ABB ConVac Owner's manual

•Improve efficiency and increase your output
•Optimize investments to reduce your
operating costs
•Safe and reliable protection of your electrical
equipment
—
INSTALLATION AND OPERATION INSTRUCTION
ConVac Vacuum Contactor
7.2/12 kV, ...400 A

04
05
06
06
07
07
07
08
10
11
11
12
24
26
33
33
For your safety!
I. Foreword
II. Environmental protection program
III. Application of the X-ray emission standards
IV. Safety Information
V. Operator requirements
VI. Site Commissioning
1. Overview
2. Delivery inspection and acceptance
3. The loading and unloading
4. Transportation and storage
5. Installation
6. Putting into service
7. Maintenance
8. Spare parts and accessories
9. Product quality and environmental protection
—
Table of contents

—
For your safety!
4CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
Please read this manual carefully before installing
and using contactor
•Contactor should only be installed indoors
where electrical equipment is suitable for work
•Ensure that installation, operation and
maintenance are carried out by dedicated
electricians
•Must ensure the connection conditions of the
electrical equipment on site and the application
of the working procedures with security
•All operations related to contactor shall comply
with the relevant provisions in the manual
Attention！
Pay special attention to the notes marked
with this danger sign in the manual.
•Do not exceed the load specified in the technical
parameters of the contactor under normal
operating conditions
•The manual should be placed within easy reach
of all personnel involved in installation,
operation and maintenance
•User's full-time personnel shall be responsible
for all matters affecting job safety and properly
manage contactor
Warning！
•Always comply with the provisions of the
installation manual and safety operating
instructions
•high voltage hazard
•Dangerous voltage may cause electric shock and
fire
•Power must be cut off before performing any
work on the equipment

—
I. Forward
FORWARD 5
This instruction is suitable for ConVac series
vacuum contactors. In order to use this product
correctly, please read this manual carefully.
Similar to our other products, ConVac vacuum
contactors are designed for a variety of
installations and can be further modified
technically and structurally to suit the specific
requirements of the customer. Therefore, the
information provided in this manual may not
include special configuration information.
In addition to this manual, users will often need
to consult the latest technical documentation
(electrical circuit and wiring diagrams, assembly
and installation drawings, interfaces with different
integrated relays, etc.), especially in relation to
standard structural changes.
Only original spare parts can be used for repair
and maintenance. The use of non-original spare
parts will result in a significant risk of failure, at
which point ABB's warranty and commitment to
equipment quality will no longer be valid.
This manual is not meant to cover all details of
the construction and specifications, storage and
installation of the equipment. Therefore, the
following contents may not include instructions
on the use of some particular constructions. This
does not mean decreasing or reducing our
professional technical support and quality service
commitment to the installation, commissioning,
operation and maintenance of the equipment
purchased by users. For more information and
support, please contact Xiamen ABB Switches Co.,
Ltd., or visit the website to obtain:
http://www.abb.com.cn
http://cndmx-tsol.abb.com.cn
warning
High voltage is dangerous. Possible serious injury or death to the person;
Possible damage to equipment or other devices.
Power off and ground the equipment before any operation and maintenance.
Before installation, operation and maintenance of the equipment, please
read and understand this manual carefully.
Repair is only allowed by specially trained personnel with detailed knowledge
of the equipment. Don’t allow repair equipment with any non-approved
accessories; Change the structure of equipment without permission; Or the
operation or maintenance of the equipment by untrained and unqualified
personnel may result in a serious accident or even serious injury or life-
threatening injury, or cause significant damage to the equipment and other
facilities. Please carefully follow all safety instructions in this manual.

