Rockwell Automation 1503 OEM User Manual
OEM Starter Frame and Components
Bulletin 1503
2400 to 7200 volts
Installation Manual
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.
Table of Contents
Chapter 1 OEM Starter Frame Installation
Receiving ......................................................................................... 1-1
Installation ....................................................................................... 1-1
Standards and Codes ................................................................. 1-1
Imperial Tool Requirements ...................................................... 1-2
Metric Tool Requirements ......................................................... 1-2
Starter Frame Dimensions ......................................................... 1-3
Control Panel ............................................................................. 1-3
Torque Requirements ................................................................ 1-4
Fuses .......................................................................................... 1-4
Line and Load Connections ...................................................... 1-4
Commissioning ......................................................................... 1-4
Chapter 2
Component Installation
Component Layout .......................................................................... 2-1
Mounting Isolation Switch Handle Module .................................... 2-3
Mounting Isolation Switch and Trailer Fuse Block ......................... 2-5
Power Fuses ..................................................................................... 2-7
Contactor ........................................................................................ 2-10
Control Panel ................................................................................. 2-10
IntelliVAC .................................................................................... 2-10
Typical Electrical Diagrams for 400A FVNR Controller with
Electro-Mechanical Control and Electrically Held
Contactor, 120VAC ........................................................... 2-11
Electro-Mechanical Control and Mechanical Latch Contactor . 2-12
IntelliVAC Control and Electrically Held Contactor ............ 2-13
IntelliVAC Control and Mechanical Latch Contactor .......... 2-14
Door Interlock Assembly ............................................................... 2-15
Connecting Isolation Switch to Isolation Switch Handle .............. 2-17
Connecting Contactor to Isolation Switch Handle ........................ 2-18
Electrical Connection From Contactor to Trailer Fuse Block
(Clip-on Fuses) ......................................................................... 2-21
Electrical Connection From Contactor to Trailer Fuse Block
(Bolt-on Fuses) ......................................................................... 2-22
Incoming Line Connections ........................................................... 2-24
Load Connections .......................................................................... 2-24
Connecting Contactor to Control Power Transformer ................... 2-25
1503-IN050E-EN-P – June 2013
ii Table of Contents – Bulletin 1503 OEM Starter Frame and Components • Installation Manual
Chapter 3
Power Lock-out Procedure .............................................................. 3-2
Contactor Interlock Rod Adjustment ............................................... 3-5
Isolation Switch Ground Adjustment ............................................... 3-7
Isolation Switch Auxiliary Contacts ................................................ 3-8
Adjusting the Normally Open (Isa) Contacts ............................ 3-9
Adjusting the Normally Closed (Isb) Contacts ....................... 3-10
Adjusting the ‘Change of State Point’ ......................................3-11
Adjustments for 400A Equipment
Door Interlock Circumvention ......................................................... 3-1
Chapter 4 Commissioning
Vacuum Bottle Integrity Test ........................................................... 4-1
Preliminary Checklist ...................................................................... 4-2
Contactor Operation .................................................................. 4-2
Electrical Connections .............................................................. 4-2
Final Checks .............................................................................. 4-2
Hi-pot and Megger Test ................................................................... 4-1
Chapter 5
Maintenance
Contactor .......................................................................................... 5-1
Isolation Switch Mechanism – Inspection and Lubrication ............ 5-1
Auxiliary Contacts Inspection and Replacement ............................. 5-3
Chapter 6
Spare Parts ....................................................................................... 6-1
Spare Parts
Appendix A OEM Kit Chart ................................................................................A-1
1503-IN050E-EN-P – June 2013
OEM Starter Frame Installation
Chapter 1
A T T E N T I O NA T T E N T I O N
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 may result in
damage to the equipment or injury to personnel.
Receiving Refer to General Handling Procedures for Medium Voltage Controllers
– Publication MV-QS050_-EN-P. This document is included with your
shipment and contains information regarding receiving, unpacking, initial
inspection, handling, storage, opening the medium voltage doors, and site
preparation.
