Aner Electrical Automation (VELAO.1) For Product Details Annexure G ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 83Electrical Automation (VELAO.1) 49 ¢ Circuit Breakers (MCCB, 63 A to 600A) Terminals fl (ty wy Identification aE Fixed Name Plate Contacts Arcing Chamber Moving Contacts Operating Lever Microprocessor j based Controls | Fig.14a-symbol of 3P MCCB inti loon 1 Sos A Description of MCCB AMCCB is a mechanical switching device capable of Making & breaking contacts manually Blocking rated voltage (while contact is off) Carrying rated current (while contact is on) Breaking Current incase overload automatically with Inverse Time characteristics Breaking Current instantly incase short circuit conditions. ‘MCCB is a fuse free device that breaks the circuit under fault (trips...) and can be reset after removal of fault, Now days, MCCB’s have Microprocessor based control support along with Bimetallic and Magnetic controls. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 84| vg Electrical Automation (VELAO.1) TAACT MCCB comprises of * Manual switching mechanism + Contact system * Release (trip) unit for overload & short circuit * Microprocessor based control system + Are quenching system * Insulated housing for all the above mechanisms A bimetallic strip and magnetic coil is used to carry the current in series with the load. Additional Features: Bimetallic strip heats and bends due to overload. This bending of bimetallic strip further activates tripping mechanism mechanically and trips the circuit automatically. Time taken for this tripping is well understood by the Inverse Time characteristics graphs. At short circuit a plunger in the solenoid is moved with the sufficient force to physically separate the contacts. The greater the S.C current, the greater the force with which the plunger is moved and faster the circuit is disconnected. ‘The arc chute plates are designed in such a way that the gap between two plates increases as the arc moves away from the contact tips. This results in the expansion of gases as they move away from the tip & out of MCB. This expansion of gases further cools the arc. Microprocessor-based electronic technology allows protection functions that guarantee a high level of reliability, tip precision and insensitivity to the electromagnetic components. With this kind of release, over load as well as short circuit fault levels can be set as per the requirement Grune tng col Ertermnar tot Status contact (ON / OFF status...) Auxiliary Contact Fault indication Contacts ‘Shunt trip Over voltage trip Under voltage trip Earth fault trip Applications of MCCB: Incoming Supply and sub supply Motor Protection Generator protection DOL and Star-Delta Starters Transformer protection Welding applications ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 85a Electrical Automation (VELAQ.1) TAACT Selection Criteria: + Tripping Characteristics (Type of Duty) * Rated Current In + Rated short circuit breaking capacity * Rated short circuit making capacity "Operating /Rated Voltage = Max. operating voltage * No of Poles:3P, 4P * Mounting: Snap-on-to DIN-rail 35 mm * Tripping mechanism : Electromagnetic or Microprocessor based ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 864.10 TAACT Contactors: Electrical Automation (VELAQ.1) Working Principle: Automatic switches of power circuits are used to switch ON/OFF power to (different types of industrial load and machines. Contactors operate on electromagnetic principles A simple electromagnet can be fashioned by winding a wire around a soft iron core. When a DC/AC voltage is applied to the wire, the iron becomes magnetic. When the DC/AC voltage is removed from the wire, the iron returns to its nonmagnetic state. Activation of coil builds up the clectromagnetic field. Thus operating the power contacts and auxiliary contact simultaneously. Auxiliary Output contacts of relays are available as stand-alone NO / NC contacts. Contactors normally have three / four main power contacts in NO configuration and one control contact either in NO or NC configuration. One can normally add on 4/8 nos. of auxiliary control contacts of his choice of configuration I tty 3-6 Load — Auniliary Contact e—o< i Fig.13a-Contactor Coil Fig 13b -Schematic Diagram of 4Pole Contactor Stationary Movable Contacts p-—) i Cobtacts ts | re - wer Circuit, x Armature 4k Spring Ts ss Coil Electromagnet 4 Pole Contactor Fig I3e Power Contactor ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 87ie Electrical Automation (VELAO.1) all Selection TAACT * Rated coil Voltage: AC (24 / 110/240 / 415V.),DC (24 148 1 110/220V) + Rated Voltaze: AC (415V AC).DC (440V DC) * Rated current: Available for different current ratings.(Up to 1000). * KVAR of load in case of capacitive type: 7.5 to 51 KVAR * Auxiliary Contacts: No.of power contacts combination e.g. INO / INC / NO "Type of Duty * Type of lou: Resistance, Inductive, Capacitive ete ‘Troubleshooting technique: Same as in case of relay. ‘Thermal Overload Relays: Fig.10a-symbol of Overload Relay Fig 14-Bimetalic Overload Relay wre désigned to meet the special protective needs of motor control circuits "Allow harmless temporary overloads (such as motor starting) without disrupting the circuit = will tip and open a circuit if current is high enough to cause motor damage over a period of time * can be reset once the overload is removed, Overload causes deflection of bimetallic strip, which results in changeover of the NC contact of the OLR. causing load tripping. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 885 Electrical Automation (VELAO.1) TAACT ‘The OLR can be set for variable Joad current value by rotating the knob in the available range. Various ranges available are 1 10 1.4A, 1.7 to 2.4A, 2.8 to 4.0A ete. ‘Some overload relays equipped with a bimetal strip are designed to reset the circuit automatically ‘when the bimetal strip has cooled and reshaped itself, restarting the motor. If the cause of the overload still exists, the relay will trip again and reset at given intervals, Care must be exercised in the selection of this type of overload relay, since repeated cycling will eventually damage the motor. thas a TEST button for testing of the OLR before commissioning, It has auxiliary break & make contacts, which are to be used in the control circuit to indicate overloading. OLRs are not meant for short circuit protection. So in the circuit, itis recommended to have back-up fuse / MCB protection wherever necessary. Selection criteria: * Relay range: Overload relays are available in the following Current Range. 1, Direct mounting type:0.16A(0.10 to 0.16) to 80A (60 to 80) 2, Separate mounting (CT operated):90 (65 -91) to 400 (280 - 400) A * Mounting: Direct mounting on contactor/Separate mounting * Reset function: Auto, Manual or Auto/ Manual * No.of potential free contacts:example:1NO+INO Teknocrat’s Academy of Automation & Control Technology, Nashik 89: Electrical Automation (VELAO.1) TAACT 4.12 Motor Protection Circuit Breaker (Manual Starter): Fig 15- Motor Protection Circuit Breaker MPCB is a combination of DOL starter and MCB. It is used to start a motor in DOL fashion and protect it in case of overload and short circuit. Recent generation of MPCB's have other additional features like MCCB. MPCBis a combination of ... * Start/ Stop mechanism * Contactor * Overload Relay * Magnetic Coil for short circuit tripping * Auxiliary Contacts [New generation MPCB have additional protections against... * Single Phasing (Loss of Phase) Under voltage Over Voltage Shunt tripping Phase failure InMPCB, we get features of MCB & Overload relay in same unit, Hence it is = Space saving = Cost saving * Less number of joints in the control system » Less wiring ‘Telmocrat’s Academy of Autom: & Control Technology, Nashik 90Etecsical Automation (VELAO.1 TAACT € 4 vee?" > / ot A 353 — MPCB characteristics curve: vo P | I 5 ‘Thermal | ge Tripping ~~ | 3 a. | ran Three pole | i | ‘| | a | 2) ) Tortie | Lo : me ‘Multiple of the rated current. ————> Fig. 16-Tripping characteristic of MPCB Selection Criteria: Limi pies, ‘Tripping Characteristics (Type of Duty) Rated operational Coen do) only fr Dol. Stoning Rated short circuit breaking capacity J . Rated short circuit making capacity Upte lool Ynys eAly Operating / Rated Voltage Max. operating voltage Tend ep. Overload relay Range Mounting position Disconnection characteristic ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 91Electrical Automation (VELAO.1) TAACT For Product Details Annexure H ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 92cs Electrical Automation (VELAO.1) TAACT, Trswake fetuure 4.13 Earth Leakage Circuit Breaker: ELCB is used to protect device and personnel from earth fault / leakage risks, Damaged insulation & faulty wiring can cause a Leakage current to flow from live path to the carth, Besides the threat of electrocution, leakage currents are also known to start electrical fires, and cause wastage of energy. ELCB is the safest device used to reduce the risk of electrocution, by tripping off on dangerous leakage currents. [An ELCB works on the principle of residual current, As per this principle the current rough a Phase_line and the geutral Hine in case of single phase circuit should be equal and flowing in Qpposites_direction. Theit vector sum would be zero, Similarly the vector sum of all there phase Currents in a 3phase cireuit would be zero. If a magnetic core in placed around the 3-wires of a S-phase current o: 2 wires of single phase circuit, ideally no current will be induced in the core. However leakage current will cause an unbalance and a small current will star flowing in the core which is detected and used for tripping in an ELCB. Effects of electrical shocks to human Bad ‘SR_| Current (mA) | Result - J T 550 Immediate cardiac arrest results to death of a person, _| 2 70 - 100 Cardiac fibrillation ~ Heart begins to vibrate and does not beat at a steady rate. This is a dangerous & might be irreversible situation, 320-30 Muscle contraction can cause respiratory paralysis 410 ‘Muscle contraction and person may remain stuck to the Conductor 3 [1-10 Prickling sensation ‘The human body has known sustaining voltage limits: Normal dry conditions, voltage limit = SOV Damp surroundings, voltage limit = 25V General Specifications of ELCB Rated Voltage, Rated Load Current and tripping earth leakage current are important specifications of ELCB. They are available for low as well high load currents. Earth leakage Currents have setting of 10 mA, 30 mA and 300 mA, For human safety we should use 10 mA ELCB. For Machine protection, we can use ELCB of 300 mA setting. If the body of the machine is properly earthed then we do not have danger of getting shock while working on the machine. Teknocrat’s Academy of Automation & Control Technology, Nashik 93JomA -Qomf = Fos Namar sebehy ae a Electrical Automation (VELAO.1) Brief Schematic of ELCB: -——*o- ——4- ‘Single | \ me ' Phase ; te «| 5. ‘Trip € Unit & Fig I7a- Schematic of I-ph ELCB TY Se pa 3 ¥ Phase Load N ' L 1 1 ‘Trip Unit Fig 17 b- Schematic of 3-ph ELCB Senses the OUnbrienced Currents induced 10 the Mogneric core ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 94i Electrical Automation (VELAO.1) TAACT! Selection Criteria: + Tripping Characteristics (Type of Duty) * Type of voltage AC/A/AP + No ofPoles = Rated Current (In) * Rated tripping current (mA):30,100,300,500mA * Tripping range [ms] * Rated short circuit breaking capacity * Rated short circuit making capacity * Operating / Rated Voltage * Max, operating voltage + Rated frequency:50/60 Hz + Electrical life:10,000 operations * Mounting position: Any direction, plane surface * Mounting: Snap-on-to DIN-rail 35 mm * Switching mechanism: Trip-free construction ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 95is Electrical Automation (VELAO.1) TAACT) 4.14 Air-Circuit breakers: ‘These breakers are available in frame sizes ranging from 630 to 5000 A in 3- and 4-pole versions and are generally insulated for 1000V. Rated breaking capacities of up to 100 kA rms symmetric to IEC947-2 are claimed at a rated voltage of 660 V. Fixed and draw-out models are available and each unit invariably comes complete with a protection device, which is keeping with modern trends, is generally of the electronic type. ‘Typical total breaking times are of the order of 40-50 ms for short-circuit faults. Their operating speed is important, as ACB’s are applied as the main incoming devices, to the low-voltage network, where they are subject to the highest fault levels determined by the supply transformer. A typical construction of an ACB is shown in figure. Fig.18- ABB make ACB ™ACCE Current touring $80 % Gd0o Arps - ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 9652 i Electrical Automation (VELAO.1) TAACT Ch. 5.0 AC Motor and Starters Introduction: AC motors provide the motive power to lift, shift, pump, drive, blow, drill, and perform a myriad of other tasks in industrial, domestic and commercial applications, Induction motor, the most versatile of the AC motor, has truly emerged as the prime mover in industry for machine tools, Pumps, fans, compressor, and a variety of industrial equipments, Basics of three Phase AC Motor Three phase AC motors are known as the workhorse of industry because of their wide use. They are popular because they are low in cost, compact in size, require less low cost maintenance, withstand harsh industrial environment, etc. Three phase AC motors are a class of motors that convert the three phase electric power supplied atthe input terminals, to mechanical power at the rotating shaft, through the action of a rotating magnetic field, produced by a distributed winding on the stator, Three phase AC motor are broadly classified as: 1, Induction Motors 2. Synchronous Motor 3. Wound rotor induction Motor Induction Motor: As the name implies, no voltage is applied to the rotor. Voltage is applied to the stator winding and when the current flows in the stator winding, a current is induced in the rotor by transformer action. The resulting rotor magnetic field will interact with the stator magnetic field, causing torque to exert on the rotor. ‘Synchronous moto As the name suggests, rotor speed remains synchronous with that of the stator magnetic field. ‘The motor runs at the same speed, as the rotating magnetic field, Unlike induction motors, synchronous motors are not self starting. They have to be brought up to synchronous speed. Once they are locked then the rotor will continuously rotate. Wound rotor Induction Motor: This motor has a wire wound rotor from which three leads are brought out to the slip rings. Itis Possible to vary the rotor resistance by adding different resistances in the rotor circuit through {he slip rings. The additional rotor resistances during starting boost the starting torque of the Motor. As the motor picks up speed the external resistances are gradually cut out through shorting contactors. Teknocrat’s Academy of Automation & Control Technology, Nashik 7ihe TAACT Electrical Automation (VELAO.1) Motoring Principle: Fleming’s Left Hand Rule: The direction of rotation in electric motor is given by Fleming’s left hand rule which says that if you stretch out the forefinger, middle finger and thumb of your left hand, so that they are at right angle to each other and the forefinger points in the direction of magnetic field (north to south) and the middle finger points towards the direction of current, then the thumb