A Guide to Contactor Installation and Maintenance

Installation Guidelines
1.1 Inspection
Remove the contactor from its carton and open the arc chamber if present. Ensure that there is no breakage / damage to any of its parts. Check the coil voltage, frequency and contact configuration. Ensure correctness before installation. Refix arc chamber before installation.

1.2 Mounting
Mount the contactor on a vertical surface either on a DIN rail (if applicable) or with specified screws (use all mounting holes and the screws, washers, spring washers supplied). Refer mounting plan as shown in fig. 1. Do not drill holes near mounted contactors, to avoid entry of metal dust into the contactor. Metal dust will affect its performance. Refer fig.2.

Figure 1

Contactor Type 3TH 80/82 3TB 40/41 3TH 30 3TF 30/31 3TF 42/43 3TF 44/45 3TF 46/47/477 3TF 48/49 3TF 50/51 3TF 52/53 3TF 54/55 3TF 56/57 3TF 68/69

Mounting Dimensions in mm A B 35 60 35 60 35 60 35 60 35 75 45 75 70 100 80 110 100 130 110 160 120 180 130 180 150 210

For 3TH80/82, 3TB40/41, 3TF42/43 with AC coil

For 3TF44 to 3TF69, with AC coil or DC coil

Figure 2

1.3 Control Circuit Wiring

SON SON CosfON

pick - up power of the contactor coil for d.c. supply pick - up power of the contactor coil for d.c. supply the contactor coil for a.c. supply

Figure 3

Fig. 3. illustrates the permissible length of control cables with commonly used cross-sections for various rated control supply voltages and a maximum permissible voltage drop of 5%. The permissible length of cable(m) can also be calculated by using the formula below : L U 4 : 5 (U)2 dU R SON cos fON : Rated coil voltage

dU SON R

: Voltage drop ( 5%) : Coil VA / W at pick up : Ohmic resistance/ cable values as tabulated
R in W /km at & 70o C 21.70 14.47 8.71 5.45

cos fON : p.f of coil at pick up

C/s of Cu cable sq mm 1 1.5 2.5 4.0

Caution : When long control cables are used for actuating the contactor, large voltage drop may occur causing chattering of the contactor or even failure to pick up. If the length of the cable exceeds L, use of higher size of cable or use of contactor relay is suggested as shown in fig. 4.

K1 - Contactor Relay K2 - Power Contactor SO - Remote Push Button Figure 4

1.4 Effect of Cable Capacitance on the Operation of AC Operated Contactors

When long length of cables is used the stored energy in the capacitance of the cable holds the contactor even after the closing command is removed; therefore critical cable lengths must be adhered to according to the table.

1.5 Actuating Device

If overload relay is self reset type, use a momentary command device to energize the contactor, to prevent automatic reclosure after an overload trip. If overload relay is hand reset type, use momentary or maintained command device. Hand reset feature of relay prevents automatic reclosure after an overload trip.

Contactor 3TH 80/82 3TB 40/41 3TH 30 3TF 30/31 3TF 42/43 3TF 44/45 3TF 46/47 3TF 48/49 3TF 50/51 3TF 52/53 3TF 54/55 3TF 56 3TF 57 3TF 68/69 6

Critical cable length, L Momentary Maintained command command control (m) max control (m) max 142 142 130 130 130 130 416 416 644 754 1098 1500 600 1820 285 285 260 260 260 260 833 833 1326 1510 2185 2990 1010 3640

1.6 Connections for AC Operated Contactors

(a) Maintained command control

Figure 5

(b) Momentary command control

Figure 6

1.7 Connections for DC Operated Contactors.

DC contactors 3TH 80/82, 3TB 40/41, 3TF 42/43 and 3TF 44/45 have directly operated DC coils with DC magnet system. 3TF 46-51 with DC coils should be used in conjunction with aux contact block as depicted in fig. 7 . For 3TF 52-55, a separate contactor (3TB 40 17 OD) should be connected; Refer fig. 8. For 3TF 56, 3TF 42 OB

contactor should be used. Refer fig. 9. Caution : Please use the correct auxiliary contact block for connection in the circuit. Thus, the extended contact block used for 3TF 46, 47 , 477 is 3TY7 461-1F and for 3TF 48-57 is 3TY7 481-1F . This ensures proper performance. Employ recommended overload and short circuit devices which are properly coordinated.

