Motor Control Circuits- Intro Obispo

 NEC Motor Installation Requirements- Modrigo

 Motor starting- Naz
 Motor Reversing and Jogging- Nervar and Nogot
 Motor stopping- Ocay
 Motor speed- Palco
OBJECTIVE:
1. Understand the recommended procedure for a basic motor installation based on
NEC Article 430.
2. List and describe the methods by which a motor can be started.
3. Comprehend the operation of reversing and jogging motor control circuits.
4. List and describe the methods of stopping a motor.
5. Comprehend the operation of basic speed control circuits.

WHAT IS MOTOR CONTROL CIRCUIT?

A motor control circuit is the section of an electrical motor circuit that delivers high
voltage or current to an electric motor. A motor control circuit includes a disconnect
switch, a control transformer, protective devices (fuses or circuit breakers), a motor
starter, and a motor.

An electric motor can be DC, single-phase AC, or three-phase AC. Incoming power
lines must have a mechanism to switch off, lockout, and tagout the circuit power. They
must also include fuses or circuit breakers sized to protect the system. A motor can be
controlled by a magnetic motor starter or a motor drive.

WHAT ARE THE PARTS OF A MOTOR CONTROL CIRCUIT?

The control circuit consists of components of the ladder diagram, such as start and stop
pushbuttons, relay coils, pilot lights, and any other variety of contact closure devices,
like limit switches, pressure switches, temperature controllers, proximity sensors, or
float switches.
NEC Motor Installation Requirements

Basic elements of a motor branch circuit that the NEC addresses. Protecting against
overloads; Selecting a motor controller; Protecting against grounds and shorts; Sizing
branch circuit conductors Providing a control circuit; Control circuit protection; Providing
a disconnect; Motor

NEC Motor
Installation requirements
Understanding the rules detailed in the National Electrical Code (NEC) is critical to the
proper installation of motor control circuits. NEC
Article 430 covers the application and installation of motor circuits including conductors,
short-circuit and ground fault protection, starters, disconnects, and overload protection.
Ill. 1 illustrates the basic elements of a motor branch circuit that the NEC addresses. A
motor branch circuit includes the final overcurrent device (disconnect switch and fuses
or circuit breaker), the motor starter and associated control circuits, circuit conductors,
and the motor.

Sizing Motor Branch Circuit Conductors

Installation requirements for motor branch circuit conductors are outlined in NEC Article
430. Generally, motor branch circuit conductors that supply a single motor used in a
continuous-duty application must have an ampacity of not less than 125 percent of the
motor's full-load current (FLC) rating as determined by Article 430.6. This provision is
based on the need to provide for a sustained running current that's greater than the
rated full-load current and for protection of the conductors by the motor overload
protective device set above the full-load current rating.
The full-load current rating shown on the motor name plate isn’t permitted to be used to
determine the ampacity of the conductors, the ampacity of switches, or motor branch-
circuit short-circuit and ground fault protection.

The reasons for this are:

• The supply voltage normally varies from the voltage rating of the motor, and the
current varies with the voltage applied.
• The actual full-load current rating for motors of the same horsepower may vary and
requiring the use of NEC tables ensures that if a motor must be replaced, this can be
safely done without having to make changes to other component parts of the circuit.

Conductor ampacity must be determined by NEC Tables 430.247 through 430.250 and
is based on the motor nameplate horsepower rating and voltage. Overload protection,
however, is based on the marked motor nameplate rating. Use of the term full-load
current (FLC) rating indicates the table rating while use of the term full-load ampere
( FLA) rating indicates the actual nameplate rating. This makes it easier to clarify
whether the table ampacity or the nameplate ampacity is being used.
MOTOR STARTING
All motors must have a control device to start and stop the motor called a “ motor
controller”.

Motor Controller
A motor controller is an actual device that energizes and de-energizes the circuit to the
motor so that it can start and stop.

