Toshiba HCV-7HA User manual

Document: VF00W104 Rev.1
INSTRUCTION MANUAL
INSTALLATION - OPERATION - MAINTENANCE
HCV-7HA Vacuum Contactor, 7.2kV – 400A – 7.2kA
HCV-7HAL Vacuum Contactor, 7.2kV – 400A – 7.2kA
Issued: 3/20
Manufactured in the USA

INSTRUCTION MANUAL
For the Installation, Operation and Maintenance of
HCV-7HA Vacuum Contactor, 7.2kV – 400A – 7.2kA
HCV-7HAL Vacuum Contactor, 7.2kV – 400A – 7.2kA
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:
Tel [phone]
US [phone]
Canada 800/872-2192
Mexico 01/800/527-1204
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, 2020
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
Note: The contents of this manual will not become a part of or modify the warranty policy. The terms of
which are set forth at the end of this manual.
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

Page 2 SAFETY
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 HCV-7HA and HCV-7HAL vacuum contactors are designed and built in accordance with
NEMA ICS 3, UL347, and CSA 22.2 No. 253 -16. 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

Page 4 TABLE OF CONTENTS
SAFETY .................................................................................................................................................. 1
INTRODUCTION ..................................................................................................................................... 6
GENERAL DESCRIPTION...................................................................................................................... 7
Components ....................................................................................................................................................7
Indicators Provided ..........................................................................................................................................7
Figure 1 – Contactor Structure ........................................................................................................................7
RECEIVING, INSPECTION AND HANDLING ......................................................................................... 8
Receiving and Unpacking................................................................................................................................8
Acceptance Inspection ....................................................................................................................................8
Handling and Moving .......................................................................................................................................8
Figure 2 – Wear Gauge ...................................................................................................................................8
INSTALLATION ...................................................................................................................................... 9
Ambient Conditions .........................................................................................................................................9
Mounting the Contactor ...................................................................................................................................9
Main Circuit Cable Connections ......................................................................................................................9
Ground Connections........................................................................................................................................10
Control Circuit Connections.............................................................................................................................10
Figure 3 – Control Voltage Selection for Closing Coils ...................................................................................10
PRE-ENERGIZATION CHECK................................................................................................................ 11
General ............................................................................................................................................................11
Electrical Checks .............................................................................................................................................11
OPERATION ........................................................................................................................................... 12
Figure 4 – Drive Unit Block Diagram ...............................................................................................................12
Figure 5 – Internal Connection of the Magnetically Held Type .......................................................................13
Figure 6 – Internal Connection of the Mechanically Latched Type .................................................................13
Figure 7 – Typical Control Circuit for Magnetically Held Type ........................................................................14
Figure 8 – Typical Control Circuit for Mechanically Latched Type 125VDC-250VDC Trip .............................15
Figure 9 – Typical Control Circuit for Mechanically Latched Type 24VDC-48VDC Trip .................................16
MAINTENANCE ...................................................................................................................................... 17
Maintenance Program .....................................................................................................................................17
Maintenance Record .......................................................................................................................................17
Servicing Equipment........................................................................................................................................17
Recommended Inspection and Maintenance Types .......................................................................................18
Table 1 – Tightening Torque ...........................................................................................................................18
Table 2 – Check Points for Periodic Inspection...............................................................................................19
Table 3 – Gap/Wipe Standard Values (contactor in new condition)................................................................20
Vacuum Check ................................................................................................................................................21
Figure 10 – Toshiba Portable Vacuum Checker .............................................................................................21
Figure 11 – Application of Test Voltage for Vacuum Check............................................................................22
Electrical Service Life ......................................................................................................................................23
Mechanical Service Life...................................................................................................................................23
Figure 12 – Wipe Measurement ......................................................................................................................23
Service Life – Capacitor Switching ..................................................................................................................23

TABLE OF CONTENTS Page 5
Table 4 – Recommended Part Replacement Intervals ...................................................................................23
Figure 13 – Capacitor Switching Life...............................................................................................................23
STORAGE AND DISPOSAL ................................................................................................................... 24
Storage ............................................................................................................................................................24
Inspection During Storage ...............................................................................................................................24
Disposal ...........................................................................................................................................................24
SPECIFICATIONS................................................................................................................................... 25
Table 5 – Ratings.............................................................................................................................................25

Page 6 INTRODUCTION
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 metric and/or their English 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,
handling, lifting and moving 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, circuit diagrams, operating sequence
description.
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.

GENERAL DESCRIPTION Page 7
COMPONENTS
The Toshiba HCV-7HA and HCV-7HAL vacuum
contactors described in this manual are suitable for
use on systems of 7.2kV – 400A – 7.2kA.
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 over-voltage.
INDICATORS PROVIDED
On-Off Indicator – Located on the front, right side of
the contactor. 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.
Front view Back view
Front view – Latched type
1) Insulating frame
2) Vacuum bottle
3) Insulating flange
4) Auxiliary switch
5) Drive unit
6) Armature
7) Stopper
8) On-Off indicator
9) Stationary contact main terminal
10) Moving contact main terminal
11) Rotating shaft
12) Closing coils
1. 13) Latch mechanism
14) Latch trip lever
Figure 1 – Contactor Structure
9
2
3
6
4
7
5
1
8
13
14
10
11
12

Page 8 RECEIVING, INSPECTION, AND HANDLING
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 2).
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 2 - Wear Gauge
CAUTION
WARNING

INSTALLATION Page 9
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 HCV-7HA and HCV-7HAL 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 -5°C (23°F)
and +40°C (104°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 or other conditions
outside of the usual limits may require
derating or other special equipment.
Contact your nearest Toshiba
representative for additional information.
MOUNTING THE CONTACTOR
The contactor is designed to mount to a flat,
horizontal 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 M10 or M12 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.
WARNING
CAUTION

