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INSTRUCTION MANUAL [CUSTOMER MANUAL]

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instruction manual - Toshiba

INSTRUCTION MANUAL. INSTALLATION - OPERATION - MAINTENANCE. HCV-5

HCV-5HA Instruction Manual - Toshiba

INSTRUCTION MANUAL. INSTALLATION - OPERATION - MAINTENANCE. HCV-5HA Vacuum Contactor, 7.2kV – 400A – 7.0kA (4.5kA@7.2kV). HCV-5HAL ...

These instructions are not intended to cover all details, combinations or variations of the equipment, storage or installation. Toshiba medium voltage vacuum ...

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Document: VF00W103 Rev. 10
INSTRUCTION MANUAL
INSTALLATION - OPERATION - MAINTENANCE HCV-5HA Vacuum Contactor, 7.2kV � 400A � 7.0kA (4.5kA@7.2kV) HCV-5HAL Vacuum Contactor, 7.2kV � 400A � 7.0kA (4.5kA@7.2kV)
Issued: 4/20 Manufactured in the USA

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: (713) 466-0277
(800) 231-1412 (800) 527-1204 (Canada) FAX: (713) 466-8773
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.

TABLE OF CONTENTS

Page 3

SAFETY DATA Safety Data Information

Page 4
4

GENERAL

Recommended Procedure

RECEIVING & HANDLING

Receiving

Handling

Storage

GENERAL DESCRIPTION

Application

Load Data

Location Condition

Ratings

Construction

PRE-OPERATION SET-UP

Application Precautions

Installation

Controls

Power Connections-Standard

Power Connections-Latched

Drive Unit Configuration

Standard Circuit Diagram

Latched Circuit Diagrams

Trial Operation

MAINTENANCE
General Inspection Vacuum Interrupter Bearing Closing Coils Latch Mechanism Auxiliary Switch
TROUBLESHOOTING
OUTLINE DIAGRAM

Page 17
17 18 19 19 19 19
20
21

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.

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.

NOTE

Means that you might be injured if you do not follow instructions. Equipment damage might also occur.
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.

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 vacuum contactos 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, 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;

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.

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;

Is trained and authorized to energize, de-energize, clear, ground and tag circuits in

accordance with established safety practices.

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.

Is trained in rendering first aid.

KEEP THESE INSTRUCTIONS FOR FUTURE REFERENCE

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.

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:
-Ambient temperature:
-Relative humidity: -Vibration: -Shock -Weight

Less than 2,000 m (6600 ft)
Above 2,000 m consult factory -5�C min. to +40�C max.
Its average over a period of 24 hr does not exceed +35�C.
45% min. to 85% max. 20 Hz - 1G or less 30G 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.

System Voltage
2.2-2.5kV 3.0-3.3kV 4.0-5.0kV 6.0-6.6kV

Table 2 General Application and Load Data

0.8PF Ind/Syn Motor

1.0PF Syn Motor

3 Phase Transformer

1750HP 2250HP 3000HP 4500HP

2000HP 2500HP 3500HP 5000HP

1500kVA 2000kVA 3000kVA 4000kVA

3 Phase Capacitor
1500kVAR 2000kVAR 2000kVAR 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.

GENERAL DESCRIPTION

Page 9

CONTACTOR RATINGS Rated Voltage

HCV-5HA

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 *

50 - 90 ms

Opening Time *

15 - 40 ms

Arcing Time

10 ms or less

Pick-Up Voltage AC or DC (Max.) * 85% Rated (Hot) - 70% Rated (Cold)

Drop-Out Voltage AC or DC (Max.) * 70% Rated (Hot) - 60% 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)

* These are typical values measured under the following conditions: a) No external devices connected to the mechanism. b) At sea level. c) 120Vac control power applied to terminals 1 & 2. d) Contactor controlled (open/close) via 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

Page 10

STRUCTURE
Fig. 1 Construction of HCV-5HA & HCV-5HAL

PRE-OPERATION SET-UP

Page 11

APPLICATION PRECAUTIONS

Verify that the voltage and current applied is within the specified ratings. (See application

table, page 5).

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.

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,

The mounting surface should be horizontal (level: �1 mm). If the mounting surface is not

level, adjust with spacers or shims.

The contactor base has four (4) mounting holes. Use M8 or 5/16 bolts to securely mount the

contactor.

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.

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.

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 125 V DC

32 V DC 250 V DC

48 V DC

PRE-OPERATION SET-UP

Page 13

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.
Note: Connections are the same for 100V and 200V class. Only the drive unit settings should be changed to match the application control voltage.

Jumper or 2 Relay Contacts
Power Supply

Closing Coils

Control Terminal Block (Drive Unit is Attached)
Fig. 3 Connections for Magnetically Held Type.

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.

Contactor Auxiliary Switch Contact

Trip Power Supply

Jumper or 2 Relay Contacts Power Supply
Control Terminal Block (Drive Unit is Attached)

Closing Coils

Trip Coil

Fig. 4 Connections for Mechanically Latched Type.
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 contact on 3 and 4.

CONTROLS

Contacts or Jumper Wire

Page 14

Fig. 5 Internal Configuration of Drive Unit.
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.

100-125V AC/DC 200-250V AC/DC

Remote Operation
Switch

OFF OFF

ON CR

ON LOCAL REMOTE

START

INTERLOCK

STOP INTERLOCK

DOOR SWITCH

CONTROL RELAY

2E (OVERLOAD)

VACUUM CONTACTOR CR

Fig. 6 Standard Operation Circuit Diagram of Normally Energized Type.

