Toshiba Video Gaming Accessories HCV 1JBU User Manual

Document: VF010H07A  
INSTRUCTION MANUAL  
INSTALLATION - OPERATION - MAINTENANCE  
HCV-1JBU Vacuum Contactor, 1.5kV - 600A  
HCV-1KAU Vacuum Contactor, 1.5kV - 720A  
Issued: 12/05  
Manufactured in the USA  
 
TOSHIBA  
INSTRUCTION MANUAL  
For the Installation, Operation and Maintenance of  
HCV-1JBU Vacuum Contactor, 1.5kV – 600A  
HCV-1KAU Vacuum Contactor, 1.5kV – 720A  
Never attempt to install, operate, maintain or dispose of this equipment until  
you have first read and understood all of the relevant product warnings and  
user directions that are contained in this Instruction Manual.  
WARNING  
Please complete the following information for your records and retain with this manual:  
Model: ___________________________________  
Serial Number:_____________________________  
Date of Installation: _________________________  
Inspected by: ______________________________  
Reference Number: _________________________  
© TOSHIBA INTERNATIONAL CORPORATION, 2004  
 
SAFETY  
Page 1  
IMPORTANT MESSAGES  
Read this manual and follow its instructions. Signal words such as  
DANGER, WARNING and CAUTION will be followed by important safety  
information that must be carefully reviewed.  
Indicates a situation that will result in death, serious injury, and severe  
property damage if you do not follow instructions.  
DANGER  
Means that you might be seriously injured or killed if you do not follow  
instructions. Severe property damage might also occur.  
WARNING  
Means that you might be injured if you do not follow instructions. Equipment  
damage might also occur.  
CAUTION  
NOTE  
Gives you helpful information  
Note: The contents of this manual will not become apart of or modify the warranty policy. The  
terms of which are set forth at the end of this manual.  
READ SAFETY SIGNS  
To avoid injury, you must read and follow all safety signs.  
Keep the safety signs visible and in good shape. Never remove or cover any safety  
signs.  
 
Page 2  
SAFETY  
QUALIFIED OPERATORS ONLY  
Only qualified persons are to install, operate, or service this equipment according to all  
applicable codes and established safety practices.  
A qualified person must:  
1)  
2)  
Carefully read the entire instruction manual.  
Be skilled in the installation, construction or operation of the equipment and  
aware of the hazards involved.  
3)  
4)  
5)  
Be trained and authorized to safely energize, deenergize, clear, ground,  
lockout and tag circuits in accordance with established safety practices.  
Be trained and authorized to perform the service, maintenance or repair of  
this equipment.  
Be trained in the proper care and use of protective equipment such as rubber  
gloves, hard hat, safety glasses, face shield, flash clothing, etc. in  
accordance with established practices.  
6)  
Be trained in rendering first aid.  
SAFETY CODES  
Toshiba HCV-1JBU and HCV-1KAU vacuum contactors are designed and built in  
accordance with NEMA ICS 3-2, UL 508, CSA 22.2-14 and IEC 60470. Installations  
must comply with all applicable state and local codes, adhere to all applicable National  
Electric Code (NFPA 70) standards and instructions provided in this manual.  
 
SAFETY  
Page 3  
HAZARDOUS VOLTAGE will cause severe injury, death, fire, explosion, and  
property damage.  
DANGER  
Turn off and lock out Primary and Control Circuit Power before servicing.  
Keep all panels and covers securely in place.  
Never Defeat, Modify, or Bypass any Safety Interlocks  
Qualified Operators only  
 
Page 4  
TABLE OF CONTENTS  
SAFETY......................................................................................................................................................1  
INTRODUCTION ........................................................................................................................................6  
GENERAL DESCRIPTION.........................................................................................................................7  
Components....................................................................................................................................7  
- Contactor Components.................................................................................................................7  
Indicators and Controls ...................................................................................................................8  
- ON/OFF Indicator..........................................................................................................................8  
RECEIVING, INSPECTION AND HANDLING ...........................................................................................9  
Receiving and Unpacking ...............................................................................................................9  
Acceptance Inspection....................................................................................................................9  
Handling and Moving ......................................................................................................................9  
- Location of Wear Gauge...............................................................................................................9  
INSTALLATION..........................................................................................................................................10  
Ambient Conditions.........................................................................................................................10  
Rating Verification...........................................................................................................................10  
Mounting the Contactor...................................................................................................................10  
Main Circuit Cable Connections......................................................................................................10  
Ground Connections .......................................................................................................................11  
- Ground Connection Location ........................................................................................................11  
Control Circuit Connections ............................................................................................................11  
- Drive Unit Location........................................................................................................................11  
PRE-ENERGIZATION CHECK ..................................................................................................................12  
General ...........................................................................................................................................12  
Electrical Checks.............................................................................................................................12  
OPERATION...............................................................................................................................................13  
Moving Contactor from Disconnected to Connected Position.........................................................13  
Moving Contactor from Connected to Disconnected Position.........................................................13  
- Internal Connection of the Normally Energized Type ...................................................................14  
- Configuration of the Drive Unit......................................................................................................14  
- Standard Operation Circuit of the Normally Energized Type........................................................15  
MAINTENANCE .........................................................................................................................................16  
Maintenance Program.....................................................................................................................16  
Maintenance Record.......................................................................................................................16  
Servicing Equipment .......................................................................................................................16  
Inspection and Maintenance Types ................................................................................................17  
Table 1 – Tightening Torque...........................................................................................................17  
Table 2 – Check Points for Periodic Inspection ..............................................................................18  
 
