Basics of Controls For Construction

Basics of Controls for Construction
A quickSTEP Online Course
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Siemens is a trademark of Siemens AG. Product names mentioned may be trademarks or registered
trademarks of their respective companies.
National Electrical Code® and NEC® and NFPA 70® are registered trademarks of the National Fire
Protection Association.
NEMA® is a registered trademark and service mark of the National Electrical Manufacturers Association.
UL® is a registered trademark of UL, LLC.
Other trademarks are the property of their respective owners.
© Siemens Industry, Inc. 2017 Page 1-2

Course Topics
Welcome to Basics of Controls for Construction.

This course covers the following topics:
Chapter 1 - Introduction
• Symbols and Diagrams
• Overcurrent
Chapter 2 – Starter Basics
• Manual Control
• Starter Components
Chapter 3 – Motor Starters
• Heavy Duty Starters
• Reduced Voltage Starters
Chapter 4 – Other Devices
• Lighting Contactors
• Pilot Devices
• Control Power Transformers
If you do not have an understanding of basic
electrical concepts, you should complete Basics
of Electricity before attempting this course.

Course Objectives
Upon completion of this course you will be able to…

• State the purpose and general principles of control components and circuits
• State the difference between manual and automatic control operation
• Identify various symbols which represent control components
• Read a basic line diagram
• Describe the construction and operating principles of manual starters,
electromagnetic contactors, and electromagnetic motor starters
• Explain the need for motor overload protection
• Briefly describe the operation of thermal and electronic overload relays
• Describe the advantages of reduced-voltage motor starting
• Briefly describe the soft starters offered by Siemens
• Describe the types and operating principles of lighting contactors
• Summarize the types of NEMA control products offered by Siemens

Siemens Control Products
Siemens offers a full range of products designed to meet the needs of virtually any construction-related
control application. This includes manual motor starters and switches, pilot devices, NEMA starters and
contactors, lighting contactors, duplex motor controls, pump control panels, and reduced voltage
starters. Siemens also offers many additional control products intended for industrial applications as
described in Basics of Control Components.
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This chapter covers the following

topics:
• Overcurrent

Control
Control, as it relates to machines and processes, is a broad

term that means anything from basic manual control to
automated control of a complex system. Control is
considered to be manually operated when someone must
initiate an action for the circuit to operate. For example,
someone might have to flip the switch of a manual starter to
start or stop a motor.
Although manual operation of machines is still common,

many machines are controlled automatically. Frequently
there is a combination of manual and automated control.
For example, a machine that is started manually may stop
automatically when certain conditions are met.
While many control applications involve motors, control

components are also used with other equipment. Various
types of control components are used for switching,
starting, protecting, detecting, monitoring, communicating,
and other functions.
Before discussing specific control devices; however, it is

important to understand some basic symbols and diagrams.
The symbols and diagrams described in this course are
commonly used in North America.
Contact Symbols
Contacts are part of a control device, such as a control

relay or contactor. Contact symbols are used in a control
diagram to indicate an open or closed path for current flow.
Contacts are shown on a control diagram in the state that
exists when the control device is de-energized. This is
referred to as the normal state of the contacts. Therefore,
contacts are shown as normally open (NO) or normally
closed (NC). For the purpose of illustration in this course, a
contact or device shown in the opposite of its normal state
is highlighted.
In the upper part of the accompanying graphic, normally

open relay contacts are shown. When the relay is de-
energized, the contacts are open, but when the relay is
energized, the contacts are closed. When the contacts
close, current from the battery flows through the lamp.
In the lower part of the accompanying graphic, normally

closed relay contacts are shown. When the relay is de-
energized, the contacts are closed, allowing current to flow
through the lamp. When the relay is energized, the
contacts open, and the lamp turns off.

Switch Symbols
We also use symbols to show switches and to indicate

under which conditions the switch provides a path for
current flow. There are many types of switches such as limit
switches, foot switches, pressure switches, level switches,
temperature-activated switches, flow switches, and selector
switches. Each switch type has its own symbol.
Switches require another device or action to change their

state. In the case of manual switches, someone must
manually change the switch position to change the state of
the switch.
For example, there are two general types of pushbuttons,

momentary and maintained. The contacts of a momentary
pushbutton change state, open to closed or vice versa,
when the pushbutton is pressed. They return to their normal
state as soon as the button is released. In contrast, a
maintained pushbutton latches in place when pressed. It
must be unlatched to allow it to return to its normal state.
The accompanying graphic shows two circuits, one with a

normally open, momentary pushbutton, and the other with a
normally closed, momentary pushbutton. Note the condition
of the lamp when each pushbutton is in its normal state.
Coil Symbols
Motor starters, contactors, and relays are examples of

devices that open and close contacts electromagnetically.
The electromagnet in these devices is called a coil.
A coil is commonly symbolized as a circle with one or more

letters and possibly a number inside. The letters often
represent the type of device, such as M for motor starter or
CR for control relay. A number is often added to the letter to
differentiate one device from another.
The contacts controlled by a coil are labeled with the same

letter (and number) as the coil so that it is easy to tell which
contacts are controlled by each coil. A coil often controls
multiple contacts, and a combination of normally open and
normally closed contacts may be used.
In the accompanying example, the M contacts in the power

circuit for the motor are controlled by the M contactor coil.
Closing the switch completes the current path through the
coil. The M contactor coil actuates the M contacts,
providing power to the motor.

Other Symbols
There are many other types of control symbols, too many to

include in this course, but some examples of symbols you
will encounter later in this course are shown in the
accompanying graphic and described below.
Overload relays are used to protect motors from

overheating. When excessive current is drawn for a
predetermined amount of time, the overload relay’s
contacts open, removing power from the motor. The
accompanying symbol is for contacts associated with a
thermal overload relay. An overload relay used with a three-
phase motor has three such contacts, one for each phase.
An indicator light, often referred to as a pilot light, is a small

electric light used to indicate a specific condition of a circuit.
For example, a red light might be used to indicate that a
motor is running. A letter in the center of the indicator light
symbol is sometimes used to indicate the color of the light.

Line Diagrams
Control circuits are depicted with line diagrams, also called

ladder diagrams. Line diagrams show the functional
relationship of components and devices in a circuit, not the
physical relationship. In the accompanying graphic, the
upper illustration shows the physical and electrical
relationship between a pushbutton and a pilot light. In this
example, the components are mounted in the same
enclosure, but that is not always the case.
In the lower illustration, the line diagram symbolically

displays the functional relationship of these same
components. In order to properly interpret this diagram, you
must read it from left to right, starting at L1 and ending at
L2. With that in mind, note that pressing the pushbutton
allows current to flow from L1 to L2 through the pushbutton
and the pilot light. Because the pushbutton used is a
normally open pushbutton, the pilot is on only when the
pushbutton is pressed. Releasing the pushbutton stops
current flow, and the light turns off.

