Classic Control

(Day 1)

1.1 What is Industrial Control?

An industrial control system is a system of interconnected equipment used to
monitor and control physical equipment in industrial environments.

Industrial control system (ICS) is a general term that includes several types of
control systems used in industrial production, including supervisory control and
data acquisition (SCADA) systems, distributed control systems (DCS), and
other smaller control system configurations such as classic control systems and
programmable logic controllers (PLCs) often found in the industrial sectors and
critical infrastructures.

1.2 What is Classic Control?

Initially, control of manufacturing and process plants was done mechanically
either manually or through the use of mechanical controllers. Then, the
mechanical control systems were replaced by classic control systems in which
electric controllers employing transducers, relays and hard-wired control
circuits were used. These systems were large, space consuming, difficult in fault
diagnostics and maintenance and they need to be rewired in case of any
modification in the process. These disadvantages paved the way for more
advanced controllers such as programmable logic controllers (PLCs). Here, an
overview of classic control system will be presented.

1.3 Components of Classic Control Systems

The most common components of classic control systems are as follows:
1.3.1 Switch
In electrical engineering, a switch is an electrical component that can break an
electrical circuit, interrupting the current or diverting it from one conductor to

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another. Switches are made to handle a wide range of voltages and currents.

1.3.2 Push Button

A small button or knob that when pushed makes or breaks an electric circuit.

1.3.3 Relay
A relay is an electrically operated switch. Many relays use an electromagnet to
mechanically operate a switch, but other operating principles are also used, such
as solid-state relays. Relays are used where it is necessary to control a circuit by
a low-power signal (with complete electrical isolation between control and
controlled circuits), or where several circuits must be controlled by one signal.

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1.3.4 Contactor
A contactor is an electrically controlled switch used for switching an electrical
power circuit, similar to a relay except with higher current ratings. A contactor

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is controlled by a circuit which has a much lower power level than the switched
circuit.

1.3.5 Overload Relay

Overload relays are protective devices. They are designed to cut power if the
motor draws too much current for an extended period of time. To accomplish
this, overload relays contain a normally closed (NC) relay. When excessive

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current flows through the motor circuit, the relay opens due to increased motor
temperature, relay temperature, or sensed overload current, depending on the
relay type.

Overload relays are similar to circuit breakers in construction and use, but most
circuit breakers differ in that they interrupt the circuit if overload occurs
even for an instant. Thermal overload relays are conversely designed to
measure a motor's heating profile; therefore, overload must occur for an
extended period before the circuit is interrupted.

1.3.6 Fuse
A fuse (from the French fusée, Italian fuso, "spindle") is a type of low resistance
resistor that acts as a sacrificial device to provide overcurrent protection, of

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either the load or source circuit. Its essential component is a metal wire or strip
that melts when too much current flows through it, interrupting the circuit that it
connects. Short circuits, overloading, mismatched loads, or device failure are
the prime reasons for excessive current. Fuses can be used as alternatives to
circuit breakers.

1.3.7 Circuit Breaker

A circuit breaker is an automatically operated electrical switch designed to
protect an electrical circuit from damage caused by overcurrent/overload or
short circuit. Its basic function is to interrupt current flow after protective relays
detect a fault. Unlike a fuse, which operates once and then must be replaced, a
circuit breaker can be reset (either manually or automatically) to resume normal
operation. Circuit breakers are made in varying sizes, from small devices that
protect an individual household appliance up to large switchgear designed to
protect high voltage circuits feeding an entire city. The generic function of a
circuit breaker or a fuse, as an automatic means of removing power from a
faulty system is often abbreviated to ADS (Automatic Disconnection of
Supply).

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1.3.8 Sensor
A sensor is an object whose purpose is to detect events or changes in its
environment, and then provide a corresponding output. Sensors may provide
various types of output, but typically use electrical or optical signals.

1.3.9 Timer
There are two common types of timers which are as follows:
a) ON-delay Timer
When voltage is applied to the coil, the relay contacts remain in the off state and
the set time begins. When the set time has elapsed, the relay contacts transfer to
the on state. The contacts remain in the on state until the timer is reset. The
timer is reset by removing the coil voltage.

b) OFF-delay Timer
Voltage is applied to the coil at all times. When a start signal is supplied, the
contacts immediately transfer to the on state. The set time begins when the

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start signal is removed. When the set time has elapsed, the contacts transfer
to the off state.

1.4 The difference between Control Circuit and Power Circuit

Control circuit is the circuit in which the current is conducted to a contactor
coil. Since the current of contactor coil is small, the cross section area of the
wires used in the control circuit is small and the ratings of the control
components are low. On the other hand, the power circuit is the one in
which the current is conducted from the main supply to load. If the load
current is high, which is usually the case, the cross section area of the cables
is large and the ratings of the used switches, contacts… are high.

