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ELECTRIC MOTOR
CONTROL MANUAL

Laboratory Activity No. 5

MOTOR CONTROL COMPONENTS FAMILIARIZATION
AND TESTING

PREFACE

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Upon selecting the proper motor, understanding the many various control devices available
and their uses, limitations and connections, becomes an essential part related to reliable
operation and protection of the motor and the personnel using it.

Every electric motor has to have some sort of controller. The motor controller will have
different features and complexity depending on the task that the motor will be performing. A
motor controller is a device or group of devices that serves to govern in some
predetermined manner the performance of an electric motor. A motor controller might
include a manual or automatic means for starting and stopping the motor, selecting forward
or reverse rotation, selecting and regulating the speed, regulating or limiting the torque, and
protecting against overloads and faults.

This manual introduces the students to the basics of motor control, explains its importance,
applications and components and identifies various ways in which motor control can be
accomplished.

Upon completion of this manual, the student should be able to:

o Explain the role of motor control in an electrical system.

o Identify various components of a motor control system.
o Explain the difference between the various classifications and types of motor control
wiring.
o Draw motor control ladder diagrams.
o Connect various motor control circuits.
o Test and troubleshoot motor control components and circuits.
o Apply safety precautions while connecting motor control circuits.

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TABLE OF CONTENTS

LABORATORY ACTIVITY PAGE NO.

ELECTRICAL SAFETY 4

INTRODUCTION TO MOTOR CONTROL 7

MOTOR CONTROL SYSTEM SYMBOLS 11

MOTOR CONTROL CIRCUIT 17

MOTOR CONTROL COMPONENTS FAMILIARIZATION AND TESTING 22

ACROSS THE LINE MAGNETIC MOTOR STARTER (Non- Reversing) 28

TWO STATION MOTOR CONTROL (Non- Reversing) 32

FULL VOLTAGE NON-REVERSING MOTOR CONTROL WITH JOG 36

FORWARD – REVERSE MOTOR CONTROL 41

(No Immediate Reversal)

FORWARD – REVERSE MOTOR CONTROL 47

(Immediate Reversal)

SEQUENTIAL MOTOR CONTROL 53

(Manual: Using Pushbutton)

SEQUENTIAL MOTOR CONTROL 56

(Automatic using Timer)

REDUCED VOLTAGE STARTER CIRCUITS 60

REDUCED VOLTAGE STARTER 62

(Wye-Delta Starter)

APPLICATION OF FORWARD-REVERSE MOTOR CONTROL 65

MOTOR CONTROL ACTIVITIES 67

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Name: Course: Subject:

Group No. Time: Days: Rm. Date:
Professor/Instructor: Rating:

Laboratory Activity No. 5

MOTOR CONTROL COMPONENTS FAMILIARIZATION AND TESTING

I. OBJECTIVES:

At the end of the laboratory activity, the students should be able to:

1. Discuss the principle of operation of basic motor control components.

2. Check the condition of basic motor components using VOM and/or CLT.
3. Recognize the importance of gaining skills in testing motor control equipments.

II. TECHNICAL INFORMATION:

MAJOR COMPONENTS OF AC MOTOR STARTERS

Alternating current (AC) motor starters have five major functional components, these include:
• Components that provide motor overload protection.
• Components that perform the motor controller function.
• Components that protect against short-circuit and ground faults.
• Components that provide motor circuit-disconnecting means.
• An enclosure suitable to meet the requirements of the motor starter application.

Overload Protection

The function of the overload device is to monitor motor line current and to open the
motor circuit when predetermined safe levels are exceeded. In accordance with the National
Electric Code and based on specific circuit conditions, continuous duty motors rated more than
one horsepower may be protected for overloads using overload relays, integral thermal
protectors, fuses or circuit breakers. The most commonly used overload device is the overload
relay.

Two types of overload relays that respond to the heating effect of the motor line current
are the thermal and the solid-state overload relays. The thermal overload relay uses the motor
line current to produce heat within itself at a designated rate that simulates load and conductor
heating. On the other hand, the solid-state overload relay monitors motor line current and uses
semiconductor circuits to determine the heating effects that the level of current will have on the
motor and conductors.

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Controller

A major component common to all AC motor starters is the controller. The controller is
consists of the contactor that carries the motor line current and the control circuit for the
contactor. When the overload relays are added to the controller, the assembly is referred to as a
basic magnetic motor starter. The contactor portion of the controller is essentially an on-off
device operated by electromagnetic means. When the controller coil is energized through a
control circuit, the resulting magnetic field mechanically forces the main contacts to close, thus
starting the motor. The coil is then continuously energized to hold the contacts closed and keep
the motor running. When the coil is de-energized, the main controller contacts are forced open
by either spring pressure or gravity, thus stopping the motor.

Fault Protection

The device used to provide protection against short circuit and ground faults. The devices
used for this protection are typically an instantaneous trip circuit breaker, an inverse time circuit
breaker, non-time delay fuses, or dual element (time-delay) fuses.

Disconnect

Another major component that is common to all AC motor starters is the disconnecting
device. In accordance with the National Electric Code, motors and controllers must be provided
with a means of safely disconnecting them from their source of supply so that maintenance of the
controller, motor, and its driven equipment can be accomplished with no hazard to personnel.
The devices to be used for disconnecting include circuit breakers, motor-circuit switches, and
molded case switches (non-automatic circuit interrupters).

