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Medium Voltage Distribution

CLX3
Vacuum Contactors
Equiped with an electronic module

Installation, Operation & General Maintenance
Technical Manual

CLX

• Any operator must read and respect in all case this technical manual.
• Installation, comissionning and maintenance should only be conducted by qualified people.
• Before installation, check that data in rating label match with the application.
• Accidental contact with energized components or wiring can cause shock, burn or electrocution :
turn off power supplying this equipment and control voltage sources before any work on contactor.

NTV121 - 1E 2

...........................................2 Latch-in Device and Setting ........................................................................................................................ OPERATION & GENERAL INFORMATION ........ LATCH-IN DEVICE..................4 Pre-commissioning tests .......................................................12 3...............................15 4.....................................................1...............................................................22 9................17 5.............3 In the event of a malfunction of the latch .............................................3 Contactor closes but motor will not run ....16 4....5 Routine Site Voltage Test............................................................................................................................4 1....................................................2 Description & Operation .........13 3...............................20 7..12 3..................................................................2 Contactor closes and immediately re-opens ...................................................................19 6....................................................................................................................................................................................................................................................................... ANNEX ...................................................... No overtravel........................................1 Maintenance of Latch-in Mechanism.........................................................................4 1...........5 2........19 7...........................................................................................................................................23 NTV121 ................................................................12 3............18 6................4 Apparatus/Task/Skill Level Schedule for Working on the Apparatus ................................................................................................................................1 Maintenance...................................................................................................................................................................e.............................1 General Information ..................................................................................................10 3...........................................................................................................14 4...... FAULT FINDING ....................................20 7..................................6 2.....................................................................................17 5.........................................................................................................................................................................................3 Electronic card .....................................................................................................................................3 Installation .............................................................4 1.............................................................................4 Contactor closes .................................................................................................................................................................... General Information ......4 1.............................................15 4................................................................................................................................................. INSTALLATION & PRE-COMMISSIONING TESTS ..........................CLX CONTENTS 1.....21 8..13 3............................................................................................................................................. SAFETY INSTRUCTIONS................ SPARE PARTS LIST.............................6 2.....................1E 3 ...................................3 Vacuum Switch Contact Wear Check ..............................................................................................19 6................2 Critical Items During Unpacking and Installation............................................................................................................................................................................................................................................................................................................................................................................................19 6...........................................2 Mechanical & Electrical Life ...............................7 2...16 5 Auxiliary Switches ...................................................................................................................................................1 Compliance with Instructions in this Manual .............................................1 Contactor will not close at all..........15 4................................20 7........................3 Auxiliary Switch Maintenance..........................................................2 Auxiliary Contact Blocks..............17 5...........but stops at “tips touch” i.......................................................................... MAINTENANCE ........................3 Operation & Maintenance...........................................4 Wiring Diagrams ............................................2 Installation ............................................................................................................................................................1 Unpacking .............19 6.........................................................

