Unit 04 – Contactors

A power contactor is an electrical device used to turn an electrical circuit on and off. It's a
multi-pole switch, which means it can control numerous power circuits with a single
contactor. Regarded as a unique kind of relay, the main difference between the contractors
and the relay is that the contactor relay is utilized in applications that require a larger current
carrying capacity, whereas the relay is used in conditions that require a lower current carrying
capacity.
Contactors are electrical components that are used for a number of different applications in
electrical circuits and systems. They are basically devices that are used to switch an electrical
circuit on and off.
What Is a Contactor?

A contactor is a component used to switch an electrical circuit on or off. It is considered

to be part of the relay family, but the main difference is that they are used for
applications or in circuits that require more current. They are generally used to supply
power to lighting circuits or electrical motors.

Contactors include multiple contacts which are used to control other components and send
signals within an electrical system or circuit. The contacts are generally normally open but
can be normally closed also. Typically, the contacts are used to supply the power to the load
when the contactor coil has been energized.
Contactors are designed to be easily mounted and small so they can be fitted into control
panels and circuits. They come in a range of different amp (A) ratings and voltage (V)
ratings.

What Are the Main Components of A Contactor?

Contactors are not just one component; they are made up of a series of components.
Contactors have three main components, let’s take a look at them all below:

Coil

The coil is the most important part of the component as it is the part that is required to close
the contacts. The coil is not visible as it is protected in an enclosure.

Enclosure Or Body

The enclosure of a contactor provides a form of insulation and protection, this ensures that
personnel will not come into contact with the contacts or coil. Generally, the enclosure is
made from plastic such as polycarbonate.
Contacts

The contacts are the part of the contactor that carries the current. There are a number of
different contacts that can feature inside/on a contactor, contact springs, aux or auxiliary
contacts, and power contacts. Generally, the contact configuration of a contactor is normally
open (NO) but can also be normally closed (NC).

What Is The Electrical Symbol For A Contactor?

3 phase contactor
The image above shows a typical symbol for a contactor in an electrical circuit. Different
types of contactors can be shown slightly differently but this is the most common type you
will see on general electrical drawings.

What Are the Different Types Of Contactors?

Like many electrical components, contactors come in a range of different types. The working
principle of each contactor is almost the same with some minor differences. Each different
type of contactor features its own features, different capabilities and are used for specific
applications. We use different types of contactors for a range of different applications.

The different types of contactors are:

 Manual contactors
 Magnetic contactors
 Lighting contactors

Manual Contactor

Manual contactors can also be known as double-break contactors, they work by dividing the
connection which creates two sets of contacts.

As the name suggests they have to be operated by someone by manually pressing the
contactor on or off. Manual contactors are not as widely used today since the development of
automatically operated contactors. Whilst a manual contactor requires labour to operate they
are also less safe than other types of automatic contactors.

Magnetic Contactor

This type of contactor is the most commonly used in the majority of applications today. They
can operate automatically and only requires a small amount of current to turn on/off the load.
Most contactors use 24VAC or DC to operate the coil, this means that control circuits can be
used to control when the load is switched on and off. The coils can also be operated by higher
voltages but generally, you always try and use a control voltage (24V) to operate these. By
doing this you can easily integrate your control circuit to the contactor

Lighting Contactors

Lighting contactors are contactors used to switch the load onto lighting circuits normally
found in industrial and commercial environments. They are used to provide a safe local or
remote switch for lighting circuits.

Where Are Contactors Used?

Contactors are used for a number of different applications across a range of industries.

Some of the applications of contactors are:

 Electrical motor starter
 Lighting control
 Evaporator control
 Capacitor banks
 Heating systems
Electrical Motor Starter

The most common application for electrical contractors is for an electrical motor starter. A
starter is a design that is designed to provide a power supply to electric motors. They can
provide power cut-off, under-voltage cut-off, and overload protection when the correct
attachments are used.

Lighting Control

Contactors are also used in electrical circuits for lighting control, they are used for large
lighting installations. They are used to reduce power in the coil-latching contactors are used.
A latching contactor has two coils, one of the coils controls the contacts and the other coil
closes the power circuit contacts.

Who Invented Contactors?

Hein Moeller was a German engineer who developed the world’s first oil contactor. Since the
discovery of the contactor, they have been used extensively in the world of electrical systems
and circuits and are a crucial part of circuits still today.

What Is the Difference Between a Relay and A Contactor?

Typically, contactors are used in three-phase applications whereas relays are more commonly
used in single-phase applications. A contactor does not have a common between the phases
and joins 2 poles together. A relay uses a common contact that connects to a neutral.
Contactors are generally rated up to 1000v and relays are typically rated up to 250V.

The load capacity of relays is mostly used for applications that carry 10A or less. Any
applications that use 10A or more normally use contactors.

Working of Contactor
An electromagnetic field produced when the electromagnetic coil is energized. As we have
seen in the construction, the moving contact of the contactor is connected with the armature
(metallic rod) of an electromagnet.
When an electromagnetic field produced, the armature experiences the force and pulls
towards the fixed contact. The force produced by the coil is more than the force of the spring.
Both contacts remain in this position until the coil is not de-energized.
Once the coil is de-energized, the electromagnetic force is zero and the armature pulls back
due to the force of spring. And return in the normal condition (OFF position). The contactors
are designed for the rapid ON-OFF operation.
The input of the contactor coil may be AC or DC or in some cases, the universal coil is used
as an electromagnetic coil. The universal coils operate on AC and DC both. A small amount
of power loss occurs in the contacts and an economizer circuit is used to reduce this loss.
While making and breaking of contacts, an arc is produced between the contacts. This arc
may reduce the life of contactor as it increases the temperature of contacts. Due to arc,
harmful gases are produced like mono-oxide. Hence, there are several methods are used to
control and extinction of arcs.
The contactors are selected base on load current and voltage, the control range of voltage, and
application based on utilization category.