will point in the direction of motion of the conductor. Wire moves upwards Force F Toahigh current [ESB power supply or battery SS Magnetic | field B J g Current Left hand Fig.1-Fleming's Left Hand Rule 5.3 Construction details of 3-phase Induction Motor: Fig.2- Phase Induction Motor ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 98a Electrical Automation (VELAO.1) TAACT. Stator: The stator carries the 3-O winding. It is wound for a definite number of poles. When fed with 3. @ supply, it produces a magnetic flux of constant magnitude, revolving at a speed known as Synchronous Speed. Fig.3- Stator Squirrel Cage Rotor ‘This rotor consists of a cylindrical laminated core with parallel slots for locating rotor conductors. These rotor conductors are heavy bars of Copper or Aluminum. The rotor bars are. short-circuited at both ends with the help of heavy & stout end rings, —_. ong OO | | laid oe melo’ \0\ |S eee Ja g r Fig. Suirrel cage Rotor Frame Bye bolt Stator in Frame Bearing ‘Teknocrat Fig.5- Construction of 3-Phase AC Motor 9954 ite | Electrical Automation (VELAO.1) TAACT| Principle of rotating magnetic field: ‘The stator of the 3-phase Indication motor comprises of 3 individual phase windings which are physically displaced from each other by 120 electrical degrees. When a 3-phase voltage is applied to the stator, each of the phase winding produces a sinusoidal varying magnetic field of its own in the air gap. The resultant magnetic field of the three individual magnetic fields displaced from each other by 120 electrical degrees, assumes the form of a rotating magnetic field. The speed of rotation of this rotating magnetic field can be shown to be, Ns =120f/p Where, Ns = Synchronous Speed, f = frequency. p_ =noof poles in the motor. Slip: The rotating magnetic field induces emf in the rotor by the transformer action, Since the rotor is a closed set of conductors, current flows in the rotor. The rotor currents produce theit own flux, which opposes the stator flux. The interaction between the rotor flux and the stator flux produces a force on the rotor conductors and develops the torque to rotate the rotor, ‘The rotor flux now starts rotating at the speed of the rotor (Nr). As long as the rotor speed (Nr) remains less than the speed of the rotating stator (Ns) flux a positive torque continues to develop. As soon as Nr = Ns the torque becomes zero and rotor speed drops. once again generating a positive torque, The Induction motor is therefore an asynchronous motor which always runs with asmall slip. The slip of an indication motor is indicated in percentage. %e Slip = [(Ns — Nr) / Ns] * 100 Exercise1: ‘A 3-Phase, 4-pole induction motor is supplied with 50 Hz supply. Calculate the synchronou speed of the motor. If slip is 4%, calculate the rotor speed. Soluti = (120 * f) / P = (120 * 50) / 4 = 1500 RPM. It is the synchronous speed. If slip is 4% then, 0.04 = (1500 ~N,) / 1500 60 = 1500-N; Hence, N,= 1500 ~ 60 = 1440 RPM is the rotor speed. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 10056 it Electrical Automation (VELAO.1) TAACT Wo uee Rototinas Race Motor torque and power: Torque is the turning or twisting moment ofa force about an axis, Pivot Point Torque Radius (Lever Distanes)s=5) Torque = Force X Radius ff Force Fig.6-Toraue T=Fxr Newton-meter (Nm) ‘Work done by this force in one revolution (W) = Force (F) * Distance (d) Incase of rotational movement d = 2nr for one rotation. Ww Force x distance F x 2nr (joules) ‘Since power, (P) = Work-done per unit time P =F * 2nr* n (Joules / second = Watts), Where nis r.p.s, P =@*1)*2n*n (wat), P =T*2n*n (watt). (Where mis rp.s.) P =T*2n*(N/60) (watt). (Where Nisrp.m.) T = (60*P)/(2nN) ‘Therefore, T =955*P/N (Nm) Starting torque of the squirrel cage motor is poor i.e. 1.5 times its full load torque. Though the Starting rotor current I is high, it lags behind induced rotor emf by a very large angle. Torqueis sensitive to any changes in the supply voltage. Tav? ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 10157 A load @Hy Wyner tere 1) fo Stet requre brger te waned Electrical Automation (VELAO.1) Mechanical Power (Motor output power): In general, Power delivered by a motor at its output, is specified in either Horse Power (HP) or Kw or Torque and is given by P=TxN/955 kW 1 HP = 735 Watts (in MKS system) 1 HP = 550 ft. Ib / sec = 746 watts (FPS System) IKW=134HP. 1 HP=75 Kg, meter / sec = 735 watts (MKS System) 1KW= 136 HP. Electrical Power (Motor input Power): The input to the Motor in Electrical terms is given by following formulae Single phase: P = ViI,Cos@ watts Three Phase: P = V3*Vi1,Cos@ watts Induction motor losses and efficiency: While delivering the final mechanical output power an Induction motor incurs the Following losses within it, # Core losses in the stator and rotor Pray esses * Copper losses in the stator and rotor * Friction and windage losses. Core losses occur in the magnetic circuit (in this case the laminated iron core of the stator and the rotor) ippified es hysterisis and ecldy current losses. supply voltage and are assumed constant, the core losses can also be approximated as constant. ‘The copper losses are basically R losses in the stator and rotor conductors and vary in proportion to load The friction and windage losses occur in the bearings and cooling fan and may be assunied constant inrespective of the load. Efficiency of Motor: It is expressed in % (percentage) % Efficiency = (Rotor Output Power / Stator Input power) * 100 % Efficiency = (Rotor Output Power / Output power + Losses) * 100 Motor Output power = Stator Input Power ~ Losses VR losses ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 102te Electrical Automation (VELAO.1) TAACT Examplet: A pump is driven by a 3-phase 400V AC Motor. It is pumping 1600 liters of water up to a height of 70 meters in 25 minutes. Ifthe efficiency of the pump is 70%, find out the HP of the motor. Solution: Pumy ——+ Motor 10% | Mass of water = 1600 Liters * 1 kg /liter = 1600 kgs. ‘Work output of Pump = 1690- kgs. * 70 meters = 112000 kgf.m Power output of Pump = 112000 / (25 * 60) = 74.67 kgf.m / sec 1 HP =75 kgf.m /sec, hence ve Power Output of Pump in HP = 74.67 / 75 = 0.9956 HP Pump Power Input = 0.9956 / 0.7 = 1.42 HP Ans: Motor Rating = 1.5 HP Exampl Consider a 3-phase 440 V, SO Hz, six-pole induction motor. The motor takes 50 kW at 960 spin for a certain load. Assume stator losses of 1 kW and friction and windage loss of 1.5 KW. To determine the percentage slip, rotor copper loss, rotor output, and efficiency of the motor, perform the following function Solution: Percentage slip: The synchronous speed of the motor = (50 x 120) /6=1000 rpm. Slip = (Synchronous speed ~ Actual speed) = 1000 - 960 = 40 rpm Percentage slip = [(40 / 1000) x 100]=4% = Rotor copper loss Rotor input Rotor copper loss 49 x 0.04 = 1.96 kW ‘otor input ~ Rotor copper loss- Friction and Windage loss 9-1.96-1.5 Motor efficiency: Motor efficiency ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 103+ Electrical Automation (VELAO.1) TAACT 5.8 Motor operations: [A] Starting characteristics of squirrel cage Induction Motor Where, 7 1: Locked rotor torque 2: Pull up torque 3: Break down torque 4: Fall load 0 2 40 6 80 F109) Ee Speed, % Fig.7-Starting Characteristic The torque available between motor curve and load curve, is the acceleration torque to accelerate the motor to desired operating point. Running characteristics of Induction Motor on load: 100 % 95 % Speed Full load Torque Fig.8-Speed Torque Characteristics ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 104cd Electrical Automation (VELAO.1) TAACT Starting Current behavior of squirrel cage Induction Motor: When a voltage is applied to a stationary motor, a very large initial current is taken by short sircuited rotor conductors as there is no opposition at the start for a short time . Ibis normaly 5 to 7 times of full load current. This initial inrush current is not desirable as it produces a large line voltage drop, which in turn would affect the other electrical equipments connected to the same Tine. Higher HP rating motors should not be switched on directly. In case of Slip Ring motors , resistance is added to the rotor circuit that limits the inrush current, In case of squirrel eage ‘motor, this inital current can be controlled by applying a reduced voltage to the stator at the Start and raising it to full value as the motor gains sufficient speed. Different starting methodes are used for this purpose. Motor Full-Load Amy 109 | Time Fig.9-Starting current Characteristic Direction change: An interchange of any two phases reverse the direction of a three phase Induction Motor, Motor braking methods: Certain applications require a motor to be braked i.e. stopped faster than it would, by its own inertia. To stop the motor quickly, a braking mechanism is required. In electrical hoist or crane applications, itis required to control the braking torque of the drive motor so that the load docs not have undesired acceleration, Some applications require accurate positioning of the motor shaft while stopping. The speed and accuracy of stopping and reversing operations of motors improve the productivity of the system, Braking can be broadlly classified as: * Mechanical braking * Electrical braking ‘Teknoerat’s Academy of Automation & Control Technology, Nashik 105ie Electrical Automation (VELAQ.1) TAACT Mechanical Braking (Friction Brake) It is used in hoists, lifts, cranes, etc. The shoes / pads of the brake are kept apart by magnetic action of energised coils. When these coils are de-enrgized, the pads are released by spring action & spring action brakes are applied to drums mounted on rotor shaftthis type of braking helps in keeping the rotor shaft in rigid posistion after the motor stops Electrical Braking: Phase weversal [A] Countercurrent braking (Plugging): With countercurrent braking, an ordinary standard motor is switched at full speed for the opposite direction of rotation. This can be done with a reversing switch. Afier braking 10 a standstill, the motor starts in the opposite direction of rotation, unless the current is switched off at the right moment. A low speed detector is therefore used to cut off the supply to the motor when the speed approaches zero, Countercurrent braking gives a very high braking torque. The current during braking is about the same as during starting, so that there is a considerable temperature rise in the motor. Consequently the permitted frequency of braking with the countercurrent technique is only about one-quarter of the number of permitted braking which can easily be exceeded. Temperature sensors should always be used to protect the motor windings from overheating. [B] DC Injection brakin; ‘When braking with this technique, the AC supply to the motor is disconnected and the stator is excited with direct current. This causes the motor to produce a braking torque. Ordinary standard ‘motor and suitable equipment for DC excitation may be used. The AC voltage follows a decay ‘curve, and the DC voltage must not be connected until the AC voltage has fallen to a value at which it will not harm the DC equipment. The excitation current is determined by the braking time chosen, but is usually 1 to 2 times the rated current of the motor. However, saturation of the ‘magnetic circuit imposes a limit on the braking torque. Direct current braking gives a far longer braking time than the one achieved in Countercurrent braking. However higher the excitation current, braking time is less and thermal losses are lower. Hence more frequent braking is permissible. [C] Regenerative braking: This is a method of braking multi-speed motors while reducing speeds. With the motor at the lower synchronous speed than the load driven rotor speed, functions as a generator and develops a very high braking torque. During the braking the motor regenerates power which is feedback ( the supply network. The maximum braking torque is slightly higher than the starting torque of the motor at the lower speed. Regenerative braking is also used with variable speed drives. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 10639 TAACT Electrical Automation (VELAQ.1) Motor terminal identification and connection diagram: Usually, the motor terminal connection diagram is given on the motor. For a three-phase motor, three winding end connections are shown U1 and U2, V1 and V2, and W1 and W2 Motor terminals and connection diagrams for Autotransformer or DOL starting with three leads connections are shown in Fig below, Terminal connection diagram: Permanent Stern ev dette Connecter Mohr jdelta 1 Star or | ' L id [al Lines [b) R Ling Fig.10a- Typical circuit diagram (a) DOL starter; (b) Delta starter 1 \ abamcatacanaaioneertade ' 1 t \6Delta ' 6 Delta | VI) WI ' = 1 1 | 1 1 uw] yo t U2 V2! w2! v 1 ' pom poresen er es ec v---4_J_ 1 fa} Lines (b] To Fig.10b- Typical circuit diagram (a) DOL starter; (b) Delta starter ‘Teknocrat’s Academy of Automation & Control Technology, Nashik Ste Cuy, 45 Reg = 240¥yt ¥ A/K wag. resins — taneven, ‘d 4 Blectrical Automation (VELAO,1) TAACT 5.10 SL Motor nameplate: The motor nameplate gives important information about the motor. It gives among others, information about the following: > we D wind log aiostomee D chee be qutotratenten — ade * Motor rating Fat Bh * Motor supply details Ste Motor connection detail DwWsy Rewinae Hou 2 seren Motor frame type and size Motor rpm Permissible temperature rise Motor duty 3, $2 Coren epolyes fin Moled Enclosure type reec_spop ek wel Pertomted dm? pynay Number of Poles“ en - TES = Takeda enairet sontere Cute! The nameplate gives details about the motor at a glance Motor insulation: ‘The insulation utilized should withstand the voltage fluctuations of the motor under varying operating conditions. Depending on the load and its surrounding conditions, there could be a rise in the temperature of the motor. The insulation should withstand such temperature rises also. ‘The hotspot temperature in any part of the motor should not exceed the permissible limit of the insulation used. In case of insulating materials, their thermal characteristics are more sensitive than their dielectric characteristics, i.e., the failure of an insulating material is more due to thermal limitations than due to voltage limitations. Jn most cases, the temperature rise or the rise in load does not produce a fault in the winding of the conductor itself. The rise of load current or greater fault current, when it is excessive, causes a thermal breakdown in the insulation covering the conductor. This is what creates a fault in the winding, ‘Thus, the maximum permissible temperature rise, in electrical motors, must be in tune with the type of insulation used and the type of motor. ‘The main characteristics, of insulating materials used in electrical machines are: + Dielectric strength = Thermal strength ‘The insulating material used for the electrical machines should satisfy the following requirements: * High dielectric strength, high specific resistance, and minimum loss in alternating electric fields. * High mechanical strength and elasticity of material. "Thermal strength of insulation; the insulating material should preserve its insulation and ‘mechanical properties when subjected to the operating temperatures of the windings for a long time. * ‘The material should remain unaffected by chemical influences. ‘The temperature rise permissible can be determined, by deducting the ambient temperature, from the maximum permissible temperature, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 108 Nawubi Electrical Automation (VELAQ.1) TAACT For electrical machines, the following are the types of Insulating material that have been classified and standardized as follows Class A insulation: Cotton, silk, paper, and similar organic materials, impregnated or immersed ifOil, and enamel applied on enameled wires. The limiting hot spot temperature for class A insulation is 105°C. Class E insulation: An intermediate class of insulating materials between Class A and Class B iisulation materials. yc. Class B Insulation: Mica, asbestos, glass fiber, and similar inorganic materials, in built-up form Tapncrzanle binding substances. The limiting hot spot temperature for Class B insulation is 130°C. Class F Insulation: Includes insulation having mica, asbestos, or glass fiber base with a silicone or a similar high temperature resistant binding material. The limiting hot spot temperature for class F insulation is 155° c. Class HT insulation: Includes insulation having mica, asbestos, or glass fiber base with a silicone or a similar high temperature resistant binding material. The limiting hot spot temperature for Class H insulation is 180°C, Duty Types: ‘The duty types are indicated by the symbols S1....