Schaltbau CPP Series User manual

33
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

22021-06-09 / V1.0
Contactors CPP series – Installation and Maintenance Manual
Document Revision History
Date Rev. version Description Pages
2021-06-09 V1.0 Initial version All
Content
1. Important basic information......................................................................................... 4
1.1 Legal notes .............................................................................................................................. 4
1.2 Conventions for this manual............................................................................................. 4
2. General and safety information.................................................................................... 4
2.1 Observing the manual......................................................................................................... 4
2.2 Duties of the operating company................................................................................... 5
2.3 Intended use........................................................................................................................... 5
2.4 Ambient conditions.............................................................................................................. 5
3. Hazards and safety precautions.................................................................................... 6
3.1 Electrical hazards................................................................................................................... 6
3.2 Other hazards......................................................................................................................... 7
3.3 Measures for avoiding damage and malfunctions ................................................... 7
4. Product information........................................................................................................ 9
4.1 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
Dimensions/interfaces and further technical specications...............................14
Preparatory measures........................................................................................................14
Mounting holes....................................................................................................................14
Permissible mounting orientations..............................................................................14
Required minimum clearances ......................................................................................15
Ventilation requirements .................................................................................................15
Safety.......................................................................................................................................15
Tools required.......................................................................................................................15
Installing the CPP contactor with 1,200A and 2,000A CP devices...................16
Installing the CPP contactor with 600A CP devices or
as stand-alone solution.....................................................................................................16

3
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
7.2 Electrical connection .........................................................................................................17
Electrical data and other technical specications...................................................17
Preparatory measures........................................................................................................17
Safety.......................................................................................................................................18
Tools required.......................................................................................................................18
Connecting the S870 auxiliary switches.....................................................................19
Connecting the coil............................................................................................................20
Connecting the 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
Replacing the S870 auxiliary switches.........................................................................28
9. Spare parts......................................................................................................................29
10. Technical data.................................................................................................................29
11. Disposal ...........................................................................................................................29

42021-06-09 / V1.0
Important basic information
Contactors CPP series – Installation and Maintenance Manual
1. Important basic information
1.1 Legal notes
Without prior written consent of SCHALTBAU GmbH,
this manual is not allowed to be electronically or me-
chanically reproduced – as a whole or in parts – be dis-
tributed, changed, transmitted, translated into another
language or used in any other way.
SCHALTBAUGmbH cannot be held liable for damage
caused by non- or only partial observation of the man-
ual.
1.2 Conventions for this manual
This manual describes the installation 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 manual:
DANGER
Indicates a directly threatening dangerous situation.
Death or severe injuries will result if it is not prevent-
ed.
WARNING
Indicates a possibly dangerous situation. Death or
severe injuries may result if it is not prevented.
CAUTION
Indicates a possibly dangerous situation. Medium or
minor injuries may result if it is not prevented.
ATTENTION
Indicates a possibly detrimental situation. If it is not
prevented, assemblies, the system or property in its
surroundings could be damaged.
Indicates technical features and methods
to simplify working or indicates informa-
tion of particular importance.
This manual describes single pole AC and uni-direction-
al DC contactors of the following types:
-CPP1115 (NO contactors)
-CPP2115 (NC contactors)
Depending on the conguration, the following abbre-
viations are used in this manual:
NO = Normally Opened
NC = Normally Closed
Since the CPP 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 safety information
The contactors dealt with in this document are intend-
ed for use with electrical systems for special applica-
tions. They are designed and tested in compliance with
generally accepted codes of practice. However, improp-
er use, operation, handling, maintenance of or tamper-
ing with electric equipment can cause serious or fatal
injury to the user or others, and the appliance or other
property can be damaged. Consequently, the opera-
tion, maintenance and installation instructions for the
contactors must be strictly followed.
If anything is not clear, clarication must be sought
with any queries stating the device type and the serial
number.
Only authorised and trained personnel are allowed to
plan and carry out all mechanical and electrical instal-
lations, transport, commissioning, as well as mainte-
nance and repair work.
This applies to the observation of the general installa-
tion and safety regulations for electrical systems as well
as the proper use of tools approved for this purpose.
Electrical equipment requires protection from moisture
and dust during installation, operation and storage.
2.1 Observing the manual
X All personnel must read and understand the in-
structions in this manual and adhere to them
when working with the device.
X Always adhere strictly to all safety instructions!

