EBG/SDDC/KNG

21/02/2007

Estimation of Cable Length for Control Circuits of Control Relay/ Contactor

The control cables used for wiring the control circuits of control relays/ contactors have a
capacitance (control cable being equivalent to charged conductors separated by di-
electric, which is cable insulation). The cable capacitance is directly proportional to
length of control cable.

It is often experienced that when the length of control cable is long (normally in excess of
500 m) the control relay / control contactor can remain in closed condition even if the
opening or drop-off command is given...

This is due to fact that control relays or control contactors have low hold-on VA and
cable capacitance can feed this lower VA, even if the switch in series with the coil is
opened. The cable capacitance effectively shunts this switch and thus control relay or
conrol contactor can remain in closed condition.

The length of control cable which can be used to avoid malfunctioning of control relay or
contactor as explained above can be calculated from following formula

m PH x 10 9
_____
Lmax. = ------------
1+ m 2 π f r Uc2

Where,
Lmax. = Permissible cable length in meters.
m = Per unit drop-off voltage of contactor relay / contactor
(Ud/Uc , where, Ud = drop-off voltage , Uc = Rated control circuit voltage)
PH = Hold-on VA at Rated Control Voltage
r = Cable Capacitance in µF/km
Uc = Rated Control Circuit Voltage

1) SAMPLE CALCULATION FOR MXO 110 Vac CONTROL VOLTAGE

m = 0.25 (drop-off voltage 25%)
Ph = 4.5 VA
Uc = 110 V
r = 0.26 µF/km (Value given by Customer for 7C x 2.5 sq.mm. cable)

0.3 4.5 x 10 9
_____
Lmax. = ------------------------------------------ = 910 meters
1+ 0.3 2 x 3.142x 50 x 0.26 x 110 x 110

Similarly the length works out to be 191 meters for 240 Vac control voltage.
2) SAMPLE CALCULATION FOR OEN RELAY WITH 115Vac CONTROL
VOLTAGE
m = 0.4 (drop-off voltage 40%) (Value taken from Relay Data Sheet)
Ph = 2.35 VA (value Taken from Relay Data Sheet)
Uc = 115 V
R = 0.26 µF/km (Value given by Customer for 7C x 2.5 sq.mm. cable)

0.4 2.35 x 10 9
_____
Lmax. = ------------------------------------------ = 621 meters
1+ 0.4 2 x 3.142 x 50 x 0.26 x 110 x 110

Similarly, for 240 Vac control voltage the length works out to be 142 meters

Pick-up and Drop-off Voltages for MX0 a.c. control Contactors

Pick-up Voltage : 80 % Uc
Drop-off Voltage : 25 – 65% Uc

The Pick-up and Drop-off Values Claimed in OEN Catalogues are

Pick-up Voltage : 80 % Uc
Drop-off Voltage : 40 % Uc.

Hope this answers all your queries

______________________
K.N.Gurav
Switchgear Design & Development Centre