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

Name: KEN ANGELO B. ROMERO Course, Yr. & Sec.: BSEE- 1F Subject: ESW 2
Group No. 4 Time: Days: Rm. Date: ___
Professor/Instructor: ENGR. EDWIN C. ESPINA Rating:

Activity No. 4
MOTOR CONTROL COMPONENTS FAMILIARIZATION AND TESTING

I. OBJECTIVES:

At the end of the activity, the students should be able to:

1. Discuss the principle of operation of basic motor control components.
2. Check the condition of basic motor components using VOM and/or CLT.
3. Recognize the importance of gaining skills in testing motor control equipment’s.

II. TECHNICAL INFORMATION:

MAJOR COMPONENTS OF AC MOTOR STARTERS

Alternating current (AC) motor starters have five major functional components, these include:
1. Components that provide motor overload protection.
2. Components that perform the motor controller function.
3. Components that protect against short-circuit and ground faults.
4. Components that provide motor circuit-disconnecting means.
5. An enclosure suitable to meet the requirements of the motor starter application.

Overload Protection
The function of the overload device is to monitor motor line current and to open the motor circuit
when predetermined safe levels are exceeded. In accordance with the National Electric Code and based on
specific circuit conditions, continuous duty motors rated more than one horsepower may be protected for
overloads using overload relays, integral thermal protectors, fuses or circuit breakers. The most used overload
device is the overload relay.
Two types of overload relays that respond to the heating effect of the motor line current are the
thermal and the solid-state overload relays. The thermal overload relay uses the motor line current to produce
heat within itself at a designated rate that simulates load and conductor heating. On the other hand, the solid-
state overload relay monitors motor line current and uses semiconductor circuits to determine the heating
effects that the level of current will have on the motor and conductors.

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

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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

Controller
A major component common to all AC motor starters is the controller. The controller is consisting of
the contactor that carries the motor line current and the control circuit for the contactor. When the overload
relays are added to the controller, the assembly is referred to as a basic magnetic motor starter. The contactor
portion of the controller is essentially an on-off device operated by electromagnetic means. When the
controller coil is energized through a control circuit, the resulting magnetic field mechanically forces the main
contacts to close, thus starting the motor. The coil is then continuously energized to hold the contacts closed
and keep the motor running. When the coil is de-energized, the main controller contacts are forced open by
either spring pressure or gravity, thus stopping the motor.

Fault Protection
The device used to provide protection against short circuit and ground faults. The devices used for this
protection are typically an instantaneous trip circuit breaker, an inverse time circuit breaker, non-time delay
fuses, or dual element (time-delay) fuses.

Disconnect
Another major component that is common to all AC motor starters is the disconnecting device. In
accordance with the National Electric Code, motors and controllers must be provided with a means of safely
disconnecting them from their source of supply so that maintenance of the controller, motor, and its driven
equipment can be accomplished with no hazard to personnel. The devices to be used for disconnecting include
circuit breakers, motor-circuit switches, and molded case switches (non-automatic circuit interrupters).

Enclosure
A final component common to AC motor starters is the enclosure. An enclosure is a surrounding case
constructed to provide a degree of protection to personnel against incidental contact with the enclosed
equipment, and to provide a degree of protection to the enclosed equipment against environmental
conditions. Although other types of materials (e.g. polymeric) are sometimes used, enclosures are typically
sheet metal or cast metal construction. However, in all cases, only material that will not support combustion
in air is selected for enclosures.

Other Motor Control Circuit Components

Components used for control circuits include pushbuttons, selector switches, indicating lights, control
relays, control power transformers, auxiliary contacts, contactors, overload relays, circuit breakers or MCPs,
and electrical wiring.

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

2
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
Pushbuttons
One component typically used in the control circuit of motor starters is the pushbutton. The
pushbutton is used to energize the control circuit. A simple pushbutton is composed of a set of stationary
contacts, a set of moving contacts, an operating plunger, a return spring, and a housing to hold the assembly
together. Pushbuttons are basically one of two types: one with normally open contacts, and the other with
normally closed contacts. For the normally open pushbutton the operating plunger is held up by a return
spring. This spring holds the moving contacts away from the stationary contacts, and it, thereby, keeps the
control circuit open and de-energized. Depressing the plunger causes the moving contacts to engage the
stationary contacts, thus closing the circuit. Normally open pushbuttons are typically used to start a process.
In the normally closed pushbutton, the design of the contacts is opposite to that of the normally open
pushbutton. For this type, the contacts open, and the process stops when the plunger is depressed. As a result
of the internal tension caused by the return spring, the action of both the normally open and normally closed
pushbuttons is momentary. When the operator’s finger is removed from the pushbutton, it returns to its
original state.

Indicator Lights
Indicating lamps are another component used in motor starter control circuits. Their function is a
relatively simple but important one, which is to report the status of the control circuit and, as a result, the
status of the equipment controlled. Varieties of colors are used for the lens of the indicating lights to report
or warn of various circuit conditions. Colors typically offered by manufacturers include red, green, blue, amber,
white and clear. The most used types of indicating lights include the full-voltage, transformer and push-to-test
types.

