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1. 80123 413 51 TT d N D l K Y I MOV o eoor xpe BLK Mov h A B cl ST Dec E CC HC Paz amc Sais I E F G H 800T XA 800T X4 I AUXILIARY dt 2 L CONTACTS L POWER CIRCUIT O T i T QO CONTROL ra ra rA TRANSFDRMER acra Saura 5 9 FUSE Gel Lal Ll est HOLDERS 9 9 O M M M V BICDE F GH LJK amp N PINS TI Te T3 AL amp M SOCKETS P NUT USED SCHEMATIC 400A VACUUM CONTACTOR 230v COIL FAST DROP OUT AUXILIARY CONTACTS MOV M SC A B C H CC La gt p BLANC Y E F MOV M m G H N HC L i BN Y 9 M I J M E K L CC CLOSING COIL HC HOLDING COIL Figure 3 6 Wiring Diagram Electrically Held Contactor 230 V AC Fast Drop Out Time 1502 UM050C EN P December2004 Installation 3 7 WIRING DIAGRAM 400A MECHANICALLY LATCHED CONTACTOR 800T xD2 K LS AUXILIARY CONTACTS POWER WIRING j L1 Le L3 EUN 7 Lj Lj TRANSF RMER PRIMARY Lo bo Ly FUSE HOLDERS i i C D L SOCKETS ALL OTHERS PINS Tl T2 T3 SCHEMATIC 4004 MECHANICALLY LATCHED CONTACTOR AUXILIARY CONTACTS E gt F J CONTACTOR SHOWN IN OPEN seri 9 A R CTRIPPED CONDITION L CC CLOSING COIL i FER TC TRIP COIL LS LIMIT SWITCH N lt J gt P d Di De DIODE W WHITE N K I B BLUE Figure 3 7 Wiring Diagram Mechani2. 11 5 amps e At 230 VAC electrically held 8 3 amps mechanical latch N A The continuous current rating and B I L withstand are de rated for altitudes above 1000 m 3300 ft Refer to Altitude Adjustment in Chapter 4 for details IEC rating at 7200 V RMS sym 5300 amps Provided routine maintenance is performed as detailed in this manual Contactor Product Description 1 7 Contactor Ampere Rating 400A Mechanical latch trip coil inrush current s AUI20 VAG aliena ie 5 amps s At230 VA Csi NH HER ERE HERES PRICE piku N A Coil continuous economized current AUT20 V AC sonst Lian aie 0 13 amps At 230 VAG siii ilaele 0 11 amps Coil pick up voltage e At 120 V AC DEET 102 VAC S AU290 V AG annota 190 VAC Coil drop out voltage At KEIER 75 VAC AXt230 MAG TEEN 140 VAC Mechanical latch trip coil voltage S JAUCI20 VAG ies es 102 VAC s AU230 VAC use eee teri reete N A Maximum closing time 60 EZ iiia tese en depo daten 9 6 cycles 160 msec 50 HZ e e reto teats 8 cycles 160 msec Maximum opening time 6 normal drop out 60 Hz 9 6 cycles 160 msec normal drop out 50 Hz 8 cycles 160 msec fast drop out 60 Hz 3 cycles 50 msec fast drop ou
3. Mechanical Latch Mechanism Assembly Figure 4 20 Access to Replace Coil 5 Remove the roller shaft retaining ring on the right hand side and slide the roller shaft out to the left Remove the trip core mounting screw as shown in Figure 4 21 and remove the coil and core earlier version contactors with four latch mounting bolts do not have a trip core mounting screw Trip Coil e Roller Shaft i Trip Core wie Roller Shaft Retaining Ring o Sous Mounting Screw Figure 4 21 Removal of Trip Coil 6 Install the new coil onto the core Slide the core and coil into position with the leads toward the back of the contactor and install the core mounting screw Replace the roller shaft and re install the retaining ring 7 Position the latch mechanism in the contactor and install the mounting bolts leaving them loose for adjustment Maintenance 4 17 8 Route the trip coil leads as shown in Figure 4 22 and reconnect them to the auxiliary terminals Secure the leads to the back panel of the housing with wire ties Refer to the appropriate wiring diagram in this manual if control wiring details are required Access to Trip Coil Lead Terminals Trip Coil Leads Figure 4 22 Trip Coil Lead Routing 9 Replace the armature plate and the front stop Position the front stop by resting it lightly against the armature plate 10 See the Mechanically Latched Contactor Set up Procedure page 4
4. Allen Bradley Medium Voltage Contactor Series D Bulletin 1502 400A 2400 to 7200 volts User Manual Rockwell Automation Important User Information Solid state equipment has operational characteristics differing from those of electro mechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Rockwell Automation sales office or online at http www ab com manuals gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of these differences and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable 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 information circuits equipment or software described in this manual Reproduc
5. Disconnect the interlock rod from the operating lever on the right side of the contactor Remove the contactor from the cabinet Remove the three latch mechanism mounting nuts on the underside of the contactor housing as shown in Figure 4 18 on earlier series contactors there are four bolts It is easiest to do this with the contactor lying on its back Mounting Nuts 3 Figure 4 18 Removal of Mechanical Latch Mounting Nuts Maintenance 4 15 2 Remove the armature plate and front stop as shown in Figure 4 19 Armature Plate Stop Bracket Figure 4 19 Access to Mechanical Latch 3 Disconnect the trip coil leads from the auxiliary assembly Take note of the lead termination points 4 Pull the latch assembly forward and out of the contactor as shown in Figure 4 20 The loose mounting bolts can be re installed later The trip coil leads are secured with wire ties at the back of the contactor clip the ties to allow removal of the leads Note On older contactors the trip coil leads are routed under the closing coil If it is difficult to remove the leads loosen the closing core mounting bolt to allow the coil to be tilted up slightly and pull the leads out then tighten the core mounting bolt immediately Do not loosen both core mounting bolts at the same time 1502 UM050C EN P December2004 4 16 Maintenance Mechanical Latch Trip Coil Replacement Procedure cont 1502 UM050C EN P December2004
