Schaltbau CP Series User manual

33
ContactorsContactors
CP Series
1 pole bi-directional high-voltage
contactors, disconnectors,
changeover switches for
DC and AC
Installation and
Maintenance Instructions
Manual C40-M.en

22021-04-12 / V1.1
Contactors CP Series – Installation and Maintenance Instructions
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 ................................................................................................. 5
2.2 User obligations...................................................................................................................... 5
2.3 Intended use ............................................................................................................................ 5
2.4 Ambient conditions............................................................................................................... 6
3. Dangers and security measures.................................................................................... 6
3.1 Electrical dangers ................................................................................................................... 6
3.2 Other dangers.......................................................................................................................... 7
3.3 Measures for avoiding damages and malfunctions................................................... 8
4. Introduction...................................................................................................................... 9
4.1 CP series – 1 and 2 pole bi-directional high-voltage contactors,
disconnectors, changeover switches for DC and AC................................................. 9
4.2 Features...................................................................................................................................... 9
4.3 Applications ............................................................................................................................. 9
4.4 Technical information and material specication ...................................................... 9
5. Description......................................................................................................................10
5.1 Survey of the CP series (stock items).............................................................................10
5.2 Modular conguration options.......................................................................................11
5.3 Conguration examples ....................................................................................................12
6. Storage.............................................................................................................................14
7. Unpacking and handling..............................................................................................14
7.1 Unpack the device ...............................................................................................................14
7.2 Check parts for transport damage.................................................................................14
8. Installation ......................................................................................................................15
8.1 Mounting positions .............................................................................................................15
8.1.1 Dimensions/interfaces and further technical specications.................15
8.2 Mechanical installation ......................................................................................................15
8.2.1 Preparatory measures..........................................................................................15
8.2.2 Required minimum clearance ..........................................................................16
8.2.3 Ventilation requirements....................................................................................16
8.2.4 Mounting holes......................................................................................................16
8.2.5 Safety .........................................................................................................................16
8.2.6 Tools required.........................................................................................................17
8.2.7 Installation procedure .........................................................................................17
Document Revision History
Date Rev. Level Description Pages
2020-07-20 V1.0 Initial version all
2021-04-12 V1.1 Modication of torque values
General adaptations
7, 10, 22, 24-26,
30, 33-35, 40, 41

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
8.3 Installation of the optional pre-charging contactor (CPP)....................................18
8.3.1 Installation of the CPP with 1,200A and 2,000A devices.......................18
8.3.2 Installation of the CPP with 600A devices...................................................19
8.4 Electrical Installation...........................................................................................................20
8.4.1 Preparatory measures..........................................................................................20
8.4.2 Safety .........................................................................................................................21
8.4.3 Tools required.........................................................................................................21
8.4.4 Connecting the auxiliary switches..................................................................22
8.4.5 Connecting the coil terminals...........................................................................23
8.4.6 Connecting the main contacts .........................................................................24
8.4.7 Connecting the earth terminal.........................................................................25
8.4.8 Connecting the optional pre-charging contactor (CPP).........................26
8.4.9 Connecting the optional high-voltage discharging contact (CPD) ....26
8.5 Checks ......................................................................................................................................27
9. Maintenance...................................................................................................................28
9.1 Safety ........................................................................................................................................28
9.2 Preventive maintenance....................................................................................................28
9.2.1 Intervals for regular checks................................................................................28
9.2.2 Regular check activities.......................................................................................29
9.3 Corrective maintenance.....................................................................................................31
9.3.1 Replacing the complete arc chamber unit ..................................................31
9.3.2 Checking the main contacts..............................................................................32
9.3.3 Replacing the contact bridge ...........................................................................33
9.3.4 Replacing the xed contacts.............................................................................34
9.3.5 Replacing the auxiliary switch assembly ......................................................36
9.3.6 Replacing the optional pre-charging contactor (CPP).............................37
9.3.7 Replacing the optional high-voltage discharging contact (CPD)........38
9.4 Checks ......................................................................................................................................39
10. Spare parts......................................................................................................................40
10.1 Pre-charging contactor (CPP) ..........................................................................................40
10.2 High-voltage discharging contact (CPD) .....................................................................40
10.3 Auxiliary switch assembly .................................................................................................40
10.4 Arc chamber complete.......................................................................................................40
10.5 Main contacts ........................................................................................................................40
10.6 Contact bridge assembly...................................................................................................40
10.7 Magnetic drive complete (without main contacts) .................................................40
11. Technical Data ................................................................................................................41
12. Disposal ...........................................................................................................................41

