LOW VOLTAGE VACUUM CONTACTOR - LBTLOW VOLTAGE VACUUM CONTACTOR AXCA 670200.009 Version 06 In Effect...

�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 (AC�3 and AC�4) 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 con�

tactor) are based on the latest switching and

electronic control technologies. The contactor

can be used as a core component of low voltage

switchgears and as a stand�along unit. Switching

of heavy�duty AC motors is main intent of the

contactor.

Main distinctive of the contactor’s design is

application of microprocessor�based incorporat�

ed control unit. Light�duty operation instruc�

tions are applied to corresponding input of the

control module. Separate supply input allows

withstanding deep voltage sags without dropout.

This feature has particular importance when

motor’s fed is made from transformers having

comparable with the motor power.

Contactor has three modifications.

LSM/TEL�1�4/400�340 is applied at either of low

voltage AC systems.

LSM/TEL�1�4/400�341 and LSM/TEL�1�4/400�

342 contactors are used for three�phase, four�

wires AC systems 120/208V and 230/400V corre�

spondently. In these types of the contactors

Technical Manual 3Presentation

there is surge arrester unit. Surge arrester unit

provides effective motor protection against

switching overvoltages. It raises service life of

the interconnected electrical equipment.

Contactor has specific main terminals in respect

with the similars contactors. Contactor allows to

be connected with cables without cable lags. If

the cables are provided with extra seals, degree of

protection of the contactor is IP40. It provides

protection from insects and ingress of liquid

drops. However, contactor can be connected by

busbars and cables with lags through extra

adapters. In this case contactor transforms to

ordinary contactor. However application of the

seals provides abovementioned protection of the

contactor.

Contactor has four interchangeable auxiliary

switches which can be used for linking to sig�

nalling circuits.

Application of advanced technologies provides

reliable operation of the contactor during all

service life without extra maintenance and

adjustments that lowers service costs.

Technical Manual

Presentation

Technical Manual 4Product range

Product range

Product type Part number Comment Manufacturer

Module LSM/TEL�1�4/400�340Contactor for up to 1000 V AC systems (witout

surge arresters)�

Module LSM/TEL�1�4/400�341Contactor for 120/208 V AC systems (with

surge arrester unit SAU/TEL�230E)�

Module LSM/TEL�1�4/400�342Contactor for 230/400 V AC systems (with

surge arrester unit SAU/TEL�400E)�

Accessory CM/TEL�20E Control module �

Accessory ACU/TEL�01 Auxiliary contact unit �

Accessory SAU/TEL�230E Surge arrester unit for LSM/TEL�1�4/400�341 �

Accessory АAHE 296444.003 Special key �

Accessory ITEA 674152.003 Screw driver �

Component AAHE 735642.001 Seal MF TEL

Accessory SAU/TEL�400E Surge arrester unit for LSM/TEL�1�4/400�342 �

Accessory SAU/TEL�001E 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 following

main parts: switching module, control module,

surge arrester unit and two auxiliary contacts

units. Switching module, control module and

surge arrester unit are realized as polymeric�cov�

ered modules. Auxiliary contacts units are made

as PCB�based modules. Surge arrester unit and

auxiliary contacts units allow to be easily

replaced without any tools.

The contactor provides IP40 degree protection if

it is connected with up to 240 mm2 cables with�

Design

Technical Manual 5Design

out cable lags. The cables are connected directly

to main circuit terminals with special wrench and

are sealed with rubber seals. To connect cables

with lags it is necessary to use special adapters.

If the adapters are used together with rubber

seals degree protection is also provided at IP40

level.

Small wiring termination is provided with WAGO

connector that is placed under a cover. The con�

tactor is earthed through "Earth" stud.

Control module

Cover

"Earth" stud

Seals

Surge arresters unit

Switching module

Main circuit

terminals

(load outputs)

Small wiring

terminals

Auxiliary

contacts unit

Main circuit

terminals

(supply inputs)

Adapters Installation bar

Connection board

Switching module

Switching module consists of three vacuum

interrupters (VI), solenoid actuator, flexible con�

nectors and rigid busbars with clamps.

Vacuum interrupters are a peak of R&D achieve�

ments of Tavrida Electric. Despite small dimen�

sions vacuum interrupters insure reliable switch�

ing of heavy�duty circuits providing high inter�

rupting life.

