Rockwell Automation 1502 User Manual
User Manual
Medium Voltage 400A Contactor - Series E
Publication Number 1502-UM052H-EN-P
Important User Information
IMPORTANT
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.
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).
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.
Product Description
Table of Contents
Chapter 1
Contactor Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Vacuum Bottle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Standard Electrically Held Contactor Operation . . . . . . . . . . . . . . . . . . . . . 6
Mechanically Latched Contactor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 7
IntelliVAC and IntelliVAC Plus Control . . . . . . . . . . . . . . . . . . . . . . . . 7
Electromechanical Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Contactor Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Contactor Catalog Number Explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contactor Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Receiving and Handling
Installation
Maintenance
Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preliminary Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pre-Energization Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Vacuum Bottle Integrity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Insulation Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chapter 3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wiring and Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Chapter 4
Tool Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
HiPot test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Vacuum Bottle Replacement and Set-Up Procedure. . . . . . . . . . . . . . . . . 38
Coil Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Auxiliary Contact Set-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Mechanically Latched Contactor Trip Coil Replacement Procedure. . 48
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Mechanically Latched Contactor Set-up Procedure . . . . . . . . . . . . . . . . . 52
Altitude Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 3
Table of Contents
Chapter 5
Troubleshooting
Spare Parts
Troubleshooting and Contactor Coil Resistance . . . . . . . . . . . . . . . . . . . . 55
Chapter 6
Bulletin 1502 Spare Parts Diagrams and Chart. . . . . . . . . . . . . . . . . . . . . . 57
4 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Product Description
Chapter 1
Contactor Description
The Allen-Bradley, Bulletin 1502, 400 A vacuum contactors are designed for
applications in the 2400 and 7200V range. The contactor is suitable for all types
of AC loads, for example: three-phase motors, transformers, power capacitors
and resistive heating loads.
The contactor uses three interrupters (hereafter referred to as vacuum bottles)
operated by an electromagnet assembly through a mechanical linkage. They are
resistant to adverse atmospheric conditions and provide long mechanical and
electrical life.
The contactors are utilized in various starter and drive configurations, for
example: full-voltage non-reversing, full-voltage reversing, two-speed, reduced
voltage, synchronous, drive input/output and bypass applications. They are
generally fixed mounted within the structures and the line and load terminations
are made at the rear of the device. In most configurations, the main contactor is
mechanically interlocked with the external operating handle and isolating switch.
Bulletin 1502 vacuum contactors are designed for use with the IntelliVAC and
IntelliVAC Plus control module (refer to Publication 1503-UM053_-EN-P
and 1503-UM054_-EN-P
with an electromechanical (relay) control panel.
Bulletin 1502 electrically held and mechanical latch vacuum contactors are
provided with coils rated for 108 VDC. The IntelliVAC and IntelliVAC Plus control
module can accept a wide array of supply voltages for maximum flexibility (refer to
Publication 1503-UM053_-EN-P
). The mechanical latch contactor may also be applied
and 1503-UM054_-EN-P).
Figure 1 - 400A Contactor
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 5
Chapter 1 Product Description
Arc Shield
Contact Wear
Indicator Line
Fixed shaft
Ceramic
Contacts
Bellows
Bearing
Movable Shaft
Vacuum Bottle Description
Each vacuum bottle (Figure 2) consists of two contacts enclosed in a ceramic
housing: an upper contact mounted to a fixed shaft, and a lower contact mounted
to a movable shaft. A stainless steel bellows ensures the vacuum integrity of the
bottle while letting the lower contact move towards and away from the fixed
contact.
Figure 2 - Vacuum Bottle Cross Section
Standard Electrically Held Contactor Operation
Each vacuum bottle (Figure 2) consists of two contacts enclosed in a ceramic
housing: an upper contact mounted to a fixed shaft, and a lower contact mounted
to a movable shaft. A stainless steel bellows ensures the vacuum integrity of the
bottle while letting the lower contact move towards and away from the fixed
contact.
The standard electrically held contactor consists of three vacuum bottles. An
electro-magnet assembly and a mechanical linkage are used to close the contacts.
