INDUSTRIAL MOTOR

CONTROL

1
Control
Motor

COMPONENTS

Push buttons
Contactors
Wires
Pliers
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Timer
Over load relay

2
 WHAT IS MOTOR CONTROL?
Control
Motor

The term motor control can have very broad meanings.

It can mean anything from a simple toggle switch in-tended to turn a
motor on or off (Figure 21) to an extremely complex system
intended to control several motors, with literally hundreds of sensing
devices that govern the operation of the circuit.
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Figure 21: Motor controlled by a simple toggle

switch. 3
Control
Motor

WHY IS MOTOR CONTROL IMPORTANT?

The electrician working in industry should be able to

install different types of motors and the controls
necessary to control and protect them and also to
troubleshoot systems when they fail.
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4
Control
TYPES OF CONTROL SYSTEMS
Motor

Motor control systems can be divided into three major types:

i. manual
ii. semiautomatic, and
iii. automatic.
Manual controls are characterized by the fact that the operator must go to the
location of the controller to initiate any change in the state of the control system.
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Manual controllers are generally very simple devices that connect the motor directly
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to the line. They may or may no provide overload protection or low voltage release.
Manual control may be accomplished by simply connecting a switch in series with a
motor (Figure 21).

5
 CONTD
Control
Motor

Semiautomatic control is characterized by the use

of push buttons, limit switches, pressure switches,
and other sensing devices to control the operation
of a magnetic contactor or starter.
The starter actually connects the motor to the line,
and the push buttons and other pilot devices
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control the coil of the starter. This permits the

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actual control panel to be located away from the

motor or starter. Figure 22: Typical
push-button control
The operator must still initiate certain actions, such center.
as starting and stopping, but does not have to go
to the location of the motor or starter to perform
6
the action.
Control CONTD
Motor

A schematic and wiring diagram of a start-

stop push-button station is shown in Figure
23.

SCHEMATIC DIAGRAM OF A START-

STOP PUSH-BUTTON CONTROL

A schematic diagram shows

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components in their electrical sequence

without regard for physical location.

A wiring diagram is basically a pictorial

representation of the control components
with connecting wires

Although the two circuits shown in Figure

WIRING DIAGRAM OF A
23 look different, electrically they are
START-STOP PUSH-BUTTON
the same. 7
CONTROL
Control
Motor

Automatic control is very similar to semiautomatic control in that pilot

sensing devices are employed to operate a magnetic contactor or starter
that actually controls the motor.
With automatic control, however, an operator does not have to initiate
certain actions.
A good example of an automatic control system is the heating and
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cooling system found in many homes.

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Once the thermostat has been set to the desired temperature, the
heating or cooling system operates without further attention from the
home owner.
The control circuit contains sensing devices that automatically shut the
system down in the event of an unsafe condition such as motor overload,
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Control
FUNCTIONS OF MOTOR CONTROL
Motor

There are some basic functions that motor control systems perform.
The ones listed below are by no means the only ones, but are very
common.
These basic functions will be discussed in greater detail in this text.
It is important not only to understand these basic functions of a
control system, but also to know how control components are
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employed to achieve the desired circuit logic.

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Starting
Stopping
Jogging or Inching
Speed Control
Motor and Circuit Protection
Surge Protection
Safety 9
 STARTING
Control
Motor

Starting the motor is one of the main purposes of a motor control

circuit. There are several methods that can be employed, depending
on the requirements of the circuit.
The simplest method is across-the-line starting. This is accomplished
by connecting the motor directly to the power line.
There may be situations, however, that require the motor to start at
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a low speed and accelerate to full speed over some period of time.
This is often referred to as ramping.
In other situations, it may be necessary to limit the amount of
current or torque during starting.
Some of these methods will be dis-cussed later.
10
 STOPPING
Control
Motor

Another function of the control system is to stop the motor. The

simplest method is to disconnect the motor from the power line and
permit it to coast to a stop.
Some conditions, however, may require that the motor be stopped
more quickly or that a brake hold a load when the motor is stopped.
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Control
JOGGING OR INCHING
Motor

Jogging and inching are methods employed to move a motor with

short jabs of power. This is generally done to move a motor or load
into some desired position.
The difference between jogging and inching is that jogging is
accomplished by momentarily connecting the motor to full line
voltage, and inching is accomplished by momentarily connecting the
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motor to reduced voltage.

