SRI LANKA INSTITUTE of ADVANCED TECHNOLOGICAL

EDUCATION

ELECTRICAL and ELECTRONIC

ENGINEERING
Instructor Manual

Training Unit

Electrical Control 2
Theory

No: EE 015

Training Unit
Electrical Control 2
Theoretical Part
No.: EE 015

Edition:

2008
All Rights Reserved

Editor:

MCE Industrietechnik Linz GmbH & Co

Education and Training Systems, DM-1
Lunzerstrasse 64 P.O.Box 36, A 4031 Linz / Austria
Tel. (+ 43 / 732) 6987 - 3475
Fax (+ 43 / 732) 6980 - 4271
Website: www.mcelinz.com
1

ELECTRICAL CONTROL 2

CONTENTS

Page

LEARNING OBJECTIVES ...................................................................................................3

1

SCHEMATIC DIAGRAMS ............................................................................................4

1.1

Wiring diagram.....................................................................................................4

1.1.1

Hints for the design of wiring diagrams ............................................................7

1.2

Single line diagram ............................................................................................13

1.3

Complete circuit diagram ...................................................................................14

1.4

Lay-out diagram .................................................................................................15

1.5

Equipment diagram ............................................................................................15

1.6

Terminal table ....................................................................................................16

TYPES OF CIRCUIT CONSTRUCTION ....................................................................17

WIRING OF CIRCUITS ..............................................................................................18

ENVIRONMENTAL EFFECTS ...................................................................................19

4.1.

Protection against climatic influences ................................................................19

4.2.

Protection against vermin ..................................................................................19

4.3.

Protection against corrosion ..............................................................................19

FAULT FINDING ........................................................................................................20

5.1.

Tips for remedying faults....................................................................................20

SUMMARY OF SWITCHING SYMBOLS ...................................................................24

IDENTIFICATION LETTERS FOR GENERAL FUNCTIONS .....................................33

GLOSSARY OF ELECTRICAL TERMS .....................................................................35

8.1.

Definition of characteristic quantities .................................................................35

OPERATING EQUIPMENT ........................................................................................36

9.1.

Designation of operating equipment ..................................................................36

9.1.1.

Designation block "type, number, function"................................................36

9.1.2.

Designation block "plant" ...........................................................................37

9.1.3.

Designation block "location".......................................................................37

9.1.4.

Designation block "connection" ..................................................................38

ELECTRICAL CONTROL 2
LEARNING OBJECTIVES
name and describe schematic diagrams.
draw wiring diagrams complying with standards.
recognize switching symbols and design simple contactor circuits.
state the difference between wiring diagram and complete circuit diagram.
produce a terminal table.
list the types of wiring.
recognize and find minor faults.

ELECTRICAL CONTROL 2

SCHEMATIC DIAGRAMS

These are used to represent electrical devices by means of symbols. Operating

equipment can be shown in a simplified form.
Schematic diagrams always show the equipment de-energized, in the mechanically nonactivated condition.

1.1

Wiring diagram

This is the most frequently used representation of a circuit in electrical engineering.

The current paths should be drawn in straight lines, as far as possible, and without
crossovers.
The spatial position and mechanical interconnection of individual parts are not taken into
account.
The wiring diagram should show the method of operation and switching sequence of a
control system clearly and unambiguously.
The magnet coils (contactor coils) should be arranged in such a way that one terminal is
directly connected to the neutral line of the control circuit. The input to the coil is
connected to the other control line via various switching elements (contacts) of the
switchgear (pushbuttons, overcurrent relays etc.).
All contacts operated by one contactor have the same designation as the contactor itself.
Terminals are shown, and are given the same numbers as on the terminal table and the
circuit diagram.
For large circuits it is recommended that the wiring diagram should be divided into current
paths.
The equipment diagram of switchgear can be shown below the current path (as shown on
page 8).
The switch contact types, whether they are normally closed or open, the section in which
they are found and whether any of the contacts are free.

