GEH-1937SNSTRUCTIONS

HIGH-VOLTAGE CONTACTORSA-C, AIR-BREAK TYPE

IC2812-HO0 IC2S12- F100IC2812-E10I IC2812-G100

INTRODUCTION When unpacking them, handle carefully to preventdamage. See that there is no packing material or otherforeign matter inside the chutes; and make certainthat they are dry. Mount the chutes by easing themonto the upper and lower arcing horn extensions asfar as they will go. Observe the notice on the frontof the chute, shown in Fig. 2. Figure 3 shows the differ-ence between properly and improperly seated chutes.

The weight of the arc chute itself holds it in placewhen correctly seated. The chute may be mountedwith either end at the top.ELECTRICAL INTERLOCKS

The electrical interlock consists of three contactunits, each with one normally open and one normally

These instructions cover high-voltage, a-c air-breakcontactors—outlined in Table I. The contactors aredesigned for equipment used in starting a-c motorswith line voltage from 600 volts to a maximum of5200 volts.

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TABLE i

NORMALLYOPEN POLES

NORMALLYCLOSED POLES

DEVICEIC2812*

—El 00—El 01

3

-—FI 00 5 i3—G100 3 yi Ml \ i'SI

STANDARD CONTACTORS—IC2812-E100 ANDIC2812-E101

i -5 3 2 51m 55 =RATINGS

The standard contactors, IC2812-E100 and IC2812-E101 (see Fig. 1), are three-pole, normally open con-tactors, rated 200 or 400 amperes, continuous; 3000hp, maximum; with a maximum interrupting capacityof 50,000 kva, and a maximum “let-through” currentof 58,000 amperes.

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OPERATING MAGNETSThe IC2812-E100 and -E101 contactors are avail-

able with a-c or d -c operating magnets, both havingcontinuous-rated coils.

Control voltage for energizing the coils should bewithin 85 to 110 percent of the control voltage.ARC CHUTES

The arc chutes are shipped unmounted. They mustbe mounted before applying power to the contactor.

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IC2812 - E100 high-voltage contactor .Fig. 7 .

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connectionwith installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficientlyfor the purchaser’ s purposes, the matter should be referred to the General Electric Company.

G E N E R A L ^ E L E C T R I C .4 •

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GEH-1937 High-voltage A-c Ait-break ContactorsThe electrical rating of the interlock is 15 amperes,

continuous; 60 amperes, “make” current; with cur-rent interrupting values, as listed below in Table III.S e a t c h u t e s o t h i s I i n e

( l o w e r l a b e l o n l y )r e s t s o n m e t a l s u p p o r t TABLE III

A-C INDUCTIVENormally Open or Normally C8 ©sed

One Inferlock-AmpVoltsno 15220 1 0 13Vi440 2 /2550

D-C INDUCTIVENormally Open or Normally Closed

Two Interlocksin Series-AmpVolts One lnterloek» Amp

125 2.00250 0.80600 0.25

DOOR INTERLOCKThe door interlock can be furnished with all forms

of the IC2812 contactor. When applied to Limitamp*controllers or to any other form of enclosure, the in-terlock prevents the opening of enclosure doors withthe contactor in closed position.

Adjust the door interlocks according to the in-structions on Fig. 5.

Since the operation of electrical interlocks is effectedwhenever the door interlock is adjusted, the elec-trical interlock should be readjusted according toFig. 5.

Fig. 3. View showing arc chutes I and 2 properly seated( edges of chutes parallel with phase barrier and with edgeof contactor ); and arc chute 3 seated improperly, with topof chute not pushed down into place on arcing horn.closed contact. These contacts are mechanically con-nected to the main shaft of the contactor, and movewhen the contactor operates.

Adjustment of these interlocks is critical to theoperation of the contactor. Figure 4 should be followedin making this adjustment. Also, see Table II.

IC2812-F10O CONTACTORSThe IC2812-F100 contactors are identical to the

IC2812-E100 contactors except for the number ofpoles. Therefore, the instructions above for the -El00contactors also apply for the -FI00 contactors

To operate the five-pole device a d-c magnet is usedwith intermittent rated coils with an economy resistor.

)TABLE II(Refer to Fig. 4c§ for Interlock No.)

