Search the meaning and functions of the devices Until 12:30 pm

UNIT I. Introduction to Motor Control

Controlling a motor can be a simple task or it can be complicated, depending on the

needs of the machine that is powered by the motor. Motors are incorporated into many
machines. This makes it necessary for the motor to be controlled according to the needs
of the machine . Motor must be protected at all times Iit must be protected when it i runs
for long periods of times as needed for any given purpose. Keep in mind that not all
motors are meant to be variable-speed motors. Some are made to run at a constant
speed. Motors must be started, stopped, reversed and the speed must be controlled. It
can be also jogged, plugged, and in some instances stopped rather quickly. All these
operations require equipment and circuit to accomplish without any damage to the
motor.

Module I MOTOR CONTROL DEVICES AND ITS FUNCTION

This module will focus on the different motor control devices and its function which is
basically use in controlling an electric motor. This devices are basically use in starting ,
stopping jogging/ itching and reversing as well as reducing the speed of electric motor.
Objectives
At the end of this lesson the student are expected to : 1
Identify the different devices of motor control.
2. know the different function of motor control devices
3. value the importance of each devices in controlling a motor

MOTOR CONTROL DEVICES AND ITS FUNCTION

PUSHBUTTON
One of the most used symbols in control schematics is the push button. Push buttons
can be shown as normally open or normally closed (Figure 2–1). Most are momentary
contact devices in that they make or break connection only as long as pressure is applied
to them. The pressure is generally supplied by someone’s finger pressing on the button.
When the pressure is removed, the button returns to its normal position. Push buttons
contain both movable and stationary contacts. The stationary contacts are connected to
the terminal screws. The normally open push button is characterized by drawing the
movable contact above and not touching the stationary contacts. Since the movable
contact does not touch the stationary contacts, there is an open circuit and current cannot
flow from one stationary contact to the other. The way the symbol is drawn assumes that
pressure will be applied to the movable contact. When the button is pressed, the movable
contact moves downward and bridges the two stationary contacts to complete a circuit
(Figure 2–2). When pressure is removed from the button, a spring returns the movable
contact to its original position. The normally closed push-button symbol is characterized by
drawing the movable contact below and touching the two stationary contacts. Since the
movable contact touches the two stationary contacts, a complete circuit exists and current
can flow from one stationary
 contact to the other. If pressure is applied to the button, the movable contact will move
away from the two stationary contacts and open the circuit

DOUBLE ACTING PUSH BUTTONS

Double action push buttons have shown their value in a variety of industries, including manufacturing
assembly lines and high-tech medical devices. Interfaces can be made smaller thanks to their ability
to combine many operations, which frees up valuable space on control panels. In automation
systems, they are essential fail-safes that allow installers to design several reactions to ensure
uninterrupted functioning. By opening a normally closed circuit and closing a normally open circuit to
supply power to the coil, this button can be utilized to simultaneously open the holding circuit. There
are two types of push button switches: usually closed and normally open. When a switch is triggered,
it completes the circuit in the typically open (or "OFF") state and breaks the circuit in the normally
closed (or "ON") position. Dual-function pushbuttons: their importance and value a key component in
the field of equipment and user interfaces that skillfully blends efficiency and safety is the double
action push button. These dual-use devices go far beyond simple switches by offering two distinct
jobs with a single press, significantly increasing the versatility of machinery and equipment.
 STACKED PUSH BUTTONS

Stacked push buttons are a common design element seen in user interfaces, especially in digital
applications and electronic devices. These buttons allow users to do many actions in a vertical or
horizontal stack, making the most of the available space and improving user experience. Compact
Design: By stacking buttons, developers can save a significant amount of screen real estate.
Applications on mobile devices, where storage is limited, will particularly benefit from this. Well-
thought-out button stacking can improve accessibility. Stacked push buttons are made to be versatile
and can be readily tailored to do a variety of tasks. A few examples of these are menu navigation,
action initiation, and setting switching. Because of their adaptability, designers can incorporate
several functions into a single object, allowing systems to react to a wider range of commands. This
flexibility is essential in a variety of industries, including automobile controls and consumer electronics

