File 0140 L1 L2 L3 GND AC OFF L1A1 B1 START L2 13 21 L1 ON 15 B2 HUF11 H3460 VH2UF2 H4 H1 H3230 VH2 H4 Supply voltage 1BS1TB O 2BP3STO1P6S1T51O8P 2SSTTMAARRTT 3 M OLH 14LOADO22range X3 X2Green X1 115 VX2 ESlheicetlrdOoespdtta iTotinrcaaanll lsCyfoornmneerction 1168 BA32 ML2 Levels X1AC L2 R 1 2 4 F F PoOwner F F Location 5 6 8 U U U U Status 9 10 12 3 5 6 4 (N.O. or N.C.) 13 21 31 43 53 13 (–) 14 (+) X1A X2A Optional A1/+1525Z1 Z2 14 22 32 44 54 A1 B1 15 B2 HCCCFPALLLIUBAAAZSESSSAHRSSSR BDOIII IIUG IOPGTRTURTIOSCOO ULUNPOP,SCS AA E,T ,B IFO, N&C S G& D NONHAFTIRZBAAENRRSD OCOPEUTISVIC ELROCATIONS Supply voltage B11B6 2B3 16B13518 L H 16 182628A2/– SLIEMLIET CSTWOIRTC SHW, IETTCCH., CLASS 9005 TYPE FT 18 A2 M2 Levels Vs FIBER OPTIC CABLE FIBER OPTIC CABLE ELECTRICAL A1 A2 1L1 3L25L3 BA5E0OCL1ECU-C5ON TODRRADFIC RATAYNHL CES EC EN3 OAWALDTI TETIOHON ABARELCT IOINCNLNEECTIONS AA12 LLL132 CIRCUIT BREAKEROR DISCONNECT SWITCH MMM 13CCTT TTT231 MOTOR L1 L2 L3 T1T2T3 1 OVSEORLLIODA SDT RATEELAY TO 120 V SEPARATE CONTROL 2T1 4T2 6T3 MOTOR 2 T1 T2 T3 STOP STMART M OT* *OwcaonhTnde di nsMi taaiGo nnsO w oe ovixtencisrhlytt es)th m(aTpty eoprpeae tMunrsFeO Wiring Diagram Book TRADEMARKS QWIK-STOP® and ALHPA-PAK® are registered trademarks of Square D. NEC® is a registered trademark of the National Fire Protection Association. COPYRIGHT NOTICE © 1993 Square D. All rights reserved. This document may not be copied in whole or in part, or trans- ferred to any other media, without the written permission of Square D. PLEASE NOTE: Electrical equipment should be serviced only by qualified electrical maintenance personnel, and this document should not be viewed as sufficient instruction for those who are not otherwise qualified to operate, service or maintain the equipment discussed. Although reasonable care has been taken to pro- vide accurate and authoritative information in this document, no responsibility is assumed by Square D for any consequences arising out of the use of this material. Table of Contents Standard Elementary Diagram Symbols.....................1-3 Sensing Relays...............................................................30 RM2 LA1/LG1 30 NEMA and IEC Markings and Schematic Diagrams......4 Control and Power Connection Table 4 IEC Relays..................................................................31-32 IEC D-Line Control Relays 31 Terminology......................................................................5 Class 8501 32 Examples of Control Circuits..........................................6 Type P Contactors.....................................................33-35 2-Wire Control 6 Class 8502 33-35 3-Wire Control 6-9 Class 8702 35 Shunting Thermal Units During Starting Period 10 Overcurrent Protection for 3-Wire Control Circuits 11 Type T Overload Relays............................................33-35 Class 9065 33-35 AC Manual Starters and Manual Motor Starting Switches...........................................................12 Type S AC Magnetic Contactors..............................36-40 Class 2510 12 Class 8502 36-40 Class 2511 and 2512 13 IEC Contactors..........................................................41-42 2-Speed AC Manual Starters and IEC Motor Protectors......................................................14 IEC Contactors and Auxiliary Contact Blocks 41 Input Modules and Reversing Contactors 42 Class 2512 and 2520 14 GV1/GV3 14 Type S AC Magnetic Starters...................................43-50 Drum Switches................................................................15 Class 8536 43-50 8538 and 8539 45,49 Class 2601 15 1-Phase, Size 00 to 3 43 2-Phase and 3-Phase, Size 00 to 5 44 DC Starters, Constant and Adjustable Speed..............16 3-Phase, Size 6 45 Class 7135 and 7136 16 3-Phase, Size 7 46 3-Phase Additions and Special Features 47-50 Reversing DC Starters, Constant and Adjustable Speed...........................................................17 Integral Self-Protected Starters...............................51-57 Class 7145 and 7146 17 Integral 18 State of Auxiliary Contacts 51-52 Integral 32 and 63 State of Auxiliary Contacts 53-54 Mechanically Latched Contactors................................18 