C-Iic Ev

ELECTRICAL ENGINEERING
ELECTRICAL INSTALLATIONS
INDUSTRIAL PLANTS
Panel mod. C-IIC/EV
TEACHER/STUDENT manual
© COPYRIGHT BY ELETTRONICA VENETA

CIIC$$$101E0
Index
INDEX
Safety Regulations .................................................................................................................... 1
Panel description ..................................................................................................................... 3
Power engine systems ........................................................................................................... 17
Contactors .............................................................................................................................. 17
Push buttons, socket lamps ..................................................................................................... 23
Safety observations ............................................................................................................... 24
Identification codes ................................................................................................................ 25
Exercise No. 1 Contactor command from a point .................................................................. 31
Exercise No. 2 Three-phase induction motor remote starter .................................................. 38
Exercise No. 3 Contactor command switch - stop and by impulses ....................................... 45
Exercise No. 4 A.C. Contactor coil supplied by direct current ............................................. 47
Exercise No. 5 Independent command of two contactors ..................................................... 50
Exercise No. 6 Remote motor reversing switch for a three-phase induction motor ............ 53
Exercise No. 7 Remote motor reversing switch with lock push buttons ............................... 57
Exercise No. 8 Remote motor reversing switch with lock push buttons and retardant .......... 60
Exercise No. 9 Remote motor reversing switch with limit switch ......................................... 63
Exercise No. 10 Electrical gate remote motor reversing switch ........................................... 66
Exercise No. 11 Single-phase induction motor starter .......................................................... 68
Exercise No. 12 Single-phase induction remote motor reversing switch ............................. 73
Exercise No. 13 Star-Delta starting device ........................................................................... 77
Exercise No. 14 Soft resistance starting device .................................................................... 82
Exercise No. 15 Automatic starter exchange ........................................................................ 87

Index
Exercise No. 16 Rotor-resistance starting device

with a continuous variable-frequency disconnection .................................................. 91
Exercise No. 17 Rotor-resistance starting device

with graded variable-frequency disconnection ........................................................... 97
Exercise No. 18 Remote motor reversing switch; star/delta starter ..................................... 102
Exercise No. 19 Motor remote control switch for dual windings ....................................... 106
Exercise No. 20 Motor remote control switch for single windings (Dahlander) .................. 111
Exercise No. 21 Counter-current braking ............................................................................ 116
Exercise No. 22 Direct current counter-current braking ...................................................... 121
Exercise No. 23 Two-hand control device .......................................................................... 124
Exercise No. 24 Direct start-up of the motor with a manipulator switch ............................ 126
Exercise No. 25 Dual motor command with a manipulator switch .................................... 129
Exercise No. 26 Forward/backward command of a motor with an inverter manipulator .... 132
Exercise No. 27 Star/delta starting device with manipulator ............................................... 134
Exercise No. 28 Speed control of a three-phase induction motor

with dual windings and commutator manipulator ..................................................... 138
Exercise No. 29 Speed control of a Dahlander windings three-phase induction motor

with a commutator manipulator ................................................................................. 140
Activate the panel ................................................................................................................. 143
Addendum A Layout of the panel ........................................................................................ 145
Addendum B Accessories for the panel .............................................................................. 146

Safety Regulations
SAFETY REGULATIONS
Read the instructions of this manual carefully as it provides important information

regarding safety in connection with installation, use, and maintenance.
Keep this manual for any further reference.
The following operation manual describes the operation of panels for testing industrial
electrical systems principally used in industrial buildings and buildings assigned to productive
activities in general.
Refer to this manual with regard to the specifications and operation of the devices as well as
their required connection to make them operational.
UNPACKING
After removing the packaging, put all the accessories aside so that they do not get lost, and
check the integrity of the equipment. In particular, ensure that the equipment and supplied
accessories are intact and without any visible damage.
Before connecting the equipment to the power supply, ensure that the information on the
nameplate corresponds to that of the electrical distribution network. (the nominal value of
supply voltage is specified on the equipment itself).
The supply cables must be laid out in a way that they cannot be trampled on or crushed by
objects. In the event of incompatibility between the socket and the plug of the device, the
socket must be changed to a suitable one. The job must be carried out by professionally
qualified personnel. The said person must ensure that the socket cable cross-sections are
sized according to the power used up by the equipment. It is not advisable to use adapters or
multiple sockets; should these be used, they must be in compliance with the safety regulations
in force.
Should the equipment have any fissures or openings for ventilation, these must not be blocked
or covered so as to guarantee the proper function of the equipment and to protect it from
overheating.
Never place the equipment on trolleys, supports, tripods, brackets or unstable tables. The
equipment may fall and cause personal injury or damage. Any installation of the equipment
must be carried out by following the manufacturer's instructions, and must be executed by
using recommended accessories.
This equipment must only be used for the purpose for which it was specifically designed, i.e.
as teaching equipment, and should be used under the direct supervision of experienced staff.
Any other use is considered improper and therefore dangerous.
The manufacturer cannot be held responsible for any damage caused by improper,
incorrect or unreasonable use.
-1-
Safety Regulations
PRECAUTIONS!
In order to safeguard security, the operator's safety and the operation of equipment, the use of
electrical equipment requires the observance of some fundamental rules. In particular, the
following rules of use must be respected:
Room temperature from 0 to 45 C.
Relative humidity from 20 to 80 %.
Avoid any rapid change of temperature and humidity.
The equipment must be used in a place free of or far from: dust, humidity, elevated heat,
objects that radiate heat, objects that produce a strong magnetic field (HI-FI speakers, etc.),
liquids or corrosive chemical substances.
Supply Check what is stated on each panel.
Fuses only those stated on the relative electrical board.
Do not open the equipment to avoid contact with electrical parts; if necessary, only speak to
qualified staff. Before carrying out any maintenance, disconnect the equipment from the
power supply. In the event of failure and/or malfunction, immediately turn off the equipment
and do not tamper with it. For any repairs, contact the servicing department or ask for original
spare parts only. Failure to comply to the above-mentioned may compromise the safety of
the equipment.
All connections required to realize the exercises must be carried out with the equipment
turned off and by using special cables having 4 mm safety plugs.
Should any fuses need to be changed, first remove the panels from the power supply.
In the event that objects or liquid enter the equipment, disconnect the power supply and have
it checked by qualified staff prior to using it once again.
CLEANING THE EQUIPMENT
Use a soft dry cloth to clean the containers and synoptic panels. Never use insecticides or
chemicals or solvents for cleaning.
VIBRATIONS OR SHOCKS
Be careful not to cause vibrations or shocks.
DISPOSAL
These apparatuses and all their parts will be disposed of separately from
the other wastes. At the end of their lifetime, these apparatuses will be
conveyed to the proper centres of separate collection of waste.
A proper separate collection ensures that the eliminated apparatuses
will undergo the necessary treatment and recycling for preventing any
negative effect on the environment and on men’s health.
Illegal disposal of the product by the user involves the application of
administrative sanctions referred to Italy, in D.Lgs. no. N. 152/2006 art.
255 and 256, as amended; and directive 2008/98/EC of the european
parliament and of the council of 19 November 2008
For states outside the European Union comply with local laws.
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Panel description
C-IIC/EV panel layout.
-3-
Panel description
PANEL DESCRIPTION
Panel mod. C-IIC/EV makes all the electrical devices available that
can be easily connected between them in order to provide testing on a
wide range of industrial electrical systems (motor starters).
Items available on the front panel in insulated materials with wired
devices to safety terminals for fast connections with safety cables; 4
mm plugs.
F13-pole circuit breaker motor overload protection switch, In a

thermal release adjustable between 1.6 and 2.5 A, with rated breaking
capacity of lcu at 400 V - Ics 100 kA, magnetic trip 12 In max.
(terminals 1-2, 3-4, 5-6), degree of protection IP 20, mounting in any
position on a 35 mm omega rail complete with NO / NC In 6 A
auxiliary contacts (terminals 95-96, 97-98).
1 - 3 - 5 Three-phase input line terminals.

2 - 4 - 6 Output line terminals.
95 - 96 NC motor overload protection auxiliary contact terminal The
state of contact refers to the switch when closed.
97 - 98 NO motor overload protection auxiliary contact terminal. The
-4-
Panel description
F23-pole circuit breaker motor overload protection switch, In a

thermal release adjustable between 1 and 1.6 A, with rated breaking
capacity of lcu at 400 V - Ics 100 kA, magnetic trip 12 In max.
(terminals 1-2, 3-4, 5-6), degree of protection IP 20, mounting in any
position on a 35 mm omega rail complete with NO / NC In 6 A
auxiliary contacts (terminals 95-96, 97-98).
1 - 3 - 5 Three-phase input line terminals.

2 - 4 - 6 Output line terminals.
95 - 96 NC motor overload protection auxiliary contact terminal The
97 - 98 NO motor overload protection auxiliary contact terminal. The
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Panel description
Q1 - Q2 24 Vac 50-60 Hz coil contactors (terminals A1-A2), 3 main

contacts Ith 25 A Ie 9 A - 4,2 kW at 400 V (AC3) (terminals 1-2, 3-4,
5-6), complete with 2 auxiliary contacts NO and 2 NC Ith 10 A
(terminals 13-14,21-22, 31-32, 43-44), Ui 690 V.
The two contactors are mechanically interlocked by way of a
removable device(the interlock is between the two contactors)
1 - 3 - 5 Input power contact terminals.

2 - 4 - 6 Output power contact terminals.
13 - 14, 43 - 44 NO auxiliary contact terminals.
21 - 22, 31 - 32 NC auxiliary contact terminals.
A1 - A2 Contactor coil terminals, supplied in 24 Vac
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Panel description
Q3 - Q4 24 Vac 50-60 Hz contactor coils, 3 main contacts Ith 25 A

Ie 9 A - 4.2 kW at 400 V (AC3) (terminals 1-2, 3-4, 5-6), complete
with 2 auxiliary contacts NO and 2 NC Ith 10 A (terminals 13-14,21-
22, 31-32, 43-44), Ui 690 V.
The two contactors are mechanically interlocked by way of a
removable device (the interlock is between the two contactors)
1 - 3 - 5 Input power contact terminals.

2 - 4 - 6 Output power contact terminals.
13 - 14, 43 - 44 NO auxiliary contact terminals.
A1 - A2 Contactor coil terminals, supplied in 24 Vac
-7-
Panel description
S5 E-stop push button, red mushroom-head switch having a diameter

of 40 mm, mechanical connection and rotating release, complete with
2 NC Ith 10 A auxiliary contactors supplied in AC 15 (6 A–24 Vac) /
(3 A-240 Vac), supplied in DC 13 (3 A–24 Vdc) / (0,27 A-250 Vdc).
S1, S3 Red E-stop extended switch, complete with auxiliary contacts

in NO-NC, Ith 10 A supplied in AC 15 (6 A–24 Vac) / (3 A-240 Vac),
supplied in DC 13 (3 A–24 Vdc) / (0,27 A-250 Vdc).
S2, S4 green command push button, complete with auxiliary contacts

in NO-NC, Ith 10 A supplied in AC 15 (6 A–24 Vac) / (3 A-240 Vac),
supplied in DC 13 (3 A–24 Vdc) / (0.27 A-250 Vdc).
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Panel description
13 - 14 NO contact terminals.
21 - 22 NC contact terminals.
P1-P4 luminous engine block indicators having different coloured

diffusers complete with LED BA9s 24 V lamps of the same colour as
the diffuser.
Note: the buttons are interchangeable with each other based on
the colour required for each function.
X1 - X2 24 V power terminal indicator light
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Panel description
B1-B2 position limit switch with NO or NC contact, Ith 10 A.
13 - 14 NO contact terminals.
21 - 22 NC contact terminals.
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Panel description
B3 12 mm diameter inductive proximity sensor, activation distance

between 2 and 15 mm, LED status indication, supply 10 to 40 Vdc.
The inductive sensor is connected via the DIN B3 connector to the
panel where it is interfaced by means of a relay with an Ith 10 A
exchange contact in order to avoid damage.
To avoid dispersion of the parts, a stainless steel bracket enables the
sensor to be fixed to one side of the panel next to the capacitive
sensor.
B4 18 mm capacitive proximity sensor, activation distance between 2

and 10 mm (depending on the size and density of the material to
detect), LED indication status, supply between 10 and 40 Vdc. The
inductive sensor is connected by way of a DIN B4connectorto the
panel where it is interfaced by means of a relay with an Ith 10 A
exchange contact in order to avoid damage.
To avoid dispersion of the parts, a stainless steel bracket enables the
sensor to be fixed to one side of the panel next to the inductive sensor.
15Common NO / NC exchange contact terminals.

16 NC contact terminals.
18 NO contact terminals.
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Panel description
K1-K2 electronic timer, multi-voltage 24…230 Vac - 24…110 Vdc

(terminals A1-A2), multi-scale adjustable times between 0 and 1 and
full scale 1-5-10-30 s 1-5-10-30 min 1-10 h, multi-functions selected
among:
B excitation delay with Start command (terminal B1),
C excitation through a Start command (terminal B1),
Ci pause-work oscillator with Start command (terminal B1),
Ca pause-work oscillator with Start command (terminal B1),
Da De-excitation delay of the Start command (terminal B1),
Tv totalizer closure command: delayed excitation exit,
Ta totalizer closure command: excitation passage exit,
W excitation delay and de-excitation Start Command
Wa delay excitation passage and de-excitation command.
K impulse opening of the Start command (terminal B1),
A1 - A2 Coil time-switch terminals supplied in 24 Vac

B1 Star terminals supplied in 24 Vac as in A1. If you do not wish to
use the function, connect it to A1.
15Common NO / NC exchange contact terminals.
16 NC contact terminals.
18 NO contact terminals.
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Panel description
REVERSING SWITCH (Q5) Three-pole manipulator In=16 A

Un=400 V (AC1). It carries out the function of a three-pole switch
considering the position of 0-1, 0-2 or the function of a three-phase
line reverse control considering the position of 1-0-2.
L1 - L2 - L3 Input line terminals.

U - V- W Output terminals for the load or for a three-phase induction
motor.
STAR DELTA REVERSING SWITCH (Q6) reverse control

star/delta manipulator starter In=16 A Un=400 V (AC1).

U1 - V1 - W1 Output terminals for the beginning of the windings of
the three-phase induction motor.
U1 - V1 - W1 Output terminals for the end of the windings of the
three-phase induction motor.
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Panel description
POLES CHANGING SWITCH (Q7) Delta double star three-phase

induction motor manipulator starter with 2 speeds and one
"DAHLANDER" winding In=16 A Un=400 V (AC1).

