Toshiba HCV-5HA User manual

Document: VF00W103 Rev. 7
INSTRUCTION MANUAL
INSTALLATION - OPERATION - MAINTENANCE
HCV-5HA 7.2kV, 400A-7.0kA ([email protected])
HCV-5HAL 7.2kV, 400A-7.0kA ([email protected])
Manufactured in the USA
MAY 2008
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MAY 2008
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INTRODUCTION Page 2
READ THIS MANUAL carefully for important information about safety, handling, and
maintenance, for general-purpose NEMA Class E magnetic controllers.
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.
DIMENSIONS shown in the manual are in metric and/or their English equivalent.
These instructions are not intended to cover all details, combinations, or variations
of the equipment, storage, or installation.
PROBLEMS OR QUESTIONS should be addressed to:
Field Service Department
Toshiba International Corporation
13131 West Little York Road
Houston, Texas 77041 USA
Telephone: [phone]
[phone]
[phone] (Canada)
FAX: [phone]
MAY 2008
Use only Toshiba-authorized replacement parts.
This equipment is designed and built in accordance with
applicable safety standards in effect on the date of
manufacture. Unauthorized modifications can result in
severe injury, death and property damage. Do not make
any modifications to this equipment without the written
approval of Toshiba.
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Page
SAFETY DATA 4
Safety Data Information 4
GENERAL 6
Recommended Procedure 6
RECEIVING & HANDLING 7
Receiving 7
Handling 7
Storage 7
GENERAL DESCRIPTION 8
Application 8
Load Data 8
Location Condition 8
Ratings 9
Construction 10
PRE-OPERATION SET-UP 11
Application Precautions 11
Installation 11
Controls 12
Power Connections-Standard 13
Power Connections-Latched 13
Drive Unit Configuration 14
Standard Circuit Diagram 14
Latched Circuit Diagrams 15
Trial Operation 16
Page
MAINTENANCE 17
General Inspection 17
Vacuum Interrupter 18
Bearing 19
Closing Coils 19
Latch Mechanism 19
Auxiliary Switch 19
VACUUM INTERRUPTER 20
Replacement Procedure 20
Removing 20
Mounting 21
Adjustment of Contacts 21
Operation Check 21
TROUBLESHOOTING 22
OUTLINE DIAGRAM 23
WARRANTY AND LIMITATION
OF LIABILITY 24
TABLE OF CONTENTS Page 3
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Page 4 SAFETY DATA
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
practice.
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 medium voltage controllers are general purpose, Class E, magnetic
controllers designed and built in accordance with the latest applicable
provisions of NEMA ICS 3 Part 2, UL 347 and the National Electrical Code.
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.
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SAFETY DATA Page 5
IMPORTANT MESSAGES
Read this manual and follow its instructions. Signal words such as
DANGER, WARNING, CAUTION, and NOTE 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 the instructions in this manual and
on the safety signs located on the equipment.
Keep the safety signs visible and in good shape.
Never remove, damage, or cover any safety sign.
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Page 6 GENERAL
Please read this manual and all accompanying documentation in its entirety prior to installation and
operation. These instructions are not intended to cover all details, combinations or variations of the
equipment, storage or installation.
Toshiba medium voltage open vacuum type magnetic motor controllers are UL recognized and built in
accordance with the latest applicable provisions of NEMA ICS 3 Part 2, UL 347 and the National Electrical
Code.
There is a hazard of shock or
burn whenever working on or near
electrical equipment.
ALL POWER supplying the
equipment should be turned off
before starting work, and
disconnecting means should be
locked out and/or tagged out in
accordance with NFPA 70 E, Part II
and ANSI Z244.1.
Where it is not feasible to de-energize the unit, the following precautions should be taken;
A. Persons working near exposed parts that are or may be energized should be instructed to
and should use practices (including appropriate apparel, equipment and tools) in
accordance with NFPA 70 E, Part II.
B. Persons working on exposed parts that are or may be energized should, in addition to A, be
qualified persons who have been trained to work on energized equipment.
RECOMMENDED PROCEDURE
The successful and safe operation of medium voltage control equipment is dependent upon handling,
installation, operation and maintenance by qualified personnel. Failure to follow fundamental installation and
maintenance recommendations could lead to personal injury and damage to the equipment and other
property. When referred to in this manual and on product labels, a qualified person is one who is familiar
with installation, construction or operation of the equipment and the hazards involved. In addition, this
person should have the following qualifications;
1) Is trained and authorized to energize, de-energize, clear, ground and tag circuits in
accordance with established safety practices.
