437 CHAPTER 20 Basics of Industrial Motor Control 20.0 Introduction I ndustrial control, in its broadest sense, encom- passes all the methods used to control the perfor- mance of an electrical system. When applied to ma- chinery, it involves the starting, acceleration, reversal, deceleration, and stopping of a motor and its load. In this chapter we will study the electrical (but not electronic) control of 3-phase alternating- current motors. Our study is limited to elementary circuits because industrial circuits are usually too intricate to explain briefly. However, the basic prin- ciples covered here apply to any system of control, no matter how complex it may appear to be. 20.1 Control devices 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. Using only a dozen basic components, it is possible to design control 439 systems that are very complex. The basic compo- nents are the following: I. Disconnecting switches 2. Manual circuit breakers 3. Cam switches 4. Pushbuttons 5. Relays 6. Magnetic contactors 7. Thermal relays and fuses 8. Pilot lights 9. Limit switches and other special switches 10. Resistors, reactors, transformers, and capacitors The ensuing list of Basic Components for Control Circuits illustrates these devices. and states their main purpose and application. Fuses are not in- cluded here because they are protective devices rather than control devices. They are discussed in Chapter 26. The symbols for these and other de- vices are given in Table 20A. 440 ELECTRICAL AND ELECTRONIC DRIVES BASIC COMPONENTS FOR CONTROL CIRCUITS Disconnecting switches A discollnecting switch isolates the motor from the power source. It consists of 3 knife-switches and 3 line fuses enclosed in a metallic box. The knife-switches can be opened and closed simultaneously by means of an external handle. An interlocking mechanism prevents the hinged cover from opening when the switch is closed. Disconnecting switches (and their fuses) are se- lected to carry the nominal full-load current of the mo- tor. and to withstand short-circuit currents for brief in- tervals. Figure 20.1 Three-phase, fused disconnecting switch rated 600 V, 30 A. (Courtesy of Square D) Manual circuit hreakers A l11ol1lwl cirCllit bre{{ker opens and closes a circuit, like a toggle switch. It trips (opens) automatically when the current exceeds a predetermined limit. After tripping. it can be reset manually. Manual circuit breakers are often used instead of disconnecting switches because no fuses have to be replaced. Figure 20.2 Three-phase circuit breaker, 600 V, 100 A. (Courtesy of Square D) Cam switches A cam Slvitch has a group of fixed contacts and an equal number of moveable contacts. The contacts can be made to open and close in a preset sequence by rotating a han- dle or knob. Cam switches are used to control the mo- tion and position of hoists. callenders, machine tools. and so on. Figure 20.3 Three-phase surface-mounted cam switch, 230 V, 2 kW. (Courtesy of Klockner-Moeller) Pusnbuttons A pushbutton is a switch activated by finger pressure. Two or more contacts open or close when the button is depressed. Pushbullons are usually spring loaded so as to return to their normal position when pressure is re- moved. Figure 20.4 Mechanical-interlocked push buttons with NO (nor- mally open) and NC (normally closed) contacts; rated to interrupt an ac current of 6 A one million times. (Courtesy of Siemens) Control relays A control rela.v is an electromagnetic switch that opens and closes a set of contacts when the relay coil is ener- gized. The relay coil produces a strong magnetic field which attracts a movable armature bearing the contacts. Control relays are mainly used in low-power circuits. They include time-delay relays whose contacts open or close after a definite time interval. Thus, a time-delay closing relay actuates its contacts after the relay coil has been energized. On the other hand, a time-delay open in!!, relay actuates its contacts some time after the relay coil has been de-energized. Figure 20.5 Single-phase relays: 25 A, 115/230 V and 5 A, 115 V. (Courtesy of Potter and Brumfield) Thermal relays A thermal relay (or overload is a temperature- sensitive device whose contacts open or close when the motor current exceeds a preset limit. The current t10ws through a small. calibrated heating element which raises the temperature of the relay. Thermal relays are inherent time-delay devices because the temperature cannot fol- low the instantaneous changes in current. Figure 20.6 Three-phase thermal relay with variable current set- ting, 6 A to 10 A. (Courtesy of Klockner-Moeller) BASICS OF INDUSTRIAL MOTOR CONTROL 441 (continI/I'd) BASIC COMPONENTS FOR CONTROL CIRCUITS Magnetic contactors A magnetic