Toshiba CV-1GAU User manual

Document: VF010H10
TOSHIBA
INSTRUCTION MANUAL
INSTALLATION - OPERATION - MAINTENANCE
CV-1GAU and CV-1HAU Vacuum Contactors
1.5kV - 2.5kV Voltage Class
APPLICABLE MODEL NUMBERS
CV-1GAU
CV-1GAU-P2
CV-1GAUMIL
CV-1GAU-C
CV-1HAU
CV-1HAU-P2
CV-1HAUMIL
CV-1HAU-C
Issued:9/01
Manufactured in the USA

TOSHIBA
INSTRUCTION MANUAL
For the Installation, Operation and Maintenance of
CV-1GAU Vacuum Contactor, 1.5kV - 2.5kV 160A
CV-1HAU Vacuum Contactor, 1.5kV - 2.5kV 320A
Never attempt to install, operate, maintain or dispose of this equipment until
you have first read and understood all of the relevant product warnings and
user directions that are contained in this Instruction Manual.
To contact Toshiba, address all correspondence to:
Field Service Department
Toshiba International Corporation
13131 West Little York Road
Houston, Texas 77041 USA
or call:
[phone]
[phone]
[phone] (Canada)
Fax:[phone]
Please complete the following information for your records and retain with this manual:
Model: ___________________________________
Serial Number:_____________________________
Date of Installation: _________________________
Inspected by: ______________________________
Reference Number: _________________________
© TOSHIBA INTERNATIONAL CORPORATION, 2001
WARNING

SAFETY Page 1
IMPORTANT MESSAGES
Read this manual and follow its instructions. Signal words such as
DANGER, WARNING and CAUTION will be followed by important safety
information that must be carefully reviewed.
Indicates a situation which will result in death, serious injury, and severe
property damage if you do not follow instructions.
Means that you might be seriously injured or killed if you do not follow
instructions. Severe property damage might also occur.
Means that you might be injured if you do not follow instructions. Equipment
damage might also occur.
NOTE Gives you helpful information
READ SAFETY SIGNS
To avoid injury, you must read and follow all safety signs.
Keep the safety signs visible and in good shape. Never remove or cover any safety
signs.
DANGER
CAUTION
WARNING

SAFETY Page 2
QUALIFIED OPERATORS ONLY
Only qualified persons are to install, operate, or service this equipment according to all
applicable codes and established safety practices.
A qualified person must:
1) Carefully read the entire instruction manual.
2) Be skilled in the installation, construction or operation of the equipment and
aware of the hazards involved.
3) Be trained and authorized to safely energize, de-energize, clear, ground,
lockout and tag circuits in accordance with established safety practices.
4) Be trained and authorized to perform the service, maintenance or repair of
this equipment.
5) Be trained in the proper care and use of protective equipment such as rubber
gloves, hard hat, safety glasses, face shield, flash clothing, etc. in
accordance with established practices.
6) Be trained in rendering first aid.
SAFETY CODES
Toshiba CV-1GAU and CV-1HAU vacuum contactors are designed and built in
accordance with NEMA ICS 3-2, UL 508, CSA 22.2-14 and IEC 60470. Installations
must comply with all applicable state and local codes, adhere to all applicable National
Electric Code (NFPA 70) standards and instructions provided in this manual.

SAFETY Page 3
HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion and
property damage.
• Turn off and lock out Primary and Control Circuit Power before servicing.
• Keep all panels and covers securely in place.
• Never Defeat, Modify, or Bypass any Safety Interlocks
• Qualified Operators only
DANGER

