Difference Between AC Contactor and DC Contactor

The AC contactor can be replaced by DC contactor in case of emergency, but the actuation time shall not be more
than 2 hours (because the heat dissipation performance of AC coil is poorer than that of DC coil, which is
determined by their different structures). For long term use, a resistor had better to be connected in series in the
AC coil. In contrary, the DC contactor can't be replaced by the AC contactor.

AC contactor has a few coils while the DC contactor has more, they can be distinguished from the size of coil. In
case the current of main circuit is too large (Ie>250A), the contactor shall adopt a series duplex winding winding.

Coil of the DC relay has a large reactance, but small current.

Iron core of the AC contactor is usually laminated by silicon steel sheet, so as to reduce the eddy current and
hysteresis loss generated by alternating magnetic field in iron core, avoid the iron core overheating. However, iron
core in the DC contactor's coil would not generate eddy current and there is no heating problem in DC core, so the
iron core can be made of a complete cast steel or cast iron. Coil of DC circuit has no inductance, so the coil has
more turns, thus leading to large resistance and copper loss. In order to keep a good heat dissipation for the coil,
the coil is generally made into a thin and cylindrical shape. Coil of AC contactor has less turns and small resistance,
but the coil also gives heat, so the coil is generally made into a fat and short cylindrical shape. Meanwhile, a
clearance is left to facilitate heat dissipation while avoiding the coils from being burned out. In order to eliminate
vibration and noise generated by electromagnet, a short circuit ring is embedded on the surface of static iron core
of the AC contactor, while the DC contactor doesn't need a short circuit ring.

Iron core of AC contactor is laminated by silicon steel sheet, thus reducing the eddy current and hysteresis loss
generated by alternating magnetic field in iron core. When the AC passes through the magnetic coil, the coil
generates alternating actuation force on the armature. When the AC is at zero, the magnetic flow in the coil also
becomes zero, so is the actuation force on the armature. Armature will show a release trend under the action of
.reset spring

This makes the actuation force between dynamic and static core to change along with the AC change, thus
generating change and noise, accelerating the contact wear between dynamic and static core, leading to poor
contact. Seriously, it may also lead to burn out of contacts. In order to eliminate this drawback, a copper ring is
embedded in partial end of the core column and it's called a short circuited ring. This short circuited ring is
equivalent to the secondary winding of the transformer. When the coil is connected to AC power, not only the coil
generates magnetic flow, so does the induced current in the short circuited ring. At this time, the short circuited
.ring is equivalent to a pure inductance circuit

According to the phase position of pure inductance circuit, we know that magnetic flow caused by coil current and
magnetic flow caused by induced current of the short circuited ring can't be zero at a same time. Namely, when
the current provided by power supply is at zero, the induced current of the short circuited ring can't be zero, its
magnetic flow attracts the armature pair and thus overcoming the release tendency of armature, and
guaranteeing the armature is always actuated when it's powered on. As a result, the noise and vibration are
obviously reduced, so the short circuited ring is also called vibration elimination ring.DC Contactor

:Main differences between AC contactor and DC contactor

Iron core of AC contactor would generate eddy current and hysteresis loss, while the DC contactor has no core
loss. Therefore, iron core of AC contactor is made of laminated silicon steel sheets, which is generally in E shape,
.while the iron core of DC contactor is made of complete soft steel, which is generally in U shape

As single-phase alternating current passes through AC contactor, a short circuit ring is embedded on the end of
the static core to eliminate vibration and noise generated by electromagnet. However, the DC contactor doesn't
.need the short circuit ring

AC contactor adopts a grid arc extinguishing device while the DC contactor adopts a magnetic quenching arc
.extinguishing device

AC contactor has a large starting current, its maximum operation frequency is about 600 times an hour, while
.that of DC contactor can be 1200 times an hour
AC vs. DC Contactors

When people refer to DC or AC contactors they may be talking about either the control circuit or the circuit
being controlled (i.e. being switched). On this page we will use AC or DC contactor to describe the type of
power being switched, NOT the type of power energizing the coils.

Whereas the constantly changing voltage helps extinguish any arcs in an AC circuit (specifically when there
is zero voltage), a DC contactor relies on other mechanisms to suppress arcing. The most important
difference between an AC and DC contactor is that a DC contactor is designed to suppress electric arcing
when the contacts open and close in a DC circuit. For example, voltages are much lower for DC than AC
circuits, and the gaps between contacts are wider in a DC contactor.

Electric Arcing

An electric arc is simply the flow of an electric current through a gas. In electric circuits, arcing can occur
anywhere a connection is made or broken. Thus, arcing occurs most frequently at switches where contacts
repeatedly open (break) and close (make) a circuit.

Effects of Arcing

Extreme levels of heat

Electric arcs are actually examples of the less familiar but very common fourth state of matter called plasma
(e.g. electric shocks, lightning, and neon lights). In order of increasing temperature (i.e. kinetic energy or
heat) we have solids, liquids, gases, and plasma. Plasmas are essentially ionized matter where the electrons
orbiting atoms are energized to such a degree that the outermost electrons are able to escape, and the
surrounding air that is a natural insulator becomes conductive.

The level of kinetic (heat) energy carried by the ions in a plasma is on the order of thousands of degrees
Celsius and get can several times hotter than the surface of the Sun. In short, electric arcs are very very hot
and over time will damage your switch contacts as any amount of arcing will melt off or even vaporize tiny
portions of the contact surfaces.

Cleans contact surface

One benefit is that arcs burn off the thin layers of oxidation and other contaminants that prevent current flow
and build up on contact heads. In fact, contacts that are not switched for a period of days or weeks will
oxidize faster than contacts that are regularly switched.

Arcing in an AC vs. DC circuit

Since arcing is the flow of current (i.e. electric charges) through a gas, arcs occur far more easily and with
greater effect in DC circuits where the current is only flowing in one direction and has a steady voltage. In
AC circuits where the polarity, voltage, and current are constantly changing and reversing, there is much
less risk for damage from arcing.

In particular, the point where current changes direction is when there is zero voltage, and zero voltage means
no current is flowing. Since current changes direction twice in every cycle and the U.S. and Europe use 60
and 50 Hz AC power respectively, zero voltage occurs 120 and 100 times every second. This means that
arcs in AC circuits are self-extinguishing.

Arc Suppression

NOTE: When selecting contactors, you need to consider arc and surge suppressors separately. Many
devices provide both arc and surge suppression (variable resistors, diodes, zener diodes, snubbers, etc.), but
electric arcs and surges are not the same thing.

Arcing refers to electric current traveling through a gas, while surges refer to momentary spikes in voltage.

An arc will ignite and last as long as there is sufficient voltage and current in a circuit. In AC circuits, arcing
still happens, but since zero voltage occurs so frequently any arcs are quickly extinguished, though they may
reignite on their own if the voltage is too high.

Zero voltage does not occur in DC circuits unless the circuit is opened, so a good way to extinguish an arc is
to simply have a larger gap between contacts. This is why having a fast switch time matters for high power
applications (both AC and DC), because the faster a contact armature opens, the faster arcs will be
extinguished.

Having instants of zero voltage in AC and not in DC is also why a DC contactor can be rated to switch, for
example, 24V DC, but you could use the same contactor to switch 120V AC. Conversely, it would
extremely dangerous if you tried to switch 120V DC with a 120V AC contactor.