CENTERLINE Motor Control Centers

Bulletins 2100/2500 Test Procedures

Scope: All units and sections are subjected to in-process inspection and test procedures

Summary of Systems Tests

Voltage Test : Applied the correct incoming voltage per the manufacturing documentation and checked for a correct voltage readout
on the appropriate components.

Hi-POT:
A.C Dielectric strength test was made to stress the device under test to an AC high voltage and check that there is no
apparent breakdown or degradation. A HiPOT tester also checked that insulation distances, air or other, are respected.

Potential Exceptions for

Description Exceptions Applied Potential Applied Location Voltage is applied
Between all phases of power
bus and ground (cabinet
Except when there is a frame).
When Hi-Potting main bus 2750 VAC - control transformer do Between all phases of neutral
unit handles should be off to 5/+10% for a not hi-pot between the and ground and neutral,
avoid nuisance breakdowns. minimum of 2 phases that the wires/busbars (if neutral is
Main Bus in Structures Hi-Pot Main Buswork Does not apply to unit only 1 second transformer is in present)

Except when there is a

Hi-Pot all power wires Must be in the OFF position 2750 VAC - control transformer do
with breaker or for units containing electronic 5/+10% for 1 not hi-pot between the
Plug in Units and Frame disconnects in the ON devices including Drives, second 2 phases that the Between all phases of power
Mount Assemblies Position SMC's, PLC's, and SLC's minimum transformer is in wire and ground (unit frame).

For common control

units apply 2750 VAC -
Space Heaters, Thermostats, 5/+10% for 1 second
and unit containing 1650 - 2750 min. For units with
electronic/solid state devices VAC - surge suppression
including Drives, SMCs, 5/+10% for 1 apply 1650 VAC -
Plug in Units and Frame Power Monitors, SS Timers, second 5/+10% for 1 second Between Control Terminals
Mount Assemblies Hi-Pot all control wires PLCs, SLCs, SMPs, etc. minimum min. and Ground

Insert Test: The electrical portion of the Insert Test Included:

• Electrical test to insure that the unit is in phase from stab through power blocks or customer wiring
points. This includes single and multiple starter units, breakers, and disconnects
• Power applied to the unit to check for proper sequencing of the operation per diagram, made
setting adjustments where necessary, applied proper voltage and/or current per order, observed
polarity
• Verified electrical operation of all door mounted devices to ensure associated disconnect means
are functioning correctly
• Checked all devices not wired into the circuit for operation (to include auxiliaries) using a continuity
tester and external voltage or current

Phase Check Vertical Ensured that the stabs contact the vertical bus (on all three phases) and that the phase rotation is correct for all plug in
Bus: units/modules. Ensured correct phasing on all power wires for frame mounted equipment and verified that all wires are
connected to the correct points.

Main Breaker: The breaker was energized and phasing and connections were verified.

Electrical / Mechanical All solid-state controllers were tested per manufacturer's test requirements and all electromechanical devices were
Operation: operated.

Smart Motor Controller A motor was connected to the load terminal connections in the unit and start, run, and stop commands were verified
(SMC) Test: while operating as specified within the SMC Manual.

Drives Test: It was verified that the drive ramps up and down properly when using speed potentiometer, HIM's, or other inputs that
control drive speed. All options that are applicable per the diagram to ensure operation of the unit were run. All drives
were exercised using internal or external control.
 CENTERLINE Motor Control Centers
Bulletins 2100/2500 Test Procedures Continued

Node Commissioning and For DeviceNET products the node address was Hard-Set on the component per order requirements. The baud rate was set per
Setting Baud Rate: order requirements.

Registering EDS Files in

Electronic Data Sheet (EDS) Files were registered and uploaded until all unrecognized devices were registered.
RSNetworx:

IntelliCENTER/Network
Devices: It was verified that all inputs and outputs are per the requirements and functioning and that the Input Output mapping is correct.
Address nodes and baud rates were set and confirmed per customer specification. System communications, component
operation, built-in DeviceNet cable connections, DeviceNET port connections, and continuity for entire system were verified.

Verify Fan Operation:

It was verified that the fan is working and that airflow direction is correct. Voltage Ratings were checked by verifying that the
correct voltage fan is connected to the correct power supply.

Verify transformers The transformers were checked for proper connection and jumper installation according to the transformer unit label. Also
(configuration, grounding, verified primary voltages on the label (matching the application specified on the drawings), and measured the primary &
ratio, voltage ratings): secondary voltage prior to energizing further devices. Checked the ground connection by pull test, and the secondary side
grounding if present with a continuity test and pull test.

Verify current
transformers Checked for the Current Transformer ratio by reading from the label to insure it matches the ratio specified in the drawings/BOM,
grounding/ratio: measured the ground wires, performed continuity and pull test. (Simulate current for certain options)

Verify space Checked mechanical installation, performed a wires connection & pull test, verified that the heating components match the
heaters/thermostats & documentation, and verified devices are operational. Checked that the wires are not in contact with any hot surfaces. Checked
their indicators: the indicators by switching the heater ON&OFF and observing the status lights where applicable.