Vacuum interrupter

In contrast with majority of conventional con�

tactors there is level motion between the actua�

tor and vacuum interrupters. The actuator's


armature is rigidly coupled to the frame which

operates to VI’s moving contacts by linear drive

insulators. This provides direct linear movement

in both directions and avoids the use of rotating

shafts, bearings and bell cranks. As a result the

contactor is maintenance and trouble free during

all mechanical life.

The actuator has two end positions: OPEN and

CLOSED. In Open position the armature is forced

by opening spring to provide the gap between

base yoke and armature. To close the actuator it

is necessary to inject the closing current into the

coil. In CLOSED position the gap between base

yoke and armature is miserable. Holding current

that is injected into actuator's coil leads corre�

sponding magnetic flux. The flux produces hold�

ing force between base yoke and armature and

holds the magnetic system in close position.

Tripping of the actuator is provided by holding

current chopping. Position of the actuator is

indicated with internal function auxiliary con�

tact that is connected with control module

through intermediate printed circuit board.

Frame

Actuator coil

Flexible connector

Terminal

Armature

Contact pressure

spring

Opening spring

Basechannel

Guade yoke

Drive insulator

Vacuum interrupter Busbar

Function

auxiliary contact

ClampBase yoke

Bracket

Control module

Microprocessor�based control module transfers

external low�powered control signal into internal

operation instruction which are applied to mag�

netic actuator coil. There are two inputs: "Power

supply" and "Control input". "Power supply"

input is intended for charging of internal closing

capacitor bank and supplying of incorporated

source of holding current. After initial power

application the contactor needs preparation time

to charge the capacitor bank. “Control input” is

intended to accept external close instructions.

Capacitor bank is charged into actuator's coil

and it injects closing current that is independent

from quality of power supply. After closing of

magnetic actuator the control module generates

stabilized holding current into the coil. Then

close instruction is finished the holding current

is chopped and the contactor is tripped. Between

sequences of CO operations the contactor needs

a time for charging of capacitor bank. For indica�

tion of main contact's position.

Control module has internal thermosensor. The

first function of the thermosensor is generation a

signal when inside temperature of control mod�

ule exceeds Overheating Indication Temperature.

It can be caused by overloading of the contactor

or exceeding of internal temperature into

switchgear above level specified as maximum

operating temperature. The second function of

the thermosensor is generation of internal

Emergency Trip Instruction if the temperature

inside control module exceeds Emergency Trip

Temperature. In this case the contactor is tripped


and corresponding indicator starts to blink.

Control module has three LED indicators on the

front panel.

Green�color indicator "Power" is intended for sig�

naling of applying of power supply on correspon�

ding inputs and it signals about readiness of the

contactor for execution of closing instruction.

Control module executes monitoring of internal

auxiliary circuits and inside temperature of the

contactor. If some malfunction is occurred red�

color indicator "Malfunction" starts to blink suc�

cessively with intervals. The number of blinks in

series corresponds to specific malfunction.

Duration of single blink is 150 ms. Interval

between neighbour blinks is 450ms. Interval

between series of blinks is 1.5 ms.

Red�color indicator "Closed" reflects position of

the contactor.

Correspondence between modes of the contactor

and 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 specified

level

2 blinks in

series

Opened state after execution of Emergency Trip

Instruction

Nonconformity of the contactor

3 blinks in

series

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 contact

units (ACU). Each unit has one normally opened

(NO) and one normally closed (NC) contacts. The

contacts are controlled by frame of the actuator

They are used for position indication of the con�

tactor for external signalling circuits.


Surge arrester unit

Contactors LSM/TEL�1�4/400�341 and LSM/TEL �

1�4/400�342 include SAU/TEL type surge arrester

units. The first contactor is supplied with

SAU/TEL�230 and the second one with SAU/TEL�

400. Each unit include three varistors that are Y�

connected with earthed midpoint. Surge arrester

units are intended for protection of intercon�

nected electrical equipment from overvoltages

that can be occurred at switching operations of

the contactor and other reasons. The units limits

the surge voltage, so, service life of electrical

equipment become higher if the units were not

used.

Contactor LSM/TEL�1�4/400�340 is provided with

case of surge arrester unit. There are no any

varistors inside. So, this unit does not provide

overvoltage protection of the equipment. In this

case protection of equipment shall be arranged

with extra protection elements.

Small wiring termination

Contactor has auxiliary inputs and outputs in

accordance with the diagram nearby.

Outgoing arrows indicate outputs, incoming

arrows indicate inputs.

