UNDERSTANDING ELECTRICAL CONTACTORS:

TYPES, APPLICATIONS, AND OPERATION

Prepared by: Muhammad Yusuf Abdullah

Supervisor: T. Harmand

Mechanical Engineering Department

Sulaimani Polytechnic University
MAY 5, 2024
Contents

Abstract ................................................................................................................................ 2

Introduction .......................................................................................................................... 3

What is an Electrical Contactor?........................................................................................ 3

Construction of a Contactor: .......................................................................................... 3

Working of a Contactor: ................................................................................................ 4

Significance of Contactors: ............................................................................................ 4

2. Construction and Components: .............................................................................. 5

Types of Contactors ......................................................................................................... 6

1. AC Contactors ........................................................................................................... 6

2. DC Contactors ........................................................................................................... 6

3. Definite Purpose Contactors ...................................................................................... 6

4. Miniature Contactors ................................................................................................. 6

1. Motor Control ............................................................................................................... 7

2. Heating Systems ............................................................................................................ 7

3. Lighting Circuits ........................................................................................................... 7

4. Capacitor Banks and Power Factor Correction ............................................................... 7

Operation and Working Principle of Contactors ................................................................. 8

Conclusion ........................................................................................................................ 9

References .......................................................................................................................... 10

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Abstract

Abstract: Electrical contactors serve as critical components in power circuits, particularly for
managing heavy loads such as motors, heaters, and lighting systems. This report explores the
fundamental aspects of contactors, including their construction, various types, and practical
applications. By gaining a comprehensive understanding of contactors, engineers can design
more efficient and reliable electrical systems.

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Introduction

What is an Electrical Contactor?

An electrical contactor is an essential electromechanical control device used to make or break

the connection between a load (such as a motor, transformer, or lighting system) and the
power supply. While it shares similarities with a relay, a contactor is specifically designed for
higher current-carrying applications. In contrast, relays are better suited for lower current
tasks.

Construction of a Contactor:

A contactor consists of three main parts:

1. Coil or Electromagnet:
o The coil is wound around an electromagnetic core, effectively creating an
electromagnet.
o It comprises two parts: a fixed portion and a movable part (also known as the
armature).
o A spring connects these parts, allowing for a spring return arrangement.
o When the coil force exceeds the spring force, the contacts close. Conversely,
when the spring force dominates, the contacts separate.
o A small current flows through the spring from the external control circuit to
excite the electromagnet.
o For AC applications, the electromagnetic core uses laminated soft iron to
reduce eddy currents. In DC applications, solid steel cores suffice.
2. Enclosure or Frame:
o The enclosure protects the internal components of the contactor.
o It can be made of materials such as plastic, nylon 6, ceramic, or Bakelite.
o The enclosure insulates the contacts and shields them from dust, oil, weather,
and other potential hazards.
3. Contacts:
o The heart of the contactor lies in its contacts.
o These contacts are typically normally open (NO) by default.
o When the coil is de-energized, the load is disconnected.
o Some contactors can be designed for both normally open and normally closed
applications.

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Working of a Contactor:

• When the coil receives electrical energy, it generates a magnetic field.

• This magnetic force attracts or repels the contacts, either closing or opening the
circuit.
• Contactors are commonly used in motor starters, allowing equipment to be turned on
and off efficiently.

Significance of Contactors:

• High Current Handling: Contactors are indispensable for managing heavy loads,
such as electric motors, lighting systems, and heating equipment.
• Safety and Efficiency: By providing reliable switching, contactors enhance safety
and prevent damage to electrical components.
• Control and Automation: They play a crucial role in industrial automation,
controlling various processes and machinery.

