Types of Contactors

•Electromechanical contactors. They are actuated with the help of

mechanical means.
•Electromagnetic contactors. Its actuation is carried out through an
electromagnet.
•Hydraulic contactors. They are activated by the pressure of a liquid.
•Pneumatic contactors. They are activated by the pressure of a gas.
Contactors
Industrial panels
Structure of Contactors
Contactor Symbols
 Contactor Components

The following three are components of the contactor:

1. The driving force that is required to close the contacts is provided by the coil or
electromagnet of the contactor. The coil or electromagnet and contacts are protected by an
enclosure.

2. Enclosure: Just like the enclosures used in any other application, contactors also feature an
enclosure, which provides insulation and protection from personnel touching the contacts.
The protective enclosure is made from different materials, such as polycarbonate,
polyester, Nylon 6, Bakelite, thermosetting plastics, and others. Generally, the open-frame
contactor features an additional enclosure, which protects the device from bad weather,
hazards of explosion, dust, and oil.

3. Contacts: This is yet another important component of this electrical device. The current
carrying task of the contactor is done by the contacts. There are different types of contacts
in a contactor namely, contact springs, auxiliary contacts, and power contacts. Each type of
contact has an individual role to play.
 Application of Contactors
Contactors are used to control electric motors, lighting, heating,
capacitor banks, thermal evaporators, and other electrical loads

Contactor Name plate

 Parameters of a contactor

1. Number of poles
Power contactors have 3-pole or 4-pole versions.

2. Utilization category
Load characteristics are another important selection parameter. Utilization categories of
contactors are defined in IEC 60947-4-1 standard.

3. Current and power

A suitable contactor should be determined according to the current or power of the load.

4. Coil voltage
It is the control voltage applied to the coil. When the coil is energized, the magnetic field
changes the position of the main contacts. If excessive voltage is applied to the coil, it will
burn. If less voltage is applied to the coil, the power contacts make a continuous vibrating
pull-and-drop in a very short time.

5. Rated operating voltage (Ue), Insulation voltage (Ui), Impulse voltage

(Uimp)
Rated operating voltage indicates the voltage value that the contactor can be supplied at
nominal conditions. It is the phase-phase voltage in 3 phase application. Insulation voltage is a
reference voltage for dielectric tests and leakage distance. The impulse voltage indicates the
maximum voltage value that a contactor can withstand in impulses without deterioration.
These values ​should be checked from the catalogs.

6. Number of auxiliary contacts

Internal auxiliary contacts work synchronously with main contacts. Auxiliary contacts
provide information on the open or closed status of the contactor. Auxiliary contacts can be
available internally such as 1NO, 1NC, 1NO + 1NC … etc. Besides, they can be mounted
externally on the contactor.
 7. Size
The dimensions of electrical products are getting compact day by day.
The smaller the size, the better for the user. As the size of the product
decreases, the dimension of the electrical panel decreases. Besides, the
length of the consumable materials such as cables and cable ducts also
decreases.
8. Mounting types and positions
Low-voltage power contactors are generally suitable for Din Rail mounting. In models with base
plate mounting, screws should be tightened according to the torque values ​specified on the
product during assembly. Otherwise, the products may be out of warranty. Besides, the
catalogs of contactors contain information about the mounting angles to be placed in the
panel.
12. Heat dissipation at the poles
It is the value of heat emitted from one of the main contacts in nominal
operation. This value should be taken into consideration when
calculating the cooling and ventilation of the electrical panel.

10. Standards
Standards and certification are other important factors. In particular, a
contactor compliant with the UL standard may have different technical
features. A product can also comply with IEC and UL standards.

11. Accessory option

A contactor has lots of electrical and mechanical accessories. Depending on the need,
accessories such as mechanical interlock, time relay, varistor, terminal protector, terminal
expander, connection busbars .. etc .. are available. The accessories should be compatible with
the contactor type.

9. Connection type
Contactors can be produced as screw and spring terminals. During cable entry, screwed models
can be tightened with a screwdriver, and spring models can be mounted without tightening. If
assembly time is critical, spring-loaded models can be preferred.
 13. Maximum operating and storage temperature
The maximum temperature of the contactor under energy and the maximum temperature at
the time of storage is different from each other. These values ​should be considered and not
exceeded.

