Lesson 1

MOTOR CONTROL

 A portion of the electrical wiring system which starts, stops, jogs, reverses,
brakes, and regulates speed of the motor.
 A motor controller is also designed to limit the starting current and control the
starting torque of the motor.
 A motor control system also provides protection for the motor against
overload and over current.

Motor Controllers
1. Manual Controller - All the basic operations, such as closing of switches
and the movement of rheostat handles, are performed by hand.
2. Magnetic Controller - basic functions of closing of switches or the
movement of rheostat handles are performed by magnetic contactors.
a. Full Magnetic - automatically performs all it operation in the proper
sequence after the closure of a master switch, example float switch,
pressure switch, and time switch are frequently automatically operated.
b. Semi- Magnetic – Operates with a combination of manual and
magnetic performance. Some of the basic operations are performed by
hand and the rest by means of magnetic contactors.

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Lesson 2
SINGLE LINE DRAWING OF TYPICAL
MOTOR INSTALLATION

Supply
Feeder connecting means

Feeder over current

Splitter
Motor branch circuit
Over current protection

Motor branch circuit conductor

Feeder connecting means

Motor starter connecting means

Remote Control

Motor starter:
 Motor overload protection
 Under-voltage protection
 Magnetic contactor

Motor disconnecting means

Motor overheating protection

Secondary controller
(wound rotor)
Secondary controller

Secondary resistor leads

Secondary resistors

2
MOTOR CONTROL PARTS

Feeder over current protection

– A fuse or circuit breaker that protects the conductor.
Splitter
– A conductor used in connecting several motor branch circuits.
Motor branch circuit disconnecting means
– Is a device which maybe operated that will isolate the electrical
equipment. The disconnecting means must be installed so that there will be no
hazard to the trade person.
Motor branch circuit over current protection
– It is installed in the circuit to protect the conductor and may exist in the
form of fuses and circuit breaker. These are sized and selected based on the full
load amperes (FLA) of the motor.
Remote control
– It controls the motor; these are composed of motor starter such as single
pole switch, push buttons this is installed near or away from the motor.
Motor starter
– A control box where the motor overload protection, under voltage
protection, and magnetic contactor are located.
Motor disconnecting means
– A device which maybe operated that will isolate the motor this must be
installed so that there will be no hazard to the trade person, this might be
supplemented by a switch or fuse.
Motor overheating protection
– An overload protection is installed in the circuit to protect the motor in
the form of overload relays, heaters or elements.
Secondary controller
– Use only for controlling wound rotor type motor.

3
Lesson 3
AC CONTACTORS AND RELAYS

Alternating-current power contactors and control relays differ in some

respects from dc contactors and relays in construction and operation.
Alternating-current contactors are noisier than dc contactors. To reduce
noise and produce smoother operation, shading bands are used on ac contactors
cores.
The coil of a contactor, containing fewer turns than the dc contactor for the
same voltage, defends on inductive reactance in addition to resistance to limit
current flow in the coil. If an ac contactor fails to close completely, an air gap will
exist in the magnetic circuit. This air gap will reduce the ability of the coil to
generate sufficient emf to protect itself. Overheating of complete burnout of the
coil will result.
The operating parts of an ac contactor must be kept clean and free to
operate properly to avoid burnouts. The faces of the magnetic core at the

openings should be kept slightly moistened with rust preventive to inhibit the

accumulation of rust and dirt which can cause air gaps. A high-grade very light
machine oil and dry graphite are the only lubricants permissible for lubrication of
controls to avoid gumming and sticking of contactors.
When and ac control circuit is run along distance for example, several
hundred feet or more, the conductors add a significant amount of capacitance to
the circuit. This may make it difficult to stop a motor quickly since the capacitance
will permit current flow for a period of time. The effect of this resistor is to
dissipate energy in the conductor capacitance, thus stopping the flow of current.
The proper value of resistance is usually found through trial and error. A
10,000 ohms resistor may be tried to see the effect when the stop button is
pressed. Additional resistance can be added in steps of 1000 ohms until pressing
the stop button brings the motor to proper stop.

4
Thermal relays serve the same purpose in ac control circuits as they do in
dc control circuits. The same two types of operating devices, bimetal and melting
alloy are used in both ac and dc thermal relays.
AC CONTACTORS

RELAY

5
CONTACTOR OR MAGNETIC CONTACTOR

Contactors are used to make and break the electrical power-circuit to such
loads as lights heaters, transformers, motor and capacitor. This lesson explains
the operations and selection of contactors used in the motor control system. It
include a discussion of both ac and dc contactors and familiarized the trainee
with the most common causes of failure. The similarities and difference between
NEMA and IEC component specifications are discussed in detail.

Objectives
• Select a proper NEMA starter fore a motor application.

• Explain how a motor starter function and identified the components

• Identify and use IEC-rated conductors

• Inspect and determine need for contact repair and replacement.

Magnetic Contactor is an electrically operated switch rated in amperes.

Horse-power ratings are also available for most conductors. The Magnetic
contactors in smaller sizes are referred to as relays.

CONTACTOR OR MAGNETIC CONTACTOR

-Is the central component of motor control system?
-Is an electrically operated switch rated in amperes, horse power ratings
and it is in smaller sizes are referred to as relays.

6
Construction of
Magnetic Contactor

3 BASIC
PARTS
1. Stationary contacts- is wired directly to the power source while the other
side is directly to the motor
2. Movable contacts -are mounted on a spring-loaded armature assembly.
3. Electromagnet- is energized by a coil, powered through a separate
circuit, the control circuit.

Types of electromagnetic contactor

1. Clappers type
2. Vertical Action type
3. Horizontal Action type
4. Bell Crank type

1. Clapper type
- A magnet frames use a pivot type control.

7
2. Vertical Action type
- Pull the contacts up into position.

8
3. Horizontal Action type
- Pull the contacts across into position.

MOVABLE
CONTACT

ARMATURE
MAGNET
S
STATIONARY CONTACTS

HORIZONTAL ACTION TYPE

4. Bell Crank type

- Contactors pull the starter maybe opened or closed frequently.