$9 according to IS 12824-1989. The outputs siven in the tables are based on continuous running duty. $1 with rated output. $1-Continuous running duty: Pai Operation at constant load of sufficient duration for thermal equilibrium to be reached. In the absence of N any indication of the rated duty type, continuous running duty will be assumed. Pomp Fig 11-S1 Duty ‘S2-Short-time duty: Operation at constant load during a given time, less p. than required to reach thermal equilibrium, followed by a rest and de-energized period of ‘sufficient duration to re-establish motor temperatures equal to the ambient or the coolant temperature. The values 10,30,60 and 90 minutes are recommended for the rated duration of the duty cycle. are open door, Fig.12-82 Duty SHntermittent duty: A sequence of identical cycles, each including a period p of operation at constant load and a rest and de-energised petiod. The period is too short for thermal equilibrium to be obtained. The starting current does not significantly affect the temperature rise. Recommended values for the cyclic duration factor are 15, 25, 40 and 60%. The duration of the duty cycle is 10 min. Fig.13-S3 Duty ‘Teknocrat’s Academy of Automation & Control Technology, Nasnux 109 Time Time Timei TAACT S4- Intermittent duty with startin; ‘A sequence of identical duty cycles, each cycle including a significant period of starting, a period of operation at constant load and rest and de energised period. The period is t00 short for thermal equilibrium to be obtained. In this duty type the motor is brought to rest by the load or by mechanical breaking, where the motor is not thermally loaded. P Electrical Automation (VELAO.1) _ietiad of one ekg ve D Output power N= Operation under rated condition Starting R = at rest and de-enereised SSIntermittent duty with starting and electrical breaking: A sequence of identical duty cycles, each cycle consisting of a significant period of starting, a period of operation at constant toad, a period of rapid electric breaking and a rest and de-energised period. The period is too short for thermal equilibrium to be obtained. Period of one eyele =p N Fig.15-S5 Duty S6-Continuous-operation periodic duty: A sequence of identical duty cycles, each cycle consisting of a period at constant load and petiod of operation at no load. The period is t00 short for thermal equilibrium to be obtained. Recommended values for the cyclic duration factor are 15,25,40 and 60%. The duration of the duty cylices is 10 min. Period of one cycle Fig.16-S6 Duty > Time ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 10i Electrical Automation (VELAO.1) TAACT ‘ST- Continuous-operation periodic duty with electrical breaking: A sequence of identical duty cycles, each cycle consisting of a period of starting, a period operation at constant load and a period of braking. Braking method is electrical braking e.g. countercurrent braking. The period is too short for thermal equilibrium to be obtained ‘S8-Continuous-operation periodic duty with related load speed changes: A sequence of identical duty cycles, each cycle consisting of a period of starting, a period of operation at constant load corresponding to a predetermined speed of rotation, followed by one of more periods of operation at other constant loads corresponding to different speeds of rotation ‘The period is too short for thermal equilibrium to be obtained. This duty type is used for example bypole changing motors. Crane ey S9-Duty with non-periodic load and speed variations: A duty in which, generally, load and speed are varying non-periodically within the permissible operating range. This duty includes frequently applied overloads that may greatly exceed the full loads. For this duty type, suitable full load values should be taken as the basis of the overload concept. 5.13 Motor enclosures: Motors are manufactured in standard frame sizes, corresponding to the rated output, The size of the frame naturally increases with the rated output. The frame size standards stipulate various dimensions like the shaft center height, axial distance between sets of mounting holes and other mounting dimensions. This ensures interchangeability between motors of the same frame size manufactured by different vendors. In a given frame size, a number of designs are available to suit various applications, for example, types of mounting like foot-mounting or flange-mounting ‘The type of enclosure required, depends upon the conditions under which the motor has to work. Itis therefore selected s0 as to protect the internal parts against the ingress of dust and water. At the same time the enclosure is expected (o protect the surrounding areas from the internal, live and moving parts of the motor. The type of insulation and the type of cooling required is selected, depending on the temperature rise and the operating temperature limits. The position of the terminal box, which is either on top or on the side, is often required to be specified while ordering a motor, 1. Totally Enclosed, non-ventilated type: Such motors are limited to sizes up to 2 or 3 KW. The cooling is by surface radiation as there are ‘no openings for ventilation. The frame is of solid construction, 2. Splash-proof type: The frames of such motors, in corporate ventilated openings, so constructed that the liquid drops and dust particles that fall vertically or greater than 10° from the vertical angle, cannot enter the motor directly. ‘They also cannot enter the motor by striking or running along the outer surface. This is the extension of drip proof motors and is called the hose proof type. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik m1a Electrical Automation (VELAO.1) TAACT! 3. Totally enclosed fan cooled: Totally enclosed fan cooled motors, incorporate a fan, mounted on the motor shaft. The fan draws air and forces it between the inner fully enclosed frame and an outer shell. An internal fan carries the heat that is generated internally to the enclosed frame, which is cooled by the air drawn by the fan on the shaft. The enclosing frame protects the motor against corrosive and abrasive effects of dust, moisture, etc. 4. Protected-type: Protected type motors contain feature perforated covers for the openings in the end shields. Thus the internal and live parts of the motor are mechanically protected using wire mesh or metal covers without affecting the flow of air. 5. Drip-proof type: The frames in such motors afford protection against liquid drops or dust particles failing on the machine at angles greater than 15° from the vertical. Water drops and particles cannot enter the motor directly or indirectly by either striking or running along the surface. ‘The ventilated openings are protected by use of a hood. 6, Pipe or duct ventilation type: Sometimes the air surrounding the motor is such that, if itis passed through the motor winding, it can damage it. In such cases, clean air can be brought from outside, and by means of a pipe or a duct, it can be used for motor ventilation, For force induction of air, a blower is installed at either the entry side or the exit side of the duct. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 42te Electrical Automation (VELA0.1) TAACT Ordering Information: Motor output :... (KW/HP) Motor Voltage:...V Operating frequency: 50 or 60 Number of poles / operating speed Winding connection: Star, Delta, Star & Delta, Special Max. Starting current... Direction of Rotation Ambient temperature: 45°C,50°C special( specify) Insulation class: B,F,H ete 10. Duty: Continuous or other(specify) LU. Enclosure: open drip proof, etc 12, Mounting: B3,V1,Other (special) 13, Braking Details: No braking, Plugging, DC Injection, Other( specify) SEN AVASPe Summary of Motor Equations and formulae: Sr. [Parameter Formula No 1 Torque T=Fxr T=9.55*P/N (Nm) Tav TabkCosd 2 ___|Sychronous Speed [Ns = 120f/p | 3_ | % Slip % Slip = [(Ns = Ni)/ Ns] * 100 4 |Mechanical Power | 1 H.P = 550 ft. Ib 1H. 3 [Relation between | 1 HP KW&HPPower | 1K.W 1 HP 1K.W 6 Electrical Power Single phase: P= ViI,Cos@ watts ‘| Three Phase: P= Y3VLICos® watts 7 |Motor Efficiency | % Eificiency =(Rotor Output Power/Stator Input power) * 100 §__[ Motor Output power | Motor Output power= Stator Input Power Lowes ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 113i i Electrical Automation (VELAO.1) | TAACT Motor Starters 5.14 Motor Starters: Motor Starters are actually a combination of switchgears, such as contactors overload relays and Circuit Breaker. 3- Phase sq. case induction motors draw a very heavy current during starting ‘The starting current of 3-phase sq. cage induction motors in generally of the order of 5-7 times its rated full load current. Such heavy starting currents especially in the case of large motors of 25HP and above can overload the supply network and cause voltage drops in the plant. Different types of Motor starters are employed depending upon the motor rating and type of load to limit the starting currents and at the same time allow the motor to develop enough torque to accelerate the load smoothly. ‘A 3-phase induction motor runs on load with its stator windings connected normally in Delta though in some small motors they could be connected in Star also. In the case of large motors all the 6- terminals (2-per winding) are brought out upto the motor terminal box. The windings can then be connected in star or delta externally. Direct on line (DOL) starter: A DOL starter on getting activated switches ON the full line voltage across the motor terminals One has to read Nameplate of the motor to find out Voltage to apply in Star or Delta configuration. With 415V as the line voltage full 415V is applied to motor terminals. If the stator windings are designed for 415V they must be intemally connected as Delta and if they are designed for 230V they must be internally connected as star. ADOL starter would normally comprise of a. AMCCB or a switch fuse unit or MCB b. A Contactor ¢. An overload relay 4. Start / Stop push buttons. ©. ON/Trip lamp. ‘The MCB or switch fuse unit may or may not be a part of the starter. 7 R Y B MccB/ Control S'°P MCB i] 7 jt ! Gircuit a % ener Circuit Start8F C OLR an amp N Fig.17-DOL starter Teknocrat’s Academy of Automation & Control Technology, Nashik haie Electrical Automation (VELAO.1) TAACT Functioning of DOL starter: MCCB or switch fuse unit switches on the 3 phase power supply. Pressing the ON push button switches On the contactor and as shown in fig. an NO contact of the contactor is connected in Parallel to the Start Pushbutton. As the contactor is switched ON, it latched through this parallel NO contact of Contactor even after the stat push button is released, Motor gets full voltage. And remain on continues to run until the Stop pushbutton is pressed to stop the Motor or the Motor {rips due to an overload relay. At full voltage motor draws heavy starting current of 5-7 times its rated value and develops starting torque which may be anywhere between 1.5 to 2.5 times the rated torque depending upon the Motor, On attaining the rated speed the current comes down to its rated value and motor develops torque as per its rated value and load demand With DOL starters the starting current of the motors is very high and in case of large motors of 26 Hp and above can cause large voltage drops in supply network, which may upset the working of other equipment Yeu 7 Detter = Star Delta (¥/D) Starters: Construction: A Star / Delta Starter allows the motors to start with lower starting current. Three contactors are used in such a way that first the stator windings get connected in star externally with contactors and after attaining 60— 70% of rated RPM the contactors switch over to connect the windings as delta. The motor windings are not connected internally with each other and all 6 terminals (2 of cach winding) are brought to the terminal box of the motor. Contactors externally connect the windings in star or delta. The windings are individually designed for 415V. A star delta starter comprises of : MCCB or switch fuse unit 3- Nos. contactors Overload Relay Start Delta timer Start / Stop Push Buttons On/Trip/ Lamp oye eNe ‘MCCB or switch fuse unit may or may not be a part of the starter, Functioning of Star Delta Starter: On pressing the start push button the main contactor and the star contactor gets switched ON and the timer coil is also switched. The motor windings get, connected as star. With 415V as the line voltage each winding gets 240V and therefore draws lesser* current. The starting line current is not more than 1.5 to 2.5 times the rated current. After a set time during which the motor attains about 60-70% of its rated speed the timer first deactivates the star contactor and after a short delay of few milli-seconds activates the delta contactor. The main contactor remains ON throughout. A short delay between deactivation of star contactor and activation of delta contactor «ensures that the two contactors do not Switch on simultaneously and short-circuit the windings. {.Jtcan be shown by calculation that the line curent drawn by the moto when connected instars 1/3 times of the line current drawn by the same motor connected in delta, Teknocrat’s Academy of Automation & Control Technology, Nashik 1s VineeTAACT Electrical Automation (VELAO.1) RY B McB OLR Fig.18a Schematic Dia of Star-Delta Starter power Circuit R Stop Start g- MN Hamp me Fig.18b-Schematic Dia. of Star-Delta Strter Control Circuit | Bitentaoemgh Styne on ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 116* TAACT ical Automation (VELAO,1) With delta connection, the windings receive full line voltage and draw full rated current With star delta starter, the starting current of the motor gets reduced to 1.5 to 2.5 times the rated Current instead of 5 to 7 times in case of DOL starter. However this reduction in starting current hhas adown side too, In star connection the motor windings, which are designed for 415V, get only 240V and therefore develop considerably lesser torque(TaV"), A star delta starting of motor may not suit loads requiring high starting torque. Star / Delta starters are also more expensive and therefore used generally for motor above 20 ~ 25 HP. AH Autotransformer / Soft starter: Lod stenting Teme ‘o reduce the starting currents of squirrel cage induction motors an autotransformer / soft starters are sometimes considered as a better alternative than star / delta starter. An Autotransformer is an electro mechanical controller and soft starters are electronic controllers. Principally both are used to start the motor with a small voltage and gradually increase it to its full value over a period of time. In the case of soft start the starting voltage and the ramping up time can be electronically preset. With reduced voltage starting the motor starting current is proportionately reduced however the same is at the cost of reduced starting torque. Line Full Voltage Voltage Min. Start Voltage time Fig. 19b-Voltage Build up for soft starter Tl ——— oo Ramp-up time Direct On Line Starter Soft Starter Fig. 19a-Line connected Fig. 19e-Comparision of Starting Current Jor Different types of Starters Soft starter ‘Teknocrat’s Academy of Automation & Control Technology, Nashik a7* TAACT irical Automation (VELAO,1) Resistance Starters: eny Ar Wound wt Wound rotor motors with resistance starters have to be used for large rated loads, which have such starting torque requirements that Y / D or reduced voltage type starters are unsuitable. ‘These work on the principle that the torque developed by the motor is proportional to the rotor winding resistance. A high rotor winding resistance during the starting allows the motor to develop very high starting torque. However the additional resistance needs to be cut out after motor attains its full rated speed. Slip ring induction motor with wound rotor are designed for connecting external resistances to the rotor winding through slip rings and brushes and which are cut out or shorted through contactors on motor attaining full speed. ‘The starter consists of a, DOL starter to stator b. Set of rotor resistances ¢. Contactor for shorting the resistances d. Timer / Relays to activate and deactivates the rotor contactor. Slip Rings a5 Starting Resistance Fig:20-Resistance starter Variable Frequency Drives (AC Drive): AC Drive is basically a variable frequency, variable voltage controller with a constant V/F ratio. With AC Drives, Motor starting current is limited to 2 to 3 times the normal starting current without affecting the torque performance of the motor, With AC Drive the motor is always started with low voltage and frequency with Ramp up feature. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 118te Electrical Automation (VELAO.1) TAACT 5.15 Maintenance and Troubleshooting 5.15.1 Conducting an insulation-resistance tes To conduct an insulation resistance test, perform the procedure listed below: 1. Check the insulation tester by shorting its test leads. It should show zero resistance. If test leads are kept open, it should show infinite resistance. 2. Isolate the section to be tested from the power supply. 3. Disconnect all lamps or electronic devices from the circuit to be tested. 4. Select the proper operating voltage for conducting the test, depending upon the rating of the system. 5. Check for connections while conducting tests so that only the section to be tested is included in the test. ‘There should not be any stray parallel leakage paths. Check the instrument for pointer index or any other pre-adjustment necessary. ‘Test leads to be used should have good quality insulation, Before starting the test, insure that all the capacitors in the circuit are discharged by shorting their two leads together, Similarly, after the test ensure that they are in discharge condition. If this is not done they may give false readings. 10, Before touching cable ends after testing, discharge any energy that might have been stored in the cables during the test. This is most likely to occur in long nuns of larger cables due to their capacitance. 11. Checking continuity of an earthing system requires the use of low-reading ohmmeters, which should be zero-adjusted before each test and calibrated on regular intervals, 12, Where the testing of the earth electrode resistance is required (i.e., the resistance between the electrode and the general mass of earth), one of the special types of earth resistance testers must be used. vere Optional tests: ‘There still remain a few useful tests using the measuring devices. ‘These tests are used for checking single-or three phase systems and other electrical devices. ‘Some of the tests we have discussed in the next few sections. These can be used to strengthen troubleshooting techniques. [A] Megger testing cables and auxiliary devices of a single-phase system Disconnect P and N from the supply side, as well as from the other end. Now we have isolated our test circuit, making it dead. Short P and N with a temporary short link. Close switch and protection devices. As shown in Fig.-21 open motor terminals, so that the motor remains isolated from the test circuit. Check resistance with the insulation tester between the neutral link and earth, If the value shown in the meter is less than 1 MQ, then there is a fault with either the cable insulation or device terminals, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 119ie Electrical Automation (VBLAO.1) TAACT Megger Fig.21- Megger of a single-phase system [B] Megger testing cables and auxiliaries of a three phase system: Disconnect 11,12, and L3 from the supply side , as well as from the other end. This makes it a dead circuit. Short L1, L2, and L3 terminals with a temporary link. Close the breaker device and protection devices. As shown in Fig-22 open motor terminals T1, T2, and T3, so that the motor remains isolated from the test circuit. Check resistance with insulation tester between each conductor and earth. If the meter shows a low value less than IMQ, there is a fault in either cable insulation or device terminals. R Y B a) ~f--Y Breaker = on. Tf g c on TIP 129 73 M Fig.22- Mexaer of a three-phase Teknocrat’s Academy of Automation & Control Technology, Nashik 120Electrical Automation (VELAO.1) TAACT, [c] Megger testing of motor: A pre-condition for megger testing of a motor is to isolate the motor from the supply totally. Take the megger value of a motor between each conductor and earth, as shown in Fig.-23 to check the earthing of the stator winding. This will help us to conclude on earthing status of the Startor winding, Similarly, check for shorting between two windings by checking the megger value between two stator winding terminals, as shown in Fig-24 ‘Thus a low reading can identify insulation failure of any winding inside the motor. Megger Motor terminal box ; U2 v2 w2 Fig.23- Megger testing for an earthed winding condition ww Ul vi w Megger Motor U2 v2 w Fig.24- Megger testing winding to winding short ‘Tekanocrat’s Atatiemy of Automation & Control Technology, Nashik 121ie 5.16 TAACT Motor Control Trouble -Remedy Table: Trouble ‘Contacts Chattering 1)Poor Contact S use control circuit 2) Low voltage Electrical Automation (VELAO.1) — Remedy — Replace the device 2)Check —coil_—_terminal voltage/general voltage fluctuation —Jvoltage dips | during startin Welding or freezing i 3) 4) 5) Current inrush abnormal ‘Tip pressure low Low voltage Ingressed foreign matter preventing contact closing. Short-circuit/ground fault 1) Check shorts/grounds. Check motor load current. Use higher size contactor. 2) Replace ——_contacts/ springs. Contact carrier may be damaged 3) Check coil terminal voltage and voltage dips during starting. 4) Clean contacts with Freon 5) Remove fault. Ensure: correctly rated fuse/circuit breaker is used Shon tip life tip overheating b 2) 3) 4) » 6 D Filing or dressing High current interruption Low tip pressure Foreign matter ingress, Short circuits/ground fault Lose power “circuit connection Persistent overload. 1) Ensure silver tips are not field, Roughspots or discoloration do not harm tips or cause malfunctiuon. 2) Replace with higher size device. Check current levels/Faults 3) Replace contacts/springs. Contact carrier may be damaged. 4)Clean contacts with Freon. Check enclosure for ambient condition suitability. 5) Remove fault. Check correctly rated fuse/circuit breaker is used, 6\Tighten 7)Check motor load current. Install larger device. Coils open circuit 1)Mechanical damage Handle/store coils with care. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 122Electrical Automation (VELAO.1) TAAC [Trouble Cause 4 _ Remedy | Overheated Coil 1Over voltage or high ambient | I)Check terminal voltage less temperature than 110% of rated voltage 2)Coil unsuitable 2)Replace with correct coil 3)Shorted tums due to | 3) Replace Coil mechanical damage 4)Check coil terminal voltage. 4)Under voitage/magnet seals in This should be at least 85% of failure rated voltage S)Pole faces dirty 5)Clean pole faces 6)Obstruction to moving | 6)Check free movement of elements contact and armature assembly. Overload relay | 1)Persistent overload DCheck excessive motor Tripping 2)Corrosion or loosening currents, current unbalance. 3)Unsuitable thermal units ‘Take corrective action. 4)High coil voltage 2)cleamighten 3)Replaced with correct size for the application and conditions 4)Check coil voltage is within 110% of rated capacity. Trp failure 1) Thermal units not suitable TDApply proper thermal units 2)Mechanical bindings, dirt, | 2)Clean/remove corrosion, etc. Particles/obstruction, ete. to 3)Damaged relay restore to proper functioning 4)Relay contact welded condition, Replace relayithermal unit if not possible. 3)Replace relay and thermal units, 4)Replace contact or entire relay as necessary, Magnetic and | 1)Shading coil broken DReplace magnet and ‘mechanical parts | 2)Magnet faces dirty/rusty, armature assembly. noisy magnet 3)Low voltage 2)Clean 3)Check coil terminal voltage/voltage fluctuation/motor starting voltage dips. _| ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 123cecere 787799990 973599D 9359959999559TESCO OTOOCSRASSN SN YN DD77T3DADIDIIIIADIDPerr rr Fe ee NN I997N99993979939I9N9090990rr RRR Ee AAR RR RRQ Y,237999909* TAACT Trouble | Pickup and sealing failure - Cause Loss of control voltage 2)Low voltage 3)Moving part obstruction 4)Open or overheated coil 5)Coil unsuitable Electrical Automation (VELAO.1) Remedy | Check control circuit. For loose connection/poor contact continuity. 2)check coil terminal voltage/voltage fluctuation /motor starting voltage dips. 3)With power off, check contact and armature assembly movement 4)Replace S)Replace Failure to drop out 1)Sticky substance on pole face 2)Voltage persistence 3)Worm or corroded parts failing to separate 4)Residual magnetism caused by lack of air gap in magnet path. 5)Welding of contacts. 1)Clean 2)Check coil terminal voltage/control circuit 3)Replace defective parts. 4) Replace magnet and armature 5)See ‘Contacts-welding or freezing’ Pheumatic timers erratic timing Dngress of foreign matter in valve 1Replace complete timing head. Return timer to factory for repair and adjustment. Failure of contact operation TActuating screw not correctly adjusted 2)worn/Broken parts in snap switch DAdjust as per manual service instructions 2)Replace switch 2)Voltage persistence 3)Worm or corroded parts failing to separate 4)Residual magnetism caused by lack of air gap in magnet path. 5) Welding of contacts. Limit switches | T)Actuator overtravel Use resilient actuator. damaged parts Operate within device tolerance limits Manual starters | 1) Latching mechanism damaged | 1) Replace starter failure to reset Failure to drop out | 1)Sticky substance on pole face | 1)Clean 2)Check coil terminal voltage/control circuit 3)Replace defective parts. 4) Replace magnet and armature 5)See ‘Contacts-welding or _| freezing" ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 124,Me TAACT 5.17.4 Motor starter check chart: ___Trouble_ Contactor/Relay closing failure Contactor or relay fails to open Cause Supply voltage failure Low voltage Open- circuited coil pushbutton, interlocks, or relay contact not making Loose connections or broken wire, Incorrect pushbutton connection open o/l relay contact, Mechanical parts damaged, corroded, not properly aligned/assembled, etc. Incorrectly connected pushbutton worn shim in ‘magnetic circuit residual magnetism holds armature closed. Pushbutton, interlock, or relay contact fails to open coil circuit. ‘sneak’ circuits welding of contacts ‘Mechanical part malfunction due to damage corrosion, etc. Electrical Automation (VELAQ.1) Corrective Action Check fuses/disconne switch. Check power supply. Ensure correct size of wire replace. Adjust to ensure correct, ‘movement, easy operation, and correct contact pressure, Check circuit. Isolate circuit first Check with witing diagram Reset relay Clean/align and adjust for proper operation. ‘Check connection with wiring diagram and rectify replace shim Make adjustment for correct ‘movement, ease of operation, and proper opening check for insulation failure see ‘Excessive corrosion of contacts’ Clean mechanical parts. Check for free movement remove obstruction/ ingressed matter. Repair or replace worm or damaged parts ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 125sal TAACT Contact, corrosion/welding Contact spring pressure not adequate. Overheating or arcing on closing reduction of effective contact surface area due to pitting, etc. Abnormal operating conditions Chattering of contacts due to external vibrations Sluggish operation. Electrical Automation (VELAO.1) ‘Adjust for correct contact pressure, Replace spring or worn contacts if necessary dress p contacts with fine file, Replace if badly worn check rating and load. In case of severe operating condition replace open contactors with oil-immersed or dust tight equipment instruct, operator in proper control of ‘manually operated device check control switch contact pressure, Replace spring if it fails to give rated pressure tighten all connections. If problem persists mount/move control, so that vibrations are decreased clean and adjust mechanically. Align bearings. Check free movement. ‘Arc. lingers across contacts Blow out problem. Series blow ‘out may be short circuited. Shunt blow out may be open. Ineffective blowout coil. Note travel of contacts in case blowout is not used. Arc box might be left off or not in correct position if blow out is used. Check blow out type with wiring diagram. Check blow out circuit check rating. Replace in case of improper application. Check polarity and reverse coil if necessary. Increasing travel of contacts increases rupturing capacity ensure that arc box is ‘Overload. fully in place check rating : against load. Noisy AC magnet | Improper assembly broken Clean pole faces, Adjust shading coil low voltage mechanical parts replace check power supply. Check wire size. Frequent coil failure “High voltage gap in magnetic circuit. Ambient temperature may be high. ‘Check supply voltage against controller rating check travel of armature. Adjust magnetic circuit. Clean pole faces check controller rating against ambient temperature. Replace coil with correctly rated coil for ambient, from manufacturer. Burning of paneVequipment due to starting resistor heat Frequent starting Use higher-capacity resistor, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 126it Electrical Automation (VELAO.1) TAACT Exercises: 1. A 3-phase 440V Induction Motor takes a line current of 30A at power factor of 0.9. If the efficiency of the motor is 0.8, find the motor output in HP. ~ 2. A 3-Phase SOHz Induction Motor has eight poles. If full load slip is 2.55%, find the synchronous speed & rotor speed. 