SYMBOL

NO. NAME
DIN EN NEMA ICS
1
Normally close float switch

2
Normally open float switch

3
Normally close OFF delay timed
contacts

4
Normally open OFF delay timed
contacts

5
Normally close ON delay timed
contacts

6
Normally open ON delay timed
contacts

7
Time Relay holding coil

8
Holding Coil

9
Indicating light (pilot lamp)

10
Overload relay

11
Three-pole circuit breaker
 SYMBOL
NO. NAME
DIN EN NEMA ICS
12
Magnetic contactor (main
contacts)

13
Normally close contacts

14
Normally open contacts

15
Normally close held close limit
switch

16
Normally close limit switch

17
Normally open limit switch

18
Push-pull button

19
Double acting pushbutton

20
Normally close push button
switch

21
Normally open push button
switch
 SYMBOL
NO. NAME
DIN EN NEMA ICS
22
Normally open pressure switch

23
Normally close pressure switch

24
Normally open flow switch

25
Normally close flow switch

26
Normally open temperature
switch

27
Normally close temperature
switch

28
Buzzer

29
Three-phase motor

30
Joystick
 SYMBOL
NO. NAME
DIN EN NEMA ICS
31

Foot pedal switch

32

Selector switch (three positions)

33

Level switch
Item No. Component Name Description/Uses
1 It is an electromechanical switch used
in electric motors to balance the
change in frequency or state of the
Magnetic Contractor motor, which is referred to as the
motor transitioning from ON to OFF
state. The main function of the
magnetic contactor is to transmit
energy from one point to another by
switching the contacts.
2 It is the contact in the auxiliary circuit
that is operated mechanically. It is
Auxiliary or Special physically linked to the main contacts
Purpose contacts and activated at the same time. It
does not carry so much current. It is
mainly used to signal switching or
malfunction states, for interlocking
circuits or logic and sequence
controls with low to high loading..
3 It is a device that opens the circuit in
the event of an electrical, thermal, or
power overload. When mounted with
a contactor they create a motor
Overloaded Relay starter. Overload relays are normally
closed, meaning they only open if
they experience an overload. They
are used to protect motors from
damage in several applications
across industrial and commercial
sectors, among others.
4 It Is intended to prevent damage to
an electrical circuit as a result of
excess current. They are designed to
3-phase miniature trip during an overload or short circuit
circuit breaker (MCB) to protect against electrical faults
and equipment failure.

5 It is used to make the operating status

(on, off, fault) of the device on which
they are installed visible from the
Indicator lights/pilot outside by means of a small light. The
lamps color of the light emitted will therefore
be associated with a precise status of
the application, making it instantly
understandable and easy to use for
the end user.
Item No. Component Name Description/Uses
6 It allows electrical current to flow
through a conducting coil that opens
or closes a switch. It also protects the
Control relay 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.

7 It is a timing device that, using either

electronic circuitry or mechanical
components, automatically opens
Timers and closes an electrical circuit for a
specific period of time. it allows you to
program the on/off switching of
different devices in a simple and
straightforward manner.

8 It is an electrical actuator that, when

pressed, either close or open the
electrical circuits to which they are
Pushbutton switch attached. They are capable of
controlling a wide range of electronic
gadgets.

9 It is a mechanical switch that can be

turned right, center, or left to open or
close the electrical contacts. It is
Selector switch mostly used to start/stop devices or to
switch between two/three electric
circuits. It is a link between man and
machine. It performs multiple
functions and only inhabits the space
of a typical pushbutton.
10 It is a manual switch and has a
manual handle or lever to control the
position of the switch and the
direction of the motor like reverse or
Drum switch forward. Basically, this switch is used
to control the direction of motor
rotation.
Item No. Component Name Description/Uses
11 It is a switch that is simply operated by
someone’s foot by stepping on the
actuator. it frees up a person's hands
Foot switch for other work while still allowing a
human operator full control over
switching.

12 it is an electromechanical device
operated by a physical force applied
to it by an object. It automatically
Limit switch detect or sense the presence of an
object or to monitor and indicate
whether the movement limits of that
object have been exceeded.

13 It is widely used to control, steer, and

position a wide range of heavy-duty
equipment, machines, and systems. It
Joystick have a shaft mounted onto a base
which houses an electrical circuit.

14 An audio signaling device like a

beeper or buzzer may be
electromechanical or piezoelectric or
Buzzer mechanical type. The main function
of this is to convert the signal from
audio to sound.

