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MODULE 1: INTRODUCTION TO THE COURSE

EMTC 127

LESSON 1: Introduction to Industrial Motor Control

LESSON 2: Impacts of Industrial Motor Control

LESSON 3: Basic Elements of Motor Control

LESSON 4: Motor Protection

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MODULE 1: INTRODUCTION TO THE COURSE

INTRODUCTION
This module aims to provide information about Industrial Motor Control. It
contains deeper understanding about the introduction of industrial motor control
and basic elements of motor control for greater familiarization of the topic. This
module is a consolidated information in which the safety work habits are discussed
and how could it help students to perform it in the present modernization. The
intent of this module is to familiarize the reader with the terms of concepts that are
fundamental to understanding the motor control equipment and its applications.

OBJECTIVES
 Recite the DMMMSU VMGP
 Able to follow the basic guidelines and procedures of electrical safety in
the workplace as well as the proper and safe handling of tools.
 Learners will be able to understand the technical aspects of motor
control.
 Able to familiarize the impacts of motor control in the industry.
 Have the wider understanding about motor protection.
 Able to state the general principles of motor control
 Able to enumerate and discuss the different components of motor
control.

DIRECTIONS
The module contains four (4) lessons. Read carefully the different topics given
in this module. Understand each process if there are, carefully study the electrical
safety rules, basic elements of motor control, impacts of industrial motor control
and motor protection. Answer carefully the given exercises at the end of the
discussion.

If there are something that is hard for a student to understand, you may ask
questions to the faculty. Inquiries and clarification will be given for greater learning
development.
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MODULE 1: INTRODUCTION TO THE COURSE

LESSON 1

Introduction to Industrial Motor Control

What is Industrial Motor Control?

Industrial Motor Control in the broadest sense of the term encompasses the
different methods used to control an electrical system’s performance. With
reference to machinery, it involves the start-up, acceleration, deceleration,
reversal and stopping of the motor and the applied load.

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

PRINCIPLES OF MOTOR CONTROL

Figure 1: Principles of Motor Control

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MOTOR CONTROL CIRCUITS

Motor control circuits are an effective way to reduce cost by using smaller
wire and reduced-amperage devices to control a motor. Imagine trying to wire a
pushbutton station for a 100A motor using 3 AWG conductors. Many smaller motors
use the same size conductors for both control and power circuits, but as the
horsepower increases it becomes impractical to do so.

Figure 1. Motor control circuits are often connected to lower voltages than
the motor they control to make it safer for operators and maintenance personnel. A
motor control circuit, for the most part, is simply a switch (or group of switches)
and a motor. If you keep the word “switch” in mind, it helps keep the intimidating
subject of “motor control” in its proper context. For example, the following can be
considered motor controls. Many control circuits include motor overload protection
devices. Traditional overload (OL) protectors operate on the relationship between
heat and current. As current increases, heat increases. If an overload device is rated
10A, and the current exceeds that rating, the OL device will operate to open the
circuit because of the increased heat caused by the current running through it. A
magnetic starter or other motor controllers may include overload devices, or they
may be an integral part of the motor, particularly with small motors.

Two (2) Basic Designs of Motor Control Equipment

NEMA (National Electrical Manufacturers Association)

NEMA is a trade association for manufacturers of electrical equipment and

supplies. NEMA standards specify motor horsepower (hp) ratings, speeds, motor
frame sizes and dimensions, motor torques, motor starter size ratings, and enclosure
specifications.

NEMA-rated products are typically heavy duty, can be used in a broad range
of applications, and some starters can be maintained and repaired. For these
reasons, they’re often more expensive than IEC motor starters.

NEMA-rated motors and motor controllers are the type most commonly used
in North America.
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IEC (International Electro-technical Commission)

IEC is an international standards organization. IEC motor starters are often

less expensive, smaller in size, are tailored for specific motor performance
requirements, and the selection of the right starter for each application is very
important. IEC-rated motor controllers are widely used in Europe and Asia.

MOTOR CONTROL LANGUAGES

Electrical symbols, words, and line diagrams provide the information

necessary to understand the operation of motor control circuits. Used together, they
create a type of motor control “language” that’s used to transfer information and
ideas quickly and efficiently.

The symbols in motor control schematics represent devices, power

conductors, control conductors, conductor connections and terminals, and
sometimes the motor itself.

The words, phrases, and abbreviations in a schematic are generally accepted

terms that represent functions, describe actions, and list sequences of operation. In
many cases, the symbols and words have a similarity to the items they represent.
The basic types of schematics are shown in Figure 1–3. Parts A, B, and C of that
figure illustrate three different methods of representing the same control circuit.

A. Ladder Diagrams

Ladder diagrams are also called “line diagrams” or “elementary diagrams.”

They’re used to represent the function of the control circuit and the associated
devices, but don’t show the components of the control circuit in their actual
positions. As control circuits become more complex, a ladder diagram can be less
complicated to read than a wiring or connection diagram.
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Fig. 2 Ladder Diagram

The ladder diagrams in Figures 2 illustrates electrical function, showing the M

contacts in parallel with the start pushbutton to form what’s called a “holding
circuit.” The physical location of the M contacts isn’t shown in the ladder diagram.

