vacuum contactor(hca )
TRANSCRIPT
N o t i c eRead and understand these instructions before attempting anyunpacking, assembly, operation or maintenance of the circuitbreaker.This instruction manual should be applied only to HCA Seriesvacuum contactors.This instruction manual does not include all items regardinginstallation and maintenance procedures.For more information, please contact HYUNDAI Heavy IndustriesCo., Ltd. or one of our partners.
HEAVY INDUSTRIES CO.,LTD.
Vacuum Contactor
HCA Series
Instruction Manual
Safety Practices
2 << Vacuum Contactor Instruction Manual
Safety Practices
This instruction manual applies only to the HCA Series
vacuum contactor regarding installation and
maintenance procedures.
Installing and maintaining these products improperly may
result in serious personal injury, property damage, or even
death. Therefore this instruction manual must be read and
understood at any step in unpacking, assembly, operation,
and maintenance of contactors.
Only qualified persons who are familiar with installing and
maintaining contactors are permitted to work on
contactors, and this instruction manual should be
accessible to those persons at any time.
If further information is required, please contact Hyundai
Heavy Industries Co., Ltd.
Signal Words
Signal words used in this instruction manual are divided by
DANGER, WARNING and CAUTION depending on the situation.
Indicates an imminently hazardous point which, if ignored,
will result in death or serious injury.
This is the most dangerous point.
Indicates a potentially hazardous point which, if ignored,
could result in death or serious injury.
Indicates a potentially hazardous point which, if ignored,
may result in minor or moderate injury.
This signal also warns operators not to work unsafely.
Safety Practices During Installation
Excessive heavy weight could cause heserious injury, or damage. To avoid thissituation, please don’t transport a contactoron a lifting facility in the raised position.Do not work on contactors unless the primarycircuits are disconnected by the visible breaker.When connecting bus-bars, tighten boltsaccording to our standards. Contactors should be tightly mounted on ahorizontal plane. Do not install the contactors in areas withhigh temperature, high humidity, dust,corrosive or vibrating conditions. Concrete dust or any other dust should notbe inside of the product when it installed.It can cause fire or misoperation.
Safety Practices During Operation
Safety Practices During Maintenance
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VC | HCA Series
Do not touch the primary circuit and the control circuit.
Do not work on contactors unless the primary circuits are disconnected by the visible breaker.Replace the vacuum interrupter when the wipe is below 0.5 mm.
Failure to maintenance the equipment could result in serious injury and product failure and can prevent successful functioning of connected apparatus.Do not work on contactors with power being supplied to the control circuit.Do not leave maintenance tool around the contactor.Do not work on closed contactors.Be sure that bolts are tightened according to our standards after replacement and check the tightness periodically. It is important to replace the Vacuum Interrupter for the faculty of the contactor. so should consult us to guarantee proper replacement.Note and check the relationship between each wire and its associated auxiliary switch terminal.
Do not insert & drawout the contactor in the closed condition.
Do not leave contactors in anintermediate position.Always place the contactor in the test or connection position. Do not leave contactors of G cradle inunlock codition.
4 << Vacuum Contactor Instruction Manual
Safety Practices 2
1. General 51.1 Specification1.2 Operating Time & Current1.3 Application Condition1.4 Ordering System1.5 Application Considerations1.6 Fuse Selection
2. Receiving/Handling/Storage and Installation 82.1 Receiving2.2 Handling2.3 Storage2.4 Installation2.5 Inspection Before Operation
3. Structure and Operation 103.1 Structure3.2 Explanation of Operation3.3 Structure of the Vacuum Interrupter3.4 Structure of Cradle Type and Interlock3.5 Inserting & Withdrawing3.6 Control Circuit Diagrams
4. Inspection and Maintenance 174.1 Visual Inspection4.2 Periodic Inspection4.3 Checking Vacuum and the Contact Erosion Limit4.4 Replacements for Main Components4.5 Troubleshooting
Contents
HCA-Series Vacuum Contactors are suitable for switching
and controlling 3phase motors with squirrel cage of slip
ring rotor, capacitor and transformer which are dried and
molded type.
