Toshiba HCV-6KALU User manual

Document: VF010H08A
INSTRUCTION MANUAL
INSTALLATION - OPERATION - MAINTENANCE
HCV-6KAU Vacuum Contactor, 7.2kV – 720A – 7.2kA
HCV-6KALU Vacuum Contactor, 7.2kV – 720A – 7.2kA
Issued: 12/05
Manufactured in the USA
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TOSHIBA
INSTRUCTION MANUAL
For the Installation, Operation and Maintenance of
HCV-6KAU Vacuum Contactor, 7.2kV – 720A – 7.2kA
HCV-6KALU Vacuum Contactor, 7.2kV – 720A – 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:
[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, 2004
WARNING
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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 apart 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
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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-6KAU and HCV-6KALU 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.
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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
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Page 4 TABLE OF CONTENTS
SAFETY......................................................................................................................................................1
INTRODUCTION ........................................................................................................................................6
GENERAL DESCRIPTION.........................................................................................................................7
Components....................................................................................................................................7
Indicators and Controls ...................................................................................................................7
Figure 1 – Contactor Structure........................................................................................................7
RECEIVING, INSPECTION AND HANDLING ...........................................................................................8
Receiving and Unpacking ...............................................................................................................8
Acceptance Inspection ....................................................................................................................8
Handling and Moving ......................................................................................................................8
Figure 2 – Location of the 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 – Ground Connection Location .........................................................................................10
Figure 4 – Drive Unit Location.........................................................................................................10
PRE-ENERGIZATION CHECK ..................................................................................................................11
General ...........................................................................................................................................11
Electrical Checks.............................................................................................................................11
OPERATION...............................................................................................................................................12
Moving Contactor from the OFF to ON Position ............................................................................. 12
Moving Contactor from the ON to OFF Position ............................................................................. 12
Figure 5 – Internal Configuration of Drive Unit................................................................................13
Figure 6 – Internal Connection of the Normally Energized Type ....................................................13
Figure 7 – Internal Connection of the Latched Type.......................................................................14
Figure 8 – Standard Operation Circuit of the Normally Energized Type .........................................14
Figure 9 – Standard Operation Circuit of the Latched Type (Shunt Trip)........................................ 15
Figure 10 – Standard Operation Circuit of the Latched Type (Capacitor Trip)................................15
MAINTENANCE .........................................................................................................................................16
Maintenance Program.....................................................................................................................16
Maintenance Record.......................................................................................................................16
Servicing Equipment .......................................................................................................................16
Inspection and Maintenance Types ................................................................................................17
Table 1 – Tightening Torque...........................................................................................................17
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TABLE OF CONTENTS Page 5
Table 2 – Check Points for Periodic Inspection ..............................................................................18
Table 3 – Gap/Wipe Standard Values (contactor in new condition)................................................20
Vacuum Check................................................................................................................................21
Figure 11 – Toshiba Portable Vacuum Checker .............................................................................21
Figure 12 – Application of Test Voltage for Vacuum Check............................................................22
Electrical Service Life......................................................................................................................23
Mechanical Service Life ..................................................................................................................23
Figure 13 – Wipe Measurement......................................................................................................23
Service Life – Capacitor Switching..................................................................................................23
Table 4 – Recommended Part Replacement Intervals ...................................................................23
Figure 14 – Capacitor Switching Life ..............................................................................................23
STORAGE AND DISPOSAL......................................................................................................................24
Storage............................................................................................................................................24
Inspection during Storage ...............................................................................................................24
Disposal
SPECIFICATIONS......................................................................................................................................25
Table 5 – Ratings............................................................................................................................25
WARRANTY AND LIMITATION OF LIABILITY ........................................................................................26
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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.
WARRANTY AND LIMITATION OF LIABILITY – Details Toshiba International Corporation’s standard
warranty terms.
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GENERAL DESCRIPTION Page 7
COMPONENTS
The Toshiba HCV-6KAU and HCV-6KALU
vacuum contactors described in this manual are
suitable for use on systems of 7.2kV – 720A –
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.
Figure 1 – Contactor structure
Front view (Figure 1):
1. Insulating frame
2. Vacuum bottle
3. Insulating flange
4. Armature
5. Auxiliary switch
6. Stopper
7. Drive unit/Control circuit terminal block
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.
Right side view (Figure 1):
8. Rotating shaft
9. Closing coil (inside)
10. Contact wear gauge
11. Flexible conductor/terminal
12. Fixed conductor/terminal
1
2
3
4
5
6 7
89
10 11
12
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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 - Location of the Wear Gauge
CAUTION
WARNING
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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-6KAU and HCV-6KALU 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
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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 terminal is located on the right side
of the contactor as shown in Figure 3. To make
the ground connection, first remove the
fastening M8 hex head bolt and crimp-on ring
terminal (provided with the contactor) and crimp
the ring terminal to the end of the ground wire.