3. A pump is to raise 700 liters of water per minute up to a height of 60 meters. Find out the HP of the Motor if the pump efficiency is 80% and Motor efficiency is 85%, Also if the Coennty Power factor is 0.8, & voltage is 400V, find the full load current. Foo Vikers ob wate | = 1 op eo ey 5.18 General notes on motor proiection and switching Coordination tables: ‘The ratings of different switching and protection-gear used in a circuit have to have a certai relationship with each other in order to provide a certain level of protection to the equipment and the system. ‘These inter-rclationships of different switchgears for a particular rating and type of oad are given in standard co-ordination tables. These co-ordination tables have been worked out ‘0 offer two distinct levels of protections and are called co-ordination type-1 and type-2 Coordination type: ‘Type 1- Coordinati tis acceptable that in the case of short-circuit the contactor and the thermal release may be damaged. The starter may still not be able to function and must be inspected; if necessary, the Contactor and/or the thermal release must be replaced, and the breaker release reset. ‘Type 2- Coordinatio In the case of short-circuit, the thermal release must not be damaged, while the welding of the Contactor contacts is allowed, as they can easily be separated (with a screwdriver, for example), without any significant deformation. Standard used: IBC 60947 -4—1 Rated power of the motor * The tables are based on the current consumed by electric, three-phase squirrel cage ABB induction motors with four poles. * The rated power of the motor is expressed in kilo Watt ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 127ey | Electrical Automation (VELAO.t) TAACT! Protection device: As protection device, the following tables use the moulded-case circuit-breakers (MCCB) with the following types of releases: + MF fixed magnetic only release (for Tmax T2 circuit-breakers) + MA magnetic only release adjustable (for Tmax Te 3 circuit-breakers) * PR221/[ electronic release (for Tmax T4 and TS circuit-breakers) * PR222MP electronic release (for Tmax T4 and TS circuit-breakers). ‘The solutions proposed refer to an ambient temperature of 40 °C and to fixed version apparatus. For higher temperatures, please contact ABB SACE. Type of starting: » By normal starting, a starting time up to 2 s is intended in accordance with the trip time of the thermal relays in class 10 A.. * By heavy duty, a starting time up to 9 s is intended in accordance with the trip time of the thermal relays in class 30A. Two factors must be considered for normal star-delta starting: the speed the motor has reached atthe end of the starting period is 85% higher than the rated one; the transition time between the star delta connections is 80 ms shorter. Short-circuit current: ‘The valid selection for a certain value also covers lower levels of short-circuit. For example, by selecting 80 kA, protection which is also valid for lower values is obtained (70, 60..KA, at the same voltage). This means a starter with higher performances at the required breaking capacity. For more economical solutions, verifying some specific solutions for lower short-circuit levels is recommended. Notes: To determine a type of coordination unequivocaily and therefore the apparatus needed to carry it out, the following must be known: Motor power in kW and the type; Rated installation voltage; Rated current of the motor; Short-circuit current at the point of installation; ‘Type of starting: DOL or Y/. - Normal or Heavy - Type 1 0 Type 2. Example for using the tables You want to realize Y/, Normal Type 2 starting of a three-phase asynchronous squirrel cage motor with the following data Rated voltage Ur Short-circuit current Ik Rated motor power Pe 400 S0kA = 200kW ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 128ith Electrical Automation (VELAO.1) TAACT! ‘The following information is read from the table (star~delta 400 V 50 kA), in correspondence with the relative line, Te (Rated current) 1349.4, Protection device against short-circuit: T5$630 PR221-1 In630 circuit-breaker ‘Magnetic trip threshold 113 =4410A Line contactor + A210 Delta contactor 2 A210 Star contactor 1 AL85 ‘Thermal relay + E320DU320 adjustable 105-320 A ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 129Electrical Automation (VELAQ.1) TAACT For Product Details Annexure I © — Teknocrat’s Academy Of Automation & Control Té&hnology, Nashik 9 130it Electrical Automation (VELAQ.1) TAACT 5.19 Other types of Motors ‘Types of single-phase induction motors: 1. Split-phase induction motor This is single-phase split in 2-phase currents for creating a 2 phase condition. Thus phase splitting creates a rotating field. In the split-phase motor, an auxiliary winding in the stator is used for starting, with cither a resistance connected in series with the auxiliary winding, known a8 the resistance start, or a reactor in series with the main winding, known as the reactor start. ‘The start winding of a split motor is made up of a few tums of a small diameter wire giving a high resistance and a low reactance. Applications: They are used Start Winding in small machines that require low torque. Washing machines, tool grinders and small fans and blowers are among the applications that use these motors. Fig.25 Split-phase induction motor 2. Capacitor Start induction motor: A single phase induction motor with only a squirrel-cage rotor has no starting torque. In this motor, @ capacitor of suitable size is introduced in the starting winding circuit and a phase difference is created between the tow windings. In the capacitor-start single-phase motor, an auxiliary winding in the starter is connected in series with a capacitor and a centrifugal switch, During the starting and the accelerating period, the motor operates as a two- phase induction motor. At about 76% of the full load speed, the switch disconnects the auxiliary circuit and the motor thereafier runs as a single phase induction motor, Ber Starting Winding Fig.26 Capacitor Start induction Application: These are used in instances where low starting torque is needed as in air conditioner blower applications. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 131oe Electrical Automation (VELAO.1) TAACT! 3. Capacitor split-phase motor: Capacitor start / capacitor run motors are more efficient and require less running current than motors with start capacitors only. These motors have two capacitors in series with the main stator winding. Start capacitors have a high capacity while the, run capacitors do not. One optimizes starting torque while another optimizes running characteristics. Throughout both starting and operation all the windings in the motor remain energized. Starting Capacitor Running Winding At operating speed, the switch disconnects the start capacitor and turns on the run capacitor to maintain the — motor's performance. Optimum levels of both starting torque and running characteristics are achieved with this design. In the capacitor start, capacitor-run motor, the starting or the auxiliary winding remains connected in the circuit during running. In order to have a high starting torque, the capacitor rating should be high, but during running, a small value capacitor is suitable. To solve this issue, two capacitors of different ratings are used. One is known as the starting capacitor and the other, as the running capacitor. The starting capacitor is switched out of circuit one the motor reaches full speed. These motors have good starting torque and a quiet running. Fig 27Capacitor split phase motor Applications: Capacitor start / capacitor run motors are used over a wide range of single phase applications primarily starting hard loads. 4, Shaded-pole induction motor: This is another method to create two phases, with phase differences shaded pole has salient poles, each pole split into two sections, A small part of | Single Turn copper Shaded Portion of Pole| each pole face is wound with a short | conductor circuited copper ring. When supply is given the flux under the shaded portion lags behind that of the unshaded portion. Thus a phase ‘difference is created, This causes the creation of a rotating magnetic field. The shaded pole motor is inexpensive, since it does not consist of an auxiliary Unshaded Portion of Pole winding or other mechanisms. These are fow-torque motors, generally used. for Fig.28 Shaded-pole induction motor small fans and blowers. ing pole shading. The ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 132a Electrical Automation (VELAQ.1) TAACT Application: Shaded pole motors are best suited to low power household application because the motors have low starting torque and efficiency ratings. Some compatible applications include hair dryers, humidifiers and timing devices. S.Universal Motor: The series wound single phase motor, has a rotor winding in series with the stator winding, similar to the series wound DC motor. This is similar to a DC series motor with a similar high starting torque. This motor is also called the universal motor because it is designed to operate on either AC or DC supply. When an AC is applied, there is an instantaneous change in the ficld and armature polarities. Since the field winding has a low inductance, it creates reversals in the current direction at the proper timings. As the motor can also be operated on direct current (DC), it is also known as the universal motor. ‘Stator pole ‘Commutator Fig.29 Universal Motor ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 133i i] i Electrical Automation (VELAO.1) Taact! DC Motors The development of the DC motor preceded that of the AC motor. Today, even with the preponderance of AC motor applications, not only in traction, the DC motor retains its position due to its unique characteristics. DC motors are used for applications that require a wide range of torque and good speed control. DC motors comprise of four principal components: 1. Field, 2. Armature 3, Commutator 4, Brushes. The field is the equivalent of a stator in an AC motor, and the armature functions as the rotor. ‘The brushes act as contacts between an external power source and the commutator. The design of these carbon brushes allows them to move up and down on a brush holder, to compensate for the irregularities of the commutator surface. Thus they are said to ride the commutator. Each section of the commutator is connected to an armature coil, essentially a conductive loop of wire, A current induced in the armature coil, by way of the brushes and commutator, creates a magnetic field around the armature. Since the current flowing through the armature flows at a right angle to the field's magnetic lines of flux, the two magnetic forces interact, This interaction creates a third magnetic field that tends to rotate counter clockwise Application: DC motors provide excellent speed control for acceleration and deceleration with, effective and simple torque control. The fact that the power supply of a DC motor connects directly to the field of the motor allows for precise voltage control, which is necessary with speed and torque control applications. DC motors perform better than AC motors on most traction equipment. They are also used for mobile equipment like golf carts, quarry and mining equipment. DC motors are conveniently portable and well suited to special applications, such as industrial tools and machinery that is not easily run from remote power sources. ‘Types of DC motors: ‘The basic working principle of DC motors has already been dealt with. This section details the types of DC motors. The different types depend on the method of connection of the armature and the field winding and they are classified as below: Separately excited motor Series DC motors Shunt DC motors Compound DC motors Teknocrat’s Academy of Automation & Control Technology, Nashik 134iy Electrical Automation (VELAQ.1) TAACT 1. Separately excited DC motor: In a separately excited motor, as shown in Figure the field supply is provided in a manner other than by an armature supply. Since the field current is taken from a separate supply, field current is independent of the load. ‘The flux remains essentially constant and does not affect either the speed or the torque. Fig.30 Separately excited DC motor 2. Series DC motor: As shown in Fig.-30 the motor has the armature and field winding connected in series, there fore, its name ~ series motor. Field winding is made up of a relatively few turns of a large diameter wire so that the field resistance remains low. In the series wound DC motor the field windings are fixed in the startor frame and the armature windings are placed around the rotor. These are connected in series. The current passing through the armature also passes through the field. In a series wound motor, any increase in the load results in more current passing through the armature and the field windings As the increased current strengthens the field, the motor speed decreases, Conversely, of the load is decreased, the field is weakened and the speed increases. For lighter loads, the speed increase may be excessive and undesirable. In order to control this, the series wound DC motors are usually directly connected or geared to the load to prevent runaway, At times a series wound motor designated as a series shunt wound is provided with a light shunt field winding, to prevent the dangerously high speeds at light loads. ‘The increase in armature current with the increasing load produces an increased torque, 80 that the series wound motor is suited to heavy staring duty. The motor speed can be adjusted with a variable resistance placed Fig.31 Series DC motor in series with the motor, but due to the variation with the load, the speed cannot be maintained constant. The series wound DC motors are used for hoists, cranes, and elevators. Series field Supply ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 135te Electrical Automation (VELAO.1) TAACT! 3. Shunt DC motors: Shunt motors are used in applications where 2 good speed regulation is required. In the shunt wound DC motor, as shown in Fig the field winding is connected in paralle] with the armature winding. In this type of motor, the field winding has many turns of small diameter wire to keep the resistance high. ‘The strength of the field is not affected appreciably due to changes in the load, A more or less constant speed is obtainable. Shunt wound DC motors are used where a more or less constant speed, a low startor Ih SY torque, and a light ' DC Supply overload on the motor are required. ‘The shunt wound motor can also work as an adjustable speed motor by means of the armature control or field control. ‘Armature Fig.32 Shunt DC motor If a variable resistance is placed in the field circuit, the amount of current in the field windings can be controlled and the speed of the motor can be controlled. As the motor speed increases, the torque decreases proportionately, resulting in an approximately constant horsepower. Ifa variable resistance is placed in the armature circuit, the voltage applied to the armature can bbe reduced, and hence the motor speed can be reduced. With an armature control, speed regulation becomes poorer as the speed is decreased. Since the current in the field remains unchanged, the torque remains constant. Adjustable speed shunt wound motors are used on large machines for boring mills, lathes, planners, etc, These are particularly adapted to spindle drive because of the constant horse power characteristic that permits heavy cuts at low speeds and light cuts at high speeds. 