1503-IN050 - Rockwell Automation
Contents
1. ib 102 125 500 Terminal 127 5 00 pe 5 127 Te 18 50 TT 470 FRONT VIEW CLIP ON FUSES FRONT VIEW BOLT ON FUSES Cut away to show upper mounting tabs Cut away to show upper mounting tabs a 0 310 Isolation switch clearance hole location 0 310 Trailer fuse block clearance hole location All dimensions in inches millimeters Figure 2 6 Orientation of Isolation Switch 1503 INO50E EN P June 2013 Power Fuses Component Installation 2 7 Ferraz Shawmut medium voltage power fuses are recommeded for the Bulletin 1503 These motor fuses have been tested and meet the co ordination requirements for the Bulletin 1502 vacuum contactor The fuses many be purchsed from Rockwell Automation Ferraz Shawmut or from a local distributor The following part numbers are available See Figures 2 7 and 2 8 for dimensions of fuses Table 2 1 Recommended Power Fuses Clip on Fuses Fuse Rating 5 kV 5 kV 7 2 kV 7 2kV e Allen Bradley Ferraz Shawmut Allen Bradley Ferraz Shawmut Part Number Part Number Part Number Part Number 12R 230 A A072F1DORO2. 1 EP 9 53 242 D 00281168 6 8 LA ee CLEARANCE HOLES 44 12 Front Mounting Surface Cutout Dimensions 106 1 00 27 25 Front View Handle cut away to show lower L mounting holes Ii Figure 2 3 Handle Cut out Dimensions 1503 INO50E EN P June 2013 2 4 Component Installation Mounting Isolation Switch 3 From the inside of the cabinet insert the handle through the cut out and Handle Module cont line up the pilot holes with the pre drilled holes in the handle assembly Use four 4 4 20 6 3 x 1 8 Type B self tapping screws to attach the front of the handle Torque the screws according to the specifications shown on page 1 4 4 Mark the location of the rear mounting tabs of the handle module Drill two 2 0 219 in 5 5mm pilot holes see Figure 2 4 26 23 666 22 67 g 461 MA eg 19 93 130015061 1630 3 20 3 Mounting Holes Clearance 5 E z Z 2 cT D D FRONT VIEW LEFT SIDE VIEW Cut away to show lower mounting holes 2 X 0 312 Clearance Holes All dimensions in inches millimeters See Fig 2 3 f
3. 4 88 113 124 1503 INO50E EN P June 2013 All dimensions in inches millimeters eoeung Bununojy uoJ Figure 2 2 OEM Component Layout Bolt on Power Fuses Frame and other parts not shown 22 85 460 a 580 117 12 05 306 0 11 87 301 e 2 2 L a Component Installation 2 3 Mounting Isolation Switch The handle is shipped in the OFF or open position All Handle Module instructions assume the handle remains in the OFF position during installation and adjustment procedures Required Hardware mounting holes shown in Figure 2 3 Isolation Switch Handle unless otherwise stated e Six 6 4 20 x 0 5 in 6 3 x 1 8 x 13mm Type B self tapping screws One 1 5 16 in M8 x 1 25 grounding wire screw Refer to the component layout shown in Figure 2 1 or 2 2 to determine the mounting location and the location of the mounting holes for the isola tion switch handle module Refer to Figure 2 3 for a detailed view of the 1 Prepare a cut out in the cabinet for the handle using the dimensions 2 Drill four 4 0 281 in 6 8 mm clearance holes in the locations indi cated for the retaining screws a 0 53 14 po 4X 20 219 5 31 12 MOUNTING HOLES OFF Position m 0 65 25 7 M7 8 26 210 242
4. 5 1 Isolation Switch Mechanism Inspection and Lubrication 5 1 Auxiliary Contacts Inspection and Replacement 5 3 Spare Parts ar 6 1 MR CA AAA 1 Chapter 1 Receiving Installation OEM Starter Frame Installation Read this document before performing any installation procedures or adjustments Observe all applicable A safety procedures when working on the equipment Complete all installation procedures before connecting the incoming line cable Failure to do so may result in damage to the equipment or injury to personnel Refer to General Handling Procedures for Medium Voltage Controllers Publication MV QS050_ EN P This document is included with your shipment and contains information regarding receiving unpacking initial inspection handling storage opening the medium voltage doors and site preparation Note Refer to Appendix A for a listing of the that are included in your OEM Frame Kit Standards and Codes The OEM starter frame consists of a fusible non load break isolation switch an isolation switch handle a vacuum contactor control circuitry and a medium voltage door These components are not a complete motor controller The user must add appropriate control circuitry for the application power fusing current transformer control power transformer
5. Refer to the following publications for detailed maintenance information on the Bulletin 1502 contactor e 400A Publication 1502 UM050_EN P Series D e 400A Publication 1502 UMO052 EN P Series E 600A Publication 1502 UMOSI EN P Series E These user manuals contain detailed information on installation adjustment and maintenance for this product To avoid shock hazards lock out incoming power see page 3 2 before working on the equipment Verify with N a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death 1 Complete the Power Lock out Procedure see Page 3 2 2 Open the medium voltage door 3 Inspect the condition of the clevis pin and cotter pins shown in Figure 5 Replace any worn parts 1503 INOSE EN P June 2013 5 2 Maintenance Isolation Switch Mechanism Inspection and Lubrication cont 1503 INO50E EN P June 2013 Threaded Connecting Rod i Clevis Pins and Isolation Switch Cotter Pins Operating Lever Interlock Lever e oq Lubrication Points Only at replacement Contactor Interlock Rod 225A Figure 5 1 Isolation Switch Handle Mechanism Lubrication Points 4 Ifitis necessary to replace the isolation switch operating lever or the interlock lever apply Dow Corning 55 O
6. overload protection and a suitable enclosure It is recommended that the user be familiar with the following safety and design standards and codes and any additional local codes that a medium voltage starter must comply with e CEC Canadian Electrical Code e CSA 22 2 No 14 Canadian Standards Association Industrial Control Equipment e NEC National Electrical Code e NEMA ICS Standards National Electrical Manufacutrers Association e OSHA Occupational Safety and Health Administration e UL 50 Underwriters Laboratories Enclosures for Electrical Equipment e UL 347 Underwriters Laboratories High voltage Industrial Control Equipment e UL 508 Underwriters Laboratories Industrial Control Equipment e 60204 1 Safety of Machinery Electrical Equipment of Machines Part 1 General Requirements e EC 62271 200 AC Metal Enclosed Switchgear and Control Gear for Rated Voltages Above 1kV and up to 52 kV e EC 60470 High Voltage Alternating Current Contactors e EC 60529 Degrees of Protection Provided by Enclosures IP Code e EC 62271 1 Common Clauses for High voltage Switchgear and Control Gear Standards 1503 INO50E EN P June 2013 1 2 OEM Starter Frame Installation Installation Cont 1503 INO50E EN P June 2013 Standards and Codes Cont The OEM starter frame assembly was fully tested and inspected at the factory Unless damage from shipping is suspected the comm
7. 12R 18R 390 A A072F1DORO 18R 24R 450 A A072F1DORO 24R Single Barrel Fuse Double Barrel Fuse OEM must provide means to prevent fuse rotation under fault conditions Continuous ampere rating at 40 C 104 F as recommended by fuse manufacturer The fuse rating must be derated if the internal temperature will exceed 40 C 104 F Rockwell Automation recommends that the continuous load current not exceed 80 of the fuse rating Bolt on Fuses Fuse Rating 5 kV 5 kV 7 2 kV 7 2 kV e Allen Bradley Ferraz Shawmut Allen Bradley Ferraz Shawmut Part Number Part Number Part Number Part Number 12R 230 A072B1DARO 12R 18R 390 A A072B2DARO 18R 24R 450 A A072B2DARO 24R Single Barrel Fuse Double Barrel Fuse Continuous ampere rating at 40 C 104 F as recommended by fuse manufacturer The fuse rating must be derated if the internal temperature will exceed 40 C 104 F Rockwell Automation recommends that the continuous load current not exceed 80 of the fuse rating 1503 INO50E EN P June 2013 2 8 Component Installation Power Fuses cont SINGLE BOLT ON FUSE i 19 25 489 454 3 50 80 FA TOP VIEW FOUR 4 SLOTS SIDE VIEW FRONT VIEW DOUBLE BOLT ON FUSE 9 50 13 SIDE VIEW FRONT VIEW All dimensions in inches millimeters Figure 2 7 Bolt on Fuse Dimensions 1503 INO50E EN P June 2013 Component Ins