TABLE OF CONTENTS Page 4
SAFETY ..................................................................................................................................................1
INTRODUCTION .....................................................................................................................................6
GENERAL DESCRIPTION......................................................................................................................7
Components.................................................................................................................................7
- Contactor Components ..............................................................................................................7
Indicators and Controls................................................................................................................. 8
- ON/OFF Indicator.......................................................................................................................8
- Outline Drawing..........................................................................................................................8
RECEIVING, INSPECTION AND HANDLING .........................................................................................9
Receiving and Unpacking.............................................................................................................9
Acceptance Inspection .................................................................................................................9
Handling and Moving....................................................................................................................9
- Location of Wear Gauge ............................................................................................................9
INSTALLATION.......................................................................................................................................10
Ambient Conditions......................................................................................................................10
Rating Verification........................................................................................................................10
- Label Locations
Mounting the Contactor................................................................................................................11
Main Circuit Cable Connections ...................................................................................................11
Control Circuit Connections..........................................................................................................11
- Control Terminals Location.........................................................................................................11
PRE-ENERGIZATION CHECK................................................................................................................12
General........................................................................................................................................ 12
Electrical Checks..........................................................................................................................12
OPERATION ...........................................................................................................................................13
Moving Contactor from Disconnected to Connected Position .......................................................13
Moving Contactor from Connected to Disconnected Position ....................................................... 13
- Configuration of the Drive Unit ...................................................................................................14
MAINTENANCE ......................................................................................................................................15
Maintenance Program..................................................................................................................15
Maintenance Record ....................................................................................................................15
Servicing Equipment ....................................................................................................................15
Inspection and Maintenance Types..............................................................................................16
Table 1 – Tightening Torque ........................................................................................................16
Table 2 – Check Points for Periodic Inspection ............................................................................17
Table 3 – Wear and Replacement Values ...................................................................................19

TABLE OF CONTENTS Page 5
Vacuum Check.............................................................................................................................20
- Toshiba Portable Vacuum Checker............................................................................................20
- Application of Test Voltage for Vacuum Check...........................................................................21
Electrical Service Life................................................................................................................... 22
Mechanical Service Life................................................................................................................22
- Interrupter Wipe Measurement...................................................................................................22
- Auxiliary Overtravel Measurement..............................................................................................22
- Lubrication .................................................................................................................................22
STORAGE AND DISPOSAL ...................................................................................................................23
Storage ........................................................................................................................................ 23
Inspection during Storage............................................................................................................. 23
Disposal
SPECIFICATIONS...................................................................................................................................24
Table 4 – Ratings.........................................................................................................................24
WARRANTY AND LIMITATION OF LIABILITY ......................................................................................26

INTRODUCTION Page 6
It is the intent of this manual to provide a guide for safely installing, operating and maintaining Toshiba
vacuum contactors. This manual consists of a section of general safety instructions and is marked
throughout with warning symbols. Read this manual thoroughly before installation, operation and
maintenance of this equipment.
This manual and all accompanying drawings should be considered a permanent part of the equipment.
They should be readily available for review and reference at all times. This manual is not intended to
cover all details, combinations, or variations of the equipment. Always refer to drawings accompanying
the equipment for additional details.
All safety warnings must be followed to ensure personal safety. General safety instructions are
found on pages 1 through 3. Read and save these instructions for future reference.
Follow all precautions to attain proper equipment performance and longevity.
Dimensions shown in the manual are in English and/or their metric equivalent.
This manual is divided into major sections of interest, as follows:
GENERAL DESCRIPTION – Provides a description of the equipment, information on major
components and how they function, plus rating information.
RECEIVING, INSPECTION AND HANDLING – Describes procedures for receiving, unpacking,
inspecting, and handling the contactors.
INSTALLATION – Provides information on installing the contactor.
PRE-ENERGIZATION CHECK – Provides a checklist for preparing the equipment for energization.
OPERATION – Provides information on operation of the contactor and circuit diagrams.
MAINTENANCE – Lists the basic maintenance procedures for this equipment necessary for safe and
reliable operation.
DISPOSAL – Lists procedures for the safe disposal of the equipment when the service life has expired.
STORAGE – Provides guidelines for storing new equipment for an extended period of time.
SPECIFICATIONS – Covers ratings and other specifications of the contactor.
WARRANTY AND LIMITATION OF LIABILITY – Details Toshiba International Corporation’s standard
warranty terms.