PUSH-PULL BUTTONS

Figure 2 – 8Figure
2–9

Push-pull switches are often in the off condition until the user hits the button to activate the actuator. The
device or machine will continue to operate until the user moves the actuator back to its initial position. The
push button has the NO or NC supplementary block attached to it. The voltage or current ratting of these
auxiliary devices will fluctuate. A push button switch is a mechanical device that controls an electrical circuit.
The user manually presses a button on the device to activate its internal switching mechanism. Push and pull
buttons are widely used in the electronics sector to operate a variety of electrical systems and gadgets. For
mode selection, volume control, and power on/off, they are utilized in consumer electronics, industrial control
systems, and communication devices
 LIGHTED PUSH BUTTONS

Simple gadgets known as illuminated push buttons allow a user to immediately change the process control of a
CNC machine. These push buttons come in a variety of sizes and combinations, and they ignite light for
improved visibility. And also the kind of switch made to show an indicator when they are activated. These
switches are usually utilized in situations where it's critical to quickly determine whether a circuit is on or off.
Broadcast pushbuttons, anti-vandal pushbuttons, illuminated rockers and toggles, and other varieties are
typical panel mount LED illuminated button kinds. They first facilitate easier switch operation by providing
superior visibility in low-light conditions. This is particularly useful for usage at night in automobile and aviation
applications, as well as in dimly lit areas. Compared to traditional switches, they require less maintenance and
have a longer lifespan. Thirdly, because LEDs consume less energy and require less power, they are an
affordable choice for both homes and businesses. Finally, extra color and pattern options for LED-lit switches
allow for even greater customization and personalization.

Figure 2 – 15 Figure 2 – 1
SENSING DEVICE

This device that takes in input from the environment and responds to it. The specific input could be any of a
broad range of environmental events, including motion, heat, light, moisture, pressure, and more. Predictive
and preventive maintenance are two advantages of deploying sensors and sensing technology. They not only
make sure that measurement data is transferred more quickly, but they also improve accuracy, which boosts
asset health and process control. A continuous flow of real-time data from assets and processes is provided by
a new generation of sensors that can broadcast both wiredly and wirelessly. Executives now have a deeper
grasp of a process facility as a result. Firms with sensor capabilities are more connected, secure, and agile
than ever.
LIMIT SWITCHES

Figure 2 – 21 Figure 2 – 22
FLOAT, PRESSURE, FLOW, AND TEMPERATURE SWITCHES
Limit switches are used to determine if an object is present or not. These switches were originally called Limit
Switches because they were used to define an object's limit of travel. The reed contacts' placements
throughout the guide tube's length are customizable, however the positions must be stated when ordering the
level probe. A pressure switch is a control device that senses changes in pressure and mechanically opens
and closes an electrical circuit at a pre-determined point. They are used in vessels the flow or pipes to
automatically operate valves, pumps, and alarms that signal low or high levels of fluid. Limit Switches
are sensors with an electrical limit control contact output at a specific temperature. Unit allows the user to
easily select automatic or manual reset. Applications include gas fired heater limit control and burner control.

OVERLOAD
OVERLOAD PROPERTIES

Figure 4
DUAL ELEMENT FUSE

Provide motor overload, ground fault and short circuit protection. This beneficial time-current characteristic
is obtained by using two fusible elements connected in series and contained in one tube: (1) the thermal cutout
element, and. (2) the fuse link element surrounded with arc extinguishing filler. The value and importance of
dual element fuse is provide both high performance short circuit protection and reliable overload protection in
circuits subject to temporary overloads and surge currents.
THERMAL OVERLOAD RELAY

Thermal overload relays are economic electromechanical protection devices for the main circuit. Economical
electromechanical protection devices for the main circuit are thermal overload relays. They offer dependable
defense for motors against overloads and phase failures when used in conjunction with contactors. They make
it possible to set up specialized motor starting solutions based on user requirements. An essential safety
feature in electrical systems, the thermal overload relay protects motors from overheating and possible
damage from high current. It works on the basis of thermal sensing, keeping an eye on the heat the motor
produces while it is running.

