of 109 /109
Wiring Diagram Book L1 F U 1 460 V F U 2 GND L3 L2 H1 H3 H2 H4 F U 3 X1A F U 4 F U 5 X2A R Power On Optional 115 V X1 X2 230 V H1 H3 H2 H4 Optional Connection Electrostatically Shielded Transformer F U 6 OFF ON M L1 L2 2 1 OL STOP M START 3 START START STOP STOP FIBER OPTIC TRANSCEIVER CLASS 9005 TYPE FT FIBER OPTIC PUSH BUTTON, SELECTOR SWITCH, LIMIT SWITCH, ETC. FIBER OPTIC CABLE ELECTRICAL CONNECTIONS BOUNDARY SEAL TO BE IN ACCORDANCE WITH ARTICLE 501-5 OF THE NATIONAL ELECTRICAL CODE HAZARDOUS LOCATIONS NONHAZARDOUS LOCATIONS CLASS I GROUPS A, B, C & D CLASS II GROUPS E, F & G CLASS III FIBER OPTIC CABLE L1 L2 L3 1 3 5 A1 A2 T1 T2 T3 2 4 6 OR DISCONNECT SWITCH L1 L2 L3 CIRCUIT BREAKER START STOP M OT* T1 T2 T3 M M SOLID STATE OVERLOAD RELAY 1CT M M MOTOR 3CT TO 120 V SEPARATE CONTROL * OT is a switch that opens when an overtemperature condition exists (Type MFO and MGO only) T1 T3 MOTOR 3 2 L2 T2 L3 T3 T2 L1 1 T1 13 14 43 44 53 54 31 32 21 22 Status (N.O. or N.C.) Location A1 15 B1 B2 16 18 B3 A2 B1 B3 15 16 18 Supply voltage L M H 2 Levels B2 21 22 13 14 X1 X3 AC L1 L2 LOAD Orange X2 Green AC 1 5 9 2 6 10 4 8 12 14 (+) 13 (–) A1/+ 15 25 Z1 Z2 16 18 A2/– V s 26 28 A1 A2 File 0140

Wiring Diagram Book

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Page 1: Wiring Diagram Book

Wiring Diagram Book

A1

15

B1

B2

16

18

B3

A2

B1 B3 15

16 18Sup

ply

volta

ge

LM

H

2 Levels

B2

L1

FU1

460 V

FU2

GNDL3L2

H1 H3 H2 H4

FU3

X1A

FU4

FU5

X2A

R

PowerOn

Optional

115 VX1 X2

230 VH1 H3 H2 H4

Optional Connection

ElectrostaticallyShielded Transformer

FU6

OFF

ON M

L1 L2

21OLSTOP

M

START3

START

START

STOPSTOP

FIBER OPTICTRANSCEIVER

CLASS 9005 TYPE FT

FIBER OPTICPUSH BUTTON,SELECTOR SWITCH,LIMIT SWITCH, ETC.

FIBER OPTIC CABLEELECTRICALCONNECTIONS

BOUNDARY SEAL TO BE INACCORDANCE WITH ARTICLE501-5 OF THE NATIONALELECTRICAL CODE

HAZARDOUS LOCATIONS NONHAZARDOUS LOCATIONSCLASS I GROUPS A, B, C & DCLASS II GROUPS E, F & GCLASS III

FIBER OPTIC CABLE

L1 L2 L31 3 5

A1 A2

T1 T2 T32 4 6

OR

DIS

CO

NN

EC

T S

WIT

CHL1

L2

L3 CIR

CU

IT B

RE

AK

ER

STARTSTOP

M

OT*

T1

T2

T3

M

M

SOLID STATEOVERLOAD RELAY

1CT

M

M

MOTOR

3CT

TO 120 VSEPARATECONTROL

* OT is a switch that openswhen an overtemperaturecondition exists (Type MFOand MGO only)

T1 T3

MOTOR

3

2

L2

T2

L3

T3

T2L1

1

T1

13

14

43

44

53

54

31

32

21

22

Status(N.O. or N.C.)

Location

A1

15

B1

B2

16

18

B3

A2

B1 B3 15

16 18Sup

ply

volta

ge

LM

H

2 Levels

B2

21

22

13

14

X1

X3

ACL1

L2

LOAD

OrangeX2

Green

AC1

5

9

2

6

10

4

8

12

14 (+)13 (–)

A1/+ 15 25 Z1 Z2

16 18 A2/–

Vs

26 28

A1

A2

File 0140

Page 2: Wiring Diagram Book

© 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.

Electrical equipment should be serviced only by qualified electrical maintenance personnel, and thisdocument should not be viewed as sufficient instruction for those who are not otherwise qualified tooperate, 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 bySquare D for any consequences arising out of the use of this material.

COPYRIGHT NOTICE

PLEASE NOTE:

QWIK-STOP

®

and ALHPA-PAK

®

are registered trademarks of Square D.

NEC

®

is a registered trademark of the National Fire Protection Association.TRADEMARKS

Page 3: Wiring Diagram Book

Table of Contents

i

®

Standard Elementary Diagram Symbols .....................1-3

NEMA and IEC Markings and Schematic Diagrams...... 4

Control and Power Connection Table 4

Terminology...................................................................... 5

Examples of Control Circuits .......................................... 6

2-Wire Control 63-Wire Control 6-9Shunting Thermal Units During Starting Period 10Overcurrent Protection for 3-Wire Control Circuits 11

AC Manual Starters and Manual Motor Starting Switches ........................................................... 12

Class 2510 12Class 2511 and 2512 13

2-Speed AC Manual Starters andIEC Motor Protectors...................................................... 14

Class 2512 and 2520 14GV1/GV3 14

Drum Switches................................................................ 15

Class 2601 15

DC Starters, Constant and Adjustable Speed.............. 16

Class 7135 and 7136 16

Reversing DC Starters, Constant andAdjustable Speed ........................................................... 17

Class 7145 and 7146 17

Mechanically Latched Contactors ................................ 18

Class 8196 18

Medium Voltage Motor Controllers..........................18-25

Class 8198 18-25

Solid State Protective Relays...................................26-27

Class 8430 26-27

General Purpose Relays ................................................ 28

Class 8501 28

NEMA Control Relays..................................................... 29

Class 8501 and 9999 29

General Purpose Relays ................................................ 30

Class 8501 30

Sensing Relays............................................................... 30

RM2 LA1/LG1 30

IEC Relays.................................................................. 31-32

IEC D-Line Control Relays 31Class 8501 32

Type P Contactors..................................................... 33-35

Class 8502 33-35Class 8702 35

Type T Overload Relays............................................ 33-35

Class 9065 33-35

Type S AC Magnetic Contactors.............................. 36-40

Class 8502 36-40

IEC Contactors .......................................................... 41-42

IEC Contactors and Auxiliary Contact Blocks 41Input Modules and Reversing Contactors 42

Type S AC Magnetic Starters ................................... 43-50

Class 8536 43-508538 and 8539 45,491-Phase, Size 00 to 3 432-Phase and 3-Phase, Size 00 to 5 443-Phase, Size 6 453-Phase, Size 7 463-Phase Additions and Special Features 47-50

Integral Self-Protected Starters ............................... 51-57

Integral 18 State of Auxiliary Contacts 51-52Integral 32 and 63 State of Auxiliary Contacts 53-54Wiring Diagrams 55-57

Type S AC Combination Magnetic Starters ............ 58-59

Class 8538 and 8539 58-593-Phase, Size 0-5 583-Phase Additions and Special Features 59

Reduced Voltage Controllers ................................... 60-66

Class 8606 Autotransformer Type 60-61Class 8630 Wye-Delta Type 62-63Class 8640 2-Step Part-Winding Type 64Class 8647 Primary-Resistor Type 65Class 8650 and 8651 Wound-Rotor Type 66

Solid State Reduced Voltage Starters .......................... 67

Class 8660 ALPHA PAK

®

, Type MD-MG 67

Solid State Reduced Voltage Controllers ............... 68-70

Class 8660 Type MH, MJ, MK and MM 68-70

Page 4: Wiring Diagram Book

Table of Contents

ii

®

Type S AC Reversing Magnetic Starters71-72

Class 873671-722- and 3-Pole713- and 4-Pole72

Type S AC 2-Speed Magnetic Starters73-76

Class 881073-76Special Control Circuits75-76

Multispeed Motor Connections76-77

1- Phase763-Phase76-77

Programmable Lighting Controllers78

Class 886578

AC Lighting Contactors79-81

Class 890379-81Load Connections79Control Circuit Connections80Panelboard Type Wiring81

Electronic Motor Brakes81-82

Class 8922 QWIK-STOP

®

81-82

Duplex Motor Controllers82

Class 894182

Fiber Optic Transceivers82

Class 900582

Photoelectric and Inductive Proximity Switches83

Class 900683

Photoelectric and Proximity Sensors84-89

XS, XSC, XSF and XSD84XS and XTA85SG, ST and XUB86XUM, XUH, XUG, XUL and XUJ87XUE, XUR, XUD, XUG and XUE S88XUV89

Limit Switches and Safety Interlocks90-92

Class 900791XCK and MS92

Pressure Switches and Transducers93

Class 9012, 9013, 9022 and 902593

Level Sensors and Electric Alternators94

Class 9034 and 903994

Pneumatic Timing Relays and Solid State Industrial Timing Relays95-96

Class 905095-96

Timers97

Class 905097

Transformer Disconnects98

Class 907098

Enclosure Selection Guide99

Conductor Ampacity and Conduit Tables100-101

Wire Data102

Electrical Formulas103-104

List of Tables

Table 1 Standard Elementary Diagram Symbols 1

Table 2 NEMA and IEC Terminal Markings 4

Table 3 NEMA and IEC Controller Markings and Elementary Diagrams 4

Table 4 Control and Power Connections forAcross-the-Line Starters, 600 V or less4

Table 5 Motor Lead Connections 64

Table 6 Enclosures for Non-Hazardous Locations 99

Table 7 Enclosures for Hazardous Locations 99

Table 8 Conductor Ampacity100

Table 9 Ampacity Correction Factors 101

Table 10 Adjustment Factors 101

Table 11 Ratings for 120/240 V, 3-Wire,Single-Phase Dwelling Services101

Table 12 AWG and Metric Wire Data 102

Table 13 Electrical Formulas for Amperes, Horsepower, Kilowatts and KVA 103

Table 14 Ratings for 3-Phase, Single-Speed,Full-Voltage Magnetic Controllers for Nonplugglng and Nonjogging Duty 103

Table 15 Ratings for 3-Phase, Single-Speed,Full-Voltage Magnetic Controllers for Plug-Stop, Plug-Reverse or Jogging Duty 104

Table 16 Power Conversions 104

Page 5: Wiring Diagram Book

1

Table 1 Standard Elementary Diagram Symbols

SWITCHES SELECTORS

PUSH BUTTONS – MOMENTARY CONTACT PUSH BUTTONS – MAINTAINED CONTACT

PILOT LIGHTS INSTANT OPERATING CONTACTS TIMED CONTACTS

The diagram symbols in Table 1 are used by Square D and, where applicable, conform to NEMA (National Electrical Manufacturers Association)standards.

Disconnect Circuit Interrupter Circuit Breakersw/ Thermal OL

Circuit Breakersw/ Magnetic OL

Limit Switches

Foot Switches

Pressure &Vacuum Switches

Liquid Level Switches TemperatureActuated Switches

Flow Switches

Speed (Plugging)

F F

R

F

R

Anti-Plug

N.O. N.C.

Held Closed Held Open

N.O. N.C.

N.O. N.C. N.O. N.C. N.O. N.C.

N.O. N.C.

J

A1

A2

K

J K

A1

A2

J

A1

K

A2

L

J K

A1

A2

L

A

2

4

B

1

3

ContactsSelectorPosition 1-2 3-4

A

B

PushButton

FreeDepressed

FreeDepressed

= contact closed

2-Position Selector Switch

3-Position Selector Switch

2-Position Selector Push Button

N.O. N.C. N.O. & N.C.(double circuit)

MushroomHead

WobbleStick

R

Illuminated 2 SingleCircuits

1 DoubleCircuit

A

Non Push-to-Test

G

Push-to-Test

(indicate color by letter)

N.O. N.C.

w/ Blowout

N.O. N.C.

w/o Blowout

N.O.T.C. N.C.T.O.

Energized

N.O.T.O. N.C.T.C.

DeenergizedContact action retarded after coil is:

Standard Elementary Diagram Symbols

Page 6: Wiring Diagram Book

2

INDUCTORS TRANSFORMERS

OVERLOAD RELAYS AC MOTORS

DC MOTORS

WIRING

CAPACITORS RESISTORS

SEMICONDUCTORS

Table 1 Standard Elementary Diagram Symbols (cont'd)

Iron Core Air Core Auto Iron Core Air Core Current Dual Voltage

Thermal Magnetic Single Phase 3-PhaseSquirrel Cage

2-Phase, 4-Wire Wound Rotor

Armature Shunt Field(show 4 loops)

Series Field(show 3 loops)

Commutating orCompensating Field

(show 2 loops)

Not Connected Connected Power Control Terminal Ground MechanicalConnection

MechanicalInterlock

Connection

AdjustableFixed Fixed

RES

HeatingElement

H

Adjustable,by Fixed Taps

RES

Rheostat,Potentiometer or Adjustable Taps

RES

Diode or HalfWave Rectifier

Full WaveRectifier

AC

DC+

DC

AC

TunnelDiode

ZenerDiode

BidirectionalBreakdown Diode

PhotosensitiveCell

Triac SCR PUT

NPNTransistor

B

C

E

PNPTransistor

B

C

E

UJT,N Base

EB2

B1

UJT,P Base

EB2

B1

Gate Turn-OfThyristor

G

A

K

Standard Elementary Diagram Symbols

Page 7: Wiring Diagram Book

3

OTHER COMPONENTS

SUPPLEMENTARY CONTACT SYMBOLS

IEC SYMBOLS

STATIC SWITCHING 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 ThrowSPDT: Single Pole, Double ThrowDPST: Double Pole, Single ThrowDPDT: Double Pole, Double Throw

N.O.: Normally OpenN.C.: Normally ClosedT.O.: Timed OpenT.C.: Timed Closed

PUT: Programmable Unijunction TransistorSCR: Silicon Controlled RectifierTriac: Bidirectional Triode ThyristorUJT: Unijunction Transistor

Table 1 Standard Elementary Diagram Symbols (cont'd)

Battery

AnnunciatorBell Buzzer Horn, Alarm,Siren,etc.

Meter (indicatetype by letters)

VM

Meter Shunt

+ –Fuse Thermocouple

Single BreakSPST, N.O.

Double Break Single BreakSPST, N.C.

Double Break Single BreakSPDT

Double Break

Single BreakDPST, 2 N.O.

Double Break Single BreakDPST, 2 N.C.

Double Break Single BreakDPDT

Double Break

Push Buttons Coil Aux. ContactsN.O. N.C.N.O. N.C.

ContactorBreakers

Limit Switch, N.O., Static Control

Standard Elementary Diagram Symbols

Page 8: Wiring Diagram Book

4

Table 2 NEMA and IEC Terminal Markings

Table 3 NEMA and IEC Controller Markings and Elementary Diagrams

NEMA

Power Terminals Control Terminals Coil Terminals

IEC

Power Terminals Control Terminals Coil Terminals

NEMA

Typical Controller Markings Typical Elementary Diagram

IEC

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

Line Markings

L1, L2L1, L3: Phase 1L2, L4: Phase 2

L1, L2, L3

Ground, when used

L1 is always ungrounded — L2

Motor Running Overcurrent, units in:

1 element2 element3 element

L1——

—L1, L4

——

L1, L2, L3

Control Circuit Connected to

L1, L2 L1, L3 L1, L2

For Reversing, Interchange Lines

— L1, L3 L1, L3

L1

T1

L2

T2

L3

T3

Alphanumeric, correspondingto incoming line and motor

terminal designations

No specificmarking

No standarddesignation

1

2

3

4

5

6

Single digit numeric,odd for supply lines,

even for load connections

14 22

2-digit numeric, 1stdesignates sequence,

2nd designates function(1-2 for N.C., 3-4 for N.O.)

A1

A2

A1

A2 A3

A1

A2

A3 A1

A2

B1

B2

OneWinding

TappedWinding

TappedWinding

TwoWindings

3

2

1/L1

T1

L2

T2

L3

T3

STOP OLSTART1 2 3

L1 L2M

1

2

3

4

5

6

13

14

21

22

A1

A2

STOP START11 23 2412

23 24

A1 A2 95 96

NEMA and IEC Markings and Schematic Diagrams

Control and Power Connection Table

Page 9: Wiring Diagram Book

5

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.

Terminology

Page 10: Wiring Diagram Book

6

Low Voltage Release:2-Wire Control

Low Voltage Protection:3-Wire Control

FIG. 1 FIG. 2

Low voltage release is a 2-wire control scheme using a maintained contact pilot device in series with the starter coil.

This scheme is used when a starter is required to function automatically without the attention of an operator. If a power failure occurs while the contacts of the pilot device are closed, the starter will drop out. When power is restored, the starter will automatically pickup through the closed contacts of the pilot device.

The term “2-wire” control is derived from the fact that in the basic circuit, only two wires are required to connect the pilot device to the starter.

Low voltage protection is a 3-wire control scheme using momentary contact push buttons or similar pilot devices to energize the starter coil.

This scheme is designed to prevent the unexpected starting of motors, which could result in injury to machine operators or damage to the driven machinery. The starter is energized by pressing the Start button. An auxiliary holding circuit contact on the starter forms a parallel circuit around the Start button contacts, holding the starter in after the button is released. If a power failure occurs, the starter will drop out and will open the holding circuit contact. When power is restored, the Start button

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:Maintained Contact Hand-OFF-Auto Selector Switch

3-Wire Control:Momentary Contact Multiple Push Button Station

FIG. 3 FIG. 4

A Hand-Off-Auto selector switch is used on 2-wire control applications where it is desirable to operate the starter manually as well as automatically. The starter coil is manually energized when the switch is turned to the Hand position and is automatically energized by the pilot device when the switch is in the Auto position.

When a motor must be started and stopped from more than one location, any number of Start and Stop push buttons may be wired together. It is also possible to use only one Start-Stop station and have several Stop buttons at different locations to serve as an emergency stop.

Low Voltage Release and Low Voltage Protection are the basic control circuits encountered in motor control applications. The simplest schemesare shown below. Other variations shown in this section may appear more complicated, but can always be resolved into these two basicschemes.

Note: The control circuits shown in this section may not include overcurrent protective devices required by applicable electrical codes. See page11 for examples of control circuit overcurrent protective devices and their use.

M

PILOT DEVICE SUCH ASLIMIT SWITCH,PRESSURE SWITCH, ETC.

L1 L2

31OL M

L1 L2

21OLSTOP

M

START3

M A1

A2

A1A2

I

HAND OFF

2-WIRE CONTROL DEVICE

IAUTO

L1 L2

3A

2A1A

OL

M

L1 L2

21OLSTOP

M

START3

START

START

STOPSTOP

Examples of Control Circuits

2- and 3-Wire ControlElementary Diagrams

Page 11: Wiring Diagram Book

7

3-Wire Control:Pilot Light Indicates when Motor is Running

3-Wire Control:Pilot Light Indicates when Motor is Stopped

FIG. 1 FIG. 2

A pilot light can be wired in parallel with the starter coil to indicate when the starter is energized, indicating the motor is running.

