MOTOR CONTROLS

Contactor, Relays and Overloads

UNIT OBJECTIVES
After studying this unit, the reader should be able to
Describe the differences between relays, contactors and starters
List the component parts of contactors and starters
Name two types of external motor overload protection
Explain the differences between external overload protection devices
Explain the conditions under which motor safeties can be reset
What is a Switch?
A switch is a device that allows you to stop the flow of
current entirely. These are usually mechanical devices that
separates two bits of metal (contacts). When the metal
doesn't touch, current doesn't flow. When the metal
touches, is called a closed circuit. When the metal doesn't
touch, is called an open circuit. (closed = ON, open = OFF)
S1
Basic Switch Schematic Symbol
Single Pole, Single Throw = SPST
A simple on-off switch. This type can be used
to switch the power supply to a circuit.
Example
Circuit Symbol
SPST toggle switch
Single Pole, Double Throw = SPDT
This switch can be on in both positions, switching on
a separate device in each case. It is often called a
changeover switch. For example, a SPDT switch
can be used to switch on a red lamp in one position
and a green lamp in the other position.
Example
Circuit Symbol
SPDT rocker switch
Double Pole, Single Throw = DPST
A pair of on-off switches which operate together (shown by the
dotted line in the circuit symbol).
Example
Circuit Symbol
DPST rocker switch
Double Pole, Double Throw =
DPDT
A pair of on-on switches which operate together (shown by the
dotted line in the circuit symbol).
Example
Circuit Symbol
DPDT slide switch
Push Button Switches (NO/NC)
A Normally Open (NO) switch returns to its normally
open (off) position when you release the button.
A Normally Closed (NC) switch returns to its
normally closed (on) position when you release the
button.
Example
Circuit Symbol
Example Circuit Symbol
Push-to-make switch
Push-to-break switch
INTRODUCTION TO MOTOR
CONTROL DEVICES
Relays, contactors and starters pass power to the motor by closing sets of
contacts
Explain why the locked rotor amperage (LRA) affects the choice of a
motor starter
Contacts controlled by coils in the control circuit
Starting relays are only in the active circuit for a short period of time
The type of motor control used is determined by the size and application
of the motor used
Contactors
Contactors are relays that switch high current loads a.k.a
magnetic starters
Manual Motor Starter
L1 L2
CONTROL
CIRCUIT
RELAY OR
CONTACTOR
MOTOR
RUN
START
START
RELAY
L1 L2
CONTROL
CIRCUIT
RELAY OR
CONTACTOR
MOTOR
RUN
START
START
RELAY
MOTOR AMPERAGES
Running load amperage (RLA)
Similar to full load amperage (FLA)
Amperage drawn by the motor while operating
Locked rotor amperage (LRA)
Amperage drawn by motor on startup
Five to seven times greater than RLA or FLA
Both LRA and RLA must be considered when choosing a control
device
Contactor, Relays and Overloads
Upon completion of this chapter the student will be able to:
Explain the parts and operation of contactors and relays.
Explain the application of contactors and relays in control systems
Correctly install a contactor or relay in a control system
Draw a simple schematic wiring diagram using contactors and/or
relays to control load in a control system.
Understand the types and application of overloads
Troubleshoot contactor and relays.
Identify the common types of overload used to protect loads.
Explain the operation of the common overloads.
Determine the best type of overload for a specific application.
Draw schematic wiring diagrams using the proper overload to
protect loads.
Key Terms
Coil
Contactor
Contacts
Current Overload
Fuse
Inductive Load
Internal Compressor Overload
Line Break Overload
Magnetic Overload
Magnetic Starter
Mechanical Linkage
Overload
Pilot Duty Overload
Push-Button Station
Relay
Resistance Load
Relays
Relays are used to open and close a circuit to allow the automatic control of a device
or circuit.
THE RELAY
Uses a magnetic coil to open or close one or more sets
of electric contacts
The most common control voltage for both relays and
contactors is 24 volts.
Relays are not repaired. Replace on failure.