42021-04-12 / V1.1
Important basic information
Contactors CP Series – 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, commisioning
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 single pole bi-directional high-
voltage contactors, disconnectors, changeover switch-
es for DC and AC of the types:
Nominal
Voltage Un
Conventional thermal current Ith
600 A 1,200 A 2,000 A
1,500 V
CP1115/06
CP2115/06
CP3115/06
CP1115/12
CP2115/12
CP3115/12
CP1115/20
CP2115/20
3,000 V
CP1130/06
CP2130/06
CP3130/06
CP1130/12
CP2130/12
CP3130/12
CP1130/20
CP2130/20
The CP series devices can be congured as normally
open/normally closed contactors, disconnectors or
change-over switches. Depending on the congura-
tion, the following abbreviations are used in this man-
ual:
-NO = Normally Opened
-NC = Normally Closed
-CO = Change Over
Since the CP 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 security information
The contactors dealt with in this document are intend-
ed for use with high-voltage 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-

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
General and security information
tions, transport, commissioning, as well as maintenance
and repair work. This applies to the observation of the
general installation and safety regulations for high-volt-
age systems as well as the proper use of tools approved
for this purpose. Electric equipment requires protection
from moisture and dust during installation and 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!
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 recog-
nise the possible dangers of the jobs commended
to him based on his training, knowledge and ex-
perience 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 after replacement
of main contacts, contact bridge or after any other
modications, alterations or maintenance works,
always perform complete checks according to
these standards:
-IEC 60077-2
-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 our
catalogues C40 in section “Specication“, such as
voltages, currents, ambient conditions, etc. may
be changed.
X The contactors must 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 switching device meets the requirements
of basic insulation. 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 Do not use the contactor without properly mount-
ed arc chute (if applicable).
X The contactor has unprotected live parts and car-
ries labels that warn of the hazard. This caution
must be observed and the labels must not be re-
moved in any way.
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 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. 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.

62021-04-12 / V1.1
Dangers and security measures
Contactors CP Series – Installation and Maintenance Instructions
2.4 Ambient conditions
NOTICE
The contactors are constructed for specic ambient
conditions.
X Operate the contactors only according the am-
bient conditions, like temperature ranges, IP
protection classes, degree of soiling, etc., as de-
ned in our catalogue C40 in section“Specica-
tion“. The catalogue is available under:
https://www.schaltbau.com/en/media-library/
3. Dangers and security measures
3.1 Electrical dangers
DANGER
The contactors are high voltage switches. 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.
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.

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Dangers and security measures
DANGER
Interventions in the equipment may cause serious impairments to the safety of men and construc-
tions. They are not permissible and lead to an exclusion of liability and warranty.
DANGER
All checks and the replacement 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 de-
livered by or released by Schaltbau.
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.
WARNING
The contactor is heavy. Risk of injury and damage to the device.
X Take care when handling the contactor.
X Always two or more persons are required to unpack, transport and install the contactor.
X When carrying the contactor always hold it on the base plate.
CAUTION
The contactors may grow warm during operation and they may become hot depending on the am-
bient temperature and the conditions of use. Risk of burns!
X Before beginning any work on the contactors make sure that the heated 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.

82021-04-12 / V1.1
Dangers and security measures
Contactors CP Series – Installation and Maintenance Instructions
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
The contactors 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
The contactors contain strong (permanent) magnets. These magnets can destroy 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 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.

