EATON A200 Size 5 Motor Controller

J-type contact rated values (A600, R300):

120-600 V AC: continuous current of 10 A, connecting capacity of 7200 VA, breaking capacity of 720 VA

28-300 V DC: continuous current 1.0 A, on/off capacity 28 VA

GCO type current transformer

The GCO type current transformer is designed specifically for the A200 Size 5 controller and is used to drive Type A or Type B thermal overload relays. Its transformation ratio is 300/5, the shell is black, the primary winding is composed of the load connection piece of the controller, and the secondary winding leads are white and black for polarity identification.

Important warning: GCO current transformers should not be used to supply power to other auxiliary equipment, and it is strictly prohibited to power on the secondary side with an open circuit, otherwise the generated overvoltage will damage the transformer.

Installation steps (see Figure 7):

Rotate the contactor crossbar assembly to the position shown in the diagram.

Loosen the installation bolt A of the lower static contact, remove the clamping bolt B of the load connection piece, and rotate the load connection piece C.

Push the GCO transformer into the load connection piece C, with the secondary lead facing upwards, and insert the anti vibration spring clamp S.

Thread the secondary leads W1 and W2 through the contactor base, and if necessary, remove the operating coil for wiring.

Turn the load connection piece C back to its original position and tighten bolts A and B (static contact bolt torque 150-175 lb in).

Reinstall the operating coil to ensure that W1 and W2 are not sandwiched between the coil and the mounting surface.

If only two transformers are used, they should be installed on the left and right sides, with the middle omitted.

Overload relay wiring:

The overload relay must be installed vertically with the reset rod facing downwards (see Figure 8). Secure it to the screw holes of the contactor bearing bracket using two 8-32 mechanical screws. Connect the GCO secondary lead to the overload relay terminal as shown in the diagram: connect the white wire to the terminal, and each pair of wires (one black and one white) must be connected to the same pole of the overload relay.

Coverage: GCO 300/5 transformer+A/B type thermal overload relay+A200 Size 5 controller combination, can provide overload protection for motors with full load current of 118-300 A and up to 600 V.

Incoming and load terminals

Both the incoming and load terminals have holes with a diameter of 17/32 inches, suitable for fasteners with a diameter of 1/2 inch. If crimping type terminals are used, the incoming side should be installed behind the copper incoming connection piece for easy control of wiring; The load side should be installed at the front. The crimping terminal can be ordered separately, part number 2119A76H01.

mechanical interlock

When multiple controllers are used in combination, mechanical interlocking can be used to prevent both controllers from closing simultaneously. The mechanical interlocking combination of vertical and horizontal components is shown in Table VII.

Maintenance Guide

Magnetic suspension system

Both fixed and movable magnet components are installed flexibly to ensure good sealing and quiet operation of the magnets. Spiral compression springs and leaf springs are located on the back of each magnet component. The spring force and constraint of the movable armature are smaller than those of the fixed magnet component. If disassembling the magnet, it is necessary to ensure that the plate spring is located at the center of the laminated magnet assembly and is not stuck between the magnet and the molded guide protrusion. After reassembly, it should be checked that both the fixed and movable magnets can be manually pressed or shaken, and the movable armature should be more flexible than the fixed component.

Contact overtravel

The initial overtravel of the new contact is 13/64 to 17/64 inches (see Figure 10-B). When the overtravel of any pole decreases to 1/16 inch, all pole contacts must be replaced. The replacement steps are as follows:

Turn off the power, remove the arc extinguishing cover, and gently lower the crossbar.

Remove the three moving contact components.

Remove the compression spring from the component and twist the contact to remove it from the saddle.

Use a 1/4 inch hex wrench to remove the static contact.

Install the new contacts in reverse order, ensuring that all bolts are tightened (static contact bolt torque 150-175 lb in), the crossbar is correctly positioned, and the arc extinguishing cover is securely fixed.

The new contact design is to first contact the bottom surface and then the top surface, and all moving contacts of the poles should simultaneously contact the stationary contacts, with an error not exceeding 1/32 inch.

contact pressure

When using new contacts, the total contact pressure for each pole should be:

Initial pressure: 6-7 pounds (see Figure 10-A)

Final pressure: 7.5-8.5 pounds (see Figure 10-B)

arc extinguishing cover

The arc extinguishing cover provides a mechanical stop for the moving contact assembly, maintaining the opening distance of the main contact, and contains De ion type arc extinguishing grids inside. Regularly check whether the grid is damaged due to malfunction. It is strictly prohibited to power on the controller without securely installing the arc extinguishing cover.