ATTENTION: To prevent electrical shock, disconnect from power source before installing or servicing. If coil failure is suspected, check that secondary damage has not occurred that will render the contactor non-repairable.

42052-091G. Ushakow

N/A

N/A

N/A42052

10064901

INSTRUCTION SHEETBULLETIN 1102C 400A/600A VACUUM CONTACTOR

AC COIL REPLACEMENT

2-19-04

Mark Jutz 2-19-04

D. Josef 2-19-04

1 4

42052-104

REVISION AUTHORIZATION

DIMENSIONS APPLY BEFORESURFACE TREATMENT

H

A

B

C

D

E

F

G

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

REFERENCE

SHEET OFDWG.

B

DR.

CHKD.

APPD.

DATE

DATE

DATE±

±

±

ANGLES:

.XXX:

.XX:

THIS DRAWING IS THE PROPERTY OF THE ALLEN-BRADLEY CO. INC.

AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT

AS AUTHORIZED IN WRITING BY THE ALLEN-BRADLEY CO. INC.

LOCATION : MILWAUKEE, WISCONSIN U.S.A.

SIZE

1 2 3 4 5 6 7 8

E - DOC

Bulletin 1102C 400A / 600A Vacuum Contactor AC Coil Replacement Instructions(Cat 1102C-PK4D, -PK4A, -PK4N, -PK4B, 1102C-PK6D, -PK6A, -PK6N, -PK6B)

Coil Replacement

CoverCover

Auxiliary

Coil Leads

Control-Pak

RemoveCoil WireLeads from Control-Pak Remove

Coil WireLeads from

Auxiliary

VACUUM CONTACTOR

VACUUM CONTACTOR

1. Disconnect all power cables (or bus work) and all control wiring to the contactor.

2. Remove the contactor from its mounted location. The contactor is best serviced in the tabletop position.

3. Disconnect the coil wire leads from the Control-Pak or Auxiliary (Figure 2B).

4. Remove the cover attachment hardware from the contactor and remove the cover (Figure 1).

5. Remove the Control-Pak from the contactor by first rotating the retainer to release the top of the Control-Pak. Then pull out the top of the Control-Pak (the tab must clear the notch) and then push Control-Pak slightly downward to release lower tab that holds the Control-Pak to the housing (Figures 2A & 2B).

Note: The following instructions pertaining to the removal and reinstallation of the Control-Pak are applicable to the Auxiliary

Figure 2A Figure 2B

400AFigure 1

600A

VACUUM CONTACTOR

Control-Pak

This tab must clear notch priorto pushingControl-Pak downward.

Rotate retainer torelease Control-Pak

42052-091G. Ushakow

N/A

N/A

N/A42052

10064901

INSTRUCTION SHEETBULLETIN 1102C 400A/600A VACUUM CONTACTOR

AC COIL REPLACEMENT

2-19-04

Mark Jutz 2-19-04

D. Josef 2-19-04

2 4

REVISION AUTHORIZATION

DIMENSIONS APPLY BEFORESURFACE TREATMENT

H

A

B

C

D

E

F

G

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

REFERENCE

SHEET OFDWG.

B

DR.

CHKD.

APPD.

DATE

DATE

DATE±

±

±

ANGLES:

.XXX:

.XX:

THIS DRAWING IS THE PROPERTY OF THE ALLEN-BRADLEY CO. INC.

AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT

AS AUTHORIZED IN WRITING BY THE ALLEN-BRADLEY CO. INC.

LOCATION : MILWAUKEE, WISCONSIN U.S.A.

SIZE

1 2 3 4 5 6 7 8

E - DOC

Coil Replacement (Cont'd)

6. While supporting the Main Housing, remove the Main Housing from the Baseplate by removing the (4) screws which hold the housing to the Baseplate. A long philips-head screwdriver (6 inch or longer) is needed as the four screws are in deep wells (holes) in the Main Housing. Remove the shorter screws first. Separate the main housing assembly from the Baseplate and set it aside (Figure 3).

7. Remove the Return Springs and set them aside (Figure 3). Turn the Base Assembly over and remove the (4) screws that secure the Coil Assembly to the Baseplate (Figure 4).

8. Install new Coil Assembly in position using (4) screws (torque to 30 - 45 lb-inches). Replace the Return Springs by placing them over the spring support pins located within the coil magnet core assembly making sure the return springs are properly seated and not interfering with any of the control wiring (Figure 3).

