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Spec Sheet - The Reynolds Company

1. amp 1 X SS 1 W 4 N3dO 10 F 8 E B AWW fT 340 35012 pH 6 q L z al 40 vi NW T NO 353 IN34802 t wea 5 i 4 vot 9 7X s SS 55 lt lt 91000 xn rx NL 0z ZL mn AOW 7 11 vx VA00S N Ox 33 19 1 7 21 2 Jn 8 a i 53514 YIMOd AOW LNXYND II lt lt W W YOLDYLNOD NIVW vor HOOG J x HDLIMS 71 ZH09 0S P x H sna quo 4 u SL 01 6 8 INIOd 114405 1531 1 a X sna 1531 2409 05 BE 0069 0072 330 33 Rockwell Automation Publication 1502 UM052H EN P June 2013 Installation Chapter3 Rockwell Automation Publica
2. 80123 413 51 id Y gooT xD2 BER A CC HC I o F 8001 AUXILIARY x K contacts I 1 POWER CIRCUIT i 5 E F T gt D CONTROL r r r TRANSFORMER raj CODO FUSE m HOLDERS 9 M M M Z 1 1 1 BC DEF GHILLK amp PINS 11 Te T3 AL amp M SOCKETS P USED SCHEMATIC 400 VACUUM CONTACTOR 230V COIL NORMAL DROP OUT AUXILIARY CONTACTS MDV Ll ccs D BLKNC Y E F G H N B Y 1 J LAL K n CC CLOSING COIL HC HOLDING COIL 24 Rockwell Automation Publication 1502 UM052H EN P June 2013 Installation Chapter 3 Figure 15 Wiring Diagram Electrically Held Contactor 120V AC Fast Drop out Time WIRING DIAGRAM 400A VACUUM CONTACTOR 100 COIL FAST DROP OUT 80123 413 51 4 BL B MOV A B t xg HC NEP E F G H 800T XA 800T XA AUXILIARY l 4 K L contacts I 1 POWER CIRCUIT L1 Le L3 gt CONTROL TRANSFORMER PJ a O LJ LJ LJ Loa HOLDERS 9 9 Z T3 SCHEMATIC 400 VACUUM CONTACTOR 120
3. 1 Resistance values listed have a tolerance of 10 Refer to page 17 for measurement points at the contactor receptacle 2 Supplied only with mechanical latch option Rockwell Automation Publication 1502 UM052H EN P June 2013 55 Chapter5 Troubleshooting Notes 56 Rockwell Automation Publication 1502 UM052H EN P June 2013 Chapter 6 Spare Parts Bulletin 1502 Spare Parts Figure 51 Bulletin 1502 400 Electrically Held Vacuum Contactor Diagrams and Chart Vacuum Bottles S Coil Retaining Ring Auxiliary Assembly Auxiliary Assembly Return Spring Stop Bracket Mechanical Latch Trip Coil LA LIB Le m Latch Lever Assembly Rockwell Automation Publication 1502 UM052H EN P June 2013 57 Chapter6 Parts Table 8 Spare Parts Item Description of Parts Part Number 120V Control 400A 1 Three Vacuum Bottles 80157 496 52 2 Main Coils Qty 2 80026 230 01 3 Auxiliary Assemblies Electrically held 80158 743 52 Mechanical latch IntelliVAC or IntelliVAC Plus 80158 744 52 Control Electromechanical Control 80153 999 60 4 Mechanical Latch Trip Coil 120 VAC 80022 067 01 5 Return Spring standard altitude 0 1000 80153 567 01 6 Coil Retaining Ring 28325 042 01 7 Stop Bracket 80153 565 01 8 Auxiliary Actuator Plate 80153 553 02 9 Armature Plate 80153 552 02 10 Latch L
4. TCO output which pulls the latch away from the armature or by a push button mounted on the power cell door that mechanically releases the contactor Electromechanical Control When the control circuit is energized the current creates an electromagnet in the closing coil The electromagnet pulls the armature plate towards the coils core rotating the shaft and causing the actuator plate to move upwards As the actuator plate moves it pushes the insulator and movable shaft up closing the contacts in the vacuum bottle Once the contactor is closed a spring loaded mechanism moves a roller against the armature plate to hold it against the electromagnetic core The control circuit economizing auxiliary contact on the left side of the contactor changes from the normally closed state to the normally open state as the contactor closes This de energizes the relay that controls the closing coils Rockwell Automation Publication 1502 UM052H EN P June 2013 7 Chapter1 Product Description The contactor can be opened electrically by energizing a trip coil which pulls the latch away from the armature or by a push button mounted on the power cell door that mechanically releases the contactor Note The standard mechanical latch contactor requires external 120V AC or DC control relays and rectification circuit to control the standard DC closing and trip coils on the contactor when IntelliVAC or IntelliVAC Plus i
5. AUXILIARY CONTACTS F C J M G LH D B L 9 9 M gt 011 CONTACTOR SHOWN IN OPEN CTRIPPED CONDITION CC CLHSING CHIL TC TRIP COIL 22 Rockwell Automation Publication 1502 UM052H EN P June 2013 Installation Chapter3 Figure 13 Wiring Diagram Electrically Held Contactor 120V AC Normal Drop out Time WIRING DIAGRAM 400A VACUUM CONTACTOR 120v COIL NORMAL DROP OUT 80123 413 51 N D Y goot xpe BLK E HC a E m E F G H 800T XA 800T XA AUXILIARY ES 2 L contacts L POWER CIRCUIT L1 Le L3 CONTROL TRANSFORMER r3 E PRIMARY LJ LJ LJ FUSE a HOLDERS M M M 1 T T3 SCHEMATIC 400A VACUUM CONTACTOR 120 COIL NORMAL DROP AUXILIARY CONTACTS Rockwell Automation Publication 1502 UM052H EN P June 2013 CC CLOSING COIL HC HOLDING COIL 23 Chapter3 Installation Figure 14 Wiring Diagram Electrically Held Contactor 230V Normal Drop out Time WIRING DIAGRAM 400A VACUUM CONTACTOR 220V COIL NORMAL DROP OUT
6. 1581 ZH09 0S BE 0069 00 34 Tool Requirements Recommended Torque Values Chapter 4 Maintenance IMPORTANT Some components of this product incorporate Imperial hardware Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedure on these components If you cannot obtain such tools contact your area Rockwell Automation sales office for assistance When maintenance is performed on the vacuum contactor the following tools may be required 3 8 in drive ratchet wrench with extension 3 8 in drive torque wrench Standard 3 8 in drive sockets 7 16 in 1 2 in Open end wrenches 7 16 in 1 2 in 5 8 in Slot head screwdrivers 1 8 in wide wide External retaining ring pliers STANLEY PROTO 393 or equivalent Feeler gauge set 0 030 in 0 76 mm and 0 075 in 1 91 mm Feeler gauge set 0 010 in 0 25 mm Mechanical Latch 2 inch C Clamp Armature clamping fixture A B Part No 80154 149 51 Digital caliper capable of depth measurement High potential tester Part of the contactor may have to be disassembled for maintenance or replacement There are appropriate torque requirements for particular bolt sizes when reassembling the contactor For the following bolt sizes use the specified torque values in Table 4 Table 4 Torque Values 10 in Hardware 2 7 lbeft 3 6 Nem 1 4 in Hardware 6 lbeft
7. 10 Slide the coil core from the trip magnet coil and then place the replacement coil onto the coil core 11 Connect the new trip magnet coil leads to the auxiliary contact assembly 12 Re assemble the mechanical latch and auxiliary assembly in reverse order of this procedure 13 Perform the auxiliary contact assembly adjustment procedure see page 4 Note The contactor will not function correctly if this step is not performed 14 Verify that the replacement trip coil functions by using Test Power to close latch the contactor Complete the cycle by opening tripping the contactor Perform this sequence 2 3 times to ensure that the contactor closes latches and opens trips properly Rockwell Automation Publication 1502 UM052H EN P June 2013 51 Chapter4 Maintenance Mechanically Latched 1 Theovertravel contact gap and auxiliary set up procedures are the same for mechanically latched contactors as they are for electrically held Contactor Set up Procedure contactors except that instead of energizing the contactor with the TEST circuit the contactor must be held closed mechanically by means of a clamp or special fixture as shown in Figure 4 25 It is important that the contactor is held closed tightly with the armature against the magnet cores when gauging the overtravel contact gap and auxiliary positioning Allen Bradley part number 80154 149 51 is recommended however a C clamp can be used at the rear of the
