Vacuum Contactor Vacuum Testing

Performed once every three years. Note: Replace all three vacuum bottles
simultaneously if one indicates excessive wear to avoid issues with proper
alignment and contact tip pressure.
Test for vacuum integrity. This test is done with an AC Hi-pot. As this test has the
possibility of generating X-rays in the vacuum bottle, stay at least 3 feet away from
the contactor during the test. Do not use DC hi pot testers because the amount of Xray generation can be excessive and because damage can occur. Manufacturers do
not recommend using DC hi-pot for vacuum bottle testing.
Test procedure: Connect all line and load side terminals together, and connect the hi
pot leads to line and load sides. Increase the voltage from 0 to full in 1 kV
increments once per second. Hold the voltage for 1 minute, then shut down test.
During the 1 minute hold, current should not exceed 5 mA. The test may be
repeated several times if a current of 5 mA appears before reaching full voltage. If it
cannot be reached, break apart the connections between vacuum bottles and retest
to identify the bad bottle for replacement.
Test voltage:
Manufacturer
Joslyn-Clark CV-4, MVC 2.5 kV rated
Toshiba HCV-5HA, HCV-6KA; Allen Bradley 1100 series;
Joslyn-Clark USAVAC, CV-5, CV-6
Joslyn-Clark MVC 5 kV rated
Toshiba CV-H
Joslyn-Clark MVC 7.5 kV rated

Test
Voltage
7.5
10 kV
13.25
17
18.25

Vacuum Contactor Contact Erosion Test

Performed annually. Note: Replace all three vacuum bottles simultaneously if one
indicates excessive wear to avoid issues with proper alignment and contact tip
pressure.
Every manufacturer specifies performing this test, but the specific location to test
and the required gap (wipe) distance varies by manufacturer. The contactor must
be closed during this test. Except for certain Joslyn-Clark contactors, external
control power must be applied to close the contactor even though main power must
be off for safety reasons. The tests are summarized below for convenience.

Toshiba HCV-5HA, CV-H, HCV-6KA Contactors (as per Toshiba

manual)
1. Measure electrode wear by measuring the distance between the lever and
the washer in the closed (ON) state as shown in the diagram below using

feeler gauge. This dimension is called the wipe. Replace bottle when the
distance is less than 1.0 mm for HCV-5 and HCV-6 contactors. Wipe is more
than 3 mm for CV-H contactors.

Joslyn-Clark USAVAC Contactors (as per manual)

1. Unscrew all caps by rotating counterclockwise to of a turn (do not
unscrew further). If needed, a strap wrench can be used. Caps shown in B
below.

2. Close the contactor by hand or using the slot for a hex key wrench at B in
the diagram below.

3. Closing the contactor lifts the interruptor by its overtravel distance. Screw
caps down clockwise to the interruptor and stop when resistance is felt, do
not tighten further.
4. Release the hex key wrench so that the contactor is in the open position.
5. The gap between the top of the interrupter and cap should not be less than
0.010 as measured with feeler gauge.

6. Release the hex key wrench so that the contactor is in the open position.
7. Retighten caps to a snug fit. Do not overtighten. If needed, a strap wrench
can be used.

Joslyn-Clark CV Model Contactors

1. Remove cover for inspection.

2. Close contactor and measure gap (wipe) with feeler gauge. If the gap is less
than 0.010, replace. Diagram for Joslyn-Clark CV-5, CV-6 contactors:

CV-4 contactor:

Joslyn-Clark MVC Contactors

1. Test for wear using the built-in wear indicator. Wear checking is best
performed by energizing contactor in place. See diagram below. Diagram
shows contactor in off (open) position. When contactor closes, green bar will
rise towards red bar. If any of the green bar is in the red zone, contactor is
worn out and must be replaced.

Allen Bradley Bulletin 1100 series

1. Energize the coil of the contactor from a separate power source.
2. Examine the red contact life line on the movable contact shaft. When this line
is no longer visible with the contactor energized, the vacuum bottles must be
replaced.
3. Overtravel is the distance between the lever and the special nut when the
lever is pushed toward the vacuum bottle against the solid stop. Minimum
overtravel to ensure contact closing is 0.012. Check overtravel with feeler
gauge using the diagram below.

4. If overtravel needs to be adjusted, first remove the shunt securing bolt as

shown below. Then loosen the tightening nut and turn the special nut
counterclockwise to increase and clockwise to decrease the overtravel. Set
the overtravel between 0.047 and 0.059. Adjust the overtravel on all three
vacuum bottles. Torque the tightening nut to 75-100 lb-in. Replace the shunt
securing bolt and torque to 75-100 lb-in.

Line Power Vacuum Circuit Breakers

The spring housing has a red indicator mark on its upper shoulder. The springs are
factory set to hide the indicator mark. As the vacuum contacts erode from use, the
red line will become visible in the closed position. When the red line is totally visible,
replace the vacuum bottles.