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Medium Voltage Distribution

CBX
Vacuum Contactors
Equiped with an electronic module

Installation, Operation & General Maintenance


Technical Manual
CBX

Any operator must read and respect in all case this technical manual.
Installation, comissionning and maintenance should only be conducted by qualified people.
Before installation, check that data in rating label match with the application.
Accidental contact with energized components or wiring can cause shock, burn or electrocution :
turn off power supplying this equipment and control voltage sources before any work on contactor.

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CONTENTS

1. SAFETY INSTRUCTIONS ....................................................................................................................................................4


1.1 COMPLIANCE WITH INSTRUCTIONS IN THIS MANUAL ......................................................................................................4
1.2 INSTALLATION ..........................................................................................................................................................4
1.3 OPERATION & MAINTENANCE .....................................................................................................................................4
1.4 APPARATUS/TASK/SKILL LEVEL SCHEDULE FOR W ORKING ON THE APPARATUS ..............................................................5
2. OPERATION & GENERAL INFORMATION ....................................................................................................................6
2.1 GENERAL INFORMATION ............................................................................................................................................6
2.2 DESCRIPTION & OPERATION ......................................................................................................................................8
2.3 ELECTRONIC CARD ...................................................................................................................................................9
3. INSTALLATION & PRE-COMMISSIONING TESTS ......................................................................................................12
3.1 UNPACKING ...........................................................................................................................................................12
3.2 CRITICAL ITEMS DURING UNPACKING AND INSTALLATION .............................................................................................12
3.3 INSTALLATION ........................................................................................................................................................12
3.4 PRE-COMMISSIONING TESTS ....................................................................................................................................14
3.5 ROUTINE SITE VOLTAGE TEST .................................................................................................................................14
4. MAINTENANCE .............................................................................................................................................................16
4.1 MAINTENANCE ........................................................................................................................................................16
4.2 MECHANICAL & ELECTRICAL LIFE .............................................................................................................................16
4.3 VACUUM SWITCH CONTACT W EAR CHECK ................................................................................................................17
W IRING DIAGRAMS .....................................................................................................................................................................17
5. AUXILIARY SWITCHES.................................................................................................................................................18
5.1 GENERAL INFORMATION ..........................................................................................................................................18
5.2 AUXILIARY CONTACT BLOCKS ..................................................................................................................................18
5.3 AUXILIARY SWITCH MAINTENANCE ............................................................................................................................19
6. FAULT FINDING ............................................................................................................................................................20
6.1 CONTACTOR WILL NOT CLOSE AT ALL ........................................................................................................................20
6.2 CONTACTOR CLOSES AND IMMEDIATELY REOPENS ......................................................................................................20
6.3 CONTACTOR CLOSES BUT MOTOR WILL NOT RUN ........................................................................................................20
6.4 CONTACTOR CLOSES - BUT STOPS AT TIPS TOUCH I.E. NO OVERTRAVEL .....................................................................20
7. CBXS3-C CONTACTORS (SINGLE PHASE) ................................................................................................................21
8. LATCH-IN DEVICE.........................................................................................................................................................22
8.1 MAINTENANCE OF LATCH-IN MECHANISM...................................................................................................................22
8.2 LATCH-IN DEVICE AND SETTING ...............................................................................................................................22
8.3 IN THE EVENT OF A MALFUNCTION OF THE LATCH ........................................................................................................24
9. SPARE PARTS LIST......................................................................................................................................................25
10. ANNEX ...........................................................................................................................................................................26

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1. Safety Instructions
1.1 Compliance with Instructions in this Manual
The Purchaser/User should comply with the instructions and information given in this document and ensure that all
personnel to be associated with the apparatus supplied under this contract are made familiar with the information
contained herein.

1.2 Installation
The Purchaser/User should ensure that the apparatus supplied is correctly installed in a suitable location by technically
qualified and competent persons.
Apparatus supplied as loose components, devices or sub-assemblies could, when energised, constitute a safety hazard.
The Purchaser/User should ensure that such apparatus is installed in a secure location and that adequate safety
information is provided to all personnel to be associated with it.

