ww

Wiring

Diagrams

introduction
This booklet has been prepared as a guide to
some of the useful ways Allen-Bradleys
manual and magnetic

across-the-line

starters

may be applied. It will also serve as a useful

aid where simple wiring systems are to be
studied.
When applying these diagrams, it is well to
remember
that the features
described
in
several diagrams may be combined into one
to produce another useful way of applying
Allen-Bradley
equipment.
As you become
familiar with the diagrams, most such changes
will prove simple.
be extremely
understanding

Exercises

of this kind will

beneficial to a students better

of motor control wiring dia-

grams. It is important to note: A particular

application
must satisfy the needs of the user
and comply with applicable codes, laws and
standards
before using any of the typical
circuits shown in this publication.
The

symbols

used

in this

booklet

were

adopted
by Allen-Bradley
for use in all its
publications.
They are in accordance
with
NEMA standards.
The Allen-Bradley

Company

is very

inter-

ested in helping engineers, electricians

and
students to a better understanding
of motor
control

equipment.

booklet

furthers

It is our hope that this

this purpose.

WIRING DIAGRAMS

wnv

c o n t e n t s
PLATE

PAGE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Common and Important Terms. . . . . . . . . . . . . . . . . . . . . . . , . . . .

Bulletin 600 Manual Single Phase Starters . . . . . . . . . . . . . . . . .

1 thru 4

Bulletin 609 Manual Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 thru 13

Bulletin 509 Magnetic Full Voltage Starters . . . . . . . . . . . . . . . .

Three-Phase Starters . . . . . . . . . . . . . . . . . . . . . . . . .
Single-Phase Using 3-Phase Starter . . . . . . . . . . .
Variations With START-STOP Stations . . . . . . . .
Step-Down Transformer in Controls Circuits . . .
Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-Wire Control Circuits . . . . . . . . . . . . . . . . . . . .
Pump Operation (Backspin and Surge Protection)
Sequence Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 thru 17
18 and 19
20 thru 24
25
26 and 27
28 thru 32
33 and 34
35 thru 37

11
12
14
15
18
19
20
23
24

Bulletin 505 Magnetic Reversing Starter . . . . . . . . . . . . . . . . . . . .

Three-Phase Starters. . . . . . . . . . . . . . . . . . . . . . . . . .
Push Button Variations . . . . . . . . . . . . . . . . . . . . . . . .
Jogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-plugging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 and 39
40 thru 44
45
46 and 47
48

26
27
28
31
32
34

Bulletin 520 Multi-Speed Motor Starters . . . . . . . . . . . . . . . . . . . .

49 thru 51

35

Key to Symbols
Shown here are the symbols most often used in this book. Although
the explanations
accompanying
the diagrams
describe the devices used, familiarity
with the various
symbols will lead to a quicker understanding
of each circuit.
The symbols,

device designations,
and abbreviations
Standard Publication/No.

in this book are taken from the NEMA

ICS-1-1978.

Wiring Diagram Symbols

Fuse
Relay

Coils

Symbol

Device

Symbol

General

Single
Winding

Tapped

and
Switch

NE

Permanent
Magnet

Normally
Closed

Contacts

Open
(N.O.)

Time
Closing

Neon

--@I-

Economized

Indicating
Lights

OP

0
A
B
C
G
R
W
Y

Auxiliary

Main

-itMain

=E

Oranoe
Amb&
Blue
Clear
Green
Red
White
Yellow

3 Phase
Squirrel

Auxiliary

Cage
Induction

T
N.O.T.C.

P - Purple
- Opalescent

General

#S#+i?

(N.C.)

Normally

FL - Fluorescent

Coils

Motors
N.C.T.C.

Single
Time
Opening

-=-IN.C.T.O.

Phase

T
N.O.T.O.

Yellow

1AC

AC
Solenoid
Type

Rectifier

Contactors

Full Wave
with
Color Code

-_r
+IRed

Blk

Manually
Operated

AC

Yel

Yel

WIRING

DIAGRAMS

Symbol

Devise

Syfnbol

H-q+-

m c
w

Plugging

(P4Of.t Shown)
Opening On
Rising Press.

Closing On
Rising Press.

Pressure

and
Temperature

T
Opening On
Rising Temp.

Closing On
Rising Temp.

Thermal
Overload

Push Button
Standard

L
0

LLLQ

NO

NC

Relays
Push Button

IiL
0

rLl3
0
0

Heavy Duty,
Oiltight

Mushroom

Head

Switches
w

Timing

Push Button

Inst. Aux.
Contacts
(when
used)

(Pneumatic)
(ON-DELAY)

Run&Jog
0 0

and Jog
Attachment

On Delay
3p T.C.
9
T.O.

Standard

Jo

Duty
Selector

Jo
3 Position

2 Position

Switch
Heavy
Duty

Selector
2-Position

Anti-Plugging

Letter

1
AL
Bo

Posltlon

Sm.

Ed

c
R

Heavy
Duty
Selector

s$

3-Position
Normally

Open
0

Fi%d
swtwt

%
Normally

Closed

Potential
x2

Xl

Trans-

former
,

Switehea
Q-9
Held

Closed

cd6
Held

Open

Current

Polarity
Mark

m
w

WIRING

DIAGRAMS

SOME COMMON

and IMPORTANT

TERMS

In this booklet, and wherever motor control is discussed, there are several terms which are used repeatedly
but whose
meanings are often not completely
understood
by the reader. These terms represent things which are actually quite
simple and everyone
should become familiar with them as standard
motor control jargon.

