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Rockwell Automation Allen-Bradley G Series, User Manual

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Rockwell Automation Allen-Bradley G Series User Manual Download Page 41

Rockwell Automation Publication 1502-UM060A-EN-P - October 2020

41

Chapter 4          Maintenance

Figure 27 - Closing the Contactor

4. After the top screw is finger tight, continue to tighten this screw with a 

hand tool. The armature stop bracket flexes a little, which is acceptable, 
but do not overtighten and bend the armature stop plate. It is important 
that the armature plate is held tightly against the magnet cores. The 
contactor must be fully closed.

5. Place a wide blade 0.030 in. (0.76 mm) feeler gauge between the plastic 

auxiliary actuator tips and the steel actuator plate. To aid the installation 
of the feeler gauge, the gauge can be put in place as the clamping block 
screw is being finger-tightened (Step 3). See 

Figure 28

 and 

Figure 29

.

Figure 28 - Gauging the Contacts

Summary of Contents for Allen-Bradley G Series

Page 1: ...Medium Voltage 450 A Contactor Series G Bulletin Number 1502 User Manual Original Instructions ...

Page 2: ...ell Automation Inc with respect to use 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 Labels may also be on or inside the equipment to provide specifi...

Page 3: ...lectromechanical Relay Controlled Contactor 10 Contactor Identification 11 Catalog Number Explanation 12 Contactor Dropout Times 12 Specifications 13 Product Approvals 15 Chapter 2 Receiving and Handling Receiving 17 Preliminary Inspection 17 Handling 17 Pre energization Inspection 17 Vacuum Bottle Integrity Test 18 Storage 19 Insulation Resistance Test 19 Chapter 3 Installation Mounting 21 Electr...

Page 4: ...Contact Setup Procedure 39 Mechanically Latched Contactor Trip Coil Replacement Procedure 42 Parts 42 Mechanically Latched Contactor Setup Procedure 46 Chapter 5 Troubleshooting Troubleshooting and Contactor Coil Resistance 49 Chapter 6 Spare Parts Bulletin 1502 Spare Parts Diagrams and Chart 51 Index 53 ...

Page 5: ...rc resistant enclosures IntelliVAC Contactor Control Module User Manual publication 1503 UM060 Provides information on receiving and storage installation setup monitoring and spare parts for the IntelliVAC Contactor Control Module EtherNet IP Network Devices User Manual ENET UM006 Describes how to configure and use EtherNet IP devices to communicate on the EtherNet IP network Ethernet Reference Ma...

Page 6: ...6 Rockwell Automation Publication 1502 UM060A EN P October 2020 Notes ...

Page 7: ... isolation switch as well Bulletin 1502 vacuum contactors are optimized for use with the IntelliVAC control module see publication 1503 UM060 Certaincontactormodelsare availableforusewithelectromechanical relay control panels There are physical control wiring and component differences between contactors that are designed for IntelliVAC control versus those intended to be operated using electromech...

Page 8: ...ottle Description Each vacuum bottle Figure 2 consists of two contacts that are enclosed in a ceramic housing an upper contact that is mounted to a fixed shaft and a lower contact that is mounted to a movable shaft A stainless steel bellow helps the vacuum integrity of the bottle while letting the lower contact move towards and away from the fixed contact Figure 2 Vacuum Bottle Cross Section Arc S...

Page 9: ...hen the close command is removed from the IntelliVAC control module Open the coils are de energized which opens the contactor Electromechanical Relay Controlled Contactors When the main pilot relay CR1 in the control circuit is energized the circuit energizes an electromagnet in the closing coil and in the hold in coil Figure 18 The electromagnet pulls the armature plate towards the core of the co...

Page 10: ...a roller against the armature plate to hold it against the electromagnetic core The control circuit auxiliary contact on the left side of the contactor changes from the normally closed state to the normally open state as the contactor closes This action de energizes the relay that controls the closing coils see Figure 18 The contactor can be opened electrically by energizing a trip coil that pulls...

Page 11: ... Automation relay control panel 1503C XXX or 1503E CXXX is required for reliable operation of the contactor within its published specifications The relays break the DC current that is drawn by the closing coil holding coil and trip coil The relays make sure the pick up and drop out voltages are coordinated with the pick up and drop out voltages of the contactor This provides reliable operation of ...

