1. travel
2. transports
3. public transport

Instruction Booklet IM04302004E
Effective October 2010
Supersedes June 2010
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
Contents
Part
Description
Page
1
2
3
4
5
6
7
8
9
10
11
12
GeneralInformation . . . . . . . . . . . . . . . . . 2
Receiving,Handling,andStorage . . . . . . . 4
InstallingControlCenterSections . . . . . . . 5
InstallingConduitandWiring . . . . . . . . . . 9
IncomingLineConnections . . . . . . . . . . 11
OvercurrentProtectionDevices . . . . . . . 15
OverloadRelayHeaterSelection . . . . . . 16
InspectionPriortoEnergizing . . . . . . . . . 20
UnitInstallationandAdjustment . . . . . . . 22
Maintenance . . . . . . . . . . . . . . . . . . . . . . 24
PlanViews . . . . . . . . . . . . . . . . . . . . . . . . 29
RelatedInstructionLeaflets . . . . . . . . . . 31
Thiselectricalcontrolequipmentisdesignedtobe
installed,operated,andmaintainedbyadequately
trainedworkmen .Theseinstructionsdonotcover
alldetails,variations,orcombinationsoftheequipment,itsstorage,delivery,installation,check-out,
safeoperation,ormaintenance .Caremustbe
exercisedtocomplywithlocal,state,andnational
regulations,aswellassafetypractices,forthis
classofequipment .Themaximumshortcircuit
capabilityoftheequipmentshouldnotbeexceededbyconnectiontoasourcewithhighercapacity .
Ifmaintenanceortroubleshootingassistanceis
required,contactyournearestEatonsalesoffice .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 1. General information
TheMotorControlCenter
TheEatonFreedom2100MotorControlCentermaybejoinedto
existingFiveStar,Series2100,andAdvantageinstallationsusing
thesplicebarkitscommontoboth .UnitsdesignedfortheFreedom
2100canbemountedinFiveStarSeriesandSeries2100sections,
buttheoppositeisnotrecommended,becauseFiveStarandSeries
2100unitsmaylackterminalblocksandsufficientinterruptingcapacity .TheFreedom2100MCCmaybejoinedtoexistingEatonFreedom
UnitrolandF10UnitrolMCC’swithaspecialsplicebarkit,butunits
arenotinterchangable
Theoperatinghandleonthecontrollerunit(3)movesvertically .In
theONorTRIPPEDpositions,thehandleinterlockswiththeunit
doortopreventitsopening .Inthisposition,authorizedpersonnel
canopenthedoorbyturningthedefeatermechanismscrew .(21)
WiththeunitdooropenandtheoperatinghandleintheONposition,
anotherinterlocktothedividerpanpreventsremovaloftheunit .
Thissameinterlockpreventsinsertionoftheunitunlessthehandle
mechanismisintheOFFposition .Toensurethatunitsarenotenergizedaccidentallyorbyunauthorizedpersonnel,thehandlemechanismcanbepadlockedintheOFFposition .Spaceforaminimum
ofthreepadlocksisprovidedoneachhandle .Thedevicepanel(5)
ismountedonthedrawoutunit .Itwillaccommodateuptosixpilot
devices .Theoverloadresetbuttonismountedontheunitdoor .
ControlCenterNomenclature
Thenumbersshowninparenthesesinthefollowingtextrefertothe
balloonlegendsinFigure2 .
TheEatonFreedom2100MotorControlCenterconsistsofoneor
moretotallyenclosed,deadfront,freestandingstructuralassemblies90incheshighwhicharecompartmentalizedtohouseindividualcontrolunits .(2)Withcontrolunitsmountedinthefrontsideonly,
thestructuremaybe16or21inchesdeep .Formountingunitsbackto-back,thestructureis21inchesdeep .Steelcovers(7)enclose
thestructureatthetop,sidesandattherearoffront-mounted-only
structures .
Averticalbussysteminstalledineachverticalsectionisconnected
tothehorizontalbustofeedtheindividualcontrolunits .Thevertical
busisisolatedbyafullheightbarrier .(6)Anoptionallabyrinthbarrierprovidesbothisolationandinsulation .Anautomaticshutteris
includedwiththelabyrinthbarriersystemtocoverthestabopenings
foreachcontrolunit .
Atthetopofeachsection,adoorprovidesreadyaccesstothetop
horizontalwireway(11)andgroundbus .Thehorizontalwireway
isisolatedfromthebussystemsbysteelbarrierswhichcanbe
removedforinstallationandmaintenanceoperations .Adequate
spaceisprovidedforcontrolwiringandtopcableentry .
Atthebottomofeachsection,adoor(18)providesreadyaccessto
thebottomhorizontalwireway,andneutralbus(ifprovided) .The
bottomofeachsectioniscompletelyopentoprovideunrestricted
bottomentryofcableandconduit .Channelsillsmaybeinstalled
acrossthebottomofthecontrolcenterifspecified,andanoptional
bottomplatemayalsobespecified .
Averticalwireway8inchesdeep,extendingthefull90inchheightof
thecontrolcenterislocatedtotherightofeachunitcompartment .
Thiswirewayiscoveredbytwohingeddoors(15)andcontainscable
supportstosecurewirebundlesandcables .Theverticalwireway
joinsthehorizontalwirewayatthetopandbottomtoprovideunobstructedspaceforinterwiring .
Eachverticalsectionprovidesspacetomountuptosixcontroller
units(2)withaminimumheightof12inches,inincrementsofsix
inches,foratotalof72inchesofusablespace .Controllersthrough
NEMASize5aredrawouttype(exceptreduced-voltagestarters) .
Thesedrawoutunitassembliesareacompletelyself-containedpackageconsistingofasteelenclosure,operatinghandleandelectrical
components .Thedrawoutassemblyslidesintothiscompartment
onguiderails(11)toprovideeasywithdrawalandreinsertionand
toensureprecisealignmentoftheunitstabswiththeverticalbus .
Eachdrawoutunitisheldinplacebyasinglequarter-turnlatch(4)
whichcanonlybeengagedwhentheunitstabsarefullymatedwith
theverticalbus .Eachunithasaseparatedoor,(1)heldclosedbya
minimumoftwoquarter-turnfasteners .
2
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Figure1.Nameplate
Ratings
EachFreedom2100MotorControlCenterhasaratingnameplate
attachedtothedoorofthetophorizontalwirewayoftheprimary
section .SeeFigure1andFigure2 .Thisnameplateshowsthegeneralordernumberunderwhichthemotorcontrolcenterwasbuilt
anditscontinuouselectricalratings,intermsofincominglinevoltage,phases,andfrequency,andampereratingsofthehorizontal
busandtheverticalbusforeachsection .Inaddition,thisnameplate
showsthepassiveshort-circuit(withstand)ratingofthehorizontal
andverticalbussystem .Theactiveshort-circuit(interrupting)ratings
ofthemainandunitshort-circuitprotectivedevicesareshownon
labelsattachedtotheinsideofeachunit .Beforeinstallingamotor
controlcenter,calculateandrecordthefaultcurrentavailableatthe
incominglineterminals .Verifythattheshort-circuitwithstandard
short-circuitinterruptingratingsoftheunitsinthemotorcontrolcenterareappropriateforthefaultcurrentavailable .
QualifiedPersonnel
Individualswhoinstall,operate,ormaintainMCCsmustbetrained
andauthorizedtooperatetheequipmentassociatedwiththe
installationandmaintenanceofanMCC,aswellastheoperation
oftheequipmentthatreceivesitspowerfromcontrollerunitsin
theMCC .Suchindividualsmustbetrainedintheproperprocedures
withrespecttodisconnectingandlockingOFFpowertotheMCC
andwearingpersonalprotectiveequipment,whichincludesarc
flash,insulating,andshieldingmaterials,andalsouseinsulatedtools
andtestequipment,followingestablishedsafetyproceduresas
outlinedintheNationalElectricalSafetyCode(ANSIC2)and
ElectricalEquipmentMaintenance(NFPA70E) .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
(7)
Top & Side
Cover s
InstructionBookletIM04302004E
Effective October 2010
(6 )
Vertical Bus Barrier
Labyrint h
(Optional )
(5)
Device Panel
and Devices
(4)
Quarter
Turn Latch
(3)
Operatin g
Handl e
(1)
Unit Door
)
(2)
Drawout
Unit
(15 )
Vertical
Wireway
Door
(21)
Defeater
Mechanism Screw
(18)
Bottom
Wireway Door
Figure2.MotorControlCenterNomenclature
eaton Corporation www.eaton.com
3
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 2. receiving, Handling, and Storage
OverheadCrane
1. SeeFigure3forrecommendedliftingconfiguration .
 warning
MCC - Heavy equipMent StateMent
tHiS MCC Can weigH in exCeSS of 2,000 poundS. refer to SHipping
ManifeStS for exaCt weigHt of equipMent. to prevent SeriouS injury or deatH, or equipMent daMage, froM unintended
MoveMent of equipMent during tranSport, inStallation or any
otHer operationS, enSure tHat (1) only Material Handling equipMent of adequate CapaCity and rating for tHe load involved
iS uSed; (2) only qualified perSonnel are involved; and (3) all
lifting/braCing SHipping labelS and MarkingS inStruCtionS
SHipped witH tHe MCC MuSt be followed.
Receiving
Beforeandafterunloadingthemotorcontrolcenter,inspecteach
sectionandunitexteriorforevidenceofdamagethatmayhavebeen
incurredduringshipment .Ifthereisanyindicationthatthecontrol
centerhasbeenmishandledorshippedonitsbackorside,remove
thedrawoutunitsandmakeacompleteinspectionoftheinternal
structure,busbars,insulators,andunitcomponentsforpossiblehiddendamage .Reportanydamagefoundtothecarrieratonce .
Handling
Thefollowingguidelinesareprovidedtohelpavoidpersonalinjury
andequipmentdamageduringhandling,andtofacilitatemovingthe
motorcontrolcenteratthejobsite .
2. Selectoradjusttherigginglengthstocompensateforany
unequalweightdistribution,andtomaintainthemotorcontrol
centerinanuprightposition .
3. Toreducetensionontheriggingandthecompressiveload
ontheliftingangles,donotallowtheanglebetweenthelifting
cablesandverticaltoexceed45degrees .Useslingswithsafety
hooksorshackles .Donotpassropesorcablesthroughlifting
angleholes.
Lift Point
The height of the lift
point above the
spreader should be
at least 1/2 of “A”
(the distance between
eye bolts). This
ensures a maximum
angle of 45º as shown.
Max.
45º
A
Don’t pass ropes
or cables
through lift holes.
Use slings with
safety hooks
or shackles.
Lift Hole
MOTOR CONTROL CENTER
Lift Angle
Figure3.CorrectUseofLiftingAngle
4. Afterremovingtheliftingangles,replacethemountinghardware
topreventtheentranceofdirt,etc .
Fork-lifttruck
GeneralHints
1. Handlethemotorcontrolcenterwithcaretoavoiddamageto
componentsandtotheenclosureoritspaintfinish .
Motorcontrolcentersarenormallytopandfrontheavy .Balancethe
loadcarefully,andsteady,asnecessary,whilemoving .Alwaysusea
safetystrapwhenhandlingwithafork-lift.
2. Keepthemotorcontrolcenterinanuprightposition .
Rollers
3. Ensurethatthemovingmeanshasthecapacitytohandlethe
weightofthemotorcontrolcenter .
4. Thecontrolcentershouldremainsecuredtotheshippingskid
untilthemotorcontrolcenterisinitsfinallocation .
5. Exercisecareduringanymovementandplacementoperations
topreventfallingorunintentionalrollingortipping .
6. Liftinganglesforhandlingbyoverheadcraneareboltedtothe
topofeachshippingsection .Handlingbyoverheadcraneis
preferable,butwhencranefacilitiesarenotavailable,themotor
controlcentercanbepositionedwithafork-lifttruckorbyusing
rollersundertheshippingskid .
4
eaton Corporation www.eaton.com
Rodorpiperollers,withtheaidofpinchbars,provideasimple
methodofmovingthemotorcontrolcenterononefloorlevel,if
thereisnosignificantincline .Rollthemotorcontrolcenterslowly,
andsteadytheloadtopreventtipping .