Potential zones corresponding to electrically iso�

lated 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 position

by opening springs which operate to their pulling

insulators through the frame. To launch the con�

tactor into operation it is necessary to energize

corresponding WAGO terminals with "Power sup�

ply" rated voltage. Control module starts charg�

ing of internal closing capacitor bank. "Power"

indicator stars to blink. If preparation time is

over specified value the indicator lights that

means readiness of the contactor for closing.

Contactor can be closed if the following condi�

tions are met:■ Contactor is open;■ “Close” capacitors are charged, LED indicator

“Power” lights continuously.

To close the contactor, control voltage shall be

applied to “Control Input”. In a period longer

than “Close” instruction acceptance time, current

pulse from the closing capacitor bank is injected

into the coil.

The current in the coil produces a magnetic flux

in the gap between the base yoke and the arma�

ture.

1 2 2a 4 4а 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 yoke

and armature becomes more than restraining

force of the opening springs (line 1).

The armature, frame, drive insulator and moving

contacts start to move. As the armature moves

towards the upper yoke the magnetic air gap

decreases and consequently the magnetic attrac�

tion force increases. This increasing force accel�

erates the armature, drive insulator and moving

contact. Acceleration of the armature generates

back emf in the coil that reduces the coil current

(Line 1�2).

At contact close (line 2) the moving contacts

stops but the armature travel continues for 1 mm

under rapid deceleration caused by compressing

the contact pressure spring.

At the limit of its travel the armature latches

magnetically to the base yoke (Line 2a). The

travel of the armature also compresses the open�

ing spring in preparation for the next opening

operation and operates the auxiliary contacts.

The moving armature collapses and the coil cur�

rent again increases (lines 2a�3).

When closing impulse duration is expired control

module decreases the closing current (line 3) up

to holding current (lines 3a�4). The contactor

stays in closed position for unlimited period of

time even if mechanical vibration conditions and

voltage drops are occurred

Technical Manual 10Operation

Opening

To open the contactor, “Control Input” shall be

de�energized. In a period of time longer than

“Trip” instruction acceptance time, instruction is

accepted and holding current is cut off (line 4�

4b).

Magnetic flux and correspondantly holding force

of the armature decrease and when sum of

charged opening and the contact pressure spring

forces become more then holding force the arma�

ture is released and accelerated rapidly (line 4a).

After free travel it engages with drive insulators

and VI’s contact are opened.

The peak force produced by the armature ensures

easy breaking of any micro�welds at the contact

surfaces which can appear due to short circuit

current action.

The moving contact accelerates rapidly, ensuring

a high interrupting capacity. Main contacts

return to their initial position (line 5).

If the contactor breakes loaded circuit the inter�

rupting current initiates a so�called «vacuum

arc» that burns essentially in plasma originating

from evaporated contact material. The current

continues to flow through this plasma until a cur�

rent zero. At this moment the arc is extinguished

and transient recovery voltage appears across the

open gap. If the contact surface is locally over�

heated it produces a lot of vapour, resulting in

deterioration of the vacuum followed by electri�

cal breakdown. To avoid this, optimum combina�

tion of contact material and electrode shape is

applied resulting in development the smallest

vacuum interrupter ever existed.

At full travel (line 6) the armature, drive insula�

tor and moving contact assembly is again held

open by the opening spring force.

Contactor is also opened at the same way if

“Power Supply” is lost in approximately 1 second

even if “Control Input” is energized.

In this case, to close contactor it is necessary to

de�energize “Control Input”, to apply “Power

Supply”, to energize “Control Input” when

“Power” indicator is lit.

Emergency trip

If inside temperature of the control module

exceeds level of Emergency trip temperature the

contactor trips itself even if "Control Input" volt�

age is applied. To close the contactor it is neces�

sary to remove closing instruction and apply it

once more after than the temperature downs less

than Overheating indication temperature and

elimination of overheating reason.

Technical specification

General

Technical Manual 11Technical specification

Rated voltage, V

LSM/TEL�1�4/400�340 1000

LSM/TEL�1�4/400�341 230

LSM/TEL�1�4/400�342 400

Rated frequency, Hz 50, 60

Conventional thermal curent, A 400

Rated breaking capacity, kA 4

Rated making capacity, kA 4

Rated over current capacity, 10s, kA 3.2

Mechanical life, CO operations 2 000 000

Operational frequency, CO operations per hour

� mechanical 600

� AC�1 600

� AC�3 500

� AC�4 300

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 50

Drop out time, ms, not more than 60

Opening time, ms, not more than 80

* According IEC 60068�1�88 (C� Damp heat (steady state); D � Damp heat (cyclic).

