CONTROL OF ELECTRICAL MACHINES

OBJECTIVES:
At the end of the topic, participants will be able to:

Describe control of electrical machines;

Mention the different methods of controlling motors;

Identify and Maintain control circuit component;

Demonstrate the various ways of starting motors

INTRODUCTION
A control system of a Machine manages commands, directs or regulates the behaviour of the
systems. It can range from a home heating controller, using a thermostat to control a domestic
boiler, to large Industrial control systems, which are used for controlling processes of machines.

MOTOR CONTROLLER
A motor controller is a device or group of devices that govern(s) 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. Every electric motor has to have
some sort of controller.

Methods of Control of Motors

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.

Manual Control Magnetic Control

 CONTROL CIRCUIT COMPONENTS
Industrial control, in its broadest sense, encompasses all the methods used to control the
performance of an electrical system. Every control circuit is composed of a number of basic
components connected together to achieve the desired performance. The size of the components
varies with the power of the motor, but the principle of operation remains the same.

The basic devices that form the control are as follows:

Disconnecting switches
Magnetic contactors
Thermal overload relays
Pushbuttons
Pilot lamp

Description of the Disconnecting Switch

A disconnector, disconnect switch or isolator switch is used to ensure that an electrical circuit is
completely de-energized for service or maintenance. The disconnector is usually not intended for
normal control of the circuit, but only for safety isolation. Isolator is a switch operated manually,
which separate the circuit from the power main and discharges the trapped charges in the circuit.

Isolator Switch

Safety switches are reliable and provide safety to property and your personnel in addition to
providing:
Protection against overcurrent
Protection against circuit overloads
Protection against short circuiting
Protection against heat-generated damage
Safety switches are designed to interrupt the power in the event of a single fault in the circuit.

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Magnetic Contactors
A contactor is an electrically controlled switch used for switching an electrical power circuit, similar
to a relay except with higher current ratings. Contactors come in many forms with varying capacities
and features. Unlike a circuit breaker, a contactor is not intended to interrupt a short circuit current.
A contactor is used to control an electric load in control systems. Contactors make or break a set of
contacts that control the voltage applied to some load Contactors range from those having a
breaking current of several amperes to thousands of amperes.

Contactors Contactor Symbol

Contactor Coil
I. Contactor Coil Characteristics depends on the type of wire and the manner in which it
is wound.
II. Contactor Coils are typically designed to operate on 24 volts, 120 volts, 208/240 volts
and occasionally 480 volts.
III. The coil is identified by the voltage marked on it.

Contactor Contact
I. The contacts of a contactor make a complete circuit when the contactor is energized,
allowing voltage to flow to the controlled load.
II. Contactors are rated by the ampere draw they can carry.
III. There are two types of loads that a contactor can control: an inductive load, and a
resistive load.
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 IV. Contacts are made of silver and cadmium which resists sticking.
V. The contactor contacts must be in good condition to ensure that proper voltage
reaches the load.

Contactor Contacts

Common Reasons for Contactor Failure

1. Some of the common reasons are excess current flowing through the contacts. High current
can be either due to overload or due to short-circuit. High current can cause the contacts to
melt.
2. Overvoltage causes high current to flow in the coil damaging it. Chattering can be another
reason for failure. Continual chattering damages the contacts and causes arcing.
3. Age is another reason for contactor failure. The winding in the coil are bonded together with
a varnish (encapsulation). This prevents movement of the coil windings when current passes
through the coil. Age can cause these coils to crack or move causing the insulation to
break.
4. Temperature can also cause the contactor to fail. Hence, adequate provision for ventilation
needs to be provided. The contactor should not be installed in places too hot.
5. Power Quality too has an impact on the life of the contactor. Transients, voltage and
frequency fluctuations can cause the coil to get damaged.
6. A corrosive environment which contains damaging chemicals or vapors can also cause
damage to the contactor coil.

