Allen-Bradley 140M Installation Instructions Manual
Allen-Bradley 140M motor circuit protector provides reliable short-circuit protection for motors in industrial applications. With a rating of 250A, it's ideal for use with NEMA motor starters sizes 4 and 5. The 140M is designed to comply with UL489 and IEC 157-1 standards, ensuring safety and performance. It features a non-sealed construction and is marked LINE and LOAD, making it suitable for forward power flow only.
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C
BUL. 140M
Installation Instructions for
140
M JD-Frame
Motor Circuit Protector
!
WARNING
DO NOT ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT IS ENER-
GIZED. DEATH, SEVERE PERSONAL INJURY, OR
SUBSTANTIAL PROPERTY DAMAGE CAN RESULT
FROM CONTACT WITH ENERGIZED EQUIPMENT.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT
BEFORE PROCEEDING WITH THE TASK, AND
ALWAYS FOLLOW GENERALLY ACCEPTED SAFE-
TY PROCEDURES.
ALLEN-BRADLEY
IS NOT LIABLE FOR THE MIS-
APPLICATION OR MISINSTALLATION OF ITS
PRODUCTS.
The user is cautioned to observe all recommendations, warnings, and cautions relating to the safety of personnel and equipment as well as all general and local health and safety laws, codes, and procedures.
The recommendations and information contained herein are based on Allen-Bradley experience and judgement, but should not be considered to be all-inclusive or covering every application or circumstance which may arise. If any questions arise, contact Allen-Bradley for further information or instructions.
1. INTRODUCTION
General Information
The J D -frame instantaneous (magnetic)-only motor circuit protector (MCP) (Fig. 1-1 ) has a rating of
250A for application with NEMA motor starter sizes 4 and 5. The MCP is available in 3-pole frames only. The MCP is designed to comply with the applicable requirements of Underwriters Laboratories,
Inc. Standard UL489 and the International
Electrotechnical Commission Recommendations No.
IEC 157-1 .
The MCP is a UL-recognized component under file
E7819. It is used primarily to provide short-circuit protection as part of a combination controller where other circuit protective functions are performed by other devices within the controller. Since the J D -frame MCP is a non-sealed device, it is marked LINE and LOAD and is not suitable for reverse feed applications.
This instruction leaflet (IL) gives procedures for installation, operation, inspection, and field testing of J D -fra me
MCPs. For this publication, the term motor circuit protector (MCP) shall also include instantaneous (magnetic)-only circuit interrupters.
2. INSTALLATION
The installation procedure consists of inspecting the
MCP and, as applicable, installing accessories, interphase barriers and terminals; mounting the MCP; connecting the line and load conductors; torquing terminals; and attaching terminal shields. The MCPs, accessories, mounting hardware, and unmounted terminals may be supplied in separate packages.
!
Figure 1-1 J
D
-Frame Motor Circuit
P
rotector
40752-165(1) Effective March 2008
Page 2
NOTICE
Internally-mounted accessories are listed for field installation under UL File E64983. Accessory installation should be done before the MCP is mounted and connected. Refer to individual accessory instruction leaflets.
To install the MCP, perform the following steps.
2-1. Make sure that the MCP is suitable for the intended installation by comparing nameplate data with existing ratings and system requirements. Inspect the MCP for completeness, and check for damage before mounting.
NOTICE
Perform Steps 2-2, 2-3, and 2-4 only if installation of internal accessories is required.
2-2. Remove cover screws and cover.
①
➁
➁
①
➁
➁
Also
Used with
4-Pole
Circuit
Breaker
① ①
① Screw, .190-32 x 3.13 Inch, Pan-Head, Cross-Recessed
➁
Screw, No. 8 x 1.88 Inch, Pan-Head, Cross-Recessed,
Thread Forming
Figure 2-3 Cover Screw Installation Positions
40752-165(1
)
Effective March 2008
2-3. Install accessories.
!
