Eaton Vikers V200 Series User manual

Instructions for V200, V210
540 Ampere, 3 Pole Vacuum Motor
Controller Nonreversin or Reversin
I.L. 17089
Model A or B
RoHS
THE CONTROLLER
The V200 or V210 motor controller, when wired as shown
in Figure 5 or Figure 6, will operate as a ull voltage starter
and will give protection against overload, but not against short-
circuit currents, when wired and provided with overload relay
(OLR) heaters as listed in the heater selection table or when
used with any means o inherent protection activated by motor
temperature.
The controller should be protected against short circuits by
providing branch circuit protection, in accordance with the
National Electrical Code (NEC).
This industrial type control is designed to be installed,
Fig. 3 Dimension Drawing (Dimensions in inches)
Fig. 1 V200 Motor Controller
(Type Overload Relay shown)
Fig. 2 Left Portion of V210 Reversing Contactor
Rev 01
7.00
6.75
14.00
8.75
16.23

2
operated, and maintained by adequately trained work-
men. These instructions do not cover all details, varia-
tions, or combinations o the equipment, its storage,
delivery, installation, check-out, sa e operation, or main-
tenance. Care must be exercised to comply with local, state
and national regulations, as well as sa ety prac-
tices, or this class o equipment.
MOUNTING
Mount each V200 controller with our 5/16 x 18
or 1/4 x 20 bolts. Flat washers should be used on bolts
entering slotted holes or keyholes. See Table VII.
TYPE B OVERLOAD RELAY (See Fi ure 1)
This V200 motor controller is usually equipped with
a Type B block type ambient compensated overload
relay (with gray reset rod). The controller can also be
supplied with a non-ambient compensated overload
relay (with red reset rod). This relay is a bimetal
actuated type equipped with a normally-closed control
contact. An optional isolated normally-open control cir-
cuit is available or ield mounting. When the overload
relay trips, a yellow dot will appear lush with the molded
sur ace below the reset rod. Resetting the relay returns
this indicator to its normally concealed position.
TYPE A OVERLOAD RELAY (See Fi ure 4)
The V200 motor controller can be equipped with a Type A
Block type non-ambient compensated overload relay (unmarked
and with a red rest rod) or with a block type temperature
compensated overload relay (marked Ambient Compensated
and with a gray reset rod). The relay is o the bimetal actuated
type equipped with trip indicator, trip adjustment covering
±15% o rating and a normally-closed control contact. It maybe
operated with either hand or automatic reset.
Reset operation is determined by the position o the plate on
the load side o the overload base. Position the reset plate
away rom the panel to set the hand position. Loosen the
locking screw, move the reset plate toward the panel, and
tighten the screw to set the auto position.
Automatic reset should not be used with 2-wire control circuits
where automatic starting o the motor may be hazardous.
OVERLOAD RELAY HEATERS
Overload relay (OLR) heaters are not included with the motor
controller and must be ordered separately per the heater
selection table and the in ormation listed below. When installing
heaters be sure that connecting sur aces are clean and heaters
are attached securely to the relay in the proper location with
the screws provided. The trip rating o a heater in a 40°C
ambient is 125% o the minimum ull load current shown in
Table 1. When tested at 600 percent o its trip rating, the relay
will trip in 20 seconds o less.
Heaters should be selected on the basis o the actual ull
load current and service actor as shown on the
motor nameplate or in the manu acturers published literature.
When the service actor o the motor is 1.15to 1.25, select
heaters rom the heater application table. I the service actor
o the motor is 1.0, or there is no service actor shown, or a
maximum o 115% protection is desired, select one size smaller
heater than indicated. When motor and overload relay are in
di erent ambients and when using noncompensated overload
relays,
Fig. 4 Type A Block Overload Relay
TABLE I - HEATER SELECTION - A or B OLR
Motor Full Load Current in Amperes or Use With 3 Heaters Only.
Open Starter Enclosed Starter Heater
Compensated
or Noncom-
penated OLR
Compen-
sated
OLR
Noncom-
pensated
OLR
Catalog
(Code)
Number
WITH 600/5 CURRENT TRANSFORMERS
236-259
260-283
284-310
311-340
341-374
375-411
412-448
449-489
490-527
528-585
586-600
236-259
260-283
284-310
311-340
341-374
375-411
412-448
449-489
490-527
528-540
.....
