AEG CR193 Vacuum Contactor User Manual

AEG CR193 Vacuum Contactor User Manual

Caution

Please read the manual carefully before installation and operation of the contactor:
Installation and operation of the contactor must comply with the requirements of this manual.
The contactor shall be applied under normal operating conditions indoors.
Any operation and maintenance to the contactor must be performed by well- trained professional electricians.
Operating contactor in the conditions beyond its rated parameters is forbidden.
Always pay attention to any markings of the contactor.
Ensure the interlocking conditions of the contactor, as well as the applicability and safety of the working regulation.
Any maintenance with Switchgear or Secondary circuit powered-on is strictly forbidden.
Ensure protecting the contactor from any external impact, otherwise the device will be damaged.
Any irregular operation may damage the device, and even cause serious accident.
This manual should be placed in a convenient place.
Professional personnel should be responsible for the safety management of circuit breakers.

Overview

This manual provides the maintenance requirements and working specifications of CR193 vacuum contactor and fuse vacuum contactor combination apparatus to ensure safety and extend its service life.
This manual is applicable to CR193 vacuum contactor (hereinafter referred to as contactor) and fuse vacuum contactor combination apparatus (hereinafter referred to as combination apparatus).

Application standard

China national standards:

GB/T 14808 High-voltage alternating current contactors and contactor- based motor-starters
GB/T 11022 Common specifications for high-voltage switchgear and control gear standards
GB/T 15166.2 High-voltage alternating-current fuses Part 2: Current- limiting fuses
GB/T 50150 Electric equipment installation engineering standard for hand- over test of electric equipment
GB/T 311.1 Insulation co-ordination-Part 1: Definitions, principles and rules
GB/T 16927.1 High-voltage test techniques Part 1. General test requirements
GB/T 13384 General specifications for packing of mechanical and electrical product

IEC standards:

IEC 60470 High-voltage alternating current contactors and contactor-based motor-starters
IEC 60694 Common specifications for high-voltage switchgear and control gear standards
IEC 60632-1 High-voltage motor starters Part1:Direct-on-line(full voltage) a. c. starters
IEC 60282-1 High-voltage fuses Part 1: Current-limiting fuses
IEC 60071-1 Insulation co-ordination. Part 1 : Definitions, principles and rules

Fuses size and Impactor type shall comply with DIN 43625 and BS 2692 standards. Fuse electrical properties shall comply with IEC 60282 and GB/T 15166.2 standards.

Technical data

The technical parameters of Vacuum contactor and combination apparatus

(table 1)

Rated insulation level

| Power frequency Withstand voltage(1min)| kV| 42| 32| 42
Lightning impulse withstand voltage (peak)| 75| 60| 75
Rated frequency| Hz| 50| 50
Rated current| Transformer| A| 400| 6.3~250| 6.3~224
Motor| 25~315| 25~200
Short-time withstand current (4s)| kA| 4| 6.3| /
Rated peak withstand current| kA| 10| 16| /
Current overload tolerance(1s)| kA| 6| 9.5| /
Rated short-circuit breaking current| kA| 4| 6.3| 50
Rated short-circuit making current| kA| 4| 6.3| /
Rated junction current| kA| /| 3.2
Rated service mode|  | Continuing service| Continuing service
Mechanical endurance| Mechanical holding| 10000
cycles| 30| 30
Electrical holding| 10000
cycles| 30| 30
Auxiliary contact|  | 6a+6b| 6a+6b
Loop resistance (each phase)| μΩ| ≤150| ≤200*
Weight| kg| 46| 98

Note: * fuse resistance not included.

Technical parameters of control circuit (table 2)

Table 2

DC220
Closing operating current (A)| 9| 9| 4.5| 4.5| 9| 9| 4.5| 4.5
Closing holding current (A)| /| /| /| /| 1| 1| 0.5| 0.5
Opening operating current (A)| 12| 12| 6| 6| /| /| /| /
Rated working voltage range| Closing:85%-110% rated operating voltage
Opening:65%-120% rated operating voltage| Closing:85%-110% rated operating voltage
Operating frequency (cycles/h)| 600| 600

Notes: the value in this table is approximate value.

