Electrical Troubleshooting

Troubleshooting Control Circuits—Unit 210, Lesson 3

Preface

A single circuit is usually responsible for the control of a single machine function. When
the control circuit fails to operate as expected, it is the electrical maintenance specialist
who is called upon to troubleshoot the circuit and restore it to good working order.

In order to troubleshoot in an efficient and effective manner, the electrician must be quick
to locate the section of the circuit that contains the trouble, and then be able to determine
which component is defective. This requires a familiarity with all aspects of control
functions, with components, and with circuit analysis.

This lesson explains control circuits and some of the more common problems associated
with them. It also explains diagnostic steps and procedures to follow when
troubleshooting control circuits.

Objectives

After studying this lesson, you should be able to…

• Explain how severe three-phase voltage unbalance affects a three-phase motor.

• List the advantages of inherent protection.
• Explain how undervoltage release works.
• Describe how to troubleshoot a motor circuit.

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Key Terms

Two-wire control

Three-wire control

Combination motor starter

Control-Circuit Functions

Control systems are usually designed so that an individual circuit controls only one
of a particular machine. The function may be the starting and
stopping of a motor by means of pushbuttons, the controlling of solenoid valves by limit
switches, or any other function. There are many variations of individual circuits, but you
should remember that a single circuit is usually associated with a single machine
function.

When a motor burns out, the question most often asked of the maintenance department is
“Why didn’t the starter protect the unit?” A properly installed and maintained magnetic
starter should protect a motor against . When something goes wrong,
is it due to an error in the use of the starter? Is it due to poor maintenance? Or is it due to
a built-in limitation of the starter?

You may find that the proper starter was installed with the correct overload heaters, and
the control circuit was apparently in good working order. Yet the motor burned out for
reasons that may be difficult or impossible to determine.

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An ordinary “off-the-shelf” three-phase magnetic starter will do a satisfactory job of
protecting three-phase motors under most circumstances. However, it has certain
limitations.

New starter designs provide special protective features, including the following:
• three overload elements
• ambient- compensation
• a “single-phase sensor” that detects current and readjusts
the normal trip point.

Trouble Conditions

Regular maintenance is extremely important for magnetic starters. However, even the
best maintenance practices cannot change inherent design characteristics. Some problems
are common to most magnetic starters. The problems most likely to occur are described
in the following paragraphs.

Voltage surges. Sudden increases in potential difference may be caused by lightning,

switching, , and blown . Voltage-surge failures
occur more often than most people realize, and they are usually difficult to detect.
Starters are not designed to protect against voltage surges. Using the proper combination
of lightning arresters and can be effective, but this method is too
expensive for general use.

Sudden bearing failure. Antifriction bearings seldom give any warning of premature
failure. Sudden failure of a worn or defective bearing can allow the to
drag on the . After even a few revolutions, the winding usually
becomes or . The sensing elements in the starter
have a built-in time delay that often prevents the starter from responding quickly enough
to prevent winding failure.

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Severe three-phase voltage unbalance. Voltage unbalance causes losses
and losses. The motor then runs inefficiently, and the temperature
rises above normal. To give adequate protection, the starter overload-sensing elements
must measure the total effect of the motor current. But usually the
starter has no way of changing its calibration as the motor starts to lose efficiency. The
motor is doing less mechanical for a given current, but the overload
relay does not sense the condition.

Three-phase motors are designed to operate on three potential

differences spaced 120 electrical degrees apart. If these potential differences become
unequal, the rotor is subjected to a that varies
at approximately twice the line frequency. This variation causes motor heating that is not
detected by the starter.

Modern rerated motor frames do not tolerate this condition as well as older motors do.
The modern three-phase overload devices provide better protection against overheating,
but they may not soon enough when the phases become unbalanced.

Single-phasing. Here again, modern three-phase current-sensing elements give better

protection against overheating than the older models. However, they must be closely
matched to the thermal capability of the .

