Lab Experiment # 01

DISTRIBUTION SUBSTATION
Name: Roll No:

Score: Signature of Lab Tutor: Date

COMPLETE WITH CONFIDENCE, CONDUCT AND DEMONSTRATE THE MAIN

EQUIPMENTS OF DISTRIBUTION SUBSTATION AND SKETCHE THE CIRCUIT
DIAGRAMS AND CONNECTION OF SUBSTATION EQUIPMENTS

PERFORMANCE OBJECTIVE:
Upon successful completion of this experiment, the student will be able:
 To display the main equipments of distribution substation
 To sketch the circuit diagrams and connections of substation equipments.
MAIN SUBSTATION EQUIPMENTS:
1. Power transformer 2. Current transformer
3. Circuit Breaker 4. Potential transformer
5. Isolator 6. Coupling Capacitors
7. Relays 8. Metal-clad switchgear
9. Batteries 10. Lightning Arrestors
11. Control Panels 12. High voltage fuses
13. Distribution Bus 14. Shunt Reactors

INTRODUCTION

Distribution substations are located near to the end-users. Distribution transformer changes
the transmission or sub transmission voltage to lower levels for end-users. Typical
distribution voltage system in Pakistan:

1. 33 & 11KV line.

(Usually 3 – phase, rarely 1 – phase)
2. 33/0.415 KV or 11/0.415 KV transformer – 3 phase, and rarely 1 – phase,
6.350/0.240 KV.
2. 400 V LT line, 3 – phase, and 230 Volts 1 – phase.
2. Consumers services (3 – phase & 1 – phase)

Substation Functions

Substations are designed to accomplish the following functions, although not all substations
have all these functions:
 Change voltage from one level to another
 Regulate voltage to compensate for system voltage changes
 Switch transmission and distribution circuits into and out of the grid system

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  Measure electric power qualities flowing in the circuits
 Connect communication signals to the circuits
 Eliminate lightning and other electrical surges from the system
 Connect electric generation plants to the system
 Make interconnections between the electric systems of more than one utility
 Control reactive kilovolt-amperes supplied to and the flow of reactive kilovolt-amperes in the
circuits

1. POWER TRANSFORMER
Raise or lower the voltage as needed to serve the transmission or distribution circuits. The power
transformer is generally installed upon lengths of rails fixed on concrete slabs having foundations 1 to
1.5 m deep. For ratings up to 10MVA, ONAN is generally used. For higher ratings, ONAF is used.
2. CIRCUIT BREAKER
It is an equipment which can open or close a circuit under normal as well as fault conditions. It is so
designed that it can be operated manually (or by remote control) under normal conditions and
automatically under fault conditions. (automatically, relay circuit is used with circuit breaker).
Generally bulk oil CBs are used for voltages upto 66KV while for high (>66KV) voltages, low oil
CBs are used. The most important types of CBs are the following:
a. Oil Circuit breakers
b. Air Circuit breakers
c. SF6 Circuit breakers
d. Vacuum Circuit breakers
3. ISOLATOR
Disconnecting or isolating switch. It only operates at no – load. It provides physical isolation and
mostly used for disconnecting high voltage lines for maintenance personel.
4. RELAY
A device that can measure an electrical quantity, i.e., voltage, current etc., and then send the signal to
activate a sudden pre – determined change or changes in one or more electrical circuits, e.g., to trip a
circuit breaker.
An electric device designed to respond to input conditions in a prescribed manner. Inputs are usually
electrical, but may be mechanical, thermal, or other quantities, or combination of quantities. [IEEE]
5. CURRENT TRANSFORMER
An instrument transformer used as a link between the main circuit and the protection or measuring
equipment. For small currents at low voltage, trip coil and ammeters can be connected directly into
the circuit, i.e., in series with the load. However, series connection is not practical for HV systems
and for larger currents, i.e., 100 Amps and above.
Current transformers have two important qualities:
 Transform the high primary current in the circuit to small secondary current of 1 ampere or 5
ampere so that the current can be carried by small cross – sectional area cables associated with
panel wiring and relays.
 Isolate the high primary voltage of the system from the protection and measuring equipment.
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Note: Secondary of a current transformer must be shorted before removing a relay from its
case or removing any other device that the CT operates. This protects the CT from overvoltage.
6. POTENTIAL TRANSFORMER
The instrument potential transformer (PT) steps down voltage of a circuit to a low value that can be
effectively and safely used for operation of instruments such as ammeters, voltmeters, watt meters,
and relays used for various protective purposes.
PTs are designed to operate at fairly low flux densities so that the magnetizing current, and therefore
the ratio and phase angle errors, is small. This means that the core area for a given output is larger
than that of a power transformer, which increases the overall size of the unit.
The voltage rating of protective relay is usually 110 V. The nominal secondary voltage is sometimes
110 V but more usually 63.5 V per phase to produce a line voltage of 110V.