2U - 2V - 2W Output terminals to connect the same brand of windings
of the Dahlander three-phase induction motor.
1U - 1V - 1W Output terminals to connect the same brand of windings
of the Dahlander three-phase induction motor.
COMMUTING LINE SWITCH (Q8) Commuting line switch

manipulator In=16 A Un=400 V (AC1). It carries out the function of
a switch and separately activates two loads (or two electric motors) or
a 2-speed motor with separate windings.
It carries out the function of a selection switch between two electrical
lines, which enter the terminals from the bottom.
Moreover, it carries out the function of a three-pole switch taking into
consideration position 0-1 or 0-2.
- 14 -
Panel description
Application to activate two separate loads (or two motors) or a motor

with two windings:
1U - 1V - 1W Output terminals to connect the first slow-speed motor
or winding.
2U - 2V - 2W Output terminals to connect the second high-speed or
winding motor.
Use as a commuting line selector:

1U - 1V -1W First line, three-phase input terminals.
2U - 2V - 2W Second line, three-phase input terminals.
L1 - L2 - L3 Three-phase output line terminals.
0-24 V 1-pole automatic circuit breaker switch in 3 A,

specifications C, Pdi 6 kA, prevention against output overloads 24
Vac PELV (extremely low voltage protection) generated from the
single-phase transformer 115-230 V / 24 V – 96 VA, lamp indicator
signal of auxiliary voltage 24 VAC. The single-phase auxiliary power
supply line should be connected to the panel via the plug on the panel.
0 - 24 V~ Output voltage terminals 24 Vac - 3A.
Note: the PELV source has the terminal 0 (zero) connected to earth
and the terminal 24 V protected by the circuit breaker switch. Go to
SAFETY OBSERVATIONS p. 24.
- 15 -
Panel description
3 PH POWER LINE automatic circuit breaker (F0)4-pole, In 4A,

curve C, Pdi 6 kA, protects against three-phase output overload with
neutral available at terminals L1-L2-L3-N and earth protection,
inspection lamp signal of three-phase voltage 380-400 Vac.
L1 - L2 - L3 - N - PE Terminal board to withdraw the three-phase

line with neutral and earth protection.
Cable 5 x 1.5 mm2with a 5-pole socket and plug type IEC 309 400 V
- 16 A to carry the three-phase line with or without neutral given to
power circuits.
Three-phase power supply line, 3P + N + Earth should be connected
to the panel via the plug on the left.
Cable 3 x 0.75 mm2 with a French-German plug to carry the single-

phase line dedicated for the supply of control circuits.
- 16 -
Power engine systems
POWER ENGINE SYSTEMS
This part regarding power engine systems has the objective to allow
the student, by means of a series of exercises that will be taken into
consideration, to:
a) correctly interpret a functional-type electrical diagram,
b) draw the diagram for practical realisation,
c) solve any problems that may arise during working activities.
As a general rule, a series of systems will be considered in which the
induction motor, both the cage and winding types, is usually used.
The material that will be required to realise the systems will be
analysed hereunder.
CONTACTOR
A CONTACTOR is what is classified as a particular type of remote
control switch that has the function of establishing or interrupting the
wire continuity of an under-loaded electrical circuit.
It is essentially made up of:
a) a magnetic circuit
b) an excitation coil
c) main contacts
d) auxiliary contacts
MAGNETIC CIRCUIT
It is made up of ferrous metal sheets duly moulded and isolated from
each other if the excitation coil is supplied in alternating current (thus,
the magnetic losses are reduced) or from a solid block of soft iron if
the power of the excitation coil is supplied in direct current. The
sketches in figure 1 and figure 2 should be taken into consideration,
which refer to the contactor magnetic circuit whose excitation coil is
supplied in alternating current.
The said magnetic circuit depicts the engraved polar expansions, and
in the slits there are two copper rings called "silencer or phonic coils"
having the task to cancel vibrations produced by the mobile traverse
contacts door when it is in contact with the one on which the fixed
contacts are housed.
These vibrations are justified in the following manner:
electromagnetic activity produced when the coils are energised, the
contrasting mechanical action produced by the springs prevails, but in
contrast to this, in time it has a sinusoidal characteristic (see figure 3)
for which in few moments the mechanical action of the excitation coil
prevails and the movable contacts traverse door tends to move away
from the fixed one; since the frequency of the electrical quantity is 50-
60 Hz, there is insufficient time to distance the mobile traverse, but
one can notice an annoying vibration.
- 17 -
Figure 1 Magnetic equipment of the contactor
Figure 2 Resulting electrical shifts in the sheet metal pack on

account
of the phonic coil
To eliminate vibrations, a silencing coil is inserted, which works in
the following way (figure 2).
The electrical flux generated by the excitation coil when it is
energised, in the vicinity of the notch, two sections of the iron core are
split into inverse proportion to the magnetic resistance characterizing
the electrical flux i.e. 2 in phases between them.
The electrical flux ,when passing through the phonic coil, induces an
electromotive force within it that gives rise to reduced current and,
therefore, to an electrical flux induced in phase with the current
induced generated by it, which results as being delayed with respect to
the electricity flux 2 on the quadrature.
Therefore, on the pole piece, there will be 1 x out of phase fluxes
between them on an angle (variation in time).
The electromagnetic fields produced by these fluxes can never be
simultaneously null and thus, the mechanical action of the springs will
never prevail if the two magnetic fields are proportionally out of sync
in phase and module.
The phonic coil is not required in the magnetic cores used with coils
supplied in direct current since the magnetic intensity is constant in
time.
- 18 -
The ferrous metal sheets, suitably pressed, are kept in operation in

case of remote control switches dimensioned for currents contained by
the use of nails beaten through.
Figure 3.
EXCITATION COILS
The said coil may be supplied by alternating current or direct current,
however, if the coil that characterises the contactor is indicated as
alternating current supply, you must not feed it into direct current,
otherwise it would burn.
The section of the conductor used to obtain the current required to
maintain the contacts of the contactor fed with alternating current in a
closed position, depends on the supply voltage as well as on the
impedance of the coil.
The said impedance when the contactor is in rest mode is minimal
since the reactive component XL, being the relevant magnetic
resistance, is contained (L=h2/R(*)) thus feeding the contactor coil, this
will result in a traverse from proportional current to the ratio V.
Having excited the contactor, it cancels the air gap whereby the
magnetic resistance decreases and consequently increases the
inductive reactance and the impedance, which limits the value of the
current flowing through the coil to a value lower than the original.
(*) R = Reluctance.
Instead, in a contactor coil supplied by direct current, the current
absorbed by the coil itself is connected, in addition to the supply
voltage, to the resistance of the conductor used in the construction of
the coil. In order to reduce the current value that flows through the
excitation coil, after having closed the contactor contacts, one must
insert, in a series to the said coil, a resistance to save or relief with the
task of producing a voltage drop.
The method of inserting the said resistance will be taken into
consideration at the end of the first exercise.
In practice, we summarise what has been said above with the
following examples:
a) CASE OF A COIL SUPPLIED WITH ALTERNATING
CURRENT. When closing, the coil absorbs, for example, current
intensity equal to 1 Ampere; with the contactor inserted, increasing
the impedance (Z) the value of the current is reduced, for example, to
0.6 A.
The section of the conductor used in the construction of the coil will
be then referred to the current value of normal operation (0.6 A) for
- 19 -
which the coil itself, for a few moments, will be overloaded at the
time of excitation.
b) CASE OF A COIL SUPPLIED WITH DIRECT CURRENT: also
in this case, in order to excite the contactor, a current intensity equal
to 1 A is required, and a current value equal to 0.6 A is sufficient to
keep it excited.
The dimensioning of the conductor used for the construction of the
coil is reported to 0.6 A and the reduction of the value of the current 1
A to 0.6 A is obtained by inserting the limiting resistor in series with
the excitation coil, which produces a voltage drop such as to limit the
voltage applied to the coil during normal operation and, consequently,
the current that affects the coil itself.
In short, therefore, at first the coil is supplied with the full mains
voltage, and then, in normal operating conditions, with the mains
voltage less the voltage drop produced by the limiting resistance
(Figure 4).
The power supply voltages of the contactor excitation coils are joined
to the following values 24, 48, 110, 220 V. It is advisable to avoid the
use of voltages that are greater than 220 volts.
Figure 4 Limiting resistance operation.
MAIN CONTACTS
Upon request, contactors may have two or more main contacts.
The main contacts are those placed on the force or power circuit and
must be able to stop, without causing any damage, the arc which is
formed when opening and closing the contactor.
For power supplies up to 10 A, the contact pad (usually made of
copper) is appropriately silver-plated in order to limit the effect
produced from the arc.
For more intense currents, there are devices designed to turn off the
arc (deionising cells and rooms) and for extremely intense currents,
the contacts are immersed in oil.
Contacts having different phases are separated by fireproof devices.
For contactor capacity we mean the value of the current intensity that
the contactor is able to withstand permanently.
- 20 -
AUXILIARY CONTACTS
They constitute the core of the contactor and are used for control and
block signalling circuits. They are usually interested in values of
intensity of contained current and are distinguished between:
a) normally open or working or closing (Figure 5a)
b) normally closed or on stand-by or opening (Figure 6b)
Figure 5a Figure 5b.
Between the auxiliary contacts, special attention should be paid to

DEDUCTION CONTACT having the task to replace the temporary
command (button) in order to keep the contactor excitation coil fed.
The contact deduction is suppressed in the event in which the
command is constituted by a permanent contact (switch).
Among the contactor commands, there are:
- push buttons,
- auxiliary contacts of another contactor,
- float contacts,
- limit switch contacts,
- retardant contacts,
- photoelectric-cell contacts.
A contactor is also identified by the number of hourly operations it is

able to perform.
The class of a contactor is identified by the capacity and number of
hourly operations.
However, the current trend it to identify a contactor on the basis of the
size that takes account of the operating voltage and the power of the
user.
The following must be considered when ordering and choosing a

contactor:
- the number of main contacts,
- the number and type of auxiliary contacts,
- the tension of operation (NOMINAL VALUE OF THE LINE)
- the nominal current or power (value),
- the power supply voltage (value and nature, alternating or direct) of
the excitation coil,
- execution: visible, in boxes, in a container, jerrycan.
- 21 -
The symbol of a contactor is shown in Figure 6 in the versions

presently used.
Figure 6a) Figure 6b).
In the first case a), it is assumed that the coil moves the contacts from
right to left, while in the second (DIN regulations), the contacts are
moved from left to right. It is clear that it is a convention, however,
the important thing is to always use only one of the two symbols when
making a sketch.
Basically, the main contacts are identified, according to international
regulations, by the numbers 1-2; 3-4; 5-6.
The excitation coil terminals are identified by the letters A1; A2.
The auxiliary contacts are identified by a two-digit number where the
first number is a progressive number that increases according to the
number of contacts and the second number, if it is 3-4, indicates
contacts that are normally open; if it is 1-2, it indicates contacts that
are normally closed. The auxiliary contact marked 13-14 is the first
contact of the contactor under consideration and is normally open; the
auxiliary contact marked 41-42 is the fourth contact of the same
contactor and is normally a closed type, etc.
To recapitulate, for a contactor with three main contacts we will have,
two open auxiliaries, two closed auxiliaries, the following numbering
(Figure 7).
Figure 7.
- 22 -
PUSH BUTTONS
As already mentioned earlier, the command of the contactors is
normally realized with the use of temporary contacts. They are
divided into:
a) push buttons normally open for start operations,
b) push buttons normally closed for block functions.
In practice, the start button, characterized by a normally open contact,

has a "button" that is used to carry out BLACK or GREEN functions;
the stop "button", identified by a normally closed contact, is RED.
Moreover, you can also have combinations of the type shown below in
Figure 8a, which normally occurs in the condition in which pressing the
button determines the opening of the normally closed contact and
closing of the normally open contact. The diameter of the buttons
(fastening hole) is standardized to the value of 22 mm.
Figure 8a.
LAMP HOLDER INDICATOR

The lamp holder indicators (Figure 8b) are normally the type of small
connection for filament lamps of 2-3 W and with the development of
LED technology. The gems are coloured to represent the various
operating conditions; green to detect a state of rest or safe conditions,
yellow in the case of temporary situations, red to indicate the
intervention of protective equipment.
The diameter of the lamp holder is also standardized to the value of 22
mm.
Figure 8b.
- 23 -
SAFETY OBSERVATIONS
Even though there are other methods, the use of very low voltage for
contactor control circuits is consolidated. In this case, one has to adopt
the PELV system (protective low voltage) where a point of the
secondary circuit of the transformer is connected to the earth system
and the other point is protected by the overcurrent protection device,
Figure 9a.
The sagacity to connect to the earth a point of the secondary source is
necessary to trip the protective device (located on the other thread) in
the event of an initial fault to the earth and to prevent that a first fault
to the earth is not detected (Figure 9b) and the occurrence of a second
short-circuit fault, for example, the NC contact of arrest, (Figure 9c)
denying the possibility of being able to stop the machine; this is very
serious!
Figure 9a Control circuit powered by the PELV system having one point connected to the earth
and the other to the protective device against overcurrents. Correct circuit.
Figure 9b First fault not detected by the protection device in the PELV circuit not connected to
earth. Incorrect circuit function because the fault cannot be seen but it may exist.
Figure 9c A second fault is also not detected but the stop button is no longer able to open the
circuit. Incorrect circuit function with serious consequences since the machine cannot stop!
- 24 -
IDENTIFICATION CODE
It is good practice to identify the elements that comprise an electrical system
by means of a code.
The identification code may be made up of letters and numbers; in this case,
the letters must be taken from the Latin alphabet and must be uppercase (A-
Z); the numbers must be Arab numerals. To avoid misinterpretations, you
must avoid using the letters I and O, which may be confused with the
numbers 1 and 0.
According to the CEI EN 61346-1 (CEI 3-43) Regulations derived from the
IEC 1346-1, the elements that make up the system can be described by a
prefix before the code, according to three different aspects, in relation to:
- what it does (function) prefix =
- where it is installed (location) prefix +
- how it is made (product) prefix -
The EN 61346-2 (CEI 3-47) Regulation derived from the IEC 61346-2
contains the literal code to classify the elements of the electrical system, see
Table 1.
The function code is the functional aspect of the element, namely, the
purpose or task assigned to the element; the code letter is preceded by the
prefix = and followed by the digits of consecutive numbering.
For example: =T1 and =T2 indicate two transformers.
The location code allows the physical identification of the location of the
element, as the physical place such as a building, a floor, a room or as part of
the system such as the power board, a panel of the board; the alphanumeric
code is preceded by the prefix +.
Mnemonic abbreviations or acronyms, which are chosen by the designer and
reported in a legend, are generally used.
For example: +STA1+CAB2+T1 or +STA.CAB2.T1 may indicate the
transformer 1 (T1) in the cabin 2 (CAB2) of the plant 1 (STA1).
Conventionally, when the prefix signs after the first sign are all equal (in our
example, +), they may be replaced by a dot.
The product code classifies the single element irrespective of the function
and location it occupies in the system; the letter code, taken from the literal
code of Table 1, is preceded by the prefix - and followed by digits of
progressive numbering.
For example: -Q2 and -F1 respectively indicate the switch n. 2 and the fuse
n. 1 of a wiring diagram.
The identification code of the connection terminals may be numeric, literal,
or alphanumeric and is preceded by the prefix:, and is generally coupled to
the production code.
For example: -X1:1 and -X3:7 indicate the specific terminals of the terminal
boards X1 and X3.
The electrical conductors of an alternating current system are identified by:
Phase 1 L1; Phase 2 L2; Phase 3 L3; Neutral N; protection conductor PE.
The electrical conductors of a direct current system are identified by:
Positive L+; Negative L-; Middle point M.
- 25 -
Table 1 Literal references to identify materials to be used to draw diagrams of electrical systems.
Regulation EN 61346-2 (CEI 3-47) adopted from IEC 61346-2
Letter Type of material Examples of mechanical Examples of electrical products

products
A Two or more objectives or tasks / Touch screen
B Conversion of an input variable calibrated flange Buchholz relay

(physical property, condition or event) (for measuring) Detector
into a signal for further processing Sensor Fire detector
Gas detector
Element measurement
Relay measurement
Shunt measurement
Transformer measurement
Microphone
Movement detector
Photoelectric cell
Contact command
Position contact
Proximity contact
Proximity sensor
Relay protection
Sensor
Smoke sensor
Tachymetric generator
Temperature sensor
Thermal overload relay
Video camera
C Storage of materials, energy or Barrel Storage buffer

information Buffer Battery buffer
Tank Condenser
Container Events recorder *
Hot water tank Hard disk
Support for paper coils Memory
Pressure accumulator RAM
Vapour accumulator Battery accumulation
Tank Tape recorder *
Vessel Video recorder *
Voltage recorder *
* mainly used for storage
D Reserved for future standardisation / /
E Supply of thermal or radiant energy Boiler Boiler

Freezer Fluorescent lamp
Heater Heater
Gas lamp Lamp
Heat exchanger Bulb lamp
Nuclear reactor Laser
Radiator Light
Refrigerator Maser
Radiator
- 26 -

products
F Direct protection of an electricity flux, Airbag Cathode protection anode

signals, staff, or equipment from Bugger Faraday cage
dangerous or unwelcome situations. Fencing Fuse
Systems for protective purposes Protection Miniaturized switch
Burst pipe valve Discharger
Crack point disk Thermal overload releaser
Safety belt
Safety valve
Screen
Thermionics valve
G Electricity flux or material production Blower Flat battery

Generation of signals used for the Machine to insert components Generator
referral of information or as a source Conveyor belt (activated) Fuel cell
of reference Crusher Generator
Production of a new type of energy, Fan Power generator
material or product Mixer Rotating generator
Pump Signal generator
Emptying pump Solar cell
Wave generator
H Reserved for future standardisation / /
I Not to be used / /
J Reserved for future standardisation / /
K Treatment (receiving, treatment and Feedback control of fluids All or nothing relays
supply) of signals or information Pilot valve Integrated circuit analogue
Articles for protective purposes are Valve positioner Automatic parallel device
excluded, see Code F Integrated circuit rail
Auxiliary relay
CPU
Delay element
Delay line
Thermionics valve
Cathode pipe
Feedback controller
Filter
Induction mixer
Microprocessor
Process calculator
Programmable controller
Synchronisation device
Timing relay
Transistor
L Reserved for future standardisation / /
- 27 -

products
M Supply of mechanical energy Combustion motor Actuator

(mechanical, rotary or linear Fluid activator Coil command
movement) for the purpose of Hydraulic cylinder Electrical motor
activation Heat engine Linear motor
Mechanical activator
Spring activator
Turbine
Hydraulic turbine
Wind turbine
N Reserved for future standardisation / /
O Not to be used / /
P Supply of information Sound-signalling device Sound-signalling device

