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Mechanical Drawing, Electrical Graphical Symbols, Control Device Numbers, and Sequence Diagrams (JIS / JEM Standards)

Electrical Equipment Assembly – Control Panels 電気機器組立て (Grade 2 theory) · 技能検定「電気機器組立て」2級 学科(配電盤・制御盤組立て) · Written by Tokutei Pass based on the official study texts; not copied verbatim.

Third-Angle Projection, Line Types, and Dimensioning Rules in Mechanical Drawing (JIS B 0001)

In mechanical drawings under the Japanese Industrial Standards (JIS B 0001), "third-angle projection" is used in principle. Taking the "front view" showing the main face as the reference, the "top view (plan view)" is placed above it, the "right side view" to its right, the "left side view" to its left, and the "bottom view" below it.

Line types used in drawings are defined as: "visible outline = thick solid line" for visible outer shapes, "hidden line = dashed line" for invisible parts, "center line = thin chain line" for centers of circles and symmetrical shapes, "phantom (imaginary) line = thin double-dot chain line" for moving positions of movable parts, and "thin solid line" for dimension and leader lines.

Symbols placed before dimension numerals are: "φ (maru)" for diameter, "R" for radius, "□ (kaku)" for one side of a square, "Sφ, SR" for spherical diameter and radius, "t" for plate thickness, and "C" for a 45° chamfer (e.g., C2 means 2mm × 45°).

Under JIS dimensioning rules, an "angle dimension line" is drawn as a "circular arc" centered at the intersection (vertex) of the two sides forming the angle, and when the central angle of a sector arc is large, extension lines are drawn radially toward the center (indicating an angle with a straight line or drawing parallel extension lines is incorrect).

Also, on a dimension line indicating the radius R of an arc, an arrowhead is placed only on the arc side, with no arrowhead on the center side. When there are multiple holes of the same size, the quantity is written in front, such as "4−φ9 (four holes of 9mm diameter)".

Key points


  • In third-angle projection, the top view is placed above and the right side view to the right of the front view; visible outlines use thick solid lines, hidden lines use dashed lines, and center lines use thin chain lines

  • Dimension prefix symbols are "φ" for diameter, "R" for radius, "□" for a square side, "t" for plate thickness, and "C" for a 45° chamfer

  • Angle dimension lines are drawn as circular arcs centered at the vertex, and radius R dimension lines have an arrowhead only on the arc side
WordMeaning
Third-angle projection (front view, top view, right side view)
Visible outline (thick solid line), hidden line (dashed line), center line (chain line)
Dimension auxiliary symbols (φ, R, □, t, C)
JIS dimensioning rules for angles, arcs, and radii

Fits (Clearance, Transition, and Interference Fits), Shape/Position Tolerances, and Surface Texture

The relationship of tightness (or looseness) when mating a shaft and a hole is called a "fit (hameai)", which JIS classifies into three types according to the positional relationship of the hole and shaft tolerance zones: "clearance fit", "interference fit", and "transition fit".

A "clearance fit" has the minimum permissible diameter of the hole larger than the maximum permissible diameter of the shaft, always leaving a "clearance" when assembled. Conversely, an "interference fit" always has the shaft larger than the hole, always creating an "interference" when assembled.

In a "transition fit", the tolerance zones of the hole and shaft overlap, meaning "depending on the actual finished dimensions of the hole and shaft, either a clearance or an interference may result". Generally, the "hole-basis system of fits"—which fixes the hole tolerance zone (such as H7) as the reference and varies the shaft dimension—is widely used.

"Shape and position tolerances (geometric tolerances: JIS B 0021)" specifying accuracy of part shape, orientation, and location include "flatness" indicating surface flatness, as well as "parallelism, perpendicularity, coaxiality, and position" relative to a reference (datum).

"Surface texture (surface roughness: JIS B 0601)" indicating the smoothness of a machined surface uses arithmetic mean roughness "Ra (unit: μm)" and maximum height roughness "Rz", where smaller values indicate a smoother finished surface.

