Bulletin 509

NEMA Full Voltage Starters

Bulletin 509
D Broad Range of NEMA

Sizes (009)
D Exceptional Electrical Life D UL Certified Type 2

Coordination
D Dependable Coil Operation D Cost Saving Design D SMP1 or SMP3

Solid-State Overload Relays for Smart Motor Protection

TABLE OF CONTENTS
Description Page Description Page
Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2021 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2225 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Full Load Currents of AC Motors . . . . . . . . . . . . . . . . . . . . . . 27

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overload Relay Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1419

Description
Bulletin 509 starters are designed for full voltage starting of polyphase squirrel cage motors. These starters meet NEMA Standards, are easy to wire and service, simple to select, and offer a broad range of NEMA sizes (009). These starters may be operated by remote control with push buttons, float switches, thermostats, pressure switches, snap switches, limit switches, or any other suitable two or three wire pilot device. All Bulletin 509 Size 009 starters are available with Bulletin 592 Smart Motor Protectors (SMPs) solid-state overloads for additional flexibility in motor protection. See page9 for SMP overload relay information. The Bulletin 592 SMP1 solid-state overload relays directly replace eutectic alloy overload relays that are integral components of assembled Bulletin 505, 509, and 520 NEMA starters.

Conformity to Standards:
NEMA/EEMAC I. C. S. Standards (Industrial Control and Systems)

Approvals:
UL Listed File No. E3125; Guide No. NLDX File No. E10314; Guide No. NPKR CSA Certified LR1234 LR11924

Your order must include:

D Cat. No. of the starter selected. D If required, Cat. No. of any accessories.

Bulletin 509

NEMA Full Voltage Starters

Product Overview

Bulletin 509, Size 2, with SMP1 Solid-State Overload Relay Open Type Without Enclosure

Bulletin 509, Size 4, with SMP1 Solid-State Overload Relay Open Type Without Enclosure

Bulletin 509, Size 5, with SMP3 Solid-State Overload Relay Open Type Without Enclosure

Features
Contactor Exceptional Electrical Life Vertical Lift, Gravity Dropout Shock Absorbing Pads Tongue & Groove Guiding System UL Certified Type 2 Coordination Lifetime Guarantee on Coil Exclusive Shunt Plate Exclusive Thermal Cut-out Overload Self-Powered Class 10 Class 15 Class 20 Class 30 User Selectable Trip Class Phase Loss Jam Ground Fault Automatic Reset Communications Capability Control Functionality Start/Stop, etc. Remote I/O Device Net

Bulletin 509 with SMP1 Solid-State Overload Relay

n n n n n n n n n n n n 2 seconds

Bulletin 509 with SMP3 Solid-State Overload Relay

n n n n n n n n

n n n n n 2 seconds n n

n n n

An automatic reset version of the SMP1 overload relay is available. See page 7.

Bulletin 509

NEMA Full Voltage Starters

Product Selection With SMP Solid-State Overload Relay

Bulletin 509, Size 3 With SMP1 Solid-State Overload Relay Open Type Without Enclosure

Bulletin 509, Size 5 With SMP1 Solid-State Overload Relay Open Type Without Enclosure

Bulletin 509, Size 1, Type 1 With SMP1 Solid-State Overload Relay General Purpose Enclosure With Cover Removed

Type 1 General Purpose Enclosure With Push Buttons and Pilot Light

3 D 600V AC Maximum D 60 Hz D with 3 Pole Overload Protection

Maximum Horsepower Rating Full Load Current Must Not Exceed Continuous Ampere Rating Motor Voltage NEMA Size 00 0 1 2 3 4 5 6 7 8 9 Continuous Ampere Rating 9 18 27 45 90 135 270 540 810 1215 2250 50 Hz 200V 1-1/2 3 7-1/2 10 25 40 75 150 230V 1-1/2 3 7-1/2 15 30 50 100 200 300 450 800 380V 415V 2 5 10 25 50 75 150 300 600 900 1600 460V 575V 2 5 10 25 50 100 200 400 600 900 1600 Open Type Without Enclosure Cat. No. 509-TO-7 509-AO-7 509-BO-7 509-CO-7 509-DO-7 509-EO-7 509-FO-7 509-GO-7 509-HO-7 509-JO-7 509-KO-7 Type 1 General Purpose Enclosure Surface Mounting Cat. No. 509-TA-7 509-AA-7 509-BA-7 509-CA-7 509-DA-7 509-EA-7 509-FA-7 509-GA-7 509-HA -7 509-JA -7 509-KA -7 Type 12 Dust-tight Industrial Use Enclosure Cat. No. Use Size 0 Starter 509-AJ-7 509-BJ-7 509-CJ-7 509-DJ-7 509-EJ-7 509-FJ-7 509-GJ-7 509-HJ-7 509-JJ-7 509-KJ-7

Voltage Suffix Code

The Cat. No. as listed is incomplete. Select a voltage suffix code from the table below to complete the Cat. No. Example: Cat. No. 509-AA-7 becomes Cat. No. 509-AAA-7. For other voltages, consult your nearest Allen-Bradley Sales Office.

Voltage Suffix Code Description Common Control Coil Voltage or Control Transformer Primary (Line) Voltage Hz 50 60 200208V H 220230V P 230240V A 240V T 277V F 380V N 415V I U 440460V Q 460480V B 500V M 550V R 575600V C

Voltage Suffix Code Description Separate Control Hz 50 60 24V K J 110V S 115120V D

7 Overload Relay Code

The Cat. No. as listed is incomplete.Select an overload relay code from page 7 to complete the Cat. No. Example: Cat. No. 509-AAA-7 becomes Cat. No. 509-AAA-A2B.

Does not include line and load lugs. See page 17 for kits. Does not include control circuit transformer and can only be ordered in 120V Separate Control. Includes control circuit transformer for voltage above 120V, enclosed only. Also available in 120V Separate Control (without transformer).

Only available on sizes 00 to 5. When using 24V coils on sizes 4 or 5, an interposing relay may be required. See coil VA values on page 24.

Accessories Page 14 Modifications Page 20

Prices Consult Sales Office or price list

Bulletin 509

NEMA Full Voltage Starters

Product Selection, Continued With SMP Solid-State Overload Relay

Type 4 Watertight Enclosure Stainless Steel

Type 4X Watertight Corrosion-Resistant Enclosure Fiberglass-Reinforced Polyester With Push Buttons and Pilot Light

3 D 600V AC Maximum D 60 Hz D With 3 Pole Overload Protection

Maximum Horsepower Rating Full Load Current Must Not Exceed Continuous Ampere Rating Motor Voltage 50 Hz NEMA Size 00 0 1 2 3 4 5 6 7 8 9 Continuous Ampere Rating 9 18 27 45 90 135 270 540 810 1215 2250 200V 1-1/2 3 7-1/2 10 25 40 75 150 230V 1-1/2 3 7-1/2 15 30 50 100 200 300 450 800 380V 415V 2 5 10 25 50 75 150 300 600 900 1600 460V 575V 2 5 10 25 50 100 200 400 600 900 1600 Type 4 Watertight Enclosures Size 05 Stainless Steel Cat. No. Use Size 0 Starter 509-AC-7 509-BC-7 509-CC-7 509-DC-7 509-EC-7 509-FC-7 509-GC-7 509-HC-7 509-JC-7 509-KC-7 Type 4X Watertight Corrosion-Resistant Enclosure Fiberglass-Reinforced Polyester Cat. No. Use Size 0 Starter 509-AS-7 509-BS-7 509-CS-7

Voltage Suffix Code

The Cat. No. as listed is incomplete. Select a voltage suffix code from the table below to complete the Cat. No. Example: Cat. No. 509-AC-7 becomes Cat. No. 509-ACA-7. For other voltages, consult your nearest Allen-Bradley Sales Office.

Voltage Suffix Code Description Common Control Coil Voltage or Control Transformer Primary (Line) Voltage Hz 50 60 200208V H 220230V P 230240V A 240V T 277V F 380V N 415V I U 440460V Q 460480V B 500V M 550V R 575600V C

Voltage Suffix Code Description Separate Control Hz 50 60 24V K J 110V S 115120V D

7 Overload Relay Code

The Cat. No. as listed is incomplete. Select an overload relay code from page 7 to complete the Cat. No. Example: Cat. No. 509-ACA-7 becomes Cat. No. 509-ACA-A2B.

