Basic Controls: Industrial Controls Training System
Basic Controls: Industrial Controls Training System
Basic Controls: Industrial Controls Training System
Basic Controls
1-800-Lab-Volt
www.labvolt.com
39163-00
|30391630000006~
Student Manual
Industrial Controls Training System
Basic Controls
Student Manual
39163-00
A
First Edition
Published October 2013
Information in this document is subject to change without notice and does not represent a
commitment on the part of Lab-Volt. The Lab-Volt® materials described in this document are
furnished under a license agreement or a nondisclosure agreement.
All other trademarks are the property of their respective owners. Other trademarks and trade
names may be used in this document to refer to either the entity claiming the marks and
names or their products. Lab-Volt disclaims any proprietary interest in trademarks and trade
names other than its own.
Safety and Common Symbols
III
Safety and Common Symbols
IV
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
V
Table of Contents
Bibliography
VI
Preface
Control systems for electric motors are vital to the proper performance and protection
of modern equipment. They are essentially the link in every complex industrial
process. These systems may range from the simple starting and stopping of an
electric motor to directing energy flow in a completely automated factory. Between
these extremes, we find semiautomatic controllers in which a human operator must
fill some of the required functions.
The Industrial Controls Training System, Model 8036, and the related modules and
manuals, provide a thorough understanding of the theory and operation of electric
motor controllers. Many genuine industrial components are included in the system
to familiarize the student with the way they actually operate and special emphasis
is put on safety.
Training starts with the basic fundamentals, and proceeds step by step, through
various types of controls encountered in industry. The student manual explains what
kinds of controls are available, how they operate, where they are used, and why they
are used in a particular application.
The multiplicity of modules makes it possible to implement setups that fit a large
number of needs. Control equipment and components are panel mounted with
hidden fault insertion switches in each module to develop the troubleshooting skills
of the students.
This program is fully compatible with existing modular components from Lab-Volt.
VII
VIII
About This Manual
The exercises in this manual, Basic Controls, provide a foundation for further study
in the industrial control branch of knowledge. Additional material is supplied in the
following volumes of this series.
C Unit 1 provides basic safety procedures and presents most modules that will
be used in this manual;
C Unit 2 gives an overview of the data that can be found on industrial control
devices. This Unit also introduces graphical tools used to represent
industrial control circuits;
C Unit 3 presents basic motor starters and control circuits;
C Unit 4 is dedicated to jogging and braking features of a control circuit;
C Unit 5 shows methods of starting a motor smoothly;
C Unit 6 introduces time relays.
Each unit contains exercises which provide a systematic and realistic means of
learning the subject matter. Every exercise is divided into the following sections:
A ten-question test at the end of each unit allows the student’s knowledge of the unit
material to be assessed.
Safety Considerations
Make sure that you are wearing appropriate protective equipment before performing
any of the exercises in this manual. Remember that you should never perform an
exercise if you have any reason to think that a manipulation could be dangerous to
you or your teammates.
Component Specifications
IX
X
1
UNIT OBJECTIVE
Upon completion of this unit, you will be able to identify and demonstrate the utility
of different types of motor control and current protection devices. You will also be
able to understand the operation of a lockout/tagout procedure.
DISCUSSION OF FUNDAMENTALS
Motor control is a broad term that can apply to anything from a simple toggle switch
to a complex system with components such as relays, contactors, and
programmable logic controllers (PLCs). The common function of all these controls
is to command the operation of an electric motor.
A complete motor circuit is usually divided into control and power sections. The
power circuit includes the motor and therefore, operates under higher voltage. On
the other hand, the control part mostly contains switching devices and typically
operates under lower voltage.
Control description
Contactors and control relays are devices that use electromagnetic induction to
open and close contacts. Contactors are often part of the motor starter, since they
are power switching devices. Control relays are rather used as control switching
devices, because they are designed to withstand lower electrical currents.
Circuit breakers and fuses protect the motor from very high currents. Overload
protection devices are safeguards against prolonged, relatively high current levels.
The particular application of each motor and control installation must be considered
when determining the protective devices required.
Safety procedures
Most domestic electrical systems are single phase, which means that there is only
one live line per power outlet, along with a neutral wire and a ground wire.
Figure 1-1 shows the evolution of the three phases in time. With the help of this
graph, it is possible to find the relationship between line–neutral and line–line
voltages.
Say, for instance, that we want to know the voltage between line 1 and line 2. We
can subtract, for each time value, the L2–N value from the L1–N value to determine
the desired line–line voltage (VL1–N - VL2–N = VL1–L2). We observe that the amplitude
of the obtained voltage VL1–L2 is /3 times that of the VL1–N, VL2–N, or VL3–N voltages.
The same principle applies to VL2–L3 and VL3–L1 voltages.
Note also, from Figure 1-1, that there is a 120-degree phase shift between each
phase voltage. This is a very important feature, since electric motors using all three
phases can easily produce a rotating magnetic field, hence greatly simplifying the
machine design. Moreover, inverting two of the three phases has the effect of
reversing the same rotating field, thus making the motor turn in the opposite
direction.
LOCKOUT/TAGOUT PROCEDURE
EXERCISE OBJECTIVE
DISCUSSION
Many pieces of machinery are potentially hazardous because of their purpose, the
way they are built, or their location. Take, for example, a debarking machine (see
Figure 1-2). It is equipped with several moving, sharp, and heavy parts. Servicing
this type of equipment requires a number of safety precautions, because its
accidental activation may very likely be disastrous.
Prior to any operation on a machine or equipment, tasks that may expose workers
to inadvertent release of hazardous energy must have been identified and proper
training provided to the personnel. Sources of hazardous energy may be electrical,
but also mechanical, hydraulic, pneumatic, chemical, thermal, gravitational, or
others.
C Isolate and block all forms of hazardous energy, using locks and/or tags. In
general, lockout devices should be preferred to tags. If more than one person
is assigned to a task, all workers must use a personal and identifiable lock
and/or tag at each energy-isolating device. A group lockout/tagout is also
possible, provided that all workers are properly protected. The last hole of a
hasp is usually reserved to accommodate an additional hasp.
C Verify that no one is near the machine or equipment and test if it is possible
to start the equipment.
C Check that the machine or equipment is ready to operate, that the area is clear
and secure, and that guards are positioned correctly.
C Each worker must remove his own locks and tags. The machine or equipment
must not be energized as long as a lock has not been removed by its owner.
Procedure Summary
In the first part of this exercise, you will connect the Lockout Module to the AC Power
Supply module and verify that the output voltages are as stated in the theory of
Unit 1.
You will carry out a lockout/tagout procedure before connecting a first electrical
circuit. To help you with the setup, both a schematic diagram and an
interconnection diagram will be provided.
In the circuit, a control transformer is connected through fuses between lines 1 and 2
of the Lockout Module module. This transformer provides control voltage that
enables powering a pilot light without damage. An emergency button is located
between the transformer and the pilot light, to allow you to turn off the light. Fuses
inside the Fuse Holder module are deliberately blown, to make you practice fuse
replacement.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Line–neutral voltage
Turn on the AC Power Supply by setting the individual power switch to the
I position.
Note: Make sure that the main switch lever is set to the
up position.
E L1–N =
Line–line voltage
E L2–L3 =
Lockout/Tagout procedure
Fuse replacement
Note: When using the Fuse Holder, indicate the rating of the
fuses on the module faceplate. Note the rating on three blank
magnetic labels and install them above the fuse terminals. The
rating of the fuses supplied with the training system is as follows
(1.5 A for 220 and 240 V versions, and 3 A for 120 V version):
1.5 or 3 A TIME
CLASS CC
600 V ac DELAY
G 7. Make sure that the push button of the Emergency Button module is
released.
After the Lockout Module is turned on, does the L1 pilot light turn on?
G Yes G No
Remove the fuses from the Fuse Holder module and check them with an
ohmmeter. Are the fuses blown?
G Yes G No
Turn on the Lockout Module. Does the L1 pilot light turn on?
G Yes G No
G 10. Describe what happens when you press the Emergency Button, and then
reset it.
G 11. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
REVIEW QUESTIONS
2. What do you have to do if there is only one hole left in the hasp of the equipment
you are going to service, and more workers are going to work on that same
equipment?
a. Install another hasp in this last hole, in which you install your padlock and
tag
b. Install the supervisor's padlock
c. Install only a tag
d. No more padlocks are necessary because there are enough padlocks
already.
a. Mechanical
b. Electrical
c. Gravitational
d. Hydraulic
e. All of the answers above are correct.
a. On the equipment
b. On the machine
c. On each energy-isolating device
d. On the main power supply
EXERCISE OBJECTIVE
DISCUSSION
A motor controller has one or more of the following capabilities. It may cause the
motor to:
C start or stop;
C rotate forward or reverse;
C have its speed or torque limited or regulated;
C be protected against overloads and faults.
There are many factors to consider when selecting and installing motor control
devices for use with particular machines or systems. For example, to start or stop a
motor, here are some considerations that may influence the choice of a motor
controller:
Once the conditions are met, the motor may be controlled safely and efficiently.
Push buttons
Push buttons are switches that provide control of a motor by pressing a push button.
Push buttons usually have a set of NO and NC contacts which change state
momentarily when the push button is pressed.
Figure 1-4 shows the Push Buttons module, Model 3110-2. The green push button
is usually used along with its NO contact as a start push button. The red push button
is usually used along with its NC contact as a stop push button. For security reasons,
stop push buttons are more easily accessible than start push buttons.
The Selector Switches module, Model 3111-2, allows you to alternate between two
control circuit branches through the selector (at the top) or the toggle (at the bottom)
switches. The two switches work independently. Selecting a position activates or
deactivates the maintained contacts. Figure 1-5 shows the Selector Switches module
and its diagrams.
Pilot lights
Pilot lights, which are usually red or green, are used to indicate if the line is
energized, or if the motor is running. Figure 1-6 shows the Pilot Lights module,
Model 3115-2.
Procedure Summary
In the first part of this exercise, you will use one NO and one NC push button contact
to power two pilot lights. This procedure will demonstrate that push button contacts
are momentary. Once again, it is necessary to use the Control Transformer in order
to obtain a voltage compatible with the Pilot Lights module.
In the second part of the exercise, you will use a similar circuit, in which a toggle
switch is employed instead of the push buttons. You will observe that the toggle
switch differs from the push buttons in that it has a maintained contact.
In the third part of the exercise, you will verify, with the help of an ohmmeter, that the
behavior of the selector switch corresponds to the indications provided on its module
faceplate.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Momentary contacts
G 4. After the Lockout Module is turned on, which pilot light(s) illuminate(s) when:
G 5. Following your last observations, what type of contacts are connected to:
G 6. Does the state of a pilot light associated with a push button change when
the button is released?
G Yes G No
G Maintained G Momentary
Maintained contacts
G 9. Set the TS toggle switch of the Selector Switches module to the O position.
After the Lockout Module is turned on, does a pilot light illuminate? Explain
why.
G 13. Does the toggle switch contact return to its original state after you release
it?
G Yes G No
G Maintained G Momentary
Note: You will learn later in this manual that this type of table,
showing the different contact states of a device, is called a target
table.
SELECTOR POSITION
CONTACT
L O R
SS-1
SS-2
SS-3
SS-4
G 17. Does your table correspond to the one located on the module faceplate?
G Yes G No
G 18. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Push button, and toggle and selector switches are common manual controllers. The
state of their contacts change as a push button is pressed, or the position of a toggle
or knob is modified.
REVIEW QUESTIONS
3. Why is the red (stop) push button standing out compared to the green (start) one
on the Push Buttons module?
4. Which of the following conditions may affect the choice of the motor controller
to be used?
a. Blue
b. Yellow
c. Red
d. Green
EXERCISE OBJECTIVE
DISCUSSION
Motor starters are made of power switches and overload protection devices. They
can be operated manually or remotely, through a magnetic contactor commanded
by a control circuit. Full or reduced voltage can be applied to the motor, depending
on the application.
Three-pole starters are used with motors operating on three-phase systems. The
number of poles in these starters refers to the number of power contacts and does
not include control contacts for control circuit wiring.
Two basic configurations of manual motor starters will be presented in this exercise,
namely the direct-on-line (DOL), also called across-the-line or full-voltage starter,
and the reversing starter. Magnetic motor starters will be seen in Unit 3, and reduced
voltage motor starting methods will be seen in Unit 5 of this manual.
DOL starters are the simplest way of starting a motor. A manual contactor is
combined with an overload protection device. Figure 1-9 shows the Manual Starter,
Model 3126, which can be used as a motor starter in both single-phase and
three-phase operation. This particular module has a manual contactor, an adjustable
overload protection, plus a circuit breaker. This is a DOL-type starter because full
voltage is applied directly to the motor.
Reversing starters
A cam (or drum) switch allows you to change between 2 or 3 operating modes,
using a control knob to switch power lines directly. Figure 1-10 shows the Cam
Switch module, Model 3140.