 Motor controllers may include some or all of the following motor control functions:
- Starting, stopping, over-current protection, overload protection, reversing,
speed changing, jogging, plugging, sequence control, and pilot light
indication.
- Controllers range from simple to complex and can provide control for one
motor, group of motors, or auxiliary equipment such as brakes, clutches,
solenoids, heaters, or other signals.
Motor Starter
The starting mechanism that energizes the circuit to an induction motor is called
“Starters” but only two types of starting methods for induction motors:
1. Across the Line Starting
2. Reduced Voltage Starting

Across the Line Starting of Motors

Across the Line starting connects the motor windings/terminals directly to the circuit
voltage “across the line” for a “full voltage starts”
  This is the simplest method of
starting a motor. (And usually the
least expensive).
 Motors connected across the line
are capable of drawing full in-rush
current and developing maximum
starting torque to accelerate the
load to speed in the shortest
possible time.
 All NEMA induction motors up to
200 horsepower, and many larger
ones, can withstand full voltage
starts. (The electric distribution
system or processing operation
may not though, even if the motor
will)

.
Across the Line starters
There are two different types of common “across the line” starts including
1. Manual Motor Starters
2. Magnetic Motor Starters

Manual Motor Starters

A manual motor starter is a package consisting of a horsepower rated switch with one
set of contacts for each phase and corresponding thermal overload devices to provide
motor overload protection.
 The main advantage of a manual motor starter is lower cost than a magnetic
motor starter with equivalent motor protection but less motor control capability.
 Manual motor starters are often used for smaller motors – typically fractional
horsepower motors but the National Electrical Code allows their use up to 10
horsepower
 Since the switch contacts remain closed if power is removed from the circuit
without operating the switch, the motor restarts when power is reapplied which
can be a safety concern.
 They do not allow the use of remote control or auxiliary control equipment like a
magnetic starter does.

Manual Starter:

Magnetic Motor Starters

A magnetic motor starter is a package consisting of a contactor capable of opening and
closing a set of contacts that energize and de-energize the circuit to the motor along
with additional motor overload protection equipment.
 Magnetic starters are used with larger motors (required above 10 horsepower) or
where greater motor control is desired
 The main element of the magnetic motor starter is the contactor, a set of contacts
operated by an electromagnetic coil.
- Energizing the coil causes the contacts (A) to close allowing large currents
to be initiated and interrupted by a smaller voltage control signal
 - The control voltage need not be the same as the motor supply voltage and
is often low voltage allowing start/stop controls to be located remotely from
the power circuit.

Magnetic Starter:

 Closing the start button contact energizes the contactor coil. An auxiliary
contact on the contactor is wired to seal in the coil circuit. The contactor
de-energizes if the control circuit is interrupted, the stop button is
operated, or if power is lost

 The overload contacts are arranged so an overload trip on any phase will
cause the contactor to open and de-energize all phase

Reduced Voltage Starting of Motors

Reduced voltage starting connects the motor windings/terminals at lower than normal
line voltage during the initial starting period to reduce the inrush current when the motor
starts.
 Reduced voltage starting may be required when:
- The current in-rush form the motor starting adversely affects the voltage
drop on the electrical system.
- Needed to reduce the mechanical “starting shock” on drive lines and
equipment when the motor starts
  Reducing the voltage reduces the current in rush to the motor and also reduces
the starting torque available when the motor starts.
 All NEMA induction motors can will accept reduced voltage starting however it
may not provide enough starting torque in some situations to drive certain
specific loads.

If the driven load or the power distribution system cannot accept a full voltage start,
some type of reduced voltage or “soft” starting scheme must be used.

 Typical reduced voltage starter types include:

1. Solid State (Electronic) Starters
2. Primary Resistance Starters
3. Autotransformer Starters
4. Part Winding Starters
5. Wye-Delta Starters

Reduced voltage starters can only be used where low starting torque is acceptable or a
means exists to remove the load from the motor or application before it is stopped.