9. Carefully replace the Main Housing assembly loosely, making sure it is orientated correctly. Ensure that no wires are pinched between housing and baseplate. Carefully locate the magnetic armature poles (the poles sticking down from the upper housing assembly) into the coil magnet core assembly. Note: This is a blind operation with careful side to side motion. Pay close attention to alignment of the locating bosses located at the bottom of the main housing assembly. To reattach the Main Housing assembly insert the main housing locating bosses into the two mounting plate holes while compressing the return springs with the Main Housing. Start the four Main Housing screws into the mounting plate. Tighten the mounting screws equally in a diagonal pattern approximately two turns at a time until torqued to 28 lb-inches in the same diagonal pattern.

Figure 3 Figure 4

MainHousing

CoilAssembly

Baseplate

ReturnSprings

(2)

42052-091G. Ushakow

N/A

N/A

N/A42052

10064901

INSTRUCTION SHEETBULLETIN 1102C 400A/600A VACUUM CONTACTOR

AC COIL REPLACEMENT

2-17-04

Mark Jutz 2-17-04

D. Josef 2-17-04

3 4

REVISION AUTHORIZATION

DIMENSIONS APPLY BEFORESURFACE TREATMENT

H

A

B

C

D

E

F

G

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

REFERENCE

SHEET OFDWG.

B

DR.

CHKD.

APPD.

DATE

DATE

DATE±

±

±

ANGLES:

.XXX:

.XX:

THIS DRAWING IS THE PROPERTY OF THE ALLEN-BRADLEY CO. INC.

AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT

AS AUTHORIZED IN WRITING BY THE ALLEN-BRADLEY CO. INC.

LOCATION : MILWAUKEE, WISCONSIN U.S.A.

SIZE

1 2 3 4 5 6 7 8

E - DOC

Coil Replacement (Cont'd)

10. Re-install the Control-Pak or Auxiliary (Figures 5A & 5B). First, rotate the Retainer upwards. Next, insert the lower tab on the edge of the Control-Pak into the recess on the side of the contactor base. With proper installation, the Actuator will fit into the hole in the slot in the side of the contactor housing. Using a thin rod or flat blade, lift the Actuator up as necessary to insert it into the slot mentioned. Rotate the Retainer to its original position, which will slide over the upper tab on the Control-Pak.

11. Confirm position of (2) retainers (adjust if necessary) (See Figure 1).

12. Reinstall the cover and secure it with the original mounting hardware. NOTE: Cover must fit under metal bracket on Control-Pak. Tighten the four screws in a diagonal pattern to 12 lb-in. (Figure 1).

13. Reattach the coil wire leads and any auxiliary control wires to the Control-Pak (tighten to 7 lb-inches).

14. Reinstall the contactor. Torque mounting screws to 50 - 75 lb-inches.

15. Reconnect the line and load conductors and tighten the main terminal hardware and bolts to 180 - 210 lb-inches

Actuatormust fit into slotshown Auxiliary

Figure 5A Figure 5B

Control-Pak

Control-PakActuator

Thin rod or flat blade

Thin rod orflat blade

(3)

42052-091G. Ushakow

N/A

N/A

N/A42052

10064901

INSTRUCTION SHEETBULLETIN 1102C 400A/600A VACUUM CONTACTOR

AC COIL REPLACEMENT

2-19-04

Mark Jutz 2-19-04

D. Josef 2-19-04

4 4

REVISION AUTHORIZATION

DIMENSIONS APPLY BEFORESURFACE TREATMENT

H

A

B

C

D

E

F

G

(DIMENSIONS IN INCHES)TOLERANCES UNLESSOTHERWISE SPECIFIED

REFERENCE

SHEET OFDWG.

B

DR.

CHKD.

APPD.

DATE

DATE

DATE±

±

±

ANGLES:

.XXX:

.XX:

THIS DRAWING IS THE PROPERTY OF THE ALLEN-BRADLEY CO. INC.

AND MAY NOT BE COPIED, USED OR DISCLOSED FOR ANY PURPOSE EXCEPT

AS AUTHORIZED IN WRITING BY THE ALLEN-BRADLEY CO. INC.

LOCATION : MILWAUKEE, WISCONSIN U.S.A.

SIZE

1 2 3 4 5 6 7 8

E - DOC

42052-091-01 (1)Printed in U.S.A.

PARTNO. MATERIALCHG.

CHAR. SIZEFLAT FOLD

-01 1TWO SIDES PRINTED

8-1/2" W x 11" HBODY STOCK WHITEBODY INK BLACK

4-1/4" W x 5-1/2" H