Fiberglass Reinforced Polyester Hubs are included with each starter. Does not include line and load lugs. See page 17 for kits. Includes control circuit transformer for voltage above 120V, enclosed only. Also available in 120V Separate Control (without transformer). Accessories Page 14 Modifications Page 20

Only available on sizes 00 to 5. When using 24V coils on sizes 4 or 5, an interposing relay may be required. See coil VA values on page 24.

Prices Consult Sales Office or price list

Bulletin 509

NEMA Full Voltage Starters

Product Selection, Continued With SMP Solid-State Overload Relay

Unilock Enclosure

Bulletin 509, Size 1 With SMP1 Solid-State Overload Relay Bolted Enclosure (Shown with Cover Open)

3 D 600V AC Maximum D 60 Hz D With 3 Pole Overload Protection

Maximum Horsepower Rating Full Load Current Must Not Exceed Continuous Ampere Rating Motor Voltage Continuous Ampere Rating 18 27 45 90 135 270 50 Hz 200V 3 7-1/2 10 25 40 75 230V 3 7-1/2 15 30 50 100 380V 415V 5 10 25 50 75 150 460V 575V 5 10 25 50 100 200 Hazardous Locations Unilock Enclosures Type 3R, 7 & 9 Class I, Groups C & D Class II, Groups E, F & G Divisions 1 & 2 Cat. No. 509-AU-7 509-BU-7 509-CU-7 509-DU-7 509-EU-7 509-FU-7 Bolted Enclosures Type 7 & 9 Class I, Groups C & D Class II, Groups E, F & G Divisions 1 & 2 Cat. No. 509-AE-7 509-BE-7 509-CE-7 509-DE-7 509-EE-7 509-FE-7 Type 3R, 7 & 9 Class I, Groups C & D Class II, Groups E, F & G Divisions 1 & 2 Cat. No. 509-AH-7 509-BH-7 509-CH-7 509-DH-7 509-EH-7 509-FH-7

NEMA Size 0 1 2 3 4 5

Voltage Suffix Code

The Cat. No. as listed is incomplete. Select a voltage suffix code from the table below to complete the Cat. No. Example: Cat. No. 509-AC-7 becomes Cat. No. 509-ACA-7. For other voltages, consult your nearest Allen-Bradley Sales Office.

Voltage Suffix Code Description Common Control Coil Voltage or Control Transformer Primary (Line) Voltage Hz 50 60 200208V H 220230V P 230240V A 240V T 277V F 380V N 415V I U 440460V Q 460480V B 500V M 550V R 575600V C

Voltage Suffix Code Description Separate Control Hz 50 60 24V K J 110V S 115120V D

7 Overload Relay Code

The Cat. No. as listed is incomplete. Select an overload relay code from page 7 to complete the Cat. No. Example: Cat. No. 509-AUA-7 becomes Cat. No. 509-AUA-A2B.

For NEMA Type 3R application it is necessary that a drain or breather and drain combination fitting be added. Includes drain and cover gasket. NEMA Size 5 Unilock enclosed starters have a Continuous Ampere Rating of 210 amps. When using 24V coils on size 4 or 5, an interposing relay may be required. See coil VA values on page 24.

Accessories Page 14 Modifications Page 20

Prices Consult Sales Office or price list

Bulletin 509

NEMA Full Voltage Starters

Typical Wiring Diagrams
(See Applicable Codes and Laws)
A L1 L2 L3 A 3 Phase Lines L1 Separate Control Disconnect wire A from L2 when coil is to operate on a voltage other than line voltage. Reconnect to separate control power source. Auxiliary Contacts (optional) 3 L2 L3 Separate Control Disconnect wire A from L2 when coil is to operate on a voltage other than line voltage. Reconnect to separate control power source. Note Polarity Marking
CT2 CT3 O.L.

3 2
CT1

T1

T2

T3 T1 T2 T3

Ground

Motor

Motor

Size 0-4
Non-Reversing Starter with SMP1 Overload Relays To Voltage Source

Size 5
Non-Reversing Starter with SMP1 Overload Relays To Voltage Source NOTE: Control Transformer Must Be 500 VA Minimum with 5% Regulation Maximum.
H2 H1

Control Circuit Fuses (When Used)

Primary Fuses (When Used)

H3 H4

FUSE (When Used) STOP 2 START 3 CR M OL 1 STOP 2 M X 1 START 3 X 2

GRD TRANS.

OL CR

CR M

CR M

Size 6 Open Type

Non-Reversing Starter with SMP1 Overload Relays Control Circuit Schematic for Separate Control with Interposing Relay

Size 6 Enclosed Type

Non-Reversing Starter with SMP1 Overload Relays Control Circuit Schematic with Control Transformer and Interposing Relay Primary Fuses (When Used)
H2 H1

L1

L2

J H3
H4

FUSE (When Used) 1 START STOP 2 3 X 1 X 2

TRANS.

GRD

CR CR 2RES

13

OL

1RES + CR 5 CR 7 M 8

12 CR

RECT 9 8

(L.B) 1 ECON CAPS

2 ECON CAPS

MOV

Size 7 & 8
Non-Reversing Starter with SMP1 Overload Relay

Product Selection Pages 35

Bulletin 592

SMP Solid-State Overload Relays

SMP Overload Relay Codes
SMP1 Overload Relay Codes For Use With NEMA Sizes
00 00 00 00 00 0,1 0,1 0,1 0,1 0,1 0,1 1 2 2 2 3 3 3 4 4 4 5 6 7 8 9

Full Load Current Adjustment Range

0.10.32 0.321.0 1.02.9 1.65.0 3.712 0.10.32 0.321.0 1.02.9 1.65.0 3.712 5.718 1238 5.718 1238 1445 1445 2375 66110 2375 66110 57180 96300 200630 256810 3841215 802250

Manual Reset Class 10

A1A A1C A1D A1E A1F A1A-X30 A1C-X30 A1D-X30 A1E A1F A1G A1H A1G A1H A1J A1J A1K A1L A1K A1L A1M A1N A1R A1S A1T A1V

Manual/Automatic Reset V Class 10

A4A A4C A4D A4E A4F A4A-X30 A4C-X30 A4D-X30 A4E A4F A4G A4H A4G A4H A4J A4J A4K A4L A4K A4L A4M A4N A4R A4S A4T A4V

Class 20
A2A A2C A2D A2E A2F A2A-X30 A2C-X30 A2D-X30 A2E A2F A2G A2H A2G A2H A2J A2J A2K A2L A2K A2L A2M A2N A2R A2S A2T A2V

Class 30
A3A A3C A3D A3E A3F A3A-X30 A3C-X30 A3D-X30 A3E A3F A3G A3H A3G A3H A3J A3J A3K A3L A3K A3L A3M A3N A3R A3S A3T A3V

Class 20
A5A A5C A5D A5E A5F A5A-X30 A5C-X30 A5D-X30 A5E A5F A5G A5H A5G A5H A5J A5J A5K A5L A5K A5L A5M A5N A5R A5S A5T A5V

Class 30
A6A A6C A6D A6E A6F A6A-X30 A6C-X30 A6D-X30 A6E A6F A6G A6H A6G A6H A6J A6J A6K A6L A6K A6L A6M A6N A6R A6S A6T A6V

These SMP1 Solid-State Overload Relays have an interposing relay with 120V coils. See wiring diagrams on page 6.

