Table of Contents
CENTERLINE® Motor Control Centers
400 Amp Disconnect Switch Removal and Installation Instructions
Frame Mounted (Bolt-in) Units Disconnect Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Disconnect Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Plug-in (Withdrawable) Units
Disconnect Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Disconnect Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bulletin 1494F and Bulletin
2294F - Enclosed Disconnect
Switch
Disconnect Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disconnect Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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CENTERLINE® Motor Control Centers 400 Amp Disconnect Switch Removal and Installation Instructions
Publication 2100-IN053A-EN-P - June 2003
Instructions
Frame Mounted (Bolt-in) Units
Disconnect Switch
Removal
ATTENTION
!
ATTENTION
!
De-energize all power sources to the motor control center
(MCC) before replacing the disconnect switch. Verify that
all power is OFF, per NFPA 70E - Standards for Electrical
Safety Requirements. Failure to de-energize all power sources
can result in severe injury or death.
To prevent personal injury or damage to equipment, be
sure the unit handle operator is in the OFF/O position
before replacing the disconnect switch.
NOTE: Torque values shown are nominal. A torque of ±10% of the nominal
value is acceptable.
1. Open the section door. Remove the line terminal guard from the line
side of the disconnect switch. See Figure 1.
Figure 1 Example of the Line Terminal Guard.
Line Terminal
Guard
1
Publication 2100-IN053A-EN-P - June 2003
2
Frame Mounted (Bolt-in) Units
ATTENTION
!
Ensure that no voltage is present on the line side of the
disconnect switch per NFPA 70E - Standards for Electrical
Safety Requirements before proceeding.
2. For fused disconnect switches, label the line side power wires for
proper installation later.
3. For unfused disconnect switches, label the line side and load side
power wires to ensure they will be reinstalled properly.
4. For fused disconnect switches, photograph or sketch the position of
the fuse holder parts for reference in Step 12. See Figure 2.
Figure 2
Remove and fit to
new switch (only 1
type of fuse holder
is shown)
Photograph or
sketch part position
5. For fused disconnect switches, remove power fuses from the fuse
holders. Then remove the fuse holders from the existing disconnect
switch terminals, for later installation onto the replacement disconnect
switch. See Figure 2.
6. For fused disconnect switches, remove the labeled power wires from
the line side disconnect switch terminals
7. For unfused disconnect switches, remove the labeled power wires
from the line side and load side disconnect switch terminals.
8. If present, remove the control auxiliary block from the left side of the
disconnect switch. See Figure 3.
Publication 2100-IN053A-EN-P - June 2003
Frame Mounted (Bolt-in) Units
3
Figure 3
Control Auxiliary Block
9. Support the disconnect switch and then remove the four (4) screws used
to mount the disconnect switch. The disconnect switch should be loose
and now removable. See Figure 4. Screws may be either hex-head bolt
or a slotted torx head bolt.
NOTE: Figure 4 shows a plug-in unit, not a frame mounted unit. Figure 4
illustrates the disconnect switch mounting screw locations.
Figure 4
Mounting Screws
Mounting Screws
Publication 2100-IN053A-EN-P - June 2003
4
Frame Mounted (Bolt-in) Units
10. Verify both the replacement disconnect switch and the handle operator
are in the OFF/O position. See Figure 5.
Disconnect Switch
Installation
ATTENTION
!
Ensure that no voltage is present on all power wires from
Steps 2 and 3, per NFPA 70E - Standards for Electrical Safety
Requirements, before proceeding.
11. Install the replacement disconnect switch in the same location as the
original disconnect switch (removed in Step 9), using the hardware
supplied with the replacement kit. Torque mounting screws to 150
lb-in. (17 Nm). After mounting the disconnect switch, the disconnect
switch’s crossbar and mechanism parts should be in the positions shown
in Figure 5.
Figure 5
Crossbar in the
OFF/O position
When the disconnect switch
crossbar is in the OFF/O
position, all 3 movable
blades must be fully visible
When both the handle and
disconnect switch are in the OFF/
O position the crossbar so it
meets the mechanism (as shown)
sm
ni
r
a
s ba
h
ros
ec
C
M
Mechanism
Place the handle in the
OFF/O position
12. Refer to the photograph or sketch of the fuse holder parts (See Step 4),
mount the fuse holders on the replacement disconnect switch terminals.