DISTRIBUTION SUBSTATION

RELAYS
POWER TRANSFORMER 3
Current Transformer PT

Sustation Batteries

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7. LIGHTNING ARRESTERS
Lightning arresters are protective devices for limiting surge voltages due to lightning strikes or
equipment faults or other events, to prevent damage to equipment and disruption of service. Also
called surge arresters.
Lightning arresters are installed on many different pieces of equipment such as power poles and
towers, power transformers, circuit breakers, bus structures, and steel superstructures in substations.

8. BATTERIES
Batteries are used in the substation control house as a backup to power the control systems in case of
a power blackout.

9. COUPLING CAPACITORS
They are used to transmit communication signals to transmission lines. Some are used to measure the
voltage in transmission lines. In signal transmission the coupling capacitor is part of a power line
carrier circuit as shown in the figure A. A coupling capacitor is used in this circuit in conjunction
with a line trap. Line traps can be installed at the substation or on a transmission line tower.

10. METAL – CLAD SWITCHGEAR

Switchgear can be either for outdoor use or indoor use. Outdoor metal-clad switchgear is a
weatherproof housing for circuit breakers, protective relays, meters, current transformers, potential
transformers, bus conductors, and other equipment. Indoor switchgear must be protected from the
environment and contains the same types of equipment as the outdoor type.

11. SHUNT REACTORS

Shunt reactors are used in an extra high-voltage substation to neutralize inductive reactance in long
EHV transmission lines. Figure shows an installation of both an older version and a newer version of
the reactor.

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12. HIGH VOLTAGE FUSES
High voltage fuses are used to protect the electrical system in a substation from power transformer
faults. They are switched for maintenance and safety.

13. CONTROL PANELS

Control panels contain meters, control switches and recorders located in the control building, also
called a doghouse. These are used to control the substation equipment, to send power from one circuit
to another or to open or to shut down circuits when needed.

Indoor Metal – Clad Switch

gear

Cut view of out door Metal –

Clad Switchgear

SHUNT REACTORS HIGH VOLTAGE FUSE

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 Control Panels Distribution Bus

14. CONTROL PANELS

Control panels contain meters, control switches and recorders located in the control building, also
called a doghouse. These are used to control the substation equipment, to send power from one circuit
to another or to open or to shut down circuits when needed.

15. DISTRIBUTION BUS

A distribution bus is a steel structure array of switches used to route power out of a substation.

REVIEW QUESTIONS:

Q1. How inductive reactance is neutralized in long EHV transmission lines?

Q2. Why coupling capacitors are connected at substations?

Q3. Why secondary of CT must be connected to load or shorted?

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Q4. How substation is protected against lightning strikes?

Q5. What is the function of control panel at substation?

Q6. What is the function of distribution bus?

Q7. What is the difference between CB & Isolator?

Q8. In case of power blackout, how substation is energized?

Q9. Explain RELAY?

Q10. Draw a circuit diagram to show CT and PT connections.