B. Connection Diagram

Connection diagrams, or wiring diagrams, show the components of the control

circuit in a semblance of their actual physical locations. The start-stop
pushbutton station is shown more as an actual device in the control circuit wired
to a set of contacts marked 2 and 3.

Fig. 3 Wiring Connection diagram

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C. Pictorial Diagram

Pictorial diagrams are often used in educational material and as exploded

views or cut-away views in installation and maintenance literature. Pictorial
diagrams help students see actual devices and components used in motor control
circuits and how they relate to the symbols used in ladder diagrams and wiring
diagrams. For example, the start pushbutton we mentioned earlier has wires run
to the device that contains the set of contacts M.

Fig. 4 Pictorial Diagram

This lesson explained the basic concepts of motor controls, concentrating on how
specialized electrical symbols, words, and line diagrams are used to convey
information about motor control circuits. It provided an introduction to the following
types of diagrams, which are used extensively throughout this lesson:

• Ladder diagrams (these are also called “line diagrams” or “elementary diagrams”).

• Connection diagrams (also called “wiring diagrams”).

• Pictorial diagrams.
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MOTOR CONTROL CENTER (MCC)

A motor control
center (MCC) is an
assembly to control some
or all electric motors in a
central location. It consists
of multiple enclosed
sections having a common
power bus and with each
section containing a
combination starter, which
in turn consists of motor
starter, fuses or circuit breaker, and power disconnect.

A motor control center can also include push buttons, indicator

lights, variable-frequency drives, programmable logic controllers, and metering
equipment. It may be combined with the electrical service entrance for the building.

MCC's are typically found in large commercial or industrial buildings where

there are many electric motors that need to be controlled from a central
location, such as a mechanical room or electrical room.

A motor control center consists of one or more vertical metal cabinet sections
with power bus and provision for plug-in mounting of individual motor controllers.
Very large controllers may be bolted in place but smaller controllers can be
unplugged from the cabinet for testing or maintenance. Each motor controller
contains a contactor or a solid-state motor controller, overload relays to protect the
motor, fuses or a circuit breaker to provide short-circuit protection, and a
disconnecting switch to isolate the motor circuit. Three-phase power enters each
controller through separable connectors. The motor is wired to terminals in the
controller. Motor control centers provide wire ways for field control and power
cables.
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SAFETY WORK HABITS

Electrical Safety in the workplace is the most important job of an electrical

worker. No matter how much training one has received or how much employers try
to safeguard their workers, Electrical Safety is ultimately the responsibility of the
electrical worker. The human factor associated with electrical accidents can be
immeasurable. No one can replace a worker or loved one that has died or suffered
the irreparable consequences of an electrical accident.

ELECTRICAL SAFETY RULES

Rule no. 1
 Avoid contact with energized electrical circuits. Please don’t make fun of this
rule if you already know this (and you probably already know if you are reading
these lines) and remember that if something bad occurs – you probably won’t
have second chance. That’s not funny.

Rule no. 2
 Treat all electrical devices as if they are live or energized. You never
know.

Rule no. 3
 Disconnect the power source before servicing or repairing electrical
equipment.
The only way to be sure

Rule no. 4
 Use only tools and equipment with non-conducting handles when working on
electrical devices.
Easy to check

Rule no. 5
 Never use metallic pencils or rulers, or wear rings or metal watchbands when
working with electrical equipment. This rule is very easy to forget, especially
when you are showing some electrical part pointing with metallic pencil.
Always be aware.

Rule no. 6
 When it is necessary to handle equipment that is plugged in, be sure hands
are dry and, when possible, wear nonconductive gloves, protective clothes
and shoes with insulated soles.
Remember: gloves, clothes and shoes.
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Rule no. 7
 If it is safe to do so, work with only one hand, keeping the other hand at your
side or in your pocket, away from all conductive material. This precaution
reduces the likelihood of accidents that result in current passing through the
chest cavity.
 If you ever read about current passing through human body you will know, so
remember – work with one hand only.

Rule no. 8
 Minimize the use of electrical equipment in cold rooms or other areas where
condensation is likely. If equipment must be used in such areas, mount the
equipment on a wall or vertical panel.

Rule no. 9
 If water or a chemical is spilled onto equipment, shut off power at the main
switch or circuit breaker and unplug the equipment.
 Very logical. NEVER try to remove water or similar from equipment while
energized. After all, it’s stupid to do so.