Types of starter:
 Direct On Line Starter
 Star-Delta
 Auto-Transformer
 Slip Ring or Rotor Resistance Starter Motor
 Stator Resistance Starter.
DOL STARTER
A DOL starter also known as a Direct On-Line starter, is a method of starting a 3-phase
induction motor. In a DOL Starter, a three-phase Induction motor is connected directly
across its 3-phase supply, and the DOL starter applies the full line voltage to the motor
terminals.
Advantages:

 Most Economical and cheapest starter

 Simple to establish, operate and maintain
 Simple control circuitry
 Easy to understand and troubleshoot
 It provides 100% torque at the time of starting
 Only one set of cables is required from the starter motor
 Motor is connected in delta at motor terminals
Disadvantages:

 It does not reduce the starting current of the motor

 High starting current (5-8 times of full load current).
 DOL Starter causes a significant dip in voltage, hence suitable only for small motors.
 DOL Starter reduces the lifespan of the machine.
 Mechanically tough.
 Unnecessary high starting torque

STAR DELTA
A star delta starter is the most commonly used method for the starting of a 3 phase
induction motor. In star delta starting an induction motor is connected in through a star
connection throughout the starting period. Then once the motor reaches the required
speed, the motor is connected in through a delta connection.
Advantages:

 The operation of the star delta method is simple and rugged

 It is relatively cheap compared to other reduced voltage methods.
 Good torque/current performance
 It draws 2 times starting current of the full load ampere of the motor connected.
Disadvantages:
 During Load start transmission peak can occur.
 Starting Time is long compared to DOL starter.
 Soft stop is not possible.
  More components compared to DOL starter.
 Wiring is complex compared to DOL starter.
 Starting torque is reduced but cannot be adjusted.
 Cost is expensive.

AUTO-TRANSFORMER
An Autotransformer starter is used to decrease the applied voltage to a motor
throughout its beginning. When the big motors are used for a long time in the circuit,
then a voltage drop may occur, so they can lead to damage to the electrical equipment
which runs on a similar supply line.

Advantages of autotransformer starter:

 The autotransformer's most powerful ratio is between 65 and 80 percent.
 The torque per ampere of supply current is maximum.
 The current in the motor is greater than the current in the supply.
 It is less expensive.
 This approach works well for long start-up times.
 Starting voltage can be adjusted by selecting the appropriate tap on the autotransformer.
 The circuit benefits over starting with a regular autotransformer, which needs to be at some point
completely disconnected during the start inducing high voltage impulses, which can damage the
electrical insulation of the stator.
 The inrush current is greatly reduced by the autotransformer starter.
 It is used for large motors that cannot be started by connecting directly to the network. The star
delta stater cannot be used for large motors, particularly if they are started with a significant load.
 improved regulation
 The inrush current is greatly reduced by the autotransformer starter.

Disadvantages of autotransformer starter:

 The circuit is complex and involves a relatively expensive autotransformer
 Due to the size of the autotransformer starter, a much larger control, the panel is required which
increases the price.
 If space is limited, it might not be possible to connect the korndorfer starter to an existing machine
due to its physical size.
 One of its major drawbacks is the frequency constraint of its operation. It is always necessary to
know the operation frequency in order to select an autotransformer that is appropriately rated.
Slip Ring or Rotor Resistance Starter Motor
This kind of motor starter operates on a full voltage motor technique. It operates only on
a slip ring induction motor, so it is known as a slip ring starter motor. External
resistances are joined to the rotor with star combination through the slip ring.

Advantages:
 High starting torque may be obtained with the rotor resistance starter.
 It improves the power factor of the motor.
 Absence of line current harmonics.
 Reduced starting current.
 Smooth and wide range of speed control is possible

Disadvantages:
 Lower efficiency due to the I2R losses in the external resistance connected in the
rotor circuit.
 This starter can only be used for starting a slip ring induction motor.
 It needs frequent maintenance due to presence of slip rings and carbon brushes

Stator Resistance Starter.

