Motor Control
Handbook
A guide for electrical contractors
MOTOR CONTROL AND DRIVES
NHP Electrical Engineering Products Pty Ltd
AUS
NZ
1300 NHP NHP
0800 NHP NHP
nhp.com.au
nhp-nz.com
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the highest levels of quality assurance and testing, safety, standards
compliance and production quality.
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Founded in 1968 NHP 50 years of experience with motor control and
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2
Introduction
This NHP Motor Control Handbook 2018 provides technical information
of a general nature about low voltage switchgear, protective devices and
their combination. Written in an easily understood manner it is for use
by appropriately qualified and competent persons and will assist them in
designing and producing their own simple or complex control systems. In
the event of faults, a knowledge of the circuit diagrams contained herein
may also aid in rapid fault location and rectification.
Whilst NHP has made every attempt to ensure the accuracy and reliability
of the information provided in this Handbook, the information is provided
“as is” without warranty of any kind and any reliance you place on such
material is therefore strictly and entirely at your own risk. Changes
to material or information (e.g. changes to applicable standards and
regulations, technical progress or improvement) after publication may
impact upon its accuracy. Users of this Handbook are responsible for
assessing its relevance and verifying the accuracy of the content for their
specific purposes and NHP will not be liable for any loss, damage, cost or
expense incurred or arising by reason of any person or organisation relying
on the information in this Handbook. NHP further reserves the right to
make changes at any time to this Handbook, and without notification.
3
Table of contents
1. Introduction
1.1 Equipment overview
2. General
2.1 Graphical symbols with nomenclature for circuit diagrams
2.2 Marking and identification of terminals of contactors and associated
overload relays
2.3 Terminal markings for electric motors
3. Starting and switching motors
3.1 Selection criteria overview
3.2 Selecting the right contactor for an application
3.3 Selecting the right overload for an application
3.4 Characteristic features of the commonly used starting methods for
squirrel-cage induction motors
4. Diagram types
4.1 Circuit diagram
4.2 Scematic wiring diagram
4.3 Control diagram
4.4 Simplified diagram
5. Direct on line starters and reversing starters
5.1 Several command locations
5.2 Direct on line starters (Contactor with overload relay)
5.3 Direct on line starters with mechanical latch
5.4 Reversing starters
6. Reduced voltage starters
6.1 Star-delta starters
6.2 Autotransformer starters
7. Additional applications
7.1 Circuit breakers
7.2 Circuit breakers KTA7 with contactor
7.3 Electrical heating, lamps and illumination equipment
8. Soft starters PCS
8.1 Soft starter typical application duty ratings
8.2 Setup
9. Variable speed drives
9.1 Introduction
9.2 VSD control algorithms
9.3 VSD benefits
9.4 Product selection
9.5 Schematics
9.6 Start and speed configuration
10. Timers
11. Appendix
11.1 AC motor currents table
11.2 Utilisation categories
11.3 Motor terminology
11.4 Time current curves
11.6 IP ratings chart
10.7 Circuit breakers
10.7 Short circuit coordination for motor starting time current curves
4
3
5
12
12
18
21
23
23
24
24
25
26
26
27
28
29
30
30
32
36
40
44
44
48
50
50
51
52
54
54
56
60
60
61
62
63
65
66
67
67
67
68
69
70
78
79
80
1. Introduction
1.1 Equipment overview
The following pages contain a brief explanation on the various equipment
types common to motor starting applications
Motor starting with Sprecher+Schuh CA7
and CA8 contactors
Contactors are capable of switching large motor
currents whilst using standard wiring and control gear.
This is achieved by energising the coil of a contactor,
which closes the main contacts allowing the full load
current to the motor.
A contactor works in the same manner as a relay but
generally switches 3 phases and can handle high
motor starting currents.
Because only a small coil voltage and current is
required to activate the contactor coil, it is also easy
to integrate into an automatic control system where
the contactor can be controlled by electronic control
systems.
Contactors are one of the two main components
Soft_starter_symbol
Starte
that make-up a motor starter, the second one being
overload relays. Contactors are the control device
and overload relays are the protection device. Hence,
contactors are normally used in conjunction with an
overload protection device.
12
ersing
13
1
3
5
A1
K1M
14
4
6
A2
Q1
Load switching with Sprecher+Schuh CS7
and CS8 industrial control relays
mbol
_Interlock
1
2
r2
13
21
Break contact
RT7
Contactor_1
Industrial control relays contain a contact system
suitable for the switching of auxiliary circuits
Mechanical_Latching_Device
Circuit_
(command,
signalling and interlocking circuits), in
control circuits with higher voltage ratings.
Operation
is by energising the coil of the relay, which
A1
closes the
T1 contact system allowing a current path.
A1
13
21
33
43
A2A2
14
22
34
44
T2
14
22
Make contact
Themistor_RT7
5
Load switching with Finder general
purpose relays
General purpose relays are similar to industrial
control relays in that they contain a contact
system suitable for the switching of auxiliary
Starter_regulator_symbol
circuits in control circuits. General purpose relays
are physically small in size and are designed for
switching low amperage current.
12 14
22 24
A1
K1M
A2
3
6
Finder_1
Time delay relays with Sprecher+Schuh
CRZE7 electronic timers and CA7
contactors
Electronic timers are mounted on the contactor or
67
55
control relay coil terminals A1, A2.
The timers provide a set of auxiliary contacts that
change
68state with
56 a time delay after the contactor
is energised or de-energised. Timers are available in
On-delay and Off-delay versions, and both versions
include a normally open N/O and normally closed
N/C output contact as standard.
For On-delay
function, the relay is energised at the
Aux_1
end of the delay time, whereas with Off-delay,
once the control signal is interrupted the relay is
de-energised at the end of the delay time.
On delay
6
Timing devices with Sprecher+Schuh
CZE7 pneumatic timers and CA7
contactors
Pneumatic time delay relays are mounted on
the contactor or control relay in place of an
auxiliary contact block. The contacts of the
timing element switch according to the set time,
switching mechanically, on closing or opening of
the contactor.
Time delay relays with Sprecher+Schuh RZ7
electronic timers
Time delay relays provide a simple form of timebased control which allows the user to open or close
the contacts based on a specified timing function.
Time delay relays are used within a control circuit.
For example, on delay, or off delay. With star-delta
motor starting, timing relays are used to initiate the
changeover, after a set period of time, from star to
delta connection.
U
Y
∆
LED
A1/A2
t
tu=50...65ms
17/18
17/28
Refer to section 10.5 Timers for full description of all timing functions
7
Interlocking devices with Sprecher+Schuh
CA7 and CA8 contactors
Mechanical interlocking together with electrical
interlocking prevents the simultaneous closing
of two contactors due to surges or manual
actuation. This is required for situations whereby
the simultaneous making of two contactors would
cause a short-circuit, for example, in changeover or
reversing applications.
L1
L2
L3
N
PE
Q1
K1
A1
1
3
5
A2
2
4
6
1
3
5
2
4
6
V
W
F1
U
M1
M1
K2
A1
1
3
5
A2
2
4
6
M
3~
File Name: pg68_Starters_CAU7_CT7_Main_Circuit
Location: 4.1 Reversing startes CAU 3 + CT 3 Main circuit
Scale: 1:10 (Normal Size)
8
Mechanical latching with
Sprecher+Schuh CA7 contactor and
CV7 latch
Mechanical latching devices can be directly
mounted onto the contactor or control relay.
The mechanical latch prevents the contactor
from returning to it’s rest position after being
de-energised. The mechanical latch module
incorporates a de-latching magnet to allow the
contactor to drop-out. This can be accomplished
via a voltage pulse or manually.
A mechanical latch is used to save power in
the control circuit when the contactors are to
remain energized for long periods or when the
contactors cannot change state during a voltage
interruption. A typical application for mechanical
latching is lighting circuits.
9
Load_Break_Fuse_Switch_Single
Load_B
Starter_DOL_Non_Reversing
Motor Protection with Sprecher+Schuh
Thermal overload relays are a protection device
that can detect the amount of current in the
circuit. If the level becomes too high, the
overload will send a signal to indicate the trip
and further disconnect the load.
Overload relays are used to avoid the motor
overheating which can lead to a reduction in
the expected motor life and ultimately, motor
failure.
Circuit_Breaker
Thermal_O
Causes
of overloads can typically include:
- Excessive load
Duasized
l _W i n
ding_Coil
- An incorrectly
motor
- Low or imbalanced incoming voltage
It is important to understand that there are
two types of Overload devices. The Thermal
overload; sometimes referred to as the bi-metal
overload and the electronic overload.
Sprecher+Schuh CT7N and CT8 thermal
overload relays
A thermal overload detects the heat created
by the current within the circuit. Simply put,
excess current creates heat and this causes
Earth_Leakage_CB
the bi-metal
strip in the overload device to
Delay_Timer_With_Initaiting_Input
heat up and trip contacts are used to open the
contactor coil circuit.
1
3
5
95
2
4
6
96
Control_Contact_Normally_Closed
Overload_Relay
10
Con
Contro
Contactor_Norm
chanical_Latching_Device
Dual_W inding_Coil
Electronic Motor Protection with
Sprecher+Schuh CEP7 overload relays
The electronic overload relay monitors the current via
built-in current transformers. If the current exceeds a
Earth_Leakage_CB
Con
predetermined amount and time, the device will trip.
Delay_Timer_With_Initaiting_Input
Control_
Compared to a thermal overload relay, the current
setting range of the CEP7 is very large 5:1. In addition,
the overload electronics produces quick-acting phase
failure protection.
1
3
5
95
2
4
6
96
Sprecher+Schuh KTA7/KTC7 motor
protection
circuit breakers
Control_Contact_Normally_Closed
Motor
protection circuit breakers (MPCB) are Contactor_Norm
a
Overload_Relay
particular type of circuit breaker designed for motor
protection. They are a circuit breaker and thermal
overload within the one device, hence they provide
short circuit protection, thermal motor protection,
protection of connecting and turning motors off
and on. The motor protection circuit breaker has an
adjustable thermal overload trip and a non-adjustable
magnetic short-circuit trip.
The selection of a motor protection circuit breaker
is dependent on rated current, fault rating capacity,
available space and circuitry components.
• KTA7 motor protection circuit breakers are suitable
for standard motor control applications
• KTC7 motor protection circuit breakers should be
selected for high efficiency motors which have a
high inrush that can cause nuisance tripping on the
standard KTA7 product
1
L1
3
L2
5
L3
Q1
I> I> I>
T1
2
Circuit_Breakers_KTA_7
T2
4
T3
6
11
Thermistor protection with Sprecher+Schuh
RT7 relays
These thermistor-type protection units are a device
that directly monitors the temperature of a given
object via a PTC (positive temperature coefficient)
resistor, acting as a temperature sensor typically
placed on the motor windings. The outcome is
an independent and reliable method of thermal
protection that also takes external environmental
influences into account.
Thermistor
protection relay
PTC thermistor embedded in motor windings
12
A1
A2
1:10
7
B2
Control devices with Sprecher+Schuh D7
pushbuttons
These control devices which are mounted on the
outside of an enclosure, serve for operating of contacts,
Coils3
on or off or performing changeover functions, for
devices to be actuated in a control circuit.
Pushbuttons are actuated by finger pressure on the
button face, and there are differentA1
functional
A1
B1 types
of pushbutton operators; Momentary pushbuttons,
13
21
operate when pressed, and if finger pressure is removed,
the pushbutton reverts to its normal
A2
A2position
B2 (e.g. for
S..
momentary / impulse contact control).
13
22
Latched pushbuttons remain in the depressed position
after being pressed. They are released by a second
pressing action where they revert to the normal
position (e.g. for maintained contact control).
Coils1
Coils2
Mushroom operator type pushbuttons
offer an
increased
surface
area
for
reliable
actuation
when
Control_Elements_D7
wearing gloves.
Emergency Stop buttons (sometimes referred to as
Estops) are latched in the depressed state when pressed,
and are unlatched by ‘twist-to-release’ orE1
pull action.
A1
B1
1U
Emergency Stop buttons may also include a locking
device, where unlatching is only by means of a key.
A2
E2
1W
1V
Signalling devices with Sprecher+Schuh D7
pilot lights
These signalling devices (pilot lights) are mounted on the
outside of an enclosure, and are usedCoils5
for visual indication.
Pilot lights are connected in such a way so that they
Motor_Winding1_2
illuminate when the associated power device is in the
operating circumstance being monitored. Common
L1
L2
L3
operating circumstances which utilise pilot lights include
L1
U
X1
2U
power available, run, ready, and trip. Typically, red pilot
lights are used to indicate run, green pilot lights are used
H..
to indicate ready, and yellow pilot lights are used to
indicate trip or caution.
X2
1W
1V
For contactors, pilot lights are connected so that they
illuminate when the associatedWcontactor is on.VThey are
1U
2W
2V
operated by an auxiliary contact on the contactor being
L3
L2monitored. In this way, the pilot light correctly indicates
the contactor switching state. In addition, pilot lights are
Signalling_Elements_DL7 sometimes used in conjunction
Motor_Winding1
with sound and other
warning devices.
Coils4
Motor_Winding4
L1 U1
L1
1U
13
Wiring with Sprecher+Schuh V7 terminals
Terminals are detachable connector elements
for electrical conductors. The through terminals
facilitate the connection of conductors or serve as
terminals for external lines to the devices, equipment
combinations and switch cabinets. The conductors
are held directly by screws or nuts or by means of a
clamping element.
1
2
3
4
5
Controlled starting with Sprecher+Schuh
PCS soft starters
Soft starters are a reduced voltage start that works by
electronically controlling the voltage applied to the
motor. Voltage from the 3 phase power line is controlled
through a solid state device, such as a SCRs (silicon
controlled rectifier) or thyristors. These devices (SCRs
or thyristors) are switched (on/off), which then applies
voltage (3 phase) to the motor in a controlled state,
allowing the motor to slowly ramp to full speed.
Soft starters reduce the mechanical torque to the load
and reduce starting current peaks and are a component
or assembled in a switchboard or control panel.
Speed and process control with
Allen-Bradley PowerFlex variable
speed drives
Starter_r egulator_symbol
arter_symbol
3
5
4
6
A1
K1M
ntactor_1
14
A2
A variable speed drive (VSD) alters the speed of
an electric motor by changing the frequency.
Voltage from the 3 phase (or single phase) power
line is converted to DC voltage through a AC to DC
12 14 22 24
converter. Solid state
devices, referred to as IGBT
(insulated gate bi-polar transistors) are switched
to create a 3 phase waveform to the motor. This
switching allows the drive to control the frequency
and voltage, allowing
3 you to6control the motor speed
with infinite control (zero – full speed).
VSDs can vary the speed of the motor at any time
during the process for any duration, which yields the
benefits of process control and energy savings.
Finder_1
_Single
Scale: 1:10
Page: 1
Isolation of motor loads with
Sprecher+Schuh L7 load-break switches
The load-break switch is a mechanical switching
device capable of making, carrying and breaking
currents under normal circuit conditions.
Load-break switches are designed for use in local
motor isolation and disconnect switch applications.
Isolator_Switch_Single
The inclusion of the handle allows for manual
operation.
Isolat
Circuit protection with Wohner fuses and
fuse switches
Load_Break_Isolator_Switch
Load_Break_F
These fuses are an electrical safety device that
operates to provide overload and short circuit
protection of an electrical circuit. The fuse itself
is a metal wire or strip that melts when too much
current flows, which breaks the circuit in which it
is connected, thereby protecting the circuit’s other
components from damage due to excessive current.
Load_Break_Isolator_Switch_Single
A fuse switch is a switch in series with a fuse in a
single housing or enclosure.
Circuit_Breaker_Single
Circui
I>
Load_Break_Fuse_Switch
Short_Circuit_Trip_Element
15
Earth_L
Isolator_Switch
Scale: 1:10
Page: 1
Load_Break_Isolator_Switch
Load_Break_Isolator_Switch_Singl
olator_Switch_Single
Load_Break_Fuse_Switch_Single
Isolator_Switch
Load_Break_Fuse_Switch
2. General
Load_Break_Isolator_Switch
Load_Break_Isolator_Switch_Single
2.1 Graphical symbols with
nomenclature for
circuit diagrams
These are the symbols as per AS/NZS 1102.107:1997, and industry standards
which show the common devices and control
functions utilised in association
Isolator_Switch_Single
with the control of motors.
Circuit_Breaker_Single
Load_Break_Fuse_Switch_Single
Load_Break_Fuse_Switch
Drawing symbol
Item
Power Delivery
_Break_Isolator_Switch
Load_Break_Isolator_Switch_Single
Circuit_Breaker
Isolator
switch
Drawing symbol
Item
Load_Break_Fuse_Switch_Single
Load break
Thermal_Overload_Trip_Element
isolator
switch
I>
Load_Break_Fuse_Switch Scale: 1:10 Circuit_Breaker_Single
Page:
2
Load
break
Circuit
fuse switch
breaker
Isolator_Switch
Circuit_Breaker
Thermal
overload
trip element
Load_Break_Isolator_Switch_Singl
Load_Break_Isolator_Switch
Short_Circuit_Trip_Element
Thermal_Overload_Trip_Element
Short circuit
I>
trip element
rcuit_Breaker_Single
Circuit_Breaker
Load_Break_Fuse_SwitchScale: 1:10
Earth_Leakage_CB Earth
Contactor_Single
Page: 2
Contactor
leakage
- normally
circuit
open poles
breaker
Thermal_Overload_Trip_Element ConShort_Circuit_Trip_Element
tactor_Normally_Closed_Poles
I>
1
3
5
Overload
relay
Load_Break_Fuse_Switch_Single
2
4
6
Earth_Leakage_CB
Solid_State_Contactor_Single
Contactor
– normally
closed poles
Load_Break_Fuse_Switch
Circuit_Breaker_Single
Contactor_Single
Contactor
Solid_State_Contactor
Starter –
Solid state
DOL non
contactor
t_Circuit_Trip_Element
Earth_Leakage_CB reversing
Thermal_Overload_Trip_Element
ContactorContactor_Normally_Closed_Poles_Sin
_Normally_Closed_Poles
Overload_Relay
1
3
5
I>
Electronic
2
4
6 starter
Contactor_Single
Solid_State_Contactor
16
Circuit_Breaker
Overload_Relay
Contactor
1
3
5
Starter_DOL_Non_Reversing
2
4
6
Thermal_Overload_Trip_Element
Short_Circuit_Trip_Element
Contactor_Normally_Closed_Poles_Si
Early_Make_Contact
Solid_State_Contactor_Single
Electronic_Starter
y_Make_Contact
NC_Delay_On_Closing
tronic_Starter
Solid_State_Contactor
Electronic_Starter
Delay_On_Closing
Coil
Drawing
Delay_On_Closing
Item
symbol
Component controls
Coil
Coil
Coil
NC_Delay_On_Closing2
Drawing
NC_Delay_On_Closing2
Item
symbol
Starter_DOL_Non_Reversing
Dual_W inding_Coil
Solid_State_Contactor
Dual_W inding_Coil Electronic_Starter
On_DelOff
ay_delay
Timertimer
_Coil
NC_Delay_On_Closing3
coil
Coil
Electronic_Starter
On_Delay_Timer_Co
il
Dual
elay_On_Closing3
winding coil
elay_Timer_Coil Coil
On_Delay_Timer_Coil
elay_On_Opening
Off_Delay_Timer_CoOn
il delay
elay_On_Opening
timer coil
Coil
Off_DDelay
elay_timer
Timerwith
_Coil
NC_Delay_On_Opening
initiating input
Off_Delay_Timer_Coil
Off_Delay_Timer_Coil
NO_Delay_On_Closing
NO_Delay_On_Closing
Dual_W inding_Coil
On_Delay_Timer_Coil Contr
Delay_Timer_With_Initaiting_Input
Delay_Timer_With_Initaiting_Input
Control_Contact_Normally_Open_Sin
NO_Delay_On_Opening
Normally
open –
Thermal overcloses on
load contact
actuation
On_Delay_Timer_Coil
Off_Delay_Timer_Coil
Control contacts
Control_Contact_Normally_Open_Single
Control_Contact_Normally_Op
elay_On_Opening
NO_Delay_On_Opening2
Normally
Pushbutton –
closed –
momentary with
opens
on
act_Normally_Open_Single
Control_Contact_Normally_Open
Off_Delay_Timer_Coil
N/O contact
actuation
Control_Contact_Normally_Open_Single
Control_Contact_Normally_Ope
elay_On_Opening2
Thermal_Overload_Contact
Control_Contact_Normally_Open Thermal_Overload_Contact
elay_On_Opening2
Pushbutton –
Change over
momentary with
contact
Delay_Timer_With_Initaiting_Input
Control_Contact_Control_Contact_Normally_Open_Si
Normally_ClosN/C
ed contact
Control_Contact_Normally_Closed
Change_Over_Contact
Pushbutton_Momentary_NO_contact
P
ale: 1:10
ge: 3
Mushroom head
Late break
pushbutton,
contact
Control_Contact_Normally_Open_Single
Control_Contact_Normally_Op
with N/C contact
Momentary_NO_contact
Pushbutton_Momentary_NC_contact
Pus
Change_Over_Contact
Late_Br eak_Contact
Early make
e_OveControl_Contact_Normally_Open
r_Contact
Late_Br eak_Contact
Change_Over_Contaccontact
t
Late_Br eak_Contact
Momentary_NC_contact
Pushbutton_Mushroom_Head_NC_contact
L
a
t
e
_
B
r
e
a
k
_
C
o
n
t
a
c
t
Momentary_NC_contact
Pushbutton_Mushroom_Head_NC_contact
1 2
Control_Contact_Normally_Closed
2
2
Early_Make_Contact
Change_Over_Contact
Pushbutton_Mushroom_Head_Emergency
NC_Delay_On_Closing
OFF RUN START
17
A
B
OFF RUN START
e: 1:10
e: 3
NO_Delay_On_Opening
NO_Delay_On_Opening2
ay_On_Opening2
Drawing
symbol
Thermal_Overload_Contact
Item
Pushbutton_Momentary_NO_contact
Drawing
Item
symbol
Control contacts
Emergency Stop
N/C –
switch. Latching
Early_Make_Contact
NC_Delay_On_Closing
NC_Delay_On_Closing
NC_Delay_On_Closing2
opens
operator with
NC_Delay_On_Closing
NC_Delay_On_Closing2
ton_Momentary_NO_contact
instantly, Pushbutton_Momentary_NC_contact
mushroom head.
delay on
Arrow – denotes
closing
positive opening
operation
Momentary_NC_contact
Pushbutton_Mushroom_Head_NC_contact
1 2
NC_Delay_On_Closing2
N/C
–
2 position rotary
delay
on
NC_Delay_On_Closing
NC_Delay_On_Closing2
NC_Delay_On_Closing2
switch
opening
Pushbutton_Mushroom_Head_Emergency
2
N/O –
NC_Delay_On_Closing3
NC_Delay_On_Opening
delay on
NC_Delay_On_Opening closing
n_Mushroom_Head_Emergency
3 position “turn
to operate”
OFF RUN START
A
B NO_Delay_On_Closing
switch. Spring
NC_Delay_On_Opening
return from
NO_Delay_On_Closing
Two_Position_Rotary_Switch
D
C
right to centre. 2
contacts
N/O delay on
tion_Rotary_Switch
Three_Position_Turn_To_Operate_Switch
NO_Delay_On_Closingopening
NC_Delay_On_Opening
NO_Delay_On_Closing
NO_Delay_On_Closing
NO_Delay_On_Opening
NO_Delay_On_Opening2
NO_Delay_On_Opening2
NO_Delay_On_Opening2
Thermal_Overload_Contact
Thermal_Overload_Contact
Thermal_Overload_Contact
NO_Delay_On_Opening2
Thermal_Overload_Contact
Pushbutton_Momentary_NO_contact
Pushbutton_Momentary_NC_contact
18
Pushbutton_Momentary_NC_contact
Thermal_Overload_Contact
Pushbutton_Momentary_NC_contact
Pushbutton_Mushroom_Head_NC_
Pushbutton_Mushroom_Head_NC_con
Position_Switch_Make_Contact
Position_Switch_Break_Contac
Scale: 1:10
Page: 4
Position_Switch_Make_Contact
e: 1:10
n_Switch_Make_Contact
:4
p
Position_Switch_Break_Contact
Position_Switch_Break_Contact
Position_Switch_Break_Contact
Position_Switch_Make_Contact
Float_Level_Actuated_Contact
Position_Switch_Break_Contact
Position_Switch_Break_Contact
Drawing
symbol
Float_Level_Actuated_Contact
Drawing
Item
symbol
Item
p
n_Switch_Break_Contact
Float_Level_Actuated_Contact
External control functions
Position
/ limit
p Float_Level_Actuated_Contact
actuated
p
Pressure_Actuated_Contact
Float_Level_Actuated_Contact
contact
Scale: 1:10
Page:
Float / 5level
Pressure_Actuated_Contactactuated
contact
Θ
sure_Actuated_Contact
Foot actuated
contact / switch
Foot_Actuated_Contact
Θ
Θ
Position_Switch_Make_Contact
Position_Switch_Make_Contact
Position_Switch_Break_Contact
Θ
Position_Switch_Break_Contact
Temperature
p
Temperature_Actuated_Contac
Foot_Actuated_Contact
Pressure
actuated
contact
Float_Level_Actuated_Contact
ot_Actuated_Contact
Foot_Actuated_Contact
Foot_Actuated_Contact
Position_Switch_Break_Contact
Float_Level_Actuated_Contact
Foot_Actuated_Contact
Pressure_Actuated_Contact
Foot_Actuated_Contact
actuated
contact
Θ
Temperature_Actuated_Contact
A
Temperature_Actuated_Contact
p
Temperature_Actuated_Contact
A
Θ
Control
circuit fuse
Control_Circuit_Fuse
Temperature_Actuated_Contact
A
Control_Circuit_Fuse_With_The_
Capacitor
Pressure_Actuated_Contact
AmmeterFoot_Actuated_Contact
Other devices
Indicating
Θ
Control_Circuit_Fuse
Control_Circuit_Fuse_With_The_Line
light. Colour
code added
Inductor
ontrol_Circuit_Fuse
Pressure_Actuated_Contact
Foot_Actuated_Contactnext to Control_Circuit_Fuse_With_The_Line
Foot_Actuated_Contact
Temperature_Actuated_Contact
Capacitor
Ammeter
Control_Circuit_Fuse_With_The_Line
Indicating_Light
Control_Circuit_Fuse
Control_Circuit_Fuse_With_The_Line
symbol
Capacitor
Ammeter
Control_Circuit_Fuse_With_The_Line
Surge
Indicating_Light Resistor
Inductor
Temperature_Actuated_Contact
Circuit_Fuse_With_The_Line
diverter
Capacitor
Capacitor Indicating_Light
Surge_Divertor
Indicating_Light
Inductor
Earth /
ground
Control_Circuit_Fuse
symbol
arth_Ground_Symbol
U V W Indicating_Light
Potentiometer
Potentiometer
UM V Current_Transformer1
W
Current_Transformer2
Current_Transformer1
Earth_Ground_Symbol
Potentiometer
Control_Circuit_Fuse_With_The_Li
Resistor
Surge_Divertor
Surge_Divertor
Control_Circuit_Fuse_With_The_Line
Control_Circuit_Fuse
Current
Resistor
Earth_Ground_Symbol
Surge_Divertor
transformer
ResistorEarth_Ground_Symbol
Indicating_Light
Earth_Ground_Symbol
Earth_Ground_Symbol
Control_Circuit_Fuse_With_The_Line
Indicating_Light
Thermistor /
Potentiometer
U Earth_Ground_Symbol
V WCurrent_Transformer1
RTD
Potentiometer
Current_Transformer1
M1
M
U13 ~
V1 W1
Current_Transformer1
Thermistor_RTD
U1 V1 W1
M1Thermistor_RTD
M
19
Voltage_Transformer1
A
Earth_Ground_Symbol
Current_Transformer1
Drawing
Item
Current_Transformer1
symbol
Capacitor
Ammeter
Voltage transformer
Scale: 1:10
Page: 5
Voltage_Transformer1
Capacitor
Voltage_Transformer2
Inductor
A
Voltage_Transformer2
Meter. Function letter
added inside
Other devices
Resistor
U
Ammeter
M1
V
Potentiometer
U1 V1
W
M
3~
Potentiometer
Capacitor
M1
Motor AC, 3 phase.
Star or delta connected
M
3~
Thermistor_RT
U2 V2
U1 V1 W1
Motor_AC_3Phase
M1
M
3~
U2 V2 W2
Motor_AC_3Phase_Dua
Motor AC, 3 phase,
6 wire connected, 2
speed, star/delta, dual
winding
Resistor
Potentiometer
Motor_AC_3Phase_Dual_Winding
U
M1
V
Wiring_Example
U1 V1 W1
W
M
3No_Connection
~
M1
M
3~
Wiring_Junction_Con
U2 V2 W2
20
Capacitor
Inductor
Inductor
No_Connection
Inductor
Thermistor_RTD
Drawing
Resistor
Thermistor_RTD
symbol
ng_Junction_Connection
U
Terminal_For_Connection_Of_Wiring
V
Power wiring
installed
between
devices
W
M1 Potentiometer
M
3~
Thermistor_RTD
U1 V1 W1
M1Thermistor_RTD
Wiring_Examples
M
Motor_AC_3Phase
Wiring_Examples
3~
Wiring connections
Drawing Potentiometer
Item
symbol
Item
Plug_In_Connection2
U2 V2 W2
M1
M
Thermistor_RTD
Scale: 1:10
3~
Page: 6
Control
Bridge
wiring
installed
U2rectifier
V2 W2
between
Plug_In_Connection1
devices
Wiring – for
future or
customer
installation
No
Motor_AC_3Phase_Dual_Winding
Wiring_Examples
U1Plug
V1in W1
connection
connection
5
6
Mechanical
Motor_AC_3Phase_Dual_Winding
interlock
Bridge_Rectifier
Q
Mechanical
latching
Wiring_Examples
device
Mechanical_Interlock
7
8
Break contact
Mechanical_Interlock
Wiring_Examples
Wiring Mechanical_Latching_Device
Terminal_For_Connection_Of_Wiring
Wiring_Junction_Connection
No_Connection
junction
Terminal_For_Connection_Of_Wiring
7
8
connection
Make contact
Break contact
A1
13
21 33 43
Terminal
4
1
2for 3
connection
Wiring_Junction_Connection of wiring A2
Terminal_For_Connection_Of_Wirin
14
22 34 44
Make contact
Numbering_Sequence_Example
Terminal_For_Connection_Of_Wiring
3
4
bering_Sequence_Example
Terminal_For_Connection_Of_Wiring
Bridge_Rectifier
Plug_In_Connection1
Bridge_Rectifier
Identification_Number_31E
A1
13
A2
A1
13
21
21
33
Plug_In_Connection2
14
22
33
43
53
61
73
83
Plug_In_Connection2
A2
14
22 34
44
54
62
74
84 Bridge_Rectifier
34
21
Scale: 1:10
2.2 Marking Page:
and 7identification of terminals of
contactors and associated overload relays
1:10
7
Per IEC 60947-4-1, the purpose of identifying terminals of contactors and
associated overload relays is to provide information regarding the function
of each terminal or its location with respect to other terminals or for other use.
A1
2.2.1 Marking and identification of terminals of contactors
Coil terminals are always marked alphanumerically
A2
A1
A1
B1
A2
B2
A2
Coils1
Contactor coil
A1
A1Coils1B1
A1 A2
A3
A2
A2
B2
A1
B2
A1
Coils2
B1
A1
A3
B2
A2
A2
A2
Coils
two windings in parallel. Four or three terminals E1
A1 havingB1
A2
E2
Coils2
2.2.1.2
Marking andCoils3
identificationCoils4
of terminals ofCoils3
main
circuits
Coil_Marking_2
Coil_Marking_3
The terminals of the main circuits are marked by single figure numbers and
an alphanumeric system.
2/T1
1/L1
13
21
E1
Coils4
4/T2
3/L2
S..
6/T3
5/L3
13
22
E2
8/T4
7/L4
X1
H..
S..
X2
13 1321
Coils5
14
2122
22
13
L1
L2
L3
U
X1
Note: Terminals may also be identified on the wiring diagram supplied
H..
with the device.
Control_Elements_D7
Signalling_Elements_DL7
X2 Control_Elements_D7
Coils5
Main_Circuit_Marking
Auxiliary_Circuit_Marking
W
V
L1
L2
U
L3
1U
L1 U1
Signalling_Elements_DL7
22
1U
Motor_Winding1
U2
A1
A1
A2
A1 A2
A2
A1 A2
A3
A3
A1 A2
Coil_Marking_2
Coil_Marking_3
A3
A1 A2
A3
Coil_Marking_1
Coil_Marking_2
Coil_Marking_1
Coil_Marking_2
A1
A2
2.2.1.3 Marking
2/T1
1/L1 and identification of terminals of auxiliary circuits
13
14
A3
4/T2
The terminals 3/L2
of auxiliary circuits are marked or identified on the diagrams
by two
figure numbers:
6/T3
5/L3
Coil_Marking_3
22
2/T1 21
1/L1
8/T4
7/L4 is a function number;
• The unit number
2/T1
1/L1
Coil_Marking_3
4/T2
3/L2
A2
•A1TheA1
figure
4/T2
3/L2
A2of the tens is a sequence number.
6/T3
5/L3
B1 B2
6/T3
5/L3
B1 B2 examples illustrate such a marking system:
The following
8/T4
7/L4
8/T4
7/L4
Coil_Marking_3
13
14
13
14
Main_Circuit_Marking
Auxiliary_Circuit_Marking
21
22
21 numbers
22 1, 2 are allocated to circuits with break contacts and
Function
13 numbers
14 3, 4 to circuits with make contacts.
Coil_Marking_4
Main_Circuit_Marking
function
Coil_Marking_4
Main_Circuit_Marking
Examples:
21
22
·3
·4
Auxiliary_Circuit_Marking
·4
·2
·1
Auxiliary_Circuit_Marking
Note: The dot ( • ) in the above examples take the place of the sequence
·1
·2
·3
·4
numbers
· 1 which
· 2should be added appropriately to the application.
·3
·4
The terminals of circuits with change-over contact elements are marked by
Auxiliary_Circuit_Marking
the function numbers 1, 2 and 4.
·4
·1
Function_Number_2
Function_Number_3
·
2
·4
·1
·2
Function_Number_1
Function_Number_2
Function_Number_1
Function_Number_2
The function numbers 5 and 6 (for break contacts) and 7 and 8
·
·
4
1
(for make contacts) are allocated to terminals of auxiliary circuits containing
· 2contacts with special functions.
auxiliary
·7
·8
·8
·5
Examples:
Function_Number_3
·6
Function_Number_3
·5
·6
·5
·6
, ·7
·8
·7
·8
Function_Number_3
Break contact delayed on closing
Make contact delayed on closing
Function_Number_5
Function_Number_6
The terminals
with special
·8
·of5 circuits with change-over contact elements
functions
are marked by function numbers 5, 6 and 8.