Rule no. 10
 If an individual comes in contact with a live electrical conductor, do not touch
the equipment, cord or person. Disconnect the power source from the circuit
breaker or pull out the plug using a leather belt.
 Tricky situation, and you must be very calm in order not to make the situation
even
worse.
 Like in previous rules – Always disconnect the power FIRST.
Always disconnect the power FIRST

Rule no. 11
 Equipment producing a “tingle” should be disconnected and reported
promptly for repair.
Rule no. 12
 Do not rely on grounding to mask a defective circuit nor attempt to correct a
fault by insertion of another fuse or breaker, particularly one of larger
capacity.
Rule no. 13
 Drain capacitors before working near them and keep the short circuit on the
terminals during the work to prevent electrical shock.
Rule no. 14
 Never touch another person’s equipment or electrical control devices unless
instructed to do so.
Don’t be too smart. Don’t try your luck.
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Rule no. 15
 Enclose all electric contacts and conductors so that no one can accidentally
come into contact with them.
If applicable do it always, if not be very carefully.

Rule no. 16
 Never handle electrical equipment when hands, feet, or body are wet or
perspiring, or when standing on a wet floor.
Remember: Gloves and shoes

Rule no. 17
 When it is necessary to touch electrical equipment (for example, when
checking for overheated motors), use the back of the hand. Thus, if accidental
shock were to cause muscular contraction, you would not “freeze” to the
conductor.

Rule no. 18
 Do not store highly flammable liquids near electrical equipment.

Rule no. 19
 Be aware that interlocks on equipment disconnect the high voltage source
when a cabinet door is open but power for control circuits may remain on.
Read the single line diagram and wiring schemes – know your
switchboard.

Rule no. 20
 De-energize open experimental circuits and equipment to be left unattended.

Rule no. 21
 Do not wear loose clothing or ties near electrical equipment. Act like an
electrical engineer, you are not on the beach.

LEARNING ACTIVITY 1. 1

1. As a Student, how can Industrial Motor Control affects our daily

lives? Discuss your answer.
2. Choose one Safety Rules. Explain the chosen Safety rules by giving
your own opinion on how your life can be when you did not follow
this safety rules.
3. In your own words, what is the difference of NEMA and IEC?
4. Explain the Principles of Motor Control on how you understand it
in your own words.
5. Based on the module 1 – Lesson 1, discuss the three MOTOR
CONTROL LANGUAGES in a minimum of 100 words in your own
understanding.

6.
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MODULE 1: INTRODUCTION TO THE COURSE

LESSON 2

Impacts of Industrial Motor Control

Advantages commonly attributed to motor control include higher production
rates and increased productivity, more efficient use of materials, better product
quality, improved safety, shorter workweeks for labour, and reduced factory lead
times. Higher output and increased productivity have been two of the biggest
reasons in justifying the use of motor controller. Despite the claims of high quality
from good workmanship by humans, industrial motor control systems typically
perform the motor control process with less variability than human workers,
resulting in greater control and consistency of product quality. Also, increased
process control makes more efficient use of materials, resulting in less scrap.

Worker safety is an important reason for automating an industrial operation.

Automated systems often remove workers from the workplace, thus safeguarding
them against the hazards of the factory environment. In the United States
the Occupational Safety and Health Act of 1970 (OSHA) was enacted with the
national objective of making work safer and protecting the physical well-being of
the worker. OSHA has had the effect of promoting the use of automation
and robotics in the factory.

One of the key importance of industrial motor controller is the protection

system. Large motors found in the industry were coupled with motor controllers to
compensate the high amount of current drawn by the motor during the acceleration
period. Protection devices such as overcurrent protection, phase reversal protection
and other protection devices were installed in the motor control center specifically
to protect the machine, the whole power system and the personnel involved in the
operation. Some protection devices send feedbacks by means of electrical signal and
monitored by means of an alarm or signal lamps. Other protection devices will cut
off the power to the motor when the motor runs abnormally. An accidental ground
fault occurs to the motor will endanger the status of the personnel working with the
machine. Motor protection eliminate our worries and provides safety in the working
environment.
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Advantages of Industrial Motor Control

Direct on line Motor Starter

Advantages & Disadvantages
The advantages of this starter include the following.

 The Direct Online starter is an inexpensive starter.

 It gives almost complete starting torque at the beginning.
 The designing, operating and controlling this starter is very easy.
 Understanding and troubleshooting are very easy.

The disadvantages of this starter include the following.

 Starting current is very high

 This starter causes an important dip in voltage, therefore appropriate only for
small motors.
 The lifespan of the machine can be reduced.
 It is hard mechanically.
 Needless high opening torque

Manual Motor Starter over the Magnetic Motor Starter

Manual Starters
Manual starters are devices that are operated manually. These starters are
extremely easy and straightforward to operate and do not require expert
intervention. The starter includes a button (or rotary knob) which enables a user to
turn the connected equipment on or off. The buttons feature mechanical linkages,
which make the contacts open or close, starting or stopping the motor. The following
features of a manual starter make it a preferred choice over other types:

 These starters deliver a safe, as well as economical operation.

 The compact size of these devices make them suitable for a wide range
of applications.
 They provide overload protection to the motor, protecting it from any
potential damage.
 These devices come with a vast choice of enclosures.
 The initial cost of the manual starter is low.
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Magnetic Motor Starters

This is the other main type of motor starter. It is operated
electromagnetically. It means that the motor load connected to the motor starter is
typically started and stopped using a lower and safer voltage than the motor voltage.
Just like other motor starters, the magnetic starter also has an electrical contactor
and overload relay to protect the device from too much current or overheating.

