8. Insertion/Removal Handles
3. Position Release Shaft 9. Collar
4. Grounding Connection 10. Racking Lock For Tag-Out
5. Position Release Lever 11. Racking Pin
6. Wheels
13. Accessories
Lift Truck
A lift truck is required for all primary devices. The lift truck docks with the MCC, allowing a primary device to be
raised or lowered to the appropriate height and safely rolled into the controller compartment. The lift truck has
wheels for easy maneuvering in restricted aisle space common to MV MCC installations. A motor lift is available
as an option. All primary devices have self-contained wheels for easy floor rolling.
CAUTION
• Always follow safe work practices when lifting the controllers to protect the safety
of personnel and equipment.
• Always inspect lift truck for signs of wear or damage before use.
• Do not use a lift truck that is damaged or worn.
• The lift truck IS NOT to be used for insertion of drawout controllers into MCC
compartments.
• The lift truck IS NOT to be used as the sole means of support when servicing the
controller.
Fig. 6 Lift Truck
Racking Handle
The racking handle is designed to easily adjust the device into and out of a MCC compartment. It is also used
to change the position of the device from the Disconnect and Connect positions. Press down on the release
lever and rotate racking handle clockwise to rack in (toward Connect) and counter clockwise to rack out (from
Connect).
Racking Handle
CAUTION
• Use of any other racking device not approved by ABB will void the warranty!!
• ABB will not be responsible for damage caused by the use of racking tools other than ABB’s.
Test Jumper
A “test jumper” is an extension cord. It allows connection of secondary contacts on a vacuum controller to
the MCC while outside a controller compartment. This enables the controller to be electrically operated using
controls in the MCC, or electrically charged after manual operation of the controller in a MCC aisle.
Test Cabinet
A “test cabinet” is a wall-mounted control cabinet connected to a separate power source and containing
switches to open and close a controller. The test cabinet has a female connector and an umbilical cord (stored
inside the cabinet) for connection to the controller, and serves as an aid to controller inspection and maintenance
in MCC aisles or work áreas.
14. Appendix
Appendix A
Basic Controller Layout
1. Dead Front
2. Fuse Status Indicator
1 3. Position Indicator
4. Operation Counter
5. Controller Status
6. Local Trip
7. Collar
4
8. Racking Screw
2 9. Position Release Lever
3 6 10. Insertion/ Removal Handle
5 11. Cell Interlock Tab
7 8 9 10 11
16
15
12. Truck
13. Wheel
14. CPT
15. Shutter’s Charge Mechanism
16. Fuse Box
14
12
13
Appendix B
Basic Controller Dimensions
DRAWOUT 400 A CONTROLLER:
DRAWOUT 720 A CONTROLLER:
Appendix C
Antisingle Phasing
What is a Phase Loss?

When one phase of a three-phase system is lost, a phase loss occurs. This is also called ‘single phasing’. Typically, a phase loss is caused by a blown fuse, thermal
overload, broken wire, worn contact or mechanical failure. A phase loss that goes undetected can rapidly result in unsafe conditions, equipment failures, and costly
downtime.
Voltages and currents in a three-phase system do not typically just drop to zero when a phase is lost. Often measurements yield confusing values that require a
great deal of complex analysis to correctly interpret. Meanwhile, damage and downtime of the equipment continues to rise.
What happens with a phase loss?
When a 3-phase motor runs with one phase missing, the remaining 2 phases will take more load from the missing phase making them work harder, over heat and
burn out.
To avoid the above condition the SafeGear MCC controller has a blown fuse mech that envires thar all 3 phases and disconnect if only a single or two fuses blown.
Blown fuse mechanism
1
1. The fuse is working in the right position. 2
1. The “sensor” is not transmitting a signal.
1.
3 When a fuse is blown, the mechanism is activated. 1.
4 The “sensor” is transmit a signal to the relay and the
3-phases are disconnected.
NOTE: This configuration is available and depends of relay’s programming by others.
Appendix D
Instructions for Replacement of Fuses
The instructions provided below for the replacement of the motor controller fuses cover the minimum required information and considerations for proper replacement
of the fuses. Always keep in mind the recommended safety procedures when working in medium voltage equipment. The fuse replacement must only be carried
out once the controller has been electrically opened, racked out and removed from the MCC compartment.
For the safety of personnel extracting the controller of the MCC, all components should be electrically disconnected by means of a visible break, securely grounded,
locked out and tagged in accordance with personnel precautions spelled out in ANSI/ASSE Z244.1 “Control of Hazardous Energy – Lockout/Tagout and Alternative
Methods”.
Once the controller is outside the MCC compartment, follow the instructions below for the replacement of the fuses:
1.
1 Remove the 4 bolts that secure the galvanized metalsheet cover
(the dead front).
1.
2 Verify the right position of the pins of the blown fuse mechanism that
is shown in the picture below on the right.
The picture shows the

