Ac contactor common faults and maintenance case analysis

1.introduction
Ac contactor is a kind of used to automatically connect or disconnect the large current
circuit of the electric equipment, it can frequently through or breaking the circuit, and
can realize the remote control. The main control object is motor, can also be used for
other load, has a large capacity of control, overload ability, long service life, economic
characteristics such as simple equipment, so they are widely used in electric control. Ac
contactor, however, because of its special working environment, hard to avoid can
produce all kinds of fault, if not timely and effective troubleshooting and ruled out, will
inevitably impact on the normal work of electric equipment, led to the serious
consequences of electrical equipment for burning.
2, common failure analysis
2.1 coil fault
coil burned for many reasons, such as the supply voltage is too high, more than 110% of
the rated voltage could be burnt coil. On the other hand, the power supply voltage is
too low, less than 85% of the rating may also be burned contactor coil, this is because
the contactor on the armature and not, smaller values of the coil circuit reactance,
current is too large. In addition, the power frequency do not tally with the rating, the
resistance to mechanical part card which causes polar surface uneven cannot absorb,
core and magnetic gap is too big, environmental factors such as poor ventilation,
excessive moisture, environmental temperature too high, can cause the failure. Coil
break line fault is often caused by burning coil overheating, may also damage caused by
external forces.
For different reasons, different countermeasures should be taken. If it is bad coil fault,
replace the same coil, core if there are any dirt or polar surface uneven, visual situation
clear pole face or replace the core.
2.2 ac contactor noise
Too big Power supply voltage is too low, contact spring pressure, core skew can be
caused by too much noise. Ac contactor to produce large noise, access to the main
reason is that the coil is alternating current (ac), suction is fluctuating, so can add on the
extremely short circuit ring, in order to avoid the generation of noise, and short circuit
ring fracture cause too much noise. Excluded methods for checking commonly short
circuit ring, adjusting spring, clean or polar surface grinding core, etc. Low voltage
power supply voltage than the required too much, of course, also can produce this kind
of phenomenon, therefore, should check the power supply.
2.3 contactor contact burning fast
Contactor contact burning fast itself quality problem, also have choose improper contact
ablation fast. Encounter this kind of problem, should first check whether the load current
is more than rated current contactor is too much, or if used to frequent starting, it is this
kind of situation, it should be replaced the large capacity ac contactor. If the object is a
three-phase motor, should check whether three-phase contact synchronization. If out of
sync, three-phase motor when starting in a short period of time belongs to the lack of
phase operation, cause the starting current is too large, should be adjusted.
In addition, you should check whether the contact pressure is normal, the contact
pressure is too small, will cause the contact contact resistance increases, cause contact
severe fever. Available note contact pressure method, the method is to take a slightly
wider than contact piece of paper, placed in contact between, when ac contactor is
closed if the strip is easy to take out that shows lack of contact pressure; If the strip
break, pressure is too large. Small capacity of ac contactor is a bit hard to pull the note
and note in good condition, the large capacity electric force can pull a piece of paper
but there is any breakage, think contact pressure is ok.
To touch head oxide layer, burning, or the problem such as burr, welding processing can
refer to the following:
(1) contact with oxidation layer,
if it's silver oxide are not removed, so the copper oxide, used a knife to gently scrape off;
If there is any dirt, can use dishcloth dip gasoline or carbon tetrachloride to clean it;
(2) contact burning or have burr,
should use the knife or files in contact surface repair. Repair without will contact
refurbished very smooth, because too much can make smooth contact contact surface
area decreases. In addition, don't use sand paper to mend the contact surface, in order
to avoid the corundum embedded contact, contact contact.
(3) contact if there are any welding,
must find out the reason and repair the change contact. In welding load or short-circuit
reasons, operating voltage is too low to make ac contactor and unreliable or vibration,
arcing equipment and contactor capacity is too small, and so on.
2.4 does not release or not Absorb
lack of reasons in addition to mechanical failure, low supply voltage, internal resistance
is too large, such as coil wire break is a major cause of this failure. Don't release or the
reason of slow release has contact spring lose elasticity or elastic is too weak to reset the
contact force and contact polar surface welding, core guide with dirt or core and core
demagnetization of air gap decreases when closed.
3, case analysis
Case 1: a CJ10-20 ac contactor, after electrify don't respond, not action.
Cause analysis: electromagnetic institutions, after electrify coil creates a magnetic field.
Under the action of magnetic field, fixed suction between armature and core, contact
action. The reason of contactor is not action after the power supply has coil break line,
power did not add, mechanical part jammed, etc.
Inspection method: first check the power supply, it is normal; Check the contactor coil
voltage on both ends of the wire, it is normal; To remove the power supply wire, check
the coil resistance, is infinite, determine the coil break line. Open the contact with the
bottom cover, take out the core, check the coil, found that lead from the base of
terminal broken reed, the rest intact. The reeds to welding, packed contactor, electricity
test, back to normal.
Case 2: a CJ10-20 ac contactor after electrify, coil inside there is a spark,
accompanied by a blaze phenomenon, contactor.
Cause analysis: is there a spark, to show that the contactor coil circuit contactor
electricity there is open circuit or short circuit phenomenon, beating with contactor,
shows that in the process of the coil current is discontinuous. Accordingly, the problem
should be out in the electric circuit.
Maintenance methods: open contactor, remove the iron core, check the coil circuit,
found between the coil wire and end reed has been broken. Just due to the elastic wire
itself, make beheaded still are connected to the end of the wire. When the contactor
action, by vibration was built
Into the coil circuit broken open, and broken ends in a spark. Remove the coil and the
circlip, weld test electricity after assembly, returned to normal.
Case 3: an internal combustion engine starter, after electrify can work, but only 25 v,
output voltage cannot meet the normal 36 v.
Cause analysis: low voltage for various reasons. This is a thyristor controlled dc power
supply, so it is possible that the cause of low output voltage are: (1) the low voltage
power supply; (2) transformer faults; (3) rectifier part of failure.
Maintenance methods: based on the principles of easy after the difficult ones first, first
check the power supply into line, the three-phase voltage between 380 v, it is normal;
After check spiral fuse power supply voltage, between three phase is 380 v, also the
result is normal; Final inspection input voltage transformer, except between U and V to
380 V, and the rest are not normal, is low. Check contactor main contractor, main
contact all have different degrees of the ablation phenomenon, there are a pair of
contact have burn out, can't get through. Replacing contactor, troubleshooting.
4, the conclusion
No matter what happens, in short, ac contactor faults, should first ascertain the fault
type and the causes of the fault may be, and then, on the principle of easy after the first
difficult, first check the coil, check the power supply and mechanical parts, after the last
adjustment, grinding, etc., avoid blind disassembly, artificial expand maintenance
workload and even human failure.