Used for light duty applications
Can be used as a pilot-duty relay
The relay contacts must be able to handle the
amperage draw of the load being controlled
Pilot relays are designed to switch on and off larger
contactors or starters. They are very light duty and are
not designed to start motors directly.
COIL
NORMALLY OPEN CONTACTS
NORMALLY CLOSED
CONTACTS
Relay Hysteresis
Relays and contactors naturally tend to provide a differential gap for On-Off control
because of the hysteresis effect inherent in their operation. To cause a magnetic
relay to energize:
The coil current must rise beyond the pull-in current or pick-up current
Once a relay has been pulled in:
the coil current must drop below a certain value called the hold-in current or
drop-out current.
Why is there a need for a strong magnetic field to establish to pull the armature?
1. There is an air gap in the magnetic loop; this cause the magnetic field to
be weaker.
2. The attractive force between the core and armature (opposite magnetic
poles) is weak because of the distance between the poles.
Relay Logic
Basic Relays
A relay is an electronic control switch used to
open or close a mechanical contact whenever a
voltage is applied to its coil.
Basic Relays
A basic relay usually contains two sets of
contacts, normally open and normally closed.
The schematic will show the normal contact
position for a de-energized coil.
2
4
1
3
2
4
1
3
Normally Open Contact Normally Closed Contact
Relay Labeling
Always look at the relay case to identify the coil, coil voltage, max
current, NO and NC contacts.
Labeling is always shown in a de-energized state.
Coil
Contacts
Common
NC
NO
Simple Relay Logic Ckt.
Which LEDs will
illuminate in this circuit
with switch 1 open?
With switch 1 closed?
2
4
1
3
2
4
1
3
V1
48V
R1
1.0kohm
R2
1.0kohm
R3
1.0kohm
R4
1.0kohm
2
4
1
3
2
4
1
3
J1
Key = Space
V2
12V
LED_red
LED1
LED_red
LED2
LED_red
LED3
LED_red
LED4
NAND Burglar Alarm
Relay Logic? (AND, OR, NAND, NOR)
Relay Logic? (AND, OR, NAND, NOR)
Complete the ckt (AND gate)
Complete the ckt (OR gate)
Complete the Truth Table
Complete the truth table
Complete the truth table
Relay Timers
ON Delay
OFF Delay
Wired ON Delay
1. Energy applied to
power rails
X1 X2
OFF
NC
NO
ON
1
Wired ON Delay - NCTO
1. Energy applied to
power rails
2. Start PB is pressed
- Coil is energized
- Holding contact close
- Timer contact stays
closed, lamp stays on.
- Count begins (5 sec)
2
X1 X2
ON
NC
NC
ON
Wired ON Delay - NCTO
3. Timer count ends
- Coil is still energized
- Timer contact open
- lamp goes off.
4. Timer contacts remain
open until the coil is de-
energized 3
X1 X2
ON
NO
NC
OFF
The Normally Closed contact will take 5 seconds To Open when the coil is energized.
ON Delay - NOTC
1. Power is applied
to rails
X1 X2
The Normally Open contact will take 5 seconds To Close when the coil is energized.
OFF
NO OFF
1
ON Delay - NOTC
2. Start PB is pressed
Coil energizes
Holding contacts
close
Timer contacts stay
open
Lamp stays off
Counter starts to
count (5 sec)
X1 X2
The Normally Open contact will take 5 seconds To Close when the coil is energized.
ON
NC
OFF
2
ON Delay - NOTC
3. Counter finishes count
Coil stays energized
Timer contacts close
Lamp goes on
4. Timer contacts will
open when relay coil
is de-energized.
X1 X2
The Normally Open contact will take 5 seconds To Close when the coil is energized.
ON
NC
ON
3
NC
OFF Delay - NCTC
1. Power is applied to
rails
2. Coil is off, contacts are
closed, lamp is on
The timer contacts will close 5 seconds after the coil is de-energized
OFF Delay - NCTC
3. Start PB is pressed
4. Timer contacts open
5. Counter will start to
count only when coil is
de-energized.
