bulletin no. 50006-316-01 instruction bulletin june e-manuals/square d... · tactors on full...

© 1993 Square D All Rights Reserved

Bulletin No. 50006-316-01June, 1993

Raleigh, NC, U.S.A.

MEDIUM VOLTAGE VACUUM CONTACTORType V2540 2-Pole and V3540 3-Pole (5000 V) Type V2740 2-Pole and V3740 3-Pole (7200 V)Class 8110, Model 3 – Series D

Instruction Bulletin

Two-Pole and Three-Pole Vacuum Contactor


Page i © 1993 Square D All Rights Reserved

Medium voltage controllers are provided with many safety features. However, theycontrol power circuits with high voltage and high fault capacity which can result ina risk of severe electrical shock or burn.

The following list of precautions must be studied and followed during installation,operation and servicing of the equipment.

1. Read this instruction bulletin prior to installing or operating the equipment.2. If motor controllers and/or contactors are to be stored prior to installation,

they must be protected from the weather and be kept free of condensationand dust.Storage temperature should be maintained between 0° F (-18° C) to 149°F (65° C) with humidity below 85%.

3. Use extreme care when moving or positioning contactors (even if crated)as they contain devices and mechanisms which may be damaged by roughhandling.

4. Be sure all barriers are in place before operating controllers.

HAZARDOUS VOLTAGE.

Power must be disconnected from the controller and contactor prior to per-forming any installation or maintenance.

Electrical shock will cause severe injury or death.

DANGER

Electrical equipment should be serviced only by qualified electrical maintenance personnel, and thisdocument should not be viewed as sufficient instruction for those who are not otherwise qualified tooperate, service or maintain the equipment discussed. Although reasonable care has been taken to pro-vide accurate and authoritative information in this document, no responsibility is assumed bySquare D for any consequences arising out of the use of this material.

PLEASE NOTE:

Bulletin No. 50006-316-01Table of Contents June, 1993

Page ii© 1993 Square D All Rights Reserved

INTRODUCTION .................................................................................... 1GENERAL DESCRIPTION..................................................................... 1UNCRATING........................................................................................... 2INSPECTION ........................................................................................... 2

Periodic Inspection ................................................................................ 2CONTACTOR OPERATION .................................................................. 3INSTALLATION ..................................................................................... 3MAINTENANCE AND TESTING.......................................................... 3

Cleaning ................................................................................................. 3Contact Tip Gap Measurement .............................................................. 3Magnet Coil Replacement ..................................................................... 4Reactor/Rectifier Electrical Interlock Replacement .............................. 4Rectifier Testing and Replacement Procedures ..................................... 5Reactor (choke) Testing and Replacement Procedures.......................... 6Electrical Interlock Contact Block Replacement................................... 6

CONTROL CIRCUIT RECEPTACLE REPLACEMENT ...................... 7ARMATURE SPRING REPLACEMENT............................................... 7CONTACT SPRING REPLACEMENT .................................................. 8MANUAL CONTACTOR OPERATION................................................ 8CONDITION OF VACUUM INTERRUPTER ASSEMBLIES.............. 8REPLACEMENT OF VACUUM INTERRUPTER ASSEMBLIES....... 9

Removing Existing Interrupter Assembly ............................................. 9Preparing New Interrupter Assembly .................................................... 10Installing Interrupter Assembly ............................................................. 10Contact Tip Adjustment ......................................................................... 12

TROUBLESHOOTING............................................................................ 14

Figure 1 V3540/V3740 Mechanically Latched Contactor ................... 1Figure 2 Adjustment Nut and Pivot Plate............................................. 3Figure 3 Magnet Frame Hex Head Screw............................................ 4Figure 4 Interlock Operator Tab and Control Flanges ......................... 5Figure 5 Adjustment Location.............................................................. 6Figure 6 Electrical Interlock Assembly................................................ 6Figure 7 Armature Spring Assembly ................................................... 7Figure 8 Interrupter Location and Hardware........................................ 9Figure 9 Interrupter Assembly ............................................................. 10Figure 10 Interrupter Assembly and Hardware Location....................... 10Figure 11 Tip Pressure Adjustment........................................................ 11Figure 12 Gap Adjustment ..................................................................... 12Figure 13 Wiring Diagram ..................................................................... 13Figure 14 Item Locations ....................................................................... 17

Table 1 Alternate Testing.................................................................... 5Table 2 Troubleshooting Chart ........................................................... 14Table 3 Class 8110 Type V2540/V2740 & V3540/V3740 Parts List 16

NOTES:


Page iii © 1993 Square D All Rights Reserved


INTRODUCTION

GENERAL DESCRIPTION

This manual covers the description, installation, operation and maintenance ofSquare D Class 8110 Type V2540/V2740 and V3540/V3740 vacuum contactors.These instructions apply primarily to contactors as used with controllers. For otherapplications contact your local Square D sales office.