Mechanical characteristic parameters (table 3)

Notes: * actuation time of relay not included.

Product structure

Main structure of vacuum contactor

Fixed

The vacuum contactor (insulated frame) is mainly composed of vacuum interrupter, insulating frame, metal base, insulating warping plate, electromagnetic operating mechanism, etc.

The structure of combined electrical apparatus is mainly composed of fuse, vacuum contactor and chassis car

Handcart

Working principle

Working principle of fuse vacuum contactor combination apparatus

CR193 vacuum contactor is a kind of high voltage electrical apparatus which is mainly used to switch on and off the load current. The power circuit can be connected and broken by vacuum interrupter.
The fuse vacuum contactor combination device is mainly composed of high- voltage current limiting fuse, contactor and chassis car. Its basic working principle is: the normal start and stop of load depends on the contactor, which also has the task of breaking part of load current, making full use of the long mechanical life and frequent operation of the contact, and the more serious load current or short circuit The current breaking task is completed by high voltage current limiting fuse, which makes full use of the current limiting characteristics of fuse and the advantage of large expected breaking current. Combine and connect the two parts, connect them to the switch cabinet in the way of plum contact, and connect the secondary control circuit of the switch cabinet through the secondary plug. They can cooperate with each other, give full play to their advantages and avoid disadvantages, so that the F-C circuit has some characteristics different from other equipment, such as small rated current, large breaking current, frequent operation and long mechanical life.

Closing
When the contactor receives the closing command, for the mechanical vacuum contactor, the coil of the closing relay is energized, the normally open contact is closed, the circuit of the closing coil is energized, and the operating mechanism acts, that is, the closing electromagnet under the action of electromagnetic force drives the insulation rocker to rotate clockwise, and the screw of vacuum interrupter is pushed to make linear motion through the contact pressure spring. Then, the moving contact and the fixed contact are closed, at the same time, the contact spring generates the required contact stroke (i.e. overtravel), so as to ensure the required pressure between the moving contact and the fixed contact.

For the mechanical vacuum contactor, there is a mechanical closing latch to make the contactor in the closing state.
For the electric vacuum contactor, the electric holding module outputs stable current to keep the closing state.
For combined electrical apparatus, three-phase fuse must be installed, and it can complete the closing action only when it meets the unfused state.

Opening
When the contactor receives the opening command, for the mechanical vacuum contactor, the opening relay coil is energized, the normally open contact is closed, the opening coil circuit is on, and the opening tripping mechanism acts, that is, under the action of electromagnetic force, the opening electromagnet drives the roller out of the lock, the opening spring drives the electromagnetic operation mechanism to act, and drives the insulation rocker to rotate anticlockwise. Pull the bolt of the arc extinguishing chamber to separate the moving contact from the static contact at a proper speed. The buffer pad will work near the final opening position and absorb the residual kinetic energy of the opening, thus completing the whole opening process.

For the electrical holding vacuum contactor, there is no unlocking process, the electric holding module loses power and the contactor opens.

Manual opening

The mechanical vacuum contactor and combined electrical apparatus have the function of manual opening operation: directly push the manual opening lever of vacuum contactor, and the manual opening lever drives the opening electromagnet, and drives the roller to break away from the lock, so as to realize the manual opening (Fig. 1 and Fig. 2).
The combined electrical apparatus with electrical holding also has the function of manual opening operation, but it needs to be realized through the switch cabinet.

Working principle of fuse

Working principle of Fuse impactor (Fig. 3)
The fuse has a spring striker system. The system is connected with the fuse. When the fuse is fused, the pressure spring striking pin is ejected from the end face of the contact cap of the high-voltage fuse. The striker will act as the actuating part and visual display device of the fuse release device.

