Control Circuits & Devices

Electro Magnetic Relay- Operating

Principle
• Relays are electrically
operated switches
Low power High power that open and close
circuit circuit
the circuits by low
power electrical
signals. Sometimes
relay can operate
more than one circuit
simultaneously.
https://www.youtube.c
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 Relay Contacts
• Normally
Open (NO)
contacts are not
in contact with
the armature
when the relay is
not powered.
• Normally
Closed (NC)
contacts are in
contact with the
armature when
the relay is not
powered.
Application of the Mechanical Relay

• The load can be operated at a

distance.
 Relay- Types of Contacts
poles throws Name of relay
1 1 Single pole SPST
single throw

1 2 Single pole SPDT

double throw

2 1 double pole DPST

single throw

2 2 DPDT
Double pole
double throw
Some interesting videos about relays
• https://www.youtube.com/watch?v=kWqtS
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• https://www.youtube.com/watch?v=n594Ck
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• https://www.youtube.com/watch?v=MJz2D
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 Categorization of relays
• AC or DC
• According to control voltage
• Operating current
• No. poles and throws
• Operating mechanism (heat, light or
magnetism)
• Number of pins
8 pin relay pin configuration

https://www.youtube.com/w
atch?v=ZzL5KFggT-A
Relay Timers- ON Delay
• When the switch is closed, power is
applied to the coil
• but the contacts are delayed from
changing position.
• • With the switch still closed, after the
10-second timing
• period the normally open contacts (TR1-
1) close
• to energize load 1 and the normally
closed contacts
• (TR1-2) open to deenergize load 2.
• If the switch is then opened, the coil
deenergizes
• immediately, returning both timed
contacts to their
• normal state, switching load 1 on and
load 2 off.
Relay Timers- OFF Delay
• When power is
applied to the coil,
the timed contacts
will change state
immediately.
• When power is
removed, however,
there is a time
delay before the
timed contacts
change to their normal
de energized positions.
Contactors
• The magnetic contactor is similar in
operation to the electromechanical relay.
• When voltage is applied to the
• terminals of the coil, the current flows
through the coil, creating a magnetic
field.
• The coil, in turn, magnetizes the
stationary iron frame, turning it into an
electromagnet.

• The electromagnet draws the armature

toward it, pulling the movable and
stationary contacts together.
• Power then flows through the contactor
from the line side to the load side.
• Generally a contactor is available in two-,
three-, or four-pole contact
configurations.
Operating Principle of a Contactor
 Contactor Terminals
Auxiliary
contact (NO)
coil