CAUTION
WHEN REMOVED AND REINSTALLED, THREAD-
FORMING SCREWS WILL TRY TO REFORM THE
THREADS IN THE BASE. CARE SHOULD BE TAKEN
EVERY TIME A THREAD-FORMING SCREW IS USED
TO ENSURE THE SCREW STARTS IN THE ORIGI-
NAL THREADS. DAMAGED THREADS CAN RESULT
IN IMPROPER MCP COVER RETENTION.
TA250KB Terminal
Terminal
Connectors
Collar
Collar
Socket
Screw
Flat Head
Screw
Nut
T250KB Terminal
Figure 2-2 Terminal Installation
2-4. Install cover and secure with pan-head screws, followed by thread-forming screws, as shown in Fig. 2-1.
2-5. If not already installed, mount terminals as shown in
Fig. 2-2. When using aluminum body terminal (Catalog
No. TA250KB), secure the terminal to the MCP using a
1/8-inch socket wrench, and torque to 6-8 Ib-ft (8-11
N.m). After mounting the MCP and before installation of the conductors, check or retighten the terminal mounting screw through the terminal. Conductor securing screw must be removed for this check. When using non-aluminum body terminal (Catalog No.T250KB), secure the terminal to the MCP using screw and flat nut. Torque the screw to 8-lb-in (1 N.m.).
!
WARNING
THE VOLTAGES IN ENERGIZED EQUIPMENT CAN
CAUSE DEATH OR SEVERE PERSONAL INJURY.
BEFORE MOUNTING THE MCP IN AN ELECTRICAL
SYSTEM, MAKE SURE THERE IS NO VOLTAGE
PRESENT WHERE WORK IS TO BE PERFORMED.
Page 3
1.375
(34.37)
4.078
(103.58)
.688
(14.47) a. For individual surface mounting, drill mounting panel using the drilling plan shown in Fig. 2-3. For deadfront cover applications, cut out cover to correct escutcheon dimensions. (See Fig. 2-4.) b. If MCP includes factory- or field-installed internal accessories, make sure that accessory wiring can be reached with the MCP mounted.
7.250
(184.15)
Handle
.250-20
(M6-1.0) Tap
(4 Holes)
Handle
Figure 2-3 MCP Mounting Bolt Drilling Plan
.344R
(8.74)
1.562
(39.67)
.781
(19.84)
2.922
(74.22)
.718
.188R
(4.77)
.350
(88.90)
Figure 2-4 MCP Escutcheon Dimensions
Breaker
Handle
.875
(22.22)
NOTICE
Depending on the equipment configuration, the
MCP can be mounted using different styles of hardware. The following steps describe how to mount the MCP using standard hardware. When special hardware is needed (for example, with the electrical operator), the instruction leaflet describing the accessory also describes the special mounting arrangements.
2-6. To mount the MCP, perform the following steps:
NOTICE
Labels with accessory connection schematic diagrams are provided on the side of the MCP. A note should be made of the diagrams if the labels cannot be seen when the MCP is mounted.
c. Position MCP on mounting surface. d. Install MCP mounting screws and washers. Tighten screws firmly, but do not exceed 28 pound-inches (3 N.m).
!
CAUTION
WHEN ALUMINUM CONDUCTORS ARE USED, THE
APPLICATION OF A SUITABLE JOINT COMPOUND
IS RECOMMENDED TO REDUCE THE POSSIBILITY
OF TERMINAL OVERHEATING. TERMINAL OVER-
HEATING CAN CAUSE DAMAGE TO THE MCP.
2-7. Connect line and load conductors and accessory leads.
2-8. If required, install interphase barriers.
2-9. If required, install terminal shield on MCP cover with mounting screws provided.
2-10. After the MCP is installed, check all mounting hardware and terminal connecting hardware for correct torque loading. Torque values for line/load terminals are given in Table 2-1 and on the MCP nameplate.
3. MANUAL OPERATION AND TRIP DEVICE
ADJUSTMENT
Manual Operation
Manual operation of the MCP is controlled by the MCP handle and the PUSH-TO-TRIP button in the trip device.
