Professional Documents
Culture Documents
I N S TA L L AT I O N G U I D E
P R E PA R E D BY E A S Y T E C H
2015
EZTECH
ELECTRICAL INSTALLATION GUIDE
Table of Contents
ELECTRICITY SUPPLY SPECIFICATIONS.............................................................4
Legal Requirements.................................................................................................. 5
Determining Consumer Load Requirements.....................................................................6
2.
CABLE SELECTION.............................................................................................. 10
3.2 Factors Related to Cable Current Carrying Capacity.................................................11
Functions and Colour Identification of Non Flexible Cables............................................12
Conductor Insulation and Types of Wiring.....................................................................13
Functions and Colour Identification of Non Flexible Cables...............................................13
3.
4.
RESIDENTIAL BUILDINGS.............................................................................18
Why Electric Shocks Occur....................................................................................... 19
INSTALLATION CIRCUITS AND SYSTEMS..............................................................20
Working Principal of Star-Delta Starter:...................................................................21
Star-delta Starter Consists following units:.................................................................21
Power Circuit of Star Delta Starter:..........................................................................21
Control Circuit of Star-Delta Starter (Open Transition):...............................................22
What is Open or Closed Transition Starting...............................................................23
Effect of Transient in Starter (Open Transient starter).................................................25
Size of each part of Star-Delta starter........................................................................25
Motor Starting Characteristics of Star-Delta Starter:...................................................26
Advantages of Star-Delta starter:............................................................................. 26
Disadvantages of Star-Delta starter:.........................................................................26
Features of star-delta starting.................................................................................. 27
Application of Star-Delta Starter:............................................................................. 27
................................................................................................................... 28
LESSON 1: WIRING SYSTEM OF SINGLE PHASE DISTRIBUTION BOARD..................28
LESSON 2. WIRING SYSTEM OF SINGLE PHASE LIGHTING CIRCUIT.........................32
LESSON 3 WIRING SYSTEM OF SINGLE PHASE POWER CIRCUIT...........................33
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STARTER................................8
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ELECTRICITY SUPPLY
SPECIFICATIONS
Electricity supply for domestic consumers, according to MS IEC 60038 standards, meets the
following specifications: i. Single phase supply with nominal voltage of 230V, range +10%, -6%;
ii. Three phase supply with nominal voltage of 400V, range +10%, -6%;
iii. Permitted frequency is 50Hz + 1%;
iv. Earthing system type (TT System) as in Figure 2.1 and Figure 2.2.
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Legal Requirements
Regulation 11(1) of the Electricity Regulations 1994 states that all wiring or rewiring of an
installation or extension to an existing installation, which shall be carried out by an Electrical
Contractor or a Private Wiring Unit, have to obtain the approval in writing from a licensee or supply
authority.
1. Planning of Electrical Wiring Work
Prior to carrying out wiring work, the wireman/contractor should plan and determine the tasks to be
undertaken so that the work carried out is tidy, neat and safe to be used. The wireman/contractor shall:
-i. Undertake a site visit;
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The circuit breakers or fuses must be installed on the live conductors only. For three phase circuits, all
the circuit breakers or fuses must be combined in one set of circuits.
Selection of over current devices must be based on the short circuit fault current levels of the circuit
breaker or main switch (kA).
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iii. The selected cable must be capable of delivering the electrical energy efficiently;
iv. The cable size allows it to carry the current without heating the cable;
v. The voltage drop must not exceed 4% of the supply voltage. Refer to Table 4D1B in Appendix III;
vi. The cable insulation must be suitable for the surrounding conditions of the installation, such as the
ability to withstand the surrounding temperatures and the ability to provide mechanical protection;
vii. Each conductor in the installation must be protected from overcurrent by means of overcurrent
protection devices needed to prevent damage to the cable insulation.
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Flexible Cables
i. Flexible cables of cross sectional area less than 4.0 mm are used in installations for electrical
2
accessories such as ceiling roses, lamp fixtures or attachments, socket plugs for mobile
appliances, etc..
ii. Flexible cables shall not be used for permanent wiring.
iii. Flexible cables for the permanent use of electrical appliances should not exceed 3 meters in
length.
3.7 Functions and Colour Identification of Flexible Cables
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a) Switches, socket outlets, 3 pin plugs, ceiling roses, connectors, sockets construction material shall
be of polycarbonate type.
iii. For all wiring using metal conduits: - Switches, socket outlets and connectors construction
material shall be of metal clad type, and All accessories shall be effectively earthed.
iv. Switch fuse used in single phase installations shall have the fuse permanently connected and not
move with the fuse.
v. Fuse switch used in 3 phase domestic installations also has fuse and switch. The fuse connector is
installed together to allow the fuse to move simultaneously with the switch.
vi. Lamp:
a) Fluorescent lamps using magnetic ballasts (watt loss not exceeding 6 watts) shall be
equipped with dry paper type capacitor;
b) Fluorescent lamps using electronic ballasts or high frequency electronic ballasts do not
need capacitors;
c) Outdoor domestic lamp installations shall use weather proof and water proof lamps;
d) Submerged light installations (example in swimming pools, fountains, etc.) shall have water
proof lamps with a voltage not exceeding 12 Volt AC.
vii. Electric water heaters is divided into 2 types, namely
1. instantaneous water heaters and
2. stored water heaters (storage tank type)
a) Instantaneous water heaters shall be equipped with a 2 pole control switch and its own
residual current device.
b) Storage water heaters (storage tank type) shall be installed with an
Water heaters exceeding 3kW shall be permanently connected to a 20A/30A rated circuit
breaker/fuse with an isolator switch and residual current device.
viii. Electric cookers exceeding 3kW shall have its own circuit connected permanently to a 30A rated
circuit breaker or fuse with an isolator switch and cooker control unit incorporated with a 13A socket
outlet. Two or more cooker appliances may be installed in the same room within a distance of 2
meters.
ix. Electric motors (fence gate, air conditioners, fountains, swimming pools, fish ponds, water
pumps) exceeding 373W but not exceeding 2238W, shall be connected permanently to a 20A/30A
rated circuit breaker/fuse together with an isolator, motor starter and 15A socket outlet.
