A motor starter is the switching and protection package that closes the circuit to a motor on command and opens it again the instant an overcurrent, undervoltage or single-phasing condition appears, while a contactor by itself is only the switching element with no built-in protection.
The 100 models with the most complete data of 156 in Motor Starter / Contactor. Every row links to full specifications, documents and service notes.
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The other equipment types in this category.
A contactor is an electrically operated switch: a coil pulls in a set of main contacts to make or break a three-phase circuit, nothing more. A motor starter combines that contactor with protection, most commonly a thermal overload relay wired in series with the motor's current path, plus the control wiring for start/stop pushbuttons, interlocks, and status feedback to the switchboard or automation system. Direct-on-line, star-delta and soft starters are all built around this same contactor-plus-protection core; what changes between them is how much inrush current and torque the motor…
A contactor is an electrically operated switch: a coil pulls in a set of main contacts to make or break a three-phase circuit, nothing more. A motor starter combines that contactor with protection, most commonly a thermal overload relay wired in series with the motor's current path, plus the control wiring for start/stop pushbuttons, interlocks, and status feedback to the switchboard or automation system. Direct-on-line, star-delta and soft starters are all built around this same contactor-plus-protection core; what changes between them is how much inrush current and torque the motor sees at the moment of starting.
Sized by rated operational current (AC-3 duty for motor loads) and by pole count, with an auxiliary contact block usually added for interlocking and remote indication.
Thermal or electronic, set to the motor's full load current and service factor; it trips on a sustained overcurrent that a fuse or breaker would be too slow, or not sensitive enough, to catch.
A motor circuit breaker or fuses upstream of the contactor clear a true short circuit far faster than the thermal overload can react, and the two are sized to coordinate rather than duplicate each other.
Where fitted, a second and third contactor (star-delta) or a solid-state voltage ramp module (soft starter) reduce starting current, at the cost of reduced starting torque, for larger motors where a direct-on-line start would sag the switchboard bus.
The starter must be matched to the motor's full load current, starting current multiple, duty class (continuous, intermittent, or frequent reversing), and the switchboard's fault level for the short-circuit device. AC-3 utilisation category current rating is the figure to check against the motor nameplate, not the contactor's resistive AC-1 rating, which is always higher and misleading if used for sizing.
| Fault | Consequence |
|---|---|
| Contactor main contacts pitted or welded from repeated interruption of starting current | Motor fails to stop on command, or one phase fails to make, causing single-phasing |
| Overload relay set above actual motor full load current | Protection no longer trips before winding damage on a developing fault, defeating the purpose of the relay |
| Coil burnt from undervoltage chatter during a switchboard disturbance | Starter drops out and will not re-energise until the coil is replaced, taking an essential auxiliary offline |
| Star-delta timer misadjusted | Transition happens too early (high current transient) or too late (unnecessary time at reduced torque), stressing both motor and starter |
When replacing a starter after a trip, check the overload relay setting against the motor nameplate before re-energising; a starter swapped in a hurry with the previous relay setting left unchanged is a common cause of a repeat winding failure weeks later.
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