WEBINAR TRAINING, 11 JUNE 2020

Selection of Contactor for motor protection and control

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การเลือกใช้งานคอนแทคเตอร ์ เพือการป้ องกันและควบคุมมอเตอร ์ให้เหมาะสม

ABB Electrification (Thailand) Co., Ltd.

Rangsan S., Charnchanok T. (Product Marketing Team)
Agenda and The key takeaways
6 : Webinar

60 Minutes after this session start included Question

The key takeaways

• Relevant IEC Standards
• Contactor selection
• AF Contactor range
• Coordination with Short Circuit Protective Device
• Online selection tools

June 11, 2020 Slide 2

About me
Product Marketing Team

Tour Rangsan Srikaew

15Y Sales and Product Marketing at ABB Low voltage product

Main product take care

• Motor starting & safety

• Control & protection
• Electronic relays and controls
• Safety products

June 11, 2020 Slide 3

About me
Service Engineer Supervisor

Kor Charnchanok Thongprad

13Y Join in ABB Service team

ABB Electrification Products Certificate

• Level 3 Expert to service low voltage circuit breaker
• First line commissioning and service training Terra
High Power Charger (HPC)
• ABB Ability EDCS
• Level 3 Expert in order to provide service on ;ABB’s
block contactors and softstarters

June 11, 2020 Slide 4

Motor Starting and its relevant IEC Standards
Standard for LV apparatus
IEC 60947 Standard for industrial application

IEC 60947
▪ IEC 60947-1 Part 1: General rules
▪ IEC 60947-2 Part 2: Circuit breakers
▪ IEC 60947-3 Part 3: Switch disconnectors
▪ IEC 60947-4-1 Part 4: Contactors
▪ IEC 60947-5-1 Part 5: Control circuit devices
▪ IEC 60947-6-1 Part 6: Multifunction devices
▪ IEC 60947-7-1 Part 7: Auxiliary materials
▪ IEC 60947-8 Part 8: Control units for built-in thermal protection (PTC)

June 11, 2020 Slide 6

Motor starting and its relevant IEC Standards

IEC60947-1
Low-voltage switchgear and controlgear – Part 1: General rules

IEC60947-4-1
Contactors and motor-starters – Electromechanical contactors and motor-starters

IEC60947-4-2
Contactors and motor-starters – AC semiconductor motor controllers and starters

IEC60947-5-1
Control circuit devices and switching elements – Electromechanical control circuit devices

June 11, 2020 Slide 7

Motor starting and its relevant IEC Standards
Definitions according to the standards

A contactor mechanical switching device having only one position of rest,

operated otherwise than by hand, capable of making, carrying and breaking
currents under normal circuit conditions including operating overload
conditions

An electromagnetic contactor is a contactor in which the force for closing

the normally open main contacts or opening the normally closed main
contacts is provided by an electromagnet.

June 11, 2020 Slide 8

Motor starting and its relevant IEC Standards
Utilization categories defined by the standards

A contactor’s duty is characterized by the utilization category together with the rated operational voltage and current.

© ABB Group
June 11, 2020 | Slide 9
Motor starting and its relevant IEC Standards
Utilization categories defined by the standards

A contactor’s duty is characterized by the utilization category together with the rated operational voltage and current.

© ABB Group
June 11, 2020 | Slide 10
Motor starting and its relevant IEC Standards
Temperature limits of a contactor

Maximum Permitted Temperature

1. Magnet 140oC

2. Coil 150oC
Temperature Rise 110oC
(according to IEC60947) + ambient
temperature 40oC

3. Connection bars 105oC

Temperature Rise 65oC
(according to IEC60947) + ambient
temperature 40oC

© ABB Group
June 11, 2020 | Slide 11
Motor starting and its relevant IEC Standards
Trip classes according to the standards
Trip classes of overload relays

This classification refers to the characteristics of the thermal protection.

