Exercise: Xercise Bjective
Exercise: Xercise Bjective
EXERCISE OBJECTIVE When you have completed this exercise, you will be introduced to relays and
contactors, and their operation. You will be familiar with different applications of
relays. You will be introduced to the Relays module, Contactors module, and
Residential Bimetallic Thermostat module of the training system.
DISCUSSION OUTLINE The Discussion of this exercise covers the following points:
Introduction to relays
Operation of dc relays
Operation of ac relays
Relay applications
Contactors
Two-wire and three-wire control circuits
Two-wire control circuit. Three-wire control circuit.
Training system modules
Relays module. Contactors module. Residential Bimetallic Thermostat
module.
Operation of dc relays
A relay coil in which current Figure 183 shows an example of a simple dc relay. When the relay is
flows is said to be ener- de-energized, as in Figure 183a, no current flows in the coil of the relay and no
gized. A relay coil in which magnetic field is produced. Because of this, the armature is released and the
current does not flow is said relay contacts are open. Any circuit connected to terminals C and D is also open.
to be de-energized. Therefore, the relay acts just like a toggle switch in its open state.
On the other hand, when the relay is energized, as in Figure 183b, current flows
in the coil of the relay through terminals A and B. This produces a magnetic field
around the coil which attracts the armature and causes the relay contacts to
close. Any circuit connected to terminals C and D is also closed. Therefore, the
relay acts just like a toggle switch in its closed state.
C C
Coil Coil
Contacts Contacts
open closed
A A
B B
D Armature D Armature
(a) When the relay coil is de-energized. (b) When the relay coil is energized.
Figure 183. Cross-sectional view of a relay showing the position of the contacts when the
relay is energized and when it is not energized.
There are two basic types of contacts commonly found in relays: normally
open (NO) contacts and normally closed (NC) contacts. Each type of contact
indicates the state of the contact when the relay coil is de-energized, which is the
normal state of the contact. Therefore:
x A normally open (NO) contact is open when the coil of the relay is
de-energized and closed when it is energized. The relay contacts in
Figure 183 are of this type.
x A normally closed (NC) contact is closed when the coil of the relay is
de-energized and open when it is energized.
The common circuit diagram symbols for the coil and contacts of a relay are
shown in Table 23. As the table shows, the coil and contact(s) of a relay are
represented using different symbols, even though they are part of the same
component. This is because the coil and contact(s) of a relay form independent
circuits and often need to be represented separately.
Component Symbol
Relay coil
Relay NO contact
Relay NC contact
Consider the circuit in Figure 184. In this circuit, terminals A, B, C, and D across
the coil and contact of the relay correspond to the terminals identified in
Figure 183.
A D
DC power source CR
B
Indicator
light
When the coil of the relay in Figure 184 is de-energized, the relay contacts
remain open (see Figure 183a), preventing current from flowing in the indicator
light, which remains off. On the other hand, when the coil of the relay is
energized, the relay contacts close, allowing current to flow in the indicator light,
which turns on. As a result, the operation of the indicator light is controlled using
either allowing or preventing current flow in the coil of the relay.
Operation of ac relays
AC relays operate just like dc relays, with the only difference being that the
current flowing in the relay coil is alternating current instead of direct current. The
fact that ac current alternates between positive and negative has no effect on
relay operation. This is because the ferromagnetic material composing the relay
armature is attracted to the magnetic field produced by the relay coil, no matter
the polarity of the magnetic field (and thus no matter the direction of current in
the coil).
However, when the ac current flowing in the relay coil passes through zero, the
coil becomes momentarily de-energized. This produces a slight buzzing sound
known as chattering and can also cause the contacts to very briefly open or
close, which is highly undesirable. This problem is usually solved in ac relays by
adding a shading ring to the relay that ensures that a certain magnetic field is
always present in the relay coil even when the current sine wave passes through
zero. Applying dc power to an ac relay with a shading ring will not cause
problems in its operation. Since the dc current does not rise and fall, it creates a
steady magnetic field.
Note that, since coils in ac circuits are inductors, the coil of an ac relay has an
inductive reactance value that limits the amount of current flowing in it. This must
be taken into account when selecting the ac power source used to power the
relay coil.
