Replacing a (3NO) Contactor in the Rack Mount 3-Phase Power Distribution Unit

Complete the following steps before beginning this repair procedure:
  1. Power off the ATE Core Configurations Generation 2 by flipping the main disconnect branch breaker to off.
  2. If your ATE Core Configurations Generation 2 utilizes a UPS to provide backup power, press the power button on the UPS to power it down.
  3. Disconnect the ATE Core Configurations Generation 2 from facility power.
Refer to the following table to see which shipping kits this procedure applies to.
Shipping Kit Part Number Description
789094-01 440 V 3-Pole (3NO) Contactor, 24 V to 60 V DC Controlled

This procedure only applies to ATE-38U, ATE-44U, and ATE-38E racks.

Equipment

  • 3 mm hex key
  • T10 Torx head screwdriver, 0.76 N · m (6.7 in. · lb)
  • T30 Torx head screwdriver, 6.00 N · m (53.1 in. · lb)
  • #3 Phillips head screwdriver, 2.49 N · m (22.0 in. · lb)
  • #2 Phillips head screwdriver, 1.70 N · m (15.0 in. · lb)
  • T8 Torx head screwdriver, 0.76 N · m (6.7 in. · lb)
  • 4 mm hex key, 5.00 N · m (44.3 in. · lb)
  1. If necessary for easier access to the 3-Phase power distribution unit (PDU), open the rear door of the rack.
  2. Remove the right side panel of the ATE Core Configurations Generation 2 using the 3 mm hex key.
  3. Unscrew the four screws to remove the 3-Phase filter cover bracket from the 3-Phase PDU using the T10 Torx head screwdriver.


    1. 3-Phase filter cover bracket
  4. Disconnect the 3-Phase filter input cables from the 3-Phase PDU using the T30 Torx head screwdriver.
  5. Disconnect the DC contactor cable from the 3-Phase PDU.


    1. 3-Phase filter input cables
    2. DC contactor cable
  6. Unscrew the ground cable ring lug from the ATE Core Configurations Generation 2 using the #3 Phillips head screwdriver.
  7. Unscrew the four screws which mount the 3-Phase PDU to the front mounting rail brackets using the T10 Torx head screwdriver.
  8. Unscrew the four screws that mount the rear side mount brackets of the 3-Phase PDU to the rear rails of the ATE Core Configurations Generation 2 using the 1.70 N · m #2 Phillips head screwdriver.


    1. Ground cable ring lug
    2. Front mounting rail brackets
    3. Rear side mount brackets
  9. If necessary, unscrew the ground cable ring lugs from the contactor cover using the #3 Phillips head screwdriver.
  10. Unscrew the four screws to remove the rear service panel using the T10 Torx head screwdriver.


    1. Rear service panel
  11. Unscrew the five screws to remove the contactor cover using the T8 Torx head screwdriver.


    1. Contactor cover
  12. Disconnect the panel-to-contactor cables from the (3NO) contactor using the #2 Phillips head screwdriver.
  13. If necessary, disconnect the daisy chain contactor cables from the contactor using the #2 Phillips head screwdriver.
  14. Disconnect the circuit-breaker-to-contactor cables from the contactor using the 4 mm hex key.


    1. Panel-to-contactor cables
    2. Daisy chain contactor cables
    3. Circuit-breaker-to-contactor cables
  15. Remove the contactor from the DIN rail.
  16. Install the new (3NO) contactor on the DIN rail.
  17. Reconnect the panel-to-contactor cables to the new contactor using the #2 Phillips head screwdriver.
  18. If necessary, connect the daisy chain contactor cables to the new contactor using the #2 Phillips head screwdriver.
  19. Connect the circuit-breaker-to-contactor cables to the new contactor using the 4 mm hex key.
  20. Screw in the contactor cover using the T8 Torx head screwdriver.
  21. Screw in the rear service panel using the T10 Torx head screwdriver.
  22. If necessary, screw in the ground cable ring lugs to the contactor cover using the #3 Phillips head screwdriver.
  23. Mount the rear side mount brackets of the 3-Phase PDU to the rear rails of the ATE Core Configurations Generation 2 using the #2 Phillips head screwdriver.
  24. Mount the 3-Phase PDU to the front mounting rail brackets of the ATE Core Configurations Generation 2 using the T10 Torx head screwdriver.
  25. Screw in the ground cable ring lug to the ATE Core Configurations Generation 2 using the #3 Phillips head screwdriver.
  26. Reconnect the DC contactor cable to the 3-Phase PDU.
  27. Reconnect the 3-Phase filter input cables to the 3-Phase PDU using the T30 Torx head screwdriver.
  28. Reinstall the 3-Phase filter cover bracket using the T10 Torx head screwdriver.
  29. Reinstall the right side panel of the ATE Core Configurations Generation 2 using the 3 mm hex key.
  30. If necessary, close the rear door of the ATE Core Configurations Generation 2.
Once installation of the new (3NO) contactor is complete, you can reconnect facility power to the ATE Core Configurations Generation 2 and power on the rack.