070903 tm contactors

TAVRIDA ELECTRICI N D U S T R I A L G R O U P

L O W V O L T A G EV A C U U M C O N T A C T O R

In Effect Since 03.09.2007Version 06AXCA 670200.009

CONTENTS

2Contents

Presentation 3

Product range 4

Design 5

Overall design 5

Switching module 6

Control module 7

Auxiliary contact units 8

Surge arrester unit 8

Small wiring termination 8

Operation 9

Closing 9

Opening 10

Emergency trip 10

Technical specification 11

General 11

Rated operational power of AC motors (AC3 and AC4) 12

Auxiliary circuits 13

Power supply 13

Control Input 13

Auxiliary contacts unit 13

Surge arresters 14

Electromagnetic Compatibility (EMC) 15

Dielectrical Strength 15

Dimensional drawings 16

Application guide

Selection 17

Incoming inspection 17

Mounting 18

Main terminals connection 19

Wiring and earthing 21

Commissioning test 23

Maintenance 24

Operation test 24

High voltage test 24

Insulation resistance test 24

Contact resistance test 24

Failure analyses and handling 24

Replacement of auxiliary contacts 25

Replacement of surge arresters unit 25

Replacement of control module 25

Routine test 26

Type test 26

Disposal 26

Technical Manual 3

Low voltage vacuum contactors (hereinafter contactor) are based on the latest switching andelectronic control technologies. The contactorcan be used as a core component of low voltageswitchgears and as a standalong unit. Switchingof heavyduty AC motors is main intent of thecontactor. Main distinctive of the contactors design isapplication of microprocessorbased incorporated control unit. Lightduty operation instructions are applied to corresponding input of thecontrol module. Separate supply input allowswithstanding deep voltage sags without dropout.This feature has particular importance whenmotors fed is made from transformers havingcomparable with the motor power.Contactor has three modifications.LSM/TEL14/400340 is applied at either of lowvoltage AC systems. LSM/TEL14/400341 and LSM/TEL14/400342 contactors are used for threephase, fourwires AC systems 120/208V and 230/400V correspondently. In these types of the contactors

Technical Manual 3Presentation

there is surge arrester unit. Surge arrester unitprovides effective motor protection againstswitching overvoltages. It raises service life ofthe interconnected electrical equipment.Contactor has specific main terminals in respectwith the similars contactors. Contactor allows tobe connected with cables without cable lags. Ifthe cables are provided with extra seals, degree ofprotection of the contactor is IP40. It providesprotection from insects and ingress of liquiddrops. However, contactor can be connected bybusbars and cables with lags through extraadapters. In this case contactor transforms toordinary contactor. However application of theseals provides abovementioned protection of thecontactor. Contactor has four interchangeable auxiliaryswitches which can be used for linking to signalling circuits.Application of advanced technologies providesreliable operation of the contactor during allservice life without extra maintenance andadjustments that lowers service costs.

Technical Manual

Presentation

Technical Manual 4Product range

Product range

Product type Part number Comment Manufacturer

Module LSM/TEL14/400340Contactor for up to 1000 V AC systems (witoutsurge arresters)

Module LSM/TEL14/400341Contactor for 120/208 V AC systems (withsurge arrester unit SAU/TEL230E)

Module LSM/TEL14/400342Contactor for 230/400 V AC systems (withsurge arrester unit SAU/TEL400E)

Accessory CM/TEL20E Control module

Accessory ACU/TEL01 Auxiliary contact unit

Accessory SAU/TEL230E Surge arrester unit for LSM/TEL14/400341

Accessory AHE 296444.003 Special key

Accessory ITEA 674152.003 Screw driver

Component AAHE 735642.001 Seal MF TEL

Accessory SAU/TEL400E Surge arrester unit for LSM/TEL14/400342

Accessory SAU/TEL001E Case of surge arrester unit (without varistors)

Component AXCA 716212.001 Adapter MF TEL

Component AXCA 745422.017 Installation bar MF TEL

Overall design

Vacuum contactor consists from the followingmain parts: switching module, control module,surge arrester unit and two auxiliary contactsunits. Switching module, control module andsurge arrester unit are realized as polymericcovered modules. Auxiliary contacts units are madeas PCBbased modules. Surge arrester unit andauxiliary contacts units allow to be easilyreplaced without any tools.The contactor provides IP40 degree protection ifit is connected with up to 240 mm2 cables with

Design

Technical Manual 5Design

out cable lags. The cables are connected directlyto main circuit terminals with special wrench andare sealed with rubber seals. To connect cableswith lags it is necessary to use special adapters.If the adapters are used together with rubberseals degree protection is also provided at IP40level.Small wiring termination is provided with WAGOconnector that is placed under a cover. The contactor is earthed through "Earth" stud.

