Overview about industrial automation

Pneumatic
and Hydraulic
Power
Switchgear, electronics
Contactors
and Relays

Sensors Closed Loop

and Actors Controller
Automation

Electronic
Controls and Programmable
Microcontroller Logic Controller

Motors
 Control engineering with contactors

Input Control unit Output

Switches Contactors Lamps

Push-buttons Relays Valves
Sensors Motor protection Motors
Industrial Control Cabinet

Auxiliary contactors

Main Contactors

Timer, Counter …

Protective circuit breaker

Terminal strip
 Commanding and Signaling Devices

Signaling lamps Sensors Switches Push Buttons

 Contactors 1

Basic units with

three-phase Coils for different
main contacts voltages

Auxiliary contacts
side-mounting
Auxiliary contacts
top-mounting
 Contactors 2

Main contacts

Type of contact Symbol Function digit

Normally Open (NO)

Make contact 3 and 4

Auxiliary contacts Normally Closed (NC)

Break contact 1 and 2
 Motor-Protective Circuit-Breakers
L1 L2 L3 Under voltage
Adjuster for the release modules
nominal current

Auxiliary
Remote contacts
control
Motor
Short circuit protection
is fixed
 Motor-Protective Relays
Tripping characteristic

Adjuster for the

Contactor
nominal current
Test
button

1 3 5

Bimetallic Motor Selector

strip Auxiliary manual/auto
contacts and
release button
 Asynchronous Motor
Star connection

Terminal box

W2 U2 V2

U1 V1 W1

Delta connection

Clockwise direction: W2 U2 V2
L1  U1
L2  V1 U1 V1 W1

L3  W1
 Data from the rating plate

Type of
connection and
Nominal Voltage Nominal Current
Nominal Power S1 … Rating class
operating time
IP44 … Protection class
(dust and water)

1. Connect the motor in Delta, if the mains voltage is about 400V, 50Hz!
2. Use a contactor for the nominal power of 11kW!
3. Set the motor-protective relay to the nominal current of 22.1A!
Project: Ventilation Installation

Gate 1 Gate 2

Power supply: 3/N/PE , 400V, 50Hz

 Direct-on-Line Starting 1

Protective circuit breaker Protective relays With instrument transformer

 Direct-on-Line Starting 2

Fuse Short circuit

protection
Overload contact

Main
Off-push-button Switching
contacts
ON-push-button
Overload
protection
Self-holding
contact

Coil

Control circuit Main Circuit

 Practical exercises
Attention:
The circuit is operated with 400 V of AC.
This voltage is extremely dangerous.
The circuit should be built up only by professionals.

Wiring works are carried out only in the switched-off state!

For the N conductor only blue laboratory lines are used!
For the PE conductor only green-yellow laboratory lines are used!
The control is put into operation only in attendance of the teacher!

Steps:
1. Arrange the equipment practical on the grid metal sheet.
2. Give suitable names to the devices
3. Write the terminal markings of the equipment into the circuit diagram.
4. Wire the control, and check the function.
5. Test for safety first the control circuit without the main circuit.
 Project: Freight Elevator
Control cabinet
Limit switch

Gear motor
empty

Silo

Stop Operator Panel

load up
 Direct Starting with Reversing 1

Protective
Fuses
circuit
breaker

Rotational
field
reversal
Motor
protective
relays

To change the rotation direction of the motor, two phases are exchanged. So that both
contactors are never energized together, interlocks are inserted in the control circuit!
 Direct Starting with Reversing 2
Type of fuse

Type of motor
overload
protection

Push button
interlocking

Contact
interlocking

Reversing after actuating STOP Direct reversing

Project: Pump Installation

CONTROL
ON

ACTIVE FAULT

STAR DELTA Start Stop

Control cabinet Pump with motor Operator panel

 Starting Characteristics
I Delta M Delta
I Star  M Star 
3 3

Starting
current Starting
torque

With the star-delta-circuit the starting current is reduced to a third of the value in
comparison to direct starting. Because the torque is also reduced to a third, this control
can be used only with low starting load!
 Timer Relays

Time factor 1…100

Timer range (s, min, h)
Timer functions

On-delay timer Off-delay timer

In automated plants many sequences are controlled time-dependent. In the lower range
of performance with conventional contactor controls, delay time relays with different
functions are used. Modern timers with digital electronics are often multi-functionally
toggleable.
Timer Characteristics
On-delay timer

S
S1 K1T 1

t
H1
K1T H1

Off-delay timer

S
S1 K1T 1

t
H1
K1T H1
 Star-Delta Starting with contactors
Type of overload
protection

Delta
Main
contactor Star

I nom
I
3

To prevent energized star and delta contactors at the same time, interlocks have
to be inserted in the control circuit!
 Automatic Star-Delta Starting

The delay
time Interlocks
depends on
the load 5s

There is a minimal run-up time of the drive, which must be exceeded before a
switch-over can take place.
And it goes on …

more automating
with
programmable
controller !