PREVENTIVE MAINTENANCE & ROUTINE INSPECTION OF CONTACTORS

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Preventive attention is better than cure.
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PREVENTIVE MAINTENANCE & ROUTINE INSPECTION OF CONTACTORS
A. B. GENERAL INSPECTION:
A.1. Check for loose, missing, broken or corroded hardware, pivot pins, cotter pins, springs and other mechanical parts.

ARC BOXES:
B.1. B.2. B.3. Check arc boxes for broken or eroded parts and Grid plates and also for excessive collection of contact material or other foreign conducting material on the surface of insulating parts. Replace broken or badly eroded parts. Clean or replace parts having excessive build of conducting material.

C.

CONTACTS:
C.1. C.2. C.3. C.4. C.5. Remove oxide or large beads of contact materials from the faces of contacts, using a fine file or sandpaper.(Emery cloth should not be used for cleaning contacts.) Do not file or sand silver or alloy contact faces unless considerable foreign matter has collected on the surface of the contacts. When replacing contacts or other current-carrying parts, clean surfaces, which are to be bolted together. Realign contacts and set over travel if necessary. Do not substitute contact material without factory approval.

D.

SHUNTS:
D.1. D.2. Replace shunts having broken of frayed strands. Clean connection points if current-carrying parts are discolored.

E. F.

BLOWOUT COILS:
E.1. Inspect blowout coils for discolored connections, shorted turns, and loose hardware.

TERMINALS, CNTACT SUPPORTS, BUS BARS, AND CONNECTORS.
F.1. F.2. Discolored connections usually indicate that overheating has occurred, probably because of loose connections. Clean connection points which are discolored and tighten all hardware.

PERFECT ELEKTRO MEK PAKISTAN Perfection with convenience

Suit # 5, 2nd floor Business Arcade, Defense More Walton Road, Lahore-Cantt. Ph. 042-668-0902/03. Fax: 042-668-6685. E mail: pempak@hotmaul.com

Megger insulation between phases. The magnitude of the report and arcing found on opening and closing will depend upon the type of contactor.4.2. Since no absolute standard can be set for covering this detail. and hardware. I.3. Operate armature by hand and check for mechanical interference and friction. check for abnormal Magnet noise. Check for loose. Correct coil voltage. 042-668-0902/03.com . broken. J.1. and other moving parts. I. or replace interlock and series resistance so that continuous rating of coil is not exceeded when armature is sealed. to ground. Before a repaired part is put into service give it an over voltage test. 2nd floor Business Arcade. residual shims. replace the defective parts. operating load. H. Coil voltage is too high. The following table will be of great help in trouble shooting of contactors: Trouble/Defect Cause MAGNET. Protective resistance or high resistance winding is not Inserted in series with d-c coil when armature seals in. and phase angle at which the contacts separate or touch. Remove dust and dirt from insulating parts. I.2. E mail: pempak@hotmaul. Page # 2/5 G. INSULATORS. Fax: 042-668-6685. Test a sample of oil used with oil-immersed contactors and fill oil tank to the proper level with good oil. G. As a last resort. G.1.3. G. Defense More Walton Road. repair. MAGNET ASSEMBLY. PERFECT ELEKTRO MEK PAKISTAN Perfection with convenience Suit # 5. Lahore-Cantt. What to do/Remedy Replace.1. it will be necessary to judge performance on the basis of past experience with equipment when it was new or with other applications having similar equipment and operating conditions. H. Operate the contactor electrically without load and observe magnet operation to be sure it opens and closes cleanly and that armature is fully sealed in the closed position.PREVENTIVE MAINTENANCE & ROUTINE INSPECTION OF CONTACTORS: Preventive attention is better than cure. A Loud report and arcing on closing is usually due to contact bounce. I.4 Check magnet for dirty or corroded pole faces. Mechanical damage.3. If an a-c magnet is used. Inspect operating coil for evidence of electrical or mechanical damage. or missing shading coils. Operate the contactor under load and check for abnormal report and arcing both on opening and closing. If carbonized tracks or cracked or broken insulators are found. Sl A. pivot points. I. Use higher-voltage coil. H. Coil Burned out. Ph. ELECTRICAL OPERATION. G. and to the control circuit.4. H. 01 ELECTRICAL OPERATION. H. carbonized tracks may be scraped clean and painted with insulating varnish. Adjust.2.