NO NC
Push Button Push Button

Supply AC NO
NO Contact Coil AC
Supply
Contact

Load

Control Circuit Power Circuit

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 (Day 2)

2.1 Control and Power Circuit of Single-phase Heater, Single

ON/OFF, with Indicating Lamps

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2.2 Control and Power Circuit of Single-phase Heater, Single
ON/OFF, with Indicating Lamps and Heat Sensor

Legend:
H: Heat Sensor

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2.3 Control and Power Circuit of Single-phase Heater, Double
ON/OFF, with Indicating Lamps

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2.4 DC Motor
An Electric DC motor is a machine which converts electric energy into
mechanical energy. The working of DC motor is based on the principle that
when a current-carrying conductor is placed in a magnetic field, it experiences a
mechanical force. The direction of mechanical force is given by Fleming’s Left-
hand Rule and its magnitude is given by F = BIL Newton.

There is no basic difference in the construction of a DC generator and a DC

motor. In fact, the same DC machine can be used interchangeably as a generator
or as a motor.

Consider a part of a multipolar DC motor as shown in Figure below. When

the terminals of the motor are connected to an external source of DC supply:
(i) the field magnets are excited developing N and S poles;
(ii) the armature conductors carry currents. All conductors under N-pole carry
currents in one direction while all the conductors under S-pole carry currents in
the opposite direction.

Suppose the conductors under N-pole carry currents into the plane of the
paper and those under S-pole carry currents out of the plane of the paper as
shown in Figure. Since each armature conductor is carrying current and is
placed in the magnetic field, mechanical force acts on it. On applying Fleming’s
left hand rule, it is clear that force on each conductor is tending to rotate
the armature in anticlockwise direction. All these forces add together to produce
a driving torque which sets the armature rotating. When the conductor moves
from one side of a brush to the other, the current in that conductor is reversed

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and at the same time it comes under the influence of next pole which is of
opposite polarity. Consequently, the direction of force on the conductor remains
the same.

2.5 Control and Power Circuit of DC Motor, One direction,

Single ON/OFF, with Overload

Legend:
RM: Overload (Remote Monitor Model)

L + -

Fuse

RM Fuse

K
Stop

RM

Start K

K DC
N Motor

Control Circuit Power Circuit

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2.6 Control and Power Circuit of DC Motor, One direction,
Double ON/OFF, with Overload

L + -

Fuse

RM Fuse

Stop 1 K

Stop 2
RM

Start 2 K
Start 1

K DC
N Motor

Control Circuit Power Circuit

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2.7 Control and Power Circuit of DC Motor, One direction,
Double ON Pressed Simultaneously, with Overload

L + -

Fuse

RM Fuse

Stop K

Start 1 RM
K
Start 2

K DC
N Motor

Control Circuit Power Circuit

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2.8 Control and Power Circuit of DC Motor, One direction,
Instantaneous and Continuous Operation, with Overload

Legend:
S1: Instantaneous Operation
S2: Continuous Operation

L + -

Fuse

RM Fuse

Stop K

S1
RM

S2 K

K DC
N Motor

Control Circuit Power Circuit

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 (Day 3)

3.1 Control and Power Circuit of DC Motor, One Direction, with

Cooling Fan and Off-delay Timer

Legend:
T1: Off-delay Timer

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3.2 Control and Power Circuit of DC Motor, Two Directions,
with Interlock

L + -

Fuse
Fuse
RM

Stop
K1 K2

Direction K1 Direction K2
(1) (2)
RM
K2 K1

K1 K2
DC
N Motor

Control Circuit Power Circuit

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3.3 Control and Power Circuit of DC Motor, Two Directions,
with Interlock, with Timer
Legend:
T1: ON-delay Timer

L + -
Fuse
Fuse
RM

Stop

K1 K2

Start K1 T1 K2

K2 RM
K1
T1

K1 T1 K2
DC
N Motor

Control Circuit Power Circuit

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3.4 Control and Power Circuit of DC Motor, Two Directions,
with Interlock, Period of Time has to be Elapsed before
Reversing the Direction
Legend:
S1: First Direction
S2: Second Direction

L + -
Fuse
Fuse
RM

Stop

K1 K2

S1 K1 S2 K2

K2 K1 RM

T2 T1

K1 T1 K2 T2 DC
N Motor

Control Circuit Power Circuit

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3.5 Control and Power Circuit of DC Motor with Two Limit
Switches Representing the Operation of a Garage Door

