ABB GE ReliaGear Pro-Stock A2 - User Manual

1
ReliaGear
®
lighting panelboards
Pro-Stock
™
A2 circuit breaker kits, 240 Vac
Introduction
These instructions describe the installation of a Pro-Stock
240 Vac Type A2 two- or three-phase circuit breaker kit into a
ReliaGear lighting panelboard.
The catalog number for the single-phase, two-pole kit is MBA12
(Table 1). The catalog number for the three-phase, three-pole kit
is MBA13 (Table 2). The catalog number for the three-phase, six-
pole kit is MBA16 (Table 3).
Table 1. Parts list for the 240 Vac A2 single-phase, two-pole
breaker installation kit, catalog number MBA12.
Item # Description Part # Qty.
 Shield Insert  

Thread Rolling Screw
and Washer
 
  
4
   
  — 
   
 Label, “MAIN”  
Table 2. Parts list for the 240 Vac A2 three-phase, three-pole
breaker installation kit, catalog number MBA13.
Item # Description Part # Qty.
 Shield Insert  

Thread Rolling Screw
and Washer
 
  
4
   

 — 

  
 Label, “MAIN”  
Table 3. Parts list for the 240 Vac A2 three-phase, six-pole
breaker installation kit, catalog number MBA16.
Item # Description Part # Qty.
 Shield Insert  

Thread Rolling Screw
and Washer
 
  
10
   
   
  — 
9
  
 Label, “MAIN”  
Table 4. Parts list for the 240 Vac A2 three-pole subassembly
circuit breaker installation kit.
Item # Description Part # Qty.
  — 

Metric hex socket hid

 
   
   

Metric hex socket button

 

Metric STL helical SPR

 

  

AI phase barrier A”


1

  



 
5
 
2
5
 
2
5
 
4

Summary

Introduction to Pro-Stock A2 Circuit Breaker Kits

Installation Procedure for Pro-Stock A2 Kits

Electrical Safety Precautions

Turn off power before working on the panelboard. Do not remove protective devices until power is off.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The ReliaGear® lighting panelboards Pro-Stock™ A2 circuit breaker kits, 240 Vac, are designed for the installation of two- or three-phase circuit breaker kits into ReliaGear lighting panelboards. These kits are essential components for managing and distributing electrical power within a panelboard system, ensuring safe and reliable operation.

Function Description

The primary function of these kits is to facilitate the secure and proper installation of circuit breakers within a lighting panelboard. Circuit breakers are critical safety devices that automatically interrupt the flow of electricity when an overload or short circuit is detected, protecting the electrical system and connected equipment from damage. The Pro-Stock A2 kits provide the necessary hardware and components to integrate these breakers seamlessly into the panelboard structure.

The kits are available in different configurations to accommodate various electrical system requirements:

• Single-phase, two-pole kit (MBA12): Designed for single-phase electrical systems requiring two-pole circuit breakers.
• Three-phase, three-pole kit (MBA13): Suitable for three-phase electrical systems utilizing three-pole circuit breakers.
• Three-phase, six-pole kit (MBA16): For more complex three-phase systems that require six-pole circuit breakers, often used for higher capacity or multiple circuit protection.

Each kit includes a range of parts crucial for installation, such as shield inserts, thread rolling screws, various sizes of screws, nuts and washers, circuit breaker bases, and A2 breaker subassemblies. These components work together to provide a robust and compliant installation. The shield inserts, for example, are vital for maintaining proper electrical separation and protection within the panelboard, while the screws and washers ensure that all components are securely fastened, preventing loose connections that could lead to hazards.

The installation process involves several steps, starting with the subassembly of the circuit breaker itself. This includes attaching the breaker to a mounting bracket, securing it with hex socket screws, and fastening a Z-strap to the breaker using specific washers and screws. Phase barriers are also installed to maintain proper electrical isolation between phases, which is particularly important in multi-phase systems.

Once the breaker subassembly is complete, it is mounted onto the interior of the panelboard. This involves aligning the bus bar holes with the circuit breaker base and securing it with nuts. The breaker subassembly is then positioned, and its mounting bracket is aligned with the interior rail holes, followed by tightening screws to ensure a firm attachment. For six-pole kits, additional phase barriers are placed between the breakers to enhance safety and compliance.

