Automatic Motor

Control
 • Course Objectives
• Introduction to Motor Control
- Purpose of Motor Control
- Induction motor (Squirrel Cage)
• Introduction to 3-Phase Motor
• Concept of Motor Operation
Table of - Components of Induction Motor

Contents - Power Flow Diagram of Induction Motor

- Three-phase Supply
- Three-phase Supply and Rotating Flux
- Induction Motor Connections
- Dual Voltage Induction Motor Connection
- Dual Voltage, 12 Leads Across The Line Start Connection
- Two-speed diagrams for six-lead and twelve-lead motors.
• Introduction to Motor Control Components
- Main Contactor
* Class of Main Contactor
* Selection of Main Contactor
- Auxiliary Contact
- Push button
- Timer
- Indicator Lamp
• Protection of Motor Control
- Fuse (Helix Fuse)
- Fuse (CLPT Fuse)
- Fuse (CLS Fuse)
- Overload Relay (Melting Alloy)
- Overload Relay (Bi-metallic strip)
- Overload Relay (Electromagnetic)
- Miniature Circuit Breaker (MCB)
- Molded-Case Circuit Breaker (MCCB)
• Motor Control Circuit
- Direct online
- Direct online F/R
- STAR DELTA
- STAR DELTA F/R
- Auto Trans
- Selection on Motor Control Based On Horsepower
- Comparisons between Motor Control
- Electro-mechanical Star Delta (Open Transition)
- Electro-mechanical Star Delta (Close Transition)
- Comparisons between open and close transition
Course Objectives
• Determine the components and function of the motor control components.
• Choose suitable protective devices for the motor control.
• Able to perform wiring and troubleshooting of motor control.
Introduction to Motor
Control
Purpose of Motor
Control

• Prevent motor from operating

unintentionally.
• To provide protection to users and
the motor components.
• Limit the starting current and
lower the starting torque.
Induction • Consists of three common types of motor control.
motor • Direct Online (D.O.L).

(Squirrel • STAR-DELTA.
• AUTO-TRANS.

Cage)
• Used in most of the loads (motor).
• Must be installed for motors rated above 0.5hp.
Introduction to 3-
Phase Motor
• Utilizes 3-phase power supply.
• Consists of 2 types of winding connection.
• STAR.
• DELTA.
Concept of Motor
Operation
• Components of Induction
Motor
• Power Flow Diagram of
Induction Motor
• Three-phase Supply
• Three-phase Supply and
Rotating Flux
• Induction Motor
Connections
• Dual Voltage Induction
Motor Connection
• Dual Voltage, 12 Leads
Across The Line Start
Connection
• Two-speed diagrams for
six-lead and twelve-lead
motors.
Introduction to
Motor Control
Components
Main contactor.

Auxiliary contact.

Push button (ON/OFF).

Timer.

Indicator lamp.
Main • Class (AC 3 / AC 4).
• Winding (240Vac / 400Vac).
Contactor • Safety (Refer to the main contact).
• Selection (Size / Watt / Amp).
 Class of Main Contactor
NEMA SIze Continuous Amp Rating HP 230 VAC HP 460 VAC
00 9 1 2
0 18 3 5
1 27 5 10
2 45 15 25
3 90 30 50
4 135 50 100
5 270 100 200
6 540 200 400
7 810 300 600
8 1215 450 900
9 2250 800 1600
Class of • AC1- Non-inductive or slightly inductive
rows.

Main • AC2 – Starting of slip-ring motors.

• AC3 – Starting of squirrel-cage motors
Contactor and switching off only after the motor is
up to speed. (Make Locked Rotor Amps
[LRA], Break Full Load Amps [FLA])
• AC4 – Starting of squirrel-cage motors
with inching and plugging duty. Rapid
Start/Stop. (Make and Break LRA)
• AC11 – Auxiliary (control) circuits.
 • The type of load will determine the motor control
method used.
• Basic.

