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ELECTRICAL CONTROL SYSTEMS IN INDUSTRY

9. Describe how a processing line like that of Fig. 11'9, in which material is unwound from a reel at one end and rewound on anotiier reel at the other end, can be kept in co ntinuous operation, w itho ut shutdow n, \\'hile either end is stopped when it is necessary to replace an em|)t\' reel (at the entrance end) or a full reel (at the finished end). Ind ica te clearly the function of the in-feed and out-feed acc umula tors a nd the ma n ne r in which motors are speeded up or slowed down d uring change-over periods.

CHAPTER

S peci al Control Circuits and Problems

Industrial control engineers are frequently called upon to solve unusual problems, design special circuits that must fulfill definite specifications, modify existing circuits to improve operating conditions, or develop circuit arrangements that employ new types- of equipment. Considerable experience as well as specialized training are generally necessary if the assignments indicated are to be carried out so that the circuits not only are safe and reliable but do not malfunction under the most adverse conditions or even when the operator fails to follow instructions properly. Also, to reduce cost and minimize servicing requirements, the designer must use as few components as possible. This chapter will concern itself with a great many problems and circuits of varying degrees of complexity and will attempt to show, by illustrative examples, how circuits and numerical solutions satisfy given specifica tions. Although the operation of the various circuit diagrams will not be explained, it is recommended that the student make every effort to analyze them or, perhaps, suggest alternate solutions of his own. Such exercises will certainly serve to develop confidence and skill in the han dling of industrial control systems.
Problem 1. Three line-start motors are to be started and stopped from a single push-button station. Each is to have its individual across-the-line starter, and there is to be a small time delay between starts as the ma chines accelerate in sequence. Also, the tripping of the overload relay on one starter must stop the particular motor and not affect the other two. Design a control circuit to fulfill the given specifications.

419

420 Solution

ELECTRICAL C O N T R O L SYSTEMS IN INDUSTRY

SPECIAL CONT RO L CIRCUITS AND PROBLEMS 4 2 1 Problem 3. It is desired to control two motors in the following manner: a. Depressing the start button at the start-stop station will start motor No. 1. This motor will continue to run until it is stopped either by the pressing of the st op button or by the tripping of its overload relay. b . When motor No. 1 stops, motor No. 2 is to start and, after running for 1 min, will stop.

(See Fig.

12-1)

Draw a line diagram for the control circuit only.

Solution

(See Fig.

12-3)

Problem 2.

It is desired to start two line-start motors from a single Design a control circuit that will permit five motors to in the operate following manner; a. When motor No. 1 is started, motor No. 2 will also start after a short time delay and will run only while No. 1 is in operation. b. It shall not be possible to start motors Nos. 3, 4, or 5 unless motors Nos. 1 and 2 are running. c. It shall not be possible to start motor No. 3 when No. 4 is running or No. 4 when No. 3 is running. d. The tripping of the overload on motor No. 1 or 2 shall stop all motors. e. The tripping of the overload in motor No. 5 shall stop the latter and motor No. 3 or 4, whichever is running.
Problem 4.

START-STOP station simultaneously under the following conditions: a. Depressing the st op button or the tripping of the overload relay of

b.

motor No. 1 shall stop that motor only, and 4 sec later, motor No. 2 is to stop automatically. The tripping of the overload relay on starter No. 2 shall stop both motors immediately.

Design a control circuit to fulfill the given specifications.

