Bypass Contactor ("K3") (Single-Module System)
Removal Procedure
Illustration 1 | g00842703 |
(1) Input Cables "K3" (2) Contactor "K3" (3) Output Cables "K3" |
- Place the system in bypass mode by turning the keyswitch to the Bypass position.
- Isolate the system from the load by closing the bypass circuit breakers.
- Open the circuit breaker for the output of the system.
- Open the AC circuit breaker for the input of the system.
- Allow the capacitor banks to bleed down for approximately 5 minutes.
Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.
- Label all the input wires and all of the output wires.
- Remove three nuts from input power cables and remove cables (3) .
- Remove three nuts from output power cables and remove cables (1) .
- Remove cable "K3-6" (4) .
Illustration 2 | g00842716 |
(4) "K3-6" |
- Remove cable "K3-A2" (5) .
Illustration 3 | g00842751 |
(5) "K3-A2" |
- Remove cable and Diode "K13 - 14" (6 - 8) .
Note: Make sure that the diode is not damaged or inverted.
Illustration 4 | g00842756 |
(6) "K13" (7) Diode "K3" (8) "K14" |
- Disconnect two auxiliary input connectors. Connection 13 is orange and connection 14 is black.
- Disconnect the two input connectors. The connections are located on top of contact. Connection "A1" is black and connection "A2" is white.
- Remove four bolts.
- Remove contactor (2) from the cabinet.
Installation Procedure
Illustration 5 | g00842703 |
(1) Input Cables "K3" (2) Contactor "K3" (3) Output Cables "K3" |
- Place contactor (2) in the cabinet.
- Install four bolts.
- Replace cable and Diode "K3 13-14" (6 - 8) .
Note: Make sure that the arrow on the diode is pointing to "A1".
Illustration 6 | g00842756 |
(6) "K13" (7) "K3" Diode (8) "K14" |
- Replace cable "K3 A2" (5) .
Illustration 7 | g00842751 |
(5) "K3-A2" |
- Replace cable "K3-6" (4) .
Illustration 8 | g00842716 |
(4) "K3-6" |
- Replace three output power cables and Torque the nuts to 41 N·m (30 lb ft).
- Replace three input power cables and Torque the nuts to 41 N·m (30 lb ft).
Installation is complete.
Input Contactor ("K1")
Removal Procedure
Illustration 9 | g00859069 |
- Place the system in bypass mode by turning the keyswitch to the Bypass position.
- Isolate the system from the load by closing the bypass circuit breakers.
- Open the circuit breaker for the output of the system.
- Open the AC circuit breaker for the input of the system.
- Allow the capacitor banks to bleed down for approximately 5 minutes.
Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.
- Label all the input wires and all of the output wires.
- Remove three bolts (3) .
- Disconnect two coil wires (2). The connections are located on top of contact (1). Connection "A1" is black and connection "A2" is white.
- Disconnect two wires (6). The wires are located on the bottom of contactor (1). The wires are brown and orange.
- Disconnect two auxiliary input connectors (7). Connection 13 is brown and connection 14 is black.
- Remove three bolts (5) .
- Remove four screws (4) .
- Remove contact (1) from the cabinet.
Installation Procedure
Illustration 10 | g00859069 |
- Install contact (1) in the cabinet.
- Install four screws (4) .
- Install three bolts (5). Torque the bolts to 41 N·m (30 lb ft).
- Connect two auxiliary input connectors (7). Connection 13 is brown and connection 14 is black.
- Connect two wires (6). The connections are located on the bottom of contactor (1). The wires are brown and orange.
- Connect two coil wires (2). The connections are located on top of contact (1). Connection "A1" is black and connection "A2" is white.
- Install three bolts (3). Torque the bolts to 41 N·m (30 lb ft).
Output Contactor ("K2")
Removal Procedure
Illustration 11 | g00985506 |
- Place the system in bypass mode by turning the keyswitch to the Bypass position.
- Isolate the system from the load by closing the bypass circuit breakers.
- Open the circuit breaker for the output of the system.
- Open the AC circuit breaker for the input of the system.
- Allow the capacitor banks to bleed down for approximately 5 minutes.
Note: When the flywheel is spinning, the following components are energized: the bus, the armature leads and the fuses. Accomplish the procedure as quickly as possible. During the procedure, the rotor is spinning on the bottom bearing.
- Label all the input wires and all of the output wires.
- Remove three bolts (1) .
- Remove three bolts (2) .
- Remove the two wires (3) for the auxiliary contact.
- Remove the brown wire and remove the orange wire that is located on the bottom of the contactor.
- Remove two coil wires. The coil wires have the following labels: "A1" (black) and "A2" (white).
- Remove four screws.
- Remove the contactor from the cabinet.
Installation Procedure
Illustration 12 | g00985506 |
- Install the contactor in the cabinet.
- Install four screws and tighten.
- Connect the coil wires. Wire "A1" is black and wire "A2" is white.
- Connect two auxiliary input connectors (3). Connection 13 is red and connection 14 is black.
- Install the brown wire and install the orange wire that is located on the bottom of the contactor.
- Install three bolts (2). Torque the bolts to 41 N·m (30 lb ft).
- Install three bolts (1). Torque the bolts to 41 N·m (30 lb ft).
"S7" Settings
"S7" is a group of switches on the optional bypass contactor for adjusting the overcurrent trip point.
Illustration 13 | g00842928 |
Bypass Contactor "K3"     | |
Long Time "L"     | "I1" (1) = 1 "t1" (2) = 18 s or "D"     |
Short Time "S"     | "I2" (3) = 10 "t2" (4) = 0.5 s or "D" ("SW3" set to I > 12)     |
Instantaneous Trip "I"     | "I3" (5) = Off     |
Control Switches (6)     | Set to Man and 50     |
Maintenance Bypass Contactor (1)     | |
Long Time "L"     | "I1" (1) = 1 "t1" (2) = 18s or "D"     |
Short Time "S"     | "I2" (3) = "10" "t2" (4) = 0.5s or "D" ("SW3" set to I > 12)     |
Instantaneous Trip "I"     | "I3" (5) = Off     |
Control Switches (6)     | Set to Man and 50     |
Bypass Input Switch (1)     | |
Long Time "L"     | "I1" (1) = 1 "t1" (2) = 18 s or "D"     |
Short Time "S"     | "I2" (3) = 10 "t2" (4) = 0.5s or "D" ("SW3" set to I > 12)     |
Instantaneous Trip "I"     | "I3" (5) = Off     |
Control Switches (6)     | Set to Man and 50     |
( 1 ) | Optional |