The Class 8110 Type V3540/V3740 contactor is a three-pole device available only in abolted design. The V3540 is rated for 5000 V and the V3740 is rated for 7200 V. Both arerated at 360 A (enclosed), 60 KV BIL, with an interrupting rating of 7300 A symmetrical.

This basic contactor contains three vacuum interrupters, a DC operating coil with rectifiercircuit and auxiliary contacts. This contactor is used as the main (M) contactor on:

❏ Full voltage, non-reversing controllers❏ Reduced voltage, autotransformer controllers❏ Wound rotor motor controllers

The device is also used as the start (S) and run (R) contactors on reduced voltage, primaryreactor controllers.

Two contactors (two-pole or three-pole) can be mechanically interlocked in a horizontalarrangement by changing the slider mechanism of each contactor.

Three-pole mechanically interlocked devices are used as forward (F) and reverse (R) con-tactors on full voltage reversing controllers. Two-pole mechanically interlocked devicesare used as start (S) and run (R) contactors on reduced voltage autotransformer control-lers.

The Class 8110 Type V2540/V2740 contactor is a two-pole device similar to the TypeV3540/V3740 contactor but with two vacuum interrupters. Two-pole contactors are usedas the Start (S) and Run (R) contactor on reduced voltage, autotransformer controllers.

Figure 1 V3540/V3740 Mechanically Latched Contactor

A mechanical latching mechanism may be added to a basic contactor to lock the contactorclosed. An electrical release solenoid mounted on the left side of the coil is optional. TheClass 8110 Type V3540/V3740 mechanically latched contactor is used primarily for:

❏ Transformer feeder circuits❏ Transfer schemes❏ Applications where it is desirable to have the contactor remain closed,

should the voltage dip or fail.

The basic Type V3540/V3740 vacuum contactor assembly for Model 3 Series BClass 8198 and Class 8196 controllers are the same and can be interchanged withno modifications required.

Page 1© 1993 Square D All Rights Reserved


Page 2

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as notentionage is

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fer to

time. and

UNCRATING

INSPECTION

Periodic Inspection

.

When supplied for use with Class 8196 and Class 8198 controllers, the Class 8110contactor is shipped installed in the controller section. If the contactor is installedin the controller section, proceed with the steps outlined under “INSPECTIOHowever, some contactors (i.e. spare contactors) are shipped separately. Incases, the following steps should be taken.

1. Check packing list against the order to confirm that shipment is complete.2. Examine shipping crate before unpacking the contactor to make sure it h

been damaged in transit. If shipping crate is damaged, pay particular attwhen unpacking to see if contents are also damaged. Notify carrier if damfound. Also, notify your local Square D sales office of damage.

3. Take care when unpacking not to damage contents by inserting tools into Use a nail puller and wire cutter. Do not insert pry bar in crate to force ope

Proceed with the following check list:

1. Check the contactor visually for good condition. Inspect all parts for semounting and good electrical connections.

2. Check to be sure that the armature assembly operates freely. Re"MANUAL CONTACTOR OPERATION" on page 8.

3. Check to be sure that all connections are secure.4. Inspect control circuit receptacle for possible damage.

Periodic inspection and maintenance should be established to minimize downThe frequency will depend on the severity of operating conditions. Inspectionmaintenance is recommended once a year or every 20,000 operations.

CAUTIONPOSSIBLE EQUIPMENT MISALIGNMENT.

• Do not use contactor line bus to move or lift contactor. Lifting by bus may cause misalignment.

• Make sure, following any inspection, that all connections are tight. Also, make sure vacuum interrupter assemblies are not damaged and are properly installed before energizing the contactor.

Failure to observe this precaution could result in personal injury, product damage or property damage.

If problem is found during inspection, repairs should be made immediately

NOTE



CONTACTOR OPERATION

INSTALLATION

MAINTENANCE AND TESTING

Cleaning

Contact Tip Gap Measurement

For maintenance or test purposes the contactor can be operated either manually, perinstructions listed in "MANUAL CONTACTOR OPERATION" on page 8, or elec-trically by connecting a separate 120 VAC source of control power to the contactorthrough use of a contactor test cord (Square D part number 51034-241-50).

