TAVRIDA ELECTRICI N D U S T R I A L G R O U P
L O W V O L T A G EV A C U U M C O N T A C T O R
In Effect Since 03.09.2007Version 06AXCA 670200.009
CONTENTS
2Contents
Presentation 3
Product range 4
Design 5
Overall design 5
Switching module 6
Control module 7
Auxiliary contact units 8
Surge arrester unit 8
Small wiring termination 8
Operation 9
Closing 9
Opening 10
Emergency trip 10
Technical specification 11
General 11
Rated operational power of AC motors (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 15
Dimensional drawings 16
Application guide
Selection 17
Incoming inspection 17
Mounting 18
Main terminals connection 19
Wiring and earthing 21
Commissioning test 23
Maintenance 24
Operation test 24
High voltage test 24
Insulation resistance test 24
Contact resistance test 24
Failure analyses and handling 24
Replacement of auxiliary contacts 25
Replacement of surge arresters unit 25
Replacement of control module 25
Routine test 26
Type test 26
Disposal 26
Technical Manual 3
Low voltage vacuum contactors (hereinafter contactor) are based on the latest switching andelectronic control technologies. The contactorcan be used as a core component of low voltageswitchgears and as a standalong unit. Switchingof heavyduty AC motors is main intent of thecontactor. Main distinctive of the contactors design isapplication of microprocessorbased incorporated control unit. Lightduty operation instructions are applied to corresponding input of thecontrol module. Separate supply input allowswithstanding deep voltage sags without dropout.This feature has particular importance whenmotors fed is made from transformers havingcomparable with the motor power.Contactor has three modifications.LSM/TEL14/400340 is applied at either of lowvoltage AC systems. LSM/TEL14/400341 and LSM/TEL14/400342 contactors are used for threephase, fourwires AC systems 120/208V and 230/400V correspondently. In these types of the contactors
Technical Manual 3Presentation
there is surge arrester unit. Surge arrester unitprovides effective motor protection againstswitching overvoltages. It raises service life ofthe interconnected electrical equipment.Contactor has specific main terminals in respectwith the similars contactors. Contactor allows tobe connected with cables without cable lags. Ifthe cables are provided with extra seals, degree ofprotection of the contactor is IP40. It providesprotection from insects and ingress of liquiddrops. However, contactor can be connected bybusbars and cables with lags through extraadapters. In this case contactor transforms toordinary contactor. However application of theseals provides abovementioned protection of thecontactor. Contactor has four interchangeable auxiliaryswitches which can be used for linking to signalling circuits.Application of advanced technologies providesreliable operation of the contactor during allservice life without extra maintenance andadjustments that lowers service costs.
Technical Manual
Presentation
Technical Manual 4Product range
Product range
Product type Part number Comment Manufacturer
Module LSM/TEL14/400340Contactor for up to 1000 V AC systems (witoutsurge arresters)
Module LSM/TEL14/400341Contactor for 120/208 V AC systems (withsurge arrester unit SAU/TEL230E)
Module LSM/TEL14/400342Contactor for 230/400 V AC systems (withsurge 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 AHE 296444.003 Special key
Accessory ITEA 674152.003 Screw driver
Component AAHE 735642.001 Seal MF TEL
Accessory SAU/TEL400E Surge arrester unit for LSM/TEL14/400342
Accessory SAU/TEL001E Case of surge arrester unit (without varistors)
Component AXCA 716212.001 Adapter MF TEL
Component AXCA 745422.017 Installation bar MF TEL
Overall design
Vacuum contactor consists from the followingmain parts: switching module, control module,surge arrester unit and two auxiliary contactsunits. Switching module, control module andsurge arrester unit are realized as polymericcovered modules. Auxiliary contacts units are madeas PCBbased modules. Surge arrester unit andauxiliary contacts units allow to be easilyreplaced without any tools.The contactor provides IP40 degree protection ifit is connected with up to 240 mm2 cables with
Design
Technical Manual 5Design
out cable lags. The cables are connected directlyto main circuit terminals with special wrench andare sealed with rubber seals. To connect cableswith lags it is necessary to use special adapters.If the adapters are used together with rubberseals degree protection is also provided at IP40level.Small wiring termination is provided with WAGOconnector that is placed under a cover. The contactor is earthed through "Earth" stud.
