Electrical Standard Products

Switchgear Training Centre, Coonoor

C O N T A C T O R S

Switchgear Training Centre, Coonoor

C O N T A C T O R
An electro‐mechanical switching device
capable of making, carrying and breaking
currents under normal circuit conditions
including operating overload conditions.

Switchgear Training Centre, Coonoor

C O N T A C T O R
MAIN APPLICATION AREAS
• SWITCHING OF MOTORS

• SWITCHING OF LIGHTING LOADS

• SWITCHING OF HEATING LOADS

• SWITCHING OF CAPACITORS

• SWITCHING OF DC LOADS
W H Y C O N T A C T O R ?
 HIGH OPERATIONAL LIFE

 HIGH FREQUENCY OF OPERATION

 CAN BE OPERATED FROM REMOTE

 CAN BE USED FOR AUTOMATIC

SWITCHING OPERATIONS
 CAN OFFER NO VOLT PROTECTION
SELECTION OF CONTACTOR
P A R A M E T E R S
 RATED OPERATIONAL VOLTAGE, Ue

 RATED OPERATIONAL CURREN, Ie

 RATED MAKING CAPACITY

 RATED BREAKING CAPACITY

 UTILIZATION CATEGORY
SELECTION OF CONTACTOR
P A R A M E T E R S
 ELECTRICAL & MECHANICAL LIFE

 RATED CONDITIONAL SHORT CIRCUT CURRENT

 FREQUENCY OF OPERATION

 COIL VOLTAGES
SELECTION OF CONTACTOR
P A R A M E T E R S
 NUMBER OF AUXILIARY CONTACTS

 DIMENSIONS

 TERMINAL SIZE

 EASE OF MAINTENENCE

 AVAILABILITY OF SPARES
C o n t a c t o r s – S e l e c t i o n
To ensure correct operation of the contactor,
first, its rating has to be selected, keeping in
mind the intended switching application.

This is called the Utilisation Category of

contactors. The most common utilisation
categories are:
C o n t a c t o r s – S e l e c t i o n
UTILISATION CATEGORIES
AC‐1 Non‐Inductive / Slightly Inductive Loads / Resistance Furnaces

Im = 1.0Ie Ib = 1.0Ie

100% The making capacity of the

contactor should be 1.0Ie and
I
the breaking capacity also
should be 1.0Ie.
t
C o n t a c t o r s – S e l e c t i o n
U T I AC‐2
L I Slip‐Ring
S A T Induction
I O N MotorsC– Starting
A T E&GStopping
ORIES
The starting current of a slip‐ring motor, with
the optimum rotor resistance, will be around
Im = 2.5Ie I = 2.5I
b e 250% of the motor rated current. Hence, the
250% making capacity of the contactor should be
I 2.5Ie. Even though the motor normally is
100% switched off only when it is running with
rated load, in applications like cranes &
hoists, one may have to switch off the motor
tst
t even as it is accelerating. So, the breaking
tst = Starting Time
capacity of the contactor, too, should be 2.5Ie.
C o n t a c t o r s – S e l e c t i o n
UTILISATION CATEGORIES
AC‐3 Squirrel Cage Induction Motors – Starting and Stopping during
running
The starting current of a squirrel cage
Im = 6.0Ie induction motor will be around 600% of the
motor rated current. Hence, the making
600%
capacity of the contactor should be 6.0Ie. But,
I Ib = 1.0Ie here in this utilisation category, one is
100% permitted to stop only when the motor is
running normally, that is, after it has
tst accelerated fully. And, most of the
t applications in industry (about 95%) are AC‐3.
t = Starting Time
st So, the breaking capacity of the contactor
should be 1.0Ie.
C o n t a c t o r s – S e l e c t i o n
UTILISATION CATEGORIES
AC‐4 Squirrel Cage Induction Motors
Starting, inching/jogging & plugging.
Im = 6.0Ie Ib = 6.0Ie

600% But, in certain applications like cranes

I & hoists, the motor may have to be
inched/jogged (i.e.) the motor may
100%
have to be stopped even as it is
accelerating. That is both the making
tst
capacity and the breaking capacity of
t
the contactor for such an application
tst = Starting Time
should be 6.0Ie.
C o n t a c t o r s – S e l e c t i o n
UTILISATION CATEGORIES
The above 4 are the most common utilisation
categories that one comes across in industry. But,
there are some other applications too, in which
contactors are utilised. They are:
C o n t a c t o r s ‐ S e l e c t i o n
UTILISATION CATEGORIES
AC 5a SWITCHING OF ELECTRIC DISCHARGE LAMP
CONTROLS

AC 5b SWITCHING OF INCANDESCENT LAMPS

AC 6a SWITCHING OF TRANSFORMERS

AC 6b SWITCHING OF CAPACITOR BANKS

C o n t a c t o r s ‐ S e l e c t i o n
UTILISATION CATEGORIES
AC 7a SLIGHTLY INDUCTIVE LOADS IN
HOUSEHOLD APPLICATIONS

