College

Wes t

BATAM
Mec hatronics

Job Sheets

Electrical
Technology
(AC Motor Control)

Updated on 1/7/2007
 AC motors & controls

Contents

1. AC Motor Starters

2. Familiarisation of motor control components

3. DOL starter

4. Remote control

5. Inching control

6. Sequential control

7. Auto sequential control

8. Forward & Reverse starter

9. Star-delta starter

Appendix A Relay and Timer Circuit Diagram

 AC motors & controls
Job 1 AC Motor Starters

Objective To study the needs, the classification and various types of a c

motor starters.

Equipment Various types of ac motor starter.

Two Main types of AC motor starter:

Requirements of a motor starter:

 AC motors & controls
Job 2 Familiarisation of component

Objective To study various types of motor control components

Equipment AC motor control components.

1. Essential components of a DOL starter

Job 2 Familiarisation of component

2. Magnetic Contactor

3. Main Contacts

4. Auxiliary contacts
Job 2 Familiarisation of component

5. Overload Unit

6. Pushbutton
 AC motors & controls
Job 3 Direct-On-Line Starter

Objective To construct a DOL starter

Equipment Contactor, overload unit, push-button, multi-meter, wire and

hand tools.

1. Circuit diagram

L1
3-
L2 Motor

L3

Stop Start O/L

C

2. Instructions;

1. Arrange the component properly in the control box.

2. Wire ups the main circuit with the cable provided.

3. Wiring up the control circuit with the cable provided.

4. Check and test the starter with the multi-meter for correct
operation.

5. Troubleshoot and rectify the control circuit if necessary.

Job 3 Direct-On-Line Starter

3. Control Circuit

L1/1

Stop Start
A1 A2 96 95
Coil

13 14

4. Main Circuit

L1 1 2 T2

3 4 T2
L2

5 6 T3
L3

Main contacts Overload coil

Job 3 Direct-On-Line Starter

5. Wiring Diagram Power Supply

Start Stop

To motor
 AC motors & controls
Job 4 Remote Control

Objective To modify a DOL starter to provide additional remote control

Equipment A DOL starter, multi-meter, wire and hand tools.

L1
3-
L2 Motor

L3

Stop Start O/L

C

Instructions;

1. Apply the knowledge you have just acquired. Modify the given DOL
Starter control circuit, to provide additional remote stop and remote
start control.

2. Discuss among your group, plan and modify on the control circuit given;
you need to submit at least two (2) modified control circuits.

Remember that the best circuit is the circuit where the least wire is
needed

3. Practice your designed circuit by wire up the modified control circuit

with the component provided.

4. Check and test the modified starter for correct operation.

5. Troubleshoot and rectify the control circuit if necessary.

Job 4 Remote Control

Control Circuit:
 AC motors & controls
Job 5 Inching Control

Objective To modify a DOL starter to provide additional inching control

Equipment A DOL starter, multi-meter, push-button, wire and hand tools.

L1
3-
L2 Motor

L3

Stop Start O/L

C

Instructions;

1. Apply the knowledge you have just acquired. Modify the given DOL
Starter to provide additional inching control.

2. Discuss among your group, plan and modify on the control circuit given;
you need to submit at least two (2) modified control circuits.

3. Practice your designed circuit by wiring up the modified control circuit

With the component provided.

4. Check and test the modified starter for correct operation.

5. Troubleshoot and rectify the control circuit if necessary.

Job 5 Inching Control

Control Circuit:
 AC motors & controls
Job 6 Sequential Control

Objective: To build a sequential control circuit for 3 motors.

Equipment: Contactors, overload units, Push-buttons, multi-meter, wire and

hand tools.

1. Specifications: (i) Three motors need to be started in manual

sequence, motor A has to be started first and
then followed by motor B and motor C.
(ii) One stop button is used to stop the whole
system.
(iii) Overload of any motor shall trip the whole
System.

2. Instructions:

1. Apply the knowledge you have just acquired. Referring to the example
given, discuss among your group. Design and draw at least two (2)
other control circuits, which fulfill the specifications.

2. Practice your designed circuit by wiring up the control circuit

with the components provided.

3. Check and test the modified starter for correct operation.

4. Troubleshoot and rectify the control circuit if necessary.

Job 6 Sequential Control

3. Main Circuit:

L1
L2 Motor
A
L3

Motor
B

Motor
C

4. Control Circuit:
 AC motors & controls
Job 7 Auto-Sequential Control

Objective: To build an Auto-sequential motor control circuit for 3 motors.

Equipment: Contactors, overload units, Push buttons, timer, multi-meter,

wire and hand tools.

1. Specifications: (i) Three motors need to be started in auto-

sequence, motor A has to be started first and
then followed by motor B and motor C.
(ii) One stop button is used to stop the whole
system.
(iii) Overload of any motor shall trip the whole
System.

2. Main Circuit:

L1
L2 Motor
A
L3

Motor
B

Motor
C
Job 7 Auto-Sequential Control

3. Control Circuit:

Stop O/L O/L O/L

A Start A
A B C
A
A
A B
TR1
TR1
B
B
B C
TR2
TR2
C
C

4. Instructions:

1. Wire ups the control circuit with the components provided.

2. Check and test the control circuit for correct operation.

3. Troubleshoot and rectify the control circuit if necessary.

 AC motors & controls
Job 8 Forward and Reverse Starter

Objective: To build a Forward and Reverse Starter.

Equipment: Contactors, overload units, Push-buttons, multi-meter, wire and

hand tools.
1. Main Circuit
For
L1

L2
3-
Motor
L3

Rev

2. Instructions:

1. Take a close look at the main circuit. Referring to the examples

given, discuss among your group. Write down the other operational
conditions. These operational conditions are the specifications for the
control circuit of the starter.

2. Apply the knowledge you have acquired, develop the control circuit
step-by-step to fulfill the specifications that you have listed.

3. Practice your designed circuit by wiring up the starter circuit

with the components provided.

4. Check and test the starter for correct operation.

5. Troubleshoot and rectify the control circuit if necessary.

Job 8 Forward and Reverse Starter

3.Control Circuit:
 AC motors & controls
Job: 9 Star-Delta Starter

Objective: To Construct a Star-Delta Starter.

Equipment: Contactors, overload units, Push buttons, Timer, Multi-meter,

Wire and hand tools.

1. Main Circuit

L 1 L2 L3

1 3 5 1 3 5 1 3 5

2 4 6 2 4 6 2 4 6

A1 A2
B1 B2
C1 C2
Job: 9 Star-Delta Starter

2. Instructions:

1. Take a close look at the main circuit. Referring to the examples

given, discuss among your group. Write down the other operational
conditions. These operational conditions are the specifications for the
control circuit of the starter.

2. Apply the knowledge you have acquired, develop the control circuit
systematically to fulfill the specifications that you have listed.

3. Practice your designed circuit by wiring up the starter circuit

with the components provided.

4. Check and test the starter for correct operation.

5. Troubleshoot and rectify the control circuit if necessary.

3. Control Circuit
 AC motors & controls

Timer & Relay

Timer circuit Relay circuit

6
5 7
4 5
3 6 4
8
2
1 8 10 3
9

2 10

1 11

AC
Power
230 V

Timer & Relay Base (8-Pin) Relay Base ( 11-Pin)

6 5 4 3 7 6 5
8 4

9 3
7 8 1 2 10 11 1 2