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Control
SPEED CONTROL
Motor

Some control systems require variable speed. There are several

ways to accomplish this.
One of the most common ways is with variable frequency control
for alternating current motors, or by controlling the voltage applied
to the armature and elds of a direct current motor.
Another method may involve the use of a direct current clutch.
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13
Control MOTOR AND CIRCUIT PROTECTION
Motor

One of the major functions of most control systems is

to provide protection for both the circuit components
and the motor.
Fuses and circuit breakers are generally employed for
circuit protection, and overload relays are used to
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protect the motor.

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Control SURGE PROTECTION
Motor

Another concern in many control circuits is the voltage

spikes or surges produced by collapsing magnetic elds
when power to the coil of a relay or contactor is turned off.
These collapsing magnetic elds can induce voltage spikes
that are hundreds of volts (Fig-ure 18).
These high voltage surges can damage electronic
components connected to the power line.
Volt-age spikes are of greatest concern in control systems
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that employ computer controlled devices such as

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programmable logic controllers and measuring instruments

used to sense temperature, pressure, and so on.

Figure 1 8 Spike voltages

produced by collapsing
magnetic elds can be
hundreds of volts.

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Control SURGE PROTECTION CONTD
Motor

Coils connected to alternating current often have a metal oxide varistor (MOV)
connected across the coil (Figure 19).

Metal oxide varistors are voltage sensitive resistors. They have the ability to
change their resistance value in accord with the amount of voltage applied to
them.

The MOV will have a voltage rating greater than that of the coil it is connected
across. Figure 1 9 A metal oxide
varistor (MOV) is used to
An MOV connected across a coil intended to operate on 120 volts, for example,
eliminate voltage spikes on
will have a rating of about 140 volts. As long as the voltage applied to the MOV
coils connected to alternating
is below its voltage rating, it will exhibit an extremely high amount of resistance, current.
generally several million ohms. The current ow through the MOV is called
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leakage current and is so small that it does not affect the operation of the circuit.

If the voltage across the coil should become greater than the voltage rating of
the MOV, the resistance of the MOV will suddenly change to a very low value,
generally in the range of 2 or 3 ohms. This effectively short-circuits the coil and
prevents the voltage from be-coming any higher than the voltage rating of the
MOV (Figure 110). Metal oxide varistors change resistance value very quickly,
generally in the range of 3 to 10 nanoseconds. When the circuit voltage drops
below the voltage rating of the MOV, it will return to its high resistance value.Figure 1 10 The metal
oxide varistor limits the
The energy of the voltage spike is dis-sipated as heat by the MOV.
voltage spike to 140
volts. 16
Control RELAYS AND CONTACTORS
Motor

Relays and contactors are electromechanical switches.

They operate on the solenoid principle.
A coil of wire is connected to an electric current. The
magnetic eld developed by the current is concentrated in
an iron pole piece. The electromagnet attracts a metal
armature.
Contacts are connected to the metal armature.
When the coil is energized, the contacts will open or close.
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There are two basic methods of constructing a relay or

contactor. The clapper type uses one movable contact to
make connection with a stationary contact. The bridge
A magnetic relay is basically a
type uses a movable contact to make connection between
solenoid with movable contacts
two stationary contacts. attached.
When the coil is energized, the armature is attracted to the
iron core inside the coil. This causes the movable contact
to break away from one stationary contact and make
Control RELAYS
Motor

Relays are electromechanical switches that

contain auxiliary contacts.
Auxiliary contacts are small and are intended
to be used for control applications.
As a general rule, they are not intended to
control large amounts of current.
Current ratings for most relays can vary from
1 to 10 amperes, depending on the
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manufacturer and type of relay.