The ground wire should be 8 AWG or larger.
Then reattach the ring terminal using the same
bolt previously removed and torque to 9-11 ft-lb
(120-150 kgf-cm).
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 by means of a drive unit (black plastic
box) located on the bottom frame (Figure 4).
Either AC or DC supply voltage may be
connected to the drive unit. The optional
latched trip circuit uses DC as standard power.
When a latched contactor is operated using AC
power, it is recommended that a capacitor trip
device be used. The standard operating
voltage for the control circuit is as follows:
Normally energized type: 100-240V AC/DC
Latched type: 100-240V AC/DC closing voltage
Latched type: 125V DC tripping voltage
Figure 3 - Ground connection location
Figure 4 - Drive Unit location
Contactors utilizing the latch kit must follow
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 control circuit. If
DC power is not available, use an AC
closing circuit and a capacitor trip.
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 9).
WARNING
WARNING
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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.
DANGER
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
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Page 12 OPERATION
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).
3. 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.
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).
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PRE-ENERGIZATION CHECK Page 13
Figure 5 - Internal configuration of Drive Unit
Figure 6 - Internal connection of the normally energized type
16 15 14 13 12 11
26 25 24 23 22 21
52
CC
52
CC
A
uxiliar
y
Switch
Drive Unit
A
1 A2
Closing Supply
AC/DC
T4
T3
T2
T1
U V W
R S T
Vacuum Bottles
12
56
LEGEND
52 CC ….. Closing Coil
T1, T2 ….. Terminal Block
A1, A2 …. Closing Supply
AC/DC
LEGEND
52 CC ….. Closing Coil
T1, T4 ….. Terminal Block
A1, A2 …... Closing Supply
AC/DC
52
CC
T1
T2
SWITCHING
TIMER
POWER VOLTAGE
DETECT
A
1
A
2
OSCILLATION
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Page 14 OPERATION
Figure 7 – Internal connection of the latched type
Figure 8 – Standard operation circuit of the normally energized type
52
CC
52
CC
Drive Unit
A
1 A2
Closing Supply
AC/DC
T4
T3
T2
T1
U V W
R S T
16 15 14 13 12 11
26 25 24 23 22 21
A
uxiliar
y
Switch
Diode
Tripping
Supply
DC
52
TC
Vacuum Bottles
12
56
Remote
Operation
Switch
Stop
Interlock
CR
DrS
(Door Switch)
Start
Interlock
Local
Remote
ON
OFF
OFF
A2
A1
CR
16 15 14 13 12 11
26 25 24 23 22 21
VCTT
GL
52
CC
52
CC
T2
T1
2E (Overload)
ON
100/110V 200/220V
A
C/DC
Auxiliary
Switch
Dri ve
Unit
CR
CR
RL
LEGEND
52 CC ….. Closing Coil
52 TC …... Tripping Coil
T1, T4 …... Terminal Block
A1, A2 ….. Closing Supply
AC/DC
LEGEND
52 CC …. Closing Coil
T1, T2 ….. Terminal Block
GL ……… Green Light
RL ……… Red Light
A1, A2…... Closing Supply
CR……… Control Relay
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PRE-ENERGIZATION CHECK Page 15
Figure 9 – Standard operation circuit of the latched type (shunt trip)
Figure 10 – Standard operation circuit of the latched type (capacitor trip)
CR
Start
Interlock
Local
Remote
ON
A
2
A
1
CR
11 15 14 13 12
21 25 24 23 22
VCTT
GL
52
CC
52
CC
T2
T1
ON
16
26
52
TC
T3
D
OFF
2E
T4
Remote Operation Switch
100/110V 200/220V
A
C/DC
Drive
Unit
CR
RL
CR
Start
Interlock
Local
Remot e
ON
A
2
A
1
CR
11 15 14 13 12
21 25 24 23 22
VCTT
GL
52
CC
52
CC
T2
T1
ON
16
26
52
TC
T3
D
OFF
2E
T4
Remote Operation Switch
100/110V 200/220V
AC/
D
C
P U
N V
CTD
CR
Dr i ve
Unit
RL
LEGEND
52 CC ….. Closing Coil
T1, T2 ….. Terminal Block
GL ……… Green Light
RL ……… Red Light
A1, A2 …. Closing Supply
AC/DC
LEGEND
52 CC ….. Closing Coil
52 TC ….. Tripping Coil
T1-T4 ….. Terminal Block
GL ……… Green Light
RL ……… Red Light
CR ……... Control Relay
2E ……… Overload Relay
Contact
CTD ……. Capacitor Trip
Device
VCTT ….. Vacuum Contactor
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Page 16 MAINTENANCE
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
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