14. Maximum working altitude

In applications above maximum altitude, power derating calculations
should be made and the appropriate contactor should be determined.
15. Electrical and mechanical life
The electrical life is the number of switching cycles that the contactor can perform in the
loaded condition. Operating current varies according to operating voltage and utilization
category. The number of switching cycles of a contactor without energy is called mechanical
life.

16. Shock resistance and vibration resistance

Shock resistance is a value determined for vehicles, cranes, in-ship
applications and plug-in equipment. The contacts must withstand the
specified “G” values ​without changing their position. In the case of
vibration, devices at the vibration amplitude and frequency specified for
boats and other vehicles must continue to operate. Especially in
applications such as railways, these values ​are desired to be high.
17. Coil operating limits
These are the upper and lower limits of the nominal control supply voltage. If the coil is
energized between these values, the contactor must pull. For example, a contactor normally
operating at 110 VAC has a tolerance of 0.85 x Uc min … 1.1 x Uc. This means that if any
control voltage between 93,5V … 121V is applied, the contacts will change position.
18. Coil consumption values
Coils consume energy at the moment of pulling and holding. If the consumption during
pulling and holding is low enough, it may even be possible to switch the contactor directly
from the PLC without using any additional interfaces.
19. Response time
It is the time elapsed after the coil is energized until the contacts are fully closed. In high-
quality contactors this time is short.
Standard
IEC 60947-1 General requirements
IEC 60947-2 Circuit-breakers
Circuit-breakers, switch-fuse units
IEC 60947-3
and switch-disconnectors

Contactors and motor starters:

4-1 Electromechanical contactors
IEC 60947-4 and motor starters
4-2 Semiconductor motor
controllers & starters for AC voltage

Control apparatus and switching

elements:
IEC 60947-5
5-1 Electromechanical control
apparatus
Multi-function switchgear and
control gear:
6-1 Mains switches (categories AC-
IEC 60947-6
32A/B)
6-2 Control and protective
switchgear (CPS)
Auxiliary equipment:
7-1 Terminal blocks for copper
IEC 60947-7 conductors
7-2 Protective conductor terminal
blocks for copper conductors
Commonly Used Utilisation Categories
The table below gives an overview of the various different abbreviations used for low voltage switchgear
and control gear, together with the devices to which each utilisation category applies, and the IEC
standard that governs them. The table may be used to select the most suitable size of component for the
respective device type, depending on the rated voltage, the rated current, and the electrical load that
requires switching.
Utilization Category Typical Application Applicable IEC norm

Non-inductive or slightly
AC-1 inductive loads, example: 60947-4-1
resistive furnaces, heaters

AC-2 Slip-ring motors: switching off 60947-4-1

Squirrel-cage motors:
AC-3 starting, switches off motors 60947-4-1
during running time

Squirrel-cage motors:
AC-4 60947-4-1
starting, plugging, inching

AC-5a Switching of discharge lamps 60947-4-1

Switching of incandescent
AC-5b 60947-4-1
lamps

AC-6a Switching of transformers 60947-4-1

AC-6b Switching of capacitor banks 60947-4-1

Slightly inductive loads in

60947-4-1
AC-7a household appliances:
61095
examples: mixers, blenders

Motor-loads for household

60947-4-1
AC-7b appliances: examples: fans,
61095
central vacuum
 Hermetic refrigerant compressor
AC-8a motor control with manual 60947-4-1
resetting overloads

