ELC 321

Introduction

General Principles of Electric Motor

Control
 Objectives
After studying this unit, the student should be able to:
• State the purpose and general principles of electric motor
control.
• State the difference between manual and remote control.
• List the conditions of starting and stopping, speed control,
and protection of electric motors.
• Explain the difference between compensating and definite
time delay action.
 General Principles
Motor control is a broad term that means anything from a
simple toggle switch to a complex system with
components such as relays, timers, and switches. The
common function of all controls, however, is to control
the operation of an electric motor. As a result, when motor
control equipment is selected and installed, many factors
must be considered to ensure that the control will function
properly for the motor and the machine for which it is
selected.
The purpose
1. Starting - The motor may be started by connecting it
directly across the source of voltage. Slow and gradual
starting may be required, not only to protect the
machine, but also to ensure that the line current inrush
on starting is not too great for the power company’s
system. Some driven machines may be damaged if
they are started with a sudden turning effort. The
frequency of starting a motor is another factor
affecting the controller. A combination fused
disconnect switch and motor starter is shown.
 MOTOR CONTROL INSTALLATION
AND CONSIDERATIONS
1. ELECTRICAL SERVICE – Establish whether the service is Direct
Current (DC) or Alternating Current (AC).
2. MOTOR – The motor should be matched to the electrical service and
correctly sized for the machine load in horsepower rating (hp).
3. OPERATING CHARACTERISTICS OF CONTROLLER – The
fundamental tasks of a motor controller are to start and stop the motor and
protect the motor, machine, product, and operator.
4. ENVIRONMENT – In certain applications, the controller itself must be
protected from a variety environmental conditions.
5. ELECTRICAL CODES AND STANDARDS – Motor control equipment
is designed to meet the provisions of the National Electrical Code (NEC).
National Electrical Manufacturers Association (NEMA) standards practical
information concerning the construction, testing, performance, and
manufacture of motor control devices (Starters, Relays, and Contactors)
The Purpose
2. Stopping - Most controllers allow motors to coast to a
standstill. Some impose braking action when the machine
must stop quickly. Quick stopping is a vital function of the
controller for emergency stops. Controllers assist the
stopping action by retarding centrifugal motion of
machines and lowering operations of crane hoists.
3. Reversing - Controllers are required to change the
direction of rotation of machines automatically or at the
command of an operator at a control station. The reversing
action of a controller is a continual process in many
industrial application
 The Purpose
4. Protection from Damage - Part of the operation of an automatic
machine is to protect the machine itself and the manufactured or
processed materials it handles. For example, a certain machine
control function may be the prevention of conveyor pileups. A
machine control can reverse, stop, slow, or do whatever is
necessary to protect the machine or processed materials.
5. Maintenance of Starting requirements - Once properly
installed and adjusted, motor starters will provide reliable
operation of starting time, voltages, current, and torques for the
benefit of the driven machine and the power system. The NEC®,
supplemented by local codes, governs the selection of the proper
sizes of conductors, starting fuses, circuit breakers, and
disconnect switches for specific system requirements
 The Purpose
6. Running - The maintaining of desired operational speeds and
characteristics is a prime purpose and function of controllers.
They protect motors, operators, machines, and materials while
running.
7. Speed Control - Some controllers can maintain very precise
speeds for industrial processes. Other controllers can change
the speeds of motors either in steps or gradually through a
continuous range of speeds.
8. Safety of Operator - Many mechanical safeguards have been
replaced or aided by electrical means of protection. Electrical
control pilot devices in controllers provide a direct means of
protecting machine operators from unsafe conditions.
 Two types of Motor Control
Manual Control - A manual control is one whose operation is
accomplished by mechanical means. The effort required to actuate the
mechanism is almost always provided by a human operator. The motor
may be controlled manually using any one of the following devices.