8. 37 0 91 4 5 23 Front View Cut away View 136 5 10 50 267 I3 Y 00 i 0 281 7 A wide slots 0 8 7 87 200 q CU C Y 2 12 54 8 00 203 0 98 25 Bottom View Rockwell Automation Publication 1502 UM052H EN P June 2013 17 Chapter3 Installation Figure 8 Mechanical Latch Dimensions Optional f I I iT I I Q S C Ne TEX X HW TE z Ea LE ET WA mu u L U 4 4 1 41 2d BE 0 F i mU t 1 53 MOUNTING 4 06 PROVISION F 2 93 Electrical Connections A wire harness connects the control wiring to the contactor from the low voltage control panel The harness connects to a wire plug on the lower left side of the contactor If the contactor is supplied as an OEM component for installation in a custom application the following two control options and a connecting wire harness are available
9. a small surface to a large surface in one direction and vice versa when the polarity of the tester is changed The resultant current is large in one direction which would incorrectly indicate a faulty vacuum bottle At best DC testing will verify on some degree of vacuum integrity It will not give any indication of the degree of vacuum since the contact surface can change with each operation of the vacuum contactor AC testing on the other hand will provide reliable vacuum integrity indication As well the degree of vacuum within the bottle can be determined by comparing initial test results to the present readings Increases in leakage current indicate a reduction in vacuum within the vacuum bottle For these reasons Rockwell Automation recommends AC testing as the best and most reliable method of testing vacuum bottles A suitable GO NO GO DC test unit is Manufacturer Address Programma Model VIDAR Santa Rosa CA USA Use a 1000V Megger to verify that the resistance from phase to phase or phase to ground is greater than 500 megohms Rockwell Automation Publication 1502 UM052H EN P June 2013 Mounting Chapter 3 Installation The electrically held and the mechanically latched contactors are fixed mounted bolted down in the controller cabinet Two retaining tabs at the rear of the contactor s molded base can be used for mounting The two mounting slots at the front of the contactor s molded base are used to secure
10. contactor to pull up the actuator plate care must be taken not to overtighten the C clamp and bend the actuator plate Figure 49 Clamping a Mechanically Latched Contactor Closed Mechanically Latched Contactor Clamping Fixture 2 Clamp the contactor closed as detailed in Step 1 The latch mechanism should be in place with the mounting bolts loose enough to allow sliding along the adjustment slots 3 With the contactor lying on its back insert a 015 in 0 38 feeler gauge between the latch roller and the armature plate as shown in Figure 50 Tighten the mounting blots do not overtorque 1 4 inch nuts or 5 16 in bolts Figure 50 Gauging Mechanical Latch Location e Insert feeler gauge here 0 010 in 0 25 mm 52 Rockwell Automation Publication 1502 UM052H EN P June 2013 Altitude Adjustment Maintenance Chapter 4 4 With the contactor still clamped depress the latch lever and release allowing it to spring up Ensure smooth unimpeded motion 5 Remove the clamp and allow the armature to move out against the roller such that the contactor is in the latched condition To avoid injury do not place fingers between the armature plate and the stop ATTENTION The return springs exert a significant force on the armature plate bracket at any time 6 Using the manual trip lever trip drop out the contactor Apply 2 to 3 lb of force to trip the contactor If too little force is requi
11. e Two 7 16 Wrenches e 3 8 socket and ratchet 5 16 socket and ratchet e Phillips Screwdriver 3 32 Right Angle Allen Key Feller gauges Side Cutting Pliers e Wire Ties Armature Clamping Fixture 80154 149 51 Procedure 1 Cut wire ties at the rear of the contactor holding the mechanical latch coil wires in place Figure 41 Figure 41 Rear View of Mechanical Latch Contactor showing wires to trip coil Latch Coil Wires 48 Rockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 2 Using wrench remove the auxiliary contact actuator plate form the main shaft assembly Figure 42 Figure 42 Auxiliary Actuator Plate Removal Actuator Plate 3 Usingtwo 7 16 wrenches loosen the auxiliary contact assembly retaining bolt and slide the auxiliary contact assembly out of the front of the contactor Figure 43 Figure 43 Auxiliary Contact Assembly Removal Auxiliary Contact Assembly Retaining Bolt Disconnect the mechanical latch trip coil leads form the auxiliary contact assembly using a Phillips screwdriver 5 Using a 3 8 socket remove the 14 20 hardware holding the mechanical trip mechanism in place and then remove the mechanical trip mechanism Figure 44 Rockwell Automation Publication 1502 UM052H EN P June 2013 49 Chapter4 Maintenance Figure 44 Removal of Mechanical Trip Mechanism Mechanical Trip Mechanism 20 Har
12. fails Rockwell Automation recommends the replacement of all three vacuum bottles if the unit has been in service 5 After the high potential voltage is removed from the vacuum bottles the metal end caps of the vacuum bottles should be discharged with a grounding rod to remove any residual electrical charge Figure 6 Vacuum Bottle Integrity Test Circuit Vacuum Checker Vacuum Contactor in open position The allowable leakage current value of 5 mA is exclusive of leakage due to test equipment leads The test setup leakage can be determined by running the dielectric test with test leads not connected to the contactor and noting the maximum leakage current If this value is more than 2 mA it should be added to the 5 mA limit when testing the vacuum bottles Rockwell Automation Publication 1502 UM052H EN P June 2013 15 Chapter2 Receiving and Handling Insulation Resistance Test 16 Note Rockwell Automation does not recommend DC Hi pot testing because the values obtained during the test may not be a reliable indication of vacuum bottle integrity Some specific DC GO NO testers may provide suitable defective readings DC Hi pot testing is unreliable because of a phenomenon known as Cathode Ray Tube Effect This occurs when one contact of the vacuum bottle has a deformity such as a burr or deposit while the other contact remains flat and true This sets up leakage currents which flow from
13. from Rockwell Automation e IntelliVAC and IntelliVAC Plus control modules Electromechanical control panel for latch contactors only Connect incoming power to the line side terminals at the top rear of the contactor near the control fuse clips Use 3 8 in 10 mm bolts torqued to 20 Ibeft 292 Nem to secure the connection Connect outgoing power to the load side terminals halfway down the rear of the contactor Use 3 8 in 10 mm bolts torqued to 20 lbeft 292 Nem to secure the connection For mechanically latched contactors ensure the manual trip button in the cabinet door is in line with the trip lever on the contactor 18 Rockwell Automation Publication 1502 UM052H EN P June 2013 Installation Chapter3 Figure 9 Electrical Connections Rear View Control Circuit Transformer Primary Fuse Clips Line Side Terminals Control Wire Plug Load Side Terminals Rockwell Automation Publication 1502 UM052H EN P June 2013 19 Chapter3 Installation Wiring and Schematic Figure 10 Wiring Diagram Electrically Held Contactor for use with IntelliVAC and IntelliVAC p Plus control modules only Diagrams 80123 413 51 1 800T XD4 B p L F 800 AUXILIARY 1 3 CONTACTS 120V CONTACTOR PLUG POWER WIRING Lt L2 L3 CONTROL TRANSFORMER I PRIMARY LJ L FUSE LJ L 3 HOLDERS o