before opening enclosures and prove it to be dead before starting work.g. when energised.1E 4 .3. ■ During Maintenance. back feed.1 Guidance Notes for Users on the Safety of Personnel The rules for ensuring the safety of personnel can be summarised as follows: ■ During Normal Use ensure that the plant operators:  are fully conversant with all controls.  functionally check the apparatus and then mechanically and/or electrically test it in accordance with this manual and good working practice before putting the apparatus back in service. Precautions must be taken to ensure that the isolated apparatus cannot become live whilst any work is being carried out.  comply with safety warning notices and keep all enclosures shut  are trained to recognise signs of maloperation and know what action to take in the event of trouble or difficulty.  are conversant with the information provided.4] enables the user to select personnel to carry out specific tasks requiring access to the apparatus. the Purchaser/User should ensure that the apparatus is maintained in a safe condition.  are fully conversant with the apparatus and the system of which it is part. 1.  take account of the possibility that the apparatus may have been modified without proper reference to the manufacturer and take extreme caution at all times before. Testing etc. and recognise the safety hazards which could arise. The Purchaser/User should ensure that such apparatus is installed in a secure location and that adequate safety information is provided to all personnel to be associated with it. Reference to the Apparatus/Task/Skill level schedule [1. during and after and work is carried out. everyone under whose authority these persons act should ensure that appropriate safety procedures are generated and complied with.  comply with safe working procedures for the safety of themselves and others.3. ensure that only technically competent and authorised persons are permitted to carry out work and that they:  comply with statutory requirements. However.  isolate the apparatus completely. e. 1.1 Compliance with Instructions in this Manual The Purchaser/User should comply with the instructions and information given in this document and ensure that all personnel to be associated with the apparatus supplied under this contract are made familiar with the information contained herein. NTV121 . The apparatus covered in this manual has been allocated the Apparatus Grade stated above. Apparatus supplied as loose components. constitute a safety hazard. particularly those for emergency shutdown. ■ information is provided in this manual about the conditions necessary for safety and about any hazards which are reasonably foreseeable during normal use. including the use of temporary barriers and warning notices. devices or sub-assemblies could. where possible.2 Skills Required for Specific Tasks To ensure that the apparatus is safe for use under normal healthy plant operating conditions: ■ it has been designed and tested in accordance with relevant European and International standards. Safety Instructions 1. particularly on matters relating to safety. and if technically competent and authorised personnel have to gain access to apparatus which is not made completely safe as recommended.CLX 1.2 Installation The Purchaser/User should ensure that the apparatus supplied is correctly installed in a suitable location by technically qualified and competent persons. If there is any doubt as to the correct and safe method of working then further assistance should be sought from Schneider Electric 1. together with precautions to be taken to counteract them.  recognise the hazards which can arise when working on live apparatus and take all the necessary precautions.3 Operation & Maintenance 1.

. Commissioning Engineer) with a HIGH degree of electrical expertise. trained to work on live apparatus and fully conversant with the apparatus and the system of which it is part. Electrician.g.1E 5 . The skill level required to work on this equipment can be best described as the following : Authorised and competent staff (e.2]. for which the purchaser/user is responsible for assembly etc.CLX 1. If additional information relating to the apparatus is required please contact : Schneider Electric NTV121 . [1. sub-assemblies etc.4 Apparatus/Task/Skill Level Schedule for Working on the Apparatus The apparatus can be supplied as loose items.

Operation & General Information 2. Each phase has a separate Vacuum Switch which switches at the first available current zero.1. used primarily in motor starting/reversing and capacitor bank switching applications. 2.1E 6 .1 General Information This vacuum contactor was manufactured by: Schneider Electric A contactor is primarily a three phase switching device.1 Contactor Front View main terminals main terminals main moulding moulded terminal bar flexible connection Vacuum switches isolating rod rating label Auxiliary switches Electronic card NTV121 .CLX 2.

1. sheet steel side mounting plates.1E 7 . electronic card and auxiliary contacts. closing coils.1 & 2. three vacuum switches.2]. contact spring seating colar Electronic card Opening spring Closing coil NTV121 .1. a steel L-shaped armature.1. The contactor comprises a main frame moulding.CLX 2.2 Contactor rear view 4x M10 fixing holes pivot point L shaped armature 4x M10 fixing holes 2. opening spring.2 Description & Operation As shown in [2.