Solution

(See Fig. 12-2)

Fig. 12-2

Solution to Prob. 2,

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S P E CI AL CONTROL CIRCUITS AND PROBLEMS 423

Solution (See Fig. 124)

Problem 6. Design a control circuit for a five-motor conveyor system t h at will operate in accordance with the following specifications: a. Each motor is to have its own across-the-line starter and its own START-STOP station. b. It shall be necessary to start motors Nos. 1 to 5 in numerical sequence. This shall be done by depressing the start buttons in succession,' and only one motor at a time shall start when a start butt on is depressed. c. If the pressing of the stop bu t t on or the tripping of the overload relay of motor No. 5 stops the latter, it shall be the only one to stop. d. The stopping of motor No. 1 shall stop all motors. e. The stopping of any motor by the pressing of a sto p button or the tripping of its overload relay shall stop the particular motor and, in addition, all higher numbered motors. This control scheme is frequently used in conveyor systems to prevent a pile-up of material should one of the "take-awa y" sections stop.
t,

Solution (See Fig. 12-6) Problem 5. It is desired to s ta rt a nd stop four motors from a single START-STOP station. There are to be four independent across-the-line starters, and the circuit is to function as follows: a. Each overload relay is to carry the current of one contactor coil. b. No START or STOP butt on is to carry more than the current of one contactor coil. c. The tripping of any overload relay shall stop all operating motors. d. The auxiliary contact of any starter shall not carry more t han the current of one contactor coil. Design a control circuit t ha t will fulfill the given specifications'. Solution (See Fig. 12 o)

L_tt

STOP I
I

START O O

~o I o - j- o

0L3 S TOP Q I t O--if"-po 4M SI S TART

5M

Fig. 12-

Solution to Prob. 6.

Fig. 12-5

Solut ion t o Pro b. 5

Problem 7. The control circuit for a reversing compound motor (Fig. 3-15) is to be modified so that the machine can be made to slow down while running normally in forward only. One method of accomplishing this is to provide an armature shunt as in Fig. III-C of Table 7-1, page 207. Show schematically how this can be done by incorporating a special contact and a resistor in such a circuit.

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425

Solution (See Fig, 12-7)

Problem 9. It is desired to operate two motors from a single start-stop station under the following conditions; a. The pressing of the start button shall start motor No. 1, and 30 sec later motor No. 2 shall start. b. After motor No. 2 has been running for 1 min, it shall stop; motor No. 1 shall continue to run. c. T h e pressing of the sto p button shall stop both motors. d. If, during operation, the overload on motor No. 2 trips, both motors must stop. e. Th e operating cycle of motor No. 2 must not be affected by the tripping of the overload on motor No. 1. Design a control circuit to fulfill the given specifications.

Fig. 12*7

Solut ion t o Prob. 7.

Problem 8. A small synchronous motor rotates a cam which repeatedly closes and opens a contact every 15 sec. It is desired to make this contact act on two independent circuits A and B in the following manner: a. For the first contact closing, circuit A is energized. b. Wh en the contact opens, circuit A is deenergized. c. For the second contact closing, circuit B is energized. d. When the contact opens, circuit B is deenergized. " Th e above cycle of operations repeats itself. Design a control circuit for the listed cycle of operations. Solution (See Fig. 12-8)

Solution (See Fig. 12-9)

Fig. 12-9 Solution t o Prob. 9.

Problem 10. Six grid resistors are available. Four of them are tapped at center points, and two of them have taps one-third from the ends. a. If the total resistance of each of the first four sections is 6 ohms (3 ohms between taps) and the last two sections has a total of 9 ohms (3 ohms between taps), how should the resistors be connected to yield a total resistance of 2 ohms? b. 12.75 ohms? Solution (See Fig. 12-10) 32 32

30

31

311 1

3Q

32

3n

3n 1

31

Fig. 12-8

Solution t o Prob. 8.

Fig. 12*10 Solution t o Pro b, 10.