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 Lab Experiment #02
DISTRIBUTION TRANSFORMER
Name: Roll No:

Score: Signature of Lab Tutor: Date

COMPLETE WITH CONFIDENCE, CONDUCT AND DEMONSTRATE THE MAIN

COMPONENTS AND APPLICATION OF DISTRIBUTION TRANSFORMER AND
SKETCH THE THREE PHASE CONNECTION OF DISTRIBUTION TRANSFORMER
PERFORMANCE OBJECTIVE:
Upon successful completion of this experiment, the student will be able:
 To display the main components and application of distribution transformer
 To sketch the three phase connections of distribution transformer

EQUIPMENT:
 Distribution transformer

INTRODUCTION

Distribution transformers are used for lower voltage distribution networks as a means to end user
connectivity. (11kV, 6.6 kV, 3.3 kV, 440V, 230V) and are generally rated less than 200 MVA.
Distribution Transformer is used at the distribution level where voltages tend to be lower .The
secondary voltage is almost always the voltage delivered to the end consumer. Because of voltage
drop limitations, it is usually not possible to deliver that secondary voltage over great distances.
The distribution transformer is used for the distribution of electrical energy at low voltage as less
than 33KV in industrial purpose and 400V – 230V in domestic purpose. It work at low efficiency at
75%, small size, easy in installation, having low magnetic losses & it is not always fully loaded.
Iron Losses and Copper Losses
Transformers used in Distribution Network directly connected to the consumer, so load fluctuations
are very high. these are not loaded fully at all time so iron losses takes place 24hr a day and cu losses
takes place based on load cycle. the specific weight is more i.e. (iron weight)/(cu weight).average
loads are about only 75% of full load and these are designed in such a way that max efficiency occurs
at 75% of full load. As these are time dependent the all day efficiency is defined in order to calculate
the efficiency.
Maximum Efficiency

Distribution transformer is designed for maximum efficiency at 60% to 70% load as normally doesn’t
operate at full load all the time. Its load depends on distribution demand. Whereas power transformer
is designed for maximum efficiency at 100% load as it always runs at 100% load being near to
generating station.
All day efficiency = (Output in KWhr) / (Input in KWhr) in 24 hrs which is always less than power efficiency.

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CONSTRUCTION
There are three main components of distribution transformer:
1. Windings: HT and LT windings. Usually primary 11kV distribution feeder is connected to the
HT winding and secondary distribution network is connected to the LT winding of the
distribution transformer.
2. Core: laminated iron core provides low reluctance path to transfer magnetic field caused by
primary winding to secondary winding by electromagnetic induction.
3. Tank: The tank is used to accumulate the windings, core etc. in it. The tank of small transformer
is made with iron sheets having the provision of ventilation and provision for connections to the
load and supply.

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Transformer Accessories
1. Breather 2 Pressure relief device
3. Temperature Indicator 4. Tap Changer
5. Oil level indicator 6. HV & LV Bushings
7. Gap arrestors 8. Conservator tan
9. Buchholz Relay 10. Transformer oil etc
SIGNIFICANCE OF VECTOR GROUPS
A vector group is the International Electro-technical Commission (IEC) method of categorizing the
primary and secondary winding configurations of three-phase transformers. It indicates the windings
configurations and the difference in phase angle between them.
In a three-phase power system, it may be necessary to connect a 3-wire system to a 4-wire system, or
vice versa. Because of this, transformers are manufactured with a variety of winding configurations
to meet these requirements.
Different winding connections will result in different phase angles between the voltages on the
windings. This limits the types of transformers that can be connected between two systems, because
mismatching phase angles can result in circulating current and other system disturbances.
Symbol designation
The vector group provides a simple way of indicating how the internal connections are arranged. By
the IEC, the vector group is indicated by a code consisting of two or three letters, followed by one or
two digits. The letters indicate the winding configuration as follows:
 D: Delta winding.
 Y: Wye winding, also called a star winding.
 Z: Zigzag winding, or interconnected star winding. Basically similar to a star winding, but the
windings are arranged so that the three legs are "bent" when the phase diagram is drawn.
 III: Independent windings. The three windings are not interconnected inside the transformer at
all, and must be connected externally.
The HV winding is designated with a capital letter, followed by low voltage windings designated
with a lowercase letter. The digits following the letter codes indicate the difference in phase angle
between the windings, with HV winding is taken as a reference. The number is in units of 30 degrees.
For example: Vector Group Dy1 has a delta-connected HV winding and a star - connected LV
winding. The phase angle of the LV winding lags the HV by 30 degrees.