15 It is an electrical enclosure is a
housing for electrical or electronic
equipment. Its purpose is to protect
Enclosure that equipment from the environment
(especially in the case of external
electrical enclosures) and also to
protect people from the equipment
(e.g. to prevent electric shock or the
propagation of an explosion).
The term motor control can have very broad
meanings. It can mean anything from a simple
toggle switch intended to turn a motor on or off
(Figure 1–1) to an extremely complex system
intended to control several motors, with literally
hundreds of sensing devices that govern the
operation of the circuit. The electrician working in
industry should be able to install different types of
motors and the controls necessary to control and
protect them and also to troubleshoot systems
when they fail.

Controller Type

The type of controller can vary depending on the requirements of the motor.

Motor starters can be divided into two major classifications:

• NEMA (National Electrical Manufacturers Association) - an American organization that rates

electrical components.
• IEC (International Electrotechnical Commission)

Motor Type

The type of motor best suited to operate a particular piece of equipment can be different for
different types of machines. Machines that employ gears generally require a motor that can start
at reduced speed and increase speed gradually.

Wound rotor induction motors or squirrel-cage motors

o controlled by variable frequency drives are generally excellent choices for this
requirement. Machines that require a long starting period, such as machines that
operate large inertia loads such as flywheels or centrifuges, require a motor with high
starting torque and relatively low starting current.
o Squirrel-cage motors with a type A rotor or synchronous motors are a good choice
for these types of loads.
o Synchronous motors have an advantage in that they can provide power factor
correction for themselves, or other inductive loads connected to the same power
line.
o Squirrel-cage motors controlled by variable frequency drives or direct-current motors
can be employed to power machines that require variable speed.
o Squirrel-cage induction motors are used to power most of the machines throughout
industry. These motors are rugged and have a proven record of service unsurpassed
by any other type of power source.

Types of Control Systems

Motor control systems can be divided into three major types:

1. Manual
• characterized by the fact that the operator must go to the location of the controller
to initiate any change in the state of the control system.
• Manual controllers are generally very simple devices that connect the motor directly
to the line. They may or may not provide overload protection or low-voltage release.
Manual control may be accomplished by simply connecting a switch in series with a
motor
 2. Semiautomatic
• characterized by the use of push buttons, limit switches, pressure switches, and other
sensing devices to control the operation of a magnetic contactor or starter.
• The starter actually connects the motor to the line, and the push buttons and other
pilot devices control the coil of the starter. This permits the actual control panel to be
located away from the motor or starter. The operator must still initiate certain
actions, such as starting and stopping, but does not have to go to the location of
the motor or starter to perform the action.
3. Automatic.
• very similar to semiautomatic control in that pilot sensing devices are employed to
operate a magnetic contactor or starter that actually controls the motor. With
automatic control, however, an operator does not have to initiate certain actions.
Once the control conditions have been set, the system will continue to operate on
its own.
• A good example of an automatic control system is the heating and cooling system
found in many homes. Once the thermostat has been set to the desired
temperature, the heating or cooling system operates without further attention from
the homeowner. The control circuit contains sensing devices that automatically shut
the system down in the event of an unsafe condition such as motor overload,
excessive current, no pilot light or ignition in gas heating systems, and so on.

Functions of Motor Control

• Starting
o Starting the motor is one of the main purposes of a motor control circuit.
o There are several methods that can be employed, depending on the requirements
of the circuit.
▪ The simplest method is across the- line starting. This is accomplished by
connecting the motor directly to the power line.
▪ There may be situations, however, that require the motor to start at a low
speed and accelerate to full speed over some period of time. This is often
referred to as ramping. In other situations, it may be necessary to limit the
amount of current or torque during starting.
 • Stopping
o Another function of the control system is to stop the motor. The simplest method is to
disconnect the motor from the power line and permit it to coast to a stop. Some
conditions, however, may require that the motor be stopped more quickly or that a
brake hold a load when the motor is stopped.
• Jogging or Inching
o Jogging and inching are methods employed to move a motor with short jabs of
power. This is generally done to move a motor or load into some desired position.
The difference between jogging and inching is that jogging is accomplished by
momentarily connecting the motor to full line voltage, and inching is accomplished
by momentarily connecting the motor to reduced voltage.
• Speed Control
o Some control systems require variable speed.
o There are several ways to accomplish this.
▪ One of the most common ways is with variable frequency control for
alternating-current motors or by controlling the voltage applied to the
armature and fields of a direct-current motor.
▪ Another method may involve the use of a direct-current clutch.
• Motor and Circuit Protection
o One of the major functions of most control systems is to provide protection for both
the circuit components and the motor. Fuses and circuit breakers are generally
employed for circuit protection, and overload relays are used to protect the motor.
• Surge Protection
o Another concern in many control circuits is the voltage spikes
or surges produced by collapsing magnetic fields when power
to the coil of a relay or contactor is turned off. These collapsing
magnetic fields can induce voltage spikes that are hundreds
of volts
o These high voltage surges can damage electronic
components connected to the power line. Voltage spikes are
of greatest concern in control systems that employ computer-
controlled devices such as programmable logic controllers
and measuring instruments used to sense temperature,
pressure, and so on