14. to perform the vacuum bottle integrity test Megger cannot be used to measure vacuum integrity because the voltage is too low One ofthe following AC Hi pot testers is recommended as a test instrument MANUFACTURER ADDRESS Mitsubishi Type VI 4017 Chicago Ill USA Jennings Model JHP 70A San Jose CA USA Hipotronics Model 7BT 60A Brewster NY USA Rockwell Automation Publication 1502 UM052H EN P June 2013 Receiving and Handling Chapter2 1 Clean the outside of the vacuum bottles with a non linting cloth or industrial wipe before performing the test 2 The contactor may be tested while it is in the power cell The line connection of the contactor must be disconnected and the ground lead from the Hi pot tester must be connected to the load side of the contactor Any fuses in the top of the contactor must be removed 3 With the contactor in the open position connect the test leads to the contactor power terminals as shown in Figure 6 It is recommended that an AC Hi pot tester be used Apply 16 kV for 60 seconds and monitor the leakage current It should not exceed 5 mA Test each vacuum bottle individually 4 If no breakdown occurs the vacuum bottle is in an acceptable condition If a breakdown occurs repeat the test once more If the vacuum bottle fails a second time it must be replaced If no breakdown occurs in the second test the vacuum bottle is in an acceptable condition ATTENTION If one vacuum bottle
15. 10N gt ONIBIMH3WOISQO amp H wo s MOISIMNVA JAIXO AOW S1DV1NOD ay m JDIAIG YIWAN 333 F ec 0 35 zD IN3WdlnO3 310W3H 5NILD3NNOO N3HM H3dW r3AOW3H m 9p an 1uv1S 380438 YIWOLSND JHL 38 OL v 33 13 50115 INGOW 34VS 114 0115 30129102 amp 2 ez 1123443 S31 15 dN YIMOd NOILYYNDIHNOD GATIVLSNI ANOLV4 G3r1ddV YIMOd OULNOD LNOHIIM NMOHS SLVINOD AY134 LNdLNO di S3IONOVATHINI L gt ANAN 5 L A s 330 SENIUM E ec 5 5 nm j 0 os SALVIS oz YODVINOD P tH Het Es a Np 16 adis 9 5 10 AW O uvis 5 5 53604 AuVWIud YS ore 4015 NLLIWN 1433812 5 19715 go 25 zx o 1 iH a M vi M 5 1 v voz esi nos P 14 lt lt W gt 3 N 53504 u3MOd e il 1 W YOLDVINOD NIVW yb n uos NW m 4 HOLIMS 5NILV 1OSI e ZH09 0S x T y E SL 01 6 8 I 1NIOd 1 1531 wW H 1531 T
16. 8 Nem 5 16 in Hardware Grade 2 1 11 Ibeft 15 Nem 5 16 in Hardware Grade s 18 Ibeft 24 Nem 3 8 in Hardware 20 lbeft 27 Nem 1 All 5 16 hardware is Grade 2 unless otherwise specified 2 Refer to Figure 33 Rockwell Automation Publication 1502 UM052H EN P June 2013 35 Chapter4 Maintenance Routine Maintenance User Manual of the starter configuration in which the contactor is installed for all service instructions and procedures Failure to do so may result in injury to personnel or damage to the controller or contactor ATTENTION Before performing maintenance on the contactor refer to the the control plug from the contactor before working on the unit Verify with a hot stick or meter that all circuits are voltage free Failure to do so may result in Severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power and disconnect The following should be carried out on an annual basis or whenever a contactor is serviced Cleaning 1 Ensure that metal chips or filings are cleaned from around the electromagnet assembly coil core pole face and mating armature plate as they may affect proper operation of the contactor Vacuum clean if necessary IMPORTANT PDonotuse compressed to clean or remove dirt from surfaces or the enclosure as it will only redistribute the dirt 2 If dirty clean the white ceramic area of vacuum bottles with a clean lint free cloth 36 Ro
17. Contactor Coil Resistance Chapter 5 Ifan operating problem occurs use the following troubleshooting chart to isolate the cause of the failure and find corrective action If the corrective action fails to resolve the problem consult your local Rockwell Automation field support representative Table 6 Troubleshooting Symptom Possible Cause Contactor Chatters Loose connections in control circuit Coil leads reversed e Control voltage too low Foreign material on contactor magnet Improper set up of contactor auxiliary contact assembly e Faulty auxiliary contacts Faulty or CR2 interposing relay mechanical latch only Faulty IntelliVAC or IntelliVAC Plus e Latch not engaging Actions Check all connections in control circuit for tightness Check wiring from the coil to the terminal block assembly Measure control voltage Refer to Contactor Specifications for minimum pick up voltage Clean magnet cores and armature Check set up of contactor auxiliary contact assembly Check master contact cartridges on contactor Ensure N C contact from contactor auxiliary assembly is wired to auxiliary input on IntelliVAC or IntelliVAC Plus Replace IntelliVAC or IntelliVAC Plus control module Check adjustment of mechanical latch Coil Burnout e Coil leads improperly wired e Check wiring from the coil to the terminal block e Faulty IntelliVAC or IntelliVAC Plus control module assembly Imprope
18. Hn o M M M Ti D P NO CONNECTIONS SCHEMATIC 4004 VACUUM CONTACTOR 1202 AUXILIARY CONTACTS 20 Rockwell Automation Publication 1502 UM052H EN P June 2013 Installation Chapter3 Figure 11 Wiring Diagram Mechanical Latch Contactor for use with IntelliVAC and IntelliVAC Plus control modules only 80123 413 51 AUXILIARY CONTACTS Si jn Sg ss Sas iS san al POWER CIRCUIT CONTROL TRANSFORMER F4 PRIMARY LJ L 1 9 FUSE Lo HOLDERS 9 9 9 M M M A B C D I SOCKETS 1 2 T T3 SCHEMATIC AUXILIARY CHNTACTS MOV C cc CONTACTOR SHOWN IN OPEN TRIPPED CONDITION K CC CLOSING COIL TC TRIP COIL Rockwell Automation Publication 1502 UM052H EN P June 2013 21 Chapter3 Installation Figure 12 Wiring Diagram Mechanical Latch Contactor for use with Electro mechanical Control Panel 0nly 80123 413 51 Ah a m YELLUW BLACK WHITE BLUE cc E 1 G H 800T XA AUXILIARY L iles aa lin xis Vid nce MS Shs Ba Sah ab wl PDWER CIRCUIT Lt L2 L3 waPER ra 5 A r r r4 PRIMARY Li Lo FUSE L HOLDERS 9 9 9 M M M C D I SOCKETS 1 ALL OTHERS PINS Tt 1
19. I1 ddy tHMOd ET 4 1091402 LNOHLIM NMOHS SIDVINO2 AV BH LNdLNO Y 1631 5 4 OVAITBINI A Y NI D 1 1 31915504 SV SNH 3 VAITBINIO13SOD SV Y 02 61961 6L 9 LLONV SLB ELSIYM NOG3TIVISNI AYD 31893 3 LNaWdNda LOWY Y 4 GANI430USWOISND LNANI a 1 9NLDINNOD NHM HAWN 3 0W3H m Tm i SNIBIMHSWOISQO INI QN3931 AHW A SAVIS uorviNo A tH Het A NW prl 6 H z D 4015 v a E 10 wwa wa n al L AS ee 5 022 xnv 5 n n AGW 021 W g E vor pus A W e 209 x94 L2 m SL oL 6 ANIOd 1531 0 o 1 x 9 8 1531 d 330 es mm VAO0S 10 67 ag gt gt gt 5 5 S3snd Avid zala Iti LINSEED sasn4 amod C4 W SNILIWE 1 14 ED L n 13 tt M Woe LL 13 H SI HumsonyIosi GHD H ZH VA 31 Rockwell Automation Publication 1502 UM052H EN P June 2013 Figure 22 Typical Schematic Diagram for 400A Full Voltage Non Reversing FVNR Controller With IntelliVAC Control and Mechanical Latch Contactor Installation Chap
20. NTACTS Installation Chapter 3 800T LS C D 1 SOCKETS ALL OTHERS PINS L1 Le Ee ea TRANSFORMER PRIMARY FUSE HOLDERS M T T M T 1 Te SCHEMATIC 4004 MECHANICALLY LATCHED AUXILIARY CONTACTS EC H gt e eo M D Rockwell Automation Publication 1502 UM052H EN P June 2013 CONTACTOR SHOWN IN OPEN CTRIPPED CONDITION CC TC LS Dt De w B CLOSING COIL TRIP COIL LIMIT SWITCH DIODE WHITE BLUE 27 Chapter3 Installation Figure 18 Typical Electrical Diagram for 400 Full voltage Non reversing FVNR Controller with Electrically Held Contactor 120V AC Normal Drop out Time A 5 8 zv E P eX lt 2 z m LVN B BT 5 8 MEE I 1 P x 8 Ber Ber E 8 8 as 5 E b e 1 5 6 70 gt A NEZ 5 cts Lo L H g Lh j s b ap HE gl s z 8 5 5 gt 8 5 fe T j 8 Ao d
21. PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt P gt Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Irademarks not belonging to Rockwell Automation are property of their respective companies Product Description Receiving and Handling Installation Maintenance Table of Contents Chapter 1 Contactor Description 5 Vacuum Bottle 6 Standard Electrically Held Contactor Operation 6 Mechanically Latched Contactor 7 InselliVAC and Intel V AC Plus Control 7 Electromechanical Control Via s ba EE RAE 7 Contactor 8 Contactor Catalog Number Explanation 2 10 Product Approvals nd sone aqa 12 Chapter 2 Receiving P 13 Preliminary Inspection 13 Handling 13 Pre En xpization 14 von hasqa OT 14 Vacuum Bottle Integrity Test 14 Insulation Resistance Test rsrsasassssssssssasaa 16 Chap