6. Publication 1502 UM050C EN P December 2004 Copyright 2004 Rockwell Automation All rights reserved Printed in Canada Supersedes Publication 1502 5 0 May 1998
7. 12 Mech Latch Figure 6 1 Bulletin 1502 400 A Electrically Held Vacuum Contactor Figure 6 2 Bulletin 1502 400 A Mechanical Latch Assembly 1502 UM050C EN P December 2004 6 2 Spare P arts Table 6 A Spare Parts UR Description of Parts Part Number 120 V Control 400 A 1 Three 3 Vacuum Bottles 80157 496 52 2 Closing Coil electrically held 80153 576 51 3 Closing Coil mechanical latch 80154 134 51 4 Hold in Coil 80153 575 51 5 Mechanical Latch Trip Coil 120 VAC 80025 833 01 80153 554 52 Auxiliary Assemblies 80153 554 56 6 80153 999 60 7 Return Springs standard altitude 0 1000 m 80153 567 01 8 Coil Retaining Ring 28325 042 01 9 Stop Bracket 80153 565 01 10 Auxiliary Actuator P late 80153 553 02 11 Armature P late electrically held 80153 552 02 12 Armature Plate mechanical latch 80153 781 02 13 Mechanical Latch Roller Bearing 80153 748 01 14 Mechanical Latch Roller Bearing Shaft 80153 744 02 15 Mechanical Latch Roller Bearing Shaft Retaining Clip M 5605 16 Mechanical Latch Auxiliary Contact Block 800T XD2 Rem Description of Parts Part Number 230 V Control 400 A Closing Coil 80153 576 52 Hold in Coil 80153 575 52 Auxiliary Assembly 80153 554 59 Rockwell Automation recommends that if the contactor has been in service all three 3 bottles be replaced atthe same time The auxiliary assemblies include contact blocks wire hamess female connector and mounting bracket Only availabl
8. 1502 UM050C EN P December2004 2 2 Receiving and Handling Storage Vacuum Bottle Integrity Test 1502 UM050C EN P December2004 If it is necessary to store the contactor before it is put into service be certain to store it in a clean dry dust and condensation free area Do not store contactor outdoors Storage temperature should be maintained between 20 C to 65 C 4 F to 149 P 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 Power Frequency Dielectric Tests for new dry equipment are defined in Clause 8 9 of NEMA ICS 3 2 and Clause 8 4 of ICS1 Periodic field testing every 50 000 operations or annually whichever occurs first will ensure that vacuum bottle integrity exists The tests are to be performed as shown in Table 2 A Do not apply a voltage higher than 25 000 volts across the open contacts of a vacuum bottle Dangerous x ray A emissions may be produced Vacuum bottles are thoroughly tested at the factory however mishandling during shipment may cause damage A 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 otherwise perform the test annually Failure to perform this test may result in personal injur
9. 0 98 25 Bottom View Figure 3 1 Contactor Mounting Details 1502 UM050C EN P December 2004 3 2 Installation Electrical Connections 1502 UM050C EN P December 2004 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 an optional control panel with connecting wire harness is available from Rockwell Automation 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 ft Ibs 292 N m 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 ft Ibs 292 N m 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 Control Circuit Transformer Primary Fuse Clips Line Side Terminals Control Wire Plug Load Side Terminals Figure 3 2 Electrical Connections Rear View Wiring and Schematic Diagrams WIRING DIAGRAM 4004 VACUUM CONTACTOR ie0v COIL NORMAL DROP OUT CONTROL TRANSFORMER
10. PRIMARY FUSE HOLDERS 80123 413 51 Suid Ay N D J Y a gooT xpe BUS B I H mov h I le el A B I C rc ow ce HC hee expen ANS ESI essi d E F G H 800T XA 800T XA l I AUXILIARY do e bk LI contacts I w POWER TI LL JJ CIRCUIT a Le L3 s D Eas SEI 00O Loi SCH L 9 M M M By pub Installation 3 3 SCHEMATIC 400A VACUUM CONTACTOR ig0v COIL NORMAL DROP OUT AUXILIARY CONTACTS MOV A B C LEH D BLKN Y E F ei G H N e B N Y om I jj S77 K L CC CLOSING COIL HC HOLDING COIL Figure 3 3 Wiring Diagram Electrically Held Contactor 120 V AC Normal Drop out Time 1502 UM050C EN P December 2004 34 Installation Wiring and Schematic Diagrams cont WIRING DIAGRAM 4004 VACUUM CONTACTOR 230V COIL NORMAL DROP QUT 80123 413 51 DEM ANC 4 N D Y Y d amp oor xpe BLK B l CO Mov A B I cl x cc HC bo desta m CC Icd E F G H 800T XA 800T XA AUXILIARY l 4 L i contacts I POWER CIRCUIT 5 e i OOO CONTROL ea r r TRANSFORMER rane NE 5 9 O FUSE LL Ll L i el HOLDERS 9 IH O M M M S P T T AR B C D E F GH I J K amp N PINS T Te T3 AL amp M SOCKETS P NUT USED SCHEMATIC 400 VACUUM CONT
