1502-UM051_-EN-P - Rockwell Automation
Contents
1. 1042 127 127 4 10 5 00 5 00 438 71 17 27 267 311 10 52 158 21 6 23 194 1 7 64 270 10 63 Figure 3 1 Contactor Mounting Details 1502 UM051E EN P June 2013 3 2 Installation Electrical Connections Line side terminals Load side terminals 1502 UM051E EN P June 2013 The control wiring from the low voltage panel to the contactor is made through a wire harness and connects to the left side of the contactor with a male and female configured wire plug The power wiring terminates on the rear side of the contactor to the line and load terminals Holes are provided to accommodate 12 mm 1 2 in size hard ware Figure 3 2 N 9 a W LN 0 Figure 3 2 Electrical Connections Control wire plug Installation 3 3 Mechanical Latch Assembly SECTION B B Rating Label Housing Assembly 30 a Lifting Hazard 100 Label Shaft Assembly B 3 61 REF Terminal Block Assembly 4 97 CREF Contactor Mounting Hole B 5 45 REF Figure 3 3 Electrical Connections 1502 UMOSTE EN P June 2013 3 4 Installation Wiring and Schematic Diagrams WIRIN2. gt Load Terminal Load Terminal Nut Y Figure 4 6 Reassembled Vacuum Bottle Assembly 8 Position a 4 76 mm 0 1875 in diameter rod e g drill bit or screw between the armature plate and the yoke plate to prevent the contactor from closing as shown in Figure 4 7 Yoke Plate Position 3 16 rod here Figure 4 7 Set up Position 1502 UMOSTE EN P June 2013 Maintenance 4 7 9 Position the middle vacuum bottle assembly phase B in the contactor En sure that the rocker washer is below the actuator plate and that the wear in dicator line is facing towards the front Install and torque the load terminal retaining bolt and the vacuum bottle mounting bolt to 20 ftelb 27 Nem 10 With the armature plate held tightly against the 3 16 rod turn the insula tor as required such that the bottom of the overtravel spring touches the surface of the actuator plate inside the counter bore The spring must be held securely in place slightly compressed as shown in Figure 4 8 Tighten the load terminal nut Actuator Plate A ge Load Terminal Nut Overtravel Spring touches Rocker Washer surface of counterbore Figure 4 8 Insulator Actuator Plate Set up 11 With the armature plate still held tightly against the rod turn the gap adjustment nut until the rocker washer makes contact
3. DC HiPot testing is unreliable due to the occurrence 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 indicate incorrectly a faulty vacuum bottle At best DC testing will verify vacuum integrity if both contact surfaces are perfectly smooth It will not however give any indication of the degree of vacuum since the contact surface can feasibly 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 only reliable method of testing vacuum bottles Using a 1000 volt Megger the resistance from phase to phase or phase to ground shall be greater than 500 megohms 1502 UM051E EN P June 2013 Chapter 3 Installation Mounting The Allen Bradley vacuum contactor is normally fixed mounted bolted down in the enclosure of the controll
4. VOY 64 bb ZH09 ANIOd 14405 1531 AGL SL oF EN 0 9 QVO TH3AO 66 10 ly 9r vv ev 1531 x TWAYON 140 esi _ A 00 53805 AYYNIYd LN38300 53505 H3MOd IN3HHNO bd o El o uo dial TWANVN MOOTYALNI YOOd SI HOLIMS 9NILV TOSI ERAN 2H09 0S A0069 A00FZ Figure 3 12 Typical Wiring and Schematic Diagram for 800 amp FVNR Controller Series E Mechanical Latch Contactor 1502 UMOSTE EN P June 2013 Tool Requirements Recommended Torque Values Routine Maintenance Chapter 4 Maintenance When maintenance is performed on the vacuum contactor one or all of the fol lowing tools may be required e 3 8 drive ratchet wrench with extension e 3 8 drive torque wrench e Standard 3 8 drive sockets 7 16 9 16 3 4 e Open end wrenches 7 16 9 16 11 16 3 4 7 8 e 3 16 Allen key e 3 16 dia rod e Slot head screwdrivers 1 8 wide 1 4 wide e Feeler gauge set 0 125 and 0 300 e Digital caliper capable of depth measurement e High potential tester Part of the contactor may have to be disassembled for maintenance or replace ment There are appropriate torque requirements for particular bolt
5. Maintenance 4 21 Auxiliary Contact Replacement 1 Ifreplacing a single contact cartridge remove the appropriate leads and and Set Up Procedure turn the plastic retaining screws to allow removal of the cartridge as shown in Figures 4 25 and 4 26 Insert the new cartridge and position the retaining screws to hold it in place Reconnect the leads to the cartridge Ensure that the cartridge is in the proper configuration the top cartridges are normally closed the bottom cartridges are normally open refer to Figure 4 27 The normal state is when the contactor is off open position To remove cartridge turn retaining screws 5 Auxiliary contact removed Figure 4 25 Retaining Screws Figure 4 26 Cartridge Removal Note For Series E contactors the top auxiliary contact position must use a 700 cartridge All other positions must use 700 CPM cartridg es 2 Ifreplacing the entire auxiliary assembly remove the leads from all cartridges and remove the assembly complete with mounting plate by removing the mounting bolts as shown in Figure 4 27 1502 UMOSTE EN P June 2013 4 22 Maintenance Auxiliary Contact Replacement and Set Up Procedure cont See Note on previous page Top cartridges normally closed Bottom cartridges normally open p d Auxiliary
6. 1502 UMOSTE EN P June 2013 3 6 Installation AUXILIARY CONTACTS YELLOW AD MOV lt N BLACK lt COIL POWER CIRCUIT L1 L3 20080 amp 0006 90000 M M M Ti T3 A B C E F G H 1 SOCKETS J K L M N PINS D P ND CONNECTIONS SCHEMATIC AUXILIARY CONTACTS MOV M B C N M E F M G H M I gt J gt M K L CONTACTOR SHOWN IN OPEN TRIPPED CONDITION Figure 3 6 Wiring and Schematic Diagram Series E Electrically Held Contactor 1502 UMOSTE EN P June 2013 WIRING DIAGRAM 800A MECHANICAL LATCH AUXILIARY CONTACTS 000 Q 00 9 CDLAKLMNP PINS ABEF GH SOCKETS Installation 3 7 POWER WIRING VE BLUE WHITE Humo He BLUE YELLOW Lo Hi COIL BLACK NV YELLOW C SCHEMATIC 800A MECHANICAL LATCH VACUUM CONTACTOR AUXILIARY CONTACTS M THESE CONTACTS ARE USED IN THE CONTACTOR CONTROL SCHEME TO INTERLOCK CDIL SWITCHING Of YEL BLU BLK YEL CC CLOSING COIL TC TRIP COIL HC HOLDING COIL Figure 3 7 Wiring and Schematic Diagram Series D
7. Check housing for any cracks or breaks due to impact e Push on the armature plate rotating shaft to ensure mechanism is in good working order e Inspect the contactor for dirt stray loose hardware tools or metal chips and if necessary vacuum clean 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 the contac tor outdoors Storage temperature should be maintained between 20 C to 75 C 4 F to 149 F If storage temperature fluctuates or if humidity exceeds 85 space heaters should be used to prevent condensation Preferably the contactor should be stored in a heated building having adequate air conditioning Vacuum Bottle Integrity Test Receiving and Handling 2 3 The internal dielectric condition and vacuum integrity of the vacuum bottles is determined by this test Clean the outside of the vacuum bottles with a non linting cloth or industrial type wiper before performing the test Test each bottle individually during this test X ray emissions may be produced if voltage higher than 25 000 Volts is applied across the open contacts of a vacuum bottle RU he vacuum bottles are tested thoroughly at the factory prior to shipment However the bottles can be damaged by A mishandling during shipment This damage may not be vis ible so this test should be performed before the contactor is energized for the first time
