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Motor Control Functions
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The main functions of a motor controller are to start and stop the motor and to protect the
EVENT CENTER controller may also be called upon to provide other functions that could include reversing
FORUM at various speeds or at reduced current levels, and controlling motor torque.
The purpose of controller enclosures is to provide protection of operating personnel by pre
energized components. In certain applications, the controller is protected from a variety o
water, rain, snow, sleet, dirt, non-combustible dust, oils, coolants, and lubricants. Motor co
requirements of the National Electrical Code (NEC), specifically Article 430 for motors and
electric equipment in hazardous locations.

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1 Motor Control Functions
1.1 Types of Enclosures
1.1.1 NEMA 1 - General Purpose
1.1.2 NEMA 3 - Dust-Tight, Rain-Tight
1.1.3 NEMA 3R - Rainproof, Sleet-Resistant
1.1.4 NEMA 4 - Watertight
1.1.5 NEMA 4X - Watertight Corrosion Resistant
1.1.6 NEMA 7 - Hazardous Locations
1.1.7 NEMA 9 - Hazardous Locations - Class II
1.1.8 NEMA 12 - Industrial Use
1.1.9 NEMA 13 - Oil-tight, Dust-tight
1.2 Types of Controllers
1.2.1 Manual Controller
1.2.2 Semiautomatic Controller
1.2.3 Automatic Controller
1.3 Control Devices and Symbols
1.3.1 Primary Control and Pilot Control Devices
1.3.2 Contacts
1.3.3 Pushbutton Switches
1.3.4 Toggle Switches
1.3.5 Indicating Lights
1.3.6 Coils, Relays, and Contactors
1.4 Magnetic Contactors
1.4.1 Types of Magnetic Contactors
1.4.2 Inrush Current
1.4.3 Ratings
1.4.4 Voltage Variations
1.4.5 AC Hum
1.4.6 Magnetic Blowout
1.4.7 Magnetic Coil Control Circuits
1.4.7.1 Magnetic Coil Data
1.4.7.2 Holding Circuit Interlocks
1.4.7.3 Interlocks
1.4.8 Overloads
1.4.9 Ambient Compensation
1.4.10 Rotary Switches
1.4.11 Automatic Switches
1.4.12 Float Switches
1.4.13 Pressure Switches
1.4.14 Timer
1.4.15 Limit Switches
1.4.16 Foot Switches
2 Control Circuits
2.1 Diagrams
2.2 Circuit Analysis
2.2.1 Three-Wire Control
2.2.2 Two-Wire Control
2.2.3 Common Control
2.3 Control Power Transformers
2.4 Hand-Off-Auto Controls
2.5 Interlocking Methods for Reversing Control
2.5.1 Mechanical Interlocking
2.5.2 Pushbutton Interlocks
2.5.3 Auxiliary Contact Interlocking
2.6 Sequence Control
2.7 Motor Control Center Power Supplies
2.8 MCC Single-Line Diagrams
2.9 Elementary Diagram Analysis
2.10 Standard Device Numbers
2.11 Developing a Control Circuit

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Types of Enclosures

The National Electrical Manufacturers Association (NEMA) and other organizations have e
construction for control equipment. Common types of enclosures, per NEMA classification

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NEMA 1 - General Purpose

This type of enclosure is primarily intended to prevent accidental contact with the enclose
purpose applications indoors where it is not exposed to unusual service conditions. A NEM
dust and light indirect splashing but is not dust-tight.

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NEMA 3 - Dust-Tight, Rain-Tight

This enclosure type is designed to provide suitable protection against specified weather ha
application outdoors, on ship docks, canal locks, construction work, and for application in
resistant.

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NEMA 3R - Rainproof, Sleet-Resistant

This type protects against interference in operation of the contained equipment due to ra
sleet. It is designed with conduit hubs and external mounting as well as drainage provision

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NEMA 4 - Watertight

Watertight enclosures are designed to meet the following hose test: "Enclosures shall be te
A hose with a one-inch nozzle shall be used and shall deliver at least 65 gallons per minute
enclosure from a distance of not less than 10 feet and for a period of five minutes. During
or more directions as desired. There shall be no leakage of water into the enclosure."

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NEMA 4X - Watertight Corrosion Resistant

These types of enclosures are generally constructed along the lines of NEMA 4 enclosures,
is highly resistant to corrosion. For this reason, they are ideal in applications, such as paper
contaminants could destroy an enclosure over a period of time.

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NEMA 7 - Hazardous Locations

This type of enclosure is designed to meet the application requirements of the NEC for Cla
locations are those in which flammable gases or vapors are, or may be, present in the air i
explosive or ignitable mixtures.

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NEMA 9 - Hazardous Locations - Class II

Class II locations are those that are hazardous because of the presence of combustible du
number indicate the particular group of hazardous locations as defined by the NEC for wh
designation is incomplete without a suffix letter or letter. Example, NEMA 9, Class II, Group

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NEMA 12 - Industrial Use

This enclosure is designed for use in those industries where it is desired to exclude such mat
coolant seepage. There are no conduit openings or knockouts in the enclosure, and mou
feet.

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NEMA 13 - Oil-tight, Dust-tight

These generally are of cast construction, gasketed to permit use in the same environment
difference is that, due to the case housing, a conduit entry is provided as an integral part
by means of blind holes rather than mounting brackets.
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Types of Controllers

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Manual Controller

A manual controller is one having its operations controlled or performed by hand at the lo
Figure 1. Perhaps the most popular single type in this category is the manual, full-voltage m

Figure 1: Manual Control for a Motor

A manual starter is used frequently where the only control function needed is to start and
generally provides overload protection for the apparatus being powered. Manual contro
those achieved by the manual full-voltage motor starter, can be had by the use of a switc
which provides overload protection for the motor.
Examples of this type of control are very common in small metalworking and woodworking
and pipe-threading machines. Another good example is the exhaust fan generally found
operations. In this installation, the operator or maintenance person generally pushes the ST
when the plant opens, and it continues to run throughout the day. In the evening, or when
then pushes the STOP button, and the fan shuts down until needed again.
A manual controller is easily identified because it has no automatic functions of control. Th
the fact that the operator must move a switch or push a button to initiate any change in t
apparatus being operated. A manual controller must, therefore, have two components: a
protective device.

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Semiautomatic Controller

A semiautomatic controller uses a magnetic starter (a switch operated by an electromag

such as pushbuttons and other similar equipment. Figure 2 shows a simple semiautomatic
Semiautomatic control provides flexibility of control by allowing remote and multiple contr
control would otherwise be impractical.
 Figure 2: Semiautomatic Control for a Motor
The key to classification as a semiautomatic control system lies in the fact that all the pilot
the motor starter is the magnetic-type. There are probably more machines operated by se
manual or automatic. This type of control requires the operator to initiate any change in th
machine. Using the magnetic starter, however, this change may be initiated from any con
manual control requirement that the control point be at the starter.

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Automatic Controller

An automatic controller is a magnetic starter in which functions are controlled by one or m

Figure 3 shows an automatic control scheme for a motor. As shown, an automatic pilot de
as a limit switch or float switch, that functions independent of operator action to initiate a
motor or machine.