Check that the contactor nameplate information (class, type and form) matchescontactor information on label located inside of controller compartment door.

Follow contactor installation instructions, which are found in the controller servicebulletin.

Clean all dirt from the contactor. Pay particular attention to molded parts and track-ing surfaces. Foreign materials on these surfaces should be removed.

The contact tip gap measurement must be taken with the contactor fully closed. Thearmature plate must be positioned against the magnet frame for the contactor to befully closed. Refer to "MANUAL CONTACTOR OPERATION" on page 8.

Measure gap from bottom of gap adjustment nut (item 2) to the top of metal pivotplate (item 9). Refer to Figure 2 for item locations. Do not change adjustment ofnut. This measurement must be 0.020" minimum. If measurement is less than0.020", the contact tips have worn beyond acceptable tolerances and a new inter-rupter assembly is required.

Figure 2 Adjustment Nut and Pivot Plate

HAZARDOUS VOLTAGE.

All power should be disconnected from the controller equipment prior to per-forming any troubleshooting or maintenance work on the contactor.


DANGER



Page 4

Magnet Coil Replacement

Reactor/Rectifier Electrical Interlock Replacement

Coil resistance may be measured to determine if the coil is inoperative. Under nor-mal operating conditions, the coil resistance will vary from 12 to 16 ohms. If thecoil measures open or less than 12 ohms, it is inoperative and must be replaced. Ifcoil resistance exceeds 16 ohms and the coil is hot, overheating is indicated. Referto "Troubleshooting Chart" on page 14 for possible cause and corrective action.

To remove magnet coil (item 33), disconnect coil wires from the coil. Loosen ca-pacitor mounting bracket hardware (item 59) and swing capacitor (item 57) out ofcontactor molding. Remove hex head screw (item 38) from magnet frame and slidemagnet assembly to the left for removal of coil. Do not remove spring washer(item 34) from core. Install new coil (item 33) on magnet core (item 31) and rein-stall magnet assembly to contactor. Reattach coil wires, then reinstall capacitor. Re-fer to Figure 14 on page 17 for exploded view of item locations.

Figure 3 Magnet Frame Hex Head Screw

To replace these components, the contactor control assembly must be removed. Ac-cess to the control assembly mounting hardware is achieved after removing themagnet assembly. Refer to Magnet Coil Replacement on this page.

Remove hex head screws (item 47) and remove control assembly (item 48) fromcontactor. After servicing assembly, reinstall contactor control assembly. Beforetightening hex head screws (item 47), ensure that operator tab is centered betweencontrol assembly flanges. Refer to Figure 4 on next page for item locations. Referto "Electrical Interlock Contact Block Replacement" on page 6 for adjustment.

HAZARDOUS VOLTAGE.

Contactor control cable must be disconnected to prevent possible back-feeding of the control transformer and generation of hazardous voltage onthe primary side.


DANGER



tifiertputnew

meters fol-

50).

Rectifier Testing & Replacement Procedures

Figure 4 Interlock Operator Tab and Control Flanges

Rectifier output can be measured to determine an inoperative device. For this test, usetape to insulate bare ends of coil connecting leads. With contactor control assembly re-moved from contactor, apply 120 VAC to control terminals one and four. Refer to Fig-ure 13 on page 13. Measure DC output across rectifier terminals “+” and “-”. Recoutput should be 108 ± 5 VDC if the supply voltage is 120 VAC. (Rectifier DC oushould equal 90% of AC input ± 5.0 VDC). If rectifier is inoperative, replace with a one.

An alternate test not requiring an AC power source can be made with an ohmset on the 1000 ohm scale with probes connected to the rectifier terminals alows:

Replacement procedure is as follows:

1. Identify and disconnect the four wires connected to the rectifier (item 2. Remove screw in center of rectifier and remove rectifier.3. Mount new rectifier with screw.4. Reattach wires, noting their identification and connection points.

Refer to Figure 14 on page 17 for exploded view of item locations.

Table 1 Alternate Testing

Positive Probe Negative Probe Required Ohmic Value

AC1 + less than 100

AC1 - infinity

AC2 + less than 100

AC2 - infinity

+ AC1 infinity

+ AC2 infinity

- AC1 less than 100

- AC2 less than 100



Page 6

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fer tom 47,

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Reactor (choke) Testing and Replacement Procedures

Electrical Interlock Contact Block Replacement

Check reactor resistance. DC resistance should be 11 ± 3 ohms. The noclosed contact, in parallel with the reactor must be isolated. Replace if resistanot within these values.