A clapper type relay is illustrated in Figure 5
1.
When the coil is energized, the armature is
attracted to the iron core inside the coil. This
A magnetic relay is basically a solenoid
causes the movable contact to break away with movable contacts attached.
from one stationary contact and make
connection with another.
Control
Motor
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Clapper type relay that Single-pole, double-throw, single-

contains one movable break ac control relay with wiring Fig. 5-2A Eight-pole control relay with
contact and two stationary symbols four normally open and four normally
contacts. closed contacts. To change from the open
To change from the open to the closed to the closed condition, wire connections
condition, wire connections to the respective to the respective poles are changed.
Control
Motor

Relays differ in voltage ratings, number of contacts, contact

rearrangement, physical size, and in attachments to provide
accessory functions such as mechanical latching and timing.
In using a relay for a particular application, one of the rst steps
should be to determine the control (coil) voltage at which the relay
will operate.
Relays are used more often to open and close control circuits than
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to operate power circuits. Typical applications include the control of

motor starter and contactor coils, the switching of solenoids, and the
control of other relays.
A relay is a small but vital switching component of many complex
control systems. Low-voltage relay systems are used extensively in
20
switching residential and commercial lighting circuits and individual
Control
Motor

Control relays can be

obtained in a variety of
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case styles.
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Control RELAYSCONTD
Motor

There are at least 3 sets of contacts in the

main body with a wide range of contact
combinations available.
In addition there are auxiliary contact sets
which are clipped to the sides and in some
cases to the top of the main body.
Two numbers are used to mark relay contacts:
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First number identies contact positions 1,2,3, etc.;

Second number identies contact type.
For example:
1 and 2 for NC contacts;
3 and 4 for NO contacts.
 COMPONENTS (ACTIVE)
Control
Motor

Auxiliary contacts: Auxiliary

contacts can be tted to the
top or to the sides of most
contactors.
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Control
Motor

Labelling
Coils are marked alphanumerically, e.g.
A1, A2.
Odd numbers incoming supply terminal.
Even numbers outgoing terminal.
Main contacts are marked with single numbers:
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Odd numbers incoming supply terminal.

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Next even number outgoing terminal.

Auxiliary contacts are marked with two numbers:
First number sequential.
Second number functional.
Control
Motor

Overload relays are marked:

Main circuit as main contacts.
Auxiliary contacts two numbers.
First number normally 9.
Second number functional.
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Control CONTACTORS
Motor

Contactors are very similar to relays in that they are

electromechanical devices.
Contactors can be obtained with coils designed for use on
higher voltages than most relays. Most relay coils are intended
to operate on voltages that range from 5 to 120 volts AC or DC.
Contactors can be obtained with coils that have voltage ranges
from 24 to 600 volts. Although these higher voltage coils are
available, most contactors operate on voltages that generally
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do not exceed 120 volts for safety reasons.

Contactors can be made to operate on different control circuit
voltages by changing the coil.
The principal difference between a contactor and a motor
starter is that the contactor does not contain overload relays.

Control
Motor

Most motor applications require the use of remote

control devices to start and stop the motor.
Magnetic contactors are commonly used to
provide this function. Contactors are also used to
control distribution of power in lighting and heating
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circuits

27
Control CONTD
Motor

Contactors are used in combination with pilot control devices to switch

lighting and heating loads and to control ac motors in those cases
where overload protection is provided separately.
The larger contact or sizes are used to provide remote control of
relatively high-current circuits where it is too expensive to run the
power leads to the remote controlling location, gure below shows
remote control contactor.
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An advantage of a remote control load 28

Control BASIC CONTACTOR OPERATION
Motor

Magnetic contactors operate by

utilizing electromagnetic principles.
A simple electromagnet can be
fashioned by winding a wire around a
soft iron core.
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When a DC voltage is applied to the

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wire, the iron becomes magnetic.

