Contactors - Campus SupportContactors • NEMA rated for a wide range ... TDL C S R T2 L2. Crankcase...

Contactors

3 Types of Contactors3 Types of Contactors

• General Purpose

• IEC

• Definite Purpose

•• General PurposeGeneral Purpose

•• IECIEC

•• Definite PurposeDefinite Purpose

““General PurposeGeneral Purpose””ContactorsContactors

• NEMA rated for a wide rangeof applications

• Heavy duty motor startingcapability

• Life: millions of cycles in mostapplications

•• NEMA rated for a wide rangeNEMA rated for a wide rangeof applicationsof applications

•• Heavy duty motor startingHeavy duty motor startingcapabilitycapability

•• Life: millions of cycles in mostLife: millions of cycles in mostapplicationsapplications

““IECIEC”” Contactors Contactors

• International ElectrotechnicalCommission

• Applications are more limitedto a specific purpose

• More economical

•• InternationalInternational Electrotechnical ElectrotechnicalCommissionCommission

•• Applications are more limitedApplications are more limitedto a specific purposeto a specific purpose

•• More economicalMore economical

Definite PurposeDefinite PurposeContactorsContactors

• Designed for a specific job suchas HVAC

• Not designed to break lockedrotor current frequently

• 500,000 cycle design life

• Standards published by ARI

•• Designed for a specific job suchDesigned for a specific job suchas HVACas HVAC

•• Not designed to break lockedNot designed to break lockedrotor current frequentlyrotor current frequently

•• 500,000 cycle design life500,000 cycle design life

•• Standards published by ARIStandards published by ARI

ARI Standard 780ARI Standard 780

• Mechanical Life Test- No electrical load

- Cycle moving parts- 500,000 cycles

•• Mechanical Life TestMechanical Life Test

-- No electrical loadNo electrical load

-- Cycle moving partsCycle moving parts-- 500,000 cycles500,000 cycles


• Endurance Life Test

- Make at LRA- Break at 125% FLA- 200,000 cycles

•• Endurance Life TestEndurance Life Test

-- Make at LRAMake at LRA-- Break at 125% FLABreak at 125% FLA-- 200,000 cycles200,000 cycles


• Recycle Life Test

- Make and Break LRA- 10,000 cycles

•• Recycle Life TestRecycle Life Test

-- Make and Break LRAMake and Break LRA-- 10,000 cycles10,000 cycles

• Less stringent standard forDP contactors- 500,000 mechanical life test

- 100,000 endurance life test

- 1,000 recycle life test

•• Less stringent standard forLess stringent standard forDP contactorsDP contactors

-- 500,000 mechanical life test500,000 mechanical life test

-- 100,000 endurance life test100,000 endurance life test

-- 1,000 recycle life test1,000 recycle life test


Meaning To Us?Meaning To Us?

• For “high stakes” applications,use an ARI 780 contactor- Meets the highest standard

- Assurance you’ve used the best

•• For For ““ high stakeshigh stakes ”” applications, applications,use an ARI 780 contactoruse an ARI 780 contactor-- Meets the highest standardMeets the highest standard

-- Assurance youAssurance you ’’ve used the bestve used the best

Contactor StandardsContactor Standards

How DoHow DoContactors Fail?Contactors Fail?

• Some things we’ve done toprevent failure . . .

• And some things you cando

•• Some things weSome things we ’’ve done tove done toprevent failure . . .prevent failure . . .

•• And some things you canAnd some things you candodo

Coil BurnoutCoil Burnout• Apply

propervoltage

• Hightemperaturecoil wireinsulation –200ºC

•• ApplyApplyproperpropervoltagevoltage

•• HighHightemperaturetemperaturecoil wirecoil wireinsulation insulation ––200200ººCC

Coil RatingsCoil Ratings

Voltage Power (VA)

Nominal Inrush

Pickup Sealed

Dropout

VoltageVoltage Power (VA)Power (VA)

NominalNominal InrushInrush

PickupPickup SealedSealed

DropoutDropout

NEMA Standard DC 20-92NEMA Standard DC 20-922727262625252424232322222121202019191818

% of Load% of Load0 50 100 150 2000 50 100 150 200

TransformerTransformerOutput VoltageOutput Voltage

Contactor Fails toContactor Fails to““SealSeal””

• Coil remains at “Inrush”current

• Coil burns out, or . . .

• Transformer burns out

•• Coil remains at Coil remains at ““ InrushInrush ””currentcurrent

•• Coil burns out, or . . .Coil burns out, or . . .

