APN/CG/PM/Jul 15

Effect of Under-voltage on Capacitor Duty Contactor

MOC Capacitor duty contactors has, since its launch, quickly established itself as one of the most reliable
capacitor duty contactor in the market. However, we do come across some failure of this contactor. On analysis
we find that most cases of failure are due to under-voltage conditions at site. This is very typical failure and can
be identified from the state of main contacts, coil and resistor block. This article explains reason for failure
because of under-voltage and suggests solutions for prevention of such failure.

MO C, capacitor duty contactor is designed such that the main contacts never carry the peak inrush current of
the capacitor under normal condition. There is a de-latching mechanism in MO C contactor. latching mechnism
for opening and closing of the damping resistor assembly. This mechanism puts the resistor system in circuit for
first few milli seconds after the close command is given to contactor. Once the peak inrush current is passed,
main contacts are closed and resistors are disconnected from the circuit. This can be understood with the timing
diagram shown below in fig 1:

Figure 1
Timing diagram for de-latching and main contacts operation (For illustration purpose only)

With this mechanism it is ensured that peak current never passes through main contacts and resistors are taken
out from the circuit once the current attains its steady state.

Working principle of de-latchng mechanism

The fixed contacts of early make contact (with damping resistor) are 2 mm apart from the moving contacts when
the contactor is not energized. When the contactor is picked up, the early make contacts are closed and latched.
After few milliseconds when the peak inrush current is passed, main contacts are closed, latch is released and
early make contacts open . The moment main contacts are closed, a jerk is produced in the contactor. Because of
this jerk the early make contacts may bounce and close again for a moment, which may damage them. To

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prevent this undesired closing of early make contact, a 4 mm gap is maintained between the fixed and moving
contacts of early make contact when main contacts close. This is achieved with the help of a lever in top add on
block. Because of this 4mm gap the early make contacts do not close, even in case of bounce during closing of
main contacts. This mechanism ensures that the resistor contacts do not carry the current after they are de-
latched. And main contacts are closed after few milliseconds of the contactor close command. This ensures that
the main contacts never carry peak current of the capacitor.

Below sections of top-add on block show the de-latching mechanism and double contact gap principle

Contactor in OFF
condition.
Contact gap 2mm

Early make
contacts in
closed condition
when the close
command is
given to
contactor

After few milli

Figure 2
Working of the de-latching mechanism and double gap principle

Above is the explanation of working of capacitor duty contactor when the supply voltage is healthy. But in case of
under-voltage condition the electromagnetic force produced in the magnet system is not sufficient to close the
magnet system completely, which may result in two scenarios

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1. Damping resistor contacts are early make contacts, they close but the force is insufficient for closing main
contacts as a result de-latching does not occur.
2. Another scenario can be when the contactor starts chattering because of low voltage. And the latching
contacts close and open again and again with a frequency higher than the recommended switching
frequency.

In both the cases resistors heat up because of repetitive passage of high current through them. This excessive
heating can be as high as to burn the resistor block. Below photograph shows a contactor, which is damaged due
to consistent under-voltage condition.

Figure 3
Resistor assembly of MO C, burnt because of under-voltage

Because of under-voltage, coil also draws current higher than its rated current. This damages the coil. Burnt or
damaged coil again indicates the under-voltage.

Figure 4
MO C Coil damaged because of under-voltage

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As discussed above that in case of under-voltage, electromagnetic force is not sufficient to close the main
contacts. And there won’t be any damage to main contacts as shown in fig 4.

Figure 5
Main contacts of a contactor, which are intact

With above discussion it can be inferred, if capacitor duty contactor’s resistor assembly is found burnt along with
burnt coil and healthy main contacts, the contactor has failed because of under-voltage.

Solution to protect the contactor from damage because of under-voltage:

There can be two probable solutions to protect the contactor from under-voltage condition:-

1. Use APFC relays with under-voltage setting. Set the under-voltage at 75%. In case of under-voltage APFC
relay will give trip command to incomer.
2. Use under voltage relay. Connect coil supply in series with NO contact of under voltage relay (non fail-
safe relay). When the relay gets healthy supply voltage, the normally open contacts close and only then
will coil of the contactor gets supply through APFC relay output. In case of under-voltage this contact will
open and coil supply will be withdrawn.

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