PRINCIPLES OF ELECTRIC MOTOR CONTROL

MOTOR CONTROL is a broad term that means anything from a simple toggle switch to a complex system with components such as relays, timers, and switches. The common function of all control the operation of an electric motor. As a result, when motor control equipment is selected and installed, many factors must be considered to insure that the control will function properly for the motor and the machine for which it is selected.

MOTOR CONTROL INSTALLATION CONSIDERATION

2. MOTOR - it should be matched to the electrical service, and correctly sized for the machine load in horsepower rating (hp). Other considerations include motor speed and torque. To select proper protection for the motor, its full load current rating (FLC), service factor (SF), time rating (duty), and other pertinent data as shown on the motor nameplate must be used. 3. OPERATING CHARACTERISTICS OF CONTROLLER the fundamental task of a motor controller are to start and stop the motor, and to protect the motor, machine, product and operator. The controller may also be called upon to provide supplementary functions such

as reversing, jogging or inching, plugging, operating at several speeds or at reduced levels of current and motor torque. 4. ENVIRONMENT controller enclosures serve to provide safety protection for operating personnel by preventing accidental contact with live parts. In certain applications, the controller itself must be protected from the variety of environmental conditions which might include: water, rain, snow or sleet, dirt or noncombustible dust, cutting oils, coolants or lubricants.

5. ELECTRICAL CODES AND STANDARDS motor control equipment is designed to meet the provisions of National Electrical Code (NEC). Also, local code requirements must be considered and met when installing motors and control devices. Presently, code sections applying to motors, motor circuits, and controllers, Article 430 on motors and motor controllers, Article 440 on air conditioning and refrigeration equipment, and Article 500 on hazardous location of the National Code.

PURPOSE OF CONTROLLER
Factors to considered when selecting and installing motor control components for use with particular machines or systems are described in the following paragraphs: STARTING the motor may be started by connecting it directly across the source of voltage. Slow and gradual starting may be required, not only to protect the machine , but also to ensure that the line current inrush on starting is not too great for the power companys

system. Some driven machines may be damaged if they are started with a sudden turning effort . The frequency of starting a motor is another factor affecting the controller. A combination fused disconnect switch and motor starter. STOPPING most controllers allow motors to coast to a standstill. Some impose braking action when the machine must stop quickly. Quick stopping is a vital function of the controller for emergency stops. Controllers assist the stopping

action by retarding centrifugal motion of machines and lowering operation of crane hoists. REVERSING controllers are required to change the direction of rotation of machines automatically or at the command of an operator at a control station. RUNNING the maintaining of the desired operational speeds and characteristics is a prime purpose and function of controllers. They protect motors, operators, machines, and materials while running.

SPEED CONTROL some controllers can maintain very precise speeds for industrial processes. Other controllers can change the speeds of motors either in steps or gradually through continuous range of speeds. SAFETY OF OPERATOR many mechanical safeguards have been replaced or aided by electrical means of protection. Electrical control pilot devices in controllers provide a direct means of protecting machine operators from unsafe conditions.

PROTECTION FROM DAMAGE part of the operation of the automatic machines is to protect the machine itself and the manufactured or processed materials it handles. A machine control can reverse, stop, slow, or do whatever is necessary to protect the machine or processed materials. MAINTAINANCE OF STARTING REQUIREMENT once properly installed and adjusted, motor starters will provide reliable operations of starting time, voltage, current, and torques for the benefit of the driven machines and the power system.

MANUAL CONTROL
- a manual control is one whose operation is accomplished by mechanical means. The effort required to actuate the mechanism is almost always provided by a human operator. The motor may be controlled manually by any of the following devices. 1. TOGGLE SWITCH is a manually operated electric switch. Many small motors are started with toggle switches. This means the motor may

be started directly without the use of magnetic switches or auxiliary equipment. Motors started with toggle switches are protected by the branch circuit fuse or circuit breaker. These motors generally drives fans, blowers, or light loads. 2. SAFETY SWITCH in some cases it is permissible to start a motor directly across the full line voltage if an externally operated switch is used. The motors receives starting and running protection from dual element, time delay fuses.

3. DRUM CONTROLLER - drum controllers are rotary, manual switching devices which are often used to reverse motors and to control the speed of ac and dc motors. They are used particularly where frequent start, stop, or reverse operation is required. These controllers may be used without other control components in small motors, generally those with fractional horsepower ratings. Drum controllers are used with magnetic starters in large motors. 4. FACEPLATE CONTROL have been in used for many years to start dc motors. They are also used in induction motor speed control. It has

multiple switching contacts mounted near a selector arm on the front of an insulated plate. Additional resistors are mounted on the near to form a complete unit.

REMOTE and AUTOMATIC CONTROL

have the electrical capacity to carry the motor starting and running currents, magnetic switches must be included. Magnetic switch control is one whose operation is accomplished by electromagnetic means. The effort required to actuate the electromagnet is supplied by electrical energy rather than by the human operator. If the motor is to be automatically controlled, the following two-wire pilot devices may be used.

FLOAT SWITCH the raising or lowering of a float which is mechanically attached to electrical contacts may start motor driven pumps to empty or fill tanks. Float switches are also used to open or close piping solenoid valves to control fluids.

PRESSURE SWITCH are used to control the pressure of liquids and gases within the desired range. Air compressors, for example, are started directly or indirectly on a call for more air by pressure switch.

TIME CLOCK can be used when a definite on and off period is required and adjustments are not necessary for long periods of time.

THERMOSTAT it is indirectly control large motors in air conditioning systems and in many industrial applications to maintain the desired temperature range of air, gases, liquids, or solids. LIMIT SWITCH designed to pass an electrical signal only when a predetermined limit is reached. The limit may be specific position for a machine part or a piece of work, or a certain rotating speed. Limit switches are used most frequently as overtravel stops for machines, equipment, and products in process.

ELECTRICAL or MECHANICAL INTERLOCK and SEQUENCE CONTROL many of electrical control devices described in this unit can be connected in an interlocking system so that the final operation of one or more motor depends upon the electrical position of each individual control device.