ESW2 Module 4
ESW2 Module 4
ESW2 Module 4
ELECTRICAL WORKSHOP 2
LECTURE NOTES
ON
BASIC MOTOR CONTROL
ELECTRICAL WORKSHOP 2
Disclaimer
This document does not claim any originality and cannot be used as a substitute for prescribed
textbooks. The information presented here is merely a collection by the faculty assigned for their respective
teaching loads assignments. Various sources are cited and mentioned at the end of document as well as freely
available open access material from internet were utilized for preparing this document. The ownership of the
information lies with the respective authors or institutions. Further, this document is not indented to be used
for commercial purpose and the faculty are not accountable for any issues, legal or otherwise, arising out of
use of this document. The faculty make no representations or warranties with respect to the accuracy or
completeness of the contents of this document and specifically disclaim any implied warranties of
merchantability or fitness for a particular purpose. The faculty member shall not be liable for any loss of profit
or any other commercial damages, including but not limited to special, incidental, consequential, or other
damages.
Acknowledgement
The Faculty member gratefully acknowledge all references utilized for preparing this lecture note also
wants to express gratitude to the person out there who think knowledge should be free and be accessible and
sharable without any restrictions so that every single students on this university has the same opportunity to
explore, expand and become enlightened.
However apart from this lecture notes students are strongly recommended to follow the listed
references at the end of each modules and above all confer and consult with the concern faculty for through
understanding of the given subject in electrical engineering.
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Activities / Instructions
- Accomplish the student’s profile survey form. Link will be posted to your chat box.
- I will discuss the course syllabus, course requirements, student’s handbook, house rules, and basic use of
MS Teams for your familiarization.
- Course Duration: We have 6 hours session per week. For one to two hours per meeting, we will be having
a live online video discussion for the scheduled topic and the remaining hours will be a self-pace study of
additional materials, sources and exercises posted on your MS Teams.
- House Rules: Mute your microphone and off your video so as lagging of presentation can be minimize due
to bandwidth constrain and to avoid unnecessary distraction if the lecture is ongoing especially if your
surrounding area had a lot of unusual sound. Just unmute and open your video when you called to recite,
you can use the virtual raising hand if you want to answer. For any questions or clarifications, you can use
the chat box for any concerns.
- For Offline students: Study in advance or with-in given time schedule for the subjects and a lot data
allowance for your quizzes and exams for an hour or two. All of you will be given a softcopy via your TUP
e-mail add or hard copy via EE Department distribution of Lectures Notes.
- We will be having a live video online lecture discussion for each activity simulation and documentation format.
- For interactive discussion, participate on the Q&A portion during end or pausing of lecture or while in the process of
simulation
- Jot down important lesson notes for you will be able to accomplish correctly and test all simulation activities given.
- Actual presentation of simulation output will be done per activity on the first and second meeting each week.
- Complete documented activity shall be accomplished and submitted on the next meeting after it was performed. Or as
instructed on given date of submission.
- Recorded online video discussion, additional resources and materials will be given to you as well for your self-pace
study. Please study these lessons.
- For those who are offline, study and accomplished each activity on your Module 4 hard copy or soft copy.
- Lesson Proper
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Introduction
Upon selecting the proper motor, understanding the many various control devices available and their
uses, limitations and connections, becomes an essential part related to reliable operation and protection of
the motor and the personnel using it.
Every electric motor must have some sort of controller. The motor controller will have different
features and complexity depending on the task that the motor will be performing. A motor controller is a
device or group of devices that serves to govern in some predetermined manner the performance of an
electric motor. A motor controller might include a manual or automatic means for starting and stopping the
motor, selecting forward or reverse rotation, selecting and regulating the speed, regulating or limiting the
torque, and protecting against overloads and faults.
This module will serve as a manual on all activities to be undertaken, it introduces the students to the
basics of motor control, explains its importance, applications and components and identifies various ways in
which motor control can be accomplished.
Objectives:
After ten weeks the students will be able to execute, test different conditions, application of actual
simulation design of;
a. Motor Power Circuit and Control Circuit.
b. Explain the difference between the various classifications and types of motor control wiring.
c. Draw motor control ladder diagrams.
d. Connect various motor control circuits.
e. Test and troubleshoot motor control components and circuits.
f. Apply safety precautions while connecting motor control circuits.
g. Other applications of control components.
Shop Activities:
1. Introduction to Motor Control
2. Motor Control System Symbols
3. Motor Control Circuit
4. Motor Control Components Familiarization and Testing
5. Across the Line Magnetic Motor Starter (Non- Reversing)
6. Two Station Motor Control with Emergency Stop (Non- Reversing)
7. Full Voltage Non-Reversing Motor Control with Jog
8. Forward – Reverse Motor Control (No Immediate Reversal)
9. Forward – Reverse Motor Control (Immediate Reversal)
10. Sequential Motor Control (Manual: Using Pushbutton)
11. Sequential Motor Control (Automatic Using Timer)
12. Reduced Voltage Starter Circuits
13. Reduced Voltage Starter (Wye-Delta Starter)
14. Application of Forward-Reverse Motor Control
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Activity No. 1
INTRODUCTION TO MOTOR CONTROL
I. Objectives:
At the end of the activity, students should be able to:
Motor control systems control the electrical energy used to run a motor. Many of the components
used to control that energy are in the motor controller, protected by a motor control enclosure. Inside the
enclosure, at the heart of every motor controller, is the motor starter. The starter has two parts: the contactor
and the overload relay. It is easier to understand the motor control system if you think of them as divided into
two kinds of circuits: the power circuit and the control circuit.
