Overload Relays are safety devices that protect your circuit against damage from high-power loads. The relay opens if the load exceeds the safety threshold, protecting the circuit from destruction.
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Overload relays are your safety net for electrical damage to your equipment. You can destroy the circuit if you experience a power surge or any high-power influx and do not have an overload relay.
Broken circuits will prevent your compressor from operating, effectively turning it into a paperweight. It may not seem like it, but these relays can be the difference between thousands of dollars over a compressor’s lifetime. The risks of operating without one far outweigh the amount saved by not including an overload relay.
We can boil Overload Relays down to two major parts: a heater element and a set of closed contacts.
To properly monitor the electrical current, the power line from the motor is connected in series with a heater element on the relay. Any current going to the motor must run through this point. If too much power is flowing through, the heater will detect the change and stop the current to prevent damage.
The set of normally closed contacts is the key to preventing overload damage. It is connected in series with the manual or magnetic starter. The main point is that these contacts are directly connected to the component starting your compressor.
These two components work together so that when the temperature gets hot enough, the heater element will expand and break the connection of the circuit. Once the connection is broken, power will no longer be passing through and the compressor will stop. By breaking the connection, the internal circuit is protected from the high voltage and potential destruction.
Before you select the type of overload relay you need, you need to know the type of circuit you are protecting. The type of circuit and application of the relay can determine your type and placement.
You want your overload relay to be at the most sensible point. For compressors, this is where the motor wire connects to the heater element. It is all about what happens when it shuts off and how quickly it can protect your equipment. Ideally, this is near the point where power meets the equipment.
You want your overload relay to be cut off when the power entering your equipment is too high. If it is too far away from the point of use, the readings won’t be as accurate as they can be. This can cause excess energy to sneak through and damage your equipment when it should have been able to stop it.
Aside from the inherent safety aspect of incorporating overload relays into your system, they have many benefits:
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