ABB SafeGear Installation, Operation And Maintenance Manual
Motor control center controller
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- Technical and application manual (48 pages) ,
- Installation, operation and maintenance manual (22 pages)
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Summary of Contents for ABB SafeGear
- Page 1 2017 SafeGear Motor Control Center ® Controller Installation, Operation and Maintenance Manual...
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Page 3: Table Of Contents
SafeGear Motor Control Center ® Controller Installation, Operation and Maintenance Manual Table of Contents 1. Foreword 2. Introduction & Safe Practices 3. Receiving, Handling and Storage 4. General overview 5. Normal Service Conditions 6. Construction 7. Extraction Truck Assembly 8. Racking System and Disconnect 9. -
Page 4: Foreword
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 ®... -
Page 5: Introduction & Safe Practices
The specific ratings of each model controller are listed on the individual nameplates. The SafeGear controller is a protective device. As such, they are ®... -
Page 6: Receiving, Handling And Storage
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. -
Page 7: General Overview
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... -
Page 8: Construction
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. -
Page 9: Racking System And Disconnect
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). SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual 6... -
Page 10: Shutter's Charger Mechanism
Charge the spring manually (as shown in the picture). In this position, the spring is charged. (Note: When the spring is charged, it maintains its position as shown in the picture). 7 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual... -
Page 11: Insertion And Removal
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) Open MCC controller compartment door to its fully opened position. - Page 12 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. 9 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual...
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Page 13: Compartment Detail
11. Compartment Detail Fig. 4 Basic Cell Compartment Slots for engaging the lift trucle Ground Bus Interference Blocking Plate Secondary Disconnects Wheel Rails Shutter TOC Switch SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual 10 ®... -
Page 14: Maintenance
Secondary Locking Tab Cell Locking Tabs Racking Screw Insertion/Removal Handles Position Release Shaft Collar Grounding Connection 10. Racking Lock For Tag-Out Position Release Lever 11. Racking Pin Wheels 11 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual ®... -
Page 15: Accesories
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. -
Page 16: Appendix
Local Trip Collar Racking Screw Position Release Lever 10. Insertion/ Removal Handle 11. Cell Interlock Tab 12. Truck 13. Wheel 14. CPT 15. Shutter’s Charge Mechanism 16. Fuse Box 13 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual ®... - Page 17 Appendix B Basic Controller Dimensions DRAWOUT 400 A CONTROLLER: DRAWOUT 720 A CONTROLLER: SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual 14 ®...
- Page 18 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 The fuse is working in the right position.
- Page 19 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. SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual 16 ®...
- Page 20 The picture shows the right position of the pin of the blow fuse mechanism for a 720 A controller. Remove the plastic bolts on the cover that supports the blown fuse switch. Remove the blown fuse mechanism. 17 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual ®...
- Page 21 Remove the 4 bolts that fix the fuse. Extract the insulation barrier between the fuses. The failed power fuse can be removed. SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual 18 ®...
- Page 22 Replace it with a new fuse which must be the same size. Tighten the 4 bolts which fix the fuse with a torque of 13 pound-foot (lb-ft). Reinsert the insulation barrier between the fuses. 19 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual ®...
- Page 23 2 and verify its right operation. Tighten the plastic bolts on the cover that supports the blown fuse switch. The fuse replacement is complete. SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual 20 ®...
- Page 24 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. 21 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual ®...
- Page 25 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.
- Page 26 If there is a vacuum failure, it can be confirmed by pushing down on the insulating flange below the vacuum interrupter. NOTE: If the interrupter shaft can easily be moved, then the interrupter has lost vacuum. 23 SafeGear Motor Control Center Controller Installation, Operation and Maintenance Manual ®...
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Page 27: 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. - Page 28 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...