Each piece of equipment is lettered to indicate its type. 1f here are several items of the
same type of equipment, they are given consecutive numbers. A further letter indicates its
general function, e.g., K 2 A auxiliary contactor and K 4 M main contactor (motor
contactor).

a) Main circuit wiring diagram

b) Control circuit wiring diagram

1.1.1

Hints for the design of wiring diagrams

When designing a wiring diagram, the following points should be observed.

a) The current paths are drawn vertically, in between the horizontally drawn bus bars.

b) Switching appliances, switchgear and initiating equipment must be drawn at right

angles to the current path.

c) The direction of the current flow should always be from top to bottom.

d) Crossover of lines should be avoided.

e) Apparatus and equipment must be represented in zero volt condition (switched off).
Exceptions have to be clearly indicated (i.e. arrow).

f)

Control equipment e.g. coils, signal lamps must be connected directly to the neutral
conductor, or in case of an earthed supply system, to the potential earth neutral (PEN)
conductor.

10

g) Current paths must be numbered consecutively, circuit elements must be placed from
left to right, depending on their sequence of operation. Circuit elements must be
provided with code letters and consecutive numbers.
For clean representation of the various circuit elements, a table can be added below
the wiring diagram.

11

12

1.2

Single line diagram

This is a simplified, single-phase representation of the circuit.

F1

motor fuses

F2

overcurrent relay

K1

motor contractor

M1

3-phase AC motor

13

1.3

Complete circuit diagram

This is the representation of a circuit in all its details.

As both main and control circuits appear in one diagram, this can become unwieldy and
makes fault finding more difficult.

F1

motor fuses

K1

motor contractor

F2

overcurrent relay

M1

3-phase AC motor

F3

control fuses

S1

ON-OFF-pushbutton

14

1.4

Lay-out diagram

This is a document for wiring up the components. All equipment is shown in the correct
position.

1.5

Equipment diagram

This gives information on electrical switchgear (contactors, controllers, and master

switches etc.), but not on its construction. The switch positions and contacts must have
the same designation on the wiring diagram.

15

1.6

Terminal table

The terminals shown in the wiring diagram and complete circuit diagram are compiled in
the terminal table into terminal strips. The terminal table contains the cable or wire
numbers, the terminal number, the origin and the destination.

16

TYPES OF CIRCUIT CONSTRUCTION

Small circuits are built up on boards and are installed in the places provided on the
machines, e.g., star-delta starter circuit.

Cubicles are fixed directly to the machine and contain all control and switching devices.

Freestanding cubicles for large machine tool controls contain e.g. measuring equipment,
switching devices and control devices.

Freestanding contactor boards are used for extensive electrical plants, e.g., rolling mills
and cranes etc.

Contactor boards are erected separately in the switchgear rooms provided.

Control desks contain all the Instruments and control devices on one board, in order to be
able to control a plant from a central position.

17

WIRING OF CIRCUITS

Wiring in ducts:
This is affected by laying wired in plastic ducts. Note:
Always make the ducts large enough.

Back-panel wiring:
Wires are connected on the back of panels.
Note:
When wiring is taken through a panel, grommets should be used, otherwise the wiring
insulation will be damaged.

Flat wiring:
Individual wires are laid next to and above one another in layers.

Round bundle wiring:

Bundles of wires are bunched with string or held together by tapes.

Laced wiring harness:

This is a preformed and tied bundle of wires.

Quick wiring:
The wires are laid from terminal to terminal (by the shortest path).

18

4
4.1.

ENVIRONMENTAL EFFECTS
Protection against climatic influences

The required control devices may be affected by local conditions. This means that the
prevalent climatic conditions have to be taken into consideration in advance.
The control devices have to work satisfactorily in temperate and dry climates, as well as in
hot climates with high air humidity. If water condenses in a control cubicle due to frequent
temperature changes at high air humidity (changing climate), then control devices will not
function properly. Heaters may be employed to ensure that water is not deposited in the
equipment.

4.2.

Protection against vermin

Control devices may suffer adverse effects from vermin (e.g. termites). Components made
of materials containing cellulose should be avoided in electrical operating areas, and a
high degree of cleanliness and brightness of illumination should be ensured. It is useful to
employ encapsulated equipment in areas likely to be affected by vermin.