SOLDER MELTING TYPE

Alloys commonly used for electrical soldering are 60/40 Sn-Pb, which melts at 188 °C (370 °F), and 63/37 Sn-
Pb used principally in electrical/electronic work. The latter mixture is a eutectic alloy of these metals, which:
has the lowest melting point (183 °C or 361 °F) of all the tin-lead alloys. It has a low melting point and helps to
maintain a good interaction between two points of lower resistance. Thus, it is used for welding electrical wires
together.
 Figure 4 –
MAGNETIC OVERLOAD RELAYS

A Magnetic Overload Relay is a device used to protect electric motors and circuits from damage due to
excessive current. It operates by using a magnetic coil that generates a magnetic field proportional to the
current flowing through it. Magnetic Overcurrent Relay (MOR) is a device that detects and provides protection
against overcurrent conditions in electrical circuits. These relays are used to prevent serious damage caused
by excessive current and to operate electrical systems safely. Magnetic Overcurrent Relay (MOR) is a device
that detects and provides protection against overcurrent conditions in electrical circuits. These relays are used
to prevent serious damage caused by excessive current and to operate electrical systems safely.

ELECTRONIC OVERLOAD RELAYS

It is a Motor protection for overload and phase failure. Electronic overload relays offer reliable and precise
protection for motors in the event of overload or phase failure. The electronic overload relay can make up a
compact starting solution together with contactors. The primary purpose of a relay is to protect the electrical
system from too high of a voltage or current, allowing the safe operation of any equipment it connects to.
They're commonly found in a variety of applications, from commercial and industrial uses to home and
consumer products.

DASHPOT OVERLOAD RELAYS

Dashpot Magnetic Overload Relay - A magnetic overload relay. Two-

wire control. They have a series coil (6) carrying identifying the various
parts are shown in views A and the load current. Once the tripping
current passes through the coils in the event of overloading, the
magnetic field becomes more powerful, causing the plunger and piston
to start moving upward against the displacement of viscose oil through
the orifice.
 The first automatic timer, the dashpot timer has been used in
many different machines and has many variations. Pneumatic,
hydraulic-action, and mercury displacement timers. Being used
in a variety of things such as printing presses, motors, and
even irrigation systems, the dashpot timer has seen many
applications. Even in modern times with electrical and digital
timers, these old mechanical timers are still in use due to their
simplicity and ability to function in tough environments.

Figure 4 – 20 Figure 4 – 21

Figure 4 – 22 Figure 4 – 23

Figure 4 – 26
 Figure 4 – 26
Figure 4 – 27

OVERLOAD CONTACTS
 Figure 4 – 30 Figure 4 – 32

PROTECTING LARGE HORSEPOWER MOTORS

An overcurrent protective device is required for every motor circuit in order to guard against short
circuits. In the past, larger motors were protected from this using circuit breakers or fuses. The ideal
solution for both motor overload and short-circuit protection would be a fuse or circuit breaker.
Large electric motors can be protected from overcurrent damage through the use of overload heaters
and overload contacts. If the series-connected heaters get too hot from excessive current, the
normally-closed overload contact will open, de-energizing the contactor sending power to the motor.
The phase protectors are absolutely worth it. Without phase protection, problems like low voltage,
phase reversal, or voltage imbalance can quickly ruin motor windings, resulting in poor performance
or failure.

Figure 4 – 33 Figure 4 – 34
RELAYS
 Figure 5 – 1 Figure 5 – 2
BRIDGE TYPE RELAY
A bridge type relay an internal bridge function on a Token Ring switch that is responsible for
forwarding frames between port groupings with the same logical ring number. Bridge type
contacts use one movable and two stationary contacts. They can control higher voltages because
they break connection in two places instead of one. Electromagnet Construction. • The core losses
associated with alternating current are caused by the continuous changing of the electromagnetic
field.