A pilot light may be required to indicate when the motor is stopped. This can be implemented by wiring a normally-closed auxiliary contact on the starter in series with the pilot light, as shown above. When the starter is deenergized, the pilot light illuminates. When the starter picks up, the auxiliary contact opens, turning off the light.

3-Wire Control:Push-to-Test Pilot Light Indicates when Motor is

Running

3-Wire Control:Illuminated Push Button Indicates when Motor is

Running

FIG. 3 FIG. 4

When the Motor Running pilot light is not lit, there may be doubt as to whether the circuit is open or whether the pilot light bulb is burned out. To test the bulb, push the color cap of the Push-to-Test pilot light.

The illuminated push button combines a Start button and pilot light in one unit. Pressing the pilot light lens operates the Start contacts. Space is saved by using a two-unit push button station instead of three.

3-Wire Control:Fused Control Circuit Transformer

3-Wire Control:Fused Control Circuit Transformer and Control Relay

FIG. 5 FIG. 6

As an operator safety precaution, a step-down transformer can be used to provide a control circuit voltage lower than line voltage. The diagram above shows one way to provide overcurrent protection for control circuits.

A starter coil with a high VA rating may require a control transform-er of considerable size. A control relay and a transformer with a low VA rating can be connected so the normally-open relay contact controls the starter coil on the primary or line side. Square D Size 5 Combination Starter Form F4T starters use this scheme.

M

L1 L2

21OLSTOP

M

START3

R

M

L1 L2

21OLSTOP

M

START3

G

M

M

L1 L2

21OLSTOP

M

START3

RTEST

M

L1 L2

21OLSTOP

M

START*3

R *

* Pushing on pilot light operates Start contacts.

M

L1

STOP

L2

FU1 FU2

M

OL

GROUND(If used)

START

CR

L1

STOP

L2

M

OLSTART

CR

M

GROUND(If used)

Examples of Control Circuits

3-Wire ControlElementary Diagrams

Page 12: Wiring Diagram Book

8

Jogging: Selector Switch and Start Push Button Jogging: Selector Push Button

FIG. 1 FIG. 2

Jogging, or inching, is defined by NEMA as the momentary operation of a motor from rest for the purpose of accomplishing small movements of the driven machine. One method of jogging is shown above. The selector switch disconnects the holding circuit contact and jogging may be accomplished by pressing the Start push button.

A selector push button may be used to obtain jogging, as shown above. In the Run position, the selector-push button provides normal 3-wire control. In the Jog position, the holding circuit is broken and jogging is accomplished by depressing the push button.

Jogging: Control Relay Jogging: Control Relay for Reversing Starter

FIG. 3 FIG. 4

When the Start push button is pressed, the control relay is energized, which in turn energizes the starter coil. The normally-open starter auxiliary contact and relay contact then form a holding circuit around the Start push button. When the Jog push button is pressed, the starter coil is energized (independent of the relay) and no holding circuit forms, thus jogging can be obtained.

This control scheme permits jogging the motor either in the forward or reverse direction, whether the motor is at standstill or rotating. Pressing the Start-Forward or Start-Reverse push button energizes the corresponding starter coil, which closes the circuit to the control relay.The relay picks up and completes the holding circuit around the Start button. As long as the relay is energized, either the forward or reverse contactor remains energized. Pressing either Jog push button will deenergize the relay, releasing the closed contactor. Further pressing of the Jog button permits jogging in the desired direction.

3-Wire Control:More than 1 Starter, 1 Push Button Station Controls all

3-Wire Control:Reversing Starter

FIG. 5 FIG. 6

When one Start-Stop station is required to control more than one starter, the scheme above can be used. A maintained overload on any one of the motors will drop out all three starters.

3-wire control of a reversing starter can be implemented with a Forward-Reverse-Stop push button station as shown above. Limit switches may be added to stop the motor at a certain point in either direction. Jumpers 6 to 3 and 7 to 5 must then be removed.

FPO 7-1

FPO 7-2

FPO 7-3 FPO 7-4

FPO 7-5 FPO 7-6

Examples of Control Circuits

3-Wire ControlElementary Diagrams

Page 13: Wiring Diagram Book

9

3-Wire Control:Reversing Starter Multiple Push Button Station

3-Wire Control: Reversing Starter w/ Pilot Lights to Indicate Motor Direction

FIG. 1 FIG. 2

More than one Forward-Reverse-Stop push button station may be required and can be connected in the manner shown above.

Pilot lights may be connected in parallel with the forward and reverse contactor coils, indicating which contactor is energized and thus which direction the motor is running.

3-Wire Control:2-Speed Starter

3-Wire Control: 2-Speed Starter w/ 1 Pilot Light to Indicate Motor Operation at Each Speed

FIG. 3 FIG. 4

3-wire control of a 2-speed starter with a High-Low-Stop push button station is shown above. This scheme allows the operator to start the motor from rest at either speed or to change from low to high speed. The Stop button must be operated before it is possible to change from high to low speed. This arrangement is intended to prevent excessive line current and shock to motor and driven machinery, which results when motors running at high speed are reconnected for a lower speed.

One pilot light may be used to indicate operation at both low and high speeds. One extra normally-open auxiliary contact on each contactor is required. Two pilot lights, one for each speed, may be used by connecting pilot lights in parallel with high and low coils (see reversing starter diagram above).

Plugging:Plugging a Motor to a Stop from 1 Direction Only

Anti-Plugging:Motor to be Reversed but Must Not be Plugged

FIG. 5 FIG. 6

Plugging is defined by NEMA as a braking system in which the motor connections are reversed so the motor develops a counter torque, thus exerting a retarding force. In the above scheme, forward rotation of the motor closes the normally-open plugging switch contact and energizing control relay CR. When the Stop push button is operated, the forward contactor drops out, the reverse contactor is energized through the plugging switch, control relay contact and normally-closed forward auxiliary contact. This reverses the motor connections and the motor is braked to a stop. The plugging switch then opens and disconnects the reverse contactor. The control relay also drops out. The control relay makes it impossible for the motor to be plugged in reverse by rotating the motor rotor closing the plugging switch. This type of control is not used for running in reverse.

Anti-plugging protection is defined by NEMA as the effect of a device that operates to prevent application of counter-torque by the motor until the motor speed has been reduced to an acceptable value. In the scheme above, with the motor operating in one direction, a contact on the anti-plugging switch opens the control circuit of the contactor used for the opposite direction. This contact will not close until the motor has slowed down, after which the other contactor can be energized.

Examples of Control Circuits

3-Wire ControlElementary Diagrams

Page 14: Wiring Diagram Book

10

Shunting Thermal Units During Starting Period

Article 430-35 of the NEC describes circumstances under which it is acceptable to shunt thermal units during abnormally long accelerating periods.

430-35. Shunting During Starting Period.

(a) Nonautomatically Started.

For a nonautomatically started motor, the overload protection shall be permitted to be shunted or cut out of the circuit during the starting period of the motor if the device by which the overload protection is shunted or cut out cannot be left in the starting position and if fuses or inverse time circuit breakers rated or set at not over 400 percent of the full-load current of the motor are so located in the circuit as to be operative during the starting period of the motor.

(b) Automatically Started.

The motor overload protection shall not be shunted or cut out during the starting period if the motor is automatically started.

Exception. The motor overload protection shall be permitted to be shunted or cut out during the starting period on an automatically started motor where:

(1) The motor starting period exceeds the time delay of available motor overload protective devices, and

(2) Listed means are provided to:a. Sense motor rotation and to automatically

prevent the shunting or cut out in the event that the motor fails to start, and

b. Limit the time of overload protection shunting or cut out to less than the locked rotor time rating of the protected motor, and

c. Provide for shutdown and manual restart if motor running condition is not reached.

Figures 1 and 2 show possible circuits for use in conjunction with 3-wire control schemes. Figure 1 complies with NEC requirements. Figure 2 exceeds NEC requirements, but the additional safety provided by the zero speed switch might be desirable.Figure 3 shows a circuit for use with a 2-wire, automatically started control scheme that complies with NEC requirements. UL or other listed devices must be used in this arrangement.

FIG. 1

FIG. 2

FIG. 3

FPO 9-1

FPO 9-2

FPO 9-3

Examples of Control Circuits

Shunting Thermal Units During Starting PeriodElementary Diagrams

Page 15: Wiring Diagram Book

11

3-Wire Control:Fusing in 1 Line Only

3-Wire Control:Fusing in Both Lines

FIG. 1 FIG. 2

Common control with fusing in one line only and with both lines ungrounded or, if user’s conditions permit, with one line grounded.

Common control with fusing in both lines and with both lines ungrounded.

3-Wire Control:Fusing in Both Primary Lines

3-Wire Control:Fusing in Both Primary and Secondary Lines

FIG. 3 FIG. 4

Control circuit transformer with fusing in both primary lines, no secondary fusing and all lines ungrounded.

Control circuit transformer with fusing in both primary lines and both secondary lines, with all lines ungrounded.

3-Wire Control:Fusing in Both Primary Lines and 1 Secondary Line

3-Wire Control:Fusing in Both Primary and Secondary LinesFor Large Starters using Small Transformer

FIG. 5 FIG. 6

Control circuit transformer with fusing in one secondary line and both primary lines, with one line grounded.

Control circuit transformer with fusing in both primary lines and both secondary lines, with all lines ungrounded. Used for large VA coils only.

M

L1

STOP

L2

M

OL

GND

STARTFU1

M

L1

STOP

L2

M

OLSTARTFU1 FU2

M

L1

STOP

L2

FU1 FU2

M

OLSTART

PRI

SECX1 X2

M

L1

STOP

L2

FU3 FU4

M

OLSTART

PRI

SECX1 X2

FU1 FU2

M

L1

STOP

L2FU1 FU2

M

OL

GND

START

FU3

PRI

SEC

CR

L1

STOP

L2

FU3 FU4

M

OLSTART

PRI

SECX1 X2

FU1 FU2

MCR

Examples of Control Circuits

Overcurrent Protection for 3-Wire Control CircuitsElementary Diagrams

Page 16: Wiring Diagram Book

12

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AC Manual Starters and Manual Motor Starting Switches

Class 2510

Manual Motor Starting Switches:Class 2510 Type K

FIG. 1 FIG. 2

2-Pole, 1-Phase 3-Pole, 3-Phase

Fractional Horsepower Manual Starters:Class 2510 Type F

FIG. 3 FIG. 4 FIG. 5

1-Pole 2-Pole 2-Pole w/ Selector Switch

Integral Horsepower Manual Starters:Class 2510 Size M0 and M1

FIG. 6 FIG. 7 FIG. 8 FIG. 9 FIG. 10

2-Pole, 1-Phase 3-Pole, DC 3-Pole, 1-Phase 3-Pole, 3-Phase 3-Pole, 3-Phase w/ additional Interlock (Form X)

R

T1 L1L1

T3 L3L2

PILOTLIGHT(IF USED)

T1 T3

MOTOR

R

T1L1

T3L3

PILOTLIGHT(IF USED)

T1 T3

MOTOR

T2

T2L2

R

T2

L1

T1

L2

PILOTLIGHT(IF USED)

T1 T2

MOTOR

R

T2

L1

T1

L2

PILOTLIGHT(IF USED)

T1 T2

MOTOR

R

T2

L1

T1

L2

PILOTLIGHT(IF USED)

4 T2

MOTOR

2 1A

4 3H

2 4

2-WIRECONTROL

DEVICE

O

A O H

L1

T1 T2

MOTOR

T1

L2

T2 T1

L1

T1 T2

MOTOR

L2 T2

L1

T1 T3

MOTOR

T1

L3

T3

L2

T2

L1 L2

T1

L1

T1 T3

MOTOR

T2

T2

L2

T3

L3

T1

L1

T1 T3

MOTOR

T2

T2

L2

T3

L3

Page 17: Wiring Diagram Book

13

®

AC Manual Starters and Manual Motor Starting Switches

Class 2511 and 2512

AC Reversing Manual Starters and Manual Motor Starting Switches:Class 2511

FIG. 1 FIG. 2

Reversing Manual Motor Starting SwitchType K, 3-Pole, 3-Phase

Reversing Manual StarterSizes M0 and M1, 3-Pole, 3-Phase

AC 2-Speed Manual Motor Starting Switches:Class 2512 Type K

FIG. 3 FIG. 4

2-Pole, 1-Phase w/ Pilot Lights 3-Pole, 3-Phase

AC 2-Speed Manual Motor Starters:Class 2512 Type F

FIG. 5 FIG. 6

2-Unit, 2-Pole w/ Mechanical Interlock and Pilot Lights 3-Unit, 2-Pole w/ Selector Switch and Pilot Lights

T1 L1

T3 L3

FWD

T1 T3

MOTOR

T2

T2 L2

REV

T1

L1

T1 T3

MOTOR

T2

T2

L2

T3

L3

FPO12-6a

FPO12-6b

FPO13-1a

FPO 13-1b

Page 18: Wiring Diagram Book

14

®

2-Speed AC Manual Starters and IEC Motor Protectors

Class 2512 and 2520 and Telemecanique GV1/GV3

2-Speed AC Manual Motor Starters:Class 2512 Size M0 and M1

FIG. 1

2-Speed Manual Starter for Wye-Connected, Separate Winding Motor

Motor Protective Switches:Class 2520

FIG. 2 FIG. 3 FIG. 4

3-Pole, 3-Phase 2-Pole Application 1-Pole Application

IEC Manual Starters:GV1/GV3

FIG. 5 FIG. 6 FIG. 7

GV3 M• Motor Protector

FIG. 8

GV3 A0• Fault Signalling Contacts GV3 Voltage Trips GV1 A0• Contact Block

T1

L1

T1 T12

MOTOR

T3

T2

L2

T3

L3

T2 T13T11

T11 T12 T13

2/T1

1/L1

T1 T3

MOTOR

T2

4/T2

3/L2

6/T3

5/L3

2/T1

1/L1

T1 T3

MOTOR

4/T2

3/L2

6/T3

5/L3

2/T1

1/L1

T3

MOTOR

4/T2

3/L2

6/T3

5/L3

I> I> I>

1/L1 3/L2 5/L3

2/T1 4/T2 6/T3

<D1

D2

C1

C2

GV3 B•

GV3 D•

GV1 A01 GV1 A02

GV1 A03 GV1 A05

GV1 A06 GV1 A07

13 21 13 23

14 22 14 24

13 23 31 13 23 33

14 24 32 14 24 34

13 23 33 13 23 31

14 24 34 14 24 33I> I>

GV3 A08 GV3 A0995

96

97

98

Page 19: Wiring Diagram Book

15

®

Drum Switches

Class 2601

Drum Switches:Class 2601

FIG. 1 FIG. 2 FIG. 3

Internal Switching 3-Phase, 3-Wire Motor 1-Phase, Capacitor or Split-Phase Motor

FIG. 4 FIG. 5

1-Phase, 4-Lead Repulsion Induction Motor 1-Phase, 3-Lead Repulsion Induction Motor

FIG. 6 FIG. 7

2-Phase, 3-Wire Motor 2-Phase, 4-Wire Motor

FIG. 8 FIG. 9 FIG. 10

DC, Shunt Motor DC, Series Motor DC, Compound Motor

HANDLE END

REVERSE OFF FORWARD

1 2

3 4

5 6

1 2

3 4

5 6

1 2

3 4

5 6

1

3

2

4

MOTOR DRUM SW. LINE

5 65 6

MOTOR DRUM SW.

1

3

2

4

LINE

RU

N

ST

AR

T

MOTOR DRUM SW.

1

3

5

2

4

6

LINE MOTOR DRUM SW.

1

3

5

2

4

6

LINE

MOTOR DRUM SW.

1

3

5

2

4

6

LINE

COMMON

MOTOR DRUM SW.

1

3

2

4

LINE

5 6

1

3

2

4

LINE

SH

UN

T F

IELD

AR

MA

TU

RE

MOTOR DRUM SW.

5 6

1

3

2

4

LINE

SE

RIE

SF

IELD

ARMATURE

MOTOR DRUM SW.

5 6

1

3

2

4

LINE

SE

RIE

SF

IELD

ARMATURE

MOTOR DRUM SW.

5 6

SH

UN

T F

IELD

Page 20: Wiring Diagram Book

16

®

DC Starters, Constant and Adjustable Speed

Class 7135 and 7136

Constant Speed DC Starter: Class 7135

FIG. 1

Adjustable Speed DC Starter: Class 7136

FIG. 2

Acceleration Contactors: Class 7135, 7136, 7145 and 7146

NEMA Size 1 2 3 4 5

No. of Acceleration Contactors 1 2 2 2 3

FPO 15-1

Typical Elementary Diagram for NEMA Size 2, 3 and 4

FPO 15-2

Typical Elementary Diagram for NEMA Size 2, 3 and 4

Page 21: Wiring Diagram Book

17

®

Reversing DC Starters, Constant and Adjustable Speed

Class 7145 and 7146

Reversing Constant Speed DC Starter: Class 7145

FIG. 1

Reversing Adjustable Speed DC Starter: Class 7146

FIG. 2

FPO 16-1

Typical Elementary Diagram for NEMA Size 2, 3 and 4

FPO 16-2

Typical Elementary Diagram for NEMA Size 2, 3 and 4

Page 22: Wiring Diagram Book

18

®

Mechanically Latched Contactors and Medium Voltage Motor Controllers

Class 8196 and 8198

Mechanically Latched Contactor:Class 8196 Type FL13, FL23, FL12 and FL22

FIG. 1

Full-Voltage, Non-Reversing Squirrel Cage Motor Controller:Class 8198 Type FC11, FC21, FC13, FC23, FC12 and FC22

FIG. 2

FPO 17-2

150%

FPO 17-1

145%

Page 23: Wiring Diagram Book

19

®

Medium Voltage Motor Controllers

Class 8198

Full-Voltage Squirrel Cage Motor Controller:Class 8198 Type FCR1 and FCR2

FIG. 1

FPO 17-3

160%

Page 24: Wiring Diagram Book

20

®

Medium Voltage Motor Controllers

Class 8198

Reduced-Voltage, Primary Reactor, Non-Reversing Squirrel Cage Motor Controller:Class 8198 Type RCR1 and RCR2

FIG. 1

FPO 18-1

130%

Page 25: Wiring Diagram Book

21

®

Medium Voltage Motor Controllers

Class 8198

Reduced-Voltage, Primary Reactor, Autotransformer, Non-Reversing Squirrel Cage Motor Controller:Class 8198 Type RCA1 and RCA2

FIG. 1

FPO 18-2

150%

Page 26: Wiring Diagram Book

22

®

Medium Voltage Motor Controllers

Class 8198

Full Voltage, Non-Reversing Synchronous Motor Controller:Class 8198 Type FS1 and FS2

FIG. 1

FPO 19-1

170%

Page 27: Wiring Diagram Book

23

®

Medium Voltage Motor Controllers

Class 8198

Reduced-Voltage, Primary Reactor, Non-Reversing Synchronous Motor Controller:Class 8198 Type RS1 and RS2

FIG. 1

FPO 19-2

140%

Page 28: Wiring Diagram Book

24

®

Medium Voltage Motor Controllers

Class 8198

Reduced-Voltage, Autotransformer, Non-Reversing Synchronous Motor Controller:Class 8198 Type RSA1 and RSA2

FIG. 1

FPO 20-1

160%

Page 29: Wiring Diagram Book

25

®

Medium Voltage Motor Controllers

Class 8198

Full-Voltage, Non-Reversing, Brushless Synchronous Motor Controller:Class 8198 Type FSB1 and FSB2

FIG. 1

FPO 20-2

155%

Page 30: Wiring Diagram Book

26

®

Solid State Protective Relays

Class 8430

Solid State Protective Relays:Class 8430 Type DAS, DASW, DASV and DASVW

FIG. 1

FIG. 2

Solid State Protective Relays:Class 8430

FIG. 3 FIG. 4 FIG. 5

Type MPS 240V

FIG. 6

Type DIA, DIAW, DUA and DUAW Type MPD Type MPS 480V

L1

L2

L3

STARTSTOP

M

OL

T1

T2

T3

MOTOR

M OL

M OL

M OL

L1

L2L3

11

21

12

14

22

24

M

Dashed linesrepresentoptional contacts

With the line voltage connections directly at the motor terminals, the relay will detect all phase loss conditions ahead of the connection points. However, the motor may sustain a momentary “bump” in the reverse condition if the proper phase sequence is not present.

