SQUARE O No Instruction Bulletin June · Medium voltage controllers are provided with many safety...

SQUARE O Bulletin No. 50006-316-01June, 1993

Raleigh, NC, U.S.A.Instruction BulletinMEDIUM 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

Two-Pole and Three-Pole Vacuum Contactor

© 1993 Square D All Rights Reserved

www.nationalswitchgear.com

Courtesy of NationalSwitchgear.com

Bulletin No. 50006-316-01June, 1993

DANGERHAZARDOUS 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.

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 bum.

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

1. Read this instmction 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.

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:

© 1993 Square D All Rights ReservedPage i



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

INTRODUCTIONGENERAL DESCRIPTIONUNCRATINGINSPECTION

Periodic InspectionCONTACTOR OPERATIONINSTALLATIONMAINTENANCE AND TESTING

CleaningContact Tip Gap MeasurementMagnet Coil ReplacementReactor/Rectifier Electrical Interlock ReplacementRectifier Testing and Replacement ProceduresReactor (choke) Testing and Replacement ProceduresElectrical Interlock Contact Block Replacement

CONTROL CIRCUIT RECEPTACLE REPLACEMENTARMATURE SPRING REPLACEMENTCONTACT SPRING REPLACEMENTMANUAL CONTACTOR OPERATIONCONDITION OF VACUUM INTERRUPTER ASSEMBLIESREPLACEMENT OF VACUUM INTERRUPTER ASSEMBLIES 9

Removing Existing Interrupter AssemblyPreparing New Interrupter AssemblyInstalling Interrupter AssemblyContact Tip Adjustment

TROUBLESHOOTING

11222333334456677888

910101214

Figure 1Figure 2Figure 3 Magnet Frame Hex Head ScrewFigure 4 Interlock Operator Tab and Control Flanges ..Figure 5 Adjustment LocationFigure 6 Electrical Interlock AssemblyFigure 7 Armature Spring AssemblyFigure 8 Interrupter Location and HardwareFigure 9 Interrupter AssemblyFigure 10 Interrupter Assembly and Hardware LocationFigure 11 Tip Pressure AdjustmentFigure 12 Gap AdjustmentFigure 13 Wiring DiagramFigure 14 Item Locations

V3540/V3740 Mechanically Latched ContactorAdjustment Nut and Pivot Plate

13456679101011121317

Table 1Table 2Table 3 Class 8110 Type V2540/V2740 & V3540/V3740 Parts List 16

Alternate TestingTroubleshooting Chart

514

© 1993 Square D All Rights Reserved Page ii




NOTES:

© 1993 Square D All Rights ReservedPage iii




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.

INTRODUCTION

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 controllersReduced voltage, autotransformer controllersWound 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.

GENERALDESCRIPTION

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 circuitsTransfer schemesApplications 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.

- © 1993 Square D All Rights Reserved Page 1




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 “INSPECTION”.However, some contactors (i.e. spare contactors) are shipped separately. In thesecases, 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 has notbeen damaged in transit. If shipping crate is damaged, pay particular attentionwhen unpacking to see if contents are also damaged. Notify carrier if damage isfound. Also, notify your local Square D sales office of damage.

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

UNCRATING

INSPECTION Proceed with the following check list:

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

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

3. Check to be sure that all connections are secure.

4. Inspect control circuit receptacle for possible damage.

A 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 properlyinstalled before energizing the contactor.

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

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

NOTEIf problem is found during inspection, repairs should be made immediately.

© 1993 Square D All Rights ReservedPage 2




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).

CONTACTOROPERATION

INSTALLATION 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.

MAINTENANCE ANDTESTING BSDANGER

HAZARDOUS VOLTAGE.All power should be disconnected from the controller equipment prior to per-forming any troubleshooting or maintenance work on the contactor.Electrical shock will cause severe injury or death.

Cleaning 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.

Contact Tip GapMeasurement

0.020

Figure 2 Adjustment Nut and Pivot Plate

Page 3© 1993 Square D All Rights Reserved




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.

Magnet CoilReplacement

Figure 3 Magnet Frame Hex Head Screw

Reactor/RectifierElectrical InterlockReplacement

BSDANGERHAZARDOUS VOLTAGE.Contactor control cable must be disconnected to prevent possible back-feeding of the control transformer and generation of hazardous voltage onthe primary side.Electrical shock will cause severe injury or death.

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.





Assembly Flanges

Operator Tab

Figure 4 Interlock Operator Tab and Control Flanges

Rectifier Testing &ReplacementProcedures

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 Rectifieroutput should be 108 ± 5 VDC if the supply voltage is 120 VAC. (Rectifier DC outputshould equal 90% of AC input ± 5.0 VDC). If rectifier is inoperative, replace with a newone.

