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Medium Voltage Distribution

CBX
Vacuum Contactors
Equiped with an electronic module

Installation, Operation & General Maintenance
Technical Manual

CBX

• 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.

NTV120 - E 2

............................................................................................................................................................................................................................................................................................................................................18 5.4 CONTACTOR CLOSES ..............................................................................................18 5................................................................................................... CBXS3-C CONTACTORS (SINGLE PHASE) ...................................CBX CONTENTS 1..........................................2 INSTALLATION ................................................12 3................................................ SPARE PARTS LIST..........................................3 INSTALLATION ...........................E.......1 MAINTENANCE OF LATCH-IN MECHANISM..........................................21 8...................................................................................................................................................................2 CONTACTOR CLOSES AND IMMEDIATELY REOPENS ........................................................................................3 VACUUM SWITCH CONTACT W EAR CHECK ................................................................ AUXILIARY SWITCHES..................................................................................................4 PRE-COMMISSIONING TESTS ...................6 2....... INSTALLATION & PRE-COMMISSIONING TESTS ...............................................................................................................................................................................................................................20 6............................................................19 6............................14 3.... FAULT FINDING .. ANNEX ............................................4 1............................6 2.......................16 4.....14 4............................................................2 AUXILIARY CONTACT BLOCKS ....................................................................................................................8 2........4 APPARATUS/TASK/SKILL LEVEL SCHEDULE FOR W ORKING ON THE APPARATUS ...................................................4 1.............2 DESCRIPTION & OPERATION ......... MAINTENANCE ..........................................3 ELECTRONIC CARD ..............................................................22 8...................................................................................1 GENERAL INFORMATION .......................12 3........................................................................................................................................................................18 5..................................1 COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL ............ OPERATION & GENERAL INFORMATION ........................................................... NO OVERTRAVEL ......................12 3.......................20 7...................................................................................................................................................................................................17 5.....E 3 .....20 6......................................................................2 CRITICAL ITEMS DURING UNPACKING AND INSTALLATION ........................................................................................................................................................................5 ROUTINE SITE VOLTAGE TEST ............................................................16 4................................................................................................3 IN THE EVENT OF A MALFUNCTION OF THE LATCH ....................................20 6..........................................................................................................................................................................3 AUXILIARY SWITCH MAINTENANCE ...................................................................................................4 1...........................1 GENERAL INFORMATION ...............12 3....................................................................................1 MAINTENANCE .................................................................................................................17 W IRING DIAGRAMS ....................9 3..........4 1.....................................................................................................24 9............................................................................22 8. LATCH-IN DEVICE..............................................................3 OPERATION & MAINTENANCE ..........2 MECHANICAL & ELECTRICAL LIFE ..............................3 CONTACTOR CLOSES BUT MOTOR WILL NOT RUN .......22 8.................16 4............................................................................26 NTV120 .......................... SAFETY INSTRUCTIONS ...............................................................................................BUT STOPS AT “TIPS TOUCH” I..............................................20 6.................................................................................................1 CONTACTOR WILL NOT CLOSE AT ALL ................................................2 LATCH-IN DEVICE AND SETTING ......................25 10.................................................................................................................................1 UNPACKING ...............................................................................................................5 2.....................................................................................

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.CBX 1. If there is any doubt as to the correct and safe method of working then further assistance should be sought Schneider Electric 1.1 Conseils pour l’Utilisateur sur la Sécurité du Personnel Les règles permettant d’assurer la sécurité du personnel peuvent être résumées comme suit : ■ During Normal Use ensure that the plant operators:  are fully conversant with all controls.3.  recognise the hazards which can arise when working on live apparatus and take all the necessary precautions. ensure that only technically competent and authorised persons are permitted to carry out work and that they:  comply with statutory requirements. Precautions must be taken to ensure that the isolated apparatus cannot become live whilst any work is being carried out. constitute a safety hazard.  are fully conversant with the apparatus and the system of which it is part.  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. the Purchaser/User should ensure that the apparatus is maintained in a safe condition. during and after and work is carried out. and if technically competent and authorised personnel have to gain access to apparatus which is not made completely safe as recommended. The apparatus covered in this manual has been allocated the Apparatus Grade stated above. and recognise the safety hazards which could arise. back feed.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.  comply with safe working procedures for the safety of themselves and others. together with precautions to be taken to counteract them. particularly on matters relating to safety. Apparatus supplied as loose components. Safety Instructions 1. before opening enclosures and prove it to be dead before starting work. everyone under whose authority these persons act should ensure that appropriate safety procedures are generated and complied with. e.g. when energised. Reference to the Apparatus/Task/Skill level schedule [1.3. devices or sub-assemblies could. NTV120 . ■ information is provided in this manual about the conditions necessary for safety and about any hazards which are reasonably foreseeable during normal use.3 Operation & Maintenance 1.  isolate the apparatus completely.  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. 1. Testing etc. particularly those for emergency shutdown.E 4 .  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. However.  are conversant with the information provided.2 Installation The Purchaser/User should ensure that the apparatus supplied is correctly installed in a suitable location by technically qualified and competent persons. 1.4] enables the user to select personnel to carry out specific tasks requiring access to the apparatus. 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. including the use of temporary barriers and warning notices. where possible. ■ During Maintenance.

