Schaltbau CP Series Manuale utente

ContactorsContactors

CP Series

1 pole bi-directional high-voltage

contactors, disconnectors,

changeover switches for

DC and AC

Installation and

Maintenance Instructions

Manual C40-M.en

22021-04-12 / V1.1

Contactors CP Series – Installation and Maintenance Instructions

Content

1. Important basic information......................................................................................... 4

1.1 Legal notes................................................................................................................................ 4

1.2 Conventions for this manual.............................................................................................. 4

2. General and security information ................................................................................ 4

2.1 Observing the instructions ................................................................................................. 5

2.2 User obligations...................................................................................................................... 5

2.3 Intended use ............................................................................................................................ 5

2.4 Ambient conditions............................................................................................................... 6

3. Dangers and security measures.................................................................................... 6

3.1 Electrical dangers ................................................................................................................... 6

3.2 Other dangers.......................................................................................................................... 7

3.3 Measures for avoiding damages and malfunctions................................................... 8

4. Introduction...................................................................................................................... 9

4.1 CP series – 1 and 2 pole bi-directional high-voltage contactors,

disconnectors, changeover switches for DC and AC................................................. 9

4.2 Features...................................................................................................................................... 9

4.3 Applications ............................................................................................................................. 9

4.4 Technical information and material specication ...................................................... 9

5. Description......................................................................................................................10

5.1 Survey of the CP series (stock items).............................................................................10

5.2 Modular conguration options.......................................................................................11

5.3 Conguration examples ....................................................................................................12

6. Storage.............................................................................................................................14

7. Unpacking and handling..............................................................................................14

7.1 Unpack the device ...............................................................................................................14

7.2 Check parts for transport damage.................................................................................14

8. Installation ......................................................................................................................15

8.1 Mounting positions .............................................................................................................15

8.1.1 Dimensions/interfaces and further technical specications.................15

8.2 Mechanical installation ......................................................................................................15

8.2.1 Preparatory measures..........................................................................................15

8.2.2 Required minimum clearance ..........................................................................16

8.2.3 Ventilation requirements....................................................................................16

8.2.4 Mounting holes......................................................................................................16

8.2.5 Safety .........................................................................................................................16

8.2.6 Tools required.........................................................................................................17

8.2.7 Installation procedure .........................................................................................17

Document Revision History

Date Rev. Level Description Pages

2020-07-20 V1.0 Initial version all

2021-04-12 V1.1 Modication of torque values

General adaptations

7, 10, 22, 24-26,

30, 33-35, 40, 41

2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions

8.3 Installation of the optional pre-charging contactor (CPP)....................................18

8.3.1 Installation of the CPP with 1,200A and 2,000A devices.......................18

8.3.2 Installation of the CPP with 600A devices...................................................19

8.4 Electrical Installation...........................................................................................................20

8.4.1 Preparatory measures..........................................................................................20

8.4.2 Safety .........................................................................................................................21

8.4.3 Tools required.........................................................................................................21

8.4.4 Connecting the auxiliary switches..................................................................22

8.4.5 Connecting the coil terminals...........................................................................23

8.4.6 Connecting the main contacts .........................................................................24

8.4.7 Connecting the earth terminal.........................................................................25

8.4.8 Connecting the optional pre-charging contactor (CPP).........................26

8.4.9 Connecting the optional high-voltage discharging contact (CPD) ....26

8.5 Checks ......................................................................................................................................27

9. Maintenance...................................................................................................................28

9.1 Safety ........................................................................................................................................28

9.2 Preventive maintenance....................................................................................................28

9.2.1 Intervals for regular checks................................................................................28

9.2.2 Regular check activities.......................................................................................29

9.3 Corrective maintenance.....................................................................................................31

9.3.1 Replacing the complete arc chamber unit ..................................................31

9.3.2 Checking the main contacts..............................................................................32

9.3.3 Replacing the contact bridge ...........................................................................33

9.3.4 Replacing the xed contacts.............................................................................34

9.3.5 Replacing the auxiliary switch assembly ......................................................36

9.3.6 Replacing the optional pre-charging contactor (CPP).............................37

9.3.7 Replacing the optional high-voltage discharging contact (CPD)........38

9.4 Checks ......................................................................................................................................39

10. Spare parts......................................................................................................................40

10.1 Pre-charging contactor (CPP) ..........................................................................................40

10.2 High-voltage discharging contact (CPD) .....................................................................40

10.3 Auxiliary switch assembly .................................................................................................40

10.4 Arc chamber complete.......................................................................................................40

10.5 Main contacts ........................................................................................................................40

10.6 Contact bridge assembly...................................................................................................40

10.7 Magnetic drive complete (without main contacts) .................................................40

11. Technical Data ................................................................................................................41

12. Disposal ...........................................................................................................................41

42021-04-12 / V1.1

Important basic information

Contactors CP Series – Installation and Maintenance Instructions

1. Important basic information

1.1 Legal notes

Without prior written consent of Schaltbau GmbH, this

manual is not allowed to be electronically or mechani-

cally reproduced – as a whole or in parts – be distrib-

uted, changed, transmitted, translated into another

language or used in any other way.

