User Manual, Series CT1015/04 and CT1030/04 - IMPOL-1
Contents
1. Fixed contacts with main terminals FC arc chamber AC latching levers LL and lock bars LB Schaltbau GmbH Page 6 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 3 1 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 U 24 V and U 110 V tolerances from 70 up to 125 of Us Other nominal supply voltages are available on request Polarity independent overvoltage protection device 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 Double break moving contact bridge Base plate BP 4 fixation holes Earthing terminal The contactor should be mounted on a metal rack to provide a secure mounting as well as a heat sink for the magnetic drive Auxiliary contact group AG Standard 1 contact to indicate the well closed position of the main contacts EN60077 a1 1 contact to indicate the well opened position of the main contacts EN60077 60 2 CO contacts to generally indicate the position of the main contacts Option 4 CO contacts to generally indicate the position of the main con2. 16 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 5 Service CT1000 contactors are maintenance free within the rated mechanical life time data The electrical life data depend on the number of switchings under heavy load condition and vary for different application In normal use this corresponds to a decade long operating period 5 1 Recommended Service intervals Checking activity designation Checking interval Optical inspection from outside 1x annually Inspection of the main contacts 1x to 2x annually depending on application Inspection of the auxiliary contacts Every 2 years 5 2 Inspection activities 5 2 1 General If the contactors are being used in particularly dirty environments the checking intervals for the optical inspection should be shortened because dirt can impair the insulation clearances and there is therefore the possibility of a shorter service life or an operational fault 5 2 1 1 High voltage supply cables Check of the high voltage supply cables and the tightening torques of the fastening screws 5 2 1 2 Earthing Check of the supply cables and the tightening torques of the fastening screw 5 2 1 3 Cleaning In case of excessive dirt the surface of the contactors should be cleaned 5 2 1 4 Inspection of the main contacts Disconnect the main cables current bars and remove the Upper Module refer to 4 1 Inspect the main contacts both fixed and movable contacts It requi
3. be used as a replacement 5 3 1 Main contacts and ceramic protection insert If the main contacts have to be replaced all 4 contacts must be replaced the moving bridge and the 2 fixed terminals Disconnect the main cables current bars Hemove the Upper Module refer to 4 1 Remove the protection caps refer to 4 1 Dismount the contactor Remove the moving bridge Remove the nut at the bottom of the contactor with a number 8 socket wrench and put the nut and the washer aside The nut is secured with red locking varnish which will be destroyed during that operation The moving bridge can be pulled out of the guidance Schaltbau GmbH Page 19 28 Status 2010 07 16 SCHALTBAU Connect Contact Control Insert the replacement bridge Since the moving bridge construction is connected to the lever to operate the auxiliary switches the assembly must be done with great care The arrow on the axle of the auxiliary switch actuation cam must be in line with the mark on the frame when the new bridge is being inserted Mount the new bridge from the top and secure it with washer and nut Torque 5 Nm Secure the nut again with red locking varnish Correct position not activated Wrong position activated Test the replacement bridge Lift the bridge The bridge must be moved up and down easily The lever to operate the auxiliary switches must follow the movement of the bridge the arrow must change from the not activat
4. 3 Die BAU Connect Contact Control Switchgear for Railway and Industrial Applications Power contactors for AC and DC Series CT1015 04 and CT1030 04 User Manual J Te ox BAU Connect Contact Control POWER CONTACTORS FOR AC AND DC SERIES CT1015 04 AND CT1030 04 USER MANUAL Schaltbau GmbH Page 2 28 Status 2010 07 16 SCHALTBAU Connect Contact Control MEN OOo m 4 SO OO m 5 2 1 General safety instructions aa a ne me D to noi 5 22 General application notes nee 5 SHEEP 76 EEE 6 NETS e 7 cM ed ou 8 23 PUNCTONA OS SCO ER 9 COR ee eee ee eee eee 10 A UM ANON ses sc 11 E RAO AC and RONA ee a ne un 11 AZ POSIMO ____ 12 4 3 Mechanical requirements iii 12 4 3 1 Device 12 4 3 2 HS CAN CNS ________ ____ 12 44 Electrical requirements ere 13 xu O mmm 14 4 5 1 Mechanical installation dpa baxIdU dr Os 14 4 5 2 Electrical installation of the auxiliary switches 4 14 4 5 3 Electrical installation of the magnetic drive ss 15 4 5 4 4 Electrical installation of the main circuit 15 4 6 COMMISSION sn tit Eieudt intenses nier DM DN S