2) Is trained in the proper care and use of protective equipment such as rubber gloves, hard
hat, safety glasses or face shields, flash clothing, etc. in accordance with established
practices.
3) Is trained in rendering first aid.
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KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE
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RECEIVING & HANDLING Page 7
RECEIVING
Upon receipt of the equipment, make an immediate inspection for any damages which may have occurred
during shipment. When the contactor is received it should be unpacked sufficiently to inspect for concealed
damage and to determine that the shipment is complete and correct. If any damage is found it should be
noted prior to accepting the shipment if possible.
Check for things such as, damage to the container, water seepage or moisture on the contactor. Check the
nameplate to confirm that the ratings meet the intended application.
If any parts are damaged or missing, file a claim immediately with the carrier and notify the Toshiba sales
office. Try to give as much information as possible when filing a claim.
HANDLING & STORAGE
Vacuum contactors should be handled with care to avoid damage. Contactors should be kept in an upright
position and moved with suitable equipment.
If the contactor is to be stored over any length of time, the packing material should be restored for protection
during that period. Where conditions permit, the packing should be left intact until the contactor is ready for
installation. Store the contactor in a dry and dust free area. It should not be left outdoors or in adverse
conditions. If unprotected, corrosion, rust and insulation deterioration will occur.
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Page 8 GENERAL DESCRIPTION
SERVICE CONDITIONS
Application Condition
The type HCV vacuum contactor is manufactured in accordance with IEC 60470 (1974), NEMA ICS 3 Part 2
(1993). The vacuum contactor should be used in the following conditions.
Table 1
Normal Service Conditions
- Altitude: Less than 2,000 m
(6600 ft)
Above 2,000 m consult factory
-Ambient temperature: -5°C min. to +40°C max.
Its average over a period of
24 hr does not exceed +35°C.
-Relative humidity: 45% min. to 85% max.
-Vibration: 20 Hz - 1G or less
-Shock 30G
-Weight 43 lbs.
Latched type 44 lbs.
If the contactor is to be used in conditions other than those specified above, please consult Toshiba
International Corporation.
Table 2
General Application and Load Data
System
Voltage 0.8PF Ind/Syn Motor 1.0PF Syn Motor 3 Phase Transformer 3 Phase Capacitor
2.2-2.5kV
3.0-3.3kV
4.0-5.0kV
6.0-6.6kV
1750HP
2250HP
3000HP
4500HP
2000HP
2500HP
3500HP
1500kVA 1500kVAR
2000kVA 2000kVAR
3000kVA 2000kVAR
5000HP 4000kVA 2000kVAR
The above table is based on general load data and standard application. Lower limitations may apply on
specific applications (i.e. applications above 6600 feet elevations).
Location condition
The location where the contactor is to be installed should be free from dust, corrosive gas and moisture.
When it is to be used in a chemical plant or in outdoor applications, take necessary precautions against
corrosion, water seepage and condensation.
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CONTACTOR RATINGS
HCV-5HA
Rated Voltage 7200 Volts
Rated Current 400 Amps
Interrupting Capacity 7000A RMS Symmetrical @5000V Max.
4500A RMS Symmetrical @7200V Max.
Permissible Switching Frequency 1200/Hour
Mechanical Life 2,500,000 Operations
Electrical Life 250,000 Operations
Closing Time 75-100 ms
Opening Time * 20-30 ms
Arcing Time 10 ms or less
Pick-Up Voltage AC or DC 85% Rated (Hot) - 70% Rated (Cold)
Drop-Out Voltage AC or DC 50% Rated (Hot) - 40% Rated (cold)
Rated Control Voltage AC 115/120 or 230/240 V 50/60 Hz
Rated Control Voltage DC 120/125 or 240/250 V
Coil Circuit Inrush 670 VA AC (700 W DC)
Coil Circuit Holding 85 VA AC (85 W DC)
Auxiliary Contact Arrangement 3 N.O. - 3 N.C.
Auxiliary Contact Rating 10 A, 600 V (NEMA Class A600)
* - DC switching, opening terminals 3 & 4.
