Installation Instructions
Original Instructions
OEM Starter Frame and Components (400 A, 2400…7200V)
Bulletin Number 1503
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.
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.
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). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
About this Publication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 1
OEM Starter Frame Installation Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Imperial Tool Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Metric Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standards and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
400 A Starter Frame Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IntelliVAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Line and Load Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component Installation for 400
A Equipment
Adjustments for 400 A
Equipment
Chapter 2
Component Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting the Isolation-switch Handle Module. . . . . . . . . . . . . . . . . . 12
Mount Isolation Switch and Trailer Fuse Block. . . . . . . . . . . . . . . . . . 15
Power Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Door Interlock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting the Isolation Switch to the Isolation Switch Handle . . 27
Connecting the Contactor to the Isolation Switch Handle. . . . . . . . 28
Electrical Connection from Contactor to Trailer Fuse Block
(Clip-on Fuses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electrical Connection from Contactor to Trailer Fuse Block
(Bolt-on Fuses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Incoming Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Load Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connecting the Contactor to the Control Power Transformer. . . . 34
Chapter 3
Door Interlock Circumvention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Contactor Interlock Rod Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 38
To Reduce the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
To Increase the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Isolation Switch Ground Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 1
Table of Contents
Isolation Switch Auxiliary Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Adjusting the Normally Open (ISa) Contacts. . . . . . . . . . . . . . . . 43
Adjusting the Normally Closed (ISb) Contacts . . . . . . . . . . . . . . 43
Adjusting the “Change of State Point” . . . . . . . . . . . . . . . . . . . . . . 44
Chapter 4
Commissioning Hi-pot and Insulation Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Vacuum Bottle Integrity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Preliminary Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Contactor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Chapter 5
Maintenance Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Isolation Switch Mechanism Inspection and Lubrication . . . . . . . . . 49
Auxiliary Contacts Inspection and Replacement . . . . . . . . . . . . . . . . . 51
Chapter 6
Spare Parts Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Appendix A
OEM Kit Chart OEM Kit Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Preface
Summary of Changes
About this Publication
This manual contains new and updated information as indicated in the following
table.
Top ic Pag e
Replaced Ferraz-Shawmut fuses with Mersen fuses and modified Continuous
Ampere rating.
Added electrical drawing typical schematic. 21
Added electrical drawing typical schematic. 22
Change referenced publication series numbers. 49
Added kit assembly 80178-707-53. 53
Part number changes. 55
17
This manual is broken into different sections depending on the use of the parts
ordered. Review the appropriate sections according to your requirements.
Chapter 1
provides you an overview of the physical aspects of the 400A
controller frame, including product dimensions and tool requirements.
Chapter 2
outlines the characteristics of the individual components that are
included in the frame. These details are provided for those users who wish to
utilize the individual components within their own custom configurations.
Critical mounting and operating dimensions are included with typical electrical
control diagrams.
Chapter 3
outlines the requirements surrounding the adjustments testing and
verification of the operating components.
Chapter 4
provides guidance surrounding the commission of the finished
product. Always follow local code, procedures and safety standards when
working with electricity.
Chapter 5
provides the details around the requirement maintenance of the
individual and complete assembly components. Failure to follow these
requirements could lead to abnormal equipment failure.
Chapter 6
provides a complete listing of the suggested spares part required. The
quantities recommended will vary depending on your installed base.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 3
Preface
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
IntelliVAC Contactor Control Module,
publication 1503-UM053
Medium Voltage 400A Contactor - Series E and F, publication
1502-UM052
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, rok.auto/certifications
Provides information on installing, setup,
commissioning, monitoring, and troubleshooting the
IntelliVAC control module.
Provides information on installing, maintaining, and
troubleshooting the 400 A medium voltage contactor.
Provides general guidelines for installing a Rockwell
Automation industrial system.
. Provides declarations of conformity, certificates, and
other certification details.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page
.
4 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
OEM Starter Frame Installation
ATT EN TI ON : Read this document before performing any installation Read
this document before performing any installation procedures or
adjustments. Observe all applicable safety procedures when working on the
equipment. Complete all installation procedures before connecting the
incoming line cable. Failure to do so can result in damage to the equipment
or injury to personnel.
Chapter 1
Installation
The OEM starter frame consists of a fusible non-load-break isolation switch, an
isolation switch handle, a vacuum contactor, control circuitry, and a mediumvoltage door. These components are not a complete motor controller. You must
add appropriate control circuitry for the application, power, current transformer,
control power transformer, overload protection, and a suitable enclosure.
Imperial Tool Requirements
IMPORTANT Some components of this product incorporate imperial hardware. Rockwell
Automation® recommends the use of the appropriate tools to complete the
assembly and maintenance procedures for these components. If you cannot
obtain such tools, contact your Rockwell Automation sales office for
assistance.
These imperial size tools are recommended for installation and maintenance of
the OEM starter frame and components:
• Standard drive ratchet with an extension
• Standard drive torque wrench
• Standard drive sockets (in.): 9/32, 3/8, 7/16, 1/2, 9/16, 3/4
• Open-end wrenches (in.): 7/16, 1/2, 9/16, 11/16, 3/4, 7/8
• Drill and drill bits (in.): 0.172, 0.219, 0.281
• Slot-head screwdrivers
• Feeler gauge set (0.125…0.300 in.)
•Locking pliers
• High-potential tester
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 5
Chapter 1 OEM Starter Frame Installation
Metric Tool Requirements
IMPORTANT Metric equivalent sizes are provided in parentheses where applicable. The
sizes that are given are not exact substitutes for the corresponding Imperial
sizes. For proper installation, use the recommended metric hardware and
dimensions for pilot holes and clearance holes.
These metric size tools are recommended for installing the OEM frame and
components with metric hardware.
• Standard drive ratchet extension
• Standard drive torque wrench
• Standard drive sockets (mm): 8, 10, 13, 15, 18
• Open-end wrenches (mm): 8, 10, 13, 15, 18
• Drill and drill bits (mm): 4.6, 5.5, 6.8
• Slot-head screwdrivers
•Locking pliers
•Feeler gauge set (3…8 mm)
• High potential tester
Receiving
See General Handling Procedures for Medium Voltage Controllers, publication
MV-QS050, included with your shipment. It contains information regarding the
receiving, unpacking, initial inspection, the handling, storage, the opening of the
medium-voltage doors, and site preparation.
TIP See Appendix A for a listing of the items that are included in your OEM
Frame Kit.
Standards and Codes
You must be familiar with the following safety and design standards and codes,
and any additional local codes that a medium-voltage starter must comply with.
•CEC (Canadian Electrical Code).
• CSA 22.2 No. 14 (Canadian Standards Association) – Industrial Control
Equipment.
• NEC (National Electrical Code).
• NEMA ICS Standards (National Electrical Manufacturers’ Association).
• OSHA (Occupational Safety and Health Administration).
• UL 50 (Underwriters Laboratories) – Enclosures for Electrical
Equipment.
• UL 347 (Underwriters Laboratories) – High-voltage Industrial Control
Equipment.
• UL 508 (Underwriters Laboratories) – Industrial Control Equipment.
6 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
OEM Starter Frame Installation Chapter 1
.
[
4 x
Ø13 [.515]
606
[23.85]
1279
[50.36]
546
[21.50]
691
[27.22]
538
[21.17]
25
[0.97]
556
[21.89]
97
[3.83]
Front View
Bottom View
Mounting Holes
• IEC 60204-1 – Safety of Machinery – Electrical Equipment of Machines,
Part 1: General Requirements.
• IEC 62271-200 – AC Metal Enclosed Switchgear and Control Gear for
Rated Voltages above 1 kV and up to 52 kV.
• IEC 60470 – High-Voltage Alternating Current Contactors.
• IEC 60529 – Degrees of Protection Provided by Enclosures (IP Code).
• IEC 62271-1 – Common Clauses for High-Voltage Switchgear and
Control Gear Standards.
The OEM starter frame assembly was fully tested and inspected at the factory.
Unless damage from shipping is suspected, the commissioning procedures in
Chapter 4
of this manual are the only additional checks that are required for the
unit.