UNDERVOLTAGE
RELEASE
Also Called: Low-Voltage Release
Two-Wire Control

UNDERVOLTAGE
PROTECTION
Also Called: Low-Voltage Protection
Three-Wire Control

These terms mean that the starter will drop out when
there is a voltage failure and will pick up again as soon
as voltage returns. Reference to the diagram below will
show how this occurs. The pilot device is unaffected
by
the loss of voltage and its contact remains closed, ready
to carry current
as soon as line voltage
returns
to
normal.

These terms mean that the starter will drop out when
there is a voltage failure but will not pick up automatically
when
voltage
returns.
The control
circuit
is
completed
through
the STOP button and also through
a holding
contact
(2-3) on the starter.
When the
starter
drops out, this contact
opens,
breaking
the
control circuit until the START button is pressed once
again.
L3

T3 t
Three

Two wres lead from the plot devrce to the starter. Undervoltage releaseand
two-wwe
control
should brrng to mrnd an automatrc p/lot devrce such as a
lrmrt swrtch or float switch whose functron IS openmg and closrng the control
crrcurt by means of a smgle contact.

Wires

Three wjfes lead from the p/lot devtce to thestarter.

Undervoltage
protection
and three-wrre
control should brmg to mrnd a START-STOP
push button
stat/on whrch IS the most common means of provrdrng this type of control.

The main distinction

between
the above two types of control
is that with undervoltage release the coil circuit is
maintained
through
the pilot switch contact,
and with undervoltage protection it is maintained
through
a stop
contact
on the push button station and also an auxiliary
contact on the starter. The designations
two-wire
and
three-wire
are used only because they describe
the simplest applications
of the two types. Actually,
in other
systems, there might be more wires leading from pilot device to starter but the principle of two-wire
or three-wire
control would still be present.

WIRING DIAGRAMS
Most of the diagrams
in this book are shown in two
ways. There is a wiring diagram
and adjacent to it a
line diagram.
Line diagrams
are included
because
their use is becoming
more widespread
and we believe
it is advantageous
to learn to use them.
Wiring diagrams or connection
diagrams
include all
of the devices in the system and show their physical
relation
to each other. All poles, terminals,
coils, etc.
are shown in their proper place on each device. These
diagrams
are helpful
in wiring-up
systems,
because
connections
can be made exactly as they are shown on
the diagram. In following
the electrical sequence of any
circuit, however, the wiring diagram does not show the
connections
in a manner that can be easily followed.
For this reason a rearrangement
of the circuit elements
to form a line diagram is desirable.
The line diagram (sometimes
referred
to as an
elementary diagram or a schematic diagram) is a
representation

of the system

showing

it in the simplest

vs LINE DIAGRAMS
way. No attempt is made to show the various devices in
their actual relative positions.
All control
devices are
shown
between
vertical
lines which
represent
the
source
of control
power,
and circuits
are shown
connected
as directly
as possible
from one of these
lines to the other. All connections
are made in such a
way that the functioning
of the various devices can be
easily traced. Note: In this publication
the line diagrams
show the control
circuits
only - power circuits
are
omitted for clarity, since they can be traced readily on
the wiring diagrams
(heavy lines).
A wiring diagram gives the necessary information
for
actually
wiring-up
a group of control
devices or for
physically
tracing
wires
when
trouble-shooting
is
necessary.
A line diagram gives the necessary information for easily following
the operation
of the various
devices
in the circuit.
It is a great aid in troubleshooting
as it shows, in a simple way, the effect that
opening
or closing
various
contacts
has on other
devices in the circuit.

WIRING

DIAGRAMS

m c
w
600

Bulletin

Bulletin 600 manual starting switches are designed for starting and
protecting small AC and DC motors rated at 1 HP or less where
undervoltage protection is not needed. They are operated by a toggle
lever mounted on the front of the switch. Wiring diagrams do not show the
operating mechanism since it is not electrically controlled.
These motor starters consist of an ON-OFF snap switch combined with
a thermal overload device operating on the eutectic alloy ratchet principle.
Terminal markings corresponding to those shown on the diagrams will be
found on each switch.

--7

L2

--

..%.~i

Catalog No. 600-TAX4

li

Single pole switches

can be used wherever
the
electrical
requirements
permit only one motor
line to be broken.

1
*

;;F

~^LrFI

,.

-l

L.._

Catalog No. 600-TAX109

Double pole switch with built-in
to indicate when switch is on.

Neon

pilot

light

Single Phase Lines

.L2 .Ll

Closing

r-

Rising Temp.

Tl

.?

: ^..G

1 ^,~r r

i-&r

Catalog No. 600-TAX9

Catalog No. 600-TAX293

For use with automatic

pilot devices
such as
thermostats,
and float switches. A selector switch
is mounted
in the same enclosure
to allow
manual operation
of the automatically
controlled
equipment.

Two speed manual motor starter is designed

for
starting and protecting
small, single phase, twospeed AC fan motors.

*.I

3c
-se;-~.-~*-'-E~~~irnr~.~~~~~~

WIRING

DIAGRAMS

Bulletin 609 manual starters are operated by START-STOP push

buttons mounted on the front of the starter. They are used in
applications which do not require undervoltage protection. Wiring
diagrams do not show the operating mechanism since it is not
electrically controlled. Pushing the START button mechanically
closes the contacts, connecting the motor to the line. The contacts
are opened by pressing the STOP button. Terminal markings
corresponding to those shown on the diagrams will be found on
each switch.

--

Tl

i;

Sizes 0 and 1

Sizes 0 & 1
3 Phase
(For 2 Phase,

or 2 Phase,

Direct

3 Wire

Current

3 Wire, L2 and T2 are common)

Sgl. Phase Lines

Pilot
Light

Red
Black

Sizes 0,l
Single

and 1P
Phase

Sizes 0 & 1
3 Phase

With Pilot

Light

WIRING
Bulletin

DIAGRAMS
609RS

& 609TS

The Bulletin 609RS manual reversing starters and the

Bulletin 609TS manual two-speed starters consist of
two standard Bulletin 609 starters mounted in a single
enclosure. Internal wiring of these starters provides the
necessary connections for interchanging two motor
connections in the case of the 609RS or switching to
another winding in the case of the 609TS. Bulletin
609TS is for two-speed separate winding motors only.
Terminal markings corresponding to those shown on
the diagrams will be found on each switch.