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ELECTRICAL CONTROL SYSTEMS IN INDUSTRY

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427

Problem 11. A small material-processing drive is to be equipped with three line-start motors whose operations are to be controlled at a panel containing (1) a two-position selector switch marked automatic-manual, (2) a MASTER START-STOP Station, and (3) an individual start-stop station for each of the three motors. The following operating conditions are to prevail; a. When the selector switch is set on manual, each motor may be started and stopped in the conventional manner by pressing the appropriate button. Since dynamic braking will be provided, a running motor will come to rest quickly when its stop button is pressed. b. In the MANUAL position of the selector, only one motor may be operated at a time, and neither of the other two machines may be started until an operating machine is shut down. c. When the selector switch is set on a uto ma tic, the individual staetSTOP buttons are to be ineffective and the entire drive is to be con trolled at the m a s t e r station. Under this condition of operation, the pressing of the button will start the three motors in sequence, i.e., 1, 2 and 3, with a small time delay between starts. Also, while the motors are running, the pressing of the sto p button will bring them to a stop. Should an overload trip in any of the motor circuits, all of them must stop. d. It shall not be possible to make a transfer from a uto m a tic to manual control, or vice versa, unless all motors are stopped. If a transfer is attempted while motors are running, no change shall take place; a transfer must first be preceded by the pressing of the appropriate button.

Solution (See Fig. 1211)

Design a control circuit to fulfill the specifications listed.

Fig. 12-n

Solution to Prob. 11

Problem 12. The following information is given in connection with a hoist application in which a 380-rpm d-c series motor drives a drum, two gear trains, and a rope suspension;

Total weight to be lifted (load plus hook and cable) = 22 tons Gear ratios = 51 to 90 teeth and 17 to 120 teeth Rope reduction = 2 to 1 Diameter of drum = 27 in. Estimated overall eEciency of hoist mechanism = 85 per cent It is desired to specify the horsepower rating of a suitable motor for the application and to submit a sketch illustrating the arrangement of electrical and mechanical equipment.

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Solution

(See Fig.

12-12)

torque of the motor under the new operating conditions. Assume a plugging-current power factor of 0.5 lagging.
Solution

511

(See Fig. 1213)

90T.

17 T.

120 T.

Fig. 12-13 Sketches for Prob. 13.

/piuggint: (at 220 volts) = 1.1 X 90 = 100 amp 85 imotor (for a plugging current of 85 amp) = X 220 = 187 volts
Fig. 12- 1 2 Sketch for Prob. 12.

T = 44,000 X X ~ X - X 90 120 2 12 X 2 380 2,340 X = 169.5 Use 175-hp motor hp 5,250

P r o b l e m 13. In a certain shearing-machine application, the procedure is to move a steel billet into place gradually and in steps by starting and plugging a 5-hp 220-volt line-start 3-phase squirrel-cage induction motor repeatedly about five or six times. During each plugging operation it is found that the inrush current is approximately 10 per cent higher than the normal starting current of about 90 amp. Although the motor is permitted to rest about 5 to 8 min after each shearing operation, its tem perature exceeds permissible values. It is, therefore, suggested that the plugging current be reduced to 85 amp by connecting permanent resistors in the line wires. This would, of course, reduce the starting torque, but it is felt that the latter would be more than ample, the 220-volt starting torque being l.&TriDetermine the value of each of the three line resistors and the starting

-Biine (per phase) = = 127 volts V3 187 'motor (per phase) = = 108 volts V3

220

Referring to the phasor diagram. Fig. 12-13, (127)2 = [(0.5 X 108) -H ErY + (0.866 X 108) Er = 32 volts Therefore R = 3%5 0.38 ohm Per cent Tst (at 187 volts) = 160 X (/2o) = 115.5
P r o b l e m 14. A dual-voltage 220/440-volt 3-phase squirrel-cage induc tion motor is available with nine terminal leads T1 to T9 brought out and labeled in the standard manner (see Fig. 2-7). It is proposed to operate the machine on 220 volts but to connect the windings in series for starting and in parallel for running. Design an automatic switching circuit for the motor, and determine the starting current and starting torque in terms of the normal values at 220 volts.

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431

Solution (See Fig. 1214)

Solution (See Fig. 1215)

-
TR1 TR1

PUMP-SWITCH CONTACT

TR2 T.C.

-HI

Fig. 12 '1 4

D ia g r a ms fo r P ro b. 14.