• When the IntelliVAC or IntelliVAC Plus control module receives a close
command, the contactor coils (two connected in series) are energized, and
the current creates an electromagnet with the coils.
• The electromagnet pulls the armature plate towards the coils’ core,
rotating the shaft and causing the actuator plate to move upwards.
• As the actuator plate moves, it pushes the insulator and movable shaft up,
closing the contacts in the vacuum bottle.
• The IntelliVAC or IntelliVAC Plus control module supplies the current
required to close the coils for 200 milliseconds. Afterward, the coil current
is reduced to a lower hold-in value.
• When the IntelliVAC or IntelliVAC Plus control module has the close
command removed, the coils are de-energized, opening the contactor.
6 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Figure 3 - Vacuum Contactor Operation
Insulator
Armature Plate & Shaft
Auxiliary Actuator
Armature Stop Bracket
Control Wire Plug
Line Terminal
Vacuum Bottle
Load Terminal
Flexible Bus
Return Spring
Actuator Plate
Gap Adjustment Screw
Magnet/Coil Assembly
C.P.T. Fuse Clip
Contactor Open
Contactor Closed
Product Description Chapter 1
Mechanically Latched Contactor Operation
The mechanically latched contactor operates in much the same way as the
electrically held (Figure 3
) with only a few exceptions.
IntelliVAC and IntelliVAC Plus Control
• Once the contactor is closed, a spring-loaded mechanism moves a roller
against the armature plate to hold it against the electromagnetic core.
• The contactor can be opened electrically by energizing a trip coil (via
IntelliVAC or IntelliVAC Plus ‘open’ [TCO] output) which pulls the
latch away from the armature, or by a push button mounted on the power
cell door that mechanically releases the contactor.
Electromechanical Control
• When the control circuit is energized, the current creates an electromagnet
in the closing coil.
• The electromagnet pulls the armature plate towards the coils’ core,
rotating the shaft and causing the actuator plate to move upwards.
• As the actuator plate moves, it pushes the insulator and movable shaft up,
closing the contacts in the vacuum bottle.
• Once the contactor is closed, a spring-loaded mechanism moves a roller
against the armature plate to hold it against the electromagnetic core.
• The control circuit economizing auxiliary contact, on the left side of the
contactor, changes from the normally closed state to the normally open
state as the contactor closes. This de-energizes the relay that controls the
closing coils.
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 7
Chapter 1 Product Description
• The contactor can be opened electrically by energizing a trip coil which
pulls the latch away from the armature, or by a push button mounted on
the power cell door that mechanically releases the contactor.
Note : The standard mechanical latch contactor requires external 120V AC (or
DC) control relays and rectification circuit to control the standard DC closing
and trip coils on the contactor (when IntelliVAC or IntelliVAC Plus is not used).
Contactor Identification
Each contactor is identified with a rating label (Figure 4) attached to the
armature plate at the front of the contactor. The rating label information
includes the Catalog Number (Cat.) Series Letter (Ser.) Voltage Rating, NonEnclosed Current Rating, Interrupting Capacity, Altitude Range (in meters),
CSA, UL and CE markings.