When the DC voltage is removed
from the wire, the iron returns to its
nonmagnetic state
29
Control
Motor

The following illustration shows the

interior of a basic contactor.
There are two circuits involved in
the operation of a contractor: the
control circuit and the power circuit.
The control circuit is connected to
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the coil of an electromagnet, and

the power circuit is connected to the
stationary contacts.

30
Control
Motor

The operation of this electromagnet is

similar to the operation of the
electromagnet we made by wrapping wire
around a soft iron core.
When power is supplied to the coil from the
control circuit, a magnetic eld is produced,
magnetizing the electromagnet.
The magnetic eld attracts the armature to
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the magnet, which in turn closes the

contacts.
With the contacts closed, current ows
through the power circuit from the line to
the load.
When current no longer ows through the
power circuit, the electromagnets coil is de- 31
Control
Motor

The following schematic shows the

electromagnetic coil of a contactor
connected to the control circuit through
a switch (SW1).
The contacts of the contactor are
connected in the power circuit to the AC
line and a three-phase motor.
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When SW1 is closed the electromagnetic

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coil is energized, closing the M

contacts and applying power to the
motor.
Opening SW1 de-energizes the coil,
opening the M contacts and removing
power from the motor
32
Control CONTACTORS VS OVERLOAD RELAYS
Motor

Contactors are used to control power in a

variety of applications.
When used in motor-control applications,
contactors can only start and stop motors.
Contactors cannot sense when the motor is
being loaded beyond its rated conditions, and
provide no overload protection.
Most motor applications require overload
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protection, although some smaller-rated

motors (such as household garbage disposals)
have overload protection built into the motor.
Where overload protection is required,
overload relays (discussed previously, similar
to the one shown below) provide such
protection. 33
Control PUSH BUTTONS
Motor

Push buttons can be shown as normally open or normally closed

Most are momentary contact devices in that they make or break
connection only as long as pressure is applied to them.
The pressure is generally supplied by someones nger pressing on
the button.
When the pressure is removed, the button returns to its normal
position.
Push buttons contain both movable and stationary contacts.
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Control
Motor
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Figure: Combination push button: (A) Red pilot light is lit

through normally closed push-button contact (B) Green pilot
light is lit when the momentary contact button is pushed.

35
Control TIMING RELAYS
Motor

A timing relay is similar to a control relay, except that certain of its contacts are
designed to operate at a preset time interval, or time lag, after the coil is
energized, or de-energized.

Time delay relays can be divided into two general classications: the on-delay
relay, and the off-delay re-lay. The on-delay relay is often referred to as DOE,
which stands for Delay On Energize. The off-delay relay is often referred to as
DODE, which stands for Delay On De-Energize. On-delay normally
open and normally
Timer relays are similar to other control relays in that they use a coil to control the closed
operation of some number of contacts. The difference between a control relay and contacts.
a timer relay is that the contacts of the timer relay delay changing their position
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when the coil is energized or de-energized. When power is connected to the coil of
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an on-delay timer, the contacts delay changing position for some period of time.
For this example, assume that the timer has been set for a delay of 10 seconds.
Also assume that the contact is normally open. When voltage is connected to the
coil of the on-delay timer, the contacts will remain in the open position for 10 Off-delay
seconds and then close. When voltage is removed and the coil is de-energized, normally open
the contact will immediately change back to its normally open position. and normally
closed
Many industrial control applications require timing relays that can provide contacts.
dependable service and are easily adjustable over the timing ranges.
Control CONTD
Motor

The proper selection of timing relays for a particular application can be made after
a study of the service requirements and with knowledge of the operating
characteristics inherent in each available device.
A number of timing devices are manufactured with features suitable for a wide
variety of applications.
Reversal Phase Failure Relays and
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Overload Relays

37
 OVERLOAD RELAYS
Overload relays are designed to meet the special protective
Control
Motor

needs of motor control circuits.

