Document: VF010H07A INSTRUCTION MANUAL INSTALLATION - OPERATION - MAINTENANCE HCV-1JBU Vacuum Contactor, 1.5kV - 600A HCV-1KAU Vacuum Contactor, 1.5kV - 720A Issued: 12/05 Manufactured in the USA Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.ctiautomation.net - Email: info@ctiautomation.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.ctiautomation.net - Email: info@ctiautomation.
TOSHIBA INSTRUCTION MANUAL For the Installation, Operation and Maintenance of HCV-1JBU Vacuum Contactor, 1.5kV – 600A HCV-1KAU Vacuum Contactor, 1.5kV – 720A WARNING 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.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.ctiautomation.net - Email: info@ctiautomation.
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. DANGER Indicates a situation that will result in death, serious injury, and severe property damage if you do not follow instructions. WARNING Means that you might be seriously injured or killed if you do not follow instructions. Severe property damage might also occur.
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) 2) 3) 4) 5) 6) Carefully read the entire instruction manual. Be skilled in the installation, construction or operation of the equipment and aware of the hazards involved.
SAFETY DANGER 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 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.ctiautomation.net - Email: info@ctiautomation.
Page 4 TABLE OF CONTENTS SAFETY......................................................................................................................................................1 INTRODUCTION ........................................................................................................................................6 GENERAL DESCRIPTION.........................................................................................................................7 Components........................
TABLE OF CONTENTS Page 5 Table 3 – Gap/Wipe Standard Values (contactor in new condition)................................................20 Vacuum Check................................................................................................................................21 - Toshiba Portable Vacuum Checker ..............................................................................................21 - Application of Test Voltage for Vacuum Check...................................................
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.
GENERAL DESCRIPTION Page 7 COMPONENTS The Toshiba HCV-1JB and HCV-1KA vacuum contactors described in this manual are suitable for use on systems of 1.5kV, 600A and 1.5kV, 720A respectively. Arc interruption is accomplished inside sealed vacuum interrupters mounted on track-resistant insulators. Vacuum interrupters use low-surge contact materials, which exhibit low current chopping levels reducing switching overvoltage. Front view (Figure 1): 1. Insulation frame 2. Vacuum Interrupter 3. Primary terminal 4.
Page 8 GENERAL DESCRIPTION INDICATORS AND CONTROLS The following indicator is provided: On-Off Indicator - Indicates if the contactor is OFF (Green) or ON (Red). When the indicator reads OFF, the main contacts of the contactor are open. When the indication is ON, the main contacts are closed. See Figure 4. Figure 4 - ON/OFF Indicator Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.ctiautomation.net - Email: info@ctiautomation.
RECEIVING, INSPECTION AND HANDLING Page 9 RECEIVING AND UNPACKING HANDLING AND MOVING The contactor units are subjected to factory production testing prior to being packed and shipped. 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. ACCEPTANCE INSPECTION Confirm that the contactor is complete, correct as specified and undamaged from shipment and handling.
Page 10 INSTALLATION AMBIENT CONDITIONS WARNING 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-1JBU and HCV-1KAU 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).
INSTALLATION CAUTION Use two wrenches to torque the connection to prevent applying excessive force to the terminal, which can damage the frame. GROUND CONNECTIONS The contactor must be grounded in accordance with the requirements of the National Electrical Code, Article 250 or applicable local standards. WARNING Proper grounding connections must be made to the contactor before incoming power is applied.
Page 12 PRE-ENERGIZATION CHECK ELECTRICAL CHECKS GENERAL BEFORE ENERGIZING THE CONTACTOR for the first time, follow the procedure below to verify that the equipment is properly installed and functional. DANGER WARNING WARNING WARNING WARNING 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.
OPERATION Page 13 MOVING THE CONTACTOR FROM THE OFF TO THE ON POSITION TO MOVE THE CONTACTOR TO THE ON POSITION: 1. Turn ON circuit control power to move the contactor to the ON position 2. Verify that the position indicator reads ON (Red). 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). Phone: 800.894.0412 - Fax: 888.723.
Page 14 OPERATION LEGEND R S 52 CC …. Closing Coil T1-T4 ….. Terminal Block A1-A2…... Closing Supply AC/DC T Vacuum Bottles U V W T4 T3 15 26 25 14 13 12 11 24 23 22 21 52 CC 52 CC T2 16 T1 Auxiliary Switch 5 6 Drive Unit 1 2 A1 A2 Closing Supply AC/DC Figure 8 – Internal Connection of the Normally Energized Type LEGEND 52 CC …. Closing Coil T1-T2 ….. Terminal Block A1-A2…...
