Rockwell Automation Allen-Bradley 1502 User manual

Medium Voltage Contactor
800A, 2400-7200 V
Bulletin 1502 (Series D and E)
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).

1502-UM051E-EN-P – June 2013
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 Identication ............................................................................................ 1-6
Contactor Catalog Number Explanation .............................................................. 1-6
Contactor Specications ........................................................................................... 1-7
Products Approvals ......................................................................................................1-8
Chapter 2 Receiving and Handling
Receiving ....................................................................................................................... 2-1
Preliminary Inspection .......................................................................................2-1
Handling ....................................................................................................................... 2-1
Pre-Energization Inspection ..................................................................................... 2-2
Storage ........................................................................................................................... 2-2
Vacuum Bottle Integrity Test .................................................................................... 2-3
Insulation Resistance Test ......................................................................................... 2-5
Chapter 3 Installation
Mounting ...................................................................................................................... 3-1
Electrical Connections ............................................................................................... 3-2
Wiring and Schematic Diagrams:
  4FSJFT%r&MFDUSJDBMMZ)FME$POUBDUPSOPSNBMESPQPVUUJNF.............. 3-4
  4FSJFT%r&MFDUSJDBMMZ)FME$POUBDUPSGBTUESPQPVUUJNF..................... 3-5
  4FSJFT&r&MFDUSJDBMMZ)FME$POUBDUPS ........................................................... 3-6
  4FSJFT%r.FDIBOJDBM-BUDI$POUBDUPS ........................................................ 3-7
  4FSJFT&r.FDIBOJDBM-BUDI$POUBDUPS ......................................................... 3-8
Typical Electrical Diagrams:
  4FSJFT%r&MFDUSJDBMMZ)FME$POUBDUPSOPSNBMESPQPVUUJNF.............. 3-9
  4FSJFT%r.FDIBOJDBM-BUDI$POUBDUPS ...................................................... 3-10
  4FSJFT&r&MFDUSJDBMMZ)FME$POUBDUPS ......................................................... 3-11
  4FSJFT&r.FDIBOJDBM-BUDI$POUBDUPS ....................................................... 3-12
Table of Contents

1502-UM051E-EN-P – June 2013
ii Table of Contents – 800 A MediumVoltage 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
 .FDIBOJDBM-BUDI5SJQ$PJM3FQMBDFNFOU1SPDFEVSF........................................4-15
 .FDIBOJDBM-BUDI3PMMFS3FQMBDFNFOU1SPDFEVSF..............................................4-17
 .FDIBOJDBM-BUDI.FDIBOJTN3FGVSCJTIJOH1SPDFEVSF....................................4-17
Altitude Adjustment ................................................................................................ 4-18
Drop-out Time Conversion ....................................................................................4-20
Auxiliary Contact Replacement and Set-up Procedure .....................................4-21
Chapter 5 Troubleshooting
 5SPVCMFTIPPUJOHr5BCMF" .................................................................................... 5-1
 5ZQJDBM$POUBDUPS$PJM*NQFEBODF7BMVFTr5BCMF# ...................................... 5-1
Chapter 6 Renewal Parts
800A Electrically Held Vacuum Contactor .......................................................... 6-1
 .FDIBOJDBM-BUDI"TTFNCMZ .................................................................................... 6-1
 3FOFXBM1BSUT-JTUr5BCMF"................................................................................ 6-2

Chapter 1
Contactor Product Description
Scope is 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. They may not be used with IntelliVAC and IntelliVAC Plus
control modules.
Series E vacuum contactors are used with IntelliVAC and IntelliVAC Plus
control only (refer to publications 1503-UM053_-EN-P and 1503-UM054_-EN-P
respectively).
Description Allen-Bradley's Bulletin 1502, 800 amp electrically held and mechanical latch
vacuum contactors are designed for high horsepower applications in the 2400 to
7200 voltage range. ese contactors are suitable for all types of AC loads, for
example: three phase motors, transformers, power capacitors and resistive
heating loads. Mechanically latched contactors are used mainly in situations
requiring the contactor to remain closed in the event of power failure.
e contactor uses three (3) interrupters (hereaer referred to as vacuum bottles)
operated by an electromagnet assembly through a mechanical linkage. ey are
resistant to adverse atmospheric conditions and provide a long mechanical and
electrical life.
e contactors are utilized in various starter and drive congurations, e.g. full
voltage non-reversing, full voltage reversing, two-speed, reduced voltage, synchro-
nous, drive input/output and bypass applications. ey are xed mounted
within the structures and the line and load terminations are made at the rear of
the device. In most congurations, the main contactor is mechanically inter-
locked with the external operating handle and isolating switch.
Figure 1.1 – 800A Contactor
1502-UM051D-EN-P – December 2009

