Schematics Made Easy

SCHEMATICS MADE EASY

CONTENTS
POWER & CONTROL CIRCUITS.............................................................................................................................................2
POWER CIRCUITS.................................................................................................................................................................2
CONTROL CIRCUITS............................................................................................................................................................2
Wiring Diagram.......................................................................................................................................................................2
Schematic Diagram..................................................................................................................................................................2
CONTROL CIRCUITS................................................................................................................................................................3
Maintained Start-Stop..............................................................................................................................................................3
UNDERVOLTAGE PROTECTION.......................................................................................................................................3
Momentary Start-Stop..............................................................................................................................................................3
Multiple Start-Stop Stations.....................................................................................................................................................3
TWO & THREE WIRE CIRCUITS............................................................................................................................................3
Two-wire control......................................................................................................................................................................4
REVERSING CIRCUITS............................................................................................................................................................4
Forward-Reverse Compelling..................................................................................................................................................4
Forward-Reverse Optional.......................................................................................................................................................5
MULTI-SPEED CIRCUITS........................................................................................................................................................5
Two-Speed Compelling...........................................................................................................................................................5
Two-Speed Non-Compelling...................................................................................................................................................5
SEQUENCE STARTING............................................................................................................................................................6
Sequence Start by Auxiliary Contacts......................................................................................................................................6
Timed Sequence Start..............................................................................................................................................................6
SYMBOLS CHART....................................................................................................................................................................7
EXAMPLES:................................................................................................................................................................................8

Page 1 of 8
Schematics Made Easy

POWER & CONTROL CIRCUITS The control circuit is shown in light lines and consists of
the stop-start pushbuttons, holding interlock, magnetic
Circuit diagrams may seem complex when viewed in their starter coil M, and overload relay contact X2.
entirety, but they can be simplified by breaking them into
basic circuits. The overall diagram, and basic machine
functions, are then easier to understand.
Control systems are usually designed so that an individual
circuit controls only one function of a machine. For
example, this could be the starting and stopping of an
electric motor by means of pushbuttons, or controlling
solenoid valves through the use of limit switches. There
are many variations in individual circuits. The main factor
to remember is that a basic circuit is usually associated
with a basic machine function.
Electric circuits may be of two types, Power Circuits and
Control Circuits.
POWER CIRCUITS are usually shown in a diagram with
heavy lines since they are the heavy conductors or wires
carrying motor or load current.
CONTROL CIRCUITS are usually associated with pilot
or control of the power switching equipment, such as the
coil circuit in a magnetic starter. These wires are shown
using lighter lines in the diagram. Some graphic symbols
and designations used in diagrams are shown on Page 6.
These are used in the circuits described in this article. Fig. 2. Pushbutton station and 3-phase magnetic starter with arc box
Wiring Diagram — Figure 1 shows the wiring or cover removed to show contacts. Heater elements shown installed.
connection diagram of a magnetic starter with a start-stop Schematic Diagram — A schematic or elementary
pushbutton station. The location of each wire and terminal diagram of the starter shown (Fig. 2) is illustrated in Fig. 3.
identifications are shown. The schematic does not show the physical relationship of
L1 L2 L3 each wire location. It does indicate in straight line form the
circuit functions of the various devices.
2 1 Note that the same terminal identification letters and
numbers are used in both the wiring and schematic
A diagrams to designate the control and power connections.
3
The starter and pushbuttons can be wired directly from the
C M schematic, if desired, since it does show how the devices
V W are connected into the circuit. For troubleshooting, it is
much easier to work from a schematic diagram rather than
a wiring diagram. This is particularly true with a complex
X2 circuit.

T1 T2 T3A3 HEATER ELEMENTS

T2 L1
M T1
T1 T3
MOTOR
L2 MOTOR

M T2
T3
L3
Fig. 1. The wiring diagram for the 3-phase magnetic starter with
M
start-stop pushbutton control pictured in Fig. 2.
START
Note the 3-phase power circuit is shown in heavy black L1 1 2 3 L2
M
lines. L1, L2, and L3 indicate the line or supply. T1, T2, STOP V W
MOTOR
M OL RELAY
STARTER COIL CONTACTS
and T3 are on the load side or motor terminals.

Fig. 3. Schematic of the magnetic starter pictured in Fig. 2.

