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MODULE 2: ACROSS THE LINE MOTOR STARTERS

EMTC 127

LESSON 1: Direct On Line (DOL) Motor Starters

LESSON 2: Limit Switches / Contact Sensors

LESSON 3: Manual Motor Starter

LESSON 4: Magnetic Motor Starter

LESSON 5: Motor Control Circuits

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INTRODUCTION
This module aims to provide information about the Motor Control Circuits and
Motor Controller. It contains deeper understanding about the direct on line motor
starter and motor controller and circuits for greater familiarization of the topic. This
module is a consolidated information in which the limit switches and how could it
help the students to make and analyze a diagram. The intent of this module the
reader to analyze and construct a diagram by familiarizing the motor controller and
circuits.

OBJECTIVES
 To be familiarized with the design of the control circuit diagram and
wiring circuit diagram of the direct on line motor starter.
 Learners will able to perform actual board wiring activity on the
reduced voltage motor starter.
 Will able to troubleshoot possible defects and circuit faults of the
motor controller.
 To be familiarized with the control circuit diagram and wiring circuit
diagram designing of the reduced voltage motor starter.
 Learners will able to perform actual board wiring activity about the
manual and magnetic motor starter.
 Will able to troubleshoot possible defects and circuit faults of the
motor controller.
 To discuss cautions that must be observed in reversing circuits
 Will explain how to reverse a three-phase motor
 Will discuss interlocking methods

DIRECTIONS
The module contains five (5) lessons. Read carefully the different topics given
in this module. Understand each process if there are, carefully direct on line (DOL)
motor starter, limit switches/contact sensors, manual & magnetic motor starter and
motor controller. 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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LESSON 1

Direct On Line (DOL) Motor Starter

Direct On Line (DOL) Motor Starter

 Different starting methods are
employed for starting induction motors
because Induction Motor draws more
starting current during starting. To
prevent damage to the windings due to
the high starting current flow, we
employ different types of starters.
 The simplest form of motor starter for
the induction motor is the Direct On
Line starter. The Direct On Line Motor
Starter (DOL) consist a MCCB or Circuit
Breaker, Contactor and an overload
relay for protection. Electromagnetic
Direct Online Motor Starter - Square D
contactor which can be opened by the
thermal overload relay under fault
conditions
 Typically, the contactor will be controlled by separate start and stop buttons,
and an auxiliary contact on the contactor is used, across the start button, as
a hold in contact. I.e. the contactor is electrically latched closed while the
motor is operating.

Principle of Direct On Line Starter (DOL)

 To start, the contactor is closed, applying full line voltage to the motor
windings. The motor will draw a very high inrush current for a very short time,
the magnetic field in the iron, and then the current will be limited to the
Locked Rotor Current of the motor. The motor will develop Locked Rotor
Torque and begin to accelerate towards full speed.
 As the motor accelerates, the current will begin to drop, but will not drop
significantly until the motor is at a high speed, typically about 85% of
synchronous speed. The actual starting current curve is a function of the
motor design, and the terminal voltage, and is totally independent of the
motor load.
 The motor load will affect the time taken for the motor to accelerate to full
speed and therefore the duration of the high starting current, but not the
magnitude of the starting current.
 Provided the torque developed by the motor exceeds the load torque at all
speeds during the start cycle, the motor will reach full speed. If the torque
delivered by the motor is less than the torque of the load at any speed during

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the start cycle, the motor will stops accelerating. If the starting torque with
a DOL starter is insufficient for the load, the motor must be replaced with a
motor which can develop a higher starting torque.
 The acceleration torque is the torque developed by the motor minus the load
torque, and will change as the motor accelerates due to the motor speed
torque curve and the load speed torque curve. The start time is dependent
on the acceleration torque and the load inertia.

DOL starting have a maximum start current and maximum start torque
 This may cause an electrical problem with the supply, or it may cause a
mechanical problem with the driven load. So this will be inconvenient for
the users of the supply line, always experience a voltage drop when starting
a motor. But if this motor is not a high power one it does not affect much

Parts of DOL Starters

Contactors & Coil
 Magnetic contactors are electromagnetically operated
switches that provide a safe and convenient means for
connecting and interrupting branch circuits.
 Magnetic motor controllers use electromagnetic energy
for closing switches. The electromagnet consists of a coil
of wire placed on an iron core. When a current flow
through the coil, the iron of the magnet becomes
magnetized, attracting an iron bar called the armature.
An interruption of the current flow through the coil of
wire causes the armature to drop out due to the
DOL part - contactor
presence of an air gap in the magnetic circuit.
 Line-voltage magnetic motor starters are
electromechanical devices that provide a safe, convenient, and economical
means of starting and stopping motors, and have the advantage of being
controlled remotely. The great bulk of motor controllers sold are of this type.
 Contactors are mainly used to control machinery which uses electric motors.
It consists of a coil which connects to a voltage source. Very often for Single
phase Motors, 230V coils are used and for three phase motors, 415V coils are
used. The contactor has three main NO contacts and lesser power rated
contacts named as Auxiliary Contacts [NO and NC] used for the control circuit.
A contact is conducting metal parts which completes or interrupt an electrical
circuit.