400 A Starter Frame Dimensions
Figure 1 - Starter Frame Dimensions
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 7
Chapter 1 OEM Starter Frame Installation
Control Panel
1. Mount the control panel so that the control plug wiring-harness, 10 ft
(3 m) in length, can connect to the contactor control plug.
2. Connect the control panel harness to the receptacle on the left side of the
contactor.
3. Match the number codes for a proper connection. See
page 20 for more information and for the wiring diagrams.
Control Panel on
IntelliVAC
See publication 1503-UM052 for instruction on how to mount the IntelliVAC™
control module.
IMPORTANT A suitable wire harness is required (1503-WHxxx) to connect IntelliVAC to the
vacuum contactor.
Torque Requirements
Use the specified torque values for all hardware to perform maintenance or attach
components.
1/4 in. (M6) hardware 8 N•m (6 lb•ft)
5/16 in. (M8) hardware 15 N•m (12 lb•ft)
3/8 in. (M10) hardware 27 N•m (20 lb•ft)
1/2 in. (M12) hardware 65 N•m (48 lb•ft)
Fuses
See the motor nameplate for the information necessary to determine correct
power fuse size. See
1. Install clip-on or bolt-on power fuses into the isolation switch fuse-clips.
2. If control power is supplied by control power transformer within the unit,
fuses can be installed in the medium-voltage control circuit transformer
primary fuse-clips.
The fuse clips are at the top of the contactor. See page 34
8 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Power Fuses on page 17 for recommended power fuses.
ATT EN TI ON : Only qualified personnel can select the fuse type and rating.
Failure to select the correct fuses can result in injury to personnel and/or
damage to equipment.
for details.
OEM Starter Frame Installation Chapter 1
Line and Load Connections
See Incoming Line Connections on page 32 and Load Connections on page 33
of Chapter 2.
Commissioning
See Commissioning on page 45.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 9
Chapter 1 OEM Starter Frame Installation
Notes:
10 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Chapter 2
471
[18.55]
228
[8.96]
1010
[39.78]
274
[10.80]
30
[1.20]
478
[18.82]
113 [4.44]
267 [10.50]
124 [4.88]
301 [11.87]
531
[20.89]
943
[37.11]
242
[9.53]
30
[1.19]
186
[7.33]
580 [22.85]
306 [12.05]
117 [4.60]
25
[1.00]
Front Mounting Surfac e
Rear Mounting Surface
All Dimensions in mm (inch)
Lower Mounting Surface
Component Installation for 400 A Equipment
Component Layout
See Figure 2 to determine the location of the OEM components relative to each
other.
IMPORTANT The mounting location of the trailer fuse block varies depending on the type
of power fuses that are used by the unit. Figure 2
configuration for units that use clip-on power fuses. Figure 3
shows the component
shows the
component configuration for units that use bolt-on power fuses.
Figure 2 - OEM Component Layout (Clip-on Power Fuses) (Frame and Other Parts Not Shown)
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 11
Chapter 2 Component Installation for 400 A Equipment
471 [18.55]
25
[1.00]
30
[1.19]
580 [22.85]
306 [12.05]
196
[7.33]
117
[4.60]
242
[9.53]
943
[37.11]
301 [11.87]
531
[20.89]
124 [4.88]
113 [4.44]
329
[12.95]
30
[1.20]
423
[16.67]
1010
[39.78]
267 [10.50]
228
[8.96]
All Dimensions in mm (inch)
Front Mount ing Surface
Rear Mounting Surface
Lower Mo unting Su rface
Figure 3 - OEM Component Layout (Bolt-on Power Fuses) (Frame and Other Parts Not Shown)
Mounting the Isolationswitch Handle Module
IMPORTANT The handle is shipped in the OFF, or open, position. All instructions assume
that the handle remains in the OFF position during installation and
adjustment procedures, unless otherwise stated.
Required Hardware:
• Six 1/4-20 x 0.5 in. (6.3 x 1.8 x 13 mm Type B) self-tapping screws
• One 5/16 in. (M8 x 1.25) ground wire screw
Determine the mounting location and the position of the mounting holes for the
isolation-switch handle module. See the component layout that is shown in
Figure 2
or Figure 3. See Figure 4 for a detailed view of the mounting holes.
12 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
25
Front Mounting Surface Cutout Dimensions
Front View
The handle is cut away to show lower mounting holes.
Clearance Holes
Mounting Holes
[1.00]
Component Installation for 400 A Equipment Chapter 2
1. Prepare a cut-out in the cabinet for the handle, use the dimensions that are
shown in Figure 4
.
2. Drill four 0.281 in. (6.8 mm) clearance holes in the locations that are
indicated for the retaining screws.
Figure 4 - Handle Cut-out Dimensions
14
[0.53]
17
[0.65]
4 X Ø 5.31 [0.219]
210
[8.26]
44
[1.74]
242
[9.53]
27
[1.06]
12
[0.48]
242
[9.53]
4 X Ø 6.8 [0.281]
25
[1.00]
3. To attach the front of the handle, from the inside of the cabinet insert the
handle through the cut-out. Align the pilot holes with the predrilled holes
in the handle assembly. Use four 1/4-20 (6.3 x 1.8 Type B) self-tapping
screws and attach the front of the handle.
4. Torque the screws according to the specifications shown on page 8
.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 13
5. Mark the location of the rear mounting tabs of the handle module. Drill
two 0.219 in. (5.5 mm) pilot holes (see Figure 5
).
Chapter 2 Component Installation for 400 A Equipment
0.125
[3]
22.67
[576]
4.61
[117]
13.00
[330]
19.93
[506]
26.23
[666]
4 X Ø 0.219
2 X Ø 0.312
7.02
[178]
Rear Mounting Surface
Front Mounting Surface
Mounting Holes
Clearance
Left Si de View
Front View
Clearance Holes
All Dimensions inch (mm)
Grounding Wire
See Figure 4 for Punching Dimensions
Figure 5 - Mounting the Rear of Isolation-switch Handle Module
6. Install two 1/4-20 (6.3 x 1.8 Type B) self-tapping screws in the tabs at the
end of the handle module that attach it to the rear of the cabinet. Torque
the screws according to the specifications shown on page 8
.
IMPORTANT The rear mounting tabs can deform slightly when secured to the mounting
surface. The deformation is normal and helps to reduce any gap between the
handle module and the mounting surface.
7. Connect the green grounding wire to a suitable grounding surface.
14 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
Grounding Bar
Shaft
Auxiliary Contacts
Inter-phase Barriers
Dome Plugs
Clearance Holes
Mount Isolation Switch and Trailer Fuse Block
See the component layout that is shown in Figure 2 or Figure 3 to determine the
location of the isolation switch. See Figure 7
to determine the location of the
mounting holes for the isolation switch.
Figure 6 - Typical Isolation Switch
Required Hardware:
• Eight 1/4-20 x 1.0 in. (6.3 x 1.8 x 25 mm Type B) self-tapping screws
•Four dome plugs (supplied)
To mount the Isolation Switch:
1. Drill four 0.219 in. (5.5 mm) pilot holes in the mounting surface at
Location A as shown in Figure 7
for the isolation switch.
2. Attach the isolation switch with four 1/4-20 (6.3 x 1.8 Type B) selftapping screws. Torque the screws according to the specifications shown
on page 8
.
To mount the Fuse Block:
3. See the component layout that is shown in Figure 2
or Figure 3 to
determine the location of the trailer fuse block. See Figure 7
the location of the mounting holes for the trailer fuse block.
4. Drill four 0.219 in. (5.5 mm) pilot holes at Location B as shown in
Figure 7
for the trailer fuse block.
5. Attach the trailer fuse block with four 1/4-20 (4.8 x 1.6 Type B) selftapping screws. Torque the screws according to the specifications shown
on page 8
.
to determine
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 15
Chapter 2 Component Installation for 400 A Equipment
FRONT VIEW (CLIP ON FUSES)
(Cut away to show upper mounting tabs)
FRONT VIEW (BOLT ON FUSES)
(Cut away to show upper mounting tabs)
Ø 7.9 (0.310) Isolation Switch clearance hole location
Ø 7.9 (0.310) Trail Fuse Block clearance hole location
All dimensions in mm (in.)