Reversing
Starter
Bulletin
609RS
Sizes 0 & 1
3 Phase
2 Phase, 3 Wire

Two-Speed
Starter
Bulletin
609TS
Sizes 0 & 1
3 Phase
2 Phase, 3 Wire

Tl
Tl

Tll

(For separate
winding
motors
only)

WIRING

w
Bulletin

DIAGRAMS

609U

The Bulletins
609U and 609TU are the same as the standard
Bulletin
609 Manual Starters except for the addition
of UnderThese starters
provide
full line voltage
voltage
Protection.
starting,
reliable thermal overload
protection,
as well as Undervoltage
Protection.
Typical
applications
are on woodworking
machinery,
metal sawing machines,
and many other machine
tools where Undervoltage
Protection
is needed to meet safety
standards.

Sizes 0, 1 and 1P
?
1

Pilot Light
2 - v.
b-7
1-r-i
,
1

d
1

3 Phase
Remove jumper A to connect
remote emergency
stop operator wires
to vacated
terminals.
Note: The remote stop terminal
block and jumpers are not available
on devices in
NEMA Type 7 and 9 enclosures.

Sizes 0, 1 and 1P
Single

-- L
Undervoltage
Coil
Pilot Light

I
L___--------------------/
Black

T2
/

Phase

Remove jumper
A to connect
remote emergency
stop operator wires
to vacated terminals.
Note: The remote stop terminal
block and jumpers are not available
on devices
in
NEMA Type 7 and 9 enclosures.

12

Sizes 0, 1 and 1P
3 Phase With 120 Volt Separate

Coil

These
starters
must
be properly
applied with a remote control transformer to provide undervoltage
protection.
Connect
transformer
primary to the line side of the starter
and the 120 volt secondary
to the
undervoltage
coil as shown
in the
diagram.

10

WIRING

DIAGRAMS
Bulletin

w
509

THE BULLETIN 509 AS REPRESENTED BY A WIRING DIAGRAM

Coil
I

Bulletin 509 Starter, Size 1

Wiring Diagram For

Bulletin 509 Starter, Size 1

Comparison
of the picture and drawing shown above should help the reader become
familiar with the Allen-Bradley
Bulletin 509 starter as it is represented
in wiring diagram
form. Principal corresponding
parts are labeled so that the wiring diagram can be compared
with the actual starter. This should aid in visualizing
the starter when studying a wiring
diagram and will help in making connections
when it is actually wired up. Note that the
wiring diagram shows as many parts as possible in their proper relative positions. It is not
necessary to show the armature and crossbar or the overload reset mechanism in the wiring
diagram since these parts need not be considered
from the wiring standpoint.
The Size 1 starter is shown here because all of the special wiring diagrams in this booklet use
Size 1 starters as examples. The other sizes of starters have a similar appearance as the Size
1 and their principle of operation is the same. Wiring of the other sizes of starters is the same
as for Size I although some of the connections
are not physically located in the same places
as on the Size 1.

6 WIRING
w
Bulletin
509

DIAGRAMS

3-Phase Starters

T3

Bulletin 509
Sizes 0, 1, 2, 3 814

Bulletin 509
Size 00

Standard
wiring with STARTSTOP push button station

Standard
wiring with STARTSTOP push button station

3-Phase Lines

d
I

Bulletin 509
Size 5
Standard
wiring with START-STOP
push button
station.
Current
formers are utilized thereby allowing
the use of Size 1 overload

transrelays.

16

WIRING

DIAGRAMS

w
509

Bulletin

3 Phase Starters

*L-%-u

Incoming

Lines

L2

Ll

L3

I--------:
-------------------------4
21

FU

13

3
W)

(AlY)

y
(A2Y)(A2Xj

I
I

25

1A

Start
I

23

6%

(AIX)

5,
(A3X)

(A3Y)

1 Econ.

Cap.

Bulletin 509 Sizes 7 and 8

Standard

wiring

with

START-STOP

push

button

station.

O.L.
YI
lh

4
,)

w
Bulletin

WIRING

DIAGRAMS

509

Single Phase Using Standard S-Phase Starters

Sizes 0, 1, 2, 3, & 4
Standard
wiring with STARTSTOP push button station.

115 Volt Motor

230 Volt Motor

18

Variations with START-STOP Stations

More Than One START-STOP Station

Used to Control a Single Starter
This is a useful arrangement
when a
motor must be started and stopped from
any of several widely separated locations.
Notice that it would also be possible to
use only one START-STOP
station and
have several STOP buttons at different
locations
to serve as emergency
stops.
Standard
duty START-STOP
stations
are provided
with the connections
A
shown
in the adjacent
diagram.
This
connection
must be removed from all but
one of the START-STOP
stations used.
Heavy
duty
and oiltight
push button
stations can also be used but they do not
have the wiring connection
A, so it must
be added to one of the stations.

WIRING

DIAGRAMS
Bulletin

Variations With START-STOP Stations

m 5
w
509

,. .I.