 NO-normally open
 NC-normally closed

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Over Load Relay (Overload protection)

 Overload protection for an electric motor is necessary to prevent burnout and
to ensure maximum operating life
 Under any condition of overload, a motor draws excessive current that causes
overheating. Since motor winding insulation deteriorates due to overheating,
there are established limits on motor operating temperatures to protect a
motor from overheating. Overload relays are employed on a motor control to
limit the amount of current drawn.
 The overload relay does not provide short circuit protection. This is the
function of over current protective equipment like fuses and circuit breakers,
generally located in the disconnecting switch enclosure.
 The ideal and easiest way for overload protection for a motor is an element
with current-sensing properties very similar to the heating curve of the motor
which would act to open the motor circuit when full-load current is exceeded.
The operation of the protective device should be such that the motor is
allowed to carry harmless over-loads but is quickly removed from the line
when an overload has persisted too long.
 Normally fuses are not designed to provide overload protection. Fuse is
protecting against short circuits (over current protection). Motors draw a high
inrush current when starting and conventional fuses have no way of
distinguishing between this temporary and harmless inrush current and a
damaging overload. Selection of Fuse is depend on motor full-load current,
would “blow” every time the motor is started. On the other hand, if a fuse
were chosen large enough to pass the starting or inrush current, it would not
protect the motor against small, harmful overloads that might occur later.
 The overload relay is the heart of motor
protection. It has inverse-trip-time
characteristics, permitting it to hold in
during the accelerating period (when inrush
current is drawn), yet providing protection
on small overloads above the full-load
current when the motor is running.
Overload relays are renewable and can
withstand repeated trip and reset cycles
without need of replacement. Overload
relays cannot, however, take the place of
over current protection equipment. DOL part – Thermal Overload Relay
 The overload relay consists of a current-sensing unit connected in the line to
the motor, plus a mechanism, actuated by the sensing unit, which serves,
directly or indirectly, to break the circuit.

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Overload relays can be classified as being thermal, magnetic, or electronic

1. Thermal Relay: As the name implies, thermal overload relays rely on the
rising temperatures caused by the overload current to trip the overload
mechanism. Thermal overload relays can be further subdivided into two
types: melting alloy and bimetallic.
2. Magnetic Relay: Magnetic overload relays react only to current excesses and
are not affected by temperature
3. Electronic Relay: Electronic or solid-state overload relays, provide the
combination of high-speed trip, adjustability, and ease of installation. They
can be ideal in many precise applications.

Wiring of DOL Starter

1. Main Contact
 Contactor is connecting among Supply Voltage, Relay Coil and Thermal
Overload Relay. L1 of Contactor Connect (NO) to R Phase through MCCB
 L2 of Contactor Connect (NO) to Y Phase through MCCB
 L3 of Contactor Connect (NO) to B Phase through MCCB.
NO Contact (-||-):
 (13-14 or 53-54) is a normally Open NO contact (closes when the relay
energizes)
 Contactor Point 53 is connecting to Start Button Point (94) and 54 Point of
Contactor is connected to Common wire of Start/Stop Button.
NC Contact (-|/|-):
 (95-96) is a normally closed NC contact (opens when the thermal overloads
trip if associated with the overload block)

2. Relay Coil Connection

 A1 of Relay Coil is connecting to any one Supply Phase and A2 is connecting
to Thermal over Load Relay’s NC Connection (95).

3. Thermal Overload Relay Connection:

 T1,T2,T3 are connect to Thermal Overload Relay
 Overload Relay is Connecting between Main Contactor and Motor
 NC Connection (95-96) of Thermal Overload Relay is connecting to Stop Button
and Common Connection of Start/Stop Button.

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Wiring Diagram of DOL Starter

Working principle of DOL Starter
 The main heart of DOL starter is Relay Coil. Normally it gets one phase
constant from incoming supply Voltage (A1).when Coil gets second Phase relay
coil energizes and Magnet of Contactor produce electromagnetic field and
due to this Plunger of Contactor will move and Main Contactor of starter will
closed and Auxiliary will change its position NO become NC and NC become
(shown Red Line in Diagram).

Pushing Start Button

 When We Push the start Button
Relay Coil will get second phase
from Supply Phase-Main contactor
(5)-Auxiliary Contact (53)-Start
button-Stop button-96-95-To
Relay Coil (A2).Now Coil
energizes and Magnetic field
produce by Magnet and Plunger of
Contactor move. Main Contactor
closes and Motor gets supply at
the same time Auxiliary contact
become (53-54) from NO to NC.
Release Start Button
 Relay coil gets supply even
though we release Start button.
When we release Start Push
Button Relay Coil gets Supply
phase from Main contactor (5)- Direct on Line Starter – Wiring Diagram
Auxiliary contactor (53) – Auxiliary contactor (54)-Stop Button-96-95-Relay
coil (shown Red / Blue Lines in Diagram).
 In Overload Condition of Motor will be stopped by intermission of Control
circuit at Point 96-95
Pushing Stop Button
 When we push Stop Button Control circuit of Starter will be break at stop
button and Supply of Relay coil is broken, Plunger moves and close contact of
Main Contactor becomes Open, Supply of Motor is disconnected.
Motor Starting Characteristics on DOL Starter
Available starting current: 100%
Peak starting current: 6 to 8 Full Load Current.
Peak starting torque: 100%

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Advantages of DOL Starter

1. Most Economical and Cheapest Starter
2. Simple to establish, operate and maintain
3. Simple Control Circuitry
4. Easy to understand and trouble‐shoot.
5. It provides 100% torque at the time of
starting
6. Only one set of cable is required from
starter to motor
7. Motor is connected in delta at motor
terminals
DOL – Wiring Scheme
Disadvantages of DOL Starter
1. It does not reduce the starting current of the motor
2. High Starting Current: Very High Starting Current (Typically 6 to 8 times the
FLC of the motor)
3. Mechanically Harsh: Thermal Stress on the motor, thereby reducing its life
4. Voltage Dip: There is a big voltage dip in the electrical installation because
of high in-rush current affecting other customers connected to the same lines
and therefore not suitable for higher size squirrel cage motors
5. High starting Torque: Unnecessary high starting torque, even when not
required by the load, thereby increased mechanical stress on the mechanical
systems such as rotor shaft, bearings, gearbox, coupling, chain drive,
connected equipment, etc. leading to premature failure and plant
downtimes.