In particular, for the current value of (7.2 x Ie), the range of the tripping time for the different classes is
indicated as below

Class 10A 2s<t<10s Usually called Normal Start-up type

- compressors
Class 10 4s<t<10s - pumps

Class 20 6s<t<20s - fans coil

Usually called Heavy Duty Start-up type

Class 30 9s<t<30s - crushers

© ABB Group
June 11, 2020 | Slide 12
Motor starting and its relevant IEC Standards
Trip classes according to the standards

Overload Class
Ir = Setting Current
Tripping classes : 10 A 10 20 30

Max. Tripping time

at 1.5x setting current
(warm state)
120s
(2min)
240s
(4min)
480s
(8min)
720s
(12min)
Class 30 : 9 - 30 s
Tripping time Class 20 : 6 - 20 s
at 7.2x setting current 2 ... 10s 4 ... 10s 6 ... 20s 9 ... 30s
(cold state)
Class 10 : 4 - 10 s
Normal Start Longer Heavy Start
At 1.05x setting
current = no tripping
with short starting time Start with long
starting
Class 10A : 2 - 10 s
time

Motor Curve

7.2 Ir
Standard
Tripping curves are standardized in classes according to IEC 60 947-4..

June 11, 2020 Slide 13

Motor starting and its relevant IEC Standards
Definition according to IEC 60947-4
A Protected starter is an equipment consisting of a starter, a manually-operated switching device and a
short-circuit protective device, rated as a unit by the manufacturer.

Manual motor starters are defined as combination starters.

A Combination starter is an equipment consisting of a protected starter and an isolating function.

© ABB Group
June 11, 2020 | Slide 14
Motor starting and its relevant IEC Standards
Definition according to IEC 60947-4-1
Typical variants of protected starters, combination starters, protected switching devices and combination
switching devices.

1. Circuit-breaker according to IEC 60947-2

2. Contactor
3. Overload relay
4. Control switch
5. Circuit-breaker magnetic trip only
6. Switch-disconnector
7. Fuse
8. Disconnector fuse
9. Motor protection circuit breaker with overload release complying
with according to this standard

© ABB Group
June 11, 2020 | Slide 15
Motor starting and its relevant IEC Standards
Definition according to IEC 60947-4-2
Electronic compact starters

A semiconductor switching device is a switching device designed to make and/or break the current in an electric
circuit by means of the controlled conductivity of a semiconductor.

An a.c. semiconductor motor controller is a semiconductor switching device that provides the starting function for an
a.c. motor and an OFF-state

© ABB Group
June 11, 2020 | Slide 16
Contactor selection
Contactor selection
About Magnetic Contactor
Control circuit of the
contactor with

Electromagnet
Function:
Switch on and off an electrical circuit
Contactor coil and coil
Operation: terminals
Electrically/remotely from
a push button or a switch When energized,
another contactor or contactor relay electrically, the electro
a PLC (Programmable Logic Controller) magnet pushes down
the contacts carrier

Power circuit of the

Coil: contactor with
Must be adapted to the control voltage. The moving power
It can be AC or DC contacts

Contactor size: The power terminals

Power voltage determined by the
When the contact
network,
carrier is pushed, the
The contactor is dimensioned mainly contacts will close the
according to the value of current to power circuit
operate with the main contacts
More current mean larger contactor

Slide 18
Contactor selection
About Magnetic Contactor
• The temperature
Contactor limits
The permanent current involves
temperature rise. The limit is function of
the characteristics of the raw materials
(RTI)

• Making capacity Occasionnal current at switching-on or

switching-off
• Breaking capacity
the wearing due to the electrical arc on
the silver contacts involves a life
limitation
Ith : Thermal current = Maximum permanent current
Ie: Rated operational current = It’s the maximum acceptable current
according to the utilization category (AC-1, AC-3, AC-4 ...)
Contactor selection
About Magnetic Contactor Contactor limits
• The voltage