5. Before opening the packaging perform a visual inspection for any signs that could indicate damage having occurred during transport impacts bumps falling etc Unpack the contactor and put it on the table in an upright position With one hand press the release buttons on top of the arc chamber together and turn the 4 levers down one by one to unlatch the Upper Module Lift the Upper Module and put it on the table in an upright position Repeat for all Upper Modules in cases of multi pole versions Check the insulation plates for damage Remove both protection covers the small one is fixed with a M4 x 10 screw the big one with knurled thumb screws The Lower Module is ready for mounting Note If the contactor has been subject to excessive shock influence e g during transport do not install the contactor Note Only single pole contactors may be carried by Upper Module provided the contactors are safely locked and the devices are undamaged Schaltbau GmbH Page 11 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 4 2 Operating position Make sure that you have received the correct contactors for the application CT1000 contactors for horizontal mounting must only be mounted horizontally Lock bars are yellow position is also shown on the labels they can be mounted in any position in reference to the direction of movement of the vehicle Make sure that both Upper and Lower Module are for horizontal mou
6. Part 1 Equipment on board rolling stock Schaltbau GmbH Page 28 28 Status 2010 07 16
7. UP MES EE 16 AE _____ ____ ____ __ __ 17 5 1 Recommended Service ee D 17 52 D CO AR _ _ _ _________ ee 17 5 2 1 OEM Al EN 17 5 3 Spare parts 19 5 3 1 Main contacts and ceramic protection insert sise 19 Des AUDI COTES ea ne ERU ee a ee eau tit 25 CI S 28 ADOBE standards TO mE 28 Schaltbau GmbH Page 3 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 1 Introduction CT1000 contactors are air switching components with arc breaking in ceramic 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 in networks up to 5 000 V CT1000 contactors are currently available for conventional thermal currents of 400 A Versions for 800 A are in development Versions for 200 A and 1 400 A are in planning CT1000 contactors provide excellent switching performance from
8. ates of the CT1000 contactors Typical values Pull in time 120 ms Drop off time 60 ms Settling time for bO switch up to 10 ms Zero position Meaning Closed Active a1 contact Open T Open bO contact Closed Drop off time E Settling time Pull in time Off Off On Schaltbau GmbH Page 9 28 Status 2010 07 16 3 4 Order code Example CT1030 04 V 110ET 00 001 Number of poles EU 11 1 pole version 12 2 pole version 13 3 pole version Nominal voltage 15 1 5kV 30 3 kV Conventional thermal current 02 200 A 1 04 400 A 08 800 A 16 1 600 A Mounting position H Horizontal yellow lock bars V Vertical red lock bars Supply voltage 24 24V 110 110V Supply voltage tolerance E 30 25 Coil suppression T Suppressor diode Auxiliary contacts 00 1x ai 5870 refer to catalogue 070 1x 60 5870 refer to catalogue 070 M3 screw type terminals 2x CO 5826 refer to catalogue 026 1x a1 S870 refer to catalogue D70 1x 60 5870 refer to catalogue 070 Flat tabs 6 3 x 0 8 2x CO 5826 refer to catalogue 026 4x CO 5826 refer to catalogue D26 M3 screw type terminals 4x CO S826 refer to catalogue D26 Flat tabs 6 3 x 0 8 Special customer design Schaltbau GmbH Page 10 28 SCHALTBAU Connect Contact Control Status 2010 07 16 SCHALTBAU Connect Contact Control 4 Installation 4 1 Unpacking and handling
9. be in line with the plastic surface without projecting length Control the position of the nuts prior to assembly of the new fixed contacts Replace the fixed contacts and push them into the locked position Retighten the four M5 screws Torque 5 Nm Check that the cable lug is tight Take special care concerning the correct Take special care concerning the correct position of the wires close to the plastic position of the wires CT1030 04 CT1015 04 Schaltbau GmbH Page 23 28 Status 2010 07 16 SCHALTBAU Connect Contact Control Reinstall the Lower Module refer to 4 5 1 Replace the protection cap for the auxiliary switches refer to 4 5 2 Replace the protection cap for the magnetic drive refer to 4 5 3 Replace the Upper Module and secure it refer to 4 5 4 Reconnect the main cables current bars PI CT1030 04 CT1030 04 protection insert order 2 per pole CT1015 04 insulation plate for multi pole versions 1 for 2pole 2 for 3 pole versions CT1030 04 insulation plate for multi pole versions 1 for 2pole 2 for 3 pole versions IP CT1015 04 IP CT1030 04 Schaltbau GmbH Page 24 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 5 3 2 Auxiliary contacts If the auxiliary switches have to be replaced all switches of one type S826 or S870 should be replaced Disconnect the main cables current bars Hemove the Upper Module refer to 4 1 Remove the prote
