Allen-Bradley Bulletin 505 User manual

RENEWAL PARTS
I iii%
FULL VOLTAGE
REVERSING STARTERS - SIZE 4
OPERATION- Bulletin 505 starters are most commonly used for
full voltage starting and reversing of polyphase squirrel cage
motors.
Bulletin 505 starters consist essentially of a “forward” and a
“reverse” contactor mounted to a common base. These
contactors are electrically and mechanically interlocked to
guard against both contactors 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 dependable
operation. Choice of the proper NEMA enclosure type for the
application is very important.
PREVENTIVE MAINTENANCE - For recommended preventive
maintenance instructions refer to Publication GI-5.0 or the
Handy Catalog.
REPAIRS - Contactors can be disassembled as depicted in the
“exploded” illustration on Page 6. Additionally the following
procedures and techniques are suggested to aid in the
sequential disassembly and reassembly of a contactor.
WARNING - Before part replacements are attempted the
POWER SOURCE MUST BE DISCONNECTED.
NOTE - If parts are removed from both contactors, keep them
separateand replacethem in theiroriginal positions, if reused, to
avoid mismatched wear patterns.
DISASSEMBLY [Partial] - The following instructions apply to
both the left hand and right hand contactors.
1. Remove all control wires from theoperating coil (Item 7) and
tie point terminal (Item 5). Tag removed wires.
2. Loosen two captive screws and lift off thecontact 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 theoperatingcoil (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 1-5 under DISASSEMBLY
completed inspect the contact surfaces for evidence of wear.
When severe contact wear is evidenced it is recommended that
all contacts be replaced. Replacing all contacts will guard
against uneven and unequal contact closings. Order the
required number of single pole contact sets from the part listings
on Page 5.
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 contactouttoeither
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. Butt the contact spring against the side of the “seating
projection” on the movable contact support assembly. Slip
the movable contact through the opening on the movable
contact support assembly. Rock the spring into position over
the seating projection on the movable contact support and
the movable contact.
4. Check to determine that the spring is holding the contact
centered
1 Figure 1
Publication 505-6.3--November, 1981

Stationary Contacts - The screws which secure the front and
rear stationary terminals are accessible from the front. A socket
wrench should be used to loosen and tighten contact securing
screws. Note: Front and rear contacts should be removed and
replaced in pairs one pole at a time.
1. Loosen the screw securing the front contact. Remove the
contact and screw.
2. Loosen the screw securing the rear contact. Remove the
contact and screw.
3. Install the new rear contact (refer to other poles for proper
position). Tighten contact mounting screw securly (162-198
inch-pounds). Note: Front and rear contac tsar edifferent and
keyed to fit in proper position.
4. Install the new front contact (refer to other poles for proper
position). Tighten contact mounting screw securly (182-198
inch-pounds).
5. Repeat Steps 1 through 4 for the remaining poles.
REPLACING THE STATIONARY CONTACT BLOCK AND BASE
ASSEMBLY
- All power and external control wiring to the
Bulletin 505 must be disconnected and theentireassemblymust
be removed from the enclosure or panel to replace either
stationary contact block
and base assembly.Tag removed wires.
1.Remove the interconnecting power wiring from the contactor
requiring servicing and overload control wiring if the right
hand stationary contact block and base assembly is to be
replaced. Completely remove interconnecting power strap.
Tag removed wires.
2.Follow steps 1 through 5 under DISASSEMBLY.
3.The right hand contactor block and base assembly is
connected, by bus, to the overload relay. Remove the three
5/16-18 x 7/16" contactor mounting screws (Item 16), then
remove the contactor from the Bulletin 505 mounting plate
(Item 21). Turn thecontactoroversothe back of itsmounting
plate (Item 20) faces up, then remove the two #10-32 x 3/8"
screws with washers. Turn the starter over so the contactor
faces up, then remove the three 3/8-24 x5/8" overload relay
terminal screws. Theoverload relay including mounting plate
assembly will now come free of the contactor. (Step 3 is not
necessary for the left hand contactor.)