8. 2013 Adjustments 3 3 e Electrically operate the contactor by pushing the START button on the unit or at a remote location f Disengage the contactor and move the control switch to the NOR MAL position Disconnect the external power supply g Complete the Power Lock out procedure 4 Open the medium voltage door 5 Visually inspect that the isolation switch blades fully engage the grounding pins on the grounding bar The isolation switch shutters should be closed see Figure 3 3 Grounding Bar Isolation Switch Blades must fully engage Grounding Pins of Grounding Bar Verify for each phase Isolation Switch Shutters must be closed Verify for each phase Figure 3 3 Inspecting Isolation Switch in Open Position 6 Check the line and load sides of the contactor with a hot stick or appro priate voltage measuring device to verify that they are voltage free see Figure 3 4 a Check for line side voltage at the top vacuum bottle terminals b Check for load side voltage at the bottom vacuum bottle terminals 1503 INO50E EN P June 2013 3 4 Adjustments Power Lock out Procedure cont Isolation Switch Blades must fully engage Incoming Line Stabs Check incoming line voltage here 1503 INO50E EN P June 2013 Check line side power here st oies ane i dmi Check load side power here Figure 3 4
9. Ib 8 Nem 12 Move the isolation switch handle to the ON position 13 Manually close the contactor by attaching locking pliers to the contac tor operating lever and pushing down until the armature plate contacts the magnetic cores see Figure 3 7 Verify that the interlock lever overlaps the isolation switch operating lever by at least 0 125 in 3mm see Figure 3 8 Armature Plate Magnetic Core Figure 3 7 Closing Contactor Manually Some parts not shown 1503 INO50E EN P June 2013 Isolation Switch Ground Adjustment Adjustments 3 7 ER E Isolation Switch Overlap 0 125 in min Operating Lever Interlock e 3 mm Figure 3 8 Isolation Switch Operating Lever Overlap 14 Open the contactor Verify that the interlock lever and the rod move freely and that the return springs move the assembly back to the starting position MITT avoid shock hazards lock out incoming power before 1 2 3 a propriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death working on the equipment Verify with a hot stick or ap Move the isolation switch handle to the OFF position Inspect the grounding of the isolation switch blades When the isolation switch handle is in the OFF open position the isolation switch blades must fully engage the ground pins of the ground bar The iso
10. Isolation Switch b Contacts ISb are on the inside of the housing Isa Auxiliary Contacts N O Isb Auxiliary Contacts N C Figure 3 10 Location of Isa and Isb Auxiliary Contacts 1503 INO50E EN P June 2013 Adjustments 3 9 ISa and ISb contacts are exactly the same 700 CPM The cam controls the normally open or normally closed status of the contacts Refer to Figures 2 10 to 2 13 for wiring diagrams Important The Isolation Switch Ground Adjustment procedure page 3 7 must be completed before adjusting the auxiliary contacts to ensure proper synchronization of the assembly Adjusting the Normally Open ISa Contacts MTT To avoid shock hazards lock out incoming power before working on the equipment Verify with a hot stick A appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death 1 Move the isolation switch handle to the ON closed position 2 Loosen the bolt holding the outside cam to the shaft Do not loosen the bolt entirely The cam should not be able to rotate freely on the shaft 3 Insert a 0 25 in 6 35 mm diameter pin into the cam groove between the cam follower and the end of the cam groove Se gt Cam Follower Gap 0 25 in 6 35 mm Auxiliary Contact Left
11. Latch Contactor 1503 INO50E EN P June 2013 Door Interlock Assembly Component Installation 2 15 When properly installed the door interlock assembly see Figure 2 13 used in conjunction with the isolation switch is designed to provide the following interlocking features e When the isolation switch handle is in the ON position a pin on handle overlaps the Z clip to prevent the door from being opened e When the door is closed and the isolation switch handle is in the ON position a cover catch inside the door will be held in place by the interlock defeater lever and provide another means for holding the door closed while the unit 1s energized MTT The door interlock assembly must be installed for the voltage cell while the unit is energized The isolation switch handle alone will not provide safety interlocking If the door interlock assembly is not installed the OEM assumes the responsibility for providing a means to isolate the medium voltage power cell while the unit is energized Failure to install a medium voltage power cell isolation means can expose personnel to medium voltage resulting in severe burns injury or death isolation switch handle to restrict access to the medium Door Flange di Rear Door Surface Z clip Cover Catch Mounting Bracket Cover Catch Figure 2 14 Door Interlock Assembly 1503 INO50E EN P June 2013 2 16 Component Installation Door I
12. N personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death RU The following procedure requires moving the isolation switch handle to the ON position To avoid shock hazards disconnect and lock out incoming power before proceeding with servicing the equipment Failure to lock out incoming power will result in a live power cell once the isolation switch handle is in the ON position and may cause severe burns injury or death Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the following safety procedure prior to servicing the equipment 1 Disconnect and lock out all feeder power supplies to the starter 2 Move the isolation switch handle to the OFF position 3 Ifthe unit is equipped with power factor correction capacitors stored energy must be dissipated before entering the power cell Wait at least five minutes before entering the power cell or dissipate the power using the following procedure a Verify that the isolation switch handle is in the OFF position b Open the low voltage door c Plug the appropriate power supply 120 or 230V into the auxiliary power receptacle on the control panel see Figure 3 2 d Move the control switch to the TEST position Auxiliary Power Receptacle Test Switch Figure 3 2 Control Panel 120V shown 1503 INO50E EN P June
13. Torque the screws according to the specifications 1503 INO50E EN P June 2013 2 6 Component Installation Mounting Isolation Switch Refer to the component layout shown in Figure 2 1 or 2 2 to determine the and Trailer Fuse Block cont location of the trailer fuse block Refer to Figure 2 6 to determine the location of the mounting holes for the trailer fuse block 1 Drill four 4 0 219 in 5 5 mm pilot holes at Location B as shown in Figure 2 6 for the trailer fuse block 2 Attach the trailer fuse block using four 4 4 20 4 8 x 1 6 Type B self tapping screws Torque the screws according to the specifications shown on page 1 4 3 Install a dome plug over each screw AUAU Reinstall any inter phase barriers that were removed while connecting the trailer fuse block Failure to do so A may produce an electrical fault between the fuses and damage the equipment