Torque the fuse holder’s mounting hardware to the disconnect switch
terminals. See Table A.
Publication 2100-IN053A-EN-P - June 2003
Frame Mounted (Bolt-in) Units
5
Table A Torque Requirements for Fuse Holder Mounting Hardware
Disconnect Size
Required Torque
200 Amp Holder
20 lb-in. (2.2 Nm)
400 Amp Holder
30 lb-in. (3.4 Nm)
600 Amp Holder
45 lb-in. (5.0 Nm)
600 Amp Bolt-In Fuse “L” Bracket
45 lb-in. (5.0 Nm)
13. Install the labeled line side power wires, removed in Steps 6 and 7, to the
line side of the replacement disconnect switch. Ensure they are installed
in the same location and orientation as on the original disconnect
switch. Maintain a minimum 1 inch air gap between lugs of opposite
phases. Torque line side power wire connections to 240 lb-in. (27 Nm).
14. If present, install the control auxiliary block removed in Step 8 on the
left side of the disconnect switch (See Figure 3). Torque the mounting
hardware to 11 lb-in. (1.3 Nm).
15. Install the new line terminal guard supplied with replacement kit. See
Figure 1.
16. For fused disconnect switches, install the power fuses removed in Step
5. Torque the fuse clamps. See Table B.
Table B Torque Requirements for Fuse Clamps
Disconnect Size
Required Torque
200 Amp Clamp
30 lb-in. (3.4 Nm)
400 Amp Clamp
45 lb-in. (5.0 Nm)
600 Amp Clamp
45 lb-in (5.0 Nm)
600 Amp Bolt-In Fuse “L” Bracket
540 lb-in (61 Nm)
200 Amp HRCII - C
200 lb-in (23 Nm)
400 Amp HRCII - C
396 lb-in (45 Nm)
500 Amp Type 170M SCR Fuse(1)
192 lb-in (22 Nm)
(1)
Used in Bulletin 2162N and 2162P, 150-250HP, Rollout Variable Frequency
Drive Units
17. For unfused disconnect switches, install the labeled load side power
wires, removed in Step 7, to the load side of the replacement disconnect
switch. Ensure they are installed in the same location and orientation as
on the original disconnect switch. Maintain a minimum 1 inch air gap
between lugs of opposite phases. Torque the load side power wire
connections to 240 lb-in (27 Nm).
18. Replace any additional equipment that was removed for installation.
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Frame Mounted (Bolt-in) Units
19. Close the section door. With power removed from the MCC, use the
unit handle to cycle the disconnect switch to ON/I. Open the section
door and verify the unit handle, mechanism, and disconnect switch work
properly.
20. Close the section door. With power removed from the MCC, use the
unit handle to cycle the disconnect switch to OFF/O. Open the section
door and verify the unit handle, mechanism, and disconnect switch work
properly.
21. With power removed from the MCC, verify all the wiring is correctly
installed.
22. Before closing the enclosure and/or the individual units, remove all
tools, metal clips, scrap wire and other debris from the MCC interior. If
there is an accumulation of dust or dirt, clean out by using a brush,
vacuum cleaner or clean, lint-free rags. Do not use compressed
air, because it will redistribute contaminants onto other
surfaces.
23. Ensure the handle and disconnect switch are in the OFF/O positions.
Close doors and re-energize equipment in accordance with Motor Control
Center Instruction Manual, publication 2100-5.0, and NFPA 70E, Standards
for Electrical Safety Requirements.
Publication 2100-IN053A-EN-P - June 2003
Plug-in (Withdrawable) Units
Disconnect Switch
Removal
ATTENTION
!
ATTENTION
!
ATTENTION
!
Turn OFF all power to the unit before removal or
installation. Verify all power is OFF, per NFPA 70E Standards for Electrical Safety Requirements.
To prevent personal injury or damage to equipment, make
sure the unit handle operator is in the OFF/O position
before removing the unit.
If unit is not removed (withdrawn) from the MCC, follow
the instructions on pages 1 - 6, for a Frame Mounted
(Bolt-in) Unit.
NOTE: Torque values shown are nominal. A torque of ±10% of the nominal
value is acceptable.
1. Remove the plug-in unit from the MCC. If unit is not removed
(withdrawn) from the MCC, follow the instructions for a Frame
Mounted (Bolt-In) Unit, see pages 1 - 6.