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The motor starter shall be of Direct-On-Line type with the appliance together with the contactor,
overload relay and on-off control. The circuit breaker/fuse which controls the motor circuit shall be
capable of withstanding the starting current of the motor.
x. Electric bells the circuit shall have a push button switch and a AC/DC transformer.
xi. Ceiling fans shall conform to clause 21.101 of the MS 1219:2002 standard with regards to test on
the suspension system of ceiling fans.
Earthing
Earthing is a connection system between the metallic parts of an electrical wiring system and the
general mass of the earth. This will provide an easy path with a low impedence or resistance to earth to
enable the protection system to operate effectively. It will thus ensure safety to human
beings/consumers from the dangers of electric shocks if earth leakage currents are present. In general,
an electrical installation is earthed because of: i. Safety reasons.
ii. Protection system requirements.
iii. Need to limit over voltages.
iv. Need to provide a path for electrical discharge.
v. Legal requirements.
5.2 Classification of Earthing
Generally, earthing can be divided into 2 parts, namely: i. System Earthing
a. To isolate the system under fault conditions;
b. To limit the potential difference between conductors which are not insulated in an area;
c. To limit the occurrence of over voltages under various conditions.
ii. Equipment Earthing
Equipment earthing is undertaken to protect human beings/consumers. If a live source comes into
contact with the equipment body, electrical energy will flow to the earth, without flowing through the
human being/ consumers body. This is because of the fact that the human body has a greater
resistance compared with the resistance to earth.
5.3 Types and Functions of Earthing Accessories
Earthing accessories are as follows: i.
Earthing Electrode
Copper jacketed steel core rods are used as electrodes for domestic wiring.
ii. Equipotential Bonding
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This is the conductor which is connected between the consumer earthing point and the exposed
metallic part. The minimum cable size for this purpose is 10 mm 2.
iii. Protection Conductor
This is the conductor which connects the consumer earthing point with other parts of the installation
which needs earthing. Its size is as follows:a) Same size as the phase cable up to a size of 16mm 2,
b) 16 mm2, if the phase cable size is between 16 mm 2, and 35 mm2,
c) Half the size of the phase cable if the size of the phase cable exceeds 35 mm 2.
5.4 Earthing Arrangements Using a TT System
i. The first alphabet indicates the earthing arrangements from the supply side.
ii. The second alphabet indicates the earthing arrangement in the consumers installation.
T first: Indicates that the supply system has its own earthing arrangements
T second: Indicates that all metallic frames of the electrical appliances, etc. are connected directly to
earth.
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iv. Small metallic parts such as screws and name plates which are isolated by means of insulation;
v. Metallic lamp parts for filament lamps in water proof floors.
5.7 Termination to Earth
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Direct contact occurs when the worker or consumer receives an electrical shock on touching directly a
live conductor or cable.
b. Indirect Contact:
Here the electric shock occurs due to contact with a part which is connected to the electrical
installation and not to a direct contact with a live cable or conductor, possibly due to damages in the
appliance or insulation, resulting in leakages of current.
Leakage Current
Leakage currents or earth leakage currents can result in the metallic frames becoming live and
energised. This can give rise to the danger of electrical shock to the worker, consumer or the public if
they hold or come into contact with the metallic frame.
ii.
i.
Pulmonary Resuscitation
Pulmonary resuscitation has to be undertaken to assist the victim who has breathing difficulties as a
result of being drowned, receiving an electrical shock, etc.. Pulmonary resuscitation has to be carried
out in accordance to the correct method as stated in the first aid manuals issued by accredited first aid
bodies.
ii.
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A first aid box has to be provided by the building owner, construction site supervisor or brought
personally by the worker under the supervision of the responsible person.
6.5 Training Programme
The management shall conduct periodic training programmes for the workers with regards to work
safety on aspects including the following: i. Dangers of electrical work being undertaken and how to control those dangers;
ii. The safety regulations set for the work place; and
iii. First aid procedures.
6.6 Fire Prevention
Fire Extinguisher A suitable, functioning fire extinguisher to control fires has to be made available at
the work place at all times.
6.7 Competent Person
The Electricity Regulations 1994 require that all electrical work has to be undertaken by or under the
direct supervision of a competent person registered with the Energy Commission. Besides that, the
electrical contractor undertaking the electrical work has also to be registered with the Energy
Commission. The installation owner thus has to ensure that the appointed electrical contractor is
registered with the Energy Commission and that the registration is still valid.
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Star/Delta starters are probably the most common reduced voltage starters. They are used in
an attempt to reduce the start current applied to the motor during start as a means of reducing the
disturbances and interference on the electrical supply.
Traditionally in many supply regions, there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW). The Star/Delta (or Wye/Delta) starter is one of the
lowest cost electromechanical reduced voltage starters that can be applied.
The Star/Delta starter is manufactured from three contactors, a timer and a thermal overload.
The contactors are smaller than the single contactor used in a Direct on Line starter as they are
controlling winding currents only. The currents through the winding are 1/root 3 (58%) of the
current in the line.
There are two contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor. The third
contactor is the star contactor and that only carries star current while the motor is connected in star.
The current in star is one third of the current in delta, so this contactor can be AC3 rated at one
third (33%) of the motor rating.