8. Closing Times Series D Maximum Closing Time 120 VAC 50 or 60 Hz milliseconds 200 Maximum Opening Time Normal Drop Out 50 or 60 Hz milliseconds 240 Maximum Opening Time Fast Drop Out and Mechanical Latch mM o0 Capacitor Switching max KVAR 2400 V 2000 System Voltage 4160 V 3000 6900 V 4000 General Standard Altitude Capability meters feet 1 000 to 5 000 3 300 to 16 500 Contactor Weight kg Ibs 451 100 Auxiliary Contact Rating A600 Auxilairy Contacts on the Vacuum Contactor Max 3N 0 3 N C The voltage and current ratings listed are valid up to 1 000 m 3 300 feet Please refer to Table 1 C Altitude Derating Chart on page 1 8 for ratings above this altitude Control voltage as measured at the inputof the IntelliVAC and IntelliVAC Plus control modules Provided that regular maintenance is performed Acontactor drop out delay may be configured with the IntelliVAC and IntelliVAC Plus control modules refer to publications 1503 UMO053 EN P and 1503 UM054_ EN P FDO FastDrop Out NDO Normal Drop Out Q Thenumber of contactor auxiliary contacts depends on the contactor type Some of the contacts are used in the typical control schemes used Altitude adjustment required Table 1 C Altitude Code Derating Reduce Max 800 A Reduce B I L Altitude Range Continuous Current Rating Withstand Rating 8 0 to 1 000 m 0 to 3 300 ft V la 1 001 to 2 000 m 3 301 to 6 600 ft 6 0 k
9. Coil Drop out Voltage VAC 751145 oo coo The voltage and current ratings listed are valid up to 1 000 m 3 300 feet Please refer to Table 1 C Altitude Derating Chart on page 1 8 for ratings above this altitude Control voltage as measured at the inputof the IntelliVAC or IntelliVAC Plus control module Provided that regular maintenance is performed A contactor drop out delay may be configured with the IntelliVAC control module refer to publication 1503 UM053_ EN P or the IntelliVAC Plus control module publication 1503 UM054_ EN P FDO Fast Drop Out NDO Normal Drop Out The number of contactor auxiliary contacts depends on the contactor type Some of the contacts are used in the typical control schemes used 1502 UMOSTE EN P June 2013 1 8 Contactor Product Description Contactor Table 1 B Bulletin 1502 Medium Voltage 800 Amp Contactor Ratings cont Specifications con t Description Specifications Operational Characteristics TNNT Electrically Held 250 Mechanical Life Operations x 1000 Mechanical Latch 100 Electrical Life Operations x 1000 250 Switching Frequency Electrically Held 600 Operations per hour Mechanical Latch 150 Opening and Closing Times Series E Maximum Closing Time 120 240 VAC milliseconds 150 Maximum Opening Time m without delay 120 to 240 VAC milliseconds 60 Opening and
10. Figure 4 18 Terminal Block Assembly Mechanically Latched Series D Contactor B D C 8 Main Coil Figure 4 19 Terminal Block Assembly Mechanically Latched Series E Contactor 1502 UMOSTE EN P June 2013 Mechanical Latch Trip Coil Replacement Procedure Yoke Plate Latch Lever Assembly Maintenance 4 15 The closing coil is the larger of the two Series D only and is located toward the front of the contactor Refer to the appropriate wiring diagram Chapter 3 Installation to ensure that the bridge diode and or MOV leads are properly connected and for complete control wiring details Ensure that all leads diodes and MOVs are secured tightly Operate the contactor several times to ensure that the core is located properly ATTENTION Before beginning work on the contactor ensure that it is isolated from all power sources and locked out and that the contactor is in the open or tripped state Core Mounting Plate Trip Coil core hidden Manual Trip Guide Block Manual Trip Actuator Latch Roller Figure 4 20 Mechanical Latch Assembly Disconnect the trip coil leads from the terminal block assembly The trip coil leads are the blue and white wires connected to terminals and respectively see Figure 4 18 or 4 19 Cut any wire ties fastening the leads to the con
11. Renewal Parts List e Table GA mers 6 2 Scope Description Chapter 1 Contactor Product Description This User Manual pertains to Allen Bradley s Bulletin 1502 800A vacuum contactors It applies to both Series D and E versions of the Bulletin 1502 800 Amp contactors Series D vacuum contactors are intended for use with electro mechanical relay control circuits They may not be used with IntelliVAC and IntelliVAC Plus control modules Series E vacuum contactors are used with IntelliVAC and IntelliVAC Plus control only refer to publications 1503 UM053 EN P and 1503 UM054_ EN P respectively Allen Bradley s Bulletin 1502 800 amp electrically held and mechanical latch vacuum contactors are designed for high horsepower applications in the 2400 to 7200 voltage range These contactors are suitable for all types of AC loads for example three phase motors transformers power capacitors and resistive heating loads Mechanically latched contactors are used mainly in situations requiring the contactor to remain closed in the event of power failure The contactor uses three 3 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 a long mechanical and electrical life The contactors are utilized in various starter and drive configurations e g full voltage non reversing full voltage reversing two spe
12. 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 800 2400 V RMS Sym Amps 12 500 Maximum Interrupting Current Rating 5000 V RMS Sym Amps 12 500 7200 V RMS Sym Amps 12 500 2400 V Sym MVA 50 Maximum Interrupting MVA Rating 5000 V Sym MVA 100 7200 V Sym MVA 150 Short Circuit Withstand at Rated Voltage Current Peak cycle 85 Short Time Current Rating Capability B mE ry 1 Chop Current Average RMS Amps 0 5 Make and Break Capability at Rated Voltage 8 0 Ambient Temperature C 40 Contactor Coil Data Series E Control Voltage Coil Voltage Von VAC Close Current Apc 200 milliseconds 12 110 to 240 VAC 4 2 Hold Current Apc 0 7 or Max Pick up Voltage 95 110 to 250 VDC Drop out Voltage 75 e VDC Trip Current Apc 200 milliseconds 52 Trip Voltage 70 Close Current 13 1 Hold Current Apc 024 120 VAC 110 VDC Trip Current Apc 56 Pick up Voltage 102 Trip Voltage 84 Contactor Coil Data Series D 1 Coil Voltage Coil Inrush Current A Electrically Held 131174 Coil Inrush Current A Mechanical Latch 13 1 NA 120 VAC 110 VDC Coil Inrush Current A Mechanical Latch Trip 5 6 NA 230 VAC 208 VDC Coil Continuous Current A 0 24 0 13 Coil Pick up Voltage VAC 102 196
