Allen-Bradley 1512B User manual

Medium Voltage Controllers, 200/400A Two-High
Cabinet, Standard and Arc-Resistant Enclosure
Publication 1500-UM055H-EN-P
User Manual

Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
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.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Labels may also be on or inside the equipment to provide specific precautions.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 3
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Replaced inside front cover. Inside Front Cover
Replaced Typical Structure and Typical Nameplate graphics. 10
Added Environmental Conditions. 11
Replaced Center Vertical Channel graphic. 20
Updated procedure for Opening the Medium Voltage Doors. 30
Added step to procedure for Joining Sections. 32
Added information to Attention table. 39
Added information to Attention table. 42
Added information to Attention table. 43
Replaced Typical Ground Bus Splicing Configuration graphic. 47
Updated Isolation Switch Kit and stocking quantity. 79
Added (Series R or higher) to 80158-707-53 79
Added Attention table. 90
Added instructions to Cabinet preparation. 90
Added Attention table. 99
Added instructions to Cabinet preparation. 99

4Rockwell Automation Publication 1500-UM055H-EN-P - February 2015
Summary of Changes
Notes:

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 5
Table of Contents
Chapter 1
General Information
Document Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Prepared Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Series Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High Altitude Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Installation – Standard Enclosure
Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Access– Access to Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Access – Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . 24
Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Top Exiting Load Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Chapter 3
Installation– Arc-ResistantEnclosure
(ArcShield)
Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Front Access – Access to Power Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Front Access – Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . 39
Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Top Exiting Load Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Chapter 4
Common Installation
Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6Rockwell Automation Publication 1500-UM055H-EN-P - February 2015
Table of Contents
Insulated Power Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Incoming Line Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation of Current Transformer Barrier . . . . . . . . . . . . . . . . . . . . . . . . 49
Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Contactor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Testing Contactor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Chapter 5
Maintenance
Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Door Interlock Circumvention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Power Lock-out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuse Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Bolt-on Fuse Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Clip-on Fuse Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contactor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removing the Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Contactor Interlock Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
To Reduce the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
To Increase the Gap Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Isolation Switch Mechanism Inspection and Lubrication . . . . . . . . . . . . 67
Isolation Blade Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Isolation Switch Mechanism Grounding Adjustment. . . . . . . . . . . . . . . . 72
Auxiliary Contacts Inspection and Replacement . . . . . . . . . . . . . . . . . . . . 73
Isolation Switch Auxiliary Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Adjusting the Normally Open (ISa) Contacts . . . . . . . . . . . . . . . . . . . 74
Adjusting the Normally Closed (ISb) Contacts. . . . . . . . . . . . . . . . . . 75
Adjusting the Change-of-State Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Emergency Circumvention Procedure for Power Cell Entry. . . . . . . . . . 76
Installing Z-clip with Isolation Switch Handle in the OFF Position . .
78
Installing Z-clip with Isolation Switch Handle in the ON Position 78
Chapter 6
Spare Parts
Bulletin 1512 and 1512BT Units Parts List. . . . . . . . . . . . . . . . . . . . . . . . . 79
Appendix A
ArcShield Unit Information
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
ArcShield Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . . 82
Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 7
Table of Contents
Additional Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Chimney Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Appendix B
ArcShield Plenum Installation
Instructions
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 88
STEP 1 – Mounting a Single Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Plenum Placement on Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
STEP 2 – Alignment of “Side-by-Side” Plenums . . . . . . . . . . . . . . . . . . . . 91
STEP 3 – Sequence of Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
STEP 4 – Closing the Front of the Plenum Sections . . . . . . . . . . . . . . . . 93
STEP 5 – Extension and Elbow Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 93
STEP 6 – Mounting Extension/Elbow to Plenum “Line-up”. . . . . . . . . 94
STEP 7 – Additional Mounting Support. . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Appendix C
ArcShield Chimney Installation
Instructions
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 98
Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Chimney Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8Rockwell Automation Publication 1500-UM055H-EN-P - February 2015
Table of Contents
Notes:

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 9
Chapter 1
General Information
Document Scope This User Manual pertains to the Rockwell Automation Bulletin 1512B medium
voltage controller. The Bulletin 1512B structure includes provisions for two
complete MV controller units.
The installation section provides instructions for both the standard enclosure
type and Rockwell Automation arc resistant type (ArcShield).
The product Bulletin numbers covered by this document are:
•1512B 200/400 A FVNR controller
•1512BT 200/400 A Transformer Feeder
•1512BP 200/400 A Prepared Space(1)
This document may also be used as a reference guide for the following Bulletin
numbers:
•1512DM 200/400 A VFD Input Contactor Units
•1512DO 200/400 A VFD Output Contactor units
•1512M 200/400 A VFD Output Bypass Starter
•1562E 200/400 A MV SMC Flex Solid-State
(up to 4800V) Reduced Voltage Starter
•1591B Incoming Line Unit
•1592BF Fused Load Break Switch for Feeders
•1592BP Fused Load Break Switch for Feeders, prepared space
Starter Identification A structure nameplate is attached to the right-side flange of the structure (see
Figure 1). Refer to the nameplate for information such as series number, section
number, NEMA enclosure type, unit ratings and bus ratings.
IMPORTANT
This document is to be used for all Bulletin 1512B unit types, including arc
resistant (ArcShield™) units. Important information specifically for ArcShield
units can be found in Appendix A, Appendix B and Appendix C.
ATTENTION: Users must refer to the information in Appendix A, Appendix B
and Appendix C to correctly install and maintain ArcShield arc resistant units.
Failure to do so may negate the arc resistant benefits provided by ArcShield,
exposing personnel to risk of serious injury or death.
(1) Not available on arc-resistant designs.

10 Rockwell Automation Publication 1500-UM055H-EN-P - February 2015
Chapter 1 General Information
Figure 1 - Typical Structure Nameplate
A unit nameplate is also found in the low voltage compartment with specific unit
motor application information (see Figure 2).
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.