START-STOP Station with Pilot Light

to Indicate When Starter is Energized.
A pilot light is to be used with a three-wire
START-STOP
station, so that it will be
on when the starter is energized.
The light is shown
here as separately
mounted,
but it can be combined
in the
same enclosure
with the start and stop
buttons. Stations combining
all three are:

Catalog
Number
Standard
Duty
120 or 24O.V

800S-2SAP

Heavy Duty
120 V
240 V
480 V, 60 Hz
600 V, 60 Hz

800H-2HAR
800H-2HAP
800H-2HAY
800H-2HAV

Oiltight
120 v
240 V
480 V
600 V

800T-2TAR
800T-2TAP
800T-2TAY
800T-2TAV

20

Pilot Light

Station with Pilot Light to Indicate

When Starter is Deenergized.
If it is necessary
for a pilot light to show
when the starter
is de-energized,
this
requirement
is most easily fulfilled
by
attaching
a normally
closed Bulletin 595
auxiliary contact to the starter and connecting
it between
Ll and L2 in series
with the pilot light. A represents
the
Bulletin 595 auxiliary
contact which can
be added to any Allen-Bradley
Bulletin
500 Line starter, sizes 0 through
4.
If the pilot light is to be included
in the
same enclosure
with the start and stop
buttons,
any of the push button stations
listed with drawing
No. 20 can be used.
The Bulletin
595 auxiliary
contact
has
many other uses besides the ones shown
here. It can also be used to operate other
control circuit devices, interlock starters,
etc.

w
Bulletin

WIRING

DIAGRAMS

509

Variations With START-STOP Stations

--..,,_j _Is,,\.+*,
Start
r-7
I--+

I
I

Three Starters are Operated from a Single START-STOP Station. An Overload on Any
One of the Motors will Drop Out All Three Starters
Three Bulletin 509 solenoid type starters are to be connected
so that all are controlled
from a
single START-STOP
push button station. A maintained
overload
on any motor, tripping
out the overload
relays on its respective
starter, will drop out all three starters disconnecting
all motors from the line.
Assuming
that standard
Bulletin 509, Form 2 starters are to be used, then in order to obtain
the desired operation,
the wiring connection
Y must be removed from each starter. The
control
circuits
of the several starters
are interconnected.
It is therefore
necessary
to
disconnect
the power to the line terminals
of all the starters
in order to completely
disconnect
the equipment
from line voltage.

16

WIRING

DIAGRAMS

Variations With START-STOP Stations

- . .-*.T>N-r
x-e

r---i

1-L
L-A
41

Start

Start

r--i

r-7

stop

b.Td

T36

r-%Td

T26

T36

otor $J

T26

L(.otor

T36

Each Starter is Operated by Its Own START-STOP Station. Overload on One Drops
Out All Starters. A Master STOP Station Can Be Provided
Several starters (3 used in diagram)
are to be wired so that each starter is operated from its
own START-STOP
push button station. However, a maintained
overload, tripping a relay
on any one of the starters, will automatically
drop out all of the starters. A master STOP
station wired into the circuit as illustrated
will trip out all starters when pushed.
To obtain the desired operation
using standard Bulletin 509 Form 2starters, wireX
must be
removed
from all but one of the starters. The control
circuits of the several starters are
interconnected.
It is therefore
necessary
to disconnect
the power to the terminals of all the
starters in order to completely
disconnect
the equipment
from line voltage.

w
Bulletin

WIRING

DIAGRAMS

509
Variations
With
START-STOP
* .1 . i - I.cI.- apxLlllrwssY
i-a~~~~~

Stations

Two Starters are to Be Operated from a Single Station,

But a Short Delay Must Prevent Them from Being Energized Together
In some cases, the power distribution
system does not have
sufficient
capacity to start several motors simultaneously.
If
several motors are to be started
from the same push button
station under these conditions
a time delay can be provided
between
the operation
of the
motor starters.
When the START
button
is
pushed, the first starter is energized
along with a timing
relay. When the timing
relay
times out, it operates a contact
which closes the control
circuit of the second starter. (The
timer can be a Bulletin 849.)

-7TN.0.T.C

YY
Motor

If more than two starters are to

be used, additional
timers will
have to be added in the same
way as the one shown connected to Ml here.

24

Step-Down Transformer Provides Low Voltage for Control

Circuit Wired for Three-Wire
Control
The starter coil is to be operated on a voltage
lower than
line voltage. (Usually done for
safety reasons.) This requires
the use of a stepdown
transformer in the pilot circuit. The
starter
is operated
from
a
START-STOP
push button
station,
either Bulletin
8OOS
800H or 800T.
When a control
circuit
stepdown transformer
is used with
a standard Bulletin 509 starter,
the wiring connection
X must
be removed. Note that a fuse is
added to the transformer
secondary.

18

T3
$
*
Motor
b

WIRING

DIAGRAMS

Jogging

-3

Separate START-STOP-JOG with

Standard Push Buttons and a JOG Relay
The Bulletin 509 starter is to be operated by a
START-JOG-STOP
push button station.
The purpose of jogging
is to have the motor
operate only as long as the JOG button is
held down. The starter
must not lock
in
during jogging,
and for this reason the jog
relay is used.
Start

Jog

T3

stop

Istop_

1 Jog

=&CR

Relay

n,

Pushing the START

button operates the jog
relay, causing
the starter to lock in through
one of the relay contacts.
When the JOG
button is pressed, the starter operates, but this
time the relay is not energized
and thus the
starter will not lock in.
CR represents
the
Number 700-C200.

jog

relay,

a Catalog

For a surface mounted

heavy duty STARTJOG-STOP
station, specify Catalog Number
800H-3HG.
A Catalog Number 800T-3TG can
also be used.

Combined START, JOG and Separate

STOP With Selector Switch
Jogging With a Selector Switch

Here, a three-unit
push button station with a
START-STOP
and selector
switch
is used.
Heavy duty station is Catalog Number 800H3HW14 and oiltight Catalog Number is 800T3TW15.
The circuit
to the hold-in
contact
M is
broken
when the selector
is in the JOG
position.
The START
button
is used to
JOG or RUN the motor, depending
on the
position of the selector switch.