L1

L2

L3

STARTSTOP

MOL

T1

T2

T3

MOTOR

M OL

M OL

M OL

L1

L2L3

11

21

12

14

22

24 MDashed lines representoptional contacts

With the line voltage connections ahead of the starter, the motor can be started in the reverse direction. The relay cannot detect a phase loss on the load side of the starter.

A1 11 21 B1 B2

12 14 22 24 A2

InputSignal

VS

Dashed lines represent optional contacts(DIAW and DUAW devices only)

1 2 3 4 5 6

7 8 9 10 11 12

L1L2L3

12

3

L3

L2

L14 5

6

78

1 2 3

L1L2L3

4 5 6

7 8 9

A B

Page 31: Wiring Diagram Book

27

®

Solid State Protective Relays

Class 8430

Load Detector Relay:Class 8430 Type V

FIG. 1

Wiring Diagram

Elementary Diagram (Common Control)

Load Converter Relay:Class 8430 Type G

FIG. 2

FPO 22-1

FPO 22-3

FPO 22-2

Page 32: Wiring Diagram Book

28

®

General Purpose Relays

Class 8501

Control Relays:Class 8501 Type CO and CDO

FIG. 1 FIG. 2 FIG. 3 FIG. 4 FIG. 5 FIG. 6

Type CO6 and CDO6

Type CO7 and CDO7

Type CO8 and CDO8

Type CO21 and CDO21

Type CO15 and CDO15

Type CO16, CDO16, CO22 and CDO22

Control Relays:Class 8501 Type UBS

FIG. 7

Control Relays:Class 8501 Type K

FIG. 8 FIG. 9 FIG. 10

Type KL Type KU, KF, KX, KUD, KFD and KXD2-Pole

Type KP and KPD2-Pole

FIG. 11 FIG. 12 FIG. 13

Type KLD Type KU, KF, KX, KUD, KFD and KXD3-Pole

Type KP and KPD3-Pole

ML1STOP

L2

M

START

9

TERMINAL NUMBERS

10 8 5

1

B

4

A

8

7

3

6

9

COMMON LATCH

RESET

1

B

4

A

7

3

6

9

1

2

3

4 5

6

7

8

1

B

4

A

7

3

6

9

–+

LATCHRESET

+–

1

4

7

2

5

8

3

6

9

BA 2

3

4

5 7

8

9

10

6

1 11

Page 33: Wiring Diagram Book

29

®

NEMA Control Relays

Class 8501 and 9999

10 A Control Relay w/ Convertible Contacts:Class 8501 Type X

FIG. 1

Timer Attachment:Class 9999 Type XTD and XTE

FIG. 2

FPO 27-1

* Note: Class 8501 Type XO••••XL, XDO••••XL, XDO••••XDL andXO••••XDL latch relays use the same diagram except for theaddition of an unlatch coil (8 poles maximum).

14

POLE #14

13

14

13

POLE #13

2 N.O.

14

13

14

13

1 N.C. 1 N.O.

14

13

14

13

2 N.C.

ONDELAY(TDE)

OFFDELAY(TDD)

TIMED CONTACTS

No. of Timed

Contacts

Class9999Type

Pole No.*

13 14

O 1XTDXTE

2

* O = N.O. Contact1 = N.C. ContactNote: All contacts are

convertible.

Page 34: Wiring Diagram Book

30

®

General Purpose Relays and Sensing Relays

Class 8501 and Telemecanique RM2 LA1/LG1

Miniature Control Relays:Class 8501 Type RS and RSD

FIG. 1 FIG. 2

Type RS41 and RSD41 Type RS42 and RSD42

FIG. 3 FIG. 4

Type RS43 and RSD43 Type RS4, RSD4, RS14, RSD14, RS24, RSD24, RS34, RSD34, RS44 and RSD44

Control Relays w/ Intrinsically Safe Terminals:Class 8501 Type TO41 and TO43

FIG. 5 FIG. 6

Intrinsically Safe Terminals Non-Hazardous Location Terminals

Sensing Relays:RM2 LA1/LG1

FIG. 7

1

14 (+)

5

13 (–)

9

4

8

12

1

5

9

14 (+)13 (–)

1

5

9

2

6

10

4

8

12

14 (+)13 (–)

1

5

9

2

6

10

3

7

11

14 (+)13 (–)

4

8

12

OFF ON

OFFON1 2 3 4 5 6

7

SUPPLYVOLTAGE

8 9 10 11 12

A1

15

B1

B2

16

18

B3

A2

B1 B3 15

16 18Sup

ply

volta

ge

LM

HHM

B1B2

A1 15

B1 B315

16 18Sup

ply

volta

ge

B3 B2B1

16 18 A2X X

M

H

L

H = High level electrode

L = Low level electrode

M = Reference electrode (common)

2 Levels 1 LevelRM2 LG1 RM2 LA1

B2B2

Page 35: Wiring Diagram Book

31

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Control Relays: CA2 and CA3

FIG. 1 FIG. 2 FIG. 3

4 N.O. InstantaneousCA2 DN40 and CA3 DN40

3 N.O. & 1 N.C. InstantaneousCA2 DN31 and CA3 DN31

2 N.O. & 2 N.C. InstantaneousCA2 DN22 and CA3 DN22

FIG. 4 FIG. 5

2 N.O. & 2 N.C. Instantaneous, w/ 2 Make-Before-BreakCA2 DC22 and CA3 DC22

2 N.O. & 2 N.C. Instantaneous w/ Mechanical LatchCA2 DK22 and CA3 DK22

Front-Mounted Standard Instantaneous Auxiliary Contact Blocks: LA1

FIG. 6 FIG. 7 FIG. 8 FIG. 9 FIG. 10

1 N.O. & 1 N.C.LA1 DN11

2 N.O.LA1 DN20

2 N.C.LA1 DN02

2 N.O. & 2 N.C.LA1 DN22

1 N.O. & 3 N.C.LA1 DN13

FIG. 11 FIG. 12 FIG. 13 FIG. 14

2 N.O. & 2 N.C. w/ 2 Make-Before-Break LA1 DC22

4 N.O.LA1 DN40

4 N.C.LA1 DN04

3 N.O. & 1 N.C.LA1 DN31

Front-Mounted Damp- and Dust-Protected Instantaneous Auxiliary Contact Blocks: LA1

FIG. 15 FIG. 16 FIG. 17 FIG. 18

2 N.O. LA1 DX20

2 N.O. w/ Grounding ScrewLA1 DY20

2 Dusttight N.O. & 2 N.O.LA1 DZ40

2 Dusttight N.O. & 1 N.O. & 1 N.C.LA1 DZ31

Front-Mounted Time Delay Auxiliary Contacts: LA2 and LA3

FIG. 19 FIG. 20 FIG. 21

On Delay, 1 N.O. & 1 N.C.LA2 DT

On Delay, 1 N.C. w/ 1 Offset N.O.LA2 DS

Off Delay, 1 N.O. & 1 N.C.LA3 DR

Front-Mounted Mechanical Latch Adder Blocks: LA6 Side-Mounted Auxiliary Contact Blocks: LA8

FIG. 22 FIG. 23 FIG. 24 FIG. 25

LA6 DK1 LA6 DK2 1 N.O. & 1 N.C. InstantaneousLA8 DN11

2 N.O. InstantaneousLA8 DN20

A1

A2

13NO

23NO

33NO

43NO

14 24 34 44

A113NO

21NC

33NO

43NO

A2 14 22 34 44

A113NO

21NC

31NC

43NO

A2 14 22 32 44

A113NO

21NC

35NC

47NO

A2 14 22 36 48

A113NO

21NC

31NC

43NO

A2 14 22 32 44

E1

E2

53NO

61NC

54 62

53NO

63NO

54 64

51NC

61NC

52 62

53NO

61NC

71NC

83NO

54 62 72 84

53NO

61NC

71NC

81NC

54 62 72 82

53NO

61NC

75NC

87NO

54 62 76 88

53NO

63NO

73NO

83NO

54 64 74 84

51NC

61NC

71NC

81NC

52 62 72 82

53NO

61NC

73NO

83NO

54 62 74 84

53NO

63NO

54 64

53NO

63NO

54 64

53NO

83NO

54 84

63NO

73NO

64 74

53NO

83NO

54 84

61NC

73NO

62 74

55NC

67NO

56 68

55NC

67NO

56 68

57NO

65NC

58 66

A1

A2

E1

E2

A1

A2

E1

E2

45

46

53/

84

NO61/

72

NC

54/

83NO

62/

71NC

53/

84

NO63/

74

NO

54/

83NO

64/

73NO

IEC Relays

IEC D-Line Control Relays(for input modules see page 42)

Page 36: Wiring Diagram Book

32

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Miniature IEC Relays:Class 8501 Type PR 1

FIG. 1 FIG. 2

Type PR 1 and PRD 1 Relays Type PV Adder Decks for PR 1.20 E

Alternating Relays:Class 8501 Type PHA

FIG. 3

A1

A2

13NO

23NO

14 24

A113NO

21NC

A2 14 22

PRD 1.11 E

PRD 1.20 E

PR 1.11 E

PR 1.20 E

33NO

41NC

34 42

33NO

43NO

34 44

31NC

41NC

32 42

PV 02

PV 11 PV 20

13

14

23

24

A1

A2

13 14

23 24 closed

open

closed

open

energized

deenergizedrelay coil

IEC Relays

Class 8501

Page 37: Wiring Diagram Book

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Power Terminals Coil Terminals

FIG. 1 FIG. 2

Power terminals on contactors, overloads and switches are single digits – odd for line side terminals and even for load side terminals.

Coil terminals are designated by a letter and a number. Terminals for a single winding coil are designated “A1” and “A2”.

Auxiliary Contact Terminals Overload Relay Contact Terminals

FIG. 3 FIG. 4

Auxiliary contacts on contactors, relays and push button contacts use 2-digit terminal designations, as shown in the diagram above. The first digit indicates the location of the contact on the device. The second digit indicates the status of the contacts, N.O. or N.C. “1” and “2” indicate N.C. contacts. “3” and “4” indicate N.O. contacts.

Overload contact terminals are marked with two digits. The first digit is “9”. The second digits are “5” and “6” for a N.C. and “7” and “8” for a N.O. isolated contact. If the device has a non-isolated alarm contact (single pole), the second digits of the N.O. terminals are “5” and “8”.

Class 8502 Type PD or PE Contactorw/ Class 9065 Type TR Overload Relay

FIG. 5

Wiring Diagram

Elementary Diagram

2

1

4

3

6

5 A1

A2

13

14

43

44

53

54

31

32

21

22

Status(N.O. or N.C.)

Location 95

96

97

98

95

96 98With Non-Isolated

N.O. Alarm ContactWith Isolated

N.O. Alarm Contact

FPO 30-2 120%

FPO 30-2 120%

Type P Contactors and Type T Overload Relays

Class 8502 and 9065

Page 38: Wiring Diagram Book

34

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Type P Contactors and Type T Overload Relays

Class 8502 and 9065

Class 8502 Type PG or PD Contactorw/ Class 9065 Type TD Overload Relay

FIG. 1

Wiring Diagram Elementary Diagram

Class 8502 Type PE Contactorw/ Class 9065 Type TE Overload Relay

FIG. 2

Wiring Diagram Elementary Diagram

Class 8502 Type PF, PG or PJ Contactorw/ Class 9065 Type TF, TG or TJ Overload Relay

FIG. 3

Wiring Diagram Elementary Diagram

FPO 30-3 120%

FPO 30-3 120%

FPO 30-4 120%

FPO 30-4 120%

FPO 31-1 120%

FPO 31-1 120%

Page 39: Wiring Diagram Book

35

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Class 8502 Type PJ or PK Contactorw/ Class 9065 Type TJE Overload Relay

FIG. 4

Wiring Diagram Elementary Diagram

Class 8702 Type PDV or PEV Reversing Contactorw/ Class 9065 Type TR Overload Relay

FIG. 1

Elementary Diagram

Elementary Diagram

FPO 31-2 120%

FPO 31-2 120%

FPO 31-3

FPO 31-3 120%

Type P Reversing Contactors and Type T Overload Relays

Class 8502, 8702 and 9065

Page 40: Wiring Diagram Book

36

®

Type S AC Magnetic Contactors

Class 8502

AC Magnetic Contactors:Class 8502 Type S

FIG. 1 FIG. 2

1-Pole, Size 0 and 1 2-Pole, Size 00, 0 and 1

FIG. 3 FIG. 4

2-Pole, Size 2 to 5 3-Pole, Size 00 to 5

FIG. 5 FIG. 6

4-Pole, Size 0, 1 and 2 5-Pole, Size 0, 1 and 2

FIG. 7 FIG. 8

2- and 3-Wire Control for Figure 1 to 5 Separate Control for Figure 6

T1 L2

MOTOR

3

2

L1

1L2

T1

T1 T2

MOTOR

3

2

L1

1

T1

L2

T2

T1 T2

MOTOR

3

2

L11

T1

L2

T2

T1 T3

MOTOR

3

2

L2

T2

L3

T3

T2L1

1

T1

T1 T2

MOTOR

3

2

L3

T3

L4

T4

T3L1

1

T1

T4L2

T2

T1 T3

MOTOR

3

2

L2

T2

L3

T3

T2L1

T1

X2

3

X2

TOSEPARATECONTROL

Page 41: Wiring Diagram Book

37

®

Type S AC Magnetic Contactors

Class 8502

Size 6, 3-Pole Contactor – Common ControlClass 8502 Type SH Series B

FIG. 1

Wiring Diagram

Elementary Diagram

Short-Circuit ProtectionRating of branch circuit protective device must comply with applicable electrical codes and the following limitations:Type of Device Max. RatingClass K5 or RK5 time-delay fuse 600 AClass J, T or L fuse 1200 AInverse-time circuit breaker 800 A

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Page 42: Wiring Diagram Book

38

®

Type S AC Magnetic Contactors

Class 8502

Size 6, 3-Pole Contactor – Separate ControlClass 8502 Type SH Form S Series B

FIG. 1

Wiring Diagram

Elementary Diagram

Short-Circuit ProtectionRating of branch circuit protective device must comply with applicable electrical codes and the following limitations:Type of Device Max. RatingClass K5 or RK5 time-delay fuse 600 AClass J, T or L fuse 1200 AInverse-time circuit breaker 800 A

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Page 43: Wiring Diagram Book

39

®

Type S AC Magnetic Contactors

Class 8502

Size 7, 3-Pole Contactor – Common ControlClass 8502 Type SJ Series A

FIG. 1

Wiring Diagram

Elementary Diagram

Short-Circuit ProtectionRating of branch circuit protective device must comply with applicable electrical codes and the following limitations:Type of Device Max. RatingClass K5 or RK5 time-delay fuse 600 AClass J, T or L fuse 1600 AInverse-time circuit breaker 2000 A

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Page 44: Wiring Diagram Book

40

®

Type S AC Magnetic Contactors

Class 8502

Size 7, 3-Pole Contactor – Separate ControlClass 8502 Type SJ Form S Series A

FIG. 1

Wiring Diagram

Elementary Diagram

Short-Circuit ProtectionRating of branch circuit protective device must comply with applicable electrical codes and the following limitations:Type of Device Max. RatingClass K5 or RK5 time-delay fuse 600 AClass J, T or L fuse 1600 AInverse-time circuit breaker 2000 A

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Page 45: Wiring Diagram Book

41

®

IEC Contactors

IEC Contactors and Auxiliary Contact Blocks(for Input Modules see page 42)

3- and 4-Pole Contactors: LC1 and LP1(Terminal markings conform to standards EN 50011 and 50012)

FIG. 1 FIG. 2 FIG. 3

D09 10 to D32 10 D09 01 to D32 01 D40 11 to D95 11

FIG. 4 FIG. 5 FIG. 6

D12 004 to D80 004 D12 008 and D25 008 D40 008 to D80 008

Front-Mounted Standard Instantaneous Auxiliary Contact Blocks: LA1

FIG. 7 FIG. 8 FIG. 9 FIG. 10 FIG. 11 FIG. 12

1 N.O.LA1 DN 10

1 N.O. & 1 N.CLA1 DN 11

2 N.O.LA1 DN 20

2 N.C.LA1 DN 02

2 N.O. & 2 N.C.LA1 DN 22

1 N.O. & 3 N.C.LA1 DN 13

FIG. 13 FIG. 14 FIG. 15 FIG. 16 FIG. 17

1 N.C.LA1 DN 01

2 N.O. & 2 N.C. w/2 Make-Before-Break

LA1 DC 22

4 N.O.LA1 DN 40

4 N.C.LA1 DN 04

3 N.O. & 1 N.C.LA1 DN 31

Front-Mounted Damp- and Dust-Protected (IP 54) Instantaneous Auxiliary Contact Blocks: LA1

FIG. 18 FIG. 19 FIG. 20 FIG. 21

2 N.O. LA1 DX 20

2 N.O. (5-24 V) w/ Grounding ScrewLA1 DY 20

2 Dusttight N.O. (24-50 V) & 2 N.O.LA1 DZ 40

2 Dusttight N.O. (24-50 V) & 1 N.O. & 1 N.C.LA1 DZ 31

Front-Mounted Time Delay Auxiliary Contacts: LA2 and LA3

FIG. 22 FIG. 23 FIG. 24

On Delay, 1 N.O. & 1 N.C.LA2 DT•

On Delay, 1 N.O. w/ 1 Offset N.O.LA2 DS•

Off Delay, 1 N.O. & 1 N.C.LA3 DR•

Front-Mounted Mechanical Latch Adder Blocks: LA6 Side-Mounted Auxiliary Contact Blocks: LA8

FIG. 25 FIG. 26 FIG. 27 FIG. 28

LA6 DK 1 LA6 DK 2, LA6 DK 3 1 N.O. & 1 N.C. InstantaneousLA8 DN 11

2 N.O. InstantaneousLA8 DN 20

A1

A2

1L1

3L2

5L3

13NO

T12

T24

T36 14

A1

A2

1L1

3L2

5L3

21NC

T12

T24

T36 22

1L1

3L2

5L3

13NOA1

A2 T12

T24

T36 22

21NC

14

1L1

3L2

5L3

7L4

T12

T24

T36

T48

A1

A2

A1

A2

1 R1 R3 3

2 R2 R4 4

A1

A2

1R1 R33

2R2 R44

43

44

NO

94

93

53NO

61NC

54 62

53NO

63NO

54 64

51NO

61NO

52 62

53NO

61NC

71NC

83NO

54 62 72 84

53NO

61NC

71NC

81NC

54 62 72 82

41

42

NO

92

91

53NO

61NC

75NC

87NO

54 62 76 88

53NC

63NC

73NC

83NC

54 64 74 84

51NC

61NC

71NC

81NC

52 62 72 82

53NO

61NC

73NO

83NO

54 62 74 84

53N0

63NO

54 64

53N0

63NO

54 64

53N0

63N0

73N0

83N0

54 64 74 84

53N0

61NC

73N0

83N0

54 62 74 84

55NC

67NO

56 68

55NC

67NO

56 68

57NO

65NC

58 66

A1

A2

E1

E2

A1

A2

E1

E2

45

46

53/

84

NO61/

72

NC

54/

83NO

62/

71NC

53/

84

NO63/

74

NO

54/

83NO

64/

73NO

Page 46: Wiring Diagram Book

42

®

IEC Contactors

Input Modules and Reversing Contactors

Input Modules:LA4

FIG. 1 FIG. 2 FIG. 3

On Delay Timer ModuleLA4 DT

Off Delay Timer ModuleLA4 DR

Auto-Manual-Off Control ModuleLA4 DM

FIG. 4 FIG. 5 FIG. 6

Relay Interface Amplifier ModuleLA4 DF

Relay Interface Amplifier Module w/Manual Override, LA4 DL

Solid State Interface Amplifier ModuleLA4 DW

Contactors:LC2, LP2 and LA9

FIG. 7 FIG. 8 FIG. 9

Reversing Contactor3-Pole, for Motor Control

LC2, LP2 D0901 to D3201

Transfer Contactor,4-Pole, Mechanically Interlocked

LC2, LP2 D12004 to D8004

Mechanical Interlock w/ Electrical InterlockLA9 D0902, D4002 and D8002

A1

A1

0 t

A2

A2

K

AC/DC

A1 A2

K

A1 A2B2

0 t

AC

A/M

1/0

A1 A2

K

A2B1A1

PLCAC/DC

ACA1

+E1

-E2

ACA2

A1 A2

K

ACA1

+E1

-E2

ACA2

A1 A2

K

ACA1

+E1

-E2

ACA2

A1 A2

K

1 3 5

2 4 6

A1

A2

1 3 5

2 4 6

A1

A2

U V W

21

KM2

22

KM1

A2

21

KM2

22

KM1

A2

A1

A2

A1

A2

1 3 5 7

2 4 6 8

1 3 5 7

2 4 6 8

A1

A2

A1

A2

01

01

02

02

Page 47: Wiring Diagram Book

43

®

1-Pole, 1-Phase Magnetic Starters, Size 00 to 3:Class 8536 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Single Phase Starter w/ Single Voltage Motor

FIG. 2

Wiring Diagram Elementary Diagram

Single Phase Starter w/ Dual Voltage Motor

3-Pole, 3-Phase Magnetic Starters, Size 00 to 3, Connected for Single Phase:Class 8536 Type S

FIG. 3

Wiring Diagram Elementary Diagram

3-Phase Starter Connected for Single Phase, Single Voltage Motor

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is supplied

Note: Starters are factory-wired with coil connected for the higher voltage. If starter is used on lower voltage, connect per coil diagram.