Figure 3: Automatic Control for a Motor

Some systems may use a combination of manual and automatic devices in the control cir
more automatic devices, it is classed as an automatic controller.
Consider, for example, a tank that must be kept filled with water between definite limits an
needed. If we equip the pump motor with a manual starter and station a person at the pu
have manual control. Now, let us replace the manual starter with a magnetic starter and
desk. If we ring a bell to let them know when the water is low and again when it is high, the
proper button when the bell rings. This would be semiautomatic control. Now, suppose we
circuit when the water reaches a predetermined low level and open it when it reaches a
water gets low, the float switch will close the circuit and start the motor. The motor will now
level, at which time the float will open the circuit and stop the motor.
Although the automatic system is more expensive to install, it requires less operator attenti
accurately.
Automatic control systems are found in many applications, such as large power plants, wh
mechanical systems in machine shops, where precision machines, such as drill presses and
better accuracy and efficiency, and in the home, where automatic control systems are u
machines as dishwashers and washing machines.

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Control Devices and Symbols

Understanding, troubleshooting, and repairing control systems requires a knowledge and u

that are used in control circuits and the symbols and terminology that are used to designa
Most symbols used have been standardized throughout the industry to assure uniformity. F
Standard Graphical Symbols for Electrical Diagrams. The chart shown in Figure 5 shows sta
circuits.

Figure 4: American National Standard Graphical Symbols for Ele

 Figure 5: Standard Wiring Diagram Symbols

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Primary Control and Pilot Control Devices

All components used in motor control circuits may be classed as either primary control de
control device is one that connects the load to the line, such as a motor starter, whether i
devices are those that control or modulate the primary control devices. Pilot devices are t
pressure switches, and thermostats.
An example (Figure 6) would be a magnetic contactor controlled by a toggle switch used
contactor, or M coil. To start the motor, the toggle switch is switched ON, which energizes
line contacts, which energizes the motor. Switching the toggle switch OFF de-energizes the
contacts, and de-energizes the motor.
 Figure 6: Basic Motor Control Circuit
In this example, the contactor, in that it connects the motor or load to the line, would be c
switch does not connect the load to the line, but is used to energize and de-energize the
classed as a pilot control device.
For any given controller, there are generally two primary control devices used. These are t
breaker (usually a manual device), and the magnetic contactor. There may be many pilo
combinations to control the function of starting and stopping performed by the primary co
instance, which are included in the motor starter, are actually pilot devices used to contro
is overloaded.
Pilot devices vary greatly with their function and intended use. From manual switches to a
are what make a motor controller adaptable to fit a multitude of applications.

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Contacts

Symbols 1 and 2 represent electrical contact devices (see Figure 7). They may represent lin
limit switch or relay, or any other type of control device that has electrical contacts. Reca
de-energized condition. Therefore, Symbol 1 is a normally open (NO) contact, and Symbo

Figure 7: Basic Symbols Used on Motor Control Circ

The designations "a" or "b" associated with a set of contacts are used to identify the state o
reference to the main operating device. An "a" contact will normally be closed when its a
contacts are closed. These same "a" contacts will open when the associated coil is de-ene
open when its associated coil is energized, thus operating the opposite of an "a" contact.
electrical drawings will indicate the state of contacts with this designator. If not, the drawin
circuit is in the energized or de-energized state. This "a" and "b" notation holds true for auxi
main contactor. Note that all circuits are shown in the de-energized, or shelf, condition un
Two other terms often used in conjunction with contacts, either relay contacts or switch co
contact goes closed, it is said to "make," and when the contact opens, it is said to "break."

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Pushbutton Switches
Symbols 3 and 4, shown in Figure 7, represent manually operated pushbutton switches with
contacts, respectively. This spring-returned type switch will return to its normal position whe
switch returns to its original position, and its contacts are only closed or open for the mome
these contacts are referred to as momentary.

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Toggle Switches

Symbols 5 and 6, shown in Figure 7, represent manual contacts of a toggle type of switch.
and Symbol 6 contacts are normally closed. This type of switch has maintaining contacts;
position, the switch will stay in that position. When found in a circuit diagram, the switch po
FAST or SLOW, or other appropriate labeling. Symbol 7 is a toggle switch of the single-pole
contact is normally open and the other normally closed.
When more than one set of contacts are operated by moving one handle or pushbutton,
lines, as in symbols 8 and 9. The dotted lines represent any form of mechanical linkage tha
together. One other method that is used frequently to show pushbuttons that have two se
11. Symbol 10 has two normally open contacts, and symbol 11 has one normally open and
Switches can be designed to operate in one of two ways. The first, and most common, is r
arrangement. In an arrangement of this type, one set of contacts opens before the next s

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The second arrangement is referred to as make-before-break. In this arrangement, when t
position to the next, shorting or bridging of the first and second set of contacts occurs, for
transfer. This arrangement is used when it is necessary to ensure continuity of power to a c

Indicating Lights

Symbol 12, shown in Figure 7, is a pilot or indicating light that is indicated chiefly by the sho
circle. Normally, the color of the light is designated by the appropriate letter in the circle, s

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Coils, Relays, and Contactors

Symbols 13 and 14 shown in Figure 7 represent a coil. It may be a relay coil or a main line c
electromagnetic devices in the sense that magnetic forces are produced when electric c
in response to such forces, contacts are closed or opened by the motion of plungers or piv
discussed later in this text.
As defined by the National Electrical Manufacturers Association (NEMA), a relay is "a devic
conditions of one electric circuit to effect the operation of other devices in the same or an
the other hand, is "a device for repeatedly establishing and interrupting an electric power
difference between the two, noting particularly that the relay, serving a secondary role, c
the contactor is the primary unit, doing its work in the main power circuit.
A drawing showing the basic construction of a relay is shown in Figure 8. Note the relay co
 Figure 8: Relay Construction
This relay has one set of NO (C1) and one set of NC (C2) contacts. The path for current flo
movable contacts to the common terminal. In the de-energized state, contacts C2 are cl
energized, the coil attracts the movable contacts to closed contacts C1 and open conta
Figure 9 shows a contactor assembly drawing. Note the solenoid assembly, moving armat
stationary contacts with terminal connections for line and load wiring. Also, note from the
encased to protect the contact assemblies.

Figure 9: Contactor Construction

Contactor assemblies are frequently made with main contacts that serve to connect and
auxiliary contacts (both normally open and normally closed) that operate with the main c
available for use in the control circuit of this or another machine.
Auxiliary contacts are frequently used to seal in a coil. "Sealing in" is when a parallel path f
energized after the original path of current flow is interrupted. Auxiliary contacts of the co
complete the parallel path for current, but this is not always the case. Figure 10 shows a sim
contactor to illustrate sealing in.

Figure 10: Simple Control Circuit Showing Seal-In Conta

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Magnetic Contactors

 
Magnetic contactors are electromagnetically operated devices that serve to provide a sa
disconnect circuits. The magnetic circuit of this type of contactor consists of a magnet ass
current flowing through the coil causes a magnetic flux to be set up in the iron the coil is p
alternating magnetic flux (if it is an AC contactor) produces heat, which is reduced by the
The magnet assembly is simply the stationary part of the contactor. The coil is supported b
assembly to induce magnetic flux in the iron when the coil is energized. Figure 11 shows th
coil, and armature.

