Esw Activity 9

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

1
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT
ELECTRICAL WORKSHOP 2
Activity No. 9
FORWARD – REVERSE MOTOR CONTROL WITH JOG & EMERGENCY STOP
(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 immediate
reversal.
2. Connect properly the components in a Forward – Reverse Motor Control with 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.
Full-Speed Reversing (Small Motors)

One type of control logic used in full-voltage reversing starters is the full-speed reversing logic. The
circuit arrangement for this type logic allows the direction of a motor to be reversed without pushing the
stop button. This mode of operation has the advantage of reversing the direction of the motor in the shortest
possible time. However, use of this type of logic is acceptable only for small motors with relatively low mass
and thus low inertia. The arrangement of this circuit is basically the same as for all full voltage reversing
starters, except that the forward pushbutton and the reverse pushbutton have an additional normally closed
contact block. The starter has two contactors, one connected to apply the three phases to the motor so that
the motor starts and runs in the forward direction. The other 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.
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department

2
• MODULE 4
GGG
BBB
OO

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Forward – Reverse Motor Control
(Immediate Reversal)
Starting the motor and operating it in the forward direction is initiated by closing the forward
pushbutton. This action energizes the forward contactor (F), which in turn closes the main contacts to the
motor terminals, thus starting the motor in the forward direction. The same action that closes the normally
open contact of the pushbutton also opens its normally closed contact. This temporary open circuit prevents
an unwanted start in the reverse direction. As the forward contactor operates, it causes its auxiliary contacts
to operate also. The normally open auxiliary forward contact (Fa) closes to seal in the forward coil circuit, and
the normally closed auxiliary forward contact (Fb) opens to block the reverse contactor coil circuit. To reverse
the direction of the motor (without first pushing the stop pushbutton), simply push the reverse pushbutton.
The opening of the normally closed contact of the reverse pushbutton causes the coil circuit for the forward
contactor (F) to momentarily open. The circuit for the reverse contactor coil (R) circuit momentarily closes.
When the forward contactor opens, it operates its auxiliary contacts (Fa , Fb). Fa opens to keep the forward
(F) coil circuit open, while Fb closes to allow the reverse coil (R) circuit to energize.
When the reverse contactor picks up, it closes its main contacts to the motor terminals, which in this
case causes lines L1 and L3 to be interchanged, reversing the direction of the motor. Auxiliary contacts Ra and
Rb operate in unison with the reverse contactor. The normally open Ra contact closes to seal in the reverse
coil circuit, while the normally closed Rb contact opens to block the energizing of the forward coil circuit.

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• MODULE 4
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 w/ 2 pcs Php 1,500.00 Php 3,000.00

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

220V

5
• MODULE 4
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

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• MODULE 4
ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL

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

YELLOW
Schneider Illuminated Push 2 pcs Php 1,075.00 Php 2,150.00

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

button 1NC (Red) 240V 3A
Schneider Green Flush 2pcs Php 422.00 Php 422.00

Complete Pusbutton Spring
Return 1NO 240V 3AS

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• MODULE 4
Control Wire 2.0mm RYB 3 mtrs Php 18.00 Php 54.00
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

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• MODULE 4
3 Phase Fuse Switch 1 pc Php 320.82 Php 320.82

Disconnector 220V
63A
Cable Ties 6 inches 100 pcs Php 50.00 Php 50.00
TOTAL Php 29,653.07
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.

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• MODULE 4
PHILIP AND FLAT SCREWDRIVERS - To tighten and

loosen screws on different electrical devices, such
as Circuit breakers and Contactors.
PRECISION SCREWDRIVERS- A precision

screwdriver is a hand tool with a similar intended
function as a conventional screwdriver but a
smaller form factor and a sleeker handle design. It
is usually used for work on small, complicated
electronics.
Long Nose Pliers- Pliers can be used for cutting,
twisting, bending, holding, and gripping of wires
and cables.
Wire Cutter or Diagonal Pliers - Diagonal pliers are

pliers designed for cutting wire; they should not be
used to grip or turn anything.
Combination Pliers – It is also called Slip-joint Pliers
these pliers has notched inner grip which is suitable
for holding and grasping round objects. These pliers
can also be used for electronics such as bending and
cutting of wires.

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• MODULE 4
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

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• MODULE 4
Note: Simulation diagram can be print screen below
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.
9. Conduct also resistance test for the whole circuit upon pressing the mushroom head of emergency
stop push button.

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• MODULE 4
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.
c. Reverse START button pressed.
d. Pressed STOP push button.
e. Forward JOG button pressed then for a few rotations released.
f. Reverse JOG button pressed then for a few rotations released
j. Unlocked EMERGENCY STOP push button.
A: IDLE condition power ON both power and control circuit.

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

h. OVERLOAD RESET condition.
i. Pressed EMERGENCY STOP push button upon re-starting either forward or reverse
rotation.

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• MODULE 4

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• MODULE 4
B: Forward START button pressed.
C: Reverse START button pressed.