Page 2 of 8
Schematics Made Easy

Now let us consider some of the basic everyday circuits

and the meaning of the more common terms. These
circuits will be illustrated in schematic form showing only Starter coil M is energized when the start pushbutton is
the control portion and its variations for different machine depressed. This closes contact M which is connected
functions. around the start pushbutton, thus electrically “sealing” the
circuit. The start pushbutton, being of the momentary type,
CONTROL CIRCUITS spring-returns to the open position when released. The
starter, however, remains energized due to completion of
Maintained Start-Stop — The circuit in Fig. 4 does
the circuit through the now-closed M contact. This contact
exactly what its name implies — starts and stops a motor
is referred to as the “seal-in” or “holding” interlock, and
by depressing the maintained start and stop pushbuttons
would be the left contact on the starter in Fig. 2.
Should the starter coil circuit be interrupted for any reason
START
OL such as power failure, insufficient coil voltage, overload
STOP
trip, or operation of the stop button, the starter will drop
L1 M L2
out or be de-energized. The seal-in interlock opens and
prevents an unwanted restart until the start button is again
Fig. 4. Maintained Start-Stop Circuit. Motor is started by pushing
operated. This is where the protection feature comes into
button. Starter drops out whenever voltage is below hold-in value. play, since operation of the motor is completely under the
operator’s control.
This circuit has undervoltage release. Should the voltage
on the coil drop below the hold-in value, the starter will Multiple Start-Stop Stations. Extra start-stop pushbutton
drop out. When the voltage is restored, the starter will stations can be added as shown in Fig. 6. The stop
immediately pick up since the pushbutton has remained pushbuttons should be connected in series and the start
closed. buttons in parallel. Note that only a single seal-in M
contact is required around the multiple start pushbuttons to
Maintained start-stop circuits should only be used in the maintain the circuit to the motor starter coil.
application of heating, lighting and other such non-
mechanical applications. This circuit would not be used STOP STOP STOP START OL
with rotating or moving equipment due to the potential L1 M L2
hazard of an unwanted restart when power is restored. START
UNDERVOLTAGE PROTECTION may be provided in START
a circuit and assures that a magnetic controller will not
restart after a power interruption until the operator M
initiates the action with a pushbutton or other device.
Fig. 6. Multiple stations used with momentary start-stop circuit. Stop
Momentary Start-Stop. In Fig. 5 we have a momentary buttons are wired in series and start buttons in parallel.
start-stop control circuit. Here, the safety feature of under-
voltage protection is provided. The operator must push the TWO & THREE WIRE CIRCUITS
start button to reenergize the starter after it has opened due
to undervoltage release as compared to the starter in Fig. 4 The terms two-wire and three-wire control are frequently
which will energize as soon as voltage is restored. This is used — but not always understood. Using the basic circuits
accomplished by a holding interlock on the starter and shown in Figs. 7 and 8, let us clarify the origin of these
momentary actuated pushbuttons — as differentiated from two expressions.
the maintained type used in Fig. 4. MOTOR STARTER COIL
1 2
L1 M L2
STOP START OL FLOAT SWITCH OL CONTACTS
L1 M L2 Fig. 7. Two-wire control circuit. Two wires are connected to the float
switch energizing the magnetic starter.

M
Fig. 5. Momentary Start-Stop Circuit showing holding interlock and
momentary actuated pushbuttons .