Scales (for weighing) Ammeter
Bell Bell
Clock Clock
Display unit Continuous tracing recorder
Fluxmeter Display unit
Gas meter Electromechanical indicator
Level indicator Events meter
Manometer Geiger meter
Mechanical indicator LED
Printer Speaker
Gauge glass Optical-signalling device
Thermometer Printer
Water meter Voltmeter recorder
Signalling lamp
Vibration signal
Synchronoscope
Voltmeter
Wattmeter
Watt-hour meter
Q Controlled switching or variation of Brake Switch

electrical energy flux, signals, or Control valve Contactor (power)
materials Friction Isolator
Door Fuse switch
Deflector Isolator fuse switch
Slide Starter
Interception valve Power transistor
Cut-off Short-circuit device with sliding
Closure contacts
Key device Switch (power)
Thyristor
- 28 -

products
R Limitation or stabilization of Block device Diode

movement or a flow of energy, Non-return valve Inductor
information or materials Attenuation device Limiter
Brake Resistor
Interblock device
Connection device
Flange modulator (to limit the
flow)
Pressure limit valve
Transformer
Buffer
silencer
free-release mechanism
S Converting a manual operation into a Push button valve Control switch

signal for the subsequent treatment Commutator selector Discordance commutator
Keyboard
Light pen
Mouse
Button
Commutator selector
Set-point regulator
Converting energy into the same kind Fluid amplifier Converter c.a./c.c.
T of energy Gear Amplifier
Converting a definite signal and Transducer measurement Antenna
preserving the information it contains Measurement transmitter Demodulator
Changing the shape of a material Pressure amplifier Frequency converter
Torque converter Transducer measurement
Pressure die-casting machine Measurement transmitter
Cold-pressing machine Modulator
Grinding wheel (size reduction) Power Transformer
Lathe Rectifier
Saw Conversion Station
Signal converter
Signal transformer
Telephone set
Transducer
U Maintaining objects in a definite Beam Insulator

position Bearing, Ball bearing
Block
Cable ladder
Cable
Console
Corbel
Equipment
Foundation
Hook
Insulator
Mounting plate
Mounting frames
Pillar
- 29 -

products
V Treatment of materials or products Centrifuge Filter

(including the preparation and final Degreasing device
treatment) Dehydrating device
Filter
Cut-off wheel (superficial
treatment)
Packing machine
Rake
Separator
Sifter
Painting machine
Vacuum cleaner
Washing machine
Wetting mixer
W Guide or transport of energy, signals, Conveyor belt (without Omnibus bar

materials or products from one place activation) Cable
to another Conduit Conductor
Pipe Supply of information
Ladder Optical fibre
Connection (mechanical) Bushing insulator
Mirror Wave generator
Roller table (without activation)
Tube
Shaft
Shuttle
X Connection of items Flange Connector

Hook Male connector
Pipe connector Terminal
Oil pipeline Terminal board
Quick-release coupling Terminal plate
Shaft coupling
Block connection
Y Reserved for future standardisation / /
Z Reserved for future standardisation / /
- 30 -
EXERCISE 1 Contactor command from a point
Exercise 1 Contactor command from a point
AIM
Realize the complete electrical system of the power, control and
signalling circuit related to the three-phase supply device, controlled
from a point.
MATERIAL REQUIRED
1 Panel mod. C-IIC/EV.
1 Fixed single-phase power supply 220-230 Vac for a control circuit
1 Fixed three-phase power supply 380-400 Vac for a power circuit.
1 Series of cables with 4 mm diameter safety plugs.
PREPARATION FOR THE EXERCISE

Place the panel onto the worktable in a way that it is perfectly stable.
Connect the various electrical components by following the wiring
diagram in Figure 1.1.
DISCUSSION
The standard setting and development of the diagram, which will be
followed for all exercises, is the following:
THE POWER CIRCUIT,
THE CONTROL CIRCUIT,
THE SIGNAL CIRCUIT.
Each contact, whether it is the main or auxiliary, is identified by a

serial number in the diagram, as shown in the description of the
contacts of the meter
The diagram in now read from left to right (Figure 1.1).
POWER CIRCUIT
The terminals L1-L2-L3 make the three-phase supply line available to
the protected power circuit by a protection device against
overcurrents; the said line must be connected to the main contacts of
the contactor Q1 (terminals 1-3-5); terminals 2-4-6 are connected to
the three-phase load.
It is evident that when the main contacts (Q1 in the diagram) are
closed, the load is powered.
From an executive point of view, it is observed that the conductor
used for the practical realization must have a minimum section of 2.5
mm with degree of isolation H07.
- 31 -
For the determination of the section, it is noted that it is good practice

to detect it by referring to a density corresponding to 4 A/mm2 for
which, by way of example, for a current value of 10 A the conductor
must have a section equal to
I 10
S 2,5mm 2
4
CONTROL CIRCUIT
It is characterized by the stop button S1, which is normally closed
(terminals 21-22), the deduction contact normally open Q1 (terminals
13-14) with the normally open contact in parallel with the start button
S2 (terminals 13-14) lastly, the contactor coil Q1 (terminals A1-A2).
Operating the S2 start button determines the excitation of the Q1
contactor coil, for which:
a) the main contacts 1-2, 3-4, 5-6 close, thus allowing the three-
phase power supply of the load.
b) the auxiliary contacts 13-14 and 43-44 close, the auxiliary 13-14
manually replaces the exerted action on the start button and the
43-44 auxiliary contact allows the supply power of a signal lamp.
c) the auxiliary contact 21-22 opens, therefore, a signal lamp turns
off.
Attention is now given to the auxiliary contact 13-14 of Q1, which
replaces the start button when the exercised operation is stopped
manually by the operator on the button S2.
Such contact is commonly called a "LATCH" and is indispensable in
all those cases in which the control device is temporary; in fact, if it
were not there, the contactor coil would only remain energized for the
time in which the button is pressed.
In operating conditions, therefore, the coil is powered through the 13-
14 contact of Q1 and the S1 stop button. To de-energize the contactor
and disconnect the load, you must press the stop button (S1), which
will interrupt the electrical continuity of the excitation circuit and will
put the contactor in rest mode so all the working contacts are reopened
and the resting one closes.
- 32 -
SIGNAL CIRCUIT
It is necessary in all those cases in which it is impossible to directly
verify the result of the operation carried out on the control devices.
It is characterised by two lamps:
a) the one inserted in the P2 lamp socket (lamp gear) that has the
purpose of indicating to the operator that the action performed on
the start button has allowed the excitation of the contactor coil
with the consequent supply of the load;
b) the one inserted in the P1 lamp socket (rest lamp), instead, has the
purpose of indicating to the operator that the circuit is in the
condition of rest.
In rest mode, the P1 lamp (rest lamp) is turned on since it is derived
from the normally closed contact 21-22, while the P2 (gear lamp) is
turned off because the 43-44 contact is of a normally open type.
Energizing the contactor, its 21-22 contact opens so the P1 lamp (rest
lamp) turns off, while its 43-44 contact closes thus allowing power to
the P2 lamp (gear lamp).
The conductor normally used for the realization of the control and
signalling circuits is section 1-1.5 mm2.
What has been described in the exercise can be summarised as

follows:
1) In rest conditions, the P1 green lamp is lit and the load is switched
off;
2) Operating the start button S2 (green button) the Q1 contactor coil
is energised, which determines the power supply load, the
switching on of the yellow lamp P2, and the switching off of the
green one P1.
3) By operating the stop button S1 (red button) the Q1 contactor coil
is de-energized, which switches off the load, turns off the P2
lamp, and turns on the green one P1.
- 33 -
Figure 1.1 Control of a generic three-phase load with a contactor.
- 34 -
OPERATING MODE
For the practical realization of this system, also considering the
control board that contains it, you must change the functional diagram
into a multi-wired one, distinguishing between the two basic
characterising parts:
a) The BOARD and its contents
b) THE CIRCUIT OUTSIDE THE BOARD.
In this regard, it is noted that the control and signalling devices are
normally placed outside the board and it is therefore necessary to
provide an appropriate terminal on the board from which to make the
connections to those devices that do not form an integral part of the
board and that are generally placed on special control panels in the
vicinity or on the supporting structure of the load.
Figure 1.2 shows the multi-wire diagram in connection with the

exercise. Let us read it and compare it to the wiring diagram of Figure
1.1 in which the terminals of union between the two parts (inside and
outside the board) are represented at the centre of the diagram.
- The power circuit connects to the power supply line through the
terminal board X1; the contactor controls the load that is connected
via the X2 terminal board.
- Between the L1 conductor and the Neutral, the connection of the
primary winding of the transformer is obtained; these should be
adequately protected by an overcurrent device.
- The side of the transformer in protective low voltage (PELV) sees a
point directly earthed, and the other protected against overcurrents
(overload and short circuit) by the automatic circuit breaker switch
F3.
- The control circuit is created from the branch of the transformer
T1, which interconnects between the inside and outside of the
assembly via the terminal board X3.
- Downstream of protection F3 a connection to terminal X3:2 is
carried out while the terminal X3:1 is connected to the 0V of the
branch of the transformer T1. Terminals X3:1 and X3:2 show the
24 Vac voltage outside the board to power the control and
signalling circuit.
- The S1 stop button and that of S2 gear are connected to terminals
X3:2, X3:3 and X3:4; note that in parallel with the S2 start button
outside the board, there is the contact latch Q1 13-14, which is
inside the board.
- One end of the contactor coil terminal A2 must be connected to the
0V point that corresponds to the earthed point of the source PELV;
there should be no contact of any kind between the 0V point
and the A2 terminal of the Q1 contactor coil!
- The pair of contacts 21-22 and 43-44 of the Q1 controls the
respective P1 and P2 lamp indicators, which, being outside the
board, come from terminals X3:5 and X3:6 and terminal X3:1
(0V).
- 35 -
Figure 1.2. Control of a three-phase load with a contactor.

Multi-wire diagram of the board, both internal-external.
- 36 -
The student is invited to trace, as a preliminary step, the connections

between the electrical devices using the layout of the panel shown in
Appendix A; it is good to make two photocopies and draw the control-
signal circuit and the power circuit separately. An example that shows
the connections on the didactic panel is shown in Figure 1.3.
Having realized the plant and before connecting it to the power

supply, it is always advisable to carry out a visual inspection and/or
with the use of the tester designed to measure continuity, in order to
highlight any connection errors.
It is good practice not to give power to the power circuit immediately,

but first activate and check the control and signalling circuit, and only
if the operation is correct you can also enable the power circuit to
proceed to the final testing of the system.
Figure 1.3 Panel connections to control a three-phase load with a contactor.
- 37 -
EXERCISE 2 Three-phase induction motor remote starter
Exercise 2 Three-phase induction motor remote starter
AIM
signalling circuit related to the three-phase cage induction motor
starter 0.3-1 kW, controlled from a point.
MATERIAL REQUIRED
1 Fixed single-phase power supply 220-230 Vac for a control circuit
1 Three-phase cage induction motor 0,3-1 kW mod. M-4/EV or P-
4/EV, if available.

POWER CIRCUIT
Compared to the wiring diagram of the previous exercise 1, a new
device is added to the power circuit; it is a protection device against
motor overload.
Let's now look at the new device called thermal relay, whose symbol
is shown in Figure 2.1, with the numbering of the terminals according
to international standards.
Figure 2.1 Schematic representation of a thermal relay.
The protective device against overloads of the electric motor,

commonly referred to as "HEAT", is characterized by:
a) a sensing element to the increasing value of current intensity, which
consists of a bimetallic plate wheel loader inserted through the
terminals 1-2, 3-4, 5-6, in series to the power supply phases of the
motor to be protected;
b) a spring device, which stressed by the deformation of the bimetallic
plates (all it takes is for one of the three layers to bend), it determines
- 38 -
the opening of a normally closed contact (95-96) and, if necessary, by

request, the closure of a normally open contact (97-98).
It is possible to choose between two fundamental types of thermal
relays:
1) thermal relay with manual reset (with lock) in which, following the
intervention of the overcurrent, the re-closure of contact 95-96 is only
possible "manually" by operating the provided button embedded in the
said thermal relay.
2) automatic reset thermal relay (without block) in which the closing
of contact 95-96 is "automatically" carried out once the bimetallic
plates regain their position of rest (time is needed for cooling).
The curve of a thermal relay is of the dependent time type (Figure
2.2), which means that the operating time of the thermal device is
inversely proportional to the value assumed by the overload current.
The order of magnitude for the thermal relays, applied to power
motors that range from 7 to 20 kW, is as follows:
a) for a current equal to 1.5 In, intervention time is three minutes
b) for a current equal to 2 In, intervention time is one minute
c) for a current equal to 3 In, intervention time is 20 seconds.
Figure 2.2 Curve time - current intervention of a thermal relay.
At the conclusion of the topic, it is observed that thermal devices are

equipped with an adjustment screw which allows it, depending on the
need, to set the "thermal" intervention field.
- 39 -
Figure 2.3 Classes of intervention by a thermal relay.
In the case set out in Figure 2.3, the following conditions occur:
1) reference curve "a" for current intervention 3In in 40 s
2) reference curve "b" for current intervention 3In in 20 s
3) reference curve "c" for current intervention 3In in 10 s.
The student must be aware that the thermal relays are suitable to
detect overload currents ranging between 2-5 times the nominal
current and must, in turn, be protected with fuses, from short-circuit
currents, which are not able to withstand the overload because the bi-
metals would melt.
The contactor must also be protected against overcurrents; task
performed by the fuses inserted upstream and the thermal relay
inserted downstream of its power contacts.
As an alternative to the combination fuses - thermal relay, a single

device combined with a magnetic release and an adjustable thermal
hook can be used; the device is called a "motor protector". The
motor protection switch must be inserted in the power circuit,
upstream and not downstream of the contactor, as it also fulfils the
function of protection against short circuits, which are known to be
placed at the beginning of the circuit.
Figure 2.4 Schematic representation of a circuit-breaker motor protector.
- 40 -
CONTROL CIRCUIT
(terminals 21-22), the latch contact normally open Q1 (terminals 13-
14) with the normally open contact in parallel of the start button S2
(terminals 13-14), the contact normally closed 95-96 of the thermal
relay F2, and, lastly, the contactor coil Q1 (terminals A1-A2).
a) the main contacts 1-2, 3-4, 5-6 close, thus allowing the three-
phase power supply of the load.
43-44 auxiliary contact allows the supply power of the signal
lamp gear indicator.
c) the auxiliary contact 21-22 opens, therefore, the stop signal lamp
turns off.
Such contact is commonly called a ''LATCH'' and is indispensable in
were not there, the contactor coil would only remain energized for the
In operating conditions, therefore, the coil is fed through the NC
contact of the stop button S1, the contact 13-14 of Q1 and the NC
contact of the motor protector F1. To de-energize the contactor and
disconnect the motor, you must press the S1 stop button, which will
interrupt the metallic continuity of the excitation circuit and will put
the contactor in rest mode so all the working contacts are reopened
and the resting one closes. In the case of "excessive work" required
by the motor, the absorbed overcurrent triggers the thermal relay (the
time depends on the current absorbed by the motor and the adjustment
made in the relay) that, as with the stop button, interrupting the
continuity of the metal excitation circuit, shows the contactor in rest
mode.
SIGNAL CIRCUIT
verify the result of the operation carried out on the control devices and
to report anomalies.
It is characterised by three lamps:
a) the one inserted in the lamp socket P1 that has the purpose of
indicating to the operator that the engine is stopped;
a) the one inserted in the P2 lamp socket that has the purpose of
indicating to the operator that the action performed on the start
button has allowed the excitation of the contactor coil with the
consequent power supply to the motor;
c) the one inserted in the lamp socket P3, which has the purpose of
indicating to the operator the intervention of the thermal relay
and, therefore, an overload to the motor.
- 41 -
Figure 2.5 Three-phase induction motor remote starter.
- 42 -

signal circuit and the power circuit separately.
An example that shows the connections on the didactic panel is shown
in Figure 2.6.


DO IT YOURSELF
A set of buttons, start - stop are used in the proposed system; change
the control circuit to have two pairs of buttons on - off (typical case of
a motor controlled from two points).
Note: to integrate an extra start - stop button in the control circuit, it is
also necessary to re-evaluate the signalling circuit that has the purpose
of indicating the status of the motor (machine) in cases where it is
impossible to directly verify the result of the operation carried out on
the commands; you should also double the warning lights!
- 43 -
Figure 2.6 Panel connections to control a three-phase motor with a contactor.
- 44 -
EXERCISE 3 Gear contactor command - stop and by impulses
EXERCISE 3 Gear contactor command - stop / impulses
AIM
This exercise is a variation of exercise 2.
Verify the condition for which the operation of the contactor Q1
(therefore, of the motor) is also possible to pulse; namely, that by
operating another start button, (impulse button), the contactor remains
energized only for the time in which the control device is kept
pressed.
MATERIAL REQUIRED
1 Fixed single-phase power supply 220-230 Vac for a control circuit.
4/EV, if available.