1-2 Contactor Product Description
1502-UM051E-EN-P – June 2013
Vacuum Bottle Description e vacuum bottle (Figure 1.2) consists of two contacts enclosed in a ceramic
housing. One contact is mounted on a xed sha, and the other is attached to
a movable sha. e bearing and stainless steel bellows ensure that the movable
contact tracks accurately and maintains vacuum integrity within the bottle.
Arc shield
Fixed shaft
Ceramic
Contacts
Bellows
Bearing
Movable shaft
Figure 1.2 – Typical Vacuum Bottle Cross Section

Contactor Product Description 1-3
1502-UM051E-EN-P – June 2013
Contactor Operation e 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)
 r 8IFOUIFDPOUSPMDJSDVJUJTFOFSHJ[FEDVSSFOUĔPXTUISPVHICPUIBDMPTJOHDPJM
and hold-in coil, creating an electromagnet.
 r ăJTFMFDUSPNBHOFUQVMMTUIFBSNBUVSFQMBUFUPXBSETUIFDPJMDPSFTXIJDIBMTP
rotates the actuator sha.
 r ăFBDUVBUPSQMBUFJOUVSOQVTIFTUIFJOTVMBUPSBOENPWBCMFTIBĕVQDMPTJOH
the contacts inside the vacuum bottle.
 r ăFDPOUSPMDJSDVJUFDPOPNJ[JOHBVYJMJBSZDPOUBDUTMPDBUFEPOUIFMFĕTJEFPG
the contactor, change state once the contactor closes.
 r ăFDVSSFOUUIBUJTFOFSHJ[JOHUIFDMPTJOHDPJMJTUIFOTXJUDIFEPĈăFDPOUBD-
tor remains closed by the hold-in coil only.
 r ăFDPOUBDUPSJTPQFOFECZEFFOFSHJ[JOHUIFIPMEJODPJM
e mechanical latch version of the contactor operates basically the same way
with the following exceptions:
 r #PUIDPJMTBSFEFFOFSHJ[FEVQPODMPTJOHPGUIFDPOUBDUPSBOEUIFBSNBUVSFJT
held in the closed position by a spring-loaded latching mechanism.
 r ăFDPOUBDUPSJTPQFOFECZFOFSHJ[JOHBUSJQDPJMXIJDIQVMMTUIFMBUDIBXBZ
from the armature, or by engaging a manual trip mechanism via a pushbutton
located on the front of the medium voltage door (see Figure 1.4).
Note: External control relays and a rectication circuit are used to control the
standard DC closing and hold-in coils on the contactor.