The Advantages of Magnetic Motor Starters:

 They have a compact design.
 They are cost-effective.
 They have a simple construction.
 They are suitable for use in speed control applications.
 They have extremely flexible starting characteristics.
 They provide smooth acceleration.
 They can be used for manual speed control, but with limited options.
 They have extremely flexible starting characteristics.
 They have a high output torque.

Impacts of a Soft Starter motor control

Soft starter is a electrical device specializes for controlling AC motor in soft

start, soft stop, light-load energy saving and much more protection features.

Motor soft starter protection:

 Overheating protection: the soft starter detects the thyristors internal

radiator's temperature by its thermal relay, automatic cut down and send
alarm signal once the temperature exceeds allowable value.
 Phase loss protection: the soft starter detects the changes in three-phase
line current, to make phase loss protection response once the current off.
 Overload protection: the soft starter has current control loop to track and
detect the changes of the AC motor current, to cut down the thyristor and
send alarm signals when motor is overload.
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MODULE 1: INTRODUCTION TO THE COURSE

 Other functions: achieve lots of mixed protection features by combining

electronic circuits.

This soft starter is designed according to the computer analog test, has the best
electromagnetic compatibility. It is proved high quality by the high-temperature
ageing test and jigging test which done before the starter out of our factory. Such
as low voltage protection, failure voltage protection, over voltage protection, motor
overheat or starting.

Gozuk low voltage soft starter is a new type start-up equipment which integrates
electric force and electronic techniques computer technique and modern control
theory. It is the new generation AC motor starter to replace the conventional star-
delta starter, self-coupling voltage-drop starter and magnetic control voltage-drop
starter.

Multi starting methods: current limitation start, voltage ramp start, current
limitation + voltage ramp soft start. High reliability: high-performance
microprocessor to process control system's digital signal. Powerful anti-interference
feature: easy adjustment way, the control unit signals are using optical isolation,
and set a different anti-noise.

LEARNING ACTIVITY 1. 2

1. As an individual, is it really important to know the Impacts of

Industrial Motor Control especially in the industry?
2. Why do we need to consider the Advantages and Disadvantages of
Direct on Line Starter? Prove your answer in a minimum of 100
words.
3. In your own words, make a summary of what have you learned in
Module 1 — Lesson 2: Impacts of Industrial Motor Control in a
minimum of 150 words.
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MODULE 1: INTRODUCTION TO THE COURSE

LESSON 3

Basic Elements of Motor Control

Industrial Motor control in the broadest sense of the term encompasses the
different methods used to control an electrical system’s performance. The control
circuit is made up of numerous basic interconnected components that achieve the
desired performance. The components vary in size depending on the motor’s power;
however the operation principles stay the same.

Once the proper motor is selected, understanding the many various control
devices available and their uses and limitations becomes an important part related
to reliable operation and protection of the motor and the personnel using the motor.

Motor Controller

A motor controller is the actual device that energizes and de-energizes the
circuit to the motor so that it can start and stop.

Motor controllers may include some or all of the following motor control
functions:

Starting, stopping, over-current protection, overload protection, reversing,

speed changing, jogging, plugging, sequence control, and pilot light indication.
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COMPONENTS OF MOTOR CONTROLLER

a. MANUAL MOTOR STARTERS
Manual motor starters are motor control
components that are used for motor
protection. They are used to switch the
motor off or on manually. Once there is an
electrical overload or failure, the device
trips, switches off and stops the motor. This
means that they have to be manually
turned on by an operator once they switch
off. Such a starter is most suitable for small
and simple motors.

b. MOTOR CIRCUIT BREAKERS

A motor circuit breaker is similar to an
ordinary circuit breaker in they protect
from overloads and short circuits. In case of
overload or short circuit the device trips
switching off the motor. Auxiliary contacts
can be fitted to give a tripping feedback
information to a PLC or pilot light
indication. Motor Circuit Breakers are
usually used in conjunction with contactors
for the control (on/off) of the load. Electro-
mechanical links are available between the
motor circuit breaker and the contactor.
Some breakers are made in such a way that
once the current goes down to its operating
range, it automatically turns back on.
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DIFFERENT POLES OF MOTOL CONTROL BREAKER

1. SINGLE (1) POLE BREAKER

 Single Pole MCB is used to break

‘single phase’ and Double pole is used to
break ‘phase and neutral. In other words,
single pole controls 1 live wire and it trips
the respective line when the fault current
exceeds the pickup setting and double pole
can control 2 live wires/ one live & one
neutral.

2. DOUBLE (2) POLE BREAKERS

 Double-pole breakers have two hot

wires that are connected by a single
neutral wire. That means if there's a
short circuit on either of the poles' hot
wires, both trip. These breakers can be
used to serve two separate 120-
volt circuits or they can serve a single 240-
volt circuit, such as your central
AC's circuit.