PROCEDURE
Practical demonstration.
RESULT
Complete working of the distribution transformer has been understood.

REVIEW QUESTIONS:

Q1. Why distribution transformer works at low efficiency?

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Q2. How power transformer differs distribution transformer?

Q3. What is the function of conservator tank?

Q4. Why transformer core is laminated?

Q5. Differentiate between Dy11 and dY11?

Q6. Why Gap arresters are connected at HT bushings?

Q7. What is the function of breather in transformer?

Q8. What type of protection you have seen in your street pole mounted transformer?

Q9. What is the function of Buchholz Relay in a transformer?

Q10. Write down the name plate data of power transformer.

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 Lab Experiment # 03
MINIATURE CIRCUIT BREAKER (MCB)
Name: Roll No:

Score: Signature Of Lab Tutor: Date

COMPLETE WITH CONFIDENCE, CONDUCT AND EXECUTE THE WORKING

PRINCIPLE AND APPLICATION OF MINIATURE CIRCUIT BREAKER (MCB) AND
SHOW THE OVERLOAD AND SHORT CIRCUIT CHARACTERISTICS OF MCB
PERFORMANCE OBJECTIVE:
Upon successful completion of this experiment, the students will be able:
 To execute the working principle of MCB
 To execute the applications of MCB
 To show overload and short circuit characteristics of MCB

EQUIPMENT:
 MCB
 Current Source (Relay Test Set Sverker)
 220V AC supply
 Clip on ammeter

INTRODUCTION
MCBs or Miniature Circuit Breakers are electromechanical devices which protect an electric circuit
from an overcurrent. The overcurrent, in an electrical circuit, may result from short circuit, overload
or faulty design. MCB is a better alternative to a Fuse since it does not require replacement once an
overload is detected. Unlike fuse, an MCB can be easily operated and thus offers improved
operational safety and greater convenience without incurring large operating cost.
Miniature Circuit Breakers are used to protect lower current circuits and have the following
Specifications:
 Current rating - Amperes
 Short Circuit Rating - Kilo Amperes (kA)
 Operating Characteristics - B, C or D Curves

CONSTRUCITON
Figure shows the 1, 2, and 3 pole MCBs. The tripping mechanism of MCBs may be ‘thermo –
magnetic’, assisted by thermal or magneto – hydraulic system. In the thermo – magnetic type, a
bimetallic strip is heated which bends to operate a trip mechanism, this provides a time delay, which
is suitable for small overloading, but for rapid operation under short circuit conditions, a separate
magnetically operated trip coil releases a latch mechanism.

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Following are the constructional parts of MCB: [figure]
1. Bimetallic Strip 2. Electromagnet
3. Latch 4. Reset Button
5. Spring 6. Push Button
7. Heat Dissipater 8. Terminals
9. Fixed and Moving Contacts 10. Case

WORKING PRINCIPLE

There are two arrangement of operation of miniature circuit breaker. One due to thermal effect of
over electric current and other due to electromagnetic effect of over current. The thermal operation of
miniature circuit breaker is achieved with a bimetallic strip.
Whenever continuous over electric current flows through MCB, the bimetallic strip is heated and
deflects by bending. This deflection of bimetallic strip releases mechanical latch. As this mechanical
latch is attached with operating mechanism, it causes to open the miniature circuit breaker contacts.
But during short circuit condition, sudden rising of electric current, causes electro-mechanical
displacement of plunger associated with tripping coil or solenoid of MCB. The plunger strikes the
trip lever causing immediate release of latch mechanism consequently open the circuit breaker
contacts. This was a simple explanation of miniature circuit breaker working principle.