4, Compound wound motors: ‘These types of motors provide desirable characteristics of both series and shunt wound motors. ‘They provide high starting torque as in a series motor, as well as good speed regulation as in shunt wound motor. In these types of motors, there are two field windings; one is in series with the armature, while the other is in parallel with the armature. In the compound wound motor, the speed variation due to load changes is much less than that in the series wound motor, but greater than that in the shunt wound motor, Teknocrat’s Academy of Automation & Control Technology, Nashik 136ie Electrical Automation (VELAO.1) TAACT The compound wound motor has greater starting torque than the shunt wound motor and is able to withstand heavier loads for narrow adjustable speed range. Fig Series field Shunt Field Supply Fig. 33Compound motor short shunt connected Fig.34Compound motor long shunt connected Characteristics of DC motos ® DC motors have good starting torque as well as good speed regulation capabilities, * Permanent magnet type DC motors are used for exact positioning of objects with high operating torques. Series type gives high starting torque; hence the ability to start with high loads, Series motors when operated with no loads can attain high speeds causing harm to motor. Shunt type motors have good speed regulation. Direction reversal of DC motor can be done by changing the leads of the armature or the field Speed of DC motor changes either by changing armature voltage or field current, Hf armature voltage is increased, speed increases till base speed and vice versa, Similarly, speed can be increased above base speed, by decreasing field current. In shunt motors torque is proportional to armature current. In series motors torque is proportional to square of armature current. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 13761 6.2 : Electrical Automation (VELAO.1) TAACT 6. Simple motor control & LV power distribution schemes Introduction: Distribution systems used in large commercial and industrial applications can be complex. Power may be distributed through various switchboards, transformers, and panel boards. Power distributed throughout a commercial or industrial establishment is used for a variety of applications such as heating, cooling, lighting, and motor-driven machinery. Simple motor control and L.V. power distribution schemes. Feeder Busway From Utility = Fig. I Power distribution schemes ‘Most of the power consumed in the industry is in motors and to a lesser extent in heating, lighting and other low power equipments. ‘We will now look at the design of different types of feeders and selection of equipment for these feeders. Elements of Motor control feeders SFU/MCCB Contactors Overload Relay Push Buttons Indication Lamps Ammeter / Voltmeter with or w/o Selector Switch Current Transformers ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 138i TAACT 6.3 Common types of Motor Starters DOL. RDOL Ysa RY/A Auto Transformer Soft Start 64 Selection table for Feeder equipment: For selecting all switchgears cor ion (VELAO.1) ponents of Motor control feeders a typical table as below can be used, Feeder NO. Unit [Incoming | Outgoing | Outgoing feeder feeder No.1 | feeder No.2 Feeder Rating HAP7KW. Nom. Current ‘Amps Type of feeder MCCB/SF ‘Amps Contactor ‘Amps ‘Neutral Tink ‘Amps. MPCB rating ‘Amps O/L Range ‘Amps Y/D Timer YIN ‘Auto Transformer Rating KVA Soft starter KVA/ Kw ‘Ammeter ‘Qty /Range Ammeter Sel. Sw YIN cr Ratio / Burden / Ace. Class Jory Voltmeter ‘Qty /Range Voltmeter set sw. Y/N Kw /Kwh meter range PF Meter YIN SPP Relay YIN Fuse monitor Y/N Push buttons ‘ON/OFF iResetiQty indication Lamps ON/Trip Control Transformer VAUX" ratio ‘Teknocrat’s Academy of Automation & ‘Control Technology, Nashik 139TA 1 4 Electrical Automation (VELAO.1) TAACT Ch.7.0 Electrical Drawings and Basic Troubleshooting Techniques Objectives: * To understand Basic Electrical symbols + To understand Power and Control Circuits * To read Electrical Drawings * To lear Basic troubleshooting techniques * To learn different testing methods Devices and symbols: Any electrical drawing representing an electrical installation or a circuit takes the help of specific symbols to represent various electrical devices in shorthand. This provides a quick idea to the reader about a circuit or installation, and is particularly useful while troubleshooting ‘Therefore, it is important to familiarize oneself with various symbols, Some of the commonly used device symbols are detailed in the following section and in table-1 Crea weaker [— Lam Syaeaae ; at | Ws ; = aa hi yy Ses ax » ae) =a “é |) ee a Fouts [2 Position Selector Puche=ton || Painme Color by Teter Te ® eee Non [ Puster | i ES ]| pusmto-test oe [eas 2 ia at z fot 54) at cz Herein Coos Wisin Cont — [ST Shale CHaa— [Dace xs [atvenm] Wobble | Tw Snce ] One boone wo [ ne | Now Tiead | Stick” | _Ceexits Circuit ‘ 7 ee Hla. ate Hele ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 140Electrical Automation (VELAO.1) Wot Rotor bd ra consol |] | Paw or Contal_| TIED <> eta). Indicete ef) =e Tyoe by ( ) Fixed Adiustable Table:1 ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 14112 Elcetrical Automation (VELAO.1) Electrical Circuits: Electrical circuits are circuits used to interconnect different electrical equipments together to enable the working of an electrical device. Electrical schematics are commonly classified into power circuit and control circuit. A power circuit consists of the main power device (a motor, a generator, Heaters or other power devices) along with heavy power conductors, contactors, protection devices. Power Cire Power circuits are required for carrying power to or from heavy electrical equipments like motors, alternators, or any electrical installation, ‘They carry out the following function: * Isolation using devices such as isolators, linked switches and circuit breaks. = Circuit control using devices such as contactors, motor circuit breakers, etc. + Protection against overload and short circuits using thermal overload relays, Electro magnetic relays, circuit breakers, with releases, fuses, etc. Power circuits have to carry heavy power and therefore, they consist of heavy conductors along, with contactors used for switching the power on and off. Protection devices are also included in the same power circuit for resolving an overload condition or any other concerned faults. For example, Fig.1 Depicts a Direct on line (DOL) starter power circuit used for a three phase induction motor. As shown, the three phase power input is connected to the motor through a contactor. Power is passed to the motor when the contacts ( of the contactor) are in closed condition. Protection devices such as fuses, and overload relays are provided in series with power conductors to detect unhealthy conditions during operation. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 142,14 th Electrical Automation (VELAO.1) Breaker Fuse 7] 8 OIL contact d d z Om. wT ou TIP 12H 73 9 Q Figl-Power cireuitfor a Motor Control circuit: A control circuit is used for the automatic control of equipment, for safety interlocking, and sequencing the operations of the plant equipment and machines. Control circuits hardware consists of relays, contacts, hardware timers, and counters, etc. These consist of contacts (inputs) representing various conditions, coil (output) which are energized or dc-energized depending on the input conditions represented by the contact (inputs), Input contacts represent the binary state of the condition: "True or false * Onoroff. There are two main types of contacts NO (normally open) and NC (normally closed).a third type called @ changeover (c/o) contact is often used in Timers, counters and relays. This type combines an NO and NC contact with common terminal, * Input contact: These are contacts of relays, contactors, timers, counter, field instrument ‘switches, pressure switches, limit switches, etc. * Output coil: These have two states ~ On or Off. Output coil can be auxiliary contactor or ‘main contactor, R S~- A eA... N ‘0 ° ~ Change-over Contact NO NC Fig.2-Types of Contacts Teknocrat’s Academy of Automation & Control Technology, Nashik 143,it Electrical Automation (VELAO.1) TAACT A few simple control circuits are shown in Fig to represent logical AND, OR, and such conditions, 1, ‘AND’ operation cire Figure-3a shows a simple control circuit (AND operation) with two input contacts (NO) representing two conditions that must be true to complete the circuit to switch on the output relay coil and change the state of output from OFF to ON. 220R’ Operation: Figure 3-b shows a circuit with three input contacts (NO) representing three conditions at least one of which should be true to complete the circuit to switch ON the relay coil and change output state from OFF to ON. 3.‘AND? with ‘OR’ operation circuit: Figure-3c shows a control circuit, consisting of a combination of AND and OR operations. There are two parallel (OR condition) paths with two input contacts (NO) connected in series in each path representing AND conditions. The path for coil L3 will be completed when one of the path conditions comes true. The circuit then will switch ‘ON’ the relay coil and change the output state from OFF to ON Loa Lg—— || ¢>—7-2 7 Sa ‘1 2s 83 ss s2 Li Lh IN N EL N Fig: 3a -AND circuit Fig3b-OR circuit Fig3e-AND with OR circuit Reading and understanding electrical drawings: Electrical drawings can represent anything from a single-line power distribution, to a power or control circuit, and are prepared using various symbols for electrical devices and their interconnections with lines representing conductors or wires used for interconnections. To read and understand electrical drawings, it is necessary to know the following: = Symbols used for representing electrical devices. * Their interconnections, legends, terminology, and abbreviations. * Sheet numbering and column format for each sheet ‘Wire and terminal numbering (an important aspect in understanding electrical drawings) Wire and terminal numbers are quite useful during installation and termination of cables, and during fault finding and troubleshooting, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 144i Electrical Automation (VELAO.1) TAACT) It is easy to trace the connections and continuity of wires, if the wires and terminals are numbered using thorough cross-referencing terminology. Various examples of electrical ‘schematics are shown in this section to explain the drawing methodology in practical circuits and in the interest of simplifying the scheme the following have not been included. ‘These are however a MUST and will be insisted upon by the regulatory agencies. * Any power circuit has to be provided with an isolating mechanism which usually includes the fuses also in the form of a switch-fuse unit. The schematics here depict only the fuse. ‘An emergency switch or a push button has to be provided near a mechanism to positively isolate the clectrical circuit feeding the mechanism in the case of any emergency/accident. The NC contact of such a push button is connected in series with the other control contracts such as overload relay. The push button mechanisms are lockable and need a key to release once the push button is pressed. Reading a circuit + All-control devices such as switches and relay contacts are either NO or NC contacts. * The switch position normally shown in any circuit diagram is the default de-energized condition state * For denoting sensor contacts notations such as LS, PS TS are used. * A relay coil is denoted with a symbol inside a circle and contacts of relay used in the circuit are represented with the same tag as the coil. If a relay coil has multiple NO and NC contacts then the contact identification numbers, as shown or relays, are mentioned in the drawing. * In between the control supply lines Li and L2 you will find either the relay coil or a solenoid coil or the lamp load. * If several devices are to be tumed ‘ON’ at the same condition then you will find them connected in parallel between LI and L2. * If wires are common for two devices then in the diagram they are shown with the same identification number. "Generally, power circuit conductors are shown with for control circuits. A broken line indicates a mechanical function. Generally, itis used to show linkage between two different contacts of the same push button, k lines while thin lines are used ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 145i Electrical Automation (VELAO.1) TAACT 7.6 — Things to look for in an electrical drawin; 1, The symbols shown for a device in a circuit represent its de-energized state when no power is applied. It is either a timer NO/NC contact or a relay NO/NC contact in a circuit. In addition, power devices such as circuit breakers and contactors are provided with NO and NC auxiliary contacts which are used for indicating the status of the device in signaling and interlocking circuits. 2. An electrical drawing has a sheet number and each sheet is divided into columns listed vertically as A,B,C,D and horizontally as 1,2,3,4. This kind of matrix arrangement helps in quickly locating a particular device or contact in a sheet. Similarly, it is used to cross-reference a contact 3. In order to identify different coils and their contacts a letter such as KI, K2 or Cl, C2 is placed next to the circle of the coil. Contacts of the same contactor coil are shown with the same letter in the drawing. 4. Particular relay contacts may be used in different circuits at different location. To give the reader an exact idea of where it is used, a drawing mentions a cross-reference number for each contact showing the sheet number and its matrix number. 5. In general, a heavy line is used to show high current carrying conductors (mains supply lines, motor connection leads). In contrast, light looking lines are used to represent low current carrying conductors (control circuit lines). 6. Control circuit power lines are shown as L1 and L2; load (coils of relay) is connected between these two lines in series with switches, fuses, etc. 7. Conductors intersecting each other with no electrical junction in between are represented with an intersection without any dot. Conversely, conductors having an electrical junction are represented with a dot at the intersection, 8. A broken line in an electrical circuit represents mechanical action. Generally, it is associated with a push button or switch closing or opening a contact. Sometimes these lines can also indicate in combination with suitable additional symbols, a mechanical interlocking between two or more devices such as contactors or circuit breakers. 9. Dotted lines are used to differentiate an enclosure from field devices. 