Working principle of fuse linked tripping mechanism (Fig. 4)

The linkage tripping mechanism of fuse is composed of a pin, a bracket of interlocking mechanism, and a spring.
When the fuse is not installed, the linkage mechanism bracket will drive the connecting rod under the action of spring, which makes the transmission rod push the opening electromagnet, and the mechanism cannot keep closing state. Therefore, if one phase fuse is not installed, the contactor cannot be closed, which can prevent the contactor from closing in the case of lack of phase.
When the fuse is blown, the impactor will push the connecting rod. When the connecting rod pulls up the fuse connector, it will rotate the opening connector and push the opening rod to release and unlock the switch. The three-phase fuse connector and one opening connector are fixed on a square shaft. Even if only one phase fuse is blown, the contactor will trip in linkage. When three-phase fault occurs, the action error time should be considered. If only one phase fuse is fused, even if the appearance of the other phase fuses is very good, all fuses should be replaced due to over- current, so as to ensure that the fuses are not replaced with electricity. The fuse in normal operation shall be inspected regularly.

Replace Fuse

(Fig. 5,6,7)

When it is necessary to install and replace the fuse: insert the fuse with a screw driver, press down the support of the interlocking mechanism to the bottom (if there is no such action, when inserting the fuse, the fuse will collide with the bracket, affecting the interlocking mechanism), and insert the fuse into the conductive base (pay attention to the installation direction of the fuse, and insert the contact pin end into the conductive base). After the fuse is installed in place, put the rubber washer into the fuse sleeve and push the fuse holder forward. Clockwise is the rotation direction and counterclockwise is the rotation out direction. When installed in place, the opening and closing arrows of the fuse sleeve shall be at the top position. Insert the sleeve positioning plate into the gap between the sleeve and the fuse holder and lock it. vice versa.

Working principle of the chassis

(Fig. 8)

1. roller
2. closing interlocking plate
3. fixed locking plate
4. supporting beam
5. handle
6. operation position lock
7. handle socket
8. position switch
9. screw
10. earthing switch interlocking piece
11. test position lock

The support beam (4) of the chassis truck is fixed on the switch cabinet through the fixed lock plate (3), and the screw (9) is installed on the support beam, which can be rotated and connected with the base through the nut (the nut is fixed on the base). When the screw is rotated, the chassis will move forward and backward along the screw direction to drive the contactor body to advance and exit; at the front end and rear end of the turnover plate (2), there are lock locks of the screw (6 is the working position latch, and 11 is the test position latch).

Push-in and pull-out of the chassis
When the contactor and grounding switch are in the opening state and the grounding interlock is in the reset state, the screw can be freely rotated to drive the chassis and the contactor body to advance and exit within the stroke range.

After pus hing the handcart type contactor into the switch cabinet, the following steps shall befollowed:
Insert the handle into the socket and rotate the handle clockwise to push in (counter clockwise to exit).
The stroke is about 200 mm, and it should enter the working position or test position smoothly when it is opened. Rotate the handle at medium speed for 20 turns. When you hear the “click” position switch mechanism action sound, it is in place. (avoid damaging the mechanism by excessive force).

Anti misoperation function of chassis
Avoiding pulling the insulation contact on-load

When the contactor is closed, the chassis car cannot shake. There is a combined brake interlocking device above the turnover plate of the chassis truck, which presses the turnover plate of the chassis car. If the contactor is in the test position, the square hole (11) of the lock in the test position will lock the screw rod, and the chassis vehicle cannot shake; if the contactor is in the working position, the working position latch (6) will resist the screw, and the chassis vehicle cannot shake, so as to avoid pulling the isolation contact with load (Fig. 9).

Avoiding closing in earthing position, avoiding on-load earthing
When the grounding switch of the switch cabinet is closed, the interlocking mechanism of the grounding switch pushes the grounding interlocking parts to move towards the screw, so that the interlocking parts block the screw, and the chassis vehicle cannot run from the test position to the working position; on the contrary, if the contactor is in the working position, the grounding switch interlocking mechanism of the switch cabinet is blocked by the grounding switch related locking plate of the chassis vehicle, and the grounding switch handle cannot be inserted Operation hole, grounding switch cannot be closed. So as to prevent closing in the grounding state and grounding with load (Fig. 10).