1st

(series-star) = Tst (series-star) =

yiJar

(two-parallel-star) (two-parallel-star)

Problem 15. A control circuit is to be designed for a water-pumping installation in which a pressure switch actuates an auxiliary contact that

-IhCR Fig. 12-15 Solut ion t o Prob. 15.

Problem 16. In a two-wire control circuit for a motor which is turned

ON

the thermostat are generally incapable of handling the contactor-coil current. Recognizing this limitation, design a thermostatically controlled circuit for a small line-start motor that will make the thermostat con tacts carry an extremely low relay-coil current and where the operation of the relay will start and stop the motor. for this Two solutions are given problem.
Solutions (See Fig. 12-16)
T her mos ta t

and O F F at the contacts of a thermostat, an intermediate step must be used between starter and thermostat; this is because the contacts on starts and stops a motor at adjustable values of low and high water pressures. Since surges are likely to occur during starting and stopping and "backspin" is possible when a pump is shut off, timing relays should be included in the circuit for protective purposes. It should be pointed out in this connection that the force of a sudden stop of a long column of water produces surges which, operating the pressure switch, tend to subject the motor starter to chattering. A similar situation prevails on starting when the pressure switch tends to drop out as low pressure.s occur during surges. Such improper operation can be avoided by using O F F - D E L AY and O N - D E L AY timers whose contacts bypass the pressure switch momentarily during starts and stops. Backspin tends to occur when a head of water runs back through a centrifugal pump to turn the latter in a reverse direction just after a turnoff. Should a pump be started during a backspin, the pump or motor might be damaged. The use of the relays indicated above automatically provides backspin protection.

IS
CR

T h er m o s t a t

CR

--J CRi
-Jf4f
0L1 OLZ CRI

-'
CR2
OLI 0L2
()

CR

(al
Fig. 12-16 Solutions t o Prob. 16.

with single-winding .3-phase squirrel-cage motor to operate in accordance the following specifications: a. I t shall be possible to start the motor in low speed only. b. The speed of the motor can be advanced from low to high immedi ately thereafter by pressing the high button.

Problem 17. It is desired to design a control circuit for a two-speed

yh

-0-

-Tm )

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SPECIAL CONTROL CIRCUITS AND PROBLEMS 433

c. With the machine running in high, a shift may be made to low by pressing the low button, but the low contactor must pick up

Solution (See Fig. 1218)

after a designated time delay to permit the motor to decelerate sufficiently. The latter condition must be fulfilled by using a plugging switch with an N.C. contact and which can be adjusted to close (and open) at any desired speed (not zero).

Solution (See Fig. 2-17)

0L4 CRL

0L3
0L2

hi
STOP

lo w

-(crh)-

PLUGGING SWITCH

CRH

CRL

I I -i--h-

CRH

Problem 19. Specify the proper horsepower rating of a 3-phase 1,140-rpm squirrel-cage mduction motor that performs a machining opeiation on the following repetitive duty cycle; a. Ti = 33 Ib-ft for min b. T2 = 30 Ib-ft for 50 sec c. Ts = 48 Ib-ft for 3 min d. Rest period for 4 min
Solution to Prob. 17.

Fig. 12-17

Problem 18. A sequencing control system is to be designed for a machine tool t hat is equipped with three operating motor drives and a coolant pump motor. A master s t a r t - s t o p station is to be provided with, and the starters of each of two operating motors IM and 2M are to be actuated by, three-wire pilot devices. The starting and stopping of the third operating motor SM are to be controlled by a two-wire pilot device, in this case a pressure switch. Moreover, when any one of the motors IM, 2M, or 3M is started, it must automatically start coolant pump motor.4M and the tripping of the overload in the latter circuit must shut down the system. The operating motors shall be protected by independent overload relays, the tripping of any one of which shall stop the corresponding machine only.