TABLE OF CONTENTS  
Page 5  
Table 3 – Gap/Wipe Standard Values (contactor in new condition)................................................20  
Vacuum Check................................................................................................................................21  
- Toshiba Portable Vacuum Checker ..............................................................................................21  
- Application of Test Voltage for Vacuum Check.............................................................................22  
Electrical Service Life......................................................................................................................23  
Mechanical Service Life ..................................................................................................................23  
- Wipe Measurement.......................................................................................................................23  
Service Life of Capacitor.................................................................................................................23  
Table 4 – Recommended Part Replacement Intervals ...................................................................23  
- Capacitor Switching Life ...............................................................................................................23  
STORAGE AND DISPOSAL......................................................................................................................24  
Storage............................................................................................................................................24  
Inspection during Storage ...............................................................................................................24  
Disposal  
SPECIFICATIONS......................................................................................................................................25  
Table 5 – Ratings............................................................................................................................25  
WARRANTY AND LIMITATION OF LIABILITY ........................................................................................26  
 
Page 6  
INTRODUCTION  
It is the intent of this manual to provide a guide for safely installing, operating and maintaining Toshiba  
vacuum contactors. This manual consists of a section of general safety instructions and is marked  
throughout with warning symbols. Read this manual thoroughly before installation, operation and  
maintenance of this equipment.  
This manual and all accompanying drawings should be considered a permanent part of the equipment.  
They should be readily available for review and reference at all times. This manual is not intended to  
cover all details, combinations, or variations of the equipment. Always refer to drawings accompanying  
the equipment for additional details.  
All safety warnings must be followed to ensure personal safety. General safety instructions are  
found on pages 1 through 3. Read and save these instructions for future reference.  
Follow all precautions to attain proper equipment performance and longevity.  
Dimensions shown in the manual are in metric and/or their English equivalent.  
This manual is divided into major sections of interest, as follows:  
GENERAL DESCRIPTION – Provides a description of the equipment, information on major  
components and how they function, plus rating information.  
RECEIVING, INSPECTION AND HANDLING – Describes procedures for receiving, unpacking,  
inspecting, handling, lifting and moving the contactors.  
INSTALLATION – Provides information on installing the contactor.  
PRE-ENERGIZATION CHECK – Provides a checklist for preparing the equipment for energization.  
OPERATION – Provides information on operation of the contactor, circuit diagrams, operating  
sequence description.  
MAINTENANCE – Lists the basic maintenance procedures for this equipment necessary for safe and  
reliable operation.  
DISPOSAL – Lists procedures for the safe disposal of the equipment when the service life has expired.  
STORAGE – Provides guidelines for storing new equipment for an extended period of time.  
SPECIFICATIONS – Covers ratings and other specifications of the contactor.  
WARRANTY AND LIMITATION OF LIABILITY – Details Toshiba International Corporation’s standard  
warranty terms.  
 
GENERAL DESCRIPTION  
Page 7  
COMPONENTS  
The Toshiba HCV-1JB and HCV-1KA vacuum  
contactors described in this manual are suitable  
for use on systems of 1.5kV, 600A and 1.5kV,  
720A respectively.  
1
Arc interruption is accomplished inside sealed  
vacuum interrupters mounted on track-resistant  
insulators. Vacuum interrupters use low-surge  
contact materials, which exhibit low current  
chopping levels reducing switching overvoltage.  
2
3
Front view (Figure 1):  
1. Insulation frame  
2. Vacuum Interrupter  
3. Primary terminal  
4. Flexible conductor  
Figure 2 - Right Side of Contactor  
Side view (Figure 2):  
1. Drive unit  
2. Auxiliary switch  
3. Shaft  
2
3
1
Rear view (Figure 3):  
1. Closing coil  
2. Opening spring  
3. Terminal block  
1
3
2
Figure 3 - Rear of Contactor  
4
Figure 1 - Front of Contactor  
 
Page 8  
GENERAL DESCRIPTION  
INDICATORS AND CONTROLS  
The following indicator is provided:  
On-Off Indicator - Indicates if the contactor is  
OFF (Green) or ON (Red). When the indicator  
reads OFF, the main contacts of the contactor  
are open. When the indication is ON, the main  
contacts are closed. See Figure 4.  
Figure 4 - ON/OFF Indicator  
 
