Allen-Bradley Bulletin 505 User manual

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BULLETIN
RENEWAL PARTS 505
FULL VOLTAGE REVERSING STARTERS
Size 2 l Series A Construction
Size 2
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OPERATION - Bulletin 505 starters are most commonly
used for full voltage starting and reversing of
poly-
phase squirrel cage motors.
Bulletin 505 starters consist essentially of a “for-
ward” and a “reverse” contactor mounted to a com-
mon base. These contactors are electrically and
mechanically interlocked to guard against both
contac-
tors closing at the same time.
Starters are equipped with Bulletin 592 block type
manual reset overload relays.
OPERATING ENVIRONMENT - Starters should always
be maintained in a clean and dry condition for depend-
able operation. Choice of the proper NEMA enclosure
type for the application is very important.
REPAIRS-starters can be disassembled as depicted in
the “exploded” illustration on Page 4. Additionally the
following procedures and techniques are suggested to
aid in the sequential disassembly and reassembly of a
motor starter.
WARNING - Before part replacements are at-
tempted the POWER SOURCE MUST BE
DISCONNECTED.
NOTE - If parts are removed from both contactors,
keep them separate and replace them in their original
positions, if reused, to avoid mismatched wear
patterns.
DISASSEMBLY (Partial) - It is not necessary to remove
the starter from its enclosure or to remove the line
wiring. The following instructions apply to both the left
hand and right hand contactors.
1. Remove all control wires from the operating coil
(item 7) and tie point terminal (item 5).
2. Loosen two captive screws and lift off the contact
block cover (item 1).
3. Loosen four captive screws from the coil cover (item
4). The tie point terminal is now free to be removed,
if it is to be replaced.
4. With the coil cover screws loosened the auxiliary
contact block(s) (item 6) can be removed and the coil
cover lifted off.
5. Lift out the movable contact support and armature
assembly (item 2), the yoke (item 8) and the
operat-
ing coil (item 7) as a unit. The yoke and the operating
coil can now be lifted up and out of the movable
contact support assembly.
REPLACING CONTACTS - With steps l-5 under DISAS-
SEMBLY completed inspect the contact surfaces for
evidence of wear. When severe contact wear is evi-
denced it is recommended that all contacts be re-
placed. Replacing all contacts will guard against un-
even and unequal contact closings. Order the
required number of single pole contact sets from
the part listings on Page 4. Follow steps l-5 under
DISASSEMBLY.
MOVABLE CONTACTS - The following instructions
describe the replacement of movable contacts.
1. Remove the movable contact (item 9) by depressing
the contact spring (item 10) and pushing the contact
out to either side. The contact spring will fall free or
can be lifted out.
2. Hold the replacement spring and contact in one
hand as shown in Figure 1.
3. Seat the contact spring over the “seating projec-
tion” on the
movable contact
support assem-
bly. Slip the
movable contact
and spring into
position in the
opening on the
movable con-
tact support
assembly.
4. Check to deter-
mine that the
spring is holding
the contact
centered.
Figure 1
FRONT STATIONARY CONTACTS-The mounting screws
that secure the front stationary contacts (item 11) are
accessible from the front and are located directly below
and to the back of the front terminal assemblies.
1. Loosen and remove the screw and lift out the
contact.
2. Install the replacement contact (front and rear
stationary contacts are identical) and tighten the
contact mounting screw securely (approximately
14-17 inch pounds).
REAR STATIONARY CONTACTS -The mounting screws
that secure the rear stationary contacts (item 12) are
accessible from the top and are located at an angle in
the cavities directly behind the front terminal
assemblies.
1. Loosen and remove the mounting screw while hold-
ing the contact with a finger from within the contact
block assembly.
2. Push the loose contact up and out with the holding
finger or allow it to drop down. It may be necessary
to push the contact down from the top with a
screwdriver.
Publication 505-6.1 -July, 1977

3. Install the replacement contact from the top catch-
ing it from within the contact block assembly with a
finger.
4. Insert the mounting screw and tighten securely
(approximately 14-17 inch pounds).
REPLACING THE STATIONARY CONTACT BLOCK AND
BASE ASSEMBLY-The block and base assembly (item
3) can be removed from a partially disassembled
starter if necessary. First follow steps 1-5 under
DISASSEMBLY.
1. Remove the line wiring and both front and rear
power wiring interconnector assemblies (item 16).
2. The right hand contactor block and base assembly is
connected, by bus, to the overload relay. Loosen but
do not remove the three terminal screws that con-
nect the block and base assembly to the overload
relay. (This is not necessary on the left hand
contactor).
3. Each block and base assembly is secured to the
mounting plate (item 19) by three
#10-32 x .719"
Phillips pan head mounting screws with washers
(item 15). Remove these screws and the stationary
contact block and base assembly (item 3) can be
lifted up and out while tilting it slightly to the outside
to clear the projection on the mechanical interlock.
