/—°

MOTOR
CONTROL
TRAINER
TEACHER
MODULE
 I. Introduction to Motor Control Trainer...................................... ............1
Key Components of a Motor Control
T rainer..............................................1
Objectives and
Applications
......................................................................................................
2
II.
Components...................................................................................
Indicator .3
Lamp...............................................................................................
Magnetic
Contactors....................................................................................... 3
Overload
Relay...................................................................................... ..4
Timer
Relay......................................................................................
5
Circuit Breaker (
6A
2pole)..................................................................................6
Circuit Breaker
(10A
3pole)..................................................................................7
Push
Button.....................................................................................
..8
Three-Phase
Motor.............................................................................................
Banana plug female to
male.............................................................................10
Emergency
button........................................................................................10 stop
Wiring

Connections 1
Stop 1
Start..................
1
1
 I. Introduction to Motor
Control Trainer
A motor control trainer is an educational tool designed to provide hands-on training and practical
experience in motor control systems. It serves as a comprehensive learning platform for individuals, students, or
professionals seeking to understand motor control's principles, components, and applications in various industrial settings.
The primary goal of a motor control trainer is to bridge the gap between theoretical knowledge and real-world application,
allowing users to develop practical skills in designing, wiring, and troubleshooting motor control circuits.

Key Components of a Motor Control Trainer:

1. Motor Control Components

- Motor starters, contactors, relays, and other components commonly used in motor control systems.
2. Motor
- An electric motor, often a three-phase induction motor, to serve as the controlled load.
3. Control Panel
- A panel that houses all the components required for motor control, providing a real-world simulation environment.
4. Wiring Terminals
- Clearly labeled terminals and connectors for hands-on wiring exercises, promoting a practical understanding of
circuit connections.
5. Control Devices
- Push buttons, selector switches, and other control devices to initiate and manage motor operations.
6. Safety Features
- Emergency stop buttons, overload protection, and other safety mechanisms to ensure a safe learning environment.
7. Visualization
- Indicators such as pilot lamps, LEDs, and displays to provide visual feedback on the status of the motor control
circuit.
8. Documentation
- User manuals, wiring diagrams, and educational materials to guide users through various motor control concepts and
exercises.

Objectives and Applications:

1. Fundamental Understanding
- Introduce users to the basic principles of motor control, including the role of contactors, relays, and protective
devices.
2. Wiring Practices
- Develop proficiency in wiring motor control circuits, from simple start- stop configurations to more complex setups
involving timers, counters, and interlocks.

1
3. Troubleshooting Skills
- Provide opportunities for users to identify and resolve common issues in motor control circuits, enhancing
troubleshooting skills.
4. Programming (if applicable)
- For trainers with programmable logic controllers (PLCs), users can gain experience in programming and integrating
PLCs into motor control systems.
5. Industry-Relevant Skills
- Prepare individuals for careers in industrial automation, electrical engineering, and related fields by providing
practical skills applicable to real-world scenarios.
6. Compliance and Safety
- Emphasize adherence to electrical codes and safety regulations, instilling a strong awareness of safety practices in
motor control applications.
7. Experimentation and Innovation
- Encourage experimentation and innovation by allowing users to explore different configurations and applications of
motor control systems.

2
1. INDICATOR LAMP- A pilot lamp, also known as a pilot light or indicator lamp,
plays a crucial role in motor controls. Its primary purpose is to provide visual indication of
the status of a motor or a specific component in an electrical circuit.
• Green lamp- When the start button is pressed and the motor starts running, the green
lamp illuminates to confirm the initiation of the motor.
• Red lamp- A red pilot lamp may be used to indicate that the power to the motor or
the control system is off. with an emergency stop button, a red lamp may be connected to
indicate that the emergency stop has been activated.
• Yellow lamp- This could include approaching a preset limit, nearing an overload
condition, or indicating a warning state.

