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2019-05-24 / V1.0

Contactors C137/C163/C164/C165 – Installation and Maintenance Instructions

Installation

Required minimum clearance 

NOTICE

Switching electrical currents at high voltages will 

produce arcing and plasma may exit out of the arc 

chambers. It is essential to observe the minimum 

clearance to earth and to the connecting bus bars to 

avoid the risk of a flash-over.

Depending on the contactor type, the table below 

shows the required minimum clearance measurements:

Series

Minimum clearance

C137

15 mm

C163

15 mm

C164

20 mm

C165

50 mm

Ventilation requirements

 

X

Ensure sufficient ventilation, especially in the case 

of heavy arc switching. Allow the exchange of sur-

rounding atmosphere to avoid the risk of flash-

overs and excessive corrosion.

Safety

 

X

The installation has to be carried out by qualified 

trained personnel.

NOTICE

During installation, ensure that dirt caused by sur-

rounding construction activities does not get into 

the contactor.

NOTICE

Detent-edged rings and detent-edged washers have 

a limited life time. After 3 times opening of screws 

secured with detent-edged rings or detent-edged 

washers, the rings or washers must be replaced by 

new ones.

 

X

Record the frequency of screw opening in the 

work log.

 

X

After 3 times opening of screws, replace detent-

edged rings or detent-edged washers by new 

ones.

Required tools and auxiliaries

 

-

Socket wrench set

 

-

Hexagon socket wrench set

 

-

Torque wrench

Install the contactor

 

X

Make sure, that the mounting surfaces of mount-

ing plate (5) and contactor are free from dirt and 

other contamination (e. g. metal cuttings).

 

X

Place the contactor (3) on the mounting plate (5) 

with the prepared mounting holes. 

 

X

Screw the contactor with 4 screws (4) on the 

mounting plate (5).

 

-

When using threaded holes: Screw the screws 

with appropriate screw locking elements direct-

ly in the threaded holes.

 

-

When using through holes: Fasten the screws 

with appropriate screw locking elements and 

nuts. 

 

X

Depending on the contactor type, tighten the 

screws with the torque as stated in the table.

Series

C137 C163 C164 C165

Screw size

M3

M5

Torque

3 Nm

6 Nm

5

4

3

Fig. 19:  Install the contactor to the mounting plate 

Summary of Contents for C137 C

Page 1: ...3 3 Contactors C137 C163 C164 C165 series Single pole contactors for battery voltages Installation and maintenance instructions Manual B60 M en ...

Page 2: ... dangers 6 3 2 Other dangers 6 3 3 Measures for avoiding damages and malfunctions 7 4 Product information 8 4 1 Contactors of the C137 C163 C164 C165 series 8 4 2 Special features 8 4 3 Applications 8 4 4 Technical information and material specification 8 4 5 Survey of the C137 C163 C164 C165 series stock items 9 SPST NO contactor C137 C 9 Changeover SPDT contactor C137 H 10 SPST NO contactor C163...

Page 3: ... Electrical data and further technical specifications 21 Preliminaries 21 Safety 22 Required tools and auxiliaries 22 Connect the auxiliary contact 22 Connect the coil terminals 23 Connect the main contacts 24 Connect the normally closed contacts changeover SPDT contactors only 25 Tie bars for contactors in series connection 26 7 3 Checks 27 8 Maintenance 28 8 1 Safety 28 8 2 Preventive maintenanc...

Page 4: ...icu larly important information This manual refers to single pole NO contactors and sin gle pole change over contactors of the types C137 C H C163 C H C164 C H C165 C H This manual describes only stock items of the above mentioned contactor types If you need a special vari ant feel free to contact us 2 General and security information The contactors dealt with in this document are intend ed for us...

Page 5: ...ditions defined in the corresponding data sheets and in our catalogue B60 in section Specifications such as voltages currents ambientconditions etc maybechanged The catalogue B60 is available under https www schaltbau com en media library X X The contactors may only be used when all protec tive devices are present have been installed prop erly and are fully operational X X Contactors may not be us...

Page 6: ... of any capacitors in the main circuit X X Besides the main electric circuit also disconnect additional and auxiliary circuits X X Cover or insulate adjacent energized parts X X Only an electrically skilled person may determine if there is no voltage present X X When the work has been concluded proceed the other way round 3 2 Other dangers WARNING Exclusively use the contactors for purposes as ind...

Page 7: ...e magnets can de stroy data on credit cards or similar cards X X Keep credit cards or similar cards away from the contactors NOTICE During the switching off strong electromagnetic fields are generated in the surroundings of the contactors These may influence other components close to the contactors X X Make sure that the contactors are installed at a location where no other components can be affec...