Figure 5 – 3 Figure 5 –
ELECTROMAGNET CONSTRUCTION
Electromagnets usually consist of wire wound into a coil. A current through the wire creates a
magnetic field which is concentrated in the hole in the center of the coil. The magnetic field
disappears when the current is turned off. The core, a magnetic substance, is looped around copper
wire to form the electromagnet. An electric source that runs on DC is attached to these windings. As
long as the electric source continues delivering current, the electromagnet is magnetized; the instant
the source is unplugged, the magnetism in the electromagnet is turned off.
 CORE LOSSES

Figure 5 -5

Figure 5 – 6 Figure 5 – 7

Core losses are made up of eddy current losses that arise from circulating electrical currents induced in
conducting materials (the electrical steel used in the stator and copper used in the motor windings). Simple
expressions can be derived for W when the equilibrium relationship between field and induction in the material
is linear, B = µH, and the delayed response to time variations of the field is characterized by the single time
constant t. Then, the loss per cycle under sinusoidal field can be expressed as
[2]W=2p2tµB2f where B represents the induction peak value in the cycle. Under these conditions:
(1) hysteresis loops are elliptical, that is, the system response to the sinusoidal field is sinusoidal; (2) the loss
per cycle is proportional to the frequency. When the system is still linear but the dynamic response is controlled
by multiple time constants, takes the more general form
[3]W=pµB2tg?

Figure 5 – 8
 SHADING COILS

Figure 5 – 9
A shading coil or shading ring is a single (or a few) turn of electrical conductor (usually copper or aluminum)
located in the face of the magnet assembly or armature of an alternating current solenoid. The shading coil
acts in parallel to the supply coil, reducing the effective resistance, increasing the motor current and torque.
The magnetic field induced in the shading coil opposes the change in the flux from the supply coil. This creates
the net torque to start the motor. Frager spire or shading coil's purpose is to provide sizeable phase-shifted
magnetic field (in blue) to keep the contactor on when the main coil flux (in red) passes through zero, avoiding
unwanted chatter[2] and mechanical destruction of the magnet and power contacts. Because of the 90 degree
phase difference between the current in the shading coil and the current in the primary coil, the shading coil
maintains a magnetic flux and hence a force between the armature and the assembly while the current in the
primary coil crosses zero. Without this shading ring, the armature would tend to open each time the main flux
goes through zero and create noise, heat and mechanical damages on the magnet faces, so it
reduces bouncing or chatter[3] of relay or power contacts. The importance of shading coils is to reduce the
vibration of the moving parts and delays the establishment of magnetic flux in the region that it encircles and
thus produces a small component of rotating field at standstill.

Figure 5 – 11 Figure 5 – 10

Figure 5 – 12 Figure 5 – 13
 Figure 5 – 14

CONTROL RELAY TYPES

Figure 5 – 15 Figure 5 – 16

There are many types of control relays, and categorization often depends on sizes and specifications.
Some of the main types of relays are solid state, monitoring, safety, time delay, general purpose, and
latching relays. The main function of a control relay is to allow the flow of electric current through a
conducting coil, which closes or opens a switch. It also plays a role in protecting the circuit from
current surges. A control relay allows electrical current to flow through a conducting coil that opens or
closes a switch. It also protects the circuit current. With a control relay, users do not need to manually
turn the switch to isolate or change the state of an electric circuit.
 Figure 5 – 17

Figure 5 – 18

SOLID-STATE RELAYS

What Is a Solid State Relay? A Solid State Relay (SSR) is a relay that does not have a moving
contact. In terms of operation, SSRs are not very different from mechanical relays that have moving
contacts. SSRs, however, employ semiconductor switching elements, such as thyristors, triacs,
diodes, and transistors. Since there are no physical parts to move, solid state relays are able to
switch on and off faster. Extended lifecycle gives solid state relays a long service life: Contact failure,
mechanical strain, or even wearing is out of the question for solid state relays because they do not
have any moving mechanical parts. Solid State Relays switch on/off faster because there are no
physical parts to move. This means power to a load can be applied and removed very quickly and
precisely, which is especially important for applications that requires quick on-off switching. The solid-
state relay is a fairly complex device, but it has a simple purpose – to activate a single output load
when energized.
Figure 5 – 19

