INDUSTRIAL MOTOR

CONTROL

By: AC-DC TRAINING & ASSESSMENT CENTER INC.

Two General Types of Motor

 Direct Current (DC) Motors

 Alternating Current (AC) Motors
o Synchronous Motors
o Induction Motor
 Single Phase
 Three Phase

Induction Motor

It is the most commonly used electric motor in most application. It’s

also known as asynchronous motor because the running speed is less than
its synchronous speed. The running speed is less due to the lagging of flux
current in the rotor with the flux current in the stator. The rotor in this motor
can either be wound type or squirrel cage.

There are two types of Single Phase Induction Motor; a) Capacitor

Start – Capacitor Run and b) Capacitor Start - Induction Run.

Motor Controller

Motor Controller is a device or group of devices that serves to govern

in some predetermined manner the performance of an electric motor. A
motor controller might include a manual or automatic means for starting and
stopping the motor, selecting forward or reverse rotation. Depending on the
function of the motor, features and capability of the controller are different.

Common Devices used in Industrial Motor Control

 Magnetic Contactors
 Thermal Overload Relays (T.O.R.)
 Circuit Breakers
 Timer Relays
Magnetic Contactors

Magnetic contactors are electrically operated switch rated in ampere,

voltage and sometimes with horsepower. It functions as a relay but larger in
size and ratings than a typical relay. The purpose of magnetic contactor in a
circuit is switching.

Parts of Magnetic Contactor

COIL

Auxiliary Contacts Auxiliary Contacts

Power Contacts

 Coil – is an electrical conductor wound into the form of a spiral, sometimes

with a soft vide inductance or a magnetic field
 Power Contacts – these contacts are normally open contacts mainly used for
switching between start and stop of Motors. They are usually rated at higher
voltage.
 Auxiliary Contacts – in a magnetic contactor, these contacts are used only in
a control circuit. A contactor can have 1 or 2 normally open and normally
close contact. These contacts are rated in lower voltage and current
compared to the power contacts.
Operation of a Magnetic Contactor

When the coil of the magnetic contactor is supplied by its rated

voltage, it creates a magnetic field pulling both power and auxiliary contacts
changing their state for open to close and close to open. Once the supply
voltage is removed the contacts will return to their initial position with the
help of an attached spring.

Thermal Overload Relay

Thermal Overload Relays are electromechanical protection devices for

motor control or main circuit. These devices are designed to interrupt the
circuit when high current, not short circuit current, is drawn for an extended
period of time. They are also designed to be easily attached in a compatible
magnetic contactor.

The parts of a Thermal Overload Relay;

 Heating Element
o It is made of alloy or bimetal strip that shrinks or deform
when too much heat is applied and return to its initial
formation when it is cool. This

 Overload Contacts
o The Thermal overload relay has 2 overload contacts, 1
normally open and 1 normally close.
Operation of Thermal Overload Relay

In an event of overload, the circuit breaker will not interrupt the circuit
since the applied current is less that the interrupting current, but with a
thermal overload relay the heating of conductors due to overload will be
detected and triggers the T.O.R to open or close its contacts in a control
circuit. Note that without the magnetic contactor and a control circuit the
T.O.R will not function as desired.

Timer Relays

Timer relays are used to set a desired time when will the motor stop,
start or go on forward or reverse rotation. After the set time has lapse the
contacts in the timer from normally open will be closed and normally close
will be opened. Timers can either be On – Delay and Off – Delay

On – Delay timers provides time delay set by the user when energized
and automatically resets when the supply is cut off. But as long as the timer
is supplied the contacts will remain in their changed position (from close to
open or vice versa) unless the supply is cut off. While Off – Delay will directly
change the contact when the timer is supplied and the timer delay will
function once supply is cut off, after the lapse time the contacts will return to
their initial position.

Two Major Components in Motor Control

 Power Circuit
o The power circuit shows the wiring of the motor connected to the line
with other circuit elements. It usually has higher voltage for both
single and 3-phase motors thus this circuit requires larger conductor
size and rating.

 Control Circuit
o The control circuit shows the circuit diagram of your controller. This
circuit controls the motor to stop or run and forward or reverse
rotation. Compared to the power circuit, the control circuit has lower
 voltage level and usually in single phase. This circuit also has smaller
conductor size and ratings.

Induction Motor Starting

Different Starting methods are applied to induction motor since they

draw high starting current. Some of these methods are; a) Direct On Line
(DOL), b) Wye Start Delta Run, and c) Auto Transformer. For the activities
Direct On line and Wye start - Delta run will be used.
 START / STOP OPERATION OF A 3-PHASE MOTOR

Experiment 1

Objectives:

- Implement the principle of operation of a controller

- Run the motor using magnetic contactor
- Test and troubleshoot common fault according to standard test procedures
systematically.

Problem:

Implement a control and power circuit of a 3-phase motor in forward

operation using magnetic contactor. The controller is energized by a NOPB and
remains sealed. To stop the coil excitation, it is done by a NCPB. Another NOPB is
employed for jogging the motor. Supply voltage for the power and control circuit is
220 Vac. The circuit must be provided with short circuit protection using circuit
breaker. Thermal overload and pilot lamp for indication of rotation are also
required.

