AC Contactors and Starters

Catalogs > Industrial Controls Catalog > Motor Control, NEMA > Contactors, Starters, and Overload Relays > AC Contactors and Starters > Bulletin 509 Full Voltage

Bulletin 509 Full Voltage

Introduction Standards Compliance and Certifications Cat. No. Explanation Product Selection Typical Wiring Diagram(s) Modifications for Non-Combination Devices
Accessories Specifications Full Load Motor Currents Approximate Dimensions Renewal Parts
Electrical Ratings

NEMA
Size
Load
Voltage
[V]
Continuous
Current
Rating
[A]
Service
Limit
Current
Rating
[A]⋆ 
Maximum Hp Rating
(Non-plugging and non-jogging duty)
Maximum Hp Rating
(Plugging and jogging duty)‡ 
Transformer Primary
Switching kVa Rating
(Inrush Current
£ 20 times
Continuous
Current)
Transformer Primary
Switching kVa Rating
(Inrush Current = 20
to 40 times
Continuous Current)
Capacitor
Switching
kVAR§ 
Maximum
Circuit
Closing
Inrush
Current
[A] Peak
Including
Offset
1Æ 3Æ 1Æ 3Æ 1Æ 3Æ 1Æ 3Æ 3Æ 3Æ
00 115
200
230
380
460
575
9 11 1/3

1



1-1/2
1-1/2
1-1/2
2
2
1/4

1/2



1
1
1
1-1/2
1-1/2

























87
0 115
200
230
380
460
575
18 21 1

2



3
3
5
5
5
1/2

1



1-1/2
1-1/2
1-1/2
2
2
0.6

1.2

2.4
3

1.8
2.1

4.2
5.2
0.3

0.6

1.2
1.5

0.9
1

2.1
2.6





140
1 115
200
230
380
460
575
27 32 2

3



7-1/2
7-1/2
10
10
10
1

2



3
3
5
5
5
1.2

2.4

4.9
6.2

3.6
4.3

8.5
11
0.6

1.2

2.5
3.1

1.8
2.1

4.3
5.3


6

13.5
17
288
1P 115
230
36 42 3
5

1-1/2
3







2 115
200
230
380
460
575
45 52 3

7-1/2



10
15
25
25
25
2

5



7-1/2
10
15
15
15
2.1

4.1

8.3
10

6.3
7.2

14
18
1

2.1

4.2
5.2

3.1
3.6

7.2
8.9


12

25
31
483
3 115
200
230
380
460
575
90 104 7-1/2

15



25
30
50
50
50
7-1/2

15



15
20
30
30
30
4.1

8.1

16
20

12
14

28
35
2

4.1

8.1
10

6.1
7.0

14
18


27

53
67
947
4 115
200
230
380
460
575
135 156





40
50
75
100
100






25
30
50
60
60
6.8

14

27
34

20
23

47
59
3.4

6.8

14
17

10
12

23
29


40

80
100
1581
5 115
200
230
380
460
575
270 311





75
100
150
200
200






60
75
125
150
150
14

27

54
68

41
47

94
117
6.8

14

27
34

20
24

47
59


80

160
200
3163
6 115
200
230
380
460
575
540 621





150
200
300
400
400






125
150
250
300
300
27

54

108
135

81
94

188
234
14

27

54
68

41
47

94
117


160

320
400
6326
7 230
460
575
810 932

300
600
600












240
480
600
9470
8 230
460
575
1215 1400

450
900
900












360
720
900
14205
9 230
460
575
2250 2590

800
1600
1600












665
1325
1670
25380
  
⋆ Service-Limit Current Ratings — The service-limit current ratings shown represent the maximum rms current, in amperes, which the controller shall be permitted to carry for protracted periods in normal service. At service-limit current ratings, temperature rises shall be permitted to exceed those obtained by testing the controller at its continuous current rating. The current rating of overload relays or the trip current of other motor protective devices used shall not exceed the service-limit current rating of the controller.
‡ Plugging or Jogging Service — The listed horsepower ratings are recommended for those applications requiring repeated interruption of stalled motor current encountered in rapid motor reversal in excess of five openings or closings per minute and shall not be more than ten in a ten minute period.
§ If maximum available current (at capacitor terminals) is greater than 3000 A, please contact your local Rockwell Automation sales office, Allen-Bradley distributor, or NEMA ICS-2 Standard.