4.The block and base assembly is secured to the mounting
plate (Item 20) by three
5/16-24 x 1-1/4" mounting screws
with washers (Item 15). The stationary contact block and base
assembly (Item 3) can be lifted out when the screws are
removed.
5.If new contacts are not being installed, remove stationary
contacts one at a time from the old block and baseassembly
and install them in the same positions in the new assembly.
(See instructions under REPLACING CONTACTS. Follow
those Instructions also if installing new contact sets.)
6.Install the replacement block and base assembly onto the
contactor mounting plate (Item 20) and secure with the three
screws with washers (Item 15) and tighten securely (135-165
inch-pounds).
7.if the right hand contactor was removed, refasten the
overload mounting plate to the contactor mounting plate
(Item 20) with the two #10-32 x 3/8" screws with washers
(tighten to 24-36 inch-pounds torque). Note: The overload
mounting plate fits between the contactor mounting plate
and the block and base assembly. Reinstall the three
3/8-24 x
5/8" overload relay terminal screws (tighten to 205-255 inch-
pounds).
IMPORTANT - When the stationary contact block and
base assembly is positioned next to the mechanical
interlock, be sure the “projection” on the mechanical
interlock is inserted into the slot in the base of the
contactor. See Figure 3on Page 3.
8. Install the right hand contactor (if removed) onto the Bulletin
505 mounting plate (Item 21) with the three
5/16-18 x7/16”
screws (tighten to 110-130 inch-pounds).
9.Reassemble contactor per REASSEMBLY instructions.
10.Determine if the mechanical interlock isafixed oradjustable
type: The fixed type is mounted directly
to the mounting plate
(Item 21) and has no locating bracket subassembly. The
adjustable type has a locating bracket subassembly and is
shown in Figure 3on Page 3.
11. If the mechanical interlock is an adjustable type, adjust per
MECHANICAL INTERLOCK ADJUSTMENT procedure on
Page 4.
12.Reconnect interconnecting power wiring and strap. Torque
screws to 162-198 inch-pounds.
13.Reinstall thecomplete Bulletin 505 assemblyintheenclosure
and reconnect the external control, line and load wiring.
REPLACING THE OVERLOAD RELAY - The overload relay (Item
13) is connected to both the block and base assembly (Item 3)
and load lines.
1.
2.
3.
4.
5.
6.
7.
8.
Remove the control wire(s) from the overload relay.
Remove the load wiring from the overload relay lugs.
Loosen and remove the three screws that connect the
overload relay bus to the block and base assembly.
The overload relay issecured to its mounting plate
by two l/4-
20 x9/16” mounting screws with washers. Remove these two
mounting screws. Lift the overload relay out.
Install the replacement overload relay to its mounting plate
being sure the relay properly engages the mounting plate.
Secure the overload relay to the bus with the three previously
removed terminal screws. Tighten securely (205-255
inch-
pounds).
Retighten the two mounting screws to the overload relay
mounting plate(tighten to 32-48 inch-pounds).
Reconnect control and load wiring.
OVERLOAD RELAY TEST MODULE - The overload relay is
equipped with a test module (Item 14) on the right side. lt allows
opening the normally closed overload contactfortest purposes
without tripping the relay.
1. To remove, insert an appropriate size screwdriver in slot
provided on the overload relay. Push toward mounting plate
and simultaneously pull module from relay. Refer to Figure 8
on Page 6.
2. To install, squeeze the front of the replacement test module
and simultaneously snap the module into place on the relay.
2

REASSEMBLY - The reassembly process is basically the
disassembly procedure in reverse order.
1. Place the movable contact support and armature assembly
(Item 2) in the contactor base.
IMPORTANT - Be sure the movable contact support is
below the cam on the mechanical interlock.