trained to work on live apparatus and fully conversant with the apparatus and the system of which it is part..g.CBX 1.1] NTV120 . sub-assemblies etc.4 Apparatus/Task/Skill Level Schedule for Working on the Apparatus The apparatus can be supplied as loose items. [1. for which the purchaser/user is responsible for assembly etc. Commissioning Engineer) with a HIGH degree of electrical expertise.E 5 . If additional information relating to the apparatus is required please contact : SCHNEIDER ELECTRIC T&D STS [2. The skill level required to work on this equipment can be best described as the following : Authorised and competent staff (e.2]. Electrician.

E 6 . Schneider Electric A contactor is primarily a three phase switching device. Operation & General Information 2. Each phase has a separate Vacuum Switch which switches at the first available current zero.1. CBX 2. 2. used primarily in motor starting/reversing and capacitor bank switching applications. although single phase units are also available.1 General Information This vacuum contactor was manufactured by.1 Contactor Front View Armature Closing coils Moulding Pivot Point Auxiliary switches Operations counter (option) Electronic Stop pin card cover Opening Springs Fixing holes Steel Mounting Plate NTV120 .

E 7 .1.2 Contactor Rear view Phase assembly & nyloc nuc Main Terminals Moulded Terminal Bar Main Moulding Main Terminals Vacuum Switches NTV120 .CBX 2.

the Contactor comprises Main and Armature mouldings with two Pivot Points.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.CBX 2. on opening. provides kinetic energy to break minor contact welds which may occur under severe operating duty.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).1]. For use in temperatures higher than this.c. Once the vacuum switch contacts have separated arcing occurs until the first available current zero.3]. The vacuum switches provide a sealed gas-free environment making the switching operation unaffected by external conditions. 2.1. 2. [2. The vacuum switches will remain closed as long as the closing coils are energised.5 Main Terminals The main terminals consist of M10 bolts for attachment of cables or busbars. On initially energising the closing coils a high current flows through the coils. an Economy electronic card and one Auxiliary Contact Blocks. a Steel Mounting Plate. The armature moulding moves further than necessary for switch closure providing overtravel which accommodates contact wear and. at which time the current is commutated. 2. 2. 2.E 8 . allowing the vacuum switches to close under the effect of atmospheric pressure which acts on the bellows inside the vacuum switches (main circuit on).2]. The energy required to close the contactor is considerably more than the energy required to maintain a closed position. or a. The maximum torque applicable for these terminals is 40 Nm and must not be exceeded.2. three Vacuum Switches.2.c.2 Closing Coils Energised Energising the closing coils through the electronic card attracts the armature which compresses the opening springs.2.1. two Closing Coils. After a short delay the electronic card automatically reduces the current in the closing coils which allows their continuous operation without over heating. The closing coil rating enables satisfactory operation of the contactor in cubicles with internal temperatures of up to 65°C. NTV120 . two Opening Springs.2.2.1 & 2.2 Description & Operation As shown in [2. contact Schneider Electric T&D STS. The armature movement is transmitted through the pivot points. supply voltages.4 Auxiliary Contacts One auxiliary contact blocks is provided giving a maximum of 10 (ten) contacts available for customer use (5NO+5NC). For advice on cable/busbar connection see [3. Contactors are supplied fitted with closing coils and electronic card suitable for d.

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 T&D STS in order to introduce an additional opening time delay of 100 ms by means of the ST3 jumper (see pictures above). It is also possible to connect in option an operations counter to the card.E 9 . NTV120 .CBX The maximum width of the lead terminal connexions. bars or crimps is 35 mm. 2.3 Electronic card The closing coils are energised through an electronic card which automatically reduce the current when the contactor is closed. We have two types of cards depending on the voltage supply. This opening delay can be used for the coordination with fuses.

CBX Configurable pin for opening delay of 100 ms Power supply connector NTV120 .E 10 .