GENERAL DESCRIPTION Page 7
COMPONENTS
The Toshiba CV-1GAU and CV-1HAU vacuum
contactors described in this manual are suitable
for use on systems of 1.5kV, 160A and 1.5kV,
320A respectively.
Arc interruption is accomplished inside sealed
vacuum interrupters mounted on track-resistant
insulators. Vacuum interrupters use low-surge
contact materials, which exhibit low current
chopping levels reducing switching overvoltage.
This manual covers several models of typeforms
of CV-1GAU and CV-1HAU vacuum contactor.
Included are the basic GAU and HAU models
as well as the GAU-P2, HAU-P2, GAUMIL,
HAUMIL, GAU-C and HAU-C.
-P2 models have a fast opening time.
-MIL models are for mechanical interlocking.
-C models have a 480-550Vcontrol voltage.
Figure 1 - Front of Contactor
The information presented in this manual is
common to all models unless otherwise noted.
Refer to the Ratings Tables in the
SPECIFICATION section of this manual for
model details.
Contactor Components:
1. Power Terminals – Input
2. Insulating Frame
3. Vacuum Bottle
4. Contact Wear Checkpoint
5. Power Terminals – Load
6. Mounting Holes (Lower Not Visible)
7. Control Terminals
8. Auxiliary Contacts – Optional (2)
9. Auxiliary Contacts – Standard (2)
10. Typeform Label (Rating Label – Other side)
11. Drive Unit
12. Front Cover
13. ON/OFF Indicator
Figure 2 – Front/Right Side of Contactor
1
2
3
5
4
6
7
8
9
13
12
11
10

GENERAL DESCRIPTION Page 8
INDICATORS AND CONTROLS
The following indicator is provided:
On-Off Indicator - Indicates if the contactor is
OFF (Green) or ON (Red). When the indicator
reads OFF, the main contacts of the contactor
are open. When the indication is ON, the main
contacts are closed. See Figure 3.
Figure 3 - ON/OFF Indicator
Figure 4 – Outline Drawing

RECEIVING, INSPECTION AND HANDLING Page 9
RECEIVING AND UNPACKING
The contactor units are subjected to factory
production testing prior to being packed and
shipped.
ACCEPTANCE INSPECTION
Confirm that the contactor is complete, correct
as specified and undamaged from shipment and
handling.
Upon receipt of the equipment, do the following:
1. Make an immediate inspection for damage
that might have occurred during shipment. If
damage is discovered, it should be noted
with the carrier prior to accepting the
shipment, if possible.
2. Carefully unpack the equipment sufficiently
to check for missing parts or concealed
damage.
3. Check for the presence of accessories that
are shipped with the contactor:
Contactor wear gauge (Figure 5).
4. Keep the contactor upright.
Never lay the contactor on
its side or upside down.
This may cause damage.
File a claim with the carrier for any damaged or
missing items and immediately notify the nearest
Toshiba representative.
Do not install or energize
equipment that has been
damaged. Damaged
equipment can fail during
operation, resulting in fire
and explosion.
HANDLING AND MOVING
Care and caution should be used when handling
the contactor to avoid damage to the equipment
and personal injury. Always keep the equipment
in a generally upright position.
Figure 5 - Location of Wear Gauge
CAUTION
WARNING

INSTALLATION Page 10
AMBIENT CONDITIONS
Do not install this
equipment in areas where
unusual service conditions
exist. Using this equipment
in other than usual service
conditions can result in
equipment failure.
Toshiba CV-1GAU and CV-1HAU contactors are
intended for use in usual service conditions as
defined in NEMA ICS 1. The temperature of the
cooling air (ambient air temperature) surrounding
the contactor should be between the limits of -
10°C (50°F) and +50°C (122°F). The altitude of
the equipment installation should not exceed
3300-ft (1000 m).
In particular, avoid the following installation
conditions:
-Excessive dust
-Corrosive gases
-Extreme variations in temperature
-Very high or low humidity
-Vibrations
-Inclined locations
If there is a chance that condensation can occur
at the installation location, a space heater should
be installed inside the contactor enclosure.
NOTE: Temperature, altitude, capacitor
switching or other conditions outside
of the usual limits may require
derating or other special equipment.
Contact your nearest Toshiba
representative for additional
information.
RATING VERIFICATION
Prior to installation, the maximum current rating
and typeform of the contactor should be verified.
The current rating label is located on the left side
of the contactor (Figure 6). The typeform label is
located on the right side of the contactor
(Figure 7). See Table 5 – Ratings, in the
SPECIFICATION Section of this manual for
information on contactor ratings and typeforms.
Do not exceed the ratings
specified on the contactor
rating label or system
accessories. Underrated
equipment can fail during
operation causing fire,
explosion, severe injury,
death and property damage.
Figure 6 - Rating Label, Left Side
Figure 7 - Typeform Label, Right Side
WARNING
DANGER