Working principle of the counter

The fuse vacuum contactor combination has a six position electromagnetic counter, which is installed in a closed circuit. After the electrical signal is input into the counter, the electromagnetic force is generated to make the electromagnetic drive mechanism and the driving digital gear rotate. The decimal counting method is used to record the operation times of the combined electrical apparatus (Fig. 11).

Working principle of closing/opening indicator

After each closing or opening operation of fuse vacuum contactor combination apparatus, the closing and opening indication will make corresponding indication. The mechanical on-off state indicator is fixed on the contactor with locating pin. When the contactor is closed or opened, the rocker will drive the indicator rod to move the indicator, where “O” represents opening and “I” represents closing.

Working principle of state auxiliary switch

The auxiliary switch of the contactor state drives the connecting plate of the auxiliary switch to switch through the warping plate. When the contactor is closed / opened, the normally open and normally closed contacts of the auxiliary switch are switched (Fig. 12)
.

Working principle of the fuse state auxiliary switch

The contactor has two sets of fuse auxiliary switches, two groups of normally open and two groups of normally closed, one of which is used by customers. When the fuse is fused, the trip mechanism drives the fuse auxiliary switch to switch. Normally closed contacts have the same status as fuses (Fig. 13).

Working principle of chassis position state auxiliary switch

The chassis is equipped with position auxiliary switch. When running to the test position, the small block on the screw moves the test position cushion block to change the auxiliary switch S8 of the test position and reset S8 after passing the test position; when the chassis enters the working position, the small square on the screw moves the copper block of the working position to change the auxiliary switch S9 and reset when it leaves the working position S9; therefore, the position of the chassis vehicle is indicated by the change of the position switch On off control of secondary circuit (Fig. 14).

Electrical schematic diagram

fixed contactor, DC, mechanical holding

F-C combination, DC, mechanical holding

fixed contactor, AC, mechanical holding

F-C combination, AC, mechanical holding

fixed contactor, AC-DC, electrical holding

F-C combination, AC-DC, electrical holding

Dimensions

Fixed

Handcart

Maintenance period

• Contactor shall be inspected regularly, for every 3-5 years, or 6000 cycles operations.
• If insulation components damaged, fail to open, fail to close, or any other failures, contactor shall be inspected and tested. Testing items shall include: power frequency withstand test, mechanical characteristic test, mechanical operation test, and fastener inspection.
• Vacuum arc extinction chamber shall be replaced after 300000 cycles of operation. After 10 years operation, contactor shall be r e – evaluated to determine if replacement is required.

Maintenance and inspection

Maintenance and inspection for operation parts

CR193 vacuum contactor is an electromagnetic operated mechanism. Both mechanical and electrical maintenance and inspection shall be conducted.

Maintenance and inspection for mechanical part

• Visually check all components. Replace parts if damaged.
• Check fastening bolts of all connecting parts. Check if all nuts are tightened. Check if any cotter pin or stopper is broken or dropped.
• Check the moving parts of the mechanism. Lubricate all the motion parts.

Maintenance and inspection for electrical part

• Check the counter is working.
• Check auxiliary switch and travel switch contacts work well. Fasten the bolts.
• Check closing/opening coil. Replace if damaged.
• Check closing/opening intermediate relay. Replace if damaged.
• Check all the secondary circuit terminals. Fasten them.
• Check all the contact pins in air plug.

Manual opening operation

1. For contactor, pull opening rod directly to check open operation.
2. For combination, press opening button to check open operation.

Inspection for fuse link-tripping mechanism

1. Check the link-tripping pin is in right position.
2. Check the link-tripping mechanism operates well.
3. Check fuse auxiliary switch is reliable during the operation of the link-tripping mechanism.