Hermetic refrigerant compressor

AC-8b motor control with automatic 60947-4-1
resetting overloads

Control of resistive loads and solid

AC-12 state loads with opto-coupler 60947-5-2
isolation

Control of solid state loads with

AC-13 60947-5-1
transformer isolation

Control of small electromagnetic

AC-14 60947-5-1
loads
Control of A.C. electromagnetic
AC-15 60947-5-1
loads

Connecting and disconnecting

AC-20 60947-3
under no-load conditions

Switching of resistive loads,

AC-21 60947-3
including moderate overloads

Switching of mixed resistive and

AC-22 inductive loads, including 60947-3
moderate overloads

Switching of motor loads or other

AC-23 60947-3
highly inductive loads

AC-31A Non-inductive or weakly inductive

60947-6-1
AC-31B loads
AC-33A Motor loads or mixed loads including motors, resistors
60947-6-1
AC33B and up to 30 % incandescent lamp load
AC-35A
Gas discharge lamp load 60947-6-1
AC-35B
AC-36A
Incandescent lamp load 60947-6-1
AC36B
Distribution circuits of mixed resistive and inductive
AC-40 60947-6-2
loads
Non-inductive or weakly inductive loads, resistance
AC-41 60947-6-2
furnaces
AC-42 Slip ring motors: Starting, switching off 60947-6-2
Squirrel cage motors: Starting, switching off during
AC-43 60947-6-2
operation
Squirrel cage motors: Starting, counter-current braking
AC-44 60947-6-2
or reversing, typing
AC-45a Switching of gas discharge lamps 60947-6-2
AC-45b Switching incandescent lamps 60947-6-2
Induction-free or slightly inductive loads, resistance
AC-51 60947-4-3
furnaces
Control of the stator winding of a slip-ring motor: 8-
AC-52a hour operation with starting currents for starting 60947-4-2
processes, maneuvering, operation
Control of the stator winding of a slip ring motor:
AC-52b 60947-4-2
Intermittent operation
Control of a squirrel cage motor: 8-hour operation with
AC-53a starting currents for starting processes, maneuvering, 60947-4-2
operation
Control of a squirrel cage motor: Intermittent
AC-53b 60947-4-2
operation
AC-55a Switching of electrical controls of discharge lamps 60947-4-3
AC-55b Switching incandescent lamps 60947-4-3
AC-56a Switching transformers 60947-4-3
AC-56b Switching of capacitor batteries 60947-4-3
Control of a hermetically sealed refrigeration
compressor motor with automatic reset of overload
AC-58a 60947-4-2
releases: 8-hour operation with starting currents for
starting, maneuvering, operation
The control of a hermetically sealed refrigeration
AC-58b compressor motor with automatic reset of the 60947-4-2
overload trips: Intermittent operation
 Control of small electromagnetic loads with holding current =< 0.2 A;
AC-140 60947-5-2
e.g. contactor relays

A Protection of circuits, with no rated short-time withstand current 60947-3

B Protection of circuits, with a rated short-time withstand current 60947-3

DC-1 Non Inductive or slightly inductive loads, resistance furnaces, heaters 60947-4-1

Shunt-motors, starting, plugging(1), inching(2), dynamic braking of

DC-3 60947-4-1
motors

Series-motors, starting, plugging(1), inching(2), dynamic braking of

DC-5 60947-4-1
motors

DC-6 Switching of incandescent lamps 60947-4-1

Control of resistive loads and solid state loads with opto-coupler 60947-5-1
DC-12
isolation 60947-5-2
60947-5-1
DC-13 Control of D.C. electromagnetics
60947-5-2
Control of D.C. electromagnetic loads having economy resistors in the
DC-14 60947-5-1
circuit

DC-20 Connecting and disconnecting under no-load conditions 60947-5-1

DC-21 Switching of resistive loads, including moderate overloads 60947-5-1

Switching of mixed resistive and inductive loads, including moderate

DC-22 60947-5-1
overloads (i.e. shunt motors)

DC-23 Switching of highly inductive loads (i.e. series motors) 60947-5-1

 Symbol
Wiring Diagram Of Contactors
 How to wire a contactor

1) Coil terminals

On the front of the contactor, you’ll see two wire terminals of A1

and A2. This is where we can connect a 24-volt DC power to the
coil to energize it.

Contactors work with different voltages such as 12-volt 24 220-volt

DC or 24, 120, or 220-volt AC power.