Procedure Summary
In the first part of this exercise, you will examine the Manual Starter and determine
that it has both the power contacts and the overload protection necessary to be
called a motor starter. You will then test the Manual Starter with push buttons and
pilot lights, and see that power lines are not reversed by the device, making it a
DOL starter.
In the second part of the exercise, you will inspect the Cam Switch to find out that
it does not include an overload relay, and hence, cannot be considered a motor
starter. After that, you will connect the Cam Switch to push buttons and pilot lights,
and see that two power lines are inverted when switching between the forward and
the reverse modes. You will observe that the Cam Switch can thus be part of a
reversing starter.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
G 2. Examine the Manual Starter module. What is the range of the Manual
Starter overload (indicated on the module faceplate)?
G 9. Find out which lights illuminate when you press the push buttons. Fill out
Table 1-2 for all three push buttons.
G 12. Examine the Cam Switch module. Does this module permit on and off
switching?
G Yes G No
G Yes G No
G 18. Find out which pilot lights illuminate when you press the push buttons. Fill
out Table 1-3 for all three push buttons in FWD, STOP, and REV modes.
FWD
A STOP
REV
FWD
B STOP
REV
FWD
C STOP
REV
G 19. Compared to the FWD mode, which lines have been switched in the
REV mode?
G 20. What type of starter can be constructed with the Cam Switch and an
appropriate overload relay?
G 21. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Contactors and overload protection devices are the essential elements of motor
starters.
DOL starters are the simplest method of starting a motor. They provide on/off control
for small motors. The Manual Starter module is an example of a DOL starter.
Reversing starters reverse the direction of the motor by inverting two motor power
lines. The Cam Switch module, with the addition of an overload relay, can be used
for that purpose.
REVIEW QUESTIONS
2. What does the term direct-on-line refer to when talking about motor starters?
3. What does the term three-pole refer to when talking about motor starters?
a. Lockout module
b. Push button
c. Cam switch
d. Overload relay
EXERCISE OBJECTIVE
DISCUSSION
Contactors and control relays are switching devices providing electrical isolation
between the control signals and the commanded electrical circuits. Different
combinations of normally open and normally closed contacts are used to open and
close circuits.
Solenoids, such as the one shown in Figure 1-13, are extensively used to operate
contactors and control relays. Placing a coil of wire around a soft iron core sets up
a magnetic flux. When energized, a magnetic field is developed around the coil. A
north and a south pole are created and the iron core becomes a temporary magnet.
As a result, a moveable plunger is attracted to the coil, and contacts attached to the
plunger change state.
When the coil is de-energized, the force of gravity or spring tension releases the
plunger from the magnet body, causing the electrical contacts to return to their
original state.
The same principle applies to single- and three-pole circuits. Figure 1-14 shows the
motion of a single-pole magnetic contactor.
Contactors
Contactors are heavy-duty and use a small control current or manual switching to
command power-consuming loads like motors, or lighting and heating devices.
Contactors are similar to motor starters, except that they do not provide overload
protection. Figure 1-15 shows the Contactor module, Model 3127. A1–A2 are the coil
terminals. L1, L2, L3, T1, T2, T3 are the input and output power terminals. 13–14 is
an auxiliary NO contact, used to provide feedback about the contactor state.
Figure 1-16 shows the Dual Contactors module, Model 3119, made of two contactors
similar to the one of Model 3127. Auxiliary blocks are added on top of the contactors
to provide more feedback about the state of the contactors. The Dual Contactors
module can be used to reverse the direction of rotation of a three-phase motor. A
mechanical interlock is located between the two contactors. It is a safety mechanism,
preventing the motor from being powered by the two contactors at the same time,
thus preventing short-circuits from occurring. When one of the two contactors is
energized, the contacts of the other contactor are mechanically maintained, even if
the second coil is energized.
Control relays
Control relays are designed to control circuits and small loads like pilot lights, audible
alarms, and some small motors. Figure 1-17 shows the Control Relay module,
Model 3130. A1–A2 are the coil terminals, 13–14 and 43–44 are NO contacts, while
21–22 and 31–32 are NC contacts.
Note: Contact terminals ending with 1 or 2 are NC, while terminals ending
with 3 or 4 are NO.
Procedure Summary
In the first part of this exercise, you will inspect the Contactor and the Control Relay
to identify their terminals and the voltage required to energize their coils.
In the second part of the exercise, you will connect a circuit containing a toggle
switch and the Dual Contactors. This will help you fill out a target table that will show
which power lines have been inverted between the two contactors.
In the last part of the exercise, you will set up a simpler dual contactor circuit to
observe how the mechanical interlock operates.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
G 2. Examine the Contactor module, Model 3127. Choose from the following list
the purpose of each of the different terminals:
1L1 – 2T1:
3L2 – 4T2:
5L3 – 6T3:
13NO – 14NO:
A1 – A2:
G Power G Control
G 5. Examine the Control Relay module, Model 3130. Choose from the following
list the purpose of each of the different terminals:
13NO – 14NO:
21NC – 22NC:
31NC – 32NC:
43NO – 44NO:
A1 – A2:
G Yes G No
G 9. Set the TS toggle switch of the Selector Switches module to the O position.
G 11. Set the TS toggle switch to the L and R positions to energize the coils M1
and M2 respectively.
Press all push buttons alternately, and fill out Table 1-4.
M1 B
M2 B
Mechanical interlock
G 16. Which pilot light illuminates when you press the A push button?
G 17. Which pilot light illuminates when you press the B push button?
G 18. What do you observe and hear when you hold down the A push button and
press the B push button momentarily?
G 19. What do you observe and hear when you hold down the B push button and
press the A push button momentarily?
G 20. What mechanism between the contactors prevents both pilot lights from
being powered simultaneously?
G 21. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Solenoids are magnetic devices used to open and close contacts of contactors and
control relays.
Contactors are switching devices designed for power circuits, while control relays are
built for control circuits and small loads.
Dual contactors with a mechanical interlock allow reversing the rotation direction of
a motor, without risking powering both coils at the same time.
REVIEW QUESTIONS
a. Control relays
b. Contactors
c. Buchholz relays
d. Cam switches
2. What does the term "magnetic" refer to when talking about contactors?
a. Solenoid
b. Plunger
c. Contact
d. Knob
EXERCISE OBJECTIVE
• Describe and test the operation of circuit breakers, fuses, and overload relays.
DISCUSSION
Circuit breakers or fuses are necessary to avoid high current levels rushing into the
motor windings. Under such conditions, these protection devices open the circuit
immediately.
Low levels of excessive current may also cause damage to the motor over a certain
period of time. Overload protection devices will open the circuit when the current
drawn by the motor is relatively high after a time delay.
When sizing the protection devices, it is important to note that all electric motors
suffer from a condition called inrush current. When starting the motor, there is a
brief spike of current that can be several times the steady-state current. Protection
devices must be carefully chosen so that they do not unnecessarily disrupt the
system under those normal conditions.
Circuit breakers
Circuit breakers are switches that open the circuit automatically when a
predetermined current level is exceeded. Circuit breakers can be reset to resume
normal operation. Figure 1-20 shows three-phase circuit breakers.
When electrical contacts open to interrupt a large current, there is a tendency for an
arc to form between the contacts, which would allow the flow of current to continue.
The maximum short-circuit current that a breaker can interrupt safely is called the
interrupting capacity.
Fuses
A fuse protects the circuit from an overcurrent condition. Its metal alloy melts when
heated by a prescribed electric current, hence opening the circuit. Fuses are
classified by types which depend on the application. A fuse also has a rated
interrupting capacity, which is the maximum current the fuse can safely interrupt.
Figure 1-21 shows the Fuse Holder module, Model 3137.
Compared to circuit breakers, fuses have the advantage of being cheaper for similar
ratings. However, blown fuses must be replaced with new devices, which is less
convenient than simply resetting a breaker. In addition, when a single fuse blows in
a three-phase system, the two other phases may still be operational, which is
possibly hazardous. In comparison, a three-phase circuit breaker interrupts all
phases simultaneously.
Overload protection
C an undersized motor;
C increased load on the driven machine;
C low input voltage;
C numerous start/stop cycles;
C an open phase in a polyphase system.
When an overload occurs, the motor draws excessive current, causing overheating.
Since the insulation of a motor breaks down under excessive heat, limits have been
established for motor operating temperatures. Overload relays are used to limit the
amount of current drawn to a predetermined value. These relays have current
sensitive thermal or magnetic elements that de-energize the starter and stop the
motor when excessive current is drawn. Local electrical codes determine the size
and class of the overload relay.
The class number indicates how long the overload relay takes to trip when carrying
a current equal to 6 times its current rating (or the value set when the overload is
adjustable):
Class 10 overload relays are usually used with motors that heat faster, such as
hermetic motors, or submersible pumps. Class 30 overload relays are mostly used
with motors driving high inertia loads, that take more time to accelerate.
Figure 1-22 shows the tripping time as a function of the ratio between the circuit
actual current and the overload relay’s current setting for different overload relay
classes. This ratio is equal to the number of times by which the circuit actual current
exceeds the overload relay’s current setting.
Figure 1-23 shows the Overload Relay module, Model 3131. This thermal overload
device has adjustable tripping current. Figure 1-24 explains how this thermal
overload relay operates. When the current level rises, the bimetal strips heat up and
bend to trigger the auxiliary contacts. This action is more or less rapid, depending
on the ambient temperature.
The auxiliary contacts (95–96 and 97–98) subsequently switch off the load by means
of a contactor. The tripped status is signaled by means of a switch position indicator.
The contactor is either reset manually (position H) or automatically (position A).
Note: The test button on the Overload Relay module is for contacts testing.
Pressing the test button opens the NC contact, and pulling the same test button
closes the NO contact.
Procedure Summary
In the first part of this exercise, you will set up a tripping circuit for the Manual
Starter. You will first test the circuit breaker section of the Manual Starter by shorting
the circuit. After that, you will intentionally overload the circuit to make the overload
relay part trip.
In the second part of the exercise, you will use a tripping chart to identify the
overload class and theoretical tripping time of the Overload Relay module. You will
then implement a circuit with the Overload Relay module to verify the theoretical
tripping time value. You will also see that heat has an effect on an overload relay
tripping time.
Finally, you will compare the Manual Starter and the Overload Relay and observe
that the first works directly on the power lines and the latter, on the control circuit.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Set the overload potentiometer of the Manual Starter to the lowest value,
and the knob to the I position.
G 4. Start the chronometer as you set the Cam Switch to the FWD position.
How long does it take for the Manual Starter overload to trip? Explain what
happened.
Start the chronometer as the Cam Switch is set to the REV position.
Referring to the ammeter display, what is the current flowing through the
circuit?
Current:
G 6. How long does it take for the Manual Starter overload to trip?
Tripping time:
G 7. By how many times is the measured current higher than the Manual
Starter's overload current setting?
G 8. Explain what happened compared to when the Cam Switch is set to the
FWD position.
The Starting Resistors module may be hot. Please be careful when you handle
this module after use.
G 10. Referring to Figure 1-22, determine the overload class of the Manual Starter
by using the tripping time and current ratio determined from the Figure 1-25
circuit.
G 11. Referring to Figure 1-22, at six times the overload relay’s current setting,
how long should the Manual Starter take to trip?
Tripping time:
G 12. In the Figure 1-26 circuit, what would happen in case of a short-circuit (if the
only short-circuit protection device is the Fuse Holder)?
G 13. Calculate the current that will flow through line L3, using the nominal
voltage, resistor value, and Ohm's law (E = RI).
Current:
G 14. Calculate the ratio of the current calculated in the previous step to the
Overload Relay's current setting (lowest value on the potentiometer)
(ICALCULATED / IOVERLOAD).
Ratio:
G 15. Referring to Figure 1-22, how long should it take for the overload relay to
trip, when power is applied to the circuit? Use the current ratio calculated in
the previous step.
Tripping time:
G 17. Set the overload potentiometer of the Overload Relay to the lowest value,
and the reset button to the A (automatic reset) position.
Set the TS toggle switch of the Selector Switches module to the O position.
Note: Before installing the Fuse Holder module, make sure that
the fuses inside are not blown.
G 18. Start the chronometer as you set the TS toggle switch to the L position.
Referring to the ammeter display, what is the current flowing through the
circuit?
Current:
G 19. How long does it take for the overload relay to trip?
Tripping time:
G 20. How long does the Overload Relay take to reset automatically (wait for the
current to flow again)?
Reset time:
G 21. How long does it take for the overload relay to trip a second time?
Tripping time:
G 22. Compare the tripping time measured for the second reset (step 21) to the
tripping time measured for the first reset (step 19). How was the tripping
time measured for the second reset?
Note: The bimetal strip inside the Overload Relay is still hot after
the first reset.
G 23. Does the theoretical tripping time obtained with the chart correspond to the
value obtained experimentally?
G Yes G No
G 25. Do the Manual Starter and the Overload Relay take nearly the same time
to trip under similar conditions?
