Overviev

Electrical Drive Systems 324 1 Industrial Motor Control

Industrial Motor Control Introduction
Switch Gear
Industrial Motor Control Circuits
Dr. P.J Randewijk Starting three-phase induction motors
Forward/Reverse Control of Three-phase Induction
Stellenbosch University
Dep. of Electrical & Electronic Engineering
Motors
Plugging of Three-phase Induction Motors
Stephan J. Chapman Reduced-voltage Starting Methods for Three-phase
Induction Motors
Chapter 6.8 (5th Edition) Outcomes of Industrial Control

1 / 47 2 / 47

Industrial Motor Control Industrial Switch Gear

6.8 Starting Induction Motors & 8.8 DC Motor Switch gear
Starters
These two sections briefly describe the electrical
control of the three-phase induction – & DC machine,
respectively . . .
We will add a bit to this with spesific focus on:
The protection of the motors (& the electrical supply)
The STARTING & STOPPING of motors
Reduced-voltage starting methods for induction motors
The FORWARD & REVERSE-contol for induction motors
As well as electrical interlocking of the
abovementioned. . .

3 / 47 4 / 47
Industrial Switch Gear (cont.) Industrial Switch Gear (cont.)
We will be making use of IEC symbols, not the ANSI Main Circuit Breaker
5
symbols used in Chapman. 1 3 13

Main Disconnect or Main Isolator without a fuse Q0

1 3 5
14

Q0
2 4 6 I >I >I >
Or a Fused Disconnect
1 3 5 These are mostly used instead of Main Isolator since it
also protect the supply against faults, e.g. a short circuit
Q0 in the MCC.
2 4 6 The circuit breaker sometimes contain a small auxiliary
Are used to isolate the Motor Control Centre (MCC), contact which can be used to determine whether the
which controls a “big” motor or different small motors, circuit breaker is OPEN or CLOSE
from the supply, i.e, during maintenance These auxiliary contacts can be normally closed, i.e. NC,
of normally open, i.e. NO. . .
Auxiliary contacts are sometimes used for interlocking
applications

5 / 47 6 / 47

Industrial Switch Gear (cont.) Industrial Switch Gear (cont.)

The main objective of the circuit breaker is to disconnect These are usually smaller than the main isolator and are
the supply “as quickly as possible” when a state of over used to isolate certain sections controlled by the MCC.
current occur, usually caused by a short-circuit It is usually placed at the electrical motor that requires
(Itrip ≈ 5×Irated ) isolation.
As a result the motor can be “disconnected” from the
I> supply for mechanical or electrical maintenance. . .
Further it can also protect the supply cable against
thermal overloading, e.g. when the supply current are Thermal (Overload) Relays
just above the rated current value for a long time –
consist of a bi-metal strip (or electronics) which tries to
Q1
imitate the thermal time constant of the electrical motor.
Are used to protect the motor against continues
over-current to prevent the motor from failing as a result
of overheating.
Isolator Consist of a bi-metal strip (or electronics) which tries to
1 3 5 13
imitate the thermal time constant of the electrical motor.
Q2
2 4 6 14

7 / 47 8 / 47
Industrial Switch Gear (cont.) Industrial Switch Gear (cont.)
(Magnetic) Contactor This consists of a circuit breaker that provides short
A1 1 3 5 13 21 circuits protection as well as overloading protection. . .
K1 Combination Starter or Compact Starters
1 3 5 13
A2 2 4 6 14 22

A Magnetic contactor is an electromechanical device with Q1

a set of three-phase(main) contacts which can be 14

switched through a small electromechanical winding

(24 VGS/WS , 110 VWS , 230 VWS , ens.) I >I >I >
2 4 6
Motor Protection Circuit Breaker A1 1 3 5 13
1 3 5 13

Q0 K1
14 A2 2 4 6 14

Combined with a mechanical contactor (everything

I >I >I > usually already assembled) . . .

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Industrial Switch Gear (cont.) Industrial Switch Gear (cont.)

