CONTROL CIRCUITS AND MOTORS

ELECTRICAL
General principles on control of electric motors

There are some conditions that must be considered when selecting,

designing, installing or maintaining electric motor control equipment.
Engine control was a simple problem when using a common master
shaft, to which several machines were connected, because the engine had to
start and stop only a few times a day. However, with individual transmission
the motor has become almost an integral part of the machine and the
controller needs to be designed to suit its needs.
Motor control is a generic term that means many things, from a
simple step switch to a complex system with components such as relays,
timing controls and switches. However, the common function is the same in
any case: that is, to control some operation of the electric motor. Therefore,
when selecting and installing control equipment for an engine, a large
number of various factors must be considered so that it can function
properly alongside the machine for which it is designed.

Controller Purpose

Some of the factors to be considered regarding the driver, when selecting

and installing it, can be listed as follows:
 1) Starting: The motor can be started by connecting it directly through
the line. However, the driven machine may be damaged if it is started
with such sudden rotating effort. Starting should be done slowly and
gradually, not only to protect the machine, but because the line
current surge during starting may be too great. The frequency of
starting the motors also includes the use of the controller.
2) Stop: The controllers allow the motors to run until they stop and also
provide a brake action when the machine must be stopped quickly.
Quick stop is an emergency function.
3) Rotation Reversal: Controllers are needed to automatically change
the direction of rotation of machines by command from an operator at
a control station. The reversing action of controllers is a continuous
process in many industrial applications. This can be done by means
of pushbutton stations, a drum switch or a rotary reversing module.

4) Gear: The desired speeds and operating characteristics are the direct
function and purpose of the controllers. These protect engines,
operators, machines and materials while they operate.
5) Speed control: Some controllers can maintain very precise speeds for
industrial process purposes, but other types are needed to change
motor speeds stepwise or gradually.
6) Operator Safety: Many mechanical safeguards have given rise to
electrical methods. Electrical control pilot devices directly affect
controllers by protecting machine operators from unsafe conditions.
7) Protection against damage: Part of the function of an automatic
machine is to protect itself from damage, as well as the manufactured
or processed materials. For example, conveyor blockages are
prevented. Machines can be run in reverse, stopped, run at slow speed
or whatever is necessary to perform the protection work.
8) Maintaining Starting Devices: Once installed and properly adjusted,
motor starters will maintain reliable starting times, voltages, current
and torque, for the benefit of the driven machine and power system.
Properly sized fuses, circuit breakers, and disconnect switches for
starting are good installation practices governed by electrical codes.

Difference between automatic and manual control

When a circuit is considered manual it is because a person must

initiate the action for the circuit to operate, most commonly using button
stations, however an automatic one is designed so that the circuit starts by
itself and that the person has the comfort of So that it will operate without
him having to do anything, the automatic control devices can be float
switches, pressure switches or thermostats and their contact capacity must
be sufficient to conduct and interrupt the total current of the motor.
 COMMON SYMBOLS USED IN

THE CONTROL OF ELECTRICAL MACHINES

THERMAL USUALLY USUALLY

OPEN CLOSED
USUALLY USUALLY
NORMALLY OPEN USUALLY OPEN CLOSED
CLOSED

MOMENTARY LIMIT SWITCH

•N
CONTACTS
CLOSED OPEN LIQUID LEVEL
SWITCH
SWITCH FIXED LIMIT

USUALLY USUALLY USUALLY USUALLY USUALLY USUALLY

OPEN CLOSED OPEN CLOSED OPEN CLOSED

VACUUM AND .ACTIVATED BY TEMPERATURE FLOW (AIR, WATER. ETC)

PRESSURE

USUALLY USUALLY DOUBLE CRCUTO SUSTAINED USUALLY USUALLY

OPEN CLOSED OPEN CLOSED

EI
T
BUTTON STATION FOOT SWITCH

NORMALLY OPEN NORMALLY NORMALLY OPEN NORMALLY

CLOSED CLOSED

THE COLOR IS
THREE- INDICATED BY
PHASE THE LETTER ON
MAGNETIC THE LAMP
COIL
PNEUMATIC SWITCH TIMED PNEUMATIC
SWITCH

RELAY AUTOTRANSFORMER FUSE RESISTANCES

ENGINE OVERLOAD
 Control Diagrams

This diagram is called single-wire or single-phase

because it represents only one phase of current.

