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ELECTRIFICATION PRODUCTS

SafeGear® Motor Control Center

Arc-resistant metal-clad construction
Installation, operation and maintenance manual
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Medium voltage SafeGear®
Motor Control Center: controlling
energy for a safe world
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Table of contents

001 General instructions

001 – 002 Safety notes and warnings

002 – 003 Receiving, handing and storage

003 Location site preparation

004 – 009 Indoor installation

010– 012 Testing and final inspection

012 – 013 Putting into service

013 – 015 Standard construction

016 – 017 Contactor compartment

operation

019 – 022 Maintenance

023 – 026 Plenum installation

027 – 032 Appendix A

033 – 040 Appendix B

041 – 044 Appendix C

045 – 046 Appendix D

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General instructions
Read these instructions carefully before installation and use them as a guide during installation and ini-
tial operation.

File these instructions with other instruction books, drawings and descriptive data of the MCC.
Keep this book available for the installation, operation, and maintenance of equipment. Using
of these instructions will facilitate proper maintenance of the equipment and will prolongs its
useful life.
Assembly manuals available for consultation about the equipment: Frame assembly manual,
Main bus assembly manual and Wiring installation manual.

Scope of instructions
The instructions are general in nature. They cover requirements for installation, setup, checkout and
maintenance as applied to ABB medium voltage Motor Control Centers (MCC). These instructions do not
attempt to cover all variations and combinations of equipment and installations. Information on particular
installations appears in the following:
• Bills of materials that list electrical devices and equipment
• Front view in the general arrangement
• Single line drawings showing power connections
• Floor plan, representing available space for power and control conduits
• Special construction details
• Elementary and schematic diagrams
• Connection diagrams

Safety notes and warnings

Equipment operation depends on proper handling, installation and maintenance. Neglecting fundamental
requirements may lead to personal injury, failure of the equipment and property damage.

Safety as described in this instruction book involves two conditions:

• Personal injury
• Product or property damage

Note: See “Disclaimer of warranties and limitation of liability”, in this document.

Safety notations
Safety notations alert personnel to possible death, injury or property damage situations. The safety notations
appear before the step in which the condition applies. The four hazard levels are:

WARNING
Danger, indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Prior to performing any work on this equipment, qualified personnel should verify that the equipment has
been fully de-energized. You should assume that all equipment is energized until such time as you have
verified that the electrical circuits are completely de-energized and electrically isolated so that there is no
possibility that the equipment could become energized while work is being performed on, and in proximity
to, the equipment.
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WARNING
WARNING, indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION
CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

NOTICE
NOTICE, is used to address practices not related to personal injury.

Personnel installing, operating or maintaining this equipment must be qualified on all applicable local,
regional, industry, governmental and OSHA safety procedures, as well as commonly accepted safe working
practices. Personnel working in or around this equipment must also exhibit common sense and good
judgment regarding the potential hazards for themselves and other personnel in the area. These instructions
are intended for use by fully qualified personnel and are not a substitute for adequate training, experience
and supervision.

Should clarification or additional information be required, refer the matter to your ABB
sales office. When communicating with ABB regarding the product covered by this
Instruction book, always reference the ABB assigned Purchase Order (P.O.) number and/
or equipment serial number.

Note: The Occupational Safety Hazards Administration, OSHA, is an organization of the government of U.S.A. dedicated to safety.

Receiving, handling and storage

Receiving
Before shipment, the equipment is inspected and marked with its number and position. The factory ships the
contactors separately.

Upon receipt, examine the shipment for damage or loss. Check the contents against the packing list before
discarding any packing material. Notify the carrier and ABB at once of any discrepancies.

If there is damage from improper handling, file a claim for damages at once with the carrier and notify ABB.

Note: ABB standard shipments are “FOB Factory.” ABB is not responsible for damage after delivery of the equipment to the carrier unless otherwise
specified on the PO

Handling

NOTICE
For structural integrity, all doors and panels must be in place and securely fastened before moving the
equipment.

Do not move or transport the frames with contactors or other drawout equipment installed in the
compartments.

Before energizing the space heaters, remove all the packing materials. Open the breaker or cutout device
that controls the heaters when is using a separated power source.
3 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

Storage
Place the equipment on the shipping base. Store all equipment indoors in a well-ventilated area.

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).

The sections ship wrapped in plastic for protection during shipment only. Remove the plastic wrap just before
placing into storage. Cover with heavy wrapping paper or other moisture barrier. Use materials that will not
trap moisture inside the unit. Do not cover louvered openings.

For long-term storage, or in high-humidity, use space heaters to keep the interior dry. Bring power for the
space heaters to the load terminals of the device that controls the heater circuits.

Note: The heater can be energized with an external source of power.

• Store contactors upright in their original shipping base

• Do not stack
• Do not store contactors in the compartments

Location site preparation

Overview
Before installing, consult all drawings supplied for the particular order. Drawings show top and front views of
the lineup, primary and secondary connection diagrams and Bills of Materials. Study these drawings and the
following recommendations before preparing the site plan drawings.

Location
Locate the lineup in accordance with local regulations. Clearances at the front should allow installation and
removal of the draw-out equipment and lift devices. Allow enough clearance to service draw-out equipment in
back to back installations (when it is applicable).

High recommended

Nominal current Ft
25 kA 12
14 16
50 kA

* Maintain approximately 4 feet or more clearance from the top of the equipment to any obstruction.

Foundation
The factory supplies floor plan drawings for each installation. The floor must be straight and level within 0.25
inches over the full length and depth of the lineup. The finished floor under and in front of the line-up should
be smooth.

Install power and secondary (control) conduits before moving the unit to the site. Available space for the
conduits appears on the floor plans supplied with the units. Conduits should not extend more than one inch
above the station floor level. Cover the conduit openings in the floor.
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Indoor Installation
General

WARNING
Drilling or punching of holes in the equipment in any way will affect the arc- resistant integrity of the MCC.
Consult the factory engineer before proceeding.

