Trade of Electrician

Standards Based Apprenticeship

Motor Control

Phase 2

Module No. 2.4

Unit No. 2.4.2

COURSE NOTES
 Created by John Watters - Sligo TC

Revision 1 April 2000 by

John Watters - Sligo TC
Gerry Ryan - Galway TC

Revision 2 Sept 2006 by

Chris Ludlow - Dundalk TC

Revision 3. Feb 2008 by

Chris Ludlow - Dundalk TC

Revision 4. July 2009 by

Chris Ludlow - Dundalk TC

Compiled by Liam Carroll – Certification & Standards

Published by

FÁS - Training and Employment Authority

P.O. Box 456
27-33 Upper Baggot Street
Dublin 4
Ireland

© FÁS - 2009

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or
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FAS Electrical Course Notes – Module 2.4.2

Table of Contents
TABLE OF CONTENTS ..............................................................................................................................3

INTRODUCTION .........................................................................................................................................4

CIRCUIT SYMBOLS ...................................................................................................................................5

PANEL WIRING TECHNIQUES ...............................................................................................................6

TYPICAL MOTOR CONTROL INSTALLATION ................................................................................13

DEFINITIONS.............................................................................................................................................16

UNIT RELATED ETCI RULES ................................................................................................................16

TERMINAL BLOCKS................................................................................................................................17

PUSHBUTTONS, SWITCHES AND INDICATORS ..............................................................................17

RELAYS .......................................................................................................................................................21

CONTACTORS ...........................................................................................................................................23

AUXILIARY CONTACT BLOCKS..........................................................................................................28

OVERLOAD PROTECTION ....................................................................................................................29

REASONS FOR OVERLOAD PROTECTION .......................................................................................32

MOTOR STARTER....................................................................................................................................33

DIRECT ON LINE STARTER ..................................................................................................................34

TYPES OF CONTROL...............................................................................................................................37

OVERLOAD SET UP .................................................................................................................................38

PROBLEM SOLVING TECHNIQUES ....................................................................................................41

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FAS Electrical Course Notes – Module 2.4.2

Introduction
Welcome to this section of your training course, which is designed to assist you the learner,
understand the basics of how electric motors are controlled.

Objectives
By the end of this unit you will be able to:

 Recognise and use appropriate circuit symbols

 Use basic panel wiring techniques
 Select and use correct panel wiring cable
 Produce a basic motor control layout
 Understand the basic rules which apply to installing a motor
 Install flexible conduit
 Understand the operation and use of push-buttons
 Understand the operation and use of relays
 Understand the operation and use of contactors
 Understand the operation and use of auxiliary contact blocks
 Understand the operation and use of thermal overload units
 Understand the operation and use of indicator units
 Correctly set an overload unit to suit the motor protected
 Install a D.O.L. starter to control and protect a three-phase motor
 Install a D.O.L. starter to control and protect a single-phase motor
 Install a control circuit to provide Start / Stop operation
 Install a control circuit to provide Emergency Stop operation
 Install a control circuit to provide Auto / Off / Manual operation
 Install a control circuit to provide Sequential operation
 Install Power On, Motor Run and Overload Tripped indication
 Develop and interpret schematic diagrams for above circuits
 Locate and repair faults on above circuits

Reasons
The ability to understand basic motor control is vital as it is used in one form or another in
every walk of life.

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FAS Electrical Course Notes – Module 2.4.2

Circuit Symbols
The following are the circuit symbols commonly used in motor related schematic diagrams.

Note: The following symbol was developed by Telemecanique and is still in common use.

Telemecanique 95 97
Resettable Thermal R
Overload Auxiliary 96 98
Contacts

Figure 1

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FAS Electrical Course Notes – Module 2.4.2

Panel Wiring Techniques

Electrical control panels are available in all shapes and sizes to suit the particular requirements
of the situation. These panels may be small as shown in Figure 2, or very large as required to
house the necessary components. They must of course provide the required level of protection
from the prevailing conditions in the location.

Figure 2

The control equipment may be mounted in the panel in a number of ways as follows:

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FAS Electrical Course Notes – Module 2.4.2

Drilled or Tapped Mounting Plates

Figure 3 illustrates a section of a drilled and tapped mounting plate. This mounting method can
be costly unless large volume production is involved.

Figure 3

Slatted Mounting Screens

Figure 4 illustrates a section of slatted mounting screen. This mounting method suits any type
of equipment and is quick and easy to assemble.

Figure 4

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FAS Electrical Course Notes – Module 2.4.2

Mounting Rails

Mounting rails are made up of cold rolled steel. After being rolled, they are treated to prevent
corrosion. Mounting rails are used for snap-on mounting of electrical equipment. A selection of
mounting rails is illustrated in Figure 5.

Plain Top Hat

Slotted Top Hat

Slotted G. Rail

Plain G. Rail

Figure 5
Note:
All these rails are supplied in 2 metre lengths.

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FAS Electrical Course Notes – Module 2.4.2

Panel Wiring Cable

This is an insulated flexible cable without a sheath. It is generally run in slotted trunking with a
clip on lid, inside a control panel. Panel wire is available as follows:

Type Nominal C.S.A. in sq.

mm
H05V – K 0.5 - 1.0
H07V – K 1.5 - 240.0

Note: For CENELEC Cable coding system see ETCI Rules

The following cable colours are available:

Brown; blue; green/yellow; black; green; grey; orange; pink; red; yellow; violet and white.

