Allen-Bradley 509-FOD-XXX motor starter

Allen-Bradley 509-FOD-XXX Technical Overview

1. General Description

The 509-FOD-XXX belongs to the Bulletin 509 line of Full-Voltage Non-Reversing (FVNR) Motor Starters or Overload Relays, designed for protecting and controlling three-phase AC motors in industrial applications. These devices integrate overload protection, phase monitoring, and fault diagnostics, ensuring reliable motor operation in demanding environments. The “FOD” designation may imply Field Optional Device or Full Overload Detection functionality.

2. Key Technical Specifications

• Rated Voltage:
  • Motor Circuit: 208–690V AC, 50/60 Hz (varies by model).
  • Control Circuit: 24V DC, 110–120V AC, or 220–240V AC (configurable).
• Current Rating:
  • Motor Full Load Current (FLC): Adjustable via dial or software (e.g., 0.1–100 A).
  • Overload Trip Class: Class 10, 20, or 30 (adjustable for different motor starts).
• Protection Features:
  • Overload, phase loss, phase unbalance, locked rotor, ground fault, and short-circuit protection.
  • Thermal and electronic overload simulation compliant with IEC/UL standards.
• Environmental Ratings:
  • Operating Temperature: -25°C to +60°C (-13°F to +140°F).
  • Enclosure: IP20 (open type) or IP65 (optional sealed enclosure for harsh environments).
• Communications:
  • Optional communication modules (e.g., DeviceNet, Ethernet/IP, or Modbus RTU) for integration with PLCs or SCADA systems.
• Mechanical Design:
  • Compact, modular design for DIN rail or panel mounting.
  • Removable control wiring terminals for easy installation.
• Certifications:
  • UL Listed, CE Marked, IEC 60947-4-1 compliant.

3. Functional Capabilities

1. Advanced Motor Protection:
   • Monitors current, voltage, and temperature to prevent motor damage from overloads or phase faults.
   • Adjustable trip thresholds for fine-tuning protection based on application requirements.
2. Diagnostics and Fault Logging:
   • LED Indicators: Visual status for power, run, fault, and communication.
   • Fault Memory: Stores recent fault events (e.g., overcurrent, phase loss) for troubleshooting.
3. Control Flexibility:
   • Start/Stop Control: Direct interface with contactors or soft starters.
   • Remote Configuration: Adjust settings via PLC or HMI using communication protocols.
4. Integration with Automation Systems:
   • Compatible with Allen-Bradley ControlLogix, CompactLogix, and PlantPAx systems.
   • Supports Logix Tag-based configuration in Studio 5000® for seamless programming.
5. User Interface:
   • Local configuration via rotary dials, DIP switches, or a connected HMI.
   • Optional LCD display modules for real-time parameter monitoring.

4. Typical Applications

• Pumps, fans, compressors, and conveyors in manufacturing plants.
• HVAC systems, water/wastewater treatment facilities.
• Material handling systems (e.g., cranes, hoists).
• Retrofit applications replacing traditional thermal overload relays.

5. Ordering Information

• Model: 509-FOD-XXX (replace “XXX” with specific suffixes, e.g., 509-FOD-D8 for DeviceNet compatibility).
• Accessories: Auxiliary contacts, communication modules, and mounting kits.

Key Suffix Decoding (Example)

• -A: 24V DC control voltage.
• -D: DeviceNet communication.
• -E: Ethernet/IP compatibility.
• -H: High-current range (e.g., 50–100 A).