Let's discuss how to wire a relay and go through the concepts of how a relay works.

A relay is basically a switch but not like a switch that's on a wall. A wall switch relies on
someone to flip it which will then control a light or some other type load. A relay is switched
by electrical power and not a human. This is done by energizing a coil which is internal to
the relay and by energizing the coil, the relay changes state just like a wall switch would.
Therefore when you energize a relay, you are switching circuits off and on.
Relays have many purposes and are used in a variety of ways such as electronic circuit
boards, machines, appliances, automobiles and the list can go on. The main purpose of a
relay is to switch electrical circuits off and on at given times and allow circuits to be
automated. A great advantage with relays is the ability to switch many different circuits of
different voltage types all at once by using the same relay.

Wiring Relays

Although relays come in a huge variety of designs, shapes and sizes, They all basically work
with the same concept. I'm going to be covering some industrial relay logic and the images you
see here are some of the most common types used for industrial controls also called machine
controls.

These images show a square 3-pole relay and it's socket on the left and a round 2-pole relay and
it's socket on the right. The socket is used to connect your wires to the relay. This particular relay
with 3-poles means you have 3 separate switches or what we'll call contacts.
3 Common
3 Normally Closed
3 Normally Open

A 2-Pole relay will contain 2 separate contacts.

2 common
2 Normally Closed
2 Normally Open

And So On.
The square relay pinout shows how the relay socket is configured for wiring. This pinout image
is only a 2-pole diagram for room on the page purposes, but you can get the picture here with this
one since a 3-pole will just have 1 more set of contacts. As you can see, there is absolutely no
difference between the square type and the round type other than the ratings on the relay.
Otherwise they work exactly the same.

So when wiring up these relays, the coil wire's will connect to pins 2 & 7 on the socket.

One Pole Has:

Pin's 1 & 3 as Normally Open
Pin's 1 & 4 as Normally Closed

The Other Pole Has:

Pin's 8 & 6 as Normally Open
Pin's 8 & 5 as Normally Closed

See my Switch Terminology Page for more on contact arrangements if you need to.

By looking at the diagram below we can go through the basic concept of a relay and how they
operate. This diagram will show you how simple it is to control motors, lights, valves, other
relays and any type load you want. In this example we are simply turning on a light.

Let's say were using household voltage in this circuit which is 110/120 Vac. L1=Hot and
L2=Neutral. Just like basic house wiring, we always want to control (switch) the hot wire. So as
you can see below, L1 goes down into a normally closed switch. This means the current travels
through that switch until it see's an open switch and cannot go any further. In this case L1 is hot
all the way to the START switch. When the start switch is depressed, L1 now goes to the relay
coil MCR (Master Control Relay) and energizes the coil. Now the (2) MCR contacts which are
normally open as shown will now close. This allows current flow through the contacts and
energizes the light.

Now that the contact below the START switch is closed, you can now release the START switch
and the current flow goes around the open START switch, through the contact to keep the relay
coil energized which also keeps the light on. Now to turn the light off, you simply depress the
STOP button and this will open the circuit to the relay, de-energizing the coil. The relay contacts
open to their normal state and stop the current flow to light. Once you let off of the STOP button
the circuit is back to it's normal state with L1 waiting for the START button to be depressed.

There you have it. A relay circuit. Now these diagrams are known as relay logic or ladder
diagrams. It's using relays to control the circuit and also the diagram will begin to take the shape
of a ladder as the relay logic grows. It will continue downward as you will see later on.

Now in the diagram below I have added a motor starter. A motor starter is just another name for
a certain type of relay that is used to control a motor. We'll call this MTR1(Motor1). The logic
here is the same as above with the exception of adding control to the circuit so that any of the
circuit below the MTR1 contact will not be hot until the MTR1 coil is energized, which closes
the MTR1 contact. This allows current to flow to the lower part of the diagram (Not Shown) and
turns on the "MOTOR RUNNING LIGHT".
 Motor Starter
 ELECTRICAL
0 COMMENT

Induction Motor
An induction motor is a 3 phase motor consisting of the 3 phase winding as the stator
with a permanent magnet and the rotor as another 3 phase windings. It works on the
principle of rotating magnetic field, i.e. the formation of the magnetic flux from 3 phase
winding fluxes, which rotates about its axis, causing the rotor to rotate. An Induction
motor has the ability to self start owing to the interaction between the rotating magnetic
field flux and the rotor winding flux, causing a high rotor current as torque is increased.
As a result the stator draws high current and by the time the motor reaches to full
speed, a large amount of current (greater than the rated current) is drawn and this can
cause heating up of the motor, eventually damaging it. To prevent this, motor starters
are needed.