Page 10 INSTALLATION
GROUND CONNECTIONS
The contactor must be grounded in accordance with
the requirements of the National Electrical Code,
Article 250 or applicable local standards.
Proper grounding
connections must be made to
the contactor before incoming
power is applied.
The ground connection should be made to one of
the mounting bolt locations.
The ground wire should be no smaller than #10
AWG.
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.
Route control cables that connect to the contactor to
avoid interference with sharp edges and moving
parts. They should also be routed and secured so that
they are a sufficient distance from medium voltage
circuits and components. Observe minimum bending
radius for the type of cable used.
Control 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.
Either AC or DC control supply voltage may be
connected to the drive unit for operation of the
closing coils. The optional latched trip circuit uses
DC as standard power.
The standard control voltage for the closing coils is
120Vac. Other voltages may be used, provided the
switch on the drive unit is properly set. See Figure 3
for switch settings:
Figure 3 – Control Voltage Selection for
Closing Coils
Trip coils for latched type contactors are available
with 24Vdc, 32Vdc, 48Vdc, 125Vdc, and 250Vdc
ratings.
Latched contactor installations must these guidelines:
1. The electrical trip-free circuit must be remotely
located with respect to the contactor.
2. A stable DC power source such as a battery is
recommended for the trip circuit. If DC power is
not available, a capacitor trip device should be
used.
3. The Auxiliary switch contact corresponding to
terminals 11 and 21 should be used for the trip
circuit and terminals 16 and 26 for the control
relay circuit (Figure 8).
4. The latch mechanism has trip lever for tripping
the contactor without trip or control power.
Equipment using latched contactors must be
provided with an externally operated manual
release mechanism to operate this lever.
WARNING
WARNING

PRE-ENERGIZATION CHECK Page 11
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.
The operation of all control circuits should be tested
with control power only before energizing the main
power.
DANGER
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING

Page 12 OPERATION
CONTROL CIRCUITS
The HCV-7HA is a Magnetically Held type of contactor. Contactor closing is controlled by the drive unit. The
drive unit is a control board that applies a relatively high voltage to the closing coils for a short period of time to
close the contactor and then reduces the voltage to the coils for holding the contactor closed.
The HCV-7HAL is an HCV-7HA with a mechanical latch assembly installed. This is a Mechanically Latched type
of contactor. The added latch assembly contains a DC rated trip coil and an auxiliary switch with one delayed b
contact and an a contact with magnetic a blowout.For 24VDC~48VDC trip, an RC surge suppressor is supplied
separately for external installation across the a contact with the magnetic blowout. See figures 6 and 8.
Figure 4 - Drive Unit Block Diagram
LEGEND
CC ---- Closing Coil
1 & 2 ---- Control Power Input
Terminals
3 & 4 ---- Control Switch Input
Terminals
5 & 6 ---- Closing Coil Terminals
X ---- No Connection

OPERATION Page 13
Figure 5 - Internal Connection of the Magnetically Held Type
Figure 6 – Internal Connection of the Mechanically Latched Type
LEGEND
CC ---- Closing Coil
1 & 2 ---- Control Power Input
Terminals
3 & 4 ---- Control Switch Input
Terminals
5 & 6 ---- Closing Coil Terminals
7 & 8 ---- No Connection
LEGEND
CC ---- Closing Coil
1 & 2 ---- Control Power Input
Terminals
3 & 4 ---- Control Switch Input
Terminals
5 & 6 ---- Closing Coil Terminals
7 & 11 ---- Trip Coil External
Connection (DC)
8 ---- No Connection
16 & 26 ---- Delayed b Contact

Page 14 OPERATION
Figure 7 – Typical Control Circuit for Magnetically Held Type
LEGEND
PR ---- Protection Relay
PB1 ---- Stop Pushbutton
ES ---- Emergency Stop
PB2 ---- Start Pushbutton
MR ---- Master Relay
GL ---- Green Indicator Light
RL ---- Red Indicator Light
M ---- Vacuum Contactor
M/a ---- Aux a Contact
M/b ---- Aux b Contact
DU ---- Drive Unit
CC ---- Close Coils

OPERATION Page 15
Figure 8 – Typical Control Circuit for Mechanically Latched Type 125~250VDC TRIP
LEGEND
PR ---- Protection Relay
ES ---- Emergency Stop
PB1 ---- Stop Pushbutton
TRP ---- Trip Relay
PB2 ---- Start Pushbutton
MR ---- Master Relay
GL ---- Green Indicator Light
RL ---- Red Indicator Light
M ---- Vacuum Contactor
M/a ---- Aux a Contact
M/b ---- Aux b Contact
DU ---- Drive Unit
CC ---- Close Coils
TC ---- Trip Coil
D ---- Diode

Page 16 OPERATION
Figure 9 – Typical Control Circuit for Mechanically Latched Type 24~48VDC TRIP
LEGEND
PR ---- Protection Relay
ES ---- Emergency Stop
PB1 ---- Stop Pushbutton
TRP ---- Trip Relay
PB2 ---- Start Pushbutton
MR ---- Master Relay
GL ---- Green Indicator Light
RL ---- Red Indicator Light
M ---- Vacuum Contactor
M/a ---- Aux a Contact
M/b ---- Aux b Contact
DU ---- Drive Unit
CC ---- Close Coils
TC ---- Trip Coil
D ---- Diode
SS ---- Surge Suppressor
C ---- Capacitor
TC ---- Resistor