K = Contactor type 3TF46 02-OD/3TF47 02OD/3TF50 02-OD/3TF51 02-OD/3TF47 72-OD F1 = Fuse F2 = Overload relay SO = Push button S1 = Momentary contact actuator S = Maintained contact actuator I = Hold on winding h = Pick up winding Momentary Contact Actuation Figure 7 Maintained Contact Actuation

K2 = 3TB40 17-OD K1 = Contactor type 3TF52 02-ODTO 3TF55 02-OD F1 = Fuse F2 = Overload relay S = Maintained contact actuator I = Hold on winding h = Pick up winding S1 = Momentary contact actuator

Momentary Contact Actuation Figure 8

Maintained Contact Actuation

K2 = 3TF42 11-OB K1 = Contactor type 3TF56 02-OD F1 = Fuse F2 = Overload relay S = Maintained contact actuator I = Hold on winding h = Pick up winding S1 = Momentary contact actuator

Momentary Contact Actuation Figure 9

Maintained Contact Actuation

1.8 Varistors / RC Elements

When a contactor coil is switched off, voltage surges are generated, these can damage the associated surge-sensitive electronic equipment. In order to protect such equipment, RC elements & varistors are

provided as accessories; These are to be used as snap-fitting accessories to be fitted on the top cover (for 3TH 80/82, 3TB 40/41, 3TF 42-45) & on the slots in the housing (for 3TF 46-56). Refer table below.

Varistor Coil Voltage AC24-48V DC24-70V AC48-127V DC70-150V AC127-240V DC150-250V AC400-600V For 3TH80/82, 3TB40/41, 3TH30, 3TF30/31, 3TF42/45 3TX7402-3GY1 3TX7402-3HY1 3TX7402-3JY1 3TX7402-3LY1 For 3TF46/56 3TX7462-3GY1 3TX7462-3HY1 3TX7462-3JY1 3TX7462-3LY1

RC Element for 3TH80/82, 3TB40/41 & 3TH30, 3TF30/31, 3TF42/43 Coil Voltage 24-48V AC 110-220V AC 220-240V AC 3TX6 406-OD 3TX6 406-OC 3TX6 446-OB

RC Element for 3TF44/45 Coil Voltage 24-48V AC 24-70V DC 48-127 AC 70-150 DC 127-240 AC 150-250 DC 400-600 AC 3TX7 402-3RY2 3TX7 402-3SY2 3TX7 402-3TY2 3TX7 402-3VY2

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1.9 Mechanically Interlocked Contactors

In applications involving reversing feeders for crane controls, mechanically and electrically interlocked contactors are recommended. For such applications use 3TD 10/11, (9A & 12A), 3TD 42/43 (16A, 22A), C ont act or Pic kup VA ontact actor Pickup (S0N) 3TB 40 3TB 41 3TF 30 3TF 31 3TF 42 3TF 43 3TF 44 3TF 45 3TF 46 3TF 47 3TF 48 3TF 49 3TF 50 3TF 51 3TF 52 3TF 53 3 TF 54 3TF 55 3TF 56 3TF 57 3TF 68 3TF 69 P o w er f act or actor (c osf0N) (cos 77 0.81 77 0.81 68 0.82 68 0.82 68 0.82 68 0.82 101 0.83 101 0.83 183 0.6 183 0.6 330 0.5 330 0.5 550 0.45 550 0.45 910 0.5 910 0.5 1430 0.34 1430 0.34 2450 0.21 1136-1900 1 1200-1850 1 600-900 0.98

mechanically interlocked contactors which are factory built & prewired are provided. In the case of 3TF series of contactors (3TF 44-69), an interlocking kit is offered to allow site-assembly of mechanically interlocked version. For assembly and wiring diagram of the interlocked contactors, refer to the instruction sheet provided with the kit. C apacit apacitor illiv drop Curr or M illi v olt dr op Cur r ent le A C-3 r at ing at le ating (KV AR) A C3 (max) (KVAR) 4 87 9 4 120 12 4 87 9 4 120 12 7.5 82 16 7.5 123 22 16.7 7 32 16.7 9 38 30 14 45 30 17 63 50 14 75 50 18 85 60 16 110 60 18 140 100 15 170 100 18 205 150 9 250 150 13 300 200 17 400 200 14 475 300 13 630 300 14 820 11

1.10 Control Transformer Rating

To determine the size of a control transformer, the following guidelines may be used. For switching on contactors, the control rating of the transformer should be: 0.33 times the sum of the pick up VAs of the contactors which are to be switched on simultaneously.

For e.g. if 3x contactors of 3TF43 & 2x contactors of 3TF 55 are to be switched on simultaneously then the total pickup VA is 3064. Required control transformer rating: 3064/3 = 1.021 kVA. with 5% regulation. Note: In general, as control transformers have poorer regulation, usage of higher VA of transformer is recommended.

