Basics of

Control Components

Siemens Energy & Automation, Inc.

3333 Old Milton Parkway
Alpharetta, GA 30305

1-800-964-4114
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Specifications subject to change without notice.

SEA Order No. STTM-EP03G-1105 (Supersedes STTM-EP03F-0402) 2.5M1105BP Printed in USA.

Table of Contents

Introduction................................................................................2
Electrical Symbols.....................................................................6
Line Diagrams.........................................................................16
Overload Protection.................................................................22
Overload Relays......................................................................26
Manual Control........................................................................35
Magnetic Contactors and Starters...........................................41
Contactor and Starter Ratings.................................................47
Class 14 NEMA Starters with Bimetal Overload Relays..........50
Class 14 ESP100 Starters.......................................................51
SIRIUS Type 3R Starters.........................................................52
Multi-Speed Starters................................................................55
Reversing Starters...................................................................58
Reduced-Voltage Starting.......................................................60
SIRIUS Soft Starters...............................................................65
Lighting and Heating Contactors.............................................67
Pilot Devices............................................................................70
Control Transformers...............................................................81
Control Relays.........................................................................82
Solid-State Switching Devices.................................................88
Monitoring Relays....................................................................90
Time Relays.............................................................................91
Terminal Blocks and Supplementary Protectors......................96
LOGO! Logic Module...............................................................98
Fastbus Busbar Adapter System...........................................100
Review Answers....................................................................103
Final Exam............................................................................104


 Introduction

Welcome to another course in the STEP series, Siemens

Technical Education Program, designed to prepare our
distributors to sell Siemens Energy & Automation products more
effectively. This course covers Basics of Control Components
and related products.

Upon completion of Basics of Control Components you will be

able to:

• State the purpose and general principles of control

components and circuits

• State the difference between manual and automatic control

operation

• Identify various symbols which represent control

components

• Read a basic line diagram

• Describe the construction and operating principles of

manual starters

• Describe the construction and operating principles of

magnetic contactors and magnetic motor starters

• Identify various manual starters and magnetic motor

starters, and describe their operation in a control circuit

• Explain the need for motor overload protection

• State the need for reduced-voltage motor starting

• Describe typical motor starting methods


• Describe the construction and operating principles of
lighting and heating contactors

• Describe the operating principles of control relays

This knowledge will help you better understand customer

applications. In addition, you will be better able to describe
products to customers and determine important differences
between products. You should complete Basics of Electricity
before attempting Basics of Control Components. An
understanding of many of the concepts covered in Basics of
Electricity is required for Basics of Control Components.

If you are an employee of a Siemens Energy & Automation

authorized distributor, fill out the final exam tear-out card and
mail in the card. We will mail you a certificate of completion if
you score a passing grade. Good luck with your efforts.

Underwriters Laboratories Inc. is a registered trademark of

Underwriters Laboratories Inc., Northbrook, IL 60062. The
abbreviation “UL” shall be understood to mean Underwriters
Laboratories Inc.


 Control Circuits

Control Control, as applied to control circuits, is a broad term that

means anything from a simple toggle switch to a complex
system of components (which may include relays, contactors,
timers, switches, and indicating lights). Every electrical circuit
for light or power has control elements. One example of a
simple control circuit is a light switch that is used to turn lights
on and off.

Of course, there are many other devices and equipment

systems in industrial applications. Motor control, for example,
can be used to start and stop a motor and to protect the motor,
associated machinery, and personnel. In addition, motor
controllers might also be used for reversing, changing speed,
jogging, sequencing, and pilot-light indication. Control circuits
can be complex, accomplishing high degrees of automatic,
precise machine operation.


Manual Control Control is considered to be manually operated when someone
must initiate an action in order for the circuit to operate. For
example, someone might have to flip the switch of a manual
starter to start and stop a motor.

Automatic Operation While manual operation of machines is still common practice,

many machines are started and stopped automatically.
Frequently there is a combination of manual and automatic
control. A process may have to be started manually, but may be
stopped automatically.

Control Elements The elements of a control circuit include all of the equipment
and devices concerned with the circuit function: enclosures,
conductors, relays, contactors, pilot devices, and overcurrent-
protection devices. The selection of control equipment for
a specific application requires a thorough understanding of
controller operating characteristics and wiring layout. The
proper control devices must be selected and integrated into the
overall circuit design.


