Schematics Made Easy

SCHEMATICS MADE EASY

CONTENTS
POWER & CONTROL CIRCUITS.............................................................................................................................................2
POWER CIRCUITS.................................................................................................................................................................2
CONTROL CIRCUITS............................................................................................................................................................2
Wiring Diagram........................................................................................................................................................................2
Schematic Diagram..................................................................................................................................................................2
CONTROL CIRCUITS................................................................................................................................................................3
Maintained Start-Stop..............................................................................................................................................................3
UNDERVOLTAGE PROTECTION........................................................................................................................................3
Momentary Start-Stop..............................................................................................................................................................3
Multiple Start-Stop Stations.....................................................................................................................................................3
TWO & THREE WIRE CIRCUITS............................................................................................................................................3
Two-wire control......................................................................................................................................................................4
REVERSING CIRCUITS............................................................................................................................................................4
Forward-Reverse Compelling..................................................................................................................................................4
Forward-Reverse Optional.......................................................................................................................................................5
MULTI-SPEED CIRCUITS.........................................................................................................................................................5
Two-Speed Compelling............................................................................................................................................................5
Two-Speed Non-Compelling....................................................................................................................................................5
SEQUENCE STARTING.............................................................................................................................................................6
Sequence Start by Auxiliary Contacts......................................................................................................................................6
Timed Sequence Start...............................................................................................................................................................6
SYMBOLS CHART.....................................................................................................................................................................7
EXAMPLES:................................................................................................................................................................................8

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 Schematics Made Easy

POWER & CONTROL CIRCUITS The control circuit is shown in light lines and consists of
the stop-start pushbuttons, holding interlock, magnetic
Circuit diagrams may seem complex when viewed in their starter coil M, and overload relay contact X2.
entirety, but they can be simplified by breaking them into
basic circuits. The overall diagram, and basic machine
functions, are then easier to understand.
Control systems are usually designed so that an individual
circuit controls only one function of a machine. For
example, this could be the starting and stopping of an
electric motor by means of pushbuttons, or controlling
solenoid valves through the use of limit switches. There
are many variations in individual circuits. The main factor
to remember is that a basic circuit is usually associated
with a basic machine function.
Electric circuits may be of two types, Power Circuits and
Control Circuits.
POWER CIRCUITS are usually shown in a diagram with
heavy lines since they are the heavy conductors or wires
carrying motor or load current.
CONTROL CIRCUITS are usually associated with pilot
or control of the power switching equipment, such as the
coil circuit in a magnetic starter. These wires are shown
using lighter lines in the diagram. Some graphic symbols
and designations used in diagrams are shown on Page 6.
These are used in the circuits described in this article.
Fig. 2. Pushbutton station and 3-phase magnetic starter with arc box
Wiring Diagram Figure 1 shows the wiring or cover removed to show contacts. Heater elements shown installed.
connection diagram of a magnetic starter with a start-stop
Schematic Diagram A schematic or elementary
pushbutton station. The location of each wire and terminal
diagram of the starter shown (Fig. 2) is illustrated in Fig. 3.
identifications are shown.
The schematic does not show the physical relationship of
L1 L2 L3 each wire location. It does indicate in straight line form the
circuit functions of the various devices.
2 1 Note that the same terminal identification letters and
numbers are used in both the wiring and schematic
A diagrams to designate the control and power connections.
3
The starter and pushbuttons can be wired directly from the
C M schematic, if desired, since it does show how the devices
V W are connected into the circuit. For troubleshooting, it is
much easier to work from a schematic diagram rather than
a wiring diagram. This is particularly true with a complex
X2 circuit.

T1 T2 T3A3 HEATER ELEMENTS

T2 L1
M T1
T1 T3
MOTOR MOTOR
L2
M T2
T3
L3
M
Fig. 1. The wiring diagram for the 3-phase magnetic starter with
start-stop pushbutton control pictured in Fig. 2.
START
L1 1 2 3 L2
Note the 3-phase power circuit is shown in heavy black M
STOP V W
lines. L1, L2, and L3 indicate the line or supply. T1, T2, OL RELAY
and T3 are on the load side or motor terminals. MMOTOR STARTER COIL CONTACTS

Fig. 3. Schematic of the magnetic starter pictured in Fig. 2.