Z See the top row which are only motor protection circuit More than one set of contacts can be connected to a
breakers versus the bottom row which are already button, i.e. NC and/or NO.
assembled with a mechanical contactor,
Eaton Wiring Manual 2011 Pilot Lights
X1
Pushbuttons
21 11 21 13 23 H1
S00 S0 S1 X2

22 12 22 14 24 Pilot lights are usually mounted at or close to pushbuttons

to indicate operating condition, warnings or errors.
Pushbuttons refer not only to the “face” of the buttons but
also to the contacts controlled by the buttons. Control Relays
The “face” of the button can be any colour (i.e. green, A1 13 21
yellow, red, black, . . . ) depending on the function of the
button K3
A legend (“START”, “STOP”, “FORWARD”, REVERSE”) A2 24 22
are usually displayed on the button, or sometimes only a
symbol . . . These are small relays for use in the control circuits and
are not for switching three-phase machines.

11 / 47 12 / 47
Industrial Switch Gear (cont.) Industrial Switch Gear (cont.)
Are also used to isolate circuit operating at different Flasher Timers
voltages (i.e. 24 V|DC & 230 V|AC . . . Y − ∆ timer relay
Usually consist of a combination of normaly open (NO) Usually consist of a combination of normally open (NO)
and/or normaly close(NC) contacts and normally close (NC) contacts
Z For a a graphic explanation on the operation of all the
Timers or Timing Relays different timer relays see: Eaton Wiring Manual 2011
A1 17 27 35 45

K4 Limit Switches
A2 18 28 36 46
These switches switch when something touches it and it
moves far enough to switch the contacts
ON-delay Timers (contacts 17&18 with there inverse, Usually consist of a combination of normally open (NO)
contacts 35&36) and normally close (NC) contacts
OFF-delay Timers (contacts 27&28 with there inverse,
contacts 45&46)
+ N.B. Consider the “parachute” to determine whether it
moves slowely to the right or the left, as a result of “air
resistance”
Puls Timers

13 / 47 14 / 47

Industrial Switch Gear (cont.) Industrial Motor Control Circuits

Proximity Switches Industrial Motor Control Circuits
Inductive proximity switches
Electrical motor circuits can be presented as:
Capacitive proximity switches
Ultrasonic proximity switches Block diagrams
Several optic types. . . Single line diagrams
Usually consist of one or more normally open (NO) Wiring diagrams
and/or normally close (NC) output Schematic diagrams

Z For a summary of different types of sensors see We will focus on the last-mentioned.
Eaton Wiring Manual 2011 Chapman makes use of NEMA/ANSI simbole for the
L.W. The most industrial proximity switches contains electronic
schematic diagrams
without contacts that switch, it produce a HIGH (i.e. In South-Africa the IEC/DIN symboles are used for the
usually 24 V|GS ) or a LOW (i.e. usually 0 V|GS ) output. schematic diagrams, these will be used in this course. . .
Z See Eaton Wiring Manual 2011 to compare the IEC/DIN &
NEMA/ANSI symbols.