The A1 and A2 wire terminals are connected to DC positive terminal and

negative Respectively.
.
2) Contacts terminals

On the other side of the contactor, we have six other wire terminals. The
wire terminals on the top are labeled from left to right with L1, L2, and
L3. The wire terminals on the bottom are labeled from left to right with
T1, T2, and T3.
The L1, L2, and L3 terminals are where the power wires connect to the
contactor. The T1, T2, and T3 terminals are where the device wires
connect to the contactor

The L1 contact connects to the T1 contact, the L2 contact connects to the

T2 contact, and the L3 contact connects to the T3 contact.
All of my contactor’s contacts are normally open. With the coil de-
energized, the device connected to the T1, T2, and T3 terminals does not
have power. When the coil is energized, the device will now have power.
3) Auxiliary or feedback contact terminals
As you can see, we have another set of wire terminals on the front end
labeled as NO or normally open. This is a simple normally open
contact referred to as an auxiliary contact or a feedback contact.
How does a feedback contact work?
This contact is used to send a signal to the PLC input about the contactor’s health.
The way that this contact works is that when the coil is energized and these three
main contacts are closed, this feedback contact will be closed as well and send a
signal to the PLC input.

However, when the contactor is broken and energizing the coil will not result in these
three main contacts being closed, the feedback contact will not be closed either and
no signal will be sent to the PLC input.
This way, there is a way for us to be notified if the contactor
is broken.
How to wire a contactor to the PLC and motor
connect the PLC output to the coil to be able to energize and de-energize
it.

You connect a 3-phase power supply to L1, L2, and L3 from one end,
and then from the other end, you connect T1, T2, and T3 to the motor.
To be notified when the contactor is broken, you need to connect this
auxiliary or feedback contact to the PLC input.

You also need a start and stop switch to be connected to the PLC input.
This way, when you press the start switch, the coil will be energized,
the contacts will be closed and the motor will be turned on. When this
happens, the feedback contact will be closed as well and a signal will
be sent to the PLC input, telling us that the contactor is working
properly.
When you press the stop switch, the coil will be de-energized, the
contact will open and the motor will turn off.
Types of contactors DC contactors

There are many types of contactors DC-1 Magnetic Contactor

This applies to all DC loads,
in electrical systems.
mainly non-inductive loads or
These include slightly inductive ones.
AC Contactor DC-2 Magnetic Contactor
This category applies to DC Shunt
DC contactor
Current (AC) contactors
motors, where the disconnection
occurs while the motor is running
➢ AC-1 Magnetic Contactor at full speed.
➢ AC-2 Magnetic Contactor DC-3 Magnetic Contactor
➢ AC-3 Magnetic Contactor It is applied for starting and
stopping DC shunt motors,
➢ AC-4 Magnetic contactor
stopping during starting,
jogging, reversing by reverse
gear, and dynamic braking.
Solid-state contactors
Solid-state contactors are ideal replacements for electromechanical
contactors where fast and demanding switching of loads such as heaters,
solenoids, transformers, and motors, is required. Compared to
electromechanical contactors, solid-state contactors stand out due to
their considerably longer service life. Thanks to the high quality, their
switching is extremely precise, reliable, and insusceptible to faults. They
have a compact modular design complete with a heatsink. They are
available in single-phase, dual-phase, or three-phase versions. If your
application demands low maintenance, fast switching, or operation in
harsh environmental conditions, consider a solid-state contactor solution.
Vacuum contactors
Vacuum contactors are applied on low voltage and medium voltage systems up to
15kV on motors, standard and high-efficiency induction, synchronous, wound rotor
slip-ring, transformer feeder switching, and capacitor switching. They use the
vacuum interrupter to extinguish the arc, which is used to frequently turn on and
off the normal working current. Minimal contact bounce, low arc energy, and
temperatures minimize the risks of contact welding. Besides, they have a long
electrical and mechanical lifetime.
 3 pole contactors
3 pole contactors are typically used in motor starting
applications. These contactors utilize three wires to control the
electrical current direction.