—
II. Environmental protection program
6CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
ConVac vacuum contactors are manufactured in
accordance with ISO 14001 Standards (Guidelines
for environmental management) in accordance
with the environmental protection standards as
to the reduction of energy consumption and the
production of waste. All of these benefits from the
environmental protection management system of
the production process certified by the authority.
—
III. Application of the X-ray emission
standards
The contact of the vacuum arcing chamber is in
the open position and may emit X rays when it is
subjected to high test voltage, which is one of the
physical characteristics of vacuum insulation.
According to the requirements of the relevant
standards, the X-ray emitted by the vacuum arc
extinguishing chamber shall not exceed the
following limits:
•At rated voltage Ur, the amount of X-ray
emission is smaller at a distance of 1 m Not
more than 5 μSv
•At rated short-time power frequency withstand
voltage Ud, distance 1 m, X-rays The emission
rate is not more than 150 μSv per hour
The special type test of ABB vacuum arc
extinguishing chamber in relevant experimental
institutions in Germany proved that the X-ray
emission at 10 cm away from the contact surface
was less than 1 μSv per hour.
From this it can be concluded that:
•The vacuum arcing chamber is absolutely safe
for use under rated voltage
•The switchgear can be safely used under the
power frequency withstand voltage value
required by GB/T 11022 standard

—
IV. Safety information
SAFETY INFORMATION/OPERATOR REQUIREMENTS/SITE COMMISSIONING 7
All installation, operation and maintenance must
be performed by specially trained personnel who
have a detailed understanding of the characteristics
of the equipment.
This manual and other necessary information can
be provided at any time during the operation
—
V. Operator requirements
Check and confirm that the operating parameters
of the equipment do not exceed their rated
values.
According to this manual and the requirements of
the equipment label, the operator must:
•Read this manual carefully and completely
•In-depth knowledge of equipment installation,
construction and operation and clear
understanding the possible impact of each
operation
•Qualified and authorized to comply with safety
Strictly follow the requirements in this manual.
Verify that safety code standards and installation
conditions are met during the installation,
operation and maintenance phases.
regulations and local labor standards，and to
perform the equipment power on, power off,
grounding and check the circuit and other
operations
•Qualified and authorized to operate, maintain
and repair the equipment
•Have received training on how to properly use
protective equipment, such as insulated gloves,
safety helmet, goggles, face masks, fireproof
clothing, etc. within the scope of safety
regulations and local labor standards.
•First aid training
—
VI. Site Commissioning
ABB has professional after-sales service staff,
who can provide quality on-site service, technical
guidance and consultation for installation,
inspection, overhaul and maintenance of
equipment.

—
1. Overview
8CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
ConVac vacuum contactors are electrical switching
devices suitable for AC power distribution systems,
especially ideal for frequent operation.
The basic composition of contactor:
•Three insulating covers molded in thermoplastic
material containing the vacuum interrupter
•Electromagnetic mechanism
•Power control module
•Auxiliary contacts
•Opening and closing status indicator
•Counter
•Mechanical latched kit RiMe (only for mechanical
latched type )
In addition to having all the components of a fixed
version, a withdrawable contactor also contains:
•Fuse-holder of DIN or BS type fuse according to
customer requirements
•Automatic tripping device associated with fuse
of each phase
•Truck
•Interlock device to prevent the truck
racking-in/out while the contactor closed
• Self-powered VT (when needed)
ConVac vacuum contactor adopts linear drive
structure design, the movement direction is
coaxial for operation mechanism and vacuum
interrupter to ensure better dynamic
characteristics and longer mechanical life, using
three phase independent pole design to further
improve its insulation and mechanical performance.
1.1 Electromagnetic mechanism
For electrical latched type，when the closing coil
is energized by external auxiliary power，the core
may produce magnetic field and electromagnetic
force, which makes the contactor to close and
compresses the opening spring. Once the contactor
reaches the closing position, the system minimizes
the power supplied to the closing coil only to keep
the contactor in the closing position.
When the auxiliary power supply is cut off or the
voltage of the auxiliary power supply drops due to
human factors (opening command) or non-human
factors (fault on the power side), the contactor
will release the moving contact under the action
of the opening spring, so that the contactor will
be opened.
For the mechanical latched type, the closing
method is exactly the same as above. After closing,
the contactor is kept in the closing position by a
mechanical locking device (RiMe).When the
contactor got the opening command, the opening
coil is powered on, the mechanical locking device
is unlocked, so that the contactor will open by the
opening spring.
The power module is supplied with wide voltage,
and its characteristics are as follows：
Voltage
110...125 VDC/AC
50-60 Hz
220...240 VDC/AC
50-60 Hz
Inrush power
~1000 W
~1000 W
Holding power
~50 W
~50 W
Voltage
24 VDC
48...60 VDC
110...125 VDC/AC 50-60 Hz
220...240 VDC/AC 50-60 Hz
Inrush current
40 A
25 A
10 A
7 A
Operation time
100 ms
100 ms
100 ms
100 ms
1.2 Available type
The 7.2 kV and 12 kV ConVac vacuum contactors
are available in both fixed and withdrawable
version.
Electrical characteristics of mechanical latched
device (RiMe)