The selection of a motor for an apphcation whose duty cycle at regular intervals must be made on the basis of the rms itself repeats torque or horsepower. This value is then a measure of the thermal capac ity of the motor, i.e., its ability to maintain a reasonable temperature rise. Since there is a considerable reduction in cooling while the motor is at rest, it is customary to use one-third of the rest-period time in making , calculations.
Note:

X 270] + [(30) X 50] -F [(48) X 180] jmr (270 -f 50 -1- 180 + 24%) 36 X 1,140 TT -ri, 7 . 8 Use /.5-hp motor hp = - =5,250 ~
Problem 20. Design a magnetic-amplifier control circuit similar to that of Fig. 9-396 for controlling the speed of a shunt motor in an adjust-

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SPECIAL CONTROL CIRCUITS AND PROBLEMS 435

able-voltage system (Ward Leonard) by eliminating the tachometer generator. This can be accomplished by using two control windings on the magnetic amplifier, with one of them energized by the loop voltage and the other by the loop current. Be especially careful that the control windings are properly polarized so that the motor speed will remain constant for all load changes at a particular rheostat setting.
Solution (See Fig. 12-20)
(-)

The winding connections, with the proper terminal markings, should be included with the control-circuit diagram.
Solution (See Fig. 12-21)

Fig. 12-20

Solut ion t o Prob. 20.

Problem 21. A control circuit is to be designed for a two-winding threespeed constant-horsepower 3-phase nonreversible squirrel-cage motor to fulfill the following operating conditions: a. With the motor at rest, it shall be possible to start at any of the three speeds (low L, medium M, or high H) by pressing the appro priate button. b. It shall be possible to advance to a higher speed directly, i.e., from L to M, L to H, or M to H. c. To change to a lower speed, i.e., from H to M, H to L, or M to L, it shall be necessary first to press the sto p button. This procedure permits the motor to slow down slightly before an electrical change to lower speed connection takes place.

Problem 22. A complete control circuit is to be designed for a twowinding four-speed constant-torque 3-phase nonreversible squirred-cage motor to comply with the given specifications as listed: J a. With the motor at rest, it shall be possible to start the motor at any of the four speeds by pressing the appropriate button. How ever, the following limitations are imposed; (1) on high, 1,200 rpm, immediately upon closing the main control-circuit switch; (2) on 3rd, 900 rpm, 10 sec after the switch is closed; (3) on 2nd, 600 rpm, 20 sec after the switch is closed; (4) on low, 450 rpm, 30 sec after the switch is closed.

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E LE CT RI CAL CONTROL S YST E MS IN I NDUS T RY

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STOP

450 RPM o Q I

WiNOiNG

28TR

uLi OU ut-c 0L2

ifBC 2CR n;i (10 sec)

600RPM Q O I WINDING 2 A

ii

I o 2BTR 0L3 0U4 2CR ULO ULt

2CTR

HlrsirH
2CTR

Hfr

IBTR

900 RPM

, 'T.C. . 'f'T.O. (10 sec) (tisec) OTR 1CTR ' 't.c. (10 sec) (11 sec)

o WiNOING 1 2-PAR-Y

Fig. 12-22fa Wir ing connect ions fo r Prob. 22.

2CTR -Jf1CTR 0L5 0L6

i n-

ICR

Hb

<I>

WINDING 2 2-PAR-Y

1200 RPM o o j o i o

0L7 0L8

Tf H
ICR PUSH-BUTTON STATION

-aC o nt a ct o r s; A, B, C, CI, 0. Dl Control rel ays; ICR. 2CR Timing rel ays; IBTR, 2BTR, 1CTR, 2CTR, DTR

