Rockwell Automation Allen-Bradley 1502 User Manual
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Rockwell Automation Allen-Bradley 1502 User Manual

Rockwell Automation Allen-Bradley 1502 User Manual

Medium voltage contactor
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Medium Voltage Contactor
800A, 2400-7200 V
Bulletin 1502 (Series D and E)
User Manual

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Summary of Contents for Rockwell Automation Allen-Bradley 1502

  • Page 1 Medium Voltage Contactor 800A, 2400-7200 V Bulletin 1502 (Series D and E) User Manual...
  • 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: Table Of Contents

    Table of Contents Chapter 1 Contactor Product Description Scope ..........................1-1 Description ........................1-1 Vacuum Bottle Description ..................1-2 Contactor Operation Electro-Mechanical Control (Series D) ............1-3 IntelliVAC Control (Series E) ................1-4 Contactor Identification .................... 1-6 Contactor Catalog Number Explanation .............. 1-6 Contactor Specifications ...................
  • Page 4 Table of Contents – 800 A Medium Voltage Contactor User Manual Chapter 4 Maintenance Tool Requirements ..................... 4-1 Recommended Torque Values .................. 4-1 Routine Maintenance ....................4-1 Vacuum Bottle Replacement and Set-up Procedure ..........4-3 Main Coil Replacement Procedure ............... 4-11 ........4-15 ..........4-17 ........4-17...

  • Page 5: Chapter 1 Contactor Product Description

    Chapter Contactor Product Description Scope This User Manual pertains to Allen-Bradley's Bulletin 1502, 800A vacuum contactors. It applies to both Series D and E versions of the Bulletin 1502 (800 Amp) contactors. Series D vacuum contactors are intended for use with electro-mechanical (relay) control circuits.

  • Page 6: Vacuum Bottle Description

    Contactor Product Description Vacuum Bottle Description The vacuum bottle (Figure 1.2) consists of two contacts enclosed in a ceramic housing. One contact is mounted on a fixed shaft, and the other is attached to a movable shaft. The bearing and stainless steel bellows ensure that the movable contact tracks accurately and maintains vacuum integrity within the bottle.

  • Page 7: Contactor Operation

    Contactor Product Description Contactor Operation The standard electrically held contactor consists of three vacuum bottles oper- ated by an electromagnet assembly through a mechanical linkage (See Figure 1.3). Electro-Mechanical Control (Series D) and hold-in coil, creating an electromagnet. rotates the actuator shaft. the contacts inside the vacuum bottle.

  • Page 8: Intellivac Control (Series E)

    Contactor Product Description Contactor Operation (cont.) IntelliVAC Control (Series E) The electrically held vacuum contactor operates as follows: command, the contactor coil is energized, the current creates an electromagnet in the coil. shaft and causing the actuator plate to move upwards. ing the contacts in the vacuum bottle.
  • Page 9 Contactor Product Description Latch Lever Latch Spring Mechanical Latch Trip Coil Manual Trip Mechanism Contactor Closed Figure 1.4 – Top Partial Section View Showing Mechanical Latch 1502-UM051E-EN-P – June 2013...

  • Page 10: Contactor Identification

    Figure 1.5 – Contactor Label Catalog No. Explanation The following catalog number explanation will help identify the contactor and shall be used when contacting your local Rockwell Automation Sales office or the factory for assistance. 1502 - S e co n d...

  • Page 11: Contactor Specifications

    Contactor Product Description Contactor Specifications Table 1.B - Bulletin 1502 Medium Voltage 800 Amp Contactor Ratings Description Specifications Voltage Ratings Maximum Rated Voltage 7200 2400 3300 4160 System Voltages 4800 6600 6900 Dielectric Voltage Withstand Rating For 60 seconds (kV) 18.2 / 20 (IEC) Basic Impulse Level (B.I.L.) Withstand Phase to Ground, Phase to Phase (kV)

  • Page 12: Products Approvals

    Contactor Product Description Contactor Table 1.B - Bulletin 1502 Medium Voltage 800 Amp Contactor Ratings (cont.) Specifications Description Specifications (cont.) Operational Characteristics Electrically Held Mechanical Life (Operations) x 1000 Mechanical Latch Electrical Life (Operations) x 1000 Switching Frequency Electrically Held (Operations per hour) Mechanical Latch Opening and Closing Times (Series E)

  • Page 13: Chapter 2 Receiving And Handling

    Chapter Receiving and Handling Receiving Before leaving the factory, the contactors have been tested both mechanically and electrically. Immediately upon receiving the contactor, remove the packing ma- terial and check the contactor for possible shipping damage. If damage is found, do not discard any of the packaging material and, if possible, note the damage on the Bill of Lading before accepting receipt of the shipment.