Control module
Cover
"Earth" stud
Seals
Surge arresters unit
Switching module
Main circuitterminals(load outputs)
Small wiringterminals
Auxiliary contacts unit
Main circuitterminals
(supply inputs)
Adapters Installation bar
Connection board
Switching module
Switching module consists of three vacuuminterrupters (VI), solenoid actuator, flexible connectors and rigid busbars with clamps. Vacuum interrupters are a peak of R&D achievements of Tavrida Electric. Despite small dimensions vacuum interrupters insure reliable switching of heavyduty circuits providing high interrupting life.
Vacuum interrupter
In contrast with majority of conventional contactors there is level motion between the actuator and vacuum interrupters. The actuator's
Technical Manual 6Design
armature is rigidly coupled to the frame whichoperates to VIs moving contacts by linear driveinsulators. This provides direct linear movementin both directions and avoids the use of rotatingshafts, bearings and bell cranks. As a result thecontactor is maintenance and trouble free duringall mechanical life. The actuator has two end positions: OPEN andCLOSED. In Open position the armature is forcedby opening spring to provide the gap betweenbase yoke and armature. To close the actuator itis necessary to inject the closing current into thecoil. In CLOSED position the gap between baseyoke and armature is miserable. Holding currentthat is injected into actuator's coil leads corresponding magnetic flux. The flux produces holding force between base yoke and armature andholds the magnetic system in close position.Tripping of the actuator is provided by holdingcurrent chopping. Position of the actuator isindicated with internal function auxiliary contact that is connected with control modulethrough intermediate printed circuit board.
Frame
Actuator coil
Flexible connector
Terminal
Armature
Contact pressure spring
Opening spring
Basechannel
Guade yoke
Drive insulator
Vacuum interrupter Busbar
Functionauxiliary contact
ClampBase yoke
Bracket
Control module
Microprocessorbased control module transfersexternal lowpowered control signal into internaloperation instruction which are applied to magnetic actuator coil. There are two inputs: "Powersupply" and "Control input". "Power supply"input is intended for charging of internal closingcapacitor bank and supplying of incorporatedsource of holding current. After initial powerapplication the contactor needs preparation timeto charge the capacitor bank. Control input isintended to accept external close instructions.Capacitor bank is charged into actuator's coiland it injects closing current that is independentfrom quality of power supply. After closing ofmagnetic actuator the control module generatesstabilized holding current into the coil. Thenclose instruction is finished the holding currentis chopped and the contactor is tripped. Betweensequences of CO operations the contactor needsa time for charging of capacitor bank. For indication of main contact's position.Control module has internal thermosensor. Thefirst function of the thermosensor is generation asignal when inside temperature of control module exceeds Overheating Indication Temperature.It can be caused by overloading of the contactoror exceeding of internal temperature intoswitchgear above level specified as maximumoperating temperature. The second function ofthe thermosensor is generation of internalEmergency Trip Instruction if the temperatureinside control module exceeds Emergency TripTemperature. In this case the contactor is tripped
Technical Manual 7Design
and corresponding indicator starts to blink.Control module has three LED indicators on thefront panel.Greencolor indicator "Power" is intended for signaling of applying of power supply on corresponding inputs and it signals about readiness of thecontactor for execution of closing instruction.Control module executes monitoring of internalauxiliary circuits and inside temperature of thecontactor. If some malfunction is occurred redcolor indicator "Malfunction" starts to blink successively with intervals. The number of blinks inseries corresponds to specific malfunction.Duration of single blink is 150 ms. Intervalbetween neighbour blinks is 450ms. Intervalbetween series of blinks is 1.5 ms.Redcolor indicator "Closed" reflects position ofthe contactor.Correspondence between modes of the contactorand indicators is shown in the following table.