Figure 10

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1.11 Capacitor Switching

When capacitors are switched on, there is a high inrush current for a short duration. For economical switching of capacitors, it is necessary to take additional measures: 1) By switching capacitors on to the network via damping resistors: the switching currents are limited by the resistors. Refer Fig 10. or 2) By connecting 6 u H air core inductance between parallel capacitances, having adequate current carrying capacity.

used to prevent short circuits during changeover. This timer provides definite time delay between star and delta and avoids short-circuit, contact erosion / welding.

1.13 Corrosive Atmosphere

Corrosive atmosphere has a profound effect on the performance of contactors. Overheating takes place due to the formation of foreign films at the connections and on the springs. For such applications, contactors have to be suitably derated. Occasional spraying with CRC 2-26 prevents reaction of the silver parts with the atmosphere and minimizes damage.

1.12 Star Delta Application

For star delta application, 7PU 60 20 timers have to be

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Maintenance Guidelines
2.1 Routine Inspection
Inspect terminals, contacts, arc chambers periodically - two months after installation and every six months thereafter. Routine inspections help to monitor the state of the contactor. These contribute to the reliability of the plant and minimize risk of breakdown during production hours. Screws M 3.0 M 3.5 M 4.0 M 5.0 M 6.0 M 8.0 M 10.0 Tightening torque N cm 40 - 55 80 - 100 80 - 100 150 - 210 340 - 400 700 - 850 1400 - 1650

2.2 Isolation for Maintenance

Switch off the contactor & upstream devices before inspecting the contactor. Safety Precaution

2.4 Contact Arrangement

Alteration in the contact arrangement i.e from NO to NC or vice versa is forbidden. Do not remove any unutilised contact from the contactor. Such removal will impair the balance / performance of the contactor.

2.3 Terminals
Tighten Terminals periodically Connections have a tendency to loosen with time - particularly those of aluminium which is a soft material. The terminals should be tightened with a torque specified in the table.

2.5 Contact Condition

Tarnished / Blackened Contact Tarnishing is normal for any silver item, it is due to the formation of silver oxide which is a good conductor of heat & electricity, hence tarnished

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contacts need not be replaced. Blackened or sooty contacts which are otherwise in a good condition need not be replaced. These contacts can be cleaned with CRC 2-26. Do not replace slightly pitted contact. Whether a contact is good or not depends on the volume of contact material which remains

in it. Replace contacts when the contact tip has become less than 40% of its original volume. Refer Fig 11. Do not employ carbon impression method to check healthiness of contacts. Do not use abrasives e.g. do not file contacts, do not use emery paper on contacts.

Result of the visual inspection: ement is not nec essary eplacement necessary R eplac

Result of the visual inspection: ement is not nec essary eplacement necessary R eplac

Result of the visual inspection: ement is nec essary eplacement necessary R eplac
Figure 11

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Abrasives remove silver from the contact tip & drastically reduce the contact life.Do not grease the contacts. The contact condition should be inspected after a fault i.e. short circuit. If the contacts are slightly welded, separate them with a screw driver. Slight but separable welding does not affect the performance of the contactor performance, its acceptability is recognized by IS 13947 / IEC 947 specifications. If the contacts are not easily separable i.e. permanently welded, replace the contacts and use the contactor, provided its other parts are in proper condition. Replacing the complete contactor is not necessary. Replace contacts in pairs i.e. fixed & moving contacts of one pole together. This ensures proper mating of the contact tips. After replacing contacts, operate the contactor a few times before putting it back to normal service. Do not replace the contacts after the mechanical life is 16

over. Maximum number of replacements is about 7; after which the contactor requires replacement.

2.6 ARC Chambers

Do not operate the contactor without the arc chamber as there is an ARC chamber interlock. Do not use broken/cracked damaged arc chamber. Replace it immediately. Such arc chambers can cause flashovers. Replace the arc chamber as per the instructions depicted on the arc chamber as shown in fig 12. For closing, press and turn the arc chamber pin through 900 clockwise to ensure proper functioning of the interlocking mechanism. Operate the contactor manually. For opening the arc chamber the pins should be pushed and then turned through 900 in the anticlockwise direction. Standard spares are main contacts (3TF44-69), Arc chambers (3TF44-57), Auxiliary contact block (3TF 44-69) & Coils.

Do not replace parts other than the standard spares. Parts other than the standard spares are designed to last for the life time of the contactor. Do not use repaired contacts, arc chambers, coils as spares as they cannot deliver the performance of genuine spares. Contacts of 3TH 80/82, 3TH30, 3TF 30/31, 3TB 40/41 need not be replaced. Siemens does not offer these contacts as spares.

2.7 Magnets
In case of rust/dust accumulation on the magnet faces clean them with CRC 2-26 / Chamoi leather. Do not use degreasing agent as petrol. Dust/rust affect contactor performance and cause humming. Do not clean magnets with share/pointed objects. Filing upsets the mating of the magnet faces. Clean lightly with fine size 00 emery paper if required.