Contactors (Main, star and delta contactors) 3 Nos (For Open State Starter) or 4 Nos (Close
Transient Starter).
2)
3)
4)
5)
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3. In operation, the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially, and
then after a period of time, the star contactor is opened, and then the delta contactor (KM2) is
closed. The control of the contactors is by the timer (K1T) built into the starter. The Star and Delta
are electrically interlocked and preferably mechanically interlocked as well. In effect, there are
four states:
4. The star contactor serves to initially short the secondary terminal of the motor U2, V2, W2 for the
start sequence during the initial run of the motor from standstill. This provides one third of DOL
current to the motor, thus reducing the high inrush current inherent with large capacity motors at
startup.
5. Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit. The control circuit consists of push
button switches, auxiliary contacts and a timer.
The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of star
circuit and Timer Coil (KT) circuit.
2.
When Star Contactor Coil (KM1) energized, Star Main and Auxiliary contactor change its
position from NO to NC.
3.
When Star Auxiliary Contactor (1)( which is placed on Main Contactor coil circuit )became
NO to NC its complete The Circuit of Main contactor Coil (KM3) so Main Contactor Coil
energized and Main Contactors Main and Auxiliary Contactor Change its Position from NO
To NC. This sequence happens in a friction of time.
4.
After pushing the ON push button switch, the auxiliary contact of the main contactor coil (2)
which is connected in parallel across the ON push button will become NO to NC, thereby
providing a latch to hold the main contactor coil activated which eventually maintains the
control circuit active even after releasing the ON push button switch.
5.
When Star Main Contactor (KM1) close its connect Motor connects on STAR and its
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO.
6.
Once the time delay is reached its specified Time, the timers auxiliary contacts (KT)(3) in
Star Coil circuit will change its position from NC to NO and at the Same Time Auxiliary
contactor (KT) in Delta Coil Circuit(4) change its Position from NO To NC so Delta coil
energized and Delta Main Contactor becomes NO To NC. Now Motor terminal connection
change from star to delta connection.
7.
A normally close auxiliary contact from both star and delta contactors (5&6)are also placed
opposite of both star and delta contactor coils, these interlock contacts serves as safety
switches to prevent simultaneous activation of both star and delta contactor coils, so that one
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cannot be activated without the other deactivated first. Thus, the delta contactor coil cannot be
active when the star contactor coil is active, and similarly, the star contactor coil cannot also
be active while the delta contactor coil is active.
8.
The control circuit above also provides two interrupting contacts to shutdown the motor.
The OFF push button switch break the control circuit and the motor when necessary. The
thermal overload contact is a protective device which automatically opens the STOP Control
circuit in case when motor overload current is detected by the thermal overload relay, this is to
prevent burning of the motor in case of excessive load beyond the rated capacity of the motor
is detected by the thermal overload relay.
9.
At some point during starting it is necessary to change from a star connected winding to a
delta connected winding. Power and control circuits can be arranged to this in one of two
ways open transition or closed transition.
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1.
2.
Star State: The Main [KM3] and the Star [KM1] contactors are closed and the delta [KM2]
contactor is open. The motor is connected in star and will produce one third of DOL torque at one
third of DOL current.
3.
Open State: This type of operation is called open transition switching because there is an
open state between the star state and the delta state. The Main contractor is closed and the Delta
and Star contactors are open. There is voltage on one end of the motor windings, but the other end
is open so no current can flow. The motor has a spinning rotor and behaves like a generator.
4.
Delta State: The Main and the Delta contactors are closed. The Star contactor is open. The
motor is connected to full line voltage and full power and torque are available
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Closed Transition State. The Main [KM3] contactor is closed and the Delta [KM2] and Star
[KM1] contactors are open. Current flows through the motor windings and the transition resistors
via KM4.
Delta State. The Main and the Delta contactors are closed. The transition resistors are shorted out.
The Star contactor is open. The motor is connected to full line voltage and full power and torque
are available.
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In the windings means that the overload is placed after the point where the wiring to the contactors
are split into main and delta. The overload then always measures the current inside the windings.
The setting of Overload Relay (In Winding) =0.58 X FLC (line current).
Disadvantage: We must use separate short circuit and overload protections.
(2) Size of Main and Delta Contractor:
1.
There are two contactors that are close during run, often referred to as the main contractor and
the delta contactor. These are AC3 rated at 58% of the current rating of the motor.
The third contactor is the star contactor and that only carries star current while the motor is
connected in star. The current in star is 1/ 3= (58%) of the current in delta, so this contactor can
be AC3 rated at one third (33%) of the motor rating.
Size of Star Contactor= IFL x 0.33
It draws 2 times starting current of the full load ampere of the motor connected
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In this method of starting initially motor is connected in star and then after change over the motor
is connected in delta. The delta of motor is formed in starter and not on motor terminals.
High transmission and current peaks: When starting up pumps and fans for example, the load
torque is low at the beginning of the start and increases with the square of the speed. When
reaching approx. 80-85 % of the motor rated speed the load torque is equal to the motor torque and
the acceleration ceases. To reach the rated speed, a switch over to delta position is necessary, and
this will very often result in high transmission and current peaks. In some cases the current peak
can reach a value that is even bigger than for a D.O.L start.
Applications with a load torque higher than 50 % of the motor rated torque will not be able to start
using the start-delta starter.
Low Starting Torque: The star-delta (wye-delta) starting method controls whether the lead
connections from the motor are configured in a star or delta electrical connection. The initial
connection should be in the star pattern that results in a reduction of the line voltage by a factor of
1/3 (57.7%) to the motor and the current is reduced to 1/3 of the current at full voltage, but the
starting torque is also reduced 1/3 to 1/5 of the DOL starting torque .