HCV-5HAL (Latched Type Only)
Permissible Switching Frequency 300/Hour
Mechanical Life 250,000 Operations
Tripping Voltage 40-60% Rating DC
Tripping Current 4.8 A DC Max
GENERAL DESCRIPTION Page 9
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Page 10 STRUCTURE
Fig. 1 Construction of HCV-5HA & HCV-5HAL
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PRE-OPERATION SET-UP Page 11
APPLICATION PRECAUTIONS
1) Verify that the voltage and current applied is within the specified ratings. (See application
table, page 5).
2) When the contactor is used with an induction heater facility, the switching life of the vacuum
interrupter is approximately 250,000 operations. The vacuum interrupter should be replaced
after 250,000 operations.
3) When the contactor is applied to a capacitor load, be sure to use a space heater to keep
the temperature above the dew point and prevent condensation. Be sure to use a heater
adequately sized for the compartment in which the contactor is installed. The contactor
should always be applied with a protective power fuse.
INSTALLATION
During installation, protect the contactor from dust and falling debris.
The following precautions should be taken,
1) The mounting surface should be horizontal (level: ±1 mm). If the mounting surface is not
level, adjust with spacers or shims.
2) The contactor base has four (4) mounting holes. Use M8 or 5/16 bolts to securely mount
the contactor.
3) In wiring the main circuit, wires should be given sufficient length to be flexible for service.
The ground wires should be #10 AWG or larger.
4) Avoid touching the surface of the vacuum interrupter with soiled hands. You can damage
the silicon finish on the interrupter. If the interrupter becomes dirty, simply clean it with a
non-tracking cleaner such as rubbing alcohol.
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Page 12 PRE-OPERATION SET-UP
CONTROLS
The drive unit for the closing coil assembly is installed in a cavity in the molded frame housing. The
closing circuit can be operated by applying either AC or DC to this drive unit. The optional latch trip
circuit uses DC as standard. When a latched contactor is operated using AC power, it is
recommended that a capacitor trip device be used.
The standard control voltage (factory preset) is 120V AC. To operate at other ratings see the
selection chart below.
Fig. 2 Control Voltage Selection for Closing Coils
The following is a list of the available trip coil voltages for a latched type contactor:
24 V DC 32 V DC 48 V DC
125 V DC 250 V DC
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CONNECTION OF CONTROL POWER SUPPLY
Figures 3 and 4 show the internal connections of the magnetically held (normally energized) type
and the latched type respectively. Connect control power and open/close control signals according
to these connection diagrams.
PRE-OPERATION SET-UP Page 13
Note: Connections are the same for 100V and 200V
class. Only the drive unit settings should be changed
to match the application control voltage.
Note: Terminals 3 and 4 are rated for 4.8A DC max. A wire jumper (14 AWG or larger) can be used
instead of a relay on 3 and 4.
Note: Terminals 3 and 4 are rated for 4.8A DC max. A wire jumper (14 AWG or larger) can be used
instead of a relay on 3 and 4.
Fig. 3 Connections for Magnetically Held Type.
Note: Connections are the same for 100V and 200V
class. Only the drive unit settings should be changed
to match the application control voltage.
Closing Coils
Power
Su
pp
l
y
Jumper or
2 Relay
Contacts
Control Terminal Block
(
Drive Unit is Attached
)
Fig. 4 Connections for Mechanically Latched Type.
Trip
Power
Supply
Control Terminal Block
(
Drive Unit is Attached
)
Jumper or
2 Relay
Contacts
Power
Su
pp
l
y
Closing Coils Trip Coil
Contactor Auxiliary Switch Contact
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C
STANDARD OPERATION CIRCUIT
The following figures illustrate the vacuum contactor and its auxiliary circuits (control and
monitoring). Fig. 6 represents the standard operation circuit diagram of the normally
energized type and Fig. 7 (a & b) the latched type. Wiring should be implemented
according to these circuit diagrams.
ONTRO Page 14 LS
Page 14 CONTROLS
Fig. 5 Internal Configuration of Drive Unit.
Contacts or
Jumper Wire
100-125V AC/DC 200-250V AC/DC
V
ACUUM CONTACTOR
CR
DU
CONTROL
RELAY
2E
(
OVERLOAD
)
DOOR
SWITCH
STOP
INTERLOCK
START
INTERLOCK
REMOTE
CR
ON
LOCAL
ON
OFF
OFF
Remote
Operation
Switch
Fig. 6 Standard Operation Circuit Diagram of Normally Energized Type.