Features of DOL starting

 For low- and medium-power three-phase motors
 Three connection lines (circuit layout: star or delta) High starting torque
 Very high mechanical load
 High current peaks
 Voltage dips
 Simple switching devices

Direct On Line Motor Starter (DOL) is suitable for

 A direct on line starter can be used if the high inrush current of the motor
does not cause excessive voltage drop in the supply circuit. The maximum
size of a motor allowed on a direct on line starter may be limited by the
supply utility for this reason. For example, a utility may require rural
customers to use reduced-voltage starters for motors larger than 10 kW.
 DOL starting is sometimes used to start small water pumps, compressors, fans
and conveyor belts.

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Direct On Line Motor Starter (DOL) is NOT suitable for

 The peak starting current would result in a serious voltage drop on the supply
system
 The equipment being driven cannot tolerate the effects of very high peak
torque loadings
 The safety or comfort of those using the equipment may be compromised by
sudden starting as, for example, with escalators and lifts.

LEARNING ACTIVITY 2. 1

1. How does a Direct On Line Motor Starter work? Prove your answer
in a minimum of 70 words.
2. Explain the Wiring Diagram of Direct On Line Starter based on
your understanding in a minimum of 100 words.
3. As a student, Is it important to memorize the number of the
connection or the contacts? Why? Prove your answer in a minimum
of 70 words.

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LESSON 2

Limit Switches / Contact Sensors

LIMIT SWITCHES

 Limit switches are used to automatically detect or sense the presence of an

object or to monitor and indicate whether the movement limits of that object
have been exceeded. The original use for limit switches, as implied by their
name, was to define the limit or endpoint over which an object could travel
before being stopped. It was at this point that the switch was engaged to
control the limit of travel.

How does a limit switch work?

 A standard limit switch used in industrial applications is an electromechanical

device that consists of a mechanical actuator linked to a series of electrical
contacts. When an object (sometimes called the target) comes in physical
contact with the actuator, the actuator plunger’s movement results in the
electrical contacts within the switch to either close (for a normally open
circuit) or open (for a normally closed circuit) their electrical connection.
Limit switches use the mechanical movement of the actuator plunger to
control or change the electrical switch's state. Similar devices, such
as inductive or capacitive proximity sensors, or photoelectric sensors, can
accomplish the same result without requiring contact with the object. Hence,
limit switches are contact sensors in contrast to these other types of proximity
sensing devices. Most limit switches are mechanical in their operation and
contain heavy-duty contacts capable of switching higher currents than those
of alternative proximity sensors.

Components of a limit switch

 Limit switches consist of an actuator with operating head, the switch body
mechanism, and a series of electrical terminals that are used to connect the
switch to the electrical circuit that it is controlling. The operating head is the
part of the limit switch that comes in contact with the target. The actuator
contains is connected to the operating head, whose linear, perpendicular, or
rotary motion is then translated by the actuator to close or open the switch.
The switch body contains the switch contact mechanism whose state is
controlled by the actuator. The electrical terminals are connected to the
switch contacts and enable wires to be joined to the switch through terminal
screws.
 Industrial machinery that undergoes automatic operations usually requires
control switches that activate according to the movements involved in a
machine’s performance. For repeat usage, the accuracy of the electrical
switches needs to be reliable and their response rate should be prompt. Due
to the mechanical specifications and performance parameters of different

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machines, factors such as size, operational force, mounting method, and

stroke rate are important characteristics in the installation and maintenance
of limit switches. In addition, a limit switch’s electrical rating should be
matched to the mechanical system loads that it will be controlling in order to
avoid instrument failure.

Limit Switch Uses and Operation

 In most cases, a limit switch begins operating when a moving machine or a

moving component of a machine makes contact with an actuator or operating
lever that activates the switch. The limit switch then regulates the electrical
circuit that controls the machine and its moving parts. These switches can be
used as pilot devices for magnetic starter control circuits, allowing them to
start, stop, slow down, or accelerate the functions of an electric motor. Limit
switches can be installed into machinery as control instruments for standard
operations or as emergency devices to prevent machinery malfunction. Most
switches are either maintained contact or momentary contact models.

Limit Switch Contacts

 Control schematics for limit switches usually display a limit switch symbol to
indicate the state of the switch contacts. The most common contact symbols
show whether the device has normally open or normally closed limit switch
contacts. The symbol for a “normally open held closed” state indicates that
the contact has been wired as a normally open contact, but when the circuit
is put into its normal off state, part of the machine keeps the contact closed.
Likewise, a limit switch that is designated as “normally closed held open” will
have a closed wiring design but be held open. Other types of contacts, such
as those used in pressure and flow switches, can be configured in a similar
way.

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Advantages and Limitations of Limit Switches

Limit switches offer several advantages intrinsic to their design:

 The designs are generally simple and straightforward

 They work well in almost any industrial setting
 They exhibit high accuracy and repeatability
 They are low power consumption devices
 They can switch high-inductance loads
 They can be used to switch multiple loads
 They are simple to install
 They are rugged and reliable
 They typically have heavy-duty electrical contacts meaning they can be used
to switch higher levels of current directly without the need to utilize
secondary relay control

Limit switches also have several limitations, which means they may not be suited
for every application:

 Because they rely on mechanical action, they generally are used in equipment
that operates at relatively low speeds
 They are contact sensors, meaning they must make physical contact with the
target for them to operate
 The nature of their mechanical design means that the devices are subject to
mechanical wear or fatigue over time and will need eventual replacement

Key limit switch terminology

There are several key terms that are associated with the design of limit switches.
Here is a brief summary of those terms for reference:

 Pretravel — represents the distance or angle through which the actuator on

the limit switch must travel before it trips the switch contacts
 Operating Point — represents the actuator’s position when the switch
contacts move into the operating position
 Release Point — represents the actuator’s position when the contacts return
to their original state
 Differential — represents the distance or angular displacement (degrees)
between the operating and release points (i.e. between when the contacts
trip and when they reset)
 Overtravel — represents any motion of the actuator component past the trip
point of the switch
 Initial Position — represents the position of the switch’s actuator when it not
subjected to any external forces
 Operating force (torque) — represents the magnitude of the force (or the
torque for angular movement) that is needed to produce actuator movement.
 Minimum return force (torque) — represents the magnitude of the force (or
the torque for angular movement) that is required to return the switch
actuator to its initial position

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 Total Travel — the maximum distance the actuating element is capable of

traveling during its operational cycle
 Repeat Accuracy — represents a measure of the degree to which the limit
switch is able to repeat its characteristics during repeated (successive)
operations.