Figure 5 – 20

Figure 5 – 21
 Figure 5 – 22
Figure 5 – 23

CONTACTORS

Electrical devices called contactors are frequently used to turn circuits on and off. As a result,
electrical contractors belong to the relay subclass of electromagnetic switches. An electromagnetic
coil is used by a relay, an electrically powered switching device, to open and close a set of contacts.
A contactor is an electrically controlled switch used for switching an electrical power circuit. A
contactor is typically controlled by a circuit which has a much lower power level than the switched
circuit, such as a 24-volt coil electromagnet controlling a 230-volt motor switch. To switch on and off
heavy and high voltage electrical devices, like motors, fans, pumps, etc., we utilize contactors. We
don't connect the PLC directly to these output devices; instead, we use the contactor to safely and
indirectly operate these heavy and high voltage electrical devices.
 Figure 5 – 24

LOAD CONTACTS

Figure 5 – 25 Figure 5 – 26

A coil is commonly symbolized as a circle with letters and number inside. The letters often represent
the type of device, such as M for motor starter or CR for control relay. In those technologies the
common symbol for a coil is a rectangle with a diagonal line. A coil symbol typically represents the
coil of a relay that drives the contacts. This symbol can also represent a digital output from a PLC or
an electrical load.
 Figure 5 –
27 Figure 5 – 28

Figure 5 – 29
Figure 5 – 30
MOTOR STARTERS

A motor starter is an electrical device that is used to start & stop a motor safely. Like a relay, the
motor starter switches the power ON/OFF, but unlike a relay, it also provides thermal overcurrent
protection. The main function of a motor starter is: To safely start or stop a motor. The starter motor is
responsible for turning the engine over during ignition and allowing everything else to happen. When
you turn the ignition on, the starter motor engages and turns the engine over allowing it to suck in air.
Types of DC motor starter include: Direct-On-Line (DOL) Starter: Connects the motor directly to the
power supply for simple applications. Series Field Starter: Uses a series winding to limit the starting
current. Resistance Starter: Incorporates external resistors to control the starting current.
Figure 5 – 38
 Figure 5 – 39

NEMA and IEC

In measuring electric motors and motor controls, there are two standards in use: the National
Electrical Manufacturers Association (NEMA) and the International Electro technical Commission
(IEC). Basically, NEMA vs IEC. NEMA is mostly used in North America while IEC is used in most
parts of the world. NEMA power ratings account for a 15% service factor, while IEC defines a series
of 10 different 'duty types' that include some aspects of service factor and duty cycle. The rated load
current is the current drawn by the motor when operated at the rated load and speed. NEMA ratings
are more versatile, designed to apply to many different applications. NEMA caters to large-sized
devices in North American Markets only. IEC ratings are for more compact devices in the global
market. IEC ratings react faster to overloads while NEMA ratings withstand short circuits.
Figure 5 – 40 Figure 5 – 41
Figure 5 – 43

Figure 5 – 44
 Figure 5 – 45

MOTOR CONTROL CENTERS

A motor control center (MCC) is a type of electrical switchboard, which contains one or more motor
starter sections. The advantage of utilizing a CUBIC switchboard solution for motor starter sections is
that the solution can be combined with other distribution switchboards. It serves as the central point
for the management of electrical motors, integrating key functionalities such as starting, stopping,
monitoring, and protecting these vital components in industrial settings. In addition, motor controllers
can provide protection for the artificial lift system by regulating or limiting the torque, and protecting
against overloads and faults. Many motor controllers contain additional capabilities such as data
collection and data logging as well as application-specific control logic. A motor control center (MCC)
is an assembly to control some or all electric motors in a central location. It consists of multiple
enclosed sections having a common power bus and with each section containing a combination
starter, which in turn consists of motor starter, fuses or circuit breaker, and power disconnect.
Figure 5 – 46

Figure 5 – 47
Figure 5 – 48

Figure 6 – 1
 Figure 6 – 2

Figure 6 – 3 Figure 6 – 4

Figure 6 – 5 Figure

6–6
 Figure 6 - 7

POWER RATING
Power rating is the power output that an energy storage technology can generate or save at a certain
time, and it determines the capability of the energy storage technology of instantaneously change its
power output and input. The power rating of an appliance defines how much energy is being
transferred from the mains to power the device. It also highlights the maximum value of power at
which the appliance can safely operate. Power rating limits are usually set as a guideline by the
manufacturers, protecting the equipment, and simplifying the design of larger systems, by providing a
level of operation under which the equipment will not be damaged while allowing for a certain safety
margin.