In order to obtain an optimum installation sequence and ensure high quality standards, site installation of the
MCC should only be carried out by specially trained and skilled personnel.

Metal-clad MCC ships are in sections. These sections group are on disposable steel shipping bases. Equipment
is not to be permanently installed on the shipping bases.

Unload the units as close to the installation site as possible. Remove all drawout elements and secure all doors
and panels. To move the shipping sections to their final position, one of four methods can be used.

Forklift – place forks through locations provided in the shipping bases (see Figures 01 and 02).

Lift the MCC frames slowly and tilt forks slightly rearward to balance. Move carefully into the final position
taking into account the center of gravity (see Figure 04).

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01 Forklift provisions
in shipping channels.
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02 Forklift forks
penetrating shipping
channels.
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03 Complete fork
penetration of all 3
shipping channels.
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04 Lifting of switchgear
frames with forklift.

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01 02

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03 04
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Towing - use chains rated for safe handling of the shipping splits. Consult the chain manufacturer or
local code requirements for proper safety factors. Attach the chains to the holes at each end of the
shipping base. Secure chains to the towing equipment. Make sure that the floor height is consistent
or provide heavy duty steel sheets to bridge any inconsistencies. Protect the lower edge of the
switchgear from damage by the chains.

Crane - using a spreader bar and either chains or slings connected to the shipping channel extensions,
part no. 921309T01 (provided upon request), lift carefully taking into account the center of gravity.
Once located, final positioning can be done with a forklift. When using either chains or wire rope
slings, place a wooden 4” × 4” block between the equipment and the sling to protect the equipment
from damage.

Jacks and Rollers - raise the units with jacks located at the corners of the shipping bases and move
on steel pipe rollers with the shipping bases attached.

CAUTION
Use of forklift trucks for jacking or placing the jacks other than as described may result in stress
distortions and irreparable damage to the equipment.

Do not remove the shipping bases until the units are set in place. Moving the units without the shipping
base will cause irreparable damage and a hazardous condition.

Removal of the Shipping Base

Once the units are in their final place, the shipping bases can be removed.

Open the equipment doors. Remove the bolts holding each of the three shipping bases to the
equipment. If circuit breakers were installed for shipment, the lower position breakers will need to
be removed prior to this step.

Close and secure all doors and panels. Raise the units to a height that allows removal of the base. Use
four jacks located at each corner of the shipping split, just inside of the shipping bases for this
operation. Keep the units uniformly level to prevent distortion.

Select four pieces of wood thick enough to permit removal of the jack after lowering. Place one under
each corner. Slowly lower one side until it rests on the pieces of wood. Repeat this process on the
other side.
Use a pry-bar to lift each corner enough to remove the four pieces of wood.
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 6

Attaching to the Floor

Following the removal of the shipping bases, the MCC units should be secured to the floor either by bolting
per the guidelines outlined on the ABB factory drawings. Welding is not recommended and no guidelines
exist for attachment using this method.

Connections

DANGER
Before making primary source connections, verify that the primary cables are de-energized and the
equipment is properly grounded.

Bolt the separate units together. Reconnect the main bus and control wiring at the shipping splits. Follow
the connection diagram when replacing secondary and control wiring.

Bolted connections should be torqued to required levels as outlined in Appendix C.

Complete all internal connections. Make the external connections to control power sources and circuits, to
secondary and potential circuits, to feeders, power sources and to ground.

WARNING
Power cable penetrations, top entry or bottom entry, into the equipment should be secured in the provided gland
plates with sealing glands/hubs. Failure to use sealing glands/hubs will affect the arc-resistant performance of
the MCC.
Note: After completing all connections to secondary (control) circuits, follow these circuits and remove temporary connections from current
transformer secondaries (see Figure 1).

Temporary jumpers protect against voltages that may occur if the current transformer primaries carry
currents while the secondary circuits are still not complete. With the secondary circuits connected, remove
the jumpers.

Fig. 1 CT Shorting Blocks

CAUTION
Ground bus connections should not penetrate any part of the MCC not intended for cable of bus entrance. Not
following this practice will affect the arc- resistant performance of the MCC.
Note: Failure to remove the jumpers will interfere with meters, relays, or other devices in these circuits (see Figure 1).
7 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

If shorting terminal blocks are used, review the connection diagram that was shipped with the unit, for
position of shorting screws. See step 10 of the control circuit checkout.
The wiring connections are explained in Appendix C

Connection to Ground Bus

The factory bolts the ground bus bars to each frame. Connect the ground bus bars between the shipping
splits and to the station ground with a cable or bus of equal or larger gauge than the housing ground bus.

Do not run cable or bus in conduit. The cable or bus should take the most direct path to ground.

Installation of the Plenum

The MCC plenum is shipped separately in pre-assembled sections on pallets. Refer to the General Arrangement
drawings for details on the layout of the plenum.

Remove all packing material and lift plenum sections to the top of the MCC by suitable lifting means. Each
section is then bolted to the plenum base mounted on the MCC roof and also to the adjoining plenum section
with provided hardware.

Once the roof-mounted plenums are in place install additional plenum sections, for venting outside the
building, one at a time starting at the MCC boundary (see Fig. 2).

As each section is installed provide permanent support for each section, either from above or below, starting
with the first plenum section. The support should be able to brace the weight of each in accordance with
local building code requirements.

Follow the specific plenum routing shown on the General Arrangement drawings:

The exhaust vent section (see Fig. 3) should be installed in the building wall and connected to the last plenum
section (see Fig. 2). Additional plenum information can be found in the Field Installation of Plenum Sections,
1YEPMSC2516E007.

Fig. 2 Plenum Installation Fig. 3 Plenum Exhaust Vent

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The area outside the plenum exhaust vent needs to be kept clear of personnel and equipment due to the
potential for super-heated pressurized exhaust gasses being expelled in the area as a result of an arc fault in
the MCC. Specifically, a horizontal cylindrical volume, with an 96 inches diameter, centered on the plenum
exhaust vent and extending out 180 inches, needs to be clear at all times (see Fig. 4).