9
COIL / SHADING COIL (RING)

Shading coil is a single turn of conducting materials mounted on the face of the
magnet assembly
Current in coils
-When contactor coils are first energized, the initial current they draw- the
inrush current-is high. Normally, it is 6-8 times as high as seal-in current-the
required to hold the armature in place. If inrush current is not reduced to seal-in
levels, the coil may over heat and burn out.
1. AC COILS
-Is automatically reduced by use of contactors in inrush current.
2. DC COILS
-Is not automatically reduced by use of contactors in inrush current.

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Voltage in coil
-The coils of contactors are resigned to operate within a voltage range
from 85%-110% of their rated voltage (80%-110% for DC coils)

Contacts
-Long, reliable operation of a contactor can also be assured by making
certain its contacts are properly sized and properly maintained when necessary

Contacts
• CONTACT WEAR
• REPLACEMENT OF CONTACTS
• MAINTENANCE OF CONTACTS / CONTACT CHATTER

1. Contact wear was 4 Factors that contributes to excessive wear include:

1. Excessive jogging
2. High voltage to the coil
3. Low voltage to the coil
4. Severely worn contacts

2. Replacement of contacts
-Replacement of contacts is of ten part of routine maintenance to insure
proper seating and longer life.

3. Maintenance of contacts
-When maintaining starters and contactors, be sure to remove control
voltage and main power voltage.

Something to check:
• The armature is free to move.
• Ensure that all contacts are aligned and move with the armature assembly
movement.

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• Check the poles faces for wear and misalignment and be sure they are all
clean.
• Make sure that the shading rings are in place and that they have not
become an open circuit.
• Check for signs of over heating of the coil.

Operation:
The alternating main magnetic flux induces current in the shading coil and
the currents set up auxiliary flux, which is out of phase from the main flux.
The auxiliary flux produces a magnetic pull, out of phase from the pull due
to the main flux and this keeps the armature sealed in when the main flux falls to

zero. With out the shading coil the armature would tend to open each time the

main flux goes through zero. Excessive noise, wear on the magnetic faces, and
heat would result.

Lesson 4
TYPE OF OVERLOAD DEVICE

1. Metal Alloy Overload Device

Metal alloy overload relay, heater, or elements may be divided into two
groups.
Group 1 –The first group is one which the overload heater and the metal
alloy (solder pot) are combined in one factory assemble unit.

Group 2 –The second group is one in which the overload heater of

element is manufacture separately from the metal alloy (solder pot) and

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ratchet wheel. The solder pot is factory installed in the motor starters and
the overload heater is field-installed.

Operation of the Metal Alloy Device

When a motor is loaded beyond the current rating of the overload deice,

the heater element becomes hot. Heat is transferred to the metal alloy (solder

pot), causing the alloy to melt, allowing the ratchet wheel to rotate.

In a magnetic motor starter, when the ratchet wheel turn, on overload

contact in the control circuit opens, opening the circuit for the electromagnet,
stopping the motor.
2. Bimetal Overload Device
Bimetal overload protection consists of an overload heater place in the
motor starter adjacent to a bimetal strip.

Operation of the Bimetal Device

The bimetal strip is composed of two dissimilar metals fused together and

secured at one end. When the over load heater becomes hot, due to an

overload condition, the heat is transferred to the bimetal strip. The metals expand

13
at a different rate, causing the strip to bend in a predetermined direction,
mechanically stripping the manual motor starter.

3
Sketch Showing Principle of
operation of a thermal
overload relay with bimetal
4 strips.
2

1 = Bimetal Strip
2 = Compensating bimetal
Strip
3 = Slide
1
4 = Contacts

Part of Bimetal
Overload Device

Lesson 5
RELAYS

Terminology
1. Rated Load- Defined the performance of the Relay, usually expressed in
switching voltage and switching current.
2. Coil Voltage – Reference voltage applied to coil under normal operating
conditions.

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3. Maximum Switching Voltage/ Current – Maximum voltage/ current that
can be applied before relay breaks down
4. Cary Current – Current that can be applied continuously to relay without
opening or closing.

The heart of the controller is the relay, which is an electrically operated

switch. Relay finds extensive use in practically all type of electric and electronic
equipment.
A relay is an electrical switch that opens and closes under control of
another electrical circuit. In the original form, the switch is operated by an
electromagnet to open or close one or many sets of contacts. It was invented by
Joseph Henry in 1835. Because a relay is able to control an output circuit of
higher power than the input circuit, it can be considered, in a broad sense, to be
a form of electrical amplifier.

What is Relay?
1. An electrical “switch” that opens and closes under control of another
electrical circuit.
2. Base on the operating principle of, electromagnetic induction to open or
close one or many sets of contacts.
3. Unlike electric switch, because a relay is able to control an output circuit, it
can be considered, in a broad sense, to be a form of an electrical
amplifier.
How does a Relay Works?
1. Can you recalled what you have learned about electromagnet” in your
science lesson?
2. By coilingWhen
copperI’m charged
wire around a piece of iron core and changing it the iron
with current, I’ll attract
core becomes magnetic.
the iron piece
3. This principle of “electromagnet” is being adopted for the relay

15
4. When current flows to the coil in the Relay, the iron piece will be attracted
and the contact will be switched as a result.

Structure of Relay

Theory of Operation

The diagram below illustrates a very simple magnetic relay whose

essential parts are an electromagnet and a movable arm called an “armature”.
When current flows through the coil of the magnet, a magnetic field is set up
which attracts the iron arm of the armature and relay from close, completing a

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Circuit across terminal A and B. When the magnet is deenergized, the return
spring returns the armature to the open position and the contact open, breaking
the circuit across terminals AQ and B. The diagram shows only one set of
Contacts. However, there can be any number of sets of contacts. However, there
can be any number of sets of contacts. However, there can be any number of
sets of contacts, depending upon the requirements of the circuit.

When a current flows through the coil, the resulting magnetic field attracts
an armature that is mechanically linked to a moving contact. The movement
either makes or breaks a connection with a fixed contact. When the current to the
coil is switched off, the armature is returned by a force that is half as strong as
the magnetic force to its relaxed position. Usually this is a spring, but gravity is
also used commonly in industrial motor starters. Relays are manufactured to
operate quickly. In a low voltage application, this is to reduce noise. In a high
voltage or high current application, this is to reduce arcing.

If the coil is energized with DC, a diode is frequently installed across the
coil, to dissipate the energy from the collapsing magnetic field at deactivation,
which would otherwise generate a spike of voltage and might cause damage to
circuit components. If the coil is designed to be energized with AC, a small
copper ring can be crimped to the end of the solenoid. This "shading ring"
creates a small out-of-phase current, which increases the minimum pull on the
armature during the AC cycle.

How does the Relay Contact look like?

 In general, silver or silver alloys are used
 Some contacts are plate or clad with gold to protect surface and improve
reliability of electrical contact.

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What are the contact materials compositions?
 PGS (Platinum, Gold, Silver) alloy
 AgPd (Silver Platinum)
 Ag (Silver)
 AgCdO (silver, Cadmium Oxide)
 AgNi (Silver, Nickel)
 glnSn (silver, Indium, Tin)

PGS AgPd Ag AgCdO AgNi AglnSn

 Small load handling capabilities  Large load handling capabilities

 High corrosion resistance  Low Corrosion resistance
 High conductivity  Low conductivity

Types of relay
1) Small Relay

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2) Solid State Relay

4) Top, middle: reed switches,

bottom: reed relay
3) DPDT AC Coil Relay

19
What is inside a Relay?

1. Generates electromagnetic force when input voltage is applied to coil.

2. Induce EMF move the armature that switches the contacts in
synchronization.
3. Arcing is produced as a result of mechanical movement of armature.
4. Arc barrier to reduce the arc spark generated.
5. Crucial for explosive gases.

Part of Relay
Terminology

1. Relay Configuration
 SPDT – Single Pole Single Throw. 2 terminals which can be
switched on/off. In total, 4 terminals when the coil is also
included.
 SPDT – Single Pole Double Throw. 1 row of 3 terminals, One
terminal (common) switch between the other two poles. It is
the same as a single change-over switch. In total, 5 terminals
when the coil is also included.
 DPST – Double Pole Single Throw. 2 pair of terminals.
Equivalent to 2 SPST switches or relays actuated by a single
coil. In total, 6 terminals when the coil is also included.
 DPDT – Double Pole Double Throw. 2 rows of change-over
terminals Equivlent to 2 SPDT switches or relays actuated by
a single coil. In total, 8 terminals when the coil is also
included.
 QPDT –Quadruple Pole Double Throw. 4 row of change-over
terminals. Equvalent to 4 SPDT switches or relays acquated
by a single coil or 2 DPDT relays. In total, 14 terminals when
the coil is also included.
2. Contact Configuration
 Classified as Normally Open (NO), Normally Closed (NC), or Change-
Over (CO) contacts.
 NO contacts connected the circuit when the relay is activated;
disconnected when the relay is inactive. It is also called Form A contact or
“make” contact.
 NC contacts disconnected the circuit when the relay is activated; the
circuit is connected when the relay is inactive. It is also called Form B
contact or “break” contact.
 CO contacts control two circuits: one normally-open contact and one
normally-closed contact with a common terminal. It is also called Form C
contact or “transfer” contact.

Coil
Contact

These contacts can be either normally Open (NO),

Normally Closed (NC), or change-over contacts.

Normally-open contacts connect the circuit when the relay is activated;

the circuit is disconnected when the relay is inactive. It is also called Form A
contact or "make" contact. Form A contact is ideal for applications that require to
switch a high-current power source from a remote device.

Normally-closed contacts disconnect the circuit when the relay is

activated; the circuit is connected when the relay is inactive. It is also called Form
B contact or "break" contact. Form B contact is ideal for applications that require
the circuit to remain closed until the relay is activated.

Change-over contacts control two circuits: one normally-open contact

and one normally-closed contact with a common terminal. It is also called Form C
contact.

Description
The general purpose relays specially design for users demanding small
size, sturdy construction and high electrical capacity. Mechanisms are furnished
in polycarbonate dust-proof enclosure and are recommended for a multitude of
electrical control application for their reliability and compact size.

Over current relay

An "Over current Relay" is a type of protective relay. The ANSI Device
Designation Number is 50 for an Instantaneous over Current (IOC), 51 for a Time
over Current (TOC).
In a typical application the over current relay is used for over current
protection, connected to a current transformer and calibrated to operate at or
above a specific current level.
When the relay operates, one or more contacts will operate and energize
a trip coil in a Circuit Breaker and trip (open) the Circuit Breaker.
Solid State Relays

We are an authorized distributor for Payne Engineering, the oldest

manufacturer of Solid State Power Controls in the world. They control power to
process heating applications with solid state power switching technology from 10
amps to 1650 amps, single and three phase, 120vac to 600vac. Their product
scope over the years has evolved into the industry's broadest, comprising all
solid state, maintenance-free replacements for electromechanical motor controls,
power relays, variable transformers, storable reactors, and mercury relays.  "2
ms" fuses, selected according to strict criteria for clearing time and total energy
let-through, protect power semiconductors against short circuits; Proprietary heat
sink designs allow air cooling with no fans and no thermal degrading; "Voltage
Break over Clamping" protects power semiconductors against transient voltage
spikes independent of PIV ratings
Electro Mechanical relay:
The an Electro mechanical Relay a Coil activates a Magnetic field, that
operates the mechanically driven contacts On and Off in a Mechanical way

Electro Mechanical Relay

Solid State Relay:

With an Solid State Relay the Input activates an Opto-Coupler, that driven
a triac; which is a “fully Electronic Contact”. The Triac switches the Load On and
Off in an Electronical way.

Solid state relay

Comparison between Mechanical Relay and SSR

Mechanical relay
SSR
Input Output
Input Outpu
t

Load
Coil

Lo
ad
Opto- coupler
Limit on the switching No movable contacts, no mechanical
time sound
Inductive input current Uses semiconductor switching elements,
Long operation time such as thyristors, triacs, diodes, and
Mechanical sound transistors.
Contact noise Employ optical semiconductors called
photocouplers to isolate input and output
signals. Photocouplers change electric
signals into optical signals and relay the
signals through space, thus fully isolating
Function
the input and output sections while relaying
the signals at high speed, i.e shorter
operation time
Since SSR does not use switching contacts
Mechanical isolation for safety that will physically wear out, longer life
span
Low current/ no inductive phenomena
Zero-cross function

Function

More electrical feature for precise control

Lesson 6
PUSHBUTTON SWITCHES

Push button switches are classified under manually operated device. Their
function is to stop, start, reverse, or jog the motor. Installed in a circuit, these
momentarily activated in response to semi automatic starting mechanism.

Push Button

        
  Flush Button
Flush Button
she Button           

Protruding Lens
using Lens

    Protruding Lens Protruding Front Protruding Front Ring

       Ring
Protruding
Lens

Illuminated Push-Button
Switches and Indicators
Lesson 7
Over current Protective Device

1. Fuses – is basically a short length of metal ribbon made of an alloy with a low
melting point and of a size that will carry a specified current indefinitely but
which melt when a large current flow.

Type of fuses
1. Plug Fuse is made in size up to and including 30 amperes.
2. Cartridge Ferrule contact fuses are made in size up to and
including 60 ampere.
3. Cartridge knife-blade contact fuses are made in sizes from 70
amperes up to and including 600 amps.

Plug Fuse Cartridge knife-

blade

Cartridge Ferrule

Choosing replacement Fuses

 Voltage Rating of motor control fuses are usually 250 0r 600volts. The
rating must match or exceed the voltage of the circuit where the fuses
is used
 Amp rating or current carrying should capacity varies from an eight of
an 600amp
 Interrupt capacity is the total current witch the fuse can interrupt w/o
being damage

2. Circuit Breaker – is a mechanical device that performs the same protective

devise function of fuses. It can also use as an ordinary on-off switch.

Advantage and Disadvantage of circuit Breaker

 Advantage
 High quality
 Can be use as switch on-off
 Easy to use

 Disadvantage
 High price

Exploded Circuit Breaker

Lesson 8
TIMER

Timer is an automatic switching device that extends to energize and de-

energized a certain parts of a circuit on a given time setting.
Timer keeps track of time and provides certain notifications or carries out
certain function at a predetermined time.

Got to wait for 10

more minutes!

Input

Electronic timers have become much more rugged and armor versatile
many mechanical timer. The internal timing usually takes place with an RC time
constant circuitous with quartz timing. Many of the times can be set for on and off
delay, trigger timing, and they have the versatility of a very wide range of timing.
As in order electronic controls, the switching is done electronically not
mechanically, so the same precaution that apply to other electronic switching.

also apply to the electronic timers.

Types of Timers
1. Synchronous Motor Driven –consist of a set of contacts driven from the
shaft of a very small synchronous motor so that there is a definite time tag
between the starting of the motor and the closing of the contacts.]
2. Dash pot – this timer works on the principle of transferring air from one
chamber to another through an adjustable. This orifice controls the
rate of air flow in turn controlling the movement of a diaphragm and
contact assembly.
3. Solid state timer – solid state timer dative name from the fact that the
time relay is provided by the solid state electronic devices enclosed within
the timing device

Kinds of timer
1. On delay timer - is a kind of timer that starts to count the time setting
when the coil is energized. After reaching the predetermine time
setting, the contact will change in possession, the normally closed
contact will tend to open and the normally open will closed.
2. Off delay timer - is a kind of timer that start to count the time setting
after the coil is de-energized after reaching the preset time-delay
contact will change ion position.
Timer Operation

SYMBOL
TC
TO

COIL

Graphical representation of on-delay timer

SYMBOL

COIL

Graphical represent of off-delay timer

Function of Timer

Timer does more than keep track of time and outputs. It has various functions. Lets take
a look at what a timer can do here.

Operation
Various operations can be performed depending on when the timer starts counting the
time.

On-delay Operation

Off-delay Operation
Flicker Operation

Multiple Operations

How does is work?

 When a timing is input, built-in contacts executes a switch-over at the
programmed time (Operation Time = Time UP!)

This is
what I do

Time
Utilizes electronic circuitries to keep track of time.

Principle of structure & Operation

Input Built-in Relay

Output

The contact switches over at programmed time.

Internal structure
shown on the
right.

Timer Circuit

Programming Method
Select one of the two programming method
Analogue setup Digital setup

Easy setup Display of passage &

remaining time
Fine-tuning
Precise operation time
(high accuracy)
Low price
Zero setup error
Why do I need a Timer?

Need to change on/off

time to automatically
start/off machine
Lesson 9
MAGNETIC FULL VOLTAGE STARTER

Magnetic full voltage starter – which connect a motor directly across the
line starter is a starter which connects a motor directly across the lines.

Main components of full voltage starter

 Magnetic contactor
 Thermal overload relay
 The control station

Three main components of magnetic full voltage starter:

1. The magnetic contactor (K) possesses three heavy contacts and several
normally closed and open auxiliary contacts. The three contacts are
normally open are connected to the motor circuits. While the auxiliary
contacts in used in connecting the circuit components
2. The thermal over load relay (OL) protects the motor against the overloading.
The relay comprises of three individual heating elements, respectively
connected in series with the three phases. Three small, normally closed
contacts in series with the contactor coil part of the relay assembly.
3. The control station composed of start and stop from either two to three
stations, one of which is situated in remote location. In control unit diagram
the start buttons are always connected in parallel while the stop is always
connected in series. This must be done regardless of the number station.

Operations:
To start the motor, press the start button momentarily. During the time its
normally open contacts where closed, there was current path through the coil of
the contactor. Contactor becomes deenergized and all its contacts return to the
normal positions, removing power to the motor. Note the motor not restart after
the pushbutton is release because the auxiliary is already open. In case of an
overload, the opening of the contact of the overload load (OL) produces the
same effect.
Lesson 10
COMMON COMPONENT OF A MOTOR CONTROL SYSTEM

Motor Control Circuit has Two Parts as Follows:

1. Power circuit
 Sometimes are called motor or main circuit
 Is the part of the circuit which carries the current

This circuit includes:

1. Circuit breaker
2. Main contacts
3. Overload heater
4. Motor

2. Control circuit
 Are the part of the circuit which control the opening and the closing of
the power circuit main contacts.
 It carries small amount of coil currents

This circuit includes:

1. Push buttons
2. Fuse
3. Auxiliary contacts
4. Coil of contactor
5. Timer
6. Overload relay
Lesson 11
START-JOG-STOP CONTROL

Jogging – is defined as an operation in which a push button is pressed and will

stop when push button released. Jogging is used on machinery in which the
motor must run for short period of time to allow machine set-up. Another term for
jogging is inching.

Application:
 conveyor  printing machine
 sewing machine  others

Types of jog control circuit

1. Jogging by means of jog selector switch
2. Using a double contact pushbuttons
3. Using jog relay

1. Jogging by means of jog selector switch

 If a jog selector switch is in jog (open) position, the contactor k1 is
energized when s1 is actuated, at the same time the run pilot indicator is
energized
 Once the s1 pushbutton is released, the contactor k1 is de-energized
breaking the current flow of the motor

2. Using a double contact push button

 This jog circuit requires a double contact pushbutton (one normally closed
and normally opened contact)
 Pressing this jog button will activate the contactor coil k1 causing the
motor to run and after jog pushbutton is released contactor k1 is de-
energized and motor will stop
3. Using jog relay
 A double contact jog pushbutton is used and a relay
 When the start pushbutton is actuated the circuit is complete for the jog
relay, closing the normally open auxiliary contact and energizing contactor
k, maintaining the circuit for coil k
 When a jog pushbutton is actuated, only the contactor coil is energized
 Normally open auxiliary contact is energized and the contactor coil is de-
energized when the pushbutton is released causing the motor to stop.

START-JOG-STOP CONTROL
Lesson 12
INTERLOCKING

Interlocking – simply means to connect together pieces of electrical

equipment. The circuits, weather power or control, are said to be interlocked
when one circuit controls another circuit. All interlocking must be done in safe
manner. Many times interlocking will involve multiple circuits. The safely of the
electrician or service personnel is of utmost importance.

Types of interlocking:
Electrical interlock - A contact connected in a control circuit that will
insure that a particular sequence of operation is followed.

Mechanical interlock - A mechanism that is factory installed, which will

prevent two sets of contacts from closing simultaneously.

Sequence control
Sequence control means that the motor must start one after the other in a
predetermine order. A good example would be a conveyor system composes of
four sections. This section must start in the correct sequence.

PLUGGING
Plugging is a method of stopping a polyphase motor quickly, by momentarily
connecting a motor for the reverse rotation. When the motor is running, plugging
a motor more than 5 times a minute requires a larger motor starter that is
required for a given motor.

OPERATION:
As the zero speed switches rotates, centrifugal force or a magnetic clutch
causes a contact to open or closed, depending on the intended use.
Lesson 13
SEQUENCE CONTROL

Sequence control means that the motors must start one after the other in
a predetermined order. A good example would be a conveyor system composed
of four sections must start in the correct sequence. If, for some reason, one
motor will not start, the next motor in line will not start. Product

MOTOR 1 MOTOR 2
MAIN
3P C.B.

Motor Circuit
Condition:

Motor 2 cannot be started unless MOTOR 1 is running. Therefore to start

the operation, start first MORTOR 1 then start MOTOR 2.

The two motor are already running. If MOTOR 2 stops, MOTOR 1

continues running. But if MOTOR 1 stops, MOTOR 2 also stops.

When one of the overloads relays trips, the two motor stop.
Lesson 14
PLUGGING

We can stop the motor even more rapidly by using a method called
plugging. It consists of suddenly reversing the armature current by reversing the
terminals of the source armature connected to dc source.

Plugging is a method of stopping a polyphase motor quickly, by

momentarily connecting the motor for the reverse rotation, when the motor is
running. Plugging a motor more than five times a minute requires a larger motor
starter than is required a larger motor starter than is required for a given motor
This switch is often referred to as a plugging switch or an anti-plugging
switch. The other terms are used to denote the intended use.
If machine, because of the load, should not be stopped abruptly, it should
not be plugged to a stop.

Lockout Relay for Plugging

Because the plugging switch creates a path directly to the forward and
reversed coils, precautions may be necessary to prevent accidental closure of
the contacts in the switch. If the motor shaft were to be turned accidentally, you
wouldn’t want the switch to energized one of the motor starter relays. The
addition of a lock out solenoid is recommended to prevent accidental turn on of
the switch and starter. The lock out solenoid is connected so that the plugging
switch contacts will not change state unless power is allied to the motor leads.
The solenoid coil is rated so that it can be connected electrically to T1 and T2 on
the three-phase motor. When the motor is stopped, or reverse, the contacts will
remain as is until the power is reapplied to the motor in the opposite direction.
Now the plugging contacts are again free to change and they will reopen as
speed is reduced to a very low value. At this point, all power is removed from the
motor and the contacts are again inoperable.
Plugging Using Time Delay
Instead of using plugging switch connected to the motor shaft on the
driven equipment, timing relay may be used. In the circuit, the timer is set to
reopen the contact on line 3 after a preset time. Pressing start button energizes
the forward contactor and the TD coil. The TD contact on the line three closes,
but no circuit is established the NC “F” contacts are opened. The motor runs
normally until the stop button is pressed, at which time the NC “F” contacts on
line 3 reclose. The TD contacts remain closed and complete the circuit to the R
coil. This circuit stays energized until the timing contacts reopen after the time
delay.
This circuit needs careful evaluation to adjust the TDD timer. Although
cheaper than the plugging switch, this circuit is not responsive to actual motor or
shaft speed or conditions.

Antiplugging
This term refers to the way the plugging controls are applied. According to
NEMA, Antiplugging protection is achieved when a device prevents the motor
torque from being reversed until the motor torque from being reversed until the
motor speed has slowed to an acceptable level.

Speed versus time curves for various braking methods.

Under normal motor conditions, armature current / 1 is given by
I1 = (Es - Eo)IR

where Ro is the armature resistance. If we suddenly reverse the terminals

of the source, the net voltage acting on the armature circuit becomes (Eo + Es).
The so-called counter-emf Eo of the armature is no longer counters to anything
but actually adds to the supply voltage Es. This net voltage would produce an
enormous reverse current, perhaps 50 times greater than the full-load armature
current. This current would initiate an arc around the commutator, destroying
segments, brushes, and supports, even before the line circuit breakers could
open.

Dualtech Training Center. ”Industrial Machine Control Hand-Outs” Dual Tech

trading Center Foundation Inc. 1 Edition, 1996.

Keljick, Jeff, “Electric Motor and Motor Controls”, Delmar Publisher An

International Publishing Company, 1995.

Moberg, Gerald A., “AC and DC Motor Control”, New York, Chi Chester,
Toronto, Singapore: John Wiley & Son, Inc., 1987.

Armature connected to dc source Es.

Plugging.

To prevent such a catastrophe, we must limit the reverse current by

introducing a resistor R in series with the reversing circuit. As in dynamic braking,
the resistor is designed to limit the initial braking current I2 to about twice full-load
current. With this plugging circuit, a reverse torque is developed even when the
armature has come to a stop. In effect, at zero speed, Eo = 0, but I2 = Es/R, which
is about one-half its initial value. As soon as the motor stops, we must
immediately open the armature circuit; otherwise it will begin to run in reverse.
Circuit interruption is usually controlled by an automatic null-speed device
mounted on the motor shaft.

The curves of speed versus time curves for various braking methods
enable us to compare plugging and dynamic braking for the same initial braking
current. Note that plugging stops the motor completely after an interval 2To. On
the other hand, if dynamic braking is used, the speed is still 25 percent of its
original value at this time. Nevertheless, the comparative simplicity of dynamic
braking renders it more popular in most applications.
Lesson 15
FORWARD-REVERSE CONTROLLER

A three-phase motor is reverse by interchanging any two of the three

lines. Standard practice is to interchange L1 and L3.
To reverse a three motor with a magnetic starter, two sets of main line
contactors are used with suitable controls.
In operation, when the forward push button is pressed, the main line
contactors connect, L1 to T1, L2 to T2, and L3 to T3, when the reverse push
buttons is pressed, the main line contactors connect L1 to T3, L2 to T2, and L1 to
T3.
The push-button are electrically interlocked to eliminate the possibility of
energizing both the forward and reverse coils at the same time. In the electrical
interlocking shown in the diagram, the circuit to the forward coils has a series
connected normally auxiliary contact from the reverse contactor and the reverse
coil and the normally closed contact automatically opens, breaking the circuit of
the forward coil. Likewise, pushing the forward button will breaks the circuit
contact of the reverse coil.
The forward and reverse contactors are also interlocked by means of
mechanical interlock. The mechanical interlock usually consists of a bar mounted
between the contactors of a bar mounted between the contactors in such a
manner that when one set of contactors is “in” the other set is blocked out.
This interlock eliminates the possibility of both of contactors closing at the
same time and creating a short circuit between L1 and L3.
Legend:
F – Forward
R – Reverse
HC – Holding Coil
OL – Over load
STP – Stop button

MECHANICAL INTERLOCK

ELECTRICAL INTERLOCK
Lesson 16
TRANSITION

The word “transition” means change. When discussing reduces voltage

motor starting, we see that there has to be change from one state to another.
Example:
From reduce voltage starting to running voltage, or from starting
configuration. The move from one mode to another is therefore term as a
“TRANSITION”.

TYPES OF TRANSITION
1. Open Transition- Means the motor is removed from the line during the change
over period.

2. Close Transition- Means the motor is not removed from the line during the
change over period.
LESSON 17
REDUCE VOLTAGE STARTING

The purposes of installing reduce voltage or reduced current starting is to

limit the inrush of the starting current. When a motor is started on full line voltage,
the starting current rating of the motor this abnormally high starting current could
cause disturbance on the distribution lines like flickering of nearby lamps.

Listed below are different Reduced Voltage Starting Methods:

1. AUTOTRANSFORMER STARTING
 In this method an autotransformer is connected in the circuit to reduce the
voltage during starting, thereby also reducing the starting current.
2. PART – WINDING STARTING
 In this type of starting, a motor with two sets of winding us used. During
starting the first part of the winding is connected after the motor has
reached enough torque the second part is connected in parallel with the
first part.
3. PRIMARY RESISTANCE STARTING
 This starting method uses resistors with are connected in the line during
starting thereby reducing the voltage and current in the motor. After a time
delay the resistor are shunted out of the circuit so the motor can operate
on full line voltage.
4. WYE – DELTA STARTING
 This starting method uses a three-phase motor which is connected wye
during starting to reduce the phase voltage and after a time delay the
motor connected delta for full voltage operation.
5. SECONDARY RESISTANCE STARTING
 This method used in starting wound motor type induction motor. The
resistance units are connected in the rotor windings during start-up, while
the stator winding are supplied with full line voltage.
Lesson 18
STAR (WYE) – DELTA STARTING

• The wye-delta or something known as star-delta starting is one of the

most commonly used method of starting three-phase motor.
• The prerequisite for wye-delta starting is a three-phase motor designed to
run on delta connection with all six terminals brought out for wye
connection during starting.
ANSI ISO
MARKINGS MARKINGS

T1 U1 T1 U1

T2 U2 T2 U2

T3 U3 T3 U3

The motor is connected wye during the start-up period

The phase winding only received only around 58 percent of the full voltage.
The starting currents and starting torque are also reduced around 33 percent of
the full voltage.

The starting current and starting torque are also reduced around 33
percent of the full voltage values.
Where in:
VL – Line Voltage
VØ – Phase Voltage
VØ = VL
3
IØ = I
IL – Line Current
IØ – Phase Current
Wye-delta methods of starting are usually used in motor which are started
with light initial load to tolerate the 33 percent torque.

The main load of the motor is applied after the motor reaches full speed
before connecting the motor to delta.

Factor to be considered before Using the Wye- Delta Method of Starting 3-

Phase Motors
1. Initial loading (torque load) during start-up must be lower than 33 percent
of full load of motor.
2. A six-leads out, delta connected, and 3-phase motor could only be used in
the set-up.
3. Most wye-delta starter is open transition type, meaning the motor is
momentarily disconnected from the line during the change over period.

Disadvantages:
1. Required special motor design
2. Starting Torque is low
3. Inherently open transition-close transition available at added cost.
Lesson 19
AUTOTRANSFORMER STARTING

Autotransformer Starting – is so called because autotransformers are

used in the power circuit to reduce the starting voltage. With the starting voltage
reduced, the starting current will be lower than it would be if the motor were
started on full line voltage. After a present time delay the autotransformers are
removed from the circuit, and the squirrel-cage motor continuous to run on line
voltage.

Advantages:
1. It has a high value torque produce per unit of start current.
2. The motor current is reduced in portion to the voltage applied to the motor.
Terminals.
3. The line current is rounded in portion to the square of the motor-terminal
voltage because of the transformer action.
4. It has the advance of torque and rush current adjustment in the field by
simple tap selection.
5. Can be obtained with either open or closed transition.
6. Autotransformer starting can be accomplished with either two or three-
winding transformer.
7. The transformer winding are removed from the circuit once starting has
been accomplished.

Disadvantages:
1. Very Expensive design for smaller type of motor
2. Low power factor.

Starting Characteristics in percent of full voltage value:

• Voltage at motor 80,65, 50 percent
• Line current 64, 42, 25 percent
• Starting torque 64, 42, 25 percent
Lesson 20
PRIMARY RESISTANCE STARTING

Primary Resistances starting is so called because reengineering

resistance units are connected in the line to the stator winding of a squirrel-cage
motor during the start up period. The primary circuit of a squirrel cage-motor is
the stator winding. A voltage drop occur the resistors during the start-up period,
which provides reduced voltage across the stator winding. With the stating
voltage reduce; the starting current is lower than it would be if the motor were
started on full line voltage. After a present time delay, the resistance units are
shunted out of the circuit, and the motor continuous to run on line voltage. This
method of starting is available for two, three, or four- stage starting.

Advantages:
• Smooth acceleration (motor voltage increases with speed).
• High power factor during start
• Closed transition starting
• Less expensive than autotransformer in lower horsepower rating
• Available with as many accelerating point.

Disadvantages:
• Low torque efficiency
• Resistor gives off heat
• Starting time in excess of 5 seconds requires expensive resistor
• Starting voltage difficult to adjust to meet varying conditions.

Starting Characteristic in Percent of Full-Voltage Value:

• Voltage at motor, 70 percent
• Line current, 70 percent
• Starting torque, 49 percent
Lesson 21
PART – WINDING STARTING

Part – Winding is a method of starting a squirrel-cage motor, which

provides reduces current starting. Part winding is so called because the motor is
started by its connecting one part of the stator winding across line voltage. After
a present time delay the second part of the stator winding is connected in parallel
with the first part. By starting current is limited to a lower level than it would be if
both parts are connected across the line at the same movement.

Advantages:
• Least expensive reduce voltage starter
• Closed transition starting
• Most dual-voltage motor can be started part-winding on lower or two
voltages.
• Small size

Disadvantages:
• Unsuited for high Inertia long load
• Required special motor design for voltages higher than 230 volts.

Starting Characteristics in Percent of full-voltage Value;

• Voltage at motor, 100 percent
• Line current, 65 percent
• Starting torque, 48
Lesson 22
SECONDARY RESISTANCE STARTING

Secondary Resistance Motor Starting – A reduce current method of

starting a wound rotor motor. The starting method uses resistance units in the
rotor circuit.
Would rotor induction motor is the least understood motor of the
polyphase induction motor line. This text is the study of the control for the wound
rotor induction motor, and not the motor design itself.
The wound rotor induction motor is used when controlling starting tongue
and speed is a requirement. Indiscriminate matching of starting resistors and
wound rotor induction motors should be discouraged. Basic wound rotor
induction motor is a typical request forms the properly advice control engineers
and designers as the starting and running requirements for a particular
installation.
When starting a wound rotor induction motor, the stator is supplied with
the voltage, while external resistance units are connected in the rotor circuit. This
starting method is reduced current starting, and not reduced voltage starting.

Importance of secondary Circuit

It is imperative that when full voltage is applied to the stator at start, the
full external resistance be connected to the rotor circuit. Why?
 The motor will not start if the rotor circuit is open
 The starting current will be extremely high if the resistors where bypassed
Automatic Secondary Resistance Starter
Automatic Secondary Resistance Starter

Control Circuit

Lesson 23
MAINTENANCE OF CONTROL EQUIPMENT

1. Inspection and servicing

a) Detecting malfunctioning controllers. Inspection and servicing of
controllers are important functions of the repair shop since many motors
and generator troubles can be traced to the improper functioning of control
equipment from:
1. Loose connections
2. Broken connections
3. Open or short in magnetic coils
4. Loose contacts
5. Worn contacts
6. Dirty Contacts
7. Dirty pole faces
8. Improper tensions (poor adjustments)
9. Improper insulations
10. Operation in high ambient temperatures
11. Improper placements of arc chutes
12. Moisture and dirt

2. CLEANING AND DRYING

A controller to function properly, must be clean and in all its parts. The
exterior and interior must be absolutely dry, except that, where the controller is
off the oil-immersed type, all the apparatus is immersed in oil tank. A controller
box must be suited to the conditions under which the controller be selected which
is suited to the application and conditions of operation.

a) CLEANING THE CONTROLLER

The removal of dust by blowing dry compressed air under 30-50
pounds pressure is one of the methods. Used for freeing controllers of
accumulations of dirt and dust. If the blown-air method is effective, wiping
or washing with a safety type of cleaning fluid is the method used.

b) DRYING THE CONTROLLER.

Slow gradual heat is to be applied to moisture ridden controller

c) CLEANING CONTACTS.
The method of cleaning contacts is important. Cleaning is usually
done with sand paper or a buffing wheel. However, fine file is permissible
if the contact shape is maintained. Silver contacts seldom require cleaning
although they look black and dirty because of the silver oxide. Since silver
oxide is a conductor, cleaning is not necessary. When contacts are
replaced, the surface against which they are bolted is thoroughly cleaned.
This surface is usually a current carrying joint, and a clean contact bolted
to a dirty surface will give future trouble. Traces of copper oxide should be
removed.

d) HARMFUL CLEANING METHOD.