AC 7b MOTORS‐ HOUSEHOLD APPLICATIONS

AC 8a HERMETIC REFRIGERANT COMPRESSOR

WITH MANUAL RESET O/L RELEASE
AC 8b HERMETIC REFRIGERANT COMPRESSOR
WITH AUTO RESET O/L RELEASE
C o n t a c t o r s ‐ S e l e c t i o n
UTILISATION CATEGORIES
NON‐ INDUCTIVE OR SLIGHTLY
DC 1
INDUCTIVE LOADS, RESISTANCE FURNACES

DC 3 SHUNT MOTORS : STARTING,

PLUGGING AND INCHING

DC 5 SERIES MOTORS : STARTING,

PLUGGING AND INCHING
C o n t a c t o r s ‐ S e l e c t i o n
E l e c t r i c a l D u r a b i l i t y
MAKE BREAK
Ie
I / Ie U / Ue COS Ic / Ie Ur / Ue COS

AC 1 ALL VALUES 1 1 0. 95 1 1 0. 95

AC 2 ALL VALUES 2. 5 1 0. 65 2.5 1 0. 65

AC 3 Ie  17 A 6 1 0. 65 1 0.17 0. 65

AC 3 Ie  17 A 6 1 0. 35 1 0.17 0. 35
AC 4 Ie  17 A 6 1 0. 65 6 1 0. 65
AC 4 Ie  17 A 6 1 0. 35 6 1 0. 35
C o n t a c t o r s - S e l e c t i o n
MAKING & BREAKING CAPACITIES
MAKE & BREAK CONDITIONS
I / Ie U r / Ue COS
AC 1 1.5 1.05 0.80
AC 2 4.0 1.05 0.65
AC 3 8.0 1.05 0.35
AC 4 10.0 1.05 0.35

MAKE CONDITIONS

AC 3 10.0 1.05 0.35

AC 4 12.0 1.05 0.35
C o n t a c t o r s – S e l e c t i o n

Wrong selection and/or application of the

contactor might cause immediate failure of
the contactor, even causing damage to the
operator and/or the installation. So, utmost
care must be employed in choosing contactor
for a particular application. Help is readily
available in the form of selection charts.
SELECTION OF CONTACTOR
F O R S P EC I F I C A P P L I C AT I O N S
 FIND OUT THE TYPE OF UTILIZATION CATEGORY FROM THE
APPLICATION
 Ie OF THE CONTACTOR FOR THAT PARTICULAR UTILIZATION
CATEGORY SHOULD BE  THE FULL LOAD CURRENT OF THE
LOAD
 RATED MAKING CAPACITY OF THE CONTACTOR SHOULD BE
 THE TRANSIENT INRUSH CURRENT AT THE TIME OF
SWITCHING ON OF THE LOAD
 RATED BREAKING CAPACITY OF THE CONTACTOR SHOULD BE
SUFFICIENT TO BREAK OVERLOAD CURRENTS
 OPERATIONAL LIFE OF THE CONTACTOR FOR THAT
APPLICATION SHOULD MEET THE EXPECTED REQUIREMENT
Contactors – Cross‐section
 Closing

• Coil gets supply

• A magnetic field is produced
• A operating force is produced
• Operating force > Restraining force
• Moving magnet moves
• Moving contacts assembly moves
• Main contacts close
 Opening
• Supply to coil is cut
• Magnetic field collapse
• Operating force becomes zero
• Restraining force > Operating force
• Moving magnet returns
• Moving contacts return to original position
 Contactors – Shading Ring
All contactors fitted with AC Coils have a
strange operational problem. In an AC Voltage
Wave Form, in every cycle, there are two zero‐
crossings and in case here is no shading ring,
t h e co nta c to r wo u l d d ro p ‐ o ff d u r i n g e a c h o f
these voltage zeroes. This means two
operations are spent in every cycle of AC Wave
F o r m . T h a t i s 1 0 0 o p e ra t i o n s e v e r y s e c o n d ,
6000 operations every minute and 3, 60, 000
o p e r a t i o n s e v e r y h o u r .
 Contactors – Shading Ring
The contactor ’s Electrical Life in the simplest
Utilization Category of AC‐1 (Resistive
Switching) itself is about 1 Million Operations
o n l y. T h i s m e a n s , C o n t a c t o r s w i t h A C C o i l s
would have expended their life every 2 ½ to 3
Hours. Electrical life in other tougher Utilisation
Categories would be further less. But, this
cannot be avoided too, as it is the nature of an
A C W a v e F o r m .
 Contactors – Shading Ring
To overcome this problems, all contactors with
AC Coils are fitted with shading rings in their E
Cores. The job of the shading ring is to
produce a supplementary flux in the core, that
would prevent the contactor from dropping Off
during the voltage zero. Thus the life
expectancy of the contactor is increased.
 Chattering
Main Flux Aux Flux resultant