Terminals
Terminals
471
[18.55]
19
[0.76]
A
432
[17.02]
6. Install a dome plug over each screw.
ATT EN TI ON : Reinstall any inter-phase barriers that were removed while
connecting the trailer fuse block. Failure to do so can produce an electrical
fault between the fuses and damage the equipment.
Figure 7 - Orientation of Isolation Switch
94
[3.69]
A
19
[0.76]
471
[18.55]
432
[17.02]
94
[3.69]
30
[1.20]
B
228
[8.96]
274
[10.80]
228
30
[1.20]
[8.96]
423
[16.67]
A
B
125
[4.94]
127
[5.00]
470
[18.50]
127
[5.00]
A
121
[4.78]
A
133
[5.25]
127
[5.00]
127
[5.00]
470
[18.50]
102
[4.00]
23
[0.90]
B
121
[4.78]
102
[4.00]
A
A
B
16 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
Power Fuses
Mersen medium voltage power fuses are recommended for the Bulletin 1503.
These motor fuses are tested to meet the co-ordination requirements for the
Bulletin 1502 vacuum contactor. The fuses can be purchased from Rockwell
Automation, Mersen, or from a local distributor. These part numbers are
available (see Figure 8
Fuse Rating
2R, 70 A 25173-555-01
3R, 100 A 25173-555-02
4R, 130 A 25173-555-03
6R, 170 A 25173-555-04
9R, 200 A 25173-555-05
12R, 230 A 25173-555-06
18R, 390 A 25173-555-07
24R, 450 A 25173-555-08
(1) Continuous ampere rating at 40 °C (104 °F) as recommended by fuse manufacturer. The fuse rating must be derated if the internal
(2) Single-Barrel Fuse.
(3) Double-Barrel Fuse. OEM must provide means to prevent fuse rotation under fault conditions.
(1)
temperature exceeds 40 °C (104 °F). Rockwell Automation recommends that the continuous load current does not exceed 80% of the
fuse rating.
and Figure 9 for dimensions of fuses).
Clip-on Fuses
5 kV
Allen-Bradley®
Part Number
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
5 kV
Mersen
Part Number
(2)
A480R-2R
(2)
A480R-3R
(2)
A480R-4R
(2)
A480R-6R
(2)
A480R-9R
A480R-12R
A480R-18R
A480R-24R
(2)
(3)
(3)
7.2 kV
Allen-Bradley
Part Number
80025-650-01
80025-650-02
80025-650-03
80025-650-05
80025-650-06
80025-650-07
80025-691-01
80025-691-02
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
7.2 kV
Mersen
Part N umber
A072F1DORO-2R
A072F1DORO-3R
A072F1DORO-4R
A072F1DORO-6R
A072F1DORO-9R
A072F1DORO-12R
A072F1DORO-18R
A072F1DORO-24R
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
Fuse Rating
2R, 70 A 80025-296-01
3R, 100 A 80025-296-02
4R, 130 A 80025-296-03
6R, 170 A 80025-296-04
9R, 200 A 80025-296-05
12R, 230 A 80025-296-06
18R, 390 A 80025-296-07
24R, 450 A 80025-296-08
(1) Continuous ampere inch rating at an internal temperature of 40 °C (104 °F) as recommended by fuse manufacturer. The fuse rating
(2) Single-barrel fuse.
(3) Double-barrel fuse.
(1)
Bolt-on Fuses
5 kV
Allen-Bradley
Part Number
must be derated if the internal temperature exceeds an internal temperature of 40 °C (104 °F). Rockwell Automation recommends
that the continuous load current does not exceed 80% of the fuse rating.
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
5 kV
Mersen
Part Number
A051B1DARO-2R
A051B1DARO-3R
A051B1DARO-4R
A051B1DARO-6R
A051B1DARO-9R
A051B1DARO-12R
A051B1DARO-18R
A051B1DARO-24R
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
7.2 kV
Allen-Bradley
Part Number
80026-690-01
80025-690-02
80025-690-03
80025-690-05
80025-690-06
80025-690-07
80025-651-01
80025-651-02
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
7.2 kV
Mersen
Part Number
A072B1DARO-2R
A072B1DARO-3R
A072B1DARO-4R
A072B1DARO-6R
A072B1DARO-9R
A072B1DARO-12R
A072B2DARO-18R
A072B2DARO-24R
(2)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 17
Chapter 2 Component Installation for 400 A Equipment
SINGLE BOLT ON FUSE
DOUBLE BOLT ON FUSE
SIDE VIEW
SIDE VIEW
FRONT VIEW
FRONT VIEW
TOP V IEW
TOP V IEW
Four Sl ots
Four Sl ots
Figure 8 - Bolt-on Fuse Dimensions
13 [0.50] MAX.
13 [0.50] MAX.
8
[0.31]
54
[2.12]
489
[19.25]
454
[17.88]
39
[1.53]
89
[3.50]
11 X 23
[0.440 X 0.910]
39
[1.53]
54 [2.12]
[3.00]
76
[3.00]
76
489
[19.25]
18 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
454
[17.88]
102 [4.00]
11 X 23
[0.440 X 0.910]
194
[7.62]
6 [0.25] TYP.
403
[15.88]
305
[12.00]
305
[12.00]
13 [0.50]
13 [0.50]
252
[9.93]
69
[2.72]
TYP.
403
[15.88]
252
[9.93]
69
[2.72]
TYP.
76
[3.00]
76
[3.00]
92
[3.62]
SINGLE CLIP ON FUSE
DOUBLE BOLT ON FUSE
MAX. TRAVEL
MAX. TRAVEL
TOP V IEW
TOP V IEW
Component Installation for 400 A Equipment Chapter 2
Figure 9 - Clip-on Fuse Dimensions
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 19
Chapter 2 Component Installation for 400 A Equipment
Contac tor Control Wire Plug
Contactor
See these publications for Bulletin 1502 Medium Voltage Contactor for
information on installation, adjustment, and maintenance for this product:
• 400 A – Publication 1502-UM050 (Series D)
• 400 A – Publication 1502-UM052 (Series E and F)
Figure 10 - 120V and 230V Control Wire Plug Location and Configurations
TIP See the appropriate vacuum contactor User Manual for detailed wire plug
pin configurations.
Control Panel
Required hardware: Four 1/4-20 x 0.5 in. (6.3 x 1.8 x 13 mm Type B) self-tapping
screws
Mount the control panel in a suitable location.
IMPORTANT The control plug wiring harness is 3 m (10 ft.) in length. Make sure that the
wiring harness route 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 align with
codes on the contactor to make sure of a proper connection (see Figure 10
Connect the control-panel terminal blocks to a 120V or 230V grounded power
source (whichever is applicable to the control panel) and to other remote devices.
See Figure 11
or Figure 13 for electrical drawings.
).
20 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
Main Contactor (M)
CC - Closing Coil
HC- Holding Coil
Remove Jumper when connecting remote equipment.
Remote Equipment.
Low voltage door-mounted device.
‘IEEE’ number for protective device.
Metal oxide Varistor.
Economizing
Contactor (CR2)
Main Contactor Pilot
Relay (CR1)
Extra Auxiliary Contacts
Test Supply
Normal
Tes t
OFF
Power Bus
GRD Bus
Isolation Switch (IS)
Door Interlock
Current Lim iting
Power Fuses
Current Limiting
Primary Fuses
Overloa
Sto
Start
Start
Run
Off
Rectifier
Rec/Mov
Sto
Figure 11 - Typical Schematic Diagram for 400 A Full-voltage Non-reversing (FVNR) Controller
with Electromechanical Control and Electrically Held Contactor, 120V AC (Normal Drop-out Time)
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 21
Chapter 2 Component Installation for 400 A Equipment
Extra Auxiliary Contacts
Normal
Tes t
OFF
Power Bus
GRD Bus
Isolation Switch (IS)
Door Interlock
Current Limiting
Power Fuses
Current Limiting
Primary Fuses
Overloa
Manual Trip
Main Contactor
Main Contactor
Latch Relay
Tes t S upp ly
Main Contactor
Unlatch Relay
Rectifier
Rec/Mov
Closing Coil.
TC - Trip Coil.
Low voltage door-mounted device.
IEEE’ number for protective device.
Metal oxide varistor.
