Schaltbau CT1115/08 Bedienungsanleitung

Inhalt

Rundsteckverbinder für Spezialanwendungen, Baureihe SB

Besondere Merkmale

Applikationen

Baureihenübersicht

Kompetenz

Normen

Technische Daten

Bestellschlüssel

5-polig + PE Flanschstecker, Kabeldose

6-polig Flanschdose, Kabelstecker

14-polig Flanschstecker, Kabeldose

Montage

Werkzeuge Ausdrückwerkzeuge AWZ-A und AWZ-C/H, Crimpzange CWZ-600

Montagebohrungen

Kontakte Stecker: Crimpkontakte, Dosen: Lötkontakte

Deratingkurven

Sicherheitshinweise

Contactors

CT1115/08, CT1130/08 series

Single Pole NO

Power Contactors

for AC and DC

Manual C20/08-M.en

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 2/26

Revision History:

Rev.Level

Date

Page

Description

Name

1.1

26.10.2012

Part number of glue for ceramic protection insert

changed from 13600310 to 13650290

Neuwieser

2.0

21.01.2016

div

General revision; new pictures; different way of

fixing the ceramic insert; introduction of 2 differ-

ent contact bridge carriers.

Changes will be implemented step by step be-

ginning end of 2015.

For deliveries prior to that time version 1.1 will

stay valid.

Junck

2.1

08.06.2016

Recommendation: Cross section 80x8 for current

bars

Junck

2.2

24.10.2017

Amendment Functional description Aux switches

Functional diagram, page 10

Kapfer

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 3/26

CT1115/08

CT1130/08

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 4/26

Conventions for this

Manual

To highlight particularly important instructions, the following symbols are

used in this handbook.

General legal notice

 CT1000 contactors must only be used under operating conditions according to the technical specification and

the instructions in this manual.

 CT1000 contactors must only be used when all protective devices are present, have been installed properly and

are fully operational.

 CT1000 contactors must not be converted or otherwise modified without prior consent of SCHALTBAU GmbH.

Violations against this will result in the exclusion of liability on the part of the manufacturer.

 We reserve the right to make technical alterations without prior notice.

 For updated product information visit www.schaltbau-gmbh.com.



 Furthermore, we refer to our “General Terms and Conditions of Sale (GCS) for Goods and Services”.

Without prior written consent of Schaltbau GmbH, the operating instructions are not allowed to be electronically or

mechanically reproduced – as a whole or in parts – be distributed, changed, transmitted, translated into another

language or used in any other way.

NOTICE refers to technical features and methods aimed at

facilitating work or to particularly important information.

DANGER refers to processes/operations which have to be

followed exactly in order to avoid personal injuries.

CAUTION refers to processes/operations which must be fol-

lowed to avoid damaging structural components, the system

or other user materials.

WARNING refers to hazardous electrical voltages.

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 5/26

Table of Contents

Introduction....................................................................................................................................................6

Safety information .........................................................................................................................................7

Electrical hazards ..................................................................................................................................... 7

Safety notices ........................................................................................................................................... 7

General application notes ........................................................................................................................ 7

Technical data................................................................................................................................................8

Applied standards..........................................................................................................................................8

Description .....................................................................................................................................................9

Lower Module ........................................................................................................................................... 9

Upper Module ......................................................................................................................................... 10

Functional description ............................................................................................................................ 11

Order code ............................................................................................................................................. 12

Storage..........................................................................................................................................................13

Storage ................................................................................................................................................... 13

Return shipments ................................................................................................................................... 13

Installation....................................................................................................................................................13

Unpacking and handling ......................................................................................................................... 13

Operating position .................................................................................................................................. 14

Mechanical requirements ....................................................................................................................... 14

Electrical requirements ........................................................................................................................... 15

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

Electrical installation of the auxiliary switches ....................................................................................... 16

Electrical installation of the magnetic drive ............................................................................................ 16

Mounting of the Upper Module ............................................................................................................... 17

Electrical installation of the main circuit ................................................................................................. 17

Electrical installation of the earth terminal ............................................................................................. 18

Commissioning............................................................................................................................................18

Maintenance .................................................................................................................................................19

Recommended regular service intervals ................................................................................................ 19

Unscheduled service intervals ............................................................................................................... 19

Inspection activities ................................................................................................................................ 19

Spare parts, replacement of parts .......................................................................................................... 20

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 6/26

Introduction

CT1000 contactors are air switching components with arc breaking in ce-

ramic. They use a highly sophisticated principle of arc control, combining

the permanent-magnetic and electro-magnetic blow-out technique.