** IP00 at flat strip conductor or busbar connection.

*** According IEC 60721�3�4.

Applicable standards:IEC 947�4�1�90

Overheating Indication Temperature, °C 70±3

Emergency Trip Temperature, °C 80±3

Main contact resistance, microOhm 90

Current heat loss, at 400A, w 50

Ambient air temperature

� enclosed, °C �40...+40

� open, °C �40...+55

� storage, °C �40...+60

Climatic proofing C, D*

Maximum altitude above sea level, m 2000

Degree of protection IP40 (IP00)**

Mechanical vibration withstand capacity Class 3M4 (IEC 721�3�4)***

� stationary vibration, sinusoidal, g 1

� non�stationary vibration, shock, g 10

Weight, kg, not more than 10,0


10000

4000

1000

100

10

10 100 1000 10000 100000 1000000

1

Cu

rre

nt,

А

Interrupting life, operations

Rated operational power of AC motors (AC�3 and AC�4)

Rated voltage, VRated operational power, kW

LSM/TEL�1�4/400�340 LSM/TEL�1�4/400�341 LSM/TEL�1�4/400�342

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 220

Operating range, V AC 187�242

Power consumption, VA, not more than

� during preparation time (charging of closing

capacitor)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, 44�242

Minimum accepted level of close instruction,

V AC, not less than132

Minimum holding level of close instruction,

V AC, not less than88

Maximum accepted level of trip instruction,

V AC, not more than44

"Close" instruction acceptance time, ms, not

more than30

Auxiliary contact units

Maximum operating voltage, V (AC&DC) 400

Rated voltage, V (AC&DC) 250

Breaking capacity (AC, cos=0.8), VA 750

Maximum carrying current, A 10

Minimum switching current, A (AC&DC) 0.1

Dielectric strength, VDC 750

Interrupting life at maximum breaking cur�

rent, C�O cycles50 000

Mechanical life, C�O cycles 1 000 000

Maximum withstand voltage, V, peak 420

"Trip" instruction acceptance time, ms, not

more than30

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 1,0

SAU400 380, 400, 415 8000 135 1,0

2000

1000

01E�3 0,01 0,1 1 10 100

SAU400

SAU230

Vo

ltag

e, V

Current, A

Impulse duration, m s

Maxi

mu

m s

urg

e c

urr

en

t, A

Derating curves of different SAU are shown

below.

Voltage�current characteristics of different SAU

are 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 isolated

potentional zones at 500 VDC, not less than5,0 MOhm

� between isolated auxiliary circuits 4,0 kV

� between NO and NC of ACU 4,0 kV

ParameterImmunity criteriain accordance with

IEC 60947�4�1

Electrical fast transient/burst immunity in accordance

with IEC 61000�4�4:

� for "Power supply A

"for "Control input" A

Characterizations

�

�

Surge immunity in accordance with IEC 61000�4�5B

B

Power frequency magnetic field immunity in accordance

with IEC 61000�4�8

A

A

Pulse magnetic field immunity in accordance with IEC

61000�4�9A

Damped oscillatory magnetic field immunity in accordance

with IEC 61000�4�10A

common 4 kV

differential 2 kV

100 A/m

1000 A/m

1000 A/m

0,1 and 1 MHz �

� 100 A/m

Level

4

4

4

3

5

5

5

Voltage dips, short interruptions and voltage variations

immunity in accordance with IEC 61000�4�115 � A

Oscillatory waves immunity in accordance with IEC 61000�

4�12 taking into account IEC 255�22�13

1 MHz, 0,1 MHz

2 kVA

Electrostatic discharge immunity inaccordance with IEC

61000�4�23 � A

Dimensional drawings

Technical Manual 16Dimensional drawings

Application Guide 17Selection � Incoming inspection

Application guide

Selection

Selection of the contactor is made in accordance

with following table:

Type AC System Rated voltage, V AC

LSM/TEL�1�4/400�340Three�phase, three�wire or

four�wire systemsup to 1000

LSM/TEL�1�4/400�341Three�phase,

four�wire systems220, 230, 240

LSM/TEL�1�4/400�342Three�phase,

four�wire systems380, 400, 415

Incoming inspection

Each contactor before installation shall be sub�

jected under physical control.