These are designed and manufactured for the high frequent
switching, especially taken account of safety and quality
assurances.
1.1 Specification
1.2 Operating Time & Current
1.3 Application Condition
1) Ambient temperature: -5 40
2) Relative humidity: below 85%
3) Altitude: below 1000 m from sea-level
Please contact us for the special applications.
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VC | HCA Series
General01
Rated Voltage Rated Current Power frequency withstand voltage BIL Interrupting RatingCategory
Operating Cycle
Control Voltage Closing Current (A) Holding Current (A) Tripping Current (A) Closing Time (ms) Tripping Time (ms)
Do not install contactors in the hightemperature, high humid, dusty, corrosiveand vibrating condition.
1.4 Ordering System
1.5 Application Considerations
1) Verify that the voltage and current is within the
specified ratings.
2) The vacuum interrupter should be replaced after
1,000,000 operations. If the contactor is not protected
by fuses, the vacuum interrupter should be replaced
if they have interrupted fault currents at or near their
maximum interrupting rating.
6 << Vacuum Contactor Instruction Manual
01 General
ItemDigit Specification Code
H C A1 2 3 4 5 6 7 8
Digit 7 is described according to our catalogue HCA-series Vacuum Contactor
1.6 Fuse Selection
Fuse selection table
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VC | HCA Series
This table is made by catalogues of fuse makers.
Please contact fuse makers for the further details of application
data.
SIBA’s motor selection applies to the 3-phase motor with starting
time 15 seconds and starting frequency 2 times per hour.
SIBA recommend to choose fuse from the next higher voltage
range in the condensor load.
3 Motor (kW)
3.3 kV 6.6 kV 3.3 kV 3.3 kV6.6 kV 6.6 kV
3 Transformer (kVA) 3 Condenser (kVAR)Load
Fuse maker
6.3
10
16
20
25
30(31.5)
40
50
63
80
100
125
160
200
250
315
355
2 125
2 160
2 200
2 250
SIBA
-
-
-
-
-
-
-
90
100
125
160
200
275
315
400
500
600
-
500
650
750
LG
-
-
-
37~75
-
-
-
90~200
-
-
220~400
-
450~630
710~800
-
-
-
-
-
-
-
EFEN
-
-
-
30
-
55
-
75
100
-
150
200
250
350
-
-
-
400
500
710
-
LG
-
-
-
75~160
-
-
-
185~400
-
-
450~800
-
900~1250
1500
-
-
-
-
-
-
-
EFEN
-
30
55
-
75
100
-
150
200
250
300
400
500
630
-
-
-
800
1000
1250
-
SIBA
-
-
-
50
-
80
100
125
160
200
250
315
400
500
630
750
900
-
800
1000
1250
LG
-
10
-
20
-
30
50
75
-
150
200
-
300
400
-
-
-
-
-
-
-
EFEN
-
-
30
-
55
75
100
-
150
200
250
-
400
500
-
-
-
630
800
1000
-
SIBA
-
-
-
100
-
160
200
250
315
400
500
630
800
1000
1250
1500
1800
-
1600
2000
2500
LG
5
15
-
50
-
75
100
150
-
200
400
-
500
750
-
-
-
-
-
-
-
EFEN
-
30
55
75
-
100
-
150
250
300
350
400
630
800
-
-
-
1000
1500
-
-
SIBA
-
-
-
30
-
50
75
100
125
150
200
250
300
375
500
600
700
-
600
750
1000
LG
-
10
-
30
-
50
75
100
-
150
300
-
400
600
-
-
-
-
-
-
-
EFEN
-
-
30
-
55
-
75
100
150
200
300
350
400
630
-
-
-
710
800
1000
-
SIBA
-
-
-
60
-
100
150
200
250
300
400
500
650
750
1000
1200
1400
-
1200
1500
2000
LG
-
25
-
50
-
100
150
200
-
400
600
-
800
1000
-
-
-
-
-
-
-
EFEN
30
55
75
100
-
150
200
250
350
400
500
710
800
1250
-
-
-
-
-
-
-
SIBA
-
-
-
-
-
-
-
160
200
250
330
400
550
650
830
1000
1200
-
1000
1300
1500
Fuse rated
current (A)
8 << Vacuum Contactor Instruction Manual
HCA Series Vacuum Contactors are subjected to complete
factory production tests and inspection before being
packed. They are shipped in packages designed to provide
maximum protection to the equipment during shipment
and storage.