4. If new contacts are not being installed, remove
stationary contacts one at a time from the old block
and base assembly and install them in the same
positions in the new assembly (see instructions
under REPLACING CONTACTS. Follow those in-
structions also if installing new contact sets).
5. Install the replacement block and base assembly
and secure with the three screws with washers and
tighten securely (approximately 20-26 inch pounds).
6. Retighten terminal screws to overload relay bus on
the right hand contactor securely (approximately
30-40 inch pounds).
7. Reconnect line wiring and front and rear power
wiring interconnector assemblies.
REPLACING THE OVERLOAD RELAY -The overload relay
(item 13) is connected to both the block and base
assembly (item 3) and load lines.
1. Remove the control wire(s) from the overload relay.
2. Remove the load wiring from the overload relay
terminals.
3. Loosen but do not remove the three terminal screws
that connect the overload relay bus to the block and
base assembly, approximately 3 turns.
4. The overload relay is secured to its mounting plate
by two #8-32 x 1/2
" pan head mounting screws with
washers. Remove these screws, lift the overload
relay away from the mounting plate, then slide it
down and out.
5. The replacement overload relay will be furnished
secured to a mounting plate. Remove and discard
the mounting plate. install the replacement over-
load relay being sure the bus connects properly to
the terminals on the stationary contact block and
base assembly. Secure the overload relay to the
mounting plate with the two previously removed
screws with washers (NOTE: Place the flat washers
next to the molded plastic part). Tighten securely
(approximately 20 inch pounds).
6. Retighten securely the three terminal screws to
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overload relay bus (approximately 30-40 inch
pounds).
7. Reconnect control and load wiring.
OVERLOAD RELAY TEST MODULE -The overload relay is
equipped with a test module (item 14), on the right
hand side, that allows opening the normally closed
overload contact for test purposes, without tripping the
relay.
1. To remove use an appropriate size screwdriver. Hold
the blade vertically and insert the screwdriver tip
into the slot, provided on the test module, to the
point where it “bottoms”. Refer to Figure 7on
Page 5.
2. Slide the test module out to the right.
3. Slide the replacement test module into place and
press firmly until it locks in place.
REASSEMBLY - The reassembly process is basically
the disassembly procedures in the reverse order.
1. Insert the yoke into the operating coil. It is keyed and
will fit only one way.
2. Insert the yoke and operating coil into the movable
contact support assembly.
3. Insert all three parts as a unit into the stationary
contact block and base assembly.
4. Replace the coil cover. Check the tie point terminal
for proper position as shown in Figure 2 below.
Tighten the coil cover screws securely (approxi-
mately 14-17 inch pounds).
5. Replace contact block cover and tighten screws
securely (approximately
8-10 inch pounds).
6. Install the auxiliary contact block(s). Refer to de-
tailed instructions on Page 5.
REMOVAL OF MECHANICAL LOAD BALANCER - The
movable contact support and armature assembly must
be completely open (the word “OFF” totally visible).
1. Loosen the two captive screws and lift off the
contact block cover.
2. Remove the load balancer by pivoting the bottom of
the balancer housing away from the contactor and
lifting up and off.

REPLACING MECHANICAL LOAD BALANCER - The mov-
able contact support and armature assembly must be
completely open (the word “OFF” totally visible). The
contact block cover must be removed.
1. Hold load balancer at an angle, hooking the three
tabs located along the top side edge into the groove
provided on the top edge of the stationary contact
block. See Figure 3.
2. Push the load balancer toward the contactor mount-
ing plate as far as possible.
3. Exert pivotal force near the bottom of the load
balancer “snapping” it in place.
IMPORTANT - Always replace the contact block
cover and torque the two captive screws securely
(8-10 in. Ibs.) The contact block cover secures the
load balancer in its final position.
“hook on and
snap in place”
Figure 3
REPLACING MECHANICAL INTERLOCK -
1. Remove all control wiring from left hand contactor.
2. Loosen the front power wiring interconnector
assembly screws on the left hand contactor.
3. Remove rear power wiring interconnector assem-
bly completely.
4. The left hand contactor is secured to the starter
mounting plate by three #10-32 x
15/64"
Tensil-Lock
pan head screws. Remove these screws and lift the
contactor off of the mounting plate.
5. Loosen the coil cover on the right hand contactor
and remove the auxiliary contact block used for
electrical interlocking. Retighten coil cover screws
securely (approximately 14-17 in.
lbs.).
6. The mechanical interlock is secured to the mount-
ing plate by two
#10-32 x
15/64
" Tensil-Lock pan
head screws. Remove these screws and lift off the
mechanical interlock.
7. Install the replacement mechanical interlock.
right side of the mechanical interlock is inserted
right hand contactor and the cam rests on top of
Secure the mechanical interlock to the mounting
plate with the two previously removed screws and
tighten securely (approximately 24 to 29 in.
lbs.).