  • Page 14: Pre-Energization Inspection

    Receiving and Handling Handling (cont.) distribution of the load and maintain the contactor in an upright position at all times. should be taken: 1. Keep the contactor in an upright position. or tipping. contactor. Pre-energization Inspection Before placing the contactor in service, inspect it carefully for possible damage sustained in transit or during maintenance: if necessary, vacuum clean.

  • Page 15: Vacuum Bottle Integrity Test

    Receiving and Handling Vacuum Bottle Integrity Test The internal dielectric condition and vacuum integrity of the vacuum bottles is individually during this test. X-ray emissions may be produced if a voltage higher than S H O C K H A Z A R D bottle.
  • Page 16 Receiving and Handling Vacuum Bottle Integrity Test S H O C K H A Z A R D (cont.) potentially hazardous. A T T E N T I O N A T T E N T I O N used to ensure equipment is voltage free. tion of the contactor must be disconnected and the ground lead from the Note: to remove any residual electrical charge.

  • Page 17: Insulation Resistance Test

    Receiving and Handling bottles. NOTE: the values obtained during the test are not a reliable indication of vacuum bottle integrity. a faulty vacuum bottle. comparing initial test results to the present readings. Increases in leakage current reliable method of testing vacuum bottles. Insulation Resistance Test 1502-UM051E-EN-P –...

  • Page 18: Chapter 3 Installation

    Chapter Installation Mounting The Allen-Bradley vacuum contactor is normally fixed mounted (bolted down) in the enclosure of the controller. There are four (4) mounting holes at the base of the contactor (Figure 3.1) to secure it to the enclosure. For reversing, autotrans- former and 2-speed controllers, one contactor may be mounted on top of the other.

  • Page 19: Electrical Connections

    Installation Electrical Connections The control wiring from the low voltage panel to the contactor is made through a wire harness and connects to the left side of the contactor with a male and female configured wire plug. The power wiring terminates on the rear side of the contactor to the line and load terminals.
  • Page 20 Installation Mechanical Latch Assembly Rating Label Housing Assembly Lifting Hazard Label Shaft Assembly Terminal Block Assembly Contactor Mounting Hole Figure 3.3 – Electrical Connections 1502-UM051E-EN-P – June 2013...

  • Page 21: Wiring And Schematic Diagrams

    Installation Wiring and Schematic Diagrams 1502-UM051E-EN-P – June 2013...
  • Page 22 Installation WIRING DIAGRAM 800A VACUUM CONTACTOR AUXILIARY CONTACTS YELLOW BLUE COIL YELLOW BLACK A, B, C, D, E, F, G, H, I - SOCKETS J, K, L, M, N, P - PINS SCHEMATIC 800A VACUUM CONTACTOR AUXILIARY CONTACTS CC - CLOSING COIL HC - HOLD-IN COIL 80113-646-28 1502-UM051E-EN-P –...
  • Page 23 Installation 1502-UM051E-EN-P – June 2013...
  • Page 24 Installation 1502-UM051E-EN-P – June 2013...
  • Page 25 Installation 1502-UM051E-EN-P – June 2013...
  • Page 26 Installation 1502-UM051E-EN-P – June 2013...
  • Page 27 3-10 Installation 1502-UM051E-EN-P – June 2013...
  • Page 28 3-11 Installation 1502-UM051E-EN-P – June 2013...
  • Page 29 3-12 Installation 1502-UM051E-EN-P – June 2013...

  • Page 30: Chapter 4 Maintenance

    Chapter Maintenance Tool Requirements When maintenance is performed on the vacuum contactor, one or all of the fol- lowing tools may be required. Recommended Torque Values Part of the contactor may have to be disassembled for maintenance or replace- ment. There are appropriate torque requirements for particular bolt sizes when Routine Maintenance The following should be carried out on an annual basis or whenever a contactor Cleaning...
  • Page 31 Maintenance Routine Maintenance (cont.) Main Contact Inspection When any part of the wear indicator line, located on the front side of the HiPot Test Lubrication Note The grease will dry out and impede the free motion of the contactor. Mechanical Latch Roller Replacement S H O C K H A Z A R D power and disconnect the control plug from the contactor Before performing any maintenance on the contactor that is...
  • Page 32 Maintenance Vacuum Bottle Replacement The following procedure shall be used to remove and replace the vacuum Set-Up Procedure bottles. This procedure can be performed with the contactor remaining in A T T E N T I O N trol wiring from the contactor by disconnecting the control wire plug before starting any disassembly of the contactor.