OFF Delay - NOTO
1. Power is applied to
rails
2. Coil is off, contacts are
closed, lamp is on
OFF Delay - NOTO
3. Start is pressed.
4. Contacts close, lamp on
5. Counter only starts when
coil is de-energize
Relay Applications
Relays can be used to control indoor fan motors, condenser fan motors, damper
motors, starting capacitors, and control lockouts.
THE CONTACTOR
Larger version of the relay
Has movable and stationary contacts
Often times only one set of contacts opens which opens only
one side of the power to condensing units. This provides
power for off-cycle heat to the compressor.
Holding coils are rated at different voltages
Can have one or more sets of contacts
Some are equipped with auxiliary contacts, which are usually
rated at a lower amperage than the primary contacts.
Contacts and coils can be replaced, the material most used
on the contacts is silver.
Use the exact replacement whenever possible
HOLDING COIL
STATIONARY
CONTACTS
STATIONARY
CONTACTS
MOVABLE
CONTACTS AND
ARMATURE
COIL
CONNECTIONS
WHEN THE COIL IS
ENERGIZED, THE
CONTACTS ARE
PULLED CLOSED
The most common coil voltage is 24 volts.
Contactors
A contactor is used to control an electric load in a control systems.
Contactors make or break a set of contacts that control the voltage applied to some
load in cooling systems.
Contactors
Coils
Coil Characteristics depends on the type of wire and the manner in which it is wound.
Coils are typically designed to operate on 24 volts, 120 volts, 208/240 volts and
occasionally 480 volts.
The coil is identified by the voltage marked on it.
Contacts
The contacts of a contractor make a complete circuit when the contactor is energized,
allowing voltage to flow to the controlled load.
Contractors are rated by the ampere draw they can carry.
There are two types of loads that a contractor can control: an inductive load, and a
resistive load.
Contacts are made of silver and cadmium which resists sticking.
The chemical composition of contacts is such that they operate at cool temperatures
of up to 125% of their current-carrying capacity.
Contacts
The contactor contacts must be in good condition to ensure that proper voltage
reaches the load.
Overloads
An overload is an electrical device that protects a load from a high ampere draw by
breaking a set of contacts.
The simplest form of overload protection is the fuse.
Fuses can be used to protect wires and non-inductive loads, but they provide
inadequate protection for inductive loads.
A load that is purely resistive in nature with no coils to cause induction is called
resistive or non-inductive load.
Over Load Protection
Fuses
Fuses consists of two ends or conductors with a piece of wire that will melt and break
the circuit if the current passing through it exceeds the amperage rating of the fuse.
Line Break and Pilot Duty Overloads
Overloads can be divided into two basic groups: Line break and Pilot duty.
The line break overload breaks the power to a motor.
A pilot duty overload breaks an auxiliary set of contacts connected in the control
circuit.
Line Break Overload
One of the most common types of line voltage overloads is the metal disc mounted
between two contacts.
This is called a bimetal line break overload.
Internal Compressor Overload
The most popular line break overload for use in small central residential system is an
internal compressor overload.
The internal compressor overload is a small device inserted into the motor windings.
This overload can sense the current draw of the motor, as well as the winding
temperature, more effectively than external overloads.
Internal Compressor Overload
Pilot Duty Overload
The pilot duty overload breaks the control circuit when an overload occurs, which
would cause a contractor to be de-energized.
This type of overload is common on larger systems and still exists on smaller
systems currently in the field.
Two basic pilot duty overloads are being used in the industry today:
The current overload
Magnetic overload
Current Overload
Works similarly to the line break overload excepts that a pilot duty set of contacts is
opened rather than the line.
Magnetic Overload
Consists of a movable metal core in a tube filled with silicone or oil.
Surrounding the metal tube is a coil of wire.
When the current increases, so does the magnetic field of the coil.
The overload operates by the magnetic field created by the coil.
The device is designed to create a magnetic field that is strong enough to pull the coil
up, opening the pilot contacts on overload.
Magnetic Overload