push button typical wiring

Product Data

TYPICAL WIRING DIAGRAMSFor Push Button Control Stations

BULLETIN 800SSTANDARD DUTY

A-2750

BULLETIN 800TOIL TIGHT

B-130

BULLETIN 800HHEAVY DUTY

CORROSION-RESISTANTBOOTED

A-6178

BULLETIN 800HHEAVY DUTY

CORROSION-RESISTANTBOOTLESS

89-068-g

Bulletin 800 Control Stations are a rugged line ofdevices designed for use in control circuits Thesecontrol stations offer compact size and dependableoperation to meet most application requirements.Assembled control stations are available in avariety of combinations that can include pushbuttons, selector switches, pilot lights, and specialpurpose devices.

Publication 800-2.0 -June, 1989Supersedes Publication 800-2.0 Dated November, 1977

2Typical Wiring DiagramsFor Push Button Control Stations

Table of Contents

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . PUSH BUTTON CONTACT SELECTION . . . . . . . . . . . . . . . Page 3PILOT LIGHT SELECTION . . . . . . . . . . . . . . . . . . . . . . . . Page 4UNDERVOLTAGE PROTECTION . . . . . . . . . . . . . . . . . . . Page 4UNDERVOLTAGE RELEASE . . . . . . . . . . . . . . . . . . . . . . Page 4EXPLANATION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . Page 5

START-STOP CONTROL WIRING DIAGRAMSSingle Station - Basic Circuit . . . . . . . . . . . . . . . . . . . . . . . Page 6With Motor Running Pilot Light . . . . . . . . . . . . . . . . . . . . . Page 6With Motor Stopped Pilot Light . . . . . . . . . . . . . . . . . . . . . . Page 7Group of Single Stations with Master Stop Button . . . . . . . . . . . Page 7Maintained Contact Buttons- Undervoltage Release . . . . . . . . . Page 8

Multi-StationWith Momentary Contact Push Buttons . . . . . . . . . . . . . . . . . Page 8

REVERSING CONTROL WIRING DIAGRAMSReversing Station - Basic Circuit . . . . . . . . . . . . . . . . . . . . Page 9With Direction Indicating Pilot Lights . . . . . . . . . . . . . . . . . Page 9

TWO-SPEED CONTROL WIRING DIAGRAMSTwo Speed Station - Basic Circuit . . . . . . . . . . . . . . . . . . . . Page 10With Speed Indicating Pilot Lights . . . . . . . . . . . . . . . . . . . Page 10

MISCELLANEOUS WIRING DIAGRAMSSeparate Start, Stop and Jog ButtonsWith Standard Push Buttons and a Jog Relay . . . . . . . . . . . . . Page 11

Thermostat Controlled MotorWith Selector Switch - Undervoltage Release . . . . . . . . . . . . . Page 11

Ground DetectionWith Push-to-Test Pilot Lights . . . . . . . . . . . . . . . . . . . . . . Page 12

General InfoINFORMrma Information This publication is designed to serve as:1. A guide in understanding control circuits.2 . A handy reference pointing out the features of the more

common circuits.3 . A guide in the selection and installation of push button

control stations.

Typical Wiring DiagramsFor Push Button Control Stations 3

Genera/ Information @ Each circuit is illustrated with a control circuit(con tinued) schematic or line diagram and a control station wiring

diagram.l The schematic or line diagram includes all the

components of the control circuit and indicates theirfunction.

* The control station wiring diagram is a representation ofthe physical station, showing the relative positions ofunits, the suggested internal wiring, and connectionswith the starter.

Symbols common to most circuits are explained on Page 5.Less common symbols are explained where they occur.NOTE The symbols used in this publication were adaptedNOTE - The symbols used in this publication were adaptedby Allen-Bradley for use in accordance with NEMAby Allen-Bradley for use in accordance with NEMAstandards. A particular application must satisfy the needsstandards. A particular application must satisfy the needsof the user and comply with applicable codes and laws beforeof the user and comply with applicable codes and laws beforeusing any of the typical circuits shown in this publication.using any of the typical circuits shown in this publication.