The power circuit contains all the components that carry the full voltage and current to operate the
motor. Besides the contactor, these commonly include disconnects, fuses, breakers and overload heaters.
The control circuit is usually operated at a lower voltage and contains all the components necessary
to switch power to the motor on and off under the proper conditions and at the proper time. These commonly
include devices like relays, usually inside the enclosure; field devices like start and stop buttons, limit switches
and pressure switches; and indicating devices like lights and alarms to help monitor the operation of the
system.
All the components of motor control systems are linked together in circuits which determine what
function can be accomplished: starting, stopping, reversing, jogging and so on.
The seal-in circuit is one of the most common. It's also called the maintaining circuit or holding contact
because it maintains or holds-in the power to a component - like a contactor or a relay - even after a
pushbutton or other momentary switch no longer supplies power. The circuit is maintained until power is
interrupted.
Pushing the start button energizes M, the coil of the contactor. A normally open set of contacts on the
contactor are wired in parallel with the start button. When the armature on the contactor closes, these seal-
in contacts close, and remain closed until the stop button is pushed. This de-energizes the M coil and returns
the seal-in contacts to their normally open condition until the coil is energized again.
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Motor starters may also be wired for two-wire control. This requires the use of a maintained-contact
switch to keep the coil of the contactor energized after the run button is released. However, if power is
restored following a shut-down, the motor starter will be re-energized automatically.
Three-wire control is often used because it provides protection for personnel from such unexpected
start-ups. The motor will not automatically re-start after it's stopped due to a no-voltage or low-voltage
condition.
III. Evaluation:
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6. How does the auxiliary contact connect to a normally open pushbutton in a seal – in circuit?
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10. What is the role of limit switches in a motor control circuit? Explain your answer.
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b. Functions of Motor Control (3)
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DOE_____________________________________________________________________________________
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CR ______________________________________________________________________________________
TR ______________________________________________________________________________________
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NOTO____________________________________________________________________________________
NOTC____________________________________________________________________________________
OL ______________________________________________________________________________________
IV. Conclusion:
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Activity No. 2
MOTOR CONTROL SYSTEM SYMBOLS
I. OBJECTIVES:
1. Develop skills in identifying the commonly used components or parts and be able to describe
and interpret correctly the standard symbols for each component used in motor control
systems.
2. Develop skills in circuit tracing using the schematic symbols or diagrams.
3. Become familiar with the different components commonly used in motor control systems.
4. Draw the different control symbols.
In every trade or profession, there is a certain language, which must be understood in order
to transfer information and ideas rapidly and efficiently. This language may include words and phrases
as well as symbols.
Industrial electrical symbols and line (ladder) diagrams provide the information necessary to
understand the operation of any electrical control system. Industrial electrical symbols identify
electrical devices within a circuit.
The operation of a circuit is determined by the location of electrical devices. The line diagram
indicates the location of electrical devices within a circuit. Circuit arrangement and modifications to
existing circuits is possible using line diagrams. To read and troubleshoot an electrical control system,
the engineer or electrician must have a working knowledge of line diagrams.
IV. PROCEDURE:
Draw the appropriate symbol for each electrical control component in the space provided.
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ANSI Symbol & Code IEC 617 Symbol & Code
CONTROL COMPONENT (American National Standard (International Electrotechnical
DESCRIPTION Institute) Commission)
Knife Switch
(Disconnecting Switch)
Proximity Switch
Flow Switch
Limit Switch
Temperature Actuated
Switch
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ANSI Symbol & Code IEC 617 Symbol & Code
CONTROL COMPONENT (American National Standard (International Electrotechnical
DESCRIPTION Institute) Commission)
Selector Switch
Two & Three Positions
Foot Switch
Toggle Switch
Contactor Coil
Timer Coil
Solenoid Coil
Indicating Light
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CONTROL COMPONENT ANSI Symbol & Code IEC 617 Symbol & Code
DESCRIPTION (American National Standard (International Electrotechnical
Institute) Commission)
Electromechanical
Counter
3 ø Circuit Breaker
Fuse
Terminals (reference)
Fused terminals
(reference)
Bell / Barrel
Buzzer
Horn
Battery
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CONTROL COMPONENT ANSI Symbol & Code IEC 617 Symbol & Code
DESCRIPTION (American National Standard (International Electrotechnical
Institute) Commission)
Control Transformer
Ground
Wiring
(Connected,
Not Connected,
Power, Control)
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VI. EVALUATION:
2. What are the main difference between ANSI and IEC 617 symbols and codes?
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Activity No. 3
MOTOR CONTROL CIRCUIT
I. Objectives:
At the end of the activity, students should be able to:
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o Wire numbers are sometimes added to aid in locating the proper connections in the control
system. The numbers on the diagram match real numbers affixed to the wires in the system.