Key points


  • Fits include "clearance fit" (always has clearance), "interference fit" (always has interference), and "transition fit" (has either clearance or interference depending on actual dimensions)

  • In machining, the "hole-basis fit system" that keeps the hole tolerance zone (H) constant and varies the shaft tolerance zone is widely used

  • "Arithmetic mean roughness (Ra)" and "maximum height roughness (Rz)" are used for surface roughness
WordMeaning
Clearance fit, transition fit, and interference fit
Hole-basis fit system and dimensional tolerance
Shape/position tolerances (flatness, parallelism, perpendicularity) and datum
Surface texture (arithmetic mean roughness Ra, maximum height roughness Rz)

Switchboard and Control Panel Connection Diagrams (Single-Line, Elementary/Sequence, and Rear Connection Diagrams)

Drawings used in designing, manufacturing, and maintaining switchboards and control panels include "outline drawings (structural drawings)" showing external dimensions and equipment layout, as well as "single-line connection diagrams", "elementary connection diagrams (sequence diagrams)", and "rear connection diagrams (internal connection diagrams)" representing electrical connections.

A "single-line connection diagram (skeleton diagram)" represents even multi-phase circuits such as three-phase 3-wire circuits with a "single line", using electrical graphical symbols, control device numbers, and letter symbols so the overall configuration and connection relationships of main circuit equipment, meters, and protective relays can be understood at a glance.

An "elementary connection diagram (sequence diagram)" disregards the actual mounting positions or outer shapes of equipment, separating the "operating coils" and "individual contacts" of magnetic contactors and relays by function and laying them out so the flow of current and order of control operations (sequence) are easiest to understand.

In an elementary connection diagram, circuits are arranged in order of operation from top or left busbars toward the bottom or right in principle, and all contacts are drawn in the "de-energized (normal/returned) state with power off and no external force applied".

A "rear connection diagram (internal connection diagram / practical wiring diagram)" is drawn according to the actual equipment layout and terminal block positions as viewed from the "rear side (wiring work side)" of the switchboard or control panel, directly showing which terminals are connected by which wires for manufacturing and wiring work.

Switchboard and Control Panel Connection Diagrams (Single-Line, Elementary/Sequence, and Rear Connection Diagrams)

Key points


  • A "single-line connection diagram" uses graphical symbols and control device numbers to represent the overall equipment configuration and connections of multi-phase main circuits with a single line

  • An "elementary connection diagram (sequence diagram)" separates coils and contacts by function regardless of physical layout so the sequence of control operations is easy to understand

  • A "rear connection diagram" shows wire connections according to actual device positions and terminal arrangements as seen from the rear of the panel for wiring work
WordMeaning
Single-line connection diagram (skeleton diagram / overall configuration diagram)
Elementary connection diagram (sequence diagram / functional layout)
Rear connection diagram (internal connection diagram / for wiring work)
Outline drawing (structural drawing) and equipment layout drawing

Electrical Graphical Symbols (JIS C 0617): a-Contacts, b-Contacts, Operating Switches, and Timer Contacts

In JIS C 0617 (Graphical Symbols for Electrical Engineering), a contact that is open in the normal unoperated (de-energized) state and closes to conduct when operated is called a "make contact (a-contact: normally open NO)". The movable contact bar is drawn on the "right side" of the fixed contact in vertical drawings, and on the "upper side" in horizontal drawings.

Conversely, a contact that is closed in the normal unoperated state and opens to break the circuit when operated is called a "break contact (b-contact: normally closed NC)". The movable bar is drawn on the "left side" in vertical drawings and on the "lower side" in horizontal drawings. A changeover contact with a common terminal is called a "c-contact (transfer contact)".

In graphical symbols indicating the operating method of a contact, the operating symbol is drawn on the same side as the direction of movable contact movement. A "T-shaped (crossbar)" tip represents a general "manual operating switch", a "U-shaped (bracket-shaped) cap" represents a "pushbutton switch", and a pulling arrow represents a "pull switch".

Furthermore, a "limit switch (position switch)" actuated by mechanical contact (cam or dog) has a triangle mark attached to the contact bar, while a "temperature switch (thermal switch)" actuated by temperature is distinguished by a rectangle or temperature symbol.

For "time-delay contacts" of a timer (time-delay relay), an "on-delay (time-delayed operation, instantaneous return) contact"—which operates after a preset delay once the coil is energized and returns instantaneously when de-energized—is drawn with a semicircle (parachute canopy mark) bulging in the direction of operation (direction the contact moves).