Mechanical Ratings

NEMA
Size
Mechanical Life
(Millions of Operations)
Maximum Number of
Auxiliary Contacts
Operating Time [ms]
Pick-up (Average) Drop-out (Average)
00 10 5 20 16
0 10 8 21 16
1 10 8 22 14
1P 10 8 22 14
2 10 8 27 13
3 5 8 37 20
4 5 8 27 20
5 5 8 25 18
6 5 4 25…79 10…22
7 8 88 40
8 8 88 45
9 8 118 84
  

Construction

NEMA
Size
Wire Size for
Power Terminals
Required Torque on
Power Terminal Wire
Clamps and Pressure
Connectors or Lugs
Type of Power Terminal Contact Material Requirements
for Sizing of Wire
Power
Contacts
Auxiliary
Contacts
00 #16…10 AWG 9 lb•in Pressure terminals Silver alloy Silver All wire rated 167 °F
(75 °C) or higher must
be sized per the local
Electrical Code for
167°F (75 °C) wire.
0 #14…10 AWG 20 lb•in Saddle or wire clamps
1 #14…8 AWG 20 lb•in
2 #14…4 AWG 45 lb•in Pressure terminals
3 #8…1/0 AWG 150 lb•in
4 #6…4/0 AWG 275 lb•in
5 #4 AWG…500 MCM 375 lb•in
6 Lugs sold separately.
See Contactor Accessories .
7
8
9 Direct bus connections only.
  

Environmental

NEMA
Size
Operating Position Operating Temperature Range Altitude Corrosion-Resistance
00 Horizontal Starters with eutectic alloy
Overload relay
–13…+149 °F
(–25…+65 °C)

Starters with SMP
Overload relay
–13…+131 °F
(–25…+55 °C)

(provided condensation
is prevented)
10 000 feet before derating All metal parts are treated for
corrosion-resistance
0 Vertical
1
1P
2
3
4
5
6 Horizontal
7 Vertical
8
9
  

Short Circuit Rating

Combination contactors and starters with disconnect switch: Bulletin 502, 506, 512, 522E, 522F, 522G, and 1232X

Combination Contactors and Starters with Disconnect Switch: Bulletin 502, 506, 512, 522E, 522F, 522G, and 1232X
NEMA Size Fuse Type Available Short Circuit Amperes RMS Symmetrical [A] Maximum Voltage [V]
0…3 H, K 5000 600
4…5 H, K 10 000
0…5 J, R 100 000
6 L 18 000
7 L 18 000
Combination Lighting Contactors with Disconnect Switch: Bulletin 502L
Lighting Contactor Rating [A] Fuse Type Available Short Circuit Amperes RMS Symmetrical [A] Maximum Voltage [V]
20…100 H, K 5000 600
200…300 H, K 10 000
20…300 J, R 100 000
Combination Contactors and Starters with Circuit Breaker: Bulletin 503, 507, 513, 523E, 523F, 523G, and 1233X⋆ 
Enclosure Type NEMA Size Available Short Circuit Amperes RMS Symmetrical [A] Maximum Voltage [V]
1, 3R, 3R/4/12, 4/4X (stainless) 0…2 42 000 480
3…5 65 000
Unilock 3R, 7, & 9 0…2 42 000
3…5 65 000
Bolted 3R, 7, & 9 0…2 65 000
3R, 3R/4/12, 4/4X (stainless) 6 18 000
7 25 000
1, 3R, 3R/4/12, 4/4X (stainless) 0…4 25 000 600
5 35 000
Unilock 3R, 7, & 9 0…3 5000
4…5 10 000
Bolted 3R, 7, & 9 0…2 5000
3R, 3R/4/12, 4/4X (stainless) 6 18 000
7 25 000
Combination Lighting Contactors with Circuit Breaker: Bulletin 503L⋆ 
Enclosure Type Lighting Contactor Rating [A] Available Short Circuit Amperes RMS Symmetrical [A] Maximum Voltage [V]
1, 3R, 3R/4/12, 4/4X (stainless) 20…300 65 000 480
Unilock 3R, 7, & 9 20…300 65 000
Bolted 3R, 7, & 9 20…300 65 000
1, 3R, 3R/4/12, 4/4X (stainless) 20…300 25 000 600
Unilock 3R, 7, & 9 20…100 5000
Unilock 3R, 7, & 9 20…300 10 000
Bolted 3R, 7, & 9 20…300 5000
    
⋆ For the most up-to-date SCCRs, please see the on-line Industrial Controls catalog at www.ab.com/catalogs.