2. The vacuum switches provide a sealed gas-free environment making the switching operation unaffected by external conditions. On initially energising the closing coils a high current flows through the coils. 2.2. 2. The vacuum switches will remain closed as long as the closing coils are energised. 1°) Removed M10 bolts as show in 2. The energy required to close the contactor is considerably more than the energy required to maintain a closed position.2. Once the vacuum switch contacts have separated arcing occurs until the first available current zero.5. Contactors are supplied fitted with closing coils and electronic card suitable for d.1E 8 . supply voltages.1 Closing Coils Un-energised In this condition the opening springs acting against the centre limb of the armature moulding hold the vacuum switches in the normally open position (main circuit off). provides kinetic energy to break minor contact welds which may occur under severe operating duty. allowing the vacuum switches to close under the effect of atmospheric pressure which acts on the bellows inside the vacuum switches (main circuit on).5.c.2.c. at which time the current is commutated.4 Auxiliary Contacts One auxiliary contact blocks is provided giving a maximum of 10 (ten) contacts available for customer use (5NO+5NC).2. The closing coil rating enables satisfactory operation of the contactor in cubicles with internal temperatures of up to 65°C. The armature movement is transmitted through the pivot points. 2.1 (it is not allowed to reused the spring lock washer).1 Remove M10 bolts before cable connection NTV121 . 2.CLX 2.2.5 Main Terminals The main terminals consist of M10 bolts for attachment of cables or busbars. After a short delay the electronic card automatically reduces the current in the closing coils which allows their continuous operation without over heating.3]. on opening. 2. 2°) Fixed cable on main terminal as show in 2. or a.2. The armature moulding moves further than necessary for switch closure providing overtravel which accommodates contact wear and.2 For advice on cable/busbar connection see [3.3 Closing Coils De-energised When the closing coils are de-energised the opening springs will act on the armature moulding causing the vacuum switches to open.2 Closing Coils Energised Energising the closing coils through the electronic card attracts the armature which compresses the opening spring. For use in temperatures higher than this.2. contact Schneider Electric.5.

2.CLX 2. NTV121 . bars or crimps is 40 mm.1E 9 .5.m) 2 Spring lock washer 3 Plain washer 4 Cable connection or busbar 5 Plain washer 6 Nut 7 M10 Bolt (Torque 20 N.m) 8 Spring lock washer 9 Plain washer 10 Cable connection or busbar L1 = E1 + 20 mm L2 = E2 + 20 mm The width maximum of the lead terminal connexions.2 Cable fixation 01 02 L1 03 04 E1 05 06 07 08 L2 09 E2 10 1 M10 Bolt (Torque 40 N.

It is also possible to connect in option an operations counter to the card.3 Electronic card The closing coils are energised through an electronic card which automatically reduce the current when the contactor is closed. Configurable pin for opening delay of 100 ms Power supply connector NTV121 . We have two types of cards depending on the voltage supply. This opening delay can be used for the coordination with fuses.CLX 2. The electronic card accepts any control voltage in the range:  24 to 60 Vdc  110 to 240 Vac or 110 to 250 Vdc The card is configurable on demand by Schneider Electric in order to introduce an additional opening time delay of 100 ms by means of the ST3 jumper (see pictures above).1E 10 .

1E 11 .CLX No additional time delay time delay 100 ms NTV121 .

2. 3. When supplied as separate units. The carriers and suppliers should be notified of the breakages within three days of delivery.3 Everything surrounding the contactor (i.2. examine the contactor and packing material for broken or missing parts. frames. deform or restrict movement of the contactor. Nothing should be allowed to rest on top of the armature moulding or interfere with the normal operation of the moving parts of the contactor.2 Take care when fitting cables or busbars to the main terminals that the terminations do not damage. components. After removing the packing material. 3. enclosures. 3. Particular care should be taken when two or more cable terminations are fitted onto a single terminal.2 Critical Items During Unpacking and Installation 3.2. power and control cables) must be clear of the paths of the moving parts of the contactor. or mounted with other equipment. NTV121 .CLX 3. isolating rod or moulded terminal bar shown in positions below marked X. The particulars on the rating plate of the equipment must be quoted in all correspondence.1 Unpacking Contactors may be supplied as separate units.1E 12 . care must be taken during unpacking.e. Installation & Pre-commissioning Tests 3.1 Do not attempt to lift the contactor by means of auxiliary contact blocks.