,,

Push ButtonContact Selection

In the United States, contacts are normally rated byNEMA (National Electrical Manufacturers Association)standards. Internationally, contacts are rated by IEC(International Electrotechnical Commission) standards. Bymatching the contact rating to the load requirements, aproper contact block can be selected. Typically, Push Buttoncontact selection includes the following factors;Voltage/Amperage Requirements, Type of Load andEnvironment.The contacts selected must be capable of handling thevoltage and current to be switched. Control circuit loads aretypically called “pilot duty” loads. The load being switchedcan be a relay, contactor, or similar device that activates a

"power "power circuit”. Pilot Duty devices should not be used toswitch horsepower or lighting loads unless they arespecifically rated to do so.Solid state applications such as those with programmablecontrollers may require contacts that are able to switch lowcurrent and low voltage resistive loads. Logic reed typecontacts provide reliable switching of solid state loads withminimum contact bounce.Contaminated or hazardous location environments mayrequire the use of “sealed switch” type contacts. Applicablecodes should always be checked.

4Typical Wiring Diagramsfor Push Button Control Stations

Pilot Light Selection Pilot Light selection is based on the following factors;Voltage, Lamp Requirements, Environment, and Cost. 4The voltage of a pilot light must match the voltage supply.If both AC and DC voltage sources are available, AC voltageis recommended because it typically extends lamp life onincandescent units. When using an AC source of 120 Voltsor higher, a transformer type pilot light can also increaselamp life.Selection of the type of lamp can also affect lamp life. Thereare three types of lamps commonly used in pilot lights;incandescent, neon, and LED (Light Emitting Diode).Incandescent lamps have the shortest lamp life and aresusceptible to damage from shock and vibration.Incandescent lamps with lower voltages have thickerfilaments and burn cooler, plus are more durable. Neonlamps provide longer lamp life, but have slightly reducedillumination. LED lamps provide the longest lamp life andare the least susceptible to damage from shock andvibration.Illumination requirements are also important whenselecting a lamp. Depending on the color, an incandescelamp can provide brighter illumination when comparedwith a neon or LED lamn.

nt

Cost of the unit in terms of initial expense should also be 4addressed. Although it may be cost effective to initiallyinstall a device with a full voltage incandescent lamp, atransformer type, LED or neon unit can reduce downtimecosts through increased lamp life.For more information on Pilot Light selection, refer toAllen-Bradley, Milwaukee, WI.

Undervoltage Unless otherwise specified, the circuits provideProtection undervoltage protection or "three wire” control. In the

event of power failure, these circuits are designed to protectagainst automatic restarting when the power returns. Thistype of protection should be used where accidents or damagemight result from unexpected starts.

Undervoltage The circuits using undervoltage release or "two wire”Release control are noted in the Table of Contents. With any type of

control, the motor starts automatically after a power failure. 4Typically, these circuits involve automatic pilot devicessuch as thermostats, float switches, etc.


Explanation ofSymbols

Momentary Contact Push Button - Auxiliary Contacts-Operate when Operating Coil of Contactor:Depressing button opens and parent switch does. In this case, M - Main Line S - Slowcloses lower contacts. Releasing normally open (N.O.) contacts close F - Forward F - Fastbutton returns contacts to the and normally closed (NC.) contacts R - Reverse CR-Control Relaynormal condition shown. open when coil (M) is energized.

I

\I 0’

I0

\0

\J 0

J0 Overload Relay Contacts -

a0

\J 0

(One or more depending

0on starter construction).

/ 0 0 0.

\ J 0\ J 0 0))

\ 0 #)I

Ll

1, I/sTtP-,2

START

-t3 fI

,/’ CONTROL CIRCUIT /PUSH BUTTON CIRCUIT

WIRING DIAGRAM0-

04Reference Point-Identified onstarter, corresponds withnumber shown in push buttonstation wiring diagram.

