Summary ac contactor failure cause and effect

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Ac contactor common failure phenomenon is as follows:

A, contact arc extinguishing system failure
1. Contact electrical wear too serious.
2. Main, auxiliary contact welding.
3, soluble slice off.
4. Auxiliary contact bad contact.

Second, the electromagnetic system failure

1. Suction close voltage is too high.
2, release the voltage is too low.
3, coil break.
4, electromagnet noise serious.

Three, insulation breakdown or alternate with short circuit fault

Four, mechanical failure

Ac contactor concludes the reason of failure

A, contact electrical wear too serious.
1. Improper selection actual load current than the contactor rated current.

2. Use improper category

3. Dc load circuit time constant too big and ac load circuit of the power factor is too low dc load
circuit time constant too big when, arc time growth, so that the contact breaking circuit electric
wear quantity increase. Ac load circuit of the power factor is too low, can make the arc energy
increase, and make the contact breaking circuit electric wear quantity increase.
4. Operating frequency is too high when the operation frequency more than product standards
specified maximum operating frequency, can make the contact temperature increased, so that the
contact electrical wear increase.
5. On circuit surge current is too big.
6. Contact over travel and contact final pressure value partial small ultra stroke and the final
pressure value partial moment cause contact overheating and make the contactor contact
electrical wear increase.
7. Three-phase contact not synchronous ac contactor three-phase contact is not the same as the
on and off, will cause the contact wear uneven, and make the basic unit contact electrical wear
increase.

Second, the contact welding mechanism

1. Contact vibration for a long time
2. Making current is too big on capacitors and incandescent lamp and load, making current
ChangGaoDa rated current 10 times above, if contact closed vibration time is long, it is easy to
happen welding.
3. Improper selection actual load current than the contactor rated current.
4. Short circuit accident

Three, dissolve slice off

When contact welding bad, contact materials in arc under the action of thermal stress, first in
welding layer pore place produce craze, and bending upwards, finally caused by dissolved slice
off.

Four, auxiliary contact bad contact

Contact surface pollution due to pollution is covered with dust film, adsorption film and
inorganic membrane, etc. Various kinds of surface film, these surface membrane can cause
auxiliary contact bad contact.

Five, the suction close voltage is too high.

1. The reaction spring reaction is too big
2. Contact overtravel and contact stress
3. Armature is located in the open position, armature and core of the gap between too big
4. Contactor installation position undeserved
5. Movement part got stuck

Six, release the voltage is too low, even coil when the power can't release
1. The remanent magnetization suction is too big, in the ac contactor, the general in the core post
leave a degaussing air gap, in order to reduce residual suction, in actual use often for core side
column wear make core column degaussing air gap decreases, and make remanent magnetization
suction increased, leading to release voltage reduce.
2. Mechanical locks
3. Armature closed position of the reaction is too small

Seven, coil break

1. Coil working voltage is too high or too low
2. Voucher excessive current ac contactor core column gas gap big or polar between foreign
body, can lead to coil current too big and will coil burn out.
3. Coil insulation fault, cause a short-circuit, thus will coil burn out.

Eight, the electromagnet noise serious.

Mainly is the silicon steel sheet material in under the action of alternating magnetic field
produces magnetic striction, cause vibration, or when the armature by electromagnetic suction
minimum value is less than a closed position reaction, cause armature periodic vibration.

Nine, insulation breakdown or alternate with short circuit fault

1. The insulation shell wall metallization
2. Arc to insulated missing heat affected
3. Arcing cover and partition broken, leading to alternate with short circuit

10 and mechanical failure

With the aid of the mechanical failure of main performance for various spare parts, especially the
moving parts and the impact of excessive wear parts, deformation and damage.

Contactor coil burn out

Welcome,
The first thing you must do is be sure the contactor is sized correctly for the
amperage you are drawing.
Next, the coil and mechanical workings must assure that the contacts are
actually closed tightly. Often there is a poor connection somewhere in the
contactor secondary circuits which control if the contactor is open or closed
causing a weak voltage at the coil resulting in a poor quality closure of the
contacts. In all of these cases the contacts tend to over heat. If this is the
case you should be able to spot the location of the poor connection with a
heat sensor or by looking for a hot connection. This is because that
connection will also be hot, and very likely the luggs and wire connection will
now be damaged or oxidized. Check the voltage drop across the coil while it
is energized to see that it is actually the specified voltage for that coil as
delivered through all the control circuits and connections, ... if not find that
poor connection.
Also make sure, as silly as it seems, that the coil is really a match for the
voltage and Hz being used.

In the above examples a loud hummm or chatter of the contacts is often a

clue.
What is the "set protection relay to correct setting" all about?
safety relay is set to correct setting means motor load current is checked with tong
tester and setting of relay done accordingly. If motor gets heated up can it by any
chance burn contactor coil. I have experienced it. coil is 440 V Ac and motor used is
3 phase motor.

How hot is hot, can you put your hand on the motor? If you can not put your
hand on the motor and hold it there a couple of seconds it is too hot. Pain
threshold for the average human hand is about 130f.
If the motor is running too hot, you may have already damaged some of the
windings in the field coils. This in turn will can weaken the motor effeciency
reducing magnetic flux and draw extra amperage trying to do the work load
at a that poor efficency rate (less torque, more heat, at a greater current
draw).
Also, incorrect supply voltage can cause all the above. Have you tested the
voltage under load? Is the power provided off the grid or from a generator
set? Often incorrect generator settings or poor generator conditions result in
incorrect Hz and can cause these problems too.
Also, your heater circuit should be protecting the motor from overloading.
Are the elements in the heater circuit too large or if adjustable are they set
too high?