Replacement procedures are as follows:

1. Disconnect reactor leads from control contact block (item 54).2. Remove the two mounting screws and remove reactor.3. Mount new reactor with the two mounting screws, attaching reactor le

to control contact block.

Refer to Figure 14 on page 17 for exploded view of item locations.

To replace electrical interlock assembly remove the magnet coil (item 33). Re"Magnet Coil Replacement" on page 4. Remove the two front hex head screws ( iteFigure 4 on page 5) to free electrical interlock assembly. Install electrical interlock ably (item 55a) and magnet coil (item 33). Refer to Figure 14 on page 17 for expview. Loosen screw (item A in Figure 5) until loose enough to permit control assemslide back and forth. Place a .030" gage between armature (item 21) and magne(item 35) . Energize contactor and adjust assembly (front/back direction) until coil cudrops between .4 and .8 amperes, or when coil voltage is less than 18 VDC.

Figure 5 Adjustment Location

Before tightening screw (item A) ensure that operator tab is centered betweentrol assembly flanges (item C).

Figure 6 Electrical Interlock Assembly



CONTROL CIRCUIT RECEPTACLE REPLACEMENT

ARMATURE SPRING REPLACEMENT

Make sure that coil current and voltage is still as described above and that all N.O.control contacts are closed and choke N.C. contacts are open. De-energize contac-tor and remove the .030" gauge. Place a .085" gauge between armature and magnetframe. Energize contactor. All power contacts (vacuum interrupter) must be closed,all N.C. control contacts must open and all N.O. control contacts must remain open.De-energize contactor and remove the .085 gauge.

Individual contact blocks may be replaced as required with the assembly mountedto the contactor. Disconnect control wires from the contact block and unfastenblock mounting screw. Replace block and connect control wires. After the controlcontact block is replaced, assembly adjustment is not required. To check adjust-ment follow steps described under control assembly replacement.

The receptacle for the control circuit plug consists of a plug housing and male contactpins with wire leads inserted from the rear. An extraction tool (Square D Part Number29904-08400) is required for pin removal. This tool, inserted into the receptacle fromthe front, compresses the retention springs allowing the lead and pin to be withdrawnfrom the plug housing.

The complete receptacle can be removed from the contactor control module by removinghardware (Refer to item D, Figure 6 on page 6) and sliding receptacle out of mounting slot.

Before removing armature spring (item 41), evenly loosen hex head screws (item 47) and al-low spring bracket (item 42) to release spring pressure. Remove hex head screws (item 47),spring guide (item 43) and armature spring (item 41) without disturbing spring guide hex headscrew (item 27). Refer to Figure 14 on page 17 for exploded view of item locations.

Figure 7 Armature Spring Assembly

CAUTIONEQUIPMENT DAMAGE HAZARD.

Make sure, following any maintenance, that all connections are tight. Also, make sure vacuum interrupter assemblies are not damaged and are properly installed before energizing contactor.




Page 8

CONTACT SPRING REPLACEMENT

MANUAL CONTACTOR OPERATION

CONDITION OF VACUUM INTERRUPTER ASSEMBLIES

To reinstall armature spring, seat the armature spring on the spring guide locatedon the armature extension (item E). Position front spring guide onto armaturespring and fasten the spring guide to the spring bracket by evenly tightening hexhead screws (item 47).

The vacuum interrupter assembly must be removed from the contactor to replacethe contact spring (item 22, Figure 14 on page 17). Refer to "Removing ExistingInterrupter Assembly" on page 9. Prior to removing the vacuum interrupter as-sembly, the contact tip gap measurement must be recorded for use when rein-stalling the interrupter. Refer to "Contact Tip Gap Measurement" on page 3.

Reinstallation of the vacuum interrupter assembly is referred to in "Installing Inter-rupter Assembly" on page 10. Follow these instructions and ensure that the contacttip gap measurement is adjusted to the value recorded prior to vacuum interrupter as-sembly removal. This ensures accuracy of future contact tip wear measurements.

To operate the contactor manually, the armature spring must be removed. Refer to "AR-MATURE SPRING REPLACEMENT" on page 7. With the armature spring removed,the contacts are closed but the armature is not sealed against the magnet frame.