G Yes G No
G 27. Explain how the two devices make the motor stop.
G 28. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Circuit breakers and fuses protect circuits from high current levels. They open the
circuit if the current is between their rating and their interrupting capacity. Circuit
breakers can be reset, while fuses have to be replaced after use.
Overload protection is used to prevent burnout of the motor. Overload relays limit the
amount of current drawn to a predetermined value. The higher the current, the less
time it takes to de-energize the contactor and stop the motor. Thermal overload
relays heat up depending on the motor current.
REVIEW QUESTIONS
a. An oversized motor
b. The loss of a phase in a polyphase system
c. A low voltage
d. A heavy load
a. Sensors measure the strength of the magnetic field around the power line.
b. Metal alloys melt as heat goes up with the current rise.
c. Heat goes up as the current rises, causing bimetal strips to bend.
d. Bimetal strips are actuated by radio-frequency signals.
a. Class 10
b. Class 20
c. Class 30
d. Class 40
UNIT TEST
4. What is the name of the coil of wire around a soft iron core used to operate
magnetic contactors and relays?
a. Lever
b. Plunger
c. Solenoid
d. Drum
6. What is the name of the highest current that a device can interrupt at a rated
voltage?
a. Interrupting current
b. Excessive current
c. Overload current
d. High-level current
a. Fuses
b. Overload relays
c. Circuit breakers
d. Solenoids
a. Full-load current
b. Pressure overload
c. Mechanical overload
d. Inrush current
9. Which of the following control devices does not hold its state?
a. Cam switch
b. Selector switch
c. Toggle switch
d. Push button
10. What device is designed to stop the equipment rapidly and easily?
a. Pilot light
b. Emergency button
c. Cam switch
d. Overload relay
UNIT OBJECTIVE
Upon completion of this unit, you will be familiar with device ratings, symbols,
abbreviations, and circuit diagrams used to characterize control circuits.
DISCUSSION OF FUNDAMENTALS
To illustrate and define elements and functions easily, electrical diagrams are
utilized. They are made of graphic symbols and device designations. Schematic
diagrams focus on circuit functions, without taking into account the physical
arrangement, whereas wiring diagrams include all the devices in the system and
show their physical relationships.
SPECIFICATIONS READING
EXERCISE OBJECTIVE
DISCUSSION
Control devices are marked with information permitting their use under the right
conditions. Figure 2-1 is an example of label for a contactor.
Certification marks indicate that a product has been evaluated for compliance to
national and international standards by a formal process, and that it complies with
applicable standards for safety and performance. If we refer to the contactor label
shown in Figure 2-1, we see that it meets the IEC, UL, CSA, and EN standards.
Industrial control device ratings can be provided according to the National Electrical
Manufacturers Association (NEMA) and/or the International Electrotechnical
Commission (IEC). For example, if we take a motor starter or a contactor, both
NEMA and IEC ratings can be specified for that device, but they will be different for
a given motor power.
As Table 2-1 shows, NEMA motor starters and contactors are given size ratings,
which depend on the continuous current rating, or the motor power and voltage.
NEMA components are intended to be interchangeable between same-size devices.
Because the exact application is not defined, they are designed to have more
reserve capacity than their IEC counterparts. For that reason, NEMA devices are
usually bigger and more expensive.
HORSEPOWER
Continuous Service-Limit
NEMA Current 60 Hz 50 Hz Current
SIZE Rating Rating
(A) 460 OR (A)
200 V 230 V 380 V
575 V
00 9 1½ 1½ 1½ 2 11
0 18 3 3 5 5 21
1 27 7½ 7½ 10 10 32
2 45 10 15 25 25 52
3 90 25 30 50 50 104
Table 2-1. NEMA sizes for three-phase single-speed full-voltage starters and contactors (non-
plugging and non-jogging duty).
On the other hand, IEC motor starters and contactors do not have standard sizes.
Instead, they are described by their utilization category (see Table 2-2), power (hp
or kW), thermal current (Ith), rated operational current (Ie) and rated operational
voltage (Ue). For the same application, IEC devices are usually cheaper and smaller
than their NEMA counterparts. However, they are more application sensitive and
require greater knowledge from the buyer.
Squirrel cage motors, starting and switching off while running at less
than rated speed. Jogging (inching) and plugging (reversing
AC-4
direction of rotation from other than off condition). Make and break
locked rotor current.
Pilot and control-circuit devices, such as push buttons and control relays, also have
ratings. Contact rating designations, shown in Tables 2-3 and 2-4, give an
indication of the maximum make and break currents. The letter designates the
maximum continuous thermal test current of the unit or assembly. Letters A
through E are for AC devices, and letters N through R are for DC devices. Numerical
suffixes specify voltage design values of 600, 300, and 150 V.
C600 2.5 15 1.5 7.5 0.75 3.75 0.375 3 0.3 1800 180
R150 1 0.22 - - 28
Pilot and control-circuit elements have utilization categories different from contactors
and motor starters, as Tables 2-5 and 2-6 show.
AC-12 Control of resistive loads and solid state loads with optical isolation.
DC-12 Control of resistive loads and solid state loads with optical isolation.
A nameplate displays useful information about the motor. The nameplate shown in
Figure 2-2 is for a standard, three-phase, nine-lead motor.
B. Power rating: The nominal output power at the shaft of the motor is given in
horsepower (hp) or kilowatts (kW).
120 115
208 200
240 230
480 460
600 575
2400 2300
4160 4000
6900 6600
Table 2-7. NEMA standard nominal and rated 60 Hz polyphase motor voltages.
D. Current rating(s): The motor rated current at full load and rated voltage, also
called full-load ampere (FLA). When a motor draws more current than its
FLA, it is said to be overloaded.
E. Rotation speed: The rated operating speed of the motor at full load. Motors
can have more than one operating speed.
F. Frame size: NEMA and IEC have categorized the frames of motors to make
them interchangeable, regardless of the manufacturer. Refer to Appendix C
for NEMA and IEC Motor Frames Charts. NEMA motors may have a prefix
(specific to the manufacturer) and a suffix (indicating the mounting type) in
addition to the size number. A "T" or no suffix indicates current NEMA frame
standards.
G. Frequency: This refers to the frequency of the power source supplying the
motor, which is usually 60 or 50 Hz, depending on the country.
J. Locked rotor code letter: The code letter is a function of the locked kVA per
horsepower, as Table 2-8 shows. Since the inrush current approaches the
locked-rotor current, the following equation gives an indication of the starting
current that is helpful to size motors' circuit protection:
For example, a three-phase motor with a locked rotor code letter M and
rated 1/3 hp at 230 V will have an approximate locked rotor current of:
A 0.00-3.15 L 9.0-10.0
B 3.15-3.55 M 10.0-11.2
C 3.55-4.0 N 11.2-12.5
D 4.00-4.5 P 12.5-14.0
E 4.5-5.0 R 14.0-16.0
F 5.0-5.6 S 16.0-18.0
G 5.6-6.3 T 18.0-20.0
H 6.3-7.1 U 20.0-22.4
K 8.0-9.0
K. NEMA design code letter: This letter gives an indication of the torque's
behavior depending on the speed. The most common design letters
are A, B, C, and D. Design A motors are specialized motors used for their high
pullout torque. Design B motors are standard industrial duty motors. Design C
motors have higher starting torque than Design B motors. Design D motors
have the highest starting torque, but this drops significantly with speed.
Note: Locked rotor codes, NEMA design codes, and insulation classes are all
made up of letters, which may lead to some confusion.
N. Power factor: Motors are inductive loads and require reactive power. A higher
power factor means that the motor consumes proportionally more real power,
thus drawing less apparent power. In general, motors developing more power
have a superior power factor.
Q. Enclosure type: Motors have enclosures of two different types: open and
enclosed. Table 2-9 lists some of the more common designs for specific
operating conditions.
TYPES CHARACTERISTICS
Weather protected type 1 Openings minimize entrance of rain, snow, and airborne
(WPI) (Open) particles.
Weather protected type 2 Like WPI with additional passages to eject high-velocity
(WPII) (Open) particles blown into motors.
Totally enclosed Constructed with a small fan on the rear shaft to cool
fan-cooled (TEFC) motors.
Totally enclosed air over Rely upon the strong air flow of the fan or blower which
(TEAO) they are driving to cool them.
Totally enclosed
Cooled by circulating water.
water-cooled (TEWC)
Totally enclosed Used for variable speed motors. Constant speed blowers
blower-cooled (TEBC) pull air to keep motors cool at all operating speeds.
R. Motor connection diagram: The indications for proper wiring may be located
on the nameplate, in the conduit box, or on a separate plate.
S. Motor type (not shown in Figure 2-2): Manufacturers classify motors by their
electrical and mechanical characteristics (squirrel-cage, induction, split-phase,
permanent magnet, etc.).
Procedure Summary
In this exercise, you will examine data on a motor nameplate, a contactor, and a
control relay to extract some useful information.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Brake Motor
G 1. Examine the nameplate of the Brake Motor, Model 3176-A, and fill out
Table 2-10:
Number of phases
Service factor
Enclosure type
Duty rating
Insulation class
* If the nameplate of the Brake Motor, Model 3176-A, does not indicate the characteristics of the
version, refer to Appendix F.
G 2. Referring to the locked rotor code letter, determine the maximum starting
current at a 230-V rated motor voltage. Show your calculations.
Insulation life:
Contactor
50 Hz:
60 Hz:
Control Relay
G 7. Examine carefully the enclosure and rating label of the Control Relay,
Model 3130. What voltages can be used to control the coil?
50 Hz:
60 Hz:
G 8. On the rating label, what is the rated operational current for 400 V, AC-15
utilization?
CONCLUSION
Nameplates are installed on motors to help the purchaser for maintenance purposes
and the manufacturer with customer service. These plates display useful information
concerning the motor ratings, model, and connection.
Industrial control devices, including motor starters, contactors, pilot devices, and
control relays, are rated by the NEMA and/or the IEC. Those specifications are
usually located on rating labels. NEMA devices tend to be interchangeable, whereas
IEC devices are more specific to the application, and thus require more knowledge.
REVIEW QUESTIONS
2. What is the name of the ratio of mechanical power produced to the electrical
power input required by the motor?
a. Power factor
b. Power rating
c. Service factor
d. Efficiency
a. 0.7 A
b. 1.5 A
c. 1.6
d. 0.8 A
4. According to NEMA standards, what size of starter would be used with a 6 hp,
three-phase motor at 230 V?
a. 00
b. 0
c. 1
d. 2
5. What utilization category is used for a contactor frequently making and breaking
locked rotor current of a three-phase squirrel-cage motor?
a. AC-1
b. AC-2
c. AC-3
d. AC-4
EXERCISE OBJECTIVE
DISCUSSION
The width of lines does not affect the meaning of symbols. However, wider lines may
be used for power wiring in contrast to control wiring. The angle at which a
connecting line is brought to a symbol usually has no particular significance.
Wiring diagrams
Wiring diagrams are useful in building circuits, since the connections can be made
exactly as they appear on the diagram. A wiring diagram provides a means of tracing
the wires for troubleshooting or during normal preventive maintenance. Wiring
diagrams are also called connection diagrams.
Figure 2-4 shows the wiring diagram of a motor control system. This diagram
represents the station physically, the relative position of each device, and the
different connections. The main parts of the motor starter are labeled on the diagram,
so that a comparison can be made with the actual starter.
Schematic diagrams
Figure 2-5 represents the schematic diagram of the same motor control system as
in Figure 2-4. Symbols and functions of each device are indicated on this diagram.
Graphic symbols
Note: Although NEMA diagrams do not show terminals which are not
accessible, all terminals in this manual are detailed for better
comprehension.
Designations
Target tables
The diagram in Figure 2-7 indicates how the lines and the load are connected to the
Cam Switch. Table 2-11 is a target table showing which contacts close to reverse a
three-phase motor, and which contacts close to run the motor forward. Each "X"
represents a closed contact.
POSITION
CONTACT
F O R
1–2 X
3–4 X
5–6 X
7–8 X
9–10 X X
X = Contact closed
Procedure Summary
In this exercise, you will draw and identify different symbols and designations used
on electrical diagrams. You will also draw a complete schematic diagram from a
corresponding wiring diagram.
EQUIPMENT REQUIRED
PROCEDURE
ITEMS SYMBOLS
Diode
Fixed resistor
Earth ground
b. Overload:
c. Diode:
d. Circuit breaker:
e. Push button:
f. Ammeter:
g. Fuse:
h. Capacitor:
i. Pressure switch:
j. Transistor:
G 3. In the Figure 2-8 schematic diagram, identify each circled letter with the
appropriate device name (see NEMA symbols table in Appendix B).
a. h.
b. i.
c. j.
d. k.
e. l.
f. m.
g.
G 4. Draw in Figure 2-9 the schematic diagram of the wiring diagram shown in
Figure 2-10.
CONCLUSION
Schematic diagrams show simplified circuit connections and functions and are useful
for troubleshooting purposes. Wiring diagrams show the circuits as they physically
appear, making circuit construction easier.