Control Relays
A control relay is a component that is used in a motor starter’s control circuit to interface between a
pilot device and the circuit that the pilot device controls. In effect, the control relay allows the pilot device to
control a current that is too large for the contacts of the pilot device. Pilot devices used in motor controls
typically monitor parameters such as time, pressure, liquid level, and heat. Among its type are the following:
a. Electromechanical
One type of control relay is the electromechanical type. This relay uses an electromagnet to move
the output contacts from open to closed and closed to open. Relays of this type are referred to as
alternating current relays, if designed for actuation from an AC source, or direct-current relays, if
designed for DC operation.
b. Time Control Relay
The timer control relay is available as either an electromechanical or solid-state type relay. The
relay can be purchased with normally open contacts, normally closed contacts, or a combination of
the two types. This type of relay functions as described above for either the electromechanical or
solid-state type, except that it has a built-in timing circuit that delays the operation of the relay
contacts.
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
3
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
II. TOOLS and MATERIALS NEEDED:

VOM and/or Continuity Lamp Tester

Drawing Materials

Set of Motor Control Components

III. PROCEDURE:

1. After the discussion, secure motor power and control circuit components for familiarization and
testing.
2. Using your test instruments, check the conditions of various motor control components provided by
the instructor.
3. Record the data and observations below and determine the condition of the components.

IV. SUMMARY OF FINDINGS:

a. MAGNETIC CONTACTOR

Note: NE – Not Energize ES – Energized State

Main Contacts
Terminal Markings / Condition L1T1 √ / L 2 T2 √ / L 3 T3 √

Resistance Reading (NE) _____0 / 0 /____0__

(ES) _____ 1.6 / 0.9 /____1.0__

Magnetic Contactor Coil

Coil Terminal Markings / Condition A1 A2 √

Resistance Reading 393

Auxiliary Contacts
N.O. Terminal Markings / Condition 53, 54

N.O. Resistance Reading ____________ 0

N.C. Terminal Markings / Condition _____________61, 62___

N.C. Resistance Reading _______________1.3_ Ω _______

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

4
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

b. OVERLOAD RELAY
Overload Heaters

Terminal Markings / Condition T1 √ T2 √ T3 √

Overload Contacts

N.O. Terminal Markings / Condition 97, 98 √

N.O. Resistance Reading 0

N.O. Resistance Reading when tripped 24.40 Ω

N.C. Terminal Markings / Condition 95, 96 √

N.C. Resistance Reading 1.8 Ω

N.C. Resistance Reading when tripped 0

Reset Button Condition √

c. PUSHBUTTON

Green Pushbutton

Resistance when Pressed 12.5 Ω Condition √

Resistance when Released 0

Red Pushbutton

Resistance when Pressed 0 Condition √

Resistance when Released 27.3 Ω

Emergency Pushbutton

Resistance when Locked: 0 Condition √

Resistance when Unlocked: __0.6 Ω

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

5
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

d. INDICATING LIGHT
Green Pilot Lamp

Resistance Reading 8.94 Ω Condition √

Start Testing

Red Pilot Lamp

Resistance Reading 5.35 Ω Condition √

Trip Testing

Yellow/Orange Pilot Lamp

Resistance Reading 6.41 Ω Condition √

Stop Testing

V. CONCLUSION:

THE COMPONENTS WERE EVALUATED BY USING A MULTITESTER, ONNECTING THE TWO PROBES INTO THE
CORRESPONDING TERMINAL. IT IS DETERMINED THAT THE COMPONENTS ARE ALL FUNCTIONAL AND MAY BE
UTILIZED FOR CIRCUIT CONSTRUCTION. THE MAIN CONTACTS OF THE MAGNETIC CONTACTOR ARE ALL IN
WORKING CONDITION. WHEN NOT ENERGIZED, THE READINGS ARE SHOWN TO BE ZERO/ INFINITE, MEANING
THAT NO CURRENT IS FLOWING WHILE WHEN ENERGIZED, RESISTANCE VALUES ARE READ, WHICH INDICATES
THAT THERE IS A CURRENT FLOW, MEANING THAT THE CONTACTS ARE ALL IN WORKING CONDITION. THE
TERMINALS OR THE OVERLOAD RELAY ARE ALSO ALL IN WORKING CONDITION , WHERE THE NORMALLY OPEN
CONACT SHOWS ZERO/ INFINITE RESISTANCE WHEN NOT TRIPPED AND PRODUCES A RESISTANCE VALUE
WHEN TRIPPED AND THE NORMALLY CLOSE, IS VICE VERSA. THE RESET BUTTON IS ALSO IN GOOD CONDITION.
THE NORMALLY OPEN GREEN PUSHBUTTON HAS A RESISTANCE VALUE WHEN PRESSED BUT HAS ZERO/
INFINITE RESISTANCE WHEN NOT PRESSED WHILE THE RED AND THE EMERGENCY PUSHBUTTON WHICH ARE
BOTH NORMALLY CLOSE HAS ZERO/ INFINTE RESISTANCE WHEN PRESSED AND PRODUCES A RESISTANCE
VALUE WHEN NOT PRESSED, LASTLY, ALL INDICATING LIHTS HAVE ARESISTANCE VALUE READING, SHOWING

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

6
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
THAT ALLL ARE IN WORKING CONDITION. ALL THESE INDICATIONS SHOWS THAT THE COMPONENTS ARE ALL
IN WORKING CONDITION.

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

7