11. E p a T2 a RIO mo CW YOLIVLNOD Mi SISMI Age DNLLIWET ANHAND ONLIN AN3IINO MIOTGLNI 2000 WOLIAS ONILVIOSI sni oam SNE XIADA ZH09 05 et A0069 A00 2 Figure 3 9 Typical Electrical Diagram for 400 amp Full Voltage Non Reversing FVNR Controller with Mechanically Latched Contactor 120 V AC 1502 UM050C EN P December 2004 3 10 Installation 1502 UM050C EN P December 2004 Tool Requirements Recommended Torque Values Routine Maintenance Maintenance Important Some components of this product incorporate Imperial hardware Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedures 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 e Standard 3 8 in drive sockets 7 16 in 1 2 in Open end wrenches 7 16 in 1 2 in e Slot head screwdrivers 1 8 in wide 1 4 in 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 calipe
12. assemblies remain in the contactor as shown in Figure 4 5 1502 UM050C EN P December 2004 Maintenance 4 5 Insulator Stud N M ich d Load Terminal Nut Figure 4 5 Removal of Vacuum Bottles 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 shown in Figure 4 6 Use inside calipers and a 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 0 190 in 4 82 mm E Vacuum Bottles Insulator Figure 4 6 Establishing Contact Gap 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 1502 UM0
13. bracket by resting it lightly against the armature plate 1502 UM050C EN P December2004 4 10 Maintenance Auxiliary Contact Set up Procedure 1502 UM050C EN P December2004 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 Refer to Chapter 6 for the part number s required for this procedure To facilitate the set up procedure the contactor is held closed mechanically by means of a clamping fixture as shown in Figure 4 4 It is important that the contactor is held closed tightly with the armature plate against the magnet cores when gauging the over travel and auxiliary positioning To aid in closing the contactor mechanically a clamping fixture is required Allen Bradley part number 80154 149 51 is recommended Auxiliary Actuator Armature Plate Armature Stop Bracket Figure 4 12 Contactor Components Maintenance 4 11 Loosen the nuts on the auxiliary assembly retaining bolt This will require loosening and removal of the first nut which secures a ground wire at this location Leave one nut loosened just enough to permit the assembly to slide along the adjustment slot as shown in Figure 4 13 Auxiliary Assembly Retaining B
14. i 1 5 Contactor Specifications nsession iii 1 6 Prod ct Approvals ie eet een e ettet e Htc ide 1 8 Receiving and Handling Chapter 2 RECEIVING yum PM mM rd 2 1 Handling iue ette e des ile ene eere 2 1 Pre Energization Inspection i 2 1 STOrASE n c RUN ale i 2 2 Vacuum Bottle Integrity Test 2 2 Insulation Resistance Testa aaa essere 2 5 Installation Chapter 3 Mounting cri reni iii nin nicola 3 1 Electrical Confiections usa a han NEE 3 2 Wiring and Schematic Diagrams Electrically Held Contactor 120 V AC Normal Drop out Time 3 3 Electrically Held Contactor 230 V AC Normal Drop out Time 3 4 Electrically Held Contactor 120 V AC Fast Drop out Time 3 5 Electrically Held Contactor 230 V AC Fast Drop out Time 3 6 Mechanically Latched Contactor 120 V AC 3 7 Typical Electrical Diagram for 400 amp FVNR Controller with Electrically Held Contactor 120 V AC 3 8 Typical Electrical Diagram for 400 amp FVNR Controller with Mechanically Latched Contactor 120 V AC 3 9 1502 UM050C EN P December 2004 ii Table of Contents 400 A Medium Voltage Contactor User Manual Spare Parts 1502 UM050C EN P December 2004 Chapter4 Tool D 2 ot re rer te EH Lee t eio Leti 4 1 Recommended Torque Values eese 4 1 Routine Maintenance i ioni desea ne rete 4 1 Vacuum Bottle Rep
15. the values obtained during the test may not be a reliable indication of vacuum bottle integrity Some specific DC GO NO GO testers may provide suitable defective readings 1502 UM050C EN P December 2004 Receiving and Handling 2 5 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 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 only 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 indicates 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 Insu
16. will only redistribute the dirt If dirty clean the white ceramic area of vacuum bottles with a clean lint free cloth 2 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 hex shaft moves up into the bearing replace all three vacuum bottles Refer to Figure 4 1 Vacuum Bottle Wear indicator line On operating shaft Figure 4 1 Vacuum Bottle Wear Indicator 1502 UM050C EN P December 2004 Maintenance 4 3 3 HiPot test Refer to Page 2 2 Check the vacuum bottle integrity e Check the insulation resistance 4 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 4 2 Insulator a Grease Actuator Plates Grease Figure 4 2 Grease Locations Using Aeroshell No 7 1 oz tube Part No 40025 198 01 grease the pivot shaft at the bearing points on the mechanical latch mechanism option Figure 4 3 Grease Pivot Shaft Figure 4 3 Mechanical Latch Grease Locations NOTE Do not grease the armature shaft plastic bearings These bearings are self lubricating and do not require grease 1502 UM050C EN P December 2004 4 4 Maintenance Vacuum Bottle Replac ement Under normal conditions vacuum bottles will last up to 1 000 000 operations and Se
