MOTOR CONTROL

All motors must have a control device to start and stop the motor called a motor controller.
A motor controller is the actual device that energizes and de-energizes the circuit to the motor so that it can
start and stop.
Motor controllers may include some or all of the following motor control functions:
Starting, stopping, over-current protection, overload protection, reversing, speed changing, jogging,
plugging, sequence control, and pilot light indication.
Controllers range from simple to complex and can provide control for one motor, groups of motors, or
auxiliary equipment such as brakes, clutches, solenoids, heaters, or other signals.

Applications:
Every electric motor has to have some sort of controller. The motor controller will have differing
features and complexity depending on the task that the motor will be performing.
The simplest case is a switch to connect a motor to a power source, such as in small appliances or power
tools. The switch may be manually operated or may be a relay or contactor connected to some form of sensor to
automatically start and stop the motor. The switch may have several positions to select different connections of
the motor. This may allow reduced-voltage starting of the motor, reversing control or selection of multiple
speeds. Overload and over current protection may be omitted in very small motor controllers, which rely on the
supplying circuit to have over current protection. Small motors may have built-in overload devices to
automatically open the circuit on overload. Larger motors have a protective overload relay or temperature
sensing relay included in the controller and fuses or circuit breakers for over current protection. An automatic
motor controller may also include limit switches or other devices to protect the driven machinery. More
complex motor controllers may be used to accurately control the speed and torque of the connected motor (or
motors) and may be part of closed loop control systems for precise positioning of a driven machine. For
example, a numerically controlled lathe will accurately position the cutting tool according to a preprogrammed
profile and compensate for varying load conditions and perturbing forces to maintain tool position.

Motor Control Components:

Switch is an electrical device that can break and connect an
electric circuit, as well as interrupting the flow of current or
divert it from the conductor to the other.
Types of switch typically used in Motor control:
1. Pushbutton switch
2. Limit switch
3. Selector switch
4. Foot switch
5. Toggle switch

 Magnetic contactor is an electrically controlled switch used

for switching a power circuit. It than main contacts used for
power circuit and auxiliary contact used for control circuit.
Contactors are used to control electric
motors, lighting, heating, capacitor banks, thermal evaporators,
and other electrical loads.
Control relay is an electrically operated switch. The principle of
operation is similar to that of the contactor but differs in application.
While contractor is used to control motors. Control relay on the other
hand is used to control the operation of other control components
particularly the magnetic contractor.

Relay timer - Some relays are constructed with a kind of

shock absorber mechanism attached to the armature which
prevents immediate, full motion when the coil is either
energized or de-energized. This addition gives the relay the
property of time-delay actuation. Time-delay relays can be
constructed to delay armature motion on coil energization, deenergization, or both.
It Contains an auxiliary contacts NO and NC that can be
integrated into motor control circuits. The initial state of its
contact will change when activated after pre-determined value

Thermal overload relay - Thermal overload relays are

protective devices. They are designed to cut power if the motor
draws too much current for an extended period of time. To
accomplish this, thermal overload relays contain a normally
closed (NC) relay. When excessive current flows through the
motor circuit, the relay opens due to increased motor
temperature, relay temperature, or sensed overload current,
depending on the relay type.
Characteristics:
1. Allow harmless temporary overloads without
disrupting the circuit.
2. Trip and open a circuit if current if high enough
to cause motor damage over a period of time.
3. Can be reset once the overload is removed.

 Electronic overcurrent relay (EOCR) - Overcurrent protection

protects electrical power systems against excessive currents
which are caused by short circuits, ground faults, etc.
Overcurrent relays can be used to protect practically any power
system elements, i.e. transmission lines, transformers,
generators, or motors. Unlike thermal overload relay this
component uses current to trigger once there is overload.

Over/Under voltage relay- This component protects the motor

against over and under voltage situation.
A relay that has contacts that operate when the voltage drops below
a set voltage. Under voltage relays are used for protection against voltage
drops, to detect short-circuit faults, etc.

Phase sequence relays - Phase sequence protection is an

important safety for motors. Reversing the phase sequence causes
motor to reverse its direction of rotation. This can cause serious
damage and injury to personnel if for instance, the motor is
coupled to cutting equipment, or conveyor belts. The phase
sequence indicator works by monitoring the phase sequence
continually and preventing the motor from starting if the phase
sequence has been reversed in the supply.

Motor Control Circuits:

Motor control circuits are an effective way to reduce
cost by using smaller wire and reduced-amperage
devices to control a motor. Imagine trying to wire a
pushbutton station for a 100A motor using 3 AWG
conductors. Many smaller motors use the same size
conductors for both control and power circuits, but
as the horsepower increases it becomes impractical to
do so. Motor control circuits are often connected
to lower voltages than the motor they control to
make it safer for operators and maintenance personnel.
A motor control circuit, for the most part, is simply a
switch (or group of switches) and a motor. If you keep
the word switch in mind, it helps keep the intimidating
subject of motor control in its proper context.
For example, the following can be considered motor
controls:
A time clock that operates a pool or sprinkler pump
is nothing more than an automatic switch. At a preset
time, a set of contacts open or close (turn off or on).

the

An automatic garage door opener uses a radio signal to operate a switch that activates a garage door in much the
same manner as a typical up-down pushbutton station.

Types of Motor Control Schematics: