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Voltage Surges Caused by Contactor Coils
Voltage Surges Caused by Contactor Coils
For photographic records a Leica camera is mounted in consistent results, owing to the time required for the coil
front of the end of the tube. The Elmar 5 cm. / 3 • 5 lens to become fully excited.
is fitted with a No. 2 front lens and is worked at full
aperture. The film found most satisfactory is the new (3) INVESTIGATION OF D.C. COIL CIRCUITS
Kodak "Fiurodak." The insulation which was breaking down was designed
The shutter is set for 1/20 sec. or £ sec, depending on to withstand a test voltage of 3 000 volts (r.m.s.), 50 c./s.,
the size of contactor. The shutter is tripped just before and was reputed to be perfectly safe up to 5 000 volts (d.c).
the opening of the coil circuit by means of the timing Rough tests from time to time on the coils of the contactors
equipment described below. concerned led the authors to expect that the peak voltages
likely to be encountered were of the order of 3 000, but
(2.3) Timing Equipment this figure was only an estimate.
This consists of a series of relays connected as shown in In order to check this the peak voltmeter was made and
Fig. 2. On pressing the "start" button, relay R^ picks up a very large number of tests were performed on a 220-volt
d.c. coil consisting of 17500 turns, No. 34 S.W.G. enamel-
covered wire having a resistance of 1730 ohms, mounted
Contact opens after on a 150-amp. mill-duty contactor; and tests were also
I time-lag
made on larger contactors. Typical results are given in
r^_. Releases
camera Table 1.
o—l shutter From this series of tests it is evident that the voltage
peaks are not unduly higher than might be expected.
Visual tests with the oscilloscope gave very similar re-
sults, although generally the peak voltmeter gave rather
higher values than the oscilloscope. A large number of
photographic records gave very similar results, and the
voltage wave, as shown by " a " in Fig. 4, is typical except
that the voltage and time scales vary with the size of the
contactor.
From these experiments it did not seem possible that
the peaks encountered could damage the insulation, but
Low-voltage &.c. To coil some rough oscilloscopic tests of an installation appeared
calibration supply on test to show that the peaks were much higher than those ob-
Fig. 2 tained in the laboratory. This led the authors to consider
the effect of speed of contact opening. A long series of
and is maintained through its interlock contacts and its tests was made with various master drums and limit
time-lag contacts until the time-lag contacts open. On switches, using both single- and double-break contacts and
releasing the'' start'' button, relay R 2 picks up. Relay R 2 operated at various speeds.
Table 1
SWITCHING PEAKS ON D.C. CONTACTOR-COIL CIRCUITS; COILS SWITCHED BY RELAY HAVING TWO
BREAKS IN SERIES (ALL TESTS MADE ON 220 VOLTS D.C.)
Size Type Core diam. Outside diam. Length No. of turns S.W.G. Resistance Peak voltage
energizes relay R3, which picks up. R 3 energizes the coil As was to be expected, the double-contact switch
on test. During the time period, contacts on Rj apply the generally gave greater peaks than the single-contact switch,
calibration supply to the oscilloscope plates. and high speeds gave high peaks. It is not possible to give
At the end of the timed period Ri drops out, and its figures for these tests, as at this stage of the investigation
"down" contacts close to energize the shutter-release the authors were endeavouring to arrive at the cause of
solenoid momentarily. R 2 and then R 3 drop out, and the the trouble and, if possible, effect a cure, so that qualitative
coil on test is de-energized. By suitable adjustment of the results were sufficient for the purpose. It was ascertained,
pull-off springs on relays R 2 and R 3 the shutter is opened however, that the peaks were not considered excessive
a few milliseconds before the opening of the test circuit. As consistently higher peaks were being reported from
A delay of about 10 sec. was found necessary to ensure site at this stage, it was considered that the method of
92 TAYLOR AND RANDALL: VOLTAGE SURGES CAUSED BY CONTACTOR COILS
installation must have something to do with the phenomena cables about 6 in. apart, running direct from the power
and that the capacitance of the cables was the most likely house, a distance of 200 ft., the only load on the feeder
cause. at the time being the contactor under test and the laboratory
As a rough test, the 150-amp. contactor coil was lighting.