1.3 Operation & Maintenance


1.3.1 Conseils pour lUtilisateur sur la Scurit du Personnel
Les rgles permettant dassurer la scurit du personnel peuvent tre rsumes comme suit :
During Normal Use ensure that the plant operators:
are fully conversant with all controls, particularly those for emergency shutdown.
comply with safety warning notices and keep all enclosures shut
are trained to recognise signs of maloperation and know what action to take in the event of trouble or difficulty.
During Maintenance, Testing etc. ensure that only technically competent and authorised persons are permitted to
carry out work and that they:
comply with statutory requirements.
are fully conversant with the apparatus and the system of which it is part, and recognise the safety hazards which
could arise, e.g. back feed.
isolate the apparatus completely, where possible, before opening enclosures and prove it to be dead before
starting work. Precautions must be taken to ensure that the isolated apparatus cannot become live whilst any
work is being carried out.
comply with safe working procedures for the safety of themselves and others, including the use of temporary
barriers and warning notices.
are conversant with the information provided, particularly on matters relating to safety.
recognise the hazards which can arise when working on live apparatus and take all the necessary precautions.
functionally check the apparatus and then mechanically and/or electrically test it in accordance with this manual
and good working practice before putting the apparatus back in service.
take account of the possibility that the apparatus may have been modified without proper reference to the
manufacturer and take extreme caution at all times before, during and after and work is carried out.
If there is any doubt as to the correct and safe method of working then further assistance should be sought Schneider
Electric
1.3.2 Skills Required for Specific Tasks
To ensure that the apparatus is safe for use under normal healthy plant operating conditions:
it has been designed and tested in accordance with relevant European and International standards.
information is provided in this manual about the conditions necessary for safety and about any hazards which are
reasonably foreseeable during normal use, together with precautions to be taken to counteract them.
However, the Purchaser/User should ensure that the apparatus is maintained in a safe condition, and if technically
competent and authorised personnel have to gain access to apparatus which is not made completely safe as
recommended, everyone under whose authority these persons act should ensure that appropriate safety procedures are
generated and complied with.
The apparatus covered in this manual has been allocated the Apparatus Grade stated above. Reference to the
Apparatus/Task/Skill level schedule [1.4] enables the user to select personnel to carry out specific tasks requiring access
to the apparatus.

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1.4 Apparatus/Task/Skill Level Schedule for Working on the Apparatus

The apparatus can be supplied as loose items, sub-assemblies etc., for which the purchaser/user is responsible for
assembly etc. [1.2]. The skill level required to work on this equipment can be best described as the following :

Authorised and competent staff (e.g. Electrician, Commissioning Engineer) with a HIGH degree of electrical expertise,
trained to work on live apparatus and fully conversant with the apparatus and the system of which it is part.

If additional information relating to the apparatus is required please contact : SCHNEIDER ELECTRIC T&D STS [2.1]

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2. Operation & General Information


2.1 General Information
This vacuum contactor was manufactured by;
Schneider Electric

A contactor is primarily a three phase switching device, although single phase units are also available, used
primarily in motor starting/reversing and capacitor bank switching applications. Each phase has a separate
Vacuum Switch which switches at the first available current zero.

2.1.1 Contactor Front View

Armature
Closing coils
Moulding

Pivot Point

Auxiliary switches
Operations
counter (option)

Electronic Stop pin


card cover

Opening Springs

Fixing holes

Steel Mounting
Plate

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2.1.2 Contactor Rear view

Phase assembly & nyloc nuc

Main Terminals

Moulded
Terminal Bar
Main Moulding

Main Terminals

Vacuum
Switches

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2.2 Description & Operation


As shown in [2.1.1 & 2.1.2], the Contactor comprises Main and Armature mouldings with two Pivot Points, a Steel
Mounting Plate, three Vacuum Switches, two Opening Springs, two Closing Coils, an Economy electronic card and one
Auxiliary Contact Blocks.

2.2.1 Closing Coils Un-energised


In this condition the opening springs acting against the centre limb of the armature moulding hold the vacuum switches in
the normally open position (main circuit off).