Advantages & Disadvantages

The following are the advantages to be highlighted for the contactor

1. High-speed switching suitable for high breaking current

2. The high degree of safety can be maintained
3. Cheaper than circuit breakers
4. Available for different ratings
5. Maintenance Free
6. In modern days, the contactor comes along with the protective relays.

Disadvantages of Contactor:

1. The coil needs an external power supply.

 2. Wear and tear factor is high
3. AC and DC coils need to be manufactured, there are no universally operated coils.
Hence AC coil can not be used instead of DC coil.
4. Contactor Tips will be damaged easily. Hence it will be landed with the high
maintenance cost

Applications of Contactors

1. Induction motor starters

2. Control logic circuits
3. Vacuum contactor

Features of Contactors

 A contactor is a relay that is used for switching power.

 They usually handle very heavy loads like an electric motor, lighting and
heating equipment and, so on.
 Contactors are controlled by a circuit with very less power even though their
output is used for switching very high loads.
 They can vary in size from a small device to as huge as a yard depending on
the loads they have to handle.
 Like circuit breakers, they do not interrupt a short-circuit current.
 Their current and voltage breaking capacity range from a few amperes and 24
DC volts to thousands of amperes with many kilo volts respectively.

Contactor – Design and Construction

The basic construction of a contactor is almost the same as a relay. It consists of the
following parts-

1. Contact: This is one of the important parts of contactor. The current carrying task of
the contactor is completed by the contacts. There are various types of contacts present
in a contactor namely, contact springs, auxiliary contacts, and power contacts. Each of
them has their own individual role to play.
2. Electromagnet: This is the most vital component of a contactor. It provides the
driving force that is required to close the contacts of the contactor.
3. Enclosure: The enclosure provides insulation and protection from personnel touching
the contacts. Both the coil or electromagnet and contacts are protected by an
enclosure. These protective enclosures are made from various materials, such as
polycarbonate, polyester, Nylon 6, Bakelite, thermosetting plastics, etc. Generally, the
open-frame contactor has an additional enclosure, which protects the device from bad
weather, hazards of explosion, dust, and oil.
 4. Arc Suppressor: One of the key functionalities of a contactor is the arc excitation.
AC arcs are often easily extinguished since it passes through zero twice for each
cycle. Hence arc suppressors can do the job easily. But for DC arcs, magnetic
blowouts or specially designed arc chutes for arc extinction are necessary. Depending
on the application, different arc suppression arrangements are made in contactors out
of which arc chutes are one among them.
5. Economizer circuit: An economizer circuit is the one used to reduce the power
consumed by the coil. During pick up the economizer circuit supplies a high current
and later it supplies adequate power to stay the contacts closed. It is not mandatory
that each one of them must have an economizer circuit.

The contact a part of the contactor includes the facility contacts also because the
auxiliary contacts. The power contacts gain the power for the contactor and the
auxiliary contacts is used to bring a loop with the rest of the rest of the devices it is
attached to. These contacts are connected to the contact springs.

The electromagnets control the contacts of the contactor. These electromagnets give the
initial force to the contacts and make them closed. Both the contacts and electromagnet are
enclosed in a frame. The frame is usually made of insulating materials. The insulating
material that is used completely insulates the contacts and helps in preventing the touch of
contacts. For high-end contactors, an open-frame contactor is commonly used to provide
greater protection from oil, dust, weather, and also from an explosion. According to the
required voltage rating, the type of frame housing used may also differ. If the contactors are
used to manage volts higher than 1000 volts, inert gases and also vacuum is used as frame
housing.
Features of Contactors

 A contactor is a relay that is used for switching power.

 They usually handle very heavy loads like an electric motor, lighting and heating
equipment and, so on.
 Contactors are controlled by a circuit with very less power even though their output is
used for switching very high loads.
 They can vary in size from a small device to as huge as a yard depending on the loads
they have to handle.
 Like circuit breakers, they do not interrupt a short-circuit current.
 Their current and voltage breaking capacity range from a few amperes and 24 DC
volts to thousands of amperes with many kilo volts respectively.

Advantages of Contactors:

 Speed-up your projects: Simpler selection process

 Easy to install: Faster fitting by design
 Continuous operation: Proven, secure, trusted
 Save time
 Environmentally sound
 Safe and reliable control circuits
 Protect control circuits and save space
 Switching operation is very fast
  By using a single contactor switch we can control multiple circuits
 It can work for both AC and DC devices
 Construction of a contactor is quite simple

Disadvantages of Contactors

1. Coil of the contactor may burn in absence of magnetic-field. As a result, the contacts
won’t close and the contactor will not function properly.
2. Contacts may also weld shut which may cause the load to keep running even when
there is no control voltage which may cause unsafe machine or machine damage.

Difference Between a Relay and a Contactor

SL.
RELAY CONTACTOR
NO.

Relays are primarily used on low voltage, Contactors are used to power up larger
1.
low amperage circuits. loads such as induction motors.

A Relay is similar to an auxiliary

Contactors can be classified as -power
2. contactor, which is generally used in
contactors and auxiliary contactors.
control circuits.

The size of a relay is comparatively The size of a contactor is larger than a

3.
small. relay.

4. Cannot be repaired Can be repaired

Differences between a contactor and a relay

Relays, just like contactors, are devices that are used to open or close circuits
electromechanically or electronically. Relays are not just switching devices; they are primary
protection as well in most control processes or equipment. All relays can be classified with
one or more electrical quantities like current or voltage such that can close or open circuits or
contacts.

As mentioned before, a contactor is an electromechanical switch used primarily for opening

or closing electrical circuits. A contactor is usually controlled by a circuit that has a lower
power level compared to the switched circuit — for instance, a 24-volt coil controlling a 240-
volt motor switch.

Below are areas in which these devices have differences.