if components are added..3kV and 64mm for 6.4. particularly around the coils and economy resistor. checks must be made to ensure that they do not have any adverse effect on the operation of the contactor. However. 3. 3. but before applying full control voltage and power.4 Pre-commissioning tests It is good practice to subject vacuum switches or contactors to pre-commissioning tests.2. NTV121 . swarf or other material in the gaps between closing coil pole pieces and the armature plate 3.2.1E 13 .5 3.1 Check for the presence of loose screws. including cables or busbars. rectifiers. General Arrangement of Contactor 412 338 218 210 398 155 76 334 24. etc. In all cases it is important to ensure that the contactor is fixed to co-planar flat surfaces to avoid distortion of the contactor which could upset vacuum switch settings or magnet bedding etc . When installing and cabling.2 Check contactor operation at 85% of the control voltage after installation. ensure that an air gap of at least 51mm for 3. indicators. is maintained between live main circuit contactor parts and earth control circuits.CLX 3.g.4 Ensure that nothing interferes with adequate air flow over the contactor.3 Installation It is recommended that the contactor be mounted with the axes of the vacuum switches vertical and with their fixed contacts at the top.5 It is not recommend that additional components are added to the contactor e. Alternatively fixing holes are available in the vertical rear flanges of the side frames.6kV.4. The maximum torque applicable for these terminals is 40 Nm and must not be exceeded. Four M10 fixing holes are in the mounting feet formed by the bottom turned-out edges of the sheet steel side frames. 3.

Contactor Type Vacuum Switch Nominal System A. 3.C. If any doubt exists about the vacuum switch dielectric to pass the routine site test procedure given above.g. on which the voltage is continuously variable from zero up to the maximum required for that particular switch.C. on the outside of the vacuum switch envelope. Test Voltage D. current monitoring facilities are not usually available and in any event the leakage currents can be misleading due to the presence of currents associated with the vacuum switch capacitance.1E 14 . before rejecting any vacuum switch which is apparently outside the limit. 3. When carrying out a.4.5 Routine Site Voltage Test The following test should be carried out by using an a. [3. However emission of X radiation is negligible at the specified test voltages. high voltage tests. an additional criterion can be applied where the leakage current should not exceed 150 microamps at the relevant test voltage given in above table. When carrying out d. current monitoring facilities usually are available. Test Voltage Type Voltage 45/65 Hz (Test in both kV kV polarities) kV CLX3 VS3 7.2 20 20 Note : The codings given to contactors in the above table have additional suffix letters and numbers in their references. During this stage any discharge or test set tripping should be ignored unless it proves impossible to reach the full specified voltage within two minutes. ■ In special applications where the switch is in use for long periods without breaking current and without normal voltage across the contacts when switched off. Return the contactor to the supplier if the test is not successful. 2 to 4kVA.5.4 Perform auxiliary maintenance checks [5. Note : Applying very high voltages to open vacuum switches may generate harmful levels of X radiation.either in storage or in service.c.2 Slowly raise the voltage from zero to the specified test value taking approximately one minute to reach full voltage.4. ■ After a main circuit fuse has operated. 3.c.5.5] 3.c. it should be ensured that the leakage current is due to faulty switch dielectric and not due to dirt etc.5.CLX 3.1 Connect output leads of the test set across the open gap of each vacuum switch in turn. NTV121 .4] It is also advisable to test vacuum switches and contactors under the following circumstances: ■ If the contactor or switch has been standing for 5 years or more without use . high voltage tests. However.3 Perform routine site voltage test. 3.3 Hold the voltage at the specified test value for one minute. test set of limited rating e.