10. A wiring diagram of electric equipment represents the physical location of the various devices and their interconnections. HL In an electrical drawing, conductors are marked with cross lines and dimensions of conductors are given alongside. This is used to represent the conductor size of a particular section in a drawing, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 146it Electrical Automation (VELAO.1) TAACT Based on the above hints, let us consider a few common examples of electrical drawings. Example 1: Three-phase motor with DOL starter This is depicted in an electrical drawing in Fig along with the power and control circuits, R oF 9F3 Control bus Y B OFS Auto 9F6! ‘9F6 Manual Motor Bus 80 gS X23 gOF8 sto 9F) yg x04 Fig4-Typical electrical drawing of power and control circuits for a three-phase motor with DOL starter. Explanation: The power circuit consists of a three-phase main supply with a fuse unit for Protection purposes .The other side of the fuse unit is connected to a power contactor. The output terminals of the contactor are connected to an overload relay. Finally, the overload relay output terminals are connected to motor terminals ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 147ite Electrical Automation (VELAO.1) TAACT ‘The control circuit for the motor works on a 110 V AC single-phase supply. The phase of the control supply is connected to a NC contact of the overload relay (O/L) the wire from the O/L relay contact is connected to an auto/manual mode selector switch, In the auto mode, the motor gets a starvrun command through a potential-free contact (Terminals 835-836) of a relay, which in turn is energized with a programmable logic controller (PLC) output In the manual mode, the motor can be started with the help of a start pushbutton, When the start pushbutton is pressed, the control circuit is completed and the auxiliary control contactor (C1) coil is energized. A potential-free NO contact of the contactor (C1) is closed and keeps the contactor C1 is latched when the start pushbutton is released. When the auxiliary contactor (C1) is on, the motor power circuit is completed and the motor starts and remains on until the contactor C1 is de-energized and the power circuit to the motor terminals is broken. For the manual mode, additional interlocks to trip the motor are connected between terminals X3.1 and X3.2 The motor can be stopped with a stop pushbutton. The NC contact of a stop pushbutton breaks the control supply to the auxiliary control contactor (Cl) and the motor is stopped. The neutral for the control circuit is connected with a neutral link (N/L). To indicate that the motor is ON or running, an indication lamp is connected in parallel to the contactor, which gocs ON whenever the auxiliary contactor is turned on. Another indication lamp to indicate a motor trip is connected to a NO contact of the overload relay. When the motor is overloaded, the NO contact is closed and the TRIP indication Jamp is tumed ON, until the overload relay is reset. In the control circuit, potential-free contacts, 2 NO and 2 NC, of the contactor (C1) are connected to various pairs of terminals such as X3:3 — X3:4 (NC), X3:5 — X3:6 (NC), 80 - 191 (NO), and X2:3 — X2:4 (NO). ‘The NO contact of the contactor is terminated at the te: minals X2:3 and X2: parallel to the start pushbutton NO contact for latching purposes. In addition, the contact letters 9F8-9F9 is mentioned. |, and is used in Teknocrat’s Academy of Automation & Control Technology, Nashik 148fl Electrical Automation (VELAO.1) TAACT Example motor with start-delta starter The electrical drawing in Fig depicts this power circuit, 1-144 A UK Motor Fig.S- Typical electrical drawing of power circuit fora three-phase motor with star-delta starter. Explanation: The power circuit consists of a three-phase mains supply with a fuse unit, three Contactors — line contactor, start contactor, and delta contactor. The line contactor gets its three- phase power supply from the fuse unit and the output terminals of the line contractor are connected to the overload relay. Overload relay output terminals are connected to the motor terminals - Ul. V1. W1. Motor terminals U2, V2, W2 are connected through either star or delta contactors. ‘The star contactor and delta contactor are mutually interlocked in the control circuit to ensure only one contactor is om at a time. When the delta timer is on, the motor-winding terminals U2, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 149)f Electrical Automation (VELAO.1) TAACT, V2, W2 get a three-phase supply and the motor is delta-connected, When the star contactor is on, the motor terminals - UI. V1. WI. ~ are shorted and the motor is star-connected, ‘The control circuit as shown in Fig, for the motor, works on a 110 V AC single-phase supply. ‘The phase of the control supply is connected to a NC contact of the overload relay (O/L). The wire from the O/L relay contact is connected to an auto/manual mode selector switch. 4FL 463 Control bus cl X3:9 B———31O—__-& X3:10 x33 @4EL_gte x34 x3:11 pAE 9 19 AFIS ig x3:12 x35 @4E8_ 51% __ia x36 x3:7 @9EI2 jo 9FI3 9 x3:8 ars 3 x33 e467 4g x3:14 33.15 g-4EIO_ 4 1G AFI og x3.16 Fig.6- Typical electrical drawing of control circuit for a three-phase motor with start-delta starter. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 1501 ite Electrical Automation (VELAQ.1) TAACT In an auto mode, the motor ‘gels a starv/ron command through a potential free contact of arelay, which in turn is energized with a PLC output. In the manual mode, the motor can be started with the help of a start pushbutton. When the start Pushbutton is pressed momentarily, the control circuit is completed and the line contactor is energized. A potential free NO contact of the line contactor is closed and keeps the control complete when the start pushbutton is released. When the motor is started, the star contactor is closed and the motor is started with a star connection. As the motor runs for a few. seconds, the delta timer picks up, which energizes the delta contactor and de-energizes the star contactor, The ‘motor continues (o run, connected in the delta configuration, until it is stopped with the stop Pushbutton or trips due to an overload or an external interlock, As can be viewed in Fig., each contactor use contacts that are given at the end of the drawing. For example, NO contact used is shown with Jetters 4F7-4F8 and 4F8-4F9, Similarly, contact details of contactor C2 and C3 are shown, Note: The overload relay in this circuit is actually connected in series with the phase winding of the motor in the normal running mode (i.e., delta connection). The motor rated current is normally indicated in terms of the line current which is greater than the phase current by a factor of V3. Selection and setting of the overload relay must take this into consideration, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 15117 i Blectrical Automation (VELAO.1) TAACT Basic Troubleshooting Principles Introduction: We have studied about symbols, measuring meters, reading, control circuits, etc. This would help in building a planned and strategic approach for troubleshooting. Ina healthy state, any basic circuit that has a load and energy source has circuit paths, as shown in fig. Load_}-—-%e Current Energy Source = 4p aS Fig.7- A healthy electrical circuit Current flows in a closed circuit between two electrically unequal potential points. Points A and B are any two points across which voltage is measured. The conductor offers resistance to this, flow of electrons (i.e., current) depending upon the material. Generally electrical problems can be classified under two broad types. 1. A connection does not exist where it should. This is an open circuit fault and can be detected using a continuity tester (Fig. Illustrates this type of fault) Path beak Load I A B Corrent Energy Source <= ——EE aA Filg.8- Atypical open circuit fault. 2. A connection exists where none should. This is called a short circuit fault and can lead to excessive current accompanied by mechanical forces and heating of circuit conductors. Such fault happens due to insulation failures and can be detected using insulation testing instruments. ‘The process of detecting these faults and rectifying the circuit to restore normal operating condition is called troubleshooting. We will discuss about the open circuit fault first. ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 15218 dl Electrical Automation (VELAO.1) TAACT Curent has a tendency to flow between two points that are at an unequal potential (electrically), Provided the path between the two points is electrically conductive. * Resistance offered by the path is known as ‘Resistance’ ohm. "Electrical potential is denoted as ‘volts’ * Flow of electrons between two points is termed as “Current? (amp) ‘Therefore while troubleshooting; the following points have to be checked * Continuity of path (.. resistance) = Electric potential at two points of the path (i.e, voltage) * Flow of clectrons through the path (i.e., current)] An electrical circuit is made up of different paths and works on different voltages, Let us, therefore, identify the path the should be complete, also, when and how it is complete Moreover, if it does not complete, let us identify the reason, Basic principles in using a drawing and meter in troubleshooting circuits: To identify a faulty section, follow the guidelines given below, along with a drawing and a meter. "Check the Incoming supply voltages first. * Check for voltages at the specific test points in circuit (as per manufacturers test point data sheet) * Do dead test of circuit for integrity of protection devices and others * In dead test, check for continuity of circuits, as intended, and check for insulation resistance, * Ifit’s not possible to perform a dead test, connect the supply to the circuit and do a live test of circuit. As generally, any electrical circuit can be differentiated in two sections: Power circuit * Control circuit {tis always advisable to first check the power circuit. So, ifthe power circuit works, as it should, then troubleshoot the control circuit. Power circuit check lists * Incoming power to circuit and its integrity * Check for correct functioning of protection devices, "Check visual cable continuity * Check for any signs of flash or burning smell of devices, Control circuit check list: * Control circuit power first Check for proper functioning of relays, timers, and switches etc Check visual cable contin Check for wire interconnections and terminal connections of circuit Check logical operational sequence of contactor switching * Check for timer duration settings If the above criteria are checked and still the motor (final device) is not working, then test the ‘motor (final device). ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 15319 Electrical Automation (VELAO.1) TAACT Checks for cireuit cont nuity with disconnected supply: Dead circuit testing is testing performed with the power disconnected from the circuit. The main benefit of disconnection power supply while tests with an external energy source are performed is to eliminate hazardous risks to the environment or the person conducting test. A continuity test, as well as an insulation test can be performed in the dead circuit tes (a)Continuity tes ‘This is to be performed on a dead circuit for checking continuity. Using an ‘Audible Continuity Tester’ can do it .This tester consists of a battery as a source of energy, an audible device, and two test leads, Fig shows an example of this test with an audible continuity tester. By this test, the continuity of an electrical circuit is checked to ensure that the electrical path is, complete. If the path is continuous, then an audio sound is emitted to confirm path continuity and the non- ‘existence of an open circuit In some devices, along with the audio indication, an LED or some other visual indication is provided. Similarly, an ohmmeter or multimeter can also be used to check continuity. An obmmeter or multimeter consists of a battery as a source of energy, along with a meter to display the value of resistance. Fig Shows an example of this test with an ohmmeter. In an ohmmeter, the scale is calibrated from zero to an infinite range of resistance. When the meter shows a zero reading, it indicates that the path between two test leads has zero resistance. This, in tur, indicates that the path is a continuous one. If the path or the conductor is open, then it will show resistance value as infinite. A Load Fuse I BO——j <- ¢ Continuity tester v7 Ll 12 9 ‘Supply Pig.9-Continuity test with audio tester Academy of Automation & Control Technology, Nashik 154Electrical Automation (VELAO.1) Pig.10- Continuity est with ohmmeter In short, continuity testing is used to check the following purpose: * Integrity of cables: * Integrity of electrical circuit path * Integrity of the earthing system (ie., electrical continuity and low-resistance value to earth) * Accurate wiring of a control and power circuit to the correct terminals.(e.g Testing of Panel wiring) * Differentiate active and neutral conductors before connecting them to a device. * Check for wrong wiring interconnections between different control and power circuits; thus indirectly, checking for short-circuit paths. * Integrity of switches, fuses, and other devices. A few words of caution are warranted here. Checking for continuity in a control circuit can give erratic results due to the existence of parallel circuits. It is better to disconnect appropriate terminals to ensure correct results. Continuity test in power circuits can be tricky. Often, a circuit where there is an open circuit fault can register excellent continuity with a low power tester or ohmmeter. But when a voltage is applied, current may not flow. The reason for this is that the Circuit may be partially continuous (Example: a partially burnt cable where one or two conductor strands may be making contact) but when feeding a heavy load it will behave as a high impedance. This type of fault will be detected by testing on load using voltage measurements, ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 155* Blectrical Automation (VELAQ.1) TAACT 7.10 Checks for circuit continuity with live supply: Generally, if possible, troubleshooting is done with a disconnected power supply, but in some circumstances, faultfinding is only possible if the circuit is live. Therefore, the circuit under testing remains connected with the power supply. This uses the circuit power supply itself as a source of energy for testing. This kind of testing should be done with extreme care following safety precautions. As shown in Fig. the integrity of a power supply or continuity of electric path can be checked by using test lamps. Test lamps are connected in between two phases. Thus, as with the dead circuit test, a continuity test can be performed. In addition, a lamp-type visual tester can be used for simple continuity testing. Alternatively, voltage indicators or multimeters can be used for checking voltage and the continuity of the conductors or electrical path. While checking the voltage at these test points, measuring instruments must be accurate. ‘Therefore, a comparison of voltages at these test points is sufficient to draw conclusions. Diagnostics for a single-phase motor can be undertaken with this kind of visual indicators. This requires a sound knowledge of circuit and wiring arrangements-depending upon the done, interpretation varies and so does an accurate fault diagnosis. R Y B + Breaker Fuse i a a OML contact FigII-.continuty test with series lamos tis always advisable to check voltage between line to line than line to-earth, since for the latter, ‘he results may be misleading, ‘Testing on a live circuit requires extreme caution and should be restricted to LY circuit. Precautions should be taken to prevent inadvertent contact of the technician with live parts ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 