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

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 11
Chapter 1 Product Description
Contactor Identification
Each contactor is identified with a rating label (Figure 4) attached to the
armature plate at the front of the contactor. The rating label information
includes the Catalog Number (Cat.) Series Letter (Ser.) Voltage Rating, Non-
Enclosed Current Rating, Interrupting Capacity, Altitude Range (in meters),
CSA, UL, and CE markings.
Figure 4 - Contactor Rating Label (450 A)
WARNING: The Rockwell Automation® relay control panel (1503C-XXX or
1503E-CXXX) is required for reliable operation of the contactor within
its published specifications. The relays break the DC current that is
drawn by the closing coil, holding coil, and trip coil. The relays make
sure the pick-up and drop out voltages are coordinated with the pick-
up and drop out voltages of the contactor. This provides reliable
operation of the circuit in undervoltage conditions. The use of
alternative control relays is not supported or recommended. Alternative
relays do not provide the necessary control timings necessary to
provide reliable operation and coordination with all power fuses used in
combination with the contactors.

12 Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 1 Product Description
Catalog Number
Explanation
The following catalog number explanation is used to identify the contactor and
must be used when contacting your local Rockwell Automation sales office for
assistance.
Contactor Dropout Times The IntelliVAC contactor control module (publication 1503-UM060) varies the
speed at which the electrically held vacuum contactor opens.
When electromechanical relays are used to control the electrically held
contactor, there are two speeds available: normal dropout time and fast
dropout time. The opening speed is controlled by changes to the onboard
contactor control circuity (see Figure 13 through Figure 16).
Contactors that are configured for faster dropout times are used for specific
applications if faster uncoordinated action is required.
Contactors with normal dropout times are used in coordination with medium
voltage power fuses. The dropout time must be longer than the Total Clearing
Time of the medium voltage power fuses being applied in combination with
the vacuum contactor. Damage to the contactor can occur if this coordination
is not addressed appropriately.
All mechanically latched contactors are designed with the fast dropout time.
1502 – V 4 – D - B - D - A - 0
ab c d e f g
abcd
Contactor Type and Interlock Contactor Size Nominal Line Voltage Control Circuit(1)
Code Description Code Description Code Description Code Description
VVacuum, electromechanical relay
controlled 4450A D7200V B 5000V
VC Vacuum, optimized for IntelliVAC control C7200V
(1) Or voltage transformer primary fuse mounting provisions.
bc d
Coil Voltage Function Altitude Code (m)
Code Description Code Description Code Description
D110VDC A 3-pole, electrically held contactor 0 -1000…5000
E207VDC B3-pole, mechanically latched contactor with
electrical and mechanical release
D3-pole, electrically held contactor with
fast drop-out(1)
(1) Controlled by electromechanical relay.

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 13
Chapter 1 Product Description
Specifications
Table 1 - Voltage Rating(1)
(1) The voltage ratings listed are valid up to 1000 m (3300 ft). See Table 9 for ratings above this altitude.
Maximum Rated Voltage 7200V
System Voltages 2400, 3300, 4160, 4800, 6600, 6900
Dielectric Voltage Withstand Rating(2)
(2) For 60 s.
18.2 kV
20 kV (IEC)
Basic Impulse Level (B.I.L.) Withstand(3)
(3) Phase to Ground, Phase to Phase
60 kV
Frequency Ratings 50/60 Hz
Table 2 - Current Ratings(1)
(1) The current ratings that are listed are valid up to 1000 m (3300 ft). See Table 9 for ratings above this altitude.
Rated Continuous Current 450 A
Maximum interrupting current rating
2400V
6000 RMS symmetrical amps
5000V
7200V (2)
(2) The IEC rating at 7200V (RMS Sym.) is 5300 A / 66 MVA.
Maximum interrupting MVA rating
2400V 25 Sym MVA
5000V 50 Sym MVA
7200V(2) 75 Sym MVA
Short circuit withstand at rated voltage Current Peak ½ cycle 55 kA
Short time current rating capability For 1 s 6.0 kA
For 30 s 2.4 kA
Chop current (average rms amperes) 0.5
Make and Break Capability at Rated Voltage 4.0 kA
Ambient Temperature 40 °C (104 °F)
Table 3 - Contactor Coil Data, IntelliVAC Controlled
IntelliVAC Control (Electrically Held & Mechanical Latch)
110…240V AC
or
110…250V DC (1)
V AC:
VCL = x VCTL (max.)
V DC:
VCL = VCTL
Close current 4.3 ADC, 200 ms
Hold current 0.48 ADC
Pick-up voltage(1)
(1) Control voltage, as measured at the input of the IntelliVAC control module or the primary voltage to the pilot relay control
circuit.
95V
Drop-out voltage(1) 75V
Trip current 5.5 ADC, 200 ms
Trip voltage(1) 70V
2

