LOW VOLTAGE
VACUUM CONTACTOR
I N D U S T R I A L
G R O U P
TAVRIDA ELECTRIC
AXCA 670200.009
Version 06
In Effect Since 03.09.2007
Contents
2
CONTENTS
Technical Manual
3
Presentation
3
Product range
4
Design
5
Overall design
5
Switching module
6
Control module
7
Auxiliary contact units
8
Surge arrester unit
8
Small wiring termination
8
Operation
9
Closing
9
Opening
10
Emergency trip
10
Technical specification
11
General
11
Rated operational power of AC motors (AC3 and AC4)
12
Auxiliary circuits
13
“Power supply”
13
“Control Input”
13
Auxiliary contacts unit
13
Surge arresters
14
Electromagnetic Compatibility (EMC)
15
Dielectrical Strength
Dimensional drawings
15
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
Presentation
3
Technical Manual
Presentation
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 standalong unit. Switching
of heavyduty AC motors is main intent of the
contactor.
Main distinctive of the contactor’s design is
application of microprocessorbased incorporat
ed control unit. Lightduty 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/TEL14/400340 is applied at either of low
voltage AC systems.
LSM/TEL14/400341 and LSM/TEL14/400
342 contactors are used for threephase, four
wires AC systems 120/208V and 230/400V corre
spondently. In these types of the contactors
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
Product range
4
Product range
Product type
Part number
Comment
Manufacturer
Module
LSM/TEL14/400340
Contactor for up to 1000 V AC systems (witout
surge arresters)
Module
LSM/TEL14/400341
Contactor for 120/208 V AC systems (with
surge arrester unit SAU/TEL230E)
Module
LSM/TEL14/400342
Contactor for 230/400 V AC systems (with
surge arrester unit SAU/TEL400E)
Accessory
CM/TEL20E
Control module
Accessory
ACU/TEL01
Auxiliary contact unit
Accessory
SAU/TEL230E
Surge arrester unit for LSM/TEL14/400341
Accessory
SAU/TEL400E
Surge arrester unit for LSM/TEL14/400342
Accessory
SAU/TEL001E
Case of surge arrester unit (without varistors)
Accessory
АAHE 296444.003
Special key
Accessory
ITEA 674152.003
Screw driver
Component
AAHE 735642.001
Seal
MF TEL
Component
AXCA 716212.001
Adapter
MF TEL
Component
AXCA 745422.017
Installation bar
MF TEL
Technical Manual
Design
5
Design
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 polymericcov
ered modules. Auxiliary contacts units are made
as PCBbased 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
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
Connection board
"Earth" stud
Surge arresters unit
Small wiring
terminals
Switching module
Auxiliary
contacts unit
Main circuit
terminals
(load outputs)
Cover
Main circuit
terminals
(supply inputs)
Seals
Adapters
Installation bar
Technical Manual
Design
6
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 heavyduty circuits providing high inter
rupting life.
Vacuum interrupter
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.
In contrast with majority of conventional con
tactors there is level motion between the actua
tor and vacuum interrupters. The actuator's
Armature
Frame
Contact pressure
spring
Bracket
Function
auxiliary contact
Opening spring
Actuator coil
Basechannel
Flexible connector
Guade yoke
Base yoke
Clamp
Drive insulator
Terminal
Vacuum interrupter
Busbar
Technical Manual
Design
7
Control module
Microprocessorbased control module transfers
external lowpowered 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.
Greencolor 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.
Redcolor indicator "Closed" reflects position of
the contactor.
Correspondence between modes of the contactor
and indicators is shown in the following table.
LED indication mode
Contactor's condition
"Power"
"Malfunction"
"Closed"
No light
No light
No light
Preparation time for closing
Blinks
No light
No light
Opened state
Light
No light
No light
Closed state
Light
No light
1 blink in
series*
2 blinks in
series
3 blinks in
series
4, 5 or 6 blinks
in series
Light
Continuous lost of "Power supply"
Lost of "Power supply" and "Control input"
Overheating Indication Temperature exceeds specified
level
Opened state after execution of Emergency Trip
Instruction
Nonconformity of the contactor
* During not less than 30 sec.
** Light if the contactor is closed; No Light if the contactor is opened.
No light
Light
Blinks
Light
**
**
No light
**
Technical Manual
Design
8
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/TEL14/400341 and LSM/TEL 14/400342 include SAU/TEL type surge arrester
units. The first contactor is supplied with
SAU/TEL230 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/TEL14/400340 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 NO1
"Power Supply"
Auxiliary Contact NC1
"Control Input"
Auxiliary Contact NO2
Auxiliary Contact NC2
"Earth"
Technical Manual
Operation
9
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 3 3a
4
4а 4b 5
6
State
of main contacts
Actuator coil
current
Travel of armature
Speed of armature
Time
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 12).