This diagram is called bifilar or

biphasic because it represents two
phases of current.

This diagram is called three-wire or three-phase because it represents 3

phases of current.
 Function of an interlock

The interlock serves to

maintain the connection
after pressing our start
button and pressing our stop
button stops the engine

and the interlock and the start button are released. Parts of a
control
circuit.

The basic or most common elements in a control circuit are indicated below.

Power circuit.

1)Three-phase motor

Brand: Nema Type: Mm.

90-4 Series: Nr-3- 0116
HP. 0.75
RPM 1736
Volts: 220 V Amperes:
1.5/3.0 A Cycles: 60Hz
Temperature: 40º C Total
weight: 7.80Kg.

Three-Phase Motor: It is
one that requires 3 phases to operate and with a voltage greater than or equal to
220V. The characteristic of this motor is that by reversing the outputs; That is, the
phases change the direction of rotation of the rotor and, unlike alternating current
motors, it consumes less current. It has a squirrel cage rotor that has shorted bars
that rotate magnetically around its stator.
Protection.

1) Magnetic starters:

Class 8501
Type P122
I Th2 12 A
660 VAC

These starters limit the current in the starting stage, avoiding reaching
currents that could cause harmful fluctuations in the power line. These
starters have overload and short circuit protection in all 3 phases and offer
ambient temperature compensation and also have start and stop buttons,
mounted in their cabinet.

• Thermal protection
• button station
• contactor

The contactor is designed to support the load of the motors; That is, it is
connected directly to the line, whereas the relays have weaker contacts and
are not connected to the lines directly. Contactors support even more current
than relays (up to 7A). These in turn vary in size depending on the load to
be fed.
 2) Control relay: 220- 380- 500 VAC 4- 6- 8
A

It is a coil that locks normally open contacts,

allowing current to pass, and opens normally
closed contacts, preventing the passage of
current.

Automatic controls:

1) Time relay:

220- 380- 450 VAC

3- 6- 8A
160 Min

There are two types of time relays which

are as follows: *ON DELAY time control
relay: This type of relay is mainly used in
circuits where the response is required,
once the circuit has been energized, the
relay is delay in sending the signal of the
time required in the process.

*OFF DELAY time control relay: This

type of time control relay, its main
characteristic, is that it delays the response to the secondary circuits once the
control circuit has been de-energized. It consists of a capacitor that stores
said energy.
 2) Switch- level or float switch:

220- 380- 500 VAC

2- 6- 8A

The operation of a float switch is controlled by the up or

down movement of the float that is placed in the water
tank. The float mechanically opens or closes the
electrical contacts using a rod or chain with a
counterweight.
There are several types of float switches, the capsule,
counterbalanced float and electrolevel:

a) Float switch:

b) Encapsulated switch: It consists of a metal sphere that comes into

contact when the pressure drops.
 c) Electrolevel: It is an electronic control that senses the level when it is
full, half and empty, protecting the motor so that the pump does not
work under vacuum.

3) Switch or pressure switch:

220- 380- 550 VAC

3- 6- 8A

Industrial type pressure switches are designed to meet the

wide variety of requirements found in the control of
pneumatic or hydraulic machines.
These controls are most commonly used for machine
tools, high-pressure lubrication systems, pumps, and
motorized compressors.
Manual Controls.

1) Drum switch:

Back Out Forward

Class 2601
Type AG-2
Maximum capacity
Phases Monophase Polyphase CD.
Volts 115 230 110 220-550 115-230
CP 1 1/2 2 1 1/2 2 1/4

By pressing Back on the

drum switch (blue in the
diagram), terminal 1 of
the three-phase motor
will be connected to line
1, terminal 2 to line 2 and
terminal 3 to line 3, when
you want to reverse the
rotation of the rotor.
From this, the drum
switch must be in Out
(black color in the
diagram), and wait a
moment to click Forward,
since if this is not done
the rotor will be over-
forged and may be damaged; then when moving forward the phases will be
reversed which will cause the rotor to rotate in another direction (red color
in the diagram), terminal 1 of the motor will be connected to line 2, terminal
2 to line 1 and terminal 3 to line 3.
 2) Button station: 220- 380- 500 VAC
4- 6- 8A

The main purpose of the button

station is:

*Starting: The motor can be started

by connecting it directly through the
line; however, the driven machine
may be damaged if started with this
sudden rotating effort.
* Stop: The controls allow operation
until the motors stop and also print a
braking action when the machinery
must stop. Quick stop is *Rotation
reversal: Controls are needed to
7 -
8
manually change the direction of
Do not directly connect FyNala button station only when
rotation of the motors. machines by
connecting a coil! command of an
quickly. Theoperator at a
a vital control action for emergency cases.control station, the
reversal of rotation in many processes is continuous in various industrial
applications.