Crimp Connectors

A wide range of crimp connectors is readily available in both insulated and non-insulated types
to suit any particular electrical application.

Figure 6 shows some of the crimp connectors in common use.

Figure 6

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FAS Electrical Course Notes – Module 2.4.2

Figure 7 shows a typical ratchet type crimping tool used for the termination of insulated crimp
connectors to cables. It is colour coded to indicate the size of crimp connector and matching
conductor. Red for 1.52 mm, blue for 2.52 mm and yellow for 42 mm and 62 mm. Some of these
tools require that the connector be inserted the correct way round. If this is not done, a poor
joint between cable and connector will be the result.

Figure 7

Figure 8 shows a multipurpose tool. It features a cable cutter, sections for insulated and non-
insulated crimp connectors as in figure 7. It has a cutter for the common size machine thread
brass screws ( 2.6 mm to 5 mm ) which allows screws to be cut clean avoiding damage to the
start of the thread. It also has a wire stripper for cable sizes 0.752. to 62. The jaws must be fully
closed to ensure correct pressure is applied to connector etc.

Figure 8

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FAS Electrical Course Notes – Module 2.4.2

Panel Trunking

Figure 9 illustrates a section of PVC slotted trunking used inside electrical control panels to
accommodate cable runs. It is available in 2 metre lengths and various widths and heights - for
example it is available in sizes from 15mm wide x 17mm high to 100mm x 100mm. Divider
walls can be inserted for segregated compartments. The lid is simply clipped on in place.
Sections can be removed from the sides to allow cables enter or exit. The wiring can easily be
altered or modified after initial installation. It is fast to install.

Figure 9

Cable Lacing

Figure 10 illustrates a section of cable loom formed using the cable lacing method. Cable lacing
allows looms to be made up prior to assembly. This wiring method is very fast and cheap for
high volume work. Cable ties or spiral cable wrapping may also be used.

Figure 10

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FAS Electrical Course Notes – Module 2.4.2

Wiring of Enclosure Doors

Figure 11 illustrates a typical method of wiring an enclosure door. The wiring between the main
frame and the front panel should allow the door to open and close without undue strain on the
wires. A loop clamped between two points is the usual method.

Figure 11

Figure 12 illustrates how wiring from the loop is usually cable tied or laced and then clipped to
the door at convenient intervals. Flexible stranded cable should be used covered with an overall
PVC sheath, e.g. spiral wrap.

Note: The door of a steel enclosure can be regarded as an exposed conductive part and
therefore is required to be earthed. The metal hinge is not sufficient to meet this requirement.

Figure 12

Identification Tags

Cable markers are used to identify cables, wiring systems etc. It is desirable that wiring shall be
arranged or marked so that it can be identified for inspection, testing, repairs or alterations of
the installation. One practical way of quickly and easily identifying panel wires ( when trouble
shooting etc ), is by using cable marking tape. This marking tape, which is purchased in rolls
with various legends, is simply placed in a dispenser, which cuts the tape to any length
required.

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FAS Electrical Course Notes – Module 2.4.2

Typical Motor Control Installation

Figure 13 illustrates a typical layout where the isolator is remote from the motor

Motor
Circuit
Protection
Fuses
Or
MCB’s Switch off
for
mechanical maintenance
Motor
( Isolation and locking off )
Isolator
ON

OFF
LABEL
Danger do not switch on

Busbar Chamber

Main Fuses
Protection or
Circuit
Breaker
Main
Motor
Isolator ON Starter
OFF

Motor
Supply
Cable

Figure 13

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FAS Electrical Course Notes – Module 2.4.2

Figure 14 illustrates an example of a motor final circuit equipment layout.

Through Box to help draw in cables

( Depending on length of run of conduit )

Fixed Conduits

Motor
Distribution Isolator On
Board ( 3 Pole )
Off

Coupling and male

brass bush at terminations

Start
Starter ( DOL )
Stop

Flexible conduit
Terminated in gland

Three Phase
Motor

Separate Protective Conductor

Figure 14

Note: A separate earth protective conductor was fitted on the outside of the older types of
flexible conduit. Therefore mechanical protection was not provided.
In modern installations it must be installed inside the flexible conduit with the power cables.

Flexible Conduit

Flexible conduit is made of interlinked metal spirals often covered with a PVC sleeving. The
tubing must not be relied upon to provide a continuous earth path and, consequently, a separate
protective conductor must be run inside the flexible tube.

Flexible conduit is used for the final connection to motors so that the vibrations of the motor /
machine are not transmitted throughout the electrical installation. It also allows adjustments to
be made to the final motor position for drive belt tension etc.

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FAS Electrical Course Notes – Module 2.4.2

Assembly Instruction
Figure 15 shows one type of flexible conduit and gland.