Control module

Cover

"Earth" stud

Seals

Surge arresters unit

Switching module

Main circuitterminals(load outputs)

Small wiringterminals

Auxiliary contacts unit

Main circuitterminals

(supply inputs)

Adapters Installation bar

Connection board

Switching module

Switching module consists of three vacuuminterrupters (VI), solenoid actuator, flexible connectors and rigid busbars with clamps. Vacuum interrupters are a peak of R&D achievements of Tavrida Electric. Despite small dimensions vacuum interrupters insure reliable switching of heavyduty circuits providing high interrupting life.

Vacuum interrupter

In contrast with majority of conventional contactors there is level motion between the actuator and vacuum interrupters. The actuator's


armature is rigidly coupled to the frame whichoperates to VIs moving contacts by linear driveinsulators. This provides direct linear movementin both directions and avoids the use of rotatingshafts, bearings and bell cranks. As a result thecontactor is maintenance and trouble free duringall mechanical life. The actuator has two end positions: OPEN andCLOSED. In Open position the armature is forcedby opening spring to provide the gap betweenbase yoke and armature. To close the actuator itis necessary to inject the closing current into thecoil. In CLOSED position the gap between baseyoke and armature is miserable. Holding currentthat is injected into actuator's coil leads corresponding magnetic flux. The flux produces holding force between base yoke and armature andholds the magnetic system in close position.Tripping of the actuator is provided by holdingcurrent chopping. Position of the actuator isindicated with internal function auxiliary contact that is connected with control modulethrough intermediate printed circuit board.

Frame

Actuator coil

Flexible connector

Terminal

Armature

Contact pressure spring

Opening spring

Basechannel

Guade yoke

Drive insulator

Vacuum interrupter Busbar

Functionauxiliary contact

ClampBase yoke

Bracket

Control module

Microprocessorbased control module transfersexternal lowpowered control signal into internaloperation instruction which are applied to magnetic actuator coil. There are two inputs: "Powersupply" and "Control input". "Power supply"input is intended for charging of internal closingcapacitor bank and supplying of incorporatedsource of holding current. After initial powerapplication the contactor needs preparation timeto charge the capacitor bank. Control input isintended to accept external close instructions.Capacitor bank is charged into actuator's coiland it injects closing current that is independentfrom quality of power supply. After closing ofmagnetic actuator the control module generatesstabilized holding current into the coil. Thenclose instruction is finished the holding currentis chopped and the contactor is tripped. Betweensequences of CO operations the contactor needsa time for charging of capacitor bank. For indication of main contact's position.Control module has internal thermosensor. Thefirst function of the thermosensor is generation asignal when inside temperature of control module exceeds Overheating Indication Temperature.It can be caused by overloading of the contactoror exceeding of internal temperature intoswitchgear above level specified as maximumoperating temperature. The second function ofthe thermosensor is generation of internalEmergency Trip Instruction if the temperatureinside control module exceeds Emergency TripTemperature. In this case the contactor is tripped


and corresponding indicator starts to blink.Control module has three LED indicators on thefront panel.Greencolor indicator "Power" is intended for signaling of applying of power supply on corresponding inputs and it signals about readiness of thecontactor for execution of closing instruction.Control module executes monitoring of internalauxiliary circuits and inside temperature of thecontactor. If some malfunction is occurred redcolor indicator "Malfunction" starts to blink successively with intervals. The number of blinks inseries corresponds to specific malfunction.Duration of single blink is 150 ms. Intervalbetween neighbour blinks is 450ms. Intervalbetween series of blinks is 1.5 ms.Redcolor indicator "Closed" reflects position ofthe contactor.Correspondence between modes of the contactorand indicators is shown in the following table.