2.2.2 Closing Coils Energised


Energising the closing coils through the electronic card attracts the armature which compresses the opening springs. The
armature movement is transmitted through the pivot points, allowing the vacuum switches to close under the effect of
atmospheric pressure which acts on the bellows inside the vacuum switches (main circuit on). The vacuum switches will
remain closed as long as the closing coils are energised. The armature moulding moves further than necessary for switch
closure providing overtravel which accommodates contact wear and, on opening, provides kinetic energy to break minor
contact welds which may occur under severe operating duty.
The energy required to close the contactor is considerably more than the energy required to maintain a closed position.
On initially energising the closing coils a high current flows through the coils. After a short delay the electronic card
automatically reduces the current in the closing coils which allows their continuous operation without over heating. The
closing coil rating enables satisfactory operation of the contactor in cubicles with internal temperatures of up to 65C. For
use in temperatures higher than this, contact Schneider Electric T&D STS. [2.1]. Contactors are supplied fitted with closing
coils and electronic card suitable for d.c. or a.c. supply voltages.

2.2.3 Closing Coils De-energised


When the closing coils are de-energised the opening springs will act on the armature moulding causing the vacuum
switches to open. The vacuum switches provide a sealed gas-free environment making the switching operation unaffected
by external conditions. Once the vacuum switch contacts have separated arcing occurs until the first available current
zero, at which time the current is commutated.

2.2.4 Auxiliary Contacts


One auxiliary contact blocks is provided giving a maximum of 10 (ten) contacts available for customer use (5NO+5NC).

2.2.5 Main Terminals


The main terminals consist of M10 bolts for attachment of cables or busbars. For advice on cable/busbar connection see
[3.3]. The maximum torque applicable for these terminals is 40 Nm and must not be exceeded.

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The maximum width of the lead terminal connexions, bars or crimps is 35 mm.

2.3 Electronic card

The closing coils are energised through an electronic card which automatically reduce the current when the contactor is
closed.

We have two types of cards depending on the voltage supply. The electronic card accepts any control voltage in the
range:

24 to 60 Vdc
110 to 240 Vac or 110 to 250 Vdc

The card is configurable on demand by Schneider Electric T&D STS in order to introduce an additional opening time delay
of 100 ms by means of the ST3 jumper (see pictures above). This opening delay can be used for the coordination with
fuses.

It is also possible to connect in option an operations counter to the card.

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Configurable pin
for opening
delay of 100 ms

Power supply
connector

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No additional time delay

time delay 100 ms

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3. Installation & Pre-commissioning


Tests
3.1 Unpacking
Contactors may be supplied as separate units, or mounted with
other equipment. When supplied as separate units, care must be
taken during unpacking. After removing the packing material,
examine the contactor and packing material for broken or missing
parts. The carriers and suppliers should be notified of the breakages
within three days of delivery. These together with any other
evidence should accompany communications with the insurance
company and the suppliers. The particulars on the rating plate of the
equipment must be quoted in all correspondence.

3.2 Critical Items During Unpacking and


Installation
3.2.1 Do not attempt to lift the contactor by means of
the auxiliary contact blocks, or the electronic card
support shown in positions below marked X.
3.2.2 Take care when fitting cables or busbars to the
main terminals that the terminations do not damage,
deform or restrict movement of the contactor. Particular
care should be taken when two or more cable
terminations are fitted onto a single terminal.
3.2.3 Everything surrounding the contactor (i.e. frames,
enclosures, components, power and control cables) must
be clear of the paths of the moving parts of the contactor.
Nothing should be allowed to rest on top of the armature
moulding or interfere with the normal operation of the
moving parts of the contactor.
3.2.4 Ensure that nothing interferes with adequate air
flow over the contactor, particularly around the coils.
3.2.5 It is not recommend that additional components
are added to the contactor e.g. indicators, etc.. However,
if components are added, checks must be made to
ensure that they do not have any adverse effect on the
operation of the contactor.
3.3 Installation
It is recommended that the contactor be mounted with the axes of
the vacuum switches vertical and with their moving contacts at the
top. Two M10 x 1.5 fixing holes are provided on each side of the
contactor in the turned up outer edges of the steel mounting plate,
which must be used for the mechanical mounting of the contactor.
The maximum torque applicable for these terminals is 40 Nm and
must not be exceeded.
When installing and cabling, ensure that an air gap of at least
64mm for 7,2kV and 77mm for 12kV systems, is maintained
between live main circuit contactor parts and earth control
circuits.
It may, of course, be necessary to increase these dimensions
if the contactor and associated equipment have to meet a
particular impulse withstand voltage.
General Arrangement of Contactor

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Mounting holes

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3.4 Pre-commissioning tests


It is good practice to subject vacuum switches or contactors to pre-commissioning tests.