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III. Evaluation:
1. This is a ladder diagram of the control circuit for a large ventilation fan started with a maintained –
contact selector switch. In this circuit, if the power of the fan is lost, it will automatically restart when
power is restored. Modify the circuit so that the new circuit will not permit fan to restart if power is
restored after an outage.
Answer
2. Modify the given circuit so that it can be started from three other locations by using pushbuttons.
Draw your diagram and label each part.
Answer
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3. Modify the circuit you have drawn in No. 2 by adding a temperature switch that will automatically turn
the fan ON when the temperature rises to 110 ° F. The circuit must allow each push button to ON the
fan independent of the temperature switch.
Answer
4. Lastly, modify the circuit in a way that the three pushbuttons cannot turn ON the fan until the
temperature reaches 110 ° F
Answer
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5. In Figure 1, what is the function of the control relay CR for the proper operation of the motor?
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6. What is the purpose of connecting a normally closed time relay contact (TDOE) in series with the alarm?
Why a normally open time relay contact (TDOE) in series with the motor contactor coil M?
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IV. Conclusion:
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Activity No. 4
MOTOR CONTROL COMPONENTS FAMILIARIZATION AND TESTING
I. OBJECTIVES:
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.
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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.
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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
23
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
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II. TOOLS and MATERIALS NEEDED:
Drawing Materials
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.
a. MAGNETIC CONTACTOR
Main Contacts
Terminal Markings / Condition / /
Resistance Reading
Auxiliary Contacts
N.O. Terminal Markings / Condition
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b. OVERLOAD RELAY
Overload Heaters
Overload Contacts
c. PUSHBUTTON
Green Pushbutton
Red Pushbutton
Emergency Pushbutton
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d. INDICATING LIGHT
Green Pilot Lamp
Start Testing
Trip Testing
Stop Testing
V. CONCLUSION:
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Activity No. 5
ACROSS THE LINE MAGNETIC MOTOR STARTER
(Non- Reversing)
I. OBJECTIVES:
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III. Bill of Materials
TOTAL
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V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
VI. PROCEDURE:
1. Present to the instructor for checking your simulated diagram on EKTS.
2. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
3. Connect the circuit base on shown diagram if perform in actual.
4. Place the test probes of the ohmmeter to Line 1 and Line 2 to test the continuity of the circuit.
Observe resistance reading.
5. Press the start button while the test probes are still at Line 1 and 2. Observe the reading.
6. Trip the overload relay. Observe the reading also.
7. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
8. De-energize the circuit upon completion. Remove the connectors then clear the area.
9. If able to perform in actual, take pictures all conditions mentioned on number 10.
10. For simulated data, print screen all the conditions mentioned and record in the table 2.
a. IDLE condition power ON both power and control circuit.
b. START push button pressed.
c. OVERLOAD TRIP condition.
d. OVERLOAD RESET condition.
e. RE-STARTED then pressed STOP push button.
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
29
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
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Main Contacts
Holding A. Contact
Green
Yellow/Orange
Push Buttons
START
STOP
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Table 2. SIMULATED RESULTS
POWER “ON”
START
STOP
RE-START
RESET
VIII. CONCLUSION:
(Discuss how an across the line motor starter function by referring to your ladder diagram)
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IX. EVALUATION:
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Activity No. 6
TWO STATION MOTOR CONTROL WITH EMERGENCY STOP
(Non- Reversing)
I. OBJECTIVES:
At the end of the activity, the students should be able to:
11. Describe the principle of operation of a two-station motor control.
12. Connect properly the components in a two-station motor control.
13. Observe safety measures while connecting the motor control circuit.
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TOTAL
V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
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VI. PROCEDURE:
1. Present to the instructor for checking your simulated diagram on EKTS.
2. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
3. Connect the circuit base on your design diagram if perform in actual.
4. Place the test probes of the ohmmeter to Line 1 and Line 2 to test the continuity of the circuit.
Observe resistance reading.
5. Press the start button for station 1 while the test probes are still at Line 1 and 2. Observe the
reading.
6. Do the same procedure for station 2 while the test probes are still at Line 1 and 2. Observe the
reading.
7. Each emergency stops per station conduct also resistance test for the whole circuit upon pressing
the mushroom head.
8. Trip the overload relay. Observe the reading also.
9. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
10. De-energize the circuit upon completion. Remove the connectors then clear the area.
11. If able to perform in actual, take pictures all conditions mentioned on number 12.
12. For simulated data, print screen all the conditions mentioned and record in the table 2.
a. IDLE condition power ON both power and control circuit.
b. START push button pressed for each station one at a time.
c. OVERLOAD TRIP condition.
d. OVERLOAD RESET condition.
e. RE-STARTED then pressed STOP push button for each station one at a time.
f. RE-STARTED then pressed EMERGENCY STOP push button for each station one at a time.
g. Unlocked EMERGENCY STOP push button.