Stator resistance starter employs the reduced voltage starter technique to start motors.
External resistance is attached in series with all phases of a 3 phase induction motor's
stator. The resistor's function is to lessen the line voltage (subsequently decreasing the
initial current) connected to the stator.
Advantages:
 High power factor during- start.
 Smooth acceleration.
 Less expensive than auto-transformer starter in lower output ratings.
 Closed transition starting.
Disadvantages:
 Heat is given off by the resistors.
 Expensive resistors are required because starting duration usually exceeds 5
seconds.
 Low torque efficiency
MOTOR REVERSING AND JOGGING

Reversing Motor Control Circuit

A reverse sequence control circuit is a motor controller circuit that can safely control the
motor rotation both in the forward and reverse direction. A standard three-wire circuit is
used with a normally open pushbutton and a holding contact branch to design a reverse
sequence control circuit for controlling the second relay coil. Both electrical and
mechanical interlocking is provided for the coils. Two pushbuttons are connected
parallel to the circuit, namely forward and reverse pushbuttons.

Forward/Reverse Control Circuits

If a three-phase motor is to be driven in only one direction, and upon its initial
energization it is found to be rotating opposite to what is desired, all that is needed is to
interchange any two of the three line leads feeding the motor. This can be done at the
motor starter or at the motor itself

Three-phase motor rotation

Once two of the lines have been switched, the direction of the magnetic fields created in
the motor will now cause the shaft to spin in the opposite direction. This is known as
reversing the phase rotation

Reversing Magnetic Starters

If a motor is to be driven in two directions, then it will require a Forward / Reverse motor
starter, which has two three-pole horsepower-rated contactors rather than just one as in
the conventional starter. Each of the two different motor starters powers the motor with
a different phase rotation.

When the forward contactor is energized, power contacts connect line L1 to T1, line L2
to T2 and line L3 to T3 at the motor. When the reverse contactor is energized, the
power contacts connect line L1 to T3, line L2 to T2 and line L3 to T1 at the motor.

Forward/Reverse power circuit

Since the two motor starters control only one motor, only one set of overload relay heaters need be
used. The return paths for both starter coils connect in series with the normally closed contacts of the
overload relay so that if an overload occurs in either direction, the starter coils will be de-energized and
the motor will come to a stop.

Note that the two contactors must be electrically and mechanically interlocked so that they cannot be
energized simultaneously. If both starter coils became energized simultaneously, a short circuit will
occur with potentially hazardous results.
Forward / reverse starters will come with two sets of normally open auxiliary contacts to act as holding
contacts in each direction. They will also come with two sets of normally closed auxiliary contacts to act
as electrical interlocks.

Electrical interlock
The electrical interlocks prevent one coil from getting
energized if the other is active. It is achieved by making a
series connection of the relay that provides forward direction
with the reverse direction relay and vice versa. When the
forward relay is active, pushing a reverse push button will
ensure no power goes to the reverse relay.

Mechanical interlock
It is generally used as the last step for protection when the electrical interlock fails to
perform as desired. The mechanical interlock system has an additional coil. If somehow,
both the coils get energized, the adjacent coil of one of the relays is made active. Such
coil prevents the armature of the relay to make contact with the real output port. It
simply acts as a physical barrier.

Reversing Control Circuit

When designing the control schematic for forward / reverse circuits, we start with the
standard three-wire circuit, add a second normally open pushbutton, and add a holding
contact branch for the second coil. A single stop button is sufficient to disable the motor
in both directions.

The two coils are mechanically interlocked and the normally closed instantaneous
contacts provide electrical interlocking.

If the forward pushbutton is pressed, as long as the reverse coil is not engaged, current
will find a path through the normally closed reverse contact and energize the forward
coil, causing all contacts associated with that coil to change their state. The 2-3 holding
contact will close and the normally closed electrical interlock will open. If the reverse
pushbutton is pressed while the forward coil is engaged, current will not be able to get
past the forward normally closed contact, and nothing will happen.