RECEIVING, INSPECTION AND HANDLING  
Page 9  
RECEIVING AND UNPACKING  
HANDLING AND MOVING  
The contactor units are subjected to factory  
production testing prior to being packed and  
shipped.  
Care and caution should be used when handling  
the contactor to avoid damage to the equipment  
and personal injury. Always keep the equipment  
in a generally upright position.  
ACCEPTANCE INSPECTION  
Confirm that the contactor is complete, correct  
as specified and undamaged from shipment and  
handling.  
Upon receipt of the equipment, do the following:  
1. Make an immediate inspection for damage  
that might have occurred during shipment. If  
damage is discovered, it should be noted  
with the carrier prior to accepting the  
shipment, if possible.  
2. Carefully unpack the equipment sufficiently  
to check for missing parts or concealed  
damage.  
3. Check for the presence of accessories that  
are shipped with the contactor:  
Figure 5 - Location of Wear Gauge  
- Contactor wear gauge (Figure 5).  
4. Keep the contactor upright.  
Never lay the contactor on  
CAUTION  
its side or upside down.  
This may cause damage.  
File a claim with the carrier for any damaged or  
missing items and immediately notify the nearest  
Toshiba representative.  
Do not install or energize  
WARNING  
equipment that has been  
damaged. Damaged  
equipment can fail during  
operation, resulting in fire  
and explosion.  
 
Page 10  
INSTALLATION  
AMBIENT CONDITIONS  
MOUNTING THE CONTACTOR  
Do not install this  
The contactor is designed to mount to a flat,  
vertical surface. If there are any noticeable gaps  
between the contactor and the mounting surface,  
fill them in using flat washers as spacers.  
WARNING  
equipment in areas where  
unusual service conditions  
exist. Using this equipment  
in other than usual service  
conditions can result in  
equipment failure.  
Fasten the contactor using four (4) M8 hex  
head bolts. The tightening torque should be  
120-150 kgf-cm (9-11 ft-lb). See Table 1 for  
tightening torque specifications.  
Toshiba HCV-1JBU and HCV-1KAU contactors  
are intended for use in usual service conditions  
as defined in NEMA ICS 1. The temperature of  
the cooling air (ambient air temperature)  
surrounding the contactor should be between the  
limits of -5°C (23°F) and +40°C (104°F). The  
altitude of the equipment installation should not  
exceed 3300-ft (1000 m).  
MAIN CIRCUIT CABLE CONNECTIONS  
Route cables that connect to the contactor to  
avoid interference with sharp edges and moving  
parts. Observe minimum bending radius for the  
type of cable used.  
In particular, avoid the following installation  
conditions:  
Power cables should be braced and/or laced to  
withstand short-circuit forces wherever such  
cables are unsupported. Power cables should  
be adequately sized to carry the maximum  
continuous current in accordance with NEC  
requirements and should have an adequate  
voltage rating. Cables should be dressed and  
terminated as appropriate to the voltage class  
and cable manufacturer’s recommendations.  
- Excessive dust  
- Corrosive gases  
- Extreme variations in temperature  
- Very high or low humidity  
- Vibrations  
- Inclined locations  
If there is a chance that condensation can occur  
at the installation location, a space heater should  
be installed inside the contactor enclosure.  
Fasten the cables to the main circuit terminals.  
Use 35 mm Class 8.8 M10 or M12 hex head  
bolts, 2 flat washers, a lock washer and a nut.  
While securely preventing the nut from rotating  
with a wrench, torque the bolt to 250-315 kgf-  
cm (18-23 ft-lb) for M10 bolts or 450-565 kgf-cm  
(32-41 ft-lb) for M12 bolts.  
NOTE:  
Temperature, altitude or other  
conditions outside of the usual limits  
may require derating or other special  
equipment. Contact your nearest  
Toshiba representative for additional  
information.  
 
INSTALLATION  
Page 11  
Use two wrenches to  
The ground wire should be 8 AWG or larger.  
Then reattach the terminal using the same bolt  
previously removed and torque to 9-11 ft-lb  
(120-150 kgf-cm).  
CAUTION  
torque the connection to  
prevent applying excessive  
force to the terminal, which  
can damage the frame.  
GROUND CONNECTIONS  
CONTROL CIRCUIT CONNECTIONS  
The contactor must be grounded in accordance  
with the requirements of the National Electrical  
Code, Article 250 or applicable local standards.  
Hazardous Voltage. Turn off  
WARNING  
and lock out all primary and  
control circuit power  
sources prior to performing  
this pre-energization check.  
Applying the specified  
power to the drive unit will  
immediately activate the  
coils and close the  
Proper grounding  
WARNING  
connections must be made  
to the contactor before  
incoming power is applied.  
It is very important that the contactor be  
adequately grounded to protect the operator  
from injury in the event of short circuits or other  
abnormal occurrences and to ensure that the  
metal parts of the equipment, other than live  
parts, remain at ground potential.  
contactor.  
Control circuit wiring is connected to the  
contactor by means of a drive unit (black plastic  
box) located on the right side frame (Figure 7).  
Either AC or DC supply voltage may be  
connected to the drive unit.  
The ground terminal is located on the left side  
of the contactor as shown in Figure 6. To make  
the ground connection, first remove the  
fastening M8 hex head bolt and crimp-on  
terminal (provided with the contactor) and crimp  
the terminal to the end of the ground wire.  
The standard operating voltage for the control  
circuit is 100-240V AC/DC. Figure 8 in the  
OPERATION section of this manual show the  
internal connections of the drive unit, closing  
coils, and auxiliary switch.  
Figure 7 - Drive Unit  
Figure 6 - Ground Connection Location  
 