/-0

Junction of Conductors -Absence of node indicates wirescross with no connection.

Power Line - Symbolized byweighted lines.


Start-Stop ControlWiring Diagrams

SINGLE STATION -BASIC CIRCUIT

r --------- 1kla,I!I

zl

III

I III Ifo 0;1 --------- J

START23

STOP

1I N.O.Aux. I

OPERATION-Depressing the START button energizes coil M, hold-incontacts M and maintains the circuit after the START button is released.Depressing the STOP button breaks the circuit, de-energizing coil M,contacts M return to their normally open position.

OVERLOAD PROTECTION -Operation of the overload relay contactsbreaks the circuit, thus opens M. To restart the motor, the overloadsmust be reset and the START button must again be depressed.

I PUSH BUTTON STATIONS

I Type of Station I Catalog Number

rStandard Duty I-- ~800S-2SA I

UNDERVOLTACE PROTECTION - If a power failure de-energizes thecircuit, hold-in contacts open. This protects against the motor startingautomatically after the power returns. Unless otherwise stated, circuitsto follow incorporate Undervoltage Protection. I Heavy Duty- Bootless

Corrosion-Resistant I800H2HA4RL

I

1 Oiltight/Watertight 800T-2TA ISINGLE STATION -WITH MOTOR RUNNING PILOT LIGHT

r --w-----v1

PILOT LIGHT

START

STOP

‘1 START a. ‘2 ‘2U.L.

1STOP

I1%

lb

0 0 M

4)

N.O.Aux. PILOT LIGHT

23

1IIL - - - - - - - - - J

Whenever the motor is running, the pilot light is illuminated. Except for this modification, the circuit and its operation is thesame as the basic single station.

I PUSH BUTTON STATIONS II I I Type of Station I

Voltage Standard Duty Heavy DutyGeneral Purpose

Heavy Duty - Booted Heavy Duty - Bootless Oiltight/Corrosion-Resistant Corrosion-Resistant Watertight

Catalog Number Catalog Number

120V240V

480V, 60Hz600V, 60Hz

800S=2SAP800S-2SAP

800H-2HAR800H-2HAP800H-2HAY800H-2HAV

800H-2HAR4R800H-2HAP2R800H-2HAY4R800H-2HAV4R

800H-2HAR4RL800H-2HAP4RL800H-2HAY4RL800H-2HAV4RL

800T-2TAR800T-2TAP800T-2TAY800T-2TAV


Start-Stop ControlWiring Diagrams

SINGLE STATION -WITH MOTOR STOPPED PILOT LIGHTL1 START L2-_I 1 STOP 2 OI” 3 n O.L. --w..

c

I m

N.C. Aux. ’ ‘t\w6.

PILOT LIGHT

L2

4

2

3

PILOTLIGHT

START

STOP

Bulletin 1495 normally closed auxiliary contacts are required. With the motor running contacts are open; with the motor stoppedcontacts are closed and the pilot light is illuminated. The basic circuit and its operation is the same as the diagram on Page 6.

I PUSH BUTTON STATIONS I

Voltage

120V240v

480V 60Hz600V 60Hz

Type of Station

Standard Duty

Catalog Number

800S-2SAP800S-2SAP

Heavy DutyGeneral Purpose

Catalog Number

800H-2HAR800H-2HAP800H-2HAY800H-2HAV

Heavy Duty - Booted Heavy Duty - Bootless Oiltight/Corrosion-Resistant Corrosion-Resistant Watertight

Catalog Number Catalog Number Catalog Number

800H-2HAR4R 800H-2HAR4RL 800T-2TAR800H-2HAP4R 800H-2HAP4RL 800T-2TAP800H-2HAY4R 800H-2HAY4RL 800T-2TAY800H-2HAV4R 800H-2HAV4RL 800T-2TAV

GROUP OF SINGLE STATIONS-WITH MASTER STOP BUTTON

L1 MASTER STARTO.L.