3. TRIPLE (3) POLE BREAKERS

 Used most often in a three-phase
electrical system, a three-pole breaker
connects three different conductors such
as is often required by heavy duty
industrial motors. When a surge exists
anywhere in the system, across one or
more of the conductors, the breakers
trips, the power bridge collapses and the
circuit opens.
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c. CONTACTORS
Contactors are electro-mechanical devices to
switch on/off motor load. You'll need to apply
voltage across the coil terminals to switch the
contactor on. The difference is that a contactor
is used for higher power ratings as compared to
a relay and are not only used for the purpose of
interrupting short circuits.

d. MINI CONTACTORS
Mini contactors are in reality contactors in
functionality. The difference is that they
are much smaller in size. This helps
provide the efficiency and reliability of a
contactor where space is limited.

e. THERMAL OVERLOAD RELAYS

Thermal overload are used to protect
motors from current overloads causing
overheat, unrepairable damage to motors
and service disruption. They are using
bimetallic strips that heats up in case of
overcurrent. When tripping auxiliary
contacts are actuated. Used in the control
circuit, these will stop the contactor,
stopping the motor to avoid any damage.
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f. PUSHBUTTON SWITCHES
are mechanical switches defined by the method used to activate the
switch. The activation method is typically in the form of a plunger
that is pushed down to open or close the switch. There are several pole and
throw configurations for pushbutton switches.
a type of switch which consists of a simple electric mechanism or air switch
mechanism to turn something on or off. Depending on model they could
operate with momentary or latching action function. The button itself is
usually constructed of a strong durable material such as metal or plastic.
A push button switch is activated via finger pressure. Two or more contacts
close or open when the switch is depressed. Pushbutton is usually spring
loaded so it returns to its normal position once the pressure is removed.

NC Emergency Stop NO Red DPST Red Green Momentary

Green Momentary Push Push Button Switch (DOUBLE
Button Switch Station CONTACT)

Emergency Stop Push Button Single Contact Push Button

Switch
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g. CONTROL RELAYS
Is an electromagnetic switch that closes and
opens a set of contacts whenever the relay coil
gets energized. This relay coil produces a very
strong magnetic field that attracts a movable
armature that has the contacts. A control relay
is largely used in a low power circuit.

h. PILOT LAMP – used to indicate the on/off state

of remote components in a control system.

i. TIMER RELAYS
a simple form of time-based control,
allowing the user to open or close
the contacts based on a specified
timing function. They can be
designed, for example, with a set of
selector switches, which can easily
be set to a specific function and
time, thereby reducing the number
of product variations required.

 Allow necessary actions to happen at specific times in an electrical apparatus

because they, in essence, act as a timer. The purpose of time-delay relays is
to start or stop currents from moving in coils and armatures, the moving
parts of electrical mechanisms. They are designed to allow electrical circuits
to release at certain times.
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j. TERMINAL BLOCKS
A terminal block is tool used to safely
connect two or more wires together. Also known
as a terminal block connector, these blocks use a
clamping component and conducting strip to
secure and organize connecting wires.
A terminal block (also called as connection
terminal or terminal connector) is a modular block
with an insulated frame that secures two or more
wires together. It consists of a clamping
component and a conducting strip. A typical simplest terminal block is as
shown in the image below.

Motor Control Accessories - Motor control accessories are peripheral devices that
can be fitted together with a motor to help in ensuring its smooth running. There’s
a wide variety of motor control accessories available depending on the specific
motor need.

Hand auto switch

Key operated switch

FACTOR AFFECTING MOTOR CONTROL INSTALLATION

When choosing a specific device for a particular application, it is important
to remember that the motor, machine, and motor controller are interrelated and
need to be considered as a package. In general, five basic factors influence the
selection and installation of a controller.

1. ELECTRICAL SERVICE
Establish whether the service is direct (dc) or alternating current (ac). If ac,
determine the frequency (hertz) and number of phases in addition to the voltage.
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2. MOTOR
The motor should be matched to the electrical
service, and correctly sized for the machine load in
horsepower rating (hp). Other considerations
include motor speed and torque. To select proper
protection for the motor, its full load current rating
(FLC), service factor (SF), time rating (duty), and
other pertinent data-as shown on the motor
nameplate-must be used.

3. OPERATING CHARACTERISTICS OF CONTROLLER

The fundamental tasks of a motor controller are to start and stop the motor and to
protect the motor, machine, product, and operator. The controller may also be
called upon to provide supplementary function s such as reversing, jogging or
inching, plugging, operating at several speeds or at reduced level s of current and
motor torque.

