Installation relays and contactors: function and selection
Installation relays and contactors switch suitable loads in response to a control input. This separates the command from the load function. A small command does not mean every associated terminal is safe to touch.
This guide explains devices and selection. Self-holding, reversing and star–delta operation are complete circuit functions described in the contactor-circuit category, not inherent features of every contactor.
Construction and operation
Construction and operation
A conventional electromagnetic device contains a coil, a moving magnetic mechanism and associated contacts. Suitable control operates them. A typical monostable device returns to its defined rest state when control is removed.
Normally open, normally closed and auxiliary contacts have different roles. An auxiliary feedback contact is not automatically suitable for the same load as a main contact.
The diagram separates control and contact paths. A mechanical association identifies contacts operated together; it is not a conductive link between coil and load. Product data must establish any required safe separation between voltage systems.
Relay or contactor?
There is no reliable universal rule that a device becomes a contactor above one particular current. Construction, intended use and specified switching conditions determine suitability.
| Selection point | Meaning |
|---|---|
| Control | Suitable AC/DC voltage, frequency and operating conditions |
| Contacts | Number, function, loading and required separation |
| Load | Assess resistive, inductive, motor and electronic loads separately |
| Utilisation category | The manufacturer's rating for that switching task |
| Installation | Space, heat, environment, noise and permitted mounting |
Continuous-current capability is not unlimited making and breaking capability. A heater rating cannot simply become the same motor or LED rating. Use the relevant table for the actual product and conditions.
Device illustrations and operating principle
Variants, connections and selection
Connections and protection
A1 and A2 may identify coil connections. Those labels do not establish voltage or universal polarity independence. Electronic control or suppression components can add requirements.
Identify main and auxiliary contacts from the real product diagram, not the apparent position in a front photograph. Similar-looking devices can have different contact combinations and supplies.
A contactor does not automatically replace a fuse, overload protection, motor protection or a suitable isolating device. It is part of the design. Conductors, protective devices and any necessary interlocking must suit that design. PE is not an ordinary switched pole.
Functional checks
Functional checks
Predict which contacts should open or close from the diagram, then assess the real response under suitable conditions. Coil sound alone does not prove every load contact has operated.
For a monostable version, check its intended return when control is removed. Mechanically latched or electronically maintained versions require their own interpretation. Any manual override must be understood and left in the intended position.
Unexpected humming, repeated operation, excessive heating or sticking contacts need competent investigation. Supply, command, load and mounting may be involved. Do not bypass protection to make a test work.
Advantages and limitations
Advantages and limitations
Suitable products separate control tasks from load switching and may operate several contacts together. Integration into a larger control system depends on their actual specifications.
Contact wear, switching duty, coil or electronic losses and the environment impose limits. A larger current marking does not correct a mismatched application.
Questions and related information
Common questions
Is a volt-free contact dead?
Not when connected to an energised external circuit. The term describes its internal supply reference, not the state of the installation.
Is it an impulse relay?
Not necessarily. The basic impulse relay retains a new state after a brief command. An ordinary monostable relay follows its control signal.
Sources and product documentation
Electrical safety: scope, competence and precautions
Put electrical safety first.
- These explanations and simplified diagrams support learning. They are not complete installation designs, site-specific risk assessments or a substitute for competent professional assessment.
- Electrical work can be life-threatening. It requires the competence and authorisation appropriate to the actual task, installation and jurisdiction.
- Errors and omissions can occur. Check the actual equipment documentation, applicable requirements and the complete installation before relying on an example; a working device is not proof of electrical safety.
- Personal protective equipment must suit the assessed hazards and task. It does not replace isolation, appropriate tools, competence or a safe system of work.
- Do not work on exposed live parts on the basis of these guides. Identify every relevant source, isolate it, secure against reconnection and prove dead using suitable equipment and procedures before access.
- Responsibilities for design, installation and verification must be established for the actual work. A website statement does not determine liability or remove duties under applicable law.
- This summary is not exhaustive. Where the circuit, condition or protective arrangement is uncertain, obtain suitable professional assistance before work proceeds.
- Complete the required inspection, testing and documentation before use, and maintain the installation and equipment appropriately.
Electrical terms explained
Electric current
The rate of flow of electric charge, measured in amperes (A). Conventional current direction follows positive charge flow, which is opposite to electron drift in a metallic conductor.
Voltage
The electric potential difference between two points, measured in volts (V). Always identify the reference points, such as line-to-neutral or line-to-earth; a voltage is not a property of one isolated terminal alone.
Resistance
The opposition associated with resistive current flow, measured in ohms (Ω). For a component behaving as an ohmic resistance under the stated conditions, U = IR.
Electrical power
The rate of electrical energy transfer, measured in watts (W). P = UI applies to steady DC; in a sinusoidal single-phase AC circuit, active power is UI cos φ using RMS values. The general average depends on voltage and current waveforms.
Ohm's law
For an ohmic resistance, current is proportional to the applied voltage: I = U/R. Resistance can vary with temperature, and non-linear devices do not necessarily obey one constant-resistance relationship.
Kirchhoff's laws
The current law expresses charge conservation at a circuit node. The voltage law states that the algebraic sum of voltages around a closed loop is zero within the applicable circuit model; induced effects must be represented appropriately.
