Electrically Held

to Mechanically
Latched Contactor
Bulletin 1502
Series E or later

Retrofit Instructions
Important User Information
Read this document and the documents listed in the Additional Resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.

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Inc., is prohibited.

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WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

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 Table of Contents

Compatibility ......................................................................................................................................... 1
Parts ....................................................................................................................................................... 2
Required Tools....................................................................................................................................... 2
Duration ................................................................................................................................................. 2
Procedure ............................................................................................................................................... 2
Remove the Contactor Electrically Held Auxiliary Contact Assembly ....................................... 2
Install the Latch Mechanism ........................................................................................................ 3
Install the Mechanically Latched Auxiliary Contact Assembly .................................................. 5
Auxiliary Contact Assembly Set-up ............................................................................................ 6
Mechanical Latch Mechanism Set-up ......................................................................................... 7
Electrical Test .............................................................................................................................. 8

1502-IN001%-EN-P -XQH
1502-IN001%-EN-P -XQH
 Electrically Held to Mechanical Latch Contactor
Retrofit Instructions Series E or later

Compatibility This procedure applies to kit 1502-4MLK, and it is for 400A OEM
Vacuum Contactors listed at Series E or greater. The series letter can
be verified from the contactor nameplate:

Figure 1 Bulletin 1502 400A Contactor

In addition, ensure that the contactor molding has the three slotted
holes and one round hole to the right of the magnetic coils that are
required to mount latch mechanism and rubber stop.

This retrofit kit can only be applied to contactors using IntelliVAC

Control circuits:

Figure 2 IntelliVAC Control Assembly

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2 Electrically Held to Mechanical Latch Contactor Retrofit Instructions

Parts Before beginning the retrofit, ensure that the Kit includes the parts
listed below:
1 400 Amp Mechanical Latch Mechanism
1 Auxiliary Contact and Plug Assembly
1 Mechanical Latch Umbilical Cord

Required Tools Wrench

Two 7/16 Wrenches
Phillips Screwdriver
2 C-Clamp (or clamping fixture part no. 80154-149-51)
Feeler gauges
Side Cutting Pliers
Wire Ties

Duration It typically takes less than 20 minutes to complete this procedure.

Procedure ATTENTION Before performing any maintenance on the contactor,

refer to the User Manual of the starter configuration
in which the contactor is installed for all service
instructions and procedures. Failure to do so may
result in injury to personnel or damage to the
controller or contactor.

It is assumed that this procedure will be performed on a workbench.

Remove the Contactor Electrically Held Auxiliary Contact Assembly

1. Using a wrench, remove the auxiliary contact actuator plate

from the main shaft assembly.

Figure 3 Removing the Auxiliary Contact Actuator Plate

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 Electrically Held to Mechanical Latch Contactor Retrofit Instructions 3

2. Using two 7/16 wrenches, loosen the auxiliary contact assembly-

retaining bolt and slide the electrically held auxiliary contact
assembly out of the front of the contactor.
3. Disconnect the coil leads from the auxiliary contact assembly
using a Phillips Screwdriver.

Figure 3 Disconnecting Coil Leads from Auxiliary Contact Assembly

Install the Latch Mechanism

1. Place the contactor on to its back to expose the underside of the
contactor base.
2. Install the rubber stop as shown in the drawing below:

Rubber Stop

(Install rubber stop as shown

with supplied components.)

Figure 4 Installing Latch Mechanism Rubber Stop

3. Separate the latch mechanism from the latch clamp plate by

removing the 3 bolts which hold them together with a wrench.
4. Slide the latch mechanism into the front of the contactor in the
space right of the closing coils. Pull the trip coil leads out of the
back of the contactor.

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4 Electrically Held to Mechanical Latch Contactor Retrofit Instructions

Figure 5 Contactor (Front/bottom View)

Showing Mounting Bolts for Latch Mechanism

ATTENTION The return springs exert a significant force on the

armature plate. To avoid injury, do not place fingers
between the armature plate and the stop bracket at
any time.

5. Position the clamp plate under the base of the contactor so that the
three holes in the latch mechanism align with the slots in the
contactor molding and the holes in the clamp plate. Hand tighten
the three mounting bolts to hold the mechanism in position.

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 Electrically Held to Mechanical Latch Contactor Retrofit Instructions 5

Install the Mechanically Latched Auxiliary Contact Assembly

1. Wire the closing and trip coils to the Mechanically Latched

auxiliary contact assembly as shown in the diagram below:

Figure 6 Auxiliary Contact Assembly Layout

2. Slide the auxiliary contact assembly back into the contactor and
hand tighten the retaining bolt so the assembly remains in position.

3. Re-Install the auxiliary actuator plate on the main shaft assembly.

Figure 7 Contactor (front angle view) after

Auxiliary Actuator Plate is re-assembled

 1502-IN001%-EN-P -XQH

6 Electrically Held to Mechanical Latch Contactor Retrofit Instructions

Auxiliary Contact Assembly Set-Up

1. Clamp the contactor closed from the back of the unit, using a
C-Clamp (or clamping fixture, part no. 80154-149-51).

2. Insert a 0.030 (0.76 mm) feeler gauge between the plastic

auxiliary contact actuator and the steel actuator plate.
(See Figure 8)

Figure 8 Set-up of the Auxiliary Contact Assembly

3. Slide the assembly fully forward, until the contacts have fully
engaged.
4. Secure the assembly in place by tightening the auxiliary assembly-
retaining bolt.

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 Electrically Held to Mechanical Latch Contactor Retrofit Instructions 7

Mechanical Latch Mechanism Set-Up

1. Place the contactor on its side.

2. With the contactor still clamped closed, set the gap between the
Latch Roller and the contactor armature plate to 0.01 using a
feeler gauge. (See Figure 9)

Figure 9 Mechanical Latch Mechanism Adjustment

(as viewed from the front with contactor
resting on the left side)

3. Tighten the three mechanism retaining bolts from under the

contactor.

ATTENTION The return springs exert a significant force on the

armature plate. To avoid injury, do not place fingers
between the armature plate and the stop bracket at
any time.

4. Place the contactor upright and remove the C-Clamp. The

contactor should remain latched. Discharge the contactor by
unlatching it using the manual override.
5. Wire tie loose wires out of the way of moving components.
(See Figure 10)

1502-IN001%-EN-P -XQH 20

8 Electrically Held to Mechanical Latch Contactor Retrofit Instructions

Figure 10 Contactor (rear view) showing wires to be wire-tied

Electrical Test

1. Connect the contactor to the control using the supplied umbilical

cord.
2. Test the latch by electrically engaging the contactor using the
control circuit.
3. If the contactor fails to latch, re-calibrate the gaps between the
auxiliary contacts and contact actuator plate and the gap between
the latch roller and contactor armature plate.

Figure 11 Complete Contactor after Conversion

1502-IN001%-EN-P -XQH
Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb
Publication 1500-IN001B-EN-E June 2013
Supersedes Publication 1500-IN001A-EN-P September 2005 Copyright 2013 Rockwell Automation, Inc. All rights reserved. Printed in Canada.