·
6
·8
·5
Example:
·6
Function_Number_4
Function_Number_5
Function_Number_4
Function_Number_5
13
14
·8
·5
21
22
·6
35
38
Function_Number_6
13
14 36
13
14
Function_Number_6
21
22
21
22
33
34
33
34
41
42
41
42
Function_Number_6
2/T1
1/L1
4/T2
3/L2
13
14
6/T3
13 5/L314
21
22
21
22
35
38
35
38
36
36
23
Auxiliary_Circuit_Marking
·5
·6
·5
·6
·4
·2
Sequence number
·7
·8
·7
·8
·1
Terminals belonging to the same contact element are marked by the same
ction_Number_4
Function_Number_5
Function_Number_4
Function_Number_5
sequence
number. All contact elements having the same function
have
different sequence numbers.
Examples:
13
21
33
41
14
22
34
42
Function_Number_3
13
14
21
22
33
34
41
42
Four contact elements
·8
·5
·6
13
21
35
14
22
38
36
13
21
35
14
22
38
36
Three contact elements
2.2.2 Marking and identification of terminals of overload relays
uence_Number_1
Sequence_Number_2
Sequence_Number_1
Sequence_Number_2
The terminals of the main circuits of overload relays are marked in the same
manner as the terminals of the main circuits of contactors.
The terminals of the auxiliary circuits of overload relays are marked in the same
manner as the terminals of the auxiliary circuits of contactors with specific
Function_Number_6
Scale:is1:10
functions. The sequence number
9; if a second sequence number is
AnnexA_pg2
required, it is 0.
Examples:
2/T1
1/L1
4/T2
3/L2
95
98
6/T3
5/L3
96
5
7
Overload_Relay_Marking_1
95
96 96
98
97
98
Overload_Relay_Marking_2
95
05
98
96
08
06
95
05
98
96
08
06
Alternatively, terminals may be identified
on the wiring diagram supplied
oad_Relay_Marking_3
Overload_Relay_Marking_4
with theOverload_Relay_Marking_3
device.
Overload_Relay_Marki
24
ELECTRONIC
MOTOR
CONTROL
R • ROB
T MOU
C O N TA C
TO
US
NT
IN G TO
Superior motor control with
CA7 Contactors and CEP7
Overloads.
A CA7 Contactor with CEP7 electronic
overload surpasses the competition
by covering the current range of up
to 7 separate traditional bimetallic
overloads in a single unit. Save on:
• Energy usage
• Design space
• Stock simplicity
NTU Contactors and
Overloads Module
Kickstart your learning with the
NTU Contactors and Overloads
Module!
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Free Contactor Select App
Contactor and overload selection
made easy with NHP’s FREE
Contactor Select App
Visit nhp.com.au/contactorselect
Available from your local wholesaler branch
25
2.3 Terminal markings for electric motors
Terminal markings for electric motors according to standard IEC 60947.
Motor terminal markings consist of letters and numbers. These are
arranged without gaps.
Example: U1: U, V, W = identification for winding phases.
Number after the letter = number on winding phase; 1 = start of winding,
2 = end of winding (tappings are numbered consecutively from 1, by 3, 4
and so on).
Three phase
Squirrel-cage motors
Design or type of circuit
1 speed
-1 winding
2 speeds
-2 separate windings
2 speeds Dahlander or PAM (Pole Amplitude
Modulation)
circuit
-1 winding, reversible
- low speed in series-delta-connection Δ
- high speed in parallel-star-connection YY
2 speeds
-Dahlander or PAM circuit
-1 winding, reversible
-low speed in series-star-connection Y
-high speed in parallel-star-connection YY
26
Number
of motor
terminals
Motor
terminal
markings
3
U, V, W
6
U1, V1, W1
U2, V2, W2
6
1U, 1V, 1W
2U, 2V, 2W
6
1U, 1V, 1W
2U, 2V, 2W
6
1U, 1V, 1W
2U, 2V, 2W
Scale:1:10
1:10
Scale:
Page:55
Page:
AA
A2
1:10
71:10
7
A1
B1
A2
B2
Scale:
Scale:1:10
1:10
Page:
Page:77
Ammeter
Ammeter
s1
A2
Capacitor
Capacitor
A1
A1 A1
A1 B1 A1
E1
A2
A2 A2
A2 B2 A2
E2
A2
A2
A2
A2
A2
Scale: 1:10
B1Page: 9
B1
A1
A1
B2
B2
Page: 7
Resistor
Resistor
s4
Coils2
Coils5
A2
13
Potentiometer
Potentiometer
Inductor
Inductor
Coils4
B1
A1
B1
13
A2
A2
A2
S..
C
B1
B2
Coils3
Motor windings and types of circuit with
Scale:Coils1
1:10
connection
Capacitor examples
Inductor
Coils2
Coils2
Coils1
Coils1
Coils1
Coils1
A2
A1 A1
Coils2
A1
A1
A1
A1
Coils1
A1
B1
A1
L1
A1
A1
A1
A1
X1
21
H.. A2
B2
B2B2A2
X2
22
B2
B2
A2
A2
B1
W
B1 UU VV W
M1
M1
A2
A2
A2
X2
L1 A1
E1
A1 L2 B1
B1L3
U
M
M
33~~
Coils4 Potentiometer
Coils4
Capacitor
Motor_AC_3Phase
Motor_AC_3Phase
Coils4 Y
X1
X1
X1
U1
M1
H..
H..
H..
U2 X2
V2
V1
L2
X2
X2
right_arrow
M
3~
1W
E2
A2 13 B222
13
E2W2 22U2
13
22
V2
W1
L3
L1
L2 L1 L3 L2
L1
L2
U
X1U A1
L1 X1
U B1
1V
L1
L1 L3
L1L1 L2
L21U
L3
1U
2UUU
1W
L3
W V
W
1V
2U
arrow_twosides L2
V
V
W
2
Control_Elements_
Control_Elements_
Motor_W
1U
1U
E1
1U
1U
2W
1W
1V
1W 2U
W
W
1W1U
2W
two_arrows
one_to_two
L3
L3
1W1V
1W
VV
2V
L2
S..
E2
1V
1V
2V
1W1
1W
1W
1V
romanone_delta
L2
right_arrow
left_arrow
21
21
13
2W 22
13
22
V1
L2
Delta
L3
L3
A2
X2
X2
2V
13
13
S..
S..
Y
1U
H..
H..
U2 V2 W2
1W
L3
S..
S..
Control_Elements_D7
Coils5 Thermistor_RTD
Coils5
Control_Elements_D7
Coils1
Coils2
Coils5Control_Elements_D7
left_arrow
right_arrow
arrow_twosides
Coils5
Inductor
Motor_AC_3Phase_Dual_Winding
Wiring_Examples
Motor_AC_3Phase_Dual_Winding
Motor_Winding2 Wiring_Examples
Motor_Winding1_2
Coils4
Coils5
Coils4
Delta
Motor_Winding1
2W
E1
U1 13 B121
E1 L121A1
1U13
13
21
S..
M
M
33~~
U2 V2
V2 W2
W2
U2
V
U1 V1 W1
U1 V1
V1 W1
W1
U1
E2
A2
E2
Coils3
Coils3
Motor_W
Delta
Scale: 1:10
Page: 9
M1
M1
A2
A2E2
W
ements_DL7
E1
A1
E1
B2
B2
W
Coils2
Coils3
Coils3
Coils2
Coils3
Thermistor_RTD
Thermistor_RTD
Signalling_Elements_DL7
Control_Elements_D7
Y
B1A1
A1
A1
X1
C
2W
L3
arrow_twosides
Delta
Motor_AC_3Phase_Dual_Winding
Wiring_Examples
Signalling_Elements_DL7
Signalling_Elements_DL7
Motor_Winding1
Motor_Winding1
Motor_Winding1_2
Motor_Winding1_2
ng_Elements_DL7
Motor_Winding1
Motor_Winding1_2
Signalling_Elements_DL7
Motor_Winding1
Motor_Winding1_
Con
Coils4
Coils5
Capacitor
Signalling_Elements_DL7
Motor_Winding1
Motor_Winding1_2
Inductor
Thermistor_RTD
Potentiometer
Wiring_Junction_Connection
Terminal_For_Connection_Of_Wiring
No_Connection
5
A1
1
3
Wiring_Junction_Connection
Terminal_For_Connection_Of_Wiring
No_Connection
Motor_Winding5
Motor_W
nding2
Motor_Winding3
Motor_Winding4
L1 U1
L1 U1
L1
1U U1
L1
L1
L1 2U L1
1U
1U
L1
L11U
1U
X1
L1
L1
L1 U1
1U
2U U1
U1 V1 W1
U2
H..
U2 2W
2W U2 W2 U2
2V
2W
2V
M1
W2
U2
W2
W2 V2
2V
V2
M
V2 W2
V22W
V2
1V V1
X2
W1
V1 3 ~
W1
V1
W1
V1
1W
1V
W1
V1
1W1W
1V
one_to_two
1W
1V
L3
L2
L3
L2
L2
L3 romanone_delta
L2
2U
2UL3
L2
L3 2V
L2
L3
L2
2V
2U
L2
two_arrowsL3
arrow_twosides
U2 V2 W2
1U
1V
2W
L2
L2
L3A1
5
1
3
M1
2W
2V
2W
2V1W
U1 1W
V1 W1
1V
1W
L1
L12U A2
2
L2
L3 1
2U
U
4
3
6
5
2
4
6
1V
1V
L1 1U
L1 1U
L1 1U
2W
romantwo_YY
2U 2V
romanone_delta
2U
1W
1W
L3
A1 L3
1
3
5
3
5
L1
L12U
2U
L1 U1
L1
L1
L1 1U
1U2U
0
L1
L1
2U
2U
A2
2
4
6
D1 D2
F1 U<
V
4
2
1
4
3
1V
1V
1U
1U
1
Motor_Winding4
Motor_Winding4
Mo
6
5
L1
1U
2W
2W
2W
U1 V1 W1 2 4 6
U1
U1 V1 W1
U1 V1
V1 W
W
2W
U1 V1 W1
M1
M1
1V
1V
M1
1V
M1
1V
M1
U2 1V
M Contactor_With_Thermal_Overload_Relay
M1
2W
2V
ATX
Voltmeter
UV
W2
1W
1W
V2
1W
1W
U2 V2 W2
U2
2V 3 ~
2U
U2 V2 W2
U2 V2
V2 W
W
2Uromanone_Y 2V
2V1W
romantwo_YY
U2Contactor_With_Thermal_Overload_Relay
V2 W2
2V
W1
2V
2V V1 2V
2V
2V
1W
1V
1U
1U
1U
2W
1U
1V
1W
1V
2W
2W
1V
1W 2W
1V
2W
L3
L2 L2
L2
1UL2
L2
1VV2 W2
2U
2W
L2
L3
L2
U2
L3
L2
L3
L2
L2
L3
L3
L3 L3
L2
L3
L2
L3
U1 V1 W1
C1 C2
F2
100
80
Plug_In_Connection2
Bridge_Rectifier
Motor_Winding5
Motor_Winding6
Motor_Winding6
Motor_Winding7
65
or_Winding5
Motor_Winding6
Motor_Winding7
Motor_Winding5
Motor_Winding6
A2
2 Motor_Winding5
4
6
Motor_Winding2
Motor_Winding3
Motor_Winding5
Motor_Winding6
Motor_Winding7
Motor_AC_3Phase_Dual_Winding
Wiring_Examples V
50
1
3
5 Wiring_Junction_Connection
0 Terminal_For_Connection_Of_Wiring
2
1W
1W
1W
1V
1U
1U
1V Contactor_With_Thermal_Overload_Relay
2W
2V
2W
2V
2W
U2 2U
V2
2WW2W L2 1U
2V
2U
V L2
L3
L3
L2 L2
L3
L3
L3
L3
one_to_two
romanone_delta
L3
L2
1W
romanone_Y
romantwo_YY
2W
100
Wiring_Junction_Connection Motor_Winding2
Terminal_For_Connection_Of_Wiring
Motor_Winding2
Motor_Winding3
Motor_Winding3
Motor_Winding4
or_Winding2
Motor_Winding3
Motor_Winding4
Motor_Winding2
Motor_Winding3
A1
1 D13 D25
Signalling_Elements_DL7
Motor_Winding1
80
Motor_Winding2Potentiometer
Motor_Winding3
Motor_Winding4
Thermistor_RTD
65
Motor_AC_3Phase_Dual_Winding
Wiring_Examples V
2
4
6
Plug_In_Connection1 A2
Plug_In_Connection2
Bridge_Rectifier
Plug_In_Connection1
Plug_In_Connection2
Bridge_Rectifier
F1 U<
50
nding5
Motor_Winding6
Motor_Winding7
1
L1
L1
2U
2U
r_With_Thermal_Overload_Relay
UV
2U
1W
ST
2W
ATX
Motor_Winding7
Motor_Winding7
M
L1
2U
L1 1U
6
Voltmeter
D1 D2
F1 U<
Voltmeter
1V
1W
2V
1V
2W
1U
UV
2V
L2
M1
27
Three phase
Squirrel-cage motors
Design or type of circuit
1 speed in delta-connection
(operation)
-changeover facility for star-deltastarting
-connection example for clockwise
motor rotation
1 speed in delta-connection
(operation)
-connection example for
anticlockwise motor rotation
28
Number
of motor
terminals
6
6
Motor terminal
markings
U1, V1, W1
U2, V2, W2
U1, V1, W1
U2, V2, W2
L1
L2
U
L3
W
1U
1W
V
Motor_Winding1
1V
Motor_Winding1_2
Capacitor
Inductor
L1
2U
L1
1U
2W
1W
L3
2V
1W
1V
L2
2U
1V
1U
2W
L3
2V
L2
Motor windings and types of circuit with connection examples
Motor_Winding3
Capacitor
Motor_Winding4
Inductor Scale: 1:10
Page: 8
Thermistor_RTD
Potentiometer
L1
2U
L1
U1 V1 W1
1W
2W
L3
M1
1V
M
3 ~2V
1U
M1
U1 V1 W1
L3
U1
U2 V2 W2
L2
U2
U2 V2 W2
U2 V2 W2
Scale: 1:10
ale: 1:10
Potentiometer
ge: 8 Page: 8
Motor_Winding6
Thermistor_RTD
Motor_Winding7
Motor_AC_3Phase_Dual_Winding
L1
L2
U1 V1 W1
L1
L3 V1 W1
L2 L1
L3 L2 U1
U1 V1 U1
W1 V1 W1
M1
M
3~
W2 V2 W2
U2 V2 U2
W2 V2 U2
Motor_Winding8
Motor_Winding8
Motor_AC_3Phase_Dual_Winding
Wiring_Junction_Connection
Switch_012
Switch_012
Wiring_Junction_Connection
Plug_In_Connection2
RomanOne
RomanOne
Plug_In_Connection2
Switching_On
Switching_On
Motor_Winding8
M
Wiring_Examples
U1 V1 U1
W1 V1 W1
L2 L1
L3 L2
L3
U1 V1 U1
W1 V1 W1
U2 V2 W2
U2 V2 W2
U2 V2 W2
U2 V2 W2
Motor_Winding9
Motor_Winding9
Wiring_Examples
Motor_Winding10
Motor_Winding10
Switch_012
Terminal_For_Connection_Of_Wiring
Pushbutton_Manual_Actuation
Pushbutton
Pushbutton_Manual_Actuation
Terminal_For_Connection_Of_Wiring
Pushbutton
RomanOne
Bridge_Rectifier
RomanTwo
RomanTwo
Bridge_Rectifier
Switching_Off
Switching_Off
Switching_On_Off
Switching_On_Off
Switching_On
right_triangle
right_triangle
left_triangle
X
X
29
3. Starting and switching motors
3.1 Selection criteria overview
Electrical motors must be accelerated from rest up to the operating speed
with a starting device. In the case of variable speed drives, the motor
controller must also manage the motor speed during operation. The
motor and method of starting selected depend on the load torque, the
desired starting characteristic (starting current, acceleration) and on the
characteristic of the supply.
3.1.1 Main criteria for the selection of the starting method
When making the decision whether to use a
• Direct-on-line starter
• Electromechanical starter for the starting with reduced current or
• Electronic motor control devices (soft starters, variable speed drives)
the following items should be taken into account to find a suitable
solution from the points of view of application and productivity:
• How high is the torque required to start the load?
• Can transmission components such as belts, gearboxes or chains be
damaged by the high starting torque with direct starting?
• Does the plant require gentle and continuous acceleration or are
torque peaks permissible?
•
•
Are there any restrictions with respect to supply loading?
Do technologically more complex products offer additional functions
for optimisation of the application (for example pre-warning functions
of motor protection relays, mirror contacts for safety controllers,
communication links etc.)?
• Are features of controlled coasting to a stop or braking to be taken into
account?
• Are aspects of speed control to be taken into account once the motor
has started (for example from process engineering or energy saving
perspectives)?
The selection of suitable starting methods is a critical factor in achieving
optimum economic efficiency in every motor control application. The
table in section 3.4 provides guidance with respect to the various methods
for starting squirrel-cage induction motors.
Note: For assistance in selecting the best starting method for your
application requirements, contact NHP.
30
3.2 Selecting the right contactor for an application
There are a few factors that must be considered to ensure you pick the right
contactor, but the main ones are:
1. The type of load
2. The current or kW rating required
3. The coil voltage
4. Any accessories required
For motor loads the most common rating is called AC-3. AC-3 means
starting and stopping 3 phase motors and is the majority of applications for
contactors. Motors are ‘inductive’ loads which have a large starting current.