The NEMA selection process always results in a choice of a contactor you can use over a broad
range of operating conditions. For example, you could use a NEMA Size 5 contactor to run a 50hp motor operating at 230V or a 200-hp motor at 460V.
Using IEC standards, however, you can size contactors very close to their ultimate capabilities.
In many cases, this precision allows you to predict how long they'll last. For example, an IECrated contactor may run a motor that draws 40A at full load. In that duty, it should last for more
than two million operations. But, if you used it for consistent jogging and plugging, you'd have
to replace it after just a few thousand operations.
Since a contactor should last for years, don't automatically replace one that fails with an identical
unit. Instead, take a few moments to see if there is an obvious problem. A contactor really has
only two basic parts: the contacts and the coil. The coil energizes the contactor, moving the

contacts into position. The contacts transmit the current from the source to the load. Heat can
destroy either of them, so take a good look at both.
Contacts will overheat if they transmit too much current, if they do not close quickly and firmly,
or if they open too frequently. Any of these situations will cause significant deterioration of the
contact surface and the shape of that surface. Erratic operation and failure will be quick. To
check the contacts, just look at them. Some minor pitting (seen near the thumb in Photo 1) as
well as a black oxide coating is normal, but severe pitting or any melting or deforming of the
contact surface is a sure sign of misapplication. Replace contacts with such symptoms.
Coils can overheat if operating voltages are too low or too high; if the contacts fail to open or
close because of dirt or misalignment; or if they have suffered physical damage or experienced
an electrical short. Coil insulation degrades quickly when it gets too hot. When it degrades, it
will short out (and blow a fuse) or just open and stop operating.
To check a coil, stick an ohmmeter across the coil leads (Photo 2). Infinite resistance means the
coil is open. A shorted coil will usually register significant resistance, like a good coil. If you
happen to have a matching contactor nearby, compare the two coils. The shorted coil will usually
have significantly higher or lower resistance than the good one. If the difference is significant,
replace it. Replacing the contacts or coil often means replacing the whole contactor. But no
matter what you replace, compare the NEMA or IEC rating with the job the contactor will really
be doing. If you match it to the application, it should last a long time.
Problem Shooting
What are the common reasons why NA1 breaker cannot be closed?
1. Under-voltage release is not energized or is damaged;
2. Reset button on intelligent controller is not reset (protruded on the panel);
3. The body of drawer-type breaker is not rocked into the connection position;
4. Secondary circuit of drawer-type breaker has bad contact;
5. The breaker fails to store energy;
6. The mechanism interlock actions and breaker has been locked;
7. The control voltage of closed electromagnet is lower than 85% of Us or closed
electromagnet is damaged;

8. Wrong connection of wires of user has lead to energized shunt release and tripping of the
circuit breaker.

Drawer-type circuit breaker cannot be rocked to the "connection" position; what is the
cause?
1. Foreign matter has fallen into the drawer base and stuck the rocking mechanism or the
rocking mechanism has jumping chain;
2. The rated current of circuit breaker does not match that of drawer base;
3. The operation is not in place; no "click" from two sides in the drawer base.

what are the common causes for contactor noise?

1. Power voltage is too low;
2. Magnetic system is skewed or mechanically stuck, which causes that the iron core
cannot be pulled level;
3. Iron core polar surface is rusted or has foreign matter (such as grease or dust) on it;
4. Short-circuit ring of iron core is fractured.

What are the common causes for damage to the contactor coil?
1. Low power voltage causes that iron core cannot be pulled normally, and the current in
the coil will rise sharply, resulting in overheated and burnt coil.
2. High power voltage (> 110% Us) leads to overheated and burnt coil.
3. Foreign matter has fallen into the contactor, which has demagnetized contactor coil and
caused too large gap; the magnetic circuit is not closed, the coil is overheated and burnt.

What are the common causes for thermal relay malfunction?

1. Setting current value is set too small;

2. The starting time of motor is too long;
3. The cross-sectional area of connection wire is too small;
4. Strong shock and vibration;
5. Frequent reversible operation and jogging.

Main causes for and solution to the malfunction of residual current circuit breaker:
1. Operating current is selected too small;
When selecting operating current, it should be higher than 2-4 times normal leakage current in
circuit. If normal leakage current of the electronic equipment is larger, the equipment on each
circuit cannot be too many, and the total leakage current should be lower than the rated nonoperating current of RCD. For example, the leakage current of a desktop computer is 3-4mA, so
the number of computers connected to 30mA RCD circuit should not be more than five.
2. Improper use of residual current circuit breaker may cause malfunction;
When a three-pole earth residual current circuit breaker is used in a three-phase four-wire circuit,
as the normal operating current in neutral line does not go through zero sequence current
transformer, residual current circuit breaker will action once single-phase load is started.
Solution: A three-pole four-wire or four-pole residual current circuit breaker must be used for a
three-phase four-wire circuit.
3. Grounding of load-side neutral line behind the residual current circuit breaker causes
malfunction;
Grounding of load-side neutral line of the residual current circuit breaker will lead normal
operating current to the ground through the grounding point, causing malfunction of residual
current circuit breaker.
Solution: Connect the grounding wire to the neutral line on the power side of residual current
circuit breaker.
4. Leakage current and wire-to-ground capacitive current cause malfunction.

The load-side wire of residual current circuit breaker is long and is laid closely to the ground,
and there will be heavy wire-to-ground capacitive current, which may cause malfunction. Or the
earth leakage current may be heavy due to decreased insulation of load-side wire, causing
malfunction.
Solution: Use residual current circuit breaker with high leakage operating current or raise the
wires overhead.