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 2a3).
When closing impulse duration is expired control
module decreases the closing current (line 3) up
to holding current (lines 3a4). The contactor
stays in closed position for unlimited period of
time even if mechanical vibration conditions and
voltage drops are occurred
Technical Manual
Operation
10
Opening
To open the contactor, “Control Input” shall be
deenergized. 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 microwelds 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 socalled «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
deenergize “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 Manual
Technical specification
Technical specification
Applicable standards:
IEC 9474190
General
Rated voltage, V
LSM/TEL14/400340
LSM/TEL14/400341
LSM/TEL14/400342
Rated frequency, Hz
Conventional thermal curent, A
Rated breaking capacity, kA
Rated making capacity, kA
Rated over current capacity, 10s, kA
Mechanical life, CO operations
Operational frequency, CO operations per hour
mechanical
AC1
AC3
AC4
Switching capacity, CO operations
at rated current
at breaking current
at other currents
Closing time, ms, not more than
Drop out time, ms, not more than
Opening time, ms, not more than
Overheating Indication Temperature, °C
Emergency Trip Temperature, °C
Main contact resistance, microOhm
Current heat loss, at 400A, w
Ambient air temperature
open, °C
enclosed, °C
storage, °C
Climatic proofing
Maximum altitude above sea level, m
Degree of protection
Mechanical vibration withstand capacity
stationary vibration, sinusoidal, g
nonstationary vibration, shock, g
Weight, kg, not more than
* According IEC 60068188 (C Damp heat (steady state); D Damp heat (cyclic).
** IP00 at flat strip conductor or busbar connection.
*** According IEC 6072134.
11
1000
230
400
50, 60
400
4
4
3.2
2 000 000
600
600
500
300
2 000 000
50
see diagram
50
60
80
70±3
80±3
90
50
40...+55
40...+40
40...+60
C, D*
2000
IP40 (IP00)**
Class 3M4 (IEC 72134)***
1
10
10,0
Technical Manual
Technical specification
12
Rated operational power of AC motors (AC3 and AC4)
Rated operational power, kW
Rated voltage, V
LSM/TEL14/400340
LSM/TEL14/400341
LSM/TEL14/400342
220
125
125
125
230
130
130
130
240
135
135
135
380
200
200
400
220
220
415
240
240
440
255
500
290
660
340
690
360
1000
500
Switching capacity
10000
4000
Current, А
1000
100
10
1
10
100
1000
10000
100000
Interrupting life, operations
1000000
Technical Manual
Technical specification
Auxiliary circuits
“Power supply”
Power supply rated voltage, V AC
Operating range, V AC
Power consumption, VA, not more than
during preparation time (charging of closing
capacitor)
in opened position
in closed position
Preparation time, s, not more than
after initial power application
after previous open operation
Maximum withstand voltage, V, peak
220
187242
35
8
15
10
5.5
420
“Control Input”
Control input rated voltage, V AC
220
Operating range, V AC,
Minimum accepted level of close instruction,
V AC, not less than
Minimum holding level of close instruction,
V AC, not less than
Maximum accepted level of trip instruction,
V AC, not more than
"Close" instruction acceptance time, ms, not
more than
"Trip" instruction acceptance time, ms, not
more than
44242
132
88
44
30
30
Auxiliary contact units
Maximum operating voltage, V (AC&DC)
Rated voltage, V (AC&DC)
Breaking capacity (AC, cos=0.8), VA
Maximum carrying current, A
Minimum switching current, A (AC&DC)
Dielectric strength, VDC
Interrupting life at maximum breaking cur
rent, CO cycles
Mechanical life, CO cycles
400
250
750
10
0.1
750
50 000
1 000 000
13
Technical Manual
Technical specification
14
Surge arresters
Type
Rated Voltage , V AC
SAU230
SAU400
220, 230, 240
380, 400, 415
Surge Current, A
(8/20 m s)
Energy Absorption, J
(2 ms)
8000
8000
100
135
1,0
1,0
Voltagecurrent characteristics of different SAU
are shown below
Voltage, V
2000
1000
SAU400
SAU230
0
1E3
0,01
0,1
1
10
Current, A
Maximum surge current, A
Derating curves of different SAU are shown
below.