POWER CIRCUIT
CONTROL CIRCUIT
SIGNAL CIRCUIT
Figure 3.1 as regards the control-signal circuit, report the solution to
the proposed condition.
The power circuit remains the same as in the previous exercise 2,
diagram 2.5.
- 45 -
EXERCISE 3 Gear contactor command - stop / impulses
Figure 3.1 Gear contactor command - stop and by impulses
DO IT YOURSELF
Making sure that the lamp switch P2, can work without the use of the
contact 43-44 of Q1.
- 46 -
EXERCISE 4 Contactor coil in alternating current supplied by direct current
EXERCISE 4 Contactor coil in alternating current supplied by direct

current
AIM
Use an operating contactor coil with alternating current in a circuit
with a direct power supply.
In the case of a contactor with an operating excitation coil in
alternating current and direct current power supply, as it has been
written in the theory of contactors, it is necessary to insert a limiting
resistor in the contactor coil, which has the task of limiting the current
in the coil when the contactor contacts have established the metallic
continuity in the main circuit.
Compare the two control circuits shown in Figure 4.1.
Complete with the signalling circuit where even the lamp indicators
are supplied with the same DC auxiliary power supply; take cue from
Exercise 2.
The power circuit is the same as the previous Exercise 2.
MATERIAL REQUIRED
4/EV, if available.
1 Power source 24 VDC with a current of at least 2 A
1 Limiting resistance. The choice of resistance, value and nominal
power, is left to the student.

The student is invited to calculate the limiting resistance in relation to

the contactor used on the panel and, following the practical realization
of the circuit, instrumentally verify the correct dimensioning of the
resistance and power.

- 47 -
Figure 4.1 Excitation contactor coil operating in alternating current

supplied by direct current.
Although the two circuits illustrated apparently have the same

function, it is noted that:
4a in the circuit, operating the start button the contactor coil tends to
get energised since it is powered by the full voltage of DC power, but
as soon as the contact 21-22 opens, the limiting resistance in series
causes the voltage drop and the movable contactor does not hook onto
the fixed (incomplete mechanic stroke) with consequent fluctuations
in opening/closing.
In this case, you need a delayed auxiliary contact upon opening in
order to allow the contactor to operate the complete closure of the
magnetic circuit (mobile equipment attached to the fixed) before
inserting the resistance.
4b in the circuit, we always get the required result since the resident
time of the full voltage of DC power to the coil is determined by the
operation of the start button. However, it should be noted that if the
start button is stuck in the closed position because it is defective or
because it is held down, the resistance imitator is shorted and the
contactor coil is destined to burn from excess current.
- 48 -
Tip for the dimensioning of the resistance imitator:

- measure the current "Ib" absorbed by the coil energized in AC,
- Measure the "Rb" resistance of the coil.
Vdc
Calculate the Rl with the formula Rl = -------- - Rb (ohm)
Ib
Resistance power Prl = RI * Ib2 (W)
It is good practice to triple the rated power of the resistance as a factor

of safety and to contain the surface temperature.
From the above exercise, it shows that it is not convenient to use

contactors with coils in alternating current supplied in direct current
since a limiting resistor is required, which, for large contactors, takes
relevant dissipated values of power.
In this regard, there are contactors with DC coils on the market, which
feed directly.
If, in an industrial plant, it is necessary to use the auxiliary voltage AC

and DC simultaneously, you must make two separate transformers or
a single transformer with two separate secondary windings, as shown
in Figure 4.2, to satisfy the condition that a polarity of 24 Vac and 24
VDC are grounding and common to all the contactor coils or
electromagnetic valves and the other protected by fuses or circuit-
breaker switches.
Figure 4.2 Power source PELV Alternating Current and Direct

Current for control circuit mixed AC - DC.
- 49 -
EXERCISE 5 Independent command of two contactors
AIM
signalling circuit related to a machine with two small three-phase
induction motors controlled manually and independently of each
other.
The system must be completed with a signalling circuit that indicates:
a) motors in rest mode
b) active motor A
c) active motor B
d) intervention of the thermal protections.
MATERIAL REQUIRED
Three-phase cage induction motor mod. M-4/EV or P-4/EV, if
available.

COMMENT
It is important to respect the correspondence of the phases in order to
avoid the motors from having a different rotation direction between
them.
ELECTRICAL CIRCUIT
The complete wiring diagram is shown in Figure 5.1.
The realization does not present particular difficulty, since, in practice,
it is simply a matter of doubling the power circuit seen in the previous
exercise 2 and changing the signalling circuit with more lamp
indicators.
- 50 -
Figure 5.1 Independent control of two three-phase induction motors.
- 51 -
OPERATING MODE
You should remember that the pair of contactors Q1 and Q2 are

mechanically interlocked with each other; before realizing the
electrical connections on the panel, you need to remove the said
mechanical interlock.
As an alternative to contactors Q1 and Q2, use the contactors Q1 and
Q3 in this exercise.
Having realised the plant and before connecting it to the power


DO IT YOURSELF
The proposed plant uses a single stop button, which is common to
both motors; change the control circuit to have an independent stop
button for each engine and a common one for an emergency stop.
- 52 -
EXERCISE 6 Remote motor reversing switch for a three-phase induction motor
EXERCISE 6 Remote motor reversing switch for a three-phase induction

motor
AIM
Realizing a circuit to obtain a reversing switch of a three-phase
induction motor by way of a remote control with forward - backward
command switches from a point and relative lamp indicators.
Moreover, the system must be provided with protection against
overloads and relative intervention indicators of the motor protector.
MATERIAL REQUIRED
4/EV, if available.

DISCUSSION
Before considering this very important application for the wide range
of uses it has (lifts, goods lift, gates, cranes), a clarification is
required.
To obtain the reversing switch of a three-phase induction motor, as
shown in Figure 6.1, two, and only two, of the supply phases of the
winding stator must be exchanged between them.
Figure 6.1 Change of direction of rotation of a three-phase induction motor.

- 53 -
POWER CIRCUIT
From examining the power circuit shown in the wiring diagram of
Figure 6.2, it is observed that if the Q1 remote control switch is
energized, the power of the stator phases of the motor occurs with U1-
L1, L2-V1 and L3-W1, which allows the rotation of the motor shaft,
for example, clockwise.
Instead, through the contactor-Q2, it reverses the direction of rotation
of the motor shaft because its phases are supplied by L3-U1, V1-L2
and L1-W1.
We must highlight that the simultaneous activation of two remote

control switches (interlocking) should be banned as otherwise, from
an electrical point of view, a net short circuit between the exchanged
phases will occur, in our case, between L1 and L3.
CONTROL CIRCUIT
The control circuit is characterised by:
a) the 2 normally closed contacts respectively of the stop button S1
and F1 motor protection switch, in series between them and the
contactor excitation coil of the Q1 and Q2 remote controls.
b) the button contacts of the S2 forward and S4 reverse switch in
parallel with the respective contacts or automatic latch.
c) the NC interlock contacts, which prevent operation of a contactor
if the other is energised.
Remember that the pair of contactors Q1 and Q2 are
mechanically interlocked with each other but this does not exempt
one from realizing the electrical interlock as shown in c).
SIGNAL CIRCUIT
As already mentioned in previous exercises, the signal of operating
status of the motor is necessary in all those cases in which it is
impossible to directly verify the result of the operation performed on
the control devices; moreover, it is indispensable to report anomalies
to the power circuit (overloads).
a) lamp P1 that has the purpose of indicating to the operator that the
motor is static;
b) P2 lamp that has the purpose of indicating to the operator that the
action carried out on the start buttons has permitted the excitation
of the contactor coils and, as a result, powered the motor without
discriminating the direction of rotation of the motor;
c) lamp P3, which has the purpose of indicating to the operator the
intervention of the thermal relay and, therefore, an overload to the
motor.
- 54 -
Figure 6.2 Remote motor reversing switch for a three-phase induction motor
- 55 -
OPERATING MODE


DO IT YOURSELF
Make the appropriate changes to the signalling circuit in order to have
two lamp indicators respectively for the forward and reverse switches.
- 56 -
EXERCISE 7 Remote motor reversing switch with lock push buttons
AIM
Realize a circuit to obtain a reversing switch of a three-phase induction
motor by way of a remote control with forward - backward command
switches from a point, protection against overloads and relative lamp
indicators. Include the possibility to operate the reverse switch by simply
pressing the opposite switch.
MATERIAL REQUIRED
4/EV, if available.

DISCUSSION
The proposed installation is, in its essence, identical to that seen in the
previous exercise 6 with the simple addition of an NC contact in each
start button. With this circuit, the action on a start button commands the
relative contactor to a direction of rotation of the motor and
simultaneously interrupts the electrical circuit of the contactor of the
opposite direction (interlock on the buttons).
This circuit also allows reversing without having to activate the stop
button, instantaneous reversing of motion.
The mechanical interlock between the two contactors represents the
maximum security against the simultaneous closing of the two contactors
but this replaces the two NC interlocking contacts between the
contactors, which, however, introduce a slight delay in reverse; as long as
a contactor is closed, the other one cannot be activated.
- 57 -
Figure 7.1 Remote motor reversing switch for a three-phase induction motor with block buttons.
- 58 -
OPERATING MODE


- 59 -
EXERCISE 8 Remote motor reversing switch with lock push buttons and retardant
EXERCISE 8 Remote motor reversing switch with lock push buttons and
retardant
AIM
Realize a circuit to obtain a reversing switch of a three-phase
command switches from a point, protection against overloads and
relative lamp indicators. The possibility to operate the instant
reversing switch must be prevented with a timer.
MATERIAL REQUIRED
4/EV, if available.

DISCUSSION
In the system proposed in Figure 8.1, compared to the previous
exercise, the addition of a timer prevents the instant reversing switch
of the motor, which is only tolerated in small motors (low inertia) but
is harmful in machines above a kilowatt.
The timer must be regulated to allow the motor to stop before starting
once again in the opposite direction.
Note: in actual installations, an auxiliary relay with 2 NO contacts and

one NC contact, or alternatively one with 3 exchange contacts, are
used instead of the Q3 contactor.
- 60 -
Figure 8.1 Remote motor reversing switch for a three-phase induction motor with block buttons
and retardant.
- 61 -
OPERATING MODE

In the timer used, regulate:

function “B” excitation retardant with Start Terminal B1 control is to
be connected to terminal A1;
time scale of about 5 s.

DO IT YOURSELF
With this exercise, we used a multi-function timer with delayed
operation.
Add a lamp to the signalling circuit, which will indicate the possible
intervention of the motor protection switch; to draw the user's
attention, the lamp must have a flashing light (0.5 s ON OFF cycle).
Advice: use the function “Ci” in the second timer available on the
panel.
- 62 -
EXERCISE 9 Remote motor reversing switch with limit switch
AIM
Realize a remote motor forward - back reversing switch for a three-
phase induction motor of a conveyor belt, with control buttons and
stop limit switches in the two extreme positions, include protection
against overloads and signal lamp of forward switch, the backward
switch and the intervention of the thermal relay.
MATERIAL REQUIRED
4/EV, if available.

DISCUSSION
A new device is added to those used in the previous exercise: limit
switch contacts. They are operation devices that directly or indirectly
act on the command of the contactor coil when the organs of motion
of mechanical systems put into operation, for example, by an electric
motor, reach certain positions (for example picture the cabin of a lift
or hoist, the cart of a crane, an electric gate, etc;).
- 63 -
Figure 9.1 Remote motor reversing switch for a three-phase induction motor with a limit switch
control.
- 64 -
OPERATING MODE


DO IT YOURSELF
We propose you to make a variation relative to the signal circuit of
this exercise, which consists of:
use only one signalling lamp -P1, with intermittent operation, to
indicate that the conveyor belt is active (it does not matter in which
direction);
use two distinct signalling lamps -P2 and -P3 to indicate that the belt
is static at both ends;
use the signal lamp -P4 to report any possible motor overload.
Advice: to obtain a signal lamp with intermittent operation, use a
timer with the function “Ci”.
Inductive and capacitive sensors are available on the panel.

For the operation of electronic sensors, you need a 24 VDC power
supply; this is provided by an internal power supply to the panel and
the outputs of the sensors, which are known to bear a very low
current, are interfaced with relays. Therefore, for each sensor, you
have a NO-NC contact (exchange contact of 10 A) without potential,
which can also be used in alternating current circuits.
Use these two sensors as an alternative to the electrical limit switches,
since:
The inductive proximity sensors are designed to operate by
generating an electromagnetic field and detect parasitic current
losses generated into the electromagnetic field of ferrous metal
object or otherwise.
The capacitive sensors detect the variation of capacity that is
caused by the approach of an object, and it is able to recognize
almost all materials, from metals to liquids in general.
- 65 -
EXERCISE 10 Remote motor reversing switch for an electric gate
EXERCISE 10 Remote motor reversing switch for an electric gate with a

three-phase induction motor, control via a limit switch and timer
AIM
Realize the base system of control of a three-phase induction motor to
automate a sliding gate, verifying the following conditions:
a) with the open button, activate the motor that drags the gate until it is
fully open, maximum opening is controlled by the B2 limit switch
b) after 20 s from opening, automatically turn on the motor to shut the
gate, closure detected by the B1 limit switch
c) you can permanently block the gate with the stop button at any time
d) if the gate is open, with the close button, activate the motor to shut
the gate, closing limit switch detected B1.
Note: the system is defined as "basic" since it does not cover devices to control the safe
movement of the sliding door, ele invert, flashing, etc., the topic will be subject to discussion
with the teacher.
MATERIAL REQUIRED
4/EV, if available.

OPERATING MODE
Appendix A; it is good to make two photocopies and draw the control
- signal circuit and the power circuit separately.
- 66 -
EXERCISE 10 Remote motor reversing switch for an electric gate
Figure 10.1 Remote motor reversing switch for a three-phase electric gate induction motor
control via the limit switch and automatic closing timer.
- 67 -
EXERCISE 11 Single-phase induction motor starter
AIM
signalling circuit related to the single-phase supply device of an
induction motor.
MATERIAL REQUIRED
1 Single-phase cage induction motor 0.3-1 kW 0.3-1 kW mod. M-
8/EV or P-8/EV, if available.

POWER CIRCUIT
Even in this exercise, as seen in exercise 2, the overload protection
device of the motor is three-phase. The use of a thermal relay or a
three-phase motor protector in a single-phase circuit is perfectly
compatible with the device to even connect the third element of the
device in a series to one of the two poles, as shown in Figure 11.1.
In the above-mentioned devices, the manufacturer adopts some
devices to get the release in reduced time in case of a failure in one of
the phases; it is therefore necessary to transit the current in the three
poles.
Figure 11.1 Connecting a three-phase protection device into a single-

phase circuit.
- 68 -
As an alternative to the combination of the fuse-thermal relay, you can

still use the motor protector (single device combined with a magnetic
trip and an adjustable thermal trip). The motor protector must be
inserted in the power circuit, upstream and not downstream of the
contactor as it also provides the function of protection against a short-
circuit which is known to be placed at the beginning of the circuit, but
also connect the third element of the device in series to one of the two
poles, as shown in Figure 11.2.
Figure 11.2 Connecting a three-phase motor protector into a single-

phase circuit.
CONTROL CIRCUIT
(terminals 21-22), the deduction contact normally open Q1 (terminals
13-14) with the normally open contact in parallel of the start button S2
(terminals 13-14), the contact normally closed 95-96 of the protection
device, and, lastly, the contactor coil Q1 (terminals A1-A2).
a) the main contacts 1-2, 3-4, 5-6 close, thus allowing the single-
phase power supply of the motor.
43-44 auxiliary contact allows the supply power of the signal
lamp gear indicator.
c) the auxiliary contact 21-22 opens, therefore, the stop signal lamp
turns off.
Such contact is commonly called a ''LATCH'' and is indispensable in
were not there, contactor coil would only remain energized for the
In operating conditions, therefore, the coil is fed through the NC
contact of the stop button S1, the contact 13-14 of Q1 and the NC
- 69 -
contact of the protection device F1. To de-energize the contactor and

disconnect the motor, you must press the S1 stop button, which will
interrupt the metallic continuity of the excitation circuit and will put
the contactor in rest mode so all the working contacts are reopened
and resting one closes. In the case of ''excessive work'' required by the
motor, the absorbed overcurrent triggers the thermal relay or motor
protector (the time depends on the current absorbed by the motor and
the adjustment made in the relay) that, as with the stop button,
interrupting the continuity of the metal excitation circuit, shows the
contactor in rest mode.
SIGNAL CIRCUIT
verify the result of the operation carried out on the control devices and
to report the anomaly.
a) the one inserted in the lamp socket P1 that has the purpose of
indicating to the operator that the engine is stopped;
a) the one inserted in the P2 lamp socket that has the purpose of
indicating to the operator that the action performed on the start
button has allowed the excitation of the contactor coil with the
consequent power supply to the motor;
c) the one inserted in the lamp socket P3, which has the purpose of
indicating to the operator the intervention of the thermal relay
and, therefore, an overload to the motor.
- 70 -
Figure 11.3 Single-phase induction motor remote starter
- 71 -
OPERATING MODE
Appendix A; it is good to make two photocopies and draw the control
- signal circuit and the power circuit separately.


DO IT YOURSELF
Change the motor connections to obtain an opposite rotation.
If you have not succeeded, refer to the following exercise.
- 72 -
EXERCISE 12 Single-phase induction motor reversing switch
EXERCISE 12 Remote motor reversing switch for a single-phase

induction motor
AIM
Realizing a circuit to obtain a reversing switch of a single-phase
command switches from a point and relative lamp indication.
Moreover, the system must be provided with protection against
overloads and relative lamp intervention signal of the motor protector.
MATERIAL REQUIRED
1 Single-phase cage induction motor 0,3-1 kW mod. M-8/EV or P-
8/EV, if available.