Overload relays:
allow harmless temporary overloads (such as motor Starting)
without disrupting the circuit.
will trip and open a circuit if current is high enough to Cause motor
damage over a period of time
can be reset once the overload is removed
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These have three pin

connectors which engage
into the contactors screw
clamps.
The overload unit has a
changeover contact unit in
addition to the three
protected connections.
38
 TRIP CLASS
Control
Motor

Overload relays are rated by a trip class

which denes the length of time it will take
for the relay to trip in an overload
condition.
The most common trip classes are Class
10, Class 20, and Class 30.
A Class 10 overload relay, for example, has
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to trip the motor off line in 10 seconds or

less at 600% of the full load amps (which
is usually sufficient time for the motor to
reach full speed).
Many industrial loads, particularly high
inertia loads, require Class 30.
Siemens offers overload relays in all three 39
 CONNECTING ELEVEN-
Control
Motor

PIN TIMERS
The manufacturers
instructions should
always be consulted
before trying to connect
one of these timers.
Eleven-pin tube sockets.
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Pin connection diagram for Dayton timer.

Pin connection diagram fo

Allen-Bradley timer.

Dayton electronic timer

Allen-Bradley electronic timer. 40
Control
Motor

According to the pin chart shown in Figure 7 20,

pins 2 and 10 connect to the coil of the timer.
To use this timer in the off-delay mode, power must
be connected to pins 2 and 10 at all times.
Shorting pins 5 and 6 together causes the timed
contacts to change position immediately.
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When the short circuit between pins 5 and 6 is

removed, the time sequence begins. At the end of
the preset time period, the contacts will return to
their normal position.

41
Control
Motor

All electronic timers are similar, but

there are generally differences in how
they are to be connected.
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The connection diagram for the timer

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shown in Figure 7 17B is shown in

Figure 7 23.

42
Control OVERLOAD RELAY IN A MOTOR CIRCUIT
Motor

The following illustration shows a motor circuit with manual starter and an overload relay.
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Current ows through the overload relay while the motor is running.
Excess current will cause the overload relay to trip at a predetermined level, opening
the circuit between the power source and the motor.
After a predetermined amount of time, the overload relay can be reset. When the
cause of the overload has been identied and corrected, the motor can be restarted.
43
Control BIMETAL OVERLOAD RELAYS
Motor

Overload protection can be accomplished with the use of a bimetal

overload relay.
This component consists of a small heater element wired in series
with the motor and a bimetal strip that can be used as a trip lever.
The bimetal strip is made of two dissimilar metals bonded together.
The two metals have different thermal expansion characteristics, so
the bimetal strip bends at a given rate when heated.
Under normal operating conditions, the heat generated by the heater
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element will be insufficient to cause the bimetal strip to bend enough

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to trip the overload relay.

As current rises, heat also rises. The hotter the bimetal strip becomes,
the more it bends. In an overload condition, the heat generated from
the heater will cause the bimetal strip to bend until the mechanism is
tripped, stopping the motor.

44
Control
Motor

Some overload relays equipped with a bimetal strip are designed

to reset the circuit automatically when the bimetal strip has cooled
and reshaped itself, restarting the motor.
If the cause of the overload still exists, the relay will trip again and
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reset at given intervals.

Care must be exercised in the selection of this type of overload
relay, since repeated cycling will eventually damage the motor.

45
Control ELECTRONIC OVERLOAD RELAYS
Motor

Electronic overload relays are another option for motor protection. The
features and benets of electronic overload relays vary, but there are a
few common traits.
One advantage offered by electronic overload relays is a heater less
design, reducing installation cost and the need to stock a variety of
heaters to match motor ratings.
Heater less design also allows the electronic relay to be insensitive to the
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ambient temperature, minimizing nuisance tripping.