219-239
240-263
264-287
288-316
317-347
348-381
382-417
418-455
456-494
495-540
.....
FH24
FH25
FH26
FH27
FH28
FH29
FH30
FH31
FH32
FH33
FH34
 For altitudes up to 3300 eet.
* These ratings applicable only to controllers urnished with current trans ormers rated 1500
volts and with nameplates so marked.
CONTROLLER RATINGS
THREE-PHASE HORSEPOWER AT
200V 230V 380V 460V 575V 795V* 1500V*
150 200 300 400 500 700 1300
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089
Reset
Rod Line
Terminal
Load
Terminal
Mounting
Plate
Heater
Adjustment
Knob
Reset
Screw
Reset
Plate
Trip
Indicator
Normally
Open (NO)
Control
Terminal
When
Supplied
Normally
Closed (NC)
Control
Terminal

3
select heaters rom the table using adjusted
motor currents as ollows: decrease rated motor current
1% or each °C motor ambient exceeds controller
ambient. Increase rated motor current 1% or each °C
controller ambient exceeds motor ambient.
WARNING: To provide continued protection a ainst
fire and shock hazard, the complete overload relay
must be replaced if burnout of a current element
occurs. See Table III.
TABLE III - REPLACEMENT OVERLOAD RELAY
OVERLOAD RELAY CATALOG NUMBER
Type B Non-ambient compensated BN13JP
Type B Ambient compensated BA13JP
Type A Non-ambient compensated AN13P
Type A Ambient compensated AA13P
TYPE GCO CURRENT TRANSFORMERS
The Type GCO current trans ormers were specially
designed to mount on A200 and V200 controllers and
operate the Types A or B thermal overload relays.
The 600/5 ratio Type GCP trans ormers have a single
turn primary winding, provided by the controller load
connection straps. The secondary wires - one white,
the other black - are color coded or polarity identi ica-
tion.
There are two versions o the Type GCO, 600/5 ratio,
three-phase current trans ormers, one rated 1500 volts,
the other 600 volts. Each has a label nameplate showing
its maximum voltage rating. The 1500 volt version has a
red nameplate and may be used at any voltage up to 1500,
including voltages below 600.
These Type GCO current trans ormers are not to be
used to power additional auxiliary devices and should never
be energized with the secondary leads open
circuited since the open circuit overvoltage can damage
the trans ormer.
The combination o Type GCO 600/5 Ratio Current
Trans ormers, Type A or B thermal overload relay, and
V200 or V210 controller is intended to provide motor
overload protection or motors with ull load amperes
(FLA) rom 236 to 540 amperes up to the maximum
voltage shown on the controller nameplate.
common point. Both coils are encapsulated in one
environment-immune coil shell, which also contains a
ull-wave bridge. When AC is connected directly to
terminals A and B on the coil shell, the magnet excitation
is un iltered DC. The magnet will not chatter as AC
magnets sometimes do, but at less than rated voltage it
may hum slightly. A normally-closed Type L63 auxiliary con-
tact, set to open slightly be ore the armature ully closes,
is connected to terminals C and D on the coil
shell. When adjusted correctly, this contact allows a
relatively high current through the pickup winding, and
as the controller closes, the contact inserts the holding
winding, which reduces the coil current to a low value
su icient to hold the magnet closed without overheating.
No external resistors are required.
COIL DATA (TYPICAL VALUES)
Coil
Voltage
110-120
220-240
440-480
550-600
Freq.
Any
Any
Any
Any
Inrush
VA
1450
1450
1450
1450
Sealed
VA
28
28
28
28
Sealed
Watts
28
28
28
28
Part
Number
7874A24G01
7874A24G02
7874A24G03
7874A24G04
MAGNET OPERATING RANGE
When properly adjusted as described in previous
sections, the controller should operate within the
ranges shown in Table IV.
I the magnet chatters, look or mechanical inter er-
ence that prevents the magnet rom sealing. I there is
no inter erence, then the magnet itsel may be misaligned.