Prices Consult Sales Office or price list

Bulletin 509

SMP Solid-State Overload Relays for Installation on NEMA Starters

SMP Overload Relay Codes, Continued
SMP3 Overload Relay Codes Full Load Current Adjustment Range
0.72.5 210 0.72.5 210 737 737 2075 40180 40180 70300 140630 160810 2401215 5002250

Automatic/Manual Reset with Communications Class 10, 15, 20, 30

C1D C1F C1D C1F C1H C1H C1K C1M-X31 C1M-X31 C1N C1R C1S C1T C1V

For Use With NEMA Sizes

00 00 0, 1 0, 1 0, 1 2 2 3 4 5 6 7 8 9

Allen-Bradley recommends using 120 or 240V AC coils on all SMP3 NEMA Starters. When using coil voltages other than 120 or 240V AC. Consult your nearest Allen-Bradley Sales Office. The ratings of the triacs and the hard output contact (relay) internal to the SMP3 must not be exceeded. See the SMP3 Users Manual for actual ratings, or consult page 12 for specifications. Consult your nearest Allen-Bradley Sales Office for availability of enclosed NEMA starters with SMP3 Solid-State Overload Relay. These SMP3 overload relays have an interposing relay with a 120V coil. Consult your nearest Allen-Bradley Sales Office if using on other voltages.

Prices Consult Sales Office or price list

Bulletin 592

Solid-State Overload Relays for Installation in NEMA Starters

Bulletin 592
SMP1 Overload Relay D Self Powered wires the same as eutectic overload D Phase Loss Protection trips in 2 seconds on loaded motors D No Heaters 3:2:1 adjustment range is equivalent of up to 10 heater elements D Directly interchangeable mounting and reset locations are identical to eutectic overloads D Independent Trip Classes 10, 20, or 30 D Manual Reset or Automatic/Manual Reset both versions are available

Cat. No. 592-A2AT

Cat. No. 592-A5KD

Cat. No. 592-A2JC

Cat. No. 592-A5RGD

Cat. No. 592-A2NF

TABLE OF CONTENTS
Description Page Description Page
Product Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1011 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1213, 2225 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1419

Description
The Bulletin 592 SMP1 solid-state overload relays directly replace eutectic alloy overload relays that are integral components of assembled Bulletin 505, 509, and 520 NEMA starters.

Conformity to Standards:
IEC 801 UL 508 CSA C22.2 No. 14

Approvals:
CSA Certified UL Listed

Your order must include:

D Cat. No. of overload relay selected with voltage suffix code. D If required, Cat. No. of Bulletin 509 NEMA starter less overload relay. D If required, Cat. No. of any accessories.

Bulletin 592

Solid-State Overload Relays for Installation in NEMA Starters

Product Selection
SMP1 Overload Relay Manual Reset, Phase Loss Protection, Class 10, 20 or 30 Class 10 Adjustment Range (A)
0.1 to 0.32 0.32 to 1.0 1.0 to 2.9 1.6 to 5.0 3.7 to 12 1.6 to 5.0 3.7 to 12 5.7 to 18 12 to 38 5.7 to 18 12 to 38 14 to 45 14 to 45 23 to 75 66 to 110 23 to 75 66 to 110 57 to 180 96 to 300 200 to 630

For Installation on Bulletin 505 or 509 Starter Size

00 00
Cat. No. 592-A2AT

Class 20 Cat. No.

592-A2AT 592-A2CT 592-A2DT 592-A2ET 592-A2FT 592-A2EA 592-A2FA 592-A2GA 592-A2HA 592-A2GC 592-A2HC 592-A2JC 592-A2JD 592-A2KD 592-A2LD 592-A2KE 592-A2LE 592-A2ME 592-A2NF 592-A2RGD

Class 30 Cat. No.

592-A3AT 592-A3CT 592-A3DT 592-A3ET 592-A3FT 592-A3EA 592-A3FA 592-A3GA 592-A3HA 592-A3GC 592-A3HC 592-A3JC 592-A3JD 592-A3KD 592-A3LD 592-A3KE 592-A3LE 592-A3ME 592-A3NF 592-A3RGD

Cat. No.
592-A1AT 592-A1CT 592-A1DT 592-A1ET 592-A1FT 592-A1EA 592-A1FA 592-A1GA 592-A1HA 592-A1GC 592-A1HC 592-A1JC 592-A1JD 592-A1KD 592-A1LD 592-A1KE 592-A1LE 592-A1ME 592-A1NF 592-A1RGD

00 00 00 0, 1 0, 1 0, 1 1 2

es este, tendremos algo parecido en squard, siemens o telemecanique

Cat. No. 592-A2JC

2 2 3 3 3 4

Cat. No. 592-A2NF

4 4 5 6

Bulletin
505 505X 509

Retrofit Kit for Size 00 Starters Cat. No.

599-RAT 599-RAX 599-NAT

Price
$ 30 30 30

Cat. No. 599-NAT

Specifications Pages 1213 Accessories Pages 1419

10

Prices Consult Sales Office or price list

Bulletin 592

Solid-State Overload Relays for Installation in NEMA Starters

Product Selection, Continued
SMP1 Overload Relay Automatic/Manual Reset, Phase Loss Protection, Class 10, 20 or 30 Class 10 Adjustment Range (A)
0.1 to 0.32 0.32 to 1.0 1.0 to 2.9 1.6 to 5.0 3.7 to 12 1.6 to 5.0 3.7 to 12 5.7 to 18 12 to 38 5.7 to 18 12 to 38 14 to 45 14 to 45 23 to 75 66 to 110 23 to 75 66 to 110 57 to 180 96 to 300 200 to 630

For Installation on Bulletin 505 or 509 Starter Size

00 00 00 00
Cat. No. 592-A5AT

Class 20 Cat. No.

592-A5AT 592-A5CT 592-A5DT 592-A5ET 592-A5FT 592-A5EA 592-A5FA 592-A5GA 592-A5HA 592-A5GC 592-A5HC 592-A5JC 592-A5JD 592-A5KD 592-A5LD 592-A5KE 592-A5LE 592-A5ME 592-A5NF 592-A5RGD

Class 30 Cat. No.

592-A6AT 592-A6CT 592-A6DT 592-A6ET 592-A6FT 592-A6EA 592-A6FA 592-A6GA 592-A6HA 592-A6GC 592-A6HC 592-A6JC 592-A6JD 592-A6KD 592-A6LD 592-A6KE 592-A6LE 592-A6ME 592-A6NF 592-A6RGD

Cat. No.
592-A4AT 592-A4CT 592-A4DT 592-A4ET 592-A4FT 592-A4EA 592-A4FA 592-A4GA 592-A4HA 592-A4GC 592-A4HC 592-A4JC 592-A4JD 592-A4KD 592-A4LD 592-A4KE 592-A4LE 592-A4ME 592-A4NF 592-A4RGD

00 0, 1 0, 1 0, 1 1 2 2 2

Cat No. Cat. No 592-A5KD

3 3 3 4 4 4 5
Cat. No. 592-A5RGD

Bulletin
505 505X 509

Retrofit Kit for Size 00 Starters Cat. No.

599-RAT 599-RAX 599-NAT

Price
$ 30 30 30

Cat. No. 599-NAT

Specifications Pages 1213 Accessories Pages 1419

Prices Consult Sales Office or price list

11

Bulletin 592

Solid-State Overload Relays for Installation in NEMA Starters

Specifications
Electrical SMP1
Rated Thermal Current of Contacts Ith Electrical Rating of Contacts NEMA Rating Designation B600 (AC) Voltage 120V 240V 480V 600V 24V 110V 220V 440V 5A Trip 9596 N.C. 3.0A 1.5A 0.75A 0.60A 1.1A 0.4A 0.2A 0.08A 600V 50/60 Hz

(DC)

Rated Insulation Voltage CSA/UL Control Voltage Operating Frequency

Mechanical SMP1
Body Material Contact Material Control Contacts Terminal Marking Max. Wire Size Size 00 Size 0 Size 1 Size 2 Size 3 Size 4 Size 5 Size 6 Control Terminals 1 or 2 1812 AWG 1410 AWG 148 AWG 144 AWG 81/0 AWG 64/0 AWG 4500 MCM AWG 500 MCM AWG 12 AWG NEMA and Cenelec EN 50012 Thermoplastic Fine Silver

Environmental SMP1
Operation Storage Temperature Compensation Altitude 25C to 55C (13F to 131F) 50C to 70C (58F to 158F) 25C to 55C (13F to 131F) 2000M

SMP1 Wiring Schematic

L1/1 L2/3 L3/5 95 97

96 T1/2 T2/4 T3/6

98

Typical NEMA Wiring Schematic

12

SMP1 and SMP3 Solid-State Overload Relays

Specifications, Continued Typical Tripping Curves for SMP Overload Relays
Class 10 Overload Relay The tripping time of the SMP overload relays can be estimated using the tables above and to the right. 1. Select the tripping class desired. 2. Locate the intersection of the approximate trip time curve with the proper multiple of current-setting found on the horizontal axis. 3. Read the approximate trip time in seconds along the vertical axis.
1000
800 600 400

Bulletin 592

1000
800 600 400

Class 20

200

200

Approximate Trip Time (sec)

100
80 60 40

100
Approximate Trip Time (sec)
80 60 40

20

20

10
8 6 4

Approximate trip time for 3 phase balanced condition from cold start.

