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Schematics Made Easy
Schematics Made Easy
Page 1 of 12
Schematics Made Easy
POWER & CONTROL CIRCUITS The control circuit is shown in light lines and consists of
the stop-start pushbuttons, holding interlock, magnetic
Circuit diagrams may seem complex when viewed in their starter coil M, and overload relay contact X2.
entirety, but they can be simplified by breaking them into
basic circuits. The overall diagram, and basic machine
functions, are then easier to understand.
Control systems are usually designed so that an individual
circuit controls only one function of a machine. For
example, this could be the starting and stopping of an
electric motor by means of pushbuttons, or controlling
solenoid valves through the use of limit switches. There
are many variations in individual circuits. The main factor
to remember is that a basic circuit is usually associated
with a basic machine function.
Electric circuits may be of two types, Power Circuits and
Control Circuits.
POWER CIRCUITS are usually shown in a diagram with
heavy lines since they are the heavy conductors or wires
carrying motor or load current.
CONTROL CIRCUITS are usually associated with pilot
or control of the power switching equipment, such as the
coil circuit in a magnetic starter. These wires are shown
using lighter lines in the diagram. Some graphic symbols
and designations used in diagrams are shown on Page 6.
These are used in the circuits described in this article.
Fig. 2. Pushbutton station and 3-phase magnetic starter with arc box
Wiring Diagram Figure 1 shows the wiring or cover removed to show contacts. Heater elements shown installed.
connection diagram of a magnetic starter with a start-stop
Schematic Diagram A schematic or elementary
pushbutton station. The location of each wire and terminal
diagram of the starter shown (Fig. 2) is illustrated in Fig. 3.
identifications are shown.
The schematic does not show the physical relationship of
L1 L2 L3 each wire location. It does indicate in straight line form the
circuit functions of the various devices.
2 1 Note that the same terminal identification letters and
numbers are used in both the wiring and schematic
A diagrams to designate the control and power connections.
3
The starter and pushbuttons can be wired directly from the
C M schematic, if desired, since it does show how the devices
V W are connected into the circuit. For troubleshooting, it is
much easier to work from a schematic diagram rather than
a wiring diagram. This is particularly true with a complex
X2 circuit.
Page 2 of 12
Schematics Made Easy
Page 3 of 12
Schematics Made Easy
Fig. 6. Multiple stations used with momentary start-stop circuit. Stop
buttons are wired in series and start buttons in parallel.
STOP 2
1
FLOAT SW
Fig. 7. Two-wire control circuit. Two wires are connected to the float
switch energizing the magnetic starter.
Page 4 of 12
Schematics Made Easy
Two-wire control is so named because only two wires (as Fig. 8. Three-wire control circuit. Three wires must be connected to
the pilot devices to energize the magnetic starter.
shown in Fig. 7) are connected to the pilot device that
energizes the magnetic controller. In the diagram, the pilot Three-wire control, (Fig. 8), gets its name from the three
device shown is a normally open float switch used with a wires that must be connected to the pilot device used to
pump motor starter. It energizes the motor starter only as operate the motor starter. Notice here we have the basic
long as It remains closed. This type of circuit provides momentary start-stop circuit shown in Fig. 5 which
undervoltage release but not undervoltage protection, since provides the undervoltage protection feature.
a holding interlock is not used. The motor starter would
drop out on loss of voltage and then immediately pick up
REVERSING CIRCUITS Three phase
squirrel-cage motors are particularly suited to reversal of
again (without operator control) upon restoration of power
rotation by simply interchanging two of the line
provided the float switch had remained in the closed
conductors supplying the motor. This is commonly done
position.
by using two separate contactor assemblies one for
forward rotation and the other to reconnect for reverse
rotation.
M
Fig. 9. Horizontal reversing magnetic starter with mechanical and
electrical interlocks.
Page 5 of 12
Schematics Made Easy
Fig. I Normally closed (NC) auxiliary electrical interlock as mounted
on reversing starter in Fig. 9 between both arc boxes. May also be
normally open (NO) for other applications.
There are two types of reversing circuits: Forward-
Reverse Compelling and Forward-Reverse Optional.
Forward-Reverse Compelling Compelling circuits are
used with motors which are not instantly reversible. These
motors are brought to a stop before changing direction of
rotation. In Fig. 11 depressing the forward push button will
energize the forward contactor coil (F), causing the motor
to rotate forward. At the same time, it opens the normally
closed (F) contact in the reverse contactor coil (R) circuit
and closes the normally open (F) contact around the
forward pushbutton to seal-in the circuit. As long as the
forward contactor is picked up, depressing the reverse
pushbutton will have no effect. This is because the (F)
contact is open in the reverse coil circuit.
The circuit derives its name because the operator is
compelled to depress the stop pushbutton before he can
change direction of rotation. Once the forward contactor
has dropped out and reclosed its normally closed contact
(F) in the reverse coil circuit, the rotation of the motor can
be started in the reverse direction.
Limit switches (LS) are shown in this circuit since it is
sometimes used for equipment such as overhead doors,
which are stopped with a limit switch at the end of the
door travel.