Types of Mechanical limit switches

1. Lever-type limit switch

2. Push type limit switch

Lever Type Limit Switch

 In the case of the lever type limit switch, the actuating arm is a rod connected
to a lever shaft which is free to rotate when the rod is dislocated.

 When the forces displaying rod are removed, the lever shaft is returned to its
normal state by a return spring.

 The lever shaft has a roller mounted on its bottom, which rotates a rocker as
it changes its position from right side to left side.

 The mechanical action operates one are more contacts which are mounted on
the other side of the limit switch as shown in the above figure.

 The electrical contact may be open or close initially. The action of the
actuator and lever arms takes it from one state to the other state.
Hence normally open limit switch will be closed and when activated and the
closed switch will be open when actuated.

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Push Type Limit Switch

 In the push type limit switch in the above figure, the contact gets operated
from the depression of the contact lever arm.

Based on the type of motion, limit switches are classified as

1. Rotary motion
2. Linear motion

Rotary Motion Limit Switch

 It is operated by rotating a shaft. Once the shaft reaches a set number of

rotations or sets angle the switch gets activated.

 Rotary limit switches are preferred where the adjustment of limits of travel
is required frequently.

 An important application is in overhead cranes for hoisting and lowering

motion.

Linear Motion Limit Switch

 It detects and contact changes are triggered by linear motion.

 In this case the once the limit switch is fixed, only very little adjustment is
possible by adjusting the lever position.

Limit Switches are used for

 Momentary contact

 Maintained contact

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Momentary Contact

 When the target comes in contact with the actuator arm, it makes to move
the actuator from the free position to the operating position.

 At this point, the electrical contacts also change the state. When the target
moves away, the actuating arm and also the contacts become normal.

Maintained Contact

 In some applications, there is a need to remain actuator and contacts in the

same state even after the target moved away. Need to apply a force to bring
back the actuator to a normal state.

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Advantages

 High current capability

 Low cost
 Familiar with low technological sensing.

Disadvantages

 Wear and tear

 Requires physical contact with the target.
 Chances of contact bounce
 The response is slow compared with non-contact sensors such as proximity
sensors.

Applications

 Plant automation or machinery Interlocking applications.

 Limit switches are often used in machine tools to limit the travel of a machine
axis.
 Used in materials handling applications, to indicate the passage of material
from one platform to another.
 Used in overhead cranes.
 Used in control panels to control the lighting.

LEARNING ACTIVITY 2. 2

1. Are Limit Switches available that cannot be used outdoors? Why?

2. Why is the Limit Switch important?
3. What is the difference between Momentary Contact and
Maintained Contact?
4. Explain the operation of the image given below

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LESSON 3

Manual Motor Starter

MANUAL MOTOR STARTER

 Manual motor starters are electromechanical protection devices for the main
circuit. They are used mainly to switch motors manually ON/OFF and to
provide fuse less protection against short-circuit, overload and phase failures.
Fuse less protection saves costs, space and ensures a quick reaction under
short-circuit condition by switching off the motor within milliseconds. Starter
combinations are setup together with contactors.
 A manual motor starter is package consisting of a horsepower rated switch
with one set of contacts for each phase and corresponding thermal overload
devices to provide motor overload protection.
 The main advantage of a manual motor starter is lower cost than a magnetic
motor starter with equivalent motor protection but less motor control
capability.
 Manual motor starters are often used for smaller motors - typically fractional
horsepower motors but the National Electrical Code allows their use up to 10
Horsepower.
 Since the switch contacts remain closed if power is removed from the circuit
without operating the switch, the motor restarts when power is reapplied
which can be a safety concern.
 They do not allow the use of remote control or auxiliary control equipment
like a magnetic starter does.

Main Benefits:

 Harmonized main accessory range (auxiliary contacts, signal contacts, shunt

trips and under voltage releases) for MS1xx and MO1xx family
 Compact design
 Efficient planning and installation perfectly matching the ABB contactor
family
 Simple connecting links ensure electrical and mechanical connection to build
direct-on-line starter
 Less machine downtime by protecting motors and reduced trouble shooting
 Reduction of maintenance expenditures by protecting motors

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Main Features:

 Adjustable current setting for overload protection and magnetic trip

indication
 Manual control / short-circuit current and overload protection
 Disconnection function
 Temperature compensation
 Remote control via under voltage release or shunt trip
 Short-circuit service breaking capacity Ics up to 100 kA.

Why manual motor starters?

 Manual motor starters are protection devices for electrical installations and
motor applications. They combine motor control and protection in a single
device.

 These devices are mainly used to switch motors manually on/ off and protect
them against short-circuit, overload and phase failures. Fuse less protection
with a manual motor starter saves costs, space and ensures a quick reaction
under short-circuit condition, by switching off the motor within milliseconds.

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Customer benefit
 Compact design / space saving
 Various functions in one device
 Quick reaction / fast current limitation
 Motor protection concept for the world market (IEC, UL)
 Safe and cost-saving solution
How Does a Manual Motor Starter Work?