3.4.1 Check for the presence of loose screws, swarf or other material in the gaps between closing
coil pole pieces and the armature plate

3.4.2 Check contactor operation at 85% of the control voltage after installation, including cables or
busbars, but before applying full control voltage and power.

3.4.3 Perform routine site voltage test. [3.5]

3.4.4 Perform auxiliary maintenance checks [5.3]

It is also advisable to test vacuum switches and contactors under the following circumstances:
If the contactor or switch has been standing for 5 years or more without use - either in storage or in service.
In special applications where the switch is in use for long periods without breaking current and without normal voltage
across the contacts when switched off.
After a main circuit fuse has operated.

3.5 Routine Site Voltage Test


The following test should be carried out by using an a.c. test set of limited rating e.g. 2 to 4kVA, on which the voltage is
continuously variable from zero up to the maximum required for that particular switch. Return the contactor to the supplier
if the test is not successful.
Note : Applying very high voltages to open vacuum switches may generate harmful levels of X radiation. However
emission of X radiation is negligible at the specified test voltages.

3.5.1 Connect output leads of the test set across the open gap of each vacuum switch in turn.

3.5.2 Slowly raise the voltage from zero to the specified test value taking approximately one minute to
reach full voltage. During this stage any discharge or test set tripping should be ignored unless it
proves impossible to reach the full specified voltage within two minutes.

3.5.3 Hold the voltage at the specified test value for one minute.
Note: On reversing applications and on applications with VS3-C vacuum switches no discharge or test set tripping can
be tolerated whilst the voltage is being slowly raised to, and held for one minute at the specified test voltage.

Contactor Vacuum Nominal A.C. Test D.C. Test


Type Switch System Voltage Voltage
Type Voltage 45/65 Hz (Test in both
kV kV polarities)
kV
CBX3-C VS3-C 12 22 22
CBX3 VS3 7,2 22 22

Note : The codings given to contactors in the above table have additional suffix letters and numbers in their references.

When carrying out a.c. high voltage tests, current monitoring facilities are not usually available and in any event the
leakage currents can be misleading due to the presence of currents associated with the vacuum switch capacitance.

When carrying out d.c. high voltage tests, current monitoring facilities usually are available. If any doubt exists about the
vacuum switch dielectric to pass the routine site test procedure given above, an additional criterion can be applied where

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the leakage current should not exceed 150 microamps at the relevant test voltage given in above table. However, before
rejecting any vacuum switch which is apparently outside the limit, it should be ensured that the leakage current is due to
faulty switch dielectric and not due to dirt etc. on the outside of the vacuum switch envelope.

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4. Maintenance
4.1 Maintenance
These contactors are extremely reliable and only slight maintenance is normally required. The following table outlines
recommended maintenance intervals.

Installa Pre- Every Every After Infrequen Every


-tion commissio 100,000 250,000 Main t 5
n Operation Operation Fuse Switching Years
s* s* Operatio (< 1 year)
n

[3.4.1] Contactor

Operation
[5.3] Auxiliary Contacts
[4.3] Vacuum Switch

Wear 400A
[3.5] Vacuum Switch

Voltage Test

Assuming a normal starting peak of six times full load current when controlling a squirrel cage induction motor.
These totals are only for ELECTRICAL operations as the Vacuum switch assemblies will mechanically operate for the
life of the contactor.

4.2 Mechanical & Electrical Life

The contactor has a design life of 1,000,000 mechanical operations. Electrical life depends upon the type of vacuum
switch fitted and the level of current to be switched. Provided that the vacuum switch contact wear does not exceed the
maximum permissible [4.3] then contactor will continue to function correctly.

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4.3 Vacuum Switch Contact Wear Check

After isolating the main circuit of the contactor, close the


armature by energising the coils and insert the wear gauge
DRC001528-02 provided underneath the washer on top of
each phase (as indicated above).
With the gauge in position, slide it from back to front to gain a feel
for the movement. If the gauge is trapped or tight fitting i.e. phase
assembly, washer, and Nyloc nut also move, this indicates that the
switch contacts are worn and the switch is close to or at the end of
its electrical life. If one or more switches indicate worn contacts,
all three vacuum switches must be replaced.
Important : Remember to remove the gauge after
checking for wear !
Note: A switch assembly is worn out when each contact has
been reduced in thickness by 0.25mm i.e. a total of 0.5mm
per pair of contacts in a switch.