To fully close the contactor and seal the armature, avoid the threaded shaft of thevacuum interrupters and push down on the contactor shaft insulator (refer to item11, Figure 14 on page 17). Approximately 20 pounds of force is required. Reinstallarmature spring before proceeding.

If contactor has been exposed to fault conditions as indicated by blown motor fuses,the following checks must be made for the vacuum interrupter assemblies.

1. Physical evidence of stress (distorted, discolored, or cracked interrupters).2. Contact wear measurement (Refer to "Contact Tip Gap Measurement" on page 3).3. Dielectric voltage withstand test.

Remove contactor from controller to perform the inspections and tests.

The dielectric voltage withstand strength of each vacuum interrupter should bechecked. Each 5 kV rated interrupter is tested by the factory at 15.9 kV rms, 60 Hzfor one second. Repeat tests should be at 10.0 kV, 60 Hz for 60 seconds or 12 kVrms, 60 Hz for one second. Each 7.2 kV rated interrupter is tested by the factory at18.2 kV for one second. Repeat tests should be at 14.4 kV for 60 seconds or 16.4kV rms, 60 Hz for one second.

CAUTIONPOSSIBILITY OF X-RAY EXPOSURE.

This device may emit x-rays if voltage higher than rated maximum is appliedacross the open contacts or if contacts are spaced less than rated stroke.

In such a case, personnel must be protected with appropriate shielding.

Exposure to x-rays can cause injury.



REPLACEMENT OF VACUUM INTERRUPTER ASSEMBLIES

Removing Existing Interrupter Assembly

If unit fails the test, replace interrupter assembly with a new unit.

It is unlikely, but possible to have some loss of vacuum which might seriously dam-age the ability of the interrupter to interrupt the circuit. This condition may go un-noticed in a three-phase, ungrounded circuit, since it is possible for any two goodinterrupters to successfully interrupt the circuit. To guard against this condition, pe-riodic dielectric tests across open contacts are desirable. The interval between pe-riodic tests depends on the number of operations per day, environmental factors andexperience.

Three major operations are required to replace a vacuum interrupter assembly.

❏ Removing existing interrupter assembly

❏ Preparing new interrupter assembly for installation

❏ Installing interrupter assembly

Refer to Figure 8 for item locations:

1. Prior to removing vacuum interrupter assembly, the contact tip gapmeasurement must be recorded for use when reinstalling the interrupter.Refer to "Contact Tip Gap Measurement" on page 3.

2. Remove hex nut (item 20) and spring washer (item 4) holding flexibleshunt to the contactor line bus. Do not remove the bolt holding the shuntto the interrupter assembly.

3. Remove bottom cap screw (item 27) and two washers (item 5 & 6) holdingvacuum interrupter assembly to the contactor.

4. Remove the jam nut (item 1) and gap adjustment nut (item 2) from the topof the interrupter assembly.

5. Lift up on the vacuum interrupter assembly. To remove it from the contac-tor, pull out then down on the bottom portion of the interrupter assembly.

Figure 8 Interrupter Location and Hardware



Page 10

Preparing New Interrupter Assembly

Installing Interrupter Assembly


1. Remove cap screw (item 27) and washers (item 5 & 6) from the bottom ofthe interrupter assembly.

Figure 9 Interrupter Assembly

2. Remove the jam nut (item 1) and gap adjustment nut (item 2) from top ofinterrupter assembly.

3. Do not remove contact spring (item 22) and spring cup (item 21) from theinterrupter assembly.

4. Interrupter assembly is now ready to install in contactor.


1. Tilt top of interrupter assembly toward contactor frame (item 16) and gen-tly rotate interrupter assembly to one side. Do not rotate shaft of interrupterassembly. Place interrupter assembly (item 23) into contactor by puttingtop of interrupter assembly behind the line bus (item 3). Seat spring cup(item 21) in recess at top of contactor.

Figure 10 Interrupter Assembly and Hardware Location


Do not allow the shaft of the vacuum interrupter assembly to turn. Turning the shaft will damage the interrupter.




2. Place bottom of the interrupter assembly into contactor.3. Gently rotate complete assembly until the flexible shunt lines up with the

contactor line bus. Do not rotate shaft of interrupter assembly.4. Install spring washer (item 4) and hex nut (item 20) connecting shunt to

line bus. 5. Install cap screw (item 27) and two washers (items 5 & 6) to bottom of in-

terrupter assembly. 6. Install gap adjustment nut (item 2) on top of interrupter assembly and turn

nut until it rests about halfway down the shaft. Install jam nut (item 1) untilit rests above the adjusting nut, but not touching the adjusting nut.