An alternate test not requiring an AC power source can be made with an ohmmeterset on the 1000 ohm scale with probes connected to the rectifier terminals as fol-lows:

Table 1 Alternate Testing

Required Ohmic ValuePositive Probe Negative ProbeAC1 less than 100

infinityless than 100infinityinfinityinfinityless than 100less than 100

+

AC1AC2 +

AC2AC1+

AC2+

AC1AC2

Replacement procedure is as follows:

1. Identify and disconnect the four wires connected to the rectifier (item 50).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.





Check reactor resistance. DC resistance should be 11 ± 3 ohms. The normallyclosed contact, in parallel with the reactor must be isolated. Replace if resistance isnot 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 leads

to control contact block.

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

Reactor (choke)Testing andReplacementProcedures

To replace electrical interlock assembly remove the magnet coil (item 33). Refer to’’Magnet Coil Replacement” on page 4. Remove the two front hex head screws ( item 47,Figure 4 on page 5) to free electrical interlock assembly. Install electrical interlock assem-bly (item 55a) and magnet coil (item 33). Refer to Figure 14 on page 17 for explodedview. Loosen screw (item A in Figure 5) until loose enough to permit control assembly toslide back and forth. Place a .030" gage between armature (item 21) and magnet frame(item 35) . Energize contactor and adjust assembly (front/back direction) until coil currentdrops between .4 and .8 amperes, or when coil voltage is less than 18 VDC.

Electrical InterlockContact BlockReplacement

Adjustment Location

Before tightening screw (item A) ensure that operator tab is centered between con-trol assembly flanges (item C).

Figure 5

Control Contact Block

Figure 6 Electrical Interlock Assembly





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.

ACAUTIONEQUIPMENT DAMAGE HAZARD.Make sure, following any maintenance, that all connections are tight. Also, makesure vacuum interrupter assemblies are not damaged and are properly installedbefore energizing contactor.Failure to observe this precaution could result in personal injury, productdamage or property damage.

CONTROL CIRCUITRECEPTACLEREPLACEMENT

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.

ARMATURE SPRINGREPLACEMENT

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.

Armature Spring AssemblyFigure 7





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.

CONTACT SPRINGREPLACEMENT

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.

MANUAL CONTACTOROPERATION

CONDITION OF VACUUMINTERRUPTERASSEMBLIES

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.

ACAUTIONPOSSIBILITY 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.

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.





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 assemblyPreparing new interrupter assembly for installationInstalling interrupter assembly

REPLACEMENT OF VACUUMINTERRUPTER ASSEMBLIES

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.

Removing ExistingInterrupter Assembly

Figure 8 Interrupter Location and Hardware






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

Preparing NewInterrupter Assembly

A CAUTIONEQUIPMENT DAMAGE HAZARD.

Do not allow the shaft of the vacuuminterrupter assembly to turn. Turningthe shaft will damage the interrupter.Failure to observe this precautioncould result in personal injury,product damage or propertydamage.

Interrupter AssemblyFigure 9

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.

Installing InterrupterAssembly


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.

LLFigure 10 Interrupter Assembly and Hardware Location





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 turnnut 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 Aj = A - (.274").

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

R8DANGERHAZARDOUS VOLTAGE.

Voltage is present at coil terminals, rectifier and electrical interlocks, avoidcontact.Electrical shock will cause severe personal injury or death.

2

V/

AiA 2 1 2

36O

J

Figure 11 Tip Pressure Adjustment






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.

Contact TipAdjustment 1.

0.095"Gauge

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.

A CAUTIONEQUIPMENT DAMAGE HAZARD.• 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 notdamaged and are properly installed before energizing contactor.

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

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





NOTEMaximum 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.

BASIC CONTACTORin AUXILIARY

, CONTACTI BLOCKS

1 VACUUM CONTACTOR(2 OR 3 POLE)(3 POLE SHOWN)

r ~(3 POLE ONLY) CONTROLCONTACTBLOCK % -d 0-

CAPAClTOR -a D-t[

1A [2]

L1 L2 L3RECTIFIER 2

*&*I / > Iis-—w~6

o Q o(+)

3A

\ (-) 4 © © ©>0 )»(2)3>(3)M BLK »(4)

o o oCOIL REACTOR RECEPTACLEBLK

LATCHING CONTACTORAUXILIARY

, CONTACT| BLOCKS

[1]5 VACUUM CONTACTOR

(2 OR 3 POLE)(3 POLE SHOWN)

r_

CONTROLCONTACTBLOCK

D3rdRS 6 -aI1

(2)SOLENOID(IF USED)

L1 L2 L32 O o Q3A

i ib-—w—i

(+>(23)

>(24)> (5)> (6)> (1)> (2)> (3)> (4)

(-) © © ©4

3 RECTIFIER

COIL

o o o

Figure 13 Wiring Diagram





TROUBLESHOOTING ESDANGERHAZARDOUS VOLTAGE.

