READ THIS MANUAL carefully for important information about safety, handling, and
maintenance, for general-purpose NEMA Class E magnetic controllers.
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.
DIMENSIONS shown in the manual are in metric and/or their English equivalent.
These instructions are not intended to cover all details, combinations, or variations
of the equipment, storage, or installation.
PROBLEMS OR QUESTIONS should be addressed to:
Field Service Department
Toshiba International Corporation
13131 West Little York Road
Houston, Texas 77041 USA
Telephone: (713) 466-0277
(800) 231-1412
(800) 527-1204 (Canada)
FAX: (713) 466-8773
Use only Toshiba-authorized replacement parts.
This equipment is designed and built in accordance with
applicable safety standards in effect on the date of
manufacture. Unauthorized modifications can result in
severe injury, death and property damage. Do not make
any modifications to this equipment without the written
approval of Toshiba.
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) Carefully read the entire instruction manual.
2) Be skilled in the installation, construction or operation of the
equipment and aware of the hazards involved.
3) Be trained and authorized to safely energize, de-energize, clear,
ground, lockout and tag circuits in accordance with established safety
practice.
4) Be trained and authorized to perform the service, maintenance or
repair of this equipment.
5) 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 medium voltage controllers are general purpose, Class E, magnetic
controllers designed and built in accordance with the latest applicable
provisions of NEMA ICS 3 Part 2, UL 347 and the National Electrical Code.
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.
Please read this manual and all accompanying documentation in its entirety prior to installation and
operation. These instructions are not intended to cover all details, combinations or variations of the
equipment, storage or installation.
Toshiba medium voltage open vacuum type magnetic motor controllers are UL recognized and built in
accordance with the latest applicable provisions of NEMA ICS 3 Part 2, UL 347 and the National Electrical
Code.
There is a hazard of shock or
burn whenever working on or near
electrical equipment.
ALL POWER supplying the
equipment should be turned off
before starting work, and
disconnecting means should be
locked out and/or tagged out in
accordance with NFPA 70 E, Part II
and ANSI Z244.1.
Where it is not feasible to de-energize the unit, the following precautions should be taken;
A. Persons working near exposed parts that are or may be energized should be instructed to
and should use practices (including appropriate apparel, equipment and tools) in
accordance with NFPA 70 E, Part II.
B. Persons working on exposed parts that are or may be energized should, in addition to A, be
qualified persons who have been trained to work on energized equipment.
RECOMMENDED PROCEDURE
The successful and safe operation of medium voltage control equipment is dependent upon handling,
installation, operation and maintenance by qualified personnel. Failure to follow fundamental installation and
maintenance recommendations could lead to personal injury and damage to the equipment and other
property. When referred to in this manual and on product labels, a qualified person is one who is familiar
with installation, construction or operation of the equipment and the hazards involved. In addition, this
person should have the following qualifications;
1) Is trained and authorized to energize, de-energize, clear, ground and tag circuits in
accordance with established safety practices.
2) Is trained in the proper care and use of protective equipment such as rubber gloves, hard
hat, safety glasses or face shields, flash clothing, etc. in accordance with established
practices.
RECEIVING
Upon receipt of the equipment, make an immediate inspection for any damages which may have occurred
during shipment. When the contactor is received it should be unpacked sufficiently to inspect for concealed
damage and to determine that the shipment is complete and correct. If any damage is found it should be
noted prior to accepting the shipment if possible.
Check for things such as, damage to the container, water seepage or moisture on the contactor. Check the
nameplate to confirm that the ratings meet the intended application.
If any parts are damaged or missing, file a claim immediately with the carrier and notify the Toshiba sales
office. Try to give as much information as possible when filing a claim.
HANDLING & STORAGE
Vacuum contactors should be handled with care to avoid damage. Contactors should be kept in an upright
position and moved with suitable equipment.
If the contactor is to be stored over any length of time, the packing material should be restored for protection
during that period. Where conditions permit, the packing should be left intact until the contactor is ready for
installation. Store the contactor in a dry and dust free area. It should not be left outdoors or in adverse
conditions. If unprotected, corrosion, rust and insulation deterioration will occur.
The type HCV vacuum contactor is manufactured in accordance with IEC 60470 (1974), NEMA ICS 3 Part 2
(1993). The vacuum contactor should be used in the following conditions.
Table 1
Normal Service Conditions
- Altitude: Less than 2,000 m
(6600 ft)
Above 2,000 m consult factory
-Ambient temperature: -5°C min. to +40°C max.
Its average over a period of
24 hr does not exceed +35°C.
