Rockwell Automation 1102C-BOx93 User Manual
Bulletin 1102C Vacuum Contactor Maintenance and
Installation Instructions (Current Ratings 200A -- 200V-1500V)
(Cat 1102-BO_93 -- 200A, 3 Pole Contactor - 1500V Max)
ATTENTION: To prevent electrical shock, disconnect from power source before installing or servicing.
Inspection page 1
Installation page 2
Coil Replacement page 2, 3
Control Pak Replacement page 4
Aux. Contact Assembly Installation page 4
Vacuum Interrupter Phase Assembly Replacement page 4, 5
Contact Life Over-Travel Measurement page 5
Cleaning and Maintenance page 6
Vacuum Interrupter Integrity Test page 6
Wiring page 6
Dimensions page 7
Replacement Parts page 8
VA
CUUM
CON
TACTO
R
Vacuum Contactor - 200A
Inspection - Unpacking
Before the contactor is placed in service, check carefully for shipping damage. Any damage should be reported to the carrier within (3)
three days of receipt. For overseas deliveries, it is important to obtain a certificate of examination from the nearest insurance inspector and
photographs of the damage. This and other evidence should accompany any communication to the insurance company or shippers. In the
event equipment is to be returned to the factory, contact Allen-Bradley Customer Service Department or our local A-B Distributor for return
authorization. A returned material authorization (RMA) number will be issued which should appear on all correspondence and the returned
container.
The Bulletin 1102C Vacuum Contactor is shipped in a shock resistant filled cardboard box. The following steps should be taken when
unpacking the contactor:
1. Check the packing list against the order to make sure the shipment is complete and components are received.
2. Examine the shipping box before unpacking the contactor to make sure it has not been damaged in shipment. If the shipping box is
damaged, pay particular attention when unpacking to see if the contents are also damaged. Notify the carrier if damage is found and notify
your local Allen-Bradley order field sales office of damage.
Installation Instructions
The vacuum contactor may be used in any mounting plane. In any non-horizontal mounting plane, the top of the contactor should point up
(so that the label appears right-side up). Care should be taken to insure that the mounting hardware does not warp the mechanism frame. If
the surface of the contactor to which the contactor is mounted is twisted, shims should be used to correct the condition. Any appreciable
degree of end to end twist will result in phase to phase discrepancies and timing of the main contact could cause increased pickup in control
voltage values.
1. Figure 1 illustrates the field terminals for line and load terminations. Mount the contactor with the hardware specified in Figure 2. Loosely
install the (4) mounting bolts into the intended mounting surface. Torque the mounting bolts to 50-75 lb-inches.
2. Connect control wires to the vacuum contactor control terminals A1 and A2 located on the Control-Pak using #18 to #12 gauge 75°C
stranded copper or tin stranded copper wire tightening screw terminals to 7 lb-inches torque.
3. Using 75°C wire copper cable, connect the line and load conductors to the main terminals (Figure 1) and proper phase rotation, tighten the
main terminal bolts to 132 lb-inches torque.
4. Check all connections for accuracy and mechanical connection before energizing.
Line Terminals
Control Pak
1/4 Lock Washer
1/4 Flat
Washer
VACUUM CONTACTOR
A1
Coil
V
A
CU
U
M
C
O
N
T
A
C
T
O
R
Terminals
A2
1/4" or 7mm Bolt
Load Terminals
Figure 1 Figure 2
ATTENTION: If coil failure is suspected, check that secondary damage has not occurred that will render the contactor non-repairable.
Coil Replacement Instructions
1. Disconnect all power cables (or bus work) and all control wiring to the contactor.
2. Remove the contactor from its mounted location. The contactor is best serviced in the benchtop position as shown.
3. Remove the cover attachment screws from the contactor and remove the Cover and Retainer (Figure 3A).
4. Disconnect the two wire leads from the Coil to the Control-Pak. Remove the Control-Pak from the contactor and set on benchtop (Figure 3B).
5. Remove the (6) screws that secure the Upper Housing to the Lower Housing by first removing the (4) outer screws and then (2) center
screws. NOTE- Removing the center screws will release the Return Springs. Carefully remove the Upper Housing leaving the Return Springs
in the Lower Housing (Figure 3B)).
Center
Screws
Cover
Control-Pak
V
A
C
U
U
M CO
N
T
A
C
T
O
R
Retainer
Return
Springs
Figure 3A Figure 3B
(2)
Upper
Housing
Contact
Operator
Lower
Housing
Coil Replacement Instructions (Cont'd)
6. Remove and replace the coil. Ensure that the Shim Plate remains in the proper position between the magnet core and coil (Figure 3C).
7. Carefully replace the Upper Housing, ensuring that it is orientated correctly and that the Return Springs are seated on the outer two
bumps on the bottom of the Contact Operator (Figure 3D). Replace the (6) screws that secure the Upper Housing. Tighten the screws
equally in a diagonal pattern approximately two turns at a time until tightened to 12 lb-inches in the same diagonal pattern (Figure 3A).
8. Reinstall the Control-Pak (Figures 3E & 3F). First, insert the lower tab into the recess on the side of the contactor base. With proper
installation, the Control-Pak Actuator will fit into the hole in the slot in the side of the contactor housing. Using a thin rod or flat blade, lift the
Control-Pak Actuator up as necessary to insert it into the slot mentioned
9. Reinstall the cover with Retainer and secure it with the original mounting hardware. Tighten the four screws in a diagonal pattern to 5 lbinches (Figure 3A).
10. Reattach the coil wire leads to the Control-Pak (tighten to 7 lb-inches).
11. Reinstall the device and reconnect any auxiliary control wires. Reconnect the line and load conductors and tighten the main terminal
hardware and bolts to 132 lb-inches.
Coil
Shim
Plate
.
Bumps
Figure 3C
Figure 3D
Thin rod or flat blade
Control-Pak
Actuator
Actuator
must fit into slot
shown
Figure 3E Figure 3F
(3)
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