Key points


  • A contact that closes when operated is called a "make contact (a-contact)", and a contact that opens when operated is called a "break contact (b-contact)"

  • In JIS graphical symbols, an operating line with a T-shaped tip indicates a general "manual switch", and one with a bracket/cup tip indicates a "pushbutton switch"

  • An on-delay (time-delayed operation, instantaneous return) timer contact is represented with a semicircular symbol opening toward the direction of contact operation
WordMeaning
Make contact (a-contact) and break contact (b-contact)
Graphical symbols for manual operating switches and pushbutton switches
Graphical symbols for limit switches and temperature switches
On-delay time contacts and off-delay time contacts

JEM Control Device Numbers (27, 49, 51, 52, 59, 72, 88) and Letter Symbols (RSC, X, Y, W)

The Japan Electrical Manufacturers' Association standard (JEM 1090) defines functional "basic device numbers (control device numbers)" for equipment in switchboards and control panels. Voltage-related numbers include: "27 = AC undervoltage relay (UVR)", "59 = AC overvoltage relay (OVR)", and "64 = ground overvoltage relay (OVGR)".

Current, thermal, and synchronizing numbers are defined as: "49 = AC thermal relay (THR)", "51 = AC overcurrent relay (OCR)", "67 = AC directional overcurrent relay (directional ground relay DGR)", "25 = synchronizing check or synchronizing closing device", and "30 = annunciator relay (fault indicator)".

Switch and circuit breaker numbers include: "52 = AC circuit breaker (CB)", "72 = DC circuit breaker (DCCB)", "42 = running circuit breaker or contactor", "43 = manual control transfer switch", "88 = auxiliary motor or motor magnetic contactor", and "89 = line switch (disconnector DS)" (describing 72 as a DC overcurrent relay is incorrect).

Furthermore, JEM letter symbols representing control methods are defined as: "AMC = automatic control", "SQC = sequence control", "PMC = program control", and "RSC = remote supervisory control" (defining RSC as follow-up control is a frequent exam trap).

In addition, among JEM letter symbols for circuit breaker accessories: "CC = closing coil", "TC = trip coil", "X = auxiliary relay for closing", "Y = anti-pumping relay (re-closing prevention)", and "W = auxiliary switch" (options defining W as a trip-free relay are incorrect).

Key points


  • JEM control device numbers are "27 = AC undervoltage relay, 49 = thermal relay, 51 = AC overcurrent relay, 52 = AC circuit breaker, 59 = AC overvoltage relay"

  • Device number "25" is a synchronizing device and "72" is a DC circuit breaker; calling 72 a DC overcurrent relay is incorrect

  • In JEM letter symbols, "RSC = remote supervisory control (not follow-up control)", and "X = closing auxiliary relay, Y = anti-pumping relay, W = auxiliary switch"
WordMeaning
Basic device numbers (27: UVR, 51: OCR, 59: OVR)
Device numbers 25 (synchronizing), 52 (AC CB), and 72 (DC CB)
Control method letter symbols (AMC, SQC, PMC, RSC = remote supervisory control)
Circuit breaker accessory symbols (X: closing aux, Y: anti-pumping, W: auxiliary switch)

Basic Sequence Circuits (AND, OR, Self-Holding Circuit, and Stop-Priority Circuit)

In basic sequence control circuits, a circuit connecting two a-contacts in "series" so a lamp or relay operates only when both are pressed is an "AND circuit (logical product)", whereas connecting two a-contacts in "parallel" so pressing either one operates the load is an "OR circuit (logical sum)".

A spring-return start pushbutton switch BS1 (a-contact) opens as soon as the finger is released. Therefore, the circuit constructed to maintain the operating state of magnetic contactor MC even after releasing the button is called a "self-holding circuit (seal-in circuit)".

A self-holding circuit is made by connecting the magnetic contactor's own "auxiliary a-contact (MC-a)" in "parallel" with the start pushbutton switch BS1 (a-contact). Once coil MC is energized, MC-a closes, allowing current to continue flowing through MC-a even after BS1 is released.

To release the self-holding state and stop operation, a stop pushbutton switch BS2 (b-contact) and the overload protection thermal relay contact (THR-b) are connected in "series" with the parallel self-holding loop and coil.

As a result, even if the start button BS1 and stop button BS2 are pressed simultaneously, or if the thermal relay THR trips due to overload, coil current is reliably interrupted to stop safely, forming a "stop-priority (off-priority) circuit".