4 pole contactors
4 pole contactors are typically used in commercial and industrial
applications. These contactors utilize four wires to control the electrical
current direction. The additional 4th pole for neutral wire connection.
 Modular contactor

A modular contactor ensures silent

operation

The modular contactor is similar to contactor relays (auxiliary

contactors) in terms of contact combination. 1NO + 2NC, 2NO +
2NC etc.
• It is compact and does not take up much space.
• Accessory mounting options are very limited compared to power contactors.
• It looks like miniature circuit breakers. Because it has a din-rail profile. It may be
difficult to distinguish visually when used with MCBs inside the enclosure. But the
general appearance of the panel looks very fine with the usage of modular
contactors.
• It is generally produced up to 15 kW. Therefore it can be used for the switching of low
loads.
• The coils of the advanced models can be supplied with AC and DC. Besides they
have surge protective functions.
• Some models can be controlled manually.
• It is equipped with contact indications.

Selection parameters
When selecting a modular contactor, the below parameters should be
considered:

• Combination of contacts.
• Rated operational voltage.
• Rated operational current.
Electrical Contactors Specifications
• Application of Contactors and Panel wiring

HVAC

AC circuit distribution
KM1 STAR .KM2 DELTA ,KM3 MAIN CONTACTORS AND KT TIMER
Lift Control

PUMP CONTROL PANEL

 Contactor Maintenance
Reasons for Contactor Failure Reasons for contactor failure are:

1.Overcurrent in the main contacts

High current-carrying loads create heat at the main contacts of the contactor, which causes
welding in the closed position. Please choose your contactor correctly based on the full load
current and utilization category. If you are at the performance limit, select a bigger contactor.
On the other hand, pole wear is normal during the contactor’s lifetime. Contacts can be
changed with a set of spare contact kits when the end of life is reached. But if this wear
appears very early after commissioning, it could be due to a non-adequation between the
contactor’s selection and application.

2.Overvoltage and undervoltage in the coil

The operational limit of the contactor is between 85 and 110% of the
rated coil. A voltage variation of
±5% of the above limits will increase the contact bounce which leads to
increased contact wear. The
reason for this is that higher voltages will increase the speed of the
electromagnet at closing. Lower voltages will decrease the speed at
closing. Both these factors can lead to a higher level of contact bounce at
closing. High voltage and the increased speed at closing also contribute to
some increased sound.
The control voltage of less than 85% during pick-up may not be enough to
safely close the contactor and can cause the coil to melt due to
overheating. This is because the coil is designed to withstand the inrush
current for a limited time only. One common reason is when the coil
supply is taken from the main supply where a high current is causing the
voltage to drop. Too high continuous control voltage could also cause the
coil to melt.
3.Wrong product selection
Wrong product selection is another cause of contactor failure. Contactor should be selected according
to the type of load. The standard utilization categories define the current values which the contactor
must be able to make or break. These values depend on:
• The type of load being switched: squirrel cage or slip ring motor, resistors.
• The conditions under which making or breaking takes place: motor stalled, starting or running,
reversing, plugging.
Category AC-1
This category applies to all types of a.c. load with a power factor equal to or greater than 0.95 (cos Φ
0.95). Application examples: heating, distribution.
Category AC-2
This category applies to starting, plugging, and inching of slip ring motors. On closing, the contactor
makes the starting current, which is about 2.5 times the rated current of the motor. On opening, it
must break the starting current, at a voltage less than or equal to the mains supply voltage.
Category AC-3
This category applies to squirrel cage motors with breaking during normal running of the motor. On
closing, the contactor makes the starting current, which is about 5 to 7 times the rated current of the
motor. On opening, it breaks the rated current drawn by the motor; at this point, the voltage at the
contactor terminals is about 20 % of the mains supply voltage. Breaking is light. Application examples
all standard squirrel cage motors: lifts, escalators, conveyor belts, bucket elevators, compressors,
pumps, mixers, air conditioning units, etc.
Category AC-4
This category covers applications with plugging and inching of squirrel cage
and slip ring motors. The contactor closes at a current peak that may be as
high as 5 or 7 times the rated motor current. On opening, it breaks this same
current at a voltage that is higher, the lower the motor speed. This voltage
can be the same as the mains voltage. Breaking is severe. Application
examples: printing machines, wire drawing machines, cranes and hoists,
metallurgy industry.