5
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
General and safety information
2.2 Duties of the operating company
X Observe all applicable national regulations, all
safety, accident prevention and environmental
protection regulations as well as the recognised
technical rules for safe and correct working.
X Regularly check all tted protection and safety
equipment for correct function.
X Work on electrical equipment must only be car-
ried out by a qualied electrician or by instructed
persons under the supervision and control of a
qualied electrician in accordance with electrical
regulations.
X A specialist is someone who, on the basis of their
technical training, knowledge and experience as
well as knowledge of the relevant regulations,
is able to assess the work assigned to them and
identify possible dangers.
X Work on the contactors must only be carried out
by personnel who meet the requirements set out
in this manual.
X Personnel must be clearly informed about who is
responsible for the maintenance of the contactors.
X Always perform complete checks after any instal-
lation work and/or after any other conversions, al-
terations or maintenance, in accordance with the
following standards:
-EN/IEC 60077-2
-EN/IEC 60947-4-1
2.3 Intended use
X 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 wide range of industrial applications.
X The contactors must only be used under operat-
ing conditions according to the technical speci-
cations and the instructions in this manual.
X None of the conditions of use, such as voltages,
currents or ambient conditions, dened in the
corresponding 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.
X Operation without a correctly installed arc chan-
ber is not permitted.
X The device contains unprotected live parts.
X The prescribed clearances relative to other live
parts or earth and other parts must be complied
with as well as the safety regulations of the appli-
cable standards.
X Switching at close to the maximum breaking ca-
pacity may require increased minimum clearanc-
es! Do not hesitate to ask our advice in respect of
any dimensioning.
X 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.
X Improper handling of the contactors, e.g. impacts
on the oor, may result in breakage, cracks or de-
formation. Always handle the device with care.
X Only use the contactors for the specied applica-
tion and only with original parts. Any other usage
of or tampering with the contactors is considered
contrary to their intended use. No liability is as-
sumed for damages and accidents caused due to
non-compliance with the instructions in this man-
ual or improper use of the contactors.
2.4 Ambient conditions
ATTENTION
The contactors have been designed for specic am-
bient conditions.
X Only operate the contactors in ambient condi-
tions, such as temperature ranges, degree of
soiling, etc., as dened in the corresponding
data sheets and in our catalogue C45. The C45
catalogue is available under:
https://www.schaltbau.com/en/media-library/

62021-06-09 / V1.0
Hazards and safety precautions
Contactors CPP series – Installation and Maintenance Manual
3. Hazards and safety precautions
3.1 Electrical hazards
DANGER
The contactors are used for high voltage switching. Contact with live electrical parts can result in
serious injuries or even death!
Live parts are all metal parts belonging directly to one of the circuits or wires connecting to them.
All other visible metal parts and wiring may also be live if a fault exists.
Before starting any work on the contactors, always comply with the following safety rules:
X Disconnect on all sides
X Secure to prevent switching back on
X Clearly identify the working area
X Check that a voltage-free state exists
X Earth and short circuit; this includes discharging any capacitors in the main circuit
X Besides 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 identied by a qualied 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 Make sure that the contactors are connected to earth.
X 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;
X don‘t use it anymore
X immediately contact the manufacturer.
DANGER
Interventions in the equipment may cause serious impairments to the safety of men and constructi-
ons. They are not permissible and lead to an exclusion of liability and warranty.
DANGER
All checks and the raplacement 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 deli-
vered by or released by Schaltbau..

