Lesson Index

Lesson No Lesson Topic

1) Introduction to PCP

2) Basics of Motors

3) Protection System in Motors

4) Motor Starting Methods

5) Coordination Motor Starters

6) Selection of Contactors
i. Introduction
ii. Working of Contactors
iii. Electrical definitions related to Contactors
iv. Utilization Categories
v. Selection Based on Applications

7) Schneider PWCTR/PCP Offer

8) PCP Innovations

9) Starter Offer

10) Introduction to i MCC

11) TeSys U

12) TeSys T
Introduction
An industry is a conglomerate of various loads – motors, lighting,
capacitors, furnaces etc. switching on or off of every load has to be
carefully studied because the instant of making or breaking of a
circuit, the load characteristics at the time of starting and running of
a motor, initial conditions of the loads etc affect the performance of
the switch. Switchgears were developed to cater to the standard
requirements of switching various loads under normal and
abnormal conditions with in-built features of protection against
various hazards. One such device which is located closer to the
load is the “CONTACTOR”.

Working Principal of Contactor

When a definite voltage is applied
across a coil energizing an Contact Moving
spring contact
electromagnet system
compromising fixed and moving
Parts, the moving part gets
attracted to the fixed part. By way
of its movement towards the fixed
part the electrical contacts situated Fixed
on a carrier bridge on the moving contact
Moving
part get to make with some fixed m Return
contacts and thus enabling an spring
electrical circuit to be completed Fixed A
through this contact system. When Coil
magnet
the magnets system is de energized, A
the magnet gets pushed back by a
spring and the contacts open.

Parts of Contactor

Magnet System & return springs:

The Electromagnet of contactor is made up of E shape core. For Ac control this core is
laminated to avoid eddy current and hysteresis losses, whereas for DC control it is
made up of solid core as DC supply has zero frequency. To absorb the vibration on the
E- Core fixed part while switching, Rubber pads are provided. Return spring help to
retain the moving contact assembly in its position and open the contacts after removal
of supply.

Coil, Contact system & terminals:

The control coil of the contactor can be AC or DC as per the application; it is mounted
on the centre limb of the electromagnetic. Moving Power contacts are mounted on
moving bridge assembly and fixed contacts are mounted on contactor housing and
connected to terminals. Terminals are provided on incoming and outgoing side to
connect supply and load. These are connected to fixed contacts and fixed to housing.

Electrical definitions related to Contactors

Rated Control Circuit Voltage (Uc) – The rated value of the control circuit
voltage, on which the operating characteristics are based. For A.C. applications,
the values are given for a near sinusoidal wave form (less than 5% total harmonic
distortion).

Operational voltage (Ue) - This is the voltage value which, in conjunction with
the rated operational current, determines the use of the contactor or starter, and
on which the corresponding tests and the utilization category are based. For 3-
phase circuits it is expressed as the voltage between phases.

Rated Operational Current (Ie) – This is defined taking into account the rated
operational voltage, operating rate and duty, utilization category and ambient
temperature around the device.

Rated conventional thermal current (Ith) -The current which a closed contactor
can sustain for a minimum of 8 hours without its temperature rise exceeding the
limits given in the standards.

Permissible short time rating -The current which a closed contactor can sustain
for a short time after a period of no load, without dangerous overheating.

Rated Making Capacity - This is the current value which the contactor can make
in accordance with the making conditions specified in the IEC standard.

Rated Breaking Capacity - This is the current value which the Contactor can
break in accordance with the breaking conditions specified in the IEC standard.

Mechanical Durability -This is the average number of no-load operating cycles

(i.e. with zero current flow through the main poles) which the contactor can
perform without mechanical failure.

Ambient air temperature – The temperature of the air surrounding the device,
measured near to the device. The operating characteristics are given :with no
restriction for temperatures between - 5 and + 55 ° with restrictions, if necessary,
for temperatures between - 50 and + 70 °C.