Starters with three overload-sensing elements may not protect the equipment if an open
circuit occurs in one primary line of an ungrounded Y-delta or delta-Y transformer
supplying the motor.

If the motor continues to run on single-phase power (which it probably will, if not fully
loaded), two lines will carry low current and one will carry high current. The current in
one line can become double the current in the other two.

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The value of the current depends on the motor . If the high current is
in the phase without an overload-sensing element, the starter may fail to trip. This failure
is a fairly common cause of motor failure. It may affect a group of motors or an entire
system.

Improper calibration. Occasionally, thermal overload-sensing elements—of both the

bimetallic and the melting-alloy types—vary greatly from the manufacturer’s typical
time-current curves. The best way to detect this fault is to test the starter with a high-
current .

Defective insulation. Even under normal voltage stress, insulation may fail. The failure
may be caused by defects in manufacture, environmental conditions, ,
, and chafing.

Ordinary ohmmeter and high-potential ground tests will not detect weak insulation
between turns or from phase to phase. When insulation breakdown occurs, thermal
overload-sensing elements usually act too slowly to save the winding. Current-limiting
will minimize the damage, but they will not always prevent it.

Overvoltage. Overvoltage causes increased current because of increased copper and

core losses. Certain motors—including high-torque, multispeed, short-time-rated, and
slow-speed motors—are especially affected by overvoltage. These motors have problems
more often than ordinary motors. Generally, the the motor runs
the worse the effect, because the effect of overvoltage increases with the number of
in the motor.

If overvoltage is more than %, nuisance tripping can occur in the circuit

breakers. If larger overload heaters are substituted in the motor starter, you can expect
trouble. The first time there is an overload, stall, or unbalanced potential difference, the
oversized heaters will likely react too to prevent a burnout.

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NEMA rerated frames have improved operating characteristics in all areas of design
except tolerance to and voltage . Older 480 V
motors have been known to operate for years on 550 V. Today, manufacturers warn that
rerated motors should be limited to % overvoltage.

Rapid loading and unloading. If a motor is or rapidly,

thermal overload relays may not completely protect it. The mass of the thermal overload
device is less than the mass of the motor, so the thermal device more
quickly. A motor cannot get rid of heat as rapidly as an overload relay can. Therefore the
temperature of the overload relay will not match the temperature of the motor. The larger
the motor, the the difference between the two temperatures.

Conditions of Protection

There are other situations in which a conventional starter may not offer full protection.
The starter may be operating in surroundings where the ambient temperature is lower
than the temperature at the motor location. Or, the motor may not be properly ventilated.
These conditions are not caused by limitations in the starter, but by improper application
or maintenance.

Special equipment can be used to protect a motor against almost any set of
circumstances. However, such protection is not usually justified except for large or very
important motors. For smaller motors, -protection devices offer a
basic improvement over conventional magnetic starters. protection
has two advantages over conventional current overload-sensing devices.
• It permits loading the motor to its maximum output.
• It prevents restarting a hot motor before it has cooled.
Inherent protection consists of either or buried
in each phase of the stator winding.

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Heat-sensing may be placed in the windings when the stator is being
wound. They protect the motor from overheating caused by overloads, stalls, lack of
ventilation, single-phasing, high ambient temperature, and unbalanced voltages.
Large motors may be protected by custom-engineered starters having a number of
protective devices. These devices protect the motor against lightning, voltage surges,
premature bearing failure, excessive vibration, defective insulation, overload, low
voltage, single-phasing, and unbalanced voltages.

Differential relays cannot prevent failure, but they can disconnect

the motor quickly so that the resulting damage is . Often this rapid
action saves the cost of a complete motor rewind.

Where there are certain “problem” motors with many unexplained burnouts, the situation
should be analyzed and the basic reasons pinpointed.
• First, study the application carefully. Determine if the motor is .
See whether it has the proper . Check to see whether the
potential difference is reasonably .
• Then, consider some of the basic circuits.

