Motor Logic Retrofit Applications
 DANGER |
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Hazard of Electric Shock, Explosion, or Arc Flash
Failure to follow these instructions will result in death or serious injury.
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| NOTICE |
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incorrect operation
Failure to follow these instructions can result in equipment damage.
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Remove the starter from the unit to replace the overload (melting alloy/bi-metallic). See Removing the Control Unit.
Terminal blocks (OEKTTBML) should be used for applications requiring multiple passes to achieve the proper adjustment range.
Restrain looped load cabling between the overload and the terminal block with wire ties or the equivalent when terminal kits are used.
On Size 3 and 4 starter units, the overload reset button is 1-5/8 in. (41 mm) further from the unit door and may require an alternative reset assembly (80420-862-51).
Retrofitting NEMA rated Compac 6, six-inch (52 mm) units is not recommended. The Motor Logic overload relay is available factory installed in Compac 6.
On 600 V Size 1 applications, add a third wire tie between the circuit breaker and contactor near the contactor line lugs. Refer to instruction bulletin 30072-013-29 for additional information.
Use copper wire only on device power and control terminals. Conductors must be sized for 60°C or 75°C National Electrical Code® (NEC®) ratings.
Pressure wire terminals are suitable for wire sizes #16–12 AWG, solid or stranded. Terminal instruction labels are located adjacent to the terminal block or on the wireway door.
Box lugs (on interposing power terminal blocks supplied with selected units) are suitable for wire sizes #14–8 AWG, solid or stranded. Terminal instruction labels are located adjacent to the terminal block. Lug Types and Wire Sizes provides additional termination data.
Lug Types and Wire Sizes
| Class 9065 Motor Logic Overload Relay Size* | Rating | Lug Type | Wire Size* | Torque Values* |
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| 00B | 1.5–4.5 A | Pressure Wire* | 14–8 AWG (2.5–6 mm2) | 25 lb-in (2.8 N•m) |
| 00C | 3–9 A | Pressure Wire* | 14–8 AWG (2.5–6 mm2) | 25 lb-in (2.8 N•m) |
| 0 | 6–18 A | Box Lug | 14–4 AWG (2.5–16 mm2) | 50 lb-in (5.6 N•m) |
| 1 | 9–27 A | Box Lug | 14–4 AWG (2.5–16 mm2) | 50 lb-in (5.6 N•m) |
| 3 | 30–90 A | Box Lug | 14–1/0 AWG (2.5–50 mm2) | 100 lb-in (11.3 N•m) |
| 4 | 45–135 A | Box Lug | 8–250 MCM (6–120 mm2) | 200 lb-in (22.6 N•m) |
| 5 | 90–270 A | Box Lug | 250–500 MCM (120–240 mm2) | 250 lb-in (28.2 N•m) |
| 6 | 180–540 A | Clamp Lug | 250–500 MCM (120–240 mm2) | 375 lb-in (42.4 N•m) |
Size 00B, 00C, 0, and 1 relays have conductor (CT) windows through which the motor leads must pass before being connected to the load terminals on the contactor (T1, T2, and T3). By allowing multiple passes (turns) of the load leads through these CT windows, overload protection can be provided for motors with a full-load current lower than the specified operating range.
Two passes of the load leads through each window effectively increase (by a multiple of two) the current that the overload relay senses. Three passes effectively increase the current by a multiple of three. All three conductor windows must have the same number of passes, looped in the same direction, for the overload relay to operate properly (see Looping Passes).
Looping Passes
Passes should begin from the load side of the overload through the CT window and return via the windows provided between the baseplate and overload (see Motor Logic Overload (Bottom View)). The final pass terminates on the load side of the contactor.