Q3
C

WIRING

Bxtin

DIAGRAMS

509

Two-Wire Control Circuits

Starter Operated by Pressure Switch or Thermostat with Manual Control Provided by a

Selector Switch. High Pressure Cut-Out
Switch Can be Added
The selector switch
part of the starter.

feature

can be obtained

as

The selector
switch
makes it possible
to
operate the starter manually
for testing or in
case of failure of the automatic
pilot control.
When a standard
Bulletin 509 across-the-line
starter without
push buttons is used, connection Y is removed and the wiring follows the
solid lines of the diagram.
If a high pressure cut-out switch is added, it
should be inserted in the line leading from Ll
to the HAND
terminal of the selectorswitch.
A represents
the thermostat
or low
sure switch
and B represents
the
pressure
cut-out
or safety
switch.

preshigh

For the HAND-OFF-AUTO

selector switch,
either a Catalog Number 800T-R3SX
(standard duty),
a Catalog
Number
800H-R3HA
(heavy
duty),
or a Catalog
Number
800TR3TA (oiltight)
can be used.

Two-Wire Control with Control Relay Added

to Provide Under Voltage Protection
Undervoltage
protection
is often necessary
when two-wire
control
is used in a location
where line disturbances
are frequent.
Since
the two-wire
pilot device is not affected
by
loss of voltage, its contact will remain closed
even though there is no power on the line. This
means that without
the feature
of underrepeated
voltage
dips
voltage
protection,
would
cause
the starter
to chatter
and
welding
of contacts
might result.
Undervoltage
protection
can be
improve
safety,
where automatic
after a power outage is hazardous.

Reset
-~I2-q
-0%
---_
CR

added
to
restarting

If a voltage failure relay is added, it will open

the pilot circuit at a bad voltage dip or power
outage and will not permit the starter to close
again until the relay has been reset.
A

represents

the two-wire

pilot

device.

The reset button,

can be a Catalog
800H-1 HG (heavy duty) or a Catalog
800T-1 TG (oiltight).

Number
Number

Ll
Reset
1-L
L

CR represents
the voltage
failure
relay. A
Catalog Number 700-C200 relay can be used.
Device

20

WIRING

DIAGRAMS
Bulletin

m
mnv
509

Two-Wire Control Circuits

Starter is Controlled by a Gauge-Type

Thermostat
Since the contacts of a thermostat
of this type
usually cannot handle the current to a starter
coil, a thermostat
relay must be used as an
intermediate
step between
thermostat
and
starter.
The relay
is energized
when
the
CLOSE
contact
is made and de-energized
when
the OPEN
contact
is made. The
OPEN
contact
by-passes
the relay coil to
de-energize
it. A resistor, built into the relay,
guards
against
a short circuit
when this is
done.

The thermostat
contacts
must
be adjusted
too close to one
this may burn out the resistance
advisable
to check the inrush
relay against the current rating
stat. This scheme
can also
pressure controls.

1 Close A Open
I7

A represents
the three-wire
temperature
control device.

Res.

not overlap or
another,
since
unit. It is also
current
of the
of the thermobe used with

gauge

type

CR represents the thermostat

relay. A Catalog
Number 700-BA200
can be used here.

L3

Open

I
A Close

l-b

Starter is Controlled by a Gauge-Type Thermostat Whose Contacts Can Switch Only a

Small Amount of Current
Here is another method of protecting
thermostat contacts from high current. This scheme,
however,
is for use with a thermostat
whose
contacts can handle even less current than the
ones in the previous
example.
In a case like this, it is advisable
to use relays
having
coils which operate
at a very small
value of volt-amperes.
This will reduce the
burden
on the thermostat
contacts
and is
especially
advisable where frequent operation
is required.
A represents
the three-wire
sensitive gauge type control.
CR1 and CR2 represent
low coil current
relays, Catalog Numbers 700-CL200 and 700CL1 10, respectively.

21

WIRING
w
Bulletin

DIAGRAMS

509
Two-Wire

Control

Circuits

Float Switch Controls Starter

The diagram shows a floatswitch
intended for
tank operation.
When the water reaches low
level the float switch closes. Pumping
action
will continue
until the water reaches high
level.
For sump
pumping
remove
wire A and
connect
as per the dotted line. At low level
the float
switch
operates
and stops
the
pumping
action.
Sump pumping
action will
not commence
until the water reaches high
level.
A Bulletin
840 Float Switch with an appropriate float switch accessory
may be used for this
application.

22

Float
Switch

WIRING

Pump Operation
Surge Protection is often

DIAGRAMS

m
d

Bulletin

509

Backspin is the name given to the backward

necessary
when the pump is
turned off and the long column
of water is stopped
by a
check valve. The force of the sudden stop may cause surges
which operate the pressureswitch
contacts, thus subjecting
the starter to chattering.
jr- _, , - r ,.
.L.
,. .

,w
)
/I

turning of a
centrifugal
pump when a head of water runs back through
the pump just after it has been turned off. Obviously
starting
the pump during
backspin
might damage
the pump or
motor.

System Provides Backspin Protection and

Surge Protection on Stopping.- Time Delay
Between Pressure Switch Closing and Motor
Starting
The pressure switch energizes the timer (TR),
but the motor cannot start until the time delay
contact has closed. The timer can thus be set
for a time long enough to allow all surges and
backspin
to stop.
The dotted lines show how a selector switch
can be added to by-pass the pressure switch if
necessary. This is often used for motor testing
purposes.
It does not eliminate the time delay
however.
If the selector switch is added, the
wire A must be removed.

33

T.C.