* Marked “OL” if alarm contact is supplied

Type S AC Magnetic Starters

Class 85361-Phase, Size 00 to 3

Page 48: Wiring Diagram Book

44

®

Type S AC Magnetic Starters

Class 85362-Phase and 3-Phase, Size 00 to 5

4-Pole, 2-Phase Magnetic Starters:Class 8536 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Size 0, 1 and 2

FIG. 2

Wiring Diagram Elementary Diagram

Size 3 and 4

3-Pole, 3-Phase Magnetic Starters:Class 8536 Type S

FIG. 3

Wiring Diagram Elementary Diagram

Size 00 to 4

FIG. 4

Wiring Diagram Elementary Diagram

Size 5

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is supplied

If alarm contact is supplied, a single (3 thermal unit) overload block is furnished, fed from 3 current transformers.

* Marked “OL” if alarm contact is supplied

Page 49: Wiring Diagram Book

45

®

3-Pole, 3-Phase Magnetic Starters, Size 6 – Common ControlClass 8536/8538/8539 Type SH Series B

FIG. 1

Wiring Diagram

Elementary Diagram

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Type S AC Magnetic Starters

Class 8536, 8538 and 85393-Phase, Size 6

Page 50: Wiring Diagram Book

46

®

3-Pole, 3-Phase Magnetic Starters, Size 7 – Common ControlClass 8536 Type SJ Series A

FIG. 1

Wiring Diagram

Elementary Diagram

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Type S AC Magnetic Starters

Class 85363-Phase, Size 7

Page 51: Wiring Diagram Book

47

®

Type S AC Magnetic Starters

Class 85363-Phase Additions and Special Features

3-Pole, 3-Phase Magnetic Starters, Size 00 to 4:Class 8536 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Form A – Start-Stop Push Button Mounted in Cover

FIG. 2

Wiring Diagram Elementary Diagram

Form C – Hand-Off-Auto Selector Switch Mounted in Cover

FIG. 3

Wiring Diagram Elementary Diagram

Form F4T – Control Circuit Transformer and Primary Fuses

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is supplied∆ Single or dual voltage primary connection

per transformer nameplate. ∆ Single or dual voltage primary connection per transformer nameplate.

Page 52: Wiring Diagram Book

48

®

Type S AC Magnetic Starters

Class 85363-Phase Additions and Special Features

3-Pole, 3-Phase Magnetic Starters, Size 00 to 4:Class 8536 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Form S – Separate Control

FIG. 2

Wiring Diagram Elementary Diagram

Form X – Additional Auxiliary Contacts

3-Pole, 3-Phase Magnetic Starters, Size 5:Class 8536 Type S

FIG. 3

Wiring Diagram Elementary Diagram

Form F4T – Control Circuit Transformer and Primary Fuses

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is suppliedOn NEMA Size 3 and 4 starters, holding circuit contact is in position #1. Max. of 3 external auxiliary contacts on NEMA Size 00.

* Marked “OL” if alarm contact is supplied∆ If alarm contact is supplied, a single (3 thermal unit) overload

block is furnished, fed from 3 current transformers

Page 53: Wiring Diagram Book

49

®

3-Pole, 3-Phase Magnetic Starters, Size 6 – Separate ControlClass 8536/8538/8539 Type SH Form S Series B

FIG. 1

Wiring Diagram

Elementary Diagram

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Type S AC Magnetic Starters

Class 8536, 8538 and 85393-Phase Additions and Special Features

Page 54: Wiring Diagram Book

50

®

3-Pole, 3-Phase Magnetic Starters, Size 7 – Separate ControlClass 8536 Type SJ Form S Series A

FIG. 1

Wiring Diagram

Elementary Diagram

This symbol denotes the coil function, provided by a solid-state control module, 30 VA transformer, two fuses in the secondary of the transformer, N.C. electrical interlock and DC magnet coil.

Type S AC Magnetic Starters

Class 85363-Phase Additions and Special Features

Page 55: Wiring Diagram Book

51

®

Integral Self-Protected Starters

Integral 18State of Auxiliary Contacts

State of Auxiliary Contacts for LD1

FIG. 1

LA1-LB015 LA1-LB017 LA1-LB019 LA1-LB001

LA1-LB031

LA1-LB034

LD1

86

5 7

6 8

5 7

86

5 7

86

5 7

86

5 7

86

5 7

86

5 7

86

5 7

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 31

14 32

13 31

14 32

14 32

13 31

13 31

14 32

13 31

14 32

13 31

14 32

13 31

14 32

13 31

14 32

98

97

97

98

97

98

97

98

97

98

97

98

97

98

97

98

96 98

95 97

95 97

96 98

96 98

95 97

96 98

95 97

96 98

95 97

96 98

95 97

96 98

95 97

96 98

95 97

14 32

13 31

13 31

14 32

13 31

14 32

13 31

14 32

13 31

14 32

13 31

14 32

13 31

14 32

13 31

14 32

96

95

96

95

96

95

96

95

96

95

96

95

96

95

96

95

41

42

41

42

41

42

41

42

41

42

41

42

41

42

41

42

L11

L23

L35

2 4 6T1 T2 T3

A1 A2

AUTO

AUTO

TRIP. +

TRIP. +

TRIP. +

RESET

TRIP. +

AUTO + 0

15

16 18

17

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

AUTO + 0

15

16 18

17

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

15 17

16 18

Auxiliary contact actuators

Auxiliary contacts

Contact openContact closed

Off

On, contactoropen

On, contactorclosed

Tripped onoverload

Tripped onshort circuit

Off after shortcircuit

Manual reset

Page 56: Wiring Diagram Book

52

®

Integral Self-Protected Starters

Integral 18State of Auxiliary Contacts

State of Auxiliary Contacts for LD5

FIG. 1

8613 31 95 41

15

RESET

TRIP. +

AUTO

AUTO

AUTO

TRIP. +

TRIP. +

TRIP. +

AUTO + 0

13 23 31

14 24 32

96 98

95 97

13 31

14 32 98

97 13 31

14 32 96

95 41

42

13 23 31

14 24 32

16 18

17

41

42

6 8

5 7

13 23 31

14 24 32

95 97

96 98

14 32

13 31

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

13 23 31

14 24 32

13 31

14 32

96 98

95 97

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

96 98

95 9713 23 31

14 24 32

13 31

14 32

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

96 98

95 9713 23 31

14 24 32

13 31

14 32

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

96 98

95 9713 23 31

14 24 32

13 31

14 32

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

96 98

95 9713 23 31

14 24 32

13 31

14 32

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

96 98

95 9713 23 31

14 24 32

13 31

14 32

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

96 98

95 9713 23 31

14 24 32

13 31

14 32

8613 31 95 41

5 7

97

98 14 32 96 42

13 23 31

14 24 32 15 17

16 18 41

42

LA1-LB015 LA1-LB017 LA1-LB019 LA1-LB001

LA1-LB021 LA1-LB001

LD5

5 7

L11

L23

L35

A1A2A1A2

2 4 6T1 T2 T3

OnIntegral

Auxiliary contact actuators

Auxiliary contacts

Contact openContact closed

Off

On, contactoropen

On, contactor IIclosed

On, contactor Iclosed

Tripped onoverload

Tripped onshort circuit

Off after shortcircuit

Manual reset

Page 57: Wiring Diagram Book

53

®

State of Auxiliary Contacts for LD4

FIG. 1 Auxiliary contact actuators

Off + isolation

LA1-LC012

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

A1 A2

L1 L2 L31 3 5

2 4 6T1 T2 T3

LD4

96 98

95

96 98

95

96 98

95

96 98

95

96 98

95

96 98

95

U

96 98

95

96 98

95

96 98

95

96 98

95

95

98

95

98

95

98

95

98

95

98

98

95

U

95

98

95

98

95

98

95

98

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

LA1-LC010

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

16 18

15

16 18

15

16 18

15

1618

15

AUTO + 0

16 18

15

16 18

15

16 18

15

16 18

15

16 18

15

16 18

15

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

LA1-LC020

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

53

54

53

54

(63)53

54(64)

LA1-LC030

53

54

53

54

53

54

53

54

53

54

53

54

53

54

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

LD4

TRIP. +

RESET

TRIP. +

TRIP. +

TRIP. +

TRIP. +

AUTO

AUTO

Contact openContact closed

Off

On, contactor open

On, contactor closed

Tripped, on overload

Off, after overload

Tripped, on short circuit

Off, after short circuit

Manual reset

Auxiliary contacts

Integral Self-Protected Starters

Integral 32 and 63State of Auxiliary Contacts

Page 58: Wiring Diagram Book

54

®

State of Auxiliary Contacts for LD5

FIG. 1

LA1-LC012

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

06 08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

08

05

U

96 98

95

95

96 98

96 98

95

96 98

95

96 98

95

96 98

95

95

96 98

95

96 98

95

96 98

95

96 98

96 98

95

U

98

95

95

98

95

98

95

98

95

98

95

98

95

98

95

98

95

98

95

98

95

98

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

AUTO + 0

1618

15

15

16 18

16 18

15

16 18

15

15

16 18

16 18

15

16 18

15

16 18

15

16 18

15

16 18

15

16 18

15

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

53

54

63

64

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

LA1-LC021

2 4 6T1 T2 T3

L1L2 L31 3 5

A1A2 A1A2

LD5

LA1-LC010 LA1-LC031

TRIP. +

RESET

AUTO

TRIP. +

TRIP. +

TRIP. +

TRIP. +

AUTO

AUTO

LA1-LC020

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

Off + isolation

Off

On, both contactors open

On, contactor open

On, contactor closed

Tripped on overload

Off, after overload

Tripped on short circuit

Off after short circuit

Manual reset

Auxiliary contact actuators

Auxiliary contacts

Contact openContact closed

Integral Self-Protected Starters

Integral 32 and 63State of Auxiliary Contacts

Page 59: Wiring Diagram Book

55

®

Integral 18

FIG. 1 FIG. 2

Self-Protected Starter w/ Protection Module LB•Integral 18 LD1 L80

Self-Protected Reversing Starter w/ Protection Module LB•Integral 18 LD5 LB130 + LB1 LB03P

Integral 32

FIG. 3 FIG. 5

Starter w/ IsolatorIntegral 32 LD4

FIG. 4

Starter w/o IsolatorIntegral 32 LD1

Reversing Starter w/ IsolatorIntegral 32 LD5

Protection Modules: LB•

FIG. 6 FIG. 7

Thermal and Magnetic TripLB1

Magnetic Trip OnlyLB6

5L3

31L1

A1 A2

T1 T2 T3642

L2 L11

L23

L35

A1 A2 A1 A2

2 4 6T1 T2 T3

I II

L1 L2 L31 3 5

A1 A2

T1 T2 T32 4 6

g ( )

L1 L2 L3

1 3 5

T1 T2 T32 4 6

A1 A2 A1 A2

L1 L2 L3

1 3 5

T1 T2 T32 4 6

A1 A2

External control circuit

Handle operator

Protectionmoduletripmechanism

Protection moduleThermal trip

Magnetic trip

Instantaneoustripmechanism(Trip coil)

Control circuit contact

T1 T2 T32 4 6

T1 T2 T32 4 6

Integral Self-Protected Starters

Wiring Diagrams

Page 60: Wiring Diagram Book

56

®

Integral Self-Protected Starters

Wiring Diagrams

Auxiliary Contact Blocks

FIG. 1

For LD1 or LD4 and reverser LD5 (mounted on right)LA1 LC010, LA1 LC012 and LA1 LC020

FIG. 2 FIG. 3 FIG. 4

For LD4 w/ isolating contacts(mounted on left)

LA1 LC030

For reversing LD5(mounted on left)

LA1 LC021

Isolating contacts(mounted on left)

LA1 LC031

Remote Reset Units

1

for LD1, LD4 and LD5Trip Units

for LD1, LD4 and LD5Interface Modules

FIG. 5 FIG. 6 FIG. 7

LA1 LC180, LA1 LD180

FIG. 8

LA1 LC052 LA1 LC07•• LA1 LC580, LA1 LD580

13 23 31

14 24 32

13 23 31

14 24 32

13 23 31

14 24 32

9698

95

98

95

0608

05

16 18

15

08

05

LA1 LC010 LA1 LC012 LA1 LC0201

Trip signal

Short-circuit signal

Knob position signalAuto + O

Contactor signalling placed on the right

1

(63)53

54(64)

(63)53

54(64)

1 or 2 LA1 LC030

LA1 LC030

13 23 31

14 24 32

LA1 LC021 2

Contactor signalling placed on the left

2

LA1 LC031

AC AC

B4

B2

B3

AUTO

+

ORESET

TRIP

B1M

Use of theLA1 LC020contactblockprevents the mountingof trip or remote units

For starter and reverser already fitted with a block, LA1 LC010 or LA1 LC012.

U <

C1

C2

D1

D2

AC A1E1+

- E1A2AC

A1

A2

AC A1E1+

- E1A2AC

A1

A2

Page 61: Wiring Diagram Book

57

®

Integral Self-Protected Starters

Wiring Diagrams

Add-on Blocks: LA1 LB0••

FIG. 1

For LD1 (mounted on right)

FIG. 2 FIG. 3

For LD1 (mounted on left) For LD5 (mounted on left)

Time Delay Modules Control Module

FIG. 4 FIG. 5 FIG. 6

On ModuleLA4 DT

Off ModuleLA4 DR

Auto-Man-Stop ModuleLA4 DM

Interface Modules

FIG. 7 FIG. 8 FIG. 9

Solid State ModuleLA4 DW

Relay ModuleLA4 DF

Relay Module w/ Manual OverrideLA4 DL

Voltage Converters: LA1 LC080 and LA1 LD080

FIG. 10 FIG. 11 FIG. 12

For 24 or 48 V Supply For 110 V Supply For 24 or 48 V Supply w/ Low Voltage Input

13 23 31

14 24 32

95 97

96 98

LA1 LB015

97

98

13 31

14 32

LA1 LB01713 31

14 32

95

96

LA1 LB01941

42

LA1 LB001

and

Trip signal

Contactor breakers

5 7

6 8

LA1 - LB034 LA1 - LB031

15 17

16 18

15

16

17

18

0Knob position

Shortcircuitsignal

Auto

Signal

41

42

LA1 - LB001 LA1 - LB021

5 7

6 8

13 23 31

14 24 32

15 17

16 18

0

Contacts integratedinto device

Contactor breakers

Knob position

Auto

Shortcircuitsignal

Signal

KA1 A2

A1 A2

0 t

AC

KA1 A2

A1 A2B2

0 t

AC

KA1 A2

A1 A2B1

A/M 1/0

TSX AC

K

A1 A2E1 E2+ -

A1 A2

AC AC

K

A1 A2E1 E2+ -

A1 A2

AC AC

K

A1 A2E1 E2+ -

A1 A2

AC AC

E1

E3

E2

+

- (OV)

A1

A2

DC

AC

Control by supply switching 24 or 48V

E1

E2

DC

AC

+

- (OV)

A1

A2

110V

DC

AC

A1

A2Sup

ply

Low voltage control 24 or 48V

E1

E2

E3

Low voltage input

+

-

Page 62: Wiring Diagram Book

58

®

Type S AC Combination Magnetic Starters

Class 8538 and 85393-Phase, Size 0-5 (see pages 45 and 49 for Size 6)

3-Pole, 3-Phase Combination Starters:Class 8538 and 8539 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Size 0-4

FIG. 2

Wiring Diagram Elementary Diagram

Size 5

* Marked “OL” if alarm contact is supplied

* Marked “OL” if alarm contact is supplied

Page 63: Wiring Diagram Book

59

®

Type S AC Combination Magnetic Starters

Class 8538 and 85393-Phase Additions and Special Features

3-Pole, 3-Phase Combination Starters w/ Control Circuit Transformer and Primary Fuses:Class 8538 and 8539 Type S Form F4T

FIG. 1

Wiring Diagram Elementary Diagram

Size 0-4

FIG. 2

Wiring Diagram Elementary Diagram

Size 5

PRI

STOP

M

3-WIRE CONTROL

GROUND(If used)

T1 T3

MOTOR

T2

DISCONNECTING MEANS,PROVIDED BY USER OR

WITH CONTROLLER

L1 L2 L3

3

2 A A

ALARM (IFSUPPLIED)

T1 T2 T3

*COM OL

1

X2

L1 L2 L3

FU1

SEC

FU2

2-WIRE CONTROL

3

1

3

1

2START

* Marked “OL” if alarm contact is supplied

OL

M

SECX2

PRIFU1 FU2 GROUND

(If used)

STOPSTART

3

M OL

M OL

M OL

L1

L2

L3

2-WIRE CONTROL(If used)