Page 12  
PRE-ENERGIZATION CHECK  
GENERAL  
ELECTRICAL CHECKS  
Electrical shock hazard.  
BEFORE ENERGIZING THE CONTACTOR for  
the first time, follow the procedure below to verify  
that the equipment is properly installed and  
functional.  
WARNING  
Do not touch energized  
components during a test  
using auxiliary power.  
Hazardous Voltage. Turn off  
DANGER  
An electrical insulation resistance test should be  
performed to verify that the contactor and  
associated field wiring are free from short circuits  
and grounds. Refer to the MAINTENANCE  
Section of this manual for additional information.  
and lock out all primary and  
control circuit power  
sources prior to performing  
this pre-energization check.  
Do not operate this  
WARNING  
Hazardous voltages are  
equipment until a complete  
present during dielectric  
testing which can result in  
serious injury or death.  
High potential tests should  
be performed only by  
WARNING  
safety inspection has been  
made.  
Do not energize damaged  
equipment that has not  
been repaired or verified.  
WARNING  
qualified personnel.  
Do not remove, cover or  
destroy any safety signs.  
WARNING  
WARNING  
Do not operate this  
equipment if any panels or  
covers have been removed.  
All blocks or other temporary braces used for  
shipment must be removed.  
Install all panels, guards, and covers if  
removed.  
Check for any loose connections and confirm  
that all wiring is correct per wiring diagrams.  
A
supply of spare parts should be  
established.  
Instruction manuals and diagrams should be  
collected and filed.  
 
OPERATION  
Page 13  
MOVING THE CONTACTOR FROM THE OFF  
TO THE ON POSITION  
TO MOVE THE CONTACTOR TO THE ON  
POSITION:  
1. Turn ON circuit control power to move the  
contactor to the ON position  
2. Verify that the position indicator reads ON  
(Red).  
MOVING THE CONTACTOR FROM THE ON  
TO THE OFF POSITION  
TO MOVE THE CONTACTOR TO THE OFF  
POSITION:  
1. Turn OFF circuit control power to move the  
contactor to the OFF position  
2. Verify that the position indicator reads OFF  
(Green).  
 
Page 14  
OPERATION  
LEGEND  
52 CC …. Closing Coil  
T1-T4 ….. Terminal Block  
A1-A2…... Closing Supply  
AC/DC  
R
U
S
V
T
Vacuum Bottles  
W
T4  
T3  
T2  
T1  
16 15 14 13 12 11  
52  
CC  
52  
CC  
26 25 24 23 22 21  
Auxiliary  
Switch  
5
6
Drive Unit  
1
2
A1  
A2  
Closing Supply  
AC/DC  
Figure 8 – Internal Connection of the Normally Energized Type  
LEGEND  
52 CC …. Closing Coil  
T1-T2 ….. Terminal Block  
A1-A2…... Closing Supply  
AC/DC  
T1  
52  
A1  
A2  
TIMER  
CC  
T2  
VOLTAGE  
DETECT  
OSCILLATION  
POWER  
SWITCHING  
Figure 9 – Configuration of the Drive Unit  
 
OPERATION  
Page 15  
LEGEND  
Remote  
OFF  
52 CC …. Closing Coil  
T1-T2 ….. Terminal Block  
GL ……… Green Light  
RL ……… Red Light  
CR……… Control Relay  
A1-A2…... Closing Supply  
AC/DC  
CR  
CR  
Operati on  
Swit ch  
OFF  
VCTT  
ON  
ON  
A1  
Local  
16 15 14  
13 12 11  
CR  
Remote  
Auxiliary  
Switch  
Dri ve  
Uni t  
St art  
I nterlock  
T1  
26 25 24  
23 22 21  
St op  
I nterl ock  
52  
CC  
52  
CC  
DrS  
(Door Swit ch)  
GL  
RL  
2E (Over load)  
T2  
A2  
CR  
Figure 10 - Standard Operation Circuit of the Normally Energized Type.  
 
Page 16  
MAINTENANCE  
MAINTENANCE PROGRAM  
MAINTENANCE RECORD  
In order to ensure continued reliable and safe  
operation of the equipment, a program of  
periodic maintenance must be established.  
Operating and environmental conditions will  
usually dictate the frequency of inspection  
required. NFPA Publication 70B "Electrical  
Equipment Maintenance" may be used as a  
guide for setting up the maintenance program.  
Keep a permanent record of all maintenance  
work. At a minimum, this record should include  
information on:  
1. Items inspected  
2. Reports of any testing  
3. Equipment condition  
4. Corrective actions or adjustments  
5. Date of work  
Contact with energized  
DANGER  
6. Comments  
components can cause  
severe injury, death and  
property damage. Turn off  
and lock out primary and  
control circuit power before  
servicing.  
The degree of detail of the record will depend  
somewhat on the operating conditions.  
SERVICING EQUIPMENT  
For your safety, turn off and lock out main and  
control circuit power before servicing the  
contactor. Certain minimum safety procedures  
must be followed:  
Improper maintenance can  
cause severe injury, death  
and property damage. Only  
qualified and authorized  
persons are to install,  
operate or service this  
equipment.  
WARNING  
WARNING  
1. Only qualified personnel should attempt  
this service.  
2. Never perform service on or next to  
exposed components energized with line  
voltage.  
Grease is conductive. Do  
not allow grease or any  
other substances to  
contaminate insulating  
materials. Contaminated  
insulators can allow a  
short-circuit or ground  
fault to occur.  
Failure to adhere to these  
safety procedures can  
WARNING  
result in severe injury,  
death and property  
damage.  
NOTE:  
Refer to the SAFETY section of this  
manual for important information.  
 