14. UM051 EN P 1503 UMO052 EN P for IntelliVAC mounting instructions Note that a suitable wire harness 15 required 1503 WHxxx to connect IntelliVAC to the vacuum contactor Refer to Inteli V AC page 2 10 for more information and wiring diagrams Torque Requirements Use the specified torque values for all hardware whenever performing maintenance or attaching components 1 4 in M6 hardware 6 ftelb 8 Nem 5 16 in M8 hardware 12 ftelb 15 Nem 3 8 in M10 hardware 20 ftelb 27 Nem 1 2 in M12 hardware 48 ftelb 65 Nem Fuses Refer to the motor nameplate for the information necessary to determine correct power fuse size See page 2 7 for recommended power fuses MTT Only qualified personnel should select the fuse type and rating Failure to select the correct fuses may result in N injury to personnel and or damage to equipment 1 Install clip on or bolt on power fuses into the isolation switch fuse clips 2 Ifcontrol power is supplied by control power transformer within the unit fuses may be installed in the control circuit transformer primary fuse clips at the top of the contactor see page 2 24 for details Line and Load Connections See Incoming Line Connections page 2 24 and Load Connections page 2 24 Commissioning See Commissioning Chapter 4 chapter Component Installation for 400A Equipment Component Layout Refer to the following diagram to determine the loca
15. a 4 9 6 SASN4 AYVWINd DNLLIWI LN 9 Oa 1X TH L G e oSI VAOOG SASN4 AAMOd LNAXANI MOTTIILNI 2000 SD HOLIMS DNILYVIOSI 6 CAD 31D 1 SNE ZH09 0S BE A0069 A00 2 el 11 Figure 2 10 Typical Schematic Diagram for 400 amp Full Voltage Non Reversing FVNR Controller with Electro Mechanical Control and Electrically Held Contactor 120 V AC Normal Drop out Time 1503 INO50E EN P June 2013 Component Installation 2 12 ONIAVeI SIHL NO NADHS LON ONIZIS LNANOdWOD 401 ONIMVAT NOISNAWIC OL 43438 3FLON YSWOLSND 777 VPE WN YOLSTSYVA 3GIXD Wilaw ADN 39IA3d SAILOSLOYNd YSEWNN 3331 3931 30 CILNNDW 39VLIDA ADT dI L 9L 91 09 DNISOTI 99 440 9 NNA e 2 AvA HOLYINN SDLIVINDI NIVW el 14 E AVIIY H21V1 SOLOVLNOO NIVW AI cd YI 1 3 1 AOLOVLNOO NIVN I oq ZH09 06 ON A021 8 db SL 01 INIOd AlddNS 1541 18531 y WWaBIDN 440 VIE y WI LE X W oT EE A E OT 95 Ay X AUN 234 N3I 411239 GI gt GSI vo e 9 SLOVINDI ASVIIIXOV VelLX3 ax 2H Ix TH L G e TRI si VA00S 10 19NNVW SASNA AYVWIad ONILIWIT LN33 3
16. ring lubricant or equivalent to the pivot points before installing the new components see Figure 5 1 5 Inspect the mounting hardware the isolation switch operating lever and contactor interlock rod see Figure 5 1 Tighten any loose hardware 6 Inspect the isolation switch blades and the incoming line stabs see Figure 3 9 The mating surfaces must be clean and well lubricated 7 Remove any dirt and dried grease Do not scrape or file the parts This may remove the plat ing and expose the underlying copper to corrosion 8 Lubricate the isolation switch blades and the isolation switch blade pivot points with Nyogel 759G part number T9327 105 see Figure 5 2 TTITTTIBE Lubricate the isolation switch blades a minimum of once per year to avoid excessive wear to the components and to prevent the isolation switch blades from overheating Lubricate Isolation Switch Blades Lubricate Pivot Points Auxiliary Contacts Inspection and Replacement Maintenance 5 3 p iL E lt lt dr B Figure 5 2 Isolation Switch Lubrication Points BETTI To avoid shock hazard lock out incoming power before 1 2 3 4 5 6 7 appropriate voltage measuring device that all circuits are voltage free Failure
17. sna 49 sna AJADd ZH09 0S A0069 A00v2 Figure 2 12 Typical Schematic Diagram for 400A Full Voltage Non Reversing FVNR Controller with IntelliVAC Control and Electrically Held Contactor 1503 INO50E EN P June 2013 Component Installation 2 14 ONIAVAC SIHL NO NADHS LON DNIZIS LNSNOdWO9 404 ONIMAVAC NOISNANIO OL 414434 DNISIA AAWOLSNS dOLSIAVA ACIXO WLAN JJA SAILISALONd 05 MILNNN 3331 39IA3G GaLNNOW wood 39VLTOA WOO didl IL 7109 SNISO19 dN LAVLS 340114 ASWOLSNS 3HL CIINDIANTI TINNWVADOYA OL IVATTILNI 4495 IV SNLYLS INTON 34VS SNLYLS AOLOVINOD 194444 NI 33V 541915 d N3ADd NDLLVSODIJNDIO CATIVLSNI ONIMO 7101 AHL O3 IddY INDHITA NMOHS SLOVINOO AVT38 SALON IVATTISINI 21 99 Ci gt WE FE LOVINDO AUYITIXNY ValLX3 AW 3 N 6 SE 0 0 9 11 ZH09 0G SN A027 0 H SL 07 6 ast 8 lNIHd AlddNS 1541 j 1541 WWAON 440 gt ZH09 0S 951 GE 0069 A00p2 dI L TYNNYW SISNA ANYWIAd DNILIATI LN32RINI 2x 1 CRI WA00S TLd3 SISNA s3ADd ONILIHNI LN3eaf3 MOOTZALNI 2000 HOLIMS DNILWIOSI sna CAD sna Figure 2 13 Typical Schematic Diagram for 400A Full Voltage Non Reversing FVNR Controller With IntelliVAC Control and Mechanical
18. to do so may result in severe burns injury or death i working on the equipment Verify with a hot stick or Move the isolation switch handle to the OFF position and open the controller door Inspect the auxiliary contacts for wear scorching or heat damage Replace any damaged contacts The contacts have a mean time between failure MTBF rating of 20 million operations if used within the oper ating specifications To remove the contact turn both of the D head fasteners until the flat sections are aligned with the edge of the contact See Figure 5 3 Remove the contact from the housing Disconnect the wires from the auxiliary contact Reverse the procedure to replace the auxiliary contact Ensure the contact is correctly positioned into the contact carrier See Figure 5 3 1503 IN050E EN P June 2013 5 4 Maintenance Auxiliary Contacts Inspection and Replacement cont 1503 INO50E EN P June 2013 D head Ia Fastener Incorrect Positioning Install as Shown Above Figure 5 3 Auxiliary Contact Orientation Chapter 6 Spare Parts M Recommended 80144 491 02 Fuse Extractor For Clip on Power Fuses 1 The Low Voltage Control Panel includes the following CR1 relay CR2 Relay rectifier MOV assembly test switch test plug Refer to Publication 1503 UM051_ EN P or 1503 UM052_ EN P for spare part information for IntelliVAC control modules Refer
19. to the following publications for information on spare parts for the Bulletin 1502 medium voltage 400A contactor 120V and 230V e 400A Publication 1502 050 EN P Series D e 400A Publication 1502 UM052 EN P Series E 600A Publication 1502 UMOSI EN P Series E These user manuals contain detailed information on installation adjustment and maintenance for this product 1503 INOSOE EN P June 2013 6 2 Spare Parts 1503 INO50E EN P June 2013 Appendix A OEM Kit Chart Table A 1 Items That Should be Included with the Power Cell and Frame Final Part at Des as Saleable Part RA Internal Number Number Part Number 400 Amp 2 3 5 0 kV Electrically held Clip On Fuse Electro Mechanical 1503F E4GCD 1503F E4GCD 80158 951 61 110 120 VAC Control Frame Electrically Held 120V Control panel 1503C E4D 80158 143 51 400 Amp 2 3 5 0 kV Electrically Held Clip On Fuse Electro 1503F E4GCE 80158 951 65 1503F E4GCE Mechanical 220 230VAC Control Frame 1503C E4E 80158 143 53 1503F E4GCU 400 Amp 2 3 5 0 kV Electrically Held Clip On Fuse IntelliVAC 110 1503F E4GCU 80178 373 58 120VAC Control Frame 1 1503VC BMC5 80178 370 52 1503 WHE4V_ 80178 142 57 1503F E4GBD 400 Amp 2 3 5 0 kV Electrically Held Bolt On Fuse Electro 1503F E4GBD 80158 951 59 Mechanical 110 120VAC Control Frame 1 1503C E4D 80158 143 51 1503F E4GBE 400 Amp 2 3 5 0
20. 0 20 89 18 82 531 478 T L Lower Mounting Surface AJ D m 9 C 1187 2 444 113 124 5 put 3 e e DI 3 z All dimensions in inches millimeters Figure 2 1 OEM Component Layout Clip on Power Fuses Frame and other parts not shown 1503 INO50E EN P June 2013 2 2 Component Installation Component Layout cont 471 7 33 186 1 19 I 30 Em 1 00 25 9 53 H 242 39 78 16 67 1010 423 37 11 943 P 343 Agi O E 5 20 89 1 20 531 30 12 95 seal 329 mre oi IL Y Lower Mounting Surface 1050 267 444