Note: Refer to Appendix A for a listing of the items that are included in
your OEM Frame Kit.
Installation Standards and Codes
The OEM starter frame consists of a fusible non-load-break
I M P O R T A N TI M P O R T A N T
isolation switch, an isolation switch handle, a vacuum contactor, control
circuitry and a medium voltage door. These components are not a complete
motor controller. The user must add appropriate control circuitry for the
application, power fusing, current transformer, control power transformer,
overload protection and a suitable enclosure. It is recommended that the
user be familiar with the following safety and design standards and codes,
and any additional local codes that a medium voltage starter must comply with.
• CEC (Canadian Electrical Code)
• CSA 22.2 No. 14 (Canadian Standards Association) – Industrial Control
Equipment
• NEC (National Electrical Code)
• NEMA ICS Standards (National Electrical Manufacutrers’ 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
• 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 1kV 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
1503-IN050E-EN-P – June 2013
1-2 OEM Starter Frame Installation
Installation (Cont.) Standards and Codes (Cont.)
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 should be the only additional checks
required for the unit.
Imperial Tool Requirements
I M P O R T A N TI M P O R T A N T
Some components of this product incorporate Imperial
hardware. Rockwell Automation recommends the use of the appropriate
tools to successfully complete the assembly and maintenance procedures
for these components. If you cannot obtain such tools, contact your area
Rockwell Automation sales offi ce for assistance.
The following Imperial size tools are recommended for installation and
maintenance of the OEM starter frame and components:
• Standard drive ratchet with extension
• Standard drive torque wrench
• Standard drive sockets: 9/32, 3/8, 7/16, 1/2, 9/16, 3/4 in.
• Open-end wrenches: 7/16, 1/2, 9/16, 11/16, 3/4, 7/8 in.
• Drill and drill bits: 0.172, 0.219, 0.281 in.
• Slot-head screwdrivers
• Feeler gauge set (0.125 in to 0.300 in.)
• Locking pliers
• High potential tester
Metric Tool Requirements
I M P O R T A N TI M P O R T A N T
Metric equivalent sizes are provided in parentheses
where applicable. It is important to note that all sizes given are not exact
substitutes for the corresponding Imperial sizes. To ensure proper installation, use the recommended metric hardware and dimensions for pilot holes
and clearance holes.
The following metric size tools are recommended for installing the OEM
frame and components with metric hardware.
• Standard drive ratchet with extension
• Standard drive torque wrench
• Standard drive sockets: 8, 10, 13, 15, 18 mm
• Open-end wrenches: 8, 10, 13, 15, 18 mm
• Drill and drill bits: 4.6, 5.5, 6.8 mm
• Slot-head screwdrivers
• Locking pliers
• Feeler gauge set (3mm to 8 mm)
• High potential tester
1503-IN050E-EN-P – June 2013
400 Amp Starter Frame Dimensions
23.85
[606]
21.50
[546]
50.36
[1279]
27.22
[691]
OEM Starter Frame Installation 1-3
All dimensions in inches [millimeters]
4 X ø.515 [13]
MOUNTING HOLES
21.17
[538]
FRONT VIEW
Figure 1.1 – Starter Frame Dimensions
Control Panel
1) Mount the control panel in a suitable location. Be aware that the control plug wiring harness is 10 ft. (3 meters) in length. Ensure that the
wiring harness route still allows for a proper connection to the contactor control plug.
2) Connect the control panel harness to the receptacle on the left side of
the contactor. Observe the matching number codes to ensure a proper
connection. See Control Panel, page 2-10, for more information and for
wiring diagrams.
0.97
[25]
21.89
[556]
BOTTOM VIEW
3.83
[97]
1503-IN050D-EN-P – June 2012
1-4 OEM Starter Frame Installation
Installation (Cont.) IntelliVAC
Refer to Publication 1503-UM051_-EN-P or 1503-UM052_-EN-P for
IntelliVAC mounting instructions. Note that a suitable wire harness is
required (1503-WHxxx) to connect IntelliVAC to the vacuum contactor.