Page 3 of 8
Schematics Made Easy
Two-wire control is so named because only two wires (as closed contact of the reverse (R) contactor is used in the
shown in Fig. 7) are connected to the pilot device that forward (F) contactor coil circuit.
energizes the magnetic controller. In the diagram, the pilot Figure 10 shows an interlock which mounts on the starter
device shown is a normally open float switch used with a and is actuated whenever the starter is operated. These
pump motor starter. It energizes the motor starter only as normally closed electrical interlocks are shown mounted
long as It remains closed. This type of circuit provides between the forward and reverse starter arc boxes, in
undervoltage release but not undervoltage protection, since Figure 9.
a holding interlock is not used. The motor starter would
drop out on loss of voltage and then immediately pick up
again (without operator control) upon restoration of power
— provided the float switch had remained in the closed
position.
1 3 STARTER COIL
MOTOR
STOP START
L1 M L2
2 OL CONTACTS
Fig. I Normally closed (NC) auxiliary electrical interlock as mounted
on reversing starter in Fig. 9 between both arc boxes. May also be
M normally open (NO) for other applications .
Fig. 8. Three-wire control circuit. Three wires must be connected to There are two types of reversing circuits: Forward-
the pilot devices to energize the magnetic starter.
Reverse Compelling and Forward-Reverse Optional.
Three-wire control, (Fig. 8), gets its name from the three
wires that must be connected to the pilot device used to Forward-Reverse Compelling — Compelling circuits are
operate the motor starter. Notice here we have the basic used with motors which are not instantly reversible. These
momentary start-stop circuit shown in Fig. 5 which motors are brought to a stop before changing direction of
provides the undervoltage protection feature. rotation. In Fig. 11 depressing the forward push button will
energize the forward contactor coil (F), causing the motor
REVERSING CIRCUITS — Three phase to rotate forward. At the same time, it opens the normally
squirrel-cage motors are particularly suited to reversal of closed (F) contact in the reverse contactor coil (R) circuit
rotation by simply interchanging two of the line and closes the normally open (F) contact around the
conductors supplying the motor. This is commonly done forward pushbutton to seal-in the circuit. As long as the
by using two separate contactor assemblies — one for forward contactor is picked up, depressing the reverse
forward rotation and the other to reconnect for reverse pushbutton will have no effect. This is because the (F)
rotation. contact is open in the reverse coil circuit.
The circuit derives its name because the operator is
compelled to depress the stop pushbutton before he can
change direction of rotation. Once the forward contactor
has dropped out and reclosed its normally closed contact
(F) in the reverse coil circuit, the rotation of the motor can
be started in the reverse direction.
Limit switches (LS) are shown in this circuit since it is
sometimes used for equipment such as overhead doors,
which are stopped with a limit switch at the end of the
door travel.
STOP FOR.
L1 F L2
LS R OL
Fig. 9. Horizontal reversing magnetic starter with mechanical and F
electrical interlocks. REV. LS F
R
R
A reversing starter is electrically and mechanically
Fig. 11. Forward-Reverse Compelling Circuit. Operator is compelled
interlocked so that both contactors cannot close at the same to depress stop button before changing motor rotation.
time and cause a dead short circuit. Mechanical
interlocking is done by means of an interference
mechanism which blocks the operation of the open
contactor when the other one is closed. Electrical
interlocking — known as “cross electrical interlocking” --
is done by auxiliary interlocks on each contactor. A
normally closed contact of the forward (F) contactor is
used in the reverse (R) contactor coil circuit. A normally
Page 4 of 8
Schematics Made Easy

Forward-Reverse Optional — The optional circuit in Speed Compelling because the operator is compelled to
Fig. 13 is similar to the compelling circuit with one start in the lower speed.
exception It utilizes a pushbutton with both normally open LOW HIGH
and normally closed contacts such as shown in Fig. 12. L1 L L2
STOP HIGH H L-OLH-OL
Each pushbutton with two sets of contacts is indicated by
the dotted lines connecting the two parts of the single H
CR L CR L
buttons. The normally closed contact on the forward push H
button is connected in the reverse contactor coil circuit and CR
the normally closed contact of the reverse pushbutton in Fig. 14. Two Speed Compelling Circuit. Motor must be started in low
speed. Stop button must be pushed before going from high to low.
the forward coil circuit.
A control relay (Fig. 15)— designated as CR in the
diagram and referred to as a compelling relay — ensures
that the motor is started in the low speed. The relay has
two normally open contacts. One is to seal it in after being
energized through a contact on the low-speed starter (L).
The other is located in the high-speed starter coil circuit to
prevent initial start on high speed. Upon changing from
low to high speed note that the low speed starter coil
circuit is opened by the normally closed contact of the
high- speed pushbutton.

Fig. 12. Pushbutton with Double Contacts.