7
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Hazards and safety precautions
3.2 Other hazards
WARNING
Contactors must only be used for the purposes specied in the specications and data sheets. Incor-
rect use can cause accidents and severe personal injury.
X The manufacturer will not be responsible for accidents arising from improper use of the prod-
uct.
CAUTION
During continuous operation the contactors may become hot. Risk of burns!
X Before beginning any checks or maintenance on the contactors ensure that the heated com-
ponents have cooled down.
CAUTION
The contactors contain sharp-edged parts. Risk of injuries!
X Use appropriate tools for installation and maintenance work on the contactors.
X Wear safety gloves when handling sharp-edged components.
3.3 Measures for avoiding 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 oor, can result in breaks, cracks and deformation.
X Ensure the contactors are always handled correctly.
X Do not throw the contactors on the oor.
X At regular intervals perform a visual check of the contactors for possible damage.
X Immediately replace any damaged parts.
ATTENTION
Depending on the product type, contactors can contain permanent magnets. Such magnets can attract ferro-
magnetic parts resulting in damage to the contactors.
X Ensure that the contactors are installed in a location where it is not possible for them to attract any ferro-
magnetic parts.
ATTENTION
Depending on the product type, contactors can contain permanent magnets. These permanent magnets can
destroy the data on the magnetic strips of credit or similar cards.
X Keep credit or similar cards away from the contactors.

82021-06-09 / V1.0
Hazards and safety precautions
Contactors CPP series – Installation and Maintenance Manual
ATTENTION
During switching o, strong electromagnetic elds are generated in the vicinity of the contactors. These may
inuence other components close to the contactors.
X Make sure that the contactors are installed in a location where no other components are aected.
ATTENTION
In the case of damage, wear and/or soiling of the contactors - in the form of a partial break, sharp edges and
discoloured 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 secured with detent-edged
rings or detent-edged washers have been undone three times, the rings or washers must be replaced by new
ones.
X Record the frequency of undoing of the screws in the work log.
X Replace detent-edged rings or detent-edged washers with new ones after the screws have been undone
three times.

9
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Product information
4. Product information
4.1 CPP – 1-pole NO or NC contactors
for DC or AC
Compact single-pole NO and NC contactors up to
3,600 volts rated insulation voltage. Making current
up to 2,000 amps; conventional thermal current up to
200amps; short-time currents up to 2,000 amps.
The super-compact DC contactors of the CPP series are
the smallest Schaltbau switching devices in the power
class up to 200 amps and suitable for rated operating
voltages up to 3,000 volts. The single-pole switching
devices are available as NO or NC contactors.
They are used in main and auxiliary converters of rail-
way vehicles, but also in converters and inverters in the
eld of renewable energies or, more generally, in indus-
trial environments.
4.2 Features
X Compact dimensions – high rated insulation
voltage UNm up to 3,600 volts
Small dimensions – great performance! All air gaps
in the contact area are generously dimensioned.
The rated insulation voltage is 3,600 volts for OV2
and 3,000 volts for OV3. A highly ecient ceramic
arc chamber with permanent magnetic blowout
is used to handle arcs.
X High making capacity Icm of up to 2,000 amps
The CPP can switch on currents of up to 2,000
amps in the make contactor version. In the version
as a break contactor, up to 850 amps. High contact
forces and optimised 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 mm², NC contactor 35 mm², maxi-
mum ambient temperature: 70 °C. The values are
achieved through high contact forces.
X High short-time withstand current rating Icw
of up to 2,000 amps
For 100 milliseconds, the normally open contact
can carry a maximum current of 2,000 amps. The
short-circuit current carrying capacity of the NC
contact is 1,800 amps.This time is sucient to trig-
ger the short-circuit protection and prevent weld-
ing of the main contacts. The short-time current
carrying capacity is supported by high contact
forces and optimised silver contacts.
X Auxiliary contacts with snap-action switches
Two S870 series auxiliary switches are optionally
available for extensive diagnostics and switching
condition monitoring.
The switches have robust silver or gold contacts.
4.3 Reliable, robust and economical
Contactors of the CPP series are designed for continu-
ous currents up to 200 A. Among other features, the
robust switchgear has a high breaking and breaking
capacity as well as a high short-time rated current. This
ensures long operational reliability. Depending on the
application, dierent requirements are placed on elec-
tromechanical components.
The new DC contactors are very robust against shock
and vibration loads and meet the requirements of
IEC60077.