000.000 mechanical operations. Provided that the vacuum switch contact wear does not exceed the maximum permissible [4. Electrical life depends upon the type of vacuum switch fitted and the level of current to be switched.2] Vacuum Switch Wear ■ ■ ■ =< 400A ψ [3.1 Maintenance These contactors are extremely reliable and only slight maintenance is normally required. 4.5] Vacuum Switch Voltage ■ ■ ■ Test ψ Assuming a normal starting peak of six times full load current when controlling a squirrel cage induction motor. Maintenance 4.3 & 5.3] then contactor will continue to function correctly. Every Every After Infreque Every 5 on commissi 100. Installati Pre.000 Main nt Years on Operatio Operatio Fuse Switchin ns * ns * Operatio g (< 1 n year) [3. ∗ These totals are only for ELECTRICAL operations as the Vacuum switch assemblies will mechanically operate for the life of the contactor.2 Mechanical & Electrical Life The contactor has a design life of 1.4] Auxiliary Contacts ■ ■ ■ ■ [4.1E 15 . NTV121 .CLX 4.4. The following table outlines recommended maintenance intervals.1] Contactor Operation ■ ■ ■ ■ ■ ■ [5.000 250.

washer. If the gauge is trapped or tight fitting i. NTV121 . 4.3 Vacuum Switch Contact Wear Check After isolating the main circuit of the contactor.CLX 4. this indicates that the switch contacts are worn and the switch is close to or at the end of its electrical life.1E 16 . If one or more switches indicate worn contacts.e. Important : Remember to remove the gauge after checking for wear ! Note : A switch assembly is worn out when each contact has been reduced in thickness by 0.e. all three vacuum switches must be replaced. slide it from back to front to gain a feel for the movement. close the armature by energising the coils and insert the wear gauge DRC 001528-01 provided underneath the washer on top of each phase (as indicated above). and Nyloc nut also move.25mm i.5mm per pair of contacts in a switch. phase assembly.4 Wiring Diagrams Magnetically held See Electric diagram contactor DRC003793-01 in annex With mechanical latch See Electric diagram contactor DRC003793-02 in annex5. With the gauge in position. a total of 0.

e NC for NO and vice versa). Common Auxiliary contacts are 5 NO and 5 NC positively driven. For each normally open or closed contact.8 NO type.Faston blade 6.1. General Information The microswitches used are 16A / 250 Vac. 5. They must be connected directly at their terminal.3 x 0.1E 17 .2 Auxiliary Contact Blocks NTV121 .CLX 5 Auxiliary Switches NC 5. the complement contact is available (i.

Where reliability of operation is particularly critical .1 Examine moving parts for side play.g. badly worn pivots etc. inspection of the auxiliary switches is recommended at intervals of approximately 100.3. 5.2 Operate the contactor to check that the contacts have satisfactory wipe and break and that movement is free.. NTV121 . mine winding installations..3.000 operations.1E 18 . which indicate that the auxiliary switch should be replaced. continuous processes.e.CLX 5.3 Auxiliary Switch Maintenance The auxiliary contacts require little attention but should be kept free of dust and dirt 5. etc.

4 Contactor closes . 6. ■ Check that all switches have vacuum using the site voltage test [3. stop pin locking nut or opening springs.e.[4. loss of vacuum in one or more switches on the 7. swarf or other material in the gaps between closing coil pole pieces and the armature plate.1E 19 .CLX 6.. and any other protection equipment ■ Check with vacuum switch contact wear gauge if contactor is nearing the end of its life. if fitted.3 Contactor closes but motor will not run ■ Check fuses. 6. badly worn or screws loose. NTV121 . pivot point screws and nuts. It is unlikely that any of these will have altered to the extent of causing malfunction of a contactor which was previously satisfactory. Note B : Do not adjust nyloc nuts on top of the phase assemblies. ■ Check the electric circuit (connection diagram).5]. No overtravel Check for the presence of loose screws.5].1 Contactor will not close at all ■ Check power supply to the electronic card ■ Check auxiliary switch drive and pivots are not broken. If not possible to close with moderate force. Note A : As the contactor relies on atmospheric pressure acting on the switch bellows. swarf or other material in the gaps between closing coil pole pieces and the armature plate. check that sufficient voltage (see rating label) appears across the coil terminals.but stops at “tips touch” i. ■ Manually assist closure with coils energised. Fault Finding In cases of apparent contactor malfunction carry out the following checks after the isolation of the main circuit. 6.2kV contactors will possibly prevent closure depending on actual supply voltage and whether the coils are cold or hot. 6.3] ■ Check that all switches have vacuum using the site voltage test [3.2 Contactor closes and immediately re-opens ■ Check for the presence of loose screws.