Power and Control Circuits
Line diagrams are made up of two types of circuits, control

circuits and power circuits. Within a line diagram, control
circuit wiring is represented by a light line, and power circuit
wiring is represented by a heavy line. A small dot or node at
the intersection of two or more wires indicates an electrical
connection.
The accompanying line diagram includes both power and

control circuits. The power circuit, drawn with a heavy line,
is the circuit that supplies power to the motor. The control
circuit, drawn with a light line, controls the distribution of
power to the motor.

Control Load Connections
A typical control circuit includes a control load and one or

more components that determine when the control load will
be energized. Some control loads, such as relays and
contactors, activate other devices, but other control loads,
such as indicator lights, do not.
For example, in the accompanying graphic, circuit 1 shows

the connection of a pilot light and a pushbutton. The power
lines are drawn vertically and marked L1 and L2. In this
example, the voltage between L1 and L2 is 120 VAC.
While it is proper to place contacts in series, it is not proper

to wire control loads in series as shown in circuit 2,
because, when the loads are energized, the voltage is
divided, and the full voltage is not applied to the loads.
Circuit 3 shows an example of a correctly connected circuit

with a few more components. In this circuit, a normally open
pushbutton is connected in series with two parallel
branches. One parallel branch has a pilot light, and the
other has a contactor coil in series with normally closed
overload contacts (OL). This configuration is proper
because closed contacts have minimal voltage drop, so the
full control voltage is applied to both the pilot light and coil
when the pushbutton is pressed.
Control Device Connections
Often a control load is controlled by more than one control

device. These control devices may be connected in series,
parallel, or in a combination series-parallel circuit.
For example, in circuit 1 two normally open pushbuttons are

connected in parallel. Pressing either pushbutton, or both
pushbuttons, allows current to flow from L1, through the
indicator light, to L2.
In circuit 2, two normally open pushbuttons are connected

in series. Both pushbuttons must be pressed at the same
time to allow current to flow from L1 through the load to L2.
In circuit 3, normally open pushbuttons 1 and 2 form parallel

branches in series with normally closed pushbutton 3. If
either pushbutton 1 or 2 or both are pressed, current flows
from L1 through the load to L2, unless pushbutton 3 is
pressed. When pushbutton 3 is pressed, no current can
flow from L1 to L2 regardless of the states of pushbuttons 1
and 2.
For these examples, the control devices are all

pushbuttons, but other types of control devices or contacts
are often, used and the circuits can be much more complex.

topics:
• Overcurrent

Current and Temperature
Some of the control components covered in this course are

designed to protect motors or other equipment. In order to
understand these control components, you must know
some common circuit faults.
To begin with, current flow always generates heat. The

amount of heat generated is proportional to both the
amount of current flow and the resistance of the conductive
path. Because conductors can be damaged by excess heat,
each conductor has a continuous current rating, also called
its ampacity.
Excessive current is referred to as overcurrent. An

overcurrent can result from a short circuit, overload, or
ground fault. The first two types of overcurrent faults are
described in the following pages.

Short Circuits
A short circuit occurs when two or more bare conductors

touch causing the resistance between the conductors at
that point to drop significantly. This reduction in resistance
causes current to rise quickly.
For example, if the voltage between the conductors is 240

volts, and the resistance of the conductors from one side of
the power source to the other is 24 ohms, the current in the
conductors is 10 amps. With the insulator intact, no current
flows through the insulator from one conductor to the other.
However, if the insulator between the conductors is

damaged, and the bare conductors touch, the resistance
between the conductors drops and the current rises rapidly.
For example, if the resistance between the bare conductors
drops to 0.024 ohms, and the voltage applied is 240 volts,
the current will be 10,000 amps. Therefore, the conductors
must be protected by a circuit breaker or fuse to stop the
flow of current before it reaches this dangerous level.

Overloads
An overload is a typically a much lower current than a short

circuit. An overload occurs when too many devices or the
wrong type of devices are connected to a circuit or when
electrical equipment is made to work beyond its rated
capabilities. For example, if a conveyor jams, its motor may
draw two or more times its rated current.

Temporary Overloads
In the previous example, the overload resulted when a

circuit exceeded its rated capacity for an extended time. In
such a situation, an overcurrent protection device should
shut down the circuit.
A different response is required for a short-duration

overload. In such a situation, it may be undesirable to
disable the circuit. To understand this better, consider what
happens when an electric motor is started.
When most motors start, they draw current in excess of

their full-load current rating. For example, a NEMA
design B motor typically has a starting current that is about
six times its full-load current. For some high-efficiency
motors, the starting current is even higher. Motors are
designed to tolerate a high starting current for a short time.
As a motor accelerates to operating speed, its current drops
off quickly.
In the accompanying example, the motor’s starting current

is 600% of full load current, but after eight seconds, current
has dropped to the rated value.

Overload Protection
Fuses and circuit breakers are designed to protect circuit

conductors in the event of a short circuit or overload. Under
such conditions, these devices open the path for current
flow before damage to conductors occurs.
In a motor circuit, circuit conductors and the fuse or circuit

breaker designed to protect them, must be sized to allow for
the high starting current of the motor. Because of this,
overload protection for the motor must be provided
separately.
For example, the accompanying graphic shows the power

and control circuits for a motor. An instantaneous,
magnetic-trip only circuit breaker is used to provide short-
circuit protection for the power circuit and an overload relay
is used to provide overload protection for the motor.

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topics:
• Manual Control

Manual Control
As the name implies, manual controls are devices that are

operated by hand. A manual starter consists of a manual
contactor, such as a simple switch mechanism, and an
overload protection device.
Each set of contacts engaged by the manual starter is

referred to as a pole.
The accompanying graphic shows a single starter pole for

simplicity, but manual starters typically have two or three
poles.

Two-Pole Manual Starter
A starter is connected between the power source and the

motor. This example shows the connections for a two-pole
manual starter used for a single-phase AC motor. A similar
arrangement is used for a DC motor.
When the starter is in the OFF position, the starter contacts

are open and current cannot flow through the motor.
When the starter is in the ON position, the starter contacts

are closed, current flows through the motor, and the motor
runs, unless an overload condition causes the overload
contacts to open.

