Contactor vs Relay: Understanding the Differences and Applications

Umar Waseem 20 Sep, 2023

Contactor vs relay used in electrical devices

This article aims to provide a comprehensive comparison between contactors and relays,
highlighting their key differences, applications, and factors to consider when choosing
the right device for your needs.

Introduction

Contactors and relays are essential components in electrical systems, serving as switches for
controlling power flow. Both devices share similarities in their basic function, so there is usually
confusion about the difference between a contactor vs relay! Typically used for switching the loads,
contactors and control relays are integrated into an electrical circuit subject to the resultant load. A
wrong decision in deciding the electrically operated switches for a particular application can cost a
huge amount of investment, damaging the integrated electrical circuit. By understanding the
fundamental principles and technical aspects of contactor vs relay, you will be better equipped to
make informed decisions when designing or maintaining electrical systems.

Basic Definitions

What is a Contactor?
Electromagnetic contactor switch used in an industry

A contactor is an electromechanical switch designed to control the flow of electrical current in high-
power applications. It consists of three main components: a coil, contacts, and an enclosure. When
energized, the coil generates a magnetic field, which attracts the contacts, causing them to close and
complete the circuit. This allows the flow of current through the connected electrical load.

Contactors are typically used in applications where high currents, typically above 15 amperes, need to
be switched on and off. These are known for their capability to handle currents of over 5000
amperes and high power over 100 kW. [1] Contactors are designed to handle high inrush currents
when starting large motors or other inductive loads. The contacts in a contactor are usually made of
materials with high electrical conductivity, such as silver or copper, to minimize contact resistance and
ensure efficient current flow. The enclosure, often made of plastic or metal, protects against
environmental factors and electrical hazards.

One of the key features of contactors is their ability to handle high currents while maintaining a
relatively small form factor. This is achieved through arc suppression techniques, such as arc chutes
or blowout magnets, which help extinguish the electrical arc that forms when the contacts open or
close. These features enable contactors to operate reliably and safely in demanding electrical
environments.

What is a Relay?
Electromagnetic relays for load management in the electrical control panel

A relay is an electromechanical or solid-state device that serves as a switch to control the flow of
electrical current in low to medium-power applications. It consists of a coil, contacts, and an
enclosure similar to a contactor. When the coil is energized, it generates a magnetic field that attracts
the contacts, either closing or opening the circuit, depending on the relay's configuration. This allows
the flow of current through the connected electrical load.

Relays are commonly used in applications with lower current requirements, typically below 15
amperes. They are often employed to control smaller loads or as an intermediary between a low-
power control signal and a higher-power load. The contacts in a relay can be made of various
materials, such as silver or gold, depending on the specific application requirements. The enclosure,
typically plastic, protects against environmental factors and electrical hazards.

One of the main advantages of relays is their ability to isolate the control circuit from the load circuit.
This means that a low-power control signal can switch a higher power load without the risk of
electrical interference or damage to the control circuit. Additionally, relays can be designed with
multiple contacts, allowing them to control multiple circuits simultaneously. These also provide
different switching configurations, such as single-pole double-throw (SPDT) or double-pole double-
throw (DPDT) arrangements. [2]

Key Differences Between Contactors and Relays

Load Capacity

Load capacity is the maximum allowable force that can be applied to a stage in a specified direction
while meeting stage specifications. [3] One of the primary differences between contactors and relays
is their load capacity. Contactors are designed to handle high-current loads, while relays are suitable
for low to medium-current loads. This difference in load capacity results from the design and
construction of the devices, with contactors featuring larger and more robust auxiliary contacts to
accommodate higher currents. Special contactors are utilized to switch three phases of power
simultaneously.
In practical terms, contactors are often used in applications involving large motors, heavy machinery,
or other high-power equipment, where the current requirements can reach hundreds or even
thousands of amperes. On the other hand, relays are more commonly found in control systems,
automation, and low-power devices, where the current requirements are relatively modest. Relays are
typically limited to single-phase applications.

The choice between a contactor and a relay for a specific application depends on the current
requirements of the load. When starting motors or inductive loads, considering both the continuous
current rating and the initial surge of current, known as inrush current, is essential. Selecting a device
with an appropriate load capacity ensures reliable operation and minimizes the risk of device failure.

Switching Mechanism

RCD circuit breaker board with many switches

Switching is a way to control continuity between two points in an electrical circuit. [4] Another key
difference between contactors and relays is the way they switch electrical currents. Both devices use
an electromechanical mechanism, where an energized coil generates a magnetic field that attracts the
spring-loaded contacts, either opening or closing the circuit. However, the specific design and
construction of the switching mechanism can vary between the two devices, leading to differences in
performance and suitability for specific applications.

In contactors, the switching mechanism is designed to handle high currents and minimize the effects
of electrical arcing. This is achieved through the use of arc suppression techniques, such as arc
chutes or blowout magnets, which help extinguish the electrical arc that forms when the contacts
open or close. Contactors typically have larger contacts made of materials with high electrical
conductivity, like silver or copper. This ensures efficient current flow by minimizing contact resistance.

Conversely, relays have a more compact switching mechanism, suitable for lower current applications.
The contacts in relays can be made of various materials, such as silver or gold, depending on the
specific application requirements. Relays are less robust than contactors in preventing wear and
damage caused by electrical arcing in high-current situations. Capacitor banks can be used to reduce
the inrush current when a relay switches on a high-power load.

The choice between a contactor and a relay for a specific application depends on the switching
requirements, including the current levels, the frequency of switching, and the need for arc
suppression. Selecting the most appropriate device for your application minimizes the risk of device
failure or damage to the connected equipment.

Recommended reading: Switching vs Linear Power Supply: What's the difference

2.3. Open/closed contact standards

Relays are designed to operate both normally open and normally closed depending on the required
function, but contactors are designed to operate with normally open contacts. This means there is no
contactor connection when the coil is de-energized, which is not necessarily true regarding relays.

An electronic relay - upside down

Easy to remember:

Normally closed (NC) = Current flows

Normally open (NO) = Current does not flow

In normally open conditions, no current flow is in its normal or initial state. But energizing it and
switching it on will close the contacts to allow it to flow current. On the other hand, normally closed in
NC contacts is a condition with a flow of current in its normal or initial state. But contrary to what
happens in NO, de-energizing and switching it on will open the contact to stop the current flow.
Contactors are typically used to switch high-voltage circuits, while relays are typically used to switch
low-voltage circuits.

2.4. Size and Construction

The size and construction of contactors and relays also differ, with each device designed to
accommodate its intended applications and load capacities.

Contactors are generally larger and more robust than relays due to their ability to handle high
currents. The contacts in contactors are typically made of materials with high electrical conductivity to
minimize contact resistance and ensure efficient current flow. Contactors are typically designed to
handle AC and DC loads; their coil draws significant power. Additionally, they come with provisions for
arc suppression to prevent any damage from electrical arcing.

Conversely, relays are more compact and lightweight, making them suitable for low to medium-
current applications. The contacts in relays can be made of various materials depending on the
specific application requirements. They are designed to open or close circuits electronically or
electromechanically. Since they manage smaller loads, relays don‘t usually require the same level of
arc suppression as contractors.

When selecting between a contactor and a relay for a specific application, it is essential to consider
the size and construction requirements of the device. This includes factors such as available space,
mounting options, and environmental conditions. By understanding the differences in size and
construction between contactors and relays, you can choose the most appropriate device for your
application, ensuring reliable operation and minimizing the risk of device failure or damage to the
connected equipment.

2.5. Electrical Noise

Electrical noise, or electromagnetic interference (EMI), is an unwanted electrical signal disturbance

affecting electronic devices' performance and reliability. Contactors and relays, as electromechanical
switches, can generate electrical noise during their operation, with the level of noise depending on
the design and construction of the device.

Due to their larger size and higher current handling capabilities, contactors can generate more
electrical noise than relays. The opening and closing of contacts in a contactor can create electrical
arcs, which produce electromagnetic radiation that can interfere with nearby electronic devices. To
mitigate this issue, contactors often employ arc suppression techniques to extinguish the electrical arc
and reduce the amount of electrical noise generated.

Conversely, relays generate less electrical noise due to their smaller size and lower current handling
capabilities. However, they can still produce some electrical noise during their operation, particularly
when switching inductive loads. Solid-state relays use semiconductor components that offer lower
levels of electrical noise, making them suitable for applications where EMI is a concern.

When choosing between a contactor and a relay for a specific application, it is essential to consider
the potential impact of electrical noise on the performance and reliability of the connected equipment.
In situations where EMI is a concern, such as in sensitive electronic systems or environments with
strict electromagnetic compatibility (EMC) requirements, selecting a device with lower electrical noise
generation may be more appropriate.