PLAagTeCH14ED CIRCUIT

CONPTaRgOe L1S5

Fig. 7a Standard Operation Circuit Diagram of Latched Type Using Shunt Trip

D C

LOCAL
REMOTE
START INTERLOCK

REMOTE OPERATION SWITCH
CR

OFF

OFF 2E

VCTT

CONTROL RELAY
Fig. 7b Standard Operation Circuit Diagram of Latched Type Using Capacitor Trip Device
REMOTE OPERATION SWITCH

LOCAL
REMOTE
START INTERLOCK

OFF OFF 2E
CR VCTT
CTD
P N

A C

CONTROL RELAY

Page 16

TRIAL OPERATION

MAKE SURE MAIN POWER IS OFF.

After mounting and wiring of the vacuum contactor, make the following inspections.

Check for any loose connections.

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.

MAINTENANCE

Page 17

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.
Table 3 Items for Inspection

CRACKS DISCOLORATION CONTAMINATION
RUST WEAR LOOSE PARTS INCOMPETE OPERATION VIBRATIO N SOUND INSPECTIO N INTERVALS

PARTS TO BE INSPECTED

INSPECTION ITEM

VISUAL CHECK ONCE A YEAR OR EVERY 20,000 OPERATIONS

MAIN CIRCUIT

MECHANISM SECTION

VACUUM INTERRUPTER

OOO

O O MOVABLE
CONDUCTOR

UPPER &

LOWER

TERMINALS

MOLDED FRAME

OOO

O INSULATION FLANGE

BEARING

CLOSING COIL

ARMATURE & CORE

AUXILIARY SWITCH

TRIP COIL

ELECTRO MAGNET

LATCH MECHANISM

ROLLER

OO O

OTHERS

NOTE

BOLTS & NUTS

O INSULATION WIRE
THE LIFE EXPECTANCY OF THE ELECTRICAL PARTS (VACUUM INTERRUPTER, AUXILIARY SWITCH) IS 250,000 OPERATIONS

Page 18

MAINTENANCE

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.

UPPER FLANGE

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.

LOWER FLANGE
WEAR GAUGE

SHAFT

2.7mm MINIMUM
INSULATING
FLANGFEig. 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.

MAINTENANCE

Page 19

Location Vacuum Interrupter Bearing Closing Coil
Latch Mechanism
Auxiliary Switch

Maintenance Procedure

Gap/Wipe Standard Values (contactor in new condition)

Contactor

Contact Gap

Wipe (new)

Allowable Wear

Normally Energized Type

4.0-4.2mm

>2.3mm

1.8mm

Latched Type

4.0-4.2mm

>2.1mm

1.6mm

* Check for loose mounting bolts. Tighten if loose.

Torque M6 bolts to 48 in-lb.

* Check for discoloration.

Yellow (Gold) ...... available for continued use.

Dark Brown or Black ...... replace with new coil.

If the closing coil is overheating, contact Toshiba.

* Check that the holding latch reliably engages.

Note: To manually close the latch, hold the central area of the rotating shaft with a wrench and operate it.

* Check the condition of the roller. It should be smooth.

* Lubricate the rotating parts with a molybdenum disulfide

or gear lubricant.

* Verify that there is remaining auxiliary shaft travel.

Approximately 2.3 - 2.5mm.

* Check for burnt or worn contacts.

Replace if burnt or worn.

* Check if auxiliary switch is mounted at an incline or if

mounting plate is loose. If inclined or loose, correct it.

(Reference) Values for gap and wipe

Contact Type

Contact Gap

Normally Open Contact

4mm +/- 0.4

Normally Closed Contact

4mm +/- 0.4

Wipe 3mm +/- 0.3 3mm +/- 0.3

Delayed N.C. Contact (For latched type contactor only. Contacts 16-26)

2.5mm +/- 0.3

4.5mm +/- 0.5

Page 20

MAINTENANCE

TROUBLESHOOTING

Turn off main power before any inspections are conducted.

SYMPTOM

Table 4 Trouble Shooting Procedure
SOURCE OF TROUBLE/PROBLEM

SOLUTION

Contactor does not close. Contactor does not open
(Latch type). Trip coil overheated. Closing coil overheated. Latch does not engage.

Conduct investigation with main power "OFF".

If inspection and/or countermeasure is difficult, inform Toshiba immediately.

Lower the voltage drop to
0 Control power supply is low. increase the voltage to 90%
or more of the rating.

0 0 0 0 0 Incorrect control voltage.

Apply proper rating.

Defective control circuit. Check connection diagram.

Bad connection and/or loose connection.

Make proper connection.

Bad control switch contact. Clean or replace device.

00 0 00

Incorrect terminal connection.

Connect correctly.

Blown power supply fuse(s).

Remove cause of fault and replace fuse(s).

Disconnected coil.

Survey cause and reconnect coil.

Faulty drive unit.

Replace drive unit.

Defective latch mechanism.

Excite closing coil and check latch hook.

0 0
0

Mechanism jammed.

Lubricate corresponding portion.

Incorrect auxiliary adjustment.

Adjust delayed N.C. contact gap to 2.5mm +/- 0.3mm when
connected.

Bad auxiliary contact.

Clean or replace auxiliary contact block.

OUTLINE

Page 21

MOUNTING HOLE LAYOUT
Fig. 12 Types HCV-5HA, HCV-5HAL

Motors and Drives Division Power Apparatus & Components 13131 West Little York Road | Houston, TX 77041 Tel: 713-466-0277 | US: 800-231-1412 | CAN: 800-872-2192
www.toshiba.com/tic
Printed in USA