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LATCHED CIRCUIT Page 15
Fig. 7a Standard Operation Circuit Diagram of Latched Type Using Shunt Trip
Fig. 7b Standard Operation Circuit Diagram of Latched Type Using Capacitor Trip Device
DC
AC
VCTT
VCTT
CR
2E
OFF
OFF
CONTROL
RELAY
START
INTERLOCK
REMOTE
LOCAL
DU
ON
ON
REMOTE OPERATION
SWITCH
CTD
P
N
CR
DU
CONTROL
RELAY
START
INTERLOCK
REMOTE
LOCAL
OFF OFF 2E
ON ON
REMOTE OPERATION
S
WIT
C
H
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Page 16 TRIAL OPERATION
TRIAL OPERATION
MAKE SURE MAIN POWER IS OFF.
After mounting and wiring of the vacuum contactor, make the following inspections.
1) Check for any loose connections.
2) Check for any wiring errors. Perform this test with only the control circuit energized.
Confirm that the operation is correct. For the latched type contactor, check that the latch
correctly engages and trips when the close/trip signals are applied. Also, manually trip the
contactor using the trip lever to verify proper operation. For latch kit adjustment and
maintenance please refer to manual no. 6F9G0132 - Installation Instructions of Latch Kits
for HCV-5HA.
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GENERAL INSPECTION
MAINTENANCE AND INSPECTION
The following maintenance and inspections are recommended to maintain the performance level
and extend the operational life of the vacuum contactor.
BEFORE CONDUCTING MAINTENANCE AND INSPECTIONS, MAKE SURE
THAT ALL POWER IS TURNED OFF.
ITEMS FOR INSPECTION
Table 3
MAINTENANCE Page 17
PARTS TO BE
INSPECTED
INSPECTION
ITEM
CRACKS
DISCOLORATION
CONTAMINATION
RUST
WEAR
LOOSE PARTS
INCOMPETE
OPERATION
VIBRATION
SOUND
INSPECTION
INTERVALS
VACUUM
INTERRUPTER OOO O
MOVABLE
CONDUCTOR OO
UPPER &
LOWER
TERMINALS OO
MOLDED
FRAME OOO
INSULATION
FLANGE OO
BEARING OO
CLOSING COIL O
ARMATURE &
CORE OO
AUXILIARY
SWITCH OO O
TRIP COIL O
ROLLER OOOO
BOLTS & NUTS O
INSULATION
WIRE O
OTHERS
VISUAL CHECK ONCE A YEAR OR EVERY 20,000 OPERATIONS
THE LIFE EXPECTANCY OF THE ELECTRICAL PARTS (VACUUM INTERRUPTER,
AUXILIARY SWITCH) IS 250,000 OPERATIONS
NOTE
MAIN CIRCUIT
MECHANISM
SECTION
ELECTRO-
MAGNET
LATCH
MECHANISM
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Make Sure Power Is Turned Off.
MAINTENANCE
Location Maintenance Procedure
Vacuum
Interrupter
Check the upper and lower flanges and interrupter shaft to see if they are
contaminated or corroded.
If contaminated...use a clean cloth
and rubbing alcohol.
If corroded.........replace with a
new interrupter.
NOTE: Avoid touching the ceramic surface.
Skin oils may harm the silicon
varnish.
Check the main contact wear in the
vacuum interrupter.
If the wear gauge can be inserted,
then there is sufficient contact material
available for continued use.
If the gauge cannot be inserted, replace
the interrupter.
NOTE: This check is made with the
contactor closed.
Check vacuum in the vacuum interrupter. Fig. 8 Vacuum Interrupter
Apply 10kVAC between the upper and lower terminals for one minute.
If there is no voltage breakdown, the vacuum interrupter is acceptable for continued use.
If there is voltage breakdown, replace with a new vacuum interrupter before continued
use.
NOTE: If there is a vacuum failure, it can be confirmed by pushing down on the insulating
flange below the vacuum interrupter. If the interrupter shaft can easily be moved, then the
interrupter has lost vacuum.
Page 18 MAINTENANCE
WEAR
GAUGE
INSULATING
FLANGE
2.7mm
MINIMUM
SHAFT
LOWER
FLANGE
UPPER
FLANGE
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