Target tables are used to show the state of contacts on control devices.
REVIEW QUESTIONS
a. Wiring diagram
b. Schematic diagram
c. Elementary diagram
d. One-line diagram
a. Elementary diagrams
b. Connection diagrams
c. Schematic diagrams
d. Floor diagrams
3. What letter or combination of letters is used with graphic symbols to specify the
function of a device?
a. Written form
b. Name code
c. Indication
d. Designation
a. Future connections
b. Control lines
c. Power lines
d. Standard-size cables
UNIT TEST
a. NO limit switch
b. NO limit switch, held closed
c. NC limit switch
d. NC limit switch, held open
a. Resistors
b. Transistors
c. Reactors
d. Transformers
a.
b.
c.
d.
a. Elementary diagrams
b. Wiring diagrams
c. Connection diagrams
d. Isometric diagrams
a.
b.
c.
d.
a. Temperature rise
b. Ambient temperature
c. Intrinsic temperature
d. None of the answers above is correct.
9. Which of the following enclosures protects the motor from liquids of entry angles
up to 100 degrees from vertical?
a. Guarded
b. Weather protected
c. Drip proof
d. Splash proof
10. Which type of device is designed with more reserve capacity to allow
interchangeability?
a. IEC-type devices
b. CCC-type devices
c. NEMA-type devices
d. CSA-type devices
UNIT OBJECTIVE
Upon completion of this unit, you will be able to construct and analyze simple control
circuits with various control devices.
DISCUSSION OF FUNDAMENTALS
Different motor control circuits are chosen to suit particular needs. They can be
simple, offering only manual on/off control. But they can also be more complex,
permitting direction reversal, braking, or offering protection against sudden restarts
or short-circuits.
When a motor needs to be operated from more than one location, multiple control
stations can be used. Multiple push button stations, for instance, permit the starting
and stopping of machinery at different places along a production line.
Each control circuit can be wired to restart automatically or not, following a voltage
failure. Two-wire control allows a machine to restart automatically following a power
outage, whereas three-wire control keeps the motor at rest until an operator
accomplishes a restart procedure.
Motor reversal
But when two reversing contactors are used, there is a risk of energizing both of
them simultaneously, thus creating a short-circuit. To safely reverse the direction of
a motor, interlocking means are employed. Mechanical interlock and push button
interlock are two of these methods.
Control voltage
When control circuits are simple enough, the system designer may decide to use
controls connected directly to power lines, or between a power line and the neutral.
This approach proves to be less expensive because no voltage conversion device
is required. Control elements must, however, be built to sustain higher voltages.
In many cases, though, motor control circuits are powered with a voltage different
than that of the power circuit. In this manual, the technique used to provide low
AC voltage suitable for control devices consists in utilizing a control transformer. This
method also has the advantage of providing electrical isolation between power and
control circuits.
Brake Motor
In this unit, you will make use of the Brake Motor, Model 3176-A, shown in
Figure 3-1. This is a general purpose, three-phase motor, coupled to a friction disc
brake. The characteristics of the Brake Motor are shown on the motor nameplate
and in Appendix F.
The labels on the motor and on the brake indicate how to make the connections,
depending on the supplied voltage and frequency. Table 3-1 indicates the low and
high voltage values for different network voltages and frequencies.
Table 3-1. Low and high voltage values for different network voltages and frequencies.
To manually disengage the friction brake, set the knob on the brake cover to the
RELEASE position as shown in Figure 3-2. The operation of the friction brake will be
covered in Unit 4.
MOTOR STARTERS
EXERCISE OBJECTIVE
DISCUSSION
Motor starters are made out of contactors and overload protection devices. Full
voltage can be applied directly to the motor, although this produces rather high
inrush current.
The overload relay is chosen so as to protect the motor against a sustained, low
level of excessive current. The contactor coil de-energizes when the overload relay
trips.
Inertia Wheel
Figure 3-3 shows the Inertia Wheel, Model 3147. This metal wheel can be coupled
to a motor to increase its acceleration and deceleration time. In the following
exercises, we will utilize the Inertia Wheel to observe the phenomena occurring while
motors start and stop.
Separate control
It is sometimes possible to control motor circuits with the voltage between a power
line and the neutral line, or between two power lines. However, there may be no
neutral line available, or the provided voltage may not be desirable.
There is a considerable hazard in using high voltages for control circuits. Although
push buttons and other pilot devices are often designed to withstand higher voltages,
breaks in insulation and careless wiring may subject the operator to a serious shock.
Therefore, it is common practice to use a control voltage transformer to provide low
AC voltage suitable for control circuits. Figure 3-4 shows the Control Transformer,
Model 3138 (208:120 version), used to provide AC control voltage compatible with
coils and indicating lights of the Industrial Controls Training System.
Figure 3-5 is the schematic diagram of a separate motor control system. In this
diagram, the control circuit is isolated from the power lines because of the control
transformer, which takes voltage between two power lines to provide low control
voltage. When power is applied to the circuit and the toggle switch is set to the
START position, the contactor coil (M) is energized, actuating power contacts. If the
NC overload contacts or the toggle switch open, the contactor coil (M) is
de-energized and the power contacts are opened.
Procedure Summary
In this exercise, you will verify that the control transformer converts the line-line
voltage from the power distribution system to a voltage compatible with the control
pilot lights and coils.
You will then implement a basic motor starter circuit from a schematic diagram. This
setup will use a control transformer and a toggle switch to activate a contactor. The
instructor will be invited to verify your connections before power is applied to the
circuit. When starting the motor, you will observe with the ammeter the inrush current
phenomenon that was discussed in Exercise 1-5.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Voltage:
G 3. Is this voltage compatible with the pilot light rating of the Pilot Lights
module?
G Yes G No
G 4. Is this voltage compatible with the coil rating of the Contactor module?
G Yes G No
G 6. Install the Brake Motor, Inertia Wheel, and Safety Guard as described in
Appendix E.
Connect the circuit shown in Figure 3-5. Use the toggle switch O-R contact
of the Selector Switches module.
G 7. Manually disengage the friction brake by setting the knob on the brake cover
to the RELEASE position.
Set the START toggle switch of the Selector Switches to the O position.
G 8. Observe the ammeter display as you set the START toggle switch to the
R position. Repeat your observation if necessary.
How does the motor current level behave, when the motor is started?
G 9. Explain what happens in the circuit when the START toggle switch is reset
to the O position.
G 10. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
The use of a control voltage transformer is a way to isolate control and power
circuits. It provides suitable low voltage for the control circuit.
Motor starters are made of contactors and overload protection devices. When loads
are coupled to the motor shaft, the motor accelerates and decelerates slower.
The current level is higher upon starting than during normal operation. This
phenomenon, discussed in Exercise 1-5, is called inrush current.
REVIEW QUESTIONS
1. How would you explain that direct line-neutral connection of a control circuit is
often not desirable?
2. Apart from a control transformer, what other device can be used to provide
control circuit voltage?
a. Lockout module
b. Time relay
c. DC power supply
d. Cam switch
a. H2 and X1
b. X1 and X2
c. H1 and X2
d. H1 and H2
4. In the Figure 3-5 circuit, what are the coil terminals of the main contactor?
a. 1 L1 - 2 T2
b. 3 L2 - 4 T2
c. 5 L3 - 6 T3
d. A1 - A2
5. In Figure 3-5, where does the Control Transformer take the voltage for the
control circuit?
EXERCISE OBJECTIVE
DISCUSSION
Electrical motor controls can be wired so that they restart the motor automatically or
not, after power is removed from and returned to the circuit.
Two-wire control
Two-wire control of a starter means the starter drops out when there is a voltage
failure and starts up by itself when the voltage returns. This type of control is often
used on fans or exhaust blowers.
The two-wire control circuit is so named because only two wires are connected to the
pilot device used to energize the magnetic controller. The pilot devices used can hold
their contacts closed, even if there is a power failure. These controls may be
thermostats, float switches, pressure switches, toggle switches, or selector
switches. Two-wire control is also called no-voltage release or low-voltage
release.
Figure 3-6 shows a two-wire control circuit. When the control contact closes, the
coil (M) is energized. The power contacts close, causing the motor to start. When the
control contact opens, or power is removed from the circuit, the coil (M)
de-energizes, which opens the power contacts and stops the motor. When power
returns, the motor restarts automatically if the control contact is closed.
Three-wire control
Three-wire control of a starter means that the starter drops out when a voltage failure
occurs, but does not restart when the voltage returns, therefore not constituting the
same hazard as the two-wire control.
The three-wire control circuit gets its name from the three wires that must be
connected to the pilot device. A holding contact must be used in addition to control
devices that do not hold their state, like momentary contact push buttons. This
method is also called no-voltage protection or low-voltage protection.
C When the START push button is pressed, the coil (M) energizes and the
holding contact (M) closes to keep the coil energized.
C When the STOP push button is pressed or power is removed, the circuit is
broken, causing coil (M) to de-energize, and the holding contact to open.
C The START push button must be pressed again to energize the coil.
Procedure Summary
In this exercise, you will implement a two-wire control circuit and verify that this
circuit restarts automatically, after power is removed and restored.
After that, you will set up a three-wire control circuit to see that such a circuit does
not restart by itself, after power is restored following a disruption.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Set the START toggle switch of the Selector Switches to the O position.
Number of leads:
G 6. Explain what happens as you set the START toggle switch to the R position.
G 7. While the Brake Motor is running, turn off the Lockout Module, then turn it
on. Explain what happens.
G 12. Press the START push button briefly. Explain what happens.
G 13. While the Brake Motor is running, turn off the Lockout Module, then turn it
on. Explain what happens.
G 15. What happens if you press the STOP push button while the motor is
running?
G 16. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Two-wire control circuits restart a motor automatically when voltage returns, following
a power failure. A two-wire controller can be a toggle switch, float switch, limit
switch, or any other device with maintained on-off positions.
Three-wire control circuits require that an operator be present to restart the machine,
following a power failure. Three-wire controls can be, for example, momentary
contact push buttons.
REVIEW QUESTIONS
2. Why are three-wire control circuits less hazardous to personnel in industries than
two-wire control circuits?
4. Which of the following control devices can be used for three-wire control?
a. Toggle switch
b. Float switch
c. Selector switch
d. Push button
5. In three-wire control circuits, what path does the control current take when the
momentary contact is released?
a. Starting coil
b. Holding contact
c. Power contact
d. Stop push button
EXERCISE OBJECTIVE
DISCUSSION
The phase switching can be accomplished manually, with the help of a cam switch,
or with magnetic devices, as will be seen later in this manual.
When the Cam Switch, shown in Figure 3-8, is set to the FWD position, lines are
connected in the usual order (L1 to T1, L2 to T2, and L3 to T3), so that the motor
runs in the forward direction.
In the REV position, lines 1 and 2 are interchanged (L2 to T1, L1 to T2, and L3 to T3)
to reverse the motor rotation direction. Placing the Cam Switch to the STOP position
simply opens the three lines and shuts off the motor.
Procedure Summary
In this exercise, you will manually change the motor terminal connections to observe
the relationship between line sequence and motor rotation direction.
You will then use a cam switch to reverse the motor rotation direction without having
to disconnect power leads.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
G 4. Observe the rotation direction of the motor shaft (viewed when facing the
end of the motor shaft) as you set the knob of the Manual Starter to the
I position.
Enter the rotation direction and the line sequence in the appropriate row of
Table 3-2.
G 5. Repeat the previous step for all the configurations shown in the Connections
column of Table 3-2. Change configuration by modifying the connections at
the Brake Motor terminals.
Note: Turn off the Lockout Module while you modify the
connections.
MOTOR ROTATION
LINE SEQUENCES
DIRECTIONS
CONNECTIONS
CW CCW 1-2-3-1-2-3 3-2-1-3-2-1
L1 - T1
L2 - T2
L3 - T3
L2 - T1
L1 - T2
L3 - T3
L3 - T1
L2 - T2
L1 - T3
L1 - T1
L3 - T2
L2 - T3
L3 - T1
L1 - T2
L2 - T3
L2 - T1
L3 - T2
L1 - T3
G Yes G No
Reversing the rotation direction using a cam switch to change the line
sequence
Connect the motor in the usual manner (L1 to T1, L2 to T2, and L3 to T3).
Determine the motor rotation direction as you set the Cam Switch to the
FWD position.
G Clockwise G Counterclockwise
G 9. Determine the motor rotation direction as you set the Cam Switch to the
REV position.
G Clockwise G Counterclockwise
G 10. Compared to the FWD operation, does the motor turn in the other direction?
G Yes G No
G 11. Does using the Cam Switch have the same effect as manually inverting
motor connections of lines 1 and 2?
G Yes G No
G 12. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Changing the motor terminal's line sequence reverses the motor rotation direction.
There are only two possible sequences in a three-phase system: one for the forward
direction, and one for the reverse direction.