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Introduction
4. Introduction
4.1 CP series – 1 and 2 pole bi-direc-
tional high-voltage contactors, dis-
connectors, changeover switches
for DC and AC
Modular and compact switchgear for modern power
converters
With the CP series Schaltbau is introducing once more
an innovative concept to the switchgear market. The
arc-handling is done exclusively by permanent-mag-
netic blowout. This patented technology ensures fully
bi-directional breaking capability and a more compact
design. By reducing dimensions and weight we save
you valuable space.
For the rst time the universal devices can be cong-
ured as NO/NC contactor, disconnector or changeover
switch. This enables us to react exibly to changing
customer requirements. The high switching function-
ality and reliability ensure practical and cost eective
operation.
The combination of innovative technology, compact
design and high versatility makes the CP-power contac-
tors particularly suitable for use in railway and indus-
trial applications.
Thanks to its unique modular design, the new product
family includes a variety of possible congurations ca-
tering to a wide range of applications.
4.2 Features
Innovative Design
X Available as NO/NC/CO contactor.
X DC bi-directional or AC up to 60 Hz max.
X Eective arc-handling – no critical currents and
low wear of main contact system thanks to perma-
nent-magnetic blowout
X High making capacity, also as disconnector and
changeover switch
X Low total cost of ownership, modular and compact
Main contact system
X Conventional thermal current: 600 A/ 1,200 A/
2,000 A
X Nominal voltage: 1.5 kV, 3 kV
X Double-break contacts
X 1 pole (NO/NC) and 2 pole (CO) versions
Easy maintenance:
X Toolless inspection of main contact tips (only ap-
plicable for NO/NC contactors with arc chamber)
X Toolless replacement of the arc chamber (only ap-
plicable for NO/NC contactors with arc chamber)
4.3 Applications
Main contactor, optional with pre-charging
contactor and high-voltage discharging contact for:
X Traction converters
X Inverters for auxiliary equipment
Switchgear for various mobile and stationary
applications
X Locomotives and multiple-unit trains
X Photovoltaic systems, wind turbines, cranes, weld-
ing systems, mining
Contactor for:
X Field circuits of motors
X Conventional resistor based traction units
X Activating the brake unit for DC drives
X Starter and compressor motors, solar cells
Switchgear for the conguration of electrical system
X Selection from among various energy sources
X Filter conguration for multisystem operations
X Connect/disconnect the DC link
4.4 Technical information and material
specication
For technical information, dimensions and material
specications, refer to our catalogue C40. The cata-
logue is available under:
https://www.schaltbau.com/en/media-library/

10 2021-04-12 / V1.1
Description
Contactors CP Series – Installation and Maintenance Instructions
5. Description
5.1 Survey of the CP series (stock items)
Conventional
thermal current Ith
NO/NC with
large arc chamber
NO/NC with
medium arc chamber
NO/NC without arc
chamber (load-free)
CO without arc
chamber (load-free)
600 A
1,200 A
2,000 A ---
The devices for 600 A, 1,200 A and 2,000 A dier opti-
cally mainly in the device dimensions and in the thick-
ness of the main contacts.
However, if the illustrations on the following pages do
not correspond exactly to the present device, the de-
scriptions and illustrations are equally valid for the oth-
er device models (600 A, 1,200 A, 2,000 A ).

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Description
5.2 Modular conguration options
B
or
or or
CDE
C
D
E
or
A
Fig. 1: CP series: Example of modular conguration options for 1,200 A and 2,000 A devices
A Main Contactor/Disconnector
B Pre-charging contactor (CPP) to be mounted on the base
plate of the main contactor
C High-voltage discharging contact (CPD)
D Auxiliary switch assembly 2x S826
E Auxiliary switch assembly 2x S870 a1/b0
B
or
or or
CDE
C
D
E
or
A
Fig. 2: CP series: Example of modular conguration options for 600 A devices
A Main Contactor/Disconnector
B Pre-charging contactor (CPP) to be mounted at a separate
mounting position next to the main contactor
C High-voltage discharging contact (CPD)
D Auxiliary switch assembly 2x S826
E Auxiliary switch assembly 2x S870 a1/b0

