Coil-Hold-in-Devices (Coil-Locks®)

A cost-effective, low intrusive way to

protect your vital equipment from
voltage sags and dips

Electric Power Voltage

Sag Solutions
1
 SUMMARY

Starting System 3

Fault Transients 4

Effect of SAG 7

Problem of SAG 8

PQSI Coil Lock® 9

Installation Manual 11

Application in Power System 13

Field Installation 14

2
 Starting System

Direct on-line Star-delta Autotransformers

Motor Standard Standard Standard
Motor starting current 5 to 10 RC 2 to 3 RC 1.7 to 4 RC
Voltage and current harmonics High Moderate Moderate
Power factor Low Low Low
2-3 times more
Number of starts available Restricted
than DOL
Available torque Approx. 2.5 RT 0.2 to 0.5 RT Approx. 0.5 RT
Thermal stress Very high High Moderate
High on connection Low; precautions to take
Voltage dip High
change in DOL connection

3
 Fault Transients

1 Single phase to Ground faults

Figure 1(a)

Figure 1(b)

For simulation it is assumed that a single phase fault has appeared on phase A . Phase
voltages Waveform, rms voltages, and their phase angles are shown in Figure 1. The
waveform shown in Figure 1 shows an overvoltage at the end of the sag in faulted phase A.
This overvoltage is almost certainly related to the cause of the fault. The voltage of phase A
drops nearly zero is up to 0.2 pu, while phases B and C voltages normally remains pre fault
level as shown in figure.

4
 2 Phase to Phase faults

Figure 2(a)

Figure 2(b)

In addition to single phase-to-ground faults, the phase-to-phase faults also cause voltage
sag. However, characteristics for magnitude changes and phase-angle jump are not similar
to those of SLG faults. Figure 2 shows the voltage waveform, rms voltage and phase-angle
jump characteristics for phase voltages due to phase-to-phase fault between phases B and
C. In Figures 2(a) and (b), magnitudes and phase angles of phases B and C, with a large
voltage drop in the two phases Vb and Vc but phase voltage Va remains unchanged. The
phase voltages drop in magnitude Vb = 0.63 and Vc = 0.39 pu.

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 3 Two phase to Ground faults

Figure 3(a)

Figure 3(b)

A voltage sags due to a two-phase-to-ground fault between phases B, C and ground. The
voltage waveform, rms voltages and phase-angle jump are recorded at the pcc as shown in
Figure 3. This shows a significantly large drop in rms voltage in the faulted phases B and C,
but no change in phase A. The phase voltages drop in magnitude Vb = 0.2 and Vc = 0.2 pu.

Detailed simulation result of faults shows that voltage dip in phase is in between 50% to
80%. Fault transients could sustain for many frequency cycles depending on line parameters
and could cause serious problems in contactors and relays. Such voltage drop deteriorates
the performance of contactor coil and could cause the unusual supply interruptions.

6
 Effect of SAG

Effect of voltage sag

 Lose contact
 Electromagnetic interference
on contactor coil

 Arc Production between contacts

 Unwanted trips during voltage sag
 Malfunction of contactor
 Fire Hazard

7
 Problem of SAG

Detailed study had been carried out on contactors behavior on voltage sag. Below figure
shows that contactor coil attraction force drastically reduces as supply voltage drops
(figure reveal that attraction force is reduce 60% compare to 40% drop in voltage).If the
voltage fall below 50% the contactor loose its contacts.

On the occurrence of short circuit, the voltage at the point of fault falls to zero and the
current in the network increases abnormally to a higher value, but in overload current is
above rated value(125% to 150%) and cause excessive voltage dip.