4. ENVIRONMENT

Controller enclosures serve to provide safety protection for operating personnel by

preventing accidental contact with live parts. In certain applications, the controller
itself must be protected from a variety of environ mental conditions which might
include:

• Water, rain, snow or sleet

• Dirt or non-combustible dust

• Cutting oils, coolants or lubricants

Both personnel and property require protection in environments made hazardous by

the presence of explosive gases or combustible dusts.
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5. ELECTRICAL CODES AND STANDARDS

Motor control equipment is designed to meet the provisions of the National Electrical
Code® (NEC®). (National Electrical Code® and NEC ® are registered trademarks of
the National Fire Protection Association Inc., Quincy, MA 02269.) Also, local code
requirements must be considered and met when installing motors and control
devices. Presently, code sections applying to motors, motor circuits, and controllers
and industrial control devices are found in Article 430 on motors and motor
controllers, Article 440 on air conditioning and refrigeration equipment, and Article
500 on hazardous locations of the NEC.

CONTACT CONFIGURATIONS

Normally Normally
Open Contact Close Contact
Circuit Breaker

Pilot Lamp

Magnetic Contactor Magnetic Contactor

(Normally Close) (Normally Open)
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ELECTRIC MOTOR SYMBOLS

AC Motor
o This symbol represents an AC motor. This type of motor only
runs on alternating current. It converts AC electrical energy
into mechanical energy.

DC Motor
o This symbol is used for representing a DC motor in any
electrical schematic. It converts DC electrical energy into
mechanical energy. It only runs on direct current.

Linear Motor
o This is a generic symbol used for representing a linear motor.
A linear motor has unrolled stator that results in producing a
linear force instead of rotating torque.

Stepper Motor
o Stepper motor or step motor is a type of brushless DC motor
whose full rotation is divided into number of equal steps. It
rotates one step at a time instead of continuous motion.
They are used for precise positioning using a control signal.

Electrical Machine
o This type of symbol is used for such machines that can be
used as both a motor & generator. The motor converts
electrical energy into mechanical energy & the generator
does the vice versa.

Permanent Magnet DC Motor

o Such type of brushless DC motors uses a permanent magnet
to create the poles instead of the field windings. The symbol
above represents a DC motor with a magnet icon to represent
the permanent magnet type.
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MODULE 1: INTRODUCTION TO THE COURSE

AC Single Phase Series Motor

o This symbol represents an AC single phase series motor. It
runs on a single phase AC supply & its field winding is in series
with the armature winding. It is also known as modified DC
series motor.

DC Series Motor
o A DC motor whose field winding is in series with the armature
winding is called DC series motor & it is represented by this
symbol in schematic designs.

AC Single Phase Induction Motor with Winding Terminals brought out

o It is also known as split phase induction motor. This type of
AC single phase motor has an accessible separate winding
known as starting winding having high resistance. The
starting winding is used for starting motor.

Single Phase Repulsion Motor

o It is a single phase AC motor that operates on the principle
of the repulsion between the magnetic field of the stator &
rotor. The rotor magnetic field is generated by the induced
current & can be rotated by rotating the brushes along its
axis. This rotating magnetic field is used for changing the
direction of the motor.

DC Shunt Motor
o It is the symbol used for DC shunt motor whose field winding
is connected in parallel to the armature winding. Both
windings are connected to a common Direct Current supply.

Single Phase Synchronous Motor

o This symbol represents a single phase AC synchronous motor.
Synchronous motors initially starts as an induction motor but
later achieves a synchronous speed which only depends on
the input supply frequency.
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MODULE 1: INTRODUCTION TO THE COURSE

DC Compound Excitation Motor

o Such type of DC motor has both the series field winding and
shunt (or parallel) field winding. The shunt field winding
enhances the magnetic field generated by the series
winding. it has the advantages of both series wound & shunt
wound DC motors i.e. high starting torque & speed
regulation.
3 Phase AC Motor
o It is a generic symbol used for 3 phase AC motor. The 3 phase
AC supply creates a rotating magnetic field which reacts with
the magnetic field generated by the rotor thus rotating the
rotor.

3 Phase Star Shaped Motor

o This is a three phase motor whose windings are connected
together in star or wye configuration. this symbol also
represent the auto start function of the motor.

3 Phase Wound Rotor Motor

o This symbol represents a 3 phase wound rotor motor. It is a
type of 3 phase AC motor whose rotor is connected with
external resistance through slip rings. The advantage of
wound rotor motor is that it generates high starting torque
using less current.

3 Phase Linear Motor

o This symbol represents a linear motor that runs on 3 Phase
AC power supply. The stator of such motor is unrolled for
generating a linear force instead of a rotating torque.
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MODULE 1: INTRODUCTION TO THE COURSE

LEARNING ACTIVITY 1. 3

1. When it comes to the components of motor control, how can

you familiarize the use of different components given in the
lesson? Explain your answer in your own words.
2. As a student, is it important to know the Contact Configuration
and Electric Motor symbol?
3. Provide an explanation on how to make the components of
motor controller to be used in a long term basis.
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MODULE 1: INTRODUCTION TO THE COURSE

LESSON 4

Motor Protection

MOTOR PROTECTION
Motor protection safeguards the motor, the supply system and personnel from
various operating conditions of the driven load, the supply system or the motor
itself.

