Description
TOSHIBA HCV-5HA-80
1. Basic Information
Model: HCV-5HA-80
Brand & Origin: TOSHIBAProduct Type: 7.2kV three-phase medium-voltage vacuum contactor with a rated operating current of 80A under the HCV-5HA series. Two operating structures are optional: electrically held type and mechanically latched type, supporting two cabinet mounting methods: fixed type and draw-out type.Product Positioning
The HCV-5HA is Toshiba’s first generation of medium-voltage vacuum contactors equipped with an electronic coil drive unit. It eliminates the traditional energy-saving resistor structure and greatly improves the reliability of the coil control loop. It is mainly applied for frequent start-stop control of high-voltage motors, switching of capacitor banks and frequent switching operations of transformer circuits in industrial and mining plants, power plants and metallurgical facilities at 6kV/7.2kV. Compliant with international standards including NEMA, IEC and UL, it can directly replace old air contactors and legacy vacuum switches, and is suitable for switching and control scenarios of high-voltage fans, water pumps, belt conveyors and reactive power compensation devices.
Hardware Architecture
The equipment adopts a modular structure with three independent vacuum interrupters and an epoxy insulating support frame, featuring physical isolation between strong and weak current circuits. It consists of five core functional units:
Three-Phase Vacuum Arc Extinguishing Unit
Each phase is equipped with an independent high overcurrent-resistant vacuum interrupter. The sealed vacuum structure suppresses electric arcs, enables frequent closing and opening operations, withstands short-circuit current surges, and delivers excellent arc extinguishing performance and insulation withstand capability.Electronic Coil Drive & Control Unit
Built-in solid-state electronic drive module supporting wide-range AC/DC control voltage input. It provides high-current pull-in at the moment of closing and operates at low power consumption during the holding phase. By removing traditional energy-saving resistors, the failure rate of coil burnout due to overheating is reduced, and it comes with built-in chopping resistance and inrush current suppression functions.Mechanical Operation & Locking Unit
The electrically held type maintains the closed state via continuous coil energization; the mechanically latched type locks through a mechanical buckle after closing, with the coil only energized at the closing moment, which significantly cuts down energy consumption and coil heat generation. A manual opening release mechanism is also equipped.Auxiliary Contact Signal Unit
Multiple sets of normally open and normally closed auxiliary contacts are provided as standard for uploading breaker opening/closing position feedback signals to DCS and PLC systems, and can be extended to electrical interlock and fault alarm loops.Insulating Frame & Cabinet Mounting Structure
The flame-retardant epoxy glass fiber insulating base features moisture resistance, creepage resistance and pollution resistance. It is compatible with fixed cabinet installation or draw-out truck structure for convenient on-site maintenance and replacement.Mounting Specifications
- Rated Voltage Level: 7.2kV
- Mounting Method: Optional fixed type or draw-out truck type
- Net Weight: Approximately 15.88kg
- Compatible Switchgear: Standard 6kV/7.2kV medium-voltage switchgear complying with NEMA Class E installation specifications
- Mechanical Operating Life: ≥1,000,000 times; Electrical Operating Life (under rated load): ≥250,000 times
Supporting Systems
Supporting Hardware
Medium-voltage switchgear, control power supply, secondary control cables, high-voltage current transformers, comprehensive protection devices, DCS remote signal terminal blocks.
Commissioning Tools
Insulation megohmmeter, loop resistance tester, coil voltage calibrator, mechanical travel measuring tool.
Upper-level Connection System
Power plant DCS, factory SCADA, comprehensive motor protection devices; breaker position and fault alarm signals are uploaded via auxiliary contacts.
Typical Application Industries
High-voltage motor control for auxiliary equipment in thermal power plants, high-voltage transmission equipment in metallurgy and mining, high-voltage water pumps and fans in the petrochemical & oil-gas industry, switching of reactive power compensation capacitors in substations, front-end switches of high-voltage frequency converters in the cement and building materials industry.
Product Features
Energy-saving Electronic Coil Drive Design
High-frequency Reliable Closing & Opening Capacity
The maximum rated operating frequency reaches 1,200 operations per hour, suitable for frequent switching of motors and capacitor banks. The vacuum arc extinguishing structure generates minimal electric arcs and slight contact erosion, enabling long maintenance cycles.Dual Insulation Safety Protection
Dual insulation composed of epoxy insulating base and vacuum interrupters offers strong pollution resistance and creepage resistance, allowing stable operation in dusty, humid and slightly corrosive factory environments.Two Optional Operating Structures
The electrically held type is suitable for short-time switching circuits; the mechanically latched type applies to long-term closed circuits without tripping upon power failure, eliminating the risk of motor shutdown caused by power loss.Complete Position Signal Feedback
Multiple auxiliary contacts are provided as standard to realize electrical interlocking, remote position transmission and fault alarming, facilitating remote monitoring via automated control systems.High Compatibility for Retrofit Projects
The installation dimensions and secondary wiring definitions are compatible with multiple legacy medium-voltage contactors, eliminating the need for cabinet re-drilling and extensive secondary circuit modification during renovation.
