BASIC MOTOR CONTROL

Enabling a 1
Microelectronic World
Objectives:
Using the Industrial Motor Control board , participants should
be able to learn the following:
• Understand the basic concept of an Industrial Motor control.
• Describe the basic construction & components of a motor.
• Read the basic line / schematic diagram, and identify various symbol therein.
• State the difference between manual and automatic operation.
• Describe the typical motor starting methods.
• Perform troubleshooting of Industrial motor.

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COURSE OUTLINE:
• Intro to DC Motor
• Principle & Operation of DC Motor
• Parts & Components of a DC motor
• Control System for DC motor
• Intro to AC Motor – 3 phase
• Principle & Operation of AC Motor(3 phase)
• Parts & Components of an AC motor
• Control system for AC motor
• Motor Troublshooting

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 INTRODUCTION of DC Motors
D.C. motors are motors that run on Direct Current from a battery or D.C. power
supply. Direct Current is the term used to describe electricity at a constant
voltage. When a battery or D.C. power supply is connected between a D.C.
motor's electrical leads, the motor converts electrical energy to mechanical work
as the output shaft turns.

The armature and field in a DC motor can be wired three different ways to
provide varying amounts of torque or different types of speed control. The
armature and field windings are designed slightly differently for different types of
DC motors. The three basic types of DC motors are the series motor, the shunt
motor, and the compound motor.

It is important to understand each of the function and operation of the basic

components of the DC motor, since motor controls will take advantage of these
design characteristics to provide speed, torque, and direction of rotation control.

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 What is a DC Motors?
The DC motor has two basic parts: the rotating part that is called the armature,
and the stationary part that includes coils of wire called the field coils. The
stationary part is also called the stator. The armature is made of coils of wire
wrapped around the core, and the core has an extended shaft that rotates on
bearings. The ends of each coil of wire on the armature are terminated at one
end of the armature. The termination points are called the commutator, and this
is where the brushes make electrical contact to bring electrical current from the
stationary part to the rotating part of the machine.

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How DC motor works?

In DC motors, DC voltage is applied directly to the field winding and the brushes.
The armature and the field are constructed as a coil of wire. When voltage is
applied to the motor, current begins to flow through the field coil from the
negative terminal to the positive terminal. This sets up a strong magnetic field in
the field winding. Current also begins to flow through the brushes into a
commutator segment and then through an armature coil. The current continues
to flow through the coil back to the brush that is attached to other end of the coil
and returns to the DC power source. The current flowing in the armature coil sets
up a strong magnetic field in the armature that makes the shaft to rotate.
+ +

Field Winding
Pole Piece
Armature

i armature Commutator
Carbon Brush
i field
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DC Motor Construction

Field Windings
Field windings are mounted on the pole pieces to form electromagnets once DC
voltage is supplied to the windings.

Armature
The armature rotates between the poles of the field windings. The armature is made up of
shaft, core, armature windings, and a commutator. The armature windings are normally
wound in every slots of the core.

Commutator
Is an electrical assembly that acts as a switch that periodically reverses the current in
an electric motor or electrical generator. It enables a motor to run on, and a generator
to produce, a direct current.
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Brushes
The brushes are made of carbon-composite material. Usually the brushes have copper
added to aid in conduction. Other material is also added to make them wear longer. The end
of the brush that rides on the commutator is contoured to fit the commutator exactly so that
current will transfer easily. The process of contouring the brush to the commutator is called
seating. Whenever a set of new brushes is installed, the brushes should be seated to fit the
commutator. The brushes are the main part of the DC motor that will wear out. The brushes
ride on the commutator segments to make contact so that current will flow through the
armature coil.

Brush Rigging
The brush rigging is an assembly that securely holds the brushes in place so that they
will be able to ride on the commutator. It is mounted on the rear end plate so that the
brushes will be accessible by removing the end plate.

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DC Motor Operation & Principle
1
2

As the DC voltage is applied to the winding field and armature coils thru carbon brushes that ride on the commutator, this will create of what we called magnetic
field. Once the conductors starts to rotate (along with the commutator), the current will flow from the negative side of the commutator to the positive side of the
commutation.
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 3 Types of Brush DC Motors
• Series DC Motor
• Shunt DC Motor
• Compound DC Motor
• Short-shunt
• Cummulative
• Differential
• Long-shunt
• Interpole

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SERIES DC Motor provides high starting torque and is able to move very large
shaft loads when it is first energized. Series connection of field winding & armature
attribute that gives the series motor its name.

