Schaltbau CPP Series Installation And Maintenance Instructions Manual Download Page 1

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Contactors

CPP Series

1 pole

AC and uni-directional DC

NO and NC contactor

1 Installation and

Maintenance Instructions

Manual C45-M.en

GA Connectors – Installation and Maintenance Instructions // Schaltbau

Summary of Contents for CPP Series

Page 1: ...3 3 Contactors CPP Series 1 pole AC and uni directional DC NO and NC contactor 1 Installation and Maintenance Instructions Manual C45 M en ...

Page 2: ...1 CPP 1 pole NO or NC contactors for DC or AC 9 4 2 Features 9 4 3 Reliable robust and economical 9 4 4 Application 10 4 5 Technical information and material properties 10 4 6 Overview 11 CPP contactors stand alone versions 11 CPP contactors built in versions 12 5 Storage 13 6 Unpacking 13 6 1 Unpacking the device 13 6 2 Check parts for transport damage 13 7 Installation 14 7 1 Mounting 14 Dimensi...

Page 3: ... earth ground terminal only for stand alone versions 20 Connecting the main contacts 21 7 3 Checks 22 8 Maintenance 23 8 1 Safety 23 8 2 Preventive maintenance 23 Intervals for regular tests checks 23 Regular tests checks 24 Removing the arc chamber 26 Inserting the arc chamber 26 Checking the arc chamber 27 Checking the main contacts 27 8 3 Corrective maintenance 28 Replacing the arc chamber 28 R...

Page 4: ...tion the following abbre viations are used in this manual NO Normally Opened NC Normally Closed Since the CPP series devices offer a wide range of con figuration options not all possible configurations can be presented in this manual Even if the configurations shown do not correspond ex actly to the present device the installation and mainte nance steps can be carried out identically as described ...

Page 5: ...technical data sheets or in our C45 catalogue may be overridden The C45 catalogue is available under https www schaltbau com en media library X The contactors may only be used when all protec tive devices are present have been correctly in stalled and are fully operational X Contactors may not be used without other safety precautions in potentially explosive atmospheres and or in aggressive media ...

Page 6: ...er or insulate adjacent live parts X The presence of a voltage free state can only be clearly identified by a qualified electrician X When the work has been concluded follow the procedure in reverse 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 X Mak...

Page 7: ...g damage and malfunctions ATTENTION Aggressive liquids may damage the contactors X Ensure the contactors do not come into contact with aggressive liquids ATTENTION Improper handling of the contactors e g dropping on the floor can result in breaks cracks and deformation X Ensure the contactors are always handled correctly X Do not throw the contactors on the floor X At regular intervals perform a v...

Page 8: ...d surfaces the functional reliability of the contactors is no longer ensured X Visually inspect the contactors regularly to detect wear and soiling X Replace damaged parts immediately X Immediately remove any soiling without leaving any residues X Immediately replace any parts with persistent soiling ATTENTION Detent edged rings and detent edged washers have a limited life time After screws secure...

Page 9: ... silver contacts favour the ex cellent breaking capacity X High thermal continuous current Ith of up 200 amps The CPP series can permanently carry currents of up to 200 amps in the NO contactor version In the version as a NC contactor currents of 120 amps can be carried Connection cross section NO contactor 120 mm NC contactor 35 mm maxi mum ambient temperature 70 C The values are achieved through...

Page 10: ... Main contactor CP or CT series Converter Catenary Rail NO Precharging NO contactor Use as a classic precharging con tactor in the make contact variant connecting and disconnecting the resistor for precharging the DC link in converters of railway vehicles NC Discharging NC contactor Use as discharge contactor in the NC contact variant discharging the capacitor in the DC link in convert ers of rail...

Page 11: ...g 1 CPP 1115 NO 2115 NC contactors stand alone version A Arc chamber unit removable B Main contacts connection M5 torque 4 5 Nm C ON OFF indication D Coil terminal A1 A2 connection spring clamp ter minal block E Base plate with 4 fastening holes Ø 6 mm for M5 screws F Auxiliary switches S870 flat plug connections 6 3 x 0 8 mm G Earthing connection M5 torque 4 5 Nm ...

Page 12: ...in contactor A Arc chamber unit removable B Main contacts connection M5 torque 4 5 Nm C ON OFF indication D Coil terminal completely wired the coil control wires can be connected directly to the designated spring clamp ter minals on the CP main contactor E Angeled mounting flange with 2 threaded fastening holes for M5 screws F Auxiliary switches S870 flat plug connections 6 3 x 0 8 mm For CP main ...

Page 13: ...ging is not available care must be taken to pack the contactor in a way that prevents dam age during shipment 6 Unpacking 6 1 Unpacking the device X Before opening the packaging perform a visual inspection for any signs that could indicate dam age having occurred during transport impacts bumps dropping etc X If any signs indicate that the contactor has been subject to excessive impacts do not inst...

Page 14: ...ting screws The length of the mounting screws must be de termined dependent on the structural circum stances To secure the mounting screws so that they do not come loose appropriate screw locking elements must be provided Schaltbau recom mends using Schnorr washers or similar The mounting screws must be equipped with washers resting on the device Installation without washers is not permitted The m...

