UNIT: BASIC MOTOR CONTROL

Element02. Primary Control and Pilot Control Devices

Instructional and learning objectives:-

o State the functions of control pilot devices

o Describe various control pilot device

PRIMARY CONTROL AND PILOT CONTROL DEVICES

All components used in motor control circuits may be classed as either primary control devices
or pilot control devices.

Primary control devices

A primary control device is one that connects the load to the line, such as a motor starter,
whether it is manual or automatic. The main types of primary control device may includes;
contactor and relay.

Control pilot device

A number of control pilot devices can be used in motor control system and circuit, and without
the input devices, the motor could function.

Pilot control devices are those that control or modulate the primary control devices or are
sensors and/or switches that provide the input to the motor control system and device/primary
control devices. Also pilot device may be defined as a device that directs the operation of
another device. Pilot device is typically a low – power de vice that creates a circuit to control a
large power – handling device.

Pilot devices may include pushbuttons, float switches, pressure switches, and thermostats.
These switches are called pilot devices because they are rated for control circuit voltage and
current. The control circuits that use pilot duty switches are used to energize or de-energize the
coil of a relay, motor starter, solenoid, or an indicator lamp.

Pilot devices vary greatly with their function and intended use. From manual switches to
automatic control devices, pilot devices are what make a motor controller adaptable to fit a
multitude of applications.

Example

An example would be a magnetic contactor controlled by a toggle switch used to energize and
de-energize the contactor, or M coil. To start the motor, the toggle switch is switched ON,
which energizes the contactor coil and closes the main line contacts, which energizes the
motor. Switching the toggle switch OFF de-energizes the contactor coil, opens the main line
contacts, and de-energizes the motor.

In this example, the contactor, in that it connects the motor or load to the line, would be
classed as a primary control device. The switch does not connect the load to the line, but is
used to energize and de-energize the coil of the starter. Therefore, it would be classed as a pilot
control device.
TYPES OF CONTROL PILOT DEVICES

Manually control pilot device

Pushbutton Switches/momentary switch

Manually operated pushbutton switches with normally open and normally closed contacts,
respectively. This spring-returned type switch will return to its normal position when released
by the operator or pushbuttons come with either N/O or N/C or a combination contact block.
Because the switch returns to its original position and its contacts are only closed or open for
the moment (however long) the switch is pushed, these contacts are referred to as momentary.

Toggle Switches

This type of switch has maintaining contacts; that is, once switched to a different position, the
switch will stay in that position.

Switches can be designed to operate in one of two ways. The first, and most common, is
referred to as break-before-make contact arrangement. In an arrangement of this type, one set
of contacts opens before the next set of contacts closes.

The second arrangement is referred to as make-before-break. In this arrangement, when the

switch is being switched from one position to the next, shorting or bridging of the first and
second set of contacts occurs, for a short period, during the contact transfer. This arrangement
is used when it is necessary to ensure continuity of power to a circuit during the switching
evolution.

Indicating Lights

Pilot lights provide visual information of the circuit`s operating condition. Pilot lights are
normally used for ON/OFF indication, caution, changing conditions, and alarm signaling. Pilot
come with a color lens, such as red, green, amber, blue, white or clear.

Rotary/selector Switches
A rotary switch is a multicontact switch with the contacts arranged in a full or partial circle.
Instead of a pushbutton or toggle, the mechanism used to select the contact moves in a circular
motion and must be turned. Rotary switches can be manual or automatic switches.

Some rotary switches are made with several layers or levels. This arrangement makes possible
the control of several circuits with a single switch. Selector switches are available in 2, 3, and 4
position types

Foot Switches

Foot switches are floor – mounted switches used to start or stop equipment by use of foot
control. Switches of this type are often used in applications that require the machine or process
cycle to be started at a time when the operators hands are both engaged in loading or handling
the materials. Foot-operated switches are frequently employed for such purposes. Typical
examples of foot switches are punch presses, drill presses, and sewing machines. Foot switches
are actually limit switches enclosed in a convenient and rugged casing for foot operation and
are available in a variety of contact arrangements such as single-pole double-throw, two-pole
double-throw, or other arrangements to suit a specific need.
Automatic control pilot device/switches
An automatic switch is a switch that is controlled by a mechanical or electrical device; there is
no need to turn an automatic switch on or off. Any switch that turns a circuit on or off without
operator action is an automatic switch.

Float Switches

Float/liquid level switches take many forms in their physical or mechanical construction. They
consist of one or more sets of contacts, either normally open or normally closed, operated by a
mechanical linkage. Many float switch units, as well as other pilot devices; use a mercury switch
in place of metallic contacts.

As the water level rises, it would lift the float, thus moving the contact end of the level
downward and either making or breaking the contact, depending on whether the stationary
contact were mounted above or below the arm. If a single-pole, double-throw action of the
contacts were desirable, then one stationary contact could be mounted above and one below
the center of the arm. If the float were all the way up, it would make the lower set of contacts,
and if the float were all the way down, it would make the upper set of contacts.

Float Switch
Air pressure/vacuum Switches

The switch uses a diaphragm to monitor pressure changes. These switches are commonly used
to control air pressure in air compressor. This mechanical motion is used to operate one or
more sets of contacts. Two other common sensing elements used are the diaphragm and the
bourdon tube. The type of detector is determined by the system requirements. Most devices of
this type have a means to adjust the set point of the sensing device.

Pressure Switch, Bellows Type

Temperature –activated switch/thermostats

The switch will either make or break on temperature rise. Commonly called thermostats. Many
different types of thermostats are available that employ different methods of sensing
temperature. The two most common are bellows and bimetallic strips. As in the pressure
switch, the mechanical motion of the sensing elements is used to operate a set of contacts.