Emery cloth or coarse files should not be employed. Emery
particles may adhere to moving parts and contact surfaces causing
unnecessary wear. Coarse, crude filing wastes contact material and
makes it difficult to maintain original contact shape.
Lesson 24
MAINTENACE OF MAGNETIC CONTACTOR

1. Contactor Maintenance
a. The Core – The core surface of the contactor must not be grease.
Dirt might collect in the grease on the core surfaces and this can
increase the rash of sticking.
b. Checking the Control Voltage – Checking if the control voltage of
the contactor is correct, the control voltage should remain + 10% of
the rate voltage. The contactor will then operate down 85% of the
rated voltage. The impacts of the electromagnet any cause contact
bounce that may cause serve contact wear.
c. HUM – If dirt is present between the magnet and armature a slight
hum will develop. Hum also occurs if the pole surfaces have been
deformed. A louder hum also may occur if the adjustment has been
made incorrectly, so that the contact pressure is too high.
d. Sticking and Eminence (residential Magnetism) – If sticking
occurs the ore surface of the operating coil with a grease solvent
(tricks or petrol). If sticking persists despite cleaning, magnetic flux
in the iron core after the control Voltage has been disconnected.
This flux known as remanence or residual magnetism and happen
with all iron cores. In a contactor there must be another force
available greater than the force due to the remenence. This
counteracting force is provided by the contact and tripping springs.
Sticking may occur if the two outer legs have worn down so far that
there is no air gap at the inner of the E core. The air gap is normally
0.2 mm.
e. Contactor Wear and Welding
Contact wear depend on the three factors:
i. Contact material – Contact material used is silver
cadmium oxide; Ag CdO is far superior to pure silver. It has
harder surface and with a higher melting point. These
properties reduce the risk of Welding and cut down wear.
EF and EG contactors have double breaking points. The
fixed contact is designed in such a way that a field is
formed which blows the arc away from the contact and to
the arc shield. The arc shield is fitted with de-ionizing plate
which divide’s the arc up into small sections. These
through zero.
ii. Causes of Contact bounce:
a) Higher supply voltage – contact bounce can
be prevented by using coils of slightly higher
voltage.
b) Fault in control – If contacts in the control,
auxiliary contacts or push button contacts are
wrongly adjusted.
c) Contact Wear – is due to the effect of the arc
which causes the contact of some loose
materials.

Arc always occur when two current carrying

contact are separated. The effective contact area
is gradually reduce and the contact resistance
increases and will result in rise of temperature.
The metal becomes liquid and forms a bridged
which vaporizes and forms and arc.

Arc occur on breaking if an arc occur on

making if an arc occurs on making is caused by
contact bounce. If the current is heavy, contact
wear is also severe

iii. Contact Welding

a) If severe contact bounce occurs when the
contactor closes and the current is high.
Example; when starting a squirrel-cage motor,
the arc that occurs may melt the surface layer
of the contacts, and then the contacts stick
together.
b) If sudden short circuit happens the current
forces may lift the contact together.

Lesson 25
TROUBLE SHOOTING MOTOR CONTROL EQUIPMENT
CAUSES REMEDY

1. Contact Chatter
a. Broken shading coil. a. Replace magnet and armature.
b. Poor Contact in Control Circuit. b. Replace the contact device or use holding
c. Low voltage. circuit interlock.
c. Correct Voltage condition, check momentary
voltage dip.

2. Welding or Freezing Contact

a. Abnormal inrush of current. a. Check for ground and shorts.
b. Rapid jogging. b. Install larger device rated for jogging circuit.
c. Insufficient tip pressure. c. Replace contacts and springs, check contact
d. Low voltage preventing carrier for deformation.
magnet from sealing. d. Incorrect voltage condition.
e. Foreign matter preventing e. Clean contacts with Freon.
contacts from closing. f. Removed short or fault and check to be sure
f. Short circuit. or fuse or breaker size.

3. Short Tip Life or Overheating of

tips a. Don’t file tips. Rough spot or discoloration
a. Filling or dressing. may occur.
b. Interrupting excessively high b. Install larger device rated for jogging.
current. c. Install larger device rated for jogging.
c. Excessive jogging. d. Replace contacts and spring, check carrier
d. Weak tip pressure. for deformation.
e. Dirt or foreign matter on e. Clean contact with Freon.
contact surface. f. Remove short or fault circuit to be sure.
f. Short circuit. g. Clean and tighten contact screw.
g. Loose Connection. h. Check for excessive motor load current or
h. Sustained Overload. install larger device.

4. Open Contactor Coil Circuit

a. Mechanical damage a. Handle and store coils carefully.

5. Roasted Coil
a. Over voltage. a. Check the applied voltage and correct.
b. Incorrect coil. b. Install correct coil.
c. Dirt or rush on pole faces c. Replace coil.
increasing air gap. d. Correct system voltage.
d. Under voltage, failure of
magnet to seal in.

CAUSES REMEDY
6. Tripping Overload Relay
a. Sustain over load. a. Check for grounds, shorts or excessive
b. Loose connection on load wire. motor current.
c. Incorrect heater. b. Clean and tighten.
c. Heater should be replacing with correct size.

7. Noisy Magnet
a. Broken shading coil. a. Replace magnet and armature.
b. Magnets face not mating. b. Replace magnet and armature.
c. Dirt or rust on magnet faces. c. Clean.
d. Low voltage. d. Check system voltage dips during starting.

8. Magnet Fails to Pick-up and Seal

a. Low voltage. a. Check system voltage and voltage dips
b. Coil open or shorted. during starting.
c. Wrong coil b. Replace.
d. Mechanical obstruction. c. Replace.
d. With power off, check for free movement of
contact and armature assembly.

9. Magnet fail to Drop – Out

a. Gummy substance on pole a. Clean pole faces.
faces. b. Check coil circuit.
b. Voltage not removed c. Replace parts.
c. Worn or rusted part causing d. Replace magnet and armature
binding. Residual magnetism
due to lack of air gap in
magnetic path.
d. Residual magnetism due to
lack of air gap in magnetic
path.