  • Page 33: Vacuum Bottle Replacement And Set-Up Procedure

    Maintenance Vacuum Bottle Replacement and Set-up Procedure (cont.) Compression Bolt and Locking Nut Return Spring Figure 4.2 – Removal of Return Spring tor and the main mounting bolt at the top of one vacuum bottle as shown Vacuum Bottle Mounting Bolt Load Terminal Retaining Bolt and Nut Figure 4.3 –...
  • Page 34 Maintenance the remaining vacuum bottle assemblies. Vacuum Bottle Assembly Overtravel Spring Figure 4.4 – Removal of Vacuum Bottle Assembly the bottom. Vacuum Bottle Load Terminal (flexible) Lock- washer Load Terminal Nut Insulator Wear Washer Overtravel Spring Rocker Washer Gap Adjustment Nut Lock- washer Gap Locking Nut...
  • Page 35 Maintenance Vacuum Bottle Replacement and Set-up Procedure (cont.) the remaining vacuum bottle assemblies. 9.58” (243.3 mm) Movable Shaft Load Terminal Load Terminal Nut Figure 4.6 – Reassembled Vacuum Bottle Assembly Yoke Plate Armature Plate (Position 3/16” rod here) Figure 4.7 – Set-up Position 1502-UM051E-EN-P –...
  • Page 36 Maintenance dicator line is facing towards the front. Install and torque the load terminal tor as required such that the bottom of the overtravel spring touches the surface of the actuator plate inside the counter bore. The spring must be the load terminal nut.
  • Page 37 Maintenance Vacuum Bottle Replacement and Set-up Procedure (cont.) Rocker Bar Rocker Bar Rocker Washer Gap Adjustment Nut Gap Locking Nut Side View Front View Figure 4.9 – Rocker Washer Adjustment Note ment. REMOVE THE 3/16” ROD DRILL BIT OR SCREW INSERTED IN STEP 8 FROM BETWEEN THE ARMATURE AND YOKE PLATES.
  • Page 38 Maintenance Armature plate Stop Armature plate makes contact with Stop Figure 4.10 – Return Spring Installation bottom of the bearing and the top of the wear indicator line on all three 7.6 mm (0.30 in.) Min. Vacuum Bottle Wear indicator line on operating shaft Insulator Figure 4.11 –...
  • Page 39 4-10 Maintenance Vacuum Bottle Replacement and Set-up Procedure (cont.) Note compress the return spring further if necessary. Note procedure. If any tools are unaccounted for, do not energize the equipment. 2.5 mm 2.5 mm (0.100 in.) (0.100 in.) Min. Min. Side View Front View Figure 4.12 –...

  • Page 40: Main Coil Replacement Procedure

    Maintenance 4-11 cloth. unaccounted for, do not energize the equipment. Main Coil Replacement A T T E N T I O N Procedure contactor by disconnecting the control wire plug before starting any disassembly of the contactor. hold-in coils are both wound on one bobbin, therefore, all four coil leads must Terminal block assembly Magnet assembly Figure 4.13 –...
  • Page 41 4-12 Maintenance Main Coil Replacement Procedure (cont.) tap the core out with a hammer. Core Hold-in Coil Core Closing Coil Coil Lead Coil Leads Mounting Plate Mounting Plate Series E Series D Figure 4.14 – Magnet Assembly to the core mounting holes. electrically held contactors, connect the leads from the coil to the terminal Series D: Series E:...
  • Page 42 Maintenance 4-13 mechanical- ly latched contactors Series D Series E Note: Closing coil (yellow lead) Closing coil (black lead) Hold -in coil (yellow lead) Hold -in coil (blue lead) MOVs Figure 4.15 – Terminal Block Assembly (Electrically held Series D Contactor, regular terminal block) Closing coil (yellow lead) Note: Figures 4.15 and 4.16 show the fast drop-out...
  • Page 43 4-14 Maintenance Main Coil Replacement Procedure (cont.) Yellow Black Figure 4.17 – Terminal Block Assembly (Electrically Held Series E Contactor) Trip Coil (blue lead) Trip Coil (white lead) Closing Coil (black lead) Closing Coil (yellow lead) Hold-in Coil (blue lead) Hold-in Coil (yellow lead) Figure 4.18 –...
  • Page 44 Maintenance 4-15 properly connected and for complete control wiring details. contactor several times to ensure that the core is located properly. Mechanical Latch Trip Coil A T T E N T I O N Replacement Procedure Core Mounting Plate Trip Coil (core hidden) Manual Trip Guide Block Yoke Plate Manual Trip Actuator...
  • Page 45 4-16 Maintenance Mechanical Latch Trip Coil lever assembly and install the latch pivot bolt. The spring must be seated Replacement Procedure (cont.) properly in the retaining holes in both the core and the lever. Latch Pivot Bolt Latch Spring Lever Assembly Figure 4.21 –...
  • Page 46 Maintenance 4-17 Mechanical Latch Roller Replacement Procedure remove the lever assembly. The latch spring is no longer retained at this to be removed. lever assembly and install the latch pivot bolt. The spring must be seated properly in the retaining holes in both the core and the lever. Latch roller Trip Coil Lever Roller mounting bolt...