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Industrial Motor Control Circuits (cont.)
According to the IEC convention, schematic diagrams
are divided into:
main circuit, i.e. the three-phase circuit
control circuit, usually 24 V DC or 24/110/230/400 V 1φ
AC
+ N.B. Remember the main and control circuit are
connected through relays or contactors, consequently
the voltage of the control circuit can be anything.
17 / 47
Starting three-phase induction motors (cont.)
Z mechanical shock can occur as a result of the sudden
increase in torque.
A three-phase motor cannot be connected “directly” to
the supply without protection for the
Z three-phase supply &
Z the three-phase motor.
To protect the supply against possible short circuits
fuses or, the more modern, circuit breakers are installed
in series with the supply.
The trip value of the circuit breaker needs to be set high
enough for it not the trip as a result of the high current
associated with the motor starting. . .
Therefore the trip value is required to be more than 6
times the rated current of the motor, preferably more,
say, 10 times but lower than, say, 20 times. . .
19 / 47
Starting three-phase induction motors
6.8 Starting three-phase induction motors
Three-phase cage rotor induction motors are usually
connected:
directly to the three-phase supply when started, or
by making use of reduced-voltage starting methods.
The staring method depends on:
the size of the motor,
the capability of the three-phase supply &
the type of load (mechanical).
The main advantages of Direct On Line starting are:
Z simple en
Z inexpensive.
The disadvantages of DOL starting are:
Z the starting current can be 5 to 6 times the rated current
of the motor,
Z the high starting current can cause voltage dips at the
supply. This might damage sensitive equipment&
18 / 47
Starting three-phase induction motors (cont.)
In the event of a short-circuit the supply current tends to
∞ and is only limited by the impedance of the supply
wires (which usually is very small).
The aim of the circuit breaker is then to open as quickly
as possible to prevent possible damage to the supply
wires. . .
In the case where the motor is operated above its rated
current (say at 150% of its rated value) the motor can
still fail thermally (i.e. burnout) since the circuit breaker
provides no protection. . .
To protect the motor, Thermal (Overload) relays are
required to be installed in series with the supply and the
circuit breaker.
A thermal (Overload) relay’s trip time constant tries to
emulate the thermal time constant of the motor what it
needs to protect.
20 / 47
Starting three-phase induction motors (cont.)
i.e. for a small over-current, the relay will take longer to
trip than for a higher over-current.
Direct On Line switching using contactors
In most cases the control panel and the motor are not
together, but a distance apart.
A more elegant manner is to make use of a pushbutton
and contactor to switch the motor “ON” and “OFF”.
This means that:
the electrical panel of the motor and the motor do not
need to be together
the motor can have more than one “START” and/or
“STOP” button
the motor can be controlled simultaneousness through
more than one button and/or sensors that are equipped
with auxiliary contacts
21 / 47
Starting three-phase induction motors (cont.)
Z A schematic diagram of the main and control circuit of a
typical DOL application according to the IEC/DIN
convention are shown in Eaton Wiring Manual 2011
L.W. According to the IEC/DIN convention, the main and the
control circuit are drawn separately, from top to
bottom. . .
23 / 47
Starting three-phase induction motors (cont.)
In the main circuit a (mechanical) contactor is now
placed in series with the circuit breaker (or fuse) and the
overload relay.
The control circuit is responsible for activating the
(mechanical) contactor (energise).
Z A NEMA/ANSI schematic diagram of the main- en
control circuit for a typical DOL application are shown in
Fig. 6–37
L.W. Chapman makes use of NEMA/ANSI symbols en draws
the main- and the control circuit (“control station”)
together, from left to right in the so-called ladder
format. . .
22 / 47
Starting three-phase induction motors (cont.)
Main (three-phase) circuit
Fuses were traditional used for short-circuit protection
with separate thermal (overload) relays to protect the
motor
These days Motor Protection Circuit Breakers are used,
these provide short-circuit as well as thermal (overload)
protection. . .
24 / 47
D.O.L. IEC Main Circuit D.O.L. IEC Main Circuit
Using Fuses & a thermal (overload) relay
L1 Using a Motor Protection Circuit Breaker L1
L1 phase “A” L1 phase “A” L2
L2
L2 phase “B” L2 phase “B”
L3 L3
L3 phase “C” L3 phase “C”
F1 fuse for short-circuit protection 1 3 5 Q1 the motor protection circuit breaker with build 1 3 5 13

F2 thermal (overload) relay in short-circuitand thermal (overload)

F1 protection Q1
terminals 1–6 are the terminals of the main
contacts and 13 & 14 are those of the N/O 2 4 6 terminals 1–6 are the terminals of the main 14

axillary contacts contacts and 13 & 14 are those of the N/O

A1 1 3 5 13 axillary contacts I> I> I>
K1 mechanical three-phase contactor
terminals 1–6 are the terminals of the main K1 K1 mechanical three-phase contactor 2 4 6

contacts and 13 & 14 are those of the N/O A2 2 4 6 14

terminals 1–6 are the terminals of the main
axillary contacts with A1 & A2 the terminals of contacts and 13 & 14 are those of the N/O A1 1 3 5 13

the winding of the contactor used in the axillary contacts with A1 & A2 the terminals of K1
1 3 5 13
control circuit the winding of the contactor used in the

M1 the three-phase induction machine

F2 control circuit A2 2 4 6 14

2 4 6 14 M1 the three-phase induction machine

M M
M1 M1
3∼ 3∼

25 / 47 26 / 47

D.O.L. Control Circuit D.O.L. IEC Contol Circuit

Control Circuit Generic Control Circuit L+
The control are implemented using (momentary) L+ the +24 V control circuit voltage 13

pushbuttons. M the 0 V (ground) of the control circuit voltage F2/Q1

A START button switches on a contactor. F0 (not shown) a single-phase circuit breaker
or fuse for short-circuit protection of the
14

