Over Load Relay & Contactor for Starter

May 20, 2011 4 Comments

Over Load Relay & Contactor for Motor Starter:

Types of Over Load Relay:
1. Class 10: Would Trip after 10 seconds.
2. Class 20: Would Trip after 20 seconds.
3. Class 30: Would Trip after 30 seconds.

Over Load Relay should be set 115% to 130% of Motor Full Load Current.

Class 10 is faster than Class 20 and Class 30 over Load Relay.

Size of over Load Relay:

Size

Amp Capacity

0.1 To 0.4

0.4 To 0.6
S00
1.6 To 6

3 To 12

3 To 12
S0
6 To 25

6 To 25
S2
13 To 50

13 To 50
S3
25 To 100

S6

50 To 200

55 To 250

S10 & S12

200 To 540

300 To 63

Contactor Coil:
Coil Voltage (40 To 50
Hz)
24V
48V
110V To 127V
220V To 240V
277V
380V To 415V

Suffix
T
W
A
B
H
L

Type of Contactor for Starter:

Contacto
r

Application

AC1

Non-Inductive or Slightly Inductive ,Resistive

Load

AC2

Slip Ring Motor

AC3

Squirrel Cage Motor

AC4

Rapid Start / Stop

AC5a

Switching of Electrical Discharge Lamp

AC5b

Switching of Electrical Incandescent Lamp

AC6a

Switching of Transformer

AC6b

Switching of Capacitor Bank

AC7a

Slightly Inductive Load in Household or same

type load

AC7b

Motor Load in Household Application

AC8a

Hermetic refrigerant Compressor Motor with

Manual O/L Reset

AC8b

Hermetic refrigerant Compressor Motor with

Auto O/L Reset

AC12

Control of Restive Load and Solid State Load

with optocoupler Isolation

AC13

Control of Restive Load and Solid State with T/C

Isolation

AC14

Control of Small Electro Magnetic Load

( <72VA)

AC15

Control of Small Electro Magnetic Load

( >72VA)

Making and Breaking Capacity of Contactor:

Contactor Making
Capacity(Amp)
AC1
1.5 X motor rated
current
AC2
4 X motor rated current
AC3
10 X motor rated current
AC4
12 X motor rated current
AC5a
3 X motor rated current
AC5b
1.5 X motor rated
current
AC6a
12 X motor rated current
AC6b
12 X motor rated current
AC7a
1.5 X motor rated
current
AC7b
8 X motor rated current
AC8a
6 X motor rated current
AC8b
6 X motor rated current
AC12
AC13
10 X motor rated current
AC14
6 X motor rated current
AC15
10 X motor rated current

Breaking Capacity (Amp)

1.5 X motor rated current
4 X motor rated current
8 X motor rated current
10 X motor rated current
3 X motor rated current
1.5 X motor rated current
10 X motor rated current
10 X motor rated current
1.5 X motor rated current
8 X motor rated current
6 X motor rated current
6 X motor rated current
1.1 X motor rated current
6 X motor rated current
10 X motor rated current

Contactor Status:
Contactor Status

Power Not Applied

Continuity Between Pins (N/C) Non Continuity Between Pins

(N/O)
32 and 33

21 and 22

11 and 12

A1 and A2

B1 and B2

21 and 22

11 and 12
Power Applied

32 and 33
A1 and A2

B1 and B2

Main Circuit Voltage of O/L Relay & Contactor:

1. A.C= 240V,415V
2. D.C=230V,460V,600V

Contactors Coil Voltage:

1. A.C= 40V,220V,240V,415V
2. D.C=24V(For PLC),110V,230V,460V

Rated Current of Contactor: (Thermal and Intermediate

Duty):
1. A.C= 6,10,16,25,63,100,160,200,315,400,630,800 Amp

2. D.C= 16,20,80,160,315,1250,8000 Amp.

Contactor / Relay Setting / Fuse / Cable for DOL STARTER

Relay setting
H.P

KW

FLC

Contactor
Size (Amp)

