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FUNCTION:
‡ CLOSING COIL - CLOSING the ACB from remote
‡ SHUNT TRIP COIL - TRIPPING the ACB from remote
‡ UNDERVOLTAGE COIL - TRIPPING the ACB when system voltage dips or vanishes

ADDITIONAL FUNCTIONS:
‡ CLOSING COIL ± Anti-pumping*
‡ SHUNT TRIP COIL ± Interlocking
‡ UNDERVOLTAGE COIL ± Interlocking, though not recommended

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ECHANICAL PART
Yoke

Snap-fit spring

Coil 1 Coil ÿ

Pole piece 1
Pole piece ÿ
St.steel plunger
St. steel Return Spring

Armature
(moving core) Electronics

Non-magnetic spacer

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TRAVEL

Constructional difference between

CC/ST and UV

Travel in all coils is 9 mm

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ELECTRICAL PART
COIL
Why two coils ?
‰ÿ ÿ

For pickup, we require a high AT
.5 For holding, we require much less

Why not for Closing coil ?

Dm 15
It does not need to hold on. It
should operate once and come
back. About ÿ

ms ON

Why ?
Ôength of   turn
X a * (15 + ´) (allowing
.5mm for tape) G


 



X a * ÿ1 X ´
 mm

Ôm * No of turns = Total length of wire

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Design

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Design ± —



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Design ± —



Steps :

1. What is the force required ?

a) To pick up ±
b) To hold ±
m Ampere turns to develop the force« how to calculate ? Very difficult.. So?
m Trial and error to establish what will work

ÿ. Having established the AT required for pickup and hold«

a) Try various gauges of wire to see which ones work.*
b) Wind the coils
c) Test them alone
d) Then with electronics
e) Then with ACB
f) Then for cyclic performance
g) Then for continuous heat-run

* see the slide after the next one for explanation Ô




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J 
 

Let us take this one ± ÿÿ
U
Coil

‡ Original was OK, but running a bit hot
‡ So we tried the next smaller wire ± Temp rise OK, but too weak to hold ÿ kg spring
‡ One size larger, holding OK, but ran even hotter. So what option do we have ? J

‡ So decided to cram EVEN ORE turns of å SWG. Even at the risk of bulging. Worked OK
‡ Winding tension (‰ÿ g) absolutely important «
‡ If too low, winding will bulge beyond limits
‡ If too high, wire will stretch, thin down, and resistance will go haywire. So must be wound
at TC with lots of care
‡ If this gives a problem still, what to do ?
‡ try to make the ÿ kg requirement less. Ie., make the trip system of ACB smoother.
‡Then we can use say 1.ÿ kg spring, and then the åË SWG coil may be OK «

 

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Design ± —


‡ Put in wire values ±
‡ bare wire dia for resistance calculation
‡ over-enamel dia (gr 1 or ÿ) for max turns calculation
‡ calculate area values for both
‡ take ëå winding factor and calculate number of turns accommodatable
‡ calculate resistance
‡ divide V by R to get current value, hence get AT, VA
‡ iterate all above for different wire gauges to get different coil data

you can then get peripheral useful data like adiabatic 1 sec temp rise, weight etc

Things you should know :

‡ Coil odesign is based on 
´ ë cm resistivity of copper which is true for annealed copper
@ ÿ
C. Due to work-hardening, and some other reasons, it can go up to 
 ë cm
‡ When coil resistance is measured, the ambient temperature must be noted, and a
o
correction factor applied. This factor is
 / C

‡ IEC specifies E
 tolerance on resistance per meter of Copper wire
‡ Coil resistance must be measured using the resistance method. A calculator is available.