In certain industries short overload period of load (motoring, lighting, heating) usually
occurs, during overload period the current increase above full load rated value. Higher
current produce abnormal voltage sag in supply lines, if the load is fetching through
contactor, condition could become even worse. Contactor loses its contacts, as the
voltage sag is in between 40% to 60 %( as the pick-up value of contactor fall below the
designed value). Generally voltage sags occurs many times lasting for time range in
between 10 mille sec to few sec depending upon overload period. Our product PQSI coil
lock® helps to sustain the supply, holding the contactors even if the voltage sag is in range
of 75%.

Comparison between the strength characteristic and the mechanical characteristics of

the drive coil at different voltage supply.

8
 PQSI Coil Lock®

1 Coil Lock® Application

Relays, contactors, and motor starters are used extensively in commercial and industrial
facilities to control business machines and process equipment. These devices often have
a low tolerance to electric service voltage sags, and are diagnosed as “weak links” in
automated production lines.
During common voltage sags, the
solenoid coils in these motor-
driven systems may de-energize
long enough to cause the power
circuit mechanical contacts to
open, and the connected
electrical equipment to shut
down. This situation can disrupt
business operations and impact
an entire manufacturing facility.
The Coil-Lock eliminates costly
process downtime, installs in
minutes, and can be a cost-
effective alternative to other voltage sag protection methods. The Coil-Lock product is
available in different models to be compatible with most relays,
contactors, or solenoid coils, and is ideal for protecting master
control relays, and E-stop circuits. The Coil-Lock is designed to
ensure that at any time input voltage is present (down to ~25% of
nominal voltage), the protected AC coil will maintain enough energy
to hold-in the critical process element. When the input voltage goes
below 25% of nominal, the Coil-Lock releases the coil, thereby
ensuring that safety is not compromised, and the “on/off state”
operation of the existing process functions as intended. The key to
properly applying Coil-Locks is to determine the DC resistance of
the AC coil of the relay/contactor unit you want to protect from
deep voltage sags. Once you have the AC coil’s DC resistance value,
the next step is to select the appropriate model Coil-Lock listed on
the back of this brochure.

9
 3 Coil Lock® Specifications
Momentary Voltage Sag Range: Provides continuous output voltage to hold-in relay and
contactor coils for all IEEE Std.P1159 defined voltage sags to approximately 25% of
nominal

Interruption Ride-Through Range: Designed to act as a discrete on/off device and will
turn off the coil voltage if the Coil-Lock input voltage is interrupted for a few cycles
(depending on the relay/contactor rating and vendor model)

Coil Inrush Current: Provides required high inrush coil current during startup

Transient Surge Protection: Provides transient voltage surge suppression for the
relay/contactor coil circuit

Transient Surge Withstand: Designed to survive ANSI/IEEEC62.41 Category A and

Category B defined transient voltage surges to 6kV/500A

Applied Environment: Designed to be compatible with stress and vibration common to

typical commercial and industrial applications

Ambient Temperature Operating Range: 10° C (14°F) to +55° C (131°F)

Steady-State Operating Voltage Range: Designed to operate normally within ±10% of

nominal coil voltage

4 Coil Lock® Models

240V Models Models*
(All Coli-Locks Include Din-Rail Octal Mounting Base Socket)
AC Coil Resistance
Models Number Comments
Measured w/DC Ohmmeter
1001-240V 601 to 17.5k Ohms UL Complaint File E255764
1002-240V 155 to 600 Ohms UL Complaint File E255764
1003-240V 20 to 154 Ohms UL Complaint File E255764
*For use with 200 - 240 V ac 50/60 Hz relays and contactors only

5 PQSI coil lock® Warranty

Unconditional free Coil-Lock replacement for one year from date of purchase. Neither
PQSI nor its business associates are responsible for any production loss or damage
caused by a Coil-Lock misapplication or Coil-Lock failure.

10
 Installation Manual

1 PQSI coil lock® Installation

Step #1 – Remove wires A and B, shown in
Figure 1, from the relay/contactor coil and
connect to octal mounting base socket
terminals 1 and 2, shown in Figure 2.