 Electrical Symbols

Language has been developed in order to transfer ideas and

information. In order to understand the ideas and information
being communicated, an understanding of the language is
necessary. The language of controls consists of a commonly
used set of symbols which represent control components.

Contact Symbols Contact symbols are used to indicate an open or closed path
of current flow. Contacts are shown as normally open (NO) or
normally closed (NC). Contacts shown by this symbol require
another device to actuate them.

The standard method of showing a contact is to indicate the

circuit condition produced when the actuating device is in the
de-energized state. For example, in the following illustration a
relay is used as the actuating device. The contacts are shown
as normally open, meaning the contacts are open when the
relay is de-energized. A complete path of current does not exist
and the light is off.


Normally Open Contact In a control diagram or schematic, symbols are usually not
Example shown in the energized or operated state. However, for the
purposes of explanation in this text, a contact or device shown
in a state opposite of its normal state will be highlighted. For
example, in the following illustration the circuit is first shown
in the de-energized state. The contacts are shown in their
normally open (NO) state. When the relay is energized, the
contacts close, completing the path of current and illuminating
the light. The contacts have been highlighted to indicate they
are now closed. (This is not a legitimate symbol. It is used here
for illustrative purposes only.)

Normally Closed Contact In the following illustration the contacts are shown as
Example normally closed (NC), meaning the contacts are closed when
the relay is de-energized. A complete path of current exists and
the light is on. When the relay is energized, the contacts open
turning the light off.


Switch Symbols Switch symbols are also used to indicate an open or closed
path of current flow. Variations of this symbol are used to
represent limit switches, foot switches, pressure switches,
level switches, temperature-actuated switches, flow switches,
and selector switches. Like contacts, switches require another
device or action to change their state. In the case of a manual
switch, someone must manually change the position of the
switch.

Normally Open Switch In the following illustration a battery is connected to one

Example side of a normally open switch and a light to the other. Current
is prevented from flowing to the light when the switch is open.
When someone closes the switch, the path of current flow is
completed and the light illuminates.

Normally Closed Switch In the following illustration a battery is connected to one

Example side of a normally closed switch and a light to the other.
Current is flowing to the light when the switch is closed.
When someone opens the switch, the path of current flow is
interrupted and the light turns off.


Pushbutton Symbols There are two basic types of pushbuttons: momentary and
maintained. A normally open momentary pushbutton closes as
long as the button is held down. A normally closed momentary
pushbutton opens as long as the button is held down. A
maintained pushbutton latches in place when the button is
pressed.

Normally Open In the following illustration, a battery is connected to one

Pushbutton Example side of a normally open pushbutton, and a light is connected to
the other side. When the pushbutton is depressed a complete
path of current flow exists through the pushbutton, and the light
is illuminated.

Switch is shown
opposite of its
normal state (NO).

Normally Closed In the following example, current will flow to the light as
Pushbutton Example long as the pushbutton is not depressed. When the pushbutton
is depressed, current flow is interrupted and the light turns off.

Switch is shown
opposite of its
normal state (NC).


Coil Symbols Coils are used in electromagnetic starters, contactors, and
relays. The purpose of contactors and relays is to open and
close associated contacts. Letters are used to designate the
coil; for example, “M” frequently indicates a motor starter and
“CR” indicates a control relay. The associated contacts have
the same identifying letter. Contactors and relays use an
electromagnetic action (which will be described later) to open
and close these contacts. The associated contacts can be
either normally open or normally closed.

Coil Example Using In the following example, the “M” contacts in series with
Normally Open Contacts the motor are controlled by the “M” contactor coil. When
someone closes the switch, a complete path of current flow
exists through the switch and “M” contactor coil. The “M”
contactor coil actuates the “M” contacts which provide power to
the motor.

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Overload Relay Symbols Overload relays are used to protect motors from overheating
resulting from an overload on the driven machinery, low line
voltage, or an open phase in a three-phase system. When
excessive current is drawn for a predetermined amount of time,
the relay opens and the motor is disconnected from its source
of power.

Indicator Light Symbols An indicator light (sometimes referred to as a pilot light) is

a small electric light used to indicate a specific condition of a
circuit. For example, a red light might be used to indicate a
motor is running. The letter in the center of the indicator light
symbol indicates the color of the light.

Other Symbols In addition to the symbols discussed here, there are many other
symbols used in control circuits. The following chart shows
many of the commonly used symbols.