2.6. Lifespan and Durability

The lifespan and durability of contactors and relays are important factors when selecting the
appropriate device for a specific application. Both devices are subject to wear and tear due to their
electromechanical nature. Still, the extent of wear and the expected lifespan can vary depending on
the design, construction, and operating conditions.
Contactors, designed to handle high currents, typically have a longer lifespan and greater durability
than relays. The contacts in contactors are made of materials with high electrical conductivity, which
minimize contact resistance and ensure efficient current flow. Additionally, contactors often employ
arc suppression techniques which help extinguish the electrical arc that forms when the contacts
open or close, reducing wear on the contacts and extending the device's lifespan.

Relays have a shorter lifespan and lower durability than contactors due to their smaller size and lower
current handling capabilities. The contacts in relays wear out more quickly than those used in
contactors, particularly when switching inductive loads or operating at high frequencies. Solid-state
relays offer improved durability and longer lifespans compared to electromechanical relays. Still, they
may not be suitable for all applications due to their specific characteristics and limitations.

Factors that can affect the lifespan and durability of contactors and relays include the frequency of
switching, the current and voltage ratings, and the type of load being switched. This also includes the
environmental conditions, such as temperature, humidity, and the presence of dust or corrosive
substances. By understanding the differences in lifespan and durability between contactors and
relays, you can select the right device to ensure reliable operation and minimize the risk of device
failure.

Recommended reading: General Purpose Port Protection Against Electrical Stress

Parameters Contactor Relay

An electromagnetic switch that can An electromagnetic switch that can

Definition carry a current load of up to 12,000 carry a current load of up to 10
amperes amperes

Comparatively smaller or of the same

Size Large in size
size as the contactor

Cost More cost Less cost

It consists of at least one set of

three-phase power contacts, and Comes with at least two contacts-NC
Auxiliary Contacts
built-in auxiliary contacts can also be and NO
present

Load 9A and above 10A or below

Voltage Maximum 1000 volts Maximum 250 volts

Phase 1 or 3 phase 1 phase

Life Span Shorter Longer

Switching Device The average switching speed for a The average switching speed for a
Speed contactor is between 20 and 250 relay is between 3 and 100 ms
Coil Power
More coil power consumption Less coil power consumption
Troubleshooting

Relays have better troubleshooting

They do not come with any
Troubleshooting features, such as flags or small lights
troubleshooting features
indicating the position of the relay

Sound level of humming noise is The sound level is lesser than that of
Humming Noise
higher a contactor

Maintenance Requires more maintenance Requires less maintenance

At least three-phase electrical

Applications networks, such as transformer or Single-phase applications
induction motor

Applications of Contactors and Relays

Contactors and relays for electric equipment motor starter control and industrial
machines

Industrial Applications

Contactors and relays are crucial in controlling and managing electrical loads in industrial settings.
Their specific applications depend on load capacity, switching requirements, and environmental
conditions.

Contactors are commonly used in industrial applications involving high-power equipment, such as
large motors, heavy machinery, heating, ventilation, and air conditioning (HVAC) systems. These
devices require high current handling capabilities, which contactors are designed to accommodate.
For instance, contactors can be found in motor control centers responsible for starting and stopping
large motors and providing overload protection. [5] Additionally, contactors can be used in power
distribution systems to control the flow of electricity to various parts of an industrial facility. In
automotive applications, contactors are typically used for high-power loads, including starter motors,
EV motors, air conditioning compressors, and electric power steering motors.

Contactors used in electromagnetic motor protection device

Relays, on the other hand, are more suitable for low to medium-current applications in industrial
environments. They are often employed in control systems, automation, and safety circuits, where
their ability to isolate the control circuit from the load circuit is essential. For example, relays can be
used in programmable logic controllers (PLCs) to control the operation of machinery or in safety
systems, such as emergency stop circuits, to ensure the safe operation of equipment. Relays can also
be found in monitoring and alarm systems, which activate alarms or initiate corrective actions in
response to specific conditions, such as temperature or pressure deviations.
Magnetic contactor and overload relay used in main distribution board

By understanding the specific requirements of industrial applications and the capabilities of contactors
and relays, you can select the most appropriate device, ensuring reliable operation and optimal
performance of your electrical systems.

Commercial Applications

In commercial environments, contactors and relays control and manage electrical loads in various
applications.

Contactors are often employed in commercial applications that involve high-power equipment, such
as HVAC systems, lighting control, and large appliances. For example, contactors can be used in
commercial buildings to manage the operation of air conditioning units, ensuring efficient energy
usage and maintaining a comfortable indoor environment. In lighting control systems, contactors can
be utilized to switch large groups of lights on and off, either manually or based on a predetermined
schedule, helping to reduce energy consumption and extend the lifespan of the lighting equipment.

Magnetic contactors in electricity control devices used commercially

Relays, on the other hand, are more suitable for low to medium-current applications in commercial
settings. They are commonly found in control systems, automation, and safety circuits, where their
ability to isolate the control circuit from the load circuit is essential. For instance, relays can be used
in building automation systems to control various aspects of the building's operation, such as lighting,
heating, and security. In safety systems, relays can be employed to monitor and control emergency
lighting, fire alarms, and access control systems, ensuring the safety and security of the building's
occupants.
Relays and fuses installed in electrical cabinet of automation system in building

By understanding the specific requirements of commercial applications and the capabilities of

contactors and relays, you can select the most appropriate device, ensuring reliable operation and
optimal performance of your electrical systems.

Residential Applications

In residential environments, contactors and relays have various applications in controlling and
managing electrical loads.

Contactors are used in residential applications that involve high-power equipment, such as central air
conditioning systems, electric water heaters, and solar power installations. For example, contactors
can be employed in solar power installations; contactors can be utilized to switch between grid power
and solar power, depending on the availability of solar energy and the requirements of the electrical
loads in the home. [6]

Relays are more suitable for low to medium-current applications in residential settings. Relays can be
used in home automation systems to control various aspects of the home's operation, such as
lighting, heating, and security. In safety systems, relays can be employed to monitor and control
smoke detectors, carbon monoxide alarms, and security systems, ensuring the safety and security of
the home's occupants.

By understanding the specific requirements of residential applications and the capabilities of

contactors and relays, you can select the most appropriate device, ensuring reliable operation and
optimal performance of your electrical systems.

Recommended reading: Innovative Transformer Solution Addresses Traditional

Challenges
Selecting the Right Device for Your Application

Load Requirements

When choosing between a contactor and a relay for a specific application, the load requirements is
one of the most critical factors to consider. This includes both the continuous current rating and the
inrush current, which is the initial surge of current that occurs when starting a motor or other
inductive loads.

To determine the load requirements, you should first identify the current and voltage levels of the
electrical load you need to control. This information can typically be found on the equipment's
nameplate or in the manufacturer's documentation. It is essential to select a device with a continuous
current rating that meets or exceeds the maximum current requirement of the load. Additionally,
consider the inrush current, which can be significantly higher than the continuous current rating,
especially for inductive loads like motors.

Once you have determined the load requirements, you can compare the specifications of contactors
and relays to find a suitable device. Contactors are generally more appropriate for high-current
applications, while relays are better suited for low to medium-current applications. By selecting a
device with the appropriate load capacity, you can ensure reliable operation and minimize the risk of
device failure or damage to the connected equipment.

Environmental Factors

Environmental factors can also play a significant role in determining the most suitable device, whether
a contactor or a relay, for your specific application. These factors include temperature, humidity, dust,
and the presence of corrosive substances, which can affect the performance, reliability, and lifespan
of the device.

Contactors, with their robust construction and larger size, are generally better suited for harsh
environments. where high temperatures, humidity, or dust may be present. The enclosures of
contactors, typically made of plastic or metal, protect against environmental factors and electrical
hazards. Additionally, contactors often feature arc suppression techniques, such as arc chutes or
blowout magnets, which help extinguish the electrical arc that forms when the contacts open or close,
reducing wear on the contacts and extending the device's lifespan.

Relays are more compact and may be less resistant to harsh environmental conditions. The
enclosures of relays, typically made of plastic, protect against environmental factors and electrical
hazards but may not be as durable as the enclosures used in contactors. Solid-state relays, which use
semiconductor components instead of mechanical contacts, can offer improved resistance to
environmental factors. Still, they may not be suitable for all applications due to their specific
characteristics and limitations.