10. ct with conductive parts of the contactors can result in serious injury or even death Active parts are all piece parts associated with the main circuit All metal parts visible may potentially become active under fault conditions A respective label is attached to the contactor 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 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 environment has no disconnecting and earthing device other suitable measures must be used to ensure that no voltage is present 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 During continuous operation the contactors will warm up It is recommended to wait an appropriate time before starting any service and touch the contactors 2 1 General safety instructions The 2 black protection caps must not be removed for operation 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 according to Schaltbau s
11. ction caps refer to 4 1 Dismount the contactor Removal of the auxiliary switch subassembly Remove the 2 knurled thumb screws and the 2 Allen head screws MA Note the mounting position of the subassembly and the individual switches Pull the subassembly out in the direction of the arrow pa 4 E 8 c 2 Ts The actual version may differ from the photos Standard versions are 4x S826 and 2x S826 2x S870 as shown Schaltbau GmbH Page 25 28 Status 2010 07 16 SCHALTBAU Connect Contact Control Dismount and mount the switches or the S870 switch group one by one to avoid wrong mounting If all switches are removed together and mounted again a readjustment of the frame is necessary Changing the S870 assembly Use a POZIDRIV 6G cruciform screw driver size 1 to remove the 2 screws on the top of the frame Mount the replace assembly in the same mounting positition Do not forget the washers Changing the S826 snap action switches Use a POZIDRIV cruciform screw driver size 1 to remove the screws 2 for each switch on the bottom of the frame Mount the replace switch in the same mounting positition Do not forget the washers Reassembly of the switch subassembly After all switches have been replaced and the frame has been adjusted to a rectangular position the subassembly can be carefully reinserted into its original mounting position Make sure to mount it in the correct same position as befor
12. e Tighten the 2 Allen head screws M4 The 2 knurled thumb screws should be just turned once Do not forget the washers Schaltbau GmbH Page 26 28 Status 2010 07 16 SCHALTBAU Connect Contact Control Reinstall the Lower Module refer to 4 5 1 Replace the protection cap for the auxiliary switches refer to 4 5 2 Replace the protection cap for the magnetic drive refer to 4 5 3 Replace the Upper Module s and secure it refer to 4 5 4 Reconnect the main cables current bars Spare parts CC CT1030 04 Protection cap coil terminal CA CT1030 04 Protection cap auxiliary switches 826 aL Snap action switch S826 order 2 or 4 per contactor AS 870 Switch group with S870 order 1 per contactor if appropriate Schaltbau GmbH Page 27 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 6 Technical data Refer to catalogue C20 and measured drawings 7 Applied standards Refer also to catalogue C20 Railway applications Electric equipment for rolling stock Part 1 General service conditions and general rules IEC 60077 1 1999 modified Railway applications Electric equipment for rolling stock Part 2 Electrotechnical components General rules IEC 60077 2 1999 modified EN 50124 1 2001 Railway applications Insulation coordination A1 2003 A2 2005 Part 1 Basic requirements Clearances and creepage distances for all electrical and electronic equipment Shock and vibration tests
13. ed position to the activated position when the moving bridge is being lifted Schaltbau GmbH Page 20 28 Status 2010 07 16 SCHALTBAU Connect Contact Control Remove and replace the fixed contacts and r ceramic protection insert Put the Upper Module onto the table upside down on a smooth surface The latching levers must be in the closed position to avoid damage Remove all four M5 screws with a number 8 socket wrench and put the screws and washers aside Two screws are secured with red locking varnish which will be destroyed during that operation The fixed contacts must be pushed slightly to the middle and can then be removed easily The copper wire may be pushed slightly to the side Schaltbau GmbH Page 21 28 Status 2010 07 16 SCHALTBAU Connect Contact Control The following steps concerning the ceramic protection insert are for CT1030 04 only The ceramic protection insert is fixed with Cut the glue carefully with a knife and pry it glue It has to be replaced only in case of open apparent wear or damage Remove all remains of old glue Apply glue to the replacement insert use Weicon Speed Flex white part number 13600310 only Schaltbau GmbH Page 22 28 Status 2010 07 16 SCHALTBAU Connect Contact Control Place the new protection insert in the correct position and push it against the plastic guidance Remove excessive glue The insert must