Refer to “IntelliVAC”, page 2-10 for more information and wiring diagrams.
Torque Requirements
Use the specifi ed torque values for all hardware whenever performing
maintenance or attaching components.
1/4 in. (M6) hardware
6 ft•lb (8 N•m)
5/16 in. (M8) hardware 12 ft•lb (15 N•m)
3/8 in. (M10) hardware 20 ft•lb (27 N•m)
1/2 in. (M12) hardware 48 ft•lb (65 N•m)
Fuses
Refer to the motor nameplate for the information necessary to determine
correct power fuse size. See page 2-7 for recommended power fuses.
A T T E N T I O NA T T E N T I O N
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 may be installed in the control circuit transformer primary
fuse clips at the top of the contactor (see page 2-24 for details).
Only qualifi ed personnel should select the fuse type and
rating. Failure to select the correct fuses may result in
injury to personnel and/or damage to equipment.
Line and Load Connections
See Incoming Line Connections (page 2-24) and Load Connections (page
2-24).
Commissioning
See Commissioning, Chapter 4.
1503-IN050E-EN-P – June 2013
Chapter 2
Component Installation for 400A Equipment
Component Layout Refer to the following diagram to determine the location of the OEM
components relative to each other.
39.78
[1010]
1.20
[30]
8.96
[228]
10.80
[274]
18.82
[478]
18.55
[471]
I M P O R T A N TI M P O R T A N T
1.00
9.53
[242]
20.89
[531]
[25]
The mounting location of the trailer fuse block varies
depending on the type of power fuses used by the unit.
Figure 2.1 shows the component confi guration for units
using clip-on power fuses and Figure 2.2 shows the component confi guration for units using bolt-on power fuses.
4.60
[117]
22.85
[580]
7.33
[186]
1.19
[30]
37.11
[943]
12.05
[306]
4.44
[113]
10.50
[267]
(All dimensions in inches [millimeters])
Lower Mounting Surface
4.88
[124]
Figure 2.1 – OEM Component Layout (Clip-on Power Fuses)
(Frame and other parts not shown)
Front Mounting Surface
Rear Mounting Surface
11.87
[301]
1503-IN050E-EN-P – June 2013
2-2 Component Installation
Component Layout (cont.)
39.78
[1010]
1.20
[30]
8.96
[228]
16.67
[423]
12.95
[329]
4.44
[113]
18.55
[471]
10.50
[267]
1.00
[25]
9.53
[242]
20.89
[531]
Lower Mounting Surface
4.88
[124]
1.19
[30]
37.11
[943]
22.85
[580]
7.33
[186]
Front Mounting Surface
12.05
[306]
11.87
[301]
4.60
[117]
Rear Mounting Surface
1503-IN050E-EN-P – June 2013
(All dimensions in inches [millimeters])
Figure 2.2 – OEM Component Layout (Bolt-on Power Fuses)
(Frame and other parts not shown)
Component Installation 2-3
The handle is shipped in the OFF, or open, position. All
Mounting Isolation Switch
Handle Module
I M P O R T A N TI M P O R T A N T
instructions assume the handle remains in the OFF
position during installation and adjustment procedures
unless otherwise stated.
Required Hardware:
• Six (6) ¼-20 x 0.5 in. (6.3 x 1.8 x 13mm Type B) self-tapping screws
• One (1) 5/16 in. (M8 x 1.25) grounding wire screw
Refer to the component layout shown in Figure 2.1 or 2.2 to determine the
mounting location and the location of the mounting holes for the isola-
tion switch handle module. Refer to Figure 2.3 for a detailed view of the
mounting holes.
1) Prepare a cut-out in the cabinet for the handle using the dimensions
shown in Figure 2.3.