Wiring Diagrams 55-57 Class 8196 18 Type S AC Combination Magnetic Starters............58-59 Medium Voltage Motor Controllers..........................18-25 Class 8538 and 8539 58-59 3-Phase, Size 0-5 58 Class 8198 18-25 3-Phase Additions and Special Features 59 Solid State Protective Relays...................................26-27 Reduced Voltage Controllers...................................60-66 Class 8430 26-27 Class 8606 Autotransformer Type 60-61 Class 8630 Wye-Delta Type 62-63 General Purpose Relays................................................28 Class 8640 2-Step Part-Winding Type 64 Class 8501 28 Class 8647 Primary-Resistor Type 65 Class 8650 and 8651 Wound-Rotor Type 66 NEMA Control Relays.....................................................29 Class 8501 and 9999 29 Solid State Reduced Voltage Starters..........................67 Class 8660 ALPHA PAK®, Type MD-MG 67 General Purpose Relays................................................30 Class 8501 30 Solid State Reduced Voltage Controllers...............68-70 Class 8660 Type MH, MJ, MK and MM 68-70 ® i Table of Contents Type S AC Reversing Magnetic Starters71-72 Pneumatic Timing Relays and Solid State Class 873671-72 Industrial Timing Relays95-96 2- and 3-Pole71 Class 905095-96 3- and 4-Pole72 Timers97 Type S AC 2-Speed Magnetic Starters73-76 Class 905097 Class 881073-76 Special Control Circuits75-76 Transformer Disconnects98 Class 907098 Multispeed Motor Connections76-77 1- Phase76 Enclosure Selection Guide99 3-Phase76-77 Conductor Ampacity and Conduit Tables100-101 Programmable Lighting Controllers78 Class 886578 Wire Data102 AC Lighting Contactors79-81 Electrical Formulas103-104 Class 890379-81 Load Connections79 Control Circuit Connections80 Panelboard Type Wiring81 Electronic Motor Brakes81-82 List of Tables Class 8922 QWIK-STOP®81-82 Table 1 Standard Elementary Diagram Symbols 1 Table 2 NEMA and IEC Terminal Markings 4 Duplex Motor Controllers82 Table 3 NEMA and IEC Controller Markings and Class 894182 Elementary Diagrams 4 Table 4 Control and Power Connections for Fiber Optic Transceivers82 Across-the-Line Starters, 600 V or less4 Class 900582 Table 5 Motor Lead Connections 64 Photoelectric and Inductive Proximity Switches83 Table 6 Enclosures for Non-Hazardous Locations 99 Class 900683 Table 7 Enclosures for Hazardous Locations 99 Table 8 Conductor Ampacity100 Photoelectric and Proximity Sensors84-89 Table 9 Ampacity Correction Factors 101 XS, XSC, XSF and XSD84 Table 10 Adjustment Factors 101 XS and XTA85 SG, ST and XUB86 Table 11 Ratings for 120/240 V, 3-Wire, XUM, XUH, XUG, XUL and XUJ87 Single-Phase Dwelling Services101 XUE, XUR, XUD, XUG and XUE S88 Table 12 AWG and Metric Wire Data 102 XUV89 Table 13 Electrical Formulas for Amperes, Horsepower, Kilowatts and KVA 103 Limit Switches and Safety Interlocks90-92 Table 14 Ratings for 3-Phase, Single-Speed, Class 900791 Full-Voltage Magnetic Controllers XCK and MS92 for Nonplugglng and Nonjogging Duty 103 Table 15 Ratings for 3-Phase, Single-Speed, Pressure Switches and Transducers93 Full-Voltage Magnetic Controllers for Plug- Class 9012, 9013, 9022 and 902593 Stop, Plug-Reverse or Jogging Duty 104 Table 16 Power Conversions 104 Level Sensors and Electric Alternators94 Class 9034 and 903994 ® ii Standard Elementary Diagram Symbols The diagram symbols in Table 1 are used by Square D and, where applicable, conform to NEMA (National Electrical Manufacturers Association) standards. Table 1 Standard Elementary Diagram Symbols SWITCHES SELECTORS Disconnect Circuit Interrupter Circuit Breakers Circuit Breakers 2-Position Selector Switch w/ Thermal OL w/ Magnetic OL J K A1 A2 J K A1 A2 Pressure & Liquid Level Switches Temperature Vacuum Switches Actuated Switches 3-Position Selector Switch N.O. N.C. N.O. N.C. N.O. N.C. K J L A1 A2 J K L Limit Switches Speed (Plugging) Anti-Plug A1 N.O. N.C. F F F A2 2-Position Selector Push Button A B Held Closed Held Open 1 2 3 4 R R Selector Push Contacts Position Button 1-2 3-4 Flow Switches Foot Switches Free N.O. N.C. N.O. N.C. A Depressed Free B Depressed = contact closed PUSH BUTTONS – MOMENTARY CONTACT PUSH BUTTONS – MAINTAINED CONTACT N.O. N.C. N.O. & N.C. Mushroom Wobble Illuminated 