A Complete Guide to Contactors

Our guide provides everything you need to know about contactors,

including how they work and how to use them.

Topics Covered in this Guide

This introductory guide to contactors aims to provide clear and

comprehensive answers to common questions about contactors. We will
include a brief look at how electrical contactors work, how they are used,
and which types are sold online.

We will also cover some of the more popular types and brands of
contactors available and identify how to choose the best for your needs.

What is a Contactor?
A contactor is an electrical switch designed to handle high-current loads in
industrial and large-scale electrical systems throughout Malaysia. The
function of a contactor is to act as heavy-duty relays, opening and closing
circuits to control the flow of electricity to demanding loads such as motors,
pumps and HVAC systems.

Contactors differ from standard switches due to their robust construction

and ability to withstand the stresses of high currents. This resilience is
achieved through several key features:

 Sturdy Contacts: Contactors utilise large contact surfaces made of

durable materials like silver-cadmium oxide or tungsten, which can
withstand the heat and arcing generated during high-current
switching.
 Arc Suppression: They incorporate arc chutes or other suppression
mechanisms to quickly extinguish the electrical arc that forms when
 the contacts open, preventing damage to the contacts and ensuring a
long lifespan.
 Magnetic Blowouts: Some contactors employ magnetic blowouts,
which use magnetic fields to stretch and cool the arc, further
minimising wear and tear on the contacts.

A contactor operates through electromagnetic principles. When an

electrical current is passed through the contactor's coil, it generates a
magnetic field. This magnetic field attracts a movable contact, closing the
circuit and allowing electricity to flow to the load. When the current to the
coil is interrupted, the magnetic field collapses, and the contact returns to
its open position, breaking the circuit. This simple yet effective mechanism
allows for reliable and safe switching of high-current loads in countless
applications across Malaysia.

Contactor Capacities

Contactors come in a wide range of capacities to handle diverse electrical

loads. In Malaysia, you'll commonly find contactors with the following
capacities and typical applications:

Low-capacity contactors (9A - 25A): These are often used for controlling
lighting systems, small motors in household appliances, and HVAC
systems in residential buildings.

Medium-capacity contactors (40A - 100A): These are commonly found in

industrial settings, powering machinery like pumps, conveyors, and small
machine tools. They are also used in commercial buildings for controlling
larger HVAC systems and elevators.

High-capacity contactors (150A - 800A and above): These heavy-duty

contactors are essential for large-scale industrial applications, such as
controlling large motors in manufacturing plants, cranes, and power
distribution systems. They are also vital for infrastructure projects, powering
pumps in water treatment plants and ventilation systems in tunnels.

What Is the Main Function of a Contactor?

 To safely and efficiently control high-current electrical loads.

 To open and close circuits, allowing or interrupting the flow of
electricity to a load.
 To provide remote operation of electrical equipment.
 To protect expensive equipment from damage due to overloads or
short circuits (when combined with appropriate protective devices).
 What Are Contactors Used For?

An electrical contactor is used in a wide range of situations where there is a

need to switch power to a circuit repeatedly. Like relay switches, they are
designed and built to perform this task over many thousands of cycles. In
Malaysia, this is crucial for industries like palm oil processing, where
contactors control motors in mills and refineries, ensuring continuous
operation.

Contactors are mainly chosen for higher power applications than relays.
This is because of their ability to allow low voltages and currents to switch,
or power cycle, a far higher voltage/current circuit on and off.

Typically, a contactor will be used in situations where power loads need to

be turned on and off frequently or rapidly. However, they can also be
configured either to power on a circuit when activated (normally open, or
NO contacts), or to shut down power to a circuit when activated (normally
closed, or NC contacts).

The two classic applications for a contactor are as an electric motor starter,
such as those that use auxiliary contacts and connectors for use in
electrical vehicles, and in high-powered lighting control systems.
When a contactor is used as a magnetic starter for an electric motor, it will
usually also provide a range of other safety features such as power-cutoff,
short circuit protection, overload protection, and under-voltage protection.