Note: See dimension drawing for component sizing not
shown on this drawing.
Figure 12 - Typical Schematic Diagram for 400 A Full-voltage Non-reversing (FVNR) Controller
with Electromechanical Control and Mechanical Latch Contactor
22 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
CCCC
Intelivac Notes
Output Relay contacts shown without control power applied. These
factory-installed configuration/power-up states are in effect:
Contactor Status - FAIL-SAFE
Module Status - FAIL-SAFE
IntelliVAC to be programmed/configured by the customer before start up.
Remove Jumper when connecting remote equipment.
Remote Equipment
Remote Equipment
Low Voltage door-mounted device
IEEE number for protective device
Customer wiring
See dimension drawing for component sizing not shown in this drawing.
Main Contactor
Tes t S upp ly Poi nt
Contactor Status
Isolation Switch
GRD Bus
Power Bu s
Door Interlock
Current Limiting
Power fuses
Current Lim iting
Primary fuses
Extra Auxiliary Contacts
OL
Overload
Run
Off
Figure 13 - Typical Schematic Diagram for 400 A Full-voltage Non-reversing (FVNR) Controller
with IntelliVAC Control and Electrically Held Contactor
Figure 14 - Typical Schematic Diagram for 400 A Full-voltage Non-reversing (FVNR) Controller
with IntelliVAC Control and Mechanical Latch Contactor
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 23
Chapter 2 Component Installation for 400 A Equipment
IntelliVAC Notes
Output Relay Contacts that are shown without
control power applied. The
following factory-installed configuration/power-up states are in effect.
Contactor Status - Fail Safe
Module Status - Fail Safe
IntelliVAC to be programmed/configured by customer before start-up.
Closing Coil
TC - Tri p Coil
Low Voltage Door Mounted Device
IEEE Number for Protective Device
Metal Oxide Varistor
Customer Wiring
See Dimension Drawing for component sizing not shown on this drawing
Extra Auxiliary Contacts
Power Bus
Isolation Switch
Current Limiting Power Switches
GRD Bus
Door Interlock
Current limiting
Primar y fuses
Main Contactor
Tes t S upp ly Poi nt
Normal
Tes t
Off
Off
Run
Manual
Tri p
OL
Overload
24 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
Rear Door Sur face
Cover Catch
mounting-bracket
Door Flange
Z-cl ip
Cover Catch
Door Interlock Assembly
The door interlock assembly (see Figure 14), when used with the isolation switch,
provides these interlocking features:
• When the isolation switch handle is in the ON position, a pin on the
handle overlaps the Z-clip to help prevent the door from being opened.
• When the door is closed and the isolation switch handle is in the ON
position, a cover catch inside the door is held in place by the interlock
defeater lever. This feature provides another means for holding the door
closed while the unit is energized.
ATT EN TI ON : The door interlock assembly must be installed for the isolation
switch handle to restrict access to the medium-voltage cell while the unit is
energized. The isolation switch handle alone does 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 that can
cause severe burns, injury, or death.
Figure 15 - Door Interlock Assembly
IMPORTANT All mounting hardware for the door interlock assembly is supplied. Metric
equivalents are provided if you wish to substitute metric hardware.
1. Mount the door interlock assembly. See Figure 16 for the dimensions.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 25
Chapter 2 Component Installation for 400 A Equipment
1.95
[49]
1.55
[39]
3.13
[80]
0.35
[9]
0.88
[22]
0.84
[21]
MAX.
2.11
[54]
MIN.
2 X Ø 0.219 [5.31]
3.38
[86]
3.50
[89]
0.65
[17]
2 X Ø 0.172 [4.09]
Pilot Holes
(For rib-necked
Carriage bolts)
Customer
Supplied Door
Customer Supplied Structure
Customer
Supplied Door
Customer Supplied Structure
FRONT VIEW
RIGHT SIDE VIEW
Pilot Holes
TOP V IEW
See Figure 4
2. Drill two 0.172 in. (4.6 mm) pilot holes on the right side of the door for
the Z-clip.
3. Drill two 0.219 in. (5.5 mm) pilot holes on the front of the door for the
cover catch mounting-bracket.
Figure 16 - Mounting Locations for Door Interlock Assembly
4. Attach the Z-clip with #10 (4.8 x 1.6 Type B) self-tapping screws, but do
not tighten them.
5. Attach the cover catch mounting-bracket with #10-32 x 0.500 (M5 x 0.8)
rib-necked carriage screws, lock washers, and hex nuts.
6. Attach the cover catch to the cover catch mounting-bracket with the
supplied #10-32 x 0.219 pan-head machine screw.
IMPORTANT The pilot holes in the cover catch are threaded. To avoid damaging the
thread, use the hardware that is provided to attach the cover catch to the
mounting-bracket.
7. Move the handle to the OFF position. Swing the door closed and inspect
the position of the Z-clip in relation to the handle pin.
8. 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.
9. Close the door and move the isolation switch handle to the ON position.
If the handle does 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.
10. Verify that the door interlock assembly is functioning properly.
26 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Connecting the Isolation
Disconnect Lever
Connecting Rod
Connection Point
(Clevis and Cotte r Pin)
Isolation Switch
Operating Lever
Right Side View
Switch to the Isolation
Switch Handle
Component Installation for 400 A Equipment Chapter 2
IMPORTANT The mechanical interlock is the primary safety mechanism that helps prevent
access to the medium-voltage power cell. The mechanism also helps prevent
the isolation switch from being opened or closed while under load (meaning,
it is a non-load-break switch).
A secondary electrical interlock is intended to disengage the contactor if a
mechanical interlock failure occurs. See
Isolation Switch Auxiliary Contacts
on page 42 for additional information.
When properly connected, the isolation switch operating mechanism is designed
to provide these safety features:
• Prevent the opening of any medium-voltage door that is 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 providing energy to
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.
Figure 17 - Handle Mechanism Connection
Perform the handle mechanism connection with the handle in the OFF position.
The isolation switch must be in the open position with isolation switch blades
rested against the ground bar (see Figure 17
).
1. Lengthen or shorten the threaded connecting rod until it aligns 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.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 27
Chapter 2 Component Installation for 400 A Equipment
Interlock Lever
Clevis
Contactor Interlo ck Rod
Contac tor Operat ing Lever
Isolation Switch Operating lever
IMPORTANT Complete all installation procedures before beginning any adjustment
procedures described in Chapter 3
.
Connecting the Contactor to the Isolation Switch Handle
When properly connected, the contactor interlock, with the isolation switch
handle mechanism safety features:
• Prevent the isolation switch from being opened while the contactor is
closed and energized.
• Prevent the contactor from closing if the isolation switch is in an
intermediate position (that is at halfway point during adjustment).
• Disengage the contactor if the isolation switch moved to the closed
position during a contactor test procedure.
Figure 18 - Contactor Interlock Rod Connection
28 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
2-1/4-20 (M6 x 1.0) Hex Head Cap Screws)
2-1/4 in. (M6) Lock Washers
2-1/4 in. (M6) Flat Washers
Contactor Shaft
Contac tor
Interlock Rod
Nylon Contactor
Bushing
Contactor
Operatin g Lever
Required hardware: All imperial hardware is supplied.
IMPORTANT Metric hardware is not supplied. Metric equivalents are given if you wish to
substitute metric hardware
• Two 1/4 in. (M6) lock washers
• Two 1/4 in. (M6) flat washers
• Two 1/4-20 in. (M6 x 1.0) hex-head cap screws
• One 5/16-18 in. (M8 x 1.25) nylock nut
• Two 5/16 in. (M8) hex nuts
• One 5/16 in. (M8) lock washer
•One contactor operating lever
• One 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 with 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 washers (see Figure 19
).
IMPORTANT The contactor operating lever is threaded for the supplied 1/4-20 hex-head
cap screws. To substitute metric hardware, drill 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 18
).
4. Turn the contactor interlock rod into the nut until approximately
1/2 in. (13 mm) of the lever extends above the nut.
Figure 19 - Connecting the Contactor to Isolation Switch Handle
5. Tighten the bottom nut up to the clevis.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 29
Chapter 2 Component Installation for 400 A Equipment
Anti-turn Brackets
6. Insert the lower end of the rod into the nylon contactor bushing. Turn a 5/
16–18 in. (M8 x 1.25) nyloc nut onto the lower end of the rod and tighten
it up to the flat of the contactor operating lever.