Page 15: ...ure that there is sufficient space for routing the wires for auxiliary switches and coil terminals Otherwise if the wires are routed too tightly the auxiliary switch connections and or coil terminals can break off or bend Ventilation requirements X Ensure sufficient ventilation in the installation area especially when switching heavy loads This allows the plasma to be dissipated more quickly and r...

Page 16: ...stallation at a seperate mounting position e g next to a CP main contactor For CP contactor types with 600 A the CPP can only be mounted at a separate mounting position X Ensure that the contact surfaces on the moun ting plate 3 and the bottom of the CPP 1 are free from dirt and other contamination e g metal chips X Position the CPP 1 on the mounting plate 3 which is provided with mounting holes X...

Page 17: ... Undersized conductor cross sections for the earth connection may produce a safety hazard X The minimum conductor cross sections for the main terminal connection and the earth ground connection must be observed X The connecting wires must be selected taking into consideration the insulation class and the ambient conditions X The connecting wires of the main power circuit must be fitted with approp...

Page 18: ...uit this includes discharging any capacitors in the main circuit X Beside the main power circuits also disconnect additional and auxiliary circuits X Cover or insulate adjacent live parts X The presence of a voltage free state can only be clearly identified by a qualified electrician X When the work has been concluded follow the procedure in reverse ATTENTION Detent edged rings and detent edged wa...

Page 19: ...s to mi nimise feedback effects of forces caused by the wires e g shock vibrations acting on the terminals X Route the control wires 1 to the terminals 2 of the auxiliary switches X Plug the pre assembled control wires with the re ceptacles 1 to the terminals 2 X Check the routing of the wiring Wires must not be squeezed or bent X If applicable bundle and secure the wires using cable ties 6 3 x 0 ...

Page 20: ... the control wires 1 The polarity need not be observed X Check that the coil control wires are correctly in stalled X Check the routing of the wiring Wires must not be squeezed or bent X If applicable bundle and secure the wires using cable ties 2 1 Fig 12 Connecting the coil stand alone versions Built in versions For built in versions the coil control wires 1 are com pletely wired and can be conn...

Page 21: ...C versions make sure to observe the correct polarity X Screw the ring terminals 3 in place using the ter minal screws 4 and suitable screw locking ele ments Schaltbau recommends using Schnorr washers or similar X Tighten the terminal screws 4 to a torque of 4 5 Nm 4 5 Nm 1 4 3 4 3 4 5 Nm 2 2 Fig 15 Connecting the main contacts Connection example of a built in version 4 5 Nm 4 3 2 2 1 4 4 5 Nm 3 Fi...

Page 22: ... the control wires of the coil terminals are correctly installed X Check that the control wires are correctly connect ed to the auxiliary switches Check the correct assignment and function of the auxiliary switch using a continuity tester X Switch the contactor several times without acti vating the main power circuit X Check the pull in and drop off voltage based on the Schaltbau specifications Se...

Page 23: ...w the procedure in reverse 8 2 Preventive maintenance Contactors of the CPP series are maintenance free within the rated mechanical life time The electrical life time depends on the number of switching cycles under heavy load conditions and may vary for different ap plications In normal use this corresponds to a decade long operating period Intervals for regular tests checks To ensure the correct ...

Page 24: ...ghtening torque of the terminal screws In case of faults X immediately replace damaged wires or cable lugs X immediately replace damaged bus bars X remove corrosion and replace cor roded parts X tighten loose fastening elements im mediately replace missing fastening elements X tighten the terminal screws to the rated torque Earthing cable only for stand alone versions Check for X damaged cable cab...

Page 25: ...hamber is latched securely Main contacts both stationary contacts and moving contact bridge Prior to checking the main contacts the arcing cham ber must first be removed see section Removing the arc chamber Thereafter the main contacts are accessible and can be checked for X damage or wear X traces of combustion residue slight soot deposits permitted A certain level of experience is required to as...

Page 26: ...y from the contactor and keep it in this position X Remove the arc chamber 2 upwards from the housing 1 2 3 Fig 17 Removing the arc chamber stand alone versions 1 2 3 Fig 18 Removing the arc chamber unit built in versions Inserting the arc chamber Refer to Fig 17 and Fig 18 X Press the latching lever 1 sideways slightly away from the contactor and keep it in this position X Insert the arc chamber ...

Page 27: ... 19 Checking the arc chamber for wear Checking the main contacts Precondition The arc chamber must be removed from the contactor housing See section Removing the arc chamber Tools required Inspection mirror Checking the main contacts for wear X Check the main contacts In doing so check both the stationary contacts 1 as well as the contacts 2 on the underside of the moving contact bridge X To get a...

Page 28: ...orque spanner Precondition Only for built in versions The CPP contactor must be removed from the base plate of the CP main contactor See section Installing the CPP contactor with 1 200 A and 2 000 A CP devices Procedure To secure the auxiliary switch use only the original plas tic self tapping screws 3 x 20 Torx drive T10 do not use any screws with a standard regular screw thread X Pull off the re...

Page 29: ...duct is designed for exclusive professional use by commercial companies The owner is responsible for ensuring an environmentally sound disposal of this product at the end of its working life This product or parts of it may not be disposed of with other household waste To prevent possible harm to the environment or hu man health from uncontrolled waste disposal please separate this product or parts...

Page 30: ...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 customer r...

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