Cable (mm2)
Fuse

Min

Max

Cu

Allu

0.5

0.37

0.8

1.17

1.5

0.75

0.55

1.3

1.5

1.5

0.74

1.9

1.6

2.3

1.5

2.5

1.5

1.11

2.6

1.5

2.5

1.49

3.7

2.5

3.7

10

1.5

2.5

2.2

4.8

5.9

16

1.5

2.5

3.73

7.8

6.3

9.4

20

1.5

2.5

5.22

11.2

12

11.7

25

2.5

10

7.46

16

16

12.5

18.7

25

12.5

9.32

19

32

16

23.4

32

15

11.19

20.8

32

16

23.4

50

10

20

14.92

28

32

20

30

50

10

25

18.65

34

38

32

37.4

63

10

16

30

22.38

40

45

32

47

80

16

25

40

29.84

53

63

50

59

100

25

35

50

37.3

65

70

57

65.5

125

25

50

60

44.76

78

85

70

88.9

125

25

50

75

55.95

96

110

85

98.2

160

50

70

100

74.6

131

140

115

168

200

70

95

125

93.25

156

170

115

168

250 120

150

150

111.9

189

205

160

234

315 150

240

180

134.28

227

250

160

234

355 185

300

215

160.39

271

300

200

299

400

270

201.42

339

400

250

374

500

335

249.91

338

475

320

468

500

Relay Range & Back up Fuse for DOL Starter

Back Up Fuse
Full
Load
Relay
Current Rang(Amp)
(amp)
Min
Max

H.P

KW

10

7.5

13.6

13 To 20

25

50

12.5

9.3

17

13 To 20

25

50

15

11.2

20

20 To 30

35

80

20

14.9

28

20 To 30

60

80

25

18.7

35

30 To 45

60

100

30

22.4

40

30 To 45

80

100

35

26.1

47

45 To 63

80

125

Relay Range & Back up Fuse for Star / Delta Starter

Back Up Fuse
Full
Load
Relay
Current Rang(Amp)
(amp)
Min
Max

H.P

KW

20

14.9

28

13 To 20

60

60

25

18.7

35

20 To 30

60

100

30

22.4

40

20 To 30

60

100

35

26.1

47

20 To 30

80

100

40

29.8

55

30 To 35

80

125

50

37.3

66

30 To 35

100

125

60

44.8

80

45 To 63

100

160

75

55.95

95

45 To 63

125

160

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About Jignesh.Parmar
Electrical engineer having more than 11 years experience in Power Transmission-Power
Distribution-Electrical Maintenance-Electrical Projects-Planning-Designing-coordinationExecution.Currently associated with one of the leading business group as a Asst.Manager at
Ahmedabad,India.Freelancer Programmer of Advance Excel.Design useful Excel Sheets of
Electrical Engineering as per IS,NEC,IEC,IEEE codes. Technical Author for "Electrical Mirror"
and "Electrical India" Magazines. Technical Blogger. Familiar with English, Hindi, Gujarati,
French languages. Share experience and knowledge and help technical enthusiasts to find
suitable solutions and updating themselves on various Engineering Topics.

4 Responses to Over Load Relay & Contactor for Starter

1.

Hament Kaushik says:

September 30, 2011 at 8:13 am

thanks sir ji
tis is very usfull for us.
Reply

2.

Saahib Ghouse says:

November 12, 2011 at 9:58 am
Please provide relay coordination examples ..hand calculations if included and
developing curves, selection of relay curves.
Thumb rules or any logic or technic or any hidden knowledge in performing relay
coordination studies and settings.
Thanks for your knowledge sharingyou are a real master..
Best Regards,
Reply

3.

nikhil says:
May 19, 2012 at 6:16 am
sir please insist me the contactor size for the star delta stater also.. and simple hand
cluculations.
Reply

4.

TANVEER SHAH says:

May 19, 2012 at 11:44 am
definitely your sharing valueable knowledge is a great task remembered to be ever for
comforting other keep it up good job good contribution wish u more grow to show such a
contributon to deliver spreading valueable knowledge.
thanks
TANVEER SHAH
Reply

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Electrical engineer having more than 11 years experience in Power Transmission-Power
Distribution-Electrical Maintenance-Electrical Projects-Planning-Designing-coordinationExecution.Currently associated with one of the leading business group as a Asst.Manager at
Ahmedabad,India.Freelancer Programmer of Advance Excel.Design useful Excel Sheets of
Electrical Engineering as per IS,NEC,IEC,IEEE codes. Technical Author for "Electrical Mirror"
and "Electrical India" Magazines. Technical Blogger. Familiar with English, Hindi, Gujarati,
French languages. Share experience and knowledge and help technical enthusiasts to find
suitable solutions and updating themselves on various Engineering Topics.
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