17. 050C EN P December2004 Maintenance 4 19 Insert feeler gauge here 0 010 in 0 25 mm Figure 4 24 Gauging Mechanical Latch Location 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 Naruto The return springs exert a significant force on the armature plate To avoid injury do not place fingers between the A armature plate and the stop bracket at any time 6 Using the manual trip lever trip drop out the contactor Apply 2 to 3 Ib of force to trip the contactor If too little force is required 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 adjust ment is required the contactor must be clamped closed and the set up procedure repeated with thicker or thinner feeler gauges as required Important This is a sensitive and critical set up A few thousandths of an inch makes a noticeable difference in the function of the latch A 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 1502 UM050C EN P December2004 4 20 Maint
18. 18 for establishing the position of the latch mechanism 1502 UM050C EN P December2004 4 18 Maintenance Mec hanically Latched Contactor 1 The overtravel contact gap and auxiliary set up procedures are the same Set Up Procedure for mechanically latched contactors as they are for electrically held 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 23 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 contactor to pull up the actuator plate care must be taken not to overtighten the C clamp and bend the actuator plate Jua sti _ U Mechanically Latched Contactor Clamping Fixture Figure 4 23 Clamping a Mechanically Latched Contactor Closed 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 an 015 in 0 38 mm feeler gauge between the latch roller and the armature plate as shown in Figure 4 24 Tighten the mounting bolts do not overtorque 1 4 inch nuts or 5 16 inch bolts 1502 UM
19. 50C EN P December 2004 4 6 Maintenance Vacuum Bottle Replac ement 7 Close the contactor by using the TEST control circuit in the starter Insert and Set up Procedure cont a feeler gauge of 0 065 in 1 65 mm into the overtravel gap of a bottle assembly Figure 4 7 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 Overtravel Gap 0 065 in 1 65 mm Figure 4 7 Establishing Overtravel 8 With the contactor still energized measure dimension A1 for all three bottles Figure 4 8 De energize drop out the contactor and measure dimension A2 for all three bottles The contact gap is the difference of A2 minus A1 Record the gap for all three bottles d K Figure 4 8 Measuring Contact Gap 1502 UM050C EN P December2004 Maintenance 4 7 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 tur
20. ACTOR 230v COIL NORMAL DROP OUT AUXILIARY CONTACTS CC CLOSING COIL HC HOLDING COIL Figure 3 4 Wiring Diagram Electrically Held Contactor 230 V AC Normal Drop Out Time 1502 UM050C EN P December 2004 Installation 3 5 WIRING DIAGRAM 4004 VACUUM CONTACTOR 190v COIL FAST DROP OUT 80123 413 51 pec EU d N D I Y I Mov eoor xpe BLK B l mov h l d c A B I C In CC HC Ee feta puc pu Z p E F G H 800T XA 800T XA l I AUXILIARY L EN E CONTACTS I L POWER CIRCUIT x A LI Le L3 D CONTROL r ra r TRANSFORMER aa ill a SO FUSE La Lal Lal 1 HOLDERS 9 o M M M p T Te T3 SCHEMATIC 4008 VACUUM CONTACTOR 120V COIL FAST DROP QUT AUXILIARY CONTACTS MOV A B C D BLK Y E F MOV G H N B Y o M I J gu K L CC CLOSING COIL HC HOLDING COIL Figure 3 5 Wiring Diagram Electrically Held Contactor 120 V AC Fast Drop Out Time 1502 UM050C EN P December 2004 3 6 Installation Wiring and Schematic Diagrams cont WIRING DIAGRAM 4004 VACUUM CONTACTOR 230V COIL FAST DROP OUT
21. NT SE PRODUIRE uto MADE IN CANADA Figure 1 4 Contactor Rating Label 400A 1502 UM050C EN P December 2004 Contactor Product Description 1 5 Contactor Catalog Number The following catalog number explanation is used to identify the contactor Explanation and should be used when contacting your local Rockwell Automation Sales office or the factory for assistance Table 1 A Contactor Catalog Number Explanation 1502 V 4 D B D A 1 r A s SR A First Second Third Fourth Fifth Sixth Seventh Eighth Position Position Position Position Position Position Position Position Bulletin Contactor Type Contactor Nominal Fuse Mounting Coil Function Altitude Number and Interlock Size Line Voltage Provisions Voltage Code meters 1502 V Vacuum 4 400A D 7200 V B 5000V D 110VDC Refer to ang 8000 VD Vacuum C 7200V E 207 VDC TABLE 1 B 3505 1000 Drawout 2 1001 2000 3 2001 3000 VC Vacuum 4 3001 4000 Optimized for 5 4001 5000 IntelliVAC control Table 1 B Vacuum Contactor Function A 3 pole electrically held contactor B 3 pole mechanically latched contactor with electrical and mechanical release D 3 pole electrically held contactor with fast drop out 1502 UM050C EN P December 2004 1 6 Contactor Product Description Contactor Specifications 1502 UM050C EN P December 2004 Contactor Ampere Rating 400A Continuous curr
