1997 STANDARD for

DEFINITE PURPOSE AND LIMITED DUTY DEFINITE PURPOSE MAGNETIC CONTACTORS

Standard 780/790

4301 NORTH FAIRFAX DRIVE

ARLINGTON, VIRGINIA 22203

IMPORTANT

SAFETY RECOMMENDATIONS
It is strongly recommended that the product be designed, constructed, assembled and installed in accordance with nationally recognized safety requirements appropriate for products covered by this standard. ARI, as a manufacturers' trade association, uses its best efforts to develop standards employing state-of-the-art and accepted industry practices. However, ARI does not certify or guarantee safety of any products, components or systems designed, tested, rated, installed or operated in accordance with these standards or that any tests conducted under its standards will be non-hazardous or free from risk.

Note: This standard supersedes ARI Standards 780-86 and 790-86.

Price $10.00 (M) $20.00 (NM) Printed in U.S.A.

Copyright 1997, by Air-Conditioning and Refrigeration Institute Registered United States Patent and Trademark Office

TABLE OF CONTENTS SECTION Section 1. Section 2. Section 3. Section 4. Section 5. Section 6. Section 7. Section 8. Section 9. Section 10. PAGE Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sizes and Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Test Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Performance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Minimum Data Requirements for Published Ratings . . . . . . . . . . . . . . . . . . . 6 Marking and Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Voluntary Conformance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

TABLES Table 1. Table 2. Sizes and Ratings - Definite Purpose and Limited Duty Contactors . . . . . . . 2 Load Test Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FIGURES Figure 1. Load Test Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

APPENDICES Appendix A. Appendix B. References - Normative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 References - Informative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ARI STANDARD 780/790-97

DEFINITE PURPOSE AND LIMITED DUTY DEFINITE PURPOSE MAGNETIC CONTACTORS

Section 1. Purpose 1.1 Purpose. The purpose of this standard is to establish, for definite purpose and limited duty definite purpose magnetic contactors within its scope: definitions; classifications; sizes and ratings; requirements for testing and performance; minimum data requirements for published ratings; marking and nameplate data; and conformance conditions. 1.1.1 Intent. This standard is intended for the guidance of the industry, including manufacturers, engineers, installers, contractors and users. 1.1.2 Review and Amendment. This standard is subject to review and amendment as technology advances. the motor protection system and may be either an integral part of an air conditioning or refrigeration unit, or mounted on the control panel for such a unit. 3.3 Limited Duty Definite Purpose Magnetic Contactors. A device for repeatedly establishing and interrupting an electric power circuit for application on compressor motors, fan and pump motors, other motors, and resistive heater loads, and may be an integral part of an air-conditioning or refrigeration unit, but where the contactor itself is not a part of the safety circuit or motor protection system of the unit. 3.4 "Shall," "Should," "Recommended" or "It Is Recommended." "Shall," "should," "recommended" or "it is recommended" shall be interpreted as follows: 3.4.1 Shall. Where "shall" or "shall not" is used for a provision specified, that provision is mandatory if compliance with the standard is claimed. 3.4.2 Should, Recommended or It Is Recommended. "Should," "recommended" or "it is recommended" is used to indicate provisions which are not mandatory but which are desirable as good practice. 3.5 Published Rating. A statement of the assigned values of those performance characteristics, under stated rating conditions, by which a unit may be chosen to fit its application. These values apply to all units of like nominal size and type (identification) produced by the same manufacturer. As used herein, the term "published rating" includes the rating of all performance in specifications, advertising or other literature controlled by the manufacturer, at stated rating conditions. 3.5.1 Standard Rating. A rating based on tests performed at Standard Rating Conditions. Section 3. Definitions 3.1 Definitions. All terms in this document will follow the standard industry definitions established in the current edition of ASHRAE Terminology of Heating, Ventilation, Air Conditioning, and Refrigeration, unless otherwise defined in this section. 3.2 Definite Purpose Magnetic Contactors. A device for repeatedly establishing and interrupting an electric power circuit for application on compressor motors, fan and pump motors, other motors, and resistive heater loads as part of 3.5.2 Application Rating. A rating based on tests performed at application rating conditions (conditions other than Standard Rating Conditions).