Finally, low terminal covers are installed on the lug side of the breakers, and the shield insert is integrated into the panelboard. The type of shield insert installation varies depending on whether it's a main breaker or subfeed breaker application and the panel's amperage. For main breaker installations, the shield insert is placed over the existing shield, aligning holes and securing it with screws. For subfeed breaker installations, blank inserts may need to be removed from the shield before installing the new shield insert supplied with the kit. This ensures that the panelboard maintains its protective integrity while accommodating the new breaker.

Usage Features

The ReliaGear Pro-Stock A2 circuit breaker kits are designed for straightforward integration into existing ReliaGear lighting panelboards, making them a practical choice for electrical contractors and maintenance personnel. The kits provide a complete set of components, reducing the need to source individual parts and simplifying the ordering process.

Key usage features include:

• Comprehensive Kits: Each kit contains all necessary hardware for a specific breaker configuration (single-phase two-pole, three-phase three-pole, or three-phase six-pole), ensuring that installers have everything they need for a complete installation.
• Standardized Components: The use of standardized screws, nuts, and washers means that common tools can be used for installation, streamlining the process and reducing specialized tool requirements.
• Clear Instructions: The installation guide provides detailed, step-by-step instructions with corresponding item numbers and illustrations, making the installation process clear and manageable, even for complex configurations. This clarity helps minimize errors and ensures proper assembly.
• Safety-Focused Design: The inclusion of shield inserts and phase barriers highlights the emphasis on safety. These components are crucial for preventing accidental contact with live parts and maintaining proper electrical isolation, which is paramount in any electrical installation.
• Versatility: The different kit types (MBA12, MBA13, MBA16) cater to a range of electrical system demands, from simpler single-phase setups to more complex three-phase, high-capacity applications. This versatility allows for flexible system design and expansion.
• Compatibility: Designed specifically for ReliaGear lighting panelboards, these kits ensure perfect fit and function, avoiding compatibility issues that can arise with generic or third-party components.
• Torque Specifications: The provision of specific torque values for fasteners (e.g., 64-78 lb-in for H1 and 9-11 lb-in for H2) is a critical usage feature that ensures connections are tightened to the correct specifications. This prevents both under-tightening, which can lead to loose connections and arcing, and over-tightening, which can damage components.

Maintenance Features

While the kits themselves are primarily for installation, their design contributes to the overall maintainability of the panelboard system.

• Modular Design: The modular nature of the circuit breaker subassembly means that individual breakers, if they need replacement or maintenance, can be accessed and serviced without necessarily dismantling the entire panelboard. This design facilitates easier troubleshooting and component replacement.
• Accessibility: The design of the panelboard and the kit components ensures that once installed, the circuit breakers and associated wiring remain accessible for inspection, testing, and maintenance. The shield inserts, while protective, are designed to be removed and reinstalled, allowing access to the internal components when necessary.
• Clear Labeling: The instruction to attach a "MAIN" label to the front of the shield insert for main breaker installations is a simple yet effective maintenance feature. Clear labeling helps maintenance personnel quickly identify the main breaker, which is crucial for safe power disconnection during servicing.
• Durable Components: The components included in the kits are designed to be durable and withstand the operational environment of an electrical panelboard. This inherent durability reduces the frequency of component failures and the need for premature replacements.
• Standard Fasteners: The use of standard fasteners (e.g., #10-32 screws, 5/16-18 nuts, M4xS5 hex socket screws) means that common tools are sufficient for any future maintenance or adjustments. This simplifies tool requirements for maintenance teams.
• Safety Warnings: The explicit warning about turning off power before working inside the panelboard is a fundamental maintenance safety feature. It reinforces the importance of safety protocols, which are paramount during any maintenance activity to prevent electrical shock or injury.

In summary, the ReliaGear Pro-Stock A2 circuit breaker kits provide a robust, safe, and user-friendly solution for integrating circuit breakers into lighting panelboards. Their design focuses on ease of installation, operational safety, and long-term reliability, contributing to the overall efficiency and maintainability of the electrical distribution system.

ABB GE ReliaGear Pro-Stock A2 Specifications

General

Bus Ampacity	1600A, 2000A, 2500A, 3000A, 4000A
Short Circuit Current Rating (SCCR)	65kA, 100kA
Enclosure Type	NEMA 1, NEMA 3R
Standards Compliance	UL 1558, ANSI C37.20.1
Bus Material	Copper
Operating Temperature	-30°C to +40°C