Storage
Whenanmotorcontrolcentercannotbeinstalledandplacedinto
operationimmediatelyuponreceipt,takestepstopreventdamage
bycondensationorharshenvironmentalconditions .Ifthemotorcontrolcentercannotbeinstalledinitsfinallocation,storeitinaclean,
dry,ventilatedbuilding,heatedtopreventcondensation,andprotectedfromdirt,dust,water,andmechanicaldamage .Whenstorage
conditionsarelessthanideal,installtemporaryelectricalheating,
typicallyintheformoflightbulbs,totaling150wattspersection,
hungintheverticalwireway,orbyapplyingpowertoself-contained
spaceheatersthatthemotorcontrolcentermaybeequippedwith .
Removeallloosepackingandflammablematerialsbeforeenergizing
anyoftheheatingelements .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
part 3. installing Control Center Sections
General
Freedom FlashGardmotorcontrolcenters(MCCs)aredesignedfor
installationinaccordancewithboththeNationalElectricalCodeT
(NECT),NFPA70,andtheNationalElectricalSafetyCode(NESC),
ANSIC2 .
 Caution
if work iS involved in ConneCting tHe Control Center
witH exiSting equipMent, enSure tHat inCoMing power iS
diSConneCted before work beginS. diSConneCting MeanS
SHould be loCked out and/or tagged out of ServiCe. wHere
it iS not feaSible to de-energize tHe SySteM, tHe following
preCautionS SHould be taken:
A. Personsworkingnearexposedpartsthatareormaybeenergizedshouldbeinstructedandshouldusepractices(including
appropriatepersonalprotectiveequipment,whichincludesarc
flash,insulating,andshieldingmaterials,andinsulatedtoolsand
testequipmentinaccordancewiththeNFPA70E) .
B. Personsworkingonexposedpartsthatareormaybeenergized
should,inaddition,bequalifiedpersonswhohavebeentrained
toworkonenergizedcircuits .
Installation
1. Beforeanyinstallationworkbegins,consultalldrawings
furnishedbyEaton,aswellasallapplicablecontractdrawings
fortheinstallation .Giveparticularattentiontothephysicallocationofunitsinthecontrolcenterandtheirrelationtoexisting
orplannedconduit,busways,etc .Provideforfutureconduit
entrancepriortocontrolcenterinstallation .
2. Locatethecontrolcenterintheareashownonthebuildingfloor
plans .Ifinawetlocationoroutsideofthebuilding,protectthe
controlcenterfromwaterenteringoraccumulationwithinthe
enclosure .Recommendedclearancesorworkingspacesare
asfollows:
a. Clearancefromwalls(wherenotrearaccessible)—
aminimumof1/2inchforindoorand6inchesforoutdoor
orwetlocations .
b. ClearancefromfrontofMCC(workingspace)—minimum
of3feetforcontrolcenterswithoutexposedliveparts .
SeeNEC110-13 .
Notee: Thisworkingspaceshouldnotbeusedforstorageandshould
haveadequatelighting .
3. SinceMCCsareassembledatthefactoryonsmoothandlevel
surfacestoensurecorrectalignmentofallparts,MCCsshould
besecurelymountedonalevelsurface .Thefoundationfurnished
bythepurchasermustbetrueandlevel,orthebottomframes
mustbeshimmedtosupporttheentirebaseinatrueplane .Itis
recommendedthatleveledchannelsillsunderboththefrontand
rearofthecontrolcenterbeusedtoprovidethislevelbase .Drill
andtapthechannelsillsformountingboltsinaccordancewith
theapplicablefloorplandrawingandtheneitherinstalltheMCC
levelwith,orontopof,thefinishedfloor .Ifsillsaregroutedin
concrete,themountingboltsshouldbescrewedinplaceand
remainuntiltheconcretehashardened .
InstructionBookletIM04302004E
Effective October 2010
4. Forbottomentry,positiontheMCCsothattheconduitstubs
orflooropeningsarelocatedintheshadedareasshownonthe
MCCfloorplandrawings(refertopage29andpage30forfloor
plandimensions) .Theshadedareasrepresenttheopenspace
availableforconduitentrythroughthebottomofeachsection .
Ashadedareamayberestrictediflargecontrollersorauto-
transformersaremountedinthebottomofthesections .If
optionalbottomplatesaresupplied,theplatesmayberemoved
anddrilledforconduitentry .
5. InstalltheMCCinitsfinalposition,progressivelylevelingeach
sectionandboltingtheframestogetheriftheyareseparated .
Ifnecessary,securetheMCCtowallsorothersupporting
surfaces .Donotdependonwoodenplugsdrivenintoholesin
masonry,concrete,plaster,orsimilarmaterials .SeeNEC110-13 .
6. Iftwoormoreshippingsectionsaretobejoinedintoanintegral
assemblyorashippingsectionistobejoinedtoanexisting
section,refertoparagraphsbelowbeforeproceedingwith
theinstallation .
7.
GroundandbondtheMCCasfollows:
a. MCCsusedasserviceequipmentforagroundedsystemor
asanincominglinesectionforaseparatelyderived,previouslygroundedsystem:
1. Runagroundingelectrodeconductor(groundwire)
havingasizeinaccordancewithNEC250-94fromthe
groundingelectrodetotheMCCgroundbusorground
terminal
provided .SeealsoNEC250-92(A)and92(B) .
2. Ifthesystemisgroundedatanypointaheadofthe
MCC,thegroundedconductormustberuntotheMCC
inaccordancewithNEC250,andconnectedtothe
ground
busterminal .
3. Donotmakeanyconnectionstogroundontheloadside
ofanyneutraldisconnectinglineoranysensorusedfor
ground-faultprotection .Donotconnectoutgoinggroundingconductorstotheneutral .
b. MCCsusedasserviceequipmentforanungroundedsystem
orasanincominglinesectionforaseparatelyderived,
previouslyungroundedsystem:
1. Runagroundingelectrodeconductor(groundwire)
havingasizeinaccordancewithNEC250-94fromthe
groundingelectrodetotheMCCgroundbusterminal .
SeeNEC250-92(A)and92(B) .
c. MCCsnotusedasserviceequipmentnorasanincomingline
sectionforaseparatelyderivedsystem,andusedoneithera
groundedorungroundedsystem:
1. GroundtheMCCgroundbusbymeansofequipment
groundingconductorshavingasizeinaccordancewith
NEC250-95orbybondingtotheracewayenclosing
themainsupplyconductorsinaccordancewith
NEC250-92(B) .
8. Whenallwiringandadjustmentsarecomplete,closeallunitand
wirewaydoors .
9. Indampindoorlocations,shieldtheMCCtopreventmoisture
andwaterfromenteringandaccumulating .
10. UnlesstheMCChasbeendesignedforunusualservice
conditions,itshouldnotbelocatedwhereitwillbeexposed
toambienttemperaturesabove40°C(104°F),corrosiveor
explosivefumes,dust,vapors,drippingorstandingwater,
abnormalvibration,shock,ortilting .
eaton Corporation www.eaton.com
5
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
JoiningCompatibleSections
Iftwomoreshippingsectionsaretobejoinedintoanintegral
assembly,orasectionaddedtoanexistinginstallation,splicingof
horizontalbus,groundbus,neutralbus,andjoiningoftheadjacent
verticalsectionsmustbeplannedwiththeinstallation .
1. Removethesidesheetsfromadjacentverticalsectionstobe
joined .(Thesesheetswillhavebeenremovedfromfactoryassembledsections .)
2. Thehorizontalbusspliceplatesandconnectionhardwarewillbe
shippedwiththeMCCattachedtooneendofshippingsection .
RefertoFigure4 .
3. Thismethodprovidesthemostconvenientaccesstothebolts,
andeliminatestheneedtoremovethehorizontalbusbarriersin
thatstructure .Shouldtheexistingbusbeoxidized,sandlightly
withafinealuminumoxidepaper .
 Caution
do not uSe eMery ClotH or any abraSive Containing Metal.
4. Removetheupperhorizontalwirewaydoorfromthestructureon
therightsideoftheleft-hand(LH)section,andremovethetwopiecewirewaybarriertoprovideaccesstotheendsofthebusin
thatsection .
Figure4.SplicePlatesAttachedtoRight-HandSection
5. Movethesectionintoplace,aligningtheuprightstructuralchannelsandbottomchannels .Alignmentofthesectionwithfloor
sillsandfoundationprovisionswillbefacilitatedbyremoving
thebottomhorizontalwirewaydoors .Usingthe“U”typeframe
clampsprovided,clampadjacentfrontuprightchannelstogether
atthetop,bottom,andapproximatecenterofthevertical
structure .“U”clampplacementsmustbeplaced4inches
(101 .6mm)aboveorbelowthedrawoutunit—1/4turnlatch
andunitinterlockfeatureonthecovercontrolmodule;see
detailsonpage30bottomleft-handcorner .Thisoperationwill
befacilitatedbyremovingtheverticalwirewaydoorsfromthe
left-handstructureandoneormoredrawoutunitsfromthe
right-handstructure .SeePart9,page22 .
6. Ifrearaccessisavailable,“U”clampsshouldalsobeusedto
clamptherearuprightchannelstogether .Infront-mounted-only
structures,thiswillrequireremovaloftheadjacentbacksheets .
Inaback-to-back-mountedstructure,removetheverticalwirewaydoorsandoneormoredrawoutunitsasabove .
7.
Securethesectionstothefloorsillsormountingboltsas
providedfortheinstallation .
8. Boltthehorizontalbusspliceplatestothebusintheleft-hand
structure,torquingallbusspliceboltsto360pound-inches
(30pound-feet) .SeeFigure5 .
9. Replaceallunits,busbarriers,anddoors .
JoiningIncompatibleSections
JoiningaFreedom MCCtootherequipment,suchasTypeWand
11-300controlcenters,willusuallyinvolveatransitionsection
installedbetweenthetwovarietiesofequipment .This
transitionsectionwillbedetailedondrawingsprovidedbyEaton
andtheapplicablecontractdrawings .Ifprovidedseparately,
itshouldbeinstalledfirst .Reviewtheoverallinstallationtaskto
determinewhetherthetransitionsectionshouldbeattachedtothe
existingequipmentortotheFreedomFlashGardsection,beforeit
ismovedintoplace,andselectthesequencethatwillprovidebest
accesstobussplicingandjoiningofthestructures .
6
eaton Corporation www.eaton.com
Figure5.AccesstoLeft-HandSplicePlateConnections
SplicePlates
Eachspliceplatekitconsistsofshortpiecesofbusbarthesame
widthasthemainhorizontalbusoftheMCCthekitisshippedwith,
fourboltsperphase,andappropriatequantitiesofrelatedhardware .
Forasinglebusbarperphase,thehardwareisusedasshownin
Figure6foreither16-or21-inchdeepenclosures .Eachspliceplate
ispunchedwithrectangularholestoacceptasquareshankcarriage
boltthatwillnotrotateasthenutistightened .
WheretheMCCisbuiltwithtwohorizontalbusbarsperphase,the
spliceplatesareinstalledasshowninFigure7 .Thetopedgeof
Figure7throughFigure10representsthebacksideoftheMCC .
Thetopportionofeachofthesefiguresappliesto21-inchdeep
enclosuresandthelowerportionto16-inchdeepenclosures .Note
thatforallbutthesingle-barperphase(Figure6)installation,the
16-inchdeepenclosuresrequiretheuseofanutplatethatis
mountedwiththesamecarriageboltusedtoattachthehorizontal
busbarstothechannel-shapedinsulators .Installthesenutplates
beforemountingthespliceplates .Tightenthespliceplateboltswith
adrivingtorqueof360pound-inches(30pound-feet) .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Type 3R Enclosures
WheretheMCCissuppliedinaType3Renclosureforanoutdoor
application,applyroofsplicecapsateachshippingblockjunctionto
maintaintheenclosureintegrity .