14. nting CT1000 contactors for vertical mounting must only be mounted vertically Lock bars are red position is also shown on the labels they can be mounted with the auxiliary group either on top or at the bottom Make sure that both Upper and Lower Module are for vertical mounting In most cases the contactors are mounted on mounting plates or mounting frames They must be solid enough to carry the weight of the contactors under the shock and vibration conditions of the railway environment The contactors Lower Module are fixed with 4 or more mounting screws depending on the number of poles The screws and if applicable the nuts must be steel grade 8 8 Schaltbau strongly recommends Schnorr Washers or similar to secure the screws The screws must be tightened with the rated torque permissible for the screws and the nuts 4 3 Mechanical requirements 4 3 1 Device dimensions Refer to the dimensioned drawings of the contactors 4 3 2 Installation dimensions Refer to the dimensioned drawings of the contactors Schaltbau GmbH Page 12 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 4 4 Electrical requirements The minimum clearances to earth or other components must be observed Refer to the dimensioned drawings for details owitching electrical currents at high voltages will produce arcing and plasma will exit out of the top of the arc chamber It is essential to observe the minimum clearance to earth t
15. o avoid the risk of a flash over The minimum clearance has been tested and specified in relation to the switching capacity of the contactors For switching heavy loads allow a minimum time of app 30 s between switchings Allow a recovery time of at least 10 min after 3 heavy load switchings in succession Ensure sufficient ventilation especially in the case of heavy arc switching Allow the exchange of surrounding atmosphere to avoid the risk of flashovers and excessive corrosion The minimum wire current bars gauges for the main terminals and the earth terminal must be observed Smaller gauges for the main terminals will reduce the rated thermal current Smaller gauges for the earth terminal may produce a safety hazard Refer to catalogues for the power consumption of the magnetic drive system and the electrical data of the auxiliary switches C20 Catalogue for Contactors CT1015 04 and CT1030 04 D26 Catalogue for Snap Action Switches 5826 D70 Catalogue for Snap Action Switches S870 Schaltbau GmbH Page 13 28 Status 2010 07 16 4 5 SCHALTBAU Connect Contact Control Installation Installation must be carried out by qualified personnel 4 5 1 Mechanical installation Clean the surface of the mounting plate and the base plate of the contactor Lower Module Put the Lower Module on the mounting plate and secure with the appropriate screws using the correct tightening torque Schaltbau strongl
16. oding pins are provided to ensure the proper positioning Do not try to force the Upper Module into the wrong position In case of multiple pole contactors make sure that the insulation plates between the poles are correctly positioned between the poles Close the 4 latching levers and make sure that all 4 lock bars have snapped in safely The Upper Module must be fixed tightly to the Lower Module Connect the main cables or current bars with the appropriate screws Schaltbau strongly recommends Schnorr Washers or similar to secure the screws The screws must be tightened with the rated torque permissible refer to label on the Upper Module Connect the earthing cable to the earth terminal with the appropriate screw Schaltbau strongly recommends a Schnorr Washer or similar to secure the screw Schaltbau GmbH Page 15 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 4 6 Commissioning After installation the following checks are recommended a O gt Check the protective earth Check the main connections Check the control connections Check the latching and locking between Upper and Lower Module s Check that both protection covers are fitted Check that all insulation plates are fixed and not broken Several activation and deactivation operations of the contactor without the main circuit active Check the function of the auxiliary contacts Schaltbau GmbH Page