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12
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Abbreviations Abbreviations are frequently used in control circuits. The
following list identifies a few commonly used abbreviations.

AC Alternating Current MTR Motor

ALM Alarm MN Manual
AM Ammeter NEG Negative
ARM Armature NEUT Neutral
AU Automatic NC Normally Closed
BAT Battery NO Normally Open
BR Brake Relay OHM Ohmmeter
CAP Capacitor OL Overload
CB Circuit Breaker PB Pushbutton
CKT Circuit PH Phase
CONT Control POS Positive
CR Control Relay PRI Primary
CT Current Transformer PS Pressure Switch
D Down R Reverse
DC Direct Current REC Rectifier
DISC Disconnect Switch RES Resistor
DP Double-Pole RH Rheostat
DPDT Double-Pole, Double-Throw S Switch
DPST Double-Pole, Single-Throw SEC Secondary
DT Double Throw SOL Solenoid
F Forward SP Single-Pole
FREQ Frequency SPDT Single-Pole, Double Throw
FTS Foot Switch SPST Single-Pole, Single Throw
FU Fuse SS Selector Switch
GEN Generator SSW Safety Switch
GRD Ground T Transformer
HOA Hand/Off/Auto Selector Switch TB Terminal Board
IC Integrated Circuit TD Time Delay
INTLK Interlock THS Thermostat Switch
IOL Instanstaneous Overload TR Time Delay Relay
JB Junction Box U Up
LS Limit Switch UV Under Voltage
LT Lamp VFD Variable Frequency Drive
M Motor Starter XFR Transformer
MSP Motor Starter Protector

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Review 1
1. A control is ____________ operated when someone
must initiate an action for the circuit to operate.

2. Which of the following symbols represents a normally

open contact?

a. b. c.

3. Which of the following symbols represents a normally

closed contact?

a. b. c.

4. Which of the following symbols indicates a normally

open pushbutton?

a. b. c.

5. Which of the following symbols indicates a mushroom

head pushbutton?

a. b. c.

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 Line Diagrams

The method of expressing the language of control symbols

is a line diagram, also referred to as a ladder diagram. Line
diagrams are made up of two circuits, the control circuit
and the power circuit. Electrical wires in a line diagram are
represented by lines. Control-circuit wiring is represented by a
lighter-weight line, and power-circuit wiring is represented by
a heavier-weight line. A small dot or node at the intersection of
two or more wires indicates an electrical connection.

Line diagrams show the functional relationship of components

and devices in an electrical circuit, not the physical
relationship. For example, the following illustration shows the
physical relationship of an indicator light and a pushbutton.

Indicator
(Pilot) Light

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 The functional relationship can be shown pictorially with the
following illustration.

Reading a Line Diagram This functional relationship is shown symbolically with a line
diagram. Line diagrams are read from left to right. Depressing
the pushbutton would allow current to flow from L1 through the
pushbutton, illuminating the indicator light, to L2. Releasing the
pushbutton stops current flow turning the indicator light off.

Power Circuit and The power circuit (indicated by the heavier-weight line) is
Control Circuit what actually distributes power from the source to the connected
load (motor). The control circuit (indicated by the lighter-weight
line) is used to “control” the distribution of power.

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Connecting Loads and Control circuits are made up of control loads and control
Control Devices devices. Control loads are electrical devices that use electrical
power; for example, indicator lights, relays, and contactors.
Control devices (such as pushbuttons and switches) are used
to activate the control load.

The following illustration shows the proper connection of an

indicator light (load) with a pushbutton (control device). The
power lines are drawn vertically and marked L1 and L2. In this
example, the voltage potential between L1 and L2 is 120 VAC.
The indicator light selected must be rated for 120 VAC. When
the pushbutton is depressed, the full 120 volt potential is applied
to the indicator light.

Connecting the Load to L2 Only one control load should be placed in any one circuit line
between L1 and L2. One side of the control load is connected to
L2 either directly or through overload relay contacts.

In the following example, an indicator light is directly connected

to L2 on one circuit line. A contactor coil is indirectly connected
through a set of overload contacts (OL) to L2 on a second,
parallel circuit line. Depressing the pushbutton would apply 120
VAC to the indicator light and to the “M” contactor.

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 Control loads are generally not connected in series. The
following illustration shows why.