Contactors being used to control high-power lighting installations will often

be arranged in a latching configuration, to lower overall power
consumption. This arrangement involves two electromagnetic coils working
in tandem. One coil will close the circuit contacts when briefly energised
and hold them closed magnetically. The second coil will open them again
when powered.

With Malaysia's target to achieve 23 percent energy savings from industrial

and commercial sectors by 2050, contactors play a key role in reducing
power consumption. For example, in large-scale commercial buildings and
infrastructure projects, latching configurations are employed to minimise
energy usage in lighting systems.

As contactors are intended specifically for these sorts of high-voltage

applications, they tend to be physically larger and more robust than
standard relay switching devices. However, most electrical contactors are
still designed to be easily portable and mountable and are generally
considered highly suitable for use in the field.

How Do Contactors Work?

To better understand how a contactor works, it is helpful to know about the
three core components of any electrical contactor device when assembled.
These are normally the coil, the contacts, and the device enclosure.

Contactor Components

 The coil, or electromagnet, is the key component of a contactor.

Depending on how the device is set up, it will perform a specific
action on the switch contacts (opening or closing them) when it
receives power.
 The contacts are the components of the device that carry power
across the circuit being switched. There are various types of contacts
found in most contactors, including springs and power contacts. Each
type performs a specific function in transferring current and voltage.
 The contactor enclosure is another important part of the device. This
is the housing that surrounds the coil and contacts, helping to
insulate the contactor’s key components. The enclosure protects
users against accidentally touching any conductive parts of the
switch, as well as offering robust protection against risks such as
 overheating, explosion, and environmental hazards like dirt and
moisture ingress.

The operating principle of an electrical contactor is straightforward. When

the electromagnetic coil has a current passed through it, a magnetic field is
created. This causes the armature within the contactor to move in a certain
way regarding the electrical contacts.

Depending on how the specific device has been designed and the role it is
intended for, this will normally be to either open or close the contacts.

 If the contactor is designed as normally open (NO), exciting the coil

with voltage will push the contacts together, establish the circuit, and
allow power to flow around the circuit. When the coil is de-energised,
the contacts will be open, and the circuit will be off. This is how most
contactors are designed.
 A normally closed (NC) contactor works the opposite way. The circuit
is complete (contacts closed) while the contactor is de-energised but
interrupted (contacts open) whenever current is supplied to the
electromagnet. This is a less common configuration for contactors,
although it is a relatively common alternative setup for standard relay
switches.

Contactors can rapidly perform this switching task over many thousands (or
indeed millions) of cycles during their full working lives.

Contactor Wiring
Wiring a contactor correctly is crucial for proper function and to ensure safe
and reliable operation in electrical systems. Here’s how to wire a contactor:

1. Identify the Terminals:

 Coil Terminals (A1 and A2): These terminals are for connecting the
control circuit, which energises the contactor's coil.
 Power Terminals (L1, L2, L3 for three-phase; L1 and L2 for
single-phase): These are the incoming power supply terminals.
 Load Terminals (T1, T2, T3 for three-phase; T1 and T2 for single-
phase): These terminals connect to the load you want to control
(e.g., motor, pump).

2. Wiring the Coil Circuit:

 Connect the control circuit's power supply to terminal A1.

  Connect the other side of the control circuit (often a switch or relay
contact) to terminal A2.

3. Wiring the Power Circuit:

 Connect the incoming power supply lines to the corresponding L

terminals (L1, L2, L3 for three-phase or L1 and L2 for single-phase).
Ensure proper phase sequencing if it's a three-phase system.
 Connect the wires leading to the load to the corresponding T
terminals (T1, T2, T3 for three-phase or T1 and T2 for single-phase).

4. Secure All Connections:

 Tighten all terminal screws securely to ensure good electrical contact

and prevent loosening due to vibrations.
 Double-check all connections against the contactor wiring diagram to
ensure accuracy.

5. Test the Contactor:

 Turn on the power supply and activate the control circuit.

 The contactor should energise, and you should hear an audible click
as the contacts close.
 Use a multimeter to verify that the voltage is present at the load
terminals.

What Is the T1 and T2 on a Contactor?