Contactor's condition"Malfunction"

Continuous lost of "Power supply" No light

Preparation time for closing No light

Opened state No light

Closed state No light

Lost of "Power supply" and "Control input"1 blink in

series*Overheating Indication Temperature exceeds specifiedlevel

2 blinks inseries

Opened state after execution of Emergency TripInstruction

Nonconformity of the contactor

3 blinks inseries

4, 5 or 6 blinks in series

"Closed"

No light

No light

No light

Light

**

**

No light

**

* During not less than 30 sec.** Light if the contactor is closed; No Light if the contactor is opened.

"Power"

No light

Blinks

Light

Light

No light

Light

Blinks

Light

LED indication mode

Auxiliary contact units

Contactor is provided with two auxiliary contactunits (ACU). Each unit has one normally opened(NO) and one normally closed (NC) contacts. Thecontacts are controlled by frame of the actuatorThey are used for position indication of the contactor for external signalling circuits.


Surge arrester unit

Contactors LSM/TEL14/400341 and LSM/TEL 14/400342 include SAU/TEL type surge arresterunits. The first contactor is supplied withSAU/TEL230 and the second one with SAU/TEL400. Each unit include three varistors that are Yconnected with earthed midpoint. Surge arresterunits are intended for protection of interconnected electrical equipment from overvoltagesthat can be occurred at switching operations ofthe contactor and other reasons. The units limitsthe surge voltage, so, service life of electricalequipment become higher if the units were notused. Contactor LSM/TEL14/400340 is provided withcase of surge arrester unit. There are no anyvaristors inside. So, this unit does not provideovervoltage protection of the equipment. In thiscase protection of equipment shall be arrangedwith extra protection elements.

Small wiring termination

Contactor has auxiliary inputs and outputs inaccordance with the diagram nearby.Outgoing arrows indicate outputs, incomingarrows indicate inputs.Potential zones corresponding to electrically isolated terminals are separated with lines.

Auxiliary Contact NC1

Auxiliary Contact NO2

Auxiliary Contact NC2

"Power Supply"

"Control Input"

"Earth"

Auxiliary Contact NO1

Operation

Closing

The initial position of the contactor is open.Vacuum interrupters are held in opened positionby opening springs which operate to their pullinginsulators through the frame. To launch the contactor into operation it is necessary to energizecorresponding WAGO terminals with "Power supply" rated voltage. Control module starts charging of internal closing capacitor bank. "Power"indicator stars to blink. If preparation time isover specified value the indicator lights thatmeans readiness of the contactor for closing.Contactor can be closed if the following conditions are met:

Contactor is open; Close capacitors are charged, LED indicator

Power lights continuously.To close the contactor, control voltage shall beapplied to Control Input. In a period longerthan Close instruction acceptance time, currentpulse from the closing capacitor bank is injectedinto the coil.The current in the coil produces a magnetic fluxin the gap between the base yoke and the armature.

1 2 2a 4 4 653 3aStateof main contacts

Actuator coilcurrent

Travel of armature

Speed of armature

Time

4b

Technical Manual 9Operation

Current increment increases the magnetic flux.Electromagnetic attraction between yokeand armature becomes more than restrainingforce of the opening springs (line 1).The armature, frame, drive insulator and movingcontacts start to move. As the armature movestowards the upper yoke the magnetic air gapdecreases and consequently the magnetic attraction force increases. This increasing force accelerates the armature, drive insulator and movingcontact. Acceleration of the armature generatesback emf in the coil that reduces the coil current(Line 12).At contact close (line 2) the moving contactsstops but the armature travel continues for 1 mmunder rapid deceleration caused by compressingthe contact pressure spring.At the limit of its travel the armature latchesmagnetically to the base yoke (Line 2a). Thetravel of the armature also compresses the opening spring in preparation for the next openingoperation and operates the auxiliary contacts.The moving armature collapses and the coil current again increases (lines 2a3).When closing impulse duration is expired controlmodule decreases the closing current (line 3) upto holding current (lines 3a4). The contactorstays in closed position for unlimited period oftime even if mechanical vibration conditions andvoltage drops are occurred