The transition from star to delta transition usually occurs once nominal speed is reached, but is
sometimes performed as low as 50% of nominal speed which make transient Sparks.
2.
3.
4.
5.
6.
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loaded, there will not be enough torque to accelerate the motor up to speed before switching over
to the delta position.
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Objectives
1. Identify component and the specification
2. Wire component according to the schematic diagram
3. Test the functionality of the circuit .
TOOLS / MATERIAL
1.
2.
3.
4.
SPECIFICATION
Wiring bay
Perforated metal 180 cm x 180 cm
Cut out fuse
63 A, 240 V
Neutral link
Single pole one way switch c/w 5A , 240Vac
switch box
5. single pole two way switch c/w
5A . 240Vac
switch box
6. RCCB
In = 40
7.
8.
9.
10.
11.
12.
13.
Main switch
kWatthour meter
Single pole MCB
Self tapping / Wood screw
DIN rail
PVC trunking
Terminal blocks
QUANTITY
1
1
1
4
2
A,
Tripping current
100mA,240 Vac, 50 Hz
32 A, 240V
40 A, 240 Vac
6A, 240 Vac
35 mm width
50 mm x 50 mm
5A
1
1
1
1
As required
As required
As required
As required
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Procedures
1. Identify each component and quantity of required from the schematic diagram attached
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram
1. One way switch to control one lamp
2. One way switch to control two lamps
3. Two of two way switch to control one lamp
4. Two of single pole two way switch and one of an intermediate switch to control one
lamp
5. One unit of ceiling fan and fan regulator to be controlled by one way switch .
4.
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Objectives
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Mounting board
kWh meter
Socket outlet
RCCB
5. 3 pin socket
6. Single pole MCB
7. DOL starter
8. 1 phase induction motor
9. Cooker control unit
10. Water heater point
11. DIN rail
12.PVC casing
13. Flexible wires
14. Terminal block
SPECIFICATION
QUANTITY
Perforated Metal
240 V , 40 A
13A , 240Vac
40A
Trip
Amps
1
1
4
1
30mA,240 Vac
240Vac, 13A
20A, 240 V
1 kW, 240Vac
2Hp , 240 Vac
4kW, 240Vac
4kW, 240 Vac
35 mm
20mm
0.5 mm
10 A
4
2
2
1
1
1
As required
As required
As required
As required
Procedures
1. Identify each component and quantity of required from the schematic diagram attached
2. Wire two unit of 13 A socket outlet in radial circuit .
3. Wire four units of 13 A socket outlet in ring circuit .
4. Wire one unit DOL starter for air-conditioner point
5. Wire one unit of cooker control unit point
6. Wire one unit of water heater point
7. Test the functionality of each component by using m/meter or power supply whichever
applicable .
8. Wire component according to circuit diagram
9. Test the functionality of completed project .dead circuit test , life circuit test.
Note:
Ensure that the correct rating of protection device and size of wire used.
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Objectives
1. Identify conduit fitting and the specification
2. Measure and Cut steel conduit according to specified dimension
3. Bend and fabricate conduit at 45 ,90 , according to layout diagram
4. Wire component according to the schematic diagram
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SPECIFICATION
19 mm, ( )
3 metre
30cm
20 mm
50 mm x 50 mm
20mm
20 mm
0.5 mm
5A
2.5 mm 2
QUANTITY
1
1
1
1
1
1
1
1
1
1
As required
As required
As required
Procedures
1. Identify each component and quantity of required from the schematic diagram attached
2. Wire two unit of 13 A socket outlet in radial circuit .
3. Wire four unit of 13 A socket outlet in ring circuit .
4. Wire one unit DOL starter for air-conditioner point
5. Wire one unit of cooker control unit point
6. Wire one unit of water heater point
7. Test the functionality of each component by using multimeter or power supply whichever
applicable .
8. Wire component according to circuit diagram
9. Test the functionality of completed project .
Note:
Ensure that the rating of protection device and size of wire
K prior to 31 March
2004 (BS 7671)
(formerly)
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POWER CIRCUITS
a. Radial circuits
Radial circuits are arranged in the same way as item 1, above, in lighting layouts, in that each socket
outlet is supplied via the previous one
Points to note
1 The number of socket outlets, complying with BS 1363, is unlimited for a floor area of up to 50m 2 if
the circuit protection is a 30 A or 32 A cartridge fuse or circuit breaker, the cable being 4 mm PVC
copper or 2.5 mm2 mineral insulated (m.i.).
2 The number of socket outlets is unlimited for a floor area up to 20 m 2 with any type of circuit
protection of 20 A using 2.5 mm2 PVC copper cable or 1.5 mm2 m.i.
3 The total number of fused spurs is unlimited.
b. ring final circuits
These circuits are the same as radial circuits except that the final socket outlet is wired back to the
supply position. In effect any outlet is supplied from two directions (Fig. 15.2).
Points to note
1 Every twin-socket outlet counts as two single-socket outlets.
2 The number of non-fused spurs must not exceed the total number of points on the ring. Fig. 15.8
shows seven points on the ring and five spurs.
3 The fuse rating of a fused spur box must not exceed 13 A and the current rating of all points supplied
by the fused spur must not exceed 13 A.
4 Non-fused spurs must supply no more than one single or one double socket on the ring. Fig. 15.8
shows seven points on the ring and five spurs. rating of all points supplied by the fused spur must not
exceed 13 A. or one stationary appliance.
