Classic Control

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Classic Control
Course
Chapter 1 : Basics & Introduction
Prepared By: Eng, Abd ulkawy Mobarak

Tel: 01014871075
E-Mail: Eng.Abdelkawy.Mobarak@Gmail.com
:
.
Types of electrical Loads:
ENG. ABD EL-KAWY MOBARAK | Classic Control Course
The Stages Of the Electrical Power untile reaching the Electrical Loads
)Power (P) = Volt (V) * Current (I

)(Amp
)(Volt
)(Watt
:

.

o

o

:

)High Voltage (220KV
o More reliable

o

Volt
??????
Transformers

o Short Circuit Under Voltage
o Surge Over Voltage
Power volt
:
10000W 100V
Power 100A
:
10000W 1000V
Power 10A
:
1000W 100V
Power 10A
:
1000W 1000V
Power 1A

Volt is Controllable But Current is UnControllable
Transformers
Types Of Transformers:
1. Power Transformer
2. Tertiary Transformer
3. Auto-Transformer
4. Current Transformer
5. Potential Transformer
Power Transformer:
: AC
:
:
o : Primarry Windings
N1
o : Secondary Windings
N2
o :
Eddy Current
:
( )

7
:
Step Up Transformer
Step Down Transformer
:
.
o :
Transformers Volt

Step Up Transformer:
Step Down Transformer:
Power Transformers Electric Power

10000W <----- 400V 25A
400V 400V
25A
400V Step-Up Transformer

4000V 4000V Step-Down Transformer
400V
Transmission 2.5A
:

3Phase Power Transformer:

Single Phase Transformer
3PH
01
3PH Power Transformer

Star or Delta
Star Delta
Delta Delta
Delta
Star
Star Connection:
=
=
Delta Connection:
=
=
Different Connections Of Transformers:

Star/Star Connection
Delta/Delta Connection
00
Delta/Star Connection
What is the Difference Between Groung & Neutral:

Neutral:
Star Connection
220VAC = Phase & Neutral
220VAC
: Single Phase
220VAC
Single Phase Step Down Transformer

380VAC 220VAC
) Protective Earthing ( PE
Ground ( Earth ):
02
: Short Circuit
Eddy Current Static
Charges

Earth Neutral

: Electric Chock
: Earthing
5m
) ( Rod
1.5 Ohm
Earth Tester
Earth Nutral :
Transformer 3 ) (3 Phase
Neutral ) ( Earthing
380VAC
220VAC )( 1 Phase + Earth
Ground Neutral
S.C 220VAC

Earth Nutral :
03
Transformer 4 ) ( 3Phase + Neutral

.
) 3Phase ( 380VAC )1Phase(1PH+N) ( 220VAC
)( Protective Earthing
S.C
Tertiary Transfromer:
3 Coil/Phase
1 Primary Winding + 1 Secondary Winding
1 Primary Winding + 2 Secondary Winding Teriary
Third Harmonic Industrial Applications Earthing Protection
Block
:
st
Primarry + 1 Secondary
Primary + 2nd Secondary
Delat Start Secondaries

\ Delta Star
30 Phase Angle O/P Voltage Star
04
Auto Transformer:
Primary Secondary
Transformer Power Transformer
Voltage Division Secondary
. Primary Voltage
Step Down
05
:
: Control I/P
PLC , Inverters
: Power Soft Starter
Instrumentation Transformers:
Power Meter
PLC Relays Protection
AutoTransfromer Transformers Control
Potential Transformer:
Transformer
High Voltage

3Phase Potential Transformer Power

Current transformer:
Transformer
5A
Primary
Primary is the Line (Conductor ) which I want to measure its Current
Transformer
Secondary 5A
-
Secondary Current transformer Open

Step Up Transformer S.C

Potential Transformer & Current Transformer

Single Phase Motor Volt & Current
Current Transformer Protective Relay
Current Transfprmer & Potential Transformer Power

06
Distribution System
07
Main Feeder
) Medium Voltage ( 11KV Primary Switchgear
Protection Transformer Feeder
) Step Down Transfromer(11KV / 380V Low
)Voltage(380VAC
Main Secondary Breaker Transformer
.

Feeder Breakers
08

:
Main Secondary Breaker

Secondary Side Transformer

.

Outdoor Feeder Busway:
Feeder Breaker
-
Switchboard:
Feeder Busway :
BanelBoard:
09
21
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20

Classic Control
Course
Chapter 2: Classic Control Component

Tel: 01014871075
): (Automatic Control
) (Instruments
:
Process Variable Set Point

.
The need of automatic controls :
: .1Safety :

.
.
.2 Stability :
Down Time .3 Accuracy :
manual : Automatic control
-
Operator
Inlet Valve
-
operator ::
3 Sight Glass

.1
. 2
:
-
Operator Discharge Valve

Inlet Valve
. 2
Set Point Level 3
Discharge Valve .
Tank Level
Inlet Valve Discharge
Valve
:
.:
o Level .
.
o
.
:
)Control methods: (controllers
Classic control PLC DSC
Monitoring and data collector:

SCADA
Input device:
Buttons ( push button selectors toggle switches) limit switches.
Sensors ( proximity sensors photo cell pressure sensor temperature sensor ).
Output device:
Contactors signal lamp.
Operator panel:
Classic panel , consists of (P.B Switches Selector SW - signal lamp - Ammeters).
Screen or OP
Indication instruments:
Voltage ammeter Current ammeter.
Measuring device:
Current transformer (C.T) Potential transformer.
3
Classic Control
-
- Relays Switches (selectors , push buttons ) digital sensors limit Switches

Analog sensors PLC Analog input O/P
Sensor
:classic control
: Contactor
mechanical coupling power circuit control circuit

power
: .
.E ) (coil

Contacts
) (Main Contacts ) N.O(Normally Open
Auxiliary Contatcs ) N.C(Normally Close . N.O
Coil
N.O Close N.C .Open
Coil Spring
. .
:Contactor
:
Main Contacts
N.C N.O . Coil
-
: Main Contacts
Main Contacts Normally Open
: Auxiliary Contacts
) N.O(Normally Open )N.C(Normally Close
: N.O Auxiliary Contacts

-
13/14 . 3&4
: N.C Auxiliary Contacts

-
11/12 . 1&2
N.O N.C
OHM

-

----- .0 ohm
----- O.L
). N.O(Normally Close
:
------ .O.L :
------ 0 ohm:
)N.C(Normally Close
-----
:
-
.
.
. .Coil

.
:Coil
-
Coil A1/A2 . A/B

. Coils Volt
380VAC,220VAC,110VAC,48VDC,24VDC Coil Volt

Contactor Coil 24VDC 380VAC Coil

Volt Coil Coil
.
:
-
3 :
-1 .
-2 .
-3 .
:
-
Main Contacts
Motor
.

.
( )
. .
.

9Amp
VOLT
KW
HP
220VAC
220
2.2
3
Motor 3HP Motor
380
4
5.5
660
5.5
7.5
380VAC Motor 5.5HP
9,12,16,20,25 AMP
:
-
.
coil 24VDC Coil
24VDC .
:
-

.
Auxiliary Contactor or Relay:
:
:
-

NO or NC
Main Contacts Coil

Coils 9AMP
:
-

Relay
.
relay
Relay
.
Current value is uncontrolled:
:
The Electric energy consists of two main parameters:
)I (AMP
Current
)Voltage V (volt
)Power P = Voltage * Current (Watt
volt .current
Voltage Controlled
volt Transformer
.volt
Current Uncontrolled.
volt current
power :
current .
current
-
.
current
.
2phase 380VAC
Current current .
:
Voltage is controlled:
.
Current is uncontrolled:

: Rated current 10A .
Behavior

Motor current rated current
No Load Current = (2/3)Rated Current

Motor current rated current
- Load Current = 9 AMP

)(approximately
over load gear box

Motor Current rated Current
Over load current > Rated current
Case
Case 1:
No load
Case 2:
Loaded
Case 3:
Over
loaded

Motor Current rated current
Case 4:
over load current

Current > Over load current > Rated current
S.C
Motor Current rated current
over load current current
Motor Current Motor
Rated Current . 10 Sec
Starting
). Direct On Line (DOL
Case 5:
S.C
Case6:
Starting
)Istarting = 6 In (6* Rated Current

)Start/Delta Starting (S/D Start
)Istartting = 3 In (3* Rated Current
01
.Soft Starter
)Istarting= 2 In (2* Rated Current

=Istarting

=Istarting
: 3 & 4
-
over load
.
: 5
-
S.C
.
.
limitation Current .
: 6
-
Motor Current Motor

Rated Current 10 Sec
Overload Motor
Starting Current Starting
Starting Trip Motor
Current
limitation .
:
Over load, Motor Circuit Breaker (Motor C.B), Motor protection, Miniature, Molded Case
Circuit Breaker (MCCB), Fuse.
Power Circuit Control Circuit

Fixed .
00
Photos
Description
Overload motor

motor
.
motor overload
.......

overload
coil
motor
. motor

.
:
overload 97-98 95-96
.
Feedback PLC
overload Reset
) (test .