Technical Manual 10Operation

Opening

To open the contactor, Control Input shall bedeenergized. In a period of time longer thanTrip instruction acceptance time, instruction isaccepted and holding current is cut off (line 44b).Magnetic flux and correspondantly holding forceof the armature decrease and when sum ofcharged opening and the contact pressure springforces become more then holding force the armature is released and accelerated rapidly (line 4a).After free travel it engages with drive insulatorsand VIs contact are opened.The peak force produced by the armature ensureseasy breaking of any microwelds at the contactsurfaces which can appear due to short circuitcurrent action.The moving contact accelerates rapidly, ensuringa high interrupting capacity. Main contactsreturn to their initial position (line 5).If the contactor breakes loaded circuit the interrupting current initiates a socalled vacuumarc that burns essentially in plasma originating

from evaporated contact material. The currentcontinues to flow through this plasma until a current zero. At this moment the arc is extinguishedand transient recovery voltage appears across theopen gap. If the contact surface is locally overheated it produces a lot of vapour, resulting indeterioration of the vacuum followed by electrical breakdown. To avoid this, optimum combination of contact material and electrode shape isapplied resulting in development the smallestvacuum interrupter ever existed.At full travel (line 6) the armature, drive insulator and moving contact assembly is again heldopen by the opening spring force.Contactor is also opened at the same way ifPower Supply is lost in approximately 1 secondeven if Control Input is energized. In this case, to close contactor it is necessary todeenergize Control Input, to apply PowerSupply, to energize Control Input whenPower indicator is lit.

Emergency trip

If inside temperature of the control moduleexceeds level of Emergency trip temperature thecontactor trips itself even if "Control Input" voltage is applied. To close the contactor it is necessary to remove closing instruction and apply it

once more after than the temperature downs lessthan Overheating indication temperature andelimination of overheating reason.

Technical specification

General

Technical Manual 11Technical specification

Rated voltage, VLSM/TEL14/400340 1000LSM/TEL14/400341 230LSM/TEL14/400342 400

Rated frequency, Hz 50, 60Conventional thermal curent, A 400Rated breaking capacity, kA 4Rated making capacity, kA 4Rated over current capacity, 10s, kA 3.2Mechanical life, CO operations 2 000 000Operational frequency, CO operations per hour

mechanical 600 AC1 600 AC3 500 AC4 300

Switching capacity, CO operations at rated current 2 000 000 at breaking current 50 at other currents see diagram

Closing time, ms, not more than 50Drop out time, ms, not more than 60Opening time, ms, not more than 80

* According IEC 60068188 (C Damp heat (steady state); D Damp heat (cyclic).** IP00 at flat strip conductor or busbar connection.*** According IEC 6072134.

Applicable standards:IEC 9474190

Overheating Indication Temperature, C 703Emergency Trip Temperature, C 803Main contact resistance, microOhm 90Current heat loss, at 400A, w 50Ambient air temperature

enclosed, C 40...+40 open, C 40...+55

storage, C 40...+60Climatic proofing C, D*Maximum altitude above sea level, m 2000Degree of protection IP40 (IP00)**Mechanical vibration withstand capacity Class 3M4 (IEC 72134)***

stationary vibration, sinusoidal, g 1 nonstationary vibration, shock, g 10

Weight, kg, not more than 10,0


10000

4000

1000

100

10

10 100 1000 10000 100000 10000001

Curr

ent,

Interrupting life, operations

Rated operational power of AC motors (AC3 and AC4)

Rated voltage, VRated operational power, kW

LSM/TEL14/400340 LSM/TEL14/400341 LSM/TEL14/400342

220 125 125 125

230 130 130 130

240 135 135 135

380 200 200

400 220 220

415 240 240

440 255

500 290

Switching capacity

660 340

690 360

1000 500

Auxiliary circuits

Power supply


Power supply rated voltage, V AC 220Operating range, V AC 187242Power consumption, VA, not more than

during preparation time (charging of closingcapacitor)

35

in opened position 8 in closed position 15

Preparation time, s, not more than after initial power application 10 after previous open operation 5.5

Control Input

Control input rated voltage, V AC 220

Operating range, V AC, 44242

Minimum accepted level of close instruction,V AC, not less than

132

Minimum holding level of close instruction,V AC, not less than

88

Maximum accepted level of trip instruction,V AC, not more than

44

"Close" instruction acceptance time, ms, notmore than

30

Auxiliary contact units

Maximum operating voltage, V (AC&DC) 400Rated voltage, V (AC&DC) 250Breaking capacity (AC, cos=0.8), VA 750Maximum carrying current, A 10Minimum switching current, A (AC&DC) 0.1Dielectric strength, VDC 750Interrupting life at maximum breaking current, CO cycles

50 000

Mechanical life, CO cycles 1 000 000

Maximum withstand voltage, V, peak 420

"Trip" instruction acceptance time, ms, notmore than

30

Surge arresters


Type Rated Voltage , V ACSurge Current, A

(8/20 m s)Energy Absorption, J

(2 ms)Average PowerDissipation, W

SAU230 220, 230, 240 8000 100 1,0SAU400 380, 400, 415 8000 135 1,0

2000

1000

01E3 0,01 0,1 1 10 100

SAU400

SAU230

Volt

age,

V

Current, A

Impulse duration, m s

Max

imum

sur

ge c

urre

nt, A

Derating curves of different SAU are shownbelow.