2. MAGNETIC CONTACTORS- in motor controls encompasses several critical

functions that contribute to the safe, efficient, and controlled operation of electric motors.
Here's a concise overview of its primary roles:
• Switching Functionality-Opens and closes the electrical circuit to control the
power supply to the electric motor, allowing for the motor to be started or stopped as
needed.
• Remote Control Operation- Enables remote control of the motor through
integration with control devices such as start and stop buttons, relays, or PLCs.

3
• Overload Protection- Monitors motor current and provides overload protection by disconnecting power if the
current exceeds predetermined limits, preventing damage due to overheating or overloading.
• Emergency Stop Capability- Integrates with emergency stop buttons to rapidly de-energize the motor in
emergencies for immediate shutdown and safety.
• Control of Multiple Motors- Versatile in controlling multiple motors within a system, offering flexibility in
wiring configurations based on the specific requirements of the motor-driven equipment.

3. OVERLOAD RELAY- an overload relay in motor controls is to protect an electric motor from damage caused by
excessive current or prolonged overloads. Overload relays are essential components in motor control systems, and they
serve the following key functions:
• Overload Protection- The primary function of an overload relay is to monitor the current flowing through the
motor and protect it from damage due to overloads. When the current exceeds a preset threshold for a sustained period, the
overload relay is triggered.
• Trip the Circuit- When the overload relay detects an excessive current, it activates a mechanism to open the
electrical circuit supplying power to the motor. This effectively disconnects the motor from the power source, preventing
further damage.

4
• Prevent Overheating- Overloads can lead to overheating of the motor's winding insulation and other components.
By disconnecting power when an overload is detected, the overload relay helps prevent excessive heat buildup and protects
the motor from thermal damage.
• Motor Longevity- Overload protection provided by the relay contributes to the overall longevity and reliability of
the motor. Continuous operation under overloading conditions can significantly reduce the lifespan of a motor.
• Safety- Overload relays play a crucial role in ensuring the safety of personnel and equipment. They help prevent
catastrophic failures and potential hazards that could result from prolonged overloads or excessive

4. TIMER RELAY- Timers in motor controls play a significant role in managing the timing and sequencing of various
events within a motor control system. Here are some main roles and functions of timers in motor controls
• Delaying Start or Stop- Timers can introduce a delay before the motor starts or stops. This delay can be useful in
preventing simultaneous starting of multiple motors, allowing time for system stabilization, or facilitating sequential
operations.
• Soft Starting and Stopping- Timers are often used to implement soft starting and stopping of motors. Instead of
an abrupt start or stop, the motor's power is gradually increased or decreased over a specific time period. This helps reduce
mechanical stress on the motor and connected machinery.

5
5. CIRCUIT BREAKER ( 6A 2pole)- A 6-ampere, 2-pole circuit breaker in motor
controls serves as a protective device to safeguard the motor and associated electrical circuits
from overcurrent conditions. Here are the primary roles and functions of a 6-ampere, 2-pole
circuit breaker in motor control applications:
• Overcurrent Protection- The circuit breaker is designed to interrupt the electrical
circuit and disconnect power in the event of an overcurrent condition. This is crucial for
preventing damage to the motor and associated equipment due to excessive current flow.
• Short Circuit Protection- In the case of a short circuit, where a low-resistance path is
created, the circuit breaker acts quickly to interrupt the current flow. This helps prevent
extensive damage to the motor and the electrical system.
• Motor Branch Circuit Protection- The 6-ampere rating is specific to the capacity of the circuit breaker to
handle current up to 6 amperes. This ensures that the motor and its associated branch circuit are protected from excessive
currents that could lead to overheating or damage.
•Trip Indication- Many modern circuit breakers include trip indication features. When the circuit breaker trips due to
an overcurrent event, it often provides a visual or remote indication of the tripped state, aiding in troubleshooting and
maintenance.