When selecting between a contactor and a relay for a specific application, it is essential to consider
the environmental conditions in which the device will operate. By understanding the differences in the
construction and materials used in contactors and relays, you can choose the most appropriate device
to ensure reliable operation.

Cost Considerations

Cost considerations can be significant in the decision-making process when selecting between a
contactor and a relay for a specific application. The costs associated with these devices can vary
depending on factors such as load capacity, construction materials, and additional features, such as
arc suppression techniques.

Contactors, due to their larger size and higher current handling capabilities, are generally more
expensive than relays. The materials used in contactors, such as silver or copper contacts, can
contribute to their higher cost. Additionally, the arc suppression techniques employed in contactors,
such as arc chutes or blowout magnets, can add to the overall cost of the device.

Relays, on the other hand, are typically less expensive than contactors, making them a more cost-
effective option for low to medium-current applications. However, the cost of relays can vary
depending on the specific materials used for the contacts, such as silver or gold, and the type of
relay, such as electromechanical or solid-state. Solid-state relays, which use semiconductor
components instead of mechanical contacts, can be more expensive than electromechanical relays
but offer improved durability and lower electrical noise generation.

When considering the cost of contactors and relays; it is essential to factor in the initial purchase
price and the long-term costs associated with the device, such as maintenance, replacement, and
energy consumption. By understanding the cost implications of contactors and relays and considering
the specific requirements of your application, you can make an informed decision that balances
performance, reliability, and cost-effectiveness.

Installation and Maintenance

Installing Contactors and Relays

Contactors and relays on a DIN rail in the electrical panel

Proper installation of contactors and relays is essential to ensure reliable operation and minimize the
risk of device failure or damage to the connected equipment. While the specific installation
procedures may vary depending on the manufacturer's recommendations and the type of device,
some general guidelines can be followed for both contactors and relays.
 1. Choose the appropriate location: Select a suitable location for the device, considering
available space, mounting options, and environmental conditions. Ensure that the device is
installed in a clean, dry, and well-ventilated area, away from heat, moisture, or excessive
vibration sources.

2. Mount the device securely: Use the appropriate mounting hardware, such as screws or
DIN rail clips, to securely attach the device to a panel, enclosure, or other suitable surface.
Ensure that the device is mounted in the correct orientation, as the manufacturer specifies.

3. Wire the device according to the manufacturer's instructions: Follow the wiring
diagram and guidelines to connect the device to the control circuit and the load. Use the
appropriate wire size and type, as specified by the manufacturer, and ensure that all
connections are secure and properly insulated.

4. Verify proper operation: Before energizing the device, double-check all connections and
ensure that the device is installed and wired correctly. Once the device is energized, test its
operation by manually activating the control circuit and observing the response of the load.
Verify that the device operates as expected and that there are no signs of overheating,
arcing, or other issues.

By following these general guidelines and the specific instructions provided by the manufacturer, you
can ensure a successful installation of contactors and relays, providing reliable operation and
minimizing the risk of device failure or damage to the connected equipment.

Troubleshooting and Maintenance

Troubleshooting electromagnetic contactor switch

Regular maintenance and timely troubleshooting of contactors and relays work is essential to ensure
their reliable operation and extend lifespan. While the specific maintenance procedures and
troubleshooting steps may vary depending on the manufacturer's recommendations and the type of
device, some general guidelines can be followed for both contactors and relays.

1. Inspect the device regularly: Perform visual inspections to check for wear, damage, or
contamination signs. Look for signs of overheating, such as discoloration or deformation of
the enclosure or contacts. Check for loose or corroded connections, leading to increased
resistance and reduced performance.

2. Clean the device as needed: Remove dust, dirt, and other contaminants using a soft brush
or compressed air. Be cautious not to damage the main contacts or other sensitive
components during cleaning. If necessary, use a mild cleaning solution and a soft cloth to
remove stubborn dirt or grease, but ensure the device is completely dry before re-energizing
it.

3. Check the contacts for wear: Examine the set of contacts for signs of wear, such as
pitting, erosion, or excessive buildup of contact material. If the power contacts are severely
worn or damaged, these may need to be replaced to maintain reliable operation. Consult the
manufacturer's guidelines for specific information on contact replacement and maintenance
intervals.

4. Test the device's operation: Periodically test the operation of the contactor or relay by
manually activating the control circuit and observing the response of the load. Verify that the
device operates as expected and that there are no signs of abnormal behavior, such as
chattering, arcing, or excessive noise.

5. Monitor the device's performance: Keep track of the device's performance over time,
noting any changes in operation, such as increased response times, reduced contact force, or
increased electrical noise. These changes may indicate that the device requires maintenance
or replacement.

By following these general guidelines and the specific instructions provided by the manufacturer, you
can ensure the proper maintenance and troubleshooting of contactors and relays, providing reliable
operation and minimizing the risk of device failure or damage to the connected equipment.

Conclusion

In summary, contactors and relays are essential components in electrical systems, serving as switches
for controlling power flow. While they share similarities in their basic function, they differ in load
capacity, switching mechanisms, size, construction, electrical noise generation, and lifespan.
Understanding these differences and considering factors such as load requirements, environmental
conditions, and cost can help you select the most appropriate device for your specific application,
ensuring reliable operation and optimal performance of your electrical systems.

Frequently Asked Questions (FAQs)

1. What is the main difference between a contactor and a relay?

A. The main difference between a contactor and a relay is their load capacity. Contactors are
designed to handle high currents, typically above 15 amps, while relays are more suitable for low to
medium current loads, usually below 15 amps.

2. Can a relay be used in place of a contactor?

A. Relays can sometimes be used in place of contactors for low to medium-current applications, but
they may not be suitable for high-current applications due to their lower current handling capabilities
and reduced durability compared to contactors.

3. What are some common applications of contactors and relays?

A. Contactors are commonly used in high-power applications, such as large motors, heavy machinery,
and HVAC systems. Relays are often employed in control systems, automation, and low-power
circuits, where their ability to isolate the control circuit from the load circuit is essential.

4. How do I choose between a contactor and a relay for my application?

A. To choose between a contactor and a relay, consider load capacity, switching requirements,
environmental conditions, and cost factors. By understanding the differences between these devices
and considering the specific requirements of your application, you can select the most appropriate
device for your needs.

5. How can I extend the lifespan of my contactor or relay?

A. Regular maintenance, such as visual inspections, cleaning, and testing, can help extend the
lifespan of contactors and relays. Additionally, ensuring proper installation and following the
manufacturer's guidelines for operation and maintenance can contribute to the longevity of these
devices.

References

[1] c3controls. THE BASICS OF A CONTACTOR & DIFFERENT TYPES OF CONTACTOR DEVICES. [Cited
2023 September 17] Available at: Link

[2] Galco. RELAYS – HOW RELAYS WORK. [Cited 2023 September 17] Available at: Link

[3] ScienceDirect. Load Capacity. [Cited 2023 September 17] Available at: Link

[4] Allaboutcircuits. Selector Switches. [Cited 2023 September 17] Available at: Link

[5] c3controls. OVERLOAD RELAYS: TYPES & TRIPPING & WHAT IS OVERLOAD PROTECTION? [Cited
2023 September 17] Available at: Link

[6] Veris. What is a Relay? Relay Types, How They Work, & Applications [Cited 2023 September 17]
Available at: Link
Contactors versus Relays - Differences and Applications

May 13, 2022 by Anish Devasia

Although there are similarities in operating theory, relays and contactors are used in industrial circuits
for different specific applications, and should not be used interchangeably.

Relays and contactors are widely used in industrial automation applications. Both these terms for
components are used interchangeably by many engineers. Both the devices act like switches and both
of them use the principles of electromagnetic induction to function. But does this mean that relays
and contactors can be used interchangeably? No, is the short answer.

In terms of operation, relays and contactors actually are the same. At the core, relays and contactors
are used to separate the control circuit from the main circuit. But functionally, relays and contactors
are used in industrial circuits for different specific applications. They cannot be used interchangeably.
As automation engineers, we need to have a deeper understanding of relays and contactors, to use
them for the right application. In this article, let us take a deep dive into these two topics:

 The working principles of relays and contactors.

 How are they different?

Though there are many different types of relays and contactors, but for this discussion we will be
considering only electromechanical relays and contactors. Solid-state and safety-rated
components are left for articles of a different scope.

Figure 1. Relays and contactors, although they both work on the principle of magnetic field action,
are very different components.