In order to send the motor in the reverse direction, the forward coil must be de-
energized. To do this, the stop button must be pressed, then the reverse pushbutton will
be able to energize the reverse coil.

Regardless of the direction the motor is spinning in, this circuit will operate as a
standard three-wire circuit providing low-voltage protection (LVP) until either the stop
button is pressed, or an overload occurs.
Pushbutton Interlocks

Pushbutton interlocking requires the use of four-contact momentary push buttons with
each pushbutton having a set of normally open and normally closed contacts.

To achieve pushbutton interlocking, simply wire the normally closed contacts of one
pushbutton in series with the normally open contacts of the other pushbutton, and the
holding contacts will be connected in parallel with the appropriate button’s normally
open contacts.

This circuit still requires the installation of electrical interlocks.

Pushbutton interlocking doesn’t require the motor coils to be disengaged before

reversing direction because the normally closed forward contacts are in series with the
normally open reverse contacts, and vice-versa. Pushing one button simultaneously
disengages one coil while starting the other. This sudden reversal (plugging) can be
hard on the motor, but if quick reversal of the motor is required, this circuit can be a
solution.

Motor Jogging
What is motor jogging?
Jogging refers to repeated starting and stopping of a motor in short bursts to perform a
particular movement such as moving a crane to a particular location. The motor is
operated on full power.

Inching is similar to Jogging and the two are often confused with each other. Inching
involves short thrusts of motion at reduced power. The motor is made to run at a
reduced voltage

Jogging and Inching

The definition of jogging or inching as described by
NEMA is “the quickly repeated closure of a circuit to
start a motor from rest for the purpose of
accomplishing small movements of the driven
machine.”

The term jogging actually means to start a motor with

short jabs of power at full voltage. The term inching
means to start a motor with short jabs of power at
reduced voltage.

Although the two terms mean different things, they are

often used interchangeably because both are
accomplished by preventing the holding contacts from
sealing the circuit.

Jogging Operation
Jogging should not be done more than 5 times in a minute. This is because jogging can
cause the motor to overheat.

If Jogging is to be done frequently, the starter of the motor should be derated.

Application or Purpose of jogging a motor

The purpose of jogging a motor is to align some other part of a machine or to slowing
advance a machine through its sequence of operation. This is usually done during a
repair or maintenance operation.

An example of jogging or bumping a machine might be when greasing linkages the

machine is bumped over so as to position the linkages for access so they can be
greased.

MOTOR STOPPING
The most common method of stopping a motor is to remove the supply voltage and
allow the motor and load to come to a stop. In some applications however, the motor
must be stopped more quickly or held in position by some sort of braking device.

Plugging and Antipluggin

Plugging stops a polyphase motor quickly, by momentarily
connecting the motor for reverse rotation while the motor is still
running in the forward direction. This acts as a retarding force for
rapid stop and quick reversal of motor rotation. Plugging produces
more heat than most normal-duty applications. NEMA
specifications call for starters used for such applications to be
derated. That is, the next size larger reversing starter must be
selected when it’s used for plugging to stop or reverse at a rate of
more than five times per minute.

 Pressing the start button closes and seals in the forward contactor. As a result,
the motor rotates in the forward direction.
  The normally closed auxiliary contact F opens the circuit to the reverse contactor
coil.
 The forward contact on the speed switch closes.
 Pressing the stop button de-energizes the forward contactor.
 The reverse contactor is energized, and the motor is plugged.
 The motor speed decreases to the setting of the speed switch, at which point its
forward contact opens and deenergizes the reverse contactor.
 This contactor is used only to stop the motor by using the plugging operation; it’s
not used to run the motor in reverse.

The Antiplugging circuit may be used to prevent reversing the motor before the motor
has slowed to near zero speed. In this application the motor can be reversed but not
plugged.