Contactor's condition"Malfunction"
Continuous lost of "Power supply" No light
Preparation time for closing No light
Opened state No light
Closed state No light
Lost of "Power supply" and "Control input"1 blink in
series*Overheating Indication Temperature exceeds specifiedlevel
2 blinks inseries
Opened state after execution of Emergency TripInstruction
Nonconformity of the contactor
3 blinks inseries
4, 5 or 6 blinks in series
"Closed"
No light
No light
No light
Light
**
**
No light
**
* During not less than 30 sec.** Light if the contactor is closed; No Light if the contactor is opened.
"Power"
No light
Blinks
Light
Light
No light
Light
Blinks
Light
LED indication mode
Auxiliary contact units
Contactor is provided with two auxiliary contactunits (ACU). Each unit has one normally opened(NO) and one normally closed (NC) contacts. Thecontacts are controlled by frame of the actuatorThey are used for position indication of the contactor for external signalling circuits.
Technical Manual 8Design
Surge arrester unit
Contactors LSM/TEL14/400341 and LSM/TEL 14/400342 include SAU/TEL type surge arresterunits. The first contactor is supplied withSAU/TEL230 and the second one with SAU/TEL400. Each unit include three varistors that are Yconnected with earthed midpoint. Surge arresterunits are intended for protection of interconnected electrical equipment from overvoltagesthat can be occurred at switching operations ofthe contactor and other reasons. The units limitsthe surge voltage, so, service life of electricalequipment become higher if the units were notused. Contactor LSM/TEL14/400340 is provided withcase of surge arrester unit. There are no anyvaristors inside. So, this unit does not provideovervoltage protection of the equipment. In thiscase protection of equipment shall be arrangedwith extra protection elements.
Small wiring termination
Contactor has auxiliary inputs and outputs inaccordance with the diagram nearby.Outgoing arrows indicate outputs, incomingarrows indicate inputs.Potential zones corresponding to electrically isolated terminals are separated with lines.
Auxiliary Contact NC1
Auxiliary Contact NO2
Auxiliary Contact NC2
"Power Supply"
"Control Input"
"Earth"
Auxiliary Contact NO1
Operation
Closing
The initial position of the contactor is open.Vacuum interrupters are held in opened positionby opening springs which operate to their pullinginsulators through the frame. To launch the contactor into operation it is necessary to energizecorresponding WAGO terminals with "Power supply" rated voltage. Control module starts charging of internal closing capacitor bank. "Power"indicator stars to blink. If preparation time isover specified value the indicator lights thatmeans readiness of the contactor for closing.Contactor can be closed if the following conditions are met:
Contactor is open; Close capacitors are charged, LED indicator
Power lights continuously.To close the contactor, control voltage shall beapplied to Control Input. In a period longerthan Close instruction acceptance time, currentpulse from the closing capacitor bank is injectedinto the coil.The current in the coil produces a magnetic fluxin the gap between the base yoke and the armature.
1 2 2a 4 4 653 3aStateof main contacts
Actuator coilcurrent
Travel of armature
Speed of armature
Time
4b
Technical Manual 9Operation
Current increment increases the magnetic flux.Electromagnetic attraction between yokeand armature becomes more than restrainingforce of the opening springs (line 1).The armature, frame, drive insulator and movingcontacts start to move. As the armature movestowards the upper yoke the magnetic air gapdecreases and consequently the magnetic attraction force increases. This increasing force accelerates the armature, drive insulator and movingcontact. Acceleration of the armature generatesback emf in the coil that reduces the coil current(Line 12).At contact close (line 2) the moving contactsstops but the armature travel continues for 1 mmunder rapid deceleration caused by compressingthe contact pressure spring.At the limit of its travel the armature latchesmagnetically to the base yoke (Line 2a). Thetravel of the armature also compresses the opening spring in preparation for the next openingoperation and operates the auxiliary contacts.The moving armature collapses and the coil current again increases (lines 2a3).When closing impulse duration is expired controlmodule decreases the closing current (line 3) upto holding current (lines 3a4). The contactorstays in closed position for unlimited period oftime even if mechanical vibration conditions andvoltage drops are occurred
Technical Manual 10Operation
Opening