IC2812-G100 CONTACTORSMAIN CONTACTS FULLY CLOSED( Magnet Armature Laminations Held Against Stat ionary Magnet ) The IC2812-G100 contactors consist of three nor-

mally open poles which are identical to the IC2812-E100 contactors and are mechanically interlocked tothree normally closed poles. The instructions givenabove for the -El00 contactors apply to the -G100contactors, with the following exceptions:

The normally open poles and normally closed polesof the -G100 each have their own d-c magnet. The

( Dimensions in Inches )Interlock No. 1 2 3

3/8Dimension “J ” 3 /8 1 /3217/32Travel “K ” 17/32 17/32

1 /16N. O. Tip Wipe 1 /16 1 /163 /32N.C. Tip Gap 3 /32 3/32 J

* Trade-mark of General Electric Company.

2

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High-voltage A-e Air-break Contactors GEH-1937f normally closed part has no blowouts or arc chutes;

therefore, this contactor has no interruption rating.These contacts establish circuit only, and should notbe opened with current flowing.

The operating magnets for the IC2812-G100 nor-mally open contacts are the same as the d-c magnets(previously described) of the -El00 contactor. The

ECCENTRICSCREW

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©©“iJUT*1BEARINGS

—^ELECTRICALINTERLOCKS® ® if FIRIGHT HANDFRAME

.J lc A® ®*1 # 2 *3 RIGHT HAND FRAME\LINK-— \00 0 0 00ARCCHUTES Groove on link must line up with edge of bearing

within Adjust if necessary by turningeccentric screw. This also changes electricalinterlock set ting

000See Fig. 4bfor view ofinterlock inthis direction

'O'K - J\ |V ^-yli i\00 00000 00 Fig. 5. View looking down on door interlock.ELECTRICAL ±

INTERLOCKSy

normally closed contacts are operated by an inter-mittent rated magnet. A resistor is added to the coilcircuit after the contactor has closed, to reduce thecurrent in the coils.

Fig. 4a. View from front of contactor showing electricalinterlock arrangement.

CONTACTORMAGNET-®:r INSTALLATIONADJUSTy+J-“6 4 CLOSED For convenience and safety in moving the con-

tactor, use the lifting holes at the top of the steel sideplates; and, likewise, use an equalizer bar or spreaderfor the cable sling.

Although the contactor has self -aligning bearings,it is advisable to mount it on a flat, horizontal surface.The contactor should be anchored by screws or studsat the mounting feet. If the contactor is not installedin a metal enclosure, at least eight to ten feet of arcingclearance in front of the unit is advised for protectionof personnel.

Observe the following precautions before applyingpower to the contactor for the first time.

1. Remove shipping supports, blocks or ties usedfor protecting the contactor in transit.

2. Carefully inspect all parts of the contactor.Operate it by hand to see if all parts work freely. Besure that contacts strike squarely with their sides inline within 1/16-inch.

3. Remove protective grease or oil which may beon the magnet face, as the grease could collect dustand dirt, thus promoting a sticking of the magnet.

4. See that all parts of the contactor are clean.High-voltage equipment fails if too much dirt ac-cumulates.

5. It is of utmost importance to mount the arcchutes before applying power to the contactor, since

OPERATING /ARM L\1 ra>

GEH-1937 High-voltage A-c Air-break Contactors

the arc chutes are essential to confine and extinguishthe arcs. Without the chutes, the arcs may do seriousdamage. See the section on “Arc Chutes” and alsorefer to Fig. 2 and 3.

force. Lubricate the bearings once a year with a goodgrade of ball-bearing lubricant.WHEN TO REPLACE CONTACTS

Outlined below is the proper method for deter-mining when it is necessary to replace contacts:

1. Use Fig. 6 as a guide. With the contacts in thecompletely open position, measure the distance, B0,between the two spring supports. Take measurementsat the indicator lines moulded into the support andbracket.

2. Next, with the contacts in the completely closedposition, measure the distance, Bc, between the twospring supports.

3. Subtract Bc from B0. If the difference, A, isless than 3/32-inch* (see Table IV), replace both themovable and stationary contacts. Contacts not re-placed at this time may overheat or weld together.

In making measurements, any of the normally opencontacts may be held in the closed position by block-ing the armature with a wooden block or wedge. A-carmatures should be closed by applying pressuredirectly to the laminated armature. An incorrect in-dication of the contact wear and wipe will be obtainedif pressure is applied to the support, due to the normalamount of play between the armature and the support.