Figure 12

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2.8 Mechanical Life

When the mechanical life of a contactor is over, replace the complete contactor. Following are the indicators of the end of mechanical life. For E shaped magnets, air gap between the central limbs is reduced to zero. This is indicated when there is rubbing of paint on the central pole face of the upper magnet.

Broken shading ring of magnet. Flaring of magnet pole faces, hence difficulty in removing coil. Incurable humming Sluggish operation Contactor does not drop off

Figure 13

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Figure 14

Figure 15

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Major Problems in Contactors their causes and remedies

1 Excessive pitting and welding of c ont act s Chat t er ing ering cont ontact acts Chatt Low voltage - Coil not picking up properly Ensure correct voltage conditions. In case of persistent low voltage change coil to lower voltage or change control transformer tapping The mechanical life of contactor is over. Replace the contactor Check & correct the condition in the control circuit Select sizes as per guideline in sect on control wiring. Use proper lugs for termination Use correct control transformer. Refer sect on control transformer rating Follow wiring diagram and use correct auxiliary switch.Sect on connections for DC contactors Use correct contactor & follow guidelines Use 7PU 60 20 timer Use interlocked contactors with electrical interlocking Remove the foreign matter

Broken Short circuit ring Chattering in switching device Small cross section/long length of control cable Improper termination of control cable Inadequate capacity of control transformer Faulty switching devices/incorrect wiring for e.g. In DC contactors normal NC used in place of extended NC Capacitor switching Short circuit during star delta changeover Reversing application (cranes)

2 O v er heat ing of main c ont act path heating cont ontact Foreign matter on the magnet pole faces or jamming of contact carrier preventing contact closing Improper termination of cables. Improper cross section of cable & busbar 20

Check the millivolt drop across cable strand/busbar & terminals. The mV drop should be < 4.0 mV at rated currents otherwise clean busbar or recrimp cable Refer sect. on healthiness of terminals.

Presence of harmonics Improper ventilation of panel N ois y M a gnet s oisy Ma gnets Broken shading ring Magnet faces not mating Dirt or rust on magnet faces

Suitable derating to be employed. Provide suitable cooling for the panels. The mechanical life of contactor is over The mechanical life of contactor is over Wipe/clean lightly with fine emery paper size 00 Correct voltage conditions-In case of persistent low voltage change to lower voltage coil or change transformer tap Replace the coil Clean and check free movement of contact assembly Ensure proper fitting of arc chute Check wiring of the coil circuit The mechanical life of contactor is over Remove the foreign substance

4 F ailur et o pic k up & seal ailure to pick Low voltage

Coil open or shorted Mechanical obstruction

Coil excitation without arc chute or arc chute not properly fixed 5 F ailur et o dr op out ailure to drop Coil not disconnected from supply Residual magnetism due to lack of air gap in the central limb of the magnet Gummy substance on pole faces causing binding 6 O v er heat ing of c oil erheat heating coil Overvoltage Undervoltage-failure of magnet to seal in Interturn short circuit of Coils (Coil getting Excessively hot Turned brown in colour) Dirt or rust on pole faces increasing the air gap

Check & correct terminal voltage/ replace with higher voltage coil Correct terminal voltage / replace with lower voltage coil or change transformer tap Replace coils

Clean pole faces. Dont use grease solvents or sharp objects while cleaning 21

Method of Checking Healthiness of Joints and Contactors

Checking mV drop with an accurate meter which indicates< 0.2mV when shorted Twist the connecting leads while measuring to avoid false pick ups Measure current with clip on meter The values of drop measured should be less than 4.0mV at the rated current of contactor for AC3 duty. (Note-The mV drop at rated current can be calculated as
mV drop at mV drop at (Rated current) = X rated current actual current (Actual current)

][

][

Corrective Action: If values of millivolt are more (bad joints) Case A & B: Clean the surfaces, apply Dowells crimping compound & recrimp cables. Case C : Higher value of mV drop in this case could be due to either case A or B; In case of persistent higher value, replacement of the entire contactor is necessary.

a) Cable/Contactor

CONTACTOR TERMINAL INSULATION BARE WIRE LUG

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b) Busbar/Contactor

c) Across Contactor

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Standard Products Division LV Control & Distribution Products Thane Belapur Road Thane - 400 601 Tel:(022) 7600001 Fax:(022) 7600076 Siemens Ltd.
SGR-01-101-059 (This replaces SGR-01-101-051)
'Product development is a continuous process. Consequently the data indicated in this leaflet is subject to change without prior notice. For latest issue contact our Sales Office.