Gland Claw Seal Compression Flexible

Nut Conduit

Figure 15

1. Cut the conduit square with a knife edge blade rather than a hacksaw.

2. Dismantle the gland body.

3. Fix the gland body in the enclosure entry.

4. Assemble the compression nut and claw seal loosely on the conduit end
( correct way round ).

5. Push the conduit down into the gland body.

6. Assemble the compression nut onto the body thread while continuing to apply a force
on the conduit.

7. Tighten the compression nut until finger tight.

8. Using a spanner tighten the compression nut two further turns to provide a dust and
water tight seal between the conduit and gland.

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FAS Electrical Course Notes – Module 2.4.2

Definitions
Contactor ( mechanical ): A mechanical device having only one position of rest, operated
electromechanically and capable of making, carrying and breaking currents under normal
circuit conditions, including overload operations.

Note: A contactor is usually intended to operate frequently.

Emergency: An unexpected occurrence or condition that could cause danger and requires
immediate action.

Emergency Switching: An operation intended to remove as quickly as possible, danger that

may have occurred unexpectedly. This includes emergency stopping.

Undervoltage: Any voltage less than the nominal voltage of the installation.

Unit Related ETCI Rules

Protection against Under-voltage 445
451.1, 451.5
Isolation 462
462.5
Switching for Mechanical Maintenance 463

Emergency Switching including 464

Emergency Stopping 464.2

Identification and Marking 514

514.1
Voltage drop in Consumers Installation 525
525.2 ( note, only in relation to motors )
Devices for Protection against 533
Overcurrent 533.3, 533.3.4

Devices for Protection against Under- 535 ( note1, item 2 only )

voltage

Devices for Isolation and Switching 537

537.3 All
537.4 All
Motors and Control Equipment 552
552.1, 552.1.1, 552.1.2, 552.1.3
552.2, 555.2.1
Motor Rotation 613
613.9

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FAS Electrical Course Notes – Module 2.4.2

Terminal Blocks
Figure 16 shows a simple terminal block arrangement. Individual terminals are designed to clip
onto a variety of mounting rails. They are manufactured in a variety of sizes to accommodate
any cable CSA. Green / Yellow earth terminals are designed to make good contact with the
mounting rail on tightening of the centre screw. Other colours are available but are not
essential.

Figure 16

The terminals must be installed the correct way round as each one is generally insulated on one
side only. An end insulator must be installed to insulate the last terminal. An end clamp must be
used to prevent the terminals from spreading apart. An earth terminal doubles as an end clamp.
Terminals with solid links or fuse holders are also available.

Pushbuttons, Switches and Indicators

Pushbutton, switch and indicator units are manufactured in various styles. While they may
differ in appearance, they operate basically the same way. They are available in different IP
ratings to suit the environment in which they are to be installed. Pushbuttons with ‘built in’
indicator lamps are also available.
All these devices are generally known as control and signalling units. The more commonly
used units are 22 mm in diameter. They are manufactured in metal for mounting on metallic
doors of control panels. These doors must be earthed. Plastic versions are also available and are
generally used to provide double insulated control stations etc.

Pushbuttons are colour coded as follows:

Start Button Green
Stop Button Red
Inch Button Black ( Optional exercise for faster apprentices ).

Indicator Units may be colour coded as follows:

Run Indicator Green
Fault Indicator Red
Power “ON” White

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FAS Electrical Course Notes – Module 2.4.2

Start Button
A start button consists of a green coloured actuator, which when pressed operates a normally
open contact. On pressing the green actuator the normally open contact will close. These are
fitted on the panel door via a mounting collar. The actuator is fitted through a suitable hole in
the panel door. A rubber washer is used on the outside to provide ingress protection. The
actuator is locked into the collar. The collar is secured to the panel door by a screw. This action
compresses the rubber seal on the actuator. Finally the contact block is simply clipped on to the
collar. See Figure 17.

Colour
and / or N/O
symbol Contact
to indicate Block
function

Actuator Rubber Mounting

Seal Collar
Figure 17

Stop Button
A stop button consists of a red coloured actuator, which when pressed operates a normally
closed contact. On pressing the red actuator the normally closed contact will open.
See Figure 18

Colour
and / or N/C
symbol Contact
to indicate Block
function

Actuator Rubber Mounting

Seal Collar

Figure 18

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FAS Electrical Course Notes – Module 2.4.2

Emergency Stop Button

This is an emergency stop button and it differs from a standard stop button as follows:

 It has a large, easy to operate, mushroom shaped actuator.

 This actuator must be mounted on a yellow background.
 When operated, the actuator latches in the “Off “ position.
 The actuator is released by twisting the mushroom shaped head.

Figure 19

Auto / Off / Hand Selector

This is a three position switch, having an “Off “position in the centre. When turned to the left, a
normally open contact is closed. This operation selects an automatic function. When turned to
the right, a different normally open contact is closed. This operation selects a manual or hand
operated function.

Figure 20

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FAS Electrical Course Notes – Module 2.4.2

Signal Lamp Units

A signal lamp unit consists of an appropriately coloured lens, lamp holder and mounting
arrangement similar to a push button unit. A 230 V “small centre contact” ( SCC ) lamp is used
in the holder shown in Figure 21. An incandescent lamp or a neon lamp may be used. The phase
conductor must be connected to the terminal marked X1.