SMF Fractional-Horsepower Manual Starters
Siemens SMF fractional-horsepower starters provide

overload protection and manual ON/OFF control for small
motors.
SMF starters are available in one-pole or two-pole versions

suitable for AC motors up to 1 HP and 277 VAC. The two-
pole version is suitable for DC motors up to 3/4 HP and
230 VDC. A melting-alloy type overload relay is used for
overload protection.
SMF manual starters are available in a variety of

enclosures. A two-speed version is also available.

MMS and MRS Manual Switches
Siemens MMS and MRS manual switches are similar to

SMF starters, but do not provide overload protection. MMS
and MRS switches only provide manual ON/OFF control of
DC and single-phase or three-phase AC motors where
overload protection is provided separately.
These devices are suitable for use with three-phase motors

up to 10 HP and 600 VAC and up to 1-1/2 HP and 23 VDC.
MMS and MRS manual switches are available in various

enclosures. Two-speed and reversing versions are also
available.

Class 11 – 3RV Manual Starters and Switches
Siemens Class 11 across-the-line manual starters and

switches provide control for machinery where remote start
and stop control is not required.
Class 11 - 3RV manual starters are used for single-phase

and three-phase motors up to 20 HP at 575 VAC and have
bimetallic heater elements that provide class 10 overcurrent
protection. These starters have ambient temperature
compensation. A built-in differential trip bar reduces tripping
time in the event of a phase loss condition. Magnetic trip
elements in each starter take the device off line when it
senses current of 13 times the maximum full load ampere
(FLA) dial setting.
Class 11 - 3RV switches provide control where overload

protection is not required or is provided separately.
Class 11 - 3RV controllers are available with low voltage

protection, which automatically opens the power poles
when the voltage drops or power is interrupted. They are
available in an open style (without enclosure), in a NEMA 1
general purpose enclosure, or in NEMA 7 & 9 or
NEMA 7 & 9/NEMA 3 & 4 enclosures .

3RV Motor Starter Protectors
Motor starter protector (MSP) is a name used in the U.S.

and some other countries to identify a type of component
that is referred to in International Electrotechnical
Commission (IEC) standards as a circuit breaker. Siemens
3RV MSPs are part of the SIRIUS modular system of
control products described throughout this course.
3RV2 MSPs are UL listed as UL 508 Type E self-protected

combination motor controllers. In this application, all the
required functions for a motor branch (disconnect, short
circuit protection, motor control, and overload protection)
are provided in one device. A type E terminal adaptor is
required.
3RV2 MSPs are also approved for use as follows:

• Manual motor controller
• Group Installation
• Tap conductor protection in group Installation in
compliance with the National Electric Code (NEC)
When a 3RV2 MSP is used with one of the three above

mentioned approvals, it can be installed downstream of one
circuit breaker or fuse set.


topics:
• Manual Control

Magnetic Contactors
Most motor applications require the use of remote control

devices to start and stop the motor. Magnetic contactors,
similar to the ones shown here, are commonly used to
provide this function.
Like many other control components, contactors are most

often manufactured to specifications provided either by the
National Electrical Manufacturer’s Association (NEMA) or
the International Electrotechnical Commission (IEC).
As discussed later in this course, some magnetic contactors

are used to control the distribution of power in lighting and
heating circuits.

Electromagnetic Principles
Magnetic contactors utilize basic electromagnetic principles.

To understand these principles, consider a simple
electromagnet fashioned by winding a wire around a soft
iron core and connecting the coil to a DC voltage source.
Current flowing through the wire temporarily magnetizes the

iron core coil. When the coil is disconnected from the DC
voltage, the current stops and the soft iron core coil returns
to its nonmagnetic state.

Basic Contactor Operation
The accompanying graphic shows the interior of a basic

contactor. There are two circuits involved with the operation
of a contactor, the control circuit and the power circuit. The
control circuit is connected to the coil of an electromagnet,
and the power circuit is connected to the stationary
contacts.
The operation of this electromagnet is similar to the

operation of the electromagnet made by wrapping a wire
around a soft iron core. When the control circuit supplies
power to the coil, a magnetic field is produced, magnetizing
the electromagnet. The magnetic field attracts the armature
to the magnet, which, in turn, closes the contacts. With the
contacts closed, current flows through the power circuit
from the line to the load.
When current no longer flows through the control circuit, the

electromagnet’s coil de-energizes, the magnetic field
collapses, and the movable contacts open under spring
pressure.

Basic Contactor Circuit
The accompanying graphic symbolically shows the

operation of a contactor in a simple three-phase motor
circuit. The contacts of the contactor are in the power circuit
for the motor. The OL contacts are part of an overload relay
used to protect the motor. Overload relays are discussed
later in this course.
The electromagnetic coil of the contactor is connected

through a switch (SW1) to L1. Normally other components
are used instead of a toggle switch, but the principle
remains the same.
When SW1 closes, the contactor’s coil energizes, closing

the M contacts and applying power to the motor. Opening
SW1 de-energizes the coil, opening the M contacts and
removing power from the motor.

Overload Relays
Contactors are used to control power in a variety of

applications. When used in motor-control applications,
contactors can only start and stop the motors. Contactors
cannot sense when the motor is being overloaded, and they
provide no overload protection.
Most motor applications require overload protection.

Although some small motors have overload protection built
into the motor, more commonly, overload relays (such as
the ones shown in the accompanying graphic) are used.
Overload relays are designed to meet the special protective

needs of motors. Overload relays continue to provide power
during the short duration overloads that occur when a motor
starts. If an overload condition persists, however, the
overload relay removes power from the motor. Once the
overload condition has been corrected, the overload relay
can be reset to allow the motor to be restarted.

Trip Class
An overload relay has a trip class rating which identifies the

maximum time (in seconds) it takes for the overload relay to
trip at a specific current, typically six times its continuous
current rating. The most common trip classes are 5, 10, 20,
and 30.

Overload Relay in a Circuit
The accompanying graphic symbolically shows a motor

circuit with contactor contacts (M) and overload relay
contacts (OL). The top circuit shows the contractor and
overload relay contacts closed, and the motor running.
In the bottom circuit, an overload has occurred and the

overload relay contacts have opened. The normally closed
overload relay contacts in the control circuit also opened
when the overload relay tripped. This interrupted current
flow in the contactor coil, causing the contactor contacts to
open.
In this circuit, if the overload relay is reset with SW1 switch

closed, the motor will automatically restart. For this reason,
most motor control circuits are configured differently, as will
be described later in this course.