21. 02 53804 ONILIWIT LNIANO 3000 HOLIMS ONILV TOSI sna CHI 135 SNE 21 ZHO9 0G GE A0069 A00 2 11 Figure 2 11 Typical Schematic Diagram for 400A Full Voltage Non Reversing FVNR Controller with Electro Mechanical Control and Mechanical Latch Contactor 1503 INO50E EN P June 2013 2 13 Component Installation ONIMVAC SIHL NO NADHS LON ONIZIS LNANOdWOD 214 ONIAVAC NDISN3WIC OL 23 3432 DNIZIA AIWOLSNO aOLSTAVA ACIXO WLAW JAAA SAILIALOAd A04 AaSEWNN 1331 5591 36 CILNNON A000 39YL170A ADI LNAWdINOA ILONAN LNAWdINOA SLOWS DNILIANNDI 3ADW33M dA LAVLS 340134 AAWOLSND JHL AE T3YNDIANDI TIMNWIDOAd 38 OL IVATTTALNI 3395 IVI SNLYLS I37NCON 4495 SALVLS NADLOVINDI 1193443 NI 541915 dN aSMOd NOILVAENDIANOO C3TIVLSNI AAOLIVA DNIMOTIOI JHL a3 nd WaLNOS NAOHS SLOVLNOD AVT38 SALON IVATTIALNI SNLVLS YDLIVINDI MDILOVINDO OH K RER o 5 ZH09 0G 75 H SL 07 INIOd ATddNS 1541 D 1531 IVNSION o EN gt o ELUN LE TW 9 KP dE m SLOVINDI ANVITIXNV V g E o I GE SE ve o lt VI INS 9 i gt 951 SISNI ASVAINd ONILINI 1 LNIANO G VAO0S FLd9 951 54504 aaMOd ONILIWIT LN3228N9 ADOC HOLIMS DNILVIOSI
22. 60 80158 143 60 80178 374 55 80178 370 52 80158 142 55 80158 333 58 80158 143 54 80178 374 57 80178 370 52 80158 142 58 80158 333 61 80158 143 55 80178 374 60 80178 370 52 80158 142 55 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www ab com mvb Publication 1503 IN050E EN P June 2013 Supersedes Publication 1503 IN050D EN P June 2012 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in Canada
23. 80158 143 53 400 Amp 5 1 6 9 kV Electrically Held Clip On Fuse IntelliVAC 110 120 1503F E4KCU 80178 373 68 VAC Control Frame 1 IntelliVAC Base 1503VC BMC5 80178 370 52 1503F E4KCU 80158 142 57 1503F E4KBD 400 Amp 5 1 6 9 Electrically Held Blot On Fuse Electro Mechanical 80158 951 60 110 120 VAC Control Frame 1 80158 951 51 1503F E4KBE 400 Amp 5 1 6 9 kV Electrically Held Bolt On Fuse Electro 80158 951 64 Mechanical 220 230 VAC Control Frame 30158 14553 1503 INO50E EN P June 2013 A 2 OEM Kit Chart Table A 1 Items That Should be Included with the Power Cell and Frame cont 400 Amp 5 1 6 9 kV Electrically Held Blot On Fuse IntelliVAC 110 120 VAC Control Frame IntelliVAC Base Final Part Number 1503F E4KBU 1503F M4KCD 1503 M4KBD 1503F M4KBU 1503F E6GBD 1503F E6GBU 1503F M6GBD 1503F M6GBU 1503F E6KBD 1503F E6KBU 1503F M6KBD 1503F M6KBU 1503 INO50E EN P June 2013 Saleable Part Number 1503F E4KBU 1503VC BMC5 Wire Harness IntelliVAC 400 Amp 5 1 6 9 kV Mechanical Latch Clip ON Fuse Electro Mechanical 110 120 VAC Control Frame Wire Harness IntelliVAC 400 Amp 5 1 6 9 kV Mechanical Latch Bolt On Fuse Electro Mechanical 110 120 VAC Control Frame 400 Amp 5 1 6 9 kV Mechanical Latch Blot On Fuse IntelliVAC 110 120 VAC Control Frame 600 Amp 2 3 5 0 kV Electrically Held Blot On Fuse Electro Mechan
24. Contactor Voltage Checkpoints 7 Use the Door Interlock Circumvention procedure described on page 3 1 to move the isolation switch handle to the ON position 8 Check the isolation switch blades with a hot stick or appropriate volt age measuring device to verify that they are voltage free see Figure 3 5 Figure 3 5 Isolation Switch Voltage Check Points 9 Once all power circuits are verified to be voltage free move the 1sola tion switch handle back to the OFF position The unit is now safe to service Contactor Interlock Rod Adjustment Gap 0 03 in to 0 78 in 1 00 mm to 2 0 mm Interlock Lever Adjustments 3 5 To avoid shock hazards lock out incoming power see 1 2 3 4 a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death page 3 2 before working on the equipment Verify with Complete the Power Lock out Procedure see Page 3 2 Open the medium voltage door Use the Door Interlock Circumvention procedure described on page 3 1 to move the isolation switch handle halfway between the OFF and ON position see Figure 3 6 Keep the handle in this position until the adjustment procedure 1s completed With the contactor in the OFF position insert a 0 050 in 1 3 mm feeler gauge in the gap between the interlock lever and the isolation switch operating lever The gap must be between 0 045
25. OEM Starter Frame and Components Allen Bradley Bulletin 1503 2400 to 7200 volts Installation Manual Rockwell Allen Bradley Rockwell Software Automation 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 o
26. Side View Figure 3 11 Adjusting Auxiliary Contacts Isa Auxiliary Contact Shown 1503 IN050D EN P June 2012 3 10 Adjustments Isolation Switch Auxiliary Contacts cont 1503 INO50E EN P June 2013 4 6 7 Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin 0 25 in 6 35 mm Move the isolation switch handle to the OFF open position and check that nothing prevents the cam from rotating with the shaft Tighten the bolt holding the cam to the shaft Move the isolation switch handle to the ON position and recheck the gap using the pin Verity that auxiliary contact ISa is open when the isolation switch 15 open Verify that ISa contact is closed when isolation switch is closed Adjusting the Normally Closed ISb Contacts 1 2 3 4 5 6 7 8 Move the isolation switch handle to the OFF open position Loosen the bolt holding the inside cam to the shaft Do not loosen the bolt entirely The cam should not be able to rotate freely on the shaft Insert a 0 25 in 6 35 mm diameter pin into the cam groove between the cam follower and the end of the cam groove Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin 0 25 in 6 35 mm Move the isolation switch handle to the ON closed position and check that nothing prevents the cam from rotati
27. Standard drive sockets 8 10 13 15 18 mm e wrenches 8 10 13 15 18 mm e Drill and drill bits 4 6 5 5 6 8 mm e Slot head screwdrivers e Locking pliers e Feeler gauge set 3mm to 8 mm e High potential tester OEM Starter Frame Installation 1 3 400 Amp Starter Frame Dimensions 23 85 606 All dimensions in inches millimeters see 4 X 9 515 13 MOUNTING HOLES t Il 21 50 546 50 36 1279 2447 bo M 538 MMI P ALA FL LL CL T oe TG a 21 89 97 0 97 25 556 FRONT VIEW BOTTOM VIEW Figure 1 1 Starter Frame Dimensions Control Panel a eee Li RE RENN cia ee co np 1 Mount the control panel in a suitable location Be aware that the con Plast Sale trol plug wiring harness is 10 ft 3 meters in length Ensure that the wiring harness route still allows for a proper connection to the contac tor control plug 2 Connect the control panel harness to the receptacle on the left side of the contactor Observe the matching number codes to ensure a proper connection See Control Panel page 2 10 for more information and for wiring diagrams 1503 IN050D EN P June 2012 1 4 OEM Starter Frame Installation Installation Cont 1503 INO50E EN P June 2013 IntelliVAC Refer to Publication 1503
28. arness route still allows for a proper connection to the contactor control plug Connect the control panel harness to the contactor control wire plug on the lower left side of the contactor The number codes on the plug must line up with those on the contactor to ensure a proper connection See Figure 2 9 Use the terminal blocks on the control panel to connect the unit to a 120 or 230 volt grounded power source whichever is applicable to the control panel and to other remote devices see Figure 2 10 or 2 12 for electrical drawings Refer to Publication 1503 UM051 EN P or 1503 UMO052 EN P for information regarding the IntelliVAC control module Refer to Figure 2 12 or 2 13 for typical electrical drawings 2 11 Component Installation AAD AV I34 LOWd I0LOVINDI NIVW 2425 IDTLIVINDI DNIZIWONDII MEOS ONIC 1OH 9H DNISOT9 99 CW ADLOVLNOD dOLSIAVA ACIXO 1VL3N ADIAAC FAILIILONA AOA JJEWNN 333L 329IA3C CILNNDW ADVLIOA ADI LNAWdINOA ILOWIN LNAWdINOS SLOWSS ONILOANNOO NAHA ANA 3ADW3S AVA Va SLIVINDI AUVITIXNY 440 ce NG mor C HW I E CU Nna AT 0 B y ei OT anis LAVLS Le ees ee Comi ala 1491 9015 ET CN W y LT T NOW 93 81411 95 voa 4 gt a E ES LES PH eU YI II II ZH09 0S JL A021 lt 8 IT SL 01 6 Bs 8 INIOd AlddAS 1531 WWAON gt