DISCUSSION
Before considering this very important application for the wide range
of uses it has (ele inverts, gates, hoist), a clarification is required.
To obtain a reversing switch of a single-phase induction motor, as
shown in Figure 12.1, you must change the direction of the current in
one of the two windings of the motor (switch or start).
There are two typical constructions of single-phase motors:
- single-phase motor with two identical windings where the use of one
as a switch and the other as an auxiliary is irrelevant.
- single-phase motor with two different windings where one is
exclusive for the switch and the other, the one with the capacitor in
series, is exclusive to start.
Therefore, in relation to the type of motor, we change the connections;

it changes the power diagram.
- 73 -
Figure 12.1 Change of direction of rotation of a single-phase

induction motor.
a) same windings and auxiliary
b) different windings and auxiliary.
POWER CIRCUIT
From examining the power circuit shown in the wiring diagram of
Figure 12.2, it is observed that if the Q1 remote control switch is
energized, the power of the motor's windings occurs with L1-U1, N-
U2 and the auxiliary winding in series with the capacitor between L1-
Z1, N-Z2 allows the rotation of the motor shaft, for example,
clockwise.
Instead, through the contactor -Q2, the direction of rotation of the
motor shaft is inverted because the winding switch remains connected
in the same way but the one that starts is inverted L1-Z2, N-Z1.
Four power contacts for each contactor are required for this inverter
element; given the small single-phase power motor used, in this
exercise, we have used an auxiliary contact instead of a power contact
in the two contactors.
We must highlight that the simultaneous activation of two remote

control switches (interlocking) should be prohibited as otherwise,
from an electrical point of view, a net short circuit phase and neutral
would occur.
CONTROL CIRCUIT
The control circuit is characterised by:
a) the 2 normally closed contacts respectively of the stop button S1
and F1 motor protection switch, in series between them and the
excitation coil of the Q1 and Q2 remote controls.
- 74 -
b) the button contacts of the S2 forward and S4 reverse switch in

parallel with the respective contacts or automatic latch.
c) the NC interlock contacts, which prevent operation of a contactor if
the other is energised.
Remember that the pair of contactors Q1 and Q2 are
mechanically interlocked with each other but this does not exempt
one from realizing the electrical interlock as shown in c).
SIGNAL CIRCUIT
As already mentioned in previous exercises, the signal of operating
status of the motor is necessary in all those cases in which it is
impossible to directly verify the result of the operation performed on
the control devices; moreover, it is indispensable to report anomalies
to the power circuit (overloads).
a) lamp P1 that has the purpose of indicating to the operator that the
motor is static;
b) lamp P2 that has the purpose of indicating to the operator that the
action performed on the start button has allowed the excitation of
the contactor coil with the consequent power supply to the motor;
c) lamp P3, which has the purpose of indicating to the operator the
intervention of the thermal relay and, therefore, an overload to the
motor.
OPERATING MODE


DO IT YOURSELF
Redraw the power diagram for a single-phase motor with the same
winding gear and auxiliary.
Are 4 power contacts still required for each contactor?
- 75 -
Figure 12.2 Remote motor reversing switch for a single-phase induction motor.
- 76 -
EXERCISE 13 Star-Delta starting device
EXERCISE 13 Star-Delta starter
AIM
Realize an electrical system complete with a power, control and
signalling circuit attributed to the start-up of a Star Delta three-phase
cage induction motor. The system must be completed with a
signalling circuit that indicates:
- motor in rest mode,
- motor in starting phase,
- motor started,
- protection intervention against overloads.
MATERIAL REQUIRED
1 Three-phase cage induction motor mod. M-4A/EV or P-4A/EV, if
available.
Note: with voltage networks equivalent to 380-400 V, you need a
motor wound for voltage 660-690 / 380-400 V.

DISCUSSION
Three-phase induction motors are distinguished into two big families:
a) cage induction motor
b) induction motor with winding rotor.
The constructive characteristics, presentations, and choices of either

one kind or another are beyond this discussion, however, it is
important to remember that in both cases, when the engine is powered,
and in the subsequent start-up phase, the duration of which is linked to
the resistant torque, the current absorbed by it is higher than the rated
current value, even up to 6 times. In these conditions it so happens,
especially in high-powered motors, that in the starting phase it
manifests an excessive voltage drop in the supply line enough to affect
the correct functioning of other appliances and the protective devices
of the motor (fuses, thermal) during the start-up phase may intervene
in an untimely way.
- 77 -
It must also be noted that in coupled motors, for example in machine

tools, conveyor belts with coupling gears, the transmission requires a
start-up devoid of sharp blows.
All these conditions refer to the need to resort to the use of starting
systems able to contain the starting current (in this regard, remember
that the value of the starting current is independent of the fact that the
motor is powered by vacuum or underload).
The table below summarizes the means to limit the starting current in
three-phase induction motors, bearing in mind that the ones which
have a cage rotor should be distinguished from the ones with a wound
rotor.
Starting three-phase induction motors

CAGE ROTOR WOUND ROTOR
Double cage Grading with continuity
Caution to be taken in the design stage, Linear disconnection of the starting
which concerns the magnetic circuit of rheostat (located in series with the winding
the motor. rotor).
Star - Delta start-up

Grading with steps
Soft resistance start-up (or inductive Cyclic disconnection of portions of the
reactance) starting rheostat (located in series with the
winding rotor).
Automatic transformer starting
device
STAR - DELTA STARTER STARTING DEVICE

The complete electrical system of the power, control and signalling
circuit related to the starting device is shown in Figure 13.2. The
starter should be applied to three-phase cage rotor induction motors
having the connection voltage of the delta stator winding equal to that
of the power line. If the voltage line is 400 V, you must use motors
equipped for voltage equivalent to 400/690 V.
The power circuit is characterized by contactors identified by the

letters - Q1 (line) - Q3 (star) and - Q4 (triangle). Of these contactors,
the Q1 (line) is equipped with a protection device against overload.
The choice of the thermal relay or motor protector should, in contrast
to what has been established in the previous exercises, not only be
made exclusively in relation to the nominal current of the motor but in
synergy with the insertion point of the sensitive elements of the
thermal.
- 78 -
As seen in Figure 13.1, the thermal relay inserted upstream of the

connection delta concerns the current line IL, while if it is inserted
between the phases, it is sized according to the current of the phase IF,
which is smaller than the corresponding value of the line (current of
phase IF = IL / 3).
Figure 13.1 At the same nominal power of the electric motor, the
choice of current of the thermal relay should be made in relation to
the insertion point in the power circuit.
In the start-up phase, the motor starts with the stator winding
connected to the star; after the time necessary to reach nearly 70% of
the nominal rotation speed, the star connection opens (contactor Q3)
and the delta closes (contactor Q4).
The star - delta starting device is equivalent, in the start-up phase, to
the supply of the motor with a voltage lower than the nominal value,
so if a starting torque greater than 1/3 of the nominal value is required
(departure load), you must resort to using other starting systems.
- 79 -
Figure 13.2 Star-Delta starting device
- 80 -
OPERATING MODE
Particular attention should be paid to the connection of the stator
winding of the motor; note that the correspondence of the phases must
be respected since, otherwise, the operation of the motor with a delta
connection may be defective.
The motor terminal board normally shows the start and end windings
of the electrical connections by the three pairs of letters U1-U2, V1-
V2, W1-W2.

It should be noted that the pair of contactors Q1 - Q2 and Q3 - Q4

are mechanically interlocked with each other; for this reason the
contactor Q1 is the line, while Q3 - Q4 are respectively the star -
delta, Q2 is not used.


DO IT YOURSELF
With an ammeter or current tongs for alternating currents, measure
and record the currents circulating the line (in the motor protector) and
U1 V1 W1 terminals of the motor in order to establish the relationship
between the two currents. The case of insertion of the protective
device in the line or motor terminals. Review figure 13.1.
- 81 -
EXERCISE 14 Soft resistance starting device
EXERCISE 14 Stator resistance starting device
AIM
signalling circuit attributed to the starting of a three-phase cage
induction motor with resistance in series to the stator. The system
must be completed with a signalling circuit that indicates:
- motor in starting / started phase,
MATERIAL REQUIRED
1 Three-phase cage induction motor mod. M-4/EV or P-4/EV, if
available.
1 Divisible three-phase rheostat into at least two parts or two triads of
resistance, if available.

DISCUSSION
Refer to what is listed in "discussion" of exercise 13.
STATOR RESISTANCE START-UP

Three variants of the complete electrical system of the power, control
and signalling circuit related to the motor starter stator device with
two steps are shown in figures 14.1, 14.2 and 14.3. The starter in
question applies to three-phase induction motors with cage rotors that
do not have operating voltages compatible with the star - delta starting
device. Therefore, apply resistance or inductance in series with the
winding to reduce the starting current.
Compared with the star - delta starting device, starting with stator
resistance or inductance always has a reduced starting torque but
allows you to split the said start-up into more steps; a softer starting.
In the past, the choice of the number of starting steps was on the basis
of cost - benefit; today, this concept has been taken over by electronic
- 82 -
devices (inverter) that not only realize the start-up with reduced
currents but they also allow you to adjust the starting speed and
torque.
In the start-up phase, the motor starts with the stator winding
connected in series with the two groups of resistors; after the time
necessary to reach approximately 50% of the nominal rotation speed,
the first group of resistors is placed in short circuit, the motor
accelerates further and after more time needed to get to about 80% of
speed, all resistances are placed in short circuit; starting finished,
resistors excluded; (every start-up results in wasted energy dissipated
on the resistors).
OPERATING MODE
It should be noted that the contactors Q1 - Q2 and Q3 - Q4 are

mechanically interlocked with each other; this explains why the
contactor Q1 is the line while the mechanical interlock for Q3 - Q4
should be removed, which, at least in the first variant presented,
must be activated simultaneously.


DO IT YOURSELF
With an ammeter or current tongs for alternating currents, measure the
currents circulating the line (in the motor protector) during the start-up
phase.
- 83 -
Figure 14.1 Start-up with two steps with stator resistance. Variant 1.
At the end of the start-up, the three contactors Q1, Q2 and Q3 must remain active.
- 84 -
Figure 14.2 Start-up with two steps with stator resistance. 2A Solution
At the end of the start-up, contactors Q1-Q3 must remain active.
- 85 -
Figure 14.3 Start-up with two steps with stator resistance. Variant 3.
At the end of the start-up, the Q3 contactor must remain active.
- 86 -
EXERCISE 15 Automatic starter exchange
EXERCISE 15 Autotransformer start-up
AIM
signalling circuit attributed to the start-up of a three-phase cage
induction motor with an autotransformer. The system must be
completed with a signalling circuit that indicates:
MATERIAL REQUIRED
available.
1 Three-phase autotransformer for start-up motor M-4 or P-4, if
available.

DISCUSSION
Refer to what is listed in ''discussion'' of exercise 13.
AUTOTRANSFORMER START-UP
circuit related to the three-phase cage induction motor starter 0.3-1
kW, by way of an autotransformer is shown in Figure 15.1. The
starter is to be applied to three-phase induction motors with cage
rotors that do not have working voltages compatible with the star -
delta starting device and eliminates much of the energy dissipated at
the beginning of the start-up with stator resistances. Therefore, use a
three-phase autotransformer to reduce the voltage and thus the starting
current of the motor.
Compared with the star - delta start-up device, the start-up via an
autotransformer always has a reduced starting torque but allows you to
split the said start-up into two steps; a softer start-up equivalent to a
start-up in two steps with stator resistances or inductances.
- 87 -
This type of start-up has also been taken over by electronic devices
(inverters) that not only realize the start-up with reduced currents but
they also allow you to adjust the starting speed and torque.
POWER CIRCUIT
The power line must be connected to terminals L1-L2-L3, which is
lead, through the motor protector, to the main contacts of the contactor
Q1 (terminals 1-3-5); the three-phase autotransformer T2, connected
to the star device via the closure of contactor Q4 is connected to
terminals 2-4-6.
In the start-up phase, by activating Q4 and Q1, the motor starts with
the stator winding supplied from reduced voltage from the
autotransformer, after the time necessary to reach approximately 50%
of the nominal rotation speed, the star centre of the autotransformer
opens by de-energizing Q4, the motor accelerates further and only
finds in series three inductances (portion of the winding
autotransformer), after more time needed to get to about 80% of the
speed, the 3 inductors have short-circuited through the insertion of
contactor Q3. The start-up phase has ended.
CONTROL CIRCUIT
The auxiliary or control circuit is fed to the alternating voltage of 24V
supplied by the transformer T1, protected from the secondary side of
the device F3.
The operation of the circuit is as follows: by pressing the S2 switch
button, the contactor Q4, which predisposes the star connection of the
autotransformer, is activated. The Q4 contactor, through its contact
13-14 supplies the contactor line Q1, which allows the motor to start
at a reduced voltage supplied by the autotransformer. The Q1
contactor powers itself via its contact 13-14 and keeps the Q4
contactor and K1, K2 timers supplied.
After the time needed, first starting phase, set in the timer K1, through
its contact 16-15, the Q4 contactor is disconnected, which opens the
star centre of the autotransformer T2 and allows the motor M1 in
series with the winding of T2 a second acceleration phase.
After some time, the second start-up phase, set in the timer K2
through its contact 18-15, the contactor Q3 is activated since the
contact 21-22 of Q4 closed; Q3 shorts-circuits the portion of the
autotransformer winding T2 in series with the motor M1 exhausting
the start phase.
The closed contacts 21-22 of Q3 in series with the coil of Q4 and 21-
22 of Q4 in series with the coil of Q3 form the electrical interlock able
to exclude the short circuit on the motor power line.
- 88 -
Stopping the motor is always guaranteed by pressing the stop button

S1 or by the intervention of the thermal protection via contact 95-96
of F1.
SIGNAL CIRCUIT
a) the one inserted into the lamp socket P1 is there to show the
operator that the action carried out on the start button has activated the
start-up transitory phase in reduced voltage.
b) the one inserted into the lamp socket P2 is there to show the
operator that the start-up phase has ended and the motor M1 is
supplied at nominal voltage.
c) the one inserted into the lamp socket P3 is there to show the
operator that the thermal protection has intervened.
In rest mode, all three lamps are off.
The start-up indicated by the lamp P1 is obtained by supplying the
lamp with the contact 43-44 of Q1 activated in series to non-activated
contact 31-32 of Q3.
The activation of contact 13-14 of Q3 powers the lamp that signals the
end of the start-up phase.
The anomaly in the operation of the motor is obtained by closing
contact 97-98 of the motor protector F1, which supplies the red lamp.
OPERATING MODE
Remember that contactors Q3 - Q4 are, and may be, mechanically

interlocked between each other.


- 89 -
Figure 15.1 Autotransformer start-up
- 90 -
EXERCISE 16 Rotor-resistance starter with a continuous variable-frequency disconnection
EXERCISE 16 Rotor-resistance starting device

Continuous change disconnection
AIM
signalling circuit attributed to the starting of a three-phase induction
motor with a wound rotor. The disconnection of resistance is linear,
interlocked by a cage induction motor. The system must be completed
with a signalling circuit that indicates:
MATERIAL REQUIRED
available.
1 Rheostat motorized for the start-up of a continuously variable rotor,
if available.

