1 Basic Principles of

UNIT

Motor Controls

Unit 1Introduction

This unit discusses the basic concepts of motor control,

including motor control language and the types of
wiring diagrams used.

Motor Control Circuits

Motor control circuits are an effective way to reduce

cost by using smaller wire and reduced-amperage
devices to control a motor. Imagine trying to wire a
pushbutton station for a 100A motor using 3 AWG
conductors. Many smaller motors use the same size Figure 11
conductors for both control and power circuits, but
as the horsepower increases it becomes impractical to
do so, Figure11. Motor control circuits are often con-
nected to lower voltages than the motor they control to
make it safer for operators and maintenance personnel.
A motor control circuit, for the most part, is simply a
switch (or group of switches) and a motor. If you keep
the word switch in mind, it helps keep the intimidat-
ing subject of motor control in its proper context.
For example, the following can be considered motor
controls:

A time clock that operates a pool or sprinkler pump

is nothing more than an automatic switch. At a preset
time, a set of contacts open or close (turn off or on).
Figure12
Figure 12
An automatic garage door opener uses a radio signal to
operate a switch that activates a garage door in much

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 Unit 1 Basic Principles of Motor Controls

the same manner as a typical up-down pushbutton device will operate to open the circuit because of the
station. increased heat caused by the current running through
it. A magnetic starter or other motor controllers may
Many motors are controlled by computerized con-
include overload devices, or they may be an integral part
trol systems, solid-state logic controls, or program-
of the motor, particularly with small motors.
mable logic controllers (PLCs). The fundamentals of
control systems still apply. The PLC controls an exter-
nal output based on the logic of a control program, and Authors Comment: Short circuits and ground faults
that output controls the motor or groups of motors by arent considered overloads.
using a magnetic starter, and in some cases additional
relays. PLCs and other solid-state control devices were
There are two basic designs of motor control equip-
originally invented to provide less expensive replace-
ment, NEMA and IEC.
ments for older automated systems that used large num-
bers of relays and mechanical timers. In some cases, a NEMA (National Electrical Manufacturers Association).
single PLC can replace thousands of relays resulting in NEMA is a trade association for manufacturers of elec-
less expensive wiring systems that offer greater flexibility trical equipment and supplies. NEMA standards spec-
in control designs. ify motor horsepower (hp) ratings, speeds, motor frame
sizes and dimensions, motor torques, motor starter size
ratings, and enclosure specifications.
Authors Comments:
In industrial processes, the control of pressure, flow, NEMA-rated products are typically heavy duty, can be
speed, temperature, and other items are essential for used in a broad range of applications, and some start-
efficient productivity and safety. Devices such as solid- ers can be maintained and repaired. For these reasons,
state sensors, static controls, solid-state relays, and theyre often more expensive than IEC motor starters.
programmable controls can provide very precise control NEMA-rated motors and motor controllers are the
for an industrial process. type most commonly used in North America.
Although the subject of solid-state controls isnt covered IEC (International Electrotechnical Commission). IEC
in detail in this textbook, the concepts are very simi- is an international standards organization. IEC motor
lar to other motor controls in that they essentially use starters are often less expensive, smaller in size, are tai-
switches to control motors. lored for specific motor performance requirements, and
Many experts agree that the best way to learn about the selection of the right starter for each application is
motor controls is to start with the standard control meth- very important. IEC-rated motor controllers are widely
ods covered in this textbook. This statement also applies used in Europe and Asia.
when electronic controls are the subject being studied.