IMPORTANT Complete all installation procedures before beginning any adjustment
procedures described in Chapter 3
.
Electrical Connection from Contactor to Trailer Fuse Block (Clip-on Fuses)
Required hardware:
• Three horizontal bus links or suitable cable and lugs. Bus links are
recommended to be 1/4 in. (6 mm) thick and 1 in. (25 mm) wide.
• Three 3/8-16 in. x 1 in. (M10 x 1.5 x 25 mm) bolts
• Three 3/8-16 in. (M10 x 1.5) nuts
• Three 3/8 in. (M10) lock washers
• Six 3/8 in. (M10) flat washers
Supplied hardware:
• Three 5/16-18 x 1 in. bolts
• Three 5/16 in. lock washers
• Three 5/16 in. flat washers
ATT EN TI ON : Double-barrel, clip on power fuses requires an anti-turn bracket
to maintain sufficient clearance between the power phases. Do not use such
fuses without this safety feature. Failure to do so can result in injury to
personnel or damage to the equipment. The brackets are supplied if specified
at the time of order, otherwise contact Rockwell Automation to obtain the
brackets. Order Allen-Bradley part number 80253-262-51. Installation
instructions are included with the kit.
Figure 20 - Trailer Fuse Block with Anti-turn Brackets
1. Use the supplied 5/16 in. hardware to mount the bus link or suitable cable
to the trailer fuse block (see Figure 21
30 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
specifications shown on page 8
.
). Torque the bolts to the
Component Installation for 400 A Equipment Chapter 2
Tra ile r Fu se
Tra ile r Fuse Blo ck
Attachment Point
Contac tor
Attachment Point
(Line Side)
IMPORTANT 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.
Figure 21 - Linking the Trailer Fuse Block to Contactor (Clip-on Power Fuses)
Electrical Connection from Contactor to Trailer Fuse Block (Bolt-on Fuses)
2. Attach the bus links, or suitable cable, to the line side of the contactor
(upper terminals) with 3/8 in. (M10) hardware (see Figure 21
bolts according to the requirements shown on page 8
.
ATT EN TI ON : Maintain at least 3 in. (76 mm) clearance between power
phase connections. Insufficient distance could cause power faults in the unit
and damage equipment.
Required hardware:
• Three horizontal bus links or suitable cable and lugs. Bus links are
recommended to be 1/4 in. (6 mm) thick and 1 in. (25 mm) wide.
• Six 3/8-16 in. x 1 in. (M10 x 1.5 x 25 mm) bolts
• Six 3/8-16 in. (M10 x 1.5) nuts
• Six 3/8 in. (M10) lock washers
• Twelve 3/8 in. (M10) flat washers
1. Attach the bus links or cables to the line terminals on the trailer fuse block
(see Figure 22
2. Torque the bolts to the specifications shown on page 8
).
.
). Torque the
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 31
Chapter 2 Component Installation for 400 A Equipment
Tra ile r Fu se B loc k
Attachment Point
Contactor
Attachment Point
(Line Side)
Tra ile r Bl ock F use
3. Attach the bus links, or suitable cable, to the line side of the contactor
(upper terminals) with 3/8 in. (M10) hardware (see Figure 22
).
4. Torque the bolts according to the specifications shown on page 8
ATT EN TI ON : Maintain at least 3 in. (76 mm) clearance between power
phase connections. Insufficient distance could cause power faults in the unit
and damage equipment.
Figure 22 - Linking the Trailer Fuse Block to Contactor (Bolt-on Power Fuses)
.
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 1/2 in. (M12) hardware. Torque the hardware according to the
specifications shown on page 8
.
IMPORTANT Cable size cannot exceed 1-500 or 2-250 MCM per phase.
32 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Component Installation for 400 A Equipment Chapter 2
Attach Incoming Line
Cables Here
Load Terminals
Figure 23 - Isolation Switch Incoming Line Connections (Rear View)
Load Connections
Secure load cables to load terminals of contactor with suitable lugs and 3/8 in.
(M10) hardware. Torque the hardware according to the specifications shown on
page 8
.
IMPORTANT It is your responsibility to determine a suitable means to complete the power
connection from the contactor to the motor, which is current transformers,
power fuses, and such.
Figure 24 - Load Terminals - 400 A Contactor (Rear View)
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 33
Chapter 2 Component Installation for 400 A Equipment
Remove screws to Mount Lugs
(Front of Contactor)
Connecting the Contactor to the Control Power Transformer
IMPORTANT A control power transformer (CPT) is not supplied as part of the OEM starter
kit. This procedure only describes how to connect wires to the contactor that
supplies power to the control circuit. You are responsible to determine the
correct CPT, primary fuse sizes, power wire, lugs, and current transformer for
the control circuit.
A. Remove the #10-32 hex head screw securing the fuse clips at the front of
the contactor (see Figure 25
Figure 25 - Attaching the Control Power Wires to Contactor (Top View)
).
2. Attach lugs with a 90° bend (Allen-Bradley part # G6666 – suitable for
#12-10 AWG wire) and suitable power wire, use a #10 flat washer and lock
washer.
3. Torque the screws to 3.6 N•m (32 lb•in).
4. Fasten the control power transformer cables in position on the contactor
with the provided wire clips. This procedure avoids cables from coming
into contact with live parts and to meet dielectric test requirements.
34 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Door Interlock Circumvention
Chapter 3
Adjustments for 400 A Equipment
IMPORTANT For proper functionality of the isolation switch assembly, perform the
following adjustments in the order they are presented.
ATT EN TI ON : The door interlock mechanism is designed to stop 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 lockout incoming power (See
page 36) before proceeding with any adjustments that require the handle to
be moved to the ON (closed) position. Failure to do so can result in electric
shock with severe burns, injury, or death.
Power Lockout Procedure on
Some of the following sections require the isolation switch handle to be in the
ON position while the medium-voltage door is open. The interlocking
safeguards in the mechanism are designed to stop the handle from moving to the
ON position while the cabinet door is open.
• To circumvent this safety feature, use a screwdriver, or other tool, to
depress the interlock defeater lever in the switch.
• Hold the lever down while moving the handle to the ON (closed)
position.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 35
Chapter 3 Adjustments for 400 A Equipment
Interlock Defeater Lever
Figure 26 - Interlock Defeater Lever
Power Lockout Procedure
AT TE NT IO N: Always perform the power lockout procedure before servicing
the equipment. Use personal protective equipment (PPE) as per local codes or
regulations. Failure to do so can result in severe burns, injury, or death.
ATT EN TI ON : The following procedure requires the isolation switch handle to
be in the ON position. To avoid shock hazards, disconnect and lockout
incoming power before proceeding with the equipment servicing. Failure to
lockout incoming power results in a live power cell once the isolation switch
handle is in the ON position. The live power cell can 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 before servicing the equipment.
1. Disconnect and lockout all feeder power supplies to the starter.
2. Move the isolation switch handle to the OFF position.
3. If the unit is equipped with power factor correction-capacitors, the stored
energy must be dissipated before entering the power cell. Wait at least 5
minutes before entering the power cell or dissipate the power with this
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 (120V or 230V) into the auxiliary
Power receptacle on the control panel (see Figure 27
).
d. Move the control switch to the TEST position.
36 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Adjustments for 400 A Equipment Chapter 3
Tes t S wit ch
Auxiliar y Power
Receptacle
Grounding Bar
Isolation Switch Shutters must
be closed.
(Verify for each phase).
Isolation switch blades must be
in full contact with the
grounding Pins of grounding
bar.
Verify for each phase.
Figure 27 - Control Panel (120V Shown)
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
NORMAL position. Disconnect the external power supply.
g. Complete the Power Lockout Procedure
on page 36.
h. Open the medium-voltage door.
4. Visually inspect that the isolation switch blades are in full contact with the
grounding pins on the grounding bar. The isolation switch shutters must
be closed
(see Figure 28
Figure 28 - Isolation Switch in Open Position
5. Check that the line and load sides of the contactor are voltage free with a
hot stick or appropriate voltage measurement device. See Figure 29
a. Check for line-side voltage at the top vacuum-bottle terminals.