14 Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 1 Product Description
Table 4 - Contactor Coil Data
Control Voltage (VCTL) Coil Voltage (VCL)
Electromechanical Relay Controlled (Electrically Held)
120V AC 110V DC
Close current inrush 7.3 ADC
Economized holding current 0.13 ADC
Minimum CR1 coil pick-up voltage 102V AC
CR1 coil drop-out voltage 75V AC
Electromechanical Relay Controlled (Electrically Held)
230V AC 210V DC
Close current inrush 8.3 ADC
Economized holding current 0.11 ADC
Minimum CR1 coil pick-up voltage 190V AC
CR1 coil drop-out voltage 140V AC
Electromechanical Relay Controlled (Mechanical Latch)
120V AC 110V DC
Close current inrush (ADC)5.6A
DC
Pilot Relay (CR1) pick-up voltage 102V AC
Minimum trip coil voltage 84V AC
Trip coil current 6 A
Electromechanical Relay Controlled (Mechanical Latch)
230V AC 210V DC Not available at this control voltage
Table 5 - Operational Characteristics
Mechanical life (1)
(1) Provided that regular maintenance is performed, as detailed in this manual.
Electrically held 2,500,000 operations
Mechanical latch 100,000 operations
Electrical life (1) 1,000,000 operations
Switching frequency Electrically held 600,000 operations per hour
Mechanical latch 150,000 operations per hour
Table 6 - Opening and Closing Times
IntelliVAC Control (Electrically Held & Mechanical Latch)
Maximum closing time (50…60 Hz) 120 / 240V AC 100/70 ms
Maximum opening time (without delay, for 50…60 Hz)(1)
(1) A contactor drop-out delay may be configured with the IntelliVAC control module, publication 1503-UM060.
60 ms
Electromechanical (Relay) Controlled
Maximum closing time (120V AC)(2)
(2) Control/Pilot relay, other than the standard Rockwell Automation Control Panel assembly (1503C-E4_ or 1503C-M4D), must
provide a constant closing signal for at least this period of time. The use of control components other than Rockwell
Automation products is not recommended and may pose reliability concerns.
50/60 Hz
160 ms
Maximum opening time (120V AC)(3)
(3) Mechanical latched.
50 ms
Maximum opening time (120V AC)(4)
(4) Electrically held, normal dropout.
160 ms
Table 7 - Capacitor Switching
System Voltage
2400V 800 KVAR
4160V 1400 KVAR
6900V 2000 KVAR

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 15
Chapter 1 Product Description
Product Approvals •UL347
• CSA22.2 No. 14 and T.I.L. D-21
• IEC 62271-106
•CEMarked
Table 8 - General
Standard Altitude Capability (1) (2)
(1) The voltage and current ratings that are listed are valid up to 1000 m (3300 ft). See Table 9 for ratings above this altitude.
(2) The full altitude range is available with both relay and IntelliVAC control module. The IntelliVAC control module must be
configured accordingly (see publication 1503-UM060).
1000…5000 m (3300…16,500 ft)
Contactor Weight 21.8 kg (48 lb)
Auxiliary Contact Rating A600
Auxiliary Contacts on the Vacuum Contactor (max.)(3)
(3) The number of contactor auxiliary contacts depends on the contactor type. Some of the contacts are used in the typical
control schemes used.
3 N.O., 3 N. C.
Table 9 - Altitude Derating
Altitude Rating Max. Continuous Current Rating Reduce B.I.L. Withstand Rating by:
-1000…0 m (-3300…0 ft)(1)
(1) Only supported with IntelliVAC controlled contactors.
450 A —
0…1000 m (0…3300 ft)
1001…2000 m (3301…6600 ft) 440 A 6.0 kV
2001…3000 m (6601…9900 ft) 430 A 12.0 kV
3001…4000 m (9901…13,200 ft) 420 A 18.0 kV
4001…5000 m (13,201…16,500 ft) 410 A 24.0 kV

16 Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 1 Product Description
Notes:

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 17
Chapter 2
Receiving and Handling
Receiving The contactors have been tested both mechanically and electrically before
leaving the factory. Immediately upon receiving the contactor, remove the
packing material and check the contactor for possible damage from shipping.
If damage is found, do not discard the packaging materials and, if possible,
note the damage on the Bill of Lading before accepting the shipment. Report
any damage immediately to the claims office of the common carrier. Provide a
description of the damage and as much identification as possible.
Preliminary Inspection
Check for any cracks or breaks that were caused by impact.
Push armature plate to verify that the mechanisms are functional.
Use a HiPot tester to test vacuum bottle integrity (refer to Vacuum Bottle
Integrity Test on page 18)
Handling The contactor weighs approximately 21.8 kg (48 lb). When transporting the
contactor over longer distances or for sustained lifting, use a forklift.
When a forklift is used to handle the equipment, adhere to the following
precautions:
• Keep the contactor in an upright position.
• Carefully balance the contactor on the forks.
• Use a safety strap to steady the contactor and avoid shifting or being
tipped.
• Avoid excessive speeds and sudden starts, stops, and turns.
• Never lift a contactor above an area where personnel are located.
Pre-energization Inspection Before placing the contactor in service, inspect for possible damage sustained
in transit or maintenance:.
• Check housing for any cracks or breaks.
• Push the armature plate and rotating shaft to verify that the mechanism
is in good working order.
• Inspect the contactor for dirt, stray or loose hardware, tools, or metal
chips. Vacuum if necessary.

18 Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 2 Receiving and Handling
Vacuum Bottle Integrity
Test
The internal dielectric condition and vacuum integrity of the vacuum bottles is
determined by this test.
High-potential test instruments can be purchased to perform the vacuum
bottle integrity test. An insulation resistance tester cannot be used to measure
vacuum integrity because the voltage is too low. One of the following AC Hi-
pot testers is recommended as a test instrument.
1. Clean the outside of the vacuum bottles with a lint-free cloth or industrial
wipe before performing the test.
2. The contactor can be tested while it is in the power cell. The line
connection of the contactor must be disconnected and the ground lead
from the Hi-pot tester must be connected to the load side of the
contactor. Any fuses in the top of the contactor must be removed.
3. With the contactor in the open position, connect the test leads to the
contactor power terminals as shown in Figure 5. It is recommended that an
AC Hi-pot tester be used. Apply 16 kV for 60 seconds and monitor the
leakage current. It must not exceed 5 mA. Test each vacuum bottle
individually.
4. If no breakdown occurs, the vacuum bottle is in an acceptable condition.
If a breakdown occurs, repeat the test once more. If the vacuum bottle
fails a second time, it must be replaced. If no breakdown occurs in the
second test, the vacuum bottle is in an acceptable condition.
5. After the high potential voltage is removed from the vacuum bottles, the
metal end caps of the vacuum bottles must be discharged with a
grounding rod.
ATTENTION: Do not apply a voltage higher than 25,000V across the
open contacts of a vacuum bottle. Dangerous x-ray emissions can be
produced.
ATTENTION: Vacuum bottles are thoroughly tested at the factory;
however, damage during shipment can occur. It is important to
perform the vacuum bottle integrity test before energizing the
contactor for the first time, and before it is returned to service after
maintenance or repair. The test may result in personal injury or
damage to the equipment if the vacuum bottle integrity fails.
ATTENTION: A high-voltage test is potentially hazardous. Use caution
when performing the Hi-pot test. Failure to do so may result in severe
burns, injury, or death.
ATTENTION: Only AC high potential tests are recommended. Rockwell
Automation does not recommend DC power frequency withstand voltage
tests as they do not provide reliable results.
Manufacturer Address
Vacuum Interrupters Inc.
Model MAC-TS4 Vacuum Interrupter Tester Farmers Branch, Texas 75244
Hipotronics Model 7BT60A Brewster, NY, USA
ATTENTION: If one vacuum bottle fails, Rockwell Automation
recommends replacing all three vacuum bottles, if the unit has been
in service.

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020 19
Chapter 2 Receiving and Handling
Figure 5 - Vacuum Bottle Integrity Test Circuit
The allowable leakage current value of 5 mA is exclusive of leakage due to test
equipment leads. The test setup leakage can be determined by running the
dielectric test with test leads not connected to the contactor and noting the
maximum leakage current. If this value is more than 2 mA, it must be added to
the 5 mA limit when testing the vacuum bottles.
Rockwell Automation does not recommend a DC Hi-pot test. The values that
are obtained during the test are not a reliable indication of vacuum bottle
integrity. An AC test provides a reliable vacuum integrity indication.
Additionally, the degree of vacuum within the bottle can be determined by
comparing initial test results to the present readings. Increases in leakage
current indicate a reduction in vacuum within the vacuum bottle.
Storage To store the contactor before it is in service, store it in a clean, dry area, free
from dust and condensation. Do not store contactor outdoors.
Storage temperature must be between -20…+65 °C (-4…+149 °F). If storage
temperature fluctuates or if humidity exceeds 85%, use space heaters to
prevent condensation.
Insulation Resistance Test Use a 1000V insulation resistance tester to verify that the resistance from
phase-to-phase or from phase-to-ground is greater than 500 megohms.
Vacuum Contactor
in Open Position
Vacuum
Checker

20 Rockwell Automation Publication 1502-UM060A-EN-P - October 2020
Chapter 2 Receiving and Handling
Notes: