Motor Control

Fundamentals
by:
Celestino A. Cole, Jr.

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OBJECTIVE
At the end of the presentation we will know the following:

1. Power circuit and control circuit

2. Ladder diagram and logic equivalent
3. Control components and motor control
protection
4. Advance applications.

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I. CONTROL
CIRCUIT AND
POWER CIRCUIT
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POWER CIRCUIT AND CONTROL CIRCUIT

POWER CIRCUIT- is a circuit used to supply

electric energy to the motor.

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POWER CIRCUIT AND CONTROL CIRCUIT

CONTROL CIRCUIT- is a circuit used to supply

control components in the motor control
circuit.

CONTROL
CIRCUIT

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POWER CIRCUIT AND CONTROL CIRCUIT

POWE
R
CIRCUI
T

COMPLETE
MOTOR
CONTROL
CIRCUIT

POWER CIRCUIT + CONTROL CIRCUIT= COMPLETE MOTOR

CONTROL CIRCUIT
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II. LADDER
DIAGRAM AND
LOGIC
EQUIVALENTS
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LADDER DIAGRAM

LADDER DIAGRAM- is a specialized schematics

used to document industrial logic system.
They are called "ladder"
diagrams because they
resemble a ladder, with
two vertical rails (supply
power) and as many
"rungs" (horizontal lines)
as there are control
circuits to represent.

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LADDER DIAGRAM

Advantages:
1. Capable of simplifying complicated motor
control circuits compare to schematic
diagrams.

VS.

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LADDER DIAGRAM

Advantages:
2. Easy to trace faults.

System start/stop

Float control

motor starter

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LADDER DIAGRAM
Advantages:
3. Easy to translate with logical circuits for advance
applications such as in PLC, process control automation,
embedded intelligent systems and SCADA.
PB1

PL = PB1* PB2

PL = PB1 +
PB2

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PB2

PB1
PB2

PL

PL

11

LADDER DIAGRAM

HOW TO CREATE A LADDER DIAGRAM

+24VDC

0V

VERTICAL
RAILS
COMPONENT
S

RUNG

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RULES IN LADDER DIAGRAM

Input

Output

Auxiliary
contact
Input determines the initial state of the system.
Output functions either ON/OFF depending on the logic of the
input combination.
Auxiliary contact is dependent to the state of the device that
they are into. It changes its initial state from close to open or
vice versa once the device is activated

RUN SIMULATION
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III. MOTOR
CONTROL
COMPONENTS
AND
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MOTOR CONTROL COMPONENTS

SWITCH
Switch is an electrical device that can break and connect an
electrical circuit, as well as interrupting the flow of current or
divert it from one conductor to the other.
Types
of
switches
typically used in motor
control applications:
1.
2.
3.
4.
5.

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Pushbutton switch
Limit switch
Selector switch
Footswitch
Toggle switch

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15

MOTOR CONTROL COMPONENTS

MAGNETIC CONTACTOR
main contacts

A magnetic contactor is an
electrically
controlled
switch used for switching a
power circuit. It has main
contacts used for power
circuit and auxiliary contact
used for control circuit.
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Supply
terminals

Auxiliary
contact(s)

16

MAGNETIC CONTACTOR

Control circuit

RUN
RUN SIMULATION
SIMULATION

Power circuit

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CONTROL RELAY
A relay is an
electrically operated
switch. The principle
of operation is
similar to that of the
contactor but differs
in application.
While contactor is
used to control
motors. Control relay
on the other hand is
used to control the
operation of other
control components
particularly the
magnetic contactor.
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CONTROL RELAY
B

In PLC application the

voltage that activates
V1 and V2 is coming
from the PLC. The
circuit is transitioned
When terminals V1 and V2
from PLC to magnetic
contactor via control
are energized the initial
relays for safety
state of each contacts will
purposes. Although
possible, it is not
change accordingly. From
technically practical
close to open and vice
to wire directly
versa.
magnetic contactor
to PLC since a large
feedback AC current
from the contactor
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circuit may harm the

Magnetic
contactor

19

TIMER
Relay timer contains an auxiliary
contacts NO and NC that can be
integrated into motor control
circuits. The initial state of its
contact will change when
activated after pre-determined
value.
The timer unit can be set into
seconds or minutes depending
on the application requirements.
For longer and iterative tasks,
real RUN
time SIMULATION
timers are available.