Inducation Motor
Need for Motor Starting
In an induction motor, when supply is given to the stator windings, the rotating magnetic
field flux and the produced flux in the rotor windings due to the back emf, causes the
motor torque to increase, causing a high rotor current. During the time between the
application of electric supply to the motor and the actual acceleration of the motor to its
full speed, a large amount of current is drawn by the stator from the supply. This starting
current is about 5 to 6 times more than the full load current. This time duration can be
for few seconds or longer. This causes the electrical equipments to damage because of
the increasing voltage drop in electrical systems due to flow of larger currents across
the cable. For this reason, a definite method of starting the motor is needed.

Definition of Motor Starter

It is the device connected in series with the motor to decrease its starting current and
then increase it as the motor starts rotating gradually. It consists of a connector which
acts as a switch to control flow of current to the motor and a overload unit which
measures the flow of current through the motor and controls the halting of motor in case
of large current being drawn.

Principle of Motor Starter

The current drawn by the motor can be controlled by reducing the back emf (possible by
reducing the supply voltage) or by increasing the rotor resistance during the motor
starting.

Types of Motor Starters

Direct On line: It consists of simple push button as the controller. When the start button
is pressed, the switch connecting the motor and the main supply is closed and the
motor gets the supply current. In case of over current, the stop button is pressed and
the bypass auxiliary contact is opened.

Star Delta: The 3 windings are first

connected in star connection and then after some time (decided by the timer or other
controller circuit) the windings are connected in delta connection. In star connection, the
current drawn is 0.58% of the normal current and also the phase voltage is reduced to
0.58%. Thus the torque is reduced.
 Auto Transformer starter: It consists of an
auto transformer (A Transformer with a single winding tapped at different points to
supply percentage of it primary voltage across secondary) in star connection, which
reduces the voltage applied to the motor terminals. It consists of 3 tapped secondary
coils connected to the three phases. In the starting period the transformer allows
application of lower voltages to the three windings.

Stator Resistance Starter: It consists of three resistors in series with each phase of the
stator windings, which causes a voltage drop across each resistor and as a result a low
voltage is applied to each phase.
Rotor Resistance Starter: It consists of 3 resistances connected in series with the rotor
windings, thus reducing the rotor current, but increasing the torque.

Application of Star Delta Starter to Control Starting of

Induction Motor
The star delta starter is the cheapest among all the starters and is suitable for
applications like machine tools, pumps, motor generators etc. A star delta starter can be
used in starting an induction motor by using 2 relays as the connector and the timer as
the controller. 1 connector is used to provide the mains supply while the other connector
controls the connection of motor in star or delta connection.
Transformers are used, primaries of which are connected to the 3 phase supply and the
secondaries are connected to the relays and the timer in such a way that failure of any 1
phase will stop the supply to the timer. The two relays are used to trigger the timer,
which develops a high logic output at pin 3, thus switching on the relay 4, causing the
supply in star connection, which offers low power intensity to the load by isolating the
load from the normal 3 phase supply through relay 3 (operated by the two triggering
relays). After some time, the timer (operating in mono stable mode) output goes low
(time being decided by the RC combination at pins 2 and 6) and the relay 4 is switched
off, thus causing the 3 phase supply to be given to the motor and the motor operates in
delta mode.

Some more regarding this starting of induction discussed below.

Soft Start of Induction Motor by Stepped Delay of Reducing

Firing Angle
Soft Start and Soft Stop:
In normal startup of the induction motor, more torque is developed, which causes the
stress to be transferred to the mechanical transmission system resulting in excessive
wear and failure of the mechanical parts. Also as acceleration increases, high current is
drawn which is about 600% of the normal run current. This can be seldom solved using
a star delta starter.
Soft start provides a reliable and economical solution to these problems by delivering a
controlled release of power to the motor, thereby providing smooth, steeples
acceleration and deceleration. The damage to windings and bearings are reduced,
resulting in an extended motor life.