Diameter = 96in [2.44m]2. 3/8”-16 UNC X 1.0 in

Length = 180in [4.57m]

Fig. 4 Plenum exhaust area

Installation of bus bar connections between shipping splits

The factory assembles the main bus bar in each section. The splices at the shipping splits are unbolted for
shipment. Refer to the General Arrangement Drawings.

The contact surfaces of the bus at bolted joints are plated. Clean contact surfaces with a clean cloth and an
OSHA approved solvent.

CAUTION
Do not use alcohol or freon. Limit the use of solvents to removing grease and contamination from primary
conductors, insulation and unpainted metallic surfaces. Use an OSHA approved, non- flammable solvent with a
threshold limit of 300 PPM or higher in accordance with local regulations. Use solvents in well-ventilated areas.

Note: Take care not to remove or tarnish plating.

Remove barriers to access the main bus compartment. Bolt the main bus together using supplied hardware.
Conductivity of a bolted joint depends on the pressure or torque applied.

Note: All bolted joints must be torqued per ABB specifications – see Appendix B.
9 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

Secondary and control connections

The MCC was wired in the factory in accordance with the Project specific Connection Diagrams. Refer to
project specific drawings for locations of the incoming and outgoing wiring terminal blocks.

Openings in the side of the MCC in the Low Voltage/Instrument compartment area allow control connections
between sections. When shipped in groups of several units each, the factory installs interconnection wiring
between groups. The factory then disconnects and tags one end of each of the connections, then pulls the
wire bundle back across the split within the adjacent frame. Reconnect these interconnections according to
the project specific connection diagrams after the equipment shipping sections are installed in place. See
Appendix C.

WARNING
All secondary power and control wiring should be routed through the provided locations and utilize the rubber
grommets cut with the appropriate size center hole to accommodate the wiring bundle. Failure to do so will affect
the arc-resistant integrity of the MCC.

Primary cable connections

Area for connection of primary cables is provided in the cable compartment either through the roof or floor
as indicated in the General Arrangement drawings. The gland plates are made of .074” stainless steel - these
plates must be utilized in the final assembly. Holes for entrance of power cables or conduits must be cut in
the gland plate(s) and a sealing type bushing used.

WARNING
Use of sealing bushings for all power cable entries is required. Failure to do so will affect the arc-resistant integrity
of the MCC.

Connection to control source

The control source wiring should be properly sized to support the requirements of the control circuit. Connect
the control source leads to the terminal blocks as indicated on the project Connection Diagrams.

Note: Check the electrical phasing before connecting.

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Testing and final inspection
Testing

DANGER
Disconnect the primary power source during testing. Do not exceed the listed voltage class of the equipment
during testing. Disconnect shunt connected coils such as potential transformer. Do not test sensors in solid
state and relay with high voltage. Disconnect them before applying voltage.

With the equipment raised, assembled and connected, perform the following process:
1. Remove packing and shipping materials.
2. Make sure that all internal parts are clean and dry. If moisture is present, blow dry with warm air.
3. Remove any shipping blocks from relays.
4. Check for damaged insulation by applying potential tests to the primary bus. Apply potential tests phase-to-
phase and phase to ground in accordance with “Field Test” values.
5. When the main circuit is de-energized and grounded, check the continuity of all circuits after installing the
contactors. After this, energize the control source and operate the equipment. The indicating instruments verify
the continuity of current transformer circuits and the energizing of the main circuit.

Test voltages for dielectric voltage-withstand test

Rated control voltages Factory test

0 V to 600 V 2 x nominal voltage +1000 V plus
601 V to 7200 V 2.25 x nominal voltage +2000 V plus

Control circuit checkout

DANGER
The contantor or cutout device of the local control power circuit must be opened when is used a separated
control power source.

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 contactors
should be racked out (“DISCONN.” 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.
11 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

1. Make sure all contactor assemblies are open (OPEN).

2. Rack the contactors out to the disconnected position.
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 contactor to the connected position (CONN.). Open and close the contactor to verify the correct
connection in the secondary plug. Repeat the same operation for every contactor assembly, one at a time.
7. Test the contactors 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.
10. Remove shorting screws from the terminal blocks in the current transformers circuits. Store screw in the tapped
holes in the corners of the blocks (see Figure 5).

NOTE: Verify the proper phasing of all main circuits according to diagram of control.

To open the short circuit device:

1. Make sure that the transformers circuits are completed. Do not put one of energized switch in a secondary open
circuit.
2. To open the short circuit device:
2.1) Single Ratio – Remove and store the shorting screw “a”. Do not remove the ground screw “b”.
2.2) Multi Ratio – Remove the shorting screw “a” and insert it according to the connection diagram below.

b b

Single Ratio Multi Ratio

Fig. 5 Short circuit device

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Final inspection

DANGER
The contactor or cutout device of the local control power circuit must be opened when is used a separated
control power source.

Once installed and all connections made, perform a final check and test on the equipment and its controls.
Check for correct equipment installation and that all connections are complete. Take extreme care to prevent
the controlled equipment (load) from being connected to the system while performing preliminary tests.

Disconnect the line wirings if the line contactors are not in the system according to the connection diagram
supplied with the equipment.

Typical circuit diagram HCV-5HA

Fig. 6 Standard operation circuit diagram of normally energized type

Putting into service

Safety precautions

DANGER
There are hazards of electrical shocks and/or burns whenever working in or around electrical equipment.
Turn off power of the MCC before performing any inspection or maintenance operations.
Check incoming line terminals to verify that the equipment is de-energized and grounded.
Check outgoing terminals to ensure that no back feed condition exists.
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All contactors must be in “DISCONN.” position, when service or maintenance personnel are working on the
MCC, unplug the main bus feed and ground the whole system.
Before energizing the MCC, do a complete review of the mechanical operation of all devices. Remove clips of
the relays, contactors, meters, etc.
Manually operate all contactors and relays. Moving parts should not bend. Verify that there are no foreign
objects in the equipment.
Use compressed, clean, dry air to clean all inside and outside surfaces.