Carriage
Bolt
Splice
Plate
21" Deep
3/8" -16
Nut
Flat
Washer
Lock
Washer
Front
Face
Figure6.Single-BarSpliceKit
21" Deep
Nut
Plate
21" Deep
16" Deep
16" Deep
Hex–Head Bolt
Flat
Washer
Lock
Washer
Figure9.Quadruple-BarSpliceKits
Figure7.Double-BarSpliceKit
21" Deep
Six Bars per Phase—21" Deep
16" Deep
Figure8.Triple-BarSpliceKit
Eight Bars per Phase—21" Deep
Front Face
Figure10.Six-andEight-BarSpliceKits
eaton Corporation www.eaton.com
7
InstructionBookletIM04302004E
Effective October 2010
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
Joining to a Freedom FlashGard, Freedom Unitrol,
orF10Unitrol
ConsulttheassemblyinstructionsuppliedwitheveryFreedomMCC
setupforsplicetoFreedomFlashGard,FreedomUnitrol,orF10
Unitrol .
 warning
SpeCifiC Safety note for inStalling and reMoving MCC unitS—
reCoMMend tHe uSe of new aCCeSSory.
Figure13.SplicePlateAttachedtoFreedomFlashGardGround
BusatBottom
Figure11.SplicePlatesAttachedtoFreedom2100Horizontal
BusandGroundBusatTop
Figure14.SplicePlateAttachedtoFreedomFlashGard
NeutralBus
Figure12.HorizontalBusSpliceFreedomUnitrolonLeft,
Freedom2100onRight
8
eaton Corporation www.eaton.com
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
part 4. installing Conduit and Wiring
Conduit
Installconduitinsuchamannerastopreventwaterfromentering
andaccumulatingintheconduitortheenclosure .Eliminatesags
inconduit .Havetheconduitenterthemotorcontrolcenter(MCC)
intheareasdesignatedforconduitentryontheplanviews .See
page29andpage30ofthisbookletandoutlinedrawingsshipped
withtheMCC .Keepingconduitwithintheshadedareasshownin
theplanviewswillavoidcableinterferencewithstructuralmembers
andlivebus .SeePart12 .
InstructionBookletIM04302004E
Effective October 2010
Bringloadwiringfromtheverticalwireway,underthebottomrighthandsideoftheunit,toterminationswithintheunit .Ifoptional
loadterminalsareprovided,terminateloadwirestoloadterminals
locatedadjacenttotheverticalwireway .Togainaccesstothese
terminals,placetoolbetweenright-handwrappersideandwireway
postasshowninFigure15a .
Wiring
Installthelineandloadconductorssizedinaccordancewith
theNEC .Usecopperwireonlyforcontrolterminations.Use
copperwireonlyforpowerterminationsunlesstheyaremarked
“CU/AL.”Useconductorswithatemperatureratingof167ºF(75°C)
orhigher,butregardlessoftheinsulationtemperaturerating,select
thewiresizeonthebasisof167ºF(75°C)wire
ampacity .Usingahighertemperaturewireampacitytableoften
resultsinasmallercross-sectionofcopperavailableforcarrying
heatawayfromterminals .
Installinsulatedwireandcableatatemperaturesufficientlywarmto
preventtheinsulationfromcrackingorsplitting .
Whenmorethanoneconduitisrunfromacommonsourceortoa
commonload,besuretohaveeachconduitcarryconductorsfrom
eachphaseandthesamenumberofconductorsperphase .Ifthe
phaseconductorsarenotdistributeduniformly,eddycurrentswill
begeneratedinthesteelbetweentheconduits .
Figure15.UnitTerminalBlocks
LocateconductorswithintheMCCtoavoidphysicaldamageand
toavoidoverheating .Secureincomingpowerlinesinamanner
adequatetowithstandtheforcesthatwillacttoseparatethe
conductorsundershort-circuitconditions .Usethecableties
furnishedinbothhorizontalandverticalwirewaystosupportthe
loadandinterconnectionwire .Useashieldedcommunicationscable
insideofflexiblemetalconduittoprotectverylowvoltagesignals
transmittedtoorfromacomputerorprogrammablecontroller .
LugsfurnishedwiththeMCCanditscomponentsareforClassB
andClassCstranding .Verifythecompatibilityofwiresize,type,and
strandingwiththelugsfurnished .Wheretheyarenotcompatible,
changethewireorlugsaccordingly .Ifcrimplugsareused,crimp
withthetoolsrecommendedbythemanufacturer .
Usecareinstrippinginsulationtoavoidnickingorringingthemetal .
Allfieldwiringtocontrolunitsshouldbemadeinaccordancewith
thewiringdrawingsthatarefurnishedwiththecontrolcenter .Load
andcontrolwiringcanbebroughtinthroughtheupperand/orlower
horizontalwireways .Determinethetypeofwiringinstalledinthe
controlcenter(NEMATypeBorC)andproceedperthefollowing
appropriateparagraph .
Thephasesequenceofthepowercircuitloadterminals(top-tobottom:T1,T2,T3)inunitsmountedontherearsideoftheMCCis
oppositetothatoftheloadterminalsinunitsmountedonthefront
sideofaback-to-backMCC .Toobtainthesamedirectionofrotation
foramotorconnectedtoarear-mountedunitasforoneconnected
toafront-mountedunit,re-labeltheterminalsintherear-mounted
unit:T3,T2,T1,andwireaccordingly .Refertothewarningsticker
suppliedwithrear-sideunits .Whenmakingpowerconnections
tothestarterterminals,besuretoleavesufficientslackinthe
wiressothattheunitcanbewithdrawntothedetentpositionfor
maintenance .SeeTable8 .
NEMATypeBWiring
Eachcontrolunitisfactoryassembledwithdevicesinter-wiredwithin
theunit .Inaddition,allcontrolwiringiscarriedtounitterminal
blocksmountedontheright-handsideoftheunit .SeeFigure15 .
Bringthefieldwiringofcontrolwiresfromahorizontalwirewayinto
theverticalwirewayontheright-handsideoftheapplicablecontrol
unitandterminatethemattheunitterminalblocks .
Figure15a.Pull-ApartTerminalBlocks
EngagingPull-apartTerminalBlocks
Themaleportionofthepull-apartterminalblockislocatedina
plasticbagtiedtothepivotrodinsidetheunit .Thisterminalblock
canbewiredoutsideoftheverticalwireway .Toengagetheterminal
block,alignthefingersofthemaleconnectorwiththeslotatthe
backofthefemaleportionoftheterminalblock .Thenrotatethe
maleportionforwardandtotheleftintothefemaleportionofthe
terminalblock .Eachmaleportionofthepull-apartterminalblock
hastwocavitiesadjacenttothecenterterminalscrewtoaccept
thebladeofanelectrician’sscrewdriverusedtocamtheblockinto
andoutofengagement .Eachmaleportionalsohasarearslotthat
canengagetheedgeoftheunitframewhereitcanbemountedfor
easeintroubleshooting .
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9
InstructionBookletIM04302004E
Effective October 2010
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
NEMA Type C Wiring
Eachcontrolunitisfactoryassembledwithdevicesinter-wired
withintheunit .Inaddition,allcontrolwiringiscarriedtounit
terminalblocksonthesideoftheunitandfromtheseunitblocks,
alongwithloadwiringthroughSize3,tomasterterminalblocks
locatedatthetoporbottomofthestructure .SeeFigure16 .Master
terminalblockscanbeeitherfixedordrawoutmounted .Inthe
drawoutdesign,theterminalblocksarerackmountedtopermit
withdrawaloftheentireassemblyforeaseofwiringduring
installationandmaintenance .Bringfieldwiringfromthehorizontal
wirewaytothemasterterminalblocksexceptforloadwiring
largerthanSize3 .Theselatterloadwiresshouldbecarriedinto
theverticalwirewayandunderthebottomright-handsideofthe
unittoterminationswithintheunit .
Figure16.MasterTerminalBlock
10
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Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 5. incoming Line Connections
OvercurrentProtection
Allungroundedconductorsinamotorcontrolcenter(MCC)
installationrequiresomeformofovercurrentprotectioninorderto
complywithSection240-20oftheNEC .Suchovercurrentprotection
fortheincominglinestotheMCCisintheformoffusesoracircuit
breakerlocatedatthetransformersecondarythatsuppliestheMCC .
Theconductorsfromthetransformersecondaryconstitutethe
feedertotheMCC,andthe“10-footrule”andthe“25-footrule”
ofNEC,240-21apply .Theselatterexceptionstothegeneralrule
allowthedisconnectmeansandovercurrentprotectiontobe
locatedintheMCC,providedthefeedertapsfromthetransformer
aresufficientlyshortandotherrequirementsaremet .
Note that
with reverse
feed, the
bottom
terminals of
the circuit
breaker are
still energized
when the
circuit breaker
is turned off!
Acircuitbreakeroracircuitinterruptercombinedwithfuses
controllingthepowertotheentireMCCmayprovidethe
overcurrentprotectionrequiredasdescribedaboveormaybe
asupplementarydisconnect(isolation)means .SeeFigure17,
Figure18,andFigure19 .
WhentheMCChasamaindisconnect,bringtheincominglines
(thefeeders)tothelineterminalsofthecircuitbreakerorcircuit
interrupter .Theloadsideofthecircuitbreakerortheloadsideof
thefusesassociatedwiththecircuitinterrupterhasalreadybeen
connectedtotheMCCbusbardistributionsystem .Inthecaseof
maindisconnectsrated400Aorless,thisloadconnectionismade
bystabconnectionstoverticalbusbarsthatconnecttothe
horizontalbusdistributionsystem .SeeFigure17 .
Figure18.MainCircuitBreakerwithReverseFeed
Vertical
Wireway
Stab
Connections
Figure17.MainDisconnectwithStabLoadConnections
OvercurrentProtectiontobeLocatedintheMCC,Providedthe
FeederTapsfromtheTransformerareSufficientlyShortand
OtherRequirementsareMet
Figure19.MainCircuitBreaker
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InstructionBookletIM04302004E
Effective October 2010
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
Incoming Line Lugs
WheretheovercurrentprotectionfortheMCCisataremote
location,theMCCfeederlinesareconnectedtoincominglinelugs
attachedtothebusbardistributionsystem .SeeFigure20 .Forhighampereratedhorizontalbusbarsystems,theincominglinelugsare
mountedonverticalrisersthatconnecttothehorizontalbusbars .
SeeFigure21 .
Figure20.IncomingLineLugConnections
Figure21.IncomingLineCompartment,2000A
12
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Freedom 2100 Motor Control Center
Installation and Maintenance Manual
Short-circuit Bracing
Allincominglinestoeitherincominglinelugsortomaindisconnects
mustbebracedtowithstandthemechanicalforcescreatedbya
highfaultcurrent .WiththeremainderofaFreedom2100MCCrated
fornotlessthan65,000A(rmssymmetrical),theinstallingelectrician
needstoanchorthecablesattheincominglineconnectionssufficientlyandtightenthelugscorrectly .
Eachincominglinecompartmentisequippedwithtwo-piecesheet
steelbracketsthatformacablebracingsupportbracketthatis
approximately9inchesfromtheconduitentrypoint,forbothtop-
andbottom-feedapplications .Usethebracketandappropriate
lashingmaterialtotiethecablessecurelytogetherifbundledorto
holdapartwhentheyarerequiredtobeseparated .SeeFigure22,
whichshowsthetwo-partmounting/bracingbracket,inatopentry
incominglugconfiguration .
InstructionBookletIM04302004E
Effective October 2010
MakingConnection
 Caution
all inCoMing line CoMpartMentS preSent an obviouS Hazard
wHen tHe door iS opened or CoverS are reMoved witH power
on. wHen working in tHiS area, tHe inCoMing feeder SHould be
de-energized.
Beforebeginningworkonincominglineconnections,refertoall
drawingsfurnishedbyEaton,aswellasallapplicablecontract
drawingsfortheparticularinstallation .
Dependingonthelocation,size,andtypeoftheincomingarrangement,removeoneormorehorizontalandverticalwirewaydoors,
andselectedunitstoprovidecompleteaccess .SeePart9,page22
forunitremovalinstructions .