Figure 4 - Contactor Rating Label (400A)
8 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Product Description Chapter 1
1502-V4DBDA-1
First
Position
Bulletin
Number
1502
Second
Position
Contactor Type
and Interlock
V
= Vacuum,
VC
=Vacuum,
Optimized for
IntelliVAC control
Third
Position
Contactor
Size
4
= 400 A
Fourth
Position
Nominal
Line Voltage
D
= 7200 V
Fifth
Position
Fuse Mounting
Provisions
B
= 5000 V
C
= 7200 V
Sixth
Position
Coil
Voltage
D
=110VDC
Seventh
Position
Function
Refer to
TABLE
Eighth
Position
Altitude
Code (meters)
0 = -1000 – 5000
1 = 0 – 1000
2 = 1001–200 0
3 = 2001–300 0
4 = 3001–400 0
5 = 4001–500 0
E
= 207 V DC
1502-V4DBDA-1
First
Position
Bulletin
Number
1502
Second
Position
Contactor Type
and Interlock
V
= Vacuum,
VC
=Vacuum,
Optimized for
IntelliVAC control
Third
Position
Contactor
Size
4
= 400 A
Fourth
Position
Nominal
Line Voltage
D
= 7200 V
Fifth
Position
Fuse Mounting
Provisions
B
= 5000 V
C
= 7200 V
Sixth
Position
Coil
Voltage
D
=110VDC
Seventh
Position
Function
Refer to
TABLE 1
Eighth
Position
Altitude
Code (meters)
0 = -1000 – 5000
1 = 0 – 1000
2 = 1001–200 0
3 = 2001–300 0
4 = 3001–400 0
5 = 4001–500 0
E
= 207 V DC
1502-V4DBDA-1
First
Position
Bulletin
Number
1502
Second
Position
Contactor Type
and Interlock
V
= Vacuum,
VC
=Vacuum,
Optimized for
IntelliVAC control
Third
Position
Contactor
Size
4
= 400 A
Fourth
Position
Nominal
Line Voltage
D
= 7200 V
Fifth
Position
Fuse Mounting
Provisions
B
= 5000 V
C
= 7200 V
Sixth
Position
Coil
Voltage
D
=110VDC
Seventh
Position
Function
Refer to
TABLE
Eighth
Position
Altitude
Code (meters)
0 = -1000 – 5000
1 = 0 – 1000
2 = 1001–200 0
3 = 2001–300 0
4 = 3001–400 0
5 = 4001–500 0
E
= 207 V DC
Contactor Catalog Number Explanation
The following catalog number explanation is used to identify the contactor and
should be used when contacting your local Rockwell Automation Sales office, or
the factory, for assistance.
Figure 5 - Contactor Catalog Number Explanation
Table 1 - Vacuum Contactor Function
A 3 pole, electrically held contactor
B 3 pole, mechanically latched contactor with electrical and mechanical release
C 3 pole, electrically held contactor with fast drop-out
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 9
Chapter 1 Product Description
2
Contactor Specifications
Table 2 - Bulletin 1502 Medium Voltage 400 Amp Contactor Ratings
Voltag e Ratings
Maximum Rated Voltage 7200
System Voltages 2400, 3300, 4160
Dielectric Voltage Withstand Rating For 60 seconds (kV) 18.2 / 20 (IEC)
Basic Impulse Level (B.I.L.) Withstand Phase to Ground, Phase to Phase (kV) 60
Frequency Ratings Hertz 50/60
Current Ratings
Rated Continuous Current (Amps) 400
Maximum Interrupting Current Rating 2400 V (RMS Sym Amps) 6300
Maximum Interrupting MVA Rating 2400 V (Sym MVA) 25
(1)
4800, 6600, 6900
(1)
5000 V (RMS Sym Amps) 6300
7200 V (RMS Sym Amps)
(2)
6000
5000 V (Sym MVA) 50
7200 V (Sym MVA)
(2)
75
Short-Circuit Withstand at Rated Voltage Current Peak ½ cycle (kA) 60
Short Time Current Rating Capability For 1 second (kA) 6.0
For 30 seconds (kA) 2.4
Chop Current (Average RMS Amps) 0.5
Make and Break Capability at Rated Voltage (kA) 4.0
Ambient Temperature °C 40
Contactor Coil Data
Control Voltage
)
(V
CTL
Coil Voltage (VCL)
Electro-Mechanical (Relay) Control (Mechanical Latch Only)
120 VAC 110 VDC Close Current (A
Trip Current (A
)5.6
DC
)6.0
DC
Pick-up Voltage 102
Tri p Vo lt age 84
IntelliVAC and IntelliVAC Plus Control (Electrically Held & Mechanical Latch)
110 to 240 VAC
or
110 to 250 VDC
VAC:
= X V
V
CL
(3)
(Max.)