Selection of • Traditional.
• Combination.
Main • Important factors on the selection of main
contactor.
Contactor • Load : AC1- AC4
• Duty : one direction / reversing / plugging
• HP : horsepower
• FLA : full load amps
• Main Contactor.
 • Has 2 contacts.
• N.O = normally open.
• N.C = normally close.
• N.O = 3,4

Auxiliary • Example : 13, 14 / 53, 54 / 83, 84

• No 1, 5, 8 are to determine the terminal used for
Contact the motor control circuit.
• N.C = 1,2
• Example : 21, 22 / 61, 62 / 71, 72
• No 2, 6 and 7 are to differentiate the terminal used
in the motor control circuit.
• Auxiliary Contact.
Push button
Timer
 Color Device Type Typical Function Examples
RED Pushbutton Emergency Stop, Emergency Stop
Stop, Off button, Master Stop
button, Stop of one
or more motors.

Pilot Light Danger or alarm, Indication that a

Indicator
abnormal condition, protective device has
requiring immediate stopped the machine,
attention. e.g. overload.

Lamp Illuminated
Pushbutton
Machine stalled
because of overload,
etc. (the color RED
for the emergency
stop actuator shall
not depend on the
illumination of its
light).
 Color Device Type Typical Function Examples
YELLOW Pushbutton Return, Emergency Return, Return of machine elements to
(AMBER) Intervention – suppress safe position, override other
abnormal conditions. functions previously selected.
Avoid unwanted changes.

Indicator Pilot Light Attention, caution/marginal

condition. Change or
impending change of
Automatic cycle or motors
running; some value (pressure,
temperature) is approaching its

Lamp
conditions. permissible limit. Ground fault
indication. Overload that is
permitted for a limited time.

Illuminated Attention or caution / Start of Some value (pressure,

Pushbutton an operation intended to temperature) is approaching
avoid dangerous conditions. its permissible limit; pressing
button to override other
functions previously selected.
 Color Device Type Typical Function Examples
GREEN Pushbutton Start-On General or machine
start; start of cycle or
partial sequence.
Pilot Light Machine Ready, Safety Indication of safe
condition or
authorization to

Indicator proceed. Machine

ready for operation
with all conditions
normal or cycle

Lamp compete and machine

ready to be restarted.

Illuminated Machine or Unit ready Start or On after

Pushbutton for operation / Start or authorization by lights;
ON start of one or more
motors for auxiliary
functions; start or
energization of
machine elements.
 Color Device Type Typical Examples
Function
- Pushbutton No specific Shall be permitted

Indicator function
assigned
to be used for any
function except for
buttons with the
Lamp sole function of
Stop or Off;
inching or jogging.
 Color Device Type Typical Function Examples
WHITE OR Pushbutton Any function not Control or auxiliary
CLEAR covered by three function not directly
above related to the
working cycles.

Indicator Pilot Light Normal Condition

Confirmation
Normal pressure,
temperature.

Lamp Illuminated
Pushbutton
Confirmation that a
circuit has been
energized or function
Energizing of
auxiliary function or
circuit not related to
or movement of the the working cycle;
machine has been start or preselection
started / Start On, or of direction of feed
any preselection of a motion or speeds.
function.
Protection of
Motor Control
• Fuse
• Overload Relay
• Miniature Circuit Breaker (MCB)
• Molded-Case Circuit Breaker (MCCB)
Fuse (Helix
Fuse)
Fuse (CLPT
Fuse)
Fuse (CLS
Fuse)
Overload Relay
(Melting Alloy)
• Most popular type of overload protection.
• The motor current passes through a small heater
winding and under overload conditions.
• The heat causes a special solder to melt allowing a
rachet wheel to spin thus opening the control
circuit contacts.
• It must be reset by hand operation and Heater coil
and solder pot in one unit non-tamperable.
Overload Relay
(Bi-metallic strip)
• This design uses a bimetal strip associated with a current-
carrying heater coil.
• When an overload occurs, the heat causes the bimetal to
deflect and actuate a tripping mechanism which opens a set
of contacts in the control circuit.
• This interrupts the flow of power to the coil resulting in the
opening of the power contacts.
• Adjustable over a range from 85% to 115% of their value.
• Available with ambient compensation.
• An ambient compensated devices’ trip point is not affected
by ambient temperature and performs consistently at the
same value of current.
Overload Relay
(Electromagnetic)
• An electro-mechanical relay operated by the current flow in
a circuit.
• When the level of current in the circuit reaches a preset
value, the increased magnetic field opens a set of contacts.
• Electromagnetic overload relays operate on the magnetic
action of the load current flowing through a coil.
• When the load current becomes too high, a plunger is pulled
up into the coil, interrupting the circuit.
• The tripping current is adjusted by altering the initial
position of the plunger with respect to the coil.
Miniature Circuit
Breaker (MCB)
• 1. On and OFF (Closed an open) must be marked
(NEC240.81). 1 and 0 signs are also used around
the world (although not required by UL).
• 2. Ampere rating (less than 100 A) must be
handled by itself or on the front panel of the
circuit breaker. If more than 100 A, the sign for it
is not that obviously shown on the device.
• 3. HACR type: Indicating it is suitable for motor
installation (can be found in heating equipment,
air conditioning and fridge). Even so, this sign is
no longer used since all breakers can be used for
motors.
Miniature Circuit
Breaker (MCB)
• 1. Manufacturer
• 2. Type designated (model no.)
• 3. Voltage rating. If not indicated with AC or DC,
then it can be used for both.
• 4. SWD. It can be used for fluorescent lightning
loads at normal usage.
• 5. High intensity discharge or fluorescent
lightning loads at normal usage.
• 6. Trip and reset.
Miniature
Circuit
Breaker
(MCB)
Molded-Case
Circuit
Breaker
(MCCB)
Molded-Case
Circuit
Breaker
(MCCB)
 MCB TYPE Ampere Rating (In) Explanation