Schaltbau GmbH cannot be held liable for damage

caused by not observing (or only partly observing) the

manual.

1.2 Conventions for this manual

This manual describes the installation, commisioning

and maintenance of the contactors.

Cross references are presented in bold italics.

To highlight particularly important safety instructions

and other information, the following symbols are used

in this instructions:

DANGER

Indicates a hazardous situation with a high level

of risk which, if not avoided, will result in death or

serious injury.

WARNING

Indicates a hazardous situation with a medium level

of risk which, if not avoided, could result in death or

serious injury.

CAUTION

Indicates a hazardous situation with a low level of

risk which, if not avoided, may result in minor or

moderate injury.

NOTICE

Indicates a hazardous situation which, if not avoided,

may result in property damage, such as service inter-

ruption or damage to equipment or other materials.

Refers to technical features and methods

aimed at facilitating work or to particu-

larly important information.

This manual refers to single pole bi-directional high-

voltage contactors, disconnectors, changeover switch-

es for DC and AC of the types:

Nominal

Voltage Un

Conventional thermal current Ith

600 A 1,200 A 2,000 A

1,500 V

CP1115/06

CP2115/06

CP3115/06

CP1115/12

CP2115/12

CP3115/12

CP1115/20

CP2115/20

3,000 V

CP1130/06

CP2130/06

CP3130/06

CP1130/12

CP2130/12

CP3130/12

CP1130/20

CP2130/20

The CP series devices can be congured as normally

open/normally closed contactors, disconnectors or

change-over switches. Depending on the congura-

tion, the following abbreviations are used in this man-

ual:

-NO = Normally Opened

-NC = Normally Closed

-CO = Change Over

Since the CP series devices oer a wide range of con-

guration options, not all possible congurations can

be presented in this manual.

Even if the congurations shown do not correspond ex-

actly to the present device, the installation and mainte-

nance steps can be carried out identically as described

in this manual.

2. General and security information

The contactors dealt with in this document are intend-

ed for use with high-voltage systems for special instal-

lations. They are designed and tested in compliance

with the generally recognised state of the art. However,

improper use, operation, handling, maintenance of or

tampering with electric equipment can cause serious

or fatal injury to the user or others, and the appliance or

other property can be damaged.

The operation, maintenance and installation instruc-

tions for the contactors must therefore be strictly fol-

lowed.

Any uncertainties must be claried and all queries must

include details of the type of device and the serial num-

ber.

Only authorized and trained personnel are allowed to

plan and carry out all mechanical and electrical installa-

2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions

General and security information

tions, transport, commissioning, as well as maintenance

and repair work. This applies to the observation of the

general installation and safety regulations for high-volt-

age systems as well as the proper use of tools approved

for this purpose. Electric equipment requires protection

from moisture and dust during installation and storage.

2.1 Observing the instructions

All sta must read and understand the instructions

in this manual and adhere to them when working

with the device.

Always carefully observe all safety warnings!

2.2 User obligations

Observe all applicable national provisions, all safe-

ty, accident prevention and environmental regula-

tions as well as the recognized technical rules for

safe and proper working.

Carry out regular inspections of all protection and

safety devices to see if they work properly.

Work on electric equipment may only be per-

formed by an expert or trained personnel working

under the direction and supervision of an expert

according to the applicable rules of electrical en-

gineering.

An expert is a person who can judge and recog-

nise the possible dangers of the jobs commended

to him based on his training, knowledge and ex-

perience and by knowledge of the appropriate

regulations.

Work on the contactors must only be carried out

by sta who meets the requirements set out in this

manual.

Sta must be informed clearly about who is re-

sponsible for the maintenance of the contactors.

After each installation work and after replacement

of main contacts, contact bridge or after any other

modications, alterations or maintenance works,

always perform complete checks according to

these standards:

-IEC 60077-2

-IEC 60947-4-1

2.3 Intended use

The contactors have been designed and tested ac-

cording to national and international standards.

Due to their unique features they can also be used

in a variety of applications.

The contactors must only be used under operating

conditions according to the technical specication

and the instructions in this manual.

None of the operating conditions dened in our

catalogues C40 in section “Specication“, such as

voltages, currents, ambient conditions, etc. may

be changed.