Section 2. Scope 2.1 Scope. This standard applies to contactors intended for use in refrigeration and air-conditioning equipment. 2.1.1 Definite Purpose Magnetic Contactors. These contactors are suitable for use with pilot duty protected compressor motors where they are part of the motor protection system. They are also applicable as controls for fan motors, pump motors, resistive loads, etc. 2.1.2 Limited Duty Definite Purpose Magnetic Contactors. These contactors are intended for use where the contactor is not part of the compressor motor protection circuit or primary safety circuit, and may also be applicable as controls for fan motors, pump motors, resistive loads, etc.

Section 4. Classification 4.1 Contactor Classifications. Contactors are classified into two types as defined in Section 3; definite purpose magnetic contactors and limited duty definite purpose magnetic contactors.

ARI STANDARD 780/790-97 Section 5. Sizes and Ratings 5.1 Sizes. Contactors of the sizes listed in Table 1 shall bear the ratings shown. Table 1.1, 2 Sizes and Ratings Definite Purpose and Limited Duty Contactors
Locked-Rotor Current (Amperes) Contactor Size Full-Load Current (Amperes) 240V or Less 120 150 180 240 300 360 450 540 480V 600V

6.1.3

Optional Test.

6.1.3.1 Part Winding and Two Contactor Test. For definite purpose magnetic contactors only. (See 7.7) 6.1.4 Load Test Voltages. Load test voltages shall be those shown in Table 2.

Table 2. Load Test Voltages Nameplate Rated Voltage Range 110-120V 200-208V 220-240V 254-277V 440-480V 550-600V Test Voltage 120V 208V 240V 277V 480V 600V

20AR/20ARL 25AR/25ARL 30AR/30ARL 40AR/40ARL 50AR/50ARL 60AR/60ARL 75AR/75ARL 90AR/90ARL

20 25 30 40 50 60 75 90

100 125 150 200 250 300 375 450

80 100 120 160 200 240 300 360

Note 1: These ratings correspond to two-pole single-phase or three-pole three-phase load connections unless the nameplate states that ratings are "per pole." (See 7.9.1) Note 2: It shall not be construed that other sizes and ratings cannot or will not be produced.

Any device rated at a voltage not included in the above table will be tested at its nameplate rated voltage.

Section 6. Test Requirements 6.1 General Requirements. 6.1.1 Test Samples. Test samples are to be preproduction or production units, not experimental or prototype units. Contactors equipped with auxiliary contacts shall be tested with those contacts in place. 6.1.2 Required Tests. All test samples shall first be subject to the following test: 6.1.2.1 Pick-Up and Drop-Out. (See 7.2)

6.1.4.1 Supply Circuit. The open circuit voltage of the supply circuit is to be not less than 100% nor more than 110% of the specified test voltage, except that a higher voltage may be employed if agreeable to those concerned. The current carrying capacity of the supply circuit is to be such that the closed circuit voltage, with test current flowing (see 7.5.1 and/or 7.6.1), is within 2-% of the specified test voltage. 6.1.4.2 Cycling Tests. All cycling tests shall be performed with random switching relative to the instantaneous supply voltage. This may be accomplished by using non-synchronous switching timers or other equivalent means. 6.1.5 Test Loads. Test loads may be one of the following types: 6.1.5.1 Air-Core Loads, shunted in accordance with Paragraph. 11.7 of UL Standard 489. 6.1.5.2 Iron-Core Loads, having transient characteristics similar to actual motor loads. 6.1.6 Mounting Positions. A device capable of being mounted in more than one position shall be tested in the position which, as determined by the

A separate sample shall be subjected to each of the following tests: 6.1.2.2 6.1.2.3 6.1.2.4 6.1.2.5 6.1.2.6 Coil Temperature Tests. (See 7.3) Mechanical Life Test. (See 7.4) Recycle Load Test. (See 7.5) Endurance Load Test. (See 7.6) Environmental Test. (See 7.8)