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Main Contacts
Holding A. Contact
Green
Yellow/Orange
Push Buttons
STN. 1 START
STN. 1 STOP
STN. 1
EMERGENCY STOP
STN. 2 START
STN. 2 STOP
STN. 2
EMERGENCY STOP
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Table 2. SIMULATED RESULTS
POWER “ON”
START 1
STOP 1
RE-START 1
EMERGENCY STOP 1
START 2
STOP 2
RE-START 2
EMERGENCY STOP 2
RE-START 1 OR 2
RESET
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VIII. CONCLUSION:
(Discuss how two station motor control function by referring to your design diagram)
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IX. EVALUATION:
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4. Draw and simulate a circuit diagram of two start push button for synchronize operation with single
emergency stop and single stop push button. Discuss for what application such design of a circuit?
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Activity No. 7
FULL VOLTAGE NON-REVERSING MOTOR CONTROL WITH JOG & EMERGENCY STOP
I. OBJECTIVES:
At the end of the activity, the students should be able to:
a. Describe the principle of operation of motor control system with jog.
b. Connect properly the components in motor control system with jog.
c. Observe safety measures while connecting the motor control circuit.
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III. Bill of Materials
TOTAL
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V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
VI. PROCEDURE:
1. Present to the instructor for checking your simulated diagram on EKTS.
2. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
3. Connect the circuit base on design diagram if perform in actual.
4. Place the test probes of the ohmmeter to Line 1 and Line 2 to test the continuity of the circuit.
Observe resistance reading.
5. Press the JOG button while the test probes are still at line 1 and 2. Observe the reading.
6. Press the start button while the test probes are still at Line 1 and 2. Observe the reading.
7. Conduct also resistance test for the whole circuit upon pressing the mushroom head of emergency
stop push button.
8. Trip the overload relay. Observe the reading also.
9. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
10. De-energize the circuit upon completion. Remove the connectors then clear the area.
11. If able to perform in actual, take pictures all conditions mentioned on number 12.
12. For simulated data, print screen all the conditions mentioned and record in the table 2.
a. IDLE condition power ON both power and control circuit.
b. JOG button pressed then for a few rotations released.
c. START push button pressed.
d. OVERLOAD TRIP condition.
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
47
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
ELECTRICAL WORKSHOP 2
e. OVERLOAD RESET condition.
f. RE-STARTED then pressed EMERGENCY STOP.
g. Unlocked EMERGENCY STOP push button.
h. RE-STARTED then pressed STOP push button.
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Main Contacts
Holding A. Contact
Green
Yellow/Orange
Push Buttons
JOG
START
STOP
EMERGENCY STOP
ELECTRICAL WORKSHOP 2
POWER “ON”
JOG PRESSED
JOG RELEASED
START
STOP
RE-START
EMERGENCY STOP
RE-START
RESET
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VIII. CONCLUSION:
(Discuss how a Start-Stop-Jog Motor Starter function by referring to your design diagram)
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IX. EVALUATION:
1. What is the function of the double contact pushbutton in a Start-Stop-Jog motor control circuit?
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Activity No. 8
FORWARD – REVERSE MOTOR CONTROL WITH JOG & EMERGENCY STOP
(No Immediate Reversal)
I. OBJECTIVES:
At the end of the activity, the students should be able to:
1. Describe the principle of operation of a Forward – Reverse Motor Control with no immediate
reversal.
2. Connect properly the components in a Forward – Reverse Motor Control with no immediate
reversal.
3. Observe safety measures while connecting the motor control circuit.
ELECTRICAL WORKSHOP 2
ELECTRICAL WORKSHOP 2
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III. Bill of Materials
TOTAL
ELECTRICAL WORKSHOP 2
V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
VI. PROCEDURE:
1. Present to the instructor for checking your simulated diagram on EKTS.
2. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
3. Connect the circuit base on design diagram if perform in actual.
4. Place the test probes of the ohmmeter to Line 1 and Line 2 to test the continuity of the circuit.
Observe resistance reading.
5. Press the forward start button while the test probes are still at Line 1 and 2. Observe the reading.
6. Press the reverse start button while the test probes are still at Line 1 and 2. Observe the reading.
7. Press the forward JOG button while the test probes are still at line 1 and 2. Observe the reading.
8. Press the reverse JOG button while the test probes are still at line 1 and 2. Observe the reading.
9. Conduct also resistance test for the whole circuit upon pressing the mushroom head of emergency
stop push button.
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
59
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
ELECTRICAL WORKSHOP 2
10. Trip the overload relay. Observe the reading also.
11. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
12. De-energize the circuit upon completion. Remove the connectors then clear the area.
13. If able to perform in actual, take pictures all conditions mentioned on number 14.
14. For simulated data, print screen all the conditions mentioned and record in the table 2.
a. IDLE condition power ON both power and control circuit.
b. Forward START button pressed, then test interlocking by pressing Reverse START.
c. Pressed STOP push button.
d. Reverse START button pressed, then test interlocking by pressing Forward START.
e. Pressed STOP push button.
f. Forward JOG button pressed then for a few rotations released.
g. Reverse JOG button pressed then for a few rotations released
h. OVERLOAD TRIP condition upon re-starting either forward or reverse rotation
i. OVERLOAD RESET condition.
j. Pressed EMERGENCY STOP push button upon re-starting either forward or reverse
rotation.
k. Unlocked EMERGENCY STOP push button.
