Esw Activity 8

Ayala Blvd. cor. San Marcelino St.
Ermita, Manila
• MODULE 4
COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT
Republic of the Philippines

Technological University of the Philippines
ELECTRICAL WORKSHOP 2
Activity No. 8
FORWARD – REVERSE MOTOR CONTROL WITH JOG & EMERGENCY STOP
(No Immediate Reversal)
I. OBJECTIVES:
At the end of the activity, the students should be able to:
1. Describe the principle of operation of a Forward – Reverse Motor Control with no immediate
reversal.
2. Connect properly the components in a Forward – Reverse Motor Control with no immediate
reversal.
3. Observe safety measures while connecting the motor control circuit.
II. TECHNICAL INFORMATION:

To reverse the direction of a three-phase motor, it is possible to simply interchange any two-phase
conductors at the motor or the motor starter. But if the reversing of the motor is a required operation of the
machine, then reversing motor starters are available.
The Forward-Reverse motor control is used in a system where forward and backward or upward and
downward movement in the operation is needed.
Stop Before Reversing (Medium Motors)

The stop before reversing logic is generally used for medium size motors. Stopping the motor first,
before reversing its direction, eliminates the overcurrent surge and potentially damaging mechanical stress
that can result with the attempt to rapidly reverse a large rotating inertia (load). Operation of the circuit in
Figure 1 & 3 begins by closing the forward pushbutton to energize the forward contactor coil (F). This action
closes the main forward contacts to the motor terminals starting the motor in the forward direction. In
sequence with this action, auxiliary N.O. contact F closes to seal in the forward coil (F) circuit, and auxiliary
N.C. contact F opens to block the reverse coil (R) circuit. To reverse the motor when it is running in the
forward direction, it is necessary to first push the stop pushbutton. Pushing the stop pushbutton deenergizes
the forward contactor, which in turn opens the main forward contacts and allows N.O. F to open and N.C. F
to close. At this point, the reverse pushbutton can be pushed to energize the reverse contactor coil (R) circuit.
In sequence then, the main contacts of the reverse contactor close (reversing motor lines L1 and L3), N.O. R
closes to seal in the reverse coil circuit, and N.C. R opens to block the forward coil circuit. The circuit logic for
the stop before reversing starter requires only that the stop button be pushed before an attempt is made to
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

2
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4

reverse the direction of the motor. Whether the motor can come to a complete stop before reversing is an
option of the operator based on the motor’s size and inertia.
Figure 1. Forward – Reverse 1ø Motor Control w/ Electrical Interlocks

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Figure 2. Elementary diagram of a 3ø reversing starter power circuit
Source: cengage learning

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Figure 3. Forward – Reverse 3ø Motor Control w/ Electrical Interlocks
Mechanical and Electrical Interlocks

All reversing starters have two magnetic contactors mounted in one enclosure. The contactors provide
for connection of the power leads to the motor terminals. One contactor (forward contactor) is connected to
the three phases of the motor so that the motor starts and runs in the forward direction. The other contactor

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(reverse contactor) is connected so that when it closes, two of the lines to the motor are interchanged, thus
reversing the direction of rotation of the motor. About the operation of the two contactors, it is necessary
that they be interlocked to prevent both from closing at the same time. If both contactors were to close at
the same time, the result would be a dead short circuit across two of the phases. Interlocking is used to prevent
this condition from happening. Both mechanical and electrical interlocks are used. Mechanical interlocks
typically use an insulated linkage fastened between the moving assemblies of the two contactors to prevent
their simultaneous closing. Electrical interlocking circuits vary in purpose and complexity, but the basic
technique consists of using normally open and normally closed contacts in both the forward and reverse coil
circuits to maintain each coil circuit open while the other is closed.
III. Bill of Materials
ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL (₱)
UNIT (₱)
Schneider MCCB 3 Pole 15A 1 pc Php 2,467.25 Php 2,467.25
Schneider Magnetic Contactor 220V 2 pcs Php 1,500.00 Php 3,000.00
Schneider Thermal Overload Relay 1 pc Php 5,100.00 Php 5,100.00

220V

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Schneider MCB 2 Pole 6A 1 pc Php 843.00 Php 843.00
EATON Pilot Light 220V RED 1 pc Php 290.00 Php 290.00
EATON Pilot Light 220V GREEN 2 pcs Php 290.00 Php 580.00
ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL

UNIT (₱) (₱)
EATON PILOT LIGHT 220V 1 pc Php 290.00 Php 290.00

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EATON PILOT LIGHT 220V 1 pc Php 290.00 Php 290.00

YELLOW
Schneider Illuminated Push 4 pcs Php 422.00 Php 1,688.00

button NC/NO(Green) 240V 3A
Schneider Illuminated Push 1 pc Php 422.00 Php 422.00

button (Red) 240V 3A
Control Wire 2.0mm RYB 3 mtrs Php 18.00 Php 54.00

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• MODULE 4

ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL

UNIT (₱) (₱)
ABB THREE PHASE 1 pc Php 9,900.00 Php 9,900.00
MOTOR
- 230/460 Volts
- 450 HP
- 60 Hz
Schneider Electric 1 pc Php 1,200.00 Php 1,200.00

Harmony Emergency
Stop Push Button
600V
OMRON LY4J Control 2 pcs Php 1,137.00 Php 2,274.00

Relay 10A 220VAC
3 Phase Fuse Switch 1 pc Php 320.82 Php 320.82

Disconnector 220V
63A

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Cable Ties 6 inches 100 pcs Php 50.00 Php 50.00
TOTAL Php 28,499.07
IV. List all the tools and equipment needed:
IMAGE DESCRIPTION
ELECTRICAL GLOVES – For electrical work, electricians
often wear three types of safety hand gloves, each with
a distinct function: Rubber work gloves are used for
insulation. Work gloves made of leather are used to
protect against cuts and burns. When working without
power, ordinary cotton string knit work gloves are
utilized.
SCREDRIVERS - To tighten and loosen screws on

different electrical devices, such as Circuit breakers and
Contactors.
PLIERS - Pliers can be used for cutting, twisting, bending,

holding, and gripping of wires and cables.

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WIRE STRIPPER - Wire strippers are used to remove the

insulation of wires, mostly medium-sized wires ranging
from gauge 10 to gauge 16.
MULTIMETER - A multimeter is a essential equipment

for electricians who do maintenance and
troubleshooting on electrical devices. A multimeter is a
piece of multi-purpose equipment that may be used to
measure a variety of electrical values such as voltage,
current, resistance, and so on.
V. Draw your complete Control and Power Circuit Diagram Via EKTS or SIMURELAY
Note: Simulation diagram can be print screen below

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VI. PROCEDURE:
1. Present to the instructor for checking your simulated diagram.
2. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
3. Connect the circuit base on design diagram if perform in actual.
4. Place the test probes of the ohmmeter to Line 1 and Line 2 to test the continuity of the circuit.
Observe resistance reading.
5. Press the forward start button while the test probes are still at Line 1 and 2. Observe the reading.
6. Press the reverse start button while the test probes are still at Line 1 and 2. Observe the reading.
7. Press the forward JOG button while the test probes are still at line 1 and 2. Observe the reading.
8. Press the reverse JOG button while the test probes are still at line 1 and 2. Observe the reading.

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9. Conduct also resistance test for the whole circuit upon pressing the mushroom head of emergency
stop push button.
10. Trip the overload relay. Observe the reading also.
11. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
12. De-energize the circuit upon completion. Remove the plugs then clear the area.
13. If able to perform in actual, take pictures all conditions mentioned on number 14.
14. For simulated data, print screen all the conditions mentioned and record in the table 1 & 2.
a. IDLE condition power ON both power and control circuit.
b. Forward START button pressed, then test interlocking by pressing Reverse START. c.
Pressed STOP push button.
d. Reverse START button pressed, then test interlocking by pressing Forward START. e.
Pressed STOP push button.
f. Forward JOG button pressed then for a few rotations released.
g. Reverse JOG button pressed then for a few rotations released
h. OVERLOAD TRIP condition upon re-starting either forward or reverse rotation
i. OVERLOAD RESET condition.
j. Pressed EMERGENCY STOP push button upon re-starting either forward or reverse
rotation.

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k. Unlocked EMERGENCY STOP push button.
A: IDLE condition power ON both power and control circuit.

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B: Forward START button pressed, then test interlocking by pressing Reverse START.

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FORWARD
REVERSE

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C: Pressed STOP push button.
D: Reverse START button pressed, then test interlocking by pressing Forward START.
REVERSE
ELECTRICAL WORKSHOP
Prepared by: Engr. Edwin C. Espinas,2for TUP COE-EE Department
17
• MODULE 4

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D: Reverse START button pressed, then test interlocking by pressing Forward START.