29. at of the contactor operating lever Complete all installation procedures before beginning any adjustment procedures described in Chapter 3 Electrical Connection from Contactor to Trailer Fuse Block Clip on Fuses Component Installation 2 21 Required Hardware three 3 horizontal bus links or suitable cable and lugs bus links are recommended to be 1 4 in 6mm thick and 1 in 25mm wide three 3 3 8 16 in x 1 in MIO x 1 5 x 25mm bolts three 3 3 8 16 in M10 x 1 5 nuts three 3 3 8 1n M10 lock washers six 6 3 8 in M10 flat washers Supplied Hardware three 3 5 16 18 x 1 in bolts three 3 5 16 in lock washers three 3 5 16 in flat washers ATTENTION Double barrel clip on power fuses require an anti turn power phases Do not use such fuses without this safety feature Failure to do so may result in injury to personnel or damage to the equipment The brackets are supplied if specified at the time of ordering otherwise contact Rockwell Automation to obtain the brackets Order Allen Bradley part number 80253 262 51 Mounting instructions are included with the kit bracket to maintain sufficient clearance between the Anti turn Brackets Figure 2 19 Trailer Fuse Block with Anti turn Brackets 1503 INO50E EN P June 2013 2 22 Component Installation Electrical Connection From 1 Use the supplied 5 16 in hardware to mount the bus link or suitable Co
30. encing and that the connections are tight See Torque Requirements page 1 4 Verify power fuse ratings and condition Verify control fuse ratings and condition Check that components were not damaged during power cable installation and that electrical spacings are sufficient Final Checks 1 2 3 4 Remove all tools from the cabinet All tools and hardware used during installation and commissioning must be accounted for prior to energizing the unit Remove all temporary jumpers and grounding devices used during the installation procedures Ensure that all barriers or covers removed during installation have been securely reattached Close and secure all doors Verify that all interlocks preventing access to medium voltage power cells are functioning correctly Use suitable personal protective equipment PPE per 5 6 7 local codes or regulations Failure to do so may result in A severe burns injury or death Restore incoming power from main power supply Move the isolation switch handle to the ON position The controller is now ready to supply power to the load Chapter 5 Contactor Isolation Switch Mechanism Inspection and Lubrication Maintenance Establish a maintenance and inspection schedule for the equipment Annual servicing or every 20 000 operations whichever comes first is the minimum recommended however extreme operating conditions may warrant ad ditional attention
31. ensure proper functioning of the isolation switch as A sembly perform the following adjustments in the order they are presented The door interlock mechanism is designed to prevent access to the medium voltage cell while the unit is energized When the unit is in operation do not circumvent this interlocking safety feature Always disconnect and lock out incoming power see Power Lock out Procedure pg 3 2 before proceeding with any adjustments requiring the handle to be moved to the ON closed position Failure to do so may result in electric shock causing severe burns injury or death Some of the following sections may require moving the isolation switch handle to the ON position while the medium voltage door is open The interlocking safeguards in the mechanism are designed to prevent the handle from moving to the ON position while the cabinet door is open circumvent this safety feature use a screwdriver or other tool to depress the door interlock defeater lever in the switch e Hold the lever down while moving the handle to the ON closed posi tion Interlock Defeater Lever Figure 3 1 Door Interlock Defeater Lever 1503 IN050D EN P June 2012 3 2 Adjustments Power Lock out Procedure ATTENTION Always perform the power lock out procedure before proceeding with servicing the equipment Use suitable
32. f 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 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 PP IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions 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 Follo
33. hown on page 1 4 2 Attach the bus links or suitable cable to the line side of the contactor upper terminals using 3 8 in M10 hardware See Fig 2 21 Torque the bolts according to the specifications shown on page 1 4 MUC Maintain at least 3 in 76 mm clearance between power phase connections Insufficient distance could cause A equipment damaging power faults in the unit Contactor Attachment Point Trailer Fuse Block Attachment Point Figure 2 21 Linking Trailer Fuse Block to Contactor Bolt on Power Fuses 1503 IN050D EN P June 2012 2 24 Component Installation Incoming Line Connections Mounting hardware is suitable for use with lugs incorporating two hole NEMA drilling Secure incoming cables to line terminals of the isolation switch with suitable lugs and in M12 hardware Torque the hardware according to the specifications shown on page 1 4 Cable size should not exceed 1 500 or 2 250 MCM per phase Attach Incoming Line Cables Here Figure 2 22 Isolation Switch Incoming Line Connections Rear View Load Connections Secure load cables to load terminals of contactor using suitable lugs and 3 8 in M10 hardware Torque the hardware according to the specifications shown on page 1 4 Itis the user s responsibility to determine a suitable means of completing the power connection from the contactor to the motor ie current transforme
34. ical 110 120 VAC Control Frame 600 Amp 2 3 5 0 kV Electrically Held Blot On Fuse IntelliVAC 110 120 VAC Control Frame 600 Amp 2 3 5 0 kV Mechanical Latch Blot On Fuse Electro Mechanical 110 120 VAC Control Frame 600 Amp 2 3 5 0 kV Mechanical Latch Blot On Fuse IntelliVAC 110 120 VAC Control Frame 600 Amp 5 1 6 9 kV Electrically Held Bolt On Fuse Electro Mechanical 110 120 VAC Control Frame 600 Amp 5 1 6 9 kV Electrically Held Bolt On Fuse IntelliVAC 110 120 VAC Control Frame IntelliVAC Base 1503 WHE4V 1503F M4KCD 1503C M4D 1503F M4KCU 1503VC BMC5 1503 WHM4V 1503F M4KBD 1503C M4D 1503 WHM4V 1503F E6GBD 1503FC E8D 1503F E6GBU 1503VC BMC5 1503 WHE8V 1503F M6GBD 1503C M8D 1503F M6GBU 1503VC BMC5 1503 WHM8D 1503F E6KBD 1503C E8D 1503F E6KBU 1503VC BMC5 Wire Harness IntelliVAC 600 Amp 5 1 6 9 kV Mechanical Latch Bolt On Fuse Electro Mechanical 110 120 VAC Control Frame 600 Amp 5 1 6 9 kV Mechanical Latch Bolt On Fuse IntelliVAC 110 120 VAC Control Frame IntelliVAC Base Wire Harness IntelliVAC 1503 WHE8V 1503F M6KBD 1503C M8D 1503F M6KBU 1503VC BMC5 1503 WHM8D RA Internal Part Number 80178 373 65 80178 370 52 80158 142 57 80158 951 70 80158 143 52 80178 373 73 80178 370 52 80158 142 59 80158 951 68 80158 143 52 80158 142 59 80158 333 57 80158 143 54 80178 374 52 80178 370 52 80178 142 58 80158 333