MAINTENANCE  
Page 17  
RECOMMENDED INSPECTION AND  
MAINTENANCE TYPES  
Table 1 - Tightening Torque  
Screw Nominal  
Diameter  
Tightening Torque  
NOTE:  
Refer to the SAFETY section of this  
manual for important information.  
M4  
M5  
15-20 kgf-cm (13-17 in-lb)  
30-40 kgf-cm (26-34 in-lb)  
50-65 kgf-cm (43-56 in-lb)  
120-150 kgf-cm (9-11 ft-lb)  
250-315 kgf-cm (18-23 ft-lb)  
450-565 kgf-cm (32-41 ft-lb)  
1. Acceptance Inspection  
This inspection confirms that the contactor is  
complete, correct as specified and  
undamaged from shipment. The procedure  
for this inspection is outlined in the  
M6  
M8  
RECEIVING,  
INSPECTION  
AND  
M10  
M12  
HANDLING section of this manual.  
2. Patrol Inspection  
Inspection is made of the condition of the  
contactor while it is energized. Check that  
no unusual sounds or smells exist externally.  
Check for any abnormal discoloration due to  
overheating. Inspect for signs of damage to  
the insulation frame, OPEN/CLOSE indicator  
and other components.  
Inspection Frequency: Once every 6 months  
3. Periodic Inspection  
Inspection is performed with the contactor  
de-energized. The lubrication of sliding and  
rotating parts is checked and the mechanism  
is lubricated if needed.  
Inspection Frequency: Once every 1-2 years  
or every 20,000 operations (normal).  
NOTE:  
Refer to Table 2 for the schedule of  
Periodic Inspections.  
4. Unscheduled Inspection  
Inspections are implemented as required.  
Inspection Frequency: As needed  
NOTE:  
The inspection frequency and points  
to be inspected may vary from the  
above recommendations depending  
on the status of use, frequency of  
switching and other factors.  
 
Page 18  
MAINTENANCE  
Table 2 - Check Points for Periodic Inspection  
Check  
Point  
Check Item  
Check Method  
Criteria  
Disposition  
Operating  
Mechanism nuts or  
screws  
Loose bolts,  
Tighten using  
screwdriver or  
wrench.  
Make sure all bolts,  
nuts and screws are  
tight.  
Tighten if loose.  
See Table 1 for  
tightening torque  
specifications.  
Dust or  
foreign  
matter inside  
Visual inspection.  
Visual inspection.  
The contactor should be Wipe with a clean  
clean and contain no  
foreign matter.  
dry cloth.  
Electro-  
magnets  
Check for rust,  
discoloration, wear, or  
loose mountings.  
Wipe with a clean  
dry cloth.  
Closing coil  
Spring  
Visual inspection.  
Visual inspection.  
Check for discoloration, Wipe with a clean  
and burned parts.  
dry cloth.  
Check for rust,  
deformation,  
discoloration, or  
damage.  
Wipe with clean dry  
cloth. Lubricate if  
necessary.  
Smooth  
operation  
Visual inspection or  
touch. Check  
lubrication.  
Make sure moving parts Apply a small  
operate smoothly.  
amount of  
lubrication.  
Main Circuit Terminals  
conductors.  
Visual inspection.  
and movable Tighten using  
Make sure there is no  
discoloration or loose  
fasteners.  
Check the cause  
and repair. Tighten  
connections to  
contactor. See  
(Table 1) for  
screwdriver or  
wrench.  
tightening torque  
specifications.  
Loose bolts,  
nuts or  
screws  
Tighten using a  
wrench.  
Make sure all bolts,  
nuts and screws are  
tight.  
See Table 1 for  
tightening torque  
specifications.  
Vacuum  
See Electrical  
Check contact wear and Replace vacuum  
wipe. interrupter.  
contact wear. Service Life (Page  
23).  
Vacuum  
level.  
Apply 10kV AC for 1 Check vacuum level by If breakdown occurs,  
minute. withstand voltage test. contact Toshiba.  
 