4.3.

Protection against corrosion

There is a corrosive atmosphere in many plants due to the manufacturing processes e.g.
in chemical and electroplating works and steelworks etc.

The following information may serve as a rough guide:

In atmospheres in which human beings can exist, normal encapsulation of equipment will
provide resistance to corrosion.

Metal parts used as contacts must be suitable for the constructional and switching load
requirements. They are male of precious metals or appropriate alloys.
The above considerations do not only apply for contactors and switchgear, but for all
electrical machines and electrical installations.

19

FAULT FINDING

For rated voltages above 42 V up to a voltage of 250 V to earth, work on live parts is only
permitted, if, in order to prevent danger or for other important reasons, it is impossible to
make those parts of the plant dead, on which work is to be carried out. Such work may
only be carried out by an "expert". An expert is one who can judge and recognize possible
dangers based on his technical training, knowledge and experience as well as his
knowledge of the appropriate regulations applying to the work entrusted to him.
Electricians with completed electro-technical engineering training fulfil these conditions.

Note:
Under no circumstances may apprentices work on live parts of a plant.

5.1.

Tips for remedying faults

This table includes the faults which occur most frequently on contactors.

CAUSE

REMEDY

Contactor does not switch on:

Control fuse burnt out.

Fist remove cause of short circuit, then

replace the fuse.

Thermal overload relay has operated

Wait for cooling period, press reset button.

Switch on again.

Coil defective

Replace coil

Coil for wrong voltage, wrong

Replace coil. Change the circuit.

frequency or wrongly connected.

20

Low voltage (permitted lower limit

Replace coil, use special coil for increased

0.85 x UC) particularly for DC operated

voltage security

contactors.

(0.75 x UC). Provide stable mains supply.

Low voltage 214 V.

Note the voltage drop. If necessary, choose

higher control voltage.

Circuit errors.

Look for and remove the cause. Go

through the wiring diagram step by step.
By-pass normally closed contacts in circuit,
one by one.

Broken wire.

Pull the wires to check whether they are

broken inside the insulation. Frequently the
break in the wire, caused by incorrect
removal of the insulation, is inside the
insulation.

Contactor with thermal overcurrent device

trips

Thermal overcurrent trip not operating Set trip to motor operating current. Note
correctly

that, in the delivered condition, the trip is

always set to the lowest current value.

21

Long starting time due to starting against Install thermal overcurrent

the load, too low voltage.

trip with saturation transformer. During start

up the load should be switched off
(coupling) so that rotary Pumps should not
be started against a closed gate valve.
Measure voltage at motor terminals.
Check cross section of wires (possibly
voltage drop). Thermal trips are by passed
during starting period.

Too high switching frequency.

Use

thermistor

protection.

Thermal

overload trips are only suitable up to 15

operations/ hour.

Bimetal strip has turned blue or burnt out; Change overload trip. Install fuses suitable
overload due to too high current; short for overload trip.
circuit with wrong (too high) fuse ratings.

Loss of one-phase (motor does not start - it Possibly a burnt-out fuse, loose or broken
hums).

main connection to motor winding.

Contactor does not switch off

Contactor contacts welded together.

Break the contacts apart and replace them.

Install bigger type of contactor.

The control wires between contactor and Lower the control voltage. Install contactor
operating device is too long (holds itself in with smaller holding capacity.
due to capacitive currents).

22

Stop push Button is short circuited.

Remove short circuit, break the contacts

apart, if necessary, and renew them.

Faulty star-delta circuit switching.

Use timing relay with changeover time .of

40 - 100 s. Set timing relay to longer time
period. The motor must nearly reach the
nominal speed in the star circuit.

Contactor flutters.

Ensure that the operating signal is correct.

Remove

fault

on

operating

elements.

Check rated voltage of the contactor coil.

Contactor hums

Coil of wrong voltage or wrong frequency.

Replace coil.

Magnet surfaces dirty or corroded (after Clean magnet surfaces. Do not file, do not
long period of shutdown).

grease them.