The magnet gap can be seen rom the le t and right sides
with the help o a lashlight. A screwdriver inserted into
one o the long slots (Y-Figure 8) can be used as a lever
to put a corrective set into the mounting plate around the
magnet. It should not be necessary to do this unless the
contactor has been damaged and it can be seen that the
armature does not it against the magnet. A poor mag-
net-to-armature it usually produces a high dropout
voltage and/or the chatter.
Mechanical inter erence can be produced by various
incorrect adjustments. Two speci ic points to check are:
A. Armature travel incorrect, causing the contact
springs to be compressed into a solid, non-
resilient tube that stops the crossbar rigidly.
Re er to Eaton Service or assistance.
B. The auxiliary contact mounting brackets are mis-
adjusted, so that a contact plunger bottoms solidly
COIL
The operating coil has a  igure-eight shape and is
really two coils in series, with a connection to their
TABLE IV - OPERATING RANGES
Rated Coil
Voltage
Pick-Up-To-Seal
Voltage
Drop-Out-To-Full
Open Voltage
Above Below Above Below
110-120 VAC
220-240 VAC
440-480 VAC
550-600 VAC
60
120
240
300
77
152
304
385
10
20
40
50
50
100
200
250
TABLE III - OVERLOAD RELAY
CONTROL CONTACT RATINGS
Normally Closed Normally Open
AC Volts Make Break Make Break
Type A
24 - 120 20A 2A 5A .5A
120 - 600 2400VA 240VA 600VA 60VA
Type B
24 - 120 30A 3A 30A 3A
120 - 600 3600VA 360VA 3600VA 360VA
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089

4
be ore the magnet seals. When the contactor is
ully sealed closed, there should still be a small
amount o travel remaining or the plungers. See
L63 Auxiliary Contact Adjustment.
SHORT-CIRCUIT RATINGS
This motor controller is suitable or use on a circuit
capable o delivering not more than the current (rms
symmetrical amperes) shown below in circuits rated not
more than the voltage shown in table below:
TABLE V - SHORT-CIRCUIT PROTECTION
Short-Circuit
Protective
Device
(SCPD)
Max.
size
SCPD
Current
Breaker
Inturrpting
Rating
Short-Circuit
Rating
Typical
Disconnect
Device
Cat No.
Pre ix
Current Voltage
Class L Fuse
Class R or J
Fuse
Magnetic Only¹
Type CB²
Thermal/Mag³
Type CB²
Thermal/Mag³
Type CB²
800A
600A
600A
600A
600A
600A
800A
800A
-
-
22,000A
30,000A
25,000A
30,000A
35,000A
14,000A
22,000A
14,000A
22,000A
100,000A
100,000A
18,000A
25,000A
25,000A
30,000A
42,000A
25,000A
30,000A
42,000A
14,000A
600V
600V
600V
480V
480V
480V
600V
480V
1000V
1000V
1000V
MCS (High
Mag. Trip)
MCS (High
Mag. Trip)
LA
HLB, HLC,
HMC
LA, LC
HLB, HLC,
HMC
HNAM
HPBN
HNAM
HPBM
¹ Instantaneous Adjustable Trip
² Circuit Breaker
³ Inverse Time
TABLE VI - POWER CIRCUIT TERMINALS
Lu s
(when used)
Wire Size
(2) 2/0 AWG - (2) 500 MCM
Wire with copper conductors only. Use 75°C wire.
AUXILIARY CONTACTS - TYPE J
Two mounting brackets or auxiliary contacts are
provided or each contactor. Auxiliary contacts them-
selves must be ordered separately. An auxiliary con-
tact with one or more normally-open poles may be used
as the holding circuit auxiliary. A maximum o our
auxiliary units can be installed in the brackets or each
non-reversing contactor (three in each reversing con-
tactor). They mount by means o a spring clip and
retainer screw. To remove the auxiliary contacts, loosen the
TYPE J AUXILIARY CONTACTS
Contact Type Catalog No.