Circuit Operation:

This circuit is to control a three phase motor in forward with jog function
only. The motor is connected directly to the power contacts of a contactor. This
means that whenever the coil of a contactor is energized these sets of power
contacts will close that allows the current to flow to the windings of the motor. A
sealing contact is applied to maintain the coil. A NO auxiliary contact is connected
in parallel with NOPB. A NCPB in series with NC contact of TOR is connected to the
coil of the magnetic contactor.

Materials:

2-NOPB 3-pilot lamps 1-2P CB

1-NCPB 1-3 phase motor 1-TOR
1-Magnetic contactor 1-3P 20A CB 1-3P CB
Control Circuit:

Power Circuit
 FORWARD / REVERSE OPERATION OF A THREE PHASE MOTOR

Experiment 2

Objectives:

- Control a 3-phaase motor in forward and reverse rotation

- Run the motor using magnetic contactor
- Test and troubleshoot common fault according to standard test procedures
systematically.

Problem:

Implement a control and power circuit of a 3-ph motor in forward and

reverse rotation using magnetic contactors. The forward rotation can be energized
by NOPB and remain sealed. The reverse rotation can be executed by another
NOPB. Transition of rotation must be done after stopping the previous rotation. To
stop the coil excitation, it is done by a NCPB. Supply voltage for both control and
power circuit is 200 Vac. The circuit must be provided with short circuit protection
using circuit breaker. Thermal overload and pilot lamp for indication of rotation are
also required.

Circuit Operation:

This circuit is to control a three phase motor in forward or reverse rotation.

The motor is connected directly to the power contacts of the two contactors. This
means that whenever the coil of a contactor is energized these sets of power
contacts will close that allows the current to flow to the windings of the motor. A
sealing contact is applied to maintain the coil. The motor can be operated in either
forward or reverse rotation. However, transition from one rotation to another can
be done only after the previous rotation is cut-off. Interlocking of contacts is
required for protection of the operation. A reset button (NCPB) is use to stop the
operation. A TOR for overloading and pilot lamps as indicator are to be installed.
Materials:

2-NOPB 4-pilot lamps 1-2P CB

1-NCPB 1-3 phase motor 1-TOR
2 Magnetic contactor 1-3P CB

Control Circuit:

Power Circuit
 AUTOMATIC REVERSION OF A THREE PHASE MOTOR USING ON-DELAY
TIMER

Experiment 3

Objectives:

- Control a 3-phaase motor in forward with automatic reversion.

- Understand the principle of operation of a timer relay.
- Test and troubleshoot common fault according to standard test procedures
systematically.

Problem:

Implement a control and power circuit of a 3-phase motor in forward and

reverse rotation using magnetic contactors. The forward rotation can be energized
by NOPB and remain sealed. The reverse rotation is automatically executed using
timer. Returning to forward rotation can be done by stopping the reverse rotation
first. To stop the coil excitation, it is done by a NCPB. Supply voltage for both
control and power circuit is 220 Vac. The circuit must be provided with short circuit
protection using circuit breaker. Thermal overload and pilot lamp for indication of
rotation are also required.

Circuit Operation:

This circuit is to control a three phase motor in forward or reverse rotation.

The motor is connected directly to the power contacts of the two contactors. This
means that whenever the coil of a contactor is energized these sets of power
contacts will close that allows the current to flow to the windings of the motor. The
motor can be operated in forward rotation and reverse automatically using timer.
However, returning to forward rotation can be done only if the circuit for reverse is
cut-off. Interlocking of contacts is required for protection of the operation. A sealing
contact is applied to maintain the coil. A reset button (NCPB) is use to stop the
operation. A TOR for overloading and pilot lamps as indicator are to be installed.
Materials:

2-NOPB 4-pilot lamps 1-2P 15A CB

1-NCPB 1-3 phase motor 1-relay
2 Magnetic contactor 1-3P 20A CB 1-TOR

Control Circuit:

Power Circuit
 WYE-DELTA MOTOR STARTING

Experiment 4

Objectives:

- To implement the principle of operation of a controller in Y-∆ configuration

- Test and troubleshoot common fault according to standard test procedures
systematically.

Problem:

Implement a control and power circuit of a 3-phase motor in forward Y-∆

rotation using magnetic contactors. The controller is energized by a NOPB in
forward-star configuration and remains sealed. The transition from forward-star to
forward-delta is done automatically by timer. To stop the coil excitation, it is done
by a NCPB. Supply voltage for both control and power circuit is 200 Vac. The circuit
must be provided with short circuit protection using circuit breaker. Thermal
overload and pilot lamp for indication of rotation are also required.

Circuit Operation:

This circuit is to control a three phase motor Y-∆ in forward rotation. The
motor is connected directly to the power contacts of the contactors. This means
that whenever the coil of a contactor is energized these sets of power contacts will
close that allows the current to flow to the windings of the motor. The motor will
first operate in forward-star. Through interlocking contacts, the motor cannot
initially operate in forward delta. Through the use of a timer, the automatic
transition is made possible. Interlocking of contacts is required for protection of the
operation. A sealing contact is applied to maintain the coil. A reset button (NCPB) is
use to stop the operation. A TOR for overloading and pilot lamps as indicator are to
be installed.
Materials:

2-NOPB 4-pilot lamps 1-2P 15A CB

1-NCPB 1-3 phase motor 1-TOR
3 Magnetic contactor 1-3P 20A CB

Control Circuit:

Power Circuit