Installation Instructions
Original Instructions
Contact Kit
Bulletin Number 802R
This contact kit includes a replacement contact unit along with a mounting clamp,
ground screw post, and ground screw for your convenience. The contact unit has
been factory set for nominal operating values.
3.
Figure 1 - Top, Front, and Bottom View
3/16 in. Hex Head
Adjustment Screw
4.
Terminal
Screws
IMPORTANT
5.
Top View
Ground Screw and
Ground Screw Post or
Mounting Screw Only
Front View
Slide the contact unit gently into the switch enclosure, positioned so that
the ground screw post engages the tapped hole near the bottom of the
cavity. Do not force the contact unit if it stops short of full insertion into
the cavity. With certain types of operating heads, it is necessary to hold
the operating mechanism in the fully operated position while maintaining
light pressure on the contact unit to achieve full insertion. When the
contact unit is fully inserted (flush with front face of switch enclosure),
tighten the ground screw post by turning clockwise to 8…12 in•lb of torque.
Install the ground screw into the end of the ground screw post.
Connect a continuity indicator across the terminals of the contact unit.
Now operate the limit switch by hand. If positive contact operation is
indicated, no adjustment is necessary. If not, proceed to step 5.
Mounting
Clamp
To gain access to the adjustment screw (see Figure 1), either remove the
contact unit as in step 1, or remove the operating head, which is attached
to the switch housing by four screws. Use a 3/16 in. nut driver to turn the
adjustment screw out (counterclockwise) 1/4-turn.
IMPORTANT
Ground
Screw
6.
Mounting
Clamp
1.
Bottom View
Remove the front cover from the switch enclosure. To remove the contact
unit that is to be replaced:
a. Turn the ground screw and then the ground screw post (or just
mounting screw) counter-clockwise until unscrewed completely.
b. Slide the contact unit out of the switch enclosure (see front and
bottom views in Figure 1).
IMPORTANT
2.
Ground
Screw Post
Leave the sheet metal shield in the switch enclosure.
Place the ground screw post in the mounting clamp, and the mounting
clamp in the replacement contact unit, positioned as shown in Figure 1.
IMPORTANT
Depending on the mounted position of the switch into
which the contact unit is to be installed, it may be
necessary to hold the mounting clamp and ground
screw post in position with a screwdriver while
inserting the contact unit into the switch enclosure.
The adjustment procedures that are outlined in step 5
have to be made on a trial and error basis. This method
is necessitated since the effect of turning the
adjustment screw varies with the type of operating
head being used.
This position is the maximum counterclockwise
position of the adjustment screw — further movement
in this direction could damage the device. Replace the
contact unit (step 2 and step 3) or the operating head,
whichever was removed for access to the adjustment
screw.
Retest the switch as in step 4. If further adjustment is needed, repeat step
5 except turn the adjustment screw 1/6-turn clockwise and retest again as
in step 4. Repeat the modified (clockwise adjustment 1/6-turn) step 5,
followed by step 4, as many times as necessary to obtain satisfactory
contact operation. Keep count of the number of turns the adjusting screw
is turned clockwise in case it is necessary to repeat the procedure and
begin again the maximum counterclockwise position. Do not force the
adjustment screw if it bottoms out before correct operation is achieved —
check the continuity indicator and repeat the entire adjustment sequence.
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Publication 802R-IN002B-EN-P - April 2021 | Supersedes Publication 802R-IN002A-EN-P - January 2019
Copyright © 2021 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.
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40060-290-01 Ver 01
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