Fortopentry,thetopcoverplatesareeasilyremovedfordrillingor
punchingoperations .
Figure22.IncomingLineCompartmentShowingTwo-Piece
SupportBracket,withOpeningforCables
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13
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
MCC with a Magnum or a main lug only incoming line
(Figure21)section—cablebracing/lashingfortop-and
bottom-feedarrangements
1. Allcablemustbeterminatedwithtwo-holemountedcompressionormechanicalset-screwtypelugs .
2. Allnon-current-limitingcircuitbreakersratedabove42kAand
withcircuitsratedfor800Aandbelowrequirecablelashing
perFigure23 .
3. Circuitbreakerrated42kAand belowrequirenocablelashing .
4. Nocablelashingisrequiredforcurrent-limitingcircuitbreakers .
5. Nocablelashingisrequiredforcircuitsusingmorethanfour(4)
cablesof500kcmilorlargersizewireperphase,regardlessof
shortcircuitrating .
Rope Requirements:
3/8" diameter
Nylon, twisted
Size = #12
3 strand
Tensile strength = 3340 lbs (1515 kg)
Working load = 278 lbs (126 kg)
Cable
Rope
Note 1
Cable
Lugs
(Note 2)
Note 1
6.00
(152.4)
6.00
(152.4)
12.00
(304.8)
Instructions:
1. Route cable as close together as possible.
2. Wrap rope around the cable 6 in (152.4 mm) from lugs (see Note 1).
3. The second wrap is to be applied 6 in (152.4 mm) from the first wrap.
4. After the second wrap, the cables should be wrapped at 12 in (304.8 mm) increments to the entry or exit point of the switchgear.
5. Verify that each set contains 5 loops and that all ropes are pulled as tight as possible.
Note 1: The goal is to bundle all cables together in one bundle, but near the lug landings, so the bundles may need to separate.
In this case, the rope between cables should be wrapped to provide support.
Note 2: The center pole cable lugs are shown in-line with outer poles; Figure 21 shows lugs with center pole offset either leading
or lagging outer poles, depending on top or bottom feed cables. The six-inch dimension shown in these arrangements is from the closed lug,
which is the center pole for top entry and outer poles for bottom entry as shown in Figure 21.
Figure23.CableLashingInstallationInstructions
14
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Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 6. overcurrent protection devices
C306OverloadRelaySetting
DeviceSelection
FLADialAdjustment—Formotorshavinga1 .15servicefactor,
rotatetheFLAadjustmentdialtocorrespondtothemotor’sFLA
rating .EstimatethedialpositionwhenthemotorFLAfallsbetween
twolettervaluesasshowninFigure25 .
Articles240and430oftheNECcontaintherulesforselecting
fuses,circuitbreakers,andoverloadrelaysbytypeandbyvoltage
andampererating .Followtheserulesforfeedercircuits,andthe
instructionsattachedtotheinsideoftheleft-mostverticalwireway
door,formotorbranchcircuits .Selectandinstalloverloadrelay
currentelements(heaters)basedonthemotorservicefactorand
full-loadcurrent .Ambient-compensatedoverloadrelaysareusedin
motorcontrolcenters(MCCs)tooffsetthetemperaturegradient
thatoccursfromtoptobottominaloadedverticalsection .
Heatersmustbeinstalledinthestarteroverloadrelay
assembliesbeforethestarterisenergized.
C306ThermalOverloadRelays(Figure24)
Formotorshavinga1 .0servicefactor,rotatetheFLAdialone-half
positioncounterclockwise(CCW) .
Manual/AutomaticReset—Theoverloadrelayisfactoryset“M”
formanualresetoperationasshowninFigure25 .Forautomatic
resetoperation,turntheresetadjustmentdialtothe“A”position .
Automaticresetisnotintendedfortwo-wiredevices .
TestForTripIndication—Totestoverloadrelayfortripindication
wheninmanualreset,pullouttheblueresetbutton .Anorangeflag
willappearindicatingthatthedevicehastripped .Pushresetbutton
toreset .
C306overloadrelaysareprovidedonFreedomstarters .Foursizes
areavailableforoverloadprotectionupto114A .Featuresinclude:
•
Selectablemanualorautomaticresetoperation
•
Interchangeableheaterpacksadjustable±24%tomatchmotor
FLAandcalibratedforusewith1 .0and1 .15servicefactor
motors .Heaterpacksfor32Aoverloadrelaywillmountin75A
overloadrelay—usefulinderatingapplicationssuchasjogging
•
Class10or20heaterpacks(Figure24) .UseClass10heaters
withfusibleorthermal-magneticbreakerdisconnectsonly
•
Bimetallic,ambient-compensatedoperated .Trip-freemechanism
•
ElectricallyisolatedNOandNCcontacts(pullRESETbutton
totest)
•
Overloadtripindication
•
Single-phaseprotection
•
ULlisted,CSAcertified,andNEMAcompliant
 warning
to provide Continued proteCtion againSt fire or SHoCk Hazard,
tHe CoMplete overload relay MuSt be replaCed if burnout of
tHe Heater eleMent oCCurS.
FLADialAdjustment
1 .0Service
Factor
ResetAdjustmentDial
1 .15Service
Factor
A
M
Exampleof12 .0FLASettingforHeater
PackNumberH2011BShowingPosition
for1 .0or1 .15ServiceFactorMotors
ExampleofSetting
forManualReset
Figure25.OverloadRelaySettings
CurrentTransformers
Whencurrenttransformersareusedwithoverloadrelays,the
currentthroughtheoverloadrelayheaterisrelatedtothemotor
full-loadbytheinverseofthecurrenttransformerratio .
 warning
do not ever reMove HeaterS froM Size 5 and larger StarterS to
CHeCk unit operation. tHeSe StarterS uSe Current tranSforMerS
to drop tHe Current to tHe range of tHe Size 1 overload relay.
operation witH HeaterS reMoved will not interrupt voltage to
tHe Motor and will generate dangerouS voltageS in tHe open
SeCondary of tHe Current tranSforMer.
Figure24.C306ThermalOverloadRelayandHeaterPack
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15
InstructionBookletIM04302004E
Effective October 2010
Motor Circuit Protector (HMCP)
Afterinstallationofthecontrolcenter,eachMCPmustbe
adjustedtoactualmotorfull-loadamperes(FLA)sothatitwill
tripatanycurrentthatexceedsstartinginrush.Thissetting
provideslow-levelfaultprotection .Thefirsthalf-cycleinrushwill
varywiththemotorcharacteristics .Motorswithlocked-rotor
currentsof6timesmotorfull-loadampereswillusuallyrequirean
instantaneousmagneticsettingof7to11timesmotorfull-load
amperestopreventtrippingwhenstarting .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
ThePUSH-TO-TRIPbuttonchecksthetrippingfunctionandisused
toperiodicallyexercisethebreakeroperatingmechanism .Thebutton
isdesignedtobeoperatedbyusingasmallscrewdriver .
Oncethebreakerhastripped,applyforcewhenmovingtheunit
operatinghandlefromtheTRIPPEDtotheRESETposition,whichis
slightlypassedtheOFFposition
Freedom2100MCCsaresuppliedwithTypeHMCPmotorcircuit
protectorshavinganinterruptingratingtomatchtheshort-circuit
withstandratingofthebusbarsystem .ForHMCPsin225,400,and
600Aframesizes,themagnetic-tripadjustmentissetforeachpole .
Athree-poleHMCPhasthreetripsettingstoadjust .Placeallthree
polesatthesamesetting .
CurrentLimitersforUsewithTypeHMCPandFDBreakers
Theadditionofthecurrentlimiterprovidesinterruptingcapacity
abovetherangehandledbytheHMCPinmotorstartersorbyFD
thermal-magneticfeederbreakers .
EachHMCPorFDbreakerratedupto150Ahasitsowncurrent
limitertoprovidecoordinatedprotectionagainstfaultsupto
100,000A,rmssymmetrical .
Figure26.HMCPMagneticAdjustment
Acamtoacceptasmallnarrow-bladeelectrician’sscrewdriver
isnearthelowerleftcornerandaroundthatareeightlettered
adjustmentpoints,calibratedintripamperes .SeeFigure26 .
Adjustmentshouldneverexceed13timesFLA,whichisin
accordancewithNECrequirementsformagnetic-trip-only
breakers .Adjustmentshouldbemadeasfollowse:
1. ObtainFLAfrommotornameplate .
2. MultiplyFLAby13 .
3. Setthecamtothehighesttripsettingthatdoesnotexceedthe
calculatedfigureofItem2 .Thisisthemaximumsettingthat
shouldbeused .
4. Depressandturnthescrewdriveradjustmentcounterclockwise
onesettingatatime,untilthebreakertripsinstartingandthen
adjustupwardonesettingposition .Thiswillensurethatthecircuitwillopeninstantlyonanycurrentabovethemotorinrush,
usually7to11timesFLA .
16
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Built-intripindicatorsineachphaseimmediatelyshowwhenafault
hasblownthecurrentlimiterandtrippedthecircuitbreaker .Thisprovidesprotectionagainstsinglephasing .Afterinterruptingafault,
thecurrentlimiterwillrequirereplacement.Afterthefaulthas
beencleared,thecurrentlimiterisreplacedbytheremovalofthree
screws .Thebreakercanthenberesettoprovideforsubsequent
highovercurrentprotection .
TypeHMCPandFDCircuitBreakerswithTerminalEnd
Covers
Circuitbreakersinstalledinunitsconnectedto600Vdistribution
systemsrequireaterminalendcaptobeinstalledonthelineside .
Replacetheterminalendcapwhenreplacingcircuitbreakersin
suchunits .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 7. overload relay Heater Selection
Theoverloadisnowsetfor1.15servicefactor.
HeaterSelectionandInstallation
D. If the motor nameplate is 1.0 service factor, rotate the FLA
adjustment dial counterclockwise one-half (1/2) position.
Heatersshouldbeselectedonthebasisoftheactualfullload
currentandservicefactorasshownonthemotornameplateorin
themotormanufacturer’spublishedliterature .
Whenmotorandoverloadrelayareinthesameambientand
theservicefactorofthemotoris1 .15to1 .25,selectheaters
andsetFLAadjustmentdialfromtheheaterapplicationtable .
Iftheservicefactorofthemotoris1.0,orthereisnoservice
factorshown,rotatetheFLAadjustmentdialcounterclockwise
one-half(1/2)position.
E. The overload is factory set for M(MANUAL) reset operation.
If automatic reset is required, turn the reset adjustment dial
to A(AUTO). Automatic reset is not intended for two-wire
control devices.
B
B
C
A
D
A
C
A
D
M
Theconductorsattachedtotheterminalsofanoverloadrelayact
asaheatsinkandareaconsiderationinestablishingthecurrent
ratingofeachheaterelement .Topreventnuisancetripping,which
willoccurifundersizedconductorsareused,selectthewiresize
asiftheconductorshadaninsulationtemperatureratingof167ºF
(75°C),eveniftheconductorsactuallyusedhaveatemperature
ratinghigherthan167ºF(75°C) .
ToRemoveHeaterPacks
Protectheaterandstarteragainstshortcircuitsbyprovidingbranch
circuitprotectioninaccordancewiththeNationalElectricalCode .
Loosentwo(2)heaterpackmountingscrewsandremoveheater
packfromoverloadrelay .
Notee: Beforeinstallingheaterpacks,refertothemotornameplateforFLA
(fullloadamps)andservicefactor(1 .5or1 .0) .Selecttheheaterpackfromthe
propertableonthispage .
OverloadRelaySetting
Toinstalle:
1.15 Service
Factor
1.0 Service
Factor
Thisbimetallicambient-compensatedoverloadrelayisadjustable
withintheFLArangeoftheheaterpack .Eachheaterpackismarked
withitsFLAratings .Withproperheaterselection,theoverloadrelay
willultimatelytripat125%FLAfora1 .15servicefactormotorandat
115%FLAfora1 .0servicefactormotor .
HeaterSelection/installation
Selecttheappropriateheaterpacknumberthatcorrespondstothe
motorFLAratingforyourapplication .Inserteachheaterintothe
overloadrelayandtightenheatermountingscrewssecurelypertable
below .