22. User Manual Allen Bradley Medium Voltage 400 Contactor Series E Publication Number 1502 UM052H EN P Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the Additional Resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of inform
23. V COIL FAST DROP OUT AUXILIARY CONTACTS B C D BLK Y CLOSING COIL HC HOLDING COIL Rockwell Automation Publication 1502 UM052H EN P June 2013 25 Chapter3 26 Installation Figure 16 Wiring Diagram Electrically Held Contactor 230V AC Fast Drop out Time WIRING DIAGRAM 400 VACUUM CONTACTOR 230V COIL FAST DROP OUT 80123 413 51 Y 8001 BLK h B 7 E Ge HC F G H 800T XA 800T XA AUXILIARY ES E CE POWER CIRCUIT T 2000 CONTROL r1 r1 r1 TRANSFORMER 000 FUSE 07 HOLDERS 9 M M M M A B C D E F GH LJK amp PINS Ti Te T3 L amp M SOCKETS P USED SCHEMATIC 4008 VACUUM CONTACTOR 230V COIL FAST DROP OUT AUXILIARY CONTACTS MOV B E D Y gt c6 H H N lt roe M 2 M CC CLOSING COIL HC HOLDING COIL Rockwell Automation Publication 1502 UM052H EN P June 2013 Figure 17 Wiring Diagram Mechanically Latched Contactor 120V AC WIRING DIAGRAM 400A MECHANICALLY LATCHED CONTACTOR POWER WIRING 800T XA J AUXILIARY CO
24. VWYON ZH09 0S A0069 A00rZ 330 4 Rockwell Automation Publication 1502 UM052H EN P June 2013 30 Chapter 3 Installation Figure 21 Typical Schematic Diagram for 400A Full Voltage Non Reversing FVNR Controller With IntelliVAC Plus Control and Electrically Held Contactor Basic pe L dIMLIINGOW ODL Y FINGOW S142 VATTIININODVINOD NWW T 1NANI YOLDYAYDTYNY DA SINGOWDVANTAINI 23 G x 0 10410011029 5 FINGOWIVATTAINI 022 ANI 1 1 310 QOWOVATTTINI too 4 18 15 3uOd3guawOtSnO 2 38 OL 5014 2VATTBLNI Q3NI3Gu3WOISrD 1ndNi 34VS 194 SALVIS NGON 1 34VS 1IV3 SD 1V1S HOLIVLNOD NDINA 9 NI EC qaNIH3Qu3WO1SnD 1ndNI T 123443 NI HY S31 V IS dN YIMOd NOILYYNDHNOD ae G3TIV1SNIABO DV3SNIMOTIO43H
25. armature plate towards the coils core rotating the shaft and causing the actuator plate to move upwards Asthe actuator plate moves it pushes the insulator and movable shaft up closing the contacts in the vacuum bottle The IntelliVAC or IntelliVAC Plus control module supplies the current required to close the coils for 200 milliseconds Afterward the coil current is reduced to a lower hold in value e When the IntelliVAC or IntelliVAC Plus control module has the close command removed the coils are de energized opening the contactor Rockwell Automation Publication 1502 UM052H EN P June 2013 Product Description Chapter 1 Figure 3 Vacuum Contactor 0peration C P T Fuse Clip Line Terminal Insulator Vacuum Bottle Armature Plate amp Shaft Load Terminal Flexible Bus Auxiliary Actuator Return Spring Actuator Plate Control Wire Plug Gap Adjustment Screw E Magnet Coil Assembly Armature Stop Bracket Contactor Open Contactor Closed Mechanically Latched The mechanically latched contactor operates in much the same way as the Contactor Operation electrically held Figure 3 with only a few exceptions IntelliVAC and IntelliVAC Plus Control Once the contactor is closed a spring loaded mechanism moves a roller against the armature plate to hold it against the electromagnetic core The contactor can be opened electrically by energizing a trip coil via IntelliVAC or IntelliVAC Plus open
26. ation circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence P P IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment
27. ation 1502 UM052H EN P June 2013 43 Chapter4 Maintenance 6 Install the armature plate auxiliary actuator and stop bracket Position the stop bracket by resting it lightly against the armature plate IMPORTANT This procedure applies to adjustment of existing auxiliaries and installation of new auxiliaries Under normal conditions auxiliaries will last at least 1 000 000 operations If auxiliary contacts must be replaced discard the entire assembly and install a new assembly This is easier than replacing a single contact block Auxilia ry Contact Set up Refer to Chapter 6 for part number s required for this procedure Procedure To facilitate the set up procedure the contactor is held closed mechanically by means of a clamping fixture as shown in Figure 4 13 It is important that the contactor is held closed tightly with the armature plate against the magnet cores when gauging the overtravel and auxiliary positioning To aid in closing the contactor mechanically a clamping fixture is required Allen Bradley part number 80154 149 51 is recommended Figure 35 Contactor Components Auxiliary Actuator Armature Plate Armature Stop Bracket 1 Loosen the nuts on auxiliary assembly retaining bolt This requires loosening and removal of the first nut which secures a ground wire at this location Leave on nut loosened just enough to permit the assembly to slide along the adjustment slot as shown in Figure 36 44 R
28. ckwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 Main Contact Inspection Visually inspect the wear of the main contacts with the contactor energized When any part of the wear indicator line located on the front side of the shaft moves up into the bearing replace all three vacuum bottles Figure 25 Figure 25 Vacuum Bottle Wear Indicator Vacuum D x Wear indicator line on operating shaft HiPot test Check the vacuum bottle integrity see page 14 Check the insulation resistance Lubrication Using Aeroshell No 7 1 oz tube Part No 40025 198 01 grease the actuator plate where the overtravel springs and washers make contact Figure 26 Rockwell Automation Publication 1502 UM052H EN P June 2013 37 Chapter4 Maintenance Figure 26 Grease Locations Insulator n Grease Actuator Plates Grease IMPORTANT grease the armature shaft plastic bearings These bearings self lubricating and do not require grease Vacuum Bottle Replacement Under normal conditions vacuum bottles will last at least 1 000 000 operations however all three bottles must replaced if any wear indicator line reaches the and Set Up Procedure bearing regardless of the number of operations Refer to FIX THIS or the part number s required for this procedure Use the following procedure to remove and replace the vacuum bottles This p
29. d Ee E ONIAN 1N34802 s 4 voz 9 zx tH 6 a S 59 2 022 xnv N x S ZL 9 NS SL v 2 ix ui AOW 7 1 5 a z VA00S gt 3L lt 0 3H 142 8 g NW i S3snd u3MOd 1N34802 1 lt e m W YOLDYLNOD NIVW vor DOMES HOLIMS 9NLLV1OSI ET 209 05 7 N sao E T u SL x 6 8 INIOd 414405 1531 i wW H sng u3 Mod 4 1531 TWWHON 7409 05 BE A0069 A00FZ 440 4 32 Chapter 3 Installation Figure 23 Typical Schematic Diagram for 400A Full Voltage Non Reversing FVNR Controller With IntelliVAC Plus Control and Electrically Held Contactor with Input Examples SIHL NO NMOHS 2 2 AON 2 5 LNINOdWOD 303 NOISN3IWIG OL 33333 310 gt S lt SNIBIMHWOISQO we Sule 1 JAIXO AOW aN N e 3DIA3Q 3ALID3LOUd YIIWNN 3331 3DIA3q MOT 702 41 21 SE 15 TODONISOID 22 S mE np 40 1815 380438 1 E 3 0 A8 G3un9I3NOD G3WWVu5Oud 38 OL JDVLNOD VHLDG v rae 93395 3 SALVIS FINGOW 3375 SALWLS 3012105 6v QVOTAO 1123343 NI 38V S31V IS dN Y3MOd NOLLVYNDIANOD 10 G3TIVISNI AHO12V3 ONIMOTIOS JHL G3 1ddV YAMOd 7031402 LNOHUM NMOHS 512 1 AV HS 1nd1nO S31ONDVATBINI 1 ev