Page 8: ...d to make and break current Bistable versions C163 Series contactors are also avail able with magnetic latching The change towards one of the two bistable positions of the main contact is op erated by a pulse of 100 msec duration The coil con sumes no power except for the short pulse necessary to close and reopen the main contact see also catalogue B164 4 2 Special features X X Compact design X X ...

Page 9: ...k current like an open style power relay Terminals M6 Tightening torque max 3 Nm E Coil terminals A1 and A2 Flat tabs 6 3 x 0 8 mm Fig 2 SPST NO Contactor C137 C fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M3 Tightening torque 2 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open...

Page 10: ... out designed to carry current only but not to make and break current Terminals M6 Tightening torque max 3 Nm Fig 4 Changeover SPDT contactor C137 H fitted with auxiliary contact F an varistor G or diodes H A Mounting holes for screws M3 Tightening torque 2 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power r...

Page 11: ... power relay Terminals M8 Tightening torque max 6 Nm E Coil terminals A1 and A2 Flat tabs 6 3 x 0 8 mm Fig 6 SPST NO Contactor C163 C fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M5 Tightening torque 6 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power relay Terminals...

Page 12: ...out designed to carry current only but not to make and break current Terminals M8 Tightening torque max 6 Nm Fig 8 Changeover SPDT contactor C163 H fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M5 Tightening torque 6 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power r...

Page 13: ... power relay Terminals M8 Tightening torque max 6 Nm E Coil terminals A1 and A2 Flat tabs 6 3 x 0 8 mm Fig 10 SPST NO Contactor C164 C fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M5 Tightening torque 6 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power relay Terminal...

Page 14: ...out designed to carry current only but not to make and break current Terminals M8 Tightening torque max 6 Nm Fig 12 Changeover SPDT contactor C164 H fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M5 Tightening torque 6 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power ...

Page 15: ...ower relay Terminals M10 Tightening torque max 10 Nm E Coil terminals A1 and A2 Flat tabs 6 3 x 0 8 mm Fig 14 SPST NO Contactor C165 C fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M5 Tightening torque 6 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power relay Terminal...

Page 16: ...t designed to carry current only but not to make and break current Terminals M10 Tightening torque max 10 Nm Fig 16 Changeover SPDT contactor C165 H fitted with auxiliary contact F and varistor G or diodes H A Mounting holes for screws M5 Tightening torque 6 Nm B Plasma exits C Permanent magnets D Main contacts normally open contact make designed to make and break current like an open style power ...

Page 17: ...e must be taken to pack the contactor in a way that prevents damage during shipment 6 Unpacking 6 1 Unpack the device X X Before opening the packaging perform a visual inspection for any signs that could indicate dam age having occurred during transport impacts bumps falling etc X X If any signs indicate that the contactor has been subject to excessive shock influence do not install the contactor ...

Page 18: ...37 C163 C164 C165 Dimension a mm 30 0 2 35 0 2 40 0 2 60 0 2 Dimension b mm 62 0 2 85 0 2 105 0 2120 0 2 Screw size c M3 M5 Torque 3 Nm 6 Nm X X The mounting holes can either be threaded holes for threaded screws or through holes for threaded screws and nuts X X The length of the fixing screws has to be deter mined according to the constructional conditions X X In order to secure the mounting scre...

Page 19: ...ged rings and detent edged washers have a limited life time After 3 times opening of screws secured with detent edged rings or detent edged washers the rings or washers must be replaced by new ones X X Record the frequency of screw opening in the work log X X After 3 times opening of screws replace detent edged rings or detent edged washers by new ones Required tools and auxiliaries Socket wrench ...

Page 20: ...screws M3 x 5 6 and 4 washers 5 on the mounting plate 3 Torque for the cylinder screws 0 6 Nm X X Place the mounting plate 3 at the rear side of the contactor an fix it from the front side with 4 cylin der screws 1 and 4 washers 2 X X Tighten the cylinder screws 1 with the deter mined torque according to the table Series Cylinder screws 1 Torque C137 M3 x 8 0 6 Nm C163 M5 x 10 1 4 Nm C164 C165 X X...

Page 21: ...r the required cross sections of wires busbars refer to our catalogue B60 The catalogue is available under https www schaltbau com en media library X X If wires are used the wire gauges must be selected in coordination with their insulation class and the operating conditions X X Depending on the contactor type the wires of the main current circuit must be fitted with appropri ate cable lugs for te...

Page 22: ... way round NOTICE Detent edged rings and detent edged washers have a limited life time After 3 times opening of screws secured with detent edged rings or detent edged washers the rings or washers must be replaced by new ones X X Record the frequency of screw opening in the work log X X After 3 times opening of screws replace detent edged rings or detent edged washers by new ones Required tools and...

