Allen-Bradley 500LC Pole Conversion Modification Installation Instructions
Allen-Bradley 500LC Pole Conversion Modification kits make it easy to change the number of poles on your Bulletin 500LC Lighting Contactors. These kits contain all the necessary parts, including contact blocks, leaf springs, and actuators, to convert your existing contactor to a different number of poles. Use these conversion kits to change the number of poles on your existing lighting contractor. No other special tools are needed, except for a screwdriver for nameplate catalog number changes.
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Instructions
Publication 500LC–IN004A–EN–P May 2005
N. O. Pole Conversion Kits
500LC–2PCK, 500LC–4PCK,
500LC–6PCK, 500LC–LS3 for
Bulletin 500LC Lighting Contactors
Use these instructions to change poles on Bulletin 500LC Lighting Contactors.
Contact
Block
Kit
number
Number of Contactor Poles (Normally Open)
Block
Kit No.
number
of Poles 2 4 6 8 10 12
500LC–2PCK 2 1 top 1
bottom
500LC–4PCK 4 1 top 1
bottom
500LC–6PCK 6 1 top 1 top 1 top 2 both
500LC–LS3 leaf spring 1 1 1
A new and different contact block is needed in the lighting contactor when
the number of poles is changed. A leaf spring must be used on 2–...6–pole
(without a bottom contact block). Two actuators are used on all
configurations. When changing poles, also change catalog number on
nameplate.
Recommended Tools Screwdriver and scriber (to change nameplate catalog number)
Figure 1 Contact block and actuator
* leafspring is not used
on 8–...12–pole
Be sure to change the catalog
number on the nameplate.
leaf spring *
(2–...6–pole only)
base
actuator
(2 used; 1 top, 1 bottom)
lower
contact block
When a lower contact block is
added remove the leafspring.
nameplate screw
nameplate
Tighten nameplate screws
evenly to 10 in–lb.
upper
contact block
Two actuators are always
used (top and bottom).
CAM / CORE must be white.
This kit should not be applied
to Lighting Contactors with
black CAM / CORE.
Publication 500LC–IN004A–EN–P May 2005
N. O. Pole Conversion Kits
500LC–2PCK, 500LC–4PCK,
500LC–6PCK, 500LC–LS3 for
Bulletin 500LC Lighting Contactors
Use these instructions to change poles on Bulletin 500LC Lighting Contactors.
Contact
Block
Kit
number
Number of Contactor Poles (Normally Open)
Block
Kit No.
number
of Poles 2 4 6 8 10 12
500LC–2PCK 2 1 top 1
bottom
500LC–4PCK 4 1 top 1
bottom
500LC–6PCK 6 1 top 1 top 1 top 2 both
500LC–LS3 leaf spring 1 1 1
A new and different contact block is needed in the lighting contactor when
the number of poles is changed. A leaf spring must be used on 2–...6–pole
(without a bottom contact block). Two actuators are used on all
configurations. When changing poles, also change catalog number on
nameplate.
Recommended Tools Screwdriver and scriber (to change nameplate catalog number)
Figure 1 Contact block and actuator
* leafspring is not used
on 8–...12–pole
Be sure to change the catalog
number on the nameplate.
leaf spring *
(2–...6–pole only)
base
actuator
(2 used; 1 top, 1 bottom)
lower
contact block
When a lower contact block is
added remove the leafspring.
nameplate screw
nameplate
Tighten nameplate screws
evenly to 10 in–lb.
upper
contact block
Two actuators are always
used (top and bottom).
CAM / CORE must be white.
This kit should not be applied
to Lighting Contactors with
black CAM / CORE.
Installing Pole Conversion Kits 500LC–2PCK, 4PCK, 6PCK, LS3 to Bulletin 500LC Lighting Contactors2
Publication 500LC–IN004A–EN–P May 2005
F
12 Pole
E
10 Pole
D
8 Pole
C
6 Pole
B
4 Pole
A
2 Pole
Figure 2 Location of contact block(s) in relation to number of poles
top
bottom
Table A – N. O. Pole Conversion Kits
Total
Poles
Number of Poles on Existing Bulletin 500LC Lighting Contactor
Poles
Needed 2 4 6 8 10 12
2
see
Fig. 2A
Remove top
block. Install
new block
500LC–2PCK
on top.