OPERATION Page 15 LEGEND Re mo t e Op e r a t i o n Swi t ch OF F CR OF F CR VCTT AC/DC 100/110V 200/220V ON ON Local A1 CR 15 14 13 12 11 26 25 24 23 22 21 GL RL Auxi l i ar y Swi t c h R e mo t e St ar t I nt er l ock 16 52 CC …. Closing Coil T1-T2 ….. Terminal Block GL ……… Green Light RL ……… Red Light CR……… Control Relay A1-A2…...
Page 16 MAINTENANCE MAINTENANCE PROGRAM MAINTENANCE RECORD 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. Keep a permanent record of all maintenance work.
MAINTENANCE RECOMMENDED INSPECTION AND MAINTENANCE TYPES NOTE: Refer to the SAFETY section of this manual for important information. 1. Acceptance Inspection This inspection confirms that the contactor is complete, correct as specified and undamaged from shipment. The procedure for this inspection is outlined in the RECEIVING, INSPECTION AND HANDLING section of this manual. 2.
Page 18 MAINTENANCE Table 2 - Check Points for Periodic Inspection Check Point Check Item Operating Mechanism Loose bolts, nuts or screws Tighten using screwdriver or wrench. Make sure all bolts, nuts and screws are tight. Tighten if loose. See Table 1 for tightening torque specifications. Dust or foreign matter inside Visual inspection. The contactor should be clean and contain no foreign matter. Wipe with a clean dry cloth. Electromagnets Visual inspection.
MAINTENANCE Page 19 Table 2 – Check Points for Periodic Inspection (cont.) Check Point Check Item Check Method Criteria What to do Main Circuit Dust on surface of vacuum interrupter Visual inspection. Make sure there is no dust on the surface. Wipe with a clean, dry cloth. Insulation Frame and Flanges Dust, foreign matter or damage Visual inspection. Make sure there is no dust, foreign matter or breakage. Wipe with a clean, dry cloth. If damaged, contact Toshiba.
Page 20 MAINTENANCE Table 2 – Check Points for Periodic Inspection (cont.) Check Point Dielectric Strength Open/Close Operation Check Item Measure main circuit --- Check Method Criteria What to do Measure dielectric strength between phases and between circuits and ground. 10kV AC or 14kV DC for 1 minute. If breakdown occurs, contact Toshiba. Perform open/close operation by electric operation test to confirm the correct operation. --- If not normal, check and repair.
MAINTENANCE VACUUM CHECK A sufficient level of vacuum is necessary for proper performance of the vacuum interrupters. Although vacuum leaks are rare, the vacuum integrity should be checked periodically. The relationship between dielectric breakdown voltage of the contact gap and internal vacuum interrupter pressure has been found to be generally predictable. Therefore, vacuum interrupter integrity is checked by performing a high potential test across the open gap of the interrupter.
Page 22 MAINTENANCE CRITERIA: 1. If a current flow above 5 milli-amperes is observed or if breakdown occurs, one or more of the interrupters has insufficient vacuum and must be replaced. 10kV AC (14kV DC) Exception: If the current exceeds 5 milliamperes the first time the voltage is brought up, reduce the voltage to zero and increase it again. It may be necessary to repeat this procedure a few times. Voltage 2.
MAINTENANCE The electrical service life of the vacuum interrupter is defined by the electrode wear and the number of open/close operations (mechanical life). To determine electrode wear, measure the distance between the lever and washer in the closed (ON) state, as shown in Figure 13. This dimension is called the “wipe”. If the 1.0mm contact wear gauge cannot be inserted, then the end of the service life has been reached.
Page 24 DISPOSAL AND STORAGE STORAGE If the contactor is to be stored for any length of time prior to installation, the following precautions should be taken. 1. The original packing should be restored, if possible. 2. Do not subject the equipment to moisture or sunrays. Store in cool, clean, and dry location. 3. Place a dust cover over the contactor packaging to protect against dirt and moisture. 4. Store in an upright position.
SPECIFICATIONS Page 25 Table 5 - Ratings Items HCV-1JBU HCV-1KAU Rated Insulation Voltage kV 1.5 Rated Operation Voltage V 208-1500 Rated Operational Current A Rated Frequency Hz Rated Making Current kA Rated Breaking Current kA 600 720 50/60 6.0 7.2 (close 100 times) (close 100 times) 4.8 5.76 (close-open 25 times) (close-open 25 times) Rated Insulation Level kV AC 10 Impulse 45 AC 10 Impulse 30 Rated Short-Time Current kA 9.0 – 1 sec. 10.8 – 1 sec. 3.6 – 30 sec. 4.
WARRANTY AND LIMITATION OF LIABILITY Page 26 Toshiba International Corporation ("Company") warrants that all equipment and parts described herein will be free from defects in materials and workmanship.