Symbols and Schematic Diagrams

Push Buttons
o Push buttons can be shown as normally open or normally closed.
o Most are momentary contact devices in that they make or break connection only
as long as pressure is applied to them.
o 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.
o 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. Because 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.
Double-Acting Push Buttons
o Double-acting push buttons contain both normally open and normally closed
contacts.
o When components are shown connected by a dashed line in a schematic diagram,
it indicates that the components are mechanically connected together.

Stacked Push Buttons

o Double-acting push buttons contain both
normally open and normally closed
contacts.
o Push buttons that contain multiple contacts
are often called stacked push buttons.
Stacked push buttons are made by
connecting multiple contact units together
that are controlled by a single push button.
Stacked Push Buttons Push–Pull Buttons
o Some push–pull buttons contain both normally open and normally closed contacts
much like a double-acting push button, but the contact arrangement is different.
o This push–pull button is intended to provide both the start and stop functions in one
push button, eliminating the space needed for a second push button.
o When the button is released, the normally open contact returns to its normal
position, and the normally closed section remains closed. When the button is
pushed, the normally closed section opens to break the circuit, and the normally
open section remains open.

Switch Symbols
o Switch symbols are employed to represent many common control sensing devices.
There are four basic symbols:
▪ normally open (NO);
▪ normally closed (NC);
▪ normally open, held closed (NOHC); and
▪ normally closed, held open (NCHO).

o Normally open switches are drawn with the movable contact below and not touching
the stationary contact.
o Normally closed switches are drawn with the movable contact above and touching
the stationary contact.
Sensing Devices

They act very much like the senses of the body. The brain is the control center of the body. It
depends on input information such as sight, touch, smell, and hearing to determine what is
happening around it.

Limit Switches
o Limit switches are drawn by adding a wedge to one of the four basic switches

Float, Pressure, Flow, and Temperature Switches

o The symbol for a float switch illustrates a ball
float. It is drawn by adding a circle to a line.
The flag symbol of the flow switch represents
the paddle that senses movement. The flow
switch symbol is used for both liquid and
airflow switches.
o The symbol for a pressure switch is a half-
circle connected to a line. The flat part of
the semicircle represents a diaphragm. The
symbol for a temperature switch represents
a bimetal helix. The helix contracts and
expands with a change of temperature.

Coils
o The most common coil symbol used in schematic diagrams is the circle. The reason
for this is so that letters and/or numbers can be written in the circle to identify the
coil. Contacts controlled by the coil are given the same label.
Timed Contacts
o Timed contacts are either normally open
or normally closed. They are not drawn as
normally open, held closed or normally
closed, held open.
o There are two basic types of timers, on
delay and off delay.
o Timed contact symbols use an arrow to
point in the direction that the contact will
move at the end of the time cycle.

Contacts
o The symbol is two parallel lines connected by wires.
o The normally open contacts are drawn to represent an
open connection.
o The normally closed contact symbol is the same as the
normally open symbol, with the exception that a
diagonal line is drawn through the contacts. The diagonal
line indicates that a complete current path exists.

Selector Switches
o Selector switches are operated by turning a knob instead of pushing a button.
o A very common selector switch is the MAN-OFF-AUTO switch.
o MAN stands for Manual and AUTO stands for Automatic.
Manual Starters

-Manual starters are characterized by the fact that the operator must go to the location of the
starter to initiate any change of action. There are several different types of manual starters. Some
look like a simple toggle switch with the addition of an overload heater. Others are operated by
push buttons and may or may not be capable of providing low voltage protection.

Overload Relays

Overloads should not be confused with fuses or circuit breakers. Fuses and circuit breakers are
designed to protect the circuit from a direct ground or short-circuit condition. Overloads are
designed to protect the motor from an overload condition.

Overload Properties

There are certain properties that all overload relays must possess in order to protect a motor:

1. They must have some means of sensing motor current.

- Some overload relays do this by converting motor current into a proportionate
amount of heat, and others sense motor current by the strength of a magnetic field.