Brush

Brush

HOW Series motor operate?

Since the field winding is connected in series w/ the armature this means that
power will be applied to one end of the series field winding and to one end of the
armature winding. When voltage is applied, current begins to flow from negative
power supply terminals through the series winding and armature winding this
cause the motor to draw current from the power supply and will create a strong
magnetic field for the armature to rotate
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SHUNT DC Motor is different from the series motor in that the field winding is
connected in parallel with the armature instead of in series. Since the field winding
is placed in parallel with the armature, it is called a shunt winding and the motor is
called a shunt motor.

HOW SHUNT motor operate?

A field coil is made of fine wire, it cannot produce the large current for starting like
the series field. This means that the shunt motor has very low starting torque,
which requires that the shaft load be rather small.
When voltage is applied to the motor, the high resistance of the shunt coil keeps
the overall current flow low. The armature for the shunt motor is similar to the
series motor and it will draw current to produce a magnetic field strong enough to
cause the armature shaft and load to start turning.
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DC COMPOUND Motor is a combination of the series motor and the shunt motor.
It has a series field winding that is connected in series with the armature and a
shunt field that is in parallel with the armature. The combination of series and
shunt winding allows the motor to have the torque characteristics of the series
motor and the regulated speed characteristics of the shunt motor.

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Exercises : Forward – Reverse using Series DC Motor

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Exercises : Forward – Reverse using Shunt DC Motor

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 INTRODUCTION of AC Motors
Motors are electromagnetic devices that are used to convert electrical energy
into mechanical work. A.C. motors run on Alternating Current, which oscillates
with a fixed cycle between a positive and negative value. There are three classes
of AC motors – synchronous motors, induction motors and series wound motors.
The most common motor classes are synchronous and induction.

An induction machine is an asynchronous machine that has a magnetic circuit

interlinked with two electric circuits, or sets of circuits, rotating with respect to
each other. Power is transferred from one circuit to another by electromagnetic
induction.

A synchronous machine is an alternating-current machine in which the average

speed of normal operation is exactly proportional to the frequency of the system
to which it is connected.

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 WHAT is a AC Motor?

• Also termed as a polyphase motors – (a 2 or more windings or coils)

• Smaller in size, lighter in weight and have higher efficiency per HP
• Extremely rugged and require little maintenance

Trainer’s guide:
AC motor is a device which uses electrical energy to produce motion.
Motors may be parts of pumps or fans or connected to other equipment
Such as Winders, Conveyors and Mixers.

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How AC motor works?

AC motor has a fixed outer portion which is called the STATOR and a ROTOR
that spins inside. Between the stator and the rotor, there exists an air gap,
through which due to induction, the energy is transferred from the stator to the
rotor. The generated torque forces the rotor and then the load to rotate.
Regardless of the type of rotor used, the principle employed for rotation
remains the same.

Air gap

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AC Motor Construction

Stator Core
The stator consist of a core made of thin, stacked laminations of aluminum or
cast iron that are wound with insulated wire. As current passed through the
wire, the stator acts as a electromagnet. The number of poles of an AC motor
depends on the internal connection of the stator winding. The stator winding is
connected directly to the power source.

FRONT VIEW

ISOMETRIC VIEW

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Parts & Constructions
Rotor
The rotor is made up of several thin steel laminations with evenly spaced bars, which
are made up of aluminum or copper, along the periphery. The rotor consists of a
cylindrical laminated core with axially placed parallel slots for carrying the conductors.
Each slot carries a copper, aluminum, or alloy bar. These rotor bars are permanently
short-circuited at both ends by means of the end The rotor is mounted on the shaft
using bearings on each end; one end of the shaft is normally kept longer than the other
for driving the load.

Slip ring Slip ring

Conductors

Shaft

Bearing
Bearing Skewed slots
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Parts & Constructions
Slip Ring
These are metal rings that provide a continuous electrical connection through brushes
on stationary contacts. They are generally mounted on the rotating part of a machine.
When selecting slip rings, try to consider the operating speed, operating temperature,
maximum switching voltage/current, maximum operating voltage/current (rotor side).

Brushes
Mostly made of carbon materials. Carbon brush provide the switching/contact with the
slip rings. They are normally found in all DC motors.

