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Summary of Contents for Rockwell Automation Allen-Bradley 1512A
- Page 1 User Manual Medium Voltage Controllers Bulletin 1512A 800A One-High Cabinet Standard and Arc Resistant Enclosure Catalog Numbers 1512A, 1512AT, 1512DM, 1512M...
- Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
- Page 3 Location of ISa and ISb Auxiliary Contacts, Adjusting Auxilary Contacts (ISa Auxiliary Contacts shown). Added part numbers 80178-750-51, 80158-147-52, PN-272006. Increased the unit quantity of PN-272006 Added 50 kA to ArcShield™ Unit Information. Added Attention and Warning Tables. Added Attention and Warning Tables. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 4 Summary of Changes Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 5: Table Of Contents
Power Lockout Procedure ........45 Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 6 STEP 7 – Additional Mounting Support ......79 Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 7 Chimney Placement on Structure......83 Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 8 Table of Contents Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 9: Scope
Chapter General Information Scope This document pertains to the Rockwell Automation® Bulletin 1512A medium voltage (MV) controller. The Bulletin 1512A structure provides one complete MV controller unit. The product Bulletin numbers that are covered by this document are: • 1512A... -
Page 10: Recommended Torque Values
2) with unit motor application information. Figure 2 - Typical Unit Nameplate Refer to these nameplates whenever you contact Rockwell Automation for assistance. Be prepared to provide such information as series number, structure series, unit series, diagram schematic, and catalog number. -
Page 11: Door Opening Procedure
2. The door is now released and swings open. 3. To secure the door, reverse the procedure. Figure 3 - Access to Low Voltage Compartments, Standard Enclosure 1/4 turn Fasteners for Upper LV Door Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 12: Opening The Medium Voltage Doors
Tightened the bolts until the door is even with the flange. Do not over tighten the bolts. If the door is not securely fastened, the isolation switch handle cannot be moved to the ON position. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 13: Anchoring
Line Cable Conduit opening. Front Load Cable Conduit opening. Control Wire Conduit opening. Mounting Holes for M12 (1/2 in.) Diameter Anchor Bolts. Removable Lifting Angle (2). 1.00 [25] X 3.00 [76] Non- removeable Sill Channels. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 14: Joining The Sections
Front Access – Top Incoming Load Cables on page 17 Front Access – Bottom Incoming Line Cables on page 6. Secure the right section to the floor using ½ in. (M12) floor mounting- bolts (see Anchoring on page 13). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 15: Access To The Power Bus
1. Remove the hardware that secures the center rear bus access-cover (Figure 2. Remove the center rear bus access-cover. 3. When the rear bus cover is removed, you see the three power bus bars and grounding bus (Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 16: Side Access
1. Remove the hardware from the appropriate side bus access cover. 2. Remove the side bus access cover. 3. When the side bus access cover is removed, you see the three power bus bars and grounding bus (Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 17: Front Access - Top Incoming Load Cables
Installed for shipment purposes – Figure Figure 10 - Removal of Access Panel with Low Voltage Panel Rotated. Self-tapping screws 1/4 turn fasteners 5. Use a flat head screwdriver to turn the 1/4 turn fasteners counterclockwise 180°. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 18 10. Reverse procedure after cables are installed. ATTENTION: Make sure that all barriers are installed before re-energizing the equipment. Failure to do so can result in electrical faults, damage equipment, or severe injury to personnel. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 19: Front Access - Bottom Incoming Line Cables
The current transformers can be positioned for top or bottom cable exit. Follow IMPORTANT the appropriate procedure that is described for your starter configuration. Cable size cannot exceed 1-1000 MCM, 2-750 MCM, 3-500MCM, or IMPORTANT 4-500 MCM per phase. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 20 6. Reinstall the current transformer barrier and reassemble the cabinet. Figure 14 - Access to Load Cable Conduit Openings (Top Exit Configuration Shown) Current Transformer Bottom-exit removable load cable conduit-plate Control Cable Conduit Opening Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 21 Figure 16 - Routing of Load Cables (Top exit shown) Current Transformer ATTENTION: Install all barriers before re-energizing the equipment. Failure to do so can result in electrical faults and damage equipment or severe injury to personnel. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 22 Chapter 2 Installation - Standard Enclosure (Not Arc Resistant) Figure 17 - Load Cable Conduit Openings, Top Exit Roof Plan Line Cable Conduit Opening. Load Conduit Opening. Control Wire Conduit Opening. Front Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 23: Door Opening Procedure
Chapter Installation – Arc Resistant Enclosure (ArcShield™) This installation section contains information on the Rockwell Automation® “ArcShield™” arc resistant enclosure. For information on the installation site preparation, see General Handling IMPORTANT Procedures for MV Products, Publication MV-QS050. The levelness of floors must meet the levelness specification that is outlined in this document. -