2.1 Receiving
When contactors are delivered, receivers should examine
the contents for any signs of damage such as broken,
damage, missing or loose components.
If damage or loss is detected, notify the nearest HHI office
or representatives.
Inspection after unpacking
1) Check the type rating and quantities with the
specification sheet.
2) Check contactors for any damage or missing materials.
3) Check all the accessories and spares supplied.
2.2 Handling
Contactors must be handled with care to avoid damage.
Ensure that vacuum contactors do not suffer impact or
other injurious physical stress during handling. Damage
could cause serious damage to both persons and property.
2.3 Storage
If contactors must be stored for a period prior to use, they
should be stored only in dry, dust-free and well ventilated
rooms, with contactors in the open condition.
Concrete dust or any other dustshould not be inside of the productwhen it installed.
It can cause fire or misoperation.
Excessive weight can cause seriousinjury or damage.
To avoid this situation, Do NOT transport a contactor on a lifting facility in the raised position.
Receiving / Handling / Storage and Installation02
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VC | HCA Series
2.4 Installation
1) Confirm the type and rating, make sure no damage
and clean contactors with dry cloths, before installing
contactors into the switchgear.
2) Mount contactors on a level floor referring to
guidelines for mounting dimensions in our catalogue
“HCA Series Vacuum Contactor”.
3) Clean the connecting surface with dry cloths, and then
connect main-circuit buses and earth terminals.
Be careful not to shock enclosures and contactors.
2.5 Inspection Before Operation
1) Confirm whether contactors are installed properly.
If not, install contactors each again according to clause 2.4.
2) Operate contactors a few times manually to ensure
that contactors closes and opens smoothly.
Then, operate contactors electrically in the test
position, and confirm that the ON/OFF indicator works
properly.
3) Confirm that no tools and materials are left near the
contactor.
Do not work on contactors unless the primary circuit are disconnected by the visible breaker.When connecting bus-bars, tighten bolts by the our standard. Contactors are mounting on the horizontal plane tightly.
10 << Vacuum Contactor Instruction Manual
3.1 Structure
The Fig. 3-1 is the section-drawing of the mechanism part
in the HCA Series Vacuum Contactor.
3.2 Explanation of Operation
1) Closing
When the Closing Coil is energized,
the Moving Core moves toward the Closing Coil
and compresses the Opening Spring .
At the same time, the Pressing Plate , which is fixed
on the Main Shaft , pushes the Pressing Spring ,
so the Movable Stem of the Vacuum Interrupter
is moved up to make the CLOSED condition.
For latched type (mechanical latching), the latch device
holds the Moving core of the contactor closed against
the closing coil after the contactor is energized (closed)
and the control source is removed.
Structure and Explanation of Operation03
>> 11
VC | HCA Series
2) Opening
For continuously energized types, if the closing coil is
de-energized by the OFF signal and the opening
spring is released to the OPEN condition,
then the opening of contactor is completed.
For latched type, if the trip coil is energized by OFF
signal or the trip button is pushed, the hook roller of
the latch device is released and the moving core
moves to OPEN condition by the opening spring.