13. and each time it is returned to service after maintenance adjustment or repair Otherwise this test should be performed annually Caution should be exercised during this test since high voltage testing is poten tially hazardous High potential test instruments can be purchased to perform the vacuum bot tle integrity test megger can not be used to measure vacuum integrity because the megger voltage is too low One of the following Hi pot testers is recom mended 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 1502 UM051E EN P June 2013 2 4 Receiving and Handling Vacuum Bottle Integrity Test cont 1502 UM051E EN P June 2013 High voltage is present during this test Caution should be exercised during this test since high voltage testing is potentially hazardous RL Before doing any work on the contactor the controller isolat ing switch must be in the open position and locked out If any control power is used from a separate source it should also be isolated It is also suggested that a Hot Stick be used to ensure equipment is voltage free The contactor may be tested while it is in the power cell The line connec tion 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 With the
14. assembly The latch spring is no longer retained at this point and may fall out of the core do not misplace this spring Remove the roller mounting bolt as shown in Figure 4 23 allowing the roller to be removed Insert the new roller and install the roller mounting bolt Make sure that the latch spring is seated properly in the core position the lever assembly and install the latch pivot bolt The spring must be seated properly in the retaining holes in both the core and the lever Latch roller Roller mounting bolt Figure 4 23 Mechanical Latch Assembly With the exception of the roller the latch mechanism will last the rated life of the contactor If the contactor is used beyond the rated life the latch mecha nism should be refurbished by replacing the lever assembly latch spring and the armature plate These parts can be ordered pre assembled as Refurbishing Kit 80158 058 51 1 Remove latch pivot bolt with 3 16 Allen key as shown in Figure 4 21 and remove the lever assembly The latch spring is no longer retained at this point and can be removed and discarded Make sure that the new latch spring is seated properly in the core position the new lever assembly and install the latch pivot bolt The spring must be seated properly in the retaining holes in both the core and the lever Loosen the locking nut on the return spring compression bolt and withdraw the compression bolt until the return spring is relaxe
15. contactor in the open position connect the test leads to the contactor power terminals as shown in Figure 2 2 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 If no breakdown occurs the bottle is in an acceptable condition If a break down occurs the bottle should be replaced Note Rockwell Automation recommends that if the contactor has been in service all three 3 bottles be replaced at the same time After the HIGH POTENTIAL VOLTAGE is removed from the bottles the metal end caps of the bottles should be discharged with a grounding rod to remove any residual electrical charge Vacuum Checker Vacuum contactor in open position Figure 2 2 Vacuum Bottle Integrity Test Circuit Receiving and Handling 2 5 Insulation Resistance Test The allowable leakage current of 5 mA is a maximum for new dry equipment and 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 5 mA limit when testing the vacuum bottles NOTE Rockwell Automation does not recommend DC HiPot testing because the values obtained during the test are not a reliable indication of vacuum bottle integrity
16. sizes when reassembling the contactor For the following bolt sizes use the specified torque values listed below 1 4 Hardware 6 ft lb 8 N m 3 8 Hardware 20 ft lb 27 N m 1 2 Hardware 48 ft lb 65 N m The following should be carried out on an annual basis or whenever a contactor is serviced Cleaning e 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 If necessary vacuum clean Note Do not use compressed air to clean or remove dirt from surfaces or the enclosure as it will only redistribute the dirt e Ifdirty clean the white ceramic area of vacuum bottles with a clean lint free cloth 1502 UMOSTE EN P June 2013 4 2 Maintenance Routine Maintenance cont 1502 UMOSTE EN P June 2013 Main Contact Inspection e 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 Re fer to Figure 4 11 Under normal conditions this will not be necessary until the contactor has gone beyond the 250 000 rated life 100 000 for mechani cal latch contactors HiPot Test Refer to Chapter 2 e Check the vacuum bottle integrity e Check the insulation resistance Lubrication Note Lubrication of the contacto
17. the contactor by disconnecting the control A wire plug before starting any disassembly of the contactor 1 Before removing the vacuum bottles mark the installed bottles clearly to avoid confusing them with the replacement vacuum bottles 2 Remove the front retaining brace and all four interphase barriers as shown in Figure 4 1 we N 2 m gt RY 4 ll Interphase Barriers a SY E Retaining Brace Figure 4 1 Removal of Interphase Barriers 1502 UMOSTE EN P June 2013 4 4 Maintenance Vacuum Bottle Replacement and Set up Procedure cont 1502 UMOSTE EN P June 2013 3 Loosen the locking nut on the return spring compression bolt and withdraw the compression bolt until the return spring is relaxed Remove the return spring as shown in Figure 4 2 l i A i Figure 4 2 Removal of Return Spring Compression Bolt and Locking Nut 4 Remove the bolts which retain the load terminals at the rear of the contac tor and the main mounting bolt at the top of one vacuum bottle as shown in Figure 4 3 ifthe contactor is still mounted in the controller disconnect cables from the load terminals first Load Terminal Retaining Bolt and Nut Figure 4 3 Mounting and Retaining Bolt Removal Maintenance 4 5 Slide the vacuum b
18. A as shown per Figure 4 24 Note Dimension A will vary from contactor to contactor there is no predetermined value E Locking Nut Return Spring Compression Bolt Figure 4 24 Return Spring Assembly Loosen the compression bolt locking nut and adjust the position of the compression bolt according to Table 4 A Dimension A is changed by the amount shown on the table For example if the contactor s existing range is 0 1000 m and the desired range is 3000 4000 m increase dimension A by 4 93 mm 0 194 in If the contactor existing range is 4000 5000 m and the desired range is 2000 3000 m decrease dimension A by 2 69 mm 0 106 in After dimension A has been set for the desired altitude range re tighten the locking nut Maintenance 4 19 Table 4 A Dimension A Settings in Inches millimeters in brackets EXISTING NEW ALTITUDE RANGE ALTITUDE Increase or Decrease Dimension A by RANGE 0 1000 m 1000 2000 2000 3000 3000 4000 4000 5000 m 1000 2000 m 0 173 4 39 3000 4000 m 40 052 1 32 4 On the rating label change the catalog number altitude suffix the stated altitude range and the current rating Refer to Table 4 B for the derated continuous current and B LL withstand ratings for each altitude range A contactor will only function properly in the altitude range ATTENTION for which it is set up If functio
19. B Medium Voltage Contactor 800A 2400 7200 V Allen Bradley Bulletin 1502 Series D and E User Manual Rockwell 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 us
