g GE Consumer & Industrial
GE Appliance Controls
GENERAL INFORMATION
3ARR2, 3ARR12, 3ARR12P, 3ARR18
Current Type Motor Starting Relays
General Description
GE Current Type Motor Starting Relays are
used for assisting in the starting function
of single phase AC motors of resistance
start, induction run; and capacitor start,
induction run types. Generally, the size of
the motor is limited to approximately 1/3
HP, 120 Volts AC and 3/4 HP, 240 Volts AC.
The most common applications are
household refrigerator and freezer
compressors, automatic dishwasher
motors, and automatic laundry motors.
Operation
The Current Type Motor Starting Relay
utilizes the changes in the main winding
current to actuate the relay contacts to
energize and de-energize the start
winding.
See Figs 1 and 2. The contacts of the
relay are open when the motor is
stopped. When the motor accelerates
from zero to full load speed in the starting
process, the main winding has an initial
current, or inrush current, which is high
due to the low impedance of the motor at
low speed. The relay responds to this
inrush current and closes the circuit to the
start winding. As the motor accelerates to
full load speed, the current in the main
winding decreases as the back EMF
increases, and the main winding current
falls below the dropout current of the
relay. At that point, as the relay drops
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out, the contacts open, de-energizing the
start winding.
The relay is designed for a specific motor
and application. Curves of Motor Speed vs.
Main Winding Current and Motor Speed vs.
Torque are utilized to determine the main
winding current at zero speed with
minimum expected supply voltage. This
value is the maximum allowable pickup
current of the relay. Also, the current at the
time the motor has sufficient torque to pull
the motor up to full speed on the main
winding alone must be determined. The
latter is the design minimum dropout
current of the relay and must be higher
than the main winding current at full motor
speed with maximum supply voltage.
Motor Starting or Running
Conditions
Generally, the motors using current type
starting relays do not require start
capacitors. However, for applications
where very high starting torque is required,
a start capacitor may be used.
Run capacitors have not been extensively
used in the past; however, in the moves to
improve motor efficiency, there are more
run capacitors being used, especially on
motors with PTCR starting devices.
However, it is not recommended to apply
both a start and a run capacitor. This
may cause a relay contact failure due to
welding if one capacitor discharges
through the contacts to the other.
Typical Circuit Diagrams
Design Features
The GE relays are air core, solenoid
actuated electromagnetic relays with
single-pole, single throw, double-break
contacts that are normally open. See Fig.
3. The contacts are actuated by a steel
plunger assembly. The line of action of
the solenoid is vertical. When the relay
coil is energized, the plunger assembly is
pulled up into the coil by magnetic action,
closing the double-break electrical
contacts.
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Gravity and contact spring force, acting on
the plunger as the current drops down
during acceleration, re-opens the contacts.
Because of this action, the relay must be
mounted in the vertical position in the
application.
Because the relay coil is in series with the
main winding of the motor, it sees the full
load current of the motor. Relays operate
on ampere-turns, and consequently with
relatively high currents, the number of coil
turns is very small compared to relay coils
intended for operation on voltage signals.
With the relay coil in series with the main
winding, the resistance of the relay coil
must be low so that it will not adversely
affect the performance of the motor. This
requires relatively large wire sizes to keep
the resistance low and to keep the
temperature rise of the coil low during the
motor running period. This resistance is
generally below 1/2 ohm.
Current Type Relays have an advantage
over thermal-resistive types such as
PTCR’s in that when the motor stops, it is
immediately ready for a re-start. No
cooling-off period is required before a re-
start can take place. It is an advantage,
especially in appliances where the motor
may cycle frequently.
Additionally, the Current Type Relay is
calibrated to respond to the speed and
torque characteristics of the specific motor
in the application allowing the motor
system to compensate for load variations
that cause variations in the starting time.
g Basic Current Type Starting Relay
Fig. 3
PTCR type starting devices are essentially
timing devices and do not recognize the
variations in the acceleration time of the
motor under varying load conditions.
Basic Model Types
There are three types of GE Current Type
Starting Relays available. All three are of
the same solenoid actuated types. Each