2. Remove the top plate from the unit. See Figure 6.
7
Publication 2100-IN053A-EN-P - June 2003
8
Plug-in (Withdrawable) Units
Figure 6
Top Plate
Line Terminal
Guard
3. Remove the line terminal guard from the line side of the disconnect
switch.
4. For fused disconnect switches, label the line side power wires to ensure
they will be reinstalled properly.
5. For unfused disconnect switches, label the line side and load side
power wires to ensure they will be reinstalled properly.
6. For fused disconnect switches, photograph or sketch the position of
the fuse holder parts for reference in Step 15. See Figure 8.
7. For fused disconnect switches, remove power fuses from the fuse
holders.
8. For fused disconnect switches, remove the labeled power wires from
the line side disconnect switch terminals.
9. For unfused disconnect switches, remove the labeled power wires
from the line and load side of the disconnect switch terminals.
10. If present, remove the control auxiliary block from the left side of the
disconnect switch. See Figure 7.
Publication 2100-IN053A-EN-P - June 2003
Plug-in (Withdrawable) Units
9
Figure 7
Control Auxiliary Block
11. For fused disconnect switches, remove the fuse holders from the
existing disconnect switch terminals, for later installation on the
replacement disconnect switch. See Figure 8.
Figure 8
Remove and fit to
new switch (only 1
type of fuse holder
is shown)
Photograph or
sketch part position
12. Support the disconnect switch and then remove the four (4) screws used
to mount the disconnect switch. The disconnect switch should be loose
from the unit and removable. See Figure 9. Screws may be either hex
head bolts or slotted torx head bolts.
Publication 2100-IN053A-EN-P - June 2003
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Plug-in (Withdrawable) Units
NOTE: Figure 9 is only meant to illustrate the disconnect switch mounting screw locations.
Figure 9
Mounting Screws
Mounting Screws
13. Ensure both the replacement disconnect switch and the handle operator
are in OFF/O position. See Figure 10.
Disconnect Switch
Installation
ATTENTION
In
!
Ensure that no voltage is present on all power wires (from
Step 4 and 5), per NFPA 70E - Standards for Electrical Safety
Requirements, before proceeding.
14. Install the replacement disconnect switch in the same location as the
original disconnect switch, removed in Step 12, using hardware supplied
with the replacement kit. Torque the mounting screws to 150 lb-in. (17
Nm). After mounting the disconnect switch, the switch’s crossbar and
mechanism parts should be in position, as show in Figure 10.
Publication 2100-IN053A-EN-P - June 2003
Plug-in (Withdrawable) Units
11
Figure 10
Crossbar in the
OFF/O position
When the disconnect switch
crossbar is in the OFF/O
position, all 3 movable
blades must be fully visible
When both the handle and
disconnect switch are in the OFF/O
position the crossbar so it meets
the mechanism (as shown)
M
ism
ar
an
h
ssb
ec
Cro
Mechanism
Place the handle in the
OFF/O position
15. Refer to the photograph or sketch of the fuse holder parts (from Step
6), mount the fuse holders onto the replacement disconnect switch
terminals. Torque the fuse holder’s mounting hardware to disconnect
switch terminals, see Table C.
Table C Torque Requirements for Fuse Holder Mounting Hardware
Disconnect Size
Required Torque
200 Amp Holder
20 lb-in. (2.2 Nm)
400 Amp Holder
30 lb-in. (3.4 Nm)
600 Amp Holder
45 lb-in. (5.0 Nm)
600 Amp Bolt-In Fuse “L” Bracket
45 lb-in. (5.0 Nm)
16. For fused disconnect switches install the labeled line side power wires,
removed in Step 8, to the line side of the replacement disconnect switch.
Ensure they are installed in the same location and orientation as on the
original disconnect switch. Maintain a minimum 1 inch air gap between
lugs of opposite phases. Torque line side power wire connections to 240
lb-in. (27 Nm).
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12
Plug-in (Withdrawable) Units
17. For unfused disconnect switches, install the labeled line side and load
side power wires, removed in Step 9, to the line side and load side of the
replacement disconnect switch. Ensure they are installed in the same
location and orientation as on the original disconnect switch. Maintain a
minimum 1 inch air gap between lugs of opposite phases. Torque line
side power wire connections to 240 lb-in. (27 Nm).