30. dware Qty 2 Contactor 6 Remove the E clip and washer from the latch lever assembly shaft and then remove the shaft Figure 45 Remove the latch lever assembly from the mechanical latch base Note that the return spring is seated on the right side of the mechanical latch base Note Contactor not shown for clarity Figure 45 Removal of Latch Lever Assembly Latch Lever Assembly Shaft E Clip and Washer Return Spring Seat 7 Using a 5 16 socket remove the 10 32 hardware holding the stainless steel guide stop plate in place and then remove the guide stop plate Figure 46 Note Contactor not shown for clarity Figure 46 Removal of Guide Stop Plate Guide Stop Plate 50 Rockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 8 Remove the flapper by sliding it to the right untilit stops and then pulling it towards the front of the contact Figure 47 The trip magnet coil and coil core are now exposed Note Contactor not shown for clarity Figure 47 Removal of Flapper Step 1 Flapper Slide flapper to right Step 2 Pull flapper forward to remove 9 Usinga right angle Allen key remove the coil core Figure 48 and trip magnet coil Note Contactor not shown for clarity Figure 48 Trip Coil and Core Removal Use right angle Allen key to remove coil core Magnet Coil Coil Core
31. e changed Electrically held contactors Series E or later may only be used with IntelliVAC control Refer to publication 1503 UM053_ EN P or 1503 UM054_ EN P IMPORTANT Do not change springs on contactors whose catalog number end in 0 Ifa relay controlled latch contactor is to be moved to a different altitude refer to Table 5 to determine the correct return springs for the new altitude range Simply replace the springs and correct the rating label information catalog number altitude range and current rating per Table 5 Note the change Basic Impulse Rating B LL as it relates to altitude Rockwell Automation Publication 1502 UM052H EN P June 2013 53 Chapter 4 54 Maintenance Table 5 Altitude Range Spring Requirements 400A Mechanical relay control only Altitude Range Spring Part No Color Code Continuous Rating Current Rating 0 1000 m 80153 567 01 Bronze 400A 60 kV 1000 2000 m 80026 007 02 Green 390A 54kV 2000 3000 m 80026 008 02 Blue 380A 48 kV 3000 4000 m 80026 009 02 Black 370A 42 4000 5000 m 80026 010 02 0live 360A 36kV IMPORTANT A contactor will only function properly in the altitude range for which it is set Rockwell Automation Publication 1502 UM052H EN P June 2013 up If functional tests are required they must be performed at the proper altitude or in a pressure chamber which simulates the proper altitude Troubleshooting Troubleshooting and
32. ever Assembly 80158 768 51 11 Bottle Clamp Qty 3 PN 129674 1 Rockwell Automation recommends that if the contactor has been in service all three 3 bottles be replaced at the same time 2 The auxiliary assemblies include contact blocks wire harness female connector and mounting bracket 3 Refer to Table 5 on page 54 for Return Spring part number for higher altitude contactors if mechanical latch contactors are used without Intelli VAC or IntelliVAC Plus control 58 Rockwell Automation Publication 1502 UM052H EN P June 2013 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If
33. ible note the damage on the Bill of Lading before accepting the shipment Report any damage immediately to the claims office of the common carrier Provide a description of the damage and as much identification as possible Preliminary Inspection Check for any cracks or breaks due to impact Push on armature plate to ensure mechanisms are in good working order Use a HiPot tester to ensure vacuum bottle integrity refer to Vacuum Bottle Integrity Test on page 14 The contactor weighs approximately 48 Ib 21 8 kg and it is possible for one person to safely handle the contactor for a short time When transporting the contactor over longer distances or sustained lifting a forklift should be considered When a forklift is used to handle the equipment the following precautions should be taken e Keep the contactor in an upright position e Carefully balance the contactor on the forks Use a safety strap to steady the contactor and avoid shifting or tipping Avoid excessive speeds and sudden starts stops and turns Never lift a contactor above an area where personnel are located Rockwell Automation Publication 1502 UM052H EN P June 2013 13 Chapter2 Receiving and Handling Pre Energization Inspection Storage Vacuum Bottle Integrity Test 14 Before placing the contactor in service inspect it carefully for possible damage sustained in transit or maintenance e Check housing for any cracks or breaks due
34. ightened Step 3 Reference Figure 39 and Figure 40 Figure 39 Gauging the Contacts 46 Rockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 Figure 40 Gauging Auxiliary Contact Location Put feeler gauge here Auxiliary Actuator Bolt 0 030 in 0 76 mm 6 With the gauge in place slide the assembly forward until the contact actuator bottoms out With the gauge still in place carefully tighten the auxiliary assembly retaining nut IMPORTANT Always use a wrench to hold the bolt head as you tighten the nut Make sure the auxiliary assembly does no move as you tighten the nut 7 When the first nut is tightened slide out and remove the feeler gauge 8 Reinstall the green ground wire on the auxiliary assembly retaining bolt Install and carefully tighten the second nut 9 Slowly loosen the top screw of the contactor clamping fixture to remove the pressure on the armature plate Loosen the two mounting screws on the contactor clamping fixture Remove the fixture 10 Energize the control circuit in TEST mode and exercise the contactor to verify set up Contactor should open and close smoothly and solidly Rockwell Automation Publication 1502 UM052H EN P June 2013 47 Chapter4 Maintenance Mechanically Latched Parts Contactor Trip Coil US Replacement Procedure Refer to Chapter 6 for the part number s required for this procedure Required Tools
35. in 4 57 mm and 5 08 mm If this is the case the replacement procedure is complete If further adjustment is required all three gaps can be adjusted simultaneously by loosening the stop bracket bolts and adjusting the height of the gap adjustment screw at the rear of the contactor as shown in Figure 32 To adjust the height of the screw first loosen the locking nut 12 When the gap is correct tighten the gap adjustment screw locking nut Position the stop bracket lightly against the armature plate and tighten the bolts securing the stop in position Make sure that the actuator plate contacts the gap adjustment screw and the armature plate contacts the stop bracket as shown in Figure 32 Rockwell Automation Publication 1502 UM052H EN P June 2013 41 Chapter4 Maintenance Figure 32 Contact Gap Adjustment Gap Adjustment Screw Gap Adjustment Screw Stop Bracket Bolts Locking Nut Stop Bracket the control plug from the contactor before working on the unit Verify with a hot Stick or meter that all circuits are voltage free Failure to do so may result in Severe burns injury or death ATTENTION avoid shock hazards lock out incoming power and disconnect oil Replacement Procedure Refer to Chapter 6 for the part number s required for this procedure 1 Remove the auxiliary actuator front stop bracket and armature plate as shown in Figure 33 Do not remove the bolts which secure the stop bracket simply lo
36. ing 2400 V Sym MVA 25 5000 V Sym MVA 50 7200 V Sym 75 Short Circuit Withstand at Rated Voltage Current Peak cycle 60 Short Time Current Rating Capability For 1 second kA 6 0 For 30 seconds kA 2 4 Chop Current Average RMS Amps 0 5 Make and Break Capability at Rated Voltage kA 4 0 Ambient Temperature C 40 Contactor Coil Data Control Voltage Coil Voltage Electro Mechanical Relay Control Mechanical Latch Only 120 VAC 110 VDC Close Current Apc 5 6 Trip Current Apc 6 0 Pick up Voltage 102 Trip Voltage 84 IntelliVAC and IntelliVAC Plus Control Electrically Held amp Mechanical Latch 110 to 240 VAC VAC Close Current Apc 200 milliseconds 43 110o 250 voc 9 Not l a Curent Ap 0 48 iit Pick up Voltage 95 Va Ven Drop out Voltage 75 Trip Current Apc 200 milliseconds 55 Trip Voltage 70 10 Rockwell Automation Publication 1502 UM052H EN P June 2013 Product Description Table 2 Bulletin 1502 Medium Voltage 400 Amp Contactor Ratings Continued Operational Characteristics Mechanical Life Operations x 1000 4 Electrically Held 2500 Mechanical Latch 100 Electrical Life Operations x 1000 1000 Switching Frequency Operations per hour Electrically Held 600 Mechanical Latch 150 Opening and Closing Times Electro Mechanical Relay Control Mechanical Latch Only Ma