Different protection units are used for the safeguard of the electric motors.
Motors are use at various levels in various applications. Induction motors are hugely
use at the domestic level as well as industrial or commercial level. Different
categories of induction motors are use in industrial units. The big industrial motors
are costly, thus the protection of a motor is an important parameter. Different
motor protection units are used for the protection of motors. The motor protection
were divided into various categories depending upon the operation of the motor.

The different protection categories for a motor are discuss below

Motor protection categories includes

Overcurrent Protection, Overload Protection, Other Types of Protection.
• The National Electrical Code requires that motors and their conductors be
protected from both overcurrent and overload conditions.
Overcurrent Protection
Whenever an excessive amount of
current passed through the motor, the
motor protection unit trips. Circuit
breakers and fuses are use as protection
units for the different motors.
Overcurrent protection can protect
personnel from electric shock, the
control equipment of the motor, the
conductors of the motor branch circuits
and the motor itself from high currents.
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MODULE 1: INTRODUCTION TO THE COURSE

Overcurrent protection interrupts the electrical circuit to the motor upon excessive
current demand on the supply system from either short circuits or ground faults.
• Overcurrent protection is required to protect personnel, the motor branch circuit
conductors, control equipment, and motor from these high currents.
• Overcurrent protection is usually provided in the form of fuses or circuit breakers.
These devices operate when a short circuit, ground fault or an extremely heavy
overload occurs.
 Motor Damage
 Allowable Operation Area
 Amperage
 Time
 Motor Current Draw
 Motor Running Current
 Starting In-Rush Current

Overload Protection
Overload protection is the type of protection
which is against the mechanical overload
conditions. The mechanical overload
conditions can occur in a motor due to various
reasons when a motor is in a running state. The
overload situations can result in the increased
temperature of the motor which can damage
the motor. The protection used for the
overload conditions can disconnect the motor
in overload conditions from the main power
supply. When the motor is overload due to any
circumstance the windings of the motor
arphote subjects to fire as the temperature of
the motor is increased in overload conditions
and as a result, the windings of the motor can
be damaged. Similarly, if the outlets of the motor are covered and there is no point
for the heat emission then the temperature of the motor increases as the motor
keeps on running this can also result in damaging the windings of the motor. The
overload protection units are trip in case of an overload condition and the supply of
the motor is cut-off and the motor is protect from motor damage.
Overload protection is installed in the motor circuit and/or motor to protect the
motor from damage from mechanical overload conditions when it is
operating/running.
• The effect of an overload is an excessive rise in temperature in the motor windings
due to current higher than full load current.
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MODULE 1: INTRODUCTION TO THE COURSE

 Properly sized overload protection disconnects the motor from the power
supply when the heat generated in the motor circuit or windings approaches
a damaging level for any reason.
 The larger the overload, the more quickly the temperature will increase to a
point that is damaging to the insulation and lubrication of the motor.
 Unlike common instantaneous type fuses and breakers, overload devices are
designed to allow high currents to flow briefly in the motor to allow for:
 Typical motor starting currents of 6 to 8 times normal running current when
starting. Short duration overloads such as a slug of product going through a
system.
 If the motor in lets and outlets are covered by a blanket of lint or if a
bearing should begin to lock, excessive heating of the motor windings will
“overload” the motors insulation which could damage the motor.
 The overcurrent device will not react to this low level overload. The motor
overload device prevents this type of problem from severely damaging the
motor and also provide protection for the circuit conductors since it is rated
for the same or less current as the conductors.

• Overload protection trips when an overload exists for more than a short time. The
time it takes for an overload to trip depends on the type of overload device, length
of time the overload exists, and the ambient temperature in which the overloads
are located.

Two Types of Overload relay

A. Bi-metallic strip located close to a heater deflects as the heater temperature
rises until it mechanically causes the device to trip and open the circuit,
cutting power to the motor should it become overloaded.

B. Thermal overload relay uses a eutectic alloy, like a solder, to retain a spring-
loaded contact. When too much current passes through the heating element
for too long a time, the alloy melts and the spring releases the contact,
opening the control circuit and shutting down the motor.
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MODULE 1: INTRODUCTION TO THE COURSE

Other Motor Protection Devices

Low Voltage Protection
The protection unit or the device is use to
disconnect the motor from the voltage
source or the power source in case the
voltage drops down below the rated value
for the motor. The motor operates again
whenever the voltage is balance to the
normal value. Different protection units
have their own resetting points. Some
protection units manually reset. It
automatically reset to normal following
different algorithms. Some protection units
reset to normal after some predefined
interval of time. Some units can be reset to
normal when the voltage stabilizes to its
normal value.
a. Low Voltage Disconnects - Protection device operates to disconnect
the motor when the supply voltage drops below a preset value. The
motor must be manually restarted upon resumption of normal supply
voltage.
b. Low Voltage Release - Protection device interrupts the circuit when
the supply voltage drops below a preset value and re-establishes the
circuit when the supply voltage returns to normal.

Phase Failure Protection

Phase failure protection is use to protection of motor in case of any phase
failure during the operation of the motor. It is normally use in three-phased motors
and upon failure, in any phase, the motor disconnects from the power supply.
A motor without phase failure protection
keeps on running even if a phase failed in the
circuit which can damage the motor or it can
affect the operation of the motor. If one phase
failed the other phase starts to deliver more
current to the circuit which can burn the motor
or the circuit it is attach with.

