Rockwell Automation 1102C-COx93 User Manual

Bulletin 1102C Vacuum Contactor Maintenance and Installation Instructions (Current Ratings 400A and 600A -- 200V-1500V)

(Cat 1102C-CO_93 -- 400A, 3 Pole Contactor - 1500V Max) (Cat 1102C-DO_93 -- 600A, 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

CUUM

CON

TACTO

ACTOR

Vacuum Contactor - 400A Vacuum Contactor - 600A

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

Coil Terminals

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 (Figure 3A).

4. Disconnect the coil wire leads from the Control-Pak. Remove the Control-Pak from the contactor and set on benchtop (Figure 3B).

5. While supporting the Main Housing, remove the Main Housing from the Baseplate by removing the (4) screws which hold the housing

to the Baseplate. A long phillips-head screwdriver (6" or longer) is needed as the four screws are in deep wells (holes) in the Main Housing. Remove the shorter screws first. Separate the main housing assembly from the Baseplate and set it aside. (Figure 3C).

FIGURE 3A FIGURE 3B

(2)

Rotate retainer to release Control-Pak

This tab must clear notch prior to pushing Control-Pak downward.

Control-Pak

Coil Replacement Instructions (Cont'd)

Main

Housing

Coil

Assembly

Return Springs

Baseplate

FIGURE 3C FIGURE 3D

6. Remove the return springs and set them aside. Turn the Base Assembly over and remove the (4) screws that secure the coil assembly to the Baseplate. (Figure 3D)

7. Install new coil assembly in position using (4) screws (tighten to 30 lb-inches). Replace the Return Springs by placing them over the

spring support pins located within the coil magnet core assembly making sure the return springs are properly seated and not interfering with any of the control wiring. (Figure 3C).

8. Carefully replace the Main Housing assembly loosely, making sure it is orientated correctly. Carefully locate the magnetic armature poles (the poles sticking down from the upper housing assembly) into the coil magnet core assembly. Note: This is a blind operation with careful side to side motion. Pay close attention to alignment of the locating bosses positioned at the bottom of the main housing assembly. To reattach the Main Housing assembly insert the main housing locating bosses into the two mounting plate holes while compressing the return springs with the Main Housing. Start the four Main Housing screws into the mounting plate. Tighten the mounting screws equally in a diagonal pattern approximately two turns at a time until tightened to 40 lb-inches in the same diagonal pattern.

9. Reinstall the Control-Pak (Figures 4). First, rotate the Retainer upwards. Next, 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 center of the brass stud - which can be viewed through the slot in the side of the contactor housing. Using a thin screw driver or other thin rod, push the Control-Pak Actuator up or down as necessary to insert it into the brass stud mentioned. Rotate the Retainer to its original position, which will slide over the upper tab on the Control-Pak.

10. Reinstall the cover and secure it with the original mounting hardware. Tighten the four screws in a diagonal pattern to 5 lb-inches. (Figure 3A).

11. Reattach the coil wire leads to the Control-Pak (tighten to 7 lb-inches).

12. Reinstall the device and reconnect any auxiliary control wires. Reconnect the line and load conductors and tighten the main terminal

hardware and bolts to 180 lb-inches.

Thin rod or

flat blade

Control-Pak Actuator

Actuator must fit into slot shown

FIGURE 4A FIGURE 4B

(3)

Control-Pak

+ 5 hidden pages