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VII. OBSERVATIONS AND SUMMARY OF DATA:
ELECTRICAL WORKSHOP 2
POWER “ON”
FORWARD START
STOP
REVERSE START
STOP
EMERGENCY STOP
RESET
ELECTRICAL WORKSHOP 2
VIII. CONCLUSION:
(Discuss how a Forward-Reverse with no immediate reversal function by referring to your design diagram)
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IX. EVALUATION:
1. Why is there a need to stop medium motors before reversing its direction in a control circuit?
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2. List some applications where-in forward reverse motor control are utilized.
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Activity No. 9
FORWARD – REVERSE MOTOR CONTROL WITH JOG & EMERGENCY STOP
(Immediate Reversal)
I. OBJECTIVES:
At the end of the activity, the students should be able to:
1. Describe the principle of operation of a Forward – Reverse Motor Control with immediate
reversal.
2. Connect properly the components in a Forward – Reverse Motor Control with immediate
reversal.
3. Observe safety measures while connecting the motor control circuit.
ELECTRICAL WORKSHOP 2
GGG
BBB
OO
Starting the motor and operating it in the forward direction is initiated by closing the forward
pushbutton. This action energizes the forward contactor (F), which in turn closes the main contacts to the
motor terminals, thus starting the motor in the forward direction. The same action that closes the normally
open contact of the pushbutton also opens its normally closed contact. This temporary open circuit prevents
an unwanted start in the reverse direction. As the forward contactor operates, it causes its auxiliary contacts
to operate also. The normally open auxiliary forward contact (Fa) closes to seal in the forward coil circuit, and
the normally closed auxiliary forward contact (Fb) opens to block the reverse contactor coil circuit. To reverse
the direction of the motor (without first pushing the stop pushbutton), simply push the reverse pushbutton.
The opening of the normally closed contact of the reverse pushbutton causes the coil circuit for the forward
contactor (F) to momentarily open. The circuit for the reverse contactor coil (R) circuit momentarily closes.
When the forward contactor opens, it operates its auxiliary contacts (Fa , Fb). Fa opens to keep the forward
(F) coil circuit open, while Fb closes to allow the reverse coil (R) circuit to energize.
ELECTRICAL WORKSHOP 2
When the reverse contactor picks up, it closes its main contacts to the motor terminals, which in this
case causes lines L1 and L3 to be interchanged, reversing the direction of the motor. Auxiliary contacts Ra and
Rb operate in unison with the reverse contactor. The normally open Ra contact closes to seal in the reverse
coil circuit, while the normally closed Rb contact opens to block the energizing of the forward coil circuit.
TOTAL
ELECTRICAL WORKSHOP 2
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V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
VI. PROCEDURE:
1. Present to the instructor for checking your simulated diagram on EKTS.
2. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
3. Connect the circuit base on design diagram if perform in actual.
4. Place the test probes of the ohmmeter to Line 1 and Line 2 to test the continuity of the circuit.
Observe resistance reading.
5. Press the forward start button while the test probes are still at Line 1 and 2. Observe the reading.
Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
72
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
ELECTRICAL WORKSHOP 2
6. Press the reverse start button while the test probes are still at Line 1 and 2. Observe the reading.
7. Press the forward JOG button while the test probes are still at line 1 and 2. Observe the reading.
8. Press the reverse JOG button while the test probes are still at line 1 and 2. Observe the reading.
9. Conduct also resistance test for the whole circuit upon pressing the mushroom head of emergency
stop push button.
10. Trip the overload relay. Observe the reading also.
11. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
12. De-energize the circuit upon completion. Remove the connectors then clear the area.
13. If able to perform in actual, take pictures all conditions mentioned on number 14.
14. For simulated data, print screen all the conditions mentioned and record in the table 2.
a. IDLE condition power ON both power and control circuit.
b. Forward START button pressed.
c. Reverse START button pressed.
d. Pressed STOP push button.
e. Forward JOG button pressed then for a few rotations released.
f. Reverse JOG button pressed then for a few rotations released
g. OVERLOAD TRIP condition upon re-starting either forward or reverse rotation
h. OVERLOAD RESET condition.
i. Pressed EMERGENCY STOP push button upon re-starting either forward or reverse
rotation.
j. Unlocked EMERGENCY STOP push button.
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POWER “ON”
FORWARD START
REVERSE START
STOP
EMERGENCY STOP
RESET
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VIII. CONCLUSION:
(Discuss how a Forward-Reverse with immediate reversal function by referring to your design diagram)
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IX. EVALUATION:
1. Why is “immediate reversal” motor circuit applicable only for controlling small motors?
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Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
81
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
ELECTRICAL WORKSHOP 2
Activity No. 10
SEQUENTIAL THREE 3ø MOTOR CONTROL
(Manual: Using Pushbutton)
I. OBJECTIVES:
At the end of the activity, the students should be able to:
1. Describe the principle of operation of a manual Sequential Motor Control using pushbutton.
2. Connect properly the components in a Sequential Motor Control using pushbutton.
3. Observe safety measures while connecting the motor control circuit.
ELECTRICAL WORKSHOP 2
III. Bill of Materials
TOTAL
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V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
ELECTRICAL WORKSHOP 2
VI. PROCEDURE:
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VII. OBSERVATIONS AND SUMMARY OF DATA:
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Table 2. SIMULATED RESULTS
POWER “ON”
MOTOR 1 START
MOTOR 2 START
MOTOR 3 START
STOP
EMERGENCY STOP
RESET
RESET
RESET
POWER OFF
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VIII. CONCLUSION:
(Discuss how does a manual sequential motor control function by referring to your design diagram)
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IX. EVALUATION:
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Name: Course, Yr. & Sec. Subject:
Group No. Time: Days: Rm: Date:
Professor/Instructor: Rating:
Activity No. 11
SEQUENTIAL THREE 3ø MOTOR CONTROL
(Automatic using Timer Relay)
I. Objectives:
At the end of the activity, students should be able to:
1. Discuss the operation of a sequential motor control circuit.
2. Draw accurately a manual and automatic sequential motor control circuit.
3. Appreciate the importance of gaining skills in drawing and interpreting a sequential motor
control.
Figure 1. Auxiliary contacts used for automatic sequence control. Contact (M1) energizes coil
(M2); contact (M2) energizes coil (M3)
ELECTRICAL WORKSHOP 2
In a circuit, it is an advantage to have a timing contact as well as instantaneous contact from the same
energized relay coil. The timing contact can be arranged to delay after energizing or de-energizing the coil.
TR
a b c d
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Figure 3 shows a typical schematic diagram of a timer where in number 2 and 7 represent coil terminal
and are connected to a source while terminal number 8 is common to terminal number 5 and 6, same as
terminal number 1 common to terminal number 3 and 4. Mode B setting are not time dependent they will
actuate once the timer coil is energize whether you utilize the normally close (4-1) terminal or normally open
(3-1) terminal , not like Mode A and left side of the relay in which both contacts of normally open and normally
closed are all time setting dependent. Contacts conditions will change after time setting elapsed at Mode A
terminals N.O. (3-1) and N.C. (4-1) also at left side of the circuit terminals N.C. (5-8) and N.O. (6-8).
ELECTRICAL WORKSHOP 2
TOTAL
ELECTRICAL WORKSHOP 2
V. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below
ELECTRICAL WORKSHOP 2
VI. PROCEDURE:
1. Draw the ladder diagram of two motors that will functions as follows: Pressing Start push button,
motor 1 will energize. After a preset time of ten seconds, motor 2 will function but de-energizing
motor 1 at the same time. Then after another 10 seconds motor 1 will run back and both motors
are running until pressing the Stop pushbutton turning off both motors. Draw all indicator lamps.
2. Present to the instructor for checking your simulated diagram on EKTS.
3. Draw the ladder diagram of three motors (M1, M2, M3) that will energize one after another using
timer relay with an interval of 10 seconds. Ten seconds after energizing motor three, all motor will
be de-energize and the sequence will be repeated until Stop button is pressed turning off the
whole circuit interrupting the sequence. Show the idle and fault conditions using pilot light
indicators.
4. Present to the instructor for checking your simulated diagram on EKTS.
5. Prepare tools, materials and devices needed for the activity. Check their condition using an
ohmmeter. Record continuity resistance reading on table 1 for actual activity execution.
6. Connect the circuit base on design diagram if perform in actual.
7. Energize the circuit only if you are totally sure of your connections are secured and correct since
no supervision of your Instructor for face to face checking, Safety First! Record your observation
in evaluation.
8. De-energize the circuit upon completion. Remove the connectors then clear the area.
9. If able to perform in actual, take pictures all conditions mentioned on number 10.
10. For simulated data, print screen all the conditions mentioned and record in the table 2.
a. IDLE condition power ON both power and control circuit.
b. START button pressed.
c. STOP button pressed.
d. OVERLOAD TRIP condition one by one for each motor.
e. OVERLOAD RESET condition one by one for each motor.
f. Pressed EMERGENCY STOP push button upon re-starting to initial sequence.
g. Unlocked EMERGENCY STOP push button.
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VII. OBSERVATIONS AND SUMMARY OF DATA:
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Table 2. SIMULATED RESULTS
POWER “ON”
MOTOR 1 START
STOP
EMERGENCY STOP
RESET
RESET
RESET
POWER OFF
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VIII. CONCLUSION:
(Discuss how does a automatic sequential motor control function by referring to your design diagram)
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XI. Evaluation:
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Activity No. 12
REDUCED VOLTAGE STARTER CIRCUITS
I. Objectives:
At the end of the laboratory activity, students should be able to:
1. Discuss the operation of some types of reduce voltage starters motor starters.
2. State the importance of reduced voltage /current starters.
3. Draw accurately some examples of reduce voltage starters motor starter circuits.
4. Appreciate the importance of gaining skills in drawing and interpreting a reduce voltage
starters.