Relays

A relay consists of two distinct circuits: the control circuit and the main circuit. The control circuit
controls the flow of electricity in the main circuit. The control circuit has a solenoid coil that, when
energized, produces a magnetic field. This attracts the movable contacts that in turn open or close
the main circuit. The control circuit is powered by a battery or small energy source independent from
the main circuit. This is the basic working principle of an electromagnetic relay. Typically, the control
circuit consumes less current at a smaller voltage than the main circuit.
There are two types of relays: normally open (NO) and normally closed (NC). The NO and NC relays
are different only by different mechanical designs for armature and contacts. A good many relays
have a double-throw configuration, meaning each main circuit contains both an NO and NC output,
supplied by a single dry contact.

Contactors

In operating theory, contactors work similarly to relays. They also separate the control circuit from all
main circuits with higher power ratings. The control circuit is powered by a low power external source
to close the high-powered main circuit. When the control circuit is powered, the electromagnetic coils
of the contactor get energized and pull the connector. This closes the main circuit and power flows
through the contactor. Contact terminals of contactors are always normally open and contact
terminals close when the control circuit is energized.

Figure 2. Contactors are usually larger than their relay counterparts. Image used courtesy of Iskara

Differences

Let us go through some of the major differences between relays and contactors.

Load Capacity

The load-carrying capacity of contactors and relays vary significantly. Contactors have a much larger
load-carrying capacity than relays, at least for typical situations (there are relays with higher
tolerances). Both contactors and relays have the following ratings:

Voltage rating

Ampere rating
Horsepower rating

The ampere rating and horsepower rating for the contactors will be significantly more than that of the
relays. Usually, the ampere rating of the relays is less than 10 A and the horsepower rating is less
than 0.5 HP. Contactors are rated for higher amperes and horsepower. Common voltage ratings for
control relays are generally less than 250 V and contactors can be rated for up to 1000 V.

AC/DC Loads

Contactors are more suitable when the power in the main circuit is alternating current. Contactors do
not fare well for DC-powered main circuits, since the large inductive loads on typical contactors can
generate dangerous reverse ‗flyback‘ arcs. Relays work well for both AC and DC power. If the main
circuit is powered by direct current, it is better to use relays. This is applicable only if the horsepower
rating and ampere rating suit that of relays.

Multi-Phase

Contactors can be used in three-phase circuits and single-phase circuits. They are more
prevalently used in three-phase circuits. Relays only support single-phase operation. If relays have to
be used in a three-phase circuit, three main relay contacts have to be used, one for each phase. This
makes the circuit more complex and wiring cumbersome, and once again, maximum power ratings
must be observed.

NC/NO

Control relays can be designed to be normally closed (NC) or normally open (NO). For normally open
relays, the main circuit is open when the control circuit is not energized. The main circuit closes when
the control circuit is powered. For normally closed relays, the main circuit is closed when the control
circuit is not energized. The main circuit opens when the control circuit is powered.

Figure 3. This relay has two poles, each with a normally open and closed, making it a double-pole-
double-throw (DPDT). Image used courtesy of IDEC
Contactors are usually designed to be normally open. This means the main circuit is open when the
control circuit is not powered and closes when the control circuit is powered. In the case of a control
power failure, the main circuits will always open and load operation will halt.

Auxiliary Contacts

Contactors have auxiliary contacts to verify operation of three-phase power input and output circuits.
Some contactors have built-in aux contacts, but others must be purchased and installed separately.

Relays, being reserved usually for smaller power circuits, do not often have auxiliary contacts. They
simply make use of the other remaining contacts to indicate when the main load-bearing circuits are
open and closed. Some contactors, and even occasional relay designs do have separate auxiliary
contacts for normally open operation and normally closed operation.

Safety Features

Contactors operate with a larger power rating. During switching, there are chances for electric arc
formation. Due to this reason, contactors are generally fitted with built-in arc chutes for suppressing
electric arcs. Control relays work with smaller voltages, amperes, and horsepower.

Physical size

As contactors need to accommodate multiple phases at a higher power rating, they are physically
larger. Some contactors are surprisingly large. Control relays are physically much smaller than
contactors. The additional safety and auxiliary features needed for contactors also increase their
physical size even further.

Multiple circuits

Contactors are typically only used to control a single main 1-phase or 3-phase load circuit. Relays also
generally control a single main circuit, but relays can be easily used to control multiple main circuits,
or hand logic to another control circuit (they relay information, the main purpose of their name).

Symbols

The symbol for the respective devices is shown below:

Figure 4. The symbol for a relay (left) and for a contactor (right).

Applications

Relays are more commonly used in control automation and protection circuits. Contactors are used
for switching high-power equipment like motors, lights, and capacitors.
Summary

Contactors and relays have the basic core functionality. They assist in closing and opening power
circuits based on the inputs to a control circuit. The key difference is in the applications for which
they are used and the features they possess. Relays are commonly used in control automation circuits
that have small power ratings. Contactors are used in higher power applications. Due to this
fundamental difference in the applications they are used for, they have various differing attributes.

Even though the core functionality of contactors and relays may be the same, they cannot be used
interchangeably, and it is always important to recognize when to use the right tool for the right job.

Love relays? So do we! Check out our whole collection of relay content:

Electrical Motor Nameplate Details

An electrical motor nameplate details provide important information to understand the construction
characteristics and design parameters of the motor.

The motor is the most widely used type of equipment in an industry. It is important to understand the
details of a motor properly; for getting it working. The details can be understood by its nameplate.

A motor nameplate, stickled on its body, gives all the information regarding its working. An
engineer is required to interpret its understanding so that he can properly choose the one required in
its application.

Motors run in two electrical standards – NEMA and IEC. NEMA stands for National Electrical
Manufacturers Association. IEC stands for International Electrotechnical Commission.

Basically, NEMA is majorly used in North American markets and businesses relating to North America.

But, IEC is used in most parts of the world. Both have set a certain slot of standards for an electrical
motor to run in the market. Without their ratings, no one will purchase a motor. That‘s because that
motor has not been approved by any standard and no one knows how it will function.

Table of Contents

Motor Nameplate Details

Depending on the manufacturer and standard used, every motor nameplate will vary in some of the
other parameters. But, we will discuss the most general used ones in the nameplate, which will help
us to interpret it properly. A sample motor nameplate details image is shown below.
Rated Operating Voltage (VOLTS)

This specifies the rated voltage at which the motor should operate. Any deviation from this can
hamper or even permanently damage the performance of the motor. The voltage specified here is the
incoming voltage that it will accept.

Normally, all the motors have a tolerance of + / – 10%. That means, suppose the rated voltage is
440V; then, the motor can operate between 396V to 484V.

Number of Phases (PH)

This specifies the number of phases at which the motor should operate. The phase can be a single
phase or three phases.

KW / HP Rating (PF)

The motor is used to drive a shaft load and that load will require a force from the motor for it. This
force is measured in KW (Kilowatt) or HP (Horsepower).

A motor must be able to apply the specified force in the nameplate to the motor.

Connection Diagram

A motor requires to be started by various means like start-delta, direct online, reverse direct online,
and other means of starter. The connection diagram shows how a motor must be started. The wrong
starter method can damage the motor.
Degree of Protection

This rating specifies the motor protection rating against various hindrances like liquid entry, dust
ingress, accidental contact by a human, and solid entry. IP code is specified in two numbers.

The first digit means the protection level that the enclosure provides to its internal circuit against solid
ingress and the second digit means the protection level that the enclosure provides to its internal
circuit against liquid ingress.

Efficiency (EFF)

It is defined as the percentage of input electrical power that will be converted to output mechanical
energy. Losses occur in the motor and it is not possible to convert the whole electrical energy into
mechanical energy. It is small, but not profitable.

So, it must be important to know how efficiently the motor produces mechanical power from an
electrical input. The losses can be reduced and efficiency thus is increased if the manufacturer pays
proper attention to it.

Frequency (HZ)

The frequency of the motor means the input frequency that will be fed to the motor. The standard
ones used are 50 Hz and 60 Hz.

Rated Motor RPM (RPM)

RPM means revolutions per minute. It determines the speed of the motor at full input frequency and
full load. Normally, it depends on the frequency of line voltage and the number of poles on the motor.

Insulation Class (CLASS)

Insulating materials used inside the motor have an operating temperature, exceeding which can
damage them. The insulation class indicates this temperature and its types are – B, F, and H.

B class has the lowest operating temperature and H class has the highest operating temperature;
with F class between them.

Rated Motor Current (FL AMPS)

It indicates the maximum current that a motor will draw when it is running at rated voltage, load, and
speed.

This is an important parameter that can be used to determine the power requirements of the motor.

Ambient Temperature (RATING)

The ambient temperature of the motor at which it should operate; is determined by this parameter. If
the temperature is not indicated, the default value is 40deg.C for IE2 motors and 60deg.C for IE3
motors.