3.3 Structure of the Vacuum Interrupter
The Vacuum Interrupter has, the ContactStem , the Contacts , the Bellows and the Ceramic Insulator . The contact is designed to guarantee 1million operations and to restrain thetransient recovery voltage under 1 Achopping current. The low pressure in the VacuumInterrupter is maintained for over 30 years of service, so the VacuumInterrupter is maintenance-free. But if necessary, it is checked by the HYUNDAI VACUUM TESTER (HVT-1).
12 << Vacuum Contactor Instruction Manual
3.4 Structure of Cradle Type and Interlock
1) Structure of cradle type
The Fig. 3-3 is the cradle type of HCA Series Vacuum
Contactor.
ON/OFF Indicator
ON means Closed condition, OFF means Open condition.
Counter
The Counter shows how many times the contactor
has operated since it was made.
The Counter may read 100 when you receive the
contactor, because it was tested in our factory or in
other place after manufacturing.
Trip Button
Only the latched types have the Trip Button which is
used in emergencies.
Control Plug
The control source is supplied through the Control Jack.
Position Interlock
The Position Interlock makes the contactor operate
only in the test and service position and prevents the
contactor from closing mechanically between TEST
and CONNECTION position.
Manual Closing Hole
Only latched types have a Manual Closing Hole which
is used to close the contactor manually.
ON/OFF IndicatorCounter (Trip Button (Control Plug (Position Interlock (
Manual Closing Hole (Fuse (Fuse Melting Indicator (Position Switch (Fuse Barrier (
Structure and Explanation of Operation03
>> 13
VC | HCA Series
Fuse
Fuses prevent the magnification of the short-circuit current.
Fuse Melting Indicator
The Fuse Melting Detector can show electrically
whether the Fuse was blown or not.
Position Switch
The Position Switch indicates electrically where the
contactor is in the TEST or CONNECTION position.
2) Interlock
1
2
If the contactor is closed, it cannot insert and withdraw contactor in the TEST or CONNECTION position
The contactor cannot be closed during the process of inserting and withdrawing
Move the contactor to TEST or CONNECTION position, and then close the contactor.
The Interlock Pin, attached in frame inside, prevents the contactor from inserting mechanically.
The Interlock Pin prevent the closing mechanically.
The Auxiliary Switch cuts off the control source (electrical interlock)
Open the contactor Standard
Standard
Option
14 << Vacuum Contactor Instruction Manual
Structure and Explanation of Operation03
3.5 Inserting & Withdrawing
1) How to insert the contactor in the E, F2 cradle.
InsertingSet the wheels of the contactor exactly on the guide rail of the cradle. At this time, more than two person have to lift up the breaker for full safety. If the contactor is pushed to the TEST position, the Interlock Pin prevents the draw-in at this position. Hold up the Interlock Lever (Fig. 3-4) and push the Contactor to the CONNECTION position. If the contactor is in the correct position, put the Interlock pin puts into the hole on the guide plate and the Female Contact will be inserted fully into the terminal.
Withdrawing
When a contactor is withdrawn, the contactor cannot
be operated because of the interlock.
In OPEN condition, hold up the Interlock Lever
(Fig. 3-4) and pull out a contactor to the TEST position.
Do not insert and withdraw the contactor in the closed condition.Hold up the Interlock Lever during the inserting and withdrawing.
Interlock Lever
Interlock Plate
>> 15
VC | HCA Series
How to insert the contactor in the G cradle.
The interlock, which is screw operation type,
will be conducted automatically in each Test and
Service position separately.
Before inserting contactor
Make sure that contactor is open.
Set the Manual Lock Handle to the UNLOCK position.
Inserting to the TEST position
Put a contactor into the switchgear and push it slowly
until it stops. This is the test position.
Set the Manual Lock Handle to the LOCK position.
Please refer to Fig. 3-6.
Inserting to the CONNECTION position
Insert the Rack Handle to the head of the Fixing Screw.