Thermal Overload Relays
A thermal overload relay, also called a bimetal overload

relay, incorporates a small heater element wired in series
with the motor and a bimetallic strip. For simplicity, the
accompanying graphic shows only one circuit phase.
The bimetallic strip functions as a trip lever. It is made of

two dissimilar metals bonded together. These metals have
different thermal expansion characteristics, causing the
bimetallic strip to bend when heated.
Under normal operating conditions, the heat generated by

the heater element causes the bimetallic strip to bend only
slightly, not enough to trip the overload relay.
If an overload occurs and persists long enough, the

bimetallic strip bends until the overload relay is tripped. This
causes the overload relay’s contacts to open, removing
power from the motor.
Some thermal overload relays are designed to reset

automatically after the bimetallic strip has cooled.
Depending on the circuit, the motor may then restart
automatically. For some applications, this is desirable, but
for most applications it is not.
Ambient Compensated Thermal Overload Relays
In some applications, submersible pumps for example, the

motor is installed in a location with a constant ambient
temperature while the overload relay is installed in a
location with a varying ambient temperature. Because the
bimetallic strip in an overload relay bends more as ambient
temperature rises, this can lead to nuisance tripping if a
standard thermal overload relay is used.
Ambient compensated thermal overload relays overcome

this problem by using a compensated bimetallic strip along
with the primary bimetallic strip. In the accompanying
graphic, the circuit on the top shows how, as the ambient
temperature rises, both bimetallic strips bend equally, and
the overload relay does not trip. For simplicity, the
accompanying graphic shows only one circuit phase.
In the circuit on the bottom in the accompanying graphic,

current flow through the motor and the heater element
affects only the primary bimetallic strip. When the current
rises to the level of an overload, the primary bimetallic strip
bends enough to trip the overload relay.

Class 48 Ambient Compensated
Siemens Class 48 ambient compensated thermal overload

relays are available in single-phase and three-phase
designs and can be set for manual or self-resetting
operation.
An adjustment dial located on the unit allows the ampere

trip setting to be adjusted +/-15%.
A manual test button is provided to test the operation of the

overload relay control contacts.
The ambient compensated thermal overload relay heater

elements are available in Class 10 or Class 20 ratings. A
normally open or normally closed auxiliary contact is
available as an option.

Electronic Overload Relays
Electronic overload relays are another option for motor

protection. The features of electronic overload relays vary,
but there are some common advantages.
One advantage of electronic overload relays is that they do

not require heaters. This eliminates the need to stock
multiple heaters to match motor ratings. This heaterless
design also allows electronic relays to be insensitive to
ambient temperature, minimizing nuisance tripping.
In addition, electronic overload relays can detect a power

phase loss and quickly disconnect the motor from the
power source. This is an important advantage because,
without phase loss protection, loss of a power phase can
quickly result in damaged motor windings

ESP200 Electronic Overload Relays
Like other electronic overload relays, ESP200 electronic

overload relays eliminate the need for heaters. Instead of
installing a heater, a dial on the overload relay is set to the
motor’s full-load current rating.
Class 48 ESP200 electronic overload relays, like the one

shown in the accompanying graphic, have two dual in-line
package (DIP) switches accessible from the front that
simplify selection of any of four trip classes (5, 10, 20, and
30). Additional DIP switches provide on or off settings for
phase unbalance, phase loss, or ground fault detection as
well as selection of manual or automatic reset. Also
accessible from the front are the Reset button, for use
when manual reset is selected, and the Test button, that
triggers a complete electronic functions test. One normally
open auxiliary contact and one normally closed auxiliary
contact are standard.
In addition to Class 48 ESP200, two other types of ESP200

electronic overload relays are available. 958 ESP200
electronic overload relays are specifically designed for
hermetically sealed and artificially-cooled motors. 958L
electronic overload relays are designed for the oil market
and pumping applications with a precise trip curve.
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topics:

NEMA Motor Starter
Contactors and overload relays are separate control

devices. When a contactor is combined with an overload
relay, it is called a motor starter.
Motor starters manufactured to NEMA specifications are

referred to as NEMA starters or heavy duty starters.
Starters manufactured to IEC standards are discussed in
the Basics of Control Components course. Siemens offers
both types of starters and associated components.
When a starter’s contactor is set up to supply the full line

voltage to a motor, it is called a full-voltage, across-the-line,
or direct motor starter.
As discussed later in this course, some starters are capable

of reversing motor direction, controlling the starting voltage,
or controlling two speed motors. However, the most
common type of motor starter is designed to turn a motor
on and off and provide overload protection. The overload
relay used may be a thermal overload relay or, as in the
accompanying graphic, an electronic overload relay.

Motor Starter in a Control Circuit
The accompanying graphic shows the electrical relationship

between the contactor and overload relay in a full-voltage
motor starter circuit. The contactor, highlighted in light blue,
includes the electromagnetic starter coil, the main motor
contacts, and the auxiliary contact. The overload relay,
highlighted in gray, includes the overload relay heaters and
the overload relay contact.
In this circuit, no power flows in either the power or control

circuits when the starter coil is de-energized. When the
Start pushbutton is pressed, current flows through the
starter coil (M) and the associated contacts close. This
causes current to flow to the motor. Even after the Start
pushbutton is released, the starter coil remains energized
because the normally open auxiliary contact (Ma) closed
when the coil first energized.
Current will continue to flow to the motor unless the Stop

button is pressed or an overload causes the overload relay
contacts to open

NEMA Contactor and Starter Ratings
NEMA-rated contactors and starters have size numbers

from size 00 to size 8 based upon their continuous current
and horsepower ratings.
Siemens also has what are called Half Sizes available for
some Siemens motor starters. The ratings for these devices
fall between the ratings of normal NEMA sizes, allowing the
user to more closely match the motor control to the actual
application. Half Sizes are beneficial because they cost less
than larger NEMA size starters. The accompanying table
shows both the NEMA sizes and Siemens Half Sizes
available.
NEMA motor starters and contactors can be used in

virtually any application at their stated rating, from simple
ON and OFF applications to more demanding applications
that include plugging and jogging.
To select a NEMA motor starter for a particular motor, one

needs only to know the horsepower and voltage of the
motor. However, if there is considerable plugging and
jogging duty involved, even a NEMA-rated device may
require de-rating.

Class 14 NEMA Starters with
Class 14 NEMA starters with Class 10 or 20 ambient-

compensated thermal overload relays are available for
three-phase applications up to 100 HP at 460 VAC (NEMA
sizes 00 to 4). In addition to whole sizes, this range
includes Siemens 1¾, 2½, and 3½ sizes.
Single-phase starters are also available up to 10 HP at

208/230 VAC (NEMA size 00 to Siemens 2½ size).