INSTALLATION Page 11
MOUNTING THE CONTACTOR
The contactor is designed to mount to a flat,
grounded metal, vertical surface. If there are
any noticeable gaps between the contactor and
the mounting surface, fill them in using flat
washers as spacers.
Fasten the contactor using four (4) M8 hex
head bolts. The tightening torque should be
120-150 kgf-cm (9-11 ft-lb). See
Table 1 for tightening torque specifications.
MAIN CIRCUIT CABLE CONNECTIONS
Route cables that connect to the contactor to
avoid interference with sharp edges and moving
parts. Observe minimum bending radius for the
type of cable used.
Power cables should be braced and/or laced to
withstand short-circuit forces wherever such
cables are unsupported. Power cables should
be adequately sized to carry the maximum
continuous current in accordance with NEC
requirements and should have an adequate
voltage rating. Cables should be dressed and
terminated as appropriate to the voltage class
and cable manufacturer’s recommendations.
Fasten the cables to the main circuit terminals.
Use 35 mm Class 8.8 M8 or M10 hex head
bolts, 2 flat washers, a lock washer and a nut.
While securely preventing the nut from rotating
with a wrench, torque the bolt to 250-315 kgf-
cm (18-23 ft-lb) for M10 bolts or 450-565 kgf-cm
(32-41 ft-lb) for M12 bolts.
Use two wrenches to torque
the connection to prevent
applying excessive force to
the terminal, which can
damage the frame.
CONTROL CIRCUIT CONNECTIONS
Hazardous Voltage. Turn off
and lock out all primary and
control circuit power sources
prior to performing this pre-
energization check. Applying
the specified power to the
drive unit will immediately
activate the coils and close
the contactor.
Control circuit wiring is connected to the
contactor through the drive unit by terminals
located at the top of the base (Figure 8). Either
AC or DC supply voltage may be connected to
most drive units.
The standard operating voltage for the control
circuit for most CV-1 contactors is 100-240V
AC/DC. The operating voltage of CV-GAU-C
and CV-1HAU-C contactors is 460-550 VAC.
Refer to the SPECIFICATIONS for model
ratings. (Figure 11) in the OPERATION section
of this manual show the internal connections of
the drive unit, closing coils, and auxiliary switch.
Figure 8 – Control Terminals Location
CAUTION
WARNING

PRE-ENERGIZATION CHECK Page 12
GENERAL
BEFORE ENERGIZING THE CONTACTOR for
the first time, follow the procedure below to verify
that the equipment is properly installed and
functional.
Hazardous Voltage. Turn off
and lock out all primary and
control circuit power
sources prior to performing
this pre-energization check.
Do not operate this
equipment until a complete
safety inspection has been
made.
Do not energize damaged
equipment that has not
been repaired or verified.
Do not remove, cover or
destroy any safety signs.
Do not operate this
equipment if any panels or
covers have been removed.
•All blocks or other temporary braces used for
shipment must be removed.
•Install all panels, guards, and covers if
removed.
•Check for any loose connections and confirm
that all wiring is correct per wiring diagrams.
•A supply of spare parts should be
established.
•Instruction manuals and diagrams should be
collected and filed.
ELECTRICAL CHECKS
Electrical shock hazard.
Do not touch energized
components during a test
using auxiliary power.
An electrical insulation resistance test should be
performed to verify that the contactor and
associated field wiring are free from short circuits
and grounds. Refer to the MAINTENANCE
Section of this manual for additional information.
Hazardous voltages are
present during dielectric
testing which can result in
serious injury or death.
High potential tests should
be performed only by
qualified personnel.
DANGER
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING

OPERATION Page 13
MOVING THE CONTACTOR FROM THE OFF
TO THE ON POSITION
TO MOVE THE CONTACTOR TO THE ON
POSITION:
1. Turn ON circuit control power to move the
contactor to the ON position
2. Verify that the position indicator reads ON
(Red). (Figure 9)
MOVING THE CONTACTOR FROM THE ON
TO THE OFF POSITION
TO MOVE THE CONTACTOR TO THE OFF
POSITION:
1. Turn OFF circuit control power to move the
contactor to the OFF position
2. Verify that the position indicator reads OFF
(Green). (Figure 10)
Figure 9 – Closed contactor – ON indication
Figure 10 – Open contactor – OFF indication

OPERATION Page 14
Figure 11 – Configuration of the Drive Unit
SWITCHING
OSCILLATION POWER
TIMER
VOLTAGE
DETECTION
CC
A1
A2
52
A1 A2
AC/DC CONTROL SOURCE
100-240V AC/DC (COMMON)
CV-1GAU-C, CV-1HAU-C 460-550 VAC
(NO) (NC)(NO) (NC)
AUX AUX
R
UV
S
W
T
AUX
(NO) (NC)(NC)(NO)
AUX
OPTIONAL AUX: AUXILIARY
CONTACTS

MAINTENANCE Page 15
MAINTENANCE PROGRAM
In order to ensure continued reliable and safe
operation of the equipment, a program of
periodic maintenance must be established.
Operating and environmental conditions will
usually dictate the frequency of inspection
required. NFPA Publication 70B "Electrical
Equipment Maintenance" may be used as a
guide for setting up the maintenance program.
Contact with energized
components can cause
severe injury, death and
property damage. Turn off
and lock out primary and
control circuit power before
servicing.
Improper maintenance can
cause severe injury, death
and property damage. Only
qualified and authorized
persons are to install,
operate or service this
equipment.
Grease is conductive. Do
not allow grease or any
other substances to
contaminate insulating
materials. Contaminated
insulators can allow a
short-circuit or ground
fault to occur.
NOTE: Refer to the SAFETY section of this
manual for important information.
MAINTENANCE RECORD
Keep a permanent record of all maintenance
work. At a minimum, this record should include
information on:
1. Items inspected
2. Reports of any testing
3. Equipment condition
4. Corrective actions or adjustments
5. Date of work
6. Comments
The degree of detail of the record will depend
somewhat on the operating conditions.
SERVICING EQUIPMENT
For your safety, turn off and lock out main and
control circuit power before servicing the
contactor. Certain minimum safety procedures
must be followed:
1. Only qualified personnel should attempt
this service.
2. Never perform service on or next to
exposed components energized with line
voltage.
Failure to adhere to these
safety procedures can
result in severe injury,
death and property
damage.
DANGER
WARNING
WARNING
WARNING

MAINTENANCE Page 16
RECOMMENDED INSPECTION AND
MAINTENANCE TYPES
NOTE: Refer to the SAFETY section of this
manual for important information.
1. Acceptance Inspection
This inspection confirms that the contactor is
complete, correct as specified and
undamaged from shipment. The procedure
for this inspection is outlined in the
RECEIVING, INSPECTION AND
HANDLING section of this manual.
2. Patrol Inspection
Inspection is made of the condition of the
contactor while it is energized. Check that
no unusual sounds or smells exist externally.
Check for any abnormal discoloration due to
overheating. Inspect for signs of damage to
the insulation frame, OPEN/CLOSE indicator
and other components.
Inspection Frequency: Once every 6 months
3. Periodic Inspection
Inspection is performed with the contactor
de-energized. The lubrication of sliding and
rotating parts is checked and the mechanism
is lubricated if needed.
Inspection Frequency: Once every year or
every 50,000 operations at 1.5kV, or every
10,000 operations at 2.5kV.
NOTE: Refer to Table 2 for the schedule of
Periodic Inspections.
4. Unscheduled Inspection
Inspections are implemented as required.
Inspection Frequency: As needed
NOTE: The inspection frequency and points
to be inspected may vary from the
above recommendations depending
on the status of use, frequency of
switching and other factors.
Table 1 - Tightening Torque
Screw Nominal
Diameter Tightening Torque
M4 15-20 kgf-cm (13-17 in-lb)
M5 30-40 kgf-cm (26-34 in-lb)
M6 50-65 kgf-cm (43-56 in-lb)
M8 120-150 kgf-cm (9-11 ft-lb)
M10 250-315 kgf-cm (18-23 ft-lb)
M12 450-565 kgf-cm (32-41 ft-lb)