connected to the switch through 10 yards of twin tough-
rubber-covered workshop flexible cable having a capa- (3.1) Methods of Reducing the Peak Voltage
citance of 0 001 fxF between wires. Tests with the The obvious method of reducing the peak is to connect
peak voltmeter immediately showed that the peak was a resistance across the coil terminals. This is based on the
practically doubled, and oscilloscope tests gave a voltage well-known law
wave-form generally as " b " in Fig. 4. A large number of Vx = V(r + R)/r
tests were made on the various sizes of contactor, and here
again the form remained, although the scales altered. where V = applied voltage, V{ = peak voltage, r = circuit
Tests were made feeding the circuit from both the switch resistance, and R = added resistance.
and the coil ends of the cable, with practically identical A resistance equal to the coil resistance will therefore pre-
results, so it appeared that the phenomenon was due to vent the peak from exceeding twice normal voltage, and a
capacitance. All subsequent tests were therefore made resistance in shunt of twice the coil resistance keeps the
with a bank of glass-plate condensers, of which one was peak below 3 times line volts, and so on.
infinitely variable. Unfortunately this method of reducing the peak retards
It was found that there was an optimum capacitance for the opening of the contactor. For many duties this does
each size of coil and that at smaller values the peak not matter, but if the contacts of the usual steel-mill type
diminished rapidly, but that with larger capacitance the are allowed to wear right down, the spring push-off may
peak fell off gradually. become so weak that the interval between switching off
The optimum capacitances for the range of coils tested and the opening of the contactor becomes a nuisance. For
are given in Table 2, from which it is evident that the worst certain duties a delay is advantageous, and on this type of
condition may occur in almost any installation having equipment a "slug" resistance is frequently fitted.
wiring external to the control panel, and on large panels A similar reduction of peak occurs if the contactor is
it may occur on the panet itself. fitted with an additional short-circuited winding. This
may be a normal coil short-circuited externally, but more
Table 2 frequently it consists of a copper tube slipped over the
SWITCHING PEAKS WHEN LINE CAPACITANCE IS PRESENT. magnetic core of the contactor, or a ring or rings at one
RECORD OF TESTS AT 220 VOLTS D.C. ON COILS AS end or both ends of the coil. Here again the delay in
IN TABLE 1, BUT WITH OPTIMUM LINE CAPACITANCE opening the contactor is in inverse ratio to the peak
voltage.
Optimum Peak Peak voltage As the contactors under test and the coils fitted to them
Size Type when core
capacitance voltage sleeve fitted were of standard manufacture, it was essential that whatever
was done should not interfere with the stock articles.
amp. volts volts There was room on the core ends to fit "slug" rings up to
150 Open 00015 5 750 •J in. thick, but copper sleeves could not be fitted between
150 Spring-closed 0 003 6 000 4 500 the coil and core except on the spring-closed contactors,
300 Open 0003 6000 which are designed to be slow releasing.
300 Spring-closed 0 0035 5 500 4 500 Tests with the slug rings £ in. thick showed a reduction
600 Open 0 003 6 250 of the peak to the extent of 10 to 15 %. Tests were made
600 Spring-closed 0011 3 000 with special cores and more slugging, which showed that,
1 200 Open 0012 8 250 with the type of contactor used by the authors' firm,
objectionable time-lags crept in.
It was suggested to the authors that a bank of selenium-
Experiments were made to find what effect the speed of thallium rectifier units with the elements mounted in
opening had on the peaks, and it was soon evident that opposition in pairs [see Fig. 3(b)] would act as an efficient
low speeds might be even more dangerous than- high safety valve. Tests were made with such a bank and no
speeds. Certain experiments led the authors to believe appreciable peak occurred, but the slugging was most
that as the speed of break is increased from a low value, the effective. Such an arrangement appears to be most suit-
peak passes through a series of minima and maxima; here able for industrial use with magnetic chucks, separator
. again, owing to lack of time, only qualitative results were pulleys and the like apparatus, where time of flux decay
obtained. does not matter, also for deliberately slugging relays. The
It was definitely proved that with very slow breaks very advantage over a copper sleeve is that the whole of the
large high-frequency oscillations could be set up, and on a core may be used to accommodate the exciting winding.