DISCUSSION
ROTOR-RESISTANCE STARTING DEVICE WITH A CONTINUOUS VARIABLE-

FREQUENCY DISCONNECTION
When the start-up is particularly difficult, use induction motors that
have a rotor that has proper windings, which refer to three slip ring
terminals. The motor, when starting, can be regarded as a transformer
whose secondary circuit is constituted by the rotor windings.
If in series with the rotor windings, suitable value resistances are
connected, the value of the current flowing in the rotor windings,
when the motor is supplied from nominal voltage, depends exactly on
the value of the resistors inserted.
Similarly, the stator will obtain a limit of the current absorbed from
the supply power line.
- 91 -
A starter rotor for an induction motor with a wound rotor is

constituted by one or more groups of resistors connected to the rotor
windings, which, during the starting phase, are excluded manually or
automatically by means of contactors or by a servomotor.
This type of start-up, which as mentioned is only used with induction
motors with a wound rotor, allows you to obtain specific values of
engine torque or, if necessary, limit the starting current; this
possibility to control is done by appropriately adjusting the inserted
resistance value on the rotor.
With this type of motor, stator windings are connected to the supply
line while the rotor windings are connected to a group of resistors.
The basic components to realize a start-up rotor are:
• a line contactor with its motor protector or thermal relay having the
function to connect the motor to the power supply system;
• a three-phase rheostat connected to the rotor windings of the motor;
• a servomotor required to move the three-phase rheostat cursor
connected to the rotor windings of the motor.
Advantages: a progressive start and at par with the torque allows to
absorb a starting current inferior to the other types of start-up.
Disadvantages: the cost of this type of motor is higher than three-
phase cage induction motors; moreover, it requires maintenance to the
slip rings and their brushes.
Use: this start is used for heavy, long and frequent start-ups such as
lifts, cranes and lifting devices in general.
This type of start-up has also been taken over by electronic devices
(inverters) that not only realize the start-up with reduced currents but
they also allow you to adjust the starting speed and torque.
POWER CIRCUIT
lead, through the motor protector, to the main contacts of the contactor
Q1 (terminals 1-3-5); downstream, (terminals 2-4-6) the stator
winding of motor M1 is connected. The rotor winding of motor M1 is
to be connected to three-phase rheostat R1 controlled by servomotor
M2.
In the start-up phase, the rheostat has the highest resistance inserted;
by activating Q1, the motor starts with the stator winding supplied by
the nominal network voltage, but it absorbs a reduced current thanks
to the resistor inserted in the rotor circuit.
The servomotor M2 is supplied through the Q3, which takes care of
gradually disconnecting the starting rheostat as the M1 motor slowly
accelerates and reaches its rated speed.
The servomotor is disconnected at the complete switching off of the
starting rheostat by means of a limit switch.
When the engine is stopped, the M2 servomotor is activated once
again through the Q4 contactor, which, rotating in the opposite
direction, restores the R1 three-phase rheostat on the maximum ohmic
value in series with the winding rotor of the main motor M1.
- 92 -
CONTROL CIRCUIT
supplied by the transformer T1, protected against overloads from the
secondary side of the device F3.
By pressing the S2 start button (the B1 limit switch is closed since the
R1 rheostat resistance is maximum), the Q1 contactor is activated,
which powers the stator of the main motor M1. The contactor Q1,
through its contact 43-44 powers the contactor Q3 that allows the
activation of the servomotor M2 for the gradual phasing-out of the
starting rheostat inserted on the winding rotor of motor M1.
The contactor Q1 powers itself via its contact 13-14 and keeps the
contactor Q3 powered until the B2 limit switch is activated (it is
activated once the resistance of the rheostat is completely switched
off), which de-energizes the Q3 and concludes the start-up phase.
S1 or by the intervention of the thermal protection via contacts 95-96
of F1 and F2. Once the stopping phase has completed and in order to
prepare a new start-up, if the resistance of the rheostat is not at its
maximum value, the Q4 contactor is activated, which, powering the
servomotor with reverse rotation, it restores resistance of the R1
rheostat to its maximum value.
The closed contacts 21-22 of Q4 in series with the coil of Q3 and 21-
22 of Q3 in series with the coil of Q4 form an electrical interlock able
to disconnect the short circuit on the servomotor start-up line.
SIGNAL CIRCUIT
a) lamp P1, which is there to show the operator that the action carried
out on the start button has activated the start-up transitory phase
in reduced voltage.
b) lamp P2, which is there to show the operator that the start-up phase
has finished and that the M1 motor, supplied by the nominal
voltage, does not have any resistance inserted in the rotor circuit.
c) lamp P3, which is there to show the operator that the thermal
protector of the main motor, or the servomotor, has intervened.
In rest mode, all the lamps are off.
OPERATING MODE
Remember that contactors Q3 - Q4 are, and may be, mechanically

- 93 -


- 94 -
Figure 16.1 Rotor-resistance starting device with a continuous variable-frequency

disconnection.
- 95 -
In the case (which is common) where the limit switch automation

control (stroke control of the motorized rheostat) has an exchange
contact, the diagram in Figure 16.1 is not directly applicable; it is
necessary to make a change to the control diagram.
The diagram in Figure 16.2 shows, only for the control circuit, a
solution that allows the use of limit switches with contact exchange.
The teacher and students are asked to analyse the wiring diagrams
given and find other solutions such as interfacing the limit switch
contact with an auxiliary relay with multiple contacts in exchange
and/or NO/NC.
Figure 16.2 Variation of the starter control circuit via rotor resistors having a continuously
variable disconnection.
- 96 -
Exercise 17 Rotor-resistance starter, graded disconnection
EXERCISE 17 Rotor-resistance starting device

Step variation disconnection
AIM
signalling circuit attributed to the starting of a three-phase induction
motor with a wound rotor. The start-up is carried out with the timed
disconnection of two groups of resistors. The system must be
- static motor,
MATERIAL REQUIRED
available.
1 R1 wheel loader resistors dedicated to the slip-ring motor to start
1 R2 wheel loader resistors dedicated to the slip-rig motor to start

DISCUSSION
ROTOR-RESISTANCE STARTING DEVICE; GRADED DISCONNECTION

When the start-up is particularly difficult, use induction motors that
have a rotor that has proper windings, which refer to three slip ring
terminals. The motor, when starting, can be regarded as a transformer
whose secondary circuit is constituted by the rotor windings.
If in series with the rotor windings, suitable value resistances are
connected, the value of the current flowing in the rotor windings,
when the motor is supplied from nominal voltage, depends exactly on
the value of the resistors inserted.
Similarly, the stator will obtain a limit of the current absorbed from
the supply power line.
A starter rotor for an induction motor with wound rotor is constituted
by one or more groups of resistors connected to the rotor windings,
- 97 -
which, during the starting phase are excluded manually or

automatically by means of contactors.
This type of start-up, which as previously mentioned, is only used
with induction motors with a wound rotor, allows you to obtain
specific values of engine torque or, if necessary, limit the starting
current; this possibility of control is done by appropriately adjusting
the inserted resistance value on the rotor.
With this type of motor, stator windings are connected to the supply
line while the rotor windings are connected to a group of resistors.
The basic components to realize a start-up rotor are:
• a line contactor with its motor protector having the function to
connect the motor to the power supply system;
• one or more groups of resistance connected to the rotor windings
of the motor;
• the same number of contactors required to disconnect the
resistance groups.
Advantages: a progressive start and at par with the torque allows to
absorb a starting current inferior to the other types of start-up.
Disadvantages: the cost of this type of motor is higher than three-
phase cage induction motors; moreover, it requires maintenance to the
slip rings and their brushes.
Use: this start is used for heavy, long and frequent start-ups such as
lifts, cranes and lifting devices in general.
circuit related to the three-phase induction motor with wound rotor is
shown in Figure 17.1.
POWER CIRCUIT
lead, through the protection device (thermal magnetic motor
protector), to the main contacts of the line contactor Q1 (terminals 1-
3-5); downstream, the stator winding of motor M1 is connected. The
rotor winding of the motor M1 is connected to two sets of three
resistors, R1, R2, placed in series between each other.
In the start-up phase, with the highest resistance inserted (R1 + R2),
activating Q1, the motor starts with the stator winding supplied by the
nominal network voltage, but it absorbs a reduced current thanks to
the resistors inserted in the rotor circuit.
The motor accelerates and gradually reduces its power consumption;
after an interval set by the K1 timer, the contactor Q4 is activated,
which short circuits the triad of resistors R2. The resistance in series
with the rotor is reduced to value R1 and, consequently, a new
acceleration phase for the rotor starts. After the time set by the timer
T2, the triad of resistors R1 placed in the rotor short circuit, are also
short-circuited. At this point, having exhausted the last acceleration,
the start-up phase can be considered concluded.
When the engine stops by de-energizing the contactor Q1, contactors
Q4 and Q3 are de-energized thus restoring, in series with the rotor
winding of the slip ring motor M1, the R1 and R2 resistors.
- 98 -
CONTROL CIRCUIT
supplied by transformer T1, secondarily protected by the F3 device.
By pressing the start button S2, the contactor Q1 is activated, which
supplies the stator of the main motor M1.
The Q1 contactor powers itself via its contact 13-14 and keeps the K1
timer supplied.
The timer K1, after the set time, closes its contact 15-18 and activates
the Q4 contactor, which disconnects the triad of resistors R2 by short
circuiting them; moreover, contactor Q4 supplies the K2 timer via its
auxiliary contact 13-14.
The K2 timer, after the set time, closes its contact 15-18 and activates
the Q3 contactor, which also disconnects the triad of resistors R1 by
short circuiting them. After the final acceleration, the start-up phase
may be considered concluded.
of F1.
SIGNAL CIRCUIT
a) lamp P1, which has the purpose of indicating to the operator that
the motor M1 is static,
b) lamp P2, which has the purpose of indicating to the operator that
the motor is in motion, start-up phase and/or starting concluded,
c) lamp P3, which has purpose of indicating to the operator of any
possible intervention of the protection device against overload.
- 99 -
Figure 17.1 Rotor-resistance starting device, graded disconnection
- 100 -
OPERATING MODE
Remember that contactors Q3 - Q4 are mechanically interlocked

with each other and the interlock must be removed or:
change the control circuit in such a way that Q4 is released once Q3 is
activated. (do it yourself)
Having realised the plant and before connecting it to the power


DO IT YOURSELF
Even though it is not directly implementable on the panel, for lack of a
third timer, redraw the electrical power and control diagram in order
to obtain a start-up in three steps.
- 101 -
EXERCISE 18 Remote motor reversing switch; star/delta starter
AIM
signalling circuit attributed to the starting of a star - delta three-phase
cage induction motor in two directions. The system must be
- static motor,
MATERIAL REQUIRED
1 Three-phase cage induction motor mod. M-4A/EV or P-4A/EV, if
available. Note: with voltage networks equivalent to 380-400 V,
you need a winding motor for voltage 660-690 / 380-400 V.

DISCUSSION
STAR - DELTA REMOTE MOTOR REVERSING STARTER

It involves joining into a single circuit all that you have acquired in
exercises 6, 7 and 8 regarding the remote motor reversing switch and
exercise 13 regarding the star - delta start-up to which you can refer
to.
POWER CIRCUIT
lead, through the motor protector, to the main contacts of contactors
Q1 and Q2 (terminals 1-3-5); downstream of the said contactor
(terminals 2-4-6), the beginning of the stator winding of motor M1
(terminals U1-V1-W1) is connected. The end of the stator windings of
motor M1 (terminals U2-V2-W2) are connected via contactor Q3,
downstream of the line contactors Q1 and Q2 via a star connection.
- 102 -
Contactor Q4, by short-circuiting the end of the stator windings,

realizes connection of the motor to star.
In the start-up phase, with clockwise rotation through Q1, or inverse
rotation through Q2, the motor starts with the stator winding
connected to the star via the insertion of Q4; after the time necessary
to reach about 70% of the nominal rotation speed, the star connection
opens (contactor Q4) and the delta closes (contactor Q3).
Particular attention should be paid to the connection of the stator
winding of the motor; note that the correspondence of the phases must
be respected since, otherwise, the operation of the motor with a delta
connection may be defective.
CONTROL CIRCUIT
the device F3.
By pressing the start button S2, the main line contactor Q1 is
activated, which supplies the stator of the main motor M1.
The contactor Q1 powers itself via its contact 13-14. Through a
second auxiliary contact 43-44, the K1 timer coil and the Q4 contactor
(connected to star) are supplied, the motor starts with clockwise
rotation.
After the starting time, introduced into the timer K1, the contact 15-16
of K1 opens and de-energizes the contactor coil Q4 causing the
closure of its contact NO 21-22; simultaneously, through the contact
15-18 of K1, the excitation of contactor coil Q3 is obtained, which
completes the start-up phase thus connecting the M1 motor to delta.
After the final acceleration, the start-up phase may be considered
concluded.
Contacts 21-22 of Q3 in series to the coil Q4 and Q4 in series with the
Q3 coil form an electrical interlock between the contactors in order to
prevent a short circuit to the supply line.
To activate the motor switch with anti-clockwise rotation, which is not
enough to press the anti-clockwise switch gear S3, you have to pass
through the stop phase via the S1 button since the two line contactors
Q1 and Q2 are electrically interlocked through their respective closed
contacts 21-22.
Now, with button S4, you can activate the anti-clockwise rotation
switch, contactor Q2 powers itself through its contact 13-14, through
contact 43-44 the temporary phase of star connection (K1 and Q4) and
the star connection (Q3) are reactivated.
You can avoid short circuiting the line by contactors Q1 and Q2,
which appear to be electrically interlocked, through their contacts NC
21-22.
of F4.
- 103 -
SIGNAL CIRCUIT
As a well-established practice, it is necessary in all those cases in
which it is impossible to directly verify the result of the operation
carried out on the control devices.
a) the aim of lamp P2 is to show the operator that the motor is
powered and is turning clockwise.
b) the aim of lamp P4 is to show the operator that the motor is
powered by an inverted line and is turning anti-clockwise.
c) the aim of lamp P3 is to show the operator that the thermal
protection of the main motor M1 has intervened.
OPERATING MODE
Remember that contactors Q1 - Q2 and Q3 are, or may be,

mechanically interlocked between each other.


- 104 -
Figure 18.1 Remote motor reversing switch; star-delta starter.
- 105 -
EXERCISE 19 Motor remote control switch for dual windings
AIM
signalling circuit attributed to a three-phase cage induction motor with
two separate windings. The system must be completed with a
signalling circuit that indicates:
- static motor,
- motor started in first speed
- motor started in second speed
- protection interventions against overloads.
MATERIAL REQUIRED
1 Three-phase cage induction motor with two speeds, two separate
windings mod. M-7/EV or P-7/EV, if available.

DISCUSSION
The three-phase induction motor is characterized by a practically
constant rotation speed, which is variable within certain limits
depending on the importance of the load applied to its rotor and
slightly lower than the speed of the rotating field.
The substantially constant speed is close to that of the rotating
magnetic field (no), whose value is determined by the relation between
the supply frequency (f) and the number of pole couples (p);
n0 = 60 f /p
this means that in order to change the speed with continuity, you need
to change the frequency of supply power, even though the change of
frequency alone would alter the point of operation of the magnetic
circuit of the motor and also its characteristics.
Therefore, if you reduce the frequency in order to avoid magnetic
saturation, you need to proportionally reduce the supply voltage; the
opposite should be done if you increase the frequency.
- 106 -
Ignoring the secondary effects, the adjustment of the speed of an

induction motor must be carried out with a power supply that has a
characteristic voltage/frequency (constant V/f), a technique that is
mainly used in activations. If it is sufficient to vary the speed
between two or three fixed values at maximum speed, then the
solution most widely used in the type with a short-circuited rotor is the
switching of poles, while for the type with a wound rotor, a rheostat
inserted onto the rotor windings is normally used.
The speed variation, obtained by pole switching, finds its theoretical
foundation in the report shown above, in which one can see how the
speed depends on the number of poles and is generally used with
three-phase induction motors with a short circuit rotor.
In practice, it is sufficient to connect the stator windings relative to
either poles to the power supply line.
Manufacturers supply the market with two types of engines with more
poles: the type with two separate windings, or the type with a single
winding with connections according to the Dahlander diagram.
POLARITY MOTOR REMOTE CONTROL SWITCH FOR DUAL WINDINGS

The polarity remote control switch for two motor windings, generally
use a squirrel cage motor with two independent three-phase windings
inserted in the stator with a star connection; this allows a rather varied
relationship between the two speeds, for example 1:2 , 1:3, 1:4, etc..
The commonly commercialized standard speeds, are:

2 poles 3000 rounds/min.
Switching velocity may also be carried out when the motor is in gear.
For stator windings with slightly different currents between them, the
system can be protected by a single device against overcurrent and
overload.
POWER CIRCUIT
The power supply line must be connected to terminals L1-L2-L3,
which leads, through the motor protector, to the main contacts of
contactor lines Q1 and Q2 (terminals 1-3-5).
The first stator winding of motor M1 (terminals coded 1U - 1V - 1W)
is connected downstream of contactor Q1 (terminals 2-4-6).
The second stator winding of motor M1 (terminals coded 2U - 2V -
2W) is connected downstream of contactor Q2 (terminals 2-4-6).
The system is structured so that it can supply only one winding at a
time, therefore, the electrical interlocks between contactors Q1 and Q2
must be provided for in the auxiliary circuit; the best solution is to use
contactors also equipped with a mechanical interlock.
- 107 -
By activating contactor Q1, the motor turns in slow gear; activating

contactor Q2, the motor turns in fast gear. The passage between slow
and high speed, or vice-versa, must pass through a stop phase.
CONTROL CIRCUIT
the device F3.
By pressing button S2, slow gear, contactor Q1, which activates the
first stator winding of motor M1 relative to slow speed of rotation, is
activated. The contactor Q1 powers itself via its contact 13-14.
A similar operation occurs by pressing the S4 button, fast gear, which
activates the line contactor Q2 that supplies the second stator winding
of the motor M1, relative to the high speed of rotation. The contactor
Q2 powers itself via its contact 13-14.
The contacts 21-22, of Q1 in series with the Q2 coil of 21-22 in series
with the Q1 coil, form an electrical interlock between the contactors in
order to prevent the possibility that both the stator windings of the
motor are supplied simultaneously.
To activate the motor's speed change, which is not enough to press the
corresponding gear switch, you first have to pass through the stop
phase via the S1 stop button since the two contactors Q1 and Q2 are
electrically interlocked through their respective closed contacts 21-22.
of F1.
SIGNAL CIRCUIT
powered and is turning at low speed.
powered and is turning at high speed.
- 108 -
OPERATING MODE
Remember that contactors Q1 - Q4 are, or may be, mechanically



DO IT YOURSELF
In order to avoid the machine from stopping during the passage from
low and high speed or between high and low speed, change the
auxiliary circuit control.
Let's assume the case of an engine with very different nominal powers
between the high and low speeds, for example 2 poles and 8 poles,
change the power and control circuit and insert a motor protector with
appropriate currents for each winding.
- 109 -
Figure 19.1 Polarity motor remote control switch for two separate windings.
- 110 -
EXERCISE 20 Motor remote control switch for single winding (Dahlander)
EXERCISE 20 Polarity motor remote control switch for a single winding

(Dahlander)
AIM
signalling circuit attributed to a three-phase 2-speed cage induction
motor with one Dahlander winding. The system must be completed
- static motor,
- motor started in first speed
- motor started in second speed
MATERIAL REQUIRED
1 Three-phase cage induction motor with two speeds, one Dahlander
winding mod. M-6/EV or P-6/EV, if available.