Altitude- The rarefied atmosphere at high altitude reduces the dielectric strength
of the air and hence the rated operational voltage of the contactor. It also reduces
the cooling effect of the air and hence the rated operational current of the
contactor (unless the temperature drops at the same time). No derating is
necessary up to 3000 m.

Rated Operational Power - The rated power of the standard motor which can be
switched by the contactor, at the stated op\rational voltage.

Utilization Categories

Utilization categories: AC

AC-1 Non-inductive or slightly inductive loads, resistance ovens.

AC-2 Slip-ring motors: starting, disconnection.

AC-3 Cage motors: starting, disconnection of running motors.

AC-4 Cage motors: starting, reversal of direction, inching.

AC-5a Control of discharge lamps.

AC-5b Control of incandescent lamps.

AC-6a Control of transformers.

AC-6b Control of capacitor banks.

AC-8a Control of sealed compressor motors for refrigeration with manual reset
of overload trip.

AC-8b Control of sealed compressor motors for refrigeration with automatic
reset of overload trip.

Utilization categories: DC

DC-1: Non-inductive or slightly inductive loads, resistance ovens.

DC-3: Shunt motors: starting, current reversal, inching. Dynamic motor
disconnection.

DC-5: Series motors: starting, current reversal, inching. Dynamic motor
disconnection.

DC-6: Control of incandescent lamps.
Contactor must endure for below new tests as per IEC 60946-4-1 & 5-,
After making & baking capacity test contactor shall give 6000 operations, followed by
dielectric test
Making & breaking current of some of the utilization categories are mentioned in below

table.

Selection of contactors based on application

Motor applications

AC3 - DOL starting

AC3 - Star- Delta starting

AC4 -Inching / Plugging (crane application)

DOL: AC 3 Application

This is the most frequent application.

Operation corresponds to utilisation category
AC3.

This use may involve a large number of
operations.

The current peak on starting (6 to 8 In) is not
high as it is always less than

the contactor making capacity.

The contactors chosen for this duty are fully capable of supporting accident
related category AC4 operations (disconnection of stalled motor: repeat for
positioning operations, for example).

AC 3 Selection chart at 440 V

Example of AC 3 Selection
Question: Which contactor should we select to control 55 kw /400 V 3 phase
asynchronous squirrel cage motor for AC3 duty at ambient temperature 40 degree
centigrade. Durability required is 10 years. For operation 365 days, 24 hrs, 12 start per
hour (0.75pf)
Answer: A 55 KW / 400 V has a rated current of 105 A .The corresponding contactor is
LC 1D115, with a making capacity of 1250 A. We have utilization I of 105<1250/10 Now
we check the durability of the contactor,
= 12*24*365*10.= 1.05 M
The durability of the contactor should be more than this.
Star Delta Starting

The motor is initially connected in star configuration and then, after a preset
time, the motor is disconnected from the supply and reconnected in delta
configuration.

The current and torque in the star configuration are one third of the full voltage
current and torque when the motor is connected in delta.

There are three contactors required for making star- delta starter, main and delta
contactors are selected at 0.58 times of the rated current and star is selected for
1/3 times of rated current

AC 4 Selection

This is category AC4 for asynchronous cage
motors (or AC2 for slip-ring motors).

This type of use generally involves a high
number of operations.

The current to be disconnected is higher. On
each break, the arc damages a tiny part of the
contact. Wear is faster than for AC3.

To prolong contact life relative to the power
disconnected, a contactor with a higher rating
must be chosen (see graph).

In practice, the motor is never used at 100% in category AC4. Generally, in

difficult conditions, some dis-connections are made in AC3, others in AC4.

AC 4 Selection Chart at 440 V

Example of AC 4 Selection
Question: Which contactor we shall select for switching of crane motor of 2.2kW/ 400V,
with control voltage of 24V. The crane is used 365days/year, 8 hours/day and the
motor is started 10 times per day, for at least 5 years.

Answer: This application is an AC4 duty, because the contactor has to switch on and off
the motor during starting period. Ful load current for 2.2 kW motor will be 4.2 A, We
need 10x10x365x5 = 182500 operations. So we can select a D09 device, which has a life
of 2100000 operations. (selection with AC4 durability curves).
Control voltage : 24 V DC = BD => LC1D09BD.

