Allen-Bradley 1512B User manual

Medium Voltage Controllers, 200/400A Two-High

Cabinet, Standard and Arc-Resistant Enclosure

Publication 1500-UM055H-EN-P

User Manual

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.

Labels may also be on or inside the equipment to provide specific precautions.

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.

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.

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).

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 3

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Replaced inside front cover. Inside Front Cover

Replaced Typical Structure and Typical Nameplate graphics. 10

Added Environmental Conditions. 11

Replaced Center Vertical Channel graphic. 20

Updated procedure for Opening the Medium Voltage Doors. 30

Added step to procedure for Joining Sections. 32

Added information to Attention table. 39

Added information to Attention table. 42

Added information to Attention table. 43

Replaced Typical Ground Bus Splicing Configuration graphic. 47

Updated Isolation Switch Kit and stocking quantity. 79

Added (Series R or higher) to 80158-707-53 79

Added Attention table. 90

Added instructions to Cabinet preparation. 90

Added Attention table. 99

Added instructions to Cabinet preparation. 99

4Rockwell Automation Publication 1500-UM055H-EN-P - February 2015

Summary of Changes

Notes:

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 5

Table of Contents

Chapter 1

General Information

Document Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Starter Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Prepared Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Series Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Motor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Starter Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

High Altitude Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2

Installation – Standard Enclosure

Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Front Access– Access to Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Front Access – Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . 24

Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Top Exiting Load Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Chapter 3

Installation– Arc-ResistantEnclosure

(ArcShield)

Door Opening Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Opening the Low Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Opening the Medium Voltage Doors. . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Anchoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Joining Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Access to the Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Rear Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Side Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Front Access – Access to Power Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Front Access – Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . 39

Load Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Top Exiting Load Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Bottom Exiting Load Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chapter 4

Common Installation

Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Power Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6Rockwell Automation Publication 1500-UM055H-EN-P - February 2015

Table of Contents

Insulated Power Bus Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Incoming Line Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Installation of Current Transformer Barrier . . . . . . . . . . . . . . . . . . . . . . . . 49

Hi-Pot and Megger Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Contactor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Testing Contactor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Chapter 5

Maintenance

Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Recommended Torque Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Door Interlock Circumvention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Power Lock-out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fuse Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Bolt-on Fuse Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Clip-on Fuse Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Contactor Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Removing the Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Contactor Interlock Rod Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

To Reduce the Gap Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

To Increase the Gap Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Isolation Switch Mechanism Inspection and Lubrication . . . . . . . . . . . . 67

Isolation Blade Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Isolation Switch Mechanism Grounding Adjustment. . . . . . . . . . . . . . . . 72

Auxiliary Contacts Inspection and Replacement . . . . . . . . . . . . . . . . . . . . 73

Isolation Switch Auxiliary Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Adjusting the Normally Open (ISa) Contacts . . . . . . . . . . . . . . . . . . . 74

Adjusting the Normally Closed (ISb) Contacts. . . . . . . . . . . . . . . . . . 75

Adjusting the Change-of-State Point . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Emergency Circumvention Procedure for Power Cell Entry. . . . . . . . . . 76

Installing Z-clip with Isolation Switch Handle in the OFF Position . .

Installing Z-clip with Isolation Switch Handle in the ON Position 78

Chapter 6

Spare Parts

Bulletin 1512 and 1512BT Units Parts List. . . . . . . . . . . . . . . . . . . . . . . . . 79

Appendix A

ArcShield Unit Information

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

ArcShield Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Exhaust Systems: Chimney or Plenum Option . . . . . . . . . . . . . . . . . . . . . . 82

Plenum Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Plenum Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 7

Table of Contents

Additional Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Chimney Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Chimney Exhaust Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Appendix B

ArcShield Plenum Installation

Instructions

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Plenum Bracing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 88

STEP 1 – Mounting a Single Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Plenum Placement on Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

STEP 2 – Alignment of “Side-by-Side” Plenums . . . . . . . . . . . . . . . . . . . . 91

STEP 3 – Sequence of Final Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

STEP 4 – Closing the Front of the Plenum Sections . . . . . . . . . . . . . . . . 93

STEP 5 – Extension and Elbow Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 93

STEP 6 – Mounting Extension/Elbow to Plenum “Line-up”. . . . . . . . . 94

STEP 7 – Additional Mounting Support. . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Appendix C

ArcShield Chimney Installation

Instructions

Recommended Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

General Plenum Layout for ArcShield Line-up . . . . . . . . . . . . . . . . . . . . . 98

Cabinet Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Chimney Placement on Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

8Rockwell Automation Publication 1500-UM055H-EN-P - February 2015

Table of Contents

Notes:

Rockwell Automation Publication 1500-UM055H-EN-P - February 2015 9

Chapter 1

General Information

Document Scope This User Manual pertains to the Rockwell Automation Bulletin 1512B medium

voltage controller. The Bulletin 1512B structure includes provisions for two

complete MV controller units.

The installation section provides instructions for both the standard enclosure

type and Rockwell Automation arc resistant type (ArcShield).

The product Bulletin numbers covered by this document are:

•1512B 200/400 A FVNR controller

•1512BT 200/400 A Transformer Feeder

•1512BP 200/400 A Prepared Space(1)

This document may also be used as a reference guide for the following Bulletin

numbers:

•1512DM 200/400 A VFD Input Contactor Units

•1512DO 200/400 A VFD Output Contactor units

•1512M 200/400 A VFD Output Bypass Starter

•1562E 200/400 A MV SMC Flex Solid-State

(up to 4800V) Reduced Voltage Starter

•1591B Incoming Line Unit

•1592BF Fused Load Break Switch for Feeders

•1592BP Fused Load Break Switch for Feeders, prepared space

Starter Identification A structure nameplate is attached to the right-side flange of the structure (see

Figure 1). Refer to the nameplate for information such as series number, section

number, NEMA enclosure type, unit ratings and bus ratings.

IMPORTANT

This document is to be used for all Bulletin 1512B unit types, including arc

resistant (ArcShield™) units. Important information specifically for ArcShield

units can be found in Appendix A, Appendix B and Appendix C.

ATTENTION: Users must refer to the information in Appendix A, Appendix B

and Appendix C to correctly install and maintain ArcShield arc resistant units.

Failure to do so may negate the arc resistant benefits provided by ArcShield,

exposing personnel to risk of serious injury or death.

(1) Not available on arc-resistant designs.

10 Rockwell Automation Publication 1500-UM055H-EN-P - February 2015

Chapter 1 General Information

Figure 1 - Typical Structure Nameplate

A unit nameplate is also found in the low voltage compartment with specific unit

motor application information (see Figure 2).

Figure 2 - Typical Unit Nameplate

Refer to these nameplates whenever you contact Rockwell Automation for

assistance. Be prepared to provide such information as series number, structure

series, unit series, diagram schematic and catalog number.

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