In the first instance, the control loads are improperly connected

in series. When the pushbutton is depressed, the voltage
across L1 and L2 is divided across both loads with neither load
receiving the full 120 volts necessary for proper operation. If
one load fails in this configuration, the entire circuit is rendered
useless.

In the second instance, the loads are properly connected

in parallel. In this circuit, there is only one load for each line
between L1 and L2. The full 120 volts will appear across each
load when the pushbutton is depressed. If one load fails in this
configuration, the other load will continue to operate normally.

Connecting Control Control devices are connected between L1 and the load.
Devices The control device can be connected in series or parallel,
depending on the desired operation of the circuit.

In the following illustration, the pushbuttons are connected

in parallel. Depressing either pushbutton will allow current to
flow from L1, through the depressed pushbutton, through the
indicator light, to L2.

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 In this second illustration, two pushbuttons are connected in
series. Both pushbuttons must be depressed in order to allow
current to flow from L1 through the load to L2.

Line Numbering Numbering each line makes it easier to understand more

complex line diagrams. In the illustration below, line 1 connects
pushbutton 1 to indicator light 1; line 2 connects pushbutton 2 to
indicator light 1; and line 3 connects switch 1 to indicator light 2
and to the “M” contactor on line 4.

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Review 2
1. Line diagrams are read from ____________ to ______
______ , or L1 to L2.

2. Match the items on the line diagram with the associated

list.

A ____________

B ____________

C ____________

D ____________

E ____________

F ____________

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 Overload Protection

Before discussing specific control components, it is necessary

to review what an overload is, and what steps can be taken to
limit the damage an overload can cause.

Current and Temperature Current flow in a conductor always generates heat due to
resistance; the greater the current flow, the hotter the conductor.
Excess heat is damaging to electrical components. For that
reason, conductors have a rated continuous current carrying
capacity or ampacity.

Overcurrent protection devices are used to protect conductors

from excessive current flow. Overload relays are designed to
protect the conductors (windings) in a motor. These protective
devices are designed to keep the flow of current in a circuit at a
safe level to prevent the conductors from overheating.

Excessive current is referred to as overcurrent. An overcurrent

may result from a short circuit, overload, or ground fault.

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Short Circuits When two bare conductors touch, a short circuit is created, and
resistance drops to almost zero. Short-circuit current can be
thousands of times higher than normal operating current.

Ohm’s Law demonstrates the relationship of current, voltage,

and resistance. For example, a 240 volt motor with 24 ohms of
resistance would normally draw 10 amps of current.

where I represents Current,

E represents Voltage, and
R represents Resistance

As noted above, resistance drops in the event of a short circuit.

If resistance drops to 24 milliohms, current will be 10,000 amps.

I = 240
0.024

I = 10,000 amps

The heat generated by this current will cause extensive damage

to connected equipment and conductors. This dangerous
current must be interrupted immediately when a short circuit
occurs.

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Overload Conditions An overload occurs when too many devices are operated on a
single circuit, or a piece of electrical equipment is made to work
harder than it is designed for. For example, a motor rated for
10 amperes may draw 20, 30, or more amperes in an overload
condition.

In the illustration below, a package has become jammed on

a conveyor causing the motor to work harder and draw more
current. Because the motor is drawing more current, it heats
up and will be damaged within a short time if the problem is not
corrected or the circuit is not shut down by the overload relay.

Temporary Overload Due Electric motors are rated according to the amount of
to Starting Current current they will draw at full load. When most motors start, they
draw current in excess of the motor’s full-load current rating.
Motors are designed to tolerate this overload current for a short
period of time. Many motors require 6 times (600%) the full-load
current rating to start. High-efficiency motors may require up
to 12 times (1200%) starting current. As the motor accelerates
to operating speed, the current drops off quickly. The time it
takes for a motor to accelerate to operating speed depends on
the operating characteristics of the motor and the driven load.
For example, a particular motor might require 600% of full-load
current and take 8 seconds to reach operating speed.

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Overload Protection Fuses and circuit breakers are designed to protect circuit
conductors in the event of a short circuit or overload condition.
If a short circuit or overload condition occurs, these devices will
open the path for current flow before damage to conductors
occurs.

When fuses or circuit breakers are used in a circuit providing

power to a motor, the protective devices and the circuit
conductors must be sized to allow for the high starting current
of the motor. Because of this, overload protection for the motor
must be provided by a separate device known as an overload
relay. In the next section, you will learn about overload relays.

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