22. agnet assembly and a mechanical linkage are used to close the contacts Figure 1 3 When the control circuit is energized the current creates an electromagnet in the closing coil and hold in 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 The control circuit economizing auxiliary contacts on the left side of the contactor change from the normally closed state to open as the contactor closes This de energizes the closing coil The hold in coil remains energized and keeps the contactor closed De energizing the hold in coil opens the contactor Note The contactor requires external control relays and a rectification circuit to control the standard DC closing and hold in coils on the contactor Refer to Chapter 3 for typical control schematics C P T Fuse Clip BS CO n ZZZZLZAL EI Insulator Line Terminal Vacuum Bottle Armature Plate amp Shaft Load Terminal Auxiliary Actuator Flexible Bus Return Spring Control Wire Plug Actuator Plate Gap Adjustment Screw Magnet C oil Assembly Armature Stop Bracket PELZZZZZZZ ZAN Contactor Open Contactor Closed Figure 1 3 Vacuum Contactor Operation 1502 UM050C EN P December2004 1 4 Contactor Product Description Mec hanically Latched The mech
23. anically latched contactor operates in much the same way as the Contactor Operation electrically held with only a few exceptions When the control circuit is energized current flows only to the closing coil and creates an electromagnet the hold in coil is not supplied 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 which pulls the latch away from the armature or by a push button mounted on the power cell door that mechanically releases the contactor Contactor Identification Each contactor is identified with a rating label Figure 1 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 and UL markings VACUUM CONTACTOR CAT CONTACTEUR SOUS VIDE SER 1502 V4DBDA 1 2500 7200 V 30 400 AMP 50 60 HZ INTERRUPTING CAPACITY 6000 AMP POUVOIR DE COUPURE rl ALTITUDE RANGE PLAGE D ALTITUDE 0 1000 M DI Spe READ INSTRUCTIONS BEFORE ENERGIZING C US A THIS DEVICE MAY PRODUCE HARMFUL X RAYS men use LIRE LES INSTRUCTIONS AVANT D ALIMENTER Rockwell CET APPAREIL DES RAYONS X DANGEREUX mation PEUVE
24. auging the Contacts 1502 UM050C EN P December2004 Auxiliary Actuator Bolt 10 Maintenance 4 13 Put feeler gauge here 0 030 in 0 76 mm Figure 4 17 Gauging Auxiliary Contact Location 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 not move as you tighten the nut When the first nut is tightened slide out and remove the feeler gauge Reinstall the green ground wire on the auxiliary assembly retaining bolt Install and carefully tighten the second nut 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 Energize the control circuit in TEST mode and exercise the contactor to verify set up Contactor should open and close smoothly and solidly 1502 UM050C EN P December2004 4 14 Maintenance Mechanical Latch Trip Coil Replacement Procedure 1502 UM050C EN P December2004 The following procedure requires the removal of the contactor from the cabinet open contactor first Remove the two mounting bolts at the front of the contactor Disconnect the incoming and load line connections at the rear of the contactor
25. cally Latched Contactor 120 V AC 1502 UM050C EN P December2004 Installation 3 8 BDLSIMVA 3CIXO 1V13W JMA 3AIL2310Bd 30 4 B38W N 333IL 33IA3 CILNNDW 3000 39V17DA MATT AN3WdIN0I 31DW33 IN3WdINO3 3LOW3 ONILIANNOD NIHA s3dWn 3ADW3 SLOVLNOD ABVITIXDV Velx3 siva 3 a CID AVTI 1L0UId Y0LIVINDI NIVW 282 IDLIVINDI DNIZIWONDII 07 9NId IDH 2H 7109 DNISDI9 99 AOW 938 SILA LIZA CW AOLOVLNOD NIVW OLI ELI K er eene epes ER ECK EN Sa ANIOd AlddNs LSIL asal TW WIEN 340 1 gt a N o 4 7 LEI D7133AD 265 SISNA ASW ONILIWIT 1N332303 S3SN4 SIMDd ONILIWIT 1N332303 MODITSILNI 2000 SD HOLIAS ONILYIOSI sng cao sna a3 Dd ZHO9 0S BE A0069 A00 2 Figure 3 8 Typical Electrical Diagram for 400 amp Full Voltage Non Reversing FVNR Controller with Electrically Held Contactor 120 V AC Normal Drop out Time 1502 UM050C EN P December 2004 3 9 Installation ONCAVAT SHL NO NADHS 1UN ONIZIS LN3ND WOO ADi 9NIAVMI NOCSN3WIG OL 33338 ILON Aa Pr gutt NiWniSn2 ant d WN S0ISIIVA 3 XU RUN ADW 30ELA3 3AIL231D8d 203 AIAWNN 333L 0 33IA30 CILNNDW YOO vA ADI D SLOVINDI Age au o sl A 239 Lg D HOLWINN SOLIVINOO NIVH AID AV TIA HOLYI ADLIVINOD NIVA MD2 didL oL 07 ONS LTE 311238 H YST Oe F xl VU
26. cond time it must be replaced If no breakdown occurs in the second test the vacuum bottle is in an acceptable condition If one vacuum bottle 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 1502 UM050C EN P December 2004 2 4 Receiving and Handlin Vacuum Bottle Integrity Test cont Vacuum Checker Vacuum Contactor in open position J K 4 44 44 LAD Figure 2 1 Vacuum Bottle Integrity Test Circuit Table 2 A Vacuum Integrity Testing Values TAC Dielectric Test Voltage AC Allowable System Duration Leakage Vacuum Integrity 16 0 kV 60s lt 5 mA The vacuum integrity cannot be tested using a Megger as the voltage of a Megger is too low The allowable leakage current value shown in Table 2 A 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 milliamperes it should be added to the value shown in Table 2 A when testing the vacuum bottles NOTE Rockwell Automation does not recommend DC Hi pot testing because
27. e for electrically held contactors Refer to Table AA for Return Spring part number for higher altitude contactors 1502 UM050C EN P December2004 www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions 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 SA NV Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Middle East Africa Rockwell Automation Br hlstra amp e 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 6356 9077 Fax 65 6356 9011 Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www ab com mvb