The MCP handle has three positions, two of which are shown on the cover with the international symbols 1/0 and raised lettering to indicate ON and OFF. On the sliding handle barrier, ON, OFF, and trip are also shown
40752-165(1) Effective March 2008
E
Page 4 by a color-coded strip for each MCP handle position: red for ON, white for tripped, and green for OFF. (See Fig.
3-1.)
Handle Position Indicator
Color
Red – ON
White – TRIP
Green – OFF (Reset)
ON
TRIP
OFF
(Reset)
International
Symbols
ON
OFF
Electro-Mechanical Trip
Device Adjustment Button
(3 Places)
Push-To-Trip
Button
F
G
D
E
I
H
A
B
C
I
G
H
E
F
C
D
A
B
F
G
D
E
I
H
A
B
C
Table 3-1 MCP Trip Settings
Cam
Setting
Motor
Full Load
Current
Amperes
NEMA Continuous MCP
Starter Amps
Size
Catalog
Number
38.5 – 43.4
43.5 – 48.0
48.1 – 53.0
53.1 – 57.6
57.7 – 62.3
62.4 – 67.3
67.4 – 71.9
72.0 – 76.9
77.0 – 81.6
57.7 – 64.6
64.7 – 71.9
72.0 – 79.2
79.3 – 86.5
86.6 – 93.8
93.9 – 101.1
101.2 – 108.4
108.5 – 115.3
115.4 – 122.4
67.4 – 75.3 5
75.4 – 83.8 5
83.9 – 92.3 5
92.4 – 100.7 5
100.8 – 109.2 5
109.3 – 117.6 5
117.7 – 126.1 5
126.2 – 134.6 5
134.7 – 142.8 5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
MCP
Trip
Setting
500
565
625
250 140M-JD8P-C80
690
750
810
875
935
1000
250
750
840
935
1030
140M-JD8P-D12 1125
1220
1315
1410
1500
250 140M-JD8P-D14
875
980
1090
1200
1310
1420
1530
1640
1750
Figure 3-1 MCP Manual Controls
Table 2-1 Terminal Types
①
Terminal Terminal Screw
Cat. No.
Material Head
Body Type
AWG
Wire
Range
Standard
Terminal
TA250KB Aluminum Socket 4-350
MCM
Metric
Wire
Range
Wire
Type
Torque
Value lb-in
(N.m.)
25-185 Cu/AI 275 (31)
Standard
Terminal
T250KB Stainless Socket
Steel
4-350
MCM
25-185 Cu 180 (20)
①
Terminal wire connectors are listed for standard wire sizes as defined in UL486A and UL486B.
40752-165(1) Effective March 2008
Page 5
Table 3-1 MCP Trip Settings (Cont.)
F
G
D
E
I
H
A
B
C
Cam
Setting
Motor
Full Load
Current
Amperes
NEMA
96.2 – 108.0 5
108.1 – 119.9
120.0 – 132.3
5
5
132.4 – 144.2
144.3 – 156.1
156.2 – 168.0
168.1 – 179.9
180.0 – 192.3
192.4 – 204.0
5
5
5
5
5
5
Continuous MCP
Starter Amps
Size
250
Catalog
Number
140M-JD8P-D20
MCP
Trip
Setting
1250
1405
1560
1720
1875
2030
2185
2340
2500
Trip Device
Adjustment Buttons
See above For Trip Setting Values
To Set: Rotate Dials
Push to Trip Button
Figure 3-2 Trip Device Adjustment Buttons
MCP Reset
After an automatic or accessory initiated trip, or a manual Push-to-Trip operation, the MCP is reset by moving the MCP handle to the extreme OFF position.
NOTICE
No MCP should be reclosed until the cause of trip is known and the situation rectified.
PUSH-TO-TRIP Button
The PUSH-TO-TRIP button checks the MCP tripping function and is used to periodically exercise the operating mechanism. The button is designed to be operated by a small screwdriver.
Trip Device Adjustment for MCPs
The magnetic element of each pole of the trip device can be adjusted by rotating the adjustment buttons (Fig.
3-2) on the front face of the trip unit with a screwdriver.