Turn it clockwise direction.
If the contactor is inserted fully, the Fixing Screw
cannot be rotated and the Position Sticker indicates the
CONNECTION POSITION.
When you pull out the Rack-in Handle at this position,
the Stopper is pushed out to prevent the unexpected
moving of the Fixing Screw.
Do not touch the primary circuit and the control circuit.
Rack-in Handle
Stoper
Inserting
Do not leave contactors in an intermediate position.Always place the contactor in the test or connection position.Do not leave contactors of G cradle in unlock codition.
Manual Lock Handle
FRONT COVER
16 << Vacuum Contactor Instruction Manual
Structure and Explanation of Operation03
3.6 Control Circuit Diagrams
VZ: Closing SwitchR: Resistor
CC: Closing CoilZ: TNR
X: RelayTC: Trip Coil
CTD: Condensor Trip DeviceAux. SW: Auxiliary Switch
FOR FIXED TYPE
FOR DRAWOUT TYPE
CONTROL PLUG
FOR FIXED TYPE
FOR DRAWOUT TYPE
CONTROL PLUG
CONTROL PLUG
CONTROL PLUG
CONTROL PLUG
FUSE MELTING INDICATORTEST CONNECTIONPOSITION SWITCHPT 2SETSPT 1SET
>> 17
VC | HCA Series
Maintenance shall be carried out to preserve trouble-free
operation and achieve the longest possible working life of
contactors.
HCA Series Vacuum Contactors are characterized by their
simple and robust construction and they have a long life
expectancy. Their operating mechanisms have a low
maintenance requirement, and the interrupters are
maintenance-free during their working life.
The maintenance is determined by environmental
influences, switching frequency, and so on.
4.1 Visual Inspection (every 1-6 months)
The purpose of a visual inspection has to be done
whenever you can.
1
2
3
Failure to maintain the equipment could result in serious injury and product failure and can prevent successful functioning of connected apparatus.Do not work on contactors with power being supplied to the control circuit.Do not leave maintenance tools around the contactor.Do not work on closed contactors.Be sure that bolts are tightened by the our standard after replacement and check the tightness periodically.
Inspection and Maintenance04
18 << Vacuum Contactor Instruction Manual
Inspection and Maintenance04
Object Items Standardinterval Check procedure
Clean and dry when the dust or humidity is extreme
If a component is badly damaged, replace it.
Check if the strike pin of fuse is outIf it is blown, each fuse for 3 phases should be replaced at the same time.
Check if the fuse melting indicator operates smoothly.If not,put the grease on the moving parts.
Check and tighten bolts.
Check if the contact erosion is expired. If it is expired, each VI of 3 phases should be replaced at the same time.
Check and tighten bolts.
Check for scratches or rust.
If the coil discolored, replace it.Check and tighten bolts.One should be operated at 85 110% of rating.
Check for scratches or rust.Put grease on the moving parts. The gap between the roller and the operating plate should be 0.2 0.5 mm. If not, replace the Latch Device.
If coil is discolored, replace it.One should be operated at 85 110% of rating.
The resistance of contact of auxiliary switch should be below 200 m . If not, clean the contact. The connection plug is completely inserted.
Put grease on the moving parts.The female contact should be inserted above 10 mm.
Check if it moves smoothly.
Above 1000 M between line-earth, electrodes, and line-earth.
Above 2 M between the control line and the earth.
Main body
Fuse
Vacuuminterrupter
Open andclose
mechanism
Latch mechanism
Auxiliary Switch,ClosingSwitch
Insertingmechanism
Insulation resistance
Contactwear
Pressure
Tightness
Spring
ClosingCoil
Hook Roller
Trip Coil
Switch
Wiring
IsolatingContact
Interlock mechanism
Main conductor
Controlcircuit
3 years
1 years
3 years
3 years
3 years
3 years
3 years
3 years
3 years
3 years
3 years
Insulation 3 years
6 years
3 years
3 years
Overall
Fuse
FuseMelting
Indicator
4.2 Periodic Inspection
>> 19
VC | HCA Series
4.3 Checking Vacuum and the Contact Erosion Limit
1) Checking the vacuum
The low pressure in the Vacuum Interrupter is
maintained for over 30 years of service.