20. DEVICE Figure 3 11 Typical Wiring and Schematic Diagram for 800 amp FVNR Controller Series E Electrically Held Contactor 1502 UMOSTE EN P June 2013 Installation 3 12 1089110 1109 dl31 FINGOW 021 310GON OVAITISLNI YOLOVLNOO 1 dNI YOLIOVdVS WNYALXS JINON OVAITISLNI 93 1Nd1NO 1109 9 8019 JINON OVAITISLNI 099 ALNANI ABVETIXQ V YOLOVLNOD WANDWA 31000 OVAITISLNI Xnv 1 15 340138 HINOLSNI AHL A8 G3HNOIANOO CINNVHOO d 38 OL JAYS 11 4 SNLVLS FINGOW 33VS V4 SALWLS YOLOVLNOD 193333 NI 33V SALVLS dN H3MOd NOILVHNOIANO9 GATIVLSNI ANOLOVS ONIMOTIOS JHL Gal 1ddv TOYLNOD LNOHLIM NMOHS SLOVLNOO AV T33 LAdLNO SALON OVAITTALNI ANAWdINOA SLOWSY 391430 3ALLO31O8d 404 YASWAN 3931 LNAWdINOA 31038 9NILO3NNOO N3HM HAdWNT SAOWSY 391430 GALNNOW 400 39VL10A MOT YSWOLSND QN3931 Sli d WN s gt H N 9 SLOVINOD VYX LE 10 o 4 dois o e 0 YOLOVLNOO NIV e 1 9 Hi m Ve u avis 10 amp AR 099 xnv N 021 93 AW 44 voc v
21. Figure 4 15 to 4 19 Do not install washer if it was not originally supplied 1502 UMOSTE EN P June 2013 Part Number 80157 496 56 80025 697 01 80026 231 02 700 CPM 700 CP1 80157 305 51 80158 870 51 80157 305 52 80158 870 52 1492 HC6 1492 HJ86 22105 221 01 80157 311 01 80157 312 01 80157 315 02 80157 314 01 80026 012 02 80026 011 02 80012 021 01 80157 313 02 80154 422 01 80145 581 08 24808 451 01 80025 853 01 80026 013 02 28300 614 01 80153 748 01 80158 058 51 3 bottles should be 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 Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 42 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 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 Publication 1502 UM051E EN P June 2013 Copyright 2013 Rockwell Automation Inc All rights reserved Printed in Canada Supersedes Publication 1502 UM051D EN P December 2009
22. G DIAGRAM 800A VACUUM CONTACTOR AUXILIARY CONTACTS BLUE YELLOW Nes i i x4 151 495 COIL Esi yb tsp MOV BLACK ANTE N YELLOW db A I SOCKETS JKLMNP PINS SCHEMATIC 800A VACUUM CONTACTOR AUXILIARY AR CONTACTS FA B C e e D gt J MOV 4 lt P E F i sh G H CC CLOSING COIL HC HOLD IN COIL Figure 3 4 Wiring and Schematic Diagram Series D Electrically Held Contactor normal drop out time 1502 UMOSTE EN P June 2013 Installation 3 5 WIRING DIAGRAM 800A VACUUM CONTACTOR AUXILIARY CONTACTS YELLOW BLUE A db B C COIL db J MOV YELLOW K db L D BLACK P E F MOV G H N i D EH amp D REO i LO QU QD A B C D E F 1 SOCKETS J KL M N P PINS SCHEMATIC 800A VACUUM CONTACTOR AUXILIARY CONTACTS MOV M A B C e CC e D M E F MOV M G H N HC P M J M u A K L CC CLOSING COIL HC HOLD IN COIL 80113 646 28 Figure 3 5 Wiring and Schematic Diagram Series D Electrically Held Contactor fast drop out time
23. Mechanical Latch Contactor 1502 UMOSTE EN P June 2013 3 8 Installation AUXILIARY CONTACTS o r lt k gt K lt ux us TE Lol MOV gt J a lt BLACK Ld MOV C C YELLOW G p H EY G COIL person N lt d p P Il POWER CIRCUIT 5 9 OO 1 all Q O M M aM D 9 1 Te T3 D E F H SOCKETS B J K L M N P PINS SCHEMATIC AUXILIARY CDNTACTS M E Se F YELLOW J MOV M G H WHITE BLUE L CONTACTOR SHOWN IN OPEN TRIPPED CONDITION N lt THESE CONTACTS ARE CC CLOSING COIL USED IN THE CONTACTOR TRIP NIL CONTROL SCHEME TO 1 INTERLOCK COIL SWITCHING Figure 3 8 Wiring and Schematic Diagram Series E Mechanical Latch Contactor 1502 UMOSTE EN P June 2013 Installation 3 9 Typical Electrical Diagrams Le E OFF Normal I PUWER Bus az Em TE
24. ST SUPPLY POINT k uL it y iid elle Talla TAS ES ISOLATING SWITCH j 7 d g ep Jr DOOR INTERLOCK m om my EL Et FI power ruses NGC ea SODVA ISe CRB 3 19 m x 154 He xe CURRENT LIMITING PRIMARY FUSES START 10M OK START gy D 2 Ne MANUAL 0 m x MIB 5 TRIP E 30 1 OVERLOAD T ss OFF 44 Te cum rh CUSTOMER WIRING EXTRA AUNILIARY CONTACTS LOW VOLTAGE DOOR MOUNTED DEVICE Hus REMOTE EQUIPMENT i B S MI REMOVE JUMPER WHEN CONNECTING RENDTE EQUIPMENT Wik ge METAL OXIDE VARISTUR gt D IEEE NUMBER FOR PROTECTIVE DEVICE Figure 3 9 Typical Electrical Diagram for 800 amp FVNR Controller Series D Electrically Held Contactor 120 VAC normal drop out time MAIN CONTACTER b CC CLDSING COIL TC TRIP COL MAIN CONTACTOR LATCH RELAY CRI MAIN CONTACTOR UNLATEH RELAY lt CR2 1502 UMOSTE EN P June 2013 3 10 Installation WIRING DIAGRAM AUXILIARY CONTACTS ad Eq 3 YELLOW BLACK KORN e gt X H 4 l POWER CIRCUIT te L3 M M M A B E F G I SOCKETS J K L M N PINS D P NO CONNECTIONS SCHEMATIC AUXILIAR
25. V 2 001 to 3 000 6 601 to 9 900 ft 12 0 3 001 to 4 000 m 9 901 to 13 200 ft 18 0 kV 4 001 to 5 000 m 13 201 to 16 500 ft 24 0 kV Product Approvals UL347 e CSA22 2 No 14 and T LL D 21 e IEC60470 e CE Mark 1502 UM051E EN P June 2013 Receiving Handling Chapter 2 Receiving and Handling Before leaving the factory the contactors have been tested both mechanically and electrically Immediately upon receiving the contactor remove the packing ma terial 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 receipt of 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 e 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 42 kg 93 Ib and it is feasible for two 2 people to safely handle the contactor for a short duration injury may occur should one person attempt to handle the equipment The following procedure shall be used if a crane or hoist is used to handle the contactor l Insert two 2 3 8 16 UNC lifting bo
26. Y CONTACTS MOV M B E N M E F M G H z L gt M J M K t CONTACTOR SHOWN IN OPEN TRIPPED CONDITION Figure 3 10 Typical Electrical Diagram for 800 amp FVNR Controller Series D Mechanical Latch Contactor 120 VAC 1502 UM051E EN P June 2013 Installation 3 11 A OFF wogwaL POWER BUS 1 TEST SUPPLY POINT P n slt Falla AP ene ISOLATING SWITCH as d 7 l M WO 200g INTERLOCK 2 ad LMI CURRENT LIMITING LV ec rug prn CONTACTER cho n Fil POWER FUSES et 3 M is LA ta 17 cer i NOT aux uo E soova 15 12 5 20 t cies yp 7 Hi x 11 L G N CT enc u 18 en dee amp L amp N CURRENT LIMITING PRINARY FUSES M IV E MW f a START dc a Mo ERES s Way stoe MANUAL N oss o n 7 ure uL m 5 M B se RUN Or WoL end cmd cta be HR s CUSTOMER WIRING EXTRA AUXILIARY IBUNTA TE D Low VOLTAGE DOOR MOUNTED DEVICE n m 4 METAL OXIDE VARISTOR ets D cere FOR PROTECTIVE
27. assembly removed Figure 4 27 Auxiliary Contact Assembly 3 Position the new assembly on the left side plate of the contactor with the cam followers see Figure 4 28 protruding through the rectangular holes in the operating lever Install and allow the mounting bolts to remain loose so that the assembly can slide vertically on its mounting slots 4 With the contactor off push the entire auxiliary assembly up until the cam followers bottom out against the top of the rectangular holes in the operat ing lever as shown in Figure 4 28 make sure the armature plate is against the stop such that the contactor is fully open At this point the top set of auxiliary contacts are closed and the bottom set of auxiliary contacts are open 5 Tighten and torque 6 ft lb the mounting bolts to fix the position of the auxiliary assembly 1502 UMOSTE EN P June 2013 Maintenance 4 23 H Ins J Mounting Bolt j Auxiliary Contact Assembly H O a Cam Followers Po Operating Lever ses Mounting Bolt Figure 4 28 Auxiliary Contact Assembly Set up 6 Connect all contro