8. Replace the auxiliary contact block used for electri-
cal interlocking on the right hand contactor, posi-
tion PI. See page 5for installation instructions.
9. Replace the left hand contactor to the mounting
plate.
side of the mechanical interlock is inserted into the
contactor and the cam rests on top of the movable
Secure the contactor to the mounting plate with the
three previously removed screws and tighten se-
curely (approximately 24 to 29 in.
lbs.).
10. Replace the rear power wiring interconnector as-
sembly and tighten the front and rear power wiring
interconnector assembly screws securely (approx-
imately 14 to 17 in.
lbs.).
11. Reconnect all control wiring.
Movable Contact Support
Figure 4
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110-115
50 cc322
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I ZOO-208 I 60 I
cc249
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220-230 50 cc339
60 CC254
230-240
50
CC342
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380 50 cc354
1
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415
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50
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cc357
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440-460 50 CC360
460-480 60 CC273
500
50 CC364
575-600 60 CC278
For coils other than those listed specify coil number and
complete rating found’on coil’s identification label.
NOTE
- Parts indicated with Q are recommended spare
parts.
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0 Heater Element
Type W (Specify)
Item Description of Part Part Number
1 Contact Block Cover
40420-499-01
02
Movable Contact Support and Armature Assembly 40420-498-01
03
Right Hand Stationary Contact Block and Base Assembly 40420-495-02
Left Hand Stationary Contact Block and Base Assembly 40420-496-02
Less contacts, order Single Pole Sets as required.
Starters are furnished with one of the above auxiliary contact blocks on each contactor as standard for
electrical interlocking contact.
NOTE
- Parts indicated with 0 are recommended spare parts.
ORDERING INFORMATION -Your order cannot be entered unless the following information is given: Part number,
description of part, catalog number and series letter of starter. This renewal parts list applies also to these starters
when used on control apparatus listed under other Bulletin numbers.

MODIFICATIONS
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Cat. No. 595-A Cat. No.
595-AB
(1 N. 0.)
(1 N.O.-1 N.C.)
AUXILIARY CONTACTS - Bulletin 505 starters are de-
signed to accept one to four auxiliary contact blocks
which can provide up to eight auxiliary contacts of the
user’s choice. Auxiliary contact blocks mount at posi-
tions PI and P2 on the coil cover of the left hand
contactor, and P3 and P4 on the coil cover of the right
hand contactor. Normally, the inboard mounting posi-
tions on both contactors are used for or obstructed by
factory installed interlock contact blocks. Auxiliary
contact blocks can be mounted without the use of tools
or additional hardware.
OAuxiliary Contact Description
One Normally Open (1 N.O.)
One Normally Closed (1 N.C.)
One Normally Open-One Normally Closed
(1 N.O.-1 N C )
Catalog Number
595-A
595-B
595-AB
Two Normally Open (2 N.O.)
Two Normally Closed (2 N.C.)
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595-AA
595-BB
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NOTE - Parts indicated with 0 are recommended spare parts.
REMOVAL OF AUXILIARY CONTACT BLOCK -Loosen coil
cover and lift out the auxiliary contact block by pivoting
its back end away from starter.
INSTALLING OR REPLACING AN AUXILIARY CONTACT
BLOCK
- The movable contact support and armature
assembly must be completely open (the word “OFF”
totally visible). The coil cover must be in place and
properly secured.
1. Align arrows molded on auxiliary contact block. See
Figure 5.
2. Locate molded tabs on side with arrows. See Fig-
ure 5.
3. Hook tabs under coil cover at any pocket location
(PI, P2, P3, or P4).
4. Exert a pivotal force at the lower end of the block
until it snaps into place. Refer to Figure 6.
NOTE - When replacing the “inboard” auxiliary con-
tact blocks (between the contactors) it may be neces-
sary to use a tool, such as a screwdriver. to exert this
force because of restricted space
Molded Tabs
Figure 5
Figure 6
Cat. No. 595-A02
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AUXILIARY CONTACT (N.O.) FOR OVERLOAD RELAY-This
contact can easily be added to the block type overload
relay used on Bulletin 505 Starters. It mounts in place of
the standard overload relay test module. A typical
application would be for an alarm circuit indicating
when the overload relay has tripped.
INSTALLING (N.O.) AUXILIARY CONTACT - First remove
the test module as indicated below.
1. Use an appropriate size screwdriver.
2. Hold the blade vertically and insert the screwdriver
tip into the slot provided on the test module to the
point where it “bottoms”. See Figure 7.
3. Slide the test module out to the right.
4. Slide the N.O. auxiliary contact block into the over-
load relay in place of the test module.
5. Secure the block, using the mounting screw pro-
vided, through the hole in the overload relay hous-
ing. See Figure 8.
Figure 7
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Csrew
Block
Figure 8
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