MAINTENANCE  
Page 19  
Table 2 – Check Points for Periodic Inspection (cont.)  
Check  
Point  
Check Item  
Check Method  
Criteria  
What to do  
Main Circuit Dust on  
surface of  
Visual inspection.  
Make sure there is no  
dust on the surface.  
Wipe with a clean,  
dry cloth.  
vacuum  
interrupter  
Insulation  
Frame and  
Flanges  
Dust, foreign Visual inspection.  
matter or  
damage  
Make sure there is no  
dust, foreign matter or  
breakage.  
Wipe with a clean,  
dry cloth. If  
damaged, contact  
Toshiba.  
Control  
Circuits  
Auxiliary  
Switch  
See Table 3.  
Contact wear and wipe. Replace if wear or  
Make sure there is no  
dust.  
damage is  
excessive. See  
Table 1 for  
tightening torque  
specifications  
Drive unit  
Wiring  
Visual inspection.  
Check for overheating  
and discoloration.  
Replace if damaged.  
Visual inspection.  
Tighten using a  
screwdriver.  
Check for discoloration  
and tightness.  
Repair if  
disconnected.  
Tighten if loose.  
See Table 1 for  
tightening torque  
specifications.  
Insulation  
Resistance  
Measure-  
ment  
Resistance  
from main  
circuit to  
ground  
Measure insulation  
resistance between  
phases, between  
electrodes, and  
between circuits and  
ground. Megger test  
at 1000V.  
Resistance should be  
50Mor greater.  
If the insulation  
resistance is low,  
wipe off the vacuum  
interrupter and other  
insulation surfaces  
with a clean dry  
cloth and then  
repeat the test. If  
necessary, replace  
faulty parts.  
Resistance  
from control  
circuits to  
ground  
Measure insulation  
resistance between  
circuits and ground.  
Megger test at  
500V.  
Resistance should be  
1Mor greater.  
 
Page 20  
MAINTENANCE  
Table 2 – Check Points for Periodic Inspection (cont.)  
Check  
Point  
Check Item  
Check Method  
Criteria  
What to do  
Dielectric  
Strength  
Measure  
main circuit  
Measure dielectric  
strength between  
phases and between  
circuits and ground.  
10kV AC or 14kV DC for If breakdown occurs,  
1 minute.  
contact Toshiba.  
Open/Close  
Operation  
---  
Perform open/close  
operation by electric  
operation test to  
confirm the correct  
operation.  
---  
If not normal, check  
and repair. If  
necessary, replace  
faulty parts.  
Table 3 - Gap/Wipe Standard Values (contactor in new condition).  
Parts  
Gap  
Wipe  
Allowable Wear  
Vacuum  
Interrupter  
Normally  
energized  
type  
0.091-0.098 in.  
(2.3-2.5 mm)  
0.091-0.102 in.  
(2.3-2.6 mm)  
0.051 in. (1.3 mm)  
Auxiliary  
Switch  
a-contact  
---  
0.157±0.016 in.  
(4±0.4 mm)  
0.118±0.012 in.  
(3±0.3 mm)  
b-contact  
0.157±0.016 in.  
0.118±0.012 in.  
(4±0.4 mm)  
(3±0.3 mm)  
Delayed  
b-contact  
0.098±0.012 in.  
(2.5±0.3 mm)  
0.177±0.020 in.  
(4.5±0.5 mm)  
 
MAINTENANCE  
Page 21  
VACUUM CHECK  
Hazardous voltages are  
WARNING  
present during dielectric  
testing which can result in  
severe injury or death.  
Only qualified personnel  
should conduct this testing.  
A sufficient level of vacuum is necessary for  
proper performance of the vacuum interrupters.  
Although vacuum leaks are rare, the vacuum  
integrity should be checked periodically. The  
relationship between dielectric breakdown  
voltage of the contact gap and internal vacuum  
interrupter pressure has been found to be  
generally predictable. Therefore, vacuum  
interrupter integrity is checked by performing a  
high potential test across the open gap of the  
interrupter.  
TEST PROCEDURE:  
1. The contactor should be disconnected from  
the main circuit and be in the OFF position.  
2. Connect all the line side primary terminals  
together and to the output of the vacuum  
checker or AC hi-pot machine. Connect all  
the load side primary terminals together and  
to the ground terminal of the vacuum  
checker or AC hi-pot machine.  
TEST EQUIPMENT:  
Toshiba offers a compact vacuum checker (Type  
CI35-1D, Figure 11) which enables a quick and  
easy check on vacuum interrupter internal  
pressure. Alternatively, any commercially  
available AC high potential tester may be used  
which is capable of delivering at least 25 milli-  
amperes at 10 kV for a period of one minute.  
3. Increase the voltage from zero to 10kV AC at  
a rate of approximately 1kV per second.  
Hold the voltage at this value for 1 minute  
and observe the current drawn by the  
interrupter. See Figure 12.  
PRECAUTIONS:  
4. Decrease the voltage back to zero.  
Applying abnormally high voltage across a pair  
of contacts in vacuum may produce X-rays. The  
radiation may increase with the increase in  
voltage and/or decrease in contact spacing. X-  
radiation produced during this test with  
recommended voltage and normal contact  
spacing is extremely low and well below the  
maximum permitted by standards.  
As an  
additional safety measure, however, it is  
recommended that all personnel keep at least 1  
meter (3.3 ft) away from the vacuum circuit  
breaker while this test is performed.  
Radiation exposure hazard.  
WARNING  
X-rays may cause illness or  
injury. Stay at least 1 meter  
(3.3 ft) away from the circuit  
breaker during the vacuum  
check test.  
Figure 11 - Toshiba Portable Vacuum  
Checker  
 
