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
VA
CUUM
CON
TACTO
R
VA
CU
UM
C
ON
T
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
A1
Coil
Terminals
A2
1/4" or 7mm Bolt
V
A
C
U
U
M
C
ON
T
A
C
T
OR
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).
V
A
C
U
U
M
C
O
N
T
A
C
T
O
R
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
Control-Pak Replacement Instructions
1. Disconnect all control wiring to the Control-Pak.
2. Remove the cover attachment screws from the contactor and remove the cover (Figure 3A) page 2.
3. Remove the Control-Pak from the contactor (Figure 3B) page 2.
4. Install the new Control-Pak (Figure 4A & 4B). 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.
5. 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).
6. Reconnect all control wiring removed per Step 2. Tighten to 7 - 9 lb-inches.
(Auxiliary Contact Assembly) Installation Instructions
(Cat 1195C-N3 -- 2-N.O./2-N.C. - 600V @ 10A-A600)
(Cat 1195C-N4 -- 2-N.O./2-N.C. - 5V @ 10mA, DC)
(Positioned left hand side of contactor when facing front)
1. If replacing the existing 1195C Auxiliary Contact, disconnect all control wires from the auxiliary terminals.
2. Remove the cover attachment screws from the contactor and remove the cover (Figure 3A) page 2.
3. Install the new 1195C Auxiliary Contact (Figures 5). First, rotate the Retainer upwards. Next, insert the lower tab into the recess on
the side of the contactor base. With proper installation, the 1195C 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 1195C 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.
4. 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) page 2.
5. Connect all control wiring (Tighten to 7 - 9 lb-inches).
1195C Auxiliary
Contact Actuator
Retainer
Thin rod or
flat blade
Auxiliary
FIGURE 5A FIGURE 5B
Vacuum Interrupter Phase Assembly 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 tabletop position.
3. Remove the cover attachment screws from the contactor and remove the cover (Figure 3A) page 2.
4. Remove the Control-Pak from the contactor and set on benchtop (Figure 3B) page 2.
5. Locate the replacement vacuum interrupter phase assembly that needs to be replaced.
6. For the outer interrupters, remove the Retainer. Remove the screw from the line side terminal (Figure 6A).
7. Remove the screw from the load side terminal. This will free the shunt. Note the position of the shunt prior to removing the
interrupter assembly. Carefully remove the interrupter assembly (Figure 6B).
(4)
Vacuum Interrupter Phase Assembly Replacement Instructions (Cont'd)
8. The replacement interrupter is factory set for contact gap and does not require adjustment in the field. The flexible shunt will feed through
the flexible shunt path in the molding of the contactor and the assembly can be pushed firmly back into place (See Figure 6B showing
locations for applying hand pressure to snap interrupter into plastic molding), observe the adjacent phases to see precisely how this is located.
While holding the Interrupter in position with the provided wrench, replace the line terminal screw (Figure 6A). Replace the shunt connection
(See Figure 6B). Use open end wrench (provided) to hold centerline alignment of copper top end of interrupter during bolt tightening. Tighten
bolts to 60 - 80 lb-inches.
Interrupter
Special wrench
supplied with kit
Phase Assembly
Retainer
Shunt
Pressure points for
interrupter installation
A
Terminal
Screw
Shunt
A
Shunt
Screw
SECTION A-A
Shunt
Screw
FIGURE 6A FIGURE 6B
Contact Life over Travel Measurement
The purpose of this measurement is to determine how much vacuum interrupter electrical life remains on the contact and is performed using a
standard wire gauge in a "go, no go" check.
1. De-energize the contactor and isolate from all power sources. The control source can be maintained if coming from a separate supply or if
taken from a line to line connection by application then an additional control source needs to be connected to terminals A1 and A2. Reenergize the contactor insuring that the main power circuits are open and isolated.
2. Remove Phase Cover as described (Figure 3A) page 2, earlier to access inspection area (Figure 7).
3. When the contactor is closed, a gap occurs, and this gap should
accept a standard wire (.010") gauge. If the gauge can be inserted in
the space then sufficient life remains for an additional 100,000
operations. Check all phases.