If the temperature exceeds this parameter, then the insulation windings will be affected in the longer
run.

Service Class (SF)

When torque demand increases, the current drawn by the motor from the incoming power supply
increases. The service factor indicates the amount of overload current that a motor can withstand,
without damaging its internal insulation windings.
For example, a motor with a factor of 1.2 can handle overloads of up to 20% of its rated horsepower.
It means that a 10 HP motor can run maximum at 12 HP. But, one should avoid this in long run, as it
causes continuous heating.

Serial Number (SN)

It is a unique identifier used to identify the motor. Normally, it is a location – year- month – day-
motor code. It can be simply said that a motor will be identified by this number; as you are familiar
with the serial numbers of other products.

Enclosure Type (ENCL)

The enclosure is designed to protect the motor housing against any damage. It can be a liquid spill,
mechanical damage, abrasion, solid spill, etc. There are more than 20 types of enclosures generally
used in motor enclosures.

In this way, we saw some general parameters which are mentioned in a motor nameplate.

Wade offers a comprehensive range of quality floor drains, to suit a myriad of applications. For most
floor finishes and construction types, we can offer a tailor made solution from our standard floor drain
range. For applications beyond that, we can also design and produce special products to suit your
specification.

Vari-Level floor drains, floor gullies and access covers / rodding points have a fine thread to enable
accurate installation at finished floor level. The range covers all floor finishes, including drainage in
tiled floors, drainage in resin floors, drainage in vinyl finished floors and drainage in concrete floors,
with trapped and non-trapped versions
The term Vari-Level refers to the fine adjustability of the height of a grating or access
cover above a body; this feature enables installation exactly at finished floor level by
rotating the grating or access cover.

A Vari-Level gully comprises, as a minimum, a Vari-Level body and a Vari-Level grating; in some
versions these items fit together directly, but, mostly, connection is by means of an inter-connecting,
dual-purpose part – a membrane clamping collar. To address a myriad of applications, different
versions of Vari-Level bodies are available for use with a wide range of Vari-Level gratings, Vari-Level
access covers and Vari-Level accessories.
Wade offers a comprehensive range of high quality gratings which complement floor finishes. Vari-
Level threaded gratings are height adjustable with a fine thread to enable accurate installation at
floor level.

Wade offers a comprehensive range of high quality access covers, sometimes referred to as cleanouts
or rodding eyes, which complement wall and floor finishes. Vari-Level threaded access covers are
height
adjustable with a fine thread to enable accurate installation at floor level.

Most covers are sealed; ‗SuperSeal‘ covers have additional benefits of being quick release and double
sealed as illustrated opposite. Vari-Level covers may also be connected to pipework and proprietary
gullies by means of adaptors.

How to Pick a Centrifugal Pump Part 7: Mechanical Seal Components and Materials

July 24, 2017

By Chad Edmondson

Part 6 of the ―How to Pick a Centrifugal Pump‖ explained the value of internally flushed seals. One
question that our customer service team fields every week concerns the material of construction of
seals for various applications. This week we‘ll look at the seal material you should specify.

Mechanical seals are simple devices. There are metal parts including a spring, a stationary seat, and a
rotating seat (also called the primary ring) and there are the elastomers parts.

Water is the most common heat transfer fluid used in HVAC pump applications; glycol-based fluids
are the second most common. In either case, the fluid in these applications contain very little
particulate and are typically well below 225°F. Given these ―easy service‖ conditions, the majority of
seals used in HVAC applications are what is known as ―carbon-ceramic.‖

For typical HVAC applications, carbon-ceramic have stainless steel metals, BUNA elastomers, a 99.5%
pure aluminum oxide ceramic stationary seal face, and a carbon rotating face. These seals work well
with the temperatures mentioned above and a pH neutral range of 7.0-9.0. They can handle up to
400 ppm of dissolved solids and 20 ppm of undissolved solids which satisfied most system
requirements.

In most applications carbon-ceramic seals work fine but there are certain circumstances when a
different type of material for the mechanical seal should be specified. These include:
Systems with high pH levels. Most HVAC applications maintain a pH from 7.0 to 9.0. Once in a
while the pH is too high for the carbon-ceramic seal material. The main issue may be located in the
chemical treatment portion of your specification. There are specifications that call for the pH to be
maintained at levels in the 9.0-11.0 range. If your specification calls for this range, the pump seal
material specification should be changed to EPR/Carbon/Tungsten Carbide (TC) or EPR/Silicon
Carbide (SiC) /Silicon Carbide (SiC). We recommend the EPR/SiC/SiC material since that seal can
handle pH up to 12.5 which gives some ―wiggle room.‖

Higher solids levels. Solids, otherwise known as dirt, are another area of concern for mechanical
seals. If the system is dirty or has silica in the water, you may find, once again, that you need the
EPR/SiC/SiC seal. The standard Buna/Carbon/Ceramic seal in HVAC systems cannot handle any silica
and the solids handling capability was mentioned earlier in this article. The silicon carbide seal can
handle 60 times the dissolved solids content and double the undissolved solids content with 20 ppm
silica content thrown in for good measure.

So, why not just always specify EPR/SiC/SiC seals? There are two reasons: cost and lead-time. This
seal will cost three times as much as the standard seal. In addition, since the carbon-ceramic seal is
standard, there may be additional lead-time to get a pump with a special seal.

Improperly mixed glycols. The term glycol is a bit of a misnomer when it comes to heat transfer
solutions in HVAC systems. Glycol is used in many applications from shaving lotions to whipping
cream to automotive antifreeze. In HVAC systems you want a properly mixed glycol-based heat
transfer fluid that has the correct inhibitors for the application. If you use automotive antifreeze in
HVAC systems, the silica based inhibitors will create a gel in the coils that blocks heat transfer and
flow. That is, if the seals don‘t leak first!

We commonly see Dowtherm® SR-1 and Dowfrost™ HD heat transfer fluids used for these type of
applications. These products are made for use in our industry but should be mixed according to the
manufacturer‘s instructions. Dow recommends they be pre-mixed with deionized water before filling
the system. If you simply mix these product with city or well water the calcium and magnesium in
water will mix with inhibitors and cause a particulate that exceeds the ppm of normal seals.

Occasionally contractors will put the glycol based fluid in the system, filled it with water and then turn
on the pump to ―mix‖ the solution in the piping system. This subjects the pump seals to shots of up
to 100% ethylene or propylene glycol which is well beyond the maximum recommended amounts for
even silicon carbide seals.

Our experience is that the standard carbon ceramic seal work fine with properly mixed glycol products
designed for our industry. However, brands vary in their quality and make-up so we cannot say that
carbon-ceramic seals are appropriate for all glycol mixtures. These fluids do carry a higher pH than
water, so we recommend specifying a glycol seal if there is any question.
What is the installation process of Mechanical Seal?

December 7, 2022 | 11:19 am

What is a Mechanical Seal?

In centrifugal pump systems, mechanical seals are essential components. By excluding impurities and
preventing fluid leaks, these devices maintain the integrity of the pump systems. On various seal
designs, mechanical seal systems are employed to check for leaks, regulate the sealed environment,
and lubricate secondary seals. There are different mechanical seal kinds to choose from depending on
the type of pump and the process variables. Each type of seal is distinct in appearance and features,
making it appropriate for a particular use.

How does a Mechanical seal work?

A stuffing box or seal chamber allows a centrifugal pump‘s rotating shaft to enter the casing from the
back. A mechanical seal‘s main function in a centrifugal pump is to stop fluid from leaking along this
revolving shaft and into the atmosphere. Considerations for safety and dependability must be
considered when choosing the appropriate mechanical seal for each pump application. One of the
main causes of pump failure is frequently mechanical seal failure. The professionals in the industry
usually demonstrate in this guide how to install a mechanical seal in the centrifugal pump with the
least amount of downtime.

Two extremely flat and smooth (lapped) seal faces must be in contact for a mechanical seal; one
must rotate with the shaft, and the other must be stationary with the casing. Through the application
of secondary seals, these seal faces are attached to their proper holders (o-rings or gaskets). The
faces can be brought into contact and moved to correct for static and dynamic misalignments and
wear because they are mechanically powered and flexible. When fluid tries to escape through the seal
faces, it is broken down by the seal faces, causing a small amount of vapor to be released. All
mechanical seals, when chosen and sized properly, leak vapor.

