Rockwell Automation 500LC Pole Conversion Modification - Manual (Page 3)

Installing Pole Conversion Kits 500LC–2PCK, 4PCK, 6PCK, LS3 to Bulletin 500LC Lighting Contactors 3
Publication 500LC–IN004A–EN–P May 2005
How to Install a Contact Block
To avoid personal injury or property
damage, de–energize both line and control
power connected to the Bulletin 500LC
Lighting Contactor before proceeding.
CAUTION
1. Open circuit breakers, then use a voltmeter to verify no voltage is present at
both control and line terminal screws.
2. Label, disconnect, and tape all wires (control, line, load) from the lighting
contactor.
3. Loosen the mounting screws and remove the Bulletin 500LC Lighting
Contactor from the enclosure.
Disassembly
The contact blocks are mounted on the top and bottom of the lighting contactor.
A bottom contact block is used only for lighting contactors with more than six
poles. See Figure 2 and Table A.
1. Remove the contact block(s). Skip this step if it is not necessary to move or
remove a contact block. Loosen the two screws in each contact block. Then
pull the contact block straight out.
Do not remove the captive screws from the contact block. The lower actuator
may drop out when the bottom contact block is removed.
2. Remove leaf spring if converting a 2–...6–pole lighting contactor to an
8–...12–pole lighting contactor. For leaf spring removal see Figure 1.
Note: When converting an 8–...12–pole N.O. lighting contactor to a
2–...6–pole lighting contactor a leaf spring and new actuator must be installed.
See Figure 1.
Reassembly
Be sure the contact blocks and actuator are correct for the number of poles
required. Lighting contactors with more than six poles use two contact blocks.
When two are used, always mount the six pole contact block on the top of the
lighting contactor. See Figure 2 and Table A.
1. Slide the actuator into the cavity (roller facing in, with the guides facing away
from the base of the lighting contactor) before installing the contact block.
2. With actuator(s) already installed, install the new contact block(s) onto the
base. Tighten the two screws in each contact block to 10 in–lb. See Figure 1.
3. Converted lighting contactors must be assembled as shown with contact blocks as
shown in Figure 2. If any contact blocks are removed to accomplish the
conversion, a leaf spring must be installed.
4. Use a scriber to change the nameplate catalog number (number of poles).
5. Install the manual operating screw. Insert the #8–32 screw (from the kit) into
the center of the coil and carefully turn it clockwise until the threads engage
the cam/core. See Figure 3. Tighten hand tight. See Figure 3.
6. Manually operate the lighting contactor. Use the plastic screw to close and
open the lighting contactor by pushing it inward and pulling it outward.
Observe the buttons in the contact blocks(s); the contacts are open when the
buttons are out. The action should be smooth, without any binding. If not,
recheck alignment of contact block(s) and actuator.