Short circuiting ring broken.

Replace contactor.

Foreign bodies in air gap.

Switch on and off several times.

Remove foreign bodies.

23

SUMMARY OF SWITCHING SYMBOLS

Contacts with two or three positions Description

Symbol

Description

24

Wiring contacts with two positions

Leading and lagging contacts

25

Contacts showing delay in actuation and resetting

Contacts with automatic and non-automatic resetting

26

Switches

Symbols

Description

27

Switches, which are actuated by pushing or pulling, normally have an inherent reset force.
It is therefore not necessary to draw the symbol for automatic reset.
In exceptional cases, where switches have latching qualities, the symbol for latching is to
be used.

Switchgear

Symbol

Description

28

Electromechanical and electromagnetic drives

Symbol

Description

29

Fused and fuse switches

30

Electrical machines and transformers

31

32

IDENTIFICATION LETTERS FOR GENERAL FUNCTIONS

Letter

General function

Auxiliary function

Direction of movement (forwards, backwards, raising, lowering,

clockwise, anticlockwise)

Counting

Differentiation

---

Protection

Test

Alarm

Integration

Pushbutton operation

---

Main function

Measurement

Proportional

Condition

Reset, cancel

Storage, indication

Time measurement, time delay

---

Speed (acceleration, braking)

Addition

Multiplication

Analogue

Digital

(start, stop,

limits)

33

For example:

34

8.1.

GLOSSARY OF ELECTRICAL TERMS

Definition of characteristic quantities

Rated insulation voltage

Ui is the standardised value of voltage for which the insulation is suitable.
Rated voltage (rated operating voltage)
Ue is the reference voltage for switching.
Continuous current (thermal rated current)
Ith2 is the current which the switchgear can carry for an unlimited period of time in normal
operating conditions, without the controls having to be cleaned and without the limiting
maximum temperatures being exceeded.

Rated operating current

Ie is the current reached in normal operation
Mechanical life span
The mechanical life span in expressed by the number of switching cycles possible under
no-load condition.

Life span of switching contacts

The life span of switching contacts is determined by the number of switching cycles which
can be achieved under full load conditions.

Frequency of switching
Frequency of switching is the number of switching operations (number of switching cycles)
per hour.

Rated actuating voltage UC

Control voltage is the voltage for which the coil or the tripping mechanism is suitable. It is
also called the coil rated voltage.

35

OPERATING EQUIPMENT

9.1.

Designation of operating equipment

The complete system of designation contains four blocks. Each block has a prefix for
designation.

Prefix
-

Information in identification block

Type of operating equipment

Consecutive number

Plant

Location

Connection

Function

The four designation blocks can be arranged in any sequence. i.e.:

: A 1 = B4 + D1 K 3 A
or
- K 3 A + D1 = B4 : A1

For small units it is sufficient to quote one or two designation blocks. Normally only the
designation block "Type of operating equipment - consecutive number - function" is used,
so that the prefix can be omitted.
i.e.: instead of - K 3 A only K 3 A

9.1.1. Designation block "type, number, function"

For the designation of "type" an identification letter from the table "identification letters for
type of equipment" must be used.
The consecutive number is obligatory, and must always be stated. In some cases the
number alone might be sufficient to designate operating equipment.
The function relative to other operating equipment is indicated by a letter from the table
"identification letters for general functions".

36

The designation of the function may be omitted if is not required. However it is not
permitted to use the designation "function" by itself.

9.1.2. Designation block "plant"

The designation "plant" is written down only once in a suitable place on the switching
document. The designation of the plant may be omitted if not required.

9.1.3. Designation block "location"

The designation "location" states, where the operating equipment is located. The
designation of location may be omitted if not required.

37

9.1.4. Designation block "connection"

The designation "connection" has a colon as prefix. The designation of connection may be
omitted if not required.