Remove top
block. Install
new block
500LC–2PCK
on top.
Remove top block.
Remove bottom
block and
reinstall it on top.
Install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Install new block
500LC–2PCK
on top. Remove
bottom block and
install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Install new block
500LC–2PCK
on top. Remove
bottom block and
install a new
leaf spring
500LC–LS3
on bottom.
4
see
Fig. 2B
Remove top
block. Install
new block
500LC–4PCK
on top.
Remove top
block. Install
new block
500LC–4PCK
on top.
Remove top block.
Install new block
500LC–4PCK
on top. Remove
bottom block.
Install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Remove bottom
block and
reinstall it on top.
Install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Install new block
500LC–4PCK
on top. Remove
bottom block and
install a new
leaf spring
500LC–LS3
on bottom.
6
see
Fig. 2C
Remove top
block. Install
new block
500LC–6PCK
on top.
Remove top
block. Install
new block
500LC–6PCK
on top.
Remove bottom
block. install a
new leaf spring
500LC–LS3.
Remove bottom
block. install a
new leaf spring
500LC–LS3.
Remove bottom
block. install a
new leaf spring
500LC–LS3.
8
see
Fig. 2D
Remove leaf
spring. Remove
top block and
reinstall it on
bottom. Install
new block
500LC–6PCK
on top.
Remove top
block. Install
new block
500LC–2PCK
on top.
Remove leaf
spring. Install
new block
500LC–2PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–2PCK
on bottom.
Remove bottom
block. Install
new block
500LC–2PCK
on bottom.
10
see
Fig. 2E
Remove leaf
spring. Remove
top block and
reinstall it on
bottom. Install
new block
500LC–6PCK
on the top.
Remove leaf
spring. Install
new block
500LC–4PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–4PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–4PCK
on the bottom.
12
see
Fig. 2F
Remove top block.
Install new block
500LC–6PCK
on top. Remove
leaf spring. Install
another new block
500LC–6PCK
on the bottom.
Remove top block.
Install new block
500LC–6PCK
on top. Remove
leaf spring. Install
another new block
500LC–6PCK
on the bottom.
Remove the leaf
spring. Install
new block
500LC–6PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–6PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–6PCK
on the bottom.
NOTE: Top and bottom actuators are required for all configurations;
top actuator with a contact block, bottom actuator with a contact block or a leaf spring.
Publication 500LC–IN004A–EN–P May 2005
F
12 Pole
E
10 Pole
D
8 Pole
C
6 Pole
B
4 Pole
A
2 Pole
Figure 2 Location of contact block(s) in relation to number of poles
top
bottom
Table A – N. O. Pole Conversion Kits
Total
Poles
Number of Poles on Existing Bulletin 500LC Lighting Contactor
Poles
Needed 2 4 6 8 10 12
2
see
Fig. 2A
Remove top
block. Install
new block
500LC–2PCK
on top.
Remove top
block. Install
new block
500LC–2PCK
on top.
Remove top block.
Remove bottom
block and
reinstall it on top.
Install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Install new block
500LC–2PCK
on top. Remove
bottom block and
install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Install new block
500LC–2PCK
on top. Remove
bottom block and
install a new
leaf spring
500LC–LS3
on bottom.
4
see
Fig. 2B
Remove top
block. Install
new block
500LC–4PCK
on top.
Remove top
block. Install
new block
500LC–4PCK
on top.
Remove top block.
Install new block
500LC–4PCK
on top. Remove
bottom block.
Install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Remove bottom
block and
reinstall it on top.
Install a new
leaf spring
500LC–LS3
on bottom.
Remove top block.
Install new block
500LC–4PCK
on top. Remove
bottom block and
install a new
leaf spring
500LC–LS3
on bottom.
6
see
Fig. 2C
Remove top
block. Install
new block
500LC–6PCK
on top.
Remove top
block. Install
new block
500LC–6PCK
on top.
Remove bottom
block. install a
new leaf spring
500LC–LS3.
Remove bottom
block. install a
new leaf spring
500LC–LS3.
Remove bottom
block. install a
new leaf spring
500LC–LS3.
8
see
Fig. 2D
Remove leaf
spring. Remove
top block and
reinstall it on
bottom. Install
new block
500LC–6PCK
on top.