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THERMAL OVERLOAD
RELAY
Line
terminals

Thermal overload relay

is
an
electrical
component used in
motor
control
applications which
provide protection for
motor
against
excessive current.

reset
Set value dial

Auxiliary contact(s)
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THERMAL OVERLOAD
RELAY
Principles of operation:

This component has a

bimetal strip that 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.
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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.

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THERMAL OVERLOAD
RELAY

Typical set-up of contactor and overload relay

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THERMAL OVERLOAD
RELAY

Characteristics:
1. Allow harmless temporary overloads
(such as motor starting) without disrupting
the circuit.
2. Trip and open a circuit if current is high
enough to cause motor damage over a
period of time.
3. Can be reset once the overload is
removed.
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ELECTRONIC OVERCURRENT RELAY (EOCR)

Electronic overcurrent
relay
is
used
to
protect
the
motor
against
Unlike overload.
thermal
overload relay this
component
uses
current to trigger once
there is overload.

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Typical installation diagram for EOCR

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25

OVER/ UNDER VOLTAGE RELAY

This component
protects the motor
against over voltage
and under voltage
situation.

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Typical installation diagram

for over/under voltage
protection

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OVER/ UNDER VOLTAGE RELAY

OPERATION
Motor contactor
1
1

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1
1

1
4

2
1

2
4

1
2

2
1

2
2

Over-voltage
alarm
Under-voltage
alarm

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PHASE LOSS/ PHASE SEQUENCE

RELAY

Phase control relays

monitor:
Phase sequence
Loss of one or more
phases
Unbalance level
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In 3-phase system, phase

loss
Is the event when one or
two
phases
is/are
disconnected in the main
supply. Phase sequence on
the other hand is when
two of the phases are
interchanged resulting to
a reverse rotation of a 3phase motor.

Phase loss is mandatory

protection to every motor
operation.
Phase
sequence is for selective
purposes only such as
pumps that reversing the
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motor direction may cause

28

PHASE LOSS/ PHASE SEQUENCE

WIRING DIAGRAM
Motor contactor

PL/PS NC contacts

PHASE
PROTECT
ION
RELAY

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TRANSMITTER, TRANSDUCER AND SENSOR IN MOTOR CONTROL

Transmitter, transducer and sensor sometimes used
interchangeably in industrial applications. It may simply called
sensor, detector or switch. This devices can be integrated in
motor control systems to facilitate the function of the motor in
industrial processes.
any
Depending upon the nature of requirements and device
specification these components can be installed individually,
composite or can be installed with the aid of the other.
Commonly integrated in motor control applications are:
1.
2.
3.
4.
5.
6.

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Temperature controller
Pressure transmitter
Humidity sensor
Gas leak detector
Proximity switch
Light sensor

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WORKING WITH TRANSMITTERS

IN MOTOR CONTROL
Example of composite system where two separate devices are
integrated together to perform the desired function.

Example: The specs indicate that the controller needs PT100 type
thermocouple to operate

Example of stand-alone unit.

Example: A photo sensor that is commonly used in

street lightings that can also be used in motor control
applications can be installed stand alone.

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TRANSMITTERS AND SENSORS

IN MOTOR CONTROL
Input in its raw form
such as:
Temperature
Pressure
Light
Color
Moisture
These inputs are
detected by the
sensor and to be
carried out as
electrical signals:
-

Temperature sensor
Pressure transmitter
Gas leak detector
Smoke sensor

INPU
T
INPU
T
INPU
T

The controller
will
process the
detected signal
and
transformed it
into an output
in the form of
discrete or
analogue.