That means the Vacuum Interrupter is maintenance-free.
But if necessary, it is checked by the HYUNDAI
VACUUM TESTER (HVT-1).
2) Checking the contact erosion
Since the contacts are contained inside the interrupter,
they remain clean and require no maintenance.
However, during high current interrupting, there may
be a minimum amount of erosion from the contact
surfaces. To check the erosion of the interrupter
contacts and carry out the following operations.
Close the contactor.
Open the Rear cover.
Measure the distance between the Dish Washer
and the Pressing Plate.
With new interrupters this distance is about
1.0~2.0 mm.
If it is reduced to 0.5mm, the three interrupters
must be replaced.
Checking the contact erosion is important to
evaluate the efficiency of the interrupters
(Refer to the Fig. 4-1).
Replace the vacuum interrupter when the wipe is below 0.5 mm.
1.0~2.0 mm 0 mm
Dish Washer
Pressing Plate
20 << Vacuum Contactor Instruction Manual
Inspection and Maintenance04
4.4 Replacements for Main Components
Remove the contactor from the enclosure to ensure that all
high voltage sources are disconnected.
1) Replacing the fuse
Remove the fuse barriers.
Loosen the upper fixing bolts and Supportors .
Loosen the lower fixing bolts.
Renew the fuses.
The fuse must have the striker facing towards
the Front Cover.
If new fuses are longer than old ones,
rear Fuse holders move the 100 mm backward.
Insert new fuses and tighten the bolts.
Reverse the action in the previous step.
Strike /
Fuse Holder / Supportor /
Upper fixing bolt Lower fixing bolt
2) Replacing the closing coil
The contactor employs a pair of magnet coil for each
contactor.
Remove the moving core (Fig. 3-1
Remove the rear cover
Cut off the leads of the closing coil after marking the
leads and noting the relationship between each lead.
Loosen the bolts , fixing the closing coil.
Remove the defected coils toward the front cover.
After reassembling, check the operation of the
contactor electrically.
Connect the leads of the closing coil
Reverse the action in the previous step.
>> 21
VC | HCA Series
3) Replacing the Auxiliary Switch
Release the pusher .
Release the support and remove the wires from
the auxiliary switch.
If the closing switch needs replacement ,
loosen the bolt and wires.
If need to replace the auxiliary switch , release
the bolt and cable.
Reverse the action in the previous step and check the
operation of the switch manually using the closing handle
Check the operation of the Switch electrically.
Note and check the relationship between each wire and its associated Auxiliary Switch terminal.
Coil support / Closing Coil / Rear Plate Coil Core Bolt Gap plate Stainless Rubber Plate
Auxiliary Switch Support / Auxiliary Switch / Closing Switch M4 Bolt M4 Bolt Pusher M5 Bolt Closing Handle
CLOSING
4) Replacing the vacuum interrupter
Release the pressing plate.
Release the Insulation rod from the vacuum
Interrupter, and separate the flexible connector .
Loosen the upper fixing bolts from the upper connector .
Replace the new vacuum interrupter.
Reverse the action in the previous step and check the
stroke and wipe of the vacuum interrupter.
22 << Vacuum Contactor Instruction Manual
Inspection and Maintenance04
Vacuum Interrupter / Insulation Rod / Upper ConnectorFlexible Connector
It is important to replace the Vacuum Interrupter for the faculty of the contactor.So should consult us to guarantee proper replacement.
M6 NUT
WIPE
4.5 Troubleshooting
>> 23
VC | HCA Series
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