38

Examples of block combinations

Designation

Block combination

Explanation

= Plant
= C 1 -K 5 A

- Type, consecutive

Auxiliary contactor K 5 in plant C 1

number, function

+L2:3

=B2+2D4

+ Location

Terminal 3 of component L 2

: Connection

= Plant

4th component of control panel 2 on

+ Location

floor D of plant B 2

- Type, consecutive
- K 2 M. : 11

number, function

Terminal 11 of main contactor K 2

: Connection

= Plant
=B3B+D=Q

Circuit breaker Q of panel D, Plant B

+ Location
- Type, number, function

3B

+ Location
+ A 2 - S 10 : 4

- Type, number,

Terminal 4 of push button S 10 on

function

control desk A 2

: Connection

: Connection
: A 1 = B 4+ D 1 - K 3 A

Terminal A 1 of

= Plant

auxiliary contactor K 3, control panel

+ Location
- Type, number, function

39

D 1, plant B 4

EE 015

Electrical Control 2
Theoretical Test

40

ELECTRICAL CONTROL 2
TEST 1

1. Explain the purpose of schematic diagrams.

2. Name the six different types of schematic diagrams.

3. Draw an equipment diagram for a contactor with three main contacts and four auxiliary
contacts (two normally closed and two normally open contacts).

4. What information is provided by a terminal table?

5. State how back panel wiring is carried out.

6. What is the purpose of a control desk?

7. State what is meant by the term "laced wiring harness".

8. The contactor of a switching circuit "hums". Name possible sources of error.

41

ELECTRICAL CONTROL 2
TEST 2

1. State four points which have to be observed when designing a wiring diagram.

2. Describe the design of a complete circuit diagram.

3. Describe the term "flat wiring".

4. Draw an equipment diagram for a contactor with three main contacts and two auxiliary
contacts (one normally closed and one normally open).

5. Explain the term "frequency of switching" of a contactor.

6. Name the two main parts of a wiring diagram.

7. Trouble shooting in control circuits must be carried out by experts only. Which persons
qualify under the stipulation of operating instructions for the term "expert"?

8. The contactor of a switching circuit "flutters". Name possible sources of error.

42

ELECTRICAL CONTROL 2
TEST 1
(Solution)

1. Representation

of electrical installations through switching

symbols.

Simple

representation of operational equipment.

Schematic diagrams always show the equipment in a de-energized state, i.e. in the
mechanically non-activated condition.

2. Wiring-, single-line-, complete circuit-, lay out-, equipment diagram and terminal table.

3.

4. Cable or wire number, terminal number, the origin and the destination.

5. Wires are connected on the back of panels. Always use grommets through the panel.

6. All instruments and control equipment assembled on one panel for purpose of
controlling a plant from one central place.

7. This is a preformed and tied bundle of wires.

8. Coil on wrong voltage or frequency; dirt on the mating faces of the magnetic core;
short circuiting ring broken; foreign body in the air gap.

43

ELECTRICAL CONTROL 2
TEST 2
(Solution)

1. The current paths are drawn vertically in between the horizontally drawn bus bars.
Circuit elements must be drawn at right angles to the current path.
The direction of current flow should always be from top to bottom. Crossovers of lines
should be avoided.
Circuit elements must be represented in zero volt condition (switched off).
Control equipment such as coils, signal lamps etc. must be connected directly to the
neutral conductor.
Current paths must be numbered consecutively, circuit elements must be provided
with code letters and consecutive numbers.

2. The complete circuit diagram is the representation of a circuit in all its details.
If the main and control circuits appear in one diagram, it can become unwieldy and
makes fault finding more difficult.

3. Individual wires are laid next to end above one another in layers.

4.

5.

The number of switching cycles per hour.

6. Main circuit and control wiring diagrams.

44

7. An expert is one who can judge and recognize possible dangers, based on his
technical training, knowledge and experience as well as his knowledge of the
appropriate regulations applying to the work entrusted to him. Electricians with
completed electro-technical engineering training fulfil these conditions.

8. The operating signal is not correct. Fault on the operating elements. Contactor coil
voltage is incorrect.

45

KEY TO EVALUATION

PER CENT

MARK

88 100

75 87

62 74

50 61

0 49

46