Lampholder
Coloured
Lens
Terminals

Mounting Incandescent Neon

Collar Lamp in Lamp
Lampholder
Figure 21

Other types of signal lamp units are available however they are not covered in Phase 2.

Figure 22 shows a small control panel which consists of a number of the control and signalling
devices previously described.

Figure 22

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FAS Electrical Course Notes – Module 2.4.2

Relays
Operation of a Relay

A relay is an electro-magnetically operated switch. It consists of an operating coil wound

around an electromagnet pole piece, a moving armature and one or more sets of contacts. When
a voltage of the correct value is applied across the coil terminals, the resulting current flow
through the coil produces a magnetic field similar to a bar magnet. The armature is attracted by
the magnetic field and so moves a small distance.
This movement operates the contact(s). The pole piece is magnetically soft. When current flow
through the coil ceases, the pole piece loses its magnetism and the armature returns to its de-
energised position. This allows the contact(s) return to the de-energised or normal state.
See Figure 23.

Springy Conductor Material Fixed

Contact
Moving
Contact Contact
Connections

Insulator

Iron
Armatur
Relay Coil

Magnetic
Circuit Electromagnet
Pole Piece
Coil Connections

Figure 23

A relay is a device in which a low value of current and / or voltage operates an electromagnetic
coil. This coil in turn operates a contact or contacts, which control or switch a high or relatively
high value of current and / or voltage.

Normally Open Contact ( NO )

This is the normal state of the contact when the electromagnet ( coil ) is de-energised. This
contact will close instantaneously when the electromagnet is energised. On de-energising the
coil, this contact will return to its normal state i.e. open.

Normally Closed Contact ( NC )

This is the normal state of the contact when the electromagnet is de-energised. The contact will
open instantaneously when the electromagnet is energised. On de-energising the electromagnet,
the contact will return to its normal state i.e. closed.

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FAS Electrical Course Notes – Module 2.4.2

There are a large number of different designs on the market. In general relays are used to
receive an electrical signal from some source ( pushbutton, timeswitch, thermostat, pressure
switch ) and relay it on to another device. They are usually capable of switching currents in the
region of 10 Amps, although relays up to 30 Amps are available. They are not normally used
to switch inductive loads such as electric motors. Some relays are designed for this purpose.
In Phase 2 we examine the type more commonly used in motor control panels. Figure 24 shows
two 4 pole ( 4 sets of contacts ) relays. They look identical, but on closer examination they are
not. The manufacturer has identified them with type numbers, CA2-DN 40 and CA2-DN 31.
The 40 section of the number on the first relay signifies that it has 4 normally open contacts and
0 normally closed contacts. The 31 section of the number on the second relay signifies that it
has 3 normally open contacts and 1 normally closed contact.

Figure 24

Each contact is identified by a two digit number. The first digit signifies the position of the
contact on the relay 1 to 4 in this case. The second digit signifies the type of contact. A contact
marked 1-2 is a normally closed contact. A contact marked 3-4 is a normally open contact. The
coil terminals are marked A1 and A2. Relay coils are usually identified by the letter K,
followed by a digit up to the total number involved in the circuitry, e.g. K1 to K5.
Note: It is conventional to draw contacts in their de-energised positions.

CA2-DN 22 Relay

Figure 25

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FAS Electrical Course Notes – Module 2.4.2

Contactors
Contactors are very similar to relays. They are specifically designed for switching load
currents. They are used to supply electric motors, heaters, lamps etc. Contactors are designed
for high switching frequency, long life and short switching times. The making / breaking
capacity of the main contacts is matched to the possible motor starting current. High value
overload currents or short circuit currents can damage the main contacts, therefore protection
must be provided by fuses or MCB’s.

Generally contactors have three main contacts plus one auxiliary contact. The current rating of
the main contacts will depend on the load to be switched and may be as low as 10 Amps or as
high as 2000 Amps. The current rating of the auxiliary contact(s) is generally around 10 Amps.

Figure 26 shows a 65 Amp contactor. The 3 Phase supply is connected to the three main
terminals on the top of the contactor. The load is connected from the three main terminals on
the bottom. On the right hand side of figure 26, the cover has been removed to show the three
main contacts and one of the auxiliary contacts.

Note the difference in the physical size of the main ( 65 Amp ) contacts and
the auxiliary ( 10 Amp ) contact.

Supply Cover
In Removed

Supply Main Auxiliary

Out Contacts contact
Figure 26

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FAS Electrical Course Notes – Module 2.4.2

Figure 27 shows a 9 Amp contactor which is suitable for any motor up to 4 kW. On this size of
contactor the auxiliary contact appears to be the same as the main contacts. The difference is
only visible on dismantling the contactor and examining the contacts. The auxiliary contact is
not designed to switch power to or from a load such as a motor. If used for such a purpose it
would quickly fail. The coil terminals are located towards the base of the contactor. A1 is top
left and A2 is available both top right and bottom right.

Figure 27

Figure 28 shows the contact arrangement inside the contactor. The difference between the three
main contacts and the auxiliary contact is visible.