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FORWARD
E: Pressed STOP push button.

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F: Forward JOG button pressed then for a few rotations released.

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PRESSED
RELEASED

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G: Reverse JOG button pressed then for a few rotations released.

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• MODULE 4
PRESSED
RELEASED

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H: OVERLOAD TRIP condition upon re-starting either forward or reverse rotation.

25
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I:
OVELOAD RESET condition.

26
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J: Pressed EMERGENCY STOP push button upon re-starting either forward or reverse rotation.

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START
ES PRESSED

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K: Unlocked EMERGENCY STOP push button.

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VII. OBSERVATIONS AND SUMMARY OF DATA:
Table 1. MOTOR CONTROL COMPONENTS CONDITION

NOT ENERGIZE ENERGIZE OR
Component ACTIVATED SIMULATION RESULTS IMAGE
N.C. / N.O. OPEN / CLOSE
NOT YET ENERGIZE ENERGIZE
Magnetic Contactor
Main Contacts Forward N.O. CLOSE
Main Contacts Reverse N.O. CLOSE
Forward Holding Contact N.O. CLOSE
For. Interlocking Contact N.C. OPEN

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Reverse Holding Contact N.O. CLOSE
Rev. Interlocking Contact N.C. OPEN
Magnetic Contactor
Idle Aux. Contact N.C. OPEN
Thermal Overload
OL Aux. NC N.C. OPEN

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OL Aux. NO N.O. CLOSE
Pilot Lights
Red (Trip) N.O. CLOSE
Green (Forward) N.O. CLOSE

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Green (Forward)
Blue (Reverse) N.O. CLOSE
Yellow/Orange (Idle) N.C. OPEN

ELECTRICAL WORKSHOP 2 33
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Push Buttons
JOG Forward N.O. CLOSE
JOG Reverse N.O. CLOSE
Forward START N.O. CLOSE
Reverse START N.O. CLOSE
STOP N.C. OPEN
EMERGENCY STOP N.C. OPEN

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Table 2. SIMULATED RESULTS
INDICATOR LAMPS (PILOT LAMP IMAGE)
CONDITION
FORWARD REVERSE IDLE TRIP
POWER “ON”
FORWARD START
STOP
REVERSE START
STOP

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FORWARD JOG
PRESSED
FORWARD JOG
RELEASED
REVERSE JOG
PRESSED
REVERSE JOG
RELEASED
RE-START EITHEIR
F/R
EMERGENCY STOP

37
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UNLOCKED
EMERGENCY STOP
RE-START EITHEIR
F/R
THERMAL
OVERLOAD TRIP
RESET

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POWER OFF

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VII. CONCLUSION:
(Discuss how a Forward-Reverse with no immediate reversal function by referring to your design diagram)
For starters, this activity is called Forward Reverse Motor Control, which is different from the previous
motor control because, in this diagram, there are 2 Magnetic contactors that we will use as interlocking and
will control the forward and reverse operation of the motor. This motor control also has a Jog Push button for
inching forward and reverse operation of the motor. To operate this, we should know that there are two types
of a circuit in this motor control, which are the power circuit and the control circuit. Power Circuit, this circuit
is where the energy coming from the power source comes that will help to energize the whole circuit. Next is
the control circuit, this circuit is where you will control the motor by operating the contactor on and off.
To start the operation of this motor control, we need to turn on the disconnecting switch, Motor
circuit protection, and control circuit protection to energize the power and control circuit. After energizing, we
will now focus on accomplishing the objectives. Since the power and control circuit are energized the idle
signal lamp will light up, which states that the motor is in idle condition. In terms of electrical supply, I switched
the connection of lines 2 and 3 so that the first MCC is for forwarding and the second is for reverse rotation.
Going on to the control circuit, we have an emergency stop push button, a Stop push button, and four start
push buttons.
Forward and reverse starters will include two sets of typically open auxiliary contacts that will serve
as holding contacts in both directions. They will also have two sets of typically closed auxiliary contacts that
will function as electrical interlocks. To energize the motor, first, we need to push the start push-button for
forwarding rotation, since it has holding contacts it will latch, thus it will continuously provide energy to the
moto. IN addition to that, the forward button is connected to the Normally close contactor of the second MCC
for interlocking, so that when the button is pressed it will prevent the other coil from being energized. Next,
to reverse the rotation of motor control we must first stop the push button, then pressed the reverse button,
it also has Holding contacts which act to continuously supply the motor in reverse operation, this button is
connected to the Normally close contactor for forwarding rotation so that it will interlock.
Forward and reverse starters must never close their power contacts at the same time. The best way

