Motor Controls

EETE 2 Technical Elective 2

OUTLINE
Symbols: NEMA vs IEC Pilot Devices Wiring vs Schematic Diagrams Overcurrent vs Overload Protection Low Voltage Release vs Low Voltage Protection

SYMBOLS

Symbols
Motor control language consists of symbols to form a circuit diagram. Contactors and motor starters are rated according to size and type of load they are designed to handle. The National Electrical Manufacturers Association (NEMA) and the International Electrotechnical Commission (IEC) are two organizations that rate contactors and motor starters. Each organization has its own set of symbols.

NEMA
NEMA Contactors and Starters are designed in standardized sizes from 00 to 9. Each of these sizes has a defined current, and a resultant voltage and frequency dependent horsepower rating. No matter who manufactures the device, the current and horsepower rating will be identical for a given size.

NEMA
If a standard motor is being used, once its horsepower rating is selected, the Contactor or Starter horsepower rating is simply matched to that of the motor. The nameplate of the Contactor or Starter is labeled with the NEMA size, the various horsepower and voltage ratings assigned to the size, and its continuous current capability at which the NEMA Standard temperature rise will not be exceeded.

NEMA
NEMA motor-control devices have generally become known for their very rugged, heavy-duty construction. Because of their rugged design, NEMA devices are physically larger than IEC devices.

IEC
IEC Contactors and Starters are not designed to a standardized size. Instead a manufacturer certifies that he/she has designed the device to meet a number of defined applications referred to as Utilization Categories.

IEC
To properly match the IEC Contactor or Starter to the application requirements, the user must know both the application requirements and the capability of the Contactor or Starter being selected. If the Contactor or Starter will not provide a reasonable operational life in the application, a larger device would need to be selected.

IEC
Not all applications require a heavy-duty industrial starter. In applications where space is more limited and the duty cycle is not severe, IEC devices represent a costeffective solution.

NEMA and IEC Ratings Comparison

NEMA Contactors and Starters can be applied to AC-3 applications. They may also be applied at their normal standardized ratings to AC-4 applications where there will be no more than five openings per minute and no more than 10 openings during a 10-minute period. Beyond this level, NEMA provides a plug reversing and jogging duty table with modified ratings for improved operating life. Many IEC devices also have a NEMA rating.

Additional Comparisons

Other Organizations
There are several other organizations that have developed standards and tests for electrical equipment. For example, contactors are tested by Underwriters Laboratory (UL) using test procedure UL508, which specifies a maximum horsepower rating for which a contactor can be used. Deutsches Institut fr Normung (DIN), the German national standards organization

NEMA vs IEC
The following comparison of circuit symbols is based upon the following international/national specifications: IEC 60617 graphic symbol database (DIN EN 60617-2 to DIN EN 60617-12) NEMA ICS 19-2002, ANSI Y32.2/ IEEE 315/315 A, CSA Z99

NEMA vs IEC

NEMA vs IEC

NEMA vs IEC

NEMA vs IEC

NEMA and IEC Terminal Markings

NEMA and IEC Controller Markings and Elementary Diagrams

PILOT DEVICES

Pilot Devices:Pushbuttons
A pushbutton is a control device used to manually open and close a set of contacts. Pushbuttons are available in a flush mount, extended mount, with a mushroom head, illuminated, or non-illuminated. Pushbuttons come with either normally open, normally closed, or a combination contact block.

Pilot Devices: Selector switches

Selector switches are also used to manually open and close contacts. Selector switches can be maintained, spring return, or key operated. Selector switches are available in 2-, 3-, and 4-position types.

Pilot Devices: Pilot lights

Pilot lights provide visual information of the circuits operating condition. Pilot lights are normally used for ON/OFF indication, caution, changing conditions, and alarm signaling. Pilot lights are available with a variety of lens colors, such as red, green, amber, blue, white, or clear.