For reversing starters, two contactors are required and if the duty includes
inching or jogging the motor, you may need to use AC-4 ratings. Generally,
applications like crane hoist would use this duty; otherwise you can still use
AC-3.
If you are switching a heater bank or some lighting loads you can use AC-1
ratings. AC1 means switching ‘Non Inductive’ or resistive’ loads. The contactor
ratings for AC-1 are higher than AC-3.
The second factor to consider is the current or kw rating of the motor (Motor
nameplate full load current or kW) or the current rating of the heater load for
AC-1. Next, the coil voltage (or control voltage) used to activate the coil must
be known. It is often a different voltage to the motor mains 3 phase voltage.
Applying incorrect voltage to a coil will cause it to burn out so you need get
this one right.
What type of auxiliary contacts and accessories are required? For example It
may include a mechanical interlock for a reversing starter.
3.3 Selecting the right overload for an application
When it comes to overload relay selection, the major difference between
electronic overloads – commonly referred to as EOL’s - and thermal bi-metal
relays is that EOL’s have a more accurate tripping tolerance band.
Overload selection is based on the Motor Nameplate Full Load Current rating
of the motor it will be protecting and because overloads are normally fitted
directly to contactors, this needs to be considered as there may be a number
of different versions for the same current rating. Ultimately, the final selection
of the part number is determined by which size contactor it is being fitted to.
Correct trip class selection can be determined from the motors maximum
locked rotor current and maximum locked rotor time. This information can
be typically found on the Motor Nameplate or from the manufacturer.
By simply downloading NHP’s Contactor Select App on the iTunes App
Store, you can select the right contactor and overload for your application in
seconds.
31
3.4 Characteristic features of the commonly
used starting methods for squirrel-cage
induction motors
Kind of motor
Method of starting
Mains
Starting procedures for squirrel-cage standard motors
(typical values)
Direct on Line
(DOL)
Υ–Δ- (star delta)
Auto- transformer
strong
weak
weak-medium
Load during start
full
low
low-medium
Relative starting
current IA/ Ie
6 ... 8 (= IAD)
1.3 ... 2.7
(= 1/3 IAD)
1 ... 5
(=0.25…0.65 IAD)
selectable
Relative starting
torque TA/Te
1.5 ... 3
(= TAD)
0.5 ... 1
(= 1/3 TAD)
0.4 ... 2
(=0.25…0.65 TAD)
Run-up time
(normal)
0.2 ... 5 s
2 ... 15 s
2 ... 20 s
Run-up time
(heavy duty start)
5 ... 30 s
15 ... 60 s
20 ... 60 s
Characteristic
features
High acceleration
with high starting
current
Start with reduced
torque and current;
current and torque
peaks at switchover
Similar to Υ–Δ, but
without switchoverinterruption;
selectable steps
Application area
Sites with strong
power supply
which permit
the high starting
torque
Motors which are
only loaded after
run-up
Remote / rural and high
torque loads
Notes:
IA = Motor starting current
Ie (FLC) = Rated operational current of motor
TA= Motor-Starting torque
Te (FLT) = Rated operational torque of motor
k = Voltage reduction factor
TAD = Motor starting torque at full voltage
1) Start frequency controlled, torque wide range adjustable
32
Soft starters
Variable speed drives
weak-medium
weak
low-medium
low-medium
2 ... 6
1 ... 2
0.15 … 2
TA = k2 ∙TAD
TA adjustable 1)
0.5 ... 10 s
0.5 ... 10 s
10 ... 60 s
5 ... 60 s
Adjustable starting characteristics.
Also controlled Stop possible. No
harmonics
High available torque at low current.
Adjustable starting characteristics.
Harmonic mitigation to be considered
Starts which require a gentle or
adjustable torque characteristic,
or reduced starting currents
Usually for operational speed adjustment.
Energy saving possible
33
4. Diagram types
A diagram is a graphical representation of the circuit. It shows how the
circuit elements must be connected to enable a predetermined function to
be fulfilled. In the power and installation fields, circuits are always drawn in
the power-off, switched-off state. There are various diagram types: circuit
diagram, schematic wiring diagram, simplified diagram.
4.1 Circuit diagram
The circuit diagram shows clearly the sequence of the control process,
without regard to the physical arrangement of the equipment. According to
task and effect, a distinction is made between main, control and measuring
circuits, etc. For the extensive circuit diagrams of larger systems, the use of
drawing proformas with section numbers is recommended. By this means it
will be easier to locate the switching elements of the different equipment.
Main circuit
L1
L2
L3
N
PE
Q1
K1
A1
1
3
5
A2
2
4
6
1
3
5
2
4
6
V
W
F1
U
M1
34
M
3~
M1
K2
A1
1
3
5
A2
2
4
6
Representative Main circuit diagram
for a reversing starter
e Name: pg39_Schematic_Wiring_Diagram
ation: 2.2 Schematic Wiring Diagram
le: 1:13 (Normal Size x 0.77)"
4.2 Schematic wiring diagram
The schematic diagram contains all the equipment, all elements and
connections for main and control circuits being shown in their correct spatial
locations. In the case of small diagrams, the schematic wiring diagram is clear
and easily surveyed. With larger diagrams it can soon become difficult to
survey and requires a large outlay on drawings. In spite of this, the schematic
wiring diagram is still widely used.
L1
L2
L3
N
PE
F7
Q1
A
1
K1
F1
3
5
N
2
4
6
1
3
5
97
95
2
4
6
98
96
1U 1V 1W
M1
A1
13
21
A2
14
22
K1
F2
1U
3
5
2
4
6
1
3
5
97
95
2
4
6
98
96
A1
13
21
A2
14
22
2U
M
3~
2U 2V 2W
1
13
21
14
22
13
21
S3
1W
1V
2W
2V
S2
14
22
21
S1
22
Representative schematic diagram for a 2 speed motor with separate
motor windings
35
4.3. Control circuit diagrams
4.3.1 Momentary contact control
Momentary or impulse contact control can be achieved using momentary
pushbuttons and/or selector switches with momentary action.
Us (L1)
F7
95
97
96
98
F1
21
S1
22
21
21
22
22
S3
13
S2
K1
14
K2
21
13
13
14
14
K1
22
N (L2)
36
14
21
A2
H1
A1
13
22
A2
K1
K2
K2
H2
A1
(F8)
Representative control circuit diagram for a 2 speed motor with separate
motor windings
File Name: pg38_Momentary_Contact_Control
Location: 2.1 Circuit Diagram Control Circuit
Impulse contact control
Scale: 1:10 (Normal Size)
4.3.2 Maintained contact control
Maintained contact control can be achieved by using latched pushbuttons
and/or selector switches.
Us (L1)
F7
95
97
96
98
F1
S1
K1
13
K2
14
K2
21
K1
22
21
A2
K2
A1
14
22
A2
K1
13
H1
H2
A1
(F8)
N (L2)
Representative control circuit diagram for a 2 speed motor with separate
motor windings
File Name: pg38_Maintained_Contact_Control
Location: 2.1 Circuit Diagram Control Circuit
Maintained contact control
Scale: 1:10 (Normal Size)
37
4.4 Simplified diagram
Simplifications to circuit diagrams can be of practical value for:
• Improving ease of use
• Reducing the number of circuit documents
Simplifications should only be made to the extent that the informative
value of the circuit diagram is not impaired and its use rendered more
difficult.
By far the most frequent simplification is the single-line representation of
multiple conductor systems. The terminal markings here can be omitted as
long as they are already contained in the detailed documentation.
2
Two conductors
3
Three conductors e.g. L1/L2/L3
4
Four conductors e.g. L1/L2/L3/PE
5
Five conductors e.g. L1/L2/L3/N/PE
The diagrams in chapters 5…7 are structured on the following
principle:
• Circuit diagram for main circuit and control circuit (auxiliary circuit)
• Description of functional sequence
• Application information
• Characteristics (special technical features)
• Application examples
The circuit diagrams are relatively generic; however the designation of
the terminals can differ from that shown on the drawings on certain
devices.
The specific circuit diagrams for the devices are to be found on
Sprecher+Schuh data-sheets and are available from NHP.
Please take into account your local Service and Installation Rules (SIR),
as well as any site specific requirements.
Where required, diagrams can be combined.
38
5
L1 / L2 / L3 / N / PE
4 L1...3 / PE
3
4
A1
K1
1, 3, 5
3
A2
F1
3
3
2, 4, 6
A1
K2
1, 3, 5
3
A2
F2
4
3
2, 4, 6
3
1U, 1V, 1W
M1
M
3~
2U, 2V, 2W
Representative simplified diagram for a 2 speed motor
File Name: pg40_Simplified_Diagram
Location: 2.3 Simplified Diagram
Scale: 1:10 (Normal Size)
39
5. Direct on line starters and reversing starters
5.1 Several command locations
Contactors and starters can be actuated from several locations using the
concept below.
5.1.1 Momentary contact control
- Connect ON command button contacts in parallel
- Connect OFF command button contacts in series
In this way ON and OFF can be selected as required and independently from
one another at any of the three locations A, B or C.
Control circuit
Momentary contact control
F7
Us (L1)
S1
A
S2
B
S3
C
C
13
S13
B
13
S12
14
A
13
S11
14
14
K1
13
14
95
F1
96
A2
K1
N (L2)
A1
File Name: pg58_Momentary_Contact_Control
Location: 3.4 Several Command Locations Impulse contact control
Scale: 1:10 (Normal Size)
40
5.1.2 Maintained contact control
Two-way switching allows activation from either switch. Operation optional by
- Switch S11 – command location A or
- Switch S12 – command location B
Control circuit
Maintained contact control
Us (L1)
F7
S11
A
B
S12
95
F1
96
A1
K1
N (L2)
A2
File Name: pg58_Maintained_Contact_Control
Location: 3.4 Several Command Locations Maintained contact
Scale: 1:10 (Normal Size)
41
5.2 Direct on line starters (Contactor with
overload relay)
Main circuit
L1
L2
L3
N
PE
Q1
K1
F1
A1
1
3
5
A2
2
4
6
95
1
3
5
96
2
4
6
V
W
U
M1
M
3~
File Name: pg54_Starters_CA3_CT3_Main_Circuit
Location: 3.2 Starters CA 3 + CT 3 Main Circuit
Scale: 1:10 (Normal Size)
42
Control circuit
Maintained contact control
Us (L1)
F7
13
S1
K1
14
13
14
95
97
96
98
F1
A2
K1
H1
A1
N (L2)
File Name: pg54_Maintained_Contact_Control
Location: 3.2 Starters CA 3 + CT 3 Control Circuit
Maintained contact control
Scale: 1:10 (Normal Size)
43
5.2.1 Maintained contact control
Connection
Switching on
Actuate control switch S1: 13-14 (Ο  I).
Control circuit to contactor coil K1: A2 is made.
Contactor coil system actuates main contacts (K1:1-2,
3-4, 5-6) and auxiliary contacts (K1: 13-14).
K1 is closed and the load is connected to the mains.
With control switch S1 closed, the starting command
is maintained – contactor K1 remains closed.
A break in the control voltage causes the contactor
to drop out.
Reapplying control voltage closes the contactor once
more. Therefore, any connected devices are on.
Switching off
Takes place by:
- Actuate control switch S1: 13-14 (from I  O ) or
- Responding to thermal overload relay F1: 95-96 or
responding to the control circuit fuse F7.
The control voltage Us to contactor coil K1: A2 is
interrupted, causing contactor K1 to drop out. The
mains contacts disconnect the load from the mains.
Note
To prevent danger for e.g. the operating personnel,
uncontrolled restarting of machines and equipment
should be avoided (thermal overload relay to
«Manual reset»). On the other hand, the restarting of
equipment can be necessary for certain purposes.
Reliable signalling (e.g. by means of lamp H1) can be
provided by means of the auxiliary contact K1: 13-14.
Contactor
sizing
According to the motor rated operational current
Ie AC-3. For applications such as high number of
operations per hour, inching duty or ambient
temperatures above 60° C, you may need to use a
different current rating. Consult NHP for advice.
Characteristics
44
Connections to be made on installation
Locked rotor starting current 4…8 Ie (FLC)
Locked rotor torque
1.5…3 Te (FLT)
Acceleration time
0.2…5s
Example of application: Direct switching of threephase motors.
5.2 Direct on line starters (Contactor with
overload relay)
Main circuit
Control circuit
Momentary contact control
Us (L1)
L1
L2
L3
N
PE
F7
21
S1
Q1
22
13
K1
F1
A1
1
3
5
S2
K1
14
A2
2
4
6
95
1
3
5
96
2
4
6
V
W
U
M1
M
3~
13
14
95
97
96
98
F1
A2
K1
H1
A1
N (L2)
File Name: pg55_Momentary_Contact_Co
Location: 3.2 Starters CA 3 + CT 3 Control C
Impulse contact control
File Name: pg54_Starters_CA3_CT3_Main_Circuit
Location: 3.2 Starters CA 3 + CT 3 Main
Circuit
Scale:
1:10 (Normal Size)
Scale: 1:10 (Normal Size)
45
5.2.2 Momentary contact control
Connection
Switching on
Switching off
46
Connections to be made on installation
Actuate ON button S2: 13-14 (I).
Control circuit to contactor coil K1: A2 is made.
Contactor K1 coil system actuates main contacts
(K1:1-2, 3-4, 5-6) and auxiliary contacts (K1: 13-14).
K1 is closed and the load is connected to the mains.
Normally open contact K1: 13-14 ensures that control
voltage Us is not interrupted after releasing switch S2
(self-holding contact).
Therefore contactor K1 remains closed.
An unintentional control voltage interruption causes
the closed contactor to drop out.
Takes place by:
- Actuation of OFF button S1: 21-22 (O) or
- Responding to thermal overload relay F1: 95-96 or
responding to control circuit fuse F7.
The control voltage Us to contactor coil K1:A2 is
interrupted, causing contactor K1 to drop out. To
recommence the start procedure, reactuate button S2.
Note
No automatic remaking of contactor takes
place following a supply failure (control voltage
interruption). Unintentional, automatic restart is not
possible.
Signalling (e.g. by means of signal lamp H1) can be
provided by means of the self-holding contact K1:
13-14 or via a separate auxiliary contact.
Contactor
sizing
According to the motor rated operational current
Ie AC-3. For applications such as high number of
operations per hour, inching duty or ambient
temperatures above 60° C, you may need to use a
different current rating. Consult NHP for advice.
Characteristics
Locked rotor starting current 4…8 Ie (FLC)
Locked rotor torque
1.5…3 Te (FLT)
Acceleration time
0.2…5s
Example of application: Direct switching of threephase motors.
5.3 Direct on line starters with mechanical latch
Main circuit
L1
L2
L3
N
PE
Q1
K1M
F1
A1
1
3
5
13
A2
2
4
6
14
95
97
1
3
5
96
98
2
4
6
V
W
U
M1
K1R
E1
57
65
E2
58
66
M
3~
File Name: pg60_Starters_CA7_CT7_CV7_Main_Circuit
Location: 3.6 Starters CA 3 + CT 3 with latch CV 3 Main circuit
Scale: 1:10 (Normal Size)
47
Control circuit
Maintained contact control
Us (L1)
F7
97
F1
S1
98
K1R
65
K1M
66
13
K1R
14
57
58
96
F1
95
A2
K1M
A1
E2
K1R
H1
E1
F8
N (L2)
File Name: pg60_Maintained_Contact_Control
Location: 3.6 Starters CA 3 + CT 3 with latch CV 3 Control Circuit
Maintained contact control
Scale: 1:10 (Normal Size)
48
5.3.1 Maintained contact control
Connection
Switching on
Switching off
Connections to be made on installation
Takes place by:
- Actuation of control switch S1 (ΟI ).
The actuating of S1 completes the control circuit to
contactor coil K1M: A2.
Contactor K1M closes (contacts K1M: 13-14 close)
Latch K1R engages (contacts K1R: 57-58 close)
Latch mechanism K1R holds the starter
mechanically in the start position without the
coil system being continuously energised.
In delayed fashion contact K1R: 65-66 switches off
control voltage to contactor coil K1M:A2.
Takes place by:
- The changeover of control switch S1( I  Ο).
The actuating of S1 completes the control circuit to
the tripping coil of latch K1R:E2.
The latch mechanism unlocks, causing contactor
K1M to drop out.
The control circuit to the tripping coil is opened by
contact K1M: 13-14.
Note
By the responding to the overload relay, the control
circuit of
- Starting coil K1M is opened by contact F1: 95-96
- Cut-off coil K1R is closed by contact F1: 97-98,
Thus the contactor drops out in each case (trip-free
release).
Operation signalling is provided with signal lamp H1
by means of contact K1R: 57-58.
It must be ensured that the control circuit to cut-off
coil K1R is interrupted. Command contact S1 can
have either two or three switching positions.
Contactor
Sizing
According to the motor rated operational current Ie
AC-3, For applications with ambient temperatures
above 60° C, you may need to use a different
current rating.
Consult NHP for advice.
Examples of
applications
Controls with maintenance of the switching state in
the event of a power failure.