Main Auxiliary
Contact Contact

Figure 28

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FAS Electrical Course Notes – Module 2.4.2

Each main contact is identified by a single digit number. The coil terminals are marked A1 and
A2. The coil, of a contactor used to switch supply to a motor is usually identified by the letters
KM, followed by a digit up to the total number involved in the system, e.g. KM1 to KM5.

Figure 29

Figure 30 shows a more modern 9 Amp contactor. The most noticeable differences are;

 The inclusion of a normally closed auxiliary contact

 The position of the auxiliary contacts
 The position of the coil terminals

Figure 30

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FAS Electrical Course Notes – Module 2.4.2

Figure 31 shows the main parts of a contactor. It consists of an insulated base which houses a
laminated magnetic core. This core is mounted on rubber for quiet operation. The operating coil
is fitted between the magnetic core and the armature which carries the moving contacts. When
the correct supply is applied across the terminals of the coil, magnetism is produced and the
armature is pulled towards the magnetic core. This movement occurs very fast and operates the
contactor contacts. Each contact is spring-loaded to ensure positive closure and minimum
contact bounce. When supply is disconnected from the coil, the armature is quickly returned to
its original position by the main spring.

Insulated
Base

Laminated
Magnetic Core

Operating
Coil

Main
Spring

Iron Armature

Contact
Housing

Figure 31

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FAS Electrical Course Notes – Module 2.4.2

Contactor Coils

The coils of most modern contactors can be quickly changed without the use of any special
tools. These contactor coils may be AC or DC operated.
AC standard coil voltages are 24, 110, 230, 400 Volts 50 Hz.
DC standard coil voltages are 12, 24, 48, 230 Volts DC.
Other non-standard voltage ratings are available on request.

It is most important that the coil voltage, type and value are matched to the supply available. A
230 Volt supply will not energise a 400 Volt coil. A 400 Volt supply will operate a 230 Volt
coil, however the coil will quickly overheat and burn-out.

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FAS Electrical Course Notes – Module 2.4.2

Auxiliary Contact Blocks

Frequently it is necessary to have more auxiliary contacts operated by a single contactor.
Additional contacts may be made available by the use of auxiliary contact blocks. These
contact blocks are available with one, two or four contacts. From these it is possible to obtain
any number of normally open and / or normally closed contacts from one to four.
Figure 32 shows an auxiliary contact block having four contacts. It has two N/O and two N/C
contacts ( LADN22 ).

Figure 32

These auxiliary contact blocks are designed to be clipped piggyback style to a contactor. When
the contactor is energised, it also operates the auxiliary contact block. See Figure 33.

Figure 33

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FAS Electrical Course Notes – Module 2.4.2

Overload Protection
High temperatures have an adverse effect on insulating materials. It is essential therefore, that
electric motors should be provided with protection against overheating. Excess current taken by
a motor causes overheating. The protective devices most commonly used, detect this excess
current. However excess currents do exist during starting, but as these are not for long periods
of time they do not cause overheating. Fuses or MCB’s, cannot be used since the starting
current of the motor would cause them to blow / trip. It is therefore desirable for over-current
protective devices to have a built in “time lag” to facilitate such starting currents. The over-
current protective device referred to above is called an overload relay. Fuses or MCB’s are
used in conjunction with overload relays to provide protection against short circuits, earth faults
or faults in the main wiring.

Overload Relay

There are two types of overload device in use;

 The thermal overload relay
 The magnetic overload relay

The thermal overload relay is the more popular type and is the only one covered in Phase 2.

Thermal Overload Relay

Figure 34 shows a popular type of thermal overload relay. It is suitable for the protection of a
motor with a Full Load Current of any value from 1.6 Amps to 2.5 Amps. This value can be set
using the current range adjustment. It also features a stop button, a hand / auto – reset button
and a test button. It has one N/O and one N/C auxiliary contact. When installed and properly
adjusted it may be sealed to prevent / monitor any unauthorised interference with the settings.

Figure 34

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The three pins protruding from the top are connected directly into the outgoing terminals of a
contactor. Two of these pins are adjustable so that they can be matched up to a number of
different size contactors. See underneath pins for this information.

The overload relay may also be installed using a terminal block for separate mounting. Again
the pins are adjusted to suit the terminal block. See Figure 35.

Figure 35

OVERLOAD UNIT AUXILIARY CONTACTS

Figure 36

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FAS Electrical Course Notes – Module 2.4.2

Operation of Thermal Overload Relay

A thermal overload relay works on the principle that, current flowing through a conductor
produces heat. If the current is doubled in value the amount of heat produced will be
quadrupled. The current taken by a three phase motor is passed through a set of three small
heater elements. One heater is wrapped around each of the three bi-metal strips as shown in
Figure 37.

Supply
Terminals Trip Levers

Bi-metal
Strip Insulation

Load
Heater Terminal
Element

Figure 37

The operation of the thermal overload relay is as follows:

Under normal conditions the heat produced by the heater elements is just balanced by the heat
lost from them to the surroundings and consequently there is no effect on the bi-metal strips.
When an overload current flows, more heat will be produced by the heater elements, resulting
in further heating of the bi-metal strips, thus causing them to bend more. This bending of the bi-
metal strips changes the position of the trip lever, which causes the auxiliary contacts to change
over.
The N/C contact opens and is used to disconnect supply from the contactor coil, thereby
disconnecting the supply from the motor. The N/O contact closes and is generally used to
supply a signal lamp to indicate that the overload relay has tripped.