Interrupts the power in all phases of a three-

phase circuit upon failure of any one phase.
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MODULE 1: INTRODUCTION TO THE COURSE

Normal fusing and overload protection may not adequately protect a polyphase
motor from damaging single phase operation. Without this protection, the motor
will continue to operate if one phase is lost. C Large currents can be developed in
the remaining stator circuits which eventually burn out. C Phase failure protection
is the only effective way to protect a motor properly from single phasing.

Phase Reversal Protection

It is a protection technique that is use to
protect a motor from the phase reversal
condition. Phase reversion in a motor can
occur due to numerous reasons which can
cause safety and operational problems. If
two connections out of three connections of
a motor are reverse somehow the motor
starts rotating in the opposite direction.
Upon detection of the opposite rotation of
the motor, the protection unit for phase
reversal disconnects the motor from the
mains supply.

Used where running a motor backwards (opposite direction from normal) would
cause operational or safety problems.

Most three phase motors will run the opposite direction by switching the
connections of any two of the three phases. C The device interrupts the power to
the motor upon detection of a phase reversal in the three phase supply circuit. C
This type of protection is used in applications like elevators where it would be
damaging or dangerous for the motor to inadvertently run in reverse.

Ground Fault Protection

Ground fault protection is use to protect the motor from different short circuit
conditions. An excessive amount of current flows through the motor or the circuit
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MODULE 1: INTRODUCTION TO THE COURSE

in case of the short circuit. Ground fault

protection is use to disconnect the motor in
case of any ground fault.

Operates when one phase of a motor shorts

to ground preventing high currents from
damaging the stator windings and the iron
core.

Other Motor Protection Devices

Bearing Temperature Monitors & Protection Winding Temperature Monitors &
Protection Devices Current Differential Relays (Phase Unbalance) Vibration Monitors
& Protection
Once the proper motor is selected, understanding the many various control devices
available and their uses and limitations becomes an important part related to
reliable operation and protection of the motor and the personnel using the motor.

LEARNING ACTIVITY 1. 4

1. Differentiate Phase Reversal Protection between Phase Failure

Protection based on your own understanding. Discuss it briefly and
thoroughly.
2. Is Phase Reversal Protection, Ground Fault Protection and Phase
Failure Protection helpful in the near future? Why do you say so? Prove
your answer.
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MODULE 1: INTRODUCTION TO THE COURSE

SUMMATIVE TEST

1. Make a video showing what kind of breaker you have at home.

Tell what kind of breaker it is and how does it work according to
what you have learned in Motor Control Breakers. Your video
should not exceed 5 minutes and will not be shorter than 3
minutes. That video will contain the following:
a. What kind of breaker is that?
b. How does it work?
c. Possible cost of the breaker you have?
d. Advantage of having such breaker?
e. Why you or your household did chose that kind of breaker?
Note: Your video will entails the total score for this part so you
need to do your best in editing and captioning. Please take note
that the 5 questions above should be answered and properly
explained in the video.

SUMMARY

This module discussed the topics about the different theories, elements,
impacts of motor control and motor protection. This module will emphasized the
innovations and development of motor control that will involve the interaction of
scientific and technical discipline.
The basic definitions and terminologies in this module have been presented
to establish some consistency in discussions of the basics of motor control and its
technologies. Given in this module are the components and different devices which
contribute to the function of motor control and geared towards motor protection.
In applying the principles being manifested in this module, students must
follow the safety rules and guidelines proceeding to the work. Steps and procedure
are properly listed and rules must be properly abided.
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MODULE 1: INTRODUCTION TO THE COURSE

REFERENCES

Edvard (2012). 21 Safety Rules for Working with Electrical Equipment. Retrieved
from: https://electrical-engineering-portal.com/21-safety-rules-for-working-with-
electrical-equipment
Electric Equipment (2020). General Principles of Motor Control. Retrieved from:
http://machineryequipmentonline.com/electric-equipment/general-principles-of-
electric-motor-control/
Electrical Technology (2012). Symbols of AC / DC, Single Phase & Three Phase
Electric Motor. Retrieved from:
https://www.electricaltechnology.org/2019/09/electric-motors-symbols.html
Groover (2017). Automation. Retrieved from: https://www.britannica.com/
technology/automation/Advantages-and-disadvantages-of-automation
ILO Content Manager (2011). Hand and Portable Power Tool Safety. Retrieved from:
https://www.iloencyclopaedia.org/component/k2/item/949-hand-and-portable-
power-tool-safety
Industrial Control Direct (2017). Motor Control. Retrieved from:
https://www.industrialcontroldirect.com/motor-control-247/
Mike Holt Enterprises (2009). Unit 1: Basic Principles of Motor Controls. Retrieved
from https://www.mikeholt.com/instructor2/img/product/pdf/1245861713
sample.pdf