Service How To Procedures K1 Contactor - Replacement
Last updated: 03/19/2020

K1 Contactor - Replacement

AD0254

Introduction

This procedure tells you how to replace the K-1 contactor.

The new contactor may mount to the back of the circuit breaker assembly [1]. This type of circuit breaker has quick-disconnect terminals. The new contactor may mount to the chassis plate [2] of the control. This type of contactor does not have quick-disconnect terminals. Both types of contactors operate the same.

This document applies to these parts:

PN: 93-2311, IEC CONTACTOR ELECTRICAL KIT

Electrical Safety

 Caution: When you do maintenance or repair on CNC machines and their components, you must always follow basic safety precautions. This decreases the risk of injury and mechanical damage.

  • Set the main circuit breaker to the [OFF] position.

 Danger: Before beginning any work inside the control cabinet the High Voltage indicator light on the 320V Power Supply / Vector Drive must have been off for at least 5 minutes.

Some service procedures can be dangerous or life-threatening. DO NOT attempt a procedure that you do not fully understand. If you have any doubts about doing a procedure contact your Haas Factory Outlet (HFO) and schedule a service visit.

K1 Contactor - Breaker Mount Type - Replacement

1

Do this procedure to install a contactor which mounts to the control chassis plate. This type of contactor replaces the type that mounts to the back of the circuit breaker. This kind of contactor does not have quick-disconnect terminals.

Push [POWER OFF].

Danger: Disconnect the main power supply to the machine.

Danger: After you disconnect the main power supply, wait for the LEDs on the early power-fault detection module (EPFDM) and the vector drive to go off fully. This may take 20 or more minutes.

2

Disconnect the electrical supply wires [1] to the circuit breaker assembly [2]. Record the color sequence of the wires.

Remove the cover from the PSUP PCB. This makes it easier to remove the circuit breaker assembly.

Disconnect the (3) transformer cables [3] at the transformer.

Remove the circuit breaker assembly.

Remove the contactor [4] from the circuit breaker assembly.

3

Move the cables from the used contactor to the replacement contactor [1].

Attach the replacement contactor to the rear of the circuit breaker assembly [3].

Connect the contactor cables [4].

Install the main circuit breaker assembly to the side of the cabinet.

Connect the transformer cables [5] from the contactor to the transformer.

Connect the electrical supply wires [2] to the circuit breaker.

K1 Contactor Breaker Mount Type

1

Do this procedure to install a contactor which mounts to the control chassis plate. This type of contactor replaces the type that mounts to the back of the circuit breaker. This kind of contactor does not have quick-disconnect terminals.

Push [POWER OFF].

Danger: Disconnect the main power supply to the machine.

Danger: After you disconnect the main power supply, wait for the LEDs on the early power-fault detection module (EPFDM) and the vector drive to go off fully. This may take 20 or more minutes.

2

Disconnect the electrical supply wires [1] to the circuit breaker assembly [2]. Record the color sequence of the wires.

Remove the cover from the PSUP PCB. This makes it easier to remove the circuit breaker assembly.

Disconnect the (3) transformer cables [3] at the transformer.

Remove the circuit breaker assembly [2].

Remove the contactor [5] from the circuit breaker.

Disconnect the 71-73 cable [4] at the power supply (PSUP) PCB.

Disconnect the auto/off cable [6] at the I/O PCB.

3

Connect these cables:

  • Circuit breaker cables [1] to the ports that have the label "1 L1", "3 L2", and "5 L3."
  • CABLE 71/72/73 POWER K1 TO PS [B] to the ports that have the label "1 L1", "3 L2", and "5 L3"
  • CABLE 170 AUX/COIL CABLE leads that have the label "COIL" [A-1]:
    • Red to the port that has the label "A1"
    • Black to the port that has the label "A2"
  • CABLE 170 AUX/COIL CABLE leads that have the label "AUX" [A-13]:
    • red to the port that has the label "13"
    • black to the port that has the label "14"
  • transformer cables [3] to the ports that have the label "2 T1/4 T2/6 T3"

Attach the replacement contactor [4] to the CONTROL CONTACTOR ADAPTER PLATE [C]. Attach the adapter plate to the chassis plate of the control cabinet.

4

Connect the contactor-circuit breaker cables [3] to the circuit breaker [2].

Install the main circuit breaker to the side of the cabinet.

Connect the transformer cables [4] from the contactor to the transformer.

Connect the electrical supply cables [1] to the circuit breaker in the order you removed them.

5

Connect the cables in the kit to the contactor. Read the labels on the cables to make these connections:

  • Cable 71/72/73.
    • Classic Control with I/O PCB version S
      • PSUP PCB P25 [1]
      • PSUP PCB P23 [2]
    • Next Generation Control
      • PSUP PCB P19 [3]
      • PSUP PCB P14 [4]
  • Cable 170
    • I/O PCB P42 [5]

K1 Contactor -Chassis Plate Mount Type - Replacement

1

Do this procedure to install a contactor which mounts to the control chassis plate. This kind of contactor does not have quick-disconnect terminals.

Push POWER OFF.

Danger: Disconnect the main power supply to the machine.

Danger: After you disconnect the main power supply, wait for the LEDs on the early power-fault detection module (EPFDM) and the vector drive to go off fully. This may take 20 or more minutes.

2

Disconnect the electrical supply wires [1] to the circuit breaker assembly [2]. Record the color sequence of the wires.

Remove the cover from the PSUP PCB. This makes it easier to remove the circuit breaker assembly.

Disconnect the (3) contactor/circuit breaker cables [3] from the circuit breaker.

Remove the circuit breaker assembly [2].

Disconnect the (3) transformer cables [5] at the transformer.

Remove the contactor bracket [4] from the control chassis plate.

Remove the contactor from the contactor bracket.

3

Move the cables from the used contactor to the replacement contactor [1].

Attach the replacement contactor [1] to the adapter plate [2].

Attach the adapter plate to the chassis plate of the control cabinet.

4

Connect the contactor/circuit breaker cables [3] to the circuit breaker [2].

Install the main circuit breaker to the side of the cabinet.

Connect the transformer cables [4] from the contactor to the transformer.

Connect the electrical supply cables [1] to the circuit breaker in the order you removed them.

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