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Application Note AP040079EN Effective July 2014

IT Starter Repair –HVX Intellipass Drives

Introduction

This guide is to assist with the separation and replacement of one contactor section on

the IT series reversing starter assemblies. The repair of the assembly may be required

due to burnt sections of a contacor, or a contactor coil not pulling in and sealing. The

guide is only used to repair the assembly with an operational electronic overload. This

guide includes frame size/series B/E501B, C/E501C, D/E501D, and E/E501E.

E501B and E501C Assemblies

1. If the starter/contactor is mounted to a plate remove the plate by removing the 2

screws on the bottom side (see Figure 1-1).

2. Remove contactor covers by turning out the 4 cover screws, 2 per cover, until

they are fully released from the contactor (see Figure 1-2). Carefully pull up on

each cover and un-seat from the contactor (see Figure 1-2a).

3. Turn out all 6 Allen/hex head lugs/screws all the way and then turn back in 1.5

turns to keep the lugs/screws from falling out. (See Table 1-2, Figure 1-3)

- For B Frame use 2.5mm

- For C Frame use 3mm

4. Pull up on the electronic overload, right side of the overload section, and remove.

Gently pull back the locking clip on top of the bus bar block and then lift up and

remove the left side of the overload section (see Figure 1-4 and Figure 1-4a).

a. NOTE: Be careful not to lose the small spring located at the foot of the

right side contactor (see Figure 1-5)

5. Carefully separate each half of the contactors from the interlock. The interlock is

clipped into each contactor on the 4 corners of the interlock (See Figure 1-6 and

1-6a)

6. Take the new contactor and remove the top cover (same 2 screws as on the

starter). Turn out all 6 lugs/screws and then turn each one back in 1.5 turns to

keep the lugs/screws from falling out.

7. If the side being replaced is the right contactor be sure to transfer the small

spring over from the old contactor (see Figure 1-5).

8. To reassemble observe the position of the interlock. To insert the interlock into

the first side use one of two methods:

a. Method A: Press down firmly onto the contactor to engage it fully and in-

sure the interlock pin is down on the side you are inserting. Carefully in-

sert and snap the interlock onto the contactor (see Figure 1-7).

b. Method B: Leave contactor in the up/disengaged state. Place the interlock

pin in the up position on the side you are to insert into the contactor. To

hold it in that position use your thumb or finger to hold the opposite side

interlock pin down, this will engage the interlock from changing positions.

Carefully insert and snap the interlock onto the contactor (see Figure 1-

7a).

9. To connect the other contactor to the installed interlock move the exposed inter-

lock pin to the up position (see Figure 1-8). Once it is in the up position press

firmly on the contactor with the interlock installed to keep the interlock from

changing positions (see Figure 1-8a). Carefully line up the interlock pin and the

clips on the interlock with the other contactor and snap the two together.

10.Test Interlock Functionality: Only one side will engage at a time and it shall en-

gage fully. Press and hold one contactor side down and the opposite contactor

should not go down when pressed. Reverse to test the other contactor (see Fig-

ure 1-9).

11.Re-install the remainder components in the reverse order

12.When installing the left side of the overload place the buss pins into the contactor

terminals and then gently press down until the locking clip on the upper left snaps

into place (see Figure 1-10). Before installing the right side of the overload check

for the little spring again and ensure it is installed (see Figure 1-10b). Install the

electronic overload (see Figure 1-10a).

13.Firmly tighten down the lug/screws onto the overload assembly (see Figure 1-

11). For specific torque specifications refer to the cut sheet included with the

new contactor and reference to the line and load side torque specifications or see

Table 1-1.

14.Re-install covers and secure the cover screws (see Figure 1-12). If a plate was

used, re-install the plate and secure with the two screws that were removed (see

Figure 1-12a). There are multiple holes on the plate, but only 2 of them will line

up with the contactor assembly.

E501B and E501C Assemblies

1. If the starter/contactor is mounted to a plate remove the plate by removing the 4

screws on the bottom side (see Figure 2-1 and Figure 2-1a).

2. Remove the contactor covers by turning out the 4 cover screws, 2 per cover, until

they are fully released from the contactor. Carefully pull up on each cover and

un-seat from the contactor (see Figure 2-2 and Figure 2-2a).

3. Turn out all 6 Allen/hex head lugs/screws all the way and then turn back in 1.5

turns to keep the lugs/screws from falling out (see Figure 2-3).

- For D Frame use 4mm

- For E Frame use 8mm

4. Pull up on the electronic overload, right side of the overload section, and remove.

Gently pull back the locking clip on top of the bus bar block and then lift up and

remove the left side of the overload section (see Figure 2-4).