) (H ) (A

) (Reset ).(Test
overload 95 ) 96(N.C )98(N.O
O.L Power Auxiliary contact . control
normal case overload N.C trip open
Motor C.B motor

motor
.
motor Motor C.B
.......

3 Main contacts power
3PH
N.O Auxiliary contact Motor C.B
coil
02
Item
Over load
overload

O.L
N.C

close

open
trip
normal
O.L

Motor C.B
Motor
Protection

over
load

N.O

motor
.

.
:
Auxiliary Contacts Motor C.B N.O N.C
Motor C.B
normally motor protection N.O close
Automatic
.S.C
single phase 3 ph 2ph power motor
power circuit control circuit . S.C
. Auxiliary contacts power circuit .control circuit
Auxiliary contacts indication I/P
PLC indication control voltage
S.C
normally miniature .S.C
electronics ( ) power circuits .control circuits

NOT NOW
03
Motor C.B
open
Close

Normal
Motor C.B
Miniature
Fuse
MCCB
Overload :Motor C.B

.i Motor name plate
. MAX.Rated Current
.ii Over load SW Motor C.B MAX.Range .Max.Rated current
.iii Over load SW MAX.Rated Current
.iv Full load current .Full load
.v Over load SW Motor C.B MAX.Rated Current
Full load current.
MAX.Rated current for motor 1.5 A = Over load SW
.vi
.full load current
MAX.Rated current for motor - .5 A = Over load SW
.vii
.viii
load current
of motor Rated
current of motor
Siemens .Overload
04
contactor feedback overload

feedback
OVERLOAD CONTROL COIL

Motor C.B 3PHASE
:
.i ).P.B(Push Buttons
.ON Switch

).N.O(Normally Open
.OFF Switch

).Double Pole Switch (N.O+N.C

Normally Open
Normally Close
.
05

.
.Selector Switch .ii

.iii
.Toggle Switch
P.B
.
P.B Selector key switch

N.O N.C Single Pole Multi Poles
:
.1
.2 ) (ohm range 3ph

) (kilo ohm
0 ohm S.C
motor

.3
.4
.5 )(Bearing
06
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Classic Control
Course
Chapter 3: Introduction to Classic Control Circuit Desigen

Tel: 01014871075
): (power circuit & control circuit

-
):(POWER CIRCUIT

) (POWER CIRCUIT:
.1 MINIATURE .
.2 .
.3 .OVERLOAD

.
):(CONTROL CIRCUIT
Coils
) (CONTROL CIRCUIT:
.1
.2
.3
.4
.5
.6
.7
).Coils(CONTROL VOLTAGE
MINIATURE .
OVERLOAD
.
( )
.
COILS
.
RELAYS TIMERS THERMORELAY
SELECTOR SWITCH push button limit switch float switch proximity sensors
.pressure switch

):(control voltage
control circuit coils
contactors relays .volt
Control Voltage :
24VDC , 48VDC , 110VAC , 220VAC , 380VAC
) (control voltage ) (control circuit
:
:
-
L1-L2-L33PH Power Supply
. Motor
Q1
. ( )
.
Main Contacts KM1
.Motor
Overload F2 Motor
Motor .U-V-W
:
-
Coil Contactor KM1

KM1 . Coil
Overload Coil
Contactor .Motor
:
-
:
-
control circuit S.CF1: Fuse

Q1: N.O contact of motor protection
overload
ON motorS1: N.O Push Button
motorKM1: Contactor
:
-
N.O contact Motor protection normally

Motor protection .
S1
:
-
selector switch
:
-
S1: 2 position Selector switch
:
-
2 position selector SW
position (12):
current selector
current selector Position (13):
selector SW ) (13
current KM1 motor
selector SW ) (12 current
KM1 .Motor
:
-
start stop
:
-
Stop motor N.C- S2:Stop P.B

)motor- KM1(13-14
:
-
) S1 (Start P.B coil

) Contactor (KM1 Main contacts
Auxiliary contact
) KM1(13-14 coil Contactor
2 current coil contactor
) S1(Start P.B
).Auxiliary contact KM1(13-14
) S1(Start P.B
contactor Auxiliary contact
) S2(Stop P.B current
coil contactor contactor .
:
-
:
- S1& S3: Start N.O P.B
:
-
motor

) Start (N.O P.B
current coil
contactor motor
Stop motor stop )S2(N.C P.B
:
-
:
-
P.B N.C Stop
- S2 & S4:
:
-

) Stop (N.C P.B
coil contactor
current coil
contactor .motor
:
-
:
-
P.B N.O Start

P.B N.C Stop
- S1& S3:
- S2 & S4:
:
-
circuit 2 circuits
) Start (N.O P.B
) Stop (N.C P.B Start/Stop
circuit
:
-
:
-
P.B N.C )motor- S1 : Stop (N.C P.B

P.B N.O Start )motor- S2 & S3 : Start (N.O P.B
N.O motor- KM1(13-14) :
:
-
2 N.O SW Start Motor

current coil contactor
contactor Main contacts
Auxiliary contacts
2 SWs
current contactor
2 SWs contactor
).Auxiliary contact KM1(13-14

M/C
(:)7
-
Start/Stop
overload
:
-
- H1,H2,H3
:
-
Auxiliary contact motor protection (

coil )contactor
: current coil contactor
current +ve -ve coil contactor
. contactor
(
motor (
signal lamp:
-

overload - H3 O.L tripping
- H1 OFF
- H2 RUN
(:)8
-
2 volts
Control Voltage = 220VAC & 24VDC
2 Control voltage
24VDC circuit) (Start/Stop 220VAC

Volt isolated Volt Volt
Volt .S.C
- 220VAC 220VAC & Neutral
- 24VDC 24VDC & 0VDC
S.C 2Volts
PLC 24VDC 24VDC S.C . 220VAC & 24VDC
220VAC volt .
:
-

24VDC . 220VAC

. Coil
. 220VAC ) ( latching . 24VDC
.
(:)01
-
220VAC
220VAC Control Voltage
phase 220VAC neutral Control Circuit

2 phase 380VAC power Transformer 380VAC/220VAC
220VAC control circuit
:
-
:
) (Start/Stop motor

:
) (Contactor + Auxiliary Contacts & overload & Start P.B & Stop P.B
Start P.B ).(Start P.B + N.O Contact
Stop P.B P.B contacts

Stop overload
overload ) N.C Contact(95-96
coil contactor
:
-

Start P.B )(Start P.B + N.O Contact
Start P.B N.O Contact
P.B
contactor
)KM1(13-14
current coil contactor
Stop current
motor
(:)00
-
Automatic
) (Start/Stop
Float SW motor
01
Float N.O or N.C

function .
.N.C Contact
N.O Contact
(:)01
-
Start/stop manual
selector switch Automatic
:
- S2: 3 Position Selector Switch
3 Manual
2 Stop
1 Automatic
Position (2):Stop
) Position(2 current
Manual or Automatic
Position (1): Automatic
) Position(1 current
Position (3): Manual

) Position(3 current coil contactor
selector ) position(3 .selector
(:)02
manual start/stop Automatic
Pressure Switch
:
-
P : Pressure SW
:
-
)3position selector(Stop ,Manual, Automatic

Position (0): Stop
motor manual Automatic
Position (A): Automatic
00
Pressure SW
pressure
Pressure SW
Position (M): Manual
manual
direct on selector Start/Stop
(:)03
-

double pole push button switch
manual P.B
:
S5 : Double pole P.B SW
P.B ).(N.O+N.C
:
-
) S3(Start P.B
coil contactor KM1
Motor
KM1
Motor .

)S5(Start instantenouse P.B Double pole
coil contactor Motor
contactor
Motor .
(:)04
-
selector switch
manual Automatic

:
S3 : 2 Position Selector.
Selector .
:
-
02
) S3 (Selector SW 2 position Single pole

1
) S3(Start P.B
Contactor KM1
Current

)S3 (Selector SW 2 position Single pole
2 ) S3(Start P.B
Contactor KM1

Contactor KM1 .Motor
:
-
coil .
.
Conditions
(:)0
-
Start Motor
Stop
Motor
(:)1
-
03
Start
Ready

(:)2
-
Ready

Motor
.
(:)3
-
Start
Ready
Normal ( )

(: )4
-
Ready
Ready

Motor
04
(: )5
-

K2

Ready
Motor
:
-
Auxiliary contacts overloads control circuits

control circuits . motor
:
2 motors overload 2
motors Motor
....
(:)05
-
Auxiliary Contact
overload 2 motors
2 motors

:
-
05
2 Motors
overload

Motor
Circuit
(:)06
-
Auxiliary Contact overload

2 motors
2 motors
overload
:
-
2 Motors
overload 2 Motors
overload 2Motors
Source
2 Motors
: Emergency Switch
-
Emergency Stop

M/C

Double Acting Emergency Stop
06

Emergency Stop

(: )07
-
2 motors M1 M2
M2 M1
:
-
07
M1 M2 OL M2 .M1
Q2 KM2
M2 M1 O.L M1
KM1&KM2
(:)08
-
2 motors
) motor (2 )motor (1
:
-
Start/Stop Motor
N.O Contact KM1 coil
contactor KM2
) S3(Start 2 M2
Coil Contactor KM2
).KM1(11-12
) S1(Start 1 M1
coil contactor KM1
) S3(Start 2
M1 M2 Coil
Contactor KM2
KM1 M1
) S2(Stop 1 2 Motors M1
N.O Contact contactor KM1 coil Contactor KM2
Contactor KM2 M2.
.Contactor KM1
Motor M1 Motor M2 M1
(:)11
-
2 motors

:
-
08
Start/Stop Motor
N.C Contact KM1 coil
contactor KM2
) S3(Start 2 M2
) S1(Start 1 M1
coil contactor KM1
) S3(Start 2 M1
M2 Coil
Contactor KM2
KM1 M1
) S1(Start 1 Motor M2 Motor M1 Motor
M2 contactor ) KM1(11-12
M1 N.O Contact contactor KM1 coil Contactor
KM2 Contactor KM2 M2.
.Contactor KM1
Motor M1 Motor M2 M1
(:)10
-
2 motors
S1
) S2 ( double pole P.B
2 motors
S3 S2

:
)S2(double pole P.B NC+NO Contacts
) Motor(1 ). Motor(2
:
-
09
) S1 (Start M1 P.B M1
) S2(Stop M1& Start M2 P.B M1 M2
) S2(Stop M1& Start M2 P.B M1 M2 M1
(:)11
-
2 motors M1 S1 M1 M2
M2
S2 M2 M1
:
-
M1 P1:
M2 P2:
:
-
21
)S1(Start M1&Stop M2 )S1(13/14 Coil

KM1 Main Contacts M1 M1
) KM1(23-24 P1 ) S1(11/12
Coil KM2 M2
) S2(Stop M1&Start M2 ) S2(13/14 Coil
KM2 Main Contacts M2 M1
) KM2(23-24 P2
) S2(21/22 Coil KM1 M1
(:)12
-
motor S1

:
-
20
S1 P.B coil KM1

M1 KM2
S3 P.B Coil KM1 Coil
KM1 M1
Coil KM2
S2 P.B KM2 KM1
KM1
S2 P.B M1 Coil KM2
M2 brigde
)S3 P.B (Stop M1
S4 P.B KM2 Coil
KM2M2
S3 P.B M2 M1 KM2
M2 Bridge Stop
:
Power Circuit For 3 Motors:
22
.

. Miniature
. .Motor
(:)13
-
3 motors
motor start stop
M2 M1 M3
M2
3 Motors
O.L
:
-
23
) S1P.B(Start M1 Coil KM1

o M1
o Coil KM2
) S3 P.B(Stop M1 M1
)S2(Start M2
: M1 Coil KM2
KM1 .
o Main Contatcs M2
o Coil KM3
: M1 Coil KM2
KM1 . .M2
) S4(Stop M2 M2
) S3(Stop M1 M1 & M2
)S5(Start M3
: M1 & M2 Coil KM3
KM2 .
: M1 & M2 Coil KM3 .
o .M3
) S3(Stop M1 Stop
): (Limit Switches
-
24
Push Button Switch N.O Contact N.C Contact

application
limit SW feedback
feedback N.C N.O
feedback

L.S L.S


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Classic Control
Course
Chapter 4: Advanced Classic Control Circuits

Tel: 01014871075
: 3 Phase
-

120 RST
S T
RTS RST
.

R S RST

:
-
.

.
:
-
KM1 & KM2

KM1 Source Motor :
KM2 Source Motor :
Motor .
Phase L1 U . W Phase L3
W U L2 V
:
-
(.
).
Overload Motor
Overload Motor Forward .Reverse
(
) Interlock
S.C .

: Interlock
2 contactors . interlock
1. Electrical interlock ( interlock ):
2. Mechanical interlock:
: interlock
.1 :
2 contactors
phase T . phase R S.C
O.L
interlock 2 contactors
.
.2 : Star/Delta starting

)2 Contactors(Contactor Stare & Contactor Delta
3phase
S.C O.L
interlock
. 2 contactors
: interlock
)(N.C Auxiliary contact

coil contactor

coil
.volt
.
1. Electrical interlock:
2. Mechanical interlock:
component 2 contactors interlock
Auxiliary contacts contactor 2 contactors

mechanical interlock
electrical interlock

symbol mechanical interlock
2 contactors KM1 & KM2
mechanical interlock
(:)52
-
control 2 P.B SW P.B SW

forward , revers O.L
:
-
) S1(Start Forward Coil

KM1 ( M1 )Forward
( Bridge S1 Coil
) KM1 ( Coil KM2 S2(Start
) backward coil KM2 Backward
. Foraward
) S2(Start Backword Sequence
) S8(Stop Motor
(:)52
-
220VAC
24VDC = Control Voltage

220VAC = Control Voltage
380VAC = Power Circuit Step Down Transformer 220VAC
(:)52
-
motor
3positin selector SW
:
)S1(3 Position Selector Switch
1 Start Forward
1 ) S1(13/14 Coil KM1

Motor Forward
) KM1(21/22 Coil KM2 Coil.
2 Stop
Selector 2 ) S1(13/14) & S1(23/24 Open
Coils KM1 & KM2
3 Backward
2 ) S1(23/24 Coil KM2
Motor Backward
) KM2(21/22 Coil KM1 Coil.
Forward Backward Stop position

Forward Backward.
(:)52
-
33 motor mechanical
interlock
Motor
100KW mechanical interlock

Forward & Reverse
2 Contactors Volt
Coils 2Contactors
(:)52
-
motor 2 direction
STOP
(:)03
-
motor
motor
limit SWs
:
S4(Limit Switch) Forward Limit Switch
.Forward
S5(Limit Switch) Backward limit Switch

.Backward
:
-
Motor Forward ) S4(Limit Switch

) S4(21/22 Coil KM1 Motor
Forward Forward ) S2(Start Forward
Limit Switch Coil . KM1
Reverse Coil KM2
Reverse . Limit SW
(:)01
motor

:
)- S2( Double Pole Push Button Switch
P.B Start Forward

Stop Reverse
)- S3( Double Pole Push Button Switch
Start Reverse
Stop Forward
:
-
)S2( Start Forward & Stop Reverse :

o ) S2(11/12 Coil KM2
:
.Reverse
)KM2(61/62 Coil KM1
o ) S2(13/14 Coil KM1 :
Forward
) KM1(61/62 Coil KM2
M2
Interlock:
Electrical Interlock o N.C & )KM1(61/62
)KM2(61/62
Mechancial interlock o
:
.1

.2
(mechanical
)interlock
.3 overload
01
brake
-
Supply Voltage
.
.

. Wire
.
:
.A
)Plugging & AntiPlugging (Inverse Current Brake
.B .
DC Injection Braking
.C .
Electromeckanical Friction Brakes

contacts
normal N.O N.C
N.O & N.C .
Control Circuit
Motor
Centrifugal Switch , Zero Speed Switch , Plugging Switch
Inverse Current Brake & DC Injection Braking

Centrifugal SW
contact
00
Motor .
(50:200
)RPM
.A
Inverse Current Brake
3PH Induction Motor

Motor Reverse Forward
( )
. Motor

5 ) (5 Times/Min
0 rpm

.

( Motor 0rpm )
.

.
:
.1
.

.2 ( )

02
(:)05
3PH Induction Motor . Inverse Current Braking
-
Start KM1

o Motor
Forward
o ) KM1(11/12 Interlock
Motor Forward
o Centrfugal SW
)R(13/14
Stop
o KM1
Motor
)KM1(11/12
) R(13/14
o KM2

) KM2(11/12 Interlock
) (50-200 rpm Centrfugal SW
o ) R(13/14 KM2
. Motor
(:)00
3PH Induction Motor . Inverse Current Braking
Stop
)Stop S2(NO + NC
KM1
KM2 KM1 & KM2
03
.B .
Injection DC Brake
Squirrel cage induction .

