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Over Load Relay & Contactor for Starter

MAY 20, 2011 11 COMMENTS

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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

S00 0.1 To 0.4

0.4 To 0.6

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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 Suffix

Hz)
24V T
48V W
110V To 127V A
220V To 240V B
277V H
380V To 415V L

Type of Contactor for Starter:

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Contactor 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:

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Contactor Making Breaking Capacity

Capacity(Amp) (Amp)
AC1 1.5 X motor rated 1.5 X motor rated current
current
AC2 4 X motor rated 4 X motor rated current
current
AC3 10 X motor rated 8 X motor rated current
current
AC4 12 X motor rated 10 X motor rated current
current
AC5a 3 X motor rated 3 X motor rated current
current
AC5b 1.5 X motor rated 1.5 X motor rated current
current
AC6a 12 X motor rated 10 X motor rated current
current
AC6b 12 X motor rated 10 X motor rated current
current
AC7a 1.5 X motor rated 1.5 X motor rated current
current
AC7b 8 X motor rated 8 X motor rated current
current
AC8a 6 X motor rated 6 X motor rated current
current
AC8b 6 X motor rated 6 X motor rated current
current
AC12
AC13 10 X motor rated 1.1 X motor rated current
current
AC14 6 X motor rated 6 X motor rated current
current
AC15 10 X motor rated 10 X motor rated current
current

Contactor Status:

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Contactor Continuity Non Continuity

Status Between Pins (N/C) Between Pins (N/O)
21 and 22

11 and 12
Power Not
32 and 33
Applied
A1 and A2

B1 and B2

21 and 22

11 and 12
Power
32 and 33
Applied
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

Contactor’s 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.

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Contactor / Relay Se ing / Fuse / Cable for DOL STARTER

Contactor Relay se ing Cable (mm2)

H.P KW FLC Size Fuse
(Amp) Min Max Cu Allu

0.5 0.37 1 – 0.8 1.17 4 1 1.5

0.75 0.55 1.3 9 1 1.5 4 1 1.5

1 0.74 1.9 9 1.6 2.3 6 1.5 2.5

1.5 1.11 2.6 9 2 3 6 1.5 2.5

2 1.49 3.7 9 2.5 3.7 10 1.5 2.5

3 2.2 4.8 9 4 5.9 16 1.5 2.5

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5 3.73 7.8 9 6.3 9.4 20 1.5 2.5

7 5.22 11.2 12 8 11.7 25 2.5 4

10 7.46 16 16 12.5 18.7 25 4 6

12.5 9.32 19 32 16 23.4 32 4 6

15 11.19 20.8 32 16 23.4 50 6 10

20 14.92 28 32 20 30 50 6 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

H.P KW Full Relay Back Up Fuse

Load Rang(Amp)
Current

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(amp) Min Max

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

Full Back Up Fuse

Load Relay
H.P KW
Current Rang(Amp)
(amp) Min Max

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

FILED UNDER UNCATEGORIZED

About Jignesh.Parmar
Jignesh Parmar has completed M.Tech (Power System Control), B.E(Electrical). He is member of
Institution of Engineers (MIE) and CEng,India. Membership No:M-1473586.He has more than 16 years

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experience in Transmission -Distribution-Electrical Energy theft detection-Electrical Maintenance-

Electrical Projects (Planning-Designing-Technical Review-coordination -Execution). He is Presently
associate with one of the leading business group as a Deputy Manager at Ahmedabad,India. He has
published numbers of Technical Articles in “Electrical Mirror”, “Electrical India”, “Lighting
India”,”Smart Energy”, “Industrial Electrix”(Australian Power Publications) Magazines. He is Freelancer
Programmer of Advance Excel and design useful Excel base Electrical Programs as per IS, NEC,
IEC,IEEE codes. He is Technical Blogger and Familiar with English, Hindi, Gujarati, French languages.
He wants to Share his experience & Knowledge and help technical enthusiasts to find suitable solutions
and updating themselves on various Engineering Topics.

11 Responses to Over Load Relay & Contactor for Starter

Hament Kaushik says:

September 30, 2011 at 8:13 am
thanks sir ji
tis is very usfull for us.

Reply
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 se ings.

Thanks for your knowledge sharing…you are a real master..

Best Regards,

Reply
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
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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rishabh says:
January 16, 2013 at 10:11 am
thank you for posting it but it is incomplete knowledge for an engineer . he also deserves to know
about various specifications as what is voltage and power factor that you have taken into
consideration for making this chart. . please provide some basics so that i can select mccb, contactor .
o\l relay. for dol and s\d starter.
kindly provide some information.

THANKS

Reply
Jignesh.Parmar says:
January 16, 2013 at 3:43 pm
Thanks for your valuable Suggestion !
To calculate Size of Fuse/MCCB,Cable of Motor Please refer another Post Of this Blog

Reply
MUHAMMAD AFROOQ JAMAL says:
September 22, 2013 at 5:05 am
really great and very helpfull…

Reply
Yatindra says:
December 1, 2013 at 1:17 pm
To calculate size of fuse, contactor, relay,cable of motor please help us.

Reply
Jignesh.Parmar says:
December 1, 2013 at 1:34 pm
Already given in the blog…Please search…

Reply
arjun says:
December 12, 2013 at 1:40 pm
Dear Sir,
Your electrical basic note are very valuable as compare to diamond these notes cover all data which
are very important for gaining knowledge of career growing engineers. please help me for
understanding how 11kv transmission line enter in the plant , how its connected to the LT panel
please help me.

Reply
u.murali says:
September 30, 2016 at 9:42 am
we are using all motor 3ph 200 volt motor. any specification is required. based on current selecting is
ok?

Reply

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