With this technique, a controlled starting and stopping is achieved with proper selection
of ramp times and setting of the current limit.

 Less mechanical stress.

 Improved power factor.
 Lower maximum demand.
 Less mechanical maintenance.
This technique is suitable for applications where torque transients are frequent, such as
in pumping fluids, which can ultimately lead to rupture pipes and couplings.

Technology followed in Soft Starter:

A soft starter is a type of reduced voltage starter for AC induction motors. The soft
starter is similar to a primary resistance or primary reactant starter in that it is in series
with the supply to the motor. The input current to the started equals its output current. It
consists of solid state devices to control the current flow and the voltage applied to the
motors. The soft starters can be connected in series with the line voltage or connected
inside the delta loop.

Voltage Control:
Solid state AC switches are arranged in series with one or more phases to achieve
voltage control.

Use of Solid state switches:

1 x Triac per phase

1 x SCR and 1 x Diode reverse parallel connected per phase.

2 x SCRs reverse parallel connected per phase.

Varying the conduction angle of the switches can control the average voltage as
increasing conduction angle can increase the average output voltage. This process
proves advantageous with improved efficiency and lesser power dissipation. Also the
average voltage can be easily altered using control electronics.
 Photos Credit:

What is a Protection Device?

Different types of Protection
Devices
 ELECTRICAL
 ELECTRONICS
0 COMMENT

Protection devices for electrical circuits accomplish two main functions namely
consistency as well as protection. Protection is assured through detaching power supply
in a circuit through overcurrent protection, which removes fire hazards and
electrocution. Additionally, the accurate protection may be required to obey with
organization principles for some products. Designers must take time to know the
different protection devices for circuits. Protection devices used to protect circuits from
extreme voltages or currents. This article discusses what is a protection device, and
types of protection devices used in electrical and electronic circuits.
What is a Protection Device?
The circuit protection device is an electrical device used for preventing an unnecessary
amount of current otherwise a short circuit. To ensure the highest security, there are
many protection devices available in the market which offers you a total range of
protection devices for circuits such as a fuse, circuit breakers, RCCB, gas discharge
tubes, thyristors, and more.
Different types of Protection Devices
The different types of circuit protection devices examples include the following.
 Fuse
 Circuit Breaker
 PolySwitch
 RCCB
 Metal Oxide Varistor
 Inrush Current Limiter
 Gas Discharge Tube
 Spark Gap
 Lightning Arrester

Types of Circuit Protection Devices

Fuse
In electrical circuits, a fuse is an electrical device used to protect the circuit from
overcurrent. It consists of a metal strip that liquefies when the flow of current through it
is high. Fuses are essential electrical devices, and there are different types of fuses
available in the market today based on specific voltage and current ratings, application,
response time, and breaking capacity.
The characteristics of fuses like time and current are selected to give sufficient
protection without unnecessary disruption. Please refer the link to know more about:
Different Types of Fuses and Its Applications
 Fuse

Circuit Breaker
A circuit breaker is one kind of electrical switch used to guard an electrical circuit
against short circuit otherwise an overload which will cause by excess current supply.
The basic function of a circuit breaker is to stop the flow of current once a fault has
occurred. Not like a fuse, a circuit breaker can be operated either automatically or
manually to restart regular operation.

Circuit breakers are available in different sizes from small devices to large switch gears
which are used to protect low current circuits as well as high voltage circuits. Please refer
the link to know more about: Types of Circuit Breaker and Its Importance

Circuit Breaker

Poly Switch or Resettable Fuse

A resettable fuse is a passive electronic component used for protecting electronic
circuits from over-current mistakes. This device is also called as a poly switch or multi
fuse or poly fuse. The working of these fuses is same as PTC thermistors in particular
situations, however, work on mechanical transforms instead of charge-carrier-
effects within semiconductors.
Resettable Fuses are used in several applications like power supplies in computers,
nuclear or aerospace applications where substitution is not easy.