Figure 11: Magnetic Contactor Assembly

The armature is the moving part of the magnetic circuit. When energized, the coil induces
attracts the armature, which moves toward it. When the armature has been attracted to
part of the magnetic circuit.
When the armature has sealed in, it is held tightly against the magnet assembly. Notice in
when the armature is in the sealed position. This is because, when the coil is de-energized,
magnet assembly. The air gap in the iron circuit prevents the residual magnetism from bein
held in its sealed-in position.

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Types of Magnetic Contactors

There are four basic types of electromagnetic contactors (Figure 12):

Clapper Type - It contains a hinged armature that pivots to seal in, thus closing the m
contacts.
Horizontal Action - The armature and the contacts move horizontally in a straight line
Vertical Action - The armature and contacts move in a straight vertical line.
Bell Crank - A bell crank converts the vertical movement of the armature into a horiz
reduced contact bounce result from lessened shock on armature pickup.
 Figure 12: Magnetic Contactors

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Inrush Current

When a magnetic controller is in its OPEN position, a large air gap exists between the arma
impedance of the coil is low, and thus, when the coil is energized due to the air gap, it wil
armature moves closer to the magnet assembly, the air gap gets smaller and smaller. The
seals into its CLOSED position. This inrush current is typically 6 to 10 times the sealed-in value
Magnet coils that are energized by AC voltage should never be connected in series. This i
ahead of the second, the increased impedance of the circuit will reduce the second coil
either not pick up or will pick up but not seal. AC magnetic coils should, therefore, be con

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Ratings

The ratings of magnetic coils are usually given in volt-amperes, or VA. An example would b
and 60 VA sealed-in current. The inrush current would then be 600/120 =5 amps.

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Voltage Variations

If the applied voltage to a magnetic contactor is too high, the coil will draw more than its
result, and this will cause early failure of the insulation of the coil. In addition, the magnetic
armature to close with excessive force. This, in turn, will result in a wearing of the contact fa
contact life.
When the applied voltage is too low, similar effects occur. There will be a low coil current a
pull. On some types, especially vertical action, this may result in a contactor that picks up
continuous draw of inrush current. It will quickly burn up. Another effect is chattering as the
armature.

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AC Hum
AC magnetic contactors have a certain hum associated with their operation. This noise is
magnetic pull due to the alternating flux in the magnet. This humming, and changing mag
vibrations.
Excessive chattering and loud humming can result when:

There is a broken shading coil. Shading coils are small copper turns placed near the
induced magnetic flux 90 degrees out-of-phase with the magnetic assembly itself. T
as the alternating current falls through zero 120 times-per-second.
The operating voltage drops too low.
There is misalignment between the armature and the magnet assembly, causing the

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Magnetic Blowout

Some larger magnetic contactors, especially older clapper models, have arc chutes insta
copper coils, or blowout coils. These are mounted above the main contacts and are in se
Blowout coils are installed for contacts opening under AC and DC loads. The electric arc i
process.
Contacts that are subject to frequent interruption of large currents suffer a destructive bur
extinguished. Magnetic blowout coils work on the principle of motor action; that is, the arc
magnetic field setup due to a current-carrying conductor. Since the blowout coil is in serie
strength of the magnetic field setup and the resultant extinguishing action will be in propo
Figure 13 shows a section of a magnetic blowout coil with an arc conducting between th
lengthening the arc. At first, the arc begins to deflect due to the blowout coil field. Next, a
magnetic field lengthens the arc, and it moves near the tip of the horns. Finally, the arc is s
unable to conduct.

Figure 13: Magnetic Blowout Coil

Figure 14: Lengthening the Arc

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Magnetic Coil Control Circuits

Although the power circuit can be single-phase or three-phase, the control circuit to the m
control circuit includes:

The magnet coil

The contacts of the overload relay assembly
Momentary or maintained contact pilot device such as a pushbutton, pressure, tem
signal
Relay contacts or timers taking the place of pilot devices
Auxiliary contact on the starter, designed as a holding circuit interlock; may be requ

Figure 15 shows a Size One starter control circuit.

Figure 15: Size One Starter Control Circuit

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Magnetic Coil Data

Published charts list identification numbers, ratings, and operating characteristics of magn
voltage and the coil volt-amperes for both inrush and sealed conditions. AC magnetic co
line voltages fluctuating as much as 15% below, and 10% above, nominal rating. DC coils
and 10% above, nominal rating.

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Holding Circuit Interlocks

The holding circuit interlock is a normally open (NO) auxiliary contact provided on standar
closes when the coil is energized to form a holding circuit for the starter after the START bu
typically mounted on the upper-left portion of magnetic contactors.
Auxiliary contacts are frequently used to seal in a coil. Sealing in creates a parallel path fo
after the original path of current flow is interrupted. Auxiliary contacts of the coil being sea
the parallel path for current, but this is not always the case. Figure 16 shows a simple contr
illustrate sealing in. The starting sequence for Figure 16 is shown below.
 Figure 16: Simple Control Circuit
Starting sequence is a series of events that occurs to energize a machine once the seque
either manual or automatic. When the START button is pushed, the M coil is energized, whi
the M coil energized when the START button is released. The M coil is now sealed in. The M
energizing the motor. The "M" designation used here is frequently used in control circuits to
controls the switching of line power to the device being controlled. Multifunction controlle
more specific designations such as F or R for forward and reverse.

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Interlocks

Control circuits frequently control more than one contactor, such as in a two-speed moto
controlling the direction (forward or reverse) on a motor. In many situations such as this, eq
contactors were closed at the same time.
Two methods are used to provide an interlock to prevent this from occurring. First is an ele
contactor is in series with the operating coil from the other contactor. Thus, if contactor A
would prevent energizing contactor B. The opposite would be true if contactor B was ene
The second method employed is a mechanical interlock. To accomplish this, the two cont
side in the control box. A mechanical linkage that prevents both contactors from being c
one contactor was closed and something occurred to energize the other contactor, the c
the contact assembly would be physically blocked.

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Overloads

Symbol 15, shown previously in Figure 7, represents the heating element of an overload rel
all motor controllers in one form or another. The current that a motor draws while running is
motor. An overload condition, whether caused by mechanical or electrical fault, will resul
Overload protection is achieved in almost all controllers by placing heating elements in se
motors. These heater elements activate electrical contacts, which open the coil circuit wh
used on manual starters or controllers, the heating elements release a mechanical trip to d
controllers use two overloads, while newer units are required to have three overloads in ac
Electrical Code.
The overload relay is sensitive to the percentage of overload; therefore, a small overload w
whereas a heavy overload will cause an almost instantaneous opening of the circuit. The
protection, however. It is quite possible that, under short-circuit conditions, the relay might
damage to the motor and other equipment.
Short-circuit protection is provided by installing either a fused disconnect or a circuit break
lines.
There are three types of overload relays in general use today. The first uses a low-melting-p
as shown in Figure 17.
 Figure 17: Melting-Pot Relay for a Thermal Overloa
When the metal is heated beyond the melting point, the ratchet releases, causing a set o
and open the main line contactor.
The second type of overload device, shown in Figure 18, uses a bimetallic element. The bi
metals bonded together. When heated, the metals expand at different rates, and the ele
releases a trip mechanism that opens contacts in the control circuit, and the main line co

Figure 18: Bimetallic Type of Thermal Overload

Figure 19 shows the third type of overload relay the magnetic type. A magnetic trip eleme
the circuit load. With normal current, the electromagnet is not affected. As load current in
opens a set of contacts in the control circuit, and the main line contactor trips open.