 Manual motor starters are the simplest kind of motor starter and consist of an
on/off switch and an overload relay. They are, as their name suggests,
operated manually. A button, toggle, or rotary switch mounted directly on
the starter is pressed to start or stop the connected electrical equipment.
Mechanical linkages from the buttons or toggle force the contacts to open and
close, starting and stopping the motor.
 In the manual motor starter, the capacitor and coils present in the motor will
control the direction on a single-phase induction motor. If the motor reaches
a specific speed, the built-in starter winding starts to produce a click sound.
Manual motor starters give motors overload protection. They make sure that
the required amount of current passes to the motor and help with the
temperature control in the motor.
 All motor starters share certain power control functions. They are rated by
current (amperes) or power (horsepower) and have remote on/off control and
motor overload protection. They have plugging and jogging functions that
rapidly make or break a current.
 A self-protected starter is a variation of the manual starter and is often used
in multiple-motor control panels. The control panels have low-level,
instantaneous overcurrent protection which lets a single upstream short-
circuit-protection device protect several starters. This means the motors
don’t need individual short-circuit protection. These manual starters can be
used on both single and three-phase motor loads.

Applications and Industries

 Since manual motor starters do not usually provide for disengagement of

motor power in the event of power interruption, they are generally used for
smaller motors where it is beneficial to resume operating upon restoration of
power. This includes small pumps, fans, power saws, blowers, packaging,
sorting, and other machinery. Manual starters with under-voltage protection
provide a means of de-energizing the starter circuit after a power interruption
and hence are used for conveyors, etc. where there is danger from an
automatic restart to both equipment and personnel. Manual motor starters
with under-voltage protection are used on machine tools, woodworking
equipment, etc. where safety requirements call for the motor to drop out
after power failure.
 They are available in both NEMA and IEC configurations and standard sizes.
Manual starters are smaller starters and have a lower initial cost than other
starters. They are used in full voltage, across-the-line applications for small
to medium-sized single- and three-phase motors

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Considerations

 Manual motor starters are limited to the size motor they can start, starting
at the fractional HP levels and usually extending up to a maximum of 10-15
HP, depending on voltage. They tend to be used with equipment that is
started infrequently or which run continuously with few stops. Beyond there,
specifiers need to consider magnetic starters or even soft starters. Special
cases such as reversing or multi-speed service are addressed by application-
specific styles. Other considerations beyond motor size and voltage include
what looking at the applications and looking into options such as explosion-
proof, enclosure ratings, and fuse or breaker protected.

LEARNING ACTIVITY 2. 3

1. Can I use the Manual Motor Starter on a single phase motor? Why?
2. Can the Manual Motor Starter be used alone or only with a contactor?
3. Explain the difference between manual motor starters that provide
low voltage release and those that do not.

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LESSON 4

Magnetic Motor Starter

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.

Motor Starter Circuitry & Operation

There are two circuits in a motor starter, which are as follows:

1. Power Circuit: The power circuit connects the line to the motor. It provides
transmission of electricity through the starter contacts, overload relay, and then to
the motor. The motor current is carried by the power (main) contacts of the
contactor.

2. Control Circuit: This is the other motor starter circuit, which operates the contactor
to turn it on or off. The contactor main contacts are responsible for allowing or
interrupting the flow of current to the motor. To do this, the contacts in the control
circuit are either opened or closed. The control circuit energizes the contactor coil,
which creates an electromagnetic field. The power contacts are pulled by this
electromagnetic field to a closed position. This completes the circuit between the
motor and the line. This way, remote operations are made possible by the control
circuit.

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The control circuit can be wired in the following two ways:

1. Method 1: One of the most widely used methods employed for wiring the control
circuit is referred to as the “Two-wire method”. A maintained contact type of pilot
device like presence sensor, thermostat, or float switch is used in the two-wire
method of wiring the control circuit.

2. Method 2: Unlike the two-wire method, the “Three-wire method” of wiring the
control circuit uses a holding circuit contact and the momentary contact pilot
devices.

The control circuit can derive the power from either of the following three ways:
 Common Control: This type of control is when the power source of the
control circuit is the same as the motor.
 Separate Control: This is the most popular type of control. As the name
suggests, the control circuit derives power from a
separate source in this arrangement. Generally, the power
derived is lower in voltage as compared to the motor’s
power source.
 Transformer Control: As the name suggests, the control circuit derives power
from a control circuit transformer. Generally, the power
derived is lower in voltage as compared to the motor’s
power source.

Types of Magnetic Motor Starters

Depending on how they are connected in a circuit, there are many types of magnetic
motor starters, such as:

1. Direct-On-Line Starter

 The direct-on-line starter is the simplest form of motor starter, other than a
manual starter. The controller of this starter is typically a simple push button
(but could be a selector switch, limit switch, float switch, etc.). Pressing the
start button closes the contactor (by energizing the contactor coil) connected
to the main supply and motor. This provides the supply current to the motor.
To turn the motor off, a stop button is provided. To protect it from over
current, the control circuit is wired through a normally closed auxiliary
contact of the overload relay. When the overload relay trips, the normally
closed auxiliary contact opens, and de-energizes the contactor coil, and the
contactor main contacts open.

The Advantages of Using Direct-On-Line Motor Starters:

 They have a compact design.
 They are cost-effective.
 They have a simple construction.

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2. Rotor Resistance Starter

 In the rotor resistance starter, the three resistances are connected such that
they are in series with the rotor windings. This helps reduce the rotor current
considerably, as well as increases the motor torque.

The Advantages of Using Rotor Resistance Motor Starters:

 They are cost-effective.
 They have a simple speed control method.
 They provide low starting current, large starting torque, and large pull-
out torque

3. Stator Resistance Starter

 The stator resistance starter consists of three resistors, which are
connected in series with each phase of the stator windings. At each resistor,
a voltage drop is caused, so it becomes necessary to apply low voltage to each
phase. These resistances are set at the start or maximum position during the
motor start stage. The starting current is kept at a minimum in this type of
starter. Also, the starting torque to the motor needs to be maintained.