OUTPU
T

Discrete output
such as NO and
NC contacts

OUTPU
T

Analogue
output such as
4-20 mA and 010 volts

Theoretical background

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TRANSMITTER AND SENSORS IN

MOTOR CONTROL APPLICATIONS

w/ analog
output
PLATINUM
RESISTANCE
THERMOMETERS FOR
REMOTE SENSING

w/ auxiliary
contacts

TEMPERATURE CONTROLLER WITH

ANALOG AND DIGITAL OUTPUT
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TRANSMITTER AND SENSORS IN

MOTOR CONTROL APPLICATIONS
In motor control discrete output are characterized by normally
close and normally open contacts. This contact output are to
be integrated to control circuits.

15

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34

TRANSMITTER AND SENSORS IN

MOTOR CONTROL APPLICATIONS
In industrial control systems analog signals are commonly
characterized by 4-20 mA or 0-10 volts. This is used when the
application does not require fully activated or deactivated systems.
This output signal is then integrated into other devices that directly
controls the motor such as Variable Frequency Drive.

<--- 4-20 mA or 0-10 volts

feedback signal

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IV. SOLID
STATE MOTOR
CONTROL AND
PLC
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Motor Control Using

Solid State Relays
Solid state relay- Asolid state relay (SSR)is
an electronic switching device in which a small
control signal controls a larger load current or
voltage.
Small electronic
signal input

48 VAC

supply

Control relay
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PRINCIPLE OF SOLID STATE RELAY

(optocoupler)

Light from the source can change the initial state of a

phototransistor

The same with optocouplers when a small voltage signal is present it

would activate the LED and change the state of phototransistor in the
dual-in-line package
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PRINCIPLE OF SOLID STATE RELAY

(Silicon Controlled Rectifiers)
AC supply

In the normal "off" state, the

device restricts current to the
leakage
When current.
the
gate-to-cathode
voltage exceeds a certain
threshold, the device turns "on"
and conducts
current.
The
device will
remain in the
"on" state even after gate
current is removed so long as
current through the device
remains above the holding
current. Once current falls below
the holding current for an
appropriate period of time, the
device will switch "off". If the
gate is pulsed and the current
through the device is below the
holding current, the device will
remain in the "off" state.

THIS CAN BE FOUND

INSIDE THE PLC UNIT
Control relay
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PROGRAMMABE LOGIC CONTROLLERS

(PLC)
A PLC can receive
supervisory
information, such as
production
changes
or
scheduling
information, from a
host
computer.
A
standard I/O system
includes a variety of
digital, analog, and
special
interface
modules, which allow
sophisticated control
without the use of
expensive,
customized interface
electronics.
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SOLID STATE MOTOR CONTROL PROCESS FLOW

The motor will

operate based
on the above
operations.

The action of the

relay will control the
operation of the
magnetic contactor.

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*SOFTWA
RE
*FIRMWA
RE
*PROGRA
M

The program
is downloaded
to PLC or
microcontrolle
r

MICROMICROCONTROLLER
CONTROLLER
,, PLC,
PLC,

ELECTRIC
ELECTRIC
MOTOR
MOTOR

MAGNETIC
MAGNETIC
CONTACTOR
CONTACTOR

CONTROL
CONTROL
RELAY
RELAY

cole.celestino/motor control fundamentals

The PLC or
microcontrolle
r will process
the
instructions
received.

For every logic true

a small voltage
signal is received by
the control relay from
the PLC. That signal
will then control its
action.

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APPLICATION OF SOLID STATE

MOTOR CONTROL
Problem:
From the headquarter to the
pumping station the management
wanted to have override control on
the operation of their pump motor.
The headquarter is 20 km away from
the pumping station. Using copper
wires is technically impractical and
using fiber optics is financially
unfeasible.

FEEDBA
CK
SIGNALS

SENSOR
DETECTION

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CONTROLLER,
TRANSDUCER
AND
TRANSMITTER

42

THANK YOU
VERY MUCH!
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THANK YOU
VERY MUCH!
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