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 Types of AC Induction motor
• Single phase induction motor
• Three-phase induction motor
• Induction motor
• Synchronous motor

Trainer’s guide:
We will discuss only the 3 phase AC motor

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Squirrel cage motor
This type of motor acts the same as the magnet. It consist of this laminated conducted
bars that have their end shorted by the end plates (or rings). When the power is applied to
the stator and as the current flows to the winding, a electromagnetic field is develop
causing to induced a voltage on the conductor bars. In effect, the rotor becomes an
electromagnet with alternating NORTH & SOUTH poles since the AC supply current
continuously change direction and amplitude.
• Wound rotor motor
The difference of wound rotor to squirrel cage is instead of conductor bars, wound rotor
consist of wounded coils that are connected (shorted) through the slip rings and brushes
to external variable resistors. Once supplied, the rotating magnetic field of the stator
induces a voltage in the rotor windings causes the rotor to rotate. This type of motor
varies the speed of its rotation, increasing the resistor decrease the speed of the motor.
Deceasing the value of resistor increase the speed of the motor.
• Synchronous motor
Sync motor sometimes its called is constructed somewhat like a squirrel cage rotor. In
addition to conductor bars, a coil winding are added. This coils windings are connected to
an external DC supplies thru the slip rings and ring brushes. As the AC source is applied,
the rotor will act as squirrel cage and once attain its maximum speed a DC supply will
apply to the rotor coils creating a strong constant magnetic field in the rotor. This event is
sometimes called LOCKED ROTOR STEP as it locks in step with the rotating magnetic
field in the stator.
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Input/Output Devices

Pushbuttons
A pushbutton is a control device used to manually open and close a set of contacts.
Pushbuttons come either normally-open , normally-closed or combination of contacts.

Switches
Is a device for making or breaking an electric circuit, or for selecting between multiple
circuits.

Pilot Lamp
This type of devices provide visual information of the circuit’s operating condition. They
are typically used as “ON/OFF” indicators, caution alerts, changing condition signals,
and alarm signal.

Buzzer
Same purpose as the pilot lamp. However, instead of visual it gives audio information.

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Control Components
Fuse/Circuit Breakers
Fuses and Circuit breakers are components that protects the motor circuits against
short circuits, ground faults and overloads.
Overload Relays
Overload relays are designed to meet protection needs of the motor circuits. It is
designed to TRIP and OPEN a circuit if the current is high enough to cause motor
damage over a period of time.
Contactors/Starters
These are devices that makes/breaks of your motor. They are used to control power in a
variety of applications. For motor applications, contactors/starters used for Start/Stop of
motors.
Motor starters
Motor starters is the combination of contactors & overload relays.

Control Relays
Operation of control relays is the same as contactors. However, they only operate in
light loads such as starting coils, audible alarms and pilot lamps.
Timing Relays
Timing relays are used in control switching operations which require delayed switching.
It is has 2 types of delay, Time Delay – ON and Time Delay – OFF functions.
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Contactor basic operation
There are two circuits involved in the contactor operation, the control circuit and the
power circuit.

The control circuit is connected to the coil of an electromagnet, while the power circuit
is connected to the stationary contacts.

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Exercises : Full Voltage starting

Power
M circuits
L1
OL
M
L2 Motor
OL
M
L3
OL

Start OL
MM
Control circuits

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 Exercises : Start-Stop, Full-Voltage Starter (w/alarm silencing)

POWER CIRCUIT CONTROL CIRCUIT

STOP START
OL

GL RUN
CB
M

RL IDLE
M
M

OL
RL BUZZER
BZ

OL
YL FAULT

S
SILENCE

3 ~ Motor

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 Exercises : 2 STATION Start-Stop, Full-Voltage Starter

POWER CIRCUIT CONTROL CIRCUIT

START 1
STOP 1 STOP 2 OL

M
START 2

CB
M
GL RUN

RL IDLE
M
M

OL

YL FAULT

OL

3 ~ Motor

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Reduced – Voltage Starting
This method is necessary in reducing the inrush current going to the motor. In effect, it
also reduces the amount of starting torque of a motor that can deliver. There are
several methods available to reduced-voltage starting. The purpose of confining the
rate of change of the starting current of the motor to predetermined limits depends on
the application or the type of the motor.

Types of Reduced – Voltage Starting

• Autotransformer RVS
• Part Winding Starters
• Wye-Delta Starters
• Primary Resistance Starter
• Solid State RVS

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Autotransformer

This type of method provides the highest starting torque per ampere of line current and
is one of the most effective means of starting a motor for an application in which
starting current must be reduced with a minimum sacrifice of starting torque.