2 Normally Closed
2 Normally Open
1 Normally Open and 1 Normally Closed
1 Normally Open and 1 Normally
Closed, Delayed Breaker
J02
J20
J11
J1C
TYPE J CONTACT RATINGS (A600, R300)
Volta e
120-600 VAC
72-120 VAC
28-72 VAC
28-300 VDC
Continuous
10A
10A
10A
1.0A
Make
7200VA
60A
60A
28VA
Break
720VA
720VA
10A
28VA
MECHANICAL INTERLOCKS
Mechanical interlocks are used when a pair o
contactors must be mechanically protected against the
closing o one when the other is already closed. For the
horizontal reversing con iguration, the Type M33-6VH
mechanical interlock assembly is used. The M-33-6VH
mechanical interlock can be adjusted or variations in
contactor height. Mechanical interlocks which are
retainer screw several times (counterclockwise) and then
slide the auxiliary contact unit out o the bracket.
Fig. 6 Reversing Control Circuit
Fig. 5 Nonreversing Control Circuit
6713C28
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089

5
TABLE VII - RECOMMENDED DRIVING TORQUE
Driving
Torque
(lb-in.)
Fig. 7
Item
Re er.
Fig. 8
Item
Re er.
Driving
Torque
(lb-in.)
Fig. 7
Item
Re er.
Fig. 8
Item
Re er.
Location (Qty.)
Coil Terminals (4)
OLR Bus Connections (6)
V200 Base Mounting Screws (4)
Mechanical Interlock Adjustment
Screws (reverse only) - (4)
Location (Qty.)
7-9
380-400
60-65
25-30
1
2
4
-
-
-
S
-
Coil Mounting Screws (2)
Lug Bolts (6)
Preasure Wire Connectors (6)
10-15
380-400
380-400
5
6
7
M
-
-
CONTACT FORCE AND ALTITUDE
A Vacuum motor controller is a ected by atmospheric
pressure on the bellows o the vacuum bottle. Up to
an altitude o 2km (6600 eet), the contactor is designed to
tolerate normal variations in barometric pressure. I the
contactor is to be operated over 2km (6600 eet) above sea
level, consult the actory.
CONTACT WEAR ALLOWANCE
Contact material vaporizes rom the contact aces
during every interruption and condenses inside the
bottle. This is normal, and is provided or by overtravel,
or wear allowance. When the contactor is ully closed,
there is a gap underneath the lower bottle nut and the pivot
plate. See Figure 8. As the contacts wear, this gap
decreases. When any gap goes below .020 in., the unit
should be replaced. Use the .020 in. thick ork-shaped
overtravel gauge supplied or this measurement. Part
No. 7874A59H01.
CHECK-OUT, VACUUM INTERRUPTERS
The dielectric strength o the interrupters should be
checked be ore the contactor is energized or the irst
time and regularly therea ter to detect any deterioration
GENERAL
The contactor portion o a V200 or V210 controller
(see Figure 7) has its main contacts sealed inside
ceramic tubes rom which all air has been evacuated,
i.e., the contacts are in a vacuum. No arc boxes are
required, because any arc ormed between opening
contacts in a vacuum has no ionized air to sustain it. The
arc simply stops when the current goes through zero as
it alternates at line requently. The arc usually does not
survive beyond the irst hal cycle a ter the contacts
begin to separate. The ceramic tube with the moving and
stationary contacts enclosed is called a vacuum interrupter
or a bottle, and there is one such bottle or each pole o
the contactor. A three-pole contactor has three vacuum
bottles. A metal bellows (like a small, circular
accordion) allows the moving contact to be closed and
pulled open rom the outside without letting air into the
vacuum chamber o the bottle. Both the bellows and the
metal-to-ceramic seals o modern bottles have been
improved to the point that loss o vacuum is no longer cause
or undue concern.
The moving contacts are driven by a molded plastic
crossbar supported by two pre-lubricated ball bearings
that are clamped in alignment or long li e and ree
motion.
The contacts in an unmounted bottle (vacuum inte-
rupter) are normally-closed, because the outside air
pressure pushes against the lexible bellows. For
mounted on reversing contactors rom the actory are
adjusted at the actory. I the mechanical interlock is
removed and reinstalled or any reason, its per ormance
must be checked and readjusted i necessary. This is
done by energizing the orward contactor at rated volt-
age and then momentarily energizing the reverse
contactor with the electrical interlocks overridden. The
electrical interlocks can be overridden by removing them
rom their recesses. With the reverse contactor locked
out, the bottle stem arthest orm the mechanical inter-
lock on the reverse contactor should close about .040.