7. With contacter de-energized, turn hex nut (item 36) until contact spring(item 22) is firmly seated between spring cups (item 21) but not com-pressed. Measure distance (A) between spring cups (refer to Figure 11).Energize contacts, turn hex nut (item 36) counter clockwise until distancebetween spring cups (item 21) is equal to A1 = A - (.274").

8. Close contactor by energizing main coil with contactor test cord (Square Dpart number 51034-241-50).

Figure 11 Tip Pressure Adjustment

HAZARDOUS VOLTAGE.

Voltage is present at coil terminals, rectifier and electrical interlocks, avoid contact.

Electrical shock will cause severe personal injury or death.

DANGER



Page 12

Contact Tip Adjustment


1. Upon replacing a new interrupter assembly, place a 0.095" gauge between con-tactor pivot plate (item 9) and gap adjustment nut (item 2).For reinstallation of a used interrupter assembly, ensure that the contact tipgap measurement is adjusted to the value recorded prior to removal.

Figure 12 Gap Adjustment

2. Tighten gap adjustment nut until it touches the gauge. Do not tighten ortorque down this nut.

3. Hold gap adjustment nut with a wrench. Do not allow the nut and shaftto rotate. Tighten jam nut (item 1) down on gap adjustment nut.

4. Remove gauge.

For reinstallation of a used interrupter, adjust gap nut (item 2) to produce a gapequal to the one recorded before removing interrupter assembly.

5. Open contactor by de-energizing main coil.6. Do not make adjustments to interrupter assemblies that have not been changed.7. It is recommended that the condition of vacuum interrupter assemblies be

checked. Refer to "CONDITION OF VACUUM INTERRUPTER ASSEM-BLIES" on page 8.


• Do not allow shaft of the vacuum interrupter assembly to turn. Turning the shaft will damage the interrupter.

• Make sure, following any maintenance, that all connections are tight. Also, make sure vacuum interrupter assemblies are not damaged and are properly installed before energizing contactor.




Maximum of eight auxiliary contact blocks may be installed.

Pin & wire numbers are assigned by the following rule:• N.O. blocks use pairs of consecutive, ascending numbers starting with #7.• N.C. blocks use pairs of consecutive, descending numbers starting with #24.

See controller W/D for auxiliary contact block configuration.

NOTE

Figure 13 Wiring Diagram



Page 14

Problem Poss

Contactor does not close 1) Lo

2) Ex

3) Inint

4) Co

TROUBLESHOOTING

Since many operating problems are traced to loose circuit connections, the controlcircuit receptacle and wiring should be inspected before proceeding.

If a separate source of 120 VAC control power is available, troubleshooting can beperformed using either the contactor control circuit receptacle and a contactor testcord (Square D part number 51034-241-50) or the controller service plug suppliedon some controllers (refer to controller service bulletin). When either is used, thecontrol transformer is disconnected from the control voltage..

Table 2 Troubleshooting Chart

ible Causes Corrective Action

w control voltage 1) Check that voltage to control terminals 1 & 4 is 102 to120 VAC (refer to Figure 13 on page 13). If control voltage is low, refer to TROUBLESHOOTING section of controller service bulletin.

ternal control interlock open 2) Check that voltage at terminals 2 & 3 is zero VDC (refer to Figure 13 on page 13). If voltage is present, refer to TROUBLESHOOTING section of controller service bulletin.

terference with mechanical erlocks

3) Refer to Interlock Check section of controller service bulletin and check mechanical interlocks.

ntrol rectifier inoperative 4) Refer to "Rectifier Testing & Replacement Procedures" on page 5.

HAZARDOUS VOLTAGE.

All power should be disconnected from the controller equipment before performing any troubleshooting or maintenance work on the contactor.

The equipment has been designed to permit maintenance and /or testing on the contactor after it has been isolated from the main power.


DANGER

HAZARDOUS VOLTAGE.

If separate control power is applied to the contactor by other means, the control cable must be disconnected from contactor to prevent possible backfeeding of the control transformer and generation of hazardous voltage on the primary side.