 Application
o The major difference between both devices is that contactors are more
powerful than relays, so they are used for high power applications
 Load Capacity
 o Contactors can be used in control circuits that have both high and low current
capacity that is between 9A to 1250A. While
o Relays are used in control circuits with only low current capacity, that is,
between 5A and 15A.
 Design
o Contactors are designed mainly for three-phase applications. However, relays
are primarily designed for single-phase applications.
 Safety Components

Contactors are designed to handle high voltage applications and high voltage translates to
more danger. So, to prevent accidents, safety features such as spring-loaded contacts have
been added to the device. Spring-loaded contact is a feature that prevents internal short circuit
if the contactor gets into overload situations. Another safety feature on the device is the
Magnetic Arc Suppressor. This feature helps to remove or reduce sparks formed when
contacts carrying currents are separated.

Relays, whereas, do not have these safety features.

 Switching Speed
o Contactors are much slower than Relays when it comes to switching speed, so
because of this, relays can be operated using electronic signals.
 Power Consumption
o Contactors consume more power than relays because relays make use of
smaller electromagnets than contactors.
 Size and Cost
o Because contactors are used for high current capacity applications, they are
relatively larger and heavier than relays. Obviously, because of the difference
in size, efficiency, and functionality, contactors are costlier than relays.

Construction and Operation of Contactors

A contactor consists of three basic parts: the operating coil, the associated magnetic circuit
and the contacts that are actuated by the coil.

Figure 1 is a representation of a very old type of contactor. It clearly shows the coil, the
operating part of the magnetic circuit and a single contact.
Modern contactors look like that shown in Figure 2, but the principle of operation is exactly
the same as the representation in Figure 1.
 When the coil is energized a magnetic field is produced in the magnetic
circuit. This attracts the hinged armature, against the tension of the spring, to
complete the magnetic circuit.
 The movable contact attached to, but insulated from, the armature closes
against the fixed contact.
 When the coil is de-energized the armature springs open and also opens the
contact.

Figure 1 Operating parts (components) of a contactor

Contactors may have many contacts, but those in use in power work seldom have more than
six. In most contactors there are at least three power contacts.
These contacts are designed to carry the full rated current of the contactor. When used for
motor starting duty they are designed to carry five times their rated current for a short time.
The other contacts on the contactor are often termed ‘auxiliary contacts’, or sometimes
‘control contacts’. While one or two of them might be able to carry full load current, in most
circuits they only carry control current, which may be in the order of about 100 mA.

Difference between AC contactors and DC contactors

Property AC contactors DC contactors

The magnetic core is made of DC contactor coils are made of
laminated silicon sheet steel to cast iron and do not have
Core structure
reduce the eddy current and lamination, since eddy currents
hysteresis. are not generated in DC.
Heat is generated in an AC
Due to the absence of core losses
Heat generation contactor core due to losses. The
in a DC coil, core laminations are
in core silicon steel laminations prevent
not required.
overheating.
Shape of core E shape U shape
DC contactors possess a risk of
There is no risk of damage due to generating a high voltage across
Freewheeling high voltage during instantaneous their terminals when the current
diode interruption of current flow flow is suddenly cut off. In order
through AC coils. to overcome, this issue. a free-
wheeling diode is used.
DC contactors have a
Number of coils Less number of turns. comparatively greater number of
poles than AC contactors.
Basic Structure of AC Contactor
Contactor is an automatic electromagnetic switch for long-distance frequently connected or
disconnected AC and DC main circuit and high-capacity control circuit. The main control
object of a contactor is the motor, it can be used to control other loads as well.
According to the current types that through the main contacts, contactor is divided into AC
contactor and DC contactor. The structure and working principle of both are basically the
same, which mainly consists of three parts, electromagnetic mechanism, contact system and
arc-extinguishing equipment. In the electrical control circuit of machine tool, AC contactor is
mainly used. This article focuses on the basic structure of the AC contactor.

Electromagnetic System
Electromagnetic system of the AC contactor mainly consists of three parts, which are the coil,
static iron core and armature (moving iron core). Through the power-on and power-off of
electromagnetic coil, it pulls in or releases the armature and static iron core, thus completing
the close or disjunction between movable contact and static contact, realizing the purpose of
connecting or disconnecting the circuit. When the AC contactor operates, alternating current
(AC) in the coil will generate an alternating magnetic flux in the iron core, so the suction
between the iron core and armature is also changing, which will lead the armature to vibrate
and make noise. To eliminate this phenomenon, a slot could be opened at two different ends
of the iron core and armature of the AC contactor, in which a short-circuit ring made from
copper, constantane or nicochrome is embedded. The short-circuit ring is also called for
damping ring or divided magnetic ring. After the iron core is installed with a short-circuit
ring, the coil current generates a magnetic flux Φ1 as the coil is connected to the alternating
current. Part of Φ1 go through the short-circuit ring and generate induced current in the ring,
as a result, another magnetic flux Φ2 will be produced. According to the law of
electromagnetic induction, Φ1 and Φ2 have different phase position, namely Φ1 and Φ2 can't
be zero at a same time, thus the magnetic adhesion F1 and F2 produced by Φ1 and Φ2 can’t
be zero at a same time. By this way, the iron core and armature have a suction at any time,
the armature will always be suck, thus the vibration and noise will be significantly reduced.
Contact System
Contact can be divided into three types of point contact, line contact and surface contact by
contact conditions, the contract of AC contactor is generally double breakpoints bridge
contact.
According to the make-break capacity, contract of AC contactor is mainly divided into main
contact and auxiliary contact. The main contact is used for main circuit that has a large on-off
current, it generally consists of three couples of make contacts which have larger contact
surface. Auxiliary contact is used for control circuit that has a small on-off current, it
generally consists of two couples of make contacts and two couples of break contacts.

