Schaltbau C295 Series User manual

33
Contactors
C295 series
Double pole
NO contactors
Installation and maintenance
instructions
Manual B295-M.en

22020-05-13 / V1.0
Contactors C295 – Installation and Maintenance Instructions
Document Revision History
Date Rev. Level Description Pages
2020-05-13 1.0 First release all
Content
1. Important basic information......................................................................................... 4
1.1 Legal notes .............................................................................................................................. 4
1.2 Conventions for this manual............................................................................................. 4
2. General and security information ................................................................................ 4
2.1 Observing the instructions................................................................................................ 4
2.2 User obligations..................................................................................................................... 5
2.3 Intended use........................................................................................................................... 5
2.4 Ambient conditions.............................................................................................................. 5
3. Dangers and security measures.................................................................................... 6
3.1 Electrical dangers.................................................................................................................. 6
3.2 Other dangers ........................................................................................................................ 6
3.3 Measures for avoiding damages and malfunctions ................................................. 7
4. Product information........................................................................................................ 8
4.1 Double pole NO contactor, C295Series........................................................................ 8
4.2 Features .................................................................................................................................... 8
4.3 Applications ............................................................................................................................ 8
4.4 Technical information and material specication..................................................... 8
4.5 Overview .................................................................................................................................. 9
5. Storage.............................................................................................................................10
6. Unpacking.......................................................................................................................10
6.1 Unpack the device ..............................................................................................................10
6.2 Check parts for transport damage................................................................................10
7. Installation ......................................................................................................................11
7.1 Mechanical installation.....................................................................................................11
7.1.1 Dimensions and further technical specications....................................................11
7.1.2 Preliminaries .........................................................................................................................11
7.1.3 Correct mounting positions............................................................................................11
7.1.4 Required minimum clearance .......................................................................................12
7.1.5 Ventilation requirements .................................................................................................12
7.1.6 Safety.......................................................................................................................................12
7.1.7 Required tools ......................................................................................................................12
7.1.8 Install the contactor ...........................................................................................................12

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2020-05-13 / V1.0 Contactors C295 – Installation and Maintenance Instructions
7.2 Electrical installation..........................................................................................................13
7.2.1 Electrical data and further technical specications................................................13
7.2.2 Preliminaries .........................................................................................................................13
7.2.3 Safety.......................................................................................................................................13
7.2.4 Required tools ......................................................................................................................14
7.2.5 Connect the auxiliary contacts.......................................................................................14
7.2.6 Connect the coil terminals...............................................................................................15
7.2.7 Connect the main contacts .............................................................................................15
Main contact connection with cables .........................................................................15
Main contact connection with busbars ......................................................................16
7.3 Checks .....................................................................................................................................17
8. Maintenance...................................................................................................................18
8.1 Safety.......................................................................................................................................18
8.2 Preventive maintenance...................................................................................................18
8.2.1 Intervals for regular checks..............................................................................................18
8.2.2 Regular check activities ....................................................................................................19
8.3 Corrective maintenance ...................................................................................................20
8.3.1 Replace the auxiliary contacts........................................................................................20
Required spare parts..........................................................................................................20
Required tools ......................................................................................................................20
Disassembly ..........................................................................................................................20
Assembly................................................................................................................................21
8.3.2 Check the main contacts..................................................................................................21
Preliminaries .........................................................................................................................21
Required tools ......................................................................................................................21
Check the main contacts for wear and tear...............................................................21
8.3.3 Replace the complete contact unit ..............................................................................23
Required spare parts..........................................................................................................23
Required tools ......................................................................................................................23
Disassembly ..........................................................................................................................23
Assembly................................................................................................................................23
8.3.4 Replace the magnetic drive.............................................................................................24
Required spare parts..........................................................................................................24
Required tools ......................................................................................................................24
Disassembly ..........................................................................................................................24
Assembly................................................................................................................................24
9. Spare parts......................................................................................................................25
10. Technical data.................................................................................................................26
11. Disposal ...........................................................................................................................26