The contact gap (“C” in Fig. 6) is set correctly atthe factory, and it is not necessary to recheck this gapunless some major work is done on the contactor.The gap is measured as the shortest distance betweenthe movable and stationary contacts. The force re-quired to close the armature through the last partof its stroke will be high, because close to its sealedposition it operates against a kick-out spring nor-mally used to assure quick release of the magnet.

>MAINTENANCE

Contact life depends on the severity of service re-quired for the device. The contactor should be thor-oughly inspected after every 50,000 operations.

CAUTION: All power should be discon-nected from the contactor before any in-spection is made.

In routine inspection, check for loosened screws,nuts, bolts, cable clamps, and electrical interlocks.It is important to check contact wear and contact

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Blowout support Insulationr? /rĈ -lStationary i

contact / 1 ContactsupportInsulation shouldered\ bushingv -̂Washer

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Yr Pivot ofcontact assembly5"8Loop can be overmounting screw -

hardware x;Indicator"7 lines

Springbalanc ©

View of contacts in open position with lettersdesignating important contact dimensions.

Fig. 6.* 1/16-inch on the IC2812-G100 normally closed contacts

TABLE IV(Refer to FigQ 6)

CONTACTS IN WIPEDPOSITION

MEASUREMENT “A”)CONTACT FORCE(POUNDS)NEW CONTACTS IN

OPEN POSITIONMEASUREMENT “C"

CONTACTORIC2812- Replace When

Measyrement "AReaches

Initial(Contacts Open)

Final(Contacts Closed)

9 9New Contacts

—El 00—E101— F100—G100(N.O. contacts only)

3/16-in. 3/32-in. 3/4-in. 814 to 1014 14 to 16

—G100(N. C. contacts) **914 to 11 '/427/64-in. **814 to 10149/64-in. 1/16-in. )^Measured when gaps be tween movable and two sta t ionary contac ts a re equal.

**Tota l force for one br idge contac t.

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High-voltage A-t Ait-break Contactors ©EH-1937r In taking measurements on the normally closed

contacts of the IC2812-G100 contactors, the arma-ture must be forced to the closed position in orderto fully open the contacts.

REPLACING CONTACTSReplacing Normally Open Contacts

In replacing normally open contacts, work fromthe front of the contactor, following the steps de-scribed below.

1. Remove the arc chute by lifting gently from theupper and lower arcing horn extensions. Exercise carein handling the chutes so that they will not be dam-aged by tipping or accidental blows.

2. See Fig. 7. Using a long (14-inch) screwdriveror 9/16-inch socket wrench, remove the front boltholding the upper arcing horn. Using an open-end1/2-inch wrench, remove the bolt at the back, andremove the upper arcing horn.

3. Reaching in between the pole pieces, remove theloose compound arc deflector resting on the stationarycontact.

4. See Fig. 8. Remove the stationary contact byremoving the bolt immediately above the contact.Use either a standard 14-inch screwdriver or 1/ 2-inch socket wrench.

5. Before removing the movable contact, the sta-tionary contact should be replaced first to retain theproper contact alignment of 1/16-inch. When re-placing the bolt and lockwasher, the bolt is threadedinto the nut which has been held in place by a nutretainer.

6. See Fig. 9. To remove the movable contact,block the magnet armature closed, thus exposing themovable contact bolt. Using a 1/2-inch socket wrenchor screwdriver, remove the bolt and contact. Re-place the contact, being certain that the shunt is be-tween the flatwasher and the movable contact. Themovable contact support is tapped to receive the bolt.

7. Check the alignment of the edges of the con-tacts to make certain that the movable and stationarycontacts are within 1/16-inch.

8. Make certain that all contacts in all phases openand close at the same time or within 1/32-inch. Afteradjustment, tighten all bolted connections.

9. Replace the compound arc deflector over thestationary contact before replacing the upper arcinghorn.10. Replace the arc chute.

Replacing Normally Closed Contacts for IC2S12-G10OContactors Only

Both the stationary and movable contacts in thenormally closed part of the -G100 contactor are ac-

r Fig. 7. View showing method of removing upper arcing horn.