ELECTRICAL WORKSHOP 2
Figure 1 illustrate an automatic, primary-resistor-type reduced voltage starter with two steps of
acceleration. The circuit consists of resistors connected in series with a three-phase squirrel cage induction
motor. A control transformer is used to reduce the line voltage, supplying the motor to 120 volts to operate
the control circuit. When the start button is pressed, a circuit is completed to the coil of M starter, causing all
M contacts to close. The three M load contacts connect the motor to the line through the series resistors. The
three resistors limit the amount of current supplied to the motor. Current flowing through the resistors
produces a voltage drop across them. The resistor voltage drop causes a voltage drop across the motor
terminals also. The motor starts with reduced voltage applied to it. As the motor accelerates, the current flow
to the motor decreases, causing less voltage drop across the resistors and more voltage to be applied to the
motor. When M coil is energized, the two M auxiliary contacts also close. One is used as a holding contact,
and the other energizes the coil of on delay timer TR. At the end of the timing period, TR contacts close and
energize the coil of S contactor. When S coil energizes, the S load contacts connected in parallel with the
resistors close and short circuit the resistors. The motor is now connected directly to the power line. When
the stop button is pressed, M starter coil de-energizes, causing all M contacts to return to their open position.
The three M load contacts open and disconnect the motor from the power line. The M auxiliary contact
connected in series with TR coil opens and causes on-delay timer TR to de-energize. This causes TR contact to
open and de-energize S coil. When the three S load contacts reopen, the circuit is back in its original de-
energized state. For maximum operating efficiency, push buttons and other pilot devices are usually located
on the driven machine or in easy reach of the operator. The starter is located near the motor to keep the
power circuit wiring as short as possible. Only three small connecting wires are necessary between the starter
ELECTRICAL WORKSHOP 2
and the pilot devices. A motor can be operated from any of several remote locations if a number of push
buttons or pilot switches are used with one magnetic starter, such as on a conveyor system. AC primary
resistor starters are available for use on single-phase and three-phase reversing operations. They are also
available with multi points of acceleration.
ELECTRICAL WORKSHOP 2
Shown on Figure 2, when the start-button is pressed a circuit is completed to the coil of control relay
CR, causing all CR contacts to close with reversing starters. When the S load contacts close the motor is
connected to the power line through the autotransformers. The autotransformers supply 65% of the line
voltage to the motor. This reduced voltage produces less in-rush current during starting and reduces the
starting torque of the motor. When the time sequence for TR timer is completed, both TR contacts change
position. The normally closed TR contact opens and disconnects contactor S from the line causing all S contacts
to return to their normal position. The normally open TR contact closes and supplies power through the now
closed S contact to coil R. When contactor R energizes, all R contacts change position. The normally closed R
contact connected in series with S coil opens to provide interlocking for the circuit. The R load contacts closed
and connect the motor to full voltage.
ELECTRICAL WORKSHOP 2
In a two-step part winding starter, Figure 3, pressing the start button energizes the start contactor (S).
As a result, half of the motor windings are connected to the line and a timing relay (TR) is energized. After a
time delay of approximately 5 seconds, the timer contacts (TR) close to energize the “run” contactor. This
contactor connects the second half of the motor windings to the line in parallel with the first half of the
windings. Note that the control circuit is maintained with an instantaneous normally open contact (TR)
operated by the timing relay (TR) and the starting contact (S). Pressing the stop button or tripping any overload
relay disconnects both windings from the line. When starting on one winding, the motor draws approximately
two-thirds of the normal locked rotor current and develops approximately one-half of the normal locked rotor
torque.
III. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below, draw the ladder diagram of the following using
magnetic contactors and time delay relay. Indicate pilot light indicators to show Idle, Run and Fault
conditions.
1. PRIMARY RESISTANCE
2. AUTOTRANSFORMER
3. PART WINDING MOTOR STARTERS
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IV. Conclusion:
(Explain how a reduced voltage starter function. Select a circuit to be discussed in full details)
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V. Evaluation:
List all the advantages of reduced voltage starters, what its main purpose? and why it is required
especially on large or high rated motor?
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Activity No. 13
STAR - DELTA REDUCED VOLTAGE STARTER
I. Objectives:
At the end of the laboratory activity, students should be able to:
1. Discuss the operation of a Star-Delta Starter motor control circuit.
2. Draw accurately a Wye-Delta Starter motor control circuit.
3. Appreciate the importance of gaining skills in drawing and interpreting a Star-Delta Starter.
ELECTRICAL WORKSHOP 2
configuration. This start-run scheme is called open transition because there is a moment in which the motor
circuit is open between the opening of the power contacts (S) and the closing of the contacts (2M).
One advantage of this starting method is that it does not require accessory voltage reducing
equipment. A star-delta starter has the disadvantage of open circuit transition, but it does give a larger
starting torque per ampere of line current than a part winding starter.
Figure 1. Controller connects motor in wye on start and in delta for run. Note that the overload relays are
connected in the motor winding circuit, not in the line. Note also that the line current is higher than the
phase winding current in the diagram for the delta connection (B). Winding current is the same as the line
in diagram (A).
ELECTRICAL WORKSHOP 2
III. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below, draw the ladder diagram of STAR - DELTA motor starter
using magnetic contactors and time delay relay. Indicate pilot light indicators to indicate IDLE, START,
RUN, TRIP conditions.
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IV. Conclusion:
(Explain how a STAR-DELTA reduced voltage starter function, discussed in full details your design circuit)
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V. Evaluation:
List all the advantages of STAR-DELTA reduced voltage starters in comparison to other types.