All power should be disconnected from the controller equipment beforeperforming any troubleshooting or maintenance work on the contactor.The equipment has been designed to permit maintenance and /or testing on thecontactor after it has been isolated from the main power.Electrical shock will cause severe personal injury or death.

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.

BSDANGERHAZARDOUS VOLTAGE.If separate control power is applied to the contactor by other means, the controlcable must be disconnected from contactor to prevent possible backfeeding ofthe control transformer and generation of hazardous voltage on the primaryside.Electrical shock will cause severe personal injury or death.

Table 2 Troubleshooting Chart

Problem Possible Causes Corrective ActionContactor does not close 1) Low control voltage 1) Check that voltage to control terminals 1 & 4

is 102 to120 VAC (refer to Figure 13 on page13). If control voltage is low, refer toTROUBLESHOOTING section of controllerservice bulletin.

2) Check that voltage at terminals 2 & 3 is zeroVDC (refer to Figure 13 on page 13). Ifvoltage is present, refer toTROUBLESHOOTING section of controllerservice bulletin.

3) Refer to Interlock Check section of controllerservice bulletin and check mechanicalinterlocks.

4) Refer to "Rectifier Testing & ReplacementProcedures" on page 5.

2) External control interlock open

3) Interference with mechanicalinterlocks

4) Control rectifier inoperative





Table 2 Troubleshooting Chart (Continued)

Possible Causes Corrective ActionProblem5) Operating coil inoperative6) Control electrical interlock

inoperative or out of adjustment

5) Refer to "Magnet Coil Replacement" on page 4.6) Refer to "Electrical Interlock Contact Block

Replacement" on page 6.Magnet/armature chatters 1) Low control voltage 1) Check that voltage to control terminals 1 & 4

is 102 to 120 VAC (refer to Figure 13 on page13). If control voltage is low, refer toTROUBLESHOOTING section of controllerservice bulletin.

2) Refer to "Electrical Interlock Contact BlockReplacement" on page 6.

3) Refer to "Reactor (choke) Testing andReplacement Procedures" on page 6.

4) Refer to "Magnet Coil Replacement" on page 4.

2) Control electrical interlock out ofadjustment

3) Reactor inoperative

4) Operating coil inoperativeSluggish contactoroperation

1) Low control voltage 1) Check that voltage to control terminals 1 & 4is 102 to 120 VAC (refer to Figure 13 on page13). If control voltage is low, refer toTROUBLESHOOTING section of controllerservice bulletin.

2) See “operating coil hot” below3) Refer to "MANUAL CONTACTOR

OPERATION" on page 8.4) Refer to "CONDITION OF VACUUM

INTERRUPTER ASSEMBLIES" on page 8and "REPLACEMENT OF VACUUMINTERRUPTER ASSEMBLIES" on page 9.

2) Operating coil hot3) Contactor moving parts binding

4) Vacuum interrupter assembly out ofadjustment or inoperative

Operating coil hot 1) Control electrical interlock out ofadjustment

2) Reactor inoperative

1) Refer to "Electrical Interlock Contact BlockReplacement" on page 6.

2) Refer to "Reactor (choke) Testing andReplacement Procedures" on page 6.

3) Refer to "Magnet Coil Replacement" on page 4.3) Operating coil inoperative1) Check contact spring. If broken, refer to

"CONTACT SPRING REPLACEMENT" onpage 8.

Vacuum interrupterassembly and/orassociated powerconnectors overheat

1) Contact spring inoperative

2) Loose connections3) Vacuum interrupter assembly

inoperative

2) Check and tighten as necessary.3) Refer to "CONDITION OF VACUUM

INTERRUPTER ASSEMBLIES" on page 8and "REPLACEMENT OF VACUUMINTERRUPTER ASSEMBLIES" on page 9.




