Classic Control Tutorial Note Book

This course teaches to design & trouble shoot a Relay control system

Written by E.E. Student Ali Yousif

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Introduction
As an introduction there are two types of electricity AC & DC.

Direct current (DC):

This type has a constant value, an example of this type is electricity of
batteries.

Alternating current (AC):

The value of voltage & current in this type keeps changing between 0 & max .
Also AC electricity has a frequency, in power systems its either 50 Hz or 60 Hz

Note: Frequency of power systems is 50 Hz in Iraq.

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Voltage & current (Ohms Law): -
Voltage is Force that make electrical current flow in the circuit.

Current = Voltage / Resistance → I = V / R

Voltage in Series & Parallel connection:

In parallel → V supply = VR1 = VR2

In series → V supply = VR1 + VR2

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 Contactor
A number of switches controlled by a coil.
→ it consists of number of NC & NO contacts
As it shows in the symbol

Note: when coil is activated (current passed through it) → acts like magnet
→ so, it changes the contacts (switches state)

Here A1 & A2 are→ the coil terminals

Note: Normally → Coil is not activated (coil OFF)

NO: switch is Normally open (OFF) & becomes closed (ON) if coil is activated

NC: switch is Normally closed (ON) & becomes open (OFF) if coil is activated

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types of contacts in contactor
Main contacts → can take high currents &
voltages (power circuit in panel)

Auxiliary contacts → can take Low currents &

voltages (like control circuit in panels)

An example of contactor

we see that
→ the symbol, NC & NO is written on contactor side.
→ Also, it has two of A2, so we can use any of them with A1
→ we can use A1 & A2 are coil terminal we can use them in any direction

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 Circuit Breaker

It’s an ON/OFF switch that → is controlled manually

Also, this switch is called

Miniature circuit breaker (MCB)
turns off when →current pass a certain limit

they come in many shapes, types & number of poles

like single pole, two pole, three pole, four pole.

For example:
C10 → 10 A circuit breaker → become open circuit (OFF)
→ when current is larger than 10 A

Note: usually we can connect them in both directions

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molded case circuit breaker (MCCB): -
same purpose of MCB
→But used for high current application

Sometimes to avoid high current

→ we divide the supply current path
here
(Input current is divided between 3 paths)
And
(Output current is same as total input current)

Same method is used with the contactor

Notes
________________________________________________
________________________________________________
________________________________________________
________________________________________________

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 Project 1

Simple household panel → two power supplies main (LA) & backup (LB)
(So, if LA is shut down, LB will supply)

LA is connected with NO (works when coil is activated)

LB is connected with NC (works when coil is OFF)

LA is ON → coil (A1 & A2) is ON → NO is activated & NC is OFF

So → LA is supplying

LA is OFF → coil (A1 & A2) is OFF → NC is activated & NO is OFF

So→ LB is supplying

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A connection diagram for the panel is shown Below.

Notes
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 Relays

Relay works like a contactor but for low current values.

Note: Relay is usually used in control circuits
Relays come in many types & shapes.
Also, there are DC & AC relays.

for example, for this relay

when coil is activated
→ NO (A’s will be closed)
→ NC (B’s will be open)

Lamps indicators

Lamps used in control circuit to indicate ON/OFF.

For example: use red & green to indicate which Line is supplying at the
moment.

Note: we also can use relay to control

the lamps (which is better).

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 Project 1.1

Adding two lamps indicator & controlling them using relay to project 1

When
LA is ON → contactor & relay coils activated → LA supplies Load & Red Lamp
(Because LA & Red lamp connected to N.O of the contactor & relay)
& when
LA is OFF → contactor & relays coils OFF → LB supplies Load & Green Lamp
(Because LA & Green lamp are connected to N.C of the contactor & relay)

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 Project 2

Using three contactors to control three Power supplies LA, LB & LC.
if
LA is ON → (KM1 coil is activated) → LA supplies
Else if
LA is OFF & LB is ON →(KM2 coil is activated) → LB supplies
Else
LA is OFF & LB is OFF & LC is ON → (KM3 coil is activated) → LC supplies

Note: if a coil is not activated → NC for that coil’s contactor is closed circuit

Note: priority is for LA then LB then LC.

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 Electric valve

A Valve that is controlled Electrically using a coil. It’s used to control the flow
of fluid (liquid or gas) in a pipe.

Electrical valves have many designs & sizes. Also, we have NC & NO valves.

How they work…?

When coil activated → acts like a magnet → closes or opens the valve
(Depending on current direction in the coil)

Voltage & current indicators

Small voltmeters and Ammeter used in control panels.

→ Used to measure & display the voltage & current.

They come in many shapes & sizes. Their types are analog & digital
(The Digital one is mostly used nowadays)

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Voltage indicator: -
→ Measures & display voltage
→ connected like a voltmeter in parallel

Current indicator: -
→ Measures & displays current
→ measures the current of the wire inserted in
its loop (like a clamp meter)

Also, we have indicators that can measure both of (V & A)

Push button

Buttons that when pressed → change its state

And when released → returns to its previous state

For example: NC push button, when:

Pressed → becomes open
Released → returns to NC condition

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 Single Phase motor

Using single phase current → to give us mechanical rotating force (Also called
torque)
Notes:
Rotor → rotating part of motor
Stator → stationary part & carries the coils

Non-self-starting: -
Single phase can’t start motor rotation.

For positive cycle of AC wave

The magnetic force of coils A
→ pushes Rotor inward
(It doesn’t rotate)

For Negative cycle of AC wave

The magnetic force of coils A
(Coils polarity reversed)
→ pulls rotor outward Rotor
(It doesn’t rotate)

So, Single phase → Unable to make a motor start rotating

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Starting by external force: -
now, if we rotate the motor by hand
→ then it keeps rotating in direction we rotated it

For example: the Coil attracts the rotor

By time the rotor reaches coil

Polarity is reversed (coil pushes rotor)

As we now this way of starting is unpractical

Single Phase motor Capacitor

We can make single phase motor self-starting by

→Adding (Series capacitor & extra coil) in parallel with main coil

Let
Ia: auxiliary current
Im: main winding current

Also, we can say that we

“split” the two-phase
single phase into 2 phases
with 90° phase difference

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Capacitor provide 90° phase difference. (Capacitor makes → Ia leads Im by 90°)

Note: - since its parallel voltage is equal in phase & magnitude.

Every time one of the

currents is max the
other one will be 0.
(Same for magnetic
field)

1st: when A=0 at (θ =0) → B= + max 2nd: when A= max at (θ =90) → B= 0

3rd: when A=0 at (θ =180) → B= - max 4th: when A= - max at (θ =360) → B=0

Note: 0 means current (magnetic field) = 0.

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Now the magnetic field appears like its rotating & it attracts the rotor with it
(So, it’s called rotating magnetic field)
→ Means the problem is solved.
Note: So, we need a rotating magnetic field → for motors rotation

3 phase motor

Here no need for a capacitor → motor already supplied by 3 phases with 120°
phase difference.

Note: Also angle between coils

positions in stator
P1 & P2, P2 & P3, P3 & P1
→ 120°

So, when θ=0°

Phase 1= 0
Phase 2= - 0.866 of max
(Polarity reversed)
Phase 3= + 0.866 of max
(Same for magnetic field)

And so on magnetic field appears to rotate attracting rotor with it.

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Terminal box of 3 phase motor
Used to set → connection type for the motor’s coils

it usually appears like shape below. But the coils are connected like this

Coils terminals check: -

If you’re not sure coils are connected like this
→ check coils connection using multimeter (continuity test) or (ohmmeter)

Check terminals of same coil (like W)

beeping sound or small resistance

→ then two terminals connected
through a coil

No sounds or big resistance

→ two terminals are not connected or coil is damaged

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Coils isolation check: -
To check if there is a short-circuit (insulation fail) between coils of different
phases.

Checking terminals of different coils

(like U & V)

No sound or Open circuit reading

→ coils are isolated (nice)

Beeping sound or small resistance

→ coils are short-circuited (insolation fail)

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Coils connection of 3 phase motor: -
There is two main connections Delta & star

Delta: -
Draws more current because
V line = V phase
Which Gives larger line current

Delta Draws more line current (IL)

Gives → Stronger magnetic field
Thus → Stronger Torque

Note: Torque force that makes rotation

Note: Vp: phase voltage is the voltage on the coils that controls coil current.