-Relative humidity: 45% min. to 85% max.
-Vibration: 20 Hz - 1G or less
-Shock 30G
-Weight 43 lbs.
Latched type 44 lbs.
If the contactor is to be used in conditions other than those specified above, please consult Toshiba
International Corporation.
Table 2
General Application and Load Data
System
Voltage
2.2-2.5kV
3.0-3.3kV
4.0-5.0kV
6.0-6.6kV
The above table is based on general load data and standard application. Lower limitations may apply on
specific applications (i.e. applications above 6600 feet elevations).
Location condition
The location where the contactor is to be installed should be free from dust, corrosive gas and moisture.
When it is to be used in a chemical plant or in outdoor applications, take necessary precautions against
corrosion, water seepage and condensation.
Rated Voltage 7200 Volts
Rated Current 400 Amps
Interrupting Capacity 7000A RMS Symmetrical @5000V Max.
4500A RMS Symmetrical @7200V Max.
Permissible Switching Frequency 1200/Hour
Mechanical Life 2,500,000 Operations
Electrical Life 250,000 Operations
Closing Time 75-100 ms
Opening Time * 20-30 ms
Arcing Time 10 ms or less
Pick-Up Voltage AC or DC 85% Rated (Hot) - 70% Rated (Cold)
Drop-Out Voltage AC or DC 50% Rated (Hot) - 40% Rated (cold)
Rated Control Voltage AC 115/120 or 230/240 V 50/60 Hz
Rated Control Voltage DC 120/125 or 240/250 V
Coil Circuit Inrush 670 VA AC (700 W DC)
Coil Circuit Holding 85 VA AC (85 W DC)
Auxiliary Contact Arrangement 3 N.O. - 3 N.C.
Auxiliary Contact Rating 10 A, 600 V (NEMA Class A600)
* - DC switching, opening terminals 3 & 4.
HCV-5HAL (Latched Type Only)
Permissible Switching Frequency 300/Hour
Mechanical Life 250,000 Operations
Tripping Voltage 40-60% Rating DC
Tripping Current 4.8 A DC Max
1) Verify that the voltage and current applied is within the specified ratings. (See application
table, page 5).
2) When the contactor is used with an induction heater facility, the switching life of the vacuum
interrupter is approximately 250,000 operations. The vacuum interrupter should be replaced
after 250,000 operations.
3) When the contactor is applied to a capacitor load, be sure to use a space heater to keep
the temperature above the dew point and prevent condensation. Be sure to use a heater
adequately sized for the compartment in which the contactor is installed. The contactor
should always be applied with a protective power fuse.
INSTALLATIONDuring installation, protect the contactor from dust and falling debris.
The following precautions should be taken,
1) The mounting surface should be horizontal (level: ±1 mm). If the mounting surface is not
level, adjust with spacers or shims.
2) The contactor base has four (4) mounting holes. Use M8 or 5/16 bolts to securely mount
the contactor.
3) In wiring the main circuit, wires should be gi ven sufficient length to be flexible for service.
The ground wires should be #10 AWG or larger.
4) Avoid touching the surface of the vacuum interrupter with soiled hands. You can damage
the silicon finish on the interrupter. If the interrupter becomes dirty, simply clean it with a
non-tracking cleaner such as rubbing alcohol.
CONTROLSThe drive unit for the closing coil assembly is installed in a cavity in the molded frame housing. The
closing circuit can be operated by applying either AC or DC to this drive unit. The optional latch trip
circuit uses DC as standard. When a latched contactor is operated using AC power, it is
recommended that a capacitor trip device be used.
The standard control voltage (factory preset) is 120V AC. To operate at other ratings see the
selection chart below.
Fig. 2 Control Voltage Selection for Closing Coils
The following is a list of the available trip coil voltages for a latched type contactor:
24 V DC 32 V DC 48 V DC
The following figures illustrate the vacuum contactor and its auxiliary circuits (control and
monitoring). Fig. 6 represents the standard operation circuit diagram of the normally
energized type and Fig. 7 (a & b) the latched type. Wiring should be implemented
100-125V AC/DC
200-250V AC/DC
Fig. 6 Standard Operation Circuit Diagram of Normally Energized Type.
After mounting and wiring of the vacuum contactor, make the following inspections.
1) Check for any loose connections.
2) Check for any wiring errors. Perform this test with only the control circuit energized.
Confirm that the operation is correct. For the latched type contactor, check that the latch
correctly engages and trips when the close/trip signals are applied. Also, manually trip the
contactor using the trip lever to verify proper operation. For latch kit adjustment and
maintenance please refer to manual no. 6F9G0132 - Installation Instructions of Latch Kits
for HCV-5HA.