Electronic relays also offer phase loss protection. If a power phase is lost,
motor windings can burn out very quickly.
Electronic overload relays can detect a phase loss and disconnect the
motor from the power source. Phase loss protection is not available on
mechanical types of overload relays. 46
Control MOTOR STARTER
Motor

A motor starter is a contactor

combined with an overload
relay.
The principal difference
between a contactor and a
motor starter is that the
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contactor does not contain

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overload relays.

47
Control MOTOR STARTER IN A CONTROL CIRCUIT
Motor

The following diagram shows the electrical

relationship of Control Circuit the contactor and
overload relay.
The contactor (highlighted with the darker grey)
includes the electromagnetic coil, the main motor
contacts, and the auxiliary contacts.
The overload relay, highlighted by the lighter grey,
includes the OL heaters and overload contacts.
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The contactor and the overload relay have

additional contacts (known as auxiliary contacts)
for use in the control circuit.
In this circuit, a normally closed OL contact has
been placed in series with the M contactor coil
and L2. A normally open M auxiliary contact
(Ma) has been placed in parallel with the Start 48
Control
MOTOR CONTROL CENTERS
Motor

Motor starters are often

grouped with other
devices such as circuit
breakers, fuses,
disconnects, and control
transformers.
This set of equipment is
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referred to as a
combination starter.
These components are
A combination starter with fused disconnect,
often contained inside control transformer, push buttons, and motor
one enclosure (Figure 5 starter.
46). 49
Control
CONTD
Motor

Motor control centers employ the

use of combination starters
mounted in special enclosures
designed to plug into central buss
bars that supply power for several
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motors.
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Motor control center

50
 Prepared by Motor
G/Tsadik T. Control

THE MOTOR AND

STARTING METHODS

51
Control WYE-DELTA STARTING
Motor

Wye-delta starting is often used with large horsepower

motors to reduce in-rush current during the starting period
and to reduce starting torque.
Wye-delta starting is accomplished by connecting the
motor stator windings in wye or star during the starting
period and then re-connecting them in delta during the run
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period. This is sometimes called soft starting.

If the stator windings of a motor are connected in delta
during the starting period, the starting current will be three
times the value if the windings were connected in wye.
52
Control EXAMPLE
Motor

Assume that a motor is to be connected to a 480 volt

three-phase power line.
Also assume that the motor windings have an impedance
of 0.5 ohms when the motor is rst started.
If the stator windings are connected in delta (Figure 39
1), the voltage across each phase winding will be 480 volts
because line voltage and phase volt-age are the same in a
delta connection.
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The amount of current ow in each phase winding (stator

winding) can be determined with Ohms Law.
In a delta connection, the line
current is greater than the
phase current by a value of
the square root of 3 or 1.732.

53
Control
Motor

If the stator windings are connected in wye (Figure 39

2), the voltage across each phase winding will be 277
volts, because in a wye connected load, the phase
voltage is less than the line voltage by a factor of the
square root of 3 or 1.732.

The
a
be moun
det
erm t of in
ine -r
d u ush cu
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sing rr
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Ohm ent ca
s L n
aw

In a wye connected load, the line current and phase cur-rent

are the same.
Therefore, the starting current has been reduced from
1662.72 amperes to 554 amperes by connecting the stator
windings in wye instead of delta during the starting period.
54
Control
WYE-DELTA STARTING REQUIREMENTS
Motor

There are two requirements that must be met before wye-delta

starting can be used
.
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1. The motor must be designed

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2. All stator windings leads

for the stator windings to be must be accessible.
connected in delta during the
run period.

55
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57
ELECTRIC MOTOR CONTROL CIRCUITS

Magnetic Starter Connected in WYE DELTA

connection
Star(Y)-connection

By short-circuiting the terminals W2, U2 and V2

and connecting the mains to the W1, U1 and V1
you get a star(Y)-connection.

Current: Iphase = Imains

Voltage: Uphase = Umains / 3

Delta()-connection
When connecting the end of a phase to the start of
another phase you get a delta()-connection

Current: Iphase = Imains / 3

Voltage: Uphase = Umains

61