Note: Current transformers secondary circuits should be short circuited.

Clean contact surfaces with a clean cloth and an OSHA approved solvent. Bolt the bus together. Conductivity
of a bolted joint depends with the proper torquing of the bolts.
All contact surfaces of the bus will be bolted and plated.
Clean all surfaces with a clean cloth and use only OSHA approved solvent. Join bus bars with the correct
screws a good conductivity depends of the appropriate torque applied.

Energizing main bus

After completing the control circuit checkout, energize the main bus as follows:
1. Verify that all doors and panels are in place and secured. All contactors must be racked out (“DISCONN.”).
2. Energize the incoming bus to the equipment’s main circuit breakers or any other device located in the incoming
of the lineup.
3. Verify if operation of instruments and relays are correct.
4. Activate the independent control power source.
5. Energize the main bus closing the main circuit breaker; verify that the relays and other instruments are functioning
correctly.
6. Place the contactors from the out position (“DISCONN.”) to the inserted position (“CONN.”).
7. Close the desired contactors.

Standard construction
Contactor compartment
The principle of manufacturing is modular, for 400 and 720 A contactors the compartment dimensions are
30” wide, 33.625” deep and 38” high. For control low voltage (LV) compartment the dimensions are 30” wide,
15.12” deep, and 19” or 57” high. For main bus and cable compartment rated at 1200, 2000 and 3000 A the
dimensions are 30” wide, 31.38” deep and 95” high. The general dimensions of the SafeGear™ MCC are 30”
wide, 68” deep and 95” high without plenum (21 in extra).

The compartments are manufactured of galvanized steel material. The main parts of each compartment are
designed with a double-bend in the end sides in order to get higher mechanical strength. The contactor truck
has a galvanized steel base with wheels, in which are set the contactor and the fuses box. Three phases are
connected by finger contacts.

The new design of the contactor truck allows manual insertion only when the contactor compartment door
is closed, using a tool (racking lever). The secondary automatic system is auto adjustable so it does not
require manual connection.

The standard paint color is Grey ANSI 61. This powder paint has an electrostatic finish applied in a ferrous
phosphate covering. This process reaches uniform and soft texture. Pieces that are not painted are fabricated
with C.R.S. (Cold Rolled Steel) galvanized.

Painted pieces are of black sheet C.R.S. or could have another finish to meet the IEEE C37.20.2.
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 14

Fig. 6 Contactor compartment Fig. 7 Power cables compartment Fig. 8 Bus supports and bus bars

Fig. 9 Controller ground contact Fig. 10 Automatic secondary Fig. 11 Finger contacts

Power cables compartment Bus bars and supports

The power cables compartment has Bus bars are electrolytic copper sheathed in heat epoxy hysol (coating shrinkable
provisions for several devices, for tubing as an option). They run horizontally and vertically along the bus and cable
instance: current transformers (up to 3 compartments. The cross section allows meeting the current specified by the design.
per phase), surge arresters and ground The bus supports are polyester GPO-3, this design supports the electrodynamic forces
sensor. caused by short circuit effects.

The power cables compartment has Secondary connection Primary connection

enough space to lodge up to 2 power Each contactor compartment includes Consists of a set of three copper contact
cables per phase of 350 MCM (133% an automatic device that connects the fingers compressed by springs, these can
insulation level) with a stress cone each. contactor low voltage control circuit, as be inspected by removing the contactor
well as to connect the circuit of opening from the compartment. Line side finger
and closing of the contactor. contacts apply the correct pressure over
the terminals, achieving self-alignment
Contactor ground contact of the devices. All copper parts are
The ground contact is located at the front silverplated (tin plated are an option) for
of the contactor compartment. better conduction.
The contactor is grounded in each position.
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Contactor Assembly Ratings
Contactor model HCV-5HA HCV-5HAL (Latched Type) HCV-6KAU HCV-6KALU* (Latched Type)

Rated voltage 2400/4200/6900 V (7.2 kV Max) 2400V/4200/6900 V (7.2 kV Max)

Rated current 400 A 720 A

7000A RMS Symmetrical @5000V Max.

Interrupting capacity 7200 A
4500A RMS Symmetrical @7200V Max.

Peak withstand current 15.8 kA 20 kA

Impulse withstand 60 kV

Permissible switching 1200/Hour 300/Hour 600/Hour 300/Hour

Mechanical life operations 2,500,000 250,000 1,000,000 200,000

Electrical life operations 250,000 250,000 200,000

Closing time 50-110 ms 80-120 ms

Standard opening time 10-60 ms 35-85 ms
Arcing time 10 ms or less

Rated control voltage AC 115/120 or 230/240 V 50/60 Hz 100-240V AC

Rated control voltage DC 120/125 or 240/250 V 100-240V DC

Trip voltage - 24, 32, 48 ,125, 250 VDC - 24, 32, 48 ,125, 250 VDC

Control circuit burden (closing) 5.4 A peak @ 120 VAC, 670 VA (AC), 700 W (DC) 6 to 7.0 A @ 120 VAC, 840 VA (AC), 875 W (DC)

Control circuit burden (holding) 0.12 A Avg. @ 120 VAC,85 VA (AC), 85 W (DC) 0.8 to 1 A @ 120 VAC 48 VA

Auxiliary contact arrange 3 N.O. - 3 N.C. 2 N.O.-2 N.C. 3 N.O.-3 N.C. 2 N.O.-2 N.C.

Auxiliary contact rating 10 A, 600 V (NEMA Class A600)

Fuse replacement
Please, refer to the Installation and operation manual for the
controller for fuse replacement procedure.
The fuses replacement and installation are carried out with the
contactor. Fuses are fixed by hexagonal screws. The fuses can be
one barrel or double barrel; both have the same setup to fix, so
additional attachment is not required.