Indicators

1) Pilot lights:
110-220 VAC
50/60Hz
1.5W
The main function of the lights is to signal that something is happening:
*Green: Indicates that the engine is running or in good condition.
Relaxation.
*Red: Indicates that the engine has stopped or is in poor condition. Alarm.
*Amber: Indicates caution or that something is about to happen.

2) Digital ohmmeter:
It is an instrument used to measure electrical
resistance (R). Its unit of measurement is the
Ohm (Ω). There are 2 types of ohmmeters, the
first, which is the one that comes integrated with
the multimeter and the second, the analog one.
These types of devices should not work
with any voltage and/or amperage otherwise they
could be damaged. If this scale is not known, it
will not be damaged if it is not correct; However,
it would not mark the value, so the scale would have to be selected well to
give us the value accurately!
To measure high resistances, multiples are used and to measure small
resistances, submultiples are used.
Megaohms (M Ω) = 1,000,000Ω
Kilohms (K Ω) = 1000 Ω
Hectohms (Ω) = 100 Ω.
This instrument can be used to verify that terminals have continuity.

3) Cicada:
Generally, the buzzer, like the
red light, indicates prevention
or alarm; as well as the engine
being stopped.
Terminals:

They are the conductors of the current and must be verified with the
multimeter on the Ohms (Ω) scale to see if they are not cut from one point.

1. Reversal of rotation by means of button stations

Material:

• 2 Button Stations
• 2 Magnetic starters
• 1 Three-phase motor
• 35 terminals
• 1 multimeter

Diagram:

a) Control
 b)
Strength

Symboogea

| B A1 Commonly closed
Flow of current
BQH/I of sorzargue one connection of Mi
oo II

IB Start button 8
Coartco comrzmenf
AS closed from M2
A.C.
OO Termal
numbering.
Coil of Mi
M
BPI Q©
Stop button one

| B.P.S.
AC Bobirza

A.C.
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LE2 eende

Told cosnúnmen^ open of

M? My

redlight
Commonly open goniactoi
of MS
Functioning:

When BA is pressed, current flows through BP and the commonly closed

1 1

contact of M and energizes the coil of M and the green light, then the
2 1

interlock of M closes, (While the commonly closed contact of M remains

1 1

open), while in the power circuit the contacts of M close and make the motor
1

rotate clockwise. Even if BA is released, the M coil and the green light will
1 1

remain energized by said interlock. And even if BA is pressed, the coil of M

2 2

will never be energized because the normally closed contact of M will be 1

open.

Pressing BP will de-energize M and the green light and the normally open
1 1

contact will open and the normally closed contact will close and the motor will
stop running.

When BA is pressed, current flows through BP and the commonly closed

2 2
contact of M and energizes the coil of M and the red light, then the interlock
1 2

of M closes, (While the commonly closed contact of M remains open), while

2 2

in the power circuit the contacts of M close and make the motor rotate
2

counterclockwise (Since line 3 is bridged to line 1 of the second starter and

line 1 to 3, reversing the power supply phases to stop the three-phase motor).
Even if BA is released, the M coil and the red light will remain energized by
2 2

said interlock. And even if BA is pressed, the coil of M will never be

1 1

energized because the normally closed contact of M will be open.

2

Pressing BP will de-energize M and the normally open contact will reopen
2 2

and the normally closed contact will close and the motor will stop running.