Wiring Diagrams

Magnetically held
See Electric diagram contactor DRC003793-01 in annex

With mechanical latch


See Electric diagram contactor DRC003793-02 in annex

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5. Auxiliary Switches
NC 5.1 General Information
The microswitches used are 16A / 250 Vac- Faston blade 6.3 x 0.8
NO type.

Common

Auxiliary contacts are 5 NO and 5 NC positively driven. They must


be connected directly at their terminal. For each normally open or
closed contact, the complement contact is available (i.e NC for NO
and vice versa).

5.2 Auxiliary Contact Blocks

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5.3 Auxiliary Switch Maintenance


The auxiliary contacts require little attention but should be kept free of dust and dirt

5.3.1 Examine moving parts for side play, badly worn pivots etc., which indicate that the auxiliary
switch should be replaced.

5.3.2 Operate the contactor to check that the contacts have satisfactory wipe and break and that
movement is free.

Where reliability of operation is particularly critical - e.g. continuous processes, mine winding installations, etc., inspection
of the auxiliary switches is recommended at intervals of approximately 100,000 operations.

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6. Fault Finding
In cases of apparent contactor malfunction carry out the following checks after the isolation of the main circuit.
Note A :As the contactor relies on atmospheric pressure acting on the switch bellows, loss of vacuum in one or
more switches on the 7,2kV and 12kV contactors will possibly prevent closure depending on actual supply
voltage and whether the coils are cold or hot.
Note B :Do not adjust nyloc nuts on top of the phase assemblies, pivot point screws and nuts, stop pin locking nut or
opening springs. It is unlikely that any of these will have altered to the extent of causing malfunction of a contactor which
was previously satisfactory.

6.1 Contactor will not close at all


Check power supply to the electronic card
Check auxiliary switch drive and pivots are not broken, badly worn or screws loose.
Check that all switches have vacuum using the site voltage test [3.5].
Manually assist closure with coils energised. If not possible to close with moderate force, check that sufficient voltage
see rating label) appears across the coil terminals.

6.2 Contactor closes and immediately reopens


Check for the presence of loose screws, swarf or other material in the gaps between closing coil pole pieces and the
armature plate.
Check the electric circuit (connection diagram).

6.3 Contactor closes but motor will not run


Check fuses, if fitted, and any other protection equipment
Check with vacuum switch contact wear gauge if contactor is nearing the end of its life.[4.2.1]
Check that all switches have vacuum using the site voltage test [3.5].

6.4 Contactor closes - but stops at tips touch i.e. No overtravel


Check for the presence of loose screws, swarf or other material in the gaps between closing coil pole pieces and the
armature plate.

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7. CBXS3-C Contactors (Single Phase)

The information given elsewhere in this manual is, in general, also applicable to the single phase contactors except where
reference is made to more than one phase or vacuum switch.

In particular the following information applies to the specific contactors listed below :

Wiring Diagram for CBXS3-C

 Magnetically held
See Electric diagrams contactor DRC004287-01 (Dc + Ac) in annex.

 Mechanically latch
See Electric diagrams contactor DRC004287-02 (Dc + Ac) in annex.

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8. Latch-in Device
8.1 Maintenance of Latch-in Mechanism

No maintenance is required for the latch-in mechanism, beyond an occasional light application of molybdenum disulphide
loaded grease to the sliding parts.

8.2 Latch-in Device and Setting

8.2.1 Latch in Close position

M4 GRUB
SCREW

ROLLER

PROP

CLEVIS

8.2.2 Latch in open position

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8.3 In the event of a malfunction of the latch


The following points should be examined:

8.3.1 Check freedom of moving parts. (It is possible that the alignment of the whole latch assembly
may have been disturbed during transit).

8.3.2 Check with a clock gauge, the set-back of the clevis holding the roller behind which the prop is
located. (ie. its free movement in relation to the latch body in the horizontal direction, from the
contactor coil energised condition to the latched-in, coil de-energised state).