Voltagecurrent characteristics of different SAUare shown below

Electromagnetic Compatibility (EMC)


Dielectrical Strength

Power frequency voltage between main contacts 3,5 kV between main contacts and auxiliary circuits 3,5 kV between auxiliary circuits 2,0 kV

Lighting impulse 1,2 m s/50 ms/0,5 J between main contacts 8,0 kV between main contacts and auxiliary circuits 8,0 kV between auxiliary circuits and Earth 4,0 kV

Insulation resistance between isolatedpotentional zones at 500 VDC, not less than

5,0 MOhm

between isolated auxiliary circuits 4,0 kV between NO and NC of ACU 4,0 kV

ParameterImmunity criteriain accordance with

IEC 6094741

Electrical fast transient/burst immunity in accordancewith IEC 6100044:

for "Power supply A

"for "Control input" A

Characterizations

Surge immunity in accordance with IEC 6100045BB

Power frequency magnetic field immunity in accordancewith IEC 6100048

AA

Pulse magnetic field immunity in accordance with IEC6100049

A

Damped oscillatory magnetic field immunity in accordancewith IEC 61000410

A

common 4 kVdifferential 2 kV

100 A/m1000 A/m

1000 A/m

0,1 and 1 MHz 100 A/m

Level

4

4

43

5

5

5

Voltage dips, short interruptions and voltage variationsimmunity in accordance with IEC 61000411

5 A

Oscillatory waves immunity in accordance with IEC 61000412 taking into account IEC 255221

31 MHz, 0,1 MHz

2 kVA

Electrostatic discharge immunity inaccordance with IEC6100042

3 A

Dimensional drawings

Technical Manual 16Dimensional drawings

Application Guide 17Selection Incoming inspection

Application guide

Selection

Selection of the contactor is made in accordancewith following table:

Type AC System Rated voltage, V AC

LSM/TEL14/400340Threephase, threewire or

fourwire systemsup to 1000

LSM/TEL14/400341Threephase,

fourwire systems220, 230, 240

LSM/TEL14/400342Threephase,

fourwire systems380, 400, 415

Incoming inspection

Each contactor before installation shall be subjected under physical control. Inspection shall be made in accordance with thetable below.If contactors appearance has any nonconformi

tyes customer has to made a decision in respectwith application of the contactor.In any cases customer shall arrange activity inaccordance with Complaints handling procedure.

Conformity criteriaInspection

Absence of severe damages resulted from: product drops excessive moistening of package package deformation caused by external impacts excessive external load applied to package Compliance of box label to order dataAbsence of undamaged seals

Packaging

Absence of undamaged seals

Absence of mechanical damages, scratches and colored spots

Sealing

Plastic parts

Absence of mechanical damages, scratches and corrosion on paintedsurfaces and galvanized terminals.

Metal parts

Mounting

The contactor can be installed directly on lowvoltage switchgear's panel or through extrainstallation bars AXCA745422.017 The last way isused if there is no access from the back side oflow voltage switchgear panel.

Application Guide 18Mounting

Each contactor is provided with paper templateto make marking on switchgear's panel. Mounting holes, required fasteners and torquesare shown below.

4 holes 7

8 holes 3.2

1680.2

2100.2

155

0.2

115

0.2

400

.2

155

0.2

*

4 Screws M6204 Spring Washers4 WashersTorque 10 N.m

1...4

8 Screws 4,28 Washers

1680.2

2100.5

235

2 holes 7 5

40

2

10

50

* for 1..2 mm thickness of the panel, f3.7 mm if thickness is more than 2 mm

Application Guide 19Main terminals connection

Primary connections to the contactor shall bemade using unprepared copper* or aluminumcables which types and sizes are shown below.