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 Schematics Made Easy
Now let us consider some of the basic everyday circuits
and the meaning of the more common terms. These circuits
will be illustrated in schematic form showing only the
control portion and its variations for different machine
functions.
CONTROL CIRCUITS
Maintained Start-Stop The circuit in Fig. 4 does
exactly what its name implies starts and stops a motor
by depressing the maintained start and stop pushbuttons
Fig. 4. Maintained Start-Stop Circuit. Motor is started by pushing
button. Starter drops out whenever voltage is below hold-in value.
This circuit has undervoltage release. Should the voltage
on the coil drop below the hold-in value, the starter will
drop out. When the voltage is restored, the starter will
immediately pick up since the pushbutton has remained
closed.
Maintained start-stop circuits should only be used in the
application of heating, lighting and other such non-
mechanical applications. This circuit would not be used
with rotating or moving equipment due to the potential
hazard of an unwanted restart when power is restored.
UNDERVOLTAGE PROTECTION may be provided in
a circuit and assures that a magnetic controller will not
restart after a power interruption until the operator
initiates the action with a pushbutton or other device.
Momentary Start-Stop. In Fig. 5 we have a momentary
start-stop control circuit. Here, the safety feature of under-
voltage protection is provided. The operator must push the
start button to reenergize the starter after it has opened due
to undervoltage release as compared to the starter in Fig. 4
which will energize as soon as voltage is restored. This is
accomplished by a holding interlock on the starter and
momentary actuated pushbuttons as differentiated from
the maintained type used in Fig. 4.
M
Fig. 5. Momentary Start-Stop Circuit showing holding interlock and
momentary actuated pushbuttons.
Starter coil M is energized when the start pushbutton is
depressed. This closes contact M which is connected
around the start pushbutton, thus electrically sealing the
circuit. The start pushbutton, being of the momentary type,
spring-returns to the open position when released. The
starter, however, remains energized due to completion of
the circuit through the now-closed M contact. This contact
is referred to as the seal-in or holding interlock, and
would be the left contact on the starter in Fig. 2.
Should the starter coil circuit be interrupted for any reason
such as power failure, insufficient coil voltage, overload
trip, or operation of the stop button, the starter will drop
out or be de-energized. The seal-in interlock opens and
prevents an unwanted restart until the start button is again
operated. This is where the protection feature comes into
play, since operation of the motor is completely under the
operators control.
Multiple Start-Stop Stations. Extra start-stop pushbutton
stations can be added as shown in Fig. 6. The stop
pushbuttons should be connected in series and the start
buttons in parallel. Note that only a single seal-in M
contact is required around the multiple start pushbuttons to
maintain the circuit to the motor starter coil.
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 Schematics Made Easy
Fig. 6. Multiple stations used with momentary start-stop circuit. Stop
buttons are wired in series and start buttons in parallel.

TWO & THREE WIRE CIRCUITS

The terms two-wire and three-wire control are frequently
STOP used but not always understood. Using the basic circuits
shown in Figs. 7 and 8, let us clarify the origin of these
two expressions.

STOP 2
1

FLOAT SW

Fig. 7. Two-wire control circuit. Two wires are connected to the float
switch energizing the magnetic starter.

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 Schematics Made Easy
Two-wire control is so named because only two wires (as
shown in Fig. 7) are connected to the pilot device that
energizes the magnetic controller. In the diagram, the pilot
device shown is a normally open float switch used with a
pump motor starter. It energizes the motor starter only as
long as It remains closed. This type of circuit provides
undervoltage release but not undervoltage protection, since
a holding interlock is not used. The motor starter would
drop out on loss of voltage and then immediately pick up
again (without operator control) upon restoration of power
provided the float switch had remained in the closed
position.
M
Fig. 8. Three-wire control circuit. Three wires must be connected to
the pilot devices to energize the magnetic starter.
Three-wire control, (Fig. 8), gets its name from the three
wires that must be connected to the pilot device used to
operate the motor starter. Notice here we have the basic
momentary start-stop circuit shown in Fig. 5 which
provides the undervoltage protection feature.
REVERSING CIRCUITS Three phase
squirrel-cage motors are particularly suited to reversal of
rotation by simply interchanging two of the line
conductors supplying the motor. This is commonly done
by using two separate contactor assemblies one for
forward rotation and the other to reconnect for reverse
rotation.
Fig. 9. Horizontal reversing magnetic starter with mechanical and
electrical interlocks.
A reversing starter is electrically and mechanically
interlocked so that both contactors cannot close at the same
time and cause a dead short circuit. Mechanical
interlocking is done by means of an interference
mechanism which blocks the operation of the open
contactor when the other one is closed. Electrical
interlocking known as cross electrical interlocking -- STA
is done by auxiliary interlocks on each contactor. A
normally closed contact of the forward (F) contactor is
used in the reverse (R) contactor coil circuit. A normally
closed contact of the reverse (R) contactor is used in the
forward (F) contactor coil circuit.
Figure 10 shows an interlock which mounts on the starter
and is actuated whenever the starter is operated. These
normally closed electrical interlocks are shown mounted
between the forward and reverse starter arc boxes, in
Figure 9.
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 Schematics Made Easy
Fig. I Normally closed (NC) auxiliary electrical interlock as mounted
on reversing starter in Fig. 9 between both arc boxes. May also be
normally open (NO) for other applications.
There are two types of reversing circuits: Forward-
Reverse Compelling and Forward-Reverse Optional.
Forward-Reverse Compelling Compelling circuits are
used with motors which are not instantly reversible. These
motors are brought to a stop before changing direction of
rotation. In Fig. 11 depressing the forward push button will
energize the forward contactor coil (F), causing the motor
to rotate forward. At the same time, it opens the normally
closed (F) contact in the reverse contactor coil (R) circuit
and closes the normally open (F) contact around the
forward pushbutton to seal-in the circuit. As long as the
forward contactor is picked up, depressing the reverse
pushbutton will have no effect. This is because the (F)
contact is open in the reverse coil circuit.
The circuit derives its name because the operator is
compelled to depress the stop pushbutton before he can
change direction of rotation. Once the forward contactor
has dropped out and reclosed its normally closed contact
(F) in the reverse coil circuit, the rotation of the motor can
be started in the reverse direction.
Limit switches (LS) are shown in this circuit since it is
sometimes used for equipment such as overhead doors,
which are stopped with a limit switch at the end of the
door travel.