35. in to 0 060 in 1 1 mm to 1 5 mm To reduce the gap distance follow steps 5 7 To increase the gap distance follow steps 8 10 e Isolation Switch Operating Lever Stop Bracket Contactor Interlock Rod Contactor Operating Lever Isolation Switch Handle at Halfway Position SC Nylock Nut Figure 3 6 Isolation Switch Handle Adjustments 1503 INO50E EN P June 2013 3 6 Adjustments Contactor Interlock Rod To Reduce the Gap Distance Adjustment cont 5 Loosen the two screws in the stop bracket and move the stop bracket up against the interlock lever 6 With the feeler gauge positioned in the gap move the interlock lever and the stop bracket closer to the isolation switch operating lever to reduce the gap space Tighten the stop bracket screws 7 Tighten the nylock nut until it is snug against the contactor operating lever Do not overtighten the nylock nut as it will move the interlock lever and reduce the gap Proceed to Step 11 To Increase the Gap Distance 8 Loosen the two screws in the stop bracket and move the stop bracket away from the interlock lever 9 Loosen the nylock nut until the gap reaches the desired size 10 Move the stop bracket until it just touches the interlock lever and tighten the screws 11 Apply Loctite 290 or equivalent adhesive to the stop bracket screws and torque the screws to 6 ft
36. issioning pro cedures in Chapter 4 of this manual should be the only additional checks required for the unit Imperial Tool Requirements Some components of this product incorporate Imperial hardware Rockwell Automation recommends the use of the appropriate tools to successfully complete the assembly and maintenance procedures for these components If you cannot obtain such tools contact your area Rockwell Automation sales office for assistance The following Imperial size tools are recommended for installation and maintenance of the OEM starter frame and components e Standard drive ratchet with extension e Standard drive torque wrench e Standard drive sockets 9 32 3 8 7 16 1 2 9 16 3 4 in e wrenches 7 16 1 2 9 16 11 16 3 4 7 8 in e Drill and drill bits 0 172 0 219 0 281 in Slot head screwdrivers e Feeler gauge set 0 125 in to 0 300 in e Locking pliers e High potential tester Metric Tool Requirements Metric equivalent sizes are provided in parentheses where applicable It is important to note that all sizes given are not exact substitutes for the corresponding Imperial sizes To ensure proper installa tion use the recommended metric hardware and dimensions for pilot holes and clearance holes The following metric size tools are recommended for installing the OEM frame and components with metric hardware e Standard drive ratchet with extension e Standard drive torque wrench e
37. it should indicate 50 megohms or greater if the unit 1s isolated from the line and the motor If the unit 1s connected to a motor the Megger should indicate 5 megohms or greater Refer to the following publications for the procedure to test vacuum bottle integrity of the Bulletin 1502 contactor e 400A Publication 1502 UM050 EN P Series D e 400A Publication 1502 UM052 EN P Series E 600A Publication 1502 UMOSI EN P Series E These user manuals contain detailed information on installation adjustment and maintenance for this product 1503 INO50E EN P June 2013 4 2 Commissioning Preliminary Checklist 1503 INOSOE EN P June 2013 Contactor Operation AUAU To avoid shock hazards lock out incoming power before 1 2 3 appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death working on the equipment Verify with a hot stick or Connect the appropriate external power supply 120 or 230 VAC to the test receptacle in the control panel Turn the selector switch to the TEST position see Figure 3 2 Electrically operate the contactor several times Inspect the armature plate to verify that it fully contacts the cores 400A or yolk plate 800A Turn the selector switch back to the OFF position and disconnect the test power supply Electrical Connections 1 2 3 4 Verify correct power cable phase sequ
38. kV Electrically Held Bolt On Fuse Electro 1503F E4GBE 80158 951 63 Mechanical 220 230VAC Control Frame 1 1503C E4E 80158 143 53 400 Amp 2 3 5 0 kV Electrically Held Blot On Fuse IntelliVAC 110 120 1503F E4GBU 80178 373 55 VAC Control Frame 1503VC BMC5 80178 370 52 1503 WHE4V 80158 142 57 400 Amp 2 3 5 0 kV Mechanical Latch Clip On Fuse Electro 1503F E4GBU 1 1 1503F M4GCD 1503F M4GCD 80158 951 69 Mechanical 110 120VAC Control Frame 1 1503C M4D 80158 143 52 400 Amp 2 3 5 0 kV Mechanical Latch Clip On Fuse IntelliVAC lt 110 1503F M4GCU 80178 373 63 120 VAC Control Frame 1503F M4GCU 1 1503VC BMC5 80178 370 52 1 1503 WHM4V 80158 142 52 1503F M4GBD 400 Amp 2 3 5 0 kV Mechanical Latch Blot On Fuse Electro 1503F M4GBD 80158 951 67 Mechanical 110 120 VAC Control Frame 1 1503C M4D 80158 143 52 1503F M4GBU 400 Amp 2 3 5 0 kV Mechanical Latch Blot On Fuse IntelliVAC lt 110 1503F M4GBU 80178 373 61 120VAC Control Frame 1503VC BMC5 80178 370 52 1503 WHM4V 80158 142 52 400 Amp 5 1 6 9 kV Electrically Held Clip On Fuse Electro 1 1 1503F E4KCD 1503F E4KCD 80158 951 62 Mechanical 110 120 VAC Control Frame Electrically Held 120V Control Panel 1503C E4D 80158 143 51 1503F E4KCE 400 Amp 5 1 6 9 kV Electrically Held Clip On Fuse Electro 1503F E4KCE 80158 951 66 Mechanical 220 230 VAC Control Frame 1 1503C E4E
39. lation switch blades must also be within 0 060 in 1 5 mm of the ground bar when the handle is in the OFF open position see Figure 3 9 When the isolation switch handle is in the ON or closed position the blades must fully engage the line stabs see Figure 3 5 To adjust the distance from the blades to the bar disconnect the threaded connecting rod at the isolation switch operating lever see Figure 2 16 Turn the threaded connecting rod to lengthen or shorten it This will adjust the position of the isolation switch blades in the ON and OFF position 1503 INO50E EN P June 2013 3 8 Adjustments Isolation Switch Ground Adjustment cont Maximum Gap 0 06 in 1 5 mm between Ground Bar and Isolation Switch Blade in open position Isolation Switch Blade Incoming Line Stab ajo Auxiliary Contact oa n il Ka _ Isolation Switch Cut away view from right side Figure 3 9 Isolation Switch Ground Adjustment Isolation Switch Auxiliary The auxiliary contacts are mounted on the left side of the isolation switch Contacts slightly below the cams on the isolation switch shaft Normally open contacts Isolation Switch a Contacts ISa are on the outside of the isolation switch housing and normally closed contacts
40. lation switch under load conditions Improper adjustment may result in damage to the equipment and or severe burns injury or death to personnel 4 Ifthe auxiliaries do not change state before the isolation switch opens adjust the threaded connecting rod as described in the Isolation Switch Adjustment procedure see page 3 7 1503 IN050e EN P June 2013 3 12 Adjustments 1503 INO50E EN P June 2013 Chapter 4 Hi Pot and Megger Test Vacuum Bottle Integrity Test Commissioning Insulation integrity should be checked before energizing electrical equipment Use a high voltage AC insulation tester or a Megger for this test If a Megger is used a 5000 volt type is recommended MUOU Exercise caution when performing high voltage tests on the equipment Failure to do so may result in electric A shock causing severe burns injury or death ERUITHIIB Lo avoid shock hazards lock out incoming power before working on the equipment Verify with a hot stick or N appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death Insulation can be tested from phase to phase and from phase to ground The recommended level for AC Hi Pot testing is 2 X V volts where is the rated line to line voltage of the power system The leakage current must be less than 20 mA Record the result for future comparison testing If a Megger is used