Remove top
block. Install
new block
500LC–2PCK
on top.
Remove leaf
spring. Install
new block
500LC–2PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–2PCK
on bottom.
Remove bottom
block. Install
new block
500LC–2PCK
on bottom.
10
see
Fig. 2E
Remove leaf
spring. Remove
top block and
reinstall it on
bottom. Install
new block
500LC–6PCK
on the top.
Remove leaf
spring. Install
new block
500LC–4PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–4PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–4PCK
on the bottom.
12
see
Fig. 2F
Remove top block.
Install new block
500LC–6PCK
on top. Remove
leaf spring. Install
another new block
500LC–6PCK
on the bottom.
Remove top block.
Install new block
500LC–6PCK
on top. Remove
leaf spring. Install
another new block
500LC–6PCK
on the bottom.
Remove the leaf
spring. Install
new block
500LC–6PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–6PCK
on the bottom.
Remove bottom
block. Install
new block
500LC–6PCK
on the bottom.
NOTE: Top and bottom actuators are required for all configurations;
top actuator with a contact block, bottom actuator with a contact block or a leaf spring.
Installing Pole Conversion Kits 500LC–2PCK, 4PCK, 6PCK, LS3 to Bulletin 500LC Lighting Contactors 3
Publication 500LC–IN004A–EN–P May 2005
How to Install a Contact Block
To avoid personal injury or property
damage, de–energize both line and control
power connected to the Bulletin 500LC
Lighting Contactor before proceeding.
CAUTION
1. Open circuit breakers, then use a voltmeter to verify no voltage is present at
both control and line terminal screws.
2. Label, disconnect, and tape all wires (control, line, load) from the lighting
contactor.
3. Loosen the mounting screws and remove the Bulletin 500LC Lighting
Contactor from the enclosure.
Disassembly
The contact blocks are mounted on the top and bottom of the lighting contactor.
A bottom contact block is used only for lighting contactors with more than six
poles. See Figure 2 and Table A.
1. Remove the contact block(s). Skip this step if it is not necessary to move or
remove a contact block. Loosen the two screws in each contact block. Then
pull the contact block straight out.
Do not remove the captive screws from the contact block. The lower actuator
may drop out when the bottom contact block is removed.
2. Remove leaf spring if converting a 2–...6–pole lighting contactor to an
8–...12–pole lighting contactor. For leaf spring removal see Figure 1.
Note: When converting an 8–...12–pole N.O. lighting contactor to a
2–...6–pole lighting contactor a leaf spring and new actuator must be installed.
See Figure 1.
Reassembly
Be sure the contact blocks and actuator are correct for the number of poles
required. Lighting contactors with more than six poles use two contact blocks.
When two are used, always mount the six pole contact block on the top of the
lighting contactor. See Figure 2 and Table A.
1. Slide the actuator into the cavity (roller facing in, with the guides facing away
from the base of the lighting contactor) before installing the contact block.
2. With actuator(s) already installed, install the new contact block(s) onto the
base. Tighten the two screws in each contact block to 10 in–lb. See Figure 1.
3. Converted lighting contactors must be assembled as shown with contact blocks as
shown in Figure 2. If any contact blocks are removed to accomplish the
conversion, a leaf spring must be installed.
4. Use a scriber to change the nameplate catalog number (number of poles).
5. Install the manual operating screw. Insert the #8–32 screw (from the kit) into
the center of the coil and carefully turn it clockwise until the threads engage
the cam/core. See Figure 3. Tighten hand tight. See Figure 3.
6. Manually operate the lighting contactor. Use the plastic screw to close and
open the lighting contactor by pushing it inward and pulling it outward.
Observe the buttons in the contact blocks(s); the contacts are open when the
buttons are out. The action should be smooth, without any binding. If not,
recheck alignment of contact block(s) and actuator.
Publication 500LC–IN004A–EN–P May 2005
How to Install a Contact Block
To avoid personal injury or property
damage, de–energize both line and control
power connected to the Bulletin 500LC
Lighting Contactor before proceeding.
CAUTION
1. Open circuit breakers, then use a voltmeter to verify no voltage is present at
both control and line terminal screws.
2. Label, disconnect, and tape all wires (control, line, load) from the lighting
contactor.
3. Loosen the mounting screws and remove the Bulletin 500LC Lighting
Contactor from the enclosure.