HeaterPack
MountingScrew
Notee: Atotalofthreeindividualheatersmustbeinstalledinorderforthe
overloadrelaytoworkproperly .
Heater pack numbers
torque
H2001B thru H2017B
H2018 thru H2024
9 lb-in
24–30 lb-in
FLADialAdjustment
Formotorshavinga1 .15servicefactor,rotatetheFLAadjustment
dialtocorrespondtothemotor’sFLArating .EstimatethedialpositionwhenthemotorFLAfallsbetweentwolettervaluesasshown
intheexample .Formotorshaving1 .0servicefactor,rotatetheFLA
dialone-half(1/2)positioncounterclockwise(CCW) .
Figure27.HeaterPack
A. Insertthree(3)identicallynumberedheaterpacksintotheoverloadrelaywithanFLAratingthatincludesthemotornameplate
FLA(fullloadamps) .
FLA
ADJUSTMENT
DIAL
B. Tightentheheaterpackmountingscrewssecurelyperrecommendedtorquevalueslistedbelow .
Exampleofa12 .0FLAsettingforaheaterpacknumberH2011B
showingpositionfor1 .0or1 .15servicefactormotor .
Heater pack numbers
recommended torque
H2001B thru H2017B
H2018 thru H2024
9 lb-in (1 Nm)
24-30 lb-in (2.7–3.4 Nm)
1 .0
SERVICE
FACTOR
C. Adjust the FLA adjustment dial to the motor nameplate FLA
(full load amps).
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17
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Manual/automatic Reset
Table2. NEMASize2HeaterPackSelectionTable
Theoverloadrelayisfactorysetat“M”formanualresetoperation
asshownintheillustration .Forautomaticresetoperation,turnthe
resetadjustmentdialtothe“A”position .Automaticresetisnot
intendedfortwo-wirecontroldevices .
Motor FLa rating a
FLa Dial positions
RESET
ADJUSTMENT
DIAL
Exampleof
settingfor
manualreset .
A
M
TestforTripIndication
Totestoverloadrelayfortripindicationwheninmanualreset,pull
outtheblueResetbutton .Anorangeflagwillappearindicatingthat
thedevicehastripped .PushResetbuttonintoreset .
Formoreinformation,gotowww .1800oldunit .comorcall
1-800-OLD-UNIT .
Table1. NEMASize0and1HeaterPackSelectionTable
Motor FLa rating
FLa Dial positions
B
C
D
Size F
Standard
trip
Class 20
0.254
0.375
0.560
0.814
1.20
0.306
0.452
0.676
0.983
1.45
0.359
0.530
0.791
1.15
1.71
0.411
0.607
0.907
1.32
1.96
H2001B
H2002B
H2003B
H2004B
H2005B
1.79
2.15
3.23
4.55
6.75
2.16
2.60
3.90
5.50
8.17
2.53
3.04
4.56
6.45
9.58
2.90
3.49
5.23
7.40
11.0
H2006B
H2007B
H2008B
H2009B
H2010B
9.14
14.0
18.7
23.5
10.8
16.9
22.7
28.5
12.4
19.9
26.7
33.5
14.0
22.8
30.7
—
H2011B
H2012B
H2013B a
H2014B a
A
a After the above referenced settings have been made, rotate the FLA dial one position clockwise for
these heaters (see table). If less than one position is available, rotate dial maximum. This does not
apply when these heaters are used with adapter base. Catalog No. C306TB1. Exception: does not
apply to AN16DN0.
Notee: Formaximumratings,seetablebelow .Use75°Ccopperconductors
only .Maximumwiresize—8AWG .
neMa Size
amperes
Size
amperes
0
18
—
—
1
27
F
32
 warning
to provide Continued proteCtion againSt fire or SHoCk Hazard,
tHe CoMplete overload relay MuSt be replaCed if burnout of
tHe Heater eleMent oCCurS.
18
eaton Corporation www.eaton.com
B
C
D
Size J and K
Standard trip
Class 20
3.23
4.55
6.75
9.14
14.0
3.90
5.50
8.17
10.8
16.9
4.56
6.45
9.58
12.4
19.9
5.23
7.40
11.0
14.0
22.8
H2008B
H2009B
H2010B
H2011B
H2012B
18.7
23.5
29.0
39.6
53.9
22.7
28.5
34.0
45.5
60.9
26.7
33.5
39.1
51.5
67.9
30.7
38.5
44.1
57.4
74.9
H2013B
H2014B
H2015B
H2016B b
H2017B b
a
a For motor FLA values not listed, turn the dial clockwise for higher or counterclockwise for lower
ratings.
b After the above reference settings have been made, rotate the FLA dial one position clockwise for
these heaters (see table). If less than one position is available, rotate dial to maximum. This note
does not apply when these heaters are used with adapter base. Catalog No. C306TB1.
Notee: Formaximumratings,seetablebelow .Use167ºF(75°C)copper
conductorsonly .Maximumwiresize—3AWG .
neMa Size
amperes
Size
amperes
2
45
J
60
—
—
K
73
Table3. NEMASize3and4HeaterPackSelectionTable
Motor FLa rating a
FLa Dial positions
A
B
C
D
Size n
Standard trip
Class 20
18.0
24.6
33.5
45.7
20.2
27.6
37.5
51.2
22.3
30.5
41.5
56.7
24.5
33.4
45.6
62.1
H2018
H2019
H2020
H2021
62.2
84.7
106.0
69.7
94.9
118.0
77.1
105.0
131.0
84.6
115.0
144.0
H2022
H2023
H2024
a For motor FLA values not listed, turn the dial clockwise for higher or counterclockwise for
lower ratings.
Notee: Formaximumratings,seetablebelow .Minimumwiresize—6AWG .
neMa Size
amperes
Size
amperes
3
90
N
14
4
135
—
—
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Table6. MagneticReduced-VoltageStarterClassesF600,F700,
F890withC306ThermalOverloadRelay
Table4. NEMASize5HeaterPackSelectionTable
Motor FLa rating a
FLa Dial positions
a
B
C
D
Standard trip
Class 20
34
49
72
41
59
87
48
69
103
54
79
118
H2003B
H2004B
H2005B
Starter type
107
129
194
130
156
234
152
182
274
174
209
—
H2006B
H2007B
H2008B
Autotransformer
Part-winding
Star-delta
Class
Multiply actual Motor Full Load
Current by Factor Below and refer
to adjusted Full Load Current
Column in tables
Quantity
of
Heaters
required
per
Starter
F600
1
3
F700
0.5
6
F800
0.575
3
a FLA rating marked on heater pack multiplied by a transformation ratio. For motor FLA values not
listed, turn the dial clockwise for higher or counterclockwise for lower ratings.
Notee: Formaximumratings,seetablebelow .Minimumwiresize—2AWG .
neMa Size
amperes
5
270
Table5. NEMASize6HeaterPackSelectionTable
Motor FLa rating a
FLa Dial positions
a
B
C
D
Standard trip
Class 20
144
215
174
259
205
304
235
348
H2005B
H2006B
258
388
312
468
365
547
419
—
H2007B
H2008B
a FLA rating marked on heater pack multiplied by a transformation ratio. For motor FLA values not
listed, turn the dial clockwise for higher or counterclockwise for lower ratings.
Notee: Formaximumratings,seetablebelow .
neMa Size
amperes
6
540
eaton Corporation www.eaton.com
19
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 8. inspection prior to energizing
1. Beforeenergizingthemotorcontrolcenter(MCC),conducta
thoroughinspectiontomakecertainthatallforeignmaterials,
suchastools,scrapsofwire,andotherdebris,areremoved
fromallunitsandthestructure .Removeanyaccumulationof
dustanddirtwithavacuumcleaner .
2. Allcircuitconnectionsaretightenedattimeofassembly
bypower-driventoolswithcontrolledtorque .However,the
vibrationsexperiencedintransitmayloosensomeofthese
connections .Checkatleast10%ofthetotalconnectionsfora
tightconnection .Shouldthisspot-checkrevealsomeloose
connections,itwillbenecessarytocheckallconnection
points.Theconnectionstobecheckedincludebushardware,
circuitbreakerandswitchterminals,contactorandrelay
terminals,andterminalblocks .Alwayschecktheincomingline
connections .TightentothetorquevaluesshowninTable7 .
3. Removeallblocksorothertemporaryholdingmeansusedfor
shipmentfromallcomponentdevicesintheMCCinterior .
15. Topreventpossibledamagetoequipmentorinjurytopersonnel,
checktoensurethatallpartsandbarriersthatmayhave
beenremovedduringwiringandinstallationhavebeen
properlyreinstalled .
16. Conductanelectricalinsulationresistancetesttomakesure
thattheMCCandfieldwiringarefreefromshortcircuitsand
grounds .Dothistestphase-to-phase,phase-to-ground,and
phase-to-neutral,withtheswitchesorcircuitbreakersopened .
17. IftheMCCcontainsalabyrinthverticalbusbarriersystem,
verifytheoperationoftheautomaticshutters .SeePart9for
adjustmentsofthismechanism .
18. Installcovers,closedoors,andmakecertainthatnowires
arepinchedandthatallenclosurepartsareproperlyaligned
andtightened .
19. TurnallcircuitbreakersandfusibleswitchestotheOFFposition
beforeenergizingthebus .
Table7. DrivingTorque
4. Checktheenclosuretoseethatithasnotbeendamagedsoas
toreduceelectricalspacings .
Description
5. Compareallcircuitsforagreementwiththewiringdiagramsthat
accompanytheMCC .Besurethateachmotorisconnectedto
itsintendedstarter .
Coil leads
Relays
Pushbuttons
Control fuse blocks
Auxiliary contacts
6. Makecertainthatfieldwiringisclearoflivebussesand
physicallysecuredtowithstandtheeffectsoffaultcurrent .
7.
Checktodeterminethatallgroundingconnectionsare
madeproperly .
8. Checkalldevicesfordamage .Makeallnecessaryrepairsor
replacements,priortoenergizing .
9. Manuallyexerciseallswitches,circuitbreakers,andother
operatingmechanismstomakecertainthattheyareproperly
alignedandoperatefreely .
10. Testanyground-faultprotectionsystemsthatwerefurnished .
11. Setanyadjustablecurrentandvoltagetripmechanismstothe
propervalues .
12. Ensurethatoverloadrelayheaterelementsareinstalledand
selectedtothefull-loadcurrentshownonthenameplateof
eachmotor .
13. Installpowercircuitfusesinthefusibleswitchesinaccordance
withNECapplicationrequirements .Makesurethatfusesare
completelyinsertedintheclipsprovided .Donotattemptto
defeattherejectionfeatureonthefuseclip,whenprovided .
14. Donotoperateacurrenttransformerwithitssecondarycircuit
open .Ensurecurrenttransformerisconnectedtoaload,ora
secondaryshortingbarisinstalled .
20
eaton Corporation www.eaton.com
lb-in
Control wiring
8 lb-in
8 lb-in
8 lb-in
8 lb-in
8 lb-in
Control wiring terminal blocks
Side-mounted lug/compression
Rail-mounted lug type
Rail-mounted compression type
9 lb-in
12 lb-in
18 lb-in
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Table9. FusedSwitches
Table8. PowerWiringe:Starters
For Freedom Starters
with C306 overload &
Freedom Contactors
tightening torque
Conductors
Size 1 Contactor
20 lb-in
Use 75°C copper
conductors
Size 2 Contactor
Size 3 and
Freedom Compact Size 4
(CN15MN)
Wire size (AWG)
Torque (lb-in)
14–10
35
8
40
6–4
45
3–2
50
Wire size (AWG)
Torque (lb-in)
Slotted head screw
8
40
6–4
45
3–1/0
50
Socket head screw
lb-in
30A fuse assembly
60A fuse assembly
100A fuse assembly
25 lb-in
50 lb-in
50 lb-in
200A fuse assembly
400A fuse assembly
600A fuse assembly
300 lb-in
300 lb-in
300 lb-in
Breakers—Refertotorquevaluesonbreakercase .