).
.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 37
Chapter 3 Adjustments for 400 A Equipment
Check line-side power here.
Check load-side power here.
Isolation Switch Blades must be in full
contact with Incoming Line Stabs
Check incoming
line voltage here
b. Check for load-side voltage at the bottom vacuum-bottle terminals.
Figure 29 - Contactor Voltage Checkpoints
6. Move the isolation switch handle to the ON position. Use the Door
Interlock Circumvention on page 35.
7. Check that the isolation switch blades are voltage free with a hot stick or
appropriate voltage measurement device. See Figure 30
.
Contactor Interlock Rod Adjustment
Figure 30 - Isolation Switch Voltage Check Points
8. When all power circuits are verified to be voltage free, move the isolation
switch handle back to the OFF position. The unit is now safe to service.
ATT EN TI ON : To avoid shock hazards, lockout incoming power (see page 36)
before working on the equipment. Verify with a hot stick or appropriate
voltage measurement device that all circuits are voltage free. Failure to do so
can result in severe burns, injury, or death.
1. Complete the Power lockout Procedure (see page 36).
2. Open the medium-voltage door. Use the Door Interlock Circumvention
on page 35 to move the isolation switch handle halfway between the OFF
38 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
and ON position (see Figure 31
the adjustment procedure is completed.
). Keep the handle in this position until
Adjustments for 400 A Equipment Chapter 3
Isolation Switch Operating Lever
Isolation Switch Handle at Halfway Position
Contactor Operating Lever
Nyloc Nut
Gap
(0.03. … 0.78 in.)
(1.00…2.0 mm)
Contactor Interlock Rod
Interlock Lever
Stop Bracket
3. 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…0.060 in. (1.1…1.5 mm).
4. To reduce the gap distance, follow steps 5…7.
To increase the gap distance, follow steps 8…10.
Figure 31 - Isolation Switch Handle Adjustments
To Reduce the Gap Distance
5. Loosen the two screws in the stop bracket and move up the stop bracket
against the interlock lever.
6. With the feeler gauge that is 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 nyloc nut until it is snug against the contactor operating lever.
Do not overtighten the nyloc nut as it moves the interlock lever and reduce
the gap. Proceed to Step 11.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 39
Chapter 3 Adjustments for 400 A Equipment
Magnetic Core
Armature Plate
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 nyloc 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 8 N•m (6 lb•ft).
12. Move the isolation switch handle to the ON position.
13. Manually close the contactor by attaching locking pliers to the contactor
operating lever and push down until the armature plate contacts the
magnetic cores (see Figure 32
14. Verify that the interlock lever overlaps the isolation-switch operating lever
by at least 0.125 in. (3 mm), see Figure 33
Figure 32 - Closing the Contactor Manually (Some Parts Not Shown)
).
.
40 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Adjustments for 400 A Equipment Chapter 3
0.125 in. (3 mm)
Interlock Lever
Isolation Switch Operating Lever
Figure 33 - Isolation Switch Operating Lever Overlap
15. 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.
Isolation Switch Ground Adjustment
ATT EN TI ON : To avoid shock hazards, lockout incoming power before
working on the equipment. Verify with a hot stick or appropriate voltage
measurement device that all circuits are voltage free. Failure to do so can
result in severe burns, injury, or death.
1. Move the isolation switch handle to the OFF position.
2. Inspect the grounding of the isolation switch blades. When the isolation
switch handle is in the OFF (open) position, the isolation switch blades
must come in full contact with the ground pins of the ground bar. The
blades must be within 0.060 in. (1.5 mm) of the ground bar when the
handle is in the OFF (open) position (see Figure 34
). When the isolation
switch handle is in the ON (closed) position, the blades must come in full
contact with the line stabs (see Figure 30
).
3. To adjust the distance from the blades to the bar, disconnect the threaded
connecting rod at the isolation-switch operating lever (see Figure 17 on
page 27).
4. Turn the threaded connecting rod to lengthen or shorten it. This
adjustment changes the position of the isolation switch blades in the ON
and OFF position.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 41
Chapter 3 Adjustments for 400 A Equipment
Maximum Gap 1.5 mm (0.060 in.) between Ground
Bar and Isolation Switch Blade in open position.
Ground Bar
Auxiliary Contact
Isolation-switch Blade
Incoming-line Stab
ISb Auxiliary Contacts (N.C.)
ISa Auxiliary Contacts (N.O.)
Figure 34 - Isolation Switch Ground Adjustment
Isolation Switch Auxiliary Contacts
The auxiliary contacts are mounted on the left side of the isolation switch, 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. Normally closed contacts (Isolation Switch b
Contacts - ISb) are on the inside of the housing.
Figure 35 - Location of ISa and ISb Auxiliary Contacts
ISa and ISb contacts are the same (700 CPM). The cam controls the normally
open or normally closed status of the contacts.
See Figure 11 on page 21
to Figure 14 on page 23 for the wiring diagrams.
IMPORTANT Complete Isolation Switch Ground Adjustment on page 41 before adjusting
the auxiliary contacts for proper synchronization of the assembly.
42 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Adjustments for 400 A Equipment Chapter 3
CATALOG NO.
700-CPM
SER. A
20
AMP
Gap 0.25 in. (6.35 mm)
Cam
Cam Follower
Auxiliary Contact
Adjusting the Normally Open (ISa) Contacts
ATT EN TI ON : To avoid shock hazards, lockout incoming power before working
on the equipment. Verify with a hot stick appropriate voltage measurement
device that all circuits are voltage free. Failure to do so can result in severe
burns, injury, or death.
1. Move the isolation switch handle to the ON (closed) position.
2. Loosen the bolt that holds the outside cam to the shaft. Do not loosen the
bolt entirely. The cam must 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.
Figure 36 - Adjusting Auxiliary Contacts (Isa Auxiliary Contact Shown)
4. Adjust the cam on the shaft. The gap from the cam follower to the end of
the cam groove must be the width of the pin, 0.25 in. (6.35 mm).
5. Move the isolation switch handle to the OFF (open) position and check
that nothing stops the cam from rotating with the shaft.
6. Tighten the bolt that holds the cam to the shaft. Move the isolation switch
handle to the ON position. Use the pin to recheck the gap.
7. Verity that auxiliary contact ISa is open when the isolation switch is open.
Verify that ISa contact is closed when isolation switch is closed.
Adjusting the Normally Closed (ISb) Contacts
1. Move the isolation switch handle to the OFF (open) position.
2. Loosen the bolt that holds the inside cam to the shaft. Do not loosen the
bolt entirely. The cam must not be able to rotate freely on the shaft.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 43
Chapter 3 Adjustments for 400 A Equipment
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.
4. Adjust the cam on the shaft. The gap from the cam follower to the end of
the cam groove must be the width of the pin, 0.25 in. (6.35 mm).
5. Move the isolation switch handle to the ON (closed) position and check
that nothing stops the cam from rotating with the shaft.
6. Tighten the bolt that holds the cam to the shaft. Move the isolation switch
handle to the OFF position. Use the pin to recheck the gap.
7. 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.
8. Verify that auxiliary contact ISb is closed when isolation switch is open.
Verify that ISb contact is open when isolation switch is closed.
Adjusting the “Change of State Point”
IMPORTANT This procedure sets the secondary electrical interlock. When properly
adjusted, the electrical interlock is designed to open the control-circuit
power connections before the isolation switch opens when the handle is
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 measurement 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 change of state stops the
isolation switch from being opened while the unit is energized and under
load conditions.
ATT EN TI ON : The auxiliary contacts must be properly adjusted to avoid
opening the isolation switch under load conditions. Improper adjustment can
result in damage to the equipment and/or severe burns, injury, or death to
personnel.
4. If the auxiliaries do not change state before the isolation switch opens,
adjust the threaded connecting rod as described in Isolation Switch
Ground Adjustment on page 41.
44 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Commissioning
Chapter 4
Hi-pot and Insulation Resistance Test
Insulation integrity must be checked before energizing electrical equipment. Use
a high-voltage AC insulation tester or an insulation resistance tester for this test.