Figure 19: Magnetic Overload

Overload relays must be reset after each tripping, either automatically or manually. The a
except on equipment that is so designed. There can be no danger to life or equipment fro
overload relay has been tripped, it requires a little time to cool so that there is some delay
Factors that determine the overload relay thermal units or overload heaters are:
 Motor full-load current
Type of motor
Possible difference in ambient temperature between motor and controller

Motors with the same speed and horsepower do not necessarily have the same full-load c
full-load current and not to published charts. Charts tend to show averages of normal full-
specific motor may be different. Selection tables are usually based on continuous duty mo
operating under normal conditions.

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Ambient Compensation

Bimetallic overload relays that are ambient-compensated are designed for one particular
constant temperature and the controller is located somewhere else where the temperatu
used, it may not trip consistently at the same level or motor current if the temperature of th
surrounding temperature affects standard thermal overload relay.
To compensate for temperature variations that the controller may be subjected to, an am
should be selected. Its trip point is not affected by temperature, and so it will consistently t

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Rotary Switches

The last symbol in Figure 7, symbol 16, is a rotary selector switch. A rotary switch is a multico
in a full or partial circle. Instead of a pushbutton or toggle, the mechanism used to select t
and must be turned.
Rotary switches can be manual or automatic switches. An automobile distributor and the
rotary switches (Figure 20). Some rotary switches are made with several layers or levels. Thi
of several circuits with a single switch.

Figure 20: Rotary Snap Switch

Switches can be either automatic or manual. A manual switch is a switch that is turned on
common manual switches, such as the toggle, pushbutton, or rotary switches already cov
button, and a TV channel selector switch. Each of these requires operator action to initiate

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Automatic Switches

An automatic switch is a switch that is controlled by a mechanical or electrical device, th

switch on or off. Two examples of automatic switches are a thermostat and the distributor
turn a furnace or air conditioner on or off by responding to the temperature in a room. The
plug circuit at the proper time by responding to the mechanical rotation of a shaft. Even t
refrigerator when the door is opened is an automatic switch.
Automatic switches are not always as simple as the examples given above. Limit switches
level, mechanical movement, pressure, or an electrical quantity, are automatic switches t
Any switch that turns a circuit on or off without operator action is an automatic switch. Fig
automatic switches commonly used.
 Figure 21: Symbols of Various Automatic Switche

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Float Switches

Symbols 1 and 2 shown in Figure 22 represent normally open and normally closed liquid-lev
many forms in their physical or mechanical construction. They consist of one or more sets o
normally closed, operated by a mechanical linkage. Many float switch units, as well as oth
place of metallic contacts. The simplest mechanical arrangement for a float switch, show
having the contacts fastened to one end and a float suspended from the other end.

Figure 22: Float Switch

As the water level rises, it would lift the float, thus moving the contact end of the level dow
contact, depending on whether the stationary contact were mounted above or below th
action of the contacts were desirable, then one stationary contact could be mounted ab
arm. If the float were all the way up, it would make the lower set of contacts, and if the flo
the upper set of contacts.

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Pressure Switches

Symbols 3 and 4, shown in Figure 21, represent normally open and normally closed vacuum
motion is used to operate one or more sets of contacts. A typical pressure switch design u
element is shown in Figure 23. Two other common sensing elements used are the diaphrag
detector is determined by the system requirements. Most devices of this type have a mea
device.
 Figure 23: Pressure Switch, Bellows Type
Symbols 5 and 6 shown in Figure 21 represent temperature-activated switches, more comm
types of thermostats are available that employ different methods of sensing temperature.
bimetallic strips. As in the pressure switch, the mechanical motion of the sensing elements
typical thermostat is shown in Figure 24.

Figure 24: Thermostat, Bellows Type

Symbols 7 and 8 represent flow switches that are used to sense the flow of liquid, air, or oth
transform this flow or lack of flow into the opening or closing of a set of contacts.
One type of flow switch, shown in Figure 25, uses a pivoted arm that has contacts on one
end. The end with the paddle or flag is inserted into the pipe so that the flow of liquid or ga
close the contacts.
 Figure 25: Flow Switch, Paddle Type

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Timer

Symbols 9, 10, 11, and 12 shown in Figure 21 represent timer contacts that are normally op
and contact arrangement provides two important advantages of automatically controlle
events in a control system. Many types of timing relays are available that can be adjusted
fraction of a second to as much as several minutes. Moreover, extremely long time delays
timing relays that are motor-driven. Since most industrial control systems do not run throug
relays for such installations are generally non-cyclical. Thus, timers are used to separate ev
occurs instantaneously from those that are delayed. Instantaneous events are those that o
the only delay being the time it takes coils to operate or contacts to open or close. Delaye
of controlled delay provided by a pilot device.
Common designs are pneumatic, dashpot, and motor-controlled timers. Motor-controlled
that are repeatable, such as traffic signal controllers and sequentially operated, motor-sta
in many homes is used to control the wash cycles of automatic washing machines.
A dashpot timer, shown in Figure 26, consists of a plunger which, when the coil of the time
bath of oil and closes a contact at the end of its stroke. The dashpot is usually provided wi
that the contact is permitted to close with a snap action. Snap action allows quick-closing
closing cycle. In addition, a valve is included in its construction to allow the oil to flow free
energized. Many of these relays also have an adjustment that can be varied to change th

Figure 26: Time Delay Relay, Dashpot Type

Another popular timer is the pneumatic timer. It uses the restricted airflow across a diaphra
passes through an adjustable orifice so the time delay is adjustable.
The time delay of a timing relay can be applied when the relay is energized or when it is d
Figure 21, represent timer contacts that have timed closing after energization (TCAE) and
respectively. Symbols 11 and 12, also shown previously, represent timer contacts that have
(TOAD) and timed closing after de-energization (TCAD), respectively. Some timers may be
are delayed but with contacts that operate instantaneously.
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Limit Switches

Symbols 13, 14, 15, and 16, presented in Figure 21, represent direct-actuated limit switches
protruding from the switch that will be bumped or pushed by some piece of moving equip
used to operate a set of contacts. Limit switches vary widely in size and design. There are l
use, such as that shown in Figure 27 , and smaller, more accurate and precise units that us
very minute movements of the operating lever.

Figure 27: Limit Switch

Symbols 13 and 14 of Figure 21 show limit switches in their normally open or closed conditio
open limit switch, which is held closed; symbol 16 represents the opposite.

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Foot Switches

Symbols 17 and 18 of Figure 21 represent foot switches. Switches of this type are often used
or process cycle to be started at a time when the operators hands are both engaged in lo
operated switches are frequently employed for such purposes. Typical examples of foot sw
and sewing machines. Foot switches are actually limit switches enclosed in a convenient a
are available in a variety of contact arrangements such as single-pole double-throw, two-
arrangements to suit a specific need. Figure 28 shows a typical foot switch.

Figure 28: Industrial Foot Switch

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Control Circuits

Simple control circuits are sometimes referred to as ladder diagrams in that they are draw
simple control circuit and its components.
 Figure 29: Simple Control Circuit and Component
Wiring diagrams will not have wires jumping one another. Wires are shown as crossing eac
or dot, are not connected. Mechanical connections, such as those found on double-pole
interlocks, are shown as broken lines.
 