34

30

24

17

Line

1

Line

2

Line

3

11

Cablecrosssection,

mm2

507095

120150185240

Cutting line

Conductor of3phase cable

111122

Conductor of1phase cable

1112223

Main terminals connection

Third step cut seals at appropriate size

Fourth step fit seal on cables

Fifth step fix cables with special key tightly

Attention: The load shall be connected to terminals near surge arrester unit

Sixth step fit seals on the contactor

Conductor

sectional stranded core

sectional solid core

round stranded core

round solid core

Crosssection

mm2

70 240

95 300

50 185

70 240

AWG

00 500

000 600

0 350

00 500

Connecting cables shall be inserted through rubber seals as the figure below. The seals shall becut in accordance with the diameter of cable inaccordance with the table below.

First step cut cable isolation at 30 mm length

* Note: Cupper cables shall be tinned

Second step find cutting line of seal in accordance with the following table and outline

Application Guide 20Main terminals connection

To provide connection with busbars or cableswith lags additional adapters shall be used.Sequence of connection is shown below.

First step cut seals at appropriate size

Second step fit seals over adapters

Third step fix cables with special key tightly

Fourth step fit seals on the contactor

Fifth step connect cables

Attention: If prospective shortcircuit current ofthe circuit exceeds of rated parameters of the contactor extra shortcircuit protective device (SCPD)shall be connected seriously. SCPD shall provideovercurrent discrimination between contactor andshortcircuit currents.

Application Guide 21Wiring and earthing

Terminal Designation

1 Control Input (1)2 Control Input (2)3 Free4 Power Supply (1)5 Power Supply (2)

Wiring and earthing

The contactor shall be earthed through M5 stud.The "Earth" stud shall be connected with not lessthan 2.5 mm2 wire that is tagged with 5 mm diameter lag.

To connect "Power Supply", "Control Input", auxiliary contacts and "Earth" circuits push theclamp of the cover and move it towards thearrow. Connection is made through WAGO connectors"Power Supply" and "Control Input" terminals.The circuits are connected with (0.51.5) mm2

singlecore or multicore wires. The insulation ofthe wires shall be reared on 610 mm. Connectionis made with special screw that is included indelivery set.

Application Guide 22Wiring and earthing

DesignationTerminal

Auxiliary contact (1) (NO)1Auxiliary contact (1) (NO)

Auxiliary contact (2) (NC)

2

3

Auxiliary contact (2) (NC)4

Wires of auxiliary contacts with Power supply,Control input and Earth wires are placedtogether and are fixed by strips. The cover hasfour plugs, so the plug (or two plugs if necessary)shall be broken with pliers and sharp edges on

the cover shall be smoothed with knife or roundfile. To place the cover it is necessary to alignjoggles on the cover and corresponding holes inthe switching module and to clamp the cover.

Auxiliary contacts connection

Terminals of auxiliary contact units are notnumerated. The order of the terminal corresponds to the following figure.

Commissioning test

Before beginning of application each contactorshall be subjected to the following commissioning tests:

Operation test

Application Guide 23Commission test

Action Expected reaction

Apply supply voltage to 4 and 5 terminals

contactor shall open "Power" LED shall light "Malfunction LED shall not light "Closed LED shall not light contacts 3 and 4 of ACU shall close contacts 1 and 2 of ACU shall open

Apply control voltage to 1 and 2 terminals

contactor shall close "Power" LED shall light "Malfunction LED shall not light "Closed" LED shall light contacts 3 and 4 of ACU shall open contacts 1 and 2 of ACU shall close

Switch off control voltage from 1 and 2 terminals

contactor shall open "Power" LED shall light "Malfunction LED shall not light "Closed" LED shall not light contacts 3 and 4 of ACU shall close contacts 1 and 2 of ACU shall open

Apply control control voltage to 1 and 2 terminals

contactor shall close "Power" LED shall light "Malfunction LED shall not light "Closed" LED shall light contacts 3 and 4 of ACU shall open contacts 1 and 2 of ACU shall close

Switch off supply voltage from 4 and 5 terminals

contactor shall open "Power" LED shall not light (in 5 seconds) "Malfunction LED shall not light "Closed" LED shall not light contacts 3 and 4 of ACU shall close contacts 1 and 2 of ACU shall open

Switch off control voltage from 1 and 2 terminals

No reaction

High voltage test

Use standard method (IEC 94741) to checkinsulation level.