2 Single 1 Double (double circuit) Head Stick Circuits Circuit R PILOT LIGHTS INSTANT OPERATING CONTACTS TIMED CONTACTS Non Push-to-Test Push-to-Test w/ Blowout w/o Blowout Contact action retarded after coil is: Energized Deenergized N.O. N.C. N.O. N.C. A N.O.T.C. N.C.T.O. N.O.T.O. N.C.T.C. G (indicate color by letter) 1 Standard Elementary Diagram Symbols Table 1 Standard Elementary Diagram Symbols (cont'd) INDUCTORS TRANSFORMERS Iron Core Air Core Auto Iron Core Air Core Current Dual Voltage OVERLOAD RELAYS AC MOTORS Thermal Magnetic Single Phase 3-Phase 2-Phase, 4-Wire Wound Rotor Squirrel Cage DC MOTORS Armature Shunt Field Series Field Commutating or (show 4 loops) (show 3 loops) Compensating Field (show 2 loops) WIRING Not Connected Connected Power Control Terminal Ground Mechanical Mechanical Connection Interlock Connection CAPACITORS RESISTORS Fixed Adjustable Fixed Heating Adjustable, Rheostat, Element by Fixed Taps Potentiometer or Adjustable Taps RES H RES RES SEMICONDUCTORS Diode or Half Tunnel Zener Bidirectional Triac SCR PUT Photosensitive Wave Rectifier Diode Diode Breakdown Diode Cell Full Wave NPN PNP UJT, UJT, Gate Turn-Of Rectifier Transistor Transistor N Base P Base Thyristor AC C C B2 B2 A + E E B B DC DC G B1 B1 E E K AC 2 Standard Elementary Diagram Symbols Table 1 Standard Elementary Diagram Symbols (cont'd) OTHER COMPONENTS Bell Annunciator Buzzer Horn, Alarm, Meter (indicate Siren,etc. type by letters) VM Battery Fuse Thermocouple Meter Shunt + – SUPPLEMENTARY CONTACT SYMBOLS SPST, N.O. SPST, N.C. SPDT Single Break Double Break Single Break Double Break Single Break Double Break DPST, 2 N.O. DPST, 2 N.C. DPDT Single Break Double Break Single Break Double Break Single Break Double Break IEC SYMBOLS Push Buttons Coil Aux. Contacts Contactor N.O. N.C. N.O. N.C. Breakers STATIC SWITCHING CONTROL Limit Switch, N.O., Static Control Static switching control is a method of switching electrical circuits without the use of contacts, primarily by solid state devices. To indicate static switching control, use the symbols shown in this table, enclosing them in a diamond as shown. TERMS SPST: Single Pole, Single Throw N.O.: Normally Open PUT: Programmable Unijunction Transistor SPDT: Single Pole, Double Throw N.C.: Normally Closed SCR: Silicon Controlled Rectifier DPST: Double Pole, Single Throw T.O.: Timed Open Triac: Bidirectional Triode Thyristor DPDT: Double Pole, Double Throw T.C.: Timed Closed UJT: Unijunction Transistor 3 NEMA and IEC Markings and Schematic Diagrams Control and Power Connection Table Table 2 NEMA and IEC Terminal Markings NEMA L1 L2 L3 T1 T2 T3 No specific No standard Alphanumeric, corresponding marking designation to incoming line and motor terminal designations Power Terminals Control Terminals Coil Terminals IEC 1 3 5 A1 A1 A1 A3 A1 B1 14 22 2 4 6 A2 A2 A3 A2 A2 B2 2-digit numeric, 1st Single digit numeric, designates sequence, One Tapped Tapped Two odd for supply lines, 2nd designates function Winding Winding Winding Windings even for load connections (1-2 for N.C., 3-4 for N.O.) Power Terminals Control Terminals Coil Terminals Table 3 NEMA and IEC Controller Markings and Elementary Diagrams NEMA 3 1/L1 L2 L3 L1 L2 1 STOP 2 START 3 M OL 2 T1 T2 T3 Typical Controller Markings Typical Elementary Diagram IEC A1 1 3 5 13 21 11 STOP 12 23 START 24 A1 A2 95 96 A2 2 4 6 14 22 23 24 Typical Controller Markings Typical Elementary Diagram Table 4 Control and Power Connections for Across-the-Line Starters, 600 V or less (From NEMA standard ICS 2-321A.60) 1-Phase 2-Phase, 4-Wire 3-Phase L1, L3: Phase 1 Line Markings L1, L2 L1, L2, L3 L2, L4: Phase 2 Ground, when used L1 is always ungrounded — L2 Motor Running 1 element L1 — — Overcurrent, 2 element — L1, L4 — units in: 3 element — — L1, L2, L3 Control Circuit Connected to L1, L2 L1, L3 L1, L2 For Reversing, Interchange — L1, L3 L1, L3 Lines 4 Terminology WIRING DIAGRAM A wiring diagram shows, as closely as possible, the actual location of all component parts of the device. The open terminals (marked by an open circle) and arrows represent connections made by the user. Since wiring connections and terminal markings are shown, this type of diagram is helpful