42020-05-13 / V1.0
Important basic information
Contactors C295 – Installation and Maintenance Instructions
1. Important basic information
1.1 Legal notes
Without prior written consent of Schaltbau GmbH, this
manual is not allowed to be electronically or mechani-
cally reproduced – as a whole or in parts – be distrib-
uted, changed, transmitted, translated into another
language or used in any other way.
Schaltbau GmbH cannot be held liable for damage
caused by not observing (or only partly observing) the
manual.
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 instructions:
DANGER
Indicates a hazardous situation with a high level
of risk which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a hazardous situation with a medium level
of risk which, if not avoided, could result in death or
serious injury.
CAUTION
Indicates a hazardous situation with a low level of
risk which, if not avoided, may result in minor or
moderate injury.
NOTICE
Indicates a hazardous situation which, if not avoided,
may result in property damage, such as service inter-
ruption or damage to equipment or other materials.
Refers to technical features and methods
aimed at facilitating work or to particu-
larly important information.
This manual refers to double pole NO contactors of the
C295 series
This manual describes only stock items of the above
mentioned contactor types. If you need a special vari-
ant feel free to contact us.
2. General and security information
The contactors dealt with in this document are in-
tended for use with electrical systems for special instal-
lations. They are designed and tested in compliance
with the generally recognised state of the art. However,
improper use, operation, handling, maintenance of or
tampering with electric equipment can cause serious
or fatal injury to the user or others, and the appliance or
other property can be damaged.
The operation, maintenance and installation instruc-
tions for the contactors must therefore be strictly fol-
lowed.
Any uncertainties must be claried and all queries must
include details of the type of device and the serial num-
ber.
Only authorized and trained personnel are allowed to
plan and carry out all mechanical and electrical installa-
tions, transport, commissioning, as well as maintenance
and repair work.
This applies to the observation of the general installation
and safety regulations for work on 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 or storage.
2.1 Observing the instructions
X All sta must read and understand the instructions
in this manual and adhere to them when working
with the device.
X Always carefully observe all safety warnings!

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2020-05-13 / V1.0 Contactors C295 – Installation and Maintenance Instructions
General and security information
2.2 User obligations
X Observe all applicable national provisions, all safe-
ty, accident prevention and environmental regula-
tions as well as the recognized technical rules for
safe and proper working.
X Carry out regular inspections of all protection and
safety devices to see if they work properly.
X Work on electric equipment may only be per-
formed by an expert or trained personnel working
under the direction and supervision of an expert
according to the applicable rules of electrical en-
gineering.
X An expert is a person who can judge and recognise
the possible dangers of the jobs assigned to him
based on his training, knowledge and experience
and by knowledge of the appropriate regulations.
X Work on the contactors must only be carried out
by sta who meets the requirements set out in this
manual.
X Sta must be informed clearly about who is re-
sponsible for the maintenance of the contactors.
X After each installation work and/or after any other
modications, alterations or maintenance works,
always perform complete checks according to
these 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 variety of applications.
X The contactors must only be used under operating
conditions according to the technical specication
and the instructions in this manual.
X None of the operating conditions dened in the
corresponding data sheets and in our catalogue
B295 in section “Specications“, such as volt-
ages, currents, ambient conditions, etc. may be
changed. The 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 installed prop-
erly and are fully operational.
X The contactors must not be contaminated with
aggressive media.
X Contactors may not be used without further pro-
tective measures in potentially explosive atmos-
pheres.
X The contactor meets the requirements of basic in-
sulation. Make sure the frame or plate onto which
the drive of the contactor is mounted is earthed in
a shock and vibration resistant way.
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 The contactor has unprotected live parts
X The required clearance of live parts to earth and
other parts of the contactor is to be observed as
well as the safety regulations of the applicable
standards.
X Switching at maximum breaking capacity might
require larger clearance! Do not hesitate to ask our
advice for dimensioning.
X Improper handling of the contactors, e.g. when
hitting the oor with some impact, can result in
breakage, cracks and deformation. Always handle
the contactors with care.
X Use the contactor only according to its intended
use. Replace or repair damaged parts exclusively
with original parts. Any other usage of or tamper-
ing with the contactors is considered contrary to
its intended use. No liability is assumed for damag-
es and accidents caused due to non-compliance
with the instructions in this manual or improper
use of the contactors.
2.4 Ambient conditions
NOTICE
The contactors are constructed for specic ambient
conditions.
X Operate the contactors only according to the
ambient conditions, like temperature ranges,
pollution degree, etc., as dened in the cor-
responding data sheets and in our catalogue
B295. The catalogue is available under:
https://www.schaltbau.com/en/media-library/

62020-05-13 / V1.0
Dangers and security measures
Contactors C295 – Installation and Maintenance Instructions
3. Dangers and security measures
3.1 Electrical dangers
DANGER
The contactors are used to switch voltage. The touching of electrically conducting parts may result
in serious injuries or even death!
Energized parts are all metal parts belonging directly to one of the circuits or wires leading there. All
other visible metal parts and wires may also be energized in the case of a failure.
Before beginning any work on the contactors, always observe the following safety regulations:
X Disconnect on all sides
X Ensure that it is not possible to reconnect unintentionally
X Clearly mark your work area
X Make sure that there is no voltage present
X Earth and short circuit the installation; this also includes the discharging of any capacitors in
the main circuit
X Besides the main electric circuit, also disconnect additional and auxiliary circuits
X Cover or insulate adjacent energized parts
X Only an electrically skilled person may determine if there is no voltage present
X When the work has been concluded, proceed the other way round.
3.2 Other dangers
WARNING
Exclusively use the contactors for purposes as indicated in the specications and data sheets.
A wrong application can cause accidents and severe damages to persons!
X The manufacturer doesn‘t take the responsibility for accidents which were caused by improper
use of the product.
CAUTION
During continuous operation the contactors may become hot. Risk of burns!
X Before beginning any checks or maintenance work on the contactors make sure that the heat-
ed components have cooled down.
CAUTION
The contactors contain sharp-edged parts. Risk of injury!
X Use appropriate tools for installation and maintenance works on the contactors.
X Wear protective gloves when working with sharp-edged components.