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2. Construction and Components:

1. Electromagnet:
o The electromagnet (also known as the coil) is the driving force behind a
contactor.
o When energized, it generates a magnetic field that attracts or repels the
contacts.
o The input terminals (A1 and A2) connect to the power supply, allowing
current to flow through the coil.
o This magnetic force pulls the moving contacts toward the stationary contacts,
closing the circuit.
2. Stationary and Moving Contacts:
o Stationary Contacts: These fixed contacts remain in place within the
contactor body.
▪ They are typically made of high-quality materials such as silver alloy
to ensure good conductivity.
▪ Stationary contacts provide a stable connection when the contactor is
closed.
o Moving Contacts (Armature): These contacts move along with the iron core.
▪ When the electromagnet activates, the moving contacts are drawn
toward the stationary contacts.
▪ Moving contacts are also coated with silver alloy to withstand high
temperatures caused by arcing during switching.
3. Arc Quenching Structure:
o During contactor opening, an electric arc forms between the separating
contacts.
o To prevent excessive arcing and ensure safe operation, an arc chute is
employed.
o The arc chute is made of zircon-filled phospho-asbestos material.
o It effectively extinguishes the electric arc by providing a controlled path for
the arc to dissipate its energy.
o By quenching the arc, the contactor avoids damage to the contacts and
minimizes wear.
4. Contactor Body/Enclosure:
o The contactor body houses all the components.
o It is made from materials like Nylon 6, Bakelite, or thermosetting plastic.
o The enclosure serves several purposes:
▪ Guards the coil and contactor from physical contact, dust, and external
interference.
▪ Provides insulation to prevent accidental electrical shocks.
▪ Ensures safety during operation.
5. Mounting Mechanism:
o The mounting mechanism secures the contactor components together.
o Two screws lock the enclosure, contactor, and arc chute in place.
o For higher-rated contactors, the arc chute can be removed by pushing these
screws.
o Smaller-rated contactors have a fixed arc chute.

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Types of Contactors

1. AC Contactors

AC contactors are specifically designed for alternating current (AC) circuits. Here are some
key points about AC contactors:

• Function: AC contactors handle AC loads efficiently, making them suitable for

applications where the power source is AC.
• Construction: They have similar components as other contactors (electromagnet,
stationary and moving contacts, and arc quenching structures).
• Applications: AC contactors are commonly used in motor control, lighting circuits,
and HVAC systems.

2. DC Contactors

DC contactors serve direct current (DC) applications. Here’s what you need to know about
them:

• Purpose: DC contactors are specifically designed to handle DC voltage.

• Design Considerations: Unlike AC contactors, DC contactors must account for
factors like arcing due to the absence of zero-crossing points in DC circuits.
• Applications: DC contactors find use in battery-powered systems, solar panels, and
other DC-powered devices.

3. Definite Purpose Contactors

Definite purpose contactors are specialized for specific tasks. Here’s an overview:

• Function: These contactors are tailored for particular applications, such as motor
starters, lighting control, or HVAC systems.
• Customization: Manufacturers design them with specific features to meet the
requirements of the intended purpose.
• Examples: Motor starters use definite purpose contactors to protect motors from
overload and control their operation.

4. Miniature Contactors

Miniature contactors are compact versions used in control panels and smaller applications:

• Size: They are smaller than standard contactors.

• Applications: Miniature contactors are commonly found in control panels,
automation systems, and low-power circuits.
• Advantages: Their compact size allows for efficient use of space in electrical
enclosures.

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1. Motor Control

Motor control is one of the primary applications of contactors. Here’s how contactors are
involved in starting, stopping, and reversing motors:

• Starting Motors: When a motor needs to start, the contactor’s coil is energized. This
creates a magnetic field that attracts the moving contacts, closing the circuit. The
motor receives power and begins to rotate.
• Stopping Motors: To stop a motor, the contactor’s coil is de-energized. The magnetic
field disappears, causing the contacts to open. This interrupts the current flow to the
motor, bringing it to a halt.
• Reversing Motors: For reversible motors (e.g., those used in conveyor belts), two
contactors are used. By energizing the appropriate contactor, the motor direction can
be reversed.