LS R
LS F REV.
R
Fig. 11. Forward-Reverse Compelling Circuit. Operator is compelled
to depress stop button before changing motor rotation.
Page 6 of 12
Schematics Made Easy
Forward-Reverse Optional The optional circuit in Fig. Speed Compelling because the operator is compelled to
13 is similar to the compelling circuit with one exception It start in the lower speed.
utilizes a pushbutton with both normally open and
normally closed contacts such as shown in Fig. 12. Each
pushbutton with two sets of contacts is indicated by the
dotted lines connecting the two parts of the single buttons.
The normally closed contact on the forward push button is
connected in the reverse contactor coil circuit and the
normally closed contact of the reverse pushbutton in the
forward coil circuit.
STOP
FOR.
Fig. 13. Optional Forward-Reverse Circuit. Stop button need not be
pushed when changing direction.
Page 7 of 12
Schematics Made Easy
Fig. 14. Two Speed Compelling Circuit. Motor must be started in low
speed. Stop button must be pushed before going from high to low.
A control relay (Fig. 15) designated as CR in the
diagram and referred to as a compelling relay ensures
that the motor is started in the low speed. The relay has
two normally open contacts. One is to seal it in after being
energized through a contact on the low-speed starter (L).
The other is located in the high-speed starter coil circuit to
prevent initial start on high speed. Upon changing from
low to high speed note that the low speed starter coil
circuit is opened by the normally closed contact of the
high- speed pushbutton.
Fig. 15. Control Relay (CR) with 2-pole contact block and magnetic
HIGH operator. Poles may be either Normally Open or Normally Closed.
Two-Speed Non-Compelling These circuits are used in
applications where the motor may be started in either high
or low speeds (Fig. 16). Speed can also be changed during
HIGH
operation between low and high by the operator, without
having to first bring the motor to a stop. This circuit is
LOW similar to the Forward-Reverse Optional circuit shown in
Fig. 13 and utilizes both normally open and normally
closed contacts on each of the low and high speed
pushbuttons.
STOP
L1
CR
L
Page 8 of 12
Schematics Made Easy
H
L
H
LOW
HIGH
CR
L
H
L2
H-OL
L-OL
H
CR
Page 9 of 12
L
Schematics Made Easy
Fig. 20. Starter with timer head accessory operated from starter
armature.
In summary . . . it can be readily seen that although wiring
diagrams may seem to be complicated and unwieldy they
need not be. Much of the confusion and mystery can be
Fig. 18. Solenoid operated adjustable time delay relay.
removed by simply breaking the over-all control diagrams
into their basic circuits.
The power circuit furnishes power for the motor and load.
The individual control circuits usually operates only one
motor controller function.
Page 10 of 12
Schematics Made Easy
SYMBOLS CHART
Page 11 of 12
Schematics Made Easy
EXAMPLES:
L1 START L2
1 STOP2 3 OL
M M
Fig. 1. Three Wire Control Giving Low Voltage Protection Single Two
Button Pushbutton Station
L1 FOR FOR LS OL
L2
L1 L2 1 STOP REV2 6R
F
START OL F
1 STOP STOP STOP
2 3
M
START REV REV LS
FOR4 5 7F R
R
START Fig. 8. Three Wire Control for Instant Reversing Applications Using
Single Three Button Pushbutton
M Station
Fig. 2. Three Wire Control Giving Low Voltage Protection Multiple Two
Button Pushbutton Station
L1 FOR FOR LS L2
1 STOP2 3 R6 8
F
OL
L1 SAFE START L2
1 STOP 2 3 OL F
M REV LS
RUN M REV
Fig. 3. Three Wire Control Giving Low Voltage Protection with Safe-Run 5 F 7 9
4 R
Selector Switch R
Fig. 9. Three Wire Control for Reversing Using Single Three Button
L1 START L2 Pushbutton Station
1 STOP 3 OL
M
JOG 2 M L1 FOR LS L2
SLOW FAST
RUN 1 STOP4 2 6 8 S OL
Fig. 4. Three Wire Control for Jog or Run Using Start- Stop Pushbuttons
and Jag-Run Selector Switch F 5 CR S
CR S F
CR
L1 JOG L2 Fig. 10. Control for Two Speed with a Compelling Relay to Insure
1 STOP 2 4 OL Starting on Slow Speed
M
CR
L1 L2
START FOR RFOR LS
3 1 STOP REV2 3 6 8 OL
F
CR F
CR M
Fig. 5. Control for Jogging-Start-Stop All with Push buttons FOR4 REV5 F 7REV 9LS
R
L1 OFF L2 R
HAND AUTO 3 OL HIGH 10 LO
M HI
OFF 11 HI
AUTOMATIC SWITCH LO
LOW
Fig. 6. Two Wire Control Giving Low Voltage Release Only Using Hand- Fig. 11. Control for Two Speed Reversing Starter Forward, Reverse, Stop,
Off-Auto Selector Switch with High, Law Selector Switch
Page 12 of 12