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Contact Tip Inspection
Contact Tip Inspection
Contact Tip Inspection
These contacts are both considered in good condition (source: ABB Guidelines for Contactor inspection and maintenance). The major difference is that the contacts in photo #1 are the result of very low usage:
A contact tip is not worn out just because the surface is rough and discolored. In fact signs of wear are good because this means the contacts are electrically seated and match each other better than a new set. Different amounts of contact wear, both between the fixed and movable parts, and between different phases, is normal. Filing, grinding, and other attempts to restore contact surfaces actually cause more harm than good. Maintenance should be limited to inspection for the amount of wear to determine whether or not the contacts need to be replaced before the next inspection.
Replace components in complete sets to avoid uneven contact pressure. Photos below show progression. Early life in squirrel cage motor application:
End of life in squirrel cage application. Notice shoulders are gone on contacts on the left:
End of life in plugging application. Photo at right shows material on arc chutes.
2. Cracks on lower portions and portions outside the area where the arc is extinguished do not require replacement unless they are severe enough to possibly affect the ability of the assembly to stay in position and in one piece. 3. Surface chips, abrasions, and indentations do not require replacement. Chips shown below acceptable. As long as loose pieces do not have a chance to become an impediment to operation of the mechanism, they are acceptable.
4. When it is apparent that sections of the arc chute have broken off in pieces > square or there is a gap > 1/16 between sections, the arc chute should be replaced.