10 2021-06-09 / V1.0
Product information
Contactors CPP series – Installation and Maintenance Manual
4.4 Application
Thanks to many years of experience and expertise in the development of
electromechanical switchgear and the control of arcs, especially DC arcs,
Schaltbau has a compact contactor for high rated insulation voltages in its
range with the CPP series. The device, which is available as a NO or NC con-
tactor, is suitable as a precharging contactor for the large Schaltbau CP and
CT series. It can also be used as a universal contactor.
CPP
NC
NO
AC DC
R
C
R
Precharge contactor Discharge contactor
Main contactor
CP or CT series
Converter
Catena
ry
Ra
il
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 railway vehicles or in indus-
trial test systems.
Universal contactor
NO or NC contactor for switching
single-pole loads for small and me-
dium switching capacities.
4.5 Technical information and material
properties
For technical information and material properties, refer
to the corresponding data sheets and to our C45 cata-
logue. The C45 catalogue is available under:
https://www.schaltbau.com/en/media-library/

11
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Product information
4.6 Overview
CPP contactors – stand alone versions
D
C
F
G
A
B
B
E
Fig. 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, at plug connections
6.3x0.8mm
G Earthing connection M5 (torque: 4 - 5 Nm)

12 2021-06-09 / V1.0
Product information
Contactors CPP series – Installation and Maintenance Manual
CPP contactors – built-in versions
CPP pre-charging contactors as built-in versions have a
special angeled mounting ange for direct integration
into CP main contactors.
For CP contactor types with 1,200 A or 2,000 A the CPP
can be mounted directly on the base plate of the CP
main contactor.
C
F
E
A
B
B
CP
CPP
D
CPP
Fig. 2: CPP 1115 NO/2115 NC pre-charging contactor, built-in version, integrated into a 1,200 A or 2,000 A CP main 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 ange with 2 threaded fastening
holes for M5 screws
F Auxiliary switches S870, at plug connections
6.3x0.8mm
For CP main contactor types with 600 A, the CPP precharging contactor cannot be directly integrated. If CPP pre-
charging contactors are combined with 600 A CP main contactors, a stand-alone CPP version must be used.
CP
CPP
Fig. 3: CPP 1115 NO/2115 NC pre-charging contactor, stand-alone version in combination with a 600 A CP main contactor

13
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Storage
5. Storage
ATTENTION
Moisture and dust can damage the contactors. If the
device is to be stored for a prolonged period of time:
X Store the device in its original packaging,
X Store the device in a dry and dust-free location.
Return shipments
Schaltbau recommends retaining the original packag-
ing for any return shipments.
If the original packaging 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 install it.
6.2 Check parts for transport damage
ATTENTION
If parts are damaged, functional reliability of the con-
tactor has been lost.
X Before installing, check all parts for possible
transport damage.
X Do not install damaged parts.

14 2021-06-09 / V1.0
Installation
Contactors CPP series – Installation and Maintenance Manual
7. Installation
7.1 Mounting
Dimensions/interfaces and further
technical specications
The dimensions and other technical specications are
given in the respective data sheets or can be found in
our C45 catalogue. The C45 catalogue is available un-
der: https://www.schaltbau.com/en/media-library/
Preparatory measures
X For stand alone versions, a suitable mounting
plate with 4 mounting holes in accordance with
the following dimensional drawing (Fig. 4) must
be provided for fastening of the contactors.
X The mounting holes can be either:
-threaded holes (for threaded screws)
-or through holes (for threaded screws and nuts)
X Fastening of the contactors on the mounting plate
is performed using 4 M5 mounting 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 mounting screws (and if applicable the
nuts) must be strength class 8.8 or higher.
-The mounting screws must be tightened to
the specied torque, which depends on the
strength class (min. 8.8) of the screws/nuts used.
Mounting holes
[mm]
or M54 x Ø 6±0.1
51±0.1
111
±0.1
Fig. 4: Dimensions and layout of mounting holes
(stand-alone version)
Permissible mounting orientations
±180° ±180
°±
180°
–90°
+90° –90° +90°
±180°
CPP1115/02 series
CPP2115/01 series
Horizontal assembly
"Table mounting"
Horizontal assembly
"Table mounting"
Vertical assembly
"Wall mounting"
Fig. 5: Permissible mounting orientations (stand-alone
version)