Verify control station

lights/indicators, selector Verified the order, colors, and description of control station lights, push buttons, selector swtiches, and E-stops. Checked for
switches, buttons, E- functionality by assuring that corresponding devices reacted when pressing the button or switching the selector and verified that
stops: the lights lit according to their function.

Verify existing measuring

systems: Measuring systems were verified for reliable and proper measurements, including voltage, current, and frequency.
 CERTIFIED TEST CHECKLIST

Customer: Rockwell automation de Mexico, S.A. Engineer:

A-B Order Serial Number: Operations Quality Manager:

Rockwell Factory: Mark with "X" the factory where assembled and inspected Brazil
Katowice
Monterrey
Richland Center
Shanghai
Tecate

The following

Order Item # Test Status

Test Name
Voltage Test
HI-POT
Insert Test
Phase Check vertical bus
Main Breaker
Electrical / Mechanical operation
Smart Motor Controller Test
Drives Test
Node Commissioning and Setting Baud Rate
Registering EDS Files in RSNetworx
IntelliCENTER/Network Devices
Verify fan operation (airflow direction, voltage ratings)
Verify transformers (configuration, grounding, ratio, voltage ratings)
Verify current transformers grounding/ratio
Verify space heaters/thermostats & their indicators
Verify control station lights/indicators, selector switches, buttons, E-stops
Verify existing measuring systems (powermonitor, meters)

Test Exceptions: Any ship-less items or customer agreed exceptions

1)
2)
3)

System Testers Signatures:

Dates Tests Completed:

 CERTIFIED INSPECTIONS

Customer: Rockwell automation de Mexico, S.A. Quality Lead:

A-B Order Serial Number: Operations Quality Manager:

The following verification and inspection items are typical controls within our MCC factories. Throughout the manufacturing process, appropriate
inspections are performed either in process or during end of line check or audits.

General Workmanship and Quality of Work Status Comments

Verified Symmetry is Adhered To Where Indicated On Drawings PASS
Verified Wiring In Vertical and Horizontal Directions PASS
Verified Wiring In Vertical and Horizontal Directions PASS
Verified Doors are Flushed and Adjusted Properly PASS
Verified that Bus Bolts are Torqued Properly PASS
Adequate Clearance/Support Bracing for In/Out going Cables PASS
Verified Equipment Is Clean PASS
Verified there is No Damage To Equipment PASS
Verified that the Color of exterior is in accordance with Specification/Data Sheet PASS
Verified there are no Major Scratches on Paint PASS

Wiring Status Comments

Verified Wires are Correct Type and Size PASS
Verified Wire Markings are Present Where Applicable PASS
Verified Wire Terminals are per order specification PASS
Verified Wiring Matches Drawings PASS
Verified Safety Grounding provided for Current Transformers, Voltage transformer,
PASS
relays, doors, etc.
Verified Control/DeviceNet Wiring is complete PASS

Component Inspection Status Comments

Verified All Devices and Features Listed Are Supplied PASS
Verified Equipment Ratings Match Specs And Data Sheets PASS
Verified all Bus is Continuous (Vertical, Horizontal & Ground) PASS
Verified Acceptable Horizontal & Vertical Bus Rating and Insulation PASS
Verifed Acceptable Ground Bus Rating and Location PASS
Verified the Starter, Contactor, Disconnect Switch Sizes Match Drawings PASS
Verified Fuse Types Match Drawings PASS
Verified the Starter, Contactor, Disconnect Switch Locations are Correct PASS
Verified All Operable Functions and Indicating Lights are Working PASS
Verified All Switch Handles and Closing Hardware Work Properly PASS
Verified Proper Alignment of Bucket Ground Clips PASS
Verified Control Power Transformer, Current Transformer, Voltage Transformer
PASS
Ratios/Ratings Match Drawings, Spec, Data Sheet
Verified that Shorting Devices On Current Transformer Secondaries are Supplied PASS
Verified that All Components Match Approved Documentation PASS
Circuit Protective Devices:
Checked the Magnetic circuit protector and Breaker Settings PASS
Verified Overload Heaters are Sized/Set Correctly PASS
Verified Fuse Size and Fuse Clip Ratings PASS
Verified Timing Relays are the Correct Range and Set Per Diagram PASS
Verified Solid-State Controller Processor Works Properly PASS

Structure Status Comments

Verified Dimensions are Per Documentation PASS
Verified Weight Before Shipping PASS
Verified Door Swing Clearances PASS
Verified Footprint is Per Documentation PASS
Verified Floor Mounting is Per Documentation PASS
Verified Elevation is Per Documentation PASS
Verified Proper Gauge of Sheet Metal and Doors for the Structure PASS
Verified Cable Knock-Out Plates are present where required PASS
Verified Lifting Eyes for Lifting Angle are Correct PASS
Verified Shipping Splits Match Drawings PASS

Labels and Nameplates Status Comments

Verify Letter Size is per documentation PASS
Verified that Nameplate Data is Per the Documentation Provided PASS
Verified section serial plate PASS
Verified warning labels are present PASS
Verified wiring labels are present PASS