Fig. 8 . Method of removing stationary contact.5

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&EH-1937 High-voltage A-c Air-break Contactors

)CONTACT FORCEInsufficient contact force can cause overheating or

welding of the contacts. Excessive contact force cancause the magnet, if it is of the a-c type, to be noisy.In addition, it may prevent proper closing of thecontacts. It is not necessary to check the contactforce under normal operating conditions unless thecontact springs have been damaged or there is somereason to suspect incorrect contact force.

When contact force is checked, a spring balancemay be used in the- manner indicated in Fig. 6. Notethe positioning of the loop of string (or fine wire).Also note the line of pull in relation to the contactpivot. The spring balance reading should be correctedfor zero reading when held in the same position. Ifthe shunt is removed, an equivalent spacer should beused to locate the wire from the balance in the correctposition. If the line of pull is slightly off, the readingwill be increased. Move the balance to find the lowestreading. Use Table IV for reference figures.

Final contact force is the force required to causethe contact assembly to start to turn around itspivot when the contacts are fully wiped.

Initial contact force is the force required to causethe contactor assembly to start to turn around itspivot when the contacts are open.

To determine when the assembly starts to turnaround its pivot, use a thin piece of paper between thecontacts in checking final contact force—and be-tween the die cast and moulded supports to checkfor this motion when the contacts are open.REPLACING A-C COILS

By the use of two 9/16-inch box wrenches, removethe two bolts holding the movable fulcrum. Loosenthe coil spring holder bolts and rotate the coil springholders to clear the coil. Then the coil can be removed.

When reassembling it, make sure that the projec-tion on the armature fulcrum faces away from thestationary magnet and coil. The purpose of this pro-jection is to provide self -alignment of the movablearmature.REPLACING THE CONTACT SPRINGS

To replace the contact springs, first remove thebarriers by removing the bolts in front of the con-tactor and sliding the barrier forward. Reach underthe lower arcing horn assembly with a screwdriverand pry the spring forward, out of its lower seat.

Thread a length of heavy cord around the top ofthe spring and drop the cord down to the bottom.Pull the spring out with the cord (refer to Fig. 11).To replace the spring, slide one end of the spring intothe recess formed by the shaft insulator and the con-tact holder. Compress the spring with the thumbs

Fig. 9. Method of removing movable contact.

cessible from the front. Block the armature closed andreplace the movable contact by removing the holdingscrew and bracket (see Fig. 10). The contact lifts offthe pin. After replacing the movable contact it shouldbe free to pivot slightly on the pin.

The screws holding the stationary contacts aredirectly accessible from the front. Before tighteningthem, after replacing the contacts, remove the arma-ture block ; this will allow the movable contacts, bythe pull of the main springs, to align the stationarycontacts. The stationary contacts must strike themovable contacts squarely, and all poles must openand close together, within l /32 -inch.

)ContactPi n 4-H o l d i n gb racket

H o l d i n gscrew

Contact bracket

jFig . 10. Position of the holding screw and bracket.

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High-voltage A-c Air-hreak Contactors GEH-1937

REPLACING D-C COILSCoils for Normally Open Section of 1C2812-E100,-E101, -F100, -G100 Contactors

For replacing d -c coils in normally open contactors,loosen the core bolt on the front coil (these are thebolts which project upward through the coil bracket).Detach the harness from the coil and remove thecoil. It is helpful to tag all leads. Repeat with backcoil. When replacing the coils, the washer must becentered around the core before the core bolts aretightened.

iJv- \

Loop of

(Coils for Normally Closed Section of IC2812-G100Contactors

Before attempting to remove the lower coils ofthe IC2812-G100 contactor, block the armature ofthe normally open contactor and remove the top ofthis contactor to provide clearance for removal of thenormally closed core bolts. To replace the coils, pro-ceed as outlined above under the preceding para-graph.

Screw driver

Method of replacing contact spring.

and insert the spring in the top seat. The bottom canthen be seated by prying with a screwdriver. Replacethe barriers.

Fig. 77.

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w n c n v v/u i i c c yIF YOU NEED TO REPAIR, recondition, or rebuild any electric apparatus, a G-E service shop near you is available dayand night, seven days a week, for work in the shops or on your premises. Latest factory methods and genuine G-E renewalparts are used to maintain the original performance of your G-E equipment. For full information about these services,contact the nearest service shop or sales office listed below:

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