LS R
LS F REV.
R
Fig. 11. Forward-Reverse Compelling Circuit. Operator is compelled
to depress stop button before changing motor rotation.

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 Schematics Made Easy

Forward-Reverse Optional The optional circuit in Fig. Speed Compelling because the operator is compelled to
13 is similar to the compelling circuit with one exception It start in the lower speed.
utilizes a pushbutton with both normally open and
normally closed contacts such as shown in Fig. 12. Each
pushbutton with two sets of contacts is indicated by the
dotted lines connecting the two parts of the single buttons.
The normally closed contact on the forward push button is
connected in the reverse contactor coil circuit and the
normally closed contact of the reverse pushbutton in the
forward coil circuit.

Fig. 12. Pushbutton with Double Contacts.

With the motor running forward, pushing the reverse
pushbutton will open the circuit to the forward contactor
and cause it to drop out and close its normally closed (F)
contact in the reverse contactor coil circuit. The motor will
immediately be connected for reverse rotation. It will seal-
in and operate continuously in this direction until either
stopped with the stop pushbutton, or changed to the
forward direction again.
Note that it is not necessary to push the stop button before
changing directions as in the compelling circuit shown in
Fig. 11. Thus the terminology, Forward-Reverse
Optional. For this application, motors must be de signed
to go directly from full speed in one direction to full speed
in the other direction.

STOP

FOR.
Fig. 13. Optional Forward-Reverse Circuit. Stop button need not be
pushed when changing direction.

MULTI-SPEED CIRCUITS. Control of two-

speed motors, both single and two-winding, is
accomplished by the following two circuits depending
on application requirements. The common types of two-
speed circuits are known as Compelling and Non-
Compelling.
Two-Speed Compelling The circuit in Fig. 14 is used
in applications requiring: ( that the motor be started in low
speed before going to high speed, and (2) that the motor
not be switched from high speed to low speed with out first
depressing the stop pushbutton. This is known as Two-

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 Schematics Made Easy
Fig. 14. Two Speed Compelling Circuit. Motor must be started in low
speed. Stop button must be pushed before going from high to low.
A control relay (Fig. 15) designated as CR in the
diagram and referred to as a compelling relay ensures
that the motor is started in the low speed. The relay has
two normally open contacts. One is to seal it in after being
energized through a contact on the low-speed starter (L).
The other is located in the high-speed starter coil circuit to
prevent initial start on high speed. Upon changing from
low to high speed note that the low speed starter coil
circuit is opened by the normally closed contact of the
high- speed pushbutton.

Fig. 15. Control Relay (CR) with 2-pole contact block and magnetic
HIGH operator. Poles may be either Normally Open or Normally Closed.
Two-Speed Non-Compelling These circuits are used in
applications where the motor may be started in either high
or low speeds (Fig. 16). Speed can also be changed during
HIGH
operation between low and high by the operator, without
having to first bring the motor to a stop. This circuit is
LOW similar to the Forward-Reverse Optional circuit shown in
Fig. 13 and utilizes both normally open and normally
closed contacts on each of the low and high speed
pushbuttons.
STOP

L1

CR
L

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 Schematics Made Easy

Fig. 16. Two-Speed Non-Compelling Circuit. For applications where

motor may be started in high or low speeds.