WIRING VS SCHEMATIC DIAGRAMS

WIRING DIAGRAM
A wiring diagram shows, as closely as possible, the actual location of all component parts of the device. The open terminals (marked by an open circle) and arrows represent connections made by the user. Since wiring connections and terminal markings are shown, this type of diagram is helpful when wiring the device or tracing wires when troubleshooting.

WIRING DIAGRAM
Bold lines denote the power circuit and thin lines are used to show the control circuit. Black wires are conventionally used in power circuits and red wire in control circuits for AC magnetic equipment.

SCHEMATIC DIAGRAM
An elementary diagram is a simplified circuit illustration. Devices and components are not shown in their actual positions. All control circuit components are shown as directly as possible, between a pair of vertical lines representing the control power supply.

SCHEMATIC DIAGRAM
Components are arranged to show the sequence of operation of the devices and how the device operates. The effect of operating various auxiliary contacts and control devices can be readily seen. This helps in troubleshooting, particularly with the more complex controllers. This form of electrical diagram is sometimes referred to as a schematic or line diagram.

OVERCURRENT VS OVERLOAD PROTECTION

OVERCURRENT PROTECTION
Overcurrent protection devices are installed in the power circuit to protect the conductors and may exist in the form of fuses or circuit breakers

OVERLOAD PROTECTION
Overload protection is installed in the circuit to protect the motor windings and may exist in the form of overload relays, heaters, or elements.

OVERLOAD PROTECTION
If one overload contact is used, an overload on any line will cause the overload contact to open.
When three overload contacts are used, the overload contacts are connected is series. Each contact is controlled by the adjacent overload heater.

TYPES OF CONTROL CIRCUITS

Low Voltage Release

The following terms are generally accepted as having the same meaning:
A. Under voltage release (UVR) B. Low voltage release (LVR) C. No Voltage release (NVR) Operation: The motor will stop when there is supply voltage failure and will restart automatically when the supply voltage is restored.

The term two-wire control is given to this type of circuit. Pilot devices such as float switches, limit switches, and temperature controls are single contact devices requiring two conductors.

Low Voltage Release

Low Voltage Release

The term 2-wire control is derived from the fact that in the basic circuit, only two wires are required to connect the pilot device to the starter.

Low Voltage Protection

The following terms are generally accepted as having the same meaning:
A. Under voltage protection (UVP) B. Low voltage protection (LVP) C. No Voltage protection (NVP) Operation: The motor will stop when there is supply voltage failure and will NOT restart automatically when the supply voltage is restored.

The term three-wire control is given to this type of circuit.

An auxiliary contact is connected in parallel with the start button. The auxiliary contacts seal in the circuit to keep the coil energized after the start push button is released.

Low Voltage Protection

Low Voltage Protection

The term 3-wire control is derived from the fact that in the basic circuit, at least three wires are required to connect the pilot devices to the starter.

Example
A three phase, 575 V, 60 Hz, 40 Hp Squirrel Cage Induction Motor is to be connected for full-voltage starting. It has a service factor of 1.15. Ambient Temperature is 28C. Nameplate current is 38 A. Determine:
1. FLC of the motor 2. NEMA Starter Size 3. FLA of the motor

Example 1
Solution:
1. FLC of the motor See Table 430.250 NEC 2011 or Table 4.30.14.4 PEC 2002 Nameplate values: three phase ,575 V, 60 Hz, 40 Hp FLC = 41 A 2. NEMA Starter Size: See NEMA Motor Starter Sizing Chart Use: NEMA Size 3 3. FLA = Nameplate Value FLA = 38 A

Example 2
A 3 phase, 460 V, 60 Hz, 10 Hp Squirrel Cage Induction Motor is to be connected for fullvoltage starting. It has a service factor of 1.15. Ambient Temperature is 28C. Nameplate current is 12 A. Determine:
1. FLC of the motor 2. NEMA Starter Size 3. FLA of the motor

Example