Page 12: ... times are used in coordination with medium voltage power fuses The dropout time must be longer than the Total Clearing Time of the medium voltage power fuses being applied in combination with the vacuum contactor Damage to the contactor can occur if this coordination is not addressed appropriately All mechanically latched contactors are designed with the fast dropout time 1502 V 4 D B D A 0 a b c...

Page 13: ...ating 2400V 6000 RMS symmetrical amps 5000V 7200V 2 2 The IEC rating at 7200V RMS Sym is 5300 A 66 MVA Maximum interrupting MVA rating 2400V 25 Sym MVA 5000V 50 Sym MVA 7200V 2 75 Sym MVA Short circuit withstand at rated voltage Current Peak cycle 55 kA Short time current rating capability For 1 s 6 0 kA For 30 s 2 4 kA Chop current average rms amperes 0 5 Make and Break Capability at Rated Voltag...

Page 14: ... performed as detailed in this manual Electrically held 2 500 000 operations Mechanical latch 100 000 operations Electrical life 1 1 000 000 operations Switching frequency Electrically held 600 000 operations per hour Mechanical latch 150 000 operations per hour Table 6 Opening and Closing Times IntelliVAC Control Electrically Held Mechanical Latch Maximum closing time 50 60 Hz 120 240V AC 100 70 ...

Page 15: ...ngly see publication 1503 UM060 1000 5000 m 3300 16 500 ft Contactor Weight 21 8 kg 48 lb Auxiliary Contact Rating A600 Auxiliary Contacts on the Vacuum Contactor max 3 3 The number of contactor auxiliary contacts depends on the contactor type Some of the contacts are used in the typical control schemes used 3 N O 3 N C Table 9 Altitude Derating Altitude Rating Max Continuous Current Rating Reduce...

Page 16: ...16 Rockwell Automation Publication 1502 UM060A EN P October 2020 Chapter 1 Product Description Notes ...

Page 17: ...t tester to test vacuum bottle integrity refer to Vacuum Bottle Integrity Test on page 18 Handling The contactor weighs approximately 21 8 kg 48 lb When transporting the contactor over longer distances or for sustained lifting use a forklift When a forklift is used to handle the equipment adhere to the following precautions Keep the contactor in an upright position Carefully balance the contactor ...

Page 18: ...epeat the test once more If the vacuum bottle fails a second time it must be replaced If no breakdown occurs in the second test the vacuum bottle is in an acceptable condition 5 After the high potential voltage is removed from the vacuum bottles the metal end caps of the vacuum bottles must be discharged with a grounding rod ATTENTION Do not apply a voltage higher than 25 000V across the open cont...

Page 19: ...tion of vacuum bottle integrity An AC test provides a reliable vacuum integrity indication Additionally the degree of vacuum within the bottle can be determined by comparing initial test results to the present readings Increases in leakage current indicate a reduction in vacuum within the vacuum bottle Storage To store the contactor before it is in service store it in a clean dry area free from du...

Page 20: ...20 Rockwell Automation Publication 1502 UM060A EN P October 2020 Chapter 2 Receiving and Handling Notes ...

Page 21: ...hepowercellsofAllen Bradleycontrollers If the contactor is supplied as an OEM component for installation in a custom application refer to the dimensional information in Figure 6 If the contactor is mounted in an enclosure designed by an OEM there must be a minimum of 3 in 76 mm of air space between live parts terminals and vacuum bottles and the enclosure Figure 6 Contactor Mounting Details in mm ...

Page 22: ...ions vary by contactor type If the contactor is supplied as an OEM component for installation in a custom application the following two control options and a connecting wire harness are available from Rockwell Automation IntelliVAC control module Electromechanical control panel Connect incoming medium voltage power to the line side terminals at the top rear of the contactor near the control fuse c...

Page 23: ...ion Publication 1502 UM060A EN P October 2020 23 Chapter 3 Installation Figure 8 Electrical Connections Rear View Line Side Terminals Load Side Terminals Control Circuit Transformer Primary Fuse Clips Control Wire Plug ...

Page 24: ...c Diagrams Figure 9 Wiring Diagram Electrically Held Contactor for use with IntelliVAC Control Modules Only Yellow Black Yellow Black Power Wiring Control Transformer Primary Fuse Holders 120V Contactor Plug A N Pins D P No Connections Auxiliary Contacts Schematic 450 A Vacuum Contactor IntelliVAC Controlled ...

