Why are 120V relay and 150A contactor coils burning in my control circuit?

Hi,

I have one circuit which have one 150amp contactor which controlled by external relay.

The realy operated from 120v and it supplies to contactor coil.

But now we have installed in consumer premises.but now we are getting complaint like the relay and contactor coils are burning.

Can any one help on this

 

Thanks

 

1. Schematic?
2. Relay data sheet?
3. Contactor data sheet?
4. 120VAC or 120VDC?

No My relay will work from 120v AC

I need to active my contactor after 120V as per my site requirement.

bellow 120V the realy and contactor bothe should be in cut off mode.

Hi John did you have checked my inputs

Hi DavidMarsetty, what is your load current , your relay contacts current rating  should be rated50% more than your load current ,because the starting  curent will be higher than your load current  . you can add a 5  watts 2.2 ohms resistor in series to your relay coil supply  for the safety of the relay coil.Sambath kumar.

the Load current 30A max(it may be 10A or 5A)
Yes the contacts current rating more than 50% of load current.
ya we added resistor of same but it is not withstanding continuous 230voltage AC even if rated.

1. provide  a polyster cap 0.1 ie 100k  600v parallel to the relay coil supply.2.  provide a 1 ohm 20 watt resistor series to the relay supply  coil negative terminal,( for this you take a heating coil of an electric stove measure the resistance and  cut the required length).actually this is not  required i am suggesting this since you have failure of the relay  coil. Relay coil will fail if your relay  coil voltage goes  high .3. check your actual load current using a current clamp meter   make sure you check the switch on time  current it will be higher than the normal working  current buy relay current 50% moe than the switching  on time current.4,check any shot  or leakage of  the phase circuit of the load to  neutral or to the ground circuit.5. switch off the power and clean relay contacts,and relay coil supply terminals.and the relay fixing areaswith isopropile alcohol solution. switch on the circuit olny after the solution is dryed.