MAINTENANCE Page 17
Table 2 - Check Points for Periodic Inspection
Check
Point Check Item Check Method Criteria Disposition
Operating
Mechanism Loose bolts, nuts or
screws
Tighten using
screwdriver or wrench. Make sure all bolts, nuts and screws are
tight.
Tighten if loose.
See (Table 1) for
tightening torque
specifications.
Dust or
foreign
matter inside
Visual inspection. The contactor should
be clean and contain
no foreign matter.
Wipe with a clean
dry cloth.
Smooth
operation Visual inspection or touch. Check
lubrication.
Make sure moving
parts operate
smoothly.
Wipe with a clean
dry cloth. Lubricate if
necessary
Main Circuit Terminals
and movable
conductors.
Visual inspection.
Tighten using
screwdriver or wrench.
Make sure there is no
discoloration or loose
fasteners.
Check the cause
and repair. Tighten
connections to
contactor. See
(Table 1 )for
tightening torque
specifications.
Loose bolts,
nuts or
screws
Tighten using a
wrench. Make sure all bolts, nuts and screws are
tight.
See (Table 1) for
tightening torque
specifications.
Vacuum
contact wear. See Electrical Service Life (Page 22) and
Table 3.
Check contact wear,
wipe. Contact factory.
Vacuum
level. Apply 10kV AC for 1 minute. Check vacuum level by withstand voltage
test.
If breakdown occurs,
contact Toshiba.
Lubrication See Electrical Service
Life (Page 22). Check grease on interrupter shaft and
bearing washer
Lubricate if
necessary.

MAINTENANCE Page 18
Table 2 – Check Points for Periodic Inspection (cont.)
Check
Point Check Item Check Method Criteria What to do
Main Circuit Dust on
surface of
vacuum
interrupter
Visual inspection. Make sure there is no
dust on the surface. Wipe with a clean, dry cloth.
Insulation
Frame and
Flanges
Dust, foreign
matter or
damage
Visual inspection. Make sure there is no
dust, foreign matter or
breakage.
Wipe with a clean,
dry cloth. If
damaged, contact
Toshiba.
Control
Circuits Auxiliary Switch See Electrical Service Life (Page 22) and
Table 3.
Contact wear and
wipe. Make sure there
is no dust.
Replace if wear or
damage is
excessive. See
(Table 1) for
tightening torque
specifications
Drive unit Visual inspection. Check for overheating
and discoloration. Contact factory.
Wiring Visual inspection.
Tighten using a
screwdriver.
Check for
discoloration and
tightness.
Repair if
disconnected.
Tighten if loose.
See (Table 1) for
tightening torque
specifications.
Insulation
Resistance
Measure-
ment
Resistance
from main
circuit to
ground
Measure insulation
resistance between
phases, between
electrodes, and
between circuits and
ground. Megger test
at 1000V.
Resistance should be
100MΩor greater.
Resistance
from control
circuits to
ground
Measure insulation
resistance between
circuits and ground.
Megger test at 500V.
Resistance should be
5MΩor greater.
If the insulation
resistance is low,
wipe off the vacuum
interrupter and other
insulation surfaces
with a clean dry
cloth and then
repeat the test. If
necessary, replace
faulty parts.