Capacity
size (mm2)
capacity (A)
Up to 600 W
1.5
1.5
6001,200 W
1.5/2.5
1.5
10
1,2001,800 W
2.5/4
2.5
16
2.5
1.5
30/32
4.0
2.5
30/32
Ring circuit
(floor area 100 m2)
A2 radial circuit
(floor area 75 m2)
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A3 radial circuit
2.5
1.5
20
6.0
6.0
30/32
Cooker
6.0
6.0
30/32
Water heater
4.0
4.0
20
Objectives
1. Identify component and the specification
2. Wire component according to the schematic diagram
3. Test the functionality of the circuit .
TOOLS / MATERIAL
SPECIFICATION
QUANTITY
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ELECTRICAL INSTALLATION GUIDE
1.
2.
3.
4.
5.
Mounting board
Cut out fuse and neutral link
kWh meter
Switched Socket outlet
Single pole two way switch c/w switch
box
6. RCCB/ ELCB
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
3 pin plug
Single pole MCB
Single pole MCB
Single pole MCB
DOL starter
1 phase induction motor
Self tapping / Wood screw
DIN rail
PVC pipe
End box
Flexible wires
Connectors
Perforated
60A, 240V
240V, 40A
13A , 240Vac
5A . 240Vac
1
1each
1
4
2
415 Vac
240Vac, 13A
20 A
6A
20A
240Vac
2hp , 240 Vac
Stainless steel /allum35 mm
20mm dia
20 mm dia
0.5 mm 2
5A
4
2
1
2
2
1
As required
As required
As required
4
As required
As required
Procedures
1. Identify each component and quantity of required from the schematic diagram attached .
2. Test the functionality of each component by using multimeter or power supply whichever
applicable .
3. Wire component according to circuit diagram
4. Test the functionality of completed project .
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Objectives
1. Identify each component and the specification
2. Wire component according to the schematic diagram given
3. Test the functionality of the circuit .
TOOLS / MATERIAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
SPECIFICATION
Perforated metal
415V ac, 32A
60 A
415V, 60A
In=63A,415 Vac, I trip= 300mA
In=63A,415 Vac, I trip= 30mA
6A, 240 V
20A, 240 V
20 A, 240Vac
15 A, 240 Vac
13 A, 240 Vac
5A , 240 Vac
5A, 240 Vac
5A, 240 Vac
1 kW, 240Vac
30 mm x30 mm
4 mm x 20 mm
25 mm x 1mm
20mm
20mm
20 mm
0.5 mm 2
1.5 mm 2
2.5 mm 2
10 A
QUANTITY
1
1
3
1
1
1
1
3
3
2
1
3
3
2
2
1
As required
As required
As required
As required
4
As required
As required
As required
As required
Procedures
1. Identify each components and quantity of required from the schematic diagram attached.
2. Test the functionality of each component by using multimeter or power supply whichever
applicable.
3. Wire component according to circuit diagram
4. Test the functionality of completed project
1. dead circuit test
2. life circuit .
Note : Proper earthing should be made .
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Objectives
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and
SPECIFICATION
QUANTITY
1
1
6A
20A
60A
240Vac
2hp , 415 Vac
1
2
1
2
1
1
As required
As required
plug
6. Single pole MCB
7. Triple pole MCB
8. Triple pole Main switch
9. DOL starter
10. 3 phase induction motor
11. 1 phase induction motor
12. Metal trunking
13. Self tapping / Wood screw
14. DIN rail
15. GI steel rigid conduit
16. Flexible conduit
17. End box
18. Flexible wires
19. Connectors
Procedures
30 mm x30 mm
4 mm x 20 mm
25 mm x 1mm
20mm
20mm
20 mm
0.5 mm
10 A
1
4
As required
As required
4
As required
As required
1. Identify each components and quantity of required from the schematic diagram attached .
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram
4. Test the functionality of completed project
1. dead circuit 2. life circuit test.
5. Record the current drawn by the load as connected in star and . delta
Note : Proper earthing should be made .
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2. Connected the test leads as in the Figure 8.1; The meter reading shall be less than 1 .
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CONTINUITY TEST
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Polarity Test
i. Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor.
ii. Intermediate contact of Edison screw lamp holder is connected to the phase conductor.
iii. Ensure that phase, neutral and earth conductors at socket outlets are connected at the correct
terminals.
iv. Test Equipment Multimeter (Ohm range) or Ohm meter.
v. Test Method:
1. Switch off Main switch;
2. Disconnect all loads
3. Switch on all circuit control switches;
4. Carry out test as in Figure 8.5;
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5. Test switches and single phase control devices at the phase conductors.
6. Test socket outlet connection sources.
7. Test Edison screw lamp holder connections.
8. Meter reading value shall be less than 1 .
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Polarity test
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ii.
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet.
Select the RCD sensitivity to be the same as the sensitivity of the RCD to be tested, to
determine if the RCD can trip. The time to trip shall not exceed 40 mS.
iii.
Test method
a) Position the selection switch in accordance with the sensitivity of the RCD used.
Example: 100 mA / 0.1 A
b) Position the operations switch to No Trip ( Rated mA = 50%), connect the 3 pin plug to
the 13A socket outlet.
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c) Switch on the 13A socket outlet ensure that the P-N and P-E lights light up.
This shows that the polarity is correct. (Note: if both the lights as above do not light up, the test cannot
be continued).
d) Press the test button the reading shows less than 200 mS and simultaneously the test light lights
up and the P-N and P-E lights do not light up. At that instant the RCD will not trip.
e) Move the selection switch to 180o (+ve wave) repeat steps (d) and (e). Move the operations
switch to Trip (Rated mA = 100%).
g) Press the test button RCD will trip and the indicated reading shall not exceed 200mS.
h) Move the selection switch to 0o (-ve wave).
i) Press the test button RCD will trip and the indicated reading shall not exceed 200 mS.
j) The above test is repeated until a near correct reading is obtained.
k) Record the test results.
l) Change the operations switch to Fast Trip and press the test button RCD will trip within a
time not exceeding 40 millisecond.
m) Repeat a number of times at 0o or 180o.