1STOP STOP 2 - 3

0 I - M l

0 0 0 0

- O - G --O yk

M lI ;STOP

A u x . lo 01

START L - - - - - - - - - 1O.L. r - - - - - - - - - 1

STOPol- I

1-h 0 /STARTI

0 0 M2 II

\

Aux.1 STOP

IO 0;12 i., -v-w---- J

r”--------1

I-0 IO-I

I 0

I

1 L0 I

- - - - - - - - - J

MASTERSTOP

800H-2HA4RLI I I I IA momentary contact MASTER STOP button is connected in series with a group of parallel connected circuits. Depressing thebutton de-energizes all of the circuits.The circuits above are the basic START-STOP circuit shown on Page 6. They could be any of the preceding or following circuits thatprovide undervoltage protection. Two wire control or undervoltage release circuits are not applicable because they would beenergized as the master stop button IS released.


Start-Stop ControlWiring Diagrams 4

SINGLE STATION - MAINTAINED CONTACT PUSH BUTTONSt--- - - - - - - - t

L1 UNDERVOLTAGE RELEASEO.L.

L 2 i-c-[ STARTII 1 I1 I I

lr\0 I

/

;

: $77

III

II I

; STOP!

L-m,----e- 1

The START button mechanically maintains the contacts that take the place of hold-in contacts. Depressing the START buttonmaintains the circuit; depressing the STOP button breaks the circuit by opening the start contacts.

If the contactor is de-energized by a power failure or overload operation, the start contacts are unaffected. The motor startsautomatically.

PUSH BUTTON STATIONS1

Type of Station Standard Duty Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/WatertightGeneral Purpose Corrosion-Resistant Corrosion-Resistant 1

Catalog Number 800S-2SBM 800H-2HAM 800H-2HAM4R 800H-2HAM4RL 800T-2TAM\

MULTI-STATION-WITH MOMENTARY CONTACT PUSH BUTTONS

L1 START

1 STOP STOPoln +-o

0 0 0 00 I Q

A u x .

Operation-The motor can be started or stopped from a number of separate stations by connecting the ! ISTART buttons in parallel and the STOP buttons in series. Operation of each station is the same as the I

lbbas ic un i t on Page 6 .I

1 o- &TOP

Pilot Lights- It is possible to add motor running, stopped, or push-to-test pilot lights to any or all of the I 0 0II

stations by connecting the lights to the circuit as shown in the diagrams below. Catalog numbers of the L---------Jrequired push button stations are listed in the appropriate pilot light circuits on Pages 6 and 7.

L 2 L1 L 2 L1 3 L 2

MB 4

r---v

O-0 1 B

A u x .I

BB

MOTORRUNNING

MOTORSTOPPED

PUSH BUTTON STATIONS

PUSH-TO-TESTRUNNING

Type of Station Standard Duty Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/WatertightGeneral Purpose Corrosion-Resistant Corrosion-Resistant 1L

Catalog Number 800S-2SA 800H-2HA 800H-2HA4R 800H-2HA4RL 800T-2TA


Reversing ControlWiring Diagrams

REVERSING STATION -BASIC CIRCUIT

FOR. L 2O.L.

REV. 2 I 3 .IRI n \I II

STOP-0 I

0 0

R Aux.I

4 ’

~

I

II

3 :I

I2 ’ I

I

*; pj

1 :II

FOR.

REV.

STOPIO 0;L - - - - - - - - - .I

Operation - Depressing the FORWARD button begins the following sequence:1. Coil F is energized. 2. Normally open contacts F close to hold in the FORWARD contactor; Normally closed interlock contacts Fopen to prevent the REVERSE contactor from being energized.

Changing the Direction of Rotation -Through the use of normally open contacts in the FORWARD and REVERSE push button units,it is unnecessary to depress the STOP button before changing the direction of rotation. Depressing the REVERSE button whilerunning forward: 1. De-energizes the FORWARD control circuit, and 2. Energizes and holds in the REVERSE contactor in a mannersimilar to the forward operation outlined above. This results in “plug-reversing”, that is, the motor acts as a brake until rotationstops, then the motor immediately starts turning in the opposite direction.