Inspection shall be made in accordance with the

table below.

If contactor’s appearance has any nonconformi�

tyes customer has to made a decision in respect

with application of the contactor.

In any cases customer shall arrange activity in

accordance 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 painted

surfaces and galvanized terminals.Metal parts

Mounting

The contactor can be installed directly on low

voltage switchgear's panel or through extra

installation bars AXCA745422.017 The last way is

used if there is no access from the back side of

low voltage switchgear panel.

Application Guide 18Mounting

Each contactor is provided with paper template

to make marking on switchgear's panel.

Mounting holes, required fasteners and torques

are shown below.

4 holes �7

8 holes �3.2

168±0.2

210±0.2

15

5±

0.2

11

5±

0.2

40

±0

.2

15

5±

0.2

*

4 Screws M6х20

4 Spring Washers

4 Washers

Torque 10 N.m

1...4

8 Screws 4,2

8 Washers

168±0.2

210±0.5

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 be

made using unprepared copper* or aluminum

cables which types and sizes are shown below.

�3

4

�3

0

�2

4

�1

7

Lin

e 1

Lin

e 2

Lin

e 3

�1

1

Cablecross�section,

mm2

50

70

95

120

150

185

240

Cutting line

Conductor of3–phase cable

�

1

1

1

1

2

2

Conductor of1–phase cable

1

1

1

2

2

2

3

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 termi�

nals near surge arrester unit

■ Sixth step � fit seals on the contactor

Conductor

sectional stranded core

sectional solid core

round stranded core

round solid core

Cross�section

mm2

70 � 240

95 � 300

50 � 185

70 � 240

AWG

00 � 500

000 � 600

0 � 350

00 � 500

Connecting cables shall be inserted through rub�

ber seals as the figure below. The seals shall be

cut in accordance with the diameter of cable in

accordance 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 accor�

dance with the following table and outline

Application Guide 20Main terminals connection

To provide connection with busbars or cables

with 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 short�circuit current of

the circuit exceeds of rated parameters of the con�

tactor extra short�circuit protective device (SCPD)

shall be connected seriously. SCPD shall provide

over�current discrimination between contactor and

short�circuit currents.

Application Guide 21Wiring and earthing

Terminal Designation

1 “Control Input” (1)

2 “Control Input” (2)

3 Free

4 “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 less

than 2.5 mm2 wire that is tagged with 5 mm diam�

eter lag.

To connect "Power Supply", "Control Input", aux�

iliary contacts and "Earth" circuits push the

clamp of the cover and move it towards the

arrow.

Connection is made through WAGO connector’s

"Power Supply" and "Control Input" terminals.

The circuits are connected with (0.5�1.5) mm2

single�core or multi�core wires. The insulation of

the wires shall be reared on 6�10 mm. Connection

is made with special screw that is included in

delivery set.

Application Guide 22Wiring and earthing

DesignationTerminal

“Auxiliary contact (1)” (NO)1

“Auxiliary 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 placed

together and are fixed by strips. The cover has

four 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 round

file. To place the cover it is necessary to align

joggles on the cover and corresponding holes in

the switching module and to clamp the cover.

Auxiliary contacts connection

Terminals of auxiliary contact units are not

numerated. The order of the terminal corre�

sponds to the following figure.

Commissioning test

Before beginning of application each contactor

shall be subjected to the following commission�

ing 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



� "Closed" LED shall light



Switch off control voltage from 1 and 2 ter�

minals




� "Closed" LED shall not light



Apply control control voltage to 1 and 2 ter�

minals

� contactor shall close



� "Closed" LED shall light



Switch off supply voltage from 4 and 5 ter�

minals


� "Power" LED shall not light (in 5 seconds)


� "Closed" LED shall not light



Switch off control voltage from 1 and 2 ter�

minalsNo reaction

High voltage test

Use standard method (IEC 947�4�1) to check

insulation level.

Insulation resistance test

Use standard methods to check the insulation

resistance of the auxiliary insulation. It shall not

be below the limits given in the contactor tech�

nical specification.

Main contact resistance test

Use standard methods to check resistance of the

main contacts of the contactor. Values must not

exceed limits specified in the contactor technical

specification.

Application Guide 24Maintenance

Maintenance

The contactor is inherently maintenance free.

However, if customer has periodical test proce�

dure the contactor can be subjected under fol�

lowing commissioning tests. If some nonconfor�

mity is found the contactor shall be handled as

described in subsection Failure analisys and han�

dling (see below).