28. enance Altitude Adjustment 1502 UM050C EN P December2004 Altitude will affect the performance of a 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 400 A contactors are equipped with return springs appropriate for the specific altitude they will be operating at If a contactor is to be moved to a different altitude refer to Table 4 A 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 4 A Note the change in Basic Impulse Rating B I L as it relates to altitude Table AA Altitude Range Spring Requirements 400A Mechanical Latch Contactor Altitude Range Spring PartNo Color Code scade oath BLL Rating 0 1000 m 80153 567 01 Bronze 400A 60 kV 1000 2000 m 80026 007 02 Green 390A 54 kV 2000 3000 m 80026 008 02 Blue 380A 48 kV 3000 4000 m 80026 009 02 Black 370A 42 kV 4000 5000 m 80026 010 02 Olive 360A 36 kV Important A contactor will only function properly in the altitude range for which it is set up If functional tests are required they must be perfo
29. ent rating 6 400 amps Maximum rated voltage i 7 2 kV Maxium ambient temperature for rated current 40 C 104 F Frequency EEN 50 60 Hz Short circuit interruption current rating 1500 V to 5000 V RMS sym 6300 amps 7200 V RMS Sym rene 6000 amps e Short circuit withstand at rated voltage 60 kA peak Dielectric voltage withstand for 60 seconds 18 2 kV 20 kV IEC Make amp break capability at rated voltage 4 0 kA Short time capability for 1 second 6 0 kA for 30 seconds 2 4 kA Basic Impulse Level B LL withstand 60 kV Mechanical life operations electrically held a a asas 2 500 000 mechanical latch 100 000 Electrical Life operations 1 000 000 Standard altitude ong 1000 m 3 300 ft Max altitude limit with spring replacement 5000 m 16 500 ft Chopping current average RMS 0 5 amps Switching frequency electrically held 600 ops hr mechanical latch 150 ops hr Coil inrush current At 120 VAC electrically held A 7 3 amps mechanical latch
30. er set up of auxiliary contact assembly Faulty CR1 or CR2 interposing relay Check all connections in control circuit for tightness Check wiring from the coil to the terminal block assembly Replace auxiliary contact assembly Measure control voltage Referto Contactor specifications for minimum pick up voltage Check set up of auxiliary contact assembly Check CR1 and CR2 relay If faulty contactor coils are the suspected cause of malfunction please refer to Table 5 B for typical coil impedance values and check the contactor coils Table 5 B Typical Contactor Coil Impedance Values Coil Part Number Description Impedance Q 80153 576 51 Closing Coil electrically held 120 V AC 14 8 80153 575 51 Hold in Coil electrically held 120 V AC 826 0 80153 576 52 Closing Coil electrically held 230 V AC 25 0 80153 575 52 Hold in Coil electrically held 230 V AC 1960 0 80154 134 51 Closing Coil mechanical latch 120 V AC 9 4 80025 833 01 Trip Coil mechanical latch 120 V AC 21 0 Impedance values listed have a tolerance of 10 Refer to Chapter 3 for measurement points at the contactor receptacle Supplied with mechanical latch option only 1502 UM050C EN P December 2004 5 2 Troubleshooting 1502 UM050C EN P December 2004 Chapter Spare Parts 2 Elect Held 3 Mech Latch UT Sg V il Fal W 10 11 Elect Held
31. ipment 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 e Check for any cracks or breaks due to impact Push on armature plate to ensure mechanisms are in good working order e Use a HiPot tester to ensure vacuum bottle integrity refer to Vacuum Bottle Integrity Test later in this Chapter The contactor weighs approximately 48 Ib 21 8 kg and it is possible for one 1 person to safely handle the contactor for a short time When transporting the contactor over longer distances or sustained lifting a fork lift should be considered When a forklift is used to handle the equipment the following precautions should be taken Keep the contactor in an upright position Carefully balance the contactor on the forks e Use a safety strap to steady the contactor and avoid shifting or tipping e Avoid excessive speeds and sudden starts stops and turns e Never lift a contactor above an area where personnel are located Before placing the contactor in service inspect it carefully for possible damage sustained in transit or maintenance Check housing for any cracks or breaks due to impact Push on the armature plate and rotating shaft to ensure mechanism is in good working order e Inspect the contactor for dirt stray or loose hardware tools or metal chips Vacuum clean the contactor if necessary
32. lacement and Set up Procedure 4 4 Coil Replacement Procedure ie 4 8 Auxiliary Contact Set up Procedure ne 4 10 Mechanical Latch Trip Coil Replacement Procedure 4 14 Mechanically Latched Contactor Set up Procedure 4 18 Altitude Adjustment 2 nei baila ie 4 20 Chapter 5 Troubleshooting e Table S A ie 5 1 Typical Contactor Coil Impedance Values Table 5 B 5 1 Chapter 6 400A Electrically Held Vacuum Contactor Figure 6 1 6 1 400A Mechanical Latch Assembly Figure 6 2 6 1 Spare Parts List Table 6 A iii 6 2 Scope Contactor Description Chapter L Product Description This User Manual applies to the Allen Bradley Bulletin 1502 Series D 400 A electrically held vacuum contactors designed for applications in the 2400 to 7200 volt 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 3 vacuum interrupters hereafter referred to as vacuum bottles operated by an electromagnet assembly through a mechanical linkage They are resistant to most adverse atmospheric conditions and provide long mechanical and electrical life The contactors are utilized in various starte