Molded-Case 1
B
2.7 – 4
3–5
Domestic and Commercial

Circuit 2 4–7 General use, small motor

Breaker C
3
5 – 10
7 – 10
(MCCB) D 10 – 20 High in rush equipment
4 10 – 50
K Frequent short duration
Z Semiconductor devices
Motor Control Circuit
• D.O.L
• D.O.L F/R
• STAR DELTA
• STAR DELTA F/R
• AUTO TRANS
• AUTO TRANS F/R
Direct online
Direct online
• Used to turn on and turn off the motor.
• To prevent the motor operates unintentionally.
• To provide protection to the users.
Direct
online
F/R
 • Used to turn on and turn off the motor.
• To prevent the motor operates
Direct online unintentionally.
F/R • To provide protection to the users.
• Operates forward and backward.
STAR DELTA
STAR DELTA
• Used to turn on and turn off the motor.
• To prevent the motor operates unintentionally.
• To provide protection to the users and the system.
• To limit the starting current and lower the starting torque.
STAR
DELTA F/R
STAR • Used to turn on and turn off the motor.
• To prevent the motor operates
DELTA F/R unintentionally.
• To provide protection to the users and the
system.
• To limit the starting current and lower the
starting torque.
• Operates forward and backward.
Auto
Trans
Auto Trans
• Used to turn on and turn off the motor.
• To prevent the motor operates unintentionally.
• To provide protection to the users and the system.
• To limit the starting current and lower the starting torque.
Selection on Motor Control Based On
Horsepower

Horsepower (hp) Type of Starter

< 0.5 D.O.L, Frequency Inverter
0.5 - 3 D.O.L, Frequency Inverter
3 - 10 Star Delta, Auto Trans, Soft Starter, Frequency Inverter

> 10 Variable Speed Drive, Frequency Inverter, Soft Starter

Comparisons between Motor Control

Type of Problem Type of Starting Method

Direct-On-Line Star-Delta Frequency Inverter Soft starter
Slipping belts Yes Medium No No
Heavy wear on bearings Yes Medium No No

High inrush current Yes No No No

Heavy wear and tear on gear boxes Yes Yes No No

Damaged goods products during stop Yes Yes No No

Water hammering in pipe system Yes Yes Best Solution Reduce

Transmission peaks Yes Yes No No

Electro-
mechanical Star
Delta (Open
Transition)
Electro-
mechanical Star
Delta (Close
Transition)
Comparisons
between open
and close
transition
 Equipment / Cable Rating (V) DC Test Voltage (VDC)

24 - 50 50 - 100

Comparisons 50 - 100 100 - 250

between open
and close 100 - 240 250 - 500

transition 440 - 550 500 - 1000

2400 1000 - 2500

4100 1000 - 2500