With the motor running forward, pushing the reverse
pushbutton will open the circuit to the forward contactor
and cause it to drop out and close its normally closed (F)
contact in the reverse contactor coil circuit. The motor will
immediately be connected for reverse rotation. It will seal-
in and operate continuously in this direction until either
stopped with the stop pushbutton, or changed to the
forward direction again.
Fig. 15. Control Relay (CR) with 2-pole contact block and magnetic
Note that it is not necessary to push the stop button before operator. Poles may be either Normally Open or Normally Closed.
changing directions as in the compelling circuit shown in
Two-Speed Non-Compelling — These circuits are used in
Fig. 11. Thus the terminology, “Forward-Reverse
applications where the motor may be started in either high
Optional.” For this application, motors must be de signed
or low speeds (Fig. 16). Speed can also be changed during
to go directly from full speed in one direction to full speed
operation between low and high by the operator, without
in the other direction.
having to first bring the motor to a stop. This circuit is
STOP STOP FOR. similar to the Forward-Reverse Optional circuit shown in
L1 F L2 Fig. 13 and utilizes both normally open and normally
LS R OL
F closed contacts on each of the low and high speed
REV. LS F pushbuttons.
R
FOR. R STOP STOP HIGH
L1 H L2
Fig. 13. Optional Forward-Reverse Circuit. Stop button need not be H L L-OLH-OL
pushed when changing direction.
HIGH LOW H
L
MULTI-SPEED CIRCUITS. Control of two- L
speed motors, both single and two-winding, is Fig. 16. Two-Speed Non-Compelling Circuit. For applications where
accomplished by the following two circuits — depending motor may be started in high or low speeds.
on application requirements. The common types of two-
speed circuits are known as “Compelling” and “Non-
Compelling.”
Two-Speed Compelling — The circuit in Fig. 14 is used
in applications requiring: ( that the motor be started in low
speed before going to high speed, and (2) that the motor
not be switched from high speed to low speed with out first
depressing the stop pushbutton. This is known as Two-

Page 5 of 8
Schematics Made Easy

SEQUENCE STARTING. Often, motors

controlled with separate starters must be started in
sequence from a single start-stop pushbutton station. This
can be done in two ways — as shown in Figs. 17 and 19—
depending on application requirements.
Sequence Start by Auxiliary Contacts — In Fig. 17, STOP START
L1 M1 L2
auxiliary contacts on the motor starters are used to provide M1 M1 OLOLOL
automatic sequence start from a single pushbutton station. M2
This ensures that motor No. 1 must be running before TR1 M2
motor No. 2 is started and that motors 1 and 2 must be in M3
operation before motor No. 3 can start. All the overload TR2
relay contacts are wired in series so that an overload Fig. 19. Timed Sequence Start Circuit uses adjustable time delay
relays. One motor comes up to speed before second is started.
condition on any one of the motors will shut down the
complete system. This type of circuit is used to permit one motor to come up
to speed before the second motor is thrown on the line. Its
STOP START action prevents heavy line surges which result when more
L1 M1 L2
M1 OLOLOL than one motor is started at once on lines that do not have
M1 sufficient capacity. Proper adjustment of the time delay
M2
relays permits the power regulating equipment to recover
M2 between automatic starting of multiple motors — and
M3 prevents serious dips in line voltages.
Fig. 17. Sequence start with auxiliary contacts on the motor starters.
Sequence start activated from a single pushbutton station. Individual pneumatic timing heads, operated directly from
Timed Sequence Start — The timed sequence start circuit the movement of the magnetic starter armatures, can also
in Fig. 19 employs time delay relays with their coils be used on some types of starters (Fig. 20). They eliminate
connected in parallel with the motor starter coils. Their the need for time delay relay coils.
time delay contacts provide the automatic sequence
starting of the motors.

Fig. 20. Starter with timer head accessory operated from starter
armature.
In summary . . . it can be readily seen that although wiring
diagrams may seem to be complicated and unwieldy they
need not be. Much of the confusion and mystery can be
Fig. 18. Solenoid operated adjustable time delay relay. removed by simply breaking the over-all control diagrams
into their basic circuits.
The power circuit furnishes power for the motor and load.
The individual control circuits usually operates only one
motor controller function.