Page 22  
MAINTENANCE  
CRITERIA:  
1 minute  
1. If a current flow above 5 milli-amperes is  
observed or if breakdown occurs, one or  
more of the interrupters has insufficient  
vacuum and must be replaced.  
10kV AC  
(14kV DC)  
Exception:  
If the current exceeds 5 milli-  
Voltage  
amperes the first time the voltage is brought  
up, reduce the voltage to zero and increase it  
again. It may be necessary to repeat this  
procedure a few times.  
Zero  
2. If the contactor fails to meet criteria 1, then  
repeat the test on each pole separately to  
identify the damaged interrupter or  
interrupters.  
10 sec  
10 sec  
Time  
Figure 12 - Application of Test Voltage for  
Vacuum Check  
3. If the voltage can be held for 1 minute and  
the current flow does not exceed 5 milli-  
amperes, the interrupter has a sufficient  
vacuum level.  
After the test is complete, discharge any residual  
static charge from the primary terminals of the  
circuit breaker.  
If a vacuum checker or AC hi-pot tester is not  
available, a DC hi potential test may be  
conducted. If a DC test is conducted, the test  
voltage must be increased to 14kV DC. The test  
duration for DC tests and the criteria for  
acceptance remain the same as for AC tests.  
Do not use DC hi-pot  
WARNING  
testers which employ  
unfiltered half-wave  
rectifiers. The peak  
voltages produced by these  
testers may exceed the  
recommended value of  
14kV. This can result in the  
production of harmful X-  
rays and may invalidate the  
test results.  
 
MAINTENANCE  
Page 23  
ELECTRICAL SERVICE LIFE  
Table 4 - Recommended Part Replacement  
Intervals  
The electrical service life of the vacuum  
interrupter is defined by the electrode wear and  
Part Name  
Number of Operations  
for Replacement  
the  
number  
of  
open/close  
operations  
(mechanical life).  
Vacuum Interrupter 500,000  
To determine electrode wear, measure the  
distance between the lever and washer in the  
closed (ON) state, as shown in Figure 13. This  
dimension is called the “wipe”. If the 1.0mm  
contact wear gauge cannot be inserted, then  
the end of the service life has been reached.  
The maximum number of open/close operations  
is 500,000 regardless of the magnitudes of the  
Auxiliary Switch  
Moveable Core  
200,000  
Detailed inspection and  
cleaning every 500,000  
operations.  
Stationary Core  
Closing Coil  
Detailed inspection and  
cleaning every 500,000  
operations.  
currents interrupted.  
Contact Toshiba for  
information regarding replacement of the  
vacuum interrupters.  
500,000  
The drive unit and the closing coils also have  
an electrical service life of 500,000 operations.  
As a result, these parts should be replaced  
around 500,000 operations.  
Flexible Conductor 500,000  
SERVICE LIFE – CAPACITOR SWITCHING  
Switching of the capacitor loads produces  
severe conditions for contactors, such as high  
frequency inrush current and phase-to-phase  
recovery voltage more than twice the normal  
voltage.  
MECHANICAL SERVICE LIFE  
The normally energized type has a mechanical  
service life of 2.5 million operations. The  
mechanical service life of the vacuum  
interrupters is 500,000 operations.  
The criterion for the maximum number of the  
capacitor current switching operations is shown  
in Figure 14. The vacuum interrupter should be  
replaced when the number of switching  
operations in the graph is reached.  
For the components listed in Table 4,  
replacement or detailed inspection and cleaning  
are recommended after the indicated number of  
operations.  
10  
8
Isolation  
Flange  
6
4
2
1
A
20  
40 60  
200  
400 600  
1000  
10  
100  
Switching Current (A)  
Figure 14 - Capacitor Switching Life  
Figure 13 - Wipe Measurement  
 
Page 24  
DISPOSAL AND STORAGE  
STORAGE  
If the contactor is to be stored for any length of  
time prior to installation, the following  
precautions should be taken.  
1. The original packing should be restored, if  
possible.  
2. Do not subject the equipment to moisture or  
sunrays. Store in cool, clean, and dry  
location.  
3. Place a dust cover over the contactor  
packaging to protect against dirt and  
moisture.  
4. Store in an upright position.  
INSPECTION DURING STORAGE  
Routine scheduled inspection is necessary if  
storage is for an extended period. The unit  
should be checked for condensation, moisture,  
corrosion, and vermin.  
Prior to installation, the contactor should be  
carefully examined for evidence of physical  
damage, corrosion, or other deterioration. Refer  
to the PRE-ENERGIZATION Section of this  
manual.  
The MAINTENANCE section of this manual  
describes various types of inspections  
recommended for this contactor during the  
operation period.  
DISPOSAL  
Contact your state environmental agency for  
details on disposal of electrical components and  
packaging in your particular area.  
 