I it closes more than .40,. the mechanical interlock must
be readjusted. Per orm the same test locking out the other
contactor. When adjusted correctly, the mechanical interlock
arms should have room to pivot back and orth reely. I
they do not, the mechanical interlock is adjusted too tightly
and must be readjusted. A ter The mechanical interlock is
correctly adjusted, be sure and tighten all screws.
CAUTION: Any work on the controller should be
performed only with the power OFF. Remember to
enable the electrical interlocks before returnin
the unit to service. Failure to do so may result in
serious injury!
Note: The momentary energization o the locked out
contactor should only last a ew seconds or the contactor
coil could be damaged. This lockout test should be per ormed
with all o the busswork in place. Failure to do
so could damage the mechanical interlock.
contactor duty, the contact must be normally-open when
the operating magnet is not energized. There ore, the
contacts o the vacuum bottles must be held apart
mechanically against the air pressure when used in a
contactor. In the contactor, all o the bottles are held
open by a single kickout spring in the rear o the con-
tactor. The kickout spring pulls against the moving
armature and crossbar and thereby orces the bottles
into the open position. In the open position, the cross-
bar is pulling the moving contacts to hold them open.
The controller is intended to be mounted with its
mounting plate vertical and the moving stem o the
vacuum bottles aimed down. However, mounting posi-
tion is not critical. I an unusual position is required, it
is wise to check the pickup voltage on a bench be ore
installation, with the controller oriented as it will ulti-
mately be installed. The kickout spring ca be adjusted
as described under Kickout Sprin Adjustment, i
required to obtain the correct pickup voltage.
CAUTION: The easiest way to close the contactor
is to ener ize the coil. If the coil is ener ized for this
or other maintenance, use adequate care to uard
a ainst electrical shock.
Do not re-adjust the bottle nuts to reset overtravel
as the bottles wear. Once placed into service, overtravel
should be checked but not adjusted. A star-wheel
lock is included or locking the bottle nuts o each bot-
tle to prevent tampering.
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089

6
I the controller is checked in its cabinet, make cer-
tain that the contactor coil is electrically isolated, to pre-
vent eedback into a control trans ormer that could be
hazardous.
Connect a separate power source o correct AC volt-
age to the coil o the contactor. Operate appropriate
pushbuttons to close and open the contactor. I the con-
tactor does not close ully or does not drop out ully
re er to Ma net Operatin Ran e.
While the contactor is closed, observe the overtravel
gap between the pivot plates on the crossbar and the
bottle nut on each pole. This overtravel gap should be
not less than .045 inch when the contactor is new. I less
re er to Contact Wear Allowance. Disconnect separate
power source be ore proceeding.
While the contactor is open, attempt to pull the arma-
ture orward. The armature should not move because
it should already be irmly against the plastic main
rame. I it does move re er to Kickout Sprin
Adjustment.
CHECK-OUT, INSULATION LEVEL
A ter installation, and be ore energizing the controller
or the irst time, measure and record the insulation
resistance between poles and rom each pole to ground.
It is not practical to speci y an absolute value or this
reading since it is dependent on other connected
apparatus, and conditions o service. However, any
unusually low reading or sudden reduction in this reading
a ter the contactor has been in service indicates a
possible source o trouble, and the cause should be
determined and corrected be ore restoring power.
MAINTENANCE
Establish a maintenance program as soon as the
controller is installed and put into operation. A ter the
controller has been inspected a number o times at monthly
intervals, and the condition noted, the requency o
inspections can be increased or decreased to suit the
conditions ound, depending upon the severity o the
controller duty. It is a matter o operator judgment.
This industrial type control is designed to be installed,
operated, and maintained by adequately trained work-
men. These instructions do not cover all details, varia-
tions, or combinations o the equipment, its storage,
delivery, installation, check-out, sa e operation, or main-
tenance. Care must be exercised to comply with local,
state, and national regulations, as well as sa ety prac-
tices, or this class o equipment.
All work on this controller should be done with the
main circuit disconnect device open. Also, disconnect
power rom any other external circuits. Discharge any
hazardous capacitors.
LOSS OF VACUUM
Gross loss o vacuum is highly unlikely, but it can be
checked easily. With the contactor open, pull downward
on the bottle nuts, one pole at a time, using an e ort
o about 20 pounds. I the bottle nuts (see Figure 8)
move easily away rom their pivot, the vacuum has probably
ailed and the bottle unit must be replaced.
