DEFINITION

• A broad term that means anything from a single switch to a complex system with components
such as relays, timers, switches and other control devices.

• A portion of the electrical system which starts, stops, changes the speed reverses and
regulates motors that drive various pieces of equipment.

• It is designed to limit the starting current and control the starting torque of the motor.

• Help protect equipment & personnel from damage and contribute to efficient & safe
operations and production.

• Encompasses all the methods used to control the performance of an electrical system. When
applied to machinery, it involves the starting, acceleration, reversal, deceleration, and
stopping of a motor and its load

Every control circuit is composed of a number of basic components connected together to

• Disconnecting switches

• Manual circuit breakers

• Cam switches

• Pushbuttons

• Relays

• Magnetic contactors

• Thermal relays and fuses

• Pilot lights

• Limit switches and other special switches

• Resistors, reactors, transformers, and capacitors

Motor control systems can be divided into three major types:

➢ manual

➢ semiautomatic

➢ automatic.
 Manual controls are characterized by the fact that the operator must go to the location of the
controller to initiate any change in the state of the control system. Manual

controllers are generally very simple devices that connect the motor directly to the line. They may or
may not provide overload protection or low voltage release. Manual control may be accomplished by
simply connecting a switch in series with a motor (Figure 1–1).

Semiautomatic control is characterized by the use of push buttons, limit switches, pressure
switches, and other sensing devices to control the operation of a magnetic contactor or starter. The
starter actually connects the motor to the line, and the push buttons and other pilot devices control the
coil of the starter. This permits the actual control panel to be located away from the motor or starter.
The operator must still initiate certain actions, such as starting and stopping, but does not have to go to
the location of the motor or starter to perform the action. A typical control panel is shown in Figure 1–6.
A schematic and wiring diagram of a start-stop push-button station is shown in Figure 1–7. A schematic
diagram shows components in their electrical sequence without regard for physical location.

A wiring diagram is basically a pictorial representation of the control components with

Automatic control is very similar to semiautomatic control in that pilot sensing devices are
employed to operate a magnetic contactor or starter that actually controls the motor. With automatic
control, however, an operator does not have to initiate certain actions. Once the control conditions have
been set, the system will continue to operate on its own. A good example of an automatic control
system is the heating and cooling system found in many homes. Once the thermostat has been set to
the desired temperature, the heating or cooling system operates without further attention from the
home owner. The control circuit contains sensing devices that automatically shut the system down in
the event of an unsafe condition such as motor overload, excessive current, no pilot light or ignition in
gas heating systems, and so on.
 FUNCTIONS OF MOTOR CONTROL

There are some basic functions that motor control systems perform. The ones listed below are
by no means the only ones, but are very common. These basic functions will be discussed in greater
detail in this text. It is important not only to understand these basic functions of a control system, but
also to know how control components are employed to achieve the desired circuit logic.

Starting

Starting the motor is one of the main purposes of a motor control circuit. There are several
methods that can be employed, depending on the requirements of the circuit. The simplest method is
across-the-line starting. This is accomplished by connecting the motor directly to the power line. There
may be situations, however, that require the motor to start at a low speed and accelerate to full speed
over some period of time. This is often referred to as ramping. In other situations, it may be necessary
to limit the amount of current or torque during starting. Some of these methods will be discussed later
in the text.

Stopping

Another function of the control system is to stop the motor. The simplest method is to
disconnect the motor from the power line and permit it to coast to a stop. Some conditions, however,
may require that the motor be stopped more quickly or that a brake hold a load when the motor is
stopped.

Jogging or Inching

Jogging and inching are methods employed to move a motor with short jabs of power. This is
generally done to move a motor or load into some desired position. The difference between jogging and
inching is that jogging is accomplished by momentarily connecting the motor to full line voltage, and
inching is accomplished by momentarily connecting the motor to reduced voltage.

Speed Control

Some control systems require variable speed. There are several ways to accomplish this. One of
the most common ways is with variable frequency control for alternating current motors, or by
controlling the voltage applied to the armature and fields of a direct current motor. Another method
may involve the use of a direct current clutch. These methods will be discussed in more detail later in
this text.
Motor and Circuit Protection

of the major functions of most control systems is to provide protection for both the circuit
components and the motor. Fuses and circuit breakers are generally employed for circuit protection,
and overload relays are used to protect the motor. The different types of overload relays will be
discussed later.

Surge Protection

Another concern in many control circuits is the voltage spikes or surges produced by collapsing magnetic
fields when power to the coil of a relay or contactor is turned off. These collapsing magnetic fields can
induce voltage spikes that are hundreds of volts (Figure 1–8). These high voltage surges can damage
electronic components connected to the power line.

Figure 1–8