Eutectic Alloy Overload Relays
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Bulletin 592
- A Rockwell Automation exclusive — overload relay is the same for all three trip classes (10, 20, and 30) for each Starter Size.
- Trip current ratings are easily selected by choosing the proper heater element — no need to change the overload relay.
- The trip-free mechanism means you still have overload protection even if the reset button is held down.
Bulletin 592 overload relay is a manual reset, eutectic alloy, thermal type overload device. When coordinated with the proper short circuit protection, the overload relay is intended to protect the motor, motor controller, and power wiring against overheating due to excessive overcurrents.
All Bulletin 592 block type relays are furnished with an OPTICAL INDICATOR which becomes visible when the relay has tripped. A manual contact test module is provided as standard on block type Bulletin 592 overload relays. One N.O. or N.C. auxiliary contact may be field added to block type Bulletin 592 overload relays. This extra contact module physically replaces the contact test module.
Standards Compliance and Certifications
Standards Compliance
UL 508
CSA 22.2 No. 14
CE Mark
Certifications
UL Listed (File No. E14840, Guide No. NKCR)
CSA Certified (File No. LR1234)
Your order must include: 1) Cat. No. of overload relay selected, 2) order heater element as a separate item. See Eutectic Alloy Overload Relay Heater Elements, and 3) if required, Cat. No. of any accessories.
Product Selection
Eutectic Alloy Type — Manual Reset, Starter Mount
STARTER MOUNT — For installation on Rockwell Automation NEMA starters.
Heater Elements — Overload relays require 1 or 3 overload heater elements. See Eutectic Alloy Overload Relay Heater Elements for heater element selection.
| Starter Size | Number of Poles | Open Type without Enclosure |
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| N.C. Contact | N.O.-N.C. Contact | ||
| Cat. No. | Cat. No. | ||
| 00 (Series B & D) | 3 | 592-JOV16 | 592-JOV169 |
| 0,1 | 3 | 592-BOW16 | 592-BOW169 |
| 2 | 3 | 592-COW16 | 592-COW169 |
| 3 | 3 | 592-DOW16 | 592-DOW169 |
| 4 | 3 | 592-EOW16 | 592-EOW169 |
Eutectic Alloy Type — Manual Reset, Panel Mount¬
PANEL MOUNT — For installation and wiring separate from the contactor.
Heater Elements — Overload relays require 1 or 3 overload heater elements. See Eutectic Alloy Overload Relay Heater Elements for heater element selection.
| Type | Maximum Continuous Current (A) | Number of Poles | Open Type without Enclosure |
Type 1 General Purpose Enclosure |
||
| N.C. Contact | N.O.-N.C. Contacts | N.C. Contact | N.O.-N.C. Contacts | |||
| Cat. No. | Cat. No. | Cat. No. | Cat. No. | |||
| Compact | 24 | 3 | 592-JOV16 | 592-JOV169 | — | — |
| 32 | 3 | 592-KOV16 | 592-KOV169 | — | — | |
| Standard | 40 | 1 | 592-BOV4 | 592-BOV49 | — | — |
| 3 | 592-BOV16 | 592-BOV169 | 592-BAV16 | 592-BAV169 | ||
| 62 | 1 | 592-COV4 | 592-COV49 | — | — | |
| 3 | 592-COV16 | 592-COV169 | 592-CAV16 | 592-CAV169 | ||
| 125 | 3 | 592-DOV16 | 592-DOV169 | — | — | |
| 165 | 3 | 592-EOV16 | 592-EOV169 | — | — | |
| ¬ For Renewal Part Overload Relay used on starter mounted devices, see page Bulletin 500 Line of Contactors and Starters, Continued. | ||||||
Current Transformer Type — Eutectic Alloy, Manual Reset
Heater Elements — Overload relays require 3 overload heater elements. See Eutectic Alloy Overload Relay Heater Elements for heater element selection.
| Full Load Current Range (A) | Cat. No.T | Lug Kits Cat. No. |
| 60…200‡ | 592-TPD200 | 199-LF1 |
| 120…300‡ | 592-TPD300 | 199-LG1 |
| 160…496 | 592-TPD400 | 199-LH1 |
| 250…630‡ | 592-TPD630 | 199-LJ1 |
| T Terminal lugs are not included. | ||
| ‡ Can be applied up to 1500V. | ||
Approximate Dimensions
Open Type without Enclosure for Bulletin 592 Eutectic Alloy Type — Manual Reset — Panel Mount
Dimensions are shown in inches (millimeters). Dimensions are not intended to be used for manufacturing purposes.