Remote and Automatic Control - The motor may be controlled by

remote control using push buttons. When push-button remote control
is used or when automatic devices do not have the electrical capacity
to carry the motor starting and running currents, magnetic or electric
switches must be included. Magnetic switch control is one whose
operation is accomplished by electromagnetic means. The effort
required to actuate the electromagnet is supplied by electrical energy
rather than by the human operator. If the motor is to be automatically
controlled, the following two-wire pilot devices may be used.
Manual Control
Toggle switch - A toggle switch is a manually operated
electric switch. Many small motors are started with
toggle switches. This means the motor Combination
fused disconnect switch and motor starter.(Courtesy of
Schneider Electric) may be started directly without the
use of magnetic switches or auxiliary equipment.
Motors started with toggle switches are protected by
the branch circuit fuse or circuit breaker. These motors
generally drive fans, blowers, or other light loads.
Manual Control
Safety Switch - In some cases it is permissible to start a motor directly
across the full-line voltage if an externally operated safety switch is
used (EXO), Figure 1–5. The motor receives starting and running
protection from dual-element, time-delay fuses. The use of a safety
switch requires manual operation. A safety switch, therefore, has the
same limitations common to most manual starters.
Drum controllers - are rotary, manual switching devices that are often
used to reverse motors and to control the speed of AC and DC
motors. They are used particularly where frequent start, stop, or
reverse operation is required.These controllers may be used without
other control components in small motors, generally those with
fractional horsepower ratings. Drum controllers are used with
magnetic starters in large motors. A drum controller is shown in
Figure 1–6.
Manual Control
Faceplate Control - Faceplate controllers have been in use
for many years to start DC motors. They have been used
for AC induction motor speed control. The faceplate
control has multiple switching contacts mounted near a
selector arm on the front of an insulated plate. Additional
resistors are mounted on the rear to form a complete unit.
Technological developments, however, have fewer
faceplate controllers being installed.
 Remote and Automatic Control
Float switch - The raising or lowering of a float that is mechanically
attached to electrical contacts may start motor-driven pumps to
empty or fill tanks. Float switches are also used to open or close
piping solenoid valves to control fluids.
Pressure switches - are used to control the pressure of liquids and
gases (including air) within a desired range, Figure 1–9. Air
compressors, for example, are started directly or indirectly on a
call for more air by a pressure switch. Electrical wiring symbols
are shown as normally closed and normally open in Figure 1–9.
Time clocks - can be used when a definite “on and off” period is
required and adjustments are not necessary for long periods of
time. A typical requirement is a motor that must start every
morning at the same time and shut off every night at the same time,
or switches the floodlights on and off.
 Remote and Automatic control
Thermostats - Thermostats indirectly control large motors in air-
conditioning systems and in many industrial applications to maintain the
desired temperature range of air, gases, liquids, or solids. There are
many types of thermostats and temperature-actuated switches.
Limit switch - Limit switches are used most frequently as over travel
stops for machines, equipment, and products in process. These devices
are used in the control circuits of magnetic starters to govern the
starting, stopping, or reversal of electric motors
Electrical or Mechanical Interlock and Sequence Control - Many of
the electrical control devices described in this unit can be connected in
an interlocking system so that the final operation of one or more motors
depends on the electrical position of each individual control device. For
example, a float switch may call for more liquid but will not be satisfied
until the prior approval of a pressure switch or time clock is obtained
Starting and Stopping
 Frequency
 Light-or-heavy duty starting
 Fast or slow (Hard or soft)
 Smooth starting
 Manual or automatic starting and stopping
 Quick stop or slow stop
 Accurate stop
 Frequency of Reversals required
 Speed Control of Motors
 Constant-speed motors are used on water pumps. Maintenance of constant
speed is essential for motor generator sets under all load conditions. Constant-
speed motors with ratings as low as 80 rpm and horsepower ratings up to 5000
hp are used in direct drive units. The simplest method of changing speeds is by
gearing. Using gears, almost any “predetermined” speed may be developed by
coupling the input gear to the shaft of a squirrel cage induction motor.
 Varying speed is usually preferred for cranes and hoists. In this type of
application, the motor speed slows as the load increases and speeds up as the
load decreases.
 Adjustable speed controls, an operator can gradually adjust the speed of a
motor over a wide range while the motor is running. The speed may be preset,
but once it is adjusted it remains essentially constant at any load within the
rating of the motor
 Multispeed - or multispeed motors, such as the type used on turret lathes in a
machine shop, the speed can be set at two or more definite rates. Once the
motor is set at a definite speed, the speed will remain practically constant
regardless of load changes.
 Protective features
 Overload Protection. This protection may be an integral part of the
motor or be separate. A controller with electrical overload protection
will protect a motor from burning up while allowing the motor to
achieve its maximum available power under a range of overload and
temperature conditions. An electrical overload on the motor may be
caused by mechanical overload on driven machinery, a low line voltage,
an open electrical line in a polyphase system resulting in single-phase
operation, motor problems such as too badly worn bearings, loose
terminal connections, or poor ventilation within the motor
 Open-Field Protection - DC shunt and compound-wound motors can
be protected against the loss of field excitation by field loss relays.
Other protective arrangements are used with starting equipment for DC
and AC synchronous motors. Some sizes of DC motors may race
dangerously with the loss of field excitation, whereas other motors may
not race due to friction and the fact that they are small
 Open-phase Protection - Phase failure in a three-phase
circuit may be caused by a blown fuse, an open connection,
a broken line, or other reasons. If phase failure occurs when
the motor is at a standstill during attempts to start, the stator
currents will rise to a very high value and will remain there,
but the motor will remain stationary (not turn). Because the
windings are not properly ventilated while the motor is
stationary, the heating produced by the high currents may
damage them. Dangerous conditions are also possible while
the motor is running. When the motor is running and an
open-phase condition occurs, the motor may continue to
run. The torque will decrease, possibly to the point of motor
“stall”; this condition is called breakdown torque.
 Reversed-phase Protection - If two phases of the supply of a three-phase
induction motor are interchanged (phase reversal), the motor will
reverse its direction of rotation. In elevator operation and industrial
applications, this reversal can result in serious damage. Phase failure and
phase reversal relays are safety devices used to protect motors,
machines, and personnel from the hazards of open-phase or reversed-
phase conditions.