The contactors must only be used when all protec-

tive devices are present, have been installed prop-

erly and are fully operational.

The contactors must not be contaminated with

aggressive media.

Contactors may not be used without further pro-

tective measures in potentially explosive atmos-

pheres.

The switching device meets the requirements

of basic insulation. Make sure the frame or plate

onto which the drive of the contactor is mounted

is earthed in a shock and vibration resistant way.

Do not use the contactor without properly mount-

ed arc chute (if applicable).

The contactor has unprotected live parts and car-

ries labels that warn of the hazard. This caution

must be observed and the labels must not be re-

moved in any way.

The required clearance of live parts to earth and

other parts of the contactor is to be observed as

well as the safety regulations of the applicable

standards.

Switching at maximum breaking capacity might

require larger clearance! Do not hesitate to ask our

advice for dimensioning.

Coil suppression for reducing surges when the coil

is switched o is optimally attuned to the contac-

tor‘s switching behaviour. The existing opening

characteristic must not be negatively inuenced

by parallel connection with an external diode.

Improper handling of the contactors, e.g. when

hitting the oor with some impact, can result in

breakage, cracks and deformation. Always handle

the contactors with care.

Use the contactor only according to its intended

use. Replace or repair damaged parts exclusively

with original parts. Any other usage of or tamper-

ing with the contactors is considered contrary to

its intended use. No liability is assumed for damag-

es and accidents caused due to non-compliance

with the instructions in this manual or improper

use of the contactors.

62021-04-12 / V1.1

Dangers and security measures

Contactors CP Series – Installation and Maintenance Instructions

2.4 Ambient conditions

NOTICE

The contactors are constructed for specic ambient

conditions.

Operate the contactors only according the am-

bient conditions, like temperature ranges, IP

protection classes, degree of soiling, etc., as de-

ned in our catalogue C40 in section“Specica-

tion“. The catalogue is available under:

https://www.schaltbau.com/en/media-library/

3. Dangers and security measures

3.1 Electrical dangers

DANGER

The contactors are high voltage switches. The touching of electrically conducting parts may result

in serious injuries or even death!

Energized parts are all metal parts belonging directly to one of the circuits or wires leading there. All

other visible metal parts and wires may also be energized in the case of a failure.

Before beginning any work on the contactors, always observe the following safety regulations:

Disconnect on all sides

Ensure that it is not possible to reconnect unintentionally

Clearly mark your work area

Make sure that there is no voltage present

Earth and short circuit the installation; this also includes the discharging of any capacitors in

the main circuit

Besides the main electric circuit, also disconnect additional and auxiliary circuits

Cover or insulate adjacent energized parts

Only an electrically skilled person may determine if there is no voltage present

When the work has been concluded, proceed the other way round.

DANGER

The contactors are equipped with a protective earth terminal. Without earth connection, metal

parts and wires may be energized in the case of a failure. Risk of serious injuries or even death!

Make sure that the contactors are connected to earth.

Make sure that the wire gauge of the earthing cables complies with the specic short circuit

conditions.

DANGER

In the case of a failure of the equipment;

don‘t use it anymore

immediately contact the manufacturer.

2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions

Dangers and security measures

DANGER

Interventions in the equipment may cause serious impairments to the safety of men and construc-

tions. They are not permissible and lead to an exclusion of liability and warranty.

DANGER

All checks and the replacement of components or groups of components may only be carried out

by qualied personnel according to the instructions of Schaltbau. All spare parts must be parts de-

livered by or released by Schaltbau.

3.2 Other dangers

WARNING

Exclusively use the contactors for purposes as indicated in the specications and data sheets.

A wrong application can cause accidents and severe damages to persons!

The manufacturer doesn‘t take the responsibility for accidents which were caused by improper

use of the product.

WARNING

The contactor is heavy. Risk of injury and damage to the device.

Take care when handling the contactor.

Always two or more persons are required to unpack, transport and install the contactor.

When carrying the contactor always hold it on the base plate.

CAUTION

The contactors may grow warm during operation and they may become hot depending on the am-

bient temperature and the conditions of use. Risk of burns!

Before beginning any work on the contactors make sure that the heated components have

cooled down.

CAUTION

The contactors contain sharp-edged parts. Risk of injury!

Use appropriate tools for installation and maintenance works on the contactors.

Wear protective gloves when working with sharp-edged components.

82021-04-12 / V1.1

Dangers and security measures

Contactors CP Series – Installation and Maintenance Instructions

3.3 Measures for avoiding damages and malfunctions

NOTICE

Aggressive uids may damage the contactors.

Make sure that the contactors are not exposed to aggressive uids.

NOTICE

Improper handling of the contactors, e.g. when hitting the oor with some impact, can result in breakage, cracks

and deformation.