Class 8110 Type V2540 and V3540 Vacuum Contactor Parts ListTable 3

13 =CD CD

~0 Item No. Part No. DescriptionItem No. Part No. Description c03CQ 3/8 Lock washer

1/4 - 20 X 3/4 Hex head screw1 0 - 2 4 H e x n u t5/1 6 - 1 8 X 2 1/2 Hex head screwControl assembly for basic contactor (includes items 49 - 54)Control assembly for mechanically latched contactor(includes items 49 - 54)Control assembly for mechanical latch w/ MTM wire (includesitems 50 - 54)Control assembly for mechanical latch w/ SIS wire (includesitems 50 - 54)ReactorRectifierReceptacleMale contact pinMOV assemblyControl contact blockN.O. Electrical interlock contact block assembly (includes9001 KA2 contact block, wire and male contact pins (item 53)N.C. Electrical interlock contact block assembly (includes9001 KA3 contact block, wire and male contact pins (item 53)#10 -24 X 1 1/2 Pan head screwCapacitorCapacitor bootCapacitor mounting bracketMechanical latch attachment (includes item 5, 6, 7, 17, 24, 32,61, 62, 63 & 65#10-24 X 1 1/8 Pan head screwSolenoid mounting bracketSpringArm bar1/4 - 20 X 7/8 Hex head screw3/16 X 1" Spring pinRoller angle assembly#8 -32 X 3/4 Hex head screw#8 -32 Lock nut w/ Nylon insert1/8 X 1 Large spring pin#10 - 24 X 3/8 Hex head screwShaftShaft mounting bracketLatch bar assembly (left)Latch bar assembly (right)Solenoid and plunger, 120 VACSolenoid and plunger, 125 VDCConnector Link10 -32 x 3/4 pan head screw1 0 - 3 2 hex nut, lockingVertical latch bar

04401 5/1 6 - 1 8 Jam nutGap adjustment nutLine bus (straight)Line bus (90° bend) For reduced voltage run or start contactor5/16 Spring washer5/16 Lock washer5/16 Plain washer1/4 - 20 Nylok nut1/4 Plain washerPivot plate#10 -32 X 1 hex head screwShaft insulator

CD0452 51034-036-01

51034-238-5051034-278-5023903-32002

13O) CD z046 CD3a

CO o0473b cno48a 51034-218-50

51034-218-514 oo48b05 03

06 co48c 51034-218-5223201-002007 03

08 o51034-218-5348d9 51034-038-01

O10 52911-064-5027907-3410125410-0373925410-0608951034-239-509001 KA551034-240-50

4911 51034-002-50

51034-219-5051034-219-5151034-225-50

5012a Mounting base

Mounting base w/ interlockMounting base w/o interlock (standard three- pole contactor)1/4 - 20 X 5/8 Hex head screw1/4 Lock washerBearing retainerContactor frame#10 Plain washer#1 0 - 3 2 Nylok nutBearing5/1 6 - 1 8 Nut assemblySpring cupContact springVacuum bottle assembly#10 Lockwasher1/4 - 28 X 3/4 Hex head screw5/1 6 - 1 8 X 1 1/4 Hex head screw5/1 6 - 1 8 X 1 Hex head screwArmature plate1/4 - 20 X 1 1/8 Hex head screwRoller angle assemblyMagnet core5/16 - 18 Hex nut

5112b 5212c 53

013 54014 55a

15 51034-035-0151034-001-50

co51034-240-5155bco 16co

017CO_Q 05618 23201-0017029002-5400023427-0220051034-039-0150502-601-4051034-293-50

cQ) 52904-021-50

52011-385-0129903-0397051034-292-67

5719CD 58U 2059> 216022Z

CD 23=r 0 61C/) 024 51034-317-01

MA10251034-316-01

62Z 025CD 63V)026CD 64< 027CD 0 65Q_

28 51034-232-01 0 66029 51034-298-5167

51034-298-5051034-230-01

30 0 6831 23201-00140

24209-0832169

032 7051034-306-5051020-041-0151034-229-0123201-2025122903-25480

Coil33 0 71Spring washerMagnet frame3/8 - 24 Hex jam nut3/8 - 24 X 1 1/2 Set screw3/8 - 1 6 X 1 1/4 Hex head screwC.C.C operatorArmature stopArmature springSpring bracketSpring guide

34 51034-319-0151034-318-0151034-314-5051034-314-5151034-324-0151034-324-0251034-075-01

7235 7336 7437 75

038 76a39 51034-231-01

51034-234-0150502-602-3151034-227-5051034-228-01

76b40 7741 0 7842 0 7943 80 51034-315-01

O Standard hardware, listed without a Square D part number, should be obtained from a local hardware supplier.




Figure 14 Item Locations





NOTES:




SQUARE O No Instruction Bulletin June · Medium voltage controllers are provided with many safety...

Documents

Transcript of SQUARE O No Instruction Bulletin June · Medium voltage controllers are provided with many safety...