2. They must have some type of time delay.

3. They are divided into two separate sections: the current sensing section and the contact
section.

a. Thermal Overload Relays

There are two major types of overload relays: thermal and magnetic.

• Thermal overloads operate by connecting a heater in series with the motor. The amount of
heat produced is dependent on motor current.
• Thermal overloads can be divided into two types: solder melting type, or solder pot, and
bimetal strip type.
• Because thermal overload relays operate on the principle of heat, they are sensitive to
ambient (surrounding air) temperature. They trip faster when located in a warm area than
they do in a cool area.
 b. Magnetic Overload Relays

-Magnetic-type overload relays operate by sensing the strength of the magnetic field
produced by the current flowing to the motor. The greatest difference between magnetic
type and thermal type overload relays is that magnetic types are not sensitive to ambient
temperature. Magnetic-type overload relays are generally used in areas that exhibit extreme
changes in ambient temperature. Magnetic overload relays can be divided into two major
types: electronic and dashpot.

Relays, Contactors, and Motor Starters

• Relays and contactors are electromechanical switches. They operate on the solenoid
principle.
• A coil of wire is connected to an electric current. The magnetic field developed by the
current is concentrated in an iron pole piece. The electromagnet attracts a metal
armature.
• Contacts are connected to the metal armature. When the coil is energized, the contacts
open or close.
• There are two basic methods of constructing a relay or contactor.
o The clapper type uses one movable contact to make connection with a stationary
contact.
o The bridge type uses a movable contact to make connection between two
stationary contacts.
Relays

Relays are electromechanical switches that contain auxiliary contacts. Auxiliary contacts are
small and are intended to be used for control applications.

Core Losses

The continuous change of both amplitude and polarity of the magnetic field causes currents to
be induced into the metal core material. These currents are called eddy currents because they
are similar to eddies (swirling currents) found in rivers.

Another type of core loss associated with alternating- current devices is called hysteresis loss.
Hysteresis loss is caused by the molecules inside magnetic materials changing direction. Magnetic
materials such as iron or soft steel contain magnetic domains or magnetic molecules.

Contactors

Contactors are very similar to relays in that they are electromechanical devices. Contactors can
be obtained with coils designed for use on higher voltages than most relays.

Motor Starters

Motor starters are contactors with the addition of an overload relay. Because they are intended
to control the operation of motors, motor starters are rated in horsepower. Magnetic motor starters
are available in different sizes. The size of starter required is determined by the horsepower and
voltage of the motor it is intended to control. There are two standards that are used to determine
the size of starter needed: NEMA and IEC.

Timing Relays

• Time-delay relays can be divided into two general classifications: the on-delay relay, and
the off-delay relay. The on-delay relay is often referred to as DOE, which stands for “Delay
On Energize.” The off-delay relay is often referred to as DODE, which stands for “Delay On
De-Energize.”
• Timer relays are similar to other control relays in that they use a coil to control the operation
of some number of contacts. The difference between a control relay and a timer relay is
that the contacts of the timer relay delay changing their position when the coil is energized
or de-energized. When power is connected to the coil of an on-delay timer, the contacts
delay changing position for some period of time.

Pressure Switches

Pressure sensors are designed to produce an output voltage or current that is dependent on the
amount of pressure being sensed.
Float Switches

A float switch is used when a pump motor must be started and stopped according to changes in
the water (or other liquid) level in a tank or sump. Float switches are designed to provide
automatic control of AC and DC pump motor magnetic starters and automatic direct control of
light motor loads.

Flow Switches and Sensors

Flow switches are used to detect the movement of air or liquid through a duct or pipe. Airflow
switches are often called sail switches because the sensor mechanism resembles a sail

Limit Switches

Limit switches are used to detect when an object is present or absent from a particular location.
They can be activated by the motion of a machine or by the presence or absence of a par ticular
object. Limit switches contain some type of bumper arm that is impacted by an object. The type
of bumper arm used is determined by the application of the limit switch. When the bumper arm is
impacted, it causes the contacts to change position.

Schematics and Wiring Diagrams

• Schematic and wiring diagrams are the written language of control circuits.
• Maintenance electricians must be able to interpret schematic and wiring diagrams to
install control equipment or troubleshoot existing control circuits.
• Schematic diagrams are also known as line diagrams and ladder diagrams. Schematic
diagrams show components in their electrical sequence without regard to physical
location.
• Schematics are used more than any other type of diagram to connect or troubleshoot a
control circuit. Wiring diagrams show a picture of the control components with connecting
wires.
• Wiring diagrams are sometimes used to install new control circuits, but they are seldom
used for troubleshooting existing circuits.