Material taken from Chapter 3 of Electric Motor Controls, G. Rockis, 2001
One-Line Diagrams
One-line diagram – a diagram that uses single lines and graphic symbols to indicate the path and components of an electrical circuit. One-line diagrams are used when information about a circuit is required but detail of the actual wire connections and operation of the circuit are not.
1
Line Diagrams
A line (ladder) diagram is a diagram that shows the logic of an electrical circuit or system using standard symbols. A line diagram is used to show the relationship between circuits and their components but not the actual location of the components. Line diagrams provide a fast, easy understanding of the connections and use of components.
Electric Motor Controls, G. Rockis, 2001
2
Electric Motor Controls, G. Rockis, 2001
Wiring Diagrams
Wiring (connection) diagram – a diagram that shows the connection of an installation or its component devices or parts. Wiring diagrams show, as closely as possible, the actual location of each component in a circuit, including the control circuit and the power circuit.
3
Electric Motor Controls, G. Rockis, 2001
Manual Control Circuits
Manual control circuit – any circuit that requires a person to initiate an action for the circuit to operate. A line diagram may be used to illustrate a manual control circuit of a pushbutton controlling a pilot light. A line diagram may be used to illustrate the control and protection of a 1ϕ motor using a manual starter with overload protection.
4
Electric Motor Controls, G. Rockis, 2001
Electric Motor Controls, G. Rockis, 2001
5
Automatic Control Circuits
Automatically-controlled devices have replaced many jobs that were once performed manually. As a part of automation, control circuits are designed to replace manual devices.
Electric Motor Controls, G. Rockis, 2001
6
Magnetic Control Circuits
Although manual controls are compact and sometimes less expensive than magnetic controls, industrial and commercial installations often require that electrical control equipment be located in one area while the load device is located in another. Solenoids, contactors, and magnetic motor starters are used for remote control of devices.
Solenoids
A solenoid is an electrical device that converts electrical energy into a linear mechanical force.
Electric Motor Controls, G. Rockis, 2001
7
Electric Motor Controls, G. Rockis, 2001
Contactors
Contactor – a control device that uses a small control current to energize or deenergize the load connected to it. A contactor does not include overload protection. A contactor has a frame, plunger, and coil like a solenoid.
8
Contactors
The action of the plunger, however, is directed to close (or open) sets of contacts. The closing of the contacts allows electrical devices to be controlled from remote locations.
Electric Motor Controls, G. Rockis, 2001
9
Electric Motor Controls, G. Rockis, 2001
Magnetic Motor Starters
A magnetic motor starter is an electrically-operated switch (contactor) that includes motor overload protection. Magnetic motor starters are identical to contactors except that they have overloads attached to them.
10
Magnetic Motor Starters
The overloads have heaters or electronic overloads (located in the power circuit) which sense excessive current flow to the motor. The heaters open the NC overload contacts (located in the control circuit) when the overload becomes dangerous to the motor.
Electric Motor Controls, G. Rockis, 2001
11
Logic Applied to Line Diagrams
Chapter 4
Material taken from Chapter 4 of Electric Motor Controls, G. Rockis, 2001
Basic Rules
The electrical industry has established a universal set of symbols and rules on how line diagrams (circuits) are laid out.
12
One Load Per Line
No more than one load should be placed in any one circuit line between L1 and L2. A pilot light can be connected into a circuit with single-pole switch.
Electric Motor Controls, G. Rockis, 2001
13
One Load Per Line
Two loads must not be connected in series on one line of a line diagram. If the two loads are connected in series, then the voltage between L1 and L2 must divide across both loads when S1 is closed. The result is that neither device receives the entire 120 V necessary for proper operation.
One Load Per Line
Loads must be connected in parallel when more than one load must be connected in the line diagram. This circuit has two lines, one for the pilot light and one for the solenoid.
Electric Motor Controls, G. Rockis, 2001
14
Load Connections
A load is the electrical device in the line diagram that uses the electrical power from L1 to L2. Control relay coils, solenoids, and pilot lights are loads that are connected directly or indirectly to L2.
Electric Motor Controls, G. Rockis, 2001
15
Load Connections
Magnetic motor starter coils are connected to L2 indirectly through normally closed overload contacts. Anywhere from 1 to 3 NC overload contacts are shown between the starter and L2 in all line diagrams. To avoid confusion, it is common practice to draw one set of NC overload contacts and mark these contacts all overloads (OLs).
Electric Motor Controls, G. Rockis, 2001
16
Control Device Connections
Control devices are connected between L1 and the operating coil (or load). Operating coils of contactors and starters are activated by control devices such as pushbuttons, limit switches, and pressure switches.
Electric Motor Controls, G. Rockis, 2001
Figure 4-5. Control devices are connected between L1 and the operating coil.
17
Control Device Connections
Each line includes at least one control device. The operating coil is ON all the time if no control device is included in a line. A circuit may contain as many control devices as is required to make the operating coil function as specified.
Electric Motor Controls, G. Rockis, 2001
18
Line Number Reference
Each line in a line diagram should be numbered starting with the top line and reading down.
Electric Motor Controls, G. Rockis, 2001
Numerical Cross-Reference Systems
Numerical cross-reference systems are required to trace the action of a circuit in complex line diagrams. Common rules help to quickly simplify the operation of complex circuits.
19
NO Contacts
Relays, contactors, and magnetic motor starters normally have more than one set of auxiliary contacts. These contacts may appear at several different locations in the line diagram. Numerical cross-reference systems quickly identify the location and type of contacts controlled by a given device. A numerical cross-reference system consists of numbers in parenthesis to the right of the line diagram.