has special features for specific
applications.
3ARR2 - Utilizes auxiliary terminals for
wiring harness flexibility.
3ARR12 – More cost effective for specific
function. Has low and high contact rating
capability.
3ARR12P – Plugs onto motor connections
on compressor shells. Available in high
rating.
3ARR18 – For heavier duty relay
applications.
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GE Consumer & Industrial
GE Appliance Controls
Materials
Materials used in the relay are corrosion
resistant or plated for long life in typical
applications.
Case and cover materials are selected
based on the application requirements.
General Purpose Phenolic is the standard
plastic. Melamine Phenolic material which
has a much higher CTI is available for more
severe application conditions.
Electrical Contacts
The electrical contacts are silver/cadmium
oxide (Ag/CdO) composition for reliable
making and breaking of the start winding
circuit.
Terminal Options
There are several options of terminal types,
depending on the particular basic model
type (like 3ARR2, 3ARR12, and 3ARR18).
Quick-Connect terminals are the most
commonly used. However, screw type
terminals are available on some models.
See the specification sheet for the specific
model type.
On some models, there are spare terminals
for auxiliary connections.
For compressor applications, a “plug-in”
version of the 3ARR12 relay is available
which plugs directly onto the 3-pin
terminals on the compressor shell.
Relay Internal Circuits
The most common basic internal circuit
configuration for current relays is a three-
terminal, common coil and contact circuit.
A four-terminal, isolated coil and contact
configuration is available for use when a
start capacitor is employed.
Coils
All coil windings are Class B insulation,
and in combination with the case and
cover materials have an overall Class B
insulation rating with a maximum
allowable coil temperature of 110° C
when measured by the thermocouple
method.
A relay which is applied in a maximum 40°
C ambient is limited to a 70° C coil
temperature rise, and a relay which is
applied to a compressor shell, where the
ambient temperature may be 70° C may
be limited to a 40° C coil temperature rise.
It is important for the relay application
engineer to know the details of the
application requirements.
Mounting
A variety of mounting brackets and
mounting means are available depending
on the basic model type. See the
specification sheets for the basic model
types for the application details.
All relays must be mounted in a vertical
position so that pick up and drop out are
not restricted due to friction of the
plunger rubbing on the case.
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Electrical Contact Ratings:
3ARR2
20 Amps (max), 240 VAC, 60 Hz
13 Amps (max), 250 VAC, 50 Hz
3ARR12
13 Amps (max), 277 VAC, 50/60 Hz
3ARR12K
26 Amps (max), 277 VAC, 50/60 Hz
3ARR12 P and W (Plug-in)
13 Amps (max), 277 VAC, 50/60 Hz
3ARR12 KP and KW (Plug-in)
26 Amps (max), 277 VAC, 50/60 Hz
3ARR18
30 Amps (max), 277VAC, 50/60 Hz
Approvals
All current relay model types have
recognized component listings at U.L. and
CSA. Some basic model types have listings
at VDE under the IEC 730-1 and –2.
3ARR2, 12 U.L. File No. SA639
3ARR18 U.L. File No. E27551
CSA Included in U.L.
3ARR2, 12, 18 VDE Approved
General Application Considerations
The parameters and characteristics, which
must be evaluated for a satisfactory
application, are:
1. Motor Curves (Zero to Full Speed)
Max, Nom, Min Supply Volts
Motor Speed vs. Torque
(Starting and Running Conditions)
Motor Speed vs. Main Winding Amps
(Starting and Running Conditions)
2. Contact Rating Required
(See individual specification sheets
for available contact ratings.)
3. Coil Ampere Rating (Maximum Full
Load Main Winding Current)
g GE Consumer & Industrial
4. Relay Calibration
If customer has determined the
Maximum Pickup and Minimum
Dropout current values, coil group
can be selected from tables.
Otherwise, the Application
Procedure (see Appendix A) may
be followed using the Motor
Curves.
5. Mechanical Form
Basic Model Type
3ARR2
3ARR12
3ARR12P (Plug-In)
3ARR18
6. Number and Type of Terminals
Quick Connect or Screws
Common or Isolated Coil
7. Mounting Bracket Type
(Select from standard designs)
GE Appliance Controls
should be examined to see if the shapes of
the curves lend themselves to a good
application.
See Figs. 4 and 5.
These curves should be obtained from the
motor manufacturer who generally is
aware of the characteristics which facilitate
the application of current type starting
relays. See Figures 4 and 5 for typical main
winding current and torque vs. motor
speed.
To make a good application, the curves
should exhibit a significant change in main
winding current with a change in speed. If
the curves are "unusually straight", it is
difficult to make a good application. Since
the relay responds to changes in main
winding current, it is desirable to have a
significant change in current for a specific
change in speed.