It is also unlikely, but possible, to have a very slight
Fig. 7 Torquing Locations
CHECK-OUT, VACUUM INTERRUPTERS (cont.)
In the dielectric strength o the contact gap. A good
interrupter will withstand a 5.5kV, 50 or 60 hertz voltage or
one minute across a 0.090 inch contact gap with less
than 1mA leakage. It will withstand a 7.8kV DC voltage
or one minute across the gap with less than .1 micro-
amperes leakage. Dielectric test using DC voltage should
be per ormed with polarities in both directions.
When the vacuum bottle is tested with voltage over
5000 volts across its open gap, there is some possibility o
generating X-rays. Test time should be minimized,
and personnel should not be closer than 10 eet. This is
a precaution until such time as the possible hazard
is better understood and standards are published.
Periodic dielectric tests across open contacts are
desirable since under certain operating conditions the
contactor may per orm satis actorily even though one
vacuum interrupter becomes de ective. Dielectric tests
should be made with the contactor in the same position
it has when operating.
The interval between periodic tests depends on the
number o operations per day, environmental actors,
and experience. It is a matter o operator judgment,
and philosophy o preventative maintenance.
CHECK-OUT, MECHANICAL
Make sure all power circuits are de-energized and iso-
lated. The controller can be checked in its cabinet or
outside.
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089

7
Chan in Operatin Coil
The operating coil has a pickup winding which is
intermittently rated. It may burn out in only minutes i
continuously energized at the rated voltage because the
L63 auxiliary contact does not open correctly.
Each AC coil contains its own recti ier to convert the
applied AC into un iltered ull-wave recti ied DC. DC
coils do not contain a recti ier. When the coil is at rated
voltage, the magnet will be silent. At reduced AC volt-
age, some slight hum may be heard. However the mag-
net must not chatter.
I or some reason a coil must be changed, proceed
as outlined below, re erring to Figure 8.
1. De-energize all circuits as previously speci ied.
2. Disconnect the leads to the coil terminals, noting
their position or later reconnecting.
3. Disconnect the line and the load leads rom the
contactor terminals.
4. Remove or ¼ x 20 screws (S) holding the rame
subassembly to the mounting base.
5. Li t the line side o the rame subassembly away
leak that does not change the bottle orce appreciably,
but which might seriously damage the ability o the bot-
tle to interrupt. In this regard, it must be remembered
that in a three-phase ungrounded circuit, it is possible
or any two good interrupters to success ully interrupt
the circuit even i the third interrupter is weak. But this
condition should not be allowed to continue. It can be
detected only by an electrical test. See Check-out
Vacuum Interrupters.
rom the mounting base until two dowels (D) are
clear o their holes. The rame subassembly will
automatically move under pressure rom the kick-
out system until the kickout bar reaches the end
o its slots in the mounting base. The rame sub-
assembly is then ree to be moved outward away
rom the coil and put elsewhere.
6. The coil is then accessible. Remove the two mount-
ing screws (M) to ree the coil.
7. Install replacement coil and replace mounting
screws.
8. Place the rame subassembly onto the mounting
base so that the two posts extending rom the
crossbar go through the oblong slots in the base
and into the notches in the kickout bar. Push the
rame subassembly a short distance along the sur-
ace o the mounting plate toward the kickout bar
until the dowels (D) slip into the dowel holes.
Replace the mounting screws (S). Make sure
that the coil leads to the L63 auxiliary contact
are not pinched under the frame feet.
9. Reconnect coil and recheck contactor or correct
adjustment per this lea let. By hand jiggle the ends
o the kickout bar(K) to make sure it is seated onto
the posts o the crossbar.
10. Reconnect line and load cables.
L63 Auxiliary Contact Adjustment
The nominal .34 pretravel gap shown or the L63
auxiliary contact (normally-closed) in the le t upper por-
tion o Figure 8 is important. I the gap is too big, the
hold winding o the operator coil will not be inserted
as the contactor closes, and the pickup winding will
burn out, because the pickup winding is only intermittently
rated. I the gap is too small, the hold winding will be
inserted too soon, reducing the orce to hold be ore the
WARNING: All work on this contactor should be
done with the main disconnect device open. As with
any contactor of this volta e, there is dan er of
electrocution and/or severe burns. Make certain that
the power is off.