156* TAACT The probes and tools must be insulated with minimum exposure of condescending parts. This will minimize inadvertent bridging of two terminals which ate at different potentials which can cause a short-circuit and arching leading to burn injuries to the technician, Electrical Automation (VELAO.1) TAL Tests and methods: Although most of the tests have been detailed above, there still remain certain tests that are common and critical to an electrical system. Parameters such as the resistance of leakage paths and resistance of a conductor have to be known for some apy ‘The tests include the following: * Effectiveness of the power earth "Effectiveness of the electronic earth * Continuity of the earthing system and required equipotentiality (so as to check the possibility of earth current loops) * Earth pit locations, resistance of earth conductor, material, and size. * Location of protection devices, so that the path taken by fault current is minimum and insures the activation of a protection device under fault conditions, = Ratings of fuse and other protection devices. * Selection of suitable cable types with proper current ratings keeping in mind environmental conditions and length of run * Materials prone to environmental hazards which may be mechanical or chemical, which might be present, such as dampness, high temperature, explosive gases, vapors, + Electrical equipment, to ensure that its operation will not cause overload conditions. * Location of installation of electrical equipment and accessories, If all the above points are considered during the installation of an electrical system, there will be a reduced need for troubleshooting. The quality of the system will also be good. 7.12 General document checklist of troubleshooting: Control circuit drawings Manufacturers operations and maintenance manuals and troubleshooting instructions. Block interlocking diagram and control sequences involving the equipment/machine. Drawings and details of power circuits of the equipmenmachine, Details of devices, control devices, contactors, timers, counters, safety/protection Power circuit of the equipment or the machine. Teknocrat’s Academy of Automation & Control Technology, Nashik 157ie rane Elcotrical Automation (VELAO.1) Ch.8.0 Transmissions and Distribution 8.1 Introduction: Electrical power is cartied from generating point up to the points of consumption by Transmission and Distribution networks. Generators in the generating stations produce power at normally 6.0 KV or 12.5 KV. This power first carried over fairly long distances of 100 of Km or more up to the receiving station and from the receiving stations to the load centers from where it gets again redistributed up to the consumers through a number of substations. Domestic consumers, small industries and commercial establishments require power at low voltages. Large industries can accept power at higher voltages from L1Kv to 110 Kv. ‘To minimize the losses in transmission and distribution, appropriate voltages have to be chosen for each section of the T & D networks. ‘The schematic diagram show a typical TOD network 12.5kV 12.5 /132 kV Step-up __(132,220,400,600kV) % ‘Transformer 132/66 KV Step- down ‘Transformer md 66/33 KV Step- down: Transformer Step- down 33/11 KV Transformer a 11/440 Vv Distribution HLT. consumer L.T. Consumer Fig. 1 schematic of Trans. & Distribution network ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 158 we aFlechiced Power ans Gantry Study of SubStahun Gm ponents i ip Electrical Automation (VELAO.1) 7 Electrical Board supply FLM] (eB. mererine ) A. Polator D.G. SET M | Metering V.CB PT Homsentnt re 7 1KV/440V oo [™] EC Distribution Transformer Be] Jacavcs aS a so g | +) sru [> ( Dist. Panel. Dist. Panel. Fans / Blowers Pumps T Lighting |[___ Heaters Fig.2 Typical LT Distribution Scheme in a mediun scale industrial unit tre metering PDO = Power Dormbsit Pom MCC & mMohy Cutel Cow Trinh ome user Conte) SEHHO Dow Dr reo $F ‘Teknocrat’s Academy of Automation & Control ‘Technology, Nashik 159cd Electrical Automation (VELAO.1) TAACT Set ____ Cable Current Capacity Proximity Sensors Sr. [Sq. | Current Type Mounting [Dimension | Sensing No. |mm _| Capacity s Distance _| 1 |050 |4 | 12X65, 25MM __ | 2 [075 (7 Flush [18x65 | SMM 3 it 4 —| Inductive M30x65__| 10MM 4 {15 [15 Misx65 | 8M 5 25 19 Non Flush | M24X65 10MM. 6 |4 26 ‘M30X80__| 15MM. 7/6 31 Flush |M24xe5__[1-5MM a ‘M30X80__ | 2-10MM. 9 [ie [57 Pi miexes | 2-10MIM 10 [25 [71 . Non Fush [M30X85 tt [35/94 M30X65 12 [50 [120 Mi2x85 4370 [161 Optical : M18X85 14_[95 [200 M30X85__| MTR 15120225 Magnetic Mi2x50__ | 1MM i6_|150 [240 Reed : Mi8x50__|3MM Switch ‘M30X65__| SMM i7_|185__ [300 Ultrasoni M50X85_| 5MTR. 48 [240 [425 ¢ : MB0x65 | 10MTR ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 160% Electrical Automation (VELAO.1) TAACT back ap Qrorech ian Direct on Linc Stoner [- DOL Cupty 1o HP) |_ ____ Selection table for Starter /Relay / Fuse J Cable | No [ornate fis Vac Gine2S [Contactor | Relay | Fuse “apogee 1_| 050 0.40 1.0 12 08-16 6 152.5 2 | 075 | 055 15 12 1-15 6 1.5/2.5 3 | 4.0 0.75 2.0 12 14-2 10 1.5/2.5 4 [415 iA 26 2 2:3 10 1.5/2.5 5 | 20 15 35 12 25-4 15 1.5/2.5 6 | 30 2.25 5.0 16 46 20 1.52.5 7 | 40 3.0 62 16 46 20 152.5 “Te 5.0 3.75 75 16 55-8 25 25 [9 | 60 45 9 16 6-10 25 2.5 10 | 7.5 5.6 it 16 12 25 4.0 11 | 10 75 14 16 11-16 35 4.0 f 2 es 93 18 30 14-20 50 6.0 13 [15 it 24 30 17-25 50 6.0 ber 14 | 47.5 13 24 30 20-32 63 10.0 aus 75 [20 15 28 30 22-32 63 10.0 goat] 18 [25 18.5 35 38 25-40 80 16 17 |__30 22 40 70 30-45 | 100 25 18 [35 26 47 70 38-63 | 125 25 19 | 40 30 55. 70 38-63 125 25 20 | 45 33.5 60 70 45-70 | 160 35 21 | 50 37.5 66 70 50-90 | 160 35 22 | 60 45 80 105 | 50-90 | 160 50 23 [75 56 100 105 {70-110 | 200 70 24 | 90 675 120 170 | 90-150 | 260 95 25 | 100 75 135 170 | 120-155 | 250 95 26 | 150 112 200 400 | 140-200 | 360 185 27 | 200 150 275 400 | 210-300 | 500 300/400 28 | 225 170 300 400 | 280-300 | 600 300/400 | ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 161Electrical Automation (VELAQ.1) TAACT Star Delta - Selection table for Starter / Relay / Fuse ./ Cable _ Sr. | 3Phase Full | Phase J No 415VAG. Load | Curren | __ Contactor Relay | Fuse |_Cable Size sq.mm_ HP. KW. Current | t Main _| Str/Del Supply Motor T| 3 [225 | 5 | 208 | i2 | 12 | 15-4 | 10 | 1525 | 15/25 2| 5 3.75 | 7.5 | 4.32 | 12 12 20 | 1.5/2.5 | 1.5/2.5 3/75 | 55 | i1 | 634 | 12 | 12 | 25 | 25 | 15725 [4 | 10 | 75 | 15 | 810 | i6 | 16 25 4 1.5/2.5 5 | 125 | 93 18 | 10.02 | 16 16 | 35 4 25 e] 5 | 11 21 | 12.10 | 16 | 16 50 6 25 7 | 20 | 15 | 28 | 1600] 30 | 30 63_| 10 4.0 8 25 18.5 35 20,20 30 30 63 16 6.0 9 {30 | 22 | 40 | 23.00 [30 | 30 | 100 | _16 6.0 jo| 35 | 26 | 47 [27.00 | 38 | 30 100 | 25 10.0 11 | 40 | 30 | 55 [30.30 | 38 | s0 “400 [25 16.0 12| 45 | 335 | 60 | 346 | 70 | 30 125 | 35 16.0 13 | 50 | "37.0 | 66 | 35.0 | 70 | 30 125 | 35 16.0 14{ 60 | 45 | 80 | 45 | 70 | 70 160 | 50 25.0 15 | 65 | 485 | 87 | 50 | 70 | 70 160 | 70 35 16 | 70 52 94 54 70 70 160 70 35 i7| 75 | 56 | 400 | 57.5 | 70 | 70 200 | 70 35 18 | 90 67.5 120 69.0 105, 70 200 95 50 19 | 100 | 75 | 135_| 78.0 | 105 | 70 250 | 95 50 20 | 125 | 90 | 165 | 95.0 |"160 | 70 250 | 120 70 [21 | 150 | 112 | 200 | 415 | 170 | 170 300 | 185 70 22 | 175 | 132 | 230 | 133 | 170 | 170 | 90-135 | 350 | 225 | 120 23 | 200 | 150 | 275 | 159 | 300 | 170 | 140-170 | 400 | 300/400 | 150 24 | 240 | 175 | 320 | 494.5 | 400 | 170 | 140-170 | 400 | 300/400 | _185 25 | 250 | 187.5 [323 | 185 | 400 | 170 | 140-200| 400 | 400 185 26 | 275 204 360 200 400 170 175-250 | 400 500 185 27 | 300 | 225 | 385 | 222 | 400 | 400 | 210-300 | 500 | 500 225 28 | 400 | 300 | 500 | 390 [| 400 | 400 | 280-400| 700 | 625 | 300/400 ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 162ie Electrical Automation (VELAO,1) TAACT Full load current for Standard Motors se { With respect to different voltage | No [3 Phase 415VAC Single Phase ‘Three Phase Direct Current HP __{|KW___| 115v [230v | 400v | 230v | 400v | 440v | 110V | 220v [440 1} 125 | 0.09375 | 3.0 [1.5 [086 | 0.70 | 0.4 | 036 | 18 | 09 | 045 2} 25 | 0.1875 [52 | 26 | 15 | 113 | 065 | 059 | 29 | 05 | 073 3} 5 | 0375 [| 8 | 4 [23 [2112 [ii fs 2s} a3 4} 75 { 0.5625 | 112 [756 [3.2 [28 | 16 | 144 [75-37 | 19 3] O75 {14 | 7 | 4 [3s [2 [18 | 96 | 48 | 24 6 {15 { 112s | is [9 [52 [49 [28 | 26 | 14 [7135 7T| 2 15 | 22 | uu {63 [61 [35 | 32 [17s | sa | 44 gj} 3 | 225 | 32 | 16 | 92 |37 | 5 | 46 | 25 | 1251] 63 9 | 5 [| 375 | 52 | 36 | is [4 | 8 | 73 | 42 |-31 T105 [40 | 7.5 | 5.625 [76 | 38 | 22 [20 [a1 [05 | 63} 32 Pasa ni} 19 [75 | 100 [0 | "29 | 26 [1.4138 | a4] 42 at qa} is [125 | 144 | 72 | 41 [3899 20 | at] 6130 13 | 20 1s_| 180 | 90 [52 | 50 | 29 [27 | 160 | 80] 40 14 | 25 [18.75 [220 | 110 [63 _| 63 | 36 | 32 | 195 | 97} 9 15 | 30_| 22.5 “| 260 | 130_|75_|73_|42_| 38 | 234] 117 | 38 16 | 40 | 30 = = =| 9836 [st [310 | 15s | 78 17 | 30 | 375 | - = =| 122 [70 |" 64 | 376_| 188 [94 18 | 60 [45 = s [146 {84 [776 |450_| 225 | 113 19 | 75_ [56.25 | _- : 180_[ 104 [~ 95 |“550_|_275_[ 138 20 | 100 |" 75 = : =| 240 [138 [124 |" | 370- [185 ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 163Electrical Automation (VELAO.1) TAACT Sold mm GS Copper Bus Bar Continuous Current Capacity Sr. | Sizein ratte Wea Continuous current capacity in Amps. area ACNo. of Buses DC No. of Buses 1 2 3 4 1 2 3 4 1 [2x2 | 23.5 0.209 | 110 | 200 | - = [115 | 205 | 2 15X2 29.5 0.262 140. | 200 - - 145 | 245 = - 3 1SX3 44.5 0.396 170. | 300 = 175_|_ 305 = 4 20X2 39.5 0351 185 | 315 < 190 | 325 3 | 20x3 | 395 | 0529 | 220 | 380 | - 225 | 390 6 20X5 99.1 0.882 295 | 500 7 = 300 | 510 T_| 2x3 | 745 | 0663 | 270 | 460 | - | - | 275 | 470 2 8 | 25x 124 iit_| 350 | 600 | - | - | 355 | 610 9 | 30x3 | 89.5 0.796 315 | 540 - = 320 | 560 - - 10 30X5 149 133 400 | 700 - : 410 | 720 = = ef 40X3 119 1.06 420 | 710 = 430 | 740 - - 12_| 40x5 199) 1.77 | 520 | 900 ~_[ 530 | 930 | - = 13__[ 40x10 [399 3.55 | 760 | 1350 | 1850 | 2500 | 770 | 1400 | 2000 | - 14 S0X5 249 2.22 63U_| 1100 | 1650 | 2100 | 650 | 1150 | 1750 = 15 50X10. 499 4.44 920 | 1600 | 2250 | 3000 | 960 | 1700 2500 | = 16 60X5 299 2.66 760 | 1250 | 1760 | 2400 | 780 | 1300 | 1900 | 2500 17_| 60x10 |_599 5.33 | 1060 | 1900 | 2600 | 3500 | 1100 | 2000 | 2800 | 3600 18 | 80xs | 399 3.55_| 970 | 1700 | 2300 | 3000 | 1000 | 1800 | 2500 | 3200 19 80X10 799 TAL 1380 | 2300 | 3100 | 4200 | 1450 | 2600 | 3700 | 4800 20 100X5, 499 4.44 1200 | 2050 | 2850 | 3500 | 1250 | 2250 | 3150 | 4050 21 100X10 999 8.89 1700 | 2800 | 3650 | 5000 | 1800 | 3200 | 4500 5800 2 | 120x10[ 1200 10.7 | 2000 | 3100 | 4100 | 5700 | 2150 | 3700 | 5200 | 6700 23 160X10 1600 142 | 2500 | 3900 | 5300 | 7300 | 2800 | 4800 | 6900 | 9000 24 (| 200X10 2000 178 3000 | 4750 6350_ 8800 | 3400 | 6000 | 8500 | 10000 Teknocrat’s Academy of Automation & Control Technology, Nashik 164Electrical Automation (VELAO.1) TAACT Induction Motor Recommended capacitor rating Sr.No. | 3 phase 415VAC KVAR rating when motor speed is uP KW | 3000 71500 | 1000 | 750rpm | 5500 rpm] rpm | rpm rpm 1 25 1875 1 I 15 2 25 2 5 375 2 2 25 35 4 3 75 5.625 25 3 35 45 55 4 10 75 3 4 45 55 65 5 15 | 11.25 4 5 6 5} 9 6 20 15 3 6 7 9 12 7 25 18.75 6 7 9 105 145 8 30 22.5 7 8 10 2 17 9 40 30 9 10 B 15 21 10 50 375 in 125 16 18 25 0 0. 5 B 145 18 20 28 12 70 3525 15 165 20 2 31 B 80 60 17 19 2. 24 34 i 90 675 19 21 24 26 7 5 100 5 21 2B 26 28 40 16 110 5 2B 25 28 30 B 7 120 90 25 27 30 32 6 8 130 O75 27 29 3 34 49 p 140 105 29 31 4 36 32 20 145 | 108.75 | 30 32 35 37 4 2 150 | 1125 31 33 36 38 33 2 155 [ 11625 | 32 34 37 39 36 B 160 120 3 35 38 40 37 24 165 [123.75 [34 36 39 a 9 B 170__ | 1275 35 37 40 2 60. 26 is | 13125 | 36 38 4a B 1 2 180 135 37 39 cy co 2 2B 185 | 13875 | 38 0 B 5 3 2 190 | 1425 38 co B 5 6 30 200 150 40 2 45 a7 o7 3 250 | 1875 5 30 55 60 70 ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 165AACT Electrical Automation (VELAO.1) 7 ‘Aluminium Bus Bar ~ 1 Continuous Current Capacity | Sr. ]Sizein ]Cross | Weight Continuous current capacity in Amps. | No | mm sectiona | Kg/mtr | area ‘AC No. of Buses DC No. of Buses! 1 2 a 4 | ot 2 3 at 1 | 12x2 | 23.5 | 0.0633 | 80 | 140 | -_ | 80 | 145 | 2 | 15x2_ | 295 | 0.0795 | 95 | 170 = 95 | 175 - | 3 | t5xa_ [445 [| of2 [415 [210 | - 115 | 220 | - | 4 | 20x2 | 395 | 0.107 | 120 | 220 | - >| 125 | 225 = 5 | 20xs | 595 | 0161 [145 | 270) - | - | 150 | 280) - a4 6 | 20xs | 99.1 | 0.268 | 195 | 350 | - 200 | 370 | - = 4 7 | 25x38 | 74.5 180 | 330 | - 185 | 340 =| 8 | 25x5_| 124 | 0.335 | 230 | 430 235 | 440 | - = 9 | 30xs | 89.5 | 0.242 | 205 | 385 =_| 220 | 400 |= =| 10 | _30xs | 149 .403_| 270 | 500 =_| 275 [520 | - : 1 | 40xs_| 119 | 0323 | 280 | 500 | - ~_| 285 [525 | - cary 12 | 40xs_| 199 | 0538 | 350 | 650 | - =| 360 | 660 | - =f 43 | 40xio | 309 | 1.08 | 515 | 975 | 1350 | 1800 | 540 | t000 | 1420 | - ; 14 [sxe | 249 [0.673 | 425 | 780 [1120 | 1500 | 445 | ets | 1220, — 15 | 50x10 | 499 | 1.35 | 625 | 1150 | 1600| 2160 | 655 | 1220| 1730 | - 16 | 60xs | 209 | 0.808 | 600 | 900 | 1300] 1730 | 530 | 960 | 1420 | 1850 ' 17 | 60x10 | 599 1.62 [730_| 7330 | 1900 | 2500 | 770 | 1430 | 2030 | 2600 | Te} soxs | 399 | 1.08 | 680 | 1170 | 1650] 2230 | 700 | 1260 | 1850 | 2400 | ¥9 | 8oxio | 799 | 216 | 940 | 1700 | 2560] 3150 | 985 | 1840 | 2640 | 3400 , 20 | tooxs | 499 |" 1.35 | 820 | 1440 | 2000 | 2600 | 855 | 1550 | 2220 | 2900 21 | {00x10 | 999 2.7 | 1160 | 2050 | 2800 | 3700 | 1200 | 2240 | 3200 | 4200 22 | 100x1s | 1500 | 4.04 | 1450 | 2500 | 3350 | 4400 | 1500 | 2750 | 4000 | 5200 | 23 | 120x10 [1200 | 3.24 | 1350 | 2400 | 3250 | 4300 | 1420 | 2700 | 3900 | 5100 | 24 | 120x185 | 1800 | 4.86 | 1650 | 2900 | 3900 | 5000 | 1750 | 3250 | 4800 | 6300 , 24 | 160X10 | 1600 4.32 1750 | 3000 | 4150 | 5300 | 1850 | 3450 | 5000 | 6500 25 | 160x15 | 2400 | 6.47 | 2100 | 3600 | 4850 | 6250 | 2300 | 4300 | 6200 | 8100 | 26 | 200x10 | 2000 |" 5.4 __| 2150 | 3650 | 4950 | 6400 | 2300 | 4300 | 6200 | 8100 | 27 | 200x18 [3000 | 8.09 | 2500 | 4200 | $600 | 7300 | 2850 | 5250 | 7650 | 101001 ‘Teknocrat’s Academy of Automation & Control Technology, Nashik 166te Electrical Automation (VELAO.1) TAACT, ELECTRICAL DRAWING SYMBOLS Start Stop Emergency Stop NO Power NC Power Push Button Push Button Push Button contact contact ) ny C | | | | T oT NO Auxiliary NC Auxiliary MCB18-— OverloadNC Auxiliary Solenoid Contact Contact Contact Suply/Coil coil Transformer Hooter Selector ‘Indication Motor Motor , Switch Herre 30 1p pw ry ISN AW HOE \) Resistor DC Motor ‘Thermocouple Heater RTD Sendo ‘Sensor id ib 6 Ny lo | I Pai o g Diode LED Internal Extemal i Terminal Terminal Contactor Power Terminal a = -} | T PhotoDiods Phototransistor Choke. Inductive coil Limit switch Rea & | Vv A {wt = t ? Volt cut Changeover NO- Meter Meter Power Meter FRMANGs Academy of Automation & Control Technology, Nashik 167Electrical Automation (VELAO.1) Pressure 4 four pave Sor ipa RLS) BS + eee E FteouRe ROueR Saar a cu/, a mA cm Bowe Yu woros—~—~ORESSURE ROLLER SURE ROMER reo 32. AGND AGND m/ ; Lamesa “Ts saepice Ts souererae Si WhaNIE om BF HES MAL OWE GAS falBt e one rere |S [GLE 1 WONDEROAGK WO, PED. | TEKNESCRATS [owe 2/12/00 ran e [mw [praiect > 8 6 Acne Bee [an um [nen —| RENO. — F135 708/05 EEE TS pct 1 OTE 168 ‘Teknocrat’s Academy of Automation & Control Technology, NashikElectrical Automation (VELAO.1) AL onisa 2) & BARREL BARREL ZONE 2 CUENT 1 WONDERPAGK IND. PVT. LID. (S60 MACHINE 135/08 /05 169 ‘Teknocrat’s Academy of Automation & Control Technology, Nashik93° o2 cCocsao0go0 Oo ‘eecececcececcccccoo