6
6. CIRCUIT BREAKER (10A 3pole)- A 10-ampere, 3-pole circuit breaker in motor controls serves similar
protective functions as the 6-ampere, 2-pole circuit breaker, but it is designed for applications that involve three-phase
motors or three-phase electrical systems.
Here are the primary roles and functions of a 10-ampere,
3-pole circuit breaker in motor control applications:
• Overcurrent Protection for Three-Phase Motors- The primary role of
the 3-pole circuit breaker is to protect three-phase motors and associated electrical
circuits from overcurrent conditions. It interrupts the power supply when the current
exceeds the specified rating, preventing damage to the motor and connected equipment.
• Short Circuit Protection- In the event of a short circuitJ where a low-
resistance path is created, the circuit breaker acts quickly to interrupt the current flow.
This helps prevent extensive damage to the motor and the electrical system in three-
phase configurations.
Li LZ-L3
• Branch Circuit Protection- The 10-ampere rating is specific to the capacity
of the circuit breaker to handle current up to 10 amperes in each phase. This ensures L1 L2 L3
that the motor and its associated branch circuit are protected from excessive currents
that could lead to overheating or damage in a three-phase system.
• Three-Pole Configuration- The 3-pole configuration indicates that the circuit
breaker can interrupt all three phases of the electrical circuit. This is essential for disconnecting power to the entire three-
phase motor system during maintenance or emergencies.
• Trip Indication- Many modern circuit breakers include trip indication features. When the circuit breaker trips due
to an overcurrent event, it often provides a visual or remote indication of the tripped state, aiding in troubleshooting and
maintenance.

7
7. PUSH BOTTON devices that allow operators to initiate or interrupt the
operation of an electric motor or other electrical devices. Here are some key roles
and functions of push buttons in motor controls:
• Start Operation- Push buttons are commonly used as start buttons to
initiate the operation of an electric motor. When the operator presses the start
button, it sends a signal to the motor control system to energize the motor and
begin its operation.
• Stop Operation- Push buttons also function as stop buttons to interrupt
the operation of the motor. Pressing the stop button sends a signal to the motor
control system to de-energize the motor and bring it to a stop.

8. THREE-PHASE MOTOR- A three-phase motor plays a pivotal role in

motor controls, and it is widely used in industrial and commercial applications
due to its efficiency, reliability, and versatility. Here are some key roles and
functions of a three-phase motor in motor control systems:
• Mechanical Power Generation- The primary role of a three-phase
motor is to convert electrical energy into mechanical power. When energized
with a three-phase electrical power supply, the motor produces a rotating
magnetic field that drives the mechanical rotation of the motor's shaft.
• Induction Motor Operation- Many three-phase motors operate on the
principle of induction. Induction motors are robust and widely used due to their
simplicity, low maintenance, and ability to handle a variety of loads.
• Variable Speed Control- Three-phase motors can be used in applications where variable speed control is
required. Variable frequency drives (VFDs) are often employed to control the speed of the motor by adjusting the
frequency and voltage of the three-phase power supply.

8
• Directional Control- Three-phase motors can change direction of rotation by reversing the phase sequence of the
power supply. This is commonly achieved through the use of a motor starter or a reversing contactor in motor control
systems.
• Multiple Horsepower Ratings- Three-phase motors come in a range of horsepower ratings, making them
suitable for a variety of applications. Whether for small appliances or large industrial machinery, there are three- phase
motors available to meet different power requirements.
• Efficiency and Power Factor- Three-phase motors are known for their high efficiency and power factor,
making them energy-efficient and suitable for applications where power quality is a consideration.
• Integration with Motor Control Components- Three-phase motors are integrated into motor control
systems along with components such as contactors, starters, overload relays, and control devices like push buttons and
timers. This integration allows for precise control and protection of the motor.
• Power Transmission- Three-phase motors are commonly used in power transmission systems for driving pumps,
compressors, conveyors, fans, and other machinery. They are well-suited for applications requiring continuous and reliable
operation.
• Synchronization in Industrial Systems- In certain industrial applications, multiple three-phase motors may
need to operate in synchronization. This is achieved by ensuring that the motors receive the same frequency and are
properly phased to work together seamlessly.
• Industrial Automation and PLC Integration- In automated systems, three- phase motors are often
controlled by programmable logic controllers (PLCs). PLCs allow for advanced control strategies, monitoring, and
integration with other automation components.
9. BANANA PLUG FEMALE TO MALE -also known as