21

X1

M

DIS

CO

NN

EC

TIN

GM

EA

NS

PRI

STOP

M

3-WIRE CONTROL

GROUND(If used)

T1 T3

MOTOR

T2

DISCONNECTING MEANS,PROVIDED BY USER OR

WITH CONTROLLER

L1 L2 L3

3

2 A A

ALARM (IFSUPPLIED)

T1 T2 T3

*COM OL

1

X2

L1 L2 L3

FU1

SEC

FU2

2-WIRE CONTROL

3

1

3

1

2START

CR

* Marked “OL” if alarm contact is supplied

OL

CR

SECX2

PRIFU1 FU2 GROUND

(If used)

STOPSTART

3

M OL

M OL

M OL

L1

L2

L3

2-WIRE CONTROL(If used)

21

X1

M

CR

M

DIS

CO

NN

EC

TIN

GM

EA

NS

Page 64: Wiring Diagram Book

60

®

Reduced Voltage Autotransformer Controllers w/ Closed Transition Starting: Class 8606 Size 2-5

FIG. 1

Reduced Voltage Autotransformer Controller w/ Closed Transition Starting: Class 8606 Size 6

FIG. 2

OR

DIS

CO

NN

EC

T S

WIT

CH

L1

L2

L3

CIR

CU

IT B

RE

AK

ER

R

R

R

2S

2S

2S

1S

1S

OL

OL

OL

TR TR 1S

R

R

1S

2S

1S

STARTSTOP

TRTR

OL

2 WIRE CONTROL DEVICE (IF USED)

1 2 3

AT

AT

T1

T2

T3

050

658410

0

50

658410

0 0

2S

MOTOR

OR

DIS

CO

NN

EC

T S

WIT

CH

L1

L2

L3

CIR

CU

IT B

RE

AK

ER

R

R

R

2S

2S

2S

1S

1S

1TR 1TR

1S

R

R

1S

2S

1S

STARTSTOP

1TR

OL

2 WIRE CONTROL DEVICE (if used)

1 2 3

AT

AT

T1

T2

T3

050

658410

0

50

658410

0 0

2S

GROUND(if used)

R

2TR

2TR

1TR

PRI

SEC

(H1)

(X1) (X2)

PRI

SEC

(H1)

(X1) (X2)

1OL

1CT

2OL

2CT

3OL

3CT

MOTOR

Reduced Voltage Controllers

Class 8606Autotransformer Type, Size 2-6

Page 65: Wiring Diagram Book

61

®

Reduced Voltage Autotransformer Controllers w/ Closed Transition Starting:Class 8606 Size 7

FIG. 1

OR

DIS

CO

NN

EC

T S

WIT

CH

L1

L2

L3C

IRC

UIT

BR

EA

KE

R

R

R

R

2S

2S

2S

1S

1S

1TR 1TR

1S

R

R

1S

2S

1S

STARTSTOP

1TR

OL

2 WIRE CONTROL DEVICE (If used)

1 2 3

AT

AT

T1

T2

T3

050

658410

0

50

6584100 0

GROUND(If used)

R

2TR

2TR

1TR

PRI

SEC

(H1)

(X1) (X2)

SOLID STATEOVERLOAD RELAY

SEC

(H1)

(X1) (X2)

1CT

2CT

3CT

2S

SEC

(H1)

(X1) (X2)

SEC(X1) (X2)

PRI

PRI

PRI(H1)

MOTOR

Reduced Voltage Controllers

Class 8606Autotransformer Type, Size 7

Page 66: Wiring Diagram Book

62

®

Reduced Voltage Controllers

Class 8630Wye-Delta Type, Size 1Y

-5Y

Wye-Delta Type Reduced Voltage Controllers, Size 1Y

-5Y

:Class 8630

FIG. 1

Size 1Y

-5Y

Controllers with Open-Transition Starting

FIG. 2

Size 1Y

-5Y

Controllers with Closed-Transition Starting

FPO46-1110%

FPO46-2110%

Page 67: Wiring Diagram Book

63

®

Reduced Voltage Controllers

Class 8630Wye-Delta Type, Size 6Y

Wye-Delta Type Reduced Voltage Controllers, Size 6Y

:Class 8630

FIG. 1

Size 6Y

Controller with Open-Transition Starting

FIG. 2

Size 6Y

Controller with Closed-Transition Starting

FPO46-3110%

FPO46-4110%

Page 68: Wiring Diagram Book

64

®

Reduced Voltage Controllers

Class 86402-Step, Part-Winding Type

Table 5 Motor Lead Connections

Part Winding Schemes Lettered Terminals in Panel Part Winding Schemes Lettered Terminals in Panel

A B C D E F A B C D E F

1/2 Wye or Delta 6 Leads T1 T2 T3 T7 T8 T9 2/3 Wye or Delta 6 Leads T1 T2 T9 T7 T8 T3

1/2 Wye 9 Leads

[1]

T1 T2 T3 T7 T8 T9 2/3 Wye 9 Leads

[1]

T1 T2 T9 T7 T8 T3

1/2 Delta 9 Leads

[2]

T1 T8 T3 T6 T2 T9 2/3 Delta 9 Leads

[2]

T1 T4 T9 T6 T2 T3

[1]

Connect terminals T4, T5 and T6 together at terminal box.

[2]

Connect terminals T4 and T8, T5 and T9, T6 and T7 together in 3 separate pairs at terminal box.

Part-Winding Reduced Voltage Controllers: Class 8640, Size 1PW-7PW

FIG. 1 FIG. 2

Size 1PW-4PW, 2-Step Part-Winding Controllers Size 5PW, 2-Step Part-Winding Controller

FIG. 3 FIG. 4

Size 6PW, 2-Step Part-Winding Controller Size 7PW, 2-Step Part-Winding Controller

Disconnect means (optional): 2 required, 1 for each motor winding.

See Table 5 for motor lead connections.

Page 69: Wiring Diagram Book

65

®

Reduced Voltage Controllers

Class 8647Primary-Resistor Type

3-Phase Primary-Resistor Reduced Voltage Controllers:Class 8647, Size 1-7

FIG. 1 FIG. 2

Size 1-4 Size 5

FIG. 3 FIG. 4

Size 6 Size 7

DIS

CO

NN

EC

T M

EA

NS

(OP

TIO

NA

L)

L1

L2

L3

M RES

A

STARTSTOP

TR

OL

2 WIRE CONTROL DEVICE (if used)

1 2 3

T1

T2

T3

A

M

TR

TR

OLM RES

A

M RES

A

TR

OL

OL

MOTOR

L1

L2

L3

M RES

A

STARTSTOP

TR

OL

2 WIRE CONTROL DEVICE (if used)

1 2 3

T1

T2

T3

A

M

TR

TR

OLM RES

A

M RES

A

TR A

OL

OL

DIS

CO

NN

EC

T M

EA

NS

(OP

TIO

NA

L)

MOTOR

L1

L2

L3

M RES

A

FU1

1TR

STARTSTOP

1TR

OL

2 WIRE CONTROL DEVICE (if used)

1 2 3

T1

T2

T3

M

GROUND(if used)

M

2TR

2TR

1TR

PRI

SEC

(H1)

(X1) (X2)

PRI

SEC

(H1)

(X1) (X2)

1OL

1CT

2OL

2CT

3OL

3CT

M RES

A

M RES

A

A

A

FU2

FU3

1TR

DIS

CO

NN

EC

T M

EA

NS

(OP

TIO

NA

L)

MOTOR

L1

L2

L3

M RES

A

FU1

1TR

STARTSTOP

1TR

OL

2 WIRE CONTROL DEVICE (if used)

1 2 3

T1

T2

T3

GROUND(if used)

M

2TR

2TR

1TR

PRI

SEC

(H1)

(X1) (X2)

PRI

SEC

(H1)

(X1) (X2)

M RES

A

M RES

A

A

A

FU2

FU3

1TR

SOLID STATEOVERLOAD RELAY

1CT

2CT

3CT

PRI

SEC

(H1)

(X1) (X2)

M

DIS

CO

NN

EC

T M

EA

NS

(OP

TIO

NA

L)MOTOR

Page 70: Wiring Diagram Book

66

®

Reduced Voltage Controllers

Class 8650 and 8651Wound-Rotor Type

Wound-Rotor Reduced Voltage Controllers:Class 8650 and 8651

FIG. 1

Non-Reversing Wound-Rotor Motor Controller w/ 3 Points of AccelerationClass 8650

FIG. 2

Reversing Wound-Rotor Motor Controller w/ 3 Points of AccelerationClass 8651

FPO 49-3135%

FPO 49-4135%

Page 71: Wiring Diagram Book

67

®

Solid State Reduced Voltage Starters

Class 8660ALPHA PAK

®

, Type MD-MG

ALPHA PAK

®

Solid State Reduced Voltage Starters:Class 8660 Type MD-MG

FIG. 1

Type MD (16 A), ME (32 A), MF (64 A) and MG (128 A)

FIG. 2

Type MD (16 A), ME (32 A), MF (64 A) and MG (128 A) w/ Isolation Contactor

OR

DIS

CO

NN

EC

T S

WIT

CHL1

L2

L3 CIR

CU

IT B

RE

AK

ER

STARTSTOP

M

OT*

T1

T2

T3

M

M

SOLID STATEOVERLOAD RELAY

1CT

M

M

MOTOR

3CT

TO 120 VSEPARATECONTROL

* OT is a switch that openswhen an overtemperaturecondition exists (Type MFOand MGO only)

OR

DIS

CO

NN

EC

T S

WIT

CHL1

L2

L3 CIR

CU

IT B

RE

AK

ER

STARTSTOP

M

OT*

T1

T2

T3

M

M

SOLID STATEOVERLOAD RELAY

1CT

M

M

MOTOR

3CT

ISO

ISO

ISO

TO 120 VSEPARATECONTROL

CR

ALARM

TR

TRISO

CR

* OT is a switch that openswhen an overtemperaturecondition exists (Type MFOand MGO only)

Page 72: Wiring Diagram Book

68

®

Solid State Reduced Voltage Controllers

Class 8660Type MH, MJ, MK and MM

Solid State Reduced Voltage Controllers: Class 8660 Type MH, MJ, MK and MM

FIG. 1

Type MH (200 A), MJ (320 A), MK (500 A) and MM (750 A)

FIG. 2

Type MH (200 A) w/ Shorting Contactor

FIG. 3

Type MJ (320 A), MK (500 A) and MM (750 A) w/ Shorting Contactor

Page 73: Wiring Diagram Book

69

®

Solid State Reduced Voltage Controllers

Class 8660Type MH, MJ, MK and MM

Solid State Reduced Voltage Controllers: Class 8660 Type MH, MJ, MK and MM

FIG. 1

Type MH (200 A) w/ Isolation Contactor

FIG. 2

Type MJ (320 A), MK (500 A) and MM (750 A) w/ Isolation Contactor

FPO51-1130%

FPO51-2130%

Page 74: Wiring Diagram Book

70

®

Solid State Reduced Voltage Controllers: Class 8660 Type MH, MJ, MK and MM

FIG. 1

Type MH (200 A) w/ Isolation Contactor and Shorting Contactor

FIG. 2

Type MJ (320 A), MK (500 A) and MM (750 A) w/ Isolation Contactor and Shorting Contactor

FPO51-3130%

FPO51-4130%

Solid State Reduced Voltage Controllers

Class 8660Type MH, MJ, MK and MM

Page 75: Wiring Diagram Book

71

®

Type S AC Reversing Magnetic Starters

Class 87362- and 3-Pole

Reversing Starters, 2- and 3-Pole, Size 00-1:Class 8736 Type S

FIG. 1

Wiring Diagram Elementary Diagram

2-Pole, w/ Single Phase, 3-Lead Motor

FIG. 2

Wiring Diagram Elementary Diagram

3-Pole, w/ Single Phase, 4-Lead Repulsion-Induction Motor

FIG. 3

Wiring Diagram Elementary Diagram

3-Pole, w/ Single Phase, 4-Lead Capacitor or Split-Phase Motor

* Marked “OL” if alarm contact is supplied

FPO 52-1

FP

O 5

2-1

* Marked “OL” if alarm contact is supplied

FPO 52-2FPO52-2

* Marked “OL” if alarm contact is supplied

FPO 53-1

FP

O 5

3-1

Page 76: Wiring Diagram Book

72

®

Reversing Starters, 3- and 4-Pole:Class 8736 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Size 00-2, 4-Pole, 2-Phase

FIG. 2

Wiring Diagram Elementary Diagram

Size 00-4, 3-Pole, 3-Phase

FIG. 3

Wiring Diagram Elementary Diagram

Size 5, 3-Pole, 3-Phase

* Marked “OL” if alarm contact is supplied

FPO 53-2 FPO53-2

* Marked “OL” if alarm contact is supplied

FPO 53-3 FPO53-3

FPO 54-1

FPO54-1

Type S AC Reversing Magnetic Starters

Class 87363- and 4-Pole

Page 77: Wiring Diagram Book

73

®

Type S AC 2-Speed Magnetic Starters

Class 8810

Starters for 2-Speed, 2-Winding (Separate Winding), 3-Phase Motors:Class 8810 Type S

FIG. 1

Wiring Diagram Elementary Diagram

Size 0-4

FIG. 2

Size 5 Wiring Diagram

Starters for 2-Speed, 1-Winding (Consequent Pole), Constant or Variable Torque, 3-Phase Motors:Class 8810 Type S

FIG. 3

Wiring Diagram Elementary Diagram

Size 0-2

FP

O 5

4-2

FPO

54-2

FPO 54-3

FP

O 5

5-1

* Marked “OL” if alarm contact is supplied

FPO

55-1

Page 78: Wiring Diagram Book

74

®

Starters for 2-Speed, 1-Winding (Consequent Pole), Constant or Variable Torque, 3-Phase Motors:Class 8810 Type S

FIG. 1 FIG. 2

Size 3 and 4 Wiring Diagram Size 5 Wiring Diagram

Starters for 2-Speed, 1-Winding (Consequent Pole), Constant Horsepower, 3-Phase Motors:Class 8810 Type S

FIG. 3

Wiring Diagram Elementary Diagram

Size 0-2

FIG. 4 FIG. 5

Size 3 and 4 Wiring Diagram Size 0, w/ High-Off-Low Selector Switch (Form C7) Wiring Diagram

FPO

* Marked “OL” if alarm contact is supplied

55-2

FPO

55-3

FP

O 5

5-4

* Marked “OL” if alarm contact is supplied

FPO

55-4

FPO 56-1

* Marked “OL” if alarm contact is supplied75%

FPO 56-2

75%

* Marked “OL” if alarm contact is supplied

Type S AC Reversing Magnetic Starters

Class 8810

Page 79: Wiring Diagram Book

75

®

2-Speed Magnetic Starters

Class 8810Special Control Circuits

Form R1 Form R2

FIG. 1 FIG. 2

Compelling Relay, Requiring Motor Starting in Low Speed Accelerating Relay, Providing Timed Acceleration to Selected Speed

Form R3 Form R2R3

FIG. 3 FIG. 4

Decelerating Relay, w/ Time Delay During Transfer from Higher to Lower Speed

Accelerating Relay and Decelerating Relay

Form R1R3 Form A10C

FIG. 5 FIG. 6

Compelling Relay and Decelerating Relay Hand-Off-Auto Selector Switch and High-Low Push Button

Form CC17 Form A10CR1

FIG. 7 FIG. 8

Hand-Off-Auto Selector Switch and High-Low Selector Switch Hand-Off-Auto Selector Switch and High-Low Push Button w/ Compelling Relay/Timer

FPO

57-1

FPO 57-2

FPO

57-3

FPO

57-4

FPO 57-5

FPO

57-6

FPO

57-7 FPO

57-8

Page 80: Wiring Diagram Book

76

®

2-Speed Magnetic Starters and Multispeed Motor Connections

Class 8810Special Control Circuits and 1- and 3-Phase Motor Connections

Form C25 Form CC17 R2R3

FIG. 1 FIG. 2

High-Low-Off-Auto Selector Switch Hand-Off-Auto Selector Switch and High-Low Selector Switch w/ Accelerating and Decelerating Relay/Timer