System Provides Surge Protection on Both

Starting and Stopping. Backspin Protection
Automatically Included

T3

Two timing
relays
are used here, one to
provide surge protection
on starting and one
to provide surge protection
on stopping
and
backspin
protection.
TRl
is an on-delay
timer used for surge protection
on starting.
When the pressure
switch
contact
closes,
relay CR, the starter and the two timers are
energized.
The instantaneous
contact on TRl
closes, by-passing
the pressure switch contact and preventing
the pump motor starter
from dropping out even though starting surges
open the pressure
contact.
After the timing
period, the time delay contact TRl opens the
by-pass and PS can then stop the pump at the
proper pressure.
TR2 is an off-delay
timer
for surge protection
on stopping
and backspin protection.
Once turned off, the system
cannot be operated again until timer TR2 has
timed out and its normally
closed contact
is
closed.
When a standard
Bulletin 509 starter without
push buttons is used, connection
Y must be
removed.

34

23

1
WIRING
w
Bulletin
509

DIAGRAMS

Sequence Control

a2
iL3
TTT

Start
r--1

Sequence Control of Two Motors- One

to Start and Run for a Short Time After the
Other Stops

I-I
I

In this system
it is desired
to have a
second motor started automatically
when
the first is stopped. The second motor is
to run only for a given length of time.
Such
an application
might
be found
where the second motor is needed to run
a cooling fan or a pump.
To accomplish
this an off-delay
timer
(TR) is used. When the start button
is
pressed,
it energizes
both Ml and TR.
The operation
of TR closes its time delay
contact but the circuit to M2 is kept open
by the opening
of the instantaneous
contact.
As soon as the stop button
is
pressed,
both Ml and TR are dropped
out. This closes the instantaneous
contact on TR and starts M2. M2 will continue
to run until TR times out and the time
delay contact opens.

T19

T29

T39

TlQ

w
T29

Motor

Ll

TR

Inst.

TR

Off

Delay

O.L.
YI
h

T39

L2

T.O.

35

Starters Arranged for Sequence Control

of a Conveyor System
The two starters
are wired so that M2
cannot
be started
until Ml is running.
This is necessary
if Ml
is driving
a
conveyor
fed by another conveyor
driven
by M2. Material
from the M2 conveyor
would pile up if the Ml conveyor
could
not move and carry it away.

I-I
M--J
stop

If a series of conveyors
is involved,
the
control circuits of the additional
starters
can be interlocked
in the same way. That
is, M3 would be connected
to M2 in the
same step arrangement
that M2 is now
connected
to Ml, and so on.
The Ml stop button or an overload on Ml
will stop both conveyors.
The M2 stop
button or an overload on M2 will stop only
M2.

L2

If standard Bul. 509 starters are used, wire

X must be removed
from M2.

NOTE:

Control

circuit

is connected

only

to the lines of Motor

1.

Bulletin

L
--- Start

1-1

Ii-i

Motor 3

II

Pressure

MlOL

Switch

YI

Start

stop

M20L
0

\I -k

3
II
stop

Start

M30L

00

I2

M3
,,
II

\I Ir,

1)

3
Motor 4

ii
NOTE: Line phase connections
for all motors

must be same

Operation of Any One of Several Starters Causes a Pump or Fan Motor to Start
Several motors are to be run independent
some by three-wire
pilot devices. Whenever
run.

of each other, with some of the starters actuated

by two-wire
and
any one of these motors is running, a pump or fan motor must also

A master start and stop push button station with a control relay is used to shut down the entire system in an
emergency.
Control
relay (CR) provides three-wire
control
for Ml which is controlled
by a two wire control
device

such

as a pressure

Auxiliary
contacts
on Ml,
one of them may start M4.
standard hold-in
contact
required when a two-wire

switch.

Motors

M2 and M3 are controlled

by START-STOP

push button

stations.

M2, and M3 control M4. These auxiliary

contacts are all wired in parallel so that any
Bulletin 595 auxiliary
contacts have been added to M2 and M3 for this purpose. The
on Ml may be used as an auxiliary
if wire Y is removed. Hold-in
contacts are not
control device is used.

The Bulletin 595 auxiliary

contacts are designed as A and B on the wiring
added to any Allen-Bradley
Bulletin 500 starter sizes 0 through
4.

diagram.

These contacts

are easily

When this system is used, the phase connections

on all of the starters must be the same. That is, Ll of each
starter must be connected
to the same incoming
phase line, L2 and L3 of each starter must besimilarly
phased
out.

509

w
Bulletin

26

WIRING

DIAGRAMS

505

Wiring

Diagram

Bulletin

505, Size

of
1

WIRING

3-Phase Starters

DIAGRAMS
Bulletin

w
505

3 Phase Lines

Push
Button
Stallon
r---7

Bulletin 505
Size 00
Standard
wiring
with
WARD-REVERSE-STOP
button station.

FORpush

A mechanical
interlock
is provided, however electrical interlocks are not furnished
on size
00 reversing
starters.
Electrical interlocking
can be provided within
the push button
station,
as shown in the diagram.
When
using
this arrangement,
wire X must be
removed.

Tl

Limit switches can be added to

stop the motor at a certain
point in either direction.
Connections
A and B must be
removed
when limit switches
are used.

3 Phase Lines

FW.
Rev.

kF
---1
I-LI
/ -

Stop
L---l
J-ware Control

Bulletin 505
Sizes 0, 1, 2, 3 and 4
Standard
wiring
with FORWARD-REVERSE-STOP
push
button
station.
The STOP
button must be depressed
before changing
directions.
A mechanical
interlock
and
electrical
interlocks
are supplied as standard
on all reversing
starters
size 0 and
larger.
Limit switches can be added to
stop the motor at a certain
point in either direction.
Connections
A and B must be
removed
when limit switches
are used.

27

Bulletin

505

Push Button Station Variations

. ,

Control
Transformer
Pri.
Hl H2 H3 H4

Grd.

Fuse

r-

- 1 For.