Fundamentals of Mechanical Seal

The goal of mechanical seals is to stop fluid (liquid or even gaseous) leakage through the space
between a shaft and the fluid container. The seal rings on which a mechanical force produced by
springs or bellows and a hydraulic force produced by the pressure of the process fluid are acting are
the major parts of a mechanical seal. The seal ring connected to the machinery‘s casing is referred to
as the ―stationary ring,‖ The seal ring that rotates with the shaft is known as the ―rotary ring.‖
Secondary seals are necessary to perform static sealing between stationary rings and the machinery‘s
casing, as well as between rotating rings and shafts.

Although alternate solutions, such as those detailed in the following sections, can be employed,
elastomeric O-Rings are typically used as secondary seals. On mixers and pumps, mechanical seals
are typically installed. As mentioned above, an appropriate mechanism must be installed to seal the
fluid inside the case on both of the setups.

The sheet of liquid An effective lubrication is needed to reduce the amount of friction between the
seal rings. With twin mechanical seals, an appropriate auxiliary fluid can lubricate the seal faces and
the process fluid. A stable and full layer of lubrication significantly impacts a mechanical seal‘s
performance and lifespan.

The proper selection of a mechanical seal must take into account the following factors to ensure
enough cooling and efficient lubrication of the seal rings:

1. The temperature of the process fluid

2. The pressure of vaporization at operational temperature

Features of process fluid

Spindle speed

The ideas and guidelines previously covered apply to any mechanical seal that uses a liquid fluid. The
differences in operation between dry-running and gas seals are something to keep in mind.

Leakage

Every mechanical seal results in leakage. The explanation is found in the lubrication theory that was
previously mentioned; it is evident that a continuous lubrication layer implies some degree of leakage.
Calculating leakage is possible and depends on several variables, including rotating speed, fluid
pressure and properties, and balancing ratio. However, the machinery on which the mechanical seal
is mounted may also have some bearing. Frequently, leakage is so minimal that it is not visible
(vaporization).

The extent of freedom readily available

For a mechanical seal to function properly, the elastic parts (spring or even bellow gaskets) are
crucial.

Because it must follow the movement of the ring caused by unavoidable occurrences like vibrations,
misalignment, and shaft run-out, the gasket installed on the seal ring driven by the bellow or spring
(often the rotary ring) is known as a ―dynamic‖ gasket. It follows that for proper application of a
mechanical seal, factors, including working length, gasket compatibility with the process fluid,
dimension, and shaft finishing, must be properly considered.

Equilibrium ratio
When consistent pressure is given to a piston, it is known that the force generated will be
proportional to the area of the piston. In mechanical seals, the fluid pressure creates a hydrostatic
force that operates on the seal ring in addition to the closing force produced by the springs or
bellow. As was already mentioned, the hydrostatic flow also creates a lubricating film between the
seal faces and generates an opening force. The balancing ratio is the proportion between the forces
closing the seal ring and those opening it.

Different Types of Mechanical Seals

Different mechanical seal types have different configurations and methods for distributing the
hydraulic forces that operate on their faces. The following are some of the most typical seal varieties:

Balanced seals

A system where the forces exerted at the seal faces are balanced in a mechanical seal arrangement.
Due to the lower face loading, the seal faces are lubricated more evenly, which extends the seal life.
Today, find out more about our lubricating systems for mechanical seals.

Higher operating pressures, often exceeding 200 PSIG, are where balanced mechanical seals excel.
They are also a wise choice when working with liquids high in volatility and low in lubricity.

Unbalanced seals

Unbalanced mechanical seal varieties are frequently used as a more cost-effective substitute for
balance seals, which are more intricate. Due to greater control over the face film, unbalanced seals
may also show less product leakage but, as a result, may have a substantially lower mean time
between failures. Unbalanced seals are not advised for high-pressure applications or the majority of
hydrocarbon uses.

Pusher seals

Pusher seals use one or more springs to sustain the seal‘s closing forces. The mechanical seal‘s
revolving or stationary component may have springs. The elastomer behind the primary seal face of
pusher-type seals, which can be worn out as the face advances down the shaft or sleeve during
operation, is a problem that prevents them from sealing at very high pressures.

Non-pusher seals

A metal or elastomeric bellows is used by non-pusher seals to maintain seal closing forces.
Applications involving dirt and high temperatures are best suited for these seals. Bellows seals can
only be used in applications with medium to low pressure. Both balanced and unbalanced variants are
available for pusher and non-pusher designs.

Conventional seals

Ordinarily less expensive and frequently put on standard service equipment are conventional seals. As
they are installed as separate components, these seals demand a greater level of operator skill to
service.

Cartridge seals

Mechanical cartridge seals combine all seal components into a single assembly. As a result, the
possibility of assembly errors and the time needed for seal changes are significantly decreased. Find
out more about the distinction between mechanical seals that use cartridges and those that do not.

How to choose a Mechanical Seal?

Operators must choose the seal system for a centrifugal pump based on the specifics of their
application. Failure to choose the right seal type can result in lost pump integrity, breakdowns, and
expensive repairs. Before making a choice, all operators must consider the following to avoid these
negative outcomes.

The Fluid to Be Pumped Type

The most crucial element to consider when choosing a seal type is the fluid one is pumping. Elements
including cleanliness, lubricity, and volatility will greatly impact the mechanical seal‘s design and the
seal support system.

Fluid Pump Pressure

The performance of a mechanical seal is significantly influenced by force applied to its faces. An
imbalanced mechanical seal will work well if a pump is to be run at low pressures. However, balanced
seals will be a more dependable solution in circumstances where higher pressures are predicted.

Temperature Considerations to be taken into account

When working temperatures are usually higher than usual, balanced mechanical seals outperform
their unbalanced counterparts. Compared to other seal types, balanced mechanical seals retain heat-
sensitive components better.

Operator Safety Concerns

Operator safety is considered the main consideration, as it is for all machines. Double mechanical
seals, which have a greater sealing capacity and are generally more dependable, are used in
centrifugal pumps to give additional protection.

How to Replace a Mechanical Seal?

Using a centrifugal pump causes water to flow through the plumbing system due to the principle of
centrifugal force. In this pump, an impeller is rotated by a shaft that spins incredibly quickly. As a
result, centrifugal force draws water into a vacuum, which is then formed. Behind the centrifugal
pump‘s impeller is a mechanical seal that keeps water out of the electrical system.

It becomes necessary to repair the seal when wear and tear result in damage. One must access the
pump system and remove the impeller from the shaft to complete the work. Understand the
procedures for changing a mechanical seal on a water pump.

Remove the power

The centrifugal motor must be turned off, so it is not in motion. Close the main power source and
make sure there is no danger of the device restarting. After this is finished, it‘s time to start working
again.

Keep the Fluid Separate from the Pump

Close the pump‘s inlet and outlet isolation valves before removing the casing drain plug to drain the
pump‘s casing.

Disconnect the Centrifugal Pump

Remove the spacer piece from the pump coupling if the pump has a ―back pull-out‖ configuration.
Slide the remaining pump portion away from the casing after removing the casing bolts. The casing is
no longer connected to the inlet and outlet pipework, making it possible to access the mechanical seal
without doing so. If the pump is not a ―back pull-out‖ design, one must first remove the coupling that
connects the pump and motor shaft before removing the entire pump. One will need to remove the
complete pump and motor if the pump is a close-coupled design, which means that the motor‘s shaft
serves as the pump‘s shaft. Bolts holding the casing in place should be removed.

Get rid of the impeller

On the pump shaft, the mechanical seal is situated behind the impeller. Both screws and bolts are
used to secure impellers to the shaft. With the shaft securely held with a wrench, spin the screwed-
on impeller counterclockwise until it is entirely unscrewed. A fastened impeller can be removed by
holding the shaft in place while removing the bolt.

Remove the Seal

Now that direct access has been reached to the stationary and rotating seal components. Set screws
are often used to secure the rotational components along the shaft. Slide the rotating seal
components off after removing the set screw. Remove the stationary seal component from the seal
chamber bore or casing.

Change the Seal

It‘s time to attach a fresh mechanical seal to the shaft. Slide the replacement seal components along
the shaft with caution. Press the stationary component into the casing or seal chamber bore using a
fresh o-ring or gasket material. To properly reattach the rotary component to the shaft, according to
the instructions. This is an important action.

It is important to note that one should always operate in a spotless environment when installing
mechanical seals. Avoid touching the front of the seal faces since they are vulnerable to body oils and
could get compromised, leading to poor performance. Before installing the seal, keep it in its box.

Putting in the Impeller

As one screws the impeller onto the pump‘s shaft using a fresh impeller o-ring or gasket, they may
use the wrench to maintain the shaft in place. Alternatively, one can fasten the impeller to the shaft‘s
end using the impeller bolt and a fresh o-ring or gasket.