Insulation resistance test

Use standard methods to check the insulationresistance of the auxiliary insulation. It shall not

be below the limits given in the contactor technical specification.

Main contact resistance test

Use standard methods to check resistance of themain contacts of the contactor. Values must notexceed limits specified in the contactor technicalspecification.

Application Guide 24Maintenance

Maintenance

The contactor is inherently maintenance free.However, if customer has periodical test procedure the contactor can be subjected under following commissioning tests. If some nonconformity is found the contactor shall be handled asdescribed in subsection Failure analisys and handling (see below).

Operation test

The contactor shall be operable as pointed in thechapter above.

High voltage test

Dielectric strength of vacuum interrupters andsupport insulation in respect to power frequencywithstandability shall not deteriorate in service.During the test, apply voltages as pointed in subsection Dielectrical strength. However, impulsewithstandability of vacuum interrupters candecrease in service. So, producer specifies lightimpulse withstandability on 5 kV level for interrupters. Impulse withstandability of supportinsulation shall be the same as for a new contactor.

Insulation resistance test

The insulation resistance shall comply with valuethat is pointed in subsection Dielectrical strength.In the case of noncompliance tryto find the weak point. Note that, generally,other devices can be installed in parallel to thecontactor.

Contact resistance test

If contactor has contact resistance whichexceeds the specified limit but it is less thantwice this limit, continuation of use is possible, ifthe actual continuous current does not exceedthe following value:

where:Ia, Ra actual current and current resistancerespectively,Rr rated contact resistance,Ir rated current or conventional enclosed thermal current,

Ia

Replacement of auxiliary contacts

The auxiliary contacts units are maintenancefree. However, if damage of auxiliary contactoccurs under any circumstances the unit can bereplace as follows.

ATTENTION: Contactor shall be open beforereplacement of auxiliary switches.

Take off the cover; Press to auxiliary contact blocks slot and draw

out the block; Insert a new ACU/TEL01; Install the cover.

Application Guide 25Failure analyses and handling

Replacement of surge arresters unit

Order of SAU/TEL replacement is as follows. Press upwards to surge arresters units flanges

with two hands simultaneously. Install a new unit that corresponds to rated volt

age of the system.

Replacing of control module

Attention: The contactor shall be competelly powered down. Order of control modules replacement is as follows: Take off the cover Remove surge arrester unit Screw off four captive screws at connectionboard Disconnect connection board Disconnect earthing wire from the controlmodule

Screw off four captive screws at control module

Remove the failed module Install new control module in inverse sequence Perform operation test

Application Guide 26Routine test Type test Disposal

Type tests

Type tests shall be arranged in accordance withthe following table.Where:NL no limitations: supervisory from test lab isnot required

Type test Type test features

Dielectric testsTEL

Temperature rise testsNL

Making and breaking testsNL

Shorttime withstand current testsNL

Mechanical life testsNL

Measurement of resistance of the main circuitNL

Standard

IEC 9474190

IEC 9474190

IEC 9474190

IEC 9474190

IEC 9474190

IEC 9474190

TELGOST 3001196

NLGOST 3001196

NLGOST 3001196

NLGOST 3001196

NLGOST 3001196

NLGOST 3001196

Test Conformity criteria

Design and visual checks

correctness of nameplate data compliance of the module type to order absence of mechanical damages, scratches, colour variations affecting

module appearance

Mechanical operation tests(1000 CO operations at rated operating voltage)

proper operation of main and auxiliary contacts compliance of the closing and opening times with the requirements of

technical specification absence of contact bounce

Power frequency voltage withstand of the main circuits (between open contacts)

absence of breakdowns inside vacuum interrupter

Power frequency voltage withstand of the auxiliarycircuits (between terminals and earth)

absence of breakdowns

Routine test

Each contactor before delivery shall be subjectedto the following routine test procedure.Malfunction to meet any of the abovementioned

requirements means failure to pass routine testprocedure

TEL supervisory from TEL is required. It includesapproval of the test program, order and preparation of test samples and possible participation attests with test lab of Tavrida Electric.

Disposal

Modules do not contain any materials that arehazardous for environment or personnel. No special methods of disposal are required.

Attention:

Only electronic version of this document distributed through designated channels to designated users canbe considered valid.

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070903 tm contactors

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