Overview 9
Auxiliary contact class
Rated continuous current
Insulation test voltage
Rated short- time withstand current
Breaking capacity (110 V ≤ Ue ≤ 250 V)
1
10 A
2000 V/1 min 50 Hz
100 A/30 ms
440 W
1.3 Main technical parameters
1.4 Auxiliary contacts
6NO6NC auxiliary contacts are available on the
contactor for the customer’s use, with the
following characteristics.
1.5 Compliance with Standards
ConVac contactors comply with the Standards of
the major industrialized countries and in particular
with the following standards:
GB/T 14808
IEC 62271-106
1.6 Protection against short-circuit
The value of the short-circuit current at the
installation site could exceed the breaking capacity
of the contactor. End-user is responsible for
protecting the contactor against short circuit
through installation of fuses or other means.
Fuse replacement must only be carried out
by qualified personnel.
Technical parameters
Rated voltages (Ur)
Rated short-duration power frequency
withstand voltage (Ud ) 50/60 Hz
Rated lightning impulse withstand voltage (Up)
Rated frequency ( fr)
Rated operational current ( Ie )
Short-time withstand current Ik (4 s)
Rated peak current (Ip)
Overload withstand current Ik (1 s)
Overload withstand current Ik (30 s)
Short-circuit breaking capacity
Short circuit making capacity
Short circuit breaking current ( Isc )-combined with fuses
Rated short-circuit making current ( Ima )-combined with fuses
category of use
Rated duty
Mechanical life
Opening time
Closing time
Ultimate performances for back-to-back capacitors banks
Operating temperature
Weight 2）
Overall dimenstions
Unit
kV
kV (1 min)
kV peak
Hz
A
A
kA peak
A
A
kA
kAp
kA
kA
Cycles/hour
Cycles
Cycles
ms
ms
ms
A
kA
Hz
℃
kg
mm
mm
mm
ConVac 7 ConVac 7/P
7.2
30
60
50-60
400
4000
10
6000
2400
5
12.5
50
130
AC-4
1200
1,000,000
100,000
70...150
15...35
40...70
C2
250
8
2500
ConVac 12 ConVac 12/P
12
42
75
50-60
400
4000
10
6000
2400
5
12.5
50
130
AC-4
1200
1,000,000
100,000
70...150
15...35
40...70
C2
160
8
2500
Electrical latched
Mechanical latched
Electrical latched
Mechanical latched
Rated current
Max. transient current of the capacitor
Max. transient frequency of the capacitor
H
W
D
-15...+40 1）
15
380
342
231
50
652
530
658
20
405
342
256
60
652
530
658
1）For higher temperature please contact ABB.
2）Reference value, Actual weight differ due to configuration.

10 CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
—
2. Delivery inspection and acceptance
On receipt, immediately check integrity of the
packing，confirm if the shipping document is in
allegiance with the order.
The accompanying documents in the shipping
packing are:
•instruction manual (this document)
•test report
•certificate of qualification
•shipping document
To remove the contactor from the packing,
proceed as follows:
•Open the plastic bag
•Remove the contactor, avoiding any kind of
mechanical stress to the insulating parts 、
contact arms, contact finger and terminals etc.
•Use the special lifting tools for the
withdrawable version
•Check the technical parameter of nameplate
and make sure to match order confirmation and
shipping notification
If product is damaged or does not conform to the
order, notify ABB (directly or through the agent or
supplier) as soon as possible but no later than
five days of receipt. Only valid order information
confirmed by ABB at the time of order shall be
provided in the package