15
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Installation
Required minimum clearances
Switching of high voltage currents produces electric
arcs and it is possible that plasma will escape from the
openings of the arc chambers. Therefore, it is extreme-
ly important to maintain the minimum clearances to
ground/earth and the connecting contacts to avoid
ash-overs.
Minimum clearances for CPP contactors
A minimum clearance (A, B) to earth/ground potential
and insulating structure parts is required on all sides
and above the contactor. See C45 catalogue.
In addition, a distance (C) of 30 mm to the top is re-
quired to be able to remove the arc chamber in case of
maintenance work.
Fig. 6: CPP stand alone versions: For minimum clearance to
earth/ground potential and insulating structure parts
see C45 catalogue.
Fig. 7: CPP built-in versions: For minimum clearance to
earth/ground potential and insulating structure parts
see C45 catalogue.
ATTENTION
Make sure that there is sucient 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 o or bend.
Ventilation requirements
X Ensure sucient ventilation in the installation
area, especially when switching heavy loads. This
allows the plasma to be dissipated more quickly
and reduces the risk of ash-over and corrosion.
Safety
X Installation must be performed by qualied
trained personnel.
ATTENTION
When installing, ensure that no dirt can get into the
contactor as a result of surrounding building activi-
ties.
ATTENTION
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.
X Record the frequency of undoing of the screws
in the work log.
X Replace detent-edged rings or detent-edged
washers with new ones after the screws have
been undone three times.
Tools required
-Socket spanner set
-Hexagon socket spanner set, hexagon socket bits
-Set of Torx bits or Torx screwdrivers
-Torque spanner

16 2021-06-09 / V1.0
Installation
Contactors CPP series – Installation and Maintenance Manual
Installing the CPP contactor with 1,200A
and 2,000A CP devices
CPP pre-charging contactors as built-in versions have a
special angeled mounting ange for direct integration
into CP main contactors.
For CP contactor types with 1,200 A or 2,000 A, the CPP
can be mounted directly on the base plate of the CP
main contactor.
X Position the CPP (2) at the base plate (3) of the CP
main contactor (4).
X Screw in the 2 xing screws (1).
X Tighten the 2 xing screws (1) to a torque of
3.2-4Nm.
13.2 - 4
Nm
2
3
4
Fig. 8: With 1,200A and 2,000A CP devices: Example for
the installation of the CPP at the base plate of the
CPmain contactor
Installing the CPP contactor with 600A
CP devices or as stand-alone solution
CPP pre-charging contactors as stand-alone versions
have a special mounting ange for the installation 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 Screw the CPP (1) on the mounting ange to the
mounting plate (3) using 4 mounting screws M5
including washers (2).
-In designs with the mounting holes implemen-
ted as threaded holes, screw the mounting
screws into the holes directly, not forgetting the
washers.
-In designs with through holes, t the moun-
ting screws and washers and tighten the screws
using suitable screw locking elements and nuts.
X Tighten the mounting screws to the specied tor-
que, which depends on the strength class (min.
8.8) of the screws/nuts used.
3
2
Nm
1
4
Fig. 9: With 600 A devices or as stand-alone solution:
Example for the installation of the CPP (1) at a sepa-
rate mounting position next to the CP main contactor
(4)

17
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Installation
7.2 Electrical connection
Electrical data and other technical
specications
For the power consumption of the magnetic drive sys-
tem and electrical data of the auxiliary switches as well
as other technical specications, refer to the respective
data sheets and to our C45 catalogue. The C45 cata-
logue is available under:
https://www.schaltbau.com/en/media-library/
Preparatory measures
X The minimum clearances to live and earthed parts
are given in the corresponding data sheets or in
our C45 catalogue and must be adhered to. The
catalogue is available under:
https://www.schaltbau.com/en/media-library/
X Switching of high voltage currents produces elec-
tric arcs and it is possible that plasma will escape
from the openings of the arcing chambers. There-
fore, it is extremely important to maintain the min-
imum clearances to live and earthed parts to avoid
ashovers. These minimum clearances have been
tested and specied in relation to the switching
capacity of the contactors.
X Only for stand-alone versions: The earth/ground
connecting cable must be tted with an appropri-
ate ring terminal (for M5 terminal screw).
X 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 tted with appropriate ring terminals (for
M5 terminal screws).
X To secure the main terminal screws so that they
do not come loose, appropriate screw locking ele-
ments must be provided. Schaltbau recommends
using Schnorr washers (or similar).
X The main terminal screws must be tightened to a
torque of 4-5Nm.
X The connections for the auxiliary switches are
made with at plugs. Consequently, the control
wires must be equipped with corresponding at
receptacles 6.3 x 0.8 mm.
X The maximum permissible conductor cross-
section of the auxiliary contact control wires is
1mm2/ AWG 18 stranded wire.
X For stand-alone versions a receptacle spring
clamp terminal block is provided for the coil con-
trol wires. The control wires for the coil connection
must be stripped accordingly (if necessary, t with
appropriate wire end sleeves).
X For the power consumption of the magnetic drive
system and the electrical data of the auxiliary
switches refer to our catalogues:
-C45 (Catalogue CPP series devices)
-D70 (Catalogue auxiliary switches S870)