number of occasions the effect was so great that gas-filled This means either fewer watts in the coil or a shorter iron
lamps in the laboratory flashed across inside the envelope, circuit. There is also a very decided advantage over a
and in a couple of instances they were "blown." This resistance shunt, as practically no loss occurs in the rectifier
occurred when experimenting with the 600-amp. and discharge-path. Rectifier discharge-paths of the copper-
1 200-amp. contactors. It is thought that the blowing of oxide type have been much used, but as far as the authors
the lamps occurred owing to the inductance of the mains are aware they must be connected with the correct polarity
feeding the laboratory. These consist of two separate [see Fig. 3(o)]. With industrial control gear, which is
TAYLOR AND RANDALL: VOLTAGE SURGES CAUSED BY CONTACTOR COILS 93
Fig. 5. The large high-frequency component in " b j " and (4.1) Reducing the Peak Voltage
the very high peak in "b 2 " are especially interesting. Tests with a Metrosil discharge block reduced the peak
to something approaching the peak value of the applied
(4) TEST ON ALTERNATING-CURRENT COILS voltage. Fig. 6(c) is typical, but not the worst case.
During the investigation of the d.c. switching peaks a Tests with a suppressor reduced the peaks still further,
series of insulation breakdowns occurred on a.c. circuits, and no peak has been observed in excess of 125 % of the
and the authors were asked to investigate the possibility of maximum value of the applied voltage. A typical form
high-voltage switching peaks occurring with a.c. contactor is shown in Fig. 6{d). The suppressor does not appear to
coils and small tractive solenoids. Whilst it was realized quench the arc at the contacts as completely as it does in
that such peaks were likely to occur from time to time, it the case of d.c. coils, but this may be due to the optimum
was expected that the investigation would be extremely value of the discharge resistance not having been found.
arduous, as the coil under test might be switched off at any Much more investigation is required on this point.
part of the cycle. A few oscilloscope tests were made on
the coil of a standard 15-amp. contactor. The coil con-
sisted of 4 700 turns of No. 42 S.W.G. enamel-insulated (5) COMPARISON OF THE VARIOUS TYPES OF PEAK
wire, having a resistance of 1 200 ohms. This coil is
designed for use on 400 volts, 50 c./s., but as it was found (5.1) Direct Current
essential to keep one end of the potential divider at earth When the switch is connected to the coil without capa-
potential it was not possible to use the full voltage owing citance an arc which is of a pale green colour is drawn at
to lack of apparatus. All tests were made on 340 volts, the contacts (silver); and with the double-break contacts
which gives a crest voltage of practically 500. used, having an air gap of \ in. at each contact, the arc
These preliminary tests snowed that voltage peaks appeared to extend to the full extent of travel before ex-
occurred with considerable regularity, and values up to tinguishing. While the arc was burning, the voltage rose
1 250 volts were observed, but of course it is not possible irregularly to a peak at fhe moment of breaking.
to say that this represents the maximum peak. Photo- When capacitance is present the arc is of a greenish blue
graphs were taken and a typical trace is shown in Fig. 6(a). colour and is much more brilliant and concentrated. • In
this case also the arc appears to extend to the full travel.
3000i- Practically all photographs show that during the arcing
period there is a high-frequency component which appears
as a blur covering several hundreds of volts in certain cases.
2000- Certain observers have noticed a distinct whistle. Where
(»)
the time scale of the oscilloscope has been opened up,
1000- this oscillation is resolved and may be clearly observed
visually, although with the apparatus available it is not
_ ^ 6 5 10 possible to obtain photographic records.
Milliseconds Rough tests with the coil under test laid on the bench
show oscillations of similar form and probably similar
2000 2000 frequency, so it is possible that during the arcing period the
coil behaves as if the iron circuit were missing.
(d) No traces have been observed of oscillation after the
1000 1000 rupture of the arc. This is doubtless due to the high
relative resistance and to damping in the non-laminated
iron of the core and frame.