DELIVERY INSPECTION AND ACCEPTANCE/SHIPPING AND STORAGE 11
—
4. Shipping and storage
Place a minimum of one standard packet of
desiccant bags inside the packing. Replace the
bags approximately every 6 months.
If the original packing no longer be available and
immediate installation is not possible, store in a
covered, well-ventilated, dry, dust-free, non-corrosive
—
3. Delivery inspection and acceptance
The following precautions must be taken during
contactor handling：
•Keep the contactor in the upright position.
•Make sure that the load is balanced on the truck
or on the transport plate/pallet
•Place protective material between the contactor
and the truck to avoid any damage or scratches
•Fix the contactor onto the truck or the transport
plate/pallet to prevent it moving or overturning
•Avoid excessive speed, sudden starts and stops
or sharp changes in direction during contactor
handling
•Only lift the contactor enough to avoid any
obstacles on the floor
•Take care to avoid any impacts with structures,
other apparatus or with personnel when handling
the contactor
•Never lift a contactor over an area where
personnel are present
•Ensure that no force is applied to insulating parts
or terminals of the contactor during handling of
the apparatus
3.1 Handling using a lifting or fork-lift truck. (Fig 3a)
3.2 Handling and lifting using a crane
•Insert the lifting plates
•Lift
•Remove the lifting plates after lifting operation
finish
—
Fig 3a
ambient, with a dry atmosphere, away from any
flammable materials and at a temperature
between -15 °C and +40 °C.
In any case, avoid any accidental impacts or
positioning which stresses the structure of the
apparatus.

12 CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
—
5. Installation
5.1 General
Correct installation is of primary importance. The
manufacturer’s instructions must be carefully
studied and followed. It is good practice to use
protecting gloves during installation.
The areas involved in the primary circuits and
auxiliary circuits must be protected against
access of any animals which might cause damage
or disservices.
The contactor enclosure must be installed in a
clean, dry and good ventilation place. It must
be easily accessible for cleaning and inspection,
and must be levelled, placed on the supporting
foundations and securely fixed into position.
When the contactor is connected to a capacitive
load, make sure that there is a heater to keep the
humidity down and of suitable size for the
compartment where the contactor is installed.
The contactor must always be installed
associated with a suitable protection device (e.g.:
fuses).
The fixed version of ConVac contactors must be
installed by the customer so as to guarantee a
minimum degree of protection of IP2X.
5.2 Installation and operating conditions
The following standards must be taken into
particular consideration during installation and
service:
•GB/T 14808 Alternating-current high-voltage
contactor
•GB/T 11022 Common specification for
high-voltage switchgear and control-gear
standards
5.3 Normal conditions
Follow the recommendations in the GB/T 11022,
GB/T 14808, IEC 62271-1 and 62271-106 standards.
In more detail:
Ambient temperature:
•Maximum +40℃
•Average maximum over 24 hours +35℃
•Minimum apparatus for indoor installation -15℃
Humidity:
•The average value of the relative humidity,
measured for a period longer than 24 hours,
must not exceed 95%
•The average value of the water vapor pressure,
measured for a period longer than 24 hours,
must not exceed 2.2 kPa
•The average value of the relative humidity,
measured for a period longer than 1 month,
must not exceed 90%
•The average value of the water vapour pressure,
measured for a period longer than 1 month,
must not exceed 1.8 kPa
Altitude:
≤1000 m.
5.4 Special conditions
>1000 m above sea level.
With the increase of altitude, the insulation
performance of air may decrease，thus the
impact of external insulation need to be taken
into account while using in high altitude areas.
Climate－temperature fluctuations
In order to avoid the risk of erosion and other
damages to the product in areas of high-humidity
or large temperature fluctuations, necessary
measures (for example, fitting a suitable heater)
shall be taken to prevent condensation.
For special installation requirements or other
operating conditions, please contact ABB.