8. Ambient Temperature at Relay

Determines allowable coil heat
rise.
Typical Remote Mount - 40° C
Typical Compressor Mount – 70° C

Endurance

100,000 to 500,000 operations depending

on relay type and load.

Motor Curves

Prior to beginning the procedure for

determining the functional characteristics
of the relay characteristics, the motor
curves for speed vs. main winding current
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Definitions:

Supply (Line) Voltage.

Value of voltage at the input terminals of

the motor. Specified as “Nominal”,
“Maximum” (+ 10 %), “Minimum”
(- 15 %).
Ims

Main winding current with start winding in

the circuit.

Imr

Main winding current with start winding

out of the circuit. Motor in the “run”
condition.

Transfer Speed

Speed at which start winding is

disconnected from the circuit and motor
will pull up to normal running speed.

Crossover Speed

Speed above which the running torque

exceeds the starting torque.

Coil Current Rating

Maximum current which is applied

to the coil when the motor is at full
speed with maximum supply voltage.
Coil temperature must not exceed
allowable winding temperature.

Pickup Current

Value of current in the main winding

at which the relay picks up, energizing the
start winding.

Must be less than zero-speed current with

minimum supply voltage.

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g GE Consumer & Industrial
GE Appliance Controls

Typical Motor Curves for Current Relay

Main Winding Current and Torque vs. Motor Speed

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Dropout Current
Value of current in the main winding
at which the relay drops out, de-
energizing the start winding.
Must be higher than the main winding
current at full load speed with maximum
supply voltage.
Electrical Contact Rating
The maximum start winding current with
maximum supply voltage and maximum
motor speed.
Application Procedure
General
There are various procedures used to
select the correct functional elements and
characteristics of the relay to be applied,
depending on the amount of information
available. The more operating
information available, the better.
Key information required to make an
application is the basic model type;
3ARR2, 3ARR12, 3ARR12P, or 3ARR18.
Within the 3ARR12 type, a decision is
required as to whether the “K” version is
required for a higher electrical rating of
the contacts.
A very important item of information is
the Motor Curves that the relay will be
used with. These provide the main
winding current vs. motor speed, and
torque vs. speed from zero to full speed
RPM. It is these curves which determine
the pick up and drop out specifications for
the relay.
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Other information required is the electrical
circuitry of the relay, mounting means,
numbers and types of terminals, etc.
The coil must withstand continuous main
winding current without exceeding the
allowable heat rise. Wire size can be
adjusted to meet the requirements. It must
also be of low enough resistance so that it
will not affect the motor performance.
Coils – General Information
The only real control of the calibration of
the relay is the coil design, which is “wire
size and number of turns”. There are only
minor adjustments to the plunger
assemblies which may be made . However,
the fact that normally, the only
specifications are maximum pickup and
minimum dropout. A correct coil design is
relatively easy to make.
Current Type Starting Relays involve
compromises to ensure that specific
performance requirements are not violated.
This means reviewing data and preliminary
calculations and refining them to provide
optimum relay characteristics.
Coil Group Selection
If the customer has already determined
what pickup and dropout currents are
required, coil design selection may be
determined by a review of coil designs
already on drawing, and selecting a coil
which fits the customer specification
closely. The customer can verify its
acceptability.
Each of the relay basic models has a
drawing listing all of the coils that have
been applied, along with the calibration
data, wire diameter and number of turns.
g
On current relays, coils are generally
listed as “groups”. However, unlike
potential relays where the coil is a
separate component, the current relay
coil is just wire wound around the body, or
case of the relay which is already
assembled with other functional
components.
Consequently, a coil group for a current
relay is a listing of the wire size, number of
turns, and the pickup and dropout current
values.
Calibration Specifications– From Motor
Curves
If a new coil design is required, samples
must be made and approved.
If calibration characteristics are not