Class 14 ESP200 Starters
Class 14 ESP200 starters are available for three-phase

applications with contactors up to NEMA size 8, including
Siemens 1¾, 2½, and 3½ sizes. Single-phase starters are
also available up to 15 HP at 208/230 VAC (NEMA sizes 0
to 3).
ESP200 overload relays provide the specific level of

protection needed for an application. For example, the trip
class (5, 10, 20, or 30) is set using DIP switches on the
front of the unit and the full-load ampere (FLA) dial allows
for a wide range (4:1) of adjustment.
958 and 958L ESP200 solid state overload relays are also
available for specialized applications.

Reversing Starters
Many applications require a motor to run in either direction.

Changing the direction of rotation requires changing the
direction of current flow in the motor windings. For a three-
phase induction motor, this is done by reversing two of the
motor leads, typically T1 and T3.
The accompanying graphic shows a three-phase reversing

motor circuit with two sets of contacts. The forward (F)
contacts are controlled by the forward contactor, and the
reverse (R) contacts are controlled by the reverse
contactor.
When the F contacts are closed, current flow through the

motor causes it to turn in a clockwise direction. When the R
contacts are closed, T1 is connected to L3 and T3 is
connected to L1 causing the motor to rotate in a
counterclockwise direction. Mechanical interlocks prevent
both forward and reverse circuits from being energized at
the same time.
Siemens offers Class 22 reversing starters and Class 43

reversing contactors in NEMA sizes 00 through 8, including
Siemens Half Sizes. Class 25 and 26 combination reversing
starters are available as well.
Two Speed Heavy Duty Starters
The synchronous speed of a three-phase induction motor is

a function of the supply frequency and the number of poles.
This speed is the rate in RPMs for the motor’s rotating
magnetic field. The actual speed of the motor is the
synchronous speed minus slip caused by the motor’s load.
Two types of induction motors that allow for two-speed

control using magnetic starters are separate winding motors
and consequent pole motors. Consequent pole motors with
two speeds on a single winding require a starter which
reconnects the motor leads to half the number of effective
motor poles for high speed operation. For this type of
motor, the low speed is one half the high speed.
Separate winding motors have a winding for each speed

and provide more varied speed combinations because the
low speed need not be one half the high speed. Starters for
separate winding motors consist of a starter unit for each
speed.
Siemens offers Class 30 two-speed heavy duty starters for

separate-winding and consequent-pole motors used in
constant torque, variable torque, and constant horsepower
applications. Siemens also offers Class 32 combination two
speed heavy duty starters.
NEMA Enclosed Starters
Combination starters incorporate a motor starter, short

circuit protection, and a means to safely disconnect power.
Siemens offers a variety of enclosed combination starters

and non-combination starters with NEMA components in a
full range of enclosure types.
Duplex motor controllers consist of two motor starters in a

common enclosure. Siemens duplex motor controllers are
specifically designed for industrial and commercial
applications that require duplex controls such as dual
pumps or blowers. Siemens Class 83 is a non-combination
duplex motor controller. Siemens Class 84 is a combination
duplex motor controller with two separate disconnects or
circuit breakers.

Pump Control Panels
Pump controllers monitor flow and/or level variables and

control a pump to maintain the desired values. Pump
control can involve simply turning a pump on and off or can
include more advanced controls for pump speed, output
pressure, etc.
Siemens pump control panels are factory wired to simplify

installation, provide flexible control, and protect against
short circuits and overloads. Ample space is provided for
field modifications and installation of accessories.
Siemens offers Class 82 Slim Line, Class 87 full voltage

and vacuum starters as well as Class 88 autotransformer
starters, part-winding starters, and wye-delta starters.

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topics:

Full-Voltage Starting
The motor starters discussed thus far have all been full-
voltage starters, also called across-the-line starters. This is
the most common type of motor starter because the initial
component cost is low.
When a motor is started with full voltage, starting current

can be as high as 600% of full-load current for a standard
three-phase induction motors and as high as 1200% of full-
load current for high efficiency motors. This high starting
current causes power fluctuations that affect other
equipment. As a result, many power companies require
reduced-voltage starting for large-horsepower motors.
Another potential problem with full-voltage starting is the

high torque developed when power is first applied to the
motor. As shown in the accompanying speed-torque curve
for a NEMA B motor, the initial torque, also called locked
rotor torque, is typically around 150 percent of full-load
torque. Additionally, the torque can rise as high as 175 to
200 percent of full-load torque as the motor accelerates to
rated speed.
Many applications require the starting voltage and torque to

be applied gradually to reduce the repeated stress on
electrical and mechanical components.
Reduced-Voltage Starting
Starting methods which start a motor with less than full

voltage are referred to reduced-voltage starting. These
approaches also reduce starting torque.
Siemens offers the following types of reduced-voltage

starters with NEMA components: autotransformer starters,
part-winding starters, and wye-delta starters. Siemens also
offers wye-delta starters and soft starters with IEC
components as described later in this course.
One of the more basic types of reduce-voltage starters is

the autotransformer reduced voltage starter.
Autotransformer reduced-voltage starters provide a high
starting torque per ampere of line current and are typically
used for applications where starting current must be
reduced while retaining good starting torque.
Autotransformers have adjustable taps to set the reduced

starting voltage as a percentage of the full-line voltage.
Siemens offers autotransformer starters as Class 36 non-

combination starters and Class 37 combination starters with
a fusible or non-fusible disconnect or circuit breaker.

Part-Winding Starters
Part-winding reduced-voltage starters are used with motors

which have two separate parallel windings on the stator.
One magnetic starter engages the first set of windings
when the motor is started. These windings draw about 65 to
85% of the rated locked rotor current.
After a set time, a second magnetic starter energizes and

places the second set of windings in parallel with the first.
Part winding reduced-voltage starters are the least

expensive type of reduced-voltage starters and use a
simplified control circuit. However, they require a special
motor design, are not suitable for high-inertia loads, and do
not have adjustments for current or torque.
Siemens offers part winding starters as Class 36 non-


Wye-Delta Starters
Wye-delta reduced voltage starters are applicable only for

motors with stator windings not connected internally and all
six motor leads available for external connections.
The motor starts with windings connected in a wye

configuration, providing a significantly lower inrush current
than if the motor windings had been connected in a delta
configuration.
After a set time, starter contacts connect the stator

windings in a delta configuration. This increases the voltage
applied across each stator winding.
This type of starter is a good choice for applications that

require frequent starts, low starting torque, or long
accelerating times.
Siemens offers wye-delta starters as Class 36 non-