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Design ± —


Resign guide: Closing coil
Coil is intrinsically DC operated
If customer applies AC or DC, it will go through a rectifier bridge (can be SCR bridge), so that the coil only sees DC.
The coil can be only one, with enough amp-turns to operate the plunger.
Simple electronics ± feeds the coil for ÿ

ms, and then cuts off the supply to the coil.
The timing circuit can be simple, just to time ÿ

ms and give the cut-off signal.
However, the timing circuit UST RE AIN µAR ED¶ AS LONG AS THE CLOSING CO AND PERSISTS,
so that it satisfies the anti-pumping requirement. When the command is removed, the timing circuit can re-set, so that
it is ready for the next closure
Resign guide: Shunt trip
Coil is intrinsically DC operated.
If customer applies AC or DC, it will go through a rectifier bridge (can be SCR bridge), so that the coil only sees DC.
The coil can be one, but may have to be double, with enough amp-turns to operate the plunger, and keep it held in
Tripped condition.
The electronics may need to be a little more complex than that of the CC, feeding the coil high AT during pickup, reducing
it to the adequate holding AT, keeping the coil within acceptable temperature limits on cyclic duty and long term tests.
Resign guide: Undervoltage release
Coil is intrinsically DC operated. If customer applies AC or DC, it will go through a rectifier bridge (can be SCR bridge),
so that the coil only sees DC.
The coil has to be double, with enough amp-turns to operate the plunger, and keep it held in energised condition.
The electronics will have to be the most complex of the three coils. It will have to feed enough AT to make the plunger
pickup against a force of at least 1
N , reducing it to the adequate holding AT to keep it held against at least 1 N,
keeping the coil within acceptable temperature limits on long term tests.
Capacitor in a time delayed UV circuit should maintain enough AT during the time delay period to µhold¶ the plunger in
attracted position

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Design ± —


osfet for pickup coil
The electronic system
osfet for hold coil
Electronic circuit has three sections

1 Obtaining power supply for the Electronic circuit

Pickup coil ÿ easuring and comparing the voltage based on that taking decision
whether to activate driving circuit or not and if so for how much time
‰ Driving circuit using OSFETs which receive command from
Hold coil measuring and comparator ckt.
In addition to this since the circuit has to withstand High impulse voltages there is
a varistor in the circuit which limits the input voltage and protects the OSFETs
Ac voltage is rectified and converted to DC.For obtaining correct power supply
zeners are used which limit the voltages applied to electronic circuit including for
reference and ICs.
Resistance divider brings down the voltage to an appropriate level and feeds the
same to the comparator. This voltage reaches the threshold at the set point of pick
up and forces comparator to change its output .A pulse of the required time is
generated by µRC¶ network and is applied to OSFET, which turns on and
operates the coil. On the second OSFET a hold coil is connected and this
OSFET also turns on however it doesn¶t turn off. As a result plunger remains
operated even if pick up coil OSFET turns off. Second OSFET turns off only
Jumpers for selection when the voltage drops below the set limit.
of voltage In case of closing coil there need be only one OSFET, but for standardisation, we
use the same PCB.
Jumpers for selection There are jumpers to select type of the coil (CC or UV or Shunt) and voltage of the
of type of coil coil.
The basic principle of working for 11
V ÿÿ
V and å15 V is same. Except that the
varistor rating changes « up to ÿÿ
V coils we use ÿË5V varistor and for å15 V coils
we use 55
V varistor

Capacitor used for antipumping function

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Spec limits
IEC 
9åË / IS 1‰9åË

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New Spec limits for Shunt Releases

IEC 
9åË

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Spec limits —

«

IEC 
9åË / IS 1‰9åË

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What options are there for a ³Fallback (contingency) plan´ ?

1. Interchange Pickup and Holding winding windows !

a) Done in ÿ

5
b) Trade offs ,,, if Pickup goes better, hold goes worse and vice versa .. Dead end
ÿ. Wind one winding OVER another !
a) Done quite normally in Transformers and our own F Range contactors
b) + point is that we get a little more winding area
c) - point is the need to insulate with tape the two windings
Seems to give some benefit.. Will use after the present design stabilises

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