Push Button Wired so Starter Can Be Switched from One Direction to the Other
Without Pushing STOP Button
This scheme allows immediate
reversal of the motor when it is running
in either direction.
It is not
necessary
to depress the STOP
button when changing
direction.
A standard
Bulletin
505 reversing
switch can be used if wire W is removed.
The diagram
shows the control
circuit set up for reduced
voltage
control,
although
this may not be
necessary
in many cases. Notice that wire X must be removed when reduced voltage control is used. The
push button station can be a Catalog Number 800S-3SA
(standard
duty), 800H-3HA
(heavy duty) or a
Catalog
Number 800T-3TA
(oiltight).

40

28

_1

WIRING

DIAGRAMS
Bulletin

w
505

;
Starting and Stopping in Both
Directions. Lights Indicate Direction in Which Motor is Operating

Lc)

Light -

Motor

This setup provides

exactly
the
same operation
as shown in the
previous
diagram,
except
that
pilot lights have been added to
show which way the motor is running. Once again, standard Bulletin 505 reversing
switch can be
used if wire W is removed. The
pilot lights can either be separately mounted
or mounted
in the
push button station. If they are to
be mounted
in the station a Catalog Number 800H-3HA2P
can be
used.

41

__
3 Phase Lines

The Motor Runs in a Preselected

Direction Which is Determined by
The Setting of a Selector Switch
The motor can be run in either
direction,
but the desired direction must be set on a selector
switch before starting. The motor
is then operated from a STARTSTOP station as a single direction motor.
The wiring of the standard
Bulletin 505 reversing
starter must be
modified
slightly
to fill this requirement.
Note that the connections which
normally
lead from
the electrical
interlock
contacts
to points
3 and 5 have been
removed
and that different
connections
have been made to the
electrical
interlocks
and points 3
and 5.
It is usually
most convenient
to
include theselector
switch as part
of the push button station. This
can be done with either a Bulletin
800H
heavy
duty
station
or a
Bulletin 800T oiltight
station.

WIRING
w
Bulletin

DIAGRAMS

505

Limit Switch Controls

Reversing
Here the direction
of the motor
is determined
by the position
of a limit switch.
A STARTSTOP push button
station
is
used to energize
the system
and the motor will start according
to the position
of the
limit switch. The wiring of the
standard Bulletin 505 need not
be modified
for this type of
operation.
Limit switch
connections
are made directly
to
the electrical
interlocks.
It is necessary to use a control
relay in this system such as a
Catalog Number 700-C200. The
limit switch
can be any of
several
in the Bulletin
802T
line having
one NO and one
NC contact.

43

Jogging With Relays

In this arrangement
for jogging
and running
in either
direction
jogging
relays are
used to provide
proper
jogThese
relays
guard
ging.
against either the forward
or
reverse
contactor
locking
in
during jogging.
The push button
station
can
be a Bulletin 800H, heavy duty,
or a Bulletin
800T oiltight.
Catalog Number 700-C200 relays may be used.

WIRING

DIAGRAMS
Bulletin

w
505

Jogging

stop

Starting, Stopping and Jogging in Either Direction. Jogging Controlled Through a Jogging Selector Switch
i

Here, the motor can run normally in either direction

or can be jogged in either direction. With theselector
in the
RUN position, the motor can be started in either direction and will stop when the STOP button is pressed. It is
not necessary
to press the STOP button before changing
from forward to reverse.
With the selector in the JOG position, the FORWARD
and REVERSE
buttons act as jogging buttons. The
motor will run in the indicated
direction
when one of them is pressed but will stop as soon as the button is
released.

The wiring of the standard Bulletin 505 must be modified for this type of operation.
Note that the wires shown
with dotted lines must be removed from the standard starter. The push button station can be either a Bulletin
800H heavy duty, or a Bulletin 800T, oiltight.

31

v&w
Bulletin

WIRING

DIAGRAMS

SOS

3 Phase Lines

Plugging a Motor to a Stop from One Direction-

This system is for a motor that is to run in one direction only and must come toan immediate stop when the stop
button is pressed. The reverse contactor
of the Bulletin 505 reversing switch is used only for plug-stopping
and
not for running in reverse. When a standard
Bulletin 505 is used, wire W and all wires represented
by dotted
lines should be removed.

I
1
i

The lockout
solenoid
is built into the Bulletin
808 Speed Switch and its function
is to guard against an
accidental
turn of the motor shaft closing the speed switch contacts
and starting the motor. This protective
feature is optional
and the speed switch can be furnished
without
lockout solenoid
if desired.
The push

32

Lockout Solenoid Provided

button

station

is a Catalog

Number

800H-2HA

or a Catalog

Number

800T-2TA.

Bulletin

Plugging

To Motor
Terminals
LS

Speed
Switch

stop

CR

Tl

L2
For.
-ho
0
stop

I
I
I
!
I
I
I

Rev.
0

I
I

CR

O.L.

Lockout
Solenoid
NOTE:

CR must

be located

within

the starter

Plugging a Motor to a Stop from Either Direction4

:

enclosure.

Lockout Solenoid Provided

With the system wired as shown, the motor can be started in either direction
by pressing the proper button.
Pressing the STOP button will plug the motor to a stop from either direction,
A standard Bulletin 505 reversing
switch is used for this application.
The lockout solenoid is a built-in part of the Bulletin 808 Speed Switch and it guards against
of the motor shaft closing the speed switch contacts and starting the motor. This protective
and the speed switch can be furnished
without
lockout solenoid
if desired.
The control relay necessary with this system is a Catalog Number
a Catalog Number 800H-3HA
or a Catalog Number 800T-3TA.