 Overtravel ProtectionControl devices - are used in motor starter circuits

to govern the starting, stopping, and reversal of electric motors. These
devices can be used to control regular machine operation or they can be
used as safety emergency switches to prevent the improper functioning
of machinery.
 Overspeed Protection - excessive motor speeds can damage a driven
machine, materials in the industrial process, or the motor. Overspeed
safety protection is provided in control equipment for paper and printing
plants, steel mills, processing plants, and the textile industry.
Reversed current Protection-accidental reversal of currents in direct-current
controllers can have serious effects. Direct-current controllers used with
three-phase alternatingcurrent systems that experience phase failures and
phase reversals are also subject to damage. Reversed-current protection is an
important provision for battery charging and electroplating equipment.
Mechanical Protection - An enclosure may increase the life span and
contribute to the trouble-free operation of a motor and controller.
Enclosures with particular ratings such as general purpose, watertight,
dustproof, explosion proof, and corrosion resistant are used for
specific applications. All enclosures must meet the requirements of
national and local electrical codes and building codes.
Short-Circuit Protection - For large motors with greater than fractional
horsepower ratings, short-circuit and ground fault protection are generally
installed in the same enclosure as the motor-disconnecting means.
Overcurrent devices (such as fuses and circuit breakers) are used to protect
the motor branch circuit conductors, the motor control apparatus, and the
motor itself against sustained overcurrent due to short circuits and grounds,
and prolonged and excessive starting currents.
 Classification of automatic motor starting
control systems
Current-limiting acceleration - This is also called compensating
time. It refers to the amount of current or voltage drop required
to open and close magnetic switches when used in a motor
accelerating controller. The rise and fall of the current or
voltage determines a timing period.
Time-delay acceleration - For this classification, definite time
relays are used to obtain a preset timing period. Once the period
is preset, it does not vary regardless of current or voltage
changes occurring during motor acceleration. The following
timers and timing systems are used for motor acceleration;
some are also used in interlocking circuits for automatic control
systems. ■ Pneumatic timing ■ Motor-driven timers ■
Capacitor timing ■ Electronic timers
Test yourself
1. What is a controller and what is its function? (Use the Glossary
and the information from this unit to answer this question.)
2. What is meant by remote control?
3. To what does current limiting, or compensating time,
acceleration refer?
4. List at least four devices that are used to control a motor
automatically. Briefly describe the purpose of each device.
Select the best answer for each of the following.
5. The general purpose of motor control is a. to start the motor
b. to stop the motor c. to reverse the motor d. all of the
above
6. A motor may be controlled manually by using a a. float switch
b. pressure switch c. toggle switch d. time clock
7. A motor may be controlled remotely or automatically by using a a. drum
controller b. thermostat c. safety switch d. faceplate control
8. Conditions that may affect starting and stopping of a motor and the
machinery that it drives are a. fast or slow starts b. starting under light
or heavy loads c. how often the motor is started and stopped d. all of
the above
9. Which of the following is not considered as motor speed control? a.
Constant speed b. Varying speed c. Multispeed d. Short-circuit
protection
10. Which of the following is not a protective feature of a motor controller?
a. Overload b. Short circuit c. Adjustable speed d. Mechanical
11. Which function is not a fundamental job of a motor controller? a. Start
and stop the motor b. Protect the motor, machine, and operator c.
Reverse, inch, jog, speed control d. Motor and controller disconnect
switch
12. What factors are to be considered when selecting and installing a
controller? a. Electrical service b. Motor c. Electrical codes and
standards d. All of the above