Rotor
.
:
M1: 3 Phase Squirrel Cage Induction Motor
F1: Fuse

Recifier:
3 ( + )-
F2: Fuse

KM1: Motor Contactor

KM2: Brake Contactor
( )
Q1: Motor Overload
()
KM2(13/14): N.O Contact From Brake Contactor
Rectifier Motor
AC Voltage
- R : Rehostat
:
Rectifier Motor . KM2
-
04
05
Motor KM1 Motor AC Aoltage

KM1 KM2
.
:
.
.
B A
.Motor
Single Phase
. 3 Phase
Motor
Volt .

.

Centrifugal Switch

(:)03
-
DC Brake
:
-
KM1
Motor
Centrfugal SW
KM2 ) KM1(11/12
KM1
KM2 Motor
Motor
Centrfugal SW
Motor
(:)02
-
DC Brake
brake
motor
:
-
06

. KM1 KM2
KM2
KM1
.C
-
Electromechanical Friction Brakes

Plugging DC Injection Brkes
Dynamic Brake Electromechanical Friction
Brakes Motor
: 3PH Induction Motor

AC Electromagnetic Brake.
07
3 PH Induction Motor:
o
o
:
o .
Brakes
.
o Power Source
o Coil OF Bake

o Rotor Free
o Stop
) (Spring Rotor

.....
: DC Motors
Electromechanical Drum and Shoe-type Friction Brake Used ON DC Series Motor Drives.
08
Rotor Rotor

Rotor
Motor Brake Solenoid
Rotor Motor
Motor Brake Solenoid Rotor

Rotor


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09

Classic Control
Course
Chapter 5: Sensors

Tel: 01014871075
:(SENSORS)

pressure
.distance temperature
: sensors
-
Proximity sensors: ( Inductive Inductive magnetic Capacitive)

Optical sensors : (Through beam Retro reflective Diffuse )
Switches : (Reed SW Pressure SW liquid level SW Flow SW Limit SW )
Physical quantity sensors : ( Pressure sensor Temperature sensor Flow sensor Wight sensor)
Feed voltage O/P sensors
: sensors
: Feed voltage .1
24VDC 220VAC feed voltage sensors
: Digital Analog sensor O/P .2
classification
O/P types
Usage
types
Digital sensor
: O/P
- 0 0VDC
- 1 24VDC
: O/P
O/P =1
O/P= 0
Sensors

object
limit SW sensor
-
Proximity sensors :
( inductive capacitive
inductive magnetic )
Optical :
( Through beam Diffuse
Retro reflective )
Switches :
( Reed SW Pressure SW
Liquid level SW Flow SW )
Analog sensor
O/P
DC volt ( 0VDC 10VDC)
mille AMP (4MA 20MA)
: O/P
sensor range

Physical quantity sensors :

( Pressure sensor Temperature
sensor Flow Quantity sensor
Wight sensor)
Digital Sensors:
:proximity sensors
-

.
.O/P
:
: INDUCTIVE PROXIMITY SENSOR
.

Inductive Proximity Sensors Symbole
Operation Of Inductive Proximity Sensor
:
.
conductivity
.sensor
: CAPACITIVE PROXIMITY SENSOR
.
Capacitive Proximity Sensors Symbole
Operation Of Capacitive Proximity Sensor
: Capacitive Proximity Sensor

. Adjusting Screw

: inductive magnetic sensors
inductive proximity sensor

Solid stat device High switching frequency 1KHZ
.

)( PHOTO-ELECTRIC SENSOR
Inductive Magnetic Proximity Sensors Symbole
Operation Of InductiveMagnetic Proximity Sensor
:(Optical sensors)
Optical-through beam:
transmitter receiver transmitter
receiver transmitter Receiver
Optical Throgh Beam Sensor Sympole:
Operation Of Optical-throgh Beam Sensor
sensor
:

30 m .
Optical-retro reflective:
transmitter/receiver reflector
transmitter/receiver
reflector transmitter/receiver
Optical-retro reflective Sensor Symbole:
Optical-retro reflective Operation:
reflector
transmitter/receiver
:

transmitter/receiver sensor
target reflector
Optical-diffuse:
.transmitter/receiver
Optical-diffuse Symbole:
Operation of Optical-diffuse Sensor :
sensors sensor
sensor sensor
Target Reflector
:

sensor
:
-
proximity sensor
. receiver
.reflector
.
.
.
sensors PNP NPN

PNP
NPN
Connection
O/P = 24VDC

coil contacts
O/P PLC -
PLC
target
O/P = 0VDC
O/P = 0VDC
coil contacts
Normal
operation
O/P PLC
PLC
target
O/P = 24VDC
-
coil contacts
O/P PLC
PLC
target
O/P :Relay
Function N.O or N.C
sensor .function
O/P I/P .PLC
sensor
target .1 or 0 = O/P
O/P .inverter
inverter sensor inverter
inverter deep SW PNP & NPN inverter

sensors inverter .

coil
Target O.K
contacts
O/P PLC
PLC
target
classification sensor PNP or NPN O/P
relay I/P PLC I/P inverter
: Proximity sensors
-
01

coil( ) .
. I/P PLC .
. .
.
. coil :coil
sensor . PNP
sensor .NPN
Sensor .4 Wires
photo-cell
.proximity sensors
5 photo-cell .
volt
coil
sensor
00
Switches:
Reed Switch:
.Magnetic Field
.contact
Sympole of Reed Switch Sensor:
Operation Of Reed Switch Sensor:
02
:
-
sensor contact

current contact
:Pressure switch
-
()
pressure SW contact .
Pressure Switch Sympole :
:Liquid level switch

-
03
Liquid Level Switch Symbole :
Liquid Level Switch Operation :
: Flow switch
-
Flow Flow
flow
flow SW contact
Flow Switch Symbole:
04
Analog Sensors:
Type of output:
Output type
O/P Range
Curve
EX: 0 10
Bar Pressure
sensor
Max & Min

limits
O/P when
P = 5 bar
Equation
Max & Min

limits
O/P when
P = 5 bar
Voltage
0 10 VDC
Current
4mA 20 mA
0 bar 0VDC
10 bar 10 VDC
5 bar 5 VDC
DCV = (Reading(bar)*10 VDC)/

Max bar
0 bar 4 mA
10 bar 20 mA
5 bar 12 mA
mA = ((Reading (bar)*16 mA)/Max

bar)+ 4 mA
sensor O/P . sensor range

sensor range sensor O/P 0 100 bar range sensor
- 0 bar 0 VDC
- 0 bar 4 mA
- 100 bar 10 VDC
- 100 bar 20 mA
- 5 bar .5 VDC
- 5 bar 4.8 mA
-
5 Bar pressure
sensor O/P
:
sensor Range from 0 bar to 10 bar :
range from 0 bar to 100 bar
max.limit range :

05
: range O/P 100 bar

10 bar
: Range from 0 bar to 100 bar sensor

. range from 0 bar to 10 bar
:
: 10 bar 10 bar
range sensor O/P PLC

:
PLC O/P sensor Range
sensor sensor range

range .O/P
Troubleshooting
:Analog sensors
Analog sensors sensor :O/P
Current
)Reading = - (max.bar Range/4
O/P sensor = 0
O/P = 0mA
sensor - range
pressure sensor
ve zero
range - sensor
range
pressure ve
-
zero

sensor
O/P
range
06
ve

pressure
ve zero
Voltage
Reading = 0 bar
O/P = 0 VDC
sensor
range
pressure sensor
Fault
Reading
O/P
Procedure

zero

range
sensor
range
pressure
zero

sensor
O/P
range
zero

pressure
07

zero ve

zero Analog PLC
pressure
Analog PLC

pressure
O/P

sensor
O/P sensor
sensor :
O/P
Range


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Classic Control
Course
Chapter 6: Timers

Tel: 01014871075
) : (Timers
-
Timer component contacts

.
time time
timers :
o :

o :
Relay
. .
o :

coil
.

.

