Editorial Technical Reference

Overload Relay

This page explains how Overload Relay is classified within Electrical Equipment Manufacturing. Technical values and manufacturer relationships are research references; confirm the current specification and supplier evidence for each order.

Technical Definition & Core Assembly

A protective electrical device that automatically interrupts circuit current when it detects excessive load conditions to prevent motor damage.

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Product Specifications

Technical details and manufacturing context for Overload Relay

Definition
An overload relay is a protective component used in motor control circuits, typically mounted within a starter bucket or unit. Its primary function is to monitor the current drawn by an electric motor and to disconnect power when an overload condition is detected, thereby preventing overheating and potential damage to the motor. The relay operates by sensing motor current through either thermal or magnetic elements. Thermal overload relays use bimetallic strips that bend when heated by excessive current, while magnetic types use electromagnetic coils that trip at specific current levels. When the current exceeds a preset threshold for a specified duration, the relay's contacts open, interrupting the power supply to the motor circuit. This device is essential for safeguarding motors in industrial applications, ensuring reliable operation and extending equipment life. The overload relay is available with a range of technical parameters that must be verified for the specific model and application. These include rated insulation voltage up to 690 V, rated operational voltage from 24 to 690 V AC, an adjustable current setting range from 0.1 to 630 A, trip class 10A–30, frequency range 50–60 Hz, operating temperature from -20 to 70 °C, degree of protection from IP20 to IP65, contact rating for auxiliary contacts (AC-15) from 5 to 10 A, reset time from 2 to 60 seconds, mechanical endurance of 100,000 operations, electrical endurance of 10,000 operations, and weight ranging from 0.1 to 5 kg. These parameters are referenced to standards such as IEC 60947-4-1, IEC 60529, and IEC 60947-5-1. It is important to note that the listed values are directory reference ranges; the actual model-specific values and compliance with standards must be confirmed with the legal manufacturer or supplier before procurement and installation.
Working Principle
The overload relay operates by continuously monitoring the current flowing to the motor. In thermal types, the current passes through a bimetallic strip, which heats up and bends as the current increases. When the bending reaches a certain point, it triggers a mechanism that opens the relay's contacts, cutting off power to the motor. In magnetic types, an electromagnetic coil generates a magnetic field proportional to the current; when the current exceeds a set level, the magnetic force pulls an armature to trip the contacts. The trip delay is determined by the trip class, which defines the maximum time the relay can withstand an overload before tripping. After tripping, the relay can be reset manually or automatically after a specified reset time.
Common Materials
Copper, Plastic, Steel, Bimetallic alloy
Technical Parameters
ParameterTypical rangeNotes & selection driver
Rated Insulation Voltage690 VMaximum voltage the relay can withstandIEC 60947-4-1
Rated Operational Voltage24–690 V ACRange for motor circuit applicationIEC 60947-4-1
Current Setting Range0.1–630 AAdjustable overload trip thresholdIEC 60947-4-1
Trip Class10A–30Defines trip delay under overloadIEC 60947-4-1
Frequency50–60 HzOperating frequency rangeIEC 60947-4-1
Operating Temperature-20–70 °CAmbient temperature range for reliable operationIEC 60947-4-1
Degree of ProtectionIP20–IP65Higher IP for harsh environmentsIEC 60529
Contact Rating5–10 AAC-15 utilization category for auxiliary contactsIEC 60947-5-1
Reset Time2–60 sTime for manual or automatic reset after trip
Mechanical Endurance100000 operationsNumber of operations without mechanical failureIEC 60947-4-1
Electrical Endurance10000 operationsNumber of operations under rated loadIEC 60947-4-1
Weight0.1–5 kgVaries with current rating and enclosure

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM
  • Bimetallic Strip Part
    Senses temperature changes from overcurrent and triggers mechanical trip mechanism
    Material: Bimetallic alloy
  • Heater Element Part
    Converts electrical current to heat that affects the bimetallic strip
    Material: Copper alloy
  • Trip Contacts Part
    Electrical contacts that open to interrupt circuit when overload is detected
    Material: Silver alloy
  • Reset Mechanism Part
    Allows manual or automatic resetting of the relay after tripping
    Material: Plastic/Steel
  • Electromagnetic Coil Optional
    Produces a pull proportional to motor current on magnetic-type relays.
  • Armature Optional
    Gets pulled in once current passes the set level and trips the contacts.