Relay applications
Relays are also often used for circuit protection and are thus referred to as
protection relays. Protection relays are designed to open a circuit when certain
conditions occur, thus preventing current flow. For example, they can be used to
prevent overvoltage. As soon as the voltage applied to the relay coil reaches a
certain value, it becomes energized and the relay contacts open.
Figure 185. Typical overload relay used for motors. This relay stops motor operation as soon
as certain predetermined ratings are exceeded (© Siemens AG 2014, all rights reserved).
Contactors
As for relays, contactors are available with normally open or normally closed
contacts or a combination of both (main contacts). Furthermore, they are often
equipped with auxiliary contacts. Auxiliary contacts are additional contacts that
are usually smaller and rated at lower current values than the main contacts that
are physically linked to the main switching mechanism and activated at the same
time as the main contacts. Auxiliary contacts are often used for control purposes
such as holding contacts and indicator lights. They are usually modular snap-on
units which can be added or removed as required. The right contactor of the
Contactors module is provided with auxiliary contacts.
Contactors are usually equipped with a push-to-test button. This button is used to
bypass the control circuit when testing or troubleshooting a system.
Two-wire control is the simplest type of load control. Depending on the state of a
control device, the load is energized or not energized. The control device can be
a thermostat, float switch, pressure switch, toggle switch, selector switch, or any
type of switch that can hold its contacts closed even if there is a power failure.
When a power failure occurs, the load drops out and restarts by itself when the
power returns. Since this type of control does not require an operator to restart a
machine following a power failure, it can be hazardous to personnel and
machinery, due to the sudden restart of equipment.
The two-wire control circuit gets its name from the number of wires that must be
connected to the control device to operate the load.
x If a power failure occurs at this moment, coil CR will de-energize and the
motor will stop. However, the motor will restart by itself when the power
returns because the toggle switch has remained closed, allowing coil CR
to re-energize and causing contact CR-1 to close and the motor to run.
The circuit in Figure 187 uses a 24 V control circuit to control a motor operating
at line voltage. It is a common practice to use low power control circuits to control
high power loads.
Start / Stop
CR-1
Line voltage 24 V CR
N
M Motor
Three-wire control consists of two push buttons and one contact. One push
button is normally closed and is used as a stop button, the other push button is
normally open and is used as a start button. The contact is called holding
contact; it is normally open and is controlled by a coil connected in series with the
two push buttons. When a power failure occurs, the load de-energizes and
remains de-energized when the power returns. This type of control requires an
operator to restart the system following a power failure.
The three-wire control circuit gets its name from the three wires that must be
connected to the control device used to operate the load.
x When the Start push button is pressed, the coil CR energizes. This
causes the holding contact CR-1 to close and keep the coil energized.
This also causes the power contact CR-2 to close. This allows the
current to flow through the motor, and the motor to run.
x When the Stop push button is pressed, or power is removed, the coil CR
de-energizes. This causes the holding contact CR-1 and the power
contact CR-2 to open, and the motor to stop.
Stop Start
CR-2
L
Network
CR-1 CR
voltage
N
M Motor
Relays module
24 V relay coil
NO contact
Ground terminal
NC contact
The Relays module consists of two identical relays. Each relay consists of a coil
rated at 24 V, 50/60 Hz, a set of normally open contacts, and a set of normally
closed contacts. The contacts are rated at 8 A, 250 V, 50/60 Hz. The coils are
supplied using 2 mm terminals and the contacts are designed to operate at high
voltage using the 4 mm terminals.
The Relays module is also equipped with four fault switches and two ground
terminals.
Contactors module
Auxiliary contacts
Push-to-test button
24 V relay coil
NO contact
Ground terminal
The Contactors module is shown in Figure 190. The module consists of two
contactors: the contactor at the left has two sets of normally open contacts. The
operating coil is supplied using 2 mm terminals.
The contactor at the right also has two sets of normally open contacts (main
contacts). This contactor is provided with auxiliary contacts made of a set of
normally open and a set of normally closed contacts. The operating coil is
supplied using 4 mm terminals.
Both contactors are provided with a push-to-test button. The push-to-test buttons
allow the contactors to be actuated without energizing the coil.