10
8 6 4

Approximate trip time for 3 phase balanced condition from cold start.

2 Approximate trip time for 3 phase balanced condition from hot start.

1 1 1.2
2 4 6 8

Approximate trip time for 3 phase balanced condition from hot start.

1 1 1.2
2 4 6 8

10

10

Multiples of Full Load Current

Multiples of Full Load Current

Class 15 (SMP3 Overload Relays Only)

1000
800 600 400

Class 30
1000
800 600 400

200

200

100
Approximate Trip Time (sec)
60 40

100
Approximate Trip Time (sec)
80 60 40 Approximate trip time for 3 phase balanced condition from cold start.

80

20 Approximate trip time for 3 phase balanced condition from cold start.

20

10
8 6 4

10
8 6 4 Approximate trip time for 3 phase balanced condition from hot start.

1 1 1.2
2 4 6 8

Approximate trip time for 3 phase balanced condition from hot start.

1 1 1.2
2 4 6 8

10

10

Multiples of Full Load Current

Multiples of Full Load Current

13

Bulletin 500 Line

Accessories Field Installed

Accessories
Description Used With Pkg. Qty. Cat. No. V

Anti-Tamper Shield

SMP1 SMP2

193-BC4

Current Adjustment Shield

SMP1 SMP2

193-BC5

Remote Reset Solenoid

SMP1 SMP2

193-ER1

Communication Module

SMP3 Remote I/O Comm Adapter (120/240V Power)

1203-GD1

Human Interface Module

SMP-3

193-HIM1

Cable Length 1/3 meter Communication Cable SMP-3 1 meter 3 meters 10 meters Illuminated Push Button Reset SMP-3 1 meter Remote Reset Cable SMP3 3 meters 6 meters 1 1 1

1202-C03 1202-C10 1202-C30 1202-C90 800T-NX1311 1202-RRC1 1202-RRC3 1202-RRC6

Voltage Suffix Code

The Cat. No. as listed is not complete. Select a voltage code from the table below to complete the Cat. No. Example: Cat. No. 193-ER1 becomes 193-ER1A. For other voltages, consult your local Allen-Bradley Sales Office.

Voltage
60 Hz 50 Hz DC

24
J J Z24

48
Z48

110
D

115
Z01

120
D

220
A

240
A

These accessories require removal of the large, white Reset button that is factory installed on all SMP1 overload relays on NEMA starters. This large, white reset button provides the capability for external reset on enclosed NEMA starters. The Current-Adjustment Shield and Remote Reset Solenoid can be installed simultaneously. However, neither may be used in conjunction with the Anti-Tamper Shield.

14

Prices Consult Sales Office or price list

Bulletin 500 Line

Accessories Field Installed

Accessories, Continued
Description
AUXILIARY CONTACTS FOR CONTACTORS AND STARTERS A maximum of 4 auxiliary contact blocks (8 contacts max.) can be field installed. Contacts in the double circuit block are electrically isolated. N.O. Auxiliary Contact The N.O. contact is designed to be open when the contactor or starter is de-energized. N.C. Auxiliary Contact The N.C. contact is designed to be closed when the contactor or starter is de-energized. No overlap is provided with the standard N.O. contact. N.C. Late Break Used in combination with the normally open auxiliary contact to provide overlapping auxiliary contacts. Maximum AC Contact Rating Per Pole Amperes AC Rating Designation Heavy Duty Maximum Voltage 60 or 50 Hz 120 240 480 600 Voltamperes

NEMA Size

Cat. No.
595-A (1 N.O.) 595-B (1 N.C.)

0-5 (See page 19)

595-AB (1 N.O-1 N.C.) 595-AA (2 N.O.) 595-BB (2 N.C.) 595-BL (1 N.C. Late Break)

Cat. No. 595-AB N O 1 N.C.) NC) (1 N.O.

Make 60 30 15 12

Break 6 3 1.5 1.2

Continuous Carrying Current (Amperes) 10 10 10 10

Make 7200 7200 7200 7200

Break 720 720 720 720 6-9

See page 19.

TIMER ATTACHMENT KIT A pneumatic timer attachment may be field installed in the space of two adjacent auxiliary contact blocks. Timing units are available for either On Delay or Off Delay operations with a timed set of one (1) N.O. and one (1) N.C. snap action contacts that are electrically isolated. Adjustment within the timer range of 0.1 to 180 seconds is accomplished by means of a ten turn knurled knob. Repetitive accuracy within the timer range is approximately 10% provided a minimum reset time of 75 milliseconds is allowed. Note: 1. Sizes 0-5: Timers can be added to the left- or right-hand side of the contactor body. On Size 00 they can be mounted to the front of the contactor. 2. Size 0, 1 and 2: Timers cannot be used on the same side as power pole adders. 3. Size 2 Devices: The operating coil must be changed. See page and refer to the Size 2 operating coil listing. Order the coil listed for a 4-5 pole device. 4. Enclosed Devices: Contact your nearest Allen-Bradley Sales Office. Maximum AC Contact Rating Per Pole Amperes
Cat. No. 596-TR32

00 Open Type Only

196-FTA (On Delay) 196-FTB (Off Delay) 596-TL32 (Left Hand) (On Delay)

AC Rating Designation A600

Maximum Voltage 60 or 50 Hz 120 240 480 600

Make 60 30 15 12

Break 6 3 1.5 1.2

Continuous Carrying Current (Amperes) 10 10 10 10

Voltamperes

0-5

596-TL33 (Left Hand) (Off Delay) 596-TR32 (Right Hand) (On Delay) 596-TR33 (Right Hand) (Off Delay)

Make 7200 7200 7200 7200

Break 720 720 720 720

Prices Consult Sales Office or price list

15

Bulletin 500 Line

Accessories Field Installed

Accessories, Continued
Description NEMA Size Cat. No.
599-P01A (1 N.O.) 0-1 599-P01B (1 N.C.) 599-P01BL (1 N.C. Late Break) 599-P2A (1 N.O.) POWER POLE ADDERS The N.O. and N.C. power poles may be field added to all Size 0-4 Bulletin 500 line starters. Each adder pole kit includes a mechanical load balancer to be used when only one power pole is added. 2 599-P2B (1 N.C.) 599-P2BL (1 N.C. Late Break) 599-P3A (1 N.O.) 599-P3B (1 N.C.) 599-P4A (1 N.O.) 599-P4B (1 N.C.)

C No. 599-P01A ( O) Cat. (1 N.O.) Size 0-1, 27 Amps.

0, 1 (Bulletin 509 with SMP-1 Overload Relay Only) ADAPTER PLATES For easy replacement of: D Allen-Bradley (Bulletin 709) D Cutler Hammer (Citation & Freedom Series) D Furnas (Class 14 and ESP 100) D General Electric (Series 300) D Joslyn-Clark (Type HP) D Square D (Type S) D Westinghouse (A200 and W200 Advantage) 2

599-CP01

599-CP2

Cat. No. 599-CP01

Cat. No. 599-CP2

CONTROL CIRCUIT FUSING KITS Rejection type control circuit fuse holder designed to accept one Class CC Bussman KTK-R or equivalent fuse with 200,000 ampere interrupting capacity and reject all others. Fuse holders may be mounted on each starter in any one of the four auxiliary contact pockets available. A bracket for panel mounting is also included.

0-5

599-FR04

16

Prices Consult Sales Office or price list

Bulletin 500 Line

Accessories Field Installed

Accessories, Continued
Description
TIE POINT TERMINAL The tie point terminal provides a convenient terminal point for control circuit wiring. One tie point is supplied AS STANDARD on the right side of the coil cover on the Bulletin 509 starters. A second terminal may be added to the left side of the coil cover.