28. d Remove the return spring as shown in Figure 4 2 Remove the armature plate mounting bolts Discard the armature plate and install the new armature plate Reinstall the return spring and advance the compression bolt until the armature plate makes contact with the stop as shown in Figure 4 10 Advance the bolt one additional full turn to ensure that the contactor opens fully Holding the compression bolt in position with a wrench tighten the compression bolt locking nut 1502 UMOSTE EN P June 2013 4 18 Maintenance Altitude Adjustment 1502 UMOSTE EN P June 2013 Vacuum contactors are sensitive to the altitude at the installation site This is due to the fact that the atmospheric pressure assists in closing the main contacts by exerting force on the bellows at the movable end of the vacuum bottles Since this force is proportional to the difference between internal bottle pressure and external atmospheric pressure the return spring must be adjusted for the ap propriate altitudes Contactors are factory set for the altitude at which they are originally installed If a contactor is relocated to a different altitude range see Table 4 A a spring adjustment is necessary for proper operation The following procedure shall be used to make the correct settings 1 Determine what altitude range the contactor is set up for by checking the rating label also refer to the Catalog Number Explanation Measure and record dimension
29. e Electrically Held Contactor nn 3 6 Series D e Mechanical Latch Contactor ss 3 7 Series E e Mechanical Latch Contactor ns 3 8 Typical Electrical Diagrams Series D Electrically Held Contactor normal drop out time 3 9 Series D e Mechanical Latch Contactor aa 3 10 Series E e Electrically Held C ontactor ss 3 11 Series E e Mechanical Latch Contactor aaa 3 12 1502 UM051E EN P June 2013 ii Table of Contents 800 A Medium Voltage Contactor User Manual Chapter 4 Chapter 5 Chapter 6 1502 UMOSTE EN P June 2013 Maintenance Tool Reg irements RD 4 1 Recomimended Turaue Vallis 4 1 Routine MATE tonne M MEIN DS 4 1 Vacuum Bottle Replacement and Set up Procedure sn 4 3 Main Coil Replacement Procedure iet peteret riore 4 11 Mechanical Latch Trip Coil Replacement Procedure sms 4 15 Mechanical Latch Roller Replacement Proc dure 4 17 Mechanical Latch Mechanism Refurbishing Procedure 4 17 Altitude Adjustment ioa etinm von re vendis eril torpe ii 4 18 Drop out Time Conversion sens nn 4 20 Auxiliary Contact Replacement and Set up Procedure 4 21 Troubleshooting Troubleshooting Table 5 1 Typical Contactor Coil Impedance Values e Table 5 8 ss 5 1 Renewal Parts 800A Electrically Held Vacuum Contactor 252 oreet eterne 6 1 Mechanical Lateh Assembly sssini 6 1
30. e H W Flexible Bus O lt Armature Plate d 4 B and Shaft Magnet Coil gt Assembly H HL I H 14 Armature Stop Return Spring N Compression Bolt Return Spring Figure 1 3 Vacuum Contactor Operation 1502 UM051E EN P June 2013 Contactor Product Description 1 5 Latch Lever Latch Spring Mechanical Latch Trip Coil Manual Trip Mechanism Contactor Closed Figure 1 4 Top Partial Section View Showing Mechanical Latch 1502 UMOSTE EN P June 2013 1 6 Contactor Product Description Contactor Identification Each contactor is identified with a nameplate Figure 1 5 attached to the interphase barrier retainer at the front of the contactor The nameplate informa tion includes the Catalog Number Series Letter Voltage Rating Non enclosed Current Rating Interrupting Capacity Altitude Range CSA and UL markings VACUUM CONTACTOR CAT CONTACTEUR SOUS VIDE SER 2500 V 30 50 60 HZ INTERRUPTING CAPACITY AMP POUVOIR DE COUPURE IEC60470 ALTITUDE RANGE PLAGE D ALTITUDE AJY lt B READ INSTRUCTIONS BEFORE ENERGIZING US THIS DEVICE MAY PRODUCE HARMFUL X RAYS 00e LR12235 LIRE LES INSTRUCTIONS AVANT D ALIMENTER Rockwell CET APPAREIL DES RAYONS X DANGEREUX ion PEUVENT SE PRODUIRE utomat MADE IN CANADA F
31. e is solidly positioned against the stop and compress the return spring further if necessary Note Account for all tools including the set up rod used during the above 5 5 procedure If any tools are unaccounted for do not energize the equipment 17 Using the TEST control circuit in the starter energize the contactor and check for minimum allowable overtravel on all three vacuum bottle assemblies with a feeler gauge The overtravel dimension shall be 2 5 mm 0 100 in mini mum as shown in Figure 4 12 1 2 5mm 0 100 in Min Ss l Side View Front View Figure 4 12 Minimum Allowable Overtravel If the overtravel dimension is less than 2 5 mm 0 100 in leave the contactor ener gized and loosen the load terminal nut on all three 3 phases Turn the insulator downwards on phase B until the dimension of 2 5 mm 0 100 in is achieved then tighten the load terminal nut Repeat this procedure for phases A and C ensuring that the measurements are equal for all three 3 phases Tighten and torque the gap locking nuts on all three 3 phases Note Both the 7 6 mm 0 300 in and 2 5 mm 0 100 in dimensions must be achieved for proper function If it is not possible to achieve these dimensions consult your local Rockwell Automation field support representative Main Coil Replacemen
32. e of information 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 ARC FLASH 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 Protecti
33. e to the core mounting plate as shown in Figure 4 14 Slide the core out of the coil as shown in Figure 4 14 If there is a tight fit tap the core out with a hammer Hold in Coil Core Closing Coil Coil Lead Mounting Plate Series E Figure 4 14 Magnet Assembly Slide the core into the new coil with the mounting hole end located towards the closing coil Ensure that the coil leads are oriented properly with respect to the core mounting holes Bolt the core to the mounting plate and position the magnet assembly in the contactor Install the three 3 bolts which retain the assembly and torque all bolts to 20 ft lb Referring to Figures 4 15 and 4 16 for Series D or Figure 4 17 for Series E electrically held contactors connect the leads from the coil to the terminal block assembly as follows Series D Closing coil yellow lead to Closing coil black lead to D Hold in coil yellow lead to P Hold in coil blue lead to N Series E Closing coil yellow lead to Closing coil black lead to N Maintenance 4 13 Referring to Figure 4 18 for Series D or Figure 4 19 for Series E mechanical ly latched contactors connect the leads from the coil to the terminal block assembly as follows Series D Closing coil yellow lead to H1 Closing coil black lead to H2 e Hold in coil yellow lead to C1 e Hold in coil blue lead to C2 Trip Coil w
34. ed reduced voltage synchro nous drive input output and bypass applications They are 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 inter locked with rhe external onerating handle and isolating switch Figure 1 1 800A Contactor 1502 UM051D EN P December 2009 1 2 Contactor Product Description Vacuum Bottle Description The vacuum bottle Figure 1 2 consists of two contacts enclosed in a ceramic housing One contact is mounted on a fixed shaft and the other is attached to a movable shaft The bearing and stainless steel bellows ensure that the movable contact tracks accurately and maintains vacuum integrity within the bottle Fixed shaft Ceramic Arc shield Contacts Bellows Bearing Movable shaft Figure 1 2 Typical Vacuum Bottle Cross Section 1502 UM051E EN P June 2013 Contactor Operation Contactor Product Description 1 3 The standard electrically held contactor consists of three vacuum bottles oper ated by an electromagnet assembly through a mechanical linkage See Figure 1 3 Electro Mechanical Control Series D e When the control circuit is energized current flows through both a closing coil and hold in coil creating an electromagnet e This electromagnet pulls the armature plate towards the coil cores which also rotates the actuator shaft e The actuat