improper position of the
pins of the blown fuse
mechanism for 400 A
controller.
The picture shows the right position of the pin of the blow fuse
mechanism for a 720 A controller.
3
1. Remove the plastic bolts on the cover that supports the
blown fuse switch.
4
1. Remove the blown fuse mechanism.
5
1. Remove the 4 bolts that fix the fuse.
6
1. Extract the insulation barrier between the fuses.
7
1. The failed power fuse can be removed.
8
1. Replace it with a new fuse which must be the same size.
9
1. Tighten the 4 bolts which fix the fuse with a torque of 13
pound-foot (lb-ft).
10 Reinsert the insulation barrier between the fuses.

1.
11 Reinsert the blown fuse mechanism.
1.
NOTE: Ensure the right position of the pins of the blown fuse
mechanism just as mentioned in point 2 and verify its right operation.
1.
12 Tighten the plastic bolts on the cover that supports the
blown fuse switch.
13 The fuse replacement is complete.

1.
14 Place the dead front (galvanized metal sheet cover) and tighten
1.
the 4 bolts.
Appendix E
Opening time and ride through

The standard opening time is 280-320 ms for 400 A non- latched contactors .
In the contactor unit the ride-through capability is achieved by operating the contactor coil at a excess current of that required to keep the contacts closed during
normal operation.
The coils have the ability to store energy, the contactor has the ability to ride through a voltage sag or complete voltage dropout.
HCV-5HA (No Latch) Opening time

The HCV-5HA opening time, with terminals 3 & 4 jumpered, and switching power on and off to terminals 1 & 2, is between 280-320 ms.
The HCV-5HA opening time, with terminals 1 & 2 continuously powered, and switching (opening) contacts connected to terminals 3 & 4, is between 20-30 ms.
When required decrease of the opening time to 20-30 ms, it must be verified according with the protections coordination (considering the fuses operation time) for
a safe operation. For example: particularly for 24R fuse, is mandatory increase 100ms the trip time in the protection relay in order to ensure that contactor opening
time is not less than fuse operation time.
If required more information, please consult the factory.
Appendix F
Local trip on the front

The SafeGear MCC can be provided with latched or unlatched controllers
The type latch controller has the feature of mechanical interlock, where its contacts remain closed in spite of loss energy.
A button in front of the controller (Fig.1) is used for manual trip manually when deenergized.
The trip mechanism is located on the contoller compartment door (Fig. 2). This is an optional feature that can be requested when the MCC is ordered.
Manual trip Trip mechanism
Fig. 1 Controller front Fig. 2 Controller compartment door
Appendix G
Maintenance Procedure for Vacuum Interrupter

Always keep in mind the recommended safety procedures when working in medium voltage equipment.
For the safety of personnel extracting the controller of the MCC, all components should be electrically disconnected by means of a visible break, securely grounded,
locked out and tagged in accordance with personnel precautions spelled out in ANSI/ASSE Z244.1 “Control of Hazardous Energy – Lockout/Tagout and Alternative
Methods”.
UPPER
FLANGE
Procedure
• Check the upper and lower flanges and interrupter shaft to see if they are
contaminated or corroded.
If contaminated use a clean cloth and rubbing alcohol.
If corroded replace with a new interrupter.
NOTE: Avoid touching the ceramic surface. Skin oils may

harm the silicon varnish.
LOWER
FLANGE SHAFT
• Check the main contact wear in the vacuum interrupter.

If the wear gauge can be inserted, then there is sufficient contact material
available for continued use.
WEAR
If the gauge cannot be inserted, replace the interrupter.
GUAUGE
NOTE: This check is made with the controller closed.

2.7 mm
MINIMUM
INSULATION
FLANGE
• Check vacuum in the vacuum interrupter.