ARI STANDARD 780/790-97 contactor manufacturer, imposes the greatest electrical and/or mechanical burden on the contactor. 6.1.7 Line and Load Connections. The line and load conductors shall be 600 volt, 167EF (75EC) copper wire, of the minimum size allowable in Table 310-17 of the 1996 edition of the National Electrical Code (no temperature correction factor) for an ampacity of 125% of the contactor full-load rating. readings, taken at intervals of 10% of the previously elapsed duration of the test, but not less than five-minute intervals, indicated no change. Temperature measurements by thermocouple or resistance method are acceptable. 7.2.1.2 Ambient. Ambient temperature shall be 150EF 5EF [65.6E C 2.8EC] in still air (less than 25 fpm [0.127 m/s]). 7.2.1.3 Voltage Application/Removal Rate. Voltage application/removal rate shall be 5% of nominal coil voltage per second. 7.2.2 7.1.1 Line-Voltage Devices. A definite purpose magnetic contactor, mounted on a 12 in. V 12 in. V 0.053 in. [304.8 mm V 304.8 mm V 1.35 mm] metal plate, shall be capable of withstanding for one minute, without breakdown, the application of a 60 Hz alternating potential of 1000 volts plus twice maximum rated voltage: a. Between uninsulated line-voltage live-metal parts and the mounting plate, with the contacts open and closed; b. Between line-voltage terminals of opposite polarity, with the contacts closed. The holding coil of the contactor normally connected between lines of opposite polarity shall be disconnected from one side of the line or isolated when making this test. c. Between uninsulated live-metal parts of line- and low-voltage circuits, and different line-voltage circuits. 7.1.2 Low-Voltage Devices. A device employing a low-voltage circuit (30 volts or less) shall be capable of withstanding for one minute, without breakdown, the application of a 60 Hz alternating potential of 500 volts applied between uninsulated low-voltage livemetal parts of opposite polarity (with contacts, it any, closed), and between uninsulated low-voltage livemetal parts and the enclosure and grounded deadmetal parts. 7.2 Pick-Up and Drop-Out Test. 7.2.1 Conditions. Requirements.

Section 7. Performance Requirements 7.1 Dielectric Test.

7.2.2.1 Pick-Up and Drop-Out Voltages. On slowly rising voltage under conditions 7.2.1, the seal voltage shall be equal to or less than the pickup voltage. On slowly falling voltage, the contactor shall remain sealed until drop-out occurs. Drop-out voltage shall be at least 10% less than the pick-up voltage. 7.2.2.2 Low-Voltage Pick-Up and Seal. The contactor shall pick-up and seal at 85% or less of rated voltage, with the coil hot (see 7.2.1.1). 7.3 Coil Temperature Tests. 7.3.1 Conditions.

7.3.1.1 Temperature Stabilization. Temperatures shall be stabilized by the procedure outlined in 7.2.1.1. 7.3.1.2 Load Current. The load current shall be 125% of the rated current on each pole (low voltage source may be used). (Auxiliary pole loaded per its rating.) 7.3.1.3 Voltage. The coil test voltage shall be 24, 120, 208, 240, 480 or 600V for 60 Hz ratings. For the temperature test, the coil voltage shall be 105% of the test voltage. For 50 Hz and other frequency ratings, the coil temperature test shall be conducted with a coil voltage of 110% of the manufacturers' voltage rating and the specified frequency or 105% of the 60 Hz test voltage. 7.3.1.3.1 For single winding, dual or multi voltage coils, the test shall be conducted on the highest voltage winding at 60 Hz. (Coil voltage, 105% of the test voltage.)

7.2.1.1 Temperature Stabilization. The coil shall be subjected to 100 percent of the coil test voltage (see 7.3.1.3), with no load on contacts, until its temperature is constant. Temperature is considered to be constant when three successive