Instead of manually modifying the line sequence, a cam switch may be used to
simplify the reversal of motor rotation direction.
REVIEW QUESTIONS
a. Selector switch
b. Toggle switch
c. Push button
d. None of the answers above is correct.
a. 1
b. 2
c. 3
d. 4
4. What happens when the Cam Switch, Model 3140, is set to the STOP position?
5. Which of the following power line terminal connection orders is part of a different
line sequence?
a. 3-1-2
b. 2-3-1
c. 3-2-1
d. 1-2-3
REVERSING STARTERS
EXERCISE OBJECTIVE
DISCUSSION
When phase reversal is executed in magnetic circuits, one contactor is used for each
direction. But a short-circuit can occur if the two contactors are energized at the
same time. Look at the power circuit in Figure 3-9, for example. If all contacts of the
F and R contactors close, lines 1 and 2 will be short-circuited. That is the reason why
forward and reverse contactors are usually electrically and/or mechanically
interlocked together.
When the FWD push button in Figure 3-9 is pressed, the coil (F) is energized and
the related holding contact closes. If the REV push button is pressed while the motor
is running in the forward direction, the forward control circuit de-energizes. At the
same time, the reverse contactor (R) is energized and held closed, making the motor
run in the reverse direction. Note that it is not necessary to press the STOP push
button to reverse the direction. This fact facilitates plugging.
If the FWD and REV push buttons are simultaneously activated, both contactors will
stay open. That is because the push button NC contacts open the control circuit
completely, thereby forcing contactor coils to de-energize.
However, if a contactor coil is stuck closed or does not open fast enough, there can
still be a short-circuit when the other coil is activated.
Mechanical Interlocking
A mechanical lever is another manner of preventing both starter coils from being
energized simultaneously. Figure 3-10 displays the mechanical interlock located
between the two contactors of the Dual Contactors, Model 3119.
Refer to the circuit of Figure 3-11. A mechanical interlock (in dashed lines) is located
between the two contactor coils. When one of the two contactors is energized, the
contacts of the other contactor are mechanically maintained, even if the second coil
is energized. This method provides a level of security against short-circuits resulting
from stuck contactors. This explains why mechanical interlocks are so common in
the industry.
Procedure Summary
In the first part of this exercise, you will set up a reversible starter circuit with push
button interlocking and verify that this circuit enables changing the motor direction.
You will also observe that motor direction reversing can be accomplished without
having to press the STOP push button, to stop the motor faster. You will then verify
that both contactors remain de-energized if the operator accidentally presses the two
push buttons. Finally, you will simulate a stuck contactor to see that push button
interlocking does not protect against short-circuits resulting from that type of trouble.
In the second part of this exercise, you will study, with the assistance of pilot lights,
how a mechanical interlock operates. By manually applying pressure on the dual
contactors plungers, you will check that it is not possible to activate both contactors
at the same time. You will then visualize that, when both coils are powered, only the
first contactor has its related contacts closed.
In the last part of this exercise, you will connect a reversing starter with push button
and mechanical interlocks. You will see that this circuit, like the push button interlock
circuit, enables motor direction reversal and opens completely when both push
buttons are pressed. You will also discover that the mechanical interlock included
adds protection against stuck contactors.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Note: Use one of the two contactors from the Dual Contactors,
Model 3119, as the forward direction contactor, and the
Contactor, Model 3127, as the reverse direction contactor, to
make sure that there is no mechanical link between contactors.
Determine the motor rotation direction as you press the FWD push button.
G Clockwise G Counterclockwise
G 4. Press the STOP push button and observe the time taken by the motor to
stop.
G 5. Determine the motor rotation direction as you press the REV push button.
G Clockwise G Counterclockwise
G 6. Compared to the forward operation, does the motor turn in the other
direction?
G Yes G No
Note: The contactors are all AC-4 rated. This class allows for
plugging operation (reversing direction of rotation from other than
off condition).
G 7. While the motor is running in the reverse direction, press the FWD push
button until the motor halts. Press the STOP push button before the motor
starts rotating in the opposite (forward) direction. Repeat if necessary.
Note: Repeated motor starts and stops may cause the Overload
Relay to trip.
Did the motor stop slower or faster than with the STOP push button only?
G Slower G Faster
G 8. When the FWD push button was pressed, why were both contactors
(F and R) not activated at the same time, thereby causing a short-circuit?
G 9. What happens when you keep the FWD and REV push buttons pressed
simultaneously?
G 10. Describe how the circuit operates while you simultaneously keep the FWD
and REV push buttons pressed.
G 11. What happens if you do not release both push buttons simultaneously?
Explain why.
G 13. Describe how the circuit operates while you simultaneously hold the forward
contactor plunger down and press the REV push button.
G 14. Does push button interlocking offer a good protection against stuck
contactors?
G Yes G No
Mechanical interlocking
Note: Use the two contactors from the Dual Contactors module.
G 18. Can you (manually) hold down completely the two contactor plungers
simultaneously? Explain why.
G 19. When you press the FWD push button alone, which contactor coil is
energized? (Refer to the respective pilot lights.)
GF GR
G 20. When you press the REV push button alone, which contactor coil is
energized? (Refer to the respective pilot lights.)
GF GR
G 21. Does pressing the FWD and REV push buttons energize both contactor
coils simultaneously?
G Yes G No
G 22. When both push buttons are pressed, which contactor coil(s) energize(s),
in regard to the order in which the corresponding push buttons were
pressed?
G 24. Connect the circuit shown in Figure 3-9, this time using the two contactors
from the Dual Contactors module.
Determine the motor rotation direction as you press the FWD push button.
G Clockwise G Counterclockwise
G 26. Press the STOP push button and wait for the motor to stop.
G 27. Determine the motor rotation direction as you press the REV push button.
G Clockwise G Counterclockwise
G 28. While the motor is running in the reverse direction, press the FWD push
button. Does the motor direction change? Explain what happens,
considering that the circuit now contains a mechanical interlock.
G 29. Press both push buttons simultaneously, and determine which contactor(s)
energize(s), in regard to the order in which the corresponding push buttons
were pressed.
G 30. Press the FWD push button to start the motor. To simulate a stuck
contactor, manually hold the forward contactor plunger down (using the tip
of a pen). Press the REV push button.
Does the motor still run in the forward direction? Explain why.
G Yes G No
G 32. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Reversing magnetic starters are built with two contactors, one per rotation direction.
If both contactors are actuated at the same time, a short-circuit can occur. This is
why electrical and/or mechanical interlocks are used.
Mechanical interlocking uses a lever to artificially keep the second contactor de-
energized, while the first coil is actuated. This method is more rugged in the way that
it prevents short-circuits resulting from a stuck contactor.
REVIEW QUESTIONS
a. 2
b. 3
c. 4
d. 5 or more
3. What is the motor braking method that uses the counter torque produced by
reversing connections?
a. Inching
b. Plugging
c. Jogging
d. DC injection
4. In mechanical interlocking, which item prevents both coils from being actuated
simultaneously?
a. Coil
b. Lever
c. Push button
d. Diode
5. In the Figure 3-9 circuit, which lines have been interchanged in the reverse
mode compared to the forward mode?
EXERCISE OBJECTIVE
• Understand the differences between stop push button and emergency button.
DISCUSSION
A standard three-wire push button control circuit may be expanded by adding one
or more push button stations. With start push buttons connected in parallel and stop
push buttons connected in series, the motor may be started or stopped from a
number of separate locations. Figure 3-12 represents a multiple push button station.
Although they are both designed to stop a motor, stop push buttons and emergency
buttons have one major difference. Contrary to the stop push button, the emergency
button maintains its contact open after it has been pressed. It is also more
accessible, with a larger contact surface.
Procedure Summary
In this Exercise, you will implement a multiple push button circuit including an
emergency button. You will apply power to the circuit to verify that any start or stop
push button can make the motor run or come to a halt.
You will then short-circuit the start push buttons to make the motor run inadvertently.
This will help you discover how useful an emergency button can be in this type of
situation.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
G Yes G No
G Yes G No
G Yes G No
G Yes G No
G 5. What conclusion about start and stop controls in a multiple push button
circuit can you draw from the preceding manipulations?
In the next procedure step, a fault will be added to the circuit, making
the motor start automatically as power is turned on.
Emergency Button
Stay alert as you turn on the Lockout Module. Describe and explain what
happens.
G 8. What happens when you press and release a stop push button?
G 10. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
A motor can be started or stopped from more than one location by using multiple
push buttons. To implement such a circuit, the stop push buttons are connected in
series and the start push buttons in parallel.
Emergency buttons are easily accessible and maintain their contact open after they
have been pressed.
REVIEW QUESTIONS
1. What reasons can motivate the use of multiple push button stations?
a. Its size is typically smaller than that of a same-circuit stop push button.
b. When pressed, the contact is momentarily opened.
c. It is located where is it not easily accessible.
d. When pressed, the contact is maintained open.
a. Power contacts
b. Normally open contacts
c. Normally closed contacts
d. Emergency contacts
a. Power contacts
b. Normally open contacts
c. Normally closed contacts
d. Emergency contacts
a. Yellow
b. Orange
c. Red
d. Green
UNIT TEST
a. AC-1
b. AC-2
c. AC-3
d. AC-4
4. What should be taken care of, when servicing a two-wire control circuit?
a. Electrical interlocking
b. Mechanical interlocking
c. Braking method
d. Lockout/tagout procedure
7. What happens if two contactors are energized at the same time in a reversing
circuit without interlocking?
a. Open circuit
b. Short-circuit
c. Nothing happens
d. The motor starts turning in the opposite direction.
9. In push button interlocking, what happens if the motor is running in the forward
direction and you push both forward and reverse push buttons?
10. What circuit configuration can be used to allow motor control from more than one
location?
a. Two-wire control
b. Three-wire control
c. Multiple push buttons
d. Push button interlock
UNIT OBJECTIVE
Upon completion of this unit, you will be able to understand how friction brakes work,
and connect selected jogging control circuits.
DISCUSSION OF FUNDAMENTALS
Jogging can be used to accomplish precise positioning in machine tools. It may also
be used in lifting appliances (see Figure 4-1), where the operator is required to be
present to make the machine accomplish a movement, hence improving the security
level. Additionally, jogging can be practical to perform checks during maintenance
operations.
Figure 4-2 is a diagram of a simple jogging control circuit. Pressing the JOG push
button momentarily closes the power contacts of the contactor. The motor then runs
only as long as the JOG push button is pressed, because no holding contact is
present to keep the contactor energized.
Friction brakes
Friction brakes are a common way of holding a position, in applications where the
load is subject to a force such as gravity. For instance, they can be utilized in lifting
appliances to prevent objects from falling in case of power losses. Friction brakes
provide a faster and more precise means of stopping a motor than simply
disconnecting power from the motor. That is why they are often used in jogging
circuits. Friction brakes are also called magnetic brakes.
FRICTION BRAKES
EXERCISE OBJECTIVE
DISCUSSION
Friction brakes, or magnetic brakes, are used to secure (hold) the position of a motor
in lifting appliances. They are also used to reduce motor stopping time and execute
precise control.
The action of friction brakes is smooth in either direction. This can be very useful
when working with high inertia loads. As a result, they are often found on cranes,
hoists, elevators, and other machines where soft braking is desirable.
Friction brakes are rated according to their braking torque, which should be equal to
or greater than full-load motor torque. The latter can be calculated from the following
formula:
Figure 4-3 shows the friction brake, which is coupled to the end bell of the Brake
Motor, Model 3176-A. The brake is released as long as its solenoid is actuated. But
as soon as the solenoid de-energizes, the pads are pressed against the braking disk,
forcing the motor to stop and hold its position. A label on the end bell of the Brake
Motor shows how to wire the brake depending on the supplied voltage.
The circuit shown in Figure 4-4 is a simplified motor circuit with a brake coil. When
the motor is powered, the brake solenoid energizes. The friction brake then releases
the pressure off the motor shaft, and the motor runs normally. Once power to the
motor is removed, the brake coil de-energizes, pressure is applied to the shaft, and
the motor stops smoothly. It is important to be aware that friction brakes will apply
instantly in case of a power failure.
Procedure Summary
In the first part of this exercise, you will examine a friction brake label to determine
its braking torque. You will then verify that this value is greater than the full-load
motor torque, calculated from the ratings of the motor nameplate.
In the second part of the exercise, you will release and apply the brake manually.
You will subsequently do the same via the Manual Starter, to make sure that the
shaft turns freely when the brake is released and is blocked otherwise.
Finally, you will set up a simple motor starter circuit to test how the friction brake
reduces the motor stopping time.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Braking torque:
G 4. Enter the rating of the following parameters shown in the motor nameplate.
Service factor:
G 5. Determine the full-load torque (T) of the motor using the formula of the
DISCUSSION section and the ratings shown in the motor nameplate.
Full-load torque:
G Yes G No
Does the motor Inertia Wheel turn freely (no lead is connected to the motor
terminals)?
