EATON A200 Size 5 Motor Controller

Eaton A200/A210/A250 Size 5 motor controller: providing reliable full voltage starting and overload protection for industrial applications

Product Overview: Full voltage starting and overload protection

The A200, A210, and A250 Size 5 motor controllers, when properly wired according to the connection diagram, can operate as full voltage starters and provide overload protection through overload relays. It should be noted that the controller itself does not provide short-circuit protection and needs to be used in conjunction with appropriate short-circuit protection equipment. Two pole controllers and three pole devices have the same current rating, but are not suitable for controlling three-phase motors.

This series of controllers is suitable for circuits up to 600 V, and its short-circuit withstand capability depends on the type of short-circuit protection equipment provided, as shown in Table I. For example, when combined with Class J, K, R, or T fuses, the short-circuit rating can reach 65000 A @ 600 V; When combined with specific models of thermal magnetic circuit breakers (such as HKD, KDC), the short-circuit rating can reach 65000-100000 A.

Installation requirements and mechanical inspection

The controller must be installed on a vertical surface, with the incoming terminal located above the load terminal. After installation, the controller mechanism and accessories should be inspected for the following before powering on:

The crossbar and spring should move freely.

The electrical and mechanical interlocking devices are installed correctly and adjusted in place.

Install the appropriate operating coil and connect it correctly.

The arc extinguishing cover must be in place and firmly fixed: it is strictly prohibited to power on the controller without installing the arc extinguishing cover.

The main contact should have sufficient overtravel and spring force.

Dimensional information: The external dimensions of the A210 controller are shown in Figure 2, measured in inches.

Types and configurations of overload relays

B-type overload relay (see Figure 1)

The A200 controller is typically equipped with a B-type block type environmental compensation overload relay (gray reset lever). Non environmental compensation type (red reset lever) is also optional. This relay is a bimetallic strip with a normally closed control circuit contact and an optional isolated normally open control circuit contact. When the overload relay trips, a yellow dot will be exposed below the reset lever, and the indicator will return to its hidden state after resetting.

A-type overload relay (see Figure 4)

Type A overload relay is either non environmental compensation type (red reset lever) or temperature compensation type (gray reset lever, marked as "ambient compensated"). Its characteristics include:

Release indicator

Tripping adjustment with a setting range of ± 15%

A normally closed control circuit contact

Can choose manual or automatic reset

The reset method is determined by the position of the metal plate on the load side of the overload base: moving the metal plate away from the panel is in the "manual" position, and moving it towards the panel is in the "automatic" position. Warning: It is strictly prohibited to use the automatic reset function in situations where a two-wire control circuit is used and the motor automatically starts, which may cause danger.

Overload relay heating element

Heating elements need to be ordered separately and selected based on the full load current and service factor on the motor nameplate. The selection principle is as follows:

When the motor service factor is 1.15-1.25, select directly according to the heating element application table.

When the service factor is 1.0, the service factor is not specified, or the maximum 115% protection is desired, select a heating element that is one level lower than the indicated value.

When the motor and overload relay are at different ambient temperatures, the motor current needs to be corrected: for every 1 ° C higher than the controller environment in the motor environment, the rated current of the motor decreases by 1%; On the contrary, every 1 ° C increases by 1%.

Warning: If overcurrent components burn out, the entire overload relay must be replaced to ensure fire and electric shock protection. The replacement model is shown in Table IV.

Rated values of overload relay control circuit contacts (see Table III):

Type A: normally closed contact 20 A on/2 A off (24-120 V AC); Normally open contact 5 A connected/0.5 A disconnected

Type B: normally closed contact 30 A on/3 A off (24-120 V AC); Normally open contact 30 A for connection/3 A for disconnection

Auxiliary contact - J-type

Each Size 5 controller can install up to two auxiliary contact units, providing a total of four auxiliary circuits. The auxiliary contact unit is fixed in a metal bracket through a spring clip and driven by a metal operating component installed on the crossbar. During installation, the L-shaped operating component needs to be adjusted so that it touches the beveled edge of the push rod exactly. The contact type and catalog number are shown in Table VI.

J-type contact rated values (A600, R300):

120-600 V AC: continuous current of 10 A, connecting capacity of 7200 VA, breaking capacity of 720 VA

28-300 V DC: continuous current 1.0 A, on/off capacity 28 VA

GCO type current transformer

The GCO type current transformer is designed specifically for the A200 Size 5 controller and is used to drive Type A or Type B thermal overload relays. Its transformation ratio is 300/5, the shell is black, the primary winding is composed of the load connection piece of the controller, and the secondary winding leads are white and black for polarity identification.

Important warning: GCO current transformers should not be used to supply power to other auxiliary equipment, and it is strictly prohibited to power on the secondary side with an open circuit, otherwise the generated overvoltage will damage the transformer.

Installation steps (see Figure 7):

Rotate the contactor crossbar assembly to the position shown in the diagram.

Loosen the installation bolt A of the lower static contact, remove the clamping bolt B of the load connection piece, and rotate the load connection piece C.

Push the GCO transformer into the load connection piece C, with the secondary lead facing upwards, and insert the anti vibration spring clamp S.

Thread the secondary leads W1 and W2 through the contactor base, and if necessary, remove the operating coil for wiring.

Turn the load connection piece C back to its original position and tighten bolts A and B (static contact bolt torque 150-175 lb in).

Reinstall the operating coil to ensure that W1 and W2 are not sandwiched between the coil and the mounting surface.

If only two transformers are used, they should be installed on the left and right sides, with the middle omitted.

Overload relay wiring:

The overload relay must be installed vertically with the reset rod facing downwards (see Figure 8). Secure it to the screw holes of the contactor bearing bracket using two 8-32 mechanical screws. Connect the GCO secondary lead to the overload relay terminal as shown in the diagram: connect the white wire to the terminal, and each pair of wires (one black and one white) must be connected to the same pole of the overload relay.

Coverage: GCO 300/5 transformer+A/B type thermal overload relay+A200 Size 5 controller combination, can provide overload protection for motors with full load current of 118-300 A and up to 600 V.

Incoming and load terminals

Both the incoming and load terminals have holes with a diameter of 17/32 inches, suitable for fasteners with a diameter of 1/2 inch. If crimping type terminals are used, the incoming side should be installed behind the copper incoming connection piece for easy control of wiring; The load side should be installed at the front. The crimping terminal can be ordered separately, part number 2119A76H01.

mechanical interlock

When multiple controllers are used in combination, mechanical interlocking can be used to prevent both controllers from closing simultaneously. The mechanical interlocking combination of vertical and horizontal components is shown in Table VII.

Maintenance Guide

Magnetic suspension system

Both fixed and movable magnet components are installed flexibly to ensure good sealing and quiet operation of the magnets. Spiral compression springs and leaf springs are located on the back of each magnet component. The spring force and constraint of the movable armature are smaller than those of the fixed magnet component. If disassembling the magnet, it is necessary to ensure that the plate spring is located at the center of the laminated magnet assembly and is not stuck between the magnet and the molded guide protrusion. After reassembly, it should be checked that both the fixed and movable magnets can be manually pressed or shaken, and the movable armature should be more flexible than the fixed component.

Contact overtravel

The initial overtravel of the new contact is 13/64 to 17/64 inches (see Figure 10-B). When the overtravel of any pole decreases to 1/16 inch, all pole contacts must be replaced. The replacement steps are as follows:

Turn off the power, remove the arc extinguishing cover, and gently lower the crossbar.

Remove the three moving contact components.

Remove the compression spring from the component and twist the contact to remove it from the saddle.

Use a 1/4 inch hex wrench to remove the static contact.

Install the new contacts in reverse order, ensuring that all bolts are tightened (static contact bolt torque 150-175 lb in), the crossbar is correctly positioned, and the arc extinguishing cover is securely fixed.

The new contact design is to first contact the bottom surface and then the top surface, and all moving contacts of the poles should simultaneously contact the stationary contacts, with an error not exceeding 1/32 inch.

contact pressure

When using new contacts, the total contact pressure for each pole should be:

Initial pressure: 6-7 pounds (see Figure 10-A)

Final pressure: 7.5-8.5 pounds (see Figure 10-B)

arc extinguishing cover

The arc extinguishing cover provides a mechanical stop for the moving contact assembly, maintaining the opening distance of the main contact, and contains De ion type arc extinguishing grids inside. Regularly check whether the grid is damaged due to malfunction. It is strictly prohibited to power on the controller without securely installing the arc extinguishing cover.

pop-up spring 

Under normal circumstances, no maintenance is required, just ensure that the spring is correctly seated on the molded crossbar assembly. If it accidentally falls off, you can use pointed pliers to clamp the front end of the spring, rotate the offset pin end to reduce the outer diameter, and then re insert it into the base hole.

Operating coil

When replacing the coil, it is necessary to check the part number, voltage, and frequency on the label. Commonly used coils are shown in Table IX, and coil data (typical values) are shown in Table X

Exchange suction VA: 1700 (surge)/180 (sealed)

DC suction VA: 600 (surge)/22 (sealed)

Sealing power: 32 W (AC)/20 W (DC)

Replacement steps:

Cut off the power supply between the controller and the coil.

Remove the coil lead wires.

Remove the arc extinguishing cover.

Gently lower the crossbar.

Remove the two mounting screws and take out the old coil.

Place the new coil and install the screws.

Reset the crossbar to the correct position.

Reinstall the arc extinguishing cover and tighten the bolts.

Connect the coil leads and manually check if the crossbar moves flexibly.

AC/DC coil conversion

If low drop voltage or ultra quiet operation is required, an AC/DC coil conversion kit can be selected. This kit rectifies AC control voltage into DC and needs to be used in conjunction with intermediate control relays. The conversion kit and corresponding control relay are shown in Table XI.

Recommended tightening torque (see Table XII):

Arc extinguishing hood screw: 90-100 lb in

Coil terminal screw: 15-18 lb in

Coil installation screw: 15-18 lb in

Static contact screw: 150-175 lb in

Power cord lug: 300-400 lb in

Screw for moving contact assembly: 55-65 lb in

Anchor mounting screw: 100-120 lb in

Fixed magnet mounting screw: 125-150 lb in

Summary of Technical Parameters

Parameter specifications

NEMA Specification Size 5

Three phase motor power (60 Hz) 200 V: 100 HP; 230 V：100 HP； 460/575 V：200 HP； Open: 300 HP

Short circuit rating up to 200000 A (depending on SCPD)

Maximum voltage 600 V

Polar number 2 or 3

Overload relay type A or B, environmental compensation or non compensation

Current transformer GCO type, 300/5 ratio

Auxiliary contacts up to 4 circuits, J-type

Multiple AC voltages are available for coil operation, and AC/DC conversion kits are also available

Installation method: Vertical surface installation