Combination Contactors and Starters with Disconnect Switch: Bulletin 502, 506, 512, 522E, 522F, 522G, and 1232X
NEMA Size Fuse Type Available Short Circuit Amperes RMS Symmetrical [A] Maximum Voltage [V]
0…3 H, K 5000 600
4…5 H, K 10 000
0…5 J, R 100 000
6 L 18 000
7 L 18 000
    

AC Coil Data

NEMA Size Operating Volt Amperes Burden [VA] Heat Dissipation [W] Coil Operating Limits
60 Hz Coils
Inrush Sealed
00 70 8 2.7 85…110%
0 192 29 5.9
1 & 1P 192 29 5.9
2 (2…3 poles) 240 29 5.9
2 (4…5 poles) 315 38 5.9
3 (2…3 poles) 660 45 10
3 (4…5 poles) 840 58 10
4 (2…3 poles) 1225 69 14.8
4 (4…5 poles) 1490 96 14.8
5 (Series L) 1490 96 19.8
6⋆  4860 254 65.7
6 (Interposing relay) 52.44 3.96
7‡  Economized DC Coil
7 (Interposing relay) 74.40 9.84
8§  Economized DC Coil
8 (Interposing relay) 74.40 9.84
9♣  Economized DC Coil
9 (Interposing relay) 144 19.20
  
⋆ This rating is for the size 6 contactor coil only. All starters are shipped with an interposing relay as standard.
‡ Size 7 starters are shipped with a 250 VA control circuit transformer and an interposing relay with a 120V coil. Voltage is then rectified to DC for the contactor coil.
§ Size 8 starters are shipped with a 350 VA control circuit transformer and an interposing relay with a 120V coil. Voltage is then rectified to DC for the contactor coil.
♣ Size 9 starters are shipped with a 750 VA control circuit transformer and an interposing relay with a 120V coil. Voltage is then rectified to DC for the contactor coil.

Auxiliary Contacts (NEMA A600 and P300) — Bulletin 595, 596

Maximum AC Contact Rating Per Pole
AC Rating
Designation
Maximum Voltage
60 or 50 Hz
[A] Continuous
Carrying Current
[A]
[VA]
Make Break Make Break
A600 120 60 6 10 7200 720
240 30 3 10 7200 720
480 15 1.5 10 7200 720
600 12 1.2 10 7200 720
Maximum DC Contact Rating Per Pole for 595, 596 Auxiliary Contacts (Maximum Continuous Carrying Current is 5 A)
DC Rating
Designation
125V DC 250V DC 600V DC
P300 0.55 A 0.55 A
(Requires 2 Contacts in Series)
1.1 A
(Requires 2 Contacts in Series)
  

Load-Life Curves

Bulletin 500 Line contactors and starters are designed to provide superior performance in a variety of applications. These load-life curves are based on Rockwell Automation 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 contactor’s estimated electrical life, follow these guidelines:



Contact Life for Mixed Utilization Categories AC3 and AC4

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:

Click to enlarge - ContactLife_AC3_AC4_equation


Where:

Lmixed = Approximate contact life for a mixed AC3/AC4 utilization category application

LAC3 = Approximate contact life in operations for AC3 utilization category (from AC3 life-load curves below)

LAC4 = Approximate contact life in operations for AC4 utilization category (from AC4 life-load curves below)

PAC4 = Percentage of AC4 operations


Utilization Categories

Category Typical Duty

AC3 Starting of squirrel cage motors and switching off only after the motor is up to speed.

AC4 Starting of squirrel cage motors with inching and plugging duty.


Bulletin 500 Load/ Life Curves — AC3 and AC4

Click to enlarge - 500Line-1_124-1


Click to enlarge - 500Line-1_124-2