Page 24: Opening The Medium Voltage Doors
10. Unbolt the lower left-hand MV door locking bolts. 11. Swing open the door that is now released. 12. To close the doors, reverse the procedure. Tighten door-lock bolts to the recommended torque values on page Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 25 19). The arc latching mechanism can be damaged by forcing the arc latching handle. ATTENTION: Complete the Power Lockout Procedure on page 45 before beginning any service procedures to the unit. Failure to do so can result in severe burns, injury, or death. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 26: Anchoring
The joining hardware can be found in a package mounted to the front of the IMPORTANT shipping skid. See Publication MV-QS050_-EN-P for level floor surface requirements. 1. Remove the side bus access covers if applicable. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 27 Figure 21 - Joining the Sections Power Bus Cutout holes must align To help prevent gas leakage between joined cabinets, apply Silicone around Power Bus cutout area. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 28: Access Power Bus
A side bus access cover is on each side of the controller, when required. 1. Remove the hardware from the appropriate side bus access cover. 2. Remove the side bus access cover (Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 29 This connection must be maintained to ensure unit arc resistant performance. Figure 23 - ArcShield Side Bus Access Cover Warning Label Figure 24 - Side Bus Access-cover Ground Connection (Rear Access-cover removed to show connection point) Side Bus Access-cover Ground Connection Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 30: Front Access - Top Entry
6. Locate the two removable bus access barriers. 7. Remove the retaining screws from removable bus access barriers. This step exposes the incoming cable connections to main bus (see Figure 27). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 31 Figure 28 - Removal of Low Voltage Barriers to Access Power bus Barriers Remove four screws from each panel 10. When the insulating barrier is removed, you see the power bus bars. (Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 32 14. Connect the cables to the current transformers and tighten the connections to 48 lb•ft (65 N•m). 15. Connect cable shields (if present) to the ground lug. 16. Install all barriers and reassemble the cabinet. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 33 1.00 [25] x 30 [76] Non-removable Sill Channels. ATTENTION: Make sure that all barriers are installed before re-energizing the equipment. Failure to do so can result in electrical faults, damage to equipment, or serious injury to personnel. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 34 Chapter 3 Installation – Arc Resistant Enclosure (ArcShield™) Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 35: Bus Splicing
IMPORTANT front of the unit. Place bus clamps on the rear side of each main horizontal bus or splice bar, as IMPORTANT viewed from the front of the unit, see Figure 32 Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 36: Insulated Power Bus Splicing
Insulated Power Bus Splicing If the starter is equipped with insulated power bus, a splice kit with insulated links, insulating boots, and tape is provided. See the kit for installation instructions. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 37: Ground Bus
1-750 MCM or 2-500 MCM per phase. For ArcShield units, incoming line cable size must not exceed 1-500 MCM or 2-4/0 per phase. For larger cables, an incoming line module must be used for either cabinet styles. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 38: Hi-Pot And Megger Test
Hi-Pot test. Failure to do so can result in personal injury or damage to the equipment. See Power Lockout Procedure on page 45 information on how to dissipate any stored power in the capacitors. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 39: Start-Up Procedure
• Interior of cabinet is free from dirt, loose bolts, tools, or metal chips. Vacuum clean if necessary. • All tools are accounted for. If you cannot locate a tool, do not energize the unit until it is found. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 40: Testing The Contactor Operation
Customer must program/configure Intellivac before M-IV Close start-up Intellivac Module Vacuum Contactor Auxiliary-input Contactor Status Intellivac Module Closing Coil Output Intellivac Module External Capacitor Input Main Contactor Intellivac Module M-IV Intellivac Module Trip Coil Output Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 41 K M L HC Holding Coil Legend Economizing Customer Wiring Contactor (CR2) Low Voltage Door-mount Device Start Stop Main Contactor Remove jumper when connecting Contactor (CR1) Remote Equipment IEEE Number for Protection Device Remote Equipment Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 42 Chapter 4 Common Installation Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 43: Tool Requirements
If you cannot obtain such tools, contact the Rockwell Automation sales office in your area for assistance. If you cannot obtain the required tools, contact the Rockwell Automation sales office in your area for assistance. -
Page 44: Door Interlock Circumvention
1. To depress the door interlock lever in a downward movement, use a screwdriver, or other tool 2. Hold the lever down while moving the handle to the ON (closed) position. Figure 38 - Door Interlock Lever Door Interlock Lever Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 45: Power Lockout Procedure