NEMA Size
0-1-2 3-4-5

Cat. No.
599-TP02 599-TP34

DEVICE MARKERS Snap easily into the coil cover of starters for component identification. A maximum of five markers will fit on each starter. (Standard: 50 Device Markers per Package)
Bulletin 500 with Device Markers

0-5

599-DM 5

0-1 TOP WIRING KIT Consists of (3) power lugs for the purpose of making extra connections to the load side of the contactor. A second set of overload relays can be wired to these lugs if two motors are being controlled by a single contactor.
Cat. No. 599-TW01

599-TW01 599-TW2 599-TW3 599-TW4 599-TW5P 199-LJ1 199-LG1

2 3 4 5

Two 1/0-500 MCM AWG 1 Required per terminal TERMINAL LUGS (Standard: 3 Lugs per Package) #4-500 MCM AWG 3 Required per terminal for Size 7 and 4 Required per terminal for Size 8.

6 7-8

To complete Cat. No. insert in the third position the desired numeric symbol (0 through 9) or one of the following letters A, B, C, D, E, F, H, L, M, P, R, S, T, U, or W.

Bulletin 1490 Non-Metallic Conduit Hubs (Conduit Connectors)

Conduit Connector (Hub) Size (inches) mm (1/2) 12.7 (3/4) 19 (1) 25.4 (1-1/4) 31.75 (1-1/2) 38.1 (2) 50.8 (2-1/2) 63.5 Cat. No. 1490-N1 1490-N9 1490-N10 1490-N11 1490-N5 1490-N6 1490-N7 1490-N8

Grounding Bushing

Wire Range #14-#10 #14-#8 #14-#8 #14-#4 #8-#1/0 #8-#1/0 #6-#2/0 #6-#4/0

Cat. No. 1490-N19 1490-N20 1490-N21 1490-N22 1490-N23 1490-N24 1490-N25 1490-N26

(1-1/4) 31.75 Hub Cat. No. 1490-N11

(1) 25.4 Grounding Adapter Cat. No. 1490-N21 (Includes Lock Nut)

(3) 76.2

For Use on Type 4X Combination Starters

Conduit Connector (Hub) NEMA Size 0-1 2 3 4 5 6 Size (inches) mm (3/4) 19 (1) 25.4 (3/4) 19 (1-1/4) 31.75 (3/4) 19 (1-1/2) 38.1 (3/4) 19 (2-1/2) 63.5 (3/4) 19 (3) 76.2 (3/4) 19 (3) 76.2 No. included 1 2 1 2 1 2 1 2 1 2 1 4 Grounding Bushing Cat. No. 1490-N20 1490-N21 1490-N20 1490-N22 1490-N20 1490-N23 1490-N20 1490-N25 1490-N20 1490-N26 1490-N20 1490-N26

Grounding Bushings Bulletin 1490 grounding adapters are available for use with these conduit hubs. These bushings provide a convenient method of connecting a ground wire to the conduit system Approximate Dimensions Dimensions are shown in (inches) millimeters. Dimensions are not to be used for manufacturing purposes.
Grounding Bushings are necessary for NEMA Type 4X installations using metallic conduit as a ground conductor. Grounding Bushings provide a method of bonding between conduit connectors and internal devices for the purpose of creating a continuous ground path. See table to the left for proper size.

Prices Consult Sales Office or price list

17

Bulletin 500 Line

Accessories Field Installed

Accessories, Continued
Description NEMA Size Cat. No.
195-FA20 (2 N.O.) 195-FA11 (1 N.O. 1 N.C.) AUXILIARY CONTACT ADDER DECKS The same 2 and 4 pole auxiliary contact blocks in various combinations of normally open and normally closed will slide and snap onto the front of the contactor. Adder decks have convenient backed out wire clamps to make lugging of control wires unnecessary. Fits on Open Type devices only. 195-FA02 (2 N.C.) 00 195-FA40 (4 N.O.) 195-FA31 (3 N.O. 1 N.C.) 195-FA22 (2 N.O. - 2 N.C.)
4 Pole

195-FA04 (4 N.C.) 24 VOLT DC INTERFACE MODULE Mounts to the top of the contactor. It provides a 24 volt DC, 0.5 watt input signal which can be used to operate the 24-240 volt AC coil of the contactor. Total operating times are 22-32 milliseconds for pick-up and 14-20 milliseconds for drop-out. Fits on Open Type devices only. LATCH ATTACHMENT On the front of the contactor. Fits on Open Type devices only. The unlatch VA (continuously rated) are as follows: Inrush: 14.4 at 60 Hz and 13.0 at 50 Hz Seal: 3.7 at 50/60 Hz

00

199-FIMZ24

00

197-FL

00 SURGE SUPPRESSOR Made to be easily mounted directly across the coil terminals of starters with 120 or 240 volt AC coils. The purpose of the suppressor is to limit voltage transients for applications requiring interface with solid state components. One suppressor is required per coil.

120 Volts 199-FSMA1 240 Volts 199-FSMA2 120 Volts 599-K04 240 Volts 599-KA04 199-FSMA1 199-GSMA1 700-N24

0-5

6
Cat No. No 599-K04 Cat.

7-8

INTERPOSING CONTACTOR (120V 60 Hz) For Open Type Size 6, Bulletin 509 starters with 120 volt Control.

500-NX3

Voltage Suffix Code

The Cat. No. as listed is incomplete. Select a voltage suffix code from the table below to complete the Cat. No. Example: Cat. No. 197-FL becomes Cat. No. 197-FLA1. For other voltages, consult your nearest Allen-Bradley Sales Office. Voltage 50 Hz 60 Hz 24V B24 A24 110V A1 120V A1 220V A2 240V A2 380V B3 415V B41 -

For use on the interposing relay. For use on the contactor or starter.

18

Prices Consult Sales Office or price list

Bulletin 500 Line

Accessories Field Installed

Accessories, Continued
Description of Accessory Kit
Control Circuit Transformer 208V Pri. 120V Sec., 60 Hz 220/440V Pri. 110V Sec., 50 Hz 240/480V Pri. 120V Sec., 60 Hz 550V Pri. 110V Sec., 50 Hz 600V Pri. 120V Sec., 60 Hz 100 Watt Extra Capacity 208V Pri. 120V Sec., 60 Hz 220/440V Pri. 110V Sec., 50 Hz 240/480V Pri. 120V Sec., 60 Hz 550V Pri. 110V Sec., 50 Hz 600V Pri. 120V Sec., 60 Hz Auxiliary Contact Blocks For Mounting on Contactor or Starter One Normally Open (1 N.O.) Two Normally Open (2 N.O.) One Normally Closed (1 N.C.) Two Normally Closed (2 N.C.) One Normally Open and Closed (1 N.O. 1 N.C.) One Normally Closed Late Brake (1 N.C.LB.) For additional information, see page 15. 595-A 595-AA 595-B 595-BB 595-AB 595-BL 595-A 595-AA 595-B 595-BB 595-AB 595-BL 595-A 595-AA 595-B 595-BB 595-AB 595-BL 595-A 595-AA 595-B 595-BB 595-AB 595-BL 195-GA10 195-GA20 195-GB01 195-GB02 195-GB11 195-GL01 1495-J6 1495-K6 1495-J6 1495-K6 1495-K6 1495-J6 1495-K8 1495-J6 1495-K8 1495-K8 1497-N15 1497-N16 1497-N17 1497-N7 1497-N8 1497-N9 1497-N10 1497-N11 1497-N12 1497-N18 1497-N19 1497-N20 1497-N1 1497-N2 1497-N2 1497-N3 1497-N3 1497-N4 1497-N5 1497-N5 1497-N6 1497-N6 1497-N7 1497-N8 1497-N8 1497-N9 1497-N9 1497-N10 1497-N11 1497-N11 1497-N12 1497-N12 1497-N18 1497-N19 1497-N19 1497-N20 1497-N20 Included as Standard Included as Standard

Size 0-1-2 Cat. No.

Size 3 Cat. No.