when wiring the device or tracing wires when troubleshooting. Bold lines denote the power circuit and thin lines are used to show the control circuit. Black wires are conventionally used in power circuits and red wire in control circuits for AC magnetic equipment. A wiring diagram is limited in its ability to completely convey the controller’s sequence of operation. The elementary diagram is used where an illustration of the circuit in its simplest form is desired. ELEMENTARY DIAGRAM An elementary diagram is a simplified circuit illustration. Devices and components are not shown in their actual positions. All control circuit components are shown as directly as possible, between a pair of vertical lines representing the control power supply. Components are arranged to show the sequence of operation of the devices and how the device operates. The effect of operating various auxiliary contacts and control devices can be readily seen. This helps in troubleshooting, particularly with the more complex controllers. This form of electrical diagram is sometimes referred to as a “schematic” or “line” diagram. 5 Examples of Control Circuits 2- and 3-Wire Control Elementary Diagrams Low Voltage Release and Low Voltage Protection are the basic control circuits encountered in motor control applications. The simplest schemes are shown below. Other variations shown in this section may appear more complicated, but can always be resolved into these two basic schemes. Note: The control circuits shown in this section may not include overcurrent protective devices required by applicable electrical codes. See page 11 for examples of control circuit overcurrent protective devices and their use. Low Voltage Release: Low Voltage Protection: 2-Wire Control 3-Wire Control FIG. 1 L1 L2 FIG. 2 L1 L2 1 3 M OL 1 STOP 2 START 3 M OL M PILOT DEVICE SUCH AS LIMIT SWITCH, PRESSURE SWITCH, ETC. Low voltage release is a 2-wire control scheme using a Low voltage protection is a 3-wire control scheme using maintained contact pilot device in series with the starter coil. momentary contact push buttons or similar pilot devices to energize the starter coil. This scheme is used when a starter is required to function automatically without the attention of an operator. If a power This scheme is designed to prevent the unexpected starting of failure occurs while the contacts of the pilot device are closed, motors, which could result in injury to machine operators or the starter will drop out. When power is restored, the starter damage to the driven machinery. The starter is energized by will automatically pickup through the closed contacts of the pressing the Start button. An auxiliary holding circuit contact on pilot device. the starter forms a parallel circuit around the Start button contacts, holding the starter in after the button is released. If a The term “2-wire” control is derived from the fact that in the power failure occurs, the starter will drop out and will open the basic circuit, only two wires are required to connect the pilot holding circuit contact. When power is restored, the Start button device to the starter. must be operated again before the motor will restart. The term “3-wire” control is derived from the fact that in the basic circuit, at least three wires are required to connect the pilot devices to the starter. 2-Wire Control: 3-Wire Control: Maintained Contact Hand-OFF-Auto Selector Switch Momentary Contact Multiple Push Button Station FIG. 3 L1 L2 FIG. 4 L1 START L2 A1 I A2 I HANDOFF AUTO M OL 1 STOP STOP STOP 2START 3 M OL A1 3A START 1A 2A A2 M 2-WIRE CONTROL DEVICE A Hand-Off-Auto selector switch is used on 2-wire control When a motor must be started and stopped from more than one applications where it is desirable to operate the starter manually location, any number of Start and Stop push buttons may be as well as automatically. The starter coil is manually energized wired together. It is also possible to use only one Start-Stop when the switch is turned to the Hand position and is station and have several Stop buttons at different locations to automatically energized by the pilot device when the switch is serve as an emergency stop. in the Auto position. 6