I PUSH BUTTON STATIONS IType of Station Standard Duty Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/Watertight

General Purpose Corrosion-Resistant Corrosion-Resistantr

Cataloa Number 800S-3SA 800H-3HA 800H-3HA4R 800H-3HA4RL 800T-3TA

REVERSING STATION -WITH DIRECTION INDICATING PILOT LIGHTS

L1 FOR. L 2

IO.L.

1 STOP REV. 2 - 3 R -8,~\I I

Aux. IOperation is the same as the basic circuit, except that separate lights indicate in whichdirection the motor is running.

; REV.; PL.I

I, FOR.; PL.

I I

4ain-I

I

I 0i FOR.I

3 ; I

2 : o I 9;; h REV.I

:-o 0 i

5 iII

1 i OlQ+ I STOP!

lo 0 I;,,,,,,-----a


Voltage

120V240V

480V, 60Hz600V, 60HZ

Type of Station &Catalog Number I

Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/WatertightGeneral Purpose Corrosion-Resistant Corrosion-Resistant

800H-3HA2R 800H-3HA2R4R 800H-3HA2R4RL 800T-3TA2R800H-3HA2P 800H-3HA2P4R 800H-3HA2P4RL 800T-3TA2P 800H-3HA2Y 800H-3HA2Y4R 800H-3HA2Y4RL 800T-3TA2Y800H-3HA2V 800H-3HA2V4R 800H-3HA2V4RL 800T-3TA2VA2V


Two-Speed ControlWiring Diagrams

TWO-SPEED STATION - BASIC CIRCUIT

L1 SLOW L 2

FAST 4 - 5B

0 0

I IF Aux.

r - - - - - - - - - l

Operation - Depressing the SLOW button begins the following sequence: 1. Coil S is energized. 2. Normally open contacts S closeto hold in the SLOW contactor; Normally closed interlock contacts S open to prevent the FAST contactor from being energized.

Changing Speeds- Through the use of the normally closed contacts in the SLOW and FAST push button units, it is unnecessary todepress the STOP button before changing speeds. Depressing the SLOW button while running fast: 1. De-energizes the fast controlcircuit. 2. Energizes and holds in the SLOW contactor as outlined above.

Type of Station

Catalog Number


Standard Duty Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/WatertightGeneral Purpose Corrosion-Resistant Corrosion-Resistant

800S-3SF 800H-3HF 800H-3HF4R 800H-3HF4RL 800T-3TF

TWO-SPEED STATION -WITH SPEED INDICATING PILOT LIGHTS

L1

1 STOPIW

0 0

SLOW r O.L. L1: :

t

;L2 1II.

i4 - I -

I

I!~~~IIO 0

Operation is the same as the basic circuit, except that separate lights indicate the motor speed. L-----------

PUSH BUTTON STATIONS I

Voltage

120V240V

480V 60HZ600V 60HZ

Type of Station &Catalog Number

Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/WatertightGeneral Purpose Corrosion-Resistant Corrosion-Resistant

800H-3HF2R 800H-3HF2R4R 800H-3HF2R4RL 800T-3TF2R800H-3HF2P 800H-3HF2P4R 800H-3HF2P4RL 800T-3TF2P800H-3HF2Y 800H-3HF2Y4R 800H-3HF2Y4RL 800T-3TF2Y800H-3HF2V 800H-3HF2V4R 800H-3HF2V4RL 800T-TF2V

lSLOW; PL.I

!I FAST; PC.II

i FAS TI:lSLOWIII

!; STOPII


MiscellaneousWiring Diagrams

SEPARATE START, STOP, & JOG -WITH STANDARD PUSH BUTTONS AND JOG RELAY

L1 START L 2 r - - - - - - - - -0 I O

1

0 0

C R3 f

1 STOP 4 CR M010-qAt-14

1-124-o I JOG

0 0 Aux. If

1 :010-q1

It

JOGI 0 0 I STOP

0 I O 4 iII

L - - - - - - - - - J

0

OPERATION - Depressing the START Button begins the following sequence: 1. Coil CR is energized; 2. Contacts CR close; 3. Coil M isenergized; 4. Contacts M close to hold in the contactor.