Thermal Overload Relay Elements

Supply in
1 3 5

2 4 6
Load out

Figure 38

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FAS Electrical Course Notes – Module 2.4.2

Reasons for Overload Protection

As stated earlier, excess current flowing through a motor winding will cause overheating. This
in turn will result in damage to the winding insulation. If this occurs the motor is described as
being “burned out” and must be rewound or replaced.
Here are some of the reasons why motors burn out:

No overload protection
Incorrect overload relay fitted
Incorrect overload relay setting

The main functions of thermal type overload relays are to prevent burn out of windings due to
overloading or single phasing. Overloading applies to all motors, while single phasing only
applies to three phase motors. See below.

Overloading

When the load is increased on an induction motor the rotor speed reduces and the current taken
by the motor increases. When this current rises above the motor Full Load Current, the motor is
considered to be overloaded. Generally speaking, motors can cater for a 110 - 120% overload.
Consequently overload devices are calibrated to allow for this. An overload relay set at 10
Amps will trip after a time delay, on a load current of 10 + 15% = 11.5 Amps.

A thermal overload relay will allow for the starting current of an induction motor. It takes time
to heat the bi-metal strips. This provides a time lag to allow the starting current flow for a
sufficient period of time to get the motor up to full speed.
Low value overloads will be detected and acted upon after a period of time.
Higher value overloads will be detected and acted upon in a shorter time.

Single Phasing

If a break occurs in any one phase of the supply to a three-phase induction motor, the motor
will continue to run on two phases depending on the load. If fully loaded it will probably stall
and must be quickly disconnected from the supply as the load current will rise sharply. If it is
not fully loaded it will continue to operate the load. In order to do so it will slow down and
draw more current from the remaining two phases. This condition is called “single phasing”.
A bad connection, a blown fuse or a faulty contactor main contact will produce this effect.
A motor will generally not start on two phases; if it does start it will do so very slowly.

This is undesirable and will cause damage to the motor winding(s). Most thermal overload
relays are equipped with a differential device. This simply means that they can differentiate
between all three bi-metals being heated and only two being heated. If only two bi-metals are
heated the relay will operate at a lower load current. In this way it provides protection against
damage due to single phasing.

Note This is the reason why all three heater elements must be used on a single phase motor
circuit.

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Motor Starter
Direct On Line Starter

The term motor starter is used to describe a device which is used to:

 Safely apply power to an electric motor to cause it to start up and run

 Protect a motor from the effects of overloading or single phasing
 Safely disconnect a motor from the supply to stop it
 Prevent the motor re-starting after a supply failure ( only where danger may exist )
 This is referred to as No Volt Protection.

The simplest form of motor starter for the induction motor is the Direct On Line starter. The
DOL starter comprises a contactor and an overload protection relay. The contactor switches the
supply to the motor. It is controlled by a start button and a stop button. The stop button is an
integral part of the overload relay. An auxiliary contact on the contactor is used to maintain the
supply to the contactor coil after the start button is released. If the supply to the contactor coil
fails, the contactor is de-energised and the motor stops. The start button must be pressed to
energise the contactor again. The overload relay monitors the current being taken by the motor.
Figure 39 shows an enclosed starter.

Figure 39

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FAS Electrical Course Notes – Module 2.4.2

Direct On Line Starter

A DOL starter connects the three main lines ( L1, L2 and L3 ) directly to the motor terminals
when the start button is pressed. The drawing of a DOL starter is generally done in two separate
stages. These are called the Power Circuit and the Control Circuit.

Power Circuit

The power circuit shows all the components or parts of components required to handle the load
current of the motor. Remember that the motor in question may be a small 1.5 kW ( 2 HP ) or a
large 225 kW ( 300 HP ). As the motor power rating increases so too must the current rating of
the contactor, overload relay and supply cables.
N.B. When wiring circuits, the supply should be fed in on the low number terminal and out
on the high number terminal. See figure 40.

Figure 40

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FAS Electrical Course Notes – Module 2.4.2

Control Circuit

The control circuit shows all the components or parts of components required to control the
motor. These components are basically the same regardless of the power rating of the motor in
question.
Note When wiring circuits, the supply should be fed in on the low number terminal and out
on the high number terminal. See figure 41.

L1

1
Control Circuit
F0 Fuse / MCB
2

Reset Button 95
Auxiliary Contact
Blue R F1 of Overload Relay
96

Stop Button
1
Red O S1
2

Start Button 3 13
Hold On
Green I S2 KM1 Contact
4 14
Insulated
Mechanical
Link
A1
KM1 Contactor
Coil 230 V
A2

N
Figure 41

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FAS Electrical Course Notes – Module 2.4.2

Identification of Equipment

 F Protective device
 H Signalling device
 K Relay, contactor
 M Motor
 Q Mechanical switching device for power circuit
 S Switch, pushbutton
 X Terminal, plug and socket

Circuit Description

Refer to the circuit illustrated in Figure 41.

The motor being controlled by KM1 will START if:

 Supply voltage is present between L1 and N

 The control fuse F0 is good
 The normally closed ( NC ) contact 95 – 96 is closed
 The stop pushbutton S1 is not operated
 The start pushbutton S2 is operated
 The coil is energised by the presence of a voltage and the circuit is complete through the
coil to the neutral
 The auxiliary contact 13 – 14 ( NO ) is closed by the operation of the coil
 When the start pushbutton S2 is released current continues to flow through the auxiliary
contact 13 – 14 ( hold on contact ), the coil remains energised and the motor continues
to run.

The motor being controlled by KM1 will STOP if:

 The control circuit fuse blows or MCB trips or is switched off.

 The overload trips or F1 is pressed causing 95 – 96 ( NC ) contact to open
 The stop button S1 is pressed
 The voltage reduces to a level which cannot keep the coil energised
 The supply fails

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FAS Electrical Course Notes – Module 2.4.2

Types of Control
The control system for a single motor may be very simple or it may be reasonably complicated.
A process line may consist of a number of motor driven machines. They all have to start and
stop as the process demands. There are basically two types of control.

Hand Control

The motor used to drive a basic type pedestal drilling machine is a good example. It is usually
controlled as in Figure 41. This is ideal as it provides No Volt Protection. This means that if the
supply fails for any period of time, the motor will not restart when supply is restored again.
Imagine the result, if the drilling machine started up while the operator was tightening a drill bit
in the machine chuck.

The motor used to drive a ventilation fan may be controlled by a one way switch. This switch
energises the contactor and the motor starts. If the supply fails for any period of time and the
switch is left in the “On“ position, the motor will restart when supply is restored again. In this
case No Volt Protection is not provided, as there is no danger to health or safety due to the fan
starting unexpectedly.

These are referred to as Hand Control or Manual Control.

Automatic Control

The motor used to drive an air compressor at a petrol filling station is controlled in a slightly
different manner. An automatic air pressure switch is attached to the air reservoir. When the
pressure in the reservoir reaches the level at which the pressure switch is set, a N/C contact on
the pressure switch opens. This disconnects the power from the contactor coil and the motor
which drives the compressor, stops. When the pressure falls to a predetermined level the
pressure switch contact closes again and applies power to the contactor coil. This starts the
motor again. This process continues once the isolator for the air compressor is in the “On”
position. As a result there is always an ample supply of compressed air available for any
motorist wishing to avail of it.

This is referred to as Automatic Control.

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FAS Electrical Course Notes – Module 2.4.2

Overload Set Up
When setting up an overload relay to protect a motor in a given situation, the following two
questions must be considered:

1. Should the overload relay be set to the Hand Reset or Auto Reset position?
2. What load current value should the overload relay be set at?

Hand Reset Position

In the case of motors that are manually controlled, the overload relay must be set to Hand reset.
The motor will stop if the overload relay trips out and will not restart automatically, regardless
of the position of any control switch, until the overload relay is reset.

Auto Reset Position

In the case of motors that are automatically controlled, the overload relay may be set to Hand
or Auto reset as the situation requires.

 If the automatic starting up of the driven machine may cause danger, then the overload
relay must be on Hand reset. This means that an operator is alerted that the overload
relay has tripped out and has to be manually reset. Part of the operator’s function is to
ensure that the restarting of the machine does not cause any health or safety problem.

 If the automatic starting up of the driven machine will not cause danger, then the
overload relay may be on Auto reset. This means that the operation of the machine is
interrupted for the least amount of time possible. This is very important in various cases
for example: air compressors, refrigeration units, liquid pumps where the liquid may
congeal ( set ) if allowed cool in the pipe work, etc. An operator could still be aware of
the fact that the overload relay tripped out. This information could be recorded
automatically if necessary.

Load Current Setting

Overload relays are designed to operate between 110% and 120% of the set value. It is essential
that they be accurately set to the Full Load Current of the motor.

 If set too high, they will not provide proper protection for the motor. Damage may be
done to the motor windings through overheating if overloading occurs.

 If set too low they will operate before the motor is fully loaded. This will result in low
output from the driven machine and the motor will not be operating at full efficiency.

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FAS Electrical Course Notes – Module 2.4.2

The setting up of overload relays, differ slightly as type and / or manufacturer changes. The
overload relay shown in Figure 39 has a sealable transparent cover over all its adjustable items.
Lifting this cover provides access to all these items.

One of these is a large blue dial which is adjustable using a screwdriver. This dial is marked in
terms of motor Full Load Current. It is simply rotated so that the required figure in Amps is in
line with the white arrow on the body of the relay. The overload relay in Figure 42 is suitable
for any motor with a FLC of 1.6 Amps to 2.5 Amps. The next relay in this range is suitable for
any motor with a FLC of 2.5 Amps to 4 Amps. In this way all motor FLC values are catered
for.

