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.

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CONTENTS

1. SAFETY INSTRUCTIONS................................................................................................................................................4
1.1 Compliance with Instructions in this Manual .........................................................................................................4
1.2 Installation .............................................................................................................................................................4
1.3 Operation & Maintenance......................................................................................................................................4
1.4 Apparatus/Task/Skill Level Schedule for Working on the Apparatus ....................................................................5
2. OPERATION & GENERAL INFORMATION ....................................................................................................................6
2.1 General Information ..............................................................................................................................................6
2.2 Description & Operation ........................................................................................................................................7
2.3 Electronic card ....................................................................................................................................................10
3. INSTALLATION & PRE-COMMISSIONING TESTS ......................................................................................................12
3.1 Unpacking ...........................................................................................................................................................12
3.2 Critical Items During Unpacking and Installation.................................................................................................12
3.3 Installation ...........................................................................................................................................................13
3.4 Pre-commissioning tests .....................................................................................................................................13
3.5 Routine Site Voltage Test....................................................................................................................................14
4. MAINTENANCE .............................................................................................................................................................15
4.1 Maintenance........................................................................................................................................................15
4.2 Mechanical & Electrical Life ................................................................................................................................15
4.3 Vacuum Switch Contact Wear Check .................................................................................................................16
4.4 Wiring Diagrams .................................................................................................................................................16
5 Auxiliary Switches ..............................................................................................................................................17
5.1. General Information ............................................................................................................................................17
5.2 Auxiliary Contact Blocks......................................................................................................................................17
5.3 Auxiliary Switch Maintenance..............................................................................................................................18
6. FAULT FINDING ............................................................................................................................................................19
6.1 Contactor will not close at all...............................................................................................................................19
6.2 Contactor closes and immediately re-opens .......................................................................................................19
6.3 Contactor closes but motor will not run ...............................................................................................................19
6.4 Contactor closes - but stops at tips touch i.e. No overtravel.............................................................................19
7. LATCH-IN DEVICE.........................................................................................................................................................20
7.1 Maintenance of Latch-in Mechanism...................................................................................................................20
7.2 Latch-in Device and Setting ................................................................................................................................20
7.3 In the event of a malfunction of the latch ............................................................................................................21
8. SPARE PARTS LIST......................................................................................................................................................22
9. ANNEX ...........................................................................................................................................................................23

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1. Safety Instructions
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.

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.
Apparatus supplied as loose components, devices or sub-assemblies could, when energised, constitute a safety hazard.
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.

1.3 Operation & Maintenance

1.3.1 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, particularly those for emergency shutdown.
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.
During Maintenance, Testing etc. ensure that only technically competent and authorised persons are permitted to
carry out work and that they:
comply with statutory requirements.
are fully conversant with the apparatus and the system of which it is part, and recognise the safety hazards which
could arise, e.g. back feed.
isolate the apparatus completely, where possible, before opening enclosures and prove it to be dead before
starting work. Precautions must be taken to ensure that the isolated apparatus cannot become live whilst any
work is being carried out.
comply with safe working procedures for the safety of themselves and others, including the use of temporary
barriers and warning notices.
are conversant with the information provided, particularly on matters relating to safety.
recognise the hazards which can arise when working on live apparatus and take all the necessary precautions.
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.
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, during and after and work is carried out.

If there is any doubt as to the correct and safe method of working then further assistance should be sought from
Schneider Electric

1.3.2 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.
information is provided in this manual about the conditions necessary for safety and about any hazards which are
reasonably foreseeable during normal use, together with precautions to be taken to counteract them.
However, the Purchaser/User should ensure that the apparatus is maintained in a safe condition, and if technically
competent and authorised personnel have to gain access to apparatus which is not made completely safe as
recommended, everyone under whose authority these persons act should ensure that appropriate safety procedures are
generated and complied with.
The apparatus covered in this manual has been allocated the Apparatus Grade stated above. Reference to the
Apparatus/Task/Skill level schedule [1.4] enables the user to select personnel to carry out specific tasks requiring access
to the apparatus.