2. Technical Specifications
2.1 Main Circuit Electrical Parameters
- Rated Operating Voltage: 7.2kV
- Rated Operating Current: 80A
- Rated Short-time Thermal Withstand Current: 5,000A for 1 second
- Rated Peak Withstand Current: 12,500A
- Rated Short-circuit Breaking Current: 4.5kA (at 7.2kV)
- Rated Short-circuit Making Current: 7.0kA
- Standard Operating Cycle: CO-3min-CO (Close-Open with a 3-minute interval followed by Close-Open)
- Contact Loop Resistance: ≤120μΩ per phase
2.2 Control Circuit Parameters
- Coil Control Voltage: Wide-range adaptive 100~240VAC / 100~250VDC
- Closing Time: 50~90ms
- Opening Time: 15~40ms
- Operating Mode: Either electrically held type or mechanically latched type
- Auxiliary Contact Rating: 10A/250VAC, standard configuration: 3NO + 3NC auxiliary contacts
2.3 Mechanical & Service Life Parameters
- Mechanical Life: ≥1,000,000 operations
- Electrical Service Life under Rated Load: ≥250,000 operations
- Maximum Operating Frequency: 1,200 operations per hour
- Power-frequency Withstand Voltage between Phases & Phase-to-Earth: 28kV for 1 minute
2.4 Environmental Resistance Parameters
- Operating Ambient Temperature: -25℃ ~ +55℃
- Storage & Transportation Temperature: -40℃ ~ +70℃
- Relative Humidity: 5%~95% RH, non-condensing, free of corrosive gas and conductive dust
- Seismic Grade: Compliant with IEC 60068-2-6, resistant to long-term switchgear vibration
- Ingress Protection Class: IP20 for the module; to be installed inside sealed medium-voltage switchgear
2.5 Physical Structural Parameters
- Mounting Form: Fixed type, draw-out truck type
- Insulating Material: V0 flame-retardant epoxy glass fiber
- Arc Extinguishing Method: High-vacuum hermetic ceramic vacuum interrupter
- Secondary Wiring: Standard terminal-type secondary terminals for convenient control circuit wiring
3. Key Features
High-frequency Reliable Switching of High-voltage LoadsLeveraging vacuum arc extinguishing technology, frequent closing and opening of high-voltage motors, capacitors and distribution transformers can be achieved. Electric arcs are rapidly quenched inside the sealed vacuum chamber with little contact wear, effectively preventing arc ablation and phase short-circuit faults of air switches, and ensuring safe and stable frequent start-stop operation of high-voltage circuits.
Stable Driving via Wide-range Voltage Electronic Coil
The built-in dedicated electronic drive board enables reliable pull-in and closed-state holding under wide fluctuations of control voltage, eliminating faults such as failed closing under low voltage and coil overheating burnout under high voltage existing in traditional resistor voltage reduction schemes, and adapting to grid voltage fluctuations on site.Two Operating Modes for Power-failure Safety Protection
- Electrically held type: Trips immediately upon loss of control power supply, suitable for motor circuits requiring safe shutdown during power failure.
- Mechanically latched type: Locked mechanically after closing to maintain the closed position when power is lost; opening can only be performed manually or electrically to ensure uninterrupted operation of continuous-production equipment.
Remote Signal Upload via Multiple Auxiliary Contacts
Real-time upload of breaker closing/opening position signals through multiple passive auxiliary contacts, enabling remote status monitoring, electrical interlocking and fault alarming via relay protection and DCS systems, meeting the requirements of centralized control for unattended automated substations and factories.Stable Operation with High Insulation against Harsh Conditions
The epoxy insulating base delivers excellent creepage resistance, dust resistance, moisture resistance and pollution resistance, allowing long-term uninterrupted operation in complex industrial environments with heavy dust and high humidity such as metallurgical, chemical and power plants, and reducing the probability of insulation breakdown and earth short-circuit accidents.4. Working Principle
Closing Stage: The secondary control circuit energizes the electronic drive coil, and the operating mechanism drives the three-phase moving contacts upward to make contact with fixed contacts inside the vacuum interrupters, thus switching on the main circuit.For the electrically held type, the coil remains energized to keep the closed position; for the mechanically latched type, the mechanical buckle locks the contacts once fully closed, so the closed state can be maintained even after the coil is de-energized. Meanwhile, the auxiliary contacts switch over to upload the closing position signal to the control system.
Opening Stage: Upon receipt of the opening control signal, the electromagnetic tripping mechanism actuates to separate the moving contacts rapidly. With no air inside the vacuum interrupter, the electric arc is extinguished instantly, reliably disconnecting the main circuit, and the auxiliary contacts reset to send the opening position signal.
During equipment operation, the vacuum interrupter isolates air to prevent arc leakage, while the insulating base avoids creepage short-circuits between phases and to earth. The electronic drive board stabilizes the coil operating current in real time to prevent overheating damage, ensuring safe and reliable equipment performance under frequent switching operations.
5. Application Scenarios
- Thermal & Gas-fired Power Plants: Start-stop control of 6kV high-voltage induced draft fans, forced draft fans and circulating water pump motors; switching of auxiliary power reactive power compensation capacitor banks.
- Metallurgy & Mining Industry: Frequent start-stop control of high-power high-voltage equipment including high-voltage belt conveyors, crushers and mine drainage pumps.
- Petrochemical Facilities: Circuit switching of high-voltage process water pumps and compressor motors, load switching of high-voltage distribution transformers.
- Municipal Waterworks & Waste Incineration Power Plants: High-voltage circuit control for pumping stations and auxiliary equipment of waste heat generating units.
- Legacy Electrical Retrofit Projects: Replacement of old air-type medium-voltage contactors and faulty conventional vacuum switches to upgrade high-voltage circuit equipment.