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i. Ensure that there is no leakage current between phase conductors, phase and neutral conductors and
phase conductor and earth.
ii. Test the strength of the cable insulation.
iii. Test Equipment Insulation Resistance Tester. Operating voltage is 250VDC or 500VDC.
iv. Test Method:
1. Switch off main switch;
2. Disconnect all loads;
3. Switch on all circuit control switches;
4. Carry out test as in the Table below;
5. Meter reading value shall be less than 1 Megaohm.
Polarity Test
i. Ensure that each fuse or single pole control and protection device is connected only in the phase
conductor.
ii. Intermediate contact of Edison screw lamp holder is connected to the phase conductor.
iii. Ensure that phase, neutral and earth conductors at socket outlets are connected at the correct
terminals.
iv. Test Equipment Multimeter (Ohm range) or Ohm meter.
v. Test Method:
1. Switch off Main switch;
2. Disconnect all loads
3. Switch on all circuit control switches;
4. Carry out test as in Figure 8.5;
5. Test switches and single phase control devices at the phase conductors.
6. Test socket outlet connection sources.
7. Test Edison screw lamp holder connections.
8. Meter reading value shall be less than 1 .
Earth Electrode Resistance Test
i. To test the earth electrode resistance.
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i. Ensure that the residual current device (RCD) trips within the set time on the occurrence of current
leakage to earth.
ii. Test Equipment RCD Tester/ RCCB Tester
iii. Test Method 1
1. Use the Trip Test Button
2. Press the trip button found on the RCD to determine if it trips or otherwise. This test would
not be able to determine the sensitivity of the RCD nor the time taken for it to trip.
iv. Test Method 2
Use a RCD Tester
This equipment is equipped with a 13A plug which can be connected to a 13A socket outlet. Select the
RCD sensitivity to be the same as the sensitivity of the RCD to be tested, to determine if the RCD can
trip. The time to trip shall not exceed 40 mS.
Test method
a) Position the selection switch in accordance with the sensitivity of the RCD used.
Example: 100 mA / 0.1 A
b) Position the operations switch to No Trip ( Rated mA = 50%), connect the 3 pin plug to the
13A socket outlet.
c) Switch on the 13A socket outlet ensure that the P-N and P-E lights light up. This shows that
the polarity is correct. (Note: if both the lights as above do not light up, the test cannot be
continued).
d) Press the test button the reading shows less than 200 millisecond and simultaneously the
test light lights up and the P-N and P-E lights do not light up. At that instant the RCD will
not trip.
e) Move the selection switch to 180o (+ve wave) repeat steps (d) and (e). = 100%).
f) Press the test button RCD will trip and the indicated reading shall not exceed 200 mS.
g) Move the selection switch to 0o (-ve wave).
h) Press the test button RCD will trip and the indicated reading shall not exceed 200 mS.
i)
j)
k) Change the operations switch to Fast Trip and press the test button RCD will trip within a
time not exceeding 40 mS.
l)
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Objectives
1. Identify component and the specification
2. Design Direct on line starter
3. Wire component according to the schematic diagram
4. Test the functionality of the circuit .
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TOOLS / MATERIAL
SPECIFICATION
6A . 240 V
2A . 240 V
20A , 415 V
30 cm x 40 cm x 3 cm
10 A, 240 Vac
10 A, 240 Vac
20A, 240Vac
240Vac , 5A
240Vac , 40W
415V , 20A
5 hp
2500VA
1mm 2
2.5mm 2
35 mm
50 mm x 50 mm
4
0.5 mm
5 A, & 20 A, 240 V
QUANTITY
1
1
3
1
4
3
3
2
3
3
3
1
As required
As required
As required
As required
As required
As required
As required
Procedures
1. Identify each component according to specification and quantity required from the schematic
diagram attached.
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram
a. optional exercise
i. Simple DOL starter
ii. Forward reverse DOL starter
iii. Forward Reverse Dahlander motor
iv. Three motors operated in sequence by DOL starter operated by manual push
button or time delay relay
a. One loop per-cycle
b. Continuous operation in a loop
c. optional circuit design to represent the same task
v. Only one out of three motors to be operated at a time . (quiz)
4. Test the functionality of completed project .
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Objectives
1. Identify component and the specification
2. Design Direct on line starter
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SPECIFICATION
6A . 240 V
2A . 240 V
20A , 415 V
30 cm x 40 cm x 3 cm
10 A, 240 Vac
10 A, 240 Vac
20A, 240Vac
240Vac , 5 A
240Vac , 5A
240Vac , 40W
415V , 20A
5 hp
QUANTITY
1
1
1
1
4
3
3
3
2
3
3
3
motor
13. Single core PVC insulated 1mm 2
As required
Cable
14. Single core PVC insulated 2.5mm 2
As required
15.
16.
17.
18.
19.
Cable
DIN rail
PVC type Cable tray
Cable ties
Flexible wires
PVC Connectors
35 mm
50 mm x 50 mm
4
0.5 mm
5 A, & 20 A, 240 V
As required
As required
As required
As required
As required
Procedures
1. Identify each component according to specification and quantity required from the
schematic diagram attached.
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram optional exercise
4. Simple DOL starter
5. Forward reverse DOL starter
6. Test the functionality of completed project .
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Objectives
1. Identify component and the specification
2. Design Direct on line starter
3. Wire component according to the schematic diagram
4. Test the functionality of the circuit .
TOOLS / MATERIAL
1.
2.
3.
4.
