Learning Module 1: (WEEK 2 and 3)

Republic of the Philippines
CAMIGUIN POLYTECHNIC STATE COLLEGE

Balbagon 9100, Mambajao, Camiguin
Tel(088)8890183
www.cpsc.edu.ph|camiguinpolytechnic@yahoo.com
INSTITUTE OF TECHNOLOGY
LEARNING MODULE 1
(WEEK 2 and 3)
Second Semester
MOTOR CONTROL AND SYMBOLS
BT 2-A&B- Electrical
1
RUDYLITO A. NAKILA
Electrical Instructor
Tel(088)8890183
INTRODUCTION:
Once the proper motor is selected, understanding various control

devices available and their uses and limitations becomes an important part
related to reliable operation and protection of the motor and the personnel
using the electric motor.
This module deals with the theoretical aspect of the operation of
various electrical controls in industry. It covers the knowledge, skill, and
attitudes in motor control connection.
LEARNING OUTCOMES:
On completion of this module, you should be able to:
1. State the purpose and general principles of control components.

2. State the difference between manual and automatic control
operation and other various related conflicting words.
3. Identify various symbols which represent control components.
4. Read the basic line diagram.
5. Select:
o Which switches are to be used for starting and stopping a
motor?
o Which relay is to be used for controlling a group of lamps
in more than two locations?
6. Draw the symbols correctly as what needed on the diagram.
MOTOR CONTROL
Control
Control, as applied to control circuits, is a broad term that
means anything from a simple toggle switch to a complex
system of components which may include relays, contractors,
timers, switches, and indicating lights. Every electrical circuit
for light or power has control elements. One example of a
simple control circuit is a light switch used to turn lights on and
off.
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Of course there are many other devices and equipment

systems in industrial applications. Motor control, for example
can be used start and stop a motor and protect the motor,
associated machinery, and personnel, in addition, motor
controllers might also be used for reversing, changing speed,
jogging, sequencing, and pilot-light indication. Control circuits
can be complex: accomplishing high degrees of automatic and
precise machine operation.
A motor controller is a device or set of devices that help in regulating the

manner in which a motor works. There are two modes through which motor control
components can start or stop the motor, either manual or automatic. The controller is
also able to engage the motor into forward or reverse rotation as well as regulating
and limiting the rotary speed, torque, and protecting against electrical fails and
overloads.
As evident, there is a variety of motor controls, and all cannot be controlled by
the same device since different mechanisms are used in each. Therefore, there are
some motor control components available, and it's important to know what they are
and what they are used. This helps ensure that the user gets the right device for their
motor related component.
Types of Control Systems
Motor control systems can be divided into three major types: manual,
semiautomatic, and automatic.
Manual controls are characterized by the fact that the operator must go to the
location of the controller to initiate any change in the state of the control system.
Manual controllers are generally very simple devices that connect the motor directly
to the line. They may or may not provide overload protection or low-voltage release.
Manual control may be accomplished by simply connecting a switch in series with a
motor.
Semiautomatic control is characterized by the use of push buttons, limit

switches, pressure switches, and other sensing devices to control the operation of a
magnetic contactor or starter. The starter actually connects the motor to the line, and
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the push buttons and other pilot devices control the coil of the starter. This permits
the actual control panel to be located away from the motor or starter. The operator
must still initiate certain actions, such as starting and stopping, but does not have to
go to the location of the motor or starter to perform the action. A typical control panel
is shown in FIG. 1. A schematic and wiring diagram of a start-stop push button
station is shown in FIG. 2. A schematic diagram shows components in their electrical
sequence without regard for physical location. A wiring diagram is basically a pictorial
representation of the control components with connecting wires. Although the two
circuits shown in FIG. 2 look different, electrically they are the same.
FIG. 1 Typical push button control center.
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FIG. 2 Schematic and wiring diagram of a start-stop push button control.

