509-6.0: Bulletin 509 3-Phase Full Voltage NEMA …

1 Bull etin 509 3-PhaseFull Voltage NEMA Starters with Eutec tic All oyandSMP Soli d-state Ove rload RelaysSizes 0through4 (all se ries ), Size 5(se riesL)Renewal PartsSize 1with Eutectic All oyOverloadRelaySize 3with Eutectic All oyOverloadRelaySize 5with SMP-- 1 Soli d-stateOverloadRelayImportant:Save renewal parts li st for f uture reference .Desc ription 2..Renewal Parts 3..Operating Coil s 4..Coil Data 4..SMP Soli d-state overload Relay 5.

2 Disass embly 7..Replacing Contacts 7..Movable Contacts 8..Front Stationary Contacts 8..Rear Stationary Contacts 9..Replacing the Stationary Contact Block and Base Ass embly 9..Reass embly 10..Eutectic All oy overload Relay Test Module 10.

3 Replacing the Eutectic All oy overload Relay 11..Replacing the SMP Soli d-state overload Relay 11..Replacing Curr ent Transformer 12..Modifications 14..Auxili ary Contacts 14..Removal of Auxili ary Contact Block 14..Installi ng or Replacing an Auxili ary Contact Block 15..Auxili ary Contact for Eutectic All oy overload Relay 16.

4 Installi ng ( or ) Auxili ary Contact for Eutectic All oy overload Relay or Auxili ary Contact in Place of Circuit Test module onEutectic All oy overload Relay for Sizes 3 and 4 Starters 17..Replacing or Auxili ary Contact on anOverloadRelay(for sizes 3 and 4 Starters) 19..SMP, SMP-1, SMP-2, andSMP-3 are trademarksof All en -Brad ley Company, I of ContentsSize5(seriesL)RenewalPartsBullet in509,Sizes0through4(allseries) ,areeasytowireandservice,simpletoselect, andofferClass10,15,20, ,floatswitches,thermostats,pressureswitc hes,snapswitches,limitswitches, (SMPs)--Solid-stateOverloadsforadditiona lflexibilityinmotorprotection.!ATTENTION :Topreventelectricalshock, exploded illustration, ,overloadrelays, (Specify)Contacts13A3D143F3E14A13D13C3B3 C13E1717 (seriesL)RenewalPartsBulletin509,Sizes0t hrough4(allseries)3 ItemDescriptionofRenewalPartsSize0 Size1 Size2 Size3 Size4 Size5(SeriesL) MovableContactSupportandArmatureAssembly 40410-498-01 SeriesA40410-498-03 SeriesB40420-498-0140430-452-5140440-453 -5142450-801-013 StationaryContactBlockandBaseAssembly404 10-494-0340410-494-0440420-495-0240430-4 62-5240440-462-5242450-307-623 ASaddleClampAssembly(forsize0and1)

5 X-225492 3 BLug X-31601240430-461-5140440-461-5142450-80 4-013 CBolt M-6289M-6532M-6834 3 DFrontTerminalwithoutContact40430-022-02 40440-030-0242450-302-523 ERearTerminalwithoutContact 40430-024-0240440-314-5140440-314-513 FFront/RearTerminalScrew 28168-107-2628168-502-26 4 CoilCover40410-496-0140420-497-0140430-4 54-5140440-454-5142450-803-015 TiePointTerminal599-TP02599-TP346 AuxiliaryContactBlock(refertopage14)J595 -A(usedashold-incontact)7 OperatingCoilSeeTableonpage48 Yoke(50--60Hz)J40410-497-01J40410-497-02 J40430-455-51J40440-458-519 MovableContact10 ContactSpringOrderSinglePoleContactSet11 FrontStationaryContactOrderSinglePoleCon tactSet12 RearStationaryContact9--12 SinglePoleContactSet(includes(1)eachitem 9--12)J40410-331-51J40410-331-52J40420-3 22-51J40430-300-51J40440-300-51J42450-80 5-0113 EutecticAlloyOverloadRelay(includesitem1 3 Btestmodule)42185-800-0140185-800-014018 5-801-0140185-802-01J592-B0V16 13 AEutecticAlloyHeaterElementScrewM-1552 13 BTestModule(includedwithitem13overloadre lay)40185-499-0140430-459-5142450-807-01 13 COverloadRelayAuxiliaryContact(includedw ithitem13) J595-A34 13 DOverloadMountingPlate 40430-045-0240440-028-0242450-028-0213 EJumper 42195-800-0114 SmartMotorProtection(SMP)Solid-stateOver loadRelaySeeTableonpage514 ASMPR esetBarOnly(SMP-1,SMP-2) (3req d)28169-100-2628169-101-2640430-460-5140 440-459-51 16 MountingPlateforEutecticAlloy,SMP-1 ,SMP-2 40410-124-0240420-083-0240430-044-024044 0-027-0216 MountingPlateforSMP-3 40794-031-0240794-032-0240430-044-024044 0-027-0217 CurrentTransformer X-241563 17 ATransformerSpring 42450-806-01 PartsindicatedwithJarerecommendedsparepa rts.