Fig. 12 Contactor

Hardware Qty. per fuse

Hexagonal 3/8”–16 X 1” UNC head
4
screw Grade 5
Spring washer 4
Flat washer 4

Fig. 13 Fuse replacement

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Contactor compartment operation

Fig. 14 TOC Fig. 15 Line side shutter

Truck operated contact

The TOC interacts with the position of the contactor, either “CONN.”, “DISCONN.” or intermediate positions.
Note: TOC are factory calibrated, no further adjustment is necessary.

Line side shutter

The contactor compartment features a mechanical shutter lock to prevent access to the line side bus when the
contactor is not in the compartment.

DANGER
Do not attempt to deactivate the shutter system. It only operates when the contactor is in the compartment.
Hazardous voltage can cause electrical shock and burns. Disconnect power, then earth and short-circuit
before accessing for any components in this area.

Additional features include provision for padlock, when maintenance is required.

Contactor mounting in compartment

The contactor is located outside the compartment ready to be inserted.

NOTICE
Before putting the contactor into the contactor compartment, place the automatic secondary at its initial
position (at the front of the compartment).

1. Use a Lift Truck to move the contactor to the height of the compartment.
2. Insert the tray guides of the Lift Truck in position in the compartment slots.
3. Release the contactor of the tray with the front hand grips and slide them firmly to the compartment until reach
the slots located on the rails of the compartment.
4. Release Lift Truck.

At this point the Contactor is not connected to the load side bus. The position indicator is “DISCONN.”
(extracted) and the status indicator is “OPEN”.
The automatic secondary pins are connected to the contactor control board, which can close the contactor for
testing in the status “CLOSED”.
17 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

Fig. 16 “DISCONN” position Fig. 17 Insertion of the contactor

Secondary connections mechanism alignment

In order to ensure proper engagement without damage of the control connections of the controller, it
shall be reviewed the condition of the secondary connection mechanism ensuring that is aligned with the
correspondent parts on the controller truck.
To follow this simple instructions helps to eliminate risk of crashing the mechanism causing damage in the
connectors that finally can produce loss of the control signals.

Please review following instructions previous to insert the controller into the MCC cell:

1. Identify the secondary connection

mechanism on the floor of the 2. Review that frontal tongue is not 3. The tongue of the secondary
controller module. damaged or folded during any connections mechanism shall be
commissioning or maintenance aligned coming to the front of
activities, also review good the MCC cell, it means being
condition of the spring bellow of parallel to the sides and floor
the tongue. planes just as indicated.
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 18

4. Finally, check that thinner tongue bellow of the 5. This tongue shall be aligned to be received in the
secondary connector on the controller truck is also female part located just bellow of the secondary
aligned according to the instructions above. connector inside of the module.

Racking-in the contactor

The contactor has a mechanical lock that interacts with the door to start the racking.

CAUTION
Do not attempt to rack the contactor with the door open, this may create a risk of electrical arcing and damage
the equipment.

1. Close the door bolting all the screws.

2. Ensure that the contactor is open “OPEN”.
3. Turn the door shutter to insert the lever.
4. Insert the handle and turn clockwise 10 complete cycles. Continues until the mechanical stop position is activated.

The contactor is now in the inserted position “CONN.”, connected to the main bus through the line side bus.
The load side bus is energized when the contactor is closed “CLOSED”.

Racking-out the contactor

1. Open the contactor “OPEN”.
2. Turn the door shutter to insert the lever.
3. Insert the handle and turn counter-clockwise 10 complete cycles. Continues until the mechanical stop position is
activated.
4. The contactor position is “DISCONN.” again.

Emergency door unlocking

To open the door using the emergency door lock, follow the steps below:
1. Remove the 10-32 UNF round head screw that is at the bottom of the contactor compartment door.
2. Using a slim screwdriver tool, introduce it through the door hole until it reaches the pin that is locking the door.
3. Move up the tool to release the locking pin that is locking the door.
19 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

NOTICE
Put the 10-32 UNF screw in place after
10-32 unlocking the door
UNF screw

Fig. 18 Door locking mechanism

Door hole
Flat screwdriver
Door hole

Maintenance
Overview
Inspect all MCC installations at frequent intervals. Visually inspect the front and back to note any warped piece,
loose bolts or screw undue vibration. Take corrective actions if any of these conditions is found.
Keep the MCC covered to prevent any dripping liquids from falling on it, but do not cover the air vents.

DANGER
There are risks of electrocution and/or burns every time you work on or around electrical equipment.
Disconnect power from the board before performing any maintenance.
Check the terminals of the input line to verify that the equipment is disconnected.
Check the output terminals to verify that there is no feedback.

CAUTION
Limit the using of solvents to remove grease and contaminants to the primary conductors, insulators and metal
surfaces without paint. Do not use alcohol or freon. Use OSHA approved solvents according to local regulations.
Use a nonflammable solvent equal to 300 PPM.
Use solvents in well ventilated areas.

Removing the contactor with ramp (lower compartment only)

Safegear® MCC has provisions to

put a ramp in front of the contactor
compartment to withdraw the contactor,
instead of using a crane or lift truck. This
ramp carries the contactor outside the
contactor compartment for maintenance
or servicing.

Fig. 19 Contactor ramp for lower contactor compartment

 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 20

Semi annual inspection

Perform a thorough inspection of the MCC at least semiannually. Emphasize the following points:
• Perform an overall visual inspection.
• Check all indicators, meters and instruments for proper operation.
• Make sure all bolted connections are secure.
• Verify operation of heaters and thermostats, if used.
• Check for undue noise and or vibration that might c bee loosen bolted connections.
• Look for evidence of moisture in the MCC.
• Note any unusual amount of ozone odor (distinctively pungent smell).