Adjust. Ph. Check factory for special coil. drops open to contact touch. Re-adjust operating cycle. Replace residual shim or magnet assembly. Relocate starter. Repair or replace relay. 03. Use lower-voltage coil. or series resistance is too high (For DC Magnets). Residual air gap is pounded down. (DC Magnet) Shading coil broken or out of place. Check mechanical operation by hand and make necessary Adjustments and/or repairs. Coil voltage too low. Repair or replace relay. Coils of two-coil d-c magnet have bucking polarity. Jogging duty is too severe. Adjust spring length if adjustment is provided. Correct coil Voltage or System Voltage. or Dirt or grease on pole faces. Contact force too high. 042-668-0902/03. Defective coil. PERFECT ELEKTRO MEK PAKISTAN Perfection with convenience Suit # 5. 2nd floor Business Arcade. E mail: pempak@hotmaul. Abnormal atmosphere. Readjust operating cycle.com . Check mechanical operation by hand and make necessary adjustments and/or repairs. Use nonmagnetic-armature-stop details.PREVENTIVE MAINTENANCE & ROUTINE INSPECTION OF CONTACTORS: Preventive attention is better than cure. Intermittent coil is energized too long.) Mechanical interference or friction. Add nonmagnetic Shim between armature and armature stop. Correct coil voltage or system Voltage. Adjust or Replace. Replace coil. Series protective resistance or high-resistance coil winding is inserted too early. dropout is sluggish. hesitates at Contact touch. repair. Reverse polarity of one coil and check operation with load disconnected. Kick out spring is defective or missing. Provide better ventilation. 02 Does not pick up. or replace interlock and/or series resistance. Does not dropout. Fax: 042-668-6685. Add contact in control circuit. Ambient temperature is too high. Check factory for special coil. Remove friction from moving contact assembly. Replace. Clean. Defense More Walton Road. Residual shim is pounded down or is missing. Mechanical interference or friction. Magnet chatter or Shorted coil turns. 04. Relocate starter. Replace (Kick out spring is not used on all contractors). Replace springs. Low voltage. (This condition may exist only when operating coil is hot or line voltage is low. 05. Does not seal. Mechanical interference or friction Magnetic lockout. Check factory for special coil. Check mechanical operation by hand and make necessary adjustments and/or repairs. Lahore-Cantt. Control relay does not open d-c side of rectifier. Control relay has long arcing time.

Ambient temperature is too high. Defense More Walton Road. Armature does not seal in tight. replace contacts. Load current too high. Noisy a-c magnet. Correct coil over voltage condition. Reduce load. Use dust -tight enclosure for dusty atmosphere. Remove mechanical interference and/or friction. Use larger contactor. Contact bounce on closing. Over travel and/or contact force is too low. Magnet chatter. Adjust over travel. Line and/or load cables are too small. pumping. Move control device to a location having less vibration. and replace contact Springs as required to correct defect. File pole faces as a last resort If new parts are not available. Contacts. PERFECT ELEKTRO MEK PAKISTAN Perfection with convenience Suit # 5. E mail: pempak@hotmaul. Apply cable in line with existing load. 06. B. Magnet drops open at contact touch due to voltage dip. See Magnet. 02. Clean with fine file or sandpaper. Load is on in excess 8hr. Loose connections. Shading coil broken or out of place. Pole faces rough.com . Magnet stalls or hesitates at contact touch point.) Chattering contacts on control relay. Loose connections. Ph. Lahore-Cantt. 01. Change operating procedure. Collection of copper oxide or foreign matter on contact Faces. Replace control device. or series resistance is too high or is open. this table. Overheating. Adjust over travel. Check over travel and contact force on control device. See Magnet this table. Coil voltage is low. temperature switch. Fax: 042-668-6685. replace contacts. Correct coil voltage or system voltage. Pressure switch. Clean pole faces. Magnet misaligned. control switch. Relocate starter. Check factory for more Suitable contacts Reduce load. Use larger contactor. Replace magnet assembly. this table. 2nd floor Business Arcade. Repair or replace interlock and/or series resistance. Replace. Tighten connections. (Applies to DC magnets having over voltage during Pickup. Welding of contacts.PREVENTIVE MAINTENANCE & ROUTINE INSPECTION OF CONTACTORS: Preventive attention is better than cure. etc. Series protective resistance or high-resistance coil Winding is inserted too early. Realign. Over travel and/or contact force too low. or insulate control device from shock And vibration. 042-668-0902/03. Correct mechanical defects. Clean discolored or dirty Connections and retighten. Adjust. and replace contact spring See Magnet. Provide better ventilation.

Magnet opening is sluggish. Clean or replace insulating parts having a heavy Coating of foreign conducting material. Use larger contactor. Poor arc interruption. Fax: 042-668-6685. Check factory for more durable contact material. See Magnet. Check factory for more weld-resistant contact material. ARC INTERRUPTION Arc box not in place. Insulate starter from shock and vibration. C. Correct mechanical defects in stop assembly. Install arc box in line with instruction-leaflet data. Remove insulating materials. 2nd floor Business Arcade. which may have accumulated on arc horns and steel grid plates. hardware in arc box and blowout assemblies. Air break contactors may have 10 to 20 times longer contact life than oil-immersed contactors of equal ratings Vibration in starter mounting. Use larger contactor. Provide more rigid Support for starter. Move starter to location having less shock and vibration. this Table. Replace broken or eroded insulating parts. Replace coil. Defense More Walton Road. Reduce jogging cycle. Check factory for more weld-resistant contact material. Reduce jogging cycle. 042-668-0902/03.com . Poor contact alignment.PREVENTIVE MAINTENANCE & ROUTINE INSPECTION OF CONTACTORS: Preventive attention is better than cure. Oil-immersed contactor is used where an air break Contactor could be used. PERFECT ELEKTRO MEK PAKISTAN Perfection with convenience Suit # 5. Lahore-Cantt. Arc box damaged. Correct Mechanical defects in latch if one is used. Jogging cycle is too severe. Use larger contactor. Readjust accelerating time or operating sequence. Adjust contacts to touch simultaneously within 1/32 in. Correct defect. Jogging duty is too severe. Contacts rebound to contact touch when opening. Blowout coil reversed or short-circuited. Excessive inrush current. Dirt or paint on arc horns or steel grid plates. Ph. Magnetic hardware substituted for nonmagnetic Replace with correct hardware. and grid plates. arc horns. E mail: pempak@hotmaul.