CTRLPSB044:

X131 Contactor Tip

replacement guide
(inclusive)

Author: Tin Man Wong / John Palmer

Revision: Rev 0

Date: April 3, 2014

Guidelines for Contactor p/n 41A296327ALP2 & P11 Tip Replacement

(InvertexTM AC Drive RP1, RP2, RP3 Retard Contactors)

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT OR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE
MET IN CONECTION WITH INSTALLATION OPERATION OR MAINTENANCE. SHOULD FURTHER INFORMATION BE DESIRED, OR SHOULLD PARTICULAR
PROBLEMS ARISE WHICH ARE NOT COVERED SUFFICIENTLLY FOR THE USER’S PURPOSES, THE MATTER SHOULD BE REFERRED TO GE. AN APPLICABLE
FEDERAL, STATE, LOCAL REGULATIONS OR COMPANY SAFETYOR OPERATION RULES MUST TAKE PRECEDENCE OVER ANY INSTRUCTIONS GIVEN IN THIS
MATERIAL. GE HAS NO OBLIGATION TO KEEP THE MATERIAL UP TO DATE AFTER THE ORIGINAL PUBLICATION.
THERE ARE NO WARRANTIES OF ACCURACY MECHANTABILIBTY OR FITNESS PARTICULAR PURPOSE.

Safety Cautions and Warnings appear throughout these instructions. WARNING indicates
the potential for personal injury and CAUTIONS indicate the potential for equipment
damage. The following warnings should be read prior to working on this drive system.

WARNING: Equipment must be isolated and confirmed as de-energized prior to

commencing any work on this equipment. Follow all site specific lockout, isolation and
safe work procedures.

WARNING: Hazardous voltages are present in this equipment. Ensure the Control
Power Switch (CPS) is in the OFF position and the Generator Field Contactor (GFCO)
switch is in the CUTOUT position before attempting any work. Check that the Capacitor
Charge Lights (CCL’s) are NOT illuminated. Use a suitable voltage measuring device to
VERIFY that no voltage is present before touching any terminal. Failure to observe
these precautions may results in death or serious injury.

1. DESCRIPTION

The objective of this document is to provide guidelines for the correct replacement of
contact tips used in GE Part # 41A296327ALP2 and 41A296327ALP11 contactors.

2. IMPORTANT! REPLACE ALL CONTACT TIPS AS A SET

Note: Whenever the contactor plate material is within 1/32” of the base metal on one
of the contacts, the complete contact set must be replaced.

3. IMPORTANT! USE ONLY GENUINE GE PARTS

There are only two genuine GE part numbers for the contact tip sets (which include all
contact tips, springs and caps):
 41A296327ALP103 (standard tip), 41A296327ALP105 (tungsten carbide tip – gives
longer life)
Refer to GE TIPS Issue 49 for identification of non-genuine tips. Located in GE
Customer Web Center, “Product Content and Manuals” tab, click on tip sheets “2000-
2009”.

4. Open contactor cabinet door; push down on tab L/H/S to remove Arch Chute covers.

5. To remove the RP link bus bar, remove 2 bolts on each contactor connection point
behind the blowout coil and the 2 nuts from the main connection point on each
contactor. Note: The 2 bolts are not removed. (welded to lower bus bar)
6. Remove the 2 horizontal Allen-head bolts to remove the blowout coil.

7. Remove the front contact tip and the 2 Allen-head bolts from the rear tip retaining
plate. This plate and the rear Allen-head bolts will be reused.
8. Remove the rear contacts; 3 tips, 3 caps and 6 springs. Check the stationary tips
retaining plate for wear and replace the plate is excessive wear at the spring and caps
area is observed (excessive wear can cause the stationary tips not align properly after
new tips are installed).

9. Contactor should be vacuumed for all loose debris and all surfaces cleaned (do not
use compressed air).
10.Replace 6 springs (larger springs to the front) and the 3 caps. Fit all new springs and
caps to the base of the stationary tips. Recommend to align all 3 stationary tips and
carefully place the tips on the caps/springs, ensure all 3 tips are seated correctly then
install the retaining plate.

11.Tighten 2 Allen-head bolts (with lock washers) to 150-250 IN-LBS that hold the
retaining plate for the stationary tips. Check each pivot contact to ensure pivot and
return freely. Check the pivot gap between each tips and the retaining plate 0.025 to
0.050 inches.
12.Install the new front tip with the supplied new Allen-head bolts and lock washers,
tighten the bolts to 110-150 IN-LBS.
13.The diagram below and measurement instructions are from GEK_91698A Seimens-
Hubbell RP contactor document.
Use this guide to test if tips are seated properly. Or use the alignment tool if
available.

With the horizontal alignment tool, insert the tool into the moveable tip and the tip
should close properly without any interference. If the tips cannot be closed, adjust
the horizontal alignment until the tips are closed.

With the vertical alignment tool, the contact tips would close properly if the vertical
alignment is within spec. If the tips cannot be closed properly, re-adjust the movable
tips until the tips are closed properly with the alignment tool.

If the alignment tools are not available at the site, reinstall the arc chute to the
contactor after the new tips are installed. Activate to close the contacts a couple of
times to listen for the sound when the tip is dragging along the arc chute walls.
Remove the arc chute to check for new drag marks on the arc chute interior walls. If
there is no new mark found and no abnormal dragging sound is noted then the
vertical alignment is acceptable.
14.Reinstall the blow out coil and RP bus bar link. Note: Ensure the vertical Allen-head
bolts are started correctly, if they are cross threaded when reinstall the contactor will
have to be replaced.

15.Reinstall the arc chutes and test contactor action (use manual digital output test if
wPTU and laptop are available).

End of Procedure