Annual inspection
In addition to the semi-annual inspection, perform the following recommended inspection and maintenance once a
year, or sooner.
If required by local conditions or regulations.
• Bolted connections should be properly tight. Discoloration, excessive corrosion and discolored insulation may
indicate an overheated connection. If found, follow the procedure described under section “suspect joint
maintenance”. Verify the existence of safety connections and spacing adapted in the wiring.
• Check the control wiring for signals of damage or wear. Change the wires that present doubtful conditions.
• Check the resistors and other devices prone to over-heating.
• Open all hinged doors and remove bolted panels.
• Clean insulation thoroughly.
• Withdraw and clean all removable components.
• Clean the stationary portion of the MCC by wiping with a clean cloth. Use dry, compressed air for inaccessible
areas.
• Remove the covers of all panel devices where possible. Check wiring for secure connections. Clean contacts on
relays and switches wherever necessary. Replace covers.
• Remove air filters when used. Flush with clean water if necessary.
• Follow the recommendations of any individual device instructions furnished for maintenance of the device.
• Perform maintenance of contactors as recommended in contactor instruction manual, furnished with the MCC.

24 months inspection
In addition to the annual inspection, perform the following recommended inspection and maintenance at 24
month intervals, or sooner, if required by local conditions or regulations.
• Perform maintenance of contactors as recommended in instructions furnished with the MCC
• Check wiring for signs of discoloration of the secondary disconnect the plug due to heating or wear. Check if the
insulation is cracked or fissured. Replace the wire with doubtful condition
• Inspect the insulation system for the accumulation of contaminants. Wipe with a dry cloth or blow with compressed
air and if necessary, wipe with a solvent approved by OSHA.
• Check calibration of protective relays every two years.

10 years maximum inspection

In addition to the annual inspections and maintenance, perform the following recommended inspections and
maintenance every ten years, or sooner, if required by local conditions or regulations.
• Disassemble, inspect, clean, lubricate, adjust and calibrate contactor mechanisms.
• Torque all primary conductor connection bolts to recommended values. See table Torque values.
• Tighten all secondary control wire connections. Check for loose lug crimps and broken wire strands.
21 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

Suspect joint maintenance

1. Open the equipment and inspect the mounting surfaces.
2. Clean surfaces with a solvent approved by OSHA, restore contact surfaces from corrosion rubbing lightly with a
cloth to polish as “3M Scotch Brite”. Take care to remove as little as possible the silver contact finish.
3. Replace parts that show signs of excessive corrosion, bowing, or casting.
4. Change contact jaws after being exposed to overheating in the failure of the contactor.
5. Protect the mating surfaces before assembly, with “ NO-OX-ID A-Special Electrical Grade” a product of Sanchem
Chemical Co., or equivalent.
6. Use proper torque to tighten the bolts

Torque values
Screw Torque
(in) (lb-in)
3/8 15 min - 35 max
1/2 30 min - 80 max

Care of finish
The finished MCC is strong and durable. Always keep the MCC clean. Cleaning with a dry cloth is usually
sufficient. To remove oil and grease stains, use soap and warm water, drying with a soft clean cloth.

Because the color and finish can vary, see the Materials List before touching up with paint. Standard color is
ANSI 61, light gray.
A 12-ounce aerosol ANSI 61 ABB touch-up paint is available under part number 3A31540G03.

Spare parts
Previous experience and the number of vertical sections in service are the best guidelines for determining
the stocking of replacement parts. Order factory original replacement parts from ABB only. Specify quantity,
part numbers, description, and nameplate data of the device requiring the replacement parts. For replacement
parts, call your nearest ABB office or representative.

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.

Methods of disposal
Disposal can either be carried out in a manner of ways depending upon material of product. Below is the
recommended 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.
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 22

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

Disclaimer of warranties and limitation of liability

There are no understandings, agreements, representations of warranties, expressed or implied, including
warranties of merchantability or fitness for a particular purpose, other than those specifically set out by an
existing contract between the parties. Any such contract states the entire obligation of the seller.

The contents of this document shall not become part of or modify any prior or existing agreement,
commitment or relationship.
The information, recommendations, descriptions and safety notations in this document are based on ABB
experience and judgment with respect to Motor Control Center. This information should not be considered
to be all inclusive or covering all contingencies.

No warranties, expressed or implied, including warranties of fitness for a particular purpose or merchantability,
or warranties arising from course of dealing or usage of trade, are made regarding the information,
recommendations, descriptions and safety notations contained herein.

In no event will ABB be responsible to the user in contract, in tort (including negligence), strict liability or
otherwise for any special, indirect, incidental or consequential damage or loss whatsoever including but not
limited to damage to or loss of use of equipment, plant or power system, cost of capital, loss of profits or
revenue, cost of replacement power, additional expenses in the use of existing power facilities, or claims
against the user by its customers resulting from the use of information, recommendations, descriptions and
safety notations contained herein.
23 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
Plenum installation

General instructions
Refer to the specific applicable General Arrangement and Floor Plan drawings for the plenum location. Follow
the specific applicable plenum routing shown on the floor plan. Instructions are the same for 1200, 2000,
3000 A main bus.

1. Install plenum sections on MCC roof as shown on the General Arrangement drawing. Each section is bolted to the
roof base and also to the adjoining plenum section.
2. Install additional plenum sections for venting outside of the building, in accordance with the field boundary. See
Figure 4 and 5.
3. As each section installed is supported by the adjoining section and roofs, start with the first plenum section. The
plenum bases should be able to support the weight of each section, in accordance with local building code
requirements.
4. The exhaust vent section, shown in Figure 3, should be installed in the building wall and connected to the last
plenum section as shown in Figure 4. The opening of the exhaust vent section cannot be installed pointing
upwards due to environmental considerations.
5. The area outside the plenum exhaust vent needs to be kept clear of personnel and equipment due to the potential
for pressurized exhaust gasses that would be expelled in the area in case of an arc fault in the MCC. Specifically, a
horizontal cylindrical volume, with an 8 foot diameter, centered on the plenum exhaust vent and extending out 15
feet, as shown in Figure 5, needs to be clear all the time.
6. Ensure that all bolts are correctly installed; a wrong assembly could allow toxic gas to escape through any given
space left.
7. Do not remove exhaust mesh; incandescent particles might go outside the MCC in case of an arc fault.