SIRIUS 3RW Soft Starters
Solid state, reduced-voltage starters, often called soft

starters, limit motor starting current and torque by ramping
up the voltage applied to the motor during the selectable
starting time.
Soft starters accomplish this by gradually increasing the

portion of the power supply cycle applied to the motor
windings, a process sometimes referred to as phase
control.
Once the start up has completed, SIRIUS soft starters use

integrated bypass contacts to bypass power switching
devices (thyristors). This improves efficiency, minimizes
heat, and reduces stress on thyristors.
Some soft starters (such as SIRIUS 3RW40 and 3RW44)

also allow the phase control process to be applied in
reverse when the motor is being stopped. This controlled
starting and stopping significantly reduces stress on
connected devices and minimizes line voltage fluctuations.
The SIRIUS modular system includes SIRIUS 3RW30 and

3RW40 soft starters for standard applications and SIRIUS
3RW44 soft starters for high feature applications.
SIRIUS 3RW30 and 3RW40 Soft Starters
SIRIUS 3RW30 soft starters have an especially compact

design that saves space and easily integrates with other
SIRIUS components. They are available for supply voltages
up to 480 VAC and operating current up to 106 A at 40
degrees C. Potentiometers on the front of the unit provide
settings for ramp-up time and starting voltage.
SIRIUS 3RW40 soft starters have all the advantages of

3RW30 soft starters, but have more features and are
available for operating current up to 432 A at 40 degrees C.
3RW40 soft starter features include: selectable motor

overload protection (Class 10, 15, or 20), manual or remote
reset, and optional thermistor motor protection. 3RW40 soft
starters are also equipped with integrated intrinsic device
protection to prevent thermal overloading of the power
switching devices (thyristors).
Potentiometers on the front of the unit provide settings for

current limit, starting voltage, and ramp-up and ramp-down
times.

SIRIUS 3RW44 Soft Starters
SIRIUS 3RW44 soft starters make soft starting and

stopping attractive for demanding applications and combine
a high degree of functionality and extensive diagnostics.
3RW44 soft starters are available for operating current up

to 1214 A at 40 degrees C. A backlit display with 4-key
operation simplifies the process of changing parameters.
An RS-232 serial interface is provided to communicate with
Soft Starter ES software for easy configuration or a display
for external operation and monitoring.
Additional features include, but are not limited to:

• Motor overload protection
• Thermistor motor protection
• Selectable current limiting
• Multiple starting and stopping/braking modes
• Intrinsic device protection for thyristors
• Optional PROFINET or PROFIBUS DP communication

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topics:
• Pilot Devices

Electrically Held Lighting Contactors
Many commercial lighting and heating applications require

use of contactors to control the loads. One type of contactor
used in these applications is an electrically held contactor,
which is similar to the contactor used with a magnetic motor
starter. Unlike a starter contactor, however, a lighting
contactor is designed for lighting and resistive heating loads
rather than motor loads.
Because electrically held lighting contactors have the same

operating principles as the magnetic contactors covered
earlier in this course, the control circuit for an electrically
held lighting contactor (shown in the accompanying
graphic) is similar to the start-stop circuit for a motor starter.
Because the contacts of this type of contactor open when

control power is lost, electrically held contactors are used in
applications where automatic restart after a power failure is
not required or is undesirable.
Also, because electrically held contactors hum when

current is supplied to the coil to hold the contacts closed,
this type of contactor is not recommended where the
humming will disturb building occupants.

Class LE Electrically Held Lighting Contactors
Siemens Class LE electrically held lighting contactors are

an economical offering with a compact, lightweight design.
They are rated for tungsten lighting (incandescent filament)
and ballast lighting (fluorescent, HID, metal halide, mercury
vapor, quartz halogen, and sodium-lamp) as well as for
resistive and general use loads.

Class LC Lighting Contactors
Siemens Class LC lighting contactors can be ordered as

either electrically held or mechanically held and can be
converted from electrically held to mechanically held.
Mechanically held contactors, as the name implies, have

contacts that, once closed remain closed until opened by
the contactor, even if a power outage occurs. This means
that the associated load will be automatically restarted
when power resumes following an outage. This also means
that the contactor only receives momentary current to open
or close its contacts. Therefore, less energy is used and
contactor hum is eliminated.
Siemens Class LC contactors are rated for tungsten lighting

(incandescent filament) and ballast lighting (fluorescent,
HID, metal halide, mercury vapor, quartz halogen, and
sodium-lamp) as well as for resistive and general use loads.
These contactors have a modular design that enables you

to stock the building block components to assemble
configurations of electrically held and mechanically held
contactors with reduced inventory.

Class CLM Lighting Contactors
Siemens Class CLM magnetically held and mechanically

held lighting contactors are used in applications where it is
critical that contacts remain in the closed position during a
power outage. When power resumes following an outage,
the associated load is automatically restarted. Because the
contactor only receives momentary current to open or close
its contacts, less energy is used and contactor hum is
eliminated.
A magnetically held contactor contains a permanent

magnet. When the contactor is energized, current through a
coil creates a magnetic field that reinforces the permanent
magnet and closes the contacts. Current through the coil is
then interrupted, and the contacts are held closed by the
permanent magnet, even if control power is lost. Contacts
are opened magnetically when an OFF coil is energized.
A mechanically held contactor has contacts that are

mechanically held closed when the contactor is energized
and remain held until a trip solenoid receives a signal to
release the mechanical latch.
Siemens Class CLM contactors are rated for tungsten

lighting and ballast lighting, and resistive and general use
loads.
Lighting Contactor Enclosures
Siemens offers enclosures for all sizes of contactors that

meet NEMA 1, 3/3R, 4, 4/4X stainless steel or 12
standards.

Combination Lighting Contactors
Siemens combination lighting contactors provide a

disconnect means for lockout and maintenance as well as
short-circuit protection. They are UL rated as Service
Entrance Equipment, permitting equipment to be pole
mounted and installed directly off of utility power lines.
This makes the product ideal to control lighting in remote

locations such as sports facilities, parks, fair grounds,
streets, and highways as well as for control of industrial
and general area lighting.

Combination Lighting Contactors
Numerous control options and accessories are available to

customize the product to your exact specifications. To add
flexibility, modifications are available as either factory
installed or field kits. Nearly all these accessories are
common for all lighting contactors, reducing cost of
inventory.
Some of the common options include:

• Auxiliary contacts
• Solid-state control module
• On/Off pushbuttons
• On/Off and Hand-Off-Auto selector switches
• Pilot lights to display on and off conditions
• Control power transformers
• Control relays
• 24-hour and 7-day time clocks


topics:
• Pilot Devices

Pilot Devices
A pilot device directs the operation of another device or

indicates the status of an operating machine or system.
Siemens pilot devices and enclosed pilot devices are
available with a variety of features and include product
selections appropriate for a broad range of applications.
The pilot devices listed below have a 30 millimeter (mm)

mounting diameter, which refers to the size of the knockout
hole required to mount a device.
• Class 50 standard duty control stations

• Class 51 hazardous duty pilot devices
• Class 52 oil tight pilot devices and BlackMax corrosion
resistant pilot devices
The following pages provide basic information for some of

the types of devices listed above; however, before
discussing these specific types of devices, we will review
some basic device concepts.