6 Lesscontacts,orderSinglePoleContactSetsa srequired. Forsize5starteracurrenttransformerassemb ly(whichincludesitems13,15,17,and17A) Size0,1,and2 Eutecticalloy,SMP-1, ,4,and5eutecticalloy,SMP-1, (seriesL)RenewalPartsBulletin509,Sizes0t hrough4(allseries) 2460CB013CC013CD013 115--12060CB236CC236CD236CE236AF23611050 CB236CC236CD236CE236AF236110--11550CB322 CC322CD322CE322AF322200--20860CB249CC249 CD249CE249AF249220--23050CB339CC339CD339 CE339AF339230--24060CB254CC254CD254CE254 AF254230--24050CB342CC342CD342CE342AF342 27760CB260CC260CD260CE260AF26038050CB354 CC354CD354CE354AF35441550CB357CC357CD357 CE357AF357440--46050CB360CC360CD360CE360 AF360460--48060CB273CC273CD273CE273AF273 50050CB364CC364CD364CE364AF364575--60060 CB278CC278CD278CE278AF278 PartsindicatedwithJarerecommendedsparepa rts. ForSize5 SeriesAcoils, MotorPoles24 Volts115-120 Volts200-208 Volts230-240 Volts460-480 Volts575-600 VoltsMotorLoadInrushSealedInrushSealedIn rushSealedInrushSealedInrushSealedInrush Sealed02--519229192291922919229192291922 912--519229192291922919229192291922922-- 324029240292402924029240292402924--53153 8315383153831538315383153832--3660456604 56604566045660456604534--584058840588405 884058840588408842--3 12256912256912256912256912256944--5 1490961490961490961490961490965(SeriesL) 2--3 149096149096149096149096149096 For50 Hzcoils, (seriesL)RenewalPartsBulletin509,Sizes0t hrough4(allseries)5 StarterSizeAdjustmentRange(A) ,PhaseLossProtection,Class10,20,or300, , , , , , ,PhaseLossProtection,Class10,20,or300, , , , , , (seriesL)RenewalPartsBulletin509,Sizes0t hrough4(allseries)6 StarterSizeAdjustmentRange(A)

7 Class10,15,20, ,FieldSelectableTripClass10,15,20,or30,P haseLoss,Jam,andGroundFaultProtection0, , , , , , ,FieldSelectableTripClass10,15,20,or30,P haseLoss,JamProtection,GroundFaultProtec tionandCommunicationCapability 0, ,12to10592-C1FA0,17to37592-C1HA27to37592 -C1HC220to75592-C1KC320to90592-C1LD440to 180592-C1ME5 70to300592-C1 NFD ForNEMA starterssizes0--2, , , ,consultyournearestAllen-BradleySalesOff ice. Theratingsofthetriacsandthehardoutputcon tact(relay) sManualforactualratings. (cont.)Size 5(series L)Renewal PartsBull etin 509, Sizes 0 through 4(all series)7!ATTENTION:To prevent elec trica l sho ck, disconnec t fr ompo wer sou rcebefore installi ng or servicing . Install in suit ableenclosure. Kee p fr eefr omcon foll owing proce du res andtec hn iqu es are suggested to aid in thedisass embly andrea ss embly of a typ ica l motor starter . It i s no t necess ary toremov e the starter from its enclosure or to remov e the li ne wiring.