  • Page 47: Altitude Adjustment

    4-18 Maintenance Altitude Adjustment to the fact that the atmospheric pressure assists in closing the main contacts by Note predetermined value. Return Spring Locking Nut Compression Bolt Figure 4.24 – Return Spring Assembly 1502-UM051E-EN-P – June 2013...
  • Page 48 Maintenance 4-19 Table 4.A – Dimension “A” Settings in Inches (millimeters in brackets) EXISTING NEW ALTITUDE RANGE ALTITUDE Increase or Decrease Dimension “A” by: RANGE 0-1000 m 1000-2000 m 2000-3000 m 3000-4000 m 4000-5000 m 0-1000 m +0.073 (1.85) +0.140 (3.56) +0.194 (4.93) +0.246 (6.25) 1000-2000 m...

  • Page 49: Drop-Out Time Conversion

    4-20 Maintenance Drop-out Time Conversion Series D ate schematic. Normal drop-out parts: Fast drop-out parts: Series E 1502-UM051E-EN-P – June 2013...

  • Page 50: Auxiliary Contact Replacement And Set-Up Procedure

    Maintenance 4-21 Auxiliary Contact Replacement turn the plastic retaining screws to allow removal of the cartridge as shown and Set-Up Procedure To remove cartridge, turn retaining screws. Auxiliary contact removed Figure 4.25 – Retaining Screws Figure 4.26 – Cartridge Removal Note: and remove the assembly complete with mounting plate by removing the 1502-UM051E-EN-P –...
  • Page 51 4-22 Maintenance Auxiliary Contact Replacement and Set-Up Procedure (cont.) (See Note on previous page) Top cartridges normally closed Bottom cartridges normally open Auxiliary assembly removed Figure 4.27 – Auxiliary Contact Assembly the operating lever. Install and allow the mounting bolts to remain loose so that the assembly can slide vertically on its mounting slots.
  • Page 52 Maintenance 4-23 Mounting Bolt Auxiliary Contact Assembly Cam Followers Operating Lever Mounting Bolt Figure 4.28 – Auxiliary Contact Assembly Set-up 1502-UM051E-EN-P – June 2013...
  • Page 53 4-24 Maintenance 1502-UM051E-EN-P – June 2013...

  • Page 54: Chapter 5 Troubleshooting

    If an operating problem occurs, use the following troubleshooting chart to isolate the cause of the failure and find the corrective action. If the corrective action fails to resolve the problem, consult your local Rockwell Automation field support representative. Table 5.A – Troubleshooting (Series D contactors)
  • Page 55 Troubleshooting 1502-UM051E-EN-P – June 2013...
  • Page 56 Chapter Renewal Parts Figure 6.1 – Bulletin 1502, 800A Electrically Held Vacuum Contactor 20 (hidden) Figure 6.2 – Mechanical Latch Assembly 1502-UM051E-EN-P – June 2013...
  • Page 57 80153-748-01 Mechanical Latch Refurbishing Kit 80158-058-51 Notes: Rockwell Automation recommends that if the contactor has been in service, all three (3) bottles should be replaced at the same time. Refer to Figure 4.4. Refer to Figure 4.28. Refer to Figure 4.15 to 4.19.
  • Page 58 M M edium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb Publication 1502-UM051E-EN-P – June 2013 Copyright © 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada. Supersedes Publication 1502-UM051D-EN-P – December 2009...

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