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to accomplish this is to use interlocks, that prevent one coil from being energized while the other is activated.
Interlocking failure might lead both coils to be powered at the same time. When the forward motor contactor
is energized the Gree Indicator light should light up, on the other hand when if the reverse is operating Blue
Indicator light should light up. Next, since we used control relay, the jog push button is connected to relay coils
so once we pushed the jog push button the normally open relay coil will close and the normally closed relay
coil that is series connected to the start push button. It will immediately power the motor and will be
deenergized when released.As a result, when the jog is pushed, the motor is instantaneously powered up and
de-energized when released.
Furthermore, we may encounter unexpected problems when operating the motor like overheating,
overcurrent, and short circuits. That's why our motor has a protection component to protect the motor and
other parts from damage, and we call this Thermal overload relay. Once the motor tripped, the T.O.L will act
and the signal lamp for the trip condition will light up. Moreover, once the motor control tripped we can just
reset it and the idle signal lamp must light up. Lastly, we may stop the motor from running by pushing the stop
push button, and again the idle lamp should light up. However, if the stop pushbutton does not work or if there
is an issue, we may de-energize the motor by pressing the emergency stop button.
VIII. EVALUATION:
1. Why is there a need to stop medium motors before reversing its direction in a control circuit?
When you turn on a motor directly, it draws its full load current. If the motor is spinning in the opposite
direction when it is switched to reverse, the initial current will be extremely high in comparison to the full load
current. This will cause the circuit breaker to trip, and if the current is too high, you will damage the Motor
Contactors, the Motor Overload Relay, and your motor. Nevertheless, because the windings are inductive, the
voltage in an inductor might decrease to zero while the current remains constant. Before stopping, your
controller should decelerate the motor, then reverse it and accelerate it up to speed. Furthermore, it needs a
stop push medium for safety factors, imagine you are driving a car forward and you immediately change the
gear to reverse without stopping, of course, it will damage the motor and may cause danger.
2. List some applications where-in forward reverse motor control are utilized.
Forward-reverse motor control is convenient because we can apply this in different fields such as
Industrial, Construction, and even in our home. In addition, in terms of industrial, we can apply this type of
motor control for the conveyor belt in creating products in factories, we can also use this for processing or

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mixing different ingredients. Additionally, when it comes to construction, we can utilize this for mixing cement
and lifting heavy materials, or we can use this on cranes. Lastly, we can apply this type of motor to our homes,
such as electrical vertical door lifts and home tools.

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Ayala Blvd. cor. San Marcelino St.

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

II. TECHNICAL INFORMATION:

Stop Before Reversing (Medium Motors)

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Figure 1. Forward – Reverse 1ø Motor Control w/ Electrical Interlocks

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Figure 2. Elementary diagram of a 3ø reversing starter power circuit

Source: cengage learning

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Figure 3. Forward – Reverse 3ø Motor Control w/ Electrical Interlocks

Mechanical and Electrical Interlocks

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Schneider Magnetic Contactor 220V 2 pcs Php 1,500.00 Php 3,000.00

Schneider Thermal Overload Relay 1 pc Php 5,100.00 Php 5,100.00

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Schneider MCB 2 Pole 6A 1 pc Php 843.00 Php 843.00

EATON Pilot Light 220V RED 1 pc Php 290.00 Php 290.00

ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

EATON PILOT LIGHT 220V 1 pc Php 290.00 Php 290.00

Schneider Illuminated Push 4 pcs Php 422.00 Php 1,688.00

Schneider Illuminated Push 1 pc Php 422.00 Php 422.00

Control Wire 2.0mm RYB 3 mtrs Php 18.00 Php 54.00

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL

Schneider Electric 1 pc Php 1,200.00 Php 1,200.00

OMRON LY4J Control 2 pcs Php 1,137.00 Php 2,274.00

3 Phase Fuse Switch 1 pc Php 320.82 Php 320.82

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Cable Ties 6 inches 100 pcs Php 50.00 Php 50.00

TOTAL Php 28,499.07

SCREDRIVERS - To tighten and loosen screws on

PLIERS - Pliers can be used for cutting, twisting, bending,

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

WIRE STRIPPER - Wire strippers are used to remove the

MULTIMETER - A multimeter is a essential equipment

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Republic of the Philippines

Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department