c. With the motor running in high, i.e., 1,200 rpm, it shall be possible to shift (1) to 3rd after a 10-sec delay, (2) to 2nd after a 20-sec delay, or (3) to low after a 30-sec delay. This may be done in either of two ways: (1) by keeping the appropriate button depressed for the time periods indicated or (2) by first pressing the stop button and then, after a suitable time delay, pressing the appropriate button. d. With the motor running in 3rd, i.e., 900 rpm, it shall be possible to shift (1) to 2nd after a 10-sec delay or (2) to low after a 20-sec delay. This may be done in a manner similar to that indicated in c. e. With the motor running in 2nd, i.e., 600 rpm, it shall be possible to shift to low after a 10-sec delay in either of the two ways indicated in c. Solution (See Fig. 12-22a and b) Not e: The winding-connections diagram of Fig. 12-226 illustrates how the two windings are normally open-circuited at the T3-T7 and the T13-T17 terminals. Thus, when winding 1 is energized, inductively coupled winding 2 can carry no current, and no induced current can pass through winding 1 when winding 2 is energized. Also observe that for this constant-torque motor: (1) winding 1 gives the low speed, i.e.,

[a]
Circuit connect io ns fo r P ro b. 22.

Fig. 12 -22o

b. With the motor operating at any speed (in accordance with the conditions specified in a) it shall be possible to advance to a higher speed; e.g., it shall be possible to advance directly from low.to 2nd, low to 3rd, or low to high, from 2nd to 3rd or 2nd to high, and from Srd to high.

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439

450 rpm, when it is connected delta by joining TZ to T7 through contact A] (2) winding 2 gives the 2nd speed, i.e., 600 rpm, when connected delta by joining T'lS to T17 through contact B] (3) winding 1 gives the 3?"d speed, i.e., 900 rpm, when connected two-parallel-star (2PY) by joining Tl, T2, T2>, and T7 through contacts C I; (4) winding 2 gives the high speed, i.e., 1,200 rpm, when connected two-parallel-star (2PY) by joining Til, T12, TIZ, and Til through contacts Dl. Moreover, the windings are connected consequent-pole when they provide their respective low speeds, i.e., 4.'i0 rp m for winding 1 and 600 rp m for winding 2; the windings are connected conventionally when they give their respec tive high speeds, i.e., 900 rpm for winding 1 and 1,200 rpm for winding 2.
Problem 23. Make a wiring diagram illustrating how a reversing series motor on a crane bridge m a y be provided with dynamic braking. This practice is desirable to permit the machine to shut itself down quickly in the event of a power failure or to delay the setting of the mechanical brake when the master is returned to the off position. Under the latter operating condition, severe braking torque and shock at high speed are prevented, and soft dynamic-braking action precedes the application of th e mechanical brake. Unlike the dynamic-braking procedure for shunt motors (Fig. 3-21), where the shunt-field excitation is maintained by the source and the armature is connected to a DB resistor, a slightly different method must be employed for series motors. Here, the armature series field, and resistor are connected into a series loop, and, during the dynamicbraking period, the series-field excitation is maintained in the same direction by the generated voltage in the armature, i.e., the cemf. Although the application of this method is comparatively simple for nonreversing series-motor drives, it is somewhat more involved to obtain dynamic braking for machines t h a t operate in both directions. A simple sketch illustrating how a nonreversing series motor is connected for emergency dynamic braking is given in Fig. 12-23a. Note the use of N.C. DB con

close freely; thus, contactors bu t permits the IDB and 2 D B contactors to 2DB contacts close when there is a power failure, only the IDB and as current while the armature is rotating, and dynamic braking occurs series the field, the of the made armatine, the up loop passes through the motor running with 2DB and (4) the IDB contacts; and DB resistor, the ID B and in a reverse direction, the camshaft mechanism locks out close freely; to contactors 4 DB and 2 DB contactors but permits the ZDB contacts and iDB 3DB the a only is failure, power thus, when there is close while the armature is rotating, and the dynamic-braking loop 3 DB and the the DB resistor, made up of the armature, the series field, or reveree and iDB contacts; (5) for dynamic braking from forward same. the remains series the i n current field the direction of rotation, the
Solution (See Fig. 12-23a and h)

