Professional Documents
Culture Documents
Control Components
Table of Contents
Introduction................................................................................2
Electrical Symbols.....................................................................6
Line Diagrams.........................................................................16
Overload Protection.................................................................22
Overload Relays......................................................................26
Manual Control........................................................................35
Magnetic Contactors and Starters...........................................41
Contactor and Starter Ratings.................................................47
Class 14 NEMA Starters with Bimetal Overload Relays..........50
Class 14 ESP100 Starters.......................................................51
SIRIUS Type 3R Starters.........................................................52
Multi-Speed Starters................................................................55
Reversing Starters...................................................................58
Reduced-Voltage Starting.......................................................60
SIRIUS Soft Starters...............................................................65
Lighting and Heating Contactors.............................................67
Pilot Devices............................................................................70
Control Transformers...............................................................81
Control Relays.........................................................................82
Solid-State Switching Devices.................................................88
Monitoring Relays....................................................................90
Time Relays.............................................................................91
Terminal Blocks and Supplementary Protectors......................96
LOGO! Logic Module...............................................................98
Fastbus Busbar Adapter System...........................................100
Review Answers....................................................................103
Final Exam............................................................................104
Introduction
Control Circuits
Control
Manual Control
Automatic Operation
Control Elements
Electrical Symbols
The standard method of showing a contact is to indicate the
circuit condition produced when the actuating device is in the
de-energized state. For example, in the following illustration a
relay is used as the actuating device. The contacts are shown
as normally open, meaning the contacts are open when the
relay is de-energized. A complete path of current does not exist
and the light is off.
Switch Symbols
Pushbutton Symbols
Normally Open
Pushbutton Example
Switch is shown
opposite of its
normal state (NO).
Normally Closed
Pushbutton Example
Switch is shown
opposite of its
normal state (NC).
Coil Symbols
10
Other Symbols
11
12
13
Abbreviations
14
Alternating Current
Alarm
Ammeter
Armature
Automatic
Battery
Brake Relay
Capacitor
Circuit Breaker
Circuit
Control
Control Relay
Current Transformer
Down
Direct Current
Disconnect Switch
Double-Pole
Double-Pole, Double-Throw
Double-Pole, Single-Throw
Double Throw
Forward
Frequency
Foot Switch
Fuse
Generator
Ground
Hand/Off/Auto Selector Switch
Integrated Circuit
Interlock
Instanstaneous Overload
Junction Box
Limit Switch
Lamp
Motor Starter
Motor Starter Protector
MTR
MN
NEG
NEUT
NC
NO
OHM
OL
PB
PH
POS
PRI
PS
R
REC
RES
RH
S
SEC
SOL
SP
SPDT
SPST
SS
SSW
T
TB
TD
THS
TR
U
UV
VFD
XFR
Motor
Manual
Negative
Neutral
Normally Closed
Normally Open
Ohmmeter
Overload
Pushbutton
Phase
Positive
Primary
Pressure Switch
Reverse
Rectifier
Resistor
Rheostat
Switch
Secondary
Solenoid
Single-Pole
Single-Pole, Double Throw
Single-Pole, Single Throw
Selector Switch
Safety Switch
Transformer
Terminal Board
Time Delay
Thermostat Switch
Time Delay Relay
Up
Under Voltage
Variable Frequency Drive
Transformer
Review 1
1. A control is ____________ operated when someone
must initiate an action for the circuit to operate.
2. Which of the following symbols represents a normally
open contact?
a.
b.
c.
a.
b.
c.
a.
b.
c.
a.
b.
c.
15
Line Diagrams
Indicator
(Pilot) Light
16
17
Only one control load should be placed in any one circuit line
between L1 and L2. One side of the control load is connected to
L2 either directly or through overload relay contacts.
18
Connecting Control
Devices
19
Line Numbering
20
Review 2
1. Line diagrams are read from ____________ to ______
______ , or L1 to L2.
2. Match the items on the line diagram with the associated
list.