SPECIFICATIONS  
Page 25  
Table 5 - Ratings  
Items  
HCV-1JBU  
HCV-1KAU  
Rated Insulation Voltage  
Rated Operation Voltage  
Rated Operational Current  
Rated Frequency  
kV  
V
1.5  
208-1500  
A
600  
720  
7.2  
Hz  
kA  
50/60  
Rated Making Current  
6.0  
(close 100 times)  
(close 100 times)  
Rated Breaking Current  
kA  
4.8  
5.76  
(close-open 25 times)  
(close-open 25 times)  
Rated Insulation Level  
kV  
kA  
AC 10 Impulse 45  
AC 10 Impulse 30  
Rated Short-Time Current  
9.0 – 1 sec.  
10.8 – 1 sec.  
4.3 – 30 sec.  
3.6 – 30 sec.  
Method of Operation  
Mechanical Operation  
Electrical Operation  
Operational Voltage  
Auxiliary Switch  
Non-latch  
Million  
Million  
2.5  
0.5  
Standard  
100-240V AC/DC  
3 N.O. – 3 N.C.  
1200  
Switching Frequency  
Times/h  
 
WARRANTY AND LIMITATION OF LIABILITY  
Page 26  
Toshiba International Corporation ("Company") warrants that all equipment and parts described herein will be free  
from defects in materials and workmanship. THIS WARRANTY WILL EXPIRE EIGHTEEN (18) MONTHS AFTER  
THE DATE ON WHICH SUCH EQUIPMENT AND PARTS (EXCLUDING REPAIRED OR REPLACEMENT  
EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS WARRANTY) ARE SHIPPED BY THE COMPANY  
TO THE INITIAL PURCHASER OR TWELVE (12) MONTHS AFTER SUCH EQUIPMENT AND PARTS  
(EXCLUDING REPAIRED OR REPLACEMENT EQUIPMENT AND PARTS FURNISHED PURSUANT TO THIS  
WARRANTY) ARE FIRST PLACED IN OPERATION, WHICHEVER PERIOD FIRST EXPIRES.  
The Company will, at its option, repair or replace such equipment or part which is defective under the terms of the  
foregoing warranty, free of charge; provided the purchaser (1) promptly notifies the Company in writing of such  
defect, and (2) furnishes the Company satisfactory proof thereof, and (3) establishes that the equipment or part has  
been properly installed, maintained and operated within the limits of rated capacity and normal usage and in  
accordance with this manual, and (4) if requested by the Company, returns the defective equipment or part to the  
Company and pays all expenses incurred in connection with such return. The repaired or replacement equipment or  
part will be delivered, free of charge, to the purchaser F.O.B. the Company's warehouse or, at the Company's  
option, F.O.B. a Company authorized service shop, not loaded on truck or other carrier. The purchaser will pay the  
costs applicable to the equipment or part following such delivery, including, without limitation, all handling,  
transportation, assembly, insurance, testing and inspection charges.  
THE FOREGOING OBLIGATION TO REPAIR OR REPLACE EQUIPMENT PARTS SHALL BE THE SOLE AND  
EXCLUSIVE REMEDY OF THE PURCHASER, ITS CUSTOMERS AND USERS OF THE EQUIPMENT AND  
PARTS FOR BREACH OF THE FOREGOING WARRANTY. THE COMPANY WILL HAVE NO OBLIGATIONS TO  
DISASSEMBLE ANY EQUIPMENT OR PART WHICH IS DEFECTIVE WITHIN THE TERMS OF THE ABOVE  
WARRANTY OR TO INSTALL ANY REPAIRED OR REPLACEMENT PART OR EQUIPMENT OR TO PAY ANY  
COSTS INCURRED IN CONNECTION WITH ANY SUCH DISASSEMBLY OR INSTALLATION. THE COMPANY,  
TOSHIBA CORPORATION AND THEIR SUPPLIERS AND SUBCONTRACTORS HEREBY DISCLAIM ALL  
OTHER EXPRESS, STATUTORY AND IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, ALL  
EQUIPMENT AND PARTS FURNISHED PURSUANT TO THE FOREGOING WARRANTY AND ALL IMPLIED  
WARRANTIES OF MERCHANTABILITY.  
The total liability of the Company, Toshiba Corporation and their suppliers and subcontractors for any  
loss, damage or claim, whether in contact, tort (including negligence and liability without fault), or  
otherwise, arising out of, connected with or resulting from the equipment and parts described in this  
manual or the performance or breach of any contract for the sale or supply of such equipment and  
parts, or from the design, manufacture, sale, delivery, resale, installation, technical direction or  
supervision of installation, inspection, testing, repair, replacement, operation, maintenance or use of  
any such equipment or part or any service relating thereto furnished by the Company shall not in any  
event exceed the price allocable to the equipment, part or service which gives claim, loss or damage.  
In no event, whether as a breach of contract or warranty, alleged negligence, liability without fault, or  
otherwise, shall the Company, Toshiba Corporation or their suppliers or subcontractors be liable for  
special or consequential damages, including, without limitation, loss or profits or revenue, loss of  
equipment described herein or any associated equipment, cost of capital, cost of substitute equipment  
or parts, facilities or services, down-time costs, labor costs or claims of customers of the purchaser for  
such damages.  
 

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