Use the existing casing bolts to reattach the casing

Slide the back pull-out component against the fitted casing in back pull-out designs and secure it with
a bolt. After the step below, it will be important to check the alignment of the pump. Use the casing
bolts to reinstall the casing for closely linked designs or do not have a back pull-out. Always follow the
pump installation, operation, and maintenance (IOM) instructions when tightening the casing nuts.

Connect the pump again

The spacer element must be reinstalled to the existing coupling hubs along the pump and motor
shafts for back pull-out designs, and the mounting feet of the assembly must be secured with bolts to
the pump baseplate. Reposition the motor and pump. Reinstall the pump and re-connect the inlet and
output pipework for close-coupled pumps. Replace the pump on the baseplate, connect the inlet and
outlet pipes, re-bolt the pump to the baseplate, connect the coupling, and then realign the pump and
motor for non-back pull-out pump and motor designs.

Restart the apparatus

By releasing the isolation valves at the inlet and output, confirm that the pump casing has been filled
again. Refer to the pump IOM to determine whether venting is necessary for some pump designs. It
is usually a good idea to double-check the motor‘s rotation to ensure it is accurate before starting the
pump. Before re-connecting the pump and motor coupling, this is done. A motor bump will
demonstrate spinning. The coupling should then be re-connected before the pump may operate.

Exercise the necessary caution

Always go over the safety measures listed in the pump IOM. When working on any pump, utilize the
Pump IOM at all times. Following the manufacturer‘s detailed directions, install the mechanical seals.
Last but not least, always ensure that the motor and pump are adjusted between 001″ and 002″.
Mechanical seals will fail early as a result of misalignment.

Materials used in making Mechanical Seal

Perfect planarity of the seal faces is necessary for effective sealing, even in constant temperature
gradients. Additionally, seal faces must be lubricated and cooled at an optimal level due to the high
relative speed and pressure at which they must work. Combining the elements above results in
selecting suitable materials that are easily developed and manufactured (lapping).

The first and most crucial step to ensuring extended wear and positive outcomes is selecting the right
seal face material. One seal face made of graphite and the other made of silicon carbide, tungsten
carbide, or ceramic is the most durable material combination. The primary benefit of a graphite seal
ring is its ability to quickly and flawlessly complement the counterface.

It is advised to install two hard faces, such as silicon carbide or tungsten carbide, when the fluid to be
sealed is abrasive. In the latter scenario, extra caution should be used to avoid the potential of
temporary dry running, which might result in long-term damage to the seal.

Graphite

This material is the top option for the seal face due to its self-lubricating qualities. There are many
different types on the market, and each one is made by sintering carbon and graphite powder that
has been properly linked with resins or metals. Bonding is necessary to close the microporosity
caused by the high temperature (over 1000°C) required for the sintering process.

The main typical varieties of graphite are

 With a high level of chemical resistance and suitability for most chemical applications, resin-
impregnated graphite.

 Graphite with a metal impurity (usually antimony or bronze) can withstand greater operating
temperatures and pressures.

 High-temperature sintered electrographite, 2500 °C. Suited to extremely abrasive fluids and
high temperatures.

 The ability of graphite to quickly remove modest initial planarity flaws is one of its main
advantages. Good self-lubricating qualities that allow for brief dry running

PTFE

Graphite-like qualities are shared by PTFE, except for low mechanical strength. Various bonding
materials are used to boost the wearing resistance, with glass being the most popular. When mated
to a silicon carbide or ceramic counterface, PTFE is inert and suited for any hostile fluid. Stellite and
Chromium steel are inappropriate partners.

Stellite

Cobalt, tungsten, and chromium, which contribute to this alloy‘s exceptional surface hardness, are the
main ingredients. Usually used as a coating on rings made of stainless steel to create a firm sliding
surface. Inability to withstand thermal dilatation

Chromium Steel

This stainless steel has a high percentage of chromium, which provides a great balance of hardness
and corrosion resistance. Stellite‘s disadvantages in thermal dilatation are not present in seal rings
manufactured of this substance. Graphite counterfaces are typically coupled with chrome steel.

Ceramic

This substance, called aluminum oxide, is made by sintering powders and is machined by grinding.
The amount of material purity helps distinguish between the various sorts offered on the market.
Fluiten uses a highly chemical and wear resistant 99.7% pure Al2O3. Ceramics is quite hard, making
it a good material for abrasive items. The main drawback is a lack of thermal shock
resistance. Typically, it is mated with counterfaces made of reinforced PTFE or graphite saturated
with resin.

Tungsten carbide

This material has a high degree of mechanical resistance, making it acceptable for use with abrasive
fluids. It also has a small but extremely useful capacity to survive brief transitory conditions of
inadequate lubrication. Tungsten can be combined with nickel or cobalt to form the alloy. The
bonding materials provide different qualities.

Cobalt is frequently used in machining tools because of its great mechanical strength. Nickel is
preferred for making seal faces because it provides slightly less mechanical and better chemical
resistance. The production is accomplished through sinterization in a vacuum environment, followed
by grounding machining. The material is perfect for seal faces because of its extremely low porosity.

Sinterization in a vacuum environment creates the product, which is ground to shape. Its extremely
low porosity is the perfect material for seal faces. When working with highly abrasive goods, installing
a counterface in tungsten or silicon carbide is customary, always ensuring effective lubrication. The
standard mating material is resin or antimony-impregnated graphite.

Silicon carbide

This substance is created by sintering silicon carbide particles, often with pure silicon. There are two
main varieties of silicon carbide on the market, depending on the production method.
Pressure switches are designed to automatically sense when the pressure has changed. They
are used widely in the Water Well Industry as they are mainly used in systems that have
pressurized liquids.

Most pressure switches have the capability of making field adjustments, but some do not. In this
blog, we will cover how to properly adjust a standard pressure switch to ensure the safety of
you and your switch. Let's dive in.

Looking for information about the different components in a Submersible Pump installation?
Check out, A Complete Guide of All Submersible Pump Components Ebook.

CUT-IN AND CUT-OUT

All Pressure switches have two operating points known as the cut-in (Reset Point) and cut-out (Trip
Point) settings. The cut-in point is for the falling pressure and the cut-out point is for the rising
pressure. Every switch also includes a differential or a range based on the cut-in and cut-out points.
Both the cut-in and cut-out on most switches can be adjusted if certain applications require that. For
example: if the cut-in is 40 PSI and the cut-out is 60 PSI the differential is 20 PSI.

ADJUSTMENT TIPS FOR A STANDARD SWITCH

1. To protect you and your switch, the first thing to do is disconnect the power to the switch from the
power supply before you attempt to make any adjustments.

2. After the power is disconnected, measure and write down the distance from the exposed thread
from the top of the nut to the top of the stud that you are adjusting. Write it in fractions of an inch or
mm, this is in case you need to start over so then you know where you started.
3. The first adjustment you should make is to the cut-in and cut-out settings. Once you have made
the desired adjustments to those, you can adjust the differential as a secondary adjustment. As you
can see in the picture, the larger nut adjusts the cut-in, the smaller nut adjusts the range.

4. There should be only 3 turn per nut maximum, either up or down each time.

To learn more about Pressure Switches and the different types available, check out our Webinar, An
Essential Guide to Understanding Pressure Switches.

ADJUSTING THE CUT-IN

In order to increase or decrease the cut-in or the cut-out setting you will need to use a 3/8" nut
driver or socket to adjust the switch, while still maintaining the same differential. To do this, follow
the below.

1. Rotate the range nut in a clockwise direction for higher cut-in pressure and counter clockwise for
lower cut-in pressure. Note: changing these settings DOES NOT change the differential.

2. As you start to change the cut-in value, the cut-out value will change by the same amount and in
the same direction. For an example, if you increase the cut-in pressure by 10 PSI it will also increase
the cut-out pressure by 10 PSI, saving you from having to adjust the cut-out value as well.

MONITORING IS IMPORTANT

You should then monitor the system closely to ensure the pressure setting is what you desired. Note
that the adjustment you make to the pressure switch can only be read after the pump has reached its
first adjusted shut off. The next cut-in and cut-off pressure is your new setting.

1. By opening the boiler drain or sediment faucet you can drain the water from the pressure system
until the pressure drops below what the current cut-in point is and then the pump turns on.

2. You can then turn the faucet off.

3. The system's pressure should then be monitored as the pump builds pressure and fills the tank.
Keep a close eye on the pressure gauge so that you can identify the exact point that the pump turns
off.
4. Lastly, you can repeat adjustments if necessary and continue monitoring for a couple more cycles.
Repeat adjustments and monitor until you reach the setting you require.