Impulse duration, m s
Average Power
Dissipation, W
100
Technical Manual
Technical specification
15
Electromagnetic Compatibility (EMC)
Parameter
Level
Characterizations
Immunity criteria
in accordance with
IEC 6094741
Electrical fast transient/burst immunity in accordance
with IEC 6100044:
for "Power supply
4
A
"for "Control input"
4
A
Surge immunity in accordance with IEC 6100045
4
3
common 4 kV
differential 2 kV
B
B
Power frequency magnetic field immunity in accordance
with IEC 6100048
5
100 A/m
1000 A/m
A
A
Pulse magnetic field immunity in accordance with IEC
6100049
5
1000 A/m
A
Damped oscillatory magnetic field immunity in accordance
with IEC 61000410
5
0,1 and 1 MHz 100 A/m
A
Voltage dips, short interruptions and voltage variations
immunity in accordance with IEC 61000411
5
A
Oscillatory waves immunity in accordance with IEC 61000
412 taking into account IEC 255221
3
1 MHz, 0,1 MHz
2 kV
A
Electrostatic discharge immunity inaccordance with IEC
6100042
3
A
Dielectrical Strength
Power frequency voltage
between main contacts
between main contacts and auxiliary circuits
between auxiliary circuits
Lighting impulse 1,2 m s/50 ms/0,5 J
between main contacts
between main contacts and auxiliary circuits
between auxiliary circuits and “Earth”
between isolated auxiliary circuits
between NO and NC of ACU
Insulation resistance between isolated
potentional zones at 500 VDC, not less than
3,5 kV
3,5 kV
2,0 kV
8,0 kV
8,0 kV
4,0 kV
4,0 kV
4,0 kV
5,0 MOhm
Technical Manual
Dimensional drawings
Dimensional drawings
16
Application Guide
Selection Incoming inspection
17
Application guide
Selection
Selection of the contactor is made in accordance
with following table:
Type
LSM/TEL14/400340
LSM/TEL14/400341
LSM/TEL14/400342
AC System
Rated voltage, V AC
Threephase, threewire or
fourwire systems
Threephase,
fourwire systems
Threephase,
fourwire systems
up to 1000
220, 230, 240
380, 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
Inspection
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 criteria
Packaging
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
Sealing
Absence of undamaged seals
Plastic parts
Absence of mechanical damages, scratches and colored spots
Metal parts
Absence of mechanical damages, scratches and corrosion on painted
surfaces and galvanized terminals.
Application Guide
Mounting
18
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.
Each contactor is provided with paper template
to make marking on switchgear's panel.
Mounting holes, required fasteners and torques
are shown below.
1...4
155±0.2
8 Screws 4,2
8 Washers
4 Screws M6х20
4 Spring Washers
4 Washers
Torque 10 N.m
155±0.2
115±0.2
168±0.2
210±0.2
8 holes
3.2*
40±0.2
4 holes 7
5
168±0.2
210±0.5
235
* for 1..2 mm thickness of the panel, f3.7 mm if thickness is more than 2 mm
50
2
40
2 holes 7
10
Application Guide
Main terminals connection
19
Main terminals connection
Primary connections to the contactor shall be
made using unprepared copper* or aluminum
cables which types and sizes are shown below.
■
Third step cut seals at appropriate size
Crosssection
Conductor
sectional stranded core
mm2
AWG
70 240
00 500
sectional solid core
95 300
000 600
round stranded core
50 185
0 350
round solid core
70 240
00 500
■
Fourth step fit seal on cables
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
■
Fifth step fix cables with special key tightly
* Note: Cupper cables shall be tinned
■
Second step find cutting line of seal in accor
dance with the following table and outline
Cutting line
50
70
95
120
150
185
240
1
1
1
1
2
2
1
1
1
2
2
2
3
30
11
17
24
34
Line 3
Conductor of
1–phase cable
Line 2
Conductor of
3–phase cable
Line 1
Cable
crosssection,
mm2
Attention: The load shall be connected to termi
nals near surge arrester unit
■
Sixth step fit seals on the contactor
Application Guide
To provide connection with busbars or cables
with lags additional adapters shall be used.
Sequence of connection is shown below.
■
Main terminals connection
■
Fourth step fit seals on the contactor
■
Fifth step connect cables
20
First step cut seals at appropriate size
■
Second step fit seals over adapters
■
Third step fix cables with special key tightly
Attention: If prospective shortcircuit current of
the circuit exceeds of rated parameters of the con
tactor extra shortcircuit protective device (SCPD)
shall be connected seriously. SCPD shall provide
overcurrent discrimination between contactor and
shortcircuit currents.