The T1 and T2 terminals on a contactor are the load terminals. These are
the connection points where the wires leading to the electrical load (e.g.,
motor, pump, or other equipment) are connected.

 In a single-phase contactor, you'll have T1 and T2.

 In a three-phase contactor, you'll have T1, T2, and T3.

When the contactor is energised, the contacts close, and electricity flows
from the power terminals (L1, L2, etc.) through the contactor to the load
terminals (T1, T2, etc.), powering the connected equipment.

Contactor Wiring Diagram

A common example of a contactor wiring diagram might look something
like this. This example diagram would be for a three-pole contactor with
one N.O. base contact.

Example of a Contactor Wiring Schematic

This schematic provides a visual representation of how a contactor is
integrated within a typical electrical control circuit.

Main Contactor (K1): This is the heart of the circuit. It consists of the main
power contacts (represented by the thicker lines) and the electromagnetic
coil (A1 and A2 terminals). When the coil is energised, it closes the main
contacts, allowing electricity to flow through to the motor (represented by
the circle).

Auxiliary Contacts (K1): These smaller contacts are linked to the main
contactor. They are used for control and signalling purposes. In this
schematic, they are likely connected to indicator lamps or pilot lights to
show the status of the motor (on or off).

Control Circuit: This circuit provides the "signal" to energise the

contactor's coil. It includes:

 Start Button (S1): When pressed, this button completes the control
circuit, sending power to the contactor coil (A1 and A2).
 Stop Button (S2): This button interrupts the control circuit, de-
energizing the coil and opening the main contacts, thus stopping the
motor.
 Thermal Overload Relay (F1): This crucial safety device protects
the motor from overheating. If the motor draws excessive current, the
thermal overload relay will trip, breaking the control circuit and
stopping the motor.

Power Circuit: This circuit carries the high current to the motor. It includes:

 Main Power Supply (L1, L2, L3): This represents the incoming
three-phase power supply.
 Motor: The load being controlled by the contactor.

The Difference Between Contactors and Relays

Although contactors are generally used for higher power applications
compared to relays, the full technical differences between the two are
slightly more complex.

A more complete list of the differences between a contactor and a relay

would include the following:

 Load Capacity: Contactors are designed and built to handle much

higher power-switching applications than control relays. Relays are
 typically reserved for use with loads of around 5A-15A, and they are
most often rated for 10A or less.
 Contact Standards: Contactors are almost always set up in a
normally open (NO) configuration. This means that the circuit will only
be established while the electromagnet in the contactor is receiving
current. Relays are easy to find with both NO and NC contacts.
 Protections and Safety Features: Contactors typically offer a much
wider range of safety cut-offs and protections, reflecting the fact that
they are designed for higher-power applications. Indeed, a specific
type of switch known as contactor overload relays is specifically
designed for use in preventing machinery and power circuits from
overheating.

Elsewhere, common examples of standard contactor safety features

include:

 Spring-loaded contacts, for interrupting an electrical circuit if the

contactor is powered off.
 Overload protection that kicks in if the circuit receives a current surge
for a defined period.
 Magnetic arc suppression, forcing any current arcs to travel a greater
distance than the energy they carry can sustain.

What Happens When You Use a Contactor in Place of a Relay, and

Vice Versa?

 Using a Relay for a Contactor Application: If you use a relay to

switch a high-current load that exceeds its capacity, it can lead to
overheating, contact welding, and even fire hazards. The relay's
contacts are not designed to handle the high currents and may fail
prematurely, causing damage to the connected equipment.
 Using a Contactor for a Relay Application: While a contactor can
technically switch a low-current load, it's not always the best choice.
Contactors are generally bulkier, more expensive, and consume
more power than relays. Using a contactor for a small load can be
overkill and inefficient.

Due to contactors being intended for heavy-duty, higher-power

applications, they tend to be physically bigger and heavier than relays, and
their switching speed is considerably slower. They are also more expensive
than relays in most cases and consume more power due to their larger
electromagnetic coils.