VDC:
= V
V
CL
CTL
Close Current (ADC, 200 milliseconds) 4.3
CTL
Hold Cu rrent (A
Pick-up Voltage
Drop-out Voltage
Trip Current (A
Tri p Vo lt age
)0.48
DC
(3)
(3)
, 200 milliseconds) 5.5
DC
(3)
95
75
70
10 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Table 2 - Bulletin 1502 Medium Voltage 400 Amp Contactor Ratings (Continued)
Operational Characteristics
Mechanical Life (Operations) x 1000
Electrical Life (Operations) x 1000
(4)
(4)
Switching Frequenc y (O perations per hour) Electrically Held 600
Opening and Closing Times
Maximum Closing Time (120 VAC) 50 or 60 Hz (milliseconds) 160
Maximum Opening Time (120 VAC) 50 or 60 Hz (milliseconds) 50
Maximum Closing Time (50 to 60 Hz) 120 / 240 VAC (milliseconds) 100 / 70
Maximum Opening Time
(without delay, for 50 to 60 Hz)
(5)
Capacitor Switching (max. KVAR)
System Voltage 2400V 800
Electrically Held 2500
Mechanical Latch 100
1000
Mechanical Latch 150
Electro-Mechanical (Relay) Control (Mechanical Latch Only)
IntelliVAC and IntelliVAC Plus Control (Electrically Held & Mechanical Latch)
120 to 240 VAC (milliseconds) 60
4160V 1400
Product Description Chapter 1
6900V 2000
General
Standard Altitude Capability (meters / feet)
(1)(6)
-1000...5000 / 3300...16,500
Contactor Weight (kg / lbs) 21.8 / 48
Auxiliary Contact Rating A600
Auxiliary Contacts on the Vacuum Contactor (Max.)
(1) The voltage and current ratings listed are valid up to 1,000 m (3,300 ft). Please refer to Tab le 3 for ratings above this altitude.
(2) The IEC rating at 7200V (RMS Sym.) is 5300 A / 66 MVA.
(3) Control voltage, as measured at the input of the IntelliVAC or IntelliVAC Plus control module.
(4) Provided that regular maintenance is performed, as detailed in this manual.
(5) A contactor drop-out delay may be configured with the IntelliVAC or IntelliVAC Plus control module (refer to publications 1503-UM053_-EN-P
EN-P).
(6) The full Altitude range is available with the IntelliVAC or IntelliVAC Plus control module only, and the IntelliVAC or IntelliVAC Plus is to be configured accordingly (refer
to publications 1503-UM053_-EN-P
for -1000...1000 m (-3300...3300 ft). Higher altitudes are possible by changing the contactor return springs (refer to Figure 5
(7) The number of contactor auxiliary contacts depends on the contactor type. Some of the contac ts are used in the typical control schemes used.
(7)
and 1503-UM054_-EN-P). The standard mechanical latch contactors, if used with electro-mechanical control, are designed
3 N.O. / 3 N.C.
and 1503-UM054_-
for suitable catalog numbers).
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 11
Chapter 1 Product Description
Table 3 - Altitude Derating
Altitude Rating Reduce Max. Continuous Current Rating By: Reduce B.I.L. Withstand Rating by:
400 A 800 A
0...1000 m (0...3300 ft) – – –
1001...2000 m (3301...6600 ft) 10 A 20 A 6.0 kV
2001...3000 m (6601...9900 ft) 20 A 40 A 12.0 kV
3001...4000 m (9901...13,200 ft) 30 A 60 A 18.0 kV
4001...5000 m (13,201...16,500 ft) 40 A 80 A 24.0 kV
Product Approvals
• UL347
• CSA22.2 No. 14 and T.I.L. D-21
• IEC60470
• CE Mark
12 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Receiving and Handling
Chapter 2
Receiving
Handling
The contactors have been tested both mechanically and electrically before leaving
the factory. Immediately upon receiving the contactor, remove the packing
material and check the contactor for possible shipping damage. If damage is
found, do not discard any of the packaging material and, if possible note the
damage on the “Bill of Lading” before accepting the shipment. Report any
damage immediately to the claims office of the common carrier. Provide a
description of the damage and as much identification as possible.
Preliminary Inspection
Check for any cracks or breaks due to impact.
Push on armature plate to ensure mechanisms are in good working order.