contactor is basically a control relay designed to open and close a power circuit. It possesses a relay coil and a magnetic plunger, which carries a set of movable contacts. When the relay coil is energized, it at- tracts the magnetic plunger, causing it to rise quickly against the force of gravity. The movable contacts come in contact with a set of fixed contacts, thereby closing the power circuit. In addition to the power contacts, one or more normally open or normally closed auxiliary con- tacts are usually available, for control purposes. When the relay coil is de-energized. the plunger falls, thereby opening and closing the respective contacts. Magnetic contactors are used to control motors ranging from 0.5 hp to several hundred horsepower. The size, dimensions, and performance of contactors are standardized. Figure 20.7 Three-phase magnetic contactor rated 50 hp, 575 V, 60 Hz. Width: 158 mm; height: 155 mm; depth: 107 mm; weight: 3.5 kg. ( Courtesy of Siemens) Pilot lights Apilot light indicates the onloff state of a remote com- ponent in a control system. Figure 20.8 Pilot light, 120 V, 3 W mounted in a start-stop push- button station. (Courtesy of Siemens) Limit switches and special switches A limit switch is a low-power snap-action device that opens or closes a contact, depending upon the position of a mechanical part. Other limit switches are sensitive to pressure, temperature, liquid level, direction of rota- tion, and so on. Figure 20.9a Limit switch with one NC contact; rated for ten million operations; position accuracy: 0.5 mm. (Courtesy of Square D) Figure 20.9b Liquid level switch. (Courtesy of Square D) (a) (b) Proximity detectors Proximity detectors are sealed devices that can detect objects without coming in direct contact with them. Their service life is independent of the number of opera- tions. They are wired to an external dc source and gen- erate an alternating magnetic field by mean" of an inter- nal oscillator. When a metal object comes within a few millimeters of the detector, the magnetic field decreases, which in turn causes a dc control current to flow. This current can be used to activate another control device. such as a relay or a programmable logic controller. Capacitive proximity detectors. based on a similar prin- ciple but generating an ac electric field, are able to de- tect nonmetallic objects, including liquids. Figure 20.10 Proximity detector to monitor the loading of a conveyor belt. (Courtesy of Telemecanique, Groupe Schneider) In order to understand the sections that follow. the legends in Table 20A should be read before proceeding further. 20.2 Normally open and normally closed contacts Control circuit diagrams always show components in a state of rest, that is, when they are not energized (electrically) or activated (mechanically). In this state. some electrical contacts are open while others are closed. They are respectively called normally open contacts (NO) and normally closed contacts (NC) and are designated by the following symbols: normally open contact (NO) -1 ~ normally closed contact (NC) * 20.3 Relay coil exciting current When a magnetic contactor is in its de-energized or open position, the magnetic circuit has a very long air gap, compared to when the contactor is closed. Consequently, in the case of an ac contactor the in- ductive reactance of the relay coil is much lower when the contactor is open than when it is closed. Because the coil is excited by a fixed ac voltage, the magnetizing current is much higher in the open than in the closed contactor position. In other words, a considerable inrush current is drawn by BASICS OF INDUSTRIAL MOTOR CONTROL 443 the relay coil at the moment it is excited. This places a heavier than expected duty on auxiliary contacts that energize the coil. Example 20-1 A 3-phase NEMA size 5 magnetic contactor rated at 270 A, 460 V possesses a 120 V, 60 Hz relay coil. The coil absorbs an apparent power of 2970 VA and 212 VA. respectively, in the open and closed con- tactor position. Calculate the following: a. The inrush exciting current b. The normal, sealed exciting current c. The control power needed to actuate the relay coil compared to the power handled by the contactor Solution a. The inrush current in the relay coil is ISlE = 2970/120 = 24.75 A b. The normal relay coil current when the contac- tor is sealed (closed) is 1= SIE 2121120 = 1.77 A c. The steady-state apparent control power needed to actuate the relay coil is 212 VA. The appar- ent power that the contactor can handle is 5,' = EI 460 X 270V3 215 120 VA 444 ELECTRICAL AND ELECTRONIC DRIVES TABLE 20A GRAPHIC SYMBOLS FOR ELECTRICAL DIAGRAMS 1 0
32 + 15 or or 2
33 =@ =0 3
or
16 or or
34 -t>I- or 8 4 -I-H- or jJ 35 8 17 o or tv 5