Reset
Push Button Button Electromagnet

Spring
Latch

Moving
contact

Heat Bimetallic strip

dissipater
Spring
Fixed
contact

P
Socket

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15
Miniature Circuit Breakers are usually available in the range of 0.5A to 100A. An MCB's Short
circuit rating is given in Kilo amps (kA), and this indicates the level of its ability to work. For example
a domestic MCB would normally have a 6kA fault level, whereas one used in an industrial application
may need a unit with a 10kA fault capability.
OVERLOAD CHARACTERISTICS
For the overload protection, MCB employs thermal tripping. Thermal tripping mechanism uses a heat
sensitive “bimetallic element”. When the element is heated to a predetermined temperature, the
resultant deflection is arranged to trip the circuit breaker. The time taken to heat the element to this
temperature provides the necessary time – delay characteristics. The bimetallic element may be
arranged to carry the circuit current and so be directly self-heated. Indirect heating of the element may
also be used. Because of the time log associated with heating. Tripping by this means is not as rapid as
with magnetic tripping.
In the circuit condition when a small sustained overload occurs, the thermal trip will come into
operation after a few seconds or even minutes.
SHORT CIRCUIT CHARACTERISTICS
In case of short circuit condition, the magnetic tripping device is employed to open the circuit. The
MCB with the magnetic tripping employs a solenoid, which is a coil with an iron slug. The normal
circuit current flow through the coil is not sufficient to produce a significant magnetic flux to open the
circuit.
At short circuit condition, circuit current increases to predetermined level, the magnetic field strength
increases to cause the iron slug to move within the solenoid and collapse the attached tripping linkage
to open the contacts.
TRIP FREE MECHANISM
This safety feature of MCCB and MCB (and some overload relays) allows the trip action to open the
contacts even if the operator is pressing the handle / button in “ON” position. This means that when an
operator is closing the breaker into a circuit where a fault exists, the breaker will trip and interrupt
the fault irrespective of handle / button being in “ON” position from outside due to the force applied
by the operator.

TYPES OF MCB BASED ON TRIPPING CHARACTERISTICS

MCBs are classified according to tripping over range of fault current as follows:
1. Type B MCB 2. Type C MCB 3. Type D MCB

Type B:
This type of MCB trips between 3 and 5 times full load current. Type B devices are mainly used in
residential applications or light commercial applications where connected loads are primarily lighting
fixtures, domestic appliances with mainly resistive elements.
Type C:
This type of MCB trips between 5 and 10 times full load current. This is used in commercial or
industrial type of applications where there could be chances of higher values of short circuit currents
in the circuit. The connected loads are mainly inductive in nature (e.g. induction motors) or fluorescent
lighting.
Type D:
This type of MCB trips between 10 and 20 times full load current. These MCBs are use in specialty
industrial / commercial uses where current inrush can be very high. Examples include transformers or
X-ray machines, large winding motors etc.
All the above three types of MCBs provide tripping protection within one tenth of a second.
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TYPES OF MCB BASED ON NUMBER OF POLES
Another practical way of distinguishing MCBs is by way of the number of poles supported by the
circuit breaker.

1. Single Pole (SP) MCB: A single pole MCB provides switching and protection only for one single
phase of a circuit.
2. Double Pole (DP) MCB: A two Pole MCB provides switching and protection both for a phase
and the neutral. Triple Pole (TP) MCB: A triple/three phase MCB provides switching and
protection only to three phases of the circuit and not to the neutral.
3. 3 Pole with Neutral [TPN (3P+N) MCB]: A TPN MCB, has switching and protection to all three
phases of circuit and additionally Neutral is also part of the MCB as a separate pole. However,
Neutral pole is without any protection and can only be switched.
4. 4 Pole (4P) MCB: A 4 pole MCB is similar to TPN but additionally it also has protective release
for the neutral pole. This MCB should be used in cases where there is possibility of high neutral
current flow through the circuit as in cases of an unbalanced circuit.

MCB CHARACTERISTIC CURVES

Characteristic curve is the curve between release current and tripping time. MCB have

The classification of Type B, C or D is based on fault current rating at which magnetic operation
occurs to provide short time protection (typically less than 100ms) against short circuits. It is
important that equipment having high inrush currents should not cause the circuit-breaker to trip
unnecessarily, and yet the device should trip in the event of a short-circuit current that could damage
the circuit cables.
OBSERVATION TABLE
Type of MCB taken……………………………….

S.No. Current Time taken by MCB to trip

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MCB AND WIRE SELECTION CHART FOR DOMESTIC LOADS

First calculate total connected load using individual equipment wattage as given above, then find out
total load current using given formula. This load current gives main incomer rating.