This set-back should be between 0.2mm and 0.4mm. The set-back can be adjusted by slackening the screws fixing the
whole latch assembly to the contactor coil support angle, and adding (to decrease the set-back) or removing (to increase
set-back) slotted shim washers between the collars and the angle. Retighten screws and recheck set-back.Coarse
adjustment necessitates removal of the latch assembly and screwing the clevis further on to or off its drive rod in one full
turn steps. (The E-clip on the roller pivot pin must be located against the lower slotted guide plate).

8.3.3 Check prop engagement behind roller. Assuming the set-back is correct (see 8.3.2 above), but
the latch is reluctant to trip, it is possible that the prop is too far into engagement behind the roller.
Conversely, insufficient engagement can result in failure to latch. The engagement can be reset as
follows:

Slacken the locknut on the M4 grubscrew in the prop and adjust this grubscrew until the contactor ust fails to latch.
1
Unscrew the grubscrew 1 /2 full turns from this position so that the prop is further into engagement behind the roller. Lock
with locknut and recheck 8.3.2 above.

8.3.4 Check solenoid tripping action and adjust as follows if necessary.

Three solenoids are available, for nominal voltages of 24 Vdc, 48 Vdc and 110/240 volts ac or dc. having cold resistances
of 3, 14 or 54 ohms respectively. (Coils are marked 24Vd.c. 5%, 25% or 100% respectively).With the contactor latched,
there should be a clearance of 0.5mm to 1mm between the outer end of the prop and the 10mm diameter collar fixed to
the trip rod passing through the prop. This dimension can be adjusted by addition or removal of M3 washers behind this
collar.With the 10mm diameter collar loose on the trip rod, allow the solenoid plunger to retract as far as possible without
forcing. Push in the plunger 1mm from this position and tightly secure the collar to the trip rod by means of the two grub
screws and lock with the locknuts. The collar now acts as a stop for the lever/plunger assembly. The dimension between
the outer end of the plunger and the solenoid mounting plate should be at least 24mm. Check that the solenoid plunger is
not sticking at any stage in its movement.

Notes:

To ensure correct operation, closing coils and tripping coil must be energised for a
minimum of 300 milliseconds. Closing coils and Tripping coil must not be energised for
more than 2 seconds.The closing supply however, should not be wired directly through a
normally closed contact on the auxiliary contact block, as this could cause the closing
supply to be disconnected before the contactor is fully closed.

The use of an auxiliary switch on the vacuum contactor or on the latch (if fitted) to interrupt the contactor coil
supply during the closing action is not recommended unless an intermediate relay with a delay of at least
0.3 seconds is employed.

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9. Spare parts list


Recomanded
CBX3 CBX3-C CBXS3-C quantity by
contactor
Closing coils
24 V to 60 Vdc DRC001966-01 2
110 to 250 Vdc
DRC001966-04 2
110 to 240 Vac
Electronic card
24 V to 60 Vdc DRC003817-01 1
110 to 250 Vdc
DRC003817-02 1
110 to 240 Vac
Operations counter
DRC002617-01 1
Equipped auxiliary switch
5NO + 5NC DRCN01726-01 1 set
Tripping coils (latch)
24-30 Vdc DRC001749-03 1
48 Vdc DRC001749-02 1
110-240 Vdc DRC001749-01 1
240 Vac DRC001749-01 1

Replacement of parts should be performed only by qualified personnel.


Always de-energize a contactor and remove it from the equipment before performing any tests,
maintenance or repair.
Please contact SCHNEIDER ELECTRIC T&D STS for training course. Use of unauthorized parts
in the repair of the equipment, altering of the design, or tampering by unqualified personnel will
result in dangerous conditions : can cause death, serious personal injury or equipment
damage.

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10. Annex

Magnetically held

Electric diagram contactor CBX DRC003793-01


Electric diagram contactor CBXS DRC004287-01

With mechanical latch

Electric diagram contactor CBX DRC003793-02


Electric diagram contactor CBXS DRC004287-02

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2011 Schneider Electric - All rights reserved

Schneider Electric
35, rue Joseph Monier As standards, specifications and designs change from time to time, please
CS 30323 ask for confirmation of the information given in this publication.
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This document has been printed
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www.schneider-electric.com
Publishing: Schneider Electric
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Printing:

NTV120 - E 02/2011