Disassembly
The contact blocks are mounted on the top and bottom of the lighting contactor.
A bottom contact block is used only for lighting contactors with more than six
poles. See Figure 2 and Table A.
1. Remove the contact block(s). Skip this step if it is not necessary to move or
remove a contact block. Loosen the two screws in each contact block. Then
pull the contact block straight out.
Do not remove the captive screws from the contact block. The lower actuator
may drop out when the bottom contact block is removed.
2. Remove leaf spring if converting a 2–...6–pole lighting contactor to an
8–...12–pole lighting contactor. For leaf spring removal see Figure 1.
Note: When converting an 8–...12–pole N.O. lighting contactor to a
2–...6–pole lighting contactor a leaf spring and new actuator must be installed.
See Figure 1.
Reassembly
Be sure the contact blocks and actuator are correct for the number of poles
required. Lighting contactors with more than six poles use two contact blocks.
When two are used, always mount the six pole contact block on the top of the
lighting contactor. See Figure 2 and Table A.
1. Slide the actuator into the cavity (roller facing in, with the guides facing away
from the base of the lighting contactor) before installing the contact block.
2. With actuator(s) already installed, install the new contact block(s) onto the
base. Tighten the two screws in each contact block to 10 in–lb. See Figure 1.
3. Converted lighting contactors must be assembled as shown with contact blocks as
shown in Figure 2. If any contact blocks are removed to accomplish the
conversion, a leaf spring must be installed.
4. Use a scriber to change the nameplate catalog number (number of poles).
5. Install the manual operating screw. Insert the #8–32 screw (from the kit) into
the center of the coil and carefully turn it clockwise until the threads engage
the cam/core. See Figure 3. Tighten hand tight. See Figure 3.
6. Manually operate the lighting contactor. Use the plastic screw to close and
open the lighting contactor by pushing it inward and pulling it outward.
Observe the buttons in the contact blocks(s); the contacts are open when the
buttons are out. The action should be smooth, without any binding. If not,
recheck alignment of contact block(s) and actuator.
Installing Pole Conversion Kits 500LC–2PCK, 4PCK, 6PCK, LS3 to Bulletin 500LC Lighting Contactors4
Publication 500LC–IN004A–EN–P May 2005
Remove the plastic operating screw !
7. Remove the plastic operating screw from the lighting contactor.
8. Reinstall the lighting contactor into the enclosure and tighten the mounting
screws.
9. Reconnect all wires previously removed. Tighten control connections to
10 in–lb. Tighten the line and load connections to 18 in–lb.
10. Close circuit breakers and check electrical operation of the lighting contactor
with the new control voltage.
manual
operating
screw
Figure 3 Manual operating screw
Do not manually operate
until all power and control
circuits are disconnected.
push — pull
2005 Rockwell Automation. All rights reserved. Printed in USA.
381339–266
Publication 500LC–IN004A–EN–P May 2005
Remove the plastic operating screw !
7. Remove the plastic operating screw from the lighting contactor.
8. Reinstall the lighting contactor into the enclosure and tighten the mounting
screws.
9. Reconnect all wires previously removed. Tighten control connections to
10 in–lb. Tighten the line and load connections to 18 in–lb.
10. Close circuit breakers and check electrical operation of the lighting contactor
with the new control voltage.
manual
operating
screw
Figure 3 Manual operating screw
Do not manually operate
until all power and control
circuits are disconnected.
push — pull
2005 Rockwell Automation. All rights reserved. Printed in USA.
381339–266
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Key Features
- Easy pole conversion
- Complete kits
- Compatible with 500LC Contactors
- Detailed instructions
- Includes new parts
Related manuals
Frequently Answers and Questions
What is the purpose of the Allen-Bradley 500LC Pole Conversion Modification kits?
These kits are designed to help you convert your existing Bulletin 500LC Lighting Contactors to a different number of poles.
What is included in the Allen-Bradley 500LC Pole Conversion Modification kits?
The kits contain contact blocks, leaf springs, actuators, and a manual operating screw. The specific parts included will vary depending on the number of poles you are converting to.
What tools are required to install the Allen-Bradley 500LC Pole Conversion Modification kits?
The only tool you will need is a screwdriver. The instructions recommend using a scriber to change the catalog number.
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