SPECIFICATION
6A . 240 V
2A . 240 V
20A , 415 V
30 cm x 40 cm x 3
QUANTITY
1
1
3
1
cm
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10 A, 240 Vac
10 A, 240 Vac
20A, 240Vac
240Vac , 5 A
240Vac , 5A
240Vac , 40W
415V , 20A
5 hp
2500VA
transformer
14. Single core PVC insulated
1mm 2
As required
Cable
15. Single core PVC insulated
2.5mm 2
As required
16.
17.
18.
19.
20.
21.
22.
23.
24.
Cable
DIN rail
PVC type Cable tray
Cable ties
Flexible wires
PVC Connectors
Single pole MCB
Single pole MCB
Triple pole MCB
Mounting board
35 mm
50 mm x 50 mm
4
0.5 mm
5 A, & 20 A, 240 V
6A . 240 V
2A . 240 V
20A , 415 V
30 cm x 40 cm x 3
As required
As required
As required
As required
As required
1
1
1
1
25.
26.
27.
28.
29.
30.
31.
32.
cm
10 A, 240 Vac
10 A, 240 Vac
20A, 240Vac
240Vac , 10 A
240Vac , 10A
240Vac , 25W
415V , 20A
5 hp
2
3
3
3
2
3
1
1
down
240:24Vac 2500VA
transformer
34. Single core PVC insulated
1mm 2
As required
Cable
35. Single core PVC insulated
2.5mm 2
As required
35 mm
50 mm x 50 mm
4
0.75 mm
5 A, & 20 A, 240 V
20A, 240Vac
As required
As required
As required
As required
As required
As required
5.
6.
7.
8.
9.
10.
11.
12.
13.
induction motor
33. Single phase
36.
37.
38.
39.
40.
41.
step
Cable
DIN rail
PVC type Cable tray
Cable ties
Flexible wires
PVC Connectors
Terminal block
4
3
3
3
2
3
3
3
1
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Procedures
5. Identify each component according to specification and quantity required from the schematic
diagram attached.
6. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
7. Wire component according to circuit diagram
8. Three motors operated in sequence by DOL starter operated by manual push button or time
delay relay
a. One loop per-cycle
b. Continuous operation in a loop
c. optional circuit design to represent the same task
d. Only one out of three motors to be operated at a time . (quiz)
9. Test the functionality of completed project .
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Objectives
1. Identify component and the specification
2. Design Direct on line starter
3. Wire component according to the schematic diagram
4. Test the functionality of the circuit .
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TOOLS / MATERIAL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
SPECIFICATION
6A . 240 V
2A . 240 V
20A , 415 V
30 cm x 40 cm x 3 cm
10 A, 240 Vac
10 A, 240 Vac
20A, 240Vac
240Vac , 5 A
240Vac , 5A
240Vac , 40W
415V , 20A
5 hp
2500VA
1mm 2
2.5mm 2
35 mm
50 mm x 50 mm
4
1 mm
10A, 240 V
QUANTITY
1
1
3
1
4
3
3
3
2
3
3
3
1
As required
As required
As required
As required
As required
As required
As required
Procedures
1. Identify each component according to specification and quantity required from the schematic
diagram attached.
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram
a. optional exercise
i. Forward Reverse dahlander motor
4. Test the functionality of completed project .
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The automatic version of this starter incorporates a timing relay which automatically changes the
connections from star to delta. Figs. 8.34 and 8.35 show the wiring and schematic diagrams for a star
delta starter.
Objectives
1. Identify component and the specification
2. Design forward reverse star delta starter
3. Wire component according to the schematic diagram
4. Test the functionality of the circuit .
R
Y
B
N
S
-S
W
MAIN CIRCUIT
FORWARD
REVERSE STAR
DELTA.
LEGEND:
MCCB : Moulded
Case Circuit Breaker
TOR :
Thermal
Over Load Relay
FOW-C : Mains
Forward Contactor
REV-C : Mains
Reverse Contactor
DC
: Delta
Contactor
SC
: Star
30A
MC
CB
F
O
WC
T
O
R U
1
RE
V
-C
T
O
RV
1
3
PHA
SE
T
O
RW
1
IND
V
U
UCTI
2
ON
2
2
MOT
EASYTECH ENTERPRISE
S
OR
D
C
2 96
S-SW : Mains
Selector Switch
EZTECH
ELECTRICAL INSTALLATION GUIDE
TOOLS / MATERIAL
SPECIFICATION
QUANTITY
1
1
1
3
4
1.
2.
3.
4.
5.
Mounting board
Triple pole MCB
Single pole MCB
Relay
Triple pole Contactor
600 x 600 x 25 mm
20 A, 415 V
6 A, 240 V
10 A, 240V
240Vac , 20 A
6.
7.
8.
9.
10.
11.
12.
415 V
240vac , 5 A
240Vac , 5A
35 mm
1 mm
2.5 mm
1
4
2
As required
As required
As required
13.
14.
15.
16.
wire
Terminal block
Squirrel cage motor
5 pin plug and socket
5 core flexible wire
20 A
5kW
415V , 20A
20A , 500V
As required
1
1
2 metre
Procedures
1. Identify each component and quantity of required from the schematic diagram attached .
2. Test the functionality of each component by using multimeter or power supply whichever
applicable .