DANGER



5) Op

6) Coino

Magnet/armature chatters 1) Lo

2) Coad

3) Re

4) Op

Sluggish contactor operation

1) Lo

2) Op

3) Co

4) Vaad

Operating coil hot 1) Coad

2) Re

3) Op

Vacuum interrupter assembly and/or associated power connectors overheat

1) Co

2) Lo

3) Vain

Problem Poss

erating coil inoperative 5) Refer to "Magnet Coil Replacement" on page 4.

ntrol electrical interlock perative or out of adjustment

6) Refer to "Electrical Interlock Contact Block Replacement" on page 6.

w control voltage 1) Check that voltage to control terminals 1 & 4 is 102 to 120 VAC (refer to Figure 13 on page 13). If control voltage is low, refer to TROUBLESHOOTING section of controller service bulletin.

ntrol electrical interlock out of justment


actor inoperative 3) Refer to "Reactor (choke) Testing and Replacement Procedures" on page 6.


w control voltage 1) Check that voltage to control terminals 1 & 4 is 102 to 120 VAC (refer to Figure 13 on page 13). If control voltage is low, refer to TROUBLESHOOTING section of controller service bulletin.

erating coil hot 2) See “operating coil hot” below

ntactor moving parts binding 3) Refer to "MANUAL CONTACTOR OPERATION" on page 8.

cuum interrupter assembly out of justment or inoperative

4) Refer to "CONDITION OF VACUUM INTERRUPTER ASSEMBLIES" on page 8 and "REPLACEMENT OF VACUUM INTERRUPTER ASSEMBLIES" on page 9.

ntrol electrical interlock out of justment


actor inoperative 2) Refer to "Reactor (choke) Testing and Replacement Procedures" on page 6.


ntact spring inoperative 1) Check contact spring. If broken, refer to "CONTACT SPRING REPLACEMENT" on page 8.

ose connections 2) Check and tighten as necessary.

cuum interrupter assembly operative

3) Refer to "CONDITION OF VACUUM INTERRUPTER ASSEMBLIES" on page 8 and "REPLACEMENT OF VACUUM INTERRUPTER ASSEMBLIES" on page 9.

Table 2 Troubleshooting Chart (Continued)

ible Causes Corrective Action



or

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or

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ctor

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ms

49 -

54)

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art

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nd V

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uum

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or P

arts

Lis

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Item

No

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art

No

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escr

ipti

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➊1

5/16

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8 Ja

m n

ut2

5103

4-03

6-01

Gap

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ustm

ent n

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5103

4-23

8-50

Line

bus

(st

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3b51

034-

278-

50Li

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For

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uced

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25/

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55/

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Pla

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200

1/4

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ount

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g ba

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e➊

131/

4 -

20 X

5/8

Hex

hea

d sc

rew

➊14

1/4

Lock

was

her

1551

034-

035-

01B

earin

g re

tain

er16

5103

4-00

1-50

Con

tact

or fr

ame

➊17

#10

Pla

in w

ashe

r18

2320

1-00

170

#10

- 32

Nyl

ok n

ut19

2900

2-54

000

Bea

ring

2

023

427-

0220

05/

16 -

18

Nut

ass

embl

y

2151

034-

039-

01S

prin

g cu

p22

5050

2-60

1-40

Con

tact

spr

ing

2351

034-

293-

50V

acuu

m b

ottle

ass

embl

y➊

24#1

0 Lo

ckw

ashe

r➊

251/

4 -

28 X

3/4

Hex

hea

d sc

rew

➊26

5/16

- 1

8 X

1 1

/4 H

ex h

ead

scre

w➊

275/

16 -

18

X 1

Hex

hea

d sc

rew

2851

034-

232-

01A

rmat

ure

plat

e➊

291/

4 -

20 X

1 1

/8 H

ex h

ead

scre

w30

5103

4-29

8-50

Rol

ler

angl

e as

sem

bly

3151

034-

230-

01M

agne

t cor

e➊

325/

16 -

18

Hex

nut

3351

034-

306-

50C

oil

3451

020-

041-

01S

prin

g w

ashe

r35

5103

4-22

9-01

Mag

net f

ram

e36

2320

1-20

251

3/8

- 24

Hex

jam

nut

37

2290

3-25

480

3/8

- 24

X 1

1/2

Set

scr

ew➊

383/

8 -

16 X

1 1

/4 H

ex h

ead

scre

w39

5103

4-23

1-01

C.C

.C o

pera

tor

4051

034-

234-

01A

rmat

ure

stop

4150

502-

602-

31A

rmat

ure

sprin

g42

5103

4-22

7-50

Spr

ing

brac

ket

4351

034-

228-

01S

prin

g gu

ide

➊ S

tand

ard

hard

war

e, li

sted

with

out a

Squ

are

D p

art n

umbe

r, sh

ould

be

o

➊44

3/8

Lock

was

her

➊45

1/4

- 20

X 3

/4 H

ex h

ead

scre

w➊

4610

- 2

4 H

ex n

ut➊

475/

16 -

18

X 2

1/2

Hex

hea

d sc

rew

48a

5103

4-21

8-50

Con

trol

ass

embl

y fo

r ba

sic

cont

acto

r (in

clud

es it

e48

b51

034-

218-

51C

ontr

ol a

ssem

bly

for

mec

hani

cally

latc

hed

cont

ac(in

clud

es it

ems

49 -

54)