Fig. 8 Contactor Portion of a V200 Motor Controller
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089

8
contactor is closed, and producing an oscil-
lation like a doorbell. In a particular contactor, the .34
gap may need slight adjustment to avoid these problems.
The key is not the measurement, but the per ormance o
the magnet. Replacement L63 auxiliary contacts are available
as Part No. 578D461G03.
The other auxiliary contacts are not as critical. In
the open position, their plungers may rest lightly against
the operating arm, or may have a small clearance.
However, neither L63, Type J nor L56 plunger should
bottom solidly in the closed contactor position, as discussed
under Ma net Operatin Ran e. I required, the auxiliaries
can be adjusted by resetting their mounting brackets in their
slotted holes. Adjust the L63 by loosening the two slotted
hexagonal washer head screws the hold the L63
mounting bracket, repositioning and tightening. These
bracket mounting screws are visible rom the top
side o the contactor and are recognized by the slotted
holes under their heads.
Kickout Sprin Adjustment
The kickout spring is not disturbed by any maintenance
described in this lea let, and it should not need to be adjusted.
However, when the contactor is in the de-energized, open
position, the crossbar should be solidly against the rame,
so that it cannot move any urther open even when pulled.
It can removed, the kickout spring must be stretched to
hold the crossbar irmly
against the rame. Re er to igure 9. Loosen the lock nuts
and tighten the adjusting screws alternately (to keep the
spring on centerline) until the orce orm the spring holds
the crossbar properly open. Lock the two lock nuts again.
Inspection After Short Circuit
The V200 or V210 motor controller is intended to be
protected by power uses and/or a circuit breaker in
accordance with the NEC. However, the magnitude o a
short circuit may exceed the damage threshold o the
vacuum bottles. A ter a short circuit, the unit should be
examined or any apparent physical damage, or de ormation
o conductor bars and cables. I there is any evidence o
severe stress, it is recommended that the unit be replaced.
I the overtravel has changed signi icantly ( rom the last
inspection) on one or more bottles, the unit should be
replaced.
A dielectric test would not by itsel con irm that the unit
should be returned to service a ter a ault. However, i there
is no physical evidence o stress, and i the overtravel
exceeds the .020 in. minimum, the bottles can then be
dielectrically tested as outlined previously. I physical stress,
overtravel, and dielectric are O.K., it is reasonable to return
the unit to service a ter a ault.
Insulation Level
Re er to the insulation resistance measurements
between poles and rom each pole to ground that were
recorded at start-up and subsequent intervals. Measure
the same points in the same manner and record. Investigate
any sudden reduction in resistance or any unusually low
reading.
Dust and moisture are detrimental to electrical equipment.
Industrial equipment is designed to tolerate a
less-than-per ect environment. However, excessive dust
can cause trouble, and should be wiped or blown o
at appropriate intervals. I the contactor is wet or any
reason, it must be dried until insulation resistance between
poles and rom each pole to ground has returned
to normal.
Fig. 9 Kickout Spring
Kickout
Sprin
Lock
Nuts
Adjustin
Screws
TABLE VIII - ACCESSORIES
Fuse Block Kits - Meet requirements of
NEC concernin common control fusin .
Qty. Description
*Use when available ault current exceeds 10,000 amperes
F56
FKR
Order
Cat No.
2
1
Contactor mounted Fuse Holder
or 1 600 volt Buss KTK Fuse
Panel mounted Fuse Holder or 2
Class CC (Bussman KTKR) Fuses*
Controller
Size
Order Fuses Separetely By Ampere Ratin .
Minimum Wire
Size in Control Circuit
Su ested
Fuse Size 
 When using a control trans ormer, select use size per
the National Electrical Code.
540A #16 AWG 10 AMP
E ective 5/07
Supersedes il17089B (6/98)
Eaton Corporation
Electrical Components Division
4201 North 27th Street
Milwaukee, WI 53216
Printed in USA
V200, V210, 540 AMPERE VACUUM MOTOR CONTROLLER I.L. 17089