Contactors Selection Guide

Choosing the right contactor for your application is crucial for ensuring the
proper function, safety, efficiency, and reliability of your electrical systems.
Here's a comprehensive guide to help you make informed decisions when
selecting contactors in Malaysia:

1. Load and Power Ratings:

 Voltage: Ensure the contactor's voltage rating matches your

electrical system (240V in Malaysia). Using a contactor with a lower
voltage rating can lead to overheating and damage.
 Current: The contactor's current rating should be equal to or greater
than the full load current of the equipment it will control. This prevents
overloading and ensures safe operation.
 Power: Consider the power rating (HP or kW) of the contactor to
ensure it can handle the demands of the load. For heavy-duty
applications common in Malaysian industries like palm oil processing
or manufacturing, higher power ratings are necessary.

2. Coil Voltage vs. Load Voltage:

 Coil Voltage: This is the voltage required to energize the contactor's

electromagnetic coil. It can be different from the load voltage.
 Load Voltage: This is the voltage that the contactor switches.
  Important: While the coil and load voltages can differ, they must be
compatible with your control circuit and power supply.

3. Contact Configuration:

 Normally Open (NO): The contacts are open in their de-energized

state. When the coil is energized, the contacts close, completing the
circuit. This is the most common configuration for contactors.
 Normally Closed (NC): The contacts are closed in their de-
energized state. When the coil is energised, the contacts open,
interrupting the circuit. NC contactors are less common and typically
used for specific safety applications.

4. Safety Features:

 Overload Protection: Essential for preventing motor damage due to

excessive current. Thermal overload relays are commonly used in
conjunction with contactors to provide this protection, complying with
Malaysian safety standards.
 Short Circuit Protection: Fuses or circuit breakers are used in the
power circuit to protect the contactor and connected equipment from
damage caused by short circuits.
 Under-Voltage Protection: This feature prevents unexpected motor
restarts after a power outage, ensuring safety in industrial settings.
 Compliance with Standards: Ensure the contactor complies with
relevant Malaysian safety standards, such as MS IEC 60947-4-1,
which specifies requirements for contactors and motor starters.

5. Environmental Suitability:

 IP Ratings: Consider the IP (Ingress Protection) rating of the

contactor, which indicates its level of protection against dust and
moisture. In Malaysia's tropical climate, a higher IP rating is often
desirable to ensure reliable operation in humid and dusty conditions.
 Temperature Tolerance: Choose a contactor with a suitable
operating temperature range for the environment it will be installed in.
 Shock Resistance: For applications with vibrations or potential
impacts, select a contactor with adequate shock resistance to ensure
durability and prevent malfunctions.

Types of Contactors
Magnetic Contactor
A magnetic switch contactor operates entirely via electromagnetism and
therefore does not need any direct intervention to perform its role
consistently. This makes it one of the more efficient and reliable designs
since electromagnetic switching only requires a small amount of power. It
also enables the full remote operation of the contactor. Almost all electrical
contactors work on this basis today.

Solid State Contactors

Solid state contactors use semiconductor devices to switch loads, offering

advantages like increased speed, longer lifespan, silent operation, and
improved efficiency. However, they can be more expensive, have a higher
voltage drop, and be sensitive to temperature. In Malaysia, they are used in
renewable energy systems, HVAC, and industrial automation.

Single Phase & 3-Phase Contactors

Single-phase contactors are used in residential and small-scale

applications with single-phase power supply (two wires). They have one set
of contacts to switch the live wire, while the neutral wire remains
uninterrupted. Three-phase contactors, on the other hand, are designed for
industrial settings with three-phase power supply (three wires carrying
alternating current). They have three sets of contacts to switch all three
phases simultaneously, enabling them to handle much higher power loads
compared to single-phase contactors. This makes them ideal for controlling
large motors, heavy machinery, and other power-hungry equipment
commonly used in Malaysian industries like manufacturing and palm oil
processing.

AC vs DC Contactors

Contactors are designed to operate on either alternating current (AC) or

direct current (DC) power supplies, and the type you choose depends on
the specific application and electrical system. AC contactors are more
prevalent, especially in Malaysia where the standard power supply is 240V
AC. They utilise an AC coil to generate the magnetic field that closes the
contacts. These contactors are commonly found in industrial settings,
controlling motors, pumps, and lighting systems.