18. If present, install the control auxiliary block removed in Step 10 on the
left side of the disconnect switch. Torque the mounting hardware to 11
lb-in. (1.3 Nm). See Figure 7.
19. Install the new line terminal guard supplied with replacement kit.
See Figure 6.
20. For fused disconnect switches, install the power fuses removed in Step
7. Torque fuse clamps, see Table D.
Table D Torque Requirements for Fuse Clamps
Disconnect Size
Required Torque
200 Amp Clamp
30 lb-in. (3.4 Nm)
400 Amp Clamp
45 lb-in. (5.0 Nm)
600 Amp Clamp
45 lb-in. (5.0 Nm)
600 Amp Bolt-In Fuse “L” Bracket
540 lb-in. (61 Nm)
200 Amp HRCII - C
200 lb-in. (23 Nm)
400 Amp HRCII - C
396 lb-in. (45 Nm)
500 Amp Type 170M SCR Fuse(1)
192 lb-in. (22 Nm)
(1)
Used in Bulletin. 2162N and 2162P, 150 - 250HP, Rollout Variable Frequency
Drive Units
21. Perform continuity check between all stab assemblies mounted on the
back of the respective unit to ensure the power wires are connected
appropriately.
22. Replace unit top plate (if removed in Step 2). See Figure 6.
23. Replace any additional equipment that was removed for installation.
24. Verify that all wiring is correctly installed.
25. Use the unit handle to cycle the disconnect switch to ON/I. Verify the
unit handle, mechanism, and disconnect switch work properly.
26. Use the unit handle to cycle the disconnect switch to OFF/O. Verify
the handle, mechanism, and disconnect switch work properly.
Publication 2100-IN053A-EN-P - June 2003
Plug-in (Withdrawable) Units
13
27. With the unit handle in the OFF/O position, and with all three movable
blades of the disconnect switch in the open and visible position, replace
the unit in MCC and secure.
28. Before closing the enclosure and/or the individual units, remove all
tools, metal clips, scrap wire and other debris from the MCC interior. If
there is an accumulation of dust or dirt, clean out by using a brush,
vacuum cleaner or clean, lint-free rags. Do not use compressed
air, because it will redistribute contaminants onto other
surfaces.
29. Ensure the handle and disconnect switch are in the OFF/O positions.
Close the doors and re-energize equipment in accordance with Motor
Control Center Instruction Manual, publication 2100-5.0, and per NFPA
70E, Standards for Electrical Safety Requirements.
Publication 2100-IN053A-EN-P - June 2003
14
Plug-in (Withdrawable) Units
Publication 2100-IN053A-EN-P - June 2003
Bulletin 1494F and Bulletin 2294F - Enclosed
Disconnect Switch
Disconnect Switch
Removal
ATTENTION
!
ATTENTION
!
De-energize all power sources to the enclosure before
replacing the disconnect switch, per NFPA 70E - Standards
for Electrical Safety Requirements. Failure to de-energize all
power sources can result in severe injury or death.
To prevent personal injury or damage to equipment, be
sure the enclosure’s handle operator is in the OFF/O
position before replacing the disconnect switch.
NOTE: Torque values shown are nominal. A torque of ±10% of the nominal
value is acceptable.
1. Open the enclosure door. Remove the line terminal guard from the line
side of the disconnect switch. See Figure 11.
Figure 11
Line Terminal
Guard
15
Publication 2100-IN053A-EN-P - June 2003
16
Bulletin 1494F and Bulletin 2294F - Enclosed Disconnect Switch
ATTENTION
!
Ensure that no voltage is present on the line side of the
disconnect switch per NFPA 70E - Standards for Electrical
Safety Requirements before proceeding.
2. Label the line side and the load side power wires to ensure they will be
reinstalled properly.
3. Remove the labeled power wire lugs from the line and load side of the
disconnect switch terminals.
4. If present, remove the control auxiliary block from left side of
disconnect switch. See Figure 12.
Figure 12
Control Auxiliary Block
5. Support the disconnect switch and remove the four (4) screws used to
mount the disconnect switch. The disconnect switch should be loose
from the enclosure and removable. See Figure 13. Screws may be either
hex head bolts or slotted torx head bolts.