ARI STANDARD 780/790-97 7.3.1.3.2 For multi-winding 60 Hz coils the test shall be conducted on each winding and each combination of windings. (Coil voltage, 105% of the test voltage.) 7.3.1.4 Mounting. The device is to be mounted on a 12 in. V 12 in. V 0.053 in. [304.8 mm V 304.8 mm V 1.35 mm] metal plate for this test. 7.3.1.5 Ambient. Ambient temperature shall be 150EF 5EF [65.6EC 2.8EC] in still air (less than 25 fpm [0.127 m/s]). 7.3.1.6 Temperature Measurement. Coil temperature shall be measured by the resistance method; other temperatures, by the thermocouple method. 7.3.1.7 Selection for Test. Not less than six units of the same voltage rating are to be checked for coil wattage, and the one with the highest wattage shall be subjected to temperature test. 7.3.2 Requirements. The final temperature of the coil in still air (less than 25 fpm [0.127 m/s]) shall not exceed a temperature of 230EF [110EC] for Class A coil insulation and 266EF [130EC] for Class B coil insulation or 284EF [140EC] for Class F insulation. 7.4 Mechanical Life Test. 7.4.1 Conditions. 7.6 7.4.1.1 Ambient. The ambient temperature shall be 150EF 5EF [65.6EC 2.8E C]. 7.4.1.2 Voltage. The coil voltage shall be 105% test voltage (see 7.3.1.3). 7.4.1.3 Load. There shall be no load on the contacts. 7.4.1.4 Cycling Rate. The cycling rate shall be such that it assures full motion of the moving parts of the device and shall be no slower than 0.5 second on and 0.5 second off. 7.4.2 Requirements. There shall be no mechanical malfunction in 500,000 operations. After completion of the test, the device shall pass the Dielectric Test (see 7.1) and the Pick-Up and Drop-Out test (see 7.2). 7.5 Recycle Load Test. 7.5.1 Conditions. Endurance Load Test. 7.6.1 Conditions. 7.5.1.1 Load Cycle. Make and break locked rotor current at test voltage. 7.5.1.2 Maximum power factor: single-phase--50% three-phase--50% Cycle rate: on time--0.5 to 2 sec. off time--Ratio of off time to on time; to be 20 to 1, maximum

7.5.1.3

7.5.1.4 Ambient. Ambient temperature shall be 70 to 90EF [21.1 to 32.2EC]. 7.5.1.5 Voltage. The coil voltage shall be 100% of the coil test voltage (see 7.3.1.3). 7.5.2 Requirements.

7.5.2.1 Definite Purpose Magnetic Contactor. The contactor shall withstand 10,000 operations with no failure. After completion of this test, the device shall pass the Dielectric Test (see 7.1) (One sample for each load test.). 7.5.2.2 Limited Duty Definite Purpose Magnetic Contactor. The contactor shall withstand 1000 operations with no failure. After completion of the test, the device shall pass the Dielectric Test (see 7.1). (One sample for each load test.)

7.6.1.1 Load Cycle. Make locked rotor current and break 125% full load current at test voltage. 7.6.1.2 Maximum Power factor:

a. Locked rotor current: single-phase--50% three-phase--50% b. Full load current: single-phase--80% three-phase--80% 7.6.1.3 Cycle rate: on time--1 sec. (0.25 sec. locked rotor current, 0.75 sec. 125 percent full load current) off time--9 sec.

ARI STANDARD 780/790-97 7.6.1.4 Ambient. Ambient temperature shall be 70 to 90EF [21.1 to 32.2EC]. 7.6.1.5 Test Voltage. The coil voltage shall be 100% of the test voltage per 7.3.1.3. 7.6.2 Requirements. 7.7.1.6 Requirements. The contactor shall withstand 30,000 operations with no failure, followed by a Dielectric Test (see 7.1). 7.8 Environmental Test. Devices shall be maintained without energizing in the following environments for a total of 10 cycles: a. Hold for 15 hours at 110EF [43.3EC], 90-95% R.H. b. Reduced temperature and humidity gradually over a 2.5 hour period to 40EF [4.4EC] and 30-50% R.H. c. Hold for 4 hours at 40EF [4.4EC], 30-50% R.H. d. Increase temperature and humidity gradually over a 2.5 hour period to 110EF [43.3EC], 90-95% R.H. At the end of the 10th 24-hour cycle, increase temperature to room temperature (instead of 110EF [43.3EC]) and maintain for 2 hours. Note: 7.7 Part Winding and Two Contactor Test (Optional) for Definite Purpose Contactors Only. (NOT FOR LIMITED DUTY DEFINITE PURPOSE MAGNETIC CONTACTORS.) 7.7.1 Qualifications. If the manufacturer desires to qualify the contactor for either two contactor across the line, or two contactor part-winding start application, the following test criteria shall apply. 7.7.1.1 Load Cycle. Make full load current and break, locked rotor current at test voltage. (If the manufacturer desires to derate the contactor to 80% of its normal rating for two contactor applications, the test may be run making full load current and breaking 80% of rated locked rotor current.) 7.7.1.2 Maximum power factor: a. Locked rotor current--50% b. Full load current--80% 7.7.1.3 Cycle Rate: on time--1 sec. (0.75 second full load current, 0.25 sec. locked rotor current) off time--9 sec. 7.7.1.4 Ambient. Ambient temperature shall be 70 to 90EF [21.1 to 32.2EC]. 7.7.1.5 Voltage. The coil voltage shall be 100% of the test voltage (see 7.3.1.3). Condensation on devices being tested is not permitted. At the conclusion of the

