User: jrudyk1, Location: BC, Canada
Asked on: Monday, December 23, 2024 at 5:52 pm EST
Answered on: Thursday, March 6, 2025 at 6:36 am EST
Question: This shop replaced the motor for their lathe and I was sent to hook it up. The lathe has a forward/reverse switch hooked up to a pair of contacters. I am wondering how to hook up the new motor so it works with the existing setup. The old motor has already been discarded so I don't have that for reference. Originally 4 leads would go to the motor from the terminal block. I've drawn up what I think would work and attached some pictures of the motor and schematics. The new motor is not instant reverse so it would have to come to a stop to change direction but that's a compromise they can live with. Motor will be running on 208v.https://imgur.com/a/zkdEN9J
Okay, I've reviewed your drawings and the motor information. Your proposed wiring diagram in "Lathe Wiring.jpg" is CORRECT and should work to achieve forward/reverse functionality with your new motor on 208V. Here's a breakdown of why, along with some important considerations
Explanation of Why Your Wiring Works:
Motor Wiring (Based on Motor Nameplate and Wiring Diagram)
The motor nameplate indicates that leads T1, T2, T3, T4, T5, T6, T7, T8 are used. The internal wiring diagram shows that to reverse the motor, you essentially swap the connections to leads T5 and T8. Your diagram correctly connects the motor for High Voltage 230V (which is suitable for 208V, the motor will just run a little slower). It connects the 208V across T1 & T4.
Contactor Arrangement
Forward Contactor Engaged
With the forward contactor closed: L1 connects to T1 L2 connects to T5 L3 connects to T4
Reverse Contactor Engaged
With the reverse contactor closed: L1 connects to T1 L2 connects to T8 L3 connects to T4 This arrangement effectively swaps the connection of the L2 phase to T5 and T8, which is what the motor's internal wiring diagram dictates for reversing.
Important Considerations and Steps Before Connecting
Verify Motor Nameplate Voltage
Double-check that the motor is indeed rated for 208-230V operation. A motor designed only for 460V or higher will be damaged if connected to 208V.2. Motor Overload Protection
CRITICAL! You must have properly sized overload protection for the motor. This is typically a thermal overload relay integrated into the contactors or a separate device. Without proper overload protection, the motor will burn out if it's overloaded. You need to determine the motor's full-load amps (FLA) from its nameplate and size the overloads accordingly. The FLA rating will be slightly higher if connected to 208V than 230V. Use a formula like (Nameplate FLA @ 230V) * (230V/208V).3. Grounding
Ensure the motor frame is properly grounded (earthed) according to your local electrical codes. This is a safety requirement.4.
Wire Gauge
Verify that the existing wiring from the terminal block to the contactors and from the contactors to the motor is of the appropriate gauge (size) to handle the motor's full-load amps (FLA). Undersized wiring can overheat and cause a fire.5.
Contactor Rating
Confirm that the contactors are rated for at least the motor's FLA and the voltage you are using (208V).6.
Test the Contactors
Before connecting the motor, use a multimeter to ensure the contactors are working correctly and that they are properly interlocked (i.e., only one can be energized at a time). You don't want both contactors trying to engage simultaneously, as this would create a short circuit.7.
Disconnect Power
Turn off and lock out/tag out the main power supply before doing any wiring.8.
Labeling
Label all wires and connections clearly to prevent future confusion.9.
Rotation Direction
Once wired, bump the motor in forward and reverse to ensure it is going the correct way. If not swap any two of L1, L2, or L3.
Wiring Steps (Assuming Everything Else Checks Out)
Disconnect Power
Lock out/tag out the power.2.
Wire the Motor
Connect the motor leads as shown in your "Lathe Wiring.jpg" diagram to the output terminals of the contactors.3.
Wire the Power to Contactors
Connect L1, L2, and L3 from the terminal block to the input terminals of the contactors.4.
Ground the Motor
Ensure a solid ground connection to the motor frame.5.
Double-Check Everything
Thoroughly inspect all wiring for proper connections and tightness.6.
Turn on Power
Turn on the main power supply.7.
Test Rotation
Briefly activate the forward contactor and observe the direction of rotation. Then do the same for the reverse contactor.8.
Overload Trip
Put the machine under a load and verify the overload protection trips appropriately.
Safety is Paramount!
If you are not a qualified electrician, it is highly recommended to consult with one to ensure the installation is done safely and according to code. Working with electrical power can be dangerous. Flag for review