Make sure that the contactors are always used properly.

Do not throw the contactors to the oor.

Regularly sight-check the contactors for potential damages.

Immediately replace damaged components.

NOTICE

The contactors contain strong (permanent) magnets. These magnets can attract ferromagnetic particles and

may damage the contactors.

Make sure that the contactors are installed at a location, where no ferromagnetic particles can be attracted..

NOTICE

The contactors contain strong (permanent) magnets. These magnets can destroy data on credit cards or similar

cards.

Keep credit cards or similar cards away from the contactors.

NOTICE

During the switching o, strong electromagnetic elds are generated in the surroundings of the contactors.

These may inuence other components close to the contactors.

Make sure that the contactors are installed at a location, where no other components can be aected.

NOTICE

In the case of damage, wear and tear and/or soiling of the contactor components - in the form of a partial break,

sharp edges and discoloured surfaces - the functional safety of the contactors is no longer guaranteed.

Carry out regular visual checks to detect wear and tear and dirt.

Immediately replace damaged parts.

Immediately remove dirt without leaving any residues.

Immediately replace parts with stubborn dirt.

NOTICE

Detent-edged rings and detent-edged washers have a limited life time. After screws secured with detent-edged

rings or detent-edged washers have been undone three times, the rings or washers must be replaced by new

ones.

Record the frequency of undoing of the screws in the work log.

Replace detent-edged rings or detent-edged washers with new ones after the screws have been undone

three times.

2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions

Introduction

4. Introduction

4.1 CP series – 1 and 2 pole bi-direc-

tional high-voltage contactors, dis-

connectors, changeover switches

for DC and AC

Modular and compact switchgear for modern power

converters

With the CP series Schaltbau is introducing once more

an innovative concept to the switchgear market. The

arc-handling is done exclusively by permanent-mag-

netic blowout. This patented technology ensures fully

bi-directional breaking capability and a more compact

design. By reducing dimensions and weight we save

you valuable space.

For the rst time the universal devices can be cong-

ured as NO/NC contactor, disconnector or changeover

switch. This enables us to react exibly to changing

customer requirements. The high switching function-

ality and reliability ensure practical and cost eective

operation.

The combination of innovative technology, compact

design and high versatility makes the CP-power contac-

tors particularly suitable for use in railway and indus-

trial applications.

Thanks to its unique modular design, the new product

family includes a variety of possible congurations ca-

tering to a wide range of applications.

4.2 Features

Innovative Design

Available as NO/NC/CO contactor.

DC bi-directional or AC up to 60 Hz max.

Eective arc-handling – no critical currents and

low wear of main contact system thanks to perma-

nent-magnetic blowout

High making capacity, also as disconnector and

changeover switch

Low total cost of ownership, modular and compact

Main contact system

Conventional thermal current: 600 A/ 1,200 A/

2,000 A

Nominal voltage: 1.5 kV, 3 kV

Double-break contacts

1 pole (NO/NC) and 2 pole (CO) versions

Easy maintenance:

Toolless inspection of main contact tips (only ap-

plicable for NO/NC contactors with arc chamber)

Toolless replacement of the arc chamber (only ap-

plicable for NO/NC contactors with arc chamber)

4.3 Applications

Main contactor, optional with pre-charging

contactor and high-voltage discharging contact for:

Traction converters

Inverters for auxiliary equipment

Switchgear for various mobile and stationary

applications

Locomotives and multiple-unit trains

Photovoltaic systems, wind turbines, cranes, weld-

ing systems, mining

Contactor for:

Field circuits of motors

Conventional resistor based traction units

Activating the brake unit for DC drives

Starter and compressor motors, solar cells

Switchgear for the conguration of electrical system

Selection from among various energy sources

Filter conguration for multisystem operations

Connect/disconnect the DC link

4.4 Technical information and material

specication

For technical information, dimensions and material

specications, refer to our catalogue C40. The cata-

logue is available under:

https://www.schaltbau.com/en/media-library/

10 2021-04-12 / V1.1

Description

Contactors CP Series – Installation and Maintenance Instructions

5. Description

5.1 Survey of the CP series (stock items)

Conventional

thermal current Ith

NO/NC with

large arc chamber

NO/NC with

medium arc chamber

NO/NC without arc

chamber (load-free)

CO without arc

chamber (load-free)

600 A

1,200 A

2,000 A ---

The devices for 600 A, 1,200 A and 2,000 A dier opti-

cally mainly in the device dimensions and in the thick-

ness of the main contacts.

However, if the illustrations on the following pages do

not correspond exactly to the present device, the de-

scriptions and illustrations are equally valid for the oth-

er device models (600 A, 1,200 A, 2,000 A ).

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