Automation and Drives

Power Contactors
Low Voltage Controls & Distribution

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

A&D CD-BD

May2003

Automation and Drives

What is a Contactor ??
Low Voltage Controls & Distribution

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

It is an electro-mechanical switching device It is a remotely operated device It should be capable of making,carrying and breaking currents under normal conditions and during operating overload conditions It is placed nearest to the load center e.g. for Switching motors, lights, capacitors,heaters,furnaces etc High service reliability in terms of high mechanical and electrical life is demanded

A&D CD-BD

May2003

Automation and Drives

Construction
Low Voltage Controls & Distribution

Introduction Basics Constructions Construction Operation Parameters Selection Maintenance Surges

A contactor consists of 3 subsystems

Electromagnet system Contact and Arc quenching system Housing

A&D CD-BD

May2003

Automation and Drives

Construction
Low Voltage Controls & Distribution

Internal construction 3TF 50 AC Contactor

Box terminals Arc chute with arc quenching plates

Introduction Basics Constructions Construction Operation Parameters Selection Maintenance Surges

Current path with Z-shaped contact pieces Magnet coil Magnet system Auxiliary contact block

Mechanical interlock prevents closing of contacts when arc chute is removed

A&D CD-BD May2003

Automation and Drives

Operating Principle
Low Voltage Controls & Distribution

Contact spring Moving contact

Introduction

1
Basics Constructions Operation Operation Parameters Selection Maintenance Surges
Fixed magnet Coil Moving magnet Y

Fixed contact
Return spring

A1 A2

X = total stroke Y = Opening X-Y = wipe

A&D CD-BD

May2003

Automation and Drives

DC-Operation
Low Voltage Controls & Distribution

Closing and holding currents

80

Introduction
a) DC-Magnet system
i[mA] 1500

b) DC-Economy circuit
imax = 1630 mA

Basics
i[mA]

Constructions Operation Construction

60
imax = 45 mA 40 1000

Parameters Selection Maintenance Surges

50 100 150 t [ms] 5 10 t [ms] 500 20

A&D CD-BD

May2003

Automation and Drives

Magnet Systems
Low Voltage Controls & Distribution

Comparison of holding power

90

Introduction Basics Constructions Operation Operation Parameters Selection Maintenance Surges

Holding power P [W]

70 60 50 40 30 20 10

DC-Magnet system AC-Magnet system DC-Economy circuit

P AC-3 400V/50Hz 00 4 0 5,5 7,5 1 11 15 18,5 22 2 3 30 37 4 45 55 6 75 90 110 132 160 200 250 335 450 8 10 12 14 Size

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May2003

Automation and Drives

Critical Parameters
Low Voltage Controls & Distribution

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

Stroke Wipe Contact pressure Pick-up VA Hold-on VA Coil current

A&D CD-BD

May2003

Automation and Drives

Parameters
Low Voltage Controls & Distribution

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

Mechanical Life
Switching ON/OFF at no load 3TH30 30 million 3TF30/31/32/33 15 million 3TF44 upto 3TF57 10 million

Electrical life
Contact life at the specified breaking current The life depends on the type of Duty Electrical life curves are available for each rating

A&D CD-BD

May2003

Automation and Drives

Parameters
Low Voltage Controls & Distribution

Mechanical Life is over when

In the E shaped Magnets - Air gap reduces to Zero - The contactor fails to drop out - Shading rings breaks Damage to mechanical parts Damage to Springs

Introduction Basics Constructions Operation Parameters Parameters Selection Maintenance Surges

Electrical Life is over when

The contact Silver material wears away

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May2003

Automation and Drives

Parameters
Low Voltage Controls & Distribution

Contactors - High Electrical Endurance

6 4 107 6 4

Contactor Type
3TF30 3TF31 3TF32 3TF33 3TF44

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

2
106 Make/ break 6 operations 4 at 690V 2 2 105 6 4 2 2 104 104 6 4 2 103 103 1 Ia (A) 2 4 6 10 105 6 4

Make/ 106 break operations 6 4 at 400V

3TF45

6 4
2

20

40 60

100

200

400

9 12 16 22 32 38 4 5,5 7,5 11 15 18,5

Ie (A) PN (kW)

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May2003

Automation and Drives

Parameters
Low Voltage Controls & Distribution

Electrical Endurance
Contacts with 30% remaining life

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

A&D CD-BD

May2003

Automation and Drives

Selection
Low Voltage Controls & Distribution

Permissible Length of Control Cable

Formula L = 5 x (U2)x u R x P x Cos Rated coil voltage Voltage drop ( 5%) Coil VA / W at pick-up Power factor of coil at pick-up Ohmic resistance of cable

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges Cross section of cable (sq mm) 1.0 1.5 2.5 4.0
A&D CD-BD

where... U = u = P = Cos R =

Resistance in 21.70 14.47 8.71 5.45

May2003

km

Automation and Drives

Selection
Low Voltage Controls & Distribution

Choice of control transformer

Rating = 0.33 x Sum of Pick up VA of all contactors to be switched on Simultaneously e.g. : 3X 3TF33 and 2 x 3TF55 contactors are to be switched on Simultaneously Total Pick up VA of contactors = 3064VA Control transformer rating = 0.33 x 3064 1KVA

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

A&D CD-BD

May2003

Automation and Drives

Maintenance
Low Voltage Controls & Distribution

Possible Problems in a contactor Overheating of contacts Chattering

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

Humming
Coil burning Welding of contacts Contact life Mechanical Life

A&D CD-BD

May2003

Automation and Drives

Maintenance
Low Voltage Controls & Distribution

Causes of Problems Arc Chamber interlock Mechanical interlocking of contactors Coil,main contacts replacement Auxiliary contact block replacement / addition
A&D CD-BD

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

AC coil to DC coil conversion. Cleaning of magnets Examination of main contacts for erosion
May2003

Automation and Drives

Maintenance
Low Voltage Controls & Distribution

Please ensure
Do not operate contactor without Arc Chamber Do not use repaired contacts or coils or Arc chambers Do not file or rub the surface of contacts with abrasives Clean contacts with CRC 2-26 Replace contact in pairs Proper connection of the cable/bus bar at the contactor terminal Please Ensure correct tightening torque Use only Genuine spare parts
A&D CD-BD May2003

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

Automation and Drives

Maintenance
Low Voltage Controls & Distribution

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

Connection with Lugs / Busbars Busbars Should be

Wire brushed Wiped with clean cloth chambers Apply Dowells compound Tighten with requisite tightening torque Use bimetal washers when using 2 different metals

The mV drop across a joint should be less than 4mW

A&D CD-BD May2003

Automation and Drives

Surge Suppression
Low Voltage Controls & Distribution

Voltage surge without suppression

USp [V]

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

1000 0 3000

USp

50

100

t [ms]

A&D CD-BD

May2003

Automation and Drives

Surge Suppression
Low Voltage Controls & Distribution

Voltage surge without suppression

USp [V]

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

USp

200 0

20

t [ms]

A&D CD-BD

May2003

Automation and Drives

Surge Suppression
Low Voltage Controls & Distribution

Surge suppression through RC element

USp [V]

Introduction Basics Constructions Operation Parameters Selection Maintenance Surges

200 0

USp

t [ms]

A&D CD-BD

May2003

Automation and Drives

Surge Suppression
Low Voltage Controls & Distribution

Surge suppression through diode

USp [V]

Introduction Basics
USp

Constructions Operation Parameters Selection Maintenance Surges

20

= 0,6 V ^ = USP of diode

200

t [ms]

A&D CD-BD

May2003