Check the upper and lower flanges and interrupter shaft to see if they are
contaminated or corroded.
If contaminated...use a clean cloth
UPPER
FLANGE
and rubbing alcohol.
If corroded.........replace with a
new interrupter.
NOTE: Avoid touching the ceramic surface.
Skin oils may harm the silicon
varnish.
LOWER
FLANGE
SHAFT
Check the main contact wear in the
vacuum interrupter.
If the wear gauge can be inserted,
WEAR
GAUGE
then there is sufficient contact material
available for continued use.
If the gauge cannot be inserted, replace
2.7mm
MINIMUM
the interrupter.
NOTE: This check is made with the
INSULATING
FLANGE
contactor closed.
Check vacuum in the vacuum interrupter. Fig. 8 Vacuum Interrupter
Apply 10kVAC between the upper and lower terminals for one minute.
If there is no voltage breakdown, the vacuum interrupter is acceptable for continued use.
If there is voltage breakdown, replace with a new vacuum interrupter before continued
use.
NOTE: If there is a vacuum failure, it can be confirmed by pushing down on the insulating
flange below the vacuum interrupter. If the interrupter shaft can easily be moved, then the
interrupter has lost vacuum.
Ga p/ Wip e St andard Values (contactor in new condi tion)
Contac torContact GapW ipe (new)Allowable Wear
Normally
Energized Type
L atche d Type4.0-4.2mm>2.1mm1.6mm
* Chec k for l oos e mounting bolts. Tight en i f loose.
Torque M6 bo lt s to 48 in-lb.
* Check f or discoloration.
Ye llow (Gold) …… av ailable for cont inued us e.
Dark Brown or Black …… replace with new coil.
If the cl osing coil is ov er heating, contact Toshib a.
* Chec k that the holding la tch re liably engages.
N ote: To ma nuall y c lose th e latch, hold the centra l area of th e ro tating
* Check t he condition of the roller. It should be smooth.
* Lubr icat e the rotating par ts wi th a mo ly bden um dis ulfide
or gear lubric ant.
* Ve r i fy that the re is remainin g auxiliary shaft travel.
Ap prox imate ly 2.3 - 2.5mm .
* Chec k for bur nt or wo r n c ont ac ts.
4.0-4.2mm>2.3mm1. 8mm
shaf t w i t h a wren c h an d operate it .
Auxiliary
Switch
Replace if bur nt or w or n.
* Chec k if aux iliar y s witch i s mounted at an inc line or if
mounting plate is l oose. If inclined or loos e, correct it.
1) Remove the conductive nut from the vacuum interrupter
being replaced and attach it to the new vacuum
interrupter as shown in Fig. 10.
2) Put the conductive collar on the upper part of the
vacuum interrupter (stationary terminal) and assemble
the vacuum interrupter.
3) Hold the vacuum interrupter and fasten bolt "B" (torque
to 120kg-cm or 102in-lb).
CONDUCTIVE NUT
0.5-1.0mm
4) Push down the insulating flange and align the insulating
flange stud with the movable shaft of the vacuum
interrupter. Then, while turning the flange counterclockwise, insert it. (Install the insulating flange with only
3 to 4 turns, then stop).
Fig. 10
ADJUSTING THE MAIN CONTACT GAP OF THE VACUUM INTERRUPTER
1) With the control circuit energized, close the
vacuum contactor. Check that the armature is
attracted to the coil cores.
VACUUM
INTERRUPTER
WEAR
GAUGE
(SUPPLIED)
2) As shown in Fig. 11, turn the insulating flange until
the distance is 41.5mm or use the wear gauge
supplied.
3) With the adjustment made, hold the insulating
flange still with the hand and secure nut "A".
CONDUCTIVE
NUT
Note: -Arrange so that the movable conductor is
straight and flat.
41.5mm
-Check that the conductive nut does not rotate.
"A"
(M8 NUT)
4) Turn off the control circuit power supply.
INSULATING
FLANGE
5) Operate manually to confirm that the vacuum
interrupters close simultaneously.
6) Operate the contactor electrically and check that
Fig. 11 Adjusting the Main Contact Gap.
the main contact gap is 4mm +0.2mm. If
necessary, loosen nut “A” and turn the insulating
flange (clockwise or counterclockwise as
necessary) until the correct contact gap is
achieved. Then tighten nut “A”.
OPERATION CHECKIn a no-load condition, electrically operate the contactor through 20 operations to confirm normal
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
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.
the purchaser (1) promptly notifies the Company in
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