Arc-extinguishing Equipment
When the AC contactor disconnects circuits with large current or high voltage, a strong arc
will be produced between the movable and static contacts. On one hand, the produced arc
would burn the contacts and reduce the service life of the contacts; On the other hand, the arc
will extend the cut-off time of the circuit, even lead to arc short circuit or fire accidents. All
contactors with a capacity higher than 10A are equipped with the arc-extinguishing
equipment. In the AC contactor, commonly used arc-extinguishing methods are as follows:
1. Double-break electrodynamic arc-extinguishing. This kind of electrodynamic arc-
extinguishing has a double-break structure. It divides the whole arc into two
segments, and elongates the arc to both sides with the electrodynamic force F of the
contact circuit, so that the arc heat will be emitted, cooled and extinguished during the
enlongation process.
 2. Narrow slot arc-extinguishing. There is one or more narrow slots in each phase of the
arc chute which is made from arc resistant clay and asbestos cement, bottom of the
slots are relatively wider, so as to place the contracts. Upper part of the slots are
relatively narrow, so as to compress the arc and ensure a good contact between the arc
and arc chute walls. When the contacts disconnect, the arc will be blown into the slots
by an external magnetic field or electric power, its heat will be transferred to the arc
chute walls, thus the arc will be quickly cooled and quenched.
3. Splitter arc-extinguishing. The metal splitter is generally made from copperized iron
sheet or galvanized sheet iron with a shape of herringbone. The splitters are inserted
in the arc chute and each piece keeps insulated from others. When the moving contact
and the static contact are disconnected, arc generates between contacts, the arc current
produces a magnetic field around it. As the magnetic reluctance of metal splitter is
much less than that of air, the magnetic flux at the upper part of the arc are easy to
pass the metal splitters and forms a closed magnetic circuit, which leads the magnetic
field in the air around the arc in helical shape. This magnetic field produces an
upward force on the arc, thus pulling the arc to the gap of splitters, the splitters divide
the arc into several series-wound short arc. Each splitter becomes the electrode of a
short arc and divides the total arc pressure drop into several sections, the arc voltage
between splitters is lower than arc voltage. Meanwhile, splitters absorb and emit the
arc heat, thus cooling the arc quickly and extinguishing the arc as soon as possible.

Contactor Ratings

Ratings of a contactor are given according to the pole of the contactor. It also depends on
factors like fault withstand current, coil voltage and so on. According to their rating,
contactors are classified into the following.

 AC1 – Non-inductive rows

 AC2 – Contactors for starting of slip-ring motors
 AC3 – Starting of squirrel-cage motors and switching off only after the motor is up to
speed.
 AC4 – Starting of squirrel-cage motors with inching and plugging duty.
 AC11 – Auxiliary control circuits

Wide Band AC/DC operated Coil Voltages

Wideband coils ranging from 100V to 250V are available and electronic coils ranging from
24V to 60V are available.

These products are available for all applications including wind, solar, starter panel, UPS,
traction, EV, safety contactors, and more.

The main advantage of using wideband coils is that the inventory costs can be significantly
reduced.
The Coils of a contactor can be energized by below voltage ratings in AC/DC,

In AC -24V, 110V, 220-230V and 400-415V

In DC – 20-60V, 48-130V, 100-250V, 250-500V and 77-143V

AC And DC Contactors

Contactors can also be classified as AC and DC contactors.

 AC Contactors

AC contactors work on the principle of electromagnetic attraction. They have a

shading coil which is a metallic ring with high remanence which provides magnetism
during the zero crossing of AC voltage. The presence of the shading coil in AC
contactors can result in higher drop-off voltage which can cause delay in contact
operation.

 DC Contactor

DC contactors also work on the principle of electromagnetic attraction. But they do

not have any shading coils. Hence, if a DC coil is powered with AC voltage, the
contactor can chatter as the magnetism becomes zero during the zero crossing of the
AC voltage. It can produce an audible noise and can cause contact to change state and
lead to malfunction or unwanted interruption in the circuit.

High Voltage Contactor:

A high-voltage contactor, also called a high-voltage relay without distinction in the industry,
is widely used in electric vehicles (EV) and hybrid electric vehicles (HEV). It is an
electromechanical switching device with a coil to generate a magnetic force that
mechanically operates an electric contact. However, it is more common to use a high-voltage
contactor to represent high-power applications in EV and HEVs.
As a key safety device in new energy vehicles, a high-voltage contactor needs basic functions
that are resistant to high voltage, load, shock, strong arc extinguishing, and breaking capacity.
An appropriate current is applied to the coil to ensure proper force to drive the contacts for
robust operation. Even though there are many different types of contactors for different
functions in a vehicle, the driving current profiles of all the contactor coils are similar.

Automatic Acceleration Control

The nature of the DC motor start, and the way in which the motor accelerates, is governed by
the starter itself. When series resistance stages are removed from the armature circuit there
are surges in both current and torque. These surges might be unacceptable. For example, if a
wrong value of resistor is chosen, a motor might not start on the first stage but will surge
violently on a second stage.
To achieve good starting sequences with surges reduced to a minimum, the operation should
be taken out of the hands of an operator and made automatic. Then the rates of acceleration
will be consistent and reliable.
Some of these methods are described below.

Definite Time Acceleration

Relays are activated in accordance with strict time intervals.

A circuit illustrating the action of an automatic starter for a shunt DC motor is shown in
Figure 4. Operation is by push-buttons with the accelerating stages controlled by delayed
action relays.

Figure 4 Example of an automatic DC motor starter circuit diagram

The circuit has been divided into two parts with a broken line to distinguish between power
and control circuits.

The power circuit is shown to the left of the line, with the motor field, motor armature and the
accelerating resistors. The control circuit is to the right of the line, with the pushbuttons, main
relays, timing relays and their respective contacts.
Two of the relays are of the delayed-action type. Relay K3/1 has a reaction time of
approximately twice that of relay K2/1; for example, 5 seconds for K2/1 and 10 seconds for
K3/1.

When the starting button is pressed, relay K1/2 is activated. One of its contacts K1.1 closes
and applies full power to the field and also to the armature in series with the starting resistors.
The armature current creates torque and the motor commences accelerating. The second
contact K1.2 latches the starting button and ensures that power continues to be applied to the
motor when the start button is released.

Simultaneously, full voltage is applied to both time-delay relays K2/1 and K3/1. After an
elapsed time of, say, 5 seconds, relay K2/1 is activated and contact K2.1 shorts out resistor
R2. The reduced resistance in the armature circuit causes an increase in armature current and
creates additional torque. This in turn enables further acceleration to a higher speed.