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1.4 Apparatus/Task/Skill Level Schedule for Working on the Apparatus

The apparatus can be supplied as loose items, sub-assemblies etc., for which the purchaser/user is responsible for
assembly etc. [1.2]. The skill level required to work on this equipment can be best described as the following :

Authorised and competent staff (e.g. Electrician, 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.
If additional information relating to the apparatus is required please contact : Schneider Electric

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2. Operation & General Information

2.1 General Information
This vacuum contactor was manufactured by:
Schneider Electric

A contactor is primarily a three phase switching device, used primarily in motor starting/reversing and capacitor bank
switching applications. Each phase has a separate Vacuum Switch which switches at the first available current zero.
2.1.1 Contactor Front View

main terminals

main terminals main moulding

moulded terminal bar

flexible connection

Vacuum switches

isolating rod
rating label

Auxiliary switches

Electronic card

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2.1.2 Contactor rear view

4x M10 fixing holes

pivot point

L shaped armature

4x M10 fixing holes

2.2 Description & Operation

As shown in [2.1.1 & 2.1.2], The contactor comprises a main frame moulding, a steel L-shaped armature, sheet steel side
mounting plates, three vacuum switches, opening spring, closing coils, electronic card and auxiliary contacts.

contact spring

seating colar
Electronic card

Opening spring

Closing coil

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2.2.1 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).
2.2.2 Closing Coils Energised
Energising the closing coils through the electronic card attracts the armature which compresses the opening spring. The
armature movement is transmitted through the pivot points, allowing the vacuum switches to close under the effect of
atmospheric pressure which acts on the bellows inside the vacuum switches (main circuit on). The vacuum switches will
remain closed as long as the closing coils are energised. The armature moulding moves further than necessary for switch
closure providing overtravel which accommodates contact wear and, on opening, provides kinetic energy to break minor
contact welds which may occur under severe operating duty.
The energy required to close the contactor is considerably more than the energy required to maintain a closed position.
On initially energising the closing coils a high current flows through the 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 65C. For
use in temperatures higher than this, contact Schneider Electric. Contactors are supplied fitted with closing coils and
electronic card suitable for d.c. or a.c. supply voltages.
2.2.3 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. The vacuum switches provide a sealed gas-free environment making the switching operation unaffected
by external conditions. Once the vacuum switch contacts have separated arcing occurs until the first available current
zero, at which time the current is commutated.
2.2.4 Auxiliary Contacts
One auxiliary contact blocks is provided giving a maximum of 10 (ten) contacts available for customer use
(5NO+5NC).

2.2.5 Main Terminals

The main terminals consist of M10 bolts for attachment of cables or busbars.
1) Removed M10 bolts as show in 2.2.5.1 (it is not allowed to reused the spring lock washer).
2) Fixed cable on main terminal as show in 2.2.5.2
For advice on cable/busbar connection see [3.3].

2.2.5.1 Remove M10 bolts before cable connection

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2.2.5.2 Cable fixation

01

02 L1

03

04
E1

05

06

07

08 L2

09

E2
10

1 M10 Bolt (Torque 40 N.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,

bars or crimps is 40 mm.

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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. 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). This opening delay can be used for the coordination with fuses.

It is also possible to connect in option an operations counter to the card.

Configurable pin
for opening
delay of 100 ms

Power supply
connector

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No additional time delay

time delay 100 ms

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3. Installation & Pre-commissioning Tests

3.1 Unpacking
Contactors may be supplied as separate units, or mounted with other equipment. When supplied as separate units, care
must be taken during unpacking.
After removing the packing material, examine the contactor and packing material for broken or missing parts. The carriers
and suppliers should be notified of the breakages within three days of delivery.
The particulars on the rating plate of the equipment must be quoted in all correspondence.

3.2 Critical Items During Unpacking and Installation

3.2.1 Do not attempt to lift the contactor by means of auxiliary contact blocks, isolating rod or
moulded terminal bar shown in positions below marked X.

3.2.2 Take care when fitting cables or busbars to the main terminals that the terminations do not
damage, deform or restrict movement of the contactor. Particular care should be taken when two or
more cable terminations are fitted onto a single terminal.

3.2.3 Everything surrounding the contactor (i.e. frames, enclosures, components, power and control
cables) must be clear of the paths of the moving parts 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.
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3.2.4 Ensure that nothing interferes with adequate air flow over the contactor, particularly around the
coils and economy resistor.