49
5.3 Direct on line starters with mechanical latch
Main circuit
L1
L2
L3
N
PE
Q1
K1M
F1
A1
1
3
5
13
A2
2
4
6
14
95
97
1
3
5
96
98
2
4
6
V
W
U
M1
K1R
E1
57
65
E2
58
66
M
3~
File Name: pg60_Starters_CA7_CT7_CV7_Main_Circuit
Location: 3.6 Starters CA 3 + CT 3 with latch CV 3 Main circuit
Scale: 1:10 (Normal Size)
50
Control circuit
Momentary contact control
Us (L1)
F7
21
13
97
S1
F1
22
14
98
13
S2
14
K1R
65
K1M
66
13
K1R
14
57
58
96
F1
95
A2
K1M
A1
N (L2)
E2
K1R
H1
E1
F8
File Name: pg61_Momentary_Contact_Control
Location: 3.6 Starters CA 3 + CT 3 with latch CV 3 Control Circuit
Impulse contact control
Scale: 1:10 (Normal Size)
51
5.3.2 Momentary contact control
Connection
Switching on
Switching off
Note
52
Connections to be made on installation
Takes place by:
- Actuation of ON button S2: 13-14 (I).
The control circuit to contactor coil K1M: A2 is completed by the start impulse.
Contactor K1M closes (contacts K1M: 13-14 close)
Latch K1R engages (contacts K1R: 57-58 close)
Latch mechanism K1R holds the starter mechanically
in the start position without the coil system being
continuously energised.
In a delayed fashion contact K1R: 65-66 switches off
the control voltage to contactor coil K1M: A2.
Takes place by:
- Actuation of OFF button S1: 21-22 (O).
The control circuit to the tripping coil of latch K1R:
E2 is completed by the cut-off impulse. The latch
mechanism unlocks, causing contactor K1M to drop
out. The control circuit to the tripping coil is opened
by contact K1M: 13-14.
By the responding of the overload relay, the control
circuit of
- Starting coil K1M is opened by contact F1: 95-96
- Cut-off coil K1R is closed by contact F1: 97-98,
Thus the contactor drops out in each case (for trip-free
release).
Operation signalling is provided with signal lamp H1
by means of contact K1R: 57-58.
It must be ensured that the control circuit to cut-off
coil K1R is interrupted.
Connection
Connections to be made on installation
Contactor
Sizing
According to the motor rated operational current Ie
AC-3, For applications with ambient temperatures
above 60° C, you may need to use a different current
rating.
Consult NHP for advice.
Examples of
applications
Controls with maintenance of the switching state in
the event of a power failure.
53
5.4 Reversing starters
Main circuit
L1
L2
L3
N
PE
Q1
K1
A1
1
3
5
A2
2
4
6
1
3
5
2
4
6
V
W
F1
U
M1
M1
K2
A1
1
3
5
A2
2
4
6
M
3~
File Name: pg68_Starters_CAU7_CT7_Main_Circuit
Location: 4.1 Reversing startes CAU 3 + CT 3 Main circuit
Scale: 1:10 (Normal Size)
54
Maintained contact control
Us (L1)
F7
95
97
96
98
F1
S1
K1
13
K2
14
K2
21
22
A2
A2
K2
A1
14
21
22
K1
N (L2)
K1
13
H1
H2
A1
(F8)
File Name: pg69_Maintained_Contact_Control
Location: 4.1 Reversing startes CAU 3 + CT 3 Control Circuit
Maintained contact control
Scale: 1:10 (Normal Size)
55
5.4.1 Maintained contact control
Connection
Connections to be made
on installation
Actuate control switch S1 either clockwise ( ) or
anticlockwise ( ) according to motor rotation
required.
Clockwise
Actuate control switch S1 ( )
- Contactor coil system actuates main contacts
(K1: 1-2, 3-4, 5-6) and auxiliary contacts
(K1: 13-14)
- K1 is closed and the load is connected to the mains
for clockwise motor rotation
-Electrical interlocking: auxiliary contacts (K1:21-22)
are opened, preventing anticlockwise motor rotation
- With control switch S1 closed the starting command
is maintained – contactor K1 remains closed for
clockwise motor rotation
Anticlockwise
Actuate control switch S1 ( )
- Contactor coil system actuates main contacts (K2:
1-2, 3-4, 5-6) and auxiliary contacts (K2: 13-14)
- K2 is closed and the load is connected to the mains
for anticlockwise motor rotation
- Electrical interlocking: auxiliary contacts (K2:21-22)
are opened, preventing anticlockwise motor rotation
- With control switch S1 closed the starting command
is maintained – contactor K2 remains closed for
anticlockwise motor rotation
Note: Contactors K1 and K2 can be mechanically
interlocked for additional reliability and safety
Switching off
Takes place by:
- Actuation of control switch S1 to O (off position)
- Responding to thermal overload relay contact F1:
95-96 or control circuit fuses (S) F7 (F8).
The control voltage Us to contactor coil K1 (with
clockwise rotation), respectively K2
(with anticlockwise rotation) is interrupted, causing
the closed contactor to drop out.
s
s
Switching on
s
s
56
Connection
Connections to be
made on installation
Characteristics
Locked rotor
starting current
Locked rotor
starting torque
Acceleration
time
Clockwise
Anticlockwise
4…8 Ie
1.5…3 Te
4…8 Ie
1.5…3 Te
0.2…5 s
0.2…5 s
Examples of
applications
Motors for cranes, conveyors, spindle motors,
thread-cutting units and roller doors.
Contactor
dimensioning
Both contactors K1 and K2 according to the motor
rated operational current Ie AC-3.
For applications such as high number of operations
per hour, inching duty or ambient temperatures
above 60° C, you may need to use a different current
rating. Mechanical interlock required. Consult NHP
for advice.
57
Main circuit
L1
L2
L3
N
PE
Q1
K1
A1
1
3
5
A2
2
4
6
1
3
5
2
4
6
V
W
F1
U
M1
M1
K2
A1
1
3
5
A2
2
4
6
M
3~
File Name: pg68_Starters_CAU7_CT7_Main_Circuit
Location: 4.1 Reversing startes CAU 3 + CT 3 Main circuit
Scale: 1:10 (Normal Size)
58
Control circuit
Momentary contact control
Us (L1)
F7
95
97
96
98
F1
21
S1
22
21
21
22
22
S3
13
S2
K1
14
K2
13
13
14
21
14
K1
22
14
21
A2
H1
A1
13
22
A2
K1
K2
K2
H2
A1
(F8)
N (L2)
File Name: pg69_Momentary_Contact_Control
Location: 4.1 Reversing startes CAU 3 + CT 3 Control Circuit
Impulse contact control
Scale: 1:10 (Normal Size)
59
5.4.2 Momentary contact control
Connection
Connections to be
Actuate control button S2 either clockwise (
S3 anticlockwise ( ) according to
motor rotation required.
Clockwise
Actuate control switch S2 ( )
- Interruption of contactor K2 control circuit
- Closing of contactor K1
- Self-holding of K1 by contact K1: ..13-..14
Anticlockwise
Actuate control switch S3 ( )
- Interruption of contactor K1 control circuit
- Closing of contactor K2
- Self-holding of K2 by contact K2: ..13-..14
Switching off
Takes place by:
- Actuation of control switch to O (off position)
- Responding to thermal overload relay contact F1:
95-96 or control circuit fuses (S) F7 (F8).
The control voltage Us to contactor coil K1 (with
clockwise rotation), respectively K2
(with anticlockwise rotation) is interrupted, causing
the closed contactor to drop out.
Characteristics
Locked rotor
starting current
Clockwise
Anticlockwise
4…8 Ie
4…8 Ie
Locked rotor
starting torque
1.5…3 Te
1.5…3 Te
Acceleration time
0.2…5 s
0.2…5 s
) or
s
s
Switching on
s
s
The changeover from clockwise to anticlockwise
rotation can take place direct since switches S1
and S2 are electrically interlocked via contacts S1:
21-22, S2: 21-22
Actuation of button S2 ( ) causes:
-Drop-out of contactor K1 by means of contact S2:
21-22
-The time-delayed closing of contactor K2
(reversing time tu min. 50ms)
-The self-holding of K2 by means of contact K2:
..13-..14.
s
Reversal
60
Connection
Connections to be made
Note
Reversal of motor rotation direction from
anticlockwise to clockwise takes place in reversed
sequence. Reversal using for instance, limit switches
with quick-break action necessitates an additional
interruption of 40 ms; use timer element Z 01 in
place of contacts K1, K2: 21-22.
Direction of rotation is signaled with lamps H1 and
H2. Contactors K1 and K2 can be mechanically
interlocked for additional reliability and safety.
Examples of
applications
Motors for cranes, conveyors, spindle motors,
thread-cutting units and roller doors
61
6. Reduced voltage starters
6.1 Star-delta starters
Main circuit
L1
L2
L3
N
PE
Q1
Scale: 1:10
Page: 9
LS
K1M
H
1
A1
A2
F1
Y
LH
3
5
2
4
6
1
3
5
2
4
6
A1
K2M
D
A2
right_arrow
M1
4
4
5
K3M
Y
6
LD
A1
1
3
5
A2
2
4
6
De
left_arrow
Motor connections
for clockwise rotations
U2 V2 W2
F1 : 2
2
3
Y
Delta
U1 V1 W1
M1
1
6
U1 V1 W1
arrow_twosides
LD
right_arrowtwo_arrows
arrow_t
Motor connections
for anti-clockwise
rotations
U2 V2 W2
Ie = motor rated operational current
File Name:
pg74_Starters_Stardelta_CAY7_CT7_Main_Circuit
= current
in the supply leads L s
Location: 5.1 Star-delta starters CAY3 + CT 3 Main circuit
Y
=
star
Scale: 1:13 (Normal Size x 0.77)
∆ = delta
one_to_two
romanone_delta
A1
A2
62
1
3
one_to_two
romanone_Y
romano
5
2
1
4
3
6
5
2
4
6
100
80
65
50
0
A1
1
A2
2
1
2
Maintained contact control
Us (L1)
F7
95
97
96
98
F1
13
13
14
14
K1M
S1
17
K4T
18
28
K3M
21
K2M
22
K1M
H
A2
A1
K2M
D
A2
A1
21
22
K3M
Y
A2
A1
K4T
A1
H1
A2
(F8)
N (L2)
File Name: pg75_Maintained_Contact_Control
Location: 5.1 Star-delta starters CAY3 + CT 3 Control Circuit
Maintained contact control
Scale: 1:13 (Normal Size x 0.77)
63
6.1.1 Maintained contact control
Connection
Description
Switching on
Switching off
64
Connections to be made
A traditional method for reducing starting current is the
YΔ (star delta) circuit; the voltage at the
motor winding in the Y-circuit being reduced as opposed to the voltage in the Δ-circuit by a factor 1/3. The
torque and the locked rotor starting
current in the Y-circuit being still approx. 30% of
the values with Δ-connection. As soon as the
motor reaches 80% rated speed in Y-connection, it’s
windings are switched to Δ.
Actuate control switch S1
- Closing of contactor K1M, closing of contact
K1M:13-14
- Closing of star contactor K3M
- Interruption of delta contactor K2M (K3M:21-22 opens)
- Closing of timer K4T, time setting is initiated
- Once timer has expired interruption of star contactor
K3M occurs (K2M:21-22 opens)
- K4T:17-28 contacts close and delta contactor K2
closes
Takes place by:
- Opening control switch S1:13-14 or
- Responding to thermal overload relay F1:95-96 or
responding to the control circuit fuse F7(F8).
The control voltage Us to contactor coil K1M and
K2M:A2 is interrupted, causing contactor K1 and K2 to
drop out. The main contacts disconnect the load from
the mains
Contactor
dimensioning
Contactors K1M and K2M according to 0.58 Ie .
Contactor K3M according to 0.34 Ie
(starting time < 20s, up to 12 starts/h).
Lead
dimensioning
Minimum line cross-section Ls, LD corresponding to
fuse F9. Line cross-section LH
corresponding to 0.58 Ie. Set scale F1 (designation YΔ,
i.e. scale value = √3 • current in F1) to 0.58 Ie.
Connection
Connections to be
Time delay
when changing
over from star
to delta
Delay of approx. 40 ms due to brief delay of auxiliary
contact block, guarantees short-circuit proof
changeover with the briefest possible current-free
pause.
Clockwise and
anticlockwise
motor rotation
Connection in conformity with circuit diagram
provides for minimum motor loading due to
reversing surge.
Direction of rotation changed by reversing U1, V1 and
U2, V2 on motor.
Characteristics
Y-Connection Starting
Locked rotor
starting current
Locked rotor
starting torque
Acceleration
time
1.5…2.4 Ie
After Delta transition at
80% ns
93% ns
3.3…5 Ie
1.5…2.4 Ie
0.4…0.8 Te
1.5…2.5 Te
1….2 Te
2….16s
1…8s
0.2…4s
Example of
application:
Starting of large three-phase motors in a weak
network.
65
Main circuit
L1
L2
L3
N
PE
Q1
Scale: 1:10
Page: 9
LS
K1M
H
1
A1
A2
F1
Y
LH
3
5
2
4
6
1
3
5
2
4
6
A1
K2M
D
A2
Delta
right_arrow
M1
4
U1 V1 W1
6
Y
A1
1
3
5
A2
2
4
6
D
left_arrow
right_arrowtwo_arrows
arrow_
Motor connections
for anti-clockwise
rotations
Ie =Filemotor
operational current
Name:rated
pg74_Starters_Stardelta_CAY7_CT7_Main_Circuit
starters
CAY3
=Location:
current5.1inStar-delta
the supply
leads
L s + CT 3 Main circuit
Scale: 1:13 (Normal Size x 0.77)
Y = star
∆ = delta
one_to_two
romanone_delta
A2
66
Y
LD
arrow_twosides
A1
romantwo_YY
K3M
6
U2 V2 W2
one_to_two
4
5
Motor connections
for clockwise rotations
U2 V2 W2
F1 : 2
2
3
LD
U1 V1 W1
M1
1
1
3
romano
romanone_Y
5
2
1
4
3
6
5
2
4
6
Contactor_With_Thermal_Overload_Relay
100
80
65
50
0
A1
1
A2
2
1
2
romantwo_YY
ATX
Contactor_With_The
Momentary contact control
Us (L1)
F7
95
97
96
98
F1
21
S1
22
13
13
14
14
K1M
S2
17
K4T
18
28
K3M
21
K2M
22
K1M
H
A2
A1
K2M
D
A2
A1
21
22
K3M
Y
A2
A1
K4T
A1
H1
A2
(F8)
N (L2)
File Name: pg75_Momentary_Contact_Control
Location: 5.1 Star-delta starters CAY3 + CT 3 Control Circuit
Impulse contact control
Scale: 1:13 (Normal Size x 0.77)
67
6.1.2 Momentary contact control
Connection
Connections to be made
Description
A traditional method for reducing starting current
is the YΔ (star delta) circuit; the voltage at the
motor winding in the Y-circuit being reduced as
opposed to the voltage in the Δ-circuit by a factor
1/3. The torque and the locked rotor starting
current in the Y-circuit being still approx. 30% of
the values with Δ-connection. As soon as the
motor reaches 80% rated speed in Y-connection,
it’s windings are switched to Δ.
Actuation of control switch S2:
- Closing of main contactor K1M with timer K4T and
star contactor K3M, motor runs in star connection.
Switching on
After expiry of the time set at timer K4T, contact
K4T: 65-66 opens and contact K4T: 57-58 closes,
causing star contactor K3M to drop out. After
approx. 40 ms, contact K4T:17-18 closes, causing
delta contactor K2M to close.
The motor continues to run in delta connection.
Electrical interlocking of star and delta contacts is
achieved via contacts.
Switching off
Contactor
dimensioning
68
Takes place by:
- Actuation of control switch S1: 21-22 or
- The responding to thermal overload relay F1 by
means of contact F1: 95-96 or control circuit fuse(s)
F7 (F8).
Interruption in control voltage Us causing
contactors and timer to drop out.
Contactors K1M and K2M according to 0.58 Ie .
Contactor K3M according to 0.34 Ie
(starting time < 20s, up to 12 starts/h).
Connection
Connections to be made
Lead
dimensioning
Minimum line cross-section Ls, LD corresponding to
fuse F9. Line cross-section LH
corresponding to 0.58 Ie. Set scale F1 (designation YΔ,
i.e. scale value = √3 • current in F1)
to 0.58 Ie.
Time delay
when changing
over from star
to delta
Delay of approx. 40 ms due to brief delay of
auxiliary contact block, guarantees short-circuit proof
changeover with the briefest possible current-free
pause.
Clockwise and
anticlockwise
motor rotation
Connection in conformity with the circuit diagram
provides for minimum motor loading due to reversing
surge.
Direction of rotation changed by reversing U1, V1 and
U2, V2 on motor.
Characteristics
Y-Connection Starting
After Delta transition at
80% ns
93% ns
Locked rotor
starting current
1.5…2.4 Ie
3.3…5 Ie
Locked rotor
starting torque
0.4…0.8 Te
1.5…2.5 Te
1….2 Te
Acceleration
time
2….16s
1…8s
0.2…4s
Example of
application:
Starting of large three-phase motors in a weak
network.