Page 25: ... with IntelliVAC Control Modules Only Power Circuit Control Transformer Primary Fuse Holders Yellow Black Yellow Black Blue White Auxiliary Contacts A B C D I Sockets All Others Pins Auxiliary Contacts Contactor Shown in Open Tripped Condition CC Closing Coil TC Trip Coil Schematic 450 A Mechanically Latched Vacuum Contactor IntelliVAC Controlled ...

Page 26: ...se with Electromechanical Control Panel Only Power Circuit Control Transformer Primary Fuse Holders Yellow Black Yellow Black Blue White C D I Sockets All Others Pins Auxiliary Contacts Contactor Shown in Open Tripped Condition CC Closing Coil TC Trip Coil Auxiliary Contacts Schematic 450 A Mechanically Latched Vacuum Contactor Relay Controlled ...

Page 27: ...trically Held Contactor 120V AC Normal Dropout Time for use with Electromechanical Control Panel Only Control Transformer Primary Fuse Holders Yellow Black Yellow Blue A N Pins Auxiliary Contacts CC Closing Coil HC Holding Coil Schematic 450 A Vacuum Contactor 120V Coil Normal Dropout Power Circuit Auxiliary Contacts ...

Page 28: ...or 230V AC Normal Dropout Time for use with Electromechanical Control Panel Only Control Transformer Primary Fuse Holders Yellow Black Yellow Blue B C D E F G H I J K N Pins A L M Sockets P Not used Auxiliary Contacts CC Closing Coil HC Holding Coil Schematic 450 A Vacuum Contactor 230V Coil Normal Dropout Power Circuit Auxiliary Contacts ...

Page 29: ...ectrically Held Contactor 120V AC Fast Dropout Time for use with Electromechanical Control Panel Only Control Transformer Primary Fuse Holders Yellow Black Yellow Blue A N Pins Auxiliary Contacts CC Closing Coil HC Holding Coil Schematic 450 A Vacuum Contactor 230V Coil Fast Dropout Power Circuit Auxiliary Contacts ...

Page 30: ...ctor 230V AC Fast Dropout Time For Use with Electromechanical Control Panel Only Control Transformer Primary Fuse Holders Yellow Black Yellow Blue B C D E F G H I J K N Pins A L M Sockets P Not used Auxiliary Contacts CC Closing Coil HC Holding Coil Schematic 450 A Vacuum Contactor 230V Coil Fast Dropout Power Circuit Auxiliary Contacts ...

Page 31: ...TED DEVICE ISOLATING SWITCH 50 60Hz 120V CT1 CT2 CT3 OVERLOAD T1 T2 T3 M CPT H1 H2 X1 X2 500VA ISa 5 7 6 49 42 44 46 47 6 5 X 4 0A 7 8 X ISb 1 2 3 4 NORMAL OFF TEST X X D D D D RUN OFF M E F M I J 1 1 0 1 9 8 1A 2 3 1 1 34 30 31 35 OL 4 12 12 M K L H M G 32 33 36 37 D D CONTACTOR STATUS FAIL SAFE INTELLIVAC NOTES MODULE STATUS FAIL SAFE 1 14 1 2 0A 2400V 6900V 3Ø 50 60Hz CURRENT LIMITING PRIMARY F...

Page 32: ... 44 46 47 OVERLOAD OL MANUAL TRIP GRD L3 L2 L1 CURRENT LIMITING 2400V 6900V 3Ø 50 60Hz ISOLATING SWITCH POWER BUS DOOR INTERLOCK GRD BUS POWER FUSES CPT 500VA CURRENT LIMITING PRIMARY FUSES 5 ISa 7 6 REFER TO DIMENSION DRAWING FOR COMPONENT SIZING NOT CUSTOMER WIRING METAL OXIDE VARISTOR NOTE MOV INTELLIVAC TO BE PROGRAMMED CONFIGURED BY THE CONFIGURATION POWER UP STATES ARE IN EFFECT POWER APPLIE...