tacts which are spring closed (see Fig. 3-22). Controller wiring connections t h a t provide emergency dynamic braking for a reversing series motor are given in Fig. 12-236. Note the Jour N.C. DB contacts, spring closed, and the DB resistor. To understand how the system operates it wl l be necessary to recognize t ha t : (1) the DB con tactor coils are energized a t the in stant the master is moved out of the OFF position and, with the motor running in either direction, all DB con tacts are open; (2) in the event of a power failure or if the master is returned to the off position, only two contactors are permitted to close and the other two are locked out mechanically; (3) with the motor running in a forward direction, a camshaft mechanism locks out the 3DB and iDB

[b)

for a reversing series motor Emergency dynomic-braking connections

Fig. 12-23

Circuit diagrams for Prob. 23.

a duplex, seriesProblem 24. Make a wiring diagram illustrating how motor drive for a crane bridge m a y be provided with dynamic braking

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441

by the Wilson-Ritchie method. The scheme, named after its inventors, employs four standard spring-closed DB contactors for the braking circuit (as in Fig. 12-23) and the usual combination of resistors and contactors. However, unlike the duplex control system of Fig. 4-12, where reversing the two series motors is accomplished by changing the current directions in both armatures, the Wilson-Ritchie method reverses the motors by interchanging the armature terminals in one machine and the seriesfield terminals in the other. The unique feature of this arrangement is that special mechanisms are unnecessary (as in Fig. 12-236) and con ventional devices are used. The four N.C. DB contacts of Fig. 12-24 open at the instant the motors are started and close during the braking period. When the bridge crane is moving forward or reverse, the two motor circuits are completely independent, with the armature and field of motor A in series in one path and the armature and field of motor B in series in the other. However, while the motors are undergoing a dynamicbraking stop and all directional contactors are open, one loop circuit consists of armature A, series-field B, and a DB resistor while a second loop circuit comprises armature B, series-field A, and a DB resistor. Moreover, an especially important aspect of the system is that the series-field current directions in both motors do not reverse, although the armature currents do, as the machines brake to a stop.
Soluti on

(See Fig. 12-24)

Problem 25. As explained in Chap. 6 (see Figs. 6-25 to 6-27), the speed of a phase-wound rotor motor can be adjusted by inserting varying values of resistance in the secondary. For installations requiring consider able speed ranges with a miniinuiii number of contactors, it is sometimes found desirable to employ sets of resistors having a succession of values that vary according to a geometric ratio. The master controller can then be wired to insert resistances equal to one base unit at each step of the secondary controller, varying the magnitude of the phase resistance from a maximum value (represented by the sum of all sections) to zero. This scheme of speed adjustment has been applied satisfactorily to large printing presses where the mode of operation is to set the master at the desired speed point before energizing the primary; a push-button starter is then actuated to start the motor and bring it up to a preset speed. An added feature for such controllers is to include a so-called high-torque contactor in the secondary so that the motor will always develop suf ficient starting torque regardless of the controller setting. The latter action is implemented by making the high-torque contactor pick up at the same time the line contactor closes and have it energized as long as the operator keeps the start button depressed; the release of the start button after the machine has accelerated causes the high-torque con tactor to drop out and the insertion of the required secondary resistance. Make a wiring diagram showing the connections for a wound-rotor motor with four sections of resistance in each "of the three phases gradu ated according to a geometric ratio. Show in tabular form how 16 dif ferent speeds can be obtained with this arrangement. Solution (See Fig. 12-25)
4A 3 A 2A 1A

MASTER CONTACTORS 1 1A 2A 3A 4A 2 3 4 5 6 7 8

POSITION 9 10 11 12 13 14 15 16

X X X X X X X X X XX XX XXXX

Fig. 12-24

Wilson-Ritchie circuit diagram for P ro b. 24.

Fig. 12-25 Circuit connect ions and table for Prob. 25.