Pushbutton Control Circuits

The motor in the circuit shown below starts and stops when the operator presses the
start and stop pushbuttons. This circuit is not commonly used, because it lacks
protection. If the potential difference across the coil drops below
the - value, the starter contacts drop out and shut off
the motor. But the contacts close again as soon as the potential difference returns to
normal, and the motor restarts without warning.

L1 Start L2
Stop MS1 OL

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The maintained start-stop device provides only undervoltage . It
interrupts the power to the main circuit when the potential difference falls below a preset
limit, but it does not maintain the interruption when the power returns to normal. This
characteristic is acceptable for and circuits, but
not for mechanical equipment. The restarting of machinery should be controlled only by
the operator.

The diagram below shows a momentary start-stop control circuit. This circuit
provides undervoltage protection. In this circuit, the power remains interrupted
after a reduction or loss of potential difference. This is accomplished by a
on the starter and momentary-actuated
pushbuttons.

L1 L2
Start MS1
Stop OL

MS1

Starter coil MS1 is energized when the operator presses the start pushbutton. The coil
closes contact MS1, which is connected in parallel with the start pushbutton, thus
electrically “sealing” the circuit. The start pushbutton then returns to the open position.
The starter remains energized because of the completion of the circuit through the MS1
contact.

The starter coil becomes de-energized and the seal-in contacts open if any one of the
following events occurs.
• The across the coil drops below the
minimum hold-in value.
• An in the motor causes the overload-relay contacts to open.
• The operator presses the stop pushbutton.

When the potential difference returns to normal after a reduction, the motor does

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not restart until the operator presses the start pushbutton. This is the undervoltage
feature. The operator is in complete control of restarting the motor.

Extra start-stop stations can be provided, as shown by the diagram below. Notice that the
stop pushbuttons are connected in , and the start buttons are
connected in with one another and with the seal-in contacts. Any
start pushbutton can start the motor, and any stop pushbutton can stop it.

L1 L2
Start MS1
Stop Stop Stop OL

MS1

Some control installations require an additional emergency stop button located some
distance from the master stop button. This feature can be provided by wiring an
additional stop button in with the master stop button. Either button
can break the holding-coil circuit and open the line contacts.

Many long conveyor lines and other large applications require two, three, or more start-
stop control stations located along the length of the equipment. The additional control
stations are wired into the same control circuit. Remember that buttons
are connected in series with one another, and buttons are connected in
parallel.

Sequence-Control Circuits

Two-wire control means that only two wires are connected to the device
that energizes the control. An example of this circuit is shown
below. In the diagram, the pilot device is a normally open pressure switch that energizes
the motor starter only as long as it remains .

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 L1 L2
MS1 OL
1 Pressure switch 2

This circuit provides undervoltage . However, it does not provide

undervoltage , because no seal-in contacts are provided. The motor
starter contacts drop out upon loss of voltage. But they immediately pick up again
(without operator control) when the potential difference returns to normal, provided the
pressure switch is then in the position.

In a three-wire control, as shown below, three wires must be connected to the pilot device
in order for it to operate the motor starter. Note that the momentary start-stop circuit
provides undervoltage protection.

L1 Start L2
Stop MS1 OL
3
1 2 MS1

The timed-sequence start circuit shown below uses - relays.

The coils of these relays are connected in with the motor-starter coil.
The time-delay relay contacts provide automatic sequence starting of the motors.
Individual timing heads, operated directly by the movement of the
magnetic-starter armatures, can also be used on some types of starters. They eliminate the
need for time-delay relay coils.

L1 Start L2
Stop MS1 OL
TR1
MS1
MS2

TR1 TR2
MS3

TR2

Troubleshooting Control Circuits

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A basic start-stop control circuit is used to start and stop a motor on command by the
operator. Other circuits may use switches instead. For example, a
float switch may start or stop a pump motor without action by an operator.

Timed- circuits permit one motor to come up to speed before a

second motor starts. This action prevents heavy line that result when
two or more motors start at the same time on lines that lack sufficient overcurrent
capacity. Proper adjustment of the time-delay relays allows the power-regulating
equipment to recover between automatic starting of multiple motors. The timed sequence
prevents serious drops in potential difference across the line.