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Star: -

Draws less current because

V phase = V line / √3
Gives less line current

Star draws less line current (IL)

Gives → less magnetic field
Thus → less torque

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Starting & rated current
3 phase induction motor draws very high current at start. Now when:

Delta connected
• Draws very High Istarting

• Draws high Irated

→which gives more Torque

for high Irated (stronger Torque)→ Use Delta

Star connected
• Istarting less than Delta

• Irated less than Delta

→gives less Torque than Delta

But to reduce Istarting →Use Star

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We need to reduce staring current of motor because: -
High Istarting will
• Burns motor winding
• Large voltage drops in the system since (using KVL, voltage drop = I x Z)
(z is the impedance of wires & other electrical loads)

Note: when voltage drop is high → the remaining voltage not enough for 220v
devices operation

Star-Delta method
A Good method that is
• Using Star to reduce Istarting

• Then Delta to increase Irated

Which gives strong Torque

Reading motor Name plate: -

Motor name plates carries a lot of data but the Necessary ones are:
phases, Connections, Voltage, frequency, current, Mechanical output.

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Phases & Mechanical output:
• Three phase Induction motor.
• Mechanical output of (0.5 HP) or
(0.37 KW).

Note: 1 HP = 0.7457 kw (so 0.5 x 0.7457 = 0.37 KW)

Speed & frequency:

• Rated speed is 2730 rpm.
(Revolution per minute)
• Motor nameplate value is for
supply Frequency of 50 Hz.

Connection, Voltage & current:

• (Delta/Star) means coils can be
connected in both

• (1.67/0.97 A) like (Delta/Star) means motor at rated speed (2730 rpm)

will: -

i. Draws Line current (IL) of → 1.67 A for Delta connection

ii. Draws Line current (IL) of → 0.97 A for Star connection

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• (230/400) like (Delta/star) means to reach Line current needed for rated
speed (2730 rpm):

i. We Make Supply Line voltage → 230v for Delta-connection.

ii. We Make Supply Line voltage → 400v for Star-connection.

Why motor needs higher line voltage (VL) for Star to reach
same speed as Delta …?

Note: 230v is the phase voltage (Vp) that this motor’s coils need to create:
Current that → creates magnetic field that → gives us Torque for 2730 rpm

For Delta:
if supply VL = 230v → since Vp = VL → makes Vp = 230v
Which is the voltage that coils need to create rated speed current

But for Star:

If Line supply VL = 230v → since Vp= VL/√3 → gives Vp= 230/√3 ≠ 230v
So, make supply VL= 400 → since Vp= VL/√3 → gives Vp= 400/√3 = 230v

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 Over Load Relay (O.L)

A device that has NC & NO contacts. The NO & NC coil will be activated
if an over Load occurs (current pass certain value).

O.L is usually connected with

contractor to control a motor

Note: Usually used with contactor to control a 3-phase motor and protect it
from overload current.
Note: we can say that thermal relays make a contactor works like MCB but for
motors because thermal relays have better sensitivity.

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 Project 3

Controlling a motor by push buttons using contactor & overload relay.

For better understanding → divide the circuit into Power & control.

Power circuit (project 3)

Consists of (Circuit breaker, Contactor, Overload).

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Control circuit (project 3)
Consists of (Circuit breaker, Push buttons, Contactor’s NC & NO)

Turn the motor ON

when
N.O push button pressed → KM1 is activated → NO, K1 is activated (closed)
→ motor is ON
(Now current flows to KM1 through N.O pushbutton & N.O, K1)

Even after Releasing N.O push button → KM1 still activated

(Current still flows to KM1 → through NO, K1 path since it was activated)

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Turn the motor OFF
If pressed NC push button → KM1 is OFF → NO, K1 is OFF → motor is OFF

Even after released NC push button → KM1 still OFF

(Since no current flows to KM1)

Protection
If overload happens → NC, O.L is activated (becomes open) → motor is OFF
(Since no current flows to KM1)

Note: we can also turn motor off by using → Emergency NO push button.