Apply 10kVAC between the upper and lower terminals for one minute.
If there is no voltage breakdown, the vacuum interrupter is acceptable for continued use.
If there is voltage breakdown, replace with a new vacuum interrupter before continued use.
NOTE: If there is a vacuum failure, it can be confirmed by pushing down on the insulating flange below the vacuum interrupter.
If the interrupter shaft can easily be moved, then the interrupter has lost vacuum.
15. End of life of product
ABB products are manufactured to meet or exceed the standards of compliance for quality and environmental management systems in accordance with ISO 9001
and ISO 14001. All of these items can be supplied with a certificate of quality. ABB is committed to complying with all legal and other relevant requirements for
environmental protection in accordance with the ISO 14001 standards. The responsibility of the company is to facilitate subsequent recycling or disposal at the
end of the product’s life. During disposal of the product, it is always necessary to act in accordance with all local and national legal requirements that are in effect
at the time of disposal.
16. Methods of disposal

Disposal can either be carried out in a manner of ways depending upon material of product. Below is thecrecommended method of disposal for various raw
materials.
ABB is committed to complying with the relevant legal and other requirements for environmental protection according to the ISO 14001 standard. The duty of the
company is to facilitate subsequent recycling or disposal at the end of product life. During disposal of the product, it is always necessary to act in accordance with
local legal requirements in force.
Raw material Recommended method of disposal

Metal material (Fe, Cu, Al, Ag, Zn, W, etc.) Separation and recycling
Thermoplastics Recycling or disposal
Epoxy Resin Separation of metal and disposal of remains
Rubber Disposal
Oil (transformer oil) Draining and recycling or proper disposal
SF6 gas Discharging from equipment
Packing material Recycling or disposal
Contact us
Your sales contact: The information contained in this document is

www.abb.com/contacts for general information purposes only. While
ABB strives to keep the information up to date
More product information: and correct, it makes no representations or
new.abb.com/medium-voltage/switchgear/motor-control-centers/ warranties of any kind, express or implied, about
ansi/ansi-air-insulated-motor-control-switchgear-safegear the completeness, accuracy, reliability, suitability
or availability with respect to the information,
products, services, or related graphics contained
in the document for any purpose. Any reliance
placed on such information is therefore strictly
at your own risk. ABB reserves the right to
discontinue any product or service at any time.
www.abb.com
© Copyright 2016 ABB. All rights reserved.
1YEPMSC2517E013-Rev. A, MCC 2.5 April 2017

SafeGear MCC IOMM Controller July 2017

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2017

SafeGear® Motor Control Center

DO NOT work on an energized controller.

DO NOT work on a closed controller.

DO NOT work on a controller with charged energy.

Do not stack controllers.

·· Fuse status indicator

Fig. 1 SafeGear® MCC Controller

5. Normal Service Conditions

Normal operation conditions

Controller Weight Approximate

7. Extraction Truck Assembly

Fig. 2 Extraction truck assembly

Fig. 3 Spring before being charged

Steps for charging the springs manually:

• NOTE: ABB has specific accessories to be used with ABB controllers.

1. Open MCC controller compartment door to its fully opened position.

CONTROL CIRCUIT CHECKOUT:

1. Make sure all controller are open (OPEN).

Fig. 4 Basic Cell

1. Compartment Slots for engaging the lift trucle

Fig. 5 Truck shown with controller removed

1. Secondary Locking Tab 7. Cell Locking Tabs

Basic Controller Layout

3 6 10. Insertion/ Removal Handle

5 11. Cell Interlock Tab

Basic Controller Dimensions

DRAWOUT 400 A CONTROLLER:

DRAWOUT 720 A CONTROLLER:

What is a Phase Loss?

Blown fuse mechanism

NOTE: This configuration is available and depends of relay’s programming by others.

Instructions for Replacement of Fuses

The picture shows the

10 Reinsert the insulation barrier between the fuses.

13 The fuse replacement is complete.

Opening time and ride through

HCV-5HA (No Latch) Opening time

Local trip on the front

Manual trip Trip mechanism

Fig. 1 Controller front Fig. 2 Controller compartment door

Maintenance Procedure for Vacuum Interrupter

NOTE: Avoid touching the ceramic surface. Skin oils may

• Check the main contact wear in the vacuum interrupter.

NOTE: This check is made with the controller closed.

• Check vacuum in the vacuum interrupter.

16. Methods of disposal

Raw material Recommended method of disposal

Your sales contact: The information contained in this document is

1YEPMSC2517E013-Rev. A, MCC 2.5 April 2017

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