ON position. A live power cell can cause severe burns, injury, or death. Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the... - Page 46 Verify that they are voltage free (see Figure 41). 7. Check for line-side voltage at the top vacuum bottle terminals. 8. Check for load-side voltage at the bottom vacuum bottle terminals. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 47 Figure 42 - Isolation Switch Voltage Check ISaincoming line voltage 11. When all power circuits are verified to be voltage free, move the isolation switch handle back to the OFF position. The unit is now safe to service. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 48: Fuse Removal And Replacement
ATTENTION: The fuses can be hot for up to one hour after operating. Verify the temperature before handling and use insulated hand protection if needed. Failure to do so can result in burns. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 49: Bolt-On Fuse Removal And Installation
2. Disconnect the control wiring-harness from the wire plug at the lower left side of the contactor (see Figure 43). 3. Use a 9/16 in. Socket wrench to disconnect the power cables from the rear of the contactor. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 50 ATTENTION: The contactor weighs approximately 100 lb (45 kg) and assistance can be required to remove it safely from the cabinet and transport it. Failure to use caution when moving the contactor can result in equipment damage and/ or personal injury. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 51: Contactor Interlock Rod Adjustment
To increase the gap distance follow steps 8…10. Figure 46 - Isolation Switch Handle Adjustments Isolation Switch Operating Lever Gap Distance Switch Interlock lever Isolation Switch handle at halfway position Stop Bracket Contactor Interlock Rod Contactor Interlock Lever Nylock Nut Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 52: Reduce The Gap Distance
47). Verify that the interlock lever overlaps the isolation switch operating lever by at least 3 mm (0.125 in.). See Figure Figure 47 - Closing the Contactor Manually (Front View -some parts not shown) Armature Plate Magnetic Core Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 53: Isolation Switch Mechanism Inspection And Lubrication
(see Figure 49). Use Dow Corning 55 O-ring lubricant (Rockwell Automation part no. RU-8216, or equivalent) Figure 49 - Isolation Switch Handle Mechanism Lubrication Points Threaded Connecting Rod Isolation Switch Operating Lever... -
Page 54: Isolation Switch Mechanism Grounding Adjustment
The blades must also be within 1.5 mm (0.06 in.) of the ground bar (see Figure 40). When the isolation switch handle is in the ON position, the blades must fully engage the incoming line stabs. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 55: Auxiliary Contacts Inspection And Replacement
5. Disconnect the wires from the auxiliary contact. 6. To reinstall the auxiliary contact, reverse the procedure. 7. Make sure that the contact is correctly positioned into the contact carrier (see Figure 52). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 56 Figure 37 on page 41 for wiring diagrams. Isolation Switch Mechanism Grounding Adjustment on page 54 must be IMPORTANT completed before adjusting the auxiliary contacts to make sure of proper synchronization of the assembly. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 57: Isolation Switch Auxiliary Contacts
ON position and recheck the gap using the pin. 8. Verify that auxiliary contact ISa is open when the isolation switch is open. Verify that ISa contact is closed when isolation switch is closed. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 58: Adjusting The Normally Closed (Isb) Contacts
4. If the auxiliaries do not change state before the isolation switch opens, repeat the auxiliary contacts adjustment procedure (see page 57). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 59: Emergency Circumvention Procedure For Power Cell Entry
2. Remove the two door locking bolts. 3. Using a flat-headed screwdriver, turn the defeater pin on the right side of the isolation switch handle (see Figure 56). 4. Open the power cell door. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 60 Z-clip. 13. Using the self-tapping screws, reattach the Z-clip. 14. Complete steps 5…10 at the earliest opportunity to confirm that the Z- clip assembly is correctly installed. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 61: Spare Parts List
Spare Parts The list of spare parts is valid for typical Bulletin 1512A and 1512AT units. Contact your local Rockwell Automation® office to help ensure that the following part numbers are available. For 800A contactor spare parts, refer to Bulletin 1502 800A Medium Voltage Contactor User Manual, Publication 1502-UM051_-EN-P. - Page 62 Chapter 6 Spare Parts Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 63: Overview
• The medium-voltage power cell doors must be properly secured by using both the handle mechanism and the door bolts (refer to instruction label on the power cell door and in Chapter 3). Failure to do so voids the arc resistance integrity. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 64: Exhaust Systems: Chimney Or Plenum Option
Extensions can be added to the plenum. The extensions can allow the arc flash energy and plasma gases to be safely vented to an area further away from the ArcShield line-up. Figure 57 - Elements of the ArcShield Plenum Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 65: Plenum Exhaust Considerations