Page 23: ...or tabs A 6 3 x 0 8 mm NOTICE X X Bending of the coil terminals is not permissible X X Move and lay the control wires and flat recepta cles for tabs only in plugging direction see Fig 24 und Fig 25 X X Attach the control wires mechanically in order to minimize retroactivities e g shock vibra tions from the wires to the terminals X X Plug the prepared control wires with the flat re ceptacles 3 to b...

Page 24: ...acts Example for the connec tion with wires the figure shows C164 the procedure for C137 C163 and C165 is the same Main contact connection with busbars As an alternative to the connection with wires the main current circuit can also be connected with busbars Examples for the connection with busbars are shown in Fig 27 and Fig 28 X X Lay the busbars 7 to both main contacts 1 X X Depending on the in...

Page 25: ...y closed contacts 1 X X Makesure thatbothcontactbolts 1 areequipped with washers and counter nuts 6 X X Put the cable lugs 2 on the contact bolts 1 X X Put the washers 4 on the contact bolts 1 Schaltbau recommends Schnorr Washers or similar to secure the nuts X X Screw the terminal nuts 5 on the contact bolts 1 X X Hold the counter nuts 6 using an open end wrench X X Tighten the terminal nuts 5 wi...

Page 26: ...C164 and C165 is the same Tie bars for contactors in series connection To realise series connections with contactors Schaltbau offers suitable connecting tie bars For dimensions and ordering codes of the tie bars refer to our catalogue B60 The catalogue is available under https www schaltbau com en media library An example of a series connection with tie bars is shown in Fig 31 X X Make sure that ...

Page 27: ... correct polarity X X Check the function of the auxiliary switches Use a continuity tester to check that the wiring is correct and the auxiliary switches are functioning correctly X X Check the pull in voltage and drop off voltage according to the requirements of Schaltbau Refer to catalogue B60 X X Check the laying of cables Cables must not be squeezed or bent If applicable bundle the cables and ...

Page 28: ... When the work has been concluded proceed the other way round 8 2 Preventive maintenance Contactors of C137 C163 C164 C165 Series are main tenance free within the rated mechanical life time The electrical life time depends on the number of switch ings under heavy load conditions and may vary for dif ferent applications In normal use this corresponds to a decade long operating period Intervals for ...

Page 29: ... the terminal nuts with the rated torque Contactor housing Check for X X dirt X X damage or wear and tear X X loose or missing fastening elements In case of faults X X remove existent dirt X X if the contactor housing is damaged replace the entire contactor X X thighten a loose contactor housing X X immediately replace missing fasten ing elements Arc chamber Check for X X damage or wear and tear X...

Page 30: ... Set of flat head screwdrivers X X Torque wrench Remove the arc chamber cover DANGER Before removing the arc chamber make sure that X X there is no voltage present X X all safety regulations are fully ob served X X Refer also to section 8 1 Safety on page 28 X X Uninstall wires or busbars if necessary Contactor types C137 and C163 X X Unscrew the screw 1 and remove it together with the washer X X ...

Page 31: ...move it The main contacts are now accessible and can be checked See Check the main contacts for wear and tear further on in this manual X X After the main contacts have been checked re install the arc chamber in reverse order 3 2 3 Fig 34 Remove the arc chamber the figure shows C164 C the procedure for C165 C is the same 3 2 3 Fig 35 Remove the arc chamber the figure shows C164 H the procedure for...

Page 32: ...cedure for C163 C C164 C and C165 C is the same Changeover SPDT contactor types C 137 H C163 H C164 H and C165 H X X Check the main contacts for damage wear and tear as well as traces of burn off slightly sooting is acceptable In doing so check both the fixed contacts 4 and the contacts 5 at the lower side of the moving bridge X X If the loss of contact material is more than 70 replace the entire ...

Page 33: ...eters Do not unscrew complete ly X X Pull out the angled mounting bracket of the auxil iary contact assembly 2 X X Slide the new auxiliary contact assembly 2 with the angled mounting bracket underneath the washer at the screw head 1 X X Press the magnet yoke against the housing and screw in the hexagon screw 1 X X Adjust the angled mounting bracket of the auxil iary contact assembly 2 The auxiliar...

Page 34: ... schaltbau com en media library The updated catalogues render the previous issues in valid 11 Disposal This product is designed for exclusive professional use by commercial companies The owner is responsible for ensur ing an environmentally sound disposal of this product at the end of its working life This product or parts of it may not be disposed with other household wastes To prevent possible h...

Page 35: ...35 2019 05 24 V1 0 Contactors C137 C163 C164 C165 Installation and Maintenance Instructions Notes Notes ...

Page 36: ...ower supplies Contactors for railway applications Terminal bolts and fuse holders DC emergency disconnect switches Special contactors to suit customer requirements Electrics for rolling stock Equipment for driver s cab Equipment for passenger use High voltage switchgear High voltage heaters High voltage roof equipment Equipment for electric brakes Design and engineering of train electrics to custo...

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