To Start : Close 2, 4, 5, 6, 7 To Run : Open 2, 5, 6, 7

Open 1, 3 Close 1, 3

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Primary Resistance Starters
As shown below, to start the motor it is initially energized through a resistor in each of
the three incoming lines. This makes the voltage to drop through the resistor. This type
of method is simple & effective starting though it is limited by the amount of heat the
resistor can dissipate.

To Start : Open all R Contacts To Run : Close all R Contacts

Close all S Contacts Open all S Contacts

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Wye-Delta Starters
This method is applicable only with motors having stator windings not connected
internally and all six motor leads available. This type of starter is a good method for
applications requiring frequent starts.

To Start : Close 1, 2, 3, 4, 5, 6 To Run : Open 4, 5, 6

Open 7, 8, 9 Close 7, 8, 9

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Part Winding Starters
Part winding reduced-voltage starters are used with motors having two separate stator
windings. Part winding starters are the least expensive type of reduced-voltage starters.
They need only a simple control circuit. However, they require specially –designed motors
and not suitable for high-inertia loads. There is also no adjustment for current or torque.

To Start : Close only 1, 2, and 3 To Run : Close 1, 2, 3, 4, 5, 6

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 Exercises : Forward – Reverse Starter

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3
FORWARD
R OL
STOP
F
CB
F

REVERSE F
R
R

F R M

OL
FAULT
F

OL FORWARD
R
REVERSE

3~ IDLE
Motor
F R

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 Exercises : Forward – Reverse Starter

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3

FORWARD REVERSE OL
STOP
F
CB

F R

F R

OL
FAULT
F

OL FORWARD
R
REVERSE

3~ IDLE
Motor
F R

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 Exercises : JOG Control

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3
START
OL
JOG STOP
M
CB

M IDLE

M
OL
FAULT

OL

3~
Motor

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 Exercises : JOG Control (USING CONTROL RELAY)

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3

START
OL
STOP
CR
CB
CR

JOG

M
CR
M

OL

M
IDLE

3~ OL
Motor FAULT

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 Exercises : WYE-DELTA STARTER( open transition )

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3

START
OL
STOP
M
CB
M
TR

TR D
Y

M D Y
D

OL

3~
Motor

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 Exercises : WYE-DELTA STARTER( close transition )

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3

START
OL
STOP
TR
CB
TR 2M 2S
1S
1M

2M
TR
2S
RES

2S
1S
1M
OL

1M 1S
2M
3~
Motor

1S

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 Exercises : Primary Resistance Starting

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3

START
OL
STOP
1M
CB
1M
TR
1M

TR
2M

2M
RES

OL

3~
Motor

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 Exercises : Primary Resistance Starting

POWER CIRCUIT CONTROL CIRCUIT

L1 L2 L3

START
OL
STOP 2M
1M
CB
1M
TR

1M 2M
TR
2M

RES

2M

OL

3~
Motor

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 Motor Trouble-Shooting
Caution:
1. Disconnect power to the motor before performing service or maintenance.
2. Discharge all capacitors before servicing motor
3. Always keep hands and clothing away from moving parts.
4. Be sure required safety guards are in place before starting equipment.

Problem: Like Causes: What To Do:

Motor fails to start Motor is miswired. Verify motor is wired correctly.
upon initial May be able to reassemble; otherwise,
Motor damaged and rotor is striking
installation. motor should be replaced.
stator.
Fan guard bent and contacting fan. Replace fan guard.

Motor has been Fuse or circuit breaker tripped.
running, then fails to Stator is shorted or went to ground.
start. Motor will make a humming noise
and the circuit breaker or fuse will
trip.
Replace fuse or reset the breaker.
Disassemble motor and inspect
windings and internal connections.a
blown stator will show a burn mark.
Motor must be replaced or the stator
rewound.

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Problem: Like causes: What to do:
Motor has been running, Motor overloaded or load jammed. Inspect to see that the load is free.
then fails to start Verify amp draw of motor versus
nameplate rating.

Capacitor (on single phase motor) First discharge capacitor. To check

may have failed. capacitor, set volt-ohm meter to
RX100 scale and touch its probes to
capacitor terminals. If capacitor is
OK, needle will jump to zero ohms,
and drift back to high. Steady zero
ohms indicates a short circuit;
steady high ohms indicates an open
circuit

Starting switch has failed. Disassemble motor and inspect

both the centrifugal and stationary
switches. The weights of the
centrifugal switch is not loose on the
shaft. Inspect contacts and
connections on the stationary switch
. Replace switch if the contacts are
burned or pitted

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Problem: Like causes: What to do:
Motor runs but dies down Voltage drop. If voltage is less than 10% of the
motor’s rating contact power
company or check if some other
equipment is taking power away
from the motor

Load increased. Verify the load has not changed.