A ____________
B ____________
C ____________
D ____________
E ____________
F ____________
21
Overload Protection
22
Short Circuits
23
Overload Conditions
24
Overload Protection
25
Overload Relays
Trip Class
26
Overload Relay in a
Motor Circuit
27
As current rises, heat also rises. The hotter the bimetal strip
becomes, the more it bends. In an overload condition, the heat
generated from the heater will cause the bimetal strip to bend
until the mechanism is tripped, stopping the motor.
28
Class 48 Ambient
Compensated Bimetal
Overload Relay
29
SIRIUS 3RU11
Bimetal Overload Relay
30
Class 48 ESP100
Electronic Overload Relay
31
Siemens 3RB10/20
Electronic Overload Relay
Siemens 3RB12/22
Electronic Overload Relay
32
PROFIBUS DP
SIMOCODE pro
33
Review 3
1.
34
Manual Control
Basic Operation
35
36
SMF Fractional-
Horsepower Manual
Starters
37
Class 11 - 3RV
Manual Starters
and Switches
38
Max Current
at 460 VAC
Max HP
at 460 VAC
3RV101
12 Amps
7.5
3RV102
25 Amps
20
3RV103
50 Amps
40
3RV104
100 Amps
75
The 3RV101 is available in both screw-terminal and springloaded terminal versions. The 3RV102, 3RV103, and 3RV104
are available with screw terminals.
39
Spring-Loaded Terminals
40
41
42
Contactors vs.
Overload Relays
43
Motor Starter
Starter
Overload Relay
44
Contactor
Contactor
ESP100 Solid-State
Overload Relay
Ambient Compensated
Bimetal Overload Relay
Motor Starter in a
Control Circuit
Combination Starters
45
Review 4
1. A starter with two sets of contacts would be called a
____________ -pole starter.
2. ____________ will automatically disconnect power from
the motor when incoming power drops or is interrupted.
3. The Class 11 - 3RV manual starter protects motors up
to ____________ HP at 460 VAC.
4. The 3RV102 motor starter protector protects motors up
to ____________ HP at 460 VAC.
5. When a contactor is combined with an overload relay, it
is called a ____________ ____________ .
6. A ______________ _____________ incorporates a
motor starter, short circuit, and a means of safely
disconnecting power.
46
Continuous
Amp Rating
HP
230 VAC
HP
460 VAC
00
18
27
10
45
15
25
90
30
50
135
50
100
270
100
200
540
200
400
810
300
600
1215
450
900
2250
800
1600
47
Continuous
Amp Rating
HP
230 VAC
HP
460 VAC
40
10
15
60
20
30
115
40
75
IEC
48
AC1
AC2
AC3
AC4
AC11
Definite Purpose
Other Organizations
49
50
51
52
Spring-Loaded Terminals
Overload Relays
53
Review 5
1. ____________ is an organization primarily associated
with rating equipment used in North America and ____
________ is associated with rating equipment used in
many countries worldwide including the U.S.
2. A NEMA Size ____________ starter is rated for 200 HP
at 460 volts .
3. IEC utilization category ____________ applications are
described as the starting of squirrel-cage motors and
switching off only after a motor is up to speed.
4. Siemens Class 14 NEMA starters are available in
NEMA sizes 00 through ____________, including sizes
1, 2, and _____________.
5. The ESP100 trips within ____________ seconds of
loss of one of the power-supply phases.
6. SIRIUS Type 3R starters are available in seven frame
sizes: ________, S0, S2, S3, ________, S10, and
S12.
7. SIRIUS 3R contactors and overload relays are designed to operate in ambient temperatures up to
____________________.
54
Multi-Speed Starters
55
Consequent-Pole
Motors
56
Speed Selection
There are three control schemes of speed selection for multispeed motors: selective control, compelling control, and
progressive control.
Class 30 Two-Speed
Starters
57
Reversing Starters
58
Class 22 Reversing
Starters
Class 43 Reversing
Contactors
3RA13 Reversing
Contactors
59
Reduced-Voltage Starting
Full-Voltage Starting
With this type of starter, the motor receives the full-line voltage
immediately upon being energized. When a motor is started
with full voltage, starting current can be as high as 600% of fullload current on standard squirrel cage motors. It can be as high
as 1200% of full-load current for high efficiency motors.