33. lation Resistance Test Use a 1000 volt Megger to verify that the resistance from phase to phase or phase to ground is greater than 500 megohms 1502 UM050C EN P December2004 2 6 Receiving and Handling 1502 UM050C EN P December2004 Chapter 3 Installation Mounting The electrically held and the mechanically latched contactors are fixed mounted bolted down in the controller s 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 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 a OEM component for installation in a custom application refer to the dimensional information in Figure 3 1 If the contactor is to be mounted in an enclosure designed by an OEM make sure there is a minimum of 3 inches 76 mm of air space between live parts terminals and vacuum bottles and any part of the enclosure 8 64 219 0 75 19 R113 22 336 17 24 438 4 96 126 8 53 217 S LOTES m BL A L AIA 0 37 9 0 37 9 0 91 23 1 36 35 10 50 267 e 5 00 127 d 4 25 4 25 1108 gt 108 gt Front View Cut away View 7 87 200 Note Dimensions shown in inches mm 2 12 54 E 8 00 203 n L
34. n 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 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 4 9 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 4 9 ENTE NI est i e Gap Adjustment Screw Gap Adjustment Screw Locking Nut Stop Bracket Bolts Stop Bracket Figure 4 9 Contact Gap Adjustment 1502 UM050C EN P December2004 4 8 Maintenance Coil Replacement Procedure To avoid shock hazards lock out incoming power and disconnect the control plug from the contactor before A 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 Refer to Chapter 6 for the part number s required for this procedure 1 Remove the auxiliary actuator fron
35. olt Figure 4 13 Auxiliary Contact Adjustment Slide the clamping fixture part number 80154 149 51 over the top of the armature stop bracket Figure 4 14 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 Contactor Clamping Fixture Figure 4 14 Clamping Contactor Closed Place a 5 8 wrench on the main shaft of the contactor pull down and close the contactor Figure 4 15 while finger tightening the top middle screw on the clamping fixture Care should be taken not to bend the actuator stop plate 1502 UM050C EN P December 2004 4 12 Maintenance Auxiliary Contact Set up Procedure cont Figure 4 15 Closing the Contactor with the aid of a wrench 4 After the top screw is finger tight continue to tighten this screw with a hand tool Note 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 tightened Step 3 Reference Figures 4 16 and 4 17 Figure 4 16 G
36. r 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 electrically held vacuum contactors are available in 120 volt and 230 volt control configurations Mechanically latched contactors are only available in 120 volt control configurations Figure 1 1 400A Contactor 1502 UM050C EN P December 2004 1 2 Contactor Product Description Vacuum Bottle Desc ription Each vacuum bottle Figure 1 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 Fixed shaft Kee Ceramic Contacts Bellows Bearing Contact Wear Movable Shaft Indicator Line Figure 1 2 Vacuum Bottle Cross Section 1502 UM050C EN P December 2004 Contactor Product Description 1 3 Standard Electrically Held The standard electrically held contactor consists of three vacuum bottles An Contactor Operation electro m
37. r 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 listed below 1 4 in Hardware 6 ft Ib 8 N m 5 16 in Hardware 11 ft Ib 15 N m 3 8 in Hardware 20 ft Ib 27 N m Before performing any maintenance on the contactor refer to the User Manual of the starter configuration in which the A 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 1502 UM050C EN P December 2004 4 2 Maintenance Routine Maintenance cont To avoid shock hazards lock out incoming power and disconnect the control plug from the contactor before A 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 The following should be carried out on an annual basis or whenever a contactor is serviced 1 Cleaning 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 Note Do not use compressed air to clean or remove dirt from surfaces or the enclosure as it
38. rmed at the proper altitude or in a pressure chamber which simulates the proper altitude Troubleshooting If an 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 5 A Troubleshooting SYMPTOM POSSIBLE CAUSE REMEDY Loose connections in control circuit Check all connections in control circuit for Coil leads reversed tightness Check wiring from the coil to the terminal block assembly Control voltage too low Measure control voltage Refer to Contactor Contactor Chatters Faulty hold in coil Specifications for minimum pick up voltage Foreign material on magnet Clean magnet cores and armature Improper set up of auxiliary contact Check set up of auxiliary contact assembly assembly Faulty auxiliary contacts Check contact cartridges on contactor e Faulty CR1 or CR2 interposing relay Check CR1 and CRI relay Coil leads improperly wired Check wiring from the coil to the terminal block assembly Coil Burnout Improper set up of auxiliary contact Check set up of auxiliary contact assembly assembly Control voltage too high Check for correct control voltage Contactor does notenergize Loose connections in control circuit Damaged auxiliary contacts Control voltage too low mprop