AC 1 Selection

The resistive heating elements are controlled by a
contactor. Such use conforms to category AC1.

The variation in resistance between the hot and cold
states produces a current peak which never exceeds 2
to 3 In on power-up.

In general, this type of circuit is not affected by
overload currents. It only has to be protected against
short-circuits.

The operating cycles are low for this application.

Only the thermal current of the contactor needs to be considered, as cos L (power
factor) is close to 1.

For single-phase use, a 4-pole contactor with the poles connected in parallel
reduces the cost.

AC-1 selection Chart at 440 V

Example of AC 1 Selection
Question: Which contactor we shall select for a resistive heater of 5kW, with 220V.

Answer: This application is an AC1 duty, as we know the variation in resistance

between the hot and cold states produces a current peak which never exceeds 2 to 3 In
on power-up. Therefore Making & breaking current is equal to the rated current.
5kw load at 220V AC will have max current of 22A. So LC1D9 can be used as it is rated
for Ac1 duty of 25A.

Contactors Selection for Single Phase Application

With single phase applications it can be of interest to select a 4 pole contactor with the
poles connected in parallel in pairs. This enables the contactor with a lower rating that
the rated current of the load. Paralleling of 2 poles enables multiplication of the
contactor thermal current by 1.6.

Question: What contactor should be used to control 22 kW 3- phase heating resistances

400V.
Answer: Power taken P=UI√3
Hence I=P/(U √3)
I=22*1000/(400* √3)=32 A
In=32*1.05=34 A
A Contactor with AC1 rating of more than 34 A will be used.
LC1D25, Ith=40 A at 40 C

Contactor selection for Capacitor Switching

On power-up, since the capacitors are

discharged, the current peak corresponds in
practice to the short-circuit current (it is
slightly limited by the line impedance).

At switch on the capacitor behaves like a short
circuit. The circuit is subjected to high stresses
when switching that is high inrush current
transients 180 times In and high frequency
level of 15 KHz

When the current peak risks exceeding the
value of the current peak permitted by the
contactor, it must be limited by inserting
chokes or resistors (short-circuited in steady state).

In steady state, harmonic currents circulate in the circuit. The standards
recommend using a contactor with a thermal current AC1 = 1.43 * In.
Contactor Selection Transformer Switching

Irrespective of the load, the magnetising current peak during the first half-wave
may reach 25 to 30 In.

This must be borne in mind when choosing the contactor (making capacity) and
short-circuit protection (fuses or circuit breaker).

Utilization category AC- 6 a

The first current peak can reach 30-40 times rated current
depending on the characteristics of the magnetic circuits.

Quality of lamination, air gap, type of transformer,
transformer power.

The peak current should not exceed maximum contactor
values: MC *√2 so that there is no risk of welding of poles.

Example Selection of Contactor for Transformer Switching

Question: What is the power of a 3-phase 400 V transformer which can be supplied
by an LC1D18 contactor, given that the contactor can switch 420 Â
(peak current) and that the transformer has a peak of I/In = 30?

Answer: Since I/In=30 , the transformer rated current will be 1/30 of the peak
withstand current of the contactor that is 420/30=14A Max.power of the
transformer will be 400*14* √3=9.7kva.

Switching a 3-phase 80 kVA/400 V transformer - Which contactor

should be used when considering a current peak such as I/In= 25 ?

Transformer rated current I = S/(U √3) = 80*1000/(400 √3) =111A

Contactor making capacity MC=KIn/√2 =111*25/ √2 = 1962 A LC1F185 is
suitable with MC OF 2100 A.

Contactor selection for slip ring Motor

Rotor Circuit: These contactors are used to eliminate starting resistance in the rotor
circuit of slip ring motors. The rotor circuit contactors are interlocked with the stator
contactor and therefore do not open until after the stator contactor has opened,
when the rotor voltage has disappeared.
Based on rotor connection and voltage , current coefficients are applied. Based on
these values required contactor is selected.
 Stator Circuit: These ratings are selected as per AC-2 duty selection depending on
current required.