There are situations where this method of starting is not
acceptable. On large motors, the high starting current is
reflected back into the power lines of the electric utility, causing
lights to flicker and (in more serious situations) computers
to malfunction. Many power companies in the U.S. require
reduced-voltage starting on large-horsepower motors.
60
Reduced-Voltage Starting
61
Autotransformer Reduced-
Voltage Starters
L2
L3
Open
Close
Part-Winding Starters
62
Wye-Delta Starters
1
2
Motor
4
6
9
8
To Start: Close 1, 2, 3, 4, 5, 6
Open 7, 8, 9
To Run: Open 4, 5, 6
Close 7, 8, 9
63
Class 36 and 37
Reduced-Voltage Starters
Review 6
1. A ____________ - ____________ ____________
provides multi-speed control by utilizing taps brought
out from a reconnectable winding.
2. With ____________ ____________ the motor is started
at the lowest speed and automatically increments to the
selected speed.
3. Starting methods which deviate from full-voltage starting by providing a lower starting voltage are referred to
as ___________ ___________ ___________ .
4. A reduced-voltage starter reduces all of the following
during startup:
1. _____________________________
2. _____________________________
3. _____________________________
5. ____________ reduced-voltage starters have adjustable taps to reduce starting voltage to 50%, 65%, or
80% of full-line voltage.
64
65
SIRIUS 3RW40
Soft Starters
SIRIUS 3RW44
Soft Starters
66
Electrically Held
Contactors
Basic Contactor
Operation
Some Typical
Applications
67
L2
ON
OFF
( 2)
( 3)
M
M
A1
A2
Basic Contactor
Operation
(Magnetically Held)
68
Basic Contactor
Operation
(Mechanically Latched)
Some Typical
Applications
69
Pilot Devices
Pushbuttons
70
Normally Open
Pushbuttons
Normally Closed
Pushbuttons
71
72
Holding Circuit
Three-Wire Control
73
Two-Wire Control
OL
T1
OL
T2
OL
L1
L2
L3
Motor
T3
OL
Start/Stop
M
Selector Switches
74
Two Position
Selector Switch
75
Three-Position
Selector Switch
Indicator Lights
76
77
78
Signaling Columns
79
Review 7
1. Soft starters limit motor starting current and torque by
gradually increasing the portion of the
______________ ________________ _____________
applied to the motor windings
2. Potentiometers on the front of SIRIUS 3RW40 soft
starters provide settings for:
1. ________________________________________
2. ________________________________________
3. ________________________________________
3. A (an) _______________ _______________ lighting and heating contactor is best used in applications
where noise is not an issue.
4. Lighting and heating contactors are rated by:
a. Horsepower
b. Amperes
5. ____________ ____________ and _____________
____________ lighting and heating contactors are not
affected by a loss of control power.
6. A ____________ ____________ directs the operation
of another device, or indicates the status of the operating system.
7. Label each of the circuits below as representing either
two-wire control or three-wire control.
8. Indicator lights provide ____________ information of
the circuits operating condition.
9. A ____________ indicator light normally indicates a
motor is running, while a ____________ indicator light
normally indicates that the motor is stopped.
80
Control Transformers
81
Control Relays
Relays are widely used in control circuits. They are used for
switching multiple control circuits, and for controlling light loads
such as starting coils, indicator lights, and audible alarms.
Relay Operation
82
Contact Arrangement
Pole
Throw
Single-Pole, Single-Throw
Single-Pole, Double-Throw
Double-Pole, Single-Throw
Double-Pole, Double-Throw
83
Break
84
Interposing a Relay
85
SIRIUS 3RH
Control Relays
86
3TX71
Plug-In Relays
87
88
SIRIUS SC
Solid-State Contactors
SIRIUS SC 3RF23 solid-state contactors incorporate a solidstate relay in an optimized heat sink to form a ready to use
device with defined current ratings.
