Schaltbau CT1115/04 User manual

3
Inhalt
Rundsteckverbinder für Spezialanwendungen, Baureihe SB 2
Besondere Merkmale 2
Applikationen 2
Baureihenübersicht 2
Kompetenz 2
Normen 2
Technische Daten 3
Bestellschlüssel 4
5-polig + PE Flanschstecker, Kabeldose 4
6-polig Flanschdose, Kabelstecker 5
14-polig Flanschstecker, Kabeldose 5
Montage 6
Werkzeuge Ausdrückwerkzeuge AWZ-A und AWZ-C/H, Crimpzange CWZ-600 6
Montagebohrungen 6
Kontakte Stecker: Crimpkontakte, Dosen: Lötkontakte 7
Deratingkurven 7
Sicherheitshinweise 7
ContactorsContactors
CT1115/04, CT1130/04 series
Single Pole NO
Power Contactors
for AC and DC
Manual C20/04-M.en

Page 2/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
Revision History:
Rev.Level
Date
Page
Description
Name
1.1
26.10.2012
21
Part number of glue for ceramic protection insert
changed from 13600310 to 13650290
Neuwieser
1.2
24.10.2017
10
Functional decription, diagram of switching status,
page 10
Kapfer

Page 3/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
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”.
Copyright notice
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.

Page 4/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
Table of Contents
Introduction ....................................................................................................................................................5
Safety information..........................................................................................................................................6
Electrical hazards.....................................................................................................................................6
Safety notices...........................................................................................................................................6
General application notes.........................................................................................................................6
Technical data................................................................................................................................................7
Applied standards..........................................................................................................................................7
Description .....................................................................................................................................................8
Lower Module...........................................................................................................................................8
Upper Module...........................................................................................................................................9
Functional description ............................................................................................................................10
Order code..............................................................................................................................................11
Storage..........................................................................................................................................................12
Storage...................................................................................................................................................12
Return shipments ...................................................................................................................................12
Installation....................................................................................................................................................12
Unpacking and handling.........................................................................................................................12
Operating position..................................................................................................................................13
Mechanical requirements.......................................................................................................................13
Electrical requirements...........................................................................................................................14
Mechanical installation...........................................................................................................................14
Electrical installation of the auxiliary switches........................................................................................15
Electrical installation of the magnetic drive............................................................................................15
Mounting of the Upper Module...............................................................................................................16
Electrical installation of the main circuit .................................................................................................16
Electrical installation of the earth terminal..............................................................................................17
Commissioning............................................................................................................................................17
Maintenance .................................................................................................................................................18
Recommended regular service intervals................................................................................................18
Unscheduled service intervals................................................................................................................18
Inspection activities ................................................................................................................................18
Spare parts, replacement of parts..........................................................................................................19

Page 5/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
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 400 A. For single contactors for 800 A refer to
manual C20/08-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:
oEasy inspection of main contact tips, easy replacement of
main contacts
oEasy 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:
oFunctional insulation for main circuit
oBasic insulation between main circuit and protective earth
oReinforced 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.

Page 6/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
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.

Page 7/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
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: 2010-11
Railway applications –Environmental conditions for equipment
Part 1: Equipment on board rolling stock

Page 8/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
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.
FC
MD
Upper Module
Lower Module
TG
AG
BP
MC
AC
LL
LB
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.

Page 9/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
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.

Page 10/25 Rev.1.1 User Manual, Power contactors, series CT1115/04 and CT1130/04
Functional description
The diagram below shows the switching states of the CT1000 contactors.
Typical values:
Typical pull-in time: 120 ms
Typical drop-off time: 60 ms
Time constant of magnetic drive: app. 90 ms
Settling time for b0 switch: up to 10 ms
Zero position
Off
Pull-in time
On
Drop-off time
Settling time
Off
Meaning:
Main contacts
Coil actuation
a1 contact
(well closed)
b0 contact
(well opened)
- Closed
- Open
- Active
- Passive
- Closed
- Open
- Closed
- Open