Rockwell Automation Allen-Bradley 1502 - User Manual

Medium Voltage Contactor
800A, 2400-7200 V
Bulletin 1502 (Series D and E)
User Manual

Rockwell Automation Allen-Bradley 1502 Specifications

General

Model	1502
Category	Controller
Type	Programmable Logic Controller (PLC)
Mounting Type	DIN Rail
Communication Protocol	Ethernet/IP
Communication Ports	Ethernet
Operating Temperature	0°C to 60°C

Summary

Important User Information

Contactor Product Description

Scope

Details the manual's coverage of Bulletin 1502, 800A vacuum contactors and their series.

Description

Explains the 800A contactors for high horsepower applications (2400-7200V) and their uses.

Vacuum Bottle Description

Describes the components and function of a typical vacuum bottle, including contacts and bellows.

Contactor Operation

Explains how electrically held and mechanically latched contactors operate via electromagnetism.

Contactor Identification

Explains how to identify contactors using the nameplate and catalog number.

Contactor Catalog Number Explanation

Provides a breakdown of the catalog number's structure and meaning.

Contactor Specifications

Lists voltage, current, frequency, and other operational ratings for the contactors.

Product Approvals

Lists the certifications and approvals for the contactors, such as UL, CSA, and CE.

Receiving and Handling

Receiving

Instructions for checking contactors for shipping damage immediately upon receipt.

Preliminary Inspection

Steps for inspecting contactors for damage and functional checks before installation.

Handling

Guidance on safely handling contactors using cranes, hoists, or forklifts.

Pre-energization Inspection

Final inspection before powering up, checking for damage and proper assembly.

Storage

Recommendations for storing contactors in a clean, dry environment to prevent damage.

Vacuum Bottle Integrity Test

Procedure for testing the dielectric condition and vacuum integrity of vacuum bottles.

Insulation Resistance Test

How to perform an insulation resistance test using a Megger to ensure electrical safety.

Installation

Mounting

Details on how to securely mount the vacuum contactor in its enclosure.

Electrical Connections

Information on connecting power and control wiring to the contactor terminals.

Series D Electrically Held Contactor Wiring and Schematic

Wiring diagram and schematic for Series D, electrically held contactors with normal drop-out.

Series D Electrically Held Contactor Fast Drop-out Wiring and Schematic

Wiring diagram and schematic for Series D, electrically held contactors with fast drop-out.

Series E Electrically Held Contactor Wiring and Schematic

Wiring diagram and schematic for Series E, electrically held contactors using IntelliVAC.

Series D Mechanical Latch Contactor Wiring and Schematic

Wiring diagram and schematic for Series D, mechanical latch contactors.

Series E Mechanical Latch Contactor Wiring and Schematic

Wiring diagram and schematic for Series E, mechanical latch contactors using IntelliVAC.

Typical Electrical Diagram FVNR Controller Series D Electrically Held

A typical electrical diagram for an 800A FVNR controller with Series D contactor.

Typical Electrical Diagram FVNR Controller Series D Mechanical Latch

A typical electrical diagram for an 800A FVNR controller with Series D mechanical latch.

Typical Wiring and Schematic Diagram FVNR Controller Series E Electrically Held

Typical wiring and schematic for an 800A FVNR controller with Series E electrically held contactor.

Typical Wiring and Schematic Diagram FVNR Controller Series E Mechanical Latch

Typical wiring and schematic for an 800A FVNR controller with Series E mechanical latch contactor.

Maintenance

Tool Requirements

Lists the necessary tools for performing maintenance on the vacuum contactor.

Recommended Torque Values

Provides specific torque values for reassembling contactor components.

Routine Maintenance

Outlines the annual maintenance tasks, including cleaning and inspections.

Vacuum Bottle Replacement and Set-up Procedure

Detailed steps for removing, replacing, and setting up vacuum bottles.

Main Coil Replacement Procedure

Step-by-step instructions for replacing the main coil assembly of the contactor.

Mechanical Latch Trip Coil Replacement Procedure

Procedure for replacing the trip coil in mechanical latch contactors.

Mechanical Latch Roller Replacement Procedure

Instructions for replacing the roller in the mechanical latch mechanism.

Mechanical Latch Mechanism Refurbishing Procedure

Steps to refurbish the mechanical latch mechanism by replacing key parts.

Altitude Adjustment

Procedure for adjusting the return spring for different installation altitudes.

Drop-out Time Conversion

Information on converting between normal and fast drop-out times for Series D contactors.

Auxiliary Contact Replacement and Set-up Procedure

Steps for replacing individual contact cartridges or the entire auxiliary assembly.

Troubleshooting

Troubleshooting Table 5.A

A chart listing common symptoms, possible causes, and remedies for contactor issues.

Typical Contactor Coil Resistance Values Table 5.B

A table providing resistance values for different contactor coils.

Renewal Parts

Bulletin 1502, 800 A Electrically Held Vacuum Contactor Parts

Lists part numbers for components of the electrically held contactor.

Mechanical Latch Assembly Parts

Lists part numbers for components specific to the mechanical latch assembly.

Renewal Parts List Table 6.A

A comprehensive list of all available renewal parts with part numbers.