•• Transformer burns outTransformer burns out

BindingBinding

• Avoid applyingleverage onmolded parts

• Careful to makemolded partsvery precise

•• Avoid applyingAvoid applyingleverage onleverage onmolded partsmolded parts

•• Careful to makeCareful to makemolded partsmolded partsvery precisevery precise

Coil Terminal BreakingCoil Terminal Breaking

• Avoid flexingterminal

• Moldedterminal“Nest”

•• Avoid flexingAvoid flexingterminalterminal

•• MoldedMoldedterminalterminal““ NestNest ””

Stripped Terminal ScrewsStripped Terminal Screws

• Extruded holes•• Extruded holesExtruded holes

Coil Wire BreakageCoil Wire Breakage

• Ruggedbobbin

• Fusionwelded

•• RuggedRuggedbobbinbobbin

•• FusionFusionweldedwelded

Shading Coil BreaksShading Coil Breaks

• Shading coilsmade of solidaluminum

• Staked in placeto eliminate anymotion

•• Shading coilsShading coilsmade of solidmade of solidaluminumaluminum

•• Staked in placeStaked in placeto eliminate anyto eliminate anymotionmotion

Shading Coil OperationShading Coil Operation

Magnet CoilCurrent

Shading CoilCurrent

Magnet SeparationMagnet Separation

• Heavy dutyconstruction

• Multiple rivets

•• Heavy dutyHeavy dutyconstructionconstruction

•• Multiple rivetsMultiple rivets

““KissKiss”” Potential Potential

• Non-Kissspring

• Coil design

•• Non-KissNon-Kissspringspring

•• Coil designCoil design

Cross Arm BreakageCross Arm Breakage

• Robust design

• Avoid usingexcess force

•• Robust designRobust design

•• Avoid usingAvoid usingexcess forceexcess force

Spring BreaksSpring Breaks

• Stainlesssteel spring

•• StainlessStainlesssteel springsteel spring

Loss of Armature/Loss of Armature/CrossarmCrossarm Connection Connection

• Precisematingdesign

•• PrecisePrecisematingmatingdesigndesign

Residual MagnetismResidual Magnetism

•• Air gapAir gapbetweenbetweencenter legscenter legsof magnetof magnetand armatureand armature

Cross Arm ImbalanceCross Arm Imbalance

• Singleconicalspring

•• SingleSingleconicalconicalspringspring

Excessive ArcingExcessive Arcing

• Always usewithin ratings

• Closetoleranceguidingsystem

•• Always useAlways usewithin ratingswithin ratings

•• CloseClosetolerancetoleranceguidingguidingsystemsystem

Excessive Contact BounceExcessive Contact Bounce

• Cushionedsuspensionsystem

•• CushionedCushionedsuspensionsuspensionsystemsystem

WeldingWelding

• Cadmiumoxide silvercontacts

• Apply withinratings

•• CadmiumCadmiumoxide silveroxide silvercontactscontacts

•• Apply withinApply withinratingsratings

Contact RatingsContact Ratings

VoltageVoltage CurrentCurrent

Up to 600Up to 600 Full LoadFull Load

Locked RotorLocked Rotor

ResistiveResistive

Contact DetachmentContact Detachment

• Good heat sink

• Composite rivets

•• Good heat sinkGood heat sink

•• Composite rivetsComposite rivets

ContaminationContamination

• Encloseddesign

• Cleanperiodically

•• EnclosedEncloseddesigndesign

•• CleanCleanperiodicallyperiodically

Contact ContinuityContact Continuity

• Film breakercontacts

• Avoidmechanicaldamage tocontactsurface

•• Film breakerFilm breakercontactscontacts

•• AvoidAvoidmechanicalmechanicaldamage todamage tocontactcontactsurfacesurface

Short CircuitShort CircuitWithstandabilityWithstandability

• 5000 ampswithstand

•• 5000 amps5000 ampswithstandwithstand

Power Terminal Hot SpotsPower Terminal Hot Spots

• Tighten terminalscrews properly

• Terminal designedfor superiorcontact with wire

•• Tighten terminalTighten terminalscrews properlyscrews properly

•• Terminal designedTerminal designedfor superiorfor superiorcontact with wirecontact with wire