Verify equipment hasn’t got tighter.
If fan application verify the air flow
hasn’t changed.

Motor takes too long to Defective capacitor. Test capacitor per previous
accelerate instructions.

Faulty stationary switch. Inspect switch contacts and

connections. Verify that switch
needs have some spring in them.

Bad bearings. Noisy or rough feeling bearings

should be replaced.

Voltage too low. Make sure that the voltage is within

10% of the motor’s nameplate
rating. If not, contact power
company or check if some other
equipment is taking power away
from motor.

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Problem: Like causes: What to do:
Motors runs in the wrong Incorrect wiring. Rewire motor according to wiring schematic
direction. provided.

Motor overloaded protector Load too high. Verify that the load is not jammed. If motor is a
continually trips. replacement, verify that the rating is the same
as the old motor. If previous motor was a
special design, stock motor may not be able to
duplicate the performance. Remove the load
from the motor and inspect the amp draw of
the motor unloaded. It should be less than the
full load rating stamped on the nameplate.

Ambient temperature too Verify that the motor is getting enough air for
high. proper cooling. Most motors are designed to
run in an ambient temperature of less than
40 oC. (Note: A properly operating motor may
be hot to the touch.

Protector may be Replace the motor's protector with a new one

defective. of the same rating

Winding shorted or Inspect stator for defects, or loose or cut wires

grounded. that may cause it to go to ground.

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Problem: Like causes:
Motor vibrates. Motor misaligned to load
Load out of balance.
(direct drive application.)
Motor bearings defective.
Motor may have too much endplay
Winding may be defective.
Basic motor control
What to do:
Realign load
Remove motor from load and
inspect motor by itself. Verify that
motor shaft is not bent. Rule of
thumb is .oo1” run out per every
inch of shaft length.
Test motor by itself. If bearings are
bad, you will hear noise or feel
roughness. Replace bearings are
good, it may be that the rotor was
improperly balanced at the factory.
Rotor must be replaced or
rebalanced.
With the motor disconnected from
power turned shaft. It should move
but with some resistance. If the
shaft moves in and out too freely,
this may indicate a preload problem
and the bearings may need
additional shimming
Test winding for shorted or open
circuits. The amos may also be
high. Replace motor or have stator
rewound.
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Problem: Like causes: What to do:
Bearings continuously fail Load to motor may be excessive or Besides checking load, also inspect
unbalance. drive belt tension to ensure it’s not
too tight may be too high. An
unbalanced load will also cause the
bearing fail.

High ambient temperature. If the motor is used in a high

ambient, a different type of bearing
grease may be required. You may
need to consult the factory or a
bearing distributor.

The motor, at start up, Rotor may be striking stator. Ensure that motor was not damaged
makes a loud rubbing or in shipment. Frame damage may
grinding noise. not be repairable. If you cannot see
physical damage, inspect the
motor’s rotor and stator for strike
marks. If signs of rubbing are
present, motor should be replaced.
Sometimes simply disassembling
and reassembling motor eliminates
rubbing. End bells are also
sometime knocked out of alignment
during transportation.

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Problem: Like causes: What to do:
Starts capacitors The motor is not coming up to Motor may not be sized properly.
continuously fail. speed quickly enough Verify how long the motor takes to
come up to speed. Most single
phase capacitor start motors should
come up to speed within three
seconds. Otherwise the capacitors
may fail.

The motor is being cycled too Verify duty cycle. Capacitor

frequently. manufacturers recommend no more
than 20, three-second starts per
hour. Install capacitor with higher
voltage rating, add bleed resistor to
the capacitor

Voltage to motor is too low. Verify that voltage to the motor is

within 10% of the nameplate value .
If the motor is rated 208-230V, the
deviation must be calculated from
230V.

Starting switch may be defective, Replace switch

preventive the motor form coming
out of start winding.

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Problem: Like causes: What to do:
Run capacitor fail. Ambient temperature too high. Verify that ambient does not exceed
motor’s nameplate value.

Possible power surge to motor, If a common problem, install surge

caused by lightning strike or other protector.
transient voltage.

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