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Prepared by: Engr. Edwin C. Espinas, for TUP COE-EE Department
122
Republic of the Philippines
Technological University of the Philippines
Ayala Blvd. cor. San Marcelino St. Ermita, Manila
• MODULE 4
ELECTRICAL WORKSHOP 2
Name: Course, Yr. & Sec. Subject:
Group No. Time: Days: Rm: Date:
Professor/Instructor: Rating:
Activity No. 14
APPLICATION OF FORWARD-REVERSE MOTOR CONTROL
I. Objectives:
At the end of the activity, students should be able to
1. Discuss circuits involving the application of Forward-Reverse Motor Control.
2. Draw accurately Forward-Reverse motor control circuit
3. Appreciate the importance of gaining skills in using Forward-Reverse Circuit in actual
situations.
ELECTRICAL WORKSHOP 2
III. Draw your complete Control and Power Circuit Diagram Via EKTS or Technical Drawing
Note: EKTS diagram can be print screen below. Show the IDLE, FORWARD, REVERSE, STOP/EMEGENCY
STOP, JOG FWD. & REV., TRIP conditions for both applications.
1. Draw the ladder diagram of a motor control circuit that limits the Forward and Reverse motion of an
overhead crane driven by a motor using two single pole limit switches X and Y. Limit switches
automatically stops the motor once the crane reaches the other end. Pressing the Reverse pushbutton
allows the motor to run in counter direction, moving the crane to the opposite side.
2. Draw the ladder diagram of a motor control circuit that limits the Forward and Reverse motion of an
elevator driven by a motor using two limit switches X and Y both with NC and NO contacts. The circuit
should allow automatic reversal of the elevator once the lift reaches the topmost part and vice versa.
IV. Conclusion: (Explain the function of the limit switch in a Forward-Reverse Motor Circuit)
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Assessment Procedures
- Online presentation per activity, will be rated with the following criteria:
- Documented activities must be submitted on your MS Team notebook or files on or before given
deadline per activity.
- For Offline submit accomplish activity soft copy thru my TUP e-mail add [email protected]
or thru messenger on or before given deadline per activity. Portfolio type hardcopy is required via LBC
or other courier services if totally no net availability but subject for approval.
Learning Resources
References:
Carroll, L. (2013). Motor Control Phase 2 Module No. 2.4 Trade of Electrician Standards Based Apprenticeship
COURSE NOTES (pp. 1-42). 27-33 Upper Baggot Street Dublin 4 Ireland: SOLAS.
Csanyi, E. (2016, November 7). 6 Lockout Operations Every Electrician MUST Perform And Respect. Retrieved
from electrical-engineering-portal.com
Electrical 4 U. (2019, June 2). Fleming's Left and Right Hand Thumb Rules Explained. Retrieved from E4U:
https://www.electrical4u.com
Electrical 4 U. (2019, July 11). Single-Phase Induction Motors. Retrieved from E4U:
https://www.electrical4u.com
Formisano, B. (2020, January 2). Multi-meter or Volt-ohmmeter. Retrieved from The Spruce:
https://www.thespruce.com
Herman, S. L. (2010). Electric Motor Control, 9th ed. 5 Maxwell Drive Clifton Park, NY 12065-2919 USA: Delmar,
Cengage Learning.
ELECTRICAL WORKSHOP 2
Herman, S. L. (2017). Understanding Motor Control, 3rd ed. 20 Channel St., Boston, MA 02210: Cengage
Learning.
Hydro One Network Inc.,. (2013). Electrical Safety Handbook for Emergency Responders. Ontario, Canada:
Hydro One Networks Inc.
Ibraheem Alnaib, A. M. (2019, May). Single-Phase Induction Motors. Retrieved from ResearchGate:
https://www.researchgate.net/publication/332835297
IIEE. (2017). Philippine Electrical Code Part 1. Cubao, Quezon City: Institute of Integrated Electrical Engineers
of the Philippines, Inc.
Kuphaldt, T. R. (2007, July 25). Lessons In Electric Circuits, Volume II – AC, 6th ed. Retrieved from
https://www.ibiblio.org/kuphaldt/electricCircuits/AC/AC.pdf
RV TechMag Electrical Tutorial. (2017). Chapter 1. Introduction to Elecricity. Retrieved from RV TechMag:
https://www.rvtechmag.com
Safety Management Group. (2016, February 2). Eight steps for safer lockout tagout programs. Retrieved from
https://safetymanagementgroup.com//
Service Titan. (2020, May 22). 25 Essential Electrician Tools for 2020. Retrieved from
https://www.servicetitan.com/blog
Siskind, C. S. (1966). Electrical Machines Direct and Alternating Current, 2nd ed. McGraw-Hill.
Theraja, B. a. (2005). A Textbook of Electrical Technology Vol. II AC & DC Machineries, 1st Multicolor ed.
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ELECTRICAL WORKSHOP 2
Other Resources
- Power Point Lecture, Module 1-5 Lecture Notes
- YouTube Videos
EATON (Motor Controls 101)
Automation Academy (Motor Controls 101)
Jun Aux TV
Electrical PH Tutorial
RYB Electrical
Pinoy Teknisyan
Pinoy Electrisyan