Heat DeteriorationHeat Deterioration

• HighTemperatureglass-filledcompound

• Keep terminalscrews tight

•• HighHighTemperatureTemperatureglass-filledglass-filledcompoundcompound

•• Keep terminalKeep terminalscrews tightscrews tight

Loose TerminalsLoose Terminals

• Terminalscrewsthreadedinto metal

•• TerminalTerminalscrewsscrewsthreadedthreadedinto metalinto metal

Phase-to-Phase FaultsPhase-to-Phase Faults

• RuggedNon-TrackingBarriers

•• RuggedRuggedNon-TrackingNon-TrackingBarriersBarriers

Phase-to-Ground FaultsPhase-to-Ground Faults

• Generouselectricalclearances

• Selectlocationcarefully

•• GenerousGenerouselectricalelectricalclearancesclearances

•• SelectSelectlocationlocationcarefullycarefully

Loose Quick ConnectsLoose Quick Connects

• Riveted

• Anti-rotationdesign

•• RivetedRiveted

•• Anti-rotationAnti-rotationdesigndesign

Mechanical FatigueMechanical Fatigue

• Cushionedconstruction

•• CushionedCushionedconstructionconstruction

Rubber CushionRubber Cushion

Barrier DamageBarrier DamageDuring InstallationDuring Installation

• Use right sizescrewdriver

• High strengthbarriers

•• Use right sizeUse right sizescrewdriverscrewdriver

•• High strengthHigh strengthbarriersbarriers

Rust DeteriorationRust Deterioration

• Rust resistantcoatings

• Metal plating

•• Rust resistantRust resistantcoatingscoatings

•• Metal platingMetal plating

Broken Mounting PlateBroken Mounting Plate

• Platedcold rolledsteel base

•• PlatedPlatedcold rolledcold rolledsteel basesteel base

Noisy OperationNoisy Operation

• Broken shading coil

• Coil voltage low

• Wrong coil

• Armature/magnetmisalignment

•• Broken shading coilBroken shading coil

•• Coil voltage lowCoil voltage low

•• Wrong coilWrong coil

•• Armature/magnetArmature/magnetmisalignmentmisalignment

Proper Control VoltageProper Control VoltageIs Very importantIs Very important

• Too High- Excess current- Overheating- Shortens life

• Too Low- Chatter- Fails to Pull-in- Noise

•• Too HighToo High-- Excess currentExcess current-- OverheatingOverheating-- Shortens lifeShortens life

•• Too LowToo Low-- ChatterChatter-- Fails to Pull-inFails to Pull-in-- NoiseNoise

Contactor ReplacementContactor Replacement

Can I use a 2-polecontactor to replacea 1-pole model?

Can I use a 2-poleCan I use a 2-polecontactor to replacecontactor to replacea 1-pole model?a 1-pole model?

Manufacturer InstalledManufacturer InstalledOne Pole ContactorOne Pole Contactor

Jumper One ContactJumper One Contact

Crankcase HeaterCrankcase Heater

T1T1L1L1

CCHCCH

CCSS

RRT2T2 L2L2

Crankcase Heater - 2Crankcase Heater - 2

T1T1L1L1

CCHCCH TDLTDL

CCSS

RRT2T2 L2L2

Crankcase Heater - 3Crankcase Heater - 3

T1T1L1L1

CCHCCH

CCSS

RRT2T2 L2L2

Second Pole Switches FanSecond Pole Switches Fan

T1T1L1L1 CC

SS

RR

T2T2L2L2CC

SS

RR

CompComp

FanFan

NomenclatureNomenclature

DPDP3040A 50023040A 5002

Product IdentifierProduct Identifier

D Definiteefinite P Purposeurpose Contactor Contactor


DPDP33040A 5002040A 5002Number of PolesNumber of Poles

00 = 1 no shunt = 1 no shunt11 = 1 with shunt = 1 with shunt22 = 2 poles = 2 poles33 = 3 poles = 3 poles44 = 4 poles = 4 poles


DP3DP3040040A 5002A 5002

Amperage RatingAmperage Rating020020 = 20 Amps = 20 Amps 060060 = 60 Amps = 60 Amps030030 = 30 Amps = 30 Amps 075075 = 75 Amps = 75 Amps040040 = 40 Amps = 40 Amps 090090 = 90 Amps = 90 Amps050050 = 50 Amps = 50 Amps 120120 = 120 Amps = 120 Amps


DP3040DP3040A A 50025002

Coil VoltageCoil Voltage

AA = 24 Volts = 24 VoltsBB = 120 = 120CC = 208/240 = 208/240DD = 277 = 277EE = 480 = 480FF = 600 = 600


DP3040A DP3040A 50025002

Specification NumberSpecification Number

1000 = Economy Series1000 = Economy Series

5000 = Deluxe5000 = Deluxe PowerPro PowerPro Series Series

Questions?Questions?

Contactors - Campus SupportContactors • NEMA rated for a wide range ... TDL C S R T2 L2. Crankcase...

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