Figure 42

Just below the blue dial there is a small red button. Pressing this button with a small flat
screwdriver will simulate the tripping function. The N/C auxiliary contact 95-96, opens and
N/O auxiliary contact, 97-98 closes. A small orange coloured flag appears to the right of the
blue dial. This is very useful for checking the control circuit wiring during commissioning.
The red button with a white circle in the centre is simply a local stop button. Pressing it opens
the N/C auxiliary contact, 95-96. It does not close the N/O auxiliary contact, 97-98.
The blue reset button may be set in either the Hand or Auto position as necessary. This may be
done using a suitably sized screwdriver. When set in the Hand position the button is allowed to
pop out under spring pressure. It must now be pressed to reset after a trip has taken place. When
set in the Auto position ( press in using screwdriver before attempting to turn ) the button is
held in. This means that the unit will reset itself after a trip has taken place.

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FAS Electrical Course Notes – Module 2.4.2

The overload relay shown in Figure 43 has a sealable hinged cover over all its adjustable items.
Pulling this cover from the right hand side provides access to all these items.

One of these is a small white dial which is adjustable using a screwdriver. This dial is marked
in terms of motor Full Load Current. It is simply rotated so that the pointer is in line with the
required figure in Amps, on the body of the relay. This overload relay is suitable for any motor
with a FLC of 2.5 Amps to 4 Amps. The next relay in this range is suitable for any motor with a
FLC of 4 Amps to 6 Amps. In this way all motor FLC values are catered for.

Figure 43

Above and to the right of the white dial there is a small black Test lever. Pressing this lever
with a small flat screwdriver, in the direction of the arrow above it, will simulate the tripping
function. The N/C auxiliary contact 95-96, opens and N/O auxiliary contact, 97-98 closes. The
letter T will appear on the lever. This is very useful for checking the control circuit wiring
during commissioning.
The red button is simply a local stop button. Pressing it opens the N/C auxiliary contact, 95-96.
It does not close the N/O auxiliary contact, 97-98.
To the right of the white dial there is a small white tab with H printed on it. This indicates that
the relay is supplied set in the Hand reset position.
To change to Auto reset this white tab must be prised away with a small flat screwdriver. This
reveals a small blue lever. When this lever is moved downwards, an A appears indicating that
the relay is now set in the Auto reset position. The Test lever will not operate in the Auto
position.

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FAS Electrical Course Notes – Module 2.4.2

Problem Solving Techniques

To successfully fault find on even simple motor control circuits, one must understand the
system and all the components involved in it. All relevant information such as diagrams,
drawings, record sheets should be available and used to assist in solving the problem. Company
safety procedures must be adhered to. Phase 2 apprentices are not allowed to fault find on live
projects. The approximate resistance of all of the following items must be known or available to
compare against actual readings at the time of the fault.

 Open Circuit Infinity

 Closed Circuit approx. Zero Ohms
 Contactor Coil approx. 500 Ohms ( depends on rating of contactor )
 Signal Lamp approx. 2500 Ohms
 Motor Winding example 10 Ohms ( depends on rating of motor )

Control Circuit
The following steps assume that power was present when the faulty operation was discovered.

Step 1 Note all information provided by way of the following:-

signal lamps, relay / contactor / motor noises etc.

Step 2 Check all safety devices such as emergency stop units for correct position to
allow the system start up.

Step 3 Ensure that all overload relays are set. ( Remember that signal lamps may be
faulty or missing ).

Step 4 Check the resistance of the start circuit components from the control protective
device, through all switches, push buttons, contacts, coils etc. to the supply
neutral. This will involve operating switches, start buttons, stop buttons etc. to
prove that the contacts are opening or closing as required.

The problem could be caused by any one or more of the following list of faults:-

 Switch contact open circuit

 N/C contact open circuit or not opening when operated
 N/O contact closed or not closing when operated
 High resistance or open circuit termination
 Open circuit relay or contactor coil
 Short circuit caused by burned out relay or contactor coil
 Physical damage to wiring or components
 Circuit wiring incorrect

Step 5 Repair or replace faulty item(s) as necessary. Test for correct and safe operation.
Report on fault found.

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FAS Electrical Course Notes – Module 2.4.2

Power Circuit
The control circuit may be functioning correctly, but the motor is not running. In this case the
driven machinery should first be checked to ensure that it is free to rotate. The motor will not
start against a mechanically jammed load. Remember that the loss of one phase to a loaded
three phase motor will result in failure to start. As with the control circuit, the assumption is
made that full power was present when the faulty operation was discovered.

Having proven that the fault is electrical, the following items should be checked out:-

 Motor isolator closed

 Motor protective device(s) closed
 Contactor main contacts closing correctly
 Motor winding resistance correct
 All interconnecting wiring correct

The problem could be caused by any one or more of the following list of faults:-

 Isolator contact open circuit

 Motor protective device open circuit
 Contactor main contact(s) not closing when operated
 High resistance or open circuit termination
 Open circuit motor winding(s)
 Short circuit motor winding(s)
 Delta connected motor actually connected in Star
 Physical damage to wiring or components
 Circuit wiring incorrect

Insulation Resistance Faults

Remember that an insulation resistance fault will also trip an MCB or rupture a fuse. A fault of
this nature is most likely to occur on the following items:-

 Cables
 Motor windings,
 Relay or contactor coils
 Signal lamp units

These faults may occur between current carrying conductors or between current carrying
conductors and earth. The use of an Insulation Resistance Tester is required to locate
problems of this nature.

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