A axillary contact of the contactor serves as a self control circuit are sometimes placed in
13

series with the contol circuit (usually in a S2 E-STOP

sealing contact to keep the contactor pulled in after the 110/230/400 V 1φ AC control circuit)
14

START button is released F2/Q1 (terminals 13 & 14) a axillary contact of

11
F2/Q1 to switch off the contactor K1 if
A STOP button in series met N/C-contacts switches off F2/Q1 trips S0 STOP
the contactor when the it is pushed S0 contacts of STOP pushbutton (per 12
convention always N/C)
According to the law(in R.S.A. it is the Factories act of S1 contacts of START pushbutton (per
11 43

1985, i.e. Law’85) a E-STOP button is required to cut all convention always N/O) S1 START K1
the power to the motor, when it is pushed. S2 contacts of E-STOP emergency stop
pushbutton (always N/C)
12 44

K1 the winding of the mechanical contactor

(terminals A1 & A2) A1
terminals 13 & 14 are the axillary contacts
of the mechanical contactor used for self K1
sealing (self sealing contacts) A2
M

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Forward/Reverse Control Forward/Reverse IEC Main Circuit
Forward/Reverse Control using contactors FORWARD/REVERSE L1

To change the direction a three-phase induction machine IEC Main Circuit L2

L3
rotates two of its phases needs to be changed, thus L1 phase “A”
L2 phase “B”
changing the phase sequence from (say) ABC to CBA.
1 3 5 13

L3 phase “C” Q1
This can be accomplished by making use of two Q1 the motor protection circuit breaker
14

contactors, one for the Forward or CW rotation and one with build-in short-circuit and
thermal (overload) protection
I> I> I>
2 4 6

for Reverse or CCW rotation. 13 & 14 are the terminals of the

N/O axillary contact
K1 the mechanical three-phase A1 1 3 5 13 21 A1 1 3 5 13 21

contactor K1 K2
(say for CW rotation) A2 2 4 6 14 22 A2 2 4 6 14 22

13 & 14 is the terminals of the N/O

axillary contact
21 & 22 is the terminals of the N/C
axillary contact
K2 the mechanical three-phase
contactor
(say for CCW rotation) M
M1
13 & 14 is the terminals of the N/O 3∼
axillary contact
21 & 22 is the terminals of the N/C
axillary contact
M1 the three-phase induction machine

Z Eaton Wiring Manual 2011

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Forward/Reverse IEC Control Circuit Forward/Reverse IEC Control Circuit (cont.)

IEC Control Circuit
Again we are looking for a solution that does not make
use of mechanical latching, since it is not that safe. . .
A system needs to be designed that if “something” fails,
the system will fail to a safe operating condition. . .
Furthermore, the use of a E-STOP as a STOP is a BAD
design. . .
A design with mechanical latching also makes it
impossible to have more than one FWD, REV or STOP
button as well as to make use of safety devices.
Therefore control is done using (momentary)
bpushbuttons with “electronic” latching. . .
The following pushbuttons are therefore required:
A FWD button to activate contactor K1
A REV button to activate contactor K2
A STOP button to switch-off both contactors when
pushed, and
A E-STOP button according to law
A N/O axillary contacts of contactors K1 & K2 serves as
self sealing contact to keep each of the contactors in
when the FWD or REV button is pressed and
released. . .
A N/C axillary contacts of contactors K1 & K2 serves as
protection against the possibility of both contactors K1 &
K2 being switched on simultaneously. . .
’n N/C axillary contacts of pushbuttons S1 & S2 serves
as protection against the possibility of both buttons S1 &
S2 being pressed simultaneously resulting in K1 & K2
momentarily switching on simultaneously and causing a
short-circuit. . .