To open the contactor, Control Input shall bedeenergized. In a period of time longer thanTrip instruction acceptance time, instruction isaccepted and holding current is cut off (line 44b).Magnetic flux and correspondantly holding forceof the armature decrease and when sum ofcharged opening and the contact pressure springforces become more then holding force the armature is released and accelerated rapidly (line 4a).After free travel it engages with drive insulatorsand VIs contact are opened.The peak force produced by the armature ensureseasy breaking of any microwelds at the contactsurfaces which can appear due to short circuitcurrent action.The moving contact accelerates rapidly, ensuringa high interrupting capacity. Main contactsreturn to their initial position (line 5).If the contactor breakes loaded circuit the interrupting current initiates a socalled vacuumarc that burns essentially in plasma originating
from evaporated contact material. The currentcontinues to flow through this plasma until a current zero. At this moment the arc is extinguishedand transient recovery voltage appears across theopen gap. If the contact surface is locally overheated it produces a lot of vapour, resulting indeterioration of the vacuum followed by electrical breakdown. To avoid this, optimum combination of contact material and electrode shape isapplied resulting in development the smallestvacuum interrupter ever existed.At full travel (line 6) the armature, drive insulator and moving contact assembly is again heldopen by the opening spring force.Contactor is also opened at the same way ifPower Supply is lost in approximately 1 secondeven if Control Input is energized. In this case, to close contactor it is necessary todeenergize Control Input, to apply PowerSupply, to energize Control Input whenPower indicator is lit.
Emergency trip
If inside temperature of the control moduleexceeds level of Emergency trip temperature thecontactor trips itself even if "Control Input" voltage is applied. To close the contactor it is necessary to remove closing instruction and apply it
once more after than the temperature downs lessthan Overheating indication temperature andelimination of overheating reason.
Technical specification
General
Technical Manual 11Technical specification
Rated voltage, VLSM/TEL14/400340 1000LSM/TEL14/400341 230LSM/TEL14/400342 400
Rated frequency, Hz 50, 60Conventional thermal curent, A 400Rated breaking capacity, kA 4Rated making capacity, kA 4Rated over current capacity, 10s, kA 3.2Mechanical life, CO operations 2 000 000Operational frequency, CO operations per hour
mechanical 600 AC1 600 AC3 500 AC4 300
Switching capacity, CO operations at rated current 2 000 000 at breaking current 50 at other currents see diagram
Closing time, ms, not more than 50Drop out time, ms, not more than 60Opening time, ms, not more than 80
* According IEC 60068188 (C Damp heat (steady state); D Damp heat (cyclic).** IP00 at flat strip conductor or busbar connection.*** According IEC 6072134.
Applicable standards:IEC 9474190
Overheating Indication Temperature, C 703Emergency Trip Temperature, C 803Main contact resistance, microOhm 90Current heat loss, at 400A, w 50Ambient air temperature
enclosed, C 40...+40 open, C 40...+55
storage, C 40...+60Climatic proofing C, D*Maximum altitude above sea level, m 2000Degree of protection IP40 (IP00)**Mechanical vibration withstand capacity Class 3M4 (IEC 72134)***
stationary vibration, sinusoidal, g 1 nonstationary vibration, shock, g 10
Weight, kg, not more than 10,0
Technical Manual 12Technical specification
10000
4000
1000
100
10
10 100 1000 10000 100000 10000001
Curr
ent,
Interrupting life, operations
Rated operational power of AC motors (AC3 and AC4)
Rated voltage, VRated operational power, kW
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
Switching capacity
660 340
690 360
1000 500
Auxiliary circuits
Power supply
Technical Manual 13Technical specification
Power supply rated voltage, V AC 220Operating range, V AC 187242Power consumption, VA, not more than
during preparation time (charging of closingcapacitor)
35
in opened position 8 in closed position 15
Preparation time, s, not more than after initial power application 10 after previous open operation 5.5
Control Input
Control input rated voltage, V AC 220
Operating range, V AC, 44242
Minimum accepted level of close instruction,V AC, not less than
132
Minimum holding level of close instruction,V AC, not less than
88
Maximum accepted level of trip instruction,V AC, not more than
44
"Close" instruction acceptance time, ms, notmore than
30
Auxiliary contact units
Maximum operating voltage, V (AC&DC) 400Rated voltage, V (AC&DC) 250Breaking capacity (AC, cos=0.8), VA 750Maximum carrying current, A 10Minimum switching current, A (AC&DC) 0.1Dielectric strength, VDC 750Interrupting life at maximum breaking current, CO cycles
50 000
Mechanical life, CO cycles 1 000 000
Maximum withstand voltage, V, peak 420
"Trip" instruction acceptance time, ms, notmore than
30
Surge arresters
Technical Manual 14Technical specification
Type Rated Voltage , V ACSurge Current, A
(8/20 m s)Energy Absorption, J
(2 ms)Average PowerDissipation, W
SAU230 220, 230, 240 8000 100 1,0SAU400 380, 400, 415 8000 135 1,0
2000
1000
01E3 0,01 0,1 1 10 100
SAU400
SAU230
Volt
age,
V
Current, A
Impulse duration, m s
Max
imum
sur
ge c
urre
nt, A
Derating curves of different SAU are shownbelow.