Plenum sections

Vent mesh End cover

Exhaust Two-sections plenum One-sections plenum

—
01
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 24

2. 3/8”-16
1. 3/8”-16 UNC X 1.0 in
UNC X 1.0 in

SAE grade 5 screws, 30-40 lb-ft torque to bolt MCC Plenum Exhaust vent assembly
— —
02 03

Front View. The exhaust vent can be righ side exit or left side exit (as shown).

Building wall.
Opening must be sealed weather tight
(by others).

Vent exhaust. 3

— Optional aditional plenum sections.

04
Note:
All bolts must be tightened; a loose section could let toxic gases escape into the building.
Do not remove exhaust mesh; incandescent particles might escape the MCC in case of an arc fault.

Recommended plenum exhaust “keep clear area”

Diameter = 96in [2.44m]2

Clear area 3/8”-16 UNC X 1.0 in

Length = 180in [4.57m]

—
05
25 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

General dimensions

(in[mm])
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 26

—
Appendix A Frames Assembly

DANGER
DETAILED DESCRIPTIONS OF STANDARD REPAIR PROCEDURES, SAFETY PRINCIPLES AND SERVICE
OPERATIONS ARE NOT INCLUDED. IT IS IMPORTANT TO NOTE THAT THIS DOCUMENT CONTAINS SOME
WARNINGS AND CAUTIONS AGAINST SOME SPECIFIC SERVICE METHODS WHICH COULD CAUSE PERSONAL
INJURY TO SERVICE PERSONNEL OR COULD DAMAGE EQUIPMENT AND RENDER IT UNSAFE. PLEASE
UNDERSTAND THAT THESE WARNINGS COULD NOT COVER ALL CONCEIVABLE WAYS IN WHICH SERVICE,
WHETHER OR NOT RECOMMENDED BY ABB, MIGHT BE DONE OR OF THE POSSIBLE HAZARDOUS
CONSEQUENCES OF EACH CONCEIVABLE WAY, NOR COULD ABB INVESTIGATE ALL SUCH WAYS. ANYONE
USING SERVICE PROCEDURES OR TOOLS, WHETHER OR NOT RECOMMENDED BY ABB, MUST SATISFY
HIMSELF THOROUGHLY THAT NEITHER PERSONAL SAFETY NOR EQUIPMENT SAFETY WILL BE JEOPARDIZED
BY THE SERVICE METHOD OR TOOLS SELECTED. INFORMATION CONTAINED IN THIS MANUAL IS BASED ON
THE LATEST PRODUCT INFORMATION AVAILABLE AT THE TIME OF PRINTING. THE RIGHT IS RESERVED TO
MAKE CHANGES AT ANY TIME WITHOUT NOTICE.
FAILURE TO FOLLOW THE INSTRUCTIONS AND/OR WARNINGS PROVIDED HEREIN COULD RESULT IN SERIOUS
BODILY INJURY AND/OR DEATH.

CAUTION
DO NOT REMOVE THE GASKET BETWEEN THE ADJOINING FRAMES. IT MUST REMAIN IN PLACE.
27 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

1. Scope/Introduction
This procedure applies to the assembly of
the ABB MCC 2.5 frames at the customer
site.

2. Disclaimer
This document was created with the intent
of providing a general instruction guide.
Models shown in this document may not
match exactly with the product you
received.

3. Safety practice
Safety glasses, gloves, and steel toe shoes
should be used as standard safety practice.

4. Target result

5. Tools required (not supplied)

(8’’ or longer)
Extension– 1 (9/16’’) Socket- 1 Ratchet– 1

6. Parts required

Universal joint socket-1 Pry bar-1

1’’ Bolts (not supplied) (not supplied)

Colors of parts in this document do not represent actual colors; it is for illustration purposes only.
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 28

7. Procedure

—
01 Put the two frames
to be assembled in
place next to each other.
Make sure all doors and
panels are secured while
moving the frames. Use
the pry, bar if required,
for alignment.

The line-up you received

might include more than
one frame on either side,
the rest of the frames are
assembled together in
the plant and excluded
from the pictures in this
manual for simplicity.

—
02 Open the LV
compartment door and
the controller door in —
the left frame. Look 01
inside the left frame on
the right and notice the
Tinnerman nuts installed
(highlighted in green). View front (right frame)

Tinnerman
Nuts

Bolts

Tinnerman
Nuts

—
02
29 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

— View front (left frame)

03 Notice the Tinnermen
nuts installed along the
frame wall (except in the
part marked “Bolts”).
That means, that the
bolts will be screwed
where it is marked “Bolts”
(from the left frame
to the right frame).
Notice the Tinnermen
nuts installed along Bolts
the frame wall that is
highlighted in green.
(Except in the part
where says “Bolts”). That
means, that the bolts will
be screwed from the right
frame to the left frame.

—
04 This diagram is for
illustration purposes
only, it may not fully
Tinnerman
represent all or any of nuts
the frames you received.

—
05 The picture shows
a side view of the
frame indicating the
holes for each bolt.

—
Bolts
06 The next picture
shows the location of
the Tinnerman nuts
and where the bolts
will be installed.

The picture shows a —

front view of the frames. 03
If the Low Voltage
compartment is 57 in,
the same rule applies.

—
05

—
04

—
06
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 30

—
07 Remove the rear
covers of the back
frame. Looking at the
frames from the back,
the Tinnerman nuts are
installed in the left frame.
Insert a bolt in every
hole in the right frame
at the left side that is
aligned with a Tinnerman
nut on the left side.

Notice the Tinnerman

nuts behind the
highlighted panel.

NOTE: For main

bus installation,
consult “10 Main Bus
Assembly Manual”.

—
08 The following picture
shows the location of
the Tinnerman nuts
and where the bolts
will be installed.

—
07

Rear view of the frames

31 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
09 Place a bolt in all
holes. (22 shown,
highlighted in blue).

Before to place the

main bus bars, place
a bolt for each hole
through bus support
(highlighted in green).