31 / 47 32 / 47
Forward/Reverse IEC Control Circuit “Plugging”
FORWARD/REVERSE L+
Plugging of Three-phase Induction Motors
IEC Control Circuit
Q1
13
To quickly stop a three-phase induction machine
Q1 (terminals 13 & 14) an axillary contact
of Q1 to switch off the contactors
14
plugging is used.
In effect two phases of the induction machine are
11
K1/K2 if Q1 trips
E-STOP – S00
S00 E-STOP Emergency Stop 12
interchanged, exactly the same as for forward/reverse
S0 STOP pushbutton 11

S1 FWD pushbutton
STOP – S0 control.
terminals 21 & 22 are the axillary
12
The main circuit therefore look exactly the same as for
contacts to interlock S2
11 13

S2 “REV” drukknoppie
FWD – S1
13
REV – S2
13
forward/reverse control, with the only difference a
centrifugal-type switch used to stop the motor when the
12 14

terminals 21 & 22 are the axillary K1 K2

21 21
contacts to interlock S1
speed reach 0 rpm, otherwise the motor starts rotating
14 14
S2 S1
K1 terminals A1 & A2 are the contactor’s
in the opposite direction.
22 22

winding for say “CW” rotation

terminals 13 & 14 are the contacts 21 21

used for self sealing K2 K1

terminals 21 & 22 are the axillary 22 22

contacts used for interlocking K2 A1 A1

K2 terminals A1 & A2 of the contactor’s K1 K2

winding for say “CCW” rotation M
A2 A2

terminals 13 & 14 are the contacts

used for self sealing
terminals 21 & 22 are the axillary
contact used for interlocking K1

Z Eaton Wiring Manual 2011

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Plugging IEC Main Circuit Plugging IEC Control Circuit

Plugging IEC Main Circuit L1
Plugging IEC Control Circuit
L1 phase “A”
L2 The following pushbuttons are required:
L3
L2 phase “B” A START button to activate contactor K1
A PLUG button to activate contactor K2
1 3 5 13
L3 phase “C”
Q1
Q1 the motor protection circuit breaker 14 A STOP button to switch off both the contactors when
with build-in short-circuit and
thermal (overload) protection I> I> I> pressed, and
13 & 14 are the terminals of the
An E-STOP button according to the law
2 4 6

N/O axillary contacts

K1 the mechanical three-phase A N/O axillary contact of contactors K1 & K2 serves as
contactor
self sealing contacts to hold in the contactors after the
A1 1 3 5 13 21 A1 1 3 5 13 21

(for say CW rotation) K1 K2

13 & 14 is the terminals of the N/O
axillary contacts
A2 2 4 6 14 22 A2 2 4 6 14 22
START or the PLUG button have been pressed and
21 & 22 is the terminals of the N/C released. . .
axillary contacts
K2 the mechanical three-phase
A N/C axillary contacts of contactors K1 & K2 serves as
contactor protection against the possibility of both contactors K1 &
(for say CCW rotation)
K2 switched on simultaneously. . .
13 21

13 & 14 is the terminals of the N/O M F1 (n > 0)

M1
axillary contacts 3∼
21 & 22 is the terminals of the N/C
14 22
The N/C axillary contact of F1 is used to assure that K1
axillary contacts will only switch on (using the “START” button) if the
M1 the three-phase induction machine
motor is stationary.
F1 the centrifugal switch with a set of
N/O & N/C axillary contacts

35 / 47 36 / 47
Plugging IEC Control Circuit (cont.) Plugging IEC Control Circuit
The N/O axillary contact of F1 is used to assure that K2 Plugging IEC Control Circuit L+
will only switch on if the motor is rotation and the “PLUG” 13

Q1 (terminals 13 & 14) an axillary Q1

button are presses, it also help to switch off K2 when the contact of Q1 to switch off the 14

contactors K1/K2 if Q1 trips

speed of the motor reaches 0 rpm. E-STOP – S00
11

S00 E-STOP Emergency Stop

’n N/C axillary contacts of pushbuttons S1 & S2 serves S0 STOP pushbutton
12

11

as protection against the possibility of both buttons S1 & S1 FWD pushbutton STOP – S0 (Coast Stop)

S2 pressed simultaneously resulting in K1 & K2

12
terminals 21 & 22 are the axillary
11 13
contact to interlock S2
START – S1 PLUG – S2
momentarily switching on simultaneously and causing a S2 Plug pushbutton 12
13
14
13

K1 K2
short-circuit. . . terminals 21 & 22 of the axillary
contact to interlock S1 F1
21
14
S1
21
14

22 22
K1 terminals A1 & A2 of the 21 13
contactor’s winding for say “CW” Centrifugal
S2 F1
rotation 22 14
terminals 13 & 14 are the self 21 21
sealing axillary contact K2 K1
terminals 21 & 22 the axillary 22 22

contacts used for interlocking K2 A1 A1

K2 terminals A1 & A2 of the K1 K2

contactor’s winding for say M
A2 A2

“CCW” rotation
terminals 13 & 14 are the self
sealing axillary contact
terminals 21 & 22 of the axillary
contacts for interlock K1
F1 Centrifugal switch

37 / 47 38 / 47

Reduced-voltage Starting Methods Reduced-voltage Starting Methods (cont.)