The buttons have nine settings, which are indicated on the nameplate with letters A through l; The ampere settings are shown on the MCP nameplate and in Table 3-
1. To adjust the setting, rotate each button clockwise until arrow on button points to desired setting.
Conforming to NEC requirements, the maximum MCP trip ampere value is set by the motor FLA. Since there are various types and classes of motor designs (based on duty cycle, electrical load, and manufacturer's discretion) locked rotor currents(and therefore inrush current magnitudes)vary.These are normally identified by NEC codes. The Listed MCP trip ampere value is considered typical but not all inclusive. This is the reason for the adjustable magnetic trip setting; that is, to compensate for different actual motor Inrush currents. That adjustments need be made, is not only normal, but sometimes necessary to enable the motor to start without nuisance trip ping, particularly when motor or system conditions induce higher than expected inrush currents. These circumstances could be beyond the control of the MCP so far as its allowable trip setting is concerned and should be treated as a special case, referable to Allen-Bradley.
40752-165(1) Effective March 2008
Page 6
4. INSPECTION AND FIELD TESTING
MCPs are designed to provide years of almost maintenance-free operation. The following procedure describes how to inspect and test an MCP in service.
Inspection
MCPs in service should be inspected periodically. The inspection should include the following checks (4-1 through 4-7):
!
WARNING
BEFORE INSPECTING THE MCP IN AN ELECTRICAL
SYSTEM, MAKE SURE THE MCP IS SWITCHED TO
THE OFF POSITION AND THAT THERE IS NO VOLT-
AGE PRESENT WHERE WORK IS TO BE PER-
FORMED. THE VOLTAGES IN ENERGIZED EQUIP-
MENT CAN CAUSE DEATH OR SEVERE PERSONAL
INJURY.
!
CAUTION
MAKE SURE THAT CLEANING AGENTS OR SOL-
VENTS USED TO CLEAN THE MCP ARE SUITABLE
FOR THE JOB. SOME COMMERCIAL CLEANING
AGENTS WILL DAMAGE THE NAMEPLATES OR
MOLDED PARTS.
4-1. Remove dust, dirt, soot, grease, or moisture from the surface of the MCP using a lint-free dry cloth, brush, or vacuum cleaner. Do not blow debris into MCP. If contamination is found, Iook for the source and eliminate the problem.
4-2. Switch MCP to ON and OFF several times to be sure that the mechanical linkages are free and do not bind. If mechanical linkages are not free, replace MCP.
4-3. With the MCP electrically isolated, switch handle to the ON position and press the PUSH-TO-TRIP button to mechanicalIy trip the MCP. Trip, reset, and switch MCP
ON several times. If mechanism does not reset each time the MCP is tripped, replace the MCP.
4-4. Check base, cover, and operating handle for cracks, chips, and discoloration. Replace MCPs if cracks or severe discoloration is found.
4-5. Check terminals and connectors for looseness and signs of overheating. Overheating shows as discoloration, melting, or blistering of conductor insulation, or as pitting or melting of conductor surfaces due to arcing.
If there is no evidence of overheating or looseness, do not disturb or tighten the connections. If there is evidence of overheating, terminations should be cleaned or replaced. Before reenergizing the MCP, all terminations and cable should be refurbished to the condition when originally installed.
4-6. Check MCP mounting hardware. Tighten if necessary.
4-7. Check area where MCP is installed for any safety hazards, including personal safety and fire hazards.
Exposure to certain types of chemicals can cause deterioration of electrical connections.
Field Testing
Any field testing should be done in accordance with
NEMA Standards Publication AB2-1984.
40752-165(1) Effective March 2008
4
40752-165(1) Effective March 2008
NOTES
Page 7
40752-165(1) Effective March 2008
Printed in USA/TQC
Page 8

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Key features
- Suitable for NEMA motor starter sizes 4 and 5
- Magnetic-only instantaneous tripping
- Interphase barriers can be installed for increased safety
- Can be used with aluminum conductors with suitable joint compound
- Internally-mounted accessories are available for field installation
- Terminals can be installed before or after mounting
- Cover screws are thread-forming for secure retention