Page 33: ... 3 4 NORMAL OFF TEST X X 1 1 0 1 9 8 12 12 12 M I K P M N 34 34A 36 36A REC MOV RECTIFIER CR1 CR1 CR1 CR1 CR2 CR2 19 17B 15A 15 17A 17 17C M T TC R CC D1 B D A C M 20 MOV MANUAL TRIP MAIN CONTACTOR TC TRIP COIL CLOSING COIL E G 1 32 1 30 3 F M 31 L M 37 M H 33 OL M J 35 OL 2 RUN OFF D D D D CR1 CR2 T1 T2 CT1 CT2 T3 OVERLOAD CT3 47 46 44 42 OL 49 L1 GRD L3 L2 2400V 6900V 3Ø 50 60Hz ISOLATING SWITCH...

Page 34: ...tage Non reversing FVNR Controller with Electrically Held Contactor 120V AC Normal Drop out Time a a CR1 CR2 and the wiring of their contacts into the control circuit are part of the Rockwell Automation relay control panel 1503C XXX or 1503E CXXX This control panel provides reliable operation of the contactor within its published specification ...

Page 35: ...of depth measurement High potential tester Recommended Torque Values Part of the contactor may have to be disassembled for maintenance or replacement There are appropriate torque requirements for particular bolt sizes when reassembling the contactor Use the torque values that are specified in Table 10 IMPORTANT Some components of this product incorporate imperial hardware Rockwell Automation recom...

Page 36: ...rt of the wear indicator line located on the front side of the shaft moves up into the bearing replace all three vacuum bottles Figure 20 Figure 20 Vacuum Bottle Wear Indicator ATTENTION Before performing any maintenance on the contactor refer to the User Manual of the starter configuration Failure to do so can result in injury to personnel or damage to the controller or contactor ATTENTION To avo...

Page 37: ...ease Locations Vacuum Bottle Replacement Rockwell Automation does not recommend that the vacuum bottles be replaced in the field If the vacuum bottles need to be replaced remove and return the entire vacuum contactor to Rockwell Automation for refurbishment Coil Replacement Procedure See Spare Parts on page 54 for the part numbers that are required for this procedure 1 Remove the auxiliary actuato...

Page 38: ... MOVs and or diodes are secure See the appropriate wiring diagram in this manual for further control wiring details page 24 5 Slide the new coil into position and install the retaining ring on the core Install the auxiliary assembly leaving the retaining bolt loose for adjustment later See the Auxiliary Contact Setup Procedure page 39 for determining the position of the auxiliary assembly Grade 5 ...

Page 39: ...positioning To aid in closing the contactor mechanically a clamping fixture is recommended PN 195987 Figure 24 Contactor Components 1 Loosen the nuts on auxiliary assembly retaining bolt This requires loosening and removal of the first nut that secures a ground wire at this location Leave the nut loosened enough to permit the assembly to slide along the adjustment slot as shown in Figure 25 IMPORT...

Page 40: ...unting bolts against the armature stop bracket You might have to push the armature plate a little to the rear to put the clamp in place Figure 26 Clamping Contactor Closed 3 Place a 5 8 in wrench on the main shaft of the contactor pull down and close the contactor Figure 27 while finger tightening the top middle screw on the clamping fixture PN 195987 ATTENTION Do not bend the actuator stop plate ...

Page 41: ... overtighten and bend the armature stop plate It is important that the armature plate is held tightly against the magnet cores The contactor must be fully closed 5 Place a wide blade 0 030 in 0 76 mm feeler gauge between the plastic auxiliary actuator tips and the steel actuator plate To aid the installation of the feeler gauge the gauge can be put in place as the clamping block screw is being fin...

Page 42: ...unting screws on the contactor clamping fixture Remove the fixture 10 Energize the control circuit in TEST mode and exercise the contactor to verify set up Contactor must open and close smoothly and solidly Mechanically Latched Contactor Trip Coil Replacement Procedure Parts See Spare Parts on page 54 for the part numbers required for this procedure Required Tools Two 7 16 in Wrenches 3 8 socket a...

Page 43: ...r View of Mechanical Latch Contactor showing wires to trip coil 2 Using in wrench remove the auxiliary contact actuator plate from the main shaft assembly Figure 31 Figure 31 Auxiliary Actuator Plate Removal 3 Using two 7 16 in wrenches loosen the auxiliary contact assembly retaining bolt and slide the auxiliary contact assembly out of the front of the contactor Figure 32 Trip Coil Wires Actuator ...