.
Timers:
T1 Coil Contacts
.Timers
o ON-Delay Timer
Time
Relay Timer Volt

) : T1(11/12 Normally Open ) Timer (T1

) : T1(11/13 Normally Close ) Timer(T1

A1/A2 : Power Supply for timer

Contact T1(11/12) &T1 (11/13):
Contact T1(15/18) & T1(15/16):
ON-Delay Contact
) : T1(15/18 Normally Open
) : T1(15/16 Normally Close
Current Timer
:
) : T1(8/9 Normally Open Timer
.
) : T1(8/10 Normally Close Timer
.
Contact T1(8/9) & T1(8/10):
o OFF-Delay Timer
Relay Timer Volt



Contact T1(11/12) &T2 (11/13):
Contact T1(8/9) & (8/10):
Current Timer
OFF-Delay Contacts :
.
.
o OFF-Delay with auxiliary supply Timer

OFF-Delay timer A1/A2
B1 B1
Timer
B1: Operation Signal of the timer
Relay Timer Volt



Contact T1(8/9) & (8/10):
.
Contact T1(11/12) &T2 (11/13):
Current Timer
:
.
.
o ON & OFF -Delay Timer

2 Timers ON-delay OFF-delay contacts
A1/A2 B1
B1 ON-delay time
B1 OFF-delay time
time
Timer
Relay Timer Volt




Contact T1(11/12) &T2 (11/13):
Contact T1(21/22) & T1(21/23):
ON-OFF Delay Contact

) : T1(21/22 Normally Open Ton
Toff
) : T1(21/23 Normally Close Ton
Toff
)o Interval ON Timer (Step Up ON timer

timer Step up A1/A2
Impuls timer
Relay Timer Volt



Contact T1(11/12) &T2 (11/13):
Contact T1(15/18) & T1(15/16):
ON-Delay Contact
) : T1(15/18 Normally Open Normal
( ) Power . Timer
) : T1(15/16 Normally Close Normal
( ) Power . Timer
Contact T1(8/9) & (8/10):
Current Timer
:
.
.
)o Interval OFF Timer (Step Down ON timer

Step down A1/A2
Relay Timer Volt



Contact T1(11/12) &T2 (11/13):
Contact T1(8/9) & (8/10):

Power Timer Normal
.Timer
) : T1(8/9 Normally Open Power Timer
( Normal) .Toff
) : T1(8/10 Normally Close Power Timer
( Normal) Toff
)o Interval ON/OFF Timer (Step Up/Down ON timer

Timer 2 . 2 time
A1/A2 .
A1/A2 .
Relay Timer Volt



Contact T1(11/12) &T2 (11/13):
Contact T1(8/9) & (8/10):
01
Current Timer
. Ton Power
. Toff
) : T1(8/9 Normally Open Instantenous Power Timer
( Normal) .Ton
o Instantenouse Power Timer
( Normal) . Toff
) : T1(8/10 Normally Close Instantenouse Power Timer
( Normal) . Ton
o Instantenouse Power Timer
( Normal ) Toff
o ONE Shot timer
) Timer (A1-A2
B1 timer
Zero B1
.Timer
Relay Timer Volt




Contact T1(11/12) &T2 (11/13):
Contact T1(8/9) & (8/10):
00
)Signal (B1 Timer

:
.
.
) o Repeat cycle starting with off ( flasher timer starting with OFF case
Flasher timer Starting with off ON time & OFF time
cycle timer A1/A2
Relay Timer Volt



)Contact T1(21/22) & T1(21/23

Cycled Ton & Toff
) : T1(21/22 Normally Open Toff Power
( Normal) Ton Tof Power
Contact T1(11/12) &T2 (11/13):
.
-
02
) : T1(21/23 Normally Close Toff Power

( Normal) Ton Toff power
) o Repeat cycle starting with ON ( flasher timer starting with ON case

Flasher timer Starting with off ON time & OFF time
cycle timer A1/A2
contacts timer .
Relay Timer Volt



)Contact T1(21/22) & T1(21/23

Cycled Ton & Toff
) : T1(21/22 Normally Open Insantenouse Power
( Normal) Ton Toff Power
Contact T1(11/12) &T1 (11/13):
.
-
03
) : T1(21/23 Normally Close Instantenouse Power

( Normal) Ton Toff power
: Timers
(:)66
-
2 Motors Start P.B 2 Motors

Stop P.B M1 M2 ).(t
:
T1 : OFF Delay Timer
:
. Start Coil
KM1 .T1
KM1
.M1
T1
. OFF-Delay Timer
Coil . KM2
) S2(Stop Coil
KM1 . T1 M1
T1
Coil KM2
M2
(:)63
-
2 Motor Start 2Motors T1 M1

T2 M1 . M2
:
T1: ON Delay Timer
T2: OFF Delay Timer
04
:
) S1(Start
KM1 T1 . T2
KM1 .M1
T1
T2
KM2 .M2
T1
KM1 & T1 & T2
M1
T2
T2
KM2 M2
:)63(
M2 T1 M1 Start 2 Motors
.M2 T3 M1 T2
.ON-Delay Timer&ON/OFF-Delay Timer
:
T1: ON-Delay Timer

T2: ON/OFF Delay Timer
: OFF-Delay Timer & 2 ON-Delay Timer

:
T1 : ON-Delay Timer
T2 : ON-Delay Timer
T3 : OFF-Delay Timer
05
(:)63
-
Motor Start P.B T interval OFF Timer

. Or ONE-Shot Timer
:
T1 : Interval Timer
:
) S1(Start T1
.
T1

T1
KM1 M1

KM1
. M1
Off-Delay Timer
(:)04
-
2 Motors Start M1 T1 M1 M2
.T2 . ON & OFF Delay Timer
:
T1: ON-Delay Timer
T2: Interval OFF Timer
06
:
Start Power
KM1 & T1 & T2
KM1
M1
T1
T1

Power KM1 & T1 & T2
KM1
M1
T1
T2
Power KM2 . M2
T2 KM2
. M2
(:)04
-
2 Motos Start M1 Stop M2 .T

:
T1: Interval OFF Timer
:
) S1(Start KM1 & T1
KM1 . M1
Stop KM1 & T1
KM1 M1
T1 Power

T1

Power KM2
M2
(:)04
-
control 3 Motors Start M1 M2 T1

M2 Stop M1 M3 .T2
:
T1: Interva-ON Timer
T2: Interval-OFF Timer
07
:
Start
Power KM1 & T1 & T2
KM1 M1
T1

KM2
.M2
T1

KM2
M2
Stop Power
KM1 & T1 & T2
Power T2
T2
Power KM3 M3
(:)06
-
Start T
:
T1: Interval-ON Timer
:
Start Power Impulse T1
T1 Power

Power KM1 M1
T1
Power KM1
. M1
(:)00
Motor Motor
.
.
:
T1: Interval-OFF Timer
08
:
)S1(Start Forward
KM1
M1
Forward
Normally Open T1
Power T1
Stop Power T1
T1
KM3 Power KM3
T1
KM3 KM3
KM1 KM2 KM2 KM1 Interlock
S.C
Reverse S2
(:)04
Start T1
T2 M3
M1&M2 Stop
:
T1:Interval-OFF Timer
T2: ON-Delay Timer
09
:
) S1(Start KM1 & T1
KM1 M1
KM2 KM2 & T2
KM2 .M2
T2
T2
KM1 & T1
KM1 M1 KM2 & T2
KM2 M2
T1
T1 KM3 KM3 M3
T1
KM3 KM3 . M3
(:)06
Start P.B
T1 EV1 T2 EV2
. T3
: T1
:
T1: Interval-ON Timer
T2: Flasher Timer Starting with ON or OFF
21
:
) S1(Start KM1 & T1 & T2
KM1

T1 .
KM1 T1
T2
T2 t1
t2

T1

: T1 : Stop
T1

T1
)S2(Stop
: T1 T4
20
T3: ON-Delay Timer

T1 T3
T3
T1 & KM1 & T2 T3
(: )03
3 Motors Start M1 T1
M2 M3 T2 M1 T3 M2
.M3
:
T1: ON&OFF-Delay Timer
T2: ON-Delay Timer
22
:
) S1(Start KM1 B1 T1
KM1 M1 K1 & T1
T1 Ton
Ton T1 T2 & KM2 & KM3
T2
KM2 M2
KM3 M3
T2
)KM1 & Signal Of T1(B1
KM1 M1
T1 Toff
Toff T1 T2 & KM2 & KM3
T2 ( )
KM2 M2
KM3 M2
3 ON-Delay Timer
:
Start K1 & T1
T1
K1 KM1 . M1
T1 . K2 & T2
T2
K2 K1 KM2 & KM3
K1 KM1 K2
T2 K3 & T3
T3
K3 K2 KM2 & KM3
K2 KM1
KM1 M1
KM2 & KM3 K3 M1 & M2
T3 K3
K3 KM2 & KM3 M2 & M3
T1, T2, T3 : ON-Delay Timer

K1, K2, K3 : Relay
KM1, KM2, KM3 : Contactor
23
(: )03
:
) S1(Open P.B )S3(Key Switch

:
S3: Key Switch
P.B SW
.
T1: ON-Delay Timer
24
:
S1 OR S3 K1 M1 Forward
) Limit SW(LS1 K1
T1
T1 K2
K2 M1 Reverse
) Limit Switch(LS2 K2