2.CLX 7. 7.2 Latch-in Device and Setting 7.1E 20 .1 Latch in Close position NTV121 . Latch-in device 7. beyond an occasional light application of molybdenum disulphide loaded grease to the sliding parts.1 Maintenance of Latch-in Mechanism No maintenance is required for the latch-in mechanism.

This gap should be 0.CLX 7. closing coils and tripping coil must be energised for a minimum of 300 milliseconds.3mm maximum.3. (It is possible that the alignment of the whole latch assembly may have been disturbed during transit). (Coils are marked 24Vd. reset the latch: Move the beam DRC004056-01 tangent to the hole on the plate DRC004054-01 and set the gap between the roller DRC004200-01 and the beam using the two screws ST411-012-254 7.c.2 Latch in open position Hole 7.3.3.3 In the event of a malfunction of the latch The following points should be examined: 7.1 Check freedom of moving parts.1E 21 .3 Check solenoid tripping action Three solenoids are available. In case the gap is not correct. NOTES: To ensure correct operation. 7. 5%. the gap between the roller DRC004200-01 and the beam DRC004056 with the contactor closed electrically. 14 or 54 ohms respectively. having cold resistances of 3. 48 Vdc and 110/240 volts ac or dc.2 Check with a clock gauge. for nominal voltages of 24 Vdc. Closing coils and Tripping coil must not be energised for more than 2 seconds. It is forbidden to use an auxiliary switch on the vacuum contactor or on the latch (if fitted) to interrupt the contactor coil supply during the closing action NTV121 . 25% or 100% respectively).2.

CLX 8. serious personal injury or equipment damage. Use of unauthorized parts in the repair of the equipment. Spare parts list Recomanded CLX3 quantity by contactor Closing coils 24 V to 60 Vdc DRC001966-01 2 110 to 250 Vdc DRC001966-04 2 110 to 240 Vac Electronic card 24 V to 60 Vdc DRC003817-01 1 110 to 250 Vdc DRC003817-02 1 110 to 240 Vac Operations counter DRC002617-01 1 Equipped auxiliary switch 5NO + 5NC DRCN02277-01 1 set Tripping coils (latch) 24-30 Vdc DRC001749-03 1 48 Vdc DRC001749-02 1 110-240 Vdc DRC001749-01 1 240 Vac DRC001749-01 1 Replacement of parts should be performed only by qualified personnel.1E 22 . Always de-energize a contactor and remove it from the equipment before performing any tests. or tampering by unqualified personnel will result in dangerous conditions : can cause death. maintenance or repair. altering of the design. NTV121 . Please contact Schneider Electric for training course.

Annex Magnetically held Electric diagram contactor DRC003793-01 With mechanical latch Electric diagram contactor DRC003793-02 NTV121 .1E 23 .CLX 9.

92506 Rueil Malmaison Cedex This document has been printed RCS Nanterre 954 503 439 on ecological paper.schneider-electric. rue Joseph Monier As standards.com Publishing: Schneider Electric Design: Schneider Electric Printing: NTV121 . F . © 2011 Schneider Electric .1E 02/2011 . please CS 30323 ask for confirmation of the information given in this publication. specifications and designs change from time to time.All rights reserved Schneider Electric 35. Capital social 896 313 776 € www.