—
09
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 32

—
Appendix B Main bus assembly
1. Scope/Introduction
This procedure applies to the assembly of the SafeGear MCC main bus at the customer site.

2. Disclaimer
This document was created with the intent of providing a general instruction guide. Models shown in this
document may not match exactly the product you received.

3. Safety practice
Safety glasses, gloves, and steel toe shoes should be used as standard safety practice.

4. Tools required (not supplied)

¾” Wrench ¾” Socket Torque wrench

9/16” Socket
Ratchet Socket head
Screwdriver 7/16’’
5. Parts required (supplied)

(½ ‘’ x 13) Bolt. (½ - 13) Hex nut (½”) Flat washer (½”) Lock washer
Length de-pends on
bus rating

Seal putty Cu bus spacer

(If required)

Cu bus bars
33 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
01 Open the
compartment doors
in the back of the two
frames where the main
bus is to be installed
and remove the upper
and lower bus barriers
in both frames.

—
02 Start by removing
the bus side cover
in both frames (the
number one first and
then the number two).

—
03 Remove the top bus
cover in both frames (the
number three first and
then the number four).

—
01

Top bus cover (3, 4)

2 1

Side bus cover (1, 2)

—
02
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 34

6. Procedure

2 1

—
03
35 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
04 Remove the plastic
bolts of the bus boots, in
some cases, these bolts
are not in the bus boots,
but in a bag they are
included. Remove all the
bus boots. The bus boots
must be reinstalled after
the main bus is installed.

—
04
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 36

—
05 Slide the main bus
bars through the through
three openings in the bus
support (red rectangular
sheet installed bet-
ween both frames).

—
06 The picture shows
the bus with the
boots removed.

Slide bus bars

through here

—
05
37 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
07 Place bar spacers
where needed. Insert a
bolt in all four holes to
secure the bus bar. Do
not tighten any of the
bolts before you place the
main bus bar. Once the
main bus bar is placed
tighten the eight bolts.
If spacers are needed,
they are going to be
supplied by the factory.

—
08 This picture is for
reference only it may not
represent your actual
setup. Please refer to
the standard or special
drawing provided to you
by the project engineer
for guidelines. Use the
torque wrench to tighten
all ½” – 13 UNC bolts,
they must be tightened
to ABB specifications
- see Appendix D.
Bar
spacer

—
07

Bar
spacer

Bolts

—
08
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 38

—
09 Reinstall all
the bus boots.

—
10 Place the plastic bolts
and tighten them.

—
11 Apply the provided
seal putty around
the inside rim of the
through bus support
in the right frame. Cut
any excess putty.

—
10

—
11

—
12

Seal Puttty
39 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
13 Reinstall the bus
barriers, start by
reinstalling the top bus
cover (the number four
first followed by the
number three) followed
by the side bus covers
(the number one followed
by number two).

—
14 Connect the ground
bus bar from frame
4
to frame. It is located
in the back frame.
(highlighted in green).

2 1

—
13

—
14
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 40

—
Appendix C Wiring interconnections
1. Scope/Introduction
This procedure applies to the installation of wiring interconnects for SafeGear MCC at the customer site.

2. Disclaimer
This document was created with the intent of providing general instructions. Models shown in this document
may not match exactly the product you received.

3. Safety practice
Safety glasses, gloves, and steel toe shoes should be used as standard safety practice.

4. Tools required (not supplied)

Philips screwdriver – 1

5. Distribution of the electrical connections

The picture shows the distribution of the electrical connections, such as: customer connection, control relays
and power supply of the control circuits.

6. Procedure
This manual will show you how to reinstall the wires across the shipping splits or wiring Interconnects.
41 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
01 Refer to the
interconnect diagram
provided to you by the
project engineer to find
the shipping splits and
exact frames where
rewiring is necessary.

Locate the wires to be

interconnected. (Refer
to the interconnect
diagram to find the
frame housing the wires
to be interconnected).

—
02 Transfer all the wires
to be interconnected
from one frame to the
next frame through the
opening provided in
the LV compartment.

Opening
provided
in the LV
compartment.

—
02
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 42

—
03 Route the wires
according to the
interconnect diagram.

—
04 Remove the
plastic cover for to
place the wires.

—
03

—
04
43 S A F E G E A R ® M O T O R C O N T R O L C E N T E R /A R C - R E S I S TA N T M E TA L - C L A D C O N S T R U C T I O N

—
05 All the wires are
shipped tagged and
lugged from the
factory and are ready
to be connected. Place
the wires across the
shipping splits or
wiring Interconnects
like in the green square
that’s shown.

—
06 Place the plastic
cover and connect the
wires according to the
connection diagram.

—
05

—
06
 I N S TA L L AT I O N , O P E R AT I O N A N D M A I N T E N A N C E M A N U A L 44

—
Appendix D Torque requirements for SAE grade 5 steel hardware
The table below applies to SAE Grade-5 unlubricated steel hardware into unlubricated, threaded steel material
unless otherwise stated. Torque hardware within the maximum/minimum tolerance.

SAE Grade 5 steel hardware

Hardware
Torque value
Size (inch.)
20 lb-ft-Max
5/16 - 18
Target = 17 lb - ft
(hex head)
13 lb - ft - Min
40 lb - ft - Max
3/8 - 16
Target = 35 lb - ft
carriage bolt
30 lb - ft - Min
40 lb - ft - Max
3/8 - 16
Target = 35 lb - ft
hex bolt
30 lb - ft - Min
20 lb-ft-Max
3/8 - 16
Target = 19 ft - lb
steel threaded stud - (CT mounting)
18 ft.lb - Min
12 lb.ft - Max
3/8 - 16
Target = 11 ft - lb
fiberglass threaded stud - (CT mounting)
10 ft.lb - Min
75 lb - ft - Max
1/2 - 13
Target = 67 lb - ft
hex bolt
60 lb - ft - Min
75 lb - ft - Max
5/8 - 11
Target = 67 lb - ft
hex bolt - (for polyester stand-off insulator)
60 lb - ft - Min
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1YEPMSC2520E001

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