Size 4 Cat. No.

Size 5 Cat. No.

Size 6 Cat. No.

Size 78 Cat. No.

Size 9 Cat. No.

19

Bulletin 500 Line

Modifications Factory Installed

Modifications
For Use On Non-Combination Starters Bulletin 509 Listed on this and the following page are factory installed modifications and special features which are available for the low voltage (600 volt maximum) starters listed in this catalog. To order, add a dash followed by the suffix number listed in these tables to the end of the product Cat. No. Example: 509-BAD-A2E-1. Starter Size 3 4 5 V

Description of Modification
Pilot Devices in Cover or Flange Full Voltage Non-Reversing Single Speed Starters START-STOP Push Button

Suffix No.

Enclosure Type

00

1 1 1 1 1E 1E 1E 1E 3 3 3 3 3E 3E 3E 3E 3 4R 4R 4R 5R 5R 1 1 3 3 3 1 1 3 3 3J 4R 6P 6P 6P 6XP 6XP 6XP

1 4, 4X, 12 Bolted Unilock 1 4, 4X, 12 Bolted Unilock 1 4, 4X, 12 Bolted Unilock 1 4, 4X, 12 Bolted Unilock All Listed 1, 4, 4X, 12 Bolted Unilock 1,12 Bolted 1, 4, 4X, 12 Bolted 1, 4, 4X, 12 Bolted Unilock 1, 4, 4X, 12 Bolted 1, 4, 4X, 12 Bolted 1, 4, 4X, 12 1, 4, 4X, 12 1, 4, 4X, 12 Bolted Unilock 1, 4, 4X, 12 Bolted Unilock

A NA NA NA A NA NA NA A NA NA NA A NA NA NA NA A NA NA A A NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA

A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

A A A A A A A A A A A A A A A A A A A A A A A A A A NA A A A A A A A A A A A A

A A A A A A A A A A A A A A A A A A A A A A A A A A NA A A A A A A A A A A A A

A A A A A A A A A A A A A A A A A A A A A A A A A A NA A A A A A A A A A A A A

A A A A A A A A A A A A A A A A A A A A A A A A A A NA A A A A A A A A A A A A

A A A A A A A A A A A A A A A A NA A NA NA NA NA A NA A NA NA A NA A NA A A NA NA NA A NA NA

A A A A A A A A A A A A A A A A NA A NA NA NA NA A NA A NA NA A NA A NA A A NA NA NA A NA NA

A A A A A A A A A A A A A A A A NA A NA NA NA NA A NA A NA NA A NA A NA A A NA NA NA A NA NA

A A A A A A A A A A A A A A A A NA A NA NA NA NA A NA A NA NA A NA A NA A A NA NA NA A NA NA

ON-OFF Push Button

HAND-OFF-AUTO Selector Switch

OFF-ON Selector Switch

HAND-OFF-AUTO Selector Switch (For Permanent Magnet Latch Type Contactor Only) PILOT LIGHT (Red Lens) PUSH-TO-TEST PILOT LIGHT (Red Lens)

Full Voltage Reversing and Multi-Speed Starters FOR-REV-STOP Push Button FOR-OFF-REV Selector Switch

HIGH-LOW-STOP Push Button HIGH-OFF-LOW Selector Switch HIGH-LOW-OFF-AUTO Selector Switch PILOT LIGHTS (2) Control Circuit Transformer Includes 2 Primary Fuses and 1 Secondary Fuse With Standard Capacity 60 or 50 Hz With 100 Watt Extra Capacity 60 or 50 Hz

Only one push button or one selector switch (not both) may be added to a Bulletin 509 for NEMA Type 1 without transformers. Only one pilot light may be added to a Bulletin 509 Type 1 without transformers. OFF pilot lights for non-reversing and non-multi-speed applications require a normally closed auxiliary contact. Red and amber are the only colors available on Type 1 non-combination starters. On Type 12 and Type 4 non-combination starters, specify other lens colors by changing the letter to: A = Amber; B = Blue; C = Clear; G = Green; W = White. Bolted suitable for Types 7 & 9 or Types 3R/7 & 9. Unilock suitable for Types 7 & 9 or Types 3R/7 & 9 with the addition of a drain or a breather/drain. For multi-speed and reversing starters, one pilot light for each contactor. Add additional letters to identify two lens colors. The first letter specifies FORWARD or HIGH, or ON; the second letter specifies REVERSE or LOW, or OFF; e.g. 4AG.

A = Available

NA = Not Available

20

Prices Consult Sales Office or price list

Bulletin 500 Line

Modifications Factory Installed

Modifications, Continued
For Use On Non-Combination Starters Bulletin 509 Starter Size 3 4 5 V
NA NA NA NA A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A A

Description of Modification
Control Circuit Auxiliary Contact installed on contactor N.O. N.C.

Suffix No.
90 91 21 22

Enclosure Type
All Listed All Listed 1, 3R, 4, 4X, 12 1, 3R, 4, 4X, 12 All Listed 1, 3R, 4, 4X, 12

00

Fused Control Circuit for Applications Less Transformer (1 Fuse Fuse Included) (2 Fuses Fuses Included)

Surge Suppression for 120 or 240 Volt AC Coil Terminal Blocks (Cat. No. 1492-CA1 or similar) Per Block

17

NA NA

A A

A A

A A

A A

A A

A A

A A

A A

A A

A A

DC operation of control circuit (Power Circuit remains AC) Add letters DC to Bulletin Number (Add per Solenoid) Overload Relays N.O. Alarm Contact Adder (Bulletin 592) N.C. Alarm Contact Adder (Bulletin 592) Substitute Automatic Reset Relays (Bulletin 593) with 1 N.C. Contact with 1 N.O. and 1 N.C. contact (Price per Pole) Substitute Overload Relay with Ambient Temperature Compensation (Bulletin 593) (Manual Reset) (Per 3 Pole O.L. Relay) (Automatic Reset) (Per 3 Pole O.L. Relay) Auxiliary Relays (Indicate Contact Arrangement and Coil Voltage) Control Relay (4 Pole Maximum) Addition of Timing Relay

Open 1, 4, 4X, 12

NA NA

A NA

NA NA

NA NA

NA NA

NA NA

9 9A 7 7&9

All Listed All Listed All Listed

NA NA NA NA

A A A A

A A A A

A A A A

A A A A

A A A A

A A A A

A A A A

A A A A

A A A A

A A A A

7C 7D

All Listed All Listed 1, 3R, 12 4, 4X Unilock 1, 3R, 12 4, 4X Unilock Open Type Open Type Bolted Unilock Bolted Bolted and Unilock

NA NA NA NA NA NA NA NA NA NA NA NA NA

A A A A A A A NA A A A A A

A A A A A A A NA A A A A A

A A A A A A A NA A A A A A

A A A A A A A A A A A A A

A A A A A A A A A A A A A

A A A A NA A A A A A A A A

NA NA A A NA A A NA NA NA NA NA NA

NA NA A A NA A A NA NA NA NA NA NA

NA NA A A NA A A NA NA NA NA NA NA

NA NA A A NA A A NA NA NA NA NA NA

Bulletin 596 (Used on Bulletin 509 3 Pole Maximum) Enclosure Breather Breather and Drain Drain

On Delay Off Delay

87A 87B 136 137 138

Consult your nearest Allen-Bradley District Office for ordering information. Unilock suitable for Types 7 & 9 or Types 3R/7 & 9 with the addition of a drain or a breather/drain. Bolted suitable for Types 7 & 9 or Types 3R/7 & 9.