 Pressing the forward button completes the circuit for the F coil, closing the F
power contacts and causing the motor to run in the forward rotation.
 The F zero-speed switch contact opens because of the forward rotation of the
motor.
 Pressing the stop button de-energizes the F coil, which opens the F power
contacts, causing the motor to slow down.
 Pressing the reverse button won’t complete a circuit for the R coil until the F
zero-speed switch contact recloses.
 As a result, when the rotating equipment reaches near zero speed, the reverse
circuit may be energized, and the motor will run in reverse rotation.
Dynamic Braking
Dynamic braking is achieved by reconnecting a running motor to act as a generator
immediately after it’s turned off, rapidly stopping the motor. The generator action
converts the mechanical energy of rotation to electrical energy that can be dissipated as
heat in a resistor. Dynamic braking of a DC motor may be needed because DC motors
are often used for lifting and moving heavy loads that may be difficult to stop.

This circuit shows how dynamic braking is applied to a DC motor.

 Assume the motor is operating and the stop button is pressed.
 Starter coil M de-energizes to open the normally open M power contact to the
motor armature.
 At the same time, the normally closed M power contact closes to complete a
braking circuit around the armature through the braking resistor, which acts like a
load.
 The shunt field winding of the DC motor remains connected to the power supply.
 The armature generates a counter-emf voltage. This counter emf causes current
to flow through the resistor and armature. The smaller the ohmic value of the
braking resistor, the greater the rate at which energy is dissipated and the faster
the motor comes to rest.
DC Injection Braking
DC injection braking is a method of braking in which direct current is applied to the
stationary windings of an AC motor after the applied AC voltage is removed. The
injected DC voltage creates a magnetic field in the motor stator winding that doesn’t
change in polarity. In turn, this constant magnetic field in the stator creates a magnetic
field in the rotor. Because the magnetic field of the stator isn’t changing in polarity, it will
attempt to stop the rotor when the magnetic fields are aligned (N to S and S to N).
This circuit shows is one example of how DC injection braking can be applied to a three-
phase AC induction motor.
 The DC injection voltage is obtained from the full wave bridge rectifier circuit,
which changes the line voltage from AC to DC.
 Pressing the start button energizes starter coil M and off-delay timer coil TR.
 Normally open M1 auxiliary contact closes to maintain current to the starter coil
and normally closed M2 auxiliary contact opens to open the current path to
braking coil B.
 Normally open off-delay timer contact TR remains closed at all times while the
motor is operating.
 When the stop button is pressed, starter coil M and off-delay timer coil TR are
de-energized.
 Braking coil B becomes energized through the closed TR contact.
 All B contacts close to applying DC braking power to two phases of the motor
stator winding.
 Coil B is de-energized after the timer contact time out. The timing contact is
adjusted to remain closed until the motor comes to a complete stop.
 A transformer with tapped windings is used in this circuit to adjust the amount of
braking torque applied to the motor.
 The motor starter (M) and braking contactor (B) are mechanically and electrically
interlocked so that the AC and DC supplies are not connected to the motor at the
same time.
Electromechanical Friction Brakes

Unlike plugging or dynamic braking, electromechanical friction brakes can hold the
motor shaft stationary after the motor has stopped.

The picture shows an electromechanical drum and shoe-type friction brake used on DC
series motor drives. The brake is set with a spring and released by a solenoid. When
the motor is running, the solenoid is energized to overcome the tension of the spring,
thus keeping the brake shoes clear of the drum. When the motor is turned off, the
solenoid is deenergized and the brake shoes are applied to the drum through the spring
tension. The brake operating coil is connected in series with the motor armature and
release and sets in response to motor current. This type of braking is fail-safe in that the
brake is applied in case of an electrical failure

When the motor is turned off, the solenoid is deenergized and the brake shoes are
applied to the drum through the spring tension. The brake operating coil is connected in
series with the motor armature and release and sets in response to motor current. This
type of braking is fail-safe in that the brake is applied in case of an electrical failure