Voltagecurrent characteristics of different SAUare shown below
Electromagnetic Compatibility (EMC)
Technical Manual 15Technical specification
Dielectrical Strength
Power frequency voltage between main contacts 3,5 kV between main contacts and auxiliary circuits 3,5 kV between auxiliary circuits 2,0 kV
Lighting impulse 1,2 m s/50 ms/0,5 J between main contacts 8,0 kV between main contacts and auxiliary circuits 8,0 kV between auxiliary circuits and Earth 4,0 kV
Insulation resistance between isolatedpotentional zones at 500 VDC, not less than
5,0 MOhm
between isolated auxiliary circuits 4,0 kV between NO and NC of ACU 4,0 kV
ParameterImmunity criteriain accordance with
IEC 6094741
Electrical fast transient/burst immunity in accordancewith IEC 6100044:
for "Power supply A
"for "Control input" A
Characterizations
Surge immunity in accordance with IEC 6100045BB
Power frequency magnetic field immunity in accordancewith IEC 6100048
AA
Pulse magnetic field immunity in accordance with IEC6100049
A
Damped oscillatory magnetic field immunity in accordancewith IEC 61000410
A
common 4 kVdifferential 2 kV
100 A/m1000 A/m
1000 A/m
0,1 and 1 MHz 100 A/m
Level
4
4
43
5
5
5
Voltage dips, short interruptions and voltage variationsimmunity in accordance with IEC 61000411
5 A
Oscillatory waves immunity in accordance with IEC 61000412 taking into account IEC 255221
31 MHz, 0,1 MHz
2 kVA
Electrostatic discharge immunity inaccordance with IEC6100042
3 A
Dimensional drawings
Technical Manual 16Dimensional drawings
Application Guide 17Selection Incoming inspection
Application guide
Selection
Selection of the contactor is made in accordancewith following table:
Type AC System Rated voltage, V AC
LSM/TEL14/400340Threephase, threewire or
fourwire systemsup to 1000
LSM/TEL14/400341Threephase,
fourwire systems220, 230, 240
LSM/TEL14/400342Threephase,
fourwire systems380, 400, 415
Incoming inspection
Each contactor before installation shall be subjected under physical control. Inspection shall be made in accordance with thetable below.If contactors appearance has any nonconformi
tyes customer has to made a decision in respectwith application of the contactor.In any cases customer shall arrange activity inaccordance with Complaints handling procedure.
Conformity criteriaInspection
Absence of severe damages resulted from: product drops excessive moistening of package package deformation caused by external impacts excessive external load applied to package Compliance of box label to order dataAbsence of undamaged seals
Packaging
Absence of undamaged seals
Absence of mechanical damages, scratches and colored spots
Sealing
Plastic parts
Absence of mechanical damages, scratches and corrosion on paintedsurfaces and galvanized terminals.
Metal parts
Mounting
The contactor can be installed directly on lowvoltage switchgear's panel or through extrainstallation bars AXCA745422.017 The last way isused if there is no access from the back side oflow voltage switchgear panel.