After a longer delay, say 10 seconds, relay K3/1 is activated and closes contact K3.1. This
shorts out the remaining resistor in the armature circuit and allows full voltage to be applied
to the armature.
The DC motor is protected against overloads by a thermal overload and the use of contactor
coils ensures that there is protection against low voltages.

The time taken by a motor to reach operating speed is dependent on the starting torque and
the load imposed on the motor.
In the example given above, the stage times are fixed and this may not always be a
satisfactory solution to DC motor starting. More effective means might be required.

The circuit in Figure 4 is typical of such a method. The method uses timing relays (electrical
or mechanical), oil dashpots or electronic timers. No allowance is made for load or motor
conditions. For example, a DC motor could be stalled but after a definite time interval, the
next stage is activated, that is, less resistance and still more armature current.

Current-Limited Acceleration
This method is suitable for DC motors that have to cope with varying loads where the starting
conditions may also vary. The maximum current is predetermined and the starting intervals
depend on the magnitude and inertia of the load. Each successive stage is controlled by a
contactor that is itself controlled by the previous stage. Auxiliary contacts and coil
interlocking methods are used. Current operated relays are used and each relay consists of a
set of cylindrical coils designed to carry the armature current. Each will release its iron core
at different current levels.
On starting, the first relay will attract its iron core. As the motor accelerates, the armature
current will gradually decrease until the relay can no longer hold the core and releases it.
Auxiliary contacts are then made.
These activate the next relay in the circuit and at the same time bypass some of the starting
resistance in the armature circuit. Acceleration and torque are then increased until the next
relay in the sequence goes through the same procedure.
If at any stage the load becomes too much for the motor and the current remains at a high
level, the next stage in the starting sequence cannot be initiated.

Back EMF Starting

With back EMF starting, voltage-dependent relay coils are connected in parallel with the
armature. As the back EMF generated by the armature rises, the current flowing in the
armature falls. This causes the armature voltage to increase until it reaches values that
progressively activate relays. These relays remove part of the starting resistance from the
armature circuit and the current again increases and repeats the sequence.
If for any reason the DC motor is unable to accelerate to full speed, the current remains high
and the relays are unable to reduce the resistance in the armature circuit. The principle of
operation is illustrated in Figure 5.

Figure 5 Back EMF DC starter circuit diagram

Summary contactor vs relay

S.
No Criteria Relay Contactor
.
1 Power Source Work on both A.C & D.C. Work on both A.C & D.C
Compatibility Used for single
2 Device Size It is smaller in size It is comparatively larger in size
3 Current Switching Used for low current-carrying Used for higher current
Capacity capacities around 1-10 A. application of around 10 to 2700
A.
4 Auxiliary Contacts Relay has only auxiliary Contactor has three or four main
contacts (at least two NO/NC contacts and few auxiliary
contacts) contacts
5 Safety features It is used for low power Used for high power application
application hence inbuilt safety therefore additional safety
features for the relay is less features are provided such as
common. Spring-Load, Arc suppression,
overload,
6 Open/Closed Some relays have both Contactors typically have
Contact Standards normally open and normally multiple sets of normally open
closed contacts, and many contacts. They are exclusively
 relays have multiple sets of designed to operate with
contacts. normally open contacts.
7 Voltage Capacity They operate on voltages that Contactors can be obtained with
range from 5 to 120 volts AC coils that have voltage ranges
or DC from 24 to 600 volts.
8 Application Routing signals, switching Motor control duty, electric
current, control circuits, or as a motor control, switching electric
form of logic for some heating elements, and large
applications. Used for low- banks of lights. Used for high
power applications. power applications.
9 Cause of failure Open circuit (break) or high High current, electrodynamic
resistance, contacts burned, forces during a short circuit,
contacts welded or stuck in the overvoltage, continual
closed (energized) position. chattering, aging temperature,
power quality, Corrosive
environment, voltage and
frequency fluctuation, and
mechanical shock.

1) DOL Starter
DOL stands for Direct Online Starter, most commonly used in the industry
to start the motor.

In this method, full voltage is applied to the motor, but the starting current
would be very high(usually 5-8 times more than it’s rated current). For a low
capacity motor, there is no need to reduce the voltage at the starting.

Although, it provides all other functionality like overloading, single phasing,

and low voltage.

To develop the PLC ladder logic of the DOL starter, first, we have to look at
the control circuit of this starter.
 DOL Starter
Advantages:
 Cost-Effective
 Simple in Construction
Disadvantages:
 Initial high current
 Unable to use on Heavy Motors

Here we have inputs like Start push button, Stop push button, Safety
switch, Overload relay, and outputs like contactor and ON/OFF indicator.

The conversion of DOL starter in PLC ladder logic is as below,

Ladder Logic of DOL Starter

2) Forward/Reverse Starter
Forward/Reverse starter is another starter used when we need to change
the direction of the motor, Through this starter, it is possible to operate the
motor in both directions.

Forward/Reverse starter works on the same principle as the DOL starter,

but it has additional functionality to change the direction of the motor.

Here you can find the control and power wiring of this starter.

Forward Reverse Starter

Advantages:
 Cost-Effective
 Simple in Construction
 High Starting Torque
Disadvantages:
 Initial high current
 Unable to use on Heavy Motors
Here we have inputs like Start forward, start to reverse and stop
pushbuttons, Safety switch, Overload relay, and outputs like forward and
reverse contactors.

The conversion of Forward/Reverse starter in PLC ladder logic is as below,

Ladder Logic of Forward-Reverse Starter

3) Star-Delta Starter
Star-Delta starter is used for heavy motors applications like Pump, Blower,
Crusher, etc.

Star-Delta starter supplies a low voltage initially at the start, this reduces a
torque also. This starter uses a timer, contactor, overload, etc.