4.Voltage drop during start-up of the motor

A voltage drop to less than 85 % of nominal voltage for 5 to 10 ms can be
enough for the contactor to start opening. Also, other disturbances in the
control voltage such as poor relay contacts or too small control
transformer/power supply could be responsible for this problem. The
result of these voltage problems can be increased contact wear and also
lead to welding of main contacts.
5.Current peaks used by heavy-duty starting
If the application requires a high level of torque during start-up, for
example, a big fan or a pump, it is important that the contactor’s making
capacity and short-time withstand currents are capable of handling the
starting current and current peak.
6.Restarting with motor idling
Attempting to restart the motor before it has come to a full stop will cause a current peak that theoretically can
reach twice the current compared to starting the motor from a standstill. This can result in welded contacts.

7.Change over time between star and delta

Setting the change over time between star and delta too short
will not allow the motor to reach 80-90% of its nominal speed.
This will cause the star contactor to break a higher current
than expected.
If the starter stays in the star position for too long of a period; this will
increase the stress of the star contactor because the star contactor is
mainly sized for the short time current rating.
The change over time between the star and delta is important. If no timer
or other device is used to get an idle time between the opening of the
star contactor and the closing of the delta contactor, there is a risk that
the arc inside the star contactor could remain and create a short circuit. If
the elapsed time is too long, the motor starts to decelerate and the delta
closing will create a higher current peak than expected. This can result in
welded contacts. Generally, the idle time should not exceed 50 ms.

8.Product coordination
Lack of product coordination with fuse or breaker missing or wrongly sized
can cause excessive contact wear or lead to welded contacts.
9.Transients affecting coils
Voltage peaks/transients are not uncommon, especially in poor-quality or
weak networks. Too high voltage peaks/transients may cause damage to
the coil. You can use RC filters or varistors to protect the coil from
transients.
10..High temperature
High temperature causes contact welding and coil melting. The standards
define temperature raise regarding the ambient temperature. In case the
contactor is overheating, you will have to sum the ambient temperature
and the temperature raise allowed. When concerned about high
temperatures on and around the contactor please check the following:
• Make sure the connections are properly torqued.
• Make sure the ventilation of the electrical panel is correct.
• Make sure the cable size is what is recommended.
• Make sure the correct coil is selected for the applications.
11.Wrong cable selection
An incorrect cable section choice in regard to the current level creates
cable overheating. The consequence is contactor overheated.
12.Vibration
If the contactor vibrates for a long time, it will cause the internal coil to
burn. You should check the vibration and shock parameters of the
contactors from the manuals of the manufacturers. You can also prefer
special contactors produced for high-vibrated applications such as the
railway.
13.Environmental factors
Pollution of the magnet pole surfaces will create a slight hum coming from
the contactor in the closed position. Hum can also occur if the pole surfaces
are deformed. A louder hum will occur if the shading coil is broken because
the magnet will cause the contactor to chatter.
Contactors need to be protected from condensation to keep the pole
surfaces of the magnet free from corrosion. Besides, the contactor should
be mounted inside an enclosure that protects the unit from dust and water.
Unclean terminals increase connection resistance and, in this case, create an
overheating effect.
 14.Connection and mounting mistakes
Make sure the recommended torque values given in the instructions are followed and that proper
torque checks depending on the application are done. A loose connection on the terminal creates
an overheating condition. On the other hand, the terminal screw can be damaged when the
assembly torque is excessive.

15.High altitudes
With a decrease in atmospheric pressure, the spacing required to prevent
flashover increases substantially. Since arc-over occurs more readily at
higher altitudes, contact life decreases substantially with operation at
these altitudes. To compensate for increased arcing at high altitudes,
users must derate the current ratings given by the manufacturer.
 16. Mounting position
Some contactors are position-sensitive. The mounting positions and distances should be checked
properly.

17.Lack of maintenance
Generally, contactors do not need so much maintenance. But to be able to
stay on the safe side, a maintenance program should be established as soon
as the contactor is installed and put into operation. After the contactor has
been inspected several times at monthly intervals, and the condition noted,
the frequency of inspection can be increased or decreased to suit the
conditions found since this will depend upon the severity of the contactor
duty.
Questions
Project