1.5…2.4 Ie
69
6.2 Autotransformer starters
Main circuit
L1
L2
L3
N
PE
Q1
K1M
S
A1
A2
1
2
3
4
5
6
K2M
T
A1
A2
1
2
3
4
5
6
K3M
R
100
80
65
50
0
A1
1
3
5
A2
2
4
6
1
3
5
2
4
6
V
W
F1
U
M1
M
3~
File Name: pg82_Starter_Autotransformer_Main_Circuit
Location: 5.5 Autotransformer starters Main Circuit
Scale: 1:13 (Normal Size x 0.77)
70
Control circuit
Momentary contact control
Us (L1)
F7
33
K5A
34
21
17
S1
K4T
22
18
13
K5A
S2
14
13
K3M
14
95
97
96
98
A2
K1M
A1
N (L2)
K4T
A2
A1
21
22
F1
K5A
28
K1M
S
A2
A1
K2M
T
13
13
14
14
K2M
A2
A1
K1M
21
22
K3M
R
A2
A1
(F8)
File Name: pg83_Momentary_Contact_Control
Location: 5.5 Autotransformer starters Control Circuit
Impulse contact control
Scale: 1:13 (Normal Size x 0.77)
71
6.2.1 Momentary contact control
Connection
Description
As opposed to star-delta circuits, only three motor
lines and connections are required here. Therefore,
the motor starts with the voltage reduced by the
transformer ratio and a correspondingly smaller
current. By this means the mains current is reduced
by the square of the transformer ratio, although
it is in most cases appreciably higher since it
includes the relatively high transformer losses.
On the other hand, the motor torque falls by a
square of the voltage at the windings. Usually the
autotransformers have three selectable tapping’s
in each phase for matching the motor starting
characteristics to the starting conditions.
Switching on
Actuation of control switch S2: 13-14 causes:
- Closing of control contactor K5A
- Starting of the time set at timing relay K4T by
contact K5A : 13-14 and
- Closing of star contactor K1M by means of
contact K4T: 17-18
- Contact K1M: 13-14 causes transformer contactor K2M to close
The following takes place after expiry of the set time
at timing relay K4T:
- Opening of contact K4T : 17-18, causing
drop-out of star contactor K1M
- Closing of the delay contact K4T: 17-28 and thus
the closing of main contactor K3M
- Transformer contactor K2M drops out by means
of contact K3M: 21-22.
Switching off
Takes place by:
- Actuation of control switch S1: 21-22 or - the
responding to thermal overload relay F1 by means
of contact F1: 95-96 or control circuit fuse(s) F7 (F8).
Interruption of control voltage Us causing the
dropout of auxiliary contactor, contactors
and timing relay.
Notes
72
Connections to be made
Starting transformers are only supplied for limited
number of operations per hour and short starting
times (short-time operation transformer).
Connection
Connections to be
Contactor
dimensioning
The main contactor is selected according to the
motor rated operational current. Transformer contactor
and star contactor are only made for a brief period
during starting, but they cannot usually be selected
according to this short-time loading because they have
to possess sufficient closing/opening capacity, with
both contactors dropping out in a random fashion
during starting, (the star contactor at each start during
changeover).
Characteristics
Starting
Locked rotor
starting current
Locked rotor
starting torque
Acceleration
time
Example of
application:
Starting of large three-phase motors in a weak
network.
1.3…5 Ie
After line at
80% ns
3.3…5.5 Ie
93% ns
2.2…3.5 Ie
1…2.4 Te
1.5…2.5 Te
1….1.6 Te
2.5….50s
1…8s
1…10s
73
7. Additional applications
7.1 Circuit breakers KTA7 for motor starting
Main circuit
L1
L2
L3
PE
1
L1
3
L2
5
L3
Q1
I> I> I>
T1
2
M1
T2
4
T3
6
M
3~
Manually actuated circuit breakers can be employed for the switching
and protection of motors in continuous or low frequency operation.
For effective ON and OFF switching with remote control or with a high
frequency of operation, a contactor is connected on the load side.
The circuit breaker then functions as an overload and short-circuit
protection, whilst the normal operating currents are switched by the
contactor.
The contactor can be controlled from one or more command locations
via maintained or momentary contacts.
74
7.2 Circuit breakers KTA7 with contactor
Main circuit
L1
L2
L3
PE
Q1
13
21
14
22
1
L1
3
L2
5
L3
I> I> I>
K1M
M1
T1
2
T2
4
T3
6
1
3
5
2
4
6
M
3~
File Name: pg90_KTA7_With_Contactor
Location: 7.2 Circuit Breakers KTA 3 with contactor Main Circuit
Scale: 1:10 (Normal Size)
75
Control circuit
Momentary contact control
Us (L1)
Q2
Q1
Control circuit breaker
(not shown on main circuit)
13
21
14
22
21
S1
22
13
S2
13
33
14
34
K1M
14
A2
K1M
H1
H2
A1
N
H1 Operation
H2 Maintenance
File Name: pg90_Control_Circuit_KTA7_With_Contactor
Location: 7.2 Circuit Breakers KTA 3 with contactor Control Circuit
7.2.1 Momentary
Scale: 1:10contact
(Normalcontrol
Size)
Switching on
Switching off
76
Actuate MPCB Q1 and pushbutton S2
- Contactor K1M is closed
- Contacts K1M:13-14 and 33-34 close, ensuring
uninterrupted supply after S2 button is released
- Motor is now connected to mains
Takes place by:
- Actuation of the off button S1
- MPCB Q1: 13-14 removes power from coil, opening
the contactor K1M
- Tripping of the MPCB, causing contacts 21-22 to
close and signal a fault
- Tripping of the circuit breaker upstream
7.3 Electrical heating, lamps and illumination
equipment
Correct contactor selection is important to ensure efficiency of use and
longevity of both the equipment and switchgear in use.
The following table contains an overview of the AC ratings covered in this
topic and a description of the typical applications associated with them.
Category
Typical Application
AC-1
Non-inductive or slightly inductive loads,
resistance furnaces
AC-5b
Switching of incandescent lamps
AC-6b
Switching of capacitor banks
AC-21
Switching of resistive loads, including moderate
overloads
DC-1
Non-Inductive or slightly inductive loads,
resistance furnaces
77
7.3.1 Electrical heating devices
Electrical heating devices are for example used for heating rooms,
industrial resistance furnaces and air conditioning plants.
When contactors are used utilisation category AC-1 should be used as a
basic for AC current and DC-1 for direct current. For manual switching,
a load-switch with corresponding load-switching capacity (AC- 21) is
sufficient.
Lamps and illumination equipment
Lamps can basically be divided into two categories, with selection of
the contactor being dependent on the type of lamp being used. The
following table indicates the AC rating that will need to be used to select
the correct contactor:
78
Tungsten Filament Lamps
Utilisation category
General purpose incandescent
AC-5b
Special purpose incandescent
AC-5b
Infrared
AC-5b
Sodium iodine
AC-6b
Discharge Lamps (with Ballast)
Utilisation category
Fluorescent lamps - mercury vapour
AC-6b
High/low pressure sodium
AC-6b
Quartz
AC-5b
Halogen metal-vapour
AC-5b
8. Soft starters PCS
8.1 Soft starter typical application duty ratings
Soft starter ratings are strongly influenced by the starting time and
starting current characteristics of the driven machine. The following table,
is designed to be used in conjunction with the soft starter current ratings
table to ensure accurate soft starter selection.
Application
Duty
Agitator
Heavy
Atomiser
Heavy
Bottle washer
Normal
Centrifuge
Severe
Chipper
Severe
Compressor – Recip (Loaded)
Severe
Compressor – Recip (Unloaded)
Heavy
Compressor – Screw (Loaded)
Heavy
Compressor – Screw (Unloaded)
Normal
Conveyor – Belt
Severe
Conveyor – Roller
Normal
Conveyor – Screw
Heavy
Crusher – Cone
Normal
Crusher – Jaw
Severe
Crusher – Rotary
Normal
Crusher – Vertical impact
Normal
Debarker
Normal
Dryer
Severe
Dust collector
Normal
Edger
Normal
Fan – Axial (Damped)
Normal
Fan – Axial (Un-damped)
Severe
Fan – Centrifugal (Damped)
Normal
Fan – Centrifugal (Un-damped)
Severe
79
8.1 Soft starter typical application duty ratings
Application
Duty
Fan – High pressure
Severe
Grinder
Normal
Hydraulic power pack
Normal
Mill
Severe
Mill – Ball
Severe
Mill – Hammer
Severe
Mill – Roller
Severe
Mixer
Severe
Palletiser
Severe
Planer
Normal
Press
Normal
Pump – Bore
Normal
Pump – Centrifugal
Normal
Pump – Positive displacement
Heavy
Pump – Slurry
Severe
Re-pulper
Severe
Rotary table
Heavy
Sander
Heavy
Saw – Bandsaw
Severe
Saw – Circular
Normal
Separator
Severe
Shredder
Severe
Slicer
Normal
Tumbler
Heavy
The above table is intended as a guide only. Individual machine and
motor characteristics will determine the actual start current and start
time requirements.
Notes:
80
Normal duty rating - 350% FLC, 10 second start
Heavy duty rating - 400% FLC, 20 second start
Severe duty rating - 450% FLC, 30 second start
8.1.1 Applying PCS starting modes to your application
The starting mode selected on the PCS soft starter depends on
the application and what the primary goal of achievement is. The
below information is to be used as a guide, for detailed and specific
information, including PCS product brochure please refer to NHP.
To reduce high inrush currents or to reduce peak demand utility
charges
This can be accomplished by using the Current Limit Start mode. The
current limit setting can be adjusted to provide 150%, 250%, 350% or
450% of full load amps during start. The start time is also user adjustable
to 2, 5, 10 or 15 seconds.
Note: if the motor is not up to speed after the selected time elapses, the
PCS will transition to full voltage.
% FLC
500
400
Current limit
300
200
100
0
0
2
4
6
8
10
Time - seconds
12
13
14
16
Applications:
• All applications where the main focus is to reduce electrical stress
although significant mechanical advantages will also be realised.
• Ideal for high inertial loads, e.g., fans, chippers, grinders, etc.
81
To reduce excessive starting torque or to reduce damage, loss or
spillage of product
This can be accomplished by using the Timed Voltage Ramp Soft Start
mode. The timed voltage ramp soft start mode offered by the PCS has
the most general application. User adjustments for initial torque and start
ramp allow the PCS to be configured for a variety of applications.
The initial torque can be adjusted to 15%, 25%, 35% or 65% of locked rotor
torque. The start ramp time can be adjusted to 2, 5, 10 or 15 seconds.
% Voltage
100
80
Start ramp time
60
40
Start voltage
20
0
0
2
4
6
8
10
Time - seconds
12
13
14
16
Applications:
• All applications where the main focus is to reduce mechanical stress
although significant electrical advantages will also be realised.
• Ideal for pumps, conveyors, small fans, compressors, etc.
82
To minimise damage to product caused by sudden stopping
This can be accomplished using the Soft Stop mode. The soft stop
function can be used to extend the stopping time of the motor and
connected load. When enabled, the ramp down time can be set to either
once, twice or three times the start ramp time setting.
The motor will stop when the output voltage from the PCS reaches the
point where the load torque is greater than the motor torque.
% Voltage
100
80
60
Stop ramp time
40
20
0
0
2
4
Time - seconds
6
8
10
Applications:
• Any application where sudden stopping may cause damage to
products or injury to persons being transported.
• Typical examples include pumps and conveyors.
83
8.2 Setup
2
3
4
5
6
7
8.2.1 DIP switches and motor full load current
Dip
Sequence Switch
Number
Settings
Settings
Current Limit
1
(3)
3
3
Initial Torque (%LRT)
US
Current Limit (%FLA)
IS
150%
2
4 5
(4, 5)
250%
4 5
15%
IS
4 5
Ie
4 5
25%
350%
4 5
450%
4 5
3
8
1 2
8
5
10
1 2
8
1 2
8
1 2
8
1 2
8
65%
4 5
1 2
8
2
1 2
8
1 2
8
Ue
IS
5
Ie
10
1 2
8
1 2
8
1 2
8
1 2
8
1 2
8
15
20
t1
25
4
9 10
30
Kick Start t2(sec)
Ik
Off
Is
9 10
0.5
Ie
9 10
t2
1.5
Off
Off
6 7
2 x t1
6 7
3 x t1
6 7
t3
t1
6 7
Aux. #1
Normal
Up To
Speed
14
Normal
14
Up to
Speed
14
Overload (OVLD)
Trip
Trip
Class
Class
OFF
11 12
10
11 12
11 12
15
Trip
Class
11 12
20
Overload (OVLD) Reset
Manual
13
Line or Delta
Up To
Speed
Optional Aux. #2
14
Trip
Class
13
8
t2
3 x t1
t1
Up To
Speed
Normal
Up to
Speed
Normal
Phase Rotation
A
B
C
A
1 L1
3 L2
5 L3
1 L1
C
3 L2
5 L3
Disabled
16
Enabled - No Fault
Disabled- No Fault
Auto
Line
B
Enabled
16
Enabled - Fault
Disabled- No Fault
Fault Contact (97, 98)
Delta
A1 - A2
(15)
Line
15
15
2 / T1
4 / T2
M
Delta
6 / T3
12 / T6 2 / T1 8 / T4 4 / T2 10 / T5 6 / T3
M
3~
97 - 98
Fault
9
t3
Normal
Normal
14
(16)
Us
2 x t1
14
Up To
Speed
14
Optional Aux. #2
(11,12)
7
1 x t1
Aux. #1
14
(13)
Ue
6 7
1 x t1
6 7
6 7
(14)
t1
9 10
Soft Stop t3(sec)
Ue
6 7
(14)
t2
1.5
t1
9 10
6
Us
1.0
9 10
Soft Stop t3(sec)
(6, 7)
Ue
Off
0.5
1.0
9 10
5
t1
25
30
9 10
(9, 10)
Us
15
20
Kick Start
Ik = 450% FLA t2(sec)
Us
Start Time t1(sec)
2
1 2
Ue
35%
4 5
Start Time t1(sec)
(1, 2, 8)
Soft Start
Soft Start
Current Limit Start
Push to Reset
Set Motor FLA
(2)
NCE
84
VISION
RIZATION
DIMENSIONS APPLY BEFORE
SURFACE TREATMENT
(DIMENSIONS IN INCHES)
SPRECHER + SCHUH PCS SOFT STARTER
(3 - 37A)
INSTALLATION INSTRUCTION SHEET
E - DOC
THIS DRAWING IS THE PROPE
ROCKWELL AUTOMATION
1
2
3
4
To adjust overload trip current, turn dial until the desired current is
PCS
Overload
aligned
with
the s pointer. Trip rating is 120% of dial setting.
Surcharge PCS
To adjust overload trip current, tu
Überlast PCS
aligned with the
pointer. Trip ratin
Pour régler l'intensité de déclenchem
Sovraccarico
PCSdelta) mode, the overload
When
using the PCS intermico
6 wire (inside
current
cadran jusqu'à ce que le pointeur
el motor
PCS FLC.
La valeur nominale de déclenchemen
mustSobrecarga
be set to 58% en
of the
PCS Sobrecarga
Zum Einstellen des Überlast-Aus
drehen, bis der Zeiger auf die gew
PCS
Auslösung erforderliche Strom betr
Per regolare la corrente di sovracca
quando la corrente desiderata no
valore nominale di intervento corris
9
Service Factor _ _
FLA _ _
Service Factor <1.15
= .9 X FLA
6
7
Service Factor >1.15
Para ajustar la corriente de dispar
hasta que la corriente deseada que
. El rango del disparo es 120% del
Para regular a corrente de disparo d
até que a corrente desejada esteja al
disparo
corresponde a 120% do ajus
8
= 1 X FLA
120%
or
Maximum Continuous
Rated (MCR) Motors
= 1 X FLA
If the service factor is unknown, set to 90% of motor FLC
e, tournez le
é souhaitée.
e cadran.
lter so weit
eigt. Der zur
en Wertes.
Overload Trip Curve Default Settings
Shown
Courbe
de déclenchement
en cas de surcharge
1 L1
3 L2
5 L3
Dip Switches
Überlast-Auslösekurve
2 3 4sgancio
5 6 7 8
1 2 3 4 5 6 7 8
Curva1 di
sovraccarico
termico
Curva9 de
Disparo
de
sobrecarga
10 11 12 13 14 15 16
9 10 11 12 13 14 15 16
Curva de Disparo de Sobrecarga
o mostrador
. A classe de
400
200
100
80
60
PUSH TO RESET
40
Reset / Test
LED
ON
1
2
3
4
5
6
7
STATUS START
COLD
RUN / ON
DEMARRAGE
A FROID
OVLD
TEMP
KALTSTART
PHASE
REVERSAL
AVVIO
A FREDDO
PHASE LOSS/
OPEN LOAD
ARRANQUE
PHASE / IMBALANCE EN FRÍO
SHORTED SCR
PARTIDA
A RUN
FRIO
TEST
/ FAULT
A1 A2 1N2 1N1 97 98 13 14
Motor
HOTFLA
START
4 T2
6 T3
9
DEMARRAGE A CHAUD
WARMSTART
Optional
Aux #2
AVVIO
A CALDO
1 - N.O. EN CALIENTE
ARRANQUE
2 - N.O. A QUENTE
PARTIDA
1 - N.C.
1 - N.O. / 1 - N.C.
Aux #1
1 - N.O.
2 T1
Class 15
800
600
HOLD TO TEST
egolatore fin
ntatore . Il
e regolato.
l cuadrante
a indicadora
Class 10
1000
t(sec)
d current is
g.
20
10
8
6
4
2
1
.8
.6
.4
.2
.1
1
Fault Contact
1 N.O.
2
4
Mult
Vielfac
Manual / Auto Overload Adjustment
Class 20
Réglage
manuel/auto
du déclenchement en cas de surcharge th
1000
800
Überlast-Einstellung
Manuell/Auto
600
400
Regolazione
manuale/automatico del sovraccarico termico
200Set dip switch 13 to Auto position. The relay resets automatically when motor thermal model
Auto:
drops below 75% of motor thermal capacity.