Troubleshooting Common Magnetic Contactor Problems

1. Open Circuits: The very first thing that you should check is if the contactor coil can still move
the contact assembly. If the answer is no, you may be having an open circuit. An open circuit
stems from the inability of the contactor to energize. To be really certain, check the voltage
of the coil terminals. Do this with a circuit that has been power down. Set your multimeter in
a low ohm setting. The multimeter will record a high resistance. If this is the case, you should
try replacing the contactor coil.
2. Holding Does Not Close: If the problem isnt because of an open circuit, check the holding,
also known as sealing circuit, instead. Observe for if it closes. If the sealing circuit does not,
observe for any inconsistencies in the control circuit and any loose wiring connections in the
contactor auxiliary contacts. Normally, the contactor holding should close when there is
power.
3. Dirty Assembly: A sticky magnetic assembly can actually cause technical problems. If this is
the case, correct the problem with a non-conducting cleaner.

Description of the Overload Relay

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Thermal overload relays also known as Overload Release are economic electromechanical
protection devices for the main circuit. They offer reliable protection for motors in the event of
overload or phase failure.

Main benefits
Reliable protection for motors
Easy to create starters
Single mounting kits and wire reset for remote control available for specific applications.
Main features
Adjustable current setting ranges
Overload protection with phase loss sensitivity
Temperature compensation up to +60C
Automatic or manual reset, sealable
Stop and test function.

Overload Relay
Contact maintenance
To clean the contact tips, use this maintenance procedure:
1. Rub the contact tips lightly with fine emery paper.
DO NOT FILE THE CONTACT.
2. Remove small particles by rubbing with wet cotton wool or with a wet, clean cloth.
3. Remove the water on the contact tip surface with a dry, clean cloth. If possible, apply
acetone or carbon terachloride. Do not use petrol.

Contact replacement
Contact replacement becomes necessary if less than one- third of the original contact tip remains on
the contact. This can be ascertained by comparing the contact with a new one of the same starter.
When replacing contacts, change contact springs and leaf springs, if any.

Description of the Push-Button

A push-button is a simple switch mechanism for controlling some aspect of a machine or a process.

Push-Buttons Symbol

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Red pushbuttons can also have large heads (called mushroom heads) for easy operation and to
facilitate the stopping of a machine. These pushbuttons are called emergency stop buttons. The
contact block of a push button (spring return momentary contact) has two contacts, one normally
open (NO) and the other normally closed (NC). When the push button is pressed, NC contacts opens
and NO contacts closes. When the push button is released a spring inside the actuator assembly
brings back the push button and a spring inside the contact block brings the contacts back to their
normal position.

Pilot lamp
An electric lamp, used in association with a control, which by means of position or colour indicates
the functioning of the control; an indicator light or a control light.

MOTOR STARTERS
The primary function of a motor starter is to start and stop the motor to which it is connected.
These are specially designed electromechanical switches similar to relays in actions. The main
difference between a relay and a starter is that a starter contains overload protection for the motor.

Types of Motor Starters

Most of the industrial operation uses three-phase induction motors, as compared to any other type
of motor. The common AC Starters are:

Direct On Line Starters

Forward Reverse Starter
Star-Delta Starters

Direct-on-line (DOL) Motor Starter

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For motors rated below 5 HP, they are directly connected using DOL starter without reducing the
supply voltage (at initial condition). They are provided with overload Relay. This is because such
motors can withstand high starting current for short duration.

During start condition, normally open contact (NO) is pushed for fraction of a second and this makes
the magnetising coil becomes energised. The magnetic flux produced by the coil attracts the
contactor so that the motor is now connected to the supply.

It is the simplest, cheapest and most reliable method, hence widely used. The main disadvantage of
DOL starter is that the motor draws a very high current during start for a short period.

DOL starter connection circuit and diagram in animation

DOL Common faults and their remedies

S/N Complaint Reasons / Solutions

1. Motor does not start even though a) Coil does not get energised (see control wiring
'Start' button is pressed. However on diagram)
lifting the moving magnet manually,
motor starts. b) Check nylon strip on relay, Check nylon button below
start button.

