Topic 5_2

Electrical control system

components

Dr. Mahesh S. Narkhede

Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/
 Course Outcome
After studying this topic you will be able to
• Explain construction, working and applications of
level control switch, pressure-sensing switch,
Overload sensing switch
• List Applications of Contactors, Solenoid
actuated valves, pilot lamps
• State the basics and thumb rule of control circuit
development
• State the Definition, Use & specifications of
control transformer
• Develop Power and control circuits for Skip
Hoist, Overhead Crane, conveyor belt &
compressor motor
2
Level Control Switch

3
 Level Control Switch
• The Float switch shown in the figure is used to
maintain liquid levels within a certain range in a
tank by energizing a pump when a liquid level
falls to a certain lower pre set height and by de-
energizing the pump when liquid level rises
above a certain higher pre set height.

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Level Control Switch

• Level switches can also be

designed to detect the
level of solid materials
such as wood chips, grain,
coal, or animal feed in a
storage silo, bin, or hopper.

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 Level Control Switch
• A common design uses a "tuning fork" shaped
metal prong, inserted into the bin from the
outside at the desired height.
• The fork is vibrated at its resonant frequency by
an electronic circuit and magnet/ electromagnet
coil assembly.
• When the bin fills to that height, the solid
material dampens the vibration of the fork, the
change in vibration amplitude and/or frequency
is detected by the electronic circuit.

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Pressure Switch
• A Pressure switch is a
form of switch that
makes electrical contact
when a certain set
pressure has been
reached on its input.
• This is used to provide
on/off switching from a
pneumatic or hydraulic
source.
• The switch may be
designed to make
contact either on
pressure rise or on
pressure fall.
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Pressure Switch
• Pressure switches are
used in control systems
to sense pressure of
gas, air or liquid and
feed signal to electrical
circuit.
• Pressure switch can
have NO or NC or both
contacts.
• It can use Bellow or
diaphragm or tube of
semicircular shape to
sense the pressure.
8
 Pressure Switch
Applications
In Pneumatics :
• switching off an electrically driven compressor
when a set pressure is achieved in the
reservoir
In Hydraulics :
• To switch on a warning light if engine oil
pressure falls below a safe level
• To switch on brake lights automatically by
detecting a rise in pressure in hydraulic brake
pipes

9
 Overload sensing Switch
• All overload protective devices work by sensing
the force of the load. When the load exceeds a
preset percentage of rated capacity (usually 100
to 125 percent), the overload protective device
temporarily inhibits the hoist so that the crane
can only lower the load.
• There are four types of overload protective
devices:
1) Mechanical devices achieve overload
protection with a mechanical switch, which is
connected to the hoisting mechanism. For
example, when the overload exerts excessive
force on the hoist’s rope anchorage, it causes a
spring within the device to collapse, thus
flipping the switch and disabling the hoist.
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 Overload sensing Switch
2) Electric overload protection devices,
similarly, sense how much current is drawn by
the motor and disengage the hoist when the
current drawn indicates excessive force.
3) Electrical/Mechanical device combine a
strongback with a monitoring sensor that
adjusts voltage based on the amount of
deflection that occurs.
4) Chain hoist overload protective devices act like
a car in neutral. These devices utilize a slip
clutch mechanism when overload is detected,
the slip clutch continues to turn without lifting
the load.

11
 Relays
• Control relays are similar in construction to
contactor. They accept the information from
some sensing device and feed it to control
circuit.
• The sensing devices used in conjunction with
the relays are known as pilot devices.
• Pilot devices sense the variables like current,
voltage, overload, frequency, temperature,
pressure and many other.
• Relays are also used to multiply the contacts
available on the pilot devices like pressure
switches, level switches etc.
• With the help of relays the interlocking wiring is
possible which removes the complexity in the
circuit
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 Output Devices
• Applications of Contactors, Solenoid actuated
valves, pilot lamps.
• Contactors : Contactors are used to control
electric motors, lighting, heating, capacitor
banks, thermal evaporators, and other electrical
loads.
• Solenoid actuated valves : Solenoid valves are
used in pneumatic and hydraulic systems, to
control cylinders, fluid power motors or larger
industrial valves
• Pilot Lamps : Indication

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 Control Circuit Development
Basics & Thumb rule
• All control components like contactors, relays,
push buttons etc. are designated by alphabets.
For example In a forward and reverse operation
of motor there are two contactors. Forward
contactor is designated as F and reverse
contactor is designated as R.
• All contacts of various contactors , relays shown
in the diagram are in de – energized state.
• The various contacts of contactor are designated
by numerals. For example various contacts of a
contactor F will be represented as F1, F2, F3 and
so on.

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 Control Circuit Development
• The control wires are also designated with
numbers in the diagram. These numbers are
marked on wires by inserting ferrules on the
wires.
• The thumb rule is to mark two supply leads of
control transformer as L1 and L2 . Here L1 acts
as phase supply and L2 is generally grounded.
• The control diagrams are classified in to
following 3 types.
o Wiring Diagram
o Elementary line diagram or schematic
diagram
o Wireless connection diagram

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 Control Circuit Development
• In wiring diagram the components are shown
exactly according to their physical relationship
and location in the panel.
• In schematic diagram representation of circuit is
done in proper electrical sequence.
• In wireless connection diagram only location of
components is shown. It is not used frequently.
• All these three types of diagrams are shown in
coming slides.

16
Control Circuit Development

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Control Circuit Development

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Control Circuit Development

19
 Control Supply
Control Transformer

• Control Transformers are specifically used to

provide control supply voltage for the control
circuits of the equipment .
• They are used in AC motor starters, timers,
indicating lamps, electronics protection relays etc.
• These are two winding transformers with both
windings made of copper.
• They are available for single phase and three
phase inputs and are in the range from 15 VA to
30 KVA.
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 Control Transformer
Specifications:
• Input supply- Voltage, Frequency and
Number of Phases i.e. Single or Three
Phases. In case of Three Phase system
Type of connection- Star / Delta / Vector
group.
• Out put supply- voltage and current in of
each secondary winding( if multiple out put
windings are required).
• Class of insulation
• Service conditions if other than standard
service conditions.
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Power and control circuit for Skip Hoist

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Power and control circuit for Skip Hoist

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Power and control circuit for Overhead Crane

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Power and control circuit for Overhead Crane

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Power and control circuit for Overhead Crane

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Power and control circuit for Overhead Crane

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Power and control circuit for Conveyor Belt

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Power and control circuit for Conveyor Belt

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Power and control circuit for Conveyor Belt

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Power and control circuit for Compressor

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 References
• https://www.electricalclassroom.com
• https://www.electricalonline4u.com
• https://circuitdigest.com
• https://automationforum.co
• https://www.instrumentationtoolbox.com
• https://www.konecranes.com
• Control of Electrical Machines by S. K.
Bhattacharya & Brijinder Singh

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 HAPPY LEARNING!
Dr.Mahesh S. Narkhede
Electrical Engineering Department
Government Polytechnic, Mumbai
msnarkhede@ymail.com
https://drmaheshsnarkhede.wordpress.com/ 33