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ALLEN-BRADLEY 509-FOD-XXX

Product Type: Overload Relay / Heater Element (for Bucket Motor Starter)
Series: 509-FOD (Flex Overload Device)

Product Introduction:
The Allen-Bradley 509-FOD-XXX is a bimetallic overload relay heater element used in conjunction with Allen-Bradley 509-COD / 509-BOD motor starter buckets. The “XXX” suffix is a placeholder for the specific amperage rating (e.g., 509-FOD-6, 509-FOD-9, 509-FOD-12, etc.). This document covers the product family.

Category:
Description

Technical Specifications (Family):

Parameter Value
Product Type Bimetallic Overload Heater Element
Compatible Starter 509-COD / 509-BOD Bucket (NEMA Size 0–3)
Amperage Range 1.6 A to 630 A (depending on XXX suffix)
Trip Class Class 10 (standard) / Class 20 / Class 30 (selectable)
Voltage Rating 600 V AC max
Poles 3-Pole (3 heater elements per set)
Element Type Bimetallic Strip with Manual Reset
Trip Time Class 10: Trips at 600% of rating in ≤10 seconds
Mounting Clips into 509 starter bucket
Housing Material Phenolic / Thermoset Plastic
Reset Type Manual (push-to-reset)
Standards UL 508, IEC 60947-4-1, CSA C22.2

Common Amperage Variants (XXX):

Suffix Rating (A)
509-FOD-3 3 A
509-FOD-6 6 A
509-FOD-9 9 A
509-FOD-12 12 A
509-FOD-16 16 A
509-FOD-20 20 A
509-FOD-25 25 A
509-FOD-30 30 A
509-FOD-40 40 A
509-FOD-50 50 A
509-FOD-60 60 A

Functional Features:

  • Bimetallic thermal element — heats and bends under overcurrent, triggering trip mechanism
  • Class 10/20/30 selectable — changes trip curve for different motor types
  • Manual reset — prevents auto-restart after overload
  • Phase-loss protection — trips on single-phasing (all 3 poles linked)
  • Replaceable element — swaps in/out without replacing entire starter

Applicable Industries:
All industrial motor applications — Pumps, Fans, Compressors, Conveyors, Machine Tools

Installation Requirements:

  • Install in 509-COD or 509-BOD starter bucket only
  • Set heater amp rating to match motor FLA (Full Load Amps) exactly
  • Use Class 10 for general-purpose motors, Class 20 for high-inertia loads (conveyors, crushers), Class 30 for very high-inertia (cranes, hoists)

Usage Notes:

  • The “XXX” must be replaced with the actual amperage — e.g., 509-FOD-25 for a 25 A heater
  • Never bypass or jumper the overload relay
  • Test trip function after installation by pushing the test button
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