DISCUSSION
The polarity motor remote control switch for a motor with a
Dahlander winding, generally use a squirrel cage type of motor with a
single three-phase winding, composed of six sections suitably
connected.
As shown in Figure 20.1, the six sections of the windings can be

connected in delta or double star, and thus obtain two rotation speeds
in the ratio 1:2.
In motors with a Dahlander winding, the greater number of poles
corresponds to the lower speed with the connection of the phases in
delta, while the lower number of poles corresponds to the higher speed
with the connection of the phases in double star.
Combining the number and type of the stator windings in a suitable
manner, it is possible to implement the following motor remote
control polarity switch:
• with one Dahlander winding to obtain two speeds;
• with two separate windings to obtain two speeds;
- 111 -
• with a Dahlander winding and a separate winding to obtain three

speeds;
• with two separate Dahlander windings to obtain four speeds;
The commonly commercialized standard speeds, are:
Figure 20.1 Stator windings connection of a Dahlander motor.
POWER CIRCUIT
The power supply line must be connected to terminals L1-L2-L3,
which leads, through the protection device, to the main contacts of
contactor lines Q1 and Q2 (terminals 1-3-5).
The stator winding of the motor is connected downstream of the two
contactors (terminals 2-4-6).
In order to obtain low speed of motor M1, you need to supply the
terminals coded 1U - 1V - 1W and terminals coded 2U - 2V - 2W
must remain open, see Fig. 20.1.
In order to obtain high speed of motor M1, you need to supply
terminals coded 2U - 2V - 2W and terminals coded 1U - 1V - 1W
must be placed in short circuit by Q3, review Fig. 20.1.
The system is structured so that it can supply the winding in only one
way at a time, or via a delta connection (low speed), or with a double
star connection (high speed), therefore, the electrical interlocking
between the line contactors Q1 and Q2 and the between the control
buttons must be provided for in the auxiliary circuit.
By activating contactor Q1, the motor runs at the first speed, low,
delta connection winding; activating contactor Q2 together with Q3,
the motor runs at the second speed, high, double star winding
connection.
The passage between slow and high speed, or vice-versa, passes
through the stop phase.
- 112 -
CONTROL CIRCUIT
supplied by transformer T1, secondarily protected by F3.
By pressing the slow gear button S2, the line contactor Q1, which
feeds the stator winding of motor M1 connected in delta, low rotation
speed, is activated.
The contactor Q1 powers itself via its contact 13-14.
Instead, if you press the fast gear button S4, the contactor Q3 is
activated, which closes the stator winding in short circuit at points 1U
- 1V - 1W that prepares the double star connection; Q3 through its
contact 13-14 allows the excitation of line contactor Q2, which
supplies the stator winding of motor M1 connected to double star,
high speed of rotation.
The contactor Q2 powers itself via its contact 13-14, also keeping Q3
powered.
The contacts 21-22, of Q1 in series with the Q2 coil and Q3 in series
with the Q1 coil, form an electrical interlock between the contactor
lines in order to prevent the possibility that both the stator windings of
the motor are supplied simultaneously.
To activate the motor's speed change, which is not enough to press the
corresponding gear switch, you first have to pass through the stop
phase via the S1 stop button since the two line contactors Q1 and Q2
are electrically interlocked through their respective closed contacts 21-
22.
of F1.
SIGNAL CIRCUIT
powered by a delta connection and is turning at low speed.
b) the aim of lamp P2 is to show the operator that the motor is
powered by a double star connection and is turning at high speed.
- 113 -
OPERATING MODE
Remember that contactors Q1 - Q2 and Q3 are, or may be,

mechanically interlocked between each other.


DO IT YOURSELF
In order to avoid the machine from stopping during the passage from
low and high speed or between high and low speed, change the
auxiliary circuit control.
- 114 -
Figure 20.2 Polarity motor remote control switch for single winding (Dahlander)
- 115 -
EXERCISE 21 Counter-current braking
AIM
signalling circuit attributed to the braking control of a three-phase
cage induction motor. The system must be completed with a signalling
circuit that indicates:
- static motor,
- motor started
MATERIAL REQUIRED
available.
1 braking relay, if available
1 three-phase rheostat limit action braking, if available

DISCUSSION
In a system that uses a three-phase induction motor, once the stop
button is activated, if no other type of braking system is available, the
rotor of the motor does not stop immediately but continues its motion
of inertia for a time that depends on the moment of inertia and the
braking torque due to friction and ventilation.
With many industrial applications you cannot wait until the
spontaneous stopping of the engine, but you need to brake in a shorter
time.
The ideal solution would be to build a motor linked to an electrical
brake, which frees the rotor at the same time in which the motor is set
into gear. If the motor does not have this device, the most common
braking systems can be obtained in counter-current or in direct
current.
Counter-current braking is the fastest and most powerful way to stop,
by way of the reversing gear, the motion of three-phase induction
motors.
- 116 -
For the proper performance of the brakes, the device that performs this
task must be accurately set, according to the power and the moment of
inertia of the motor; the brake can be timed.
It is clear that sudden reversal stops the rotation of the motor shaft and
carries out an abrupt and violent braking that can be softened with the
insertion of resistances in series to the stator.
Evidently, the intervention time of the "brake" remote control switch
must be contained to prevent the motor from inverting its direction.
To effectively control of the braking drive, you must resort to an
electromechanical relay (alnico relay) mechanically coupled to the
motor shaft or to any other shaft connected to it with a fixed ratio of
speed; it is required to prevent the motor from restarting in the
opposite direction: therefore, a contact intervenes in the clockwise
rotation of the shaft while another anti-clockwise, as shown in Fig.
21.1.
Contact switching determines the reversal of the motor via a pulse (in
fact, the said contact, re-opens immediately); the brevity prevents the
engine from starting in the reverse direction.
For the practical realization, therefore, you need to resort to the use of
a control device that determines the operation of auxiliary contacts in
opening and closing phases at different speeds; by way of example, it
is noted that: the increase in speed exceeding a few tens of rounds per
minute, the contacts of the control device are maintained in working
position, for lower speeds they assume a rest position.
Figure 21.1 Operation of Alnico relay contacts.
Two different solutions of counter-current braking are being proposed;

their close examination will allow you to judge the one that performs
best.
POWER CIRCUIT
It is the same for the two solutions proposed. To all intents and
purposes, it is a reversion of a three-phase induction motor, as in
exercise 6 to which you are referred for explanations.
The triad of resistance or variable rheostat consents a milder braking
action.
- 117 -
CONTROL AND SIGNALLING CIRCUIT

It is different for the two proposed solutions since the two methods are
different; only some insights are given since the concepts are the same
as seen in the previous exercises.
In the diagram of Figure 21.2, the K1 timer is used to determine the

braking action. Contactor Q3 is used as a memory to insert the brake,
after the action on the stop button S1, only when the motor is
effectively in operation.
In the diagram of Figure 21.3, a braking relay (alnico) is used to

determine the action of braking. Its Rf contact, which is open in rest
mode, closes when the rotation speed of the motor is greater than a
few dozen rounds a minute.
The action on the stop button S1 involves the release of contactor Q1
with the consequent stopping of the motor that immediately, via
contactor Q2 receives power exchanged with phases and is induced to
rotate in the opposite direction; it brakes suddenly until it reaches
approximately zero speed where the Rf contact opening releases the
braking action, preventing the restart in the opposite direction.
Use an electric limit switch of the panel (for example, B1) to replace
the alnico relay; press the limit switch at the moment when you start
the engine, keep this condition until, having carried out the halt, you
notice that the motor brakes and the speed is close to zero; at this
point, release the limit switch. What has just been carried out with the
limit switch is the exact operation of the contact with braking relay.
OPERATING MODE



- 118 -
Figure 21.2 Timed counter-current control braking
- 119 -
Figure 21.3 Alnico relay counter-current control braking.
- 120 -
EXERCISE 22 Direct current counter-current braking
AIM
signalling circuit attributed to the braking control of a three-phase
cage induction motor in direct current. The system must be completed
- static motor,
- motor started
MATERIAL REQUIRED
available.
1 Single-phase or three-phase rectifier bridge, if available.
1 Limit action braking rheostat, if available

DISCUSSION
Braking in direct current consists in supplying the stator with direct
current voltage of a value such as to create a fixed magnetic field in
the air gap, which causes a braking torque capable of stopping the
motor in a shorter time than that of a spontaneous arrest.
Direct current creates fixed magnetic poles that induce, in the rotor
cage, different currents such to oppose the cause that generated them
(Lenz's law); the cause of occurrence of these induced currents is the
rotation, and they oppose each other, thus determining a braking
action.
The braking action obtained is much softer than in counter-currents
and does not require any particular relay to avoid rotation of the motor
in the opposite direction. In any case, after stopping movement, you
must disconnect the direct current in the stator windings.
- 121 -
POWER CIRCUIT, CONTROL AND SIGNALLING CIRCUIT

No explanation is given since the circuits are similar to those used in
the timed counter-current braking.
OPERATING MODE



- 122 -
Figure 22.1 Direct current braking
- 123 -
EXERCISE 23 Two-hand control device
AIM
Realization of a circuit that impedes the starting of a machine or a
sequence in a productive cycle unless two contact buttons are pressed
simultaneously. The two buttons in question must obviously be
distant from each other in such a way as to prevent the operation from
being carried out with one hand; occupy both the operator's hands to
prevent him from keeping one in a dangerous place.
MATERIAL REQUIRED

DISCUSSION
The circuit has been proposed to "stimulate" the student, who,
together with the teacher, can start a discussion regarding the concept
of risk assessment of making automatic machines safe.
If the two buttons cannot be pressed within the shortest time set by the
K1 timer (set: mode = B, t = 0,5 s), the sequence will not start.
CONTROL CIRCUIT
Only the circuit control is given in the exercise, which is to be
understood as a "functional halt" to be included in the control circuit
of the machine.
OPERATING MODE
between the electrical devices using the panel layout shown in
appendix A; make a photocopy.
- 124 -
Figure 23.1 Two-hand control device
- 125 -
EXERCISE 24 Direct start-up of the motor with a manipulator switch
AIM
Realize the system attributed to the direct control of a three-phase
cage induction motor.
MATERIAL REQUIRED
available.

DISCUSSION
The cam switches, also called manipulators, are non-automatic control
devices that function by means of a mechanism able to rotate driven
by a control knob.
The contacts, double silver alloy, which refer to the connection
terminals, are activated by a cam, which converts the rotary motion of
the control knob into linear motion of the pawl.
The cam switches represent an economic solution, as switching
apparatus in auxiliary circuits, light circuits, measurement circuits, but
can also be used as switches for the control of electric motors, for
small and medium power up to 10 kW.
The manipulators do not have a high power of interruption, they must
be protected against short circuits by way of fuses or automatic
switches placed upstream.
Various tasks may be carried out, they work in different circuit
configurations; the most important ones are highlighted hereunder:
simple switch in unipolar, bipolar, three-pole, four-pole versions
line commutator in unipolar, bipolar, three-pole, four-pole versions.
switches for motors with the following functions: three-pole gear
inverter, star-delta starters, polarity switch, star-delta starters with
gear inverters, polarity commutators with gear inverters, gear
inverters for single-phase motors, etc..
- 126 -
MANIPULATOR SWITCH
The manipulator switch works as a direct control of a three-phase, or
single-phase, user when provision is made for direct manual insertion
of the electrical device to be powered.
POWER CIRCUIT
The power line must be connected to terminals L1-L2-L3 protected
against overloads and short circuits. The motor (or load) must be
connected downstream of the manipulator switch (terminals U-V-W).
The manipulator contacts are shown in Figure 24.1
When the control knob is in position 0 (zero), all its contacts are open
and, therefore, the motor is not supplied.
When the control knob is placed in position 1 (one), all its contacts are
closed and, therefore, the motor is supplied with direct connection.
The control auxiliary circuit is not necessary and no signalling circuit
is foreseen.
Figure 24.1 Manipulator switch: internal connection of the contacts.
OPERATING MODE
appendix A.

For this practical exercise, the reversing manipulator is used,

considering only positions 0 - 2.
- 127 -
Figure 24.2 Application of a manipulator switch.
- 128 -
EXERCISE 25 Dual motor command with manipulator switch
AIM
Realize a system referred to the direct control of two three-phase cage
induction motors, one alternative to the other.
MATERIAL REQUIRED
Three-phase cage induction motor mod. M-4/EV or P-4/EV, if
available.

diagram in Figure 25.2 or Figure 25.3.
MANIPULATOR SWITCH (VERSION 1)

The circuit used by the manipulator switch is suitable for the direct
control of two three-phase, or single-phase, electrical appliances when
a direct manual insertion (not simultaneously by one of the two) is
foreseen.
POWER CIRCUIT (VERSION 1)

against overloads and short circuits. A three-phase induction motor (or
an electrical load) is connected downstream of the manipulator switch
(terminals 1U-1V-1W), while the second three-phase induction motor
(or the second electrical load) is connected to terminals 2U-2V-2W.
The manipulator commutator contacts are shown in Figure 25.1
and, therefore, the motors / loads are not supplied.
When the control knob is in position 1 (anti-clockwise), the contacts
are closed between the line L1-L2-L3 and terminals 1U-1V-1W,
therefore, the first motor or load is supplied.
When the control knob is in position 2 (clockwise), the contacts are
closed between lines L1-L2-L3 and terminals 2U-2V-2W, therefore,
the second motor or load is supplied.
It is possible to power a three-phase induction motor with two
separate windings with the same manipulator and obtain a polarity
switch for a 2-speed motor.
- 129 -
Figure 25.1 Manipulator switch: internal connection of the contacts.
MANIPULATOR SWITCH (VERSION 2)

The circuit used by the manipulator switch is suitable for the direct
control of a three-phase, or single-phase, electrical appliance when a
direct manual insertion in two distinct sources of energy is foreseen.
POWER CIRCUIT (VERSION 2)

The power line must be connected to terminals 1U-1V-1W suitably
protected against overloads and short circuits.
The power supply line 2 must be connected to terminals 2U-2V-2W,
this should also be adequately protected against overcurrents.
The induction motor (or electrical load) must be connected to
terminals L1-L2-L3 of the manipulator switch.
and, therefore, the motor / load is not supplied.
therefore, the motor or load is supplied by line 1.
the motor or load is supplied via line 2.
Note: By using two energy sources with different frequencies, it is
possible to obtain two rotation speeds from the induction motor.
OPERATING MODE
appendix A.

- 130 -
Figure 25.2 Application of a manipulator switch (version 1).
Figure 25.3 Application of a manipulator switch (version 2).
- 131 -
EXERCISE 26 Forward/backward command of a motor with an inverter manipulator
EXERCISE 26 Forward/backward command of a motor with an

inverter manipulator
AIM
Realize the system attributed to the direct control, forward/backward
gear of a three-phase cage induction motor.
MATERIAL REQUIRED
available.

REVERSING GEAR MANIPULATOR

The reversing gear manipulator circuit is suitable for the direct
control of a three-phase electric appliance, electrical motor or load,
when it is necessary to control the direction of the cyclic phases.
A normal three-phase squirrel cage motor with direct winding is
powered in this exercise.
POWER CIRCUIT
against overloads and short circuits.
The three-phase motor is connected downstream of the reversing gear
manipulator (terminals U(W)-V-W(U)).
The reversing gear manipulator contacts are shown in Figure 26.1
When the reversing gear manipulator is in position 0 (zero), all its
contacts are open and, therefore, the motor is not supplied.
When the manipulator is placed in position 1, the motor is supplied by
direct connection and is activated by a direction of rotation.
When the manipulator is placed in position 2, the motor is supplied
with inverse connection and the direction of rotation changes.
The control auxiliary circuit is not necessary and no signalling circuit
is foreseen.
- 132 -
EXERCISE 26Forward/backward command of a motor with an inverter manipulator
Figure 26.1 Reversing gear manipulator: internal connection of the

contacts.
OPERATING MODE
appendix A.