Application Guide 18Mounting
Each contactor is provided with paper templateto make marking on switchgear's panel. Mounting holes, required fasteners and torquesare shown below.
4 holes 7
8 holes 3.2
1680.2
2100.2
155
0.2
115
0.2
400
.2
155
0.2
*
4 Screws M6204 Spring Washers4 WashersTorque 10 N.m
1...4
8 Screws 4,28 Washers
1680.2
2100.5
235
2 holes 7 5
40
2
10
50
* for 1..2 mm thickness of the panel, f3.7 mm if thickness is more than 2 mm
Application Guide 19Main terminals connection
Primary connections to the contactor shall bemade using unprepared copper* or aluminumcables which types and sizes are shown below.
34
30
24
17
Line
1
Line
2
Line
3
11
Cablecrosssection,
mm2
507095
120150185240
Cutting line
Conductor of3phase cable
111122
Conductor of1phase cable
1112223
Main terminals connection
Third step cut seals at appropriate size
Fourth step fit seal on cables
Fifth step fix cables with special key tightly
Attention: The load shall be connected to terminals near surge arrester unit
Sixth step fit seals on the contactor
Conductor
sectional stranded core
sectional solid core
round stranded core
round solid core
Crosssection
mm2
70 240
95 300
50 185
70 240
AWG
00 500
000 600
0 350
00 500
Connecting cables shall be inserted through rubber seals as the figure below. The seals shall becut in accordance with the diameter of cable inaccordance with the table below.
First step cut cable isolation at 30 mm length
* Note: Cupper cables shall be tinned
Second step find cutting line of seal in accordance with the following table and outline
Application Guide 20Main terminals connection
To provide connection with busbars or cableswith lags additional adapters shall be used.Sequence of connection is shown below.
First step cut seals at appropriate size
Second step fit seals over adapters
Third step fix cables with special key tightly
Fourth step fit seals on the contactor
Fifth step connect cables
Attention: If prospective shortcircuit current ofthe circuit exceeds of rated parameters of the contactor extra shortcircuit protective device (SCPD)shall be connected seriously. SCPD shall provideovercurrent discrimination between contactor andshortcircuit currents.
Application Guide 21Wiring and earthing
Terminal Designation
1 Control Input (1)2 Control Input (2)3 Free4 Power Supply (1)5 Power Supply (2)
Wiring and earthing
The contactor shall be earthed through M5 stud.The "Earth" stud shall be connected with not lessthan 2.5 mm2 wire that is tagged with 5 mm diameter lag.
To connect "Power Supply", "Control Input", auxiliary contacts and "Earth" circuits push theclamp of the cover and move it towards thearrow. Connection is made through WAGO connectors"Power Supply" and "Control Input" terminals.The circuits are connected with (0.51.5) mm2
singlecore or multicore wires. The insulation ofthe wires shall be reared on 610 mm. Connectionis made with special screw that is included indelivery set.
Application Guide 22Wiring and earthing
DesignationTerminal
Auxiliary contact (1) (NO)1Auxiliary contact (1) (NO)
Auxiliary contact (2) (NC)
2
3
Auxiliary contact (2) (NC)4
Wires of auxiliary contacts with Power supply,Control input and Earth wires are placedtogether and are fixed by strips. The cover hasfour 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 roundfile. To place the cover it is necessary to alignjoggles on the cover and corresponding holes inthe switching module and to clamp the cover.
Auxiliary contacts connection
Terminals of auxiliary contact units are notnumerated. The order of the terminal corresponds to the following figure.
Commissioning test
Before beginning of application each contactorshall be subjected to the following commissioning tests:
Operation test
Application Guide 23Commission test
Action Expected reaction
Apply supply voltage to 4 and 5 terminals
contactor shall open "Power" LED shall light "Malfunction LED shall not light "Closed LED shall not light contacts 3 and 4 of ACU shall close contacts 1 and 2 of ACU shall open
Apply control voltage to 1 and 2 terminals
contactor shall close "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
Switch off control voltage from 1 and 2 terminals
contactor shall open "Power" LED shall light "Malfunction LED shall not light "Closed" LED shall not light contacts 3 and 4 of ACU shall close contacts 1 and 2 of ACU shall open
Apply control control voltage to 1 and 2 terminals
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
Switch off supply voltage from 4 and 5 terminals
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
Switch off control voltage from 1 and 2 terminals
No reaction
High voltage test
Use standard method (IEC 94741) to checkinsulation level.