100 Set dip switch 13 to Manual position. Reset by pushing Reset/Test button in.
Manual:
80
Test:60Push and hold Reset/Test button for 5 seconds to manually trip. This action causes LED to
indicate a test state and N.O. fault contact (97,98) to change state. Pushing Reset/Test button again
40
Prova: t
modo la
nuovame
Tutti gli
85
Auto: E
1:10
8.2.2 Main circuit
Ensure DIP switch is set in the position which matches the motor
connection. Note that Delta mode refers the PCS soft starter being inside
the “delta loop”.
Main circuit
Line connected
(3 wire motor connection)
L1
L2
Main circuit
Inside delta connected
(6 wire motor connection)
L3
2M
1M
T1
1/L1
T2
T3
3/L2 5/L3
L1
L2
L3
AC/DC/AC
Converter
T1 T2 T3
1M
2M
10/T5
8/T4
12/T6
1/L1
3/L2 5/L3
1M
2/T1 4/T2 6/T3
VSD_SS_blocks_1
M
1M
2/T1 4/T2 6/T3
VSD_SS_blocks_2
M
3~
PCS_Line_Power_Circuit1
Line
2/T1 4/T2 6/T3
M
1M =
2M =
86
Delta
12/T6PCS_Delta_Power_Circuit1
2/T1 8/T4 4/T2 10/T5 6/T3
M
3~
PCS soft starter
Optional line contactor – useful for isolation and disconnecting
the motor in the event of a trip / fault condition. Also known as
isolation contactor.
PCS_Line_Power_Circuit2
PCS_Delta_Power_Circuit2
8.2.3 Control circuit
Maintained contact control (two-wire control)
Us (L1)
Sprecher + Schuh PCS Soft Starter
Q1
PCS
IN1
IN2
A1
A2
97
98
13
14
ON/OFF
N (L2)
LINE
CONTACTOR
K1M
Momentary contact control (three-wire control)
PCS_two_wire
Us (L1)
Sprecher + Schuh PCS Soft Starter
Q1
PCS
IN1
IN2
A1
A2
97
98
13
14
S1
S2
N (L2)
LINE
CONTACTOR
K1M
PCS_three_wire
87
9. Variable Speed Drive
9.1 Introduction
•
A Variable Speed Drive (VSD) is a device that controls the rotational
speed of an AC electric motor by controlling the frequency and voltage
of the electrical power supplied to the motor. VSDs allow a motor to continuously operate in low slip providing optimal control of acceleration, deceleration and operating speed. One key benefit which sets VSDs apart from other reduced voltage starting techniques is that it allows full motor torque at speeds up to the synchronous speed of the applied motor.
• A typical 6-pulse drive consists of three main power structures
- The rectifier bridge converts the AC supply to DC
- The filter circuit absorbs any remaining ripple thereby offering a
smooth DC supply
- The inverter converts the DC supply to pseudo AC using Pulse Width Modulation allowing control of the pulse width and frequency which
in turn controls the motor voltage and speed
• The VSD also consists of a control section which oversees the operation
of the drive and attached motor. It continuously monitors the VSD
power structures and controls the inverter as required. The control
circuit is also responsible monitoring and operation of the VSD’s internal protection features as well as any motor protection features.
88
9.1.1 Regions of Operation
A motor attached to a VSD is able to operate in one of two regions;
• The Constant Torque region - spans from 0V to 100%V and from zero
speed until motor rated speed. By maintaining a constant V/f (Volts per
Hertz) ratio the VSD enables the motor to generate motor rated torque
theoretically, from zero speed until rated speed.
• The Constant Power region – any speed above rated motor speed.
As the V/f ratio cannot be held constant above rated speed due to the
voltage being clamped at 100%, the drive will enable the motor to operate
at constant power, however, the available torque will decrease. Therefore, a
motor can be commanded to run faster than rated speed provided there is
sufficient torque available and provided the motor is mechanically capable
of operation at higher speeds.
9.2 VSD Control Algorithms
9.2.1 Overview
The control method determines how the VSD controls the motor operation.
Choosing a method depends on the type of application and it is important
to select the correct method as it can make or break your application.
Discussed below are a few of the most commonly used control methods.
9.2.2 Volts/Hertz (V/Hz) Control
•
•
•
•
This method takes a speed reference from an external source and varies the speed of the motor by maintaining a constant V/Hz ratio
It’s a simple method and gives the ability to have high frequency references
A drawback is the lack of starting torque available at low speeds (only 150% at ~3 Hz)
This method is well suited for most applications, typically fans and pumps
89
V/Hz
3.0
2.5
Torque
Per Unit
2.0
1.5
1.0
0.5
1 2 5
10
20
30
40
50
60
Speed in Hertz
Graph is a theoretical
andcurve
toand
betotaken
asa rough
a rough
guide only
Graphcurve
is a theoretical
be taken as
guide only
9.2.3 Sensorless Vector Control
• Similar principle to V/Hz control however this method provides much better speed regulation and the ability to produce a high starting torque
• Controls both the magnitude and angle between the voltage and current whereas the V/Hz method only controls magnitude
• This method can be operated in both open and closed loop control
• The auto tune feature is required to automatically detect motor parameters
• Suited for applications that require high dynamic performance, situations where the motor runs at very low speeds and applications that require direct control of motor torque
Sensorless vector control
3.0
2.5
Torque
Per Unit
2.0
1.5
1.0
0.5
1 2 5
10
20
30
40
50
Speed
Hertz guide only
Graph is a theoretical curve and to be taken
asina rough
Graph is a theoretical curve and to be taken as a rough guide only
90
60
9.3 VSD Benefits
•
•
•
•
•
•
•
Energy savings
Speed control optimises factory processes and thus improves process
control
Inherent direction control
Low start currents (theoretically gives way for infinite motor starts with
low system impact)
Soft starting/stopping capabilities protects equipment
Improves system reliability
Over-speed capability
9.4 Product Selection
A lot of information is required to ensure the selected VSD is adequate to
meet the needs of the user and application.
• Is the motor suitable for use with VSD?
• What is the application duty rating? (normal or heavy)
- This rating defines the overload capability of the VSD.
- Normal duty: Current limitations up to 110% of rated current for
60 seconds max
- Heavy duty: Current limitations up to 150% of rated current for
60 seconds max
• What voltage rating is required?
• What is the motor power rating (kW) and full load current (FLC) rating?
• What IP rating is needed? What environment will the VSD be installed in?
• What control capabilities (number of I/O) are required?
• What communications (if any) are required?
91
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Page 4
TIMER HANDBOOK
10. Timers
TIMER
A Timer
(Time
Delay
Relay)Relay)
is a device
that provides
a time delay
A Timer
(Time
Delay
is a device
that provides
a timebetween
2 events
processes.
delayor
between
2 events or processes.
Switching off a light globe consist of two separate events or processes i.e.
Switching
a light
separate
events
or events
flicking
off theoff
switch
andglobe
light consist
turning of
off.two
Without
a timer
the two
processes ie. flicking off the switch and light turning off.
occur simultaneously.
Without a timer the two events occur simultaneously.
LEGEND:
Legend
T
= Time (sec, min, hr)
1 C/O = 1 changeover contact
2 C/O = 2 changeover contacts
= Time Delayed changeover contact
DIMENSIONS (mm)
MINI D Housing
4
92
93
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Page 6
TIMER HANDBOOK
10.1 On Delay Timer
ON Delay Timer
Also known as:
• Delay ON
Also known as
• Delay “ON Energisation”
• •Delay
DelayON
“ON Make”
• •Delay
Delay“On
“ONMake”
Operate”
• Delay “On Energisation”
• Delay “On Operate”
MODE
ModeOF
of OPERATION:
Operation
• • Timing
immediately
when
power
is applied.
Timingstarts
starts immediately
when
power
is applied.
DelayedOutput
output relay
ONON
afterafter
the set
time
• •Delayed
relayturns
turns
the
set(T)time (T)
•
On the 2 C/O version the second output relay is selectable to operate
•
Disconnection of supply at any time will turn the output relays OFF
• Onasthe
2 C/O
version the
either
instantaneous
or second output relay is selectable
to operate
as either
instantaneous
output.
delayed output.
For example:
2 delay oror
(1 delayed
delay + 1 instant).
ie 2Instantaneous
delay or (1 output
delay will
+ 1mirror
instant).
Instantaneous
the power supply status.output
will mirror the power supply status.
• Disconnection
of supply
and reset the delay
time (T).at anytime will turn the output
relays
OFF and reset
the relay
delay
(T).
instantaneous
The instantaneous
output
willtime
mirror
theThe
power
supply.
output relay will mirror the power supply.
1 C/O
2 C/O
TYPICAL APPLICATIONS:
Typical Applications
Staggerstart
start of
of motors
limit
peakinrush
currentcurrent
• •Stagger
motorstoto
limit
Securitysystems,
systems, delay
system
lock lock
downdown
for set period.
allows the
• •Security
delay
system
for setItperiod.
person setting the alarm to clear the area.
It allows the person setting the alarm to clear the area.
6
94
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9:31 AM
Page 8
TIMER HANDBOOK
10.2 Off Delay Timer
Also known as:
OFF Delay Timer
• Delay OFF
Also known as
•• Delay
Delay “ON
Off De-energisation”
• Delay “On De-energisation
•• Delay
Delay “ON
“OnBreak”
Break”
MODE OF OPERATION:
Mode of operation
mustbebe
connected
for timer
to operate
•• Power
Power must
connected
for timer
to operate.
The output relay turns
ON asoutput
soon asrelay
signalturns
is applied
• The
ON as soon as trigger is applied.
• Timing
Timing starts
trigger
release.
The output relay turns OFF after a
startsonon
trigger
release.
set time delay (T)
• The output relay turns OFF after a set time delay (T)
• Disconnection of supply at any time will reset both the relay output
• and
Disconnection
delay time (T)of supply at any time will reset both the
relay output and delay time (T)
TYPICAL APPLICATIONS:
Typical applications
•
•
••
•
Stairwell light operated via momentary “ON” switch
Stairwell light operated via momentary “ON” switch
Switch OFF
of of
toilet
exhaust
fan fan. If used in
Switch
OFFdelay
delay
toilet
exhaust
If used in conjunction
withcircuit
a light circuit
the timer
will allow
conjunction
with a light
the timer
will allow
the the fan
to continue
to operate
(for a set
time)
after
the light
fan
to continue
to operate
(fordelay
a set
delay
time)
afterhas been
turned
OFF
the
light
has been turned OFF.
8
95
TIMER HANDBOOK
TRUE OFF Delay Timer
Also known as
• True
Delay
10.3
TrueOff
Off Delay Timer
• True Delay “On Break”
Also known as:
• True
Delay “On De-energisation”
• True Delay OFF
• True
“ON Break”
MODE
OFDelay
OPERATION:
• True Delay “ON De-energisation”
• The output relay turns ON as soon as power is connected
Mode of operation
• The output
soon as power is connected
• Timing
startsrelay
on turns
lossON
ofaspower.
•
Timing starts on loss of power
• The
output relay turns OFF after the delay time (T).
• The output relay turns OFF after the delay time (T)
• True
Delay timer
timer require
a minimum
charge time
before operation
• True
OffOFF
Delay
require
a minimum
charge
time
Please
consult specsPlease
as the charge
time will
vary depending
on the time
before
operation.
consult
specs
as the charge
model and the set delay time (T)
will vary
depending on the model & the set delay time (T).
Typical Applications
Switching on an extractor fan if a machine is on and to switch it off for a
fixed period
of time after the last machine has turned off
TYPICAL
APPLICATION:
• Connected to the main light switch a True Off Delay timer
allows the last person sufficient time to clear the building
before all lights are turned off.
0
96
TIMER HANDBOOK
Asymmetrical Recycler Timer
• Timer operates as soon as power is connected
• The output relay will continuously CYCLEs “ON / OFF” as
10.4
Asymmetrical Recycler
long as power is connected.
Timer
operates
as soon
as power
connected.
Theare
output relay will
• The
duration
of delay
timeis“T1”
and “T2”
continuously
cycle “ON
/ OFF” as long as power is connected. The
independently
adjustable.
duration of delay time “T1” and “T2” are independently adjustable. The
• The CYCLE can be set to begin with either the “ON” or
cycle can be set to begin with either the “ON” or “OFF” state.
“OFF” state.
TYPICAL APPLICATION:
Typical applications
Running
a discharge
pump
forevery
1hr every
hrs cycle
• • Running
a discharge
pump
for 1hr
10 hrs10
cycle
•
Turning
a
beacon
“ON”
for
2
secs
every
6
secs
• Turning a beacon “ON” for 2 secs every 6 secs cycle cycle
12
97
10.5 Multifunction Timer
The multifunction timer incorporates 7 of the most popular functions in a
single unit.
1.
[Dr] OFF Delay
2.
[Op] ON Delay
3.
[In] Interval
4.
[Id] Double Interval
5.
[Io] Fleeting OFF (ie. Interval on trigger open)
6.
[R] Symmetrical Recycling (ON first)
7.
[Rb] Symmetrical Recycling (OFF first)
The timer can be wired to operate on “Automatic” or “Manual” start.
Please refer to details on the specific timing functions as “Automatic” and
“Manual start” operation is not applicable to every function.
Important notes
• On the 2 C/O version the second output relay is selectable to operate
as either instantaneous or delayed output. i.e. 2 delay or (1 delay + 1 instant)
CGGB 06-111 30/5/06 9:32 AM Page 16
• In the case of “Automatic start/trigger ”, timing will start as soon as power
is applied. Trigger input (ie. terminal “Y1” or “5”) must be bridged to the supply (ie. Terminal “A1” or “2”).
• In the case of “Manual start/trigger ” timing will start after the trigger
signal (via external switch “S”) has been applied.
TIMER HANDBOOK
Multifunction
Multifunction Timer
Timer continued
10.5.1
[Dr]
Off delay
start)
1. [ Dr
] OFF
Delay(manual
(manual
start)
As
as as
signal
is applied
the output
relay turns
on. Timing
starts on
Assoon
soon
trigger
is applied
the output
relay
turns on.
trigger
release.
Timing
starts on trigger release. The output relay turns OFF
The
output
OFF Interruption
after a set timeofdelay.
Interruption
of supply
after
a setrelay
timeturns
delay.
supply
at any time
will
at
any time
both
the relay
delay
reset
bothwill
thereset
relay
output
andoutput
delayand
time
(T).time (T).
98
TIMER HANDBOOK
TIMER HANDBOOK
Multifunction Timer continued
Multifunction Timer continued
2. [ Op ] ON Delay (automatic & manual start)
10.5.2
[Dr]Delay
Off delay
(manual start)
2.
[ Op
] ON
(automatic
& manual start)
The output relay turns ON after a set time delay.
The output relay turns ON after a set time delay.
The
output
turns ON start
after /atrigger,
set timetiming
delay.will start
In the
case relay
of “Automatic”
In the case of “Automatic” start / signal, timing will start immediately on
immediately
on
power
up.
In the power
case of
up.“Automatic” start / trigger, timing will start
immediately
power
up. will start on the rising edge of
On “Manual”on
trigger,
timing
On “Manual” signal, timing will start on the rising edge of the “Trigger”
the “Manual”
“Trigger”
pulse.
Subsequent
of
Trigger
pulse
On
trigger,
timing
will start
onpulse
the rising
edge
of time (T) has
pulse. Subsequent application
ofapplication
signal
before
the delay
before
the delay
time
(T)time
hasdelay.
elapsed
will reset
the time
the
“Trigger”
pulse.
Subsequent
application
of Trigger
pulse
elapsed
will
reset
the
delay. the delay time (T) has elapsed will reset the time
before
Interruption of supply at any time will reset both the relay output and
delay.
Interruption
of supply
at anytime will reset both the relay
delay time
(T).
output and delay
time at
(T).
Interruption
of supply
anytime will reset both the relay
output and delay time (T).
17
17
99
TTI IMMEERR HHAANNDDBBOOOOKK
MultifunctionTimer
Timercontinued
continued
Multifunction
3. [[In
In]] Interval
Interval(automatic
(automatic&&manual
manualstart)
start)
3.
In10.5.3
thecase
case
of
“Automatic
start”the
theoutput
output
relay
turnsOn
Onas
as
In
the
“Automatic
start”
relay
turns
[In]of
Interval
(automatic
and
manual
start)
soonas
aspower
powerisisapplied.
applied.Timing
Timingbegins
beginsimmediately
immediatelyand
and
soon
In the case of “Automatic start” the output relay turns ON as soon as
the
output
relaywill
willremain
remain
On
forthe
theset
set
time
delayrelay
(T).will
the
output
relay
for
delay
(T).
power
is applied.
Timing
beginsOn
immediately
andtime
the output
Interruption
of
supply
at
anytime
will
reset
both
the
relay
Interruption
of
supply
at
anytime
will
reset
both
the
relay
remain ON for the set time delay (T). Interruption of supply at any time
output
and
timing.
output
and
timing.
will reset
both
the relay output and timing.
InIn
the
case
of“Manual
“Manual
start”
theoutput
output
relay
turns
On
as
In
the
of
“Manual
start”
the
relay
On
thecase
case of
start”
the output
relay turns
ONturns
as soon
asas
trigger
soon
as
triggersignal
signalis
isapplied.
applied.
Timing
will
begin
on
the
soon
as
begin
the
signal
istrigger
applied.
Timing
will
begin onTiming
the
risingwill
edge
of theon
trigger
rising
edgeof
ofthe
thetrigger
triggersignal.
signal.The
Theoutput
outputrelay
relayturns
turnsOff
Off
rising
edge
signal.
after
thedelay
delay
time
(T).
Subsequent
trigger
pulsesprior
prior
to
after
trigger
to
Thethe
output
relaytime
turns(T).