4. If the .010" wire gauge cannot be inserted into this gap with the
contactor energized, then over travel has been exhausted and thus
contact life used up. The contactor should be replaced.
(5)
FIGURE 7
Cleaning and Maintenance
1. The vacuum contactor requires no adjustment. Preventative maintenance is recommended on a routine basis, once every twelve
months, dependent upon the environment that the contactor is exposed to. In general, maintenance consists of keeping the device free of
dirt and dust and ensuring the power and control terminals are tight.
2. Maintenance should verify the mechanical operation of the device for freedom of movement. Clean dirt from the surfaces. Pay
particular attention to molded parts and tracking surfaces. Foreign materials on these surfaces should be removed by vacuum or wiping,
do not use compressed air.
Vacuum Interrupter Integrity Test
ATTENTION: Excercise caution while performing high voltage potential tests.
1. A high potential test will determine the di-electric strength and condition of the vacuum interrupter. A high potential test should be
performed on each vacuum interrupter phase in sequence and should be performed approximately once every twelve months.
2. The vacuum interrupter integrity test should be performed if the contactor has been known to be exposed to fault conditions - either
phase to phase or phase to ground.
3. When doing this check, make visual inspection for physical evidence of stress, distorted, discolored or cracked interrupters.
4. A contact resistance test can be done as defined below or if preferred a high potential test; di-electric test should be performed as
follows.
Contact Resistance
A contact resistance test can be performed using a micro-ohmeter. This test determines the condition of contact surfaces. With the
contactor closed, the resistance across the terminals should be less than 400 micro-ohms. If higher contact resistance values are
measured then a high potential test should be performed, as follows:
ATTENTION: The following test should be performed using a 50/60 Hz test set. Where the voltage is continuously variable up to at least
20 kV. X-radiation at this level is negligible. However, personnel should not be closer than ten feet to the interrupter and the test cables to
avoid high voltage shock hazards. The contactor should be free of dust and other contaminants before conducting this test.
1. Disconnect the line and load conductors from the contactor.
2. Connect the leads of the test set across the interrupter terminals with the contactor in the open position.
3. Slowly raise the voltage to 10 KV and hold for 15 seconds.
4. The leakage current should not exceed 5 MA during the test and any tripping of the test set circuit protector during the test should be
repeated two to three times. If it becomes impossible to reach the 10 KV level, then the interrupter needs to be replaced, and should be
replaced by utilizing a Allen-Bradley replacement phase assembly kit.
Wiring
STOP
OPTIONAL (1195C-N3 OR 1195C-N4)
SCHEMATIC
SEPARATE
AC SOURCE
START
M
(14)(13)
(A1)
M
STOP
(A2)
SCHEMATIC SCHEMATIC
SEPARATE
125V DC SOURCE
START
(B1)
M
(34)(33)
(45)
M
LATE
BREAK
STOP