INSTALLATION 13
5.5 Overall dimensions
5.5.1 Fixed version
In any case, avoid pressing the supporting structure of the contactor: if necessary, arrange slots in the
fixing area to facilitate correct positioning of the apparatus.
ConVac 7
ConVac 12
142
380
207.5
177.5
350.5
405
224
296
200
209
194
8
249
183
140
320
(231)
226
160
54 18
36 22
342
115 115
24
36
47
105
58
54
34
237
917
8
36
15
15
6-∅12
Electrical latched Mechanical latched
Only for mechanical latched
4-∅11
231
256 273
298
15.5
9.5
103
36
= =
6-∅12
231
142
380
207.5
177.5
140
226
160
320
4-∅11
36
36
15
15
(231)
54 18
36 22
342
115 115
24
36 15.5
47
105
115
54
103
17
958
8
8
194
350.5
209
237 34
273
Electrical latched Mechanical latched
Only for mechanical latched
9.5

14 CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
Installation of fixed ConVac contactors
The contactor can be installed in the following
positions:
A) Floor-mounted with moving contacts at the
bottom.
B) Wall-mounted with moving contacts horizontal
and terminals at bottom.
E
A
C
BD
5.5.2 Withdrawable version
Only for mechanical latched
622
85
22
632
652
205260
35
155
602
85 63
4
40.5
3
433 4
56
458
150 150
77
4
187 30
118
530
503
99.5
155
101.4
161
C) Wall-mounted with moving contacts horizontal
and terminals at top.
D) Wall-mounted with moving contacts horizontal,
interrupters on the front (or rear) and vertical
terminals.
E) Ceiling-mounted with moving contacts at top.

INSTALLATION 15
5.6 Wiring diagram
The following standard wiring diagram is for your
reference. The actual diagram may differ due to
product upgrade or non-standard requirements.
5.6.1 ConVac Fixed version
Electrical latched type
Mechanical latched type
Mechanical interlock or equal
For coil continuity supervision

16 CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
The contactor circuits are illustrated in the
diagrams below by way of example. In any case,
in view of product upgradation and for specific
applications, it is always useful to refer to the
electric circuit diagram provided with each
piece of apparatus.
Operating state shown
The diagram illustrates the following conditions:
•Contactor open and in working position
•Secondary circuits de-energized
Description of diagram figures
Fig.1 Control circuits of electrical latched
contactor
Fig.2 Control circuits of mechanical latched
contactor
Fig.5 Auxiliary contacts
Key symbols
□ =Reference number of the diagram
figure
-XDB... =Connectors for the contactor circuits
-QAC =Contactor
-SFC =Push-button or contact for contactor
closing
-SFO =Push-button or contact for contactor
opening
-KFA =Auxiliary control relay or contactor
-MBC =Closing coil
-AA =Power module
-BGB1...6 =Contactor auxiliary contacts
-RLM =Mechanical interlock (or equal)
Notes
A) The contactor is delivered complete with the
sole applications specified in the ABB order
confirmation. Consult the catalog of the
apparatus when making out the order.
B) Control command duration (-SFO and -SFC) at
rated voltage Ua Fig. 1 and Fig. 2: -SFC minimun
300 ms, -SFO minimum 300 ms.

INSTALLATION 17
5.6.2 ConVac/P Withdrawable Version
Electrical latched type
Mechanical latched type
-XDB
-QAC
-BGF2 -BGF2
31
2
4
12 31
47
48
1
12
12A
48 47
30 31
-XDB
-XDB1:1
-XDB1:3 -XDB2:1
-XDB1:2
-XDB2:2
30
1
2
-BGF1
-BGT3
-XDB12
-XDB12 2
O
12
-XDB40 2
-XDB40
1
7
30A
31E
36
-SFC -KFA
-SFO
-KFA
31D
2
-AA
3
4
31A
1
31B
31C
2
1
-PGC
-MBC
36
-XDB
-BGF1
-SFO
2
31
41
41A
-XDB
30
13
-RLM
-QAC
-BGF2 -BGF2
31
2
4
12
4
47
48
12
12A
48 47
14
-XDB1:1
14
1
2
-BGF1
O
2
1
7
-SFC
-XDB2:1
-XDB1:2
-XDB2:2
12
-XDB1:3
14A
4C
711712
-XDB40
-XDB40
-XDB3:1
-XDB3:3
4131
30
-XDB3:2
13
-RiMe
3
4
4B
-AA
4A
2
1
-PGC
2
-MBC
43
44
-BGT1
-XDB71
-XDB71
-BGT2 43
44
11
12
711A
712A
4
For coil continuity
supervision
Mechanical interlock or equal