Selection chart as per Duty cycle and electrical life for Stator and Rotor current is
given below.

AC-2 current (temperature < 60°C)

STATOR ROTOR

Contactor for short circuit Contactors for resistance starting

Make & break

200,000 1 million 2 millions 2 millions 1 million 2 millions
operations

AC-1 Motor start time

current Duty factor 25% 40% 60% 25% 40% 60% 25% 40% 60% 25% 40% 60%
rating ≤ 5s ≤ 10s ≤ 5s ≤ 10s
20 LC1K06 7.2 6.5 5.8 3.2 2.9 2.6 2.2 2.0 1.8 14.4 13 12 19 17 14.4 13.0
20 LC1K09 9 8.1 7.3 4.8 4.3 3.9 2.72 2.4 2.2 18 16 15 29 26 22 19
20 LC1K12 10 9.0 8.1 6.4 5.8 5.2 3.8 3.4 3.1 20 18 16 38 35 29 26
25 LC1D09 13 12 10 6.4 5.8 5.2 3.6 3.2 2.9 21 19 17 29 26 22 19
25 LC1D12 19 17 16 8.4 8 7 4.8 4 4 25 23 20 38 35 29 26
32 LC1D18 24 22 19 10 9 8 6.4 6 5 32 29 26 58 52 43 39
40 LC1D25 32 29 26 15.2 14 12 8.8 8 7 40 36 32 80 72 60 54
50 LC1D32 36 32 29 17.6 16 14 11.2 10 9 50 45 41 102 92 77 69
50 LC1D38 36 32 29 17.6 16 14 12 11 10 50 45 41 122 109 91 82
60 LC1D40 40 36 32 18.8 17 15 14 13 11 60 54 49 128 115 96 86
80 LC1D50 44 40 36 20.4 18 17 16 14 13 80 72 65 160 144 120 108
80 LC1D65 64 58 52 28.8 26 23 21.2 19 17 80 72 65 208 187 156 140
125 LC1D80 72 65 58 32.8 30 27 26 23 21 120 108 97 256 230 192 173
125 LC1D95 76 68 62 35.2 32 29 28 25 23 125 113 101 304 274 228 205
200 LC1D115 88 79 71 40 36 32 30 27 24 200 180 162 336 302 252 227
200 LC1D150 108 97 87 48 43 39 36 32 29 200 180 162 442 397 331 298
275 LC1F185 160 144 130 74 67 60 48 43 39 275 248 223 544 490 408 367
315 LC1F225 200 180 162 90 81 73 60 54 49 315 284 255 656 590 492 443
350 LC1F265 232 209 188 106 95 86 68 61 55 350 315 284 784 706 588 529
400 LC1F330 260 234 211 126 113 102 80 72 65 400 360 324 960 864 720 648
500 LC1F400 300 270 243 148 133 120 96 86 78 500 450 405 1184 1066 888 799
700 LC1F500 348 313 282 180 162 146 120 108 97 700 630 567 1472 1325 1104 994
1000 LC1F630 392 353 318 204 184 165 140 126 113 1000 900 810 1792 1613 1344 1210
1600 LC1F780 480 432 389 244 220 198 176 158 143 1600 1440 1296 2272 2045 1704 1534
1000 LC1F800 416 374 337 224 202 181 160 144 130 1000 900 810 1968 1771 1476 1328
1000 LC1BL 680 612 551 232 209 188 180 162 146 1000 900 810 1872 1685 1404 1264
1250 LC1BM 720 648 583 280 252 227 192 173 156 1250 1125 1013 2672 2405 2004 1804
2000 LC1BP 920 828 745 400 360 324 272 245 220 2000 1800 1620 4000 3600 3000 2700
2750 LC1BR 1160 1044 940 492 443 399 360 324 292 2750 2475 2228 4800 4320 3600 3240