Page 44: ...hanical trip mechanism Figure 33 Figure 33 Removal of Mechanical Trip Mechanism 6 Remove the E clip and washer from the latch lever assembly shaft and then remove the shaft Figure 34 Remove the latch lever assembly from the mechanical latch base The return spring is seated on the right side of the mechanical latch base the contactor is not shown for clarity Figure 34 Removal of Latch Lever Assembl...

Page 45: ...pulling it towards the front of the contact Figure 36 The trip magnet coil and coil core are now exposed The contactor not shown for clarity Figure 36 Removal of Flapper 9 Remove the coil core Figure 37 and trip magnet coil using a right angle Allen key The contactor is not shown for clarity Figure 37 Trip Coil and Core Removal 10 Slide the coil core from the trip magnet coil and then place the re...

Page 46: ...gap and auxiliary set up procedures are the same for mechanically latched contactors as they are for electrically held contactors except that instead of energizing the contactor with the TEST circuit the contactor must be held closed mechanically with a clamp or special fixture as shown in Figure 38 It is important that the contactor is held closed tightly with the armature against the magnet core...

Page 47: ...ctor a If too little force is required the mechanism must be moved away from the armature slightly toward the front of the contactor b If too great a force is required the mechanism must be moved toward the armature slightly toward the back of the contactor If adjustment is required the contactor must be clamped closed and repeat the set up procedure with thicker or thinner feeler gauges as requir...

Page 48: ...48 Rockwell Automation Publication 1502 UM060A EN P October 2020 Chapter 4 Maintenance Notes ...

Page 49: ...red to auxiliary input on the IntelliVAC control module Replace IntelliVAC control module Check adjustment of mechanical latch Only use approved Rockwell Automation control relay panels on relay controlled contactors Coil Burnout Coil leads improperly wired Faulty IntelliVAC control module 2 Improper set up of contactor auxiliary contact assembly 1 Control voltage too high 2 Check wiring from the ...

Page 50: ...50 Rockwell Automation Publication 1502 UM060A EN P October 2020 Chapter 5 Troubleshooting Notes ...

Page 51: ...art Figure 40 Bulletin 1502 450 A Electrically Held Vacuum Contactor Figure 41 Bulletin 1502 450 A Mechanical Latch Assembly Vacuum Bottles Coil Retaining Ring Auxiliary Actuator Plate Auxiliary Assembly Stop Bracket Bottle Clamp Armature Plate Auxiliary Assembly Return Spring Coil Mechanical Latch Trip Coil Latch Lever Assembly ...

Page 52: ... Electrically held contactor 4 6 80153 554 59 1 11 Electrically held contactor 4 7 80153 554 60 1 12 Auxiliary contact assemblies 5 120V relay controlled Mechanically latched contactor 4 80158 744 54 1 13 Not available 14 Auxiliary contact assemblies 5 IntelliVAC controlled Electrically held contactor 2 80158 743 52 1 15 Mechanically latched contactor 2 80158 744 52 1 16 Auxiliary contact plastic ...

Page 53: ...ontactor 10 handling 17 identification 11 inspection 36 maintenance 35 mounting 21 opening and closing times 14 rating label 11 specifications 13 storage 19 weight 15 CR1 9 current rating 13 D DC hi pot test 19 DC resistance 49 derating 15 description 7 diagrams schematic 24 wiring 24 dropout times 12 E electrical connections 22 electrical life 14 electrically held contactor operation 9 electromec...

Page 54: ...iving 17 relay control panel 1503C XXX 11 1503E CXXX 11 required tools 35 resistance values 49 retaining tabs 21 S schematic diagrams 24 series letter electrically held contactors 7 location 7 mechanical latch contactors 7 specifications 13 storage 19 switching frequency 14 T TCO 10 temperature storage 19 tools 35 torque requirements 35 trip coil 11 42 troubleshooting 49 V vacuum bottle arc shield...

Page 55: ...Rockwell Automation Publication 1502 UM060A EN P October 2020 55 Medium Voltage 450 A Contactor Series G User Manual ...

Page 56: ...ok auto knowledgebase Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Download firmware associated files such as AOP EDS and DTM and access product release notes rok auto pcdc ...

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