Ui Rated insulation voltage: maximum voltage acceptable by the

product. Value of voltage to which dielectric tests and creepage
distances are referred
Ui = 1000V on AF contactors → dielectric test at 2200 Vac
Ue Rated operational voltage: is combined with the rated operational
current to define the application and to make the relevant type
tests (Ue  Ui)

Uimp Rated impulse withstand voltage: peak value of a prescribed

form (1.2/50µs) and polarity, withstood by the contactor without
failure, to which the values of clearances are referred
Contactor selection
About Magnetic Contactor

Non-inductive loads Squirrel-cage motors Slip-ring motors

Current Current

AC-2
Current

AC-1 AC-3
In Direct on-line start
Direct on-line start
Making and breaking In Making about 2-3 times
In Making about 6 times
nominal current nominal current
nominal current
Time Time
Time

Inching Transformers Capacitor

Current
AC-6a AC-6b
Current

AC-4
Current

Making 6 times
Transformer switching Capacitor switching
nominal current
Making 20-30 times In Making 100 times In or
In Breaking 6 times In In
or more more
nominal current
Time Time Time

Slide 21
AF Contactor range
Right Choice of Motor Control Solution
Magnetic Contactor

Contactor coil
Continuous current and voltage coil control trough
the entire operating cycle
Electronic PCB

• Distinct closing sequence

• Low consumption holding sequence
• Monitored opening sequence
• Strong making force
• Low heat dissipation in closed position
• Humming and buzzing free

Coil
terminals

June 11, 2020 Slide 23

Right Choice of Motor Control Solution
Magnetic Contactor
45 coils 4 coils

AC DC

Code 11: 20 – 60V DC

24 – 60V 50/60 Hz AC
Code 12: 48 – 130V 50/60 Hz AC, DC

AC/DC Code 13: 100 – 250V 50/60 Hz AC, DC

Code 14: 250 – 500V 50/60 Hz AC, DC

June 11, 2020 Slide 24

Right Choice of Motor Control Solution
Magnetic Contactor
Coil consumption

Conventional
coil

AF coil

AFZ coil

Conventional
Solid core DC coil

Time

June 11, 2020 Slide 25

Right Choice of Motor Control Solution
Magnetic Contactor

V V V

T T T

Conventional technology, Surge protection with conventional AF technology

• Surge generated at coil opening technology • Built-in surge protection
• In AC and in DC • Residual overvoltage remains function
• In AC and in DC • No residual overvoltage
• In AC and in DC

June 11, 2020 Slide 26

Right Choice of Motor Control Solution
Magnetic Contactor
AF coil
275V
+10%
IEC standard Conventional coil 250 V

requirement
253V
253V
+10%
+10% 230 V

Uc 230 V

220 V

-15%
-15%
187 V
187 V
100 V
Drop-out at around
Uc x 75% with AC coil -15%
Depends of number of accessories, mounting
position, … 85 V
It is an is an uncertainty area

June 11, 2020 Slide 27

Right Choice of Motor Control Solution
Magnetic Contactor

▪ Insufficient voltage at contactor coil terminals is

critical, especially at contactor closing
▪ This may create contactor busing at closing and result
in burning contactor coil, welding contacts or both
▪ Several parameters may create insufficient control
voltage when the contactor closes
▪ Poor network conditions
▪ Undersized control circuit: transformer, cable cross-
section
▪ Cable length, cascading of control contacts/relays
▪ Motor inrush current when starting (DOL starting…)

June 11, 2020 Slide 28

Right Choice of Motor Control Solution
Let Choose low loss magnetic contactor for better efficiency

Sample of cost saving by lower power consumption

ABB Conventional
AF16 holding (VA) 2.2 >6
Unit per 1 year (KWH) 19.27 52.55

AF09 to AF2850 The latest technology of 5THB per unit (Baht) 96.35 262.77
electronically controlled coil is our standard ……………………………………………………………….
Total energy cost @ 100 pcs 9,635 26,277