Note:

1. While calculation you should consider diversity factor and power factor of Loads.
2. Add 10% - 15% extra for future expansion depending upon the situation.

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REVIEW QUESTIONS:

Q1. What is the primary function of MCB?

Q2. Explain trip free mechanism of MCB?

Q3. Write few applications of MCB?

Q4. What is the difference between overload and short circuit current?

Q5. Why there is a time delay element in the overload fault?

Q6. Draw the detailed internal wiring diagram of MCB

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 Lab Experiment # 04
MAGNETIC CONTACTOR (MC)
Name: Roll No:

Score: Signature Of Lab Tutor: Date

COMPLETE WITH CONFIDENCE, CONDUCT AND EXECUTE THE WORKING

PRINCIPLE AND APPLICATIONS OF MAGNETIC CONTACTOR (MC) AND
CONSTRUCT THE LADDER DIAGRAMS

PERFORMANCE OBJECTIVE:
Upon successful completion of this experiment, the students will be able:
 To display the working principle and application of magnetic contactor.
 To construct the ladder diagrams.

EQUIPMENT:
 Contactor MV 1402
 AC power supply

INTRODUCTION
A contactor is a switching device capable of making, carrying and breaking currents under normal
circuit conditions including operating in overload conditions (1000 operations and releases per hour).
Based on the working principle, there are so many types of contactors are available, i.e., Pneumatic,
Hydraulic, Electromagnetic etc., But the most commonly used one is Electromagnet type because of
its simple operating principle and rugged construction.
Contactors are used in applications ranging from the light switch to the most complex, automated
industrial equipment. Contactors are used by electrical equipment that is frequently turned off and on
(opening and closing the circuit), such as lights, heaters, and motors.
Whatever the application, the function of the contactor is always the same: to make and break all
power supply lines running to a Load. Or, as defined by NEMA, to repeatedly establish and interrupt
an electrical power circuit.
DEFINITION
Electromagnetic Contactors are power utilization electro mechanical switches, which are magnetically
closed and magnetically held. In electromagnetic contactors the force for closing the main contacts is
provided by an electromagnet. They are multiple-pole air break switches capable of repetitive
operations with mechanical life expectancy that may approach 10 million operations.

OPERATING PRINCIPLE
Basic operation principle is converting electrical energy in to mechanical energy in a magnetic field.
When the supply extended to the coil, it will energize and become an electromagnet, which attracts the
moving core towards fixed core. Figure 4.3
While starting, coil draws more current than holding period as moving core has to overcome the initial
inertia. The ratio of starting and holding currents are approximately 10. When the moving

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contact”Just” touches the fixed contact, it experiences bounce. Bounce is detrimental to the life of
contacts, as every bounce will generate an arc and reduce the contact material. Bounce is minimized
by, reducing the speed of armature movements and improving the material property of contacts. While
in “just” touch position of the main contacts, moving core of the electromagnet is still not in contact
with fixed core. This gap is desirable as the further travel of the core generates the extra contact
pressure on the contacts. This extra travel of the core is called “over travel”. Simultaneously auxiliary
N/C contact opens first and then N/O contact closes. This design is called for in most applications, e.g.
Star contactor is connected to the coil of the Delta contactor to ensure this.

CONSTRUCTION OF CONTACTOR

A contactor is composed or the following 3 systems. Figure 4.2

1. Contact System:

This is the current carrying part of the contactor. This includes Power contacts (main contacts),
Auxiliary contacts & contact springs. Contactors making capacity is at 10 times the rated current of the
contactor.

Main Contacts (Power Contacts): These are designed to make, carry and break the current in the
power circuit. They include a fixed contact and a moving contact. During closing operation, the
moving contacts, which are linked to moving cores, are pulled towards the fixed contacts, thus closing
the circuit. They are highly conductive and suitably arranged for bounce free operation. Main contacts
are always normally open (NO).

Auxiliary Contacts: They are used for signaling/interlocking purpose. They are available in different
versions: Normally Open (NO), Normally Closed (NC). The combination of NO and NC depends on
the usage.