Flow switch
The switches are mounted as water flow impellers or as sail switches to monitor air flow in
duct. That is used to sense the flow of liquid, air or other gas through a pipe or duct and to
transform this flow or lack of flow into the opening or closing of a set of contacts. The switch
uses a pivoted arm that has contacts on one end and a paddle or flag on the other end. The end
with the paddle or flag is inserted into the pipe so that the flow of liquid or gas causes a lever to
move and open or close the contacts.

Flow Switch, Paddle Type

Limit Switches

Limit switches use an arm, lever, or roller protruding from the switch that will be bumped or
pushed by some piece of moving equipment. This movement is then used to operate a set of
contacts. Limit switches vary widely in size and design. There are large, rugged devices for
heavy industrial use, and smaller, more accurate and precise units that use micro switches that
can operate on very minute movements of the operating lever. Limit switches, which sense
some limit such as fluid level, mechanical movement, pressure, or an electrical quantity, are
automatic switches that are sometimes quite complicated
 Limit Switch
Timer

This type of relay and contact arrangement provides two important advantages of
automatically controlled circuits: sequencing and delaying events in a control system. Many
types of timing relays are available that can be adjusted to give time delays of as little as a
fraction of a second to as much as several minutes.
MAGNETIC CONTACTOR

A contactor is an electrically controlled switch used for switching a power circuit, similar to a
relay except with higher current ratings. A contactor is controlled by a circuit which has a much
lower power level than the switched circuit.

Magnetic contactors are electromagnetically operated devices that serve to provide a safe,
convenient way to connect and disconnect circuits. Contactor may be defined as an
electromagnetic switch that used to make or break the circuit to an electrical load.

Contactors come in many forms with varying capacities and features. Unlike a circuit breaker, a
contractor is not intended to interrupt a short circuit current

Application of contactor

Contactors are used to control electric motors, lighting, heating, capacitor banks, thermal
evaporators, transfer switch and other electrical loads.

Parts of a magnetic contractor

A contactor has three components.

Contacts

The contacts are the current carrying part of the contactor or are conducting part that acts with
another conducting part of a circuit. This includes power contacts (main contacts, auxiliary
contacts, and contact springs.

The main contacts serve to connect and disconnect the main power circuit and auxiliary
contacts (both normally open and normally closed) that operate with the main contacts. The
auxiliary contacts are then available for use in the control circuit of this or another machine.
Electromagnet (or "coil")

The A basic contactor will have a coil input (which may be driven by either an AC or DC supply
depending on the contactor design). The coil may be energized at the same voltage as a motor
the contactor is controlling, or may be separately controlled with a lower coil voltage better
suited to control by programmable controllers and lower-voltage pilot devices. The main
function of Electromagnet (or "coil") is provides the driving force to close the contacts.

Enclosure/housing

The enclosure is a frame housing the contact and the electromagnet. Enclosures are made of
insulating materials to protect and insulate the contacts and to provide some measure of
protection against personnel touching the contacts.

Electromechanically/armature

Electromechanical is made up with stationary part (contact), movable contact and pressure
springs. The armature is the moving part of the magnetic circuit. When energized, the coil
induces a magnetic flux in the iron core and attracts the armature, which moves toward it.
When the armature has been attracted to its sealed position (closed), it completes part of the
magnetic circuit.

Operating principle

When current passes through the electromagnet, a magnetic field is produced; this attracts the
moving core of the contactor. The electromagnet coil draws more current initially, until its
inductance increases when the metal core enters the coil. The moving contact is propelled by
the moving core; the force developed by the electromagnet holds the moving and fixed
contacts together. When the contactor coil is de-energized, gravity or a spring returns the
electromagnet core to its initial position and opens the contacts.
Classification of magnetic contactor

Magnetic contactor may be classified based on various factors as follows:-

Based on input coil voltage

a. Contactor working on A.C voltage

b. Contactor working on D.C voltage

Based on current rating of load contacts

a. 20A
b. 25A
c. 30A
d. 50A
e. 80A

Based on number of auxiliary contact

a. 4NC with 1NO

b. 5NO with 2 NC
c. 2NO with 2 NC
d. 6NO

Based on contraction

a. Clapper Type - It contains a hinged armature that pivots to seal in, thus closing the
moveable contacts against the stationary contacts.
b. Horizontal Action - The armature and the contacts move horizontally in a straight line.
c. Vertical Action - The armature and contacts move in a straight vertical line.
d. Bell Crank - A bell crank converts the vertical movement of the armature into a
horizontal motion. Longer contact life and reduced contact bounce result from lessened
shock on armature pickup.
Factor to be considered when choosing contactor

1. Current rating of main contacts

2. Coil voltage
3. Number of auxiliary contacts
4. Supply frequency
5. Physical appearance
Primary Control and Pilot Control
Devices
All components used in motor control circuits may be classed as either primary
control devices or pilot control devices. A primary control device is one that connects the
load to the line, such as a motor starter, whether it is manual or automatic. Pilot control
devices are those that control or modulate the primary control devices. Pilot devices are
things such as pushbuttons, float switches, pressure switches, and thermostats.
For any given controller, there are generally two primary control devices used. These are
the disconnecting means, or circuit breaker (usually a manual device), and the magnetic
contactor. There may be many pilot devices used in parallel and series combinations to
control the function of starting and stopping performed by the primary control device. The
overload relays, for instance, which are included in the motor starter, are actually pilot
devices used to control the primary device whenever the motor is overloaded.