Rockwell Automation Allen-Bradley 1512A User manual

Medium Voltage Controllers Bulletin 1512A 800A
One-High Cabinet Standard and Arc Resistant Enclosure
Catalog Numbers 1512A, 1512AT, 1512DM, 1512M
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 ArcShield™, IntelliVAC™ Control, IntelliVAC™, IntelliVAC™ Plus 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 1512A-UM102C-EN-P - November 2015 3
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes that are made to this revision.
Topic Page
Changed description for 1512DM and 1512M Bulletin Numbers 9
Modified figure Typical Structure Nameplate. 10
Modified figure Typical Unit Nameplate. 10
Modified figure Access to Power Bus from Side and Rear Cabinet Typical. 16
Modified information in Figure 14 for current transformer. 20
Modified figure Access to Low Voltage Compartments, Arc Resistant. 23
Added steps to Opening the Medium Voltage Door. 24
Added All MV doors must be securely bolted closed before the ArcShield latch
handles are rotated.
25
Added Important table. 26
Added Important table. 27
Added figures Low Voltage Panel, Access to Power Bus with Low Voltage Panel
Rotated, Removal Of Access Panel with Low Voltage panel Rotated, Removal of
Low Voltage Barriers, and Power Bus with Bottom Access Barrier Removed.
30 … 32
Modified Access Power Bus Front Access - Top Entry procedure. 30
Added Typical Ground Bus Splicing Configuration (Front View) illustration. 37
Modified Important table. 43
Added Attention table. 44
Modified figures Door Interlock Lever, Inspecting Isolation Switch in Open
position, Contactor Voltage Checkpoints, Isolation Switch Voltage, Removing the
Contactor Front View), Closing Contactor Manually (some parts not shown),
Isolation Switch Lubrication Points, Isolation Switch Grounding Adjustment,
Location of ISa and ISb Auxiliary Contacts, Adjusting Auxilary Contacts (ISa
Auxiliary Contacts shown).
44 … 57
Added part numbers 80178-750-51, 80158-147-52, PN-272006. 61
Increased the unit quantity of PN-272006 61
Added 50 kA to ArcShield™ Unit Information. 63
Added Attention and Warning Tables. 73
Added Attention and Warning Tables. 82

4Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015
Summary of Changes
Notes:

Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015 5
Table of Contents
Chapter 1
General Information
Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2
Installation-StandardEnclosure(Not
Arc Resistant)
Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Opening the Medium Voltage Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Joining the Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Access – Top Incoming Load Cables . . . . . . . . . . . . . . . . . . . . . 17
Front Access – Bottom Incoming Line Cables . . . . . . . . . . . . . . . . . . 19
Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 3
Installation – Arc Resistant Enclosure
(ArcShield™)
Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Access Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Front Access – Top Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Chapter 4
Common Installation
Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Insulated Power Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ground Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Incoming Line Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Vacuum Contactor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Testing the Contactor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Chapter 5
Maintenance
Tool Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Door Interlock Circumvention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015
Table of Contents
Fuse Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bolt-on Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Bolt-on Fuse Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contactor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removing the Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Contactor Interlock Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Reduce the Gap Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Increase the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Isolation Switch Mechanism Inspection and Lubrication . . . . . . . . . . . . 53
Isolation Switch Mechanism Grounding Adjustment. . . . . . . . . . . . . . . . 54
Auxiliary Contacts Inspection and Replacement . . . . . . . . . . . . . . . . . . . . 55
Isolation Switch Auxiliary Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Adjusting the Normally Open (ISa) Contacts . . . . . . . . . . . . . . . . . . 57
Adjusting the Normally Closed (ISb) Contacts. . . . . . . . . . . . . . . . . . 58
Adjusting the Change of State Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Emergency Circumvention Procedure for Power Cell Entry . . . . . . 59
Chapter 6
Spare Parts
Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Appendix A
ArcShield™ Unit Information
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
ArcShield Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . . 64
Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Additional Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Chimney Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Appendix B
ArcShield™ Plenum Installation
Instructions
Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
General Plenum Layout for ArcShield Line-up. . . . . . . . . . . . . . . . . . . . . . 71
STEP 1 – Mounting a Single Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Plenum Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
STEP 2 – Alignment of “Side-by-Side” Plenums . . . . . . . . . . . . . . . . . . . . 74
STEP 3 – Sequence of Final Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
STEP 4 – Closing the Front of the Plenum Sections. . . . . . . . . . . . . . . . . 76
STEP 5 – Extension and Elbow Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 76
STEP 6 – Mounting Extension/Elbow to Plenum “Line-up” . . . . . . . . . 77
STEP 7 – Additional Mounting Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015 7
Table of Contents
Appendix C
ArcShield™ Chimney Installation
Instructions
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 81
Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Chimney Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015
Table of Contents
Notes:

Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015 9
Chapter 1
General Information
Scope This document pertains to the Rockwell Automation® Bulletin 1512A medium
voltage (MV) controller. The Bulletin 1512A structure provides one complete
MV controller unit.
The product Bulletin numbers that are covered by this document are:
•1512A 800A FVNR controller
•1512AT 800A Transformer Feeder
This document can also be used as a reference guide for these Bulletin numbers:
•1512DM 800A (FVIO) Input Contactor with Output Isolator
•1512M 800A (FVOP) Output Bypass Controller
Starter Identification A nameplate is attached to the right-side flange of the structure (Figure 1). See
the nameplate for information such as series number, section number, NEMA
(National Electrical Manufacturers Association) enclosure type, unit ratings, and
bus ratings.
IMPORTANT
This document is used for all Bulletin 800 amp1512A unit types, including arc
resistant (ArcShield™) units. Important information specifically for ArcShield
units can be found in Appendix A, B, and C.
ATTENTION: See the information in Appendix A, B, and C to install and
maintain ArcShield arc resistant units. Failure to do so can negate the arc
resistant benefits that are provided by ArcShield, which exposes personnel to
risk of serious injury or death.

10 Rockwell Automation Publication 1512A-UM102C-EN-P - November 2015
Chapter 1 General Information
Figure 1 - Typical Structure Nameplate
A nameplate is also found in the low voltage compartment (see Figure 2) with
unit motor application information.
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.
Recommended Torque
Values
When you are installing components, or when assembling the cabinet, tighten
these bolt sizes to the specified torque values.
Table 1 - Torque Values
1/4 in. Hardware 6 lb•ft (8 N•m)
5/16 in. Hardware 12 lb•ft (15 N•m)
3/8 in. Hardware 20 lb•ft (27 N•m)
1/2 in. Hardware 48 lb•ft (65 N•m)