48c

5103

4-21

8-52

Con

trol

ass

embl

y fo

r m

echa

nica

l lat

ch w

/ MT

M w

irite

ms

50 -

54)

48d

5103

4-21

8-53

Con

trol

ass

embl

y fo

r m

echa

nica

l lat

ch w

/ SIS

wire

item

s 50

- 5

4)49

5291

1-06

4-50

Rea

ctor

5027

907-

3410

1R

ectif

ier

5125

410-

0373

9R

ecep

tacl

e52

2541

0-06

089

Mal

e co

ntac

t pin

5351

034-

239-

50M

OV

ass

embl

y54

9001

KA

5C

ontr

ol c

onta

ct b

lock

55a

5103

4-24

0-50

N.O

. Ele

ctric

al in

terlo

ck c

onta

ct b

lock

ass

embl

y (i

9001

KA

2 co

ntac

t blo

ck, w

ire a

nd m

ale

cont

act p

in55

b51

034-

240-

51N

.C. E

lect

rical

inte

rlock

con

tact

blo

ck a

ssem

bly

(i90

01 K

A3

cont

act b

lock

, wire

and

mal

e co

ntac

t pin

➊56

#10

-24

X 1

1/2

Pan

hea

d sc

rew

5752

904-

021-

50C

apac

itor

5852

011-

385-

01C

apac

itor

boot

5929

903-

0397

0C

apac

itor

mou

ntin

g br

acke

t60

5103

4-29

2-67

Mec

hani

cal l

atch

atta

chm

ent (

incl

udes

item

5, 6

, 7,

61, 6

2, 6

3 &

65

➊ 6

1#1

0-24

X 1

1/8

Pan

hea

d sc

rew

6251

034-

317-

01S

olen

oid

mou

ntin

g br

acke

t63

MA

102

Spr

ing

6451

034-

316-

01A

rm b

ar➊

65

1/4

- 20

X 7

/8 H

ex h

ead

scre

w➊

66

3/16

X 1

" S

prin

g pi

n67

5103

4-29

8-51

Rol

ler

angl

e as

sem

bly

➊ 6

8#8

-32

X 3

/4 H

ex h

ead

scre

w69

2320

1-00

140

#8 -

32 L

ock

nut w

/ Nyl

on in

sert

7024

209-

0832

11/

8 X

1 L

arge

spr

ing

pin

➊ 7

1#1

0 -

24 X

3/8

Hex

hea

d sc

rew

7251

034-

319-

01S

haft

7351

034-

318-

01S

haft

mou

ntin

g br

acke

t74

5103

4-31

4-50

Latc

h ba

r as

sem

bly

(left)

7551

034-

314-

51La

tch

bar

asse

mbl

y (

right

)76

a51

034-

324-

01S

olen

oid

and

plun

ger,

120

VA

C76

b51

034-

324-

02S

olen

oid

and

plun

ger,

125

VD

C77

5103

4-07

5-01

Con

nect

or L

ink

➊ 7

810

-32

x 3

/4 p

an h

ead

scre

w➊

79

10 -

32

hex

nut,

lock

ing

8051

034-

315-

01V

ertic

al la

tch

bar

l har

dwar

e su

pplie

r.

Page 16 © 1993 Square D All Rights Reserved


Figure 14 Item Locations

17

24

46

81

42

5

6 5

27

58

57

59

56

16

10

1 2 9

78

20 4

32

1

22

21 6 36 23

6 5 32

17

18

19

8 14

13

47

56

48

49

50

53

71

43

0

27

43

27

47

56

32

325

65

38

44

35

42

33

47

6

12

34

31

32

56

41

36

45

37

29

8

29828

39

81

41

3

51

52

7 81

31

4

8 15

11

55

54

40

Lat

chin

g M

ech

anis

m



Page 18

NOTES:



NOTES:


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