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Automatic control is very similar to semiautomatic control in that pilot sensing
devices are employed to operate a magnetic contactor or starter that actually controls
the motor. With automatic control, however, an operator does not have to initiate
certain actions. Once the control conditions have been set, the system will continue
to operate on its own. A good example of an automatic control system is the heating
and cooling system found in many homes. Once the thermostat has been set to the
desired temperature, the heating or cooling system operates without further attention
from the home owner. The control circuit contains sensing devices that automatically
shut the system down in the event of an unsafe condition such as motor overload,
excessive current, no pilot light or ignition in gas heating systems, and so on.
Manual Motor Starters
Manual motor starters are motor control components that are used for motor
protection. They are used to switch the motor off or on manually. Once there is an
electrical overload or failure, the device trips, switches off and stops the motor. This
means that they have to be manually turned on by an operator once they switch off.
Such a starter is most suitable for small and simple motors.
Motor Circuit Breakers
A motor circuit breaker is similar to an ordinary circuit breaker in that they

protect from overloads and short circuits. In case of overload or short-circuit the
device trips switching off the motor. Auxiliary contacts can be fitted to give tripping
feedback information to a PLC or pilot light indication. Motor Circuit Breakers are
usually used in conjunction with contactors for the control (on/off) of the load. Electro-
mechanical links are available between the motor circuit breaker and the contactor.
Some breakers are made in such a way that once the current goes down to its
operating range, it automatically turns back on.
Contactors
Contactors are electro-mechanical devices to switch on/off motor load. You'll

need to apply voltage across the coil terminals to switch the contactor on. The
difference is that a contractor is used for higher power ratings as compared to a relay
and are not only used for the purpose of interrupting short circuits.
Mini Contactors
Mini contactors are in reality contactors in functionality. The difference is that

they are much smaller in size. This helps provide the efficiency and reliability of a
contactor where space is limited.
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Thermal Overload Relays
Thermal overload are used to protect motors from current overloads causing
overheat, unrepairable damage to motors and service disruption. They are using
bimetallic strips that heats up in case of overcurrent. When tripping auxiliary, contacts
are actuated. Used in the control circuit, these will stop the contactor, stopping the
motor to avoid any damage.
Motor Control Accessories
Motor control accessories are peripheral devices that can be fitted together
with a motor to help in ensuring its smooth running. There’s a wide variety of motor
control accessories available depending on the specific motor need.
Mini Contactors
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Thermal Overload Relays
Basic Components Used in Industrial Motor Control System
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Industrial Motor Control
In the broadest sense of the term encompasses the different methods used to
control an electrical system’s performance. With reference to machinery, it involves the
start-up, acceleration, deceleration, reversal and stopping of the motor and the
applied load. Here, we take a look at the electrical control of three-phase alternating
systems.
Industrial circuitry can be very complex and can’t be explained briefly and the
information on this blog is restricted to elementary circuits. But the basic principles that
are mentioned here are applicable to all types of control systems, regardless of how
complex they are.
Control Elements The elements of a control circuits include all of the

equipment and devices concerned with the circuit
function. This includes enclosures, conductors, relays,
contractors, pilot devices, and over current-protection
devices. The selection of control equipment for a
specific application requires a thorough understanding
of controller operating characteristics and wiring layout.
The proper control devices must be selected and
integrated into the overall plan.
Control devices
A control circuit is made up of numerous basic interconnected components

that achieve the desired performance. The components will vary in size depending
on the motor’s power; however, the operation principles stay the same. It’s possible
to design a complex industrial control system, using these few basic components:
Manual circuit breakers

Disconnecting switches
Fuses haven’t been included in this list because they aren’t control devices; they
are categorized as protective devices. Here is a more detailed look at what some
of these components do.
Disconnecting switch
This switch isolates the system’s motor from the main power source. It is
made up of three line fuses and three knife-switches that are enclosed in a
metallic box. The latter can be closed & opened simultaneously with the use
of an external handle. These switches are selected to carry the motor’s
nominal full-load current as well as to withstand short-circuit currents for short
intervals.
Manual circuit breakers