Auxiliary
Three main contact (NC)
contacts

https://www.youtube.com/w
atch?v=WT14nfmu1cI
 NO & NC Auxiliary Contacts
23 33
• Addition
43 51 61 71
al
auxiliary
contacts
can be
added to
24 34 the
44 52 62 72
Auxiliary contact end points numbering is done such that
contactor
NO contact (blue colour) line side number 3 and load side
number 4. In a NC contact (red colour) line side is number
1 and load side is number 2. lack colour numbers are
auxiliary contact number . Ere altogether 7 number of
auxiliary contacts are there
Arc Suppression
Arc Chute Chamber
• splitting up the
arc into a
number of
shorter arcs in
series by metal
plates(arc
segmentation)
• increasing the
arc length by
using isolating
plates as
barriers.
Double pole manual motor starter
• Apply full line voltage to the motor upon starting.
• If the high starting current does not affect the power supply
system
and the machinery will stand the high starting torque,
full-voltage starting may be acceptable.
• Full-voltage starters may be either manual or magnetic.
• Manual motor starters are hand-operated
• It has motor overload protection.
• The starter’s contacts remain closed during a power
interruption.
• When power is restored, the motor immediately restarts.
• Manual starters for fractional-horsepower,.
• When thermal overload rises, and at a predetermined
temperature point, the device actuates to open the contact.
• When an overload is sensed, the starter handle
automatically
moves to the center position to signify that the contacts
have opened because of overload .
• The three-pole manual
starter shown in Figure 8-
11
• provides three overload
heaters to protect the
motor windings.
• This starter is operated by
pushing a button on the
• starter enclosure cover
that mechanically
operates the
• starter. When an overload
relay trips, the starter
mechanism
• unlatches, opening the
contacts to stop the
motor.
• The contacts cannot be
reclosed until the starter
mechanism
• has been reset by pressing
the stop button; first,
however,
• the thermal unit needs
time to cool. These
starters
• are designed for
infrequent starting of
small AC motors
• (10 hp or less) at voltages
ranging from 120 to 600
V.
contactor used in combination with an
overload relay
The load current that goes to the motor coils also passes
through the thermal elements of the overload relay.
The thermal element is connected mechanically
to an NC overload (OL) contact. When an excessive current
flows through the thermal element for a long enough time
period, the contact is tripped open. This contact is connected
in series with the control coil of the starter. When the contact
opens, the starter coil is de energized. In turn, the starter’s
main power contacts open to disconnect the motor from the
line.
 Contactor Wiring
• https://www.youtube.com/watch?v=8z0nrL0xl
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Magnetic motor starter with separately mounted start
stop pushbutton station
• Pressing the start
button energizing the
starter coil. Energized
coil closes the
contacts of the
contactor. De
energizes the starter
coil when stop
button is pressed or
in case of overload
relay trips.
• In case of a sudden
power failure motor
will not start running
when the power is
restored.
Reduced Voltage DC Starter
• Pressing the start button energizes the M and TR coils
• The M main contact closes, starting the motor at
reduced current and torque with the resistor connected
in series with the armature.
• After a preset time delay, timed contact TR closes
to energize contactor R coil.
• Contact R closes, bypassing the resistor and allowing
full line voltage to be applied to the armature.
• Starting resistance can be shorted out in one or more
steps, depending on motor size and the smoothness
of acceleration desired.
• The shunt field has full line voltage applied to it
any time the motor is on.
 Solid State Relays SSR
• Use semiconductor switching devices such as
bipolar transistors, MOSFETs, silicon-controlled
rectifiers (SCRs) or Triacs mounted on a printed
circuit board.
• All SSRs are constructed to operate as two
separate sections: input and output.
• The input side receives a voltage signal from the
control circuit and the output side switches the
load.
SSR
 Basic Sensor Types
Proximity sensor

• Detect the presence of an object (usually

called the target) without physical contact.
• Detection of the presence of solids such as
metal, glass, and plastics, as well as most liquids
Photo sensors

• photoelectric sensor
is an optical control
device that
operates by detecting
a visible or invisible
beam of light,
• Photoelectric sensors
are composed of two
basic
• components: a
transmitter (light
source) and a
receiver
• (sensor), as
Hall effect sensor
• Hall effect sensors are used to detect
the strength of a magnetic field.
• When a current-carrying conductor is
placed into a magnetic field, a voltage
will be generated perpendicular to
both the current and the field.
• This principle is known as the Hall
effect.
• A Hall effect sensor switch is
constructed from a small integrated
circuit (IC) chip like that shown in
• A permanent magnet or electromagnet
is used to trigger the sensor on
and off. The sensor is off with no
magnetic field and triggered on in the
presence of a magnetic field.
Ultra sonic sensor

• An ultrasonic sensor operates by

sending high-frequency sound
waves toward the target and
measuring the time it takes for
the pulses to bounce back.
• The time taken for this echo to
return to the sensor is directly
proportional to the distance or
• height of the object because
sound has a constant velocity.
• Figure illustrates a practical
application in which the returning
echo signal is electronically
converted to a 4-to 20-mA output,
Thermocouple
• Thermocouples
operate on the
principle that when
two dissimilar
metals are joined, a
predictable DC
voltage will be
generated
• That relates to the
difference in
temperature
between the hot
junction and the
cold junction