3. Wire component according to circuit diagram
a. Manual star delta
b. Manual Forward reverse star delta starter
c. Automatic star delta starter
d. Automatic Forward reverse star delta starter
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Objectives
1. Identify component and the specification
2. Design auto transformer starter
3. Wire component according to the schematic diagram
4. Test the functionality of the circuit .
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Autotransformer starter is used to start a 3 phase induction motor that has a rating between 10 to 15 hp
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TOOLS / MATERIAL
SPECIFICATION
QUANTITY
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Mounting board
Triple pole MCB
Single pole MCB
Autotransformer set
Triple pole Contactor
Batten type Lamp holder
Start stop button
Filament lamp (Bulb )
DIN rail
Flexible wires
Single core PVC insulated
600 x 600 x 25 mm
20 A, 415 V
6 A, 240 V
10Kw, 415 V, 50 Hz
240Vac
240 Vac , 105 A
240Vac ,10A
240Vac , 40W
35 mm
1 mm
2.5 mm
1
1
1
1
4
4
4
4
As required
As required
As required
12.
13.
14.
15.
wire
Terminal block
Squirrel cage motor
5 pin plug and socket
5 core flexible wire
20 A
10kW
415V , 20A
20A , 500V
As required
1
1
2 metre
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Procedures
1. Identify each component and quantity of required from the schematic diagram attached .
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram
a. open transient autotransformer starter
b. close transient autotransformer starter
c. Forward reverse autotransformer starter
4. Test the functionality of completed project .
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STARTER
Objectives
1. Identify component and the specification
2. Design rotor resistance starter
3. Wire component according to the schematic diagram
4. Test the functionality of the circuit .
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TOOLS / MATERIAL
SPECIFICATION
QUANTITY
1. Mounting board
2. Triple pole MCB
3. Single pole MCB
4. Rotor Resistor set
5. Triple pole Contactor
6. Indicating light
7. Start stop push button
8. DIN rail
9. Flexible wires
10. Single core PVC insulated wire
11. Terminal block
12. Slip Ring motor
13.5 pin round 3 phase socket
14. 5 core flexible wire
600 x 600 x 25 mm
20 A, 415 V
6 A, 240 V
10kW
240Vac , 20A
240vac , 5 A
240Vac , 5A
35 mm
1 mm 2
2.5 mm 2
20 A
10kW
415V , 20A
20A , 500V
1
1
1
1
4
4
4
As required
As required
As required
As required
1
1
2 metre
Procedures
1. Identify each component and quantity of required from the schematic diagram attached .
2. Test the functionality of each component by using multi-meter or power supply whichever
applicable .
3. Wire component according to circuit diagram .
4. Test the functionality of completed project .
a. Dead circuit test
b. . Life circuit test
5. Measure starting and running Amps.
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LESSON 16
TROUBLESHOOTING AND FAULT FINDING OF 3 INDUCTION MOTOR
An installation in general will suffer damage.
Damage usually occurs on the electric motor control as follows:
1. Damage to the main circuit
2. Damage to the control circuit
The cause of the damage.
i. Overcurrent, overload, short circuit.
ii. Leakage current to ground.
iii. Equipment malfunction.
iv. The main control circuit
a. Trip of main circuit protection devices, fire.
b. Defect of motor terminal such as short circuit, fire, loose
v. The control circuit is not functioning a. contactor / relay / relay time / overload relay does not work / damaged, burned
b. Loose cable connection / disconnected
Detecting and Repairing Damage
Examples of damage are as follows:
i. Motor does not work
ii. Motor function and overload relay trips
iii. Motor function but only partially functional control circuit
Methods of detecting damage
Among the known methods necessary to detect damage are as follows:
1. Turn off the electricity at the main switch (main switch) in order to avoid any danger during the
work carried out to detect damage.
2. Check all the protective gear that controls the motor control main circuit
3. Make sure the damage / function control circuit
4. Check the control circuit according to the schematic circuit diagram of the motor control
5. Check the operation of the control circuit
Note:
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Use wiring that has been installed on the SYSTEM OF MOTOR CONTROL BOARD by Forward
Reverse control circuit for Star Delta to test and look for damage.
SELF-ASSESSMENT QUESTIONS
1 (a) Explain what is meant by the term back e.m.f. in a motor.
(b) Outline the basic differences between series, shunt and compound wound d.c. motors.
2 (a) With the aid of diagrams explain how the speed of series, shunt and compound-wound motors
may be controlled.
(b) A 440V d.c. shunt-wound motor has a field resistance of 200R and an armature resistance of 0.6 R.
When its speed is 20 rev d second the current drawn from the supply is 12.2A. Calculate its back
e.m.f. at this speed. If the speed were decreased to 19 revs/second, the field flux remaining unchanged,
calculate the new back e.m.f. and the new armature current.
3 . A load of 6.4 kW at 240 V is supplied from the terminals of a shunt-wound d.c. generator. The field
resistance is 180 A. Calculate the armature current.
4 (a) Explain with the aid of a diagram how a rotating magnetic field may be
(b) What is meant by synchronous speed?
Calculate the synchronous obtained. speed of a 12 pole motor if the supply frequency is 50Hz.
5 (a) Explain the action of a synchronous motor.
(b) What methods are available to start a synchronous motor? Explain with diagrams.
6 (a) Explain the action of a cage induction motor.
(b) What is meant by the term slip?
Calculate the percentage slip of a six pole induction motor running at 16.2 revs/second from a 50 Hz
supply.
7 Describe with sketches three different ways of starting a single-phase induction motor.
8 Explain with the aid of a sketch the action of a three-phase DOL starter.
What are dashpots used for? How are remote start and stop buttons connected?
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9 A I0 kW, 240V, 50Hz single-phase cage rotor induction motor is 85%efficient and has a PF of 0.68
lagging. Calculate the motor current and the value of capacitor required to raise the PF to 0.93
lagging.
10 Calculate the torque developed by an 18 kW four-pole induction motor run at 3.5% slip from a
50Hz supply.
APPENDIX 1
APPENDIX 11
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APPENDIX 111
Attachment :
Reference
https://www.tlc-direct.co.uk/Book/6.2.1.htm
http://www.st.gov.my/index.php/ms/
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