Multispeed Motor Connections:1-Phase, 2-Speed Motors

FIG. 3 FIG. 4 FIG. 5

2 Windings 2 Windings 1 Winding

FIG. 6 FIG. 7 FIG. 8

1 Winding 1 Winding 1 Winding

Multispeed Motor Connections:3-Phase, 2-Speed Motors

FIG. 9 FIG. 10 FIG. 11

1 Winding, Constant Horsepower 1 Winding, Constant Torque 1 Winding, Variable Torque

FIG. 12 FIG. 13 FIG. 14

Separate Windings Separate Windings Separate Windings

FPO

57-9

FPO

57-10

120%

T1 T2 T3 T4

Speed L1 L2 Open Together

Low T1 T2 T3,T4 —High T3 T4 T1,T2 —

T1 T2 T3 T4

Speed L1 L2 Open Together

Low T3 T4 T1,T2 —High T1 T2 T3,T4 —

COM A B

Speed L1 L2 Open Together

Low COM A B —High COM B A —

T1 COM T4

Speed L1 L2 Open Together

Low COM T1 T4 —High COM T4 T1 —

T1 COM T4

Speed L1 L2 Open Together

Low T1 T4 COM —High T1 COM — T1,T4

T1 COM T4

Speed L1 L2 Open Together

Low T1 COM — T1,T4High T1 T4 COM —

T3

T5 T6

T1

T2

T4

Speed L1 L2 Open Together

Low T1 T2 — T4,T5,T6High T6 T4 All others —

L3

T3T5

T3

T5 T6

T1

T2

T4

Speed L1 L2 Open Together

Low T1 T2 All others —High T6 T4 — T1,T2,T3

L3

T3T5

T3

T5 T6

T1

T2

T4

Speed L1 L2 Open Together

Low T1 T2 All others —High T6 T4 — T1,T2,T3

L3

T3T5

T3

T1

T2

Speed L1 L2 Open

Low T1 T2 All othersHigh T11 T12 All others

L3

T3T13

T13

T11

T12 T3

T1

T2

Speed L1 L2 Open

Low T1 T2 All othersHigh T11 T12 All others

L3

T3T13,T17

T13

T11

T12T17 T13

T11

T12

Speed L1 L2 Open

Low T1 T2 All othersHigh T11 T12 All others

L3

T3,T7T13

T3

T1

T2T7

Page 81: Wiring Diagram Book

77

®

Multispeed Motor Connections

3-Phase

Multispeed Motor Connections:3-Phase, 2-Speed Motors

FIG. 1 FIG. 2 FIG. 3

Separate Windings 2-Phase, 1 Winding, Variable Torque 2-Phase, Separate Windings

Multispeed Motor Connections:3-Phase, 3-Speed Motors

FIG. 4 FIG. 5 FIG. 6

2 Windings, Constant Torque 2 Windings, Constant Torque 2 Windings, Constant Torque

FIG. 7 FIG. 8 FIG. 9

2 Windings, Variable Torque 2 Windings, Variable Torque 2 Windings, Variable Torque

Multispeed Motor Connections:3-Phase, 4-Speed Motors

FIG. 10 FIG. 11 FIG. 12

2 Windings, Constant Horsepower 2 Windings, Constant Horsepower 2 Windings, Constant Torque

FIG. 13 FIG. 14 FIG. 15

2 Windings, Constant Torque 2 Windings, Variable Torque 2 Windings, Variable Torque

Speed L1 L2 Open

Low T1 T2 All othersHigh T11 T12 All others

L3

T3,T7T13,T17

T3

T1

T2T7 T13

T11

T12T17 T3

T1

T2

Speed L1 L3 Open

Low T1 T5 T3,T4High T1,T5 T3 —

L2

T2T2,T6

T4T6

T5

L4

T6T4

T3

T1

T2

Speed L1 L3 Open

Low T1 T3 All othersHigh T11 T13 All others

L2

T2T12

T4

L4

T4T14

T13

T11

T12T14

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T6 T4 — T1,T2,T3,T7

L3

T3,T7T5

T13

T11

T12

T7

T5 T6

T1

T2

T4

T3

High T11 T12 All others —T13

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T11 T12 All others —

L3

T3,T7T13

T13

T11

T12

T7

T5 T6

T1

T2

T4

T3

High T6 T4 All others T1,T2,T3,T7T5

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T11 T12 All others —

L3

T3T13,T17

T3

T1

T2

T17

T15 T16

T11

T12

T14

T13

High T16 T14 All others T11,T12,T13,T17T15

T3

T5 T6

T1

T2

T4

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T6 T4 All others T1,T2,T3

L3

T3T5

T13

T11

T12

High T11 T12 All others —T13

T3

T5 T6

T1

T2

T4

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T11 T12 All others —

L3

T3T13

T13

T11

T12

High T6 T4 All others T1,T2,T3T5

T13

T15 T16

T11

T12

T14

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T11 T12 All others —

L3

T3T13

T3

T1

T2

High T16 T14 All others T11,T12,T13T15

T5

T4

T6T7 T15

T14

T16T17

Speed L1 L2 Open Together

Low T1 T2 All others T4,T5,T6,T72nd T6 T4 All others —

L3

T3T5,T7

High T16 T14 All others —T15,T17

T3 T1

T2 T12

T13 T11

3rd T11 T12 All others T14,T15,T16,T17T13

T5

T4

T6T7 T15

T14

T16T17

Speed L1 L2 Open Together

Low T1 T2 All others T4,T5,T6,T72nd T11 T12 All others T14,T15,T16,T17

L3

T3T13

High T16 T14 All others —T15,T17

T3 T1

T2 T12

T13 T11

3rd T6 T4 All others —T5,T7

L1 L2 Open Together

Low T1 T2 All others —2nd T6 T4 All others T1,T2,T3,T7

L3

T3,T7T5

High T16 T14 All others T11,T12,T13,T17T153rd T11 T12 All others —T13,T17

T7

T5 T6

T1

T2

T4

T3T17

T15 T16

T11

T12

T14

T13

Speed

L1 L2 Open Together

Low T1 T2 All others —2nd T11 T12 All others —

L3

T3,T7T13,T17

High T16 T14 All others T11,T12,T13,T17T153rd T6 T4 All others T1,T2,T3,T7T5

T7

T5 T6

T1

T2

T4

T3T17

T15 T16

T11

T12

T14

T13

Speed L1 L2 Open Together

Low T1 T2 All others —2nd T6 T4 All others T1,T2,T3

L3

T3T5

High T16 T14 All others T11,T12,T13T153rd T11 T12 All others —T13

Speed

T3

T5 T6

T1

T2

T4

T13

T15 T16

T11

T12

T14

L1 L2 Open Together

Low T1 T2 All others —2nd T11 T12 All others —

L3

T3T13

High T16 T14 All others T11,T12,T13T153rd T6 T4 All others T1,T2,T3T5

Speed

T3

T5 T6

T1

T2

T4

T13

T15 T16

T11

T12

T14

Page 82: Wiring Diagram Book

78®

Programmable Lighting ControllersClass 8865

Programmable Lighting Controller:Class 8865 Type TC12

FIG. 1

+ 1 – + 2 – + 3 – + 4 – + 5 – + 6 – + 7 – + 8 – DemandInput

24 VACINPUT

INPUTS1CIR

CU

IT 1

23

4CIR

CU

IT 2

56

7CIR

CU

IT 3

89

10CIR

CU

IT 4

1112

13CIR

CU

IT 5

1415

16CIR

CU

IT 6

1718

RE

LA

Y O

UT

PU

T C

ON

NE

CT

ION

SC

IRC

UIT

S 1-6

19 C

IRC

UIT

7

2021

22

CIR

CU

IT 8

2324

25

CIR

CU

IT 9

2627

28 CIR

CU

IT 1

0

2930

31 CIR

CU

IT 1

1

3233

34 CIR

CU

IT 1

2

3536

RE

LA

Y O

UT

PU

T C

ON

NE

CT

ION

SC

IRC

UIT

S 7

-12

Page 83: Wiring Diagram Book

79®

AC Lighting ContactorsClass 8903

Load Connections

Load Connections for AC Lighting Contactors:Class 8903

FIG. 1 FIG. 2

1-Phase, 2-Wire, Single Load 1-Phase, 2-Wire, Multiple Loads

FIG. 3 FIG. 4

1-Phase, 3-Wire, Loads Connected Line-to-Neutral 1-Phase, 3-Wire, Load Connected Line-to-Line

FIG. 5 FIG. 6

3-Phase, 3-Wire, Wye-Connected Load 3-Phase, 3-Wire, Delta-Connected Load

FIG. 7

Application Limits:

1. Voltage between line side conductors must notexceed line-to-line voltage rating of contactor.

2. Vload must not exceed volts-per-load rating ofcontactor.

3. Line current carried by any contact must notexceed ampere rating of contactor.

For contact ratings, refer to the Square D Digest.

3-Phase, 4-Wire, Loads Connected Line-to-Neutral

LOAD

L1 L2

IFUSED

Vload = Vline-tol-lineLOAD

L1 L2

IFUSED

LOAD

LOAD

L1 LNL2Vload = Vline-to-line

LOAD

L1 LN

IFUSED

LOAD

L2

Vload = Vline-to-neu-

LOAD

L1 LN

IFUSED

L2

Vload = Vline-to-line

LOAD

L1

LOAD

L2 L3

LOAD

L1 L2 L3 LN

Vload = Vline-to-line

1.732

LOAD

L1 L2 L3

LOADLOAD

Vload = Vline-to-line Iload = Icontacts

1.732

LOAD

L1

LOAD

L2 L3

LOAD

LN

IFUSED

Vload = Vline-to-neu-

Page 84: Wiring Diagram Book

80®

AC Lighting ContactorsClass 8903Control Circuit Connections

Control Circuit Connections for Electrically-Held Contactors:Class 8903 Type L and S

FIG. 1 FIG. 4

On-Off Push Button (Form A12)

FIG. 2

Direct Control from Pilot Device

FIG. 3

On-Off Selector Switch (Form C6) Hand-Off-Auto Selector Switch (Form C)

Control Circuit Connections for Mechanically-Held Contactors:Class 8903 Type LX and S

FIG. 5 FIG. 6

On-Off Push Button (Form A3) On-Off Selector Switch (Form C6)

FIG. 7 FIG. 8

Control from 2-Pole Pilot Device 1-Pole Pilot Device w/ CR relay (Form R6)

COILOFF

M

ON

To AC commonor separatecontrol supply

COIL

To AC commonor separatecontrol supply

A1

A2

A1A2

I

HAND OFF

2-WIREPILOTDEVICE

IAUTO

COIL2-WIREPILOT DEVICE

To AC commonor separatecontrol supply

COIL

To AC commonor separatecontrol supply

A1

A2

A1A2

I

ONI

OFF

LATCHON

To AC commonor separatecontrol supply

UNLATCH

COIL CLEARINGCONTACTS(Supplied)

B

A14

15

17

18

OFF

LATCH

To AC commonor separatecontrol supply

UNLATCH

COIL CLEARINGCONTACTS(Supplied)

B

A14

15

17

18

A1

A2

A1A2

I

ONI

OFF

LATCH

To AC commonor separatecontrol supply

UNLATCH

COIL CLEARINGCONTACTS(Supplied)

B

A14

15

17

18

2-POLEPILOT

DEVICE

LATCH

To AC commonor separatecontrol supply

UNLATCH

COILCLEARINGCONTACTS(Supplied)

B

A14

15

17

18

CR

CR

1-POLEPILOT

DEVICE

CR

Page 85: Wiring Diagram Book

81®

AC Lighting Contactors and Electronic Motor BrakesClass 8903 and 8922

Panelboard Type Wiring:Class 8903 Type PB, 30-225 A

FIG. 1 FIG. 3 FIG. 4

Control Circuit – Standard

FIG. 2

Control Circuit – 2-Wire Control (Form R6)

Control Circuit – Long-Distance Control (Form R62)

Power Circuit

QWIK-STOP® Electronic Motor Brake:Class 8922

FIG. 5

Type ETB10, ETB18 and ETBS18 w/ Internal Braking Contactor

FIG. 6

Type ETB20-ETB800 and ETBS20-ETBS800

OFFL

O

CON

L1

L2/N

CR2L

O

CCR1

L1

L2/N

CR2

CR1

OFF

ON

L1

T1

C

SO

+ –

L2

T2

L3

T3L

O

C BR

SC

L = Line (common)O = Open (unlatch)C = Close (latch)

Omit middle polefor 2-pole unit

CRL

O

CCR

L1

L2/N

CR

2-WirePilot Device

L1

L2

L3

STARTSTOP

M

OL

T1

T2

T3

M

M

PLC

MOTOR

CUSTOMER CONTROL CIRCUIT

F1 F1

Xo Xo

ETB 10/18

When controlling electronic motor brakeETB 10/18 with a PLC (programmable logiccontrol), terminals Xo-Xo must be jumpered.

[2]

[2]

MF2 OL

MF2 OL

MF2 OL

L+L1

L–L2

B–

B+B1

ETB 10/18

POWER CIRCUIT

F3

F324 VDC

+

[4]

Connection for ETBS only.[4]

15 18

[1]

Contacts 15 and 18 close whenL1 and L2 are energized.

[1]

[3]

[3]

Semiconductor fuses.[3]

L1

L2

L3

STARTSTOP

M

OL

T1

T2

T3

M

M

PLC

MOTOR

CUSTOMER CONTROL CIRCUIT

F1 F1

Xo Xo

ETB 20/800

When controlling electronic motor brake ETB 20/800 with a PLC(programmable logic control), terminals Xo-Xo must be jumpered.

[2]

[2]

MF2 OL

MF2 OL

MF2 OL

L+L1

L–L2

B–

B+B1

ETB 20/800

POWER CIRCUIT

F3

F324 VDC

+

[4]

Connection for ETBS only.[4]

15 18

[1]

Contacts 15 and 18 close when L1 and L2 are energized.[1]

[3]

[3]

Semiconductor fuses.[3]

M25 28

B

B

B

B

QWIK-STOP is a registered trademark of Square D.

Page 86: Wiring Diagram Book

82®

Electronic Motor Brakes, Duplex Motor Controllers and Fiber Optic TransceiversClass 8922, 8941 and 9005

QWIK-STOP® Electronic Motor Brake: Class 8922 Type ETBC

FIG. 1

Type ETBC

AC Duplex Motor Controller: Class 8941 Fiber Optic Transceiver: Class 9005

FIG. 2 FIG. 3

Elementary Diagram for Duplex Motor Controller w/ Electric Alternator Transceiver, Front View

FIG. 4

Location

L1

L2

L3

STARTSTOP

M

OL

T1

T2

T3

M

M

MOTOR

CUSTOMER CONTROLCIRCUIT

F1 F1

To control electronic motor brake ETBC with input B+/B–,terminals 3 and 4 must bejumpered.

[1]

MF2 OL

MF2 OL

MF2 OL

T1/2L1

T2/4L2

ETBC

F3

F3

[1]

[2]

[2]

Semiconductor fuses.[2]

B

B

M

PLC

24 VDC INPUT+

1

2

3

4

5

6

7

B+ 9

B– 10QWIK-STOP is a registered trademark of Square D.

A2

FIBER

A1

FIBER RELEASE

OUTPUT SETUP

GAIN

POWER

1112

OUTPUT14

86

OUTPUTSTATUSLED SETUP

LED

FIBERRELEASELEVER

GAINADJ.SCREW

INPUT

FIBER OPTICTRANSCEIVER

CLASS 9005 TYPE FT

FIBER OPTICPUSH BUTTON,SELECTOR SWITCH,LIMIT SWITCH, ETC.

FIBER OPTIC CABLEELECTRICALCONNECTIONS

BOUNDARY SEAL TO BE INACCORDANCE WITH ARTICLE501-5 OF THE NATIONALELECTRICAL CODE

HAZARDOUS LOCATIONS NONHAZARDOUS LOCATIONSCLASS I GROUPS A, B, C & DCLASS II GROUPS E, F & GCLASS III

FIBER OPTIC CABLE

Page 87: Wiring Diagram Book

83®

Photoelectric Switches:Class 9006 Type PE1 (Obsolete)

FIG. 1

Connect load in series. To prevent damage, all switches except emitters must have load connected to switch.

FIG. 2AC thru-beam emitter has no output switching capability, therefore leakage current is not applicable. Thru-beam emitter is connected directly across the AC line and typically draws 15 mA.

2-Wire AC, Single Device Operation AC Emitter

FIG. 3

DC switches cannot be wired in series. To prevent damage, all switches except emitters must have load connected to switch.

FIG. 4DC thru-beam emitter has no output switching capability, therefore it requires only a 2-wire cable connected directly across the DC. Thru-beam emitter draws a maximum of 45 mA.

4-Wire DC, Single Device Operation, 10-30 VDC, 250 mA Max. Load DC Emitter

Photoelectric Switches:Class 9006 Type PE6 and PE7 (Obsolete)

Photoelectric Switches:Class 9006 Type PEA120 (Obsolete)

FIG. 5

These switches are light operated only.

Beam broken = load deenergizedBeam unbroken = load energized

FIG. 8

Diagram shows contact arrangement with beam broken.

12-24 VDC, Sinking (NPN)

FIG. 6

12-24 VDC, Sourcing (PNP)

FIG. 7

120 VAC, Emitter Only 120 VAC Amplifier

Inductive Proximity Switches:Class 9006 Type PS (Obsolete)

FIG. 9 FIG. 10 FIG. 11

2-Wire AC, N.O. 2-Wire AC, N.C. 2-Wire AC, N.O. or N.C.

FIG. 12 FIG. 13 FIG. 14

2-Wire DC, N.O. 4-Wire DC, Sinking (NPN) 4-Wire DC, Sourcing (PNP)

Photoelectric and Inductive Proximity SwitchesClass 9006

Page 88: Wiring Diagram Book

84

®

Inductive Proximity Sensors

XS, XSC, XSF and XSD

XS Tubular Inductive Proximity Sensors

FIG. 1 FIG. 2

2-Wire DC, Non-Polarized 2-Wire AC/DC

FIG. 3 FIG. 4 FIG. 5

3-Wire DC, N.O. or N.C. 3-Wire DC, N.O. and N.C., Complementary 3-Wire DC, Selectable PNP/NPN, N.O./N.C.

XSC Rectangular Inductive Proximity Sensors

FIG. 6 FIG. 7 FIG. 8 FIG. 9

2-Wire DC, Non-Polarized 2-Wire AC, Programmable 2-Wire AC/DC, Programmable 3-Wire DC, N.O. or N.C.

XSF Rectangular Inductive Proximity Sensors

FIG. 10 FIG. 11

2-Wire AC, Programmable N.O. or N.C. 3-Wire DC, N.O. or N.C.

XSD Rectangular Inductive Proximity Sensors

FIG. 12 FIG. 13 FIG. 14

2-Wire DC, Non-Polarized 2-Wire AC, Programmable N.O. or N.C. 3-Wire DC, N.O. or N.C.

NO

BN/3

BU/4

+/–

–/+

BN/2

BU/3

L1 +/–

L2 –/+

for connector version only

AC/DC

PNP

NO

BN/1

BK/4 NO

BK/2 NC

+

–BU/3

NPN

NO

BN/1

BK/4 NOBK/2 NC

+

–BU/3

PNPNO

BN/1BK/4

WH/2

+

–BU/3

NPNNO

BN/1

WH/2

BK/4

+

–BU/3

NC

NC

PNP

BN/1 (NO), BU/3 (NC)

BK/4+

NPN

BU/3 (NO), BN/1 (NC)

BK/4

+

–BN/1 (NO), BU/3 (NC)

NC

3

4

+/–

–/+

NO

3

4

+/–

–/+

NC

5

6

L1

L2

NO

5

6

L1

L28 BK

7 BK

NC

5

6

AC/DC

NO

5

6

AC/DC

7 8

7 8

PNPNO

4

2

+

–3

NPNNO

1

2

4

+

–NC

NC

3

1

NC

1

4

L1

NO

1

2

L1

L2

L2

PNPNO

4

2

+

–3

NPNNO

1

2

4

+

–NC

NC

3

1

NC

3

4

+/–

–/+

NO

3

4

+/–

–/+L1

NO

L2

8

7NC

8

7

LOAD

PNPNO

4

2

+

–3

NPNNO

1

2

4

+

–NC

NC

3

1

Page 89: Wiring Diagram Book

85

®

Inductive and Capacitive Proximity Sensors

XS and XTA

XS Tubular Inductive Proximity NAMUR Sensors

FIG. 1 FIG. 2

Non-Intrinsically Safe Applications (Normal Safe Zone),Connected to a Solid State Input

With XZD Power Supply/Relay Amplifier Unit

XS Inductive Proximity Sensors w/ Analog Output

FIG. 3

Output current Value of Load R (max.)@ 24 V:

0-10 mA 1800

Ω

0-16 mA 1125

Ω

@ 48 V:0-10 mA 4200

Ω

FIG. 4

Output current Value of Load R (max.)@ 24 V:

4-14 mA 640

Ω

4-20 mA 450

Ω

@ 48 V:4-14 mA 2350

Ω

These sensors may be wired in the 2- or 3-wire mode, depending on the current output characteristics required.

2-Wire DC 3-Wire DC

XTA Tubular Capacitive Proximity Sensors

FIG. 5 FIG. 6

2-Wire AC 3-Wire DC

ed to a solid state in ut (e.g. : ST1 CC/CS, TSX DET 466)

_ +

BU-2

BN-1Ri = 1K

I > 3mA

7...12V DC

BU-2

BN-1Ri = 1K

I < 1mA

7...12V DC

AAA

+

+

-

-

+

+

-

-

Objectpresent

Objectabsent

+ _

BN BU

4 2.F 1.+

1 2(110...240V) AC P=

XZD

Aproximity sensor

Wiring diagram

2.0

(110...240 V)AC P = 5 VA, 50 Hz

,BN

BU

L1

L2

Gn*

* Ground for XTA A115 only

BN +

-

BK

BU

PNP

BN +

-

BK

BU

NPN

Page 90: Wiring Diagram Book

86

®

Magnet Actuated Proximity Sensors and Photoelectric Sensors

SG, ST and XUB

SG Magnet Actuated Proximity Sensors, Surface Mount Style

FIG. 1 FIG. 2 FIG. 3

SGA 8016, SGA 8031, SGA 8182, SGA 8053, SGA 8176, SGA 8177, SG0 8168 and SG08239

SGB 8175 SG2 8195

SG Magnet Actuated Proximity Sensors, Limit Switch Style

FIG. 4 FIG. 5 FIG. 6

SG0 8003, SG1 8004, SGA 8005 and SGA 8040 SG0 L8003 and SG1 L8004 SGC 8027 and SGC 8025

FIG. 7 FIG. 8

SG0 B8114, SG1 B8147, SG0 BL8114, SG0 BL8147 and SGC 8142-T-P

SG0 8079 and SG1 8056

SG Magnet Actuated Proximity Sensors, Tubular Style

FIG. 9 FIG. 10

SGA 8057, SGA 8189, SGA 8072, SGA 8179, SGA 8180 and SGA 8038

SGC 8058 and SGC 8181

SG Magnet Actuated Proximity Sensors, Maintained Contact

FIG. 11 FIG. 12

SGA 8018, SGO 8026 SGO 8110

ST Grounded Probe Switch

FIG. 13 FIG. 14

ST switches may be wired in series or parallel. For series operation, connect red lead (terminal 4) to black lead (terminal 1) of other switch. The voltage drop across each switch (in the closed state) does not exceed 2 VAC.