In this starter, Star connection is used at the start and Delta connection is
used for a normal run.
 Star-Delta Starter
Advantages:
 Low starting current
 Good for long acceleration time
Disadvantages:
 Complex wiring

Here we have inputs like start, stop pushbuttons, safety switch, overload
relay, and output like a star, delta, and main contactors.

The conversion of Star-Delta starter in PLC ladder logic is as below,

Ladder Logic of Star-Delta Starter

What is DOL Starter?

The Direct On Line starter is a simple motor control device which is used to provide the
power supply to the motor with a basic protection & control circuit.

When we power the industrial motors, it results in a heavy rush of the current of the order of
six to eight times the normal full load current drawn by the motors.

The high current rapidly decreases as the motor picks up speed but it is at a very low power
factor and thus tends to disturb the voltage of the supply in the distribution lines. For this
reason, this type of starter is limited to the motor up to 5 HP rating.

A direct online starter essentially consists of a contactor having four normally open (NO)
and an OFF contact which are used to start and stop the motor.

To protect against overload, thermal or magnetic over-load coils are connected in each phase.
(overload relay)

DOL Starter working Principle

To start the motor, the ON push button (green) is pressed which energies the no-volt coil by
connecting it across the two phases.
The no-volt coil pickups its plunger in such a direction that all the normally open (NO)
contacts are closed and the motor is connected across the power supply through three
contacts.

The fourth contact (NO) serves as a hold-on contact which keeps the no-volt coil circuit
closed even after the ON push button is released. (Latching circuit)

To stop the motor, the OFF-push button (red) is pressed momentarily which de-energies the
no-volt coil opening the main contacts which disconnects the power to the motor.

When the motor is overloaded, the thermal overload relay contact, connected to the control
circuit opens thus disconnecting the no-volt relay from the supply.

Overload protection is accomplished by thermal element overload relay.

Star delta Connection circuit diagram:

Star delta starters consist of a power circuit and control circuit. The power circuit uses to
create contact between the motor and three-phase power supply. The control circuit uses to
control the starter circuit such as ON, OFF and tripping operations. Refer to the below star
delta circuit,

Power circuit

Power circuit consists of

MCCB Q1 – One Number; while selecting the MCCB, it should able to withstand the motor
high starting current and it should work as back protection for the motor. The rating should
be 150% of the full load current.
Contactor – 3 Numbers are used. Here 2 numbers of identical contactors such as one is for
Delta connection (K2) and Main connection (K1). The third contactor uses for Star operation
(K3) and the one end of K3 contactor will be short circuited for performing star operation.
Mostly AC3 contactors are used for circuit breaking and the rating should be more than 100%
of the Full Load current. In each switch operation, the contactor’s tip- contact gets damages,
if we use under capacity. Note that, the contact tips are costlier and it is about 70% of the
contactor.

Relays (K80) – One number of thermal overload relay is required. By adopting magnetic
tripping in the thermal overload relay, the motor can be protected from overcurrent and short
circuit fault. If the motor capacity is more than 100 HP, we recommend using CT operated
thermal overload relay. Since the life span of CT operated relays are high. Relay can be 58%
of the full load current.

The control circuit is a logic circuit to help us to interchange the motor operation from star to
delta.
They are consisting of,

Push buttons Two number – The green color is for Start – NO (P1) and red color for Stop –
NC (P2), Here NO and NC terminology indicate Normally Open and Normally Closed

Control MCB (X1) use to protect the control circuit.

MCCB feedback contact Q1-1 No

Timer T1 and Timer contact T2No. Here, timers are changing the motor connection from star
to delta. A dial adjustment in the timer is used to adjust the delay time. In general, star-delta
timer or off delay timer

K80NC1 is a relay feedback contact. It is Normally NC => Normally closed and under fault
condition, it will become NO.

Other auxiliary contacts will be taken from the contactors K1, K2, and K3. These contacts are
used to build the circuit diagram as shown in the figure.

A1 and A2 terminal indicates the contactor’s coil connection.

Working Principle:

Power circuit working sequence: After pressing the green button, the motor star and main
contactor will hold. Here the three-phase input directly going to MCCB => Contactor (K1
and K3) => Relay => motor terminal. At the same time, the Timer T1 starts, after reaching
set value, The star contactor K3 will open and delta contactor K2 will hold immediately.

K1 and K2 contactor will be in hold position to run the motor continuously. In case,
interruption in the power supply or fault in the motor means, the OLR K80 NC will open the
control circuit. Then the motor stops.

Here one terminal of the star contactor will be short circuit as shown in the figure.

Control Circuit Working sequence:

Start Button (P) pressed:

Lets us assume, the start pushbutton (P) is pressed, Start Pushbutton (P) NO become NC, then
the control current directly goes to Timer (T1) Coil, then T1NO2 goes to a Normally closed
state. Immediately K2 – Star contactor will be closed. The control sequence is below table.

STAR DELTA STARTER:

Star Delta Starter Power Circuit Diagram:

You can see in the below figure, I have shown the Star Delta Starter Connection with a Three
Phase Motor.

First, a Main switch or MCB or MCCB is connected to give the power supply to the Circuit.

Then a Thermal Overload Relay is connected for the protection purpose. The Thermal Over
Load relay will trip the circuit if a short circuit or overload fault occurs in the Motor.

In the Power Circuit of Star Delta Starter, three contractors are used. One is the main
Contactor which will be always ON after starting the motor. The other Contactors are Star
Contactor and Delta Contactor.

The star contactor is used to make Star connection. Only during the starting time, the Star
Contactor remain ON after a small time it will be OFF and the Delta Contactor will be ON.

Delta Contactor is used to make the delta connection. It will be Turn ON after turning OFF
the Star contactor and remain ON until we stop the Total operation.

Don't Confuse with the terms Star Contactor and Delta Contactor. They are not any special
types of Contactor. Here all contactors are the same type of contactor. Here the terms Delta
Contactor and Star contactor are used according to their operation.
Star Delta Starter Control Circuit Diagram:

First, an NC push Button switch is connected to Stop the operation.