8 Refer toexp lod ed view, Figu re 1 for it emnu e all con trol wires fr om the op erati ngcoil (it em7) andti e po intterminal (it em5). sen two ca pti ve screws andli ft off the con tac t block cov er ( it em1). sen fou r ca pti ve screws fr om the coil cov er ( it em4). The ti e po intterminal i s no w fr eeto be remov ed, if it is to be h the coil cov er screws loo sened, the aux ili ary con tac t block(s)(it em6) ca n be remov ed andthe coil cov er li fted off . ou t t he mov able con tac t support andarmature ass embly (it em2), theyoke (it em8) andthe op erati ngcoil (it em7) as a un it . The yoke andtheop erati ngcoil ca n now be li fted upand out of the mov able con tac tsupport ass severe con tac t wea r is evidence d, it is rec ommend ed that all con tac tsbe replaced, which willgu ard against un even con tac t closing s.

9 Be sure tochec k con tac t springflexibility andreplaceif necess ary. Order the requ irednu mber of sing le po le con tac t sets fr om the part li sti ng s on Page 3. Foll owsteps 1-- 5 under Disass for Stationary Contac t ReplacementSizeFront andRear Torque(approximately)08-- :Torqu e for coil cov er size s 0 to 2are app rox imately 14-- s 3 to 5are app rox imately 25-- tinued on next ingContac tsSize5(seriesL)RenewalPartsBulletin509, Sizes0through4(allseries)8 MovableContactsFigure2 SeatingProjection RefertoFigure2andexplodedview, (item9)bydepressingthecontactspring(item 10) seatingprojection , (item11) :Frontandrearcontactsshouldberemovedandr eplacedinpairs, (frontandrearstationarycontactsareidenti cal) (cont.)Size 5(series L)Renewal PartsBull etin 509, Sizes 0 through 4(all series)9 Rear Stationary ContactsRefer to exp lod ed view, Figu re 1 for it emnu mounti ngscrews or bo lt s that sec ure the rea r stati on ary con tac ts (it em12 ) are access ible fr om the topandare loca ted at an ang le in the caviti esdirec tl y behindthe fr on t t erminal ass embli sen andremov e the mounti ngscrew or bo lt whil e ho ldingthe con tac twit hin the con tac t block ass the loo se con tac t upand out or all ow it to drop the replacement con tac t fr om the topca tchingit fr omwit hin thecon tac t block ass t he mounti ngscrew or bo lt andti gh ten sec Stationary Contact Block andBaseAssemblyRefer to exp lod ed view, Figu re 1 for it emnu block and base ass embly (it em3) ca n be remov ed fr oma parti all ydisass embled starter , if necess ary.

10 First foll ow steps 1-- 5 under Disass block and base ass embly is connec ted to the incomingli nes andtheov erload relay (it em13 ). e the li ne wiringandlabel or mark all block and base ass embly is connec ted by bus to the ov erload sen, bu t do not remov e the threeterminal screws that connec t t heblock and base ass embly to the ov erload relay for size s 0, 1, 2, and size s 3 and 4starters, remov e the threebo lt s that connec t t he blockbase ass embly to the ov erload relay. Then turn the starter ov er so that t hebac k of the mounti ng plate faces up . Remov e the two screws wit hwashers. The ov erload relay wit h the mounti ng plate can be remov ed toexpose the mounti ngscrew wit h washer ( it em15 ). block and base ass embly is sec ured to the mounti ng plate (it em16 )bythreemounti ngscrews wit h washers (it em15 ). Remov e these screwsandthe stati on ary con tac t block and base ass embly (it em3) ca n be li ftedupand new con tac tsarenotbeinginstall ed, remov e stati on ary con tac tsone ata timefr om the old block and base ass embly andinstall them in thesamepositionsin the new ass embly.