2. Install the contact block cover and tighten screws securely
(25-30 inch-pounds).
3. Insert the yoke (item 8) into theoperating coil (Item 7). Place
the yoke-coil assembly into the contactor base. The parts are
keyed to fit only one way.
4. Replace the coil cover (Item 4). If used, check the tie point
terminal for proper position. Tighten the coil cover screws
securely
25-30 inch-pounds).
5. With the movable contact support and armatureassembly in
the "OFF" position, install the auxiliary contact block(s) (Item
6), using instructions on Page 6.
6. Reconnect control wires to the operating coil and tie point
terminal.
Proper Tie Point
Terminal Position
REPLACING MECHANICAL INTERLOCK - All power and
external control wiring to the Bulletin 505 must be
disconnected and the entire assembly must be removed from
the enclosure or panel to replace the mechanical interlock.
Tag removed wires.
1.Loosen and remove from the right hand contactor all
interconnecting power wires leaving these wires
connected to the left hand contactor. Completely remove
the interconnecting power strap.
2.Loosen and remove from the right hand contactor all
interconnecting control wires by removing them from
terminals and by removing the auxiliary contact blocks.
(See Page 6 for auxiliary contact block removal.)
3.Each contactor mounting plate (Item 20) is secured to the
Bulletin 505 mounting plate (Item 21) with three
5/16-18 x
7.16" screws (Item 16). Remove these screws from the right
hand contactor and slide it off the mounting plate.
4.Determine if the old mechanical interlock is a fixed or
adjustable type: The fixed type is mounted directly to the
mounting plate (Item 21) and has no locating bracket
subassembly. The adjustable type has a locating bracket
subassembly and is shown in Figure 3.
5.If the mechanical interlock is an adjustable type, no
mounting plate modifications will be necessary and steps
6, 7, 8 and 9 are omitted. Remove and discard the entire old
interlock assembly and proceed to step 10.
6.If the mechanical interlock is a fixed type, remove and
discard it, and mark the two
#10-32 mounting screw holes
for future reference.
7.Remove the left hand contactor in the same manner as
step 3.
8.Modify the Bulletin 505 mounting plate per MOUNTING
PLATE MODIFICATIONS FOR ADJUSTABLE
MECHANICAL INTERLOCK supplied with the new
mechanical interlock.
9.Install the left hand contactor onto the Bulletin 505
mounting plate with the 5/16-18 x 7/16" screws. (Torque to
110-130 inch-pounds).
10. Install the new adjustable mechanical interlock and
locating bracket subassembly on the Bulletin 505
mounting plate using the
#10-32 x 7/8" Tensil-Lock
mounting screws with spacers. Securely tighten the lower
locating bracket screw only (24-29 inch-pounds). The
upper and middle mounting screws should remain hand
tight to allow for later adjustment.
Refer to Figure 4on Page
4. Do not install support bracket at this time.
IMPORTANT- Be sure the “projection” on each side
of the mechanical interlock is inserted into
the slot in
that each cam is above the movable contact
11.Install the right hand contactor onto the Bulletin 505
mounting plate with the
5/16-18 x 7/16" screws. See
important note above. (Torque screws to 110-130
inch-
pounds).
12.Adjust mechanical interlock per MECHANICAL
INTERLOCK ADJUSTMENT procedure on Page 4.
13.Reconnect the interconnecting power wires and strap.
Tighten screws securely (162-198 inch-pounds). Verify
proper connections per wiring diagram supplied with
starter.
14.Replace all interconnecting control wires and auxiliary
contact blocks that were removed in step 2. (See Page
6for
auxiliary contact block installation.) Verify proper
connections per wiring diagram supplied with starter.
15.Reinstall the complete Bulletin 505 assembly in the
enclosure and reconnect theexternal control,
line and load
wiring
Figure 3
Adjustable
Mechanical
Interlo
’ Locating
\
Bracket
Subassembly
Movable
Contact Support
ck
3