Contact Tip: Contact tips brazed to each contacts. These tips are made of Silver Cadmium Oxide to
provide high mechanical strength & resistance to welding.

Contact Springs: Moving contacts and auxiliary contacts are provided with contact spring. These
springs are provided to exert sufficient pressure on the contacts, so that, that flow of rated current does
not cause over-heating. These springs are energized during “over travel”.

2. ELECTRO MAGNET SYSTEM

This is a driving unit of contact system. Force for closing of contacts is provided by this system.

Electromagnet: it consists of Fixed & Moving core & coil. Its shape varies as a function of the type
of contactor, alternating or direct current. A small gap provided in the magnetic circuit in the closed
condition between the central limbs of fixed & moving cores eliminates any residual magnetism
(becoming a permanent magnet). This gap is generated by removal of metal or by insertion of a non-
magnetic material (e., copper, brass).

Magnet Gap: This is the distance between moving core and fixed core in OFF condition. Contact gap:
This is the distance between fixed contact and moving contact when the contactor is in OFF condition.
Over travel of moving contact: This is the distance between moving core & fixed core when the fixed
and moving contacts “just” touch during contactor closing operation. Therefore we can say,
Magnet Gap = Contact Gap + Over travel
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AC Magnetic Cores: The moving core and the fixed cores are made of riveted silicon steel
laminations. Laminated cores are used in order to reduce eddy current, which are created in any metal
body subjected to an alternating current flux. Grinding of pole faces is done to ensure silent operation.
Pole faces are generally matched perfectly to ensure low reluctance path for magnetic core. Two
shading rings (made of non-magnetic material) are fitted on the extreme and pole faces of the
fixed/moving core to create a flux out-of-phase with the main alternating flux. This out-of-phase flux
prevents periodic cancellation of total flux and thereby chattering.

DC Magnetic cores: In case of DC no eddy currents are formed. So these parts can be solid/laminated
cores. To avoid permanent magnetism a small gap is provided between the armature and magnet by a
non-magnetic material piece. Coil is the driving force for the contactor operation. The coil produces
the magnetic flux required to attract the moving core of the electromagnet.

The coil is designed to withstand mechanical shocks caused by the closing and opening of the moving
& fixed cores. In order to reduce mechanical shocks, the coil or the core, and sometimes both, are
mounted on shock absorbers. The coil is made of super enameled copper wire. The windings are
wound on a Bobbin and covered with polyester tapes suitable for withstanding high temperature. Coils
are generally designed to 0.8 to 1.1 of rated voltage. Return spring: This spring is fitted in between
moving core & fixed core. When the moving core closes, it closes against the fore of the turn spring.
This spring is provided to avoid accidental touch of moving & fixed core in OFF condition. This helps
in breaking of contacts very effectively.

3. ENCLOSURE SYSTEM

An external frame housing the contact and the electromagnet made of insulating materials like
Bakelite, Nylon 6, thermosetting plastics etc. to constitute a protective structure, adequate insulation,
protection to the components within, protection to personnel coming in contact & protection against
dust & ingress of vermin.

Arc Chutes: Arc Chutes are fitted above the moving and fixed power contactor. The purpose of Arc
chutes is to split the arc established at contactor tips while breaking the current and to quench the arc.
Arc chutes also provides phase barriers between the phases.

Terminals: These are hold the input / output supply cables.

A type of relay which is made for high currents high switching frequency (1000 operations and
releases per hour) is called a contactor. Contactors control the electric current to the motor. Their
function is to repeatedly establish and interrupt an electrical power circuit.

A contactor can stand on its own as a power control device, or as part of a starter. Contactors are used
in applications ranging from the light switch to the most complex, automated industrial equipment.
Contactors are used by electrical equipment that is frequently turned off and on (opening and closing
the circuit), such as lights, heaters, and motors.

Whatever the application, the function of the contactor is always the same: to make and break all
power supply lines running to a Load. Or, as defined by NEMA, to repeatedly establish and interrupt
an electrical power circuit.

