Motor Control Centers MCC
Development Program for Preventive Maintenance Engineers
Mombasa Kenya 2016
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015
Safety First
When doing maintenance on MCC’s ..
• Be aware that:
• all MCC’s contains dangerous voltage
• Even low voltage MCC can arc and explode
• Low voltage is anything less than 1000 volts.
Typical MCC voltages are 380, 400 or 440 V!
• Make sure the load is disconnected and locked prior to
maintenance
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Agenda
• Operating principle
• Types and function
• Lifetime
• Failure causes
• Maintenance
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 3
Objective
• Understand the principle, function and types of motor control centers
(MCC).
• Know failure causes and the maintenance tasks that have to be
implemented in order to minimize, if not totally prevent, unexpected
failures.
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Motor Control Centers (MCC)
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 5
Motor Control Center (MCC)
Functions of MCC
• Switching of large load (high voltage and current) by a
low level signal
• Provide Protection to the load and source
• Provide Isolation of control system from low voltage
• Provide status indication or signaling to the control system
• Provide convenient isolation of the load from the power
source during maintenance (Lock-Out)
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Motor Control Center (MCC)
Busbar (power source)
Control Interface OFF ON
Available
FEEDBACK Running Breaker
Drive Command
Fault
COMMAND Contactor
Other
Interlocks Overload protection
Over current (thermal
overload relay)
Logic
MCC
Motor
Low voltage and current High voltage and current
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 7
Motor Control Center: Operation
Busbar (Power Source)
Control Interface OFF ON
Available
FEEDBACK Running Breaker
Drive Command
Fault
COMMAND Contactor
Other Interlocks
Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
Low Voltage and Current High Voltage and Current
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 8
MCC on, motor off
Busbar (Power Source)
Interface OFF ON
Available
Running Breaker
Drive Command
Control Fault
Contactor
Other Interlocks
Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
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MCC on, motor off, interlocks ok
Busbar (Power Source)
Interface OFF ON
Available
Running Breaker
Drive Command
Control Fault
Contactor
Other
Interlocks Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
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MCC on, motor starting
Busbar (Power Source)
Interface OFF ON
Available
Running Breaker
Drive Command
Control Fault
Contactor
Other
Interlocks Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
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MCC on, motor running
Busbar (Power Source)
Interface OFF ON
Available
Running Breaker
Drive Command
Control Fault
Contactor
Other
Interlocks Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 12
MCC on, motor running, overload condition
Busbar (Power Source)
Interface OFF ON
Available
Running Breaker
Drive Command
Control Fault
Contactor
Other Interlocks
Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 13
MCC on, motor tripped due to overload
Busbar (Power Source)
Interface OFF ON
Available
Running Breaker
Drive Command
Control Fault
Contactor
Other Interlocks
Overload Protection
Over Current (Thermal
Overload Relay)
Logic
Local Start&Stop MCC
Motor
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Motor Control Centers
Power
bus bar
MCC
Module
Outside View Inside View
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Draw-Out type MCC
Power
MCC
MCCMCC
Module
Module
Module Control
Spring-loaded
contact
Busbar
MCC
Module
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Fixed type MCC
Power
MCC
Module Control
Bolted
connections
Busbar
MCC
Module
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MCC types
Open, Fixed Enclosed, Draw-out
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MCC types / Control
• Conventional MCC
• Interface via discrete Input-Output signals
• Requires at least 3 signal lines per motor
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MCC Types
Conventional MCC
Busbar (Power Source)
E-Room
MCC1 MCC2
Signals
Control System
Drive Cmd. Drive Cmd.
Available Available
Running Running
I/O Card
I/O Card
I/O Card
I/O Card
I/O Card
Fault Fault
Signals
M2
M1
Field
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MCC component lifetime: Contactor
• Normally a contactor is rated
at mean cycle between failure
(MCBF)
• MCBF is a number derived
from simulating the contactor
during testing
• Typical MCBF rating is at
least 500,000 cycles
• In a plant, unless the motor is
used for hoist or damper,
number of cycle do not
exceed 20 per day
• Theoretically a contactor
would last 68 years!
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 21
MCC failure cause
Contactor failure
• Contact failure
• Corrosion due to humidity
• Mechanism and contact failure due to dust
• Frequent overloading
• Switching during overload condition
• Pitting due to arcing (spark)
Almost all MCC rely on mechanical contacts as the
main switching element
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MCC failure cause
Contactor failure
• Coil failure: Open circuit
• High voltage exceeding the coil rating
• Low voltage not enough to activate the
contactor resulting in high current
• Cracking of shading rings used in AC contactors will increase the current
and eventually burn the coil
• Dirt build-up that will not completely seat the contactor, will also result in
high current
Telltale sign of the last 2 conditions is the rattling or
buzzing sound of the contactor
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MCC failure cause
Other Failures
• Bus Contact problems (for draw-out type MCC)
• Dust, overload will make the spring loose its strength
• Loose connection on contactors and breakers
• Heat is generated and in time will result to greater damage
Loose connection
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MCC Maintenance
MCC: M C otor ontrol Center
Maintain good Connection and Contacts
Maintenance of MCC is just making sure that the
contacts and the connection have the lowest
resistance possible.
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 25
MCC Preventive Maintenance
• PMR, Preventive Maintenance Routines
• Cleanliness in the area is the key, visual inspection of the MCC rooms at
least every month is recommended
• MCC inside the room is rated IP42, dust and moisture can easily go inside
• Filters for room ventilators and air-conditioning unit should be checked at least every
month
• Check for noisy contactors (buzzing sound). This is a sign of a damaged shading coil or
dirt buildup that will cause the coil to overheat and lead to premature failure. Should be
replaced or cleaned (coil only) on the next opportunity
• Check for burned smell, MCC’s are normally unmanned and fires will result to great
damage
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 26
MCC Preventive Maintenance
• Thermal Scanning every year is recommended
• Normally done before the
kiln SPS while the MCC’s
are still loaded
• The result will be the basis which contactor or breaker to be
tightened
• Bolt Tightening on all panel without basis is not recommended.
Too much torque can do more harm than good
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MCC: Condition monitoring
• Thermography
• Thermography survey is recommended depending on the MCC type
(accessibility).
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MCC: Condition monitoring
• Thermography
• In installations where it is not possible to open the panel to do the survey,
inspection windows are now available and can be installed in very critical MCC’s
P35 Motor Control Centers MCC, 2015-06-10 FOR INTERNAL USE ONLY © LafargeHolcim 2015 29
MCC Preventive Maintenance
• Bolt Tightening
• Retightening of all bolts in the MCC panel is normally not
recommended
• Over tightening will damage the thread and will result to further
loss of good electrical contact
• If tightening is necessary, apply the right amount of torque, use
torque screw driver, refer to individual manuals.
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Sample contactor specification
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Summary/Conclusion
• A well designed and well installed MCC will last for ~30 years,
sometimes will outlast the motor
• MCC need basic maintenance if the environment is well maintained
• Cleaning and correct settings of the overload relay is key
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Contactor principle
OPEN CLOSED
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IP-- Rating
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