SIRIUS SC
Function Modules
89
Monitoring Relays
90
Time Relays
Time Delay
91
92
93
94
Instantaneous Contacts
95
Terminal Blocks
8WA2 Spring-Loaded
Terminals
Through-type terminals
Through-type terminals
Two-tier terminals
Insta or three-tier terminals
N isolating terminals
Ground terminals
Two-tier terminals
Fuse terminals
Sliding-link terminals
96
Supplementary
Protectors
97
Hard-Wired Control
98
Design Features
99
100
supervisory level
Industrial Ethernet
host computer
programmable controllers
e.g. SIMATIC S7
production or
process control level
PROFIBUS
actuator/
sensor level
AS-Interface
sensors, actuators
e.g. BEROs contactors,
interface relays
101
Review 8
1. ___________ is the total number of different circuits
each pole controls.
2. ___________ describes the number of isolated circuits
that can pass through a relay at one time.
3. An SPDT relay has ___________ pole(s) and _______
_____ closed contact position(s).
4. A timing relay that receives a signal to turn on, and then
delays a predetermined amount of time before performing this action, is referred to as ____________ delay.
5. ____________ ____________ relays and contactors
eliminate the mechanical wear and noise characteristics
of conventional electromechanical switching devices.
6. ____________ ____________ can monitor electrical
and mechanical quantities and fault conditions, and
provide appropriate diagnostic indications.
7. Siemens terminal blocks are available with either
____________ connections or ____________
____________ terminals.
8. Siemens UL1077 ____________ ____________ are
designed to trip faster than standard UL489 circuit
breakers, providing additional protection for more
sensitive devices.
102
Review Answers
Review 1
Review 2
Review 3
(1) a; (2) overcurrent; (3) overload; (4) a; (5) bimetal; (6) reset;
(7-1) heater elements; (7-2) phase loss; (7-3) insensitive
Review 4
(1) two; (2) low voltage protection (LVP); (3) 15; (4) 20;
(5) motor starter; (6) combination starter
Review 5
(1) NEMA, IEC; (2) 5; (3) AC3; (4) 4, 3; (5) three; (6) S00, S6;
(7) 140F (60C)
Review 6
(1) consequent-pole motor; (2) progressive control; (3) reducedvoltage starting; (4-1) inrush current; (4-2) starting torque;
(4-3) stress on mechanical linkage; (4) Autotransformer
Review 7
(1) power supply cycle; (2-1) current limit; (2-2) starting voltage;
(2-3) starting and stopping times of the voltage ramp;
(3) electrically held; (4) b; (5) magnetically held, mechanically
latched; (6) Pilot device; (7-top) Three-Wire Control;
(7-bottom) Two-Wire Control; (8) visual; (9) red, green
Review 8
(1) Throw; (2) Pole; (3) one, two; (4) ON; (5) Solid-State;
(6) Monitoring Relays; (7) screw, spring-loaded;
(8) Supplementary Protectors
103
Final Exam
104
a.
c.
normally closed
energized
2.
a.
c.
3.
a.
b.
c.
d.
4.
a.
c.
5.
a.
b.
c.
d.
green
amber
b.
d.
decrease
remain the same
b.
d.
normally open
de-energized
red
white
b.
d.
increase
fluctuate
6.
a.
b.
c.
d.
7.
a.
b.
c.
d.
8.
a.
b.
c.
d.
9.
a.
c.
10.
a.
c.
11.
a.
c.
armature
electromagnetic coil
overcurrent sensing device
stationary contacts
selective
progressive
NEMA
ICS
b.
d.
SINAMICS
MICROMASTER
b.
d.
compelling
consequent pole
UL
IEC
b.
d.
LOGO!
SIMOCODE Pro
105
106
12.
a.
c.
13.
a.
c.
14.
a.
c.
15.
a.
c.
16.
a.
c.
17.
18.
a.
c.
a.
c.
pushbutton
proximity switch
DPST
SPST
b.
d.
b.
d.
selector switch
pilot or indicator light
DPDT
SPDT
electrically-held
b. magnetically-held
mechanically-latched d. both b and c
200
810
PROFIBUS
AS-Interface
4
8
b.
d.
b.
d.
b.
d.
540
1600
Ethernet
proprietary network
6
10
b.
d.
primary resistance
autotransformer
19.
a.
b.
c.
d.
20.
a.
c.
SIRIUS 3UG
SIRIUS SC
b.
d.
SIRIUS 3RH11
SIRIUS 3RW40
107
108