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http://electrical-engineering-portal.com/how-to-predict-life-span-of-the-switchgear
Figure 1 - Example of a diagram for determining the electrical life span of contactors as a function of the rated operational current Ie for
utilization category AC-3
Example 1
Background:
Squirrel-cage induction motor 7.5 kW, 400 V, 15.5 A, AC-3 (switching off only when running), operating cycle 2
minutes ON / 2 minutes OFF, 3-shift operation, expected service life 8 years.
Objective:
Selection of the contactor
Solution:
2 min ON + 2 min OFF = 15 switching operations/h. This results for 3-shift operation over 8 years in around 1
million switching operations.
From diagram Figure 1 yields for a rated operational current of 15.5 A and 1 million required switching operations
the contactor C16 (electrical life span approx. 1.3 million switching operations).
Figure 2 - Example of a diagram for determining the electrical life span of contactors as a function of the rated operational current Ie for
utilization category AC-4
Example 2
Background:
Squirrel-cage induction motor 15 kW, 400 V, 29 A, plugging, switching off rotor at standstill at IA = 6Ie, expected
life span = 0.2 million switching operations.
Objective:
Rating of starting and braking contactors.
Solution:
The starting contactor (circuit making only) is selected according to the maximum permitted rated power at AC-3
(see Figure 1): C30.
The brake contactor is selected according to the maximum permitted rated operational power at AC-4 and 0.2
million switching operations according to Diagram Figure 2 C72.
For mixed service, i.e. service of the contactor with AC-3 and AC-4 switching operations, the life span results from
the sum of the loadings. In the catalogs, diagrams for certain %-rates of AC-4 operations, for example 10 %, are
provided. The RALVET electronic documentation is available for determining the life span for other percentage
rates, or direct inquires must be made.
If in practice the electrical life span was considerably shorter than desired, there are several possible
causes and explanations:
More switching operations than expected, e.g. operated by extremely sensitive controller.
More frequent inching than expected, e.g. unskilled operation.
Permitted frequency of operation exceeded, e.g. chattering contacts
Short-circuits, e.g. switching pause too short for reversing or star-delta starters.
Synchronization with the supply voltage. Semiconductors as controllers could for example always switch
off at the same phase angle and act in the same direction of current-flow
(results in one-sided material migration to the contacts like in direct current control).
Figure 3 - Contacts of a power contactor at various stages of the life span with AC-3 loading