Legend:
S: Inductive Proximity Sensor
LS 1: Limit Switch (“Open” Case)
LS 2: Limit Switch (“Closed” Case)

L
+ -
Fuse

RM

Stop Fuse

Open S K1 Close S K2 K1 K2

LS 1 LS 2
RM
K2 K1

K1 K2 DC
N Motor

Control Circuit Power Circuit

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3.6 Control and Power Circuit of Two DC Motors with Interlock

L + -
F3

RM 1

RM 2
F1 F2

Stop
K1 K2

Start 1 K1 Start 2 K2
RM 1 RM 2
K2 K1

K1 K2 Motor
Motor
N (1) (2)

Control Circuit Power Circuit

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3.7 Control and Power Circuit of Two DC Motors
(a) First Motor must be running to start the second one
L + -
F3

RM 1

RM 2
F1 F2

Stop
K1 K2

Start 1 K1 Start 2 K2
RM 1 RM 2
K1

K1 K2 Motor
Motor
N (1) (2)

Control Circuit Power Circuit

(b) First Motor must be stopped to start the second one

L + -
F3

RM 1

RM 2
F1 F2

Stop
K1 K2

Start 1 K1 Start 2 K2
RM 1 RM 2
K1

K1 K2 Motor
Motor
N (1) (2)

Control Circuit Power Circuit

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 (Day 4)
4.1 Control and Power Circuit of Two DC Motors

a) S: Stop the First Motor and Start the Second One Simultaneously
L + -
F3

RM 1

RM 2
F1 F2
Stop
K1 K2

Start 1 K1

RM 1 RM 2
S
K2

K1 K2 Motor
Motor
N (1) (2)

Control Circuit Power Circuit

b) S1: Start the First Motor and Stop the Second One Simultaneously
S2: Start the Second Motor and Stop the First One Simultaneously
L + -
F3

RM 1

RM 2
F1 F2
Stop
K1 K2

K1 S1

RM 1 RM 2
S2
K2

K1 K2 Motor
Motor
N (1) (2)

Control Circuit Power Circuit

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4.2 Control and Power Circuit of Two DC Motors, Motor (2) Starts
after a Period of Time from Starting Motor (1)

Legend:

T1: On-delay Timer

L + -
F3

RM 1

RM 2
F1 F2

Stop
K1 K2

Start K1
RM 1 RM 2

T1

K1 T1 K2 Motor Motor
N (1) (2)

Control Circuit Power Circuit

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4.3 Control and Power Circuit of Two DC Motors, Motor (2) Starts
after a Period of Time from Starting Motor (1) and Motor (1) Stops

L + -
F3

RM 1

RM 2
F1 F2

Stop
K1 K2

Start K1 T1 K2
RM 1 RM 2
K2

K1 T1 K2 Motor Motor
N (1) (2)

Control Circuit Power Circuit

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4.4 Control and Power Circuit of Three DC Motors, Motor (1) and
Motor (2) Start First, Motor (3) Starts and Motor (1) Stops after a
Period of Time, with Interlock between Motor (1) and Motor (3)

L + -

F4

RM 1

RM 2

RM 3
F1 F2 F3
Stop

K1 K2 K3
Start K2

K1 T1
RM 1 RM 2 RM 3
T1
K1
K3
K1 K2 T1 K3 Motor Motor Motor
N (1) (2) (3)

Control Circuit Power Circuit

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4.5 Control and Power Circuit of Three DC Motors, Motor (1) Starts
First, Motor (2) Starts after a Certain Period of Time from Starting
Motor (1), Motor (3) Starts after a Certain Period of Time from
Starting Motor (2)

L + -

F4

RM 1

RM 2

RM 3
F1 F2 F3
Stop

K1 K2 K3
Start K1 T1 K2 T2 K3

RM 1 RM 2 RM 3

K1 T1 K2 T2 K3
K2 K3 Motor Motor Motor
N (1) (2) (3)

Control Circuit Power Circuit

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4.6 Control and Power Circuit of Three DC Motors, Motor (1) Starts
First, Motor (2) Starts after a Certain Period of Time from Starting
Motor (1) and Motor (1) Stops, Motor (3) Starts after a Certain
Period of Time from Starting Motor (2) and Motor (2) Stops,
Motor (1) Starts after a Certain Period of Time from Starting
Motor (3) and Motor (3) Stops and so on

L + -

F4

RM 1

RM 2

RM 3
F1 F2 F3
Stop

K1 K2 K3
Start K1 T3 T1 K2 T2 K3

K2 K3 K1
RM 1 RM 2 RM 3

K1 T1 K2 T2 K3 T3
Motor Motor Motor
N (1) (2) (3)

Control Circuit Power Circuit

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 (Day 5)

Exam

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