G 9. Turn the friction brake knob to the normal position (applied). Does the motor
Inertia Wheel turn freely?
G 12. Set the overload potentiometer of the Manual Starter to the lowest value,
and the knob to the O position.
A sound should come from the friction brake enclosure. Does the motor
Inertia Wheel turn freely?
G 13. Return the knob of the Manual Starter to the O position. Does the motor
Inertia Wheel turn freely?
G 14. Following your last observations, in what manner does the brake operate?
G Fail-safe G Non-fail-safe
Start the chronometer as you press the STOP push button. How long does
it take for the motor to come to a complete stop?
Start the chronometer as you press the STOP push button. How long does
it take for the motor to come to a complete stop?
G 19. Did the motor stop faster or slower with the help of the friction brake?
G Faster G Slower
G 20. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
In friction brakes, the movement of a solenoid makes shoes or pads come in contact
with a disk mounted on the motor shaft. Fail-safe brakes, which apply automatically
when power is turned off, provide an extra level of security to weight-lifting
equipment.
Friction brakes are used in applications where a motor has to hold a certain position,
and when quick and precise stops are required. Additionally, they provide a smooth
braking action that can be useful with high inertia loads.
To stop a motor, the braking torque must be greater than the motor torque.
Therefore, friction brakes usually provide a braking torque greater than the full-load
motor torque.
REVIEW QUESTIONS
1. In Figure 4-6, what would happen if the motor was running and the power was
interrupted momentarily?
a. Control relays
b. Solenoids
c. Starting resistors
d. Contactors
EXERCISE OBJECTIVE
DISCUSSION
Jogging (also called inching) is used when an operator desires to make a motor
accomplish small movements, without having to press the stop button every time.
With jogging control circuits, the starter is energized only as long as the jog button
is pressed.
Jog/Run circuits
Figure 4-7 shows a jog/run circuit using a control relay. When the RUN push button
is pressed on, the control relay (CR) is energized and holding circuits are formed for
both the control relay (CR) and the main contactor (M). The motor then starts and
keeps running until the JOG/STOP push button is pushed, causing the control
relay (CR) to de-energize.
Pressing the JOG/STOP push button when the system is at rest causes the motor
to start and run normally until the JOG/STOP push button is released.
Many other jogging circuits can be implemented. For example, a selector switch can
be employed to switch between run and jog modes, the jog mode simply disabling
the holding contacts.
Procedure Summary
In the first part of this exercise, you will set up a simple jogging circuit. You will make
it work to verify that the motor only works when the JOG push button is pressed. You
will also see that using a friction brake adds precision to the stop.
In the second part of the exercise, you will implement a jog/run circuit that uses a
selector switch to change between jog and run modes.
In an additional exercise, you will be asked to replace the preceding circuit with one
that includes three push buttons and a control relay.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Press the JOG push button. Does the motor start to run?
G Yes G No
G 4. Release the JOG push button. Does the motor keep running?
G Yes G No
Press and release the JOG push button. Is stopping more precise when the
friction brake is connected?
G Yes G No
G 7. Connect the circuit shown in Figure 4-8. Use the SS-1 contact of the
Selector Switches module.
G 8. Set the RUN/JOG selector switch of the Selector Switches to the O position
(open contact).
Press and release the START push button. What happens to the motor?
G 9. Does the START push button work like a normal jog push button?
G Yes G No
G 10. Set the RUN/JOG selector switch of the Selector Switches to the L position
(closed contact).
Press and release the START push button. What happens to the motor?
G 11. Does the START push button work like a normal start/stop motor starter
circuit?
G Yes G No
G 12. Do your observations confirm that a selector switch can be adequately used
to select between jog and run modes?
G Yes G No
G 13. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
ADDITIONAL EXERCISE
Your client wants you to change the control circuit of Figure 4-8 to include three
different push buttons: one for jogging, one for starting, and one for stopping.
To implement the new circuit, you decide to set up a jogging circuit with a control
relay. Implement the Figure 4-7 circuit and verify that it corresponds to what the
client wants.
CONCLUSION
In jogging control circuits, the motor starter remains energized only as long as the
jog push button is pressed. No holding circuit is operating. Because of the repeated
switching of high currents, jogging greatly reduces the life expectancy of contactors.
C Start and stop push buttons can be used along with a jogging circuit to
enable continuous motor operation.
C Selector switches enable the choice between run and jog operating modes
for the same start push button.
C Control relays make it possible for more specialized circuits. For example,
in a jog/run circuit, they can make jogging independent of normal (run)
operation.
REVIEW QUESTIONS
2. In the Figure 4-7 circuit, what happens if the motor is running continuously and
the JOG push button is pressed and released?
a. A short-circuit occurs.
b. Both coils (CR and M) de-energize and the motor stops running.
c. The overload trips and the motor stops.
d. The control relay de-energizes after the JOG push button is released,
opening the holding circuits and making the motor stop.
4. In jogging circuits, which device uses its power contacts prematurely due to
rapid and repeated switching of inrush current?
a. Contactor
b. Push button
c. Friction brake
d. Selector switch
a. Control relay
b. Inertia
c. Friction brake
d. Selector switch
EXERCISE OBJECTIVE
DISCUSSION
Some machine tool processes require both forward and reverse jog controls. When
repeated clockwise and counterclockwise inching is necessary, a jogging control
circuit with a reversing starter can be implemented.
Pressing the FWD push button starts and runs the motor in the forward direction.
Pressing the REV push button runs the motor in the reverse direction. The
FJOG/STOP, or RJOG/STOP, push button must be pressed to stop the motor before
changing direction, due to the mechanical interlock between the two contactors.
Pressing the FJOG/STOP push button runs the motor in the forward direction. Once
the push button is released, the motor stops. The RJOG/STOP push button operates
in the same manner, only in the reverse direction.
Many other configurations of reversing circuits with jogging can be implemented. For
example, a selector switch may be utilized to switch between jogging and running
modes. Such a circuit is shown in Figure 4-10 and is proposed as an additional
exercise.
Procedure Summary
In the first part of this exercise, you will implement a reversing starter having jogging
and running capabilities in both motor rotation directions. The circuit will use push
buttons, as well as a control relay and a dual contactor with mechanical interlock to
provide the aforementioned features. You will subsequently test the different push
button combinations to verify that the circuit functions correctly.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Reversing starter with jogging circuit using push buttons and a control relay
Press the FWD push button. Does the motor start and keep running?
G Yes G No
G F (forward contactor)
G CR (control relay)
G R (reverse contactor)
G None
G 5. What happens when you momentarily press the FJOG/STOP push button?
G Yes G No
G 7. Press the FJOG/STOP push button. What happens to the motor while you
keep the FJOG/STOP push button pressed?
G Yes G No
G 10. Which contact(s) is(are) closed while you keep the FJOG/STOP push button
pressed?
G F (forward contactor)
G CR (control relay)
G R (reverse contactor)
G None
G 11. Explain how the control circuit operates while you keep the FJOG/STOP
push button pressed?
What happens to the motor when the RJOG/STOP push button is pressed?
G 14. What happens to the motor when the RJOG/STOP push button is released?
G 15. Do your observations confirm that the control circuit acts as a reversing
starter having jogging and running capabilities in both motor rotation
directions?
G Yes G No
G 16. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
ADDITIONAL EXERCISE
Your client wants you to change the control circuit of Figure 4-9 to incorporate a
selector switch. He does not like the idea of having a control relay and wants the
circuit to be simpler. He also wants a push button interlock permitting immediate
reversal of motor rotation direction.
Finally, he would like to have a selector switch that, when turned to the JOG position,
permits switching off a motor running continuously.
To fulfill the demands of the client, implement the Figure 4-10 circuit and verify that
it corresponds to what the client wants.
CONCLUSION
A jogging control circuit using a reversing starter can be implemented when repeated
clockwise and counterclockwise inching is necessary.
Push buttons and control relays can be utilized to set up a reversing control circuit
with jogging. Using a selector switch permits employing the same push buttons for
jogging and running modes.
REVIEW QUESTIONS
1. In the Figure 4-9 circuit, what happens if the lead between the RJOG/STOP NC
contact and the control relay coil is disconnected?
2. In the Figure 4-9 circuit, what happens if both jog buttons (FJOG/STOP and
RJOG/STOP) are pressed simultaneously?
3. In the Figure 4-9 circuit, what happens if both start buttons (FWD and REV) are
pressed simultaneously?
4. In the Figure 4-10 circuit, what happens when the selector switch is turned to the
JOG position?
5. In the Figure 4-10 circuit, what happens if the emergency button is pressed?
UNIT TEST
a. Inching
b. Starting
c. Running
d. Maintaining
7. Which of the following designations is not an alternate name for fail-safe brakes?
a. Safety brakes
b. Spring-set brakes
c. Power-on brakes
d. Electrically-released brakes
9. In a jogging control circuit with reversing starter, why would a control relay be
used?
UNIT OBJECTIVE
Upon completion of this unit, you will be able to utilize a primary resistor starter and
a soft starter. You will also understand the underlying principles of reduced AC
voltage starters.
DISCUSSION OF FUNDAMENTALS
Induction motors started with full voltage draw high inrush currents from power
lines. When large motors are started, this phenomenon can result in power line
disturbances and spikes in the electrical power demand (often leading to higher utility
bills). Sudden starts are also tougher on the mechanical elements of the system,
because the acceleration is more abrupt.
Figure 5-1 shows the current used by an induction motor at various speeds. Note
how the starting current is high compared to the running current, until the motor
reaches its fully rated speed.
Reduced voltage and current methods are often employed to limit the negative
consequences of direct-on-line starting. Common alternate motor starting techniques
are:
C Wye-delta starters: The stator is wye connected for starting and delta
connected for running. This method requires a motor designed for this
purpose, in which no internal connection is made.
C Variable frequency drive: AC drives initially apply low frequency and voltage
to the motor. This avoids high inrush current, while producing high starting
torque.
In the following Unit, you will experiment with two reduced AC voltage methods,
namely the primary resistor and the solid-state starters.
EXERCISE OBJECTIVE
DISCUSSION
High starting torque can result in sudden acceleration and damage to the driven
machinery. Excessive current inrush is likely to provoke unwanted power line
disturbances. Primary resistor starters can be used to start motors where limited
torque or inrush current is required. This type of starter provides smooth acceleration
without the line current surges usually experienced with other reduced voltage
methods.
Primary resistor starters have resistors connected in series, between each line and
the motor. The presence of resistors reduces the voltage applied to the motor, but
they produce heat. The lesser potential results in minimized motor starting current.
But since motor torque is proportional to the square of the potential, the starting
torque is low. As a result, this solution is impractical for systems such as conveyors,
which require high torque upon starting.
One or more stages of resistors can be implemented, depending upon the motor size
and the desired starting smoothness. More steps provide a more gradual
acceleration. The resistors are bypassed by contactors when the motor reaches a
certain speed, so that the motor eventually runs on full line voltage.
A typical resistor starter circuit is shown in Figure 5-2. When the Manual Starter is
turned on, the resistors are connected in series with the motor. A voltage drop occurs
across the resistors and the motor starts on reduced voltage. Once the motor has
reached a sufficient speed, the operator shorts the resistors by closing the selector
switch commanding the run contactor. The motor is then connected across full line
voltage.
Procedure Summary
In the first part of this exercise, you will set up a circuit to measure the Brake Motor
locked rotor current. You will then compare this value with the motor full-load current
(FLA) to see that it is many times higher.
In the second part of the exercise, you will implement a circuit including resistors in
series with the motor. You will observe that the presence of the resistors diminishes
the motor locked rotor current, and consequently, the motor starting current.
Finally, you will start the motor with primary resistors. You will discover that resistors
are bypassed during normal operation to avoid making the motor run under lower
voltage and lose power through resistors.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
G 4. Observe the ammeter display as you set the knob of the Manual Starter to
the I position for three seconds.
Note the locked rotor current going through the power line. Repeat once to
confirm the result.
What is the full-load ampere rating (FLA) indicated on the nameplate of the
Brake Motor?
G 7. By how many times is the locked rotor current higher than the full-load
ampere rating (FLA)?
G 9. Connect the circuit shown in Figure 5-2. Use the SS-1 contact of the
Selector Switches module.
Set the RUN selector switch of the Selector Switches to the O position
(open contact).
G 11. Observe the ammeter display as you set the knob of the Manual Starter to
the I position for three seconds.
Note the locked rotor current going through the power line. Repeat once to
confirm the result.
By how many times is the locked rotor current measured with resistors
higher than the full-load ampere rating (FLA)?
G 13. Does the presence of primary resistors diminish the motor locked rotor
current? Explain why.
G 14. Remove the ammeter and install a voltmeter between two motor power
lines.
Set the knob of the Manual Starter to the I position, and wait for the motor
to reach full speed.
G 15. Set the RUN selector switch of the Selector Switches to the L position
(closed contact) to bypass the resistors via the R contactor. Note the voltage
between the two lines.