known, the Motor Curves must be used to
determine the correct calibration for the
application.
The design procedure for current relay
coils is somewhat different from that of
the potential relay.
On a current relay, when the motor is
stopped, the relay contacts are open.
When the motor is energized, the relay
must pick up and close its contacts in
order to have the start winding in the
circuit during the starting operation. This
means that the pickup current must be
less than the current in the main winding
at zero motor speed.
The value selected must be for a hot
motor with the minimum expected supply
voltage. Normally, a safety factor is
added to keep the relay from dropping
out prematurely if there is a temporary
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GE Consumer & Industrial
GE Appliance Controls
“drop”, or “sag” in the supply voltage when
the motor is started.
For the dropout current, the dropout
current of the relay must be higher than full
load current (motor running) of a “cold”
motor with maximum expected supply
voltage.
It also must not be so high as to take the
start winding out of the circuit before the
motor has enough torque from the run
winding to bring the motor up to full speed
after the start winding is de-energized.
Because of the nature of the design and
the calibration requirements, the current
relay has a rather small differential
between pickup and dropout. Normally,
the pickup calibration will be within 2% to
10% of the dropout value.
Coil Design
Once the pickup and dropout currents are
determined from the Motor Curves,
reviewing the existing Coil Groups from
basic model types may yield a presently
used coil group designation.
Any coil which is selected from existing coil
groups or as a new design from the Motor
Curves must be evaluated for heat rise
when the motor is running at full speed.
The coil of the relay has main winding
current flowing at all times the motor is
running.
Once the coil wire size and number of turns
have been selected, the manufacturers full
load running current must not cause the
temperature of the coil windings to exceed
the maximum allowable. If the rise is too
high, then the coil must be made with a
larger wire size to reduce resistance.
Only the necessary increase in wire size
should be made, since larger wire sizes
increase the bulk of the coil. The size of
the coil must not be greater than the
dimensions of the relay.
Another consideration of wire size is that
the coil resistance should be maintained
at ½ ohm or less so that it does not impair
the performance of the motor.
Effects of Frequency (50/60 Hz)
In the case of current relays, the
frequency of the supply does not have
any significant effect on calibration or coil
rating as it does on potential relays. On
potential relays, where the coils have
many thousands of coil turns, the
inductive reactance makes substantial
effects on the electrical impedance of the
coil and consequently, on the calibration
and rating.
However, on current relays where there
are relatively few coil turns, usually 60 or
less, inductive reactive reactance is not a
significant factor. So it is ignored, and
relays can be used interchangeably on 50
Hz or 60 Hz, assuming that the
calibrations are correct for both
applications and the motor currents are
equivalent.
It should be noted that a 50 Hz , two-pole
motor has a synchronous speed of 3,000
RPM, whereas a 60 Hz two-pole motor has
a synchronous speed of 3,600 RPM.
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Mounting Location
The relay should not be mounted in a
location where there is close proximity to
large pieces of magnetic material which
may link the magnetic flux of the relay and
change the calibration If another location is
not possible, the calibration of the relay
may be modified to compensate for the
effect.
The relay should not be located where it is
subject to severe vibration or shock which
may alter the function.
The relay must be mounted in a vertical
position since gravity is the means of
dropping out, or resetting the relay for the
next cycle. If the mounting position is not
vertical, the plunger will ride on the inside
of the case where friction will affect the
calibration of the relay.
Mounting Brackets
Mounting means and brackets vary
depending on the basic model type. For
the 3ARR12 and 3ARR18 type relays, some
of the mounting brackets are
interchangeable.
See Appendix “B” for some typical
mountings for the various model types.
There are applications where the customer
provides the mounting means, and no
bracket is supplied.
If there are special mounting requirements
not covered by standard mounting means,
any special tooling will be the customer’s
responsibility.