2. Spin reversal by means of a spin inverter module.

Material:
• 2 button stations
• 1 turn inverter module
• 1 pilot lights
• 35 terminals
• 1 multimeter

Diagram:

R normally
Green open contact
light Wiring
numbering
F normally
Cicada open contact

Coil start button F Coil stop button R

R lab start button

Coil stop button F

Coil R

Functioning:
By pressing BAR , current passes to the R coil, which closes its normally open
contact, which is the interlock, and operates the red light and the buzzer that
are connected in parallel in relation to the R coil, indicating that the motor is
rotating clockwise. Since in the power circuit the normally open contacts of R
were closed

A disadvantage of this circuit would be that when I do not have electrical

protection and I press BAF , the F interlock does not close and therefore the F
coil is not energized by the mechanical protection of the starters, so the green
light only turns on when I leave pressed the BAF , and obviously there is
rotation reversal in the force circuit. Since the normally open contacts of F are
never closed

Or the other way around, BAF could be pressed first, energize the F coil that
sends an interlock signal to the commonly open F and turn on the green light,
indicating that the motor is rotating counterclockwise, then now the interlock
would not occur nor would it occur. would energize the R coil by pressing
BAR ; Otherwise, the red light and the buzzer would only be energized, but
without reversing the rotation, since the mechanical protection prevents the 2
coils from being energized at the same time.
time. In both cases the system is de-energized by pressing any stop button.

The same circuit with electrical protections:

Function of electrical protections:

When you press BAF, the current passes to the F coil which, once energized,
sends a locking signal to its normally open contact, the green light turns on
indicating that the motor is rotating counterclockwise and the electrical
protection is activated and energized. the coil A of the control relay which
commands to open its commonly closed contact of A , this is the one that is
connected in series with the start button of R , that is why when you want to
press it the red light, the buzzer or the buzzer no longer turns on. the coil of R ,
since the line is disconnected.
CONTROL CIRCUIT

Or conversely, the BAR could be pressed, and the current passes to the coil R
which, once energized, sends a locking signal to its normally open contact,
turns on the red light and the buzzer indicating that the motor is rotating
clockwise. clockwise and the other electrical protection is activated,
energizing coil B of the control relay which commands the opening of its
normally closed contact of B, which is the one connected in series with the
start button of F , so when you want to press it The green light or the F coil no
longer turns on because the line is disconnected.

In both cases the system is de-energized by pressing any power button.

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3. Automatic, off and manual control of a three-phase motor

Material:
•
1 Limit switch
• 1 level switch
• 1 Drum Switch
• 1 Magnetic starter
• 2 Button Stations
• 1 Pilot lights
• 35 Terminals
 • 1 Multimeter
• 1 Three-phase motor

Diagram:

CONTROL CIRCUIT
 Switch of
drum

Green light

Coil M
current flow

Remote stop button

Remote start button Wiring
numbering

Local stop button

Normally open contact of coil M

Contact normally
closed coil M

Functioning:

When energizing the circuit, it will be in the off position, then current will
flow through the normally closed contact of M and the red light will be
energized. Indicating that the engine is out of service.

CONTROL CIRCUIT

When selecting automatic

When the circuit is energized, the motor must turn on and the green
light indicating that the motor is energized. If the level switch and the limit
switch are closed, both will allow the electric current to pass.
 The motor will stop working if there is a level (since the switch will be
open) or if the limit switch is open. If any of the 2 switches open, the flow of
current will be prevented; On the other hand, if they were connected in
parallel, it did not matter if one was open, as long as one was closed, it would
be enough for the current to pass through there. Meanwhile, when coil M is
energized, it commands its normally open M contact to open and turns off the
red light. Then in the power circuit its normally open contacts close and
energize the motor.

When selecting manual

By energizing the circuit and pressing any start button, either BAR or BAL, coil
M is energized and the green light turns on indicating that the engine is
running, then coil M commands its normally open M contact to close and the
circuit and opens the normally closed contact of M turning off the red light.
While in the power circuit the normally open contacts of M are closed and the
motor is energized.
In both cases; Whether manual or automatic, pressing BPL de-energizes coil M
which commands its normally open contact to open (unlocks) and to close the
normally closed contact of M , turning on the red light again indicating that the
motor is out of service.

CONTROL CIRCUIT

4. Timed ignition of 2 motors by means of time relays.

Material:
• 1 Control relay
• 2 Button Stations
• 1 Pilot lights
• 2 Magnetic starters
• 1 Cicada
• 2 Time relays (10 and 20 seconds)
• 35 Terminals
• 1 Multimeter
 • 2 three-phase motors

Diagram:
 Symbology

Local stop button

AX Relay Coil
'RT1h time 1

Remote stop button

M-, Relay coil
RT2) time 2

Normally open contact of

Remote start button coil RT1 Thermal Elern ent

Normally open contact of

Local boot button
coil RT2

current flow

Coil A normally open

contact

Wiring
Normally closed contact numbering
of coil A

Control relay coil A

Functioning:

When you energize the circuit, the buzzer will turn on, RT will start counting 1

10 seconds and after those 10 seconds RT will close its normally open contact
1

of RT but engine 1 will not work as long as neither of the 2 start buttons is
1

pressed. (Either local or remote)

By pressing any start button (either local or remote), coil A will be energized,
its normally closed contact will open and the buzzer will stop working, the
normally open contact will close and latch the circuit and start engine 1 and
the green light indicating that it is in service, RT will also be energized and
2

will begin to count 20 seconds, after 20 seconds RT will order its normally
2

open contact to close RT energized motor 2 and its red light indicating that it
2,

is last is in service.

Pressing any stop button (whether local or remote) will de-energize all the
coils, returning their contacts to their normal position, turning off the lights,
the motors and turning on the buzzer again. The exception here is the RT coil 1

which will remain energized and its normally open contact will remain closed.
And nothing will happen until the entire system is de-energized or any start
button is pressed.
 5. Timed ignition of 2 motors by means of time relays.

Material.
• 1 Control relay
• 2 Button Stations
• 1 Pilot lights
• 2 Magnetic starters
• 1 Cicada
• 2 Time relays (10 and 20 seconds)
• 35 Terminals
• 1 Multimeter
• 2 three-phase motors
Diagram:
Functioning:

When energizing the circuit, the current will pass through the normally closed
contact of A and will turn on the buzzer indicating that both motors are out of
service.

Pressing any start button (whether local or remote) will energize coil A , which
will open its normally closed contact and turn off the buzzer, close its
normally open contact and interlock the circuit, energizing RT and RT , then
1 2

RT counts 10 seconds to close its normally open contact and energize motor 1
1

and a green light to indicate that it is running. Like RT , RT counts 20 seconds

1 2

to close its normally open RT contact and energize motor 2 and a red light to
2

indicate that it is running.

 CONTROL CIRCUIT
POWER CIRCUIT

Pressing any stop button (whether local or remote) will de-energize all the
coils, returning their contacts to their normal position, turning off the lights,
the motors and turning on the buzzer again.

FORCE CIRCUIT
CONTROL CIRCUIT

6. Ignition with automatic, off and manual timing of 2 motors through

time relays.

Material:
• 1 Drum Switch
• 1 Limit switch
• 1 level switch
 • 1 Control relay
• 2 Button Stations
• 1 Pilot lights
• 2 Magnetic starters
• 1 Cicada
• 2 Time relays (2 for 10 seconds)
• 35 terminals
• 1 Multimeter
• 2 three-phase motors.

Diagram:
Functioning:

When energizing the circuit, it will be in the off position, then current will
pass through the normally closed contact of A and the buzzer will be energized
indicating that both motors are out of service.

CONTROL CIRCUIT

When selecting automatic:

When the circuit is energized, the coil of A must be turned on, which
commands its normally closed contact of A to open and at the same time the
buzzer goes off, it also commands its normally open contact of A to close,
locking the circuit and energizing RT and RT , both count 20 seconds to close
1 2

their normally open contacts of RT and RT respectively and at the same time
1 2

energize the coils M and M then turn on the green and red lights also
1 2

indicating that the 2 motors are in service.

Both motors will stop working if there is a level (since the switch will
be open) and if the limit switch is open. If the 2 switches are opened, the flow
of current will be prevented; On the other hand, if only one is opened, it does
not matter since the current can flow through the other switch, since they are
connected in parallel.
 FORCE CIRCUIT
CONTROL CIRCUIT

When selecting manual:

When you press the local or remote start button, coil A should turn on,
commanding its normally closed contact of A to open and at the same time the
buzzer goes off, it also commands its normally open contact of A to close,
interlocking the circuit and energizing RT and RT , both count 20 seconds to
1 2

close their normally open contacts of RT and RT respectively and at the same
1 2

time energize the coils M and M then the green and red lights also turn on
1 2

indicating that the 2 motors are in service. Pressing any of the 2 stop buttons
will de-energize the motors and lights, then the coil contactors return to their
initial position and the buzzer is energized again indicating that the 2 motors
are out of service again.
 FORCE CIRCUIT
CONTROL CIRCUIT

REFERENCES

[1] Control of Electric Motors, Enríquez Harper, Ed.Limusa

[2] Electrical Drives, Enríquez Harper, Ed. Purrua