A typical motor-control circuit with a start-stop station has seal-in contacts connected in
with the start contacts. When the operator presses the start button,
the circuit is completed to the solenoid coil, which closes both the main contacts and the
seal-in contacts.

The auxiliary contacts provide a path for the current to the coil.
When the operator releases the pushbutton, the seal-in contacts remain closed and the coil
remains energized. The coil therefore keeps the main contacts closed unless the potential
difference across the holding coil drops too low. The usual cause of a drop in potential
difference is the pressing of the , which is
connected in series with the auxiliary contacts.

When the operator presses the stop button, the coil releases the seal-
in contacts as well as the main contacts. The operator can then release the stop button.
The main contacts will remain open until the operator presses the start button.

If the seal-in contacts do not remain closed when the operator releases the start button,
you should examine the control circuit for the cause. Broken , poor
contacts, and connections are common causes of this problem.

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Overload-Protection Circuits

If an unprotected motor becomes overloaded, it draws more and more current until it
burns out. The motor can be protected from burnout by overload
relays. The addition of a overload relay changes the magnetic
contactor to a magnetic motor .

Thermal overload relays are placed in with two or three of

the motor leads. In this position they constantly monitor the motor current. The
current in the overload relays produces heat, which raises the temperature of a
contact mechanism. When the temperature becomes too high, the
thermal element opens a normally closed contact wired in series with the holding coil.
The holding coil is then de-energized. The motor starter contacts then drop out, and the
motor stops.

Overload relays can generally be reset after cooling for about min, and the
motor can be started again. If an overload persists, the overload relays will trip out again.
If that happens, you should find out why the motor is drawing excessive current.

Overload relays will not protect the motor unless they are the proper .
Check the manufacturer’s recommendations when installing an overload-relay element.
If the element is too , the motor will trip out frequently. If it is too
, the motor will not have the proper protection and may burn out.

Thermal overload elements are placed in series with the wires supplying the motor. In
this position, all the current to the motor must pass through the overload relays.

Thermal overload relays operate relatively . As a result, they do not

provide - protection. A fused safety switch may
be placed in the line ahead of the starter or built right into the same enclosure.

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The magnetic motor starter may be equipped with a circuit breaker. This kind of starter is
called a motor starter. It combines both overload protection and
short-circuit protection in one unit.

Troubleshooting a Motor Circuit

When a motor stops for no apparent reason, you may be called to determine the trouble.
Follow a step-by-step method of checking the motor starter to identify the problem.
The first item to check is the set of thermal overload relays. The operator may not have
allowed enough time for them to , or he may have failed to press the
button fully.

Open the door of the starter enclosure and observe the on

the thermal overload relays. Generally you can see if they are tripped. If the overload
relays seem to be in proper position, then make a thorough check with a .

On any service call, always make sure your voltmeter works properly. In a control system
the first things to check are the and the thermal overload elements.
These are the devices that protect the motor against short circuits and overloads.

With the cover of the motor control open, operate the safety latch so that the fused switch
can be thrown to the on position. Use a 500 V voltmeter to check the potential differences
from A to B, A to C, and B to C.

These three readings should all equal the line voltages. If not, check ahead of the fuses to
make sure that the correct potential differences exist between the incoming lines. If the
line-to-line voltages ahead of the fuses are not equal, trace the line back to the
distribution panel and measure the potential differences there.

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If the motor fuses check out properly, the next step is to check the fuse.
Then check the overloads. (Refer to the on-line material if you need
to review detailed procedures.)

If these preliminary tests check out perfectly, you will need to make more tests to locate
the source of trouble. It generally takes longer to make these tests and the
problem than to the problem. For this reason, effective
troubleshooting techniques must be fast and accurate, and they must help locate the
trouble as quickly as possible.

Effective troubleshooting is accomplished by first studying the diagram

and following the circuit through in a logical manner. At the same time, you place the
voltmeter across selected parts of the starter. The numbers on both the schematic diagram
and the wiring diagram help to locate these test points.