A = Available

NA = Not Available

Prices Consult Sales Office or price list

21

Bulletin 500 Line

NEMA Specifications
Specifications
Electrical Ratings
Max. Circuit Closing Inrush Current (A) Peak Including Offset 3 87

NEMA Size 00

Load Voltage (V) 115 200 230 380 460 575 115 200 230 380 460 575 115 200 230 380 460 575 115 230 115 200 230 380 460 575 115 200 230 380 460 575 115 200 230 380 460 575 115 200 230 380 460 575 115 200 230 380 460 575 230 460 575 230 460 575 230 460 575

Continuous Current (Amps.) (A) 9

Service Limit Current (Amps.) (A) 11

Max. HP Rating (Nonplugging and Nonjogging Duty) 1 1/3 1 1 2 2 3 3 5 3 7-1/2 7-1/2 15 3 1-1/2 1-1/2 1-1/2 2 2 3 3 5 5 5 7-1/2 7-1/2 10 10 10 10 15 25 25 25 25 30 50 50 50 40 50 75 100 100 75 100 150 200 200 150 200 300 400 400 300 600 600 450 900 900 800 1600 1600

Max. HP Rating (Plugging and Jogging Duty) 1 1/2 1 1 2 1-1/2 3 2 5 7-1/2 15 3 1-1/2 1-1/2 1-1/2 2 2 3 3 5 5 5 7-1/2 10 15 15 15 15 20 30 30 30 25 30 50 60 60 60 75 125 150 150 125 150 250 300 300

Transformer Primary Switching kVa Rating (Inrush Current t = 20 times Continuous Current) 1 0.6 1.2 2.4 3 1.2 2.4 4.9 6.2 2.1 4.1 8.3 10 4.1 8.1 16 20 6.8 14 27 34 14 27 54 68 27 54 108 135 3 1.8 2.1 4.2 5.2 3.6 4.3 8.5 11 6.3 7.2 14 18 12 14 28 35 20 23 47 59 41 47 94 117 81 94 188 234

Transformer Primary Switching kVa Rating (Inrush Current = 20 to 40 times Continuous Current) 1 0.3 0.6 1.2 1.5 0.6 1.2 2.5 3.1 1 2.1 4.2 5.2 2 4.1 8.1 10 3.4 6.8 14 17 6.8 14 27 34 14 27 54 68 3 0.9 1 2.1 2.6 1.8 2.1 4.3 5.3 3.1 3.6 7.2 8.9 6.1 7.0 14 18 10 12 23 29 20 24 47 59 41 47 94 117

Capacitor Switching 3 kVAR 1 6 13.5 17 12 25 31 27 53 67 40 80 100 80 160 200 160 320 400 240 480 600 360 720 900 665 1325 1670

18

21

140

27

32

288

1P 2

36 45

42 52

483

90

104

947

135

156

1581

270

311

3163

540

621

6326

810

932

9470

1215

1400

14205

2250

2590

25380

22

Bulletin 500 Line

NEMA Specifications
Specifications, Continued
Mechanical Ratings
Mechanical Life (Millions of Operations) 10 10 10 10 5 5 5 Maximum Number of Auxiliary Contacts 8 8 8 8 8 8 8 8 8 8 8 Operating Time (Milliseconds) Pick-up (Average) 21 22 27 37 27 25 Drop-out (Average) 16 14 13 20 20 18

NEMA Size 0 1 1P 2 3 4 5 6 7 8 9

Construction
Contact Material NEMA Size 0 1 1P 2 3 4 5 6 7 8 9 Silver Alloy Silver Pressure Terminals Power Contacts Auxiliary Contacts Type of Power Terminal Wire Size for Power Terminals 1410 AWG 148 AWG 148 AWG 144 AWG 81/0 AWG 64/0 AWG 4500MCM AWG Required Torque on Power Terminals 20 lb-in 20 lb-in 20 lb-in 45 lb-in 150 lb-in 275lb-in 375 lb-in All wire rated 75C or higher must be sized per the National Electric Code for 75C wire. Requirements for Sizing of Wire

Environmental
NEMA Size 0 1 1P 2 3 4 5 6 7 8 9 25_C to +55_C (13_F to +131_F) (provided condensation is prevented) 10,000 Feet Before Derating All Metal Parts Are Treated for Corrosion Resistance Vertical Operating Temperature Range Altitude Corrosion Resistance Operating Position

23

Bulletin 500 Line

NEMA Specifications
Specifications, Continued
AC Coil Data
Volt Amperes 60 Hz NEMA Size 0 1 1P 2 3 4 5 6 7 8 9 Inrush 192 192 240 660 1225 1490 Sealed 29 29 29 45 69 96 Heat Dissipation (Watts) 5.9 5.9 5.9 10 14.8 19.8 85110% Coil Operating Limits

Auxiliary Contacts (NEMA A600 and P300)

Maximum Inrush Current NEMA Size 09 Maximum Continuous Current AC Current = 10A DC Current = 5A AC Current 120V = 60 A 240V = 30A 480V = 15A 600V = 12A DC Current 125V = 1.1A 250V = 0.55A

24

Bulletin 500 Line

NEMA Specifications
Specifications, Continued
Load-Life Curves Bulletin 500 Line starters are designed to provide superior performance in a variety of applications. These load-life curves are based on Allen-Bradley tests according to the requirements defined in IEC 947-4. Actual contact life may vary based on the application, duty cycle and environmental conditions from that indicated by the curves. To find the contactors estimated electrical life, follow these guidelines: 1. 2. Choose the appropriate graph that most closely approximates the utilization category of the application. Locate the intersection of the life-load curve of the appropriate contactor with the applications operational current (le) found on the horizontal axis. Read the estimated contact life in millions of operations along the vertical axis. Lmixed LAC3 In many applications, the utilization category cannot be defined as either purely AC3 or AC4. In those applications, the electrical life of the contactor can be estimated from the following equation:

L mixed +

L AC3 1 ) P AC4

L L

AC3 AC4

Where

Approximate contact life for a mixed AC3/AC4 utilization category application. Approximate contact life in operations for AC3 utilization category (from AC3 life-load curves below). Approximate contact life in operations for AC4 utilization category (from AC4 life-load curves below). Percentage of AC4 operations.

3.

LAC4

Contact Life for Mixed Utilization Categories AC3 and AC4 Utilization Categories Category AC3 AC4

PAC4

Typical Duty Starting of squirrel cage motors and switching only after the motor is up to speed Starting of squirrel cage motors with inching and plugging duty. Bulletin 500 Load/Life Curves AC3 and AC4

NEMA SIZE

0 1

NEMA SIZE
10M

10M 8M 6M

AC3

8M 6M

AC4

4M

4M

2M

2M

OPERATING CYCLES

1M 800K 600K 400K

OPERATING CYCLES

1M 800K 600K 400K

200K

200K

100K 80K 60K 40K

100K 80K 60K 40K

20K

20K

10K 1 2 4 6 8 10 20 40 60 80 100 200 400 600 800 1000

10K 1 2 4 6 8 10 20 40 60 80 100 200 400 600 800 1000

OPERATIONAL CURRENT Ie (AMPERES)

OPERATIONAL CURRENT Ie (AMPERES)

Consult your nearest Allen-Bradley Sales Office for additional information.

25

Bulletin 592

NEMA AC Starters
Dimensions, Continued Approximate Dimensions
Open Type Enclosure for Bulletin 509 Full Voltage Starters with SMP1 or SMP3 Overload Relay Dimensions are shown in (inches) millimeters. Dimensions are not intended for manufacturing purposes.
C

B D

F E A

NEMA Size
01

Overload Relay
SMP1 SMP3 SMP1

A Width
(3-9/16) 90.4 (3-9/16) 90.4 100 (3-15/16) (3-15/16) 100 (6-1/8) 155.5 (6-1/8) 155.5 (7) 177.8 (7) 178 (7-3/8) 187.5 (7-3/8) 187.5 (13-1/4) 336.6 (13-1/4) 336.6

B Height
(7-5/8) 193.3 (9-25/32) 248.3 (9-5/32) 232.6 (10-25/32) 273.6 (12-7/16) 315.4 (14-9/16) 370 (14-5/32) 359.4 (15-13/32) 391 (16-29/32) 429 (16-29/32) 429 (25-3/32) 637 (25-3/32) 637

C Depth
(4-15/32) 113 (4-15/32) 113 (4-11/16) 119 (4-23/32) 120 (6-19/32) 168 (6-19/32) 168 (7-13/16) 198.4 (7-13/16) 198.4 (8-9/16) 217 (8-9/16) 217 (11-13/32) 289 (11-13/32) 289

D
(7-1/16) 179.4 (9-1/4) 234.4 (8-5/8) 219.2 (10-1/4) 260.2 (8-21/32) 219.9 (8-21/32) 219.9 (9-27/32) 250 (9-27/32) 250 (14-31/32) 380 (14-31/32) 380 (17-23/32) 450 (17-23/32) 450