17. pecification All components which have to be replaced must be original components defined by Schaltbau 2 2 General application notes CT1000 contactors are designed to be mounted in environments defined by pollution degree PD3 EN60077 1 Conductive pollution or dry non conductive pollution occurs Occasionally however a temporary conductivity caused by condensation is to be expected when the equipment is out of operation Example Location in an enclosure ensuring an efficient protection against pollution at least equivalent to IP54 according to EN60529 CT1000 contactors contain strong magnets for the permanent magnetic blow out Make sure that these magnets do not attract any ferromagnetic particles into the contactors either 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 Schaltbau GmbH Page 5 28 Status 2010 07 16 SCHALTBAU Connect Contact Control AC 3 Description LB gt O z D amp LL 2 AG 8 O D O BP 3 TG 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
18. res some experience to evaluate the state of the contacts Even after only a few switchings under load the contacts look used and dirty for the inexperienced eye Contacts need only to be replaced if the wear of the contact tips is more than 7096 Replace the Upper Module and secure it refer to 4 5 4 Reconnect the main cables current bars Schaltbau GmbH Page 17 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 5 2 1 5 Inspection of the auxiliary contacts Disconnect the main cables current bars and remove the Upper Module refer to 4 1 Remove the protection cover The auxiliary switches are visible for a simple optical inspection from the outside housings are clean and do not show signs of short circuits etc Under normal working conditions no short circuit switching the life time of the auxiliary switches exceeds those of the contactors Replace the protection cap and the Upper Module and secure it refer to 4 5 3 and 4 5 4 Reconnect the main cables current bars Schaltbau GmbH Page 18 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 5 3 Spare parts replacement of parts The contactors are maintenance free There is therefore no general provision for replacing components during its service life However in case of permanent heavy load switchings of failures of short circuit switchings or in similar cases spare parts are offered by Schaltbau Only original parts are to
19. tacts 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 Schaltbau GmbH Page 7 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 3 2 Upper Module Fixed contacts with main terminals FC Press nuts M10 for easy connection 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 Note The Upper Module must be latched and completely locked before starting operation Note Red bars indicate contactors for vertical mounting position Yellow bars indicate contactors for horizontal mounting position Schaltbau GmbH Page 8 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 3 3 Functional description The diagram below shows the switching st
20. very small up to heavy loads CT1000 contactors are available in 1 2 and 3 pole versions 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 4 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 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 Schaltbau GmbH Page 4 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 2 Safety notice CT1000 contactors are high voltage switches Coming into conta
21. y recommend Schnorr Washers or similar to secure the screws 4 5 2 Electrical installation of the auxiliary switches Connect the wires for the auxiliary contacts For the a1 and bO contacts Switches S870 no polarity must be observed For the general purpose contacts Snap action switches S826 the polarity must be observed The position of the switches and the terminal numbers are shown on a label on the protection cap Bundle and fix the wires as shown below Fix the protection cap and tighten the knurled thumb screws Make sure that all the washers are close to the nuts when you mount the cover The washers must remain outside of the cover Secure the nuts by hand force as tightly as possible It is not allowed to operate the contactors without the cover Schaltbau GmbH Page 14 28 Status 2010 07 16 SCHALTBAU Connect Contact Control 4 5 3 Electrical installation of the magnetic drive Connect the coil control wires to the cage clamp terminals No polarity must be observed Bundle and fix the wires as shown below Fix the protection cap with the M4 x 10 screw plus flat washer and Schnorr washer 4 5 4 Electrical installation of the main circuit Mount the Upper Module s onto the Lower Module s Make sure all 4 latching levers are in the open position Attention The modules are mechanically coded Only one mounting position is possible Attach the Upper Module in the correct position Optical marks and c
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