3.2.5 It is not recommend that additional components are added to the contactor e.g. rectifiers,
indicators, etc.. However, if components are added, checks must be made to ensure that they do not
have any adverse effect on the operation of the contactor.

3.3 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. Four M10 fixing holes are in the mounting feet formed by the bottom turned-out edges of the sheet
steel side frames. The maximum torque applicable for these terminals is 40 Nm and must not be exceeded. Alternatively
fixing holes are available in the vertical rear flanges of the side frames. 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, ensure that an air gap of at least 51mm for 3.3kV and 64mm for 6.6kV, is maintained
between live main circuit contactor parts and earth control circuits.

General Arrangement of Contactor

412
338 218

210

398

155

76
334

24.5

3.4 Pre-commissioning tests

It is good practice to subject vacuum switches or contactors to pre-commissioning tests.

3.4.1 Check for the presence of loose screws, swarf or other material in the gaps between closing
coil pole pieces and the armature plate

3.4.2 Check contactor operation at 85% of the control voltage after installation, including cables or
busbars, but before applying full control voltage and power.

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3.4.3 Perform routine site voltage test. [3.5]

3.4.4 Perform auxiliary maintenance checks [5.4]

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 - either in storage or in service.
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.
After a main circuit fuse has operated.

3.5 Routine Site Voltage Test

The following test should be carried out by using an a.c. test set of limited rating e.g. 2 to 4kVA, on which the voltage is
continuously variable from zero up to the maximum required for that particular switch. Return the contactor to the supplier
if the test is not successful.
Note : Applying very high voltages to open vacuum switches may generate harmful levels of X radiation. However
emission of X radiation is negligible at the specified test voltages.

3.5.1 Connect output leads of the test set across the open gap of each vacuum switch in turn.

3.5.2 Slowly raise the voltage from zero to the specified test value taking approximately one minute
to reach full voltage. 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.

3.5.3 Hold the voltage at the specified test value for one minute.

Contactor Type Vacuum Switch Nominal System A.C. Test Voltage D.C. 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.

When carrying out a.c. high voltage tests, 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.

When carrying out d.c. high voltage tests, current monitoring facilities usually are available. If any doubt exists about the
vacuum switch dielectric to pass the routine site test procedure given above, an additional criterion can be applied where
the leakage current should not exceed 150 microamps at the relevant test voltage given in above table. However, before
rejecting any vacuum switch which is apparently outside the limit, it should be ensured that the leakage current is due to
faulty switch dielectric and not due to dirt etc. on the outside of the vacuum switch envelope.

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4. Maintenance
4.1 Maintenance
These contactors are extremely reliable and only slight maintenance is normally required. The following table outlines
recommended maintenance intervals.

Installati Pre- Every Every After Infreque Every 5

on commissi 100,000 250,000 Main nt Years
on Operatio Operatio Fuse Switchin
ns * ns * Operatio g (< 1
n year)

[3.4.1] Contactor Operation

[5.3 & 5.4] Auxiliary Contacts

[4.2] Vacuum Switch Wear

=< 400A
[3.5] Vacuum Switch Voltage

Test

Assuming a normal starting peak of six times full load current when controlling a squirrel cage induction motor.
These totals are only for ELECTRICAL operations as the Vacuum switch assemblies will mechanically operate for
the life of the contactor.

4.2 Mechanical & Electrical Life

The contactor has a design life of 1,000,000 mechanical operations. Electrical life depends upon the type of vacuum
switch fitted and the level of current to be switched. Provided that the vacuum switch contact wear does not exceed the
maximum permissible [4.3] then contactor will continue to function correctly.

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4.3 Vacuum Switch Contact Wear Check

After isolating the main circuit of the contactor, 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).
With the gauge in position, slide it from back to front to gain a feel
for the movement. If the gauge is trapped or tight fitting i.e. phase
assembly, washer, and Nyloc nut also move, this indicates that the
switch contacts are worn and the switch is close to or at the end of
its electrical life. If one or more switches indicate worn contacts, all
three vacuum switches must be replaced.

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. a total of 0.5mm per pair of
contacts in a switch.