>-- APPLICATION 6 18 -cD- or
1 36 7 i 19 f"VYY"\ 8 -./ - 20 --If- 37
] 9 1 1- \ 21 J[ T or or 38 0 i) 22 A::\ C4 10 * or r or t 23 3t identified by an appropriate letter 1- 24 ----11-- -< 11 o 0 ili 25 ----11-- or 39 26 12 ,,-.., or -0- 27 --< 13 0-0 0 28 0 0 40
29
0 0-"10 14 I 30
0 0 41 1. terminal; connection 2. conductors crossing 3. conductors connected 4. three conductors 5. plug; recep- tacle 6. separable connector 7. ground connection; arrester 8. disconnecting switch 9. normally open con- tact (NO) 10. normally closed contact (NC) 11. pushbutton NO; NC 12. circuit-breaker 13. single-pole switch; three-way switch 14. double pole double throw switch 15. fuse 16. thermal overload element 17. relay coil 18. resistor 19. winding, inductor or reactor 20. capacitor; electrolytic capacitor 21. transformer 22. current transformer; bushing type 23. potential transformer 24. dc source (general) 25. cell 26. shunt winding 27. series winding; commutating pole or compensating winding 28. motor; generator (general symbols) 29. dc motor; dc generator (general symbols) 30. ac motor; ac generator (general symbols) 32. 3-phase squirrel-cage induction motor; 3-phase wound-rotor motor 33. synchronous motor; 3-phase alternator 34. diode 35. thyristor or SCR 36. 3-pole circuit breaker with magnetic overload device, drawout type 37. dc shunt motor with commu- tating winding; permanent magnet dc generator 38. magnetic relay with one NO and one NC contact. 39. NPN transistor 40. PNP transistor 41. pilot light For a complete list of graphic symbols and references see "IEEE Standard and American National Standard Graphic' Symbols for Electrical and Electronics Diagrams" (ANSI Y32.2/IEEE No. 315) published by the Institute of Electrical and Electronics Engineers, Inc., New York, NY 10017. Essentially the same symbols are used in Canada and several other countries. Thus, the small control power (212 VA) can control a load whose power is 215 120/212 = 1015 times greater. 20.4 Control diagrams A control system can be represented by four types of circuit diagrams. They are listed as follows, in or- der of increasing detail and completeness: block diagram one-line diagram* wiring diagram schematic diagram Also called single-line diagram. 600 V 3-phases Figure 20.11 fused disconnecting switch Block diagram of a combination starter. BASICS OF iNDUSTRIAL MOTOR CONTROL 445 A block diagram is composed of a set of rectan- gles, each representing a control device, together with a brief description of its function. The rectan- gles are connected by arrows that indicate the di- rection of power or signal flow (Fig. 20.11). A one-line diagram is similar to a block diagram, except that the components are shown by their sym- bols rather than by rectangles. The symbols give us an idea of the nature of the components; conse- quently, one-line diagrams yield more information. A list of typical symbols is displayed in Table 20A. The lines connecting the various components repre- sent two or more conductors 20.12). A wiring diagram shows the connections be- tween the components, taking into account the physical location of the terminals and even the color thermal overload relay T thermal motor 600 V overload Figure 20.12 3-phase A elay M disconnecting fuse 'NO t t switch con ac start pushbutton cAJ relay coil PB2 'r =::J pilot light [ .. ' "- r--- stop A pushbutton auxiliary contact One-line diagram of a combination starter. 446 ELECTRICAL AND ELECTRONIC DRIVES 600 V 3-phase Figure 20.13 2 3 disconnecting switch 81 82 83 Wiring diagram of a combination starter. S Figure 20.14 Schematic diagram of a combination starter. F F of wire. These diagrams are employed when in- stalling equipment or when troubleshooting a cir- cuit (Fig. 20.13). A schematic diagram shows all the electrical connections between components, without regard to their physical location or terminal arrangement. This type of diagram is indispensable when trou- bleshooting a circuit or analyzing its mode of oper- ation 20.14). In the sections that follow, this is the kind of diagram we will be using. The reader should note that the four diagrams in Figs. 20.11 to 20.14 all relate to the same control 8 9 L 1 L2 L3 starter motor T1 AG 2 T2 80 0 T3 C 0 6 0 start-slop 7 pushbutton 8 station ~ A ~ A T T3 start stop T circuit. The symbols used to designate the various components are given in Table 20B. 20.5 Starting methods Three-phase squirrel-cage motors are started either by connecting them directly across the line or by applying reduced voltage to the stator. The starting method depends upon the power capacity of the supply line and the type of load. Across-the-line starting is simple and inexpen- sive. The main disadvantage is the high starting cur-