it's my absolute pleasure to be in the workshop today and i'm joined by Matt O'Dell hello matt
what are we going to be up to in this video presentation so then Gaz today we're going to
look at direct online starters okay we're going to we're going to this is an online starter
in this case we've got a three phase online starter set up and a single
phase direct online starter set up and we're just going to look at how they're wired up and we're
going to go upstairs and look at the actual wiring diagrams how it all works and just just go through
just go through that really and it's really important as we're looking with one eye on AM2S
we believe and it will evolve over time so it could change that at the moment there is a
three phase direct online starter that has to be wired up and tested so we're in that process of
actually looking at wiring connections in this video yes we're going to pop upstairs hopefully
Joe will be up there with his whiteboard pens and calculator and we'll disturb him and we'll look
at the wiring diagrams that go with these direct online starters so then Joe today we're looking
at a direct online starter layout very co-ops into the classroom we briefly saw downstairs
the um what a direct online starter is i think we had the single phase and the three phase online
starter and now we're just going to look through the connections or how to do the connections um on
the whiteboard fantastic could you maybe just tell me what these bits and bobs are Matt so
what do we got going on up here okay so when you when you take the plate of an online starter off
it doesn't quite look the same as this but this is just the basic principle of how of how a coil
will operate the contacts and so we'll go through the video as we go along we'll explain what bit
does what but um but the basic principle is that you've got a direct online starter here
represented this square and we have a single phase motor so this will just be wired up single phase
so this is what we're going to try and get running this is what we're going to try and connect to
yeah okay great yeah so what we have then we're going to bring a line conductor in and so the line
conductor will come in on on number one and it will simply come out on number two and go directly
to the motor okay so it's passing through this contact here which is basically just a switch as
yes okay and then it goes from there and this part here which is the overload for the motor
that's just kind of that's normally that's hardwired into the bottom of the contactor
it's pressed in screwed in yeah and actually that output terminal kind of becomes that out
right and and and they're quite awkward to do actually physically put them in but they
that's what this this is representing there so the three contacts there are now in in line with the
overload relay yeah so the as i said this um the line conductor comes in and literally comes out
the neutral then becomes a bit more of a bit more of a problem okay okay so you could just
simply bring the neutral in number three and out on number four and everything would
be fine yeah but the problem is there we're missing out this contact so that contact then
doesn't do anything okay and what's more inside of the overload relay where you've got your your
physical overload relays they're not all being utilized okay and so it's a good idea to ensure
that they are all being utilized to make sure it just everything's balanced out okay so instead of
going so we're coming on number three with our neutral and instead of going out to number four
and to the motor we bring the neutral all the way back in on number five oh let's see right
and then we come simply out on number six oh that's a clever little pro tip i like that
yeah so so it doesn't actually matter whether you did this you did it with the line conductor or the
neutral i just think it's better to do a neutral and you've got less shall we say live wires yeah
floating around sort of thing so it's about to take the neutral background and use that again and
pass that through the twice yes i think so yeah so that way the overload relays internally are all
being utilized yeah that's clever i like that okay so that's the basic um that's that's basically
when you put an online starter in that is exactly what you'll generally that's all you have to do
those are the connections you'll make yeah you just connect if it's single phase or three phase
however you do you just connect them in and connect them out and that's it as well the more
awkward thing is is when you start um connecting up the um uh the the start and the stop buttons
sure and the actual coil sometimes they are already pre-wired but in this case
we're going to go through the wiring for that oh brilliant so we're going to put that in and we can
trace it around and place it around obviously so we have contacts number 13 and 14. as you can see
they look exactly the same as the other contacts but they are called our retaining contacts right
and so that's our retaining contacts there number 13 and 14. and what they do is they they hold the
motor they hold the um the contacts in when the start button has been has has been depressed
so if we didn't have this going on when we pressed the start button the motor would turn on and then
when we took a finger off it would just turn off and if you want to leave it running obviously you
want to you know i'm standing with your finger on the button so in this case then we take a line
conductor through to there just take a conductor from there to there
easy as that cool so that side of the contact will be permanently live effectively yes this
one we then simply take of these wires to number 17 of the start yeah okay now the numbers are
um these these numbers are always numbered 17 and 18. these numbers here always numbered 13 and 14.