DC contactors, on the other hand, have a DC coil and are typically used in
applications with DC power sources, such as battery-powered systems,
renewable energy systems, and electric vehicles. They are also employed
in specific industrial processes where DC power is preferred. The key
distinction lies in the coil design and how the magnetic field is generated to
activate the contactor.
Auxiliary Contactors

Auxiliary contactors are smaller contactors with lower current ratings than
the main contactors they are associated with. They are primarily used for
control and signalling purposes, enhancing the functionality and safety of
electrical control systems. For instance, in a motor control circuit, an
auxiliary contact can be used to activate an indicator light, signalling that
the motor is running. They can also be used to create interlocking circuits,
ensuring that certain safety conditions are met before a machine can
operate.

In complex industrial settings in Malaysia, auxiliary contactors play a crucial

role in automating processes, improving safety, and providing valuable
feedback on the status of equipment.

Switch Ratings and Coil Ratings (Contact Voltage and Current)

Contactor switch ratings are usually given as two separate metrics -

maximum switching voltage and maximum switching current. The upper
limits of both voltage and current that a design, brand, or model of a switch
can handle must always be directly assessed in terms of the requirements
for the circuit or motor where it is being used.

While a product may be listed as a 230V contactor, 240V contactor, or

1000V DC contactor, more detailed manufacturer specifications will usually
make direct reference to the maximum coil voltage, contact current rating,
contact voltage rating, and overall power rating of a device. They will also
list the number of auxiliary contacts, terminal type, normal state
configuration, and minimum and maximum operating temperatures.
Contactors generate more heat than relays, and this must be factored in
when choosing a suitable unit for installation.

Various electrical ratings for contactors will often be given as either

resistive or inductive, depending on the intended use of the module.
Resistive ratings are more common for contactors being used with heating
elements or lighting control installations, whereas inductive load ratings
tend to be more common for motors, transformers, and solenoids.

It is also worth bearing in mind that the contactor coil voltage (control circuit
voltage) does not necessarily have to be the same as the load voltage
being switched on and off. For example, the coil voltage could be 24VDC,
but the motor being switched on and off could be 400VAC. Typical coil
voltages available include 12, 24, 48, 110, 230, and 400V.
 Frequently Asked Questions About Contactors in
Malaysia
What is the most common reason for contactor failure?

There are several reasons why an electrical contactor could suffer a failure
and need repair or replacement. The most common is contact welding or
contact sticking, where the contacts of the device become stuck or fused in
one position.

This is typically a result of excessive inrush currents, unstable control

voltages, too low transition times between high peak currents, or simply
due to normal wear and tear. The latter usually manifests as a gradual
burning off of the alloys coating the contact terminals, causing the exposed
copper underneath to weld together.

Another less common reason for a failing contactor is coil burn, most often
caused by an excessive (or insufficient) voltage at either end of the
electromagnetic coil. Dirt, dust, or moisture ingress into the air gap around
the coil can also be a contributing factor.

What do A1 and A2 mean on a contactor?

A1 and A2 on a contactor typically refer to either end of the electromagnetic
coil assembly. Most contactor manufacturers use A1 and A2 to designate
the two terminals connecting electrical power to the contactor’s magnetic
coil.
What are 13 and 14 on a contactor?
13 and 14 on a contactor also refer to common manufacturer designations.
In this case, they are used to label the terminals on the normally open
contacts in the device.
What is the difference between a relay and a contactor?
Relays and contactors are both electromagnetic switches used to control
electrical circuits, but they differ primarily in their applications and load
capacities. Relays are designed for low-power applications, typically
handling currents less than 10A and voltages up to 250V, making them
suitable for control circuits and automation tasks. In contrast, contactors
are built for high-power applications, capable of switching larger loads over
10A and up to 1000V, often used in industrial settings to control motors and
heavy machinery. Additionally, contactors usually have mechanically linked
contacts for reliable operation under load, while relays may not have this
feature, making contactors more robust for demanding electrical
environments.