This breaker closes and opens a circuit just like any toggle switch. When it
trips, it can be reset manually. These types of breakers are commonly used in
place of disconnecting switches because you don’t need to worry about
replacing fuses.
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Cam switches
A cam switch is used to control the motion as well as the position of
callenders hoists, machine tools etc.
Push-buttons
A push-button switch is activated via finger pressure. Two/more contacts
close or open when the switch is depressed. A push-button is usually spring-
loaded so it returns to its normal position once the pressure is removed.
Control relays
Pushbuttons
Cam switches
Magnetic contactors
A push-button switch is activated via finger pressure. Two/more contacts
close or open when the switch is depressed. A push-button is usually spring-loaded
so it returns to its normal position once the pressure is removed.
Control relays
This is an electromagnetic switch that closes & opens a set of contacts

whenever the relay coil gets energized. This relay coil produces a very strong
magnetic field that attracts a movable armature that has the contacts. A control relay
is largely used in a low-power circuit.
Thermal relays
This is essentially a temperature-sensitive/overload device whose contacts

close/open whenever the motor’s current exceeds its pre-set limit. The current then
flows through a calibrated heating element that raises the relay’s temperature. A
thermal relay is a basic component in any time-delay device because the system’s
temperature can’t follow instantaneous alterations in current.
Relays
Thermal relays and fuses
Limit switches and other special switches
Pilot lights
Resistors, transformers, capacitors and reactors
Magnetic contactors
They are control relays that are designed to close and open a power circuit.
They have a magnetic plunger and a relay coil that carries a complete set of movable
contacts. Magnetic contactors are utilized to control motors ranging from 0.5 hp –
several hundred hp.
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Tel(088)8890183
Power contactors for switching motors
There is a very wide range of power contactors used for switching motors,
such as 3-pole standard contactors, vacuum contactors, 4-pole power relays,
coupling relays, and miniature contactors.
Proximity detectors
These sealed devices are able to detect objects without actually coming into
direct contact with them.
Pilot light
Pilot lights indicate the on/off state of remote components in a control system.
ELECTRICAL SYMBOLS
Language has been developed in order to transfer ideas and information. In
order to understand the ideas and information being communicated, an
understanding of the language is necessary. The language of controls consists of a
commonly used set of symbols which represents control components.
Contact Symbols Contact symbols are used to indicate an open or closed

path of current flow. Contacts are shown as normally
open (NO) or normally closed (NC). Contacts shown by
this symbol require another device to actuate them.
The standard method of showing a contact is by

indicating the circuit condition it produces when the
actuating device is in the deenergized or nonoperated
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 deenergized. A complete path of current
does not exist and the light is off.
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RUDYLITO A. NAKILA
Tel(088)8890183
Normally Open Contact In a control diagram or schematic, symbols are usually
Example not shown in the energized or operated state. For the
purpose of explanation in this text, a contact or device
shown in a state opposite of its normal state will be
highlighted. For example, in the following illustration
the circuit is first shown in the deenergized state. The
contacts are shown in their normally open (NO) state.
When the relay is energized, the contacts close
completing the path of current and illuminating the
light.
Normally Closed Contact In the following illustration the contacts are shown
Example normally closed (NC), meaning the contacts are
closed when the relay is deenergized. A complete path
of current exists and the light is on. When the relay is
energized, the contacts open turning the light off.
\Switch Symbols Switch symbols are also used to indicate an open or

closed path of current flow. Variations of this symbol
are used to represent limit switches, foot switches,
pressure switches, level switches, temperature-
actuated switches, flow switches, and selector
switches. Switches, like contacts, require another
device or action to change their state. In the case of a
manual switch someone must manually change the
position of the switch.
Normally Open Switch In the following illustration a battery is connected to one

Example side of a normally open switch and a light to the other.
Current is prevented from flowing to the light when the
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switch is open. When someone closes the switch, the
path of current flow is completed and the light
illuminates.
Normally Closed Switch In the following illustration a battery is connected to one