OFF Subsequent
after
the delay time
(T). pulses
Subsequent
trigger
the
delay
time
(T)delay
have
elapsed
will
resetwill
the
timing.
The The
the
delay
time
(T)
have
elapsed
will
reset
the
timing.
The
pulses
prior
to the
time
(T) have
elapsed
reset
the timing.
output
relay
however
will
remain
in
the
Onstate.
state.
output
however
will
remain
the
On
outputrelay
relay however
will
remain
in thein
ON
state.
18
18
100
TIMER HANDBOOK
Multifunction Timer continued
4. [ Id ] Double Interval (manual start)
As soon as trigger signal is applied the output relay turns On
[Id]
Double
interval
start)
and10.5.4
timing
begins.
The
output(manual
relay then
turns Off after the
As soon
trigger
signal
is applied
output relay
ON signal
and timing
delay
timeas(T)
for the
1st
intervalthe
whether
the turns
trigger
is
begins. Theoroutput
maintained
not. relay then turns OFF after the delay time (T) for the
1st interval whether the trigger signal is maintained or not.
Double Interval is only applicable if the trigger signal is
Double
Interval
is only
if the trigger
is applied
applied
for
longer
thanapplicable
the 1st delay
time signal
(T) and
then for longer
than the 1st delay time (T) and then released. As soon as the trigger
released.
As soon as the trigger signal is released the output
signal is released the output relay turns ON for another delay time (T) ie
relay turns On for another delay time (T) ie “Double Interval”.
“Double Interval”.
Interruption
any
time
both
the
relayand the
Interruptionofofsupply
supply atatany
time
will will
resetreset
both the
relay
output
output
and the timing.
timing.
GGB 06-111
30/5/06
9:32 AM
Page 20
TIMER HANDBOOK
Multifunction Timer continued
5. [ Io ] Interval on trigger open (manual start)
10.5.5 [Io] Interval on trigger open (manual start)
The output relay turns On as soon as the trigger signal is
The outputTiming
relay turns
ONstart
as soon
thefalling
trigger signal
released.
Timing
released.
will
onasthe
edgeis of
the trigger
will start on the falling edge of the trigger signal. The output relay turns
signal. The output relay turns Off after the delay time (T).
OFF after the delay time (T). Subsequent reapplication of trigger signal and
Subsequent
reapplication of trigger signal and release prior
release prior the output relay turns OFF will reset the delay time (T).
19
the output relay turns Off will reset the delay time (T).
6. [ R ] Symmetrical Recycler ‘ON’ first (automatic
& manual start)
The output relay will CYCLEs “ON / OFF” continuously as
long as power is connected. The delay time T1 and T2 are of
equal duration ie. Symmetrical.
101
TIMER HANDBOOK
Multifunction Timer continued
SymmetricalRecycler
recycler ‘off’
first first (automatic
7. [10.5.7
Rb ] [Rb]
Symmetrical
‘OFF’
(automatic and manual start)
& manual start)
The time period begins as soon as the trigger signal input contact is closed.
relay isrelay
OFF during
set “ON / OFF” continuously as long
TheThe
output
will the
CYCLE
delay period,
after this timeThe
it operates
the same
time T2
period.
as power
is connected.
delayfortime
T1 and
areThis
of
sequence continues with equal OFF- and ON-time periods until power
equal duration ie. Symmetrical.
supply is interrupted.
21
102
Star-delta Timer
MODE OF OPERATION:
When poser is applied to the timer, the output relay
changes over to the Star (Y) configuration for a duration
of TY.
CGGB 06-111
30/5/06
9:32 AM
Page 20
At the
end
of Delta
the TY
the output relay goes back to its
10.6
Star
Timer
normal de-energised state for a duration of TY∆.
Mode of Operation
When power is applied to the timer, the output relay changes over to the
Star (Y) configuration for a duration of T .
At the end of TY∆, the outputy relay changes over to
the
outputD relay
goes back to its normal open state for
At the end of the TTyI M
E R H A Nand
BOOK
the Delta
configuration
remains in this state until
a duration
of power supply being
applied.
power
is end
diconnected
from
the timer.
At the
of Ty ∆, the output
relay changes
over to the Delta configuration
Multifunction
Timer
continued
and remains closed
until power
is disconnected from the timer.
5. [ Io ] Interval on trigger open (manual start)
The output relay turns On as soon as the trigger signal is
released. Timing will start on the falling edge of the trigger
signal. The output relay turns Off after the delay time (T).
Ty
Subsequent reapplication of trigger signal and release prior
the output relay turns Off will reset the delay time (T).
Ty ∆
Typical applications
TYPICAL
APPLICATION:
• Star-delta
starters
• Star-delta starters
10.5.6 [R] Symmetrical recycler ‘on’ first (automatic and
6.manual
[ R ] start)
Symmetrical Recycler ‘ON’ first (automatic
&The
manual
start)
relay operates
and the time period begins as soon as the trigger
signal input contact is closed. After the set delay period the relay releases
The
output
relay
will This
CYCLEs
“ON
/ OFF”with
continuously
for the
same time
period.
sequence
continues
equal ON- andas
long
as power
is connected.
Theisdelay
time T1 and T2 are of
OFF-time
periods until
the power supply
interrupted.
equal duration ie. Symmetrical.
20
103
10.6 IP Ratings Chart
Protection grades against contact and foreign bodies - ingress protection (IP)
The Ingress Protection Scale
104
First Number
Protection Against Solid Objects
Second Number
Protection Against Liquids
IP
IP
TEST
TEST
0
No protection.
0
No protection.
1
Protected against
solid objects up to
50mm.
(eg. accidental
touch by hands).
1
Protected against
vertical falling drops
of water.
2
Protected against
solid objects up to
12.5mm
(eg. fingers).
2
Protected against
direct sprays of
water up to 15° from
the vertical.
3
Protected against
solid objects over
2.5mm (tools +
small wires).
3
Protected against
spray to 60° from the
vertical.
4
Protected against
solid objects over
1mm (tools + small
wires).
4
Protected against
water sprayed
from all directions
- limited ingress
permitted.
5
Protected against
dust - limited ingress permitted (no
harmful deposit).
5
Protected against
low pressure jets
of water from all
directions - limited
ingress permitted.
6
Totally protected
against dust.
6
Protected against
strong jets of
water eg. for use on
shipdecks - limited
ingress permitted.
7
Protected against
the affects of immersion between 15cm
and 1m.
8
Protected against
long periods of
immersion under
pressure.
9K
Protected against
close range, high
pressure, high
temperature (80˚C)
water jets
10.7 Circuit Breakers
Circuit breakers are switching devices capable of making, carrying and
breaking currents under normal circuit conditions. They are also capable
of making, carrying for a specified time and breaking currents under
specified abnormal circuit conditions such as a short circuit.
These timely conditions are denoted by the miniature circuit breaker’s
curve type. The three main curve types are B, C and D and selection of the
curve type is application dependant. For example, a circuit breaker may
require a greater tolerance of normal periods of overcurrent conditions
such as an in-rush current in general motor starting applications. Hence,
knowledge of the application is imperative to circuit breaker and curve
selection.
A graphical representation of the main curve types is shown below:
t(s)
B
3
C
5
D
10
20
In
Incorrect selection of the curve type can cause nuisance tripping, damage
of equipment and injury.
The following table categories the different curve types along with general
information and typical applications to make selection simple.
105
B Curve
C Curve
D Curve
• 3-5x rated current
of the device
• 5-10x rated current
of the device
• 10-20x rated current
of the device
• Used for control
circuits
• Most common MCB
• High in rush loads
• General circuit
applications
• Transformers
• Fault loop
impedance
• Long cable runs
• General motor
starting
• Motors starting high
inrush
• Car park lighting,
bridges etc
Please contact NHP for more information and detail on MCB tripping
characteristics.
106
10.8 Short circuit coordination for motor
starting time current curves
Fuses and circuit breakers can be used as short-circuit protective devices
for the contactors. The test criteria that apply in this case are stipulated by
EN 60947-4-1.
Coordination types
Two types of assignment are defined in the standards that correspond to
two different levels of damage.
The following applies to both types of assignment:
In the event of a short-circuit, the short-circuit protective device used must
be able to disconnect the overcurrent that occurs. Persons or other parts
of the system must not be put at risk.
Coordination type 1
• The load feeder (e.g. motor starter) can be
inoperable after each short-circuit.
• Damage to the contactor and the overload
relay is permissible and it is only possible to
continue operation after defective devices
have been repaired or replaced.
Coordination type 2
• After a short-circuit, there must be no
damage to the load feeder devices.
• However, the contactor contacts can lightly
weld if they can be easily separated again
without distorting the contact pieces.
• Allows for the starter to be returned to service,
until a maintenance inspection can be
scheduled
Further information
For further information, including component selection and specification
tables to suit Type 2 Coordination, please contact NHP.
107
11. Appendix
11.1 AC Motor Currents Table
Standard motors have 3 windings, with 6 connection terminals.
3 phase 4 pole 50/60 Hz motors 1) 2)
108
kW 1)
hp
0.18
0.37
0.55
0.75
1.1
1.5
2.2
3
4
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
132
160
185
200
220
250
280
300
315
355
400
450
500
560
630
710
800
900
1000
0.3
0.5
0.75
1
1.5
2
3
4
5.5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
180
220
250
270
300
340
375
400
420
475
540
600
680
750
850
950
1070
1200
1340
230-240V
A
1.0
1.9
2.7
3.2
4.6
6.3
8.5
11.3
15
20
27
38
51
61
72
96
115
140
169
230
278
340
400
487
570
609
675
748
830
920
940
1061
1200
-
400V
A
0.6
1.1
1.5
1.9
2.7
3.6
4.9
6.5
8.5
11.5
15.5
22
29
35
41
55
66
80
97
132
160
195
230
280
327
350
385
430
480
520
540
610
690
770
850
950
1060
1190
1346
1518
1673
415V
A
0.58
1.05
1.4
1.8
2.6
3.5
4.7
6.3
8.2
11.1
14.9
21
28
34
40
53
64
77
93
127
154
188
222
270
315
337
371
414
463
500
520
588
665
742
819
916
1022
1147
1297
1463
1613
440V
A
0.55
1.0
1.3
1.7
2.4
3.2
4.4
5.9
7.8
10.4
14
20
26
32
37
50
60
73
88
120
145
178
210
255
300
320
350
390
436
473
490
555
625
700
770
860
960
1080
1220
1370
1510
690V
A
0.35
0.64
0.87
1.1
1.6
2.1
2.8
3.8
4.9
6.7
8.9
13
17
21
24
32
39
47
57
77
93
113
134
162
187
203
222
250
280
300
313
354
400
446
493
551
615
690
780
880
970
1000V
A
0.3
0.4
0.6
0.8
1.1
1.5
2
2.7
3.4
6
7
9
12.1
15
18
23
28
33
40
55
65
80
95
115
135
145
160
180
200
210
220
250
285
320
350
390
440
500
560
630
700
1100V
A
0.3
0.4
0.6
0.8
1
1.4
1.9
2.5
3.1
4.3
5.6
8
10.5
13
15.5
21
25
30
36
50
59
73
86
105
123
132
145
164
182
191
200
227
259
291
318
355
400
455
509
573
636
Single phase motors
kW
hp
0.18
0.37
0.55
0.75
1.1
1.5
2.2
3
4
5.5
7.5
0.25
0.5
0.75
1
1.5
2
3
4
5
7.5
10
230-240V
A
2.5
4
5
6.3
9
12
18
23
28
39
50
Notes: 1)
1) Standard values for standard squirrelcage motors, in conjunction with
IEC 60947-4-1 Table G.1:
Rated operational currents for motors with n
= 1500/min (4 pole), possible deviation ± 10 %
depending on type and manufacturer, ± 50 %
for small motors.
Deviation of rated operational currents for
motors with other speeds (greater deviations
for smaller motors):
With n = 3000 rpm (2 pole): –2 %…–10 %
With n = 1000 rpm (6 pole): +2 %…+10 %
With n = 750 rpm (8 pole): +5 %…+20 %
2) The power factor is usually around 0.8,
but this varies with the size and speed of the
motor.
Efficiency ranges from 80% in small motors to
greater than 95% for large premium efficiency
motors.
109
11.2 Utilisation categories
Utilisation Categories
CONTACTORS
CONTROL
RELAYS
AC-1 –
AC-12 –
AC-3 –
AC-15 –
Non-inductive or slightly inductive
AC loads
Examples: Heaters, furnaces
Squirrel cage motors – starting and
switching off motors during running
Examples: AC squirrel cage motors for lifts,
conveyors, compressors, pumps, mixers
Control of resistive loads and
solid-state loads with isolation by
optocouplers
Examples: Heaters, furnaces
Control of AC electromagnetic loads
Examples: Switching the AC coil of a
contactor
A1
A2
Other Contactor ratings
Other Control Relay ratings
AC-4 – Squirrel cage motors –
plugging or inching
DC-12 – Control of DC resistive loads
DC-1 – Non-inductive or slightly inductive
DC loads
DC-13 – Control of DC electromagnets
e.g. contactor coil
DC-3 – Shunt connected DC motors –
starting, plugging or inching
DC-5 – Series connected DC motors –
starting, plugging or inching
For control and switching of lighting loads contact NHP.
110
SWITCHES AND
ISOLATORS
AC-21A, AC-21B –
Switching of AC resistive loads including moderate
overloads
Examples: Heaters, furnaces
AC-23A, AC-23B –
Switching of motor loads or other highly inductive
loads
Examples: AC squirrel cage motors for lifts, conveyors,
compressors, pumps, mixers
Other Switch/Isolator ratings
DC-21 – Switching of DC resistive loads including
moderate overloads
DC-23 – Switching of DC motor loads or other highly
inductive DC loads
Note: The ‘A’ or ‘B’ suffix denotes frequency of switching
operation.
A – Frequent operation (in close proximity to the load)
B – Infrequent operation (further upstream of load)
111
11.3 Motor terminology
The motor nameplate gives us many of it’s important motor characteristics,
design and performance data.
Motor Nameplate
KW Rated kW is the power the motor is designed to deliver at its shaft with
rated frequency and voltage applied at its terminals.
Amps The current drawn by the motor at rated voltage and frequency
with full rated power delivered to its shaft.
Service Factor This is a measure of the reserve margin built into a
motor. It is expressed as a multiplier of the rated kW FLC and determines
permissible kW FLC loading which may be carried continuously under
normal environmental conditions. A corrective factor is needed for
overload protection:
S.F = 1.15
Ir = 1 x In mot
S.F = 1.00
Ir = 0.9 x 1n mot (derate overload setting)
Ir = Overload protective setting
Locked Rotor Current Current motor draws at standstill with full voltage
applied (initial starting current is higher than the FLC.
Efficiency The efficiency at rated output. Energy efficient motors will be
identified on the nameplate.
Volts The motor rated voltage. The voltage that should be present at the
motor terminals when delivering rated power.
RPM The speed of the output shaft when delivering rated power;
synchronous speed less slip.
Hertz The frequency of the supply system for which the motor is
designed.
Duty Is either Intermittent or Continuous. Intermittent will include a time
after which the motor must be shut down and allowed to cool to prevent
injury to the insulation. Continuous means that the motor may be run
continuously for years.
Bearings Indication of antifriction bearings installed.
Temperature The abbreviations AMB or TEMP on a motor nameplate
indicate the maximum ambient temperature environment for motor
operation. Ambient means the temperature of the air surrounding the
motor. In general, maximum ambient temperature for motors is 40ºC.
This general rule holds unless the motor is specifically designed for a
different temperature.
112
IE2
Type
Ser No.
Year
3 ~ Motor
xxxxxxxxxxxx
2018
V
Weight 42kg
Ins.cl.
F
Hz
50
IEC 60034-1
IP
55
kW 7.5
r/min
A
cos ϕ
Duty
690
Y
1488
8.9
0.81
S1
400
D
1488
15.5
0.81
S1
415
D
1489
14.9
0.80
S1
IE2 – 89.5 (100%) – 87.7 (75%) – 86.5 (50%)
Nmax 3200 r/min
IE3
3 ~ Motor
Model: AN-EXAMPLE-1
Serial: 1300-123-456
SF 1.15 CONT
IP55
Ins cl. F AMB 40oC
V
Hz
690 Y 50
415 D 50
kW
110
110
r/min A
1486 113
1487 188
cos φ Duty
0.85 S1
0.83 S1
IEC/EN compliance
800 kg
Examples of motor nameplates
113
11.4 Time current curves
Time Current curves
Time current curves show the overload relay tripping times for a given
multiple of full load current. They are tested by the overload relay
manufacturer and are based on tripping times from cold (room ambient)
start conditions and hot start conditions.
•
•
Hot Start
- A Hot Start is considered any time that a motor has been restarted in
less than 30 minutes from the previous start.
Cold Start
- A Cold Start is when a motor has not been run for at least 30 minutes.
Examples
TRIP CLASS 10
1000
Time (seconds)
100
10
1
0.1
1
114
FLC multiple
10
TRIP CLASS 30
1000
Time (seconds)
100
10
1
0.1
1
FLC multiple
10
TRIP CURVE LEGEND
Cold trip
Hot trip
Overload trip class selection
Correct trip class selection can be determined from the motors maximum
locked rotor current and maximum locked rotor time. This information can
be typically found on the Motor Nameplate or from the manufacturer.
115
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NEW ZEALAND
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SALES 1300 NHP NHP SALES 0800 NHP NHP
sales@nhp.com.au
sales@nhp-nz.com
NHP Electrical Engineering Products
A.B.N. 84 004 304 812
NHP57198 09/18
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