Many control circuits include motor overload protec- 1.1 Motor Control Language
tion devices. Traditional overload (OL) protectors oper-
ate on the relationship between heat and current. As Electrical symbols, words, and line diagrams provide
current increases, heat increases. If an overload device the information necessary to understand the operation
is rated 10A, and the current exceeds that rating, the OL of motor control circuits. Used together, they create a

4 Mike Holts Illustrated Guide to Understanding Basic Motor Controls

 Basic Principles of Motor Controls Unit 1

type of motor control language thats used to trans- (1) Ladder Diagrams (Figure14)
fer information and ideas quickly and efficiently.
Ladder diagrams are also called line diagrams or
The symbols in motor control schematics represent elementary diagrams. Theyre used to represent
devices, power conductors, control conductors, con- the function of the control circuit and the associated
ductor connections and terminals, and sometimes the devices, but dont show the components of the con-
motor itself. trol circuit in their actual positions. As control cir-
cuits become more complex, a ladder diagram can
The words, phrases, and abbreviations in a schematic
be less complicated to read than a wiring or connec-
are generally accepted terms that represent functions,
tion diagram. For example, in Figure 14, notice the
describe actions, and list sequences of operation.
set of contacts marked M under the start pushbutton.
In many cases, the symbols and words have a similarity The M contacts marked 2 and 3 are actually located
to the items they represent. The basic types of schemat- in the motor starter fairly close to the coil, as shown
ics are shown in Figure13. Parts A, B, and C of that in Figure 13B, and the normal physical appearance
figure illustrate three different methods of representing of these contacts often look as shown in Figure 13C.
the same control circuit. (Notice that all three examples of the M contacts are
shown with a blue background in Figure13.)

Figure 14

The ladder diagrams in Figures 14 and 15 illustrates

electrical function, showing the M contacts in paral-
lel with the start pushbutton to form whats called a
holding circuit. The physical location of the M con-
tacts isnt shown in the ladder diagram.
Figure 13

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 Unit 1 Basic Principles of Motor Controls

Figure 15 Figure 16

Figure 15 shows a more complicated version of a

Different manufacturers of control devices, as well as
ladder diagram. Notice that the horizontal lines in this
books about motor controls, use different methods
control circuit are similar to the rungs of a ladder.
of showing the control circuit wiring. For example, in
Figure 13B1, the control wiring from the start-stop
Authors Comment: An important point to remember is pushbutton station runs to the actual connection points
that schematics show motors and control equipment in the 1, 2, and 3. As the wiring diagrams become more com-
resting, or off state (sometimes called the shelf state). plicated, the optional method shown in Figure 13B2
Part of the difficulty, when first learning about motor con- is frequently used to show the connection points for
trols, is in understanding how the different components of the start-stop pushbutton station. Here, in Figure 16,
the control circuit interrelate during the operation of the instead of running the control wires to the actual con-
controls. nection point, arrowed lines represent connections to be
made by the installer.

(2) Connection Diagrams (Figure16)

Authors Comments:
Connection diagrams, or wiring diagrams, show the
Many times you see plain lines (no arrows) with num-
components of the control circuit in a semblance of
bers to indicate connections to be made by the installer.
their actual physical locations. The start-stop push-
We use both methods in this textbook.
button station is shown more as an actual device in the
control circuit wired to a set of contacts marked 2 and Many of the components and symbols used in ladder
3. In Figure 14, the wires on each side of the M con- diagrams and wiring diagrams are the same. In order
tacts trace back to points 2 and 3 on either side of the to make schematics easier to read, some manufactur-
start pushbutton. The contacts marked M in Figure14 ers combine the two types of diagrams together. Some
are the same contacts as those marked 2 and 3 in equipment comes with both ladder diagrams and wiring
Figure16. diagrams.

6 Mike Holts Illustrated Guide to Understanding Basic Motor Controls

 Basic Principles of Motor Controls Unit 1

Remember, ladder diagrams show electrical function

and wiring diagrams show the actual components.

Its very common to find different styles of schematics

combined in a single wiring diagram. The top part of
the diagram in Figure 17 is in the style of a connection
diagram, while the style showing the start-stop station
and coil is similar to a ladder diagram.