4.4 Wiring Diagrams

Magnetically held

See Electric diagram contactor DRC003793-01 in annex

With mechanical latch

See Electric diagram contactor DRC003793-02 in annex5.

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5 Auxiliary Switches
NC
5.1. General Information
The microswitches used are 16A / 250 Vac- Faston blade 6.3 x 0.8
NO type.

Common Auxiliary contacts are 5 NO and 5 NC positively driven. They must

be connected directly at their terminal. For each normally open or
closed contact, the complement contact is available (i.e NC for NO
and vice versa).

5.2 Auxiliary Contact Blocks

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5.3 Auxiliary Switch Maintenance

The auxiliary contacts require little attention but should be kept free of dust and dirt

5.3.1 Examine moving parts for side play, badly worn pivots etc., which indicate that the auxiliary
switch should be replaced.
5.3.2 Operate the contactor to check that the contacts have satisfactory wipe and break and that
movement is free.

Where reliability of operation is particularly critical - e.g. continuous processes, mine winding installations, etc., inspection
of the auxiliary switches is recommended at intervals of approximately 100,000 operations.

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6. Fault Finding
In cases of apparent contactor malfunction carry out the following checks after the isolation of the main circuit.
Note A : As the contactor relies on atmospheric pressure acting on the switch bellows, loss of vacuum in one or more
switches on the 7,2kV contactors will possibly prevent closure depending on actual supply voltage and whether
the coils are cold or hot.
Note B : Do not adjust nyloc nuts on top of the phase assemblies, pivot point screws and nuts, stop pin locking nut or
opening springs. It is unlikely that any of these will have altered to the extent of causing malfunction of a
contactor which was previously satisfactory.

6.1 Contactor will not close at all

Check power supply to the electronic card
Check auxiliary switch drive and pivots are not broken, badly worn or screws loose.
Check that all switches have vacuum using the site voltage test [3.5].
Manually assist closure with coils energised. If not possible to close with moderate force, check that sufficient voltage
(see rating label) appears across the coil terminals.

6.2 Contactor closes and immediately re-opens

Check for the presence of loose screws, swarf or other material in the gaps between closing coil pole pieces and the
armature plate.
Check the electric circuit (connection diagram).

6.3 Contactor closes but motor will not run

Check fuses, if fitted, and any other protection equipment
Check with vacuum switch contact wear gauge if contactor is nearing the end of its life.[4.3]
Check that all switches have vacuum using the site voltage test [3.5].

6.4 Contactor closes - but stops at tips touch i.e. No overtravel

Check for the presence of loose screws, swarf or other material in the gaps between closing coil pole pieces and the
armature plate..

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7. Latch-in device

7.1 Maintenance of Latch-in Mechanism

No maintenance is required for the latch-in mechanism, beyond an occasional light application of molybdenum disulphide
loaded grease to the sliding parts.

7.2 Latch-in Device and Setting

7.2.1 Latch in Close position

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7.2.2 Latch in open position

Hole

7.3 In the event of a malfunction of the latch

The following points should be examined:

7.3.1 Check freedom of moving parts. (It is possible that the alignment of the whole latch assembly
may have been disturbed during transit).

7.3.2 Check with a clock gauge, the gap between the roller DRC004200-01 and the beam DRC004056 with the
contactor closed electrically.
This gap should be 0.3mm maximum.
In case the gap is not correct, 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

7.3.3 Check solenoid tripping action

Three solenoids are available, for nominal voltages of 24 Vdc, 48 Vdc and 110/240 volts ac or dc. having cold resistances
of 3, 14 or 54 ohms respectively. (Coils are marked 24Vd.c. 5%, 25% or 100% respectively).

NOTES:

To ensure correct operation, closing coils and tripping coil must be energised for a minimum of 300
milliseconds. 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

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8. 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.

Always de-energize a contactor and remove it from the equipment before performing any tests, maintenance or
repair.
Please contact Schneider Electric for training course.
Use of unauthorized parts in the repair of the equipment, altering of the design, or tampering by unqualified
personnel will result in dangerous conditions : can cause death, serious personal injury or equipment damage.

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9. Annex

Magnetically held

Electric diagram contactor DRC003793-01

With mechanical latch

Electric diagram contactor DRC003793-02

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