Isolation Switch Handle
(OFF Position)
2) Drill four (4) 0.281-in. (6.8 mm) clearance holes in the locations indi-
cated for the retaining screws.
1.00
[25 ]
8.2 6
[21 0]
1.74
[4 4]
Front Mounting Surface
Cutout Dimensions
Front Mounting Surface
Cutout Dimensions
0.48
[12 ]
0.6 5
[17 ]
9.53
[242]
4 X Ø 0.281 [6.8]
CLEARANCE HOLES
1.0 0
[2 5]
0.53
[1 4]
4 X 0.21 9 (5.31)Ø
MOUNTING HOLES
9.53
[2 42]
1.06
[27]
Front View
(Handle cut away
to show lower
mounting holes)
Figure 2.3 – Handle Cut-out Dimensions
1503-IN050E-EN-P – June 2013
2-4 Component Installation
Mounting Isolation Switch 3) From the inside of the cabinet, insert the handle through the cut-out and
Handle Module (cont.) line up the pilot holes with the pre-drilled holes in the handle assembly.
Use four (4) ¼-20 (6.3 x 1.8 Type B) self-tapping screws to attach the
front of the handle. Torque the screws according to the specifi cations
shown on page 1-4.
4) Mark the location of the rear mounting tabs of the handle module. Drill
two (2) 0.219-in. (5.5mm) pilot holes (see Figure 2.4).
26.23
[666]
22.67
[576]
4.61
[117]
19.93
[506]
7.02
[178]
13.00
[330]
0.125
[3]
Clearance
Clearance Holes
Rear Mounting Surface
2 X Ø 0.312
See Fig. 2.3
for Punching
Dimensions
Front Mounting Surface
LEFT SIDE VIEW
Grounding Wire
4 X Ø 0.219
Mounting Holes
(All dimensions in inches [millimeters])
Figure 2.4 – Mounting Rear of Isolation Switch Handle Module
FRON
T VIEW
(Cut away to show lower mounting holes)
1503-IN050E-EN-P – June 2013
Component Installation 2-5
5) Install two (2) ¼-20 (6.3 x 1.8 Type B) self-tapping screws in the tabs
at the end of the handle module to attach it to the rear of the cabinet.
Torque the screws according to the specifi cations shown on page 1-4.
The rear mounting tabs may deform slightly when
I M P O R T A N TI M P O R T A N T
secured to the mounting surface. The deformation is
normal and helps to reduce any gap between the handle
module and the mounting surface.
6) Connect the green grounding wire to a suitable grounding surface.
Mounting Isolation Switch Refer to the component layout shown in Figure 2.1 or 2.2 to determine the
and Trailer Fuse Block location of the isolation switch. Refer to Figure 2.6 to determine the
location of the mounting holes for the isolation switch.
Grounding Bar
Shaft
Clearance Holes
Auxiliary Contacts
Inter-phase Barriers
Dome Plugs
Figure 2.5 – Typical Isolation Switch
Required Hardware:
– Eight (8) ¼-20 x 1.0 in. (6.3 x 1.8 x 25mm Type B) self-tapping screws
– Four (4) dome plugs (supplied)
1) Drill four (4) 0.219 in. (5.5 mm) pilot holes in the mounting surface at
Location A as shown in Figure 2.6 for the isolation switch.
2) Attach the isolation switch using four (4) ¼-20 (6.3 x 1.8 Type B)
self-tapping screws. Torque the screws according to the specifi cations
1503-IN050E-EN-P – June 2013
2-6 Component Installation
Mounting Isolation Switch Refer to the component layout shown in Figure 2.1 or 2.2 to determine the
and Trailer Fuse Block (cont.) location of the trailer fuse block. Refer to Figure 2.6 to determine the
location of the mounting holes for the trailer fuse block.
1) Drill four (4) 0.219 in. (5.5 mm) pilot holes at Location B as shown in
Figure 2.6 for the trailer fuse block.
2) Attach the trailer fuse block using four (4) ¼-20 (4.8 x 1.6 Type B)
self-tapping screws. Torque the screws according to the specifi cations
shown on page 1-4.