Numbers are assigned to the wires and to the terminal strips. All wires connected to a
common point have the same number. The only time the number changes is when the
circuit passes through a pushbutton, contact, coil, limit switch, or other circuit device.

The wiring diagram and the schematic drawing should be permanently mounted inside
the starter cover. The numbers on the drawing must correspond to
the numbers on the wires.

One of the secrets of effective troubleshooting is to take advantage of the test points
indicated in the . Doing so saves a great deal of time, because it is
not necessary to open the enclosure to test the components inside. Following the
schematic makes it easy to find the next component in the circuit. After finding the wires
in the physical wiring diagram, it is easy to locate the points in the starter.
(Refer to the on-line material if you need to review detailed procedures for checking a
starter control circuit having overloads, a start-stop station, and a limit switch.)

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You can improve your efficiency in troubleshooting a circuit by the process of dividing
the circuit into . Each test tells you whether the problem is to the
right or left of the test point.

You can usually make all the tests without opening any covers or disconnecting any
wires. When making these troubleshooting checks, the only time you normally need to
leave the starter locations is when checking the .

The up-or-down and forward-or-reverse starter control circuits can be checked in the
same manner. It is sometimes helpful to have the operator hold the in
the desired position during the checks.

are the most frequent cause of trouble in motor starters. They should
be inspected regularly for excessive burning or pitting, proper , and
proper pressure. When the contacts are silver-plated, the black silver oxide is a good
conductor and should never be removed. Silver contacts should never be filed unless they
are badly .

A common cause of failure of automatic control equipment is improper adjustment of

contacts and time-delay circuits. Usually the equipment manufacturer gives the proper
contact distances and supplies and other necessary information for
the proper timing of the time-delay circuit.

Coil is another common cause of trouble in motor starters. Coils

used in starters are generally well built and well insulated, which greatly reduces
problems caused by vibration and moisture. However, the coils themselves can still
burn out.

You can usually tell from a visual inspection of the components and the wiring if
insulation breakdown is the cause of the trouble. However, you can easily miss a
grounded wire in the control circuit during your visual inspection. If you suspect that a

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ground fault is the cause of the trouble, make careful checks—with the power .
Measure the to ground of the wires in that particular section if the
circuit.

The most important general rule in troubleshooting is to change only component

at a time.
• If you find a set of contacts that are not working properly, correct this problem
and try the circuit again before changing anything else
• If you find a coil burned out or otherwise defective, repair or replace it and try the
circuit again before making any other changes.
A common mistake made by some troubleshooters is to make several changes at once
before trying the circuit for operation.

Making several changes at one time can introduce more trouble than existed in the first
place. Following the two rules below will put you far ahead in and
increase your as a troubleshooter.
• Proceed through the circuit step by step.
• Correct only one problem at a time.

Now that you have studied the art of developing and testing control circuits, you should
be ready to analyze magnetic control circuits and troubleshoot them step by step.

Summary

Control systems are designed so that a single circuit usually controls a single machine
function. Regular maintenance is an important part of proper control circuit operation.
However, problems can arise, even with regular maintenance.

Magnetic starters, for example, can be adversely affected by voltage surges, bearing
failure, three-phase voltage unbalance, single phasing, improper calibration, defective
insulation, or rapid loading and unloading.

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Special equipment can be used to protect a motor against almost any set of
circumstances. However, the cost of such equipment often is not justified. Thermostats or
thermistors provide inherent protection without requiring the use of costly special
equipment.

Momentary start-stop control provides undervoltage protection. With this feature, the
operator is in complete control of restarting the motor. Three-wire control also provides
this protection.

Thermal overload relays protect against current overloads, but the relays must be of their
proper size for the motor in order to afford any protection. Such relays do not provide
short-circuit protection. Both overload protection and short-circuit protection can be
obtained by use of a combination motor starter. This is a magnetic motor starter equipped
with a circuit breaker.

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