CBX No additional time delay time delay 100 ms NTV120 .E 11 .

The carriers and suppliers should be notified of the breakages within three days of delivery.2. However..2. which must be used for the mechanical mounting of the contactor.1 Do not attempt to lift the contactor by means of the auxiliary contact blocks. 3. or the electronic card support shown in positions below marked X. enclosures.5 It is not recommend that additional components are added to the contactor e. When installing and cabling. When supplied as separate units. These together with any other evidence should accompany communications with the insurance company and the suppliers.E 12 .1 Unpacking Contactors may be supplied as separate units. General Arrangement of Contactor NTV120 . ensure that an air gap of at least 64mm for 7.2. indicators.CBX 3.2 Take care when fitting cables or busbars to the main terminals that the terminations do not damage. etc. checks must be made to ensure that they do not have any adverse effect on the operation of the contactor. deform or restrict movement of the contactor. The maximum torque applicable for these terminals is 40 Nm and must not be exceeded. care must be taken during unpacking.2 Critical Items During Unpacking and Installation 3. The particulars on the rating plate of the equipment must be quoted in all correspondence. frames. 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. components. It may. particularly around the coils. Installation & Pre-commissioning Tests 3.3 Installation It is recommended that the contactor be mounted with the axes of the vacuum switches vertical and with their moving contacts at the top.2. of course. 3.4 Ensure that nothing interferes with adequate air flow over the contactor.2kV and 77mm for 12kV systems.2. 3. examine the contactor and packing material for broken or missing parts. 3. is maintained between live main circuit contactor parts and earth control circuits. be necessary to increase these dimensions if the contactor and associated equipment have to meet a particular impulse withstand voltage. 3.5 fixing holes are provided on each side of the contactor in the turned up outer edges of the steel mounting plate. Particular care should be taken when two or more cable terminations are fitted onto a single terminal. Two M10 x 1. power and control cables) must be clear of the paths of the moving parts of the contactor.g. or mounted with other equipment. After removing the packing material. if components are added.e.3 Everything surrounding the contactor (i. 3.

CBX Mounting holes NTV120 .E 13 .

Return the contactor to the supplier if the test is not successful.4.2 Check contactor operation at 85% of the control voltage after installation. high voltage tests. When carrying out a. If any doubt exists about the vacuum switch dielectric to pass the routine site test procedure given above.either in storage or in service. ■ After a main circuit fuse has operated. including cables or busbars.1 Check for the presence of loose screws. Note : Applying very high voltages to open vacuum switches may generate harmful levels of X radiation.c.5 Routine Site Voltage Test The following test should be carried out by using an a. Contactor Vacuum Nominal A. When carrying out d. 3.3 Perform routine site voltage test. current monitoring facilities usually are available.2 Slowly raise the voltage from zero to the specified test value taking approximately one minute to reach full voltage. 3. swarf or other material in the gaps between closing coil pole pieces and the armature plate 3.4 Pre-commissioning tests It is good practice to subject vacuum switches or contactors to pre-commissioning tests.3 Hold the voltage at the specified test value for one minute. 3.c.CBX 3.4. test set of limited rating e.c.2 22 22 Note : The codings given to contactors in the above table have additional suffix letters and numbers in their references. high voltage tests. 3.4. on which the voltage is continuously variable from zero up to the maximum required for that particular switch.E 14 . Note: On reversing applications and on applications with VS3-C vacuum switches no discharge or test set tripping can be tolerated whilst the voltage is being slowly raised to. ■ 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. 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. [3. and held for one minute at the specified test voltage.C.5. 3.1 Connect output leads of the test set across the open gap of each vacuum switch in turn.C.5.3] 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 .g. an additional criterion can be applied where NTV120 . Test Type Switch System Voltage Voltage Type Voltage 45/65 Hz (Test in both kV kV polarities) kV CBX3-C VS3-C 12 22 22 CBX3 VS3 7. 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. However emission of X radiation is negligible at the specified test voltages. 3.5. Test D.4 Perform auxiliary maintenance checks [5.4. 2 to 4kVA.5] 3. but before applying full control voltage and power.

E 15 . on the outside of the vacuum switch envelope. before rejecting any vacuum switch which is apparently outside the limit.CBX the leakage current should not exceed 150 microamps at the relevant test voltage given in above table. NTV120 . However. it should be ensured that the leakage current is due to faulty switch dielectric and not due to dirt etc.

000 Main t 5 n Operation Operation Fuse Switching Years s* s* Operatio (< 1 year) n [3.3] Auxiliary Contacts ■ ■ ■ ■ [4.CBX 4. The following table outlines recommended maintenance intervals.5] Vacuum Switch ■ ■ ■ Voltage Test ψ Assuming a normal starting peak of six times full load current when controlling a squirrel cage induction motor.1 Maintenance These contactors are extremely reliable and only slight maintenance is normally required. 4. Every Every After Infrequen Every -tion commissio 100.3] Vacuum Switch ■ ■ ■ Wear አ400A ψ [3. Provided that the vacuum switch contact wear does not exceed the maximum permissible [4. Installa Pre.1] Contactor ■ ■ ■ ■ ■ ■ Operation [5.000.E 16 .4.2 Mechanical & Electrical Life The contactor has a design life of 1.3] then contactor will continue to function correctly. Electrical life depends upon the type of vacuum switch fitted and the level of current to be switched. ∗ These totals are only for ELECTRICAL operations as the Vacuum switch assemblies will mechanically operate for the life of the contactor. NTV120 .000 250.000 mechanical operations. Maintenance 4.

With the gauge in position. this indicates that the switch contacts are worn and the switch is close to or at the end of its electrical life. a total of 0. If the gauge is trapped or tight fitting i.3 Vacuum Switch Contact Wear Check After isolating the main circuit of the contactor. slide it from back to front to gain a feel for the movement.5mm per pair of contacts in a switch. and Nyloc nut also move. phase assembly. If one or more switches indicate worn contacts. all three vacuum switches must be replaced. close the armature by energising the coils and insert the wear gauge DRC001528-02 provided underneath the washer on top of each phase (as indicated above). washer.E 17 .CBX 4. 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 0.25mm i.e.e. Wiring Diagrams Magnetically held See Electric diagram contactor DRC003793-01 in annex With mechanical latch See Electric diagram contactor DRC003793-02 in annex NTV120 .

CBX 5.2 Auxiliary Contact Blocks NTV120 . For each normally open or closed contact. They must be connected directly at their terminal. Auxiliary Switches NC 5.E 18 .e NC for NO and vice versa). 5.3 x 0. the complement contact is available (i.Faston blade 6.8 NO type. Common Auxiliary contacts are 5 NO and 5 NC positively driven.1 General Information The microswitches used are 16A / 250 Vac.

E 19 .CBX 5. 5. etc. mine winding installations. NTV120 .g.. Where reliability of operation is particularly critical .e. continuous processes.3 Auxiliary Switch Maintenance The auxiliary contacts require little attention but should be kept free of dust and dirt 5.3. which indicate that the auxiliary switch should be replaced. inspection of the auxiliary switches is recommended at intervals of approximately 100.2 Operate the contactor to check that the contacts have satisfactory wipe and break and that movement is free.1 Examine moving parts for side play.000 operations.3. badly worn pivots etc..

swarf or other material in the gaps between closing coil pole pieces and the armature plate. swarf or other material in the gaps between closing coil pole pieces and the armature plate. stop pin locking nut or opening springs.2.4 Contactor closes .5].[4.e. and any other protection equipment ■ Check with vacuum switch contact wear gauge if contactor is nearing the end of its life. ■ Check the electric circuit (connection diagram). Note A :As the contactor relies on atmospheric pressure acting on the switch bellows.E 20 . ■ Check that all switches have vacuum using the site voltage test [3. 6. Note B :Do not adjust nyloc nuts on top of the phase assemblies. Fault Finding In cases of apparent contactor malfunction carry out the following checks after the isolation of the main circuit. NTV120 .but stops at “tips touch” i. If not possible to close with moderate force.2 Contactor closes and immediately reopens ■ Check for the presence of loose screws.1 Contactor will not close at all ■ Check power supply to the electronic card ■ Check auxiliary switch drive and pivots are not broken. 6.1] ■ Check that all switches have vacuum using the site voltage test [3. check that sufficient voltage see rating label) appears across the coil terminals. No overtravel ■ Check for the presence of loose screws. 6.2kV and 12kV contactors will possibly prevent closure depending on actual supply voltage and whether the coils are cold or hot.3 Contactor closes but motor will not run ■ Check fuses. ■ Manually assist closure with coils energised. if fitted. badly worn or screws loose.CBX 6. It is unlikely that any of these will have altered to the extent of causing malfunction of a contactor which was previously satisfactory.5]. pivot point screws and nuts. loss of vacuum in one or more switches on the 7. 6.