Insulation resistance test
Use standard methods to check the insulationresistance of the auxiliary insulation. It shall not
be below the limits given in the contactor technical specification.
Main contact resistance test
Use standard methods to check resistance of themain contacts of the contactor. Values must notexceed limits specified in the contactor technicalspecification.
Application Guide 24Maintenance
Maintenance
The contactor is inherently maintenance free.However, if customer has periodical test procedure the contactor can be subjected under following commissioning tests. If some nonconformity is found the contactor shall be handled asdescribed in subsection Failure analisys and handling (see below).
Operation test
The contactor shall be operable as pointed in thechapter above.
High voltage test
Dielectric strength of vacuum interrupters andsupport insulation in respect to power frequencywithstandability shall not deteriorate in service.During the test, apply voltages as pointed in subsection Dielectrical strength. However, impulsewithstandability of vacuum interrupters candecrease in service. So, producer specifies lightimpulse withstandability on 5 kV level for interrupters. Impulse withstandability of supportinsulation shall be the same as for a new contactor.
Insulation resistance test
The insulation resistance shall comply with valuethat is pointed in subsection Dielectrical strength.In the case of noncompliance tryto find the weak point. Note that, generally,other devices can be installed in parallel to thecontactor.
Contact resistance test
If contactor has contact resistance whichexceeds the specified limit but it is less thantwice this limit, continuation of use is possible, ifthe actual continuous current does not exceedthe following value:
where:Ia, Ra actual current and current resistancerespectively,Rr rated contact resistance,Ir rated current or conventional enclosed thermal current,
Ia
Replacement of auxiliary contacts
The auxiliary contacts units are maintenancefree. However, if damage of auxiliary contactoccurs under any circumstances the unit can bereplace as follows.
ATTENTION: Contactor shall be open beforereplacement of auxiliary switches.
Take off the cover; Press to auxiliary contact blocks slot and draw
out the block; Insert a new ACU/TEL01; Install the cover.
Application Guide 25Failure analyses and handling
Replacement of surge arresters unit
Order of SAU/TEL replacement is as follows. Press upwards to surge arresters units 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 modules replacement is as follows: Take off the cover Remove surge arrester unit Screw off four captive screws at connectionboard Disconnect connection board Disconnect earthing wire from the controlmodule
Screw off four captive screws at control module
Remove the failed module Install new control module in inverse sequence Perform operation test
Application Guide 26Routine test Type test Disposal
Type tests
Type tests shall be arranged in accordance withthe following table.Where:NL no limitations: supervisory from test lab isnot required
Type test Type test features
Dielectric testsTEL
Temperature rise testsNL
Making and breaking testsNL
Shorttime withstand current testsNL
Mechanical life testsNL
Measurement of resistance of the main circuitNL
Standard
IEC 9474190
IEC 9474190
IEC 9474190
IEC 9474190
IEC 9474190
IEC 9474190
TELGOST 3001196
NLGOST 3001196
NLGOST 3001196
NLGOST 3001196
NLGOST 3001196
NLGOST 3001196
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 circuits (between open contacts)
absence of breakdowns inside vacuum interrupter
Power frequency voltage withstand of the auxiliarycircuits (between terminals and earth)
absence of breakdowns
Routine test
Each contactor before delivery shall be subjectedto the following routine test procedure.Malfunction to meet any of the abovementioned
requirements means failure to pass routine testprocedure
TEL supervisory from TEL is required. It includesapproval of the test program, order and preparation of test samples and possible participation attests with test lab of Tavrida Electric.
Disposal
Modules do not contain any materials that arehazardous for environment or personnel. No special methods of disposal are required.
Attention:
Only electronic version of this document distributed through designated channels to designated users canbe considered valid.
List of changes
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