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Industrial Ecosystem & Supply Chain Structure

Complementary Systems
Downstream Applications
Specialized Tooling

Application Fit & Sizing Matrix

Operational Limits
pressure: N/A (electrical device, not pressure-rated)
other spec: Current Range: 0.1-630A typical, Voltage: up to 690V AC, Trip Class: 10, 20, 30 (motor start time tolerance)
temperature: -20°C to +60°C (operating ambient)
Media Compatibility
✓ Induction Motors (3-phase AC) ✓ Conveyor Systems ✓ Pump Applications
Unsuitable: Explosive Atmospheres (unless specifically rated for hazardous locations)
Sizing Data Required
  • Motor Full Load Current (FLC)
  • Motor Service Factor
  • Ambient Temperature

Reliability & Engineering Risk Analysis

Failure Mode & Root Cause
Contact Welding
Cause: Excessive inrush current or frequent short-circuit conditions causing contacts to fuse together, preventing proper tripping.
Calibration Drift
Cause: Thermal aging of bimetallic strips or degradation of electronic components over time, leading to inaccurate trip settings.
Maintenance Indicators
  • Audible buzzing or humming from the relay enclosure indicating loose connections or failing internal components
  • Visible discoloration, scorch marks, or melted plastic on the relay housing suggesting overheating
Engineering Tips
  • Perform regular calibration verification using a primary injection test set to ensure trip settings match motor nameplate data and application requirements
  • Implement infrared thermography inspections during normal operation to detect abnormal heating at connection points and internal components before failure occurs

Indicative industry ranges for design and RFQ preparation. Confirm the exact figures and applicable standard with the manufacturer before specifying.

Compliance & Manufacturing Standards

Applicable Standards
IEC 60947-4-1: Low-voltage switchgear and controlgear - Part 4-1: Contactors and motor-starters - Electromechanical contactors and motor-starters UL 508: Standard for Industrial Control Equipment EN 60947-4-1: Low-voltage switchgear and controlgear - Part 4-1: Contactors and motor-starters - Electromechanical contactors and motor-starters (CE marking basis)

Quoted from the published standard.

Manufacturing Precision
  • Current Setting Accuracy: +/- 5% of rated current
  • Trip Time Tolerance: +/- 10% of specified time at 600% overload
Quality Inspection
  • Dielectric Strength Test: 2500V AC for 1 minute between live parts and ground
  • Calibration Verification Test: Verify trip characteristics across entire current range using calibrated test equipment

Manufacturers of Overload Relay

4 companies list this product among what they make. Company figures are quoted from each company's own website; every card states where the relationship came from.

ZHEJIANG ETEK ELECTRICAL TECHNOLOGY CO.LTD.
Zhejiang, CN
CE VDE TUV CB
Listed on the company's own website · profile compiled by CNFX from public sources
Changan Group
Zhejiang, CN
Listed on the company's own website · profile compiled by CNFX from public sources
CNC Electric
Zhejiang, CN
Listed on the company's own website · profile compiled by CNFX from public sources
HIITIO
Zhejiang, CN
Listed on the company's own website · profile compiled by CNFX from public sources

Manufacturer listings support early research and capability understanding. They are not certification, ranking, or transaction guarantees.

Technical documentation
Request current drawings, revision history, and a signed specification sheet.
Manufacturing capability
Verify equipment lists, process limits, capacity, and representative production evidence.
Inspection readiness
Confirm test methods, calibrated equipment, sampling plans, and traceable reports.
Supplier transparency
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Frequently Asked Questions

What is the function of an overload relay?

An overload relay protects an electric motor from damage due to excessive current draw. It monitors the motor current and opens its contacts to interrupt power when an overload condition is detected, preventing overheating and potential motor failure.

What are the main types of overload relays?

The two main types are thermal and magnetic. Thermal relays use bimetallic strips that bend with heat from overcurrent, while magnetic relays use electromagnetic coils that trip at specific current levels. Both serve the same protective function but operate on different principles.

How do I select the correct overload relay for my motor?

Selection requires matching the relay's current setting range to the motor's full-load current, considering the rated operational voltage, frequency, and ambient temperature. Also, verify the trip class to ensure the relay provides appropriate protection without nuisance tripping. Always consult the manufacturer's data and standards like IEC 60947-4-1.

What maintenance does an overload relay require?

Regular inspection for signs of overheating, mechanical wear, or contact erosion is recommended. Test the trip function periodically and ensure the reset mechanism operates correctly. If the relay trips frequently, investigate the cause, such as motor overload or supply voltage issues. Replace the relay if it fails to trip or shows damage.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

Preliminary Technical Classification
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