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Diagrams

Electrical circuits are generally shown by one of two types of diagrams: line diagrams and
includes all the components in the circuit and shows the physical relationships between th
information for actually wiring the circuit and allow a troubleshooter to physically trace the
look like an enormous maze of parallel and crossing lines that make it difficult, if not impos
understand the operation of the circuit.
Line diagrams simplify the circuit to a degree necessary to understand the operation of th
elementary diagrams, do not show the components in their actual physical locations. Con
and pushbuttons, are shown on horizontal lines between two vertical lines. The vertical line
connections of line diagrams are drawn such that both the function and sequence of ope

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Circuit Analysis

There are two basic types of control circuits: three-wire and two-wire. These designations s
circuit control, only three wires are required from the ordinary across the line motor starter
control, only two wires are required.

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Three-Wire Control

A three-wire circuit uses momentary contact START-STOP buttons and a holding circuit inte
push-button START switch, to keep the circuit energized after the push-button has been re
voltage protection. A low-voltage condition or loss of incoming power will cause the starte
wire LVP control circuit. When power is restored, the starter connected for three-wire cont
maintaining contact around the start switch is now open. To restart the motor after a pow
pressed. In this way, a deliberate action must be performed, ensuring a measure of safety
 Figure 30: Three-Wire LVP Control Circuit

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Two-Wire Control

A two-wire control circuit is, by its nature, a low-voltage release circuit. A reduction or loss
power returns or comes back up to nominal value, the motor will restart. This type of restar
personnel and machinery since power may return without warning. This type of circuit is sh

Figure 31: Two-Wire LVR Control Circuit

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Common Control

The coil circuit of a magnetic starter or contactor is distinct from the power circuit. The coi
phase power source and the controller would be operable, provided the coil voltage and
is connected.
When the control circuit is tied back to lines 1 and 2 of the starter, the voltage of the contr
circuit, and the term common control is used to describe this relationship. Other variations
through a control power transformer.

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Control Power Transformers

It is sometimes desirable to operate pushbuttons or other control circuit devices at some v

example, if the main service is 480 volts, this voltage may need to be reduced to 120 volts
side of the transformer secondary while the other side is grounded.
NEC Section 250 states the requirement for grounding the secondary of 120-volt control tra
120-volt, two-wire circuit must normally have one of its conductors grounded. Other system
although they have no bearing on this aspect of motor control centers. This specific requir
applied to control circuits derived from the secondary of a control transformer that supplie
starters, contactors, and relays. For example, there may be cases where a ground fault on
can cause a hazard to personnel by blowing the protective fuse or operating a circuit bre
industrial process in a sudden, unexpected way. This may result in excessive loss of produc
that is stopped abruptly. A sudden shutdown to a ground fault in the hot leg of a grounde
in this instance.
NEC 250.21(3) provides an exception to this rule. A 120-volt control circuit may be operate
following conditions are met:

The system is used exclusively for the control circuit.

The circuit is derived from a transformer that has a primary rating less than 1,000 volts
Whether in a commercial, institutional, or industrial facility, supervision will ensure tha
will maintain and serve the control circuits.
Continuity of control power is required.
Ground detectors are installed on the control system.

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Hand-Off-Auto Controls

When it is desired to select the function of a motor controller either manually or automatic
Figure 32 shows a typical control circuit with a standard duty, three-position selector switch

Figure 32: Typical Control Circuit

When the switch is turned to the HAND position, the M coil is energized continuously and th
the motor will run whenever the contact in line with the M coil is closed. A timing relay, floa
device can control this contact.
Figure 33 shows a three-position, double-break selector switch. This is used for manual or a
as the previous circuit.

Figure 33: Three-Position Double-Break Selector Swit

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Interlocking Methods for Reversing Control

Simply interchanging any two of the three incoming leads can reverse a three-phase mot
reversing starters reverse the motor direction, as shown in Figure 34.
 Figure 34: Reversing Starter
Reversing starters in conformity with NEMA standards interchange lines L1 and L3 or phase
are needed, one for the forward direction and one for the reverse direction (Figure 35).

Figure 35: Reversing Contactor Line Connections

Interlocking is used to prevent both contactors from being energized simultaneously or clo
short circuit. Three basic methods of interlocking are:

Mechanical interlocking
Pushbutton interlocking
Auxiliary contact interlocking

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Mechanical Interlocking

Mechanical interlocks are assembled at the factory and are physically located between
interlock locks one contactor out at the beginning of the stroke of either contactor to prev
A broken or dotted line indicates a mechanical interlock. Often, the dotted line will be bro
solid bar at the middle junction.

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Pushbutton Interlocks

This method is an electrical method of preventing both starter coils from energizing togeth
pushbutton interlocking.
 Figure 36: Pushbutton Interlocking
When the forward pushbutton is pressed, the F coil is energized, and the normally open F a
circuit to operate the motor in the forward direction. Pressing the reverse pushbutton auto
F coil, dropping the forward coil out and energizing the reverse (R) coil.
Reversing the direction of motor rotation on a repeated basis is not recommended, since
overheat and disconnect the motor from the circuit. NEMA specifications require a starter
size starter whenever it is going to be used for plugging or reversing at a rate of more than

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Auxiliary Contact Interlocking

This method is also an electrical interlock. It consists of normally closed auxiliary contacts o
shown in Figure 37.

Figure 37: Electrical Interlocking

In the forward direction, the normally closed contact (F) on the forward contactor opens
being energized.

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Sequence Control

A method by which starters are connected so that one cannot be started until another is
is required whenever auxiliary equipment associated with a machine, such as a priming p
to prevent damage to the main machine. Figure 38 shows a standard starter wired for seq
 Figure 38: Sequence Control
The control circuit of the M2 coil is wired through the maintaining contacts of the M 1 coil.
prevented from starting until after the M 1 coil is energized.
Many motors can be started automatically with one START-STOP button, as shown in Figure

Figure 39: Automatic Sequence Control

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Motor Control Center Power Supplies

The power supplies to motor control centers are usually circuit breakers located in switchg
conventions of single-line diagrams for both switchgear and motor control centers is nece
conception of the motor control center as a unit. Standard symbology was discussed in a
standard electrical symbols and conventions.
 Figure 40: Standard Electrical Symbols and Convent
The Rotating Apparatus column of Figure 40 shows one-line elementary and plan symbols
inside the circle indicates horsepower, and the number at the lower right of the circle indic
number indicates 1,800 RPM.
Under the Switching and Protective Apparatus column of Figure 40, notice the numbers lo
An example is:

The top number, in this instance, indicates the trip rating of the breaker, and the lower num
true in all one-line diagrams. Many times, these two numbers will be interchanged, and the
whereas the bottom number indicates the trip rating of the breaker.
This annotation denotes that the trip rating is adjustable. Many modern breakers have this
adjustable setting on the breaker faceplate or a rating plug that is inserted into a special s
shipped separately from the breakers and must be checked upon installation to ensure th
specifications and prints.
The static trip devices shown on the motor starters rated above 600 volts, as well as some c
abbreviation ST. These are micro-logic (digital) units that are adjustable over a wide range
ground fault pickup, ground fault delay, instantaneous overcurrent, long time delay, long
phase failure, and others.
Figure 41 shows other apparatus and devices associated with motor control centers, cond
connection location symbols, and PLC input/output symbols.
Figure 43 is a one-line diagram of a 480-volt substation powering many motor control cent
substation is a main-tie-main bus scheme. This means there are two main breakers and a t
box above the tie breaker and in the circle beside the main breakers indicates that these
with a key system. The dashed lines connect both mains and the tie. This indicates that on
time. Other significant items to be seen:

Transformer ratings and connections

Breaker ratings and accessories
Current transformer ratios
Motor control center drawing numbers
 Figure 41: Standard Symbology

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MCC Single-Line Diagrams

Figure 42 and Figure 43 are one-line diagrams of 480-volt, three-phase motor control cente
symbols on these diagrams, as well as all abbreviations.
The upper left portions of both prints show the incoming power supply. MCC 3 is powered
motor control centers in-breaker is a 1,600-amp frame, 1,200-amp trip circuit breaker. An a
voltage and current drawn by the motor control center. Current transformer and potentia
as the number of each one required.
Each starter is labeled by size. MCC 3 indicates this with "Size 5," for example, written next t
number beside the starter.
The number and letter combinations shown at the lower edge of the dotted lines indicate
located in the motor control center. For example, 2D indicates that this starter is in section
regard to this labeling, so refer to the drawing that pictorially shows the motor control cen
 Figure 42: Three-Phase, 480V One-Line Diagram

Figure 43: Three-Phase, 480V One-Line Diagram

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Elementary Diagram Analysis

Refer to Figure 44, an elementary diagram, for several starters located in motor control ce
absence of a start switch. Instead of a start switch, an input from a programmable logic c
circuit. This symbol, for motor number 301M1, is at coordinate 08E. Coordinate numbers are
and the letters run horizontally across the top of the page. Notice how some devices listed
a reference number. For example, for motor number 301M1, the M coil is described as a c
11, and SP. These numbers indicate which lines (vertical numbers) have contacts or electr
spare.
The PLC input at coordinate 08E has the number 0:072/01 above it.
0 indicates a PLC output
072 indicates the PLC rack and slot
01 indicates the point
PLC input signals, such as those shown at coordinates 11J and 12J, have a similar address

Figure 44: PLC Elementary Diagram

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Standard Device Numbers

To simplify electrical diagrams, many switchgear devices are not labeled with reference to
commonly used instead of standard abbreviations. These standard numbers, like abbrevia
uncluttered drawing by minimizing the amount of writing.
The following is a list of standard numbers for labeling switchgear devices. This list can be u
numbers is not necessary. Numbers commonly used will become as familiar to you as com
Standard numbers for switchgear devices:
1. Master element 49. Thermal relay

2. Time-delay closing relay 50. Instantaneous overcurrent relay

3. Interlocking relay 51. AC time overcurrent relay

4. Master contactor 52. AC circuit breaker

5. Stopping device 53. Exciter or DC-generator relay

6. Starting circuit breaker 54. High-speed DC circuit breaker

7. Anode circuit breaker 55. Power factor relay

8. Control power disconnect device 56. Field application relay

9. Reversing device 57. Short-circuiting or grounding device

10. Unit sequence switch 58. Rectifier failure relay

11. Reserved for future application 59. Overvoltage relay

12. Overspeed device 60. Voltage balance relay

13. Synchronous-speed device 61. Current balance relay

14. Underspeed device 62. Time-delay relay

15. Speed/frequency matching device 63. Pressure switch

16. Reserved for future application 64. Ground-protective relay

17. Shunting or discharge switch 65. Governor

18. Accelerating or decelerating device 66. Jogging device

19. Starting-to-running transition device 67. AC directional overcurrent delay

20. Electrically operated valve 68. Blocking relay

21. Distance relay 69. Permissive-control device

22. Equalizer circuit breaker 70. Electrically operated rheostat

23. Temperature-control device 71. Level switch

24. Reserved for future application 72. DC circuit breaker

25. Synchronizing check device 73. Load-resistor contactor

26. Apparatus thermal device 74. Alarm relay

27. Undervoltage relay 75. Position-changing mechanism

28. Flame detector 76. DC overcurrent relay

29. Isolating contactor 77. Pulse transmitter

30. Annunciator relay 78. Phase-angle relay

31. Separate excitation device 79. AC reclosing relay

32. Directional power relay 80. Flow switch

33. Position switch 81. Frequency relay

34. Sequence device 82. DC reclosing relay

35. Brush operating device 83. Automatic transfer relay

36. Polarity device 84. Operating mechanism

37. Undercurrent/underpower device 85. Carrier receiver relay

38. Bearing protective device 86. Lockout relay

39. Mechanical condition monitor 87. Differential relay

40. Field relay 88. Auxiliary motor

41. Field circuit breaker 89. Line switch

42. Running circuit breaker 90. Regulating device

43. Manual transfer device 91. Voltage directional relay

44. Unit sequence starting relay 92. Voltage/power directional relay

45. Atmospheric condition monitor 93. Field changing contactor

46. Reverse-phase relay 94. Tripping relay

47. Phase sequence voltage relay 95 to 99 Used for specific applications

48. Incomplete sequence relay

The following gives a brief description of the function of each of the switchgear devices in
Device
Function and Description
Number

Master Element - Initiating device (control switch, voltage relay, float switch, etc
1
operation; done either directly or through a permissive device, such as a protec

Time-Delay Starting (or Closing) Relay - Device that provides a given amount of
2 in a switching sequence or protective relay system; true except as specifically p
later

Checking (or Interlocking) Relay - Relay that operates in response to the position
3 predetermined conditions in equipment; allows an operating sequence to conti
check of the position of the devices or the predetermined conditions for any pu

Master Contractor - Device that makes or breaks the necessary control circuits t
4 when the required conditions exist; generally controlled by a master element (de
protective devices

5 Stopping Device - Device in which the primary function is to place and hold equ

6 Starting Circuit Breaker - Device in which the primary function is to connect a ma

Anode Circuit Breaker - Device that is used in the anode circuits of a power rect
7
arc-back occurs

Control Power Disconnecting Device - Device (knife switch, circuit breaker, or pu

8 or disconnect the control power to and from the control bus or equipment; cont
supplies small motors and heaters

9 Reversing Device - Device that is used to reverse a machines field or to perform

Unit Sequence Switch - Switch that changes the sequence in which units may be
10
unit system

11 Reserved for future application

12 Overspeed Device - Direct-connected speed switch that functions when a mac

13 Synchronous-Speed Device - Device (centrifugal-speed switch, slip frequency re
any other type of device) that operates at approximately the synchronous spee

14 Underspeed Device - Device that functions when the speed of a machine falls b

Speed/Frequency Matching Device - Device that matches and holds the speed
15
equal (approximately equal) to that of another machine, source, or system

16 Reserved for future application

Shunting (Discharged) Switch - Switch that opens or closes a shunting circuit aro
resistor) such as a machine field, a machine armature, a capacitor, or a reactor
17
shunting operations that are necessary when a machine is started by Devices 6
load resistor, also excluded

18 Accelerating (Decelerating) Device - Device that closes circuits used to increase

Starting-to-Running Transition Contactor - Device that causes the automatic tran

19
the running power connection

Electrically Operated Valve - Motor-operated valve that is used in vacuum, air, g

20 valve may be indicated by insertion of a descriptive word, such as Brake, in the
brake valve)