Publication 2100-IN053A-EN-P - June 2003
Bulletin 1494F and Bulletin 2294F - Enclosed Disconnect Switch
17
NOTE: Figure 13 shows a disconnect switch in an MCC unit, not an enclosed
disconnect switch. Figure 13 is only meant to illustrate the disconnect switch
mounting screw locations.
Figure 13
Mounting Screws
Mounting Screws
6. Ensure both the replacement disconnect switch and the handle operator
are in the OFF/O position.
Disconnect Switch
Installation
ATTENTION
In
!
Ensure that no voltage is present on the labeled line side
power wires, per NFPA 70E - Standards for Electrical Safety
Requirements, before proceeding.
7. Using the hardware supplied, install the replacement disconnect switch
in the same location as the original disconnect switch, removed in Step
5. Torque the mounting screws to 150 lb-in (17 Nm). Once the
disconnect switch is mounted, the switch’s crossbar and mechanism
parts should be in the positions shown in Figure 14.
Publication 2100-IN053A-EN-P - June 2003
18
Bulletin 1494F and Bulletin 2294F - Enclosed Disconnect Switch
Figure 14
Crossbar in the
OFF/O position
When disconnect switch
crossbar is in the OFF/O
position, all 3 movable
blades must be fully visible
When both the handle and
disconnect switch are in the OFF/O
position the crossbar so it meets
the mechanism (as shown)
ism
an
h
bar
ec
M Cross
Mechanism
Place the handle in the
OFF/O position
8. Install the labeled line and load side power wire lugs, removed in Step 3,
to the replacement disconnect switch's power terminals. Ensure they
are installed in same location and orientation as on the original
disconnect switch. Maintain a minimum 1 inch air gap between lugs of
opposite phases.
NOTE: See Figure 15 for screw identification. Flat washers and lock washers
are NOT used with the power wire lug retaining screws (hex head cap
screw). Torque the power wire lug retaining screw connections to 240
lb-in (27 Nm).
Publication 2100-IN053A-EN-P - June 2003
Bulletin 1494F and Bulletin 2294F - Enclosed Disconnect Switch
19
Figure 15 Load Side of Disconnect Switch - line and load side lug connections are
similar
Power wire lug retaining screw
(hex head cap screw)
Power wire retaining screw
(hex socket set screw)
Power wire lugs (load side shown) for
400A enclosed disconnect switch
9. Torque the power wire retaining screw (hex socket set screw) to 275
lb-in (31 Nm). See Figure 15.
10. Re-torque the 6 power wire lug terminal screw connections, from Step
8, to 240 lb-in (27 Nm). See Figure 15. Maintain a minimum 1 inch air
gap between lugs of opposite phases.
11. If present, install the control auxiliary block, removed in Step 4, on left
side of the disconnect switch. Torque the mounting hardware to 11
lb-in (1.3 Nm). See Figure 12.
12. Install the new line terminal guard supplied with the replacement kit.
See Figure 11.
13. Replace any additional equipment that was removed for installation.
14. Close the enclosure door. With all power still removed from the
enclosure, use the handle to cycle the disconnect switch to ON/I. Open
the enclosure door and verify the handle, mechanism, and disconnect
switch work properly.
15. Close the enclosure door. With all power still removed from the
enclosure, use the handle to cycle the disconnect switch to OFF/O.
Open the enclosure door and verify the handle, mechanism, and
disconnect switch work properly.
Publication 2100-IN053A-EN-P - June 2003
20
Bulletin 1494F and Bulletin 2294F - Enclosed Disconnect Switch
16. With power OFF/O, verify all wiring is correctly installed. Before
closing the enclosure, remove all tools, metal clips, scrap wire and other
debris from the enclosure interior. If there is an accumulation of dust or
dirt, clean out by using a brush, vacuum cleaner or clean, lint-free rags.
Do not use compressed air, because it will redistribute
contaminants onto other surfaces.
17. Ensure the handle and disconnect switch are in the OFF/O positions.
Close and secure the enclosure door. Re-energize equipment in
accordance with NFPA 70E, Standards for Electrical Safety Requirements.
Publication 2100-IN053A-EN-P - June 2003
Bulletin 1494F and Bulletin 2294F - Enclosed Disconnect Switch
21
Notes:
Publication 2100-IN053A-EN-P - June 2003
Publication 2100-IN053A-EN-P - June 2003 22
© 2003 Rockwell International Corporation. Printed in the U.S.A.