INDUSTRIAL MOTOR

CONTROL
Workshop Practice II (ECEg3133)

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 Motor Control
COMPONENTS
Breakers
fuses
Push buttons
SELECTOR SWITCHES

Contactors
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Relays
Timer
Over-load relay
Wires 2
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SYMBOLS

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 WHAT IS MOTOR CONTROL?
Motor Control

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.

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 TYPES OF CONTROL SYSTEMS
Motor Control

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
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system.
Manual controllers are generally very simple devices that connect the motor
directly 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). 6
 CONTD
Motor Control

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 control the coil
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of the starter. This permits the actual control panel to be

located away from the motor or starter.
The operator must still initiate certain actions, such as Figure 22: Typical push-
starting and stopping, but does not have to go to the button control center.

location of the motor or starter to perform the action.

A typical control panel is shown in Figure 22.
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 CONTD
Motor Control
A schematic diagram of a start-stop push-button
station is shown in Figure 23.

SCHEMATIC DIAGRAM OF A START-

STOP PUSH-BUTTON CONTROL
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A schematic diagram shows 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

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 CONTD
Motor Control

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 cooling system
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found in many homes.

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, excessive
current, no pilot light or ignition in gas heating systems, and so on. 9
 Motor Control RELAYS AND CONTACTORS
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.
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When the coil is energized, the contacts will open or

close.
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 A magnetic relay is basically a
make connection with another. solenoid with movable contacts
attached.
 Motor Control
RELAYS
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
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1 to 10 amperes, depending on the

manufacturer and type of relay.

A magnetic relay is basically a solenoid with

movable contacts attached.
 Motor Control
To change from the open
to the closed condition,
wire connections to the
respective poles are
changed.
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Eight-pole control relay with four

Single-pole, double-throw, normally open and four normally closed
single-break ac control contacts. To change from the open to the
relay with wiring symbols closed condition, wire connections to the
respective poles are changed.
 Motor Control
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 first 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 to operate
power circuits. Typical applications include the control of motor starter and
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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 switching residential and
commercial lighting circuits and individual lighting fixtures.
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 Motor Control
CONTD
Control relays
can be obtained
in a variety of
case styles.
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 Motor Control
RELAYSCONTD
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
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in some cases to the top of the main

body.
 Motor Control CONTACTORS
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
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600 volts.
Although these higher voltage coils are available, most contactors operate
on voltages that generally 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.
 CONTD
Motor Control

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.
Most motor applications require the use of remote control devices to start and stop
the motor.
Contactors enable remote control of relatively high-current circuits where it is too
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expensive to run the power leads to the remote controlling location, figure below
shows remote control contactor.

An advantage of a remote control load 17

 CONTD
Motor Control

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.
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The control circuit is connected to the

coil of an electromagnet, and the power
circuit is connected to the stationary
contacts.

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 Motor Control CONTD
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 field is produced,
magnetizing the electromagnet.
The magnetic field attracts the armature to the
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magnet, which in turn closes the contacts.

With the contacts closed, current flows through
the power circuit from the line to the load.
When current no longer flows through the
power circuit, the electromagnets coil is de-
energized, the magnetic field collapses and
the movable contacts open under spring
pressure. 19
 Motor Control

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 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
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 Motor Control CONTACTORS VS OVERLOAD RELAYS
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.
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Most motor applications require overload

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 provide such protection.

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 PUSH BUTTONS
Motor Control

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.
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Push buttons contain both movable and stationary contacts.

 Motor Control
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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.

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 Motor Control
TIMING RELAYS
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 relay. 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
Timer relays are similar to other control relays in that they use a coil to control the operation open and normally
of some number of contacts. The difference between a control relay and a timer relay is that closed
the contacts of the timer relay delay changing their position when the coil is energized or contacts.
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de-energized.

When power is connected to the coil of 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 Off-delay normally
timer, the contacts will remain in the open position for 10 seconds and then close. When open and normally
voltage is removed and the coil is de-energized, the contact will immediately change back closed
to its normally open position. contacts.
 Motor Control OVERLOAD RELAYS
Overload relays are designed to meet the special protective 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.

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 OVERLOAD RELAY IN A MOTOR CIRCUIT
Motor Control

The following illustration shows a motor circuit with manual starter and an overload relay.
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Current flows 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 identified and corrected, the motor can be restarted.
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 BIMETAL OVERLOAD RELAYS
Motor Control

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.
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Under normal operating conditions, the heat generated by the

heater element will be insufficient to cause the bimetal strip to
bend enough 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.
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 Motor Control ELECTRONIC OVERLOAD RELAYS
Electronic overload relays are another option for motor protection. The
features and benefits 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.
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Heater less design also allows the electronic relay to be insensitive to the
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. 28
 MOTOR STARTER
Motor Control

A motor starter is a contactor

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

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MOTOR STARTING METHODS

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 DOL STARTING
Motor Control

A direct-on line (DOL) start is the

simplest, most common, and least
expensive method of starting squirrel-cage
induction and synchronous motors.
Direct-on line starting offers high-
acceleration torque and reduced
acceleration time.

pushbutton I energizes the coil of contactor Q11. The

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contactor switches on the motor and maintains itself

after the button is enables via its own auxiliary contact
Q11/14-13 and pushbutton 0 (three-wire control
contact). Contactor Q11 is de-energized, in the normal
course of events, by actuation of pushbutton 0. In the
event of an overload, it is de-energized via the normally Power Circuit Control Circuit
closed contact 95-96 on the overload relay F2. The coil
current is interrupted, and contactor Q11 switches the
motor off. 31
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DOL

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 Motor Control
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 Motor Control
WYE-DELTA STARTING
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 period. This is
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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.
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 EXAMPLE
Motor Control

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.

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 Motor Control
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.
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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.
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Star-Delta Starting
CONTD

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Questions

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