Two-Wire Control
A two-wire control circuit is so called because only two

wires are used to connect the Start-Stop switch into the
control circuit. This type of circuit provides low-voltage
release, but does not provide low voltage protection. This
means that when power is lost, the contactor will de-
energize; however, as long at the Start-Stop switch is
closed, the contactor will energize and the motor will restart
when power resumes.
Two-wire control is used for remote or inaccessible

installations where it is desirable to have an immediate
return to service when power is restored.

Pushbuttons
Pushbuttons are manual switches used in control circuits.

Pushbuttons may be illuminated or non-illuminated and are
available in a variety of configurations and actuator colors.
A typical pushbutton uses an operating plunger, a return

spring, and a set of contacts. The accompanying graphic
shows the operation of two pushbuttons, one with a set of
normally open contacts and one with a set of normally
closed contracts. These pushbuttons have momentary
contacts, which means that the contacts return to their
normal position when open when the pushbutton is
released. Some pushbuttons have maintained contacts,
which means that the contacts stay in the actuated position
until manually released.
Pushbuttons are available with various contact

configurations. For example, a pushbutton may have a set
of normally open contacts and a set of normally closed
contacts. This allows the pushbutton to function as a
normally open pushbutton or a normally closed pushbutton
depending upon which set of contacts are used in the
control circuit.

Three-Wire Control
The accompanying graphic shows an example of how a

normally open and a normally closed pushbutton can be
used in a control circuit.
This circuit is an example of three-wire control because

there are three connection points required to connect the
Start and Stop pushbuttons and the holding contact (Ma).
Three-wire control automatically provides low voltage
protection, meaning that, if power is lost, the motor will stop
and will not automatically restart once power is regained.
Pressing the Start pushbutton completes the path for

current flow in the control circuit and energizes the M
contactor coil. When the M coil energizes, the M and Ma
contacts close, and power is applied to the motor. Ma is an
auxiliary contact that provides a path for current flow in the
control circuit after the Start pushbutton has been released.
When an overload occurs, the OL contacts open. The

purpose of the normally closed OL contact in the control
circuit is to de-energize the M contactor when an overload
occurs so that the motor will not automatically restart after
the overload relay has been reset.

Selector Switches
Selector switches are another means to manually open and

close contacts and are commonly used to select one of two
or more circuit possibilities.
Selector switches may be maintained, spring return, or key

operated and are available in two-position, three-position,
and four-position types.
The basic difference between a pushbutton and a selector

switch is the operator mechanism. A selector switch
operator mechanism is rotated to open and close contacts.
Contact blocks used on Siemens pushbuttons are

interchangeable with those used on compatible selector
switches.

Two-Position Selector Switch
In the accompanying graphic, a two-position selector switch

is wired to activate either of two pilot lights. When the
switch is in position 1, PL1 is on, and when the switch is in
position 2, PL2 is on.
Two common methods of indicating the contact position of

a selector switch are to show an alternative position in
dotted lines or to use a truth table to show which set of
contacts will be closed for each switch position.
For the circuit shown here, the truth table indicates that
contacts A will be closed with the switch in position 1 and
contacts B will be closed with the switch in position 2.
For a simple two-position switch, a truth table has limited

value, but, as the number of switch positions increases, the
value of a truth table increases.

Three-Position Selector Switch
A three-position selector switch can be used to select any

one of three closed contact positions. In the accompanying
illustration, the selector switch positions (Hand, Off, and
Auto) are used to determine how M contactor coil for a
pump motor can be energized.
With the selector switch in the Hand position (contact

position A), the M contactor energizes when the Start
pushbutton is pressed.
With the selector switch in the Off position (contact position

B), the M contactor coil cannot be energized.
With the selector switch in the Auto position (contact

position C), the M contactor coil energizes when the liquid
level sensed by float switch FS1 rises sufficiently to close
the circuit. The M contactor de-energizes when the liquid
level falls, and the float switch contacts open.

Indicator Lights
Indicator lights, often referred to as pilot lights, provide a

visual indication of a circuit’s operating condition. An
indicator light may be wired to turn on for any
predetermined condition.
Indicator lights are available in a variety of lens colors to

allow for a quick visual indication of machine or process
status. For example, Siemens indicator lights are typically
available with a red, green, amber, blue, white or clear lens.

Using Indicators Lights in a Control Circuit
The accompanying graphic provides a simple example of

how indicator lights can be used in a control circuit.
When contactor coil M is de-energized, normally closed

auxiliary contacts Mb are closed and the green indictor light
is on to indicate that the motor is stopped.
When the Start pushbutton is pressed, contactor coil M

energizes, the green indicator light turns off, and the red
indicator light turns on to indicate that power has been
applied to the motor. The red indicator stays on after the
Start pushbutton is released because normally open
contacts Ma are now closed.

Class 50 Control Stations
Control stations are used with magnetic controllers to

control the starting, stopping, reversing, or speed of
applicable motors.
Siemens Class 50 control stations are assembled from up

to three pushbutton, selector switch, or pilot light units.
Standard duty control stations are available in type 1
surface mount or type 1B flush plate mount. Heavy duty
control stations have type 4 watertight enclosures.

Class 52 Pilot Devices
Siemens Class 52 oil tight pilot devices and accessories are

designed to provide long, trouble-free service in the most
demanding applications. As the accompanying graphic
shows, a wide range of devices are available.
Also, consider the following design features.
• Devices are smaller than earlier designs and require less

mounting space.
• The modular design reduces the inventory needed to
stock a variety of pilot devices.
• Illuminated device options include traditional
incandescent lights along with energy saving LEDs and
extra bright cluster LEDs.
• Ribbed concentric lenses improve lighting distribution
and aesthetic appeal.
• Devices are oil and dust tight and meet NEMA Type 1, 3,
3R, 4, 4X, 12 and 13 specifications.

Class 52 30 mm BlackMax Pilot Devices
Class 52 30 mm BlackMax pilot devices are designed to

withstand caustic and corrosive environments. They are
made from heavy duty, die cast parts shielded with epoxy
coating and meet NEMA 1, 3, 4, 4X, 12 and 13
specifications.
Examples of harsh fluids these devices provide protection

against include:
• Hydraulic fluid
• Heavy duty lube oil
• Methyl ethyl ketone
• Trichloroethylene

Review Question
Which of these statements are correct? Select all that apply.