If an insulation resistance tester is used, a 5000V type is recommended.
ATT EN TI ON : Exercise caution when performing high-voltage tests on the
equipment. Failure to do so can result in electric shock, severe burns, injury,
or death.
ATT EN TI ON : To avoid shock hazards, lockout incoming power before working
on the equipment. Verify with a hot stick or appropriate voltage
measurement device that all circuits are voltage free. Failure to do so can
result in severe burns, injury, or death.
Insulation can be tested from phase to phase and from phase to ground. The
recommended level for an AC Hi-Pot test is (2 X V
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 an insulation resistance tester is used, it must indicate 50 megohms or greater if
the unit is isolated from the line and the motor. If the unit is connected to a
motor, the insulation resistance tester must indicate 5 megohms or greater.
) volts, where VLL is the
LL
Vacuum Bottle Integrity Test
See these publications for the procedure to test vacuum bottle integrity of the
Bulletin 1502 contactor:
• 400 A – Publication 1502-UM050 (Series D)
• 400 A – Publication 1502-UM052 (Series E and F)
These user manuals contain detailed information on installation, adjustment, and
maintenance for this product.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 45
Chapter 4 Commissioning
Preliminary Checklist
Contactor Operation
ATT EN TI ON : To avoid shock hazards, lockout incoming power before working
on the equipment. Verify with a hot stick or appropriate voltage
measurement device that all circuits are voltage free. Failure to do so can
result in severe burns, injury, or death.
1. Connect the appropriate external power supply (120V or 230V) to the test
receptacle in the control panel.
2. Turn the selector switch to the TEST position (see Figure 27 on page 37
3. Electrically operate the contactor several times.
4. Inspect the armature plate. Verify that it fully contacts the cores (400 A) or
yolk plate (800 A).
5. Turn the selector switch back to the OFF position.
6. Disconnect the test power supply.
Electrical Connections
).
1. Verify the correct power-cable phase sequence and that the connections are
tight. See
2. Verify the power fuse ratings and condition.
3. Verify the control fuse ratings and condition.
4. Check that components were not damaged during power cable
installation, and that electrical spacings are sufficient.
Torque Requirements on page 8.
46 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Commissioning Chapter 4
Final Checks
1. Remove all tools from the cabinet. All tools and hardware that is used
during installation and the commission process must be accounted for
before the unit is energized.
2. Remove all temporary jumpers and ground devices that are used during the
installation procedures.
3. Make sure that all barriers or covers removed during installation have been
securely reattached.
4. Close and secure all doors. Verify that all interlocks that are stopping access
to medium-voltage power cells are functioning correctly.
ATT EN TI ON : Use personal protective equipment (PPE) per local codes or
regulations. Failure to do so can result in severe burns, injury, or death.
5. Restore incoming power from main power supply.
6. Move the isolation switch handle to the ON position.
7. The controller is now ready to supply power to the load.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 47
Chapter 4 Commissioning
Notes:
48 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Chapter 5
Maintenance
IMPORTANT Establish a maintenance and inspection schedule for the equipment.
Annually service (or every 20,000 operations – whichever comes first) is the
minimum that is recommended; however, extreme operating conditions can
warrant additional attention.
Contactor
Isolation Switch Mechanism Inspection and Lubrication
See these publications for detailed maintenance information on the Bulletin
1502 contactor:
• 400 A – Publication 1502-UM050 (Series D)
• 400 A – Publication 1502-UM052 (Series E and F)
These user manuals contain detailed information on installation, adjustment, and
maintenance for this product.
ATT EN TI ON : To avoid shock hazards, lockout incoming power (see page 35)
before working on the equipment. Verify with a hot stick or appropriate
voltage measurement device that all circuits are voltage free. Failure to do so
can result in severe burns, injury, or death.
1. Complete the Power Lockout Procedure on page 36.
2. Open the medium-voltage door.
3. Inspect the condition of the clevis pin and cotter pins that are shown in
Figure 37
. Replace any worn parts.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 49
Chapter 5 Maintenance
Clevis Pins and Cotter Pins
Interlock Lever
Threaded Connector Rod
Lubrication Points
Contactor Interlock Rod
Isolation Switch Operating Lever
Figure 37 - Isolation Switch Handle Mechanism Lubrication Points
4. If the isolation switch operating lever or the interlock lever is replaced,
apply Dow Corning 55 O-ring lubricant (or equivalent) to the pivot
points before installing the new components (see Figure 37
).
5. Inspect the mounting hardware on the isolation switch operating lever and
contactor interlock rod (see Figure 37
). Tighten any loose hardware.
6. Inspect the isolation switch blades and the incoming line stabs (see
Figure 34 on page 42
). The mating surfaces must be clean and lubricated.
7. Remove any dirt and dried grease.
IMPORTANT Do not scrape or file the parts as it can remove the plating and
expose the underlying copper to corrosion.
8. Lubricate the isolation switch blades and the pivot points of the isolation
switch blades with NyoGel 759G - part number T9327-105 (see
Figure 38
).
IMPORTANT Lubricate the isolation switch blades a minimum of once per year to
avoid excessive wear to the components and to help prevent the
isolation switch blades from overheating.
50 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Figure 38 - Isolation Switch Lubrication Points
Lubricate Isolation Switch Blades
Lubricate Pivot Points
Maintenance Chapter 5
Auxiliary Contacts Inspection and Replacement
ATT EN TI ON : To avoid shock hazard, lockout incoming power before working
on the equipment. Verify with a hot stick or appropriate voltage
measurement device that all circuits are voltage free. Failure to do so can
result in severe burns, injury, or death.
1. Move the isolation switch handle to the OFF position and open the
controller door.
2. 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 when used within the operating specifications.
3. Remove the contact by turning both of the D-head fasteners until the flat
sections are aligned with the edge of the contact (see Figure 39
4. Remove the contact from the housing.
5. Disconnect the wires from the auxiliary contact.
6. To replace the auxiliary contact, reverse the procedure.
7. Verify that the contact is correctly positioned into the contact carrier (see
Figure 39
).
).
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 51
Chapter 5 Maintenance
Figure 39 - Auxiliary Contact Orientation
52 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Spare Parts
Chapter 6
Spare Parts
Table 1 - Spare Part Numbers
Part Number Description Recommended Stocking Qty.
1503C-E4D Low Voltage Control Panel – 120V AC
1503C-E4E Low Voltage Control Panel – 230V AC
40266-515-03 20 A Isolation Switch Auxiliary Contact (700 CPM) 2
80178-707-53 Isolation Switch Refurbishment Kit – 400 A 1
80154-422-01 Auxiliary Switch Cam Follower 2
80154-542-51 Auxiliary Switch Housing Assembly 2
T9327-105 NyoGel 759G Isolation Switch Lubricant 1
80144-491-02 Fuse Extractor (For Clip-on Power Fuses) 1
(1) The Low Voltage Control Panel includes the following: CR1 relay, CR2 Relay, rectifier, MOV assembly, test switch, test plug.
(2) See publication 1503-UM053
for spare part information for IntelliVAC™ control modules.
(1) (2)
(1) (2)
1
1
See these publications for information on spare parts for the Bulletin 1502
medium voltage 400 A contactor (120V and 230V):
• 400 A – Publication 1502-UM050 (Series D)
• 400 A – Publication 1502-UM052 (Series E and F)
These user manuals contain detailed information on installation, adjustment, and
maintenance for this product.