Cable Wiring Terminal strip Wiring

XUB Short Range Tubular Photoelectric Sensors

FIG. 15 FIG. 16 FIG. 17

2-Wire AC AC Emitter DC Emitter

LOAD

L1 L2

LOAD

L1 L2LOAD

LOAD

Red

White

Black

LOAD

L1 L2

LOAD

L1 L2LOAD

LOAD

ComNO

NC

LOAD

Com++ –

LOAD+ -L

+ SG1 8056 is normally closed. Connect red terminal (+) to power source. Connect minus (-) terminal to load. Housing must be connected to minus.

LOAD

L1 L2LOAD

LOAD

ComNO

NC

LOAD

L1 L2

LOAD

L1 L2

6.8k

2

3

1

Blk Gnd Wht RedL1

hot

L2

neutral

LOAD

Target connected to ground

1 2 3 4L1 L2hot

neutral

LOAD

Target connected to ground. Housingmust be grounded for proper operation.

Notusedhousing

Page 91: Wiring Diagram Book

87

®

Photoelectric Sensors

XUM, XUH, XUG, XUL and XUJ

XUM Miniature High Performance Photoelectric Sensors XUH and XUG Medium Range Photoelectric Sensors

FIG. 1 FIG. 2 FIG. 3

PNP Output NPN Output 5-Wire AC

XUL Subcompact Photoelectric Sensors

FIG. 4 FIG. 5

DC AC/DC

XUJ Compact High Performance Photoelectric Sensors

FIG. 6 FIG. 7 FIG. 8 FIG. 9

5-Wire Relay, AC/DC AC/DC Microchange DC Connector

DC Output DC Output Microchange DC Connector

BN

BU

BKLOAD

+ Light

- Dark

TestW LOAD

H

Prog.

OG BN

LOAD

+ Light

- Dark

Test

OG

LOAD

J

Prog.

W

BK

BU

Emitter DCBN

BU

DC 3 wire

PNP output

BN

BU

OG

BK

+ light

- dark

Prog.

NPN outputBN

BU

BK

OG + light

- dark

Prog.

Connector, PNP output

1

3

2

4

+ light

- dark

Prog.

Connector, NPN output1

34

2+ light

- dark

Prog.

DC connector

1

2 4prog. Output

+

Emitter

BN

BU

AC/DC

AC/DC

BN

BK

BU

RDOG

Relay outputAC/DC versions

AC/DC

AC/DC

+

1Dark 2

+Light 3or

4

5

1 k6 Test

LOAD

NPN

PNP

+

Ω

Page 92: Wiring Diagram Book

88

®

Photoelectric Sensors and Security Light Barriers

XUE, XUR, XUD, XUG and XUE S

XUE Long Range Plug-In Photoelectric Sensors

FIG. 1 FIG. 2 FIG. 3

DC Emitter XUE A XUE H, NPN

FIG. 4 FIG. 5 FIG. 6

XUE H, PNP XUE F XUE T

XUR Color Registration Photoelectric Sensors

FIG. 7 FIG. 8

PNP NPN

XUD Amplifiers XUG Amplifiers

FIG. 9 FIG. 10 FIG. 11

XUD H XUD J for XUF N Plastic Fiber Optics – DC models

XUE S Security Light Barriers

FIG. 12 FIG. 13

Emitter Receiver

PNP

BN

H

Light Mode:Connect to +OG

+

–BU

Dark Mode:Connect to –

BK NPN

BN

J

+

–BU

BK Light Mode:Connect to +OGDark Mode:Connect to –

T1

T2

A1

A2

Open to

test

L1

L2

5

6

3

4

L1

L2

1

2

Page 93: Wiring Diagram Book

89

®

Photoelectric Sensors

XUV

XUV Photoelectric Sensors w/ Separate Optical Heads

FIG. 1 FIG. 2

PNP Output NPN Output

FIG. 3

AC Wiring Diagrams

+

+

H

PNP

H

W Test

BU

BKBN

Grey

Synchro

Gating Sensor

LOAD

LOAD

NPN

WTest

BUBK

BN

GreySynchro

Gating Sensor

+

J

J

LOAD

LOAD

13 15 17 19

2 4 6 8

12 3

A

21

Terminals

Potentiometers

Switches

LED indicators

Terminals

TERMINALS2 L1 Supply4 L2 Supply6-8 Relay output (1 contact)13 Receiver (white wire)15 Receiver shielded cable17 Emitter shield19 Emitter (red wire)

1 CHANNEL AMPLIFIER

13 15 17 19

2 4 6 8

1 3 5 7

33 4

B

41

Terminals

Potentiometers

Switches

LED indicators

Terminals

TERMINALS1 L1 Supply2 L2 Supply3 NC output, Channel 24 NC output, Channel 15 Common, Channel 26 Common, Channel 17 NO output, Channel 28 NO output, Channel 19 12 VDC output for synchro sensors10 12 VDC output for synchro sensors11 Synchronization, Channel 2, NPN12 Synchronization, Channel 1, NPN13 Emitter shield, Channel 114 Receiver, Channel 1 (white wire)15 Emitter, Channel 1 (red wire)16 Receiver shield, Channel 117 Emitter shield, Channel 218 Receiver, Channel 2 (white wire)19 Emitter, Channel 2 (red wire)20 Receiver shield, Channel 2

2 CHANNEL AMPLIFIER – FORM C RELAY

14 16 18 2010 12

9 11

2 5

A

1 2

SWITCHES1 Monostable timer (pulse stretcher), Channel 12 Light/Dark, Channel 13 Monostable timer (pulse stretcher), Channel 24 Light/Dark, Channel 2

A Sensitivity adjustment, Channel 1B Sensitivity adjustment, Channel 2

1 Green: power supply2 Red: unstable, Channel 13 Yellow: output, Channel 14 Red: unstable, Channel 25 Yellow: output, Channel 2

POTENTIOMETERS

SWITCHES1 Light/Dark2 Monostable timer (pulse stretcher)

1 Green: power supply2 Red: unstable3 Yellow: output

A Sensitivity adjustmentPOTENTIOMETERS

13 15 17 19

2 4 6 8

1 3 5 7

73 4

C

81

Terminals

Potentiometers

Switches

LED indicators

Terminals

TERMINALS1 L1 Supply2 L2 Supply3 Output test (1 contact relay)4 Output test (1 contact relay)5 Channel 1 output (1 contact relay)6 Channel 1 output (1 contact relay)7 Channel 2 output (1 contact relay)8 Channel 2 output (1 contact relay)9 12 VDC output for synchro sensors10 12 VDC output for synchro sensors11 Synchronization, Channel 2, NPN12 Synchronization, Channel 1, NPN13 Emitter shield, Channel 114 Receiver, Channel 1 (white wire)15 Emitter, Channel 1 (red wire)16 Receiver shield, Channel 117 Emitter shield, Channel 218 Receiver, Channel 2 (white wire)19 Emitter, Channel 2 (red wire)20 Receiver shield, Channel 2

2 CHANNEL LOGIC MODULE

14 16 18 2010 12

9 11

2

B

5 6

SWITCHES1 Time delay, Channel 1 (0.05 to 3 s or 1 to 60 s)2 Time delay, Channel 1 (On/Off)3 Time delay mode (mono. or adjustable time delay)4 Leading/Trailing edge selection

A Time delay, Channel 1B Sensitivity adjustment, Channel 1

1 Green: power supply2 Red: output test3 Yellow: output, Channel 14 Yellow: output, Channel 25 Green: synchronization, Channel 1

LED INDICATORS

POTENTIOMETERS

7 95 6 108

A

3 41 2

6 Yellow: detection, Channel 17 Red: unstable, Channel 18 Green: synchronization, Channel 2

5 Logic function (And/Or)6 Logic function (On/Off)7 Light/Dark, Channel 18 Light/Dark, Channel 2

C Sensitivity adjustment, Channel 2

9 Yellow: detection, Channel 210 Red: unstable, Channel 2

LED INDICATORS

LED INDICATORS

LED indicators

Page 94: Wiring Diagram Book

90

®

Limit Switches

Class 9007

Contact Forms forClass 9007 Limit Switches

FIG. 1

Limit Switches:Class 9007 Type C

FIG. 2 FIG. 3 FIG. 4

Types C52, C54 1-Pole

Type C622-Pole, Same Polarity Each Pole

Type C66 2-Pole, 2-Stage, Same Polarity Each Pole

FIG. 5

[1]

On CR switches, terminals 1-4 on left side are for CW rotation and terminals 5-8 on right side are for CCW rotation.

FIG. 6

Types C68T5, C68T10, CR67T5

[1]

and CR67T10

[1]

2-Pole Neutral Position, Same Polarity Each PoleType C Reeds

Limit Switches:Class 9007 Type XA

FIG. 7 FIG. 8

Type XA73 Reeds Type XA75 Reeds

Page 95: Wiring Diagram Book

91

®

Limit Switches

Class 9007

Limit Switches:Class 9007 Type AW

FIG. 1 FIG. 2

Type AW12 and AW14 Type AW18

FIG. 3

[1]

If lever arm is placed at same end of box as conduit, N.O. contacts become N.C. and vice versa.

FIG. 4

[1]

If lever arm is placed at same end of box as conduit, N.O. contacts become N.C. and vice versa.

FIG. 5

Type AW16 w/ Lever Arm Opposite Conduit Hole [1]

Type AW19 w/ Lever Arm Opposite Conduit Hole [1]

Type AW32, AW34, AW42 and AW44

FIG. 6 FIG. 7 FIG. 8

Type AW36 and AW46 Type AW38 and AW48 Type AW39 and AW49

Limit Switches:Class 9007 Type SG – GATE GARDTM Switch

FIG. 9 FIG. 10

Type SGS1DK Type SGP1

Page 96: Wiring Diagram Book

92®

Limit Switches and Safety InterlocksXCK and MS

XCK Limit Switches

FIG. 1 FIG. 2 FIG. 3

SPDT, 1 N.O. and 1 N.C.Positive Opening, Snap Action

2 SPDT, 2 N.O. and 2 N.C. SPDT, Isolated N.O. and N.C.Positive Opening, Slow-Make Slow-Break

XCK Safety Interlocks

FIG. 4 FIG. 5 FIG. 6

Note: N.O. and N.C. contacts are shown with key inserted and fully engaged.

SPDT, Positive Opening, Slow-Make Slow-Break

SPDT, w/ 24 VDC LED, Positive Opening, Slow-Make Slow-Break

SPDT, w/ 2 Pilot Lights, Positive Opening, Slow-Make Slow-Break

Contact Blocks for XY2CE Limit Switches

FIG. 7 FIG. 8 FIG. 9 FIG. 10 FIG. 11

XEN P2151, Isolated N.C. and N.O.

XEN P2141, Isolated N.C. and N.O.

XEN P2051, N.C./N.O., 12 and 14 same polarity

Indicator Light, Direct Indicator Lightw/ Resistance

MS Miniature Limit Switches

FIG. 12 FIG. 13

SPST SPDT

21

22

13

14

No polarity

21

22

13

14

X1

X3

LED 24 VDC24 VDC

0 VLOAD

Orange

21

22

13

14

X1

X3

ACL1

L2

LOAD

OrangeX2

Green

AC

21 13

22 14Zb

21 11

22 12Zb

11 13

12 14Za

X1

X2

X1

X2

Black White

Green Red

Black

Red

Orange

WhiteGreen

Page 97: Wiring Diagram Book

93®

Pressure Switches and TransducersClass 9012, 9013, 9022 and 9025

Pressure and Temperature Switches:Class 9012 and 9025 Type G

FIG. 1 FIG. 2 FIG. 3

Machine Tool, SPDT,1 N.O. and 1 N.C.

Machine Tool, DPDT,2 N.O. and 2 N.C.

Industrial, SPST,1 N.O. and 1 N.C.

FIG. 4 FIG. 5

Machine Tool, SPDT, 1 N.O. and 1 N.C. w/ Form H10 Machine Tool, SPDT, 1 N.O. and 1 N.C. w/ Form H11

Commercial Pressure Switches:Class 9013 Type CS

FIG. 6

Acceptable Wiring Schematics

Pressure Transducers:Class 9022 Type PTA and PTB

FIG. 7 FIG. 8 FIG. 9

Type PTA, 2-Wire Type PTA, 3-Wire Type PTA, 4-Wire

FIG. 10 FIG. 11 FIG. 12

Type PTB, 2-Wire Type PTB, 3-Wire Type PTB, 4-Wire

+

TRANSDUCER

DC SUPPLY –

Red BlackLOAD

+

TRANSDUCER

DC SUPPLY –

RedWhite orBrown

LOAD

Black

+

TRANSDUCER

DC SUPPLY –

4

1

LOAD

2

3

+

TRANSDUCER

DC SUPPLY –

Red GreenLOAD

+

TRANSDUCER

DC SUPPLY –

A BLOAD

C

+

TRANSDUCER

DC SUPPLY –

Red

Black

LOAD

Green

White

Page 98: Wiring Diagram Book

94®

Level Sensors and Electric AlternatorsClass 9034 and 9039

Level Sensors:Class 9034 Types LSD and LSV

FIG. 1 Wiring Diagram Elementary Diagram

Fill Cycle, Tank Full

FIG. 2 Wiring Diagram Elementary Diagram

Drain Cycle, Tank Empty

Electric Alternators:Class 9039 Type X

FIG. 3

Set pilot device A contacts to close before pilot device B contacts.

Connections shown are for common control. If motor line voltage is different from voltage rating stamped on alternator coil terminals, alternator must be connected to motor lines thru control transformers.

Control circuit conductors require overcurrent protection in accordance with applicable electrical codes.

* Overlapping contact.

Output selection of both sensors in maximum (N.C. when absent). Both devices at max. setting.

Output selection of both sensors in minimum (N.O. when absent). Both devices at min. setting.

FPO 69-1

Page 99: Wiring Diagram Book

95®

Pneumatic Timing RelaysClass 9050

Pneumatic Timing Relays:Class 9050: Type AO

FIG. 1 FIG. 2 FIG. 3 FIG. 4 FIG. 5 FIG. 6

Type AO10E Type AO10D Type AO20E Type AO20D Type AO110DE Type AO120DE

FIG. 7 FIG. 8 FIG. 9 FIG. 10 FIG. 11 FIG. 12

Type AO11E Type AO11D Type AO21E Type AO21D Type AO111DE Type AO121DE

FIG. 13 FIG. 14 FIG. 15 FIG. 16 FIG. 17 FIG. 18

Type AO12E Type AO12D Type AO22E Type AO22D Type AO112DE Type AO122DE

FIG. 19 FIG. 20 FIG. 21 FIG. 22 FIG. 23 FIG. 24

Type AO210DE Type AO211DE Type AO212DE Type AO220DE Type AO221DE Type AO222DE

Pneumatic Timing Relays:Class 9050: Type HO

Pneumatic Timing Relays:Class 9050: Types B and C

FIG. 25 FIG. 26 FIG. 27

Off Delay On Delay

FIG. 28

Off Delay On Delay

Type HO10E, On Delay Type HO10D, Off Delay Type B Type C

Page 100: Wiring Diagram Book

96®

Pneumatic Timing Relays and Solid State Industrial Timing RelaysClass 9050

Class 9050 Pneumatic Timing Relays: Typical Elementary Diagrams

FIG. 1 FIG. 2

Interval, Momentary Start

FIG. 3

On Delay Interval, Maintained Start

FIG. 4 FIG. 5

Off Delay Repeat Cycle

Solid State Industrial Timing Relays: Class 9050 Types FS and FSR

FIG. 6 FIG. 7

Elementary Diagram Wiring Diagram

Solid State Industrial Timing Relays: Class 9050 Type FT

FIG. 8 FIG. 9

Elementary Diagram Wiring Diagram

FP

O 7

1-1

L1

TimedContacts

L2 C1 C3

C2 C4

L1

InstantaneousContacts(optional)

C5 C7

C6 C8P1

AC Supply VoltageL2

External Initiating Contact

FP

O 7

1-2

L1

TimedContacts

C3 C5 C7

L1 L2

C1

InstantaneousContacts(optional)

C4

P

C6 C8C2

AC Supply VoltageL2

External Initiating Contact

Page 101: Wiring Diagram Book

97®

TimersClass 9050

Solid State Industrial Timing Relays:Class 9050 Type JCK

FIG. 1 FIG. 2

Terminals 5 and 10 are internally jumpered. Applying power to terminal 7 or jumpering from terminal 5 to 7 through an external contact initiates the timer.

FIG. 3

Type JCK 11-19, 31-39 and 51-60 Type JCK 21-29 and 41-49 Type JCK 70

Solid State Timers:Class 9050 Type D

FIG. 4 FIG. 5 FIG. 6 FIG. 7

Type DER, DZM, DTR, DWE, DEW and DBR

Type DERP, DERLP, DWEP and DZMP Type DAR Type DARP

Solid State Timers:Class 9050 Type M

FIG. 8 FIG. 9

Type MAN, MBR, MER, MEW, MTG, MWE and MZM Type MAR

1

2

3

4 5

7

6

8

Control Power+ –

Polarity markings are for DC unitsonly. JCK 60 is AC only.

2

3

4

5 7

8

9

10

6

1 11

Control Power+ –

Polarity markings are for DC units only.

External Initiating Contact

2

3

4

5 7

8

9

10

6

1 11

External Initiating Contact(used in one-shot andoff-delay mode only)

Control Power

A1/+ 15 25

16 18 A2/–

Vs

26 28

A1/+ 15 25 Z1 Z2

16 18 A2/–

Vs

26 28

A1 15 25

16 18 A2

Vs

26 28

A1 15 25 Z1 Z2

16 18 A2

Vs

26 28

17 25 A1

18 26

Vs

A2

15 A1

16 18

Vs

A2

Page 102: Wiring Diagram Book

98®

Transformer DisconnectsClass 9070

Transformer Disconnects:Class 9070

Note: Some factory modifications, depending on enclosure and transformer VA size selected, are not available. Consult factory modification chart.