The Advantages of Using Stator Resistance Motor Starters:

 They are suitable for use in speed control applications.
 They have extremely flexible starting characteristics.
 They provide smooth acceleration

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4. Auto Transformer Starter

 With an auto transformer starter, the transformer supplies a certain

percentage of the primary voltage to the secondary of the transformer. The
auto transformer is connected in a star configuration. The three tapped
secondary coils of the transformer are connected to the three motor phases
in this type of starter. This helps in reducing the voltage that is being applied
to the motor terminals.

The Advantages of Using Auto Transformer Motor Starters:

 They can be used for manual speed control, but with limited options.
 They have extremely flexible starting characteristics.
 They have a high output torque.

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5. Star Delta Starter

 Compared to the other types of starters, the star delta starter is used on a
large scale. As the name suggests, the three windings are connected in a star
connection in the star delta starters. A certain time is set by the timer or any
other controller circuit. After this time is passed, the windings are then
connected in the delta connection. The phase voltage in the star connection
is reduced to 58%, and the total current drawn is 58% of normal current. This
results in a reduced torque.

The Advantages of Using Star Delta Motor Starters:

 They are ideal for long acceleration times.
 They have a lower input surge current when compared to other
Starters
 They have a simpler construction as compared to other starters.

Features of Motor Starters

Today, motor starters are used on a large scale due to their list of beneficial
features. The following are some features of these highly useful electrical devices:

1. They facilitate the starting and stopping of the motor.

2. The starters are rated by power (horsepower, kilowatt) and current
(amperes).
3. They provide the necessary overload protection for the motor.
4. The electrical device facilitates remote on/off control feature.
5. These devices allow you to make and break current rapidly (plugging and
jogging).

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Fundamental Functions of Motor Starters

The following are the most fundamental functions that a starter has to perform:

1. Control: The control function is mainly carried out by the contactor

component of a starter. It is controlling the opening and closing of the power
electrical circuit. The switching is done by the main contacts (poles) of the
contactor. An electromagnetic coil is energized, which open or close the contacts.
This electromagnetic coil has a nominal control voltage, and can either be an AC or
DC voltage.

2. Short-Circuit Protection: In industrial applications, normal load current can

be up to thousands of amperes. In the case of a short-circuit fault, the fault current
can go over 100,000 amperes. This can cause severe damage to the equipment. The
short-circuit protection disconnects the supply and prevents the potential damage
in a safe manner. Short circuit protection is provided by fuses or circuit breakers in
a Combination Motor Controller.

3. Overload Protection: When a motor draws more current than it is designed

to, an overload condition is caused. The main objective of an overload relay is to
detect the excess currents. When an overload is detected, the auxiliary contact of
the overload relay opens the circuit and prevents the motor from burning out or
overheating. Electronic or electromechanical overload relays are used in
combination with a contactor to provide the required overload protection.

4. Disconnecting and Breaking: In order to prevent an unintended restart, it is

required to disconnect the motor from the main power circuit. In order to safely
perform maintenance on a motor or starter, a motor must be able to switch off and
be isolated from the power. The disconnect switch of the circuit provides this
function. Disconnecting and breaking is provided by a disconnect switch or circuit
breaker in a Combination Motor Controller (or can be installed remotely from the
starter).

Standards and Ratings

 There are many factors involved in motor starter ratings, such as thermal
current, continuous current, motor voltage, and power.

 The thermal current is dependent on the thermal conductivity (k), which is

the property indicating the heat conducting ability of a material. It means
that thermal current is directly proportional to the thermal conductivity.

 The continuous current, which is also commonly referred to as the continuous

ampere rating is a measure of the capability of the motor control starter to
handle current for a continuous time.

 The power rating of the motor starter is based on the type of motor used. DC
motor starters have ratings for DC horsepower. On the other hand, AC motor
starters have a single-phase power and three-phase power rating.

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 The rating of the motor starter is based on the size and type of load for which
it was designed. Starters conform to the standards and ratings from
Underwriters Laboratories (UL), Canadian Standards Association (CSA),
International Electrotechnical Commission (IEC) and National Electrical
Manufacturers Association (NEMA).

NEMA Rating
 The NEMA ratings of a starter depends largely on the maximum horsepower
ratings given in the National Electrical Manufacturers Association ISCS2
standard. The selection of the NEMA starters is done on the basis of their
NEMA size, which varies from Size 00 to Size 9.

The NEMA starter, at its stated rating, can be used for a wide range of applications,
ranging from simple on and off applications to plugging and jogging applications,
which are more demanding. It is necessary to know the voltage and horsepower of
the motor when selecting the proper NEMA motor starter. In the case where there
is a considerable amount of plugging and jogging involved, then derating a NEMA-
rated device will be required.

IEC Rating
 The International Electrotechnical Commission (IEC) has specified the
operational and performance characteristics for IEC devices in the publication
IEC 60947. Standard sizes are not specified by the IEC. The typical duty cycle
of IEC devices are defined by utilization categories. As far as general motor
starting applications are concerned, the AC3 and AC4 are the most common
utilization categories.

 Unlike NEMA sizes, they are typically rated by their maximum operating
current, thermal current, HP and/or kW rating.

 There are other parameters that are important to consider, while selecting
motor starters, such as time-limit acceleration, current-line acceleration,
control voltage, number of poles, and operating temperature. We will cover
those in a future white paper.

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LEARNING ACTIVITY 2. 4

1. If magnetic coils are powered by AC, why don’t their contacts open
and close 120 times per second?
2. Based on your own understanding, differentiate the five (5) types
of Magnetic Motor Starter in a minimum of 150 words.