35. er There are four 4 mounting holes at the base of the contactor Figure 3 1 to secure it to the enclosure For reversing autotrans former and 2 speed controllers one contactor may be mounted on top of the other There are four 4 threaded mounting holes at the top of the contactor to accommodate this configuration IMPORTANT The contactor is a bolted assembly and is therefore subject to twisting if fastened to an uneven surface The contactor mounting plate has small stand offs that permit the contactor to be fastened without twisting the frame The contactor may not function correctly if it is forced onto an uneven mounting surface 38 1 150 Typical Terminal Detail 19 1 0 75 13 49 0 531 19 1 0 75 1 31 8 1 25 1 d 4 d 4 a m mr N8 N87 1 N87 o T o oo Oo o o o 152 4 6 00 97 2 3 83 Mounting Hole Centers 9 Dimensions mm inches 17 5 0 69 12 7 0 50 437 1 17 21 61427 0 562 4 Mounting Holes 2 457 2 18 00 Mounting Hole Centers 324 2 12 77 16 7 10 66 32 4 260 7 10 27 1127 194 1 7 64 4625 1821 41 3 1 63
36. g from the coil to the terminal block assembly Check wiring per schematic Measure control voltage Refer to Contactor Specifications for minimum pick up voltage Check for free movement of latch lever Check set up of auxiliary contact assembly Check master contact cartridges on contactor Check CR1 and CR2 relay Check wiring from the coil to the terminal block assembly Check for correct control voltage Check switching frequency 600 ops hr electrically held 150 ops hr mechanically held Check all connections in control circuit for tightness Check wiring from the coil to the terminal block assembly Check wiring per schematic Measure control voltage Refer to Contactor Specifications for pick up voltage Check set up of auxiliary contact assembly Check CR1 and CR2 relay For Series E contactors with IntelliVAC control or IntelliVAC Plus control refer to Publications 1503 UM053_ EN P or 1503 UM054_ EN P respectively Table 5 B Typical Contactor Coil Resistance Values Coil Part Number Description Resistance Ed 8 4 Close 80025 697 01 Closing and Hold in Coil Assembly Series D 4 55 Hold 80026 231 02 Closing and Hold in Coil Assembly Series E 7 0 Mechancial Latch Trip Coil 80025 853 01 Series D and E 19 4 Resistance values listed have a tolerance of 10 at 20 C Refer to Chapter 3 for measurement points at the contactor receptacle Supplied o
37. hite lead to D e Trip Coil blue lead to B Series E Closing coil yellow lead to C Closing coil black lead to A Trip Coil white lead to D e Trip Coil blue lead to B Note The contactor will have either a high density 1492 HC6 or a regular 1492 86 terminal block The wiring convention is the same for both types Closing coil yellow lead Closing coil black lead Hold in coil blue lead Figure 4 15 Terminal Block Assembly Electrically held Series D Contactor regular terminal block Note Figures 4 15 and 4 16 show the fast drop out Closing coil yellow lead configuration The normal drop out contactor has only one 1 MOV Closing coil black lead Hold in coil yellow lead Hold in coil blue lead Wes qe MOVs Figure 4 16 Terminal Block Assembly Electrically Held Series D Contactor high density terminal block 1502 UMOSTE EN P June 2013 4 14 Maintenance Main Coil Replacement Procedure cont o F 1 Yellow Black Figure 4 17 Terminal Block Assembly Electrically Held Series E Contactor nm AN Trip Coil blue lead S N Trip Coil white lead L N J N Closing Coil black lead WE n N g Coil IN Closing Coil yellow lead WNW Hold in Coil blue lead Hold in Coil yellow lead
38. igure 1 5 Contactor Label Catalog No Explanation The following catalog number explanation will help identify the contactor and shall be used when contacting your local Rockwell Automation Sales office or the factory for assistance 1502 V 8 D X D 1 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 8 800A no interlock D 7200 V X None D 110VDC Refer to 1 0 1000 120 VAC Table 1 4 2 1001 2000 3 2001 3000 Vacuum Optimized for IntelliVAC E 207VDC 4 3001 4000 230 VAC 5 4001 5000 control Table 1 A Vacuum Contactor Function A 3 pole electrically held contactor B 3 pole mechanically latched contactor with electrical and mechanicalrelease D 3 pole electrically held contactor with fast drop out time 1502 UM051E EN P June 2013 Contactor Specifications Table 1 B Bulletin 1502 Medium Voltage 800 Amp Contactor Ratings Contactor Product Description 1 7 Description Specifications Voltage Ratings Maximum Rated Voltage 7200 System Voltages 2400 3300 4160 4800 6600 6900 Dielectric Voltage
39. l wire leads to the appropriate cartridge terminals per the appropriate electrical diagram Chapter 3 or per the specific electrical drawing ED supplied with the starter unit 7 Operate the contactor several times to ensure proper positioning of the auxiliary assembly as well as proper connection of the control wires 1502 UMOSTE EN P June 2013 4 24 Maintenance 1502 UM051E EN P June 2013 Chapter 5 Troubleshooting If an operating problem occurs use the following troubleshooting chart to isolate the cause of the failure and find the corrective action If the corrective action fails to resolve the problem consult your local Rockwell Automation field support representative Table 5 A Troubleshooting Series D contactors Symptom Possible Cause Contactor chatters Coil burnout Contactor does not energize Loose connections in control circuit Improper control wiring Control voltage Mechanical latch not engaging Improper set up of auxiliary contact assembly Faulty auxiliary contacts Faulty CR1 or CR2 interposing relay Coil leads improperly wired Control voltage too high Contactor operated too frequently Loose connections in control circuit Improper control wiring Control voltage Improper set up of auxiliary contact assembly Faulty CR1 or CR2 interposing relay Remedy Check all connections in control circuit for tightness Check wirin
40. lts into the holes provided on the top of the contactor Figure 2 1 and attach the lifting means to the con tactor with ropes or cables Use rigging with safety hooks or shackles Holes for lifting contactor 3 8 16UNC Figure 2 1 Lifting Holes 1502 UM051E EN P June 2013 2 2 Receiving and Handling Handling cont Pre energization Inspection Storage 1502 UM051E EN P June 2013 2 Select or adjust the rigging lengths to compensate for an unequal weight distribution of the load and maintain the contactor in an upright position at all times 3 To reduce the tension of the rigging and the compressive load on the lifting device do not allow the angle between the lifting cables and vertical to exceed 45 degrees 4 Never lift a contactor above an area where personnel are located When a forklift is used to handle the equipment the following considerations should be taken 1 Keep the contactor in an upright position Carefully balance the contactor on the forks 3 Use a safety strap when handling to steady the contactor and avoid shifting or tipping 4 Avoid excessive speeds and sudden starts stops and turns when handling the contactor 5 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 during maintenance e Check that all interphase barriers are correctly installed e