Next, the circuit goes through the NC terminals of the Thermal Over Load Relay. When the
fault occurs the thermal overload relay will trip the circuit.

Next, a NO Push Button switch is connected to start the operation.

The NO terminals of the main Contactor is connected across the NO Push Button switch for
Holding. That means when the NO push button switch is OFF, the circuit will remain ON.

The Star Contactor is Connected with the NC terminal of the Timer and the Delta Contactor
is connected with the NO terminal of the Timer.

So at the starting time, the Star contactor will be turned ON. After a small time(which is to be
set manually) the NC of the Timer will be NO and NO will be NC so the Delta contactor will
be turned ON and remain ON until we push NC Push Button Switch for Stop.

So, this was the total concept of the Star Delta Starter Diagram.
Power circuit

Figure 1 shows the circuit diagram of a typical star delta starter. As mentioned earlier, apart
from protection fuses (F1), and overload relay (F2), the circuit consists of three contactors – a
line or main contactor (K1), a delta connection contactor (K2), and a star connection
contactor (K3). The terminals (U1, V1, W1) are connected to K1 through F2 & (U2, V2, W2)
K2 and K3.

Control circuit

The control circuit controls the switching of contactors and the transition from star to delta
configuration. A typical circuit consists of a fuse, start(S1) and stop (S0) pushbuttons, star-
delta timer (K4), and auxiliary contacts of overload relay and contactors.

Working:

Under normal conditions (F1, F2, and F3 are healthy), when S1 is pressed, timer coil K4 will
pick up and it energizes the coil of the contactor K2, and that in turn energizes the coil of line
contactor K1. This will drive the motor in the star configuration. The NO contact of K1 is
wired parallel to S1 such that the circuit remains latched until S0 is pressed.

After the time duration is set on the star delta timer, the K2 coil is de-energized and K3 is
energized and the motor runs in the delta configuration. When S0 is pressed or during
overload trips or the F1 fuse blown-outs, the coils of the contactor K1 and K3 de-energize
and the motor stops.

Star contactor (K2) and Delta contactor (K3) are electrically interlocked using NC contacts,
such that both contactors are never closed at a time. Additionally, they are also mechanically
interlocked. This makes sure that the coil of K2 is energized only when K3 is open and the
coil of K3 is energized only when K2 is open.

Auto Transformer Starter Diagram

Auto Transformer Starter Power Circuit Diagram

Autotransformer Starter Control Circuit Diagram:

 Autotransformer Starter Control Circuit Diagram

The working of the starter is as under:

 When the start button is pressed, a circuit is completed to the coil of main contactor
M, timer TR and shorting contactor S. And all these get energized, the motor gets
supply through the tapings of the autotransformer.

 The normally closed S contact connected in series with R coil opens to prevent both S
and R contactors from being energized at the same time.

 When the time sequence for TR timer is completed, it operates. Its normally closed
TR contact opens. This disconnects contactor S from the line and opens the shorting
of the autotransformer. In this state, winding of autotransformer is connected is series
of motor like a reactor and keeps on running smoothly.

 After a very short time delay, normally open contact of timer TR closes that closes the
run contactor R and connects the mains supply directly to the motor. After that motor
reaches full speed and is then in normal operating mode.
  The normally open contact of the timer operates after its normally closed contact with
a very short time delay due to its special time delay design. This time delay is very
essential for the smooth operation of the motor.

 When the stop button is pressed, the main contactor M is de-energizes. This
disconnects all other control components from the power line and the circuit returns to
its normal position.

Comparison of three phase induction

motor starters
Starting
Method Starting current Pros Cons
Torque
Direct-on- 5-10 times the full 5-10 times the Economical and Higher High in-rush
Line (DOL) load current full load torque starting torque. current
Star-Delta 2-3 times the full load 2-3 times the full Inrush current can be Starting torque
Starter current load torque reduced to one-third will reduce
when compared to
DOL.
Auto- 2-3 times the full load 2-3 times the full Inrush current can be Starting torque
transformer current load torque reduced to one-third will reduce
when compared to
DOL.
Soft starter 3-5 times the full load 1.5-2.5 times the Inrush current can be Starting torque
current full load torque reduced. Starting torque will be less
can be controlled.
Variable 1.1-1.5 times full load 1.5-2.5 times the Speed and torque Higher cost
Speed drive current full load torque control, communication
and Energy saving.

What is MCC and what are the various components involved in it?
What is a motor control center?

A motor is a device that utilizes electrical energy to do mechanical operations such as

rotating a pump, fan, blower, etc. Due to industrial development, the requirement for the
automation and mechanization of the different industrial processes is increased. The
mechanization of the different industrial processes requires many motors, so in order to
control all these motors, MCC’s are required. In the below image you can see the MCC, it is
a big enclosure that would house the major motor control equipment. The MCC has the
ability to plug in the control components, these components can be plugged in or unplug and
thus there is no need for wiring the devices. The MCC would be composed of a busbar and
other control equipment which can be utilized to control the operation of the motor and also
to place the components in an integrated panel. The MCC also has different motor starting
methods such as the DOL and star-delta starter.

What are the major components in a motor control center?

1. Bus bar
2. Circuit breaker
3. Magnetic contactor
4. Contactor auxiliary contact
5. Relay control
6. Control transformer
7. Cable installation control panel enclosure
8. Limit switch

MCC can be used to control multiple motor operations. The MCC is composed of several
components such as a motor starter, bus bar, control equipment, etc. All these components are
used to control the electric motor and these components are placed in a panel which is a
mixture of iron metal and carbon iron.