One thing to keep in mind, when lowering the pressure setting, most bladder tank water systems are
designed for the pressure to be 2 PSI below the cut-in point when there is no water in the tank.
Another thing to keep in mind is the differential cannot be adjusted beyond the minimum and
maximum differential that is published for the switch.

IS THE SWITCH TRIPPING?

If you are finding that the switch is tripping the cut-in pressure is most likely too close to the tank
pre-charge. A difference of a minimum of 2-5 PSI is required to ensure the switch won't trip. For
example, if the switch cut-in is 40 PSI then the tank pre-charge should be 35-38 PSI maximum.

Another factor that you should consider is the switches are not individually tested which means if you
get a switch that is 30-50 PSI it could possibly be 28-48 PSI. Pressure switches could also stick
sometimes, so it could possibly come on 1 or 3 PSI different from one cycle to the next. Ambient
pressure can also raise the pre-charge in the tank. These are just some things to be aware of.

Keep these tips and steps in mind the next time you need to make an adjustment on a pressure
switch. But keep in mind, adjustment steps may be slightly different from one switch to another
depending on whether you have a standard switch or for example a low pressure switch. It is always
good to look into what switch you have and research if there are specific steps you should be doing
for that switch.
Why Users Should Pay Attention to the Motor Nameplate Rating

Learn the basics of a nameplate on a three-phase motor.

by Sean Cain

Flowserve

11/22/2022

Motors are like a good dog. They will try to do what is asked of them, will not question when asked to
do something they cannot, will forgive you for minor errors and need regular maintenance. However,
like dogs, they cannot read or talk. So, it is up to users to make sure everything is working properly,
to ensure that they can have a long, happy life. The nameplate is provided to help users take care of
the motor and provide it with the things it needs.

What Is a Nameplate Rating?

According to National Electrical Manufacturers Association (NEMA) motors and generators (MG)-1, ―A
permanent marking of nameplate information shall appear on each machine, displayed in a readily
visible location on the machine enclosure.‖ The information on a nameplate will vary depending on
the type of motor, but most will have an output power (in horsepower (hp) or kilowatts [kW]),
voltage, current, rotations per minute (rpm), frequency, service factor, etc., under rated conditions.
There can be additional data on the nameplate regarding temperature ratings, bearings, auxiliary
equipment, terminal markings, etc.

This article will focus on the fundamental information provided on the nameplate of a three-phase
induction motor, since they are a commonly used industrial motor type. Most of this discussion can
also apply to other motor types but would complicate the discussion, so they are omitted in order to
ensure clarity. Fundamental information includes voltage, current, power, frequency, speed and
service factor.

Does the motor use any of this information? No. The motor cannot read, right? The user of the motor
can use this information to ensure safe, reliable performance from the motor. The user can also
ignore some or all of this information and run the risk of subpar performance and possible serious
consequences, such as shortened run life or reduced safety.

Voltage

Voltage on the nameplate is generally the voltage intended to be applied at the terminals of the
motor. It is not the voltage that is on the power grid. Generally, the standard motor nameplates are
about 4% lower than the common grid rated voltage. The 4% lower voltage is because typical
voltage losses in cable and other equipment supplying the motor can be substantial, lowering the
power grid voltage at the motor terminals. Depending on the system, these voltage losses may affect
the motor performance. Low voltage can cause lower torque, higher current, slower speed, higher
motor temperature rise, etc. All of these impact motor run life and performance which is why the user
should pay attention to the voltage at the motor terminals.

The focus has been on lower voltage so far because higher voltage is rarer and has less of a negative
impact than low voltage. A slightly higher voltage may make the motor perform better. It just
depends on the motor. However, an excessively higher voltage can also have detrimental effects that
can cause overheating and affect insulation life. NEMA MG1 permits voltage variation of ―plus or
minus 10% of rated voltage with rated frequency. However, motor performance in this condition may
not be in accordance with standards established for operation at rated voltage and frequency.‖

The key takeaway with voltage is that significant variation of voltage from the nameplate will affect
the motor performance and can impact the motor life. The motor will try to do what is asked of it,
regardless of the nameplate voltage, by using the actual applied voltage.

Current

The nameplate current is the current that is being used when the motor is being operated under a
certain set of standardized conditions. The standardized conditions consist of the nameplate values
for voltage, power output, speed and frequency. Many users assume that current is a direct indication
of power output of the motor, but while they are related, they should not be equated.

While it can be a shortcut for evaluation of motor power output in certain conditions, current can be
affected by a lot of factors besides the power output of the motor. The most obvious one is voltage,
but when talking about voltage, do not forget voltage balance. If the three voltage phases are
unbalanced, higher currents will be required even if the average of the voltages matches the
nameplate voltage. Lower voltage will typically cause higher currents for the same power output, so
monitoring current does not directly reflect the power output.

Voltage with high harmonic content will also adversely affect current. In general, the current is a
characteristic of how a user is operating the motor, so it can be useful to monitor current to assure
the motor is being operated correctly. The motor will use as much current as is necessary to do the
job under the conditions it is given.

Frequency

Frequency is important as it affects not just the speed of the motor, but also output torque and
ultimately the output power. The frequency on a nameplate is most commonly a single frequency of
either 60 hertz (Hz) or 50 Hz, depending on the standard voltage supply frequency of the country.

However, many motors can be used at another frequency with some caveats. Talk to a motor
supplier or manufacturer for other allowable frequencies, especially when using a variable speed drive
(VSD).

Speed

Speed is generally a function of frequency and the motor design. The speed provided on the
nameplate is what is expected under the specific conditions on the nameplate. Other speeds can
occur and are dependent upon variables such as the actual load, voltage, frequency and other
conditions.

If required operating speeds are substantially different than the rated speed, confirm with the
manufacturer that the motor is capable of doing this. Some examples of critical characteristics that
can be affected by changes in speed include motor cooling and bearing load capabilities. The motor
will run at the speed it feels like unless controlled.

Service Factor

According to NEMA MG1, Part 1.42.,―Service factor of an alternating current (AC) motor is a multiplier
which, when applied to the rated horsepower, indicates a permissible horsepower loading which may
be carried out under the conditions specified for the service factor.‖ NEMA MG1 then refers to part
14.37, which goes into more detail; the most important of which states, ―A motor operating
continuously at any service factor greater than one will have a reduced life expectancy compared to
operating at its rated nameplate horsepower. Insulation life and bearing life are reduced by the
service factor load.‖ Keep in mind that service factor is mainly a North American thing. Most of the
world does not use or even label motors with a service factor. Also, keep in mind that every motor
supplier‘s technical recommendations are to not intentionally

design the load to use the service factor. In other words, if it is a 100 hp motor with a 1.15 service
factor, do not intentionally pick out a 110 hp pump. Service factor is intended to provide a margin of
safety in case the load is higher than expected for short-term use. The motor will perform when
operating within the power range defined by the service factor and even above—just not as normally
expected.

Power

The nameplate power is the rated output power. Always remember there is also input power that is a
function of the efficiency of the motor.

Is the power listed on the nameplate the same amount of power being provided by the motor? Highly
unlikely. Remember, the motor will try to do whatever is asked of it. The user asks the motor to do
something by applying voltage, turning it on and applying a load on the shaft. What happens if the
load on the shaft is exactly nameplate power output at nameplate voltage? Then the current and
speed should be very near the nameplate values, assuming the voltage and frequency supplied is
near the nameplate values. What happens if the load on the shaft is less than nameplate power? In
general, the induction motor will turn ever so slightly faster, and the current will be reduced. The
motor will likely run cooler and will not age as quickly as a fully loaded motor.

What happens if the load on the motor is higher but still within the service factor? As stated
previously, the motor will continue to operate but may have a reduced life and will not perform quite
as well. What happens if the load on the motor is higher than the service factor? Provided a user
does not have controls to prevent this situation, the motor will try to provide that power even if it
destroys itself in the process.

Remember the motor cannot read, so the nameplate horsepower will not be automatically followed.
As the owner and operator, users have the means to ensure the motor does not destroy itself.

The motor nameplate is for the user to read, understand and then appropriately use the information
in conjunction with the installation and operations manual. If the user installs good controls with
settings based on the nameplate information, the motor will perform as expected and will have a long
useful life.

If the nameplate is ignored, then there is a high likelihood the motor will fail to perform or have a
shortened life. And we all want a long, happy life for man‘s faithful servants, both dogs and motors.