Step #2 – Connect new wires from the

octal mounting base socket terminals 3
and 4 to the relay/contactor where you
removed the wires in Step #1.

11
 Step #3 – Figure 3 shows the physical orientation, locations, and terminal numbers of
the octal mounting base socket to provide a clearer understanding of terminal
connections.

2 Application Advisories & Notes

a) Coil-Locks are intended to interface with AC solenoid coil operated devices and
may not be compatible with DC coil operated devices or coils that have integral
electronic circuitry as part of their operating strategy.
b) In some AC coil applications, coil energy “discharge” devices such as rectifier
diodes are pre-wired across the AC coil. These devices should be removed
before installing the Coil-Lock. After the Coil-Lock is installed, the Coil-Lock’s
internal circuitry provides the required AC coil discharge feature.
c) For proper Coil-Lock operation, observe conventional isolation and grounding
techniques on all Coil-Lock terminal points and avoid any “sneak” ground
paths.
d) [d] The Coil-Lock should be installed in an electrical / fire enclosure that
complies with the applicable safety standard.
e) Safety Caution: Read all instructions thoroughly prior to installation. If this
equipment is used in a manner not specified, the protection provided by this
equipment may be impaired.
f) Safety Caution: Risk of electric shock if this equipment is not connected in
accordance with Figures 2 and 3 below.
g) [On equipment with LEDs to indicate the coil device is energized, while the coil
device will operate properly, the LED may not illuminate, since the Coil-Lock
output voltage is pulsed and polarized.

12
 Application in Power System

Power System Automation: Relays, contactors and motor starters are used extensively
in commercial and industrial supply panels to control business machine and process
equipment. These devices often have a low tolerance to electric services sag, and are
diagnosed as “weak links” in automated power lines. During common voltage sags, the
solenoid coils in these motor driven systems may de- energize long enough to cause the
power circuit mechanical contacts to open, and the connected electrical equipment to
shut down. This situation can disrupt electrical supply operation and impact entire
power systems. PQSI coil lock design to ensure that at any time input voltage is present
(down to 25% of nominal voltage), the protected AC coil will maintain enough energy to
hold in the critical process element. When the input voltage goes below 25% of nominal,
the Coil-Lock® releases the coil, thereby ensuring that safety is not compromised, and
the “on/off state” operation of the existing process functions as intended.

Industrial Motoring Loads: Over 80% of electrical load are motoring load and are
dominantly of Induction type .Induction motor draw 5 to 8 times full load current during
starting period, motor high inrush current lead to severe voltage dip in lines and can
sustain for large times (switching transient may sustain for 10 mille sec to 100 mille
sec).Such voltage dip could disengage the contactor coil and interrupted supply. PQSI
coil lock® is useful for motors rating 3KW to 650KW having supply with contactor coil.

Heating Loads: heating load (Furnaces, Industrial heater) are prone to excessive voltage
dip in supply line, thus affect performance of heating .PQSI coil lock® helpful in heating
load if supply is given through contactors.

Lighting Loads: Industrial lighting are of high rating are supplied electricity through
contactor, and are readily switched off if supply goes off below permissible level. PQSI
coil lock® helps in sustain the supply to luminaries and lighting load.

Substation Panels: Transformers are source of high inrush current when energize.
Transformer switching transient current could reach to 10 time full load current. Such
current could sustain for few second depending upon line parameter and produce heavy
voltage drop which affect the distribution network. PQSI coil lock® helps substation
panel equipment to sustain supply and ensure proper working of control panel.

Capacitor Banks: Capacitor banks in utilities and substation for power factor
improvement. Capacitor bank produces inrush current in supplies line and produce
voltage drop .High stress on the contactor reduces lifetime, welding or fast wear off the
main contacts of contactors. Capacitor banks are energized through contactors which
are goes through high voltage dip. PQSI coil lock® help contactor to hold contact even in
severe voltage sag.

13
 Field Installation

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