Use a HiPot tester to ensure vacuum bottle integrity (refer to Vac uum B ot tl e
Integrity Test on page 14).
The contactor weighs approximately 48 lb (21.8 kg) and it is possible for one
person to safely handle the contactor for a short time. When transporting the
contactor over longer distances or sustained lifting, a forklift should be
considered.
When a forklift is used to handle the equipment, the following precautions
should be taken:
• Keep the contactor in an upright position.
• Carefully balance the contactor on the forks.
• Use a safety strap to steady the contactor and avoid shifting or tipping.
• Avoid excessive speeds and sudden starts, stops and turns.
• Never lift a contactor above an area where personnel are located.
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 13
Chapter 2 Receiving and Handling
Pre-Energization Inspection
Storage
Vacuum Bottle Integrity Test
Before placing the contactor in service, inspect it carefully for possible damage
sustained in transit or maintenance:
• Check housing for any cracks or breaks due to impact.
• Push on the armature plate and rotating shaft to ensure mechanism is in
good working order.
• Inspect the contactor for dirt, stray or loose hardware, tools or metal chips.
Vacuum clean if necessary.
If it is necessary to store the contactor before it is put into service, be certain to
store it in a clean, dry area, free from dust and condensation. Do not store
contactor outdoors.
Storage temperature should be maintained between -20...65 °C (-4...149 °F). If
storage temperature fluctuates or if humidity exceeds 85%, space heaters should
be used to prevent condensation.
The internal dielectric condition and vacuum integrity of the vacuum bottles is
determined by this test.
ATT EN TI ON : Do not apply a voltage higher than 25,000V across the open
contacts of a vacuum bottle. Dangerous x-ray emissions may be produced.
ATT EN TI ON : Vacuum bottles are thoroughly tested at the factory; however,
mishandling during shipment may cause damage. It is very important to
perform the vacuum bottle integrity test before energizing the contactor for the
first time, and before it is returned to service after maintenance or repair; test
may result in personal injury or damage to the equipment if the vacuum bottle
integrity fails.
ATT EN TI ON : High voltage testing is potentially hazardous. Use caution when
performing the Hi-pot test. Failure to do so may result in sever burns, injury or
death.
High-potential test instruments can be purchased to perform the vacuum bottle
integrity test. A Megger cannot be used to measure vacuum integrity because the
voltage is too low. One of the following AC Hi-pot testers is recommended as a
test instrument.
MANUFACTURER ADDRESS
Mitsubishi Type VI #4U17 Chicago, Ill., USA
Jennings Model JHP-70A San Jose, CA., USA
Hipotronics Model 7BT 60A Brewster, NY, USA
14 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Receiving and Handling Chapter 2
Vacuum
Checker
Vacuum Contactor
in open position
1. Clean the outside of the vacuum bottles with a non-linting cloth or
industrial wipe before performing the test.
2. The contactor may be tested while it is in the power cell. The line
connection of the contactor must be disconnected and the ground lead
from the Hi-pot tester must be connected to the load side of the contactor.
Any fuses in the top of the contactor must be removed.
3. With the contactor in the open position, connect the test leads to the
contactor power terminals as shown in Figure 6
. It is recommended that an
AC Hi-pot tester be used. Apply 16 kV for 60 seconds and monitor the
leakage current. It should not exceed 5 mA. Test each vacuum bottle
individually.
4. If no breakdown occurs, the vacuum bottle is in an acceptable condition. If
a breakdown occurs, repeat the test once more. If the vacuum bottle fails a
second time, it must be replaced. If no breakdown occurs in the second
test, the vacuum bottle is in an acceptable condition.
ATT EN TI ON : If one vacuum bottle fails, Rockwell Automation recommends the
replacement of all three vacuum bottles, if the unit has been in service.
5. After the high potential voltage is removed from the vacuum bottles, the
metal end caps of the vacuum bottles should be discharged with a
grounding rod to remove any residual electrical charge.