FIG. 1 FIG. 2

For Size 1 Enclosures except w/ Form E23 For Size 1 Enclosures w/ Form E23

FIG. 3 FIG. 4

For Size 2 Enclosures except w/ Form E23 For Size 2 Enclosures w/ Form E23

L1

FU1

460 V

FU2

GNDL3L2

H1 H3 H2 H4

FU3

X1A

FU5

X1B

FU4

X2B X2A

R

PowerOn

Optional

115 VX1 X2

230 VH1 H3 H2 H4

Optional Connection

OFF

ON

L1

FU1

460 V

FU2

GNDL3L2

H1 H3 H2 H4

FU3

X1A

FU4

FU5

X2A

R

PowerOn

Optional

115 VX1 X2

230 VH1 H3 H2 H4

Optional Connection

ElectrostaticallyShielded Transformer

FU6

OFF

ON

L1

FU1

460 V

FU2

GNDL3L2

H1 H3 H2 H4

FU3

X1A

FU5

X1B

FU4

X2B X2A

R

PowerOn

115 VX1 X2

230 VH1 H3 H2 H4

Optional Connection

Optional

OFF

ON

L1

FU1

460 V

FU2

GNDL3L2

H1 H3 H2 H4

FU3

X1A

FU8

FU5

X2B

R

PowerOn

115 VX1 X2

230 VH1 H3 H2 H4

Optional Connection

ElectrostaticallyShielded Transformer

FU6

Optional

FU4

X2A

FU7

X1B

OFF

ON

Page 103: Wiring Diagram Book

99

®

Enclosure Selection Guide

Table 6 Enclosures for Non-Hazardous Locations

Provides Protection Against NEMA Type 1

NEMA Type 3

[1]

NEMA Type 3R

[1]

NEMA Type 4

[2]

NEMA Type 4X

[2]

Type 5 NEMA Type 12

[3]

Type 12K NEMA Type 13

Accidental contact w/ enclosed equipment Yes Yes Yes Yes Yes Yes Yes Yes Yes

Falling dirt Yes Yes Yes Yes Yes Yes Yes Yes Yes

Falling liquids and light splashing … Yes Yes Yes Yes … Yes Yes Yes

Dust, lint, fibers and flyings … … … Yes Yes Yes Yes Yes Yes

Hosedown and splashing water … … … Yes Yes … … … …

Oil and coolant seepage … … … … … … Yes Yes Yes

Oil and coolant spraying and splashing … … … … … … … … Yes

Corrosive agents … … … … Yes … … … …

Rain, snow and sleet

[4]

… Yes Yes

[5]

Yes … … … …

Windblown dust … Yes …

[5]

Yes Yes … … …

[1]

Intended for outdoor use.

[2]

Intended for indoor and outdoor use.

[3]

Square D Industrial Control design NEMA Type 12 enclosures may be field modified for outdoor applications.

[4]

External operating mechanisms are not required to be operable when the enclosure is ice covered.

[5]

Square D Industrial Control design NEMA Type 4 enclosures provide protection against these environments.

Table 7 Enclosures for Hazardous Locations

Provides Protection Against Class

[1]

Group

[1]

Enclosure

NEMA Type 7 NEMA Type 9

7B 7C 7D 9E 9F 9G

Hydrogen, manufactured gas I B Yes … … … … …

Ethyl ether, ethylene, cyclopropane I C Yes Yes … … … …

Gasoline, hexane, naphtha, benzine, butane, propane, alcohol, acetone, benzol, natural gas, lacquer solvent I D Yes Yes Yes … … …

Metal dust Il E … … … Yes … …

Carbon black, coal dust, coke dust Il F … … … … Yes …

Flour, starch, grain dust Il G … … … … Yes Yes

[1]

As described in Article 500 of the National Electrical Code.

Page 104: Wiring Diagram Book

100

®

Conductor Ampacity and Conduit Tables

Based on 1993 National Electrical Code

Table 8 Conductor Ampacity based on NEC Table 310-16

COPPER CONDUCTORS ALUMINUM CONDUCTORS

Wire Size AWG kcmil

75

°

C (167

°

F) Conductor Insulation

[1]

90

°

C (194

°

F)Conductor Insulation

[1]

Wire Size AWG kcmil

75

°

C (167

°

F) Conductor Insulation

[1]

90

°

C (194

°

F)Conductor Insulation

[1]

Tabl

e 31

0-16

Am

paci

ty In

sula

ted

Cop

per

THHW, THW, RW, USE THWN, XHHW

Tabl

e 31

0-16

Am

paci

ty In

sula

ted

Cop

per

THHN, XHHW

Tabl

e 31

0-16

Am

paci

ty In

sula

ted

Cop

per

THHW, THW, USE XHHW

Tabl

e 31

0-16

Am

paci

ty In

sula

ted

Cop

per

THHN, XHHW

Conduit 3W

Conduit 4W

[2]

Conduit 3W

Conduit 4W

[2]

Conduit 3W

Conduit 4W

[2]

Conduit 3W

Conduit 4W

[2]

Conduit 3W

Conduit 4W

[2]

Conduit 3W

Conduit 4W

[2]

14 20 … … 1/2 1/2 25 1/2 1/2 … … … … … … … … …

12 25 … … 1/2 1/2 30 1/2 1/2

12 20 … … 1/2 1/2 25 1/2 1/2

10 35 … … 1/2 1/2 40 1/2 1/2

10 30 … … 1/2 1/2 35 1/2 1/2

8 50 3/4 1 1/2

[3]

3/4 55 1/2

[3]

3/4 8 40 3/4 3/4 1/2 3/4 45 1/2 3/4

6 65 1 1 3/4 3/4

[4]

75 3/4 3/4

[4]

6 50 3/4 1 3/4 3/4 60 3/4 3/4

4 85 1 1-1/4 1 1 95 1 1 4 65 1 1 3/4 1 75 3/4 1

3 100 1-1/4 1-1/4 1 1-1/4 110 1 1-1/4 3 75 … … … … 85 … …

2 115 1-1/4 1-1/4 1 1-1/4 130 1 1-1/4 2 90 1 1-1/4 1 1-1/4 100 1 1-1/4

1 130 1-1/4 1-1/2 1-1/4 1-1/2 150 1-1/4 1-1/2 1 100 1-1/4 1-1/2 1-1/4 1-1/2 115 1-1/4 1-1/2

1/0 150 1-1/2 2 1-1/4 1-1/2 170 1-1/4 1-1/2 1/0 120 1-1/4 1-1/2 1-1/4 1-1/2 135 1-1/4 1-1/2

2/0 175 1-1/2 2 1-1/2 2 195 1-1/2 2 2/0 135 1-1/2 2 1-1/4 1-1/2 150 1-1/4 1-1/2

3/0 200 2 2 1-1/2 2 225 1-1/2 2 3/0 155 1-1/2 2 1-1/2 2 175 1-1/2 2

4/0 230 2 2-1/2 2 2 260 2 2 4/0 180 2 2 1-1 /2 2 205 1-1/2 2

250 255 2-1/2 2-1/2 2 2-1/2 290 2 2-1/2 250 205 2 2-1/2 2 2 230 2 2

300 285 2-1/2 3 2 2-1/2 320 2 2-1/2 300 230 2 2-1/2 2 2-1/2 255 2 2-1/2

350 310 2-1/2 3 2-1/2 3 350 2-1/2 3 350 250 2-1/2 3 2-1/2 3 280 2-1/2 3

400 335 3 3 2-1/2 3 380 2-1/2 3 400 270 2-1/2 3 2-1/2 2-1/2

[5]

305 2-1/2 2-1/2

[5]

500 380 3 3-1/2 3 3 430 3 3 500 310 3 3 2-1/2 3 350 2-1/2 3

600 420 3 3-1/2 3 3-1/2 475 3 3-1/2 600 340 3 3-1/2 3 3 385 3 3

700 460 3-1/2 4 3 3-1/2 520 3 3-1/2 700 375 3 3-1/2 3 3-1/2 420 3 3-1/2

750 475 3-1/2 4 3-1/2 4 535 3-1/2 4 750 385 3 3-1/2 3 3-1/2 435 3 3-1/2

800 490 3-1/2 4 3-1/2 4 555 3-1/2 4 800 395 … … … … 450 … …

900 520 4 5 3-1/2 4 585 3-1/2 4 900 425 … … … … 480 … …

1000 545 4 5 3-1/2 5 615 3-1/2 5 1000 445 3-1/2 4 3-1/2 4 500 3-1/2 4

[1]

Unless otherwise permitted in the Code, the overcurrent protection for conductor types marked with an with an obelisk (†) shall not exceed 15 A for No. 14, 20 A for No. 12 and 30 A for No. 10 copper, or 15 A for No. 12 and 25 A for No. 10 aluminum after any correction factors for ambient temperature and number of conductors have been applied..

[2]

On a 4-wire, 3-phase wye circuit where the major portion of the load consists of nonlinear loads such as electric discharge lighting, electronic computer/data processing, or similar equipment there are harmonic currents present in the neutral conductor and the neutral shall be considered to be a current-carrying conductor.

[3]

#8 XHHW copper wire requires 3/4" conduit for 3W.

[4]

#6 XHHW copper wire requires 1" conduit for 3Ø4W.

[5]

400 kcmil aluminum wire requires 3" conduit for 3Ø4W.

Ampacity Based on NEC® Table 310-16 — Allowable Ampacities of Insulated Conductors Rated 0-2000 Volts, Not More Than Three Conductorsin Raceway or Cable. Based on 30 °C Ambient Temperature. Trade Size of Conduit or Tubing Based on NEC Chapter 9, Table 1 and Tables 3A,3B, 3C, 4 and 5B. Refer to Chapter 9 for Maximum Number of Conductors in Trade Sizes of Conduit or Tubing. Dimensions of Insulated Con-ductors for Conduit Fill Determined from NEC Chapter 9 Tables 5 and 5A.

For information on temperature ratings of terminations to equipment, see NEC Section 110-14c. Underlined conductor insulationtypes indicates ampacity is for WET locations. See NEC Table 310-13.

NEC is a Registered Trademark of the National Fire Protection Association.

Page 105: Wiring Diagram Book

101

®

Conductor Ampacity and Conduit Tables

Based on 1993 National Electrical Code

Ampacity Correction Factors:For ambient temperatures other than 30 °C (86 °F), multiply the ampacities listed in Table 8 by the appropriate factor listed in Table 9.

Adjustment Factors:Where the number of current-carrying conductors in a raceway or cable exceeds three, reduce the allowable ampacities as shown in Table 9.

Table 9 Ampacity Correction Factors

Ambient Temperature (

°

C)75

°

C (167

°

F) Conductors

90

°

C (194

°

F) Conductors

Ambient Temperature (

°

F)

21-25 1.05 1.04 70-77

26-30 1.00 1.00 78-86

31-35 .94 .96 87-95

36-40 .88 .91 96-104

41-45 .82 .87 105-113

46-50 .75 .82 114-122

51-55 .67 .76 123-131

56-60 .58 .71 132-140

61-70 .33 .58 141-158

71-80 … .41 159-176

Table 11 Ratings for 120/240 V, 3-Wire, Single-Phase Dwelling Services

– see NEC 310-16 Note 3

Rating (A)

100 110 125 150 175 200 225 250 300 350 400

Copper

4 AWG 3 AWG 2 AWG 1 AWG 1/0 AWG 2/0 AWG 3/0 AWG 4/0 AWG 250 kcmil 350 kcmil 400 kcmil

Aluminum

2 AWG 1 AWG 1/0 AWG 2/0 AWG 3/0 AWG 4/0 AWG 250 kcmil 300 kcmil 350 kcmil 500 kcmil 600 kcmil

Ratings for 120/240 V, 3-Wire, Single-Phase Dwelling Services:The ratings in Table 11 are permitted ratings for dwelling unit service and feeder conductors which carry the total load of the dwelling. Thegrounded conductor (neutral) shall be permitted to be not more than 2 AWG sizes smaller than the ungrounded conductors, provided the re-quirements of 215-2, 220-22 and 230-42 are met.

NEC 240-3 Protection of Conductors:Conductors, other than flexible cords and fixture wires, shall be protected against overcurrent in accordance with their ampacities as specifiedin NEC Section 310-15, unless otherwise permitted in parts (a) through (m).

NEC 220-3 (a) Continuous and Noncontinuous Loads:The branch circuit rating shall not be less than the noncontinuous load plus 125% of the continuous load (see exception for 100% rated devices).

NEC 220-10 (b) Continuous and Noncontinuous Loads:Where a feeder supplies continuous loads or any combination of continuous and noncontinuous loads, the rating of the overcurrent device shallnot be less than the noncontinuous load plus 125% of the continuous load (see exception for 100% rated devices).

NEC 430-22 (a) Single Motor Circuit Conductors:Branch circuit conductors supplying a single motor shall have an ampacity not less than 125% of the motor full-load current rating (see excep-tions).

NEC is a Registered Trademark of the National Fire Protection Association.

Table 10 Adjustment Factors

No. of Current-Carrying Inductors

Values in Tables as Adjusted for Ambient Temperature

4-6 80%

7-9 70%

10-20 50%

21-30 45%

31-40 40%

41 and above 35%

For exceptions, see exceptions to Note 8 of NEC

®

Table 310-16.

Page 106: Wiring Diagram Book

102

®

Wire Data

Table 12 AWG and Metric Wire Data

AWG Size

Conductor dia. (mm)

Conductor dia. (in)

Resistance @ 20

°

C (68

°

F) AWG Size

Conductor dia. (mm)

Conductor dia. (in)

Resistance @ 20

°

C (68

°

F)

Ohm per ft Ohm per m Ohm per ft Ohm per m

29 .01126 .08180 .2684 13 1.900 .07480 .001853 .006081

.315 .01240 .06743 .2212 2.000 .07874 .001673 .005488

28 .01264 .06491 .2130 12 .08081 .001588 .005210

.355 .01398 .05309 .1742 2.120 .08346 .001489 .004884

27 .01420 .05143 .1687 2.240 .08819 .001333 .004375

.400 .01575 .04182 .1372 11 .09074 .001260 .004132

26 .01594 .04082 .1339 2.360 .09291 .001201 .003941

.450 .01772 .03304 .1084 2.500 .09843 .001071 .003512

25 .01790 .03237 .1062 10 .1019 .0009988 .003277

.500 .01969 .02676 .08781 2.650 .1043 .0009528 .003126

24 .02010 .02567 .08781 2.800 .1102 .0008534 .002800

.560 .02205 .02134 .07000 9 .1144 .0007924 .002500

23 .02257 .02036 .06679 3.000 .1181 .0007434 .002439

.630 .02480 .01686 .05531 3.150 .1240 .0006743 .002212

22 .02535 .01614 .05531 8 .1285 .0006281 .002061

.710 .02795 .01280 .04201 3.350 .1319 .0005662 .001956

21 .02846 .01280 .04201 3.550 .1398 .0005309 .001742

.750 .02953 .01190 .03903 7 .1443 .0004981 .001634

.800 .03150 .01045 .03430 3.750 .1476 .0004758 .001561

20 .03196 .01015 .03331 4.000 .1575 .0004182 .001372

.850 .03346 .009261 .05038 6 .1620 .0003952 .001296

.900 .03543 .008260 .02642 4.250 .1673 .0003704 .001215

19 .03589 .008051 .02642 4.500 .1772 .0003304 .001084

.950 .03740 .007414 .02432 5 .1819 .0003134 .001028

1.000 .03937 .006991 .02195 4.750 .1870 .0002966 .0009729

18 .04030 .006386 .02095 5.000 .1968 .0002676 .0008781

1.060 .04173 .005955 .01954 4 .2043 .0002485 .0008152

1.120 .04409 .005334 .01750 5.600 .2205 .0002134 .0007000

17 .04526 .005063 .01661 3 .2294 .0001971 .0006466

1.180 .04646 .004805 .01577 6.300 .2480 .0001686 .0005531

1.250 .04921 .004282 .01405 2 .2576 .0001563 0005128

16 .05082 .004016 .01317 7.100 .2795 .0001327 .0004355

1.320 .05197 .003840 .01260 1 .2893 .0001239 .0004065

1.400 .05512 .004016 .01317 8.000 .3150 .0001045 .0003430

15 .05707 .003414 .01045 0 .3249 .00009825 .0003223

1.500 .05906 .002974 .009756 9.000 .3543 .00008260 .0002710

1.600 .06299 .002526 .008286 2/0 .3648 .00007793 .0002557

14 .06408 .002315 .007596 10.000 .3937 .00006691 .0002195

1.700 .06693 .002315 .007596 3/0 .4096 .00006182 .0002195

1.800 .07087 .002065 .006775 4/0 .4600 .00004901 .0001608

13 .07196 .002003 .006571 11.800 .4646 .00004805 .0001577

Page 107: Wiring Diagram Book

103

®

Electrical Formulas

Table 13 Electrical formulas for Amperes, Horsepower, Kilowatts and KVA

To find Single phase 3-phase Direct current

KilowattsI x E x PF

1000I x E x 1.73 x PF

1000 I x F1000

KVA I x E 1000

I x E x 1.731000

Horsepower (output)I x E x % Eff x PF

746I x E x 1.73 x %Eff x PF

746I x E x %Eff

746

Amperes when Horsepower is known

HP x 746E x %Eff x PF

HP x 746 1.73 x E x %Eff x PF

HP x 746E x %Eff

Amperes when Kilowatts is known

KW x 1000E x PF

KW x 1000 1.73 x E x PF

KW x 1000E

AmperesKVA x 1000

EKVA x 1000

1.73 x E—

E=Volts l = Amperes %Eff = Percent efficiency PF = Power factor HP = Horsepower KVA = Kilovolt-Amps

Table 14 Ratings for 3-Phase, Single-Speed, Full-Voltage Magnetic Controllers for Nonplugglng and Nonjogging Duty

Size of Controller

Continous Current Rating

(A)

Horsepower at

[1]

Service-Limit Current Rating

(A)

60 Hz 200 V 60 Hz 230 V 50 Hz 380 V60 Hz

460 or 575 V

00 9 1-1/2 1-1/2 1-1/2 2 11

0 18 3 3 5 5 21

1 27 7-1/2 7-1/2 10 10 32

2 45 10 15 25 25 52

3 90 25 30 50 50 104

4 135 40 50 75 100 156

5 270 75 100 150 200 311

6 540 150 200 300 400 621

7 810 — 300 — 600 932

[1]

These horsepower ratings are based on typical locked-rotor current ratings. For motors having higher locked-rotor currents,use a larger controller to ensure its locked-rotor current rating is not exceeded.

Average Efficiency and Power Factor Values of Motors:

When actual efficiencies and power factors of the motors to be controlled are not known, the following approximations may be used:

Efficiencies: DC motors, 35 hp and less: 80% to 85% DC motors, above 35 hp: 85% to 90% Synchronous motors (at 100% PF): 92% to 95%

“Apparent” efficiencies (Efficiency x PF): 3-phase induction motors, 25 hp and less: 70% 3-phase induction motors above 25 hp: 80% Decrease these figures slightly for single phase induction motors.

Page 108: Wiring Diagram Book

104

®

Electrical Formulas

Table 15 Ratings for 3-Phase, Single-Speed, Full-Voltage Magnetic Controllers for Plug-Stop, Plug-Reverse or Jogging Duty

Size of Controller

Continous Current Rating

(A)

Horsepower at

[1]

Service-Limit Current Rating

(A)

60 Hz 200 V 60 Hz 230 V 50 Hz 380 V60 Hz

460 or 575 V

0 18 1-1/2 1-1/2 1-1/2 2 21

1 27 3 3 5 5 32

2 45 7-1/2 10 15 15 52

3 90 15 20 30 30 104

4 135 25 30 50 60 156

5 270 60 75 125 150 311

6 540 125 150 250 300 621

[1]

These horsepower ratings are based on typical locked-rotor current ratings. For motors having higher locked-rotor currents,use a larger controller to ensure its locked-rotor current rating is not exceeded.

Table 16 Power Conversions

From to kW to PS to hp to ft-lb/s

1 kW (kilowatt) = 10

10

erg/s 1 1.360 1.341 737.6

1 PS (metric horsepower) 0.7355 1 0.9863 542.5

1 hp (horsepower) 0.7457 1.014 1 550.0

1 ft-lb/s (foot-pound per sec) 1.356 x 10

-3

1.843 x 10

-3

1.818 x 10

-3

1

Page 109: Wiring Diagram Book

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