41. nal tests are required they must be performed at the proper altitude or in a pressure A chamber which simulates the proper altitude Table 4 B Contactor Deratings Altitude Range ln oa 0 1000 m 60 kV 1000 2000 m 54 kV 2000 3000 m 48 kV 3000 4000 m 42 kV 4000 5000 m 36 KV 1502 UMOSTE EN P June 2013 4 20 Maintenance Drop out Time Conversion 1502 UM051E EN P June 2013 Series D The average normal drop out time for the contactor is 200 ms The fast drop out contactor has a drop out time less than 60 ms Conversion from normal to fast or vice versa is easily achieved by changing the control component wired in parallel with the closing coil see Figures 3 3 and 3 4 The required compo nents can be ordered from Rockwell Automation and installed per the appropri ate schematic Normal drop out parts 1 Rectifier bridge 24808 45 1 01 1 Mounting screw M 8765 1 Wire assembly 80018 457 32 1 Wire assembly 80018 457 33 Fast drop out parts 1 MOV assembly 80145 581 03 The rectifier bridge for the normal drop out mounts on the outside of the left side plate above the auxiliary assembly mounting hole provided The MOV for the fast drop out mounts directly on the terminal blocks as shown in Figures 4 15 and 4 16 Series E Contactor drop out times are set within and controlled by the IntelliVAC or IntelliVAC Plus control modules refer to publications 1503 UM053_ EN P or 1503 UM054_ EN P
42. nly with mechanical latch option 1502 UM051E EN P June 2013 5 2 Troubleshooting 1502 UM051E EN P June 2013 Chapter 6 Renewal Parts M e Try Figure 6 1 Bulletin 1502 800A Electrically Held Vacuum Contactor 20 hidden Figure 6 2 Mechanical Latch Assembly 1502 UM051E EN P June 2013 6 2 Renewal Parts Table 6 A Renewal Parts Item Description of Parts 1 Three 3 Vacuum Bottles x Closing and Holdin 3 Master Contact Cartridge IntelliVAC or IntelliVAC Plus feedback Series E Series D Electrically Held 3i Series E 4 Auxiliary Assembly Series D Mechanical Latch Series E 6 pole Terminal Block Assembly high density 5 6 pole Terminal Block Assembly regular 6 Control Wire Connector Female only 7 Interphase Barrier 8 Barrier Retainer 9 Load Terminal 0 Insulator 1 Overtravel Spring 2 Return Spring 3 Rocker Washer 4 Auxiliary Operating Lever 15 Cam Follower 6 One 1 MOV 7 One 1 Rectifier Bridge not shown 8 Mechanical Latch Trip Coil 9 Mechanical Latch Spring 20 Brass Washer 21 Mechanical Latch Roller 22 Mechanical Latch Refurbishing Kit Notes e e 9 e Rockwell Automation recommends that if the contactor has been in service all three replaced at the same time Refer to Figure 4 4 Refer to Figure 4 28 Refer to
43. or plate in turn pushes the insulator and movable shaft up closing the contacts inside the vacuum bottle e The control circuit economizing auxiliary contacts located on the left side of the contactor change state once the contactor closes e The current that is energizing the closing coil is then switched off The contac tor remains closed by the hold in coil only e The contactor is opened by de energizing the hold in coil The mechanical latch version of the contactor operates basically the same way with the following exceptions e Both coils are de energized upon closing of the contactor and the armature is held in the closed position by a spring loaded latching mechanism e The contactor is opened by energizing a trip coil which pulls the latch away from the armature or by engaging a manual trip mechanism via a pushbutton located on the front of the medium voltage door see Figure 1 4 Note External control relays and a rectification circuit are used to control the standard DC closing and hold in coils on the contactor 1502 UMOSTE EN P June 2013 1 4 Contactor Product Description Contactor Operation cont IntelliVAC Control Series E The electrically held vacuum contactor operates as follows e When the IntelliVAC and IntelliVAC Plus control modules receive a close command the contactor coil is energized the current creates an electromagnet in the coil e The electromagnet pulls the armature plate toward
44. ottle assembly out of the contactor as shown in Figure 4 4 the overtravel spring may need to be compressed slightly Repeat this for the remaining vacuum bottle assemblies Vacuum Bottle Assembly Overtravel Spring Figure 4 4 Removal of Vacuum Bottle Assembly Disassemble one assembly at a time as shown in Figure 4 5 Leave the gap adjustment nut directly below the rocker washer on the insulator stud near the bottom Vacuum Bottle Load Terminal flexible Lock washer Load Terminal Nut Insulator Wear Washer Overtravel Spring Rocker Washer Gap Adjustment Nut Lock washer Figure 4 5 Vacuum Bottle Assembly Gap Locking Nut 1502 UMOSTE EN P June 2013 4 6 Maintenance Vacuum Bottle Replacement 7 Reassemble the assembly using a new vacuum bottle leaving the bottom gap and Set up Procedure cont locking nut and lock washer off Position the insulator to achieve the 243 3 mm 9 58 in dimension as shown in Figure 4 6 and leave the load terminal nut loose the position of the load terminal shall be in the opposite direction of the wear indicator line on the movable shaft Repeat this procedure for the remaining vacuum bottle assemblies The 9 58 dimension is not critical it is simply a good starting point in order to make the installation easier L of 9 58 243 3 mm Movable Shaft
45. p as shown in Figure 4 10 Advance the bolt one additional full turn to ensure that the contactor opens fully Hold ing the Compression bolt in position with a wrench tighten the compres sion bolt locking nut Maintenance 4 9 Armature plate makes contact with Stop Figure 4 10 Return Spring Installation 16 With the contactor in the open position measure the distance between the bottom of the bearing and the top of the wear indicator line on all three vacuum bottles with a feeler gauge This dimension shall be 7 6 mm 0 300 in minimum as shown in Figure 4 11 7 6 mm 0 30 in Min A Vacuum N Bottle Wear indicator line on operating shaft Insulator Figure 4 11 Vacuum Bottle Contact Gap Front View 1502 UMOSTE EN P June 2013 4 10 Maintenance Vacuum Bottle Replacement and Set up Procedure cont 1502 UMOSTE EN P June 2013 2 5mm 0 100 in Min If the dimension is less than 7 6 mm 0 300 in loosen the gap locking nut on all three 3 bottles Starting on phase B turn the gap adjustment nut upwards until 7 6 mm 0 300 in is achieved Repeat this procedure for phases A and C ensuring that the measurements are equal for all three 3 phases Tighten and torque the gap locking nuts for all three 3 phases Note Ensure that the armature plat