Page 6 of 8
Schematics Made Easy

SYMBOLS CHART
CIRCUIT INTERRUPTER
CIRCUIT BREAKER LIMIT SWITCH
DISCONNECT SPRING RETURN MAINTAINED
Normally Open Normally Closed Neutral Position
Thermal

NP

Held Closed Held Open

LIQUID LEVEL VACUUM & PRESSURE TEMPERATURE ACTIVATED FLOW (AIR, WATER, ETC._
Normally Open Normally Closed Normally Open Normally Closed Normally Open Normally Closed Normally Open Normally Closed

PUSH BUTTONS FOOT SWITCH

Normally Open Normally Closed Double Circuit Mushroom Head Maintained Normally Open Normally Closed

SELECTOR SWITCH LAMPS TIME DELAY CONTACT

PUSH TO TEST Normally Open Normally Open Normally Closed Normally Closed
J K L J–K-L
A1
A2 J K L R
TC TO TO TC
A1 x
B1 A2 x OR OR OR OR
B2 B1 x DENOTE COLOR BY LETTER
B2 x
x INDICATES CONTACTS CLOSED

GENERAL CONTACTS CONDUCTORS MAGNET COIL

CONTROL TRANSFORMER METER

Normally Open Normally Closed Not Connected Connected

H3 H2
H1 H4
VM

X2 X1
AM

GROUND FULL WAVE RECTIFIER

HORN, SIREN BELL, BUZZER MOTOR OVERLOAD RELAY FUSE

AC 3 Phase

DC DC
MOTOR
AC

AUTO TRANSFORMER RESISTOR LOCATION OF RELAY CONTACTS

Adjustable Fixed 1CR (2 – 3 – 4)
1
NUMBERS IN PARENTHESIS DESIGNATE THE LOCATION
1CR OF RELAY CONTACTS. A LINE UNDERNEATH A LOCATION NUM
2
RES 1 RES
1CR
3
1CR
4

Page 7 of 8
Schematics Made Easy
EXAMPLES:
L1 START L2
1 STOP 2 3 OL
M M
Fig. 1. Three Wire Control Giving Low Voltage Protection Single Two
Button Pushbutton Station
L1 FOR LS L2
1STOP REV 2 FOR 6R OL
L1 START L2 F
OL F
1 STOP STOP STOP 2 3
M
START REV REV LS
FOR 4 5 7F R
R
START Fig. 8. Three Wire Control for Instant Reversing Applications Using
Single Three Button Pushbutton
M Station
Fig. 2. Three Wire Control Giving Low Voltage Protection Multiple Two
Button Pushbutton Station
L1 FOR FOR LS L2
1 STOP 2 3 R 6 8 OL
L1 SAFE START L2 F
1 STOP 2 3 OL F
M REV LS
RUN M REV
Fig. 3. Three Wire Control Giving Low Voltage Protection with Safe-Run 5 F7 9
4 R
Selector Switch R
Fig. 9. Three Wire Control for Reversing Using Single Three Button
L1 START L2 Pushbutton Station
1 STOP 3 OL
M
JOG 2 M L1 FOR LS L2
SLOWFAST
RUN 1 STOP 4 2 6 8 OL
S
Fig. 4. Three Wire Control for Jog or Run Using Start- Stop Pushbuttons
and Jag-Run Selector Switch F 5 CR S
CR S F
CR
L1 JOG L2 Fig. 10. Control for Two Speed with a Compelling Relay to Insure
1 STOP 2 4 OL Starting on Slow Speed
M
CR
L1 L2
START FOR RFOR LS
3 1STOP REV 2 3 6 8 OL
F
CR F
CR M
Fig. 5. Control for Jogging-Start-Stop All with Push buttons FOR 4 REV5 FREV
7
LS
9
R
L1 OFF L2 R
HAND AUTO 3 OL HIGH 10 LO
M HI
OFF 11 HI
AUTOMATIC SWITCH LO
Fig. 6. Two Wire Control Giving Low Voltage Release Only Using LOW
Hand-Off-Auto Selector Switch Fig. 11. Control for Two Speed Reversing Starter Forward, Reverse,
Stop, with High, Law Selector Switch
L1 FOR FOR LS L2
1 R 6 OL L1 RUN-JOG
3 8 F 1 STOP 3 OL L2
M
REV REV LS
5 F 7 9 R 2M
Fig. 12. Selector Push Contacts as shown for “Run” (three wire operation
Fig. 7. Two Wire Control for Reversing Jogging. Using Single Two rotate switch sleeve and selector contact opens between “2’ and “Stop”
Button Pushbutton Station button (two wire operation).

Page 8 of 8