Bus bar
A bus bar is a bar that would be made up of brass, copper, etc, the major function of a bus bar
is to provide or distribute the required power to the electrical equipment. So in an MCC, the
bus bar would act as a power distributor. The major advantage of using a bus bar in an MCC
is that we can eliminate the wiring of several components, so because of this, the size of the
MCC would be reduced and also the number of parts in it. So, we can easily connect the
electrical equipment in an MCC with the help of a bus bar and this would also be useful to
locate the error. We can easily troubleshoot the problems in an MCC with the help of a bus
bar.
Overload relays
These relays would protect the motor from overheating, the overheating could be caused due
to the overload of the driven machinery. It can also be caused due to the low voltage level or
if there is an open phase in a three-phase system. So when the excessive current is drawn for
a specified amount of time the overload relay would open and the motor will be disconnected
from the power source. This relay would allow the temporary overload which could not cause
any damage to the motor and block the over-load which could damage the motor.
Miniature circuit breaker
The purpose of the MCB is to disconnect a circuit in case if there is an excessive current flow
in the circuit, or in case if there is an electrical load that exceeds capacity.
Control Transformers
Sometimes it would be necessary to operate the control circuit at low voltages than the power
circuit. So, to decrease the voltage level we can use a control transformer
Magnetic contactors
A magnetic contactor is used in an MCC to start or stop a motor. Mostly there would be a
remote-control device to start and stop the motor and for this purpose, we can use a
contractor. The operation of the magnetic contactor would be based on the electromagnetic
principle.
Time delay relay
The major purpose of a time delay relay is to provide the on delay and off delay timing. So
this device can be used for the automatic time setting, this device can be combined with the
other control equipment in an MCC, like a magnetic contactor.
Limit switch
This component is used to provide a signal in case if a specified limit is reached like if there
is an excess overload. The limit could be the rotating speed of the machine, position of the
machine part, etc. We can use this device as a replacement to the human operator and it can
be used where it is not possible for a human operator to operate.

What is the major purpose of an MCC?

Motor starting
The motor starting is an important process, and the starting of the motor should be slow and
gradual and this would be useful to protect the machine. Some industrial machines could be
damaged if it is operated very fast initially instead of gradually increasing the speed of the
machine.
Operational control
This device should maintain the required operational speeds and characteristics. So, by
maintaining or controlling the operational speed it can protect the motor, machine, materials,
and operator.
Stopping
The MCC must be capable to provide the fast stopping of the motor because in certain cases
the machine must be stopped quickly and this should be achieved by the MCC. Emergency
stops must be carried out for certain industrial machinery.
Reversing
The direction of the machine rotation would be required to change in an industrial process
and this should be done easily. In certain cases, continuous changing of direction is required
in an industrial process.
Damage prevention
The machine should be protected from any damages because it could cost a lot. An example
of this would be preventing the pileups in a conveyor by a machine. So the machine must do
the necessary actions such as reverse, stop, slow. The MCC must control the machine
according to the process requirement.
Motor protection
The MCC must protect the motor from
 Overcurrent
 Overload
 Low voltage
  Phase failure
 Phase reversal protection
 Ground fault protection

What are the considerations that must be taken while installing a motor controller?

 Electrical service – We must make sure whether the service is AC or DC, if it is AC

then frequency and number of phases in addition to the voltage must be considered.
 Motor- The motor must be connected to the electrical service and also make sure that
it is correctly sized for the machine load in case of the HP ratings. We must also
consider the speed and torque of the motor.
 The controller should be capable to start, stop, reverse the motor operation according
to the requirement
 The controller must be placed where it won’t be affected by certain environmental
conditions such as rain, snow, dirt, oils, or lubricants.

What are the different types of motor control centers?

Classification of the motor control center

We can classify the motor control center according to the type of supply voltage and also
according to their operation.
Based on supply voltage
 Low voltage MCC
 Maximum voltage MCC

Low voltage MCC

Low voltage motor control centers are typically used for low current three-phase motors from
208 V to 600 V.
Maximum voltage MCC
The maximum voltage MCC is used for large motors that run from 2300 V to 15000 V. It
uses a vacuum contactor to switch and also has separate compartments for switching and
power control.
Based on their operation
 Manual
 Semiautomatic
 Automatic

Manual control
So, in this type of MCC operation, the operator would need to directly go to the controller
location in case if any changes should be made. Basically, this is a simple device and it would
directly connect the motor to the line. This type is used to control the motor which has a
maximum of 10 horsepower. The manual operation of the starter is an ON-OFF switch,
which can be manually operated and it would also act as a safety device too.
Semiautomatic control
This type of MCC operation is carried out by pushbuttons, limit switches, pressure switches,
etc. This type of MCC also consists of certain sensing devices to control the operation of the
magnetic contactor or the starter. The starter would connect the motor to the line and the
pushbuttons would control the starter coil. Due to this, the control panel can be located away
from the motor or the starter. The operator must do certain operations such as starting or
stopping the motor but there is no need to go to the location of the motor or starter to do this
process.
Automatic control
In this type of MCC operation, there would be a control circuit and this control circuit would
be composed of certain sensing devices. This control circuit can start or stop the motor, it
would stop the motor in case of any fault conditions such as overload of the motor excessive
current.

How should we select a motor control center?

 Ampacity – We should consider the ampacity of the MCC while selecting it, ampacity
is the maximum amount of current that a horizontal bus can handle
 We must also consider the available fault current level while selecting, basically, it is
the amount of current which would flow in case of any short.
 The bussing material which is used for the electrical bussing must be considered too.
 Feeder cable is another important part of an MCC, we must consider how the feeder
cable is connected to the MCC. The connection would be of two types one will be the
overhead and the other would be the underground method. The power cables that
would provide the power to the MCC would be large in size and numerous too. So, if
we know the details of the feeder cable then it could be useful to do the cable
termination and also to avoid difficult wire bends.
 We should also consider the operating conditions such as full load current, locked
rotor current, noninductive current, number of poles, and also the total number of
expected operations.

What are the advantages of motor control centers?

 Easy installation
 Floor space can be saved
 Expandability is another feature of the MCC because we can add sections and units to
it.
 The safety level is increased
 Faster operation
 Centralized operation
 Remote control with interlock
 Downtime can be reduced because we can easily detect the problem by the MCC and
we can unplug the faulty part
What are the applications of motor control centers?

 Ships
 Refineries
 Hotels/shopping malls
 Power plants
 Steel plants