39. t 50 Hz 2 5 cycles 50 msec Mechanical latch maximum trip time 00 HZ M 3 cycles 50 msec 50 EZ iii nete iege eee ariani 2 5 cycles 50 msec Capacitor Switching KVAR max 2400 Viral ieri 800 EE HOER E 1400 6900V cia wee p p pete 2000 The 120 VAC control voltage is rectified for the contactor coils Atrated control voltage 1502 UM050C EN P December 2004 1 8 Contactor Product Description Contactor Specifications cont Product Approvals 1502 UM050C EN P December 2004 Contactor Ampere Rating 400A Contact Sap inline ia 4 8 mm 0 19 in Contact pressure iii 16 kg 35 Ib Weight canarie e etel gea 21 8 kg 48 Ib Auxiliary contacts electrically held 2 N O 2 N C mechanical latch 3 N 0 2 N C Auxiliary contact rating A600 UL347 CSA22 No 14 and T I L D 21 e IEC60470 CE Mark Receiving Handling Pre Energization Inspection 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 possible note the damage on the Bill of Lading before accepting the sh
40. t Up Proc edure however all three bottles must be replaced if any wear indicator line reaches the bearing regardless of the number of operations Use the following procedure to remove and replace the vacuum bottles This procedure can be performed with the contactor remaining in the power cell of the controller Refer to Chapter 6 for the part number s required for this procedure To avoid shock hazards lock out incoming power and disconnect the control plug from the contactor before A 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 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 4 4 Vacuum Bottle Mounting Bolt Load Terminal Retaining Bolt and Nut Figure 4 4 Mounting and Retaining Bolt Removal 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 4 5 Repeat this for the two remaining bottles The load terminals insulators and overtravel spring
41. t stop bracket and armature plate as shown in Figure 4 10 Note do not remove the bolts which secure the stop bracket simply loosen them and slide the bracket out on older contactors the bolts must be removed from the underside of the contactor housing in order to remove the stop bracket Armature P late Stop Bracket Bolts Armature Stop Bracket Figure 4 10 Access to Coils 2 Remove the retaining ring from the core of the coil you wish to replace as shown in Figure 4 11 3 Loosen the auxiliary assembly retaining bolt and slide the assembly and the coil forward and out of the contactor as shown in Figure 4 11 1502 UM050C EN P December 2004 Maintenance 4 9 Closing Coil Hold in Coil Sia Auxiliary Assembly Auxiliary Assembly Retaining Bolt Figure 4 11 Coil Removal 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 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 6 Install the armature plate auxiliary actuator and stop bracket Position the stop
42. tion of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual 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 IMPORTANT Identifies information that is critical for successful application and understanding of the product Identifies information about practices or circumstances that can ATTENTI ON lead to personal injury or death property damage or economic loss Attentions help you A identify a hazard avoid a hazard recognize the consequence SHOCK HAZARD Labels may be located on or inside the equipment to alert people A that dangerous voltage may be present BURN HAZARD Labels may be located on or inside the equipment to alert people that surfaces may be at a dangerous temperature Table of Contents Product Description Chapter 1 SCOPE aio ie iaia 1 1 Contactor Description i ira lai ii 1 1 Vacuum Bottle Description i 1 2 Standard Electrically Held Contactor Operation 1 3 Mechanically Latched Contactor Operation 1 4 Contactor Jdenpfteatton ii 1 4 Contactor Catalog Number Explanation
43. y or damage to the equipment if the vacuum bottle integrity fails High voltage testing is potentially hazardous Use caution when performing the Hi pot test Failure to do so may result A in severe burns injury or death Receiving and Handling 2 3 High potential test instruments can be purchased to perform the vacuum bottle integrity test A Megger cannot be used to measure vacuum integrity because the voltage is too low One of the following AC Hi pot testers is recommended as a test instrument MANUFACTURER ADDRESS Mitsubishi Type VI 4U17 Chicago Ill USA Jennings Model JHP 70A San Jose CA USA Hipotronics Model 7BT 60A Brewster NY USA 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 2 1 It is recommended that an AC Hi pot tester be used Use the test voltage indicated in Table 2 A 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 se
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