okay and it's quite simple that they are number 13 and 17 connect together and number 14 yep
and 18 connect together oh right and so notice with them they're in parallel with you yeah i was
just going to say the way you've laid that out there you can clearly see that they're
connected in parallel yeah like that that's good and so that's that that's the that's
the principle operation if you press the start button these contacts they're all in play with
one another all right got you now we now need to wire up the stop button because obviously
once the motor is running it needs to be able to stop so in this case we just simply take
a line conductor down to the stop button yep and then we come from here yep and we come across into
what i call the overload contacts right so when the overload operates when this
disconnects the supply it actually will trip that connection out because at the minute
that's showing it's connected yes so when a fault occurs that will actually open is that correct yes
and because it's in series with all this that will then just break the circuit and eventually the mo
and the motor will stop now we call this usually the auxiliary circuit okay and so these are known
as auxiliary connections and so we're just going to concentrate on 95 and 96. it doesn't matter
whether you take this to 96 or 95. it doesn't matter which one they go in um or
you just have to take it to one of them now these are normally what's called a normally
closed contact an NC contact normally closed and you can see that from the black contacts there
and it shows that it's closed now we then take another cable back and we go into the coil right
so if you trace this through then eventually it's making contact onto A1 so when this is energized
A1 is connected to the supply again it doesn't matter if you went to A1 or A2 okay it it's just
a simple coil it makes no difference but it's generally speaking we go to a common practices
yeah um we haven't spoken about the call too much yet so the coil in this case is a 230 volt coil
it has to be 230 volt coil because it's a single phase installation so it's um it's obvious that
the coil is also going to be 230 volts fantastic okay then so that's the basic um setup of of how
you connect up the auxiliary circuit we're missing one thing though i was just going to say i don't
know a lot about electrical science check out Joe Robinson Training to see that proved uh however i
don't think this coil is going to do anything matt because it doesn't have a neutral connection no no
so that's what we need to do brilliant so remember we came in on this side yep and so and then we
come through out on number four all the way back down to number five now number six now one of the
common mistakes that i have seen is that they take this one to be the core to be the neutral feed
to go across to here yep the problem is that's not connected is it until the contactor pulls in and
the contactor can't pull in without that without connected so you've got yourself into a catchy 22
and and that's when we have seen where you know when when
things haven't been working that's often been a go-to go-to place so from the connection here
we go along and then we come all the way just down simply
to A2 and there's the neutral connection yeah very nice that's what we call the auxiliary
circuit fantastic and that's basically how it is wired up so if we trace this through then
if i press that button in yeah current's going to flow across the start button
through the stop button which is closed through the overload contact which goes on to yeah onto
the 230 volt coil that's going to energize because we've got a neutral connection now
which is going to pull all four of these contactors in in the motor will start yeah
and then also at the same time those two make contact which means we've then got a path the
current can take down there through the stop button which still has to break the circuit yeah
through the overload and onto A1 which means then if i release that button there
the electricity is actually still flowing it becomes almost like self-sustaining
that's it yeah yeah so love it just to iterate on that we have a permanent live connection
here and we have a permanent live connection there that's really important that that's done that way
these ones aren't permanently live until this is pressed in yep which then this all becomes
live and like you said the flow the flow of the um the the current through to the coil
and then as soon as they depressed or sort of let go the the current now flows through this contact
all the way back through the circuit and keeping it all all going cool so just the principle of
operation with how a coil operates so the magnetic field is being set up and this we call it an
armature yep and so the armature when when this is end when the coil is energized the magnetic field
pulls the armature across and so i can represent that with a with an arrow head shall we say that's
going to go across into that direction yep and that's then brings all of these four contacts in
place so this is uh perhaps a piece of soft iron or something that's that's easily magnetized it'll
be attracted to the magnetic field generated here and these although again we've shown these
connected these are mechanically connected yeah they're not electrically connected so obviously we
don't have a piece of stuff done shorting out the switches yeah fantastic so one of the other things
with a direct online start we've we've said that they work for motors electric motors um usually
it's um direct online starters are often said that they're up to about four to five kilowatts okay
that's not strictly true that's what it says in the books it all it always depends on the load
that you are actually driving so for example if you've got a grain store yeah when that when that
motor driving an auger or something like that once that started if it's
already in the grain it's under maximum load straight away okay so that's where
an online starter is limited to maybe four to five kilowatts if it's safe for a water pump
when the when there's no resistance when the water's not flowing there's no resistance
then these can be actually up to maybe up to about eight or nine kilowatts sort of thing so they're
not necessarily even though it will say that in some of the books it does depend on the load and
the application that you are going to fit one and a lot of it boils down to the inrush current
and how that's managed because obviously with a direct online starter there's no management
there's no managed current either would be with say a star delta starter or something like that
so another thing that i just wanted to point out is obviously the full motor or the full
load current is going through these contacts all the way through to the motor the auxiliary side
is hardly taking anything at all okay and that's the beauty with
the the auxiliary side this can all be done in small and generally it's done in small wiring yeah
so this one could be i don't know it could be wired up in six mm this one only needs to be
wired up in sort of one mm sort of thing so it because it's taking no no current flow so you
could be reading 10 amps coming in but only um you know milliamps on the actual auxiliary side clever
stuff one thing that we do i want to point out is what this thing is here do you know what this is
uh so i'm going to say that that is a very inaccurate clock okay could say that what it
is so we've got here the overload relay okay now the relays are completely settable yep okay so in
in this case we've got one to six amps and it's reading you'll you'll see a little one here so
that's really just between five and six amps at the moment okay so i think on the AM2S you have
to set an overload relay and so you will have a predetermined setting and so i don't know it might
be five amps so then you physically have to get your screwdriver and usually it's a little slotted
a little slotted dial in there right you put your screwdriver in and you just set it and it then has
to be lined up with this arrow okay fantastic that information it they might have to calculate it it
may be found in the specification manual you know that could be in the number of different so on the
motor there's often a there's often a plate on the on on the motor and it will say what the setting
is one of the set one of the ways that you do it maybe in industry is you you get the motor running
for what it's absolutely um for what it's being used for so if it's for a grain store
or something you actually get it working yeah then you physically measure it with a clamp on ammeter
and then you set it to that right because as you know the current that's on there might not be
yeah what it's actually using when it's actually under the load yeah that makes sense good stuff
okay so i think that's the basic setting of a direct online starter fantastic so now we can
go on and have a look at some variants on this theme yes yeah now that's really interesting
matt where you've got a direct online starter by itself controlling a motor but i'm interested to
know what happens when we start thinking about adding some remote stop starts in but i think
that might be the subject of a future video we'll return to that so should we end this one yeah we
will do it Gary style okay okay let's do it GSH style yeah we hope this video has been some help
you