|
|
| Maximum Current [A] |
No. of Poles |
A Wide |
B High |
C Deep |
D | E | F | G | H | J | K |
| 24/32 | 3 | 2-11/16 (68.3) |
3-1/4 (82.6) |
3-41/64 (92.6) |
— | 2-3/4 (70) |
55/64 (22) |
— | — | 1/4 (6.4) |
29/32 (23) |
| 40 | 1 | 7/8 (22.2) |
3-1/4 (82.6) |
3-9/16 (90.5) |
2-29/32 (73.8) |
— | -— | — | — | — | — |
| 3 | 3-15/16 (100) |
— | 4-1/2 (114) |
3-21/32 (93) |
3-5/32 (80) |
3-5/32 (80) |
1-3/64 (26.5) |
1-3/8 (35) |
1-9/64 (7.5) |
25/64 (9.9) |
|
| 62 | 1 | 7/8 (22.2) |
3-13/16 (96.8) |
3-9/16 (90.5) |
3-1/8 (79.4) |
— | — | — | — | — | — |
| 3 | 3-15/16 (100) |
3-31/32 (101) |
4-1/2 (114) |
3-21/32 (93) |
3-5/32 (80) |
3-5/32 (80) |
1-3/64 (26.5) |
1-3/8 (35) |
1-9/64 (7.5) |
25/64 (9.9) |
|
| 125 | 3 | 6-7/32 (158) |
5-7/8 (149) |
4-49/64 (121) |
6-1/4 (159) |
5-1/2 (140) |
5-1/2 (140) |
1-61/64 (49.6) |
2-3/4 (69.8) |
5/16 (7.9) |
23/64 (9.1) |
| 165 | 3 | 6-7/32 (158) |
6-17/32 (166) |
4-49/64 (121) |
6-1/4 (159) |
5-1/2 (140) |
5-1/2 (140) |
1-61/64 (49.6) |
2-3/4 (69.8) |
5/16 (7.9) |
23/64 (9.1) |
Open Type without Enclosure for Bulletin 592 Current Transformer Type — Eutectic Alloy, Manual Reset
|
| Cat. No. | A Wide |
B High |
C Deep |
D | E | F | G | H | J | K |
| 592-TPD200 | 5-5/16 (135) |
5-19/32 (142) |
8-9/16 (217.5) |
4-23/32 (120) |
4-23/32 (120) |
19/64 (7.5) |
1-59/64 (49) |
29/64 (12) |
51/64 (10) |
21/64 (8.4) |
| 592-TPD300 | 6-63/64 (177.3) |
5-19/32 (142) |
9-5/32 (233) |
4-23/32 (120) |
6-9/64 (156) |
27/64 (10.6) |
22-1/2 (63.6) |
29/64 (12) |
51/64 (10) |
9/32 (7) |
| 592-TPD400 | 6-63/64 (177.3) |
10-15/32 (266) |
9-5/32 (233) |
4-23/32 (120) |
6-9/64 (156) |
27/64 (10.6) |
22-1/2 (63.6) |
29/64 (12) |
51/64 (10) |
9/32 (7) |
| 592-TPD630 | 9-27/32 (250) |
7-55/64 (210) |
8-19/32 (218) |
7-3/32 (180) |
8-57/64 (226) |
15/32 (12) |
3-19/64 (84) |
25/64 (10) |
51/64 (10) |
9/32 (7) |
| ¬ Mounting holes for Cat. Nos. 592-TPD400 and 592-TPD630 only. | ||||||||||
Type 1 General Purpose Enclosure for Bulletin 592
Dimensions are shown in inches (millimeters). Dimensions are not intended to be used for manufacturing purposes.
|
| Maximum Current [A] | A Wide |
B High |
C Deep |
D | E | F | G |
| Bulletin 592 | |||||||
| 40…60 | 6-13/16 (173) |
10-5/8 (270) |
5-23/32 (145) |
8-1/4 (210) |
2-3/8 (60.5) |
7/32 (5.5) |
5-5/16 (135) |