Distance Relay - Relay that functions when the circuit impedance or reactance
21
predetermined limits

Equalizer Circuit Breaker - Breaker that controls the equalizer or current-balancin

22
regulating equipment in a multi-unit system

Temperature-Control Device - Device that raises or lowers the temperature of a

medium) when its temperature falls below or rises above a predetermined value
23
on a space heater in a switchgear assembly when the temperature falls below t
a device that provides automatic temperature regulation between close limits (

24 Reserved for future application

Synchronizing (Synchronism-Check) Device - Device that permits or causes the p

25
are within the desired limits of frequency, phase angle, and voltage

Apparatus Thermal Device - Device that functions when the temperature of the
26 shifting resistor, a liquid, or any other medium exceeds a predetermined limit; als
protected apparatus, such as a power rectifier, decreases below a predetermin

27 Undervoltage Relay - Relay that functions on a given value of undervoltage

Flame Detector - Device that monitors the presence of the pilot or main flame in
28
steam boiler

Isolating Contactor - Contactor that is used expressly to disconnect one circuit fr

29
operations, maintenance, or tests

Annunciator Relay - Non-automatically reset device that gives a number of visua

30
protective device; may also be arranged to perform a lockout function

Separate Excitation Device - Device that connects a circuit, such as the shunt fie
31 source of separate excitation during the starting sequence; also energizes the ex
rectifier

Directional Power Relay - Device that functions on a desired value of power flow
32
power resulting from arc back in the anode or cathode circuits of a power rectif

Position Switch - Switch that makes or breaks contact when the main device or p
33
function number, reaches a given position
34 Motor-Operated Sequence Switch - Multi-contact switch that fixes the operating
starting, stopping, or other sequential switching operations

Brush-Operating (Slip-Ring Short-Circuiting) Device - Device that raises, lowers, or

35
machine or that short-circuits its slip-rings; also engages or disengages the conta

36 Polarity Device - Device that operates or permits the operation of another devic

Undercurrent (Underpower) Relay - Relay that functions when the current, or pow
37
predetermined value

Bearing Protective Device - Device that functions on excessive bearing tempera

38
conditions, such as undue wear, which may eventually result in excessive bearin

Mechanical Condition Monitor - Device that functions upon the occurrence of a

39 (except that associated with bearings as covered under Device 38); examples o
vibration, eccentricity, expansion, shock, tilting, or seal failure

Field Relay - Relay that functions on a given low value, or failure, of machine fiel
40
value of the reactive component of armature current in an AC machine, which

41 Field Circuit Breaker - Device that applies or removes the field excitation of a ma

Running Circuit Breaker - Device that connects a machine to its source of runnin
42
brought up to the desired speed on the starting connection (motor starter)

Manual Transfer (Selector) Device - Manually operated device that transfers the
43
operation of the switching equipment or of some of the devices

Unit Sequence Starting Relay - Relay that functions to start the next available un
44
the non-availability of the normally preceding unit

Atmospheric Condition Monitor - Device that functions upon the occurrence of

45
as fumes, explosive mixtures, smoke, and fire

Reverse-Phase (Phase-Balance) Current Relay - Relay that functions when the po

46
sequenced, unbalanced, or contain negative phase sequence components ab

Phase-Sequence Voltage Relay - Relay that functions on a predetermined value

47
phase sequence

Incomplete Sequence Relay - Relay that returns the equipment to the normal, o
48
the normal starting, operating, or stopping sequences are not properly complete

Machine (Transformer) Thermal Relay - Relay that functions when the temperatu
49 carrying winding (element), a power rectifier, or a power transformer (including
predetermined value

Instantaneous Overcurrent Rate-of-Rise Relay - Relay that functions instantaneou

50
on an excessive rate of current rise; used to indicate a fault in the apparatus or c

AC Time Overcurrent Relay - Relay with either a definite or inverse time characte
51
an AC circuit exceeds a predetermined value

AC Circuit Breaker - Device that closes or interrupts an AC power circuit under n

52
circuit under fault or emergency conditions

Exciter (DC Generator) Relay - Relay that forces the DC machine's field excitatio
53
functions when the machines voltage has built up to a given value

High-Speed DC Circuit Breaker - Circuit breaker that functions to reduce the cur
54
less; functions after the occurrence of a DC overcurrent or excessive rate-of-curr

Power Factor Relay - Relay that operates when the power factor in an AC circui
55
predetermined value
 Field Application Relay - Relay that automatically controls the application of fiel
56
predetermined point in the slip cycle

Short-Circuiting (Grounding) Device - Power, or stored energy, device that short-

57
to automatic or manual means

58 Power Rectifier Misfire Relay - Relay that functions if one or more of the power re

59 Overvoltage Relay - Relay that functions on a given value of overvoltage

60 Voltage Balance Relay - Relay that operates on a given difference in voltage be

61 Current Balance Relay - Relay that operates on a given difference in the current

Time-Delay Stopping (Opening) Relay - Time-delay relay that serves in conjunctio

62
shutdown, stopping, or opening operation in an automatic sequence

Liquid or Gas Pressure, Level, or Flow Relay - Relay that operates on given values
63
level, or on a given rate-of-change of these values; normally an auxiliary relay; s

Ground Protective Relay - Relay that functions on the failure of the insulation of a
apparatus to ground; also functions on a flashover to ground in a DC machine;
64 current flow from the frame of a machine (enclosing case or the structure of an
grounds on normally ungrounded windings or circuits; not applied to a device c
neutral of a current transformer, or current transformers connected in the power

65 Governor - Equipment that controls the gate or valve opening of a prime mover

Notching (Jogging) Device - Device in which the function is to allow only a spec
device or equipment, or a specified number of successive operations within a g
66
that functions to energize a circuit periodically or that is used to permit intermitte
at low speed for mechanical positioning

AC Directional Overcurrent Relay - Relay that functions on a desired value of AC

67
direction

Blocking Relay - Relay that initiates a pilot signal for blocking a trip on external fa
68 apparatus, under predetermined conditions; also cooperates with other devices
step condition

Permissive Control Device - Generally, a two-position, manually operated switch

69 breaker, or the placing of an equipment into operation, in one position, and pre
equipment from being operated in the other position

Electrically Operated Rheostat - Rheostat that is used to vary the resistance of a

70
electrical control

71 Level Switch - Switch that operates on given values or on a given rate-of-change

DC Circuit Breaker - Circuit breaker that closes or interrupts a DC circuit under no

72
circuit under fault or emergency conditions

Load Resistor Contactor - Contactor that is used to shunt or to insert a step of loa
73 resistance in a power circuit; also used to switch a space heater in a circuit and
load resistor of a power rectifier or other machine into or out of a circuit

Alarm Relay - Relay, other than an annunciator (Device 30), that is used to opera
74
visual or audible alarm

Position-Changing Mechanism - Mechanism that is used to move a removable c

75
connected, disconnected, and test positions

76 DC Overcurrent Relay - Relay that functions when the current in a DC circuit exc
77 Pulse Transmitter - Generates and transmits pulses over a telemetering or pilot-wi
receiving device