Electric Motor Controls, G. Rockis, 2001
20
NC Contacts
In addition to NO contacts, there are also NC contacts in a circuit. To differentiate between NO and NC, NC contacts are indicated as a number which is underlined.
Electric Motor Controls, G. Rockis, 2001
21
Wire-Reference Numbers
Each wire in a control circuit is assigned a reference point (number) on a line diagram to keep track of the different wires that connect the components in the circuit. Each reference point is assigned a reference number. Reference numbers are normally assigned from the top left to the bottom right.
Electric Motor Controls, G. Rockis, 2001
22
Manufacturer’s Terminal Numbers
Manufacturers of electrical relays, timers, counters, etc., include numbers on the terminal connection points. These terminal numbers are used to identify and separate the different component parts (coil, NC contacts, etc) included on the individual pieces of equipment. Manufacturer’s terminal numbers are often added to a line diagram after the specific equipment to be used in the control circuit is identified.
Electric Motor Controls, G. Rockis, 2001
23
Signals, Decisions, and Action
A circuit must respond as designed, without any changes. To accomplish this consistency, all control circuits are composed of three basic sections: the signals, the decisions, and the action sections.
Electric Motor Controls, G. Rockis, 2001
24
Signals
A signal starts or stops the flow of current by closing or opening the control device’s contacts. Current is allowed to flow through the control device if the contacts are closed. Current is not allowed to flow through the control device if the contacts are opened.
Signals
Pushbuttons, limit switches, flow switches, foot switches, temperature switches, and pressure switches may be used as the signal section of a control circuit.
25
Signals
All signals depend on some condition that must take place. This condition can be manual, mechanical, or automatic. A manual condition is any input into the circuit by a person. Foot switches and pushbuttons are control devices that respond to a manual condition.
Signals
A mechanical condition is any input into the circuit by a mechanically moving part. A limit switch is a control device that responds to a mechanical condition.
26
Signals
An automatic condition is any input which responds automatically to changes in a system. Flow switches, temperature switches, and pressure switches respond to automatic conditions.
Decisions
The decision section of a circuit determines what work is to be done and in what order the work is to occur. The decision section of a circuit adds, subtracts, sorts, selects, and redirects the signals from the control devices to the load.
27
Decisions
The way the control devices are connected into the circuit gives the circuit logic. The basic logic functions are AND, OR, NOT, NOR, and NAND logic. The decision section of the circuit accepts informational input (signals), makes logical decisions based on the way the control devices are connected into the circuit, and provides the output signal that controls the load.
Action
Once a signal is generated and the decision has been made within a circuit, some action (work) should result. In most cases it is the operating coil in the circuit which is responsible for initiating the action.
28
Action
This action is direct when devices such as motors, lights, and heating elements are turned ON as a direct result of the signal and the decision. This action is indirect when the coils in solenoids, magnetic starters, and relays are energized.
Logic Functions
Control devices such as pushbuttons, limit switches, and pressure switches are connected into a circuit so that the circuit can function in a predetermined manner. All control circuits are basic logic functions. Logic functions are common to all areas of industry.
29
AND Logic
AND logic is used in industry when two pushbuttons are connected in series to control a solenoid.
Electric Motor Controls, G. Rockis, 2001
OR Logic
OR logic is used in industry when a pushbutton and a temperature switch are connected in parallel.
Electric Motor Controls, G. Rockis, 2001
30
AND/OR Logic Combination
The decision section of any circuit may contain one or more logic functions.
Electric Motor Controls, G. Rockis, 2001
NOT Logic
NOT logic has an output if the control signal is OFF.
Electric Motor Controls, G. Rockis, 2001
31
NOR Logic
NOR logic is an extension of NOT logic in that two or more NC contacts in series are used to control a load. In this circuit, additional operator safety is provided by adding several emergency stop pushbuttons (NOT logic) to the control circuit.
Electric Motor Controls, G. Rockis, 2001
NAND Logic
NAND logic is an extension of NOT logic in which two or more NC contacts are connected in parallel to control a load.
Electric Motor Controls, G. Rockis, 2001
32
In industrial control circuits, it is more common to find pushbuttons with return spring contacts (momentary contacts) than those with mechanically stay held in one position (maintained contacts). Auxiliary contacts are added to give circuits with pushbuttons memory.
Memory
Electric Motor Controls, G. Rockis, 2001
Start/Stop Stations Controlling Magnetic Starters
Electric Motor Controls, G. Rockis, 2001
33
Two Magnetic Starters Operated by Two Start/Stop Stations with Common Emergency Stop
Electric Motor Controls, G. Rockis, 2001
Start/Stop Station Controlling Two or More Magnetic Starters
Electric Motor Controls, G. Rockis, 2001
34
Pressure Switch with Pilot Light Indicating Activation
Pilot lights are manufactured in a variety of colors, shapes, and sizes to meet the needs of industry. The illumination of these lights signals an operator that any one of a sequence of events may be taking place.
Electric Motor Controls, G. Rockis, 2001
35
Start/Stop Station with Pilot Light Indicating NO Device Activation
Pilot lights may be used to show when an operation is stopped as well as when it is started.
Electric Motor Controls, G. Rockis, 2001
Pushbutton Sequence Control
Conveyor systems often require one conveyor system to feed boxes or other materials onto another conveyor system. A circuit is needed to prevent the pileup of material on the second conveyor if the second conveyor is stopped. A sequence control circuit does not let the first conveyor operate unless the second conveyor has started and is running.