Maintenance and inspection for the primary conductive part

1. Check the fastener in the connecting part.
2. Fasten all the fasteners to required torque with torque wrench.

Maintenance and inspection for the chassis

1. Check whether the left and right interlocked plate operates normally.
2. Check whether the earth lock plate operates normally.
3. Check whether the closing locked plate operates normally
4. Check whether the push-in and pull-out operation of the chassis is normal.

Contactor body

1. Check and wipe the shell of vacuum arc extinction chamber, insulation frame.
2. Make mechanical operation test to the contactor, repeat closing and opening 5 times under rated operation voltage, high voltage, low voltage, it shall operate normally.
3. Make mechanical characteristic test to the contactor. Measure the closing and opening time, synchronism, bounce time etc.
4. Fasten all the bolts in conductive circuit. Test the loop resistance.
5. Measure the contactor insulation. Conduct power frequency withstand test.
6. Make relay protection full group test

End work

1. Clear the site and put tools in order.
2. Fill in the servicing test report and finish the handing-over procedure.

If any question during operation, first check the FAQs. If cannot be solved, please contact with the manufacturer. Disassembling the contactor is strictly forbidden.
Commissioning or operation shall be carried out by specially trained personnel. Protective and preventive measures must be taken into consideration.
Use the contactor under normal operation conditions according to IEC63201, GB/T14808 and this manual. Carefully read the data and technical parameters indicated on the product nameplates to ensure the correct parameter. Secure contactor from any damaging environment.
Clean dirt, especially dirt on insulation parts’ surface. Dirt maybe introduced by transportation or storage process. Dirt may influence insulation properties.
Connect the secondary plug on the test position. Make trial operation to close and open the contactor. Carefully observe the closing and opening position indicator, as well as the counter.

Failure analysis and treatments

manual opening, and then close the contactor.
2.Handcart does not fully come into operation position or test position.| Check the state indication of S8, S9.
Check if the indicated result is complying with the actual state.| Turn the handle clockwise, push the handcart forward till S8, S9 contact Correctly. Ensure the handcart in operation position.
Turn the handle counterclockwise, pull the handcart out till the S8, S9 contact correctly. Ensure the handcart in test

position.

3. Fuse is fused.|

1.  Check the fuse indication state, to see if the fuse is fused.
2.  Press the manual opening button, no sound from S1,S2.

| Remove the panel; check if the connecting rod comes up. If yes, fuse is fused. Replace them.
4.  Secondary circuit is not connected.| Check the state indication of switchgear.
Check if the secondary plug-in wiring is connected reliably (whether the connect pins of air plug, connectors of chassis, connectors on the terminal line are tighten correctly.)| Pull the handcart to test position, pull down the secondary plug, and check the conductivity of secondary circuit according to schematic diagram.
Connect it if disconnection.
Please pay attention to the size of screwdriver. Screwdriver with wrong size may damage the terminal.
Closing can not be maintained| Auxiliary switch shift too early.| Continuing closing and opening will be detected.| Adjust the auxiliary switch toward the metal base of chassis.
The handcart can not be pushed-in or pulled-out| 1.The contactor is in closing position.| Check the closing/opening indication window to see if in closing position.| Open the contactor
 | 2. The handle does not insert into the pushing hole correctly.| The handle does not insert into the pushing hole correctly.| Insert the handle into the pushing hole.
 | 3.The earthing lock plate is deformed. After the earthing lock release, the switchgear cannot reset.| Check if the earthing lock plate is deformed.| Replace the earthing lock plate.
 | 4.The switchgear earthing interlocking is not released| Check whether the earthing switch is opened.| Open the earthing switch.

Spare parts

When the user needs, the spare parts can be determined according to the following list, and put forward when ordering, so as to meet the needs.

Support

Web: http://www.aeg-imc.com/
Tel: 400-820-5234
2022IM1902

GEIS BREAKERS (SHANGHAI) CO.,LTD.
(An AEG Company)

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Documents / Resources

| AEG CR193 Vacuum Contactor [pdf] User Manual
CR193, Vacuum Contactor, CR193 Vacuum Contactor, Contactor
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