G 16. Is motor input voltage higher or lower, if resistors are not bypassed during
motor operation?
G Higher G Lower
G Yes G No
The Starting Resistors module may be hot. Please be careful when you handle
this module after use.
G 18. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Primary resistor starters can be used for starting motors at a reduced voltage.
Resistors are inserted in series with the motor terminals and power lines to create
a drop in the input voltage.
REVIEW QUESTIONS
5. In the Figure 5-2 circuit, what control device is used to switch the RUN contactor
on and off?
a. Control relay
b. Timing relay
c. Plugging switch
d. Selector switch
SOFT STARTERS
EXERCISE OBJECTIVE
DISCUSSION
Soft starters are solid-state devices providing gradual voltage increase, for the
purpose of starting a motor smoothly. Most soft starters also perform soft stops, to
make the motor run-down longer than if the motor were merely to coast to a stop.
Compared to primary resistor starters, soft starters present major benefits:
C No wearing parts
C Easy adjustments
C Less space needed
C Gradual voltage increase (no steps)
C Reduced power losses
By lowering the input voltage, a soft starter diminishes the motor current. The motor
torque, which is proportional to the square of motor voltage, is also lessened. This
explains why a soft started motor does not accelerate suddenly. However, if the
starting voltage is too low, the motor will not start immediately, but will nevertheless
heat up during that time.
For example, if the starting voltage is at 30%, the torque produced will only be
about 9 % of the normal value. This might not be enough to start the motor. A soft
starter is correctly set when the motor starts smoothly and runs up rapidly to its rated
speed.
Figure 5-4 shows the Soft Starter, Model 3186. This device has three adjustment
potentiometers, which are controlling:
Note: The settings of the three potentiometers are scanned before each
auxiliary voltage switching operation. If, for example, the starting time
setting is changed while the motor is running up, the change does not
come into effect until the next start.
A simple soft starter control circuit is presented in Figure 5-5. When power is applied
to the circuit, supply voltage is applied to the Soft Starter, as shown by the READY
indicator on the device. When the Manual Starter is turned on, the Soft Starter input
terminals are energized. When the START selector switch actuates, the Ramp-up
function begins, and the READY indicator begins flashing. The motor is then
gradually energized. Once the READY light turns off and the RUN indicator turns on,
it is a sign that the device has switched to normal (full voltage) running operation.
When the selector switch is turned off, the Ramp-down function starts, the RUN light
turns off, and the READY indicator begins flashing. When the READY indicator lights
up continuously, the Ramp-down function is over.
Note: Like other control devices, soft starters have their own IEC utilization
categories. AC-53a are starters that are not bypassed and AC-53b are
starters that are bypassed during run to cool them down. The Soft Starter,
Model 3186, is AC-53a rated.
Figure 5-6 is an example of the Soft Starter behavior. The ramp-up time is set to
10 s, the starting voltage to 50%, and the ramp-down time to 15 s. Power is applied
to the circuit at t = 0 s. At t = 5 s, the selector switch is turned on and starting voltage
is applied to the motor. The voltage is gradually increased to its nominal value over
the next 10 s (ramp-up time). The motor then runs under normal conditions until the
selector switch is turned off at t = 40 s. During the following 15 seconds (ramp-down
time), the motor voltage is gradually reduced to zero.
Procedure Summary
In the first part of this exercise, you will observe the influence of low starting voltage
values. You will see that a starting voltage that is too low is not effective, because
the motor does not start promptly.
In the second and third parts of the exercise, you will test the influence of different
ramp-up and ramp-down time settings on accelerating and decelerating times. You
will observe how voltage is gradually increased and decreased with the help of a
voltmeter.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Connect the circuit shown in Figure 5-5. Use the SS-1 contact of the
Selector Switches module.
Set the START selector switch of the Selector Switches to the O position
(open contact).
C Ramp-up time: 10 s
C Starting voltage: min position
C Ramp-down time: 0 s.
G 4. Set the START selector switch to the L position (closed contact) for three
seconds, then return the knob to the O position.
Does the motor start easily (during these three seconds)? Describe the
motor acceleration.
G 5. Set the starting voltage potentiometer of the Soft Starter to the 12-o'clock
position.
Set the START selector switch to the L position for three seconds, then
return the knob to the O position.
Does the motor start more easily when the starting voltage is higher?
Describe the motor acceleration.
C Ramp-up time: 20 s
C Starting voltage: 12-o'clock position
C Ramp-down time: 0 s.
G 7. Start the chronometer as you set the START selector switch to the
L position. Observe the gradual increase of motor voltage.
How long does the Soft Starter take to supply full voltage to the motor?
Time:
Start the chronometer as you set the START selector switch to the
L position. Observe the gradual increase of motor voltage.
How long does the Soft Starter take to supply full voltage to the motor?
Time:
G 9. Start the chronometer as you set the START selector switch to the
O position. Observe the decrease of motor voltage.
How long does the Soft Starter take to stop supplying voltage to the motor
(less than 2 V)?
Time:
Set the START selector switch to the L position, and wait for the RUN
indicator of the Soft Starter to turn on.
Start the chronometer as you set the START selector switch to the
O position. Observe the decrease of motor voltage.
How long does the Soft Starter take to stop supplying voltage to the motor
(less than 2 V)?
Time:
G 11. Does increasing the ramp-down time make the motor stop more softly?
G Yes G No
G 12. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Soft starters enable smoother starting than direct-on-line starters. Besides, they offer
many advantages compared to primary resistor starters: they have no wearing parts,
are easy to adjust, need less space, provide gradual voltage changes, and do not
dissipate much power.
Soft starters usually have three adjustments: starting voltage, ramp-up time, and
ramp-down time.
A lower starting voltage reduces the inrush current upon starting. However, when the
starting voltage is too, the motor produces heat and does not start immediately.
The ramp-up time is the time the soft starter takes to reach the rated motor voltage.
The longer the time, the softer the start.
Ramp-down time is used to gradually reduce the motor voltage to zero for slower
stop. Ramp-down is useful in applications where a controlled stop is needed.
REVIEW QUESTIONS
2. In the Figure 5-5 circuit, what happens when the starting voltage is too low for
the load?
3. In the Figure 5-5 circuit, what voltage is applied to the motor when the RUN
indicator is lit?
a. Full voltage
b. Starting voltage
c. No voltage
d. Increasing voltage
a. No wearing parts
b. Easy adjustments
c. Smaller size
d. Larger heat losses
UNIT TEST
1. Which of the following starters does not provide reduced voltage upon starting?
2. What can be done to primary resistor starters to obtain a more smooth start?
5. If the ramp-up time of a soft starter is increased, what is the effect on starting
time?
7. What motor starter provides a voltage that increases following the shape of a
ramp?
9. If the ramp-down time of a soft starter is diminished to zero, what is the effect on
stopping time?
UNIT OBJECTIVE
Upon completion of this unit, you will understand how time relays work. You will also
be able to utilize solid-state time relays in applications requiring time delays.
DISCUSSION OF FUNDAMENTALS
Time relays are used in control, starting, and protective circuits for all switching
operations involving time delays. Different pilot devices are employed to control the
process of energizing or de-energizing timing relays.
C Dashpot: Old technology in which a time delay results from air or liquid going
through a valve opening at a variable speed.
TIME RELAYS
EXERCISE OBJECTIVE
DISCUSSION
Lab-Volt's Time Relay, Model 3132, is a solid-state category time relay. This device,
shown on Figure 6-3, has three adjustment potentiometers, which are controlling:
Two indicator lights provide information about the Time Relay status. The one at the
top indicates the coil state. The one at the bottom indicates the contact state.
Table 6-1 describes the different functions of this module with their associated code.
The function codes are also indicated on the module faceplates.
Auxiliary
NO contact closes for t seconds as soon as the auxiliary coil
rising edge G
is switched on. The supply voltage is always on.
pulse
Figure 6-5 shows a time-delay circuit. When the selector switch closes, the time relay
coil is energized. If an on-delay is set, the NO contact closes after the preset time t,
turning on the green light. Opening the selector switch de-energizes the circuit,
turning off the green light.
Procedure Summary
In the first part of this exercise, you will implement an On-delay function in a pilot
light circuit. You will observe that this function works with supply voltage only and
that a delay is produced before the NO contact closes. You will then modify the time
adjustment potentiometer to change the set time delay.
In the second part of the exercise, you will change the time function for Off-delay.
You will observe that this function works with supply and auxiliary voltages. A delay
is produced after auxiliary voltage is lost, before the NO contact opens. The supply
voltage must be provided at all times to make this function work.
In the third part of the exercise, you will try the On- and Off-delay function. You will
discover that a delay is produced before the NO contact opens or closes, following
a change in the auxiliary voltage. The supply voltage must be provided at all times
to make this function work.
In the last part of the exercise, you will be asked to make a pilot light flash at a given
rate. To do so, you will set the function code and time-delay value potentiometers to
appropriate values.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
On-delay function
G 2. Connect the circuit shown in Figure 6-5. Use the SS-1 contact of the
Selector Switches module.
Set the START selector switch of the Selector Switches to the O position
(open contact).
Start the chronometer as you set the START selector switch of the Selector
Switches to the L position (closed contact).
G 5. Start the chronometer as you set the START selector switch to the
O position (open contact).
Start the chronometer as you set the START selector switch to the
L position.
G 7. Set the START selector and the AUX toggle switches of the Selector
Switches to the O position.
Off-delay function
G 9. Start the chronometer as you set the START selector switch to the
L position.
G 10. Explain what happens (refer to the Figure 6-4 time diagram if necessary).
G 11. Start the chronometer as you set the AUX toggle switch to the R position.
G 12. Explain what happens (refer to the Figure 6-4 time diagram if necessary).
G 13. Start the chronometer as you set the AUX toggle switch to the O position.
G 14. Explain what happens (refer to the Figure 6-4 time diagram if necessary).
G 15. Set the START selector and the AUX toggle switches to the O position.
G 16. Set the Time Relay with the following parameter values:
G 17. Start the chronometer as you set the START selector switch to the
L position.
G 18. Explain what happens (refer to the Figure 6-4 time diagram if necessary).
G 19. Start the chronometer as you set the AUX toggle switch to the R position.
G 20. Explain what happens (refer to the Figure 6-4 time diagram if necessary).
G 21. Start the chronometer as you set the AUX toggle switch to the O position.
G 22. Explain what happens (refer to the Figure 6-4 time diagram if necessary).
G 23. Set the START selector and the AUX toggle switches to the O position.
Flashing
G 24. Using the same circuit, set the time relay so that the L1 pilot light turns on
or off every 1.5 seconds with a time-delay adjustment potentiometer set
to 50%.
What function code and time-delay value have you set on the Time Relay?
Function code:
Time-delay value:
G 26. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Solid-state and programmable time relays are electronically piloted and permit more
functions. On-delay, off-delay, flashing, rising edge pulse, and falling edge pulse are
some common time functions.
REVIEW QUESTIONS
1. Which time relay type supplies a time delay corresponding to the position of the
hand on the dial?
a. Dashpot
b. Synchronous clock
c. Solid-state
d. Programmable
2. Which time relay type offers the most complex time functions?
a. Dashpot
b. Synchronous clock
c. Solid-state
d. Programmable
3. Which time function of the Time Relay, Model 3132, causes the starting signal
to be delayed, but not the stop signal?
4. Which time function of the Time Relay, Model 3132, causes the starting and the
stop signals to be delayed?
5. If you refer to Figure 6-4, which Time Relay module function does not need
auxiliary voltage to work properly?
EXERCISE OBJECTIVE
DISCUSSION
Plugging is a motor braking method that uses the counter torque produced by
reversing two power lines. In Exercise 3-4, you started a plugging operation by
pressing the forward push button while the motor was running in reverse direction.
As the motor stopped, you had to press the stop push button to prevent the motor
from rotating in the opposing direction.
When it is not possible for an operator to check when the motor is stopped, an
automatic means of stopping the motor power supply must be found. A time relay
can be utilized for this purpose, provided that the time the motor needs to stop is
known in advance. If the stopping time is variable because of a changing load, it
could be preferable to use a plugging switch. This method will be seen later in the
Industrial Controls Training System student manuals.
Figure 6-6 is a plugging circuit using a time relay to stop the motor before it rotates
backwards. To make the motor turn in the forward direction, the START push button
is pressed. The STOP push button makes the motor coast to a stop. The FSTOP
(fast stop) push button opens the forward contactor and activates the reverse
contactor, making the motor stop rapidly. The On-delay function of the time relay
opens the reverse contactor a preset time t after the forward contactor is de-
energized. If t is chosen properly, the motor stops exactly when the reverse contactor
is de-energized.
Procedure Summary
In the first part of this exercise, you will set up a reversing circuit that enables
plugging. You will do plugging with the Inertia Wheel on the motor shaft and stop the
circuit manually, before it rotates backwards. You will observe that it is difficult to
stop the circuit on time, every time.
You will then plug a time relay and adjust the delay to make the motor stop perfectly,
each time the FSTOP push button is pressed.
