Rockwell Automation Allen-Bradley G Series User manual

Medium Voltage
450 A Contactor, Series G
Bulletin Number 1502
User Manual Original Instructions

2Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Medium Voltage 450 A Contactor, Series G 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.
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 1502-UM060A-EN-P - October 2020 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 5
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Product Description Contactor Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Series Letter Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Vacuum Bottle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrically Held Contactor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IntelliVAC Controlled Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electromechanical Relay Controlled Contactors . . . . . . . . . . . . . . . . . 9
Mechanically Latched Contactor Operation. . . . . . . . . . . . . . . . . . . . . . . . 10
IntelliVAC Controlled Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electromechanical Relay Controlled Contactor . . . . . . . . . . . . . . . . . 10
Contactor Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contactor Dropout Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 2
Receiving and Handling Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preliminary Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pre-energization Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Vacuum Bottle Integrity Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Insulation Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 3
Installation Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wiring and Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 4
Maintenance Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
High Potential Voltage (HiPot) and Insulation Resistance Test. . . 37
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Vacuum Bottle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Coil Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Auxiliary Contact Setup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mechanically Latched Contactor Trip Coil Replacement Procedure . . 42
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Mechanically Latched Contactor Setup Procedure . . . . . . . . . . . . . . . . . . 46
Chapter 5
Troubleshooting Troubleshooting and Contactor Coil Resistance. . . . . . . . . . . . . . . . . . . . 49
Chapter 6
Spare Parts Bulletin 1502 Spare Parts Diagrams and Chart . . . . . . . . . . . . . . . . . . . . . 51
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 5
Preface
About This Publication This manual pertains to the Allen-Bradley® Bulletin 1502, Series G version
450 A vacuum contactors. For earlier product series letters, contact your local
Rockwell Automation representative.
Series G vacuum contactors are intended for use with electromechanical
(relay) control circuits or with IntelliVAC™ control module. See publications
1503-UM060.
This manual is intended for engineers or technicians that are directly involved
in the installation, connection, energizing, and maintenance of the medium
voltage 450 A contactor.
Download Firmware, AOP,
EDS, and Other Files
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
Medium Voltage Controllers, 400A One-High Cabinet, Standard and Arc-
Resistant Enclosure, publication 1512A-UM100 Provides information on installation, maintenance, and spare parts for standard and arc
resistant enclosures
Medium Voltage Controllers, 200/400A Two-High Cabinet, Standard and Arc-
Resistant Enclosure, publication 1500-UM055 Provides information on installation, maintenance, and spare parts for standard and arc resistant enclosures
IntelliVAC Contactor Control Module User Manual, publication 1503-UM060 Provides information on receiving and storage, installation, setup, monitoring, and spare
parts for the IntelliVAC Contactor Control Module
EtherNet/IP Network Devices User Manual, ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, SECURE-RM001 Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley industrial automation controls and
assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

6Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Notes:

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 7
Chapter 1
Product Description
Contactor Description The Allen-Bradley® Bulletin 1502 450 A vacuum contactors are designed for
applications in the 2400…7200V AC range. The contactor is suitable for all
types of loads, for example: three-phase motors, transformers, power
capacitors, and resistive heating loads.
The contactor uses three interrupters (referred to as vacuum bottles) operated
by an electromagnet assembly through a mechanical linkage. They are
resistant to most adverse atmospheric conditions and provide long mechanical
and electrical life.
The contactors are used in various motor control and adjustable speed drive
configurations, such as full-voltage non-reversing, full-voltage reversing, two-
speed, reduced voltage, synchronous, adjustable speed drive input/output, and
bypass applications. They are fixed-mounted within the structures and the line
and load terminations are made at the rear of the device. The main contactor
should be mechanically interlocked with the external isolation switch
operating handle and the isolation switch as well.
Bulletin 1502 vacuum contactors are optimized for use with the IntelliVAC™
control module (see publication 1503-UM060). Certain contactor models are
available for use with electromechanical (relay) control panels. There are physical
control wiring and component differences between contactors that are designed
for IntelliVAC control versus those intended to be operated using
electromechanical relay controls (see Catalog Number Explanation on page 12).
Series Letter Details The series letter of the Bulletin 1502 contactor is shown on the label that is
located on the front of the armature plate (Figure 4). The catalog number,
along with the series letter, define the product’s electrical and mechanical
configuration. This information must be used to select the appropriate repair
or replacement parts.
Electrically held, electromechanical relay controlled contactors moved from
Series D to Series E with the inclusion of mechanical vacuum bottle braces.
Mechanically latched, electromechanical relay controlled contactors were
moved from Series E to Series F with the inclusion of mechanical vacuum
bottle braces.
Electrically held and mechanically latched IntelliVAC controlled contactors
were moved from Series E to Series F with the inclusion of mechanical vacuum
bottle braces.

8Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 1 Product Description
All contactors were moved from series F to G with the change of current rating
from 400 A to 450 A and the unification of altitude for relay controlled
contactors
Figure 1 - 450 A Contactor
Vacuum Bottle Description Each vacuum bottle (Figure 2) consists of two contacts that are enclosed in a
ceramic housing: an upper contact that is mounted to a fixed shaft, and a lower
contact that is mounted to a movable shaft. A stainless steel bellow helps the
vacuum integrity of the bottle, while letting the lower contact move towards
and away from the fixed contact.
Figure 2 - Vacuum Bottle Cross Section
Arc Shield
Contact Wear Indicator Line
Fixed Shaft
Ceramic
Bellows
Contacts
Bearing
Movable Shaft

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 9
Chapter 1 Product Description
Electrically Held Contactor
Operation
IntelliVAC Controlled Contactors
The electrically held contactor consists of three vacuum bottles. An electro-
magnet assembly and a mechanical linkage are used to close the contacts (see
Figure 3).
• When the IntelliVAC control module receives a close command, the
contactor coils (two connected in series) are energized, and the current
creates an electromagnet with the coils.
• The electromagnet pulls the armature plate towards the core of the coils,
which rotates the shaft and causes the actuator plate to move upwards.
• As the actuator plate moves, it pushes the insulator and each vacuum
interrupter’s movable shaft up, which closes the contacts in the vacuum
bottle.
• The IntelliVAC control module supplies the current required to close the
coils for approximately 200 milliseconds. Afterward, the coil current is
reduced to a much lower hold-in value.
• When the close command is removed from the IntelliVAC control
module (Open), the coils are de-energized, which opens the contactor.
Electromechanical Relay Controlled Contactors
When the main pilot relay (CR1) in the control circuit is energized, the circuit
energizes an electromagnet in the closing coil and in the hold-in coil
(Figure 18). The electromagnet pulls the armature plate towards the core of the
coils, which rotates the shaft and causes the actuator plate to move upwards.
As the actuator plate moves, it pushes the insulator and each vacuum
interrupter’s movable shaft up, which closes the contacts in the vacuum bottle
(see Figure 3). The control circuit economizing auxiliary contacts, on the left
side of the contactor, change from the normally closed state to the normally
open state as the contactor closes, which de-energizes the closing coil.
The hold-in coil remains energized and keeps the contactor closed. De-
energizing the hold-in coil opens the contactor.
IMPORTANT The standard electrically held contactor requires an external
120V AC or 240V AC control relay and rectification circuit to
control the standard DC closing and hold-in coils on the contactor
(see Figure 19).

10 Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 1 Product Description
Figure 3 - Electrically Held Vacuum Contactor Operation
Mechanically Latched
Contactor Operation
The mechanically latched contactor operates in much the same way as the
electrically held (Figure 3) with only a few exceptions.
IntelliVAC Controlled Contactor
• Once the contactor is fully closed, a spring-loaded mechanism moves a
roller against the armature plate to hold it against the electromagnetic
core.
• The contactor can be opened electrically by energizing a trip coil (via
IntelliVAC ‘open’ [TCO] output) which pulls the latch away from the
armature, or by a push button that mechanically releases the contactor.
The push button is mounted on the power cell door.
Electromechanical Relay Controlled Contactor
• Once the contactor is fully closed, a spring-loaded mechanism moves a
roller against the armature plate to hold it against the electromagnetic
core.
• The control circuit auxiliary contact, on the left side of the contactor,
changes from the normally closed state to the normally open state as the
contactor closes. This action de-energizes the relay that controls the
closing coils (see Figure 18).
• The contactor can be opened electrically by energizing a trip coil that
pulls the latch away from the armature, or by a push button that
mechanically releases the contactor. The push button is mounted on the
power cell door.
The electromechanical relay controlled mechanical latch contactor requires
external 120V AC or 230V AC control relays and rectification circuit to control
the standard DC closing and trip coils on the contactor (when IntelliVAC control
module is not used). See Figure 19.
Insulator
Armature Plate and Shaft
Auxiliary Actuator
Control Wire Plug
Armature Stop Bracket
Control Transformer
Fuse Clip
Line Terminal
Vacuum Bottle
Load Terminal
Flexible Bus
Return Spring
Actuator Plate
Gap Adjustment Screw
Magnet Coil Assembly