2. Heating Systems

Contactors play a crucial role in heating systems, including heaters, furnaces, and industrial
ovens:

• Heaters: Electric heaters (such as space heaters or water heaters) require contactors to
manage the high current flow. The contactor ensures safe operation by controlling the
heater’s power supply.
• Furnaces: In industrial furnaces, contactors regulate the heating elements. They
enable precise temperature control and prevent overheating.
• Industrial Ovens: Similar to furnaces, contactors manage the heating elements in
industrial ovens. They ensure consistent and efficient heating.

3. Lighting Circuits

Contactors are essential for managing lighting loads in various settings:

• Commercial Buildings: In large commercial spaces, contactors control lighting

circuits. When a switch is turned on, the contactor closes, allowing electricity to flow
to the lights.
• Outdoor Lighting: Streetlights, parking lot lights, and stadium floodlights often use
contactors. They allow centralized control and efficient switching of outdoor lighting.

4. Capacitor Banks and Power Factor Correction

Capacitor banks are used for power factor correction in electrical systems:

• Power Factor Correction: In industrial and commercial setups, contactors switch

capacitor banks to improve power factor. Capacitors compensate for reactive power,
reducing energy losses and improving system efficiency.

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Operation and Working Principle of Contactors

1. Energizing the Electromagnet:

o When voltage is applied to the coil (electromagnet) of the contactor, it
generates a magnetic field.
o This magnetic field attracts the movable contacts (usually made of conductive
material) toward the stationary contacts.
o As a result, the contacts close, completing the electrical circuit.
2. De-energizing the Electromagnet:
o When the coil voltage is removed (de-energized), the magnetic field
disappears.
o The spring-loaded mechanism or gravity pulls the movable contacts away
from the stationary contacts.
o The circuit is now open, interrupting the current flow.
3. Magnetic Force and Contact Closure:
o The magnetic force between the electromagnet and the movable contacts is
crucial.
o It overcomes the spring tension or gravity, causing the contacts to come
together.
o The stronger the magnetic field (due to higher coil voltage), the more firmly
the contacts close.

In summary, contactors use electromagnets to control the opening and closing of electrical
contacts. When energized, they pull the contacts together, allowing current to flow. When de-
energized, the contacts separate, breaking the circuit. This mechanism ensures efficient and
reliable operation in various applications.

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Conclusion

Electrical contactors are indispensable components in power distribution systems. Here’s

why they matter:

1. Critical Role: Contactors serve as robust switches for heavy loads, such as motors,
heaters, and lighting circuits. Their ability to handle high currents ensures efficient
power management.
2. Safety and Efficiency: By controlling the flow of electricity, contactors enhance
safety. They prevent overload conditions, short circuits, and other electrical hazards.
Additionally, their rapid switching capability contributes to efficient system
operation.
3. Practical Knowledge: Through our lab session, we’ve gained hands-on experience
with contactors. Understanding their construction, types, and applications equips us to
design reliable electrical systems.
4. Safe Power Distribution: Whether in industrial settings, commercial buildings, or
residential spaces, contactors play a vital role in ensuring safe and efficient power
distribution.

Remember, the next time you switch on a motor or adjust the lighting in a room, there’s
likely a contactor silently managing the electrical flow behind the scenes! 🌟🔌💡

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References

1. Motor Starter: Contactors are commonly used in motor starters. They control the
ON/OFF operation of electric motors, ensuring safe and efficient motor control 1.

2. Lighting Control: In industrial, commercial, and residential settings, contactors

automate lighting circuits. They allow centralized control of lighting systems, turning
lights ON or OFF as needed1.

3. Evaporator Control: Contactors play a role in refrigeration systems. They manage

the operation of evaporator fans, ensuring proper cooling and temperature control2.

4. Capacitor Banks: For power factor correction, contactors switch capacitor banks.
These banks improve the efficiency of electrical systems by compensating for reactive
power1.

5. Heating Systems: Contactors control heaters, furnaces, and industrial ovens. They
ensure precise temperature regulation and safe operation of heating equipment 1.

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