Phase Angle Measuring (Out-Of-Step Protective Relay) - Relay that functions at a

78
two voltages, two currents, or a voltage and current

79 AC Reclosing Relay - Relay that controls the automatic reclosing and locking ou

80 Flow Switch - Switch that operates on a given value or on a given rate-of-chang

Frequency Relay - Relay that functions on a predetermined value of frequency

81
frequency) or rate-of-change of frequency

DC Reclosing Relay - Relay that controls the closing and reclosing of a DC circui
82
load circuit conditions

Automatic Selective Control (Transfer) Relay - Relay that operates to automatica

83
conditions in an equipment; can also perform automatic transfer operations

Operating Mechanism - Complete electrical mechanism (or servomechanism), i

84
position switches, etc., for a tap changer or any piece of apparatus that has no

Carrier (Pilot Wired Receiver) Relay - Relay that is operated or restrained by a sig
85
current or DC pilot-wire, fault-directional relaying

Lock-Out Relay - Electrically operated (hand or electrically reset) device that fun
86
equipment out-of-service on the occurrence of an abnormal condition

Differential Protective Relay - Protective relay that functions on a percentage, a

87
difference between two currents or some other electrical quantities

Auxiliary Motor (Motor Generator) - Motor used to operate auxiliary equipment s

88
magnetic amplifiers, etc.

Line Switch - Switch used as a disconnecting or isolating switch in an AC or DC p

89
electrically operated or has electrical accessories, such as an auxiliary switch, a

Regulating Device - Device that controls a quantity (or quantities) such as voltag
90
temperature, and load at a given value or between certain limits for machines,

Voltage Directional Relay - Relay that operates when the voltage across an ope
91
given value in a given direction

Voltage and Power Directional Relay - Relay that permits or causes the connect
92 difference between them exceeds a given value in a predetermined direction a
disconnected from each other when the power flowing between them exceeds

Field-Changing Contactor - Contactor that functions to increase or decrease, in

93
on a machine

Tripping(Trip Free) Relay - Relay that functions to trip a circuit breaker, a contact
94 tripping by other device; may also prevent the immediate reclosing of a circuit i
even though its closing circuit is maintained closed

Used only for specific applications on individual installations where none of the a
95 to 99
are suitable

When the standard numbers are used on an electrical diagram, they are sometimes prec
number or letter. This is used for more precise identification. For example, there may be dif
buses. The designation of a differential relay is 87. However, if this number is used for both b
buses are the 6,900-volt bus and the 4,160-volt bus, the 6,900-volt bus relay could be 687, a

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Developing a Control Circuit

Having been introduced to the common component parts of a control circuit, the learner
development of a control circuit. Control circuits are usually developed in one of two way

First, in an existing installation, changes are frequently made to improve the control f
operation easier for the operator or to improve the system to prevent equipment da
burning up a pump.
The second method of circuit development is when a customer fully understands the
designed to meet those requirements.

In the following example, we will improve upon an installed circuit in a step-by-step manne
performed at different times. This controller is being used to start and stop a motor, but be
to perform the function of any electrical device, such as turning on and off lights, opening
energizing and de-energizing a heater.
The basic circuit, shown in Figure 45, controls a pump that pumps water from a storage ta

Figure 45: Pump Control Circuit

Figure 46 shows the physical arrangement of the pump and the two tanks, along with the
circuit stands, it is a manual operation requiring that the START button be pushed wheneve
The pump is allowed to run until the tank is observed to be full. The operator then pushes th
stopping the flow of water into the pressure tank.

Figure 46: Water System Configuration

The owner decides that a float switch should be installed in the pressure tank near the top
START button, thus energizing the pump and starting water to flow into the tank. When the
switch 1(FS1), its contacts will be opened, stopping the pump and the flow of water. The fu
switch is that of STOP. Therefore, it must be a normally closed contact and must be conne
button, as shown in Figure 47.

Figure 47: Pump Control Circuit - Phase 1

After operating with this control for some time, the owner decides that it would be more c
automatically as well as stopped automatically. They installed another float switch to main
section of the control circuit requires that the pump be started whenever the water reach
function desired is that of START. The float switch (FS2) must have a set of normally open co
drops to the lowest desired level. These contacts must be connected in parallel with the o
function of start for the motor, as shown in Figure 48.

Figure 48: Pump Control Circuit - Phase 2

After some time of operation, it is discovered that, occasionally, the storage tank drops so
pick up water. This requires a control to prevent the pump from starting whenever the stor
the pump if it is running and the water reaches this low level in the storage tank. The new c
for the pump.
This function can be obtained by the installation of a float switch to sense the extreme low
float switch (FS3) was installed and adjusted to open a set of contacts whenever the wate
low level. Because the control function to be performed is that of STOP, float switch 3 must
will be opened whenever the water level drops to the set level of the float switch. It is, ther
components, as shown in Figure 49.

Figure 49: Pump Control Circuit - Phase 3

Later, it is decided that the pressure placed on the line by the pressure tank when it is full is
The owner requests the installation of the necessary components and controls to maintain
the proper amount of air to the top of the tank. In order for the proper balance of water le
all times, air must be let into the tank only when the water level is at its highest position and
discharge pressure of the tank.
To achieve this, we will install a solenoid valve in the air supply line that will allow air to flow
solenoid valve is energized. Now, we can install a pressure switch in the top of the tank tha
times. This pressure switch will perform the function of START for the solenoid valve. When th
the pressure switch, its contacts must close and complete the circuit to the solenoid. If the
pressure drops, we do not want the solenoid valve to open; therefore, we require the func
prevent air being put into the tank when it is not desired.
If float switch (FS1) is of the double-pole variety, having one normally-open and one norm
into the circuit, as shown in Figure 50.

Figure 50: Pump Control Circuit - Phase 4

The circuit for the solenoid valve is a two-wire control requiring that both FS1 and pressure
be placed into the tank by the energizing of the solenoid valve. When the water level rea
normally closed contact in the pump circuit will open, and the normally open contacts in
pressure is low, the contacts of PS1 will be closed until the pressure increases to normal and
the circuit as specified.
The circuit in Figure 49 gives a degree of hand operation because the pushbuttons were le
have either a definite automatic operation or hand operation as desired by the operator.
and automatic operation are shown in Figure 51.

Figure 51: Pump Control Circuit - Final Arrangeme

The starting sequence for Figure 51 above would be as follows:
 1. Place the controller switch in AUTO.
2. When the following conditions are met, the M coil will be energized:

Storage tank level high enough (FS3 shut)

Pressure tank level not too high (FS1 shut)
Pressure tank level low enough (FS2 shut)
M coil energizes, and the main contacts shut to energize the motor and start pumpi
M coil auxiliary contacts M1 and M2 shut
M1 has no affect on the automatic control circuit
M2 bypasses FS2
As pressure tank fills, FS2 will open, but pump continues to run due to M2
When pressure tank is full, FS1 will open, M coil de-energizes, and motor will stop
If control switch remains in AUTO, entire cycle will be repeated when the water leve
and FS2 to shut

If the learner had been charged with the responsibility of developing the final circuit of Fig
certain specifications or requirements as to the proper functions or operation of the comp

Have hand-off-automatic control selection

That the pump be controlled so as to maintain the water level in the pressure tank b
That the pump be prevented from running whenever the water level in the storage t
That the pressure on the pressure tank be maintained by adding air to the tank whe

To develop this circuit properly from this set of specifications, the procedure would be the
assume that the circuit was built up a little at a time by going back and adding control co

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