• Electronic control coil technology by ABB AF

Total cost saving = 16,642 THB per year !!! , Imagine for
• Low coil consumption
the whole plant efficiency improvement , how much save?
• Reduce noise to network
• Prevent stoppages caused by voltage fluctuations
(Assume to energize operating coil by 365day by 24hr , and
• Hum free, prevent coil burn problem approximate energy cost at 5Baht/unit)

June 11, 2020 Slide 29

Coordination with Short Circuit Protective
Device
Motor Starter and Protection
Coordination with Short Circuit Protective Device

Coordination

Importance of Motor protection

• Assure protection of people and assets /

installations whatever the current levels may be
reached:
overload or short-circuits
• Keep production running with high availability
• Reduce service costs in case of trouble
within decreasing operating durations
and replacement costs of products

STANDARDS : IEC 60947-4-1

(Contactors and Starters)

Slide 31
Motor Starter and Protection aM fuses
Coordination with Short Circuit Protective Device
• only have a short-circuit protection
(5s > 9 x In)

Type of Protection

MMS gL/gG fuses

• means Manual Motor Starter and is a • combination of short-circuit protection
device consisting of isolation function, and thermal overload protection
thermal overload protection and short (5s > 3.5 x In)
circuit protection

MCCB Semi-conductor fuses

• means Moulded Case Circuit Breaker is a (High speed fuses)
breaker usually providing both thermal • the only type of fuses that are fast
overload protection and short circuit enough to achieve a fully type 2
protection coordination when using a softstarter

Slide 32
Motor Starter and Protection
Coordination with Short Circuit Protective Device

Type of Protection

When found the high current :

• Semiconductor Fuse will blown first.
• gG and aM Fuse in second.
• And Breaker (MMS and MCCB) just open.

Slide 33
Motor Starter and Protection
Coordination with Short Circuit Protective Device

Coordination
Disconnector
ISOLATE
Switch Disconnector

PROTECT AGAINST Switch Fuse

SHORT-CIRCUIT Circuit Breaker (Magnetic)
Manual Motor Starter

CONTROL Contactor

PROTECT
AGAINST Thermal Overload relay
OVERLOAD Electronic overload relay
M
3 ~

Slide 34
Motor Starter and Protection
Coordination with Short Circuit Protective Device
Fault Current
Enclosure
Terminals and Conductors
Contactor/Starter Housing
Short Circuit Protective Device
(SCPD)
Contactor/Starter Contacts
Overload Relay
Contactor/Starter Operation
June 11, 2020 Slide 35
IEC 60947-4-1
Coordination Coordination
Type 1 Type 2
Fault current is successfully interrupted and no arcing to enclosure
No substantial damage to the enclosure
No damage to conductors or terminals
No cracking or breaking of the contactor/starter housing
SCPD is not separated from its mounting
Welding acceptable provided contacts
Welding acceptable.
can be easily separated.
No damage, tripping characteristics
Damage acceptable.
must be verified.
Must be operable, verified by 10
May be inoperable
operations after short circuit test.
Motor Starter and Protection
Coordination with Short Circuit Protective Device

In order to evaluate the correct table for the choice of the devices that are able to realise a motor coordiantion it is
necessary to know these data:
• Rated voltage of the plant
• Short circuit current in the installation point
• Rated current of the motors, or all the parameters for the calculation

When all these data are available, it is possible identify the ABB coordination table from which it is possible evaluate
the name of the devices that can be used.

Use of an SCPD not in compliance with the manufacturer's recommendations may invalidate the coordination.
https://applications.it.abb.com/SOC/

June 11, 2020 Slide 36

Online selection tools
Motor Protection
How to select coordination ?

▪ From catalog motor control product / UMC /Softstarters / Etc..

▪ From Selection software tool of ABB

http://applications.it.abb.com/SOC direct adress

www.abb.com/lowvoltage
Coordination
Tools
tables

© ABB Group
June 11, 2020 | Slide 38
ABB on social media

Website: www.abb.co.th Facebook: ABB Thailand Line official: @askabb

June 11, 2020 Slide 44