Contactor Components

Figure 9.2, shows the main components: an Electromagnet, an Armature, a coil, a spring, and two sets
of contacts, one movable set and one stationary set.
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Operation

When the coil is energized from mains, becomes an electromagnet. The armature, a companion to the
frame, is connected to a set of contacts. The armature is moveable but is held by a spring.

When the coil is energized, the moveable contacts are pulled toward the stationary contacts because
the armature is pulled toward the frame. Once the two sets of contacts meet, power can flow through
the contactor to the load. When the coil is de-energized, the magnetic field is broken, and the spring
forces the two sets of contacts apart. In Figure 9.3, we step through the process again, using pictures to
help you understand.

Figure 4.1. A Starter is Made Up of a Controller (Most Often a Contactor) and

Overload Protection

Fig. 4.3

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A major customer concern is the life expectancy of a contactor. It has been said that, “The worst
thing you can do to a car is start it.” The same is true for contacts. The more frequently the contacts are
opened and closed, the shorter the life of the contactor.

As contacts open and close, an electrical arc is created between them. The arcs produce additional
heat, which, if continued, can damage the contact surfaces.

Figure 4.4. Arcing Causes Corrosion, Pitting and Oxide Build-Up

Eventually, the contacts become blackened with burn marks and pitting made by the electrical arcs.
This is not a reason for contact replacement. In fact, this black deposit (Oxide) helps them to make a
better “seat” to conduct the electricity. However, contacts do need to be replaced once the surface is
badly corroded or worn away.

Contact Life: Bouncing

Applying some logic, you can conclude that the faster the contact closes, the sooner the arc is
extinguished, and the longer the life expectancy of the contact. But, modern contactors have been
designed to close so quickly and with such energy that the contacts slam against each other and
rebound, causing a bouncing action. This is referred to as Contact Bounce. When the contact bounces
away, a secondary arc is created. The contacts slam together again and again, each time the bouncing
and arcing become less and less.
So, in addition to closing the contacts as fast as possible, you also want the contacts to bounce as little
as possible, to reduce secondary arcing and wear.

APPLICTIONS
Contactors have many applications, such as
1. Remote Control
For control of an electrical apparatus, e.g. starting and stopping of an electric motor, from a remote
point the use of a contactor may be practical. The contactor in such a case placed close to the
apparatus to be controlled. Instead of running the heavy apparatus cables between the latter and the
control point, it is then enough to install small cables for operation of the contactor.
2. Automatic Control
Contactors are often used for automation of a process. A simple example: an electric fan is to be
started when the temperature exceeds a given value. Instead of reading a thermometer and
switching on the fan by hand, the thermometer is so designed that at a given temperature it closes
the contactor operating circuit. The contactor then makes the circuit to the fan motor.
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3. No Voltage Release
When the supply voltage to a motor is cut off due to a temporary breakdown, the motor stops.
When the voltage returns, the motor restarts if an ordinary switch is used. This may be dangerous
for persons working near the motor or near moving parts under its control.
By equipping the motor with contactor it can be arranged that the control device must be actuated
to start the motor even after a brief interruption of the supply voltage.

4. Heavy Manual Operation

Manually operated switches for high currents are very heavy to operate. If the current is to be
switched on and off frequently, replacing the switch by a contactor can attain a great saving of
labour and it’s easily operated control mechanism.

The contactor MV 1402 consists of an operating coil and an armature. When the coil is energized its
armature is pulled down and the moving and fixed contacts close. When the coil is deenergized,
springs press up the armature and the contacts return to normal. The contacts are divided into main and
auxiliary contacts. The breaking capacity of the main contacts is 20A at maximum 500V. The
auxiliary contacts serve to make and break control circuits.

Figures show main and auxiliary contacts of MC

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 Figure shows MC as Motor starter Switch

REVIEW QUESTIONS:
Q1. What is the function of a contactor?

Q2. Explain contact bouncing?

Q3. Explain the difference between a manual contactor and a magnetic contactor?

Q4. Explain the two main concerns with contact life?

Q5. Write few applications of magnetic contactor?

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Q6. What was the first device used to start and stop the motor?

Q7. Differentiate between MC, MCB, and MCCB

Q8. Draw the ladder diagram of motor starter using MC

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