Download - Vacuum Contactor(Hca )

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

>> 3

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.


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.

>> 5

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.


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

>> 7

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)


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

>> 9

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.


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).


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 (


>> 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



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



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



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



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.



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

HEAD OFFICE 1 JEONHA-DONG, DONG-GU, ULSAN, KOREA TEL. 82-52-230-8101~7 FAX. 82-52-230-8100

SEOUL HYUNDAI B/D, 140-2, GYE-DONG, JONGNO-GU, (Sales & Marketing) SEOUL, KOREA

TEL. 82-2-746-7589, 7522 FAX. 82-2-746-7648

ORLANDO 3452 LAKE LYNDA DRIVE, SUITE 110. ORLANDO,FLORIDA 32817 U.S.A.TEL. 1-407-249-7350 FAX.1-407-275-4940

LONDON 11TH FL., ST. MARTIN’S HOUSE, 1 HAMMERSMITHGROVE, LONDON W6 ONB, U.K. TEL. 44-208-600-7127 FAX.44-208-741-5620, 4571

TOKYO 8TH FL., YURAKUCHO DENKI BLDG.1-7-1, YURAKU-CHO, CHIYODA-KU, TOKYO, JAPAN 100-0006TEL. 81-3-3212-2076, 3215-7159 FAX. 81-3-3211-2093

CAIRO APARTMENT NO. 503, 5TH FL., BLDG. NO. 7 BLOCK2, 9TH DIVISION, EL-NASR ROAD, NEW MAADI,CAIRO, EGYPTTEL. 20-2-520-0148~9 FAX. 20-2-754-7528

SOFIA 1271, SOFIA 41, ROJEN BLVD. BULGARIATEL. 359-2-938-1068 FAX. 359-2-936-0742

www.hyundai-elec.comHEAVY INDUSTRIES CO., LTD.ELECTRO ELECTRIC SYSTEMS

HH

IS-W

Z-LK

E-012-02 2004.2 D

esigned by Design K

orea