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LESSON 5

Motor Control Circuits

CONTROL CIRCUIT
 A control circuit is a special type of circuit used to control the operation of a
completely separate power circuit. Consider a 1,000 horsepower, large
industrial motor driving a water pump. The motor is connected to a high
voltage electrical supply of 2,400 volts.
 When this motor is energized, it must draw enough current to get the water
moving and it is common for a motor to draw about six times its normal
operating current for a short period of time. When we were talking about
controlling light bulbs, it was safe to operate a simple switch on the wall. But
now this large amount of current flowing when the motor starts can be
troublesome. The first concern is the operator's ability to safely close the
switch. The second concern is that when the operator opens the switch to
turn the motor off, the electricity will continue to try to complete the path.
This will tend to arc between the contacts of the switch as it is opened. This
arcing is not only dangerous but also damages the switch by severely burning
the contact points. A control circuit is used to ensure that the motor is started
and stopped in a safe manner for both the operator and the equipment.
POWER CIRCUIT
 A power circuit is defined as any circuit used to carry electricity that operates
a load. This may seem like a simplistic definition but it is important to
distinguish power circuits from control circuits since they serve different
purposes.

 A circuit with an outlet for the source, two wires for the path, a switch for
the control device and a motor for a load is a good illustration of a power
circuit. When the switch is closed, the electrons flow through the path and
the electrons go directly through the motor windings and cause the motor to
operate. The only circuit control in this circuit is the switch wired directly in
series with the motor. There is no separate control circuit associated with
this power circuit. Most lighting and receptacle outlet circuits in a house are
power circuits since they only provide power to devices when the devices
operate, and the circuit control is part of the power circuit.
Start-Stop Motor Control
 The most common use of 3 wire control is a Start/Stop control. See
image below for an example of 3 wire contro l being used to pull in
a contactor to start a 3 phase motor. When you press the start
button and the stop button is not pressed, the 24VDC relay energizes

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and it pulls in the R1 contactor that feeds three phase power to the
motor. It also pulls in a conta ct that is tied in parallel with the start
button giving it another path for current flow once your release the
start button. This "latches" the relay until the stop button is
pressed.

WIRING DIAGRAM OF START – STOP WITH OVERLOAD RELAY

CONTROL CIRCUIT OF START – STOP POWER CIRCUIT OF START –

STOPWITH OVERLOAD RELAY WITH OVERLOAD RELAY

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HOW START – STOP CIRCUIT WORKS

JOG MOTOR CONTROL

 The jog circuit is important to create a circuit that will allow the operator to
momentarily energize the circuit without the need of pressing the
stop pushbutton. Jog circuits allow the operator to move loads to a set
position preventing the load from over traveling to the desired
position. The jog circuit can be used in almost any control circuit because it
relies on momentary energizing and de-energizing of the pilot device.

 Jogging or inching is defined as the quickly repeated closure of a circuit to

start a motor from rest for the purpose of accomplishing small movements of
rotating machine.

 The term jogging is often used when referring to full voltage starting of loads;
the term inching can be used to refer to reduced voltage starters. Generally,
the terms are used interchangeably because they both prevent a seal-in
circuit from being used.

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 There are many ways to develop a jog control circuit. In designing a jog it is
important to remember the overall outcome is to make a load operate during
the duration of the start button being activated. This means the control
circuit is designed so there is no way for the load to become energized and
stay energized through the memory/seal-in contact.

 One of the jog circuit designs is the two-circuit pushbutton. The circuit will
operate as a normal three wire circuit if the start /stop pushbuttons are used.
Pressing the jog button creates a current path directly to the load bypassing
the seal-in of the control circuit. However, the potential danger can exist
because the jog button can potentially become the active seal-in causing the
load to stay on without the assistance of someone pressing the pushbutton. If
it is possible to eliminate using pushbuttons that make and break the control
circuit at the same time in the same circuit.

The Jog circuit in Configuration 1 operates as follows:

 A switch is wired in series with the seal-in of the pilot device.

 With the switch closed the control circuit acts as a normal stop/start station
controlling a load connected to the pilot device, power is sitting on the start
and seal-in terminals of the pushbutton.
 Pressing start immediately sends power through the start pushbutton and the
seal-in contacting energizing the coil.
 The seal-in contact is now maintaining power to the coil overriding the start
pushbutton and it is no longer needed to be held down.
 The coil of the motor starter can be de-energized several ways.
 The motor could go into overload which means the normally closed overload
contacts will open breaking the circuit.
 The stop pushbutton can be pressed removing power from the seal-in contact
causing the coil to be de-energized.
 The next way the control circuit could be stopped is to turn the switch to the
jog position. This will immediately de-energized coil.
 With the switch in the jog position, the pilot device will no longer have power
through the seal-in contact.
 The coil can only be energized with the start pushbutton and only for a length
of time that the button is pressed.

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CONTROL CIRCUIT OF JOG MOTOR CONTROL

POWER CIRCUIT OF JOG MOTOR CONTROL

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FORWARD - REVERSE MOTOR CONTROL

 Is constructed from two regular contactors installed with a mechanical
interlock that prevents both coils from pulling in simultaneously.

 The direction of rotation of any three-phase motor can be reversed by

changing any two motor T leads (Fig. 1). Since the motor is connected to the
power line regardless of which direction it operates, a separate contactor is
needed for each direction. If the reversing starters adhere to NEMA standards,
T leads 1 and 3 will be changed (Fig. 2). Since only one motor is in operation,
however, only one overload relay is needed to protect the motor. True
reversing controllers contain two separate contactors and one over load relay.
Some reversing starters will use one separate contactor and a starter with a
built-in overload relay.

Fig. 1 The direction of rotation of any three-phase motor can be changed by

reversing connection to any two motor T leads.

Fig. 2 Magnetic reversing starters generally change T leads 1 and 3 to reverse the
motor

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Interlocking
 Interlocking prevents some action from taking place until some other action
has been performed. In the case of reversing starters, interlocking is used to
prevent both contactors from being energized at the same time.
 This would result in two of the three phase lines being shorted together.
Interlocking forces one contactor to be de-energized before the other one can
be energized.
 There are three methods that can be employed to assure interlocking. Many
reversing controls use all three.