37. l Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1502 UM052H EN P June 2013 Supersedes Publication 1502 UM052G EN P November 2012 Copyright O 2013 Rockwell Automation Inc All rights reserved Printed in Canada
38. les office or the factory for assistance Figure 5 Contactor Catalog Number Explanation D B D Fifth Sixth Position Position Fuse Mounting Coil Provisions Voltage A Seventh Position Function Fourth Position Nominal Line Voltage 400A D 7200 B 5000 V 7200V D 110 V DC E 207 V DC Refer to TABLE 1 Table 1 Vacuum Contactor Function Eighth Position Altitude Code meters 0 1000 5000 1 0 1000 2 1001 2000 3 2001 3000 4 3001 4000 5 4001 5000 3 pole electrically held contactor B 3 pole mechanically latched contactor with electrical and mechanical release C 3 pole electrically held contactor with fast drop out Rockwell Automation Publication 1502 UM052H EN P June 2013 Chapter1 Product Description Contactor Specifications Table 2 Bulletin 1502 Medium Voltage 400 Amp Contactor Ratings Voltage Ratings Maximum Rated Voltage 7200 System Voltages 2400 3300 4160 4800 6600 6900 Dielectric Voltage Withstand Rating For 60 seconds kV 18 2 20 IEC Basic Impulse Level B I L Withstand Phase to Ground Phase to Phase kV 60 Frequency Ratings Hertz 50 60 Current Ratings Rated Continuous Current Amps 400 Maximum Interrupting Current Rating 2400 V RMS Sym Amps 6300 5000 V RMS Sym Amps 6300 7200 V RMS Sym Amps 2 6000 Maximum Interrupting MVA Rat
39. o publications 1503 UM053 EN P 1503 UM054_ EN P The standard mechanical latch contactors if used with electro mechanical control are designed for 1000 1000 m 3300 3300 ft Higher altitudes are possible by changing the contactor return springs refer to Figure 5 for suitable catalog numbers The number of contactor auxiliary contacts depends on the contactor type Some of the contacts are used in the typical control schemes used Rockwell Automation Publication 1502 UM052H EN P June 2013 Chapter 1 11 Chapter1 Product Description Table 3 Altitude Derating Altitude Rating Reduce Max Continuous Current Rating By Reduce 1 1 Withstand Rating by 400A 800A 0 1000 m 0 3300 ft 1001 2000 m 3301 6600 ft 10 20 6 0 kV 2001 3000 m 6601 9900 ft 20 40 12 0 kV 3001 4000 m 9901 13 200 ft 30A 60 18 0 kV 4001 5000 m 13 201 16 500 ft 40A 80 24 0 kV Product Approvals e 01347 e CSA222 No 14 and T I L D 21 IEC60470 e CE Mark 12 Rockwell Automation Publication 1502 UM052H EN P June 2013 Receiving Handling Chapter 2 Receiving and Handling The contactors have been tested both mechanically and electrically before leaving the factory Immediately upon receiving the contactor remove the packing material and check the contactor for possible shipping damage If damage is found do not discard any of the packaging material and if poss
40. ockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 Figure 36 Auxiliary Contact Adjustment Auxiliary Assembly Retaining Bolt 2 Slide the clamping fixture part number 80154 149 51 over the top ofthe armature stop bracket Figure 37 Finger tighten the two outside fixture mounting bolts against the armature stop bracket You may have to push the armature plate a little to the rear to put the clamp in place Figure 37 Clamping Contactor Closed Contactor Clamping Fixture 3 Placea 5 8 wrench on the main shaft of the contactor pull down and close the contactor Figure 38 while finger tightening the top middle screw on the clamping fixture Case should be taken not to bend the actuator stop plate Rockwell Automation Publication 1502 UM052H EN P June 2013 45 Chapter4 Maintenance Figure 38 Closing the Contactor 4 After the top screw is finger tight continue to tighten this screw with a hand tool The armature stop bracket will flex a little this is acceptable but do not over tighten and bend the armature stop plate It is important that the armature plate is held tightly against the magnet cores The contactor must be fully closed 5 Place a wide blade 0 030 in 0 76 mm feeler gauge between the plastic auxiliary actuator tips and the steel actuator plate To aid the installation of the feeler gauge the gauge can be put in place as the clamping block screw is being finger t
41. on The Allen Bradley Bulletin 1502 400 A vacuum contactors are designed for applications in the 2400 and 7200V range The contactor is suitable for all types of AC loads for example three phase motors transformers power capacitors and resistive heating loads The contactor uses three interrupters hereafter referred to as vacuum bottles operated by an electromagnet assembly through a mechanical linkage They are resistant to adverse atmospheric conditions and provide long mechanical and electrical life The contactors are utilized in various starter and drive configurations for example full voltage non reversing full voltage reversing two speed reduced voltage synchronous drive input output and bypass applications They are generally fixed mounted within the structures and the line and load terminations are made at the rear of the device In most configurations the main contactor is mechanically interlocked with the external operating handle and isolating switch Bulletin 1502 vacuum contactors are designed for use with the IntelliVAC and IntelliVAC Plus control module refer to Publication 1503 UM053_ EN P and 1503 UM054_ EN P The mechanical latch contactor may also be applied with an electromechanical relay control panel Bulletin 1502 electrically held and mechanical latch vacuum contactors are provided with coils rated for 108 VDC The IntelliVAC and IntelliVAC Plus control module can accept a wide array of supply
42. osen them and slide the bracket out 42 Rockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 Figure 33 Access to Coils Grade 5 5 16 Hardware to mount return spring actuator plate Refer to page 4 1 for torque values Grade 5 5 16 Hardware to mount armature plate Refer to page 4 1 for torque values Auxiliary Actuator Armature Plate Return Spring Actuator Plate Armature Stop Bracket Stop Bracket Bolts 2 Remove the retaining ring from the core of the coil you wish to replace as shown in Figure 34 3 Loosen the auxiliary assembly retaining bolt and slide the assembly and the coils forward and out of the contactor as shown in Figure 34 Figure 34 Coil Removal Operating Coil Operating Coil V Retaining Ring Auxiliary Assembly Auxiliary Assembly Retaining Bolt 4 Disconnect the coil leads take note of their location Connect the leads of the new coil making sure that all metal oxide varistors MOVs and or diodes are secure Refer to the appropriate wiring diagram in this manual if further control wiring details are required see page 20 5 Slide the new coil into position and install the retaining ring on the core Install the auxiliary assembly leaving the retaining bolt loose for adjustment later See the Auxiliary Contact Set up Procedure page 4 10 for determining the position of the auxiliary assembly Rockwell Automation Public