18 CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
-XDB
-QAC
5
39
-BGB6
11
21
-BGB5
17 29
-BGB4
6
16
-BGB3
22
23
-XDB6 5
-XDB6
6
-XDB6 1
-XDB6
2
-XDB6 3
-XDB6
4
-XDB5 5
-XDB5
6
-XDB5
8
-XDB5
4
-XDB4 5
-XDB4
6
-XDB5 7
-XDB5 3
7
33
-XDB
-XDB5 1
-XDB5
2
28
5
15
-BGB2
-XDB4
8
7
-XDB4
8
18
-XDB4
4
3
-XDB4
-BGB1
-XDB4 1
-XDB4
2
24
8
7
2
10
9
-XDB6
-XDB6
2
1
33
6
16
7
17
39
11
21
22
23
29
28
4
3
2
1
2
1
4
3 3
42
1
2
1
4
3
5
15
2
1
8
18
3
44
3
24
2
10
9
46
4
45
-RLE2
-XDB15
-XDB15
2
1
1
2
-XDB
-QAC
3
-XDB
1a
1b
14
4
-F301
-T1
A
B
14A
-X301 2
1
45
46
4
14 4A
14B
-XDB11
42
M
-XDB11
32
2
1
-MAT
8
Red
Black
32
42

INSTALLATION 19
The above is an example of the electrical
diagram of the contactor standard circuit of
different specifications, which may vary
according to product update or engineering
non-standard customization.
Operating state shown
The diagram illustrates the following conditions:
•Contactor open and in working position
•Circuits de-energized
•Fuse installed and not blown
Description of diagram figures
Fig.1 Control circuits of electrical latching
contactor
Fig.2 Control circuits of mechanical latching
contactor
Fig.3 VT Self-supplied circuit
Fig.4 Circuit of locking electromagnet on
contactor truck
Fig.5 Auxiliary contacts
Fig.6 Signaling circuit of contactor in the
racked-in and isolated position
Fig.7 Electric operation counter
Fig. 8 Electric-drive circuit for truck
Key symbols
□=Reference number of the diagram figure
-XDB... =Connectors for the contactor circuits
-QAC =Contactor
-SFC =Push-button or contact for contactor
closing
-SFO =Push-button or contact for contactor
opening
-KFA =Auxiliary control relay or contactor
-MBC =Closing coil
-AA =Power module
-PGC =Electrical operation counter
-BGF1，-BGF2=Signaling contact for fuse status
-RiMe =Mechanical latching device
-BGB1...6 =Contactor auxiliary contacts
-BGT1 =Contacts for electrical signaling of
contactor in racked-in position
-BGT2 =Contacts for electrical signaling of
contactor in isolated position
-BGT3 =Contacts for electrical signaling of
truck status
-RLE2 =Locking magnet，when de-energized
it mechanically prevents contactor
from racking in or racking out
-T1 =Secondary coil of VT
-F301 =Protection fuse of VT secondary side
-X301 =Connection line
-MAT =Motorized truck of contactor
-RLM =Mechanical interlock (or equal)
Incompatibility
The circuits indicated by the following figures
cannot be supplied at the same time in the same
contactor：
1 – 2 2 – 3 4 – 8
Notes
A) The contactor is delivered complete with the
sole applications specified in the ABB order
confirmation. Consult the catalog of the
apparatus when making out the order.
B) Control command duration (-SFO and -SFC) at
rated voltage Ua Fig. 1 and Fig. 2: -SFC minimun
300 ms, -SFO minimum 300 ms.
-XDB
-QAC
49
-BGT2
51
52
53 54
6
-XDB71 -XDB71
-BGT2
57
58
-XDB71
-BGT2
53
54
-XDB71 -XDB71
-BGT1 -BGT1
9
10
4
1
25 3 6
24
2323
24
50
13
14
13
14
49
70170250
703
51
52
704705
706
53 54
57
70971058
-XDB
-XDB71
-XDB71 -XDB71
55
56
-XDB71
-BGT1
-XDB71
53
54
7
8
55
70770856
401