Reduced-voltage Starting Methods for Three-phase 8 External Stator Resistor Starting method
Induction Motors This method is very simple but results in major I 2 R
The supply current when starting a three-phase losses during start-up.
induction machine is usually very high, since the slip is 1 Z See Fig. 6–39
(s = 1).
By reducing the supply voltage at start-up, the start-up
current is also reduced:

∵ I1 ∝ Vφ

The disadvantage of this is since

τm ∝ I1 2 ∝ Vφ 2

the start-up torque of the induction machine might be to

small to bring the load up to speed.

Z Or the IEC example in the Eaton Wiring Manual 2011

39 / 47 40 / 47
Reduced-voltage Starting Methods (cont.)
7 Autotransformer starting method
This method is more efficient than the above-mentioned,
but are more expensive since autotransformers cost way
more that simple resistors.
Z See Fig. 6–36
Reduced-voltage Starting Methods (cont.)
3 External Stator Reactor starting method
Very simple – control is simialer to that of External Stator
Resistor starting method
But with little/no losses during start-up & relatively cheap
(i.e. more expensive than External Stator Resistor
starting method, but way less expensive than
Autotransformer starting method)

3 Slip ring induction motor with external resistor

starting
A slip ring induction motor is more expensive than a cage
rotor induction motor + there are major losses in the
external rotor resistors during starting.
Z See IEC example in Eaton Wiring Manual 2011

Z Or the IEC example in the Eaton Wiring Manual 2011

41 / 47 42 / 47

Reduced-voltage Starting Methods (cont.) Reduced-voltage Starting Methods (cont.)

3 Y-Delta starting (wye-delta)
Are often used since it is easy and inexpensive – it is the
cheapest way to start a induction motor using reduced
voltage sarting method. Can only be used for induction
motor of which the normal operating configuration is
delta.
Z See Fig. 6–35
4 Soft start
This is the best metord since the voltage gradually
increase, all the other methods have step increases in
the voltage.
Can be used on wye or delta connected induction
motors.
The cost is currently still higher that the cost of the
star-delta method, but the cost of soft starters are
decreasing. . .
Z For more information on soft starters see
Eaton Wiring Manual 2011

Z Or see the IEC example in Eaton Wiring Manual 2011

43 / 47 44 / 47
Outcomes of Industrial Control Outcomes of Industrial Control (cont.)
For Industrial Control you now need to: Motor Protection Circuit Breaker
know the difference between a: Pushbuttons (N/O and N/C)
Pilot Lights
Main Isolator (Main Disconnect)
Main Circuit Breaker know what is meant by Direct On Line (D.O.L.)
Fuse Disconnect connection.
Isolator understand the advantages of using a (mechanical)
Thermal (Overload) Relay contactor to switch a D.O.L. motor instead of by hand.
(Mechanical) contactor understand how a contactor can be electrically
Motor Protection Circuit Breaker interlocked by using a self sealing contact.
know the difference between a normally open (N/O) and know how to design and draw, using IEC symbols, a
a normally cloce (N/C) contact D.O.L. starter main- and control circuit with pushbuttons
know that a axillary contact is and self sealing contacts, that makes use of electrical
know the IEC/DIN diagram symbols of the following: interlocking.
Isolator
Fuse
Circuit Breaker
Thermal (Overload) Relay
(Mechanical) contactor

45 / 47 46 / 47

Outcomes of Industrial Control (cont.)

know how to design and draw, using IEC symbols, a
forward/reverse main- and control circuit starter using
pushbuttons and self sealing contacts, what provides
sufficient protection against the possibility of the forward
and the reverse contactors switching on simultaneously,
by using electrical interlocking.
know how to design and draw, using IEC symbols, a
“plugging” main- and control circuit.
understand what reduced-voltage starting means and
know the advantages and disadvantages.
know the different reduced voltage starting methods
together with their advantages and disadvantages.

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