Adding more buttons:

• To add more NC push buttons (for turning motor OFF)
→ Add them in Series with other NC.

• To add more NO push buttons (for turning motor ON)

→ Add them in Parallel with other NO.
Like the diagram to the right.

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 Project 4

Adding Lamps to project 3 Control circuit. (Here we used Red, Green, Yellow).

Lamps are connected to serve a different purpose:

Red: is ON → means supply is ready to operate the motor.
Green: is ON → motor is running
Yellow: is ON → Overload occurred (NC, O.L activated) & motor turned OFF.

N.O push button pressed → KM1 is activated → NO, K1 is activated (closed)

→ motor is ON → Green Lamp is ON

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 Project 5

Power circuit (project 5)

Reversing 3 phase motor direction → By switching two phases’ terminals
(Like swapping L3 with L2) or (L1 with L2) ...etc.

K1 contactor for → L1 L2 L3 sequence.

To reverse 3 ph motor rotation, Switch to K2 contactor → L1 L3 L2 sequence

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Control Circuit (project 5)
Using Push buttons to control this circuit:
For Contactor K1
NO1 pressed → K1 activated → NC, K1 & NO, K1 activated → motor rotates
in a direction.

For Contactor K2
NO2 pressed → K2 activated → NC, K2 & NO, K2 activated → motor rotates
in the opposite direction of K1.

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Note: purpose of (NC, K1) in K2 circuit → makes Contactor K2 open (OFF) if
contactor K1 is activated.

Same thing for (NC, K2) in K1 circuit → makes Contactor K1 open (OFF) if
contactor K2 is activated.

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Timer Relay

A relay that Delays (sets a time period before): -

→ the activation (energizing) or deactivation (de-energizing) of coil.

Note: Activate means changing N.C & N.O contact’s state.

There are two basic types of timer relays modes:

ON delay & OFF delay modes

ON Delay Mode:
First set the Delay time
If Coil is supplied with voltage → Coil activates after the delay time.
If Coil supply is OFF → Coil de-activates immediately.

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NO & NC Contacts in ON Delay Mode:
Here N.O contacts are called → NOTC (Normally Open – Time Closed)
(Means NO becomes closed after delay time)

Here N.C contacts are called → NCTC (Normally Closed – Time Open)
(Means NC becomes open after delay time)

OFF Delay Mode:

Set the Delay time
If Coil’s supply is ON → Coil activates immediately
If Coil’s supply is OFF → Coil de-activates after the delay time.

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NO & NC Contacts in OFF Delay Mode:
Here N.O contacts are called → NOTC (Normally Open – Time Closed)
(Means NO becomes closed after delay time)

Here N.C contacts are called → NCTC (Normally Closed – Time Open)
(Means NC becomes open after delay time)

Timer relays come in many shapes & types:

An Example of Timer pic

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Timer Diagram & information written on it

Note: Here coil input is at (2-7).

The triangle on the contact switch

→ means it is an ON-Delay type.

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 Project 6

Using (Star-Delta) starter method to start a 3-phase motor. Also, using a

timer relay in the control circuit of the motor.

Power Circuit (project 6)

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K1→ turns the power circuit ON
K2→ makes coils Star connected
K3→ makes coils Delta connected

Note: these two connections works if motor coils were arranged in this way

Circuit operation: -
First motor is Star connected → reduce starting current (less I starting)

Then motor is Delta connected → increase I rated → increase Torque

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Control Circuit (project 6)
Using (ON-Delay) Timer to Run the 3ph motor on (Star) then (Delta).

Circuit operation:
When NO push button pressed → KM1 activated → NO, K1 activated
(But KMT doesn’t activates until Delay time ends)

During delay time → KMT isn’t activated yet → Motor is Star connected

After Delay time → KMT is activated (NCTO & NOTC activated)

→ Motor becomes Delta connected

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Note: series connected coils fails to activate since voltage will be divided
between the series connected coils.

Voltage protector

Breaks connection if supply voltage is not in a certain range.

For example: t operating voltage range is (200v – 230v)

Voltage protector breaks connection if → supply < 200v or supply > 230v

Also, we can choose desired operating voltage.

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