(B2)
(46)
SEPARATE
250V DC SOURCE
START
M
WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM
L1
(53)
(54)
(61)
(62)
(73)
(74)
(81)
(82)
(53) (13)
(54)
(61)
(62) (22)
(73)
(74)
(81)
(82)
T1
L3L2L1
(14)
(21)
M
T2
(A1)
(A2)
T3
L1 L2 L3
(53) (13)
(54)
(61)
(62)
(73)
CONTROL PAK
(74)
(81)
OPTIONAL (1195C-N3 OR 1195C-N4)
(82)
M
T3T2T1
(B2)
(B1)
(14)
(21)
(22)
(33)
(34)
(45)
LATE
BREAK
(46)
1195C-N5
OPTIONAL (1195C-N3 OR 1195C-N4)
M
(B1)
(34)(33)
L2
L3
M
T2T1
T3
(26)(25) (45)(46)
LATE
BREAK
(13)
(14)
(25)
(26)
(33)
(34)
(45)
LATE
BREAK
(46)
(B2)
(B1)
(B2)
LATE
BREAK
(6)
1195C-N6
Dimensions
.38 [9.7 mm]
.6
[15.2 mm]
8.0
[203.2 mm]
6.83
[173.5 mm]
R .19 [4.8 mm]
(4) Mtg. Holes
.5 [12.7 mm]
6.46
[164.1 mm]
4.77
[121.2 mm]
8.25
[209.5 mm]
Aux. Contact
.38 [9.7 mm]
Optional
Kit
[10.2 mm]
.6
[15.2 mm]
[15.2 mm]
Ø .4
VACUUM CONTACTOR
[64.5 mm]
9.1
[231.1 mm]
2.54
7.75
[196.8 mm]
9.25
[234.9 mm]
.88 [22.4 mm]
9.15
[232.4 mm]
400A
8.0
[203.2 mm]
.6
6.83
[173.5 mm]
R .19 [4.8 mm]
(4) Mtg. Holes
.63 [16.0 mm]
6.46
[164.1 mm]
2.87
[72.9 mm]
8.25
[209.5 mm]
Optional
Aux. Contact
Kit
Ø .4
[10.2 mm]
.6
[15.2 mm]
VACUUM CONTACTOR
9.1
[231.1 mm]
2.54
[64.5 mm]
1.0
[25.4 mm]
.88 [22.4 mm]
600A
(7)
[304.8 mm]
10.7
[271.8 mm]
12.0
9.15
[232.4 mm]
Replacement Parts
380/415 VAC
1102C-CP46N
Auxiliary Kits
Type - Contact Arrangement
Coil Kit ---- This kit contains the DC coil mounted in the sheet metal frame assembly
which attaches to the contactor mounting plate.
NOTE: When changing the coil voltage, verify that the Control-Pak voltage for the coil
kits listed below is in agreement with the Control-Pak nameplate input voltage.
Control Pak ---- side mounted module for DC coil power
1102C-CP46A
220/240 VAC
110/120 VAC
1102C-CP46D
1102C-CP46B
440/480 VAC
(400 Amp.)
(600 Amp.)
(400 Amp.)
400 A Vaccum Interrupter Phase Assembly
600 A Vaccum Interrupter Phase Assembly
Current Rating W/ Wire Gauge Range
(600 Amp.)
Interrupter Phase Assembly Kit - Replacement for One Vacuum Interrupter Phase
Current Rating of Interrupter
(2) N.O. / N.C. 5 VDC 10mA
(2) N.O. / N.C. 600 VAC 10 Amp. (A600)
400 A (2) #6 - 300 MCM
600 A (2) #2 - 600 MCM
Lug Kits
Bulletin Number Voltage (input) Contactor Size (Amp. Rating)
1102C-COD93 (400 Amp.)
1102C-DOD93 (600 Amp.)
1102C-COA93 (400 Amp.)
1102D-DOA93 (600 Amp.)
1102C-CON93 (400 Amp.)
1102C-DON93 (600 Amp.)
1102C-COB93 (400 Amp.)
1102C-DOB93 (600 Amp.)
Bulletin Number Voltage (input) Control Pak Volts (Amp. Rating)
1102C-PK4D 108 VDC 110/120 VAC
1102C-PK4A 108 VDC 220/240 VAC
1102C-PK4N 108 VDC 380/415 VAC
1102C-PK4B 108 VDC 440/480 VAC
1102C-PK6D 108 VDC 110/120 VAC
1102C-PK6A 108 VDC 220/240 VAC
1102C-PK6N 108 VDC 380/415 VAC
1102C-PK6B 108 VDC 440/480 VAC
1102C-PK4G 125 VDC NONE
1102C-PK4H 250VDC NONE
1102C-PK6G 125 VDC NONE
1102C-PK6H 250VDC NONE
Accessories
Bulletin Number
1102C-VB4
1102C-VB6
Bulletin Number
1195C-N3
1195C-N4
1195C-N5
1195C-N6
Bulletin Number
1195C-LK2
1195C-LK3
For use on DC input coils only - 125 VDC maximum
(1) N.O. / N.C. & (1) N.O. /Late Break N.C.
For use on DC input coils only - 250 VDC maximum
(2) N.O. / Late Break N.C.
42052-080-01(1)
Printed in U.S.A.
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