Make sure that adequate space is provided around the plenum exhaust, as outlined in Figure 59 through Figure Equipment in the area of the plenum exhaust point can be damaged or IMPORTANT destroyed. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 66 • Minimum H = 3.5 m (138 in.) • Minimum L = 1.2 m (47 in.) • Minimum Volume of space that is required for safe pressure relief: • X *Y* H = 11 m (390 cubic feet) Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 67 ArcShield™ Unit Information Appendix A Figure 61 - Chimney Exhaust Space Requirements • Minimum H1: 1.7 m (67 in.) • Minimum H: 1 m (37 in.) Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 68: Additional Notes
A chain link fence is a suitable barrier material. Equipment that consists of more than four vertical sections that are bolted together can require additional plenum exits. Rockwell Automation® provides guidance on requirements for additional plenum exits when required. -
Page 69: Recommended Torque Values
Plan the location where the plenum exhausts (refer to Appendix A). Equipment IMPORTANT in the area of the plenum exhaust can be damaged or destroyed. Mark the plenum exhaust area as a Hazardous Zone, and labeled per Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 70 WHILE EQUIPMENT ENERGIZED. EST SOUS TENSION. - FREE OF OBSTRUCTIONS - DÉMUNI D’OBSTRUCTIONS (REFER TO USER MANUAL). (RÉFÉRER AU MANUEL) SEVERE INJURY OR RISQUE DE BLESSURES DEATH MAY RESULT. CORPORELLES GRAVES OU MÊME LA MORT. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 71: General Plenum Layout For Arcshield Line-Up
A 0.9 m (36 in.) Exhaust extension assembly is shown mounted on the extreme right side Plenum of the equipment “Line-up” (can alternatively exhaust to the left. Engineered systems can be made site specific). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 72: Step 1 - Mounting A Single Plenum
STEP 1 – Mounting a Single Before mounting a Plenum over an MV enclosure, the front duct section must first be removed, see Figure Plenum Figure 65 - Removing Front Duct Section Front Duct Section Components Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 73: Cabinet Preparation
(4) corner fasteners Remove Fasteners The Plenums are designed to fit over the fastener heads at the corners of the Relief vent. The corner fasteners are required to secure the Relief vent during installation. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 74: Plenum Placement On Structure
Use silicone caulking generously to fill any air gaps when the Plenum is securely mounted in place. STEP 2 – Alignment of “Side- Plenums that are mounted side-by-side must be fastened together through the aligning holes using 0.3125-in. supplied hardware (see Figure 69). by-Side” Plenums Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 75: Step 3 - Sequence Of Final Assembly
Assembly Figure 65). Figure 70 - Sequence of Final Assembly End Cover Plate The “End Cover Plate” must be mounted on the closed end of the Line-up using 0.3125-in. hardware (see Figure 70). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 76: Step 4 - Closing The Front Of The Plenum Sections
Attach the 36 in. Extension components and 90° Elbow Section using 0.3125-in. hardware in the following sequence: Assembly Step 5A – See Figure 74 Step 5B – See Figure 75 Step 5C – See Figure 76 The Screen Cover Plate is attached in Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... -
Page 77: Step 6 - Mounting Extension/Elbow To Plenum "Line-Up
Plenum at the exhaust side of the line-up has the front duct section removed. The Extension/Elbow to Plenum absence of the section allows access to fastener holes to mount the Extension/ “Line-up” Elbow components (see Figure 77). Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 78 Extension Assembly Attach the Extension/Elbow assembly through the fastener holes on the inside flange of the Plenum. Install the front duct section and fasten it through the holes on the outside flanges. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
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Page 79: Step 7 - Additional Mounting Support
During an arc fault, the plenum is subjected to a brief high-pressure shock wave. The Extension/Elbow assembly can experience dynamic loading. It is important to account for dynamic loading when selecting the means of support and materials. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015... - Page 80 Appendix B ArcShield™ Plenum Installation Instructions Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 81 General Plenum Layout for An example of a general chimney assembly configuration is shown in Figure Chimneys of various widths are mounted directly over the MV enclosures of the ArcShield Line-up corresponding width. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 82 Failure to reinstall this hardware makes the arc resistance of the cabinet ineffective and could subject personnel to the possibility of severe burns, injury, or death. IMPORTANT Do not remove the four corner fasteners (Figure Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 83 Chimney to the top of the enclosure. Figure 82 - Chimney Placement Use recommended torque value for 0.25-20 fasteners Use silicone caulking generously to fill any air gaps when the chimney is securely mounted in place. Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 84 Appendix C ArcShield™ Chimney Installation Instructions Notes: Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015...
- Page 86 New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.
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