43. r set up of contactor auxiliary contact Replace IntelliVAC or IntelliVAC Plus control module assembly Check set up of contactor auxiliary contact assembly e Control voltage too high Check for correct control voltage Contactor does not energize Loose connections in control circuit e Check all connections in control circuit for tightness Damaged contactor auxiliary contacts Control voltage too low Improper set up of contactor auxiliary contact assembly Faulty CR1 or CR2 interposing relay Faulty IntelliVAC or IntelliVAC Plus control module 1 Valid if mechanical latch contactors are controlled with electromechanical circuit only 2 Valid if IntelliVAC or IntelliVAC Plus control module is used refer to 1503 UM053 EN P and 1503 UM054_ EN P Check wiring from the coil to the terminal block assembly Replace contactor auxiliary contact assembly Measure control voltage Refer to Contactor specifications for minimum pick up voltage Check set up of contactor auxiliary contact assembly Check and CR2 relay 7 Check IntelliVAC or IntelliVAC Plus status LEDs If faulty contactor coil s are the suspected cause of malfunction refer to Table 7 for typical coil resistance values and check the contactor coils Table 7 Typical Contactor Coil Resistance Values Coil Part Number Description DC resistance 0 80026 230 01 Operating Coil each 19 2 9 6x 2 80072 067 01 2 Mechanical Latch Trip Coil 17 6
44. red the mechanism must be moved away from the armature slightly toward the front of the contactor If too great a force is required the mechanism must be moved toward the armature slightly toward the back of the contactor If adjustment is required the contactor must be clamped closed and the set up procedure repeated with thicker or thinner feeler gauges as required IMPORTANT Thisisa sensitive and critical set up A few thousandths of an inch makes a noticeable difference in the function of the latch mechanism which trips too easily may result in nuisance tripping A mechanism which requires too much force may result in failure of the coil to trip the latch Altitude will affect the performance ofa vacuum contactor Atmospheric pressure assists in closing the main contacts by exerting force on the bellows at the movable end of the vacuum bottles The force is proportional to the difference between the internal bottle pressure and external atmospheric pressure and adjustments to the operating mechanism must be made to balance the change in closing force The 400A contactors are equipped with return springs appropriate for the specific altitude they will be operating at Note IntelliVAC vacuum contactors typically use the bronze colored return springs and the IntelliVAC and IntelliVAC Plus control modules are used to compensate If a mechanical latch contactor is applied without IntelliVAC or IntelliVAC Plus control the springs must b
45. rminal Nut 5 Install a new bottle by tilting an insulator forward and threading the bottle onto the stud reverse of Step 3 Take care to ensure the threads are aligned as cross threading can occur Thread the bottle down leaving a gap of approximately 4 82 mm 0 25 mm 0 190 in 0 01 in between the top of the bottle and the bottom surface of the line terminal as show in Figure 29 Use inside calipers and micrometer or another accurate measuring tool to set the gap This gap is precisely calibrated later in this section The wear indicator line on the bottom of the bottle s movable shaft must be facing forward i e visible from the front of the contactor Repeat this step for the remaining two bottles Rockwell Automation Publication 1502 UM052H EN P June 2013 39 Chapter 4 Maintenance 40 Figure 29 Establishing Contact Gap 0 190 4 82 mmJ lt Vacuum Bottles Insulator Install the load terminal retaining bolts at the rear of the contactor Leave the load terminal nuts loose for fine adjustment of the overtravel and contact gap Install the vacuum bottle mounting bolts at the top of the contactor reverse of step 2 Take care to ensure the threads are aligned as cross threading can occur Hold the bottle to prevent it from turning while torquing the vacuum bottle mounting bolts Close the contactor by using the TEST control circuit in the starter Inser
46. rocedure can be performed with the contactor remaining in the power cell of the controller the control plus from the contactor before working on the unit Verify with a hot stick or meter that all circuits are voltage free Failure to do so may result in Severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power and disconnect 1 Before removing the vacuum bottles mark the installed bottles clearly to avoid confusing them with the replacement vacuum bottles 2 Ifthe contactor has not been removed from the starter first remove the lower terminal connections at the rear of the contactor 3 Remove the load terminal retaining bolt at the rear of the contactor and the vacuum bottle mounting bolt at the top of the contactor Figure 27 38 Rockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 Figure 27 Mounting and Retaining Bolt Removal Vacuum Bottle Mounting Bolt Load Terminal Retaining Bolt and Hardware 4 Loosen the load terminal nut on one bottle assembly tilt the bottle forward out of the contactor and unscrew it from the insulator stud as shown in Figure 28 Repeat this for the two remaining bottles The load terminals insulators and overtravel spring assemblies remain in the contactor as shown in Figure 28 Figure 28 Removal of Vacuum Bottles L Insulator Stud Load Te
47. s 3 9 ao 82 S 28 Rockwell Automation Publication 1502 UM052H EN P June 2013 Installation Chapter3 Figure 19 Typical Electrical Diagram for 400 Full voltage Non reversing FVNR Controller with Mechanically Latched Contactor 120V AC d DIMENSION DRAWING FUR COMPONENT SIZING NOT SHOWN DN THIS DRAWING MAIN CONTACTOR LATCH RELAY MAIN CONTACTOR UNLATCH RELAY MAIN CONTACTOR H OFF NORMAL TEST 24 He Kal gt f Gy oF E PE 58 E ES e 58 zB 4 Ta gt w a sie ax E 8 PEG E Ja Rockwell Automation Publication 1502 UM052H EN P June 2013 29 Installation Chapter3 TB SIHL NO NMOHS he e LON 215 LN3NOdWO2 NOISN3WIG OLH3 3H 3
48. s not used Contactor Identification Each contactor is identified with a rating label Figure 4 attached to the armature plate at the front of the contactor The rating label information includes the Catalog Number Cat Series Letter Ser Voltage Rating Non Enclosed Current Rating Interrupting Capacity Altitude Range in meters CSA UL and CE markings Figure 4 Contactor Rating Label 400A VACUUM CONTACTOR CAT CONTACTEUR SOUS VIDE SER 1502 V4DBDA 1 2500 7200 V 38 400 50 60 HZ wy INTERRUPTING CAPACITY POUVOIR DE COUPURE 6000 IEC60470 ALTITUDE RANGE PLAGE D ALTITUDE 0 1000 M AY 4 READ INSTRUCTIONS BEFORE ENERGIZING C US i THIS DEVICE MAY PRODUCE HARMFUL X RAYS E102991 1519235 LIRE LES INSTRUCTIONS AVANT D ALIMENTER Rockwell CET APPAREIL DES RAYONS X DANGEREUX utomation PEUVENT SE PRODUIRE MADE IN CANADA 8 Rockwell Automation Publication 1502 UM052H EN P June 2013 Contactor Catalog Number Explanation 1502 First Position Bulletin Number V Second Position Contactor Type and Interlock 1502 VC Vacuum Optimized for IntelliVAC control 4 Third Position Contactor Size Vacuum 4 Product Description Chapter1 The following catalog number explanation is used to identify the contactor and should be used when contacting your local Rockwell Automation Sa
49. t a fecler gauge of 0 065 in 1 65 mm into the overtravel gap of a bottle assembly Figure 30 Rotate the insulator until the gap is correctly set Repeat this step for the two remaining bottles This step must be performed accurately because it establishes synchronization between the three vacuum bottles Figure 30 Establishing Overtravel 8 Overtravel Gap 0 065 in 1 65 mm With the contactor still energized measure dimension A1 for all three bottles Figure 31 De energize drop out the contactor and measure dimension A2 for all three bottles The contact gap is the difference of A2 minus 1 Record the gap for all three bottles Rockwell Automation Publication 1502 UM052H EN P June 2013 Maintenance Chapter4 Figure 31 Measuring Contact Gap 1 2 9 The contact gaps must be synchronized within 0 02 in 0 5 mm If the gaps are not synchronized rotate the insulators as required to achieve this Make sure the overtravel remains a minimum of 0 065 in 1 65 mm on each bottle 10 Tighten the load terminal nut on each bottle assembly To do this without damaging the bellows apply wrenches to the load terminal nut and to the flattened section of the movable bottle shaft Tighten the load terminal nut while holding the bottle shaft steady Be careful not to turn the insulator as this will change the gap 11 The final contact gap for all three bottles must be between 0 180 in and 0 200
