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HVACR114 Electrical for Gas

Heat
Contactors

A contactor is used to control an electric load

in a control system.
Contactors make or break a set of contacts
that controls the voltage applied to some load
in HVAC systems.
A contactor consists of a coil that opens and
closes a set of contacts due to the magnetic
attraction created by the coil when it is
energized.

Parts of a contactor
Contacts
Control Voltage
Terminals

Coil
Line Voltage
Terminals

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Applications

The largest electric load in any cooling system

that requires control is the compressor.
The contactor used in a small residential air
conditioning unit probably controls the
compressor and condenser fan motor.
Larger Air conditioning systems will have
multiple contactors.

Simple schematic diagram of a contactor controlling a

compressor and Condenser fan motor

Operation
Different manufacturers design contactors in
different ways. But they serve the same
purpose: Opening and closing a set of
contacts.
The armature of a contactor is the portion that
moves.
This can be accomplished by two ways:
A sliding armature
A swinging armature

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Contactor with a sliding armature

Armature

The sliding armature is mounted between two

slots in the frame of the contactor and moves
up and down in these slots.

Contactor with a swinging armature

Armature

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The swinging armature is mounted on a pivot

or hinge and moves up and down in a
swinging motion.

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The armature of a contactor is connected by a

mechanical linkage to a set of contacts that
causes a complete circuit when the armature
is pulled into the magnetic field produced by
the coil.
This operation applies for both the swinging
armature and sliding armature.

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The magnetic
field that closes
a contactor is
created by a
coil wound
around a
laminated iron
core.

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When the coil is energized, a magnetic field is

created around the laminated core.
The core then becomes a electromagnet of
sufficient strength to attract the armature
closing the contacts.
Some contactors have a spring mounted
between the armature and the stationary
contacts to ensure the contactor opens when
the coil is de-energized.

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Coils
Coil characteristics
depend on the
type of wire and
the manner in
which it is wound.
Coils are designed
to be operated on
24, 120, 208/230
and occasionally
480 volts.
To identify the coil
voltage, the voltage
is marked on it.

Coil voltage is
marked here!

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Contacts
The contacts of a contactor make a complete
circuit when the contactor is energized,
allowing voltage to flow to the controlled load.
Contactor are rated by the ampere draw they
can carry.
There are two types of loads a contactor can
control:
Inductive loads ( Motors)
Resistive loads ( Heaters)

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Contacts are made of silver and cadmium,

which resists sticking.
The chemical composition of contacts can
operate at cool temperatures up to 125% of
their current carrying capacity.
Contactors are usually manufactured with two
or three poles.

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Two pole contactor is required for single

phase systems.
A three pole contactor is required for three
phase systems.

Troubleshooting

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To diagnose a faulty contactor requires

looking at three sections of the contactor:
The coil
The contacts
And the mechanical linkage

A defect in any part of these parts can cause

the contactor to fail.

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The coil

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The coil must be in good condition to create a

strong enough electromagnetic force to pull in
the contacts.
Its uncommon for the coil to become so
weak that it does not close the contacts,
unless there is excessive friction to the
mechanical linkage.
A coil is diagnosed as either good, open or
shorted.

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The coil can be checked with an ohmmeter.

If the coil is shorted, resistance will read 0
If the coil is opened, resistance will read OL
If the coil is good, the resistance will read some
measurable resistance.

A coil can also be checked by applying voltage

to it and observing the contactor to see if it
closes.

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A voltage reading of the coil should be taken

before checking the coil to see if the contacts
should be closed.
If voltage is applied to it, the coil will cause a
direct short and other damage could result.
So BE CAREFUL!

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Contacts

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The contacts must be in good condition to

ensure that the proper voltage reaches the
load.
A visual inspection is sufficient to diagnose
bad contacts.
A voltage reading taken across the contacts of
the same pole will show the voltage drop
across the contacts.

Contact conditions

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Pi:ed and burnt contacts

Good Contacts

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Any voltage drop above 5% of the rated

voltage is considered to be excessive.
If you come across this, replace the contactor.
Voltage must be applied to make this check.

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Mechanical linkage

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The easiest fault to diagnose.

Any problem with the mechanical linkage can
be detected by visual inspection.
The mechanical linkage will usually fail do to
wear, corrosion, or moisture

Repairing contactors

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Contactors can be repaired by using

replacement parts.
Some manufacturers do sell a kit that will
completely replace the contact portion of the
contactor.
Parts can be difficult to locate, it might be
better to just replace the contactor.

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