Direct current (DC)
Current that maintains one direction. Its magnitude may be constant or vary; pulsating DC is still distinguished from current that reverses direction.
Alternating current (AC)
Current whose direction reverses with time, commonly periodically. Public supplies normally use approximately sinusoidal AC, while electronic equipment can produce other waveforms.
Frequency
The number of cycles per second of a periodic quantity, measured in hertz (Hz). Many European public supplies operate at a nominal 50 Hz.
Phase difference
The relative position of periodic quantities of the same frequency, often expressed in degrees or radians. For sinusoidal quantities, a time displacement can be related to that phase angle.
Circuit diagram
A drawing representing circuit components and their electrical connections using symbols. It is distinct from a physical layout or a complete installation design.
Capacitor
A component that stores energy in an electric field. Its capacitance relates stored charge to voltage under the stated conditions; a practical capacitor also has voltage, current and other operating limits.
Strappers in lighting circuits
The pair of conductors linking the changeover contacts in conventional two-way lighting switching, including intermediate switching where used. They carry the alternative switching paths and are not transformer windings; identify their actual functions from the circuit.
Coil or winding
A conductor arranged in turns, commonly to produce magnetic effects. Its behaviour includes inductance as well as the resistance and other properties of the actual winding.
Inductance
The relationship between flux linkage and current in the applicable model, measured in henries (H). Changing current produces an induced voltage; for a constant inductance its magnitude relates to L di/dt with the appropriate sign convention.
Capacitance
The relationship between stored charge and voltage, measured in farads (F). For a constant capacitance, changing voltage produces current according to i = C dv/dt.
Transistor
A semiconductor device used for switching, amplification or other control functions. Its operating principle and control quantities depend on whether it is, for example, a bipolar transistor or a field-effect device.
Semiconductor
A material whose electrical behaviour can be controlled through composition, electric fields, light or other conditions. Semiconductor devices use this behaviour for functions such as rectification, switching and amplification.
Diode
A device with a strongly directional current-voltage characteristic. Real diodes have forward losses, reverse leakage and limits; they do not act as perfect one-way valves at every voltage.
Relay
A device that changes an output in response to a control input. An electromechanical relay uses a coil and contacts, while a solid-state relay uses electronic switching elements.
Switch
A device that makes, breaks or changes electrical connections. Its rating, contact arrangement and permitted duty determine the applications for which it is suitable.
Electrical network
An interconnection of electrical components and branches. Series, parallel and more complex arrangements can be analysed with an appropriate circuit model.
Transformer
A device transferring energy between magnetically coupled windings through changing flux. Turns ratio influences voltage and current relationships; losses, limits and any conductive connection depend on its construction.
Electromagnet
A magnetic arrangement energised by electric current, commonly using a coil and magnetic core. Contactors, relays and actuators use electromagnetic force for mechanical operation.
Impedance
The relationship between voltage and current phasors in a sinusoidal steady-state model, measured in ohms. It combines resistance and reactance and can vary with frequency.
Short circuit
An unintended low-impedance connection between points at different potentials. Current is limited by the complete source and fault-path impedance, not literally unrestricted.
Electric circuit
An arrangement of sources, conductors and components. Current flows where a complete conductive path exists, although a circuit can also be described in an open or disconnected state.
Series connection
Components in one unbranched path carry the same current. Their voltages add algebraically; the individual voltage shares depend on their electrical behaviour.
Parallel connection
Branches connected between the same two nodes share the same voltage. The branch currents depend on their loads and add algebraically at the connection points.
Fuse
An overcurrent protective device with an element designed to melt and interrupt the circuit under specified conditions. Its rating, characteristic and breaking capacity must suit the application.
Overcurrent protection
Protection against overload and short-circuit effects, commonly using fuses or circuit-breakers. A sensing relay may require a separate interrupting device; an ordinary RCCB does not provide this protection by itself.
Earthing
A deliberate connection of a system point or conductive part to earth. Protective earthing forms part of an electric-shock protection arrangement; it must not be confused with neutral, functional earth or a guarantee of zero touch voltage.
Frequency converter or variable-speed drive
Electronic equipment that produces a controlled output frequency, commonly with controlled voltage, to operate a suitable motor. Its pulsed output, protection and compatibility requirements differ from a direct mains supply.
Electromagnetic compatibility (EMC)
The ability of equipment to operate satisfactorily in its electromagnetic environment without causing unacceptable disturbance to other equipment. Both emissions and immunity matter.
Power loss
Energy dissipated per unit time, commonly as heat in conductors, cores, insulation or semiconductor devices. Ideal inductors and capacitors exchange stored energy without average loss; practical components have additional loss mechanisms.
Short-circuit current
The current resulting from a short circuit. Prospective fault current is assessed to select protective devices with adequate interrupting capability and to check thermal and mechanical effects.
Power factor
The ratio of active power to apparent power. For sinusoidal voltage and current it equals cos φ; with distortion it also reflects waveform effects. It is not the same as energy-conversion efficiency.
Insulation resistance
Resistance measured between specified conductive parts separated by insulation under stated test conditions. The test voltage, connected equipment and interpretation must suit the circuit; it is not a complete assessment of insulation performance on its own.