banana plugs or banana connectors, are typically used in various electrical and
electronic applications, including motor controls. Here are some common uses of
banana jacks in the context of motor controls: •Educational Demonstrations-
In educational settings, banana jacks can be used to demonstrate motor control
concepts. Students can connect and disconnect components easily, gaining hands-on
experience in building and troubleshooting motor control circuits.
•Quick Disconnects- Banana jacks provide a quick and secure method for
connecting and disconnecting wires and components in motor control setups, which can
be helpful during experimentation or maintenance.

10. EMERGENCY STOP BUTTON- An emergency stop (E-stop) button in

motor controls serves a critical role in ensuring the safety of personnel, machinery, and
the surrounding environment. It is a vital component of any motor control system and is
designed to bring a machine or motor-driven ] i equipment to an immediate stop in
emergency situations. Here are the key roles and functions of an emergency stop button in
motor controls:
• Immediate Shutdown- The primary role of an emergency | stop button is to
provide a quick and immediate means of shutting down the motor or machine in emergency situations. When pressed, it
interrupts power to the motor, stopping its operation promptly.
• Safety in Emergency Scenarios- In the event of a hazardous situation, such as a malfunction, equipment
failure, or the identification of an imminent danger, operators can press the emergency stop button to rapidly halt the motor
or machinery.

10
 III. Wiring Connections
1.STOP- START
Components Needed:
•Motor
•Magnetic Contactor •Overload Relay •Start Button •Stop
Button •Red lamp •Green lamp •Yellow lamp

What happens if the interlock of the auxiliary contact is removed?

Answer:
The magnetic contactor will be momentarily operating.

11
 1.JOG-START
Components Needed:
•Motor
•Magnetic Contactor •Overload Relay •Jog Button •Start
Button •Stop Button •Red lamp •Green lamp •Yellow lamp

What happens if the connection from the normally close (21) to the jog pushbutton and
the normally close (22) to magnetic contactor 1 (A1) is cut?
Answer:
The magnetic contactor 1 will still be in its operating state and will go along with the
magnetic contactor 2 when the push button is pressed.

12
1. FORWARD-REVERSE
Components Needed:
•Motor
•2 Magnetic Contactors •Overload
Relay •Forward Button •Reverse
Button •Stop Button •Red lamp
•Green lamp

What happens if the connection from the normally open push button of the reverse going to the normally close push
button of the forward and the normally open push button of the reverse going to the normally close push button of the
reverse is cut?
Answer:
The operation of the magnetic contactor cannot turn to reverse because there is no connection to the normally open push
button for reverse.

13
1. FORWARD-REVERSE WITH TIMER
Components Needed:
•Motor
•2 Magnetic Contactors •Overload
Relay •Forward Button •Reverse Button
•Stop Button •Timer Relay •Red lamp
•Green lamp •Yellow lamp
Question:
What happens to the connection between the stop push button going to the start push button and the start push button
going to the timer relay (TD7) if it is cut?
Answer:
The timer relay will not work or start because there is no connection going to the TD7.

F0AWAA.0

14
1. WYE-DELTA
Components Needed:
•Motor
•3 Magnetic Contactors •Timer relay
•Overload relay •Start Button •Stop
Button •Red lamp •Green lamp •Yellow
lamp

Question:
What happens if the connection from the start push button going to the magnetic contactor (A1) and the start push button
going to the timer relay (7) is cut?
Answer:
The wye magnetic contactor and delta magnetic contactor will not work because there is no connection from both their
A1.

15