41. ng with the shaft Tighten the bolt that holds the cam to the shaft Move the isolation switch handle to the OFF position and recheck the gap using the pin Operate the handle several times then recheck the 0 25 in 6 35 mm clearance between the end of the cam groove and the follower pin for both cams Verify that auxiliary contact ISb is closed when isolation switch is open Verify that ISb contact is open when isolation switch 1s closed Adjustments 3 11 Adjusting the Change of State Point This procedure sets the secondary electrical interlock When properly adjusted the electrical interlock 1s designed to open the control circuit power connections before the isolation switch opens when the handle 15 moved to the OFF position 1 Once the auxiliaries have been adjusted move the isolation switch handle to the ON position 2 Connect a conductivity measuring device across the closed auxiliary contacts 3 Slowly move the isolation switch handle towards the OFF position and observe the point at which the movable isolation switch blades separate from the incoming line stabs The auxiliary contacts must change state from the closed to open position before the isolation switch blades lose contact with the incoming line stabs This prevents the isolation switch from being opened while the unit is energized and under load condi tions AUAU The auxiliary contacts must be properly adjusted to avoid opening the iso
42. ntactor to Trailer Fuse Block cable to the trailer fuse block see Figure 2 20 Torque the bolts to the Clip on Fuses specifications shown on page 1 4 cont The trailer fuse block is equipped with 5 16 18 nuts The supplied hardware or equivalent must be used to avoid damaging the thread in the nuts Contactor Attachment Point Line Side Trailer Fuse Block Attachment Point Figure 2 20 Linking Trailer Fuse Block to Contactor Clip on Power Fuses 2 Attach the bus links or suitable cable to the line side of the contactor upper terminals using 3 8 in M10 hardware see Figure 2 20 Torque the bolts according to the requirments shown on page 1 4 MUC Maintain at least 3 in 76 mm clearance between power phase connections Insufficient distance could cause equipment damaging power faults in the unit 1503 IN050D EN P June 2012 Electrical Connection from Contactor to Trailer Fuse Block Bolt on Fuses Component Installation 2 23 Required Hardware three 3 horizontal bus links or suitable cable and lugs bus links are recommended to be 1 4 in 6mm thick and 1 in 25mm wide six 6 3 8 16 in x 1 in MIO x 1 5 x 25mm bolts six 6 3 8 16 in M10 x 1 5 nuts six 6 3 8 in M10 lock washers twelve 12 3 8 in M10 flat washers 1 Attach the bus links or cables to the line terminals on the trailer fuse block see Figure 2 21 Torque the bolts to the specifications s
43. nterlock Assembly cont All mounting hardware for the Door Interlock Assembly is supplied Metric equivalents are provided should the user wish to substitute metric hardware IMPORTANT 1 See Figure 2 15 for the mounting dimensions for the door interlock assembly 2 Drill two 2 0 172 in 4 6 mm pilot holes on the right side of the door for the Z clip 3 Drill two 2 0 219 in 5 5 mm pilot holes on the front of the door for the cover catch mounting bracket 54 0 84 Customer supplied 21 el structure P L Customer supplied door 59 Customer TOP VIEW supplied door 0 05 2 X 0 219 5 31 _ om di 17 Pilot Holes 9 JE See Fig 23 Lr For rib necked Lu iR carriage bolts E IN 3 50 N 22 pi 3 13 86 2 X 0 172 4 09 e Pilot holes Lo 49 Customer supplied structure FRONT VIEW RIGHT SIDE VIEW 1503 INO50E EN P June 2013 All dimensions in inches millimeters Figure 2 15 Mounting Locations for Door Interlock Assembly 4 Attach the Z clip using 10 4 8 x 1 6 Type B self tapping screws but do not completely tighten them Attach the cover catch mounting bracket using 10 32 x 0 500 5 x 0 8 rib necked carriage screws lockwashers and hex nuts Attach the cover catch to the cover catch mounting bracket using the s
44. or Punching Dimensions Grounding Wire Figure 2 4 Mounting Rear of Isolation Switch Handle Module 1503 INO50E EN P June 2013 Component Installation 2 5 5 Install two 2 4 20 6 3 x 1 8 Type self tapping screws in the tabs at the end of the handle module to attach it to the rear of the cabinet Torque the screws according to the specifications shown on page 1 4 The rear mounting tabs may deform slightly when secured to the mounting surface The deformation 1s normal and helps to reduce any gap between the handle module and the mounting surface 6 Connect the green grounding wire to a suitable grounding surface Mounting Isolation Switch Refer to the component layout shown in Figure 2 1 or 2 2 to determine the and Trailer Fuse Block location of the isolation switch Refer to Figure 2 6 to determine the location of the mounting holes for the isolation switch Grounding Bar Shaft Clearance Holes Inter phase Barriers Auxiliary Contacts Dome Plugs Figure 2 5 Typical Isolation Switch Required Hardware Eight 8 4 20 x 1 0 in 6 3 x 1 8 x 25mm Type B self tapping screws Four 4 dome plugs supplied 1 Drill four 4 0 219 in 5 5 mm pilot holes in the mounting surface at Location A as shown in Figure 2 6 for the isolation switch 2 Attach the isolation switch using four 4 4 20 6 3 x 1 8 Type B self tapping screws
45. r interlock in conjunction with the isolation switch handle mechanism are designed to offer the following safety features e prevent the isolation switch from being opened while the contactor 15 closed and energized e prevent the contactor from closing if the isolation switch is in an intermediate position ie at halfway point during adjustment e disengage the contactor if the isolation switch moved to the closed position during a contactor test procedure Isolation Switch Operating Lever Interlock Lever Clevis Contactor Interlock Rod Contactor Operating Lever Figure 2 17 Contactor Interlock Rod Connection Component Installation 2 19 Required Hardware all hardware supplied IMPORTANT Metric hardware 1s not supplied however metric equivalents are given should the user wish to substitute metric hardware Two 2 1 4 in M6 lock washers Two 2 1 4 in M6 flat washers Two 2 1 4 20 in M6 x 1 0 hex head cap screws One 1 5 16 18 in M8 x 1 25 nylock nut Two 2 5 16 in M8 hex nuts One 1 5 16 in M8 lock washer One 1 contactor operating lever One 1 5 16 18 x 20 5 in M8 x 1 25 x 521 mm contactor interlock rod 1 Attach the contactor operating lever to the flat section of the contactor shaft using two 1 4 20 in M6 x 1 0 hex head cap screws with two 1 4 in M6 lock washers and two 1 4 in M6 flat wa
46. rs power fuses etc Load Terminals Figure 2 23 Load Terminals 400 A Contactor Rear View 1503 INO50E EN P June 2013 Component Installation 2 25 Connecting Contactor to A control power transformer CPT is not supplied as Control Power Transformer part of the OEM starter kit This procedure only de scribes how to connect wires to the contactor that will supply power to the control circuit It is the user s responsibility to determine the correct CPT primary fuse sizes power wire lugs and current transformer for the control circuit 1 Remove the 10 32 hex head screw securing the fuse clips at the front of the contactor see Figure 2 24 Remove Screws to mount lugs Front of Contactor Figure 2 24 Attaching Control Power Wires to Contactor Top View 2 Attach lugs with a 90 degree bend AB part G6666 suitable for 12 10 AWG wire and suitable power wire utilizing a 10 flat washer and lock washer 3 Torque the screws to 32 in lbs 4 Use wire clips provided on the contactor to fasten the control power transformer cables in position This is required to avoid cables coming into contact with live parts and to meet dielectric test requirements 1503 INO50E EN P June 2013 2 26 Component Installation 1503 INO50E EN P June 2013 Chapter 3 Door Interlock Circumvention Adjustments for 400 Amp Equipment ebm To