18 2021-06-09 / V1.0
Installation
Contactors CPP series – Installation and Maintenance Manual
Safety
DANGER
The contactors are used for high voltage switching. Contact with live electrical parts can result in
serious injuries or even death!
Live parts are all metal parts belonging directly to one of the circuits or wires connecting to them.
All other visible metal parts and wiring may also be live if a fault exists.
Before starting any work on the contactors, always comply with the following safety rules:
X Disconnect on all sides
X Secure to prevent switching back on
X Clearly identify the working area
X Check that a voltage-free state exists
X Earth and short circuit; 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 identied by a qualied electrician.
X When the work has been concluded, follow the procedure in reverse.
ATTENTION
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.
X Record the frequency of undoing of the screws
in the work log.
X Replace detent-edged rings or detent-edged
washers with new ones after the screws have
been undone three times.
Tools required
X Socket spanner set
X Open-ended spanner set
X Torque spanner
X Continuity tester
X Cable ties

19
2021-06-09 / V1.0 Contactors CPP series – Installation and Maintenance Manual
Installation
Connecting the S870 auxiliary switches
The control wires for the auxiliary contacts must be t-
ted with receptacles (6.3 x 0.8 mm).
ATTENTION
X The maximum permissible conductor cross-
section of the auxiliary contact control wires is
1 mm2/AWG 18 stranded wire.
X Mechanically secure the control wires to mi-
nimise feedback eects 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 0.8 mm
1
6.3 x 0.8 mm 2
1
2
Fig. 10: Stand alone version: Connecting the S870 auxiliary
switches
6.3 x 0.8 mm
1
6.3 x 0.8 mm
2
1
2
Fig. 11: Built-in version: Connecting the S870 auxiliary switch-
es

20 2021-06-09 / V1.0
Installation
Contactors CPP series – Installation and Maintenance Manual
Connecting the coil
ATTENTION
The value of the overvoltage limitation is part of the
magnetic system and must not be modied and in
particular not be short-circuited (e.g. by an external
diode).
X Make sure that no such diode is used in your
control circuit.
ATTENTION
X Mechanically secure the control wires to mi-
nimise feedback eects of forces caused by
the wires (e. g. shock, vibrations) acting on the
terminals.
Stand-alone versions
For stand-alone versions a spring clamp terminal block
is provided for the coil control wires. The control wires
for the coil connection must be stripped accordingly (if
necessary, t with appropriate wire end sleeves).
X Route the coil control wires (1) to the spring clamp
terminal block (2).
X Connect 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 connected directly to the des-
ignated spring clamp terminals on the CP main contac-
tor.
1
Fig. 13: Connecting the coil (built-in versions)
Connecting the earth/ground terminal
(only for stand-alone versions)
X Connect an earthing cable (2) to the earth termi-
nal (1) which is provided on the mounting ange
of the CPP.
X Screw the ring terminal of the earthing cable (2)
in place using the terminal screw (3) and suitable
screw locking elements.
-Schaltbau recommends using Schnorr washers
(or similar).
X Tighten the earth terminal screw (3) to a torque of
4-5Nm
4 - 5
Nm
2
3
1
Fig. 14: Connecting the earth terminal (only for stand-alone
versions)