3) Install a dome plug over each screw.
A T T E N T I O NA T T E N T I O N
Reinstall any inter-phase barriers that were removed
while connecting the trailer fuse block. Failure to do so
may produce an electrical fault between the fuses and
damage the equipment.
18.55
[471]
0.76
[19]
A
8.96
[228]
10.80
[274]
1.20
[30]
B
A
5.25
[133]
17.02
5.00
[127]
18.50
[470]
[432]
5.00
[127]
3.69
[94]
4.78
[121]
A
0.90
[23]
4.00
[102]
B
Terminals
A
1.20
[30]
8.96
[228]
16.67
[423]
0.76
[19]
A
4.94
[125]
5.00
[127]
18.55
[471]
17.02
[432]
B
18.50
[470]
5.00
[127]
3.69
[94]
4.78
[121]
4.00
[102]
A
Terminals
FRONT VIEW (CLIP-ON FUSES)
(Cut away to show upper mounting tabs)
1503-IN050E-EN-P – June 2013
FRONT VIEW (BOLT-ON FUSES)
(Cut away to show upper mounting tabs)
A
Ø 0.310 Isolation switch clearance hole location
Ø 0.310 Trailer fuse block clearance hole location
B
(All dimensions in inches [millimeters])
Figure 2.6 – Orientation of Isolation Switch
Component Installation 2-7
Power Fuses Ferraz-Shawmut medium voltage power fuses are recommeded for the
Bulletin 1503. These motor fuses have been tested and meet the
co-ordination requirements for the Bulletin 1502 vacuum contactor. The
fuses many be purchsed from Rockwell Automation, Ferraz-Shawmut, or
from a local distributor. The following part numbers are available.
(See Figures 2.7 and 2.8 for dimensions of fuses.)
Table 2.1 – Recommended Power Fuses
1503-IN050E-EN-P – June 2013
2-8 Component Installation
Power Fuses (cont.)
1503-IN050E-EN-P – June 2013
(All dimensions in inches [millimeters])
Figure 2.7 – Bolt-on Fuse Dimensions
Component Installation 2-9
Figure 2.8 – Clip-on Fuse Dimensions
(All dimensions in inches [millimeters])
1503-IN050E-EN-P – June 2013
2-10 Component Installation
Contactor Refer to the following publications for the Bulletin 1502 Medium Voltage
Contactor:
• 400A – Publication 1502-UM050_EN-P ( Series D)
• 400A – Publication 1502-UM052_EN-P (Series E)
• 800A – Publication 1502-UM051_EN-P (Series E)
These user manuals contain detailed information on installation, adjustment
and maintenance for this product.
Contactor
Control Wire
Plug
Figure 2.9 – 120V and 230V Control Wire Plug Location and Confi gurations
Note: Refer to the appropriate vacuum contactor User Manual for detailed
wire plug pin confi gurations.
Control Panel Required Hardware:
– Four (4) 1/4-20 x 0.5 in. (6.3 x 1.8 x 13mm Type B) self-tapping screws
Mount the control panel in a suitable location. Be aware that the control plug
wiring harness is 10 ft. (3 meters) in length. Ensure that the wiring harness
route still allows for a proper connection to the contactor control plug.
Connect the control panel harness to the contactor control wire plug on the
lower left side of the contactor. The number codes on the plug must line up
with those on the contactor to ensure a proper connection. See Figure 2.9.
Use the terminal blocks on the control panel to connect the unit to a 120- or
230-volt grounded power source (whichever is applicable to the control panel)
and to other remote devices - see Figure 2.10 or 2.12 for electrical drawings.
IntelliVAC Refer to Publication 1503-UM051_EN-P or 1503-UM052_-EN-P for
information regarding the IntelliVAC control module. Refer to Figure 2.12
or 2.13 for typical electrical drawings.
1503-IN050E-EN-P – June 2013
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