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TD03309002E
For more information visit:
www.EatonElectrical.com
Technical Data
Effective: January 2005
Page
5
Storage, Handling,
Installation and
Maintenance of Controllers
Troubleshooting
Table 3. Contactor Troubleshooting Chart
Defect
Cause
Remedy
Contactor
Overheating
Load current too high
Reduce load. Use larger contactor.
Loose connections
Clean discolored or dirty connections and retighten. Replace poorly crimped
lugs.
Overtravel and/or contact force too low
Adjust overtravel, replace contacts, and replace contact springs as required to
correct defect.
Collection of copper oxide or foreign matter
on copper contact faces
Clean with fine file. Use Type 12 enclosure for dirty atmosphere.
Load is on in excess of 8 hours on copper
contacts
Change operating procedure. Check factory for more suitable contacts.
Ambient temperature is too high
Reduce load. Provide better ventilation. Relocate starter. Use larger contactor.
Line and/or load cables are too small
Install terminal block and run larger conductors between contactor and terminal
block.
Poor Arc Interruption
Arc box not in place
Install arc box.
Arc box damaged
Replace broken or eroded insulating parts, arc horns, and grid plates. Clean or
replace insulating parts having a heavy coating of foreign conducting material.
Dirt or paint on arc horns or steel-grid plates
Remove contaminating materials which may have accumulated on arc horns
and steel-grid plates.
Magnetic hardware substituted for non-
magnetic hardware in arc box and blowout
assemblies
Replace with correct hardware; brass or stainless steel as available.
Blowout coil reversed or shorted
Replace with new blowout coil or correct defect by reversing coil.
Oil level is low or oil is contaminated (in oil-
immersed contactor)
Fill tank to proper level with fresh oil. Test at 28 kV.
Welding of Contacts
Overtravel and/or contact force is too low
Adjust overtravel, replace contacts, and replace contact springs as required to
correct defect.
Magnet armature stalls or hesitates at contact
touch point
Correct low voltage at coil terminals as coil draws inrush current.
Contactor drops open to contact-touch
position because of voltage dip
Maintain voltage at coil terminals. Install low voltage protective device,
sometimes called “Brownout Protector.”
Excessive contact bounce on closing
Correct coil overvoltage condition.
Contacts rebound to contact-touch position
when opening
Correct mechanical defect in stop assembly. Correct mechanical defect in latch if
one is used.
Poor contact alignment
Adjust contacts to touch simultaneously within 1/32 inch.
Jogging duty is too severe
Reducing jogging cycle. Check factory for more weld-resistant contact material.
Use larger contactor.
Excessive inrush current
Motor has locked rotor code letter greater than G. Most contactors are designed
for motors with code letters A through G. Therefore, use larger contactor. Check
factory for more weld-resistant contact material.
Vibration in starter mounting
Move starter to location having less shock and vibration. Insulate starter form
shock and vibration. Provide more rigid support for starter.
Contacts
Contact Chatter
Low voltage
Check supply voltage, especially during starting. Check coil voltage rating.
Increase voltage or change coil rating as required.
Poor contact in control circuit
Replace the contact or use holding-circuit interlock (3-wire control).
Broken shading coil
Replace magnet and armature assemblies.
Welding
Abnormal inrush current
Use next larger size contactor or check for grounds, shorts, or excessive motor
load current.
Rapid jogging
Install larger device rated for jogging service.
Insufficient contact pressure
Replace contacts and springs, check contacts for abnormal wear or damage.
Low voltage preventing magnet from sealing
Check supply voltage to coil, especially for momentary voltage dip during
starting.
Foreign matter preventing contacts from
closing
Clean contacts with freon. Contacts used at low current and voltage levels
should be cleaned with freon.
Vibration in starter mounting
Insulate starter from shock and vibration.
Short circuit
Remove fault and check to be sure fuse or breaker size is correct.
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