Figure 6 - Vacuum Bottle Integrity Test Circuit
The allowable leakage current value of 5 mA is exclusive of leakage due to test
equipment leads. The test setup leakage can be determined by running the
dielectric test with test leads not connected to the contactor and noting the
maximum leakage current. If this value is more than 2 mA, it should be added to
the 5 mA limit when testing the vacuum bottles.
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 15
Chapter 2 Receiving and Handling
Note: Rockwell Automation does not recommend DC Hi-pot testing because
the values obtained during the test may not be a reliable indication of vacuum
bottle integrity. Some specific DC “GO-NO GO” testers may provide suitable
“defective” reading s.
DC Hi-pot testing is unreliable because of a phenomenon known as Cathode Ray
Tube Effect. This occurs when one contact of the vacuum bottle has a deformity,
such as a burr or deposit, while the other contact remains flat and true. This sets
up leakage currents which flow from a small surface to a large surface in one
direction and vice versa when the polarity of the tester is changed. The resultant
current is large in one direction which would incorrectly indicate a faulty vacuum
bottle.
At best, DC testing will verify on some degree of vacuum integrity. It will not give
any indication of the degree of vacuum since the contact surface can change with
each operation of the vacuum contactor. AC testing, on the other hand, will
provide reliable vacuum integrity indication. As well, the degree of vacuum
within the bottle can be determined by comparing initial test results to the
present readings. Increases in leakage current indicate a reduction in vacuum
within the vacuum bottle.
Insulation Resistance Test
For these reasons, Rockwell Automation recommends AC testing as the best and
most reliable method of testing vacuum bottles.
A suitable GO-NO GO DC test unit is:
Manufacturer Address
Programma, Model VIDAR Santa Rosa, CA, USA
Use a 1000V Megger to verify that the resistance from phase-to-phase or phaseto-ground is greater than 500 megohms.
16 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
Installation
8.64 [219]
4.96 [126]
8.53 [217]
0.37
[9]
0.91
[23]
Front View
Cut-away View
Bottom View
13.22 [336]
0.75 [19]
17.24
[438]
5.00
[127]
3.15 [80]
4.25 [108] 4.25 [108]
8.00 [203]
0.98 [25]
2.12 [54]
10.50 [267]
1.36 [35]
0.281 [7]
wide slots
7.87 [200]
0.37 [9]
Chapter 3
Mounting
The electrically held and the mechanically latched contactors are fixed mounted
(bolted down) in the controller’s cabinet. Two retaining tabs at the rear of the
contactor’s molded base can be used for mounting. The two mounting slots at the
front of the contactor’s molded base are used to secure the contactor with
1/4 in. bolts. The appropriate mounting configuration is provided inside the power cells
of Allen-Bradley controllers. If the contactor is supplied as an OEM component for
installation in a custom application, refer to the dimensional information in Figure 7
If the contactor is to be mounted in an enclosure designed by an OEM, make sure
there is a minimum of 3 in. (76 mm) of air space between live parts (terminals and
vacuum bottles) and any part of the enclosure.
Figure 7 - Contactor Mounting Details
.
Rockwell Automation Publication 1502-UM052H-EN-P - June 2013 17
Chapter 3 Installation
2.93
1.53
Figure 8 - Mechanical Latch Dimensions (Optional)
Electrical Connections
A wire harness connects the control wiring to the contactor from the low voltage
control panel. The harness connects to a wire plug on the lower left side of the
contactor. If the contactor is supplied as an OEM component for installation in a
custom application, the following two control options and a connecting wire
harness are available from Rockwell Automation.
• IntelliVAC and IntelliVAC Plus control modules
• Electromechanical control panel (for latch contactors only)
Connect incoming power to the line side terminals at the top, rear of the
contactor near the control fuse clips. Use 3/8 in. (10 mm) bolts torqued to
•ft (292 N•m) to secure the connection.
20 lb
Connect outgoing power to the load side terminals halfway down the rear of the
contactor. Use 3/8 in. (10 mm) bolts torqued to 20 lb
•ft (292 N•m) to secure the
connection.
For mechanically latched contactors, ensure the manual trip button in the cabinet
door is in line with the trip lever on the contactor.
18 Rockwell Automation Publication 1502-UM052H-EN-P - June 2013
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