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Description
Contactors CP Series – Installation and Maintenance Instructions
5.3 Conguration examples
2
3
1
2
3
4
5
6
4
9
78
Fig. 3: CP series: Conguration example of NO and NC devices with high breaking capacity (large arc chamber)
1 Upper arc chamber area
2 Lateral arc chamber areas
3 Locking brackets 4x (to lock/unlock the complete arc
chamber)
4 Main contact terminals
5 Earth connection
6 Coil terminal (Wago 235)
7 Base plate
8 Economy circuit for coil
9 Auxiliary switch assembly (on both sides)
- 1x S870 (a1) + 1x S870 (b0) + 2x S826
- or 4x S826
- or high-voltage discharging contact
2
3
2
3
4
4
9
7
5
6
8
Fig. 4: CP series: Conguration example of NO and NC devices with medium breaking capacity (medium arc chamber)
2 Lateral arc chamber areas
3 Locking brackets 4x (to lock/unlock the complete arc
chamber)
4 Main contact terminal
5 Earth connection
6 Coil terminal (Wago 235)
7 Base plate
8 Economy circuit for coil
9 Auxiliary switch assembly (on both sides)
- 1x S870 (a1) + 1x S870 (b0) + 2x S826
- or 4x S826
- or high-voltage discharging contact

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Description
4
4
9
7
10
5
6
8
Fig. 5: CP series: Conguration example of NO and NC devices with load-free breaking capacity (no arc chamber)
4 Main contact terminals
5 Earth connection
6 Coil terminal (Wago 235)
7 Base plate
8 Economy circuit for coil
9 Auxiliary switch assembly (on both sides)
- 1x S870 (a1) + 1x S870 (b0) + 2x S826
- or 4x S826
- or high-voltage discharging contact
10 Cover (Inspection of main contacts is not required for
devices with load-free breaking capacity. The cover must
therefore not be removed.)
5
6
9
7
10
4
4
8
Fig. 6: CP series: Conguration example of CO devices with load-free breaking capacity (no arc chamber)
4 Main contact terminals
5 Earth connection
6 Coil terminal (Wago 235)
7 Base plate
8 Economy circuit for coil
9 Auxiliary switch assembly (on both sides)
- 1x S870 (a1) + 1x S870 (b0) + 2x S826
- or 4x S826
- or high-voltage discharging contact
10 Cover (Inspection of main contacts is not required for
devices with load-free breaking capacity. The cover must
therefore not be removed.)

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Storage
Contactors CP Series – Installation and Maintenance Instructions
6. 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.
7. Unpacking and handling
WARNING
The contactor is heavy. Risk of injury and
damage to the device.
X Take care when handling the con-
tactor.
X Always two or more persons are
required to unpack, transport and
install the contactor.
X When carrying the contactor al-
ways hold it on the base plate.
7.1 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.
X Unpack the contactor with the help of a second
person.
X When carrying the contactor always hold it at the
base plate. Do not carry the contactor by holding
it at the upper part.
X With the help of a second person, place the con-
tactor in an upright position on a stable work-
bench or table.
7.2 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.

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Installation
8. Installation
8.1 Mounting positions
The contactors are designed for horizontal or vertical
mounting. Examples of permissible mounting positions
are presented in Fig. 7 and Fig. 8. Even mounting posi-
tions suspended over head are permitted.
Fig. 7: Examples of permissible mounting positions - NO/NC
devices
Fig. 8: Examples of permissible mounting positions - CO
devices
8.1.1 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 C40 catalogue. The catalogue is available under:
https://www.schaltbau.com/en/media-library/
8.2 Mechanical installation
8.2.1 Preparatory measures
X A suitable mounting frame or plate with 4 mount-
ing holes must be provided for fastening of the
contactor. See Fig. 9 and Fig. 10.
X The mounting frame or plate must be solid enough
to carry the weight of the device under shock and
vibration conditions.
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 four M8 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 (and if applicable the
nuts) must be strength class 8.8 or higher.
X 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.