Table10. IncomingLineLugs
Description
lb-in
#2/0–350 MCM
#2/0–650 MCM
360 lb-in
360 lb-in
#2/0–750 MCM
500–1000 MCM
500 lb-in
600 lb-in
Socket size (in)
Torque (lb-in)
3/16
120
1/4
200
Table11. BusBolts
5/16
250
Description
lb-in
All
276 lb-in (23 lb-ft)
Size 4
275 lb-in
Size 5
500 lb-in
Starter with C440
Solid State overload
Wire size (AWG)
Torque (lb-in)
NEMA 1 & 2
12-10
23
8-6
28
6-1
28
NEMA 3
Description
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21
InstructionBookletIM04302004E
Effective October 2010
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
part 9. Unit installation and adjustment
DoorRemovalandInstallation
All doors on the control center are mounted on pin hinges
to facilitate removal for installation and maintenance operations. With the operating handle on the OFF position, rotate
the quarter-turn latches, open the door, remove the hinge
pins as shown in Figure 28, partially close the door and lift it
from the structure. Reverse this procedure for installation.
UnitRemovalandInstallation
Afteropeningand/orremovingtheunitdoor,thecontrolunitis
exposed .Withascrewdriver,pushinonthelatchatthetopcenter
oftheunitandrotate¼turncounterclockwise .
 Caution
unitS 18” or More HigH Have a retaining braCe at tHe lower edge
of eaCH Side of tHe unit fraMe to add Stability in SHipping. tHe
SHipping braCeS May be retained or reMoved after inStallation;
unSCrew prior to unit witHdrawal.
Figure28.HingePInRemoval
Pull-apartterminalblocksintheverticalwirewaymustbedisengaged
(seeFigure29andpage9)andwiringfromtheunittootherunits,
tomasterterminalblocksortoloaddevicesmustbedisconnected
beforetheunitisremoved .GrasptheunitasshowninFigure30
andpullitoutward .Thefirstinchoftravelpullsthestabsfreefrom
theverticalbus,andthegroundingcliponthesideoftheunitframe
isalsodisengaged .
Toreplaceacontrolunit,positionthemountingpointsontheunit
framewiththematingguiderails .Slidetheunitinwarduntilallfour
mountingpointsareengaged,thenmoveitinwardwithaquick
push .Thismovementeasilyovercomesthecompressionofthe
stabsastheyengagetheverticalbus .Withtheunitinitscorrect
position,thequarter-turnlatchiseasilyengagedbypushinginward
androtating¼turnclockwise .
Figure29.DisengagingPull-ApartTerminalBlocks
Figure30.WithdrawingaUnit
22
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Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Detent Position
Formaintenanceandtestpurposes,theunitcanbepartiallywithdrawn(approximately1½inches)untilthestabsarefreeofthebus .
Inthisposition,thequarter-turnlatchcanberotatedclockwiseto
engagethedetentpositionslot;thiswillsecuretheunittoensure
thestabsremaindisengagedduringmaintenance .SeeFigure31 .
Thelatchcanbepadlockedinthisposition .
Operating Handle Linkage Adjustment
Movementoftheoperatinghandleintheverticalplaneshouldnot
berestrictedbythehandlecavityateitherthetoporbottomtoits
travel .Shouldrestrictionoccur,eliminateitadjustingthelengthof
theoperatinglinkageasshowninFigure32 .Dependingonthetype
ofprimarydisconnectdevicecontainedinthecontrolunit,itmaybe
necessarytolengthenorshortenthelinkage .
Automatic Shutter Travel Adjustment
Figure31.UnitLockedinDetentPosition
Whentheoptionallabyrinthverticalbusbarrierisinstalledinthe
controlcenter,ashutterisprovidedtoautomaticallycoverthestab
openingswhenacontrolunitiswithdrawn .Theshutterisopenedby
engagementoftheleft-handsideofthecontrolunitwiththeshutter
armlinkageattachedtotheleft-handverticalstructuralmembers .
Whentheunitiswithdrawnfreeofthelinkage,aspringautomaticallymovestheshuttertoitsclosedposition .SeeFigure33and
Figure4 .
Withthecontrolunitremoved,theshuttershouldcompletelycomer
thestabopenings .Ifitdoesnotcovertheopenings,useanadjustablewrenchtobendthelinkarmtotherightuntiltheshuttercovers
thestabopenings .
If,onre-insertionofthecontrolunit,interferenceisfeltbetweenthe
stabassemblyattherearoftheunitandtheshutter,theengagementofthecontrolunitwiththeshutterarmlinkageisinsufficient
tofullyopentheshutter .Useanadjustablewrenchtobendthelinkagearminwardtowardtheunittoincreaseitsengagementwiththe
unit .Aninwardbendofapproximately¼inchwillprovidesufficient
additionalshuttertravel
Figure32.OperatingHandleLinkageAdjustment
InstallingPilotDevices
The device panel can accommodate up to six pilot devices such as
oil-tightpushbuttons,indicatinglights,selectorswitchesandminiaturemeters .Ifunusedspaceisavailableandtheadditionofother
devicesisdesired,observethefollowingprocedure .
Afteropeningtheunitdoor,loosenthetwoscrewsatthetopofthe
devicepanel .Slidethepanel½inchlefttopermitittoswingdown
foraccess .SeeFigure34 .Withthepeenendofaball-peenhammer
orwithadriftorchisel,removethedesiredknockout .
Figure33.ShutterArmLinkage
eaton Corporation www.eaton.com
23
InstructionBookletIM04302004E
Effective October 2010
 Caution
braCe tHe panel Solidly to avoid breaking tHe Hinge pintS. uSe a
knife or SMall file to reMove reMaining plaStid burrS. inStall
and wire tHe new deviCe and re-attaCH teH top of tHe deviCe
panel to tHe unit.
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
part 10. Maintenance
PreventiveMaintenance
Preventivemaintenanceshouldbeaprogram,ascheduledperiodic
actionthatbeginswiththeinstallationoftheequipment .Atthat
time,specificmanufacturer’sinstructionliteratureshouldbe
consulted,thenstoredforfuturereference .Follow-upmaintenance
shouldbeatregularintervals,asfrequentlyastheseverityofduty
justifies .Timeintervalsofoneweek,oronemonth,oroneyear
maybeappropriate,dependingontheduty .Itisalsodesirableto
establishspecificchecklistsforeachcontrol,aswellasalogbook
torecordthehistoryofincidents .Asupplyofrenewalpartsshould
beobtainedandstored .
Thiscontrolequipmentisdesignedtobeinstalled,operated,and
maintainedbyadequatelytrainedworkmen .Theseinstructionsdo
notcoveralldetails,variations,orcombinationsoftheequipment,
itsstorage,delivery,installation,check-out,safeoperation,or
maintenance .Caremustbeexercisedtocomplywithlocal,state,
andnationalregulations,aswellassafetypractices,forthisclass
ofequipment .
Authorizedpersonnelmayopenaunitdoorofamotorcontrolcenter
(MCC)whilethestarterunitisenergized .Thisisaccomplished
bydefeatingthemechanicalinterlockbetweentheoperating
mechanismandtheunitdoor .Aclockwisequarterturnoftheslotted
headscrewlocatedabovetheoperatinghandlewillallowthedoorto
open .SeeFigure355 .
Figure34.UnitDevicePanel
InstallingaNewUnit
Itisrecommendedthatanewunitbeinstalledinaunitspaceat
thetopofaverticalcompartmentordirectlybelowanexistingunit .
Materialprovidedwiththenewunitbythefactoryincludes:Adividerpanwithintegralguiderails,aunitdoor,hinges,catchesandhardware .Observethefollowingsequenceofoperationsforinstallation .
1 . Removetheexistingblankdoor .
2 . Positionthenewunitdoorovertheopenspacetoensurethe
hingesandlatchesarealigned .Ifthespacesdiffer,thehinges
andlatchesonthestructuremustbere-locatedtomatchtheunit
doorhingesandlatches .Mountthedoor,usingthehingepins
provided .
3 . Installthenewdividerpaninthenotchesprovidedintherear
barriersothatitisalignedwiththebottomofthenewdoor .
Attachthepantotheverticalstructurechannelswithonethreadformingscrewoneachside .
4 . Removefromtheverticalbusbarriertheflatplatewhichcovers
thestabholesthatwillalignwiththestabsonthenewunit .Ifan
optionallabyrinthverticalbusbarrierisinplace,installanautomaticshutteroverthestabcutouts .Followtheinstructionsheet
providedwiththeshutterkit .
Whenservicingandadjustingtheelectricalequipment,refertothe
applicabledrawingscoveringthespecificmotorcontrolcenterMCC
andanyotherrelatedinterconnectiondrawings .Followanyinstructionsthatmaybegivenforeachdevice .Alistofinstructionleaflets
coveringstandardcomponentsisshownonpage31ofthismanual .
Anyoftheseleafletsmaybeobtainedbycontactingyournearest
Eatonrepresentative .
GeneralGuidelines—Thewholepurposeofmaintainingelectrical
equipmentcanbesummarizedintworules:
1. Keepthoseportionsconductingthatareintendedto
beconducting .
2. Keepthoseportionsinsulatedthatareintendedtobeinsulated .
Goodconductionrequiresclean,tightjoints,freeofcontaminants
suchasdirtandoxides .
Goodinsulationrequirestheabsenceofcarbontrackingandthe
absenceofcontaminants,suchassaltanddustthatbecome
hydroscopicandprovideanunintendedcircuitbetweenpointsof
oppositepolarity .
Figure35.DefeaterMechanism
24
eaton Corporation www.eaton.com
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
 Caution
MaintenanCe of tHe Control CoMponentS requireS tHat all
power to tHeSe CoMponentS be turned off by opening tHe
branCH CirCuit diSConneCt MeanS and witHdrawing tHe unit to
tHe detent poSition (See figure 31) or reMoving tHe unit entirely
froM tHe MCC. wHen unitS are fully inSerted into tHe MCC, tHe
line Side of eaCH diSConneCt iS energized. do not work on fixed
unitS unleSS tHe Main diSConneCt for tHe MCC iS off..
WhenworkingonportionsofabranchcircuitremotefromtheMCC,
lockthedisconnectmeansforthatcircuitintheOFFposition .To
positivelylocktheoperatingmechanismintheOFFposition,ametal
lockingbarrecessedinthehandlemaybeextendedandpadlocked
withfromonetothreepadlocks .SeeFigure36 .
InstructionBookletIM04302004E
Effective October 2010
thatarepresent .Itisessentialthattheforeigndebrisberemoved
fromthecontrolcenter,notmerelyrearranged .Controlequipment
shouldbecleananddry .Removedustanddirtinsideandoutside
thecabinetwithoutusingliquidcleaner .Removeforeignmaterial
fromtheoutsidetopandinsidebottomoftheenclosure,includinghardwareanddebris,sothatfutureexaminationwillrevealany
partsthathavefallenoffordroppedontotheequipment .Ifthereare
liquidsspreadinside,determinethesourceandcorrectbysealing
conduit,addingspaceheaters,orotheractionasapplicable .
MechanicalChecks.Tightenallelectricalconnections .Lookfor
signsofoverheatedjoints,charredinsulation,discoloredterminals,
andthelike .Mechanicallycleantoabrightfinish(don’tuseemery
paper)orreplacethoseterminationsthathavebecomediscolored .
Determinethecauseoftheloosejointandcorrect .Beparticularly
carefulwithaluminumwireconnections .Aluminumwireisbest
terminatedwithacrimptypelugthatisattachedtothecontrol
component .Whenscrewtypelugs(markedCU/AL)areusedwith
aluminumwire,thejointshouldbecheckedfortightnessevery200
operationsofthedevice .
Wiresandcablesshouldbeexaminedtoeliminateanychafing
againstmetaledgescausedbyvibration,thatcouldprogressto
aninsulationfailure .Anytemporarywiringshouldberemovedor
permanentlysecuredanddiagramsmarkedaccordingly .
Theintendedmovementofmechanicalparts,suchasthe
armatureandcontactsofelectromechanicalcontactors,andmechanicalinterlocksshouldbecheckedforfreedomofmotion
andfunctionaloperation .