Figure 6 – 8
 GROUNDED AND FLOATING CONTROL SYSTEMS
Circuits connected to a grounded power source, like an electric wall outlet, will be electrically
tied down and referenced to the Earth, which is abbreviated GND. Power sources that are not
electrically connected to the Earth, like a battery, are referred to as floating sources. Most
electrical circuits have a ground which is electrically connected to the Earth, hence the name
"ground". The ground is said to be floating when this connection does not exist. Properly
grounding electricity prevents it from causing harm to people, equipment, and the
environment. Grounding can prevent electric shocks, minimize the risk of damage to sensitive
electrical equipment, and reduce instances of electrical fires. Mastering this skill equips them
with a valuable tool in unexpected situations: Reduces Panic: If a child finds themselves in
deep or rough water, their natural instinct might be to panic and flail, leading to fatigue and
increased risk of water ingestion.

Figure 6 – 9 Figure 6 – 10

Figure 6 – 11 Figure 6 – 12
Figure 7 – 1 Figure 7 – 2
 Figure 7 – 3 Figure 7 – 4

Figure 7 – 5

CLOCK TIMERS

Figure 7 – 9

Timers are devices that can switch on or off an electrical circuit after a preset or variable time interval.
They are widely used in electrical controls for various applications, such as lighting, heating, cooling,
motor control, automation, and safety Timers are used to measure specific time intervals. But in
electrical engineering terms, timers are also referred to as counters often. The timer is a component
which is extensively used in different embedded systems. They are used to keep a record of time for
different events occurring in the embedded systems and also Timers can reduce energy consumption
and waste by switching on or off the devices or loads only when needed, as well as optimize the
operation and performance of the system.
 ELECTRONIC TIMERS

Electronic timers provide accurate feedback and event activation in industrial environments. Electronic timers
trigger pre-programmed events such as alarms, on/off switching by completing the pre-determined time interval
and sending an output signal to the connected equipment. The two main types of light timers are mechanical
and electronic, and come as hardwired or plug-in modules. The other two timers—astronomic and photocell—
are really types of electronic timers, but we have separated them since they are so different. 1. Manual and
analog mechanical timers Setting a watch or turning the time dial on a toaster oven is quite comparable to
using a manual, analog timer. The mechanical design, which is spring-loaded, is used to track time.
Certain ones let you to program as many on/off times as you'd want in a day. Other timers set a maximum
operating time of sixty minutes. The circuit will be totally shut off at the conclusion of the allotted time thanks to
the mechanical design. Mechanical timers are dependable, easy to use, and long-lasting. Mechanical spring-
wound timers are strong and easy to use; you may find them utilized for a lot of things, like lights, appliances,
ceiling fans, saunas, hot tubs, and pools. 2. Digital Timers (Programmable and Smart)
The programmable timers allow you to set the switch to turn on and off at specific times. They are similar to
some mechanical timers since they can have multiple on/off cycles in a 24-hour period, but they can be
scheduled for more than one day. Similar to a programmable thermostat, you can set a 7-day schedule with
the exact on/off times. Next is the Astronomic timers are a form of digital timers, but they have built-in
programming that calculates the sun’s rise and set times. This makes it better for more accurate nighttime
illumination. And last is the Photocell In addition to astronomic timers, there are also photocell models that
distinguish day from night using light-gathering sensors. Keep in mind that photocell timers may not work
properly if there is a lot of ambient light in your neighborhood.

Figure 7 – 14 Figure 7 - 15