)S4(Close
K2 M1 Reverse
) Limit Switch(LS2 K2
(:)03
-
2 motors

Automatic
:
KM1: Contactor + ON-Delay Timer
:
S1 KM1
.
o M1
o )KM1(13/14

o ) KT1(67/68 KM2
KM2 . M2
(:)44
-
25
2 motor M1
M2
M1
:
)S1(Start
KM1 & KT1
KM1 o M1
KM1 o )KM1(13/14
KT2 o
KT1
o ) KT1(67/68 KM2
KM2 M2
)KM2(13/14
)KM2(11/12
KM1

. M1
(:)44
:
S1
KM1 & T1
KM1 o
M1
)KM1(13/14
KT1 o
KT1

o ) KT1(67/68 KM2
M2
)KM2(13/14
) KM2(11/12 KM1 & KT1
KM1
M1
KT1
S2 . M2

Components
26
(:)44
-
motor

:
) S2(Start F
KM1 & T1
T1 o

KM1 o
M1
Forward
Interlock
) S3(Start R KM2 T1 & KM1
) S1(Stop M1
) S3(Start R KM2 T1
T1
T1 M1(Reverse
T2
(:)44
-
3 motors M1,M2 M1
M3 M2
:
KM2: Contactor + Timer
27
:
) S2(Start KM1
KM1
o M1
o KM2
KM2

o
o M2

o KM1

M1
o KM3
M3
(:)46
-
3 motors M1 M2 M3
:
T1: ON-Delay Timer
T2: ON-Delay Timer
28
:
) S2(Start KM1 & T1
KM1 o :
Interlock )S2(Start
M1
T1 o .
T1
o KM2
KM2 & T2
KM2 o

M2
T1
T2 o
T2
o KM3
KM3
o
o M3
o T2
(:)40
-
3 motors M1 M2 M1
M3 M2 M1 M3
:
T1,T2,T3: ON-Delay Timer
29
:
) S2(Start KM1 & T1
T1 o
KM1 o
M1 KM3 M3
T1 KM2 & T2
T2 o
KM2 o
M2 KM1 M1
T2 KM3 & T3
T3 o
KM3 o
M3 KM2 M2
T3 KM1 & T1
T1 o
KM1 o
M1 KM3 M3
)S1(Stop

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31

Classic Control
Course
Chapter 7: Starting Of Motors

Tel: 01014871075
Starting Current of Motors:
:
-
current motor current
normal operation
starting current .
Starting Current
:
-
torque

torque & current torque
. current
starting current
.
starting (
)
:
-
I/P Energy
.
O/P Energy ( ).

(
Rotor ) Stator sequence Rotor
.

.

.
brake brake .
= zero
: Starting
Start
1.
2.
3.
4.
5.
DOL (direct on line)

I starting = 6* I normal
Star-Delta Starting
I starting = 3*I normal
Soft Starting
Istarting = 2*I normal
With group of Resistance
Istarting= Depends on the Resistance Value
With group of Resistance series with Rotor coils
Istarting = Depends on the Resistance Value
DOL (Direct On Line) Startting Method:

Source
. Normal Current 6 Starting Current
Star-Delta Starting:
: Delta Full Speed Star
. Normal Current 3 Starting Current
. Start/Delta Starting Motor Power
: Delta Star
Star or Delta Main Contactor KM1 (KM)
Star Star Contactor KM2 (KS)
Delta Delta Contactor KM3 (KD)
S.C KD KS
(:)15
-

star/delta starting timer
:
) S2(Start KY
o Main Contacts
o KD
o KM KM

KD KD KY
KM & KY Star
Star . S3
S3 KY
o
o KD KD

KY KY

KM & KD Delta
Star
) S1(Stop
(:)15
-

/ / /
:
-
) S2(start KM
o
o ( ) Start
KY
o
o Interlock KD KD . KY
KM & KY Star
Star . S3
S3 KY .
o
o Interlock . KD
KD :
o
o Interlock KY KY . KD
KM & KD Delta
Delta ). S1(Stop
(:)15
-

T1: ON Delay Timer
:
Start ) KM1(Star :
o
o
o
o Interlock )KM3(Delta
T1
) KM2(Main :
o
o
o ) KM3(Delta KM3 KM1.
) KM1(Star) & KM2 (Main Star
T1 KM1
o Interlock KM3 KM3 .
Interlock KM1
) KM3 (Delta) & KM2 (Main Delta
Stop .
(:)15
-
star/delta starting
:
KM1 :

:
Start KM1
.
o ) KM2(Star .

Interlock )KM3(Delta

o KM2 KM3
KM2

Interlock . KM3
KM3

Interlock KM2
(:)11
-
star/delta starting
timer
:
T1: ON-Delay Timer
:
) S2(Start ) KM1 (Star
o .
o )KM1(11/12
o ) KM1(13/14 )KM2(Main
)KM2(13/14
T1
o ) KM1(Star
)KM1(13/14
)KM1(11/12
) KM3(Delta
o )KM3(11/12
) KM1(11/12) & KM3(11/12 Interlock
) S1(Stop
(:)15
-
star/delta starting
timer.
:
KM2: Contactor + Air Timer
:
) S2(Start
) KM1(Star
o ) KM1(13/14
)KM2(Main
KM2
KM2

o ) KM2(55/56
)KM1(Star
o ) KM2(67/68 )KM3(Delta
(:)17
-
star/delta starting

:
KA1: Auxiliary Contactor + Air Timer
:
) S2(Start ) KM1(Star
) KM1(13/14 KA1
KA1
KA1 ) KA1(13/14 ) KM2(Main
) KM2(13/14

) KA1(55/56 )KM1(Star
) KA1(67/68 )KM3(Delta
) KM1(31/32) & KM3(31/32
Interlock
) S1(Stop

star/delta
Star/Delta-Starting
KM1 & KM2
Mechanical Interlock Main
Contactor Star/Delta-Starting
) KM3(KS Star
) KM4(KD Delta
:
o ( KM1 OR KM2 ) Main
Contactor
o ) KM3(KS . Star
o ) KM4(KD Delta
01
/:
Star/Delta Starting Timers:
00
Start/Delta Starting Start contactor

Delta contactor .

.
Start contactor motor
Rated Current Delta

Motor
( ) 50 msec & 90 msec
() Start/Delta Starting Circuit
.T1&T2
(:)T1 Motor .Star
.Controlled
(:)T2 Start Contactor Delta Contactor
UnControlled
:
Start-Delta Starting
Motor
Motor .100KW
Contatcs : Timer
T1(A1/A2): 24VDC Power Terminals
Timer 24VDC
Timer 220VAC
T1(A1/A3): 220VAC Power terminals
02
T1(17/16): N.C Contact

T1+T2 Power Timer
T1(17/18): N.O Contact
T1+T2 Power Timer
Delta
Power Timer .T1
Power Timer .T1
(:)17
-
Start/Delta Starting .
:
-
03
) S2(Start ) S/DT (Start/Delta Starting Timer

) S/DT(17/28 Timer
Start Contactor :
) KM1(13/14 interlock Delta Contactor
) S2(Start
) KM1(11/12 Main contactor :
) KM2(11/12 ) S2(Start

) KM2(21/22
t1 Timer ) S/DT(17/28 .Open
Star Contactor Main Contactor .Latching
)( (t2 ) Timer )S/DT(17/18 KM3(Delta
) Contactor :
) KM3(13/14 Interlock .Start Contactor
Stop
Contatcs : Timer
04
Timer 24VDC
T1 Power Timer
Star T1
T1 Power Timer
)(T1+T2 Power .Timer
) (T1+T2 Power .Timer
(:)15
-
Start/Delta Starting
:
-
05
) S2(Start Coil
Contactor KM1 Star Coil Contactor KM1
o Main Contacts Star Power Circuit

o Coil Contactor KM3 Delta
o
) Delta (KM3 ) Main(KM2
) Delta(KM3 N.C KM1 Coil
) Main(KM2
Motor Power
Bridge ( Start Sw )
o ) Timer(T1
T1 Timer )Star(KM1

T2 ) Timer(T1 ) Delta(KM3
Coil
o Main Contacts . Delta
o . Star
) S1(Stop
Contatcs : Timer
Timer 24VDC
T1 T2
T1 T2

06
(:)15
-

.Stare/Delta Starting
:
-
07
) S2(Start Star
) Timer(T1 )Star(KM1
o Star . Power
o ) Delta(KM3
) Delta(KM3 ). Star(KM1
o Start
o

Coil ) Main(KM2 \
o Motor Motor .Star
o Start
T1 Timer
o ) Star(KM1
.
Normally Close )Delta(KM3
.
Normally Open .
o Power Timer
T2 Timer
o ) Delta(KM3 .
.Delta
) Star(KM1
Start Motor .Delta
) S1(Stop P.B
:
-

Motor Starting Current
Start/Delta-Starting

Squirrel Cage Induction Motor
(:)56
-
motor

:
KM2: Contactor + Air Timer
08
:
) S1(Start KM2
KM2 o

Power

KM2

o KM1

:
-
09
KM1

KM2

.