Example side of a normally closed switch and a light to the other.
Current is flowing to the light when the switch is closed.
When someone opens the switch, the path of current
flow in interrupted and the light turns off.
Pushbutton Symbols There are two basic types of pushbuttons: momentary

and maintained. A normally open momentary
pushbutton closes as long as the button is held down.
A normally closed momentary pushbutton opens as
long as the button is held down. A maintained
pushbutton latches in place when the button is pressed.
Normally Open In the following illustration a battery is connected to one

Pushbutton Example side of a normally open pushbutton and a light is
connected to the other side. When the pushbutton is
depressed, a complete path of current flow exists
through the pushbutton and the light is illuminated.
Normally Close In the following example current will flow to the light as
Pushbutton Example long as the pushbutton is not depressed. When the
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pushbutton is depressed, current flow is interrupted and
the light turns off.
Coil Symbols Coils are used in electromagnetic starters, contactors,

and relays. The purpose of contactors and relays is to
open and close associated contacts. A letter is used to
designate the coil; for example, “M” frequently indicates
a motor starter and “CR” indicates a control relay. The
associated contacts have the same identifying letter.
Contractors and relays use an electromagnetic action
which will be described later to open and close these
contacts. The associated contacts can be either
normally open or normally closed.
Coil Example Using In the following example, the “M” contacts in series with
Normally Open Contacts the motor are controlled by the “M” contactor coil.
When someone closes the switch, a complete path of
current flow exists through the switch and “M” contactor
coil. The “M” contactor coil actuates the “M” contacts
which provide power to the motor.
Overload Relay Symbols Overload relays are used to protect motors from
overheating due to an overload on the driven
machinery, low-line voltage, or an open phase in a
three-phase system. When excessive current is drawn
for a predetermined amount of time, the relay opens
and the motor is disconnected from its source of power.
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Tel(088)8890183
Pilot Light Symbols A pilot light is a small electric light used to indicate a
specific condition of a circuit. For example, a red light
might be used to indicate a motor is running. The letter
in the center of the pilot light symbol indicates of the
light.
Other Symbols In addition to the symbols discussed here, there are

many other symbols used in control circuits. The
following chart shows many of the commonly used
symbols.
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Republic of the Philippines

CAMIGUIN POLYTECHNIC STATE COLLEGE

MOTOR CONTROL AND SYMBOLS

Once the proper motor is selected, understanding various control

On completion of this module, you should be able to:

1. State the purpose and general principles of control components.

Of course there are many other devices and equipment

A motor controller is a device or set of devices that help in regulating the

Types of Control Systems

Semiautomatic control is characterized by the use of push buttons, limit

FIG. 1 Typical push button control center.

FIG. 2 Schematic and wiring diagram of a start-stop push button control.

Manual Motor Starters

A motor circuit breaker is similar to an ordinary circuit breaker in that they

Contactors are electro-mechanical devices to switch on/off motor load. You'll

Mini contactors are in reality contactors in functionality. The difference is that

Thermal Overload Relays

Motor Control Accessories

Thermal Overload Relays

Basic Components Used in Industrial Motor Control System

Industrial Motor Control

Control Elements The elements of a control circuits include all of the

A control circuit is made up of numerous basic interconnected components

Manual circuit breakers

Manual circuit breakers

This is an electromagnetic switch that closes & opens a set of contacts

This is essentially a temperature-sensitive/overload device whose contacts

Power contactors for switching motors

Contact Symbols Contact symbols are used to indicate an open or closed

The standard method of showing a contact is by

\Switch Symbols Switch symbols are also used to indicate an open or

Normally Open Switch In the following illustration a battery is connected to one

Normally Closed Switch In the following illustration a battery is connected to one

Pushbutton Symbols There are two basic types of pushbuttons: momentary

Normally Open In the following illustration a battery is connected to one

Coil Symbols Coils are used in electromagnetic starters, contactors,

Other Symbols In addition to the symbols discussed here, there are

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