Installation Instructions
Original Instructions
Neutral Position Limit Switch
Bulletin Number 802T
9.
The contact block and operating head for the neutral position limit switch are not
generally available as field replacement parts. These parts are not precalibrated
for field interchangeability. Do not conduct a field replacement of a contact block
or operating head in a neutral position switch unless you have the personnel and
equipment to perform the following calibration procedure.
Recheck the angles per step 7. If the reset overtravel angles are still not
within the required limits, repeat step 8 until they are obtained.
10. Replace enclosure cover and tighten screws to 0.56 N•m (5 in•lb).
Operating Head Replacement
Contact Block Replacement
1.
Remove the cover from the front of the switch enclosure.
IMPORTANT
1.
SHOCK HAZARD: Verify that all electrical power to the switch is
disconnected.
2.
3.
4.
5.
6.
7.
8.
Remove the screw and crescent-shaped retention bracket that holds the
contact block into the enclosure. This retaining bracket is on the conduit
end of the enclosure.
Lift out the contact block.
Verify that the insulator in the bottom of the enclosure stays in place and
that the U-shaped actuator slide stays attached to the operating head
plunger. See Figure 1.
Place the replacement contact block into the enclosure. Verify that the
actuator slide engages the opening in the back of the contact block.
Secure the contact block in place with the retaining bracket and screw.
Verify that the retaining bracket is placed with the deflected ends inward.
After you have replaced the contact block, measure the angular reset
overtravels of the operating shaft to verify that they are within 0.5° of one
another. The reset overtravel angles, angles A and B in Figure 1 must not be
less than 3°. You must provide a test setup for measuring these angles.
This setup must have the following (or equivalent) features:
a. The switch is secured to a surface so it cannot move.
b. An indicator or pointer to aid in angle measurement. (A catalog number
802T-W3 lever is suggested.)
c. The angles are measured with a protractor.
If the reset overtravel angles require adjustment, you must follow the
following procedure:
a. Remove the contact block following step 2 and step 3.
b. The adjusting nut is the 6.35 mm (0.25 in.) hexagon-shaped piece that
extends from the head into the switch enclosure. The groove at the end
of the adjusting nut retains the actuator slide.
c. To make the adjusting nut more accessible, rotate the operating shaft
of the head in a clockwise direction.
d. If necessary, remove the actuator slide to get sufficient access to the
adjusting nut. To remove it, rotate the actuator slide 90° and slip it out
of the groove in the adjusting nut.
e. Actual adjustment of the reset overtravel angles is accomplished by
turning the adjusting nut about 1/4 turn. If angle A is smaller, turn
adjustment nut clockwise. If angle B is smaller, turn adjustment nut
counter clockwise.
f. To replace the actuator slide, slip it into the groove on the adjustment
nut from the side and rotate it to the bottom of the casting.
g. Replace the contact block by following step 4…step 7.
You must remove the contact block from the switch
enclosure before you can replace the operating head.
Remove the cover from the front of the switch enclosure.
SHOCK HAZARD: Verify that all electrical power to the switch
is disconnected.
2.
Remove the screw and crescent-shaped retension bracket that holds the
contact block into the enclosure. This retaining bracket is on the conduit
end of the enclosure.
3. Lift out the contact block.
4. Remove the four slotted-head screws that secure the operating head to
the switch enclosure.
5. Lift the operating head from the switch enclosure. The U-shaped actuator
slide remains attached to the operating head adjustment nut.
6. Slip the actuator slide out of the groove in the adjusting nut.
7. Install the actuator slide on the replacement operating head by slipping
the slide into the groove on the replacement adjustment nut.
8. Position the replacement operating head over the switch enclosure. Slip
the actuator slide through the opening in the switch enclosure and align
the diaphragm seal with the seat in the switch enclosure.
9. Before you replace the four operating head mounting screws, confirm that
the insulator in the bottom of the switch enclosure is in place. Make sure
to position the actuator slide so that the insulated end engages the
opening in the back for the contact block.
10. Replace the four head mounting screws and tighten to a torque of
0.68 N•m (6 in•lb).
11. Follow step 5…step 10 in Contact Block Replacement.
Figure 1 - Operating Head
Reset
Reset
B
Trip
A
Trip
Adjustment Nut (6.35 mm [0.25 in.] Hex)
Rotate the shaft clockwise to make nut more
accessible.
Actuator Slide
To remove, rotate and slip the operator off the
adjusting nut.
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Publication 802T-IN011B-EN-P - June 2021 | Supersedes Publication 802T-IN011A-EN-P-February 2020
Copyright © 2021 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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