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2020-05-13 / V1.0 Contactors C295 – Installation and Maintenance Instructions
Dangers and security measures
3.3 Measures for avoiding damages and malfunctions
NOTICE
Aggressive uids may damage the contactors.
X Make sure that the contactors are not exposed to aggressive uids.
NOTICE
Improper handling of the contactors, e.g. when hitting the oor with some impact, can result in breakage, cracks
and deformation.
X Make sure that the contactors are always used properly.
X Do not throw the contactors to the oor.
X Regularly sight-check the contactors for potential damages.
X Immediately replace damaged components.
NOTICE
Depending on the product type, contactors can contain strong (permanent) magnets. These magnets can attract
ferromagnetic particles and may damage the contactors.
X Make sure that the contactors are installed at a location, where no ferromagnetic particles can be attracted.
NOTICE
Depending on the product type, contactors can contain strong (permanent) magnets. These magnets can de-
stroy data on credit cards or similar cards.
X Keep credit cards or similar cards away from the contactors..
NOTICE
During the switching o, strong electromagnetic elds are generated in the surroundings of the contactors.
These may inuence other components close to the contactors.
X Make sure that the contactors are installed at a location, where no other components can be aected.
NOTICE
In the case of damage, wear and tear and/or soiling of the contactor components - in the form of a partial break,
sharp edges and discoloured surfaces - the functional safety of the contactors is no longer guaranteed.
X Carry out regular visual checks to detect wear and tear and dirt.
X Immediately replace damaged parts.
X Immediately remove dirt without leaving any residues.
X Immediately replace parts with stubborn dirt.
NOTICE
Detent-edged rings and detent-edged washers have a limited life time. After 3 times opening of screws secured
with detent-edged rings or detent-edged washers, the rings or washers must be replaced by new ones.
X Record the frequency of screw opening in the work log.
X After 3 times opening of screws, replace detent-edged rings or detent-edged washers by new ones..

82020-05-13 / V1.0
Product information
Contactors C295 – Installation and Maintenance Instructions
4. Product information
4.1 Double pole NO contactor,
C295series
Compact double-pole high-voltage NO contactor for
DC and AC
With its compact size and ecient arc chute our C295
Series contactor allows the handling of voltages up to
1,500 V and currents of 120 A max.
Switching high amperage even at signicant induct-
ance can be achieved by series connection of the main
contacts, whereas parallel connection results in longer
contact life.
4.2 Features
X Compact in size
X Double-break contacts
X With magnetic blowout for DC arc quenching
X Switching of high inductive loads by means of
main contacts connected in series
X Parallel connection: Longer life of main contacts
4.3 Applications
Typical applications are to be found in trac engineer-
ing equipment, particularly in heating circuits, air con-
ditioning equipment and conversion engineering of
complex power supplies.
4.4 Technical information and material
specication
For technical information and material specications,
refer to the corresponding data sheets and to our cata-
logue B295. The catalogue is available under:
https://www.schaltbau.com/en/media-library/

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2020-05-13 / V1.0 Contactors C295 – Installation and Maintenance Instructions
Product information
4.5 Overview
F
A
I
G
H
E
H
C
D
E
B
Fig. 1: Overview C295 series
A Auxiliary contacts (2x S870), Terminals: Flat tabs 6.3 x 0.8 mm
B Arc chambers
C Plasma exits
D Permanent magnets
E Main contacts, Terminals: M6, Tightening torque: 6 Nm max.
F Coil suppression: Varistor
G Coil terminals: Cage clamp
H Mounting holes for screws M6, Tightening torque depends on the property class (min. 8.8) of the screws/nuts used
I Base plate

10 2020-05-13 / V1.0
Storage
Contactors C295 – Installation and Maintenance Instructions
5. Storage
NOTICE
Moisture and dust can damage the contactor. If
the device is to be stored for a prolonged period
of time,
► store it in its original packaging,
► store it in a dry and dust-free location.
Return shipments
Schaltbau recommends to keep the original packing
box for any return shipments. If no original packing box
is available care must be taken to pack the contactor in
a way that prevents damage during shipment.
6. Unpacking
6.1 Unpack 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, falling etc.).
X If any signs indicate that the contactor has been
subject to excessive shock inuence do not install
the contactor.
6.2 Check parts for transport damage
NOTICE
If parts are damaged, the functional reliability of the
contactor is no longer given.
X Before installing, check all parts for any possible
transport damage.
X Do not install a damaged contactor.