1-4 Contactor Product Description
1502-UM051E-EN-P – June 2013
Contactor Operation (cont.) IntelliVAC Control (Series E)
e electrically held vacuum contactor operates as follows:
 r 8IFOUIF*OUFMMJ7"$BOE*OUFMMJ7"$1MVTDPOUSPMNPEVMFTSFDFJWFBDMPTF
command, the contactor coil is energized, the current creates an electromagnet
in the coil.
 r ăFFMFDUSPNBHOFUQVMMTUIFBSNBUVSFQMBUFUPXBSETUIFDPJMDPSFSPUBUJOHUIF
sha and causing the actuator plate to move upwards.
 r "TUIFBDUVBUPSQMBUFNPWFTJUQVTIFTUIFJOTVMBUPSBOENPWBCMFTIBĕVQDMPT-
ing the contacts in the vacuum bottle.
 r ăF*OUFMMJ7"$BOE*OUFMMJ7"$1MVTDPOUSPMNPEVMFTTVQQMZUIFDMPTFDVSSFOU
to the coil for approximately 200 milliseconds. Aerward, the coil current is
reduced to a lower hold-in value.
 r 8IFOUIF*OUFMMJ7"$BOE*OUFMMJ7"$1MVTDPOUSPMNPEVMFTIBWFUIFDMPTF
command removed, the coil is de-energized, opening the contactor.
e mechanical latch contactor operates in much the same manner as the electri-
cally held version (see above) with a few exceptions:
 r 0ODFUIFDPOUBDUPSJTDMPTFEBTQSJOHMPBEFENFDIBOJTNNPWFTBSPMMFS
against the armature plate to hold it against the electromagnetic core.
 r ăFDPOUBDUPSDBOCFPQFOFEFMFDUSJDBMMZCZFOFSHJ[JOHBUSJQDPJMWJB*OUFM-
liVAC and IntelliVAC Plus 'open' output) which pulls the latch away from the
armature, or by a push button mounted on the power cell door that mechani-
cally releases the contactor.
Insulator
Return Spring
Compression Bolt
Magnet/Coil
Assembly
Actuator Plate
Line Terminal
Vacuum Bottle
Load Terminal
Flexible Bus
Armature Plate
and Shaft
Armature Stop
Return Spring
Figure 1.3 – Vacuum Contactor Operation

Contactor Product Description 1-5
1502-UM051E-EN-P – June 2013
Latch Lever Latch Spring
Manual Trip Mechanism
Mechanical Latch Trip Coil
Contactor Closed
Figure 1.4 – Top Partial Section View Showing Mechanical Latch

1-6 Contactor Product Description
1502-UM051E-EN-P – June 2013
Contactor Identication Each contactor is identied with a nameplate (Figure 1.5) attached to the
interphase barrier retainer at the front of the contactor. e nameplate informa-
tion includes the Catalog Number, Series Letter, Voltage Rating, Non-enclosed
Current Rating, Interrupting Capacity, Altitude Range, CSA and UL markings.
VACUUM CONTACTOR
3Ø
CET APPAREIL. DES RAYONS X DANGEREUX
READ INSTRUCTIONS BEFORE ENERGIZING
LIRE LES INSTRUCTIONS AVANT D'ALIMENTER
THIS DEVICE.MAY PRODUCE HARMFUL X-RAYS.
CONTACTEUR SOUS VIDE
E102991
MADE IN CANADA PEUVENT SE PRODUIRE
2500-
PLAGE D'ALTITUDE
ALTITUDE RANGE
POUVOIR DE COUPURE
INTERRUPTING CAPACITY
CAT.
LR12235
IEC60470
V. 50/60 HZ.AMP.
M.
SER.
AMP.
CUS
Figure 1.5 – Contactor Label
Catalog No. Explanation e following catalog number explanation will help identify the contactor and
shall be used when contacting your local Rockwell Automation Sales oce or
the factory for assistance.
A= 3 pole,electricallyheldcontactor
B= 3 pole,mechanicallylatched contactorwithelectricaland mechanicalrelease
1502 - V 8 D X D A - 1
First
Position
Bulletin
Number
1502
Second
Position
ContactorType
and Interlock
V= Vacuum,
no interlock
VC = Vacuum,
Optimized for
IntelliVAC™
control
Third
Position
Contactor
Size
8= 800 A
Fourth
Position
Nominal
Line Voltage
D= 7200 V
Fifth
Position
Fuse Mounting
Provisions
X= None
Sixth
Position
Coil
Voltage
D= 110 V D C
(120 V AC)
Seventh
Position
Function
Referto
Table1.A
Eighth
Position
Altitude
Code (meters)
1= 0 – 1000
2= 1001–2000
3= 2001–3000
4= 3001–4000
5= 4001–5000
E= 207 V D C
(230 V AC)
D= 3 pole,electrically held contactorwith fastdrop-outtime
Table 1.A – Vacuum Contactor Function