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) Suffix

24V T

48V W

110V To 127V A

220V To 240V B

277V H

380V To 415V L

Type of Contactor for Starter:

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:

Contactor Making Capacity (Amp) Breaking Capacity (Amp)

AC1 1.5 X motor rated current 1.5 X motor rated current

AC2 4 X motor rated current 4 X motor rated current

AC3 10 X motor rated current 8 X motor rated current

AC4 12 X motor rated current 10 X motor rated current

AC5a 3 X motor rated current 3 X motor rated current

AC5b 1.5 X motor rated current 1.5 X motor rated current

AC6a 12 X motor rated current 10 X motor rated current

AC6b 12 X motor rated current 10 X motor rated current

AC7a 1.5 X motor rated current 1.5 X motor rated current

AC7b 8 X motor rated current 8 X motor rated current

AC8a 6 X motor rated current 6 X motor rated current

AC8b 6 X motor rated current 6 X motor rated current

AC12    
 AC13 10 X motor rated current 1.1 X motor rated current

AC14 6 X motor rated current 6 X motor rated current

AC15 10 X motor rated current 10 X motor rated current

 Contactor Status:
Contactor Status Continuity Between Pins (N/C) Non-Continuity Between Pins (N/O)

21 and 22
11 and 12
Power Not Applied 32 and 33
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
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.
 Contactor / Relay Setting / Fuse / Cable for DOL STARTER

Contactor Relay setting Cable (mm2)

H.P KW FLC Fuse
Size (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
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
Full Load Back Up Fuse
H.P KW Current Relay Rang(Amp)
(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 Load Relay Rang Back Up Fuse

H.P KW
Current (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