700-8300

an accidental
turn
feature is optional

and the push button

station

can be

505

c
m
w
Bulletin

WIRING

DIAGRAMS

505

ANTI-PLUGGING
1-

Speed

ANTI-PLUGGING-

Motor Is to Be Reversed, but It Must Not Be Plugged

A Bulletin 808 Speed Switch with normally

closed contacts
is used for anti-plugging.
The schematic
diagram
shows that with the motor operating
in one direction,
a contact on the Speed Switch opens the control circuit of
the starter used for the opposite direction.
The open contact will not close until the motor has slowed down, and
thus, the reversing
switch cannot be energized
to change the direction
of the motor until the motor is moving
slowly.
A standard
Bulletin 505 reversing
switch
Catalog Number 800S-3SA,
or a Catalog

34

can be used with this application.

Number 800H-3HA,
or a Catalog

The push button station

Number 800T-3TA.

can be a

WIRING

DIAGRAMS

Bulletin

BULLETIN 520 MULTI-SPEED

MOTOR STARTERS

starters of the types used in the diagrams on the

Shown below are Bulletin 520 I multi-speed
following
pages. Wiring of these starters can be compared to the diagrams in the same manner as
was done for the Bulletin 509 on page 11 and the Bulletin 505 on page 26. Size 1 starters are used
in the illustrations
and diagrams, but the operating principle and wiring is similar for other sizes.

For
Separate

Winding

Motors

For
Consequent
Constant
Variable
-

Pole Motors,
Torque

or

Torque
oil For

Consequent
Constant

Pole Motors,
Horsepower

$!rJ
c

WIRING

Bulletin

DIAGRAMS

520

4
2
3

79 * 1High
f
fl
I
I A1qLow

f-udl
I0

OI

1 stop

Push button connectlons

to allow

startmg In either speed and changlng

from

wtthout

one

speed

to another

first pressing the STOF

button

wop

Ll
T126

T12

Control

by

an

wore device

automatic

A selector

used to determine

T136

T3b

T2

two-

switch IS

speed

Three Wire

L2
1

L2
Two Wire
I

2
Connections
pilot lights

for speed-lndlcatlng
Can be added lo any of

A typical connection
for a Bulletin 520 used with a two speed separate wind4ng
motor is shown above. The wiring diagram and line diagram in the above panel
%.tstrate connections
for the following method of operation: Motor can be started in
either HIGH or LOW speed. The change from LOW to HIGH c&n be made without
first pressing STOP button. When changing from HtGH to LOW the STOP button
must be pressed between speeds.

the control schemes shown on this

page

-49

36

The pilot device diagrams shown in the side panel illustrate other connections
can be made to obtain different sequences and methods of operation.

that

WIRING

DIAGRAMS

w
520

Bulletin

2 2

ConnectIons
change

1 stop

OOJ
-above

from

only without

allow

LOW

speed

to HIGH

uslrlg STOP Start

In either speed

CONNECTIONS
-

MADE BY STARTER
I

T4

Tl

Control

by

an

automatic

wire devcce A selector

used to determme

Constant
Torque

two-

swatch IS

speed

Variable
Torque

L2

Three Wire
stop
-aI*

High

L2

Two Wire
For Consequent Pole Motors -

Constant Torque or Variable Torque

4
For typical connection
for a Bulletin 520 used with a consequent
pole, constant or
variable torque motor is shown above. The wiring diagram and the line diagram in
the above panel illustrate connections
for the following
method of operation: Motor
can be started in either HIGH or LOW speed. The change from LOW to HIGH or
from HIGH to LOW can be made without first pressing STOP button.

2
Connectlons
pilot lights

;
I

The pilot device diagrams shown in the side panel illustrate other connections
can be made to obtain different sequences and methods of operation.

that

for speed-tndlcatlng
Can be added to any of

the control schemes shown on this

page

WIRING

w
Bulletin

520

y-0
1

4
2
3

I High
I

SUPI
1

DIAGRAMS

1 Low

1 stop

L--0-l

Push button connectfons

to allow

starting In eitherspeed

and chang-

ing

to another

from

without

one

speed

first pressmg the STOP

button

(Tlb

T2b

T4

CONNECTIONS
Control
wire

by an

device

automatic

A selector

used to determme

two-

switch

IS

speed

Speed
Low

Supply Lines
Ll
L2 L3
Tl
T2 T3

High 1 T6

T4

Motor
Terminal
Markings

MADE BY STARTER

T5 ITl,

Open

Together

None

T4,

2,

5,

T3

Tl

None
T5 A
Constant

T6
T2
Horsepower

Three Wire ;
stop

High

Two Wire
For Consequent Pole Motors -

Connections
pllot lights

for speed-lndlcatlng
Can be added to any of

Constant Horsepower

A typical connection
for a Bulletin
520 used with a consequent
pole constant
horsepower
motor is shown above. The wiring diagram and line diagram in the
above panel illustrate connections
for the following method of operation: Motor can
be started in either HIGH or LOW speed. The change from LOW to HIGH can be
made without first pressing STOP button. When changing from HIGH to LOW the
STOP button must be pressed between speeds.

the control schemes shown on this

page

38

The pilot device diagrams shown in the side panel illustrate other connections
can be made to obtain different sequences and methods of operation.

that

mc ALLEN-BRADLEY
w

A ROCKWELL INTERNATIONAL

COMPANY

Allen-Bradley has been helping its customers improve productivity and quality for 90 years.
It designs, manufactures and supports a broad range of control and automation products
worldwide. They include logic processors, power and motion control devices, man-machine
interfaces and sensors. Allen-Bradley is a subsidiary of Rockwell International, one of the
worlds leading technology companies.

With major offices worldwide.

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Publication GI-2.0 - June, 1990

Supersedes Publication GI-2.0 Dated January, 1983

Copyright 1993, Allen-Bradley Company, Inc. Printed in U.S.A.