KA1

(:)55
-
motor

:
-
21
) S2(Start KM1
o
o S2
o T1 T1
T1
T1
o KM2 KM2
KM2
Motor
. T1
:
-
KM1
Motor
KM2
Motor

Motor
KM3
Motor

Motor
.
:
-
(:)55
-
motor
S3 KM1 & T1
T1 KM2 T2
T2 KM3
KM1 & KM2 & T1 & T2
P1 & P2 Starting Normal
20
KM1

KM3

KM2
(:)55
-
motor

S2 KM1
o Motor
o T1
T1
T1 KM3
o Motor

22
23
Star/Delta-Starting
Starting Current
)(Starting Current
KM1 KM2 Motor KM2
KM3 Motor
KM4
:
-

.

.
o :
3
2
1

9
8
7

o :
9 3
- 8 2
- 7 1
Overload 2 .
(:)64
-
:
-
) S2(Start KM1 & T1

KM1 o

Motor
S2
T1 o
T1
o KM2
KM2

Motor
24
:
-
25

Overload

overload . Current Transformer

. .
011 5 01
0

.
: Current Transformer
-

.

Current Transformer

Overload Current Transformer
26
: Starting Current
-
Overload .
Starting Current
. Overload
Overload .
KM1
KM2
.

Motor . KM2

Starting Current
Motor
KM2

(:)51
-
:
-
27
) S2(Start
KM1
o
o KM2
o KM1

KM2 KM2

:
-
). (Slip Ring
) (Stator Squirrel Cage Induction
Motor .
) (Rotor AXE
. .
) (Rotor (
) (
) Starting Torque ) . ( Starting Current

( S.C ) .
.
.

:
-
KM1
KM2
R1
KM3
R2
:
-
28
High Starting Torque

Low Starting Current
(:)66
-
:
-
) S2(Start KM1 & T1

T1 KM2
KM2 & T2
T2 KM3
KM3
KM3 T1
. KM2 & T2
:
-
29
KM3 KM1
KM3 .
31
KM1
KM2
KM3
KM3
(:)57
-
30
motor

:
) S3(Start Forward KM1
o Forward
o Interlock KM2
o S3
o T1 T1
T1
T1
o KM3 & T2 KM3 & T2
KM3
R1

T1
T2
T2
o R2 . Rotor
) S2(Stop
) S4(Start Reverse KM2 Sequence
. Reverse
Soft Starter

Motor .
Starting Direct On Line
Star/Delta Starting
Starting Current
Soft Starter
32
: Soft Starter
33

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Classic Control
Course
Chapter 8: Motor Speed Control

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:
:
Synchronouse Speed:
Rotor

Rotor Speed:
(
S : Slip
Parameter Motor
.
Motor Freq = 60 HZ ) (2P = 4 1450 rpm
Slip :
( ) Rotor :
-
Parameter
.1 frequency frequency
. Inverter
.2 ) (2P .
Motor Frequency : inverter

+ Induction Motor
inverter DC-Motor

inverter
Motor
Motor
.

volt Freq .
inverter
:
Current .Motor
current

.
Motor
inverter .

.
Motor 60 1.
o Motor
. Deceleration
.
:
Squerril Cage Induction Motor
.

Speed at 60 HZ
3600 rpm
1800 rpm
1200 rpm
900 rpm
720 rpm
Speed at 50 HZ
3000 rpm
1500 rpm
1000 rpm
750 rpm
600 rpm
# of Poles
2
4
6
8
10
:
.i .
4 & 6 poles : .2 &10 poles
Separate Windings Iduction Motor
.ii .
2&4 Poles : .4 & 8 Poles
Dahlander Motor
Separate Windings Iduction Motor:
Motor .
.
.
36 1000 & 1500 rpm
6 &4 36 6

.

4 poles
.

.
:
12 6
. Star OR Delta
.
.
.
.
.
(:)86
-

time
:
-
S2 KA1 ) KA1(33/34 KM1

.
S3 ( KA1 ) KM1(83/84
) )KA2(55/56
) KA2(67/68
KM2
S2 KA1

. S1
Dahlander Motor:
Motor .
. 1500/3000 rpm 750/1500 rpm .

.

o
o
2/4 3000/1500 rmp

4 Poles
.2 Poles
) (1
.4 Poles
) (2
.2 Poles
): (DAHLANDER
-
DAHLANDER 6.
:
U1,V1,W1
U2,V2,W2.
:
U2,V2,W2
U1,V1,W1.
X-Y-Z,U-V-W
X-Y-Z . U-V-W
X-Y-Z.
: Dahlander
KM1
KM2 & KM3
(:)69
-
3 )(DAHLANDER

:
) S2(Start Speed 1
KM1
o
o Interlock KM2 & KM3
o )S2(Start Speed 1

Stop
) S3(Start Speed 2
KM2
o
o Interlock KM1
o KM3
o KM3

Interlock KM1

)S3(Start Speed 2
3 )(DAHLANDER
:
-
KM1
KM2 + KM3
KM4
KM5
.
.
)(Forward
)(Reverse
:
-
) (Forward + KM4
KM1
) (Reverse + KM5
KM1
+ KM4 KM2
+ KM3
+ KM5 KM2
+ KM3
(:)70
S2 KM4 ) KM4(21/22
.KM5 ) KM4(63/64 ( KM1 )
) KM4(53/54 . S2
) KM1(21/22 KM2-KM3
S3 KM1
) KM1(21/22 KM2-KM3 )KM1(53/54
( KM5 ) ) KM5(53/54
. S3
S4 KM2
) KM2(53/54 KM3 KM1 & )KM2(21/22
) KM3(21/22 ) KM3(53/54 KM4 )KM4(21/22
. KM5
) KM4(53/54 . S4
S5 KM5
) KM5(21/22 . KM4 ) KM5(63/64 KM2
) KM2(53/54 ( KM3 )
KM1 KM2 ) KM3(21/22 )KM5(53/54
. S5
01
(:)17
-
) (separate windings

:
)S2(Start Speed 1
KM1 Motor
)S3(Start Speed 2
KM2 Motor
KM1 KM2
KM2 KM1 Interlock

Interlock

Stop
(:)17
-
)(separate windings
:
)S2: Douple Pole Switch (N.O+N.C
)S3:Douple Pole Switch (N.O+N.C
00
:
)S2(Start Speed 1
KM2 KM2

)S3(Start Speed 2
KM2 KM2

KM1 KM1

) S2(Start Speed 1
) S1(Stop
(:)13
-
02
:
) S2(Start Speed 1 KM1
o
o Interlock KM2
o )S2(Start Speed 1
o KM1

o KA1
) S3(Start Speed 2 KA1
o ) & S3(Start Speed 2 KM1
o KM1 KM1

Interlock KM2
o KM2 KM2

KA1
Interlock . KM1
KM1 & KM2 Mechanical Interlock .

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03

Classic Control
Course
Chapter 9: Special Relayes

Tel: 01014871075
Special Relayes:
Classic Control
Compact Components
Components Relays : components
o Solid State Relay
Relay
Coil
Contacts
Relay .
. NO
)(NO+NC
Control Voltage & NOContact & NC Contact 2
Control Voltage & NOContact & NC Contact 3
2 ).NO(380VAC,25A
Relay 3 PH Motor
Motor
) (1/2)&(3/4
INPUT
6&7 5&8
Solid Stat Relay :

-

Relay.

.

(:)47
-
:

high level
Low level )2 Level Switch (Float
LS1 = Low Level Switch
LS2 = High Level Switch
)Pump(1
:
)LS1: Float Switch (NC
)LS2: Float Switch (NC
:
LS1
LS2
:
)S1(Control ON
K1
K1 KM1
KM1 P1
LS1 LS1
P1 KM1
LS2 LS2
KM1 P1
LS2
P1 LS1
LS1
KM1 P1 K1
) S2(Control OFF
o Liquid level Relay:

.
.