Mechanical Interlocking
 Most reversing controllers contain mechanical interlocks as well as electrical
interlocks. Mechanical interlocking is accomplished by using the contactors to
operate a mechanical lever that prevents the other contactor from closing
while one is energized. Mechanical interlocks are supplied by the
manufacturer and are built into reversing starters. In a schematic diagram,
mechanical interlocks are shown as dashed lines from each coil joining at a
solid line.

Electrical Interlocking
 Two methods of electrical interlocking are available. One method is
accomplished with the use of double acting push buttons (Ill. 6). The dashed
lines drawn between the push buttons indicate that they are mechanically
connected. Both push buttons will pushed at the same time. The normally
closed part of the FORWARD push button is connected in series with R coil,
and the normally closed part of the REVERSE push button is connected in
series with F coil. If the motor should be running in the forward direction and
the REVERSE push button is pressed, the normally closed part of the push
button will open and disconnect F coil from the line before the normally open
part closes to energize R coil. The normally closed section of either push
button has the same effect on the circuit as pressing the STOP button.

WIRING DIAGRAM OF FORWARD – REVERSE

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POWER CIRCUIT OF FORWARD-REVERSE

CONTROL CIRCUIT OF FORWARD - REVERSE

 When the “Forward” pushbutton is actuated, M1 will energize, closing the

normally-open auxiliary contact in parallel with that switch.
 When the pushbutton is released, the closed M1 auxiliary contact will
maintain current to the coil of M1, thus latching the “Forward” circuit in the
“on” state.
 The same sort of thing will happen when the “Reverse” pushbutton is pressed.
These parallel auxiliary contacts are sometimes referred to as seal-in
contacts, the word “seal” meaning essentially the same thing as the word
latch.

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CONTROL CIRCUIT OF STOP-REVERSE-FORWARD

 Now, if either forward or reverse circuits are latched, they may be

“unlatched” by momentarily pressing the “Stop” pushbutton, which will open
either forward or reverse circuit, de-energizing the energized contactor, and
returning the seal-in contact to its normal (open) state.
 The “Stop” switch, having normally-closed contacts, will conduct power to
either forward or reverse circuits when released.
 If our hypothetical motor turned a mechanical load with a lot of momentum,
such as a large air fan, the motor might continue to coast for a substantial
amount of time after the stop button had been pressed.
 This could be problematic if an operator were to try to reverse the motor
direction without waiting for the fan to stop turning.
 If the fan was still coasting forward and the “Reverse” pushbutton was
pressed, the motor would struggle to overcome that inertia of the large fan
as it tried to begin turning in reverse, drawing excessive current and
potentially reducing the life of the motor, drive mechanisms, and fan.

LEARNING ACTIVITY 2. 5

1. Explain the working principle of Forward-Reverse, Start-Stop and

Jog Motor control with your unique answers.
2. Make a Wiring Diagram of Two – Station Start Stop Motor Control.
3. What is the purpose of "TRIP" in making the simulation of Motor
Control?

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SUMMATIVE TEST

Answer the following questions:

1. Give 5 Disadvantages of DOL Starter.

2. Give 5 Features of Motor Starter.

3. Enumerate the Five (5) types of Magnetic Motor Starter.

4. List down the Jog Circuit in Configuration 1

5. What are the two circuits in a motor starter?

6. List down at least 5 key limit switch terminology.

7. Give the four (4) Fundamentals Functions of Motor Starter

SUMMARY

In this module, the Across the line motor starters were discussed. As a brief
information about this, a direct on line (DOL) or across the line starter applies the
full line voltage to the motor terminals. This is the simplest type of motor starter.
A DOL motor starter also contains protection devices, and in some cases, condition
monitoring. The module indicates the different fundamentals of the following Across
the line motor starters that will give idea to students before proceeding to the
deeper knowledge.
Switches/ Contact Sensors are also discussed in module to that aimed to give greater
understanding in schematic diagrams. This will also help students to conceptualize
their own flow and brainstorm on how these contact be interrelated to each other.
This handout also modulates the difference between the manual motor starters and
the magnetic motor starters that involves a brief description of their usage,
importance and to know the things that necessitates them. Motor Control Circuits
are those the ones being described here and will give you emphasize every area of
the lesson.

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A motor starter turns an electric motor on or off while providing overload protection.
There are two main types of starters manual and magnetic. In smaller sizes, a motor
starter is a manually operated switch. Low-voltage protection (LVP), which prevents
automatic restarting after a power failure, is usually not possible with a manual
starter. Larger motors, or those requiring remote or automatic control, use magnetic
contactors. Very large motors running on medium voltage power supplies may use
power circuit breakers

REFERENCES

[Link] (2021). Industrial Control Basics: Motor Control Starters & Magnetic
Motor Starter. Retrieved from: [Link]
paper/industrial-control-basics-motor-starters/
TW [Link] (2020). Control, Wiring – 3 Wire control – Start Stop Circuit.
Retrieved from: [Link]
start-stop-circuit
Apogee Interactive Incorporated (2021). Types of Circuit – Power Circuit. Retrieved
from:[Link]
spc=foe&id=4704
Electrical [Link] (2020). Start Stop Jog Circuit | Motor Control Circuit Diagram.
Retrieved from: [Link]
motor-control-circuit-diagram/
[Link] (2005). Electrical Engineering and Science for
Manufacturing Applications. Retrieved from: [Link]
[Link]/ind-mtr-cntrl_029.html
All About Circuits (2021). Motor Control Circuits. Rohde and Schwarz Technology
Symposium 2021. Retrieved from:
[Link]
circuits/
[Link] (2021). Limit Switch Characteristics. Retrieved from:
[Link]

Inst Tools (2020). Types of Limit Switches – Principles, Advantages, and

Disadvantages. Retrieved from: [Link]
switches/

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