2. Relay/coil has been charged. Check if red wire on the relay and black wire on the coil
However motor does not start when are properly connected.
green button is pressed.

3. Motor starts when green button is a) Blue wire is not connected properly or completely
pressed. It however stops absent,
immediately when it is released.
b) Hold-on contact moving strip is missing or

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 improperly placed.

4. Humming and/or chattering noise. a) Low supply voltage

b) Magnet faces unclean. Moving system functioning is

obstructed by dirt.

5. Use of starters on 230V supply. Coil obtains supply from across R & B supply. However
Incoming / outgoing lines wired. if in/out wires are connected on R & Y phases coil will
However motor does not start. not energise. You may connect all three phases in
series.

6. Thermostat/float switch/pressure No mistake in wiring here However it is necessary that

switch are wired to the starter. the stop button is of the stay-put type or locked in.Off
Motor cannot be stopped properly. position Alternatively, you could shut the main switch.
Motor stops on pressing stop
button. However it restarts on
releasing the same.

7. Motor does not restart immediately It takes a little time for the thermal bimetals to coil and
after tripping on O/L even though reset. Hence wait for 2-4 minutes before restarting.
resetting has been resorted to.

Forward and Reverse Motor Starter

This starter concept is same as Direct-on-Line Starter, but differs in terms of motor rotation, thus
controlling the AC induction motor rotation in either forward or reverse direction.

The forward-reverse motor control circuit consists of two DOL motor controller circuit, which are
connected side by side to accommodate the required forward and reverse function of the system.
The control circuit incorporates an interlocking contact inserted between the push button and the
contactor coils of each circuit to prevent the simultaneous activation of both forward and reverse
contactor coils at the same time.

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 1.5 kW forward Reverse single phase motor starter.

Star Delta Motor Starter

This is the most commonly used reduced voltage starter as it is the cheapest starter among all in
terms of smooth operation. In this method, induction motor is connected in star during start and
delta while running with rated speeds. The wiring diagram of this starter is shown in figure below.

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 Star delta motor starter.
Common faults and their remedies

S/N Complaint Reasons / Solutions

1. Motor works in Star. However it Check if only three wires are being terminated in
does not work properly In Delta and terminal box of motor. Six wires should be connected
refuses to take load. to starter. If shorting links are present they should be
removed.

2. a) Motor starts with difficulty in Star Reduce time delay from Star to Delta in case it is kept
or trips when additional load is very long.
present,
a) Or if a semi-automatic starter is being used, switch
b) Motor works in Star. However over from Star to Delta earlier than done previously.
stops when Delta connection comes
on. b) Possibly due to low system voltage.

3. a) Even though all six wires have a) Delta connection from motor is improper.
been connected, motor stops when
in Delta, b) Low system voltage. Star/Delta connection in starter
wrongly connected.
b) Motor stops when in Delta,
starter trips and fuse blows.

4. Relay has been changed in semi-
automatic starter, however when
the main switch is on, the motor
starts immediately without the
necessity of pressing the start
button. Motor stops in Star itself.
This is a usual complaint. You may have changed the
original relay yourself. All factory made relays have
loop-wires 2-3 wired, in semi-automatic starters. 2-4
terminals on relays must be connected. Check relay
before connecting it on starter.

5. Motor runs in reverse direction Phase sequence not correct, Interchange the supply

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 sequence

6. Motor runs in correct direction but Motor overloaded Relay tripping, Check the current &
stops immediately increase the relay setting appropriately

7. Motor not starting Low supply voltage, Wait till proper supply is restored.

CONCLUSION
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.

REFERENCES

https://en.wikipedia.org/wiki/Control_system
www.buddygo.crio.co.za/control_of_electrical_machines_for_drive

www.electrical4u.com

www.elprocus.com

www.electronicshub.org

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