3 PHASE MOTOR PROGRAMMABLE CONTROLLER

Objective
To construct a controller for 3-phase motor that automatically turns on/off using a
programmable time switch.

Principle of operation
The system has two programmable time switches for setting the starting and stopping times of
the motor and two control circuits, which are interfaced with the start and stop switches of the 3-phase
motor’s starter. Two identical power supply circuits are built around transformers X1 and X2. The
arrangement provides 12V DC to two control circuits built around two 555 timers IC1 and IC2. The two
time switches used in this system are Frontier-made, model TM-619-2. These operate on 230V AC at
50Hz. Each switch has a built-in single changeover relay with contact rating of 16A.
The time switch is a programmable digital device that has a digital real-time clock and can
program for a maximum eight time durations. 230V AC is applied across pins 1 and 2 of connectors
CON1 and CON2 for start and stop switches, with pin 1 being neutral. Live pins 2 are joined by wire to
pins 3 and output voltage is taken from pins 1 and 5. There is a provision of button cell CR2032 to hold
the clock and programmed times. That means, even if 230V AC is turned off, the clock and programmed
times are not disturbed (during mains failure). When mains power is present, the cell is charged
continuously.
The control circuit has two monostable multivibrators for the time delay of five seconds. The
start time switch1 is connected to the first monostable multivibrator built around IC1. The motor is
switched off by using the second multivibrator circuit, in which N/C and common terminals of relay RL2
are connected in series with off switch of the starter.
When programmed time is reached, the second time switch provides 230V AC across the
primary of step-down transformer X2, and the second full-wave rectifier outputs 12V DC. This voltage
goes to the second monostable multivibrator circuit.
When start switch is pressed momentarily, current flows through the coil, relay strip is pulled
towards the iron of the coil and 3-phase voltage gets applied to the motor.
As pin 3 of IC1 is high, relay RL1 gets energised for five seconds, which, in turn, shorts the start switch,
extending the 3-phase supply to the motor. This is virtually similar to physically pressing the start switch
of the 3-phase motor starter for five seconds.
When time reaches 9am, the second time switch (stop switch) provides 230V AC to the primary
of transformer X2. Again, by using a full-wave rectifier and filter circuit, 12V DC is provided to the second
monostable circuit having relay RL2.
Normally-closed (N/C) terminal of the relay is connected in series with the stop switch of the
starter of the 3-phase motor. So, the relay breaks the circuit to stop the motor.
This system can find many applications, including switching on a water pump in a multi-storeyed
commercial building to fill overhead tanks only for five or six days in a week. It can also prove useful for
farmers, industrial units or railway stations where 3-phase motors are used.
Circuit Diagram

Learning Values
We have learnt that by using Programmable controller for Motor or any other Electrical/Electronic
equipments can;
1. Save time as compared to manual operation
2. Used in water tight doors with a delay time of 15sec operated using Electro Hydraulic pump.
3. Used in soot blowers Inside exhaust uptake
4. Used for timed pre-purging of boiler
5. To control Exhaust fan that circulate air on periodical basis
6. To control lighting circuit by using a photovoltaic sensor
7. To activate Fire Pump in case the Temperature sensor/Flame detector is triggered
8. To activate Hi-Fog / Hyper-Mist system in case Temperature sensor/Flame detector is triggered
9. To activate compressor in case the pressure in Air bottle falls below set value
10. Automation on Door control
11. Used in washing machines
Market survey analysis
After surveying the market for components with available vendors we came to the conclusion
that most of the electronic components we require for the project is available in Richie street of
Chennai and the electrical components are available in Parry’s corner. The estimated cost of
components as per our vendor is described below for your kind perusal. We request your
approval to proceed further for the competition of our project.

Estimated cost for components

Frontier TM619H2 digital timer x 2 – Rs.2250/-
DOL Starter – Rs.1400/-
Enclosure for components – Rs.750/-
IC555 TIMER x 2 – Rs.90/-
IN4001 x 10 – Rs.40/-
1Mohms resistor x 2 – Rs.10/-
Capacitors x 4 – Rs.80/-
12v Relay x 2 – Rs.240/-
230 to 12-0-12 500mA transformer x 2 – Rs.380/-
Blank Circuit board and other components – Rs.100/-
Total Rs.5340/-