Depressing the JOG button energizes Coil M, but normally open contacts CR prevent against the contactor holding in; the motorwill run only as long as the operator holds in the JOG button.


Type of Station Heavy Duty Heavy Duty-Booted Heavy Duty-BootlessGeneral Purpose

Oiltight/WatertightCorrosion-Resistant Corrosion-ResistantI .

Catalog Number 800H-3HG 800H-3HG4R 800H-3HG4RL 800T-3TG

THERMOSTAT CONTROLLED MOTOR -WITH SELECTOR SWITCH

UNDERVOLTAGE RELEASEHIGH

L1 TEMPERATURE OFF

t4fg~;@<kL~

CIRCUIT OPERATION

Knob to Auto H a n d & A u t o z kSelector Switch to Auto-When the temperature is below thepreset value, the thermostat contacts are closed and contactorM is held in. Above this temperature, the contactsautomatically open the circuit. A high temperature cut-out is

Off included to open the circuit if the thermostat contacts should

Knob to Hand Hand

@

Auto al 0fail open.

Selector Switch to Hand-The thermostat is by-passed to0 0 permit testing of the circuit or emergency operation of the

Of f motor. The high temperature cut-out should be set to operate

Knob to Off Hand AutoA -0 0

in the event of dangerous temperatures.

0 0Selector Switch to Off -The circuit is open.

PUSH BUTTON STATIONSI

Type of Station Standard Heavy Duty Heavy Duty-Booted Heavy Duty-Bootless Oiltight/WatertightDuty General Purpose Corrosion-Resistant Corrosion-Resistant

Catalog Number 800S-R3SX 800H-R3HA 800H-R3HA4R 800H-R3HA4RL 800T-RT3A


MiscellaneousWiring Diagrams

GROUND DETECTION-WITH PUSH-TO-TEST PILOT LIGHTS

P L 2

P I L O TLIGHT

START

STOP

Operation -This circuit is used to detect a ground fault in ungrounded control circuits. Undernormal conditions, the lights are series connected and will burn dim. When a ground fault onL1 occurs, PL1 is short circuited and PL2 is directly across the line; PL1 is out and PL2 burnsbrightly. Similarly, when a ground fault on L2 occurs, PL2 is out and PL1 burns brightly.

Push-to-Test Pilot Lights- Because the lights are series connected, neither will light if one ofthem is burned out. The Push-To-Test feature makes it possible to quickly identify thedefective bulb by simply depressing the lens, connecting the bulb directly across L1 and L2.

I Type ofI

CatalogStation Number

ALLEN-BRADLEY Allen-Bradley has been helping its customers improve productivity and quality for 90 years.A ROCKWELL INTERNATIONAL COMPANY A-B designs, manufactures and supports a broad range of control and automation products

worldwide. They include logic processors, power and motion control devices, man-machineinterfaces and sensors. Allen-Bradley is a subsidiary of Rockwell International, one of theworld’s leading technology companies.

With major offices worldwide.Algeria l Argentina l Australia l Austria l Bahrain l Belgium l Brazil l Bulgaria l Canada l Chile l China, PRC l Colombia l Costa Rica l Croatia l Cyprus l Czech Republic l

Denmark l Ecuador l Egypt l El Salvador l Finland l France l Germany l Greece l Guatemala l Honduras l Hong Kong l Hungary l Iceland l India l Indonesia l Israel l Italy* Jamaica l Japan l Jordan l Korea l Kuwait l Lebanon l Malaysia l Mexico l New Zealand l Norway l Oman l Pakistan l Peru l Philippines l Poland l Portugal l Puerto I

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World Headquarters, Allen-Bradley, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444

push button typical wiring

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