Wrap-up.Checkallindicatinglamps,mechanicalflags,doors,
latches,andsimilarauxiliariesandrepair,ifrequired .
Logchangesandobservationsintorecordbookbeforereturning
equipmentintoservice .Donotremoveanylabelsornameplates .
Restoreanythataredamaged .
Figure36.LockingOutaDisconnect
ContactWearandReplacement
WiththedooropenandthedisconnectdeviceOFF,theoperating
handleismechanicallyinterlockedtopreventinadvertentlybeing
pushedON .Todefeatthisinterlock,thebaronthetopofthemechanismshouldbepushedinslightly,allowingthehandletomove
upwardtotheONposition .
Contactorsaresubjecttobothmechanicalandelectricalwear
duringtheiroperation .Inmostcases,mechanicalwearis
insignificant .Theerosionofthecontactsisduetoelectricalwear .
Duringarcing,materialfromeachcontactis vaporizedandblown
awayfromtheusefulcontactingsurface .
 warning
Acriticalexaminationoftheappearanceofthecontactsurfaces
andameasurementoftheremainingcontactover-travelwillgive
theusertheinformationrequiredtogetthemaximumcontactlife .
if fully inSerted, tHe power and Control CirCuitS will be
energized. padloCking to prevent tHiS Handle MoveMent
May be aCCoMpliSHed by tHe SaMe MetHod aS deSCribed above.
Separatecontrolsourcesofpowermustalsobedisconnected .If
controlpowerisusedduringmaintenance,takestepstoprevent
feedbackofahazardousvoltagethroughacontroltransformer .Be
alerttopowerfactorcorrectioncapacitorsthatmaybecharged .
Dischargethembeforeworkingonanypartoftheassociated
powercircuit .
Cleaning.Soot,smoke,orstainedareas(otherthaninsidearc
chutes),orotherunusualdeposits,shouldbeinvestigatedandthe
sourcedeterminedbeforecleaningisundertaken .Vacuumorwipe
cleanallexposedsurfacesofthecontrolcomponentandtheinside
ofitsenclosure .Equipmentmaybeblowncleanwithcompressed
airthatisdryandfreefromoil .(Bealerttobuilt-inoilersinfactory
compressedairlines!)Ifairblowingtechniquesareused,removearc
coversfromcontactorsandsealopeningstocontrolcircuitcontacts
Over-travelMeasurement
Contactlifehasendedwhentheover-travelofthecontacts
hasbeenreducedto0 .02inch .
Over-travelofthecontactassemblyisthatpartofthestrokethat
themovingcontactswouldtravelaftertouchingthefixedcontacts
iftheywerenotblockedfrommovementbythefixedcontacts .
Amethodofmeasuringover-travelisasfollows:
A. Placea0 .02-inchfeelergaugebetweenthearmatureand
magnet,withthearmatureheldtightlyagainstthemagnet .
B. Checkcontinuallyineachphase,i .e .,determineifcircuitfrom
terminal-to-terminalforeachpoleisopenundertheseconditions .
C. Ifthereiscontinuitythroughallphases,theremainingover-travel
issufficient .Ifthereisnotcontinuitythroughallphases,replace
allstationaryandmovingcontactsplusmovingcontactovertravelsprings .Afterreplacingparts,manuallyoperatecontactor
tobesurebindingdoesnotoccur .
eaton Corporation www.eaton.com
25
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Table12. ContactorTroubleshootingChart
Defect
Cause
remedy
Short contact life
Low contact force
Adjust over-travel, replace contacts,
and replace contact springs as
required to correct contact force.
Overheating
Welding of contacts
Contact bounce on
opening or closing
Correct improper voltage applied to
coil. Correct any mechanical defects
or misalignment.
Abrasive dust
on contacts
Do not use emery cloth to
dress contacts.
Load current is
too high
Reduce load. Use larger contactor.
Jogging cycle is
too severe
Reduce jogging cycle. Check factory
for more durable contact material.
Use larger contactor.
Load current too high
Install arc box.
Loose connections
Replace broken or eroded insulating
parts, arc horns, and grid plates.
Clean or replace insulating parts
having a heavy coating of foreign
conducting material.
Over-travel and/or
contact force too low
Remove contaminating materials
that may have accumulated on arc
horns and steel-grid plates.
Ambient temperature
is too high
Reduce load. Provide better
ventilation. Relocate starter.
Use larger contactor.
Line and/or load
cables are too small
Install terminal block and run larger
conductors between contactor and
terminal block.
Over-travel and/or
contact force is too low
Adjust over-travel, replace contacts,
and replace contact springs as
required to correct contact force.
Magnet armature stalls
or hesitates at contact
touch point
Correct low voltage at coil terminals
as coil draws inrush current.
Contactor drops open to Maintain voltage at coil terminals.
contact-touch position
Install low voltage protective
because of voltage dip device, sometimes called
“Brownout Protector.”
Excessive contact
bounce
on closing
Correct coil overvoltage condition.
MaintenanceofMotorControllersafteraFault
Notee: ReproducedbypermissionoftheNationalElectricalManufacturers
AssociationfromNEMAStandardsPublicationNo .ICS2-2000(R2005),
IndustrialControlDevices,ControllersandAssemblies,copyright2000
byNEMA .
Inamotorbranchcircuitthathasbeenproperlyinstalled,
coordinated,andinservicepriortothefault,openingofthe
branch-circuitshort-circuitprotectivedevice(fuse,circuitbreaker,
motorshort-circuitprotector,andsoon)indicatesafaultcondition
inexcessofoperatingoverload .Thisfaultconditionmustbe
correctedandthenecessaryrepairorreplacementsmadebefore
re-energizingthebranchcircuit .
Itisrecommendedthatthefollowinggeneralproceduresbe
observedbyqualifiedpersonnelintheinspectionandrepair
ofthemotorcontrollerinvolvedinthefault .
26
eaton Corporation www.eaton.com
Procedure
 Caution
all inSpeCtionS and teStS are to be Made on ControllerS and
equipMent tHat are de-energized, diSConneCted, and iSolated
So tHat aCCidental ContaCt Cannot be Made witH live partS
and So tHat all plant Safety proCedureS will be obServed.
Enclosure.Substantialdamagetotheunitdoororframe,suchas
deformation,displacementofparts,orburning,requiresreplacement
oftheentireunit .
CircuitBreaker.Examinetheunitinteriorandthecircuitbreaker
forevidenceofpossibledamage .Ifevidenceofdamageisnot
apparent,thebreakermayberesetandturnedON .Ifitissuspected
thatthecircuitbreakerhasopenedseveralshort-circuitfaultsorif
signsofcircuitbreakerdeteriorationappearwithintheenclosure,
thecircuitbreakershouldbereplaced .
DisconnectSwitch.Theexternaloperatinghandleofthedisconnect
switchmustbecapableofopeningtheswitch .Ifthehandlefails
toopentheswitchorifvisualinspectionafteropeningindicates
deteriorationbeyondnormalwearandtear,suchasoverheating,contactblade,orjawpitting,insulationbreakageorcharring,theswitch
mustbereplaced .
FuseHolders.Deteriorationoffuseholdersortheirinsulating
mountsrequirestheirreplacement .
TerminalsandInternalConductors.Indicationsofarcingdamage
and/oroverheating,suchasdiscolorationandmeltingofinsulation,
requirethereplacementofdamagedparts .
Contactor.Contactsshowingheatdamage,displacementofmetal,
orlossofadequatewearallowancerequirereplacementofthe
contactsandthecontactsprings .Ifdeteriorationextendsbeyond
thecontacts,suchasbindingintheguidesorevidenceofinsulationdamage,thedamagedpartsortheentirecontactormustbe
replaced .
OverloadRelays.Ifburnoutofthecurrentelementofanoverload
relayhasoccurred,thecompleteoverloadrelaymustbereplaced .
Anyindicationthatanarchasstruckand/oranyindicationofburning
oftheinsulationoftheoverloadrelayalsorequiresreplacementof
theoverloadrelay .
Ifthereisnovisualindicationofdamagethatwouldrequire
replacementoftheoverloadrelay,therelaymustbeelectricallyor
mechanicallytrippedtoverifytheproperfunctioningoftheoverload
relaycontact(s) .
ReturntoService.Beforereturningthecontrollertoservice,checks
mustbemadeforthetightnessofelectricalconnectionsandforthe
absenceofshortcircuits,grounds,andleakage .
Allequipmentenclosuresmustbeclosedandsecuredbeforethe
branchcircuitisenergized .
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Contact Tip
Contact Plate
(Brass or Copper)
New
Figure37.NormalServiceWear
Corner of Contact
Worn Away
Still
Serviceable
Replace
Figure38.EndofServiceLife
CLEAN FILTER ON
A REGULAR BASIS.
ACCESS FILTER FROM THE
OUTSIDE OF THE ENCLOSURE.
CLEAN FILTER ON
A REGULAR BASIS.
ACCESS FILTER FROM THE
OUTSIDE OF THE ENCLOSURE.
Figure39.NEMA3RMCC-AllFiltersRequireCleaningonRegularBasis
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27
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
Table13. RenewalContactKits,Coils,andOverloadRelays
part number
Description
Coil Suffix
Renewal Parts Pub.
neMa Size 1
Series B1
neMa Size 2
Series B1
neMa Size 3
neMa Size 4
neMa Size 5
Series B1
22177
22177
20426
20428
20429
6-65
6-65-2
6-65-9
6-65-10
6-65-7
6-65-8
6-65-15
6-65-16
6-43-5
6-43-6
—
—
6-44
6-44-2
—
—
6-45
6-45-2
—
—
Contact kits
2-Pole
3-Pole
4-Pole
5-Pole
Magnet Coils
120V 60 Hz or 110V 50 Hz
240V 60 Hz or 220V 50 Hz
480V 60 Hz or 440V 50 Hz
600V 60 Hz or 550V 50 Hz
A
B
C
D
9-2703-1
9-2703-2
9-2703-3
9-2703-4
9-2703-1
9-2703-2
9-2703-3
9-2703-4
9-2756-1
9-2756-2
9-2756-3
9-2756-4
9-1891-1
9-1891-2
9-1891-3
9-1891-4
9-1891-1
9-1891-2
9-1891-3
9-1891-4
208V 60 Hz
277V 60 Hz
208/240V 60 Hz
240V 50 Hz
E
H
J
K
9-2703-9
9-2703-7
—
9-2703-14
9-2703-9
9-2703-7
—
9-2703-14
9-2756-5
9-2756-9
—
9-2756-13
9-1891-13
9-1891-26
—
9-1891-20
9-1891-13
9-1891-26
—
9-1891-20
380–415V 50 Hz
380V 50 Hz
415V 50 Hz
550V 50 Hz
L
L
M
N
9-2703-8
—
—
—
9-2703-8
—
—
—
—
9-2756-12
9-2756-8
9-2756-14
—
9-1891-14
9-1891-21
9-1891-8
—
9-1891-14
9-1891-21
9-1891-8
C306GN3B
C306GN3B
C306KN3
C306NN3
C306DN3B
Overload Relays
For replacement on existing starters three-pole—
ambient-compensated bimetallic
Table14. StarterType
Unit Catalog number Designation (Class)
Disconnect Means
Description
Fusible
Circuit Breaker
Circuit Breaker with Current Limiter
Full voltage, non-reversing
F204
F206
F207
Full voltage, reversing
F214
F216
F217
Reduced voltage, autotransformer type
F604
F606
F607
Reduced voltage, part-winding type
F704
F706
F707
Reduced voltage, closed transition star-delta
F894
F896
F897
Full voltage, non-reversing, two-speed, two windings
F954
F956
F957
Full voltage, non-reversing, two-speed, one winding
F944
F946
F947
28
eaton Corporation www.eaton.com
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 11. plan Views
Removable Top Cover
Top Conduit
Space
16.00
(406.4)
5.41
(137.4)
2.20 (55.9)
1.25 (31.7)
17.50
(444.5)
20.00
(508.0)
Top Conduit
Space
Top View
1.25 (31.7)
Vertical
Wireway Door
2.20 (55.9)
1.25 (31.7)
1.25 (31.7)
1.25 (31.7)
See Note 5
5.41 (137.4)
13.97
(354.8)
6.81 (172.9)
1.58 (40.1)
0.53 (13.5) Dia.