Application Guide
Wiring and earthing
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 (0.51.5) mm2
singlecore or multicore wires. The insulation of
the wires shall be reared on 610 mm. Connection
is made with special screw that is included in
delivery set.
Terminal
1
2
3
4
5
Designation
“Control Input” (1)
“Control Input” (2)
Free
“Power Supply” (1)
“Power Supply” (2)
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.
Wiring and earthing
21
Application Guide
Wiring and earthing
22
Auxiliary contacts connection
Terminals of auxiliary contact units are not
numerated. The order of the terminal corre
sponds to the following figure.
Terminal
1
Designation
2
“Auxiliary contact (1)” (NO)
“Auxiliary contact (1)” (NO)
3
“Auxiliary contact (2)” (NC)
4
“Auxiliary contact (2)” (NC)
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.
Application Guide
Commission test
23
Commissioning test
Before beginning of application each contactor
shall be subjected to the following commission
ing tests:
Operation test
Action
Apply supply voltage to 4 and 5 terminals
Apply control voltage to 1 and 2 terminals
Switch off control voltage from 1 and 2 ter
minals
Apply control control voltage to 1 and 2 ter
minals
Switch off supply voltage from 4 and 5 ter
minals
Switch off control voltage from 1 and 2 ter
minals
High voltage test
Use standard method (IEC 94741) to check
insulation level.
Insulation resistance test
Use standard methods to check the insulation
resistance of the auxiliary insulation. It shall not
Expected reaction
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
contactor shall close
"Power" LED shall light
"Malfunction” LED shall not light
"Closed" LED shall light
contacts 3 and 4 of ACU shall open
contacts 1 and 2 of ACU shall close
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
contactor shall close
"Power" LED shall light
"Malfunction” LED shall not light
"Closed" LED shall light
contacts 3 and 4 of ACU shall open
contacts 1 and 2 of ACU shall close
contactor shall open
"Power" LED shall not light (in 5 seconds)
"Malfunction” LED shall not light
"Closed" LED shall not light
contacts 3 and 4 of ACU shall close
contacts 1 and 2 of ACU shall open
No reaction
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
Maintenance
Maintenance
24
Insulation resistance test
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).
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
Operation test
The contactor shall be operable as pointed in the
chapter above.
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:
___
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.
Ia<Ir
√
Rr ,
Ra
where:
Ia, Ra actual current and current resistance
respectively,
Rr rated contact resistance,
Ir rated current or conventional enclosed ther
mal current,
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
In any cases customer shall arrange activity in
accordance with Complaints handling procedure.
"Malfunction" LED mode
Recommended action
The contactor is not operatable,
"Power" LED indicator is not lighted
Unspecified
Check and correct power supply voltage
If the voltage is in rate replace control module
The contactor is in close position,
"Closed" LED indicator is not lighted
Unspecified
Replace contactor
Unspecified
Replace contactor
Unspecified
Replace ACU
The contactor is in open position,
"Closed" LED indicator lights
Nonconformity of auxiliary contact
Supply voltage is less than permissible limit
Other nonconformities of the module
1 Blink
Check and correct power supply voltage
4, 5 or 6 successive blinks
Replace the contactor
Failure of High voltage test
Unspecified
Replace the contactor
Failure of Insulation resistance test
Unspecified
Replace the contactor
Failure of Contact resistance test
Unspecified
Replace the contactor
Failure of surge arrester unit
Unspecified
Replace surge arrester unit
Application Guide
Failure analyses and handling
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.
■
■
■
■
25
Replacement of surge arresters unit
■
■
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/TEL01;
Install the cover.
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
Routine test Type test Disposal
26
Routine test
Each contactor before delivery shall be subjected
to the following routine test procedure.
Malfunction to meet any of the abovementioned
requirements means failure to pass routine test
procedure
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
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
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.
Standard
Type test features
IEC 9474190
TEL
GOST 3001196
TEL
IEC 9474190
NL
GOST 3001196
NL
IEC 9474190
NL
GOST 3001196
NL
IEC 9474190
NL
GOST 3001196
NL
IEC 9474190
NL
GOST 3001196
NL
IEC 9474190
NL
GOST 3001196
NL
Dielectric tests
Temperature rise tests
Making and breaking tests
Shorttime withstand current tests
Mechanical life tests
Measurement of resistance of the main circuit
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.
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