Operation test

The contactor shall be operable as pointed in the

chapter above.

High voltage test

Dielectric strength of vacuum interrupters and

support insulation in respect to power frequency

withstandability shall not deteriorate in service.

During the test, apply voltages as pointed in sub�

section Dielectrical strength. However, impulse

withstandability of vacuum interrupters can

decrease in service. So, producer specifies light

impulse withstandability on 5 kV level for inter�

rupters. Impulse withstandability of support

insulation shall be the same as for a new contac�

tor.

Insulation resistance test

The insulation resistance shall comply with value

that is pointed in subsection Dielectrical strength.

In the case of noncompliance try

to find the “weak point”. Note that, generally,

other devices can be installed in parallel to the

contactor.

Contact resistance test

If contactor has contact resistance which

exceeds the specified limit but it is less than

twice this limit, continuation of use is possible, if

the actual continuous current does not exceed

the following value:

where:

Ia, Ra � actual current and current resistance

respectively,

Rr � rated contact resistance,

Ir � rated current or conventional enclosed ther�

mal current,

Ia<Ir√Rr ,Ra

___

Failure analyses and handling

If any nonconformity during commissioning

tests, maintenance or in service is occurred the

contactor shall be handled in accordance with

the following table.

Nonconformity "Malfunction" LED mode

The contactor is not operatable,

"Power" LED indicator is not lightedUnspecified

The contactor is in close position,

"Closed" LED indicator is not lightedUnspecified

The contactor is in open position,

"Closed" LED indicator lightsUnspecified

Nonconformity of auxiliary contact

Failure of surge arrester unit

Unspecified

Supply voltage is less than permissible limit 1 Blink

Other nonconformities of the module 4, 5 or 6 successive blinks

Failure of High voltage test Unspecified

Failure of Insulation resistance test Unspecified

Unspecified

Failure of Contact resistance test Unspecified

Recommended action

Check and correct power supply voltage

If the voltage is in rate � replace control module

Replace contactor

Replace contactor

Replace ACU

Check and correct power supply voltage

Replace the contactor



Replace surge arrester unit


In any cases customer shall arrange activity in

accordance with Complaints handling procedure.

Replacement of auxiliary contacts

The auxiliary contacts units are maintenance

free. However, if damage of auxiliary contact

occurs under any circumstances the unit can be

replace as follows.

ATTENTION: Contactor shall be open before

replacement of auxiliary switches.■ Take off the cover;■ Press to auxiliary contact block’s slot and draw

out the block;■ Insert a new ACU/TEL�01;■ 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 unit’s 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 module’s replacement

is as follows:

■ Take off the cover

■ Remove surge arrester unit

■ Screw off four captive screws at connection

board

■ Disconnect connection board

■ Disconnect earthing wire from the control

module

■ 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 with

the following table.

Where:

NL � no limitations: supervisory from test lab is

not required

Type test Type test features

Dielectric testsTEL

Temperature rise testsNL

Making and breaking testsNL

Short�time withstand current testsNL

Mechanical life testsNL

Measurement of resistance of the main circuitNL

Standard

IEC 947�4�1�90

IEC 947�4�1�90

IEC 947�4�1�90

IEC 947�4�1�90

IEC 947�4�1�90

IEC 947�4�1�90

TELGOST 30011�96

NLGOST 30011�96

NLGOST 30011�96

NLGOST 30011�96

NLGOST 30011�96

NLGOST 30011�96

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 cir�

cuits (between open contacts)� absence of breakdowns inside vacuum interrupter

Power frequency voltage withstand of the auxiliary

circuits (between terminals and earth)� absence of breakdowns

Routine test

Each contactor before delivery shall be subjected

to the following routine test procedure.

Malfunction to meet any of the above�mentioned

requirements means failure to pass routine test

procedure

TEL � supervisory from TEL is required. It includes

approval of the test program, order and prepara�

tion of test samples and possible participation at

tests with test lab of Tavrida Electric.

Disposal

Modules do not contain any materials that are

hazardous for environment or personnel. No spe�

cial methods of disposal are required.

Attention:

Only electronic version of this document distributed through designated channels to designated users can

be considered valid.

List of changes

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LOW VOLTAGE VACUUM CONTACTOR - LBTLOW VOLTAGE VACUUM CONTACTOR AXCA 670200.009 Version 06 In Effect...

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