In the last part of the exercise, you will remove the Inertia Wheel and observe that
the R contactor is now energized too long, making the motor rotate in the opposite
direction.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
Manual plugging
Connect a lead between the Time Relay terminals 15 and 16 to disable the
Time Relay.
Press the START push button to start the motor, and wait for the motor to
rotate at full speed.
G 4. Press the FSTOP push button and, when the motor comes to a stop, press
the STOP push button to de-energize the motor.
Plugging time:
Note: You should notice that it is not easy to manually stop the
motor right on time, with consistency.
Disconnect the lead between the Time Relay terminals 15 and 16.
Does the motor keep on turning as the circuit is switched off by the Time
Relay? If yes, does the motor turn in forward or reverse direction?
G 9. Adjust the time delay to de-energize the motor exactly as it switches off.
Repeat the START - FSTOP sequence as often as necessary.
Note the time delay value required to stop the motor exactly as it switches
off.
Does the motor keep on turning, as the circuit is switched off by the Time
Relay? If yes, does the motor turn in a forward or reverse direction?
G 13. Why would this control circuit not be used with variable loads?
G 14. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
A motor can be plugged with a time relay to make it stop rapidly and perfectly each
time. If the motor is not stopped completely by the plugging, it is a sign that the time
delay is too short. But if it turns in the opposite direction after stopping, the time delay
is too long.
If the motor is connected to a variable load, using a time relay is not a good option;
the time delay has to be readjusted upon every change in load to obtain perfect
plugging stops. Plugging switches, which sense changes in motor speed, can be a
good alternative to time relays under those circumstances. They are, however, more
expensive.
REVIEW QUESTIONS
1. Which control device sees its NO and NC contacts states change following
preset time delays?
a. Plugging switch
b. Time relay
c. Contactor
d. None of the answers above is correct.
2. In the Figure 6-6 circuit, what happens if time relay terminals 15 and 16 are
short-circuited?
3. In the Figure 6-6 circuit, what happens when the STOP push button is pressed
while the motor is running in the forward direction?
a. Two line phases are inverted to make the motor stop rapidly.
b. The motor slows down until it stops.
c. The friction brake is automatically applied.
d. None of the answers above are correct.
4. In the Figure 6-6 circuit, how can you keep the time relay well set, if the load
increases significantly?
EXERCISE OBJECTIVE
• Understand how a time relay can be used jointly with primary resistor starters.
DISCUSSION
Primary resistor starters are used to reduce the voltage to the motor upon starting,
causing starting torque and current to diminish. When the motor is started, a voltage
drop is produced by resistors placed in series with the motor terminals. Resistors are
bypassed after a while to make the motor run under full voltage and avoid heat
dissipation through the resistors.
In Exercise 5-1, you completed such a circuit in which you bypassed the resistors
using a selector switch and a contactor. But it is also possible to automatically
bypass the resistors by using a time relay. This enables the resistors to be switched
off at an appropriate time and prevents the resistors from being left on inadvertently.
Figure 6-7 is a primary resistor circuit using a time relay. Once the power and the
Manual Starter are turned on, the motor is started under reduced voltage, because
resistors are placed in series with its terminals. The Time Relay coil is also energized
and the on delay starts. Once the preset delay has been reached, the Time Relay
NO contact closes. This energizes the running contactor, hence bypassing the
resistors and making the motor run under full voltage.
Procedure Summary
In this exercise, you will put together a primary resistor starter circuit and the Time
Relay module. This setup will utilize the On-delay function of the Time Relay to delay
the actuation of a contactor that bypasses the resistors. You will modify the delay
time to see the influence it has on motor acceleration.
EQUIPMENT REQUIRED
Refer to the Equipment Utilization Chart in Appendix A to obtain the list of equipment
required for this exercise.
PROCEDURE
Basic setup
G Yes G No
G Yes G No
The Starting Resistors module may be hot. Please be careful when you
handle this module after use.
G 6. Turn the individual power switch of the AC Power Supply off, disconnect the
circuit, remove the magnetic labels, and return the equipment to the storage
location.
CONCLUSION
Primary resistor starters are used to start motors at a lower voltage, produced by
resistors inserted in series with motor terminals. After a time delay, starting resistors
are bypassed to let motors operate at full line voltage. This bypass procedure can
be controlled manually, by an operator, or automatically, with the help of a time relay.
REVIEW QUESTIONS
1. In the Figure 6-7 circuit, when does the motor receive full voltage?
3. In the Figure 6-7 circuit, when is the Time Relay coil energized?
4. In the Figure 6-7 circuit, which control device is used to switch the R contactor
on and off?
a. Control relay
b. Time relay
c. Plugging switch
d. Rheostat
5. In the Figure 6-7 circuit, what happens to the R contactor, if the Manual Starter
is turned off while the motor is running at full voltage?
UNIT TEST
1. Which time function of the Time Relay, Model 3132, causes its NO contact to
alternately close and open at a given rate?
a. Flashing (code D)
b. On- and off- delay (code C)
c. Off-delay (code B)
d. On-delay (code A)
2. Which time relay type involves air or liquid going through a valve?
a. Dashpot
b. Synchronous clock
c. Solid-state
d. Programmable
3. Which time relay type contains electronic devices, but is not a PLC?
a. Dashpot
b. Synchronous clock
c. Solid-state
d. Programmable
4. Which time function of the Time Relay, Model 3132, causes the starting signal
to be delayed, but not the stop signal?
5. How do plugging circuits create the counter torque necessary to stop a motor?
7. In plugging circuits with a time relay, what happens if the time delay is set too
long?
EQUIPMENT EXERCISE
MODEL DESCRIPTION 1-1 1-2 1-3 1-4 1-5 2-1 2-2 3-1 3-2 3-3 3-4 3-5 4-1 4-2 4-3 5-1 5-2 6-1 6-2 6-3
3103 Mobile Workstation 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3110 Push Buttons 1 2 2 1 2 2 1 1 2 2
3111 Selector Switches 1 1 1 1 1 1 1 1 1 1
3114 Emergency Button 1 1 1 1 1 1 1 1 1 1 1 1
3115 Pilot Lights 1 1 2 2 1 1 1
3119 Dual Contactors 1 1 1 1
3125 Lockout Module 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3126 Manual Starter 1 1 1 1 1 1 1 1
3127 Contactor 1 1 1 1 1 1 1 1 1 1 1
3130 Control Relay 1 1 1 1
3131 Overload Relay 1 1 1 1 1 1 1 1 1
3132 Time Relay 1 1 1
3137 Fuse Holder 1 1
3138 Control Transformer 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3140 Cam Switch 1 1 1
3147 Inertia Wheel 1 1 1 1 1 1 1 1 1 1
3150 Starting Resistors 1 1 1
3176-A Brake Motor 1 1 1 1 1 1 1 1 1 1 1 1 1
3186 Soft Starter 1
3196 AC Power Supply 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
8951 Connection Leads 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
N/A AC Voltmeter1 1 1 1 1
1
N/A AC Clamp Ammeter 1 1 1
1
N/A Ohmmeter 1 1
N/A Chronometer 1 1 1 1 1
N/A Fuses 1 1
1
Lab-Volt model 70-38707 multimeter can be used in all exercises involving a voltmeter, a clamp ammeter, or an ohmmeter.
Accelerating A Overload OL
Ammeter AM Overvoltage OV
Figure C-1. IEC motor dimension chart (Courtesy of Baldor Electric Company).
Figure C-2. NEMA motor dimension chart (Courtesy of Baldor Electric Company).
This appendix contains the Basic Setup and Lockout/Tagout procedures specific to
the Industrial Controls Training System from Lab-Volt. It is divided into four sections:
C Basic Setup procedure, explains the basic operations that must be performed
at the beginning of the exercise procedures.
G 1. Make sure that the power switch located on your side of the AC Power
Supply is set to the O position.
Figure D-2. Make sure that the fault switches are set to the O position.
G 2. Install the lockout hasp and the student padlocks and tags on the Lockout
Module. Ask the instructor to install the lab padlock and tag as well. Refer
to Figure D-4 for details.
G 3. Check that the Lockout Module switch cannot be opened. With a voltmeter,
verify that no voltage is present between the Lockout Module output
terminals to confirm that the circuit is de-energized. You may now set up
your circuit.
Energizing procedure
G 1. Interconnect the ground terminal (green) of all AC modules with the ground
terminal of the Lockout Module.
G 2. Make sure the Security Guard is installed if you are using a motor.
G 4. Once the connections have been made, ask for the instructor to check the
circuit. When the circuit is correctly wired, notify all the people working
around the Mobile Workstation that the system will be energized.
G 6. Turn on the AC Power Supply and Lockout Module, and return to your
exercise.
Module identification
G 1. Once the setup is completed, identify all buttons, pilot lights, switches, etc,
in accordance with the circuit schematic diagram. Place the magnetic labels
on the module faceplates as shown in Figure D-5.
Figure D-6. Store the magnetic labels on the vertical surface of the Mobile Workstation.
C Position and align the mounting plate over the four holes at the left of the Mobile
Workstation.
C Fix the Brake Motor to the mounting plate of the Mobile Workstation using
hexagonal head screws with knurled nuts or with washers when placing the
head of the screw on top. Figure E-1 shows the two fixing methods.
C Install a 3/16 x 3/16 key in the shaft keyseat (at the extremity of the shaft).
C Slide the Inertia Wheel over the Brake Motor shaft taking care of aligning the
Inertia Wheel keyway with the key (see Figure E-2).
Figure E-2. Align the Inertia Wheel keyway with the key.
C Install the Safety Guard over the Inertia Wheel as shown in Figure E-4. Press
the push-locks (4) once the Safety Guard is placed.
Number of phases 3
Insulation class B
control relay An auxiliary relay that controls the operation of motor starters,
contactors, switching solenoids, and other relays.
core (magnetic The part of the magnetic structure around which the magnetizing winding
core) is placed. (IEEE)
electromechanic A device that is electrically operated and has mechanical motion such as
al device relays, servos, etc. (IEEE)
float switch A switch in which actuation of the contacts is affected when a float
reaches a predetermined level. (IEC)
friction brake Motor stopping method where shoes or pads come in contact with a
wheel mounted on the motor shaft.
full-load ampere See Full-Load Current Rating (FLC).
rating (FLA)
full-load current The current required to produce full-load torque at the motor's rated
rating (FLC) voltage and speed.
inrush current Initial surge of a current into a load before it attains normal operating
condition.
interrupting The highest current at rated voltage that the device can interrupt. (IEEE)
capacity
jogging Quickly repeated closure of a circuit to start a motor from rest for the
purpose of accomplishing small movements of the driven machine.
limit switch A switch that is operated by some part or motion of a power driven
machine or equipment to alter the electric current associated with the
machine or equipment. (ANSI)
lockout The placement of a lock on an energy-isolating device, in accordance
procedure with an established procedure, ensuring that the energy-isolating device
and the equipment being controlled cannot be operated until the lock is
removed.
low-voltage See Three-Wire Protection.
protection
low-voltage See Two-Wire Control.
release
magnetic brake See Friction Brake.
magnetic field The space around a magnetic pole or magnetized body in which the
magnetic force has an effect.
normally closed Contact that is in a closed position when the operating magnet is de-
(NC) contact energized.
normally open Contact that is in an open position when the operating magnet is de-
(NO) contact energized.
part-winding Motor starting method where power is applied first to part of the motor
starting coil windings. During normal operation, power is applied to all coil
windings.
service factor Multiplier that is applied to the rated power to indicate the permissible
power loading capacity designed into a motor.
solenoid A tubular, current carrying coil that provides magnetic action to perform
various work functions.
target table Table used to indicate the contact condition of a device, depending on its
states.
torque The twisting or turning force which tends to produce rotation in a motor.
two-wire control A control function that utilizes a maintained-contact type of pilot device to
provide undervoltage release. (IEEE)
wye-connected A polyphase circuit in which all the current paths extend from a terminal
circuit or conductor.
Rockis, G., and Glen Mazur. Electrical Motor Controls, Second Edition. Homewood,
IL: American Technical Publishers Inc., 2001, ISBN 0826916759.
Wildi, T. Electrical Machines, Drives and Power Systems, Sixth Edition. Englewood
Cliffs, NJ: Prentice Hall, 2005, ISBN 0131776916.
Herman, S.L. Industrial Motor Control, Fifth Edition. Clifton Park, NY: Thomson
Delmar Learning, 2005, ISBN 1401838022.
National Electrical Manufacturers Association. NEMA and IEC Devices for Motor
Services - A Guide for Understanding the Differences. ICS 2.4-2003.
National Center for Construction Education and Research. Electrical Level 3 Trainee
Guide. Upper Saddle River, NJ: Pearson/Prentice Hall, 2002, ISBN 0130472239.
We Value Your Opinion!
Your comments and suggestions help us produce better manuals and develop
innovative systems to meet the needs of our users. Please contact us by e-mail at:
services@labvolt.com