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• MODULE 4
D: PRESSED STOP PUSH BUTTON

ELECTRICAL WORKSHOP 2 17
• MODULE 4

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• MODULE 4

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• MODULE 4
E: FORWARD JOG BUTTON PRESSED THEN FOR FEW ROTATIONS RELEASED

Pressed
Released

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• MODULE 4

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• MODULE 4
F: REVERSE JOG BUTTON PRESSED THEN FOR A FEW ROTATION RELEASED

Pressed
RELEASED

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• MODULE 4

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• MODULE 4
G: OVERLOAD TRIP CONDITION UPON RE-STARTING EITHER FORWARD OR REVERSE ROTATION

RE-START
OVERLOAD TRIP CONDITON

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• MODULE 4

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• MODULE 4
H: OVERLOAD RESET CONDITION

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• MODULE 4
I: PRESSED EMERGENCY STOP PUSH BUTTON upon re -starting either forward or reverse rotation.
RE-START
PRESSED E.S PUSH BUTTON

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J: UNLOCKED EMERGENCY STOP PUSH BUTTON

ELECTRICAL WORKSHOP 2 29
• MODULE 4

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• MODULE 4
VII. OBSERVATIONS AND SUMMARY OF DATA:
Table 1. MOTOR CONTROL COMPONENTS CONDITION

NOT ENERGIZE ENERGIZE
Component 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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• MODULE 4
Reverse Holding Contact N.O. CLOSE
Magnetic Contactor
Rev. Interlocking Contact N.C. OPEN
Idle Auxiliary Contact N.C. OPEN
Thermal Overload
OL Aux. NC N.C. OPEN

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• MODULE 4
OL Aux. NO N.O. CLOSE
Pilot Lights
Red (Trip) N.O. CLOSE

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• MODULE 4
Red (Trip) N.O. CLOSE
Green (Forward) N.O. CLOSE
Blue (Reverse) N.O. CLOSE

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Yellow/Orange (Idle) N.C. OPEN
Push Buttons
JOG (Forward) N.O. CLOSE
JOG (Reverse) N.O. CLOSE
Forward START N.O. CLOSE
Reverse START N.O. CLOSE

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

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

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• MODULE 4
UNLOCKED
EMERGENCY STOP
RE-START EITHEIR F/R
THERMAL OVERLOAD
TRIP
RESET
POWER OFF

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• MODULE 4
VIII. CONCLUSION:
(Discuss how a Forward-Reverse with immediate reversal function by referring to your design diagram)
For starters, this activity is called Forward Reverse Motor Control (Immediate Reverse), this motor
control is slightly different than the previous because it is the immediate reverse. In addition, this motor
diagram doesn't need to press the stop push for changing the rotation of the motor. 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

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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, a double contact
push-button for immediate reversal, and jog push buttons.
Forward and reverse starters will include two sets of normally open auxiliary contacts that will serve
as holding contacts in both directions. They will also have two sets of normally closed contacts that will serve
as interlockings. 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 motor. 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. Since this is an immediate
reversal motor control, we do not need to press the stop push button before reversing. Hence, we will press
the reverse button immediately for reverse rotation of the motor it also has Holding contacts which act to
continuously supply the motor in reverse operation, this button is connected to the Normally close contact of
forwarding interlockings.
When the forward motor contactor is energized the Green 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 the 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 de-energized when released. As a result, when the jog is pushed,
the motor is instantaneously powered up and de-energized when released.

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• MODULE 4
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.
IX. EVALUATION:
1. Why is “immediate reversal” motor circuit applicable only for controlling small motors?
Based on my understanding, once our motor is energized it rotates at a high speed and it depends on its
horsepower. So, when a large type of motor is energized and immediately changes its rotation, it will cause
damage to the motor because it can't handle the load of immediate reversal/forward. That's why this kind of
motor control is only applicable to a small type of motor such as dc motors because this type of motor can
handle the load and has the least horsepower compared to larger motors. Furthermore, this type of small
motor can decelerate at the same speed when accelerating, so it can handle the stress of acceleration as well
as reverse without stopping.
2. What application this small motors are mostly used.
We can apply this type of motor, in small toy cards such as remote-controlled cars. Moreover, since this is
a small motor it is designed for small packaging and processing machines. In addition to that, we can also
integrate this kind of motor into small devices such as small fans, mixers, or devices that need to change their
rotation and speed.

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• MODULE 4

42

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Prepared by: Engr. Edwin C.

Espinas, for TUP COE-EE Department

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

II. TECHNICAL INFORMATION:

Full-Speed Reversing (Small Motors)

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Schneider Magnetic Contactor 220V w/ 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

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

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

ITEM IMAGE ITEM DESCRIPTION QTY PRICE PER SUB TOTAL

EATON PILOT LIGHT 220V 1 pc Php 290.00 Php 290.00

Schneider Illuminated Push 2 pcs Php 1,075.00 Php 2,150.00

Schneider Illuminated Push 1 pc Php 422.00 Php 422.00

Schneider Green Flush 2pcs Php 422.00 Php 422.00

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Control Wire 2.0mm RYB 3 mtrs Php 18.00 Php 54.00

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

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

3 Phase Fuse Switch 1 pc Php 320.82 Php 320.82

Cable Ties 6 inches 100 pcs Php 50.00 Php 50.00

TOTAL Php 29,653.07

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

PHILIP AND FLAT SCREWDRIVERS - To tighten and

PRECISION SCREWDRIVERS- A precision

Wire Cutter or Diagonal Pliers - Diagonal pliers are

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

WIRE STRIPPER - Wire strippers are used to remove

MULTIMETER - A multimeter is a essential

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

Note: Simulation diagram can be print screen below

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

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

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

B: Forward START button pressed.

C: Reverse START button pressed.

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT

D: PRESSED STOP PUSH BUTTON

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

COLLEGE OF ENGINEERING - ELECTRICAL DEPARTMENT