Figure 26.2 Application of a reversing gear manipulator.
- 133 -
EXERCISE 27 Star/delta starting device with manipulator
AIM
Realize the system attributed to the control of a star/delta (Y/D) start-
up of a three-phase cage induction motor.
MATERIAL REQUIRED
Panel mod. C-IIC/EV
1 Three-phase cage induction motor mod. M-4A/EV, if available.
Note: the motor to be used must have suitable windings to the supply
power voltage with a delta connection. Or, rather, the nominal voltage
of the star connection must be 3 times greater than that of the power
supply line.
If you do not have a motor with voltage 690/400 V, you may use a
normal motor 400/230 V, however, the power supply line must be
3 x 220...230V!

STAR/DELTA MANIPULATOR STARTER

Cam switches are an economical solution for electrical motor controls,
for small and medium powers up to a little more than 10 kW.
The star/delta starter manipulator circuit is used for the direct manual
control of a three-phase motor with a manual control of the start-up
phase. A star delta starter switch may be simple or you can also
incorporate a reversing gear.
The problems with the star - delta starting system are those analysed
in Exercise N. 13 and are designed to reduce the starting current of the
motor during start-up.
POWER CIRCUIT
The power line must be connected to terminals L1-L2-L3 and suitably
protected against overloads and short circuits.
- 134 -
The beginning of the stator windings of the three-phase induction

motor are connected downstream of the Q6 manipulator, terminals
U1-V1-W1.
Also downstream of the manipulator, terminals U2-V2-W2, are the
end windings
For the Q6 manipulator contacts to perform the function of a star/delta
starter, in just one direction of rotation, are shown in Figure 27.1.
When the manipulator has the control knob in position 0, all its
contacts are open and, therefore, the motor is not supplied.
When the manipulator is rotated in star position (Y) (clockwise),
contacts L1-U1, L2-V1, L3-W1 appear to be closed, which allow
connection of the line to the beginning of the stator windings of the
motor, whilst contacts of terminals U2-V2-W2 are in short circuit
between each other and carry out a star connection of the end
windings.
The situation described is depicted in Figure 27.2.
clockwise), the contacts are still closed: L1-U1, L2-V1, L3-W1, which
allow connection of the line to the beginning of the stator windings of
the motor and also contacts L2-U2, L3-V2, L1-W2, which carry out
the delta connection of the end windings.
The situation described is depicted in Figure 27.3.
Figure 27.1 Star - delta starter manipulator: internal connection of the contacts.
- 135 -
Figure 27.2 Motor winding of a star connection.
Figure 27.3 Motor winding of a delta connection.
The Q6 manipulator contacts, to perform the function of a star/delta

starter in just one direction of rotation, are shown in Figure 27.4. The
switch function of the reverse gear direction (anti-clockwise rotation
of the control knob is similar but the cyclic direction of the triad three-
phase changes direction since the supply wires L2 and L3 have been
exchanged.
Figure 27-4 Manipulator switch - star/delta starter: internal connection of the contacts.
- 136 -
Figure 27.5 Application of a star/delta starter manipulator.
Nothing changes in the power supply line connections and the three-
phase induction motor if the star-delta manipulator starter is also a
start/delta inverter starter; there are still 9 connections to make. It is
only a different combination of internal contacts that determines that
the commutator also carries out the function of reversing the motor.
- 137 -
EXERCISE 28 Speed control of a three-phase induction motor with dual windings
EXERCISE 28 Speed control of a three-phase induction motor with dual

windings and commutator manipulator
AIM
Realize the system attributed to the direct control of a three-phase
cage induction motor with two separate windings.
MATERIAL REQUIRED
available.

COMMUTATOR MANIPULATOR FOR A MOTOR WITH 2 WINDINGS.

The commutator manipulator circuit is used for the direct control of a
three-phase motor with separate windings to obtain two rotation
speeds from the dahlander motor, where the ratio is still one double
the other; separate windings can be 2 - 6 pole or 2 - 8 pole.
POWER CIRCUIT
against overloads and short circuits. The three-phase induction motor
is connected downstream of the commutator manipulator (terminals
1U-1V-1W), whilst the second winding, always of the said three-
phase induction motor, is connected to terminals 2U-2V-2W.
and, therefore, the motor is static.
therefore, the first winding of the motor is supplied.
the second winding of the motor is supplied. This is how a polarity
commutator for a 2-speed motor with separate windings is obtained.
- 138 -
EXERCISE 28 Speed control of a three-phase induction motor with dual windings
Figure 28.1 Commutator manipulator for a motor with 2 windings: internal

connection of the contacts.
Figure 28.2 Application of a speed commutator manipulator for a motor with 2 separate
windings.
- 139 -
EXERCISE 29 Speed control of a Dahlander three-phase induction motor
EXERCISE 29 Speed-change control of a three-phase induction motor

with a Dahlander winding with a commutator manipulator
AIM
Realize the system attributed to the direct control to manage two
speeds of a three-phase cage induction motor with a delta/double star
(D/YY) Dahlander winding.
MATERIAL REQUIRED
1 Three-phase cage induction motor with a Dahlander winding mod.
M-6/EV or P-6/EV, if available.

SPEED COMMUTATOR MANIPULATOR

The speed commutator manipulator circuit is used for the direct
control of a three-phase motor when a direct manual connection of the
motor in low or high speed is foreseen.
A three-phase squirrel cage induction motor with a Dahlander closed
stator winding is supplied in this exercise.
POWER CIRCUIT
The power line, which is adequately protected against overloads and
short circuits, must be connected to terminals L1-L2-L3 of the Q7
manipulator.
The ends of the stator windings of the three-phase Dahlander motor, in
order to obtain low speed (defined connection D delta), are connected
downstream of the manipulator via terminals 1U-1V-1W.
Moreover, the intermediary points of the stator windings of the three-
phase Dahlander motor, in order to obtain high speed (when the
connection becomes YY double star), are connected downstream of
the manipulator via terminals 2U-2V-2W.
The Q1 manipulator contacts are shown in Figure 29.1
When the Q7 manipulator has the control knob in position 0 (zero), all
its contacts are open and, therefore, the motor is not supplied.
- 140 -
-clockwise),
contacts L1-1U, L2-1V, L3- 1W are closed. In this condition, the
motor, with
described is shown in Figure 29.2.
When the Q7 manipulator is rotated in position YY (clockwise),
contacts L1-2U, L2-2V, L3- 2W are closed and the previous contacts
1U-1V-1W are in short circuit with each other. In this condition, the
motor, with connection YY, functions at a higher speed; the situation
described is shown in Figure 29.3.
Figure 29.1 Speed commutator manipulator for a Dahlander motor with internal connection of
the contacts.
Figure 29.2 D connections of stator windings of a Dahlander motor.
- 141 -
Figure 29.3 YY connections of stator windings of a Dahlander motor.
Figure 29.4 Application of a speed commutator manipulator for a Dahlander motor.
- 142 -
ACTIVATE THE PANEL
ACTIVATE THE PANEL mod. C-IIC/EV
Two distinct sources of power supply are needed to power

the panel: as a source of power supply, use a single-phase
220- 230 V and Earth protection, frequency 50-60 Hz for
auxiliary services, a three-phase source of power supply 3 x
380-400 V with Neutral and Earth for power circuits. The
three-phase power supply is needed after testing the control
circuit to verify the correctness of the power circuits.
Realize power and control electrical connections without

power supplies.
For the functional description of the panel and the

characteristics of the devices, see the exercises of this
manual.
This panel also applies together with the panel testing of

industrial plants electronically interlocked mod. C-IIC/EV.
- 143 -
ACTIVATE THE PANEL
Elettronica Veneta S.p.A. EQUIPMENT MAINTENANCE SHEET
Panel mod. C-IIC/EV Number: All Construction date: from January

2013
Manufacturer: Elettronica Veneta S.p.A.

Address: Via Postumia n. 16 Motta di Livenza (TV) Italy
Servicing Department: At the head office of Elettronica Veneta
Reference documents: of use
We advise you to carry out periodic maintenance every four months.

In view of a normal school year, carry out two maintenance cycles that coincide with the start
of two four-month periods.
Should the equipment have also been used beyond the classical scholastic period, it is good to
carry out a third maintenance cycle to cover the remaining four-month period.
Control and maintenance programme

Operator
Object Verification Action
(date and
signature)
Cleaning Presence of dust. Remove with a soft dry ……………..
cloth.
……………..
Visual inspection Verify that the parts are Change the damaged or ……………..
of the electrical intact and fixed well to the removed parts. Tighten ……………..
parts panel. the loose parts.
Electrical General operation test. Report or change broken ……………..

operation Refer to the exercises in the devices.
……………..
manual.
Equipment Verify the integrity of the Change the cables that ……………..
fittings cables and 4mm plugs. are not according to
……………..
standard.
- 144 -
ACTIVATE THE PANEL
- 145 -
ADDENDUM A
Rotating machines 300-500 We, recommended accessories to complete

the panel
M-4/EV Three-phase cage induction motor 230/400 V - 500 W 2 poles.
M-4A/EV Three-phase cage induction motor 400/690 V - 500 W 2 poles.
M-5/EV Three-phase induction motor with wound rotor 230/400 V - 500 W 2 poles.
M-5A/EV Three-phase induction motor with wound rotor 400/690 V - 500 W 2 poles.
M-6/EV Three-phase cage "Dahlander" induction motor 400 V - 500-350 W 2-4 poles
M-7/EV Three-phase cage induction motor with two windings 400 V - 500-200 W 2-6 poles
M-8/EV Single-phase induction motor with condenser switch 230 V - 500 W 2 poles
RAC-1/EV Rheostat for a stator and rotor start-up 2 or more steps
MAR-1/EV Rheostat with three-phase servomotor for a linear rotor winding
RC3-9T Rheostat for a stator or rotor winding with 2 steps 3x(50 Ohm-500 W)
Sa-M/EV Three-phase automatic transformer for a three-phase motor start-up 500 W
C-IID/EV Panel for advanced industrial controls with PLC
VST-1/EV Inertial flywheel for “M” series motors.
The table below indicates motors and accessories that apply to the exercise.
MAR-1/EV
RAC-1/EV
VST-1/EV
Accessories
SA-M/EV
M-4A/EV
M-5A/EV
C-IID/EV
RC3-9T
M-4/EV
M-5/EV
M-6/EV
M-7/EV
M-8EV
Exercises
Three-phase remote control starter

X X *
Remote control reversing switch for a
three-phase motor X X *
Star-delta starter
X X *
Remote motor reversing switch,
star/delta starter X X *
Start-up by way of stator resistances
X X X X X X *
Automatic transformer starting device
X X X X *
Start-up by way of rotor resistances
X X X X *
Polarity motor remote control switch
for dual windings X *
for a Dahlander motor X *
Braking against the current of a three-
phase motor X X X X X X *
Sequential starting of three-phase
induction motors between these motors
Remote control starter for a single-
phase motor X *
Remote motor reversing switch for a
single-phase motor X *
( ) With regard to the inertial flywheel, we shall highlight the currents and time required
during the start-up phase. (*) The PLC of panel C-IID or other logic-based
programmable controllers (PLC with a relay exit) are directly applied on the panel.
Name: Class: Date:

ADDENDUM A LAYOUT OF THE PANEL
Rotating machines 1kW and accessories recommended to complete the

panel
P-4/EV Three-phase cage induction motor 230/400 V - 1000 W 2 poles.
P-4A/EV Three-phase cage induction motor 400/690 V - 1000 W 2 poles.
P-5/EV Three-phase induction motor with wound rotor 230/400 V - 1000 W 2 poles.
P-5A/EV Three-phase induction motor with wound rotor 400/690 V - 1000 W 2 poles.
P-6/EV Three-phase cage ''Dahlander'' induction motor 400 V - 1000-700 W 2-4 poles
P-7/EV Three-phase cage induction motor with two windings 400 V - 1000-400 W 2-6 poles
P-8EV Single-phase induction motor with condenser switch 230 V - 1000 W 2 poles
RAC-1/EV Rheostat for a stator and rotor start-up 2 or more steps
MAR-1/EV Rheostat with three-phase servomotor for a linear rotor winding
RC3-9T Rheostat for a stator or rotor winding with 2 steps 3x(50 Ohm-500 W)
SA-P/EV Three-phase automatic transformer for a three-phase motor start-up 1000 W
C-IID/EVPanel for advanced industrial controls with PLC
VST-2/EV Inertial flywheel for “P” series motors.
BP/EV Bedplate for coupling "P" series motors
The table below indicates motors and accessories that apply to the exercise.
MAR-1/EV
RAC-1/EV
VST-2/EV
Accessories
SA-P/EV
C-IID/EV
P-5A/EV
RC3-9T
P-4/EV
P-4/EV
P-5/EV
P-6/EV
P-7/EV
P-8/EV
BP/EV
Exercises
Three-phase remote control starter

X X *
Remote control reversing switch for a
three-phase motor X X *
Star-delta starter
X X *
Remote motor reversing switch,
star/delta starter X X *
Start-up by way of stator resistances
X X X X X *
Automatic transformer starting device
X X X *
Start-up by way of rotor resistances
X X X X X *
for dual windings X *
for a Dahlander motor X *
Braking against the current of a three-
phase motor X X X X X *
Sequential starting of three-phase
induction motors between these motors
Remote control starter for a single-
phase motor X *
Remote motor reversing switch for a
single-phase motor X *
( ) With regard to the inertial flywheel VST-2/EV, we shall highlight the currents and time
required during the start-up phase. To couple the inertial flywheel to a motor in series "P",
you need a coupling bedplate BP/EV.
(*) The PLC of panel C-IID or other logic-based programmable controllers (PLC with a
relay exit) are directly applied on the panel.
- 147 -

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ELECTRICAL ENGINEERING

© COPYRIGHT BY ELETTRONICA VENETA

Safety Regulations .................................................................................................................... 1

Panel description ..................................................................................................................... 3

Power engine systems ........................................................................................................... 17

Push buttons, socket lamps ..................................................................................................... 23

Safety observations ............................................................................................................... 24

Identification codes ................................................................................................................ 25

Exercise No. 1 Contactor command from a point .................................................................. 31

Exercise No. 2 Three-phase induction motor remote starter .................................................. 38

Exercise No. 3 Contactor command switch - stop and by impulses ....................................... 45

Exercise No. 4 A.C. Contactor coil supplied by direct current ............................................. 47

Exercise No. 5 Independent command of two contactors ..................................................... 50

Exercise No. 10 Electrical gate remote motor reversing switch ........................................... 66

Exercise No. 11 Single-phase induction motor starter .......................................................... 68

Exercise No. 12 Single-phase induction remote motor reversing switch ............................. 73

Exercise No. 13 Star-Delta starting device ........................................................................... 77

Exercise No. 14 Soft resistance starting device .................................................................... 82

Exercise No. 15 Automatic starter exchange ........................................................................ 87

Exercise No. 16 Rotor-resistance starting device

Exercise No. 17 Rotor-resistance starting device

Exercise No. 21 Counter-current braking ............................................................................ 116

Exercise No. 22 Direct current counter-current braking ...................................................... 121

Exercise No. 23 Two-hand control device .......................................................................... 124

Exercise No. 27 Star/delta starting device with manipulator ............................................... 134

Exercise No. 28 Speed control of a three-phase induction motor

Exercise No. 29 Speed control of a Dahlander windings three-phase induction motor

Activate the panel ................................................................................................................. 143

Addendum A Layout of the panel ........................................................................................ 145

Addendum B Accessories for the panel .............................................................................. 146

Read the instructions of this manual carefully as it provides important information

Keep this manual for any further reference.

C-IIC/EV panel layout.

F13-pole circuit breaker motor overload protection switch, In a

1 - 3 - 5 Three-phase input line terminals.

F23-pole circuit breaker motor overload protection switch, In a

1 - 3 - 5 Three-phase input line terminals.

Q1 - Q2 24 Vac 50-60 Hz coil contactors (terminals A1-A2), 3 main

1 - 3 - 5 Input power contact terminals.

Q3 - Q4 24 Vac 50-60 Hz contactor coils, 3 main contacts Ith 25 A

1 - 3 - 5 Input power contact terminals.

S5 E-stop push button, red mushroom-head switch having a diameter

11 - 12, 21 - 22 NC auxiliary contact terminals.

S1, S3 Red E-stop extended switch, complete with auxiliary contacts

S2, S4 green command push button, complete with auxiliary contacts

P1-P4 luminous engine block indicators having different coloured

X1 - X2 24 V power terminal indicator light

B1-B2 position limit switch with NO or NC contact, Ith 10 A.

B3 12 mm diameter inductive proximity sensor, activation distance

B4 18 mm capacitive proximity sensor, activation distance between 2

15Common NO / NC exchange contact terminals.

K1-K2 electronic timer, multi-voltage 24…230 Vac - 24…110 Vdc

A1 - A2 Coil time-switch terminals supplied in 24 Vac

REVERSING SWITCH (Q5) Three-pole manipulator In=16 A

L1 - L2 - L3 Input line terminals.

STAR DELTA REVERSING SWITCH (Q6) reverse control

L1 - L2 - L3 Input line terminals.

POLES CHANGING SWITCH (Q7) Delta double star three-phase

L1 - L2 - L3 Input line terminals.