The Contactors module is also equipped with six fault switches and two ground
terminals.
Residential bimetallic
thermostat
Ground terminal
Contact screw
(connects to
Moving contact attached terminal W)
to the bimetallic element,
(connects to terminal R)
Magnet
Bimetallic strip
wound into a coil
Heat anticipator
cursor
Line voltage thermostats are also used. They are commonly used for electric
heaters such as a baseboard heater. Line voltage thermostats directly switch
system power.
The Residential Bimetallic Thermostat module is also equipped with four fault
switches and two ground terminals.
Setup
Troubleshooting a relay
Controlling two indicator lights using a relay
Two-wire control circuit
Thermostat operation. Heating element controlled using a thermostat and
a contactor. Thermostat heat anticipator setting. Contactor push-to-test
button.
Three-wire control circuit
Circuit representing a blower motor controlled using start/stop push
buttons and a contactor.
PROCEDURE
High voltages are present in this laboratory exercise. Do not make or modify any
banana jack connections with the power on unless otherwise specified.
Setup
In this section, you will install the training system modules in the workstation.
Make sure that all fault switches are set to the O (off) position.
Troubleshooting a relay
In this section, you will measure the resistance of the coil and contacts of a relay
when the coil is de-energized, as well as the resistance of the relay contacts
when the coil is energized. You will test the continuity between the contacts of
the relay when the relay coil is de-energized and energized, and confirm that the
results are as expected in theory. You will then measure the current flowing in
the coil and analyze the results.
2. You can use any relay in the Relays module to perform your measurements.
3. Make sure that the main power switch on the Power Source module is set to
the O (off) position, then connect it to an ac power outlet.
Line voltage 24 V
Figure 193. Circuit used to measure the resistance of the relay contacts.
5. What can you conclude from the resistance values you measured in steps 2
and 4 regarding the continuity between the contacts of the relay when the
relay coil is de-energized and energized? Briefly explain.
6. Measure the current ܫ flowing in the relay coil. Record the value below.
7. Compare the current ܫ you measured in the previous step to the current
rating of the relay contacts indicated on the front panel of the Relays module.
What can you conclude?
In this section, you will connect a circuit containing two indicator lights controlled
using a relay. You will predict the operation of the indicator lights, and confirm
your predictions by powering the circuit and observing the operation of the
indicator lights depending on the state of the relay coil (de-energized or
energized).
9. Set up the circuit shown in Figure 194. You can use any relay in the Relays
module to set up your circuit.
A2
A1
L
Line voltage 24 V CR CR1 CR2
N
Indicator Indicator
light ܮܫଵ light ܮܫଶ
Figure 194. Circuit containing two indicator lights controlled using a relay.
10. Based on what you know about relays, predict the operation of indicator
lights ʹܮܫ ͳܮܫdepending on the state of the relay coil (de-energized or
energized).
Describe the operation of the indicator lights when the power source is on
and the relay coil is de-energized (the toggle switch is set to the O (off)
position).
Describe the operation of the indicator lights when the power source is on
and the relay coil is energized (the toggle switch is set to the I (on) position).
13. Do your observations on the operation of the indicator lights confirm the
predictions you made in step 10?
Yes No
Thermostat operation
In this section, you will measure the resistance across the terminals R and W of
the thermostat when the temperature setting lever is set to the lowest
temperature (lever fully at the left position) and when it is set to the highest
temperature (lever fully at the right position) by using an ohmmeter. You will use
the measured resistances to determine when the thermostat contact is closed or
open.
15. Using an ohmmeter, measure the resistance across terminals R and W when
the temperature setting lever is set to the lowest temperature (lever fully at
the left position) and when the lever is set to the highest temperature (lever
fully at the right position). Record each resistance value below.
Resistance value when the temperature setting lever is set to the lowest
temperature ൌ ȍ
Resistance value when the temperature setting lever is set to the highest
temperature ൌ ȍ
The operation of the heating element is represented using indicator light ܮܫଵ .
Use the left contactor in the Contactors module (the contactor with a 24 V
coil) to implement contactor CON. Use any of the contacts of this contactor to
implement NO contact CON-1. Use a green indicator light to implement ܮܫଵ .