47. shers see Figure 2 18 The contactor operating lever is threaded for the supplied 1 4 20 hex head cap screws In order to substitute metric hardware it is necessary to drill appropriate clearance holes in the contactor operating lever and use M6 x 1 0 hex head cap screws and nuts to secure the lever to the contactor shaft 2 From the top of the contactor interlock rod turn a 5 16 18 in M8 x 1 25 hex nut at least 2 in 50 mm down the rod Place one 5 16 in M8 lock washer over the nut 3 Insert a 5 16 18 M8 x 1 25 hex nut into the clevis of the door interlock lever see Figure 2 17 4 Turn the contactor interlock rod into the nut until approximately 1 2 in 13 mm of the lever extends above the nut 1503 INO50E EN P June 2013 2 20 Component Installation Connecting Contactor to Isolation Switch Handle cont Contactor Interlock Rod Nylon Contactor Bushing Contactor Operating Lever 1503 INO50E EN P June 2013 AL gt 2 14 20 M6 x 1 0 Hex Head Cap Screws 2 1 4 M6 Lock Washers 2 1 4 in M6 Flat Washers Contactor Shaft Right Side View Figure 2 18 Connecting Contactor to Isolation Switch Handle 5 Tighten the bottom nut up to the clevis 6 Insert the lower end of the rod into the nylon contactor bushing 7 Turn a 5 16 18 in M8 x 1 25 nylock nut onto the lower end of the rod and tighten it up to the fl
48. tallation 2 9 0 50 13 MAX TRAVEL er 2 72 TYP 69 300 gt 15 88 9 93 12 0 403 252 305 5 0 25 6 TYP DOUBLE CLIP ON FUSE 0 50 13 MAX TRAVEL 272 69 15 88 9 93 12 0 403 252 305 All dimensions in inches millimeters Figure 2 8 Clip on Fuse Dimensions 1503 INO50E EN P June 2013 2 10 Component Installation Contactor Control Panel SAI LEE S CAN NS SS 22 IntelliVAC N NS STO sa NI AES 1503 INO50E EN P June 2013 Refer to the following publications for the Bulletin 1502 Medium Voltage Contactor e 400A Publication 1502 UM050_EN P Series D e 400A Publication 1502 UMO052 EN P Series E 600A Publication 1502 UMOSI EN P Series E These user manuals contain detailed information on installation adjustment and maintenance for this product Contactor Control Wire Plug Figure 2 9 120V and 230V Control Wire Plug Location and Configurations Note Refer to the appropriate vacuum contactor User Manual for detailed wire plug pin configurations Required Hardware Four 4 1 4 20 x 0 5 in 6 3 x 1 8 x 13mm Type B self tapping screws Mount the control panel in a suitable location Be aware that the control plug wiring harness is 10 ft 3 meters in length Ensure that the wiring h
49. ting mechanism is designed to provide the following safety features Prevent the opening of any medium voltage door interlocked with the mechanism while the handle is in the ON position and the unit is energized Prevent moving the handle to the ON position and energize the unit while the medium voltage door is open Disengage the contactor from the RUN mode when the handle is moved from the ON to OFF position Connecting Rod Disconnect Lever Connection Point Clevis and Cotter Pin Isolation Switch Operating Lever Right Side View Figure 2 16 Handle Mechanism Connection 1503 INO50E EN P June 2013 2 18 Component Installation Connecting Isolation Switch to Isolation Switch Handle cont Connecting Contactor to Isolation Switch Handle 1503 INO50E EN P June 2013 Perform the handle mechanism connection with the handle in the OFF position The isolation switch should be in the open position with the isola tion switch blades resting against the ground bar Refer to Figure 2 16 1 Lengthen or shorten the threaded connecting rod until it lines up with the top hole on the isolation switch operating lever 2 Insert a clevis pin through the holes and secure it with a cotter pin Complete all installation procedures before beginning any adjustment procedures described in Chapter 3 When properly connected the contacto
50. tion of the OEM components relative to each other The mounting location of the trailer fuse block varies depending on the type of power fuses used by the unit Figure 2 1 shows the component configuration for units using clip on power fuses and Figure 2 2 shows the compo nent configuration for units using bolt on power fuses 1855 471 g IE 1 19 l di 30 8 96 i n 22 2 di I 1 m EN 25 A AT 39 78 10 80 9 53 1010 274 242 37 11 1 i P5 943 1 20 3
51. upplied 10 32 x 0 219 pan head machine screw IMPORTANT 5 6 The pilot holes in the cover catch are threaded To avoid damaging the thread use the hardware provided to attach the cover catch to the mounting bracket Connecting Isolation Switch to Isolation Switch Handle 7 8 9 Component Installation 2 17 Move the handle to the OFF position Swing the door closed and inspect the position of the Z clip with respect to the handle pin Set the Z clip so that it is just above the handle pin Do not set the Z clip more than 0 125 in 3 mm above the pin Tighten the screws Close the door and move the isolation switch handle to the ON posi tion If the handle will not move to the ON position the cover catch is set too high and is not contacting the defeater lever Open the door and set the cover catch lower Verify correct functioning 10 Swing the door shut and move the isolation switch handle to the ON position Verify that the door interlock assembly is functioning properly The mechanical interlock is the primary safety mecha nism preventing access to the medium voltage power cell The mechanism also prevents opening or closing the isolation switch under load ie it is a non load break switch A secondary electrical interlock 15 intended to disengage the contactor in the event of a mechanical in terlock failure See page 3 8 for additional information When properly connected the isolation switch opera
52. w ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt 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 Table of Contents Chapter 1 OEM Starter Frame Installation ESA ARR EEEE A E 1 1 SCORE RO 1 1 Standards and COURS eee sde ne ee 1 1 Imperial Tool RSGQUISMENCS a 1 2 Metric Tool Requiterenits ee utis 1 2 Starter Frame 2 darla 1 3 Control PANNE see ee 1 3 Torque 1 4 ns TT 1 4 Lane and Load Connections 1 1 4 COMIN 1 4 2 Component Installation DOM CE Edi a nd dra 2 1 Mounting Isolation Switch Handle Module 2 3 Mounting Isolation Switch and Trailer Fuse Block 2 5 RON SES 2 7 2 10 CCOmttol PAINS 2 10 2 10 Typical Electrical Diagrams for 400A FVNR Controller with Electro Mechanical Control and Electrically Held CORALLO noia 2 11 Electro Mechanical Control and Mechanical Latch Contactor 2 12 Intell1 VAC Control and Electrically Held Contactor 2 13 IntelliVAC Control and Mechanical Latch Contactor 2 14 Door Interlock Assembl
53. y inten 2 15 Connecting Isolation Switch to Isolation Switch Handle 2 17 Connecting Contactor to Isolation Switch Handle 2 18 Electrical Connection From Contactor to Trailer Fuse Block Clip on FUSES R I 2 21 Electrical Connection From Contactor to Trailer Fuse Block COCO FSS cc en ne nc che 2 22 Incoming Line CONAI ioni 2 24 Load COHBCCHO DS eate t nina 2 24 Connecting Contactor to Control Power Transformer 2 25 1503 INO50E EN P June 2013 ii Table of Contents Bulletin 1503 OEM Starter Frame and Components Installation Manual Chapter 3 Chapter 4 Chapter 5 Chapter 6 Appendix A 1503 INO50E EN P June 2013 Adjustments for 400A Equipment Door Interlock tC ny noiosi siii 3 1 Power Lock out mn 3 2 Contactor Interlock Rod Adq stment riore tt ra eds 3 5 Isolation Switch Ground Adjustment 3 7 Isolation Switch Auxiliary Contacts 2 3 8 Adjusting the Normally Open Isa Contacts 3 9 Adjusting the Normally Closed 156 Contacts 3 10 Adjusting the Change of State Point 3 11 Commissioning Hipotand NIC SET RA 4 1 Vacuum Bottle Integrity EST 4 1 Preliminary CUS 4 2 Contactor ine 4 2 Electrical Connec LORS En 0 4 2 a 4 2 Maintenance
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