7.6.2.1 Definite Purpose Magnetic Contactor. The contactor shall withstand 200,000 operations with no failure. After completion of the test, the device shall pass the Dielectric Test (see 7.1). (One sample for each load test.) 7.6.2.2 Limited Duty Definite Purpose Magnetic Contactor. The contactor shall withstand 100,000 operations with no failure. After completion of the test, the device shall pass the Dielectric Test (see 7.1). (One sample for each load test.)

7.8.1 Requirements. conditioning period: a.

Devices shall operate normally with no evidence of sticking, either open or closed, when Pick-Up and Drop-Out Test is performed (see 7.2). b. Devices shall not exhibit corrosion of internal parts or evidence of any dimensional instability of parts which could interfere with normal operation. c. After completion of the test, the device shall pass the Dielectric Test (see 7.1) after remaining at room temperature for two hours. 7.9 Load Connections. 7.9.1 Load Test Connections. Load connections shall be chosen from Figure 1, for the tests described in 7.5, 7.6 and 7.7. 7.9.2 Grounding Circuit. For a grounded-neutral system, the enclosure shall be connected during the test through a 3-ampere cartridge fuse to the grounded conductor of the circuit. For any other system, the enclosure shall be connected through such a fuse to the live pole least likely to strike (arc) to ground. The fuse shall not open as a result of this test.

ARI STANDARD 780/790-97

Figure 1. Load Test Diagrams

Section 8. Minimum Data Requirements for Published Ratings 8.1 Published Ratings. Any published ratings such as in catalogs, specification sheets, advertising literature, etc. shall have the classification as Definite Purpose or Limited Duty Definite Purpose, clearly identified.

Recommended nameplate voltages for 60 Hertz systems shall include one or more of the equipment nameplate voltage ratings shown in Table 1 of ARI Standard 110. Recommended nameplate voltages for 50 Hertz systems shall include one or more of the utilization voltages shown in Table 1 of IEC Standard Publication 38.

Section 10. Voluntary Conformance Section 9. Marking and Nameplate Data 9.1 Marking and Nameplate Data. The contactor shall display the manufacturer's name, model designation, contactor type, electrical characteristics and "Limited Duty Definite Purpose" if applicable. 10.1 Conformance. While conformance with this standard is completely voluntary, conformance shall not be claimed or implied for products or equipment within its Purpose (Section 1) and Scope (Section 2) unless such claims meet all of the requirements of the Standard.

ARI STANDARD 780/790-97

APPENDIX A. REFERENCES - NORMATIVE

A.1 Listed here are all standards, handbooks, and other publications essential to the formation and implementation of the standard. All references in this appendix are considered as part of this standard. A1.1 ARI Standard 110-97, Air-Conditioning and Refrigerating Equipment Nameplate Voltages, 1997, Air-Conditioning and Refrigeration Institute, 4301 North Fairfax Drive, Suite 425, Arlington, VA 22203, U.S.A. A1.2 ASHRAE Terminology of Heating, Ventilation, Air Conditioning and Refrigeration, American Society of Heating, Refrigerating, and AirConditioning Engineers, Inc., 1791 Tullie Circle N.E., Atlanta, GA 30329, U.S.A. A1.3 IEC Standard Publication 38, IEC Standard Voltages, 1983, International Electrotechnical Commission, 3 rue de Varembe, P.O. Box 131, 1211 Geneva 20, Switzerland. A1.4 National Electrical Code, 1996, National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269, U.S.A. A1.5 UL Standard for Safety 489, Molded-Case Circuit Breakers and Circuit-Breaker Enclosures, Eighth Edition, 1991, Underwriters Laboratories, Inc., 333 Pfingsten Road, Northbrook, IL 60062, U.S.A.

APPENDIX B. REFERENCES - INFORMATIVE

None.