This allows practically unrestricted operation for all AC and DC voltages

and currents within the technical specification.

 CT1015 contactors are designed for nominal voltages of 1,500 V.

 CT1030 contactors are designed for nominal voltages of 3,000 V.

Due to the very high rated insulation voltage CT1030 contactors

can be used for peak voltages up to 5,000 V.

 This manual refers to single pole contactors with a conventional

thermal current of 800 A. For single contactors for 400 A refer to

manual C20/04-M. For single contactors for 1,100 A refer to man-

ual C20/11-M.

CT1000 contactors provide excellent switching performance from very

small up to heavy loads.

CT1000 contactors are available for vertical and horizontal mounting.

CT1000 contactors have been designed and tested according to National

and International Railway Standards. Due to their unique features they

can also be used in a variety of industrial applications.

CT1000 contactors offer the following design-related advantages:

 Compact, rugged design

 2 voltage levels, several current levels

 Double-break contacts, cadmium-free contact tips

 1-, 2- (and 3-) pole versions

 Easy maintenance:

o Easy inspection of main contact tips, easy replacement of

main contacts

o Easy replacement of arc chamber (upper module)

 Drive system suitable for standard railway supply voltages and

tolerances. No economy circuit required for standard versions.

Drive systems for industrial applications on demand.

 Insulation coordination:

o Functional insulation for main circuit

o Basic insulation between main circuit and protective earth

o Reinforced insulation between main circuit and control

circuit / main circuit and auxiliary circuits

 Long mechanical and electrical life

No regular maintenance required. Inspection intervals and exchange of

wear parts depending on specific application.

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 7/26

Safety information

Electrical hazards

Safety notices

General application

notes

Before carrying out any inspection and maintenance work on

CT1000 contactors, the contactors must be de-energized and

in addition life wires made safe by earthing. If the environ-

ment has no disconnecting and earthing device, other suita-

ble measures must be used to ensure that no voltage is pre-

sent. Please make sure that any capacitors in the main circuit

are discharged before touching main wires. We recommend

securing the supply lines to prevent switching back on.

The 2 black protection caps must not be removed for opera-

tion. They are part of the insulation system. Operation without

the 2 black protection caps is not permissible.

All inspections and the replacement of components may only

be performed by qualified personnel and must be done ac-

cording to Schaltbau specification.

All components which have to be replaced must be original

components defined by Schaltbau.

During continuous operation the contactors will warm up. It is

recommended to wait an appropriate time before starting any

service and touch the contactors.

CT1000 contactors are high-voltage switches. Getting into

contact with conductive parts of the contactors can result in

serious injury or even death!

Active parts are all piece parts associated with the main cir-

cuit. All metal parts visible may potentially become active un-

der fault conditions. A respective label is attached to the con-

tactor. This label must not be removed.

For safety reasons the contactors must be connected to

earth. An earth terminal is provided for that purpose. The wire

gauge must be observed according to the specific short-

circuit conditions.

CT1000 contactors are designed to be mounted in environ-

ments defined by pollution degree PD3 according to

EN60077-1:

Pollution degree PD3

Conductive pollution or dry non-conductive pollution occurs

which becomes conductive due to condensation which is to

be expected.

Example: Indoor location not directly exposed to rain, snow

and heavy dust.

CT1000 contactors contain strong magnets for the perma-

nent-magnetic blow-out. Make sure that these magnets do

not attract any ferromagnetic particles into the contactors, ei-

ther opened or closed.

