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

A control circuit using a 150A contactor coil operated via a 120V AC relay coil is experiencing coil burnouts at a consumer site. The relay and contactor coils are supplied from a 120V AC source, with the relay controlling the contactor coil activation. The load current is up to 30A, with relay contacts rated at least 50% above the load current to handle inrush currents. A 2.2 ohm, 5-watt resistor was added in series with the relay coil for protection but failed under continuous 230V AC supply. Recommendations include verifying the relay coil voltage to prevent overvoltage damage, adding a 0.1µF 600V polyester capacitor in parallel with the relay coil to suppress voltage spikes, and placing a 1 ohm, 20-watt resistor in series with the relay coil negative terminal to limit current surges. It is also advised to measure actual load current during switch-on using a clamp meter, inspect for phase-to-neutral or ground leakage, and clean relay contacts and coil terminals to ensure proper operation and prevent coil burnout.
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