See Notes 1 and 1B
7.31
(185.7)
Vertical
Wireway
16.00
(406.4)
0.70 (17.8)
Bottom
Conduit Space
See Notes 2 and 3
0.53 (13.5) Dia. See Notes 1 and 1A
Figure40.20InchesWide,16InchesDeep,
FrontMountedOnly(4710A30)
16.00
(406.4)
5.41
(137.4)
2.20 (55.9)
1.25 (31.7)
21.50
(546.1)
24.00 (609.6)
Bottom View
1.25
(31.7)
See Note 5
17.50
(444.5)
4.81 (122.2)
18.35
(466.1
5.78 (146.8)
5.41 (137.4)
0.53 (13.5) Dia.
See Notes 1 and 1B
Removable Top Cover
Top Conduit
Space
20.38
(517.7)
Top View
5.41
(137.4)
Vertical
Wireway Door
2.20 (55.9)
1.25 (31.7)
1.25 (31.7)
21.50
(546.1)
24.00
(609.6)
Cross Section
21.50
(546.1)
5.41 (137.4)
6.81 (172.9)
1.58 (40.1)
0.53 (13.5) Dia.
See Notes 1 and 1B
20.00
(508.0)
Vertical
Wireway
8.81 (233.7)
1.25
(31.7)
Removable Bottom
Frame Members
See Note 5
13.97
(354.8)
Bottom Conduit Space
See Notes 2 and 3
0.70 (17.8)
2.00 (50.8)
0.53 (13.5) Dia. See Notes 1 and 1A
Figure41.24InchesWide,16InchesDeep,
FrontMountedOnly(4710A33)
Notese:
Top View
Vertical
Wireway Door
1.25 (31.7)
Wire Tie
Brackets
Cross Section
7.31
(185.7)
1.25
(31.7)
See Note 5
Vertical
Wireway
Removable Bottom
Frame Members
See Note 4
Bottom
Conduit Space
0.70 (17.8)
See Notes 2 and 3
16.00
2.00 (50.8)
(406.4)
0.53 (13.5) Dia. See Notes 1 and 1A
1.58 (40.1)
Wire Tie
Brackets
Bottom View
7.31
(185.7)
1.25
(31.7)
Figure42.20InchesWide,21InchesDeep,
FrontMountedOnly(4710A31)
Removable Top Cover
Top Conduit
Space
Wire Tie
Brackets
Cross Section
5.41 (137.4)
Removable Bottom
Frame Members
See Note 4
Top View
Vertical
Wireway Door
1.25 (31.7)
17.50
(444.5)
20.00
(508.0)
Wire Tie
Brackets
4.81 (122.2)
17.50
(444.5)
20.38
(517.7)
5.41
(137.4)
Cross Section
Bottom View
Removable Top Cover
Bottom View
1.25 (31.7)
See Note 5
5.41 (137.4)
5.78 (146.8)
5.41 (137.4)
1.58 (40.1)
0.53 (13.5) Dia.
See Notes 1 and 1B
21.50
(546.1)
1.25 (31.7)
7.31
(185.7)
Vertical
Wireway
8.81 (223.8)
Removable Bottom
Frame Members
18.35 See Note 5
(466.1)
Bottom
Conduit Space
See Notes 2 and 3
0.70 (17.8)
20.00
2.00 (50.8)
(508.0)
0.53 (13.5) Dia. See Notes 1 and 1A
Figure43.24InchesWide,21InchesDeep,
FrontMountedOnly(4710A34)
1 . Minimumlengthofanchorboltis2 .00(50 .8)(0 .38-16grade5torqued
at31lb-ft) .
A . Fornon-seismic,mountwithtwocenterboltsperenclosure .
B . Forseismic,mountwithminimumfourcornerboltsperenclosure .
2 .Recommendedmaximumconduitheightabovefloorlineis3 .50inches
(88 .9mm) .
3 .Maximumconduitspacewithchannelsillsis17 .50x9 .73inches
(444 .5x247 .1mm) .
4 .Formultiplestructureassemblies,eitheroneorbothofthesemembers
isremovedtoprovidemaximumunrestrictedconduitspaceatthe
bottomoftheMCC .
5 .Thisconduitspaceisnotrecommendedwhenaneutralbusand/oraspace
heaterisrequired .Otherwisethisspaceisavailableforconduit .
SeeFigure4646forverticaldimensions .
eaton Corporation www.eaton.com
29
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
2.20 (55.9)
Removable
Top Cover
3.22 (81.8)
Top Conduit
Space
21.00
(533.4)
Top View
4.62 (117.3)
Wire Tie
Brackets
Rear Vertical
Wireway
17.50
(444.5)
See Note 5
1.25 (31.7)
Vertical
Wireway
Removable Bottom
Frame Members
See Note 5
18.35
(466.1)
Bottom View
5.41 (137.4)
16.00
(406.4)
1.32 (33.5)
2.00
(50.8)
0.53 (13.5) Dia. See Notes 1 and 1A
Figure44.20InchesWide,21InchesDeep,
FrontandRearMounted(4710A32)
Removable
Cover
Top
Conduit
Space
5.41
(137.4)
2.20
(55.9)
1.25
(31.7)
10.00
(254.0)
1.58 (40.1)
0.53 (13.5)
Dia. (2)
See Note 1
Removable Bus
Barrier
Flat Cover
Supplied on
Rear of Front
Mounted Only
Structure
Vertical View
7.50
(190.5)
5.00
(127.0)
Floor Line
3.0
(76.2)
1.00 (25.4)
18.35 (466.1)
Bottom Conduit Space
See Notes 2 and 3
0.70
(17.8)
5.00
(127.0)
15.73 (399.5) or
20.11 (510.8)
Neutral Bus Location
When Specified
1.00
(25.4)
3.00 (76.2) Channel
Sills Supplied Only
When Specified
3.00 (76.2)
9.73 (247.1) or
14.11 (358.4)
10.50
(266.7)
12.12
(307.8)
10.50
(266.7)
Ground Bus
Location
2.25
(57.2)
15.73 (399.5) or 20.11 (510.8)
Neutral Bus Location When Specified
Horizontal Bus Location See Note 9
Vertical Bus Location
Removable Bus Barrier
3.12 (79.2)
A
15.00
(381.0)
4.62 (117.3)
4.62 (117.3)
See Note 9A
Horizontal Wireway
7.16 (181.9) Deep
C
See Note 7
Rear Horizontal Wireway
4.97 (126.3) Deep
See Note 7
D
See Note 7
See Note 7
See Note 9A
Floor Line
5.00
E
(127.0)
B
14.11
(358.4)
20.11
(510.8)
1.00
(25.4)
10.50
(266.7)
1 . Minimumlengthofanchorboltis2 .00(50 .8)(0 .38-16grade5torqued
at31lb-ft) .
A . Fornon-seismic,mountwithtwocenterboltsperenclosure .
B . Forseismic,mountwithminimumfourcornerboltsperenclosure .
2 .Recommendedmaximumconduitheightabovefloorlineis3 .50inches
(88 .9mm) .
3 .Maximumconduitspacewithchannelsillsis17 .50x9 .73inches
(444 .5x247 .1mm) .
4 .Formultiplestructureassemblies,eitheroneorbothofthesemembers
isremovedtoprovidemaximumunrestrictedconduitspaceatthe
bottomoftheMCC .
30
5.00
(127.0)
3.00 (76.2) Channel
Sills Supplied Only
When Specified
3.00 (76.2)
Neutral Bus Location When Specified
Bottom View
Figure45.10InchesWide,16or21InchesDeep,
TransitionStructure(4710A35/6)
Notese:
B
Floor Line
3.00 (76.2)
Channel
Sills Supplied
Only When
Specified
9.73
(247.1)
or
14.11
(358.4)
10.50
(266.7)
See Note 5
5.41 (137.4)
3.12 (79.2)
4.62 (117.3)
4.62 (117.3)
Horizontal
Wireway
7.16 (181.9)
Deep
Removable Bottom
Frame Members
See Note 4. (Not to
be removed for
seismic)
7.50
(190.5)
1.25
1.25
(31.7)
(31.7)
5.78 (146.8)
Horizontal Bus
Location
2.25
(57.2)
1.25
(31.7)
Top View
5.41 (137.4)
See Note 7
Figure46.SideViewA
Ground Bus 12.12 (307.8)
Location
20.38
(517.6)
or
16.00
(406.4)
Minimum Rated Vertical
Bus Supplied as Standard in
Front Mounted Only Structure
See Note 9A
Bottom Conduit Space
See Notes 2 and 3
0.53 (13.5) Dia.
See Notes 1 and 1B
Flat Cover Supplied
on Rear of Front
Mounted Only Structure
See Note 7
7.31
(185.7)
5.41 (137.4)
5.78 (146.8)
Removable Bus Barrier
See Note 8
Horizontal Wireway
7.16 (181.9) Deep
4.81 (122.2)
4.81 (122.2)
1.25 (31.7)
4.62 (117.3)
See Note 9A
7.31
(185.7)
Cross Section
Vertical Bus Location
A
2.25
(57.2)
Vertical
Wireway Door
1.25 (31.7)
17.50
(444.5)
20.00
(508.0)
Horizontal Bus Location
3.12 (79.2)
5.41 (137.4)
2.20 (55.9)
1.25 (31.7)
12.12
(307.8)
10.50
(266.7)
Ground Bus
Location
eaton Corporation www.eaton.com
Figure47.SideViewB
5 .Thisconduitspaceisnotrecommendedwhenaneutralbusand/oraspace
heaterisrequired .Otherwise,thisspaceisavailableforconduit .
SeeFigure4747forverticaldimensions .
7 . MasterTerminalBlock(MTB)assemblyisfurnishedforTypeCwiring
onlywhenlocationnotspecified .MTBsuppliedatthebottom .
8 .Rearhorizontalbusbarriernotsuppliedwithfrontmountedonlystructure .
9 .Standardstructurearrangement:
A . Infront
WithoutMTB:AandB=9 .00(228 .6mm)
WithMTBatbottom:AandB=9 .00(228 .6mm)
WithMTBattop:AandB=3 .00(76 .2mm)
B . Inrear
WithoutMTB:C=0,D=72(1828 .8mm),E=3 .00(76 .2mm)
WithMTBatbottom:C=0,D=66 .00(1676 .4mm),
E=9 .00(228 .6mm)"
WithMTBattop:C=12,D=60(1524 .0mm),E=3 .00(76 .2mm)
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
InstructionBookletIM04302004E
Effective October 2010
part 12. related instructional Leaflets
publication
publication no.
Starters
Size 5, Non-Reversing and Reversing, vacuum
IL17087
Contactors
Size 5, Non-Reversing and Reversing, vacuum
IL16999
Size 5, Non-Reversing and Reversing, vacuum
IL17088
Circuit breakers
Magnum DS
I.B. 2C12060H08
RotoTract Remote Racking Operating Manual
IL04300001E
Series C, F-Frame
IL01219018E
Series C, F-Frame
IL29C101
Series C, J-Frame
IL01204004E
Series C, J-Frame
IL29C103
Series C, K-Frame
IL29C104C
Series C, L-Frame
IL01207002E
Series C, L-Frame
IL29C105
Series C, N-Frame
IL01209003E
Series C, N-Frame
IL29C106
Series C, R-Frame
IL29C613B
Series C, R-Frame
IL29C107
Series G, EG-Frame
IL29C515C
Series G, JG-Frame
IL01207009E
Series G, LG-Frame
IL01207001E
Transfer Switches
IL14477
eaton Corporation www.eaton.com
31
InstructionBookletIM04302004E
Effective October 2010
Freedom 2100 Motor Control Center
Installation and Maintenance Manual
EatonCorporation
ElectricalSector
1111SuperiorAve .
Cleveland,OH44114
UnitedStates
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October2010
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