These magnets may destroy data on credit cards or such.

During the short time of the switching-off operation strong

magnetic fields are generated in the vicinity of the pole plates.

They may affect other components close to the contactor.

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 8/26

Technical data

Refer to catalogue C20, data sheets and measured drawings.

Applied standards

Refer to catalogue C20.

EN60077-1: 2003-04

Railway applications - Electric equipment for rolling stock

Part 1: General service conditions and general rules

(IEC 60077-1:1999, modified)

EN 60077-2: 2003-04

Railway applications - Electric equipment for rolling stock

Part 2: Electrotechnical components; General rules

(IEC 60077-2:1999, modified)

EN 50124-1: 2010-11

Railway applications - Insulation coordination

Part 1: Basic requirements - Clearances and creepage dis-

tances for all electrical and electronic equipment

EN 61373: 2011-04

Railway applications - Rolling stock equipment

Shock and vibration tests

EN 50125-1: 2014-11

Railway applications –Environmental conditions for equipment

Part 1: Equipment on board rolling stock

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 9/26

Description

CT1000 contactors consist of two main modules:

 Lower Module:

Magnetic drive (MD) with moving contact bridge (MC, not visible);

base plate (BP); auxiliary contact group (AG); coil terminal group

(TG); AG and TG are under protection caps.

 Upper Module:

Fixed contacts with main terminals (FC); arc chamber (AC); latch-

ing levers (LL) and lock bars (LB)

Lower Module

 Magnetic drive (MD) with moving contact bridge (MC)

- Compact magnetic drive system for DC voltages.

- Designed for standard railway supply voltages and tolerances.

Standard nominal supply voltages are Us = 24 V and Us = 110 V,

tolerances from 70% up to 125% of Us. Other nominal supply

voltages are available on request.

- Double-break moving contact bridge.

- Polarity independent overvoltage protection device.

 Base plate (BP)

- 4 fixation holes

- Earthing terminal

The contactor should be mounted on a metal rack to provide a se-

cure mounting as well as a heat sink for the magnetic drive.

The value of the overvoltage limitation is part of the

magnetic system and must not be changed or short-

circuited by external means. It is explicitly stated that the

use of diodes is prohibited for that purpose. Take care

there is no such diode in the external control circuit.

Upper Module

Lower Module

User Manual, Power contactors, series CT1115/08 and CT1130/08

Rev. 2.2 Page 10/26

 Auxiliary contact group (AG)

Standard:

- 1 contact to indicate the “well closed” position of the main con-

tacts (EN60077: a1)

- 1 contact to indicate the “well opened” position of the main con-

tacts (EN60077: b0)

- 2 NO/NC contacts

Option:

- 4 NO/NC contacts

- M3 screw or 6.3 x 0.8 mm fast-on terminals

- Protection cap (can be removed and fixed only when the Upper

Module has been removed)

 Coil terminal group (TG)

- Cage clamp terminals

- Protection cap (can be removed and fixed only when the Upper

Module has been removed; fixation with screw M4 x 10)

Upper Module

 Fixed contacts with main terminals (FC)

- Press nuts M10 for easy connection of cables

- Mounting hole Ø 12.7 mm for easy connection of current bars

- Minimum wire gauges for connecting cables or current bars must

be observed.

- Double-break contacts

 Arc chamber (AC)

- Permanent-magnetic blow-out system with magnets and pole

plates

- Electro-magnetic blow-out system with blow-out coils and pole

plates

- Arc guidance plates

- Ceramic inserts for arc extinction

 Latching levers (LL)

- Latching and unlatching simply by turning pole plates. No tool

required.

- Large handles for easy operation.

 Lock bars (LB)

- Simple locking and unlocking mechanism with optical control. No

tool required for unlocking.

The Upper Module must be latched and completely

locked before starting operation.

Red bars indicate contactors for vertical mounting posi-

tion

Yellow bars indicate contactors for horizontal mounting

position.

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