Figure 18

Authors Comments:
Often a hand-drawn diagram of a control circuit con-
structed in the field helps in understanding how a circuit
functions and how to make the necessary connections,
especially during the learning process. Figure 19
shows the hand-drawn version of the 3-wire start-stop
control circuit shown in Figure13. Notice that the stop
pushbutton is in series with coil M, and that the start
Figure 17
pushbutton is in parallel with M contacts 23. The entire
control circuit in this example is in parallel between line
1 and line 2. These basic relationships can be found in
many control circuits.
(3) Pictorial Diagrams (Figure18)
The numbers in this diagram are simply for the aid of
Pictorial diagrams are often used in educational mate- the reader and it dont imply that terminal 1 on one
rial and as exploded views or cut-away views in instal- device should always be connected to terminal 1 on
lation and maintenance literature. Pictorial diagrams another device.
help students see actual devices and components used
in motor control circuits and how they relate to the
symbols used in ladder diagrams and wiring diagrams. Once you understand the terminology and symbols
For example, the start pushbutton we mentioned earlier involved in motor control circuit wiring, understanding
has wires run to the device that contains the set of con- how it works becomes easier and less intimidating.
tacts M in Figure14, and to contact points 2 and 3 in
Figure16.

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 Unit 1 Basic Principles of Motor Controls

When beginning this study of basic motor controls,

remember that motor controls are basically differ-
ent kinds of switches that turn things on and off, both
manually and automatically. This may help you keep
things in perspective.

There are many good books available for more

advanced studies about this subject. Also check with
the manufacturers of motor control equipment for edu-
cational material and standard motor control circuits.

Unit 1Conclusion
Figure 19
This unit explained the basic concepts of motor con-
trols, concentrating on how specialized electrical sym-
1.2 Motor Control Basics bols, words, and line diagrams are used to convey
information about motor control circuits. It provided
The purpose of this textbook is to introduce the basics an introduction to the following types of diagrams,
of motor controls. Many of the control circuits that are which are used extensively throughout this textbook:
covered are standard control circuits used in many differ-
Ladder diagrams (these are also called line
ent applications. Each circuit can have several variations
diagrams or elementary diagrams).
and optional devices in addition to those included in the
schematics. This textbook wont teach you all of these Connection diagrams (also called wiring
control circuit variations, but will give you a basic under- diagrams).
standing of motor controls, and how to read wiring dia-
Pictorial diagrams.
grams and understand the sequences of operation.

8 Mike Holts Illustrated Guide to Understanding Basic Motor Controls

 Practice Questions Unit 1

1 Practice Questions
UNIT

5. _____ are used to represent the function of the

Unit 1Practice Questions control circuit and the associated devices, but
dont show the components of the control circuit
Introduction in their actual positions.

1. A motor control circuit, for the most part, is (a) Ladder diagrams
simply a _____ and a motor. (b) Connection diagrams
(c) Wiring diagrams
(a) motor
(d) Pictorial diagrams
(b) switch
(c) feeder 6. Connection diagrams are also called wiring
(d) magnet diagrams.

2. Many types of overload protectors operate on the (a) True

relationship between _____. (b) False

(a) heat and current 7. _____ are used mostly in educational material and
(b) the neutral conductor and the earth as exploded views or cut-away views in installation
(c) branch circuits and feeders and maintenance literature.
(d) voltage and wattage
(a) Ladder diagrams
1.1 Motor Control Language (b) Connection diagrams
(c) Wiring diagrams
3. Schematics show motors and control equipment (d) Pictorial diagrams
in their resting or shelf state.
8. The motor control circuit shown in Figure110 is a
(a) True _____.
(b) False
(a) ladder diagram
4. Ladder diagrams are also known as _____. (b) connection diagram
(a) line diagrams (c) wiring diagram
(b) elementary diagrams (d) pictorial diagram
(c) pictorial diagrams
(d) a or b

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 Unit 1 Practice Questions

9. The motor control circuit shown in Figure111 is a

_____.

(a) ladder diagram

(b) connection diagram
(c) wiring diagram
(d) pictorial diagram

Figure 110

Figure 111

10 Mike Holts Illustrated Guide to Understanding Basic Motor Controls