Set the thermostat at the lowest temperature (lever fully at the left position).
Thermostat
A CON-1
Figure 195. Circuit representing a heating element controlled using a thermostat and a
contactor (two-wire control).
17. Based on what you know about thermostats and contactors, predict the
operation of the heating element depending on the state of the
thermostat (setpoint at the lowest or highest temperature). Assume that the
lowest temperature setting of the thermostat corresponds to a temperature
that is lower than the ambient temperature in your local, and that the highest
temperature setting of the thermostat corresponds to a temperature that is
higher than the ambient temperature in your local. Also assume that the
heating element is on when the indicator light is on.
18. Make sure that the multimeter is set to measure a current of approximately
0.5 A ac.
19. Describe the operation of the heating element when the power source is on
and the thermostat is set to the lowest temperature.
20. Set the thermostat to the highest temperature (lever fully at the right
position). Observe what happens as you do so. Describe the operation of the
heating element when the power source is on and the thermostat is set to the
highest temperature.
Yes No
In this section, you will measure the current flowing in the heating control circuit
when the system is operating in order to determine the heat anticipator setting of
the thermostat.
22. While indicator light ܮܫଵ is on, indicating that the heating element is on,
measure the current flowing in the heating control circuit.
23. Using the current measured in the previous step, determine the value of the
heat anticipator that should be set for this circuit.
a Do not modify the heat anticipator setting of your thermostat. The heat
anticipator cursor is fragile and is not designed to be operated frequently.
In this section, you will observe the behavior of the contactor when the push-to-
test button is pressed.
24. Set the thermostat at the lowest temperature (lever fully at the left position).
Push on the push-to-test button of the contactor using the tip of a 4 mm wire
connector. Observe what happens as you do so. Describe the operation of
the heating element (indicator light) when the power source is on, the
thermostat is set to the lowest temperature (open contact), and the contactor
push-to-test button is pressed.
25. Does the contactor behave as if its coil is energized or de-energized when
the push-to-test button is pressed?
Circuit representing a blower motor controlled using start/stop push buttons and a
contactor
In this section, you will connect a circuit representing a blower controlled using
start/stop push buttons and a contactor. You will predict the operation of the
circuit. You will then confirm your predictions by powering the circuit and
observing the operation of the blower depending on the state of the start/stop
push buttons.
Use a green indicator light to implement indicator light (ܮܫଵ ) and a red
indicator light to implement indicator light (ܮܫଶ ). In this circuit, the green
indicator light (ܮܫଵ ) lights when the blower is operating, and the red indicator
light (ܮܫଶ ) lights when the blower is not operating.
Note that, in actual circuits, the control section of the circuit would operate at
a voltage lower (usually 12 V or 24 V) than the power section. The control
section is usually isolated from the power section by a step-down
transformer, or supplied by a different circuit.
Stop Start
CON-2 CON-3
Figure 196. Circuit representing a blower controlled using start/stop push buttons and a
contactor.
28. Based on what you know about contactors, predict the operation of the
blower depending on the state of the start/stop push buttons. Assume that
the blower is on when the green indicator light is on, and off when the red
indicator light is on.
30. Describe the operation of the indicator lights when the power source is on
and no push button is pressed.
31. Press the Start push button. Wait for a few seconds, then release the push
button. Describe the operation of the indicator lights when the power source
is on and you press then release the Start push button.
32. Press the Stop push button. Wait for a few seconds, then release the push
button. Describe the operation of the indicator lights when the power source
is on and you press then release the Stop push button.
33. Do your observations confirm the predictions you made in step 28?
Yes No
34. Turn off the power source and the measuring instruments.
CONCLUSION In this exercise, you were introduced to relays and contactors operation. You
became familiar with different applications of relays and contactors. You were
also introduced to two-wire and three-wire control circuits. You learned how a
bimetallic thermostat operates. Finally, you were introduced to the Relays
module, Contactors module, and Residential Bimetallic Thermostat module.
4. Consider the circuit in Figure 197. Describe the operation of the indicator
lights when the relay coil is de-energized (the push button is released) and
when it is energized (the push button is pressed).
Indicator
light A
Power source CR
Indicator Indicator
light B light C