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 53
Chapter 6 Spare Parts
Notes:
54 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
Appendix A
OEM Kit Chart
OEM Kit Chart
Table 2 - Items Included with the Power Cell and Frame
Final Part
Number
1503F-E4GCD 1 400 A, 2.3…5.0 kV, electrically held, clip on fuse, electromechanical, 110…120V AC control frame 1503F-E4GCD 80158-951-61
1503F-E4GCE 1 400 A, 2.3…5.0 kV, electrically held, clip on fuse, electromechanical, 220…230V AC control frame 1503F-E4GCE 80158-951-65
1503F-E4GCU 1 400 A, 2.3…5.0 kV, electrically held, clip on fuse, IntelliVAC, 110…120V AC control frame 1503F-E4GCU 80178-373-58
1503F-E4GBD 1 400 A, 2.3…5.0 kV, electrically held, bolt on fuse, electromechanical, 110…120V AC control frame 1503F-E4GBD 80158-951-59
1503F-E4GBE 1 400 A, 2.3…5.0 kV, electrically held, bolt on fuse, electromechanical, 220…230V AC control frame 1503F-E4GBE 80158-951-63
1503F-E4GBU 1 400 A, 2.3…5.0 kV, electrically held, bolt on fuse, IntelliVAC, 110…120V AC control frame 1503F-E4GBU 80178-373-55
1503F-M4GCD 1 400 A, 2.3…5.0 kV, mechanical latch, clip on fuse, electromechanical, 110…120V AC control frame 1503F-M4GCD 80158-951-69
1503F-M4GCU 1 400 A, 2.3…5.0 kV, mechanical latch, clip on fuse, IntelliVAC< 110…120V AC control frame 1503F-M4GCU 80178-373-63
1503F-M4GBD 1 400 A, 2.3…5.0 kV, mechanical latch, bolt on fuse, electromechanical, 110…120V AC control frame 1503F-M4GBD 80158-951-67
1503F-M4GBU 1 400 A, 2.3…5.0 kV, mechanical latch, bolt on fuse, IntelliVAC< 110…120V AC control frame 1503F-M4GBU 80178-373-61
1503F-E4KCD 1 400 A, 5.1…6.9 kV, electrically held, clip on fuse, electromechanical, 110…120V AC control frame 1503F-E4KCD 80158-951-62
1503F-E4KCE 1 400 A, 5.1…6.9 kV, electrically held, clip on fuse, electromechanical, 220…230V AC control frame 1503F-E4KCE 80158-951-66
Qty Description Salable Part
Number
1 Electrically held 120V control panel 1503C-E4D 80158-143-51
1 Electrically held 230V control panel 1503C-E4E 80158-143-53
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHE4V 80178-142-57
1 Electrically Held 120V control panel 1503C-E4D 80158-143-51
1 Electrically Held 230V Control Panel 1503C-E4E 80158-143-53
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHE4V 80158-142-57
1 Mechanical Latch 120V control panel 1503C-M4D 80158-143-52
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHM4V 80158-142-52
1 Mechanical latch 120V control panel 1503C-M4D 80158-143-52
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness – IntelliVAC 1503-WHM4V 80158-142-52
1 Electrically held 120V control panel 1503C-E4D 80158-143-51
1 Electrically Held 230V control panel 1503C-E4E 80158-143-53
Internal Part
Number
Rockwell Automation Publication 1503-IN050F-EN-P - July 2019 55
Appendix A OEM Kit Chart
Table 2 - Items Included with the Power Cell and Frame (Continued)
Final Part
Number
1503F-E4KCU 1 400 A, 5.1 …6.9 kV, electrically held, clip on fuse, IntelliVAC, 110…120V AC control frame 1503F-E4KCU 80178-373-68
1503F-E4KBD 1 400 A, 5.1…6.9 kV, electrically held, bolt on fuse, electromechanical, 110…120V AC control frame 1503F-E4KBD 80158-951-60
1503F-E4KBE 1 400 A, 5.1…6.9 kV, electrically held, bolt on fuse, electromechanical, 220…230V AC control frame 1503F-E4KBE 80158-951-64
1503F-E4KBU 1 400 A, 5.1…6.9 kV, electrically held, bolt on fuse, IntelliVAC, 110…120 V ACcontrol frame 1503F-E4KBU 80178-373-65
1503F-M4KCD 1 400 A, 5.1…6.9 kV, mechanical latch, clip on fuse, electromechanical, 110…120V AC control frame 1503F-M4KCD 80158-951-70
1503-M4KBD 1 400 A, 5.1…6.9 kV, mechanical latch, bolt on fuse, electromechanical, 110…120V AC control frame 1503VC-BMC5 80178-370-52
1503F-M4KBU 1 400 A, 5.1...6.9 kV, mechanical latch, bolt on fuse, IntelliVAC, 110…120V ACcontrol frame 1503F-M4KBD 80158-951-68
1503F-E6GBD 1 600 A, 2.3…5.0 kV, electrically held, bolt on fuse, electromechanical, 110…120V ACcontrol frame 1503F-E6GBD 80158-333-57
1503F-E6GBU 1 600 A, 2.3…5.0 kV, electrically held, bolt on fuse, IntelliVAC, 110…120V ACcontrol frame 1503F-E6GBU 80178-374-52
1503F-M6GBD 1 600 A, 2.3…5.0 kV, mechanical latch, bolt on fuse, electromechanical, 110…120V ACcontrol frame 1503F-M6GBD 80158-333-60
1503F-M6GBU 1 600 A, 2.3…5.0 kV, mechanical latch, bolt on fuse, IntelliVAC 110…120V AC control frame 1503F-M6GBU 80178-374-55
1503F-E6KBD 1 600 A, 5.1…6.9 kV, electrically held, bolt on fuse, electromechanical, 110…120V AC control frame 1503F-E6KBD 80158-333-58
1503F-E6KBU 1 600 A, 5.1…6.9 kV, electrically held, bolt on fuse, IntelliVAC, 110…120V AC control frame 1503F-E6KBU 80178-374-57
1503F-M6KBD 1 600 A, 5.1…6.9 kV, mechanical latch, bolt on fuse, electromechanical, 110…120V ACcontrol frame 1503F-M6KBD 80158-333-61
1503F-M6KBU 1 600 A, 5.1…6.9 kV, mechanical latch, bolt 110…120On Fuse, IntelliVAC 110…120V AC control frame 1503F-M6KBU 80178-374-60
Qty Description Salable Part
Number
1 IntelliVAC base 1503VC-BMC5 80178-370-52
Wire harness-IntelliVAC 1503-WHE4V 80158-142-57
1 Electrically held 120V control panel 1503C-E4D 80158-951-51
1 Electrically held 230V control panel 1503C-E4E 80158-143-53
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHE4V 80158-142-57
1 IntelliVAC base 1503C-M4D 80158-143-52
1 Wire harness-IntelliVAC 1503F-M4KCU 80178-373-73
1 Mechanical latch 120V Control Panel 1503-WHM4V 80158-142-59
1 IntelliVAC base 1503C-M4D 80158-143-52
1 Wire harness-IntelliVAC 1503-WHM4V 80158-142-59
1 Electrically Held 120V Control Panel 1503FC-E8D 80158-143-54
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHE8V 80178-142-58
1 Mechanical latch 120V control panel 1503C-M8D 80158-143-60
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHM8D 80158-142-55
1 Electrically held 120V control panel 1503C-E8D 80158-143-54
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHE8V 80158-142-58
1 Mechanical latch 120V control panel 1503C-M8D 80158-143-55
1 IntelliVAC base 1503VC-BMC5 80178-370-52
1 Wire harness-IntelliVAC 1503-WHM8D 80158-142-55
Internal Part
Number
56 Rockwell Automation Publication 1503-IN050F-EN-P - July 2019
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Direct Dial Codes Find the Direct Dial Code for your product. Use the
code to route your c all directly to a techn ical support
engineer.
http://www.rockwellautomation.com/global/support/direct-dial.page
Literature Library Installation Instructions, Manuals, Brochures, and
Tec hn ica l D ata .
http://www.rockwellautomation.com/global/literature-library/
overview.page
Product Compatibility and Download
Center (PCDC)
Get help determining how products interact, check
features and capabilities, and find associated
firmware.
http://www.rockwellautomation.com/global/support/pcdc.page
.
Rockwell Otomasyon Ticaret A.Ş., Kar Plaza İş Merkezi E Blok Kat:6 34752 İçerenköy, İstanbul, Tel: +90 (216) 5698400
Rockwell Automation maintains current product environmental information on its website at http://ww w.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page.
Allen-Bradley, IntelliVAC, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation , Inc.
Trademarks not belonging to Rockwell Automation are property of their resp ective companies.
Publication 1503-IN050F-EN-P - July 2019
Supersedes Publication 1503-IN050E-EN-P - June 2013 Copyright © 2019 Rockwell Automation, Inc. All rights reserved. Printed in Canada.
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