0 5 10 0 5 10 In the case of the coil shunted with a Metrosil block the
Milliseconds Milliseconds
arc is similar to that which occurs with the coil alone. The
Fig. 6
trace is also similar, but the peaks are rounded off, the
main peak at rupture of the arc being more rounded than
As would be expected, all sorts of conditions varying from the smaller peaks which occur during the arcing period.
zero to the maximum were observed from time to time, but When a suppressor is used the arc is non-existent, and
those which were not zero showed this general form. there is usually only a feeble spark rather like the spark
From the d.c. experiments it was anticipated that the which occurs when a circuit of, say, 100 ohms is switched
addition of capacitance would increase the value of the off a 6-volt battery. In many instances the spark is not
peak, and this was found to be the case. As for d.c. coils visible. The trace, shows that the circuit is broken practi-
the peak increased to a maximum with increase of capaci- cally instantaneously. The characteristics just discussed
tance, and then slowly decreased. This conclusion was apply to conditions where the capacitance is the optimum
not arrived at from a few isolated tests but from a series or greater; but where the capacitance is less than the
of several hundred experiments. It was found that if a optimum the conditions approach those of the Metrosil
d.c. equivalent to the r.m.s. sealed current (i.e. current with block alone.
iron circuit closed) was passed through the coil, a few tests
with increasing values of capacitance enabled the optimum (5.2) Alternating Current
condition to be found with ease. The characteristics of the traces of the four circuit con-
Photographs were taken, and Fig. 6(b) is typical but not ditions (coil only, coil and condenser, etc.) are very
a true maximum. similar to those of the d.c. conditions, but as the contacts
TAYLOR AND RANDALL: VOLTAGE SURGES CAUSED BY CONTACTOR COILS 95
may open at any part of the cycle the peak value may Table 4
vary from zero to a maximum. The maximum occurs SOLENOID 2 IN SUPPRESSED CONDITION
when the arc occurs at the point of maximum current.
Owing to the low power factor of the load, maximum volts
current occurs near zero voltage. •1 250 X — —
-t
When line capacitance is present the coil-capacitance cir- 1 000 X X X X
cuit oscillates, as is shown clearly in the photographs 750 X X X X
referred to in Section (4).
x = Flash. — = No flash.
(6) TESTS OF A.C. SOLENOIDS INSTALLED ON * Reading checked at J-hour intervals up to 30 readings in 3 hours and no
MACHINE higher peaks observed,
t Flash very faint, indicating a reading just in at this point.
A series of tests in the field were made using the peak
voltmeter on an installation comprising a number of small (7) CONCLUSION
a.c. solenoids which were wired to a contactor panel by In conclusion the authors hope that this paper will shed
means of a tough-rubber-covered twin cable. The tests a little light on the large number of mysterious breakdowns
were carried out over a period of 2 days and typical results of contactor coils and other insulation troubles which are
on a machine are shown in Table 3. These tests show that only too familiar to the manufacturers and users of auto-
peak voltages of the order of 3 000 volts occurred fre- matic control gear, and that some investigator with suffi-
quently, with occasional extra high peaks of as much as cient time and really good apparatus will be sufficiently
6 000 volts. interested to make a full study of the phenomena. Control-
Table 3 gear designers are always being asked to reduce the
clearances of their apparatus in order to reduce the size,
TYPICAL PEAKS TAKEN ON A 400-VOLT 3-PHASE 50-C/S.
but it is obvious from these tests that clearances which are
MACHINE BY MEANS OF THE PEAK VOLTMETER
satisfactory for electric lamps on 230 volts are totally
inadequate for coil circuits even on 100 volts, and that on
Solenoid 1 Solenoid 2 Solenoid 3 higher voltages it is essential to have large clearances and
creepage distances. Instances are known of sparks jumping
volts volts /olts distances of as much as § in. along the surface of slate on
3 250 — — — — 6 750 x x x x 1 750 — — — —
control panels connected to 550-volt tramway supplies.
3000 X X — X Limit of range 1 500 X X X X
of instrument
2 750 X X X X 1 250 X X X X (8) ACKNOWLEDGMENTS
2 500 X X X X 1 000 X X X X The authors wish to thank the directors of the Igranic
Electric Co., Ltd., for permitting them to publish this
paper and for their encouragement throughout the course
Flash. No flash.
of the investigation. They also wish to thank those friends
Solenoid 2 was fitted with suppressor apparatus after this who, from time to time, assisted them with suggestions,
test and new readings of peaks taken are given in Table 4. criticism and material.