E
(2-3/4) 69.8 (2-3/4) 69.8 (3-5/32) 80.2 (3-5/32) 80 (5-1/2) 139.9 (5-1/2) 139.9 (6-5/16) 160 (6-5/16) 160 (6-5/16) 160.2 (6-5/16) 160.2 (11-13/16) 300 (11-13/16) 300

F Reset Depth
(4-1/2) 114 (4-5/8) 117.7 (4-1/2) 113.8 (4-5/8) 117.7 (6-1/16) 154 (5-61/64) 151 (6-7/16) 163.9 (7-1/2) 190.25 (8-9/32) 210 (8-13/16) 223 (10-5/8) 270 (11-7/16) 291

2 SMP3 SMP1 3 SMP3 SMP1 4 SMP3 SMP1 5 SMP3 SMP1 6 SMP3

26

Full Load Currents of AC Motors

Full Load Currents of AC Motors
The full load currents listed below are average values for horsepower rated motors of several manufacturers at the more common rated voltages and speeds. These average values, along with the similar values listed in the U. S. National Electrical Code (NEC), should be used only as a guide for selecting suitable components for the Motor Branch Circuit. The rated full load current, shown on the motor nameplate, may vary considerably from the listed value depending on the specific motor design. ATTENTION: The motor nameplate full load current should always be used in determining the rating of the devices used for Motor Running Overcurrent Protection.

Full Load Currents of 3 Phase, 60 Hertz AC Induction Motors HP RPM 208V 240V 480V 600V 2200V 4000V
1/4 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 3600 1800 1200 900 600 3600 1800 1200 900 600 3600 1800 1200 900 600 1.20 1.39 1.62 .... 1.48 1.69 1.89 .... 2.08 2.54 2.89 .... 2.89 3.47 3.81 .... 3.51 4.25 4.60 .... 5.04 5.80 6.49 .... 6.51 7.18 8.20 .... 9.24 10.4 11.6 .... 15.7 15.9 18.6 .... 22.1 25.0 26.6 .... 29.7 31.5 32.9 .... 43.0 46.7 49.1 .... .... 59.2 59.6 61.7 .... .... 70.9 74.7 76.0 .... .... 1.04 1.20 1.40 .... 1.28 1.46 1.64 .... 1.80 2.20 2.50 .... 2.50 3.00 3.30 .... 3.04 3.68 3.98 .... 4.36 5.02 5.62 .... 5.64 6.22 7.10 .... 8.00 9.04 10.1 .... 13.6 13.8 16.1 .... 19.1 21.7 23.1 .... 25.7 27.3 28.4 .... 37.2 40.4 42.5 .... .... 51.3 51.6 53.4 .... .... 61.4 64.7 65.8 .... .... 0.52 0.60 0.70 .... 0.64 0.73 0.82 .... 0.90 1.10 1.25 .... 1.25 1.50 1.65 .... 1.52 1.84 1.99 .... 2.18 2.51 2.81 .... 2.82 3.11 3.55 .... 4.00 4.52 5.04 .... 6.80 6.88 8.07 .... 9.57 10.8 11.5 .... 12.9 13.7 14.2 .... 18.6 20.2 21.3 .... .... 25.6 25.8 26.7 .... .... 30.7 32.3 32.9 .... .... 0.42 0.48 0.56 .... 0.51 0.58 0.66 .... 0.72 0.88 1.00 .... 1.00 1.20 1.32 .... 1.22 1.47 1.59 .... 1.74 2.01 2.25 .... 2.26 2.49 2.84 .... 3.20 3.62 4.03 .... 5.44 5.50 6.46 .... 7.66 8.66 9.22 .... 10.3 10.9 11.4 .... 14.9 16.2 17.0 .... .... 20.5 20.6 21.4 .... .... 24.6 25.9 26.3 .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 5.2 5.3 5.4 5.8 6.4 6.3 6.5 6.7 6.9 8.1 .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... 2.9 3.0 3.1 3.2 3.5 3.4 3.6 3.7 3.8 4.4 300 200 125 50

HP
30

RPM
3600 1800 1200 900 600 3600 1800 1200 900 600 3600 1800 1200 900 600 3600 1800 1200 900 600 3600 1800 1200 900 600 3600 1800 1200 900 600 450 3600 1800 1200 900 720 600 450 3600 1800 1200 900 720 600 450 3600 1800 1200 900 720 600 450 3600 1800 1200 900 720 600 450 360 3600 1800 1200 900 600 450 360 3600 1800 1200 3600 1800 1200 3600 1800 1200 3600 1800 1200

208V
85.7 88.2 91.6 .... .... 111 117 119 .... .... 141 144 147 .... .... 165 172 173 .... .... 204 211 215 .... .... 267 276 281 .... .... .... 333 340 347 .... .... .... .... 397 404 414 .... .... .... .... 524 531 538 .... .... .... .... 642 658 682 .... .... .... .... .... 774 790 804 .... .... .... .... .... .... .... .... .... .... .... .... .... .... .... ....

240V
74.2 76.4 79.3 .... .... 96.0 102 103 .... .... 122 125 127 .... .... 143 149 150 .... .... 177 183 186 .... .... 231 239 243 .... .... .... 288 294 300 .... .... .... .... 344 350 358 .... .... .... .... 454 460 466 .... .... .... .... 556 570 590 .... .... .... .... .... 670 684 696 .... .... .... .... 748 762 774 874 892 902 972 992 1004 1074 1096 1108

Full Load Current 480V 600V 2200V

37.1 38.2 39.7 .... .... 48.0 50.8 51.7 .... .... 61.2 62.3 63.4 .... .... 71.6 74.3 74.9 .... .... 88.5 91.4 93.1 .... .... 116 119 122 .... .... .... 144 147 150 .... .... .... .... 172 175 179 .... .... .... .... 227 230 233 .... .... .... .... 278 285 295 .... .... .... .... .... 335 342 348 .... .... .... .... 374 381 387 437 446 451 486 496 502 537 548 554 29.7 30.5 31.7 .... .... 38.4 40.6 41.4 .... .... 49.0 49.8 50.7 .... .... 57.3 59.4 59.9 .... .... 70.8 73.1 74.5 .... .... 92.6 95.5 97.2 .... .... .... 115 118 120 .... .... .... .... 138 140 143 .... .... .... .... 182 184 186 .... .... .... .... 222 228 236 .... .... .... .... .... 268 274 278 .... .... .... .... 299 305 310 350 357 361 389 397 402 430 438 443 .... 7.8 8.0 8.2 9.3 .... 10.0 10.3 10.6 11.5 .... 12.3 12.4 13.1 14.2 .... 14.6 14.9 15.4 16.7 .... 18.0 18.2 19.0 21.0 .... 23.6 24.2 24.8 26.4 29.8 .... 29.2 29.9 30.9 31.3 32.8 36.0 .... 34.8 35.5 37.0 37.0 38.8 42.0 .... 46.7 47.0 49.4 49.0 50.9 53.7 .... 57.5 58.5 61.5 61.5 61.0 65.3 70.0 .... 69.0 70.0 73.5 72.3 76.0 82.8 .... .... .... .... .... .... .... .... .... .... .... ....

4000V
.... 4.3 4.4 4.5 5.0 .... 5.5 5.7 5.8 6.3 .... 6.8 6.8 7.2 7.8 .... 8.0 8.2 8.5 9.2 .... 9.9 10.0 10.5 11.6 .... 13.0 13.3 13.6 14.5 16.4 .... 16.1 16.4 17.0 17.2 18.0 19.8 .... 19.1 19.5 20.4 20.4 21.3 23.1 .... 25.7 25.9 27.2 27.0 28.0 29.5 .... 31.6 32.2 33.8 33.8 33.6 35.9 38.5 .... 38.0 38.5 40.4 39.8 41.8 45.5 .... .... .... .... .... .... .... .... .... .... .... ....

1/3

40

1/2

3/4

60

1-1/2

75

100

7-1/2

150

10

15

20

250

25

350

400

450

500

27