46. r is not necessary Do not grease the armature shaft plastic bearings nor the vacuum bottle plastic bearings The grease will dry out and impede the free motion of the contactor Mechanical Latch Roller Replacement e The roller on the mechanical latch mechanism must be replaced every 50 000 operations See Mechanical Latch Roller Replacement Procedure refer to page 4 17 SHOCK HAZARD High voltage may be present which can result in severe injury or death It is suggested that a Hot Stick be used to A ensure that the equipment is dead Lock out any incoming power and disconnect the control plug from the contactor before working on this equipment ATTENTION Before performing any maintenance on the contactor that is installed inside a starter configuration for safety be sure to follow all procedures noted in the appropriate User Manual for complete instructions on accessing the power cell com partment Vacuum Bottle Replacement Set Up Procedure Maintenance 43 The following procedure shall be used to remove and replace the vacuum and bottles This procedure can be performed with the contactor remaining in the power cell of the controller After this procedure has been completed the contactor will be set up to operate properly at 1000 m 3300 ft Refer to the Altitude Adjustment procedure for other altitude setting on page 4 18 For the safety of the maintenance personnel remove the con trol wiring from
47. s the coil core rotating the shaft and causing the actuator plate to move upwards e As the actuator plate moves it pushes the insulator and movable shaft up clos ing the contacts in the vacuum bottle The IntelliVAC and IntelliVAC Plus control modules supply the close current to the coil for approximately 200 milliseconds Afterward the coil current is reduced to a lower hold in value e When the IntelliVAC and IntelliVAC Plus control modules have the close command removed the coil is de energized opening the contactor The mechanical latch contactor operates in much the same manner as the electri cally held version see above with a few exceptions Once the contactor is closed a spring loaded mechanism moves a roller against the armature plate to hold it against the electromagnetic core e The contactor can be opened electrically by energizing a trip coil via Intel liVAC and IntelliVAC Plus open output which pulls the latch away from the armature or by a push button mounted on the power cell door that mechani cally releases the contactor LLL RH LL LL EC 2 T 2 2 2 lt Line Terminal uen Vacuum Bottle B D T Insulator Load Terminal Actuator Plat
48. t Procedure 18 19 20 21 Maintenance 4 11 Operate the contactor several times to ensure proper function Wipe down the exterior surface of each vacuum bottle with a clean lint free cloth Replace the interphase barriers and retaining brace Again account for all tools used during the above procedure If any tools are unaccounted for do not energize the equipment ATTENTION Before beginning work on the contactor ensure that it is isolated from all power sources and locked out For the safety of maintenance personnel remove the control wiring from the contactor by disconnecting the control wire plug before starting any disassembly of the contactor Disconnect the coil leads from the terminal block assembly The closing and hold in coils are both wound on one bobbin therefore all four coil leads must be removed the MOVs and or bridge diode leads may come loose as well See Figures 4 15 to 4 19 for the appropriate connections Remove the three bolts from the bottom of the magnet assembly and with draw the assembly from the contactor as shown in Figure 4 13 Terminal block assembly Magnet assembly Figure 4 13 Magnet Assembly Removed 1502 UMOSTE EN P June 2013 4 12 Maintenance Main Coil Replacement Procedure cont Core Coil Leads Mounting Plate Series D 1502 UMOSTE EN P June 2013 Remove the two bolts which connect the magnet cor
49. tactor base Remove latch pivot bolt with a 3 16 Allen key as shown in Figure 4 21 and remove the lever assembly The latch spring is no longer retained at this point and may fall out of the core do not misplace this spring Remove the trip core mounting bolt as shown in Figure 4 22 and slide the core out of the coil allowing the coil to be removed Slide the core into the new coil and install the core mounting bolt 1502 UMOSTE EN P June 2013 4 16 Maintenance Mechanical Latch Trip Coil 5 Make sure that the latch spring is seated properly in the core position the Replacement Procedure cont lever assembly and install the latch pivot bolt The spring must be seated properly in the retaining holes in both the core and the lever 6 Route the trip coil leads as they were and connect to the terminal block as sembly as shown in Figure 4 18 or 4 19 Latch Pivot Bolt Lever Assembly Latch Spring Figure 4 21 Mechanical Latch Trip Coil Replacement lt TP Trip Core Mounting Bolt Trip Coil Trip Core Latch Spring Figure 4 22 Mechanical Latch Trip Coil Replacement 1502 UMOSTE EN P June 2013 Mechanical Latch Roller Replacement Procedure Mechanical Latch Mechanism Refurbishing Procedure Trip Coil Lever Maintenance 4 17 Make sure the contactor is in the open or tripped state Remove latch pivot bolt with a 3 16 Allen key as shown in Figure 4 21 and remove the lever
50. ve Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt P Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Table of Contents Chapter 1 Contactor Product Description e ead Description Vacuum Bottle neue 1 2 Contactor Operation Electro Mechanical Control Series D ee 1 3 IntelliVAC Control Series E ner 1 4 Contactor Identification snese raren oria raat 1 6 Contactor Catalog Number Explanatio unten 1 6 Contactor Sp cifications amande 1 7 Prod cts Approvals uyan ad attt Ni 1 8 Chapter 2 Receiving and Handling RECEIVIDE iiid tento 2 1 Preliminary pecto N 2 1 nt 2 1 Pre Enerpizatior IDspectI ueque Depp inan d an n ois 2 2 Nr M 2 2 Vacuum Bottle Integrity Test ns 2 3 Insulation Resistance Test nee 2 5 Chapter 3 Installation j louis 3 1 Electrical Connections aad aaa da descen bd e ves Tarai 3 2 Wiring and Schematic Diagrams Series D Electrically Held Contactor normal drop out time 3 4 Series D Electrically Held Contactor fast drop out time 3 5 Series E
51. with the round rocker bar as shown in Figure 4 9 Install the lockwasher and gap locking nut and tighten the two nuts against each other making sure that the top gap adjust ment nut does not turn Note Ensure that the overtravel spring is held securely in place with no play Should there be play in the positioning of the spring loosen the load termi nal nut and repeat Steps 10 and 11 1502 UMOSTE EN P June 2013 4 8 Maintenance Vacuum Bottle Replacement and Set up Procedure cont 1502 UMOSTE EN P June 2013 Rocker Rocker Bar Rocker Washer Gap Adjustment Nut Gap Locking Nut Side View Front View Figure 4 9 Rocker Washer Adjustment 12 Repeat steps 9 10 and 11 for the remaining vacuum bottle assemblies Note Make sure that the rocker washers for all three assemblies just make contact with the rocker bars as this will ensure synchronized contact move ment 13 REMOVE THE 3 16 ROD DRILL BIT OR SCREW INSERTED IN STEP 8 FROM BETWEEN THE ARMATURE AND YOKE PLATES 14 Move the actuator plate up and down manually and check that the rocker washers make contact simultaneously If they do not loosen the nuts below the appropriate washers and adjust accordingly 15 Reinstall the return spring and advance the compression bolt until the arma ture plate makes contact with the sto
Download Pdf Manuals
Related Search