50. ter 3 Rockwell Automation Publication 1502 UM052H EN P June 2013 n ONIMVMO SIHL NO NMOHS 27 JON DNIZIS IN3NOdWOD NOISNSWIG O18333 3LON Z S lt 3301502 vet vt WOLSIVA3GIXO TVLIW AOW SOAM u IDIA 333 T GALNNOW KON a 25 TWOIdML DL 2L s 3025NIO 22 9 eje le els 4 15 340438 3301502 NES JHL 38 OL JDVINO2 Villx3 vy 34VS 1 3 0115 JINGOW B 33VS SNLYLS HOLDVINOD amp OTO 1103433 NI S31 VIS dN Y3MOd NOLLWYNDIINOD 10 GATIVISNI ABO12V3 DNIMOTIO4 JHL O3riddv ui3MOd IOHLNOD LNOHLIM NMOHS SLOV 1NOD AV 138 104100 IS3IONDVATTHINI T E lt lt 1 NW g lt 2 uw W 4 N3dO 10 dll 8 L TVONVW 0 NW L 440 35072 pi 6 X z Q ig vi NW NO ES 3503 AuVWiti
51. ter 3 17 Electrical Connections s beri pides Ces patet da b Ur radius 18 Wiring and Schematic Diagrams sizes eet rb skr cre rebus 20 Chapter 4 Tool 35 Recommended Torque Values 35 Routine Maintenance 36 BI pr MD 36 Main Contact Inspection 37 PR 37 Lubrication ana 37 Vacuum Bottle Replacement and Set Up Procedure 38 Coil Replacement Procedure 42 Auxiliary Contact Set up Procedure 44 Mechanically Latched Contactor Trip Coil Replacement Procedure 48 48 walpa 48 Mechanically Latched Contactor Set up Procedure 52 Altitude Adjustment see 53 Rockwell Automation Publication 1502 UM052H EN P June 2013 3 Table of Contents Troubleshooting Spare Parts Chapter 5 Troubleshooting and Contactor Coil Resistance Chapter 6 Bulletin 1502 Spare Parts Diagrams and Rockwell Automation Publication 1502 UM052H EN P June 2013 Contactor Description Rockwell Automation Publication 1502 UM052H EN P June 2013 Chapter 1 Product Descripti
52. the contactor with 1 4 in bolts The appropriate mounting configuration is provided inside the power cells of Allen Bradley controllers If the contactor is supplied as an OEM component for installation in a custom application refer to the dimensional information in Figure 7 If the contactor is to be mounted in an enclosure designed by an OEM make sure there is a minimum of 3 in 76 mm of air space between live parts terminals and vacuum bottles and any part of the enclosure Figure 7 Contactor Mounting Details 0 75 19 lt 13 22 336 gt 8 64 219 gt r Ai 8 E i I 4 96 126 oO aljo 17 24 unm TER ki 438 6 gt 1 O_O ue 8 53 217 l l ND l l lt 5 00 127 EE Eje xum z E F SECTION 15 80 4 25 108 gt lt 4 25 108 0
53. tion 1502 UM052H EN P June 2013 N 4 N PA b P N 4 S J 5 u SIHL NO NMOHS yw 9 q W N fE m JON SNIZIS 303 NOISN3WIQ 0139 98 3LON ONIBIMH3WOISQO SLOVLNOD ABVIIIXQV VillX3 Je zD WOISMVA JAIXO VLIW AOW DIAZA JALDILOYd 03 33 4 9p ole BD DIAIG MOT 7102 41124 OL g 102 5012 25 zr re 5 83 os s W 5 L s s 440 a 4 TWANYW e 4 77 4 ss c 10 ss Z ZL Av THU HOLVINN LE 3 w ve 301591405 330 E 182 H ww 39503 AB Witid 5 p S 3 4 Qr jo 3 oE 1433312 YOLDVLNOD NIVW NO E ns 4 9 zx zH 8 H T 1 1 4 21 Gu 1 5 TA 1 8 e a uD VA00S 4 182 a zi gt 4 55 gt X RBS oz 51 v i 2 12 p XDOWILNI Y000 I ee horno 4 W T AOW HOLIMG 5NILV 1OSI E ZH09 0S 4 51 01 6 8 sng aus ANIOd Add NS 1531 4 Qe wW x YIMOd
54. to impact Push on the armature plate and rotating shaft to ensure mechanism is in good working order Inspect the contactor for dirt stray or loose hardware tools or metal chips Vacuum clean if necessary If it is necessary to store the contactor before it is put into service be certain to store it in a clean dry area free from dust and condensation Do not store contactor outdoors Storage temperature should be maintained between 20 65 C 4 149 F If storage temperature fluctuates or if humidity exceeds 85 space heaters should be used to prevent condensation The internal dielectric condition and vacuum integrity of the vacuum bottles is determined by this test ATTENTION Do not apply a voltage higher than 25 000V across the open contacts of a vacuum bottle Dangerous x ray emissions may be produced ATTENTION Vacuum bottles are thoroughly tested at the factory however mishandling during shipment may cause damage It is very important to perform the vacuum bottle integrity test before energizing the contactor for the first time and before it is returned to service after maintenance or repair test may result in personal injury or damage to the equipment if the vacuum bottle integrity fails performing the Hi pot test Failure to do so may result in sever burns injury or ATTENTION High voltage testing is potentially hazardous Use caution when death High potential test instruments can be purchased
55. voltages for maximum flexibility refer to Publication 1503 UM053_ EN P and 1503 UM054 Figure 1 400A Contactor Chapter1 Product Description Vacuum Bottle Description Standard Electrically Held Contactor Operation Each vacuum bottle Figure 2 consists of two contacts enclosed in a ceramic housing an upper contact mounted to a fixed shaft and a lower contact mounted to a movable shaft A stainless steel bellows ensures the vacuum integrity of the bottle while letting the lower contact move towards and away from the fixed contact Figure 2 Vacuum Bottle Cross Section Fixed shaft Ceramic Arc Shield Contacts Bellows Zi Bearing Contact Wear Indicator Line Movable Shaft Each vacuum bottle Figure 2 consists of two contacts enclosed in a ceramic housing an upper contact mounted to a fixed shaft and a lower contact mounted to a movable shaft A stainless steel bellows ensures the vacuum integrity of the bottle while letting the lower contact move towards and away from the fixed contact The standard electrically held contactor consists of three vacuum bottles An electro magnet assembly and a mechanical linkage are used to close the contacts e When the IntelliVAC or IntelliVAC Plus control module receives a close command the contactor coils two connected in series are energized and the current creates an electromagnet with the coils The electromagnet pulls the
56. ximum Closing Time 120 VAC 50 or 60 Hz milliseconds 160 Maximum Opening Time 120 VAC 50 or 60 Hz milliseconds 50 IntelliVAC and IntelliVAC Plus Control Electrically amp Mechanical Latch Maximum Closing Time 50 to 60 Hz 120 240 milliseconds 100 70 Maximum Opening Time 120 to 240 VAC milliseconds 60 without delay for 50 to 60 uz Capacitor Switching max KVAR System Voltage 2400V 800 4160V 1400 6900V 2000 General Standard Altitude Capability meters feet 9 1000 5000 3300 16 500 Contactor Weight kg Ibs 21 8 48 Auxiliary Contact Rating A600 Auxiliary Contacts on the Vacuum Contactor Max 3N 0 3N C Control voltage as measured at input of the lt EN P IntelliVAC or IntelliVAC Plus control module Provided that regular maintenance is performed as detailed in this manual A contactor drop out delay may be configured with the IntelliVAC or IntelliVAC Plus control module refer to publications 1503 UM053 EN P and 1503 0 054 lt The voltage and current ratings listed are valid up to 1 000 m 3 300 ft Please refer to Table 3 for ratings above this altitude The IEC rating at 7200V RMS Sym is 5300 66 MVA The full Altitude range is available with the IntelliVAC or IntelliVAC Plus control module only and the IntelliVAC or IntelliVAC Plus is to be configured accordingly refer t
57. you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwel

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