1.5

0.5

-0.5

-1

-1.5
 Contactors – Shading Ring
During maintenance, there is a possibility that
t h e s h a d i n g r i n g m i g h t f a l l o f f. I f i t s o
happens, one can identify this from the
chattering of the contactor when re‐
assembled and put back to service. Corrective
action must be ta ken immediately to replace
the shading ring. Any single strand Copper/
Aluminium/Steel wire can be used for the
purpose. But, remember to make the loop a
c l o s e d o n e , o t h e r w i s e i t s h a l l n o t ge n e rate a ny
flux.
 Contactors – Voltage Fluctuations
Each contactor coil is assigned some Pick‐
up and Drop‐off values by the Indian
S t a n d a r d . T h e y a r e :
For AC Coils:
Pick up – 85% to 110% of rated coil voltage
Drop Off – 20% to 75% of rated coil voltage

For DC Coils:
Pick up – 85% to 110% of rated coil voltage
Drop Off – 10% to 75% of rated coil voltage
 Contactors – Voltage Fluctuations
If during the regular operation of the
co nta c to r, t h e re are w i d e f l u c t u ati o n s i n t h e
coil voltage, the contactor would start
chattering (i.e.) repeated On‐Off, which means
life is spent. So, when chattering is observed
in a contactor, check for the coil voltage and
correct the same. If coil voltage is correct and
still the contactor is chattering, check for
shading ring. Provide if missing.
 Contactors – Dust on magnet surface
As contactors are not air‐tight, there is a
possibility that dust can enter and settle on the
surface of the magnet. This acts as a
reluctance in the flux path and the core would
produce a humming noise. Also, in an effort to
keep the contacts closed, the coil would draw
more current and in due course, would
damage. Normal tendency among some of the
u n s k i l l e d m a i n t e n a n c e p e rs o n n e l i s t o a p p l y
g re a s e o n t h e m a g n e t s u r fa c e t o a r re s t t h e
humming noise.
 Contactors – Dust on magnet surface
B u t , d u st w i t h g re a s e w i l l o n l y i n c re a s e t h e
reluctance and would cause premature coil
fa i l u re . C o r re c t m e t h o d i s to u s e a c l e a n i n g
agent like CRC 226 to clean the dust off the
magnet surface.
 Contactors – Contacts Maintenance
The contacts of the contactor are made of
Copper with the tips made of silver alloy. This
is due to the fact that at the contact tips, the
temperature is very high during making arc &
d u r i n g b re a k i n g a rc a n d t h i s m i g ht m e l t t h e
copper. So, silver alloy is used at contact tips
as it has very high temperature withstanding
capacity. As silver is also costly, the thickness
of the tip is only about 1mm, irrespective of
t h e r a t i n g o f t h e c o n t a c t o r.
 Contactors – Contacts Maintenance
During the regular operation of the contactor,
these contacts get pitted due to repeated open
– close operations under current‐carrying
conditions. Carbon deposits also can be found
on the surface of the contact tips. It has been
observed that some maintenance personnel
are removing the carbon deposits through
abrasive actions like rubbing with emery
sheet, filing with smooth/rough files, etc.
 Contactors – Contacts Maintenance
This is not at all advisable, as this would
definitely remove silver from the contact tips
and would make the raw copper of the contact
vulnerable to damage. Use of cleaning agents
l i ke C TC ( C a r b o n Te t ra C h l o r i d e ) i s a l s o n o t
advised, as CTC would only displace and not
dissolve carbon. Applying CTC would displace
the carbon from the contact tip to the
contactor housing, which is an insulator, thus
making it vulnerable to tracking and imminent
f a i l u r e / f l a s h o v e r .
 Contactors – Contacts Maintenance
C o r re c t m eth o d wo u l d b e to a p p l y a s o l ve nt
such as CRC 226, to remove any carbon
deposits. These solvents would dissolve carbon
ra t h e r t h a n d i s p l a c i n g t h e m . A l s o, i t s h o u l d
a l w ay s b e e n s u r e d t h a t t h e c o n t a c t o r n e v e r
breaks any current beyond its breaking
capacity. Also, see to it that the contactor does
not make any current beyond its making
capacity.
 Contactors – Contacts Maintenance
Also, ensure by properly selecting the overload
relay and fuse so that the I 2 t withstand limits
of the contactor are not exceeded. As per IS,
co nta c to rs c a n w i t h sta n d 8 ti m e s t h e i r rate d
c u r re nt fo r 1 0 s e co n d s w i t h o u t a ny d a m a ge .
This can be automatically achieved by truly
following the Switchgear Selection Charts
g i v e n b y r e p u t e d s w i t c h g e a r
Manufacturers.
 Workshop Exercises on Contactors
• Identification of parts

• Understanding Chattering by removing shading ring

• Understanding Humming by placing dirt on the

magnetic surface

• Understanding clean contactor performance

• Checking the Pick‐up & Drop‐off Voltages

 Thank You

stc‐[email protected]
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