H
L
H

LOW
HIGH

CR
L
H

L2

H-OL

L-OL

H
CR

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L
 Schematics Made Easy

SEQUENCE STARTING. Often, motors

controlled with separate starters must be started in
sequence from a single start-stop pushbutton station. This
can be done in two ways as shown in Figs. 17 and 19
depending on application requirements.
Sequence Start by Auxiliary Contacts In Fig. 17,
auxiliary contacts on the motor starters are used to provide
automatic sequence start from a single pushbutton station. OL OL
OL
This ensures that motor No. 1 must be running before
motor No. 2 is started and that motors 1 and 2 must be in TR1
operation before motor No. 3 can start. All the overload
relay contacts are wired in series so that an overload TR2
condition on any one of the motors will shut down the
complete system. Fig. 19. Timed Sequence Start Circuit uses adjustable time delay
relays. One motor comes up to speed before second is started.
START This type of circuit is used to permit one motor to come up
STOPto speed before the second motor is thrown on the line. Its
action prevents heavy line surges which result when more
than one motor is started at once on lines that do not have
sufficient capacity. Proper adjustment of the time delay
relays permits the power regulating equipment to recover
between automatic starting of multiple motors and
Fig. 17. Sequence start with auxiliary contacts on the motor starters. prevents serious dips in line voltages.
Sequence start activated from a single pushbutton station.
Individual pneumatic timing heads, operated directly from
Timed Sequence Start The timed sequence start circuit the movement of the magnetic starter armatures, can also
in Fig. 19 employs time delay relays with their coils be used on some types of starters (Fig. 20). They eliminate
connected in parallel with the motor starter coils. Their the need for time delay relay coils.
time delay contacts provide the automatic sequence
starting of the motors.

Fig. 20. Starter with timer head accessory operated from starter
armature.
In summary . . . it can be readily seen that although wiring
diagrams may seem to be complicated and unwieldy they
need not be. Much of the confusion and mystery can be
Fig. 18. Solenoid operated adjustable time delay relay.
removed by simply breaking the over-all control diagrams
into their basic circuits.
The power circuit furnishes power for the motor and load.
The individual control circuits usually operates only one
motor controller function.

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 Schematics Made Easy

SYMBOLS CHART

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 Schematics Made Easy

EXAMPLES:
L1 START L2
1 STOP2 3 OL
M M
Fig. 1. Three Wire Control Giving Low Voltage Protection Single Two
Button Pushbutton Station
L1 FOR FOR LS OL
L2
L1 L2 1 STOP REV2 6R
F
START OL F
1 STOP STOP STOP
2 3
M
START REV REV LS
FOR4 5 7F R
R
START Fig. 8. Three Wire Control for Instant Reversing Applications Using
Single Three Button Pushbutton
M Station
Fig. 2. Three Wire Control Giving Low Voltage Protection Multiple Two
Button Pushbutton Station
L1 FOR FOR LS L2
1 STOP2 3 R6 8
F
OL
L1 SAFE START L2
1 STOP 2 3 OL F
M REV LS
RUN M REV
Fig. 3. Three Wire Control Giving Low Voltage Protection with Safe-Run 5 F 7 9
4 R
Selector Switch R
Fig. 9. Three Wire Control for Reversing Using Single Three Button
L1 START L2 Pushbutton Station
1 STOP 3 OL
M
JOG 2 M L1 FOR LS L2
SLOW FAST
RUN 1 STOP4 2 6 8 S OL
Fig. 4. Three Wire Control for Jog or Run Using Start- Stop Pushbuttons
and Jag-Run Selector Switch F 5 CR S
CR S F
CR
L1 JOG L2 Fig. 10. Control for Two Speed with a Compelling Relay to Insure
1 STOP 2 4 OL Starting on Slow Speed
M
CR
L1 L2
START FOR RFOR LS
3 1 STOP REV2 3 6 8 OL
F
CR F
CR M
Fig. 5. Control for Jogging-Start-Stop All with Push buttons FOR4 REV5 F 7REV 9LS
R
L1 OFF L2 R
HAND AUTO 3 OL HIGH 10 LO
M HI
OFF 11 HI
AUTOMATIC SWITCH LO
LOW
Fig. 6. Two Wire Control Giving Low Voltage Release Only Using Hand- Fig. 11. Control for Two Speed Reversing Starter Forward, Reverse, Stop,
Off-Auto Selector Switch with High, Law Selector Switch

L1 FOR FOR LS L2 L1 RUN-JOG L2

1 3 R 6 8F OL 1 STOP 3 OL
M
REV REV LS 2 M
5 F 7 9R Fig. 12. Selector Push Contacts as shown for Run (three wire operation
rotate switch sleeve and selector contact opens between 2 and Stop
Fig. 7. Two Wire Control for Reversing Jogging. Using Single Two button (two wire operation).
Button Pushbutton Station

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