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Installation
Contactors CP Series – Installation and Maintenance Instructions
8.2.2 Required minimum clearance
NOTICE
Switching of high voltage currents produces electric
arcs and it is possible that plasma will escape from
the openings of the arcing chambers. Therefore, it
is extremely important to maintain the minimum
clearances to live and earthed parts to avoid asho-
vers. These minimum clearances have been tested
and specied in relation to the switching capacity of
the contactors.
X The required minimum distances to all sides and
upwards are given in the respective data sheets or
can be found in our C40 catalogue. The catalogue
is available under:
https://www.schaltbau.com/en/media-library/
8.2.3 Ventilation requirements
X Ensure sucient ventilation, especially in the case
of heavy arc switching. Allow the exchange of sur-
rounding atmosphere to avoid the risk of ash-
overs and excessive corrosion.
8.2.4 Mounting holes
The mounting holes at the mounting frame or plate can
either be
-threaded holes (for threaded screws)
-or through holes (for threaded screws and nuts).
Depending on the contactor type the dimensions and
arrangements of the mounting holes are shown in
Fig. 9 and Fig. 10.
[mm]
or M8
4 x Ø 9 ± 0.1
203±0.1
76 ±0.1
Fig. 9: Dimensions and arrangement of the mounting holes
for devices with 600 A (not to scale)
[mm]
or M8
4 x Ø 9 ± 0.1
203±0.1
96 ±0.1
Fig. 10: Dimensions and arrangement of the mounting holes
for devices with 1,200 A and 2,000 A (not to scale)
8.2.5 Safety
X The installation has to be carried out by qualied
trained personnel.
DANGER
The contactor meets the requirements
of basic insulation. Without proper
earthing 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 mounting frame
or mounting plate on which the
contactor is mounted is earthed in
a shock and vibration-proof way.
WARNING
The contactor is heavy. Risk of injury and
damage to the device.
X Take care when handling the con-
tactor.
X Always two or more persons are
required to unpack, transport and
install the contactor.
X When carrying the contactor al-
ways hold it on the base plate.

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Installation
NOTICE
When installing, ensure that no dirt can get into the
contactor as a result of surrounding building activi-
ties.
NOTICE
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.
8.2.6 Tools required
-Socket spanner set, hexagon nuts
-Open-ended spanner set
-Torque wrench
8.2.7 Installation procedure
X Make sure that the mounting surface on the
mounting plate (3) or mounting frame and the
bottom of the contactor are free from dirt and
other contaminants (e.g. metal chips).
X Place the contactor (1) on the mounting plate (3)
or the mounting frame provided with the mount-
ing holes.
X Screw the contactor (1) to the mounting plate (3)
or mounting frame using the 4 mounting screws
(2).
-If the mounting holes are designed as threaded
holes, screw the screws with suitable screw lock-
ing elements directly into the prepared threads.
-If the mounting holes are through holes, tighten
the screws with suitable screw locking elements
(on both sides) and nuts.
X Tightened the mounting screws to the specied
torque, which depends on the strength class (min.
8.8) of the screws/nuts used.
32
1
Nm
4 x M8
Fig. 11: Example for the installation of the device on a mount-
ing plate or mounting frame (the gure shows a NO/
NC device with large arc chamber)
32
1
Nm
4 x M8
Fig. 12: Example for the installation of the device on a mount-
ing plate or mounting frame (the gure shows a NO/
NC device with medium arc chamber)

18 2021-04-12 / V1.1
Installation
Contactors CP Series – Installation and Maintenance Instructions
32
1
Nm
4 x M8
Fig. 13: Example for the installation of the device on a mount-
ing plate or mounting frame (the gure shows a NO/
NC device without arc chamber)
32
1
Nm
4 x M8
Fig. 14: Example for the installation of the device on a mount-
ing plate or mounting frame (the gure shows a CO
device without arc chamber)
8.3 Installation of the optional pre-
charging contactor (CPP)
The optional pre-charging contactor (CPP) can be in-
stalled:
-with 1,200 A and 2,000 A devices either at the base
plate of the main contactor or at a separate mount-
ing position next to the main contactor using the
available special mounting ange;
-with 600 A devices only at a separate mounting posi-
tion next to the main contactor using the available
special mounting ange.
A separate installation and maintenance
manual is available for CPP contactors.
Also refer to this separate manual C45-m.
Available for download at: https://www.
schaltbau.com/en/media-library/
8.3.1 Installation of the CPP with 1,200A
and 2,000A devices
On delivery, the CPP is mounted at the base plate of the
main contactor as standard. The following installation
steps are only necessary in case of a subsequent cus-
tomer installation.
X With 1,200A and 2,000A devices position the CPP
(2) at the base plate (3) of the main contactor.
X Screw in the 2 xing screws (1).
X Tighten the 2 xing screws (1) to a torque of 4Nm.
14
Nm
2
3
Fig. 15: 1,200A and 2,000A devices: Example for the installa-
tion of the CPP at the base plate of the main contactor

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2021-04-12 / V1.1 Contactors CP Series – Installation and Maintenance Instructions
Installation
8.3.2 Installation of the CPP with 600A
devices
Preparatory measures
X With 600 A devices, 4 mounting holes at the
mounting frame or plate must be provided to fas-
ten the CPP.
X The mounting holes can be either:
-threaded holes (for threaded screws)
-or through holes (for threaded screws and nuts)
X Fastening of the CPP on the mounting frame or
plate is performed using four 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 (and if applicable the
nuts) must be strength class 8.8 or higher.
X 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.
[mm]
or M54 x Ø 6±0.1
51±0.1
111
±0.1
Fig. 16: Dimensions and arrangement of the mounting holes
for the CPP (not to scale)
Installation procedure
X Ensure that the contact surfaces on the mount-
ing 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 imple-
mented as threaded holes, screw the mounting
screws into the holes directly, not forgetting the
washers.
-In designs with through holes, t the mounting
screws and washers and tighten the screws us-
ing suitable screw locking elements and nuts.
X Tighten the mounting screws to the specied
torque, which depends on the strength class (min.
8.8) of the screws/nuts used.
3
2
Nm
1
Fig. 17: 600 A devices: Example for the installation of the CPP
at a separate mounting position next to the main
contactor

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Contactors CP Series – Installation and Maintenance Instructions
8.4 Electrical Installation
The electrical data for the control power of the mag-
netic drive and for the auxiliary switches as well as fur-
ther technical parameters can be taken from the corre-
sponding data sheets or from our catalogue C40.
The catalogue is available under:
https://www.schaltbau.com/en/media-library/
8.4.1 Preparatory measures
X The minimum clearances to live and earthed parts
are given in the corresponding data sheets or in
our C40 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 For switching heavy loads allow a minimum time
of 30 s between switchings. Allow a recovery time
of at least 10 min after 3 heavy load switchings in
succession.
X The earth connecting cable must be tted with an
appropriate ring terminal (for M8 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 connec-
tion must be observed.
X Schaltbau recommends busbars for the connec-
tion of the main terminals. The required cross-
sections of the busbars depend on the application
and must be determined by the plant operator.
X If connecting cables are used for the main power
circuit, they must be selected taking into consid-
eration the insulation class and the ambient con-
ditions.
X The connecting cables of the main power circuit
must be tted with appropriate ring terminals (for
M12 terminal screws).
-Schaltbau recommends using Schnorr washers
(or similar).
X The main terminal screws must be tightened to a
torque of max. 30 Nm.
X The auxiliary switches are provided with screw
terminals (M3). The control wires for the auxiliary
switches must be stripped accordingly (if neces-
sary, t with appropriate wire end sleeves).
X The maximum permissible conductor cross-
section of the auxiliary contact control wires is
1mm2/ AWG 18 stranded wire.
X The coil control connection is provided with a ter-
minal strip with cage clamp terminals. The control
wires for the coil connection must be stripped ac-
cordingly (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:
-C40 (Catalogue CP series devices)
-D26 (Catalogue auxiliary switches S826)
-D70 (Catalogue auxiliary switches S870)