E 21 . in general. NTV120 . also applicable to the single phase contactors except where reference is made to more than one phase or vacuum switch. In particular the following information applies to the specific contactors listed below : Wiring Diagram for CBXS3-C  Magnetically held See Electric diagrams contactor DRC004287-01 (Dc + Ac) in annex.CBX 7. CBXS3-C Contactors (Single Phase) The information given elsewhere in this manual is.  Mechanically latch See Electric diagrams contactor DRC004287-02 (Dc + Ac) in annex.

CBX 8.2 Latch in open position NTV120 .2. 8.2 Latch-in Device and Setting 8.2.1 Maintenance of Latch-in Mechanism No maintenance is required for the latch-in mechanism. Latch-in Device 8.1 Latch in Close position M4 GRUB SCREW ROLLER PROP CLEVIS 8.E 22 . beyond an occasional light application of molybdenum disulphide loaded grease to the sliding parts.

E 23 .CBX NTV120 .

With the 10mm diameter collar loose on the trip rod. from the contactor coil energised condition to the latched-in. Check that the solenoid plunger is not sticking at any stage in its movement. NTV120 .3.3. (Coils are marked 24Vd. 8. The dimension between the outer end of the plunger and the solenoid mounting plate should be at least 24mm. allow the solenoid plunger to retract as far as possible without forcing. (The E-clip on the roller pivot pin must be located against the lower slotted guide plate).2 above. coil de-energised state). This set-back should be between 0.The closing supply however. and adding (to decrease the set-back) or removing (to increase set-back) slotted shim washers between the collars and the angle.3.c. Three solenoids are available.2mm and 0. there should be a clearance of 0. Conversely.3.CBX 8. The set-back can be adjusted by slackening the screws fixing the whole latch assembly to the contactor coil support angle. The use of an auxiliary switch on the vacuum contactor or on the latch (if fitted) to interrupt the contactor coil supply during the closing action is not recommended unless an intermediate relay with a delay of at least 0. (It is possible that the alignment of the whole latch assembly may have been disturbed during transit). as this could cause the closing supply to be disconnected before the contactor is fully closed.1 Check freedom of moving parts.Coarse adjustment necessitates removal of the latch assembly and screwing the clevis further on to or off its drive rod in one full turn steps. 48 Vdc and 110/240 volts ac or dc.E 24 . its free movement in relation to the latch body in the horizontal direction. it is possible that the prop is too far into engagement behind the roller. but the latch is reluctant to trip.3 In the event of a malfunction of the latch The following points should be examined: 8.2 above).3. insufficient engagement can result in failure to latch. 14 or 54 ohms respectively. should not be wired directly through a normally closed contact on the auxiliary contact block. Closing coils and Tripping coil must not be energised for more than 2 seconds.2 Check with a clock gauge. The engagement can be reset as follows: Slacken the locknut on the M4 grubscrew in the prop and adjust this grubscrew until the contactor ust fails to latch. 8. (ie.4mm. Lock with locknut and recheck 8. 25% or 100% respectively). Assuming the set-back is correct (see 8.With the contactor latched. Push in the plunger 1mm from this position and tightly secure the collar to the trip rod by means of the two grub screws and lock with the locknuts. having cold resistances of 3. the set-back of the clevis holding the roller behind which the prop is located. 8. for nominal voltages of 24 Vdc. The collar now acts as a stop for the lever/plunger assembly.4 Check solenoid tripping action and adjust as follows if necessary. 5%.5mm to 1mm between the outer end of the prop and the 10mm diameter collar fixed to the trip rod passing through the prop.3.3 Check prop engagement behind roller. 1 Unscrew the grubscrew 1 /2 full turns from this position so that the prop is further into engagement behind the roller. Notes: To ensure correct operation. This dimension can be adjusted by addition or removal of M3 washers behind this collar.3 seconds is employed. Retighten screws and recheck set-back. closing coils and tripping coil must be energised for a minimum of 300 milliseconds.

or tampering by unqualified personnel will result in dangerous conditions : can cause death. maintenance or repair. altering of the design. NTV120 .E 25 .CBX 9. Please contact SCHNEIDER ELECTRIC T&D STS for training course. serious personal injury or equipment damage. Use of unauthorized parts in the repair of the equipment. Spare parts list Recomanded CBX3 CBX3-C CBXS3-C 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 DRCN01726-01 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. Always de-energize a contactor and remove it from the equipment before performing any tests.

CBX 10. Annex Magnetically held Electric diagram contactor CBX DRC003793-01 Electric diagram contactor CBXS DRC004287-01 With mechanical latch Electric diagram contactor CBX DRC003793-02 Electric diagram contactor CBXS DRC004287-02 NTV120 .E 26 .

E 27 .CBX Notes NTV120 .

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