Basic Sequence Circuits (AND, OR, Self-Holding Circuit, and Stop-Priority Circuit)

Key points


  • A self-holding circuit is formed by connecting the magnetic contactor's or relay's own "auxiliary a-contact" in "parallel" with the start pushbutton switch (a-contact)

  • The stop pushbutton switch (b-contact) and thermal relay b-contact are connected in "series" with the coil of the self-holding circuit

  • Placing the stop b-contact in series on the supply side creates a "stop-priority (off-priority) circuit" that safely stops even if start and stop are pressed simultaneously
WordMeaning
Contact AND circuit (series) and OR circuit (parallel)
Self-holding circuit (auxiliary a-contact in parallel with start a-contact)
Stop-priority circuit (off-priority: stop b-contact connected in series)
Overload interruption via thermal relay (THR) b-contact

Interlock Circuits and Three-Phase Induction Motor Forward/Reverse Main Circuits (Reversing Circuits)

For forward and reverse operation (reversing operation) of a three-phase induction motor, two magnetic contactors—forward contactor MCF and reverse contactor MCR—are used. If MCF and MCR are closed simultaneously, the main circuit supply phases are shorted directly together, causing a severe "power supply short-circuit accident".

Therefore, in the three-phase main circuit (R, S, T or L1, L2, L3), the connection between MCF and MCR is made by "connecting 1 of the 3 wires (e.g., the middle S phase) straight through to the same phase, and swapping only the remaining 2 wires (e.g., R phase and T phase)".

In exam questions on reversing main circuit diagrams, diagrams that "connect all 3 wires in the same phase order (does not reverse)", "cyclically shift all 3 phases (R→S, S→T, T→R: phase rotation order does not change, so it does not reverse)", or "create a phase-to-phase short circuit" appear as incorrect options.

Furthermore, in a control circuit, a circuit that locks out one contactor so it can never operate while the other is operating is called an "interlock circuit (simultaneous-closing prevention circuit)".

In an electrical interlock, "the reverse auxiliary b-contact (MCR-b) is connected in series with the forward coil MCF, and the forward auxiliary b-contact (MCF-b) is connected in series with the reverse coil MCR" so each blocks the other from closing, often combined with pushbutton or mechanical interlocks.

Key points


  • In a three-phase induction motor reversing main circuit, "swap only 2 of the 3 phases" between the forward and reverse magnetic contactors

  • Cyclically shifting all 3 wires (R→S→T→R) does not change the rotating magnetic field direction, so the motor will not reverse

  • To prevent short circuits from simultaneous forward/reverse closing, build an interlock circuit inserting the opposite contactor's "auxiliary b-contact" in series with each coil
WordMeaning
Forward/reverse main circuit (reversing main circuit: swapping 2 of 3 wires)
Interlock circuit (simultaneous-closing prevention / lockout circuit)
Electrical interlock using the opposite contactor's auxiliary b-contact
Pushbutton interlock and mechanical interlock

Timer Circuits (Y-△ Starting Sequence), Time Charts, and PLC Ladder Diagrams

In a "star-delta (Y-△) starting circuit", a representative circuit using a timer (time-delay relay TLR), pressing the start button simultaneously turns ON the main magnetic contactor MCM, star contactor MCY, and timer TLR, starting the motor at reduced voltage in Y connection.

When the timer's preset time elapses, the timer's on-delay b-contact opens to turn OFF MCY, and its on-delay a-contact closes to turn ON the delta contactor MCD, switching to normal operation in △ connection. An interlock circuit must also always be provided between MCY and MCD.

A diagram representing the ON/OFF states of devices, contacts, and indicator lamps along elapsed time (horizontal axis) as bands or step lines is called a "time chart (operation time diagram)", used for inspecting and designing complex time-staggered operations.

Furthermore, a "ladder diagram", most widely used as a PLC programming language, describes logic between left and right vertical rails using symbols very similar to elementary sequence diagrams. Basic instructions include "LD" (a-contact at rail start), "LDI" (b-contact at rail start), "AND / ANI" (series connection), "OR / ORI" (parallel connection), and "OUT" (coil output).

When an external emergency stop button (physical b-contact) is wired to a PLC input terminal (e.g., X1), input X1 is normally ON; therefore, placing an "a-contact" of X1 in series inside the ladder diagram forms a fail-safe circuit that turns OFF and stops when the button is pressed (or if a wire breaks).

Key points


  • In a Y-△ starting sequence, timer time-delay contacts automatically switch from the star magnetic contactor (MCY) to the delta contactor (MCD), with an interlock provided between them

  • A diagram showing ON/OFF states of equipment and contacts along a time axis is called a "time chart"

  • In a PLC ladder diagram, sequence control is written using instructions such as LD (start with a-contact), AND (series), OR (parallel), and OUT (output)
WordMeaning
Star-delta (Y-△) starting sequence circuit
Time chart (operation time diagram)
PLC ladder diagram (LD, AND, OR, OUT instructions)
External b-contact input and fail-safe design

Drawings, Symbols & Sequence Diagrams

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Official references

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