.
)3 Electrodes ( Upper, Lower , Base
Electrodes

) ( Senstivity
Electrodes
:
3 Electrodes Relay
2 Electrodes Base Electrode .
Upper Electrode Relay
( O/P = 1
,
1/2 = Open ,
) 2/3 = Close

Relay Lower Electrode
Lower Electrode Relay Normal Case
.( O/P = 0
,
1/2 = Close ,
) 2/3 = Open

Operation of the Relay:

: Liquid Level Control Relay
Case (1) :
Low Level Electrode
O/P = 0
&
Normal Case Relay
1/2 = Close
1/3 = Open
Case (2):
High Level Electrode Low Level Electrod
O/P = 0
&
Normal Case Relay
1/2 = Close
1/3 = Open
Case (3):
.High Level Electrode Low Level Electrode
O/P = 1
&
Non-Normal Case Relay
1/2 = Open
1/3 = Close
Case (4):
.High Level Electrode Low Level Electrode
O/P = 1
&
1/2 = Open
1/3 = Close
Case (5):
High Level Electrode Low Level Electrode
O/P = 1
&
1/2 = Open
1/3 = Close
Case (6):
Low Level Electrode
O/P = 0
&
Normal Case Relay
1/2 = Close
1/3 = Open
:
) (1/2
:
(1/2)= Close

Upper Level Electrode

Lower Level Electrode

:
) (2/3
:
(2/3) = Open
Upper Level Electrod

(2/3)= Close
Lower Level Electrode

Upper Level Electrode
: Liquid Level Control Relay

: .
.i

.ii
Electrodes . Floats
.iii
:
Liquid Level Relay
.i
Base Electrode Relay
.ii
Base Electrode
( 2 Electrodes ) U & L First
.iii
Electrod Second Electrode . B
o Electromechanical Latching Relay

2 Coils Coil ) (1/2 Coil ) (1/3
Coil ) (1/2
Coil
Coil ) (1/3
.
:
Coil .
2 Coils . . Relay
Latching Relay Coil
. Latching
. Coil.
(:)47
.Start/Stop P.B
:
)S1 : Start/Stop (3 Pole P.B
2 NO Contact + 1 NC Contact
:
)S1(Start/Stop

KM1
M1
K1
S1
KM1 S1
K1 K1
S1 .
K2 S1
K1 S1 KM1 S1
S1
S1 K2 KM1
KM1 M1
:
01
:
S1
K1
K1 KM1
KM1 M1
KM1 K1
KM1 K2
S1 K2
KM1
KM1 M1 Normal
S1 M1
o Start/Stop Relay
Electronic Relay Start & Stop M/C .

B1/B2 Relay Open Close
.
. .
.
Relay
( B1/B2
).
Relay . A1/A2
) Normally Open Contact(2/3
Relay
00
:
-
Toggel SW .
Relay :
Start/Stop Relay
) Coil(A1/A2

.
o Step Relay
02
(:)47
-
2 Pumps Level Switch

Level Sw )Pump(1
Level Sw ) P(1
Level Sw )Pump(2
Level Sw ) P(2
Level Sw
) Pump(1 .
:
)LS1: Liquid Level Switch (Float
03
:
Liquid Level SW Normal NC
KM1 ) Pump(1 K1 .
Liquid Level SW
). Pump(1
Liquid Level Switch
KM2 ) Pump(2 K1 KM1

KM2
KM2 P2 K1 P1
(:)44
3Pumps .
3 Motors 2 Relay
04
o Motor Sequence Relay
05
Relay Motor ( )
. .
) (P1
.
.
Pressure Switch N.C Relay
.
Pressure Switch Close Open
Relay .

Motor
06
(:)47
2 Pumps
:

High level Low level
2 Pumps
2 Pumps 2 Liquid level SWs

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07

Classic Control
Course
Chapter 10: Pneumatic Examples

Tel: 01014871075
Electro-Pnumatic Circuits
(:)1
-
Piston :
Start Piston Forward ) Limit SW(LS2
Reverse ) Limit SW(LS1 Cycled
.Stop
(:)2
-
Piston :
Start Piston Forward ) Limit SW(LS2
Reverse ) Limit SW(LS1
:
o .Cycled
o Pause .
o .Counter
o Counter Isolation
o Counter Rest
M/C.
o Double Acting
Emergency Switch
(:)3
-
Piston :
Start Piston Forward ) Limit SW(LS2 T
Reverse ) Limit SW(LS1 . Cycled
(:)4
-
2 Pistons :
Start P.B ) Piston(A1 Forward ) Limit SW(1S2
) Piston(A2 Forward ) Limit SW (2S2 )Piston(A1
Reverse ) Limit SW(1S1 ) Piston(A2 Reverse
) Limit SW(2S1 Operation .Cycled
:)5(
: 2 piston
01
00
:)6(
: Sequence 2 pistons
2 Bi-Stable Valves
02
03
:)7(
: Sequence Motor
04
05
:)8(
: Sequence
06
07

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Classic Control
Course
Chapter 11: Complete Projects

Tel: 01014871075
Complete Projects
Project (1):
:
-
Tank A B :
A
Start P.B
B B 3 Min A
Start
Emergency Sw Stop A&B
( ) A
Forward & Reverse Forward
Reverse
Project (2) :
Project (3):
Proiect (4) :
: M/C
Convyour 1 & Convyour 2 Start
Sensor (S1)
Piston (1A) : Forward untile reach to 1S2

Piston (2A) : Forward untile reach to 2S2
Piston (2A) : Reverse untile reach to 2S1
Piston (1A) : Reverse untile reach to 1S1
Sequence S1 2 Pistons 2 Convyour
.
Design Initial Condition & Initial Position
Project (5):
: Electrical Magent Convyour

:

.
. Design
-
:

:
.
Project (6):
: Sequence 2Fans
01
00
Project (7) :
02
03
Project (8) :
M/C :
:
-
Start M/C Sequence:

Piston(1A): Forward Untile reach 1S2
Piston(2A): Forward Untile reach 2S2
Piston(2A): Reverse Untile reach 2S1
Piston(1A): Reverse Untile reach 1S1
o
o
o
o
Start
04
05
Project (10):
:
-
Start Convyour 1 & 2 & 3 M1 & M2 & M3

21 Station 1 Station 2 2 Sec
21 Station 2 Station 1
Stop
06
07
Project(11):
4 Tanks Manual Pumps
:
-
P1 = 3KW ; P2 = 4KW ; P3 = 7KW ; P4=5KW

2 Level SW
:
-
08
10KW
09
Project (12):
21
Project (13):
20
Bar Code
) Selector (ON/OFF ON M/C Initial Position
Repeated
Sequence Reset Initial Position

: Sequence
.2 M/C Initial Position (ON/OFF ) Selector ON
.1 1A 1S2
.3 2A Bar Code 2 min
.4 M 3A Photo Sensor
.5 M 3A Sequence
22
Project (13):
:
2 Chemical Materials M/C :
Tank & S2=0 ) Outlet Valve ( Y3 .2 Start ) Inlet Valve 1 (Y1 Liquid
(S3=1) S3
.1 ) Inlet Valve 2 (Y2 Tank (S4=1) S4
.3 Heater )(S5=1
.4 Mixer 10 min
.5 ) Outlet Valve (Y3
Features
Start/Stop SWs
Emergency SW
Continue SW
Repeated /One Cycle Selector SW
23
24
25
Project (15):
26
Project (17):
M/C 2 Work Pieces 2 Rods :

-
Start ) Piston(1A Work Piece.

) Piston(2A 1st Rod .
) Piston(3A 2nd Rod .
) Piston(1A .
Cycled Cycle Work Piece

27
28

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Industrial Automation Group Link :

Prepared By: Eng, Abd ulkawy Mobarak

Types of electrical Loads:

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

)Power (P) = Volt (V) * Current (I

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Step Down Transformer:

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Power Transformers Electric Power

400V Step-Up Transformer

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

3PH Power Transformer

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Different Connections Of Transformers:

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

What is the Difference Between Groung & Neutral:

Single Phase Step Down Transformer

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Transformer 4 ) ( 3Phase + Neutral

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Primary + 2nd Secondary

Delat Start Secondaries

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

3Phase Potential Transformer Power

Secondary Current transformer Open

Potential Transformer & Current Transformer

Current Transfprmer & Potential Transformer Power

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Industrial Automation Group

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Industrial Automation Group Link :

Prepared By: Eng, Abd ulkawy Mobarak

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Operator Discharge Valve

Monitoring and data collector:

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

- Relays Switches (selectors , push buttons ) digital sensors limit Switches

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Main Contacts Normally Open

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

: N.O Auxiliary Contacts

: N.C Auxiliary Contacts

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Coil A1/A2 . A/B

Auxiliary Contactor or Relay:

Current value is uncontrolled:

- Load Current = 9 AMP

over load current

)Istarting = 6 In (6* Rated Current

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

Motor Current Motor

Power Circuit Control Circuit

ENG. ABD EL-KAWY MOBARAK | Classic Control Course

ENG. ABD EL-KAWY MOBARAK | Classic Control Course