Enclosure

A final component common to AC motor starters is the enclosure. An enclosure is a

surrounding case constructed to provide a degree of protection to personnel against incidental
contact with the enclosed equipment, and to provide a degree of protection to the enclosed
equipment against environmental conditions. Although other types of materials (e.g. polymeric)
are sometimes used, enclosures are typically sheet metal or cast metal construction. However, in
all cases, only material that will not support combustion in air is selected for enclosures.

Other Motor Control Circuit Components

Components used for control circuits include pushbuttons, selector switches, indicating
lights, control relays, control power transformers, auxiliary contacts, contactors, overload relays,
circuit breakers or MCPs, and electrical wiring.

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Pushbuttons

One component typically used in the control circuit of motor starters is the pushbutton.
The pushbutton is used to energize the control circuit. A simple pushbutton is composed of a set
of stationary contacts, a set of moving contacts, an operating plunger, a return spring, and a
housing to hold the assembly together. Pushbuttons are basically one of two types: one with
normally open contacts, and the other with normally closed contacts. For the normally open
pushbutton the operating plunger is held up by a return spring. This spring holds the moving
contacts away from the stationary contacts, and it, thereby, keeps the control circuit open and de-
energized. Depressing the plunger causes the moving contacts to engage the stationary contacts,
thus closing the circuit. Normally open pushbuttons are typically used to start a process.

In the normally closed pushbutton, the design of the contacts is opposite to that of the
normally open pushbutton. For this type, the contacts open, and the process stops when the
plunger is depressed. As a result of the internal tension caused by the return spring, the action of
both the normally open and normally closed pushbuttons is momentary. When the operator’s
finger is removed from the pushbutton, it returns to its original state.

Indicator Lights

Indicating lamps are another component used in motor starter control circuits. Their
function is a relatively simple but important one, which is to report the status of the control
circuit and, as a result, the status of the equipment controlled. Varieties of colors are used for the
lens of the indicating lights to report or warn of various circuit conditions. Colors typically
offered by manufacturers include red, green, blue, amber, white and clear. The most commonly
used types of indicating lights include the full-voltage, transformer and push-to-test types.

Control Relays

A control relay is a component that is used in a motor starter’s control circuit to interface
between a pilot device and the circuit that the pilot device controls. In effect, the control relay
allows the pilot device to control a current that is too large for the contacts of the pilot device.
Pilot devices used in motor controls typically monitor parameters such as time, pressure, liquid
level, and heat. Among its type are the following:

a. Electromechanical
One type of control relay is the electromechanical type. This relay uses an electromagnet to
move the output contacts from open to closed and closed to open. Relays of this type are
referred to as alternating current relays, if designed for actuation from an AC source, or
direct-current relays, if designed for DC operation.

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b. Time Control Relay

The timer control relay is available as either an electromechanical or solid-state type relay.
The relay can be purchased with normally open contacts, normally closed contacts, or a
combination of the two types. This type of relay functions as described above for either the
electromechanical or solid-state type, except that it has a built-in timing circuit that delays
the operation of the relay contacts.

II. TOOLS and MATERIALS NEEDED:

VOM and/or Continuity Lamp Tester

Drawing Materials
Set of Motor Control Components

III. PROCEDURE:

1. After the discussion, secure motor power and control circuit components for
familiarization and testing.

2. Using your test instruments, check the conditions of various motor control components
provided by the instructor.

3. Record the data and observations below and determine the condition of the components.

Summary of Findings
Note: NS - Normal State ES – Energized State

a. Magnetic Contactor

Main Contact/s

NO Terminal Markings / /
NO Resistance Reading/Condition NS / / ES / / /

Magnetic Contactor Coil

Coil Terminal Markings

Resistance Reading/Condition

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Auxiliary Contact/s

NO Terminal Markings
NO Resistance Reading/Condition NS ES

NC Terminal Markings
NC Resistance Reading/Condition NS ES

b. Overload Relay

Overload Heaters
Terminal Markings

Overload Contacts

NO Terminal Markings
NO Resistance Reading/Condition (NS)
Resistance Reading when tripped (ES)

NC Terminal Markings
NC Resistance Reading/Condition (NS)
Resistance Reading when tripped (ES)

Reset Button Condition

c. Pushbutton

Green Pushbutton
Resistance when Pressed (ES) Condition
Resistance when Released (NS)

Red Pushbutton
Resistance when Pressed (ES) Condition
Resistance when Released (NS)

Double Contact Red Pushbutton

Resistance when Pressed: Set 1 Set 2 Condition
Resistance when Released Set 1 Set 2

Double Contact Green Pushbutton

Resistance when Pressed: Set 1 Set 2 Condition
Resistance when Released Set 1 Set 2

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c. Indicating Light

Green Pilot Lamp

Resistance Reading Condition
CLT Testing

Red Pilot Lamp

Resistance Reading Condition
CLT Testing

Yellow/Orange Pilot Lamp

Resistance Reading Condition
CLT Testing

V. CONCLUSION:

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