Polyswitch

RCCB or RCD
The RCD-residual current device (or) RCCB- residual current circuit breaker is a safety
device which notices a problem in your home power supply then turns OFF in 10-15
milliseconds to stop electric shock. A residual current device does not give safety
against short circuit or overload in the circuit, so we cannot change a fuse instead of
RCD.

RCDs are frequently incorporated with some type of circuit breaker like an MCB
(miniature circuit breaker) or a fuse, which guards against overload current in the circuit.
The residual current device also cannot notice a human being due to by mistake
touching both conductors at a time.

These devices are testable as well as resettable apparatus. A test button securely forms
a tiny leakage condition; along with a reset button again connects the conductors after
an error state has been cleared.
 RCCB

Inrush Current Limiter

This is one type of electrical a component used to stop inrush current for avoiding
regular damage to apparatus and evade tripping circuit breakers and blowing fuses. The
best examples of inrush current limiter device are Fixed resistors as well as NTC
thermistors.

They present a high resistance firstly, which stops huge currents from flowing by turn-
on. Because the flow of current will continues, NTC thermistors heat-up, permitting high
flow of current throughout normal operation. These thermistors are generally much
superior to measurement kind thermistors, which are intentionally planned for power
applications.

Inrush Current Limiter

Lightning Protection
The lightning protection includes MOV (metal oxide varistor) and gas discharge tube
Metal Oxide Varistor
A varistor or VDR (voltage dependent resistor) is an electronic component and the
resistance of this is changeable and depends on the applied voltage. The term
varistor has been taken from the variable resistor. When the voltage of this component
increases then the resistance decreases. In the same way, when an extreme voltage
increases then the resistance will decrease significantly.
This performance creates them appropriate to guard electrical circuits throughout
voltage flows. Origins of a flow can comprise electrostatic discharges as well as
lightning strikes. The most frequent type of voltage-dependent resistor is the MOV
(metal oxide varistor). Please refer the link to know more about varistor/voltage-
dependent resistor circuit with working

Gas Discharge Tube

A gas discharge tube or gas-filled tube is a collection of electrodes in a gas inside a
temperature resistant envelope and insulating. These tubes use phenomena allied to
electric discharge within gases, also work through ionizing the gas by an applied voltage
enough to reason electrical conduction through the fundamental phenomena of the
Townsend expulsion.

An expulsion lamp is an electrical device which uses a gas-filled tube such as metal
halide lamps, fluorescent lamps, neon lights, and sodium-vapor lamps. Specific gas-filled
tubes namely thyratrons, ignitrons, and krytrons are employed as switching devices in
various electrical devices.
The required voltage to begin and maintain discharge is reliant on the force, geometry
of the tube, and composition of the fill gas. Even though the cover is normally glass,
power tubes frequently employ ceramics, as well as military tubes frequently employ
glass wrinkled metal.
 Gas Discharge Tube

Crowbar vs. Clamping

The terms Crowbar vs. Clamping is regularly used to explain how overvoltage protection
devices work in a temporary event. A crowbar protection device decreases the voltage
under the system’s operating voltage. As the impermanent is complete, the crowbar
device retunes and lets the circuit to function usually. Throughout a temporary
occurrence, a clamping device grasps the voltage just higher than the operating voltage
of the system.
ESD Protection
This device protects an electrical circuit from an ESD (Electrostatic discharge), in order
to avoid a breakdown of a device. Murata has a wide array of ESD protector devices
comprising particular devices very small devices, for high-speed communication, &
included noise filters. ESD Protection devices can also be utilized to change Zener
diodes (TVS), varistors, as well as suppressors.

ESD Protection

Surge Protection Device

The term SPD stands for Surge Protection Device is one type of component used in an
electrical fitting security system. The SPD device is allied in parallel in the power supply
circuit, which can be used on all stages of the power supply system. The surge
protection device is the most frequently used and also well-organized kind of over-
voltage protective devices.

Surge Protection Device

This is all about protection device and its types. The protection of the circuit can be
done by using different protection devices in an electrical circuit purposely in order to
stop extreme amounts of current. To make sure extreme safety, this article gives an
overview of circuit protection techniques, namely circuit breakers, ESD
protection electronic fuses, gas discharge tubes, thyristors, and many more.