 A pilot device directs the operation of another device or indicates the status of
a machine or system.
 Siemens NEMA pilot device products have 30 mm mounting diameters.
 Pushbuttons and selector switches with momentary contacts stay in the
actuated position until manually released.
 Siemens Class 52 oil tight pilot devices and accessories are designed to
provide long, trouble-free service in the most demanding applications.
 Class 52 BlackMax pilot devices are designed to withstand caustic and
corrosive environments.

Simulators
Engineered to provide a real-world experience, Siemens

simulators are fully functional, ready-to-use systems
available in a variety of configurations.
System-level design makes the simulators an invaluable

tool for program testing and debugging, reinforcing learning,
shop floor troubleshooting, and more. With portable
construction and hard-shell cases, they can be easily
transported. Custom-built systems are also available.


topics:
• Pilot Devices

Control Power Transformers
The voltage applied to the main terminals of an industrial

motor is frequently higher than the voltage needed by the
associated control circuit. In such cases, a control power
transformer (CPT) is used to step down the voltage. In
addition, the CPT isolates the control circuit from the power
and lighting circuits, thus reducing electrical noise that
could affect the operation of the control circuit.
In the accompanying graphic, the voltage applied to the

primary of the CPT is 460 VAC. This voltage is stepped
down by the transformer to 24 VAC for use by the control
circuit. Fuses on the primary and secondary sides of the
CPT provide overcurrent protection.

Control Power Transformers
Other names for a control power transformer (CPT) include:

control circuit transformer, control transformer, high inrush
transformer, Industrial control transformer, and machine
tool transformer.
High inrush transformer is a name derived from one of the

more important requirements of a CPT, the requirement to
provide a relatively stable output voltage during conditions
of high inrush current.
When a control circuit energizes, as for example when a

motor starter contactor coil is initially supplied current to
close the contactor, the current required from its power
source rises to as much as ten times the current required to
hold the contacts closed. This inrush current can last for up
to 50 milliseconds, depending on circuit characteristics. As
a result, if the power source is not designed to handle this
inrush, the control voltage can drop below the level needed
to energize the control circuit.
A CPT is designed so that, if properly sized for the

application, it will provide excellent voltage regulation in its
secondary circuit, ensuring that the control circuit it powers
receives adequate voltage.
CPT Selection Considerations
Selecting a control power transformer (CPT) requires

knowledge of the following concepts.
Inrush VA – This is the transformer load voltage (V) multiplied by the

current in amps (A) that is required during control circuit startup.
Sealed VA – This is the transformer load voltage (V) multiplied by the

current in amps (A) that is required after control circuit startup.
Primary Voltage – This is the voltage that will be supplied to the

transformer primary winding.
Secondary Voltage – This is the voltage the transformer will supply to

the control circuit.
CPTs are chosen by selecting the transformer VA rating

that will provide sufficient inrush VA , given the power factor
for the circuit. Keep in mind that, for any given transformer
VA rating, a higher level of inrush VA results in a lower
secondary voltage.
Because NEMA standards require magnetic devices to

operate successfully at 85% rated voltage, transformer
ratings charts sometimes show inrush VA values at 85%,
90%, and 95% secondary voltage.

Siemens Control Power Transformers
Siemens Class MT transformers are intended for domestic

(U.S.) and Canadian applications and are available with
maximum power ratings from 50 VA up to and including
5000 VA. Primary voltage is rated up to 600 volts, 50/60
Hz, and secondary voltage ratings range from 24 to 240
volts. These transformers are designed per NEMA ICS2
and are UL-506 listed and CSA certified.
Siemens Class MTG transformers are designed for

domestic and international applications and are available
with maximum power ratings from 50 VA up to and
including 5000 VA. Primary voltage is rated up to 600 volts,
50/60 Hz, and secondary voltage ratings range from 24 to
220 volts. In addition to being UL-506 listed and CSA
certified, these transformers meet IEC and EN
requirements.
Class KT transformers are designed for convenient

modification of enclosed products and are available from
45 VA up to and including 500 VA. Primary voltage is rated
up to 600 volts 50/60 Hz, and secondary voltage ranges
from 24 to 120 volts. These transformers are designed per
NEMA ICS2 and are UL-506 listed and CSA certified.

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• Overcurrent
• Manual Control
• Pilot Devices

Basics of Controls For Construction

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Basics of Controls For Construction

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Basics of Controls for Construction

A quickSTEP Online Course

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Welcome to Basics of Controls for Construction.

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Upon completion of this course you will be able to…

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Virtual Instructor-led Learning - Classroom lectures delivered in the convenience of your

Simulators - World-class simulation systems available for training or purchase

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This chapter covers the following

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Control, as it relates to machines and processes, is a broad

Although manual operation of machines is still common,

While many control applications involve motors, control

Before discussing specific control devices; however, it is

Contacts are part of a control device, such as a control

In the upper part of the accompanying graphic, normally

In the lower part of the accompanying graphic, normally

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We also use symbols to show switches and to indicate

Switches require another device or action to change their

For example, there are two general types of pushbuttons,

The accompanying graphic shows two circuits, one with a

Motor starters, contactors, and relays are examples of

A coil is commonly symbolized as a circle with one or more

The contacts controlled by a coil are labeled with the same

In the accompanying example, the M contacts in the power

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There are many other types of control symbols, too many to

Overload relays are used to protect motors from

An indicator light, often referred to as a pilot light, is a small

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Control circuits are depicted with line diagrams, also called

In the lower illustration, the line diagram symbolically

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Line diagrams are made up of two types of circuits, control

The accompanying line diagram includes both power and

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A typical control circuit includes a control load and one or

For example, in the accompanying graphic, circuit 1 shows

While it is proper to place contacts in series, it is not proper

Circuit 3 shows an example of a correctly connected circuit

Often a control load is controlled by more than one control

For example, in circuit 1 two normally open pushbuttons are

In circuit 2, two normally open pushbuttons are connected

In circuit 3, normally open pushbuttons 1 and 2 form parallel

For these examples, the control devices are all

This chapter covers the following

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Some of the control components covered in this course are

To begin with, current flow always generates heat. The

Excessive current is referred to as overcurrent. An

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A short circuit occurs when two or more bare conductors

For example, if the voltage between the conductors is 240

However, if the insulator between the conductors is

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An overload is a typically a much lower current than a short

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In the previous example, the overload resulted when a

A different response is required for a short-duration

When most motors start, they draw current in excess of

In the accompanying example, the motor’s starting current

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Fuses and circuit breakers are designed to protect circuit

In a motor circuit, circuit conductors and the fuse or circuit

For example, the accompanying graphic shows the power

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