20 CONVAC VACUUM CONTACTOR INSTALLATION AND OPERATION INSTRUCTION
Warning
Dangerous voltages. Risk
of death, serious injury to
people, damage to the
apparatus or other
objects.
5.7 Assembly and connections
5.7.1 Fixed version
Before carrying out any installation operations：
•Test all the power terminals to check that they
are not supplied with voltage. Only use high
voltage testing equipment approved for checking
the voltage on the power terminals. Do not
attempt to measure the high voltage (above
600 V) with a volt-ohm/meter
•Check all the control and secondary circuit
terminals with a voltmeter to ensure that all the
control and secondary input voltage sources have
been turned off
•After de-energizing but before proceeding with
any work on the apparatus, confirm that power
terminals have been grounded and are in safe
conditions
•Carry out all the operations for turning off the
voltage and grounding according to the
established safety procedures
General inspections
•Clean the insulation surface with a rough dry cloth
•Check that the contact surfaces of the connections
are flat, and are free of any burrs, traces of
oxidation or deformation caused by drilling or
impacts received
•Select the cross-section of the conductors
according to the service current and the short-
circuit current of the installation
•Prepare special support insulators near the
terminals of the contactor, sized according to
the electrodynamic forces caused by the short-
circuit current of the installation and avoid
stressing the connections laterally
ConVac installation and connection of the
primary circuit
•Fixed conductors could be installed directly on
the support frame, according to the overall
dimensions in 5.5.1
•put the connections in contact with the contactor
terminals, taking care to avoid mechanical stresses
produced, for example, by the conductor busbars
on the terminals themselves
•Interpose a spring and a flat washer between the
head of the bolt and the connection. The use of
bolts according to DIN class 8.8 Standards is
recommended, also referring to what is indicated
in the table
Bolt
M6
M8
M10
M12
Recommended tightening torque
without lubricant
10 Nm
25 Nm
50 Nm
86 Nm
•In the case of cable connections, strictly follow
the manufacturer’s instructions for making the
terminals
•Grounding of fixed ConVac is realized by
grounding bolt, accompanied by a grounding
sign as Fig 5a shows. An area of about 30 mm
around the grounding bolt should be kept clean,
reapply Vaseline lubricant to cover the joint after
installation. Use cables with a suitable cross-
section according to related standards
Connection of the auxiliary circuits
•The cables to be used for connection of the
auxiliary circuits must no less than the cable
used inside the contactor, and be insulated for
2 kV/1 min test
•Please refer to 5.6.1 for the wiring of auxiliary
circuit, make sure the cables are reliably
connected to the contactor
•Outside, the wires must run through metallic
pipes or ducts suitably grounded
5.7.2 Withdrawable version
•The withdrawable contactors are used in the
UniGear ZS1 or other switchgear with the same
dimension
•Confirm that the contact fingers are clean, and
no deformation due to shipping or crash
•The auxiliary circuit connections of withdrawable
contactor are derived via the plug. The wiring
diagram could refer to chapter 5.6.2
•The cables to be used for connection of the
auxiliary circuits must no less than the cable used
inside the contactor, and be tested for 2 kV/ 1 min
•three current-limiting fuses (prepared by
customers) with high breaking capacity connected
in series with the contactor, with dimensions
according to
-DIN 43625 Standard with maximum length e
=442 mm
-BS 2692 Standard with maximum distance L
=454 mm
5.7.3 Interlock of withdrawable version
•Electrical lock which prevents the contactor from
being closed when the truck is not in the racked-in
and isolated positions
•Mechanical lock which prevents the contactor
from being racked-in and out when it is closed
and closing of the contactor when the truck is
not in the racked-in and isolated positions
•Electrical lock which prevents closing of the
contactor when any one fuse is missing or blown
•Lock which prevents insertion of the plug-socket
and therefore apparatus (Fig 5c,interlock of
contactors with different rated current)
—
Fig 5a
•Locking electromagnet on the truck to prevent
racking-in/out when dis-energised. (Fig 5b-1)
•Mechanical lock which prevents contactor from
racking-in if the enclosure door is not closed
(Fig 5b-2)
•Mechanical interlock with earthing switch placed
on the enclosure ：with earthing switch closed
the contactor cannot be racked-in and with the
contactor racked-in or in intermediate positions
between racked-in and isolated, it is not possible
to close the earthing switch (Fig 5b-3)